Master Fuel Injection Test Kit
Contents
1. 6 Seals Tank Valve amp Gasket 7 Double End Barbed Hose Adapter 8 Single End Barbed Hose Adapter 9 6mm 1 00 Honda amp Acura Multi Port PGM FI Adapter 10 8mm 1 00 Banjo Bolt Adapter 11 10mm 1 00 Banjo Bolt Adapter 12 12mm 1 25 Banjo Bolt Adapter 13 12mm 1 50 Banjo Bolt Adapter 14 14mm 1 50 Banjo Bolt Adapter 15 8mm 1 00 Long Adapter 16 8mm 1 00 Female Adapter 17 8mm 1 00 Male Adapter with O Ring 18 8mm 1 00 Male Adapter Long 19 10mm 1 00 Female Adapter 20 10mm 1 00 Male Adapter 21 12mm 1 50 Female Swivel Adapter 22 14mm 1 50 Male amp Female Swivel Adapter 23 1 4 BSPT Male amp Female Swivel Adapter 24 16mm 1 50 Male amp Female Swivel Adapter 25 Pressure Testing amp Bleed Off Assy 26 Small Schrader Valve Test Adapter for Ford 27 Large Schrader Valve Test Adapter for GM amp Chrysler 28 5 16 Hair Pin Adapter for Ford CFI 29 3 8 Hair Pin Adapter for GM amp Chrysler 30 Spring Lock Adapter for Ford EFI 31 CIS Testing Assy w Ball Valve 32 Instruction Manual 33 Carrying Case Not Shown NOTE Some parts are listed and shown for illustration purposes only and are not available individually as replacement parts TYPICAL HOOK UPS Note Prior to using this product make sure to read and understand all instructions and safety precautions as outlined in the vehicle manufacturer s manual GM Multi Port And Chrysler Multi Port FIGURE A 1 Turn off ignition 2 R2. SCOO0OO PRESSURE TESTING AND BLEED OFF ASSY 25 XN CIS TESTING ASSEM lt lt BLY WITH BALL VALVE 31 Asian And European Multi Port Vehicles Bosch AFC FIGURE C 1 Turn off ignition 2 Relieve the fuel pressure Refer to the vehicle s service manual for specific pressure relief procedures 3 The pressure test connection for these vehicles is located at the point where the fuel inlet meets the fuel rail or cold start injector The fuel inlet is secured to the fuel rail of cold start injec tor by a banjo fitting 4 Remove the banjo fitting that secures the fuel inlet to the fuel rail or cold start injector Place a shop cloth around the bolt to catch any spilled fuel 5 Install one of the five pressure test Adapters 10 11 12 13 14 with the corresponding seal ing washer and one of the gaskets from the banjo fitting so that the fuel inlet is once again con nected to the fuel rail or cold start injector The test Adapter will hold the banjo assembly in position 6 Torque the Adapters 10 11 12 13 14 to the following specifications Adapter Size Torque Specifications 10 8mm 1 00 48in Ib 5 5 N m 11 10mm 1 00 72in Ib 8 0 N m 12 12mm 1 25 96in lb 11 0 N m 13 12mm 1 50 96in lb 11 0 N m 14 14mm 1 50 125in Ib 14 0 N m 7 Connect the Gauge 1 to the Pressure Testing and Bleed off Assembly 25 8 Attach the female quick coupler on the Pressure Testing and Bleed off Assembl
3. known as the warm up compensator The side of the test with the ball valve is connected to this circuit 5 Connect the Gauge 1 to the Pressure Testing and Bleed off Assembly 25 6 Install Adapter s 10 11 12 13 15 16 18 19 20 21 22 23 or 24 and O Ring to the engine as required Hand tighten only Then connect Hoses to Adapters 7 Attach the female quick coupler on the Pressure Testing and Bleed off Assembly 1 to the male quick coupler on the CIS Testing Assembly with Ball Valve 31 With free end of bleed off hose in a suitable container press button on side of bleed off assembly slowly to release any air in the test Hose 8 Refer to the General Safety Rules section before removing tester from vehicle Remove tester and Adapters from vehicle Reconnect vehicle s fuel injection lines to original condi tion Start the vehicle and check for leaks 9 Start the engine and check for leaks Read the fuel pressure Compare the value on the Gauge 1 to the value in the service manual Figure O PRESSURE TESTING AND BLEED OFF ASSY 25 ADAPTERS pa 11 12 13 15 16 18 19 20 21 a mr fa shaded oo0o000 19 18 Bosch Continuous Injection System CIS Testing FIGURE N 1 Turn off ignition 2 Clean the top of the fuel distributor to keep dirt from entering the fuel system 3 Relieve the fuel pressure Refer to the vehicle s service manual for specific pressure relief procedures
