Fuel Injection Fitting Kits - OTC Tools

1 fuel Injection Fitting KitsReference Guide for:Domestic KitImport KitMaster KitSafety PrecautionsWARNING: The following safety precautions must be observed to reduce the risk of fire and personal injury: Have a Class B fire extinguisher nearby whenworking on fuel Injection systems. Observe nor-mal precautions for working with flammable liq-uids: no smoking, open flames, electrical sparks,etc. Use fuel Injection Fitting kits on gasolineengines only. Release fuel system pressure before servicingfuel system components Residual line pressure can cause fuel a shop towel around pressure tap fittingswhen connecting and disconnecting adapters orremoving the gauge assembly hose.

2 Wipe up fuelspills immediately; protect painted surfaces fromfuel spills. Clean or dispose of towels accordingto local, state, and federal regulations. Tighten all connections before checking fuel pres-sure. Use the vehicle manufacturer's recommendedprocedures to service injectors. Replace injectoro-rings whenever injectors are removed. Keepdirt out of the system. Read and understand all instructions and safetyprecautions before servicing fuel Injection sys-tems. If the operator cannot read English, operat-ing instructions and safety precautions must beread and discussed in the operator's native lan-guage.

3 Si el operador no puede leer el ingl s,las instrucciones de operaci n y las precaucionesde seguridad deber n leerse y comentarse en elidioma nativo del operador. Si l'utilisateur ne peut lire l'anglais, les instruc-tions et les consignes de s curit doivent lui treexpliqu es dans sa langue maternelle. Wear eye protection that meets ANSI andOSHA requirements. Keep Tools , electrical cords, and hoses awayfrom moving engine parts. Do not modify any components of the gaugeassembly, adapters, or accessories. If it is neces-sary to replace parts, use only OTC replacementparts. Vent exhaust to the outside while running Vehicles GM.

4 18 Connecting at the fuel Filter 18 Connecting at the Throttle Body .. 19 Connecting to the Supply Line 20 Connecting into the Return Line .. 21 MPFI, MPI, PFI, and SFI Vehicles .. 22 Connecting at the fuel Filter 22 Connecting into the Supply 23 Connecting at the fuel Rail .. 24 Connecting to the Supply Line 25 Import Vehicle Connections Asian .. 26(AFC, EFI, MFI, PGM, and Single Point Vehicles)Connecting at the fuel Filter 26 Connecting at the Cold Start 27 Connecting at the fuel Rail .. 28 Connecting to the Supply Line 29 Import Vehicle Connections 30 AFC 30 Connecting at the fuel Filter 30 Connecting at the Cold Start 31 Connecting at the fuel Rail.

5 32 CIS 33 CISE 34 Kit 4 Domestic 4 Import 5 Master 6 Components / 7 About fuel Systems and Testing .. 12 General Test Instructions .. 13 Specific 14 Static (Running) fuel 14 fuel 14 fuel Pressure Leak 14 fuel Pump Output Pressure ( Dead Head ).. 14 Cold Control Pressure (CIS) .. 15 Hot Control Pressure (CIS) .. 15 Rest Pressure (CIS).. 15 Primary System Pressure (CIS)[ fuel Pump Output - Dead Head ].. 15 System Pressure (CISE).. 15 Residual Pressure (CISE).. 15 Domestic Vehicle Connections .. 16 CFI Vehicles 16 TBI Vehicles AMC and 17 Contents4 Kit ComponentsDomestic Kit111230313233425 Kit ComponentsImport Kit11126 Kit ComponentsMaster Kit11123031323342 Components / ApplicationsItem Application(see page # for connection illustration)710 518483 3-1/2" Pressure GaugeAll tests - connects to No.

6 11with protective boot and hanger0-100 psi (0-7 BAR)11 518530 Gauge Hose Assembly with relief valveAll tests - connects to No. 10 (valve used forand drain tubepressure release and for volume tests)12 518356 TBI/CIS Hose Assembly with shutoff valveConnects to Nos. 10 and 11 for pressure tests forGM TBI - supply line (page 19), fuel pump (page 20),and return line (page 21)European CIS - primary system (page 33)13 518477 Seal KitReplacement seals, o-rings, quick couplers14 518480 Double Ended Hose Adapter; 5/16", 3/8"AMC and Chrysler TBI (page 17)(use with hose and clamp in AccessoryAMC and Chrysler MPFI (pages 22, 23)compartment; use hose that fits fuel line)Diahatsu EFI (page 28)Subaru Single Point (page 28)Asian AFC (page 28)European AFC (page 32)15 518478 Single Ended Hose Adapter.

