DIY: How to fit a boost gauge on a tdi

Post by **MeanTdi** » Tue Jun 17, 2008 1:36 pm

Howzit guys,

I am trying to fit a boost gauge on a tdi. I need to drill a hole into the boost pipe. Where do i get hold of a connector from the boost pipe to the pipe that leads to the boost gauge sensor?

Thanks in advance,

Marco.

Titus · Post by **Titus** » Tue Jun 17, 2008 11:02 pm

I opeded a thread for this same thing.

try autostlying there in hans stryjdom. i think they got those t pieces for the boost pipes. im heading over there to get me a boost gauge for my soot monster.

question for you, where you gonna mount the gauge? im battling to find a place. gonna loose, my cd shuttle when i out my new head unit in and gonna see if the gauge will fit below it. your thoughts?

Post by **Neuk** » Wed Jun 18, 2008 9:45 am

Hi guys

Hold on just a second before evryone runs off and buys stuff

You cannot use a t-piece connector as supplied with the Autostyle type boost gauges as there is no central point on a TDi you can pull boost off liek on a turbocharged petrol car

What you will need to do is to drill a hole into the boost pipe which leads back to the engine intake from the intercooler

You will then need to tap a thread into this hole and buy the correct size pipe connector to fit the supplied piping as well as the thread you have just tapped

Have a look here for more explanation and pictures:

Click me!

OK - Now I am confused, as I found this and they used a t piece and pulled boost off a pipe from the intake manifold:

Click me!

Where are the experts

Cheers
Nic

Post by **MeanTdi** » Wed Jun 18, 2008 10:07 am

Titus i wrote:I opeded a thread for this same thing.

try autostlying there in hans stryjdom. i think they got those t pieces for the boost pipes. im heading over there to get me a boost gauge for my soot monster.

question for you, where you gonna mount the gauge? im battling to find a place. gonna loose, my cd shuttle when i out my new head unit in and gonna see if the gauge will fit below it. your thoughts?

Apparently you cannot use a "T" piece on a Tdi so i need a valve type bolt like on a wheel rim - almost like a bolt with a hole in it.

I have not decided on the position yet. The boost gauge is siting in the ash tray (tray removed) for now until all is working well.

Post by **Neuk** » Fri Jun 20, 2008 1:23 pm

TDi guys, have a look at this, insane work:

Click me!

De@n · Post by **De@n** » Fri Jun 20, 2008 2:54 pm

Neuk wrote:TDi guys, have a look at this, insane work:

Click me!

damn the led's look absolutely awesome!!!!!

Post by **Neuk** » Fri Jun 20, 2008 3:15 pm

De@n wrote:
Neuk wrote:TDi guys, have a look at this, insane work:

Click me!
damn the led's look absolutely awesome!!!!!

And the quality of workmanship is just insane

OEM+ is definately the way to go...

Post by **MeanTdi** » Tue Jun 24, 2008 3:18 pm

Hi guys,

i'm still having trouble finding the connection between the boost pipe going into the intake manifold on the Tdi AND the boost tube that needs to be connected that leads to the boost guage. Can anyone help?

@Shadow - what did you use? I did a search and did not find the photo of your installation?

Cheers.

Shadow · Post by **Shadow** » Wed Jun 25, 2008 7:43 pm

@MeanTDI

Howsit

Server where my pics were hosted is gone. I also bought a gauge at Autostyle that came with the T-piece and saw it wouldn't work.

I then bought one at ??(For the life of me I cant remember the name of the place. Genereic spares shop across from Mercedes in Randburg. Motorcity? someone help

) in Randburg. It came with the correct connectors. It consists of a screw type connector and tubing. I had to drill a hole and thread it. PRACTICE PRACTICE PRACTICE on a sepperate piece of plastic before you do the boost pipe. Make the hole a millimeter smaller so that you have a tight fit. Use lock tight or silicone to ensure a tight seal.
I didn't want to drill through my firewall, so I routed it behind the fender and in through a hole close to the door hinge.

Hope this helps. If you want I'll take some pics again this weekend. I have a lot of "sweating" round the connector, but I dont think it's leaking.

Post by **MeanTdi** » Thu Jun 26, 2008 4:01 pm

Thanks Shadow! Will try this week end

Post by **MeanTdi** » Tue Jul 08, 2008 10:44 am

Hey guys, anyone interested on how to fit a boost guage step by step?

babyboyvw · Post by **babyboyvw** » Tue Jul 08, 2008 10:51 am

Oh ooh ooh pick me, pick me.......

Post by **MeanTdi** » Tue Jul 08, 2008 11:41 am

Cool!

Firstly, this is a DIY installation and i am not a qualified mechanic so every thing you do is at your own risk. O.K so that's out the way.

I have highlighted some points to be careful of, but the list is not comprehensive.

The most important area point is how to connect the pipe from the boost sensor to the boost pipe. I am sure the boost pipe is expensive and there is a lot a pressure there so there is no room for error and one must ensure an air tight and strong connection. I used a cheap but logically sensible bicycle tube valve as the connection:

Prepare the valve by removing the inner valve by cutting the copper part:

Practice drilling on an old pipe 1st using a drill slightly smaller than needed. In my case i used a 5mm drill. Drill where the connector will not rub against either the engine cover or the water botle. Make sure you leave a nice path for the pipe to run to the boost guage. You can always fill gently to make the valve fit tight and to create its own thread:

Next step is fitting the prepared valve. You will need to remove the boost pipe for this by removing the engine cover and unclipping the steel clasps at each end of the boost pipe. With the boost pipe removed wash out any oil to make the job easier and cleaner. Fit the connector from inside the boost pipe:

Use a long nose plier to tighten the connector on to the boost pipe and to create a thread into the plastic. Do not over tighten the connector or it will damage the thread you have just created. Now it is very important to wash out all pieces of plastic and dirt inside the boost pipe.

