Here it is!! Pics, too!

I got it torn down far enough to remove the pipe that goes from the front of the engine, between the heads, to the water manifold at the rear of the engine. This single o-ring was the source of the leak that left a huge puddle of coolant on top of the block.
http://img.photobucket.com/albums/v380/surferfletch/pipegskt.jpg
At the rear of the engine you can see where the pipe connects to the water manifold.
http://img.photobucket.com/albums/v380/surferfletch/leakgask.jpg
I'm replacing all rubber coolant and fuel and vacuum hoses, and all gaskets that I can get to now...

what was the reason to do this?

http://img.photobucket.com/albums/v380/surferfletch/otherlk.jpg
Here is the end of the other metal coolant tube that runs along the top of the block. One end goes to the heater core, and the end you're looking at connects with one o-ring to the block just below the thermostat housing. The o-ring at the end of the tubes just crumbled in my fingers. I had a leak here, and these tubes are not accessible without removing the intake manifold, etc.... You can see the pool of coolant between the heads in the second picture.

I wonder if the 98+s have the same design.... If you have a '97 or older, I imagine this leak is imminent. This is not a fun repair.

I might add that Joel nailed the problem from the first post I made on the subject. Thanks!!

Thanks fletch! It's just one of those little tid-bits I picked up from the boards over the past few years :icon16: . Great pictures. Thanks for taking the time to post them. I've never been under the common chamber on a 1998+, but I believe they have the same coolant plumbing setup as 1993-1997. The T-stat housing is burried under the common chamber on the 1998+ as the throttle body aims out the front. Just changing out the T-stat on a 1998+ 3.2 requires lifting the common chamber and replacing the intake manifold gaskets (as they will probably crack anyway :banghead: ) No amount of PM work will help save these O-rings unfortunately. It looks like you are lucky to get 8yrs out of them. :disappoin

G/luck
Joel

Another request for advice... I went to Advance to get new hoses all around, but I ran into a problem. There is a heater core hose at the top of the water manifold at the back of the engine that makes a quick 90 degree turn to the passenger side. The new hose has a slightly thinner wall, and creases when I try to install it. Any tricks or suggestions on where I can get a thicker walled hose?

Fletch, I dunno if you have any nearby, but I'd try napa or carquest. If they don't have one, you could make up a 90deg bend with two lengths of quality bulk hose, and a brass elbow w/ hose barbs. The only thing I *might* buy from advance is oil/lubes/fluids. If I can't get whatever I need from napa or carquest, autozone is my 3rd try. As long as AZ reads OBDII codes for people, they will get my business as well!

G/luck

Did you try putting a little bit of oil on the fitting and inside the hose to make it go together easier. Maybe instead of oil, anti-freeze???

Stopped at NAPA on the way home. Gates Rubber premium 3/4" heater hose. Cheaper than the other stuff that folded, too. My buddy always suggests NAPA first, too. I'll learn....

Thanks again!

That folded, too. I'm going to order the preformed OEM hose. They were happy to send me a whopping $5 in parts, I'm sure they'll send me the $2 hose!

Yup. Much easier than trying to get something else to fit. I got the 2 hoses which come off the water manifold. They are both preformed. On in less than 2 minutes. I'd recommend ordering these parts if you plan on doing this job...

Good info! Thanks again for taking the time.

Joel

two an a half hours for this job its not bad if you have done it as many times as I have helpful hint if you did not do it smear RTV all around those O-rings and you will never replacce them again it also makes it much easier to install

Now I see the RTV suggestion! It's already back together... If I get another 140K out of these 2 o-rings, I'll be happy. It is going back together very quickly, but that's because I labeled every hose and bolt...

Got it all together and fired it up tonight! No coolant leaks. It smoked like a bastard, but I think that's old oil burning off the exhaust, not leaking oil from my new valve cover gaskets. Time will tell, I guess. I do have some sort of loud hiss coming from near the throttle body. It drives perfectly, but this definitely sounds like a vacuum leak. Timing belt and water pump this weekend...

surferfletch- Did you change the IMG's? From the pics you were right there. That could be you hiss.

I did change them. However, I didn't line up the lower intake properly the first time. I had to loosen the lower intake bolts and move the lower intake to get the long intake manifold bolts in. That may have moved something. Today the hiss is gone...
Thanks for helping!