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My dash temperature gauge has not been working. (2002 EV - MV)

First thought was that the sensor had gone bad. I'm pretty sure the
sensor is also shared by the after-run pumps which were working fine.
But for $11 I thought it was worth a shot.

I ordered a new blue 4-pin sensor and popped it in. (Once I figured
out it was located in a hose above the engine, not down by the
thermostat housing)

The temp gauge worked when I flipped the ignition on, so I thought I
was done. Unfortunately, the next time I started the engine, the
gauge was unresponsive again (after-run pumps still working, though)

Anybody have any experience with this? Do I have another dud sensor,
is the dash gauge really dead, or is something else going on here?

(Also of note: no CEL, no codes)

Thanks !

Dave

You DO need the one that is in the thermostat housing- it is not the
square one but the one with one rounded edge. May be the original
black one or have already been updated with a green one. Contact the
dealer, there is currently a "warranty extension" on the faulty
coolant temp sensors for the jettas, golfs, passats, etc...and the EV
uses the EXACT SAME ONE. Raise some hell!
gomi_

--- In ev_update@..., "davebo1896" <davebo1896@...> wrote:

My dash temperature gauge has not been working. (2002 EV - MV)

First thought was that the sensor had gone bad. I'm pretty sure the
sensor is also shared by the after-run pumps which were working

fine.

But for $11 I thought it was worth a shot.

I ordered a new blue 4-pin sensor and popped it in. (Once I figured
out it was located in a hose above the engine, not down by the
thermostat housing)

The temp gauge worked when I flipped the ignition on, so I thought I
was done. Unfortunately, the next time I started the engine, the
gauge was unresponsive again (after-run pumps still working,

though)

Anybody have any experience with this? Do I have another dud

sensor,

is the dash gauge really dead, or is something else going on

here?

(Also of note: no CEL, no codes)

Thanks !

Dave

If I recall correctly, the water temp sender should be a green 4 pin located in the thermostat housing.


Steve

636-337-7700
888-797-5994 - order desk

I replaced that one less than a year ago. (It was the old black one)
The only one I have not replaced now is the green square four pin in
the thermostat housing, could it be that one?

Dave

On your 2002, the D-shaped 4-pin sensor is used to signal the ECU
(engine control) and the temperature gauge on the dash. As Gomi said,
a green version superseded the original black sender. Sounds like
your replacement green sender isn't working or maybe there's a bad
connection?

--- In ev_update@..., "Carl Henderson" <chendermi@...> wrote:

On your 2002, the D-shaped 4-pin sensor is used to signal the ECU
(engine control) and the temperature gauge on the dash.

There was a discussion about this on vortex recently.

Note that the europarts catalog says the new green sensor is for "fuel
injection and cooling fans" but that's wrong.

Carl is right: the new sensor is for the fuel injection and the
GAUGE, not the fans as europarts states.

Dave is correct with regard to the green oval plug sensor. The function
was mislabeled on the webstore.
I have since corrected the dual function switch to read.....For fuel
injection and temperature gauge.
The square plug sensor is the sensor that controls the two cooling fans.

Steve Schock
EUROPARTS-San Diego

The Eurovan, Rialta & Sprinter parts source
Website: europarts-sd.com
Phone: 858-451-0020

Secure online ordering at:





dave_king_ev wrote:

And the new green d-shaped (oval) sensor did the trick.

The dash gauge is now working.

Another note, I think the AC was not working while this sensor was
malfunctioning. It seems to be working now. I'm not sure if this is
related.

So to sum up ...

There are two sensors under the engine in the thermostat housing.
You'll have to drop the belly pan to get to these, they are on the
driver's side.

The 4-pin d-shaped (oval) is for the dash gauge and the fuel
injection. The new sensor is green, the original one was black. the
black ones are a known problem.

The 4-pin square sensor next to the d-shaped sensor is for the fans.

There is a 4-pin blue sensor in a hose near the top of the block that
is for the after-run pumps.

Each sensor is held in with a c-clip. Each sensor has a rubber o-ring.

It is possible to swap out the sensors without draining the coolant
system, but you need to be quick with the lower ones (make sure the
coolant is cold, safety goggles and a closed mouth are advised)

The o-ring does not always come out when you pull the sensor. Make
sure it is accounted for before replacing the c-clip. Also be sure
the sensor is under the c-clip not over it, or it will pop out and
drain all your coolant.

