INSTRUCTIONS FOR:
FUEL INJECTION
PRESSURE TEST KIT
MODEL: VSE210
Thank you for purchasing a Sealey product. Manufactured to a high standard this product will, if used according to these instructions and properly
maintained, give you years of trouble free performance.
IMPORTANT: PLEASE READ THESE INSTRUCTIONS CAREFULLY. NOTE THE SAFE OPERATIONAL REQUIREMENTS, WARNINGS, AND
CAUTIONS. USE THIS PRODUCT CORRECTLY, AND WITH CARE FOR THE PURPOSE FOR WHICH IT IS INTENDED. FAILURE TO DO SO
MAY CAUSE DAMAGE AND/OR PERSONAL INJURY AND WILL INVALIDATE THE WARRANTY.
1. SAFETY INSTRUCTIONS
1.1 FUEL SAFETY
p WARNING! Ensure Health and Safety, local authority, and general workshop practice regulations are adhered to when working with
fuel injection systems and petrol in general.
p WARNING! Petrol fumes and battery gases are explosive, DO NOT smoke or allow an open flame or sparks in the work area.
1.1.1 FUEL LEAKS
3 Keep a dry chemical (class B) fire extinguisher near to the work area.
3 Avoid fire hazard by using caution when disconnecting fuel lines and installing adaptors, as some spillage is inevitable.
3 When connecting, or disconnecting from a fuel system, relieve pressure from system and wrap a cloth around the fuel line fitting to absorb any
fuel leakage. Constantly check gauge and adaptor connections for leaks. If you see leakage turn off the ignition or disable the fuel pump,
relieve fuel pressure if necessary and correct leaks before continuing.
3 When using tee adaptors, secure hose with hose clamps to ensure leak-free connections.
3 Check all adaptor sealing washers and 'O' rings are in good condition before use.
3 When connecting hose coupler to Test Port, Tee and In-Line Banjo Bolt Adaptors ensure coupler is correctly seated onto adaptor.
7 DO NOT let fuel spill onto a hot engine.
7 DO NOT allow fuel to remain in the adaptors or hoses after use. To clear any fuel trapped in the gauge/hose assembly after use, hold gauge
vertical with hose coupler end in suitable fuel container. Depress coupler valve stem and at the same time, depress pressure relief button
situated under the gauge.
p WARNING! Wipe up fuel spills immediately.
1.2 GENERAL
p WARNING! Exhaust gas contains deadly poisonous gases. Test area must well ventilated - route exhaust gas outdoors.
3 Maintain tools in good and clean condition for best and safest performance.
3 If required, ensure the vehicle to be worked on is adequately supported with axle stands, ramps and chocks.
3 Before performing a test with the engine running (unless the manufacturer's manual states otherwise), set the parking brake and place the gear
selector in neutral or park, and block the drive wheels.
3 Before repairing the fuel system, turn off the ignition switch and disconnect the battery per manufacturer's procedure. Never disconnect the
battery while the engine is running.
3 Wear approved safety goggles. A full range of personal safety equipment is available from your Sealey dealer.
3 Wear suitable clothing to avoid snagging. Do not wear jewellery and tie back long hair.
3 Keep yourself, clothing and test equipment away from all moving or hot engine parts.
7 DO NOT use tools if damaged.
7 DO NOT use the components from this kit on diesel fuel systems.
3 Account for all tools being used and do not leave them in or near the engine.
3 IMPORTANT: Always refer to the vehicle manufacturers service instructions, or proprietary manual to establish the current procedure and data.
These instructions for use are provided as a guide only.
2. INTRODUCTION
Comprehensive kit of adaptors and fittings for modern fuel injection systems.
Components fitted with quick coupling system and safety valve to prevent
inadvertent discharge of fuel under pressure. Kit supplied with large high pressure
gauge reading 0-145psi and 0-1000kpa and a small low pressure gauge for
accurate low pressure readings. Pressure release valve fitted with long drain hose
allows safe recovery of fuel. Supplied in carry-case.
NOTE: It is our policy to continually improve products and as such we reserve the right to alter data, specifications and component parts without
prior notice. IMPORTANT: No liability is accepted for incorrect use of this equipment. WARRANTY: Guarantee is 12 months from purchase date,
proof of which will be required for any claim. INFORMATION: For a copy of our latest catalogue and promotions call us on 01284 757525 and
leave your full name and address, including postcode.
Sole UK Distributor, Sealey Group, Bury St. Edmunds, Suffolk.
