Live and learn. Now you know. 

--FT
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> On Mar 11, 2024, at 11:09 PM, Allan Streib via Mercedes 
> <mercedes@okiebenz.com> wrote:
> 
> Wife's car (VW Jetta) has been alerting (annoyingly) about the oil level 
> sensor. It was intermittent and has slowly gotten to the point that it was 
> alerting every few minutes while driving. Code was "intermittent implausible 
> value" so I assumed the sensor had failed, as that is my experience with VWs. 
> Sensors fail.
> 
> Ordered one from FCP Euro, watched a YouTube video, easy enough job: drain 
> the oil, disconnect the sensor, remove three nuts holding the sensor in 
> place, pull it out, put the new one in, reconnect, refill the oil. Looked 
> like it should take 30 minutes max.
> 
> I had considered that the problem might be a bad connection but the connector 
> was in place, not loose or damaged. So I went ahead with the sensor 
> replacement. As I was reconnecting it, out of the corner of my eye I noticed 
> what looked like a cut in the split-tube cover on the wiring. Sure enough, 
> there was a cut. How in the heck it happened I don't know. The car has a 
> splash guard so nothing could have snagged it. I change the oil with the 
> extractor so I've never had the splash guard off until today. I guess at some 
> point someone had it off and managed to snag it or slice it and cut into one 
> of the wires.
> 
> So I didn't need the sensor, but at this point I've already installed it and 
> it's all oily so I can't send it back.
> 
> I soldered the wire back together and covered the splice with heat shrink 
> tubing.
> 
> Then I notice that oil is dripping from the drain plug. It was dry when I 
> removed it, and I had torqued it back to spec so what the heck. I tightened 
> it up more and more until I started to get a little uncomfortable. It has one 
> of those sealing washers that was pressed on so you can't easily remove it. 
> So I decided to run to Autozone and get a new drain plug and washer. Drain 
> oil again, install new plug, refill, and it's still leaking. I finally just 
> kept tightening it about 1mm at a time until it finally stopped.
> 
> Kicking myself for not looking at the wiring more carefully. Would not have 
> had to drain the oil or change the sensor and would have saved a lot of time 
> if I had only noticed that cut first.
> 
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