AudiWorld Forums - Replacing Engine Coolant Temperature Sensor (ECT)

Just replaced the ECT on my 2000 A6 2.8Q. It didn't take too long to replace, with the exception of figuring out how to pull the clip and harness connector out with my *big* hands. If I didn't know any better, I'd think that the assemblers for this car were midgets.

***WARNING***
BE SURE TO WORK ON THIS ONLY WHEN THE ENGINE HAS COOLED OFF. YOU CAN SERIOUSLY BURN YOURSELF IF THE ENGINE IS STILL HOT WHILE PERFORMING THIS TASK.

***DISCLAIMER***
THIS IS INFORMATIONAL ONLY.

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OK, now that's out of the way. Here it goes. First, I had to get the parts. The part numbers are:

ECT: 059 919 501A - $3.91 (www.thepartsbin.com)
O-Ring: N-903-168-02 - $5.25 (Audi Dealership)
Retention Clip: 032-121-142 - $0.91 (Audi Dealership)

<img src="http://pictureposter.audiworld.com/83960/img_0132.jpg">

The fun begins here:

First remove all covers in the engine bay. Then remove the flex hose that connects the air box to the motor.

<img src="http://pictureposter.audiworld.com/83960/img_0134.jpg">

Next, locate the sensor. It's located under the solid hose that is connected to the motor. The sensor is mounted on top of a tube coming out of the engine. (See Picture)

<img src="http://pictureposter.audiworld.com/83960/img_0135_-_marked.jpg">

Here is a close-up of the sensor.

<img src="http://pictureposter.audiworld.com/83960/img_0136.jpg">

Here is the tricky part. To remove the sensor, you need to find a way to get your hands in and around the sensor. There is only enough room for your left hand to squeeze through. Twist the connector until you can get either your thumb or index finger on the retaining clip holding the connector onto the sensor. *PUSH* on the connector down as if you are trying to plug it in. THEN SQUEEZE the retaining clip on the connector. Then and only then will the connector want to come off of the sensor. (You need to try this a few times.)

When you get the connector off, put it aside of the sensor.

<img src="http://pictureposter.audiworld.com/83960/img_0138.jpg">

After taking the connector off, the rest of the job is a lot easier.

You will need to wear rubber gloves and a pan under the car for this. Coolant will get all over the place.

Get a good grip on the sensor retaining clip. It's going to take some massaging to pull it out. The trick that I used is first pull on the clip with my thumb and index finger. When it would nudge out a bit, I would stick part of my middle finger in between the clip and the sensor as a wedge. Then I would relocate my thumb and index finger again to get a better grip. Do this a few times and eventually the retaining clip will pop out.

When the clip pops out, the sensor will be loose to be removed. When you pull the sensor out, coolant will spill out, as pressure in the system will be released through the path of least resistance.

Remove the sensor. Check to see if the O-Ring is still stuck to the sensor. If the O-Ring is not on the sensor, it is most likely still on the tube. Stick your finger into the hole and fish out the O-Ring.

Place the new O-Ring on the new sensor:

<img src="http://pictureposter.audiworld.com/83960/img_0133.jpg">

Insert the sensor into the hole on the tube. Use the NEW retaining clip and push it around the sensor holder until you hear a "CLICK". Check the sturdiness of the clip by wiggling the sensor.

Reinstall the connector onto the sensor. Make sure the orientation of the D-Clip Backshell is correct. Then push the connector onto the sensor.

The job is almost done. Just need to clean up and reinstall all the plastic covers back on.

Be sure to reinstall the flex hose onto the airbox. It's cooled off and is a bit harder to put back on. Make sure it's sturdy before clamping it back on.

You are now done.