MR2 Roadster Owners Club

The Workshop => Maintenance, Problems & Troubleshooting => Topic started by: Call the midlife! on October 15, 2020, 16:58

Title: Non standard coolant leak.
Post by: Call the midlife! on October 15, 2020, 16:58
Yesterday I noticed a small pool of coolant where I'd had the Crisis parked for half a day, before anyone starts to go down the radiator route I know it's not that.
The wet patch was in the centre rear of the car, I'd previously been refitting my big mushroom air intake so thought I'd maybe pulled one of the hoses from the expansion tank.
Ran it for a while today but couldn't see any drips so left it to see what happened over the day and sure enough a puddle on the garage floor.
It's dripping off the front of the sump.
So...
Either one of the main hoses is leaking, the throttle body feeds or the pipe on the front of the block.
I pondered the thermostat housing but the needle had barely moved and yesterday it was just start up, reverse out of the garage and park at the side.
So unless I can see from lying underneath and rectify it the problem child will be parked up until the planned engine drop later in the year/next year.
Title: Re: Non standard coolant leak.
Post by: Carolyn on October 15, 2020, 17:42
Quote from: Call the midlife! on October 15, 2020, 16:58Yesterday I noticed a small pool of coolant where I'd had the Crisis parked for half a day, before anyone starts to go down the radiator route I know it's not that.
The wet patch was in the centre rear of the car, I'd previously been refitting my big mushroom air intake so thought I'd maybe pulled one of the hoses from the expansion tank.
Ran it for a while today but couldn't see any drips so left it to see what happened over the day and sure enough a puddle on the garage floor.
It's dripping off the front of the sump.
So...
Either one of the main hoses is leaking, the throttle body feeds or the pipe on the front of the block.
I pondered the thermostat housing but the needle had barely moved and yesterday it was just start up, reverse out of the garage and park at the side.
So unless I can see from lying underneath and rectify it the problem child will be parked up until the planned engine drop later in the year/next year.
Almost certainly the water pump.
Title: Re: Non standard coolant leak.
Post by: Call the midlife! on October 15, 2020, 17:57
Quote from: Carolyn on October 15, 2020, 17:42
Quote from: Call the midlife! on October 15, 2020, 16:58Yesterday I noticed a small pool of coolant where I'd had the Crisis parked for half a day, before anyone starts to go down the radiator route I know it's not that.
The wet patch was in the centre rear of the car, I'd previously been refitting my big mushroom air intake so thought I'd maybe pulled one of the hoses from the expansion tank.
Ran it for a while today but couldn't see any drips so left it to see what happened over the day and sure enough a puddle on the garage floor.
It's dripping off the front of the sump.
So...
Either one of the main hoses is leaking, the throttle body feeds or the pipe on the front of the block.
I pondered the thermostat housing but the needle had barely moved and yesterday it was just start up, reverse out of the garage and park at the side.
So unless I can see from lying underneath and rectify it the problem child will be parked up until the planned engine drop later in the year/next year.
Almost certainly the water pump.
I considered that but it's dripping from the car front side of the sump rather than the engine front, I sort of imagined the water pump would drip pretty much off the chain cover?

Either way if it's the water pump it's definitely not getting done until the engine comes out 😆.
Title: Re: Non standard coolant leak.
Post by: Carolyn on October 15, 2020, 18:05
Quote from: Call the midlife! on October 15, 2020, 17:57
Quote from: Carolyn on October 15, 2020, 17:42
Quote from: Call the midlife! on October 15, 2020, 16:58Yesterday I noticed a small pool of coolant where I'd had the Crisis parked for half a day, before anyone starts to go down the radiator route I know it's not that.
The wet patch was in the centre rear of the car, I'd previously been refitting my big mushroom air intake so thought I'd maybe pulled one of the hoses from the expansion tank.
Ran it for a while today but couldn't see any drips so left it to see what happened over the day and sure enough a puddle on the garage floor.
It's dripping off the front of the sump.
So...
Either one of the main hoses is leaking, the throttle body feeds or the pipe on the front of the block.
I pondered the thermostat housing but the needle had barely moved and yesterday it was just start up, reverse out of the garage and park at the side.
So unless I can see from lying underneath and rectify it the problem child will be parked up until the planned engine drop later in the year/next year.
Almost certainly the water pump.
I considered that but it's dripping from the car front side of the sump rather than the engine front, I sort of imagined the water pump would drip pretty much off the chain cover?

