Harbor Freight Tools 92699 User Manual

®

FUEL INJECTION TEST KITFUEL INJECTION TEST KIT

FUEL INJECTION TEST KIT

FUEL INJECTION TEST KITFUEL INJECTION TEST KIT

92699

ASSEMBLY AND OPERATING INSTRUCTIONS

3491 Mission Oaks Blvd., Camarillo, CA 93011

Visit our W eb site at http://www.harborfreight.com

Copyright © 2005 by Harbor Freight Tools®. All rights reserved. No por tion of this
manual or any artwork contained herein may be reproduced in any shape or form
without the express written consent of Harbor Freight Tools.

For technical questions and replacement parts, please call 1-800-444-3353

Specifications

Item Description

Function Indicates if fuel pump is defective or
Pressure Gauge 2-9/16”; 0~100 PSI, 0.7 Bar; Fitting:
Fuel Injection Types For most fuel injection systems except:

Weight 1 lb.

inconsistent in pressure flow
¼”x18 NPT swivel



, C.I.S. Jethronic, and throttle

Bosch
body systems on G.M.



vehicles.

Note: Accuracy of the Gauge is ± 2%.

Save This Manual

You will need the manual for the safety w arnings and precautions, assembly
instructions, operating and maintenance procedures, parts list and diagram. K eep
your invoice with this man ual. Write the invoice number on the inside of the front
cover. Keep the manual and in v oice in a safe and dry place for future reference .

Safety Warnings and Precautions

WARNING: When using tool, basic safety precautions should always be fol­lowed to reduce the risk of personal injury and damage to equipment.

Read all instructions before using this tool!

1. Keep work area clean . Cluttered areas invite injuries.

2. Observe work area conditions. Do not use machines or po w er tools in
damp or wet locations. Don’t e xpose to rain. Keep work area well lighted.

3. Keep children away. Children must never be allowed in the w ork area. Do
not let them handle machines, tools, or extension cords .

4. Store idle equipment. When not in use, tools must be stored in a dry
location to inhibit rust. Always lock up tools and keep out of reach of children.

5. Use the right tool for the job. Do not attempt to force a small tool or
attachment to do the work of a larger industrial tool. There are certain
applications for which this tool was designed. It will do the job better and
more safely at the rate f or which it was intended. Do not modify this tool and
do not use this tool for a purpose for which it was not intended.

6. Dress properly. Do not w ear loose clothing or je welry as they can be caught
in moving parts. Protectiv e, electrically non-conductiv e clothes and non-skid
footwear are recommended when working. Wear restrictive hair covering to
contain long hair.

7. Use eye and ear protection. Always wear ANSI approved impact safety
goggles.

8. Do not overreach. Keep proper footing and balance at all times. Do not
reach over or across running machines.

REV 05/05

SKU 92699 For technical questions, please call 1-800-444-3353 Page 2

9. Maintain tools with care. Keep tools sharp and clean for better and safer
performance. F ollow instructions for lubricating and changing accessories.
Inspect tool cords periodically and, if damaged, have them repaired by an
authorized technician. The handles must be kept clean, dry, and free from oil
and grease at all times.

10. Remove adjusting keys and wrenches. Check that keys and adjusting
wrenches are removed from the tool or engine work surf ace bef ore operating.

11. Sta y alert. Watch what you are doing, use common sense. Do not operate
any tool when you are tired.

12. Check f or dama ged parts. Bef ore using an y tool, an y part that appears
damaged should be carefully checked to determine that it will operate
properly and perform its intended function. Chec k for alignment and binding
of moving parts; any broken parts or mounting fixtures; and an y other
condition that may affect proper oper ation. Any part that is damaged should
be properly repaired or replaced by a qualified technician.

13. Replacement parts and accessories. When servicing, use only identical
replacement parts. Use of any other parts will void the warranty. Only use
accessories intended for use with this tool. Appro v ed accessories are
available from Harbor Freight Tools.

