FUEL INJECTION PRESSURE TESTER KIT - … · This Fuel Injection Pressure Tester Kit is designed to perform fuel ... .Block the drive wheels with a ... • Models with electronic fuel

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(FRONT COVER)

FUEL INJECTION PRESSURETESTER KIT

#3642

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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 PressureFitting 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

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I. INTRODUCTION

Congratulations. You have purchased a precision instrument manufactured tothe highest quality standards.

This Fuel Injection Pressure Tester Kit is designed to perform fuel pressure testson most domestic and imported cars and trucks that are equipped with electron-ic fuel injection systems. The tester saves you money by helping you test andtroubleshoot fuel system problems that can affect your vehicle's performance andfuel 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 equip-ment 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 per-sonnel and technicians. Many test procedures require precautions to avoid acci-dents that can result in personal injury, and/or vehicle or equipment damage.ALWAYS read your vehicle's service manual and follow it’s safety pre-cautions before any test or procedure is performed.

a. When an engine is in operation, it produces carbon monoxide (a toxic andpoisonous gas). To prevent serious injury or death from carbon monoxide poi-soning, 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 highrate 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 theseitems as well as other potentially moving objects.

d. Engine parts become extremely hot when the engine is running. To preventsevere burns, avoid contact with hot engine parts.

e. Before starting an engine for troubleshooting, make sure the parking brakeis engaged. Put the transmission in “park” (for automatic transmission) or“neutral” (for manual transmission). Block the drive wheels with a suitableblocking device.

f. NEVER leave a vehicle unattended during testing.

g. When working on vehicles equipped with airbags, follow all cautions and testprocedures in your vehicle's service manual to avoid accidental airbagdeployment.

h. Don't wear loose clothing or jewelry when working on an engine. Loose cloth-ing can get caught on the fan, pulleys, belts, etc. Jewelry is highly conductiveto electricity, and can cause a severe burn if it makes contact between apower source and ground.

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The following safety precautions apply to fuel and fuel systems. Gasoline is anextremely flammable substance. To prevent fires and/or severe burns, alwaystake extra precautions when troubleshooting or working on fuel systems.

i. Gasoline and battery vapors are highly flammable. To prevent an explosionor fire, keep all sparks, high temperature items or open flames away fromgasoline/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 (approvedlatex gloves) when performing pressure tests. In case of contact with skin,WASH THE AREA IMMEDIATELY and perform any other necessary firstaid.

k. In case of emergency, keep a fire extinguisher handy. MAKE SURE it israted for fuel/electrical and chemical fires.

l. During testing, be careful to avoid fuel spills on hot engine parts. If spillsoccur or if leaks are present, turn ignition off IMMEDIATELY and correctthe problem. WIPE UP FUEL SPELLS IMMEDIATELY.

m. When placing the bleed-off hose into a container to collect excess fuel, MAKESURE the container is approved for gasoline.

III. VEHICLE SERVICE MANUALS

You must consult the manufacturer's service manual for your vehicle BEFOREperforming any test procedures.

Contact your local car dealership, auto parts store, bookstore, or public library foravailability of these manuals. The following companies publish valuable repairmanuals, including material that covers fuel injection systems and testing tech-niques.

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 SubaruService Manuals; Helm Inc., 14310 Hamilton Avenue, Highland Park, Michigan48203, Phone (800) 782-4356

IV. VEHICLES COVERED

This Fuel Injection Pressure Tester Kit is designed for use on vehicles equippedwith 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 appli-cations:

1. All fuel injection systems that are factory equipped with suitable fuel pres-sure Test Ports (Schrader Valves). See "Connecting To Systems With ExistingTest Ports (Schrader Valves)", page 12 for further instructions.

2. Fuel injection systems that are equipped with a removable "Fuel SystemPressure Fitting" that facilitates the use of the "Fuel System PressureFitting Adapter". See "Connecting to Systems Using Fuel System PressureFitting Adapter", page 13 for further instructions.

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3. Fuel injection systems that are not factory equipped with Fuel Pressure TestPorts or removable Fuel System Pressure Fittings but are equipped with"flexible rubber fuel supply lines" that can facilitate the use of the "TeeAdapter". See "Connecting To Systems Using the In-line Tee Adapter", page14 for further instructions.

