How-To Install Auto Meter Nexus Gauges

Auto Meter Products, Inc, an innovator in high quality, performance instrumentation, has stepped it up another notch with the release of their Nexus system of gauges. They definitely live up to their motto of the “Next generation instruments,’ as the gauges in the Nexus line up features an integrated approach that uses a master control unit, electronic sending units, and displays. Simply put, this series of gauges are the BEST gauges available, hands down. What makes them the best? What other gauges out in the market integrates modern day automotive style CAN electronics (more below), maintains high accuracy and reliability, and provides utmost ease of installation? Take a look at the following features offered by the Nexus gauges.

• Powered by digital microprocessor-controlled, rugged stepper motor drives
• Seven LED illumination colors
• Programmable warnings
• Signal Playpack
• Peaks (Peak Readouts or Peak Readings…define for the readers)
• Built in data logging on SD flash memory for PC downloading
• Expandable to accept more gauges in future

I would probably expand on the following features …the programmable warnings and how it would benefit a diesel owner (flashing color warnings that you can see out of the corner of your eye versus having to take your eyes off the road to look at the needle, benefit of PC downloading for performance tuning, what does a signal playpack do?

Unique in the aftermarket automotive instrumentation world, the Nexus gauges utilize a proprietary digital communications network between gauges. Auto Meter calls this their N1.0TM Network System, which is based on “controller area network” (CAN) technology. CAN is a broadcast, differential serial bus standard, developed originally by Robert Bosch for connecting electronic control units (ECU’s) BACK in the 1980′s. CAN was designed specifically for automotive applications, where noisy environments can cause signal degradation. This technology allows single modular cable connection for easy installation. In other words, you can “daisy chain” the gauges from one to the next, which makes installation, quite literally, a snap!

The Nexus system of gauges consist of three main components: The 2-1/16″ “gauge” display (which now functions really as an analog read out), a gauge sending unit, both plugging into the central control unit. The gauges have a 270 degree sweep, quite similar to their mechanical gauges – but with a twist. The gauges utilize precision stepper motor that drives the needle, similar to what you would find in Auto Meter’s short sweep electric gauges. Why a stepper motor? The advantage is that it provides repeatability and accuracy that exceeds a mechanical gauge. In a mechanical gauge, you’re fighting the friction and wear of the moving parts inside, which over time, may change the readout of the gauge. The user adjustable seven color gauge illumination feature can be used to match the factory dash illumination – blue, white, red, orange, green, yellow, and purple. Can’t decide on what color to use? There’s even a built in feature that when selected, the illumination color cross fades from one color to the next – very trick.

Moving on to the sending units. Track Tested & Race Proven, the Nexus system uses precision senders to keep hazardous fluids out of the driver compartment, and perform gauge calibration and sensor diagnostics at power up for extreme accuracy, every time. And that’s what makes the Nexus line so unique – all the engine characteristics are measured with these senders under the hood, and the signals sent directly to the sensor module. From there, the signals are processed, and then broadcast on the CAN bus line to the appropriate gauges. This also makes for an EASY gauge installation, as you now longer have to run pressure tubes and wires directly to the gauges. Additionally, the Nexus system uses the N1.0 network to data log all the channels as well, to review on a PC. All this is stored on a Secure Digital (SD) card accessed on the remote control.

The Nexus gauges are expandable as well. In the event that you want to add more gauges, the following are available:

• Oil Pressure
• Fuel Pressure
• Vacuum / Boost Pressure
• Boost
• Oil Temperature
• Water Temperature
• Nitrous Pressure
• Exhaust Gas Temperature
• Fuel Level
• Fuel Pressure
• Transmission Temperature
• Voltmeter
• Water Temperature

Project Rockstar recently had an engine swap, from a 7.3 liter Powerstroke to a 5.9 Cummins High Pressure Common Rail. To go with the engine overhaul, a gauge overhaul was definitely required. In a diesel truck application, the three typical gauges you’ll find are: Boost, Pyrometer, and Transmission Temperature. The Rockstar has a manual transmission, thus a transmission temperature gauge is not required. The Auto Meter Quad Pod A-pillar gauge mount will be re-used in this application, so in addition to the pyrometer and boost gauge, two more mounting locations were available – now occupied by the oil pressure gauge and fuel pressure gauge. Project Rockstar’s original Powerstroke motor has been replace by a High Output Cummins ISBe Common Rail motor from a 2003 Dodge Ram. Both gauge values are critical information to monitor on a modified Cummins Diesel.

This installation will cover an upgrade of gauges, from a set of Auto Meter Ultra Lites to their premier Nexus gauges. For a detailed installation of gauges on a new Ford Superduty – , see the write up done on Project JAKD.

The final word? The rugged automotive style electronics combined with laboratory precision measurements was the perfect match for Project Rockstar. The gauges have worked flawlessly, and impressed numerous people, leaving them slack jawed and wanting to find out where they can get their own setup. Auto Meter has definitely raised the bar in performance automotive instrumentation.

Installation Steps

The Autometer Quad Pod with the original Ultra-Lite gauges installed in the A-pillar – soon to be replaced!

Start by removing the weather seal around the driver door. Pull the Quad Pod towards the driver’s seat.

