Mityvac MV5545 User manual

USER’S MANUAL
FST PRO FUEL SYSTEM TESTER
MODEL MV5545

Cont nts
Introdu tion...............................................3
SafetyPre autions .........................................3
Spe ifi ations .............................................3
Components, Servi e Parts, and A essories . . . . . . . . . . . . . . . . . . . 3
StandardKitComponents................................3,4
Servi eParts.............................................5
FuelSystemTestAdapters................................6-7
Assembly................................................8
BypassHose ..........................................8
FlowmeterFa eplates...................................8
Conne tions .............................................8
Adapters..............................................8
BanjoConne tions......................................9
FlexHoseConne tions.................................10
Proper Use, Care, and Servi ing . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Prin ipleofOperation......................................11
Fuel Delivery Basi s . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Appli ationoftheFST ....................................11
Diagnosing Fuel Delivery Systems . . . . . . . . . . . . . . . . . . . . . . . . . . 11
SimulatingEngineDemand..............................12
Pinpointing Fuel System Malfun tions . . . . . . . . . . . . . . . . . . . . . 13
TypesofFuelDeliverySystems..............................14
Return Fuel Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
ReturnlessFuelSystems..................................14
Me hani allyRegulated.................................15
In-tank Filtering/In-tank Return . . . . . . . . . . . . . . . . . . . . . . . . . 15
External Filtering/In-tank Return . . . . . . . . . . . . . . . . . . . . . . . . 15
External Filtering/External Return . . . . . . . . . . . . . . . . . . . . . . . 15
Ele troni allyRegulated.................................16
Identifying Fuel Delivery Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
FuelSystemComponents..................................17
FuelTank...............................................17
Fuel Pump. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Fuel Inlet Strainer/So k . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Fuel Filter. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
PressureRegulator.......................................18
Fuel Lines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
SetupandInstallation......................................19
Determining Where to Install the FST . . . . . . . . . . . . . . . . . . . . . . . . 19
InlineConne tion......................................19
Alternative Conne tion Lo ations . . . . . . . . . . . . . . . . . . . . . . . . . 19
Sele ting and Installing Adapters . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
SettinguptheFSTPro....................................20
InstallingtheFSTPro.....................................20
TestingandDiagnosti s....................................22
ReturnFuelSystems .....................................22
Returnless Fuel Systems (Me hani al) . . . . . . . . . . . . . . . . . . . . . . . 26
Returnless Fuel Systems (Ele troni ) . . . . . . . . . . . . . . . . . . . . . . . . 28
Fuelvisualization.........................................31
PressureLeakdownTest ..................................31
Dis onne tingtheFST.....................................32
AppendixA..............................................34
AppendixB..............................................36
AppendixC..............................................38
AppendixD..............................................40
Page Numbe - 2

