(FRONT COVER) FUEL INJECTION PRESSURE TESTER KIT

(FRONT COVER) FUEL INJECTION PRESSURE TESTER KIT #3642 3642

TABLE OF CONTENTS Paragraph Title Page No. I INTRODUCTION............................................. 1 II SAFETY PRECAUTIONS....................................... 1 III VEHICLE SERVICE MANUALS................................. 2 IV VEHICLES COVERED......................................... 2 V FUEL SYSTEM PRESSURE TESTING............................ 10 FUEL SYSTEMS............................................ 10 BEFORE YOU BEGIN....................................... 11 TEST PROCEDURES........................................ 11 Connecting To Systems With Existing Test Ports (Schrader Valves.......................................... 12 Connecting To Systems Using Fuel System Pressure Fitting Adapter........................................... 13 Connecting To Systems Using the In-line Tee Adapter............. 14 Key On Engine Off Test..................................... 15 Key On Engine On Test..................................... 15 VI REPLACEMENT PARTS........................................ 17 VII LIMITED WARRANTY AND SERVICE PROCEDURES............... 18 i 3642

I. INTRODUCTION Congratulations. You have purchased a precision instrument manufactured to the highest quality standards. This Fuel Injection Pressure Tester Kit is designed to perform fuel pressure tests on most domestic and imported cars and trucks that are equipped with electronic fuel injection systems. The tester saves you money by helping you test and troubleshoot fuel system problems that can affect your vehicle's performance and fuel economy. The tester can help you identify and diagnose: Low fuel pressure Leaking fuel injectors Faulty fuel pressure regulator Clogged fuel filter Leaks in the fuel system Faulty fuel pump II. SAFETY PRECAUTIONS To avoid personal injury, instrument damage and/or damage to equipment under test, DO NOT operate the tester before reading this manual. ALWAYS use extreme caution when working on an automobile. This manual describes common test procedures used by experienced service personnel and technicians. Many test procedures require precautions to avoid accidents that can result in personal injury, and/or vehicle or equipment damage. ALWAYS read your vehicle's service manual and follow it s safety precautions before any test or procedure is performed. a. When an engine is in operation, it produces carbon monoxide (a toxic and poisonous gas). To prevent serious injury or death from carbon monoxide poisoning, operate a vehicle ONLY in a well-ventilated area. b. To protect your eyes from propelled objects as well as hot or caustic liquids, always wear approved safety eye protection. c. When an engine is running, several engine components rotate at a very high rate of speed (coolant fan, pulleys, fan belt, etc.). To avoid serious injury, always be conscious of moving parts and keep a safe distance from all these items as well as other potentially moving objects. d. Engine parts become extremely hot when the engine is running. To prevent severe burns, avoid contact with hot engine parts. e. Before starting an engine for troubleshooting, make sure the parking brake is engaged. Put the transmission in park (for automatic transmission) or neutral (for manual transmission). Block the drive wheels with a suitable blocking device. f. NEVER leave a vehicle unattended during testing. g. When working on vehicles equipped with airbags, follow all cautions and test procedures in your vehicle's service manual to avoid accidental airbag deployment. h. Don't wear loose clothing or jewelry when working on an engine. Loose clothing can get caught on the fan, pulleys, belts, etc. Jewelry is highly conductive to electricity, and can cause a severe burn if it makes contact between a power source and ground. 3642 1

The following safety precautions apply to fuel and fuel systems. Gasoline is an extremely flammable substance. To prevent fires and/or severe burns, always take extra precautions when troubleshooting or working on fuel systems. i. Gasoline and battery vapors are highly flammable. To prevent an explosion or fire, keep all sparks, high temperature items or open flames away from gasoline/gasoline vapors and battery. DO NOT SMOKE NEAR THE VEHI- CLE DURING TESTING. j. Gasoline and gasoline additives are toxic. AVOID CONTACT OF GASO- LINE WITH SKIN. Wear protective clothing and hand covering (approved latex gloves) when performing pressure tests. In case of contact with skin, WASH THE AREA IMMEDIATELY and perform any other necessary first aid. k. In case of emergency, keep a fire extinguisher handy. MAKE SURE it is rated for fuel/electrical and chemical fires. l. During testing, be careful to avoid fuel spills on hot engine parts. If spills occur or if leaks are present, turn ignition off IMMEDIATELY and correct the problem. WIPE UP FUEL SPELLS IMMEDIATELY. m. When placing the bleed-off hose into a container to collect excess fuel, MAKE SURE the container is approved for gasoline. III. IV. VEHICLE SERVICE MANUALS You must consult the manufacturer's service manual for your vehicle BEFORE performing any test procedures. Contact your local car dealership, auto parts store, bookstore, or public library for availability of these manuals. The following companies publish valuable repair manuals, including material that covers fuel injection systems and testing techniques. Haynes Publications, 861 Lawrence Drive, Newbury Park, CA 91320, Phone: CA (800) 442-9637, TN (800) 242-4637 Motor Publications, 5600 Crooks Road, Suite 200, Troy, Michigan 48098, Phone (800) 426-6867 Mitchell International, 14145 Danielson Street, Poway, CA 92064, Phone (888) 724-6742 Factory Source (Ford, GM, Chrysler, Honda, Isuzu, Hyundai and Subaru Service Manuals; Helm Inc., 14310 Hamilton Avenue, Highland Park, Michigan 48203, Phone (800) 782-4356 VEHICLES COVERED This Fuel Injection Pressure Tester Kit is designed for use on vehicles equipped with electronic fuel injection systems only (Multi-port, Sequential, Multi-point, Direct, Throttle Body, etc.). DO NOT USE ON DIESEL SYSTEMS. The kit includes adapters to be used on the following fuel injection system applications: 1. All fuel injection systems that are factory equipped with suitable fuel pressure Test Ports (Schrader Valves). See "Connecting To Systems With Existing Test Ports (Schrader Valves)", page 12 for further instructions. 2. Fuel injection systems that are equipped with a removable "Fuel System Pressure Fitting" that facilitates the use of the "Fuel System Pressure Fitting Adapter". See "Connecting to Systems Using Fuel System Pressure Fitting Adapter", page 13 for further instructions. 2 3642

