Question about Volkswagen Jetta

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2003 volkswagen jetta: coolant has migrated through the temperature sensor into the wiring harness causing corrosion and requiring the replacement of the wiring harness,coolant pump and instrument cluster panel.The o ring at the sensor coolant jug interface was in excellent condition. Why would coolant migrate through this location. Is this a design issue?

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Hi,

As i cannot offer you direct link in the chat, you can refer to the technical bulletin :-

http://ww2.justanswer.com/uploads/gomiotaku/2008-11-03_183046_3093Coolant_Migration.pdf

Note - Copy the same. Paste it in the browser and you would be able to see the bulletin.

You need to have Acrobat Reader to View this.

Any further Questions, let me know.

Hope i helped you.

Thanks for using ' Fixya ' and have a nice day!!

Posted on Oct 06, 2009

Testimonial: "The technical bulletin provided confirm that coolant migration was a problem the Volkwegan people were aware of. Any reason why this occurs?"

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I have a 2006 vw jetta 2.0t and the fans stay on even after the ignition is off and key is out, will run until the battery is dead. I have replaced the coolant sensor and the computer sensor on the...


The fans are run by rad temperature, not engine temp on a VW.Somewhere on the rad you should see a wire harness plugged into it.That is a thermo-switch which turns the fans on and off based on coolant temp in the rad. My car is a lot older than yours but this switch is virtually hidden on the bottom driver's side of the rad. It has 3 wires going into it.There could also be another sensor attached to the engine block or head to monitor engine compartment temps after engine shut off. This will turn the fans on or off as well based on air temp in the engine compartment.

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Code 1 senser P0118 on a 2004 V.W beetle dicesel


P0118 for Volkswagen - (ECT) Engine Colant Temperature Circuit High

Symptoms:- Engine Light ON (or Service Engine Soon Warning Light)

Possible causes:
(Inspect the following... Repair/Replace if necessary)
- Low engine coolant level
- Engine Coolant Temperature (ECT) sensor harness is open or shorted
- Engine Coolant Temperature (ECT) sensor electrical circuit poor connection
- Faulty Engine Coolant Temperature (ECT) sensor
- Faulty engine coolant thermostat

P0118 VOLKSWAGEN Description: The Engine Coolant Temperature (ECT) sensor is used to detect the engine coolant temperature. The sensor modifies a voltage signal from the Engine Control Module (ECM). The modified signal returns to the (ECM) as the engine coolant temperature input. The sensor uses a thermistor which is sensitive to the change in temperature. The electrical resistance of the thermistor decreases as temperature increases.
When is the code detected?:When an excessively high voltage from the sensor is sent to ECM.

I hope this helps! Let me know if you need further assistance.

Mar 08, 2012 | Mercedes-Benz C Cars & Trucks

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How to check temperature sensor and how to replace it on a 2003 chevy impala 3.8l


Testing: many intermittent open or shorted circuits come and go with harness and connector movement caused by vibration, engine torque, bumps and rough pavement, etc.

Test the wiring harness and connectors by performing the following:
Move the related connectors and wiring while monitoring the appropriate scan tool data.
Move the related connectors and wiring with the component commanded ON and OFF, with the scan tool. Observe the components operation.
With the engine running, move the related connectors and wiring while monitoring engine operation.
If harness or connector movement affects the data displayed, the component and system operation, or the engine operation, inspect and repair the harness or connections as necessary

Test the electrical connections and/or wiring by performing the following:
Inspect for incorrect mating of the connector halves, or terminals not fully seated in the connector body, backed-out.
Inspect for improperly formed or damaged terminals. Test for incorrect terminal tension.
Inspect for poor terminal to wire connections including terminals crimped over insulation. This requires removing the terminal from the connector body.
Inspect for corrosion or water intrusion. Pierced or damaged insulation can allow moisture to enter the wiring. The conductor can corrode inside the insulation with little visible evidence. Look for swollen and stiff sections of wire in the suspect circuits.
Inspect for wires that are broken inside the insulation.


zjlimited_1215.jpg

Fig. Identifying engine coolant temperature sensor-3.1L, 3.4L and 3.8L engines

3.8L Engines
NOTE Use care when handling the coolant sensor. Damage to the coolant sensor will affect the operation of the fuel control system.

