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    Camshaft setting, AHU

    Installed timing belt using tool at end of camshaft. Tool slips into cam slot easily. Lock pin fits smoothly into hole in pump sprocket and index hole in pump bracket. BUT there is about 0.005" more clearance between front of cam bar and cylinder head and rear of cam bar. 0.015" front; 0.010"...
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    WTB relay socket

    To the coochlyman, who said he "…might be able to find one in a Passat." That would be a good place to look. The socket holds the glow-plug relay, which has one huge pin and two husky pins. The two husky pins supply current to the starting glow plugs AND the heating glow plugs for the car...
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    Tool, to remove pins from relay socket?

    That's right; the pins are like the one you show. The relay in question is the glow plug relay, which uses large connecting pins for the heavy current for the glow plugs and the heating plugs used in cold weather. Because the relay socket's mounting clip is broken, the relay and its connector...
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    Tool, to remove pins from relay socket?

    Starting with the Mk4 Golf/Jetta, relay sockets were redesigned. The relays are used on the electrical panel and elsewhere. Is there a tool to release the relay pins from these newer relay sockets? Pins in relay sockets of Mk3 and older cars are less challenging to remove. Have a damaged...
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    WTB relay socket

    Socket is VW part # 867 937 501. It fits above and clips on to the top of the electrical panel. It was used with Mk3 Golf/Jettas, and may have been used elsewhere.
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    Vacuum reservoir needed?

    Thanks! And who is Guthrie? Surely it ain't Arlo…
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    Vacuum reservoir needed?

    When installing an AHU or ALH in a Mk2 Jetta — the gas cars had a vacuum reservoir — is the original vacuum reservoir necessary? The TDi engines have vacuum pumps…
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    Speedometer input for mechanical speedometer

    You are probably right. Now to find the actual part. It would have to fit the gizmo on the transmission AND the speedo head on the inst cluster. Thanks for the suggestion.
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    Speedometer input for mechanical speedometer

    Fourteen years ago I put an AHU Tdi and transmission in a 1991 Jetta. The 1991 car had a mechanical speedometer, but I have forgotten where I got the mechanical drive for the speedo. BUT if there were a slim drive gear for the TDi transmission and an adapter to connect that drive gear to the...
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    To test a thermal sensor

    To oilhammer and J_dude: 1. Even in hot weather, as long as the car is moving so the radiator has airflow, the engine does not overheat. Sitting still in an August traffic jam, it would. 2. Which is the answer to J_dude's comment about VW diesels "rarely running hot enough to turn on the fans…"...
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    To test a thermal sensor

    Cannot dispute the experience and opinions of experts. However, when the weather warmed, May 2023, the heater core failed. Warm weather, so I bypassed it. That ended coolant loss BUT the fans would not run unless the AC was on. Under any circumstances. Tested the fan; it worked at both...
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    To test a thermal sensor

    Switch does not apply 12 V to fan. Fan works fine, both speeds. Connecting pins of the switch connector energizes fan. Problem may be Fan Control Unit (FCU); however no one can specify how to test the FCU. I tested thermal switch in pan of water on stove, monitoring water temperature with...
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    To test a thermal sensor

    Do you use the Fluke meter to measure the voltage produced by the thermocouple? If the meter measures V from thermocouple, how does user translate thermocouple V to temperature? Thanks for you idea!
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    To test a thermal sensor

    Ideas for testing the thermal sensor wanted. The thermal sensor turns on the radiator fan when the coolant reaches a preset temperature. Thanks!
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    Hose

    Good idea. I struck out at ECS Tuning, but found the right part on ebay...
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    Hose

    Anyone know where to get the hose that connects coolant from the EGR cooler to the heater core? AHU engine, 1998 Jetta. It's a short hose with a couple bends; mine has no part # on it.
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    Direction of coolant flow, heater core

    On heater cores with plastic tops/pipes, an arrow is cast into the driver-side coolant pipe. That arrow points inward.
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    Direction of coolant flow, heater core

    Heater cores for Mk2, 3, & 4 Jettas are marked for coolant flow direction; the inbound coolant is the left (driver) side of the core and vehicle. This matches the geometry of the 1.8 and 2.0 gas engines. Coolant comes from the driver end of the cylinder head to the driver end of the heater...
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    Intercooler for Mk2–TDI conversion?

    Thirteen years—count 'em—since this thread started! Just received notice of your post. Can send photo of Passat IC installed in Mk2…
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    Coolant fan problem

    Car is 98 Jetta Tdi. Radiator coolant fan failed. Replaced fan with known good fan (apply 12 V, fan runs). Also replaced radiator coolant thermal switch with new unit. Still radiator fan does not run. Cooling system fine, it regulates as it should IF I don't climb long hills, drive fast, sit...
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