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    Thread: DIY Fuel Pressure Tester

    1. Member VanManNW's Avatar
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      06-07-2013 05:00 PM #1
      Based on this awesome writeup, I was motivated to test the fuel pressure on my CIS-Lambda equipped GTI:

      http://www.mikegabriel.net/vw/badhab...fpressure.html

      I balked for a while at the price of pressure testers though. And couldn't really find a workaround on the interwebs.

      So, after doing quite a bit of surfing on McMaster, I was able to piece together a tester for about $35, and thought I'd share my parts list with you all.

      1 4089K61 Multipurpose Gauge, Plastic Case, 2" Dial, 1/4 NPT Bottom, 0-100 PSI (1 @ 9.66 each)
      2 4464K48 Type 304 Stainless Steel Threaded Pipe Fitting, 1/4 Pipe Size, Tee, 150 PSI (1 @ 6.91 each)
      3 5779K109 Nylon and Nickel-Plated Brass Tube Fitting, Adapter for 1/4" Tube OD X 1/4" NPT Male Pipe (2 @ 2.91 each)
      4 5269K311 Steel Compression Tube Fitting, Straight Adapter for 6MM Tube OD X 1/8 NPT Male (1 @ $4.11 each)
      5 5779K129 Nylon and Nickel-Plated Brass Tube Fitting, Adapter for 1/4" Tube OD X 1/8" NPT Female Pipe (1 @ $4.06 each)
      6 8359K14 High-Strength Clear Nylon Tubing .190" ID, 1/4" OD, .030" Wall Thickness (3ft. @ $.36/ft.)

      You can see that I omitted the Gate Valve to save money in favor if just folding and crimping the flexible line to stop flow.

      This all totals out to around $35 with shipping I believe. I actually got the tubing from work, but this stuff I listed as #6 should be the same stuff.

      The hard to find M12x1.5 fittings are actually contained in part #4. Half of this part is the female portion, half is the male portion.

      I only ran the tests described once, just to see that my tester was working and everything was peachy.

      Enjoy!


    2. Member
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      06-07-2013 05:10 PM #2
      Good stuff! Not that I need it, but perhaps this will push people to stop throwing unneeded parts at the CIS system.

      -Todd

    3. Member rabbitnothopper's Avatar
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      06-07-2013 07:26 PM #3
      cool thanks for the elite write-up

      what you need however is a valve and a fuel pressure release button

    4. Member rabbitnothopper's Avatar
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      06-23-2013 01:27 PM #4
      btw the 400psi tube is only sold in 25'ft pieces ($9)
      not too bad really....you can use it for other things
      **note
      8359K tubing is non-reactive to gas and diesel!


      "gate valve" isnt good choice


      this was the best one i found
      Miniature Chrome-Plated Brass Ball Valve Wedge Handle, 1/4" NPT Female X Male Connections
      1/4" 1 11/16" 4912K72 $6.00



      or larger knob
      1/4" 1 11/16" 4912K7 $6.88

      this valve plugs into the end of the TEE



      to sum up:




















      when you are done it will look identical to this





      1 4089K61 1 Each Multipurpose Gauge Plastic Case, 2" Dial, 1/4 Npt Bottom, 0-100 Psi
      2 4464K48 1 Each Type 304 Stainless Stl Threaded Pipe Fitting 1/4 Pipe Size, Tee, 150 Psi
      3 5779K109 2 Each Nylon And Nickel-plated Brass Tube Fitting Adapter For 1/4" Tube Od X 1/4" Npt Male Pipe
      4 5269K311 1 Each Steel Compression Tube Fitting Straight Adapter For 6mm Tube Od X 1/8 Npt Male
      5 5779K129 1 Each Nylon And Nickel-plated Brass Tube Fitting Adapter For 1/4" Tube Od X 1/8" Npt Female Pipe
      6 8359K14 1 Each High-strength Clear Nylon Tubing .190" Id, 1/4" Od, .030" Wall Thickness, 25 Ft. Length
      7 4912K72 1 Each Miniature Chrome-plated Brass Ball Valve Wedge Handle, 1/4" Npt Female X Male Connections

      Merchandise total
      $45.56
      Last edited by rabbitnothopper; 06-23-2013 at 01:50 PM.

