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By chance I was at a local VW supplier on Saturday for a window winder and they happen to have brought in a VDO sensor to fit the relief valve port wich I assume is the same length as the plug. I did take out the plug yesterday and measured it to make sure when I go pick up the sender unit once they unpack their stock.
Have been fighting a bit with my old VDO gauge and original sender unit.
I made an adapter fitting in the end so my old 120'C sender could be used instead of the 150'C I bought - I didn't think it through properly and now have an extra sender unit to suite the relief valve port but to suite a 150'C gauge if anyone wants to buy it off me for R80 less (Never used)
Anyway, after my fist test drive, 30 minutes in the gauge was climbing nicely up to about 60'C and then suddenly the needle flies off the chart - had to unplug the sender and drive her home.
So I assumed the sender is faulty and tested it on my multi-meter in a pot of engine oil over a gas ring and it works fine up and down with no hiccups.
Refit in the car, this time 5 minutes in and the gauge flies off the chart.
At this point I fit my meter on the sender wire I unplugged from the gauge and the earth and Zero Resistance.
Pop outside, disconnect sender wire at the sensor and check the sender to earth and the resistance is perfect.
Reconnect wires to gauge and needle works again correctly.
Nother test run and few minutes in - same problem.
Removed sender again and tested in warm oil with multi-meter and cannot find fault.
Tapped the gauge to see if maybe a fault in the gauge but all seems fine.
Does it sound like a sender fault or a gauge problem. Also checked my sender wiring to make sure there was no chaffing and making contact with earth anywhere.