Sealey V5402.V2 User manual

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Aula Serv ice Line
INSTRUCTIONS FOR:
VACUUM TESTER AND
BRAKE BLEEDING KIT
MODEL No. V5402.V2
Thank you for purchas•ng a Sealey product Manufactured to a high standard this product will, if used according to these instruclions and properly maintained, give you years
of trouble free performance.
l
b.._ IMPORTANT: PLEASE READ TH ESE I NSTRUCTIONS CAREFULLY. NOTE THE SAFE OP E RATIONAL REQUI REMENTS, WARNINGS , AND
ili CAUTIONS . USE THIS PROD UCT CORRECTL Y, 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
./ Keep this product in good wo rking order and condition, take immediate action to repair or replace damaged parts.
./ Use approved parts only. Unapproved parts will invalid ate the warranty .
./ Keep child ren and unauthoris ed persons awa y from the work area .
./ Keep worlk area cle an and tidy and free from unrelated mate r ials .
./ En sure t he worlk area has adequate lighting.
X DO NOT use t he kit to perform a task for which it is not des igned.
X DO NOT hold pump inle t against the skin whilst usi ng the pump.
X DO NOT allow untrained persons to use the kit.
X DO NOT use whilst u nder the influence of drugs, alcohol or intoxicating medication.
./ After use , clean equipment a nd store in a cool, dry, ch ildpr oo f area.
0 WARNING! Brake fluid will damage paintwork. Any sp illage should be flushed with water immediately.
0 WARNING! Brake fluid is flammab le- keep away from sources of ignition, including hot surfaces e.g. exhaust manifold.
./ Dispos e of w aste liquids in accordance with local-authority regulations.
0 WARNING! DO NOT pollute the environment by allow ing uncontrolled discharge of fluids.
./ Always read and comp ly with the warnings on the brake fluid contalller .
./ Wear eye protection and keep skin contact to a minunum If brake fluid eMers eyes rinse with plenty of water and seek medical advice. If swallowed seek
medical advice immediately.
2. SPECIFICATION & CONTENTS
The VS402.V2 vacuum tester and brake bleeding kit is a multi-function diagnostic tool used to test a variety of essential engine a nd associated functions inclu ding
fuel, ignition, transmission and emissions. Set also includes reservoir, hoses and adaptors for bleeding brake and clutch sys t ems on cars. commercia ls and
motor cycles. Brass-bodied vacuum pump features large, easy-to-read vacuum gauge calibrated in both inches and millim et res of mercury.
ITEM
PART No .
DESCRIPTION I TE M PART
No . DESCRI PT ION
1 VS402.V2-01
VACUUM P UMP WITH GAUGE
6 VS402.V2-06 --·
·· --
HOSE ADAP T OR
2A
VS402 . V2-02A
RESERVOIR LID (FOR OPERATION ) 7 VS402.V2-07 HOSE ADAP T OR 'T-PIECE'
28 VS402.V2-02B RESERVOIR UD (FOR TRANSPORT)
8
VS402 . V2-08
HOSE ADAP TOR 'STRAIGHT'
3 VS402.V2-03
RESERVOIR JAR
9
VS402.V2-09 BRAKE BLEED NIPPLE ADAPTOR
4 VS402.V2-04 560mm VACUUM HOSE
'
10
VS402 .V2-10 UNI VERSAL CUP ADAPTOR
!:;
VS402.V2 - 05 80mm VACUUM H OS E
J
( C Jack SealeyLimited ) OriginalLanguage Verston ( VS402.V2 I
Issue : 1 - 22/05/12 I

3. INTRODUCTION
The use of a vacuum gauge is often overlooked when determining mechanical condition and carrying out fault diagnosis on internal combustion engines.
Monitoring actual manifold vacuum
is invaluable when troubleshooting engine faults. This can only be carried out by using a good qual ity vacuum gauge and this,
coupled with a hand-operated vacuum pump, also allows static testing
of all types of vacuum operated systems. Set out on the following pages are applications
that the VS402.V2 vacuum tester kit can
be used for, but it mustalways be remembered that these are examples only and reference to manufacturer's service
manuals should always be made for correct testing procedures and specifications.
