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

• To prevent accidents that could result in serious injury and/or damage to your vehicle or
test equipment, carefully follow these safety rules and test procedures at all times when
working on vehicles.
• Always wear approved eye protection.
• Never use Fuel Injector Pressure Tester on Diesel or Flex Fuel engines!
• Never attach Fuel Injector Pressure Tester to any place other than the fuel rail test port.
Do not confuse Air Conditioning Schrader valves with the fuel rail test port.
• Never attach or remove Fuel Injector Pressure Tester Kit from fuel rail test port with the
ignition key on.
• Always place end of 6 ft. bleed-off hose in an approved container for fuel during testing
and when bleeding off fuel pressure.
• Never smoke or have open ames near vehicle. Vapors from fuel and charging battery
are highly ammable and explosive.
• Never permit fuel to spill on hot engine parts. If a spill or leak occurs, immediately turn
ignition key off, and clean up fuel.
• Only use the Fuel Injector Pressure Tester Kit for measuring fuel pressure on vehicles
having Schrader valves as their fuel rail test port. Do not use this kit for any other purpose!
• Always operate the vehicle in a well ventilated area. Do not inhale exhaust gases or fuel
vapors - they are very hazardous!
• Always keep yourself, tools and test equipment away from all moving or hot engine
parts. These would include fan blades or exhaust manifolds.
• Always make sure the vehicle is in PARK (Automatic transmission) or NEUTRAL (manual
transmission) and that the parking brake is rmly set. Block the drive wheels.
ABOUT THIS TESTER
The W80595 Fuel Injection Pressure Tester is designed to perform fuel pressure tests
on most domestic and import cars and trucks. The tester saves you time and money by
helping you test and troubleshoot fuel system problems which can affect your vehicle’s
performance and fuel economy.
The tester can help you identify and diagnose the following symptoms.
• Low fuel pump pressure • Leaking fuel injectors
• Faulty fuel pressure regulator • Clogged fuel lter
• Leaks in the fuel system
1. Gauge - Shows the amount of fuel pressure present in fuel system.
2. Pressure Release Button - Removes fuel and pressure from the fuel rail as a result of the test.
3. Bleed Off Hose - Removes the fuel and pressure after the pressure release button has
been pressed. Hose should be long enough to t into an approved container for fuel.
CAUTION: Never use a short hose. Hose must be long enough to clamp into an
approved container on the oor.
4. High Pressure Hose - Carries the fuel to the gauge for measuring pressure.
5. Test Port Adapter - This adapter is used to connect GM, Chrysler, Dodge, and Jeep
models to the test port Schrader valve on the fuel rail.
6. Test Port Adapter - This adapter is used to connect Ford, Lincoln, and Mercury models
to the test port Schrader valve on the fuel rail.
7. Tee Fitting Adapter – This adapter is used to connect some Import Vehicles to the Fuel
Pressure Tester. Use this on vehicles not factory-equipped with a test port Schrader valve.
8. 5/16 and 3/8 in. Hoses - Universal high-pressure hoses used with the tee tting, and hose clamps.
The adapters included with the tester t the most common fuel injection applications. Some
vehicle applications may require additional tools or adapters to properly test the vehicle.
Always refer to your vehicle’s service manual, when doing any testing.
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This instruction manual is intended for your benet. Please read and follow the safety,
installation, maintenance and troubleshooting steps described within to ensure your safety
and satisfaction. The contents of this instruction manual are based upon the latest product
information available at the time of publication. The manufacturer reserves the right to
make product changes at any time without notice.
SAFETY GUIDELINES / DEFINITIONS
WARNING: Read and understand this entire instruction manual before attempting to
assemble, install, operate or maintain this product. Failure to comply with the instructions
may result in serious personal injury and/or property damage!
The following signal words are used to emphasize safety warnings that must be
followed when using this product:
DANGER: Indicates an imminently
hazardous situation that, if not avoided,
WILL result in death or serious injury.
WARNING: Indicates a potentially
hazardous situation that, if not avoided,
COULD result in death or serious injury.
CAUTION: Indicates a potentially
hazardous situation that, if not avoided,
MAY result in minor or moderate injury.
NOTE: Indicates important information,
which if not followed, MAY cause damage
to equipment.
FEATURES
Pressure Gauge ......................................2-1/2 in., 0-100 PSI / 0-700 kPa
Bleed Off Hose ........................................................................6 ft. (1.8 M)
High Pressure Hoses........................................................ 5/16 and 3/8 in.
Adapters .....................................Ford, GM, Chrysler and Import Vehicles
SPECIFICATIONS:
Specifications are subject to change without notice.
PRODUCT WARNINGS

PRIOR TO TESTING FOLLOW THESE PRETEST PROCEDURES.
