Date:         Mon, 12 Apr 1999 11:58:54 -0700
Reply-To:     Tom Clein <tomkat@ISOMEDIA.COM>
Sender:       Vanagon Mailing List <vanagon@gerry.vanagon.com>
From:         Tom Clein <tomkat@ISOMEDIA.COM>
Subject:      Flashing Low Coolant Light (longish)
Content-type: text/plain; charset="US-ASCII"

Yo, Gang.  Remember me?  The '87 Syncro Westy guy (TOYBOX) with
the fresh air fan replacement (dash removal, etc.) about a month
ago?  Anyway, last you heard from our hero, all was well.  After
Re/Re, I took TOYBOX to my FLSP to have the cooling system bled
and topped off.  I lost a bit of coolant (about a gallon?) from
the front heater core and a broken right rear head flange on the
engine.  Service place changed oil/filter (with 20/50W Dino & VW
Filter) at same time as bleeding/top off.

All was well until trip home (Seattle area) from Whistler, BC
(about 250 miles) 2 weekends ago.  15 minutes into the trip...the
low coolant light starts to blink - normal operating temp, though
needle seemed to flunctuate a bit more (higher) than before
coolant bleeding/top off.

I pulled over, visually checked the coolant level in both tanks
(looked good - though overflow tank was over max setting).
Started up again...light comes on/goes out as usual at
start-up...15 minutes later - same flashing LED.  Normal temp,
coolant levels (again) looked good so I continued on to US/Canada
border until I needed gas at (relatively) cheaper prices in the
good, old USA.

I decided to 'top off' expansion tank with water in an attempt to
quash the flashing LED.  I removed clamp and disconnected hose
from expansion tank to overflow tank and twisted the cap off
expansion tank.  Pressurized coolant immediately rushed to top of
expansion tank and leaked through threads of cap/tank.  Rather
than lose more coolant (overflow tank hose also began to drip
coolant in engine compartment)...I re-tightened cap and
re-attached hose and drove on.  No flashing LED for 15 miles/15
minutes (whichever comes 1st! - YMMV)...then "Here we go, again!"
Watched temp gauge (OK) and flashing LED for next 150 miles.  Glad
I'm not susceptible to epileptic seizures.

Got home, checked coolant level in both tanks next am - filled
expansion tank with plain water (system not pressurized - no
problem getting cap off)...also filled overflow tank to max line
as a small bit of coolant had leaked out of hose at border gas
stop.  TOYBOX is our 'weekend' driver so the next time I drove it
was this past week-end to/from Crystal Mountain (about 80 miles
each way).  Lo and behold, 15 minutes into trip....low coolant LED
flashing again.  Oh well.

Searched through archives.  Consensus seems to be (in following
order of $$$ fix).

1.  Air still in cooling system - will take back to FLPS to redo
bleed/top-off
2.  Incorrect composition of coolant solution - see 1 above
3.  Corroded/poor electrical contact in expansion tank coolant
level sensor - clean contacts/'crimp', coat plug with dielectric
grease or replace sensor
4.  Shorted electrical wire/bad ground or contact from sensor(s)
(Front & Rear?) to instrument cluster - trace wires looking for
short/poor connection
5.  Bad 'radiator' (expansion tank) cap - replace
6.  Low coolant level control unit - replace
7.  Dreaded Head gasket leak - repair

I'll do 3 & 4 before taking back to FLPS to rebleed/top-off
cooling system.  I'd bleed system myself if I wasn't so concerned
about phosphate-free antifreeze finding its way into the
groundwater/salmon habitat here...or worse yet - into my 2
dogs/vanagon passengers.  Besides, I paid FLSP good $$$ to do the
job right the 1st time!

My reason for contacting the list is to see if there's anything I
might have missed in searching archives for possible
problems/fixes.  Please p-mail directly as I've already used up
WAY too much bandwidth for this well documented/common affliction.
 TIA for your collective help.

Happy Motoring!

Tom Clein
'87 Syncro Westy  'TOYBOX' or 'Silver Slug', depending on my mood
or status of coolant leaks/trail
tomkat@isomedia.com