Boost Pipe Diagram + Pressure Sender

[nickmk1]

Hi all, as the title says im looking at two questions:

What size thread is the pressure sender on the 1.8t engine? (AYP).
I have a 10 bar VDO clock and could only find this place that sells the 10 bar sender http://www.etbinstruments.com/Sensors_ancillaries.htm. Says that its "⅛"NPTF Thread"???!!

Also im trying to get hold of a diagram showing all the boost pipes and their relative position etc through search i found one for the PD150 but not for my engine. Can anyone send me one or tell me of a program i can download that will give me that information?

[email protected]

Thanks so much!

 

[ibizacupra]

if by pressure sender you mean map sensor its not a threaded sender, but bolted onto a boss.
anything direct off inlet manifold will get you pressure, eg fuel pressure regulator, and these are all small hose connections @3 to 4mm

10bar? what you exactly expecting to see

1.2bar when chipped up on a 10bar scale? 0.6 bar if not chipped?

 

[PhilW]

My guess its oil pressure sender? My sender was 1/8npt and the thread on the oil filter houseing blanked off was M10x1 iirc.

 

[UncleFester]

This is for a 2001 6K16J6 Ibiza 1.820V Cupra 2P1 Ayp engine code. If this isn't correct, pm me and i'll try and do it via VID number instead, or if you know the exact Ibiza sales model number I can do it from that. Hope this helps.

1 - 40 Nm - Coat threads with -G 052 112 A3-
2 - Seal - Renew
3 - 10 Nm - Must not be loosened
4 - Pressure unit - For charge pressure regulating valve - Can only be renewed in conjunction with turbocharger
5 - Securing piece
6 - Turbocharger
7 - O-ring - Renew
8 - 10 Nm
9 - Intake pipe
10 - Gasket - Renew - Note installation position
11 - 20 Nm
12 - Heat shield
13 - 10 Nm
14 - Banjo bolt, 30 Nm
15 - Oil supply pipe
16 - 30 Nm - Renew - Coat threads and bolt head seating surface with -G 052 112 A3-
17 - Exhaust manifold
18 - Gasket - Renew - Note installation position
19 - 20 Nm
20 - Banjo bolt, 30 Nm
21 - 25 Nm - Renew - Coat threads with -G 052 112 A3-
22 - Banjo bolt, 35 Nm
23 - Coolant return pipe
24 - 25 Nm
25 - Spacer sleeve
26 - Banjo bolt, 35 Nm
27 - 10 Nm
28 - Coolant supply pipe
29 - Banjo bolt, 35 Nm
30 - 30 Nm - Only use genuine bolt from parts catalogue
31 - Retainer - Between turbocharger and cylinder block
32 - 25 Nm
33 - Gasket - Renew
34 - Gasket - Renew
35 - 10 Nm
36 - Oil return pipe - To sump
37 - 10 Nm
38 - 10 Nm - Do not alter setting - Must not be loosened

1 - Mechanical divert valve
2 - Connecting pipe/hose - To turbocharger divert valve -N249
3 - Pressure regulating valve - For crankcase breather
4 - Connecting pipe/hose - From mechanical divert valve to upper air guide pipe
5 - To crankcase breather
6 - From air cleaner
7 - Upper air guide pipe
8 - Clamp
9 - 25 Nm
10 - 10 Nm
11 - From turbocharger outlet connection
12 - Connecting pipe/hose
13 - Connecting pipe/hose - To charge pressure regulation valve pressure unit → Item
14 - Securing clip
15 - O-ring - Renew
16 - Intake hose - To intake connection on turbocharger
17 - Charge pressure regulation solenoid valve -N75- The valve will be activated from the engine control unit (pulsed)

 

[nickmk1]

Oh balls im such a tit, OIL pressure sender..!! So did you have to do anything Phil or was it straight in?

Using MSsnf, will be going into a mk1 golf so i wont really be looking for peak power as traction will just be a joke so more of a linear power or at least best i can haha!

Thanks so much for that diagram mate, looks like im missing a few tubes nothing that cant be fixed!

 

[PhilW]

Yeah, as i said, 1/8NPT to M10x1 adaptor, i think i got it from merlin motorsport. If you look in the FAQ section and in the sticky that i done you'll fine a write up of gauges which will confirm the thread size.

 

[nickmk1]

Cheers mate!

Missing the intake to airfilter pipe (16) and hence these two: Where do i go to get them other than VW as im guessing i wont come away without much left in my bank!!

4
5
3 - Pressure regulating valve - For crankcase breather

Ill get a re-circ to replace 1

 

[Fl@pper]

no.1 is about £28 ish but use it as an excuse to get a forge one or similar

no.3 is about £12 i think from memory

 

[nickmk1]

£12, thought it was going to be about 50! Ill be sleeping well tonight! Cheers, this site has been so helpfull, very differnt to others!

