Fuel Injection Fitting Kits
Contents
1. 31 NM 16 Connecting at the Fuel Rail 82 OJ 16 CIS VeEnees a Exeter OO n 17 ES Kit Components Domestic Kit 38 gt ACCESSORIES eoo hoses and clamp far 14 Kit Components Import Kit H eem Io ME 7s 67 LO 76 68 e I0 77 PO H 12 _ je 78 70 15 mn ee ACCESSORIES le EN pdt s fe oe Kit Components Master Kit Bre 1390 79 67 M PD 90 76 68 10 ME 77 69 Met Lb 78 70 lllo ho OOo U 1 rlllo PO ACCESSORIES T hoses and clamp far 14 Components Applications Reorder Description Common Application No see page for connection illustration 518483 3 1 2 Pressure Gauge All tests connects to No 11 with protective boot and hanger 0 100 psi 0 7 BAR 518530 Gauge Hose Assembly with relief valve All tests connects to No 10 valve used for and drain tube pressure release and for volume tests 518356 TBI CIS Hose Assembly with shutoff valve Connects to Nos 10 and 11 for pressure tests for Np L GM TBI supply line page 19 tuel pump page 20 and return line 21 European CIS primary system page 33 mE 518477 Seal Kit BEEN Replacement seals o rings quick couplers 518480 Double Ended Hose Adapter 5 16 3 8 AMC and Chrysler TBI page 17 use w2. Fuel 14 67 68 69 70 or 71 Pressure Regulator Filter NOTE Vehicle may have a cold start injector not shown connection is the same as shown above Import Vehicle Connections Asian EFI and MFI Vehicles Connecting to the Supply Line End using 10 and 11 with 15 15 NOTE This connection is for fuel pump pressure dead head testina Fuel Supply Fuel Intake Manifold DL A LL Fuel Return Adapter LA EA 15 i Gauge Ass y Fuel 4 Pressure Filter 10 Import Vehicle Connections European AFC Vehicles Connecting at the Fuel Filter Location using 10 and 11 with 70 70 Pressure Regulator Filter Import Vehicle Connections European AFC Vehicles Connecting at the Cold Start Injector me So using 10 and 11 with 67 68 69 or 70 67 68 69 70 Fuel Supply Gauge 109 Intake Manifold Cold Start Injector Adapter 67 68 Fuel Rail i 69 or 70 Pressure Regulator Filter Import Vehicle Connections European AFC Vehicles Connecting at the Fuel Rail met Io using 10 and 11 cz with 14 67 68 69 or 70 14 67 68 69 70 in Kits Accessory Compartment use hose that fits vehicle s fuel line Use No 14 with hose and clamp Fuel Supply Gauge Hose Ass y Intake rusa Fuel Return FuelRail Pressure Regulator Filter NOTE Vehicle may have a col
3. Pump Filter Domestic Vehicle Connections TBI Vehicles GM Connecting to the Supply Line End using 10 11 and 12 o Bum with 36 and 37 and plug 40 36 37 40 NOTE This connection is for fuel pump pressure dead head testing Fuel Supply Throttle Body Injector Fuel Filter Plug Adapters 40 Fuel Return TBI CIS Hose Ass y 12 Gauge ey Gauge 10 Engine ti Fuel Pump Filter Domestic Vehicle Connections TBI Vehicles GM Connecting into the Return Line using 10 11 and 12 Ho with 38 and 39 38 M NOTE This connection is for return line pressure testing Fuel Supply Injector Fuel Filter Throttle Engine Filter Domestic Vehicle Connections MPFI MPI PFI and SFI Vehicles Connecting at the Fuel Filter Location using 10 and 11 with 14 32 or 33 Fuel Supply Adapter 14 32 or 33 Intake no Pressure Regulator Filter Use No 14 with hose and clamp in Kit s Accessory Compartment use hose that fits vehicle s fuel line Domestic Vehicle Connections MPFI MPI PFI and SFI Vehicles Connecting into the Supply Line using 10 and 11 c With 14 32 33 or 42 14 Use No 14 with hose and clamp in Kit s Accessory Compartment use hose that fits vehicle s fuel line Intake niu LL Fuel Return FuelRail JUUL Adapter A U U L 14 32 33 42 Pressure Regulator Filter Domestic Vehicle Connections MPFI
4. fuel system components Residual line pressure can cause fuel spray Wrap a shop towel around pressure tap fittings when connecting and disconnecting adapters or removing the gauge assembly hose Wipe up fuel spills immediately protect painted surfaces from fuel spills Clean or dispose of towels according to local state and federal regulations Tightenall connections before checking fuel pres sure Use the vehicle manufacturer s recommended procedures to service injectors Replace injector o rings whenever injectors are removed Keep dirt out of the system Kit Components 1 22 2 Domest Kil APOK slo ERR Master Ki se Components Applications About Fuel Systems and Testing General Test Instructions Spee Tess Static Running Fuel Pressure Fuel Volume ssec to ee PINE Fuel Pressure Leak Down Fuel Pump Output Pressure Dead Head Cold Control Pressure CIS Hot Control Pressure CIS Rest Pressure 5 222 2 Primary System Pressure CIS Fuel Pump Output Dead Head System Pressure CISE Residual Pressure CISE Domesti
