Intake coolant tube

[hades02]

1997 Expy XLT 4x4 4.6

I was driving on the highway and got a check engine light and the Expy started bucking. Pulled over and she was leaking coolant near the firewall. Got home and this is what I found (see pictures). Looking for recommendations on where to find a replacement tube (read cheaper than stealership), how to remove the piece stuck in the manifold (preferably without removing the manifold) and how to install the new tube.

 

[hades02]

After closer inspection it looks like this tube goes into the upper part of the block. You can see where the tube broke off (just above the #4 spark plug boot). Any advice would be greatly appreciated.

 

[toms89]

The coolant tube is in the lower intake. I believe it is just pressed in but not sure you can if you can purchase just the tube. If not I would get a new/ used lower intake.

The bucking is most likely caused by coolant getting into the plug well(s) causing misfires.

 

[toms89]

After viewing your photo some more it appears the 1997 is different than the 2000 expy. On mine one hose goes to the front part of the lower intake manifold and the other comes from a tube run alone the top of the block (under the lower intake) to the water pump. The later is just pressed in with 2 orings behind the water pump and 90's up in the rear and bolted to the heads via a flange.


I am guessing both of your lines are in the rear. One from the water pump and the other from the intake manifold coolant passage.

 

[hades02]

Thank you Toms89. I am going to the stealership today to see if they have any
diagrams showing the part. Hopefully they will have the part as well. I will post my findings. I am sure that I am not the only one that has or will have this problem.

 

[hades02]

Found it!!!!

Ok so the dealership had the part. See attached and hope that this helps others. On the diagram it is part
9D428.

Does anyone have any advice as to how to attach this? Does it just compress in or do I have to use some sort of sealant or adhesive? Once I have completed this I will create a write up with pictures.

 

[toms89]

Ok so the dealership had the part. See attached and hope that this helps others. On the diagram it is part
9D428.

Does anyone have any advice as to how to attach this? Does it just compress in or do I have to use some sort of sealant or adhesive? Once I have completed this I will create a write up with pictures.

I found nothing on this in my 2000 expy service manual. It appears to me in the photo that the tube may have some sort of sealant or coating on it in already where it presses in?! Or is it a cap??

 

[hades02]

The dark end that you see is the end that presses into the engine. It is dark because the silver coating that you see on the rest of the tube doesn't extend into that area. It is not
coated with anything. I'm thinking that it is just press fit. Thank you for the reply.

 

[stamp11127]

You could use Loctite 7649 Primer & 609 Retaining compound prior to driving it into the manifold. We use that combo on injector sleeves at work.

 

[hades02]

Thank you for the response Stamp11127. That sounds like a good plan.

 

[jeffnoel]

Take care when working on the intake, the coolant tube on mine broke last Spring and the mechanic broke my intake when trying to remove the bad tube.

 

[hades02]

Thanks JeffNoel. I will definitely be careful. It's been cold here in CT so no progress. My garage is full of crap so I can't get her in there and work in
a heated space. I do however need to get this done this week as the car that I am borrowing goes back to the owner next weekend.

 

[Gibbers18]

Did you have any luck getting it in and working? I did a heater core replacement and when I started the car I had a leak right there out of the tube as well and am waiting for the part from the dealer. I have the manifold at the machine shop to pull it out at right now, but wanted to know if you put any sealant on it when reinstalling. Thanks!

 

[Gage2502]

Ya how was the install?

 

[Gibbers18]

The install is finally done, and car is running great!! Couple of recommendations based on my install experience:

1) Reinstalling the back manifold bolts can be a pain, especially trying to get a torque wrench on them! I would set the intake manifold back on with the bolts sitting through the holes already so you are not trying to get a magnet back there to get them started.

2) Keep the heater core hoses disconencted till the very end, definitly helps to move those hoses out of the way

3) Replace and grease those heater hose O-rings, suckers leaked on me twice after the isntall was done.

4) Double check cylinder #3 coil connector, hard to get lined up and hooked on, it fell off on me, cause a miss, but the engine Code led me to the fix on it.

5) Spray the EGR tube with lots of wd-40, sucker was not happy coming off at first

6) make sure the rubber grommet for the shifter cable is isntalled right, I noticed mine was out a bit and it was hitting the EGR tube and melting!

7) Replace all the spark plugs with the manifold out, MUCH easier to do this way, but before pulling the plugs, spary some air down in the recess where they sit, the fluid can build up in there and when you pull the plug it drops in the motor.

Finally, definitly be careful with those 5.4 manifolds, they are 1000 bucks from the dealer and very scarce on eBay, be gentle