Introduction
The Mityva FST Pro Fuel System Tester is an advan ed
diagnosti tool designed for troubleshooting and pinpointing
ommon automotive fuel delivery system malfun tions,
in luding:
• Failing fuel pump
• Faulty pressure regulator
• Blo ked inline filter
• Blo ked inlet strainer/so k
• Pin hed or rushed fuel line
• Fuel ontamination
• Fuel tank vortex
• Fuel system leaks
This manual fo uses on the appli ation of the FST to modern
ele troni fuel inje tion (EFI) systems. However, it is equally
apable of diagnosing earlier fuel inje tion systems su h as
throttle body inje tion (TBI), ontinuous inje tion (CIS) and even
pre-fuel inje tion arbureted systems. A separate low pressure
gauge is available from Mityva for systems that operate below
15 PSI (100 kPa).
Saf ty Pr cautions
The use of this servi e tool requires the exposure of highly
flammable gasoline. To prevent fires, explosions and/or severe
injury, always apply extra pre autions when diagnosing or
working on fuel systems.
The FST Pro is designed for servi ing a variety of vehi les in a
safe, onvenient manner. However, fuel delivery systems vary
widely between makes and models of vehi les, potentially
requiring additional steps or equipment to perform a proper
servi e job. The pro edures outlined in this manual are to serve
as guidelines for the use of this equipment. In addition to these
guidelines, always follow the manufa turer’s re ommended
pro edures when servi ing ea h unique vehi le. Use ommon
sense in the appli ation of this tester; and do not attempt to
for e a test on a fuel system for whi h this equipment is not
designed to perform.
This tester is designed for use on gasoline/petrol engines only.
It is safe for use with gasoline and most gasoline additives, but
is not ompatible with diesel fuel or alternative/flex fuels that
ontain ethanol.
• Always read arefully and understand instru tions prior to
using this equipment
• Wear safety glasses at all times
• Operate the vehi le only in a well ventilated area, and away
from potential sour es of flame or ignition.
• Prior to starting an engine, make sure all omponents of the
tester, body parts, and personal lothing are lear of rotating
engine omponents
• Avoid burns by remaining autious of engine parts that may
be ome hot when the engine is running
• Never leave a vehi le unattended while testing
• Che k and se ure all fuel system onne tions before
starting the vehi le or a tivating the fuel pump
• Wear gloves and prote tive lothing to avoid the onta t of
gasoline on skin. If onta t o urs, immediately wash the
area and perform ne essary first aid
• Always keep a fire extinguisher on hand when performing
fuel related diagnosti s. Make sure the extinguisher is rated
for fuel, ele tri al and hemi al fires
• Avoid spilling fuel on hot engine parts. Clean-up any fuel
spills immediately after they o ur.
Spec f cat ons
Maximum Flow Capa ity: 1.0 gallon/minute (3.8 liters/minute)
Maximum Rated Pressure: 200 PSI (1340 kPa) (13.8 bar)
Compon nts, S rvic Parts
and Acc ssori s
The Mityva FST Pro ombines the highest quality materials
and workmanship to reate a durable, finely tuned diagnosti
tool, whi h with proper are will provide years of valuable
servi e. All omponents are designed and quality ontrolled
in the U.S.
Following is a list of standard omponents, servi e parts and
a essories relating to model MV5545. Components and
a essories are available from your lo al Mityva distributor.
Servi e parts, warranty information and te hni al servi e
information are available at the onta t information shown on
the front of this user manual.
Standard K t Components
Model MV5545 in ludes the following high quality omponents:
• 3.5" (90 mm) diameter diaphragm style Pressure Gauge
- 0 to 120 PSI (0 to 8 bar) (0 to 800 kPa) s ale of measure
- Push-button pressure relief valve
- 360° swivel hook
- Prote tive rubber boot
• Flowmeter Assembly
- Borosili ate glass variable area flowtube with prote tive
shield and pre ision aluminum float
- 3-way Flow Control Valve
- Fuel bypass port
- Male push-to- onne t, qui k- hange oupler
w/ S hrader valve
- (2x) Male SAE J2044 qui k- onne ts
- Repla eable fa eplates with 0 to 1.0 gallon/minute
s ale of measurement
- Prote tive rubber boot
• (2x) Repla eable flowmeter fa eplates with 0 to 4 liters/
minute s ale of measurement
• 1/8" (3 mm) ID x 6' (1.8 m) long Pressure Relief Hose
• 1/4" (6.5 mm) ID x 6' (1.8 m) long Bypass Hose
• (2x) Flowmeter Conne tion Hose
• (2x) S issor Hose Clamp
• (2x) Hose Plug
• (6x) Qui k- onne t Repla ement Clip
• Custom Storage Case
• Automotive Fuel System Test Adapters
(see Fuel System Test Adapters on page 6)
Page Numbe - 3

MVA5552
MVA5549
MVA509
Standard Kit Compon nts
Part Numb r D scription
824141 High Pressure Gauge
824149 Pressure Relief Hose (1/8"/3mm ID x 6'/1.8 m long)
824148 Bypass Hose (1/4"/6.5 mm ID x 6'/1.8 m long)
824144 S issor Hose Clamps (Qty 2)
824147 Flowmeter Hose (3/8"/9.5 mm ID x 4'/1.2 m long)
824173 Hose Plug (Qty 2)
824143 Flowmeter Fa eplates (Liters/Minute)
in ludes front and ba k plate
824142 Flowmeter Fa eplates (Gallons/Minute)
in ludes front and ba k plate
824172 Qui k- onne t Repla ement Clips (Qty 6)
824179 Storage Case
824141
824149 824148
824147824144
824143
824173 824172
824142
824179
Page Numbe - 4
Acc ssori s
Part Numb r D scription
MVA500 Low Pressure Gauge
MVA501 Flowmeter Fa eplate (0 to 60 Gallons/Hour)
in ludes front and ba k plate
MVA5549 MotorVa Adapter Set
MVA5552 Pressure Test A essory Kit
MVA506 Inline Pressure Test Assembly
MVA509 Extended Pressure Test Hose

Page Numbe - 5
S rvic Parts
Part Numb r D scription
1 824182 Flow Tube Shield
2 824177 Male Qui k-Conne t Fitting
3 824176 Bypass Port
4 824175 Flow Control Valve Knob
5 824174 Flowmeter Inlet/Outlet Conne tor (Qty 2)
6 824146 Flow Control Valve
7 824145 Flowmeter Seal Kit
824183 Wing-Style Hose Clamp (Qty 4)
824181 Flowmeter Boot
824180 Adapter O-Ring Kit
824178 Ford Springlok Tether with Clip
824181
824182
824178
824180
824174
824175
824145
824146
824176824177
824183
2
3
7
1
7
7
10
7
6
4
5