quick egt sensor fix

[ta79pr]

I had a persistent EGT sensor code.
I didnt want to shell out the $300 for a new one.
I took it out, cracked it open to see what it looked like, low and behold, the signal wire coming from the probe into the circuit board had a bad solder joint. The whole thing was filled with a silicone like jelly. I scraped that off with an old toothbrush and fixed the solder joint. Refilled the enclosure with plain old silicone caulk. reinstalled, cleared the old stored code, and voila. No more EGT code.

078919529L


I hope this can help someone else out.

[vtraudt]

I am close to ordering EGT, have consistent bad passenger (Sensor/Bank 1) code. Afraid error is causing the limp mode I have (5 psi boost, 230 Nm torque cap).

Can you explain how to 'crack open' the sensor.

I will go out now and pull it, check resistance (Bentley has values) to confirm 'bad'.

Then ready to crack and give your suggestion a shot.

Post or PM or email info@regulatorfix.com

[ta79pr]

Originally Posted by vtraudt

I am close to ordering EGT, have consistent bad passenger (Sensor/Bank 1) code. Afraid error is causing the limp mode I have (5 psi boost, 230 Nm torque cap).

Can you explain how to 'crack open' the sensor.

I will go out now and pull it, check resistance (Bentley has values) to confirm 'bad'.

Then ready to crack and give your suggestion a shot.

Post or PM or email info@regulatorfix.com

Once you take the sensor out of the car, the little box opens up just by gently prying the lid open with a small screwdriver. It was virtually effortless to open, not crazy prying. You will need a magnifying glass most likely to examine the solder points.

[vtraudt]

Got the brown EGT out. In my car, it is the passenger side, 'bank 1' in (Bentley) 'position 1' (connector to the font of the car).



Cracked open the plastic case. Found they weird jelly. Trying some of the connectors for continuity first. Getting to the lead pin (sensor side) the rear connection felt loose. I was able to bent up tap (as shown in photo) with no force.

Hopefully, resoldering that connection fixes my EGT?

[vtraudt]

Is there a way to bench test the sensor?
Bentley only shows a 'in car', ignition on voltage test (and IIRC it says 2 pin connector, my above sensor has 3 pin)?

[vtraudt]

Read the Bentley again for ECT G235 sensor.
It says: check resistance between terminals 1 and 2, should be infinitive.
Mine has 3 connectors! (part number 078 919 529 E

Then under 'checking voltage':

- disconnect sensor
- switch ignition on
- measure voltage electrical harness connector terminals 1 to 2: 0.4-0.5 volts

Suggestions?

[cern123]

man I joined this forum just so I could say THANKS!! I have an 03 A6 2.7t quat that's been throwing an 'intermittent ground' code for the G236 - I cracked the sensor open and it was just a broken solder joint. I hit it with some fresh solder and filled in the jelly with rtv silicone and haven't had it throw the code 2k miles later... What a great fix! Don't buy new till you check this!!

[vtraudt]

Can someone confirm the EGT sensor locations and colors?

Exhaust Gas Temp Sensor 1 (G235):
passenger side (right), brown ???
078919529N
APD, BEL engines

Exhaust Gas Temp Sensor 1 (G236):
driver side (left), black ???
078919529M
APD, BEL engines