On Jul 31, 2006, at 9:32 AM, J S wrote:

> 1. The kit I purchased (van-cafe) and others do not include the
> grommets or seals for the two expansion tanks.  Is this because they
> rarely fail?  Or?

David Johnson addresses this in his reply.  From what I've seen, the
waterboxers don't have these (though I'm no expert).

> 2. One person I spoke with suggested that when reinstalling the
> cross-over tube, it is not necessary to place this over the coolant
> lines.  Every article I read on the web has it re-installed over the
> coolant lines.  Does it matter?

When I did mine, I remember having to put it over the coolant lines,
and let me tell you, it was a royal pain in the you-know-what.  The
crossover tube isn't really flexible or long enough to accomodate a
bend in its direction.   I would also think that it has to be kept
straight so that gas doesn't puddle up in the tube, thereby blocking
it and thus negating the whole point of allowing vapor to travel
through it.

> 3.  The Bentley manual noted to use a tool 2012A when removing /
> re-installing the fuel gauge expansion unit.  While my mechanic does
> work on VW's and other foreign cars, I would guess he does not have
> this specific tool.  What are the alternatives?

Don't know bout no stinkin VW Tool 2012A.  I did mine without it,
though if the sender was really tight, you'd want to be careful not
to force (and break) the sender.  It is plastic.

> 4. The Bentley manual noted one should test the system for leaks using
> US4487 after it is done.

I leak tested mine by putting gas in it and taking my wife along for
a ride (she's got an incredible nose).  :)  Okay, in retrospect,
that's not the smartest thing to do, but I was very meticulous and
triple-made sure I hooked everything back up correctly, so I felt
confident about it.   Seriously, though, if your tank is in good
shape, and you've replaced all the parts that can fail, then you
should be good to go.  But then, I'm not an expert, so take my advice
with a grain of salt.

Good luck.  I feel sorry for your mechanic.  It's a dirty, stinky job.

Jarrett K

'89 Westfalia - Olly
'05 Jetta Wagon TDI - Kiki
'73 Westfalia - Rita