Coolant Leak @ output to heater core!

[beafraid8]

1996 3.8L n/a. There is an ouput on the upper manifold (passenger side) that feeds into an aluminum part (says "Made in Canada") that the heater-core hoses attach to. The little elbow that connects the manifold to this aluminum part is leaking where it enters the manifold. Is there an o-ring in there or something that has gone bad? Do I need to remove the water pump to get the aluminum piece (Made in Canada) off to get this elbow out?

[Aubie]

Hi Beafraid8,
Your leak may be from the Upper Bypass Hose connection that comes from the top of the water pump via a short hose, into the manifold. That piece that the short hose connects to in the manifold is often made of plastic and will crack or shear off right at the manifold leaving the rest of the threaded plastic portion in the manifold which can be a challange to remove and a metal one and an "O" ring is availeable from autozone and other sources. I say it MAY be your problem as the same did occure in my 1994 Bonneville 3800 N\A, I'm just not sure if there are similarities in a 1996 model. It requires the removal of the serpentine belt and the altenator which will then give access to that area. I hope this helps.
Aubie

[Aubie]

[quote=Aubie]Hi Beafraid8,
Your leak may be from the Upper Bypass Hose connection that comes from the top of the water pump via a short hose, into the manifold. That piece that the short hose connects to in the manifold is often made of plastic and will crack or shear off right at the manifold leaving the rest of the threaded plastic portion in the manifold which can be a challange to remove and a metal one and an "O" ring is availeable from autozone and other sources. I say it MAY be your problem as the same did occure in my 1994 Bonneville 3800 N\A, I'm just not sure if there are similarities in a 1996 model. It requires the removal of the serpentine belt and the altenator which will then give access to that area. I hope this helps.
Aubie
Update:
You may want to disregard my post as I misunderstood the location of your leak and responded to you for what seems to be an entirely different leaking manifold problem. My apologies.

[beafraid8]

Thanks, Aubie!! That certainly was the problem, took me forever to locate!! It's not threaded, either, it's just pressed into the manifold and tensioner housing with an O-ring on each side. I couldn't find the part at any parts stores, they all looked at me like I was crazy. The dealer didn't even know they make a metal one, so I bought another plastic one. If you have a part number or any leads on where I can get a metal one, please let me know! For now, I'll be replacing that plastic elbow every 20,000 or so...

[Aubie]

Hi Beafraid8,
Your very welcome! I am glad the information was of good use to you. As to a particular part number for your type of fitting I am sorry to say that I don't know of one. One may exist someplace and if anyone out there has a part number or where to locate a metal one please post it. As for mine that is a threaded type(3/4 pipe thread) I took the old parts in to Autozone and asked if they had anything like it that was metal and it turned out they did so I didn't have to use another plastic one. Sounds like for now your plan for a regular replacement schedual may be the best way to go. If at some time I do come across a metal part number I'll be sure and post it.
Aubie

[wzvhyz4gm]

Seeking advice for best method to perform replacement of a coolant leaking black plastic tube (about 5/8" OD) with a 90 degree elbow that's on passenger side one end inserted into the lower intake manifold and opposite end inserted into metal bracket that serpentine belt tensioner pulley is attached.

Thank you,

wzvhyz4gm

[beafraid8]

Originally Posted by wzvhyz4gm

Seeking advice for best method to perform replacement of a coolant leaking black plastic tube (about 5/8" OD) with a 90 degree elbow that's on passenger side one end inserted into the lower intake manifold and opposite end inserted into metal bracket that serpentine belt tensioner pulley is attached.

Thank you,

wzvhyz4gm

Pull off the alternator and bracket, the serpentine belt, and remove the tensioner. Then, simply pull the elbow out. Be careful not to push any pieces into the intake (ask me how I know!). A few pieces made it in there, but I just let 'em be. No sign of 'em when I replaced the upper intake plenum last summer. 2 hour job, piece o' cake! Get the part from the dealer...they know it well.