Actron® Fuel Pressure Tester Kit Installation Instructions
Contents
1. and when bleeding off fuel pressure Gauge Hose Hose that carries fuel to the gauge so that pressure can be mea sured GM Chrysler Test Port Adapter This adapter is used to connect the gauge Fig 2 FUEL PRESSURE REGULATOR FUEL INJECTORS Ford CFI Throttle Body hose to GM and Chrysler vehicles equipped with a schrader valve test port on the fuel rail Ford Test Port Adapter This adapter is used to connect the gauge hose to Ford vehicles equipped with a schrader valve test port on the fuel rail Fuel Injection System Theory There are two basic types of fuel injection systems currently being used by GM Ford and Chrysler The first type is called port or multi port fuel injection In this system the fuel injectors spray fuel directly into the FUEL PRESSURE REGULATOR PRESSURE LINE GM Multi Port Fuel Injection RETURN LINE FUEL INJECTORS intake manifold be hind the intake valve These sys Fig 3 tems typically have TEST PORT one fuel injector per FUEL RAIL FUEL PRESSURE REGULATOR FUEL RAIL FUEL INJECTORS cylinder The sec a ond type is com S o monly called Throttle Body Injection TBI KS for GM and Chrysler OY vehicles or Central Fuel Injection CFI for Ford vehicles VACUUM These systems use PORT one or two fuel injec tors mounted on top of t2. 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 For GM Chrysler Vehicles e Wrap a shop rag around fuel rail test port in case a small amount of fuel drips out while unscrewing test port adapt ers e Unscrew GM Chrysler test port adapter from fuel rail test port 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 14 Store shop rags in an approved con tainer 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 situa tion General Fuel Pressure Diagnostics 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 at all Fuel pressure readings that are higher than manufacturers specifications are generally caused by a problem in the return line fuel components Conversely fuel pressure read ings that are lower than manufa
3. is bolted to the intake manifold Its purpose is to hold the fuel injectors in place and to deliver pressur ized fuel to the fuel injectors Fuel Injectors A precision valve that is controlled by a solenoid Fuel injection is controlled by the amount of fuel pressure Fig 4 FUEL RAIL TEST PORT S PROTECTIVE FUEL RAE Sea Typical GM Multi Port Fuel Injection System Fig 5 VACUUM PORT PRESSURE LINE Vacuum Actuated Compensated Fuel Pressure Regulator and the size and duration of the valve open ing 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 Pre Testing Checks 1 Read Safety Precautions 2 Do a thorough visual and hands on in spection of the engine and fuel system Look for loose or cracked electrical wir ing 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 usu ally located in the trunk 5 Verify that all fuel system fuses are good 6 Verify fuel vapor recovery system and gas Cap are in good condition 7 Verify that manifold vacuum is within manufacturers specification which is ty
4. or Flex Fuel engines e Never attach Fuel Pressure Tester to any place other than the fuel rail test port Do not confuse Air Conditioning schrader valves with the fuel rail test port Never attach or remove Fuel Pressure Tester Kit from fuel rail test port with the ignition key on Always place end of 6 ft bleed off hose in an approved container for fuel during test ing and when bleeding off fuel pressure Never smoke or have open flames near vehicle Vapors from fuel and charging bat tery are highly flammable and explosive Never permit fuel to spill on hot engine parts If a spill or leak occurs immediately turn ignition key off and clean up fuel Only use the Fuel Pressure Tester Kit for measuring fuel pressure on vehicles having schrader valves as their fuel rail test port Do not use this kit for any other purpose Always operate the vehicle in a well venti lated area Do not inhale exhaust gases or fuel vapors they are very hazardous Always keep yourself tools and test equip ment away from all moving or hot engine parts Always make sure the vehicle is in PARK Automatic transmission or NEUTRAL manual transmission and that the park ing brake is firmly set Block the drive wheels Never lay tools on vehicle battery You may short the terminals together causing harm to yourself the tools or the battery Never leave vehicle unattended while run ning tests Always keep a fire extinguisher suitabl
5. 92 96 3 9L 8 scort amp Tracer 1992 96 5 2L Y 2 0L 2 2L amp 2 5L Probe 1993 96 5 9L 5orZ 3 0L Villager 1994 96 8 0L W JEEP Multi Port Fuel Injected Vehicles Year Engine 8th VIN Digit 1991 95 2 5L P 1987 96 4 0L S 1993 96 5 2L Y Domestic EAGLE Multi Port Fuel Injected Vehicles Year Engine 8th VIN Digit 1995 96 2 0L Y 1993 96 3 3L T 1993 96 3 5L F Some 1996 engines may not have a schrader valve fuel rail test port 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 Instructions for Fuel Pressure Tester Kit Safety Precautions To prevent accidents that could result in serious injury and or damage to your vehicle or test equipment carefully follow these safety rules and test procedures at all times when working on vehicles Always wear approved eye protection e Never use Fuel Pressure Tester Kit on Diesel
