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How to fix an EGT sensor for good
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07-
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sb_gli
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How to fix an EGT sensor for good
I recently purchased a 2003 allroad that was throwing codes for the egt sensors. I searched around a bit and found that some people have been able to successfully repair their egt sensors
by resoldering the 5 solder points inside of the sensor. While this seems to have worked well for one of my sensors, it did not work for the other. I still received the following code,
immediately after clearing it:
17861 - Exhaust Gas Sensor 1 (G235)
P1453 - 35-10 - Open or Short to Plus - Intermittent
So, I figured I was going to have to fork over the $250 to buy a new EGT sensor, which by reports, would probably have a similar fate a couple years down the road.
searching and found a thread where a guy replaced board (pcb) of the egt. The intent was so he could have a real time reading of his egts in cabin.
readouts here, but just want to fix my egt sensor, and slap my car out of limp . So, with a little more searching, I found a guy in Poland who makes a replacement boards
sensors. I was able to contact him through email, sent a paypal for $45, and received the new egt pcb in the a week later. Great service, fast shipping, and a cheap price for what I
hope is a permanent solution.
Time for a mini DIY:
First, it's best to remove the senor from the car completely. For the driver's side, it might be better to get do this all with the probe attached to the exhaust, since it's a real bugger to
remove.
Open the box of EGT sensor. There's a bunch of slimy silicone that was used to protect the board. Remove all of this junk. I used a toothbrush to remove what I could.
Once you've removed as much crap as you can, you'll need to remove the board from the box completely. You can use a solder gun to melt the solder and remove
one.
After the pcb has been removed, get the rest of the box as clean as possible. I used some engine cleaner and let it sit for a few minutes to break down the rest of the
Temp
the circuit
mode
circuit
Page 1 of 5How to fix an EGT sensor for good - AudiWorld Forums
10/4/2013http://forums.audiworld.com/showthread.php?t=2850845
the box with compressed air to remove most of the remaining junk, followed by a light wash down with brake parts cleaner. I then cleaned up the leads as best as I could to
extra solder. I mostly needed to do this because I attempted to fix the unit by resoldering the legs first.
Here's what the box looked like before soldering the new board in:
Next, solder in the new board. This is pretty easy, just make the wires find there way home in the middle of the leads.
Page 2 of 5How to fix an EGT sensor for good - AudiWorld Forums
10/4/2013http://forums.audiworld.com/showthread.php?t=2850845
Use something to the board to the box, double sided tape, dab of rtv, whatever. I used rtv silicone to seal the box shut again, and held it together for an hour or so with a clamp,
and reinstalled. Note: I did not encase the pcb with silicone like it was from the factory.
I started up the car, cleared , and to my pleasure, the codes did not return!!!! SUCCESS!!! WOOHOO!! I also took some logs with vagcom, and where the ECU was only ever
requesting 6-7lbs of boost before with the egt codes, it now is requesting 10-12lbs and my car has lost the sluggishness it most surely gained when the egts
And finally, here's all the information you need to know about how to order the new .
I was able to contact him via these emails:
sidaudis4@gmail.com
sd110@go2.pl
secure
the codes
circuit boards
Page 3 of 5How to fix an EGT sensor for good - AudiWorld Forums
10/4/2013http://forums.audiworld.com/showthread.php?t=2850845
Forget about buying stupid oem replacement egts for > $250 a pop that will probably fail again in the near future. Spend $45 to get a new board or $84 for both boards shipped to your
door. I still am amazed by how fast they got it shipped over here.
http://ad.doubleclick.net/N2922/jump/audiworld.tmus/category;kw=firstpost;category=Technical_Discussion__Motors__27T_V6_Discussion;topic=How%20fix
20for%
20good;sz=300x250;ord=123456789http://ad.doubleclick.net/N2922/ad/audiworld.tmus/category;kw=firstpost;category=Technical_Discussion__Motors__27T
20fix%20an%20EGT%20sensor%20for%20good;sz=300x250;ord=123456789
07-19-2013, 01:14 PM #2
ddillenger
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Very cool.