5. Fuel Injection Fitting Kits Reference Guide for Domestic Kit Import Kit Master Kit Safety PrecautionsA Read and understand all instructions and safety precautions before servicing fuel injection sys tems If the operator cannot read English operat ing instructions and safety precautions must be read and discussed in the operator s native lan guage Si el operador no puede leer el ingl s las instrucciones de operaci n y las precauciones de seguridad deber n leerse y comentarse en el idioma nativo del operador Si l utilisateur ne peut lire l anglais les instruc tions et les consignes de s curit doivent lui tre expliqu es dans sa langue maternelle Wear eye protection that meets ANSI Z87 1 and OSHA requirements Keep tools electrical cords and hoses away from moving engine parts Do not modify any components of the gauge assembly adapters or accessories If itis neces sary to replace parts use only OTC replacement parts Vent exhaust to the outside while running the vehicle WARNING The following safety precautions must be observed to reduce the risk of fire and personal injury Have a Class B fire extinguisher nearby when working on fuel injection systems Observe nor mal precautions for working with flammable liq uids no smoking open flames electrical sparks etc Use fuel injection fitting kits on gasoline engines only Release fuel system pressure before servicing
6. MPI PFI and SFI Vehicles Connecting at the Fuel Rail using 10 and 11 with 30 or 31 Adapter 30 or 31 Pressure Regulator Filter Domestic Vehicle Connections MPFI MPI PFI and SFI Vehicles Connecting to the Supply Line End using 10 and 11 with 15 15 NOTE This connection is for fuel pump pressure dead head testina Fuel Supply Fuel Intake Manifold DL A LL Fuel Return Adapter LA EA 15 i Gauge Hose Ass y Fuel 114 Fuel Pressure i Pump Gauge Filter 10 Import Vehicle Connections Asian AFC EFI MFI and PGM Vehicles Connecting at the Fuel Filter Location o using 10 and 11 with 66 or 70 66 70 Pressure Regulator Filter Import Vehicle Connections Asian AFG EFI and MFI Vehicles Connecting at the Cold Start Injector me 0 ho feo using 10 11 with 67 68 69 70 or 71 67 68 69 70 71 Fuel Supply Gauge 109 Intake Manifold Cold Start Injector Adapter 67 68 69 FuelRail eee 70 or 71 Pressure Regulator Filter Import Vehicle Connections Asian AFG EFI MFI and Single Point Vehicles Connecting at the Fuel Rail me AO using 10 11 A with 14 67 68 69 70 or 71 14 67 68 69 70 71 Use No 14 with hose and clamp Kit s Accessory Compartment use hose that fits vehicle s fuel line Fuel Supply Gauge Hose Ass y Intake Fuel Return
7. TART RUN to restart engine for other tests Fuel Pump Output Pressure Dead Head 1 Turn ignition to OFF 2 Compare gauge pressure with pressure specified in vehicle s service manual 14 Specific Tests Follow the General Test Instructions on page 13 At step 10 do the following tests as necessary NOTE For all tests refer to the vehicle s service manual for specifications and diagnostic repair procedures Cold Control Pressure CIS NOTE Engine must be cold for this test 1 Run engine at idle until gauge pressure stabilizes 2 Disconnect electrical connector from fuel control pressure regulator Do not run engine for more than 1 minute with regulator disconnected 3 Compare gauge pressure with pressure specified in vehicle s service manual 4 Turn ignition to OFF and reconnect electrical connector to fuel control pressure regulator NOTE If necessary turn ignition to START RUN to restart engine for other tests Hot Control Pressure CIS 1 Run engine at idle until it reaches operating temperature 2 Compare gauge pressure with pressure specified in vehicle s service manual Rest Pressure CIS Same as Fuel Pressure Leak Down on page 14 Primary System Pressure CIS GM Fuel Pump Output Dead Head 1 Run engine at idle until it reaches operating temperature 2 Close shutoff valve on TBI CIS hose assembly No 12 This dead heads fuel pump Do not close valve for more
