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DIY - Replacing Coolant Temp Sensors

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  Quote ___/ __/ _/ Quote  Post ReplyReply Direct Link To This Post Topic: DIY - Replacing Coolant Temp Sensors
    Posted: 29-Jun-2008 at 13:26


Hey-

It's time for another W8 related write-up. These temp sensors suck!

Anyway, the other day I decided to make a go of swapping the buggers out- I'm tired of hearing the electric cooling fans rumbling to life first thing in the morning immediately after I start the car. With this, combined with a soft code of P3081 (Engine temp too low(????!)), I decided to do the work. And I'm quite sure the W8 community will be happy to see more write-ups specific to our tight engine compartments!


Alright.

Parts required:

- 2 new ECT sensors p/n 06A-919-501-A
- 2 new seals p/n N-903-168-02
- Patience....

Tools required:

- Long needle nose pliers
- 6mm Allen wrench
- Phillips head screw driver
- Flashlight or working light. A Mini-Mag is perfect.
- Bentley Manual
- Knuckle cream....


Start by removing the air intake tubing and the triangular mouth piece that attaches to the front wall above the radiator. Set aside. if the engine is warm, slowly unscrew the coolant reservoir to release pressure.



Once these are removed you will see the coolant return hose directly below. The sensor in question attaches at the underside of the elbow as seen below.





BEFORE you remove the metal retaining clip from the housing, have a new sensor and seal ready to insert into the hole. This will minimize the amount of coolant lost.

I decided to first remove the electrical plug before pulling the sensor from the hole. This kept the plug dry.

Pull the retaining clip out with your fingers. The plug is in the hole fairly snug, so a good tug will do the trick. At this point, have the new sensor ready to fill the hole.

You may lose a few ounces of coolant with this maneuver, but don't sweat it. Replace what you lose.

Reinsert the retaining clip as you apply firm upward pressure on the sensor. The sensor should sit securely in place with very little play. Next, reattach the plug.





Not too difficult, right? Good. The next one is a pain....





Now, onto the second sensor at the rear of the engine.



First, you need to make some room.





I found best to remove the tube completely from it's location. Use a 6mm Allen wrench to undue the attachment to the manifold. You will need every square inch/cm of space to squeeze in your grubby little hands.






Now pull the plastic clip out of the housing. Pull the sensor out. Some coolant might leak out but very little if any. Disconnect the plug and set aside.







Now, I can't begin to tell you the Hell I went through trying to secure the sensor into place! Do not...I mean DO NOT plug in the new sensor before it is secure in the housing. The inside of the housing tapers in, so the closer the sensor will get to its final resting place the HARDER you will have to push it into the hole, and this area is SO tight it's difficult to get any leverage. With the plug on the sensor you risk damaging the low voltage wires.

I couldn't muster enough hand pressure to get the sensor far enough up into the housing to install the retaining clip. Seeing as how I apparently forgot to eat my Wheatie's that morning, all I had left was to use my brain. (My brain. If my brain were a car it would have primer and bondo spots all over and the title would be salvaged.)

To get the sensor in the correct position I used an Allen wrench in my left hand and applied firm pressure to the back end.



Insert the retaining clip when the brass ring on the sensor is high enough above the clip grooves on the housing. You will know if it is in the correct position when the clip easily inserts.

With the clip back on, grip the sensor and feel for proper seating. You will want to have very little play. Attach the plug.

All that is left to do is to reattach the intake tubing and determine the amount of coolant you'll need to replace. :whistle:


Hopefully this procedure will solve the soft coding mystery and will keep the fans from turning on unnecessarily. If it doesn't work, keep your eyes open for a "DIY Thermostat Replacement for the W8" thread by yours truly!






uu8



Oh yeah....the upper intake manifold makes a GREAT work bench!




Edited by ___/ __/ _/ - 17-Sep-2008 at 05:49
"I agree that the W8 is a great car--when it works... "
-dstathos-

^Pure Genius! Why didn't I write that?!?