3. Fuel injection systems that are not factory equipped with Fuel Pressure Test Ports or removable Fuel System Pressure Fittings but are equipped with "flexible rubber fuel supply lines" that can facilitate the use of the "Tee Adapter". See "Connecting To Systems Using the In-line Tee Adapter", page 14 for further instructions. The following vehicle coverage tables and lists are to be used only as a general guide. They are in no way intended as a substitute for vehicle manufacturer's instructions and procedures. Damage to the vehicle being tested, the test equipment or personal injury can result from improper testing procedures. Always consult the vehicle's service manual for proper fitting size, application, installation and test procedures. Fuel Pressure Test Port (Schrader Valve) Application Domestic Vehicles (1980-01) Non-diesel - Includes light trucks and vans Dodge, Chrysler, Plymouth Ford, Lincoln, Mercury GMC, Chevrolet, Buick, Oldsmobile, Pontiac, Saturn, Cadillac Jeep, Eagle System Type/Application Models with electronic fuel injection systems (Multi-port, Sequential, Multi-point, Direct and Throttle Body) which are factory-equipped with a Fuel Pressure Test Port (Schrader Valve). If your vehicle is made by one of the manufacturers on this list but does not come equipped with a Test Port, see note below. NOTE: Some models of vehicles listed on the "Fuel Pressure Test Port (Schrader Valve) Application" list above do not come equipped with fuel pressure test ports (Schrader Valves). These vehicles may require additional tools and/or adapters to properly test fuel system pressure. If your vehicle is on this list but is not factory equipped with a fuel pressure test port, refer to your vehicle's service manual or consult your auto parts dealer for the availability of these items and/or for fuel system testing procedures. See "Connecting To Systems Using the In-line Tee Adapter",page 16 for further instructions. Fuel System Pressure Fitting Adapter Application Primary Optional Make (Year) Model Engine Fitting Fitting Acura (1986~1989) Integra 1.6L none Acura (1993) Integra 1.7L none Acura (1990~1998) Integra, All Models 1.8L none Acura (1986~1987) Legend, All Models 2.5L none Acura (1988~1990) Legend, All Models 2.7L none Acura (1991~1995) Legend, All Models 3.2L none Acura (1991~1998) NSX 3L none Acura (1997~1998) NSX, NSX-T 3.2L none Acura (1992~1994) Vigor 2.5L none Acura (1995~1998) TL 2.5L none Acura (1996~1998) TL 3.2L none Acura (1996~1998) RL 3.5L none Acura (1997) CL 2.2L none Acura (1998) CL 2.3L none Acura (1997~1998) CL 3L none Audi (1982~1984) 4000, S 1.7L M12 x 1.5 none Audi (1982~1983) 4000, S 2.14L M12 x 1.5 none 3642 3

Primary Optional Make (Year) Model Engine Fitting Fitting Audi (1984~1987) 4000, S 1.8L M12 x 1.5 none Audi (1982~1985) 5000, S 2.14L M12 x 1.5 none Audi (1982~1985) 5000 Turbo 2.14L M12 x 1.5 none Audi (1986~1988) 5000 S, CS 2.22L M12 x 1.5 none Audi (1987~1988) 5000 S 2.3L M12 x 1.5 none Audi(1982~1983) Coupe, Coupe GT 2.14L M12 x 1.5 none Audi(1984~1987) Coupe GT 2.22L M12 x 1.5 none Audi(1987) Coupe GT 2.3L M12 x 1.5 none Audi(1988~1990) 80 2L M12 x 1.5 none Audi(1991~1992) 80 2.3L M12 x 1.5 none Audi(1988~1992) 80 Quattro 2.3L M12 x 1.5 none Audi(1988) 90 2L M12 x 1.5 none Audi(1988~1991) 90 2.3L M12 x 1.5 none Audi(1988~1989) 90 Quattro 2.3L M12 x 1.5 none Audi (1982~1985) Turbo Quattro 2.14L M12 x 1.5 none Coupe Audi (1989~1991) 100 Quattro Sedan 2.3L M12 x 1.5 none Audi (1989~1991) 100 Sedan, Wagon 2.3L M12 x 1.5 none BMW (1982~1983) 320i 1.8L M12 x 1.5 none Dodge (1987~1991) Colt Vista 2WD 2L none Dodge (1992~1993) Colt Vista 2WD 1.8L none Dodge (1992~1993) Colt Vista 2WD 2.4L none Dodge (1987~1991) Colt Vista 4WD 2L none Dodge (1992~1993) Colt Vista AWD 1.8L none Dodge (1992~1993) Colt Vista AWD 2.4L none Dodge (1988~1994) Colt 1.5L none Dodge (1988~1989) Colt Turbo 1.6L none Dodge (1989~1990) Colt 1.6L none Dodge (1993~1994) Colt 1.8L none Ford (1993~1995) Probe 2.5L none Geo (1993~1995) Prizm 1.6L M10x1.0, M8x1.0 Geo (1993~1997) Prizm 1.8L none Honda (1985) Accord 1.8L none Honda (1986~1989) Accord 2L none Honda (1995~1997) Accord 2.7L none Honda (1995~1997) Accord 3L none Honda (1987) Civic Hatchback Si 1.5L none Honda (1988~1996) Civic, All Models 1.5L none Honda (1988~1998) Civic, All Models 1.6L none Honda (1986~1992) CRX 1.5L none Honda (1988~1992) CRX Si 1.6L none Honda (1985~1991) Prelude 2L none Honda (1993~1995) Del Sol 1.5L none Honda (1993~1997) Del Sol 1.6L none Lexus (1990~1991) ES250 2.5L M8 X 1.0 Lexus (1992~1998) ES300 3L M8 X 1.0 4 3642

