Fuel Injection Pump Tester

Owner’s Manual & Safety InstructionsSave This Manual Keep this manual for the safety warnings and precautions, assembly,operating, inspection, maintenance and cleaning procedures. Write the product’s serial number in theback of the manual near the assembly diagram (or month and year of purchase if product has no number).Keep this manual and the receipt in a safe and dry place for future reference.REV 15cITEM 62623Fuel InjectionPump TesterVisit our website at: http://www.harborfreight.comEmail our technical support at: productsupport@harborfreight.comWhen unpacking, make sure that the product is intactand undamaged. If any parts are missing or broken,please call 1-888-866-5797 as soon as possible.Copyright 2005 by Harbor Freight Tools . All rights reserved.No portion of this manual or any artwork contained herein may be reproduced inany shape or form without the express written consent of Harbor Freight Tools.Diagrams within this manual may not be drawn proportionally. Due to continuingimprovements, actual product may differ slightly from the product described herein.Tools required for assembly and service may not be included.Read this material before using this product.Failure to do so can result in serious injury.SAVE THIS MANUAL.

SpecificationsCompatibilityFor most fuel injectionsystems except:Bosch CIS Jetronic Throttle Body Systemson GM vehiclesPressure Gauge0 100 PSI, 0 7 Bar,1/4″ - 18 NPT SwivelIMPORTANT SAFETYINFORMATIONThe warnings, precautions, and instructionsdiscussed in this instruction manualcannot cover all possible conditionsand situations that may occur. It mustbe understood by the operator thatcommon sense and caution are factorswhich cannot be built into this product,but must be supplied by the operator.1.Do not use on diesel engines.2.Stop engine, loosen gas capand relieve fuel pump pressure(see service manual) beforeopening fuel line. Do not changefittings with engine running.3.Before testing fuel system,verify all connections aretight to eliminate leaking.4.Gasoline is highly flammable.Do not smoke, or test near openflames or a source of electricalsparks. Do not allow gasoline tocome in contact with the hot manifoldsor other engine components.If additional lighting is required,use only explosion proof drop-light.5.Do not drive the vehiclewhile under test.Page 26.Before testing, review and followinstructions from the vehiclemanufacturer’s service manual.7.After testing, turn engine off anddepressurize system beforeremoving test components. Placeabsorbing cloths around fittingsbefore disconnecting. Wipe upany spilled fuel immediately. Placecloths in a fireproof container.8.Clean all testing components ofresidual fuel before storing.9.Wear ANSI‑approved safety gogglesand heavy‑duty work glovesduring setup and use.10. This product is not a toy. Do not allowchildren to play with or near this item.11. Use as intended only.12. Inspect before every use; do notuse if parts are loose or damaged.13. Perform service in a well‑ventilated,outdoor location. Not only aregasoline fumes flammable, butcarbon monoxide is produced bya running engine. This is a deadlygas that you cannot see or smell.14. WARNING! The brass components ofthis product contain lead, a chemicalknown to the State of California tocause cancer and birth defects or otherreproductive harm. (California Health& Safety Code § 25249.5, et seq.)15. WARNING: This product containsdi (2-ethylhexyl) phthalate (DEHP),a chemical known to the State ofCalifornia to cause cancer andbirth defects or other reproductiveharm. (California Health &Safety Code § 25249.5, et seq.)16. Maintain product labels andnameplates. These carry importantsafety information. If unreadable ormissing, contact Harbor Freight Toolsfor a replacement.For technical questions, please call 1-888-866-5797.Item 62623

Connect Directlyto Special TestOutlet on EngineOperating InstructionsRead the ENTIRE IMPORTANTSAFETY INFORMATION sectionat the beginning of thisdocument including all text undersubheadings therein before set up or useof this product.1.WARNING! Before makingconnections and testing,place a dry chemical (Class B)fire extinguisher nearby.Fitting (3)Attach FemaleSwivel Coupling toEngine Test FittingFitting (2)FlexHose (9)NOTE: Pressure Gauge connectionsare made either directly to the pump, orin-line between the pump and engine.2.3.Relieve fuel line pressure fromvehicle fuel system. Refer tovehicle manufacturer’s servicemanual for instructions on relievingpressure from fuel line, testingprocedures and connection points,and normal pressure readings.Use various fittings and hoses toconnect Pressure Gauge (1) directlyto fuel pump; as in the case of VW ,or in-line between the fuel pumpand engine for most other vehicles.See connection examples that follow.Fuel Lineto Engine1/4″ Hose (5)from Fuel PumpTypical 1/4″ Connection1/4″ Hose (5)VW ConnectionCadillac - Bendix Connection4.Use small amount of pipe compound orPTFE thread seal tape on connectionthreads to prevent leaks.Tighten using wrench (not supplied).CAUTION! Make sure all connectionsare tight to avoid fuel leaks.5.Start engine and immediately checkfor fuel leaks. If fuel leaks are found,turn engine off and fix leaks.6.Read pressure off Pressure Gauge.7.Turn off engine and removekeys from ignition.8.Wrap cloth around hose connectionpoint before relieving pressure from fuelline and removing testing components.9.Reconnect vehicle’s fuel injection line.10. Wipe up any spilled fuel.Dispose of fuel-soaked ragsin a fireproof container.11. Start engine and check for leaks.Fix leaks if found.Fuel Lineto Engine3/8″ Hose (6)from Fuel Pump12. Clean and store Fuel Injection Test Kitcomponents and place in plastic kit bag.Typical 3/8″ ConnectionItem 62623For technical questions, please call 1-888-866-5797.Page 3

