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MV5546 - A&A Hydraulic for the best in Mityvac parts.

1. Fuel Pressure Test Kit nn aC MODEL MV5546 USER S MANUAL Have a technical question If you have questions or require technical service please contact our trained service technicians at 1 314 679 4200 ext 4782 Monday Friday 7 30 am to 4 15 pm CST Visit our website at www mityvac com for new products catalogs and instructions for product use Need service parts To order replacement or service parts visit us online at www mityvacparts com or call toll free 1 800 992 9898 OCT 2007 Form 824129 Section MV64 Page 1 Fuel Pressure Test Kit MODEL MV5546 Table of Contents injigero B e HON ERE EO TR 3 Safety PrecaullOFlso uiis reu sasinen pauta bass kiaiii iar 3 DSC CANO INS lt a cscs ae tuum eua irse see see eet 3 ACCeSSOr GS E 4 Service PAINS eerdere ieaiaia 4 FuelSystem TestAdapters cccccccsseceeeeeeseeeeeeeeseeeeeeeseeeeeaeees 5 FuelSystemPressure TeSting c ccsscccccssseeeeccsseeeesesseeeesaeees 7 TestProcedures eesesesssseeen e nennen nnne nennen 8 GB CUI OMNIS sirrcna MM ME DP LE ELI 11 Page Number 2 Form 824129 nmityvac Introduction The Mityvac Fuel System Pressure Test Kit is designed to perform fuel pressure testing on most domestic and imported cars and trucks that are equipped with return and returnless electronic fuel injection systems The tester can help identify and diagnose e Low fuel pressure e Faulty fuel pump e Faulty fuel pressure reg
2. 0 to 8 bar 0 to 800 kPa scale of measure Push button pressure relief valve 360 swivel hook Protective rubber boot e 1 8 3 mm ID x 6 1 8 m long Pressure Relief Hose e 5 16 8 mm ID x 4 1 2 m long Extended Pressure Hose e Inline Pressure Test Hose e 2x Scissor Hose Clamp e Custom Storage Case e Automotive Fuel System Test Adapters see pages 5 6 e 6x Quick connect Replacement Clip Page Number 3 Fuel P Test Kit MODEL MV5546 nmityvac Accessories Part Number Description Service Parts Part Number Description 824183 Wing Style Hose Clamp Qty 4 824179 Storage Case 824141 High Pressure Gauge 824149 Pressure Relief Hose 1 8 3mm x 6 1 8m long 824144 Scissor Hose Clamps Qty 2 Page Number 4 Form 824129 Fuel Pressure Test Kit nmityvac MODEL MV5546 Fuel System Test Adapters Description Applications nme GM Chrysler Right Angle pa g ad Pip MVAS507 Test Port Adapter ee ee thread test port on fuel rail Ford amp some Chrysler vehicles with 308 x 32 MVA508 MVA510 MVA511 MVA512 thread test port on fuel rail 16A MVA505 16B 16C GM amp some Chrysler vehicles with he x 20 thread test port on fuel rail Ford amp some Chrysler vehicles with 308 x 32 thread test port on fuel rail 13B Toyota MVA513 13A 14B Toyota MVA514 14A 15B MVA515 15A MVA516 9A 12A MVA517 12B 10A MVA518 10B F
3. amp early fuel injected systems he Flare Nut Adapter h Spring Lock Adapter Ford fuel injection systems k Spring Lock Adapter Ford fuel injection systems s Quick Change Adapter GM Chrysler Jeep Eagle nmityvac Connections Adapters The MV5546 includes a selection of adapters for connecting to the pressure test port or inline with the fuel delivery systems of a wide range of automotive makes and models The chart on pages 5 and 6 outlines the adapters available and their appli cations Each adapter is etched with an identification number for easy reference Adapters can be purchased separately in sets according to the order number indicated in the chart In most cases selecting and installing adapters into the fuel delivery system and connecting the inline pressure test hose for testing is straightforward and logical Simply match the fuel system connection to the equivalent male and female adapter set and install them as outlined in the instructions later in this manual Banjo Connections Banjo style connections are commonly used by many Asian and European manufacturers to connect a hose or fuel line to the filter and or the fuel rail Often this will be the best place to connect the inline pressure test hose with the fuel system This type of connection may be a little confusing the first time it is encountered A banjo connection consists of a round hollowed out banjo connector with tw
