Those were my symptoms of cracked head…although mine never once overheated. I had a small crack between a bolt hole connected to the water jacket and the cylinder… I would pressure test it first it will only confirm your suspicions and then it’s probably time for at least the heads to come off for inspection… this was also revealed to me in a compression test- one cylinder with really low compression…

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From: Shirewood
Sent: Sunday, October 29, 2017 2:38 PM
To: vanagon@GERRY.VANAGON.COM
Subject: Re: Cooling system '85 1.9

I was afraid you were going to say that. Thanks. It's seemed like the expansion and overflow tanks haven't been operating correctly. I've replaced the expansion tank, cap and hose to overflow. After it warms up there will be air in the expansion tank and lots of coolant in the overflow.     ?

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> On Oct 29, 2017, at 10:40 AM, Dennis Haynes <d23haynes57@hotmail.com> wrote:
> 
> Loose or cracked heads!
> 
> Dennis
> 
> 
> -----Original Message-----
> From: Vanagon Mailing List [mailto:vanagon@gerry.vanagon.com] On Behalf Of Shirewood
> Sent: Sunday, October 29, 2017 11:28 AM
> To: vanagon@GERRY.VANAGON.COM
> Subject: Cooling system '85 1.9
> 
> This has been very frustrating.  Started with serious overheating. Replaced thermostat with great effort (broken bolts). I have been adding coolant, burping air, over and over but when I test drive as soon as I hit a hill it overheats.  Any suggestions? Thanks Doug E.
> 
> Sent from my iPad