Fuel Pump Pressure ExamplesNote: Read the vehicle’s service manual to determine the actual Fuel Pump pressure.The chart below is only provides a general frame of reference for pump pressure.U.S. Built VehiclesCadillac - EFICadillac 37.5 – 41- DEFI9 – 12Imperial Lincoln 8&Versailles 30 – 40Foreign Built VehiclesAlfa Romeo Alliance (49 states)Audi-Fox Pump Pressure(PSI)16 – 18Bendix TypeAlliance (California only) L-Jetronic 28 – 363666.8 – 75.3BMW 21.7 – 40Datsun 28 – 43Fiat 28 – 30Jaguar 28 – 30MercedesBenz Porsche Renault Page 4Pump Pressure(PSI)29 – 3028.417TS35Saab 27Volkswagen 28Volvo 28For technical questions, please call 1-888-866-5797.Item 62623

PLEASE READ THE FOLLOWING CAREFULLYTHE MANUFACTURER AND/OR DISTRIBUTOR HAS PROVIDED THE PARTSLIST AND ASSEMBLY DIAGRAM IN THIS MANUAL AS A REFERENCE TOOLONLY. NEITHER THE MANUFACTURER OR DISTRIBUTOR MAKES ANYREPRESENTATION OR WARRANTY OF ANY KIND TO THE BUYER THAT HEOR SHE IS QUALIFIED TO MAKE ANY REPAIRS TO THE PRODUCT, OR THATHE OR SHE IS QUALIFIED TO REPLACE ANY PARTS OF THE PRODUCT. INFACT, THE MANUFACTURER AND/OR DISTRIBUTOR EXPRESSLY STATES THATALL REPAIRS AND PARTS REPLACEMENTS SHOULD BE UNDERTAKEN BYCERTIFIED AND LICENSED TECHNICIANS, AND NOT BY THE BUYER. THE BUYERASSUMES ALL RISK AND LIABILITY ARISING OUT OF HIS OR HER REPAIRS TOTHE ORIGINAL PRODUCT OR REPLACEMENT PARTS THERETO, OR ARISINGOUT OF HIS OR HER INSTALLATION OF REPLACEMENT PARTS THERETO.Item 62623For technical questions, please call 1-888-866-5797.Page 5

Parts List and DiagramParts ListPartQtyPart1Pressure Gauge15Rubber Hose (1/4″ x 2.5″ L)12Brass Fitting(1/8″ - 27 NPT x 1/4″ - 18 NPT)16Rubber Hose (3/8″ x 3″ L)1Short Flex Hose13Brass Fitting(1/4″ Barbed x 1/4″ - 18 NPT)718Medium Flex Hose1Aluminum Fitting(1/4″ & 3/8″ Barbedx 1/8″ - 24 NPT)9Long Flex Hose1110Hose Clamp24DescriptionDescriptionQtyRecord Product’s Serial Number Here: Note:If product has no serial number, record month and year of purchase instead.Note: Some parts are listed and shown for illustration purposesonly, and are not available individually as replacement parts.Page 6For technical questions, please call 1-888-866-5797.Item 62623

Diagram86534127109Item 62623For technical questions, please call 1-888-866-5797.Page 7

Limited 90 Day WarrantyHarbor Freight Tools Co. makes every effort to assure that its products meet highquality and durability standards, and warrants to the original purchaser that thisproduct is free from defects in materials and workmanship for the period of 90 daysfrom the date of purchase. This warranty does not apply to damage due directly orindirectly, to misuse, abuse, negligence or accidents, repairs or alterations outsideour facilities, criminal activity, improper installation, normal wear and tear, or to lack ofmaintenance. We shall in no event be liable for death, injuries to persons or property,or for incidental, contingent, special or consequential damages arising from the useof our product. Some states do not allow the exclusion or limitation of incidental orconsequential damages, so the above limitation of exclusion may not apply to you. THISWARRANTY IS EXPRESSLY IN LIEU OF ALL OTHER WARRANTIES, EXPRESS ORIMPLIED, INCLUDING THE WARRANTIES OF MERCHANTABILITY AND FITNESS.To take advantage of this warranty, the product or part must be returned to uswith transportation charges prepaid. Proof of purchase date and an explanationof the complaint must accompany the merchandise. If our inspection verifiesthe defect, we will either repair or replace the product at our election or we mayelect to refund the purchase price if we cannot readily and quickly provide youwith a replacement. We will return repaired products at our expense, but if wedetermine there is no defect, or that the defect resulted from causes not within thescope of our warranty, then you must bear the cost of returning the product.This warranty gives you specific legal rights and you may alsohave other rights which vary from state to state.3491 Mission Oaks Blvd. PO Box 6009 Camarillo, CA 93011 1-888-866-5797

to fuel pump; as in the case of VW , or in-line between the fuel pump and engine for most other vehicles. See connection examples that follow. Typical 1/4″ Connection Fuel Line to Engine 1/4″ Hose (5) from Fuel Pump Typical 3/8″ Connection Fuel Line to Engine 3/8″ Hose (6) from Fuel Pump Connect Directly to Special Test Outlet on Engine