'01 SC2 MT 181K - Coolant leaking from intake manifold heater hose pipe

Discussion in 'Saturn S-series' started by kwbills, Sep 12, 2025.

  1. kwbills

    kwbills

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    I am not sure if the hose pipe is leaking, or if the manifold is leaking. I don't think it's a head gasket, there is no white smoke during start up, or when driving. Unless the head gasket failed on the outside, not inside.

    So it looks like the pipe is leaking (best educated guess - not the easiest thing to inspect). Someone probably did a quick fix, I believe, once before. The heater hose was pushed about 3" onto the pipe and had the stock pinch type hose clamp and a screw clamp. I managed to push the hose on another 3/4" and double clamped it. No good, still leaks.

    So, I suppose I could plan on a replacement of the intake manifold gasket, hope that's what it is, and while I have the intake off, do a careful inspection of the plastic pipe, and if I find cracks, pray some high temp epoxy can fix it. Is it reasonable to think you can fix a 24 year old piece of plastic subject to high temperature operations and times of cooling?

    Can one find a replacement intake manifold for these? I've looked, and the searches take me to old sales on e-bay that are so long gone, the pages are not found.
     
    kwbills, Sep 12, 2025
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  2. kwbills

    Derf Moderator

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    That pipe extension coming off the intake manifold was a badly flawed design. Sooner or later almost every vehicle with that pipe has it crack or fail in another way. I sincerely doubt it is your intake manifold itself.
    The quick fix you speak of is actually a sanctioned repair kit to address the problem. That's how prevalent it was. There are YouTube videos out there showing how to do it properly. Probably some other workarounds as well.

    For me, step one would be getting a hold of one of these repair kits. Step two, getting the broken part off, step three installing the repair kit. I have not personally performed this repair as I have never owned a gen 3 Saturn S Series. I'm going to go look for the repair part.

    It's fairly reasonable to expect to be able to repair 25-year-old plastic that has heat cycled 8,000 times. The key is taking your time and not stressing the material anymore than you have to during the repair.
     
    Derf, Sep 12, 2025
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  3. kwbills

    Derf Moderator

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    Here's some AI stuff I found while searching.....

    To repair a cracked plastic intake manifold coolant nipple on a third-generation Saturn S-Series (2000-2002 DOHC), you'll typically perform a metal replacement modification. This involves removing the intake manifold to access the cracked nipple, then cutting off the plastic piece and installing a metal repair fitting. The replacement fitting provides a durable, crack-resistant solution to the known design flaw.
    Understanding the Problem
    • Plastic Intake Design:
      The plastic intake manifold on the third-generation Saturn S-Series (which uses the DOHC engine) has a coolant nipple that is prone to cracking and leaking coolant.
    • Symptoms:
      You may notice coolant leaks or bubbling from underneath the manifold, indicating a vacuum or coolant leak.
    Repair Process
    1. Access the Manifold:
      Begin by removing the air intake, air filter box, battery, and engine mount to gain access to the intake manifold.
    2. Disconnect Components:
      Disconnect the power steering pump, serpentine belt, fuel rail, and various hoses and electrical connections.
    3. Remove the Intake Manifold:
      Loosen and remove the nuts holding the intake manifold to the cylinder head.
    4. Remove the Cracked Nipple:
      Once the manifold is off, carefully cut off the cracked plastic coolant nipple.
    5. Install the Metal Repair Fitting:
      Install a replacement metal fitting. Ensure the flange of the fitting is perfectly flat to prevent leaks.
    6. Reassembly:
      Reassemble the intake manifold in the reverse order of removal, ensuring all nuts and bolts are torqued to the correct specifications.
    Tips for Success
    • Watch a Video:
      Refer to helpful YouTube videos demonstrating the process for a visual guide.
    • Ensure Proper Flatness:
      Before installation, ensure the new metal fitting's flange is perfectly flat using a file or vice to prevent leaks.
    • Use Correct Tools:
      You'll need a 13mm socket to remove the manifold nuts and potentially a Dremel tool for cutting.
     
    Derf, Sep 12, 2025
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  4. kwbills

    Derf Moderator

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  5. kwbills

    kwbills

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    Thank you everyone, I ordered what I needed and just need to pick it up. I plan to tackle this tomorrow.

    It's definitely a bad design and I'm not sure why someone would think this would be a good idea.
     
    kwbills, Sep 13, 2025
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  6. kwbills

    Cloudytown Scotty

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    Yes, my 2000 SW2 has just had this repair. The biggest tip is to fight your manly desire to really bear down on the nuts. The provided gasket WILL NOT like that. Mine has a cork gasket, now.
     
    Cloudytown Scotty, Nov 11, 2025
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  7. kwbills

    kwbills

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    I've put a few thousand miles on the car since the hose bib fix. Working great.
     
    kwbills, Dec 2, 2025
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  8. kwbills

    Derf Moderator

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    Awesome!
     
    Derf, Dec 2, 2025
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