7 MPI - (page 25) for fuel pump deadhead test5/16", 3/8", 1/4"EFI and MFI(page 29)30 518495 Ford MPI AdapterFord MPI (page 24)Components / ApplicationsItem KitDomesticImportDescriptionGraphicCommo n Application(see page # for connection illustration) 5185427/16" x 20 GM/Chrysler AdapterChrysler and Jeep MPFI (page 24)GM MPI (page 24)32 5184765/16" Hairpin AdapterFord CFI (page 16)Chrysler MPFI (pages 22, 23)GM MPI (pages 22, 23)33 5185273/8" Hairpin AdapterChrysler MPFI (pages 22, 23)GM MPI (pages 22, 23)34 5185345/8"-18 External Flare AdapterGM TBI - early systems, supply line (page 19)used with No.

8 3535 5185355/8"-18 Internal Flare AdapterGM TBI - early systems, supply line (page 19)used with No. 3436 518481 16 mm x External O-ring AdapterGM TBI - supply line (pages 19, 20)used with No. 3737 518472 16 mm x Internal O-ring AdapterGM TBI - supply line (pages 19, 20)used with No. 36 Components / ApplicationsItem KitDomesticImportDescriptionGraphicCommo n Application(see page # for connection illustration) 518473 14 mm x External O-ring AdapterGM TBI - return line (page 21)39 518474 14 mm x Internal O-ring AdapterGM TBI - return line (page 21)40 518482 14 mm x External O-ring PlugGM TBI - return line plug for fuel pump deadhead test (page 20)41 518487 16 mm x In-Line AdapterGM TBI - used in fuel filter location (page 18)

9 42 518499 Ford Spring Lock AdapterFord MPI - 2003 and newer with returnless fuelsystem, 1985 and newer with return fuel system(page 23)66 518490 M6 x External O-ring AdapterAcura and Honda PGM (page 26)67 518491 M8 x External Banjo AdapterAsian AFC, EFI, MFI (pages 27, 28)European AFC (pages 31, 32)European CIS and CISE (pages 33, 34)10 Components / ApplicationsItem KitDomesticImportDescriptionGraphicCommo n Application(see page # for connection illustration) 518492M10 x External Banjo AdapterAsian AFC, EFI, MFI (pages 27, 28)European AFC (pages 31, 32)European CIS and CISE (pages 33, 34)69 518493M12 x External Banjo AdapterAsian AFC, EFI, MFI (pages 27, 28)European AFC (pages 31, 32)European CIS and CISE (pages 33, 34)70 518494M12 x External Banjo AdapterAcura and Honda PGM (page 26)Asian AFC - mostly Toyota (pages 27, 28)European AFC (pages 30, 31, 32)European CIS and CISE (pages 33, 34)71 518501M14 x External Banjo AdapterToyota AFC (pages 27, 28)72 518537 M8 x Internal O-ring Adapter (long)European CIS (page 33)European CISE (page 34)73 518485 M8 x Internal O-ring AdapterEuropean CIS (page 33)

10 European CISE (page 34)74 518536 M8 x External O-ring Adapters (2)European CIS (page 33)European CISE (page 34)Components / ApplicationsItem KitDomesticImportDescriptionGraphicCommo n Application(see page # for connection illustration) 518488 M8 x External O-ring Adapter (long)European CIS (page 33)European CISE (page 34)76 518484M10 x Internal O-ring AdapterEuropean CIS (page 33)European CISE (page 34)77 518489M10 x External O-ring AdapterEuropean CIS (page 33)European CISE (page 34)78 518486M12 x Internal Swivel Adapters (2)European CIS (page 33)European CISE (page 34)79 518498M14 x External and InternalEuropean CIS (page 33)Swivel AdapterEuropean CISE (page 34)80 5184971/4" BSPT External and InternalEuropean CIS (page 33)Swivel AdapterEuropean CISE (page 34)81 518496M16 x External and InternalEuropean CIS (page 33)Swivel AdapterEuropean CISE (page 34)12 About fuel Systems and TestingA vehicle s fuel delivery and return system consists of a circularsystem of components.