Sensors and o-rings are available from Steve at


Thanks All !!

Dave

--- In ev_update@..., Steve Schock <europarts@...> wrote:

Dave is correct with regard to the green oval plug sensor. The

function

was mislabeled on the webstore.
I have since corrected the dual function switch to read.....For fuel
injection and temperature gauge.
The square plug sensor is the sensor that controls the two cooling fans.

Steve Schock
EUROPARTS-San Diego

The Eurovan, Rialta & Sprinter parts source
Website: europarts-sd.com
Phone: 858-451-0020

Secure online ordering at:





dave_king_ev wrote:

--- In ev_update@...

<mailto:ev_update%40yahoogroups.com>,

"Carl Henderson" <chendermi@> wrote:

On your 2002, the D-shaped 4-pin sensor is used to signal the ECU
(engine control) and the temperature gauge on the dash.

There was a discussion about this on vortex recently.

Note that the europarts catalog says the new green sensor is for "fuel
injection and cooling fans" but that's wrong.

Carl is right: the new sensor is for the fuel injection and the
GAUGE, not the fans as europarts states.

[Non-text portions of this message have been removed]

Something is wrong with Dave's summary. A 4-wire sensor for the
after-run pump? Wny? All it needs is an on/off switch, which would
mean two-wire, not four.

Dave, are you looking at wiring diagrams or are you relying on catalog
descriptions of the devices?




--- In ev_update@..., "davebo1896" <davebo1896@...> wrote:

And the new green d-shaped (oval) sensor did the trick.

The dash gauge is now working.

Another note, I think the AC was not working while this sensor was
malfunctioning. It seems to be working now. I'm not sure if this is
related.

So to sum up ...

There are two sensors under the engine in the thermostat housing.
You'll have to drop the belly pan to get to these, they are on the
driver's side.

The 4-pin d-shaped (oval) is for the dash gauge and the fuel
injection. The new sensor is green, the original one was black. the
black ones are a known problem.

The 4-pin square sensor next to the d-shaped sensor is for the fans.

There is a 4-pin blue sensor in a hose near the top of the block that
is for the after-run pumps.

Each sensor is held in with a c-clip. Each sensor has a rubber o-ring.

It is possible to swap out the sensors without draining the coolant
system, but you need to be quick with the lower ones (make sure the
coolant is cold, safety goggles and a closed mouth are advised)

The o-ring does not always come out when you pull the sensor. Make
sure it is accounted for before replacing the c-clip. Also be sure
the sensor is under the c-clip not over it, or it will pop out and
drain all your coolant.

Sensors and o-rings are available from Steve at


Thanks All !!

Dave

--- In ev_update@..., Steve Schock <europarts@> wrote:

Dave is correct with regard to the green oval plug sensor. The

function

was mislabeled on the webstore.
I have since corrected the dual function switch to read.....For fuel
injection and temperature gauge.
The square plug sensor is the sensor that controls the two cooling

fans.

Steve Schock
EUROPARTS-San Diego

The Eurovan, Rialta & Sprinter parts source
Website: europarts-sd.com
Phone: 858-451-0020

Secure online ordering at:





dave_king_ev wrote:

--- In ev_update@...

<mailto:ev_update%40yahoogroups.com>,

"Carl Henderson" <chendermi@> wrote:

On your 2002, the D-shaped 4-pin sensor is used to signal the ECU
(engine control) and the temperature gauge on the dash.

There was a discussion about this on vortex recently.

Note that the europarts catalog says the new green sensor is for

"fuel

injection and cooling fans" but that's wrong.

Carl is right: the new sensor is for the fuel injection and the
GAUGE, not the fans as europarts states.

[Non-text portions of this message have been removed]

Good info.

And when replacing the sensor, if you replace the cap on the coolant
reservoir (after relieving any residual pressure), the amount of coolant loss will
be less that a cup.

Bob W.

There is something wrong with this "good info" because it describes
all 3 sensors as 4-pin sensors, which would mean 12 pins total, and
that would mean 6 devices.

