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Guide: How to fit a boost gauge

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  • Guide: How to fit a boost gauge

    I finally got around to installing my Saber electronic boost gauge today, and figured why not make a 'how to' thread out of it for you all (please bare in mind, I got lazy and didn't take many photos of the wiring... sue me )

    Tools and Parts Required:

    * Good screwdriver set with torx screw bits
    * Scissors
    * Needle nose pliers
    * Soldering iron and solder
    * Lighter
    * Heat shrink (although electrical tape is fine)
    * Zip ties
    * Electrical tape
    * Sticky zip ties (can be bought at Bunnings, but look like a hook that you'd stick on a wall to mount a paining, but instead have a zip tie attached to the base. These make EXCELLENT mounting points for wires/tubes running through the cabin under the dash)

    Step 1: Engine Cover Removal

    The first step of the install is to remove the engine cover.



    To do so, there are three clips that you need to lift the cover out of (you won't break them, don't worry).



    Then just slide the cover forward out from the U shaped bracket at the back.



    Step 2: Finding the pressure regulator line and fitting the T-piece and hose

    Find the pressure regulator line below and cut it at a right angle in the middle of the line.



    At this point, I ran the hose through my firewall as it's easier to do it at this step. The grommet I used is in the passenger footwell seen here.



    I used a screwdriver to push the grommet in far enough to allow me to fit the tube through. This required me pushing the screwdriver through the grommet ~10-12cm. I then fed the tube through this point.

    You can find the exit point of this grommet behind the airbox and to the left of the ECU in the engine bay. Just slip your hand down there (I have big hands and it was a tight squeeze but I could do it) and grab it and pull it up.

    One you have the tube find a neat path to run it, or see my path in the image further down the page.

    To fit the T-piece onto the cut tubes you can do it two ways, you can put the tubes into a shot glass of boiling water and let them soften up before pushing on the T-piece, or you can use a lighter. I found the hot water trick worked well for the black fuel pressure regulator lines, but the clear boost gauge line needed the lighter to get soft. Once all three lines are connected secure them with clamps or small zip ties.



    Step 3: Dismount the center column and dash

    The panels I removed for the job were the two center console panels, I used the guide below I found elsewhere on the forums.



    The third panel I removed was the panel below and to the right of the steering wheel column, just above the shelf on the drivers side. It's a panel ~15cm x 15cm and just pops out to give access to behind the dash.

    Step 4: The wiring

    I'm going to assume you know how to wire, so instead I'm just going to tell you where the wires you need are.

    I used the 12v lighter socket for my illumination and negative lines. The illumination is the white wire, the negative the brown line, and the constant 12v on the plug is the red/yellow line.

    WARNING: Do not use the constant 12v line from the lighter socket to power your gauge, it's permanently on and will cause the gauge to eventually flatten your battery!.

    Below is the diagram of the lighter socket plug:



    Instead, for my 12v line I used a wire on the headlight controls to give my gauge it's power (particularly seeing the draw of power for the gauge is so low).

    The plug can be accessed by laying on your back in the drivers footwell and looking up behind the dash. You can then reach your hand in and release the two clips either side of the headlight plug to release it, then poke it out of the hole the removed panel has given you.

    The plug has a number of wires going into it, the wire you want to use is the wire on the far bottom right of the plug. I can't remember the color, but you can use a multimeter to check the power source if you're not sure.

    The plug looks like this, with the wire marked.



    Step 5: Enjoy the fruits of your labor

    Once all tubing and wiring is done, mount the gauge (mine came with mounting cup, mount, and double sided tape so I used that). I chose to fit mine on the steering column and have tested the position to ensure it doesn't foul with both the turning of the wheel, and that I can adjust the steering wheel for reach/rake without it fouling.

    The end product:



    I'm happy to answer any questions you guys may have. Hope this helps!
    Previous Rides: Polo GTI, Mx5 10AE, MY05 WRX WRP10, Renault Sport Clio 172
    Current Ride: Evo 8 MR, Fabia MK3

  • #2
    Nice write up mate, well done!
    sigpic
    Originally posted by Kai
    And then dont forget the most important mod for gays.
    Blow off valve - 300

    Comment


    • #3
      Nice write up!

      Few Questions as no doubt I'll want a gauge sooner or later:
      - The Vaccum hose T piece, is this supplied with the Saber unit?
      - The new length of hose is also supplied?

      Was this one expensive? Ebay?

      Comment


      • #4
        Originally posted by noone View Post
        Nice write up!

        Few Questions as no doubt I'll want a gauge sooner or later:
        - The Vaccum hose T piece, is this supplied with the Saber unit?
        - The new length of hose is also supplied?

