Actron CP7838 Operating Instructions
Contents
1. e Complete all Pre Testing Checks before beginning fuel pressure testing e Always follow vehicle manufacturer s warnings cautions and service procedures 8 GM TBI Test Adapter Adapter is used to connect gauge hose to GM TBI vehicles NOT equipped with a schrader valve test port 9 M12 X 1 25 Banjo Bolt Adapter Adapter is used to connect gauge hose to Asian European and select domestic vehicles equipped with fuel Banjo Bolt Connections 10 Dual Manifold Test Adapter Adapter is used to connect gauge hose to vehicles with rubber hose connections on the fuel rail fuel line or fuel filter Instructions in English French and Spanish Voltage 16V Instructions en Anglais Francais et Espagnol Tension de 16V Instrucciones en Ingl s Franc s y Espanol Tension 16V Fuel Injection System Theory There are two basic types of fuel injection systems currently being used The first type is called port or multi port fuel injection In this system fuel injectors spray fuel directly into intake manifold behind intake valve These systems typically have one fuel injector per cylinder The second type is commonly called Throttle Body Injection TBI for GM and Chrysler vehicles or Central Fuel Injection CFI for Ford vehicles These systems use one or two fuel injectors mounted on top of intake manifold They spray fuel into throttle body similarly to a conventional carbu2. cN N Shop Rag For Ford Lincoln Mercury vehicles with test port Note A right angle large schrader adapter part number 0180 1299 is available for close clearance connections e Remove Test Cap e Screw Ford test port adapter to fuel rail test port until finger tight e Screw GM Chrysler test port adapter to Ford test port adapter until finger tight For GM TBI vehicles without a test port e Disable fuel pump s and relieve fuel system GM Chrysler Test Port Pressu re Se Ford Test Relief Port Adapt Button ae P Fue Test Port pressure by following instructions in vehicle Pressure service manual Relef n UA PA Button WARNING Fuel Line Some vehicles may have more than to Engine one fuel pump Failure to deactivate all fuel pumps FuelLine can result in spilled fuel fire or from tank other hazardous conditions that 7 could cause vehicle damage Bleed Off Hose personal injury or death Ka Fuel Filter e Disconnect the fuel line at location described GM TBI Adapter Shop Towel in vehicle service manual using shop towels to catch any released fuel e Attach GM TBI test adapter and then attach fuel line to adapter Tighten all fittings finger tight and then tighten gently 1 2 turn with wrenches e Attach hose and pressure gauge assembly to adapter top fitting and tighten fitting until finger tight For im
3. y Actron lo reparar sin costo Esta garant a le otorga derechos legales espec ficos y tambi n podr a tener otros derechos que pueden variar de estado a estado Toda la informaci n ilustraciones y especificaciones contenidas en este manual est n basadas en la informaci n m s reciente disponible de fuentes industriales en el momento de la publicaci n No puede suministrarse garant a expresa o impl cita en cuanto a su exactitud o integridad ni Actron Manufacturing Co ni nadie relacionado con Actron asume ninguna responsabilidad por p rdida o da os sufridos por depositar su confianza en cualquier informaci n contenida en este manual o por maltrato del producto acompa ante Actron Manufacturing Co se reserva del derecho de hacer cambios en cualquier momento a este manual o el producto acompa ante sin obligaci n de notificar a ninguna persona u organizaci n acerca de dichos cambios Made in China Fabriqu en China Hecho en China 2004 Actron Manufacturing Company All Rights Reserved 2004 Actron Manufacturing Company Tous Droits R serv s 2004 Actron Manufacturing Company Todos Los Derechos Reservados 0002 001 2612
4. actron 15825 Industrial Parkway Cleveland Ohio 44135 USA EUA The Fuel Pressure Tester Kit was designed to help diagnose driveability CP7838 Instructions for Professional Fuel Pressure Tester Kit problems due to abnormally high or low fuel pressure Safety Precautions To prevent accidents that could result in serious injury and or damage to vehicle or test equipment carefully follow safety rules and test procedures at all times when working on vehicles e Always wear approved eye protection e Never use Fuel Pressure Tester Kit on Diesel or Flex Fuel engines e Never attach or remove Fuel Pressure Tester Kit from fuel rail test port with ignition key on e Always place end of 6 foot bleed off hose in an approved container for fuel during testing and when bleeding off fuel pressure e Never smoke or have open flames near vehicle Vapors from fuel and charging battery are highly flammable and explosive e Never permit fuel to spill on hot engine parts If a spill or leak occurs immediately turn ignition key off and clean up fuel e Only use Fuel Pressure Tester Kit for measuring fuel pressure e Always operate vehicle in a well ventilated area Fuel Pressure Tester Description 1 Rubber Boot Boot is used to protect gauge and maintain appearance 2 Dial Face Contains measurement scales that show amount of fuel pressure present in fuel system 3 Pressure Relief Button Used to relieve fuel pressure in ga
