Mityvac MV5546 User manual

USER’S MANUAL
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Page
Section - MV64 - 1
Form 824129
OCT - 2007
Fuel Pressure Test Kit
MODEL MV5546

Page Number - 2
Fuel Pressure Test Kit
MODEL MV5546
Form 824129
Table of Contents
Introduction...............................................................................3
Safety Precautions....................................................................3
Specications...........................................................................3
Accessories ..............................................................................4
ServiceParts.............................................................................4
FuelSystemTestAdapters..........................................................5
FuelSystemPressureTesting.....................................................7
TestProcedures.........................................................................8
Connections............................................................................11

Page Number - 3
Fuel Pressure Test Kit
MODEL MV5546
Form 824129
Introduction
The Mityvac Fuel System Pressure Test Kit is designed to
perform fuel pressure testing on most domestic and imported
cars and trucks that are equipped with return and returnless
electronic fuel injection systems.
The tester can help identify and diagnose:
Low fuel pressure•
Faulty fuel pump•
Faulty fuel pressure regulator•
Leaking fuel injectors•
Cloggedfuellter•
Pinched fuel lines•
Safety Precautions
The use of this service tool requires the exposure of highly
ammablegasoline.Topreventres,explosionsand/orsevere
injury, always apply extra precautions when diagnosing or
working on fuel systems.
The fuel pressure test kit is designed for servicing a variety of
vehicles in a safe, convenient manner. However, fuel delivery
systems vary widely between makes and models of vehicles,
potentially requiring additional steps or equipment to perform a
proper service job. The procedures outlined in this manual are
to serve as guidelines for the use of this equipment. In addition
to these guidelines, always follow the manufacturer’s recom-
mended procedures when servicing each unique vehicle. Use
common sense in the application of this tester; and do not at-
tempt to force a test on a fuel system for which this equipment
is not designed to perform.
Always read carefully and understand instructions prior to•
using this equipment
Wear safety glasses at all times•
Operate the vehicle only in a well ventilated area, and•
awayfrompotentialsourcesofameorignition.
Prior to starting an engine, make sure all components of•
the tester, body parts, and personal clothing are clear of
rotating engine components
Avoid burns by remaining cautious of engine parts that•
may become hot when the engine is running
Never leave a vehicle unattended while testing•
Check and secure all fuel system connections before•
starting the vehicle or activating the fuel pump
Wear gloves and protective clothing to avoid the contact of•
gasoline on skin. If contact occurs, immediately wash the
areaandperformnecessaryrstaid
Alwayskeepareextinguisheronhandwhenperform-•
ing fuel related diagnostics. Make sure the extinguisher is
ratedforfuel,electricalandchemicalres
Avoid spilling fuel on hot engine parts. Clean-up any fuel•
spills immediately after they occur.
Specications
Maximum Rated Pressure: 120 PSI (800 kPa) (8 bar)
Components, Service Parts and Accessories
The Mityvac Fuel Pressure Test Kit combines the highest
qualitymaterialsandworkmanshiptocreateadurable,nely
tuned diagnostic tool, which with proper care will provide years
of valuable service. All components are designed and quality
controlled in the U.S.
Following is a list of standard components, service parts and
accessories relating to model MV5546. Components and
accessories are available from your local Mityvac distributor.
Service parts, warranty information and technical service
information are available at the contact information shown on
the front of this user manual.
Standard Kit Components
Model MV5546 includes the following high quality components:
3.5” (90 mm) diameter diaphragm style Pressure Gauge•
– 0 to 120 PSI (0 to 8 bar) (0 to 800 kPa) scale of
measure
– Push-button pressure relief valve
– 360° swivel hook
– Protective rubber boot
1/8”(3mm)IDx6’(1.8m)longPressureReliefHose•
5/16”(8mm)IDx4’(1.2m)longExtendedPressureHose•
Inline Pressure Test Hose•
(2x) Scissor Hose Clamp•
Custom Storage Case•
Automotive Fuel System Test Adapters (see pages 5 – 6)•
(6x) Quick-connect Replacement Clip•