Primary Optional Make (Year) Model Engine Fitting Fitting Lexus (1990~1998) LS400 4L none Lexus (1992~1998) SC300 3L M8 X 1.0 Lexus (1992~1998) SC400 4L none Lexus (1992~1998) GS300 3L M8 X 1.0 M10 x 1.0, Lexus (1998) GS400 4L none Mitsubishi (1984~1987) Cordia, Turbo 1.8L none Mitsubishi (1984~1989) Starion 2.6L none Mitsubishi (1984~1988) Tredia, Turbo 1.8L none Mitsubishi (1985~1992) Mirage, Turbo 1.6L none Mitsubishi (1988~1998) Mirage, All Models 1.5L none Mitsubishi (1993~1998) Mirage, All Models 1.8L none Mitsubishi (1985~1998) Galant 2.4L none Mitsubishi (1988) Galant 3L none Mitsubishi (1989~1993) Galant, All Models 2L none Mitsubishi (1990~1994) Precis 1.5L none Mitsubishi (1989~1990) Sigma 3L none Mitsubishi (1990~1994) Eclipse 1.8L none Mitsubishi (1990~1998) Eclipse, All Models 2L none Mitsubishi (1996~1998) Eclipse, All Models 2.4L none Mitsubishi (1991~1998) 3000GT, All Models 3L none Mitsubishi (1992~1995) Expo, All Models 2.4L none Mitsubishi (1992~1995) Expo, All Models 1.8L none Mitsubishi (1992~1996) Diamante, All 3L none Models Mitsubishi (1997~1998) Diamante, All 3.5L none Models Mitsubishi (1990~1996) Montero, All 3L none Models Mitsubishi (1990~1996 Pickup, 2WD 2.4L none Mitsubishi (1990~1995) Pickup, 4WD 3L none Mitsubishi (1987~1990) Van Wagon 2.4L none Plymouth (1990~1994) Laser, All Models 1.8L none Plymouth (1990~1994) Laser, All Models 2L none Toyota (1982~1986) Celica Supra 2.8L M8 x 1.0 M10 x 1.0, Toyota (1986) Celica Supra 3L M8 x 1.0 M10 x 1.0, Toyota (1983~1985) Celica, 22R-E 2.4L M8 x 1.0 M10 x 1.0, Toyota (1986~1993) Celica, All Models 2L M8 x 1.0 M10 x 1.0, Toyota (1990~1998) Celica, All Models 2.2L M10 x 1.0, M8 x 1.0 Toyota (1990~1993) Celica, All Models 1.6L M10 x 1.0, M8 x 1.0 Toyota (1994~1997) Celica, All Models 1.8L M10 x 1.0, M8 x 1.0 Toyota (1987~1998) Supra, All Models 3L M10 x 1.0, M8 x 1.0 3642 5

Primary Optional Make (Year) Model Engine Fitting Fitting Toyota (1982~1988) Cressida 2.8L M8 x 1.0 M10 x 1.0, Toyota (1989~1992) Cressida 3L M8 x 1.0 M10 x 1.0, Toyota (1983~1991) Camry, All Models 2L M8 x 1.0 M10 x 1.0, Toyota (1988~1991) Camry, All Models 2.5L M8 x 1.0 M10 x 1.0, Toyota (1992~1998) Camry, All Models 2.2L none Toyota (1992~1997) Camry, All Models 3L none Toyota (1986~1989) Corolla, 4A-GE 1.6L M8 x 1.0 M10 x 1.0, Toyota (1989) Corolla, 4A-FE 1.6L M8 x 1.0 M10 x 1.0, Toyota (1990~1997) Corolla, All Models 1.6L M10x1.0, M8x1.0 Toyota (1993~199)7 Corolla, All Models 1.8L none Toyota (1990) Tercel Hatchback 1.5L M8 x 1.0 M10 x 1.0, Toyota (1991~1998) Tercel, All Models 1.5L M10x1.0, M8x1.0 Toyota (1986~1989) MR2 1.6L M8 x 1.0 M10 x 1.0, Toyota (1991~1995) MR2 2L M8 x 1.0 M10x1.0, M8x1.0 Toyota (1991~1995) MR2 2.2L M10x1.0, M8x1.0 Toyota (1993~1998) Paseo 1.5L none Toyota (1995~1997) Avalon 3L none Toyota (1984~1995) 4Runner, 22R-E 2.4L M8 x 1.0 M10 x 1.0, Toyota (1988~1995) 4Runner 3L M8 x 1.0 M10 x 1.0, Toyota (1996~1998) 4Runner 2.7L none Toyota (1996~1998) 4Runner 3.4L none Toyota (1984~1995) Pickup, 22R-E 2.4L M8 x 1.0 M10 x 1.0, Toyota (1988~1995) Pickup 3L M8 x 1.0 M10 x 1.0, Toyota (1994~1998) T100 2.7L none Toyota (1995~1998) T100 3.4L none Toyota (1993~1994) T100 3L none Toyota (1988~1992) Landcruiser 4L M8 x 1.0 M10 x 1.0, Toyota (1993~1998) Landcruiser 4.5L none Volkswagen (1982~1984) Jetta 1.7L M12 x 1.5 none Volkswagen (1984~1989) Jetta, DOHC 1.8L M12 x 1.5 none Volkswagen (1990~1992) Jetta 2L M12 x 1.5 none Volkswagen (1982~1983) Quantum 1.7L M12 x 1.5 none Volkswagen (1984~1988) Quantum 2.2L M12 x 1.5 none Volkswagen (1985) Quantum 1.8L M12 x 1.5 none 6 3642