01284 757500
01284 703534
www.sealey.co.uk
Web
sales@sealey.co.uk
email
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3. TOOL PARTS & CONTENT LIST
Issue: 1
Issue Date: 030205
ITEM PART NO. DESCRIPTION
A VSE210.A GAUGE 3-1/2
AC VSE210.AC GAUGE PROTECTOR 3-1/2
AD VSE210.AD GAUGE PROTECTOR 2-1/2
AE VSE210.AE GAUGE 2-1/2
B VSE210.B ADAPTOR HOSE 7/16 X 20 (GM/CHRYS)
BC VSE210.BC BLOW CASE
C VSE210.C ADAPTOR HOSE 308 X 32 (FORD/EFI)
D VSE210.D GAUGE HOSE C/W RELIEF VALVE
E VSE210.E SINGLE END HOSE ADAPTOR 1/4-3/8
F VSE210.F DOUBLE END HOSE ADAPTOR 5/16-3/8
G VSE210.G HOSE ASSEMBLY C/W VALVE (CIS/TBI)
H VSE210.H MALE CIS FITTING (LONG) 8MM X 1.0
HA VSE210.HA FEMALE CIS FITTING (LONG) 8MM X 1.0
I VSE210.I MALE CIS FITTING 10MM X 1.0
J VSE210.J FEMALE CIS FITTING 10MM X 1.0
K VSE210.K FEMALE CIS FITTING 12MM X 1.5
KA VSE210.KA SWIVEL FITTING M&F 14MM X 1.5
KB VSE210.KB SWIVEL FITTING M&F 16MM
KC VSE210.KC SWIVEL FITTING M&FBSPT 1/4
ITEM PART NO. DESCRIPTION
L VSE210.L FEMALE CIS FITTING 8MM X 1.0
M VSE210.M MALE CIS FITTING 8MM X 1.0
N VSE210.N BANJO FITTING 6MM X 1.0
O VSE210.O BANJO FITTING 8MM X 1.0
P VSE210.P BANJO FITTING 10MM X 1.0
Q VSE210.Q BANJO FITTING 12MM X 1.25
R VSE210.R BANJO FITTING 12MM X 1.5
RA VSE210.RA BANJO FITTING 14MM X 1.5
RK VSE210.RK REPAIR KIT
S VSE210.S UNION 5/8 X 18
T VSE210.T FEMALE TUBE ADAPTOR 16MM X 1.5
U VSE210.U MALE TUBE ADAPTOR 16MM X 1.5
UA VSE210.UA FEMALE TUBE ADAPTOR 14MM X 1.5
UB VSE210.UB MALE TUBE ADAPTOR 14MM X 1.5
UC VSE210.UC MALE PLUG 14MM X 1.5
V VSE210.V MALE FITTING 5/8 X 18
W VSE210.W SPRING LOCK HOSE (FORD)
X VSE210.X HAIR PIN HOSE 5/16 (FORD)
XA VSE210.XA HAIR PIN HOSE 3/8 (GM/CHRYS)
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4. GENERAL INFORMATION
Because fuel systems and access points are so varied, it is impractical to list all of the applications. Always refer to a reliable shop manual, or the
car manufacturer for the recommended test procedure and access points.
There are two basic types of fuel injection systems. Port Fuel Injection (PFI) uses separate injectors to supply the fuel to each cylinder.
Throttle Body Injection (TBI) injects fuel from a position above the throttle plate on the intake manifold. On both systems there is a supply side,
which brings fuel to the injectors, and a return side which brings unused fuel back to the tank.
Basically, there are three ways to check fuel pressure. First, many domestic cars with PFI are equipped with a special test port. Simply connect the
proper adaptor to the gauge assembly, thread the adaptor to the test port, and run the test (section 15). Second is an end of hose connection.
Some older PFI systems have a flexible hose connection at the cold start injector. Connect our single barb fitting (section 18) with a hose clamp to
run the test. Also, some systems have fuel bolt or banjo type fittings as an access point (section 18).
Third is in-line connecting. This means installing the proper adaptor(s) in series with the fuel line (sections 16, 17 & 19).
Unless a schrader-type test port is available, most manufacturers require that you relieve the fuel pressure before entering or leaving the system.
To relieve the pressure, it may be necessary to remove the fuel pump connector, relay, or fuse. Some models may have two fuel pumps - make
sure both are disabled. After the pump(s) are disabled, run the engine until it stalls, then try to restart it for five to ten seconds. The system is now
ready for testing. Once the proper adaptors and gauge are in place, reactivate the fuel pump and run tests.
When finished testing, repeat above procedure before removing tester.
5. BASIC DIAGNOSIS
Fuel injected engines require precise fuel pressure as well as adequate volume. Without the correct pressure and volume, performance and fuel
economy can suffer. Always consult the correct repair manual for accurate specifications.
When running tests, it may help to picture the fuel system as a circle. Fuel is pumped from the tank to the fuel regulator and injectors, and the
unused fuel is then returned to the tank. The fuel regulator serves as a divider between the supply side and the return side.
