MAHLE RTI ESX-2 User Manual
OPERATION MANUAL
ESX-2
Fuel System Cleaner
RTI Technologies, Inc
4075 East Market St.
York, PA 17402
800-468-2321
www.rtitech.com
Manual P/N 035-80873-00 (Rev A)
Table of Contents
Component Description ............................2
Safety Precautions................................3
Keypad Functions ................................4
Fuel System Identification ..........................6
Port Fuel Injection (PFI) Setup.......................7
Port Fuel Injection (PFI) Cleaning Procedure ........... 10
Throttle Body Injection (TBI) Setup .................. 11
Throttle Body Injection (TBI) Cleaning Procedure ....... 14
Continuous Injection System (CIS) Setup ............. 15
Continuous Injection System (CIS) Cleaning Procedure . . 18
Carburetor System Setup.......................... 19
Carburetor System Cleaning Procedure ............... 22
Vehicle Diagnostic ............................... 23
Intake System Cleaning ........................... 26
Maintenance ................................... 27
Parts Identification ............................... 28
Flow & Wiring Diagram............................ 29
BEFORE FIRST TIME USE
Pour one-half bottle (4 ounces) of the RTI FUEL SYSTEM CLEANER
into the Fill Port.
Then pour gasoline into the Fill Port until the level is at the EMPTY
mark in the Fuel Level Window.
This will ensure precise concentration of fuel to cleaner.
Page 1
Component Descriptions
Unpack all components. Use laminated placard to verify fitting adapter quant ities. Items not shown
are one RTI filter as well as 1 case (twel ve bottles) of RTI FUEL SYSTEM CLEANER. Unpack RTI
FUEL SYSTEM CLEANER and RTI filter. Store contents in the rear storage compartments of the
ESX. (see Page 28)
Contact RTI if any items are missing or damaged.
FITTING ADAPTER SET
KEYPAD
PRESSURE
CONTROL REGULATOR
FUEL LEVEL
WINDOW
FUEL
PRESSURE GAUGE
VACUUM GAUGE
FILL PORT
10 FT RED HOSE
10 FT BLACK HOSE
BEFORE FIRST TIME USE
Pour one-half bottle (4 ounces) of the RTI FUEL SYSTEM CLEANER
into the Fill Port.
Then pour gasoline into the Fill Port until the level is at the EMPTY
mark in the Fuel Level Window.
This will ensure precise concentration of fuel to cleaner.
Page 2
Safety Precautions
WARNING: Failure to follow these precautions can result in serious
injury or death.
• Read and understand the Operation Manual completely before operating this unit.
• Always wear proper eye and skin pr otection when operating and maintaini ng this equipment.
• Take precautions to keep clothing, hair, hands, hoses, etc. away from all moving parts of the
vehicle.
• Fuel systems can be under high pressure, even after the engine has been turned of f, and
engine parts can be extremely hot. Always use extreme caution when connecting and
disconnecting hoses and adapters.
• Always keep a fire extinguishing device nearby when working with flammable liquids.
• NOTE: Vehicle exhaust contains Carbon Monoxide, which is lethal and odorless.
Choose a well ventilated work area and avoid inhaling any fumes when operating the
equipment.
• Check engine oil and coolant level. Refill if low. Do not perform the cleaning if either is low.
• Flush solutions are combustible and are harmful if swallowed. If swallowed call a doctor
immediately and do not induce vomiting. If Flush Solution gets in the eyes flush with water
immediately. For contact with skin wash with soap and water. Apply skin lotion if necessary
to sooth irritation.
• Immediately clean up any gasoline or chemical spills and use a proper container for disposal.
• Comply with local, state, and federal regulations for fluid disposal.
• Material Safety Data Sheets (MSDS) must be obtained on all chemicals and placed in a shop
file for reference.
BEFORE FIRST TIME USE
Pour one-half bottle (4 ounces) of the RTI FUEL SYSTEM CLEANER
into the Fill Port.
Then pour gasoline into the Fill Port until the level is at the EMPTY
mark in the Fuel Level Window.
This will ensure precise concentration of fuel to cleaner.
Page 3
Keypad Functions
The ESX is an automatic fuel system cleaning machine that has state-of-the-art controls.
Operation of this machine is intuitive and easy to master . Below is a list of the keypad functions.
60
55
50
5
10
45
40
35
30
15
20
25
Fills tank inside the ESX unit from th e vehicle fuel system. Also used to purge or
relieve the pressure in the pressure line in the fuel system before disconnecting.
Stops any procedure the moment it is pushed. Also acknowledges the completion
of a process and is used to stop the buzzer.
