Water pump, blockage or thermostat?

Tiny
JIMB2020
  • MEMBER
  • 1996 FORD ASPIRE
  • 1.3L
  • 4 CYL
  • 2WD
  • AUTOMATIC
  • 140,000 MILES
So, the engine cylinder head, block and manifolds, wiring, lines and accessories are all installed after a rebuild. New thermostat was installed and all ready to go. I started the car, and it started after few cranking's (car hasn't been driven since the rebuild started 8 months ago- coolant dripped out of the tail pipe initially. The car has leaked coolant into the exhaust before the rebuild started last Spring). The engine is brought to operating temperature but I can't see gauge movements at all (the instrument panel needs replacement). On first attempt, the heater inside the car blows hot air. I feel the coolant system and something isn't right. The upper Radiator hose is ice cold after 15 minutes, the lower radiator hose is hot, the inlet and outlet heater core hoses are both hot and the radiator is ice cold top to bottom. The fan isn't kicking in but after testing it with direct current, it works. Next, I pressurized the system only to realize the idle bypass control valve coolant hose didn't have the clamp positioned correctly and the hose is dripping. Also, the main coolant bypass hose (the short curved hose up front near the exhaust) is leaking. I replaced the clamp to its correct position and replaced the Bypass hose with a new one. I emptied the coolant system, refilled the radiator and brought the engine to operating temperature: no leaks but the radiator does not want to empty into the blocks so I can add more coolant (the coolant is stagnant in the radiator). I squeezed the upper hose in an attempt to purge air and add more coolant. No go, it did not want any more coolant. The system has less than half the coolant it needs. After many attempts (all of which resulted in coolant gushing out of the radiator), I shut it down and did a coolant pressure test. It holds with no leaks, but I know there isn't enough coolant. A day later, I start all over, emptied, refilled (it won't take more than about 75 fluid ounces- full capacity is 201 fluid ounces or 6.3 quarts of coolant), heater on high and engine running for about 10 to 15 minutes: the results are bizarre (the opposite results of previous attempts: cold upper hose, cold lower hose, cold heater core hoses both inlet and outlet, heater blowing cold air inside the car and radiator stagnant dead with no flow). Now, the water pump isn't working as far as I am thinking but the thermostat maybe stuck closed. I separated the lower radiator hose while the car is running in attempt to feel any suctioning by the water pump, but I felt zero effect. The question here is very simple, can the water pump suction coolant if the lower radiator hose is placed in a bucket filled with fluid under the car (I am attempting to see if the water pump is working at all- does it draw fluid from the radiator through the lower radiator hose by suctioning force? Or does it do its circulation job by creating a centrifugal force not a suctioning force?)? Can a stuck closed thermostat cause the water to stay put in the radiator (preventing the water pump from circulating the coolant)? Does the water pump circulate fluid inside the engine before the thermostat opens? Could it be internal leak (I emptied some oil, and no coolant was present in the oil, and spark plugs were dry and not fouled at all)? If I remove the thermostat, run the car to operating temperature and separate the lower radiator hose from the radiator and stick it into a bucket filled with water, will I be able to observe coolant being suctioned if the water pump is working? I realize the system will lose pressure but can I observe initial suctioning? If the block or head have constriction(s) or blockage can that stop the water pump?
Sunday, December 6th, 2020 AT 9:01 AM

3 Replies

Tiny
ASEMASTER6371
  • MECHANIC
  • 52,797 POSTS
Good afternoon,

This sounds like you have a bad new thermostat and that is not allowing any circulation in the system itself.

https://www.2carpros.com/articles/replace-thermostat

As far as the water pump, if you put a hose in a bucket, it should pull it from the bucket but if the thermostat is closed, it will not circulate.

https://www.2carpros.com/articles/symptoms-of-a-bad-water-pump

https://www.2carpros.com/articles/how-an-engine-thermostat-works

Was the head checked for any cracks before reassembly?

Roy

WARNING: To avoid possibility of personal injury or damage to vehicle, ensure ignition switch is in "off" position before disconnecting wire from cooling fan temperature switch. If wire is disconnected from temperature switch with ignition switch in "on" position, cooling fan will turn "on".

1. Remove radiator pressure cap from radiator filler neck.
2. Drain coolant level below radiator upper hose.

Fig. 23 Thermostat Replacement
imageOpen In New TabZoom/Print

3. Disconnect electrical connector from cooling fan switch on thermostat housing.
4. Disconnect upper radiator hose at thermostat housing, then remove two thermostat housing retaining bolts from cylinder head.
5. Remove thermostat housing and gasket.
6. Remove thermostat.
7. Reverse procedure to install. Tighten thermostat housing to 19-26 Nm (14-19 lb ft).
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Sunday, December 6th, 2020 AT 11:33 AM
Tiny
JIMB2020
  • MEMBER
  • 106 POSTS
Hello Roy,

No, I did not have the head professionally checked for cracks. I had done a number of superficial tests that gave me impression that the head was alright. The last of which was temporarily bolting the head to the block, pressure testing the system and flushing the coolant after observing for leaks (that was before the problem with the head gasket if you recall- when I sprayed it with Permatex copper spray and you cautioned that shouldn't have been done). Well, after that I just installed a brand new head gasket just as you advised. Since then I did many subsequent filling and testing and none showed leaks from the engine itself. I had some issues with the heater inlet pipe and its o ring. It kept leaking and after giving up trying to mend it, I got me a new water inlet, heater pipe and o ring and finally it held good. So, today before I saw your answer, I noticed the bypass hose I installed was somewhat flat in the center (I used a random hose that was close to 9/32 in inner diameter but forgot to note that coolant hoses are constructed with threads in them to prevent collapse) which was constricting the flow of coolant out of the cylinder into the heater pipe. So, I replaced it with the exact bypass hose meant for it. This brought the results back where they were the night before (total coolant added 140 fluid ounces out of 201 fluid ounces, stagnant cold radiator, heater core hot and heat inside the car but the upper radiator hose was warm and the lower cold). Then, I read your answer which was encouraging because what you were describing was exactly where I ended up before I read your response: Stuck closed thermostat or a bad one. Now, I will remove the thermostat and check the flow. I will get back with you ASAP. Thanks again Roy.

James
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Sunday, December 6th, 2020 AT 6:41 PM
Tiny
ASEMASTER6371
  • MECHANIC
  • 52,797 POSTS
You are welcome.

Always glad to help.

Roy
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Monday, December 7th, 2020 AT 12:54 AM

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