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FUEL INJECTOR & HARNESS TESTER - Tooled

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1. every ten seconds until fuel pressure is to manufacturer s specification check vehicle service manual Note Check fuel pressure gauge connection points for leaks If leak occurs clean all fuel spills immediately and check all fittings for tightness 2 Observe pressure gauge for 10 15 seconds looking for pressure drop 3 Ifthe pressure does not drop continue with fuel injector testing If fuel pressure does drop continue looking for leaks by blocking off the return line between the fuel pressure regulator and the fuel tank Re test as described above 4 Ifthe pressure drops again there may be one or more leaky injectors Later tests will identify malfunctioning injectors VS211 0527 1 240599 3 3 Fuel Injector tests IMPORTANT Do not pulse fuel more than once per cylinder Start and run the engine briefly after pulsing fuel once into all cylinders This clears excess fuel from the intake ports Failure to do so could cause difficult starting severe engine flooding catalytic converter damage or fire 1 Carefully disconnect wiring harness from fuel injector to be tested Note Do not jerk or pull on wires some harnesses are attached with clips fig 2 It is a good ideal to test injectors in sequence beginning with cylinder No 1 2 Set Injector Harness switch to Injector Attach appropriate injector adaptor to Fuel Injector Wiring Harness interface cable 4 Connect tester to fuel injector fig 3 For most injecto
2. 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 product WARRANTY Guarantee is 12 months from purchase date proof of which will be required for any claim VS211 0527 1 240599
3. from schrader valve use a shop rag to cover the valve in case fuel sprays out Replace schrader valve cap Note Fuel system may still be under pressure even if the engine is not running Clean all fuel spills immediately b Fuel line adaptors remove adaptors using tools and procedure as outlined in vehicle service manual Reconnect all fuel lines Test for leaks Clean up all fuel spills immediately IMPORTANT Follow all procedures outlined in the fuel pressure gauge instruction manual for the safe way to remove the gauge from the schrader valve or fuel line adaptor 4 Ifthe excess fuel in the intake ports has been purged by starting the vehicle after each injector test reconnect all injector wiring harnesses to injectors IMPORTANT SAFETY NOTE If excess fuel has NOT been purged following each injector test vehicle damage may result when engine is started To clear excess fuel disconnect ALL fuel injector harnesses and then crank engine Engine may start and run roughly then die This is normal Reconnect all injectors VS211 0527 1 240599 3 6 Injector Harness tests 1 Connect Tester to vehicle battery RED clip to the positive terminal and BLACK clip to the negative terminal Ensure that Power LED is lit before continuing 2 Carefully disconnect wiring harness to be tested from fuel injector Do not jerk or pull bA Hien on wires some harnesses are attached with clips fig 2 It is a good idea to test injector wi
4. lines or gauges Avoid contact with petrol Dispose of all rags properly Clean up all fuel spills immediately Keep away from engine cooling fan On some vehicles the fan may start up unexpectedly You must follow vehicle service manual cautions when working around the air bag system If the cautions are not followed the air bag may deploy unexpectedly resulting in personal injury Note that the air bag can still deploy several minutes after the ignition key is turned OFF or even if the battery is disconnected because of a special energy reserve module Always follow vehicle manufacturer s warnings cautions and service procedures Always relieve fuel pressure before disconnecting fuel lines The Fuel Injector amp Harness Tester requires an optional fuel pressure gauge VS210 to be used for fuel injector testing Always follow all safety guidelines and testing procedures contained in the instruction manual provided with the fuel pressure gauge S SSS SSS KR KKK SSS x lt Never lay tools on vehicle battery You may short the terminals together causing harm to yourself the tools or the battery X Never smoke or have open flames near vehicle Vapours from petrol and charging batteries are highly flammable and explosive X Never leave vehicle unattended while running tests X Do not confuse Air Conditioning schrader valves with the fuel rail test port 2 INTRODUCTION In recent years fuel injection has become sta
