[Vwdiesel] Coolant Leak at Cylinder Head Flange, 1.9L NA engine

[slatersfb@aol.com]

 Cracked flange would be my guess. Look real close. I had this same problem.
 
Bob in the Entire State
 
 
 
-----Original Message-----
From: David O'Shea <DOShea at geomatrix.com>
To: vwdiesel at vwfans.com
Sent: Sun, 16 Oct 2005 19:20:54 -0700
Subject: [Vwdiesel] Coolant Leak at Cylinder Head Flange, 1.9L NA engine


I have a '83 Vanagon with a recently replaced 1.9L NA engine, 18k miles and 
3-years old. I noticed a little dribble of coolant under the van in my garage so 
I checked around for a source. It was a very slight leak coming from the 
right-side bolt of the flange for the coolant hose on the front of the cylinder 
head, the flange just below the oil pressure sender. I thought that this would 
be no big deal but my local VW dealer claimed that the gasket came up "no longer 
available" on their computer. 

I removed the flange and saw that the mating surfaces were completely flat so I 
cut a new gasket out of thin gasket material, cleaned up the both surfaces 
"baby" smooth, and remounted the flange with appropriate gasket compound. I let 
it sit overnight and then refilled the coolant reservoir and fired up the 
engine. I now have a very steady leak from the right-side bolt, much greater 
than before my repair job. It really looks like the leak is localized at this 
bolt, not from a failed gasket around the actual coolant port.

Is it possible for coolant to travel up the through the threaded bolt hole? I 
wouldn't think that it would be open to the inside of the cylinder head but I 
didn't do any exploring beyond cleaning things up and drying them out. Cracked 
head? Before I seek professional assistance, I thought I'd poll the on-line 
experts for any opinions on possible causes and solutions.

Thanks

-Dave O'Shea
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