8. c Vehicle Connections CFI Vehicles Ford enr TBI Vehicles AMC and Chrysler Contents 4 TBI Veliicles OM si 18 Orr 4 Connecting at the Fuel Filter Location 18 Connecting at the Throttle Body 19 255525222 6 Connecting to the Supply Line 20 7 Connecting into the Return Line 21 LE MPFI MPI PFI and SFI Vehicles 22 12 Connecting at the Fuel Filter Location 22 13 Connecting into the Supply Line 23 Connecting at the Fuel Rail 24 14 Connecting to the Supply Line 25 Import Vehicle Connections Asian 26 NOD 14 AFG EFI MFI PGM and Single Point Vehicles MUN 14 Connecting at the Fuel Filter Location 26 mE 15 Connecting at the Cold Start 27 mo 15 Connecting at the Fuel Rail 28 n 15 Connecting to the Supply Line 29 Import Vehicle Connections European 30 15 VENO save OO RT 15 Connecting at the Fuel Filter Location 30 15 Connecting at the Cold Start
9. d start injector not shown connection is the same as shown above Import Vehicle Connections European CIS Vehicles gt jo Ho mo 68 69 70 72 73 74 Connecting into the Return Line E using 10 11 and 12 with 67 68 69 70 72 73 74 75 76 77 78 79 80 or 81 E P appo Fuel Supply TBI CIS s SB Regulator Cold Start i Injector Injectors Distributor Adapter Filter Import Vehicle Connections European CISE Vehicles Dio mo 68 69 70 72 73 74 Connecting at the Fuel Distributor or using 10 and 11 with 67 68 69 70 E 72 73 74 75 76 77 78 79 80 or 81 gt de a appo Access Point remove Fuel Supply plug from top of fuel distributor s chamber or disconnect cold start injector if applicable Adapter S 9 Hose Ass y i Fuel 11 Distributor Injectors Filter User s Notes 35 2003 SPX Corporation Form No 518587 Rev A 08 18 03
10. e The fittings in the Fuel Injection Fittings Kit let you connect pressure gauge into the fuel system to test the pressure of the fuel pump supply delivery lines and return lines You can also use the Kit to test the fuel pump output volume NOTE When connecting to a fuel system use the illustrations provided in this Guide Some vehicles and or adapters have more than one connection option If so use the option with the easiest access to the fuel line Although manufacturers use various acronyms and names for fuel injection systems EFI etc there are two basic types of fuel injection systems throttle body injection and port injection Throttle body injection delivers fuel into an engine throttle body Port injection delivers fuel separately to each engine cylinder through fuel injectors that are connected to either a fuel rail or a fuel distributor The next column lists the various injection systems Throttle Body Injection Systems Domestic CFI Central Fuel Injection Ford TBI Throttle Body Injection AMC Chrysler GM Port Injection Systems Domestic and Import Systems with a Fuel Rail Domestic MPFI Multi Port Fuel Injection AMC Chrysler Jeep MPI Multi Port Injection Ford GM PFI Port Fuel Injection Ford GM SFI Sequential Fuel Injection AMC Chrysler Ford GM Jeep Systems with a Fuel Rail Import AFC Air Flow Control Asian vehicles Datsun Mazda Nissan Subaru Toy
11. hose assembly No 12 connect adapters to 11 or 12 as required and to vehicle at testing location For assistance use the applications list and illustrations provided in this Guide NOTE If using TBI CIS hose assembly 12 make sure shutoff valve is open Turn ignition to START RUN Wait until fuel pump stops takes about 1 5 to 3 seconds Then turn ignition to OFF NOTE Gauge pressure should stabilize If pressure does not stabilize or if pump does not run properly refer to vehicle s service manual Place loose end of clear plastic hose on hose assembly 11 into approved drain container Press and hold open relief valve on 11 until fuel drains and air bubbles are no longer visible in hose then release close valve Wait 10 seconds turn ignition to START RUN engine should start unless dead head testing Do the specific tests on the next two pages CFI TBI AFC PGM and Single Point static running fuel pressure fuel volume or fuel pressure leak down for GM TBI can also do primary system pressure dead head test MPFI MPI SFI EFI and MFI static running fuel pressure fuel volume fuel pressure leak down or fuel pump output pressure CIS fuel volume cold control pressure hot control pressure primary system pressure or rest pressure CISE fuel volume system pressure residual pressure After testing remove test components and replace vehicle compo