The following vehicle coverage tables and lists are to be used only as ageneral guide. They are in no way intended as a substitute for vehiclemanufacturer's instructions and procedures. Damage to the vehiclebeing tested, the test equipment or personal injury can result fromimproper testing procedures. Always consult the vehicle's service man-ual for proper fitting size, application, installation and test procedures.

Fuel Pressure Test Por t (Schrader Valve) Application

NOTE: Some models of vehicles listed on the "Fuel Pressure Test Port (SchraderValve) Application" list above do not come equipped with fuel pressure test ports(Schrader Valves). These vehicles may require additional tools and/or adapters toproperly test fuel system pressure. If your vehicle is on this list but is not factoryequipped with a fuel pressure test port, refer to your vehicle's service manual orconsult your auto parts dealer for the availability of these items and/or for fuelsystem testing procedures. See "Connecting To Systems Using the In-line TeeAdapter",page 16 for further instructions.

Fuel System Pressure Fitting Adapter Application

Domestic Vehicles (1980-01) Non-diesel - Includeslight 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 sys-tems (Multi-port, Sequential, Multi-point,Direct and Throttle Body) which are facto-ry-equipped with a Fuel Pressure Test Port(Schrader Valve).

• If your vehicle is made by one of the man-ufacturers on this list but does not comeequipped with a Test Port, see note below.

Primar y OptionalMake (Year) Model Engine Fitting Fitting

Acura (1986~1989) Integra 1.6L M12 x 1.25 none

Acura (1993) Integra 1.7L M12 x 1.25 none

Acura (1990~1998) Integra, All Models 1.8L M12 x 1.25 none

Acura (1986~1987) Legend, All Models 2.5L M12 x 1.25 none



Acura (1991~1998) NSX 3L M12 x 1.25 none

Acura (1997~1998) NSX, NSX-T 3.2L M12 x 1.25 none

Acura (1992~1994) Vigor 2.5L M12 x 1.25 none

Acura (1995~1998) TL 2.5L M12 x 1.25 none

Acura (1996~1998) TL 3.2L M12 x 1.25 none

Acura (1996~1998) RL 3.5L M12 x 1.25 none

Acura (1997) CL 2.2L M12 x 1.25 none

Acura (1998) CL 2.3L M12 x 1.25 none

Acura (1997~1998) CL 3L M12 x 1.25 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

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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 noneCoupe

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 M12 x 1.25 none

Dodge (1992~1993) Colt Vista 2WD 1.8L M12 x 1.25 none

Dodge (1992~1993) Colt Vista 2WD 2.4L M12 x 1.25 none

Dodge (1987~1991) Colt Vista 4WD 2L M12 x 1.25 none

Dodge (1992~1993) Colt Vista AWD 1.8L M12 x 1.25 none

Dodge (1992~1993) Colt Vista AWD 2.4L M12 x 1.25 none

Dodge (1988~1994) Colt 1.5L M12 x 1.25 none

Dodge (1988~1989) Colt Turbo 1.6L M12 x 1.25 none



Ford (1993~1995) Probe 2.5L M12 x 1.25 none

Geo (1993~1995) Prizm 1.6L M12 x 1.25 M10x1.0,M8x1.0

Geo (1993~1997) Prizm 1.8L M12 x 1.25 none

Honda (1985) Accord 1.8L M12 x 1.25 none

Honda (1986~1989) Accord 2L M12 x 1.25 none

Honda (1995~1997) Accord 2.7L M12 x 1.25 none

Honda (1995~1997) Accord 3L M12 x 1.25 none

Honda (1987) Civic Hatchback Si 1.5L M12 x 1.25 none

Honda (1988~1996) Civic, All Models 1.5L M12 x 1.25 none

Honda (1988~1998) Civic, All Models 1.6L M12 x 1.25 none

Honda (1986~1992) CRX 1.5L M12 x 1.25 none

Honda (1988~1992) CRX Si 1.6L M12 x 1.25 none

Honda (1985~1991) Prelude 2L M12 x 1.25 none

Honda (1993~1995) Del Sol 1.5L M12 x 1.25 none

Honda (1993~1997) Del Sol 1.6L M12 x 1.25 none

Lexus (1990~1991) ES250 2.5L M8 X 1.0 M12 x 1.25

Lexus (1992~1998) ES300 3L M8 X 1.0 M12 x 1.25

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Lexus (1990~1998) LS400 4L M12 x 1.25 none

