1. SAFETY INSTRUCTIONS

Transcription

1 1. SAFETY INSTRUCTIONS 1.1 FUEL SAFETY WARNING! Ensure Healh and Safey, local auhoriy, and general workshop pracice regulaions are adhered o when working wih fuel injecion syses and perol in general. WARNING! Perol fues and baery gases are explosive, DO NOT soke or allow a naked flae or sparks in he work area FUEL LEAKS Keep a dry cheical (class B) fire exinguisher near o he work area. Avoid fire hazard by using cauion when disconnecing fuel lines and insalling adapors, as soe spillage is ineviable. When connecing, or disconnecing fro a fuel syse, relieve pressure fro syse and wrap a cloh around he fuel line fiing o absorb any fuel leakage. Consanly check gauge and adapor connecions for leaks. If you see leakage urn off he igniion or disable he fuel pup, relieve fuel pressure if necessary and correc leaks before coninuing. When using ee adapors, secure hose wih hose claps o ensure leak-free connecions. Check all adapor sealing washers and 'O' rings are in good condiion before use. When connecing hose coupler o Tes Por, Tee and In-Line Banjo Bol Adapors ensure coupler is correcly seaed ono adapor. DO NOT le fuel spill ono a ho engine. DO NOT allow fuel o reain in he adapors or hoses afer use. To clear any fuel rapped in he gauge/hose assebly afer use, hold gauge verical wih hose coupler end in suiable fuel conainer. Depress coupler valve se and a he sae ie, depress pressure relief buon siuaed under he gauge. WARNING! Wipe up fuel spills iediaely. 1.2 GENERAL WARNING! Exhaus gas conains deadly poisonous gases. Tes area us be well venilaed - roue exhaus gas oudoors. Mainain ools in good and clean condiion for bes and safes perforance. If required, ensure he vehicle o be worked on is adequaely suppored wih axle sands, raps and chocks. Before perforing a es wih he engine running (unless he anufacurer's anual saes oherwise), se he parking brake and place he gear selecor in neural or park, and block he drive wheels. Before repairing he fuel syse, urn off he igniion swich and disconnec he baery per anufacurer's procedure. Never disconnec he baery while he engine is running. Wear approved safey goggles. A full range of personal safey equipen is available fro your Sealey dealer. Wear suiable clohing o avoid snagging. Do no wear jewellery and ie back long hair. Keep yourself, clohing and es equipen away fro all oving or ho engine pars. Keep children and unauhorised persons away fro working area. DO NOT use coponens fro his ki if daaged. DO NOT use he equipen for purposes oher han for which i is designed. DO NOT use he coponens fro his ki on diesel fuel syses. DO NOT use he equipen when you are ired or under he influence of alcohol, drugs or inoxicaing edicines. Accoun for all ools being used and do no leave he in or near he engine. When no in use clean ki coponens, replace in case and sore in a dry, safe, childproof area, IMPORTANT: Always refer o he vehicle anufacurer s service insrucions, or proprieary anual o esablish he curren procedure and daa. These insrucions are provided as a guide only. WARNING! I is assued ha anybody using he VSE212.V2 will have soe knowledge of he echanics of he vehicle, paricularly in regard o safe handling of fuel syses. If here is any doub refer he job o a professional echanic. 2. INTRODUCTION Coprehensive ki of hoses, adapors and fiings for esing he pressure on odern perol fuel injecion syses. Fied wih quick couplings and safey valve o preven inadveren discharge of fuel under pressure. Supplied wih Ø92 single high pressure gauge wih rubber buper, reading 0-140psi and 0-10bar. Pressure release valve fied wih long drain hose allows safe recovery of fuel. Supplied in carry-case. insrucions for: fuel injecion pressure es ki odel NO: VSE212.V2 Thank you for purchasing a Sealey produc. Manufacured o a high sandard his produc will, if used according o hese insrucions and properly ainained, give you years of rouble free perforance. 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.

