2.1 WBX: Leak, water pump and coolant crossover pipe SOLVED

[table]

Putting engine back in the van. Got it all together (yay!), coolant in, and.... drip. drip. drip.

The leak is between the water pump and the crossover pipe that goes under the pulley to the right head. (Of course. Super fun spot to work) I pulled the pump and the pump sealing face is clean and flat. As far as I can tell, the sealing face on the crossover pipe flange is good too. I noticed that the allen bolts that hold the crossover pipe flange to the water pump were pretty much bottoming out in the holes in the water pump, so I figured that was my problem and used two bolts that were 5mm shorter for the reassembly.

Still dripping in the same spot.

I used the paper gasket that came with the engine gasket kit. I could put silicone on the gasket or double up on the gasket. Or both. Although it might work, it's not very confidence inspiring to put silicone on...

Suggestions? Ideas?

Thanks all!

[T3 Pilot]

http://gasgacinch.com

Simple and it works.......plus you will always have the 1940's pinup girl on the can to cheer you up.

Pro tip: use a q tip to apply it because the included applicator makes a sloppy mess.
_________________
1988 Vanagon

The most important part in every vehicle is the nut behind the wheel......

[AtlasShrugged]

Odd that it leaks there..that is not a problem most of the time.

I would not use silicone sealants or double up the gaskets.

I would inspect the flange on the water pump and the steel pipe flange. The flange(s) may have some old gasket material on them or maybe a crack in the steel or water pump..you need to look.

When reassembling them I would use Permatex High Tack gasket sealer #80062.

[table]

I have taken the pump out again. It looks OK and I have filled it with tap water to see if it leaks. It's OK.

Has anyone ever seen a crossover tube break? I'm thinking at the seam between the flange and the tube itself. I can't see anything, but the tube is captive behind the pulley.

Thanks!

[table]

...and it's impossible to get the crossover pipe out without removing the pulley, right?

[Robw_z]

You can remove the crossover pipe without removing the pulley. I do remember some cursing during the process. Is the leak clearly at the flange near the water pump? I had a leak on the other side where it goes into the head, it was a bad plastic flange I replaced with a new stainless one.

-Rob

[djkeev]

Those tubes rust.

Make sure it is the sealing surface leaking and not the actual pipe itself rusted thin.

Dave
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[jberger]

Putting the engine back in...?? What work was done? Oversized oil pump? The cover will hold the crossover pipe off of its mating surface.

[atomatom]

perhaps you used the wrong o-ring?

it should look like this: http://www.van-cafe.com/yellow-o-ring-for-coolant-crossover-tube

_________________
84 Vanagon Westy, 1.9L, California raised but defected to Canada.

[atomatom]

i also had a similar experience with the bolts bottoming out on a new pump. i added washers instead of shorter bolts. however, i'd be surprised if this is related to your leak.
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84 Vanagon Westy, 1.9L, California raised but defected to Canada.

[rubbachicken]

that depends on the year of the van, the yellow seal is only for 1.9 engines, the upper crossover pipe into the thermostat housing, not the water pump

[atomatom]

yes, i stand corrected
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84 Vanagon Westy, 1.9L, California raised but defected to Canada.

[table]

Yeah, this is a 2.1, so there's no o-ring. One of the things done WAS a slightly larger oil pump, but I don't think it's pushing the crossover pipe out.

To provide some possible closure: I held a straight edge to the flange on another crossover pipe - it was quite flat. The one in the van has a bit of an arc to it, as though someone (no, not me!) overtorqued it at some point and pulled the edges of the flange with the bolt holes in toward the water pump.

I trimmed the edges of the paper gasket around the bolt holes, where there is no sealing action, to allow for clearance of the warped flange, and gooped it up. I used the black cylinder head goop because I had lots left over from putting the heads on. It's drying overnight, then I'll put coolant in tomorrow. Pictures to follow when I bring my camera nearer to the computer.

Hopefully it works! I spent as much time on that one leak today as I did putting the whole engine back in! Fingers crossed...

Thanks for everyone's help!

[jberger]

I'm curious.. did it work?

[table]

I filled it last night... no drips. Haven't started it yet. I do like that head sealant goop - very sticky. (I did make sure sealing surfaces were clean and oil free and dry)

[table]

Just for everyone's info, I've put a few hundred miles on the repair now, and it seems to be holding just fine. If I could do it again I'd take it right out but that wasn't going to happen easily without pulling the crank pulley.

[table]

If you're having trouble imagining all this, I finally got the pictures off my camera:

I used a feeler gauge as a straight edge. There was a big gap inboard of the fastener holes.

I modified the gasket as shown here and gooped it up real good.

[fortheloveofvdub]

I have this exact problem tonight. I got that new crossover pipe behind the pulley last winter. It took me all day. I’m going to have to attempt to re-seal there at the water pump/pipe connection. That new pipe came from bus depot and the fitment was far from perfect. Very bummed.

[Vanagon Nut]

[T3 Pilot]

.... or a belt sander
_________________
1988 Vanagon

The most important part in every vehicle is the nut behind the wheel......