Lower than recommended pressure usually indicates a problem on the supply side of the circle. Likely causes would include a damaged or
restricted fuel line, clogged fuel filter, defective fuel pump or regulator, or improper tank ventilation. Higher than normal pressure usually indicates a
problem on the return side of the circle. Likely causes are a damaged or restricted fuel line, poor venting of the tank, or a defective fuel regulator.
You may be able to pinpoint problem areas on the return side by resetting. For example - by removing the return line near the fuel regulator and
putting the fuel line into a proper container, a retest that still shows a high reading would indicate a faulty regulator. If the reading would drop into
the normal range, you know that problem is further down the return line or the tank. Again, always consult the manufacturer of the vehicle, or a
good repair manual for specific trouble-shooting procedures. When testing is completed, make sure the fuel line is reassembled correctly. Replace
any o-rings or washers, and follow the manufacturer's recommendations for proper torque on any bolts or connections. Check the entire system
thoroughly for any leaks.
Following are some typical test procedures for different models.
6. FUEL PRESSURE TESTS FOR GENERAL MOTORS (TYPICAL)
CAUTION: Fuel system test begins with checking fuel injection system pressure. High fuel pressure may be present in fuel lines and
components. Relieve fuel pressure before disconnecting any fuel system components.
6.1 FUEL PRESSURE CHECK FOR TBI
6.1.1 Disconnect negative battery cable. Remove fuel filler cap. Since these TBI units contain an internal bleed-down feature, after a short time,
system fuel pressure should dissipate.
6.1.2 Remove air cleaner and plug thermal vacuum port on throttle body. When removing fuel line, always use 2 wrenches. Install Fuel Pressure
Gauge and Adaptor in fuel system between steel line and flexible hose.
CAUTION: DO NOT pinch off fuel return line completely. DO NOT exceed pressure build-up of more than 13 psi. as regulator may be
damaged.
6.1.3 Start engine and observe fuel pressure reading. Fuel pressure should read 9-13 psi. (if fuel pressure is okay, proceed to step 4). If fuel
pressure is low, gradually pinch off fuel return line to fuel tank. If pressure remains low, check and/or replace fuel filter or fuel pump. If
pressure increases to greater than 13 psi, replace fuel pressure regulator.
6.1.4 Allow fuel pressure to dissipate. Remove pressure gauge and reconnect fuel line. Start engine and watch for fuel system leaks.
6.2 FUEL PRESSURE CHECK OF PFI
6.2.1 Disconnect fuel pump at rear body connector (electrical). Start engine and run engine until it stalls. Crank starter for 3 seconds to remove
remaining fuel from fuel lines. Reconnect rear body connector.
6.2.2 Connect Fuel Pressure Gauge to fuel pressure fitting on fuel rail.
6.2.3 Reconnect fuel pump.
6.2.4 With gauge installed at fuel rail connector, turn ignition on. With ignition on and engine off, pressure should read within specifications.
6.2.5 Start engine. Pressure should drop 3-10 psi.
7. FUEL PRESSURE TESTS FOR FORD (TYPICAL)
CAUTION: High fuel pressure may be present in fuel lines and component parts. Relieve pressure before attempting to open system for
testing or component replacement. DO NOT allow fuel to run onto engine or electrical parts or allow an open flame in area while testing
fuel system components.
7.1 FUEL PRESSURE CHECK FOR PFI
7.1.1 On 2.2L & 2.2L Turbo models, relieve fuel line pressure by disconnecting fuel pump relay and starting engine. After engine stalls, turn
ignition off. Reconnect fuel pump relay.
7.1.2 On all other models, remove fuel tank cap. Using Fuel Pressure Gauge, release pressure from system at pressure relief valve (Schrader
valve) on fuel injection manifold rail.
7.1.3 The fuel pump may be activated by grounding the fuel pump lead at the SELF-TEST connector. Use a jumper lead and ground the "FP"
terminal with ignition on. This activates the fuel pump.
CAUTION: Inspect fuel system for leaks or damage before testing fuel pump.
7.2 FUEL PRESSURE TEST FOR TBI
7.2.1 Disconnect wiring at inertia switch. Inertia switch is located behind trim panel in right rear side of cargo area on Sable and Taurus station
wagons and behind trim panel on left side of trunk on all other models. Crank engine for at least 15 seconds to reduce system fuel
pressure.
7.2.2 Disconnect fuel supply line at throttle body. Install in-Line Adaptor and fuel Pressure gauge at fuel filter. Reconnect intertia switch and start
engine. Check fuel pressure at idle and when accelerating engine. Pressure should remain stable through entire period of acceleration.
7.2.3 If gauge readings are correct, disconnect inertia switch. Crank engine for 15 seconds to reduce fuel pressure. Remove gauge and in-line
adaptor. Install original fuel line and connect intertia switch. Start engine and check for fuel leaks.
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