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DIESEL ENGINE
COMPRESSION TESTER
93644
ASSEMBLY AND OPERATING INSTRUCTIONS
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© 2005 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. Diagrams within this manual may not be drawn proportionally. Due to continuing
improvements, actual product may differ slightly from the product described herein. Tools required for
assembly and service may not be included.
For technical questions or replacement parts, please call 1-800-444-3353.
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PRODUCT SPECIFICATIONS
Pressure Scale 0<->1000 PSI / 0<->7000 kPa
Gauge 2-9/16” Diameter / 2-5/8” Bezel Diameter / 1-1/8” Deep
Air Release Type Thumb Button Release
Maximum Working Pressure 1000 PSI
Hose Size 15/64” I.D. / 35/64” O.D. / 16” Long
Accessories Carrying Case
Weight 3.50 Pounds
SAVE THIS MANUAL
You will need this manual for the safety warnings and precautions, assembly, operating, 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.
UNPACKING
When unpacking, check to make sure all the parts shown in the Parts List on page 8
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.
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
WORK AREA
1. Keep your work area clean and well lit. Cluttered and dark work areas invite
accidents.
SKU 93644 For technical questions, please call 1-800-444-3353. Page 2
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2. Keep bystanders, children, and visitors away while using the Compression
Tester. Distractions can cause you to lose control.
PERSONAL SAFETY
3. Stay alert. Watch what you are doing, and use common sense during use. Do
not use while tired or under the inuence of drugs, alcohol, or medication. A moment of inattention while operating may result in serious personal injury.
4. Dress properly. Do not wear loose clothing or jewelry. Contain long hair. Keep
your hair, clothing, and gloves away from moving engine parts. Loose clothes,
jewelry, or long hair can be caught in moving parts.
5. Do not overreach. Keep proper footing and balance at all times. Proper footing
and balance enable better control in unexpected situations.
6. Always wear eye and hand protection. Wear ANSI approved safety
impact goggles, non-skid safety shoes, and heavy duty work gloves
when using this product.
TOOL USE AND CARE
7. Store idle tools and equipment out of reach of children and other untrained
people. Tools and equipment are dangerous in the hands of untrained users.
8. Maintain the Compression Tester with care. Keep this product clean. A
properly maintained tool is easier to control. Do not use damaged tools and
equipment. Tag damaged tools and equipment “Do not use” until repaired.
9. Check for misalignment or binding of moving parts, loose or broken parts,
and any other condition that may affect the Compression Tester’s operation.
If damaged, have the tool serviced before using. Many accidents are caused by
poorly maintained tools and equipment.
10. Use only accessories that are recommended by the manufacturer for your
model. Accessories that may be suitable for one product may become hazardous
when used on another product.
SERVICE
11. Tool service must be performed only by qualied service technician. Service
or maintenance performed by unqualied personnel could result in a risk of injury.
12. When servicing the Compression Tester, use only identical replacement parts.
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 injury.
SKU 93644 For technical questions, please call 1-800-444-3353. Page 3
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SPECIFIC SAFETY RULES
1. Maintain labels and nameplates on the Compression Tester Kit. These carry
important information. If unreadable or missing, contact Harbor Freight Tools for a
replacement.
2. Use the right product for the job. There are certain applications for which this
product was designed. Do not use this product for a purpose for which it was not
intended.
3. Industrial applications must follow OSHA requirements.
4. Prior to using this product, make sure to read and understand all instructions
and safety precautions as outlined in the vehicle manufacturer’s manual and
engine diagnostic/repair manuals.
5. Use the Compression Tester in a well ventilated area. Do not operate
an engine in a closed area or in a poorly ventilated area. When running,
the Engine of a vehicle produces carbon monoxide, a colorless,
odorless, toxic fume that, when inhaled, can cause serious personal
injury or death. Early signs of carbon monoxide poisoning resemble the u, with
headaches, dizziness, or nausea. If you have these signs, get fresh air
immediately.
6. Do not exceed the maximum pressure capacity of this tool (1000 PSI).
Exceeding the maximum pressure capacity could cause personal injury and/or
property damage.
7. Always keep hands, ngers, and body away from the moving parts and hot
parts of the diesel engine.
8. When warming up a diesel engine in preparation for compression testing,
make sure the vehicle’s transmission is placed in “PARK”/“NEUTRAL” and
the emergency brake is applied.
9. WARNING! The brass components of this product contain lead, a chemical
known to the State of California to cause cancer and birth defects (or other
reproductive harm). (California Health & Safety Code § 25249.5, et seq.)
10. WARNING! People with pacemakers should consult their physician(s)
before using this product. Electromagnetic elds in close proximity to a heart
pacemaker could cause interference or failure of the pacemaker. In addition,
people with pacemakers should adhere to the following: Caution is necessary
when near the coil or distributor of a running engine. The engine should always
be off if adjustments are to be made to the distributor.
11. WARNING! The warnings and cautions discussed in this manual cannot
cover all possible conditions and situations that may occur. It must be under-
stood by the operator that common sense and caution are factors which cannot
be built into this product, but must be supplied by the operator.
