Club 80-90 Forums

The poor old misses saw a HUGE cloud os smoke out the back of our 1.9 T25 on Saturday, she pulled over and called Green Flag immediately.

The van was recovered home covered in coolant and when I looked under it I saw why.

One of the sensors below the thermostat had come out. The clip retainer was still in position and the O rings on the sensor seemed fine. I replaced it and refilled the engine and all seems OK.

I can't figure out how this happened though ? The clip seems sound and there is no damage to the pipe. Has anyone else had this happen before, and is there really that much presure in the cooling system??

you are not the first, I remember a few doing it but no one recently, iirc, replacing the `r` clip solves it, its not over pressure, its crap design and pattern parts, get a new clip from vw, if they say no, get one for a golf or polo, exactly the same thbing in the same place..........but check your groove where it fits isn't damaged


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Thanks, so am I looking for an "R" clip ? Is that what I ask my local motor factors for?

Dave

I guess we are talking about a TDI engine here?

If this is the case then its a plastic U shaped clip.

Probably a VW only part.

No, petrol 1.9 (1989) and the clip is metal.

ask them for the clip that holds the sender in, thats what they will know it as....

Turns out that this was caused by garage putting two thick O rings on the sensor when they fixed the electrical connection a while back.

This pushed the sensor out too far and the clip was not seated fully behind the sensor. I removed one of the O rings and made a special jubilee clip with a slot in to hold the retaining clip in place. That sensor should be stuck in there for life now.

DaveB wrote: I removed one of the O rings and made a special jubilee clip with a slot in to hold the retaining clip in place. That sensor should be stuck in there for life now.

Why ?

Ian

If you had ever had it come out on the motorway you would do the same!