07-21-2013, 12:30 PM #3
sb_gli
Audiworld Junior Member
2003 Audi allroad
Join Date: Jul 2013
Posts: 45
Credit must be given to this audizine thread
07-30-2013, 04:56 AM #4
mtnsearch
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Join Date: Nov 2010
Posts: 14
Good write up and post!
07-30-2013, 04:56 AM
AudiWorld
Audi R8
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10/4/2013http://forums.audiworld.com/showthread.php?t=2850845
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Repurposing the CenterSun Visor! EGTs PCB with LED, Wideband , STE-PPD install.
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Thread: Repurposing the CenterSun Visor! EGTs PCB with LED, Wideband , STE-PPD install.
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Repurposing the CenterSun Visor! EGTs PCB with LED, Wideband ,
STE-PPD install.
Here is part one of the EGTs PCB with LED,
Wideband , STE-PPD install.
After not liking the results from integrating
EGT sensor displays into my rear view mirror ( to distracting when using the mirror) I was looking for other
places to mount the displays I came up with this idea. It functions great and the sun visor
can still be flipped up to move the LEDs out of the line of Vision. I was even able to get the LEDs to dim automatically when the headlights are on. They tilt to the view of the driver. They are wired to the STE-PPD so hopefully I will be able to log the exhaust gas temperatures automatically with a future firmware update. I just
have to find some red film to overlay as the red is just a bit lighter that the Stock colors.
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Page 1 of 42Repurposing the CenterSun Visor! EGTs PCB with LED, Wideband , STE-PPD install.
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Wish i would have thought of this before I wasted a mirror.
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04-25-2013 10:23 PM
Amazing...so many ideas just came to mind.
+ 1000 reps.
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Page 2 of 42Repurposing the CenterSun Visor! EGTs PCB with LED, Wideband , STE-PPD install.
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04-25-2013 10:26 PM
that is a great idea... good job
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04-25-2013 10:27 PM
Nothing like some fresh ideas. Nice work!
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04-25-2013 10:29 PM
Re: Repurposing the CenterSun Visor! EGTs PCB with LED,
Wideband , STE-PPD install.
This is amazing
Sent from my SCH-I535 using Tapatalk 2
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04-26-2013 12:04 AM
Awesome....two questions:
1. Did you also wire in a switch to turn them off when they are flipped up?
2. Where's the DIY?!
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04-26-2013 12:36 AM
That's pretty cool!
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04-26-2013 07:15 AM
very inventive, I like it!
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Page 4 of 42Repurposing the CenterSun Visor! EGTs PCB with LED, Wideband , STE-PPD install.
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04-26-2013 07:18 AM
Nice work! Add this with my meth controller in the Homelink and everything's got a home!
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04-26-2013 07:35 AM
Subscribed for the DIY.
S vier, there is a guy on Ebay right now selling a whole RS4 kit in Chicago,
might be worth checking out.
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04-26-2013 07:47 AM
nice! i was worried the backside would look shitty when viewing from outside the car but looks like some clean work
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04-26-2013 08:10 AM
Looks awesome!!
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04-26-2013 08:17 AM
I believe I am buying that tomorrow. Thanks!
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Originally Posted by SAUDI01.5
Subscribed for the DIY.
S vier, there is a guy on Ebay right now selling a whole RS4 kit in Chicago, might be worth checking out.
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04-26-2013 08:44 AM
damn, very cool/functional mounting solution!
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04-26-2013 09:19 AM
1. There is no switch but the visor functions like stock so when you tilt it back up the displays are out of view.2. I will be putting up more DIY images and instructions later tonight or over the weekend.
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Originally Posted by sa_seahawker
Awesome....two questions:
1. Did you also wire in a switch to turn them off when they are flipped up?2. Where's the DIY?!
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04-26-2013 09:25 AM
I covered the back with thin matte black neoprene and it really does not look any different than the stock visor other than the wire harness coming out the back. But there was a molding hole there already so almost like it was meant to be.
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Originally Posted by zdriver
nice! i was worried the backside would look shitty when viewing from outside the car but looks like some clean work
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04-26-2013 09:32 AM
very nice!