14. Do not operate tool if under the influence of alcohol or drugs. Read
warning labels if taking prescription medicine to determine if your judgment or
reflexes are impaired while taking drugs. If there is any doubt, do not operate
the tool.

15. Av oid working alone. If an accident happens, an assistant can bring help.

Additional Product Specific Safety Precautions

1. Do not use Fuel Injection Test Kit on diesel engines.

2. Loosen gas cap and relieve fuel pump pressure before testing.

3. Before testing fuel system, verify all connections are tight to eliminate
leaking.

4. Do not change fittings with engine running.

5. Gasoline is highly flammable. Do not smoke, or test near open flames or a
source of electrical sparks.

6. Do not allow gasoline to come in contact with the hot manifolds or other
engine components.

7. Do not drive the vehicle while under test.

8. If portable lighting is required, use only explosion proof drop-light.

SKU 92699 For technical questions, please call 1-800-444-3353 Page 3

9. Before testing, re view and fo llow instructions from the vehicle manuf acturer’ s
service manual.

10. After testing, turn engine off and depressurize system before removing test
components. Place absorbing cloths around fittings before disconnecting.
Wipe up any spilled fuel. Place cloths in a fireproof container.

11. Clean all testing components of residual fuel before storing.

Warnings

The vehicle engine must never be started in a closed garage, or any other
sealed structure. Carbon monoxide is pr oduced during operation and is deadly
in a closed envir onment. Early signs of carbon mono xide poisoning resemble
the flu, with headaches, dizziness, or nausea. If you have any of these signs
get fresh air immediately .

The warnings, cautions, and instructions discussed in this instruction manual
cannot cover all possible conditions and situations that may occur. It must be
understood by the operator that common sense and caution are factors which
cannot be built into this product, but must be supplied by the operator.

The brass components of this product contain lead, a chemical known to the
State of California to cause birth defects (or other reproductive harm). (Cali­fornia Health & Safety Code 25249.5 et seq.)

Unpacking

When unpacking, check to make sure the following parts are included. Ref er to the
Parts List and Drawing at the end of this manual. If any parts are missing or
broken, please call Harbor Freight Tools at the number on the cover of this manual.

Operation

Caution: Before making connections and testing, place a dry chemical (Class
B) fire extinguisher nearby.

The components in this Fuel Injection Test Kit enable the testing of the fuel deliv­ery pressure to the engine. Pressure Gauge (1) connections are made either
directly to the pump, or in-line with the pump and engine.

1. Relieve the fuel line pressure from the v ehicle fuel system.
Refer to the vehicle manuf acturer’s service manual for instruction on relieving

pressure from the fuel line, testing procedures and connection points, and
normal pressure readings.

2. Use the various fittings and hoses to connect the Pressure Gauge (1) directly
to the fuel pump, as in the case of the VW®, or in-line with the fuel pump and
engine for most other vehicles . See connection examples on the next page.

SKU 92699 For technical questions, please call 1-800-444-3353 Page 4

Use a small amount of pipe compound or teflon tape on the connection
threads to prevent leaks . Tighten using a wrench (not supplied).

Caution: Make sure all connections are tight to avoid fuel leaks.

3. Start the engine and immediately check for fuel leaks. If fuel leaks are found,
turn engine off and fix leaks.

4. Read the pressure off the Pressure Gauge (1).

5. Turn off the engine and remove the keys from the ignition.

6. Wrap a cloth around the hose connection point before relie ving the pressure
from the fuel line, and remove testing components .

