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Engine/Transmission (1994 - 1998) Installing fuel pressure guage

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Engine/Transmission (1998.5 - 2002) Diesel Leak

2nd Gen Non-Engine/Transmission Fix for stuck Zerk fittings.

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I presume from what I have read that the ideal location is after the fuel filter and before the pump.



I noticed that it looks like I already have an 1/8 npt plug in the top of the fitting on my filter. Does anyone know if this has another purpose or if I can use it for my pressure guage? It is on the line that goes to the pump.



Thanks, John
 
The port on top the filter isn't 1/8" it's metric bolt thread and is your bleed screw. There are adapters available, but this is how I prefer to do since I like to use my bleed screw. :



I drill and tap the top of the injection pump banjo bolt to 1/8'' pipe thread, then install a male x female 1/8'' needle valve with 1/8'' tubing compression fitting in it. Boost gauge or oil pressure tubing pushed though some 1/4'' tubing to protect against cuts and kinks to the gauge. Some folks like to use braided stainless tubing, I feel it's an overkill and hard to route, but it does look nice. The stainless is just on the outside of rubber hose for abrasion and to protect against high pressure bursting, something that shouldn't concern you with just 20 psi.



For a gauge you can use a fuel, boost or water pressure gauge. I use rear connected, liquid filled, stainless water pressure gauges and make my own mount. They have no lighting but it's not a gauge you need to look at all the time. They can be mounted low for the same reason. Use no Teflon tape, it doesn't work with diesel. Instead use anti-seize or Permatex #2. Don't over tighten the tubing compression fittings, you will just distort the ferrule and it may leak. Remember you are working on the clean side of the filter, keep everything spotless.



If you can tap your manifold for a pyro tapping the banjo bolt is a piece of cake, Geno's also sells tapped bolts. Just drill from the inside to keep the hole straight and tap from the outside. You can also connect to the fittings on top of your fuel filter with the appropriate adapter to tubing if you don't want to tap or want a pre-filter reading also.



After the install start your engine with the needle valve closed then open it slowly till someone in the cab signals you that it's just reading pressure. If you tighten down the packing nut under the valve handle the setting can't move. The valve will control pulsation and buzzing and can also be shut down in the unlikely event that you have a leak. Since you are running the valve almost shut any leak will be very small.



Parts list; 1/8'' needle valve - $2. 50 from the hardware store, plastic oil pressure tubing kit that comes with the compression fittings - under $10 from an auto parts store. 1/4'' tubing for protective sleeve - less than $2. Gauge is your choice and may come with tubing. The water pressure gauges I use cost less than $10, bringing the total cost to less than $25 and a couple hours of your time.



I've installed several gauges that have been in service for over 5 years with zero problems though you may have to occasionally close the needle valve a bit more if the gauge starts pulsating.
 
Illflem, What does the needle valve you talk about usually fit? I'm having a hard time visualizing it. I can only visualize a needle valve from a tire air valve :rolleyes: You have any Pic's?



Thanks,



Tom
 
Tom,



It's just a standard needle valve that you find at the hardware or parts store in their brass fitting bins. I replaced my mechanical gauge with an electronic one from Westach. However, I kept the snubber and needle valve so the transducer used with the new gauge would last a while. If there is no restriction on the pressure, the pressure spikes from the mecanical fuel system will tear up the transducer.
 
I did just what Illflem did and it works great. I like the needle valve to close in the event of a leak and it saves the pulsing if no snubber is used. I used an old oil pressure guage that reads to 60 PSI.

Pressures on my fuel system were 18 PSI no matter what. I pinched the fuel return line and pressure spiked to 42 PSI. I replaced my fuel return valve. Now, I run 24 PSI at idle and 32 PSI at 3000 RPM. Under load the pressures are the same.

-Paul R. Haller-
 
Bill,



For one thing it looked bad in comparison to my other gauges which are Westach. I like to have a light in the gauge so I can read it at night. The mechanical one didn't have that. Also could not find a 40PSI gauge mechanical gauge. No problem getting that scale from Westach. The mechanical decided to seep fuel in spite of anti seeze. I've got this one snubbed down so that it takes a while to get pressure up. We will see how long that lasts.
 
Bill, i have only a boost guage now. i would like to put in a fuel pressure guage. i like the way you have hooked yours up. just one more question: i have mounted my boost guage down low. using the genos dipricol guage mount for under dash. it is a rubber wedge and does not mount very easily. so, how did you mount your fuel pressure guage down low? thanks. scott.
 
I just took a piece of stainless sheeting I had laying around, hole sawed a hole for a gauge in it then bent into an L. You can also buy this type of gauge holder at most auto parts for about 5 bucks. Mine was custom because I used a 1-1/2" dia gauge rather than the standard size.
 
Scott,



Here is another idea. I bought some plastic at a local plastic shop. It's about 3/16" or 1/4" in thickness with a texture on one side (the display side according to the plastic guy). The stuff is easy to work. The plastic I got is ABS so pipe glue works. I built a three gauge holder from it the mounts low on the dash in front of the center console. The only part that was kind of tricky was building a mount so that it was hidden. I used a couple of brackets I got from the hardware store in their collection of strong ties. The plastic was shaped with a saber saw and a Dremel belt/disk sander. I cut 45 degree angles so the joints look good. I used the same kind of plastic for my switch panel that is where the stock cup spiller was and for my Prodigy mount in the ashtray hole. If I can get hold a digital camera (Santa Claus I hope) I will post a picture of my dash.
 
Am I missing something or am I just stupid... . I have two lines going to my filter housing and they don't look big enough to tap 1/8npt in it... . and is it the line closest to the front of the truck?and is it the bleeder you tap into or the line closest to the firewall?..... boy am I confusing or what??
 
Originally posted by illflem

I tap into the top of the inlet banjo (connection) bolt on the injection pump







OOOOO... . I GUESS I AM STUPID... I WAS LOOKING AT THE FILTER HOUSING THANKS... . RICK
 
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