While doing my timing belt I discovered that the plastic thermostat housing has a small damage on its edge (you can see this damage in the picture below). I decided to reuse the thermostat housing after sanding/smoothing the edge with very fine sand. I got the ECS plus kit, so all major parts have been replaced.

After tightening the last bolt and filling the system with g12 coolant, the engine sounds fine. Yes, the timing is okay. Unfortunately, there is coolant leaking from the oil pan. I think that it may be from the thermostat housing or water pump, or from some hose. Now, I have to take everything a part again and order new thermostat housing, o-ring and maybe a water pump gasket...

Any suggestions or tips for my situation?

Is this (http://www.autopartswarehouse.com/ba...tem_id=6011484) a good replacement for the factory thermostat housing?

 

y dont you buy a new thermostat instead of the housing and o-ring ..so you wont have to do it again when the seal leaks..

 

I got new thermostat and o-ring with the timing belt kit. They were both replaced in the process. Is there second o-ring/seal for the thermostat housing itself?

 

what miles did you replace it at?

 

91k

 

Has anybody attempted to run the engine without bolting the front reinforcement and radiator? It doesn’t sound very “engine-friendly” . I am thinking of getting additional hoses in order to extend the bottom and top radiator connections. This way, I am hoping to see the exact location of the leak. Is this possible or bad idea?

 

Yea, you do that to make sure nothing is leaking before you button it all back up.

More then likely it's the WP or the thermostat leaking. You got to get back in there & find out, & replace the parts causing the leak. You can put a little bit of silicone sealant on the manifold to stop the leak, but you are better off getting a new one.

 

Thanks guys. Found the leak - thermostat housing. A new one is coming from New Jersey today or tomorrow. I will try to replace the housing without removing the timing belt. Is this doable? I want to slide it out to the left (passanger side) behind the timing belt.

 

i see you are using your laptop with pictures as a ref is ther an address with pictures like that i can use when i do mine.

 

http://www.audiworld.com/tech/eng63.shtml