Actron KM2529 - Manual

100
200
300
400
10
psi
40
60
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50
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20
Vehicle Service Information
INITIAL CHECKS
Fuel System Checks
Before doing any fuel system pressure
testing, check the following fuel sys-
tem components and correct any prob-
lems you may encounter:
1. Check fuel level and fuel tank vent-
ing (filler cap, etc.).
2. Check fuel for water or contamina-
tion.
3. Check fuel lines and hoses for dam-
age or looseness.
4. Check fuel system electrical fuses.
Pre-Testing Checks
1. Read Safety Guidelines.
2. Do a thorough visual and “hands-
on” inspection of the engine and
fuel system. Look for loose or
cracked electrical wiring, battery
cables, ignition wires, and fuel or
vacuum lines.
3. Verify that the battery is fully
charged and the fuel tank has an
adequate supply of fuel.
4. Verify that all fuel system fuses are
good.
5. Verify that the fuel vapor recovery
system and gas cap are in good
condition.
6. Verify that manifold vacuum is
within manufacturer’s specification
(typically 18-20 in. at idle).
7. Look for fuel leaks and wipe up any
spilled fuel immediately.
8. Has the vehicle been serviced
recently? Sometimes things get
reconnected in the wrong place, or
not at all.
KM2529 Components
Part Number Part Description
0180-000-1320 GM TBI adapter, M16 x 1.5
0032-000-0126 42 in. hose, gauge connector
fitting with pressure relief
button, and 72 in. plastic
tubing (bleed-off hose)
0031-000-0355 Fuel Pressure Gauge,
0-60 psi
1. Dial Face: Measurement scale that shows
amount of fuel pressure present in fuel system.
2. Pressure Relief Button: Used to relieve
fuel pressure in the gauge hose before
disconnecting the gauge from the fuel line.
3. Bleed-Off Hose: A 6-ft. hose that bleeds off
fuel pressure when the pressure relief button is
pressed. Never use a bleed-off hose shorter than
6 ft.
IMPORTANT: Always make sure end of bleed-off
hose is in an approved fuel container during
testing and when bleeding off fuel pressure!
4. Gauge Hose: Hose that carries fuel to the
gauge so that pressure can be measured.
5. GM TBI Test Adapter: This adapter is used
to connect the gauge hose to GM TBI vehicles
NOT equipped with a fuel access valve test port
on the fuel rail.
Figure 1
The following is a list of publishers
who have manuals containing fuel
system testing information. Some
manuals may be available at auto
parts stores or your local public library.
For others, you need to write for avail-
ability and pricing, specifying the
make, model and year of your vehicle.
Vehicle Service Manuals
from General Motors Corp.:
Buick, Cadillac, Chevrolet, GEO,
GMC, Oldsmobile, & Pontiac
Helm Incorporated
Post Office Box 07130
Detroit, MI 48207
Saturn
Adistra Corporation
c/o Saturn Publications
101 Union St.
Post Office Box 1000
Plymouth, MI 48170
Vehicle Service Manuals:
Chilton Book Company
Chilton Way
Radnor, PA 19089
Haynes Publications
861 Lawrence Drive
Newbury Park, CA 91320
Cordura Publications
Mitchell Manuals, Inc.
Post Office Box 26260
San Diego, CA 92126
Motor’s Auto Repair Manual
Hearst Company
250 W. 55th Street
New York, NY 10019
Suitable manuals have titles such as:
“Electronic Engine Controls”
“Fuel Injection and Feedback
Carburetors”
“Fuel Injection and Electronic
Engine Controls”
1
3
2
4
5
9. Don’t take shortcuts. Inspect wiring
which may be difficult to see
because of location beneath air
cleaner housings, alternators and
other components.
10. Inspect wiring harnesses for:
• Contact with sharp edges (this
happens often).
• Contact with hot surfaces, such
as exhaust manifolds.
• Pinched, burned or chafed
insulation.
• Proper routing and connections.
11. Check electrical connectors for:
• Corrosion on pins.
• Bent or damaged pins.
• Contacts not properly seated in
housing.
NOTE: Problems with connectors
are common in the engine control
system. Inspect carefully. Note that
some connectors use a special
grease on the contact to prevent
corrosion. Do not wipe off! Obtain
extra grease, if needed, from your
vehicle dealer. It is a special type
for this purpose.
12. Check other vehicle systems:
• Ignition—For safety reasons,
most engine computers will not
deliver fuel without an ignition
spark.
• Engine computer—The engine
computer has special drivers
which energize the fuel injectors.
These drivers are fragile and can
break easily. If you suspect a
computer driver problem, test by
replacing the computer with a
known good computer and retest.
General Safety Guidelines to
Follow When Working on Vehicles
To prevent accidents that could result in serious injury and/or
damage to your vehicle or test equipment, carefully follow
these safety rules and test procedures at all times when
working on vehicles:
• DO NOT use Model KM2529 Fuel
Pressure Tester on Diesel or Flex
Fuel engines!
• Always wear approved eye protec-
tion.
• Always operate the vehicle in a well-
ventilated area. Do not inhale ex-
haust gases – they are very poison-
ous!
• Always keep yourself, tools and test
equipment away from all moving or
hot engine parts.
• Always make sure the vehicle is in
Park (Automatic transmission) or
Neutral (manual transmission) and
that the parking brake is firmly set.
Block the drive wheels.
• Never lay tools on vehicle battery.
You may short the terminals together
causing harm to yourself, the tools
or the battery.
• Never smoke or have open flames
near vehicle. Vapors from gasoline
and charging battery are highly flam-
mable and explosive.
• Never leave vehicle unattended
while running tests.
• Always keep a fire extinguisher suit-
able for gasoline/electrical/chemical
fires handy.
• Always use extreme caution when
working around the ignition coil, dis-
tributor cap, ignition wires, and
spark plugs. These components
contain high voltage when the en-
gine is running.
• Always turn ignition key OFF when
connecting or disconnecting electri-
cal components, unless otherwise
instructed.
• Always follow vehicle manu-
facturer’s warnings, cautions and
service procedures.
CAUTION:
Some vehicles are equipped
with safety air bags. You must
follow vehicle service manual
cautions when working
around the air bag compo-
nents or wiring. If these pre-
cautions are not followed, the
air bag may deploy unexpect-
edly, resulting in personal in-
jury. Note that the air bag can
still deploy several minutes
after the ignition key is off (or
even if the vehicle battery is
disconnected) because of a
special energy reserve mod-
ule.
All information, illustrations and specifications contained in this manual are based on the latest information available from industry
sources at the time of publication. No warranty (expressed or implied) can be made for its accuracy or completeness, nor is any respon-
sibility assumed by Actron Manufacturing Co. or anyone connected with it for loss or damages suffered through reliance on any informa-
tion contained in this manual or misuse of accompanying product. Actron Manufacturing Co. reserves the right to make changes at any
time to this manual or accompanying product without obligation to notify any person or organization of such changes.
One Year Warranty
If within one year from the date of pur-
chase this equipment fails due to de-
fect in materials or workmanship, return
it to Actron and Actron will repair it free
of charge.
This warranty gives you specific legal
rights, and you may also have other
rights which may vary from state to state.