U.S. General 97706 User manual

®
FUEL INJECTION
PRESSURE TEST KIT
Model 97706
OPERATING INSTRUCTIONS
Diagrams within this manual may not be drawn proportionally.
Due to continuing improvements, actual product may differ slightly from the product described herein.
Distributed exclusively by Harbor Freight Tools®.
3491 Mission Oaks Blvd., Camarillo, CA 93011
Visit our website at: http://www.harborfreight.com
Read this material before using this product.
Failure to do so can result in serious injury.
SAVE THIS MANUAL.
Copyright©2006 by Harbor Freight Tools®. All rights reserved. No portion of this
manual or any artwork contained herein may be reproduced in any shape or form
without the express written consent of Harbor Freight Tools.
For technical questions or replacement parts, please call 1-800-444-3353.
Cover revised 08a

SKU 97706 For technical questions, please call 1-800-444-3353. PAGE 2
PRODUCT SPECIFICATIONS
SAVE THIS MANUAL
You will need this manual for the safety warnings and precautions, assembly, operat-
ing, inspection, maintenance and cleaning procedures, parts list and assembly diagram.
Keep your invoice with this manual. Write the invoice number on the inside of the front
cover. Keep this manual and invoice in a safe and dry place for future reference.
GENERAL SAFETY RULES
IMPORTANT SAFETY INSTRUCTIONS
WARNING!
READ AND UNDERSTAND ALL INSTRUCTIONS
Failure to follow all instructions detailed in this manual may
result in serious personal injury.
SAVE THESE INSTRUCTIONS
Keep your work area clean and well lit.1. Cluttered and dark work areas invite
accidents.
Stay alert.2. Watch what you are doing, and use common sense when operating
tools and equipment. Do not assemble or use this product while tired or under
the inuence of drugs, alcohol, or medication. A moment of inattention while op-
erating tools and equipment may result in serious personal injury.
3. Wear eye protection. Wear ANSI-approved safety impact glasses and
full face shield when using this product.
Do not force the Pressure Test Kit.4. Use the correct product for your applica-
tion. The correct product will do the job better and safer at the rate for which it is
designed.
Maintain the Pressure Test Kit with care.5. Keep this product clean. Properly
maintained products are less likely to malfunction. Do not use damaged prod-
ucts. Tag damaged products “Do not use” until repaired.
Product Features (A) Allows for accurate and quick diagnoses of fuel intake issues.
(B) Compatible with most domestic and import cars.
(C) Includes all necessary adapter clamps and hoses.
(D) Quick, convenient hook ups.
Material Brass / Steel / Aluminum / Polyurethane / Rubber / Vinyl / Thermoplastic
Contents Fuel Gauge w/Quick Release Valve / Seven Various Hose Assemblies
Four Metric Paired Hose Adapters / Two Steel Hose Clamps
Four Copper Washers / Fifteen Metric Sized Fittings / 8 SAE Sized Fittings

SKU 97706 For technical questions, please call 1-800-444-3353. PAGE 3
Check for any condition that may negatively affect the Pressure Test Kit’s6.
operation. If readings are inconsistent, or if it appears that the fuel gauge is not
functioning properly, the Test Kit should be serviced by a qualied service techni-
cian. Many accidents are caused by poorly maintained products.
Use only accessories that are recommended by the manufacturer for your7.
model. Accessories that may be suitable for one product may become hazard-
ous when used on another product.
Industrial applications must follow OSHA requirements.8.
Maintain labels and nameplates on the Pressure Test Kit.9. These carry im-
portant information. If unreadable or missing, contact Harbor Freight Tools for a
replacement.
Use the right product for the job.10. There are certain applications for which
this product was designed. Do not use small products to do the work of larger
industrial products. Do not use this product for a purpose for which it was not
intended.
Product service must be performed only by qualied service technician. 11.
Service or maintenance performed by unqualied personnel could result in a risk
of injury.
When servicing the Pressure Test Kit, use only identical replacement parts.12.
Follow instructions in the “Inspection, Maintenance, And Cleaning” section of this
manual. Use of unauthorized parts or failure to follow maintenance instructions
may create a risk of personal injury.
Always make sure the area of use for this product is clear of any children.13.
Do not allow children to play with this product.
Do not allow the vehicle’s engine to run while using the Pressure Test Kit.14.
When running, the engine of a vehicle produces carbon monoxide, a colorless,
odorless, toxic gas that, when inhaled, can cause serious personal injury or
death.
Prior to using this product, make sure to read and understand all instruc-15.
tions and safety precautions as outlined in the vehicle manufacturer’s
manual.
Always keep hands and ngers away from the moving parts and hot parts 16.
of an engine.
Do not use this Pressure Test Kit on diesel fuel systems.17.
Do not smoke while performing any fuel injection tests or repairs.18.
Always have a dry chemical (Class B) re extinguisher within reach.19.

