Coolant Overflow Issue After Intake Install

[88scar50]

I just got done installing a 93 cobra intake. Everything seemed like it went well but after a short test drive the engine started smoking a bit, After a quick inspection it seems that coolant is coming out under the cap of overflow reservoir. I figured maybe it was a bubble and raised the car and let it run for a while with the cap open then topped it off. Same thing happened. What's the deal?

 

[stykthyn]

how long did you let it run? Did you run the heater as well?

 

[88scar50]

Around 10-15 minutes, heater was on

 

[mikestang63]

air in the system

 

[88scar50]

Any Idea how to fix this? Could it be a thermostat issue?

 

[mikestang63]

http://www.stangnet.com/mustang-forums/threads/bleeding-air-out-of-cooling-system.574770/

 

[88scar50]

I have tried both the ways already and it didn't resolve the issue

 

[88scar50]

Gave it another shot. Jacked it up let it run for a while until I didn't see any bubbles then topped it off, then took it for a drive. About five minutes in I pulled over to check it and same thing, bubbling/boiling in reservoir and coming out of the overflow. Cleaning this coolant from the battery tray and continuing to buy more coolant is getting real annoying, any other suggestions for this stupid issue?

 

[jrichker]

Possible leak between the coolant passages on the throttle body spacer and the EGR passages. You get to bypass the coolant by using a piece of copper tubing to join the two small coolant lines. That will hold you until you decide to take the throttle body spacer off and replace both gaskets. While you have the throttle body off, check it for cracks, corrosion or damage to the throttle body passages and gasket surfaces.

Note the two small hoses on the throttle body; they are the coolant lines I was talking about.
Diagrams courtesy of Tmoss & Stang&2birds

See the following website for some help from Tmoss (diagram designer) & Stang&2Birds (website host) for help on 88-95 wiring; http://www.veryuseful.com/mustang/tech/engine/ Everyone should bookmark this site.

94-95 Mustang wiring diagrams
http://www.veryuseful.com/mustang/tech/engine/#95-95Diagrams

Complete computer, actuator & sensor wiring diagram for 91-93 Mass Air Mustangs
http://www.veryuseful.com/mustang/tech/engine/images/91-93_5.0_EEC_Wiring_Diagram.gif

Complete computer, actuator & sensor wiring diagram for 88-91 Mass Air Mustangs
http://www.veryuseful.com/mustang/tech/engine/images/88-91_5.0_EEC_Wiring_Diagram.gif

Ignition switch wiring
http://www.veryuseful.com/mustang/tech/engine/images/IgnitionSwitchWiring.gif

Fuel, alternator, A/C and ignition wiring
http://www.veryuseful.com/mustang/tech/engine/images/fuel-alt-links-ign-ac.gif

O2 sensor wiring harness
http://www.veryuseful.com/mustang/tech/engine/images/mustangO2Harness.gif

Vacuum diagram 89-93 Mustangs
http://www.veryuseful.com/mustang/tech/engine/images/mustangFoxFordVacuumDiagram.jpg

HVAC vacuum diagram
http://www.veryuseful.com/mustang/tech/engine/images/Mustang_AC_heat_vacuum_controls.gif

TFI module differences & pin out
http://www.veryuseful.com/mustang/tech/engine/images/TFI_5.0_comparison.gif

Fuse box layout
http://www.veryuseful.com/mustang/tech/engine/images/MustangFuseBox.gif

Mustang 5.0 Lights and Radio schematic, by TMoss:
http://www.veryuseful.com/mustang/tech/engine/images/mustangFoxLights-Radio_diag.gif

87-92 power window wiring
http://www.veryuseful.com/mustang/tech/engine/images/mustang87-92 PowerWindowWiring.gif

93 power window wiring
http://www.veryuseful.com/mustang/tech/engine/images/mustang93PowerWindows.gif

T5 Cutaway showing T5 internal parts
http://www.veryuseful.com/mustang/tech/engine/images/5_Speed_Cutaway_Illustrated.jpg

Visual comparison of the Ford Fuel Injectors, picture by TMoss:
http://www.veryuseful.com/mustang/tech/engine/images/Ford_Injector_Guide.jpg

Convertible top motor wiring http://www.veryuseful.com/mustang/tech/engine/images/mustang88VertTopMotorCkt.gif

Engine mounted fuel injector harness
http://www.veryuseful.com/mustang/tech/engine/images/mustangEngineHarness.gif tang/tech/engine/images/mustang88VertTopMotorCkt.gif

Location of the TPS, IAB, and the 10-pin connectors on a 5.0, picture by TMoss:
http://www.veryuseful.com/mustang/tech/engine/images/TPS_IAB_Pic.jpg

 

[88scar50]

I have the cobra intake which doesn't use the Egr spacer anymore, so those hoses are already connected together.

 

[jrichker]

Good, then keep looking. You need to find someplace where exhaust and engine coolant are in close proximity to each other. There are test kits that indicate exhaust leaks into the coolant.

A Google search turned up this gem ... http://www.autozone.com/repairinfo/...wTo&pageId= 0996b43f80a01231&subtitle=inspect

Even better is this YouTube video...

View: https://www.youtube.com/watch?v=a3J00_e7fyo

 

[88scar50]

After reading every post and thread I could find, changed out the thermostat again to the stock one and changed rad cap. No change, still doing it. This is getting very frustrating. Any other suggestions?

 

[jrichker]

After reading every post and thread I could find, changed out the thermostat again to the stock one and changed rad cap. No change, still doing it. This is getting very frustrating. Any other suggestions?

Did you do the tests I posted for checking the coolant for a combustion leak?

 

[88scar50]

I think that the problem has been resolved. I changed the fan clutch and haven't had the issue happen again yet.