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Thread: EGT sensor DIY repair with photos

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    Registered User sleeprs6's Avatar
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    EGT sensor DIY repair with photos

    I usually lurk this forum, but posts here have helped me with so many repairs that I wanted to contribute.

    I purchased VCDS and the first thing that I noticed is that both my EGT sensors were malfunctioning. Here are the codes:

    17861 - Exhaust Gas Temp Sensor 1 (G235)
    P1453 - 001 - Open or Short to Plus
    17867 - Exhaust Gas Temp Sensor 2 (G236)
    P1459 - 008 - Implausible Signal

    The EGT re-solder is well documented on this website, I followed the same steps as others have, with a few minor adjustments:

    First unbolt the EGT sensors from the firewall:

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    Gently pry off the tops with a mini screwdriver (make sure they don't break). The circuitboard is covered with silicone gel.

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    Remove as much of the silicone gel as you can with a toothbrush and a paper towel (this part took me the longest). Make sure the circled contacts are completely free of silicone gel.

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    Clean the whole circuitboard with electrical contact cleaner and compressed air. I got some at home depot. Visually inspect the contacts and make sure they are completely clean. It's really important to get any residual silicone gel off of the solder joint.

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    Now you are ready to solder. Use a good soldering iron and use a copper sponge to clean the tip before soldering.

    Coat all surfaces of the solder joint with soldering flux, heat the joint, and apply a little bit of fresh solder. Pay attention to where the solder contacts the circuit board and make sure you get a good connection (took me two tries).

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    When you've re-soldered all five contact points, put the lids back on and connect the sensors (don't bolt to the firewall yet). Clear DTCs with vag-com and log exhaust temps, engine measuring block 112. If sensors still don't work, disconnect again and re-solder.

    If both sensors work, take the lids off, and apply silicone gel to the circuitboard. I cleaned the board again before applying. Silicone protects from heat and moisture (obviously these sensors are fragile). Let it cure without the lid on.

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    Re-attach lids using your favorite adhesive (for me zip ties) and bolt back onto the firewall.

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    Treat yourself since you just saved $500 on new sensors and who knows how much on labor (sensor probes are attached to the downpipes $$$$)

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