Installing A Fuel Pressure Gauge On A 1995 Gmc

Installing a fuel pressure gauge on a 1995 GMC truck is a straightforward process, but it requires careful handling of fuel lines and some mechanical know-how. The first step is to gather the necessary parts, including a suitable fuel pressure gauge, a gauge fitting, hose clamps, Teflon tape, and other tools. The specific parts required may vary depending on the GMC model and the gauge chosen. Once the necessary parts are acquired, the installation process involves cutting the fuel line, releasing fuel pressure, mounting the gauge, and ensuring proper sealing with Teflon tape and clamps. It is crucial to minimise fuel spillage and to check for leaks before starting the engine.

Gathering essentials for the install

To install a fuel pressure gauge for your 1995 GMC, you will need to gather the following essentials:

• A fuel pressure gauge – a 60 or 100 psi gauge will be suitable.
• A gauge fitting for a 3/8 inch fuel hose.
• Two 3/8 inch hose clamps – the fuel lines are 5/16 inch inside diameter hoses, but the 3/8 inch gauge fitting will still fit.
• Teflon tape – this is to wrap the gauge's threads before screwing it into the gauge fitting. Ensure the tape doesn't extend below the threads so that none of it gets into the fuel lines.
• A large wrench or vise to hold the fitting.
• A small wrench to screw in the gauge.
• A fuel line – you can use an AN-4 stainless steel fuel line to remote mount the gauge. This will allow you to tape the gauge to your windshield for engine tuning.
• An insulated (rubber-lined) hose clamp to secure the line and gauge in the engine compartment.
• A rag to keep fuel from spraying on you when you cut the fuel line.
• Two 5/16 inch plugs to stop the fuel flow – two Bic pen-type caps will work.

You can purchase many of these items from auto parts stores, such as Advance Auto Parts or Summit Racing.

Painting the gauge pillar

Prepare the Surface:

Before painting, ensure that the gauge pillar surface is clean and free of any dirt, grease, or debris. Use a mild detergent or surface cleaner and a soft cloth to wipe down the pillar. It is important to have a clean surface for the paint to adhere properly.

Choose the Right Paint:

Select a paint that is specifically designed for plastic surfaces and is compatible with the interior of your GMC. In the example provided, the user chose Omni-Pak master blend paint, which is blended to match the OEM color and comes in a spray can. You can find similar products at automotive stores or online.

Prepare the Work Area:

Painting can be messy, so it is essential to prepare your work area. Set up your work area in a well-ventilated space, such as an open garage or outdoors. Spread out a drop cloth or newspaper to protect the surrounding areas from paint spray.

Painting Process:

Follow the instructions on your chosen paint for the best results. Typically, you will need to shake the can well and test the spray on a piece of cardboard or scrap material to get a feel for the spray pattern and coverage. Hold the can about 6-8 inches away from the surface and spray in steady, even strokes. Apply several light coats, allowing each coat to dry before applying the next. This will help ensure a smooth and even finish.

Allow the Paint to Dry:

Once you have achieved the desired coverage and color, allow the paint to dry completely. Refer to the paint instructions for the recommended drying time. Do not touch or handle the gauge pillar until the paint is fully cured to avoid smudging or fingerprints.

Reinstall the Gauge Pillar:

Once the paint is dry, carefully reinstall the gauge pillar into your GMC, following the reverse steps of its removal. Ensure that all wiring and connections are secure before finalizing the installation.

Remember to take your time during the painting process and follow all safety instructions on the paint can. With these steps, you can achieve a professional-looking paint job on your gauge pillar, matching the interior of your 1995 GMC.

Wiring the gauge

First, gather your materials: you will need 18-gauge wire, a wire coat hanger, butt connectors, wire crimpers, and wire cutters.

Next, you'll want to paint your gauge pillar to match your interior. A spray can of Omni-Pak master blend paint, blended to the OEM colour, should do the trick.

Now, it's time to start the wiring inside your vehicle. Begin by removing the door sill and the plastic cover that sits over the hood release handle. These pieces should come out easily and are typically held in place with retaining clips.

Then, start running your wires. You can go through the grommet in your firewall or, if you don't have enough room, through the door jamb. This is where the coat hanger will come in handy.

Once you've guided the wires from the battery through your fender and into the truck, you'll want to run them through the rubber in the door and into the cab of your truck. From there, guide them up through your fuse box and towards the pillar where the gauges will be mounted.

At this point, you can install the fuel pressure sender. Locate the Schrader valve on your fuel line, which is usually found under the intake resonator, behind the throttle body. Use a Schrader valve core removal tool to pull out the core, being careful to have a rag handy as some gas may spew out.

Now, Teflon tape the male end of the fitting and screw on the adapter. Teflon tape the male end of the fuel pressure sender and screw it into the adapter. Finally, Teflon tape the Schrader valve and screw the fitting/adapter/sender assembly onto it.

Turn on your truck to prime the fuel system and check for leaks around all the seals. If you notice any leaks, you may need to adjust the fittings or add more Teflon tape to the connections.

And that's it! You've successfully wired your fuel pressure gauge.

Installing the fuel pressure sender

Once the Schrader core is out, apply Teflon tape to the male end of the fitting and screw on the 1/8 NPT adapter. Now, apply Teflon tape to the male end of the fuel pressure sender and screw it into the adapter. Finally, apply Teflon tape to the Schrader valve and screw the fitting/adapter/sender onto it.

Now, turn on your truck to prime the fuel system and check for leaks around the seals. If you notice any leaks, you may have the wrong-sized fitting or may have forgotten to use Teflon tape on a connection.

Checking for leaks

After installing the fuel pressure gauge, it is important to check for leaks. Before starting the engine, make sure there is no pooled fuel anywhere. Turn on the truck (key only) to prime the fuel system, but be aware that there won't be a large amount of fuel in the system. Check for leaks around all the seals. If you notice any leaks, you may have the wrong-sized fitting or may have forgotten to use Teflon tape on a connection.

When checking for leaks, it is helpful to have an assistant. In one instance, the installer had their little brother watch under the hood while they turned the key.

If you are installing a fuel pressure sender, you will need to locate the Schrader valve on your fuel line. Be sure to do this with a rag in hand, and make sure your engine and manifolds are cool, as gas may spew out, and a drip in the wrong place could be dangerous.

If you are installing an electric pressure gauge, you can install the pressure sender in the same place and then route the output wire through the firewall to the gauge.

Frequently asked questions