[Sfds]

Thanks to those who took a look at this thread. I’ve done some more work this morning and found the problem. It’s the Dayco tank. There’s a manufacturing fault with it; a thin protruding seam of plastic lines the side of the “sensor chamber” and prevents the float from lifting. I poked my finger in the sensor hole of a genuine Ford header tank I got with one of the sensors. The sides were smooth … no interference for the float at all. By comparison, the Dayco DET0002 tank had a plastic protrusion that got in the way of the float doing its job. As best I could, I bent the seam down with my fingers. The sensor then worked instantly when I started the car. The warning light was off! Over time, I’m wondering if the plastic seam fault will move back to where it was and this time prevent the float from lowering if there’s a loss of coolant! I’ve had good stuff from Dayco in the past, but I’m disappointed in this header tank. This has cost me a bit in time and money, but the job’s now done.