Audi A4 Coolant sensor clip!!

[lifemask]

Hi all,

I am wondering if I am a complete idiot!

I have a faulty coolant sensor.
Puchased a replacement (green one) a new 'o' ring and a couple of new clips...and yes, it is the right sensor..identical to teh old one in all but colour.
Removing the clip, the old sensor along with the old 'o' ring was a doddle. As was replacing the new 'o' ring and then the senor.

But....I cannot for the life of me get the 'c' clip back in correctly!! I have read several useful guides on how to do the whole (10 minute!!) job and looked at diagrams etc.
It is obvious where the clip goes, but can I do it?? NO!!!
It seems to me that the 'o' ring and sensor don't go in far enough for the clip to be able to go through the two slots in the side of the cylinder and clip over the sensor to hold it in place.

Every time I try, the clip goes in, but pushes between the 'o' ring and the body of the sensor. meaning of course that the sensor simply pulls out leaving the 'o' ring behind.

So, would some kind soul please put me out of my misery and explain how to do this. It really does seem so simple, but........

[SWARCUP]

you sound like you have the correct procedure. When i did mine the same happened and when i looked i found the old oring in there but it was so covered in crud you couldnt see it. I dont want to sound patronising but just have a good look inside the cavity for anything still in there that shouldnt be. what engine is it?

[lifemask]

Hi Swarcup,

I took the old O ring out and have used a new one. I have also checked inside the cylinder and there is nothing there!

I'll have another look when I have gathered some more patience!!

The car is a 2.4 sport cabriolet.

I'm sure I'm just being stupid!!...so don't worry about being patronising...sometimes it is needed....

I have even tried putting the old sensor back with the original O ring and encountered the same problem.

[SWARCUP]

it can only be something in there preventing the sensor from going home all the way then do you think. just a thought is there a keyway on the sensor?

[lifemask]

No keyway on the sensor.
I'll check again in the morning or when the rain has stopped and the waves of frustration have subsided.

heh! I have checked re-checked and checked again. But then I could walk into a forest and see no trees!

daft as it seems so damned simple....or is that me?

[Adam A41.8T]

I had the same problem with mine and I think it was just a case of pushing the sensor down as hard as you can and holding it there and clipping it in then. It does fit but its really tight with the new oring to prevent the coolant leaking out. It does work honest!!

[lifemask]

That was going to be my next try.
I have to say that I have big hands and have found pushing down hard a tad difficult due to space..and am also in fear of something breaking.

[Columbo]

try putting the o-ring in boiling water for 5 minutes to soften it up and maybe the tinyest smear of copper ease, very tiny around it.

[lifemask]

Ah well. tried again today and still can't do it.
Definitely nothing in there that shouldn't be..just the one O ring.

Tried using more pressure when putting the sensor in but ...!

The O ring goes in, but sits naturrally on a lip a centimeter or so into the cylinder. This was where the original weas when I removed it. I then push the sensor down on top and it fits snuggly in place, but the damned clip will still not go.

tried putting the O ring on the sensor first and then inserting it. Again, it fits in snuggly but no clip!

I can feel a call out to a garage coming on.

[vwroyd]

Hi,

When i did mine i smeared a small amount of vaseline on the O-ring, placed the O-ring on the sensor and then pushed it firmly home, then just pushed the clip in. It is as simple as that. Don't give in, Best of luck!!!