PEUGEOT BOXER 1.9Ltr Diesel Engine Page 21


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New Page additions: 
1.Fitting a Turbo Boost Gauge
2.Replacing clutch Cable 

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1. Fitting a Turbo Boost Gauge 2. 12 Volt Meter to monitor the charge from the alternator

Fitting a Turbo Boost Gauge


      The turbo charger boost gauge can be a useful device to indicate how the Turbo charger is working on the engine. The turbo charger produces a boost pressure for the engine which in turn increases the engine power.

      With no indication of how it's operating I decided to introduce a 'Turbo Boost' gauge to monitor this function. As my vehicle is now 11 years old anything could go wrong! So it would be nice to know if the Turbo Charger is still working. The theory principles and where to fit the device can be found on the internet.

     I purchased a gauge from an internet supplier. The gauge came with a meter and cables attached. One was for ignition voltage, one was for 'Lights On' voltage and the other was the 'Earth' connection, plus the engine tube attachment and 4mm inside diameter tubing. For this tubing came a 'T' piece to be included into pipe work.

     When it arrived I realised it had to be secured somewhere so I also purchased a'Meter Pod' which has an inside diameter of the gauge, in my case 52mm. With it was a 'Stick on' pad.

     The gauge was assembled and extra cable was attached to the meter cables, then connected to:

1. One to the fuse box, fuse F4 as this was +12 volt Ignition on voltage.
2. One to the fuse box, fuse F5 as this was +12 volt  Side lights on voltage.
3. The other wire to the earth connection.

     The 'Side lights on' voltage reduce the glare on the meter when driving with side lights on.

      One thing had me thinking was the connection to the engine and how to attach the 4mm diameter tubing. Rather than drill the Engine manifold to secure the 4mm tubing and possible swarf bits getting into the engine, I decided to fit the attachment device into the Manifold feed tube, which feeds the turbo boost from the turbo charger. This device was not supplied with the meter.

     On the internet I found these devices can be purchased for £20. Seemed a bit costly, so I made my own. This was comprised of a 8mm nut and bolt. I drilled the centre with a 2mm drill. The 'T' piece which came with the bits had a brass insert into one section. This brass piece was bell shaped with a hole which had the diameter of a single, wire brush wire.  Having drilled a 2mm hole which is too large for the function, I then hammered and peened this hole in the bolt head down until the hole was as small as the brass insert hole in the 'T' piece. In use it has proved to be very functional and gives no problems.

     Why the brass insert into the 'T' piece - which has not been used - and my peening the bolt hole. When the pressure is applied by the turbo it is rhythmic and not continuous. So by reducing the aperture into the bell shape, the air which goes into the bolt hole cannot escape as fast as the input. This then ensures the meter does not have an oscillating display.

     The tube from the engine manifold feed pipe was taken to the grommet, which protect the two tubes, which control the headlamps positioning. [Top left, looking at the steering wheel from the engine side] I drilled a hole in a blank portion of the grommet and fed the tube through. The loudspeaker panel must be removed to enable working on the tube and feeding through to the interior.

See; Removing the loudspeaker - Peug2.htm on how to removed the dash loudspeaker panel.

My home made tube connect bolt

Head bolt ground to size, with centre air pressure hole

Head bolt ground to size

Head bolt, with centre peened pressure hole.

Peened over head bolt

Prepared head bolt

Here is my connect bolt with the end files down to accept the 4mm dia. meter tube

Seen is the Turbo Bolt Connected into the tube, which feeds the Manifold, from the inter cooler.

Here is seen the Turbo Bolt Connected into the tube to the Manifold, from the inter cooler.



View of the Meter and pod attached to the steering wheel cover


Also added 12 Volt Meter to monitor the charge from the alternator

Meter cable drawing

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