5. all fuel system fuses are good Fuel Pressure Testing Procedures This test procedure explains how to make fuel pressure measurements on vehicles while ignition key is on and while engine is at idle The procedure also explains the safest way to connect and disconnect fuel pressure tester kit from vehicles If fuel pressure readings measured in this test procedure are not within vehicles manufacturer s specification then use vehicle service manual along with fuel pressure tester kit to service problem This test procedure does not contain any vehicle specific diagnostics 1 Read all SAFETY PRECAUTIONS and PRE TESTING CHECKS 2 Apply a lightweight household oil to rubber O rings on test adapters 3 Turn Ignition Key OFF 4 Install Gauge 50 A 40 60 30 70 20 200 0 80 10 fea ri 100 ua y roe sum H OOO i Roe S Neots POO END Of BLEED Ol l HOSE ae MUST BE PLACED IN AN APPROVED FUEL CONTAINER exceeded It is used to keep a constant fuel pressure drop across the fuel injectors Some fuel pressure regulators have a vacuum port so fuel pressure can be adjusted based on engine load These are commonly called vacuum actuated compensated fuel pressure regulators A leaking fuel pressure regulator can cause low fuel pressure readings and hard starting problems Fuel Rail The fuel rail assembly is bolted to the intake manifold Its purpose is to hold the fuel injectors in place and to deliver pressu
6. it free of charge This warranty gives you specific legal rights and you may also have other rights which may vary from state to state All information illustrations and specifications contained in this manual are based on the latest information available from industry sources at the time of publication No warranty expressed or implied can be made for its accuracy or completeness nor is any responsibility assumed by Actron Manufacturing Co or anyone connected with it for loss or damages suffered through reliance on any information contained in this manual or misuse of accompanying product Actron Manufacturing Co reserves the right to make changes at any time to this manual or accompanying product without obligation to notify any person or organization of such changes Servicio al Cliente Para obtener informaci n del producto o servicio al cliente por favor llame al tel fono 1 800 AC TRON 7 1 800 228 7667 para EUA o env e un fax en cualquier momento al telefax 216 898 1636 para EUA Tambi n puede comunicarse con Actron a trav s del correo electr nico o el sitio de Internet Direcci n de correo electr nico sunpro actron com P gina principal de Internet http www actron com Garant a de 1 A o Para Garant a en Mexico consultor con Vendedor Si dentro de un per odo de un 1 a o a partir de la fecha de compra este juego presenta falla debido a defecto en el material o fabricaci n devu lvalo a Actron
7. tank Pressure Line A pressurized fuel line that carries fuel from the fuel tank to the fuel injectors Fuel Filter A filter that is located in line with the pressure line lts function is to prevent foreign particles from reaching the fuel injectors A clogged or restricted fuel filter can also cause low fuel pressure readings This is the only fuel system component that requires periodic replacement Refer to vehicle owners manual for replacement interval Fuel Rail Test Port A schrader valve located on the fuel rail that allows easy connection of a fuel pressure gauge to measure fuel pressure Do not confuse this valve with the schrader valves that are used for recharging air conditioning systems Fuel Pressure Regulator The fuel pressure regulator is connected across the pressure line and return line It contains a spring loaded valve assembly that opens to allow fuel to move into the return line when the pressure line fuel pressure is Pre Testing Checks 1 Read Safety Precautions 2 Do a thorough visual and hands on inspection of the engine and fuel system Look for loose or cracked electrical wiring battery cables ignition wires and fuel or vacuum lines 3 Verify that the battery is fully charged and fuel tank has an adequate supply of fuel 4 Verify that the inertia switch on certain Ford Lincoln Mercury vehicles has not been tripped The inertia switch is usually located in the trunk 5 Verify that
