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V8 Esprit weeping coolant from thermostat housing joint


jamie c

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I have done it twice and  o rings not pinched and thermostat in place properly. I have dye in coolant system to trace leaks. I have trued up the bottom of the thermostat housing on a  flat plate with 300,400 and finally 800 sand paper. The top of the engine where the thermostat housing is bolted looks good no pits but its not perfectly smooth because due to its cast aluminum. The hoses are not leaking. I can see the thermostat opening when I drive as themperature on temp gauge drops just past 80 degrees and then continues to warm up. Can anyone tell me if I should be using a sealant on the housing to help seal for leaks?

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You should not need to apply any sealant.  I have never applied sealant to the thermostat housing on any of the engines that I have build.

I typically apply a small amount of rubber grease to the o-rings, just to hold then in their ring grooves when fitting.  If you are having a proven problem there, then I would be looking at the o-ring not being correct thickness.

Where did you source the o-rings?

 

1996 Esprit V8, 1998 Esprit V8 GT, 1999 Esprit S350 #002 (Esprit GT1 replica project), 1996 Esprit V8 GT1 (chassis 114-001), 1992 Lotus Omega (927E), 1999 Esprit V8SE, 1999 Esprit S350 #032, 1995 Esprit S4s, 1999 Esprit V8 GT (ex-5th Gear project), 1999 Esprit V8SE ('02 rear)

1999 S350 #002 Esprit GT1 replica

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Well JAE are excellent, so should be supplying the right o-rings.  Could it be that the o-ring is falling out of position on installation (being upside down)?

1996 Esprit V8, 1998 Esprit V8 GT, 1999 Esprit S350 #002 (Esprit GT1 replica project), 1996 Esprit V8 GT1 (chassis 114-001), 1992 Lotus Omega (927E), 1999 Esprit V8SE, 1999 Esprit S350 #032, 1995 Esprit S4s, 1999 Esprit V8 GT (ex-5th Gear project), 1999 Esprit V8SE ('02 rear)

1999 S350 #002 Esprit GT1 replica

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You can drain the cylinder head coolant by opening the heater take-off from the back of the block (the Y-pipe in the image).

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1996 Esprit V8, 1998 Esprit V8 GT, 1999 Esprit S350 #002 (Esprit GT1 replica project), 1996 Esprit V8 GT1 (chassis 114-001), 1992 Lotus Omega (927E), 1999 Esprit V8SE, 1999 Esprit S350 #032, 1995 Esprit S4s, 1999 Esprit V8 GT (ex-5th Gear project), 1999 Esprit V8SE ('02 rear)

1999 S350 #002 Esprit GT1 replica

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If you raise the heater take-off then you can refill at the header tank.

You should follow the steps in the Service Notes for bleeding out the system.  I`ve found that this is also easier if the back of the car is jacked-up.

1996 Esprit V8, 1998 Esprit V8 GT, 1999 Esprit S350 #002 (Esprit GT1 replica project), 1996 Esprit V8 GT1 (chassis 114-001), 1992 Lotus Omega (927E), 1999 Esprit V8SE, 1999 Esprit S350 #032, 1995 Esprit S4s, 1999 Esprit V8 GT (ex-5th Gear project), 1999 Esprit V8SE ('02 rear)

1999 S350 #002 Esprit GT1 replica

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The Y-pipe is attached to flexible rubber hoses off the back of the stub pipes in the rear of the block. You can lift up the pipe.  If access is difficult or you cannot lift it enough then your other suggestion would work.  Anything to elevate the exit of the hose while you top it up.

1996 Esprit V8, 1998 Esprit V8 GT, 1999 Esprit S350 #002 (Esprit GT1 replica project), 1996 Esprit V8 GT1 (chassis 114-001), 1992 Lotus Omega (927E), 1999 Esprit V8SE, 1999 Esprit S350 #032, 1995 Esprit S4s, 1999 Esprit V8 GT (ex-5th Gear project), 1999 Esprit V8SE ('02 rear)

1999 S350 #002 Esprit GT1 replica

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  • 2 weeks later...

ok good news I have sealed the thermostat housing by using a light coating of RTV silicone and snuging up the three fasteners and letting cure over night. Torqued in the morning and refilled the cooling system by jacking up the back of the car and refilled with coolant through the Y pipe with a hose added extra length to help refill, noticed I could of refilled through the heaader tank as I had raised the the back of the about 18” higher than the front and saw header tank filled up ad well.

I started this project due to coolant loss that was very small and steady, installed a new water pump the week before. I have driven the car a total of 150 miles over the last two days and gave it plenty of occasions  of lots of boost and haven’t lost any coolant. Yeah! There were times I thought I might have headgasket issues. Thanks    

 

 

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Well done.  Good to have a positive outcome with little outlay.

Enjoy yourself.

1996 Esprit V8, 1998 Esprit V8 GT, 1999 Esprit S350 #002 (Esprit GT1 replica project), 1996 Esprit V8 GT1 (chassis 114-001), 1992 Lotus Omega (927E), 1999 Esprit V8SE, 1999 Esprit S350 #032, 1995 Esprit S4s, 1999 Esprit V8 GT (ex-5th Gear project), 1999 Esprit V8SE ('02 rear)

1999 S350 #002 Esprit GT1 replica

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