Hdi boost gauge installtion guide

1. First thing you should do is remove the air box and top pipe. This gives you a little bit more room to work. Then take the breather pipe off the top of the crankcase cover, and undo the bolt that fixes the intake pipe to the L-bend/Elbow.

2. You then have to undo the two 13mm nuts and the 2 torx bolts that fix the elbow to the manifold. You can't see them all, but the nuts are located towards the front and back of the intake pipe, and the torx bits at the top and bottom of the EGR pipe.

3. You then have to undo the jubilee clip on the hose at the bottom. This is tricky to get into but if you have small hands its slightly easier.

4. The Elbow should just pull off now with a bit of wiggling. If it's too difficult you haven't loosened the jubilee clip enough. This is what it will look like when you have it off. I have tried to highlight the amount of sh*te that is built up around the EGR pipe, compared with the inlet to the elbow. It just shows what the EGR is recirculating back through the engine!!


inlet before a clean


outlet before a clean


5. I cleaned up the pipe with some diesel and a paintbrush. It wasn't perfect but it was a lot better to say the least. This is the outlet after a cleanup:


6. On the back of the Elbow there was a little round flat bit, which seemed the perfect spot to drill and tap for the take off. I'm not sure the exact size of drill i used, but it worked. You could use any type of take-off but the one I had came with my old boost gauge and had a 1/4" BSF thread, and the size of drill you should use for this is 5.3mm. I put some PTFE tape around the top of the thread, and some threadlock on it. This is what it looked like once i'd fixed it in:



7. It was then just a case of attaching the pipe to the take-off, then re-fitting the elbow. Before i fitted it i cleaned up the surface of the manifold to make sure there wasn't going to be any leaks. The torx bits are a pain in the arse to get back in so do them first. It's because the EGR pipe moves when you take the elbow off so you have to try and line it up again. After that's on just re-fit everything and it's done. Next thing is getting the pipe into the car.

8. I had actually run the pipe through a big grommet in the passenger footwell, it's probably the one everyone uses for amp cable etc. I drilled the hole from in the car, and pushed the pipe through to the engine bay and just pulled through what length I needed. All you have to do is mount the gauge somewhere, I made a Pod in the centre heater vents.