Rear pdc genuine retrofit?

stevec

Member
Wales
Hi all.
Just acquired an almost complete genuine audi pdc kit to retrofit to my A2.
Parts i have
4x pdc sensors 4b0919275 (3 pin) 23mm diameter
Control unit
Rear bumper loom
Spare undrilled rear bumper(pdc marks clearly visible)
Rear beeper
Parts needed.
Loom from control box to cluster (kufatec)
Sensor mounting brackets

Right now here's my question.
Is there a special bumper cutting tool 23mm to fit these sensors? I see sealey make them in various sizes but unable to find a 23mm one.
Or a 23mm hole cutting drill?
Thanks Steve
 
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Definitely get a punch for doing the holes - much better than a hole saw.
I used a VAG one, 18mm for the wifes Alhambra OEM install, worked great,
For my A2 I installed a set of flush mount aftermarket sensors and used a 16.5mm punch from Amazon - it worked well too.
 
The punch I used for the A2 non genuine ones was this one: Punch

Found some pics:
Punch:
1.jpg


Pilot hole:
2.jpg


Punch from outside:
3.jpg


Inside:
4.jpg


Hole inside:
5.jpg


Outside:
6.jpg


Sensor:
7.jpg
8.jpg


Finished:
9.jpg
 
Very timely, doing the same as you. Have a bumper with PDC and hoping to fit to mine. Got a 23mm hole saw but seen comments. Will look for punch.
 
Very timely, doing the same as you. Have a bumper with PDC and hoping to fit to mine. Got a 23mm hole saw but seen comments. Will look for punch.
All the hole punches for rear pdc sensors i have seen are slightly oversized. If you find an oversized 23mm (23.2 etc) hole punch please post up part number.
If your donor bumper has genuine Audi sensors can you please accuse measure hole size in bumper?
 
All the hole punches for rear pdc sensors i have seen are slightly oversized. If you find an oversized 23mm (23.2 etc) hole punch please post up part number.
If your donor bumper has genuine Audi sensors can you please accuse measure hole size in bumper?
Will do, i'll check tomorrow.
 
All the hole punches for rear pdc sensors i have seen are slightly oversized. If you find an oversized 23mm (23.2 etc) hole punch please post up part number.
If your donor bumper has genuine Audi sensors can you please accuse measure hole size in bumper?

That's a good idea, the OEM VW sensors that I installed using the OEM 18mm punch fitted easily in the holes.
The 16.5mm sensors in the 16.5mm hole were a little tighter to fit than I remember the VW ones being.
In fairness I neither measured punch nor sensors in both cases, in hindsight it might have been better to do so especially for the aftermarket ones.
 
These are known in the trade as Q-Max hole cutters.

Vast range of sizes.

Edit, I see one of the sizes is 22.5mm.
 
These are known in the trade as Q-Max hole cutters.

Vast range of sizes.

Edit, I see one of the sizes is 22.5mm.
Thank you.
I have measured the diameter of the genuine audi sensors with a set of digital vernier calipers, and it is exactly 23mm. I think I'm Going to need at very least a 23mm hole punch.
 
Steve, as per PM earlier,

I have a hole cutter (23mm) which cuts the holes perfectly for factory sensors. The OEM sensors fit in beautifully and snug.

Soon as I’ve finished mine in the next week or 2 I can send it onto you for return once you've finished.

It took me a while to find this size without having to purchase a massive set for over £150.

Kind regards,

Tom
 
Steve, as per PM earlier,

I have a hole cutter (23mm) which cuts the holes perfectly for factory sensors. The OEM sensors fit in beautifully and snug.

Soon as I’ve finished mine in the next week or 2 I can send it onto you for return once you've finished.

It took me a while to find this size without having to purchase a massive set for over £150.

Kind regards,

Tom
Thank you Tom. I will look after it and return it.
Steve
 
The cutter arrived:-

vDU0EVo.jpg


Hole cut, used a stepped drill first, then by placing the cutter against the marks on the inside cuts a nice hole. This is on the corner, so the most difficult.
XnIrEDA.jpg


Then slide in the sensor, a perfect fit.
DnIoDDK.jpg


There is a little burr, that would not occur going from outside to in. But harder to line up to the centre of bumper marking.
 
What sensor holders did you use. I bought a set for an A2 and they don’t match the sensors (size and mounting).
Steve B
 
What sensor holders did you use. I bought a set for an A2 and they don’t match the sensors (size and mounting).
Steve B
It might be the sensors that are different (also marked as for the A2). But they are a full circle rather than the shape of yours.
 
My sensors and holders.
AFF66297-FF12-4AC1-A731-DA2BF1854035.jpeg
The holders don’t match and the opening is slightly too small. Do I need different sensors, or different holders?
What size is the cutter, that might help me figure out which is wrong
Thanks
Steve B
 
The cutter is 23mm, oem sensors fit perfect. In the end I found another bumper already fitted so didn't need to secure after all.

Loan offer is on if the right size. They are quite expensive.
 
Mine don’t match the holders that attach them to the non-PDC bumper.
So can anyone tell me if the holder is wrong or the sensor (or both?)
 
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