PT W80595 - User Manual

OWNER'S MANUAL

WARNING: READ, UNDERSTAND AND FOLLOW ALL INSTRUCTIONS AND
WARNINGS BEFORE OPERATING THIS TOOL. FAILURE TO DO SO MAY
RESULT IN PERSONAL INJURY AND/OR PROPERTY DAMAGE AND WILL
VOID WARRANTY.
FUEL INJECTION
PRESSURE TESTER
Item Number W80595
LIMITED WARRANTY
PERFORMANCE TOOL® extends only the following warranties, and only to original retail purchasers. These
warranties give specific legal rights. Except where prohibited by local law, the law of the State of Washington
governs all warranties and all exclusions and limitations of warranties and remedies. There may be other rights
which vary from state to state.
PERFORMANCE TOOL® warrants the product to be free from defects in materials and workmanship under normal
use and service. A defective product may be returned for a free replacement within 90 days from the date of
purchase, provided that product is returned to place of purchase immediately after discovery of defect. After 90
days and up to one year from date of purchase, PERFORMANCE TOOL® will replace at no charge any parts which
our examination shall disclose to be defective and under warranty. These warranties shall be valid only when a sales
receipt showing the date of purchase accompanies the defective product or defective part (s) being returned. For
part (s) after 90 days, please remit your request, postage prepaid to:
PERFORMANCE TOOL, P.O. Box 88259 Tukwila, WA 98138
These warranties exclude blades, bits, punches, dies, bulbs, fuses, hoses, and other consumables which must be
replaced under normal use and service. These warranties shall not apply to any product or part which is used for a
purpose for which it is not designed, or which has been repaired or altered in any way so as to affect adversely its
performance or reliability, nor shall these warranties apply to any product or part which has been subject to misuse,
neglect, accident or wear and tear incident to normal use and service.
PERFORMANCE TOOL® does not authorize any other person to make any warranty or to assume any liability in
connection with its products.
Except for warranties of title and the limited express warranties set forth above, PERFORMANCE TOOL® makes no
express or implied warranties of any kind with respect to its products. In particular, PERFORMANCE TOOL® makes
no implied warranty of merchantability and no implied warranty of fitness for any particular purpose, except that for
goods purchased primarily for personal, family or household use and not for commercial or business use,
PERFORMANCE TOOL® makes an implied warranty of merchantability (and, if otherwise applicable, an implied
warranty of fitness for a particular purpose), but only for the particular qualities or characteristics, and for the
duration, expressly warranted above.
The laws on limitation of implied warranties may differ from state to state, so the above limitations may not apply in
all cases.
PERFORMANCE TOOL® shall not be liable for consequential, incidental or special damages resulting from or in any
manner related to any product, or to the design, use, or any inability to use the product. The sole and exclusive
remedy for a defective product or part shall be the repair, or replacement thereof as provided above. The laws on
limitation of remedies or on consequential, incidental or special damages may vary from state to state, so the above
limitations may not apply in all cases.
© Copyright 2019 WILMAR CORPORATION, P.O. Box 88259 Tukwila, WA 98138

Summary

Limited Warranty

Warranty Terms and Conditions

Details the terms, duration, and limitations of the product warranty, including return procedures for defective parts.

Features and Specifications

About This Tester

Describes the W80595 Fuel Injection Pressure Tester and its capabilities in diagnosing fuel system issues.

Specifications

Lists the technical specifications for the pressure gauge, hoses, and adapters included with the tester.

Safety Guidelines and Warnings

General Safety Instructions

Provides critical safety instructions, definitions of signal words (DANGER, WARNING, CAUTION, NOTE), and product warnings.

Product Specific Warnings

Details specific warnings for operating the fuel injection pressure tester, emphasizing safe handling and usage.

Operation and Procedures

Pre-Test Procedures

Outlines essential pre-testing steps including safety precautions, system inspection, and verifying vehicle conditions.

Connecting and Operating the Tester

Step-by-step guide on how to connect the tester to the vehicle, perform the pressure test, and safely disconnect.

Applications and Notes

Vehicle Applications

Lists domestic and import vehicles compatible with the fuel injection pressure tester, specifying model years and engine types.

Important Notes

Provides supplementary information and reminders relevant to the tester's use and vehicle compatibility checks.

Overview

1. Function Description
2. Important Technical Specifications
3. Usage Features
4. Maintenance Features
5. Safety Guidelines

The W80595 Fuel Injection Pressure Tester is a diagnostic tool designed to measure fuel pressure in the fuel systems of most domestic and import cars and trucks. Its primary function is to help identify and troubleshoot fuel system problems that can impact a vehicle's performance and fuel economy. By providing accurate fuel pressure readings, the tester assists in diagnosing issues such as low fuel pump pressure, faulty fuel pressure regulators, fuel system leaks, leaking fuel injectors, and clogged fuel filters.

Function Description

The tester operates by connecting to the vehicle's fuel system test port, typically a Schrader valve on the fuel rail. Once connected, it measures the pressure within the fuel system, displaying the reading on its integrated gauge. The device includes a pressure release button and a bleed-off hose, which are crucial for safely relieving fuel pressure from the system after testing and for draining residual fuel into an approved container. This ensures that the system can be disconnected without fuel spray or leakage. The kit comes with various adapters to ensure compatibility with a wide range of vehicles, including Ford, GM, Chrysler, and some import models.

