quattroworld

I went through a couple extra steps more than was necessary to replace the sender so I had my intake manifold and coolant manifold off the engine. But here is some pics of replacing the sender with a new unit.

Here's the offending sender.


To remove you need a 24mm crowsfoot wrench and a couple extensions.


Next you need to buy a 034 103 179 adapter and a 035 919 561 sender and install it like in this diagram #16 = 37 ft lb and #18 G10 = 18 ft lb


Here is some actual pictures of the installation, both are 17mm
Adapter


Adapter installed.


Sender installed. You need to be a little careful with your wrenches since both are 17mm and your wrench can slip back on to the adapter if it lines up properly.


And wired


Done!! Too bad it didn't fix my problem, I was sure that the sender would stop my gauge from freaking out, but I guess the gauge will be the next step in getting my oil pressure to read sane values. It may have moderated the reading a bit, but it is still out. Otherwise this would be a compatible upgrade for anybody that needs to replace it. I also think I still have my mystery coolant leak, so more troubleshooting will be in order there.

Some other obligatory pictures:

Random 2 on the #3 intake port, I wonder why this is here?


Squeaky clean coolant ports!! No sediment here folks.
Replaced orings 3x N 028 203 4 and gasket 027 121 139 A on coolant manifold.


Other notes.
Cruise control is NON-Functional without some adjustment (I hope) with the installation of the 034 phenolic spacer. The throttle cam is spaced a bit further out so when the cruise control rod is attached, it does not return to Idle.

A real walher thermostat makes a huge difference from the 87C V6ish one (from blau). It has the same part number as the walher box stamped on it (069 121 113), but only averages around 80C instead of 90C. Easy swap.

After 21 years the manifold side injector seals were pretty cooked, but the ones on the rail side were still squishy. Injectors were tested and they checked out just fine, good for 21 years and my peace of mind.

Anyways hope this may help someone sometime.