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Coolant Temperature Sensor Replacement
 
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Pelican Technical Article:

Coolant Temperature Sensor Replacement

Jared Fenton

Time:

5 hours5 hrs

Tab:

$25

Talent:

****

Tools:

22mm socket or wrench

Applicable Models:

Porsche 955 Cayenne S (2003-08)
Porsche 955 Cayenne Turbo (2003-08)

Parts Required:

Coolant Temperature Sensor

Hot Tip:

Remove intake manifold for easier access

Performance Gain:

Cooler running engine

Complementary Modification:

Replace coolant

A failing coolant temp sensor can manifest a variety of problems. Sometimes it can give you a faulty reading on the temp gauge on the instrument panel. Other times, it can prevent the cooling fans mounted on the radiator from operating correctly. These problems can be a bit troublesome to diagnose. I recommend scanning the vehicle with the factory computer or Durametric to search for any fault codes that may be stored. Please see our article on Reading Fault Codes for more information.

Replacement of the sensor is a bit of a chore. I suggest removing the intake manifold in order to replace the sensor. It can be done with the manifold in place, however you don't have a lot of access in there. Additionally, it will be very hard to see what you are doing. This article is written with the intake manifold removed. If you choose to attempt it with the manifold in place, hopefully these pictures will be of some help. Please see our article on Intake Manifold Removal for more information. I'd also recommend disconnecting the battery as you will be working near the electrical connection for the starter motor. This connection is always live. If you manage to accidentally touch it with a wrench, you can cause damage to both the vehicle and yourself. See our article on Battery Replacement for more information.

You'll want to drain off some of the coolant in the system before you remove the sensor. If you fail to do so, you'll get coolant streaming out of the mounting hole. You just need to remove enough coolant so that the level is below the height of the sensor location. See our article on Water Pump Replacement for information. Don't forget to bleed the cooling system of air after replacing the sensor.

Here is the location of the coolant temperature sensor on the Cayenne S/Turbo (green arrow).
Figure 1

Here is the location of the coolant temperature sensor on the Cayenne S/Turbo (green arrow). Note that it may be possible to replace the sensor with the intake manifold in place. I found it easier to do the job with the manifold removed as it is nearly impossible to see what you are doing, let alone take pictures of it.

Press the tab (green arrow) on the electrical connector and pull it up and off the sensor.
Figure 2

Press the tab (green arrow) on the electrical connector and pull it up and off the sensor.

Here is the coolant temp sensor with the electrical connector removed.
Figure 3

Here is the coolant temp sensor with the electrical connector removed. If you are doing the job with the manifold in place, you'll need to use a long 22mm socket and a variety of extensions to remove the sensor.

In our case, I used a 22mm wrench to loosen and remove the sensor.
Figure 4

In our case, I used a 22mm wrench to loosen and remove the sensor. Be careful as there isn't a lot of space to work with. Once the old sensor is removed, thread the new one in place, tighten it down and re-install the connector.

You will now need to bleed the cooling system of air.
Figure 5

You will now need to bleed the cooling system of air. You can do this by using a vacuum siphon type attachment such as this Airlift product. The idea here is to draw a vacuum in the cooling system, then use the vacuum to draw the new coolant into the engine. Follow the manufacturers instructions for each type of bleeder.

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Comments and Suggestions:
HelpNeeded Comments: My engine is different. Any idea where the temp sensor is? Its an 08 Cayenne S.
August 30, 2016
  Followup from the Pelican Staff: On DFI models, it is in the coolant manifold that runs along the rear of the crankcase.- Nick at Pelican Parts  
Mick Comments: Actually, just found it in the workshop manual: 30Nm 22ftlb.
February 24, 2015
  Followup from the Pelican Staff: Thanks for the Info. We appreciate it.
- Nick at Pelican Parts
 
Mick Comments: Hi,
Do you happen to know the tightening torque for the sensor?
Thanks,
Mick
February 24, 2015
  Followup from the Pelican Staff: Sounds like you found it befor me Actually, just found it in the workshop manual: 30Nm 22ftlb.>/strong> - Nick at Pelican Parts  
kj Comments: I have 90 cadillac deville 4.5L multi-port. Because of a bad replacement coolant sensor from autozone I cracked the block where it is located. It look like a thermostAt housing to me. I need to find out the sensor is screwed into. This part sits UN top of the intake manifold and looks like it might be some kind of aluminum. Also I need to know where to find this part as all the parts places say it is no longer available.
September 30, 2014
  Followup from the Pelican Staff: I don;t have any experience with that engine. I would call a Cadillac dealer to identify the part, then a salvage yard for the replacement. - Nick at Pelican Parts  

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