        Was this one expensive? Ebay?
        All the tubing was supplied with the gauge. You could essentially install the gauge with only the items supplied in the kit, but I had to buy:

        * Another 3x 1m of wire
        * Cable ties
        * Electrical tape

        The gauge itself was $110 delivered from a vendor on evotuned.net, but can be bought from modyourcar.com.au for $110 plus postage for the series 1 (mine is a series 1, series 2 is ~$160 and can change color and also records your peak boost).
        Previous Rides: Polo GTI, Mx5 10AE, MY05 WRX WRP10, Renault Sport Clio 172
        Current Ride: Evo 8 MR, Fabia MK3

        Comment


        • #5
          Awesome and easy to follow write up. Very detailed and professional too. Its the epitome of all how to DIY write ups I say.

          Comment


          • #6
            Nice, I want to get a new boost gauge and I want to get one like yours. Looked at the Defi ones but quite expensive

            With my boost problems it would be good for me to have the one with the recall feature so I can see what is going on
            MODS- TOO MANY

            Comment


            • #7
              OT but logging with VAG-COM would be much easier.
              Gavin

              Originally posted by vwthunder View Post
              Nice, I want to get a new boost gauge and I want to get one like yours. Looked at the Defi ones but quite expensive

              With my boost problems it would be good for me to have the one with the recall feature so I can see what is going on
              optimumcode@gmail.com | https://www.vwwatercooled.com.au/for...i-;-79012.html | https://www.facebook.com/TTY-Euro-107982291992533

              Comment


              • #8
                Good write up, and good photos too. Must have a nice DSLR with decent lens!! (a lot of people just get DSLR, but with stock lens only!)
                06 Polo GTI - REVO Stage 2 = 140kw @ wheels.
                06 Golf GTI - Bluefin Stage 1 blacked out with ED30 theme, leather, xenon, etc.

                Comment


                • #9
                  mate that guide is awsome . possible sticky? or Diy guide?
                  " I wait I resolution derive pleasure this " latest spammer post

                  Comment


                  • #10
                    Originally posted by mikepologti View Post
                    mate that guide is awsome . possible sticky? or Diy guide?
                    Added to the Polo DIY thread at the bottom.



                    Gavin
                    optimumcode@gmail.com | https://www.vwwatercooled.com.au/for...i-;-79012.html | https://www.facebook.com/TTY-Euro-107982291992533

                    Comment


                    • #11
                      Glad to hear you guys liked it

                      Again, feel free to ask me any questions about it either in the thread of via PM

                      Originally posted by insanekiwi View Post
                      Good write up, and good photos too. Must have a nice DSLR with decent lens!! (a lot of people just get DSLR, but with stock lens only!)
                      My job on the side is actually a fashion/glamor/event photographer

                      The photography of Trevor de Vroome, an experienced Brisbane photographer specializing in Fashion/Glamor and Live Event work.
                      Last edited by break; 12-10-2009, 10:34 AM.
                      Previous Rides: Polo GTI, Mx5 10AE, MY05 WRX WRP10, Renault Sport Clio 172
                      Current Ride: Evo 8 MR, Fabia MK3

                      Comment


                      • #12
                        what pressure does a polo have when it's stock? 0.6bar or so?

                        verry good topic BTW

                        Comment


                        • #13
                          Originally posted by instigator View Post
                          what pressure does a polo have when it's stock? 0.6bar or so?
                          From what I've experienced so far it's ~9psi in most gears.

                          I've had it peak up to ~10psi a handful of times, and I've also found when the motor is cold of ambient temp is higher than 1st/2nd and sometimes even 3rd will only hit ~7-8psi until temps settle.
                          Previous Rides: Polo GTI, Mx5 10AE, MY05 WRX WRP10, Renault Sport Clio 172
                          Current Ride: Evo 8 MR, Fabia MK3

                          Comment


                          • #14
                            I still haven't figured out how some of you could just push that hose through the grommet without enlarging the hole whereas I tried for an hour but no amount of coaxing (dishwashing liquid, screwdriver, lots of swearing) could make the hose go any further than 1-2cm through - ended up routing it through the passenger footwell then down the left fender (see my old write up)

                            Chipped the car, its edging 17-18psi at peak but not quite there.... bog-standard, yes about 9psi

                            Screen grab from a quick vid...
                            Last edited by Roodosutaa; 13-10-2009, 10:37 AM.

                            Comment


                            • #15
                              TDI Boost pressure?

                              Anyone know what a 1.9 TDi boosts at?

                              Comment

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