Club 80-90 Forums

Hi have bought and fitted a new expansion tank with blue cap, fit's ok, but when cap tightened cap nozzle faces the wrong way. Have made the pipe from top up tank fit by re/routing it has anyone had to do this. Tony

Yes but short of uneconomic manufacturing tolerances on the part of both tank and cap manufacturers there is nothing to be done about it apart from longer pipe and a slackening of your untidiness tolerance.

Yes, I've had this slight issue in the past.

If you wrap the thread on the tank with bags of PTFE tape, you'll be able to screw the cap on and point it in the right direction whilst still getting a very good seal.

One or two rubber washers maybe?

I feel your pain...



I like the idea of the rubber washers or PTFE. Just need to tidy the rest of the engine bay after that.


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Yep, I replaced the bottle and cap and the nozzle faces 6-o-clock whereas the old one was more like 3-o-clock. Thought I'd overtightened or broken it so glad I'm not the only one

Not sure whether I posted on this subject previously but I did have to replace the pressure tank a while ago as it was impossible to stop a slow but persistent leak at the level sensor cap. Upon close examination it could be seen that there was a crack on the threaded part of the tank which spread across the "O" ring seal seat. This was barely detectable with the sensor out but would almost certainly open up when the sensor was screwed in too tight. Puzzled me for ages...
The addition of washers or tape etc, could conflict with the design intent which is based on a single "O" ring sitting in a defined location.

I have also had the header tank level sender perpetually weeping despite renewing the O-ring twice. Turned out that the problem was a slow-growing crack in the O-ring groove of the 20 year-old sender that rapidly got worse as I tightened it down...

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Seem to remember coming across spout pointing in wrong direction this some years ago.

Turned out I had unknowingly bought and fitted an early tank to my late cooling system van.

Early version is VW part No. 025 121 403A

Late version is VW part No. 025 121 403B

Early version fitted fine, except for spout pointing in wrong direction - replaced with later type and spout position returned to normal.

Regards

Martin