4. The test port is at the vehicle s fuel filter under the hood just forward of the firewall 4 The Fuel outlet is secured to the fuel filter by a double D bolt Within this bolt is a smaller hex bolt that provides access to the test connection 5 Place a shop cloth around the fuel outlet and slowly remove the smaller hex bolt 6 Screw the small male end of the Honda Adapter 9 into the hole where the removed hex bolt was Hand tighten 7 Connect the Gauge 1 to the Pressure Testing and Bleed off Assembly 25 Attach the female quick coupler on the Pressure Testing and Bleed off Assembly 25 to the male quick coupler on the Adapter 9 8 Start the engine and allow it to idle Check all connections for leaks 9 Read the Gauge 1 and compare the result with the pressure values in the service manual 10 Stop the engine and turn the ignition OFF 11 With free end of bleed off hose in a suitable container press button on side of bleed off assembly slowly to de pressurize the fuel system Refer to General Safety Rules section before removing tester from vehicle 12 Re install the hex bolt on the fuel filter Check for leaks Figure PRESSURE TESTING AND _ BLEED OF F ASSY 25 ADAPTER l 9 13
5. for specific pressure relief procedures 3 Remove the air cleaner assembly The test valve is located at the top of the throttle body unit 4 Connect the Gauge 1 to the Pressure Testing and Bleed off Assembly 25 5 Attach the female end of the Ford Adapter 26 to the test valve 6 Attach the female quick coupler on the Pressure Testing and Bleed off Assembly 25 to the male quick coupler on the Adapter 26 7 Start the engine and allow it to idle Check all connections for leaks 8 Read the Gauge 1 and compare the result with the pressure values in the service manual 9 Stop the engine and turn the ignition OFF 10 With free end of bleed off hose in a suitable container press button on side of bleed off assembly slowly to de pressurize the fuel system 11 Refer to General Safety Rules section before removing tester from vehicle 12 Start the vehicle and check for leaks Figure J GAUGE 1 PRESSURE TESTING AND _ BLEED OF F ASSY 25 ADAPTER 20 14 Ford Central Fuel Injection CFI 1 9L and 2 3L With 5 16 Hair Pin Coupling And GM And Chrysler 3 8 Hair Pin Coupling FIGURE G 1 Turn off ignition 2 Relieve the fuel pressure Refer to the vehicle s service manual for specific pressure relief procedures 3 The connection with the vehicle s fuel injection system is at the throttle body Remove the fuel line at the inlet by prying up on the hair pin from the coupling
6. 0 are included If any parts are missing or broken please call 1 800 497 0552 Before each use Inspect the general condition of the Pressure Test Kit Check for damaged parts and any other condition that may affect this product s safe operation If a problem occurs have the problem corrected before further use Do not use damaged equipment CAUTION All maintenance service and repairs not discussed in this manual should only be performed by a qualified service technician APPLICATIONS IMAGE DESCRIPTION APPLICATION 1 Q Basic Gauge with boot Connects to 8 for basic testing i and Hook 100 P S I General Motors 2 5L amp For vehicles with quick connect fuel 5 7L Non Multi port filters such as 2 5L Oldsmobile Clera 1989 amp up and 5 7L Chevrolet Caprice 1991 amp up General Motors 2 2L 1992 amp up Chevrolet Cavalier Pontiac Non Multi port Sunbird Buick Skylark and Quad 4 equipped Pontiac Grand Am mbam Hose Clamps and For use in making certain hook up connections General Motors Throttle In line Adapter Replaces fuel filter with Body Injection TBI threads on both ends Tah Hose Adapter into 1 4 5 16 or 3 8 in Fuel line hose 8 Single End Barbed All vehicles requiring end of line testing 9 Honda Acura and Sterling For vehicles with 6mm 1 00 fittings 14mm 1 5 Banjo Bolts Tests CIS Continuous Injection Systems found on European cars and Volkswagon models assembled in the U S For vehicles with m
