Actron KAL2535 User Manual

MasterÿFuelÿPressure

TestÿKit

MODEL 2535

Users

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.

1

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 manufacturers recommended procedure.

o Have a dry chemical fire extinguisher on hand, and know how to use it.

2

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.

3

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 wont 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 cylinders 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.

4

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 manufacturers 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.

5

This Page Left Blank Intentionally.

6

TYPICAL PORT FUEL INJECTION SYSTEM PRESSURE TEST

For TBI & Bosch C.I.S., see additional instructions

1. Refer to Figure 1, Typical Multi-Port Fuel Injection

System With Test Port. With engine off, locate fuel

pressure test port (Schrader valve) and attach the Test

Gauge. If no Test Port is provided, residual pressure

must be released before fuel system fittings are

loosened. Connect the Test Gauge to the access point

using the correct adapter. Always wrap a shop towel

around the fitting before loosening.

2. If the adapter you need is a banjo bolt adapter, ours

are designed for use with standard depth banjos. If

a car manufacturer uses a non-standard banjo, more

than one washer maybe needed on either or both

sides of the banjo. Our M12 x 1.25 banjo bolt

adapter may need one or more thick or thin washers

depending on the application.

3. Connect the Test Gauge into the system, and watch

the Gauge. Reactivate the fuel pump and start the

engine.

4. Fuel pressure should rise to slightly above operating

pressure and then stabilize at operating pressure,

per the manufacturers specifications.

5. Check for leaks and repair as required.

6. If engine will not start, check ignition system for

spark. If no ignition spark is present, refer to vehicle

service manual for No Start Diagnostics.

CAUTION: Pressure could exceed 75 psi and may blow

apart any loose fittings or defective lines or
hoses. Observe the condition of fuel system
components before performing this test.

9. If pressures are acceptable, some manufacturers

also require a flow test. If so, open the fuel system
into a graduated plastic container and measure the
flow rate. Consult a service manual for the
acceptable flow rate. Close the fuel system.

10. Turn ignition off and observe the residual pressure.

Some manufacturers specify a minimum holding time.

11. In conjunction with an injector pulse tester, turn the

ignition on, observe fuel pressure, pulse one injector,
turn ignition off. Move injector pulse tester to next
injector and repeat test sequence. Continue test
procedure on remaining injectors.

CAUTION: Do not repeat this test more than the

manufacturer recommends. The engine may
become flooded, or the oil can become
contaminated.

12. Deactivate the fuel pump and relieve the system

pressure. With the ignition off, put the Test Gauge
bleed-off tube in a disposal container and press the
bleed valve on the hose.

7

7. If the system has an adjustable fuel pressure

regulator, it should maintain system pressure while

the engine is running. If a compensating fuel

pressure regulator is used, fuel pressure may vary,

depending on manifold vacuum.

8. Locate a flexible hose on the fuel return side and

gently squeeze off return flow briefly. Never squeeze

a steel braided or plastic hose. Pressure should

increase rapidly.

13. Remove the Test Gauge and reconnect all the fuel

lines.

14. Start the engine and check for leaks.

15. Remove residual fuel from all Test Gauge hoses. If

fuel remains in the Test Gauge hose, install any
adapter in the test hose quick connect. Put the Test
Gauge hose and bleed-off tube in a disposal
container. Press the bleed valve on the Test Gauge.
The fuel will drain into the container.

CAUTION: Some fuel pump designs can be damaged by

this test. This test should not be performed
unless recommended by the manufacturer.

FIGURE 1

TYPICAL MULTI-PORT FUEL INJECTION SYSTEM WITH TEST PORT

FUEL RETURN LINE

FILTER

PRESSURE REGULATOR

FLEX HOSE

FILTER

MANIFOLD VACUUM

FUEL PRESSURE TEST POINT

FUEL PRESSURE LINE

IN-TANK FUEL
PUMP

PUMP INLET FILTER

FLEX HOSE

FUEL INJECTORS

8

ADDITIONAL INSTRUCTIONS FOR TESTING TBI SYSTEMS

1. Deactivate the fuel pump(s) and relieve fuel

system pressure.