Either way if it's the water pump it's definitely not getting done until the engine comes out 😆.
It tends to run down the timing cover and around the lip of the sump...
Title: Re: Non standard coolant leak.
Post by: Call the midlife! on October 15, 2020, 18:19
Quote from: Carolyn on October 15, 2020, 18:05
Quote from: Call the midlife! on October 15, 2020, 17:57
Quote from: Carolyn on October 15, 2020, 17:42
Quote from: Call the midlife! on October 15, 2020, 16:58Yesterday I noticed a small pool of coolant where I'd had the Crisis parked for half a day, before anyone starts to go down the radiator route I know it's not that.
The wet patch was in the centre rear of the car, I'd previously been refitting my big mushroom air intake so thought I'd maybe pulled one of the hoses from the expansion tank.
Ran it for a while today but couldn't see any drips so left it to see what happened over the day and sure enough a puddle on the garage floor.
It's dripping off the front of the sump.
So...
Either one of the main hoses is leaking, the throttle body feeds or the pipe on the front of the block.
I pondered the thermostat housing but the needle had barely moved and yesterday it was just start up, reverse out of the garage and park at the side.
So unless I can see from lying underneath and rectify it the problem child will be parked up until the planned engine drop later in the year/next year.
Almost certainly the water pump.
I considered that but it's dripping from the car front side of the sump rather than the engine front, I sort of imagined the water pump would drip pretty much off the chain cover?

Either way if it's the water pump it's definitely not getting done until the engine comes out 😆.
It tends to run down the timing cover and around the lip of the sump...
I'll have a feel around tomorrow, everything was wet from being out in the rain the last couple of days so see what tomorrow says. Cheers for that.👍🏻
Title: Re: Non standard coolant leak.
Post by: Joesson on October 15, 2020, 18:50
@Call the midlife!
Probably 4o years ago I pointed out to a then neighbour what I thought might be a coolant leak from his car. " Oh, that's the air con" (condensation from) says he. Not as common then as now and I don't know where all the air con bits are on a 2 but just saying.
Title: Re: Non standard coolant leak.
Post by: Call the midlife! on October 15, 2020, 18:53
Quote from: Joesson on October 15, 2020, 18:50@Call the midlife!
Probably 4o years ago I pointed out to a then neighbour what I thought might be a coolant leak from his car. " Oh, that's the air con" (condensation from) says he. Not as common then as now and I don't know where all the air con bits are on a 2 but just saying.
Unless I've been driving it for 3 years and stripped it twice without realising, it's definitely not aircon related 😆
Title: Re: Non standard coolant leak.
Post by: Joesson on October 15, 2020, 19:13
Quote from: Call the midlife! on October 15, 2020, 18:53
Quote from: Joesson on October 15, 2020, 18:50@Call the midlife!
Probably 4o years ago I pointed out to a then neighbour what I thought might be a coolant leak from his car. " Oh, that's the air con" (condensation from) says he. Not as common then as now and I don't know where all the air con bits are on a 2 but just saying.
Unless I've been driving it for 3 years and stripped it twice without realising, it's definitely not aircon related 😆

So you must have the light weight variant.
Title: Re: Non standard coolant leak.
Post by: Bossworld on October 15, 2020, 21:11
I've still got the main big four hoses from when I swapped to silicone ones (yes I'm still not sure why I did that).  Shout if it transpires you need them.
Title: Re: Non standard coolant leak.
Post by: Call the midlife! on October 15, 2020, 21:57
Quote from: Bossworld on October 15, 2020, 21:11I've still got the main big four hoses from when I swapped to silicone ones (yes I'm still not sure why I did that).  Shout if it transpires you need them.
Thanks for that, appreciated, I'm semi confident it's engine/auxiliary related though.

