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Submitted By: mrpeal
Date: October 31, 2008, 04:42:39 AM
Views: 4999

98.5-2002 24 valve cummins fuel pressure guage install - mrpeal

(Figure 1)​

next take your new fuel pressure hose adapter and screw the schrader valve end onto the pump to tap the schrader itself, (side note, at this point i would recommend turning the key on for a second and make sure fuel flows out, this will verify you have tapped the schrader valve, if no fuel comes out then bump the starter and see if you get fuel, once you have fuel your ready for the next step)

(Figure 2)​

here is the line installed on injection pump end

(Figure 3)​

next thread the sending unit onto the lines other end, the threads are both brass so you dont have to use teflon tape but most will recommend using it to prevent leaks.

(Figure 4)​

here in figure 5 i show the location of passing the signal wire through the firewall, this works well on automatics as the stock clutch master hole has a simple rubber grommet in as a plug, you can still use the hole on stick shift trucks but have to make your hole off to the side a bit.

(Figure 5)​

here is the grommet with a 3/16 hole to allow signal wire to pass

(Figure 6)​

here is grommet reinstalled with signal wire passed, note i used yellow wire for my signal but green is common.

(Figure 7)​

once the signal wire is ran into the cab make sure to leave enough room to reach the top of the column before cutting your wire, then crimp an eyelet onto the hood end of your signal wire and attach it to one of the senders two terminals, polarity is not important on this sender, pick one and make the connection by tightening the 3/8 nut on the sender.

(Figure 9)​

here is the sender attached useing the optional sender bracket offered by genos garage, note the white ground wires, this ground must go to body ground as well as the case ground of the sender.

(Figure 10)​

here I tapped a factory body ground, it is easy to get to and close by, this is located on the driverside fender.

(Figure 11)​

here are all our interior parts laid out for assembly

(Figure 12)​

here is the back of the guage itself

(Figure 13)​

here you can see the terminals that the guage uses, i have labeled them as to their designation, the instructions show them as well.

(Figure 14)​

here we are hooked up and ready to set in the pod, we installed our light as well and we tapped the ground for the light right off the guages ground, this will simply save us from running two wires for the light, just makes it a bit cleaner install.

(Figure 15)​

installed in the pod

(Figure 16)​

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set the pod on loosely just to keep it out of the way and run your wiring down under the factory knee bolster, you can easily access a good ground point and your power circuits at the fuse box from there, knee bolster is only held in with 3 phillips head screws.

(Figure 17)​

ground your black wire directly to the instrument panel screws on the steel part, there are many to choose from, i have found these to be great grounding points and very easy to get to. next you need to tap for your light and your power circuit for the guage. I used fuse number 5 labeled illumination, pull the fuse and install a fuse tap, use the lower terminal so the circuit will still be fused, the light the guage uses is minimal amp draw and will not create an excessive amount of current used, next I use the number 3 abs fuse for my power tap for the guage, I use this as in the event the abs fuse was to blow I would see the guage needle drop as well, the guage uses minimal amounts of current, or use the top terminal and just fuse the circuit. this will prevent any issues of disabling the abs in the event of a short circuit.

(Figure 18 )​

now we have all our connections made and it is time to check to see if it all works, turn the key on and look for pressure, normally you wont see much with key on only, bump the starter without cranking, you should see immediate movement. after verifying this check your hoses for leaks and then your ready to start the truck. also turn lights on and verify the lighting is funtioning before finalizing the install.

(Figure 19)​

after your done your ready to finish the install, use the supplied 3m tape on the inside of the pod, and push it down on the stock column cover, then drill a 3/16 hole to keep it in place, be careful not to drill to far on the wiper switch side as it does house wiring behind it.

(Figure 20)​

other side

(Figure 21)​

and here is the final product, a easy to read guage that can offer you protection against injection pump destruction. here is a few specs.

(Figure 22)​

factory lift pump should run around 12-15psi. if dropping below 10 then check for restriction in fuel filter, if below 8psi check for problems with delivery. if below 5 shut her down and check the lift pump for problems, something is awry and you can save yourself 2grand for a replacement. good luck and enjoy your trucks.
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