1. Read all safety precautions listed in this manual and the vehicles shop manual. Paying
close attention to air bag connections and precautions.
2. Do a thorough hands-on inspection of the fuel system. Look for fuel or vacuum line
leaks, cracked or loose electrical connections. If fuel leaks are present wipe them up
immediately.
3. Insure you have a fully charged battery and enough fuel to conduct this test.
4. Verify that the inertia switch on certain Ford/Lincoln/Mercury vehicles has not been
tripped. The inertia switch is designed to shutoff the fuel pump in the event of a collision.
This switch is typically mounted under the dash on the passenger side, or in the trunk.
5. Check that all fuel system fuses are good.
6. Verify that the fuel vapor recovery system, and gas cap are in good condition.
7. Locate the vacuum line which is attached to the fuel pressure regulator and remove it,
this line should be free of fuel, if fuel is observed the regulator has failed.
8. Once the inspection for the fuel pressure regulator is complete reinstall the vacuum line.
9. Test manifold vacuum to ensure it is within manufacturer’s specication. A typical
vacuum reading would be 18-20 in. at idle.
CAUTION: Be aware that fuel systems are UNDER PRESSURE AND HIGHLY
FLAMMABLE. Relieve system pressure before connecting the tester. Refer to your
vehicle’s service manual for those procedures. Systems without test ports require that fuel
lines be removed or disconnected. Be aware that these lines are also UNDER PRESSURE
AND HIGHLY FLAMMABLE. When removing the lines it could cause fuel to spray and/
or leakage onto hot engine parts. In addition to following all safety precautions, a basic
understanding of your fuel injection systems is necessary. Read your shop manual
thoroughly to prevent personal injury or damage to your vehicle.
1. Before connecting tester, relieve fuel system pressure. Refer to your vehicle’s service
manual for procedures. Loosen or remove cap from the fuel tank to relieve potential
tank pressure.
2. Ignition key must be in the off position.
3. Locate the fuel system’s test port, and remove the protective cap. You’re A/C test port is similar
to the fuel system. Both have a protective cap and a Schrader valve inside. The low side
A/C port is typically larger than the fuel ports. Do not get these ports confuse. Refer to your
vehicle’s service manual to ensure proper connections. Wrap shop rags around tting when
connecting or disconnecting the tester. Have shop rags ready to clean up leaks or spills.
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4. Connect the tester to your vehicle’s fuel system test port.
- FORD, LINCOLN, MERCURY AND SOME CHRYSLER VEHICLES
Install the port adapter on the throttle body or fuel rail test port. Be sure the threads are
correct, it should thread on easily. Finger tight only, then connect the gauge hose to the
adapter. Clamp bleed-off hose into an approved drain container. Make sure the hose
remains in the container until testing is complete.
-GMC, CHEVROLET, BUICK, OLDSMOBILE, PONTIAC, CADILLAC AND SOME
CHRYSLER VEHICLES
The port adapter for the above models is permanently attached to the high pressure hose.
5. Connect the gauge hose directly to the test port, and nger tighten only. Clamp bleed-off
hose into an approved drain container. Make sure the hose remains in the container
until testing is complete.
6. Make sure all of the vehicle’s accessories including the A/C, fan, radio, defroster, lights,
etc. are all off.
7. Turn your key to the on position, (KOEO), listen for the fuel pump to activate. Most injection
systems will activate the pump for about two seconds to pressurize the fuel system.
8. Check the setup connections for fuel leaks. If you have a fuel leak, turn off the ignition
immediately! Repair the leak and clean up the spilled fuel.
9. If your fuel system does not activate as described above, turn ignition key off. Refer to the
manufacturer’s service manual for repair procedures or fuel pump activation instructions.
10. When you hear the fuel pump activate, the fuel system is pressurized. Verify by looking
at the pressure gauge, it should show a system pressure.
11. Check this against the information in the Specication section of your vehicle’s
service manual. If pressure is not within specications, turn ignition off. Follow the
repair procedures in the service manual. If fuel pressure is within manufacturer’s
specications, proceed to the next step.
12.Start the engine, (KOER), bring it to a normal idle. While warming recheck connections
for fuel leaks.
13. Read the fuel pressure on the tester. If the fuel pressure is steady and within specications
for your vehicle, proceed to the next step. If pressure is not within specications, turn
ignition off and follow the test and repair procedures in your vehicle’s service manual. After
all necessary repairs have been completed, return to step 12 and retest.
14.When your test is complete and the desired pressure has been reached, record the
information and turn the ignition off. Typically in the back of a service manual there is a
“notes” section. This is a good place to record the detailed results.
15.Make sure the bleed-off hose is still clamped to the drain container.
