Erratic EGT on Madman





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  1. #1
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    Default Erratic EGT on Madman

    Just took a drive now and saw that I now have an erratic EGT reading.

    It's all over the place 200°C to 1200°c and back in a matter of seconds.

    Driving at 90Km/h in 5th gear.
    No other issues and everything sounds fine.

    So where do I start?
    Thermocouple wiring?
    '07 Land Rover Defender 110 TDI 300 Kalahari (Meisiekind˛)
    '84 Land Rover Defender 110 V8 4-speed Hardtop (Meisiekind) Sold after 12 years of fun and hard work.
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  2. #2
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    Default Re: Erratic EGT on Madman

    My Water temp reading is also jumping 5 or so degrees.

    From what I have read the first place to start is the earthing points.
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  3. #3
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    Default Re: Erratic EGT on Madman

    Mine just gave a message "Check sensor"

    So might be probe or wiring.
    '07 Land Rover Defender 110 TDI 300 Kalahari (Meisiekind˛)
    '84 Land Rover Defender 110 V8 4-speed Hardtop (Meisiekind) Sold after 12 years of fun and hard work.
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    Default Re: Erratic EGT on Madman

    Earth and where that flimsy paddle clip attach to the probes.
    I was forever having to crimp them tighter, in an effort to avoid that horrifying shock and sinking feeling when that peep-peep-peep starts!
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  5. #5
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    Default Re: Erratic EGT on Madman

    Jfh

    On the egt reading mine does that every now and then and a good squeeze / push of the connector block coming into the madman unit fixes it

    On the erratic water reading the connector on the actual sensor is probably a spade terminal - just nip it up with a pair of pliers or a bit of a twist also helps

    I wish they had left a hole in the top of the water temp sensor so one could screw it in place instead of relying on the spade terminal retaining its stiffness

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  7. #6
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    Default Re: Erratic EGT on Madman

    All other readings stable, so I'll check out the thermocouple wiring harness and connections.

    Thanks.
    Hopefully easy fix.
    '07 Land Rover Defender 110 TDI 300 Kalahari (Meisiekind˛)
    '84 Land Rover Defender 110 V8 4-speed Hardtop (Meisiekind) Sold after 12 years of fun and hard work.
    The only thing needed for evil to triumph is for a good man to do nothing.

  8. #7
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    Default Re: Erratic EGT on Madman

    Quote Originally Posted by RossJ View Post
    Jfh

    On the egt reading mine does that every now and then and a good squeeze / push of the connector block coming into the madman unit fixes it

    On the erratic water reading the connector on the actual sensor is probably a spade terminal - just nip it up with a pair of pliers or a bit of a twist also helps

    I wish they had left a hole in the top of the water temp sensor so one could screw it in place instead of relying on the spade terminal retaining its stiffness
    Mine does the same on the boost sensor connector. Fiddling with the cable block sorts it out. And I havr had a look at the plug to if there is something I can fix, but can't find anything. Not very impressed with the plug on the rear of the madman, nearly all the wires are stripped back too far, so you have a tiny bit of copper exposed outside of the rear of the block. I thought of setting it in some resin, but with my luck, I set it in the faulty position, and that will be the last time I have a boost gauge.
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  9. #8
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    Default Re: Erratic EGT on Madman

    Removed the plug behind the display and sprayed with contact cleaner.

    After test drive everything seems fine.

    Thanks for helping.
    '07 Land Rover Defender 110 TDI 300 Kalahari (Meisiekind˛)
    '84 Land Rover Defender 110 V8 4-speed Hardtop (Meisiekind) Sold after 12 years of fun and hard work.
    The only thing needed for evil to triumph is for a good man to do nothing.

  10. #9
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    Default Re: Erratic EGT on Madman

    I did not spray anything. I just wiggel it a bit and then it is fine again.
    Quote Originally Posted by jfh View Post
    Removed the plug behind the display and sprayed with contact cleaner.

    After test drive everything seems fine.

    Thanks for helping.

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  12. #10
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    Default Re: Erratic EGT on Madman

    Did some driving today, 50% gravel and the fault is back.

    Tomorrow I will check the thermocouple connections as well as the plug again.
    Last time it also came up with some gravel travel.
    '07 Land Rover Defender 110 TDI 300 Kalahari (Meisiekind˛)
    '84 Land Rover Defender 110 V8 4-speed Hardtop (Meisiekind) Sold after 12 years of fun and hard work.
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  13. #11
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    Default Re: Erratic EGT on Madman

    I removed those stupid crimp connectors and soldered the wires.
    I must admit the thermocouple wires didn't solder that easily and after soldering my EGT was at -34°C.

    All was back to normal after a smoke break.

    The pins on the display and the multi plug were cleaned with a very fine wire and screwdriver. I could see the change in colour as I removed some deposit on them.
    Only time will tell if this was successful.
    '07 Land Rover Defender 110 TDI 300 Kalahari (Meisiekind˛)
    '84 Land Rover Defender 110 V8 4-speed Hardtop (Meisiekind) Sold after 12 years of fun and hard work.
    The only thing needed for evil to triumph is for a good man to do nothing.

  14. #12
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    Default Re: Erratic EGT on Madman

    Nope! I wasn't successful.

