Fiesta 1.25 Zetec (2000) bottom hose adapter leaking

[mikdys]

Good afternoon all,

I was wondering if there is someone out there who can help me with some technical advice on this one. I have a Fiesta 1.25 Zetec Climate (I think it's the Yamaha designed engine with the plastic inlet manifold at the front next to the bonnet closing panel). The problem I have is a coolant leak from a "bottom house plastic adapter block" where this joins the engine block. This fitting is almost completely un-accessable without some other dismantling. [From some further investigation I think this might actually be the thermostat housing.]

A few questions, for anyone that might know (I have tried Wynn's Coolant Stop Leak but that didn't work unfortunately - I think this is only good for radiator leaks):

1. Can the adapter be accessed by removing the alternator and inlet manifold only (I don't want to disturb the A/C compressor - I shall give up at that point)?

2. Where the adapter joins the block is the joint sealed by a gasket or an o-ring?

3. Will I need a new adapter or just a gasket or o-ring (is the joint facing likely to have distorted)?

4. I assume that all I may need to do this job (I shall re-use the anti-freeze as it's only a couple of years old - probably changing this was the cause of the damned leak!) is an inlet manifold gasket, another gasket/o-ring for the adapter joint and a day's spare time. Anyone know different?

Thanks in advance.

Edited by mikdys on Sunday 1st September 14:10

[neiljohnson]

It does sound like your describing the stat housing
It's easily replaceable with the alternator removed, it seals with two o rings but the likely cause is that the housing itself has warped causing the leak
Part is quite cheap & you can reuse the coolant if you want

[mikdys]

Thanks for the reply - I can see the 'stat housings for sale on ebay (new) - I'll buy one of these and a couple of new O-rings.

All fixed now. Turns out it was the rubber seal on the thermostat leaking due to a small amount of corrosion pushing it slightly out of position. The Ford garage I bought this seal from (for the extortionate price of £5 for a 2 pence rubber ring!) said they sell "half a dozen a week, it's a popular part". I changed the housing at the same time as I had bought a new one anyway (from ebay for £10 not from Ford at £30 - interestingly all the markings were the same except for the Ford logo being missing). I guess all you need to fix this "common fault" is a £5 O-ring and some wet & dry to clean up its seating.

To gain access I had to remove the alternator (note the "automatic alternator belt tensioner" is underneath the car) and I also found it easier to remove the headlamp (easy to remove as it's only held in by three screws).

Not such a bad job really. Couple of hours work for the layman (probably half an hour for an experienced and skilled fitter).

Edited by mikdys on Monday 9th September 18:47