SKU 97706 For technical questions, please call 1-800-444-3353. PAGE 4
Make sure to provide a suitable container to catch released fuel when the20.
system is de-pressurized.
Take extra care to prevent fuel from contacting hot engine parts.21. It is rec-
ommended that tests be performed when the engine is cold.
If a drop light is used, do not allow fuel to contact the hot surface of the22.
bulb.
Never remove any ttings with the engine running.23.
Never loosen any ttings or attempt to remove hoses of vehicle or Pressure 24.
Test Kit until you have relieved the fuel system pressure. Refer to the ve-
hicle manufacturer’s service manual for specic fuel pressure relief procedures.
Always check all connections for leaks during the testing procedure.25. At
any sign of leaks, turn off the engine or disable the fuel pump. Clean up any
spilled fuel and repair all leaks before resuming test.
When preparing for pressure testing, make sure the vehicle’s transmission
is placed in “PARK” or “NEUTRAL” and the emergency brake is applied.
When the test is complete, de-pressurize the system and remove the Pres-26.
sure Test Kit. Re-assemble the vehicle’s fuel line(s) to its original condition.
Start the engine and check for leaks. If any leaks are present, stop the engine,
relieve fuel pressure and repair all leaks.
WARNING: The brass components of this product contain lead, a chemical27.
known to the State of California to cause birth defects (or other reproductive
harm). (California Health & Safety code § 25249.5, et seq.)
People with pacemakers should consult their physician(s) before use. Electro-28.
magnetic elds in close proximity to heart pacemaker could cause pacemaker
interference or pacemaker failure.
Caution is necessary when near coil, spark plug cables, or distributor of running
engine. Engine should be off during distributor adjustment.
The warnings and cautions discussed in this manual cannot cover all possible29.
conditions and situations that may occur. It must be understood by the operator
that common sense and caution are factors which cannot be built into this prod-
uct, but must be supplied by the operator.

SKU 97706 For technical questions, please call 1-800-444-3353. PAGE 5
UNPACKING
When unpacking, check to make sure all the parts shown in the Parts List on page 23
are included. If any parts are missing or broken, please call Harbor Freight Tools at the
number shown on the front cover of this manual as soon as possible.
APPLICATIONS
# Picture DESCRIPTION APPLICATION
1Basic Gauge with Boot
and Hook - 100 PSI Connects to #8 for basic testing
2General Motors 2.5L & 5.7L
(Non Multi-Port)
For vehicles with quick connect fuel lters such as
2.5L Oldsmobile Ciera 1989 & up, and 5.7L
Chevrolet Caprice 1991 & up
3General Motors 2.2L
(Non Multi-Port)
1992 & up: Chevrolet Cavalier, Pontiac Sunbird, Buick
Skylark, and Quad 4 equipped Pontiac Grand Am
4Hose Clamps and
Connection Hoses For use in making certain hook up connections
5General Motors Throttle
Body Injection (TBI)
Inline Adapter - Replaces fuel lter with threads on
both ends
6Parts Seals, Tank Valve, and Gasket
7Double End Barbed Hose
Adapter
When vehicles require testing by splicing into 1/4”,
5/16”, or 3/8” fuel line hose
8Single End Barbed Hose
Adapter
All vehicles requiring end of line testing with 1/4”,
5/16”, or 3/8” fuel line hose
9Honda, Acura & Sterling
Multi-Port (PGM-FI) For vehicles with 6mm-1.00 ttings
10
THRU
14
Asian and European vehicles
with Multi-Port & Bosch AFC
For vehicles with 8mm-1.00, 10mm-1.00, 12mm-1.25,
12mm-1.50, & 14mm-1.50 Banjo Bolts
15
THRU
24
E & K Jetronic Systems
Test CIS (Continuous Injection Systems) found on Eu-
ropean cars and Volkswagon models assembled in the
U.S. For vehicles with metric threads
CISE Test CISE (Constant Injection System Electronic) found
on European cars with metric threads
25 Pressure Testing and
Bleed-off Assembly
For use in performing tests with Basic Gauge (1)
and Adapters
26 Ford Multi-Port (EFI) For smaller Schrader valves
27
General Motors, Chrysler
& Imports with 7/16”-20
threaded test port
For larger Schrader valves on Multi-Port vehicles
28 Ford CFI For 5/16” hair pin connections
29 General Motors and
Chrysler Inline Adapter Inline Adapter for vehicles with 3/8” hair pins
30 Ford EFI For Spring Lock ttings
31 CIS Testing Assembly
with Ball Valve
For use in testing with Basic Gauge (1), Pressure
Testing, and Bleed-off Assembly (25) and Adapters

