Doug996InKC

Spent 3 hours last night removing supercharger parts in order to get to the coolant reservoir. There's a leak at the level sensor. I can't believe it's just a "plastic to plastic" connection... no rubber o'ring, nothing (according to the PET).

Need some ideas on how to permanently plug that hole (without the sensor). A boat plug? Whatever is used, it would have to withstand some very high (and low) temperatures.

Let the ideas flow (no pun intended)...

Macster

New tank time. The connection however it is assembled/sealed/secured should not leak. You really need the sensor there. These engines, tanks, get low on coolant enough that having that warning may be the difference between just a tank or an engine.

Doug996InKC

Tank is only 2 years old. I'd rather drill and put in my own sensor on the side of the tank. Why the heck haven't we all found a different take (with a bleeder, etc.) to use? This car is over a decade old. Ford, Chevy, Saab? Somewhere, there has to be a tank that will fit, and not cause us so much damn trouble! My 2 cents.

Ahsai

Agree with Macster. If you drill a hole, you won't get the reinforced boss like the original hole so you may create anohter weak spot waiting to be exploded.

fpb111

Glue it in.

http://www.plumbingsupply.com/pvccementglue.html

b8_rdc

+1 for a high temp glue for solution.

Macster

Yeah, that works real good for the coolant pipes in the Turbo. Not!

DBJoe996

First, if it were me, I would replace the tank since you are so far into this project. Seems like the most cost efficient permanent solution. Second, if you are willing to experiment, agree with the high temp glue/sealer for the tank sensor...then have the tank pressure tested. Doing an all out delete I think is not a good idea as there is a sound reason for having a low level sensor in the tank. That said, if going the delete route, how about a brass/rubber expansion plug like what is used on a engine block? Finding the right size might be tricky but it might work. A local radiator shop probably has one that would fit. I would take a dremel and cut off the upper housing part that holds the sensor in place leaving the reinforced tank boss. I would definitely have the tank pressure tested before reinstalling.

stevedavies

If I recall the sensor does not contact the coolant at all. It sits in a slot in the coolant tank ( held in by rotating 90 degrees?). Sensor works by sensing the radiated temperature rather than having contact with coolant.

KrazyK

Huh????

To the OP, I would just fix it rather than eliminate the sensor. Has to be a reason its leaking.

b8_rdc

Well. "..works really well..."

Anyway, apples and oranges. See the coolant sensor has a locking portion. The coolant pipes, not.

perryinva

This is correct. The sensor seals nothing. It is a non liquid contact sensor that goes through (a possibly thinner?) the tank wall. If you have leak there it is a defect in the tank and you have to replace it anyway.

KrazyK

I was referring to the temperature part of his post. This sensor does not measure temp.

StephenB

The sensor is a dry sensor. Does not touch any coolant. You can pressure test the tank without the sensor in place.

Doug996InKC

SteveDavies, perryinva, StephenB -- thank you! I assumed way too much. In fact, I pressure tested the tank tonight, and no air leaks. I used the uView vacuum. The gauge held at 25 for 5+ minutes. So... it must have been a loose worm clamp, and the coolant traveled down the bottom of the tank, making it appear that it was the sensor hole.

Now... to put all of this back together.