BRAND NEW coolant flange leak... HELP!!!
NEWS
 
+ Reply to Thread
Results 1 to 24 of 24
  1. #1
    Neutral
    Join Date
    Jan 2010
    Posts
    34

    BRAND NEW coolant flange leak... HELP!!!

    Okay, well... I had a coolant leak so I replaced the coolant flange. Filled the coolant and it started leaking bad! WITH THE NEW FLANGE^@%$!^#. Took it off twice and checked everything TWICE! Still leaks! No cracks or anything. Not sure whats going on... Anyone know what might be the problem? It doesnt seem like its sealing/seating properly... Looks like when I tighten the two bolts it still doesnt seat fluch with the head/block
    I'M GOING CRAZY!!!

  2. Remove Advertisements
    VW Passat Forum
    Advertisements
     

  3. #2
    2nd Gear
    Join Date
    Nov 2003
    Location
    Cross Roads, PA
    Posts
    659
    Did you replace the O ring? Is it getting pinched??

  4. #3
    Neutral
    Join Date
    Jan 2010
    Posts
    34
    I have the flance with the O ring that's halfway embedded in it. It doesnt seems like it seals that great. It's leaking bad no matter what torque I use. The part looks fine. I'm not sure if theres an additional O-ring....

  5. #4
    3rd Gear
    Join Date
    Apr 2007
    Location
    Jerseys Finest
    Posts
    1,218
    so the flange is new but is the O-ring? It needs a new O-ring & you might as well replace both O-rings on the flange. Make sure the back of the head is smooth & sand it briefly to ensure this.

    The flange uses 2 O-rings
    -1 where the flange attaches to the head with the 2 bolts (where yours is leaking)
    -1 where the coolant pipe attaches to the side of the coolant flange .

    EDIT - it actually uses 3 O-rings. The 3rd ring is for the coolant temperature sensor that’s connected to the flange.
    Last edited by theNofJboy; 03-17-2011 at 07:11 AM.

  6. #5
    PZ
    PZ is offline
    Redline
    Join Date
    May 2002
    Location
    Grapevine TX. 01 4M
    Age
    51
    Posts
    22,040
    Lay the flange on a table and make sure it is flat. If it is, you are catching something between the flange and the head. Most likely the oil line from the turbo.

  7. #6
    Neutral
    Join Date
    Jan 2010
    Posts
    34
    The part is flat... I sanded the head too so everything is smooth and clean.
    The new part has the o-ring that is built-in (sorta). It seems as if the part does not press against the head really tight and flat. Maybe the metal sleeves in the part art too tall? Maybe that's keeping the part from being tightened down properly.
    I might get a flat rubber gasket and use that instead of the one that the part has on it.
    I'm so frustrated right now...

  8. #7
    3rd Gear
    Join Date
    Apr 2007
    Location
    Jerseys Finest
    Posts
    1,218
    can you get a link to the coolant flange you got? Here a link to the coolant flange for my 98 AEB passat -
    http://uspmotorsports.com/images/b5a4neck.JPG

    Im curious what these "metal sleeves" look like..

    you should update your profile with what year your passat is etc..
    Last edited by theNofJboy; 03-17-2011 at 08:31 AM.

  9. #8
    Neutral
    Join Date
    Jan 2010
    Posts
    34
    Hi guys, thanks for the suggestions thus far.

    My car is a 2002 1.8 AWM.

    Nof... my flange looks just like that one (minus the extra outlet).
    It's identical to the one that came off my car with the exception of how the o-ring looks attaches.
    I'm starting to think it could be those metal spacers/sleeves. If they were too tall then that would prevent the part from being torqued down hard against the head...

    Unfortunately I have to wait until after work to look closer...

  10. #9
    3rd Gear
    Join Date
    Apr 2007
    Location
    Jerseys Finest
    Posts
    1,218
    are these the "metal sleeves" things or metal clips you are refering to that hold the O-ring in place?

    DIY: Beginner’s guide to B5/B5.5 1.8T Coolant Flange Replacement


  11. #10
    Neutral
    Join Date
    Mar 2011
    Location
    Wisconsin
    Posts
    66
    Is it the radiator? Mine was leaking bad too, and ended up being the radiator because for some odd reason, the fan broke into pieces and dinged up the radiator. But yours just might be the radiator itself.

  12. #11
    Neutral
    Join Date
    Jan 2010
    Posts
    34
    The leak is definitly from the new flange...
    the photo above is exactly what my part looks like...

    The metal part I was referring to though are the sleves that the mounting screws go through on the flange. The brass colored parts. I think they may be too tall and thus not allowing the flange to properly be pressed tight enough. The screw might be tight against the metal sleves that they go into... but not tight against the abs plastic part of the flange.

    Does that make sense?

    Other than that... I'm clueless...