But, as far as I can tell (I have a '99 12 valve, and a paper Bentley,
but there has been a discussion on vortex -- complete with wiring
diagrams posted for the 24 valve motor -- and what I've seen is
consistent with mine) there are just 5 devices:

ECU
gage
fan
afterrun pump
AC cutout

Various models -- the 5 cylinder, the 12 valve, the 24 valve -- have
various locations and combinations for all the sensors involved (for
example on some models the ECU and gage sensors are combined in a
4-pin device while on other models the ECU sensor is a 2-pin
device) but all models use only those 5 devices, which would mean only
10 total pins.

But, Dave's information shows 3 devices with 4 pins each which is 12
pins which means 6 devices.

Something is not adding up. Does the 24 valve motor have a 6th
device? If so, what is it?



--- In ev_update@..., Sea2river@... wrote:

Good info.

And when replacing the sensor, if you replace the cap on the coolant
reservoir (after relieving any residual pressure), the amount of

coolant loss will

be less that a cup.

Bob W.


In a message dated 5/25/2008 12:33:43 P.M. Eastern Daylight Time,
davebo1896@... writes:

And the new green d-shaped (oval) sensor did the trick.

The dash gauge is now working.

Another note, I think the AC was not working while this sensor was
malfunctioning. It seems to be working now. I'm not sure if this is
related.

So to sum up ...

There are two sensors under the engine in the thermostat housing.
You'll have to drop the belly pan to get to these, they are on the
driver's side.

The 4-pin d-shaped (oval) is for the dash gauge and the fuel
injection. The new sensor is green, the original one was black. the
black ones are a known problem.

The 4-pin square sensor next to the d-shaped sensor is for the fans.

There is a 4-pin blue sensor in a hose near the top of the block that
is for the after-run pumps.

Each sensor is held in with a c-clip. Each sensor has a rubber o-ring.

It is possible to swap out the sensors without draining the coolant
system, but you need to be quick with the lower ones (make sure the
coolant is cold, safety goggles and a closed mouth are advised)

The o-ring does not always come out when you pull the sensor. Make
sure it is accounted for before replacing the c-clip. Also be sure
the sensor is under the c-clip not over it, or it will pop out and
drain all your coolant.

Sensors and o-rings are available from Steve at
_ ()

Thanks All !!

Dave




****Get trade secrets for amazing burgers. Watch "Cooking

with

Tyler Florence" on AOL Food.
()


[Non-text portions of this message have been removed]

Dave,

The Bentley wiring diagrams for a 2003 show the following devices:

G2 (sensor for temp. gauge) and G62 (sensor for ECU) combined in a
4-pin device and mounted in the thermostat housing. This is the
upgraded green D-shaped device (originally black).

F163 (A/C cutout thermal switch) and F165 (3rd speed coolant fan
control thermal switch) combined in a 4-pin device and mounted in the
thermostat housing. This is the green square device.

F95 (after-run coolant pump thermal switch). The Bentley doesn't show
a location for this device.

On models WITH Climatronic (i.e., GLS and non-Weekender MV's), F95 is
shown combined with G110 (A/C engine coolant temperature sensor) into
a 4-pin device. G110 is shown in a location "behind intake manifold,
center, in coolant hose above exhaust manifold heat shield". But
maybe this device is really mounted in the thermostat housing? And
maybe the 4-pin device is installed in vehicles which aren't outfitted
Climatronic, even though one half of the device isn't actually used?
The Bentley CD isn't very helpful here.

And finally, there's FC (coolant fan control), which is a 3-pin device
shown mounted near or in the radiator and not really part of this
listing of devices in the thermostat housing, but I thought I'd list
it since it is related to coolant temperatures.

I have a 2003 Weekender. Next time I pull the belly pan, I'll have a
look at the thermostat housing to see what's there. I did replace the
black with a green D-shaped device several years ago as a preventative
measure.

Carl


--- In ev_update@..., "dave_king_ev" <dave_king_ev@...> wrote:

There is something wrong with this "good info" because it describes
all 3 sensors as 4-pin sensors, which would mean 12 pins total, and
that would mean 6 devices.