SKU 97706 For technical questions, please call 1-800-444-3353. PAGE 6
TYPICAL HOOK-UPS
Note: Prior to using this product, make sure to read and understand all instructions and
safety precautions as outlined in the vehicle manufacturer’s manual.
GM Multi-Port And Chrysler Multi-Port - FIGURE A:
GAUGE
(1)
PRESSURE TESTING
AND
BLEED-OFF ASSY.
(25)
ADAPTER
(27)
FIGURE A
1. Turn off ignition.
Relieve the fuel pressure. Refer to the vehicle’s service manual for specic pres-2.
sure relief procedures.
Connect the Gauge (1) to the Pressure Testing and Bleed-off Assembly (25).3.
Remove the protective cap from test tting on vehicle.4.
Attach the swivel female tting on the Adapter (27) to the test tting on the ve-5.
hicle. Hand tighten.
Attach the female quick coupler on the Pressure Testing and Bleed-off Assembly6.
(25) to the male quick connector on the Adapter (27).
Start the engine and allow it to idle. Check for leaks.7.
Read the Gauge (1) and compare result with the pressure in service manual.8.
Stop engine and turn ignition OFF.9.
With free end of Bleed-off Hose in suitable container, press the Button on side of10.
bleed-off assembly slowly to de-pressurize the fuel system.
Refer to the11. General Safety Rules section before removing Tester from vehicle.
Replace the protective cap onto the test tting on vehicle. Check for leaks.12.
REV 07f, 07i

SKU 97706 For technical questions, please call 1-800-444-3353. PAGE 7
Ford Multi-Port (EFI) - FIGURE B:
PRESSURE TESTING
AND
BLEED-OFF ASSY.
(25)
GAUGE
(1)
FORD ADAPTER
(26)
FIGURE B
1. Turn off ignition.
Relieve the fuel pressure. Refer to the vehicle’s service manual for specic pres-2.
sure relief procedures.
If the vehicle has multi-port fuel injection, the test valve is located on the fuel rail.3.
Remove the protective cap from the test valve.
Connect the Gauge (1) to the Pressure Testing and Bleed-off Assembly (25).4.
Attach the female end of Ford Adapter (26) to test the valve. Hand tighten.5.
Attach the female quick coupler on the Pressure Testing and Bleed-off Assembly6.
(25) to the male quick coupler on the Ford Adapter (26).
Start the engine and allow it to idle. Check for leaks.7.
Read the Gauge (1) and compare result with pressure in service manual.8.
Stop the engine and turn the ignition OFF.9.
With free end of bleed-off hose in suitable container, press the button on side of10.
bleed-off assembly slowly to de-pressurize the fuel system.
Refer to the11. General Safety Rules section before removing the tester from the
vehicle.
Replace the protective cap onto test tting on vehicle. Check for leaks.12.