8. e over approved container to catch any remaining fuel e Loosen banjo bolt test adapter and remove adapter and gaskets e Re install vehicle s fuel bolt with new gaskets on either side of banjo Install fuel bolt finger tight then wrench tighten to specifications given in service manual e Check for leaks General Fuel Pressure Diagnostics For import and domestic vehicles with rubber hose connections e Place a shop towel under dual manifold test adapter e Disconnect hose and pressure gauge assembly from dual manifold adapter e Wrap a shop towel around end of gauge hose Hold end of gauge hose over approved container to catch any remaining fuel e Loosen hose clamp securing vehicle s rubber fuel line to dual manifold adapter Disconnect fuel line from adapter e Loosen hose clamp securing dual manifold adapter hose to vehicle Disconnect adapter from vehicle e Reconnect vehicle s rubber fuel line to original location e Securely tighten hose clamps on vehicle s fuel line e Check for leaks 14 Store shop rags in an approved container so they cannot cause personal injury or a hazardous situation 15 Store Fuel Pressure Tester in a well ventilated area where it cannot cause personal injury or a hazardous situation Fuel pressure checking is an essential part of fuel injection system troubleshooting High fuel pressure will make an engine run rich while low fuel pressure will make an engine run lean or not a
9. g from gauge hose is absorbed e Remove bleed off hose from approved fuel container and hold gauge hose over container so any remaining fuel will drip into container For Ford Lincoln Mercury vehicles with test port Wrap a shop rag around fuel rail test port in case a small amount of fuel drips out while unscrewing test port adapters e Unscrew GM Chrysler test port adapter from Ford test port adapter e Wrap a shop rag around GM Chrysler test port adapter so any fuel dripping from gauge hose is absorbed e Remove bleed off hose from approved fuel container and hold gauge hose over container so any remaining fuel will drip into container e Unscrew Ford test port adapter from fuel rail test port and reinstall the Test Cap For GM TBI vehicles without a test port e Place shop rag under GM TBI adapter in case a small amount of fuel drips out while unscrewing e Disconnect Gauge Hose and wrap a shop rag around so any fuel dripping from hose is absorbed e Disconnect fuel lines from GM TBI adapter and wrap with shop rag so any fuel dripping from adapter is absorbed e Reconnect fuel lines as described in vehicle service manual For import and some domestic vehicles with a banjo bolt connection e Wrap a shop towel around banjo bolt connection while removing bolt e Disconnect hose and pressure gauge assembly from banjo bolt test adapter e Wrap a shop towel around end of gauge hose Hold end of gauge hos
10. hicle s fuel line to other side of dual manifold adapter Use vehicle s hose clamps on rubber hose e Tighten all hose clamps securely e Connect hose and pressure gauge assembly to dual manifold test fitting Tighten gauge hose fitting finger tight Place end of 6 foot bleed off hose in an approved container for fuel Bleed off hose must remain in container until testing is complete Turn all accessories OFF Radio A C Blower Fan Headlights Windshield Wipers Re activate fuel pump and turn ignition key ON Do the following checks e Listen for fuel pump Pump should run for approximately 2 seconds Pressurize fuel system by cycling ignition ON and OFF every ten seconds until fuel pressure is at manufacturers specifications check vehicle service manual for your particular application e Check fuel system for leaks If leaks are found turn ignition key OFF and wipe up fuel immediately e Read fuel pressure from dial face Pressure should rise to manufacturer s specification and hold steady e If fuel pressure is not within manufacturer s specification cycle ignition key 2 or 3 more times If fuel pressure is still not within manufacturer s specifications service vehicle according to vehicle service manual then re test e When key on engine off fuel pressure is within manufacturers specification proceed to Step 8 e To safely disconnect Fuel Pressure Test Kit proceed to Step 9 Start eng
