VACUTEC Leakfinder WV622N-VWKIT Installation instructions manual

INSTRUCTION & OPERATION MANUAL
Leak finder
®
Model No. WV622N-VWKIT
Diagnostic Smoke® Machine
with Integrated Nitrogen Generator
and non-contaminating UltraTraceUV®Tracer Dye Solution
USA | Canada | Int’l Patents • 9,417,152 • 3,060,897 • ZL201480058656.7 | 2,279,147 • 2,394,911 | 1,384,984 | Others Pending

Caution and Usage Tips
 ALWAYS USE Leakfinder® WITH VEHICLE ENGINE TURNED OFF.
 DISCONNECT Leakfinder® from the vehicle prior to starting the engine or prior
to running any on-board monitor, including the DMTL or LDP. Damage caused by not
following proper operating procedures will not be covered by the vehicle warranty or
the Leakfinder® warranty.
 Use this equipment in the manner specified by themanufacturer.
 Follow common sense safety precautions.
 Use UltraTraceUV® Smoke Solution Part No. WV0712UV in Leakfinder®. Using a
non-approved solution; may cause damage to vehicles being tested; may cause
personal injury and may void vehicle and equipmentwarranties.
 Do not leave Leakfinder® hose connected to the vehicle’s EVAP system if tests are
not being performed. Natural vacuum or pressure created by the fuel in the fuel
tank can damage the Leakfinder® pressure gauge if it exceeds the pressure
limitations of the gauge.
 Do not perform test near source of spark or ignition.
 Wear appropriate eye protection.
 Wear yellow glasses supplied when using ultravioletlight.
 Air pressure supplied to Leakfinder® can be between 3.4 to 17 bar (50 ~ 250PSIG).
 When using alternate source of UV light, use light that includes 405 nanometer (nm)
UV light range and wear yellow glasses.
 When operating Leakfinder® in near freezing temperatures, cycle the operation of
Leakfinder® 20 seconds <ON> and 20 seconds <OFF> for approximately the first
minute of operation. This will allow Leakfinder® to reach optimum operating
temperature.
 When testing an engine's intake or exhaust system for leaks, it is best if the engine is
cold. Small leaks may be sealed due to thermal expansion.
 Be sure supply hose is completely unwound when using Leakfinder® or excessive
amounts of smoke vapor will condense inside the hose.
Please note: It is essential that you maintain a proper filtration system for
the compressed air being supplied to the Leakfinder®. Excessive moisture
or oil in the air supplied to the Leakfinder® can contaminate its
integrated nitrogen generator and voiding its warranty. Proper filtration
will insure many years of trouble-free operation.
NOTE: If your compressed air system operates using an automatic air line
oiler; it must be removed from the air supply feeding the Leakfinder®, or
it will damage the nitrogen generator.

Contents
Accessories; Included & Optional
Product Overview & Technical Specifications
Initial Setup & Proper Filtration
Control Valve Overview
Basic Testing Procedure
Other Leak Samples
Basic EVAP Test
Vacuum / Pressure Gauge Overview
Leakfinder® Calibration Procedure
Troubleshooting Guide
Warranty
1-3
4
5-6
7
8-9
10-11
12
13
14
15
16
Thank You and Congratulations! Your Leakfinder® WV622N-VWKIT Evaporative Emissions System
Tester (EEST) & Smoke Machine is approved for Evaporative Emissions System (EVAP) leak-testing
for both gasoline and ethanol vehicles.
Your tester incorporates STAR Diagnostic Smoke® Technology, inside. It is the simplest and quickest
way to find many vehicle system leaks. Smoke vapor-generating leak detectors containing STAR
Technology inside are the only leak detectors in the world approved by automakers (OEMs) for EVAP
and other system testing.
The patented technology inside your Leakfinder®, including the vapor-producing solution
(UltraTraceUV®), was designed in collaboration with major OEMs, in order to establish a standard for
leak detection. It is designed to be safe for vehicle systems and will not void factory warranties.
It is also the only smoke technology in the world that meets SAE INTERNATIONAL Published Papers’
safety standards recommendation to use a smoke tester designed to function with an inert gas (such
as Nitrogen, Argon or CO2) when testing a vehicle’s fuel evaporative (EVAP) system [SAE: 2007-01-
1235 & 2008-01-0554].

1
Included with Leakfinder® WV622N-VWKIT
UltraTraceUV®: (WV0712UV) this is the only Automaker-Approved UV smoke-
producing solution in the world. This non-contaminating solution’s chemistry is
designed to not damage vehicle components and contains a special dye that
deposits at the exact location of a leak. Each bottle will perform approximately
300 tests. (12 oz. / 355 ml).
(Part No. is for one bottle. Two bottles included with WV622N-VWKIT).
Combination Light: (WVA-065) white light, for easier smoke location and
ultraviolet (UV) light, to highlight the fluorescent dye deposited at the exact
location of a leak. Also has laser pointer.
Note: For eye safety & UV enhancement; always use yellow glasses when using
UV light.
Standard Size Service Port Adapter: (WVA-006) connects to factory service
port on many OBD-II vehicles.
Plug-in battery Cables: (WVA-072) connects to Leakfinder® and 12VDC
battery.
Smoke Diffuser: (WVA-003) locates leaks around doors, windows, sunroofs and
trunk compartment seals.
Manifold: (WVA-170) Use with adapters below.
Adapter: (WVA-171) 12 mm Male and female Set with locking clip.
Adapter: (WVA-172) 10 mm Male and female Set with locking clip.
Adapter: (WVA-173) 8 mm Male and female Set with locking clip.
Adapter Cone Large: (WVA-067)
Wing Nut Expansion Plug: (WVA-180) Seals off /plug the EVAP system (NVLD)
Exhaust Cone: (WVA-001)

