Date: Fri, 23 Jul 2004 09:22:26 -0400
Reply-To: Kenneth Wilford <kenwilfy@COMCAST.NET>
Sender: Vanagon Mailing List <vanagon@gerry.vanagon.com>
From: Kenneth Wilford <kenwilfy@COMCAST.NET>
Subject: Re: Radiator pipe upgrade
In-Reply-To: <001a01c46ecb$768c2910$a5a98018@Dell1>
Content-Type: text/plain; charset="US-ASCII"
This is very doable. Actually there is a writeup on doing this swap in
the Bentley on page 19.7A with part numbers of hoses and pipes you will
need. I just did this swap on a customer's 85 Vanagon that had super
rusty metal pipes. It is not a fun job. In fact after CV joint work of
any kind it ranks as my number two Vanagon job I hate the most. There
is no way not to get multiple baths in antifreeze no matter how many
ways or times you try to drain the system. There are still low spot in
the pipes that you will be removing that will harbor more than enough
coolant to give you that "oh so fresh" feeling as it is running down
your arm or splashing into your eyes or even trickling into your ear
(BTDT).
To remove the old pipes the last time I used a sawzall to cut the old
ones up a bit and make them easier to remove. You are throwing them
away anyhow so who cares. To be ultra-safe you should probably drop the
gas tank. I didn't do this and vowed the next time that I would (you
have to cut or grind metal above the gas tank, not a good plan for long
life).
There are about 20-30 tie wraps and clamps holding the old pipes in
place which you will need to remove/loosen to get them out including
some that are above the gas tank. Have a nice set of side cutters
(dykes) handy and cut away. Even after you think that there could not
possibly be one more tie wrap I guarantee you will find two more.
After the pipes are free and you have cut off the rear section of them
you should be able to slide them to the rear of the van and get them out
from above the tank.
Now you need to make the opening that the pipes go through larger. The
Bentley gives you exact specs. I used a sawzall again and then when I
got close to the size I wanted I ground the edges so that they were not
longer sharp. You could put some trim around the new opening to help
the pipes not to chafe but if you tighten them up properly then you
shouldn't have to worry about that.
Putting the pipes in is fun. Kind of like a chinese finger puzzle. Put
one in first and then twist and turn the other one around and push it
toward the front of the van. You may have to push the first pipe
farther forward than it is supposed to end up just to get the other one
in place but you will see what I mean when you are doing it.
After the pipes are in place then tie-wrap away. Just like VW put 20-30
tie wraps on these pipes, you need to do the same thing to the new ones.
I tie wrap them to each other, to the floor of the van to other hoses,
etc. When you get done the pipes should not move. You will need two
new radiator hoses in the front. The plastic pipes have a bit larger
diameter than the metal pipes. Since you have a Tiico, then you will
not need new hoses in the rear. Your Tiico hoses were actually made for
the plastic pipes in the first place so they will fit better on the
plastic pipes than they did on the metal (they are a little too big for
the metal in case you hadn't already noticed). If you have a 1.9l
watercooled then you will also need two new coolant hoses for the rear.
The Bentley has the complete hose list or you can call me and I can get
these for you.
Put on the new hoses, bleed the system and you should be up and running
again. You might also want to take a good look at your rear heater core
"T"s while you are under the van. Your old ones are probably metal and
rusted too. I have new ones that are plastic for not too much money.
Hope this helps.
Thanks,
Ken Wilford
John 3:16
http://www.vanagain.com
http://www.strictlyvwauctions.com
http://www.eurovan.org
http://www.vwcabrio.org
Phone: (856)-327-4936
Fax: (856)-327-2242
-----Original Message-----
From: Vanagon Mailing List [mailto:vanagon@gerry.vanagon.com] On Behalf
Of Data Services
Sent: Tuesday, July 20, 2004 10:36 PM
To: vanagon@GERRY.VANAGON.COM
Subject: Radiator pipe upgrade
Hi all;
I want to get rid of the rusty metal coolant pipes that run between my
engine and the radiator in my 83.5 Westy. I know that in late '85 there
wsa a change to plastic pipes that woulsn't rust. The research I have
done indicates that maybe the metal and plastic pipes are the same
configuration (bends and turns), just different material. Anyone have
any experience with this?
Dave B.
'83.5 Tiico Westy
'83.5 WBX Westy
