New cooling system

A few weeks ago, I was feeling the need to tinker one evening, and had the time to do so.  I went out to the Thingamajigger to find the stack of parts I have waiting for just such an occasion.

The impulse hit me to tackle the radiator job.  This was something I was holding off as I had recently tackled the radiator in the wife's CR-V and that was probably the single, largest pain in my ass I have ever encountered when doing a radiator.  EVERY bolt was rusted, or seized, the access was minimal and nothing went right.  The CR-V was 15 years newer than the Vanagon, and generally better maintained.



Crusty!



So, back to the Vanagon.  I had a new Behr radiator, had a bunch of hoses and clamps, temperature sensors, mount washers and gumption to get it done. 

The offending radiator is to the right.

Secure the front end of the vehicle high enough to have plenty of work space.  With my lowered van, the ramps were barely enough and I needed to do some manipulation to get it out.

The Vanagon holds some significant amounts of coolant, and it needs to be drained and disposed of properly.  Never reuse coolant.  Stuff is cheap, buy new coolant.  No sense putting all this money into the system and fill it with used coolant.

This radiator has spooked me since the get go, I must be looked upon by the Vanagon angels to have made it through the season without popping it.

It was susted thoroughly from the bottom, and is the original (or at least OEM unit).  The weight of this unit was easily double the weight of the Behr replacement unit.

The removal of the radiator was marked with a couple minor problems.  The first was the spring clips that hold the nuts to which the supports are held on.  The clips rusted enough so that the nuts themselves were spinning, and they needed to be cut off.  I replaced them with some body clips and stainless hardware.

The picture on the right shows the older ones and the replacements.

Once the support brackets were off, hoses disconnected, fan wires disconnected, the radiator can be lowered from the van.    Be cautious, the radiator surprised me with its weight.

When the radiator is out, you can start disassembly.  The shroud needs to come off with the fan unit. I took this opportunity to wire wheel the whole thing and give it a coat of paint.  If I had access to a sandblast cabinet, I would have used it here, but I do not right now.

New hardware, temperature sensor, and a spiffy coat of paint, the unit is ready to go back in.  Now to do some hoses.

The front two hoses are definites, the others are still under consideration.  Reasons for this is that I do not wish to simply slap in hoses to a motor that will be removed come tax season for an upgrade.

From the picture on the left, you can see my hose replacements for the two front hoses.

With the radiator out, it provides access to a whole bunch of stuff. I added some more soundproofing and got to replacing the heater lines while I had great access.

Since the system was drained, I used to opportunity to replace the heater lines.  I bought 30 feet of high grade heater line, some brass T's from Home Depot, crimp clamps and set to work.

I started from the rear while the fan shroud was drying completely.  Started with the feed line from the cylinder head and worked my way forward.  I replaced the lines going to the rear heater core and plugged into the brass T.  Make sure you get new grommets to protect your lines through the bulkhead.

I ran the other line from the return tube down to the T fitting and chose to run both of the lines forward together, as I thought this to be easier than running two single lines.  Seemed to work out okay.  Not a whole lot of access down there without stripping off half the undercarriage.

Then I worked my way forward to the front end.  I ran the new lines through undercarriage in the same location as the originals.  When I got to the front of  the van, and the smaller hoses that attach to the front heater core I wished I could have found replacements, but I have not yet been able to.

After connecting up the core and double checking all my hose clamps, I returned to the radiator installation.

The lifting of the radiator assy would have been easier with a second pair of hands as you need to juggle the placement of the radiator, the installation of two support brackets and insert the bolts.

I still need to get a couple new air diverters for around the radiator to direct air in the proper manner.  Connect up the radiator fan wiring, the temperature sender wiring and make sure the fresh air inlet is not full of gunk.

Now there are a few different schools of thought on filling the system with coolant.  I happen to have an incline on my second driveway that leads to my garage, so backing it onto the incline and filling there allows for an air free system.

My confusion started when I had a half gallon to go and the system was full.  Could not figure it out.

I took the van for a ride, figuring there was an air bubble that somehow did not get out.  Van ran great, temp gauge was fine, but while driving I tried the heaters and found that the front core (which was not attached to system when I bought it) was clogged and not allowing hot coolant through.  Now that's why I couldn't get that last half gallon in there.  Guess that is a project for another day.