Speaking of coolant leaks, I remember my trip to Minn. from Chicago,
after day 2, I drove through St. Cloud, and saw a VW dealer.
when I made it to Virginia, Minn. my expansion tank on my 85GL was
leaking coolant due to a small crack. I tried the some of that silver
colored miracle tape, but it didn't solve the problem.
I checked into a local motel, and then called information for the VW
dealer in St. Cloud, well they didn't have any listings since it was
under the owners last name.
I finally had one sent to me at the local gas station. What a mess
replacing it.
Fortunately it was very hilly region and I found a hill to drive up on
to raise the front of the car and bleed the radiator.
I just had that terrible thought that I didn't do it right, but some 800
miles later the engine still worked.

Thanks, Miguel

John H. Rodgers wrote:

> -- [ From: John H. Rodgers * EMC.Ver #2.5.02 ] --
>
> A while back , on my '85 GL, I started having coolant leak problems at
> the
> expansion tank. I would drive a while, Then make a stop, and coolant
> would
> drip on the ground right under the expansion tank. . When I checked it
> the
> tank was wet on the outside, and there was coolant in the tank indent
> where
> the coolant level sensor screws into the tank. After a little more
> checking,
> I replaced the small hose from expansion tank to the overflow  tank
> and made
> sure the passageway to the overflow tank was cleare, and cleared the
> vent on
> the overflow  tank. I replaced the pressure cap on the expansion tank
> with a
> new one, and checked the expansion tank sensor to be sure it was tight
> and
> topped up the collant. Everything seemed in order.
>
>  It ran fine  with no leakage for a few miles but has started the same
> game
> again.
>
> It appears that either during warmup after a cold start, or after a
> highway
> run and suddenly getting into slow traffic when the cooling system is
> not
> cooling the coolant efficiently, sthe coolant expands sufficiently to
> try to
> force the overflow cap to open and vent coolant to the overflow tank.
> Apparently this is not happening, and the expanded coolant is forcing
> its
> way past the seal on the coolant sensor on the expansion tank.
>
> Is there a simple way to test this. There is the possiblility that the
>
> expansion tank has a crack somewhere that I can't see, that opens up
> at a
> pressure below pressure cap operating pressure, thus allowing some
> leakage,
> but with coolant around the sensor, I doubt it. The system takes
> coolant
> from the over flow tank, but never overflows back into the overflow
> tank.
>
> I am constantly adding coolant to the overflow tank, but I am loosing
> it to
> due to the leak. It never flows past the expansion tank cap back into
> the
> overflow tank. The coolant  I use is the dreaded green stuff made by
> Texaco
> --- but it says on the container its specifically for aluminum
> engines.This
> was in the van when I got it. I still use the same brand. It's been 5
> years
> and this is the only trouble I have ever had with coolant leaks.
>
> Comments would be appreciated.
>
> John Rodgers
> '85 GL Driver