2.3L coolant leak

[jbb1366]

First time poster, just wanted to throw this on here in case it helps anyone else out.

 

I had a coolant leak that manifested at first by just hearing the fan working overtime under the hood.

 

checked coolant level, was low, added some and just figured over the years I lost some via evaporation.

 

Couple days later, temp gauge was jumpy and would get up close to H, go back down to middle, repeat.

 

Popped the hood again and noticed coolant leak and steam coming from driver's side top of engine.

 

 

I thought it was coming from between engine block and exhaust manifold and panicked, thinking cracked block or something major. Mechanic buddy came over and quickly pointed out the much less serious problem.

 

 

The Water Outlet Housing was spraying coolant. I took the old one off, via the following steps:

 

disconnect large radiator hose from front, smaller one from rear of part, remove 4 bolts holding housing next to engine block. One elec connector to temp sensor. One more smaller hose on bottom to remove, and part comes out pretty easily. I took my battery out to get it out of my way but otherwise just moved elec. harnesses out of the way as needed.

 

 

After getting the old part off I quickly spotted the problem - the gasket sealing the housing to the block was shot. The gap that the housing has to allow the small tab on the gasket to show you how to line it up was allowing the pressure of the cooling system to push the gasket outward into the notch. Over time the gasket finally cracked and was allowing coolant to spray out onto the exhaust manifold.

 

$8 for a new gasket.

 

I put the old antifreeze back in (I know, should buy new, but I'm a cheap SOB) and added a little, opened the bleed air port on top of the part I had just worked on to let some air out a couple times.

 

Seems to be good to go now.

Edited April 9, 2017 by jbb1366

[Tino]

Question is the battery on the passenger side of your car. I have a 2007 with a 2.3 4 cylinder and i have the same problem. On the videos that i have watched on youtube i notice that they have to remove the power steering pump. I noticed that you didn't mention this. Is your fusion different. It seems by your instructions that it is a lot easier on yours than mine. Also do you happen to have the part numbers for the 2 hoses that go to the thermostat assembly. My problem is disappearing coolant and a sign of wetness on the pulley below the power steering pulley.

[2009FusionSESport]

Just made an account, although I've been browising around for a while now. I know this is an old thread but here goes.  I think I have the same problem, I'm hoping it's just the gasket. Much thanks to jbb1366 for the post, it greatly helped me. 

 

On 4/10/2017 at 3:53 PM, Tino said:

Question is the battery on the passenger side of your car. I have a 2007 with a 2.3 4 cylinder and i have the same problem. On the videos that i have watched on youtube i notice that they have to remove the power steering pump. I noticed that you didn't mention this. Is your fusion different. It seems by your instructions that it is a lot easier on yours than mine. Also do you happen to have the part numbers for the 2 hoses that go to the thermostat assembly. My problem is disappearing coolant and a sign of wetness on the pulley below the power steering pulley.

This confused me too, as best as I can tell there are TWO separate places, one for the water outlet housing (top, battery side of engine), and one where the thermostat is (near the power steering pump). 

Edited April 27, 2018 by 2009FusionSESport