Waterpipe connector, (it started with a drip)

[Steve T]

Pipe connector, for coolant pipe 025121058A
I had to bite the bullet and see what was causing the drip, got spare hose from a member on 80-90 and was ready....
Worst case cenario connector is buggered, completely rotted, as you can see from pic

Took some getting off, top hex allen socket not too bad, used impact driver to remove, bottom one "rounded"
when trying to undo, luckily was able to unwind it a bit to get it to move by knocking the piece anti-clockwise then
using some mole grips to remove the bolt / stud

Pic of where it goes on cylinder head, just above exhaust port pot 3


As you can see in this pic it is NOT full flow pipe as it has restrictor in place, looks like the pipe is in some
sort of bronze?? or copper derivative fixing(I think)


Viewing from the back the pipe is flush fit, the pipe edges are just visible, with the restricter a little lower
down inside the pipe



Question 1, was the pipe heat or sweat fitted, brazed or pushfited into the plate,
Question 2, I wonder if there is a VW related part that may do the job, long shot I know as the part is
no longer available (025121160)
Question 3, Why is the pipe restricted, it is to reduce the flow and why
Question 4, Could I "blank" this off at the cylinder head and not have a "through" flow to manifold, it is connected via other pipe
from system. (possibly answered that one myself)
Qustion 5, All fittings and parts are in metric size,
Poss solutions
I may be able to braize new pipe to the plate, or I might take a wander round the scrap yards in hope of finding a similar fitting from
any engine.
Any others greatly recieved. If I come by a solution I will post

Thanks, just thought I would share as others with DG engine may want to have a look in this area for same problem before it goes big time

Steve

[Fritz]

Just Kampers sell these ( Water pip[e flange) but they don't come with a gasket so you'll have to make one from a Kellogs box and a lick of sealer.

http://www.justkampers.com/shop/type_25 ... 2FC5SfQ%3D" onclick="window.open(this.href);return false;

Regards


Fritz,,,,,,,

[smurf]

The just kampers one has to small a spout for the early dg, the hose spout is at least twice the size of the JK one that is for the later 1.9 on the other head.

[Fritz]

My suggestion is basically the best option available even if it is for the later water system,,,,,,then if you look closely the internals of the rusted one it is exactly the same as the one I have suggested...

When these things are no longer available from VAG you simply have to improvise.......


Regards


Fritz,,,,,,,,,,,,,

[Steve T]

Smurf, thanks for the pipe, sure i will make use of it,

Fritz, good idea, shame they are out of stock at the moment, will try and get something at the scrapyard tommorow, or anywhere I will not give up just yet, (close to it I have had a s**t day today found the problem on the bus,got virus in PC, other family problem) now have forward plan for the bus, virus removed, family problem resolved) we want to be away in it soon for a few days, better to find the root of the problem at home in leisure I guess so to speak than on a motorway with no water in the system.

The pipe you suggest is bigger size internal than the small hole in the OEM fitting, strange it went to such a large size on the manifold.

Thanks guys

Steve

[Steve T]

Solution to the problem, found some steel tube got it to a little oversize, cleaned up to old flange plate, ready for welding,


Total disaster, lowest amps I could go to and blew hole in pipe, made another bit of tube up and did that with more care, but the heat was so hot that it distorted the plate to what I thought was too far, (any one want a paperweight) I think I should have done it from scratch in the first place and with the size of material I had

So started from scratch and found some steel plate, and some thicker steel tube, as luck would have it I had to go to one of our
depots today where they have a contract guy in to make up a few things that we need in the business, so just got him to mig weld the tube to the plate.
Brought it home and got to work on it, got it to the right shape drilled the holes flatted the back for a flush fit. all I need to do now is fit it, top up the water and antifreeze, bleed it a few times top up and keep an eye on it. I will make another when time allows with larger angled tube coming back on its-self so replacement hose when needed will be same size each end and straight hose. The hole for the water to pass is same size as original (5mm) wonder if this is the reason they are such a chore to bleed, does it help to slow water coming back from the heater, is it to allow more flow to the thermostat or slower flow through the inlet manifold, or just to ballance the system for the correct flow to the right places. I guess the last one. The water system is an add on, it was designed "around" the air cooled engine.

[getunder]

Re Kellogs gasket. Don't use Asda own brand,not so good. But seriously you can still get gasket card from good accessory stores for 1/6d, well it was last time I bought some. Cardboard might be liable to sideways bleed and break up.

[jdreamer]

Nice job. Interested to see how you get on with fitting etc. Noticed that mine looks kinda rusty too when I had the engine out recently, but didn't go there due to not being able to find a replacement anywhere (that I could find at least). How about a limited production run of say 50 to keep us all going (well, those of us lucky enough to have early 1.9 wbx!)

Cheers, J

[Steve T]

J,

sorry about the late reply but been busy at work and at play, done some 80 miles with the part in place and not a sign of any problems (touch wood (touching my forehead)) not a sign of any loss around this part. And bleeding the system was so easy again, must have the "nack" but did follow VERY closley info and guidance on bleeding and I can vouch it is correct and works. And I think the guidance may have originated from brickyard site?

As for making a few parts I could do this I suppose...............I would give it a go, as there must be few engines with this type of connector. Just wonder how many are in the condition mine was.

[Pepperami]

I got mine from VW it was only a couple of quid.

[sjmtlewy]

How much are these from classic?

[Cruz]

I knew I had seen this topic somewhere

If anyone needs one for an early engine then vw heritage sell them for £22.96.

Classic price is 20.60 euros plus tax and shipping sp there's not really much of a massive Heritage mark-up

Part numer is 025-121-160

http://www.vwheritage.com/vw_act_shop.p ... try_GB.htm" onclick="window.open(this.href);return false;

[sjmtlewy]

I think those are the ones from classic - part of the deal that heritage now have with them.

I got my one from classic in the end, very good quality. I dont remember how much it was, but £22 sounds right.