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DIY Fuel pressure test gauge

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How to....

Hi all,
for proper trouble shooting of the k-jet system, you need a fule pressure test gauge. You can buy full kits on ebay and the like, but many don;t have the right connections, and you may end up playing for more stuff that you really need. Whilst there are plenty of threads that mention building your own, I never actaully found one that listed the parts required. So, I worked it out, built my own, and am sharing my parts list in the hope that it may help others.

Parts list: All in ~£35

The above parts will be available from places other than ebay, but I really struggled to find the correct fitting for the metering head anywhere other than ebay. It is possible to use a banjo and banjo bolt in place of the adaptor screwed into the metering head, but plenty of folk have snapped the adaptor trying to remove it so I wanted to correct fitting.

My gauge doesn't use the existing pipe from the WUR to metering head, so I can use a banjo fitting at the WUR end. The banjo fitting I bought (listed above) is quite large, it didn't fit on the WUR next to the other connection. After some careful measuring, I flatted one side of the fitting by about 1mm to allow it to fit. You can probably get lower profile banjo fittings, but I didn't think of that issue when I bought mine!

I'd say that 1 metre of fuel hose is the minimum you can get away with. You'll need some PTFE tape for the threaded joints.

Assembly diagram:

KjetGauge.jpg

Installed on the car:

PXL_20210429_125331225.jpg

Note where I had to flat off the banjo on the WUR end of the pipe.

PXL_20210429_125342361.jpg

Hope this proves useful to someone.
 

Last edit: by paceman


My rebuild thread I will try and keep up to date: here

K-Jet fuel pressure test guage How-To

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Hey paceman thanks for this guide. I've ordered everything exact the last item as the eBay link is dead:

1/4" ID X M12X1.5 STR FEM CONE/O-RING

I'm trying to work out exactly what it is so I can order it elsewhere but am struggling. Can you help please?

Last edit: by gregpank


‘81 Golf GTi Mk1 TSR1600 tintop
'90s Chesil Speedster on '70 VW Beetle Chassis
‘14 Golf GTi Mk7

 

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Nice, I made a similar one from an old a/c gauge I had.  It would go up to 300psi…

What do Divorces, Great Coffee, and Car Electrics all have in common?

They all start with GOOD Grounds.

Where are my DIY Links?

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‘81 Golf GTi Mk1 TSR1600 tintop
'90s Chesil Speedster on '70 VW Beetle Chassis
‘14 Golf GTi Mk7

 

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I'll dig mine out at lunch time and look at the fitting…

My rebuild thread I will try and keep up to date: here

K-Jet fuel pressure test guage How-To

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Couple of photos below. Looks like the one you suggested but they were all imperial thread. You need one that is M12 x1.5.
The one I bought has a rubber seal in it but that isn't a requirement.

PXL_20230522_122535305.jpg

PXL_20230522_122530556.jpg

My rebuild thread I will try and keep up to date: here

K-Jet fuel pressure test guage How-To

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I've just done a quick google for M12 x 1.5 cone seat. You can get them, but by god are they expensive!
I think your best bet would be a banjo bolt and fitting straight, or a threaded tail (similar to what connects the hose to the pressure gauge albeit in metric) into the metering head. You'll need to remove the adaptor that is currently there (this is the bit the pipe connects to, you'll see it is threaded in. Mine came out really easily, but I know of others that have snapped them trying to get them out.
I'm not sure what thread size it is, I'd guess at either M8 or M10.

My rebuild thread I will try and keep up to date: here

K-Jet fuel pressure test guage How-To

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DIY Fuel pressure test gauge

Thanks again [mention]paceman [/mention]   Tbh at this point I don’t mind spending a few quid more for the right fitting. I’d rather not use the latter option and snap anything.

Would you be able to send me a link for the original more expensive item? Sorry, I’m getting a bit lost on this!

(As you may have gathered from my other post, thought I’d fixed my WUR issue by replacing the junior timer connector but the problem returned two days later )

TIA for all your help mate


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‘81 Golf GTi Mk1 TSR1600 tintop
'90s Chesil Speedster on '70 VW Beetle Chassis
‘14 Golf GTi Mk7

 

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Re: DIY Fuel pressure test gauge

gregpank said

Thanks again [mention]paceman [/mention]   Tbh at this point I don’t mind spending a few quid more for the right fitting. I’d rather not use the latter option and snap anything.

Would you be able to send me a link for the original more expensive item? Sorry, I’m getting a bit lost on this!

(As you may have gathered from my other post, thought I’d fixed my WUR issue by replacing the junior timer connector but the problem returned two days later )

TIA for all your help mate


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Have a kit will send you an imaged tomorrow willing to post at your cost and send it back to me if you're interested

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Do not know a lot but willing to help if possible

1989 Sapphire Blue Mk1 Cabriolet KR
1985 Atlas Grey Mk2 GTI 2.0 ABF

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DIY Fuel pressure test gauge

[mention]nicci21paul [/mention] that’s a very generous offer! Thank you and an image would be great. I may take you up on your offer of a lend. Out of interest, where are you?


