1995 850 GLT Coolant Leak passenger side After Repairs

[AlexBHughes]

A cracked block. I would make REAL SURE that coolant from the water pump is not running down there first.

If it were a cracked block, wouldnt it leak into something? I would have coolant in my oil or something?

[shaker_chi]

I would suggest pulling the reservoir off and setting it to the side, removing the timing cover and letting the engine run for about 15 minutes to get it good and hot. You need to get some pressure in the system. Also, do you hear any hissing or any noise of steam anywhere? Putting the reservoir tank to the side will give you a very clear shot. The aftermarket tanks are known to fail pretty quick, especially where the hose is attached at the bottom. Also, follow the hose to the block to make sure that's not leaking as well. Have you checked the bottom of the hose that comes from the top of the radiator? Maybe you have a leak there and it's running down the front of the engine?

[speedyt5]

Do you actually see coolant leaking from the passenger area? It could be a heater core and you just didn't check the carpet enough, actually pull the carpet back, pull the black plastic panel and actually look at the heater core.

[speedyt5]

Also a crack in the coolant bottle could cause this, as it expands it closes this, then the car sits, it cools, the crack opens and coolant leaks out. Always check the least complicated things first. Sounds like you need a new coolant bottle and cap, and to go from there.

[AlexBHughes]

Also a crack in the coolant bottle could cause this, as it expands it closes this, then the car sits, it cools, the crack opens and coolant leaks out. Always check the least complicated things first. Sounds like you need a new coolant bottle and cap, and to go from there.

I will double check the heater core symptoms, and the expansion tank. My windows don't fog and the heat doesn't smell like coolant. I've examined the tank so many times and I would be completely surprised if it was that.

I took it to a shop yesterday to do a pressure test, and it held pressure under 5,7,and 10, with no leaks. He also checked for CO in the coolant reservoir because if there was some then it would mean a bad head gasket, and fortunately that came out negative so i can rule out a bad HG. He mentioned that since i replaced the water pump, that maybe I didn't get every single bit of the old gasket off the motor when i replaced it with the new gasket and WP, thus leaving a small path for coolant o leak through the seal. Maybe that could be it? I took a razor to it and got off as much as i could when i did the job, but i know it wasn't all shiny and metal looking as if it were brand new(it almost seemed impossible to get it all off without digging into the metal of the motor where the seal lies!).

So i will check the coolant tank and go from there. I was looking on IPD and eEuroparts for a replacement cap, for a blue greenish one, and it doesn't say if the cheaper $5-7 cap is rated at the same pressure as the original. I just replaced the cap 1 month ago and asked if it was rated at the same pressure as the colored ones and the local store said yes. Maybe they didn't know or was just saying that?

[AlexBHughes]

I would suggest pulling the reservoir off and setting it to the side, removing the timing cover and letting the engine run for about 15 minutes to get it good and hot. You need to get some pressure in the system. Also, do you hear any hissing or any noise of steam anywhere? Putting the reservoir tank to the side will give you a very clear shot. The aftermarket tanks are known to fail pretty quick, especially where the hose is attached at the bottom. Also, follow the hose to the block to make sure that's not leaking as well. Have you checked the bottom of the hose that comes from the top of the radiator? Maybe you have a leak there and it's running down the front of the engine?

thanks for the response!

I will check those hoses under a pressurized system by letting it warm up. Ive checked the bottom reservoir tank hose where it connects to a metal fitting, and all is dry there. I've replaced the radiator and checked the hoses when doing so, and all seemed fine. I do not see or hear any hissing or steam noises from anywhere in the engine.

It is just an odd leak, it will leak every few days, and when it doesn't its the perfect cooling system! If you check out my response below to another comment about when i took it to get a pressure test, it will give you a little more info in helping me diagnose this pesky leak.

[jose456891]

Have you considered using Dry Ice?

This way you can pressurize the system without running the car. Then by removing all the noises of the engine, you could see/hear where the system is leaking.

If dry ice is not your fancy, the proper way is to use a hand pump for the cooling system. The idea is to pressurize it and see if pressure holds. And if it does not, listen for a hiss and/or look for leaks.

[AlexBHughes]

UPDATE #2!

Hello all,

As you read previously, its been a roller coaster of who, what, when, where, and why on this mysterious coolant leak. I was convinced i had left some old gasket on the block when i just did the water pump job. Before I was about to dig back into it again, I took it to Johns Auto Repair in Vancouver Wa and did one last pressure test on it. As we pressure tested at 15-17lbs, we noticed coolant where the head gasket was. CRAP. As we investigated further, we moved the upper radiator house out of the way to get a better look, and then all of the sudden PISSSSSSSSSSSSSSS!! Coolant was spraying and pissing out of the back of the lower thermostat housing. FOUND IT!

Now I have a thermostat housing job to complete. I know there is a gasket between the lower thermostat housing and the block, which im assuming is the origin of the leak. I got the gasket ordered, Some Ultra Grey for extra sealing power, and just sprayed some PB blaster on the bolts.

Is there any tips to making this a fairly easy job? I've read that some take the Pwer Steering Pump out, and some dont. Also, what tools would i need to do this? I know those crappy volvo torx bolts are a pain, so ill be sure not to strip them, and does anyone have the exact size of replacement bolts? Lastly, any advice on how to get the lower bolt out?

thanks!

[AlexBHughes]

UPDATE #3!

Al here again,

Dug into the car today, and i ended up moving the Power Steering pump out of the way. a few bolts for the casing, and three bolts behind the serpentine cog. I was able to get the top two bolts off easily, tried with the bottom and it was a pain in the ass! I tried to wiggle the housing a tad bit(very lightly!) and the the housing snapped!

Now I just ordered a new lower housing from IPD, and thankfully their warehouse here in Portland Oregon is just one bridge away from my house, so I will retrieve that part in the morning. Cleaned it all up and will put it all back together with the new lower T stat housing, new gasket, new bolts(not the torx bolts!) and everything should be in tip top shape.

Thanks for joining me in this journey everyone! Ill let you know if a new leak appears soon. haha

Alex