Paul1985
04-04-2008, 05:55 PM
Disclaimer: The following is provided as a GUIDE ONLY, and neither myself nor Ozhonda take any responsibility for the outcomes of someone else doing the following. You follow these steps at your own risk!
Aim: To setup your coolant temp sensor the easy way, no need for a fan switch and no need to order a radiator hose insert from the states or have anyone weld in a bung on your radiator. This is cheap, simple and you can get the parts/tools locally.
Required:
Firstly, you MUST have K-pro for this to work.
You also need an EG coolant temp sensor.
Tools:
- Vice Grips.
- Hammer.
- Pedastool Drill (It may be possible with a power/cordless but i wouldnt try it).
- 8.5mm / 9mm drill bit. You should be able to use either, I used a 9mm.
- 1/8" BSP tap. (Could also use a 1/8" NPT tap supposedly).
- Small/Medium sized shifter.
- 12mm open end spanner.
- 12mm socket and long extension.
- Soldering iron.
- Wire strippers.
Materials:
- Rag.
- Teflon Tape.
- Solder.
- Butt terminal connector
- Wire (approx 2 - 3 metres). You can cut it to size.
- Electrical tape, heat shrink, wire covering. (All optional depending how you want to tidy up your wiring)
Heres most of the tools/materials you will be using:
http://i16.photobucket.com/albums/b35/Paul_K_1985/zzzz105.jpg
Steps:
1. Firstly you will need to remove the housing which you will be installing the sensor into. Ensure you have no coolant in the engine. You can see where it is located on the K24A engine in my pics (step 9), on a K20A engine it is located on the front of the engine rather than the side but there is no difference in the procedure. It has two 12mm nuts and two 12mm bolts holding it in. You may have a coolant pipe in the way you will need to loosen, that's no big deal though. Do not lose the gasket when you remove this.
2. Now you need to somehow remove the vacuum barb. I used vice grips on it and hammered the vice grips which removed it quiet easily. This is a pretty dodgy way to do it, but it works. The barb is in the grips in this pic.
http://i16.photobucket.com/albums/b35/Paul_K_1985/zzzz079.jpg
3. Now you will need to set up the pedastool drill with your housing in the vice and install your drill bit (I used a 9mm, you could use a 8.5mm too, check the tap and drill chart in the link i provided below). Drill out the hole and remove the housing from the drills vice.
http://i16.photobucket.com/albums/b35/Paul_K_1985/zzzz083.jpg
4. Setup the housing in the bench vice. I used a rag so the jaws wouldnt damage the housing too much. Now get your 1/8" BSP tap (you should put some tap lube/grease on it). Start threading the tap in the hole and keep it as vertical and straight as you can. Use a shifter to thread it and every 2 or 3 turns back it off a turn and then keep going. Keep going until you have tapped an adequate sized thread in the housing. Remove the tap and clean the junk off it and blow out any shavings left in your new thread and/or housing.
http://i16.photobucket.com/albums/b35/Paul_K_1985/zzzz085.jpg
5. Check that your coolant temp sensor will thread into it by just starting to thread it in slightly by hand. Remove the sensor and add some teflon tape too it. Do not use too much. Also, when putting the teflon tape on, think about the way you wrap it around the thread as if you do it.
http://i16.photobucket.com/albums/b35/Paul_K_1985/zzzz087.jpg
http://i16.photobucket.com/albums/b35/Paul_K_1985/zzzz088.jpg
6. Now get your 12mm spanner and carefully tighten the sensor up. Do not forget this housing is made of aluminium so it does not need to be overly tight. You will be amazed at how easily you could damage your new thread.
http://i16.photobucket.com/albums/b35/Paul_K_1985/zzzz090.jpg
7. Now get your butt connector, wire strippers and your wire. Strip a small part off the end of the wire, insert it into the connector and then use your strippers to clamp the end of the butt so the wire is secured.
http://i16.photobucket.com/albums/b35/Paul_K_1985/zzzz091.jpg
http://i16.photobucket.com/albums/b35/Paul_K_1985/zzzz092.jpg
http://i16.photobucket.com/albums/b35/Paul_K_1985/zzzz093.jpg
8. Bolt your housing back on the engine, ensure the gasket is put back on or replaced if need be.
9. Install the connector onto your sensor.
http://i16.photobucket.com/albums/b35/Paul_K_1985/zzzz108.jpg
10. Route the wiring along with the Engine harness into the cabin and to your ECU.
11. Solder the wire into the appropriate wire on your conversion harness (most likely labelled "coolant sending unit"). Also solder the wire on your conversion harness which is intended for the fan switch (most likely labelled "fan switch") into pin 7 of your C101 K-series engine harness, it is a solid green wire. Plug C101 is the large plug on your engine harness which if you are using a hybrid-racing conversion harness, plugs into the large blue conversion harness plug. This pic shows the plug, i am holding the wire you need to solder into.
http://i16.photobucket.com/albums/b35/Paul_K_1985/zzzz096.jpg
12. Clean up your soldered wire and neated it all up with tape/heat shrink/wire covers. However you choose.
Done! Hope this helps someone.