Not sure what exactly and the water pump was brand new on the rebuild I'm sure, so why it's decided to start leaking when it's hardly been driven since getting back from Wales is beyond me.
Probably just feeling left out as I've been spending time working on the new bus...😆
Title: Re: Non standard coolant leak.
Post by: jonbill on October 16, 2020, 09:02
thermostat housing and oil filter heat exchanger are both in the right area for this. I think it'll be obvious when you get under and have a look
Title: Re: Non standard coolant leak.
Post by: AdamR28 on October 16, 2020, 09:15
And if not, a bottle of UV dye and a torch (cheap on ebay etc as a kit) will make a dead easy job of identifying.
Title: Re: Non standard coolant leak.
Post by: Call the midlife! on October 16, 2020, 09:15
Quote from: jonbill on October 16, 2020, 09:02thermostat housing and oil filter heat exchanger are both in the right area for this. I think it'll be obvious when you get under and have a look
Aye, it's weird that it's just decided to do it, whatever it is, I don't remember it losing any coolant on the 800 miles or so around Wales.
Title: Re: Non standard coolant leak.
Post by: Call the midlife! on October 16, 2020, 09:20
Quote from: AdamR28 on October 16, 2020, 09:15And if not, a bottle of UV dye and a torch (cheap on ebay etc as a kit) will make a dead easy job of identifying.
The amount that's dripping out over a relatively short space of time I'm imagining it'll be fairly easy to see, if it's somewhere it can be seen.

But I've got some outdoor electrical work to fettle today so I'll not be spending much time on it other than a quick check to see how big the puddle is.
Title: Re: Non standard coolant leak.
Post by: Joesson on October 16, 2020, 11:46
May or may (likely) not be relevant but my 2002 before my ownership, when serviced by Mr T the service reports referred to " leak from water pump".
Early in my ownership similar reports from Mr T but no rectification work ever done.
In past 5 years, diy service, no sign of water pump leak.

Title: Re: Non standard coolant leak.
Post by: Call the midlife! on October 16, 2020, 12:20
No major puddle this morning so it would tally with it only leaking while under pressure.
Title: Re: Non standard coolant leak.
Post by: Dev on October 19, 2020, 19:00
Quote from: Joesson on October 16, 2020, 11:46May or may (likely) not be relevant but my 2002 before my ownership, when serviced by Mr T the service reports referred to " leak from water pump".
Early in my ownership similar reports from Mr T but no rectification work ever done.
In past 5 years, diy service, no sign of water pump leak.



 I do not know if this is relevant but I know an owner that had his MR-S sit for an extended amount of time and it showed faint signs of dried up pink coolant that ran the path of where it would leak.  He wanted to address the water pump but I told him to hold off and I cleaned off the area to see if it would come back.
 Its been over four years and no leak.
 Its possible that the seals shrink letting little though if it has been sitting for an extended amount of time but soon as it gets some heat and lubricant from the coolant it swells back up.
Title: Re: Non standard coolant leak.
Post by: Call the midlife! on October 19, 2020, 19:09
Quote from: Dev on October 19, 2020, 19:00
Quote from: Joesson on October 16, 2020, 11:46May or may (likely) not be relevant but my 2002 before my ownership, when serviced by Mr T the service reports referred to " leak from water pump".
Early in my ownership similar reports from Mr T but no rectification work ever done.
In past 5 years, diy service, no sign of water pump leak.



 I do not know if this is relevant but I know an owner that had his MR-S sit for an extended amount of time and it showed faint signs of dried up pink coolant that ran the path of where it would leak.  He wanted to address the water pump but I told him to hold off and I cleaned off the area to see if it would come back.
 Its been over four years and no leak.
 Its possible that the seals shrink letting little though if it has been sitting for an extended amount of time but soon as it gets some heat and lubricant from the coolant it swells back up.
I'll keep that in mind when I start to investigate it but it seems to be leaking while just sitting there too. I've put a bowl under the sump just to save making a puddle on the floor until I can look properly at the weekend.
Title: Re: Non standard coolant leak.
Post by: Dev on October 19, 2020, 19:57
Quote from: Call the midlife! on October 19, 2020, 19:09
Quote from: Dev on October 19, 2020, 19:00
Quote from: Joesson on October 16, 2020, 11:46May or may (likely) not be relevant but my 2002 before my ownership, when serviced by Mr T the service reports referred to " leak from water pump".
Early in my ownership similar reports from Mr T but no rectification work ever done.
In past 5 years, diy service, no sign of water pump leak.



 I do not know if this is relevant but I know an owner that had his MR-S sit for an extended amount of time and it showed faint signs of dried up pink coolant that ran the path of where it would leak.  He wanted to address the water pump but I told him to hold off and I cleaned off the area to see if it would come back.
 Its been over four years and no leak.
 Its possible that the seals shrink letting little though if it has been sitting for an extended amount of time but soon as it gets some heat and lubricant from the coolant it swells back up.
I'll keep that in mind when I start to investigate it but it seems to be leaking while just sitting there too. I've put a bowl under the sump just to save making a puddle on the floor until I can look properly at the weekend.