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04-26-2013 09:36 AM
Thanks Guys,
The added bonus of all of this is that I now not only can I see the EGTs now the ECU sees two functioning EGTs. I will be able to code back in the EGTs to have that fail safe again.
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04-26-2013 01:06 PM
If I wanted to run something like this where do you get the LCD display and what do you wire them to?
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Page 8 of 42Repurposing the CenterSun Visor! EGTs PCB with LED, Wideband , STE-PPD install.
10/4/2013http://www.audizine.com/forum/showthread.php/537525-Repurposing-the-CenterSun-Vis...
Part One - warning long
Here is part one of EGTs PCB with LED, Wideband , STE-PPD install plus re-purposing the center visor . With tips some might find handy. Warning long and lots of images.
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Page 9 of 42Repurposing the CenterSun Visor! EGTs PCB with LED, Wideband , STE-PPD install.
10/4/2013http://www.audizine.com/forum/showthread.php/537525-Repurposing-the-CenterSun-Vis...
Remove all covers as it will make it easier to solder in the engine bay and you won't crack anything by leaning on them.
Page 10 of 42Repurposing the CenterSun Visor! EGTs PCB with LED, Wideband , STE-PPD install.
10/4/2013http://www.audizine.com/forum/showthread.php/537525-Repurposing-the-CenterSun-Vis...
Remove intake, y-pipe and un-attach the coolant overflow tank and flip it out of the way.
Click this bar to view the full image.
the EGTs are bolted to the back of the manifold. Remove the harnesses and weave the cases out so you can place them on top of the manifold. We will be
soldering them in place so there is no need to remove the thermocoupler from the manifolds.
Click this bar to view the full image.
Page 11 of 42Repurposing the CenterSun Visor! EGTs PCB with LED, Wideband , STE-PPD install.
10/4/2013http://www.audizine.com/forum/showthread.php/537525-Repurposing-the-CenterSun-Vis...
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Page 12 of 42Repurposing the CenterSun Visor! EGTs PCB with LED, Wideband , STE-PPD install.
10/4/2013http://www.audizine.com/forum/showthread.php/537525-Repurposing-the-CenterSun-Vis...
This is where you need to insert a screw driver to crack open the case. It is farly brittle so take your time we will need this intact.
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Page 13 of 42Repurposing the CenterSun Visor! EGTs PCB with LED, Wideband , STE-PPD install.
10/4/2013http://www.audizine.com/forum/showthread.php/537525-Repurposing-the-CenterSun-Vis...
Interesting to note the OEM PCBs. The one on the left is not working and you can see the areas where there is corrosion on the soldered leads and on the
PCB itself. The board on the right is functioning and notice that there is no corrosion and all solder points are clean and shiny. I have tried to re-solder EGTs in the past with marginal success. I am sure the reason for that is the flaws in some go further than just the main connections. Good thing we are
replacing the boards entirely.
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Page 14 of 42Repurposing the CenterSun Visor! EGTs PCB with LED, Wideband , STE-PPD install.
10/4/2013http://www.audizine.com/forum/showthread.php/537525-Repurposing-the-CenterSun-Vis...
Now it is time to remove the Gel and the OEM PCBs from the sensor housings. This shit is a nightmare.
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Page 15 of 42Repurposing the CenterSun Visor! EGTs PCB with LED, Wideband , STE-PPD install.
10/4/2013http://www.audizine.com/forum/showthread.php/537525-Repurposing-the-CenterSun-Vis...
Once all the gel is all out it is time to solder in the new boards in place of the OEM boards. There will be two additional leads on for an additional sensor output that will be run to the LED displays and to devices like the STE-PPD
and a ground. I chose to install proper harnesses with micro amps connectors & heat shields so they could be disconnected for engine pulls. Probably a good practice for anything you hook up under the hood of these things because as you all know the engine is going to come out at some time might
as well make it easier.
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I then secured the PCBs in the cases with MG Chemicals RTV Silicone Adhesive Sealant. This is the low odor stuff made for electronics. Do not use
any old silicone. If Audi used this stuff on the original PCBs I bet I would not be writing this DIY
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Page 16 of 42Repurposing the CenterSun Visor! EGTs PCB with LED, Wideband , STE-PPD install.
