In racing, temperature sensors like Exhaust Gas Temperature (EGT) probes, Cylinder Head Temperature (CHT) sensors, and fluid temperature sensors provide critical data that can make or break performance. When installed correctly, these sensors deliver the accurate, real-time information teams rely on to fine-tune engines, optimize setups, and prevent costly failures.
But when installed incorrectly, they can create misleading data—or worse, damage equipment. At The Sensor Connection, we’ve seen it all, so here are the most common mistakes racers make when installing temperature sensors—and how to avoid them.
1. Mounting in the Wrong Location
Why it matters: Sensor placement directly impacts the accuracy of your readings. For example:
- EGT probes should be installed in the exhaust manifold, ideally 1–2 inches from the exhaust port. Too far downstream and the readings could potentially lag or under-report real exhaust temps.
- CHT sensors work best under the spark plug or in a dedicated bore—mounting them elsewhere can reduce accuracy.
- Fluid temperature sensors need full contact with the fluid. Installing them in a dead-end fitting or spot with poor circulation can produce false readings.
The fix: Always follow manufacturer guidelines for recommended mounting positions.
2. Using the Wrong Fittings or Adapters
A poor-fitting sensor can leak, loosen, or fail under racing conditions. Some common mistakes racers make include the following::
- Using generic adapters that don’t match the probe diameter.
- Overtightening compression fittings, which can crush or damage the probe.
- Skipping proper weld bungs for EGT probes and instead try to “make do” with shortcuts.
The fix: Use the proper weld bung, compression fitting, or direct-weld option designed for your specific sensor. It ensures a secure fit, leak prevention, and repeatable performance.
3. Ignoring Cable Routing and Protection
Sensor wires live in harsh environments—heat, vibration, and sharp edges can all cause signal issues. Common mistakes include:
- Running cables too close to headers, turbochargers, or other heat sources causing cable insulation to fail.
- Routing wires without abrasion protection, leading to wear-through.
- Skipping strain relief, which causes connections to loosen or break under vibration.
The fix: Use heat shielding, braided sleeving, and secure routing away from hot or moving components. Always apply proper strain relief where cables enter connectors.
4. Mixing Up Sensor Types or Extension Wires
A frequent mistake is using the wrong extension wire or splicing with generic copper wire. For thermocouples especially, the wire should match the sensor type (e.g., Type K thermocouple wire). Using the wrong wire can introduce significant errors.
The fix: Match all extension wires and connectors to the sensor type, and avoid mixing materials.
5. Skipping System Calibration or Verification
A common mistake is assuming that once the sensor is installed, the readings will automatically be correct. In reality, most temperature sensors—especially thermocouples—don’t get “calibrated” in the field. Instead, it’s the measurement system or electronics (gauges, ECUs, or DAQs) that need to be calibrated or scaled to match the sensor’s specifications.
The fix: Verify that your measurement system is properly configured for the sensor type (e.g., Type K thermocouple, PT100 RTD). Perform a quick check against known conditions (like testing a coolant sensor in boiling water) to ensure the system + sensor combination is producing accurate, consistent readings.
Conclusion
Temperature sensors are the eyes and ears of your racing engine. Correct installation ensures you’re getting clean, reliable data you can trust. Avoiding mistakes like poor placement, incorrect fittings, improper wiring, or skipped calibration will save time, money, and performance headaches.
At The Sensor Connection, we build race-ready temperature sensors designed to withstand extreme conditions without compromising accuracy.
👉 Explore our full range of EGT probes, CHT sensors, and fluid temperature sensors