2
Included with Leakfinder® WV622N-VWKIT
Fuel Neck Cap Adapter Threaded: (WVA-142)
Fuel Cap Receiver Assembly:(WVA-143)
Vehicle/Cap Test Hose Assembly:(WVA-144)

3
Optional Accessories
Bladder Plug with Through Hole: (WVA-096)
For sealing irregular sizes (from 47-152mm) and to
introduce smoke.
Includes spare bladder replacement.
Bladder Plug with Through Hole: (WVA-132)
For sealing irregular sizes (from 31-90mm) and to
introduce smoke.
Includes spare bladder replacement.
Bladder tube replacement: WVA-098) for bladder WVA-096 (48.5mm ⌀)
Bladder tube replacement: (WVA-149)for bladder WVA-134 (22mm ⌀)
Filter Elements Kit: (WVRP-103) 5 micron, .01 micron and Carbon-activated.
Capless Adapter: fits Ford and G.M. double-door capless fuel tank neck
(WVA-078). Adapter for applying pressure &/or vacuum to the fuel tank.
Brilliantly simple
•Specifically designed for new double-door capless fuel tanks.
•Reusable.
•Use with any smoke machine or other leak detection device. 5-year warranty.
Universal Adapter (Standard): (WVA-063)
Brilliantly simple
•Quickly pops-on most fuel tank filler necks
•Reusable
•Use with any smoke machine or other leak detection device 5-year warranty
Power Converter (WVA-080) connects to smoke tester and grounded wall power
outlet, to avoid using the vehicle battery as a power source. (USA plug)
AC input: 100-240V AC/5A 50/60Hz | DC output: 12V 25A
Accessories Storage Case (WVA-168)

4
Product Overview
Technical Specifications
Height
13.5 in. (34 cm)
Solution Max. Volume
Length
13 in. (33 cm)
Supply pressure
Width
9 in. (23 cm)
Supply volume
Weight
20 lb. (9 kg)
Smoke supply line
Shipping weight
25 lb. (11.3 kg)
Power supply line
Power supply
12 volts DC
Power consumption
12 oz. (355 ml)
14 in. H2O (34.9 mbar | 3.49
kPa) 10 liters per minute
15 feet (4.6 mm)
8feet (2.4mm)
15 amps.
Workshop Air Inlet
Filter Assembly
Flow Meter’s Pointer Flag
Flow Meter
Scratch-Resistant Housing
Indicator Lights
<ON> <OFF> Switch
(on 5-minute timer)
Vacuum/ Pressure Gauge
Control Valve
Power Cables
(Back of tester)
Integr
ated Nitrogen Generator
and Handle Assembly

5
Initial Setup
1 .
Low Full
a. Pour entire contents of one 12 oz. UltraTraceUV® solution bottle into the smokechamber.
NOTE: Use second bottle supplied to regularly maintain at or near FULL mark.
2.
b. If not supplied; install correct air fitting onto the Leakfinder®. Use Teflon® thread-
sealer. Be sure the thread-sealer is not allowed to enter the nitrogen generator’s housing.
Connect workshop air to air fitting. Set air pressure between 3.4 to 10.3 bar (50 ~ 150 PSIG).
3.
c. Connect power cord and push white
tab toward tester to lock position.
To remove plug:
1. Pull white tab to unlock.
2. Push inner tab downward, while at the
same time pulling plug away from tester.
Bleed Hole Air fitting
NOTE: The nitrogen generator naturally expels oxygen during the nitrogen-generation process. It is normal
to hear a small amount of oxygen exiting the generator’s bleed hole when connected to workshop air.

6
Leak finder ®
Initial Setup, continued
4.
Air Compressor
Air pressure between 3.4 to 17 bar
(50 ~ 250 PSIG)
It is very important to keep the Leakfinder® nitrogen generator assembly free of
oil, water and other contaminants, in order to maintain a high nitrogen purity
and long service life. In order to do that, you need to be sure and maintain a
clean filter system on your air supply into the Leakfinder®. In addition, install
the Filter Assembly Kit WVRP-104, or equivalent.
Under normal use, we recommend you replace the filter elements inside Filter
Assembly Kit WVRP-104 once a year and use only approved Filter Elements Kit
Part No. WVRP-103, as noted in Optional Accessories page in this manual. Turn
filter bowl ¼ turn in counter-clock direction to gain access to the filter elements.
IMPORTANT NOTE: In order for the moisture and contaminants that collect in the
filter bowls to drain, air must be disconnected and re-connected to the machine’s
Air Fitting. So do not leave air source to the machine connected for days at a time,
or the filters will never drain, which can damage the nitrogen generator system. An
occasional disconnect and reconnect to air issufficient.

7
Control Valve Overview
TEST: Delivers nitrogen, without smoke, and a
very accurate flow meter reading. This setting
is for determining if a leak exists and how large
it is.
NOTE: Leak size is discussed in Basic EVAP Test
section of manual.
SMOKE: Delivers maximum smoke volume.
FLOW CONTROL: Controls smoke volume.
>Locating the leak source is sometimes easier
with less smoke volume. First, fill system with
smoke, at full volume, then reduce volume
while still introducing smoke.
Note: Flow Control does not affect delivery
pressure; it only affects flow volume.