Contents of the Nexus Boost Gauge – there will be more parts than you need for an A-pillar installation. The required parts are the gauge (obviously), gauge wiring, pressure sender, and wiring harness to connect the pressure sender to the Nexus control module.

All the pressure/temperature senders in this kit use tapered pipe thread (NPT), so be sure to use Teflon tape or pipe sealant.

The pressure sender goes into the back of the Banks High Ram intake on the engine. There was already a 1/4″ NPT port on the back of the intake – use a 1/4″ to 1/8″ bushing to properly connect the sender to the intake. If this were a new installation in a blind hole, use an 11/32″ drill, and chase it with a 1/8″ pipe tap in order to install the sender without the use of a bushing. Be sure to remove the intake from the engine, as you do NOT want any metal debris entering the engine.

Contents of the Exhaust Gas Temperature (Pyrometer) Gauge – note: do alter the length of the thermocouple wiring (the wire attached to the thermocouple, aka the temperature sender), as it will alter the temperature reading.

The existing pyrometer was installed in the exhaust manifold, pre-turbo. The manifold was drilled with a 7/16″ drill bit, and then chased with a 1/4″ pipe tap. Remove the pyrometer, and then the fitting. Installing the thermocouple upstream of the turbo gives a more accurate reading of the exhaust gas temperatures before the heat is lost driving the turbine wheel. TIP: when drilling the intake manifold, keep the engine running. Also do it in small steps, starting with a small drill bit, and work your way up. This will reduce the side of the metal shavings that will enter the exhaust housing of the turbo.

Prior to installing the new fitting, be sure to thread the set screw in with an allen wrench.

Slide the thermocouple into the port until it bottoms out, then pull back approximately 3/4″. Use an allen wrench to tighten the set screw to secure the thermocouple to the fitting. Otherwise, it will vibrate free.

Contents of the Oil Pressure Gauge.

1/8″ NPT ports on the oil filter mount provide a place for the oil pressure sender.

The Autometer sender needs to share the same port as the Ford sender. Use an 1/8″ NPT run-tee to have both senders share the same port.

The fuel pressure sending unit is a delicate device, and needs to be isolated from excessive vibration, and not see pressure spikes. Needed is a pressure snubber (lower right) to prevent the spikes, and braided stainless steel line to mount the sending unit in a remote location off the engine.

A great place to check the fuel pressure is between the lower pressure fuel pump (aka lift pump) to the high pressure fuel pump (Bosch CP3). Here is the backside of the CP3 pump, where a tapped 90° fitting provides an 1/8″ NPT port, a perfect place to connect the braided line.

The line runs to the cowl above the brake master cylinder, where the pressure snubber (1) and sending unit (2) is zipped tied to the body.

After removing the Autometer 4 pillar pod from the A-pillar, remove the Ultra Lite gauges, and slide the Nexus gauges in the pods in the order you like. Wiring the gauges are literally plug-and-play. Take the short wiring harness in the gauge kit, plug the connector to the back of the gauge, and then to the next adjacent gauge. The connectors are keyed, so you can’t plug it in incorrectly. At the end of the gauge pod, there will be one set of wires that plug directly into the Sensor Module.

TIP: remove the yellow warning label from the barrel of the gauge. It tends to catch the lip on the gauge pod, making it difficult to slide in. Be sure to leave the part and serial numbers on though!

The contents of the Nexus Sensor module. This is the control unit of the Nexus system of gauges. All the sending units plug directly into the module, where the signals are processed, and broadcast on the CAN bus line to the appropriate gauge display.

The Sensor Module needs to be in a secure area, shielded from the elements. IE, keep it away from dirt and water – so do not install it under the hood. A great place to hide the module is behind the vehicle headlight switch. Start by removing the switch, done by prying it out with a screwdriver. Then pull the dash out with a firm tug. The dash is attached with metal clips.

Run the wiring from the senders through the firewall. There are many grommets to choose from in the Superduty. Here is one next to the PCM. If you have an automatic, another option is to use the grommet otherwise occupied by the clutch linkage.

A great place to route the wiring from the A-pillar to the Control Module is through the panel behind the dash. Find a secure area, and zip tie it down. There are mounting holes in the control unit, but using then in this situation would be extremely difficult.

This wiring diagram shows exactly how to wire the gauges. Each sending plugs into its own dedicated port, and one cable is outputs all the signals necessary to the gauges to display the readouts. Then, simply provide a constant power, key-on power, and ground, and the gauges are ready to go!

The remote control is what drives the entire Nexus system. Mounted to the left of the steering wheel, the remote control controls all the features of the gauges, including the color, brightness, and playback. The red L.E.D. also provides a diagnostic output on the occasion that there is a malfunction with the gauges. Double sided foam tape, or Velcro, will secure the remote to the dash.

The top of the remote also has a slot for an SD flash memory card, if you desire to take advantage of the extended data logging abilities of the Nexus gauges, slide an SD card into the remote. From there, you can later remove the card to download the data, and review it with Nexus Software, when it is released.

Here is the entire system assembled. The Nexus gauges replace the original Ultra Lite series, and the remote is within easy access of the driver. This high tech system of gauges perfectly compliments a high horsepower custom vehicle!

Tags: Chevrolet, Diesel, Dodge, Ford, General Motors, GMC, Interior, New Products, Toyota

Category: How-To