Hi guys, I've just finished doing the intake manifold gasket replacement (which was hell, due to corroded bolts) and now I have a coolant leak somewhere. I'm trying to locate it (and really hoping that I didn't do something wrong with the gasket job), but I haven't been able to find it so far.

I'm not very knowledgeable with cars (yet--I have no desire to remain ignorant) and I don't really understand where the coolant goes and how it flows through the system.

I found this diagram in the 2nd-gen FSM:
http://img253.imageshack.us/img253/8334/02lhecoolingur4.th.png (http://img253.imageshack.us/my.php?image=02lhecoolingur4.png)
Is this very similar to the 1st-gen setup or is there a similar diagram for the 1st-gens?

I know the coolant has to go through the engine somehow--I know there's the upper radiator hose that connects to the front of the intake manifold and then there's the heater hose that comes out the back, but where does it go between those points?

If anyone has any ideas on where it could be leaking, here is what I know so far:


I can't see any visible leaks from above (and this is with a lot of stuff removed).
On the underside, the water is dripping dead-center and at the rear of the engine compartment.
I've disconnected the upper radiator hose and the heater hose from the back of the intake manifold and it still leaks (not from those hoses) if I pour more distilled water into the system. This makes me think that it's probably leaking at a lower spot in the system, but again I'm not sure how everything flows.

I'd be very appreciative for any help/insight!

your best bet to become educated with your car is to buy a repair manual and read through it. It provides alot of information even though it usually leaves out small amounts of significant information it is worth the $15. This is a generic pic but most coolant systems operate the same way. There are only a couple other places you have to check. Your water pump and the lines leading to your coolant resevoir. Your pump is timing belt driven so you cant really check it(hopefully its not that because I know its a big job). So, check the couple other hoses. Good Luck


http://autozone.com/images/cds/gif/medium/0900823d8018173b.gif

Yeah, I have the Chilson book with that same diagram, but it wasn't enough for me to figure out what was going on.

I just figured out what I did wrong that caused the leak--I'll post a new thread with a better title and a picture in a few minutes!

Okay, I seem to be unable to post a new thread. So, I will post again here.

Well, I'm an idiot. I replaced my leaky intake gaskets and in the process had to drill out a frozen bolt. Suffice to say, I drilled a hole all the way through the water passages and now it leaks.

I took a picture and it doesn't look like that big of a problem--I just need to patch it up with something.

http://img377.imageshack.us/img377/5781/oopsyt2.jpg (http://imageshack.us)

My first thought was some caulk in the bottom and then filling in the rest with KB Weld, but I'm not sure how well either of those are going to react with heat, pressure and antifreeze.

Any suggestions?

Update: I patched it with JB Water Weld. We'll see if that works or not.

shit! Well, that sucks. Havent had to use JB before, Cross your fingers or youll be junk yard hopping. From the pic I cant really notice where the hole is but hopefully its the intake not the head.