PD Engine P0183 16567 Error Code
I got the engine light on my 2004 1.9 TDi Touran and VAG diagnostic said it was the fuel temperature sensor. I looked on this forum about this error code but when I looked under the bonnet it didn't look like the photos! Bit more surfing and discovered 2004 model and couple of years after is a different engine (PD) & setup. The sensor is in the fuel line like a chunky T-piece, I found the sensor at right hand end of engine (opposite end from alternator & belt etc) tucked down under air intake pipe and behind the radiator, it's fairly obvious.
There is a piece of 8mm dia ribbed plastic harness with a couple of thin wires (approx 1 or 2mm dia) coming out the end and going through a right angle into the end of the sensor. Closer inspection showed one of these, the light coloured one, had broke. It seems a naff bit of VW design having such thin wires unprotected and assume they have gone brittle with oil/heat & vibration.
There wasn't any slack in the wire and considering what to do when I found the ribbed tube they come through is a slit 'clip on' tube with a flared ferrule on the end to stop it rubbing. I was able to prise open the rib tube behind the ferrule, pull the broken wire back and out through the side. Stripped and cleaned the end - plus there was enough wire left (approx 15mm) to do the same on the piece going in to the plug on the sensor.
Then soldered a short piece of pre-tinned wire between. Was a bit fiddly & awkward as working in a confined space, but consoled myself with thoughts of what the VW dealer would have charged to fix....
I did consider trying to feed the patch piece back inside the ribbed tube but in the end decided to leave as was coming out the side and bind the whole lot up in electrical tape from where I'd pulled it out before the ferrule right along and onto the plug, also wrapped in the other intact wire. This will also give a bit more support and protection to these wires.
The broken wire took a bit of cleaning with emery cloth before I could get the solder to tin it but otherwise fairly straightforward. I think you would struggle getting a crimp onto the shortish piece remaining on the sensor so soldering is probably best/only way to fix?
I understand that the Golf in same years is similar layout as the Touran with this engine, so if you get the Fuel temp sensor error message worth a quick check on the connection between the harness and sensor before you splash out on a new sensor.
After connecting back up reset the error code using an ebay USB cable on my laptop with VAG installed - which I got working using the instructions on this site (much appreciated) and so far all seems ok.
Hope this is of use, there doesn't seem a high instance of this sensor failing on the PD engine from what I found on the web, but wouldn't surprise me if other folks get a broke wire given the sharp angle it has to go through and how fine they are.
