On a scale of 1-10 I am a 2 when it comes to working with engines. I've lived with the smell of burning coolant (sweet smell) for the last six months. I was going to visit a carbon fiber shop so I thought I would take the jaguar plastic engine covers to them as an example.

once I removed them (breaking one plastic insert in the process) I noticed the bottom front seal on the thermostat tower was warped.

I could see the coolant puddling under it, and when i nugged the radiator hose it would cause the seal to weep Rapidly. I went and showed it to a local mechanic who said I just needed to try using a rubberized sealant called "The Right Stuff" by Permatex. http://i56.tinypic.com/b5qs13.jpg

So I went about resealing it...

First off, I dont even know where the coolant plug is, and I was wary of having to figure out how to burp the system. My quick solution was to stick some vinyl hose (like a fridge water line) deep inside the overflow reservoir (1ft) and siphon all the coolant into a bucket.

Once it was drained I backed out the t-stat house bolts only to realize that I had ruined the built in brass thread inserts.


sorry for the large image

Under arrow B is the brass inserts. I obviously couldn't reuse them as they would not bite anymore.

I kept Hose (arrow C) pulled towars the radiator at all times to prevent it from dumpling the remaining coolant out.

Arrow A, is the bolts I elected to use. they are M6 1.0 pitch by 30mm long.

The weeping was coming from gap D. where the housing had warped a bit.


Once I had the bottom-front flange removed I put the permatex sealant around it, making channels running alongside where the screws would go.

I carefully snuck the part back into place and and set the bolts lossely to keep any movement from smearing my rubber sealant. Then I tightened them down as tight as I felt was safe. Maybe 20lbs, I dunno; don't own a torque wrench. I reset the coolant hose with a stainless clamp, and refilled with new coolant.

So far I have run the engine maybe 2hrs, and 50 miles. It did not hiccup (from not bleeding the airout)

Anyone care to wager how long this seal might last? the t-stat o ring is a bit stretched, but im not seeing/smelling any coolant puddles on the block like i had before.

 

Mod, i see my image broke the text layout, will you hyperlink it for me
http://i56.tinypic.com/vinq0p.jpg

I cannot edit my own posts

 

Don't they do these in aluminium now? They are a bad design, people have a nasty habit of overtightening them and spinning the brass ferrules, the same occurs with the cam/coil pack covers.

I dont have a tower anymore.......or thermostat....or water pump to mention it

 

yes, i've seen a million people say "replace it with the aluminum one."

but I didn't want to go that deep into fixing it.
Heck, i don't even know how to drain the coolant.
My leak really was only isolated to the front coolant inlet
(the one that secures the thermostat.)

I have a warranty, that already bought this plastic house.
so rather than pay 100$, and have several days without the car,
it looks like my fix worked for 10$

 

That looks like a god fix to me! Very creative! I don't see why it wouldn't last for years.

 

Only $70 for the aluminum kit, includes the t-stat and all 0-rings, just in case the leak doesn't hold or a crack forms somewhere not repairable.

we have a link in the FAQ thread at the top of this subsection, it has a description on how to properly drain and refill your coolant system. Lots of other good DIY articles there too...while your looking for other tasks to perform.

 

Well in my infinite wisdom I thought I could solve a tiny leak at the top of the house

Looks like I will be ordering the aluminum one come monday






p.s. the DIY seal on the front never failed. More than a year passed without a leak.

 

Well that was a good result on the first fix, Sam gets the prize for the best guess.