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  Quote ___/ __/ _/ Quote  Post ReplyReply Direct Link To This Post Posted: 30-Jun-2008 at 23:14
Addendum:

After I put the car back together and started her up, the electric cooling fans came on once again. Grrrr! Anyway, I VAG-COM'd it again and got the 16502/P0118/000280 - Engine Coolant Temperature Sensor (G62): Signal too High code. After checking RossTech Wiki for the code I decided it may have been an anomaly. Long story short- i cleared the code, unhooked the cable, and started the engine with no fan turning on!

Wahoo!


Mike
"I agree that the W8 is a great car--when it works... "
-dstathos-

^Pure Genius! Why didn't I write that?!?

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  Quote VWAffe Quote  Post ReplyReply Direct Link To This Post Posted: 01-Jul-2008 at 09:48
Hope it lasts!

Nice pictures. I'm impressed you got the G62 out and back in without pulling the intake manifold for easy access.
'03 W8 Sedan 6MT     ..."it goes to 11!"
'02 V6 Wagon 4Mo 5MT (Swap In Work)     ...both black on black w/ limo tint
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  Quote ___/ __/ _/ Quote  Post ReplyReply Direct Link To This Post Posted: 01-Jul-2008 at 22:43
It's doable to not remove the manifold but very tight. I have big meaty hands, and when I removed the intake air tube it was a lot easier to do the work. Still a pain, though....


Thanks for reading my write-up.


Mike
"I agree that the W8 is a great car--when it works... "
-dstathos-

^Pure Genius! Why didn't I write that?!?

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  Quote ben Quote  Post ReplyReply Direct Link To This Post Posted: 02-Jul-2008 at 05:50
* W8 Variant -02 / 341000 kms
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  Quote fitzski Quote  Post ReplyReply Direct Link To This Post Posted: 02-Jul-2008 at 07:56
Great job, Mike - awesome pictures.

So... where did the O-ring go?

(Oh yeah... the Allen Manufacturing Company called... they want to know who "Ellen" is? )
http://en.wikipedia.org/wiki/Allen_wrench
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  Quote ___/ __/ _/ Quote  Post ReplyReply Direct Link To This Post Posted: 02-Jul-2008 at 13:58
Originally posted by fitzski

Great job, Mike - awesome pictures.

So... where did the O-ring go?

(Oh yeah... the Allen Manufacturing Company called... they want to know who "Ellen" is? )
http://en.wikipedia.org/wiki/Allen_wrench


(Thanks)

What teh?   Holy Hell- I've been calling thme the wrong name for years!!! How does this happen? I can't tell you the how many "Car Days" I had with friends and have said "Ellen" wrench!!!

I must make ammends with those whom I have offended.....


Hee, hee...



Mike

p.s.- The O-ring was in the pipe. Just had to shimmy it out.

Edited by ___/ __/ _/ - 02-Jul-2008 at 20:00
"I agree that the W8 is a great car--when it works... "
-dstathos-

^Pure Genius! Why didn't I write that?!?

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  Quote rustybronco Quote  Post ReplyReply Direct Link To This Post Posted: 02-Jul-2008 at 14:24
Nicely done. That rear sensor looks like a beast. Good to know it's doable though - seems like a job that will have to be done on any of the W8's if one keeps the ride long enough. I liked all the labels, very helpful, especially the "Towel..."
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  Quote ___/ __/ _/ Quote  Post ReplyReply Direct Link To This Post Posted: 02-Jul-2008 at 17:11
Glad somebody got the "Towel..." bit.


"I agree that the W8 is a great car--when it works... "
-dstathos-

^Pure Genius! Why didn't I write that?!?

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  Quote spinner Quote  Post ReplyReply Direct Link To This Post Posted: 02-Jul-2008 at 17:43
Very nice write-up Hope I never need it, though
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