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 identification 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 filter 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 first time it is
encountered.
A banjo connection consists of a round, hollowed-out “banjo”
connector with two flat sides. A hollow bolt with a cross-hole
passes through the banjo connector and threads into the
connecting component (i.e. filter, fuel rail). When the bolt is
tightened, it creates a secure face-to-face seal through which
the fuel flows. 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 filter or fuel rail.
3. Pass the hollow adapter with the cross-hole through the
banjo fitting. Be sure to include a washer on both sides of
the banjo fitting (Fig. 2).
4. Thread the closed-end nut onto the end of the bolt and
tighten securely with a wrench, trapping the banjo fitting.
5. Thread the hollow bolt adapter without the cross-hole into
the filter 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 filter 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 fitting
back to the vehicle’s original specification.
Fuel Rail
Banjo Fitting
Banjo Bolt
Fig. 1
Banjo Bolt
Adapter
Banjo Fitting
Closed
End Nut
Fig. 2
Fig. 3
Banjo Adapter
Fuel Filter