In addition to this, it is always recommended that additional tests, ie.
compression tests, cylinder leakage tests, ignition timing checks etc. be carried out to confirm indications
of vacuum gauge readings.
4. INLET MANIFOLD SYSTEMS
4.1. Analysing Engine Mechanical Conditi on via Manifold Vacuum Readings
4.1.1. The readin
gs shown below are only examples of what may be observed. It is
important to remember that it is the action of the needle rather than the actual
reading that is more important. Varying engine types will run different manifold
vacuum pressures, depending on camshaft profile, valve overlap, timing etc. so
<;~n
exact vacuum reading cannot be specified. The main criteria is that the needle
reading
is between 16 to 21inHg and steady.
4.1.2. Manifold vacuum is also affected by altitude and
it will drop approximately 1inHg for
every 1000 feet above sea level so this rr.ust also be considered when assessing
manifold vacuum actual readings.
4.2.
Basic Diagnostic Tests
4.2.1. Carry out the following procedures:
Step 1. Run engine until normal operating temperature is reached.
Sw itch engine off.
Step
2. Connect the vacuum gauge to a port directly on the manifold {fig.1) or on the
carburettor/throttle body below the throttle butterfly.
Step 3. Start and run the engine at idle, observing the gauge reading.
4.2.2. Refer to the following table to indicate any problems and their possible causes.
( <!:> Ja ck Sealey Limited
READING: 16·21 inHg
with
needle steady.
CAUSE: Normal.
READ
IN : Read in gs s lig h tl y l ower
han for normal engine including
hen thrott le is s udd enly opened
then released .
AUSE: Wom piston rings . Carry
ut compression test .
READING: When the throtlle is
suddenly opened then ...- the
needle should drop to below 5inHg
then bounce up to appro ximately
2SinHg settling back
to original
reading.
CA ·Normal.
READING: Reading
slightly low and
u
ctuating slowly.
AUSE: Over lea.l or rich mixture.
heck and reset in accordance with
manufacturers specifications.
Original Language Version
READING : ~ extrwnoly low
steady.
USE: l.eaD>g inl*e-
system, Faulty manifotdgasl<et,
cal'buretto.- base gasket. split
vacuum hose. EGR va l ve seized.
READING: Regular fluctua t ion
between normal and low re3dings.
CAUSE: Blown head gasketbetween
o adjacentcylinders. Carry out
yl inder leakage test
EADING: Normal when firs t starte
ut drops rapid ly when revs he ld at
OOOrpm.
AUSE: Restriction in exhaust
VS402.V2 I Issue: 1 - 22/051 12 )

4.3. Ignitio n System Vacuum Advance
4.3.1. On standard poi nts systems and some electronic ignition s ystems there are two types of advanc e methods used, both of wh ich must function correctly to
obtain maximum performa nce and fuel economy .
4.3.2.
The first method Is Mechanica l or Centrifugal, which operates by the us e of weights located in t he bas e of the dist ributor. Th e weights mov e ou tw ards
advancing ignition timing as engine
RPM incr eases. T his is tested by firstly removing the vacu um advance line to disab le the syste m, then with a timing light
connected, run the engine RPM up chec king that the !Jrr ng adv aoces 1n accordance with the manu fact ur er's specif ication.
4.3.3.
The second method is Vacuum Advanc e, which senses engine load via manifold vacuum. A vacuum diaphragm is moun te d onto the distn l)lllor an d
connected
to a rotating internal base plate which advance s or retards timing as required to suit varying eng ine loads. To t es t this system for correct
ope ra tio n, again with the ti m ing light conne cted. ra ise the engine RPM and check timing advanc e against ma nufa cture r specifications. In the event t hat the
vacuum advance is not oper 2ting, re mov e the vacu um line fr om t he distributor advanc e mechanism. Con nect the VS4 02.V2 (fig.2) and create a 5-10inHg
vacuum, monitoring the timing at
the same t im e. If a timing advance is noted this confirms that the vacuum diap hragm and mec ha nical l i nk~ are in ord er and
that the fault is a vacuum supp ly. To con fir m this, connect the VS402. •12 tc the vacu um supply line an d check the g auge reading. No vacuum should be
noted
at idle but when the engine RPM is increased a vacuum increase should be observed. If this do e::; not o ccur , 1race the va~uPm i<n e back <:ht. king for
restrictions and breaks.