2. Remove the air cleaner assembly.

3. On GM vehicles, temporarily plug the Thermac

vacuum port on the throttle body.

4. Refer to Figure 2, Typical TBI Fuel Injection

System. Using the adapters supplied, install

the Test Gauge in-line somewhere between the

fuel filter and the throttle body. If longer pieces

of 3/8 hose are needed, cut from 3/8 fuel line

hose. Use hose clamps on the hose.

5. If steel tubing is disconnected, use two

wrenches to prevent damage.

6. On some vehicles it may be easier to put the

car on a lift and test from underneath.

7. On some cars with TBI systems, it may be

difficult to install adapters. The adapters

furnished with this kit will allow many

combinations to be made.

8. Reactivate the fuel pump, start the engine, and

check for leaks.

9. When fuel pressure has stabilized, observe Test

Gauge. Consult a service manual for the exact
pressure reading required.

10. Turn ignition off. Deactivate the fuel pump and

relieve fuel system pressure. Put Test Gauge bleed­off tube in a disposal container and press bleed
valve button.

11. Remove Test Gauge and reconnect all fuel lines.

12. Start engine and check for leaks.

13. Remove residual fuel from all Test Gauge hoses. If

fuel remains in the Test Gauge hose, install any
adapter in the test hose quick connect. Put the Test
Gauge hose and bleed-off tube in a disposal
container. Press the bleed valve on the Test
Gauge. The fuel will drain into the container.

14. On GM vehicles, remove the plug from the Thermac

vacuum port.

15. Replace air cleaner.

9

FIGURE 2

TYPICAL TBI FUEL INJECTION SYSTEM

INJECTOR

PRESSURE REGULATOR

FLEX HOSE

FLEX HOSE

FILTER

FILTER

POSITION AND NUMBER OF FILTERS MAY VARY.

10

RETURN LINE

PRESSURE LINE

PUMP INLET FILTER

ADDITIONAL INSTRUCTIONS FOR TESTING BOSCH C.I.S. SYSTEMS

The following C.I.S. tests can be made with this Test Kit:

n Cold Control Pressure  engine cold, test valve open
n Warm Control Pressure  engine warm, test valve open
n System Pressure  engine cold or warm, test valve closed
n Rest Pressure  engine warm, test valve open
n Fuel Delivery Rate

CAUTION: Adapters with o-rings should be handtightened only.

In some cases, to get the right combination of threads, multiple test adapters may have to be used.
For C.I.S. test pressures specifications, consult the vehicle service manual.

Preparation:

1. Relieve fuel system pressure.

2. Clean any dirt off the top of the fuel distributor.

3. Refer to Figure 3, Typical C.I.S. Fuel Injection

System Test Gauge Connections. Hook up the Test

Gauge between the fuel distributor and the control

pressure regulator. The Test Hose without the flow

control valve should be connected to the fuel

distributor. The hose with the valve should be

connected to the hose that was removed from the

fuel distributor, or connected directly to the control

pressure regulator.

To Test Cold Control Pressure:

1. The engine should be cold after standing several

hours or overnight.

2. Disconnect electrical connector at warm-up

regulator and auxiliary air valve.

3. Connect Test Gauge and open valve on Test Hose.

4. Remove the air from the system. Put the Test Gauge

bleed-off tube in a disposal container. Activate the fuel
pump, but
operating, bleed until air is removed from system.

5. Start the engine and note pressure reading

immediately after starting. Compare to manufacturers
specifications.

6. If the Cold Control Pressure is not correct, the warm-

up regulator may be at fault.

11

do not start the engine. With the fuel pump

FIGURE 3

TYPICAL C.I.S. FUEL INJECTION SYSTEM TEST GAUGE CONNECTIONS

FUEL DISTRIBUTOR

DISPOSAL CONTAINER

PRESSURE GAUGE

BLEED OFF
VALVE

12

FLOW CONTROL
VALVE

Tests Continued on Next Page

TO TANK

CONTROL
PRESSURE
REGULATOR

To Test Warm Control Pressure:

1. Reconnect wiring to warm-up regulator and auxiliary air

valve.