 I would consider that a significant leak that only a new water pump would solve but for sure an investigation is necessary to know exactly where its coming from because the origin can be deceiving. If the car I mentioned had a leak that size  with enough coolant to create a small puddle we would have replaced the water pump once we could determine the source. 
 Good luck with the investigation. I usually use dry paper towels after I clean the surface to find the leak or a light coat of powder if its hard to see.
Title: Re: Non standard coolant leak.
Post by: Joesson on October 19, 2020, 20:46
Quote from: Dev on October 19, 2020, 19:00
Quote from: Joesson on October 16, 2020, 11:46May or may (likely) not be relevant but my 2002 before my ownership, when serviced by Mr T the service reports referred to " leak from water pump".
Early in my ownership similar reports from Mr T but no rectification work ever done.
In past 5 years, diy service, no sign of water pump leak.



 I do not know if this is relevant but I know an owner that had his MR-S sit for an extended amount of time and it showed faint signs of dried up pink coolant that ran the path of where it would leak.  He wanted to address the water pump but I told him to hold off and I cleaned off the area to see if it would come back.
 Its been over four years and no leak.
 Its possible that the seals shrink letting little though if it has been sitting for an extended amount of time but soon as it gets some heat and lubricant from the coolant it swells back up.

That sounds plausible, the reports of mine "leaking" were from different Toyota garages some years apart.
Title: Re: Non standard coolant leak.
Post by: Call the midlife! on October 24, 2020, 14:09
Early indications suggest it's not the pump..
Need to see if there's anything above that could be trailing down onto it too.
Title: Re: Non standard coolant leak.
Post by: Carolyn on October 24, 2020, 14:38
Quote from: Call the midlife! on October 24, 2020, 14:09Early indications suggest it's not the pump..
Need to see if there's anything above that could be trailing down onto it too.
You've found it.  Strange one - considering how the gasket fits around the thermostat.
Title: Re: Non standard coolant leak.
Post by: Call the midlife! on October 24, 2020, 14:57
Quote from: Carolyn on October 24, 2020, 14:38
Quote from: Call the midlife! on October 24, 2020, 14:09Early indications suggest it's not the pump..
Need to see if there's anything above that could be trailing down onto it too.
You've found it.  Strange one - considering how the gasket fits around the thermostat.
Indeed, considering how many miles I've done since installing it and the nuts are plenty tight.

Thinking about fitting a new flange for what they cost, just in case there's a crack in it that I can't see in situ.
As the flange has to come off to fit a new gasket/o ring anyway.
Title: Re: Non standard coolant leak.
Post by: Carolyn on October 24, 2020, 15:17
Quote from: Call the midlife! on October 24, 2020, 14:57
Quote from: Carolyn on October 24, 2020, 14:38
Quote from: Call the midlife! on October 24, 2020, 14:09Early indications suggest it's not the pump..
Need to see if there's anything above that could be trailing down onto it too.
You've found it.  Strange one - considering how the gasket fits around the thermostat.
Indeed, considering how many miles I've done since installing it and the nuts are plenty tight.

Thinking about fitting a new flange for what they cost, just in case there's a crack in it that I can't see in situ.
As the flange has to come off to fit a new gasket/o ring anyway.
I'll see if I've got a plastic bit in my pile....
Title: Re: Non standard coolant leak.
Post by: Call the midlife! on October 24, 2020, 15:18
There's also a strong chance of it getting a smear of Dirko grey and shoved back on as is for the time being..
Title: Re: Non standard coolant leak.
Post by: Carolyn on October 24, 2020, 15:35
Quote from: Call the midlife! on October 24, 2020, 15:18There's also a strong chance of it getting a smear of Dirko grey and shoved back on as is for the time being..

I've found a plastic bit - and I bet I've got a good gasket.  By the time you've unbolted it - might as well do it properly?
Title: Re: Non standard coolant leak.
Post by: Call the midlife! on October 24, 2020, 16:10
Quote from: Carolyn on October 24, 2020, 15:35
Quote from: Call the midlife! on October 24, 2020, 15:18There's also a strong chance of it getting a smear of Dirko grey and shoved back on as is for the time being..