7. 25 6 Attach the female quick coupler on the Pressure Testing and Bleed off Assembly 25 to the male quick coupler on the Adapter 8 7 Start the engine and allow it to idle Check all connections for leaks Read the Gauge 1 and compare the result with the pressure values in the service manual 8 Stop the engine and turn the ignition OFF 9 With free end of bleed off hose in a suitable container press button on side of bleed off assembly slowly to de pressurize the fuel system Refer to General Safety Rules section before removing tester from vehicle 10 Reconnect vehicle s fuel line and tighten all clamps securely Check all connections for leaks Figure L GAUGE 1 PRESSURE TESTING AND _ __ BLEED OF F ASSY 25 ADAPTER 8 A GM Throttle Body Injection TBI With Quick Connect Fuel Filter 2 5L 1989 And Up 5 7L 1991 And Up FIGURE E 1 Turn off ignition 2 Relieve the fuel pressure Refer to the vehicle s service manual for specific pressure relief procedures 3 Locate the fuel filter on the vehicle 4 Remove the fuel filter by compressing the tabs while pulling outward on each fuel line Use a container to catch any fuel that may spill out Wipe off any excess fuel that may spill on the vehicle 5 Install the fuel pressure Adapter 2 in place of the fuel filter by pushing each of the Adapter s male tubes into the fuel lines Make sure the nylon clips on the tubes are seated ins
8. 4 The CIS system has a primary circuit with pressure regulated at the fuel distributor This is known as supply pressure primary pressure or line pressure The side of the tester without the ball valve is connected to this circuit The other circuit is known as the control circuit This contains the control pressure regulator known as the warm up compensator The side of the test with the ball valve is connected to this circuit 5 Connect the Gauge 1 to the Pressure Testing and Bleed off Assembly 25 6 Install Adapter s 10 11 12 13 15 16 18 19 20 21 22 23 or 24 and O Ring to the engine as required Hand tighten only Then connect Hoses to Adapters 7 Attach the female quick coupler on the Pressure Testing and Bleed off Assembly 1 to the male quick coupler on the CIS Testing Assembly with Ball Valve 31 With free end of bleed off hose in a suitable container press button on side of bleed off assembly slowly to release any air in the test Hose 8 Refer to the General Safety Rules section before removing tester from vehicle Remove tester and Adapters from vehicle Reconnect vehicle s fuel injection lines to original condi tion Start the vehicle and check for leaks 9 Start the engine and check for leaks Read the fuel pressure Compare the value on the Gauge 1 to the value in the service manual Figure N ADAPTERS 10 11 12 13 15 16 18 19 20 21 23 OR 24 AND O RINGS HUH fa adaggg
9. Bleed off Assembly 25 5 Attach the female end of Ford Adapter 26 to test the valve Hand tighten 6 Attach the female quick coupler on the Pressure Testing and Bleed off Assembly 25 to the male quick coupler on the Ford Adapter 26 7 Start the engine and allow it to idle Check for leaks 8 Read the Gauge 1 and compare result with pressure in service manual 9 Stop the engine and turn the ignition OFF 10 With free end of bleed off hose in suitable container press the button on side of bleed off assembly slowly to de pressurize the fuel system 11 Refer to the General Safety Rules section before removing Tester from vehicle 12 Replace the protective cap onto the test fitting on vehicle Check for leaks Figure B GAUGE igure 1 PRESSURE TESTING AND Jh BLEED OFF ASSY 25 FORD ADAPTER 26 Constant Injection System Electronic CISE European Vehicles FIGURE O 1 Turn off ignition 2 Clean the top of the fuel distributor to keep dirt from entering the fuel system 3 Relieve the fuel pressure Refer to the vehicle s service manual for specific pressure relief procedures 4 The CIS system has a primary circuit with pressure regulated at the fuel distributor This is known as supply pressure primary pressure or line pressure The side of the tester without the ball valve is connected to this circuit The other circuit is known as the control circuit This contains the control pressure regulator