Page Number - 4
Fuel Pressure Test Kit
MODEL MV5546
Form 824129
Accessories
Part Number Description
MVA500 Low Pressure Gauge
MVA506 Inline Pressure Test Hose
MVA509 ExtendedPressureTestHose
MVA5552 Pressure Test Accessory Kit
MVA5553 Flowmeter Upgrade Kit
MVA502 American Adapter Kit
MVA503 EuropeanAdapterKit
MVA504 Asian Adapter Kit
Service Parts
Part Number Description
824183 Wing-Style Hose Clamp (Qty 4)
824178 3/8”SpringlockTetherwithClip
824193 1/2”SpringlockTetherwithClip
824172 Quick Connect Replacement Clips
824179 Storage Case
824141 High Pressure Gauge
824149 PressureReliefHose(1/8”(3mm)x6’(1.8m)long
824144 Scissor Hose Clamps (Qty 2)

Page Number - 5
Fuel Pressure Test Kit
MODEL MV5546
Form 824129

Page Number - 6
Fuel Pressure Test Kit
MODEL MV5546
Form 824129

Page Number - 7
Fuel Pressure Test Kit
MODEL MV5546
Form 824129
Connections
Adapters
The MV5546 includes a selection of adapters for connecting to
the pressure test port or inline with the fuel delivery systems of
a wide range of automotive makes and models. The chart on
pages 5 and 6 outlines the adapters available, and their appli-
cations.Eachadapterisetchedwithanidenticationnumber
for easy reference. Adapters can be purchased separately in
sets according to the order number indicated in the chart.
In most cases, selecting and installing adapters into the fuel
delivery system and connecting the inline pressure test hose
for testing, is straightforward and logical. Simply match the fuel
system connection to the equivalent male and female adapter
set, and install them as outlined in the instructions later in this
manual.
Banjo Connections
Banjo style connections are commonly used by many Asian
andEuropeanmanufacturerstoconnectahoseorfuellineto
thelterand/orthefuelrail.Often,thiswillbethebestplaceto
connect the inline pressure test hose with the fuel system. This
typeofconnectionmaybealittleconfusingthersttimeitis
encountered.
A banjo connection consists of a round, hollowed-out “banjo”
connectorwithtwoatsides.Ahollowboltwithacross-hole
passes through the banjo connector and threads into the
connectingcomponent(i.e.lter,fuelrail).Whentheboltis
tightened, it creates a secure face-to-face seal through which
thefuelows.SeeFig.1foranillustrationofthisconnection.
Two (2) threaded adapters and a closed end nut are required
to properly install the inline pressure test hose into a banjo
style connection. Refer to the adapter chart on pages 5 and 6
for a list of the banjo adapters included with the kit. To install
the banjo adapters:
1. Follow the proper procedure recommended by the manu-
facturer to relieve the fuel pressure and proportion for
disconnecting.
2. Loosen and remove the bolt from the banjo connection at
thefuellterorfuelrail.
3. Pass the hollow adapter with the cross-hole through the
banjotting.Besuretoincludeawasheronbothsidesof
thebanjotting(Fig.2).
4. Thread the closed-end nut onto the end of the bolt and
tightensecurelywithawrench,trappingthebanjotting.
5. Thread the hollow bolt adapter without the cross-hole into
thelterorfuelrail,inplaceoftheoriginalbolt,andtighten
securely with a wrench. Be sure to include a washer
betweenthefaceofthelterorfuelrail,andtheopposing
face of the adapter bolt (Fig. 3).
6. Follow normal testing procedures.
NOTE: Always throw away the original used washers, and
replacethemwithnewwhenreconnectingthebanjotting
backtothevehicle’soriginalspecication.
Fuel Rail Banjo Fitting Banjo Bolt
Fig. 1
Banjo Bolt
Adapter
Banjo Fitting
Closed
EndNut
Fig. 2
Fig. 3
Banjo Adapter
Fuel Filter

