I witnessed this firsthand today, so I have some simple tips to make the job go as smoothly and quickly as possible.
1. remove the PCV valve (One time use clamp on the low pressure side attached to the hard-pipe)
2. remove the breather hose that is attached to the crankcase breather bung and also attached to the high pressure side of the PCV valve. (Tension loaded hose clamp: reusable, although I just tossed a worm screw clamp on there instead)
3. When the PCV is out of the way, there is an SAI valve that is block mounted onto the top of the engine. This is the major piece in the way. Some may wish to remove the whole valve to replace the CTS, but it is not necessary.
BTW: the CTS is right under the SAI valve, and a little to the right. That is why it is almost impossible to see. I had to get the PCV out of the way before I even got a glimpse at the CTS.
3A: here are some pics I borrowed from another thread for reference.
That is the SAI Valve once you remove the Crankcase breather hose #2 above, and the PCV #1 above.
There are two fittings on the SAI valve: 1" side, and a 5/32" side.
The 5/32" side is the one that sits right above the CTS and is in the way.
here is the key part: In order to create some more room to remove the CTS and replace it, I cut the 5/32" SAI hose at the end of the brass bung, then moved the hose out of the way.
4. By this point, you should have a clear view of the CTS, sitting there in all its glory but causing you so much misery.
5. Remove the C-clip with a flathead screwdriver, slip the CTS out of the reservoir, and a little bit of coolant will pour out. As long as the coolant reservoir cap is sealed tightly, coolant shouldn't spill out continuously.
6. Put the new sensor in.
7. Now you're stuck scratching your ass wondering how the hell you're going to put the C-Clip back into place.
Consider: A) the clip engages with the open C facing the firewall.
B) the engine block itself blocks your view
C) There's no way in hell you can See what you're doing, AND fit your hand in there to shove the clip into retention.
What' to do?!?!?!
Here's a pic for reference.
In Martini's picture above, the C clip is facing down. When you actually install the C Clip back into onto the coolant flange, its the opposite. The C Opens upward, and your hands are smashed up against the block trying to clip the CTS back in.
YOu may have even dropped it a few times, and spent 10, 20, 30 minutes seraching for a bloody rage-enducing C Clip.
here's what I did.
I looped some masking tape onto the top of the C (in Martini's picture, where the arrow is pointing). The tape ran 10 inches or so. This way I could lower the clip down there engage the clip slot, then use the tape to pull the clip into place.
SNAP!!! goes the clip, and you're done!!!!
Many may think that there's no problem. Why use the tape trick? Well, when you get the C Clip lined up with the coolant flange in the correct slot (damn difficult already), it's nearly impossible to push the clip back into place. There is no space, and the C Clip is shoved up right against the block, so there's no room to wedge anything in there to push the clip into place. The angle is also way too steep.
Some other notes:
1. Small hands will not work. I don't care how small your hands are. Even if you are anemic and you are still eating baby food. Sorry, small hands are not the issue. The Engine block is in the way. The PCV is in the way. The Crankcase breather is in the way. The SAI vacuum line is in the way. The Bracket holding the wiring harness next to the crank case breather hose is in the way.
2. Long fingers will work better, but still not suffice
3. SAI Valve is a major pain
4. Why Audi design a service part in that location escapes my reason and evades even my zealous imagination. Inside joke? Frivolous stealer prices? Only one man knows, and it sure as shooting aint me.
Anyway, happy hunting.
Keep modding away.
Z out
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Originally Posted by jbrown7815
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