Thread: Installation of various sensors in the TD5

probably no help at all, but I systematically removed all my sensors one at a time (Td5 Defender) to see what was really necessary. the only one that stopped the car was when the crank sensor was disconnected. removing one temp sensor at a time did nothing (water temp / fuel sensor) but removing both put it into limp mode

pulling both MAF and MAP didnt even go into limp mode. Not so efficient but hey you still can drive home, Basically the only sensor you need to carry in a spares kit is a $50 crank sensor

beggars the question why are people so scared of electronics

Originally Posted by technophile

Hi all,

As i have mentioned in a previous post, i have made up a micro controller to monitor 8 system parameters. Namely, Oil temperature and pressure; water temperature; transfer box temperature; EGT; boost and Volts 1 and 2.

My Defender is currently in for a service and i thought i would get them to install the sensors while they were at it. They called me up to discuss my options, and the conclusion was that it was too hard and would be too expensive, due to not having enough room, due to existing sensor; or not enough time, i.e. drilling the manifold and tapping it.

So i thought i would do it myself... how hard can it really be?

I also thought that this thread would be good to as it will cover most of the sensor people would want to install. I have answered in red what i was thinking

My two questions are:

1. where do i install the following sensors
Oil temperature and pressure;
water temperature;
transfer box temperature;
EGT;
boost.

all threads are 1/8 NPT

2. what additional things do i need so that i also keep the factory sensors.

I have attached images of the sensors i have for your reference.

Thoughts so far:
Oil Pressure - i will use the OEM oil switch location (m10x1 thread), and have a braided extension, then a t-piece to have both the switch and sensor
EGT - Drill and thread exhaust manifold
Boost - tap into hose between intercooler hose and the turbo wastegate with a t - piece


I look forward to your input

Tee into the wastegate control hose for boost.

I would forgo the use of hoses to extend the oil pressure temp sensor port, if you can get a brass section to give you the extra port you require I'd go that way. Same for the water temp sensor at the elbow/flange attached to the head to connect to the radiator hose.

EGT sensor will need a thermocouple amplifier, I don't know if you need a voltage or current sensor, I have just used the display I got from an instrumentation supplier that I got the K thermocouple from.

This is the sort of brass fitting I mean.

I drilled & tapped the filler plugs for engine & gearbox/transfer oil temps.
Works just fine. You could argue with the engine that the sensor is too low but all is relevant. Not too sure how exposed the wire will be - yet to go bush..

Hey guys, just a bump to this thread.

I am finally getting around to installing the sender units and connecting everthing up.

I am getting the coolant adapter plate for coolant temps; have plumbed in boost; and will be using the EGR removal blate to install EGT probe, may eventially tap the manifold.

My questions are, for the oil pressure do i need to use an extension hose, or will the OEM pressure switch and pressure sender fit directly to the engine via a t-piece.

Also where do i fit the engine oil temp sender, and do i need an adapter, like a plug or a oil filter sandwich adapter?

finally what thread size is the transfer case plug, M14?

Thanks