Lexus (1992~1998) SC300 3L M8 X 1.0 M12 x 1.25

Lexus (1992~1998) SC400 4L M12 x 1.25 none

Lexus (1992~1998) GS300 3L M8 X 1.0 M10 x 1.0,M12 x 1.25

Lexus (1998) GS400 4L M12 x 1.25 none

Mitsubishi (1984~1987) Cordia, Turbo 1.8L M12 x 1.25 none

Mitsubishi (1984~1989) Starion 2.6L M12 x 1.25 none

Mitsubishi (1984~1988) Tredia, Turbo 1.8L M12 x 1.25 none

Mitsubishi (1985~1992) Mirage, Turbo 1.6L M12 x 1.25 none

Mitsubishi (1988~1998) Mirage, All Models 1.5L M12 x 1.25 none

Mitsubishi (1993~1998) Mirage, All Models 1.8L M12 x 1.25 none

Mitsubishi (1985~1998) Galant 2.4L M12 x 1.25 none

Mitsubishi (1988) Galant 3L M12 x 1.25 none

Mitsubishi (1989~1993) Galant, All Models 2L M12 x 1.25 none

Mitsubishi (1990~1994) Precis 1.5L M12 x 1.25 none

Mitsubishi (1989~1990) Sigma 3L M12 x 1.25 none

Mitsubishi (1990~1994) Eclipse 1.8L M12 x 1.25 none

Mitsubishi (1990~1998) Eclipse, All Models 2L M12 x 1.25 none

Mitsubishi (1996~1998) Eclipse, All Models 2.4L M12 x 1.25 none

Mitsubishi (1991~1998) 3000GT, All Models 3L M12 x 1.25 none

Mitsubishi (1992~1995) Expo, All Models 2.4L M12 x 1.25 none

Mitsubishi (1992~1995) Expo, All Models 1.8L M12 x 1.25 none

Mitsubishi (1992~1996) Diamante, All 3L M12 x 1.25 noneModels

Mitsubishi (1997~1998) Diamante, All 3.5L M12 x 1.25 noneModels

Mitsubishi (1990~1996) Montero, All 3L M12 x 1.25 noneModels

Mitsubishi (1990~1996 Pickup, 2WD 2.4L M12 x 1.25 none

Mitsubishi (1990~1995) Pickup, 4WD 3L M12 x 1.25 none

Mitsubishi (1987~1990) Van Wagon 2.4L M12 x 1.25 none

Plymouth (1990~1994) Laser, All Models 1.8L M12 x 1.25 none

Plymouth (1990~1994) Laser, All Models 2L M12 x 1.25 none

Toyota (1982~1986) Celica Supra 2.8L M8 x 1.0 M10 x 1.0,M12 x 1.25

Toyota (1986) Celica Supra 3L M8 x 1.0 M10 x 1.0,M12 x 1.25

Toyota (1983~1985) Celica, 22R-E 2.4L M8 x 1.0 M10 x 1.0,M12 x 1.25

Toyota (1986~1993) Celica, All Models 2L M8 x 1.0 M10 x 1.0,M12 x 1.25

Toyota (1990~1998) Celica, All Models 2.2L M12 x 1.25 M10 x 1.0,M8 x 1.0



Toyota (1987~1998) Supra, All Models 3L M12 x 1.25 M10 x 1.0,M8 x 1.0

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Toyota (1982~1988) Cressida 2.8L M8 x 1.0 M10 x 1.0,M12 x 1.25