11. ibraries For others write for availability and prices specifying make model and year of vehicle Aftermarket Vehicle Service Manuals Vehicle Service Manuals from Chilton Book Company General Motors Corporation Chilton Way Buick Radnor PA 19089 Tuar Company ae Post Office Box 354 H Publ aynes Publications Flint MI 48501 861 Lawrence Drive Newbury Park CA 91320 Oldsmobile or Lansing Lithographers Cord Publicat oi Post Office Box 23188 Mitchell Manuals Inc ee MI 48909 Post Office Box 26260 SS San Diego CA 92126 Cadillac Chevrolet Pontiac Motor s Auto Repair Manual oan cal salido Post Office Box 07130 Hearst Company Detroit MI 48207 250 W 55th Street SHAS New York NY 10019 Vehicle Service Manuals from Chrysler Corporation Vehicle Service Manuals from l i Chrysler Corporation Ford Motor Company od Ford Publication Department listadas Service Helm Incorporated Se E SUON 12200 Alameda Drive Post Office Box 07150 i Detroit MI 48207 Strongsville Ohio 44136 Customer Service For product information or customer service please call 1 800 ACTRON 7 1 800 228 7667 or fax anytime at 216 898 1636 Actron can also be reached by Email or on the Internet Email address sunpro actron com Internet home page http www actron com One Year Warranty If within one year from the date of purchase this equipment fails due to defect in materials or workmanship return it to Actron and Actron will repair
12. ine Let idle e If vehicles fuel system uses a vacuum actuated compensated fuel pressure regulator then fuel pressure should drop approximately 3 10 psi depending on manifold vacuum sm SH E A D9920 PKK XY I RR Os i WO Fuel Line Dual Manifold Test a from tank Adapter e If vehicles fuel system uses a fuel pressure regulator without a vacuum port then fuel pressure should remain constant during both key on engine off and idle e Read fuel pressure from dial face e If fuel pressure is not within manufacturer s specification service vehicle according to vehicle service manual e When repair is completed and idle fuel pressure is now within manufacturer s specification then proceed to Step 9 9 Turn Ignition Key OFF 10 Verify that 6 ft bleed off hose is still in an approved container for fuel 11 Fully DEPRESS and HOLD the pressure relief button until dial face pointer is resting on stop pin 12 Shake bleed off hose to make sure that all fuel went into approved container 13 Remove gauge hose For GM Chrysler Vehicles with test port e Wrap a shop rag around fuel rail test port in case a small amount of fuel drips out while unscrewing test port adapters e Unscrew GM Chrysler test port adapter from fuel rail test port and reinstall the Test Cap e Wrap a shop rag around GM Chrysler test port adapter so any fuel drippin
13. port and some domestic vehicles with a banjo bolt connection Note The most popular banjo bolt with 12 mm x 1 25 thread is included other bolts are available Part numbers 0180 1296 12 mm x 1 5 thread and 0180 1297 8mm x 1 0 thread e Relieve fuel system pressure by following instructions in vehicle service manual e Remove the vehicle s fuel bolt at location described in service manual Use shop towels to catch any released fuel e Install banjo bolt test adapter in place of fuel bolt Position banjo bolt gaskets on either side of banjo Banjo with fuel supply line attached should be sandwiched between banjo bolt gaskets e Tighten banjo bolt test adapter finger tight then gently snug with wrench e Connect hose and pressure gauge assembly to banjo bolt test adapter fitting Tighten gauge hose fitting finger tight END OF BLEED OFF HOSE MUST BE PLACED IN AN APPROVED FUEL CONTAINER lt Banjo Bolt Adapter For import and domestic vehicles with rubber hose connections e Relieve fuel system pressure by following instructions in vehicle service manual e Disconnect the vehicle s rubber fuel line hose at location described in service manual Use shop towels to catch any released fuel Leave rubber hose attached to fuel line e Install matching size adapter hose and hose clamps on dual manifold test adapter e Connect test adapter hose at location where vehicle s fuel line was disconnected e Connect ve
14. retor Fuel Rail Fuel Injectors Test Port Fuel Pressure Fuel Injectors j Fuel Pressure Regulator Regulator gt TO Ear Pressure NYZ ZA nus Line Return Line Return Line Fuel Injectors Ford CFI Throttle Body GM Multi Port Fuel Injection Fuel System Components Before doing any fuel pressure testing itis a good idea to understand how fuel system components work and how they relate to one another The fuel pump pumps fuel from the fuel tank to the fuel pressure regulator and fuel injectors Fuel pressure regulator divides fuel between the pressure line and return line The fuel in the pressure line goes to fuel injectors while fuel is returned to fuel tank through the return line cols fuel medio Fuel Pressure Regulator Pressure Line Fuel Filter D a Fuel Tan Fuel Pump Fuel Pump Filter Fuel Tank A large container that holds vehicles is a good idea to replace the fuel pump filter supply of fuel Fuel Pump An electric motor that pumps fuel Fuel Pump Filter A filter that is usually located nto the fuel system at a constant pressure It is in fuel tank Its function is to prevent foreign mounted in the fuel tank or on the frame Some particles from reaching the fuel pump Aclogged or vehicles have more than one fuel pump restricted fuel pump filter can cause low fuel Return Line Path way for excess fuel to return pressure readings When replacing a fuel pump it to the fuel