Held to set pressure for the cleaning processes which in turn begins the cleaning
procedure, also can be used to empty the system contents.
Holds pressure in the li nes w hile the timer counts dow n a default or adj usted time.
The default time is 5 minutes.
Page 4
Keypad Functions
Illuminates whenever there is an error with the selected procedure.
Illuminates when the selected process is complete. The buzzer will sound
continuously when this is illuminated.
Illuminates when the ESX is pumping out of the red line. Examples of this are the
cleaning procedure and when emptying the internal tank.
Illuminates when the ESX is pulling from the red line. E xamples of this are the
purging procedure and when filling from the vehicle fuel system.
Increases and decreases by 5 minute i ntervals the remaining time on the LED timer.
BEFORE FIRST TIME USE
Pour one-half bottle (4 ounces) of the RTI FUEL SYSTEM CLEANER
into the Fill Port.
Then pour gasoline into the Fill Port until the level is at the EMPTY
mark in the Fuel Level Window.
This will ensure precise concentration of fuel to cleaner.
Page 5
Fuel System Identification
The Fuel System type must be determined before proceeding with any cleaning or diagnostic
procedures. The following four systems are the only types that can be serviced w ith the RTI ESX
unit.
Port Fuel Injection (PFI)- This system uses a single electronic injector per cylinder,
mounted such that fuel spray is directed into the intake port. (See Page 7)
Throttle Body Injection (TBI) - Centrally mounted, like the carburetor system, but utiliz es
one or two electronic injectors. (See Page 11)
Continuous Injection System (CIS) - Look for the fuel distributor with solid steel or flex
steel lines running from the fuel distributor to each individual i njector . The fuel distributor
controls the amount of fuel sprayed into the intake port while the injector controls opening
and closing pressure. (See Page 15)
Carburetor System - Sizes and shapes vary, but these systems are easily identified by
locating the choke plate underneath the air filter housing. (See Page 19)
PORT FUEL INJECTION FIG. A
ESX RED HOSE
PRESSURE LINE
VEHICLE FUEL TANK
FILTER
RETURN LINE
ADAPTER
ADAPTER
TEE ADAPTER
LOOP ADAPTER
ADAPTER
ADAPTER
PRESSURE LINE
FUEL RAIL
FUEL
PRESSURE
REGULATOR
RETURN LINE
PORT FUEL INJECTION FIG. B
ESX RED HOSE
PRESSURE LINE
LOOP
ADAPTER
ADAPTER
FUEL RAIL
FUEL
PRESSURE
REGULATOR
RETURN LINE
VEHICLE FUEL TANK
FILTER
PRESSURE LINE
RETURN LINE
ADAPTER
ADAPTER
ESX BLACK HOSE
ADAPTER
CONTINUOUS INJECTION SYSTEM FIG.A
ESX RED HOSE
ADAPTER
ADAPTER
FUEL
PRESSURE
REGULATOR
FUEL DISTRIBUTOR
VEHICLE FUEL TANK
PRESSURE LINEFILTER
RETURN LINE
ADAPTER
ADAPTER
TEE ADAPTER
LOOP ADAPTER
PRESSURE LINE
RETURN LINE
CONTINUOUS INJECTION SYSTEM FIG.B
ESX RED HOSE
ADAPTER
LOOP
RETURN LINE
ADAPTER
FUEL
PRESSURE
REGULATOR
FUEL DISTRIBUTOR
VEHICLE FUEL TANK
FILTER PRESSURE LINE
RETURN LINE
ADAPTER
ADAPTER
ESX BLACK HOSE
ADAPTER
THROTTLE BODY FIG. A
FILTER
PRESSURE LI NE
VEHICLE FUEL TANK
RETURN LINE
THROTTLE BODY FIG. B
PRESSURE LINE
FILTER
VEHICLE FUEL TANK
RETURN LINE
CARBURETOR FIG. A
ESX RED HOSE
SUPPLY LINE
VEHICLE FUEL TANK
CARBURETOR FIG. B
SUPPLY LINE
VEHICLE FUEL TANK
ADAPTER
ESX BLACK HOSE
ADAPTER
ADAPTER
COMING FROM
FUEL PUMP
FUEL PUMP
LOOP ADAPTER
COMING FROM
FUEL PUMP
FUEL PUMP
LOOP
ADAPTER
TEE ADAPTER
TEE
ADAPTER
ADAPTER
ESX RED HOSE
ADAPTER
ESX RED HOSE
ADAPTER
ESX RED HOSE
GOING INTO
THE CARBURETOR
PRESSURE LINE
ADAPTER
PRESSURE LINE
ADAPTER
CARBURETOR
GOING INTO
THE CARBUR ETOR
CARBURETOR
THROTTLE BODY UNIT
ADAPTER
LOOP ADAPTER
THROTTLE BODY UNIT
ADAPTER
RETURN LINE
RETURN LINE
Page 6
Port Fuel Injection (PFI) Setup
The following steps will prepare the ESX for the cleaning procedure. Make sure the vehicle fuel
gauge reads at least 1/8th of a tank before continuing.