-- -...
(fig.3 lj
/
5.\ FUEL SYSTEMS
5.1. Testing Mechanical Fuel Pumps
5.1.1. The VS402.V2 vacuum tester can be used to evaluate the condition of a mechanical fuel pump by testing the v acuu m th at it is able to create. Locate and
remove
the suction line fro m the pump. Connect the VS402.V2 v ac uum tester to the suct ion port of the pump, start and run t he engine at idle. The vacuum
reading that should be observed wH I vary slightly on different makes and models but as a general rule app roximately 15in Hg of v acuum should be created.
This should
also be held for approximately 1 minute after engine shut down. If this vacuum reading is not achi eved or the v acuu m drops off immediately with
the engine
shut down, the fuel pul'np requires either overhaul or rep lac ement.
5.2.
Carburettors '~ ~
5.2.1. There are many different types c;>f vacuum control systems used on carburettors. Using the VS402.V2 vacuum tester kit allows quick and accura te testing of
these systems. Listed
below are just two examples of tests that can be carried out:
5.2.2. Testing a Choke Break Diaphragm. With the engine at-normal operating temperature but not running, disconnect the vacuum line to the diaphragm module.
Connect the VS402 .V 2 vacuum tester (fig.3) and apply approximately 15inHg of vacuum and wait for 30 seconds. No dr op in gauge reading should be
observed. With the vacuum still applied ensure that the choke butterfly is pulled to the fully open position.
5.2.3. Testing
Vacuum Operated Carburettor Secondary B arre t Wrth the engine at normal operating temperature but not running, remov e t he vacuum line from t he
seco nd ary diaphragm module. Connect the VS402.V2 vacuum tester {fig.4 ), hold the throttle and secondary air va lv e flaps open. Ope r ate the hand pu mp
wh ilst observing free and easy opening of the second ary throttle butterfly.
5.3. Testing Fuel Injection Pressure Regulator
5.3.1. Multi-po int fuel injection rail pressure must vary to suit changing engi ne load s and fu el delivery re quirements . This is done usi ng a v acuum oper ated
regulator which is connected to the engi ne manifold vacuum to sense the varyi ng loads.
5.3.2. To test
the fuel rail pressure, a gauge is attached to the rail, then engine loads must be created to vary engine manifold vacuum. Si mply r emove and block
off the vacuum supply line to the pressure regulator, connect and operate the VS402.V2 vacuum pu mp (fig.5) to simulate va cuum pressures in accordance
with the manufacturer's specifications and note variation in fuel pressure reading.
5.4. Testing Emission Cont rol Exhau st Gas Recirculation Valves (EGR)
5.4.1.
Start engine and run at idle until normal operati ng temperature is reached. Remove the vacuum line from t he EGR va l ve a nd a tt ac h the VS402.V 2 vacuum
tester kit (fig.6). Operate the hand pump to apply approx imately 15inHg of vacuum. If the EGR Valve is wor king correctly t he e ngin e idle will become rough.
If the idle remains unchang ed the valve is possibly seized in the closed position. If the vacuum is no t held, the diaphragm in the valve has failed.
( © Jack Sealey Limite d OriginalLanguage Version I V
S4 02.V2 I Issue: 1 • 22/05 /1 2 )

6. ADDITIONAL VACUUM SYSTEMS
6.1. Testing One-Way Valves
6.1.1. Many vacuum operated circuits use in-line one-way valves to apply vacuum in
one direction only.
6.1.2.
To test the function of the valve remove it from the circuit. Attach the VS402.V2 vacuum tester (fig.7) and operate pump to apply vacuum. In one direction
the valve shou
ld hold vacuum and in the opposite d ir ection it should not.
6.2.
Testing Electrically Operated Vacuum Solenoids
6.2.1. Electrically operated vacuum solenoids are commonly used in control c ir cuits for airconditioning/ventilation systems, emission control syste ms , idle step up
systems etc. and testing the function of these when using the VS402.V2 is extremely simple.