2. Open valve on Test Hose.

3. Start engine and run for specified time.

4. Compare Warm Control pressure readings with

manufacturers specifications.

To Test System Pressure:

1. Test can be performed with engine cold or warm.

2. Reconnect wiring to warm-up regulator and auxiliary air

valve.

3. Close valve on Test Hose (closed valve eliminates

control pressure.)

4. Start engine and run for specified time.

5. Compare System Pressure reading with

manufacturers specifications.

To Test Rest Pressure:

1. Open valve on Test Hose.

2. With engine at normal operating temperature, energize

fuel pump or start engine.

3. Turn engine off or disable pump when pressure

reading stabilizes.

4. Compare pressure readings taken at specified time

intervals with manufacturers specifications.

5. If the Rest Pressure drops too quickly, check for leaks

at o-ring and fuel line connections.

6. If no external leaks are found, consult the service

manual for causes of low fuel pressure.

To Test Fuel Delivery Rate:

1. If pressure testing finds no problems in the fuel

injection system, the fuel pump should be checked.

2. Consult manufacturers specifications for the correct

fuel volume and time period to test.

3. Hook up the Test Gauge for a pressure test and put

the bleed-off tube into a graduated container.

4. Start the engine or activate the fuel pump.

5. Collect fuel in the container for the specified period of

time. Compare the volume of fuel collected with the
manufacturers specifications.

6. Turn off the engine or disconnect the fuel pump.

To Complete Testing:

1. Deactivate fuel pump and relieve fuel system

pressure. With ignition off, put Test Gauge bleed-off
tube in a disposal container and press bleed valve on
the Test Gauge. The fuel will drain into the container.

2. Remove Test Gauge. Reconnect all fuel lines and any

vacuum lines or wiring connectors that were
disconnected.

3. Start engine and check for fuel system leaks.

13

ENGLISH / METRIC

psi kPa 6.8946
psi bar 0.0689

psi

kg/cm

2

0.0703

psi

in. H

2

O

27.68

psi in. mercury 0.4911

psi cm. mercury 0.1934
kPa psi 0.145
kPa bar 0.01

kPa

kg/cm

2

0.0102
bar psi 14.504
bar kPa 100

bar

kg/cm

2

1.02

kg/cm

2

psi 14.22

kg/cm

2

kPa 98.074

kg/cm

2

bar 0.9807

To Convert To Multiply By

PRESSURE EQUIVALENTS

psi bar kPa kg/cm2

0.5 0.034 3.45 0.0352
1 0.069 6.89 0.0703

1.25 0.086 8.62 0.0879

1.5 0.103 10.34 0.1054

1.75 0.12 12.07 0.123
2 0.138 13.79 0.1406
5 0.345 34.47 0.3515

10 0.689 68.95 0.703
15 1.034 103.42 1.0545
20 1.379 137.89 1.406
25 1.724 172.36 1.75
30 2.068 206.84 2.109
35 2.413 241.31 2.4605
40 2.758 275.79 2.812
50 3.447 344.74 3.515
60 4.137 413.68 4.218
70 4.826 482.63 4.921
75 5.167 517.1 5.2725
80 5.516 551.58 5.624
90 6.205 620.52 6.327

100 6.895 689.47 7.03

PRESSURE

CONVERSION FACTORS

14

BASIC TESTER

1000 - 5057

3 1/2, 0-100 PSI Test Gauge and Hose assembly with blow­down valve. Provides a convenient method of purging air
and relieving pressure after testing. Can also be used for

observing volume of fuel.

0032 - 0129

CIS / TBI Test Hose  use when testing CIS or TBI systems
where in line connections are needed. Includes shut-off
valve for both control & primary system pressure checks.
The gauge hose should be used with CIS testing, to purge
all air from the test gauge when running tests.