Primary Optional Make (Year) Model Engine Fitting Fitting Volkswagen (1982~1984) Rabbit 1.7L M12 x 1.5 none Volkswagen (1983~1984) Rabbit 1.8L M12 x 1.5 none Volkswagen (1982~1984) Scirocco 1.7L M12 x 1.5 none Volkswagen (1983~1988) Scirocco 1.8L M12 x 1.5 none Volkswagen (1985~1989) Golf, GTI 1.8L M12 x 1.5 none Volkswagen (1990~1992) Golf, GTI 2L M12 x 1.5 none Volkswagen (1987~1990) Fox 1.8L M12 x 1.5 none Volkswagen (1990~1993) Passat 2L M12 x 1.5 none Volkswagen (1985~1988) Cabriolet 1.8L M12 x 1.5 none Volkswagen (1991~1992) GTI 2L M12 x 1.5 none Volvo (1982~1985) 240, B21F-9 2.1L M12 x 1.5 none Volvo (1982~1983) 240, B23E 2.3L M12 x 1.5 none Volvo (1982) 260.0 2.6L M12 x 1.5 none Tee Adapter Application Tee Adapter Make (Year) Model Engine Installation Location BMW (1984~1985) 318i 1.8L Fuel delivery line between pressure regulator and filter BMW (1991~1995) 318is 1.8L Fuel inlet line at fuel injector rail BMW (1984~1988) 325e 2.7L Fuel feed line in front of pressure regulator BMW (1987~1995) 325i 2.5L Fuel feed line in front of pressure regulator BMW (1996~1998) 328i 2.8L Fuel delivery line between pressure regulator and filter BMW (1993~1995) 525i 2.5L End of inlet line BMW (1982~1988) 528e 2.7L Fuel feed line in front of pressure regulator BMW (1983~1985) 533i 3.2L Fuel feed line in front of pressure regulator BMW (1985~1993) 535i 3.4L Fuel feed line in front of pressure regulator BMW (1982~1984) 633Csi 3.2L Between Cold Start Valve and Supply hose BMW (1985~1989) 635Csi 3.4L Between Cold Start Valve and Supply hose BMW (1982~1984) 733i 3.2L Between Cold Start Valve and Supply hose BMW (1985~1992) 735i 3.4L Fuel inlet line at fuel injector rail BMW (1987~1989) L6 3.4L Fuel inlet line at fuel injector rail BMW (1986~1987) L7 3.4L Consult service manual BMW (1991~1993) M5 3.6L Fuel inlet line at fuel injector rail Infiniti (1991~1996) G20 2.0L Fuel line at fuel filter Infiniti (1996~1998) I30 3.0L Between fuel filter and fuel Infiniti (1993~1997) J30 3.0L Between fuel filter and fuel 3642 7

Tee Adapter Make (Year) Model Engine Installation Location Infiniti (1990~1998) Q45 4.1L Between fuel filter and fuel Isuzu (1989~1994) Amigo 2.6L At fuel pressure regulator Isuzu (1985~1989) Impulse 1.9L Between fuel pressure regulator and fuel distributor pipe Isuzu (1988~1995) Pickup 2.6L At fuel pressure regulator Isuzu (1991~1997) Rodeo 2.6L At fuel pressure regulator Mazda (1988~1994) 323 1.6L Hose on outlet side of fuel filter Mazda (1991~1992) 323 1.8L Hose on outlet side of fuel filter Mazda (1986~1998) 626 2.0L Hose on outlet side of fuel filter Mazda (1988~1992) 626 2.2L Hose on outlet side of fuel filter Mazda (1988~1995) 929 3.OL Hose on outlet side of fuel filter Mazda (1995~1996) Millenia 2.3L Between fuel filter and fuel distribution Mazda (1992~1996) MX-3 1.6L Between fuel filter and fuel rail Mazda (1992~1994) MX-3 1.8L Fuel filter and fuel main hose Mazda (1988~1992) MX-6 2.2L Fuel filter and fuel main hose Mazda (1995~1998) Protégé 1.5L Between fuel filter and fuel distribution Mazda (1990~1998) Protégé 1.8L Between fuel filter and fuel rail Mazda (1984~1995) RXT 1.3L Between fuel filter and fuel rail Mazda (1990~1993) Miata 1.6L Consult manual Mazda (1990~1993) Miata 1.8L Consult manual Mazda (1989~1994) MPV 2.6L On outlet hose at fuel filter Mazda (1989~1998) MPV 3.0L On outlet hose at fuel filter Mazda (1990~1993) Pickup 2.2L On outlet hose at fuel filter Mazda (1989~1993) Pickup 2.6L On outlet hose at fuel filter Nissan/Datsun (1995~1998) 200SX 1.6L Between fuel filter and fuel Nissan/Datsun (1984~1986) 200SX 1.8L Between fuel filter and fuel Nissan/Datsun (1984~1997) 200SX 2.0L Between fuel filter and fuel Nissan/Datsun (1982~1983) 200SX 2.2L Between fuel filter and fuel Nissan/Datsun (1987~1988) 200SX 3.0L Between fuel filter and fuel Nissan/Datsun (1989~1998) 240SX 2.4L Between fuel filter and fuel Nissan/Datsun (1975~1983) 280ZX 2.8L Between fuel filter and fuel Nissan/Datsun (1984~1996) 300ZX 3.0L Between fuel filter and fuel Nissan/Datsun (1993~1998) Altima 2.4L Between fuel filter and fuel 8 3642

