#3640 FUEL INJECTION PRESSURE TESTER KIT Fuel © IEC 1997
Table of Contents Paragraph Title Page No. GENERAL INFORMATION 1.1 1.2 1.3 1.4 1.5 ABOUT THE TESTER ..................................................................... VEHICLES COVERED .................................................................... BEFORE YOU BEGIN ..................................................................... SAFETY PRECAUTIONS ................................................................ VEHICLE SERVICE MANUALS ....................................................
1 General Information 1.1 ABOUT THE TESTER The Fuel Injection Pressure Tester Kit is designed to perform fuel pressure tests on most domestic and import cars and trucks. The tester saves you time and money by helping you test and troubleshoot fuel system problems which can affect your vehicle's performance and fuel economy.
1 6. Ford Adapter. Installs on the fuel system test port of Ford and some Chrysler vehicles to allow connection of the tester. 7, 8. Hose. 5/16" and 3/8" universal high-pressure hoses used in conjunction with tee fitting (5). 9, 10. Hose Clamp. High-pressure fuel line clamps used in conjunction with hoses (7, 8) and tee fitting (5). NOTE: The adapters provided with the tester are designed to facilitate the most common fuel injection system applications.
General Information a. Read and follow all safety precautions. b. Make sure the battery is fully charged and the vehicle has enough fuel in the tank. c. 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. d. Verify all related fuses are in good condition.
1 p. When placing the bleed-off hose into a container to collect excess fuel, make sure the container is approved for gasoline. q. When working on vehicles equipped with airbags, follow all cautions and test procedures in your vehicle’s service manual to avoid accidental airbag deployment. r. Gasoline and gasoline additives are TOXIC. AVOID CONTACT OF GASOLINE WITH SKIN. Wear protective clothing and hand covering (approved latex gloves) when performing pressure tests.
General Information Fuel 1-5
2 2.1 GENERAL The tests outlined in this manual are for checking Throttle Body Fuel Injection (TBI) (see Figure 2) and Multi-port Fuel Injection (MFI) (see Figure 3) fuel system pressures with the engine running (key on, engine on) and without the engine running (key on, engine off). Engine running tests are performed with the engine at idle (unless otherwise noted). The adapter for testing GM vehicles with test ports is already installed on the end of the gauge hose, while the Ford adapter is separate.
Testing • The tee 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 (see Figure 6). • The tee adapter is not suitable for use with fuel injection systems equipped with rigid, metallic or plastic fuel lines or connectors. 2.2 TEST PROCEDURES WARNING: Fuel injection systems are under high pressure. You MUST relieve system pressure before connecting the tester.
2 b. Loosen the fuel tank cap to release any pressure from the fuel tank. c. MAKE SURE the ignition is off. Locate the fuel system’s test valve or port. Remove the protective cap. WARNING: d. 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.
Testing p. Wrap a shop rag around test port area to avoid fuel spray and to absorb excess fuel. CAREFULLY disconnect the gauge hose from the port adapter. NOTE: If installed, remove the Ford adapter from the vehicle's test port. q. 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. r. Recheck all fuel system connections, then start the engine.
2 WARNING: a. Relieve fuel system pressure BEFORE connecting tester (refer to your vehicle's service manual for procedures). b. Loosen the fuel tank cap to release any pressure from the fuel tank. c. Verify the ignition is off. Locate the fuel system’s inlet line (or hose) leading to the fuel rail or throttle body. (Refer to your vehicle’s service manual for locations.) d. CAREFULLY disconnect inlet fuel line (supply line) from system connection point. INLET MAY BE UNDER PRESSURE.
Testing l. Turn ignition off and follow the test and repair procedures to correct the problem. After all necessary repairs have been completed, return to step j. m. Start and idle engine. RECHECK THE TEST SETUP FOR FUEL LEAKS. n. Read fuel pressure from the tester gauge. If the fuel pressure is within vehicle manufacturer's specifications, proceed to step p. If pressure is not within manufacturer's specifications, proceed to step o. o.
3 3.1 LIMITED ONE YEAR WARRANTY 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 Service Center with Proof of Purchase. The sales receipt may be used for this purpose.
Warranty and Service Fuel 3-2
INNOVA ELECTRONICS CORPORATION 17291 Mt.
