I had earlier posted a question about those using any AI for troubleshooting. In the interests of answering Peter's question, and trying out AI, I pushed this question up to ChatGPT5.
https://chatgpt.com/I would first say take everything with caution. But it looks like some/all may be helpful. Even feedback on the picture from Peter.
If not interested in anything from AI - please skip this!
Else, here it is, and hope it helps,
You said:
where do I mount the sensor for a turbo boost gauge in a 1989 MCI 96A3 bus?
ChatGPT said:
To mount a turbo boost gauge sensor (also called a pressure sender or MAP sensor) on a 1989 MCI 96A3 bus, you'll need to tap into the intake manifold pressure after the turbocharger but before the intake valves. This will give you an accurate reading of boost pressure. Here's where and how to do it:
✅ Sensor Mount Location:
1. Intake Manifold (Best Option):
Look for a vacuum or boost reference port on the intake manifold.
If none exist, you can drill and tap a 1/8" NPT fitting into the manifold.
Use a brass barb fitting or threaded sensor port depending on your gauge setup.
2. Charge Air Piping (Alternative Option):
Tap into the charge air pipe between the turbocharger outlet and the intake manifold.
Be aware: readings here may not be as accurate due to pressure drop across the intercooler (if equipped).
⚠️ Important Tips:
The Detroit Diesel 6V92TA engine (most common in MCI 96A3) usually has a boost reference port on or near the intake manifold already.
Use steel or brass fittings rated for pressure if modifying or tapping.
Route the sensor or hose away from heat sources (like exhaust manifolds or turbo).
🛠️ Tools & Materials Needed:
1/8" NPT tap & drill bit (if tapping)
Boost gauge sensor or MAP sensor
Hose/fittings (if using mechanical gauge)
Thread sealant (for any fittings)
Would you like help identifying a specific port on a photo or diagram of your engine? If you can provide one, I can point out the best place to mount the sensor.
You said:
<<< Phil - PlyonsMC9 attached the picture Peter attached >>>>
ChatGPT said:
Thanks for the photo — that helps a lot.
You're looking at the Detroit Diesel 6V92TA engine, and the image clearly shows the turbocharger, exhaust housing, and part of the intake manifold. The area you circled in red is on the intake side of the blower, right where we want to focus for boost pressure.
✅ Boost Sensor Mounting Location:
Yes — the area you circled is a good candidate for tapping into boost pressure.
This section is on the blower housing (above the roots blower, under the turbo), and post-turbo, so it's where manifold pressure builds. On many 6V92 engines, that casting has a flat boss or plug specifically for pressure fittings or sensors. If yours isn't already drilled and tapped, that’s exactly where you’d do it.
🛠️ To Install the Sensor Here:
Inspect the circled boss area closely — some engines have it already tapped and plugged with a pipe plug.
If plugged: Remove and install a boost hose barb or sensor fitting.
If solid: Drill and tap it (usually 1/8” NPT is common).
Use a right-angle adapter if clearance is tight.
Route the wiring or boost line cleanly away from the turbo/exhaust heat. Use heat shielding if necessary.
⚠️ A Few Warnings:
Be cautious while drilling/tapping near the blower — don’t let metal shavings fall in if the engine is assembled.
If uncomfortable drilling/tapping, have a diesel or turbo shop do it — one wrong move and you're into a major casting.
Would you like a diagram or sketch showing exactly how to install the sensor and route it from there?
You said:
yes
ChatGPT said:
Phil note: etc., etc., etc,. continues..
