In a message dated 09/12/2003 11:17:46 PM Eastern Standard Time,
LISTSERV@GERRY.VANAGON.COM writes:
I installed a low milage 2.1 and it starts and runs well.  However:  the =
coolant boils up in the filler tank and gushes out the little tab(with =
the three little holes) on the top of the tank.  The heaters blow hot =
air for awhile then go cold(at which point I shut the engine off--never =
letting the temp gauge go too high).  Once the radiator got hot and I =
got some frothy bubbles out of the bleeder.  Other attempts had the =
filler tank overflowing before the radiator ever felt warm.  The only =
culpret I can think of is, of course, the thermastat, but it was working =
fine two weeks ago.  I have carefully checked all hose connections. I =
raised the front of the vehicle as per bently. Ideas?
    Exhaust leaking into cooling system.  Have your coolant tested for
exhaust gases.  Pressure testing the cooling system or the cylinders may not show
this combustion leak.  If exhaust gases are present in the coolant then you have
a cracked head or leak between the cylinder top 0-ring and the head.  Check
the archives on this.  A few weeks ago there was quite a discussion going on as
I and someone else had a similar problem.

Cheers

Frank Condelli
Almonte, Ontario, Canada
BusFusion a VW Camper camping event, Almonte, ON, June 10 ~ 13, 2004
'87 Westy & Lionel Trains
Member: Vanagon List, LiMBO, IWCCC & CCVWC
Vanagon/Vanagon Westfalia Service in the Ottawa Valley
STEBRO/Vanagon Stainless Steel Mufflers
Frank Condelli & Associates or http://frankcondelli.com