I've found a plastic bit - and I bet I've got a good gasket.  By the time you've unbolted it - might as well do it properly?
Without a doubt, I was just imagining your expression reading the Dirko bodge..😃

I can get new for around £12 or see what you have for donations but there's no massive rush, I'm off work next week so would be doing it at a convenient point.
Title: Re: Non standard coolant leak.
Post by: Carolyn on October 24, 2020, 16:26
Quote from: Call the midlife! on October 24, 2020, 16:10
Quote from: Carolyn on October 24, 2020, 15:35
Quote from: Call the midlife! on October 24, 2020, 15:18There's also a strong chance of it getting a smear of Dirko grey and shoved back on as is for the time being..

I've found a plastic bit - and I bet I've got a good gasket.  By the time you've unbolted it - might as well do it properly?
Without a doubt, I was just imagining your expression reading the Dirko bodge..😃

I can get new for around £12 or see what you have for donations but there's no massive rush, I'm off work next week so would be doing it at a convenient point.

I've got a couple of gaskets as well, so no bother to send you the bits... 
Title: Re: Non standard coolant leak.
Post by: Call the midlife! on October 24, 2020, 17:01
Quote from: Carolyn on October 24, 2020, 16:26
Quote from: Call the midlife! on October 24, 2020, 16:10
Quote from: Carolyn on October 24, 2020, 15:35
Quote from: Call the midlife! on October 24, 2020, 15:18There's also a strong chance of it getting a smear of Dirko grey and shoved back on as is for the time being..

I've found a plastic bit - and I bet I've got a good gasket.  By the time you've unbolted it - might as well do it properly?
Without a doubt, I was just imagining your expression reading the Dirko bodge..😃

I can get new for around £12 or see what you have for donations but there's no massive rush, I'm off work next week so would be doing it at a convenient point.

I've got a couple of gaskets as well, so no bother to send you the bits... 

I'll pm you my address again with thanks in abundance..👍🏻
Title: Re: Non standard coolant leak.
Post by: Call the midlife! on October 29, 2020, 15:25
Had time to look at the leaking flange today, total pain of a job lying on my back in a puddle of coolant...
See attached photos for the part causing the leak, no ideas what caused it to do what it did, it was fitted new at the rebuild and only had OAT through it so bit of a weird one.
Compared to the new seal @Carolyn kindly sent me, together with a spare flange just in case, the failed one seems slightly larger and softer.
Just in the process of refilling and then bleeding but no standing leaks it seems.
Title: Re: Non standard coolant leak.
Post by: Carolyn on October 29, 2020, 15:46
That's weird. Looks like some sort of contamination...
Title: Re: Non standard coolant leak.
Post by: Call the midlife! on October 29, 2020, 15:53
Quote from: Carolyn on October 29, 2020, 15:46That's weird. Looks like some sort of contamination...
All I can think is maybe some residue from cleaning the mating surfaces with brake cleaner at the time of rebuild.

It's academic as well as it's still bloody weeping from the flange so I've given in for today.
I'll maybe try the flange you sent tomorrow, when I saw the state of the seal I chose the path of least resistance as I couldn't get the hose clip undone and I'm soaked to the skin in coolant so need to get cleaned and dry now.
Title: Re: Non standard coolant leak.
Post by: Carolyn on October 29, 2020, 15:59
Yes -it's a bloody pain of a job at the best of times. I feel your pain.

When you next get it apart - check the sealing surface on the block, especially where the seal actually sits.   Also, I meant to remind you to make sure the actual thermostat is the right way up - small hole to the top.
Title: Re: Non standard coolant leak.
Post by: Call the midlife! on October 29, 2020, 16:17
Have you been looking at my internet search history?? 😆 I had to Google it to check where the little valve went, there's every chance it might not have been the right way up previously.
I ran my finger round the port while I had the stat out and all felt as I expected it to but without a scope of any kind I can't see it directly, tried with my mirror on a stick but it's too big and clumsy.
I've a feeling it's going to stay as it is now until the engine comes out again, wrecked my neck trying to get it done today, unless the boy has a look at it at some point but I'm not sure it's worth the effort in the long run.
Title: Re: Non standard coolant leak.
Post by: Joesson on October 29, 2020, 17:12
Quote from: Call the midlife! on October 29, 2020, 15:53
Quote from: Carolyn on October 29, 2020, 15:46That's weird. Looks like some sort of contamination...
All I can think is maybe some residue from cleaning the mating surfaces with brake cleaner at the time of rebuild.