10. Master Fuel Injection Test Kit Stock Number W89726 OWNER S MANUAL aa HA ith h d am FOR YOUR SAFETY please read these instructions carefully and retain them for future use mige ed lad PRODUCT SPECIFICATIONS Product Features Allows for accurate and quick diagnoses of fuel intake issues Compatible with most domestic and import cars Includes all necessary adapter clamps and hoses Quick convenient hook ups Material Brass Steel Aluminum Polyurethane Rubber Vinyl Thermoplastic Contents Fuel Gauge w Quick Release Valve Seven Various Hose Assemblies Four Metric Paired Hose Adapters Two Steel Hose Clamps Four Copper Washers Fifteen Metric Sized Fittings 8 SAE Sized Fittings SAVE THIS MANUAL You will need this manual for the safety warnings and precautions assembly operating inspection maintenance and cleaning procedures parts list and assembly diagram Keep your invoice with this manual Write the invoice number on the inside of the front cover Keep this manual and invoice in a safe and dry place for future reference GENERAL SAFETY RULES IMPORTANT SAFETY INSTRUCTIONS READ AND UNDERSTAND ALL INSTRUCTIONS Failure to follow all instructions detailed in this manual may result in serious personal injury SAVE THESE INSTRUCTIONS 1 Keep your work area clean and well lit Cluttered and dark work areas invite accidents 2 Stay alert Watch what you are doing and use common sense
11. Pressure Testing and Bleed off Assembly 25 7 Attach the female quick coupler on the Pressure Testing and Bleed off Assembly to the male quick coupler on the GM TBI Adapter 5 8 Start the engine and check for leaks Read the fuel pressure Compare the value on the Gauge 1 to the value in the service manual 9 Stop the engine and turn the ignition OFF 10 With free end of bleed off hose in a suitable container press the button on side of bleed off assembly slowly to de pressurize the fuel system 11 Refer to the General Safety Rules section before removing Tester from vehicle 12 Remove the fuel pressure Adapter following the above instructions for removing the fuel filter 13 Re install the fuel filter Start the vehicle and check for leaks Figure D GAUGE ae 1 PRESSURE TESTING AND _ _ BLEED OF F ASSY 25 em GMTBI ee es ADAPTER 5 Chrysler Throttle Body Injection FIGURE M 1 Turn off ignition 2 Relieve the fuel pressure Refer to the vehicle s service manual for specific pressure relief procedures 3 Loosen the hose clamp and disconnect the fuel line hose from the inlet side of the vehicle s throttle body 4 Confirm if the size of the inlet fuel line hose is 1 4 or 5 16 5 Assemble the correct Hose 4 and Hose Clamps 4 onto the Double End Barbed Adapter 7 6 Connect the Adapter assembly between the disconnected fuel line and the throttle body inlet nipp
12. e the right product for the job There are certain applications for which this product was designed Do not use small products to do the work of larger industrial products Do not use this product for a purpose for which it was not intended 11 Product service must be performed only by qualified service technician Service or main tenance performed by unqualified personnel could result in a risk of injury 12 When servicing the Pressure Test Kit use only identical replacement parts Follow instructions in the Inspection Maintenance And Cleaning section of this manual 23 INSPECTION MAINTENANCE AND CLEANING CAUTION Make sure to wear ANSI approved safety impact goggles before performing any inspection maintenance or cleaning of Pressure Test Kit Before each use Inspect the general condition of the Pressure Test Kit Check for damaged parts and any other condition that may affect this product s safe operation If a problem occurs have the problem corrected before further use Do not use damaged equipment To clean Use a clean soft damp cloth and mild detergent Then allow to air dry Do not use solvents CAUTION All maintenance service and repairs not discussed in this manual should only be performed by a qualified service technician 22 Use of unauthorized parts or failure to follow maintenance instructions may create a risk of personal injury 13 Always make sure the area of use for this product is clear of an
