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Go Back   TDIClub Forums > TDI Model Specific Discussions Areas > VW MKIV-A4 TDIs (VE and PD)

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 April 9th, 2004, 08:12   #1
McBrew
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Location: Annapolis, MD
Fuel Economy: 54/50/44 (usually running B100)
Default Replacing fuel temp sensor, tutorial

In hopes to cure the "Quantity Adjuster - Upper Limit Reached" CEL I've been getting from time to time, I've just replaced the fuel temperature sensor. The sensor resides just under the cover of the fuel injection pump. Although one special tool is required, the job is quite simple.

Tools required:

10mm nut driver (or socket) to remove engine cover
3/8" ratchet handle
5" (at least) extension
TX30 socket (male, non security or security)
TX10 socket (male, non security or security)
13mm socket
MetalNerd injection pump tool
1 wire-tie (optional, but recommended)
some rags

Part required:

Fuel Temperature Sensor VW part no. 028 906 040 C


After removing the engine cover, you'll need to remove the injection pump cover. FIRST, place a wad of rags in front of the injection pump to catch the diesel fuel that spills out. These bolts are not very tight... even a 1/4" ratchet will remove them easily. Use a TX30 bit to remove three of the bolts. Use a 13mm socket on the DieselGeek adapter to remove the triangle bolt. Now the top will remove, and some fuel will spill out.


Use a wire-tie to secure the cover and keep it out of the way. I used a clean rag to soak up some of the diesel fuel around the sensor. Note the position of the sensor. It looks like it could be installed upside-down, which may or may not affect it's operation.


Use a TX10 bit to remove the two screws holding the sensor. This could easily be done with a nut driver, as they are not especially tight. Remove the sensor, then follow the instructions in reverse to finish the job. Use a clean rag to wipe off the mating surface between the cover and the body of the injection pump.

After the install, my car started up without a hitch. During the initial test drive, I'd swear my car's performance is up a bit. Probably back up to what it used to be. Maybe the failing temperature sensor was acting exactly opposite of a tuning box or Evry mod.

Sorry, I don't have exact torque specs for the bolts. I put them back on about as tight as they were. They were not very tight at all. Of course, I tightened them in a cross pattern, to help it seat properly and evenly.

I'm sure someone around here has the proper torque specs...

-Jesse
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Old April 9th, 2004, 08:16   #2
DLV
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Default Replacing fuel temp sensor, tutorial

Nice job! I'll be sureto save this one. Thanks
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Old April 9th, 2004, 08:18   #3
VelvetFoot
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Default Replacing fuel temp sensor, tutorial

Nice thread! Too early to tell if it cured the DTC?
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Old April 9th, 2004, 08:37   #4
McBrew
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Default Replacing fuel temp sensor, tutorial

VF, yes... too early to tell. I've gotten the CEL three times since December. Only time will tell. Like I said, though, I'm pretty sure the car was a little zippier... not like a bad MAF, but a slight improvement.
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Old April 9th, 2004, 19:14   #5
cage
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Default Replacing fuel temp sensor, tutorial

If that was the problem then your car probably is zippier. The temp sensor totally affects the timing.
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Old April 9th, 2004, 20:44   #6
brenner
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Default Replacing fuel temp sensor, tutorial

like your post .did you buy the sensor from a vw dealer? what is the cost of a temp. sensor? thanks for the great tutorial!!
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Old April 9th, 2004, 22:32   #7
McBrew
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Default Replacing fuel temp sensor, tutorial

brenner, I bought it from a VW dealership for ~$36.00.
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Old April 10th, 2004, 06:27   #8
Denis
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Default Replacing fuel temp sensor, tutorial

Nice write-up, is there a gasket for the pump cover? If so is it available from VW or is it a Bosch thing?

Denis
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Old April 10th, 2004, 06:34   #9
MOGolf
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Default Replacing fuel temp sensor, tutorial

[ QUOTE ]
Nice write-up, is there a gasket for the pump cover? If so is it available from VW or is it a Bosch thing?

Denis

[/ QUOTE ]028 130 717 A
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Old April 10th, 2004, 09:11   #10
MITBeta
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Default Replacing fuel temp sensor, tutorial

[ QUOTE ]
I bought it from a VW dealership for ~$36.00

[/ QUOTE ]

D'oh... Impex had it for $17 when I needed one...
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Old April 10th, 2004, 22:34   #11
McBrew
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Default Replacing fuel temp sensor, tutorial

[ QUOTE ]
D'oh... Impex had it for $17 when I needed one...

[/ QUOTE ]

Don't tell me that!!! [img]/images/graemlins/crazy.gif[/img]

Oh, well... I was up there anyway... I bought 12 liters of VW505.01 oil for less than $70.00. So I didn't get totally ripped off!
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Old April 11th, 2004, 06:19   #12
golfstream
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Default Replacing fuel temp sensor, tutorial

Nice write up and pics, McBrew.

I'd also like the answer to Denis' question... is there a replaceable gasket (perhaps o-ring style) for the pump cover?

Mel
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Old April 11th, 2004, 07:22   #13
MITBeta
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Default Replacing fuel temp sensor, tutorial

[ QUOTE ]
Don't tell me that!!!

[/ QUOTE ]

Okay, I won't. [img]/images/graemlins/laugh.gif[/img]
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Old April 11th, 2004, 12:10   #14
Wingnut
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Default Replacing fuel temp sensor, tutorial

Nice post McBrew.

Can I add it to the 'How to' thread for easy access?
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Old April 11th, 2004, 12:46   #15
LarryLymb
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Location: Lehigh Acres, FL
Fuel Economy: 57.9/45/42
Default Replacing fuel temp sensor, tutorial

Nice posting, McBrew. My fuel temp sensor went out and the dealer replaced the injector pump under warranty. Did you try this?
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