Hi,

My 2002 SC2 has had a very slight coolant leak for a while, but it has never been an issue unless I was parked on an uphill grade. The other day I started smelling coolant in my vehicle when parked and running.

You can see in the attached picture that on the left back side of the engine is a plastic connector that among supporting other things, has a coolant connector which broke. You can see here that it is cracked at an angle, and there is coolant pouring out (I plugged it with a small stick before and after taking the picture)

I don't have much in the means of car mechanical ability, but have family willing to help me if I can identify the part and figure out what it would take to fix it. Being a college student I would much prefer to not take it in.

Any help is appreciated, thanks!

EDIT: the picture should say Right Rear bolt of oil cover

 

I find it stupid that they put plastic intake manifolds on the 2000-2002s. Unfortunately what it looks like is that the manifold cracked at the coolant passage. Also unfortunate that your going to have to replace the whole manifold.

If you can get it to dry, and you can inspect it (so you know there isnt any cracks anywhere else) you may beable to J-b weld it for a temporary fix, depending on if theres a hole or just a crack (If theres a hole dont even try it haha youll just plug it up and lose your heater core feed)

The only good thing about this is that since these manifolds are plastic, you should beable to get on relatively cheap from a junk yard. If you replace it, be careful torquing down the bolts as you can crack the manifold if you dont do them in sequence
You can also get rid of the problem all together by switching to an aluminum manifold (from a 96-99) it will bold right up and will be stronger, but you will have to change some other things ( https://www.saturnwiki.com/wiki/inde...take_manifolds )

This shouldnt be too much of an issue, it can be done on a college budget haha. I just rebuilt my motor and got another transmission on a college budget hahaha

 

I am not personally familiar with this particular problem. My Saturn is an earlier car and not prone to it.
I am familiar with plastic parts that logic seems to say, never should have been made that way in the first place. I have yet to successfully fix one so that it no longer becomes a problem.
The solution seems to be things like this.
1. Remove ( this is the common step, if not done none of the other steps are even worth trying)
2. Replace it with a junk yard used part. Generally though this is prone to the same problem.
3. OR Try to glue it with JB Weld, Epoxy, Super Glue and anything else you can think of and re-install it. Only to find you need to remove it again, see step one.
4. Or, back fit it with an earlier part that is made of metal and as it has been said, probably change other things in order for it to work.

Now 4 is usually the one that fixes it. Requires the most work because Steps 1 (often repeated) 2 and 3 are often repeated too.

I even have almost new replacement plastic parts on my parts shelves in my garage that only lasted a few months before they too failed. I wonder why I take up space with them?

Sorry that you are unfortunate enough to have to deal with it. I find very few things more frustrating then dealing with stupid plastic parts 'specially since no one made smart ones.
See if some one here can not give you a decent parts list of what is needed to back fit it and find a junk yard locally that can fill it for you. And then a family member to give you a hand.

 

Sure looks like something was lying across it for a while and rubbed through. What is across the top of it? If you get it repaired, you need to make sure that doesn't happen again.

 

Im actually wrong! I was looking around and it appears that is a seperate piece on the plastic manifolds. You should beable to get a replacement

 

YELL LOUDER

He's out in the middle of a junkyard looking for an aluminum manifold

 

how do you replace said separate plastic part do I still have too remove entire intake??

 

Seeing that thread is over 11 years old, I don't know that you're going to get much help. You might just try searching for that on youtube.

 

I believe that goes to the heater core.
Here's all of it.

Operation CHARM: Car repair manuals for everyone.
Home >> Saturn >> 2002 >> SC2 L4-1.9L DOHC VIN 7 >> Repair and Diagnosis >> Engine, Cooling and Exhaust >> Cooling System >> Coolant Line/Hose >> Service and Repair >> Heater Inlet Hose

Heater Inlet Hose

Removal





1. Drain cooling system as directed in "Engine Coolant Check and Replacement."
2. Remove air cleaner housing cover and intake hose.





3. Remove clamp and hose from engine outlet and blow remainder of coolant out of heater core with a low pressure air hose to prevent coolant spillage.

CAUTION: MAKE SURE THE VEHICLE IS PROPERLY SUPPORTED AND SQUARELY POSITIONED PRIOR TO LIFTING. TO HELP AVOID PERSONAL INJURY THEN A VEHICLE IS ON A HOIST, PROVIDE ADDITIONAL SUPPORT FOR THE VEHICLE ON THE OPPOSITE END FROM WHICH COMPONENTS ARE TO BE REMOVED.

4. Raise vehicle.





5. Remove clamp and hose from heater core inlet.

Installation





1. Install hose and clamp on heater core inlet. Position clamp tangs at 4 o'clock.
2. Lower vehicle.





3. Install hose and clamp on engine outlet. Position clamp tangs at 8 o'clock.





4. Install air cleaner housing cover and intake air ducts.
5. Fill cooling system and leak test as directed in "Engine Coolant Check and Replacement."

pro multis · About Operation CHARM

 

There is a nice video of changing the water tube that Dorman sells on the Dorman website. They recommend that you remove the manifold to make the repair, and after watching the video I agree.