6. aiGiram4 CP7818 Fuel Pressure Tester Kit INSTRUCTIONS e Fuel pressure testing involves some contact with pressurized fuel e Do not use the Fuel Pressure Tester Kit on Diesel or Flex Fuel engines Only use the Fuel Pressure Tester Kit on Gasoline powered engines e Helps diagnose driveability problems due to abnormally high or low fuel pressure VEHICLE APPLICATION LIST The Fuel Pressure Tester Kit works on most domestic fuel injected vehicles having a schrader valve test port on the fuel rail This includes Ford high pressure central fuel injection and GM Ford and Chrysler multi port fuel injection Multi port means one fuel injector per cylinder Domestic FORD Domestic CHRYSLER LINCOLN MERCURY PLYMOUTH DODGE High Pressure Central Fuel Injected Multi Port Fuel Injected CFI Vehicles Passenger Vehicles 1981 86 Country Squire Crown Year Engine 8th VIN Digit Victoria LTD Colony Park 1995 96 2 0L Cory Grand Marquis amp Marquis 1984 93 22L Turbo E 1985 86 Mustang amp Capri 1995 96 2 4L xX 1985 87 Thunderbird amp Cougar Ratas Ber Turbo A 1981 85 ate Town Car Mark VI 1993 96 3 5L E 1987 93 3 8L L 1980 Versailles Most Multi Port Fuel Injected Vehicles Multi Port Fuellnjected Trucks amp vans 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 your lo
7. cal dealer or your local public library For others you need to write for availability and prices specifying the make model and year of your vehicle Aftermarket Vehicle Service Manuals Vehicle Service Manuals from Chilton Book Company Chilton Way Radnor PA 19089 Haynes Publications 861 Lawrence Drive Newbury Park CA 91320 Cordura Publications Mitchell Manuals Inc Post Office Box 26260 San Diego CA 92126 Motor s Auto Repair Manual Hearst Company 250 W 55th Street New York NY 10019 Vehicle Service Manuals from Ford Motor Company Ford Publication Department Helm Incorporated Post Office Box 07150 Detroit MI 48207 General Motors Corporation Buick Tuar Company Post Office Box 354 Flint MI 48501 Oldsmobile Lansing Lithographers Post Office Box 23188 Lansing MI 48909 Cadillac Chevrolet Pontiac Helm Incorporated Post Office Box 07130 Detroit MI 48207 Vehicle Service Manuals from Chrysler Corporation Chrysler Corporation Dyment Distribution Service Service Publication 12200 Alameda Drive Strongsville Ohio 44136 Note Domestic GENERAL MOTORS Most Multi Port Fuel Injected Vehicles 1984 to 1996 Not Including 1988 1 6L Nova 1988 89 1 5L Spectrum 1987 90 Sprint Turbo 1983 to 1996 Year Engine 8th VIN Digit 1996 2 4L B Not including l 1989 2 5L Turbo J 1 3L Festiva amp Aspire 1992 96 3 3L R 1 6L Capri 1994 96 3 8L L 1 8L E T 19
8. cturers speci fications are generally caused by a problem in the pressure line fuel components If fuel pressure readings are not within manu facturers specifications then refer to a ve hicle service manual for step by step diag nostic procedures that will pinpoint the faulty component for your specific vehicle Possible causes of high fuel pressure read ings are the following e Faulty fuel pressure regulator e Restriction in return line e Faulty fuel line couplings at fuel tank Possible causes of low fuel pressure read ings are the following e Clogged or restricted fuel filter e Restriction in pressure line e Faulty fuel pump e Faulty fuel pump relay e Bad 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 Care and Maintenance Apply a lightweight household oil to the rub ber O rings inside both the GM Chrysler and Ford test port adapters before each use acirons ACTRON MANUFACTURING CO HAND TOOLS
9. e for fuel electrical chemical fires handy Always use extreme caution when working around the ignition coil distributor cap igni tion wires and spark plugs These compo nents contain High Voltage when the en gine is running Complete all Pre Testing Checks before beginning fuel pressure testing e Always follow vehicle manufacturer s warn ings cautions and service procedures CAUTION Some vehicles are equipped with safety air bags You must follow vehicle service manual cautions when working around the air bag components or wiring If the cautions are not followed the air bag may open up unexpectedly resulting in personal injury Note that the air bag can still open up several minutes after the ignition key is off or even if the vehicle battery is disconnected because of a special energy reserve module Fuel Pressure Tester Description 1 Dial Face Measurement scale that shows amount of fuel pressure present in fuel system Pressure Relief Button Used to re lieve fuel pressure in the gauge hose before disconnecting the gauge hose from the fuel rail 3 Bleed Off Hose A 6 ft hose that bleeds off fuel pressure when the pressure relief button is pressed Never use a bleed off hose shorter than 6 ft Important Always make sure end of bleed off hose is in an approved con tainer for fuel at all times during testing
