MadMan EMS installation - advice on fitting the sensors?

Thanks Bond. Hopefully I'll be able to get some of a TD5 install soon. I suspect that I haven't been supplied with all the correct parts (as I did not receive the EGR plate, the thermostate housing or the coolant level float to suit the TD5 which others that have bought the TD5 kit have received).

Anyways, I have installed the following:

Oil pressure sensor - just used the t-piece in where the factory oil pressure switch is located. I am concerned with how close this is to the turbo and exhaust pipe though, I put it at the best angle to get it as far away as possible, but it's still closer than I would have liked!

http://img716.imageshack.us/img716/4...g0847hn.th.jpg
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I also installed the oil temperature sensor into the automatic transmission. Originally I used the drain plug hole due to the perfect thread match, but then removed this as I was concerned about it being so low and being caught on something when 4WDing.

http://img59.imageshack.us/img59/1308/img0848t.th.jpg
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So I moved it to this location near the metal lines for the oil cooler:

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I have received the EGR plate now and so the EGT probe will go in this weekend.

The gauge itself is mounted on top of the dash in a Speco Thomas gauge mount, next to an Autometer GS boost pressure gauge:

https://www.aulro.com/afvb/
https://www.aulro.com/afvb/
https://www.aulro.com/afvb/
https://www.aulro.com/afvb/

I have received the following information regarding the coolant temperature and level setup:

Quote:

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Madman, Landy online does not make the sandwich adapter any longer, the new
inline adapter is actually better and faster to install and less risk. With
regards to the float, again easier to install and more reliable in the long
term.

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Quote:

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The black plastic hose adapter is a combination coolant level/coolant
temp sensor.

We are using this system now as it is a much more universal fitment.

The coolant level (brown wire) goes onto the M5 screw, the green wire
toes to the tag of the temp sender and a black (earth) wire goes between
the tube and the temp sender to earth the body (using the large eye lug)

Fit this in the top coolant hose.

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Quote:

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I’m a lousy photographer but here’s a pic showing the original thermo housing that now bolts up to the Madman ‘triangular’ fitting. As you can see….and have probably done yourself, you have to use other bolts that are longer. Hope this helps – sorry for the delay

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http://img705.imageshack.us/img705/684/photoufi.jpg


For anyone interested, it would seem that NATA Enterprises still sells the old style float and sandwich plate:

Nata Enterprises
Nata Enterprises

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Originally Posted by Flamin Strides

Just looking at finally installing a few temp sendors for my EMS 1.

Can you tell me if the trans oil temp fitting you moved from the drain nut to near the trans pipe lines was an exact fit, or did you have to find an adapter? If not, what did you use and how much oil dropped out - would you suggest drainin the oil completely?

I found your post and pics very helpful

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I did a oil and filter change at the same time, so not sure on how much oil would come out. However, I suspect based on it's location, not much oil should come out when the vehicle is not running as the oil should have drained back into the sump pan.

The sensor is not a straight fit for that location. I used the included adapter from Mad Man (it came in my box along with all the other sensors and hardware). Not sure what the thread type is, but if you contact Brian from Mad Man or Jan from Nata Enterprises, I'm sure they'll be able to help you and supply the adapter if required.

Hope that helps you.

Finished installing my EMS. The last part was fitting the coolant adapter with the level sensor and temperature sensor. I had already run the wiring to it when wiring up everything else:

http://img577.imageshack.us/img577/6756/img0901i.jpg

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Originally Posted by twr7cx

The gauge itself is mounted on top of the dash in a Speco Thomas gauge mount, next to an Autometer GS boost pressure gauge:

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Apologies for the thread dredge, but I figure it's better than starting a new thread for what will hopefully be a straightforward question.

Is your gauge mount the 541-02 model? If so was there any trimming required to get it looking neat?

I'm too lazy to head down to the shed to measure the EMS2 right now but it fits into the 2" or the 2 5/8" mount?

And finally, this is the more important question I'd like comments on:

Where would one mount the boost pressure sensor/sender (VDO Pressure Sender 0-2 Bar (0-29 PSI) VDO Part Number VDO360/081/032/025) ?

There are scant references on the web to the Td5 having a sensor for this. What I have found is mostly references to the Tdi engine having a part number ERR2083.

I suspect the boost pressure sender could be placed into the tubular metal section between the intercooler and turbo.

But is it going to pick up anything of value there?

RAVE page 628/1672 Section: Manifolds and exhaust systems, part 12 states:

12. Disconnect multiplugs from turbocharger
pressure sensor, ECT sensor, AAP sensor,
MAF sensor, A/C compressor and fuel injector
harness.

Thanks for any input you can offer.

The TD5's 'turbo pressure sensor' is called the manifold absolute pressure sensor (MAP). It is located in the inlet manifold and supplies a reading to the ECM, a nanocom or similar can display a reading from this sensor but as far as I know there is no way to utilise it to supply an instrument. As you seem to be aware you need to place a vdo type sensor separately to do that.

By the sounds of it the egr equipment has been removed from your engine and replaced with the ally tube you described between the inter cooler and inlet manifold -if you can tap it and place the sensor there you will get a good reading of boost pressure.

Just make sure that anything you use to secure the sensor on the inside of that tube is robust - if anything comes loose :eek:

Ian.

Quote:

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Originally Posted by mools

The TD5's 'turbo pressure sensor' is called the manifold absolute pressure sensor (MAP). It is located in the inlet manifold and supplies a reading to the ECM, a nanocom or similar can display a reading from this sensor but as far as I know there is no way to utilise it to supply an instrument. As you seem to be aware you need to place a vdo type sensor separately to do that.

By the sounds of it the egr equipment has been removed from your engine and replaced with the ally tube you described between the inter cooler and inlet manifold -if you can tap it and place the sensor there you will get a good reading of boost pressure.

Just make sure that anything you use to secure the sensor on the inside of that tube is robust - if anything comes loose :eek:

Ian.

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Hiya mools,

Thanks for your reply.

I'll post a link and an image to try and better demonstrate which bit of pipe I was referring to.

The part here shows the metal tube between the two rubber/silicon hoses. Any Td5 owner who's spent some time under the bonnet will have looked at the proximity of this pipe to the serpentine belt and said "Sheesh, that's pretty close to that". IIRC the flat spot on the pipe is there to minimise the lilelihood of the two parts making contact.

So, this metal tube could have the turbo pressure sensor tapped into it but it is actually not that thick. There would not be sufficient thread to stabilise the sensor for my liking.

I suspect that Jan has incorrectly assumed that the boost sensor as supplied will be compatible with both the Tdi and the Td5. But it's only able to be fitted to the Tdi.

Is there something I'm not seeing here that could be the spot to fit this sensor?

My EGR soot-delivery-device is still in situ...one of these days I'll get rid of it. I saw Jan has a kit for sale on the NATA site.

I ended up drilling and tapping the inlet manifold as per instructions from Jan. It's all fine now.

And even better it works.

Quote:

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Originally Posted by bell1975

Is your gauge mount the 541-02 model? If so was there any trimming required to get it looking neat?

I'm too lazy to head down to the shed to measure the EMS2 right now but it fits into the 2" or the 2 5/8" mount?

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I didn't put the EMS through either a 2" or 2 5/8" hole. I put it BEHIND the bracket. I drilled four holes around the centre hole and used the machine screws to secure it in place. Have a look at the pictures in my post above.