Hi,

I have a 1991 Convertible that I have installed a 1988 N/A motor in. The problem is that after installing the motor, I filled up the antifreeze only to discover a leak dripping from the front of the engine, passenger side. It is running down the seam where the front cover mates to the front iron.

Some things to note:
I used an RX8 metal gasket when installing the S5 front cover. It includes a metal gasket for the water pump housing incorporated in the gasket. Also, the S5 front cover is from a TII and the small hose is plugged and not leaking.

None of the hoses are leaking anywhere that I can see.

The car has not been started yet, so it's not a blown motor or bad internal seals.

Do I need to install some o-rings on the LIM since it is a 1988 engine in a 1991 car?? When installing the S5 LIM on the motor, I did not see anywhere to place any O-Rings. Also, the gasket is a metal gasket. The install kit for the S5 N/A was from Rotary Aviation.

After filling it up with antifreeze, I get a drip. It appears to be coming from the front engine cover passenger corner where the metal gasket seals the front cover to the front iron. I assumed it was leaking from the front iron to water pump housing gasket.

I removed the metal gasket to find that the passenger side crease was not crushed. I replaced it with the original paper type gasket and also used Copper Spray gasket sealer on both sides of the gasket. I installed both washers onto the studs for the two bolts that the gasket does not cover.

I reassembled and filled the antifreeze again only to find the dripping leak again.

My only thought is that the housing may be warped or worn and not sealing where there is no bolt hole on the left side (looking at the engine from the front). Should I remove the two spacers on the left side studs to get the left side of the housing to seal better? Should I use silicone sealer?

Could it be anything else other than the pump housing to front iron seal? I would like to be sure before pulling the water pump housing off again for the 3rd time.

Any help would be appreciated.

Tim

 

Have you checked the water thermosensor and water line that are located on the back of the housing? might be the source of your leak.

 

I checked both of them when I removed the pump housing and they were both dry as a bone.

I think it is leaking at the same place again or it might have a crack leaking in the housing.

Anyone else have any ideas?

Tim

 

I'd check for warpage of the water pump housing to front housing using a straight edge and feeler gauge. Use the stock gasket with a film of sealant on both sides. Also, there should be no coolant between the front housing and front cover unless one of the coolant plugs in there are leaking.

 

I found the leak, it was the small hose coming off of the bottom of the housing for the TII coolant line. It was leaking, dripped onto the OMP, then dripped down onto the ledge on the motor just above the oil pan. I could not see it until I got into a real wierd position and noticed a drip.

Thanks for the help.
Tim