Coolant leak?

[Kevster324]

My 2001 Windstar started leaking coolant over the weekend (yeah - Merry Christmas, right?) Anyway, I smelled coolant very strongly when I got out of the van. Looked under the hood, but found no obvious leaks. Smoke coming from back side of engine (most noticeably on passenger side.)

Heard a "whistling" sound in back of engine on passenger side also. When I loosened the cap on the reservoir, the "whistling" stopped.

Any ideas, folks?

[pitteach]

Check the metal tubes coming off the top of the water pump and the intake. These are about 1" diameter and hook up to the heater hoses in the fire wall. Mine on my 2000 just let loose last week-no surprise-They looked like they were rusting out. There are brackets welded to the tube and that's where mine started to leak. Coolant smell was very strong in the van because the leak was right next to the heater fan inlet. THe whistling you heard was probably a pin hole leak from the tube. When you opened the cap, you depressurized the system so the leak was not as bad.
I replaced the tube off the top of the water pump- it "plugs" into the top of the pump with an o-ring, and is held down with a set screw at the pump. You could remove the cowl to get a better look to see where the leak is coming from- not difficult- just take your time. Let me know what you find, and if it is the tube off the pump, I have a few tips that I learned the hard way! Good luck.

[Kevster324]

Thanks. I will take a look and let you know my findings. You've been a big help so far.

[Kevster324]

OK, here's what I've got. I did a pressure test today and had coolant squirting out under the manifold. Is it possible that the manifold itself is cracked or does it sound like a blown gasket?

[pitteach]

Hard to say. I haven't heard of the manifold cracking, but I guess anything is possible. Can you actually see where the coolant is coming from? I would take the cowling off and get a mirror to get a good look at the back of the motor if that's where the coolant is coming out.

[Kevster324]

Not sure exactly where the coolant is coming from. Just wondering if there is a hose under the manifold. Haven't used a mirror yet. Will be tearing the motor down in a day or so to see what's up.

[SlimJimRD]

I had the same problem about 2 weeks ago. Mine is on a 1999 with 3.8L, not sure what you have. There is a metal tube that runs under the upper plastic intake manifold and above the lower Aluminum intake manifold. This metal pipe tends to leak.
What year and motor do you have?

[Kevster324]

I have a 2001 with the 3.8. Is the tube you are referring to on the driver's side? That is where my leak is. And the leak is coming from the same area you referred to.

[SlimJimRD]

If you work on cars this is a fairly easy job. Look here for comments on how hard the work was. This is for code 171/174 fix but the work to get to the pipe to change it is the same.
http://www.automotiveforums.com/vbul...d.php?t=589239
IMO you should remove the wiper motor assembly so that you can easily get to the back of the upper intake. Once you have the upper plastic intake manifold off you can take the two bolts that hold the metal pipe in place. I had to pry the tube up out of the lower intake manifold. the new one from Ford then will go in fairly easily. Here is a good site with pictures that will help as well.
http://leckemby.net/windstar/windstar01.html
Because I took off the wiper assembly and everything was exposed I went ahead and replaced all the heater and radiator hoses. Good thing as I could see where coolant was starting to leak around the factory clamps. Found I had to go to CarQuest not Autozone to get the right hoses for mine with rear heat and air. Took a couple trips and looking in the paperbook not computer to get them. I also cleaned the EGR holes per lockemby. Then because of all the code 171/174 issues in the forums I went ahead and replaced the isolator bolts and upper plastic intake gaskets (from Ford) as well so that I should not have a problem in the future and then need to take apart everything all over again. Because I have >90k I changed the plugs and wires while the intake and wiper assemble were out of the way. I did not change the valve cover because it looks like I can replace later if necessary without taking the manifold off.
One thing I did not do but of course but thought I should do is stuff rags into the lower intake manifold before removing the bottom half of the plastic intake. Of course I dropped one of the isolator bolts down into the intake and it took forever to fish it out. the rags also keep junk out while cleaning the EGR ports.
Good Luck
Steve

[SlimJimRD]

Oh I forgot to answer your question. The leak was just above the radiator hose and below the throttle body. It was very hard to see the leak and I found it by using paper towels to dry the area and then see if the leak is above the lower metal intake and to the passenger side of the upper radiator hose. I would think your leak is this metal tube as well. The Ford parts person knew right away what I was talking about when I called them. Of course they had it in stock.

[SlimJimRD]

I was going to try and put a picture of the pipe in here but it is easier just to have you look at http://leckemby.net/windstar/windstar01.html and go to the picture just above EGR ports exposed. The leak should be from the metal pipe that runs left to right between the intake holes. The o-ring side is on the right where you said the leak is coming from. I could only see the vertical part of the pipe when I was looking for the leak.

[Kevster324]

OK. So it's the tube in the center (black) that goes down into the manifold at a 90 degree angle?

[SlimJimRD]

That is correct.

[Kevster324]

OK, gents. Thanks for all the help. The leak was, in fact, the crossover tube mentioned by SlimJim. Took about 3 hours, and I'm an amateur. Also changed those isolator bolts to the new green ones, and all is well.

Thanks again!

[road_rascal]

Geeze- I'm wondering if this tube should be replaced as a precautionary move if one was going to do the isolator bolt job. I'm replacing those and the port seals this week once the shipment of parts comes in. How much was that metal coolant tube?