Old Library

Hi Everyone,

About 6 weeks ago, my VR6 burst a coolant hose (between the cylinder head
and heater matrix), there was a terrible mess and lots of stinky smoke, I
thought it had caught fire!  The hose was replaced (you don't want to know
how much they cost) and all was well (my amber coolant was replaced with
nice fresh green stuff too (G11)).

Yesterday, a few minutes after starting the car the coolant level warning
light started flashing so I get out to have a look and sure enough - the
coolant resoviour is empty, but this time the transmission has puddles of
coolant over it and there is no smoke.

I took it to the dealer last night (they stay open till 8:30, cool) but by
the time I got there everything had dried and it just would not leak, even
with the engine running and extra pressure applied to the system, the stains
however suggested the thermostat housing.

This morning I started up, and there was a gurgling sound, so I look under
the hood and find coolant running out from somewhere behind the thermostat
housing, presumably where it joins the engine block but of course you can't
see in there.
There is a thin trail running down the head, I presume it's source is the
seal between the thermostat housing and whetever it attaches too but I
suppose it could be something else?  (imminent head gasket failure knowing
my luck)

Anyone had any experience like this?  the dealer said that if they replaced
any part of the thermostat housing or it's seals they would need to do the
whole lot as apparently the plastic parts warp in use and will leak even
more if you put the old ones back.

It looks very difficult to get to, if it had to be done maybe it would be
easier for them (and cheaper for me) if they replaced my clutch at the same
time, with the transmission out of the way it looks a simpler job.

When I was leaving the dealer, one of the mechanics said the if it were his
car, he would try one of the products that you mix in with the coolant to
seal leaks before paying for expensive repairs, anyone have any thoughts
about this?

Thanks in advance

David.

(replies direct to me as well as the list appreciated, thanks)

1994 Golf VR6 - 5dr - Leaky Money Pit Edition - Windsor Blue Metallic
Black leather - AirCon - Twin Airbags - 115,000m :-(
Glovebox conversion - VW SYNTA synthetic oil - One? red plug lead
K&N Filter - intermittent airbox snorkel (can't decide)
Sony CD Changer - VW 80w speakers
BBS 15" cross-spoke with 205/50 General XP2000 (never heard of 'em, but they
seem to work!)
Phillips Brilliance Xenon headlamp bulbs


/
| David Neale
| Sytel Ltd.
| +44 (0)1494 793200
| http://www.sytelco.com
| mailto:&#100;avidn&#64;sytelco<img src=/i/dc.gif border=0 width=35 height=15>

>Anyone had any experience like this?  the dealer said that if they replaced
>any part of the thermostat housing or it's seals they would need to do the
>whole lot as apparently the plastic parts warp in use and will leak even
>more if you put the old ones back.

Yep.  Happened to my '97.  It started leaking at the thermostat housing, 
and the temp sender or fan switch (don't remember which, it's below the 
upper radiator hose on the side of the radiator).  This occured right 
before my 24/24 warranty was up, so I took it into the dealer for repair. 
 They replaced a whole list of things, like over 20 pieces, total.  The 
thermostat housing, a bunch of o-rings, gaskets, and seals, plus some 
small parts that I couldn't identify from the description on the invoice.
Sounds like your dealer is right - you need to replace everything in the 
vicinity of the leak, or it may return...

-Holland
&#112;hillip3&#64;apple<img src=/i/dc.gif border=0 width=35 height=15>
&#104;jp&#64;pacbell<img src=/i/dn.gif border=0 width=35 height=15>

mine has just started leaking around the case joint of
the the aux electric water pump. Nothing dripping just
gassing off when engine is hot.

Will split and re-seal tommorow!

I've had both the water pump gasket leak, and the oil
cooler to block gasket leak.  Replaced water pump, and
replaced oil cooler gasket.  So, yeah, they are not
that uncommon of issues.  Both happen between 79-84K
miles.

Damon
97' GTI

This might be a stupid question, but is it possible to have a bad spot
in the head gasket but NOT have any oil in the cooland, or vice versa?
I'm starting to think my coolant is going out my tailpipe, but from what
I understand, that would be from a head gasket, which I don't believe is
bad anymore.

My other thought is that the expansion tank and/or cap is/are bad. Any
way to test either of them, or do I just replace them blindly?

Steve Houck
'95 Jetta GLX
-case of coolant in the trunk edition

Heres my suggestion to you.  On a dry day, top off the coolant so its
at acceptable levels.

Start the car, and let it run while leaving it in the driveway.  Walk
around the car as it comes up to temp.  Do you smell coolant?  If so
check under the car, see if its leaking anywhere you can see.  Keep the
hood popped and look around.  If the drive way is dry, any external
loss of coolant is easily seen.  If your dumping it in to the engine,
you will see clouds of steam coming out the exhuast and smell maple
syrup.

Easiest way to check for things like that

Conlan

I'm losing more or less a pint of coolant a day. I have to refill my
expansion tank every 2-3 days.

Yes, I did overheat my car about 2 1/2 years ago. I was about 10 minutes
from home, and I was driving and my water pump went, and I drove home as
slow as I could in 5th gear (to keep the RPMs low) and had the heater on
full hot on high, but still, the needle got pretty high. I've never lost
coolant without a leak though. This is a new one on me.

Steve Houck
'95 Jetta GLX

Looking *at* the resevoir, it's yellowish, but there's a tint to the
tank. I just drained some of the coolant from the tank into a empty
aquafina bottle, and it's... Dark Piss Yellow. Dark. Like after a HEAVY
night of drinking. Which I might just do because of this stupid thing.

Oh yeah, I use Prestone 50/50 mix that's the typical Neon Green. I've
got two aquafina bottles side by side with new & used, I just need a
camera.

As a side note, the bottom hose from the tank looked leaky as HELL.
Maybe I'm losing it out of that. But only when driving. No freaking
idea.

Steve Houck
'95 Jetta GLX
-pissy edition

Steve it sounds like a warped head, a cracked block, or bad head gasket. Have you had the overflow cap
off, why'll the car was running. If any of the conditions I list above is really bad you will see a
volcano come out the overflow even if the car is cold. But if it's a hair line crack or head just warped
enough too make a seal when cold it might not leak untill the engine is hot and has expanded.
Good luck, let us know when you figure it out,
Shaqn Loughran

I'm losing more or less a pint of coolant a day. I have to refill my
expansion tank every 2-3 days.

Yes, I did overheat my car about 2 1/2 years ago. I was about 10 minutes
from home, and I was driving and my water pump went, and I drove home as
slow as I could in 5th gear (to keep the RPMs low) and had the heater on
full hot on high, but still, the needle got pretty high. I've never lost
coolant without a leak though. This is a new one on me.

Steve Houck
'95 Jetta GLX

Is there excessive dribbling from the headgasket right above where the intake is?  That is the corner that
is UBER thin, and will start to seep first.  A VAC gauge would also solve this problem right quick I
think.  A good idea to have on a higher mileage VR.

Interesting, a pint of coolant is alot.
Did you check your oil cap and dipstick for evidence
of oil/coolant mixture?
If you see, nothing there, then most likely you have
an
external leak, turn on your car and let it get hot and
watch for leaks.

FYI, a small leak becomes a bigger leak when you start
driving, especially on highway, then you have more
chances of over heating.