Radiator Temp Sensor Refurb

[pagurus 0]

Removed the radiator temp sensor connector and it didn't look good at all. Uh Ho !!!

The radiator temperature sensor connector on my 92 g60 corrado was knackered.

From reading up on it here; this would mean a never stopping rad fan and constant flat battery. :(

 

Looked like leakage from the rad temp sensor housing, had dried up and corroded the connector. You can see this in the pic.

stromlaufplan_gamma4.pdf001 - 2010 05 26 - Knackered Rad Temp Sensor Connector.JPG[/attachment:3d3sriik]

Here's how it was done. Any 'useful' supplementary info to fill out or embelish missed details would be appreciated. Apologies for out of focus pics. Camera's playin up, but probably my lack of camera knowhow :scratch:

 

Depending on how badly yours is damaged, you can buy -

new wire terminators (more details ???) (you'll need to get a rachet crimp tool as well if you do this(more details ???))

a new rubber boot (grommet)
VAG Part Number - "V867 972 525 B" Grommet £2.73

a new plastic connector housing
VAG Part Number - "V893 906 231" N/STK Terminal Pin H £1.93

an adapter to mate the connector to an updated temp sender
(no idea about this as it was already done on the car with the rad I am using(more details ???))

Scratched my head for a bit then made a call to my friendly 'local' VW dealers - Gilbert Lawton.

The part number on the old plastic connector housing was not recognized on the Dealer's ETKA system.

The Radiator Parts Schema Diagram for this is not brimming with detail about this part and it's sub-components.

 

stromlaufplan_gamma4.pdf003 - RadiatorPartsSchema.JPG[/attachment:3d3sriik]

 

I checked the radiator on my 'parts' car. This had a fangle adapter lug mating to the radiator temp sensor.

I liked the look of this, as it seemed the adapter lug should protect the connector from any leakage residue.

I decided to use this rad in my car with the fangle adapter lug (pic below), but I still had to fix my connector.

 

ETKA Corrado.pdf002 - 2010 05 26 - Temp Sensor Connector Adapter.JPG[/attachment:3d3sriik]

 

The connector on my parts car was mint, but you unfortunately you can't just unplug them.

I made a note on a piece of paper how the wires ran into the connector.

 

Corrado92.pdf004 - 2010 05 26 - Extracted Wires & Connectors - IMG_3224.JPG[/attachment:3d3sriik]

Using a vice to support the connector, I 'knocked' the terminals out of the connector block one at a time.

I used a very small flat bladed screwdriver and a small hammer to do this.

The terminators can be clicked out of place by pressing the blade of the screwdriver up the flat face of each terminator plate.

Once clicked out they either slip straight out of the connector, or can be eased out with a gentle tap from the screwdriver and hammer.

I took great care over this as I didn't want to damage any of the terminators. I have no idea what these are, but I am pretty sure you need a rachet crimp tool to re-make them up properly.(more details ???)

It's quite risky knocking the terminators out with a hammer and screwdriver.

You can get a proper terminator extractor tool to do this. (more details ???)

I used the small screwdriver to 'scrape' hardened residue out of the worst affected terminal.

I checked all three terminators for tightness - (Before slotting them into the new connector housing !!)

Any loose ones were 'tightened' up by pressing the copper loops against the flat face of the terminator.

Simple job to press them home one at a time into the new connector block and snap it shut. Surprising how positively they clicked into place.

It does matter which way round the loops go into the plastic housing!

(This is where the simple drawing made earlier - really comes in handy! - see below.)

 

passat climatronic wiring diags.pdf005 - 2010 05 26 - Wires Fitted Into New Housing - IMG_3228.JPG[/attachment:3d3sriik]

 

Simply pull the old rubber boot (grommet) snugly over the newly fitted plastic housing.

 

climatronic wiring-Golf from May 01.pdf006 - 2010 05 26 - Old Grommet Pulled Up To New Housing - IMG_3229.JPG[/attachment:3d3sriik]

 

If your rad is fitted with (what I assume is), an upgraded temp sensor housing, fit the adaptor lug.

 

2.8l 24v Climatronic system.pdf007 - 2010 05 26 - Adapter Fitted To Refurbed Connector - IMG_3233.JPG[/attachment:3d3sriik]

 

Another refurb job sorted. Come On !! :D

Sometimes, small things bring insane amounts of pleasure!

Welcome to the strange world of yet another Corrado lover.

Thanks people for inspired and helpful posts - furthering the cause :salute:

 

008 - 2010 05 26 - Rad Temp Sensor Connector Then & Now.JPG[/attachment:3d3sriik]

 

This refurb work is part of a larger thread about my G60 Refurb Project, and lots of other nasties occuring along the way.

The Never Ending G60 Corrado Refurbishment Project

http://the-corrado.net/.archive/forum/viewtopic.php?f=1&t=89928

[fendervg 30]

These are all still available new from the stealers - they are standard connectors found on many VAGs of the era. Go in with the part or the part #. Not expensive. If they give you the runaround, just go to another dealer that is more helpful.

 

To rewire you can order repair kits that are basically a 5 inch length of yellow wire (available in various gauges) with a pin crimped onto each end - cut them in half, insert into the connector and splice into the loom. It's also possible to order just the contact blade crimps themselves, but you will need a specialist crimp tool to form a good join. Use exterior fabric wire wrap or heatshring to seal the connection and you're done. The existing pins can be removed either with a specialist extractor tool, or a very small flat blade jeweller's screwdriver.

 

Alternatively find a car in a scrappies or one that is being broken and take the bits you need off the loom - I'm sure there are plenty on here.

[pagurus 0]

Hi - cheers for the advice. It's not clear what I'll get from the stealers.

Have you any pics to post for your advice cos it's hard to visualise exactly what you mean?

[fendervg 30]

Here's a few links to get you started:

 

Sample wiring pins -various sizes

 

Loom tape

 

 

A terminal extractor tool - you can get them cheaper than this

 

Wiring repair set

 

Connector - this a lighting one - but all the standard ones are available, just check the part # on them. The VAG parts system has a whole set of pages on connectors, wiring and terminals in the Electrical section.

 

Check this link out for some part numbers:

http://www.quattroforum.com/forum/elect ... basic.html

 

Hope this helps.

[pagurus 0]

Nice post fendervg. Will update on progress when have news from stealers. :)

[pagurus 0]

Update from the stealers - Gilbert Lawton - Mcr - ( 0161 607 1313 ) - actually really helpful guys ...

 

It's item 8 on the schema picture below.

It's for a 91 corrado rad, but the connector looks same as my 92.

 

It's actually 2 parts.

 

(#01) A black 'rubber boot' covering.

Part number - V867 972 B ( Grommet )

Price - £2.73 inc VAT.

 

(#02) The three pin connector with white plastic housing.

Part number - V893 906 231 (Terminal Pin Ho)

Price - £1.93 inc VAT.

 

008-RadElecConnector.JPG[/attachment:13gn011f]