Toyota (1989~1992) Cressida 3L M8 x 1.0 M10 x 1.0,M12 x 1.25

Toyota (1983~1991) Camry, All Models 2L M8 x 1.0 M10 x 1.0,M12 x 1.25

Toyota (1988~1991) Camry, All Models 2.5L M8 x 1.0 M10 x 1.0,M12 x 1.25

Toyota (1992~1998) Camry, All Models 2.2L M12 x 1.25 none

Toyota (1992~1997) Camry, All Models 3L M12 x 1.25 none

Toyota (1986~1989) Corolla, 4A-GE 1.6L M8 x 1.0 M10 x 1.0,M12 x 1.25

Toyota (1989) Corolla, 4A-FE 1.6L M8 x 1.0 M10 x 1.0,M12 x 1.25

Toyota (1990~1997) Corolla, All Models 1.6L M12 x 1.25 M10x1.0,M8x1.0

Toyota (1993~199)7 Corolla, All Models 1.8L M12 x 1.25 none

Toyota (1990) Tercel Hatchback 1.5L M8 x 1.0 M10 x 1.0,M12 x 1.25

Toyota (1991~1998) Tercel, All Models 1.5L M12 x 1.25 M10x1.0,M8x1.0

Toyota (1986~1989) MR2 1.6L M8 x 1.0 M10 x 1.0,M12 x 1.25

Toyota (1991~1995) MR2 2L M8 x 1.0 M10x1.0,M8x1.0

Toyota (1991~1995) MR2 2.2L M12 x 1.25 M10x1.0,M8x1.0

Toyota (1993~1998) Paseo 1.5L M12 x 1.25 none

Toyota (1995~1997) Avalon 3L M12 x 1.25 none

Toyota (1984~1995) 4Runner, 22R-E 2.4L M8 x 1.0 M10 x 1.0,M12 x 1.25

Toyota (1988~1995) 4Runner 3L M8 x 1.0 M10 x 1.0,M12 x 1.25

Toyota (1996~1998) 4Runner 2.7L M12 x 1.25 none

Toyota (1996~1998) 4Runner 3.4L M12 x 1.25 none

Toyota (1984~1995) Pickup, 22R-E 2.4L M8 x 1.0 M10 x 1.0,M12 x 1.25

Toyota (1988~1995) Pickup 3L M8 x 1.0 M10 x 1.0,M12 x 1.25

Toyota (1994~1998) T100 2.7L M12 x 1.25 none

Toyota (1995~1998) T100 3.4L M12 x 1.25 none

Toyota (1993~1994) T100 3L M12 x 1.25 none

Toyota (1988~1992) Landcruiser 4L M8 x 1.0 M10 x 1.0,M12 x 1.25

Toyota (1993~1998) Landcruiser 4.5L M12 x 1.25 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

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Tee Adapter Application


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 AdapterMake (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 pres-sure regulator

BMW (1987~1995) 325i 2.5L Fuel feed line in front of pres-sure 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 pres-sure 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 tube

Infiniti (1993~1997) J30 3.0L Between fuel filter and fuel tube

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Infiniti (1990~1998) Q45 4.1L Between fuel filter and fuel tube

Isuzu (1989~1994) Amigo 2.6L At fuel pressure regulator

Isuzu (1985~1989) Impulse 1.9L Between fuel pressure regula-tor 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 fuelfilter




Mazda (1988~1995) 929 3.OL Hose on outlet side of fuelfilter

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 tube






Nissan/Datsun (1975~1983) 280ZX 2.8L Between fuel filter and fuel tube

Nissan/Datsun (1984~1996) 300ZX 3.0L Between fuel filter and fuel tube

Nissan/Datsun (1993~1998) Altima 2.4L Between fuel filter and fuel tube

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Nissan/Datsun (1979~1984) Maxima 2.4L Between fuel filter and fuel tube

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 tube

Nissan/Datsun (1988~1989) Pulsar 1.8L Between fuel filter and fuel tube

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 throt-tle chamber

Nissan/Datsun (1998~1998) Frontier XE - truck 2.4L Between fuel filter and fuel tube

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 tube

Nissan/Datsun (1996~1998) Pathfinder 3.3L Between fuel filter and fuel tube

Nissan/Datsun (1986~1997) D21 Hardbody 2.4L TBI - Fuel inlet fitting on unit /MFI - fuel inlet hose at throt-tle chamber

