Temp sensor retaining clip hell(p)

[redsnapper]

Hi all, 

Not posted on here for a long time but regular browser for solutions but can't find an answer to this and feel I am just being an idiot

1Y Diesel engine, wires had corroded to the coolant temp sensor. Took it out to solder on some extensions, quick job, now have spent the rest of the day wondering why I can't get the retaining clip back in... I fished out the O ring and put that back on. I also had a spare temp sender and tried that one instead. Both seat well, both seem to have an obvious channel where that retaining clip should smoothly slide over and lock, but buggered if I can make that happen... it came out with no bother..




this is where it is going:


and this is as far as I can get the metal clip to go in. I've tried all sorts of angles, holding it with plyers etc.



Only other thought is to give it a tap with a small hammer, but that feels like it shouldn't be neccessary.

If anyone can put me out of my misery that would be great!


 

[davidoft1]

Push the sensor hard down into the housing

[redsnapper]

Thanks, tried that but still won't go!

[Aidan]

have you tried the plastic clip 032 121 142 ?
The wire one is later I think, but imbw

[redsnapper]

That was my thought but,
a) prefer the metal as would probably have broken the plastic one by now
b) this is the one that came out of it so should go back in, no obvious distortion!

[tobydog]

Can you get it to fit without the booty thing?

[redsnapper]

Hi Tobydog,

So yes, it fits nicely, snug, with the o-ring, and presents what should be the right curved surface for the clip when eyed through the slot.

Outside the tube the clip fits on the sensor.

Without the sensor, the clip also fits perfectly in the slot with the clips popping out the bottom slot as intended  :rollin

 

[tobydog]

A dash of lube perhaps?

Also, to quote the sheet metalworker tutor in the first year of my toolmaker's apprenticeship, "one good hit is better than lots of little ones"

[redsnapper]

Well f..k, gave it a tap and the housing has split

[redsnapper]

not the start to my 'repair day' that I was hoping for. Anyone got any advice please?

[Aidan]

a new flange 068 121 132 A and the correct plastic clips

[redsnapper]

Thanks mate guess it just turned into a bigger job!


Sent from my iPhone using Tapatalk

[Aidan]

Tis often the way with old vehicles
Do you know exactly what the 1Y came out of originally ? I'm just using Golf 1997 model year parts info as basically generic era for 1Y but engine was used in many different VW/Audi/Seat/Skoda vehicles of the era and there can be significant variations - things like the manifold with the sensors in varies depending on if air con was originally fitted and the like
With engine swaps it is best practice to retain the original donor vehicle information, including the VIN and to note anything that is changed over when fitting the engine so next owner knows exactly what they are dealing with