LOW FUEL PRESSURE WARNING KIT
INSTALL DIRECTIONS For this installation you will need the following tools: a 7/16 inch wrench for 98 and 99 trucks only, a ½ inch open end wrench, a 19 mm or ¾ inch wrench, a pair of vise grips, wire strippers and a crimp tool for the provided butt connectors. You will also need a drill with a 5/16 inch bit. For 98 1/2 and 99 Dodge Diesel trucks remove the inner brass plug ( the one closest to the center of the filter housing ) on top of the fuel filter housing and screw in the sending unit there with the ½ inch wrench. Do not overtighten. For 2000-2002 Dodge Diesel trucks remove the banjo bolt/pressure test port on the supply line on the injection pump. This looks like a pressure test port, which it is, but it doesn’t work well for a permanent connection, so remove it, being careful not to lose the rubber sealing washers on either side of the fitting. Replace this with the supplied banjo bolt with both sealing washers. Tighten finger tight. Start the sending unit into the threads on the banjo bolt and finish tightening the assembly with the ½ inch wrench on the sending unit. You need not tighten this too tight as it is possible to break the banjo bolt. To install the indicator light drill a 5/16" hole. Snap the light assembly into the hole. Take an appropriate length of wire, crimp the ¼ inch female spade terminal to the end of the wire and push it onto the terminal on the sending unit. Run the other end of this wire to one of the leads of the indicator light and make a butt connection there. Connect the other wire from the indicator light to a length of wire going to the fuse box on the left side of the dash. Put the right angle pink terminal on the end of the wire and crimp with vise grips. Be sure it is tight on the wire. Find a fuse that is powered only when the truck is running, such as fuse number nine. Remove the fuse and install the fuse tap over a leg of the fuse and reinstall the fuse so the tap is on the top when you reinstall it. This insures that your installation is fuse protected. Connect the pink terminal there. You are done! It is normal for the light to be on first thing in the morning when the fuel is cold, or immediately after take off when cold. What you should be concerned about is constant on every time you accelerate, after the truck is warm. This constant low fuel pressure will eventually break the diaphragm in the front of the injection pump and then you will prematurely wear the timing piston sleeve and slowly but surely lose your mileage and power and eventually set the code 216. This code and or low fuel pressure does not result in an intermittent dead pedal or other drivability issues. These are caused only by a bad computer on the top of the injection pump. Low fuel pressure can cause low power at high loads and will appear as a buck, sort of like turning the key on and off under load, only under hard load. For more help diagnosing your fuel system feel free to call Blue Chip at 888-472-7373 | 
