TDI 4Runner Video Part 12 - AutoMeter Fuel Gauge Universal Sender

I used an AutoMeter Phantom 2 1/16th fuel gauge. As I expected, it was not compatible with the factory fuel level sender. I cut a new hole in the tank at a better location and installed AutoMeter's universal fuel level sender. I was able to get a nice full float sweep from the bottom to the top of the tank. So far it works great.

TDI 4Runner Gauges

On past project vehicles, I have always wanted all aftermarket gauges, but never did due to cost. Early on I decided it was going to happen on this 4Runner. There's 8 gauges - oil pressure, pyrometer, boost, volts, RPM, speed, coolant temp, and fuel level. All are AutoMeter except for the Speedhut GPS 0-100 speedometer. I decided to go with Speedhut because they offered what I wanted at a much more affordable price than Autometer. It doesn't match the other gauges perfectly, but it's close enough for me. I'm happy with it. I also added transistor-controlled LEDs for the glow plug and MIL lights, and 2 LEDs for turn signal indicators.

I knew it would be some work to install all these gauges, but I really under estimated it. No idea how many hours I have in the whole setup, but there was a lot of time consumed in making it all look nice, wiring up the lights, powers, grounds, and sensor wires. It was worth it, though; the end result is exactly what I wanted.

Thanks to Alchemist from the TDIClub forums for schematic and Jimbote for bringing it to my attention that I'd need to build this circuit.

Yes, there's heat shrink tubing on each individual wire to keep them from touching each other. The large piece of heat shrink tubing on the outside is to keep the unit stationary and add structural strength.

Seat Bracket Fabrication for Summit Racing Sport Seats

The stock seats in this 4Runner were in rough shape - some stains, some missing chunks of foam in the side bolsters, and they had permastank! Rather than cover it all up with some seat covers, I opted to replace them with Summit Racing's sport seats (SUM-G1159-2). I've looked at those for years and like them, but never had a need for aftermarket seats until now. These seats look great, are comfortable, come with sliders, and appear to be a good value. 

I made my own seat brackets out of flat steel bar stock. The rounded risers are roll cage tubing cut in half. Looks a heck of a lot nicer than box tube. I used a torch to heat and bend the curved front part to match the floor board. The 4Runner floor is not level, so it took quite a bit of measuring to get the seats level and in the correct left/right orientation. Overall I have 7 or 8 hours in these brackets, but the end result are level seats exactly where I want them that are in the correct left/right location and look great. 

I was afraid the side bolsters would be a bit too much for getting in and out, but initially they don't feel too bad. We'll see how it works out. 

TDI 4Runner Video Part 11 - Cooling System

Intercooler Charge Pipe Fabrication

It's pretty tight between the intercooler and fuel filter, but it all fits with enough room for some engine movement.

I did not leave the intercooler outlet transition like that. I bought more pipe and turned it into a nice smooth bend.

The grill fits nicely after some minor trimming :) I am planning on painting that section of pipe black so it will blend in a little bit better.

Video Part 10 - Intake & Intercooler

Quick Update - Lots Going On

Quick update here - not too much work is happening on the Toyota right now. My business is in full swing due to the time of the year. I own Ride-A-Bike Bicycle Shop in Lincolnton, NC. We are covered up with sales and repairs here as the weather changes! If you're in the area or passing through, stop in and say hello. Hopefully soon I can get back to work on the TDI 4Runner project. I can't wait to get it on the road!

Next step on the TDI 4Runner will be fabricating the radiator mounts and then working on all the coolant hoses.