96 Lesabre Coolant Leak

After replacing the upper and lower maniflod gaskets, I discovered a crack at the heater bypass inlet on the front cover allowing coolant to leak at this point. Is there any fix for the problem other than replacing the cover? All of the coolant is leaking externally but will leak coolant out to that level while the vehicle is parked.

Did you replace the bypass elbow? If so, did you clean both inlets and lubricate the o-rings before installing the LIM, or tensioner. What front cover are you talking about?

The front timing cover. The heater bypass that is part of the tensioner is wher the leak is coming from.

Did you replace the elbow, which includes new O-rings?

Is the area of the leak?

http://img109.imageshack.us/img109/2044/dscn1126v.jpg

Yes, it is the fitting at the other end of the tensioner.

Is it the leaking fitting shown with the arrow pointing to it? If so, the seal (o-ring) is Part # 24502846
Engine Coolant By-Pass. Engine Fan Coolant. This is the same seal (o-ring) as used on the bypass elbow.
SEAL,DRV BELT TENSR(O-RING)(SEAL-0.799" ID,0.1.03 X-SECT DIA). Required: 01SEAL,DRV BELT TENSR(O-RING)(SEAL-0.799" ID,0.1.03 X-SECT DIA).

http://img838.imageshack.us/img838/4144/96tensioner.jpg

this was a very helpful post can you buy the elbow at the parts store or at a dealership.

I did replace this o-ring also. Where this goes into the front timing cover the fitting on the cover is cracked. Is there any fix for this other than replacing the cover?

this was a very helpful post can you buy the elbow at the parts store or at a dealership.Chick Here (http://www.automotiveforums.com/vbulletin/showthread.php?t=1073155) for a recent thread on this subject.

I did replace this o-ring also. Where this goes into the front timing cover the fitting on the cover is cracked. Is there any fix for this other than replacing the cover?If the cover is cracked, evidently the bore of the hole is now oversize. Unfortunately, the only alternative is to replace the cover.

For those who might be confused about the tensioner & elbow(s) I should mention that the 96-98 Lesabre tensioner has the lower elbow cast into the tensioner as shown in the pic above. 1999 & newer, use two plastic elbows (upper & lower) as shown by Clicking HERE (http://www.automotiveforums.com/vbulletin/showpost.php?p=6943919&postcount=5)

Looking at the drawing on the other post, on item 330 looking straight on to the timing cover the part that is cracked is on the part on the upper left corner. This is where the bypass on the tensioner attaches to the cover. Any fix for this?

Could try JB weld, worth a try.

That is all I could think of also.

Thanks

Keep in mind, when metal/aluminum cracks, it expands. If you were fortunate enough to successfully fill the crack with JB Weld, the bore will still be oversize. I hate doing the same job twice, or three times.