SKU 93644 For technical questions, please call 1-800-444-3353. Page 4
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OPERATING INSTRUCTIONS
1. NOTE: Refer to the Diesel Adapters chart to select the proper Adapter to be used
for the specic vehicle you will test. (See page #6.) After identifying the correct
adapter, assemble it securely as shown on the assembly diagram on page 8. Make
certain that the vehicle’s battery is fully charged before testing.
2. Prepare the engine for compression testing by starting the engine and allowing it
to warm up to its normal operating temperature. Then, switch off the engine.
3. Once the engine has been turned off, disconnect the fuel shutdown solenoid (refer
to the engine maintenance manual for location).
4. Remove all of the injectors or all of the glow plugs (depending on the connector used).
You may wish to label them for reassembly. (See Figure A.) Unless instructed
to do so by the engine manual, do not inject oil into the cylinders (a “wet”
test); the oil may not compress properly and damage the engine.
PRESSURE GAUGE (1)
INJECTORS/GLOW PLUGS
REMOVE
AIR RELEASE BUTTON (2)
FIGURE A
5. Using the proper Adapter, connect the Compression Tester to the rst cylinder of
the engine. Then, with the fuel pedal depressed completely, crank the engine for
eight revolutions. Do not continue to crank the engine; the engine’s starter may
overheat, causing damage to itself. (See Figure A.)
6. After cranking the engine, record the reading on the Pressure Gauge (1) of the
Compression Tester. (See Figure A.)
7. Once the maximum reading has been recorded, release the Gauge (1) pressure
on the Tester by depressing the Air Release Button (2). (See Figure A.)
8. Use caution, the engine will be hot! Remove the Compression Tester from the
rst cylinder. Then, repeat steps #5, #6, #7 for the remaining cylinders.
9. NOTE: Good engine cylinder compression will be indicated with a high initial
reading, and a progressive buildup to the nal maximum reading. Poor engine
cylinder compression will be indicated with a low initial reading and a much slower
buildup to the nal maximum reading. The compression readings for all of the
engine cylinders should not vary by more than 10%.
10. Reconnect the fuel injection solenoid and reinstall all glow plugs/injectors.
SKU 93644 For technical questions, please call 1-800-444-3353. Page 5
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DIESEL ADAPTERS
Manufacturer Engine Type Thread Adapter #
Audi Early models, see VW for TDI Injector 24 x 2.00 C
Mercedes-Benz Early models Injector 24 x 2.00 C
VW 1970’s Rabbit Injector 24 x 2.00 C
Volvo Early models except 30’s & 40’s Injector 24 x 2.00 C
BMW 2.4L Glow Plug 12 x 1.25 H
Chevette/Isuzu; Luv/Isuzu 1.8L, 2.2L Glow Plug 10 x 1.25 E
Deutz Many models Glow Plug 12 x 1.25 H
Ford/Mazda (1984-87) 2.0L;
Glow Plug 10 x 1.25 F
(1983-84) 2.2L Escort, Lynx,
Ranger, Tempo, Topaz
Ford/Mitsubishi (1985-87) Ranger 2.3L Glow Plug 10 x 1.25 F
Ford/Navistar 6.9L and 7.3L (up to 1994) Glow Plug 10 x 1.00 A
General Motors 4.3L V6, 4.3L V8, 5.7L V8 Glow Plug 10 x 1.00 A
Duramax 6.6L Turbo Diesel Glow Plug 10 x 1.25 E
Hummer Optimizer 6500 V8 Turbo Glow Plug 10 x 1.25 E
Isuzu/Isuzu Truck (1992-98) 4HE1-TC
Glow Plug 10 x 1.25 E
(1998-2005) 6HK1-TC
(1998-2005) 4HE1-TC
Glow Plug 12 x 1.25 HUI
(Up to 1998) 6HK1-TC
Kubota Some models Glow Plug 10 x 1.25 F
Lincoln, Mark VII/
Continental
2.4L used in 1984-85 autos Glow Plug 12 x 1.25 H
with Volvo engines Glow Plug 10 x 1.25 F
Mercedes-Benz (1988-89) 190E 2.5L Glow Plug 12 x 1.25 I
(1991-99) E300 Glow Plug 12 x 1.25 H
2005 E320 CDI Glow Plug 10 x 1.00 A
Mitsubishi 2 and 3 cylinder engines Glow Plug 10 x 1.25 F
Mitsubishi-Fuso Medium Glow Plug 10 x 1.25 F
Navistar/ International 6.9L and 7.3L Glow Plug 10 x 1.00 A
Nissan/ UD Truck 2.2L Glow Plug 10 x 1.25 F
Medium Glow Plug 10 x 1.25 F
Peugeot Most Glow Plug 12 x 1.25 H
Certain Models Glow Plug 18 x 1.50 H
Toyota 1.8L Glow Plug 10 x 1.25 E
2.2L Glow Plug 10 x 1.25 F
VW (1979-84) Rabbit,
Glow Plug 12 x 1.25 HUI
(1979-99) Jetta,
(1981-84) Pick-Up
(1987-99) Golf,
(1992-97) Passat,
(1992-98) Eurovan
(1995-97) Passat,
Glow Plug 10 x 1.00 A
(1997-05) Golf, Jetta & Jetta
Wagon,
(1998-05) New Beetle,
2004 Touareg
U
- Indicates that part 7 must be removed for these applications.