But, as far as I can tell (I have a '99 12 valve, and a paper Bentley,
but there has been a discussion on vortex -- complete with wiring
diagrams posted for the 24 valve motor -- and what I've seen is
consistent with mine) there are just 5 devices:

ECU
gage
fan
afterrun pump
AC cutout

Various models -- the 5 cylinder, the 12 valve, the 24 valve -- have
various locations and combinations for all the sensors involved (for
example on some models the ECU and gage sensors are combined in a
4-pin device while on other models the ECU sensor is a 2-pin
device) but all models use only those 5 devices, which would mean only
10 total pins.

But, Dave's information shows 3 devices with 4 pins each which is 12
pins which means 6 devices.

Something is not adding up. Does the 24 valve motor have a 6th
device? If so, what is it?



--- In ev_update@..., Sea2river@ wrote:

Good info.

And when replacing the sensor, if you replace the cap on the coolant
reservoir (after relieving any residual pressure), the amount of

coolant loss will

be less that a cup.

Bob W.


In a message dated 5/25/2008 12:33:43 P.M. Eastern Daylight Time,
davebo1896@ writes:

And the new green d-shaped (oval) sensor did the trick.

The dash gauge is now working.

Another note, I think the AC was not working while this sensor was
malfunctioning. It seems to be working now. I'm not sure if this is
related.

So to sum up ...

There are two sensors under the engine in the thermostat housing.
You'll have to drop the belly pan to get to these, they are on the
driver's side.

The 4-pin d-shaped (oval) is for the dash gauge and the fuel
injection. The new sensor is green, the original one was black. the
black ones are a known problem.

The 4-pin square sensor next to the d-shaped sensor is for the fans.

There is a 4-pin blue sensor in a hose near the top of the block that
is for the after-run pumps.

Each sensor is held in with a c-clip. Each sensor has a rubber

o-ring.

It is possible to swap out the sensors without draining the coolant
system, but you need to be quick with the lower ones (make sure the
coolant is cold, safety goggles and a closed mouth are advised)

The o-ring does not always come out when you pull the sensor. Make
sure it is accounted for before replacing the c-clip. Also be sure
the sensor is under the c-clip not over it, or it will pop out and
drain all your coolant.

Sensors and o-rings are available from Steve at
_ ()

Thanks All !!

Dave




****Get trade secrets for amazing burgers. Watch "Cooking

with

Tyler Florence" on AOL Food.

()

[Non-text portions of this message have been removed]

The Bentley wiring diagrams for a 2003 show the following devices:

G2 (sensor for temp. gauge) and G62 (sensor for ECU) combined in a
4-pin device and mounted in the thermostat housing. This is the
upgraded green D-shaped device (originally black).

F163 (A/C cutout thermal switch) and F165 (3rd speed coolant fan
control thermal switch) combined in a 4-pin device and mounted in the
thermostat housing. This is the green square device.

F95 (after-run coolant pump thermal switch). The Bentley doesn't show
a location for this device.

That's what I've got in my '99, too (although in a slightly different
configuration). 5 devices (G2, G62, F163, F165, F95).

On models WITH Climatronic (i.e., GLS and non-Weekender MV's), F95 is
shown combined with G110 (A/C engine coolant temperature sensor) into
a 4-pin device.

OK, then there's the new 6th device not present in earlier models:
the G110 ((A/C engine coolant temperature sensor).


So, the ECU gets one temp sender (G62) and Climatronic gets another
(G110).


Thanks for clearing that up.








--- In ev_update@..., "Carl Henderson" <chendermi@...> wrote:

Dave,

The Bentley wiring diagrams for a 2003 show the following devices:

G2 (sensor for temp. gauge) and G62 (sensor for ECU) combined in a
4-pin device and mounted in the thermostat housing. This is the
upgraded green D-shaped device (originally black).

F163 (A/C cutout thermal switch) and F165 (3rd speed coolant fan
control thermal switch) combined in a 4-pin device and mounted in the
thermostat housing. This is the green square device.

F95 (after-run coolant pump thermal switch). The Bentley doesn't show
a location for this device.

On models WITH Climatronic (i.e., GLS and non-Weekender MV's), F95 is
shown combined with G110 (A/C engine coolant temperature sensor) into
a 4-pin device. G110 is shown in a location "behind intake manifold,
center, in coolant hose above exhaust manifold heat shield". But
maybe this device is really mounted in the thermostat housing? And
maybe the 4-pin device is installed in vehicles which aren't outfitted
Climatronic, even though one half of the device isn't actually used?
The Bentley CD isn't very helpful here.

