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Old 01-28-2013, 08:51 AM   #1
CWButler
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Bypass hose leaking at Engine block

I have a 2002 ZX3 with the Zetex 2.0L 16 V motor. I noticed a leak last night so I changed out the Bypass Hose that goes form the Plastic tube above the radiator to the bottom of the engine. When I refilled it with Antifreeze, it continues to leak from the site but it apears that it is coming from the engine where the hose attaches. Can anyone tell me what that area is?


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Old 01-28-2013, 09:47 AM   #2
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It's the thermostat housing it's a common problem, also if you haven't yet replace your valve cover gasket.
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Old 01-28-2013, 10:05 AM   #3
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^^ - The reason for this good hint is that seepage from the Valve Cover area is a common contributing factor to the thermostat housing failure (oil & plastic don't always get along too well).

Luck!
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Old 01-28-2013, 10:39 AM   #4
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Dorman makes a kit that contains the replacement housing, thermostat, gaskets all put together nicely ready for you to unbold the old and bolt on the new. And one trick with getting the plastic valve cover off if it's stuck on - give it a sold wack with a soft rubber mallet and it will pop right off. The new valve cover gasket is about $35 and the Dorman kit is about $45.

Most of the failures I've seen people talking about on this housing are INSIDE the gasket sealing area - the plastic on the water side crumbles away and the gasket pops out into the water, so oil seeping down from the valve cover gasket is unlikley to be the problem - but on these older Zetecs the valve cover gaskets do harden and then stop sealing and then oil leaks make a mess out of things.

The Ford dealership techs I have talked to all say that these housings continue to fail even after being replaced (with new Ford ones) so Ford hasn't reformulated the plastic in these, apparently.
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Old 01-28-2013, 11:34 AM   #5
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^^ - Good suggestions& info!

The oil issue gets blamed when the housing is actually warped at the joining surfaces, whether it's a direct cause or not isn't proven - it simply often comes up at the same time in the life of the car so it's often addressed at the same time to prevent an apparent obvious issue from causing additional problems.
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Old 01-28-2013, 12:11 PM   #6
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Thanks

Appreciate the feed back. I thought that was what it was, just never seen a thermostate on the bottom inlet of an engine or on the smaller bypass hose. Usually they are on a main hose coming off the radiator.
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Old 01-28-2013, 02:07 PM   #7
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Help

Okay so I , looking at the Thermostat housing and connot figure out what type bolts are holding it in. Also the second bypass hose that is underneath it and goes into the block is the one we replaced yesterday and it appears that that is where it is stil leaking from. Any ideas.
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