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Now while the silicone is setting up its time for some takeout.
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Page 17 of 42Repurposing the CenterSun Visor! EGTs PCB with LED, Wideband , STE-PPD install.
10/4/2013http://www.audizine.com/forum/showthread.php/537525-Repurposing-the-CenterSun-Vis...
I adopted to run another harness for the addition of the STE-PPD Boost Controller. It is a good idea to run as much of the wiring as you can think of
because it is much easier once everything is all opened up. Pulling one wire is as hard as pulling 10.
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Page 18 of 42Repurposing the CenterSun Visor! EGTs PCB with LED, Wideband , STE-PPD install.
10/4/2013http://www.audizine.com/forum/showthread.php/537525-Repurposing-the-CenterSun-Vis...
Now it is time to cut the grommet on the firewall and cut the grommet on the main wiring harness as it enters the ECU weatherproof container. The ECU
grommet has four spaces right above the wire bundle that with a little working can be made to accommodate the three harnesses the vacuum line and the wideband cable.
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Page 19 of 42Repurposing the CenterSun Visor! EGTs PCB with LED, Wideband , STE-PPD install.
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Page 20 of 42Repurposing the CenterSun Visor! EGTs PCB with LED, Wideband , STE-PPD install.
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Page 21 of 42Repurposing the CenterSun Visor! EGTs PCB with LED, Wideband , STE-PPD install.
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Once all the wiring is through the ECU box you feed it through the back into the cabin. This is after you remove the kick panel under the steering column.
Lots of info on this if you have never done it. Just search hear or Google it.
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Page 22 of 42Repurposing the CenterSun Visor! EGTs PCB with LED, Wideband , STE-PPD install.
10/4/2013http://www.audizine.com/forum/showthread.php/537525-Repurposing-the-CenterSun-Vis...
As this is a three part DIY there is one common harness used by all three components. I made up this harness out of the harness from STE for the Wide
band port on the PPD, the harness for the Zeitronix ZT-3 controller and a fused harness that will provide ground and switched 12v for the ZT-3, the two LED displays and the wide band O2.
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Page 23 of 42Repurposing the CenterSun Visor! EGTs PCB with LED, Wideband , STE-PPD install.
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I then tested the displays by temporarily wiring them up inside the cabin. Everything OK.
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Page 24 of 42Repurposing the CenterSun Visor! EGTs PCB with LED, Wideband , STE-PPD install.
10/4/2013http://www.audizine.com/forum/showthread.php/537525-Repurposing-the-CenterSun-Vis...
Now for finding out where to put the LEDs. Along with sensor output from the Left and right banks there was ground, 12v switched power and a light switch controlled power to aid in the dimming function. I initially attempted to put it
in the rear view mirror but i didn't like the distraction the LEDs caused. This method is doable for any variety of displays but that is for another DIY. I opted to try putting them in the middle visor.
I cut the fronts with a sharp Exacto knife to the exact size of the displays. I positioned them tilted to the drivers view. They were then hot glued into place. The backs were cut to alow for the LEDs to protrude out the back and be soldered in place.
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Page 25 of 42Repurposing the CenterSun Visor! EGTs PCB with LED, Wideband , STE-PPD install.
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I then tapped up the front and back to get ready to fill in any gaps and truly integrate the LEDs into the visor. I used a flexible two part putty used for
spot repairing automotive bumpers and trim. Once sanded It was now off to the "spray boof for cheap ass bastards" for a prime and a coat or two of Duplicolor Trim paint. This stuff is great because it finishes with a texture matching the OEM plastic.
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Back from the Boof. I covered the back with a thin neoprene in flat black. I used double sided tape to fix the neoprene.
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I then removed the air bag cover button on the driver side column to reveal the one torx screw that with two clips are the only things holding the cover in
place. Just gently pull the cover away. Keep in mind there is an airbag in there. Its best to take off your Corduroy pants if you have Alcantara seats. No Sparks! Feed the 5 wires up through the pillar, zip tie it as you go. tuck it along the headliner and attach the leads to the visor. Once again I used AMP
style micro connectors. Screw the visor back in.