It's academic as well as it's still bloody weeping from the flange so I've given in for today.
I'll maybe try the flange you sent tomorrow, when I saw the state of the seal I chose the path of least resistance as I couldn't get the hose clip undone and I'm soaked to the skin in coolant so need to get cleaned and dry now.

You could be right there :

Chlorinated brake cleaner containing tetrachloroethylene will on exposure to high temperatures (above 500 °F (260 °C)) or strong UV light decompose into phosgene and hydrogen chloride, both of which are dangerous when inhaled. Rubber and some types of plastics are decomposed by brake cleaners by removing binding components.
Wikipedia
Title: Re: Non standard coolant leak.
Post by: Call the midlife! on October 29, 2020, 17:52
Quote from: Joesson on October 29, 2020, 17:12
Quote from: Call the midlife! on October 29, 2020, 15:53
Quote from: Carolyn on October 29, 2020, 15:46That's weird. Looks like some sort of contamination...
All I can think is maybe some residue from cleaning the mating surfaces with brake cleaner at the time of rebuild.

It's academic as well as it's still bloody weeping from the flange so I've given in for today.
I'll maybe try the flange you sent tomorrow, when I saw the state of the seal I chose the path of least resistance as I couldn't get the hose clip undone and I'm soaked to the skin in coolant so need to get cleaned and dry now.

You could be right there :

Chlorinated brake cleaner containing tetrachloroethylene will on exposure to high temperatures (above 500 °F (260 °C)) or strong UV light decompose into phosgene and hydrogen chloride, both of which are dangerous when inhaled. Rubber and some types of plastics are decomposed by brake cleaners by removing binding components.
Wikipedia
I'll have a look at the ingredients but it doesn't really get that hot or sunny under the lid 😆

The fact it was still weeping with the new seal doesn't fill me with confidence either, see how my neck and abs are feeling in the morning and I'll maybe have another go at it.
Title: Re: Non standard coolant leak.
Post by: Joesson on October 29, 2020, 18:03
Quote from: Call the midlife! on October 29, 2020, 17:52
Quote from: Joesson on October 29, 2020, 17:12
Quote from: Call the midlife! on October 29, 2020, 15:53
Quote from: Carolyn on October 29, 2020, 15:46That's weird. Looks like some sort of contamination...
All I can think is maybe some residue from cleaning the mating surfaces with brake cleaner at the time of rebuild.

It's academic as well as it's still bloody weeping from the flange so I've given in for today.
I'll maybe try the flange you sent tomorrow, when I saw the state of the seal I chose the path of least resistance as I couldn't get the hose clip undone and I'm soaked to the skin in coolant so need to get cleaned and dry now.

You could be right there :

Chlorinated brake cleaner containing tetrachloroethylene will on exposure to high temperatures (above 500 °F (260 °C)) or strong UV light decompose into phosgene and hydrogen chloride, both of which are dangerous when inhaled. Rubber and some types of plastics are decomposed by brake cleaners by removing binding components.
Wikipedia
I'll have a look at the ingredients but it doesn't really get that hot or sunny under the lid 😆

The fact it was still weeping with the new seal doesn't fill me with confidence either, see how my neck and abs are feeling in the morning and I'll maybe have another go at it.
My understanding is that heat is required to "decompose" into gases. The tetrachloride would act on rubber in its liquid form. Not that this helps directly but it may help with understanding what went wrong.
Title: Re: Non standard coolant leak.
Post by: Call the midlife! on October 29, 2020, 18:26
Quote from: Joesson on October 29, 2020, 18:03
Quote from: Call the midlife! on October 29, 2020, 17:52
Quote from: Joesson on October 29, 2020, 17:12
Quote from: Call the midlife! on October 29, 2020, 15:53
Quote from: Carolyn on October 29, 2020, 15:46That's weird. Looks like some sort of contamination...
All I can think is maybe some residue from cleaning the mating surfaces with brake cleaner at the time of rebuild.

It's academic as well as it's still bloody weeping from the flange so I've given in for today.
I'll maybe try the flange you sent tomorrow, when I saw the state of the seal I chose the path of least resistance as I couldn't get the hose clip undone and I'm soaked to the skin in coolant so need to get cleaned and dry now.