    5. Member rabbitnothopper's Avatar
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      06-26-2013 08:48 PM #5
      alright super fast
      shipped monday received wednesday
      great stuff

      $6ish shipping, so roughly $52 total


      you need pics
      i know you need pics

      assembled and nice


      68-69psi system pressure


      33psi "cold" control pressure (it was 98*F today) this engine is stone cold has not driven in 4 days


      48-50psi warm pressure...thats a little low


      relief pressure dropped fast down to 15psi in about 30 seconds but held there
      the fuel accumulator leaks and those old injectors....who knows...

      test on other car


      70psi system pressure


      cold control pressure was 40, it has been off for awhile
      warm control pressure was 48-50

      also relief pressure held at 35psi for more than 3 minutes
      brass injectors, new accumulator



      sorry those few pictures were reflecting the sky


      *a few of the fittings do not have teflon tape/pipe dope...
      so i know you have 10 rolls of it under the seat of your car
      and the little rolls are super cheap anyways


      best thing i discovered
      you cannot pull out those hoses
      but you press the black retainer in and it slides out easily
      perfect for simple hose replacement in case of damage
      ...with your 25ft roll
      Last edited by rabbitnothopper; 06-26-2013 at 08:56 PM.

    6. Junior Member
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      06-27-2013 10:02 AM #6
      Brilliant thread. Parts on order!
      "Being shot out of a cannon will always be better than being squeezed out of a tube." H.S. Thompson

    7. Member VanManNW's Avatar
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      06-27-2013 12:15 PM #7
      Awesome!
      I'm glad someone is getting some value from this thread. I always try to post helpful mechanical stuff, but I worry that it often gets lost between threads about rounds vs. squares and 13" vs 15" wheels.

      I'm stoked you found an affordable valve rabbitnothopper. I consider myself a pretty skilled McMaster(bater), but I couldn't find anything suitable for less than $30.

      FYI, the readings for my stock CIS-Lambda '84 GTI were:

      System pressure: 75psi
      Cold control: 22psi on a 70 degree F day.
      Warm control: 50psi (rose to this quickly in a few minutes)

      I didn't record residual pressure, other than to say it stayed pretty stable for a long while. This sort of perplexed me because I think I have a leaky accumulator and suffer from what I think must be vapor lock. Which is the reason I built the pressure tester in the first place.
      I also have a slightly "Pulsing" idle.
      Documented here:
      http://forums.vwvortex.com/showthrea...on-warm-starts

    8. Member
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      06-27-2013 03:11 PM #8
      Brilliant, thank you!

      No need yet, but someday I'm sure

    9. Member flipty's Avatar
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      12-03-2013 11:09 AM #9
      EXCELLENT thread. Thanks!

    10. 04-04-2014 10:54 PM #10
      Quote Originally Posted by flipty View Post
      EXCELLENT thread. Thanks!
      I hooked up my pressure test kit...I dont have any pressure on my gauge. ..or fuel for that matter.
      Whats going...this thing is driving me crazy.

    11. Member rabbitnothopper's Avatar
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      04-05-2014 12:50 AM #11
      Quote Originally Posted by plozano00 View Post
      I hooked up my pressure test kit...I dont have any pressure on my gauge. ..or fuel for that matter.
      Whats going...this thing is driving me crazy.

      relay failure, fuse failure

      dead fuel pump


      another possibility
      ....is the engine running?
      Last edited by rabbitnothopper; 04-10-2014 at 05:54 PM.

    12. Senior Member dubdaze68's Avatar
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      04-10-2014 12:04 PM #12
      Interesting.
      DCIVW
      CE.

    13. Member
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      08-11-2014 10:36 PM #13
      My 8 year old son and I just put this together to help us figure out why our "new" '86 cabrio runs a little rough. Thanks so much!
      little bandit needs premium!
      http://www.youtube.com/watch?v=dceB3SKBw9w

    14. Member ducatipaso's Avatar
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      08-13-2014 12:43 PM #14
      thanks for this thread. I am considering using this idea to create a permanent mount setup.
      click me
      wanted - blue GTI interior bits, must be perfect

    15. Member rabbitnothopper's Avatar
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      08-20-2014 07:51 PM #15
      Quote Originally Posted by ducatipaso View Post
      thanks for this thread. I am considering using this idea to create a permanent mount setup.
      i would suggest metal lines on the connectors similar to the stock cis lines

      the release on these hoses is not reliable enough to jeapordize them comming loose when youre driving it
      imagine opening the fuel line directly into the engine bay when youre driving
      FIRE


      for all it matters the metal lines could be a second pair of CIS lines with the connections and add 100-200psi fuel hose and clamps or compression clamp


      i recently replaced the hoses i made on mine and the connection had shrunk slightly
      luckily they shipped me a huge roll of it for $9

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      09-16-2015 06:55 PM #16
      just a heads-up to everybody so they don't make the same mistake I did
      be sure to order TWO of 5779K109,
      as the original posts state.

