dbrannon79
I'm getting there!
I've put together some links from the jungle site for fittings needed to add a permanent mounted fuel pressure gauge to a DS4 IP. keep in mind that your FFM has the fuel inlet hose routed underneath the intake and this hose is a pre-formed hose. this process will require you to pull this hose out and replace it with a normal diesel rated hose adding some extra length to it so you can connect all of these fittings together. preferably if at all possible find a method to raise the FFM up or relocate it so that you can run the hose over the intake and get it out of the valley and heat.
to start off, there is a 5/16" fitting threaded into the large nut on the IP that needs to be removed. this large nut is actually another fitting threaded into the IP housing which has a fine mesh filter screen. This part you will keep and reuse, sometimes it's necessary to remove it from the IP housing in order to loosen the smaller fitting from it.
Once you remove the 5/16" barb fitting from the inlet screen you can thread this 90deg fitting into it with an o-ring. the threads are 7/16-20 UNF and in the hydraulic world is called a male #4 boss or male -4 ORB. the other end will be a #6 JIC or -6an.
https://www.amazon.com/EVIL-ENERGY-Swivel-Adapter-Fitting/dp/B0CRH7CWQV
Next you will need the tee fitting with male to female #6 JIC or -6an with an 1/8" npt (sae pipe) in the middle. This tee is where you can install an electric sending unit for a fuel pressure gauge or for temporary diagnosis use a mechanical gauge. Use an 1/8" npt plug when diagnosis is done if going with a mechanical gauge.
BUT... NEVER permanently mount a mechanical gauge with a live fuel line going into the cab. that's asking for a load of big trouble and a huge fire risk.
https://www.amazon.com/EVIL-ENERGY-Pressure-Fitting-Aluminum/dp/B09TT5P3RV
Finally you will need a 5/16" hose barb to female #6 JIC or -6 an to connect to the rubber fuel hose coming from the FFM. This is where you will need to replace the factory pre-formed hose on the FFM with a diesel rated longer piece of 5/16" hose.
https://www.amazon.com/EVIL-ENERGY-Fitting-Straight-Aluminum/dp/B09494FV4N
Now that you have links and photos of the fittings needed, keep in mind that these links might not work some years after this is posted, the jungle site likes to change things up from time to time. I provided photos of what they look like. all of these fittings can be had at your local Napa using fuel and some hydraulic fittings. And remember to stay away from using brass fitting with fuel, steel and aluminum are fine to use.
Later on if you, like others have, decide to do what's called the "Feed The Beast" mod by increasing the fuel hose from 5/16" to 3/8" which requires you to modify the factory FFM or buy one ready to go from Leroy, you will need a different hose barb to AN fitting and better larger rubber hose. This fitting is a 3/8" push-lock type barb to female #6 JIC or -6 AN.
https://www.amazon.com/EVIL-ENERGY-Straight-Fitting-Black/dp/B08NYMGWCM
I will let others post pictures of their setups and links where they found these fittings at as well as rubber hose types. Some have even gone as far as running dual electric sending units, one at the IP with the above fittings and the other before the FFM at the lift pump and running on a toggle switch with a single gauge in the dash.
This gives you the best diagnosis on fuel pressure. Allows you to monitor when your fuel filter in the FFM or if running aftermarket filters, when it's time to replace filters rather than guessing if the filter is clogged up.
If I left anything out, please feel free to add to or correct what I have posted here too!
Disclaimer: you might see something about affiliate links on these from the jungle site. I am not affiliated with them at all and they seem to popup each time one of these links are posted.
to start off, there is a 5/16" fitting threaded into the large nut on the IP that needs to be removed. this large nut is actually another fitting threaded into the IP housing which has a fine mesh filter screen. This part you will keep and reuse, sometimes it's necessary to remove it from the IP housing in order to loosen the smaller fitting from it.
Once you remove the 5/16" barb fitting from the inlet screen you can thread this 90deg fitting into it with an o-ring. the threads are 7/16-20 UNF and in the hydraulic world is called a male #4 boss or male -4 ORB. the other end will be a #6 JIC or -6an.
https://www.amazon.com/EVIL-ENERGY-Swivel-Adapter-Fitting/dp/B0CRH7CWQV
Next you will need the tee fitting with male to female #6 JIC or -6an with an 1/8" npt (sae pipe) in the middle. This tee is where you can install an electric sending unit for a fuel pressure gauge or for temporary diagnosis use a mechanical gauge. Use an 1/8" npt plug when diagnosis is done if going with a mechanical gauge.
BUT... NEVER permanently mount a mechanical gauge with a live fuel line going into the cab. that's asking for a load of big trouble and a huge fire risk.
https://www.amazon.com/EVIL-ENERGY-Pressure-Fitting-Aluminum/dp/B09TT5P3RV
Finally you will need a 5/16" hose barb to female #6 JIC or -6 an to connect to the rubber fuel hose coming from the FFM. This is where you will need to replace the factory pre-formed hose on the FFM with a diesel rated longer piece of 5/16" hose.
https://www.amazon.com/EVIL-ENERGY-Fitting-Straight-Aluminum/dp/B09494FV4N
Now that you have links and photos of the fittings needed, keep in mind that these links might not work some years after this is posted, the jungle site likes to change things up from time to time. I provided photos of what they look like. all of these fittings can be had at your local Napa using fuel and some hydraulic fittings. And remember to stay away from using brass fitting with fuel, steel and aluminum are fine to use.
Later on if you, like others have, decide to do what's called the "Feed The Beast" mod by increasing the fuel hose from 5/16" to 3/8" which requires you to modify the factory FFM or buy one ready to go from Leroy, you will need a different hose barb to AN fitting and better larger rubber hose. This fitting is a 3/8" push-lock type barb to female #6 JIC or -6 AN.
https://www.amazon.com/EVIL-ENERGY-Straight-Fitting-Black/dp/B08NYMGWCM
I will let others post pictures of their setups and links where they found these fittings at as well as rubber hose types. Some have even gone as far as running dual electric sending units, one at the IP with the above fittings and the other before the FFM at the lift pump and running on a toggle switch with a single gauge in the dash.
This gives you the best diagnosis on fuel pressure. Allows you to monitor when your fuel filter in the FFM or if running aftermarket filters, when it's time to replace filters rather than guessing if the filter is clogged up.
If I left anything out, please feel free to add to or correct what I have posted here too!
Disclaimer: you might see something about affiliate links on these from the jungle site. I am not affiliated with them at all and they seem to popup each time one of these links are posted.
As an Amazon Associate we earn from qualifying purchases.