4. pressure on the fuel system by pressing the pressure relief valve located on the stem of the pressure gauge Fig 56 Watch the pressure gauge readings and fuel be ing released through the small clear hose to the collecting container Make sure that the pressure relief hose is routed and secured into an approved gasoline fuel container Place shop towels under the connections to capture any fuel that may spill out when the hoses are disconnected WARNING After testing a returnless fuel system use extreme caution when disconnecting the hoses to the fuel rail If the engine is hot releasing the pressure from a returnless fuel system will cause the fuel to boil in the fuel rail Even though the pressure has been released the boiling fuel will cause it to build up again once the hose is clamped To reduce the risk of fuel spray it is best to allow the engine to cool before disconnecting the hose Other wise use the pressure relief valve to relieve the pressure just before removal Try to keep a shop towel wrapped around the connection to catch any fuel spray Disconnect the Schrader port adapter or the inline pres sure test assembly Remove the fuel rail adapters if applicable Reconnect the fuel lines Page Number 11 Fuel Pressure Test Kit n MODEL MV5546 nmityvac Lincoln Industrial Standard Warranty LIMITED WARRANTY Lincoln warrants the equipment manufactured and supplied by Lincoln to be free from defects in material an
5. service information If the engine has a cover it will most likely have to be removed to gain appropriate access 4 Remove or disconnect any obstacles required to gain ac cess to the connection and place shop towels under and around the connection to absorb fuel from the disconnect ed line To minimize fuel spillage and reduce the amount of time the fuel line is disconnected try to identify the type of connection before disconnecting the fuel line and have the required fuel connection adapter s readily available 5 Follow the vehicle manufacturer s service information for the proper method to disconnect the fuel line Special wrenches or disconnect tools may be required WARNING Avoid spilling fuel on hot engine parts Clean up any fuel spills immediately after they occur 6 Install the appropriate adapter into the fuel supply line extending from the tank 7 Connect the inline pressure test assembly to the inlet and outlet fuel line adapters 8 Connect the extended pressure hose to the tee in inline pressure test assembly Form 824129 nmityvac 9 Connect the pressure gauge to the other end of the ex tended pressure hose 10 Before proceeding e Double check the connections e Route and secure the clear pressure relief hose into an approved gasoline container e Route any hoses away from any rotating engine com ponents belts fans and hot exhaust components e Remove the fuel spillage rags e Reconnect compone
6. Page Number 8 Fig 7 Form 824129 nmityvac Connection Types The Mityvac MV5546 is capable of connecting to and testing the following types of fuel systems 1 All fuel injection systems that are factory equipped with suitable fuel pressure test ports on the fuel rail Schrader valve ports 2 Fuelinjection systems that are equipped with a removable fuel pressure inlet line that can utilize one of the many adapters covered on Pages 5 amp 63 Fuel injection systems that are not equipped with a fuel pressure test port or a removable pressure line but are equipped with a flexible rubber hose line into the fuel rail The inline pressure test hose utilizes a special female quick connect fitting Fig 9 This fitting was selected because it conforms to the SAE J2044 specification for fuel fittings it is a common fuel delivery system connection on which many manufacturers are standardizing and the connection releases with a simple push button action No special tools are required to disconnect the fittings The pressure gauge extension hose as well as the adapters and fittings that connect into the fuel system have the com plimenting male SAE J2044 endform Fig 10 To secure the male to female connection simply push the male endform into the female quick connect until it snaps securely into place Fig 11 Always test the connection by trying to pull it apart without pressing the release button To release
