Repair of Coolant Leak

92 PA Base
149,000 miles

I recently had the intake manifold gasket replaced by one mechanic and after paying the bill, driving off and arriving home, I discovered that coolant was still leaking. The mechanic wanted to charge additional money to repair what he should have repaired the first time. Claims he didn't know why it was still leaking and that he needed to go back in to the same area to look around. I refused.

I took the vehicle to a different mechanic who claimed that the reason why it was still leaking coolant was that the first mechanic didn't replace the coolant hose on the passenger side of the engine located above and behind the water pump. I paid the second mechanic to do the work. A few weeks past and I noticed the coolant in the reservoir was low, and so I replenished it. A few additional weeks past and I had to add coolant a few more times. I took it back to the second mechanic who conducted a pressure test and he found no coolant puddles on the shop floor. He comes out and says the pressure test is holding at 18 lbs and there are no puddles. I asked why am I having to constantly add coolant, he replied, 'Don't know'. I stated that if its not coming out then its going into the engine and asked him if this was possible. He replied yes. I asked him when he replaced the coolant hose did he had to remove the intake manifold and he said no, he replaced it from the side.

My question; is it possible to replace the hose from the side or does the intake manifold have to be removed? If it can be changed from the side can someone please tell me the labor time for replacing that hose.

Thanks in advance; I really appreciate you all for your valued knowledge and advice.

Zeddy

I assume this is the 3.8 and the "hose" on the side is the coolant elbows. The elbows are easily changed from the side. I've replaced mine 3 times (once because they were leaking, a second time because I thought they were still leaking but it turned out to be my water pump, and the 3rd time because one actually completely split.)

The third time I replaced mine with the newer Dorman aluminum elbows on the market and I did so in a gas station parking lot with only a few hand tools. A good mechanic can have the job done in well under an hour.

As for your leak it is possible that the water pump is your issue. The system may hold pressure fine, but if the water pump is failing it will seep fluid out of the weep hole. You could actually test the water pump by loosening the belt via the tensioner to get it off the pump pulley, then grab the pulley and test for play. If there is play in the pump then that is your issue.

@ Stealthee

Mechanic kept it for a couple days and found no puddles and he stated that it held a pressure test of 19 lbs. He appeared to be baffled because he can't believe that since it's holding pressure and there's no fluid leaking anywhere, how can the car be losing coolant. He checked the water pump and it was fine. Told me to bring it back in if the coolant falls below a certain level.

Thanks for responding.