Page Number - 8
Fuel Pressure Test Kit
MODEL MV5546
Form 824129
Flex Hose Connections
In many cases it is convenient to connect the inline pressure
test hose into the fuel delivery system at a location where
aexiblerubberhoseissecuredtoasteelfuellineusing
a screw clamp. A special adapter set is included with the
MV5546 for installing the inline pressure test hose into this
type of connection. It includes a universal barb adapter, three
exiblehoseadapters(1/4”,5/16”,3/8”),andfourwingscrew
clamps.
Toinstalltheexhoseadapters:
1. Follow the proper procedure under the setup instructions
to relieve the fuel pressure and prepare for disconnecting.
2. Loosen the screw clamp securing the rubber hose to the
steel fuel line on the vehicle’s fuel delivery system, and
carefully disconnect the rubber hose (Fig. 4).
3. Insert the universal barb adapter (#16) into the rubber
hose (Fig. 5) and tighten the hose clamp (Fig. 6).
4. Selecttheappropriatesizeexhoseadapter(1/4”,5/16”,
or3/8”),andinstallitontothesteelfuelline(Fig.7).Se-
cure it with one of the wing screw clamps provided
(Fig. 8).
5. Follow normal testing procedures.
Fig. 4
Fig. 5
Fig. 6
Fig. 7
Fig. 8

Page Number - 9
Fuel Pressure Test Kit
MODEL MV5546
Form 824129
Fig. 9 Fig. 10
To release the connection, press and hold the release but-
ton on the side of the female quick-connect, while pulling
theconnectionapart(Fig.11).Donotattempttoreleasethe
quick-connect connection using a disconnect tool, as this may
damagethetting.Replacementclipsareincludedifneeded.
Connection Types
The Mityvac MV5546 is capable of connecting to and testing
the following types of fuel systems:
1. All fuel injection systems that are factory equipped with
suitable fuel pressure test ports on the fuel rail (Schrader
valve ports).
2. Fuel injection systems that are equipped with a removable
fuel pressure inlet line that can utilize one of the many
adapters covered on Pages 5 & 6. Fuel injection systems
that are not equipped with a fuel pressure test port or a
removablepressurelinebutareequippedwithaexible
rubber hose line into the fuel rail.
The inline pressure test hose utilizes a special female quick-
connecttting(Fig.9).Thisttingwasselectedbecauseit
conformstotheSAEJ2044specicationforfuelttings,itis
a common fuel delivery system connection on which many
manufacturers are standardizing, and the connection releases
with a simple push-button action. No special tools are required
todisconnectthettings.
The pressure gauge extension hose, as well as the adapters
andttingsthatconnectintothefuelsystem,havethecom-
plimentingmaleSAEJ2044endform(Fig.10).Tosecurethe
male to female connection, simply push the male endform into
the female quick-connect until it snaps securely into place
(Fig. 11). Always test the connection by trying to pull it apart
without pressing the release button.
Fig. 11