7. amages arising out of the sale resale or use of any Lincoln equipment shall in no event exceed the purchase price Some jurisdictions do not allow the exclusion or limitation of incidental or consequential damages therefore the above limitation or exclusion may not apply to you This warranty gives you specific legal rights You may also have other rights that vary by jurisdiction Customers not located in the Western Hemisphere or East Asia Please contact Lincoln GmbH amp Co KG Walldorf Germany for your warranty rights Lincoln Industrial Contact Information To find Lincoln Industrial s Nearest Service Center call the following numbers or you may also use our website Customer Service314 679 4200 Website lincolnindustrial com Americas Europe Africa Asia Pacific Copyright 2007 One Lincoln Way Heinrich Hertz Str 2 8 51 Changi Business Park Printed in USA St Louis MO 63120 1578 D 69183 Walldorf Central 2 USA Germany noue ene Web site Phone 1 314 679 4200 Phone 49 6227 33 0 ee www lincolnindustrial com Page Number 12 Form 824129
8. anjo fitting back to the vehicle s original specification Form 824129 Fuel Rail Banjo Bolt Adapter Fig 2 Banjo Adapter Fuel Pressure Test Kit MODEL MV5546 Banjo Fitting Banjo Fitting Banjo Bolt Closed End Nut Fig 3 Fuel Filter Page Number 7 Fuel Pressure Test Kit MODEL MV5546 Flex Hose Connections In many cases it is convenient to connect the inline pressure test hose into the fuel delivery system at a location where a flexible rubber hose is secured to a steel fuel line using a screw clamp A special adapter set is included with the MV55406 for installing the inline pressure test hose into this type of connection It includes a universal barb adapter three flexible hose adapters 1 4 5 16 3 8 and four wing screw clamps To install the flex hose adapters 1 Follow the proper procedure under the setup instructions to relieve the fuel pressure and prepare for disconnecting 2 Loosen the screw clamp securing the rubber hose to the steel fuel line on the vehicle s fuel delivery system and carefully disconnect the rubber hose Fig 4 3 Insert the universal barb adapter 16 into the rubber hose Fig 5 and tighten the hose clamp Fig 6 4 Select the appropriate size flex hose adapter 1 4 5 16 or 3 8 and install it onto the steel fuel line Fig 7 Se cure it with one of the wing screw clamps provided Fig 8 5 Follow normal testing procedures
9. attended while testing e Check and secure all fuel system connections before starting the vehicle or activating the fuel pump e Wear gloves and protective clothing to avoid the contact of gasoline on skin If contact occurs immediately wash the area and perform necessary first aid e Always keep a fire extinguisher on hand when perform ing fuel related diagnostics Make sure the extinguisher is rated for fuel electrical and chemical fires e Avoid spilling fuel on hot engine parts Clean up any fuel spills immediately after they occur Form 824129 Fuel Pressure Test Kit MODEL MV5546 Specifications Maximum Rated Pressure 120 PSI 800 kPa 8 bar Components Service Parts and Accessories The Mityvac Fuel Pressure Test Kit combines the highest quality materials and workmanship to create a durable finely tuned diagnostic tool which with proper care will provide years of valuable service All components are designed and quality controlled in the U S Following is a list of standard components service parts and accessories relating to model MV5546 Components and accessories are available from your local Mityvac distributor Service parts warranty information and technical service information are available at the contact information shown on the front of this user manual Standard Kit Components Model MV5546 includes the following high quality components e 3 5 90 mm diameter diaphragm style Pressure Gauge Oto 120 PSI
10. d workmanship for a period of one 1 year following the date of purchase excluding there from any special extended or limited warranty published by Lincoln If equipment is determined to be defective during this warranty period it will be repaired or replaced within Lincoln s sole discretion without charge This warranty is conditioned upon the determination of a Lincoln authorized representative that the equipment is defective To obtain repair or replacement you must ship the equipment transportation charges prepaid with proof of purchase to a Lincoln Authorized Warranty and Service Center within the warranty period This warranty is extended to the original retail purchaser only This warranty does not apply to equipment damaged from accident overload abuse misuse negligence faulty installation or abrasive or corrosive material equipment that has been altered or equipment repaired by anyone not authorized by Lincoln This warranty applies only to equipment installed operated and maintained in strict accordance with the written specifications and recommendations provided by Lincoln or its authorized field personnel THIS WARRANTY IS EXCLUSIVE AND IS IN LIEU OF ANY OTHER WARRANTIES EXPRESS OR IMPLIED INCLUDING BUT NOT LIMITED TO THE WARRANTY OF MERCHANTIBILITY OR WARRANTY OF FITNESS FOR A PARTICULAR PURPOSE In no event shall Lincoln be liable for incidental or consequential damages Lincoln s liability for any claim for loss or d
