I need a Syncro Diesel/ Electrical Guru

[vandoka]

ZsZ thanks for all the great info. At this point I tested the thermo sensor and it is functioning properly. And you were right that my truck does have the webasto heater (which does not really work right now) But after driving the truck this morning for 30 minutes I got the blower fan to start. With the truck turned off I removed the relay shown in your linked document and the blower continued to run. So I believe the issue is not with the thermo sensor or relay but somewhere else...?

[ZsZ]

found this article:
http://www.charlie-o.de/index.php?article_id=322

which shows that thermoswitch present in the flange which is at the side of the engine under the injectors

so I got confused where it should be present, Mine was in the flange at the end of the block the online ETKA shows the switch in the side flange

the color of the wire that switches the fan and the aux pump (through the relay in the relay box) is brown with red tracer

the temp sender for glow plug has a blue wire with white tracer and the temp gauge sender has yellow wire with red tracer

EDIT (again ) further ETKA investigation tells that the manifold heater switch is present in JX at the end of the head when additional WEBASTO DBW46 heater is present
_________________
Zoltan
1.9 MTdi 2wd Multivan (ex Caravelle)
Van since 2006, engine since 2008

[ZsZ]

[vandoka]

ZsZ,

Thanks for the helpful part numbers and links to diagrams on the Classic Parts sites. After following the diagrams I removed what I thought to be the temp. sensor but of course it looks unlike the two parts you have shown....

although it seemed to fit with the diagram location. Can you identify this and possibly point me in the right direction

[Team WorldTour]

[ZsZ]

As told, both the aux. coolant pump and fan are switched on by a thermoswitch marked F95 on the circuit diagram. It should be present at the coolant flange at the end of the cylinder head.
It switches on at 102C coolant temp in 2wd I think its the same switch on syncro.

There are two versions:

early for enginees with metal flange. Partnr: 251 919 521

https://www.volkswagen-classic-parts.de/temperaturschalter-d5a811.html



and late for engines with plastic flange. Partnr: 251 919 369 F

https://www.tk-carparts.de/article/3795/Temperaturschalter_20_mm_97_104_Grad_2_polig.html
_________________
Zoltan
1.9 MTdi 2wd Multivan (ex Caravelle)
Van since 2006, engine since 2008

[vandoka]

I just picked up a doka with the 1.6 turbo diesel and am having similar symptoms as Team World Tour. After driving for only 10 minutes on a mild day the fan runs for 20-30 minutes after the engine is off. Wondering if the relay on top of the fan (part #27 in the posted diagram) is the best place to start troubleshooting this issue?

[Team WorldTour]

Cool. I'll check it out in the morning.
Thanks again, Mate.
_________________
1990 Feldjäger Syncro AAZ
Click to view image
H6 Subaru Engine Swap Thread
WV2ZZZ25ZFH094138(x)/ WV2YB0257LH057308(x)/ WV2ZZZ25ZLG113270/
"Where am I going? And what am I doing in this handbasket?" -Nicodemus Jordan
When All Else Fails: Lather, Rinse, Repeat!

[?Waldo?]

I made a typo before. The number of bracket mounting bolts on the AAZ is three, not two. They are under the pump and go through the bracket to mount it to the block.
_________________
I am a high-functioning autistic into VW diesels and Vanagons along with other things that are unrelated to this site.

[Team WorldTour]

Filter is good, just checked it.
Two allen bolts under pump bracket, I'll check it in the morning.
As for the black smoke, it's not a regular thing. It happened twice before. The first time, I wrote it off as I was going up a small rise on the Autobahn, it was a warm day (for Germany), and the wind was blowing against me.
I did some reading that night.

The second time happened on the same stretch of road, only I was going downhill. This is when I started thinking about other possibilities.
Yesterday was the third time, and I was a bit more aware of my circumstances. The temp needle was just to the right of the LED. So engine being warm(er) is a factor.

Then yesterday I noticed this:

It looks to me as if the rubber boot is collapsing.
Maybe, when the engine temps are just right, the boot gets soft, and the engine starves for air.
It's a thought.
_________________
1990 Feldjäger Syncro AAZ
Click to view image
H6 Subaru Engine Swap Thread
WV2ZZZ25ZFH094138(x)/ WV2YB0257LH057308(x)/ WV2ZZZ25ZLG113270/
"Where am I going? And what am I doing in this handbasket?" -Nicodemus Jordan
When All Else Fails: Lather, Rinse, Repeat!

