94 Grand Am water outlet leak

I own a 94 Grand Am with a 2.3 OHC. A couple months ago the water outlet (located under the power stearing pump) cracked so I replaced it. Ever since I have not been able to get the damn thing to seal. It just uses an O-ring on the collar that slides into the block. I've replaced the o-ring, I've used rtv sealant on it to try to get it to seal, but it just doesn't work. My next solution is going to be to make a gasket and use that. The only problem with making a gasket for it, is that the outlet is plastic and has a honey comb surface on the flanged part that bolts (two bolts) to the engine (I'm assuming this is just to give it strength). So the whole thing is not a flat smooth surface.

If anyone is still lost as to what outlet I'm talking about, it has a line that goes to the radiator, heat core, metal line to surge tank, and also a temp sensor screwed into it.

Can anyone just please give me some advice on sealing this and fixing it once and for all. I plan to tackle this over the weekend, and I'm tired of playing/smelling antifreeze.

Thanks,
Matt

Is the head smooth where the outlet bolts on? Is it possible one of the hoses is leaking?

If it is the o-ring leaking, I would try using Ultrablack RTV sealant. It will be very difficult to remove if you do use it, but it almost always seals.

Drain the coolant down so you can thouroughly dry both surfaces. Apply lots of ultrablack to the outlet and let it dry for a few minutes. Put it on and tighten the bolts as much as you can with your fingers. Let it dry a few more minutes and then tighten the bolts to where the outlet is about 1/16" out from where it is now when it's tight. Let it dry overnight and then tighten the bolts to whatever the torque specification is. Then fill the system, and hopefully the leak is gone.

Also you might check the hole where the O ring goes couild be a bur cutting or pushing the O ring and keeping it from sealing. And as mentioned above make sure its dry.

and Welcome to AF Matt.

Thanks for your responses. I'm going to try making this work this weekend. Hopefully I'll finally succeed.