Page Number - 10
Fuel Pressure Test Kit
MODEL MV5546
Form 824129
Fuel System Pressure Testing
Fuel Systems
There are two basic types of electronic fuel injections: Throttle
Body Injection (TBI) and Multi-port or Multi-point injection
(MFI). The tests outlined in this manual are for testing fuel
system pressure on these types of systems. On most vehicles,
two basic tests are performed when checking fuel system
pressure:
“Key on, engine on” (engine running) test1.
“Key on, engine off” (engine not running) test Connecting2.
to the Fuel System
Connecting to Systems with Existing Test Ports
Be sure the vehicle transmission is in park or neutral, the1.
parking brake is engaged, and the engine is off.
Follow the vehicle manufacturer’s recommended proce-2.
dure to relieve the pressure from the vehicle fuel delivery
system.
Locate the test port on the engine’s fuel rail.3.
Attach the correct test port adapter. The 90° adapters can4.
be used if the test port is in a tight space.
Connect the test port adapter to the extended pressure5.
hose
Connect the extended pressure hose to the pressure6.
gauge
Before proceeding:7.
Doublechecktheconnections.•
Route and secure the clear pressure relief hose into•
an approved gasoline container
Route any hoses away from any rotating engine com-•
ponents, belts, fans, and hot exhaust components
Reconnect components such as PCV tubes, wiring•
harnesses, vacuum tubes, etc., that were discon-
nected to gain access to the test port.
8. Re-enable the fuel pump (if previously disabled), and
cycle the ignition switch to the ON position for a brief time,
andthenbackOFF.Donotstarttheengine.
On most vehicles, cycling the ignition ON and OFF will
allowthefuelpumptorunbriey,andprimethesystem.
After cycling the ignition, check all fuel connections for
leaks.Ifallttingconnectionsaresecure,theinstallation
is complete and the fuel pressure tester is ready to be
used for diagnostic tests.
Connecting to System with Fuel System Adapters
Be sure the vehicle transmission is in park or neutral, the1.
parking brake is engaged, and the engine is off.
Follow the vehicle manufacturer’s recommended proce-2.
dure to relieve the pressure from the vehicle fuel delivery
system.
Locate the fuel supply line to the engine’s fuel rail, and3.
select the best location to disconnect the supply line and
install the inline pressure test assembly.
For additional assistance, consult the vehicle manufac-
turer’s service information.
If the engine has a cover, it will most likely have to be
removed to gain appropriate access.
Remove or disconnect any obstacles required to gain ac-4.
cess to the connection, and place shop towels under and
around the connection to absorb fuel from the disconnect-
ed line. To minimize fuel spillage and reduce the amount
of time the fuel line is disconnected, try to identify the type
of connection before disconnecting the fuel line, and have
the required fuel connection adapter(s) readily available.
Follow the vehicle manufacturer’s service information for5.
the proper method to disconnect the fuel line. Special
wrenches or disconnect tools may be required.
WARNING: Avoid spilling fuel on hot engine parts. Clean-
up any fuel spills immediately after they occur.
Install the appropriate adapter into the fuel supply line6.
extending from the tank.
Connect the inline pressure test assembly to the inlet and7.
outlet fuel line adapters
Connect the extended pressure hose to the tee in inline8.
pressure test assembly.

Page Number - 11
Fuel Pressure Test Kit
MODEL MV5546
Form 824129
Connect the pressure gauge to the other end of the ex-9.
tended pressure hose.
Before proceeding:10.
Doublechecktheconnections.•
Route and secure the clear pressure relief hose into•
an approved gasoline container
Route any hoses away from any rotating engine com-•
ponents, belts, fans, and hot exhaust components
Remove the fuel spillage rags•
Reconnect components such as PCV tubes, wiring•
harnesses, vacuum tubes, etc., that were disconnect-
ed to gain access to the fuel line connection.
Re-enable the fuel pump (if previously disabled), and11.
cycle the ignition switch to the ON position for a brief time,
andthenbackOFF.Donotstarttheengine.
On most vehicles, cycling the ignition ON and OFF will allow
thefuelpumptorunbriey,andprimethesystem.Aftercycling
theignition,checkallfuelconnectionsforleaks.Ifalltting
connections are secure, the installation is complete and the
fuel pressure tester is ready to be used for diagnostic tests.
Test Procedures
Key On, Engine Off Test
Cycle the ignition switch to the ON position. Verify that the
pressuregaugeindicatedasystempressurewithinthespeci-
cation provided by the manufacturer. If the reading is within the
manufacturer’sspecication,proceedtothe“KeyOn,Engine
On” test. If it is not, follow the test and repair procedures out-
line in the vehicles service manual to correct the problem.
KeyOn,EngineOnTest
CompleteallthestepsindicatedintheKeyOn,EngineOff1.
test
Start the car and idle the engine. Recheck the test setup2.
for fuel leaks
Read the fuel pressure from the gauge3.
Turn the car off when the readings have been made4.
Disconnecting the Fuel Pressure Tester
When vehicle testing is completed, turn off engine and1.
relieve pressure on the fuel system by pressing the
pressure relief valve located on the stem of the pressure
gauge. Watch the pressure gauge readings and fuel being
released through the small clear hose to the collecting
container.
Make sure that the pressure relief hose is routed and
secured into an approved gasoline fuel container.
Place shop towels under the connections to capture any2.
fuel that may spill out when the hoses are disconnected.
WARNING: After testing a returnless fuel system, use
extreme caution when disconnecting the hoses to the
fuel rail. If the engine is hot, releasing the pressure from
a returnless fuel system will cause the fuel to boil in the
fuelrail.Eventhoughthepressurehasbeenreleased,the
boiling fuel will cause it to build up again once the hose is
clamped. To reduce the risk of fuel spray it is best to allow
the engine to cool before disconnecting the hose. Other-
wise, use the pressure relief valve to relieve the pressure
just before removal. Try to keep a shop towel wrapped
around the connection to catch any fuel spray.
DisconnecttheSchraderportadapterortheinlinepres-3.
sure test assembly.
Remove the fuel rail adapters if applicable4.
Reconnect the fuel lines5.

