Thread: Coolant Leak from EGR Tube, Please Help.

Did you replace the o-rings that seal between supercharger and LIM?

Also, the bolt that hold the EGR tube flange may go into the water jacket. Make sure there is thread sealant on the bolt before you put it back in.

I grabbed the NA motor UIM failure before having a chance to notice the section you posted this into. I would doubt you have any head or LIM issues beyond a gasket or o-ring. Most likely when you put the charger in place, one of your o-rings moved. Being that you don't mention your year, I'm guessing 97-03 as the o-rings were simply sitting in place and not held or molded into the gasket like the 04+ years.

Only other thing I'd think it could be would be the end seal on the LIM, it's a little cover under the TB with two 8mm bolts. This cover

Grandprix27

Not doubting you - but this one of the strangest problems I have ever hear of with the 3800. Are you sure it's not spraying from the gasket between the SC and the LIM?..as Bill has alluded to previously?

When you take it back off clean it real good and run some 220 grit sand paper in the EGR port and see if you see a crack. If it's actually spraying it should be quite obvious.

I can't wait to see the pics.

It's obvious if it's coming from there, that it'll be full.

I'm also in for the picture of the hole in that area. Never heard or seen that before. My first instinct would be that it's pushing down from one of the yellow o-rings being sligntly out of place. They are close by and could to that.

Another misc item, the EGR bolt isn't tapped into a cooling port. It shouldn't require sealant. The gasket on that end cover should be installed dry. But that is more of less installer choice.

Originally Posted by BillBoost37

It's obvious if it's coming from there, that it'll be full.

I'm also in for the picture of the hole in that area. Never heard or seen that before. My first instinct would be that it's pushing down from one of the yellow o-rings being sligntly out of place. They are close by and could to that.

Another misc item, the EGR bolt isn't tapped into a cooling port. It shouldn't require sealant. The gasket on that end cover should be installed dry. But that is more of less installer choice.

Yea, I just looked at mine and it is definitely a blind tap...good to know.

Chuck...you know how it goes. Just ask.

Most likely I've been there, broken that or at least checked it out.

You can't post pics from your PC...only from a url like photobucket.com.

When you put the EGR tube flange on did you use the original (very short) bolt? If you used a longer bolt it may have punched a hole or cracked the manifold. Check for cracks or damage to the blind tap for the bolt.

Okay well after tearing it down 4 or 5 times and putting it all back together, I cleaned that hole out, by eye I cannot see any crack, just a few scratches. Man its been a real ****ty and stressful day. Im definately gonna need another Supercharger Gasket from taking it apart so many times. This story is gonna get a lot weirder... Remember this Upper and Lower Intake has all brand new Felpro gaskets and new O-rings. (Aluminum LIM Gaskets). Bare with me while I try to explain... The first time out of 5 attempts today, it was coming from the EGR Tube----LIM connection. Took a picture with the coolant in the hole, then cleaned it out, and took a picture of that too. Ill post after I get done explaining. Put it all back together, then it starts leaking from the cap on the Lower intake (right below the EGR tube). New gasket is in there with High Temp red RTV sealant. Well take it back apart, replaced the new gasket with another one and more RTV. Hahahaha... this is where **** gets weirder... Put it back together, starts leaking from the EGR tube again, not the cap this time. ?!?!?! Take it back apart, O-rings from Supercharger are in place nothing has moved. Put RTV on the O-rings of the Supercharger, just in case. check that damn hole again... NOTHING! No crack, no holes! Put it all back together. Starts leaking from the Cap again. Nothing is coming from the EGR tube, it is completely dry. Take it back apart Supercharger gasket has torn by the bolt holes at this point... oh well its not important because its just by the bolt holes... Looked at the Supercharger to see if the coolant holes might be crack...mmmm...NO! Replace the gasket to the cap again, and literally inspect those two water jacket openings, no obvious holes or cracks... This is literally blowing my mind and making me feel like an idiot for doing all this removing and putting back together of the engine. Finally get it all back together, then it leaks from the EGR Tube. Im absolutely dumbfounded, the only thing I can possible think of is, maybe with the engine and intake warming up that the crack opens up from the heat, cause heat causes things to stretch...right? maybe its such a small crack, that you cannot see it with just your eyes. maybe needs to be X-rayed or something (Non-destructive testing)? Yeah something like that. Or another option is maybe a blown head gasket, maybe water is somehow pushing through somewhere, and its causing ths nonsense. Looked at my oil, and it looks alittle mixed, but it maybe because of my taking it apart so many times that water gets into my oil by accident. No white smoke or water comes out of the exhaust....YET! I havent even let the temp run past 195*, I always shut it down, as soon as the leak starts. So im kind of ruling the head gaskets out, although it could be a possibility. So...besides all that, my day sucked. How was yours? lol. Sorry i had a little of a rant going, I'm just frustrated at this point. If anyone has any idea please let me know. I have another spare LIM that I will put on tomorrow and see if anything changes.

Here is a picture with coolant in the hole:
IMG_8932 (600x800).jpg

Picture of cleaned out EGR Hole, Dont see any cracks, or holes, just a few scratches:
IMG_8934 (300x400).jpg

Is this where the leak is? Why are your pictures from the top?

Take the o-rings out.

1. It's not a head gasket. You are no where near the head gaskets. Please understand, it's not a head gasket.
2. The TB to SC gasket. Have you replaced that? Please check it. It can allow coolant into the charger (which you would see inside the charger and then down into the elbow.

Damn...that hole is close by


If you had any external leak from it as well, that would definately be able to look like the end cap is leaking. It's not an easy area to look for a leak.
3. Take the o-rings out and ensure the recesses are clean. Double check the bottom of the charger to be clean.

There is something small that is causing this issue. I'm thinking its a gasket or a dirty gasket surface. I highly doubt it's a cracked LIM. I am positive from your description and issue, it's not a head gasket.

All of the gaskets you are working with, should be installed dry. Meaning, no RTV. As you take it apart again today. I'd suggest cleaning all that stuff off and going at it fresh, clean and dry.

Chuck, his pics are from the top, because wiithout taking the LIM off...his exhaust is a little too close to get a good pic from the side.

Now c'mon on board with my "theory of leakism".

Bill - if it were leaking from the gasket or the o-rings it would get pulled in (at engine idle negative pressure) and blown out the exhaust, no? That area is only under positive pressure when the SC is creating boost.

I see what you're saying about the TB gasket and that could be it.

He says it's squirting out from the EGR tubing flange. This is completely baffling.

The squirting might be from the boost being generated by the SC, being recycled through the bypass and creating some pressure, which would flow into the EGR tube area as well.

Chuck: Can't back a buddies theory, it's ok... I see how you are. wink wink

This sure isn't another "leaky coolant elbow" thread. This is new and exciting. LOL

OK, I'll back that theory...but only cause it's yours.

This is exciting? We gotta spring you outta the nursing home more often.