Nissan/Datsun (1986~1995) D21 Hardbody 3.0L Between fuel filter and metal pipe/fuel tube

Subaru (1998~1998) Forester 2.5L Fuel delivery hose at fuel fil-ter

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 fil-ter

Subaru (1996~1997) Legacy Outback 2.5L Fuel delivery hose at fuel fil-ter

Subaru (1996~1998) Legacy Sedan 2.5L Fuel delivery hose at fuel fil-ter

Subaru (1984) Wagon 1.8L Fuel hose at pressure regula-tor

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 regula-tor

Suzuki (1989~1998) Swift 1.3L Fuel feed hose at fuel deliverypipe

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V. FUEL SYSTEM PRESSURE TESTING

FUEL SYSTEMS

There are two basic types of electronic fuel injection systems used in today's auto-mobiles: Throttle Body Injection (TBI) (see Figure 1) and Multi-port or Multi-point injection (MFI) (see Figure 2). The tests outlined in this manual are fortesting fuel system pressures on these type of systems. On most vehicles, twobasic tests are performed when checking fuel system pressure: "key on engine off"(engine not running) test and "key on engine on" (engine running) test. Unlessotherwise noted by the vehicle’s manufacturer, engine running tests are per-formed with the engine at idle.

NOTE: In addition to the two basic tests described in this manual, some vehiclesmay require additional testing for proper fuel pressure diagnosis. Consult yourvehicle's service manual for more details.

TBI UNITFUEL INJECTORS

THROTTLE BODYPRESSURE REGULATOR

FUEL CAP

FUEL RETURN LINE

IN-LINEFUEL FILTER

FUEL PRESSURE LINEFLEXIBLE HOSE

FUEL TANK IN-TANKFUEL PUMP

PUMP INLETFILTER

Figure 1. Typical Throttle Body Fuel Injection (TBI) System

FUEL INJECTORS

PRESSUREREGULATOR

MANIFOLD VACUUMHOSE CONNECTION

TEST PORT(SCHRADER

VALVE)

PULSEDAMPENER

FLEXIBLEHOSE

IN-LINEFUEL FILTER

FUEL RETURN LINE

FUEL PRESSURE LINEFUELCAP

FUEL TANK PUMP INLETFILTER

IN-TANKFUEL PUMP

PULSATOR

Figure 2. Typical Multi-Port Fuel Injection (MFI) System

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BEFORE YOU BEGIN

• Fix any known mechanical problems before performing any test.

WARNING: Be aware that fuel systems are UNDER PRESSURE ANDHIGHLY FLAMMABLE. In addition to following all safety precau-tions, a basic understanding of fuel systems is necessary. Read thismanual thoroughly to prevent accidents, personal injury and/ordamage to your vehicle.

• If a further understanding of fuel injection systems is necessary, many pub-lications covering this topic are available.

• Your vehicle's service manual can provide specialized test procedures andrepair methods which can make your job easier. READ YOUR VEHICLE'SSERVICE 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 thetank.

• Perform a thorough underhood inspection. Check for loose or cracked elec-trical wiring, battery cables, ignition wires, fuel and/or vacuum lines.Perform necessary repairs and ensure the fuel system is leak-free. WIPE UPANY FUEL LEAKS IMMEDIATELY.

• Verify all related fuses are in good condition. Verify integrity of all electricalcomponent connections.

• For Ford vehicles ONLY: Make sure the inertia switch (the fuel system's safe-ty switch) is not tripped and is operating properly. (Refer to your vehicle'sservice 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'sspecifications.

• If the engine does not start, refer to your vehicle's service manual for properdiagnostic procedures.

TEST PROCEDURES

WARNING: Fuel injection systems are under high pressure. You MUSTrelieve system pressure BEFORE connecting the tester. REFER TO YOURVEHICLE'S SERVICE MANUAL FOR PROCEDURES.

• The adapter for testing GM vehicles equipped with test ports (SchraderValves) is already installed on the end of the gauge hose; the Ford adapter isseparate. For Chrysler vehicles, (depending on year and model) eitheradapter 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 systemsmay be tested using the Tee Fitting Adapter provided with the tester. Pleaseconsult the vehicle manufacturer's service manual for more information.