5. not wipe off Obtain extra grease if needed from your vehicle dealer It is a special type for this purpose 12 Check other vehicle systems Ignition For safety reasons many engine management systems will not deliver fuel without an ignition spark 13 Electronic Control Unit ECU The engine management system ECU has special drivers which energize the fuel injectors These drivers are fragile and can easily fail If you suspect an ECU driver problem check by replacing the ECU with a known good one and retest 14 Perform diagnostic procedures as described in vehicle service manual to eliminate other possible causes of driveability problems Compression and ignition problems may imitate fuel injection system problems 3 2 Testing O WARNING Before proceeding with fuel injector and harness testing read and understand all safety guidelines and perform all pre test checks 3 2 1 Fuel Injector test 1 Connect Tester to vehicle battery RED clip to the positive terminal and BLACK clip to the negative Ui terminal HARNESS TESTER Ensure that Power LED is lit before continuing rawea OUTPUT Pulsas 2 Connect a Fuel Pressure Gauge VS210 not included to fuel line Some vehicles have a schrader valve located on the fuel rail for this purpose On vehicles without schrader valves you must open the fuel line at the appropriate point to insert a fuel pressure gauge adaptor IMPORTANT Always follow fuel pressure ga
6. g Harness Test Results 1 If the continuity LED lights and the output LED flashes the wiring harness for that fuel injector is good 2 Ifthe continuity LED fails to light then there is a problem with the fixed voltage wire in the injector wiring harness Use a digital multimeter to check for an open or short circuit 3 Ifthe output LED does not flash then a Check fuel injector wiring harness for an open or short circuit in the wire that turns the fuel injector ON and OFF b The driver in the engine management ECU may be faulty Substitute Known good unit and retest c Check ignition system For safety reasons most fuel injection systems will not deliver fuel without the presence of ignition reference pulses from the ignition module Note This only applies to a No Start condition 4 Disconnect Tester from wiring harness and from vehicle battery Reconnect all injector harnesses Start and run engine to be sure that all injectors are firing normally 4 CARE amp MAINTENANCE Keep all Fuel Injector amp Harness Tester electrical connections clean and free of corrosion If tester face becomes dirty wipe clean with a damp rag DO NOT use alcohol or other strong solvents as they may remove face printing Use care to prevent tester wiring insulation from becoming chafed or broken Do not use tester if insulation or wiring is damaged When not in use store instrument in a safe dry childproof location 1 2 3 4
7. ion Single or Multiple repeat test procedure with the pulse switch in the other position 3 4 Fuel Injector test results 1 Compare the pressure drop values for each injector recorded in para 3 3 9 Any injector showing a result significantly different more than 2 0 psi from the others should be retested to be certain that there were no variations in the test procedure Single Pulse test Clogged injectors will show less pressure drop that healthy injectors Leaking injectors will show more pressure drop than healthy injectors Multiple Pulse test Sticky or sluggish injectors will show less pressure drop than healthy injectors 2 Flush or clean any injector which continues to show a variation of more than 2 0 psi when compared to the other injectors Note Be sure to compare readings taken during Single and Multiple pulse testing separately Pressure drop values for single pulse tests can be very different from values for multiple pulse tests 3 Retest and then replace any injector which has not improved after being flushed or cleaned 3 5 After testing 1 Disconnect all tester leads from fuel injectors and harnesses Note Always grasp adaptor ends near terminals when removing from injectors or harnesses to prevent damage Do not tug or jerk adaptor wires from terminals 2 Remove tester clips from vehicle battery 3 Fully depressurize fuel pressure gauge and fuel system a Schrader valve when removing gauge
