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405 1.8i coolant problem - help please

Hi All, All the coolant fell out of the engine today! It turns out that the short stub of metal pipe that protrudes from the thermostat housing (not the top cover) has corrodes to nothing. It looks to be a 20mm diameter pipe about 40mm long with a rubber hose going to the heater input. Is this a replacable part or does the whole casting have to be replaced. It does not look like it is cast at manufacture and so may be 'glued' in and so replaceable. I've tried to remove the casting and taken out all 6 bolts I can find but it only loosens but will not come off. Is this part of the bearing for the camshaft? Haynes says that one of the bolts screws into no 1 camshaft bearing housing. My engine has the breakerless, distributor less ignition so there is no drive off the camshaft to the ign system. Any tips welcome TIA

Bob

Reply to
Bob Minchin
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have you completely removed the thermostat top cover bob

Reply to
Mindwipe

Hi Mindwipe,

Thanks for your reply

Things have moved on a bit. I could not remove the coil pack as the screws were siezed in the alloy casting and the torx heads are really soft. I had removed 6 x 11mm af Hex bolts from the casting but I reckon there is one more under the coil pack that i cant get to.

I have now put all the bolts back and where the heater hose fitted in I have cut a thread 1/2" BSP as the hole is just the right size.

I then took a piece of 21mm AF hex brass bar and cut a1/2" bsp thread on one end and a ridged hose connector on the other with about 3/8" in the middle left as a hexagon for a spanner. A hole down the middle completes the new hose adaptor. I have fitted this with a few turns of PTFE tape and all is water tight once again.

The fundamental problem is that the original tube is steel and fitted into aluminium. Just add water, and corosion will start due to mixed metals. Presumably the designers at Peugeot know this but leave it as a time bomb toboost the profits of repairers!

Do you know how a dealer would repair this? Does it mean a whole new casting at huge cost?

Hope all is well with you - still working on Fords?

I'm considering buying a Cmax- any thoughts? Main criteria are reliability and ease of servicing at home.

Regards

Bob

Reply to
Bob Minchin

not with fords anymore bob doing quality testing on other peoples work at an alfa romeo/fiat dealer better money less wear n tear on me and def cleaner as a rule the problem can also be caused by the anti freeze itself which goes acidic with age why i recommend a 2 yearly change but if in doubt just use litmus having said that you have probably just changed yours now anyway the torx screws on the coil packs are a pain i usually drill the heads off any that wont loosen then you can heat the housing slightly at the bottom and remove with vice grips(or similar) dont buy a cmax its the worst ford so far even crapper than the galaxy

Reply to
Mindwipe

reliability

Thanks Jeff.

Good luck in the new job.

Bob

Reply to
Bob Minchin

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