Club 80-90 Forums

I know there are some very comprehensive threads etc on here... but does anyone have a complete diagram of a late 2.1 DJ cooling system? I have air / gas getting in the system but no over heating and no signs of a cylinder leak. Have followed Mr Baxter's instructions for filling / bleeding, several times but still can't remove all of the air. Also, no sign of water getting out anywhere! Specifically, the air is in the distribution circuit and as far as I can deduce, the only place it can be coming from is the off side water jacket, but like I say, can't see any other sign of cylinder / water jacket leak.

If any one out there has a complete diagram of a late DJ, it will be very much appreciated!

thanks for reading.

Quite good diagrams on vagcat but you have to register to view the parts catalogue
http://www.vagcat.com/" onclick="window.open(this.href);return false;

They don't call them water leakers for nothing
If the system won't pressurise properly then it doesn't pull back the spare coolant on cool down from the top up tank and it draws air back in

You need to get under it and look when hot and cold
White deposits indicate leak areas

A tip from here is to place sheets of card board under the van as it shows drips better

Taken me six years to stop mine using water

Another thought
If its this you followed
http://www.brick-yard.co.uk/forum/bleed ... 29710.html" onclick="window.open(this.href);return false;

Did you open the thermostat bleed screw?
Its not on the op its mentioned a few posts down

does the air/gas appear when the engine is running?
if not...
then the air is drawn in from a leaky joint as the coolant contracts.
it should be drawing it back from the top up tank, perhaps the header tank cap is faulty.

thanks itchyfeet. have followed mr baxters instructions thoroughly, including bleeding thru 'stat valve. i will register on the other site and see if that teaches me anything! i'm wondering if it could be a leak somewhere at the front in the heater system (can't see all of the pipe work there)... otherwise i'll have to assume it's an internal cylinder leak.

Internal seal leak would cause excessive bubbling when running as kev says
You would see it in the tank

kevtherev. air appears when running. you can see bubbles in the distribution pipes at the front of the engine bay. the bit i am not sure about is the complete purpose of the distribution circuit and whether air / gas can get in from anywhere other than the cylinders. I can't find a complete diagram that shows flow direction throughout, crucially in / out of the distribution 'joint' immediately in front of the engine bay on the off side (i know that this distributes water from off side water jacket to the radiator and also to the internal heater. I do not know is any water flows back to this 'joint' from the heater system? If not, the only place gas can get in to it is from the water jacket..... I might be clutching at straws, but i'm hoping there could be another source of the air / gas.

i am happy that the header cap is OK - i replaced the old one (which i think was working fine!) with one from brickwerks.....? however i have a full expansion tank that is not emptying back into the header tank when cold. Should i just accept that i've got a cylinder head problem?

I can't see how the flow is relevant
How much air / coolnt loss are we talking about over what period of driving?

Has any wo k been done on the cooling system recently?

Remember the wiki on this site is very good....
https://club8090.co.uk/wiki/Pe ... em_diagram" onclick="window.open(this.href);return false;

if it is gassing when the engine is running then you have a cylinder leak.
As the coolant is under presssure, it would not let air in, unless it too was under pressure...like from a combustion

thanks kev. had pretty much reached the same conclusion but was hoping for an alternative ( miracle) answer!

I do births deaths and marriages.. not miracles