Coolant and Heating New radiator

HarryMann: Sometimes the only answer to consistent overheating on an older vehicle is a new radiator

... as the old one gets blocked up and loses efficiency. Cleaning (backflushing) can help, but in time the overall efficiency will obvioulsy drop as things age and corrode - this is particularly true of Turbo-Diesels as the heat-load seems to be much higher (and they not only have a more powerful fan, but diesels have a wider cooling duct running under the cab (hence carpets or rubber mats are different, as well as the gearlever gate box support under the cab).

Now, there are two radiators for T25s listed, an A version and an E. The A is listed for the 1.9 WBX vehicles and the E for 2.1s and diesels as well as 1.9's used for towing or usage in hot climates.

However, these days it seems only the A is stocked by VW (and GSF) for all vehicles although the E is probably available on back-order. GSF charge about £90 and with a discount the Genuine VW 'A' can be got for about £120...

As with a lot of parts, the design changes over the years, and the new A version is fractionally different as far as mounting the plastic fan cowling... it seems slightly taller, as well as having horizontal bracing bars instead of vertical.

-- -- I found that the fan cowl fitted only with the 3 lage self tappers down each side, with nowhere for the 2 smaller ones at the bottom, as found on the original. This and the slight increase in height, meant the cowling deformed enough at the bottom for the fan to rub the shroud... (the weight of the heavy diesl fanmotor (550W) doesn't help either).

I made up a stiffener brace (Z-section) curved in 2 planes to force the bottom edge of the plastic cowl back into line when rivetted on. I also found that tieing the two lower fan support arms together with cable ties also helped to distort the cowling back into shape... I think either solution would work, but implemented both.

Here is a pciture of the 'fix'... Hope it helps someone sometime!