6.2.2. Locate the solenoid to be tested and remove the line that goes to the component being tested. Connect the VS402.V2 to the solenoid port (fig.8) and start
the engine. With the system turned offthere should·be a zero gauge reading. Nowturn the system to the 'on' position and a gauge reading equal
to the
manifold vacuum should be observed,
if no reading exists remove the vacuum supply line and test for manifold vacuum at this point. If the vacuum does
exist this indicates that the solenoid is faulty
or it is no t receiving a 'switch on' voltage (use a multimeter to test this). If no vacuum exists trace the supply
line backto the vacuum source checking
for kinks and breaks.
6.3.
Testing Thermal Vacuum Sw itc hes
6.3.1. There are many vacuum controlled circuits that must only operate when the en gi ne reaches nonnal operating temperature. This is done usi ng thennal
switches that remain in an
'off position until a given temperature is reached.
6.3.2. To test this type of switch, remove the vacuum supply line co
mi ng from the manifold to t he switch and test for manifold vacuu m. If this vacuum is correct refit
the supply line to the thermal switch and remove the opposing line from the switch. Attach the VS402.V2 vacuum tester to the
po rt (fig.9) and start the
engine. With a cold engine
no reading shou ld be noted. When the engine reaches nonnal operating temperature a manifo ld vac uum reading should be
noted.
6.4.
Testing Vacuum Operated Heater Taps
6.4.1. Climate control ventilation systems are becoming very common on newervehicles and most of the systems use vacuum operated taps to control the heating
modes.
On the majority of makes and models, the system uses vacuum to tum the heat er tap 'on'.
6.4.2. To test these remove the supply line from the tap vacuum m
od ule and connect the VS402.V2 vacuum tester (fig.10). With the engine at nonnal operating
temperature locate and feel
the heater return hose. With the heatertap in the ' otr position, this hose should be cold. Now operate the vacu um pump to open
the tap.The gauge read
in g must hold. If the tap is in working order. the retum hose will begin to heat. If the ho se does not begin to heat, this indicates that
the tap is faulty.
6.5.
Testing Vacuum Operated Remote Central Locking Systems
6.5.1. Some makes and models use vacuum operated bellows mounted in each door to centrally lock and un lock the veh icles doors. These systems use either
manifold vacuum stored in a reservoir
for use when the engine is not running or an electrically driven vacuum pump which operates wh en the doors are
locked
or unlocked.
6.5.2. In either system, the VS402.V2 vacuum tester
is ideal for testing each individu al door bellows. To do this. removA the door trims as required. Remove the
vacuum supply lines from the bellows and attach the VS402.V2 vacuum tester (fig.11 ) and operate to apply vacuum to the bellows. Wait
for 30 seconds, no
drop on the gauge should be noted. If the bellows are found to be in order attach the vacuum supply line to the VS402.V2 vacuum tester and operate
system to test for vacuum supply.
If the vacuum supply does not exist or is low trace back down the lines to the vacuum supply looking for kinks, restrictions
or cracked lines. Repair as required and retest.
6.6.
Testing Automati c Transmission Vacuum Operated Modulator Valves
6.6.1. Automatic transmissions are nonnally equipped with a vacuum operated modulator valve in order for the automatic transmission to detect engine loads and
adj
ust shift points to suit. ·
6.6.2. The VS402.V2 vacu
um tester can be used to test both that the modulation valve diaphragm is serviceable and al so to simulate varying engine loads so
modulator pressure readings can be recorded.
To test the modulator valve diaphragm remove the vacuum supply line from the valve and attach the
VS402.V2 vacuum tester. Operate t
he vac uum pu mp until approximately 15in Hg is achieved and monitor the gauge reading for approximately 30 seconds.
No vacuum drop should be noted.
6.6.3.
To ctle ck modulator pressure readings attach a pressure gauge to the appropriate port on the transmission. RerllOYe the vaaMTI supply line from the
modu
la tor and attach the VS402. V2 vacuum tester (fig. 12 ). Start and run the engi ne and apply vac uum pressures. Monitor readings and confinn that these
are in conformance with manufacturer specifications.