16.Press and hold the pressure release valve to bleed off pressure still in the tester. Hold
the valve until the gauge indicates 0 PSI.
17.Jiggle the bleed-off hose to ensure all the fuel has been removed.
18. Use a shop towel to wrap around test port tting. This will aid in absorbing any residual
fuel, and guard against spray from potential pressure in the line.
19. Carefully unthread the tting from the port adapter. For Ford vehicles remove the
additional adapter from the vehicle’s test port. Replace protective cap on port tting.
20. After the bleed off hose has drained completely remove it from the drain container. Store
the tester in a well-ventilated area to dry completely. Service life of the port adapter’s
O-rings can be prolonged by applying a protective coating oil to them before storing.
21. Verify that all fuel system components were reconnected. Start the engine, check for
leaks and repair as necessary. It might take a few extra cranks for the fuel system to
energize after delivery was interrupted.
• Never lay tools on vehicle battery. You may short the terminals together causing harm to
yourself, the tools or the battery.
• Never leave vehicle unattended while running tests.
• Always keep a re extinguisher suitable for fuel/electrical/chemical res handy.
• Always use extreme caution when working around the ignition coil, distributor cap,
ignition wires, and spark plugs. These components contain high voltage when the engine
is running.
• Complete all pre-testing checks before beginning fuel pressure testing.
• Always follow vehicle manufacturer’s warnings, cautions and service procedures.
CAUTION: Some vehicles are equipped with SRS Supplemental Restraint System,
safety air bags. You must follow vehicle service manual cautions when working around the
air bag components or wiring. If the cautions are not followed, the air bag may open up
unexpectedly, resulting in personal injury. Note that the air bag can still open up several
minutes after the ignition key is off, or even if the vehicle battery is disconnected because of
a special energy reserve module.
PRODUCT WARNINGS
OPERATION
OPERATION

The W80595 Fuel Injection Pressure Tester works on most domestic fuel injected vehicles with
a Schrader valve test port on the fuel rail. This includes Ford high pressure central fuel injection
and GM, Ford, and Chrysler multiport fuel injection. Does not work on diesel vehicles.
Domestic FORD, LINCOLN, MERCURY
High Pressure Central Fuel Injected (CFI) Vehicles
1981-86 Country Squire, Crown Victoria, LTD, Colony Park, Grand Marquis, & Marquis
1985-86 Mustang & Capri
1985-97 Thunderbird & Cougar
1981-85 Continental, Town Car, Mark VI & Mark VII
1980 Versailles
Most Multi-Port Fuel Injected (MPI) Vehicles 1983 to 1996.
Not including the following Models:
Festiva & Aspire 1.3L
Capri 1.6L
Escort & Tracer 1.8L
Probe 2.0L, 2.2L & 2.5L
Villager 3.0L
Domestic Vehicles GMC, CHEVROLET, BUICK, OLDSMOBILE, PONTIAC, CADILLAC
Most Multi-Port Fuel Injected (MPI) Vehicles 1984 to 1996.
Not including the following Models:
1988 1.6L Nova
1988-89 1.5L Spectrum
1987-90 Sprint Turbo
Domestic Vehicles CHRYSLER, PLYMOUTH, DODGE, JEEP, EAGLE
Multi-Port Fuel Injected Passenger Vehicles
1995-96 2.0L 8th Digit VIN C or Y
1984-93 2.2L Turbo 8th Digit VIN E
1995-96 2.4L 8th Digit VIN X
1991-95 2.5L 8th Digit VIN P
1984-92 2.5L Turbo 8th Digit VIN J
1987-96 3.3L 8th Digit VIN R or T
1993-96 3.5L 8th Digit VIN F
1987-93 3.8L 8th Digit VIN L
1987-96* 4.0L 8th Digit VIN S
Multi-Port Fuel Injected Trucks & Vans
1996 2.4L 8th Digit VIN B
1989 2.5L Turbo 8th Digit VIN J
1992-96 3.3L 8th Digit VIN R
1994-96 3.8L 8th Digit VIN L
1992-96* 3.9L 8th Digit VIN X
1992-96* 5.2L 8th Digit VIN Y
1993-96 5.9L 8th Digit VIN 5 or Z
1994-96 8.0L 8th Digit VIN W
1993-96* 5.2L 8th Digit VIN Y
It’s necessary to have the 8th Digit of the Vehicle Identication Number to verify application
*Some 1996 and older vehicles may not have the Schrader valve test port on the fuel rail.
Import Vehicles GEO, ISUZU, MAZDA, NISSAN, SUBARU, SUZUKI, VOLKSWAGEN
1980-98 Vehicles that don’t have a Schrader valve test port on the fuel rail. 7
APPLICATIONS NOTES: