How-To: Fuel Gauge Kit (No Cutting)

[SilverBullet]

Here's how I did mine, probably how many other did theirs.

I was too chiken to cut the fuel line, so here's what I did. Also, I do not have pictures of the gauge and wirings since there's fairly simple.

As for the wiring, however, I routed them (grey, black, and purple) through the firewall behind the battery. I cut the wires (about one foot from the gauge connector) so I can get them through the firewall hole. Once through, I soldered them back together.

Autometer, Product #4363



I have the Mopar S3R Fuel Rail.

I removed fuel relay, cranked the car 2-4 times. I then removed Fuel Rail Shrader Valve using valve stem puller.

Next, I fitted all the fittings (1/8npt elbow, and just a bit larger than 1/4" brass fittings) and fuel hose nice and tight (I don't kow the size and pitch of the fuel rail). I used leftover hose from my WI kit, cut to length and bent to shape. I applied heat to the end of the hose before inserting the brass fittings. I used liquid sealer for the threads, 3/4 around. I did not apply the sealer on the first 2 threads.



I decided to wrap the hose since I wanted it black...and shrink wrap the ends.



Next, I applied liquid sealer 3/4 around the thread of the rail. I then fitted/threaded one end of the hose at the rail and tighten (about 8ft/lbs). I used a larger shrink wrap to fit around the end of the rail and part of the hose.



Here it is after I applied heat on the wrap.



With the Injector cover. Btw, I put some foam padding (not pictured) where the sender and the hose touch the intake manifold to help against vibration.



And for the gauge, it did not fit well in the stock gauge pod. The hole for the light was too high. The light bulb case was hitting the top part of the pod and it did not fit...until I cut some part of the pod.

I then put back the fuel realy, pressurized the system, checked for leaks, cranked the car, and sniffed for leaks. All good.

Anyway, why I did it this way? Because I did not want to cut and T off the fuel line and I wanted to keep it far enough from the turbo and the intake air filter.

Readings out of the gauge:

Idle = 46psi

4th gear, 1650rpm, 18in.HG = 46psi

Decel = 42-44psi then slowly goes back up to 46psi

I did not try to drive hard tonight because I was tired and sleepy. So those are the only readings I got.

[ptc01]

I plumbed my transducer (sending unit) right off of the end of the fuel rail and ran the wiring from there into the cabin. Its been on for 3 years now without any issues. Good thinking on keeping it away from the hot side too.

[SilverBullet]

Thanks.

Good to hear yours has been holding well. I was going to do like you did but I did not want to take a chance of it breaking the rail.