Next step is to secure the connector. I used a plastic number plate bolt as the connection will be plastic on plastic. Use an "o" ring to make sure it is air tight. Do not over tighten the bolt!!:

Now connect the tube and fit a cable tie onto it so it does not come lose or leak:

Refit the boost pipe by 1st cleaning around the pipes it connects to. Do not damage the clasps!! Run the pipe to the left of the car (you facing the car head on). Now here is where you will do much cursing and swearing and wishing you never wanted to fit the guage in the 1st place!! There is not much room but you need to find a path that does not cut the pipe. Run the pipe down the fender to the gromet that is between the two door hindges:

Next is to connect up the wiring. My gauge doubled up as a volt meter so i needed power from the key, power from the battery and an earth wire. The best way to get these and the most unobtrusive way is from behind the radio. Do not cut any wires!! Use a volt meter to see which wire you need. NB!!: disconnect the battery as you will now prepare to solder. Splice into the wire and solder the wires gently on to the required wires:

Find a place to fit you guage. I wanted a place high enough but not in direct vision as it can be very distracting. I used the centre tray to rest the guage inside it:

Double tape the gauge onto the tray and run the wires under it by running just over the edge. Make sure the wires are protected and do not cut when you refit the tray:

Connect the battery. Start the engine and make sure the pipes do not leak. Protect the pipe using plastic winding protector and cable tie it so it does not rub against anything:

Now go and enjoy your boost gauge!!

Post by **MeanTdi** » Wed Jul 09, 2008 3:57 pm

*BUMP*

DIY as promised

Cheers.

Titus · Post by **Titus** » Wed Jul 09, 2008 6:05 pm

awesome write up, very well detailed. now i know how to do it

, just need to get me a gauge n decide on the place to put it.

Hey Nic, hope u read this dude.

Post by **Neuk** » Wed Jul 09, 2008 6:26 pm

Marco - Nice work bud, a true DIY job

What boost gauge is that and is it TDi specific

MeTsU · Post by **MeTsU** » Wed Jul 09, 2008 9:38 pm

Awesome post mate.

DIY FTW!

babyboyvw · Post by **babyboyvw** » Thu Jul 10, 2008 9:48 am

Thats cool man, a real DIY job.

We need to arrange a get together for the polo guys. Do a photoshoot, take a drive and talk some kak about our cars and ideas.

What say you guys???

Dingo Dynamite · Post by **Dingo Dynamite** » Thu Jul 10, 2008 11:10 am

Thanx Mean TDi. Babyboy can't that wait until I get my TDI?

Post by **MeanTdi** » Thu Jul 10, 2008 2:43 pm

Titus i wrote:awesome write up, very well detailed. now i know how to do it , just need to get me a gauge n decide on the place to put it.

Hey Nic, hope u read this dude.

Thanks Titus i, I am always available if you have any questions

Post by **MeanTdi** » Thu Jul 10, 2008 3:18 pm

Neuk wrote:Marco - Nice work bud, a true DIY job What boost gauge is that and is it TDi specific

Thanks Nic, it took lot of research and practice.

There is no Tdi specific guage - as long as it reads up to at least 2.5 bar. This one reads to 3 bar so there is room for improvement for later developments. Its cool as it shows the battery meter as well. It flashes if the boost is over 1.5 bar for more than 3 seconds so helps in letting you know if you are over doing it. Easy to read as there is the display that show the boost in figures and also the leds light up in clockwise direction. Got it from AutoStyle - its called AutoGuage. Some say their guages are not accurate, but this seems accurate. It is digital as the boost pipe goes to a unit that translates info to the main unit.

Post by **Neuk** » Thu Jul 10, 2008 3:33 pm

MeanTdi wrote:
Neuk wrote:Marco - Nice work bud, a true DIY job What boost gauge is that and is it TDi specific
Thanks Nic, it took lot of research and practice.

There is no Tdi specific guage - as long as it reads up to at least 2.5 bar. This one reads to 3 bar so there is room for improvement for later developments. Its cool as it shows the battery meter as well. It flashes if the boost is over 1.5 bar for more than 3 seconds so helps in letting you know if you are over doing it. Easy to read as there is the display that show the boost in figures and also the leds light up in clockwise direction. Got it from AutoStyle - its called AutoGuage. Some say their guages are not accurate, but this seems accurate. It is digital as the boost pipe goes to a unit that translates info to the main unit.

VDO sells gauges that don't have any vaccuum, which are more in-line with what a TDi boost gauge needs

Titus · Post by **Titus** » Thu Jul 10, 2008 3:41 pm

agreed Nic, but they certainly not the best looking guages. So im gonna skip those.

Post by **Neuk** » Thu Jul 10, 2008 3:46 pm

Titus i wrote:agreed Nic, but they certainly not the best looking guages. So im gonna skip those.

- I'll take a VDO gauge over an Autostyle anyday

Nice sleek look, rather than in your face, but cost 3x as much

MeTsU · Post by **MeTsU** » Thu Jul 10, 2008 4:12 pm

Neuk wrote:
Titus i wrote:agreed Nic, but they certainly not the best looking guages. So im gonna skip those.
- I'll take a VDO gauge over an Autostyle anyday Nice sleek look, rather than in your face, but cost 3x as much

VDO FTW!!! But you'll

when you see the prices...