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I was driving on Tuesday (SoCal heat wave) when I had an odd smell coming through the vents.? Then some fogging on the window.

I suspected a coolant issue and saw my reservoir was empty.? I needed to get somewhere to leave it, and I hobbled to a lot.? As I my 1993 EV was hobbling, some hot liquid came out of the dash and splashed on my foot.? Therefore, I'm suspecting that it is the heater core.? I don't have time to fix properly so I'm going to try a bypass tomorrow.
Any tips from people that have bypassed the heater core on a 1993?

I posted some photos on my website - http://www.eurovanrescue.com/2022/09/09/heater-core-failure/

I imagine your year has a similar setup for the cabin heater to my 2003 EV WE. ?IF SO ITS QUICK AND EASY- As I recall, a 3/4 inch elbow ( male male ends) fits the hoses that connect just to center on the firewall (engine side) use existing clamps on the elbow. That bypasses just the cabin heater coil. Done. Also since it’s the high point of the coolant route little coolant is lost. ?I got my elbow at a radiator shop, as it was around the corner from me, but Lowes etc probably carry a copper one (mine was plastic). I keep it in my emergency pack now. Do it when fluid is cool obviously and top off coolant, then recheck level for next month for “burping out the hidden bubbles.” ?What you experienced are signs of a bad heater cabin coil, hopefully you didn’t overheat the engine with the hobbling, and were adding fluid all the way, frequently enough. YMMV?
Phil B 2003 EV WE 322 kmi

I don't know if your setup is different than my 2002, but when mine went out I located the connectors going to the heater at the firewall and was able to disconnect the in and out hoses and join them right there using only a screwdriver if I remember right.? Took 10 minutes at a rest area and we finished our summer trip without heat.? No problem.?
Pulling the dash later to change it was a pain, though.??

UPDATE: Completed the bypass yesterday in about 10 minutes as others described as well.? Definitely think keeping a bypass kit in the Eurovan is a good idea.? $20 backup plan.

Photos will be posted on my website.? Super easy and only required pliers.? I did a refill of coolant, started, drove, topped off... and today I'll check it all again to be sure there isn't another leak.

Question though: My dash temp/coolant light has been blinking even before this failure.? I had already replaced the coolant reservoir... thinking that it was a sensor/reservoir issue.? What conditions will make that dash light turn ON/blink?

- low coolant
- high temp?
- faulty/disconnected temp sensors?? (possibly bad wire or bad sensor)

Is there a VAGCOM-VCDS check I can run that would help diagnose why this is blinking?

All you are doing is connecting one hose to another.? The clamps are already there and for 2001 to 2003 I know that a union is already in place right there by the little screw vent.? You can disconnect one hose going to the firewall at that union and the other at the firewall and join them together.? There are few things under the hood easier to do than this.? Just make sure it's cooled down.

BUT perhaps the earlier versions had different plumbing and would require actually providinga union for the hose.? In that case any parts store will have a union (measure ID of hose) or even a garden hose repair kit should work fine if metal.??

So, my Eurovan did ok for about 2 weeks.? Then I think a hose failed.? I haven't had a chance to work on it yet.? I need to pull the belly pan off to find out what failed, but the coolant is bone dry right now.

I know there are some hoses that are difficult to find to purchase.? If anybody knows any good sources, please let me know.

So many coolant hoses....

I have found some hard to get hoses at the bus depot:?
Be sure to check all the plastic hose flanges, they are very prone to failure.?
At least they are still easily available.

I replaced?the oil cooler hose in my 93 a few years back and the transmission cooler lines were evidently replaced by the previous owner.
I developed a bunch of leaks last year, thankfully just after getting back from a huge southwest trip so I had the luxury of working on it while at home. Biggest leak was a no-longer-available plastic connector with sensor in the radiator hose but vanagain had them in stock. Decided to go ahead and replace all the hoses, flanges and sensors while I had the coolant drained, seems like they would all be getting ready to fail after 30 years and 250K miles. Worth the effort for the peace of mind. And bonus, temp gauge is working again

I know dash light blinks with low coolant (sensor in the reservoir), lots of troubleshooting info out there if you need help.

