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Unread 05-22-2012, 05:44 PM   #1
chetzar
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5.2 Coolant Return Tube

So I have recently done my intake/plenum/valve cover gaskets, using the Hughes Engines kit, and got everything to go back together nicely except one thing: the Coolant Return Tube.

What is the trick to this puppy? Mine fully seated, mounting holes lined up perfect and everything, but it leaking, and leaking quite a bit. I replaced the O-Ring on it (with the one included in the Hughes Engine Kit), is my best bet to try and find another O-Ring, or put the O-Ring on and RTV it? I'd rather NOT use RTV because if for some reason I have to remove it again, I know it will be a pain. Also, I'd rather not replace the water pump (however I doubt this is the issue or would solve my problem), as the coolant is leaking from around where this pipe seats into the water pump.

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Unread 05-23-2012, 11:06 AM   #2
Virmagicus
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Make sure both mating surfaces are clean and your bypass tube is in good shape. Slightly turn while installing. If it still leaks just use some quick curing RTV.
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Unread 05-23-2012, 12:52 PM   #3
chetzar
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I took it out today, got a new o-ring from advance, a slightly thicker one, it tore some of the material off when going in, but was still very tight. I ended up putting black RTV on the pipe before the O-Ring and slid it back into place, some of the RTV oozed out, so using my finger and a bit more RTV, I made sure it was nice and even all the way around. Guess I'll find out tomorrow if it works, because the tube says allow 24 hours for full cure.
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Unread 05-23-2012, 01:11 PM   #4
DeejayZeejay
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Mine leaked when I did my pump so I got another o ring and greased it. Gently putting it back together and making sure it seated properly.... No leaks thus far.
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Unread 05-23-2012, 04:45 PM   #5
Candymancan
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You wont find the correct o-ring size at any store anywhere using the O ring kits.. You only get the correct size o-ring from the fel-pro waterpump gasket kit, or from the "HELP" section heaterbypass tube from advance auto or autozone. The tube has the o ring on it. That or get one from a new water pump box..

Here is what the tube looks like on autozone.. If the link doesnt work for you just type in heater bypass tube and click on the motormyte one for $14

http://www.autozone.com/autozone/par..._&newYmme=true

Trust me, me you and countless others always have issues with this tube when putting the timingcover/waterpump back together lol. You'll only get this to work with the correct o-ring and the tube needs to go in completetly flush if its crooked itll cut the o-ring. The best way to get it in is to lube it up with some butter or oil and it will slide right in. Dont even bother keep trying using the o-rings from kits because as you see they are too thick and you'll only bend or worse scratch the waterpump inside and then you'll be screwed.. It should just slide in with the correct o-ring no force needed.
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Unread 05-23-2012, 06:53 PM   #6
SJZ
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I used two o-rings on mine, and that seemed to fix things.
EDIT: mine didn't have a groove in it, buy merely reduced down in size. Tough to put two on the one in the link above.
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Unread 05-24-2012, 11:23 AM   #7
chetzar
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RTV for the win, leak is gone, but I may have to replace the radiator drain plug, as it is leaking a very slow drip.
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Unread 05-24-2012, 05:01 PM   #8
SJZ
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Quote:
Originally Posted by chetzar View Post
RTV for the win, leak is gone, but I may have to replace the radiator drain plug, as it is leaking a very slow drip.
That's easy. They sell them in the HELP section. Di it with everything stone cold & the radiator cap on, and you shouldn't lose much coolant. I usually put a little teflon grease on the o-ring and threads.
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___________________________________________
'98 ZJ Laredo 5.2 Selec-Trac (249 to 242 swap)
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'94 ZJ Limited 5.2 Q-Trac- sold, after 17 years
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Unread 05-24-2012, 08:08 PM   #9
KJK
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I used a green A/C O-ring. Whatever size one fit the tube nicely. These are available in packs at any auto parts store. It slipped into the water pump real easy (lubed) and sealed great.
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Unread 08-21-2013, 02:19 PM   #10
jimbone007
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i just put in a new water pump and had to put a new inlet tube in and what a pain...... the inlet tube i got at advance auto was half the length of the original so when i put it on it was basically pressed up against the power steering pump/pulley.......so i bent it a little then managed to get the hose on it but its a little kinked but i don't think its bad enough to effect the flow.at least i hope not.It was also the type that had the o-ring so i put it in then used ultimate black rtv around where the inlet tube meets the pump. im letting it sit until tomorrow then filling it up with coolant and testing it out hopefully no leaks!!!
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