11. nded pressure hose to the pressure gauge 7 Before proceeding e Double check the connections e Route and secure the clear pressure relief hose into an approved gasoline container e Route any hoses away from any rotating engine com ponents belts fans and hot exhaust components e Reconnect components such as PCV tubes wiring harnesses vacuum tubes etc that were discon nected to gain access to the test port 8 Re enable the fuel pump if previously disabled and cycle the ignition switch to the ON position for a brief time and then back OFF Do not start the engine On most vehicles cycling the ignition ON and OFF will allow the fuel pump to run briefly and prime the system After cycling the ignition check all fuel connections for leaks If all fitting connections are secure the installation is complete and the fuel pressure tester is ready to be used for diagnostic tests Page Number 10 nmityvac Connecting to System with Fuel System Adapters 1 Be sure the vehicle transmission is in park or neutral the parking brake is engaged and the engine is off 2 Follow the vehicle manufacturer s recommended proce dure to relieve the pressure from the vehicle fuel delivery system 3 Locate the fuel supply line to the engine s fuel rail and select the best location to disconnect the supply line and install the inline pressure test assembly For additional assistance consult the vehicle manufac turer s
12. nts such as PCV tubes wiring harnesses vacuum tubes etc that were disconnect ed to gain access to the fuel line connection 11 Re enable the fuel pump if previously disabled and cycle the ignition switch to the ON position for a brief time and then back OFF Do not start the engine On most vehicles cycling the ignition ON and OFF will allow the fuel pump to run briefly and prime the system After cycling the ignition check all fuel connections for leaks If all fitting connections are secure the installation is complete and the fuel pressure tester is ready to be used for diagnostic tests Test Procedures Key On Engine Off Test Cycle the ignition switch to the ON position Verify that the pressure gauge indicated a system pressure within the specifi cation provided by the manufacturer If the reading is within the manufacturer s specification proceed to the Key On Engine On test If it is not follow the test and repair procedures out line in the vehicles service manual to correct the problem Key On Engine On Test 1 Complete all the steps indicated in the Key On Engine Off test 2 Startthe car and idle the engine Recheck the test setup for fuel leaks 3 Read the fuel pressure from the gauge 4 Turn the car off when the readings have been made Form 824129 Fuel Pressure Test Kit MODEL MV5546 Disconnecting the Fuel Pressure Tester When vehicle testing is completed turn off engine and re lieve
13. o flat sides A hollow bolt with a cross hole passes through the banjo connector and threads into the connecting component i e filter fuel rail When the bolt is tightened it creates a secure face to face seal through which the fuel flows See Fig 1 for an illustration of this connection Two 2 threaded adapters and a closed end nut are required to properly install the inline pressure test hose into a banjo style connection Refer to the adapter chart on pages 5 and 6 for a list of the banjo adapters included with the kit To install the banjo adapters 1 Follow the proper procedure recommended by the manu facturer to relieve the fuel pressure and proportion for disconnecting 2 Loosen and remove the bolt from the banjo connection at the fuel filter or fuel rail 3 Passthe hollow adapter with the cross hole through the banjo fitting Be sure to include a washer on both sides of the banjo fitting Fig 2 4 Thread the closed end nut onto the end of the bolt and tighten securely with a wrench trapping the banjo fitting 5 Thread the hollow bolt adapter without the cross hole into the filter or fuel rail in place of the original bolt and tighten securely with a wrench Be sure to include a washer between the face of the filter or fuel rail and the opposing face of the adapter bolt Fig 3 6 Follow normal testing procedures NOTE Always throw away the original used washers and replace them with new when reconnecting the b
