I need a Syncro Diesel/ Electrical Guru

[?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.

[Team WorldTour]

Cool. I'll check it out in the morning.
Thanks again, Mate.
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1990 Feldjäger Syncro AAZ
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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!

[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?

[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
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Zoltan
1.9 MTdi 2wd Multivan (ex Caravelle)
Van since 2006, engine since 2008

[Team WorldTour]

[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

[ZsZ]

[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
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Zoltan
1.9 MTdi 2wd Multivan (ex Caravelle)
Van since 2006, engine since 2008

[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...?