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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.

• Never use Fuel Pressure Tester Kit on

Diesel or Flex Fuel engines!

• 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 suitable 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.

• 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.

2. 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

Fig. 1

300

400

200

500

100

600

700

kPa

100

psi

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

and when bleeding off fuel pressure!!

4. Gauge Hose: Hose that carries fuel to

the gauge so that pressure can be mea-

sured.

5. GM/Chrysler Test Port Adapter: This

adapter is used to connect the gauge

hose to GM and Chrysler vehicles

equipped with a schrader valve test

port on the fuel rail.

6. 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

intake manifold be-

hind

the

intake

valve. These sys-

Fig. 3

FUEL RAIL

tems typically have

TEST PORT

FUEL

one fuel injector per

INJECTORS

cylinder. The sec-

ond type is com-

monly called Throttle

Body Injection (TBI)

for GM and Chrysler

vehicles or Central

Fuel Injection (CFI)

for Ford vehicles.

VACUUM

These systems use

PORT

one or two fuel injec-

tors mounted on top

of the 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.

Fuel System Components

Before doing any fuel pressure testing, it is 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

Fig. 2

FUEL PRESSURE

FUEL

REGULATOR

INJECTORS

Ford CFI

Throttle Body

FUEL

FUEL RAIL

INJECTORS

FUEL PRESSURE

TEST PORT

REGULATOR

PRESSURE

LINE

RETURN LINE

GM Multi-Port

Fuel Injection

FUEL INJECTORS

FUEL PRESSURE

REGULATOR

FUEL

RAIL

PRESSURE

FUEL INJECTORS

FUEL FILTER

FUEL

TANK

FUEL PUMP FILTER

FUEL PUMP

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.

PRESSURE

LINE

RETURN

LINE

FUEL

RAIL

LINE

RETURN

LINE