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‘81 Golf GTi Mk1 TSR1600 tintop
'90s Chesil Speedster on '70 VW Beetle Chassis
‘14 Golf GTi Mk7

 

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Paul is a top bloke!

So just seen this one but no idea if it is a cone seat https://www.fluidairfittings.co.uk/products/non-branded-psmfl06-04cf?variant=42923165778165

This was the one I saw earlier… A lot more expensive but definitely a cone seat.
https://pneumaticsdirect.co.uk/product/m12-x-15-metric-female-x-hose-tail-24-cone-seat

My rebuild thread I will try and keep up to date: here

K-Jet fuel pressure test guage How-To

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DIY Fuel pressure test gauge


‘81 Golf GTi Mk1 TSR1600 tintop
'90s Chesil Speedster on '70 VW Beetle Chassis
‘14 Golf GTi Mk7

 

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Looks alright to me.

My rebuild thread I will try and keep up to date: here

K-Jet fuel pressure test guage How-To

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DIY Fuel pressure test gauge

Thanks [mention]paceman [/mention] I?ve order the second one. I?d already ordered all the other parts in your list before [mention]nicci21paul [/mention] made his kind offer - so I?m committed now! But Paul will let you know if I do need to borrow yours. A photo or two wouldn?t go amiss though!

On holiday this week so all the parts will be sitting there when I get back so much fun awaits. As they say, ?What?s the WURst that can happen?? *groan* ?


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‘81 Golf GTi Mk1 TSR1600 tintop
'90s Chesil Speedster on '70 VW Beetle Chassis
‘14 Golf GTi Mk7

 

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I had this one made up by a local hydraulic engineer years ago, you just take the hose from the WUR off the metering head and connect it to the tap and connect the flexy end to the head.
But, the connections are not exact, they're probably imperial but so long as it's not over tightened it works fine, I've never had a leak from it.
DSC00762.JPG

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DIY Fuel pressure test gauge

Good news is all the parts turned up and have assembled the kit.

Bad news is i cant separate these two parts on the metering head. Im just double checking this in fact two parts and not one?


‘81 Golf GTi Mk1 TSR1600 tintop
'90s Chesil Speedster on '70 VW Beetle Chassis
‘14 Golf GTi Mk7

 

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Re: DIY Fuel pressure test gauge

gregpank said

Good news is all the parts turned up and have assembled the kit.

Bad news is i cant separate these two parts on the metering head. Im just double checking this in fact two parts and not one?

Two parts just had one to bits today must try harder

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Do not know a lot but willing to help if possible

1989 Sapphire Blue Mk1 Cabriolet KR
1985 Atlas Grey Mk2 GTI 2.0 ABF

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Re: Re: DIY Fuel pressure test gauge

nicci21paul said

gregpank said

Good news is all the parts turned up and have assembled the kit.

Bad news is i cant separate these two parts on the metering head. Im just double checking this in fact two parts and not one?

Two parts just had one to bits today must try harder

Sent from my SM-G975F using Tapatalk

End result absolutely mint dx in a stunning rivage

Sent from my SM-G975F using Tapatalk


Do not know a lot but willing to help if possible

1989 Sapphire Blue Mk1 Cabriolet KR
1985 Atlas Grey Mk2 GTI 2.0 ABF

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Re: Re: Re: DIY Fuel pressure test gauge

nicci21paul said

nicci21paul said

gregpank said

Good news is all the parts turned up and have assembled the kit.

Bad news is i cant separate these two parts on the metering head. Im just double checking this in fact two parts and not one?

Two parts just had one to bits today must try harder

Sent from my SM-G975F using Tapatalk

End result absolutely mint dx in a stunning rivage

Sent from my SM-G975F using Tapatalk

Mark Dempseys rivage

Sent from my SM-G975F using Tapatalk



1801 views (74 Kb)

1801 views (103 Kb)

Do not know a lot but willing to help if possible

1989 Sapphire Blue Mk1 Cabriolet KR
1985 Atlas Grey Mk2 GTI 2.0 ABF

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Re: Re: Re: Re: DIY Fuel pressure test gauge

nicci21paul said

nicci21paul said

nicci21paul said

gregpank said

Good news is all the parts turned up and have assembled the kit.

Bad news is i cant separate these two parts on the metering head. Im just double checking this in fact two parts and not one?

Two parts just had one to bits today must try harder

Sent from my SM-G975F using Tapatalk

End result absolutely mint dx in a stunning rivage

Sent from my SM-G975F using Tapatalk

Mark Dempseys rivage

Sent from my SM-G975F using Tapatalk



1801 views (74 Kb)

1801 views (103 Kb)
That is Mark in the picture not myself

Sent from my SM-G975F using Tapatalk


Do not know a lot but willing to help if possible

1989 Sapphire Blue Mk1 Cabriolet KR
1985 Atlas Grey Mk2 GTI 2.0 ABF
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