Good luck!
Scott

I finally had a chance to get the 1993 Eurovan Weekender MV on ramps and do a test drive.

What I found is two obvious leaks when the Eurovan was at running temp only.? At cool temp, no obvious leak was detectable.

So I drove the van for about 15 minutes.? Toward the end of the drive, I started to see fumes (coolant evaporating off the engine).? That had/has me worried.

But luckily, I was close to home.? Parked it back on the ramps and took a look.

First coolant leak - under the Eurovan, near the fuel filter -?
I'm a bit confused as to what this mysterious hose/pipe is for.? Wondering if it went to a rear heater/exchanger.? So odd.

Second coolant leak - seems to be coming from the connections on the radiator -??
I intend to take the grill off to get a better look.? Assuming it is probably best to just replace the entire radiator, unless something can easily be fixed.

The first coolant leak near the fuel filter is not a leak - it is the a/c condensation tube. Feel it and you will see it is a rubber hose. Will 'leak' with the a/c on.
Given the steam coming out, second leak is likely from the radiator. The only connections on the radiator are the inlet and outlet, both on the driver's side, along with a screw in connection for the coolant temp sensor on the passenger side. Given that it appears it is in the middle of the radiator I would suspect a leak. The other tubes running the length of the radiator are separate - the power steering tube is a black aluminum finned tube that runs the length and back in a u-shape. The a/c condensor is a separate radiator in front of the engine radiator.
Hope that helps.

Hi Ken. Thanks for the reply

The first leak (ac condenser tube) - would that be a coolant leak? ?I put a bowl under, and it collected pink coolant. Is that by design?

I’ve never replaced a radiator. Thinking I should be able to handle. I’ve got manuals ?

Anybody have thoughts/tips on 93 radiator replacement?

On Sat, Nov 26, 2022 at 04:11 PM, Droppin bombs wrote:

The first leak (ac condenser tube) - would that be a coolant leak?

Sounds to me like there may be a leak in the heater core, resulting in the coolant coming out that tube.? Normally it's only condensation from the a/c evaporator.
--
Duane
05HD Rialta
220K Miles

Duane, ok, that makes sense.? I'll check the diagrams to confirm if/where the meet up.??

Since the heater core is by-passed I suppose it could just be left over coolant?? Though, I'd say about a 1/2 cup leaked.

Here are a couple of photos form the front of the radiator.

From what I can tell the last time I had it at running temperature, the leak was coming from the top connections in these photos.? You can see the discolored drip line down the left side of the radiator adjacent to the connections.

Regardless, I think I'll just swap the radiator as this one looks toast anyway.

So based on the condition of the radiator and the leak, I've decided to replace the radiator and hoses.

While the radiator is off, I also intend to do some other maintenance.? I'm looking for suggestions of other tasks.? Please keep in mind that this 1993 Eurovan has been reliable, but has had little maintenance done in the last 6 years.

• Radiator & hoses
• Coolant temp sensors
• Valve cover & grommets
• Touch up rust/metal on headlight/radiator assemblies
• Replace filters (air, fuel, oil/oil change, etc)

Also, I've been looking for any how to's on how to remove an exhaust manifold.? I'm not sure that I want to take that on now, but if anybody has a video/docs, please let me know.? I have Bentleys that I'll be reviewing as well.

Tackling the radiator replacement finally... this weekend.
Already started with basic inspection, draining, etc.

Using this video as a guide -?

But, it appears that my front has what I guess is an AC heat exchange... or possibly trans cooler... in front of my radiator.? Thinking the AC from where the lines appear to go.

Can anyone confirm what the "front front radiator" is? I think I'll be able get behind it to swap the radiator.
With this "front front radiator", it is difficult to pinpoint the leak.? But it is definitely coming from the cooling system... and the area indicates the radiator.

I'll post back progress/completion when done.

Leak Videos

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Well, no responses here.? Guess not that many people have done this? Or it is too easy? Just no interest?

Complete. DM if you want any info.