Volkswagen Cars 2000-05

Removal & Installation

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  1. Drain the coolant until it is just below the level of the sensor.
  2.  
  3. Disconnect the harness connector from the sensor.
  4.  
  5. Remove the sensor retaining clip, and pull the sensor straight out of the housing.
  6.  

To install:

  1. Install a new O-ring on the sensor.
  2.  
  3. Using a small amount of fresh coolant, lightly lubricate the O-ring, and push the sensor in the housing.
  4.  
  5. While pushing inward on the sensor, install the retaining clip.
  6.  
  7. Plug in the harness connector to the sensor.
  8.  
  9. Refill the cooling system as necessary.
  10.  


CAUTION
Always allow the engine to cool below 100°F (37°C) and then drain the coolant before removing the Engine Coolant Temperature (ECT) gauge sending unit; otherwise, the heated engine coolant can spray out during removal, causing severe burns.

  1. Allow the engine to cool below 100°F (37°C) before working on the cooling system.
  2.  
  3. Note the anti-theft code and radio presets for the radio.
  4.  
  5. Disconnect the negative battery cable.
  6.  
  7. Locate the Engine Coolant Temperature (ECT) gauge sending unit.
  8.  
  9. Drain the engine coolant until it is just below the level of the sensor into a sealable container.
  10.  
  11. Detach the gauge sending unit electrical connection.
  12.  
  13. If the sensor is held into the coolant passage with a retaining clip:
  14.  
    1. Remove the sensor retaining clip, and pull the sensor straight out of the housing.
    2.  

  15. If the sensor is threaded into the coolant passage:
  16.  
    1. Loosen the sensor using a crowfoot wrench, a suitable boxed end wrench or a thin-walled 3 / 8 inch drive 12 point deep well socket and breaker bar.
    2.  




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Fig. This Craftsman® 3/8 inch drive thin-walled, 12-point, deep-well socket can be used for removing a threaded coolant sensor



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Fig. The Craftsman® socket slides over the sensor without risking damage to the electrical connector housing



Click image to see an enlarged view

Fig. If the coolant sensor is held in position with a retaining clip, remove the clip and carefully pull the sensor straight out of the housing

To install:

  1. If the sensor is held into the coolant passage with a retaining clip:
  2.  
    1. Install a new O-ring on the sensor.
    2.  
    3. Using a small amount of fresh coolant or an anti-seizing compound, lightly lubricate the O-ring, and push the sensor in the housing.
    4.  
    5. While pushing inward on the sensor, install the retaining clip.
    6.  

  3. If the sensor is threaded into the coolant passage:
  4.  
    1. Install the sensor with a new crush washer. Tighten the sensor to 12.5-14 ft. lbs. (17-19 Nm).
    2.  

  5. Plug in the harness connector to the sensor.
  6.  
  7. Refill the cooling system with the proper type and mixture of coolant and bleed as necessary. For additional information, please refer to the following topic(s): General Information and Maintenance, Fluids and Lubricants.
  8.  
  9. Reconnect the negative battery cable and re-code the radio as necessary.
  10.  
  11. Start the engine, allow it to reach operating temperature and check for leaks.
  12.  

 
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