Important Technical Specifications

• Pressure Gauge: The tester features a 2-1/2 inch gauge with a measurement range of 0-100 PSI (pounds per square inch) or 0-700 kPa (kilopascals). This range is suitable for most fuel injection systems.
• Bleed Off Hose: A 6 ft. (1.8 M) bleed-off hose is included, designed to safely direct fuel into a container during pressure relief. The length is critical to ensure the hose can reach an approved container on the floor, preventing spills.
• High Pressure Hoses: The kit includes 5/16 and 3/8 inch high-pressure hoses, which are essential for carrying fuel to the gauge and for connecting to various fuel system components.
• Adapters: The tester is supplied with adapters compatible with Ford, GM, Chrysler, and Import Vehicles. These adapters facilitate connection to different types of fuel rail test ports and fuel lines. Specific adapters include:
  • Test Port Adapter for GM, Chrysler, Dodge, and Jeep models.
  • Test Port Adapter for Ford, Lincoln, and Mercury models.
  • Tee Fitting Adapter for some Import Vehicles not factory-equipped with a test port Schrader valve, used with the universal 5/16 and 3/8 inch hoses and hose clamps.

Usage Features

The W80595 Fuel Injection Pressure Tester is designed for straightforward operation, but requires adherence to strict safety protocols due to the flammable nature of fuel and the high pressures involved.

• Pre-Test Procedures: Before connecting the tester, users must relieve fuel system pressure, ensure the ignition key is in the off position, and locate the correct fuel system test port, distinguishing it from A/C test ports. It's crucial to wrap shop rags around fittings during connection/disconnection to manage potential leaks.
• Connection: For Ford, Lincoln, Mercury, and some Chrysler vehicles, the appropriate port adapter is installed on the throttle body or fuel rail test port, then the gauge hose is connected. For GMC, Chevrolet, Buick, Oldsmobile, Pontiac, and Cadillac models, the port adapter is permanently attached to the high-pressure hose, which connects directly to the test port. The bleed-off hose must always be clamped into an approved drain container.
• Testing: With the ignition key in the "on" position (KOEO - Key On, Engine Off), the fuel pump activates, pressurizing the system. The gauge displays the pressure, which is then compared against the vehicle's service manual specifications. The engine can also be started (KOER - Key On, Engine Running) to observe pressure under normal idle conditions.
• Pressure Release: After testing, the pressure release button is pressed and held until the gauge reads 0 PSI, ensuring all pressure is bled off. The bleed-off hose is jiggled to ensure complete fuel removal.
• Disconnection: Once pressure is relieved, the fitting is carefully unthreaded from the port adapter, and the protective cap is replaced on the vehicle's test port.
• Vehicle Compatibility: The tester is compatible with vehicles having a Schrader valve test port on the fuel rail. It supports Ford high-pressure central fuel injection (CFI) and GM, Ford, and Chrysler multiport fuel injection (MPI). It is explicitly stated that the tester does not work on diesel vehicles. Specific application lists are provided for various domestic and some import models from the 1980s and 1990s, often requiring verification of the 8th digit of the Vehicle Identification Number (VIN) for precise application.

Maintenance Features

Proper maintenance of the tester ensures its longevity and accuracy.

• Cleaning: After use, the bleed-off hose should be drained completely, and the tester stored in a well-ventilated area to dry. Any spilled fuel must be immediately cleaned up.
• O-Ring Care: The service life of the port adapter's O-rings can be prolonged by applying a protective coating oil to them before storage. This helps maintain their sealing integrity.
• General Care: The manual emphasizes keeping the tester, tools, and oneself away from moving or hot engine parts. It also advises against laying tools on the vehicle battery to prevent short circuits and recommends having a fire extinguisher suitable for fuel/electrical/chemical fires readily available.

Safety Guidelines

Safety is paramount when using this tool. The manual provides extensive warnings:

• General Safety: Always wear approved eye protection. Never use the tester on Diesel or Flex Fuel engines. Do not confuse A/C Schrader valves with fuel rail test ports. Never attach or remove the kit with the ignition key on.
• Fuel Handling: Always place the bleed-off hose in an approved container for fuel. Never smoke or have open flames near the vehicle. Immediately clean up any fuel spills or leaks.
• Ventilation: Operate the vehicle in a well-ventilated area to avoid inhaling hazardous exhaust gases or fuel vapors.
• Vehicle State: Ensure the vehicle is in PARK (automatic) or NEUTRAL (manual) with the parking brake firmly set, and the drive wheels blocked.
• Electrical Hazards: Exercise extreme caution around ignition coils, distributor caps, ignition wires, and spark plugs due to high voltage.
• SRS Systems: Be aware of Supplemental Restraint Systems (airbags) and follow vehicle service manual cautions, as airbags can deploy unexpectedly even with the ignition off or battery disconnected.

Failure to follow these instructions and warnings can result in personal injury, property damage, and will void the warranty.

PT W80595 Specifications

General

Brand	PT
Model	W80595
Category	Test Equipment
Language	English