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Wildthings
Samba Member
Joined: March 13, 2005
Posts: 50338
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 Posted: Mon Sep 16, 2013 3:55 pm Post subject: |
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You can not run without a thermostat as the thermostat must be there to close off the bypass channel. Without the bypass closed off the radiator will be short circuited and your engine will overheat easily.
You did well to short out the connections on the plug for the coolant level sensor. With the sensor removed from the circuit the system will believe the coolant level is low, set up the warning light, and cause the gauge to peg.
When you order parts, get a new pressure(expansion) tank, a coolant level sensor and a new cap. You might want to keep an extra thermostat and o-rings on hand as well. Buy the best cap and thermostat you can find. |
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DeadSetMonkey
Samba Member
Joined: April 15, 2010
Posts: 532
Location: Denver, CO
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| Posted: Wed Sep 18, 2013 8:36 am Post subject: |
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| Terry Kay wrote: |
| clean it with CLR |
What is CLR?
_________________
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'90 Syncro Westy 2.5Subi Turbo, BFGs 215/75/15 Rheins |
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Wildthings
Samba Member
Joined: March 13, 2005
Posts: 50338
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| Posted: Wed Sep 18, 2013 9:35 am Post subject: |
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| DeadSetMonkey wrote: |
| Terry Kay wrote: |
| clean it with CLR |
What is CLR? |
I bet Google knows  |
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Ahwahnee
Samba Member
Joined: June 05, 2010
Posts: 9800
Location: Mt Lemmon, AZ
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| Posted: Wed Sep 18, 2013 9:56 am Post subject: |
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| LMGTFY |
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DeadSetMonkey
Samba Member
Joined: April 15, 2010
Posts: 532
Location: Denver, CO
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| Posted: Wed Sep 18, 2013 10:40 am Post subject: |
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What's LMGTFY  (sarcasm)
_________________
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'90 Syncro Westy 2.5Subi Turbo, BFGs 215/75/15 Rheins |
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kamzcab86
Samba Moderator
Joined: July 26, 2008
Posts: 7918
Location: Arizona
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| Posted: Wed Sep 18, 2013 10:45 am Post subject: |
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| DeadSetMonkey wrote: |
| What is CLR? |
A cleaning agent that's been around for, oh, 15 years or so.
In this instance, you need the original stuff in the gray bottle.
_________________
~Kamz 
1986 Cabriolet: www.Cabby-Info.com
 1990 Vanagon Westfalia: Old Blue's Blog
2016 Golf GTI S
"Real knowledge is to know the extent of one's ignorance." - 孔子 |
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Windig89
Samba Member
Joined: September 22, 2011
Posts: 184
Location: Montreal
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| Posted: Thu Jul 17, 2014 10:41 am Post subject: |
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| djkeev wrote: |
He is how my sensor failed. Original 1986 unit (date molded in).
Coolant seeped up the metal rods via the cracked plastic and oozed out from the top plug.
Dave |
I removed my sensor the other day during my system overhaul and found the same thing. Plastic prongs were cracked ( LED blinking until engine warm). I went to the dealer to get a new one and to my surprise thankfully VW has redesigned the sensor now. It no longer has plastic surrounds on the prongs! Have a look (old vs new picture), its a really nice quality part now. Hopefully it works as well as it looks!
_________________
1989 Vanagon GL Westfalia - 2.1L waterboxer |
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Vanagator
Samba Member
Joined: January 14, 2009
Posts: 230
Location: Cool lush mountains in Mexico
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| Posted: Thu Aug 18, 2016 10:02 am Post subject: Re: coolant level sensor? |
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I was just looking at my old sensor compared to the new one pictured above. I noticed when I pulled my off that I have no O-Ring. Are the older ones without O-ring?
Also, any tips on the correct tool to use to remove/install this sensor? |
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Vanagator
Samba Member
Joined: January 14, 2009
Posts: 230
Location: Cool lush mountains in Mexico
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| Posted: Thu Aug 18, 2016 7:34 pm Post subject: Re: coolant level sensor? |
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Man o Man....I can't believe I wrote that prev post. In fact I do have an ORing on there- It's just smashed flat after all these years.
Anyhow....replaced with a new sensor today and no more seeeeeep.
