Fitting Charge Pressure Guage kit to KAD42

BruceK

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This seems to be an optional component to the instrument cluster rather than essential with these engines. Certainly mine did not come with it and the workshop manual shows the attachment of a portable unit through various Volvo adapters in the special tool section.

The cost will be about £600 to fit these kits to both engines which is just about palatable in lieu of having a marine engineer on for a day to check the pressure in a one off. However I have come across a bit of a problem.

Where the parts diagram shows the sensor screws in is already in use with a pipe leading down to the top of the fuel pump. Part 41 in the second picture (Air vent hose - inlet pipe regulator. There are no other holes in the manifold. Now what?

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Mr Googler

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I’ve certainly got the holes (with bolts in currently) in th intake manifold.

I had an idea to get some cheap analog gauges and some kind of reducer fitting so I can just read the gauge on the engine. Haven’t got round to finding out the hole size or how small I would need to go for the gauge. Can’t see it being more than £50 all in for both.

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BruceK

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??? So where does your Part 41 in the second picture - Air vent hose - inlet pipe regulator from the top of the pump lead off too? That hose is only about 15cm long, not a lot of places for it to go.


From the Book of Words:
For yours you will need Special tools: 949 402, 999 6065, 999 6666...
Remove the plug/sensor installed in the intake pipe.
Install the standard nipple 949 402 in the hole.
Install nipple 999 6666 on the standard nipple.
Connect manometer 999 6065.

So maybe I should be looking for a plug of sorts??
 
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kashurst

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you can save a lot of money by buying a VDO boost pressure gauge from Demon Tweeks and a spare Volvo blanking plug from Volvo peeps. Take all the bits to local machine shop and ask them to make an adaptor.
Before you do this though make sure you are 110% happy with the fuel supply to the engines and the state of the charge air cooler and pipes. (And check your fuel valves all open % )
 

vas

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Bruce,

not familiar with your engine, but I'd expect that within the whole inlet manifold there must be a blank screw somewhere... Mine had a couple I just removed the bigger one, checked that it was indeed air inside it :D and just drilled and tapped the right size for the VDO sender I bought (must have been 50-70euro a pop)
Then wired them to the dash and fitted matching gauges (had to find matching ones I think they were 90-100euro each).
Or you just drill tap and fit a nipple thing and a longish pipe to the dash and buy a couple of analogue gauges for testing.

now since you do have this occupied hole, take the thing off, get the right thread bits and bobs and a tee and use that for both jobs! No drilling in this case, just matching the various threads and a bit of teflon tape.
Struggle to see where the 600quid are tbh

V.
 

BruceK

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Bruce,

not familiar with your engine, but I'd expect that within the whole inlet manifold there must be a blank screw somewhere... Mine had a couple I just removed the bigger one, checked that it was indeed air inside it :D and just drilled and tapped the right size for the VDO sender I bought (must have been 50-70euro a pop)
Then wired them to the dash and fitted matching gauges (had to find matching ones I think they were 90-100euro each).
Or you just drill tap and fit a nipple thing and a longish pipe to the dash and buy a couple of analogue gauges for testing.

now since you do have this occupied hole, take the thing off, get the right thread bits and bobs and a tee and use that for both jobs! No drilling in this case, just matching the various threads and a bit of teflon tape.
Struggle to see where the 600quid are tbh

V.

I dont know where the 600 quid goes either but I have to get 2 of:
Sensor 866837 1 £121,31
Gasket 957181 1 £1,16
Front ring 858643 1 £7,88
Turbo pressure gauge 873205 1 £152,03
Bulb 863946 1 £4,98
Bulb socket 863945 1 £8,73

I will certainly have a look at VDO sensors. If I know it will fit the hole and thread I will buy it as these gauges wont be in my instrument cluster for lack of space anyway. What I wont be doing is any drilling and tapping. I can be a bit kak-handed and if I fluff it man I will be crying in my hands as I buy a new extremely expensive manifold and then the Volvo gauges.
 

Mr Googler

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Red arrow is where the vacuum line goes to.

Blue arrow is where the gauge goes (bit obscured by the loom in that pic)

6D4FCC5B-EE61-4BB9-84CB-37E76FA09C55.jpg
 

BruceK

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Paul you are a gem!

Thank you sir. I shall take a skinny lunch tomorrow and whip it out and see if I can find a VDO sensor to fit ala Vas and save myself from the poor house.:encouragement:
 

Mr Googler

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:)

Please let me know the sizes etc so I can do the same.

The volvo part is only £7 each....but the postage doubles it!
 

vas

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Paul you are a gem!