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The last thing was finding a tap for the light switch controlled power to control the dimming function of the LEDs. Another key function that is available when
this is hooked in is that by turning on and off the lights 3 times puts the displays into configuration mode. This allows for the changing of the brightness of the displays and set the alarm threshold of the buzzer if you choose to install one. The default is set to 1000 degrees.
I chose to wire the lights controlled power to the drivers side vent wheel as it is the closest source to the all of the other wiring.
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Now just button all the panels back on the kick pad and fuse panel and you are done part one of this three part install.
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This DIY was sponsored by and Captain Morgan Black
Spiced Rum
Products used in this DIY
EGT PCBs and LEDs:
http://sidmotorsport.pl/pl/search?or...search=http://
Wideband: part 2
http://http://www.zeitronix.com/Prod...t-3/Zt-3.shtml
PPD: part 3
http://www.getste.com/
Last edited by bobkatkat; 04-27-2013 at 11:04 AM.
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04-26-2013 08:23 PM
Fucking want now!!!
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04-27-2013 08:39 AM
Awesome work, thanks for keeping the mod list going.....
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04-27-2013 08:41 AM
Nice! Love the comic panel.
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04-27-2013 09:02 AM
Best spray booth I have ever seen
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04-27-2013 09:12 AM
great job!
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04-27-2013 09:27 AM
Clearly your spray booth isn't ventilated enough....how else do you explain
your altered state of mind!
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04-27-2013 09:28 AM
This is awesome!
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04-27-2013 10:20 AM
Wow . Great job ! Were did you get the boards and led displays from ?
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04-27-2013 10:24 AM
That's fuckin' cool!
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04-27-2013 10:29 AM
What is all this suppose to do?
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04-27-2013 10:58 AM
Over Proof Rum.
Sorry forgot to put that in the DIY. I will update it.
there is a fair bit going on here.
1. Permanently repair falty Exhaust Gas Temperature Sensors (EGTs)2. Potentially be able to log Exhaust Gas Temperatures through STE's PPD
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Originally Posted by airjawed
Clearly your spray booth isn't ventilated enough....how else do you explain your altered state of mind!
Originally Posted by richmonds4
Wow . Great job ! Were did you get the boards and led displays from ?
Originally Posted by
What is all this suppose to do?
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3. Have dual Exhaust Gas Temperature Gauges4. A kewl new use for the Center Sun Visor.
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04-27-2013 11:36 AM
You my good sir are a Badass
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04-27-2013 12:41 PM
WOWOWOWOW!!!!!!!!!! This is such a clean install. My hat is off to you sir. Great write up too. So detailed Im too intimidated to even start haha.
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04-27-2013 01:39 PM
Don't be intimidated by this DIY. All three parts can be done on a Sat or Sunday. That is the Zeitronix ZT-3, STE-PPD with Options and the EGT repair with LED readouts. This is a huge amount of data display, data logging,
tuning information logging and display and EGT failsafe, bang for the buck and time spent.
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Originally Posted by InglisLeslie
WOWOWOWOW!!!!!!!!!! This is such a clean install. My hat is off to you sir. Great write up too. So detailed Im too intimidated to even start haha.
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04-27-2013 01:55 PM #35
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This is great! Plenty of extra space, too. Hmm... Boost, AFR...
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04-27-2013 01:58 PM
Very cool.
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04-27-2013 02:33 PM
Boost and AFR are already in the STE-PPD, along with a bunch of other stuff.
But I am already thinking about putting some USB ports and charge plug for radar detector. Be nice not to have wires all over the place for Smartphone-Nav and radar.
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Originally Posted by trichard3000
This is great! Plenty of extra space, too. Hmm... Boost, AFR...
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04-27-2013 10:46 PM
haha, awesome DIY!
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04-29-2013 12:30 PM
Well done. It looks great.
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04-29-2013 01:17 PM
This picture was extremely helpful for someone electrically challenged such as
myself. Question though, is it necessary to have the fuse and did you tap into 75X for power? Also, what is that connector for connecting the WB 5V out to the PPD wire?
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