Coolant and Heating main pipe leaks

Outer/offside pipe is return inner is send (to radiator)

also see[1]

Rear of pipe Hacksawbob ...in the end I didn't use the multiple o rings or the tape around it just in case it became disloged and clogged up the cooling system. but I did do the amalgamating tape around the metal pipe and whacked it home there is no way thats coming out again. My problem was that (and this may be quite common) that outer hose is used as the drain point, with the constant on and off at this point the pipe has become brittle and cracked. hose clips are used instead of the nice spring clamps. these can and are tightened up too far possibly distorting the metal and/or cracking the plastic. any way my pipe had been shortened and the metal pipe wasn't seated in the plastic. so I seated with tape then got a length of rubber coolant hose from Halfords, this was slightly longer than the hose that goes from the plastic 'tree' to the hard plastic. It was a perfect fit and length so I just added one o ring between the metal lip and the plastic body then put 2 hose clamps on the first one I tried as best to seat it on the rubber O ring.

The part I used to replace the VW hose on the outer pipe (return)from Halfords was a 38X311mm (311mm long dia 38mm) Part number HFH203 Flexible water hose. internally it has a metal spring to enable it to bend without kinking.

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Front of pipe This is best done with the van on drive on ramps or jacked and supporetd and with the spare wheel carried removd.

The front pipe had cracked and been shortened as above. his time I made up the distance between the end of the pipe with a short length of rubber hose ideally you would use a rubber hose that was the diameter of the metal pipe I couldn't find any so I used short sections of 19 heater hose crammed onto the metal then wrapped in tape leaving about an inch to get seated into the old plastic pipe. Again I wrapped self amalgamating tape around the end metal insert then whacked it home and taped over the join. Seems to be OK for now. I used a jubilee clip and a sprung ring seen in the picture to hold it all together. Update, this fix lasted for about 2 months then I had to bite the bullet and replace the whole pipe. The rear repair (as described in the top section) is still going strong on the other van.

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Coolant pipe repair1

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coolant pipe repair2