2001 SOHC Thermostat Housing Dilemma.... Need opinions/advice
Hello all, first let's start with what happened...
Thermostat housing cracked/leaking so I decided to replace it. Upon removal of the three bolts that hold the housing to the block (is it the block or lower intake) one of the bolts snapped off. I attempted to drill, heat, freeze, just about every type of trick you could to get it out, I ended up taking it to a machine shop that upon second thought was a horrible idea. (Just very lackluster service and workmanship).
At this shop they drilled out the bolt and helicoiled it and gave me a new bolt. I know this knew bolt is standard compared to the metric size it used to be.
6 months later I am still leaking coolant, at first it was the thermostat gasket, then a radiator hose, now that everything is pretty much settled I'm still using coolant. Not enough to have a drip but enough to smell it when the engine gets warmed up.
I was at a loss.
So I added some UV dye to the coolant and after a few minutes of letting it run I found the leak! It looks like the seal I used from housing to block was giving way, so I used the seal in addition to some gray rtv and it did the trick. But now somehow the coolant is leaking up through the bolt I think. The system pressurizes the hoses and if I squeeze the hoses I can't see any running coolant. Weird.
I'm at a complete loss at what to do from this point. Do I let it ride and just fill it up with water? Do I switch out the engine so I have a proper torqued bolt with correct size?
What would you do?