TracTuff K24A/ K20Z3 Water Bypass Block Off

After years of selling the OG water bypass adapter... I finally saw a sales trend that made it easy to decide on manufacturing a dedicated block-off.

The decision to make this product comes from not wanting to overcharge customers for the more expensive water bypass adapter, only to plug it! All the features that make my water bypass adapter the BEST on the market, are incorporated into this. T

Just because I make this, it does not mean that I recommend eliminating the water bypass function, it has a very valuable role in how the cooling system functions... so please do your research and understand the pros and cons associated with deleting it! 

NOTE: If you didn't select a sensor port and you would like to add one now... drill it here and flip it over and tap it for your sensors thread pitch from the front. Do NOT start tapping from this side!

Installation Guide

Please understand that the intake manifold shown is JUST AN EXAMPLE. Please also understand that my water bypass adapter was designed and machined for a perfect fit when using the Genuine Honda PRB/ PRC manifold shown. I cannot control what aftermarket intake manifold companies do with their shape. If the water bypass adapter does not fit properly, the manifold casting is to blame, and you will need to make a choice on which of the two products will be modified. I recommend you remove material from the manifold so you don't accidentally remove material that will cause a leak. 

Also,  nowhere in this write-up do I mention the use of OR recommend Hondabond or any RTV sealant. This is NOT an oversight or accident. It is NOT needed. The o-ring seals directly against the cylinder head. Do NOT install the water bypass adapter on top of any type of gasket!!

The water bypass adapter does not support EGR. By purchasing this product, it is assumed that you either don't have an engine with a complete EGR system or you have deleted it by using a water neck that renders the passage useless.  

Install the o-ring into the recess on the adapter’s backside and set the adapter aside. If you need assistance with keeping the o-ring in place... use a small dab of Hondabond or grease.

Grab the stainless steel link and the 35mm flanged bolt and insert the bolt into the unthreaded hole in the link.

Thread the bolt and stainless link into the upper right-most intake manifold flange bolt hole. Tighten lightly with the link facing upward. Depending on the intake manifolds flange thickness, you may need to use a spacer or washers to shim the link out far enough to ensure it goes over the water bypass adapter.

Grab the shorter Genuine Honda flange bolt (now an M8 socket head bolt) and adapter and install the bolt into the lower bolt hole.

Take the bolt and adapter and install it over the exposed water & EGR ports. Thread the bolt into the cylinder head until it is hand tight. Do NOT install the adapter over a gasket of any type! My water bypass adapter seals directly against the cylinder head.

Grab the stainless steel set screw and thread it into the stainless link. The pointed set screw will butt up against the counter bore and apply pressure to the top of the water bypass adapter.

Swing the stainless link and set screw down until it lines up with the counter bore (only one now). If the set screw does not line up with the center of the counter bore... it is likely that the water bypass adapter is hitting the manifold somewhere.

As you can see in these pictures, the water bypass adapter was made to work with the shape of a genuine Honda intake manifold. If the flat edge on the right side of the water bypass adapter does not follow the edge of the cylinder head, you must remove the intake manifold and remove material where the two are touching. 

Tighten the M8 hex head flange bolt and M8 socked head cap screw to 18 lb. ft. of torque. Tighten the set screw until you have sufficient crush on the adapters o-ring. Thread the thin M8 jamb (nut is not shown) here but it would either go on the exposed threads of the set screw (face of the link) if there were enough threads OR in between the link and the bypass adapter (shown) and tightened to lock the set screw in place. Congratulations! You're done.