A boost gauge can be installed on your vehicle's 7.3 Powerstroke diesel engine. Aftermarket companies produce boost gauges to fit your style, budget and your vehicle's air pressure requirements. The boost gauge port needs to be installed into the intake air-horn of your engine. This requires drilling and tapping into the air-horn. Special care needs to be taken to insure the hole is drilled accurately and straight; a faulty hole will not accept the fitting and will cause leaks in the system.
Slide the boost gauge into the front of the gauge pod until the gauge stops from going any further. Place the gauge mounting bracket onto the back side of the gauge to hold it in position in the pod. Different gauge manufacturers use different methods of securing the gauge. Refer to the owner's manual for proper bracket installation.
Mount the gauge pod onto the dashboard of your Powerstroke-equipped vehicle, using the screws provided and a screwdriver.
Route the wiring harness from the gauge to the fuse panel inside your vehicle. Attach the red wire to the fuse connector marked "Headlamp." Attach the black wire to the ground screw, using a screwdriver (the ground screw is green).
Slide the connector onto the end of the boost line. Leave about 1/2-inch of the line extending past the connector. Thread the connector onto the fitting on the gauge and tighten the nut with a wrench.
Route the boost line through the hole in the firewall. The hole is located on the driver's side of the engine, under the steering wheel.
Run the line to the intake air-horn, inside the engine compartment. The intake air-horn is on the rear of the engine cover (which has "Powerstroke" stamped on it) -- it is a cylindrical metal section that connects the large air hose to the turbocharger.
Drill a 5/16-inch hole into the top of the intake air-horn, using a metal drill bit and a power drill. Keep the drill straight to ensure that a quality hole is made.
Install the 1/8-inch NPT tap into the tapping tool hardware. Rotate the tapping tool into the hole while pressing it with your hand. This will provide threads in the hole for the NPT fitting to connect. Remove the tapping tool from the hole.
Thread the NPT fitting that came with the boost gauge into the hole. Tighten it, using a wrench.
Cut the boost hose to the desired length with a pair of scissors. Thread the NPT fitting onto the end of the boost line. Leave about 1/2-inch of line extending out from the connector and screw it onto the fitting in the intake air-horn. Tighten the fitting with a wrench.
Start the engine and check for any leaks in the system. Fix, if necessary.
