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If your radiator is leaking, you have several repair options:
You can try the cheap fix and add a bottle of cooling system sealer to the radiator. These products are designed to seal small leaks. They can also seal internal engine leaks. Some work better than others, but most provide only a temporary solution to your problem.
You can attempt to repair the radiator yourself. Copper/brass radiators on older vehicles can often be soldered to repair leaks. Cracks or pinholes in aluminum radiators in newer vehicles can often be repaired with epoxy glue. But if the core is severely corroded or damaged, the radiator may have to be professionally repaired at a radiator shop, or replaced with a new radiator.
FIXING A LEAKY HEATER CORE
As with a leaky radiator, you might try the cheap fix and add a bottle of cooling system sealer to see if that will stop the leak. If it does not, you will have to disassemble the HVAC case to replace the heater core. This is a nasty job and involves a LOT of labor on most vehicles.
If a vehicle has a history of repeat heater core failures (some Chrysler cars, for example), the problem may be electrolysis corroding the heater core. One fix is to attach a grounding strap on the heater core. Another is to replace the OEM aluminum heater core with an aftermarket copper/brass heater core.
COOLANT RESERVOIR
Another coolant component that sometimes needs attention is the coolant overflow reservoir. The coolant overflow reservoir does more than catch the overflow from the radiator. It’s main function is to serves as a storage tank for excess coolant. When the system is hot, coolant will be forced out through the radiator pressure cap and into the reservoir. Then as the system cools down, decreasing pressure will draw coolant back into the radiator.
On many newer vehicles, the coolant reservoir is pressurized and is an integral part of the cooling system. The filler cap for the cooling system is located on the reservoir tank, and the tank is connected to the radiator and engine with hoses. The reservoir is transparent plastic and you can see the coolant level inside.
If the coolant reservoir is cracked or leaking, the system may lose coolant every time the engine heats up. Eventually, this can cause the engine to overheat.
Small punctures or cracks in the overflow reservoir can usually be repaired with silicone glue. If the reservoir needs to be replaced, make sure the hoses are routed correctly between the radiator and the reservoir, and that it is free from kinks that could block the flow of coolant back and forth.
FIXING LEAKY FREEZE PLUG
There are several ways to repair a leaky freeze plug.
One is to clean the surface of the plug, then sand it lightly with sandpaper, and pack it solid with a high temperature two-part epoxy such as gas tank sealer. Let it cure overnight. This trick usually seals leaky expansion plugs that would otherwise be very difficult to replace.
Another is to use a hammer and drift to knock out the old plug. Pounding in on one side of the plug will usually cause it to twist. The plug can then be pried out with a large screwdriver. Clean the hole, then apply a liberal coating of sealer to the hole and carefully drive in a new replacement plug. The plug must go in straight or it may not seal. Another option is to install a repair plug that has an expandable rubber grommet to seal the hole. You simply place the plug in the hole and tighten the bolt until it seals tight.
FIXING LEAKY HOSES
Do not waste your time trying to patch or wrap a leaky radiator or heater hose. Sealers do not work well with hoses either. Replace the bad hose with a new one, and inspect all the other hoses because if one has failed the others are probably reaching the end of the road, too. It is also a good idea to replace the original hose clamps, especially if they are the ring type. Ring clamps can lose tension with age and may not hold the hose tightly. Worm drive clamps are recommended.
FIXING A LEAKY WATER PUMP
No stop leak will seal a water pump that’s losing coolant past the shaft seal. Replacement is your only option here. But you can save some money on the job by using a remanufactured rather than a new pump.
Replacing a water pump is not too hard a job on most engines, but on some it can be tricky. On 2.8L GM V6 engines, for example, the bolts that hold the water pump also hold the timing cover in place. If you are not careful, the timing cover seal can be broken allowing coolant to leak into the crankcase. GM recommends using a special tool (J-29176 or equivalent) to hold the timing cover tight while the pump is being changed.
Check the fan clutch because a weak clutch can cause the engine to overheat.
If your engine has a belt-driven fan with a fan clutch, it is also a good idea to check the fan clutch when replacing the water pump. The lifespan of both is about the same, so the fan clutch may also need be replaced. If the clutch is leaking silicone fluid, or has any wobble in the bearing, it must be replaced.
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