DODGE RAM 24V 5.9L CUMMINS

DODGE RAM 24V 5.9L CUMMINS

DODGE RAM 24V 5.9L CUMMINS TABLE OF CONTENTS SECTION 1 Preparing the Installation 1 SECTION 2 Boost Gauge Installation 2 SECTION Pyrometer/EGT Gauge Installation 4 SECTION 4 Transmission Temperature Gauge Installation 5 SECTION 5 Fuel Pressure Gauge Installation 6 SECTION 6 Installing & Wiring the Gauges 7 TOOLS NEEDED ACCESSORIES NEEDED 1/2 Wrench Various Drill Bits Safety Glasses Drain Pan 7/16 Wrench Center Punch Gloves Grommet /8 Wrench Marker Wire Connectors 7/8 Wrench 11mm Wrench 12mm Wrench 14mm Wrench Multi-Meter Size R Drill Bit 1/8 NPT Tap Tap Handle Thread Sealant Anti-seize Wiring Kit Zip Ties Heat Shrink Jack 16mm Wrench Wire Crimper 17mm Wrench 18mm Wrench 10mm Socket 19mm Socket Extension Ratchet #2 Phillips Screwdriver Wire Stripper Shop Vacuum Magnet Pen Ruler RECOMMENDED ACCESSORIES Gauge Wiring Kit Boost Bolt Test Port Extender Banjo Bolt / Snubber Valve Expandable Circuits

DODGE RAM 24V 5.9L CUMMINS SECTION 1 Preparing the Installation 1. Check that you have all parts required for installation, and the engine is cool. 2. Open the hood and locate the truck s batteries. Using a 1/2 wrench, disconnect the negative terminal of each battery to ensure there is no power running through the truck during the installation. Note: When it comes time to wire and connect the gauges to their power source, we will reconnect the negative terminals on the batteries. WITHOUT SPEAKER HOLE OPTION. Remove the factory trim by pulling and releasing the spring clips. 4. Insert the supplied plastic clip into the upper oval hole of the truck cab where the spring clip was secured. 5. Measure 4¼ down from the upper left side next to where the weather strip would be located and then 1¾ over. That will give you the correct hole placement for the screw. 6. Drill using a /16 drill bit. 7. Once gauges are installed and wired, secure with the supplied screw. WITH SPEAKER HOLE OPTION 1. Remove the factory trim by pulling and releasing the spring clips. 2. blade screwdriver.. Remove the speaker grill from the trim and install in the pod. Clip the speaker back into the speaker grill. 4. Insert the supplied plastic clip into the upper oval hole of the truck cab where the spring clip was secured. 4 5. Measure 4¼ down from the upper left side next to where the weather strip would be located and then 1¾ over. That will give you the correct hole placement for the screw. 6. Drill using a /16 drill bit. 7. Once gauges are installed and wired, secure with the supplied screw. 1

DODGE RAM 24V 5.9L CUMMINS SECTION 2 Boost Gauge Installation OPTION A: BOOST BOLT INSTALLATION: 1. Using a 10mm socket wrench, remove the front intake heater grid bolt. 2. boost gauge into the boost bolt and tighten using an 11mm and a 16mm wrench. Be sure to use 1. Install the boost bolt into the heater grid bolt hole and tighten with a 16mm wrench. Note: Torque to 120 inch-pounds. 4. Insert the ferrule cap and ferrule onto the boost and tighten the cap using a /8 wrench. 5. Secure with zip ties as needed. Boost Bolt 4 5 2

DODGE RAM 24V 5.9L CUMMINS SECTION 2 Boost Gauge Installation OPTION B: Drilling & Tapping the Intake Manifold Horn: 1. The boost gauge can also be installed by drilling and tapping the intake manifold horn to 1/8-27 NPT. First, mark the drilling location on the intake manifold horn using a marker and a center punch. 2. Remove the intake manifold horn from the truck to ensure no shavings enter the intake during the drilling and tapping process.. Starting with a 1/8 drill bit, drill a pilot hole into the intake manifold horn and gradually step up in drill bit size until you reach the size R drill bit. 1 4. Take the 1/8-27 NPT tap and slowly tap the size R hole in the intake manifold horn. Clean the manifold horn with a vacuum to remove all shavings. 5. Prepare the boost hose for installation by over the boost hose. Tip: clockwise on all male threads. 6. Install the compression adapter into the 1/8-27 NPT hole you tapped using an 11mm wrench. Using a 10mm wrench, tighten the compression Note: Do not overtighten. 4 5 7. driver side of the engine bay and use zip ties to secure the boost hose to ensure there is no contact with any direct heat source or moving parts of the truck. 8. Re-install intake manifold horn. 6

