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Thread: Replacing G235 Exhaust Gas Temperature Sensor 1

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  1. Replacing G235 Exhaust Gas Temperature Sensor 1 
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    I've been having a few problems with a 2011 Touareg 3.0 TDI (7P-CASA) with it going into limp mode and coil light flashing. A did a regen of the DPF a few weeks ago which temporarily sorted the problem but now it has come back again.
    Running VCDS diagnostics shows a fault below on the G235 EGT Sensor 1 which is reading 1000 degrees so looks like it is time for a replacement. Has anyone done this before, is it easy to do without removing DPF?
    ----------------------
    5260 - Sensor 1 for Exhaust Temp Bank 1 (G235)
    P0544 00 [047] - Circuit Malfunction
    Confirmed - Tested Since Memory Clear
    Freeze Frame:
    Fault Status: 00000001
    Fault Priority: 2
    Fault Frequency: 14
    Mileage: 133283 km
    Date: 2016.11.07
    Time: 17:55:29


    Engine speed: 1073.00 /min
    Normed load value: 0.0 %
    Vehicle speed: 55 km/h
    Coolant temperature: 87 C
    Intake air temperature: 8 C
    Ambient air pressure: 990 mbar
    Voltage terminal 30: 14.880 V
    Unlearning counter according OBD: 40
    Exhaust gas temperature sensor 1: 1000.0 C
    Exhaust gas temperature sensor 2: 150.0 C
    Exhaust gas temperature sensor 3: 118.0 C
    Exhaust gas temperature sensor 4: 222.0 C
    Shut-off timer: last engine shut-off time: 25840 s
     
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  2. Re: Replacing G235 Exhaust Gas Temperature Sensor 1 
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    Had a root around under the bonnet this evening, is this the G235 sensor?

    IMG_4604.jpg
     
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  3. Re: Replacing G235 Exhaust Gas Temperature Sensor 1 
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    Pretty sure it's the one closest to the turbo that looks like a nox sensor and not exhaust gas temperature sensor 1. You could always watch live readings and diconnect the sensor to work out is number 1.

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  4. Re: Replacing G235 Exhaust Gas Temperature Sensor 1 
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    We had the DPF off an A6 with that engine yesterday so it could be sent for cleaning. We have to remove the temp senders before they go away and the G235 would not come out. It would move a little either way so we put some gentle heat on it but it still would not move. Accepting we know had to kill the sensor we got the hot spanner on it but it just sheared off. They are stainless steel and near impossible to drill out so now it needs a new DPF. I looked at the sensor and could see it was fairly new and the revised part number, so whoever fitted it must have over tightened it and not used any aluminium anti seize paste. Also yesterday morning we had a Toerag in with the same fault, not looking forward to doing that one now...

    001348 - Sensor 1 for Exhaust Temp Bank 1 (G235)
    P0544 - 000 - Circuit Malfunction
    Freeze Frame:
    Fault Status: 01100000
    Fault Priority: 0
    Fault Frequency: 1
    Reset counter: 255
    Mileage: 199430 km
    Time Indication: 0
    Date: 2016.12.06
    Time: 10:26:16
    Freeze Frame:
    RPM: 756 /min
    Torque: 62.4 Nm
    Speed: 0.0 km/h
    Duty Cycle: 1.0 %
    Voltage: 14.14 V
    Bin. Bits: 00101000
    Torque: 206.7 Nm
    Readiness: 0 0 1 1 1
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  5. Re: Replacing G235 Exhaust Gas Temperature Sensor 1 
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    Quote Originally Posted by staffop View Post
    I've been having a few problems with a 2011 Touareg 3.0 TDI (7P-CASA) with it going into limp mode and coil light flashing. A did a regen of the DPF a few weeks ago which temporarily sorted the problem but now it has come back again.
    Running VCDS diagnostics shows a fault below on the G235 EGT Sensor 1 which is reading 1000 degrees so looks like it is time for a replacement. Has anyone done this before, is it easy to do without removing DPF?
    ----------------------
    5260 - Sensor 1 for Exhaust Temp Bank 1 (G235)
    P0544 00 [047] - Circuit Malfunction
    Confirmed - Tested Since Memory Clear
    Freeze Frame:
    Fault Status: 00000001
    Fault Priority: 2
    Fault Frequency: 14
    Mileage: 133283 km
    Date: 2016.11.07
    Time: 17:55:29


    Engine speed: 1073.00 /min
    Normed load value: 0.0 %
    Vehicle speed: 55 km/h
    Coolant temperature: 87 C
    Intake air temperature: 8 C
    Ambient air pressure: 990 mbar
    Voltage terminal 30: 14.880 V
    Unlearning counter according OBD: 40
    Exhaust gas temperature sensor 1: 1000.0 C
    Exhaust gas temperature sensor 2: 150.0 C
    Exhaust gas temperature sensor 3: 118.0 C
    Exhaust gas temperature sensor 4: 222.0 C
    Shut-off timer: last engine shut-off time: 25840 s
    Was the exhaust temperature sensor broken? (the one that read 1000C)
    Cuz i have a golf 7reading 1000C at the EGT after the DPF. Fault code: P246E 00


    5258 - Exhaust Gas Temperature Sensor 4 Bank 1
    P246E 00 [175] - Electrical Malfunction
    MIL ON - Confirmed - Tested Since Memory Clear
    Freeze Frame:
    Fault Status: 00000001
    Fault Priority: 2
    Fault Frequency: 1
    Mileage: 206376 km
    Date: 2020.05.25
    Time: 04:30:18


    Engine speed: 0.00 /min
    Normed load value: 0.0 %
    Vehicle speed: 0 km/h
    Coolant temperature: 88 C
    Intake air temperature: 69 C
    Ambient air pressure: 1000 mbar
    Voltage terminal 30: 12.460 V
    Unlearning counter according OBD: 40
    Turbocharger 1 turbine inlet: temp. sensor 1 bank 1: raw value: 20.0 C
    Turbocharger 1 turbine outlet: temp. sensor 1 bank 1: raw value: -0.0 C
    Particle filt.inlet temp.sens.1 bank 1: raw value: 144.6 C
    Particle filter outlet temp.sens.1 bank 1: raw value: 1000.0 C
    Shut-off timer: last engine shut-off time: 386 s
     
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