13. elieve the fuel pressure Refer to the vehicle s service manual for specific pressure relief procedures 3 Connect the Gauge 1 to the Pressure Testing and Bleed off Assembly 25 4 Remove the protective cap from test fitting on vehicle 5 Attach the swivel female fitting on the Adapter 27 to the test fitting on the vehicle Hand tighten 6 Attach the female quick coupler on the Pressure Testing and Bleed off Assembly 25 to the male quick connector on the Adapter 27 7 Start the engine and allow it to idle Check for leaks 8 Read the Gauge 1 and compare result with the pressure in service manual 9 Stop engine and turn ignition OFF 10 With free end of Bleed off Hose in suitable container press the Button on side of bleed off assembly slowly to de pressurize the fuel system 11 Refer to the General Safety Rules section before removing Tester from vehicle 12 Replace the protective cap onto the test fitting on vehicle Check for leaks Figure A GAUGE ___ 1 PRESSURE TESTING AND aes BLEED OF F ASSY is 25 __ ADAPTER 27 Ford Multi Port EFI FIGURE B 1 Turn off ignition 2 Relieve the fuel pressure Refer to the vehicle s service manual for specific pressure relief procedures 3 If the vehicle has multi port fuel injection the test valve is located on the fuel rail Remove the protective cap from the test valve 4 Connect the Gauge 1 to the Pressure Testing and
14. etric threads Tests CISE Constant Injection System Electronic found on European cars with metric threads 25 QO For use in performing tests with Basic Da Bleed off Assembly Gauge 1 and Adapters amp Imports with 7 16 in 20 Multi Port vehicles threaded test port dh gira MANUAL Chrysler inline Adapter 3 8 in hair pins CIS Testing Assembly For use in testing with Basic Gauge 1 with Ball Valve Pressure Testing and Bleed off Assembly 25 and Adapters PLEASE READ THE FOLLOWING CAREFULLY THE MANUFACTURER AND OR DISTRIBUTOR HAS PROVIDED THE PARTS LIST AND ASSEMBLY DIAGRAM IN THIS MANUAL AS A REFERENCE TOOL ONLY NEITHER THE MANUFACTURER OR DISTRIBUTOR MAKES ANY REPRESENTATION OR WAR RANTY OF ANY KIND TO THE BUYER THAT HE OR SHE IS QUALIFIED TO REPLACE ANY PARTS OF THE PRODUCT IN FACT THE MANUFACTURER AND OR DISTRIBU TOR EXPRESSLY STATES THAT ALL REPAIRS AND PARTS REPLACEMENTS SHOULD BE UNDERTAKEN BY CERTIFIED AND LICENSED TECHNICIANS AND NOT BY THE BUYER THE BUYER ASSUMES ALL RISKS AND LIABILITY ARISING OUT OF HIS OR HER REPAIRS TO THE ORIGINAL PRODUCT OR REPLACEMENT PARTS THERETO OR ARISING OUT OF HIS OR HER INSTALLATION OF REPLACEMENT PARTS THERETO PART DESCRIPTION 1 0 100 PSI 0 7 0 Bar Gauge w Boot amp Hang Up Hook 2 GM 2 5L amp 5 7L Fuel Injection Pressure Test Adapter 3 GM 2 2L Fuel Injection Pressure Test Adapter 4 Hose Clamps amp Hoses 5 GM Throttle Body Injection TBI Fuel Pressure Adapter
15. f the vehicle s throttle body or discharge side of the fuel pump 4 Assemble the Double End Barbed Adapter 7 and Hose 4 with Hose Clamps 4 5 Connect the Double End Barbed Adapter 7 as assembled above between the disconnected fuel line and the throttle body inlet or fuel pump Tighten all Hose Clamps 4 securely 6 Connect the Gauge 1 to the Pressure Testing and Bleed off Assembly 25 7 Attach the female quick coupler on the Pressure Testing and Bleed off Assembly 25 to the male quick coupler on the Adapter 7 8 Start the engine and allow it to idle Check all connections for leaks Read the Gauge 1 and compare the result with the pressure values in the service manual 9 Stop the engine and turn the ignition OFF 10 With free end of bleed off hose in a suitable container press button on side of bleed off assembly slowly to de pressurize the fuel system Refer to General Safety Rules section before removing tester from vehicle 11 Replace the vehicle s fuel line and tighten all clamps securely Check all connections for leaks Figure K PRESSURE TESTING AND _ __ __ BLEED OF F ASSY i 25 S HOSE AND HOSE CLAMPS 4 eme m m TO INLET TO THROTTLE FUEL LINE ADAPTER BODY INLET OR HOSE 7 DISCHARGE SIDE OF FUEL PUMP 15 Ford Throttle Body Injection With Small Schrader Valve FIGURE J 1 Turn off ignition 2 Relieve the fuel pressure Refer to the vehicle s service manual