  1. Partially drain the cooling system.
  2. Disconnect the ECT sensor electrical connector.
  3. Remove the ECT sensor.

    zjlimited_1216.jpg

    Fig. Removing and installing ECT sensor-3.8L engine (click image for zoom)

To install:

NOTE Replacement components must be the correct part number for the application. Components requiring the use of the thread locking compound, lubricants, corrosion inhibitors, or sealants are identified in the service procedure. Some replacement components may come with these coatings already applied. Do not use these coatings on components unless specified. These coatings can affect the final torque, which may affect the operation of the component. Use the correct torque specification when installing components in order to avoid damage.
NOTE Use care when handling the coolant sensor. Damage to the coolant sensor will affect the operation of the fuel control system.
  1. Coat the threads with sealer GM P/N 12346004 (Canadian P/N 10953480) or equivalent.
    NOTE Use the correct fastener in the correct location. Replacement fasteners must be the correct part number for that application. Fasteners requiring replacement or fasteners requiring the use of thread locking compound or sealant are identified in the service procedure. Do not use paints, lubricants, or corrosion inhibitors on fasteners or fastener joint surfaces unless specified. These coatings affect fastener torque and joint clamping force and may damage the fastener. Use the correct tightening sequence and specifications when installing fasteners in order to avoid damage to parts and systems.
  2. Install the ECT sensor and tighten to 15 ft. lbs. (20 Nm).
  3. Connect the ECT electrical connector.
  4. Fill the cooling system.

Hope helps (remember to rate this answer).


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PO103 and 116 code on a 1997 jetta 2.0


P0103 - Mass or volume air flow circuit high input.

Symptoms: Engine stalls, running rough, excessive fuel consumption, excessive smoke from the tail pipe, check engine light on.

Possible Causes: Dirty mass air flow sensor, dirty mass air filter, mass air flow sensor harness is open or shorted, mass air flow sensor electrical circuit poor connection, intake air leaks, faulty mass air flow sensor.

P0116 - Engine coolant temperature circuit range/performance.

Symptoms: Check engine light on.

Possible Causes: Low engine coolant level, ECT sensor harness open or shorted, ECT electrical circuit poor connection, faulty engine coolant temperature sensor (ECT), faulty engine coolant thermostat.

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I want to replace cooling temperature sensor but I can't locate where it is? I have a Haynes Repair Manual book but it is not clear. My car is Volkswagon Jetta TDI 2000. Does anyone know please give me...


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Find the coolant temperature sensor in the engine block on the driver side of the engine compartment. It is screwed into the block and has a wire lead running to the engine wiring harness. Once you locate the sensor, disconnect the wire lead going to the sensor with an open end box end wrench. Inspect the wire lead for melted insulation and discolored insulation. Either condition will require you to replace the wire lead. Make sure the engine has cooled enough to prevent burn injury. Use the appropriate socket and ratchet or open end box end wrench to loosen the temperature sensor. Turn the ratchet or wrench counter clockwise until the sensor is loose enough to turn by hand. Unscrew the sensor and remove from the engine block.Check the temperature sensor for corrosion and the wire lead for damage. Replace the sensor and reconnect the wire lead. Start the engine and allow it to heat up to operating temperature. The cooling fan should come on automatically as the engine temperature increases.Use a gloved hand to squeeze the input hose for pressure. If pressure exists, it means that the coolant is flowing to maintain the engine operating temperature. Now check your engine temperature sensor or warning light to see if it is reading properly.

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1 Answer

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Be sure that when you replace it you put in a new rubber gasket seal.. its a round rubber seal that should come with your new part. Dont reuse the old one or you will have a leak.

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Go here and enter your vehicle year make and model and see if there are any recalls for it. If not, you may have a problem with your coolant temp sensor harness. Get inside the vehicle once it's been warmed up and have someone wiggle the temp. sensor wire and see if it re-creates the problem. if so, your harness needs replacement.


http://www-odi.nhtsa.dot.gov/recalls/recallsearch.cfm

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