Tee Adapter Make (Year) Model Engine Installation Location Nissan/Datsun (1979~1984) Maxima 2.4L Between fuel filter and fuel Nissan/Datsun (1984~1998) Maxima 3.0L On outlet hose at fuel filter Nissan/Datsun (1987~1990) Pulsar 1.6L Between fuel filter and fuel Nissan/Datsun (1988~1989) Pulsar 1.8L Between fuel filter and fuel Nissan/Datsun (1987~1998) Sentra 1.6L Inlet hose at electro injection unit/on outlet hose at fuel filter Nissan/Datsun (1987~1990) Sentra Hatchback 1.6L Inlet hose at electro injection unit Nissan/Datsun (1984~1989) Stanza 2.0L Between fuel filter and metal pipe Nissan/Datsun (1990~1992) Stanza 2.4L Fuel line at fuel filter Nissan/Datsun (1993~1998) Quest -minivan 3.0L Inlet hose at injector rail Nissan/Datsun (1987~1990) Van 2.4L TBI - Fuel inlet fitting on unit / MFI - fuel inlet hose at throttle chamber Nissan/Datsun (1998~1998) Frontier XE - truck 2.4L Between fuel filter and fuel Nissan/Datsun (1987~1987) Pathfinder 2.4L TBI-fuel inlet fitting on unit Nissan/Datsun (1987~1995) Pathfinder 3.0L Between fuel filter and metal pipe/fuel Nissan/Datsun (1996~1998) Pathfinder 3.3L Between fuel filter and fuel Nissan/Datsun (1986~1997) D21 Hardbody 2.4L TBI - Fuel inlet fitting on unit / MFI - fuel inlet hose at throttle chamber Nissan/Datsun (1986~1995) D21 Hardbody 3.0L Between fuel filter and metal pipe/fuel Subaru (1998~1998) Forester 2.5L Fuel delivery hose at fuel filter Subaru (1993~1997) Impreza Sedan 1.8L Hose at fuel filter Subaru (1985~1988) L-Series Sedan 1.8L Outlet hose at fuel filter Subaru (1996~1997) Legacy Outback 2.2L Fuel delivery hose at fuel filter Subaru (1996~1997) Legacy Outback 2.5L Fuel delivery hose at fuel filter Subaru (1996~1998) Legacy Sedan 2.5L Fuel delivery hose at fuel filter Subaru (1984) Wagon 1.8L Fuel hose at pressure regulator Subaru (1990~1998) Legacy Wagon 2.2L Outlet hose at fuel filter Subaru (1989~1994) Loyale Sedan 1.8L Outlet hose at fuel filter Subaru (1990~1994) Justy Wagon 1.2L Fuel inlet hose at fuel rail Subaru (1992~1997) SVX 3.3L Fuel hose at fuel filter Subaru (1985~1991) XT 1.8L Outlet hose at fuel filter Subaru (1988~1991) XT 2.7L Outlet hose at fuel filter Subaru (1984~1985) Brat 1.8L Fuel hose at pressure regulator Suzuki (1989~1998) Swift 1.3L Fuel feed hose at fuel delivery pipe 3642 9

V. FUEL SYSTEM PRESSURE TESTING FUEL SYSTEMS There are two basic types of electronic fuel injection systems used in today's automobiles: Throttle Body Injection (TBI) (see Figure 1) and Multi-port or Multipoint injection (MFI) (see Figure 2). The tests outlined in this manual are for testing fuel system pressures on these type of systems. On most vehicles, two basic tests are performed when checking fuel system pressure: "key on engine off" (engine not running) test and "key on engine on" (engine running) test. Unless otherwise noted by the vehicle s manufacturer, engine running tests are performed with the engine at idle. NOTE: In addition to the two basic tests described in this manual, some vehicles may require additional testing for proper fuel pressure diagnosis. Consult your vehicle's service manual for more details. Figure 1. Typical Throttle Body Fuel Injection (TBI) System THROTTLE BODY PRESSURE REGULATOR FUEL RETURN LINE FLEXIBLE HOSE FUEL PRESSURE LINE FUEL CAP TBI UNIT FUEL INJECTORS IN-LINE FUEL FILTER FUEL TANK IN-TANK FUEL PUMP PUMP INLET FILTER Figure 2. Typical Multi-Port Fuel Injection (MFI) System MANIFOLD VACUUM HOSE CONNECTION TEST PORT (SCHRADER VALVE) PRESSURE REGULATOR PULSE DAMPENER FUEL INJECTORS FUEL RETURN LINE FUEL PRESSURE LINE FUEL CAP FLEXIBLE HOSE IN-LINE FUEL FILTER FUEL TANK IN-TANK FUEL PUMP PULSATOR PUMP INLET FILTER 10 3642

