Date:         Sun, 21 Feb 1999 23:13:16 -0800
Reply-To:     John Scheckel <jscheckel@NUTLEY.COM>
Sender:       Vanagon Mailing List <vanagon@gerry.vanagon.com>
From:         John Scheckel <jscheckel@NUTLEY.COM>
Organization: John Scheckel Architect
Subject:      Re: Coolant-Drain and Replace
Comments: To: Gordon and/or Cecilia Bonham <bon@BELLSOUTH.NET>
Content-Type: text/plain; charset=us-ascii

Gordon and/or Cecilia Bonham wrote:
>
> I bought a 1990 Westie yesterday.  During the heads inspection, which
> checked out ok, the local VW dealer noticed that coolant was leaking out
> of the expansion tank, apparently at the sensor port.
> I need advice on refilling the cooling system after I remove and
> check/replace the expansion tank.  I remember from owning an 82 diesel
> that refilling was a several step procedure and suspect that the 2.1 may
> be the same.  I have not had time to get a Bentley or a Hanes manual and
> so far have been unable to find the information I need in the archives.
> Thanks to those who gave me advice on thing to check for prior to
> purchase.
> Gordon Bonham

The coolant sensor on my van recently started to leak.  I replaced the
entire sensor, about $8.00 from the dealer.  There is a rubber O-ring on
the sensor that appears to loose its ability to seal the unit.  You can
problably pick up the O-ring for pennies somewhere, if you are on a
budget.  I did not drain down the expansion tank when I replace the
sensor.  I worked quickly and I kept the rest of the system tightly
capped, keeping most of the fluid in the tank.  What minor amount leaked
out was easily cleaned up.
If you need to remove the tank then you would need to bleed the system
which is covered in Bentley.  In general, you have to remove the front
grille, raise the front of the vehicle 8"+/- and loosen the bleed screw
on the radiator.  Run the engine until the coolant runs out of the bleed
valve. Keep an eye on the tanks and fill them as required.  It may take
several hours to completely bleed the system.

Good luck.  John S