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I don't know if this thread would be of any help,it is a different engine (SDI) but might give some ideas for fault finding.
Hopefully Alex will be along at some stage with some technical details.

viewtopic.php?f=8&t=70894&p=530206#p530206

The V68 motor for the temp control is a fiddly job but does not require a full dash stripdown.
A few years ago KITT did a great thread/guide on here.

viewtopic.php?t=52145

Are you getting power to the glow plugs ? I had one car some years ago where the glow plug control unit was not giving power to the glows,I put a multi meter onto the glow plug power leads and got a friend to turn on the ign.On the older cars that would give about 11volts to the glows if the system ...

If you are losing coolant - one place to check is down the rear of the radiator,you should be able to see the fan temp sensor (27mm ? or 29mm ? hex),if it is leaking - the rad will be stained around the sensor,I 'tweeked' mine up with a shortened open end spanner.But it is a plastic thread so it has...

To be fair - they might vary a little between models,but should be easy enough to 'bodge' with a screw etc - as long as the trim panel is not too badly damaged around the clips/pegs.

You can check the glow plugs in situ by disconnecting the power wires from them and measuring the resistance across the glow plug with a multi meter. I have never tested a VW TDI glow plug but on other cars (from memory) they should read approx 0.9 - 1.2 Ohms. Glow plugs are the easiest place to sta...

Detail of the cord/loop

Should be similar - ish to ours (2002).
As Rum/Cpt Redex posted - if ours broke I would do a fix in situ along the lines of using a screw or dowel.

Also would be a good idea to have a good look at all the Vacuum pipes - split or disconnected vac pipes can give similar symptoms.

Do you know which type of engine is fitted ?It is usually a 3 letter code - ours is an AUB 1.4 16valve. One possible problem at this time of year is intake/throttle body icing,there is an automatic actuator in the air inlet system which draws in warm air from the exhaust system to prevent intake/thr...

That is the point I was making about the fuses Rum - the fuse I found not fully engaged was not visibly 'Sticking Out'/'Protruding' - I only found it by 'pushing in' all the fuses by hand,I am not 100% sure it was the 'loose' fuse which kept the EML on - it could just be coincidence that the EML wen...

I must admit we sometimes drive for a couple of weeks with the EML glowing (as long as engine running ok of course) - our 02 9n used to throw a light up with monotonous regularity LOL,although I have gradually worked through the faults causing them. But of course it is nice if you can confirm throug...

In your first post - you said that the interior light does work ok so it may not be a door lock microswitch if you are lucky (unless I read that wrong ?).

Yeah I would probably go for Lemforder as well. I have roughly set rod ends in the past by counting the number of turns to unscrew the rod end,and then screwing the new item on the same amount,I did used to take a measurement as well - and of course the 'number of turns' method only works if the rep...

Hi John - welcome to the forum
Good luck with the engine.

rgds bvs