Hi,

Boston Bob Donalds at Bostonengine.com has a complete article on his web
site about the DIY head gasket replacement procedure.

Bye,
Mark Ingalls
85 GL
75 Beetle

>From: TinkerMan <tinkerman007@YAHOO.COM>
>Reply-To: TinkerMan <tinkerman007@YAHOO.COM>
>To: vanagon@GERRY.VANAGON.COM
>Subject: ## 1998 head gasket failure survey results
>Date: Sun, 14 Oct 2001 15:10:04 -0700
>
>Hello Volks!
>
>I have just found that my head gaskets have started
>leaking (3 out of 4). This is really a bad surprise
>because I have had the motor completely factory
>rebuilt about 3 years and 50K Km ago, and have been
>religiously using only the recommended G10 coolant.
>This van is really starting to sink money fast...:-(
>As far as I can find from the list archives, there is
>no "simple" head gasket replacement procedure. Haynes
>recommends against doing it in-vehicle (due to
>possible complications), while Bentley says it's
>possible but the procedure seems extremely complex for
>a tree-less shadetree mechanic...(actually, a parking
>lot tool-poor mechanic...).
>I get the feeling that head gasket replacement is
>still a major operation (because the heads are usually
>pitted too) and requires carefull alignment which I
>don't have sufficient experience with. I also HATE the
>feeling of going into another major engine operation
>after spending $2500 3 years ago and still feeling the
>problem might return again shortly. Indeed, my
>confidence in the motor is really shaken...
>This is in addition to the other expensive repair
>bills I've faced (Tires, Breaks, clutch, R&P steering,
>etc... I have an 11 year old GL, 6 years with me). I
>love this van but HATE it's mechanical nightmares...
>SSSooo...since I know I'll have a major problem soon
>(right now I just have coolant signs at the heads, no
>major leak) I want to be prepared.
>
>1. I've read about the ceramic head coatings and
>improved head bolts on the list and feel it's a move
>in the right direction, but before I decide, I'd like
>to know what were the survey results done around '98.
>There was even a web page for collecting inputs. I
>never found mention on the list about them, except an
>appology from the initiator (Steven Schwenk) that due
>to personal issues could not complete the mission (I
>do hope his personal difficulties were solved to the
>best in the end).
>
>2. I'd also like to know if anyone can provide a
>verified solution based on personal experience for the
>damned head gasket problem. Robert Lilly was aiming
>for a 200K miles engine life in one of his posts.
>Well Robert, did you get there?...:-)
>Anyone got a 200K motor (original or after overhaul)
>still running without a major problem?
>
>3. Can the head gasket fix be done in-situ, by a
>competent hobbiest without a lift or special tools, or
>should I stay away from it? Any detailed
>instructions/pictures on the web (Bentley is very
>sparse on explanations. Haynes doesn't recommend it at
>all).
>
>4. Of course, I'd prefer a DIY $100 gasket replacemnt
>to a $1000 major operation. Can it be done,
>considering my motor should be in good shape
>otherwise?
>
>5. What is the current life-span expectancy of the
>waterleaker if maintained properly (head gasket alone,
>and the rest of the motor if much better)?
>
>6. I'd like to stay away from a motor conversion,
>since I'm not a professional mechanic and have no
>relevant facilities. The dealer mechanics have a hard
>enough time with a standard setup, let alone a
>hybrid...
>
>Give me hope!...:-)
>
>
>=====
>Cheers,
>          TinkerMan
>
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