Page Number - 12
Fuel Pressure Test Kit
MODEL MV5546
Form 824129
Lincoln Industrial Standard Warranty
LIMITED WARRANTY
Lincoln warrants the equipment manufactured and supplied by Lincoln to be free from defects in material and workmanship for a
period of one (1) year following the date of purchase, excluding there from any special, extended, or limited warranty published
by Lincoln. If equipment is determined to be defective during this warranty period, it will be repaired or replaced, within Lincoln’s
sole discretion, without charge.
This warranty is conditioned upon the determination of a Lincoln authorized representative that the equipment is defective. To
obtain repair or replacement, you must ship the equipment, transportation charges prepaid, with proof of purchase to a Lincoln
Authorized Warranty and Service Center within the warranty period.
This warranty is extended to the original retail purchaser only. This warranty does not apply to equipment damaged from
accident, overload, abuse, misuse, negligence, faulty installation or abrasive or corrosive material, equipment that has been
altered, or equipment repaired by anyone not authorized by Lincoln. This warranty applies only to equipment installed, operated
andmaintainedinstrictaccordancewiththewrittenspecicationsandrecommendationsprovidedbyLincolnoritsauthorized
eldpersonnel.
THIS WARRANTY IS EXCLUSIVE AND IS IN LIEU OF ANY OTHER WARRANTIES, EXPRESS OR IMPLIED, INCLUDING,
BUT NOT LIMITED TO, THE WARRANTY OF MERCHANTIBILITY OR WARRANTY OF FITNESS FOR A PARTICULAR
PURPOSE.
In no event shall Lincoln be liable for incidental or consequential damages. Lincoln’s liability for any claim for loss or damages
arising out of the sale, resale or use of any Lincoln equipment shall in no event exceed the purchase price. Some jurisdictions
do not allow the exclusion or limitation of incidental or consequential damages, therefore the above limitation or exclusion may
not apply to you.
Thiswarrantygivesyouspeciclegalrights.Youmayalsohaveotherrightsthatvarybyjurisdiction.
CustomersnotlocatedintheWesternHemisphereorEastAsia:PleasecontactLincolnGmbH&Co.KG,Walldorf,Germany,
for your warranty rights.
Lincoln Industrial Contact Information
TondLincolnIndustrial’sNearestServiceCentercallthefollowingnumbers,oryoumayalsouseourwebsite
Customer Service314-679-4200
Website lincolnindustrial.com
Americas:
One Lincoln Way
St. Louis, MO 63120-1578
USA
Phone [phone]
Fax [phone]
Europe/Africa:
Heinrich-Hertz-Str 2-8
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#09-06 The Signature
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Printed in USA
Web site:
www.lincolnindustrial.com