You could be right there :

Chlorinated brake cleaner containing tetrachloroethylene will on exposure to high temperatures (above 500 °F (260 °C)) or strong UV light decompose into phosgene and hydrogen chloride, both of which are dangerous when inhaled. Rubber and some types of plastics are decomposed by brake cleaners by removing binding components.
Wikipedia
I'll have a look at the ingredients but it doesn't really get that hot or sunny under the lid 😆

The fact it was still weeping with the new seal doesn't fill me with confidence either, see how my neck and abs are feeling in the morning and I'll maybe have another go at it.
My understanding is that heat is required to "decompose" into gases. The tetrachloride would act on rubber in its liquid form. Not that this helps directly but it may help with understanding what went wrong.
I use the big cans of stuff from Boyeseseseseseseses as it's about £3/can and evaporates quite quickly and I'm sure the block was stood for days before the stat and flange went on but it's an avenue to go down before the next rebuild.
Title: Re: Non standard coolant leak.
Post by: Call the midlife! on October 31, 2020, 15:53
Swapped the flanges over today for the one replacement one, even though the original is flat and true and shows no signs of damage.
Made sure the stat was the right way up and the seal sat nicely seated, nipped the replacement flange up and replaced the pipe, after half an hour of wrestling with the spring clip.
Still leaking...
Title: Re: Non standard coolant leak.
Post by: Carolyn on October 31, 2020, 16:03
Then, perhaps it isn't coming from the thermostat gasket - but from above, where the fill/bypass pipe fastens to the top of the housing.

It is immediately above the thermostat and a leak may well find its way round the plastic and drip off the bottom?

Time to pull the engine and do all the jobs needed?
Title: Re: Non standard coolant leak.
Post by: Call the midlife! on October 31, 2020, 16:15
I considered that but can't feel any wetness above the housing when it's dripping and no dripping when the housing was off and the pipe clamped and I'd dried everything off.
The original seal being damaged also pointed to the leak coming from the housing.
I'm sure I can see the housing flex against the engine if I manipulate it and weirdly the more I tighten the screws the more the coolant leaks out.
I'm getting better at working on it though, developing a fairly good technique 😆
My neck muscles aren't happy though.
Title: Re: Non standard coolant leak.
Post by: Call the midlife! on October 31, 2020, 16:40
Just thinking back to the bypass pipe, the coolant diverts through that until the stat opens up at temperature if I'm thinking rightly?
So once it's drained down there wouldn't be any coolant leaking from it with the stat out of the engine anyway would there?
Might have another look at it tomorrow and see, it does seem to seep directly from the flange but also appears at the fastening point which made me wonder if the block was cracked there.
Can't see anything with my mirror or feel any cracks with my fingernail, what seems like a casting line maybe but can't get my mirror in the gap to see it.
Title: Re: Non standard coolant leak.
Post by: Carolyn on October 31, 2020, 17:05
The pipe is always full.

However, the fact that you can feel play and it gets worse when you tighten it, I'd say the problem is a less-than flat surface on the metal or gunk on the surface or around the base of one of the studs?  Something is preventing the spigot from sitting flat.
Title: Re: Non standard coolant leak.
Post by: Call the midlife! on October 31, 2020, 18:04
Quote from: Carolyn on October 31, 2020, 17:05The pipe is always full.

However, the fact that you can feel play and it gets worse when you tighten it, I'd say the problem is a less-than flat surface on the metal or gunk on the surface or around the base of one of the studs?  Something is preventing the spigot from sitting flat.
Agreed, I gave it all a good rub around and scratch with my fingers but could probably have had the wire brush/wet and dry at it.