10. ester Kit from the fuel rail test port proceed to Step 9 8 Start engine Let idle e If your vehicles fuel system uses a vacuum actuated compensated fuel pressure regulator then fuel pressure should drop approximately 3 10 psi de pending on manifold vacuum ACTRON If your vehicles fuel system uses a fuel pressure regulator without a vacuum port than fuel pressure should remain constant during both key on engine off and idle e Read fuel pressure from dial face If fuel pressure is not within manufac turers specification than service ve hicle according to vehicle service manual e When repair is completed and idle fuel pressure is now within manufacturers specification then proceed to Step 9 e To safely disconnect the Fuel Pressure Tester Kit from the fuel rail test port and perform repairs at a later time 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 pres sure 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 con tainer 13 Remove gauge hose from fuel rail test port For Ford Lincoln Mercury Vehicles e Wrap a shop rag around fuel rail test port in case a small amount of fuel drips out while unscrewing test port adapt ers e Unscrew GM Chrysler test port adapter from Ford test port adapter
11. eturn Line Path way for excess fuel to return to the fuel 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 Its function is to prevent foreign particles from reaching the fuel injec tors A clogged or restricted fuel filter can also cause low fuel pressure readings This is the only fuel system component that re quires periodic replacement Refer to vehicle owners manual for replacement interval Fuel Rail Test Port A schrader valve lo cated on the fuel rail Fig 4 that allows easy connection of a fuel pressure gauge to mea sure fuel pressure Do not confuse this valve with the schrader valves that are used for recharging air conditioning systems Fuel Pressure Regulator The fuel pres sure regulator Fig 5 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 ex ceeded 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 pres sure regulators A leaking fuel pressure regu lator can cause low fuel pressure readings and hard starting problems Fuel Rail The fuel rail assembly
12. he intake mani fold They spray fuel into the throttle body similarly to a conven tional carburetor See Fig 2 for illus trations of both types of fuel systems PRESSURE LINE RETURN FUEL INJECTORS LINE FUEL FILTER PUEL TANK FUEL PUMP FILTER FUEL PUMP 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 The fuel pressure regulator divides fuel between the pressure line and the return line The fuel in the pressure line goes to the fuel injectors while the fuel in the return line is returned to the fuel tank Fig 3 shows the orientation of fuel system components in a typical port fuel injection system Fuel Tank A large container that holds your vehicles supply of fuel Fuel Pump Filter A filter that is usually located in the fuel tank Its function is to prevent foreign particles from reaching the fuel pump A clogged or restricted fuel pump filter can cause low fuel pressure readings When replacing a fuel pump it is a good idea to clean or replace the fuel pump filter Fuel Pump An electric motor that pumps fuel into the fuel system at a constant pres sure It is mounted in the fuel tank or on the frame Some vehicles have more than one fuel pump R
13. pi cally 18 20 in at idle 8 Look for fuel leaks and wipe up any spilled fuel immediately 9 If engine will not PX eeraa sasa RR seer Sssses 5I start check igni Fig 6 tion system for spark If no ignition spark is present refer to vehicle ser vice manual for No Start Diagnostics END OF BLEED OFF Fuel Pressure HOSE MUST Testing BE PASER IN Procedures APPROVED This test procedure FUEL CONTAINER explains how to make fuel pressure mea surements on vehicles SHOP FUEL RAIL RAG TEST PORT while the ignition key is on and while the engine is at idle The procedure also explains the safest way to connect and disconnect the fuel pressure tester kit from vehicles equipped with schrader valves as their fuel rail test ports If the fuel pressure readings measured in this test procedure are not within your vehicles manufacturing specification then you must use your vehicle service manual along with the fuel pressure tester kit to service the problem This test procedure does not con tain any vehicle specific diagnostics 1 Read all SAFETY PRECAUTIONS and PRE TESTING CHECKS 2 Apply a lightweight household oil to the rubber O rings inside both test port adapters 3 Turn Ignition Key OFF 4 Locate fuel rail test port and remove protective cap See Fig 4 For Ford Lincoln Mercury Vehicles e Sc
14. rew Ford test port adapter to fuel rail test port until finger tight e Screw GM Chrysler test port adapter to the Ford test port adapter until finger tight For GM Chrysler Vehicles 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 at taching adapters 5 Place end of 6 ft bleed off hose in an approved container for fuel Bleed off hose must remain in container until testing is complete 6 Turn all accessories OFF i e Radio A C Blower Fan Headlights Wind shield Wipers 7 Turn ignition key ON Do the following checks e Listen for fuel pump Pump should run for approximately 2 seconds e Check fuel system for leaks If leaks found turn ignition key OFF and wipe up fuel immediately Read fuel pressure from dial face Pres sure should rise to manufacturers speci fication and hold steady even after fuel pump stops running Refer to vehicle service manual for fuel pressure speci fications If fuel pressure is not within manufac turers specification than service ve hicle according to vehicle service manual When repair is completed and key on engine off fuel pressure is now within manufacturers specification then pro ceed to Step 8 For instructions on how to safely dis connect the Fuel Pressure T
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