The first thing I noticed was that the throttle flap was binding and wouldn't return home. After removing the black epoxy covering the solder joints the new $130 Sacer sensor was covered in black epoxy all the way down the sensor and into where the DAS reads the magnet position. So that sensor was written off immediately. Time to look further as to why this throttle flap won't return. After looking down into bottom of the housing the epoxy had run down the casing and had formed a pool of black solid object in the base of the unit around the throttle flap return casing. Worse still it had run down behind the return spring assembly and appeared to be the reason for the binding of the flap.
To remove this return spring assembly meant I had to do 5 things. First I had to desolder the armature wires from the second sensor. Second I had to disconnect all 5 leads from the opposing sensor without breaking any of them. The repairer had also connected the new Sacer in PARALLEL with the old sensor without disconnecting it. Third I had to remove the brass throttle flap. Fourth I had to drill the casing to find out how the home position pins are attached (turns out they screw in with a 2mm allen) Fifth I had to remove the throttle shaft.
3 hours later I had removed the throttle shaft and removed the epoxy from behind the spring only to find that the shaft was still binding on something. The magnet was binding on the armature!! The magnet is oval and the aluminium casing around the magnet has swelled or the ETM casing had been placed in a vice and squeezed slightly to make the round armature an oval. The vernier caliper was applied and no such out of round was occurring. So back to the magnet!! By filing the aluminium casing around the magnet down and finishing with fine 800 grit I was able to stop the magnet from fouling.
I then had to recalibrate the stopper pins to prevent binding of the throttle flap against the inner housing. Reassembly a further two hours. I had been hooking up to Vida while doing this at different stages to see if it was working and fortunately was all good. I read both sensor angles and proceeded to seal the unit back up.
Rang the customer and he was pretty happy, though I had to charge for a couple more hours. I mentioned he could get a new one for around $600 but he was a 2 hour tow from a dealer so not a viable option.
There is no real moral to this story, just some friendly advice; before attempting a self-repair just take your time and follow the directions to the letter. And if you don't understand how to perform the Sacer repair really intimately don't attempt it without first logging on to this awesome forum and having a look.