Antifreeze inside an engine is extremely corrosive. Especially to Diesels.
Bearings goodbye. Big Diesel maintenance includes oil testing and one of the
things they look for is antifreeze as PPM become a problem. The air filter
of course has to be changed and get the oil out of there quick.

While the expansion tanks are known for the seams leaking catastrophic
failure is usually a symptom. For the VW Diesels you need to investigate
cracked head or bad head gasket.  The failure after the short highway run
indicates this.

Dennis

-----Original Message-----
From: Vanagon Mailing List [mailto:vanagon@gerry.vanagon.com] On Behalf Of
Frank Lee
Sent: Monday, November 14, 2011 1:01 AM
To: vanagon@GERRY.VANAGON.COM
Subject: Diesel na is breathing coolant

Yellow Sub just sprayed coolant over the top of the engine.   On a short
drive down the Baltimore 83 Expressway she choked and died, from breathing
coolant sprayed and vacuumed into the air intake.
The Coolant Expansion Tank  (82 diesel na) has a side seam crack that faces
the engine.

I followed the recent Coolant Threat and bought Zerex G-05, distilled water
and coolant tester.
But the proper replacement tank is rare I discovered. Found one OEM for
$149 + shipping.

Its HDHP --> a thick milk bottle, Right?
The crack is on a seam.  So gluing and sealing seams with fiberglass and
TAP- Poly Weld <http://www.youtube.com/watch?v=h-9yhanz5DE> should work I
think.    I like the idea of saving the rare part, like welding the oil
pan.  Or is it 30 year old brittle?

My questions
1)  am I better off just buying the $150 OEM tank?

2)  any experience using Poly Weld?  The youtube is really clear.

3)  Is my new air filter OK after breathing coolant?

4)  point me to basic the step-by-step and precautions to drain, refill and
test the coolant system~~ For Dummies and  Novice Mechanics.   Must be
flushed, right?   Bleeding?
      Is my Bentley Manual good for this?

5)  I have new Van Cafe headlights and relay to install.  Sounds like this
is a good project for same time, since bleeding is at the front end.
Correct?

Frank