8. ist FUEL INJECTOR amp HARNESS TESTER 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 OR PERSONAL INJURY AND WILL INVALIDATE THE WARRANTY The use of symbols in this document is to attract your attention to possible danger The symbols and warnings themselves do not eliminate any danger nor are they substitutes for proper accident prevention measures 1 SAFETY INSTRUCTIONS Always wear approved eye protection Always operate the vehicle in a well ventilated area Do not inhale exhaust gases they are very poisonous Always keep yourself tools and test equipment away from all moving or hot engine parts Always make sure the vehicle is in Neutral manual transmission or Park automatic transmission and that the parking brake is firmly applied Block the drive wheels Always keep handy a fire extinguisher suitable for fuel electrical chemical fires Always turn ignition key OFF when connecting or disconnecting electrical components unless otherwise instructed Use shop rags to cover fuel line fittings when connecting or disconnecting fuel
9. nd apply Section 1 safety instructions 3 1 Pre Test checks 1 Do a thorough visual and hands on inspection of the engine and fuel system Look for loose or cracked electrical wiring battery cables ignition wires and fuel or vacuum lines 2 Verify that the battery is fully charged and fuel tank has adequate fuel 3 Verify that the inertia fuel cut off switch if fitted has not been actuated see vehicle manual 4 Verify that all fuel system fuses are good 5 Verify that the fuel vapour recovery system and filler cap are in good condition 6 Verify that manifold vacuum is within manufacturer s specification typically 18 20 in Hg at idle 7 Look for fuel leaks and wipe up any spilled fuel immediately 8 Has the vehicle been serviced recently Sometimes things get reconnected incorrectly or not at all 9 Do not take shortcuts Inspect wiring which may be difficult to see because of location beneath air cleaner housings alternators etc 10 Inspect wiring harnesses for Contact with sharp edges this happens often Pinched burned of chafed insulation Contact with hot surfaces such as exhaust manifolds Proper routing and connections 11 Check electrical connectors for Corrosion on pins Bent or damaged pins Contacts not properly seated in housing Note Problems with connectors are common in the engine control system inspect carefully Note that some connectors use a special grease on the contacts to prevent corrosion Do
10. ndard equipment on most new vehicles Although far more reliable and efficient than carburettors fuel injection systems have their own unique problems In many cases fuel injection problems can be linked to blocked or sticky fuel injectors Testing fuel injectors was once a complicated and inaccurate procedure but with the VS211 Fuel Injector amp Harness Tester you can now quickly and easily locate any malfunctioning fuel injector without removing it from the vehicle The VS211 Fuel Injector amp Harness Tester is a hand held device used to check the function of fuel injectors and their associated wiring harnesses on most vehicles The VS211 tests for clogged or leaking fuel injectors by using a single half second pulse Multiple 5 millisecond pulses are used to test for sticky or sluggish fuel injectors By using a fuel pressure gauge VS210 optional and comparing fuel pressure differences as each fuel injector is pulsed faulty injectors can quickly be identified In addition the VS211 Fuel Injector amp Harness Tester is able to test fuel injection wiring harnesses for faulty wiring and connectors FUEL INJECTOR amp HARNESS TESTER POWER CONTINUITY Power LED 1 As soon as the battery clips are attached to the vehicle battery the Power LED will light This Doa ee verifies a good power connection Harness Adapter Injector Adapter Continuity LED 2 Indicates a good connection to the fuel injector or fuel injector wiring har
11. ness This must be Red lit before proceeding with any testing EDN Output LED 3 Indicates the presence of a signal from the vehicle s on board computer to the fuel injector OR GTT C Teki Ta a pulse from the tester to the fuel injector Injector Adapter Harness Adapter Trigger Button 4 Activates fuel injector test pulses Injector Harness Switch 5 Selects fuel injector or fuel injector wiring harness testing Single Multiple Pulses Switch 6 Switches between one half second and multiple 5 millisecond test pulses produced when the Trigger Button is pressed GM TBI GM TBI Injector Adapter Harness Adapter Battery Clips 7 Attach to vehicle battery to power the Fuel Injector amp Harness Tester Fuel Injector Wiring Harness Interface Cable 8 Connects the Fuel Injector amp Harness Tester to a fuel injector se or fuel injector harness for testing via adaptors Aness Adaptei Adamar Fuel Injector Wiring Harness Adaptors fig 1 Used to connect interface cable to vehicle Since all vehicles are different several colour coded adaptors are included Same colour adaptors are used for the same application one fia 1 adaptor is used to connect the interface cable to the fuel injector Ig and the other connects the interface cable to the wiring harness PRSE VS211 0527 1 240599 BOSCH Injector Adapter 3 TESTING PROCEDURE Oo WARNING Before using equipment ensure you have read understood a
