Date:         Sun, 10 Mar 2002 18:59:58 -0800
Reply-To:     dennis lockwood <luvoldvws@YAHOO.COM>
Sender:       Vanagon Mailing List <vanagon@gerry.vanagon.com>
From:         dennis lockwood <luvoldvws@YAHOO.COM>
Subject:      Re: Temp II sensor replacement
Content-Type: text/plain; charset=us-ascii

I risk heresy to write the following.  I wear flame
proof underwear so feel free to flame me.  BTW, the
following describes the process on a 91 Vanagon.
Other years may differ.

Twice I have done the following procedure
successfully.  I have pulled the Temp II sensor, let
the coolant flow out, replaced the sensor with a new
one, poured the used coolant into the reservoir, fired
it up to check my work and drove on.  No, I never have
bled the coolant system after replacing the temp II
sensor, did not need to.

Make sure the engine is cold, like first thing in the
morning after the van sets all night.  You need to
pull the wire bail that holds the sensor in the
thermostat housing.  I use a pair of needle nose
pliers and some salty language.  Sometimes you can pry
the bail out with a broad, short screw driver.  Put a
catch pan under the tstat housing to catch the coolant
that will surely flow out.  Remove the electrical
connector from the sensor.  Hint, push against the
wire bail that holds the electrical connector on the
sensor.  The sensor will slide off easily.  Pull the
temp II sensor from the tstat housing, it should slide
out with moderate effort.  Verify that the o-ring came
out with the sensor.  When the sensor is removed from
the tstat housing, coolant will gush out freely.
Don't panic.  About two quarts will come out, and then
the flow will stop.  Replace the sensor and o-ring.
Make sure that it is inserted all the way.  Make the
electrical connection (it should snap on assuringly).
Replace the wire bail that secures the sensor.  Make
double sure that it is secured properly.  Refill the
coolant into the reservoir and top up to accommodate
any lost coolant.  Start the engine, burp the air out
of the reservoir as many times as is necessary.

This procedure works as long as your van has a good
thermostat that closes tightly and the engine is ice
cold.  It should work for you also.  Hope this helps.

Dennis Lockwood
91 Carat
Original Owner

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