1997 Chevy Cavalier leaking water outlet

Tiny
CZBONE
  • MEMBER
  • 1997 CHEVROLET CAVALIER
Heater problem
1997 Chevy Cavalier Two Wheel Drive Automatic 54000 miles

Hi. I have a 1997 Chevy Cavalier Z24, 2.4 Litre engine with 54000 miles. I replaced a broken water outlet a few months back. I had the water pump replaced last week and now the water outlet is leaking. It seems to be leaking at the mating surfaces.
The outlet an odd part, made of plastic and instead of having the usual paper gasket, it just has a tube on the back that goes about an inch into the coolant cavity with a rubber o ring as the only gasket specified for the outlet. The bolt holes have metal sleeve inserts, so you can only tighten so much. It doesn't seem to leak when running, only after it's set for for a few hours, it's a very slow leak. No overheating. There seems to be no information available online and even the service manual gives no specifics.
I'm considering making a paper gasket, using sealant on both surfaces, and either using teflon plumming tape or some kind of thread sealant in case coolant might be coming thru the bolt holes. If you have any suggestions, I'd love to hear them.
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Friday, November 30th, 2007 AT 6:38 PM

3 Replies

Tiny
MHPAUTOS
  • EXPERT
Hi there,

thank you for the donation.

This type of water fitting normally works well, Check that the "O" ring has not been pinched when fitted last, use a little petroleum grease or rubber grease when fitting, make sure that both side of the "O" ring sealing surface is clean and free of foreign material. Use a liquid Teflon sealer on the bolts, but let it cure, before adding the water?Coolant and operating.

Good luck,

Mark (mhpautos)
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Friday, November 30th, 2007 AT 7:59 PM
Tiny
CZBONE
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Thanks, sounds like good advice. I'll give it a try and let you know how it works out.
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Saturday, December 1st, 2007 AT 12:02 PM
Tiny
CZBONE
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I found a hairline crack under the o-ring, had to squeeze before it became visible when coolant gushed out. It was a replacement part that I got from Auto Zone 5 months ago, made in China. Plastic parts are bad enough, cheap plastic parts are worse. Lesson learned, never again.

I purchased a replacement from a GM dealer yesterday, installed it today. It'll probably be a few days before I know for sure if the problem is fixed. Coolant leaks have been an ongoing problem for about 6 months. I've replaced the water pump, heater core and water outlet (twice) during that time, hopefully this will fix the problem.
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Saturday, December 8th, 2007 AT 8:47 PM

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