12. ith hose and clamp in Accessory AMC and Chrysler pages 22 23 compartment use hose that fits fuel line Diahatsu EFI page 28 Subaru Single Point page 28 Asian AFC page 28 European AFC page 32 518478 Single Ended Hose Adapter MPI page 25 for fuel pump deadhead test 5 16 3 8 1 4 EFI and MFI page 29 518495 Ford MPI Adapter Ford MPI page 24 Components Applications Reorder Description No 7 16 x 20 GM Chrysler Adapter 5 16 Hairpin Adapter 3 8 Hairpin Adapter 5 8 18 External Flare Adapter 5 8 18 Internal Flare Adapter 16 mm x 1 5 External O ring Adapter 16 mm x 1 5 Internal O ring Adapter QD QD lo OT QD QD Co Common Application see page for connection illustration Chrysler and Jeep MPFI page 24 GM MPI page 24 Ford CFI page 16 Chrysler pages 22 23 GM pages 22 23 Chrysler pages 22 23 GM MPI pages 22 23 GM TBI early systems supply line page 19 used with No 35 GM TBI early systems supply line page 19 used with No 34 GM TBI supply line pages 19 20 used with No 37 GM TBI supply line pages 19 20 used with No 36 Components Applications Reorder Description Common Application No see page for connection illustration 518473 14mm x 1 5 External O ring Adapter GM TBI return line page 21 518474 14mm x 1 5 Internal O ring Adapter GM TBI
13. nents as follows turn ignition to OFF repeat steps 2 3 4 and 5 disconnect test components reconnect vehicle components repeat steps 7 and 8 tighten fuel filler cap Specific Tests Follow the General Test Instructions on the previous page At step 10 do the following tests as necessary NOTE For all tests refer to the vehicle s service manual for specifications and diagnostic repair procedures Static Running Fuel Pressure 1 Run engine at idle until gauge pressure stabilizes 2 Compare gauge pressure to pressure specified in vehicle s service manual Fuel Volume 1 Run engine at idle and place loose end of clear plastic hose on No 11 into approved drain container 2 Press and hold open relief valve on 11 while keeping engine at idle monitor fuel output for 30 seconds release close valve Fuel pump should maintain engine idle and output a minimum of one pint of fuel in 30 seconds For CIS and CISE output should be one quart in 30 seconds Fuel Pressure Leak Down NOTE For GM low pressure TBI test does not work because of pressure drop caused by pressure regulator design 1 Run engine at idle and compare gauge pressure with pressure specified in vehicle s service manual 2 Turn ignition to OFF wait 15 to 20 minutes check gauge pressure Pressure should not drop more than specified in vehicle s service manual if it does pressure may be leaking down NOTE If necessary turn ignition to S
14. ota and European vehicles BMW VW EFI Electronic Fuel Injection Asian vehicles such as Diahatsu Honda Mazda Nissan Subaru Toyota etc MFI Multiple Fuel Injection Asian vehicles such as Honda Mazda Nissan Subaru Toyota etc PGM Programmable Acura Honda Single Point Subaru Systems with a Fuel Distributor Import CIS Constant Injection System European vehicles with a warm up regulator in the return line Constant Injection System Electronic European vehicles warm up regulator built into fuel distributor 12 General Test Instructions Use the following instructions as general guideline For specific steps always refer to the vehicle s service manual 1 2 3 Loosen vehicle s fuel filler cap Remove fuel pump fuse from fuse block Turn ignition to START RUN and idle engine until fuel in fuel line is consumed engine stops NOTE For some 1991 and newer GMs if engine does not start and run replace pump fuse raise and safely Support vehicle disconnect fuel pump electrical connector s lower vehicle repeat step 3 Refer to vehicle s service manual To release remaining pressure turn ignition to START RUN for 3 seconds and then turn to OFF engine should not run Replace fuel pump fuse or electrical connector s Determine adapters required for testing and make connections Connect gauge No 10 to hose assembly No 11 if required connect 11 to TBI CIS