15. rized fuel to the fuel injectors Fuel Injectors Aprecision valve that is controlled by a solenoid Fuel injection is controlled by the amount of fuel pressure and the size and duration of the valve opening Fuel injectors contain a filter used to prevent very small particles from clogging the valve Leaking fuel injectors will cause fuel pressure to slowly decrease when the ignition key is on and engine is off 6 Verify fuel vapor recovery system and gas cap are in good condition 7 Verify that manifold vacuum is within manufacturers specification which is typically 18 20 inches at idle 8 Look for fuel leaks and wipe up any spilled fuel immediately 9 If engine will not start check ignition system for spark If no ignition spark is present refer to vehicle service manual for No Start Diagnostics 10 Inspect wire harnesses and electrical connectors for damaged or corroded parts 11 Check other electrical systems including ignition and car computer system For GM Chrysler vehicles with test port Note A right angle large schrader adapter part number 0180 1299 is available for close clearance connections e Remove Test Cap e Screw GM Chrysler test port adapter to fuel rail test port until finger tight Note Always wrap a shop rag around fuel rail test port when attaching test port adapters This is a precaution in case a small amount of fuel leaks out while attaching adapters Test Port Adapter qe
16. t all Fuel pressure readings that are higher than manufacturer s specifications are generally caused by a problem in the fuel return line components Conversely fuel pressure readings that are lower than manufacturer s specifications are generally caused by a problem in the fuel pressure line components If fuel pressure readings are not within manufacturer s specifications then refer to a vehicle service manual for step by step diagnostic procedures that will pinpoint the faulty component for a specific vehicle Possible causes of high fuel pressure readings are the following e Faulty fuel pressure regulator e Restriction in return line e Faulty fuel line couplings at fuel tank e Sticking or Sluggish Fuel Injectors Care and Maintenance Possible causes of low fuel pressure readings are the following e Clogged or restricted fuel filter e Restriction in pressure line e Faulty fuel pump e Faulty fuel pump relay e Blown fuel pump fuse e Faulty fuel pump wiring e Clogged or restricted fuel pump filter e Faulty fuel pressure regulator e Leaking fuel injectors e Faulty fuel line couplings at fuel tank Apply a lightweight household oil to the rubber O rings inside adapters before each use Vehicle Service Information The following is a list of publishers who have manuals containing electronic fuel injection system information Some manuals may be available at auto parts stores local dealers or local public l
17. uge hose before disconnecting gauge hose from fuel rail 4 Bleed Off Hose A6 foot hose that bleeds off fuel pressure when pressure relief button is pressed Never use a bleed off hose shorter than 6 foot Important Always make sure end of bleed off hose is in an approved container for fuel at all times during testing and when bleeding off fuel pressure 5 Gauge Hose Hose that carries fuel to the gauge so that pressure can be measured 6 GM Chrysler Test Port Adapter Adapter is used to connect gauge hose to GM Chrysler and other vehicles equipped with a schrader valve test port on fuel rail 7 Ford Test Port Adapter Adapter is used to connect gauge hose to Ford vehicles equipped with a schrader valve test port on fuel rail Do not inhale exhaust gases or fuel vapors e Always keep yourself tools and test equipment away from all moving or hot engine parts e Always make sure vehicle is in PARK Automatic transmission or NEUTRAL manual transmission and parking brake is set Block drive wheels e Never lay tools on vehicle battery Terminals may short together causing harm to yourself tools or battery e Never leave vehicle unattended while running tests e Always keep a fire extinguisher suitable for fuel electrical chemical fires handy e Always use extreme caution when working around ignition coil distributor cap ignition wires and spark plugs These components contain High Voltage when engine is running
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