It's not so much play, more like a small flexing as I can see movement in the residue of coolant around the edges, if you see what I mean?
I'll maybe have another go tomorrow as I'd rather try and sort it before pulling the engine out as it's probably easier to tell if it's leaking or not in situ.
Title: Re: Non standard coolant leak.
Post by: Carolyn on November 1, 2020, 09:21
Has d another thought:

Perhaps the thermostat itself is not straight?
Title: Re: Non standard coolant leak.
Post by: Call the midlife! on November 1, 2020, 09:46
I'll have a look today, sod's law I only binned the one I removed on the rebuild a fortnight ago 😆
I thought the seal sealed to the edges and of the opening and face of the flange but I suppose a bit of deviation in the stat won't help.
Title: Re: Non standard coolant leak.
Post by: Call the midlife! on November 1, 2020, 12:35
I'm going out on a limb as I've not yet run it up to temp and bled it but I'm confident I've sorted it.
Basically I'm a bit of a blinkered knobhead at times, because the old seal was pretty much hanging out of the aperture when I pulled the flange off and I was looking at an exploded diagram I've previously been fitting the stat in the hole, following it with the seal and then the flange.
This morning I looked at buying a new stat and saw images of ones with the seal running around the rim of them, closer look at the seal I was using and bingo, it's got a notch around it for the stat.
So fit seal to stat, fit stat (right way up) fit flange and Bob is your mothers brother!
I never saw the notch in the seal when I first fitted it on Thursday and was confident I was doing it as per the diagram.
I can't remember how I fitted it on the rebuild 18 months or more ago, it's possible it came already sleeved onto the stat or I just got lucky and fitted it right.
So that's a fair bit of time and effort wasted but you live and learn and I'm now a dab hand at the procedure and have an amazing six pack!
Thanks as always, feel free to shake your heads and laugh, I don't mind 🤓
Donation to club funds for the parts and input from @Carolyn and everyone else.
Cheers!
Title: Re: Non standard coolant leak.
Post by: Joesson on November 1, 2020, 12:51
@Call the midlife!
Pleased to hear it's sorted now. You have "confessed" to a chain of events that I'd wager many of us have followed similarly  at some point or other, but you have done it with an audience!
Perhaps you could treat yourself to one or several from another "six pack" to celebrate.
Title: Re: Non standard coolant leak.
Post by: Call the midlife! on November 1, 2020, 12:55
Don't worry, I've put 4 IPAs in the fridge for later!
I could've styled it out with a loose mounting post or something but what's the point? Nobody learns if we all get it right first time, the blinkers were well and truly on with this one though.
Cheers!😆
Title: Re: Non standard coolant leak.
Post by: Carolyn on November 1, 2020, 13:02
It never occurred to me that you were putting the seal in wrong.

Doh!
Title: Re: Non standard coolant leak.
Post by: Joesson on November 1, 2020, 13:08
Quote from: Carolyn on November  1, 2020, 13:02It never occurred to me that you were putting the seal in wrong.

Doh!

Which does  illustrate the difficulty of remote diagnosis in general and as is particularly and unfortunately, the case now with GP's!
Title: Re: Non standard coolant leak.
Post by: Call the midlife! on November 1, 2020, 13:11
Why would it? You can't always account for stupid...😆
I blame the official, exploded assembly  diagram I was following...
Title: Re: Non standard coolant leak.
Post by: Joesson on November 1, 2020, 13:15
Quote from: Call the midlife! on November  1, 2020, 13:11Why would it? You can't always account for stupid...😆
I blame the official, exploded assembly  diagram I was following...

No wonder you had difficulty if the diagram had exploded😉
Title: Re: Non standard coolant leak.
Post by: 1979scotte on November 1, 2020, 13:24
Quote from: Call the midlife! on November  1, 2020, 12:55Don't worry, I've put 4 IPAs in the fridge for later!
I could've styled it out with a loose mounting post or something but what's the point? Nobody learns if we all get it right first time, the blinkers were well and truly on with this one though.
Cheers!😆

IPA!
Champagne is on offer a Sainsbury
Title: Re: Non standard coolant leak.
Post by: Call the midlife! on November 2, 2020, 17:47
Lovely dry garage floor this evening. And no coolant in the expansion tank so more bleeding to come.
Title: Re: Non standard coolant leak.
Post by: m1tch on November 3, 2020, 16:01
Any reason you are using a plastic neck rather than a metal one?
Title: Re: Non standard coolant leak.
Post by: Carolyn on November 3, 2020, 16:32
Quote from: m1tch on November  3, 2020, 16:01Any reason you are using a plastic neck rather than a metal one?

The vast majority are plastic.
Title: Re: Non standard coolant leak.
Post by: Call the midlife! on November 3, 2020, 17:28
Quote from: m1tch on November  3, 2020, 16:01Any reason you are using a plastic neck rather than a metal one?
Standard issue, if it ain't broke... Like the rest of the car 🤓