BEFORE YOU BEGIN Fix any known mechanical problems before performing any test. WARNING: Be aware that fuel systems are UNDER PRESSURE AND HIGHLY FLAMMABLE. In addition to following all safety precautions, a basic understanding of fuel systems is necessary. Read this manual thoroughly to prevent accidents, personal injury and/or damage to your vehicle. If a further understanding of fuel injection systems is necessary, many publications covering this topic are available. Your vehicle's service manual can provide specialized test procedures and repair methods which can make your job easier. READ YOUR VEHICLE'S SERVICE MANUAL. Keep a pencil and paper handy to make notes and record test results. Read and follow all safety precautions. Make sure the battery is fully charged and the vehicle has enough fuel in the tank. Perform a thorough underhood inspection. Check for loose or cracked electrical wiring, battery cables, ignition wires, fuel and/or vacuum lines. Perform necessary repairs and ensure the fuel system is leak-free. WIPE UP ANY FUEL LEAKS IMMEDIATELY. Verify all related fuses are in good condition. Verify integrity of all electrical component connections. For Ford vehicles ONLY: Make sure the inertia switch (the fuel system's safety switch) is not tripped and is operating properly. (Refer to your vehicle's service manual for location and instructions.) Check the vapor recovery system and fuel tank cap for proper operation. Make sure the intake (engine) vacuum is within original manufacturer's specifications. If the engine does not start, refer to your vehicle's service manual for proper diagnostic procedures. TEST PROCEDURES WARNING: Fuel injection systems are under high pressure. You MUST relieve system pressure BEFORE connecting the tester. REFER TO YOUR VEHICLE'S SERVICE MANUAL FOR PROCEDURES. The adapter for testing GM vehicles equipped with test ports (Schrader Valves) is already installed on the end of the gauge hose; the Ford adapter is separate. For Chrysler vehicles, (depending on year and model) either adapter may be used (see Figure 3). Some fuel injection systems are not equipped with a test port (Schrader Valve) or are not equipped with replaceable banjo bolts. In some cases, these systems may be tested using the Tee Fitting Adapter provided with the tester. Please consult the vehicle manufacturer's service manual for more information. The Tee Fitting Adapter is suitable for use with most fuel injection systems equipped with rubber fuel hoses secured by fuel line clamps at the fuel rail or throttle body. The Tee Fitting Adapter is not suitable for use with fuel injection systems equipped with rigid, metallic or plastic fuel lines or connectors. 3642 11

Before connecting the tester, apply a small amount of light grade household oil or lubricant to the o-rings located in the test port adapters. Loosen the fuel tank cap to release any pressure from the fuel tank. When attaching the gauge hose or adapters to the test ports, make sure you use the proper adapter for your vehicle. TAKE CARE not to damage the threads on the test port. Wrap shop rags around fittings when connecting or disconnecting the tester, and have shop rags ready to clean up leaks or spills. Connecting To Systems With Existing Test Ports (Schrader Valves) WARNING: Fuel systems are under very high pressure and require precautions that are specific to the vehicle under test. To prevent serious accidents, and to perform an accurate fuel system pressure test, you MUST consult the vehicle s service manual for proper service procedures and specifications. a. Relieve fuel system pressure BEFORE connecting the tester. (Refer to your vehicle's service manual for procedures.) b. MAKE SURE the ignition is off. c. Locate the fuel system's test valve or port. Remove the protective cap. WARNING : The air conditioning test port looks similar to the fuel system test port. DO NOT CONFUSE THESE PORTS. Refer to your vehicle's service manual to ensure proper connections. d. Connect the tester to your vehicle's fuel system. For Ford and some Chrysler vehicles: Install the Ford port adapter on the throttle body or fuel rail test port, FINGER TIGHT ONLY, then connect the gauge hose to the adapter (see Figure 3). For GM and some Chrysler vehicles: connect the gauge directly to the test port, FINGER TIGHT ONLY (see Figure 3.) e. Proceed to Key On Engine Off Test on page 15. Figure 3. Testing Systems With Schrader Valve Test Ports RELIEF VALVE TESTER GAUGE BLEED-OFF HOSE GAUGE HOSE FORD ADAPTER (FOR USE WITH FORD AND SOME CHRYSLER VEHICLES) (SCHRADER VALVE) DRAIN CONTAINER 12 3642

Connecting To Systems Using Fuel System Pressure Fitting Adapter WARNING: Fuel systems are under very high pressure and require precautions and procedures that are specific to the vehicle under test. To prevent serious accidents, and to perform an accurate fuel system pressure test, you must consult the vehicle s service manual for proper service procedures and specifications. a. The "Fuel System Pressure Fittings Adapters" included in the kit are intended for use on systems that are equipped with removable "Fuel System Pressure Fittings". Four sizes of Fuel System Pressure Fitting Adapters (M12 x1.25, M12 x 1.5, M10 x 1.0 and M8 x 1.0) are provided to accommodate various vehicle makes, models and years. Consult the "Fuel System Pressure Fitting Adapter Application" list on page 3 for the proper size of adapter to use on your particular year, make and model of vehicle. b. Relieve fuel system pressure BEFORE loosening, disconnecting or removing any fuel line or fitting from the vehicle's fuel system. (Refer to your vehicle's service manual for procedures.) c. Remove the "Fuel System Pressure Fitting" from the vehicle's fuel system and install the proper size of "Fuel System Pressure Fitting Adapter" (refer to step a, above, for proper adapter size). Depending on the year, make and model of vehicle, Fuel System Pressure Fittings are located at various points on the vehicle's fuel system, (on fuel supply line at fuel distributor, at the cold start injector, at the fuel filter, etc.). Consult the vehicle's service manual for the location and proper identification of the Fuel System Pressure Fitting for your particular vehicle before removing it from the system. CAUTION: To achieve a good seal and to prevent fuel leakage at the "Fuel System Pressure Fitting Adapter", new washers (purchased separately) must be used on the adapter when performing a fuel pressure test. The original equipment washers used on this adapter are made of a special crushable pliable material designed for high-pressure sealing and are not re-usable. New original equipment washers must be installed whenever the bolt fitting is removed. Consult your dealer or local parts distributor for availability of these parts. Two sets of washers are needed; one set to perform fuel pressure testing, and a second set for use when re-installing the Fuel System Pressure Fitting after testing is completed. Figure 4. Testing Systems With Fuel System Pressure Fittings RELIEF VALVE BLEED-OFF HOSE DRAIN CONTAINER FUEL LINE FUEL FILTER TESTER GAUGE GAUGE HOSE FUEL SYSTEM PRESSURE FITTING ADAPTER FUEL LINE d. Connect the Fuel Injection Pressure Tester to the adapter, FINGER TIGHT ONLY (See Figure 4). e. Proceed to Key On Engine Off Test on page 15. 3642 13