12. ring harnesses in sequence beginning with cylinder No 1 FUEL INJECTOR HARNESS TESTER Set Injector Harness switch to Harness Connect appropriate harness adaptor to the interface cable 5 Connect Fuel Injector Wiring Harness Interface Cable to injector harness being tested using the adaptor fig 4 For all harness adaptors either wire may be connected to either terminal of the harness The tester is designed in such a way that hook up orientation does not matter Note The continuity LED may be bright dim or off The status of the continuity LED becomes important in later testing viens ral 6 Turn vehicle ignition key ON but do not start vehicle On most vehicles the continuity LED will now be on If the continuity LED remains off further testing will determine if a problem exists 7 Start the engine if engine will not start then have an assistant crank the engine Observe the LEDs i Note vehicle may start and run even with one or more injectors disconnected This does not affect fig 4 the harness test Observe all safety precautions fF YY Verify that the continuity LED is lit and the output LED is flashing Note Output LED may flash so quickly that it appears to be continuously on This is normal If the continuity LED does not light and the output LED is not flashing then check all electrical connections If all electrical connections are good then proceed to para 3 7 3 7 Wirin
13. rs except Bosch type it does not matter which wire is connected to which terminal on the injector Make sure the injector adaptor wires are securely fastened to the fuel injector terminals and that there is no exposed metal between them For Bosch type injectors the injector adaptor is keyed and can be attached one way only 5 Verify that the continuity LED is lit If continuity LED does not light check all electrical connections If all electrical connections are secure injector is faulty and should be replaced 6 Set Pulse switch Single will test for clogged injectors Multiple will test for sticky or sluggish injectors 7 Re pressurize fuel system as described in para 3 2 2 1 Be sure that fuel pressure is stable before continuing Record this initial fuel pressure for reference Note Fuel system must be re pressurized to manufacturer s specifications before testing each fuel injector 8 Press Trigger button to energize fuel injector Output LED will flash briefly as injector is energized by the tester 9 Record fuel pressure drop 2 3 seconds after pulse Note Make sure that each injector s pressure drop is recorded at the same length of time after the pulse If this time interval varies the test results will be inaccurate due to normal fuel system leakdown 10 Repeat steps 1 4 5 7 8 9 with the next injector until all injectors have been tested 11 After testing all injectors with pulse switch in one posit
14. uge and vehicle service manual instructions and safety precautions when opening fuel lines The information in this manual is not a substitute for the procedures outlined in the vehicle service manual ALWAYS follow manufacturer s instructions and safety precautions when working on fuel systems 3 Depressurize fuel system by following procedure outlined in vehicle service manual On most vehicles this involves disconnecting or deactivating the electric fuel pump s and operating the engine until it stalls Note Some vehicles may have more than one fuel pump deactivate all pumps Failure to do so can result in personal injury vehicle damage spilled fuel fire or other hazardous conditions 4 Using proper fuel pressure gauge adaptor open fuel line at point specified in vehicle service manual and connect adaptor to fuel line 5 Attach fuel pressure gauge to adaptor and tighten fitting until finger tight IMPORTANT Read and follow all pre test checks safety instructions and fuel pressure testing procedures contained in this document and in vehicle service manual O WARNING Always use caution when working around fuel systems The fuel in the fuel rail may be pressurized even if the engine is not running Use a rag to cover the schrader valve or fitting whenever opening the fuel system to attach gauge Clean all fuel spills immediately 3 2 2 Test for fuel system leaks 1 Pressurize fuel system by cycling ignition ON and OFF

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