Changing G263 Evaporator outlet temperature sender without removing the dash

Just a little update...thanks for all the help. I definitely overestimated my capacity to do this job, but hopefully will complete it eventually. I managed to get the sensor out of its location relatively easily. But I had a lot of trouble disconnecting the connector. After about 8 hours it came free with the help of a screwdriver (and maybe a little divine intervention). In the meantime I had managed to release both the handbrake and knocked it out of gear so the car rolled down the drive and collided with the front of the house cracking 2 bricks and damaging the bumper all the while with my head under the foot pedals (yes, should have chocked the wheel...). After extracting the old sensor finally I inserted the new sensor and promptly lost it God knows where. Several hours of searching and probing with an endoscope have failed to locate it. Now waiting for a 2nd replacement sensor...then replace the bumper and rebuild the house...
 
Oh dear, but 10 out of 10 for perseverance.

Seems to me it would have been better to disconnect the connector before removing the sensor else the sensor would be flopping around (?) while trying to undo the connector, but you won in the end.

On the bright side the house will not collapse!

Andy
 
Yes, definitely easier to release the connector whilst attached to sensor - as you say, it is so difficult with the sendor flopping around. But others have reported that it is almost impossible to extract the sensor except by tugging on the connector!
 
Oh lord!

I had a bad time doing this myself and my hand was in tatters for days afterwards. Scott’s wouldn’t budge at all when we tried his. It took Timmus to get it free.

The access is so bad and the space so small that I think superhuman flexibility, finger strength and ability to work blind ‘seeing’ with only your fingers are minimum attributes before attempting.

Sorry you are having such a hard time of it. Probably still less hassle than removing the dash by yourself... hopefully.


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Oh lord!

I had a bad time doing this myself and my hand was in tatters for days afterwards. Scott’s wouldn’t budge at all when we tried his. It took Timmus to get it free.

The access is so bad and the space so small that I think superhuman flexibility, finger strength and ability to work blind ‘seeing’ with only your fingers are minimum attributes before attempting.

Sorry you are having such a hard time of it. Probably still less hassle than removing the dash by yourself... hopefully.


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Your posts, Pinky, have been a great help too. Here's my wound...
15967043003496404820416010155703.jpg
15967043003496404820416010155703.jpg
 
It’s bad new when you find the first component on Audi’s A2 build line is the G263 sensor and you need to change it


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oh man that brings back so many bad memories :)

if it breaks again the car is being scrapped!

Ha! At least your TDi90 had a rounded edge on the brake switch mount plate! The TDi75 component feels like it has been sharpened!

It was a bad day though. Sorry again I couldn’t get it.


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Ha! At least your TDi90 had a rounded edge on the brake switch mount plate! The TDi75 component feels like it has been sharpened!

It was a bad day though. Sorry again I couldn’t get it.


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Mine"s rounded now. Just be smarter than me and file it down BEFORE starting the extraction...
 
Dreading taking on this job on my car, had a go at getting the G263 sensor off a scrap A2 last week and couldn't manage it, access is ridiculously tight. i'm tempted by the motor out method having experienced just how tight the access is, anyone used that method recently? a bit worried about breaking stuff.. Oh, and joy of joys - both my a2's have the G263 fault and no air con working...
 
It isn't THAT difficult to remove the dash. I've done this a few times. Care and patience .... no need to hurry. There's lots of information here, too. There are a few "hidden" screws and in difficult locations. So if the dash is still retained, it soon becomes obvious where it's being held. Just have confidence!

David
 
Not only that you will be able to do the second car in a fraction of the time having gone through the learning cure on the first car. Probably best to do the car that is less needed first. Remember to take lots of pictures to help you along the way. You can then make a really useful guide afterwards.
 
It isn't THAT difficult to remove the dash. I've done this a few times. Care and patience .... no need to hurry. There's lots of information here, too. There are a few "hidden" screws and in difficult locations. So if the dash is still retained, it soon becomes obvious where it's being held. Just have confidence!

David

I think ease of removal is very much dependant on your size and flexibility. I removed one last week having not done one for a long time and being 6ft3 found it a bit of a pig.
 
I think ease of removal is very much dependant on your size and flexibility. I removed one last week having not done one for a long time and being 6ft3 found it a bit of a pig.
Yes, seats out and with a massive piece of foam over the entry section to the front well .... laying on your back to look up under the dash ...... NOT that easy! (but I have had a hip AND knee replacement!) In my 70's, too :)

David
 
Just an update in case anyone else has the G263 fault. This is sequence of events in my case. Had car regassed, no air con working, garage advised faulty pressure switch probably, I scanned and found the G263, erased code, it came straight back. ordered new part and took deep breathe ready to tackle the job. I thought i'd check again, scanned and erased code. checked air con, and amazingly, icey cold. maybe i have an intermittent fault on the sensor and it will fully pack up at some point, but for now its working again. So, try clearing the code a couple of times...cheers
 
Just an update in case anyone else has the G263 fault. This is sequence of events in my case. Had car regassed, no air con working, garage advised faulty pressure switch probably, I scanned and found the G263, erased code, it came straight back. ordered new part and took deep breathe ready to tackle the job. I thought i'd check again, scanned and erased code. checked air con, and amazingly, icey cold. maybe i have an intermittent fault on the sensor and it will fully pack up at some point, but for now its working again. So, try clearing the code a couple of times...cheers

Hi Nod,
I’ve had similar issues as you , G623 sensor fault intermittent, this had occurred during the last really hot spell +30c giving cooling & then stopping etc.
Whilst stuck in traffic for a time I noticed it stop working & temperature rise accordingly as soon as the traffic started moving the a/c started to work, when I got home I checked the radiator fan & found it not running when a/c was on , pointing to either rad control module or radiator fan faulty, swapped out module but fan still failed to run so I obtained a replacement fan which corrected the fault & a/c now runs as designed.
Hth
Keith
 
Its not that hard to change it if you drive at the RIGHT side of road :D
But i've got some bendiness left in me and hand's are not too large. Removed it multiple times during fault finding and eventually replaced sensor. After that needed to remove it for other reasons too.

intermittent
Since sensor is long and thin, it will vibrate and eventually wire breaks inside it. It will probably work and not work for some time as bumps etc dictate. There might be other way's to fail, but that seems to be most probable way. And Murphy said bump will disable it when you need cooling the most...
 
Dreading taking on this job on my car, had a go at getting the G263 sensor off a scrap A2 last week and couldn't manage it, access is ridiculously tight. i'm tempted by the motor out method having experienced just how tight the access is, anyone used that method recently? a bit worried about breaking stuff.. Oh, and joy of joys - both my a2's have the G263 fault and no air con working...
So, the Aircon packed in during the summer and the g263 fault couldn't be cleared, finally got around to taking on this job today. I removed the flap motor as these instructions show, even with that out it's a fiddle. Took around 3 awkward hours all told. Fault code gone. Now, will the AC blow cold on hot days and the webasto fire up in the morning???
 
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