Actron KAL2535 User Manual
MasterÿFuelÿPressure
TestÿKit
MODEL 2535
Users
Manual
SAFETY GUIDELINES TO FOLLOW WHEN WORKING ON VEHICLES
DO NOT
n DO NOT smoke when working on fuel systems.
n DO NOT use the Fuel Pressure Test Kit on diesel or flex fuel engines.
n DO NOT connect or disconnect fuel system fittings with the ignition on.
n DO NOT lay tools on the vehicle battery. A short may occur, causing damage or personal injury.
n DO NOT leave the vehicle unattended with the engine running or while performing tests.
n DO NOT allow unauthorized personnel in the test area.
n DO NOT allow test hoses or test instrument harnesses to lie near engine cooling fan, exhaust manifolds, etc.
n DO NOT work on fuel systems where a flame or spark could be present. This includes furnaces, space heaters,
exposed spark plug wires, etc.
n DO NOT allow fuel to spill on hot engine parts. If a leak or spill develops, turn off ignition, disable fuel pump, and
clean up spill immediately.
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DO
o Wear approved eye protection.
o Refer to the manufacturers vehicle service or repair manuals for specific information regarding pressure testing
values, procedures, and test port locations.
o Follow all manufacturers cautions, warnings, and instructions.
o Keep clothing, tools and yourself away from hot or moving engine parts.
o Clean fuel system connections before loosening. Dirt in the system could result in damage.
o Wrap a cloth around fittings when loosening to prevent spray or spilling of fuel.
o Provide proper ventilation of gasoline and exhaust fumes.
o Use hose clamps on all hose adapters.
o Make sure quick-disconnect couplers snap together fully and there is no fuel leakage.
o Make sure the battery is fully charged, and the vehicle has an adequate supply of fuel.
o Use two wrenches to loosen or tighten fuel system connections to prevent damage or twisting of fuel lines.
o Check the general condition of the engine and fuel system. Check the fuel lines, ignition wires, battery cables,
electrical wiring, and fuses. Check the fuel tank filler cap and the venting system.
o Carefully relieve residual fuel pressure per manufacturers recommended procedure.
o Have a dry chemical fire extinguisher on hand, and know how to use it.
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FUEL INJECTION SYSTEMS - GENERAL INFORMATION
Automotive fuel systems and access points are so varied that it is not possible to list all of the test adapter applications.
Always consult a reliable shop manual, or consult the car manufacturer for the recommended test procedure and
connections.
There are two basic types of automotive fuel injection systems:
1. Port Fuel Injection (PFI) - Separate fuel injectors supply fuel to each cylinder.
2. Throttle Body Injection (TBI) Fuel is injected from a point on the intake manifold above the throttle plate.
Both systems have a supply side, which provides fuel for the injectors, and a return side, which sends excess fuel
back to the fuel tank.
There are three basic ways to check fuel system pressure:
1. Many domestic cars with PFI systems are equipped with a test port. Connect the proper test adapter to the Test
Gauge, couple the adapter to the test port, and perform the test.
2. On some systems an end-of-hose connection is necessary. Some PFI systems have a flexible hose connection. For
this type of system, connect a single barb fitting with a hose clamp to perform the test. Other systems have a fuel bolt
or banjo type fitting as an access point.
3. The third method of fuel pressure testing is in-line connecting. This method requires separating the fuel line and
installing the Test Gauge and adapters in series.
Most manufacturers require that you relieve the fuel pressure before connecting to or disconnecting from the fuel
system. To relieve the fuel pressure, it may be necessary to disconnect or disable the fuel pump. Some models may
have two fuel pumps, and both must be disabled. After the fuel pump(s) are disabled, run the engine until it stalls,
then try to restart it for three to five seconds. When the fuel system has been drained of fuel it is ready for testing.
Connect the proper test adapters and the Test Gauge, reconnect the fuel pump and perform the tests. When the tests
are finished, repeat the procedure to relieve the fuel pressure before removing the Test Gauge.
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CHECKS TO MAKE BEFORE TESTING FUEL SYSTEM
The following items should be checked. Any faults that are found must be corrected before a proper fuel system
test can be performed.
Check for loose or disconnected vacuum lines. Look for coolant or excessive oil leaks. Listen for any audible air leaks,
unusual noises, engine rattles or knocks. Check valve timing and adjustment.
Electrical System
1. If engine wont start, check for ignition spark. If no
spark is present, service ignition system. The ignition
fires the fuel injector on most systems so that if a spark
plug is not firing, that cylinders injector will not be
firing.
2. Observe Check Engine lamps or other computer fault
indicators.
3. Look for broken, disconnected, or arcing ignition wires.
4. Look for disconnected distributor, or arcing cap or
rotor.
5. Check for loose or corroded component grounds.
6. Look for disconnected electrical components.
7. Check battery condition. A weak battery will affect
proper fuel pump delivery or injector triggering.
Battery voltage should be more than 12 volts.
8. Check basic operation of the charging system.
9. Look for loose or corroded battery cables.
Fuel System
1. Make sure fuel tank has sufficient fuel (do not rely on
the fuel gauge).
2. Look for broken, loose, or corroded metal, rubber or
plastic fuel lines.
3. Check for water or other contaminates in fuel.
4. Check condition of fuel system related fuses or
solenoids.
5. Check condition of fuel tank venting systems.
6. Check condition of fuel tank filler cap.
7. On vehicles equipped with inertia switch, check and
make sure switch has not been tripped.
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TYPICAL PROCEDURE TO RELIEVE FUEL SYSTEM PRESSURE
1. Do not smoke.
2. Wear approved safety glasses.
3. Have a Class B dry chemical fire extinguisher nearby.
4. With ignition off, release fuel tank filler cap.
5. Disable the fuel pump. Follow the manufacturers recommended procedure.
a. Some vehicles may have two fuel pumps. Both pumps must be disabled.
b. A common method of disabling the fuel pump is to remove the fuel pump fuse.
c. On some vehicles, removing the fuse also disables the fuel injectors or ignition system, so another method of
disabling the pump must be used.
d. On some vehicles, the fuel pump can be disabled by disconnecting the fuel pump wiring harness.
e. On Ford vehicles, equipped with an inertia switch, check that the switch has not been tripped. The inertia switch is
usually located in the trunk.
6. Turn on the ignition and start the engine. If engine will not start, check ignition system for spark. If no spark is present,
refer to the vehicle service manual for No Start Diagnostics.
7. Run the engine until it stalls.
8. Try to restart the engine for 3 to 5 seconds. For some Ford/Mercury/Lincoln vehicles with inertia-switch pressure relief,
engage the starter for 15 seconds to relieve fuel pressure.
9. Turn ignition off.
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