    Maybe it's the probe. I'll contact Madman and hear what they think.
    '07 Land Rover Defender 110 TDI 300 Kalahari (Meisiekind˛)
    '84 Land Rover Defender 110 V8 4-speed Hardtop (Meisiekind) Sold after 12 years of fun and hard work.
    The only thing needed for evil to triumph is for a good man to do nothing.

  15. #13
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    Default Re: Erratic EGT on Madman

    Brian Cotton from Madman just answered my query and confirmed that my thermocouple is shot.
    '07 Land Rover Defender 110 TDI 300 Kalahari (Meisiekind˛)
    '84 Land Rover Defender 110 V8 4-speed Hardtop (Meisiekind) Sold after 12 years of fun and hard work.
    The only thing needed for evil to triumph is for a good man to do nothing.

  16. #14
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    Default Re: Erratic EGT on Madman

    Okay... So here's my current way of thinking.

    The original way of fitting the thermocouple is at 90° to the blanking plate.

    Click image for larger version. 

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    For the thermocouple to go to the right place it has to be bent.

    Click image for larger version. 

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    This might lead to the thermocouple failing. I never felt comfortable with bending it and it looks like it can be done.

    Click image for larger version. 

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    So my next project will be to make a blanking plate that can hold an unbended thermocouple onto the right position.
    Something like this.

    Click image for larger version. 

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    Last edited by jfh; 2020/08/24 at 08:07 PM.
    '07 Land Rover Defender 110 TDI 300 Kalahari (Meisiekind˛)
    '84 Land Rover Defender 110 V8 4-speed Hardtop (Meisiekind) Sold after 12 years of fun and hard work.
    The only thing needed for evil to triumph is for a good man to do nothing.

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  18. #15
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    Default Re: Erratic EGT on Madman

    Mine is also too long to fit in its spot, but I was told it can protrude out the back a bit. I drove out to their workshop and checked with them that it is acceptable. What I was worried about, was that the probe bottomed out against the opposite wall, and could possibly pick up some shock or unfair vibration from being seated too deep. So I insert mine, and lift it out a "smidge".

    What was a shock for me in February, was, on replacing my probe, I could not extract it from its fitting as it had melted into a blob which could not pass through the hole. To add insult to injury, the darn screw in fitting stripped, and for no love or money could I get it out of its hole. In fear of leaving something behind in the manifold, I had to strip off the turbo to access the pickup from inside. It was mounted in a horrible place, so I took the oppertunity to weld up the old hole, and drill and tap a new one on a much thicker portion of the outlet right on the turbo flange.
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  19. #16
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    Default Re: Erratic EGT on Madman

    So to do this...
    Click image for larger version. 

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    I'll need to get the correct angle for the thermocouple.

    So I made this.
    Click image for larger version. 

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    I know! It ain't pretty, but it must only work for 10 minutes.
    The pin swivels on a shaft so that I can determine the angles where the pin touches the top and bottom of the manifold.
    I'll get the centre of the 2 angles to place the thermocouple.

    I don't want to thumb suck this.
    '07 Land Rover Defender 110 TDI 300 Kalahari (Meisiekind˛)
    '84 Land Rover Defender 110 V8 4-speed Hardtop (Meisiekind) Sold after 12 years of fun and hard work.
    The only thing needed for evil to triumph is for a good man to do nothing.

  20. #17
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    Default Re: Erratic EGT on Madman

    Most thermocouples can be bent a reasonable degree.
    Most have the sensing part at the very tip.
    Inside is two wires of different metals
    Inside those wires are protected normally by a powdery substance.
    So a careful bend will do nothing wrong.
    A very sharp bend with pliers will give you problems and kink.
    So the two different metals are joined at the very tip.
    Mine in the Kalahari is bent and running a few years without issues.
    Are we using type K or type J thermocouples.
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  21. #18
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    Default Re: Erratic EGT on Madman

    K-type.

    I know they can be bent. I just don't like it and it gives me a new project to keep me busy with.
    '07 Land Rover Defender 110 TDI 300 Kalahari (Meisiekind˛)
    '84 Land Rover Defender 110 V8 4-speed Hardtop (Meisiekind) Sold after 12 years of fun and hard work.
    The only thing needed for evil to triumph is for a good man to do nothing.

  22. #19
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    Default Re: Erratic EGT on Madman

    Mmmm. Typical Kalahari owner. You do realise i have to copy you AGAIN
    Quote Originally Posted by jfh View Post
    K-type.

    I know they can be bent. I just don't like it and it gives me a new project to keep me busy with.
    Defender Kalahari
    Series 3 SWB
    Series 1 De Luxe Cab Pickup
    Series 1 Station Wagon 88''

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  24. #20
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    Default Re: Erratic EGT on Madman

    Click image for larger version. 

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    This is where it failed. It's about 100mm from the base of the thermocouple.

    So I assume it's because of vibration/chaffing.

    Now as I'm not the richest guy around and I have time on my side, I'll try a repair until I can buy a new one.

    I've tested it off vehicle,now I'll install it and see.
    '07 Land Rover Defender 110 TDI 300 Kalahari (Meisiekind˛)
    '84 Land Rover Defender 110 V8 4-speed Hardtop (Meisiekind) Sold after 12 years of fun and hard work.
    The only thing needed for evil to triumph is for a good man to do nothing.

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