16. he connection with the vehicle s fuel injection system is on the fuel rail 4 A disconnect tool not included is required to separate the spring lock fitting on the vehicle s fuel line 5 After the spring lock fitting has been disconnected assemble the Ford Spring Lock Adapt er 30 into the line making sure both ends of the mating couplings are locked together 6 Connect the Gauge 1 to the Pressure Testing and Bleed off Assembly 25 Attach the female quick coupler on the Pressure Testing and Bleed off Assembly 25 to the male quick coupler on the Adapter 30 7 Start the engine and allow it to idle Check all connections for leaks 8 Read the Gauge 1 and compare the result with the pressure values in the service manual 9 Stop the engine and turn the ignition OFF 10 With free end of bleed off hose in a suitable container press button on side of bleed off assembly slowly to de pressurize the fuel system Refer to General Safety Rules section before removing tester from vehicle 11 Using a disconnect tool remove the test Adapter 30 and install the vehicle s fuel line Start the vehicle and check for leaks Figure H GAUGE ae 1 PRESSURE TESTING AND BLEED OFF ASSY i 25 ADAPTER 1 lt eo 12 Honda Acura amp Sterling Multi Port PGM FI FIGURE I 1 Turn off ignition 2 Relieve the fuel pressure Refer to the vehicle s service manual for specific pressure relief procedures 3
17. ide the fuel line connectors 6 Connect the Gauge 1 to the Pressure Testing and Bleed off Assembly 25 7 Attach the female quick coupler on the Pressure Testing and Bleed off Assembly to the male quick coupler on the Adapter 2 8 Start the engine and check for leaks Read the fuel pressure Compare the value on the Gauge 1 to the value in the service manual 9 Stop the engine and turn the ignition OFF 10 With free end of bleed off hose in a suitable container press button on side of bleed off assembly slowly to de pressurize the fuel system 11 Refer to the General Safety Rules section before removing Tester from vehicle 12 Remove the fuel pressure Adapter following the above instructions for removing the fuel filter 13 Re install the fuel filter Start the engine and check for leaks Figure E PRESSURE TESTING AND BLEED OF F ASSY 25 ADAPTER 2 GM 2 2L Engines 1992 And Up FIGURE F 1 Turn off ignition 2 Relieve the fuel pressure Refer to the vehicle s service manual for specific pressure relief procedures 3 Locate the fuel filter on the vehicle 4 Remove the fuel filter by unscrewing the steel fuel line from one end of the fuel filter Remove the nylon fuel line on the other end by compressing the tabs while pulling outward on the fuel line Use a container to catch any fuel that may spill out Wipe off any excess fuel that may spill out 5 Install the fuel pressure Adapter 3
18. in place of the fuel filter by threading the steel fuel line into the threaded end of the Adapter Do not overtighten Connect the other end of the Adapter by pushing the male tube into the nylon fuel line Make sure the nylon clip on the tube is seated inside the fuel line connector 6 Connect the Gauge 1 to the Pressure Testing and Bleed off Assembly 25 7 Attach the female quick coupler on the Pressure Testing and Bleed off Assembly 25 to the male quick coupler on the Adapter 3 8 Start the engine and check for leaks Read the fuel pressure Compare the value on the Gauge 1 to the value in the service manual 9 Stop the engine and turn the ignition OFF 10 With free end of bleed off hose in a suitable container press button on side of bleed off assembly slowly to de pressurize the fuel system 11 Refer to the General Safety Rules section before removing Tester from vehicle 12 Remove the fuel pressure Adapter 3 following the above instructions for removing the fuel filter Re install the fuel filter Start the engine and check for leaks Figure F PRESSURE TESTING AND __ _ BLEED OF F ASSY 25 ADAPTER Don 3 10 All Vehicles With 1 4 5 16 or 3 8 Fuel Line Hose FIGURE K 1 Turn off ignition 2 Relieve the fuel pressure Refer to the vehicle s service manual for specific pressure relief procedures 3 Loosen the hose clamp and disconnect the fuel line hose from the inlet side o
