Ideal Fuel Gauge Installation For 97 Dodge Cummins

Installing a fuel pressure gauge on a 97 Dodge Cummins involves several steps and additional parts. The fuel pressure gauge will help monitor lower fuel pressure levels and ensure the fuel system is running optimally. The process includes removing the injection pump inlet banjo bolt, drilling and tapping a 1/8 port, and installing a needle valve and grease gun hose. A snubber valve is also required to protect the fuel pressure sensor. The sensor is then connected to the fuel pressure gauge, which can be mounted on the A-pillar or dashboard of the Dodge Ram.

The fuel pressure gauge can be installed on the water separator

Alternatively, if a 12-valve banjo bolt and snubber valve combo is used, thread the fuel pressure sensor into the adapter, and tighten using a 22mm wrench and a 19mm wrench. Then, thread the snubber into the banjo bolt and tighten using an 18mm wrench and a 19mm wrench. Install the new banjo bolt into the banjo fitting, making sure to install two new crush washers, and thread into the injection pump. Tighten with a 19mm wrench.

Plug the fuel pressure sensor harness into the fuel pressure sensor. Reinstall the intercooler pipe if it was removed. Route the fuel pressure sensor harness to an opening on the firewall on the driver's side of the engine bay and use zip ties to secure. Make sure there is no contact with any direct heat source or moving parts of the truck.

It can also be installed on the injection pump inlet banjo bolt

Installing a fuel pressure gauge on the injection pump inlet banjo bolt of a 97 Dodge Cummins is a straightforward process that can be completed with the right tools and parts. Here is a detailed guide on how to do it:

Parts Required:

• Taped banjo bolt with 1/8" pipe fitting
• Fuel pressure gauge
• Teflon tape
• Grease gun hose (optional)
• Needle valve (optional)
• Snubber valve (optional)

Installation Process:

• Remove the Intake Plug: Using an 11mm wrench, remove the intake plug located under the intake horn of your 97 Dodge Cummins.
• Prepare the Boost Line Fitting: Wrap Teflon tape around the 1/8-27 NPT male threads of the boost line fitting. This will create a tight seal and prevent leaks.
• Install the Boost Line Fitting: Thread and tighten the male end of the boost line fitting into the intake port using an 11mm wrench. Make sure it is securely tightened, but be careful not to over-tighten.
• Attach the Boost Line and Ferrule: Insert the boost line into the boost line fitting and secure it with the boost line fitting cap and the ferrule. Again, be careful not to over-tighten the ferrule fitting.
• Route the Boost Line: Secure the boost line to an opening on the firewall on the driver's side of the engine bay using zip ties. Ensure that it does not come into contact with any direct heat source or moving parts of the truck.
• Fuel Pressure Sensor Installation: Now, we move on to the fuel pressure sensor installation on the injection pump inlet banjo bolt. For this, you will need a tapped banjo bolt that replaces the factory bolt and is tapped for 1/8" NPT to thread the fuel pressure sensor into.
• Prepare the Banjo Bolt: Apply Teflon tape to the male threads of the banjo bolt. This will create a seal and prevent leaks.
• Install the Fuel Pressure Sensor: Thread the fuel pressure sensor into the banjo bolt and tighten it securely using a wrench. If you are using a snubber valve, install it between the banjo bolt and the fuel pressure sensor for added protection.
• Connect the Fuel Pressure Sensor Harness: Plug the fuel pressure sensor harness into the fuel pressure sensor. Make sure the connection is secure.
• Route the Fuel Pressure Sensor Harness: Secure the fuel pressure sensor harness to an opening on the firewall on the driver's side of the engine bay using zip ties. Ensure that it does not come into contact with any direct heat source or moving parts of the truck.

By following these steps, you can successfully install a fuel pressure gauge on the injection pump inlet banjo bolt of your 97 Dodge Cummins. Remember to work carefully and consult a professional if you have any doubts or concerns during the installation process.

The gauge can be connected to the fuel filter housing

The fuel pressure gauge can be connected to the fuel filter housing. To do this, you will need to remove the injection pump feed line banjo bolt using a 19mm shallow socket, a 3" extension, and a ratchet. Make sure to have a catch pan ready for the diesel fuel that will come out.

Once the bolt is removed, you will need to install a fuel pressure sensor. Before installing the sensor, use Teflon tape on the male threads of the snubber valve. Thread the fuel pressure sensor into the snubber valve and tighten it using a 22mm wrench and an 18mm wrench.

If you are using a 12-valve banjo bolt and snubber valve combo, you can skip to the next step. Thread the snubber into the banjo bolt and tighten it using an 18mm wrench and a 19mm wrench. Install the new banjo bolt into the banjo fitting, ensuring you use two new crush washers, and thread it into the injection pump. Tighten it with a 19mm wrench.

Finally, plug the fuel pressure sensor harness into the fuel pressure sensor. You can now route the harness through an opening in the firewall on the driver's side of the engine bay and secure it using zip ties. Ensure that the harness does not come into contact with any direct heat source or moving parts of the truck.

The fuel pressure sensor can be installed on the truck

The tapped banjo bolt is for a 1/8" pipe fitting. You can purchase one from any vendor listed on the Cummins forum, and it should come with new sealing washers.

Once you have the bolt, you can install it, and then install your sender, and hook it up to the gauge.

For a mechanical fuel pressure gauge, you will need to remove the injection pump inlet banjo bolt, drill and tap a 1/8" port on top of it. Drill from the inside to keep the hole straight, and tap from the outside. Then, install a needle valve that is barely cracked open to the port, and then run a grease gun hose to the fender to mount the sender. You can purchase a needle valve from a hardware store.

Alternatively, you can put a tee fitting inline between the filter and CP3, and hook up the fuel pressure gauge to the outlet side.

It is important to note that a snubber valve is required when installing a GlowShift 30 PSI Fuel Pressure Gauge into a First Gen Cummins.

The fuel pressure gauge can be installed on the firewall

First, make sure you have all the necessary tools and parts for the installation. This includes things like wrenches, sockets, a ratchet, a drill, Teflon tape, zip ties, and the fuel pressure gauge itself. It's also important to work with a cool engine and disconnect the negative terminal of the battery to ensure there is no power running through the truck during the installation.

Next, you'll need to remove the injection pump feed line banjo bolt using a 19mm shallow socket, 3” extension, and a ratchet. Have a catch pan ready to collect any diesel fuel that may come out. Make sure to remove both crush washers or gaskets from the banjo fitting.

Before installing the fuel pressure sensor, apply Teflon tape to the male threads of the snubber valve. Thread the fuel pressure sensor into the snubber valve and tighten it securely. You can then thread the snubber into the banjo bolt and install the new banjo bolt into the banjo fitting, making sure to use new crush washers.

Now, it's time to plug the fuel pressure sensor harness into the fuel pressure sensor. If you removed the intercooler pipe earlier, you can reinstall it at this point.

Finally, route the fuel pressure sensor harness to an opening on the firewall on the driver’s side of the engine bay. Use zip ties to secure it, making sure it doesn't come into contact with any direct heat source or moving parts of the truck.

It's important to note that you may need to drill a hole in the firewall if there isn't one already. In that case, be sure to use a grommet to protect the wires from being sliced or cut on the firewall.

Once you've completed these steps, you can reconnect the negative terminal of the battery and start the engine to test the fuel pressure gauge.

Frequently asked questions