2 3. ool PARTS & conen lis ie par no. descripion 1 VSE212.V2-01 gauge 3-1/2 wih hose adapor ASSEMBLy 140psi 2 VSE212.v2-02 connecing hose & valve assebly FOr bosch cis 3 VSE212.v2-03 connecing hose for g bi 4 VSE212.v2-04 adapor ford efi 5 VSE212.v2-05 adapor ford efi 6 VSE212.v2-06 QUICK CONNECT TO ADAPTOR SMALL SCHRADER FOR FORD APPLICATIONS 7 VSE212.v2-07 QUICK CONNECT TO ADAPTOR STANDARD SCHRADER. 8 VSE212.v2-08 2X ADAPTOR Ø10MM TUBING WITH MALE 5/8" - 18UNF FITTINGS. 9 VSE212.V2-09 2x adapor Ø10 ubing wih ale 5/8"-18 o 16x1.5 wih 'o' ring fiings. 10 VSE212.v2-10 2X adapor feale 16X1.5 o feale 5/8"-18unf. 11 VSE212.v2-11 2X adapor feale 14x1.5 o Ø3/8" Tube fiing. 12 VSE212.v2-12 2X adapor feale 16X1.5 o Ø3/8" Tube fiing. 13 VSE212.v2-13 2X adapor ale 14x1.5 wih 'o' ring TO Ø3/8" ube fiing. 14 VSE212.V2-14 2X adapor ale 16x1.5 wih 'o' ring TO Ø10 ube fiing. 15 VSE212.V2-15 adapor for izuzu i-ec syses. 16 VSE212.V2-16 quick connec anifold wih Ø1/14"- 5/16" ube fiings. 17 VSE212.V2-17 adapor ale 12x1.5 o ale 10x1.0 WITH 'o' ring for MERCEDES benz 18 vse.212.v2-18 adapor ale 12x1.5 o feale M10x1.0 for ford/volkswagen 16v 19 vse212.v2-19 adapor ale 12x1.5 o feale M8x1.0 for bw applicaions. 20 vse212.v2-20 2x adapor ale 12x1.5 o ale M8x1.0 wih 'o' ring for ercedes BENz, vw golf & bw applicaions. 21 VSE212.v2-21 adapor quick connec o 12x1.25 BANJO fiing wih nyloron. 22 VSE212.V2-22 Adapor quick connec o 12x1.5 BANJO fiing wih brass washers. 23 VSE212.V2-23 adaper quick connec o 10x1.0 BANJO fiings for riuph 24 VSE212.V2-24 adaper quick connec o 8x1.0 BANJO fiing wih brass washers FOr oyoa applicaions. 25 vse212.v2-25 adapor quick connec o ale M6x1.0 wih 'o' ring for suzuki 26 vse212.v2-26 adapor quick connec o1/4" Tubing barb for Bosch ono JETronic applicaions. 27 VSE212.V2-27 adapor ale 12x1.5 o ale 8x1.0 WITH 'o' ring for audi secondary ADAPTOr applicaions. 28 vse212.v2-28 2x 14x1.5 ale adapor. 29 vse212.v x1.5 ale adapor. 30 vse212.v x1.5 feale adapor 31 vse212.v2-31 case.

3 4. general inforaion Because fuel syses and access poins are so varied, i is ipracical o lis all of he applicaions. Always refer o a reliable workshop anual, or he car anufacurer for he recoended es procedure and access poins before coencing any work on fuel injecion syses. There are wo basic ypes of fuel injecion syses. Por Fuel Injecion (PFI) (fig.1) uses separae injecors o supply he fuel o each cylinder. Throle Body Injecion (TBI) (fig.2) injecs fuel fro a posiion above he hrole plae on he inake anifold. On boh syses here is a supply side, which brings fuel o he injecors, and a reurn side which brings unused fuel back o he ank. 5. basic por fuel injecion (PFI) syse fig.1 6. BASIC THROTTLE BODY INJECTION (TBI) SYSTEM. fig.2