( C> J ac k Sealey Umited
l To Manifold
) Vawum
Original Language Version ( VS402.V2 I Issue: 1 •
2210 51 12 )

7. BRAKING SYSTEMS
7.1. Testing Brake Servo Diaphragm
7.1.1. Remove vacuum supply line from brake servo fitting. Attach VS402.V2 vacuum tester to vacuum supply port
on servo (fig.13). Operate pump to create
approximately 15inHg
of vacuum and wait for 30 seconds. No vacuum drop should be observed on the gauge reading. If the vacuum drops this indicates
that the brake servo diaphragm
is faul ty. In th is case the servo should be removed for overhaul by an authorised repa ir er or replaced.
7.2. Brake
Bleeding ·Assembly of Brake Bl eeder Kit
7.2.1. Ensure that the vacuum pump is connected to the brake bleeder reservoir in accordance with the assembly diagram (fig .1 4). Failure to do so wi ll result in
brake fluid being drawn into the vacuum pump.
7.3. Brake
Bleeding Procedure.
LJ WARNING/ Familiarise yourself with the hazards of brake fluid - read manufacturer's instructions on the container. Do not touch the vehicle's
brake pedal whilst bleeding the brakes.
7.3.1. Refer to the specific vehicle manufacturer's instructions for brake bleeding and wheel sequence procedure before proceeding. If no specific instructions
from the vehicle manufacturer exist, follow the instructions detailed below.
7.3.2. Remove the cap
of the vehicle's master brake flu id reservoir. If the fl uid level is not at maximum, top it up.
7.3.3. Attach the appropriate size bleeding attachment
to the bleed nipple on the brake calliper of the first wheel, normally nearest to master brake fluid reservoir.
7.3.4. Operate vacuum pump unt
il approximately 21inHg vacuum is created.
7.3.5. Apply copper grease to the brake bleeding nipples before and after the brake bleeding procedure to reduce the possibility
of se ized or broken ni pp les
when the brakes are next bled.
7.3.6. Open the bleed nipple about a quarter
of a tum. Allow brake fluid to be drawn until no air bubbles are visible in the brake fluid in the clear hose.
7.3.7.
lighten the bleed nipple.
7.3.8. Remove the attachment from the brake nipple.
7.3.9. Repeat the process as necessary.
NOTE! Check the master brake fluid reservoir regularly to ensure that the level does not drop too far, and top up as necessary.
NOTE! Empty bleeder container regularly
and DO NOT allow container to overfill as brake fluid will be drawn into vacuum pump.
LJ WARNING! When brak e bleeding and/or fluid changing is complete, test the action of the brake pedal to ensure th at the brakes are working
before attempting to drive the vehicle on the road and test the vehicle for satisfactory perfo rmanc e of the brakin g system.
7.4.
Cl ut ch Bleeding Procedure.
7.4.1. Refer
to the relevant vehicle manufacturer's instructions for clutch bleeding procedure. If no specific instructions from the vehicle manufacturer exist, fo ll ow
the same basic procedure as the brake bleeding instructions above.
( © Jack SealeyLimited J Original Language Version ( VS402.V2 I Issue: 1 - 22/05/12 )

t
0
NOTE: It is ou r p ol icy to continually improve products an d as such we reseNe the right to alterdata, specifications and component pa rts without prior notice.
IMPORTANT: No liability is accept ed for incorrect use of this product.
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.
~ IPrafe ssianatJ Sole UK Distributor , S ea l ~y Group, ~ 01284 757500 r.it\
l QUl..1~l..1L1 uI TDDLS Kempson Way , Suffolk BU Siness Park, u.b www.sealey .c o.uk
~----:: :'= -=::=-= =--==---.J. • Bury St. Edmu nd s, Suffolk, ~ 01284 703534 1¥11 sales@seal eyco.uk
Auta Serv•ce L•ne I P327AR ~ ~,. _
( @Jack Seal ey Limited
Original Language Version I VS402.V2 Issue· 1 - ??/OS/1? 1