15. page 33 European CISE page 34 518536 M8x1 0 External O ring Adapters 2 European CIS page 33 European CISE page 34 Components Applications Reorder Description Common Application No see page for connection illustration 518484 M10x 1 0 Internal O ring Adapter 518489 M10x 1 0 External O ring Adapter 518486 M12 x 1 5 Internal Swivel Adapters 2 518498 M14 x 1 5 External and Internal Swivel Adapter 518497 1 4 BSPT External and Internal Swivel Adapter 518496 M16x 1 5 External and Internal Swivel Adapter I co N 81 518488 8 1 0 External O ring Adapter long European CIS page 33 European CISE page 34 European CIS page 33 European CISE page 34 European CIS page 33 European CISE page 34 European CIS page 33 European CISE page 34 European CIS page 33 European CISE page 34 European CIS page 33 European CISE page 34 European CIS page 33 European CISE page 34 About Fuel Systems and Testing vehicle s fuel delivery and return system consists of a circular system of components Fuel is pumped from the fuel tank by the fuel pump The fuel flows through the hoses through the fuel filter and to the fuel regulator and injection system The fuel injection system delivers the fuel to the engine and returns unused fuel to the fuel tank For an engine to run properly the fuel system must maintain precise fuel pressure and adequate fuel volum
16. return line page 21 518482 14mm x 1 5 External O ring Plug GM TBI return line plug for fuel pump deadhead test page 20 518487 16mm x 1 5 In Line Adapter GM TBI used in fuel filter location page 18 518499 Ford Spring Lock Adapter BAS Ford MPI 2003 and newer with returnless fuel z system 1985 and newer with return fuel system JI page 23 518490 M6x1 0 External O ring Adapter Acura and Honda PGM page 26 518491 M8x1 0 External Banjo Adapter Asian AFC EFI MFI pages 27 28 European AFC pages 31 32 Ld eg European CIS and CISE pages 33 34 S li Components Applications Reorder Description Common Application No see page for connection illustration 518492 M10x 1 0 External Banjo Adapter Asian AFC EFI MFI pages 27 28 0 European AFC pages 31 32 E European CIS and CISE pages 33 34 518493 M12x 1 5 External Banjo Adapter Asian AFG EFI MFI pages 27 28 European AFC pages 31 32 European CIS and pages 33 34 70 518494 M12x1 25 External Banjo Adapter Acura and Honda PGM page 26 Asian AFC mostly Toyota pages 27 28 European AFC pages 30 31 32 European CIS and CISE pages 33 34 p a 518501 M14x 1 5 External Banjo Adapter Toyota AFC pages 27 28 518537 M8x1 0 Internal O ring Adapter long European CIS page 33 European CISE page 34 518485 M8x1 0 Internal O ring Adapter European CIS
17. than 10 seconds closed valve creates very high fuel pressure 3 Compare gauge pressure with pressure specified in vehicle s service manual System Pressure CISE Same as Static Running Fuel Pressure on page 14 Residual Pressure CISE Same as Fuel Pressure Leak Down on page 14 15 Domestic Vehicle Connections CFI Vehicles Ford Connecting at the Throttle Body using 10 and 11 with 32 Throttle Body Fuel Filter Fuel Return Intake Manifold Engine Filter Domestic Vehicle Connections TBI Vehicles AMC and Chrysler Connecting at the Throttle Body using 10 and 11 with 14 14 Use No 14 with hose and clamp in Kit s Accessory Compartment use hose that fits vehicle s fuel line Fuel Supply Throttle Injector Fuel Filter Fuel Return N Intake Manifold Engine Filter Domestic Vehicle Connections TBI Vehicles GM Connecting at the Fuel Filter Location a using 10 and 11 with 41 41 Replace Fuel Filter with No 41 Fuel Supply Engine Filter Domestic Vehicle Connections TBI Vehicles GM Connecting at the Throttle Body using 10 11 and 12 II De ie Le with 34 and 35 or 36 and 37 34 35 36 37 NOTE This connection is for supply line pressure testing Fuel Supply Throttle Body Injector Fuel Filter 34 Adapters 35 Fuel Return TBI CIS Hose Ass y 12 Gauge use Gauge 1 10 Engine g Fuel
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