14. orm 824129 Page Number 5 e Ford Chrysler Right Angle Test Port Adapter N wank MEE Y n a GM Chrysler Test Port Adapter Ford Chrysler Test Port Adapter A Quick change Adapter GM Chrysler Jeep Eagle Vehicles with hs or s rubber to steel hose connection 4 Ye Barbed Flex Hose Adapter o Vehicles with 1 4 rubber to steel hose connection Flex Hose Adapter Vehicles with 1s rubber to steel hose connection he Flex Hose Adapter Vehicles with 3 rubber to steel hose connection Flex Hose Adapter M8 x 1 0 Banjo Adapter M10 x 1 0 Banjo Adapter Toyota Lexus Geo Honda Acura Hyundai Mazda Daihatsu Chrysler imports M12 x 1 25 Banjo Adapter M12 x 1 5 Banjo Adapter Audi Volkswagen M12 x 1 5 Ball Nose Adapter European vehicles with CIS fuel system M14 x 1 5 Ball Nose Adapter European vehicles with CIS fuel system Fuel Pressure Test Kit MODEL MV5546 mityvac Fuel System Test Adapters 2595 KE Movies Se ptt i RILE ENN S 11A M16 x 1 5 Ball Nose Adapter European vehicles with CIS fuel system GM Vortec GM Vortec 3 Flare Nut Adapter Na caben en Page Number 6 Form 824129 MVA519 M16 x 1 5 Adapter M14 x 1 25 Adapter Carbureted
15. the connection press and hold the release but ton on the side of the female quick connect while pulling the connection apart Fig 11 Do not attempt to release the quick connect connection using a disconnect tool as this may damage the fitting Replacement clips are included if needed Form 824129 Fig 9 Fig 11 Fuel Pressure Test Kit MODEL MV5546 Fig 10 Page Number 9 Fuel Pressure Test Kit MODEL MV5546 Fuel System Pressure Testing Fuel Systems There are two basic types of electronic fuel injections Throttle Body Injection TBI and Multi port or Multi point injection MFI The tests outlined in this manual are for testing fuel system pressure on these types of systems On most vehicles two basic tests are performed when checking fuel system pressure 1 Key on engine on engine running test 2 Key on engine off engine not running test Connecting to the Fuel System Connecting to Systems with Existing Test Ports 1 Be sure the vehicle transmission is in park or neutral the parking brake is engaged and the engine is off 2 Follow the vehicle manufacturer s recommended proce dure to relieve the pressure from the vehicle fuel delivery system 3 Locate the test port on the engine s fuel rail 4 Attach the correct test port adapter The 90 adapters can be used if the test port is in a tight space 5 Connect the test port adapter to the extended pressure hose 6 Connect the exte
16. ulator e Leaking fuel injectors e Clogged fuel filter e Pinched fuel lines Safety Precautions The use of this service tool requires the exposure of highly flammable gasoline To prevent fires explosions and or severe injury always apply extra precautions when diagnosing or working on fuel systems The fuel pressure test kit is designed for servicing a variety of vehicles in a safe convenient manner However fuel delivery systems vary widely between makes and models of vehicles potentially requiring additional steps or equipment to perform a proper service job The procedures outlined in this manual are to serve as guidelines for the use of this equipment In addition to these guidelines always follow the manufacturer s recom mended procedures when servicing each unique vehicle Use common sense in the application of this tester and do not at tempt to force a test on a fuel system for which this equipment is not designed to perform e Always read carefully and understand instructions prior to using this equipment e Wear safety glasses at all times e Operate the vehicle only in a well ventilated area and away from potential sources of flame or ignition e Prior to starting an engine make sure all components of the tester body parts and personal clothing are clear of rotating engine components e Avoid burns by remaining cautious of engine parts that may become hot when the engine is running e Never leave a vehicle un

MV5546 - A&A Hydraulic for the best in Mityvac parts.

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MV5546 - A&amp;A Hydraulic for the best in Mityvac parts.

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MV5546 - A&A Hydraulic for the best in Mityvac parts.