U
U
U
U
U
U
U
SKU 93644 For technical questions, please call 1-800-444-3353. Page 6
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INSPECTION, MAINTENANCE, AND CLEANING
1. Before each use, inspect the general condition of the Compression Tester Kit.
Check for cracked, worn or damaged Adapters, damaged Pressure Gauge and
Hose, and any other condition that may affect the tool’s safe operation. If a problem
occurs, have the problem corrected before further use. Do not use damaged
equipment.
2. To clean, use a damp cloth and a mild detergent.
3. When storing, keep the Compression Tester Kit in its Carrying Case and in a clean,
dry, safe location out of reach of children.
4. WARNING! All maintenance, service, and repairs not discussed in this manual
should only be performed by a qualied service technician.
PLEASE READ THE FOLLOWING CAREFULLY
THE MANUFACTURER AND/OR DISTRIBUTOR HAS PROVIDED THE PARTS LIST AND
ASSEMBLY DIAGRAM IN THIS MANUAL AS A REFERENCE TOOL ONLY. NEITHER THE
MANUFACTURER OR DISTRIBUTOR MAKES ANY REPRESENTATION OR WARRANTY OF
ANY KIND TO THE BUYER THAT HE OR SHE IS QUALIFIED TO REPLACE ANY PARTS OF THE
PRODUCT. IN FACT, THE MANUFACTURER AND/OR DISTRIBUTOR EXPRESSLY STATES
THAT ALL REPAIRS AND PARTS REPLACEMENTS SHOULD BE UNDERTAKEN BY CERTIFIED
AND LICENSED TECHNICIANS, AND NOT BY THE BUYER. THE BUYER ASSUMES ALL RISKS
AND LIABILITY ARISING OUT OF HIS OR HER REPAIRS TO THE ORIGINAL PRODUCT OR
REPLACEMENT PARTS THERETO, OR ARISING OUT OF HIS OR HER INSTALLATION OF
REPLACEMENT PARTS THERETO.
PARTS LIST
Part Description Q’ty Part Description Q’ty
1 Pressure Gauge 1 10 ZG 1/8” (M) Male Quick Coupler 1
2 Air Release Button 1 11 ZG 1/8” (F)-M24X2 (M) Adapter 1
3 Rubber Hose 1 12 Adapter Sleeve 1
1
4
/8” NPT Quick Coupler 1 13 Quick Connect with Ball Tip 1
7
5
/16”-20(F) Quick Coupler 3 141/2” -19 Lock Nut 1
6 M12X1.25(M)-7/16”-20(M) Adapter 3 157/16”-20(M)-7/16”X20(F) 90° Connector 1
7 M12X1.25(F)-M18X1.5(M) Adapter 2 16 ZG 1/8” (M)-M24X1.5 (M) Adapter 1
8 M10X1.25 Short Adapter 1 17 M10X1(M) Adapter 1
9 M10X1.25 Long Adapter 1 18 Copper Washer 2
SKU 93644 For technical questions, please call 1-800-444-3353. Page 7
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ASSEMBLY DIAGRAM
Letters designate adapter assemblies.
NOTE: Some parts are listed and shown for illustration purposes only, and are not available
individually as replacement parts.
SKU 93644 For technical questions, please call 1-800-444-3353. Page 8
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LIMITED 90 DAY WARRANTY
Harbor Freight Tools Co. makes every effort to assure that its products meet high
quality and durability standards, and warrants to the original purchaser that this product
is free from defects in materials and workmanship for the period of 90 days from the date
of purchase. This warranty does not apply to damage due directly or indirectly, to misuse,
abuse, negligence or accidents, repairs or alterations outside our facilities, criminal activity,
improper installation, normal wear and tear, or to lack of maintenance. We shall in no event
be liable for death, injuries to persons or property, or for incidental, contingent, special
or consequential damages arising from the use of our product. Some states do not allow
the exclusion or limitation of incidental or consequential damages, so the above limitation
of exclusion may not apply to you. THIS WARRANTY IS EXPRESSLY IN LIEU OF ALL
OTHER WARRANTIES, EXPRESS OR IMPLIED, INCLUDING THE WARRANTIES OF
MERCHANTABILITY AND FITNESS.
To take advantage of this warranty, the product or part must be returned to us with
transportation charges prepaid. Proof of purchase date and an explanation of the complaint
must accompany the merchandise. If our inspection veries the defect, we will either
repair or replace the product at our election or we may elect to refund the purchase price
if we cannot readily and quickly provide you with a replacement. We will return repaired
products at our expense, but if we determine there is no defect, or that the defect resulted
from causes not within the scope of our warranty, then you must bear the cost of returning
the product.
This warranty gives you specic legal rights and you may also have other rights
which vary from state to state.
3491 Mission Oaks Blvd. • PO Box 6009 • Camarillo, CA 93011 • (800) 444-3353
REV 09h
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