Thank you sir. I shall take a skinny lunch tomorrow and whip it out and see if I can find a VDO sensor to fit ala Vas and save myself from the poor house.:encouragement:

Bruce, just googled the sensor serial # for images of it, and then a 2bar vdo.
you do that and come and tell me that the penta ones are not vdo painted green and at x2 the price...

https://www.google.co.uk/search?q=v...UIDigB&biw=1363&bih=753#imgrc=enAY9p_lFMzorM:

vs

https://vdo-webshop.nl/en/pressure-senders/394-vdo-pressure-sender-0-2-bar-1-8-27-nptf.html

it's your money, do as you wish :p

V.
 

BruceK

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Bruce, just googled the sensor serial # for images of it, and then a 2bar vdo.
you do that and come and tell me that the penta ones are not vdo painted green and at x2 the price...

https://www.google.co.uk/search?q=v...UIDigB&biw=1363&bih=753#imgrc=enAY9p_lFMzorM:

vs

https://vdo-webshop.nl/en/pressure-senders/394-vdo-pressure-sender-0-2-bar-1-8-27-nptf.html

it's your money, do as you wish :p

V.

Vas I have already said I would go for VDO as I couldn't get the gauges into my existing dash cluster so I dont have to worry about it all matching up. I am coming to realise that green paint must be very expensive after looking at turbo replacement prices for Borg Warner painted green and Borg Warner unpainted and a few other gems not excluding Ogura SC's. I have also found a nice site that seems to offer the sensor in all manner of threaded sizes so no tapping required with any luck. That is the only bit of your advice that scared me. The idea of tapping into my intake manifold was daunting. Too much risk for me.
 

vas

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That is the only bit of your advice that scared me. The idea of tapping into my intake manifold was daunting. Too much risk for me.

from the pics that FARSCO posted, it looks to me like there are more such bolts along the manifold, you could use any of them that's convenient (ie not have all the injection lines 20mm above it...).

Tapping into the manifold with the manifold in place is impossible, well it's possible, but what are you going to do with all the bits of alloy that fall down inside the manifold as you drill though? They are going to end up in the cylinders and that's not good at all.
Actually never said tap i the manifold, but in a plug that bolts onto it ;)

good luck, should be dead easy and safe to do!

cheers

V.
 

BruceK

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Dead easy for The Vas and dead easy for normal mortals are on completely different sliding scales. I have to look at something for a couple of hours in confusion until the penny drops because one thing I have learned about my boat is no job is ever simple. It took a whole day just to put in two trim ram pins which are a push fit because we couldn't get them to slide past the o-ring and the grease used to hydraulic them out was frozen to a hard paste. You could have doubled the size of the English thesaurus with the inventive curses employed yesterday.
 

BruceK

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Paul, the blanking plug is M18 by 1.5mm thread.

This is what we need:

Gauge housing
https://www.ebay.co.uk/itm/Black-Do...e=STRK:MEBIDX:IT&_trksid=p2060353.m1438.l2649

Boost Gauge:

Item Name: Turbo Pressure Gauge
Part Brand: VDO
Part Number: A2C3833490001
Color: Black
Hole: 52 mm - 2 1/16"

Sender:
Item Name: Pressure Sensor Insulated Return
Part Brand: VDO
VDO Part Number: 360-081-032-058C
Range: 2 bar
Dimension L1: 20.5mm
Dimension L2: 12mm
Thread Size: M18x1.5
Maximum pressure: 30 bar 2 sec
Operating temperature: -25 (degrees Celsius) to +100 (degrees Celsius)

Thanks for your help.

Final question

Does anybody know what the boost pressure should be? All the manual has to offer is to take readings above 3100 rpm at WOT to discount SC boost. No Tech data on what that boost reading should be.
 

Mr Googler

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1/4 NPT Female To M18x1.5 Male Reducer Oil Pressure Gauge Adapter Brass sump https://rover.ebay.com/rover/0/0/0?mpre=https://www.ebay.co.uk/ulk/itm/332453189111

1/8 NPT Female To M18x1.5 Male Reducer Oil Pressure Gauge Adapter Brass sump https://rover.ebay.com/rover/0/0/0?mpre=https://www.ebay.co.uk/ulk/itm/332453167716

Then buy a guage 1/4 or 1/8 npt off eBay. Loads of them for little money.

Could even go digital!

0-200PSI LCD Digital Tire Air Pressure Gauge Manometer For Car Truck Motorcycle https://rover.ebay.com/rover/0/0/0?mpre=https://www.ebay.co.uk/ulk/itm/192511978793

I think most senders are 1/8npt if it’s got to go in the dash.
 
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