Anyone want to help this dude?

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1986 Volkswagen Vanagon 2.9 L

Trans:         Standard
Mileage:       136,000 mi
VIN:           WV2YB0254GH062133

Misc Data:     Water cooled
Affected Item: Overflow tank

___________________________ FIX: ___________________________

Aloha Folks, Well the concess is wait untill van breaks
down then ether R&R heads or replace engine. I apreciate
all your help, I got LOTS of replys, most said pinholes in
head, bad o-ring seal. Mahalo All Mike

____________________ ORIGINAL MESSAGE: _____________________

Aloha members, Both cylinder heads were replaced at 78500
miles. Only VW phosphate free anitfreeze has been used
since then. Water pump replaced at 77000 miles.

The problem with the van is that the cooling system is
increasing the pressure in the system so that coolant is
being pumped from the expansion tank to the overflow tank.
When the engine cools down, the coolant does not siphon
back into the expansion tank. The pressure stays high in
the system, even overnight. In the morning, with a cool
engine, when I look at the coolant level in the expansion
tank, it is down near the minimum line. When I remove the
expansion tank cap, a lot of air pressure is released and
the coolant level gets pushed back up to the top of the
tank, sometimes even spilling over the top. If I remove the
cap when the engine is warm, there is are is lot of foam in
the top of the tank. On long trips, customer smells coolant
inside the van and outside, as if it is leaking somewhere.
Mechanic has pressure tested coolant system and has not
found any leaks. Mechanic also tested coolant for
combustion gas and did not find any evidence of combustion
gas in the coolant.

Suspect pinhole leak in head gasket, added Bars Leak to try
to seal it. Did not want to R&R head gasket if there is
something else causing the problem.

If any VW guru's out there can offer some advice, much
maholo's will go out to you.

Aloha, MTM

Michael Aiu Taber
simian@aloha.net
Owner/Technician
Mike The Mechanic
Lihue, Hawaii, USA

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___________________ TEST AND REPAIR DATA ___________________

TESTING AND RESULTS

Temp at water pump - 200 deg F
Temp at radiator, fan off - 195 deg F
Temp at radiator, fan on - 150 deg F

RELATED REPAIR HISTORY

Vehicle has been in to a reputable VW shop several times
recently. Mechanic R&R fan switch and resistor. Fan works
at hi and lo speed R&R expansion tank cap. Mechanic
properly bled cooling system

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