19. ks turn off the engine or disable the fuel pump Clean up any spilled fuel and repair all leaks before resuming test When preparing for pressure testing make sure the vehicle s transmis sion is placed in PARK or NEUTRAL and the emergency brake is applied 26 When the test is complete de pressurize the system and remove the Pressure Test Kit Re assemble the vehicle s fuel line s to its original condition Start the engine and check for leaks If any leaks are present stop the engine relieve fuel pressure and repair all leaks 27 WARNING The brass components of this product contain lead a chemical known to the State of California to cause birth defects or other reproductive harm California Health amp Safety code 25249 5 et seq 28 People with pacemakers should consult their physician s before use Electromagnetic fields in close proximity to heart pacemaker could cause pacemaker interference or pace maker failure Caution is necessary when near coil spark plug cables or distributor of running engine Engine should be off during distributor adjustment 29 The warnings and cautions discussed in this manual cannot cover all possible conditions and situations that may occur It must be understood by the operator that common sense and caution are factors which cannot be built into this product but must be supplied by the operator When unpacking check to make sure all the parts shown in the Parts List on page 2
20. le on the vehicle Tighten all Hose Clamps 4 securely 7 Connect the Gauge 1 to the Pressure Testing and Bleed off Assembly 25 Attach the female quick coupler on the Pressure Testing and Bleed off Assembly 25 to the male quick coupler on the Adapter 7 8 Start the engine and allow it to idle Check all connections for leaks Read the Gauge 1 and compare the result with the pressure values in the service manual 9 Stop the engine and turn the ignition OFF 10 With free end of bleed off hose in a suitable container press button on side of bleed off assembly slowly to de pressurize the fuel system Refer to General Safety Rules section before removing tester from vehicle 11 Reconnect vehicle s fuel line and tighten all clamps securely Check all connections for leaks Figure M GAUGE ae 1 PRESSURE TESTING AND BLEED OFF ASSY 25 HOSE AND HOSE CLAMPS i 4 pa Et e TO INLET TO THROTTLE FUEL LINE ADAPTER BODY INLET HOSE 7 NIPPLE 17 All Vehicles Requiring End Of Line Testing With 1 4 5 16 Or 3 8 Fuel Line Hose FIGURE L 1 Turn off ignition 2 Relieve the fuel pressure Refer to the vehicle s service manual for specific pressure relief procedures 3 Loosen the hose clamp and disconnect the fuel line 4 Install the Single End Barbed Hose Adapter 8 into the fuel supply hose Tighten hose clamp securely 5 Connect the Gauge 1 to the Pressure Testing and Bleed off Assembly
21. when operating tools and equipment Do not assemble or use this product while tired or under the influence of drugs alcohol or medication A moment of inattention while operating tools and equipment may result in serious personal injury 3 Wear eye protection Wear ANSI approved safety impact glasses and full face shield when using this product 4 Do not force the Pressure Test Kit Use the correct product for your application The cor rect product will do the job better and safer at the rate for which it is designed 5 Maintain the Pressure Test Kit with care Keep this product clean Properly maintained products are less likely to malfunction Do not use damaged products Tag damaged prod ucts Do not use until repaired 6 Check for any condition that may negatively affect the Pressure Test Kit s operation If readings are inconsistent or if it appears that the fuel gauge is not functioning properly the Test Kit should be serviced by a qualified service technician Many accidents are caused by poorly maintained products 7 Use only accessories that are recommended by the manufacturer for your model Accessories that may be suitable for one product may become hazardous when used on another product 8 Industrial applications must follow OSHA requirements 9 Maintain labels and nameplates on the Pressure Test Kit These carry important informa tion If unreadable or missing contact Harbor Freight Tools for a replacement 10 Us