Note: Do not proceed with this setup or any cleaning procedure if the engine oil or coolant
level is low. If necessary add appropriate amount of coolant and/or oil to the engine.
Note: If Intake System Cleaning is desired refer to page 26 for proper instructions.
1. Start the vehicle and allow engine to reach normal operating temperature. Turn vehicle
OFF when the proper temperature is reached.
2. Turn Pressure Control regulator counterclockwise until it is completely open.
3. Connect red (positiv e) cl amp on power cable to red ( positi ve) terminal on v ehicl e battery .
Connect the black (negative) clamp to a ground on vehicle frame as far from the battery
as possible. A ll LED’s on keypad should illuminate for one second and buzzer should
pulse. If not, check connections and make sure REVERSE POLARITY LED is not
illuminated. If REVERSE POLARITY LED is illuminated reverse the battery connections.
4. Remove vehicle gas cap to relieve fuel tank pressure.
5. With the engine no longer running, disconnect the vehicle fuel lines from the fuel rail. There
are now four open ends to connect to: the Pre s s u r e L i n e from the fuel ta nk, the other
Pressure Line going to the rail, the Return Line from the fuel rail, and the other Return
Line to the fuel tank.
6. Connect the proper adapters to the above listed connection points as shown in the
following illustration.
ESX RED HOSE
FILTER
PRESSURE LINE
ADAPTER
ADAPTER
TEE ADAPTER
LOOP ADAPTER
ADAPTER
ADAPTER
PRESSURE LINE
FUEL RAIL
VEHICLE FUEL TANK
RETURN LINE
FUEL
PRESSURE
REGULATOR
RETURN LINE
Page 7
Port Fuel Injection (PFI) Setup
7. Attach the Tee adapter to both pressure line adapters, the valve should be in the closed
position. Then connect the ESX Red H ose to the valve on the Tee adapter as shown in the
previous illustration.
8. Attach Loop adapter to both return side adapters as shown in the previous illustration. Note
that the ESX Black Hose is not used at this time.
9. Start the vehicle, turn the Tee adapter valv e counterclockwise to open it. C heck for leaks.
Watch the Fuel Pressure gauge on the ESX control panel. A drop in pressure could
indicate a leak.
CAUTION - CAUTION - CAUTION
-DIAGNOSTICS-
The fuel system is now ready to perform diagnostic tests. The Leakdown Test has to be
performed prior to the pre-cleaning procedure to eliminate the possibility of a leaky
injector. If an injector is leaking and the operator continues without testing, a cylinder
may fill with gasoline and cause serious engine damage or possible engine failure. For
instructions on how to perform all of the diagnostic tests, refer to the Vehicle
Diagnostic section (see Page 23 ). Once completed, continue with Step 10 below.
10. Press and hold the Fill/Purge button on the Keypad until the Fuel Level window
indicates an increase of 1/4 in the ESX fuel tank. If the vehicle stalls, turn the valve on
the Tee adapter 1/8 turn clockwise. Restart the vehicle and slowly open the valve, by
turning counterclockwise, until the engine starts to stutter. Ease the valve back until the
engine smooths and continue filling. If the vehicle repeatedly stalls repeat this step until
ESX fuel tank is 1/4 full.
11. Turn OFF the vehicle.
12. Add 8 oz. of RTI FUEL SYST EM CLEANER, through the ESX fill port for e very 1/4
added to the ESX fuel tank.
13. Press and hold the Fill/Purge button for five seconds to relieve the pressure in the ESX
Red Hose.
CAUTION: Flammable liquid can squirt out of pressurized fuel lines when connecting
or disconnecting. Always wear eye protection. Obtain zero pressure before
connecting or disconnecting any fuel lines or adapters. Always wear
chemical resistant gloves when connecting or disconnecting fuel lines.
Wrap a shop rag around the pressure point when connecting or
disconnecting. Avoid exposure to flames, sparks, hot engine parts, and/or
ignition sources. By not following the above cautionary steps the operator
will be subjecting himself to serious injury or possible death.
Page 8
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