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[Engine] Coolant leak from rear flange - how to replace?
#1
Hi all. My first post here.

I have a 2006 Berlingo 1.9D, no turbo, no AC.

I have a coolant leak from the flanged pipe at the rear of the engine. I had the STOP light come up on the dash yesterday and high temp on the gauge. I stopped the van and put about 4 litres of water in the reservoir, it got me home.

I traced the leak to this part Water pipe flange

I'm not sure if it's leaking at the flange or the plastic is cracked, it's leaking at the top somewhere. The pictures online show a slot at the top so maybe the o-ring has failed.

I took the two bolts out from the engine but couldn't figure out how to disconnect it from the large plastic pipe that runs behind the engine. I didn't want to force anything as I don't have a spare yet.

Can anyone advise how to disconnect this piece from the rear coolant pipe?

Cheers
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#2
(21-10-2020, 01:06 PM)GregS Wrote:  . . . I took the two bolts out from the engine but couldn't figure out how to disconnect it from the large plastic pipe that runs behind the engine. I didn't want to force anything as I don't have a spare yet.

Can anyone advise how to disconnect this piece from the rear coolant pipe?

Cheers


It looks like it may just be a push fit, the pipe that goes into the flange will probably have an O ring on the end, these can get quite a hold once they have been in place for a while.


.
My vehicle .... 2006 (m59) Berlingo Multispace Desire - 1.6 HDI 92 
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#3
Thanks. I did kind of think that but didn't want to force anything. I found this diagram on catcar.info which looks like it pushes on, a slip joint on a pressurised system seems counterintuitive to me.
 Item 1 and seal 3


Attached Files Thumbnail(s)
   
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#4
Yes it certainly look like it's a push fit.

Manufacturers these days love an O ring or two   Big Grin


.
My vehicle .... 2006 (m59) Berlingo Multispace Desire - 1.6 HDI 92 
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#5
I think I've found the issue, I'll post the details here, it may help someone in future.

First of all the the part is a bit of a nightmare to get out. I had to remove the plastic tube which routes from the battery side to the rear of the engine (part 1 on the drawing). The top red circled bit was the issue.
   
I had to take out the whole tube and manifold assembly as I couldn't get it separated in situ.

Here's the offending part, a hairline crack below the top lug, straight through the plastic:
   
   

The tube which pushes in to the manifold with O-Ring, this was really tight to remove.

   
   

The faulty part could be removed by removing the 2 bolts from the block, unclipping the heater matrix tube and pulling the manifold part away from the long tube but this was so tight I had to remove it all.

The block had a bit of rust around where the seal sits, this maybe pushed the plastic out over time and caused the crack. Maybe.
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#6
Very well done for spotting that crack!
Current: 2003 1.4i MS MPV - Lucifer Red
Prev: 2003 1.6 MS Desire - Bile Blue
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#7
(02-11-2020, 07:34 PM)Rasputin Wrote:  Very well done for spotting that crack!

The magic of WD40. I dried it off, put some WD40 on it then wiped it again. The water was drawn out of the crack.

I've now replaced everything and a new part. A bit of grease on the tube end and it slipped right in, it was a bit too easy, I thought it wouldn't seal but so far so good.
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