22. with a small screwdriver Use care as the hair pin is made of plastic Once disconnected re install the hair pin into the hair pin coupling 4 Attach the Hair Pin Adapter 28 for Ford and 29 for GM and Chrysler to the disconnected fuel line Make sure both ends of mating parts are seated and locked together 5 Connect the Gauge 1 to the Pressure Testing and Bleed off Assembly 25 Attach the female quick coupler on the Pressure Testing and Bleed off Assembly 25 to the male quick coupler on the Adapter 28 or 29 6 Start the engine and allow it to idle Check all connections for leaks 7 Read the Gauge 1 and compare the result with the pressure values in the service manual 8 Stop the engine and turn the ignition OFF 9 With free end of bleed off hose in a suitable container press button on side of bleed off assembly slowly to de pressurize the fuel system Refer to General Safety Rules section before removing tester from vehicle 10 Remove the fuel pressure Adapter following the above instructions Re install the vehicle s fuel line Start the engine and check for leaks Figure G GAUGE ___ 1 PRESSURE TESTING AND _ _ BLEED OF F ASSY 25 in ADAPTER 28 OR 29 11 Ford Central Fuel Injection CFI With Spring Lock Fittings 2 5L FIGURE H 1 Turn off ignition 2 Relieve the fuel pressure Refer to the vehicle s service manual for specific pressure relief procedures 3 T
23. y children Do not allow children to play with this product 14 Do not allow the vehicle s engine to run while using the Pressure Test Kit When running the engine of a vehicle produces carbon monoxide a colorless odorless toxic gas that when inhaled can cause serious personal injury or death 15 Prior to using this product make sure to read and understand all instructions and safety precautions as outlined in the vehicle manufacturer s manual 16 Always keep hands and fingers away from the moving parts and hot parts of an engine 17 Do not use this Pressure Test Kit on diesel fuel systems 18 Do not smoke while performing any fuel injection tests or repairs 19 Always have a dry chemical Class B fire extinguisher within reach 20 Make sure to provide a suitable container to catch released fuel when the system is de pressurized 21 Take extra care to prevent fuel from contacting hot engine parts It is recommended that tests be performed when the engine is cold 22 If a drop light is used do not allow fuel to contact the hot surface of the bulb 23 Never remove any fittings with the engine running 24 Never loosen any fittings or attempt to remove hoses of vehicle or Pressure Test Kit until you have relieved the fuel system pressure Refer to the vehicle manufacturer s service manual for specific fuel pressure relief procedures 25 Always check all connections for leaks during the testing procedure At any sign of lea
24. y to the male quick coupler on the test Adapter 9 Start the engine and allow it to idle Check for leaks 10 Read the Gauge 1 and compare the result with pressure in the service manual 11 Stop the engine and turn the ignition OFF 12 With free end of bleed off hose in a suitable container press the button on side of bleed off assembly slowly to de pressurize the fuel system 13 Refer to the General Safety Rules section before removing Tester from vehicle 14 Remove the Tester and the pressure test Adapter 15 Re assemble the banjo fitting to the fuel inlet and fuel rail or cold start injector New Gaskets 6 should be used when re assembling fuel lines Check for leaks Figure C PRESSURE TESTING AND BLEED OFF ASSY 25 10 11 12 13 14 GASKETS 6 O00000 GM Throttle Body Injection TBI With Fuel Filter Threaded On Both Sides FIGURE D 1 Turn off ignition 2 Relieve the fuel pressure Refer to the vehicle s service manual for specific pressure relief procedures 3 Locate the fuel filter on the vehicle 4 Remove the fuel filter by unscrewing the fuel lines from both ends of the fuel filter Use a container to catch any fuel that may spill out Wipe off excess fuel that may spill on the vehicle 5 Install the GM TBI Adapter 5 in place of the fuel filter by threading each fuel line into either end of the Adapter Do not overtighten 6 Connect the Gauge 1 to the
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