Yeehaw, think I'll take a road trip to see if the warning light comes on. |
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Honuak
Samba Member
Joined: April 21, 2009
Posts: 521
Location: AK
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| Posted: Sun Apr 09, 2017 5:46 pm Post subject: Re: coolant level sensor? |
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Reviving this thread.
My coolant level sensor failed breaking at the top of the threads. I think because it sticks up too high and gets jammed a bit by the engine lid. I have a RMW tank that puts the sensor wire connection up higher than stock.
I'd like to source/create/modify the connector to come off at a 90 deg angle instead of straight up.
Anyone had this issue and found an elegant solution? |
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Tom Powell
Samba Member
Joined: December 01, 2005
Posts: 4855
Location: Kaneohe
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| Posted: Sun Apr 09, 2017 7:29 pm Post subject: Re: coolant level sensor? |
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| Honuak wrote: |
| ... My coolant level sensor failed breaking at the top of the threads. ... |
The same has happened to me and I think it's a common problem. I carry a spare and a wrench that fits. Getting the threaded part out in situ can be a problem. I think i removed the tank from the vehicle and got it out using a dull chisel and a SFH to turn it counterclockwise.
Aloha
tp |
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IdahoDoug
Samba Member
Joined: June 12, 2010
Posts: 10248
Location: N. Idaho
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| Posted: Sun Apr 09, 2017 7:58 pm Post subject: Re: coolant level sensor? |
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The SFH is an ideal tool for this situation and I'm impressed you know of its existence. It's a sage man who knows when to leave the BFH in the toolbox for its subtle cousin.
I also had the same "top blow off" happen to a sensor. Of course in the very most remote place I've ever had the Van. Top of a snowy mountain in Montana. Had to use various bits from aspirin bottles, food wrap and the like to get it to hold to limp into town. Then one of those rubbery boat drain cam type marine plugs worked for days of normal driving. So, I would say not to assume it was from physical interference unless you know that to be the case. I used JB Weld to put mine back together and kept it in the glovebox for years as a spare get home bit.
_________________
1987 2WD Wolfsburg Vanagon Weekender "Mango", two fully locked 80 Series LandCruisers. 2017 Subaru Outback boxer. 1990 Audi 90 Quattro 20V with rear locking differential, 1990 burgundy parts Vanagon. 1984 Porsche 944, 1988 Toyota Supra 5 speed targa, 2002 BMW 325iX, 1982 Toyota Sunrader |
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otiswesty
Samba Member
Joined: November 21, 2006
Posts: 1730
Location: Portland
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| Posted: Sun Apr 09, 2017 8:09 pm Post subject: Re: coolant level sensor? |
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| Honuak wrote: |
My coolant level sensor failed breaking at the top of the threads. I think because it sticks up too high and gets jammed a bit by the engine lid. I have a RMW tank that puts the sensor wire connection up higher than stock.
elegant solution? |
The stock tank is still available and should last 15-20 years
_________________
1978 Sage Green P22 Westfalia
1989 T3 Syncro Single cab
Just a regular guy |
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Tom Powell
Samba Member
Joined: December 01, 2005
Posts: 4855
Location: Kaneohe
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| Posted: Sun Apr 09, 2017 8:21 pm Post subject: Re: coolant level sensor? |
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| IdahoDoug wrote: |
| The SFH is an ideal tool for this situation and I'm impressed you know of its existence. |
Damned by small praise. 
Aloha
tp |
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menotti
Samba Member
Joined: December 03, 2017
Posts: 65
Location: Encinitas, CA
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| Posted: Sat Feb 24, 2018 12:10 pm Post subject: Re: coolant level sensor? |
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Glad I found this thread, I have a really naive question for you all. I'm having similar symptoms as others here with the incessantly blinking coolant light. It sounds like there's a high chance that I have a bum sensor or that I might need to top off my coolant.
On to the dumb question that I had a hard time finding an answer to. If I remove the blue cap from the pressurized expansion tank while the engine is cold, can I simply add coolant and top off, replace the cap, and not have to do anything else? Like bleed the system now?
Same goes if I remove the sensor from the pressurized tank. I'm imagining this let's in outside air but is it necessary to bleed if I just replace this sensor. I imagine this air that's above the coolant is self bled?