15

0032  0128

SCHRADER VALVE TEST PORT ADAPTERS

0180 - 1462 -----Small Schrader Valve

90 Degree Adapter

0032 - 0127

Small Schrader Type Test Hose with .308 X 32 Thread
Common applications  Ford EFI.

0180 - 1463 ---------- Standard Schrader Valve 90 Degree Adapter

Large Schrader Type Test Hose with 7/16 X 20 Thread.
Common applications include Chrysler, Jeep, and GM with
test ports.

16

1000-5057

31/2 Gauge / Boot / Hose /

Valve / Tubing

IN LINE TESTING - TBI

0180 - 1444 -------- 5/8-18 to M16 Union

0180 - 1443 --------- Female M14 to 3/8 Tube

0180 - 1442 -------- Female M16 to 3/8 Tube

1000 - 5057

31/2 Gauge / Boot / Hose /

Valve / Tubing

0180 -1453---------- Bent Tube with 5/8

0180 - 1441 -------- Bent Tube with 5/8

0180 - 1459 -------- M12 X 1.25 Banjo

0032 - 0130

Connecting Hose

Flare Nut to M16 with
O-ring

Flare Nuts

Bolt

0180 - 1455 -------- M14 with O-Ring to 3/8

Tube

0180 - 1454 -------- M16 with O-Ring to 3/8

Tube

1000 - 5061 -------- Straight Flared

Tube with 5/8 Flare Nut

0400 - 2972 -------- 3/8 ID X 3 Hose

1000 - 5062 -------- Hose Clamp Kit

17

IN LINE TESTING - C.I.S., C.I.S.-E, & K-JETRONIC

0180 - 1457 -------- M8 Banjo Bolt with Washer

0180 - 1458 -------- M10 Banjo Bolt with Washer

0180 - 1460 -------- M12 X 1.5 Banjo Bolt

1000 - 5057

31/2 Gauge / Boot / Hose /

Valve / Tubing

0032 - 0129

Connecting Hose &

Valve Assembly

0180 - 1451 -------- M10 Male to M12 Male

0180 - 1445 -------- M8 Female to M12 Male

0180 - 1446 -------- M10 Female to M12 Male

0180 - 1450 -------- M8 Male to M12 Male

0180 - 1452 -------- Long M8 Male to M12 Male

0180 - 1461 -------- Long M8 Female to M12 Male

18

IN-LINE TESTING - SPECIAL ADAPTERS

1000 - 5057

31/2 Gauge / Boot / Hose /

Valve / Tubing

0180 - 1449 -------- Manifold with Quick

Connect

0180 - 1448 -------- GEO / Isuzu

Adapter

1000 - 5060-- Ford CFI Hair Pin

Hose Adapter

1000 - 5059 -- Ford EFI Spring

Lock Hose
Adapter

1000 - 5058 -- Volvo Adapter

1000 - 5063 -- 3/8 Hair Pin Hose

Assembly

0400 - 2970 --------- 1/4 ID X 2 Hose

0400  2971 -------- 5/16 ID X 3 Hose

1000 - 5064-- 5/16 Hair Pin

Hose Assembly

19

END-OF-LINE TESTING - BANJO, FUEL BOLT ADAPTERS

0180 - 1456 -----M6 Banjo Bolt with

O-ring

0180 - 1457 -----M8 Banjo Bolt with

Washer

0180 - 1458 -----M10 Banjo Bolt with

Washer

1000 - 5057

31/2 Gauge / Boot / Hose /

Valve / Tubing

0180 - 1459 ----- M12 X 1.25 Banjo

Bolt

0180 - 1460 ---- M12 X 1.5 Banjo

Bolt

0180 - 1447 --- M14 X 1.5 Banjo

Bolt

0180 - 1464 ---- Single End Hose

Adapter

0180 - 1440---- Quick Connect Plug to

1/4 Hose

20

©2003 Actron Manufacturing Company. All Rights Reserved.

0002-000-2519