Fitted this morning with some help from a more experienced friend who, more importantly, has smaller hands than me.
Only took about 20 minutes in the end and seems OK so far - codes cleared, not returned, behaves OK and temp gauge acts normally.
No particular tricks, just looking carefully and working out what and how to do it. Start with a stone-cold engine and DON'T remove the expansion tank cap:
1. Removed engine cover
2. Removed air pipe - 2 jubilee clips to loosen, one each end (don't try to split in the middle). Take off completely the jubilee clip at the manifold end as it's on a rubber moulding that gets in the way rather and without the clip you can push it aside a bit when necessary for better access.
3. Took off plug lead which is a bit awkward to get at. This was tricky as it wasn't clear how to release the catch so liberally applied WD40 first. Basically you press in the small catch that is surrounded by a plastic rim (so lifting the latch further down) and wiggle the whole plug upwards.
4. Note carefully where the retaining horseshoe clip is located then pull it out sideways (towards offside) with long-nose pliers.
5. Wiggle the sensor until it comes out. Mine seemed to rotate OK but needed a good wiggle and strong pull with pliers to release. No coolant escaped, but it was visible.
6. Extract the sealing ring - this needed a poke about with a thin screwdriver to unseat.
7. Clean all around and pop the new ring in, ensuring it's seated properly.
8. Insert new sensor - it probably won't go straight in as with a new sealing ring it's a tight fit and applying pressure with fingers is near-impossible in the small space. We pushed it down with the end of a (rubber) hammer handle easily enough. Don't use anything too solid or you risk damaging the wiring socket. MAKE SURE the sensor is fitted so that the retaining clip for the wiring plug will be accessible for removal!
9. Slide new horseshoe retaining clip back in. Bit of a swine this as it's difficult to grip and see and needs to align with slots you can't see. We had the small-fingered one holding it with me using a light and giving "golden shot" style instructions (down a bit, left a bit etc. etc.). Luckily little force is needed if the sensor has been seated first.
10. Refit the wiring plug.
11. Refit air pipe and secure, refit engine cover.
The actual sensor only cost me £7.50 delivered and seems to be a standard VAG unit.
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2003 D2 FL S8. Irish Green Pearl/Beige. Solar sunroof, auto-dim mirrors, electric rear seat functions, ski hatch retrofit; extended leather. Aftermarket DVB-T, reversing camera and full XCarlink (Bluetooth etc.).
2016 Volvo V40 T5 Cross Country (4WD) with ALL the toys including adaptive cruise etc. etc. Osmium Grey with Blonde/Charcoal leather interior. Polestar performance "optimisation".
(A much rarer model than a D2 S8 by the way!) Oh, and a brand new engine at just under 30,000 miles on the factory one!
Finally: gone, but not forgotten.....
1998 D2 PF S8. AgateGrey/Platinum. Every option (I think) except electric rear seats, tiptronic steering wheel, ski hatch, towbar & dimming door mirrors.
e.g. Cruise control, NavPlus/TV, Bose, GSM, Xenons, Solar roof, Parking sensors, Alcantara/leather everywhere of course.
(internal dimming mirror added later)
1998 (very early) Ford Focus 1.8 Zetec; ABS/TCS, Heated screen/mirrors, Aircon, Auto-dim mirror, Leather, Trip computer, Cruise control, OEM Ford SatNav with CD changer.
And before that a lot of Rover 800s, a few oddities, a lovely Triumph Dolomite 1850HL with Overdrive and way back in my schooldays an Austin Seven aka Mini 850!