DODGE RAM 24V 5.9L CUMMINS SECTION Pyrometer EGT Gauge Installation 1. Mark and drill a hole for the EGT sensor on the manifold at cylinder 4 on the collector. Start small and step up in drill bit sizes until you get to size R. 2. Use a shop vacuum and a pen magnet to ensure you remove all the shavings from the manifold.. Tap the hole using a 1/8-27 NPT tap. 1 4. Use a shop vacuum and a pen magnet to ensure you remove all of the shavings from the manifold. 5. Use anti-seize on the threads. 6. tighten with a 12mm wrench. 7. height so that it is approximately in the middle of using a 12mm wrench. 8. Route the steel braided cable to the driver side Tap Drill 7 4

DODGE RAM 24V 5.9L CUMMINS SECTION 4 Transmission Temperature Gauge Installation 1. Safely jack up the truck for optimal installation accessibility. 2. Locate the test port on the passenger side of the transmission. The test port is located in the middle of the three ports. Using a 7/16 wrench, remove the test port plug. Note: Have a drain 2. of the test port extender as well as the male threads on the sensor. 4. Thread the sensor into the test port extender and tighten using 14mm and 17mm wrenches. 5. Thread the test port extender into the test port and tighten with a 17mm wrench. 6. Route wires from the sensor to the driver side the wires are not in contact with any direct heat sources or moving parts. 4 5 5

DODGE RAM 24V 5.9L CUMMINS SECTION 5 Fuel Pressure Gauge Installation 1. a drain pan. 2. Remove the injection pump feed line banjo bolt 19mm shallow socket, extension, and a ratchet. Have a drain pan ready for the diesel fuel that will come out. Make sure to remove both crush 1. Thread the snubber valve into the banjo bolt and tighten using an 18mm wrench. Note: A snubber valve is required to install a fuel pressure gauge into a 1989-2016 Dodge Cummins. The snubber valve regulates, normalizes and eliminates fuel pressure spikes that are present during the initial ignition and startup of the Dodge Cummins diesel engine. 4. making sure to install the two new crush washers included with the kit. Thread the banjo bolt into the injection pump and tighten with an 18mm wrench. 2 5. then thread the fuel pressure sensor into the 90 6. driver side of the engine bay and secure the wiring with zip ties ensuring there is no contact with any direct heat sources or moving parts. 5 Snubber Valve Banjo Bolt Crush Washers 6

DODGE RAM 24V 5.9L CUMMINS SECTION 6 Installing & Wiring the Gauges 1. is not available drill a hole and add a grommet). a. Feed the sensor wires and the EGT probe b. Route the boost line to the boost gauge and tighten using a /8 wrench. 2 c. Route all of the power and sensor wires from the gauges down the pillar and into the fuse box location. d. Route the fuel pressure sensor harness and plug it into the gauge. 2. Using the gauge wire kit, connect all of the red wires together. Connect all of the yellow, orange and black wires together, according to color.. Secure the A-pillar and pillar pod assembly back to its original location. a. Connect the wires from the EGT probe to the wires from the EGT gauge using the waterproof connector. The connector is fully sealed when an audible click is heard locking the connector in place. b. Connect the green trans temp signal wire extension to the white wire for the trans temp. c. Connect the black wire to a clean ground source. c 7

DODGE RAM 24V 5.9L CUMMINS SECTION 6 Installing & Wiring the Gauges 4. Attach the expandable circuits to both the red wire and the yellow wire. a. Remove the red 10 amp fuse from fuse location 8 for the radio circuit. Plug the fuse in the open section of the expandable circuit for the red wire and reinstall in the fuse box. 4 b. Remove the blue 10 amp fuse from fuse location 14 for the cluster B circuit. Plug the fuse in the open section of the expandable circuit for the yellow wire and reinstall in the fuse box. OPTION A: Push/Pull Style Headlight Switch Assembly: 5. Using a #2 Phillips head screwdriver, remove the screw at the power plug and carefully remove the dash trim and headlight switch. a. Route the orange wire to the headlight obtain the correct voltage for the dimming feature of the gauges. 4b b. Reinstall the headlight switch and the dash trim. 5 5a 8

DODGE RAM 24V 5.9L CUMMINS SECTION 6 Installing & Wiring the Gauges OPTION B: Twist Style Headlight Switch Assembly: 5. Using a #2 Phillips head screwdriver, remove the screw at the power plug and carefully remove the dash trim and headlight switch. 5 a. Route the orange wire to the headlight switch. Splice into the black wire with a yellow strip located at pin #1 in the headlamp switch connector, in order to obtain the correct voltage for the dimming feature of the gauges. b. Reinstall the headlight switch and the dash trim. 6. Reconnect the batteries and test the operation of the gauges. 7. Power the truck on to ensure that the gauges are functioning properly and check for any leaks or loose sensor connections. 5a 6 7 9

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