Other comments:
Here is a good Tap and drill chart so you can see what size drill bits you are supposed to use.
http://www.newmantools.com/taps/bsp.htm
And here is where I got the wiring information for this setup, plenty more info on this in here:
http://www.k20a.org/forum/showthread.php?t=21923
Aim: To setup your coolant temp sensor the easy way, no need for a fan switch and no need to order a radiator hose insert from the states or have anyone weld in a bung on your radiator. This is cheap, simple and you can get the parts/tools locally.
Required:
Firstly, you MUST have K-pro for this to work.
You also need an EG coolant temp sensor.
Tools:
- Vice Grips.
- Hammer.
- Pedastool Drill (It may be possible with a power/cordless but i wouldnt try it).
- 8.5mm / 9mm drill bit. You should be able to use either, I used a 9mm.
- 1/8" BSP tap. (Could also use a 1/8" NPT tap supposedly).
- Small/Medium sized shifter.
- 12mm open end spanner.
- 12mm socket and long extension.
- Soldering iron.
- Wire strippers.
Materials:
- Rag.
- Teflon Tape.
- Solder.
- Butt terminal connector
- Wire (approx 2 - 3 metres). You can cut it to size.
- Electrical tape, heat shrink, wire covering. (All optional depending how you want to tidy up your wiring)
Heres most of the tools/materials you will be using:
http://i16.photobucket.com/albums/b35/Paul_K_1985/zzzz105.jpg
Steps:
1. Firstly you will need to remove the housing which you will be installing the sensor into. Ensure you have no coolant in the engine. You can see where it is located on the K24A engine in my pics (step 9), on a K20A engine it is located on the front of the engine rather than the side but there is no difference in the procedure. It has two 12mm nuts and two 12mm bolts holding it in. You may have a coolant pipe in the way you will need to loosen, that's no big deal though. Do not lose the gasket when you remove this.
2. Now you need to somehow remove the vacuum barb. I used vice grips on it and hammered the vice grips which removed it quiet easily. This is a pretty dodgy way to do it, but it works. The barb is in the grips in this pic.
http://i16.photobucket.com/albums/b35/Paul_K_1985/zzzz079.jpg
3. Now you will need to set up the pedastool drill with your housing in the vice and install your drill bit (I used a 9mm, you could use a 8.5mm too, check the tap and drill chart in the link i provided below). Drill out the hole and remove the housing from the drills vice.
http://i16.photobucket.com/albums/b35/Paul_K_1985/zzzz083.jpg
4. Setup the housing in the bench vice. I used a rag so the jaws wouldnt damage the housing too much. Now get your 1/8" BSP tap (you should put some tap lube/grease on it). Start threading the tap in the hole and keep it as vertical and straight as you can. Use a shifter to thread it and every 2 or 3 turns back it off a turn and then keep going. Keep going until you have tapped an adequate sized thread in the housing. Remove the tap and clean the junk off it and blow out any shavings left in your new thread and/or housing.
http://i16.photobucket.com/albums/b35/Paul_K_1985/zzzz085.jpg
5. Check that your coolant temp sensor will thread into it by just starting to thread it in slightly by hand. Remove the sensor and add some teflon tape too it. Do not use too much. Also, when putting the teflon tape on, think about the way you wrap it around the thread as if you do it.
http://i16.photobucket.com/albums/b35/Paul_K_1985/zzzz087.jpg
http://i16.photobucket.com/albums/b35/Paul_K_1985/zzzz088.jpg
6. Now get your 12mm spanner and carefully tighten the sensor up. Do not forget this housing is made of aluminium so it does not need to be overly tight. You will be amazed at how easily you could damage your new thread.
http://i16.photobucket.com/albums/b35/Paul_K_1985/zzzz090.jpg
7. Now get your butt connector, wire strippers and your wire. Strip a small part off the end of the wire, insert it into the connector and then use your strippers to clamp the end of the butt so the wire is secured.
http://i16.photobucket.com/albums/b35/Paul_K_1985/zzzz091.jpg
http://i16.photobucket.com/albums/b35/Paul_K_1985/zzzz092.jpg
http://i16.photobucket.com/albums/b35/Paul_K_1985/zzzz093.jpg
8. Bolt your housing back on the engine, ensure the gasket is put back on or replaced if need be.
9. Install the connector onto your sensor.
http://i16.photobucket.com/albums/b35/Paul_K_1985/zzzz108.jpg
10. Route the wiring along with the Engine harness into the cabin and to your ECU.
11. Solder the wire into the appropriate wire on your conversion harness (most likely labelled "coolant sending unit"). Also solder the wire on your conversion harness which is intended for the fan switch (most likely labelled "fan switch") into pin 7 of your C101 K-series engine harness, it is a solid green wire. Plug C101 is the large plug on your engine harness which if you are using a hybrid-racing conversion harness, plugs into the large blue conversion harness plug. This pic shows the plug, i am holding the wire you need to solder into.
http://i16.photobucket.com/albums/b35/Paul_K_1985/zzzz096.jpg
12. Clean up your soldered wire and neated it all up with tape/heat shrink/wire covers. However you choose.
Done! Hope this helps someone.
Other comments:
Here is a good Tap and drill chart so you can see what size drill bits you are supposed to use.
http://www.newmantools.com/taps/bsp.htm
And here is where I got the wiring information for this setup, plenty more info on this in here:
http://www.k20a.org/forum/showthread.php?t=21923