Thanks for putting up with my dumb question! |
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Ahwahnee
Samba Member
Joined: June 05, 2010
Posts: 9800
Location: Mt Lemmon, AZ
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| Posted: Sat Feb 24, 2018 1:37 pm Post subject: Re: coolant level sensor? |
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| menotti wrote: |
...If I remove the blue cap from the pressurized expansion tank while the engine is cold, can I simply add coolant and top off, replace the cap, and not have to do anything else? Like bleed the system now?
Same goes if I remove the sensor from the pressurized tank... |
Yes to both. With the engine cold and not running you can top off the tank and/or R&R the sender. That action alone does not require a bleed.
There is a technique for getting more coolant in the tank that involves running the engine at high RPM and holding it there while you remove the cap, fill and replace the cap - but that is a bit more involved.
If you continually have to top up that tank and there is no evidence of a leak then there are things you will want to check. |
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menotti
Samba Member
Joined: December 03, 2017
Posts: 65
Location: Encinitas, CA
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| Posted: Sun Feb 25, 2018 8:31 am Post subject: Re: coolant level sensor? |
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| Ahwahnee wrote: |
| menotti wrote: |
...If I remove the blue cap from the pressurized expansion tank while the engine is cold, can I simply add coolant and top off, replace the cap, and not have to do anything else? Like bleed the system now?
Same goes if I remove the sensor from the pressurized tank... |
Yes to both. With the engine cold and not running you can top off the tank and/or R&R the sender. That action alone does not require a bleed.
There is a technique for getting more coolant in the tank that involves running the engine at high RPM and holding it there while you remove the cap, fill and replace the cap - but that is a bit more involved.
If you continually have to top up that tank and there is no evidence of a leak then there are things you will want to check. |
Thanks a bunch. Checked under the blue cap and we're topped off on coolant.
Seems likely the sensor needs a cleaning but I'm having a heck of a time removing it. Sounds like others had to remove the whole tank to do this if it is in its original position  Any other tips on removal?
My light only started going for the coolant level when I replaced the factory foil with the gowesty pcb, but I checked all the connections there and they look good. Maybe the old foil wasn't showing the light. |
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menotti
Samba Member
Joined: December 03, 2017
Posts: 65
Location: Encinitas, CA
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| Posted: Sun Feb 25, 2018 8:40 am Post subject: Re: coolant level sensor? |
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| IdahoDoug wrote: |
The SFH is an ideal tool for this situation and I'm impressed you know of its existence. It's a sage man who knows when to leave the BFH in the toolbox for its subtle cousin.
I also had the same "top blow off" happen to a sensor. Of course in the very most remote place I've ever had the Van. Top of a snowy mountain in Montana. Had to use various bits from aspirin bottles, food wrap and the like to get it to hold to limp into town. Then one of those rubbery boat drain cam type marine plugs worked for days of normal driving. So, I would say not to assume it was from physical interference unless you know that to be the case. I used JB Weld to put mine back together and kept it in the glovebox for years as a spare get home bit. |
small friendly hammer and big friggin/friendly hammer, yes? |
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Ahwahnee
Samba Member
Joined: June 05, 2010
Posts: 9800
Location: Mt Lemmon, AZ
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| Posted: Sun Feb 25, 2018 1:46 pm Post subject: Re: coolant level sensor? |
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| menotti wrote: |
| ...My light only started going for the coolant level when I replaced the factory foil with the gowesty pcb, but I checked all the connections there and they look good. Maybe the old foil wasn't showing the light. |
Not sure what year/engine you have - but on my 84 (Digijet) a simple break in the wire from the sensor caused the light to blink.
In my case the break was where the wire got pinched (beneath the coil) and the fault was intermittent -- took a while to reliably recreate and diagnose.
The point is, although a bum sensor is a common problem, check everything for clean, tight & unbroken. |
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Vanagon Nut
Samba Member
Joined: February 08, 2008
Posts: 10371
Location: Sunshine Coast B.C.
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| Posted: Sun Feb 25, 2018 2:04 pm Post subject: Re: coolant level sensor? |
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Were it me, I'd remove the coolant low relay and see if light continues to show the same behaviour. If it does, I think that indicates the issue is at the dash.
A reliable coolant low light is quite handy to have.
Neil.
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1981 Westy DIY 15º ABA
1988 West DIY 50º ABA
VE7TBN |
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