7. Reconnect vehicle’s fuel injection line .

8. Wipe up any spilled fuel. Dispose of fuel-soak ed r ags in a fireproof container.

9. Start the engine and check for leaks. Fix leaks if found.

10. Clean and store Fuel Injection Test Kit components and place in the plastic kit
bag.

Typical Hookup

Fuel Line

From Engine

Pressure Gauge (1)

Screw on Female Swivel
Coupling to Engine Test
Fitting

1/4” Hose (5)
to Fuel Pump

VW

Cadillac

Type Hookup

®

Hookup

1/4” Hose (5)

Fitting (3)

®

- Bendix

Fuel Line

From Engine

®

Flex Hose (9)

Connect Directly to
Special Test Outlet on
Engine

Fitting (2)

3/8” Hose (6)
to Fuel Pump

SKU 92699 For technical questions, please call 1-800-444-3353 Page 5

Parts List

Item Description Qty

1.

Pressure Gauge 1

2.

Fitting, brass, 1/8”- 27 NPT x 1/4”-18NPT 1

3.

Fitting, brass, 1/4” Barbed x 1/4”-18NPT 1

4.

Fitting, aluminum, 1/4” & 3/8” Barbed x
1/8”-24 NPT

5.

Hose, rubber, 1/4” x 2.5” (L) 1

6.

Hose, rubber, 3/8” x 3.0” (L) 1

7.

Flex Hose, short 1

8.

Flex Hose, medium 1

9.

Flex Hose, long 1

10. Clamp, Rubber Hose 2

Parts Assembly

(1)

(5)

(6)

(3)

(2)

1

(8)

(7)

(4)

(9)

NOTE: Some parts are listed and shown for illustration purposes only
and are not available individually as replacement parts.

PLEASE READ THE FOLLOWING CAREFULLY

THE MANUFACTURER AND/OR DISTRIBUTOR HAS PROVIDED THE PARTS DIAGRAM
IN THIS MANUAL AS A REFERENCE TOOL ONLY. NEITHER THE MANUFACTURER
NOR DISTRIBUTOR MAKES ANY REPRESENTATION OR WARRANTY OF ANY KIND TO
THE BUYER THAT HE OR SHE IS QUALIFIED TO MAKE ANY REPAIRS TO THE
PRODUCT OR THAT HE OR SHE IS QUALIFIED TO REPLACE ANY PARTS OF THE
PRODUCT. IN FACT, THE MANUFACTURER AND/OR DISTRIBUTOR EXPRESSLY
STATES THat ALL REPAIRS AND PARTS REPLACEMENTS SHOULD BE UNDERTAKEN
BY CERTIFIED AND LICENSED TECHNICIANS AND NOT BY THE BUYER. THE BUYER
ASSUMES ALL RISK AND LIABILITY ARISING OUT OF HIS OR HER REPAIRS TO THE
ORIGINAL PRODUCT OR REPLACEMENT PARTS THERETO, OR ARISING OUT OF HIS
OR HER INSTALLATION OF REPLACEMENT PARTS THERETO.

SKU 92699 For technical questions, please call 1-800-444-3353 Page 6

ADDENDUM A

EXAMPLES OF FUEL INJECTION FUEL PUMP PRESSURES

Note: Alw ays read the vehicle’s factory service manual to determine

the actual Fuel Injection Fuel Pump pressure. The chart below is meant
to be only a guideline for pump pressure.

U.S. Built Vehic les Pump Pressure

Cadillac - EFI 37.5 to 41 PSI
Cadillac - DEFI 9 to 12 PSI
Imperial 8 PSI
Lincoln & Versilles 30 to 40 PSI

Foreign Built Vehicles Pump Pressure

Alfa Romeo 16 to 18 PSI
Alliance (49 states) Bendix Type 28 to 36 PSI
Alliance (California only) L-Jetronic 36 PSI
Audi-Fox 66.8 to 75.3 PSI
BMW 21.7 to 40 PSI
Datsun 28 to 43 PSI
Fiat 28 to 30 PSI
Jaguar 28 to 30 PSI
Mercedes Benz 29 to 30 PSI
P orsche 28.4 PSI
Renault 17TS 35 PSI
Saab 27 PSI
Volkswagen 28 PSI
Volvo 28 PSI

SKU 92699 For technical questions, please call 1-800-444-3353 Page 7