FUEL PRESSURE GAUGE AND SENSOR
INSTALLATION INSTRUCTIONS
1
2
3
Disconnect batteries. Do not reconnect battery power until
system is fully configured to avoid risk of fire.
Remove doghouse cover and locate the fuel pressure schrader valve test port located on the fuel
rail on the passenger side of the engine. It is usually covered with a black cap and is the only test
port located on the fuel rail.
Install the new sensor.
1. Installation of this fuel pressure gauge requires the removal of the fuel rail schrader
valve. It is essential that the vehicle’s ignition be turned off and the vehicle must be
completely cool.
2.Use a shop rag to absorb any fuel that leaks from the valve when opened. Depress
the valve to release any remaining pressure. Use CAUTION - EFI systems can maintain
in excess of 50 psi even when the engine is off.
3.Carefully remove the schrader valve from teh fuel outlet. A schrader valve tool (such
as is used for bicycle tire valve) is recommended.
4. Attach the aluminum fuel rail adapter to the fuel rail outlet. Tighten securely, but do
not overtighten. No sealant is required.
5. Re-connect the vehicle’s battery cable and cycle the ignition on and off several times.
This will pressurize the fuel system to allow you to confirm that there are no leaks.
4
If leakage occurs at the sensor, tighten slightly until leakage stops. Do NOT over-tighten.
Do not use the body of the sensor to tighten! Use only the hex and the correct wrench.
Do not over tighten!
5
Connect

the pressure sensor to the pressure sensor harness by pressing the connector into
the slot.
Figure 1: Pressure sensor and harness.
6
Route the sensor harness to the intended gauge mounting location, using grommets as appropriate
when passing through the firewall. Connect the sensor harness to the gauge.
Brazel’s RV Performance
3912 Harrison Ave. Centralia, WA 98531
Phone: 877-786-1576 Fax: 360-736-9497
www.brazelsrv.com
7
Connect one end of each of these wires as follows:
Ground – The black wire should connect to a clean ground on the
vehicle such as the battery negative terminal or a factory ground
bolt.
Ignition – The red wire should be connected to a circuit that
switches on with the key switch.
Figure 2: Connector.
Red wire should be fused so as not to exceed 3 amps. If the circuit
does not have a fuse, or the existing fuse is higher than 3 amps, use
an inline fuse.
1
2
3
4
5
6
Red
Orange
Black
Red/Yellow
Green
Black
Ignition
Dimmer
Ground
+5V
Sensor
Ground
Dimmer – Connect the orange/black wire to the factory gauge dimmer circuit by either tapping
into the in-cab fuse block or by connecting directly to the wire running from the dimmer on the
headlight switch.
NOTE: The gauge backlighting will only illuminate if both the ignition supply AND the
backlighting circuits are on.
8
Install the connector onto the back of the gauge (angled portion on end of connector pointing
up as in Figure 2), and then secure the gauge in its mounting location. If drilling a mounting hole in
a panel to mount this gauge, the hole size should be 2.040”.
9
Secure all wiring so that it does not interfere with moving parts or chafe on sharp edges. This
may be accomplished by routing the wiring within the factory wire harness sheath, using wire ties
and sheathing, and using appropriate grommets when passing through the firewall.
10
The warning light is designed to illuminate at 50 psi. The specification for fuel pressure on the
8.1L engine is 58-62 psi. On the 2001-2003 8.1L engine you can adjust the fuel pressure at the
fuel pressure regulator to reach desired specification. The fuel pressure regulator is located at
the rear of the engine on the driver side and has a vacuum line attached to it. Use a Torx T10
bit to adjust the pressure up by turning clockwise.
Brazel’s RV Performance
3912 Harrison Ave. Centralia, WA 98531
Phone: 877-786-1576 Fax: 360-736-9497
www.brazelsrv.com