If the t-stat is the wrong one you need to consider the vehicle was maintained by someone not knowledgeable. With the wrong by-pass disc the t-stat was not able to function as a mixing valve and control was not the same on both sides of the engine. The metal insert working out of the pipe is due to the pipe being cracked at the bulge for the hose and clamp to lock onto. Tightening the clamp can actually push the insert out further or faster. Some will push it in and use a rivet or something to lock it in place. 

As for testing the warning system just unplug the lead from the sensor on the bottle with the ignition on. It should flash the light in about 20-30 seconds. 

Dennis

-----Original Message-----
From: Vanagon Mailing List [mailto:vanagon@gerry.vanagon.com] On Behalf Of Kevin Duvernay
Sent: Sunday, December 21, 2014 9:11 PM
To: vanagon@GERRY.VANAGON.COM
Subject: Re: 87 Westy overheating after coolant change

Thanks guys.

Ill do some research on figuring out how to test the functioning of the low coolant warning system. Anyone have a link to shoot me to save time?

Dennis, thanks for the info. Ive got a proper thermostat on the way.
Luckily this ones stuck open and not closed...

Regarding the pipe fix. There are no cracks, just seems that the metal insert is just beginning to work its way out of the plastic pipe. I will order some stainless steel pipes but until then I'll just have to keep a real close eye on it and keep my fingers crossed. I'm planning on taking it on a 1200 mile round trip drive for new years, including a brief 'high ground clearance only' dirt road. Should I be concerned? I believe the '2 clamp' fix is okay. I tested it to 16PSI, no leaks.

I pumped it to 20PSI because thats what the instructions said...
I think the theory is that is a joint is weak and about to go your better off busting it in your driveway than on the road. Glad thats what happened to me.

Kevin

>
>