Losing coolant after intake change

[snidehockey]

I'm leaking coolant like crazy from where the intake meets the gasket beneath where the thermostat is.

I replaced the intake w/ the plastic coolant crossover w/ an aluminum one. The rad hose is torqued through the intake and into the head pretty tightly. Brand new gaskets around the thermostat as well as for the intake manifold. The only possibility I can think of is if for some reason the gasket isn't lined up right, but in order for the other 4 or 5 bolts to go through it I don't think it could be misaligned.

 

[SVT32VDOHC]

Pretty tight? Is it overtightened? You don't have to torque bolts too tight on plastic parts.

 

[Green&GoldGT]

Did you scrape off the excess dirt/material off the heads where the gasket mates to the manifold or clean out the dimples that hold the gaskets in place?

 

[snidehockey]

well it's pretty much tightened as much as possible...it's on the aluminum part of the intake too so I don't think it would've warped.

I was trying to avoid this but I guess I'm just gonna have to take it all apart again and double check everything.

 

[nyuk98gt]

snidehockey:

Coolant leaks in this area are tricky to pinpoint. Before you yank off the intake consider my experience with this problem. I had a tiny coolant leak [on the PI intake] using my old (NPI) t-stat cover. The true problem was that the oblong holes in the cover did not allow the bolts to clamp down enough even at the specified torque. The width was big enough to allow the stock washers to bend a little so the true torque was not being applied to the housing. Went to Lowe's and picked up some Grade 8 washers and put 2 on per side and torqued to spec. No more leak!

And, of course, check that the o-ring is on top of the t-stat and that is has not gotten pushed out of place.

HTH,

Chris

 

[Superhereaux]

:OT:

Did you need a new alternator bracket when yo swapped intakes?

 

[snidehockey]

yeah I had to drill two holes in the old bracket. No biggie. the alternator is held in place pretty solidly anyway by the bottom bolts.

And as far as the washers tip..THANK YOU, I will get some on my lunch break and hope for the best!

 

[snidehockey]

hey wait...the o-ring goes on top of the Tstat? not beneath it?

 

[nyuk98gt]

snidehockey:

Yes, the o-ring sits on TOP of the t-stat. It provide the seal against the top and the crossover. The housing joint will leak if you put the o-ring under the t-stat because there is a metal-to-metal joint without any flexible seal between!

Chris

 

[snidehockey]

ding ding ding. You're a life saver bro. Just went outside and sure enough it was underneath the Tstat doing absolutely nothing other than giving the tstat a nice soft comfortable place to sit on.

I put it on top and torqued it down, refilled the coolant and I think that should take care of it!

I guess when I dropped the new engine in I was so close to being finished I started going a little too fast and didn't bother to actually look at the o-ring and see where it made sense to go.

 

[nyuk98gt]

snidehockey:

LOL at "ding, ding, ding"! Glad you got it sorted out. I always get very excited as the end of an installation project nears and I often get something a little wrong. I forgot the trigger wheel when I put the cams in -- I was laughing so hard I was crying!! What a Homer Simpson moment that was.

Enjoy the dry engine now!

Chris

 

[snidehockey]

I thank you again, and all of the little animals of the neighborhood thank you for helping me prevent all of that great tasting, sweet smelling, lethal kool-aide coming out of my car each night!

and yeah 3 days and not a drop has been lost.