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VW MKIV-A4 TDIs (VE and PD) This is a general discussion about A4/MkIV Jetta (99.5-~2005), Golf(99.5-2006), and New Beetle(98-2006). Both VE and PD engines are covered here.

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Old December 1st, 2017, 13:14   #16
UhOh
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Quote:
Originally Posted by mr.loops View Post
I might attempt to bend the lip back a tad so the sensor will fit
By "lip" are you referring to the insert? If so, seems that you could get something that matches that flare and tap the lip back in to shape. First thing to come to MY mind would be a 3pt hitch pin (CAT1) off a tractor implement: they have nice tapers on them. Not sure if the block's casting there (looks like a repair?) obstructs true conformity (even if you had a replacement sleeve would it stay in proper shape?).
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Old December 1st, 2017, 14:20   #17
KLXD
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You sure that's not something that broke off a previous sensor?
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Old December 1st, 2017, 21:58   #18
mr.loops
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Quote:
Originally Posted by UhOh View Post
By "lip" are you referring to the insert? If so, seems that you could get something that matches that flare and tap the lip back in to shape. First thing to come to MY mind would be a 3pt hitch pin (CAT1) off a tractor implement: they have nice tapers on them. Not sure if the block's casting there (looks like a repair?) obstructs true conformity (even if you had a replacement sleeve would it stay in proper shape?).


Yessir I was referring to the insert.
I like your suggestion on the repair. I ended up taking a 12mm socket, inserted it into the hole and gently tapped it from the side. Looks good and I just saved myself a trip to the yard.

I remembered the machine shop had provided a bag of old parts that where taken off the block. I was about to throw them out last week but forgot. Anyhow, I just checked and there was the old broken CKP sensor in there. This one fits perfectly! I guess there are two different sensors out there for the ALH block.

Here's what I'm talking about:



The one on the right came off the 2002 ALH ( the runaway) and the left, was from a 1999 ALH pulled from the junkyard. They both measure 17.9mm in diameter and 41.6 mm in length. The newer one had "step" at the end which prevented the sensor to be inserted all the way into the block.

Edit: Here's a better picture of the sensor from the older 1999 block:
https://www.ebay.com/itm/Crank-Posit...-/351666922174

Notice is says crank sensor for AHU block. I wonder if I have a mix-match of parts going on here? Like a AHU sensor on a ALH block. It was on a cutoff year for the Mk3 I pulled up my car info from Pick N Pull's website. Here's the VIN: 3vwrf29m3xm031979

Last edited by mr.loops; December 1st, 2017 at 23:30.
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Old December 2nd, 2017, 09:44   #19
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Might want to check VW's part numbers (I use 1stvwparts.com). Yes, mid-year changes really can make for a pain in the behind! Anyway...

Good job on tracing this all down.
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Old December 6th, 2017, 22:17   #20
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Quote:
Originally Posted by UhOh View Post
Might want to check VW's part numbers (I use 1stvwparts.com). Yes, mid-year changes really can make for a pain in the behind! Anyway...

Good job on tracing this all down.


Will do!
It's a bummer I didn't do more research on the change over year. Well it's too late now. The block is done and is on the engine stand

Here is the game plan:

I've pulled the CKP sensor connector off a AHU and will transfer it over the the ALH harness



I know I have a Hall Effect Sensor for the CKP so there will be three wires: reference, signal, ground

Here's the AHU wiring diagram:



Black wire (T3/3) = ground
White wire (T3/2) = signal
Yellow wire T3/1) = reference

And the ALH :



Black wire (T3/3) = reference
White wire (T3/2) = signal
Brown wire (T3/1) = ground

So with my ALH engine harness connected to the AHU CKP, my wiring at the connector should look like this:

Yellow wire ->T3/3 (reference)
White wire ->T3/2 (signal)
Black wire -> T3/1 (ground)

Last edited by mr.loops; December 6th, 2017 at 22:29.
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Old December 7th, 2017, 16:35   #21
mr.loops
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Quote:
Originally Posted by KLXD View Post
You sure that's not something that broke off a previous sensor?


**** you where right!
Part of the crank sensor had broken off in the block. You couldn't tell by the old one because it looked perfectly intact



So I'm back on track. Sorry for the confusion guys


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