[?Waldo?]

[Team WorldTour]

So, before I started the deep work yesterday, I checked the pump fit. Everything was tight as it should be. I did not mess with any adjustment screws.

On a side note, while driving to the Base yesterday, my temp gauge went a little high (just to the right of LED).
Coincidently, when I would floor it (as I must on occasion), I got black smoke coming from the exhaust.
This is the third time I have gotten black smoke at WOT (similar conditions).
Could I have a ruling from someone NOT on their first Diesel (like me!)?
Cheers!
_________________
1990 Feldjäger Syncro AAZ
Click to view image
H6 Subaru Engine Swap Thread
WV2ZZZ25ZFH094138(x)/ WV2YB0257LH057308(x)/ WV2ZZZ25ZLG113270/
"Where am I going? And what am I doing in this handbasket?" -Nicodemus Jordan
When All Else Fails: Lather, Rinse, Repeat!

[Team WorldTour]

As that is work I can confidently perform, it will be on the job list, however the adjustments to the idle screws and throttle linkage I will leave to those more knowledgeable than myself.
_________________
1990 Feldjäger Syncro AAZ
Click to view image
H6 Subaru Engine Swap Thread
WV2ZZZ25ZFH094138(x)/ WV2YB0257LH057308(x)/ WV2ZZZ25ZLG113270/
"Where am I going? And what am I doing in this handbasket?" -Nicodemus Jordan
When All Else Fails: Lather, Rinse, Repeat!

[?Waldo?]

[Team WorldTour]

Thank you, Ms Taboo.
I will try that first, though when I get done with this weekend's job list, I will be going back to Bosch for the adjustments outlined by Mr. Libby.
_________________
1990 Feldjäger Syncro AAZ
Click to view image
H6 Subaru Engine Swap Thread
WV2ZZZ25ZFH094138(x)/ WV2YB0257LH057308(x)/ WV2ZZZ25ZLG113270/
"Where am I going? And what am I doing in this handbasket?" -Nicodemus Jordan
When All Else Fails: Lather, Rinse, Repeat!

[MsTaboo]

[?Waldo?]

[Team WorldTour]

So, I ended up replacing that sensor, and all is well (with that system...).


NEW QUESTION:
The new engine has just under 16,000 kilometers on it, and the AAZ pump was freshly rebuilt (by Bosch) at the same time.
Can anyone think of why the engine would be surging while driving?
In the meantime, the pump had been serviced (by the very same Bosch tech), and the fine tuning made (last year, during the 'It Started With A Thump' issue).

Also, this weekend, I'm planning on dropping the trans and replacing the main seals. At the same time, I will be dropping the tank and replacing the vent hoses and straps.
_________________
1990 Feldjäger Syncro AAZ
Click to view image
H6 Subaru Engine Swap Thread
WV2ZZZ25ZFH094138(x)/ WV2YB0257LH057308(x)/ WV2ZZZ25ZLG113270/
"Where am I going? And what am I doing in this handbasket?" -Nicodemus Jordan
When All Else Fails: Lather, Rinse, Repeat!

[Team WorldTour]

Yeah, I'm not messing with the glow plug sensor.
But on the end of the head I have two. The one on the inboard side is the gauge. This should be the same for everyone else's.
On the outboard side, is where the second sensor resides.
I found it last week, and it was covered in corrosion.
I cleaned it up, and didn't think much of it.
Next time I can get it on the lift, I'll try to find a color for it.
_________________
1990 Feldjäger Syncro AAZ
Click to view image
H6 Subaru Engine Swap Thread
WV2ZZZ25ZFH094138(x)/ WV2YB0257LH057308(x)/ WV2ZZZ25ZLG113270/
"Where am I going? And what am I doing in this handbasket?" -Nicodemus Jordan
When All Else Fails: Lather, Rinse, Repeat!

[Waldi]

There are 3 different sensors.
Temp gauge and preglowing are resistance controled, but still different.
So if you change the gauge and glowing wires, it will work, but not correct.
You can easy find out which sensor is where.
If you know the temp gauge wire, and your engine is warm not hot-hot, try all 3 sensors.
On the fan/pump sensor the temp gauge will not work.
Difficult to test the fan/pump sensor working in the engine.
Better put it off and test with a light or in hot water.