4 7. basic diagnostic CHECKS Before esing he fuel injecion syse i is recoended o carry ou he following basic checks: 7.1 FUEL SYSTEM Ensure ha here is sufficien fuel in he fuel ank. Do no rely on he vehicle's fuel gauge, ake a physical check Check for daaged, broken or loose eal and flexible fuel lines. Look for evidence of fuel leaks Ensure ha here is no waer or any oher conainans in he fuel Check he fuel ank vening syse and he condiion of he fuel filler cap Check any fuel syse relaed elecrical fuses. 7.2 ELECTRICAL SYSTEM Look for any disconneced elecrical coponens Check he vehicle igniion syse and ensure ha he spark plugs are funcioning correcly Observe for any faul laps illuinaed on he vehicle dashboard. If necessary use an EOBD code reader (available fro your Sealey dealer) o rerieve any faul codes fro he vehicle Check he condiion of he baery as he elecrical coponens on he fuel injecion syse will rely on he baery o funcion. 7.3 VACUUM SYSTEM Check he vacuu syse for any loose or disconneced pipes Wih he engine running, lisen for any air leaks or unusual noises Look for any oil leaks in or around he vacuu syse Check he inle anifold for cracks or leaking gaskes. 8. BASIC FUEL INJECTION PRESSURE TESTING. Fuel injeced engines require precise fuel pressure as well as adequae volue. Wihou he correc pressure and volue, perforance and fuel econoy can suffer. Always consul he correc workshop anual or vehicle anufacurer for accurae specificaions and esing procedures. When running ess, i ay help o picure he fuel syse as a circle. Fuel is puped fro he ank o he fuel regulaor and injecors, and he unused fuel is hen reurned o he ank. The fuel regulaor serves as a divider beween he supply side and he reurn side. The adapors supplied wih his ki are suiable for use on os fuel injecion syses fied o Aerican, European and Asian vehicles. There are hree ways o check fuel pressure. Firs, any vehicles wih PFI are equipped wih a special es por. Siply connec he proper adapor o he gauge assebly, hread he adapor o he es por, and run he es. Second is an end of hose connecion. Soe older PFI syses have a flexible hose connecion a he cold sar injecor. Connec he single barb fiing wih a hose clap o run he es. Also, soe syses have fuel bols or banjo ype fiings as an access poin.third is in-line connecing. This eans insalling he proper adapor(s) in series wih he fuel line. Unless a schrader-ype es por is available, os anufacurers require ha you relieve he fuel pressure before enering or leaving he syse. To relieve he pressure, i ay be necessary o reove he fuel pup connecor, relay, or fuse. Soe odels ay have wo fuel pups - ake sure boh are disabled. Afer he pup(s) is/are disabled, run he engine unil i salls, hen ry o resar i for five o en seconds. The syse is now ready for esing. 8.1 basic TESTING PROCEDURE Noe: The following is inended as a guide only, always refer o he vehicle anufacurer or a workshop anual for specific fuel injecion syse pressure esing. CAUTION: High fuel pressure ay be presen in fuel lines and coponen pars. Relieve pressure before aeping o open syse for esing or coponen replaceen. DO NOT allow fuel o run ono engine or elecrical pars while esing fuel syse coponens Ensure ha he igniion and engine is swiched off before he es Connec he gauge assebly o he high pressure side of fuel injecion syse by one of he ehods as described above using he correc adapor. Where necessary, ensure ha he pressure has been relieved fro he fuel syse Carry ou he es procedures as saed by he anufacurer or workshop anual. Noe: Any esing ha requires he engine o be running should only be done a ickover Observe reading on gauge assebly and copare o vehicle anufacurer's specificaions. A higher han noral pressure usually indicaes a proble on he reurn side of he circle and a lower han recoended pressure usually indicaes a proble on he supply side of he circle. 8.2 POSSIBLE CAUSES OF HIGHER THAN RECOMMENDED FUEL PRESSURE Defecive fuel pressure regulaor Resricion in fuel reurn line Defecive safey valve or fuel pup a ank Excessive ank pressure caused by iproper vening. 8.3 POSSIBLE CAUSES OF LOWER THAN RECOMMENDED FUEL PRESSURE Blocked fuel filer Resricion in fuel supply line Defecive fuel pup Defecive pressure regulaor Blocked pup inle filer Vacuu in ank caused by iproper vening. You ay be able o pinpoin proble areas on he reurn side by reesing. For exaple - by reoving he reurn line near he fuel regulaor and puing he fuel line ino a proper conainer, a rees ha sill shows a high reading would indicae a fauly regulaor. If he reading would drop ino he noral range, you know ha proble is furher down he reurn line or he ank. Again, always consul he anufacurer of he vehicle, or a good workshop anual for specific rouble-shooing procedures. When esing is copleed, ake sure he fuel line is reassebled correcly. Replace any o-rings or washers, and follow he anufacurer's recoendaions for proper orque on any bols or connecions. Check he enire syse horoughly for any leaks.

5 9. PRESSURE UNIT OF MEASUREMENT CONVERSION CHART. P.S.I BAR K/Pa Kg/c² Environenal Proecion. Recycle unwaned aerials insead of disposing of he as wase. All ools, accessories and packaging should be sored, aken o a recycle cenre and disposed of in a anner which is copaible wih he environen. Pars suppor is available for his produc. To obain a pars lising and/or diagra, please log on o eail sales@sealey.co.uk or phone NOTE: I is our policy o coninually iprove producs and as such we reserve he righ o aler daa, specificaions and coponen pars wihou prior noice. IMPORTANT: No liabiliy is acceped for incorrec use of his produc. WARRANTY: Guaranee is 12 onhs fro purchase dae, proof of which will be required for any clai. INFORMATION: For a copy of our laes caalogue and prooions call us on and leave your full nae and address, including poscode. Sole UK Disribuor, Sealey Group, Kepson Way, Suffolk Business Park, Bury S. Edunds, Suffolk, IP32 7AR Original Language Version Web eail sales@sealey.co.uk VSE212.V2 Issue: 1-11/09/13