    17. Member rabbitnothopper's Avatar
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      09-16-2015 07:43 PM #17
      3 5779K109 2 Each Nylon And Nickel-plated Brass Tube Fitting Adapter For 1/4" Tube Od X 1/4" Npt Male Pipe
      the quantity is right there

      including two of the picture

    18. Member
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      09-16-2015 08:47 PM #18
      I said, "as the original posts state". meaning, it was my mistake.

    19. Member rabbitnothopper's Avatar
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      09-16-2015 09:30 PM #19
      still says it right there.

      3 5779K109 Nylon and Nickel-Plated Brass Tube Fitting, Adapter for 1/4" Tube OD X 1/4" NPT Male Pipe (2 @ 2.91 each)

      glad the thread was helpful
      now go spend the $8 for shipping on a $3 part!

    20. Member MorningStar's Avatar
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      01-13-2016 11:40 PM #20
      Can I bump this for a little more info?

      Specifically, I just purchased all of the parts listed above and I'm having trouble figuring out how
      the Steel Compression Tube Fitting (part #4) comes apart to make the connection on the fuel distributor.

      I can see that the male end pairs up with a "quick connect" fitting adapter.. No problem there.

      But how does the female end work?

      Is the small ring supposed to pass completely over the nylon tubing? (As it is, I can't get it much more than 1mm)

      Also, do I need a 'sleeve' to fit inside the tubing before I attach it to the fuel distributor?


      Everything looks nice in the photos above but I'm unfamiliar with how these fittings work and I want to make sure I get it right the first time.

      TIA.

    21. Member
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      01-13-2016 11:48 PM #21
      IIRC, I think there was a compression ferrule that goes around the plastic tubing, then tightening the female end to the fuel-distributor compresses everything together.

    22. Member MorningStar's Avatar
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      01-15-2016 07:19 AM #22
      Gotcha.

      I haven't pulled the fuel line off the fuel distributor yet so the solution might be be right in there.

      As I mentioned, the small part included with the compression fitting is a little too small to get the nylon tube all the way through.

      It seems like everything I looked up showed a small ring that is supposed to pass easily over the tubing and then gets 'crushed'
      when it's all tightened down.

      The part I have will not at all slide over the tubing.

      I see everything assembled in the photos above so I have no reason to doubt it will all work but I just wanted to
      make sure I know what I'm doing before I pressurize the system.

    23. Senior Member dubdaze68's Avatar
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      01-15-2016 09:03 AM #23
      a 60PSI shot of unleaded to the face never hurt anyone. Wait...Yes it does.

      What's really bad is cracking the lines on a car that's been sitting for over a decade and finding pressure still in the system.

      I still need to build one of these, but I've been too busy chasing electrical and steering issues on my 'Ruck, and electrical issues on my Jetta.
      DCIVW
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    24. Member rabbitnothopper's Avatar
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      01-15-2016 07:43 PM #24
      Quote Originally Posted by MorningStar View Post
      I haven't pulled the fuel line off the fuel distributor yet so the solution might be be right in there.
      it sure is.....and i'll go take photos for you

      its simple really



      set it up like this
      make sure the outer piece is totally pushed onto the hose

      push the nut back over the nipple

      when you take off the FD incomming line you will see how it works

      #5 here



      this is the fuel line
      http://www.mk1autohaus.com/CIS-Warm-...se_p_6559.html



      when youre done...
      use the proper tool
      Last edited by rabbitnothopper; 01-15-2016 at 08:44 PM.

    25. 01-15-2016 07:59 PM #25


      imo great vid for those not understanding cis... if your vw has 1 pump its got pressurized tank... so things like roll over valves n proper gas caps required.. 2 pump cars use the tank pump to fill a box the return line feeds into to keep it topped off as the in tank pump flows less fuel then the main pump...

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