At 08:50 PM 09/19/2003, you wrote:

>Hello,
>
>Some of you are aware of the fact that I blew a hard-to-find radiator
>hose about a month ago, and I still don't have it's replacement from
>VOA.

I think Ron at Bus Depot has later hoses. I have a client with an 83 and
when needed, I will convert it to the later hoses.

>That made me think that there might be a head gasket problem, and if so
>that is probably what blew the hose in the first place.
>
>The engine starts a little rough but seems to run OK, it's the first
>diesel I've ever messed with so I'm not sure what's "right."
>
>Anyway, what else should I look for in the way of blown gasket symptoms?

 From a cold start let it idle for 30 seconds, then twist off the cap and
see if there is any pressure. There will not be any pressure from heat
build up so any pressure will verify combustion leakage pumping pressure
into the coolant. As this progresses it starts pumping coolant past the cap
into the overflow tank and overflowing and of course, overheating. By this
time you should see air bubbles and/or froth in the pressure tank.

>If it is a blown head gasket, what's usually involved in fixing them,
>and how much does it cost to have a shop do it?

The last Vanagon Diesel head gasket I did was around $900. That included
scraping and cleaning very well the head and block surfaces, applying
Kopper Kote to a new Elring gasket, and bolting it back together with a
$160 set of high tech studs and nuts to replace the bolts. These were
torqued in three stages to spec, run to operation temp, then retorqued. At
a thousand miles of use, per Bentley and the instructions with the spezial
studs, I will retorque them one more time. It also included 2 gallons
coolant, oil and filter, and a chunk of change for the government.

Jerry at NW ConRod (40+ years VW motor machining and assembly experience)
has advised that some of these motors have repeat failures for no good
reason, assembled per Bentley, and these extra steps will nip this rare but
not rare enough repeat failure problem in the bud.

Now here is one on Bentley. ANNOMALY ALERT--ERRORS AND OMISSIONS These
diesel motors used two types of head bolts. The Bentley does acknowledge
both 11mm type standard bolts and the 12mm torque to yield bolts. Then it
goes on to give the procedure for the 12mm bolts. But they do not give the
torque specs anywhere for the 11mm standard staged torque bolts. Use three
stages 30/50/65 lbs for those. That is also the spec for these high tech
studs and nuts. Also, if you have the 12mm torque to yield bolts, they
don't give the maximum length of the stretched bolt for reuse, so you must
replace them with new or risk failure.

So I have these 11 mm bolts that are just perfect for making pairs of
alinement pins for reinstalling the gasket and head which you simply must
have or you WILL bugger the gasket and spray sealant film trying to get a
bolt started. Instant re-failure is not the way to finish this job.