  13. #12
    3rd Gear
    Join Date
    Apr 2007
    Location
    Jerseys Finest
    Posts
    1,218
    ahh those metal sleeves haha - see if you can grind/sand them down or maybe you can pop them out to grind/sand them..

    maybe someone will chime in that already did this for your 02' AWM engine

    GL!

  14. #13
    Neutral
    Join Date
    Jan 2010
    Posts
    34
    Thanks for your help!

    If anyone else has any experience with this problem please let me know!

    I did buy some rubber-cellulose water and coolant gasket paper... I might cut my own gasket and see if that works... after I check the metal sleeves first...

  15. #14
    1st Gear
    Join Date
    Aug 2004
    Location
    Fairfield County, CT
    Posts
    383
    did you change o-rings in other ports/connections of the flange? is it possible that you are leaking from them instead of where the engine block and flange meet?

  16. #15
    Neutral
    Join Date
    Jan 2010
    Posts
    34
    well a few hours more tonight with the new and old flange and still have leaks. I even tried making my own gasket and used sealer... still leaked. I took everything off three times and I still had leaks no matter how good I cleaned everything etc...

    It leaked from the head, and the from the metal tube. I got the metal tube end to stop but not the leak at the head.

    I'm going to order all new o rings again... clean it again. If it doesnt work I'm seriously calling the junk yard and having them tow it. I'm done with it...

  17. #16
    murdered out Jetta, er, B5 Passat mrgreek2002's Avatar
    Join Date
    Sep 2001
    Location
    '99 1.8T - Toronto
    Age
    32
    Posts
    11,153
    I had mine done by my indy mechanic a couple weeks ago. It took him a good few hours but when it was done, it was awesome and leak free.

    He cleaned the back of the head, sanded it down a bit and used new seals.

    Good luck!

  18. #17
    Neutral
    Join Date
    Jan 2010
    Posts
    34
    I'm going to call around tomorrow for estimates... If I can get it done for $300 or less I'll do it!
    How much did he charge you?

    It's frustrating... I've done timing belts, clutches... You name it... And this little freking thing is stumping me for 4 days straight now!!!!

  19. #18
    murdered out Jetta, er, B5 Passat mrgreek2002's Avatar
    Join Date
    Sep 2001
    Location
    '99 1.8T - Toronto
    Age
    32
    Posts
    11,153
    He charged me $120 canadian labor for the flange job and the two coolant lines on the oil cooler job. He spent a good 4 hours on the job though, so it wasn't that expensive.

  20. #19
    My pornstar name came up "Jay the Snork."
    Join Date
    Oct 2002
    Location
    Conyers,GA (Atlanta)
    Age
    50
    Posts
    5,608
    The first flange I replaced developed a crack very soon after, on the inside radius of one of the elbows, making it hard to detect. Is it possible the flange itself is cracked like mine was? I know you said there were no cracks in your first post, but you might want to check again.

  21. #20
    3rd Gear
    Join Date
    Apr 2007
    Location
    Jerseys Finest
    Posts
    1,218
    hey btw OP, I found my old coolant flange for my B5 & I just used a large nail to tap the metal sleeves out...they came right out

  22. #21
    Neutral
    Join Date
    Oct 2009
    Location
    Swansea, MA
    Age
    59
    Posts
    86
    mfitz makes a good point especially if you are not using a torque wrench. In your frustration you may have tightened the beans outta that thing a cracked it. Either way, good luck.

  23. #22
    Neutral
    Join Date
    Jan 2010
    Posts
    34
    Update:
    Well, after fighting with this for 5 days I'm happy to report that my car is leak free! I bought another replacement flange this time from the dealer... All new o-rings too! I was meticulous in prepping the parts and surfaces... Gently put everything back together at spec and so far so good!!!

  24. #23
    3rd Gear
    Join Date
    Oct 2010
    Location
    palmdale,ca
    Posts
    1,013
    i did mine a few days ago..got the flange from napa for $6 and it was a meyle and made in germany..i had a leak at the metal tube..the seal pinched..now its all good..

  25. #24
    3rd Gear
    Join Date
    Apr 2007
    Location
    Jerseys Finest
    Posts
    1,218
    good to hear!

  26. Remove Advertisements
    VW Passat Forum
    Advertisements
     

Quick Reply Quick Reply

Register Now

Please enter the name by which you would like to log-in and be known on this site.
If you do not want to register, fill this field only and the name will be used as user name for your post.

Please enter a password for your user account. Note that passwords are case-sensitive.

Please enter a valid email address for yourself.

Log-in

Human Verification

In order to verify that you are a human and not a spam bot, please enter the answer into the following box below based on the instructions contained in the graphic.


Thread Information

Users Browsing this Thread

There are currently 1 users browsing this thread. (0 members and 1 guests)

Tags for this Thread

Posting Permissions

  • You may not post new threads
  • You may not post replies
  • You may not post attachments
  • You may not edit your posts
Powered by vBadvanced CMPS v4.1.2