MadMan EMS installation - advice on fitting the sensors?

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Originally Posted by bell1975

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.

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The problem with utilising this point in the inlet system is that your boost pressure readings will be post-turbo, but pre-intercooler, resulting in readings higher than that which is actually going into the engine - the reason for this is that some pressure is lost due to the length/volume of the intake pipes and the heat/pressure drop caused by the intercooler.

Really you want to get a reading from inside the inlet manifold. I have drilled a hole through and welded a nut onto my EGR replacement on the inlet manifold (wasn't comfortable hacking up the cast manifold).

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Originally Posted by twr7cx

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.

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Yes, I see that now. Thanks for clarifying your install. I ended up buying one of these mounts - it will sit to the right of the instrument binnacle on either a bit of velcro or maybe an 'L' bracket that is secured underneath the pillar trim. Photo to follow.

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Originally Posted by twr7cx

The problem with utilising this point in the inlet system is that your boost pressure readings will be post-turbo, but pre-intercooler, resulting in readings higher than that which is actually going into the engine - the reason for this is that some pressure is lost due to the length/volume of the intake pipes and the heat/pressure drop caused by the intercooler.

Really you want to get a reading from inside the inlet manifold. I have drilled a hole through and welded a nut onto my EGR replacement on the inlet manifold (wasn't comfortable hacking up the cast manifold).

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i ended up tapping the inlet manifold to the rear of the MAP sensor. The casting has left a flattened round section about 30mm diameter that suited the task.

What setting are you guys running on your EM2/EM1's for the low coolant alarm? I have had trouble setting mine up. I can't remember the actual settings but the alarm was constantly going off saying I had low water. I didnt. So I reduced the sensitivity of the sensor until it 'just' didn't go off all the time. I thought that this was the optimum setting but after replacing the intercooler and mistakenly putting a hose back in the wrong spot, my fan wore a hole through the bottom radiator hose:angel:. Whoops! The first thing I knew about it though was steam coming out from under the hood :mad:. No bloody low coolant alarm! The car didn't get hot though as I was on a test run and only 5 minutes from home.

So just something to be aware of and the reason why I'm asking about the settings you have used. I've installed my adaptor in the same place as twr7cx so it should have been at the 'top' or highest point of the radiator hose too. Not happy. My old sensor from dave at the AULRO shop on my old defender didn't need calibrating and worked a treat when I split a hose. I think the EMS may be overcomplicating things for a dufus like me maybe? I'm thinking of going back to dave's sensor for low water as it was a lot more reliable than the EMS. Although I might just not know how to set up the settings. :D

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Originally Posted by gusthedog

What setting are you guys running on your EM2/EM1's for the low coolant alarm? I have had trouble setting mine up. I can't remember the actual settings but the alarm was constantly going off saying I had low water. I didnt. So I reduced the sensitivity of the sensor until it 'just' didn't go off all the time. I thought that this was the optimum setting but after replacing the intercooler and mistakenly putting a hose back in the wrong spot, my fan wore a hole through the bottom radiator hose:angel:. Whoops! The first thing I knew about it though was steam coming out from under the hood :mad:. No bloody low coolant alarm! The car didn't get hot though as I was on a test run and only 5 minutes from home.

So just something to be aware of and the reason why I'm asking about the settings you have used. I've installed my adaptor in the same place as twr7cx so it should have been at the 'top' or highest point of the radiator hose too. Not happy. My old sensor from dave at the AULRO shop on my old defender didn't need calibrating and worked a treat when I split a hose. I think the EMS may be overcomplicating things for a dufus like me maybe? I'm thinking of going back to dave's sensor for low water as it was a lot more reliable than the EMS. Although I might just not know how to set up the settings. :D

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I'll cut/paste from the install instructions from Madman below. It sounds like you need to revisit your setup screen. Off the top of my head I can't recall what I have set mine up with sorry. I'll check after work and post back.

If you want the 16 page EMS install document you can find it here.

I have just installed my EMS2 low coolant alarm, I'm writing detailed install instructions as I go. I just tested it with the engine cold by draining coolant, drained about 1 litre (mostly from header tank) before the alarm sounded. This was with sensitivity of 10, interestingly I reduced the sensitivity down to 1 and the alarm was still active which is good. My settings are:

Time=0 Sensitivity=10

Cheers
Marc

Quote:

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Originally Posted by Mattblack59bus

I have just installed my EMS2 low coolant alarm, I'm writing detailed install instructions as I go. I just tested it with the engine cold by draining coolant, drained about 1 litre (mostly from header tank) before the alarm sounded. This was with sensitivity of 10, interestingly I reduced the sensitivity down to 1 and the alarm was still active which is good. My settings are:

Time=0 Sensitivity=10

Cheers
Marc

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Thanks for posting this up Marc. You've prompted me to look back at my settings as I completely can't recall what I set mine to...and it only got installed last week! Maybe I just left it at the default settings.

I'm curious to know where and how you've elected to mount the gauge.

I mounted my gauge in the top console, where the sunroof switches normally are. I'll have the full detail in my instructions (in the project section). But I'll post a pic here too.

Cheers
Marc.

I have just gotten around to fitting the boost sender. Its a VDO fitted into a EGR replacement pipe on the inlet manifold.
Grey wire and an earth wire have been ran to the sensor. But the guage is reading massive numbers. Just sitting in the drivway loading up the transmission in reverse, I can easily get to 80psi.

In settings should I have the sender set to - VDO2?

I will post up pictures shortly.

I have one of the older EMS low coolant alarms with the float arm that fits into the expansion tank.It was intended for a 300tdi but will now fit to a TD5.Looking at the photo of the inline hose fitting,its looks a little low in relation to the head ie below the bleed screw.I think it is possible to just have a couple of stainless screws in the expansion tank....doing the same job.I hope there is no electrolysis from this set up?

Hi there - any chance of some more pics guys? I'm about to fit to a TD5 defender and would love to see how / where you've installed the Boost sender - yes for Madman EMS2