DIY: Coolant Leak Repair (Upper T)

This is a very simple repair that has plagued many 6 owners. Right near the battery is a T shaped union that connects to the throttle body via a small hose. I noticed a leak in the small tub that connects to the throttle body and was loosing coolant ridiculously fast. My temperature gauge was fluctuating from mid range to high, and my heater wasn't working consistently.

The problem is the 3/8" connector is fragile and can break easily. To replace it, you will want Dorman part #902-003, which can be found at most auto repair stores.

There are a lot of people who eliminate the hose that runs to the throttle body, called it the tb bypass mod. I'm not going to cover that here.

1. Begin by removing your battery (10mm) and tray (10 mm), as well as the stock air intake (or CAI/SRI, if you have one installed). Now that you have some room to work with, remove the smaller hose that connects this T union to the throttle body. You can see that the small pipe from the T is broken and the broken part is stuck inside the tube! That was where the leak was coming from.
















2. Using channel locks (or pliers, as I had to) and flat heads, remove the T from the hoses it is connected to, including the base. This part really sucks. I suggest replacing those with hose clamps.



















3. This is what the troublesome T looks like. Note the large 3/4" sides are in a 90 degree angle.





















4. Here is the new part.























5. Carefully install the replacement part. Attach all the hoses and make sure everything is on tight! Re-install your air intake and battery, start the car up and make sure there are no leaks.





















6. Finally, you'll wan to make sure there is no air in your cooling system. Get a clean, empty soda bottle and cut the bottom off to create a makeshift funnel. Remove the coolant reservoir cap and place the bottle in upside down and seal it with electrical tape. Jack your car up on the front or park on an incline. Make sure to to fill your coolant up near full and start the car with the heat on max but not the fan. This will help circulate the coolant.

Run the car for about 10-15 minutes. This will help remove air bubbles inside the cooling system. Shut off your car and put your cap back on. You're all set!