• The Tee Fitting Adapter is suitable for use with most fuel injection systemsequipped with rubber fuel hoses secured by fuel line clamps at the fuel railor throttle body.

• The Tee Fitting Adapter is not suitable for use with fuel injection systemsequipped with rigid, metallic or plastic fuel lines or connectors.

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• Before connecting the tester, apply a small amount of light grade householdoil 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 youuse the proper adapter for your vehicle. TAKE CARE not to damage thethreads 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 Por ts (Sc hrader Valves)

WARNING: Fuel systems are under very high pressure and require pre-cautions that are specific to the vehicle under test. To prevent seriousaccidents, and to perform an accurate fuel system pressure test, youMUST consult the vehicle’s service manual for proper service proceduresand specifications.

a. Relieve fuel system pressure BEFORE connecting the tester. (Refer to yourvehicle'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 sys-tem test port. DO NOT CONFUSE THESE PORTS. Refer to your vehi-cle'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 adapteron the throttle body or fuel rail test port, FINGER TIGHT ONLY, thenconnect the gauge hose to the adapter (see Figure 3).

■ For GM and some Chrysler vehicles: connect the gauge directly tothe test port, FINGER TIGHT ONLY (see Figure 3.)

e. Proceed to “Key On Engine Off Test” on page 15.

DRAINCONTAINER

TESTER GAUGE

GAUGE HOSE

FORD ADAPTER (FOR USE WITH FORDAND SOME CHRYSLER VEHICLES)

(SCHRADERVALVE)

BLEED-OFFHOSE

RELIEFVALVE

Figure 3. Testing Systems With Schrader Valve Test Ports

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Connecting To Systems Using Fuel System Pressure Fitting Adapter

WARNING: Fuel systems are under very high pressure and require pre-cautions and procedures that are specific to the vehicle under test. Toprevent serious accidents, and to perform an accurate fuel system pres-sure test, you must consult the vehicle’s service manual for proper serviceprocedures and specifications.

a. The "Fuel System Pressure Fittings Adapters" included in the kit are intendedfor use on systems that are equipped with removable "Fuel System PressureFittings". 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 variousvehicle makes, models and years. Consult the "Fuel System Pressure FittingAdapter Application" list on page 3 for the proper size of adapter to use onyour particular year, make and model of vehicle.

b. Relieve fuel system pressure BEFORE loosening, disconnecting or removingany fuel line or fitting from the vehicle's fuel system. (Refer to your vehicle'sservice manual for procedures.)

c. Remove the "Fuel System Pressure Fitting" from the vehicle's fuel systemand install the proper size of "Fuel System Pressure Fitting Adapter" (referto step a, above, for proper adapter size). Depending on the year, make andmodel of vehicle, Fuel System Pressure Fittings are located at various pointson the vehicle's fuel system, (on fuel supply line at fuel distributor, at the coldstart injector, at the fuel filter, etc.). Consult the vehicle's service manual forthe location and proper identification of the Fuel System Pressure Fitting foryour particular vehicle before removing it from the system.

CAUTION: To achieve a goodseal and to prevent fuel leakageat the "Fuel System PressureFitting Adapter", new washers(purchased separately) mustbe used on the adapter whenperforming a fuel pressure test.The original equipment wash-ers used on this adapter aremade of a special crushable pli-able material designed forhigh-pressure sealing and arenot re-usable. New originalequipment washers must beinstalled whenever the bolt fit-ting is removed. Consult yourdealer or local parts distributorfor availability of these parts.Two sets of washers are needed;one set to perform fuel pressuretesting, and a second set for usewhen re-installing the FuelSystem Pressure Fitting aftertesting is completed.

d. Connect the Fuel Injection Pressure Tester to the adapter, FINGER TIGHTONLY (See Figure 4).

e. Proceed to “Key On Engine Off Test” on page 15.

