Most wheel designs make it difficult, when the car is on the ramp, why not just spend an extra 5 minutes per corner, remove the wheels, clean corrosion from spigots etc
I suspect your car works with the replcement TCU as it has no fault codes logged in it, and i don't see that you have succesfully managed to communicate or erase faults codes in the TCU
The poke through the back of the connector into the terminals, like shown in the left most image you posted. You dont poke through the insulation with them, they are as you say, like very fine needles.
You need a multimeter and some backprobe pins.
One wire (brown) will be ground. The other 2 will be signal supply and return, you need to probe them whilst its connected.
Yes should be a 5v sensor, so the supply will be 5v, and the signal will be something between 2v and 4.5v depending on...
I understand where your coming from, but I wouldn't classify an internal seal as a serviceable part. It's obviously a design flaw with the size of the cooler vs seal area but every platform has its common issue.
This is not so bad compared to the high number of common issues on the om651 engine.
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We have seen a few and your right, they are always in for damper issues and they are £££.
Also to echo the above. Definitely go for some tuning via a remap vs a tuning box
And if you pull the head to find a scored liner?
You may be able to remove from the top after undoing con rod bolts in situ but it's going to be tight.
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