I have used this method a couple of times...

 

I just took the manifold off this morning and it came off easily. I won't reuse gaskets but these ones look good. The outer intake valves look incredible while the inner ones have some deposits. Turbo looks ok but has some oil on the connecting shaft. Oil dipstick tube also decided to pop out. How difficult is to repair that?

 

 

It is the temp sensor that tells when to turn on/off the aux turbo water pump.

 

I'd post up a pic of what the wire that connects to that looks like if I could, but all those files are at home. Look for a single wire that has a round black plastic housing around a female wire connector socket. There is also a small tab on one side that clips/holds the piece onto the temp switch.

 

The same thing happened to me when i took out my injectors except it happened to all of them. The way I got them out was with my trusty set of old dental tools. I have found them to be quite useful sometimes. I had a tool that had a 45 degree bend at the end. Stuck the tool through the hole and with a little pull they come right out. Haha

 

Tom, have you replaced it before? I'm sure the coolant tank must be emptied right? The weld around the black part and the nut is no good and it wiggles and clicks. I wonder how much harder it is to do it with the intake on as quite honesty I want to mess with it later on in the month when I do a coolant change. Well I guess I could just get a cooling system pressurizer and stop doing it the old fashion way.

 

Yes, it plugs into the coolant supply. I replaced mine when I replaced the turbo, but everything was dry. I assume coolant would gurgle out if you removed it without draining the system below the level of that sensor. If you kept the cap on the reservoir and did it cold so the turbo t-stat is closed -- you might be able to do it fast enough to lose not much coolant. Sounds like it needs replacing either way, but not sure whether it would leak if it started breaking on the top end -- just don't know, but could imagine it sealing on the sensor side nonetheless.

 

That is the same place where my temp switch broke (I happened to break it) and I just used some of that 5 min epoxy stuff to glue it back together. The car obviously isn't running. so I don't know if the switch still works, but you might as well try it before buying a new $45 switch. The epoxy definitely holds it together securely, it is just a question of if any internal parts in the switch got messed up.