And finally, there's FC (coolant fan control), which is a 3-pin device
shown mounted near or in the radiator and not really part of this
listing of devices in the thermostat housing, but I thought I'd list
it since it is related to coolant temperatures.

I have a 2003 Weekender. Next time I pull the belly pan, I'll have a
look at the thermostat housing to see what's there. I did replace the
black with a green D-shaped device several years ago as a preventative
measure.

Carl


--- In ev_update@..., "dave_king_ev" <dave_king_ev@> wrote:

There is something wrong with this "good info" because it describes
all 3 sensors as 4-pin sensors, which would mean 12 pins total, and
that would mean 6 devices.

But, as far as I can tell (I have a '99 12 valve, and a paper Bentley,
but there has been a discussion on vortex -- complete with wiring
diagrams posted for the 24 valve motor -- and what I've seen is
consistent with mine) there are just 5 devices:

ECU
gage
fan
afterrun pump
AC cutout

Various models -- the 5 cylinder, the 12 valve, the 24 valve -- have
various locations and combinations for all the sensors involved (for
example on some models the ECU and gage sensors are combined in a
4-pin device while on other models the ECU sensor is a 2-pin
device) but all models use only those 5 devices, which would mean only
10 total pins.

But, Dave's information shows 3 devices with 4 pins each which is 12
pins which means 6 devices.

Something is not adding up. Does the 24 valve motor have a 6th
device? If so, what is it?



--- In ev_update@..., Sea2river@ wrote:

Good info.

And when replacing the sensor, if you replace the cap on the

coolant

reservoir (after relieving any residual pressure), the amount of

coolant loss will

be less that a cup.

Bob W.


In a message dated 5/25/2008 12:33:43 P.M. Eastern Daylight Time,
davebo1896@ writes:

And the new green d-shaped (oval) sensor did the trick.

The dash gauge is now working.

Another note, I think the AC was not working while this sensor was
malfunctioning. It seems to be working now. I'm not sure if this is
related.

So to sum up ...

There are two sensors under the engine in the thermostat housing.
You'll have to drop the belly pan to get to these, they are on the
driver's side.

The 4-pin d-shaped (oval) is for the dash gauge and the fuel
injection. The new sensor is green, the original one was black. the
black ones are a known problem.

The 4-pin square sensor next to the d-shaped sensor is for the

fans.

There is a 4-pin blue sensor in a hose near the top of the

block that

is for the after-run pumps.

Each sensor is held in with a c-clip. Each sensor has a rubber

o-ring.

It is possible to swap out the sensors without draining the coolant
system, but you need to be quick with the lower ones (make sure the
coolant is cold, safety goggles and a closed mouth are advised)

The o-ring does not always come out when you pull the sensor. Make
sure it is accounted for before replacing the c-clip. Also be sure
the sensor is under the c-clip not over it, or it will pop out and
drain all your coolant.

Sensors and o-rings are available from Steve at
_ ()

Thanks All !!

Dave




****Get trade secrets for amazing burgers. Watch "Cooking

with

Tyler Florence" on AOL Food.

()

Just reread Dave's original description--the Bentley matches the
location of F95/G110 as Dave has described.

--- In ev_update@..., "Carl Henderson" <chendermi@...> wrote:

F95 (after-run coolant pump thermal switch). The Bentley doesn't show
a location for this device.

On models WITH Climatronic (i.e., GLS and non-Weekender MV's), F95 is
shown combined with G110 (A/C engine coolant temperature sensor) into
a 4-pin device. G110 is shown in a location "behind intake manifold,
center, in coolant hose above exhaust manifold heat shield". But
maybe this device is really mounted in the thermostat housing? And
maybe the 4-pin device is installed in vehicles which aren't outfitted
Climatronic, even though one half of the device isn't actually used?
The Bentley CD isn't very helpful here.

In a message dated 5/25/2008 12:33:43 P.M. Eastern Daylight Time,
davebo1896@ writes:

There is a 4-pin blue sensor in a hose near the top of the

block that

is for the after-run pumps.