DRAINCONTAINER FUEL FILTER

TESTER GAUGE

GAUGE HOSE

FUEL SYSTEMPRESSURE FITTING

ADAPTER

FUEL LINE

FUEL LINE

BLEED-OFFHOSE

RELIEFVALVE

Figure 4. Testing Systems With Fuel System PressureFittings

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Connecting To Systems Using the In-line Tee Adapter

WARNING: Systems using the Tee adapter require that fuel lines beremoved or disconnected. Be aware that these lines may be UNDER VERYHIGH PRESSURE and, when removed or disconnected, may cause fuelspray and/or leakage onto hot engine parts. Fuel system pressure testingrequires procedures and precautions that are specific to the vehicleunder test. To prevent serious accidents, and to perform an accurate fuelsystem pressure test, you must consult the vehicle’s service manual forproper service procedures and specifications.

• The "Tee Adapter" included in the kit is intended for use on vehicles that donot come factory equipped with fuel pressure test ports (Schrader Valves) orremovable Fuel System Pressure Fittings. The Tee Adapter can only be usedon vehicles that are equipped with flexible (rubber) fuel supply lines thatfacilitate the installation of the Tee Adapter.

The Tee Adapter is not suitable for use on fuel injection systems that areequipped with rigid, metallic or plastic lines or connectors. These systemsrequire special tools and adapters to perform fuel pressure testing. Consultthe vehicle's service manual for tool availability and test procedures forthese vehicles.

a. Refer to the "Tee Adapter Application" list on page 7 for information on yourspecific year, make and model of vehicle.

■ If your vehicle is on the list: Consult your vehicle's service manualfor 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 TeeAdapter. Consult your vehicle’s service manual to determine if yourvehicle is equipped with flexible rubber fuel supply lines that facilitatethe use of the Tee Adapter.

b. Relieve fuel system pressure BEFORE disconnecting the fuel lines. (Referto your vehicle's service manual for procedures.)

c. CAREFULLY disconnect the inlet fuel line (supply line) from the systemconnection point. INLET MAY BE UNDER PRESSURE. Try to keep hosesin an upright position to avoid excess fuel leakage. BE SURE TO CLEANUP FUEL SPILLS IMMEDIATELY.

NOTE: On Throttle Body Injection (TBI) systems, the supply line connectionis typically located at the throttle body. On Multi-port/Multi-point FuelInjection (MFI) systems, the supply line connection is typically located at thefuel 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 TeeAdapter. Press the hose on to the fitting as far as it will go, then secure usinga hose clamp. Tighten the hose clamp securely.

e. Locate the two hose pieces included with the tester (there are two differentsize hose pieces). Select the hose piece which fits best on the open end of theTee Adapter and on the injection system's inlet fitting. Attach one end of thehose piece to the Tee Adapter. Press the hose on to the Adapter as far as itwill 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 hoseclamp. Tighten the hose clamp securely. (See Figure 5.)

f. Connect the gauge hose to the open fitting on top of the tee, FINGER TIGHTONLY. Proceed to “Key On Engine Off Test” on page 15.

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Connecting To Systems Using the In-line Tee Adapter (Contin ued)

Key On Engine Off Test

a. Place bleed-off hose into an approved drain container. MAKE SURE the hoseremains in the container until testing is complete.

b. Turn ignition on and listen for fuel pump activation (most systems will acti-vate the fuel pump circuit for approximately two seconds when the ignitionis initially turned on to prime the fuel system). Check the test set-up andMAKE 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 fuelsystem is not operating properly, refer to the manufacturer's service manualfor 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 withthe specifications provided in your vehicle's service manual. If the fuel pres-sure is within vehicle manufacturer's specifications, proceed to step “Key OnEngine On Test” below. If pressure is not within manufacturer's specifica-tions, proceed to step d.

d. Follow the test and repair procedures in your vehicle's service manual to cor-rect the problem. After all necessary repairs have been completed, return tostep a.

Key On Engine On Test

a. Start and idle the engine. RECHECK THE TEST SET-UP FOR FUELLEAKS and repair as necessary.

b. Read fuel pressure from the tester gauge. If the fuel pressure is within vehi-cle manufacturer's specifications proceed to step d. If pressure is not withinmanufacturer's specifications, proceed to step c.

