Build '95 4runner TDI swap

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The best placement is always as close to the center of the exhaust inlet of the turbo as you can get. This will be where she's the hottest and you'll get the best readings.

It's cast so it's usually not hard to drill a pilot hole then drill/tap to fit the retainer by nut.

The walls will be pretty thick material but I'd still want it on as flat of a spot as possible.

The ALH also has a non removable turbo. Wouldn't be a bad idea to find out where those guys are putting their egt probes so you can get a visual for where you want it.
 
From what I can see the stock position is below the manifold before the turbo but I haven't been able to find a good picture yet.

My other problem is that just tapping the manifold will hold the nut but the sensor slides within the nut. I think I need a bung like this one but without the inverted flare. The 16.7mm is the threaded part and the inverted flare is where the flat part of the sensor fits.

Part 1 (the nut) slides freely on the wire above the sensor. I drew the type of weldin bung I think I need. I hope that makes more sense.

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I believe I'd be asking David about this.

You do need some sort of step to keep the sensor from going too deep unless the cast iron is thick enough that you don't need to weld on an adapter bung.

One can weld cast if you want to remove the turbo, heat to 500 or so degrees (I may be off) then tig a bung into place before it cools.

I'd buy an BHW manifold before doing all that.

I didn't realize you were working with a g235 sensor, I thought this was a simple aftermarket probe with crush sleeve
 
I just have a connection that is labeled G507 so I looked up what that was and ordered the part for my year. I will send a message to Dave and see what he recommends.
 
Solved. I don't need a egt for this engine. The BEW doesn't use one. If I used this harness with a computer for a BHW I would need to connect it so all I have to do is ignore it.

I'd like to add one just so I can keep track of them but dont plan on it until it is up and running.
 
The only time I need to keep an eye on my egt is getting onto the freeway. Maintaining highway 70 mph speeds (at least in South Carolina) I'm fine but hitting the on ramp I'll need to let off from time to time. I let off at 1200 degrees but technically one has about 400 more degrees to go.
 
I would highly recommend installing a probe before installing the turbo on the engine, it will only be harder to access once everything is in place. Obviously your setup is quite a bit different from mine, but I don't have any trouble hitting 1300ºF or more accelerating in 5th or pulling hills, and the pyrometer is nice to have to monitor that.
 
It is easier to install out of the rig but make sure you know where your downpipe is running before you drill and tap.

Assuming you're using a 3.0 bell/input shaft you have a front drive shaft, turbo, engine mount, starter, slave cylinder, down pipe and possibly AC compressor all in one little area.

The fwd turbo manifolds set ups from the Jetta/golf/bug platforms only add to the cramped space

Like playing 5 on 5 ice hockey in a phone booth.
 
Im hoping to get a probe that is long enough to mount to the egr plate on the manifold and that I can bend to fit. Hopefully I will get some parts today so I can finally finish the fuel system. Then its on to the intake. I have an intercooler but im having a hard time finding space. Not needing an intercooler would make this much simpler.
 
An intercooler is a necessity for a small engine in a heavy vehicle. If you can't find space for an air-to-air intercooler, maybe look into getting a water-to-air unit. A little more complicated but gives you a lot more mounting options. I'm seriously considering going that route when I swap to a BHW.
 
I know I have room. Im just not being creative enough and Im feeling lazy and want something easy. Im going to start searching for a smaller intercooler that will be easier to fit. The one I have would have to be mounted in front of everything and set into the tube bumper. Getting through the front of the engine bay will require moving the wiper fluid container which is what I will probably end up doing.
 
If you are not running a winch bumper you should be able to fit it behind the front bumper, possibly without trimming much of the grill. Long and skinny

There's also room on the front skid plate for an rx7 aluminum fmic, not good if you visit mud often. Thick but smaller foot print

Toyota put them top mount if you don't mind cutting the hood for a scoop. Very small and not the most efficient but the safest location in mud

Be careful with long/bent probes, they are prone to snapping off and taking out turbos.

The cast iron is thick. Put a small 3 inch or so probe right in the center of the turbo collector. Cast iron manifolds drill out and tap really well, especially when it's on the bench and not in the rig.
 
I am running a winch bumper but i dont have a winch. I decided that for now I am going to mount it where the winch would go. The outlet on the cold side of the turbo is only about 1.25" so fitting it through the front should be easy. The outlet of the intercooler is about 2.5" so that will be a little more challenging. I dont drive in the mud very often but I will add some protection in front to be safe.

I remember seeing a stock VW intercooler and it was teeny. It looked more like an oil cooler.

I didnt think about a probe breaking. That would suck.
dohcdelsol93 said:
Toyota put them top mount if you don't mind cutting the hood for a scoop. Very small and not the most efficient but the safest location in mud

Be careful with long/bent probes, they are prone to snapping off and taking out turbos.
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I am having a hard time figuring out what fitting to use for the fuel pump. I ended up going with the EP158 like you recommended. It is much easier to mount.

I know that its m16x1.5 but since its not tapered and there doesn't seems to be a place for an o-ring I'm stumped. I put some diesel approved pipe dope on the threads and tightened it down. I'll see tomorrow if it works.
 
I'm pretty sure my pump came with fittings. 5/16 iirc

To keep from having to run lines from front to back (feed and return) I used the evap hard lines. For my 87, I was lucky there are two of them. These are 6mm lines but close enough to 1/4" for easy adaptation

the Passat side mount intercooler is small, my rx7 intercooler from eBay isn't much bigger. I run hotter egt than I'd like but egts are never an issue and even in the either when iat stays below 100 i don't see any mpg improvement so I haven't seen a need for upgrading.

Pretty sure my intercooler skid plate is pictured in my build thread
 
I'm using the stock fuel lines. There are three...feed, return, and evap. The tank has a built in sump pan the the return pours directly into.

My pump didnt come with fittings. I'll take some pictures of the intercooler setup tomorrow for you to laugh at.
 
I apologize I no longer remember the exact details of the Delco pump. A quick Google search revealed some m16x1.5 to barb fittings being sold on eBay.

It's likely I did the same same along with some diesel friendly thread sealer for good measure.

Unfortunately it's been several years since I put everything together.

She's been on the road for 3 years iirc. Almost 50k miles so far. I'm going to have to replace the rear pads/rotors this weekend, in another 10k she's due for a timing belt and nearly ready for a new set of tires.

All these are items that were new at the time of the build. Finally hitting some needed service work and hitting a few service intervals
 
I have some m16x1.5 to -6 that I am going to use. I was just wondering if its supposed to be a bubble flare or something like that.

Its awesome that your build is lasting. I wonder how many of these get used occasionally or are never fully finished. I am planning on mine being a daily driver so I want it well built but mostly I want to get it going and find out what I want to change rather than trying to outsmart every potential problem now.

I have been reading through your build and am amazed at everything you did.
 
I believe originally it was some sort of o ring sealed flair type fitting. These are low pressure systems and diesel flows about like warm 30wt motor oil so good thread sealer should work just fine.

I dropped my fuel tank back in the summer to replace my in tank fuel level and she was dusty and dry on top of the tank right below the fuel pump.

I appreciate the compliments. I did have to go back a few times to redo or make a few mods after getting her on the road
 
I mounted the intercooler. I built a front cover/brace that I will add holes to.
I also finished the fuel system except for the wiring. I haven't pumped any fuel through yet but I will use it to remove the last of the gas from the tank and hopefully find any leaks then.

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I did some high tech repairs on the radiator.
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I also made an upright stand for my bauer porta-band that turned out better than I expected.
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