Connecting To Systems Using the In-line Tee Adapter WARNING: Systems using the Tee adapter require that fuel lines be removed or disconnected. Be aware that these lines may be UNDER VERY HIGH PRESSURE and, when removed or disconnected, may cause fuel spray and/or leakage onto hot engine parts. Fuel system pressure testing requires procedures and precautions that are specific to the vehicle under test. To prevent serious accidents, and to perform an accurate fuel system pressure test, you must consult the vehicle s service manual for proper service procedures and specifications. The "Tee Adapter" included in the kit is intended for use on vehicles that do not come factory equipped with fuel pressure test ports (Schrader Valves) or removable Fuel System Pressure Fittings. The Tee Adapter can only be used on vehicles that are equipped with flexible (rubber) fuel supply lines that facilitate the installation of the Tee Adapter. The Tee Adapter is not suitable for use on fuel injection systems that are equipped with rigid, metallic or plastic lines or connectors. These systems require special tools and adapters to perform fuel pressure testing. Consult the vehicle's service manual for tool availability and test procedures for these vehicles. a. Refer to the "Tee Adapter Application" list on page 7 for information on your specific year, make and model of vehicle. If your vehicle is on the list: Consult your vehicle's service manual for procedures and to confirm the Tee adapter installation location. If your vehicle is not on the list: You may still be able to use the Tee Adapter. Consult your vehicle s service manual to determine if your vehicle is equipped with flexible rubber fuel supply lines that facilitate the use of the Tee Adapter. b. Relieve fuel system pressure BEFORE disconnecting the fuel lines. (Refer to your vehicle's service manual for procedures.) c. CAREFULLY disconnect the inlet fuel line (supply line) from the system connection point. INLET MAY BE UNDER PRESSURE. Try to keep hoses in an upright position to avoid excess fuel leakage. BE SURE TO CLEAN UP FUEL SPILLS IMMEDIATELY. NOTE: On Throttle Body Injection (TBI) systems, the supply line connection is typically located at the throttle body. On Multi-port/Multi-point Fuel Injection (MFI) systems, the supply line connection is typically located at the fuel rail. Consult the manufacturer's service manual for more information. d. Connect the inlet fuel line (supply line) from the vehicle to one end of the Tee Adapter. Press the hose on to the fitting as far as it will go, then secure using a hose clamp. Tighten the hose clamp securely. e. Locate the two hose pieces included with the tester (there are two different size hose pieces). Select the hose piece which fits best on the open end of the Tee Adapter and on the injection system's inlet fitting. Attach one end of the hose piece to the Tee Adapter. Press the hose on to the Adapter as far as it will go, then secure using a hose clamp. Tighten the hose clamp securely. Attach the other and of the hose piece to the injection system's inlet fitting. Press the hose on to the fitting as far as it will go, then secure using a hose clamp. Tighten the hose clamp securely. (See Figure 5.) f. Connect the gauge hose to the open fitting on top of the tee, FINGER TIGHT ONLY. Proceed to Key On Engine Off Test on page 15. 14 3642

Connecting To Systems Using the In-line Tee Adapter (Continued) Figure 5. Testing Systems Using the Tee Adapter RELIEF VALVE TESTER GAUGE GAUGE HOSE BLEED-OFF HOSE FUEL RETURN LINE HOSE CLAMP ADAPTER HOSE HOSE CLAMP TEE FITTING HOSE CLAMP INLET HOSE FUEL PRESSURE LINE DRAIN CONTAINER Key On Engine Off Test a. Place bleed-off hose into an approved drain container. MAKE SURE the hose remains in the container until testing is complete. b. Turn ignition on and listen for fuel pump activation (most systems will activate the fuel pump circuit for approximately two seconds when the ignition is initially turned on to prime the fuel system). Check the test set-up and MAKE SURE no fuel leaks are present. If fuel leaks are present, turn off ignition IMMEDIATELY and repair. BE SURE TO CLEAN UP FUEL SPILLS IMMEDIATELY. NOTE: If your fuel system does not operate as described in step b, or if the fuel system is not operating properly, refer to the manufacturer's service manual for repair procedures and/or activation instructions. c. When the fuel pump has been activated, the fuel system is pressurized. Verify the tester gauge indicates a system pressure, which corresponds with the specifications provided in your vehicle's service manual. If the fuel pressure is within vehicle manufacturer's specifications, proceed to step Key On Engine On Test below. If pressure is not within manufacturer's specifications, proceed to step d. d. Follow the test and repair procedures in your vehicle's service manual to correct the problem. After all necessary repairs have been completed, return to step a. Key On Engine On Test a. Start and idle the engine. RECHECK THE TEST SET-UP FOR FUEL LEAKS and repair as necessary. b. Read fuel pressure from the tester gauge. If the fuel pressure is within vehicle manufacturer's specifications proceed to step d. If pressure is not within manufacturer's specifications, proceed to step c. 3642 15