SKU 97706 For technical questions, please call 1-800-444-3353. PAGE 8
Asian And European Multi-Port Vehicles (Bosch AFC) - FIGURE C:
PRESSURE TESTING
AND
BLEED-OFF ASSY.
(25)
GAUGE
(1)
ADAPTERS
(10, 11, 12, 13, 14)
GASKETS (6)
FIGURE C
1. Turn off the ignition.
Relieve the fuel pressure. Refer to the vehicle’s service manual for specic pres-2.
sure relief procedures.
The pressure test connection for these vehicles is located at the point where the3.
fuel inlet meets the fuel rail or cold start injector. The fuel inlet is secured to the
fuel rail of cold start injector by a banjo tting.
Remove the banjo tting that secures the fuel inlet to the fuel rail or cold start 4.
injector. Place a shop cloth around the bolt to catch any spilled fuel.
Install one of the ve pressure test Adapters (10, 11, 12, 13, 14) with the corre-5.
sponding sealing washer and one of the gaskets from the banjo tting so that the
fuel inlet is once again connected to the fuel rail or cold start injector. The test
Adapter will hold the banjo assembly in position.
Torque the Adapters (10, 11, 12, 13, 14) to the following specications:6.
Adapter # Size Torque Specications
10 8mm-1.00 48 In./Lb. (5.5 N-m)
11 10mm-1.00 72 In./Lb. (8.0 N-m)
12 12mm-1.25 96 In./Lb. (11.0 N-m)
13 12mm-1.50 96 In./Lb. (11.0 N-m)
14 14mm-1.50 125 In./Lb. (14.0 N-m)
Connect the Gauge (1) to the Pressure Testing and Bleed-off Assembly (25).7.
Attach the female quick coupler on the Pressure Testing and Bleed-off Assembly8.
to the male quick coupler on the test Adapter.
Start the engine and allow it to idle. Check for leaks.9.
Read the Gauge (1) and compare the result with pressure in the service manual.10.

SKU 97706 For technical questions, please call 1-800-444-3353. PAGE 9
Stop the engine and turn the ignition OFF.11.
With free end of bleed-off hose in a suitable container, press the button on side of12.
bleed-off assembly slowly to de-pressurize the fuel system.
Refer to13. General Safety Rules section before removing tester from vehicle.
Remove the Tester and the pressure test Adapter.14.
Re-assemble the banjo tting to the fuel inlet and fuel rail (or cold start injec-15.
tor). New Gaskets (6) should be used when re-assembling fuel lines. Check for
leaks.
GM Throttle Body Injection (TBI) With Fuel Filter Threaded On Both Sides -
FIGURE D:
GAUGE
(1)
PRESSURE TESTING
AND
BLEED-OFF ASSY.
(25)
GM TBI ADAPTER (5)
FIGURE D
1. Turn off the ignition.
Relieve the fuel pressure. Refer to the vehicle’s service manual for specic pres-2.
sure relief procedures.
Locate the fuel lter on the vehicle.3.
Remove the fuel lter by unscrewing the fuel lines from both ends of the fuel lter. 4.
Use a container to catch any fuel that may spill out. Wipe off any excess fuel that
may spill on the vehicle.
Install the GM TBI Adapter (5) in place of the fuel lter by threading each fuel line 5.
into either end of the Adapter. Do not overtighten.

SKU 97706 For technical questions, please call 1-800-444-3353. PAGE 10
Connect the Gauge (1) to the Pressure Testing and Bleed-off Assembly (25).6.
Attach the female quick coupler on the Pressure Testing and Bleed-off Assembly7.
to the male quick coupler on the GM TBI Adapter (5).
Start the engine and check for leaks. Read the fuel pressure. Compare the8.
value on the Gauge (1) to the value in the service manual.
Stop the engine and turn the ignition OFF.9.
With free end of bleed-off hose in a suitable container, press the button on side of10.
bleed-off assembly slowly to de-pressurize the fuel system.
Refer to the11. General Safety Rules section before removing tester from vehicle.
Remove the fuel pressure Adapter following the above instructions for removing12.
the fuel lter.
Re-install the fuel lter. Start the vehicle and check for leaks.13.
GM Throttle Body Injection (TBI) With Quick Connect Fuel Filter (2.5L 1989 And
Up, 5.7L 1991 And Up - FIGURE E:
GAUGE
(1)
PRESSURE TESTING
AND
BLEED-OFF ASSY.
(25)
ADAPTER
(2)
FIGURE E
1. Turn off the ignition.
Relieve the fuel pressure. Refer to the vehicle’s service manual for specic pres-2.
sure relief procedures.
Locate the fuel lter on the vehicle.3.
Remove the fuel lter by compressing the tabs while pulling outward on each fuel 4.
line. Use a container to catch any fuel that may spill out. Wipe off any excess
fuel that may spill on the vehicle.