 

[UncleFester]

Happy to help if I can, not much mechanical knowledge but posting pics i can manage

 

[nickmk1]

Any chance to get the coolant system diagram?
Nick

 

[UncleFester]

I can do that, but it will be when i get home later

 

[mk1golf_jack]

Sorry, Bit off topic, just out of interest are you using the 8v 020 box or a later 02j box with custom mounts?

 

[nickmk1]

Thanks Uncle!!

Will be using 8v 020 box, 02j was going to be one arse too many. Theres millions of points better about them but in the end, just want it done and im happy to change it in the future! Im making my own mount as the bloke on the cabbyvw forum is 4 weeks behind on them. Will be using a 16v clutch though, the extra 10mm of clutch might prove worthwhile
Still need that mk3 cupra throttle body, as i have one from a 33k engine. DBW.

 

[UncleFester]

1 -  15 Nm 
2 -  Toothed belt 
q    Mark D.O.R. before removing 
q    Check for wear 
q    Do not kink 
q    Removing, installing and tensioning → Chapter 
3 -  Coolant pump 
q    Check for ease of movement 
q    If damaged or leaking renew complete 
q    Removing and installing → Chapter 
4 -  O-ring 
q    Renew 
5 -  Coolant thermostat 
q    Checking: heat-up thermostat in water 
q    Opening commences approx. 87 °C  
q    Ends approx. 102 °C 
q    Opening lift min. 7 mm 
q    Removing and installing → Chapter 
6 -  O-ring 
q    Renew if damaged 
7 -  Connection 
8 -  To heat exchanger 
q    Coolant hose connection diagram → Chapter 
9 -  O-ring 
q    Renew if damaged 
10 -  Connector 
q    4-pin 
11 -  Coolant temperature sender -G62- 
q    With coolant temperature gauge sender -G2- 
q    For engine control unit 
q    If necessary release pressure in cooling system before removing 
q    Checking → Chapter 
12 -  Retaining clip 
q    Check seated securely 
13 -  To top of radiator 
q    Coolant hose connection diagram → Chapter 
14 -  Retaining clip 
15 -  Lower coolant hose 
q    From bottom of radiator 
q    Coolant hose connection diagram → Chapter 
q    Secured to radiator with retaining clip 
q    Check securely seated 
16 -  Oil cooler 
q    Removing and installing → Item 
17 -  From heat exchanger 
q    Coolant hose connection diagram → Chapter 
18 -  Coolant pipe 
q    Secured to cylinder block 
q    Coolant hose connection diagram → Chapter 
19 -  Cap 
q    Check with cooling system tester -V.A.G 1274- or -SAT 1274- and adapter -V.A.G 1274/4- 
q    Test pressure 1.4 … 1.6 bar  
20 -  O-ring 
q    Renew if damaged 
21 -  10 Nm 
22 -  Expansion tank 
q    Carry out leak test of cooling system with cooling system tester -V.A.G 1274- or -SAT 1274- and adapter -V.A.G 1274/4- 
23 -  From upper coolant pipe, lower junction 
q    Coolant hose connection diagram → Chapter 
24 -  O-ring 
q    Renew if damaged 
25 -  Connector 
q    2-pin 
26 -  From upper coolant pipe, lower junctiong 
q    Coolant hose connection diagram → Chapter 
27 -  Coolant continued circulation pump -V51- 
28 -  To turbocharger 
q    Coolant hose connection diagram → Chapter 
29 -  10 Nm

1 -  Radiator 
q    Removing and installing → Chapter 
q    After replacing renew entire coolant 
2 -  Upper coolant hose 
q    Secured to radiator with retaining clip 
q    Check securely seated 
q    Coolant hose connection diagram → Chapter 
3 -  Radiator fan  
4 -  Additional fan 
5 -  Air ducting 
6 -  10 Nm 
7 -  Bracket 
q    For radiator fan connector 
8 -  Connector 
9 -  Expansion tank 
10 -  Cap 
q    Check with cooling system tester -V.A.G 1274- or -SAT 1274- and adapter -V.A.G 1274/4- 
q    Test pressure 1.4 … 1.6 bar  
11 -  From upper coolant pipe 
q    Upper pipe insert 
q    Coolant hose connection diagram → Chapter 
12 -  To coolant pipe 
q    Coolant hose connection diagram → Chapter 
13 -  Lower coolant hose 
q    Coolant hose connection diagram → Chapter 
14 -  15 Nm 
15 -  Thermo-switch -F18-, 35 Nm 
q    35 Nm 
q    For electric fan 
q    Switching temperatures: Stage 1 on: 92 … 97 °C off: 84 … 91 °C Stage 2 on: 99 … 105 °C off: 91 … 98 °C 
16 -  Bracket 
q    For radiator 
q    Note fitting position

1 -  Turbocharger 
2 -  Cylinder head/cylinder block 
3 -  Heating system heat exchanger 
4 -  Expansion tank 
5 -  Oil cooler 
6 -  Radiator 
7 -  Coolant continued circulation pump -V 51- 
8 -  Thermostat