NOTE: On some vehicles it may be necessary to take a reading with the fuel pressure regulator vacuum hose connected and/or disconnected. Consult vehicle service manual for proper procedures. c. Follow the test and repair procedures in your vehicle's service manual to correct the problem. After all necessary repairs have been completed, return to step Key On Engine Off Test on page 15. d. Turn OFF engine and MAKE SURE that the bleed-off hose is still routed to the drain container. Press and hold the relief valve to bleed off system pressure. Hold the relief valve until the tester gauge indicates no pressure (see Figure 6). e. Shake the bleed-off hose to ensure all residual fuel has been expelled. f. Wrap a shop rag around the test port area to avoid fuel spray and to absorb excess fuel. CAREFULLY disconnect the gauge hose from the port adapter. g. If used, remove the fuel system pressure fitting adapter and replace with the original fuel system pressure fitting. BE SURE TO INSTALL A NEW O-RING to avoid leakage. h. If installed, remove the Ford adapter from the vehicle's test port and replace any test port cover that was removed. i. If the Tee Adapter was used, loosen hose clamps and remove the Tee Adapter and any additional hose pieces which were installed to perform testing. Reconnect the fuel inlet line (supply line) to its original connection point. MAKE SURE all hose clamps are reinstalled and tightened properly (refer to your vehicle's service manual for proper connections, as necessary). j. Remove the bleed-off hose from the drain container and hold both gauge hoses over the container to let any remaining fuel drain. Store the tester in a well-ventilated area to dry completely. k. Recheck all fuel system connections, then start the engine. Check for any leaks and repair as necessary. NOTES: Figure 6. Relief Valve RELIEF VALVE The engine may crank for several seconds before restarting. Shop rags that have been exposed to any flammable liquids or materials (gasoline, etc.) should be stored in an approved container to avoid hazardous conditions. The service life of the port adapter o-rings can be prolonged by applying a film of oil to them before storing. 16 3642

VI. REPLACEMENT PARTS Fuel Injection Pressure Tester Kit Components (see Figure 7) Figure 7. Fuel Injection Pressure Tester Kit Components 6 1 10 9 11 12 8 2 7 5 13 14 3 1. Tester Gauge - Shows fuel pressure in the system during test. 2. Relief Valve - Relieves pressure in the fuel system during and after testing. 3. Bleed-off Hose - Drains bleed-off fuel into a suitable container. 4. Gauge Hose - High pressure hose with threaded female connector; connects to the vehicle's fuel system test port. 5. Tee Fitting Adapter - Universal fitting with built-in Test Port. Allows the tester to be used on some vehicles not factory equipped with a factory test port (Schrader Valve). 6. Ford Adapter - Installs on the fuel system Test Port of some Ford and Chrysler vehicles to allow connection of the tester. 7. Hose - 5/16 in. (8 mm) universal high-pressure hose used in conjunction with Tee Adapter (5). 8. Hose - 3/8 (9.5mm) universal high-pressure hose used in conjunction with Tee Adapter (5). 9. Hose Clamps - High pressure fuel line clamps used in conjunction with hoses (7, 8) 10. Hose Clamps - High pressure fuel line clamps used in conjunction with hoses (7, 8) 11. M12 x 1.5 Fuel System Pressure Fitting Adapter - replaces original fitting to test system pressure 12. Fuel System Pressure Fitting Adapter - replaces original fitting to test system pressure 13. M10 x 1.0 Fuel System Pressure Fitting Adapter - replaces original fitting to test system pressure 14. M8 x 1.0 Fuel System Pressure Fitting Adapter - replaces original fitting to test system pressure 3642 17

For ordering information and updates, visit us on the web at www.iequus.com. Refer to "SERVICE PROCEDURES AND WARRANTY" below for more information. VII. LIMITED WARRANTY AND SERVICE PROCEDURES The Manufacturer warrants to the original purchaser that this unit is free of defects in materials and workmanship under normal use and maintenance for a period of one (1) year from the date of original purchase. If the unit fails within the one (1) year period, it will be repaired or replaced, at the Manufacturer's option, at no charge, when returned prepaid to the Technical Service Center with Proof of Purchase. The sales receipt may be used for this purpose. Installation labor is not covered under this warranty. All replacement parts, whether new or re-manufactured, assume as their warranty period for only the remaining time of this warranty. This warranty does not apply to damage caused by improper use, accident, abuse, improper voltage, service, fire, flood, lightning, or other acts of God, or if the product was altered or repaired by anyone other than the Manufacturer's Technical Service Center. Consequential and incidental damages are not recoverable under this warranty. Some states do not allow the exclusion or limitation of incidental or consequential damages, so the above limitation or exclusion may not apply to you. This warranty gives you specific legal rights, and you may also have other rights, which vary from state to state. No portion of this warranty may be copied or duplicated without the expressed written permission from the Manufacturer. Obtaining Warranty Service: Products requiring service should be returned as follows: 1. Call the Technical Service Center to obtain a Return Reference Number: USA & Canada = 1-800-544-4124 Other = 714-241-6805 2. Package the product carefully to prevent shipping damage 3. Include your name, return address, and a day contact phone 4. Enclose a copy of the dated sales receipt 5. Describe the problem 6. Ship prepaid to : Technical Service Center 17291 Mt. Herrmann Street Fountain Valley, CA 92708 U.S.A. Phone: 1-800-544-4124 or 714-241-6805 Fax: 714-432-7910 Web: www.iequus.com Email: service@iequus.com 18 3642

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3642 NOTES

(BACK COVER) FUEL INJECTION PRESSURE TESTER KIT #3642 3642