HOSECLAMP

RELIEFVALVE

TESTER GAUGE

GAUGE HOSE

BLEED-OFF HOSE

DRAINCONTAINER

FUELRETURNLINE

FUELPRESSURELINE

HOSECLAMP

HOSECLAMP

TEEFITTING

ADAPTER HOSE INLETHOSE

Figure 5. Testing Systems Using the Tee Adapter

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NOTE: On some vehicles it may be neces-sary to take a reading with the fuel pressureregulator vacuum hose connected and/ordisconnected. Consult vehicle service manu-al for proper procedures.

c. Follow the test and repair procedures inyour vehicle's service manual to correct theproblem. After all necessary repairs havebeen completed, return to step “Key OnEngine Off Test” on page 15.

d. Turn “OFF” engine and MAKE SURE thatthe bleed-off hose is still routed to the draincontainer. Press and hold the relief valve tobleed off system pressure. Hold the reliefvalve until the tester gauge indicates nopressure (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 absorbexcess fuel. CAREFULLY disconnect the gauge hose from the port adapter.

g. If used, remove the fuel system pressure fitting adapter and replace with theoriginal 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 replaceany test port cover that was removed.

i. If the Tee Adapter was used, loosen hose clamps and remove the Tee Adapterand 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 (referto your vehicle's service manual for proper connections, as necessary).

j. Remove the bleed-off hose from the drain container and hold both gaugehoses over the container to let any remaining fuel drain. Store the tester ina well-ventilated area to dry completely.

k. Recheck all fuel system connections, then start the engine. Check for anyleaks and repair as necessary.

NOTES:

• 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 haz-ardous conditions.

• The service life of the port adapter o-rings can be prolonged by applyinga film of oil to them before storing.

RELIEFVALVE

Figure 6. Relief Valve

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VI. REPLACEMENT PARTS

Fuel Injection Pressure Tester Kit Components (see Figure 7)

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; connectsto the vehicle's fuel system test port.

5. Tee Fitting Adapter - Universal fitting with built-in Test Port. Allows thetester to be used on some vehicles not factory equipped with a factory testport (Schrader Valve).

6. Ford Adapter - Installs on the fuel system Test Port of some Ford andChrysler vehicles to allow connection of the tester.

7. Hose - 5/16 in. (8 mm) universal high-pressure hose used in conjunction withTee Adapter (5).

8. Hose - 3/8 (9.5mm) universal high-pressure hose used in conjunction withTee 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 totest system pressure

12. M12 x 1.25 Fuel System Pressure Fitting Adapter - replaces original fittingto test system pressure



1

10

8

5

13 14

11 12

3

2

6

9

7

Figure 7. Fuel Injection Pressure Tester Kit Components

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For ordering information and updates, visit us on the web at www.iequus.com.Refer to "SERVICE PROCEDURES AND WARRANTY" below for more informa-tion.

VII. LIMITED WARRANTY AND SERVICE PROCEDURES

The Manufacturer warrants to the original purchaser that this unit is free ofdefects in materials and workmanship under normal use and maintenance for aperiod of one (1) year from the date of original purchase. If the unit fails withinthe one (1) year period, it will be repaired or replaced, at the Manufacturer'soption, at no charge, when returned prepaid to the Technical Service Center withProof of Purchase. The sales receipt may be used for this purpose. Installationlabor is not covered under this warranty.

All replacement parts, whether new or re-manufactured, assume as their war-ranty period for only the remaining time of this warranty. This warranty does notapply to damage caused by improper use, accident, abuse, improper voltage, serv-ice, fire, flood, lightning, or other acts of God, or if the product was altered orrepaired 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 consequen-tial 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 orduplicated without the expressed written permission from the Manufacturer.

Obtaining Warranty Ser vice:

Products requiring service should be returned as follows:

1. Call the Technical Service Center to obtain a Return Reference Number:

USA & Canada = 1-800-544-4124Other = 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 Center17291 Mt. Herrmann StreetFountain Valley, CA 92708U.S.A.

Phone: 1-800-544-4124 or 714-241-6805Fax: 714-432-7910Web: www.iEQUUS.comEmail: [email protected]

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FUEL INJECTION PRESSURETESTER KIT

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