DRAPER 35891 Vacuum Test Kit (19 Piece) User Manual

35891

Original Instructions

Version 1

VACUUM

TESTING KIT

1.1 Product Reference

User Manual for: Vacuum Testing Kit

Stock No: 35891

Part No: CTEVG2

1.2 Revisions

Version 1: February 2024

First release

As our manuals are continually updated, always ensure

that the latest version is used.

Please visit drapertools.com/manuals for the latest

version of this manual and the associated parts list, if

applicable.

1.3 Understanding the Safety Content of

This Manual

WARNING!

– Situations or actions that may result

in personal injury or death.

CAUTION! – Situations or actions that may result

in damage to the product or surroundings.

Important: – Information or instructions of particular

importance.

Permission is granted to reproduce this manual for

personal and educational use ONLY. Commercial

copying, redistribution, hiring or lending is strictly

prohibited.

No part of this manual may be stored in a retrieval system

or transmitted in any other form or means without written

permission from Draper Tools Limited.

In all cases, this copyright notice must remain intact.

1. Preface

– 2 –

These are the original product instructions. This

document is part of the product; retain it for the life

of the product, passing it on to subsequent holders.

Read this manual in full before attempting to

assemble, operate or maintain this product.

This Draper Tools manual describes the purpose

of the product and contains all the necessary

information to ensure its correct and safe use.

Following all the instructions and guidance in

this manual will ensure the safety of both the

product and the operator and increase the

lifespan of the product.

All photographs and drawings within this manual are

supplied by Draper Tools to help illustrate correct

operation of the product.

Every eort has been made to ensure the

information contained in this manual is accurate.

However, Draper Tools reserves the right to amend

this document without prior warning. Always use the

latest version of the product manual.

2. Contents

– 3 –

1. Preface 2

1.1 Product Reference 2

1.2 Revisions 2

1.3 Understanding the Safety Content of This

Manual 2

2. Contents 3

3. Product Introduction 4

3.1 Intended Use 4

3.2 Specication 4

4. Health and Safety Information 5

4.1 General Health and Safety Precautions 5

4.2 Residual Risk 5

4.3 Explanation of symbols 5

5. Identication and Unpacking 6-7

5.1 Product Overview 6

5.2 What’s in the Box? 7

5.3 Packaging 7

6. Operations 8-9

6.1 Analysing Engine Mechanical Conditions

Using Manifold Readings 8

6.2 Basic Diagnostic Test 8

6.3 Ignition System Vacuum Advance 9

7. Fuel Systems Testing 10-11

7.1 Carburettor Testing 10

7.2 Fuel Injection Pressure Regulator Testing 10

7.3 Emission Control Exhaust Gas

Recirculation Valve (EGR) 10

7.4 One-Way Valve Testing 10

7.5 Electrically Operated Vacuum

Solenoid Testing 11

7.6 Thermal Vacuum Switch Testing 11

7.7 Vacuum Operated Heater Tap Testing 11

7.8 Automatic Transmission Vacuum

Operated Modulator Valves Testing 11

8. Braking Systems 12

8.1 Brake Servo Diaphragm Testing 12

8.2 Brake And Clutch Bleeding Procedure 12

9. Maintenance 13

10. Spares, Returns and Disposal 13

11. Warranty 13

3. Product Introduction

Stock No. 35891

Part No. CTEVG2

Piston Stroke: 1”³

Gauge Diameter: approx. 52mm

Gauge Pressure Range: 0-760mmHg (0-30InHg)

Gauge Pressure Accuracy: +/- 3%

Short Flexible Hose Length: 75mm

Short Flexible Hose Diameter: 10mm

Long Flexible Hose Length: 525mm

Long Flexible Hose Diameter: 10mm

– 4 –

3.2 Specication

3.1 Intended Use

This Vacuum gauge testing kit is designed as a

comprehensive accessory kit which can be used for

bleeding brakes & clutch units on most vehicles

including cars, commercial & motorbikes. Suitable for

fault nding common issues on air conditioning, fuel,

transmission, turbo waste gates, valve stem oil seals,

ignition and emissions.

Read this manual in full before assembling, operating or

maintaining this product, and retain it for later use.

4. Health and Safety Information

Important: Read all the Health and Safety instructions

before operating, maintaining or repairing this product.

Non-compliance with these instructions may result in

injury or damage to the user, test kit or vehicle.

4.1 General Health and Safety

Precautions

• Keep this product in good working order and

condition. DO NOT operate if any parts are damaged

or missing as this may cause failure and/or personal

injury.

• DO NOT modify any parts and only use accessories

and spare parts supplied by Draper Tools.

• Keep children and unauthorised persons away from

the work area.

• Keep the work area clean and tidy and ensure that

there is adequate lighting.

• DO NOT use the kit to perform a task for which it is not

designed.

• DO NOT hold the pump inlet against the skin whilst

using the pump.

• DO NOT allow untrained persons to use the kit.

• DO NOT use whilst under the inuence of drugs,

alcohol or intoxicating medication.

• After use, clean equipment and store in a cool, dry,

childproof area.

 WARNING!Brakeuidwilldamagepaintwork.

Anyspillageshouldbeushedwithwater

immediately.

 WARNING!Brakeuidisammable-keepaway

fromsourcesofignition,includinghotsurfaces

e.g.exhaustmanifold.

• Dispose of waste liquids in accordance with local

authority regulations.

 WARNING!DONOTpollutetheenvironmentby

allowinguncontrolleddischargeofuids.

• Always read and comply with the warnings on the

brake uid container.

• Wear eye protection and keep skin contact to a

minimum. If brake uid splashes into eyes, rinse with

plenty of water and seek medical advice. If swallowed

seek medical advice.

4.2 Residual Risk

The safety instructions in this manual cannot account for

all possible conditions and situations that may occur.

Exercise common sense and caution when using this

product and protect against any additional conceivable

risks.

4.3 Explanation of symbols

– 5 –

Read the instruction manual

Warning!

Do not abandon in the environment

Wear face mask and safety glasses

5. Identication and Unpacking

5.1 Product Overview

(1) Short Extension Tube X 2

(2) Long Extension Tube X 2

(3) Vacuum Gauge and Pump

(4) Hose and Nipple Adaptors

(5) Storage Case

(6) Transfer Cap

(7) Reservoir Cap

(8) 120ml Reservoir

– 6 –

(1)

(2)

(4)

(3)

(5)

(6)

(7)

(8)

5. Identication and Unpacking

5.3 Packaging

Keep the product packaging for the duration of the

warranty period for reference should the product need to

be returned for repair.

WARNING!Keeppackagingmaterialsoutofreachof

children.Disposeofpackagingcorrectlyand

responsiblyandinaccordancewithlocalregulations.

(A) 2 x Hose End Cones

(B) 7 X Tapered Hose Adaptors

(D) 1 X Stepped Adaptor

(E) 3 X Bleed Nipple Adaptors

E1. 1 X Large

E2. 1 X Medium

E3. 1 X Small

(F) 32mm Suction Cup

Please visit drapertools.com for our full range of accessories and consumables.

– 7 –

5.2 What’s in the Box?

Carefully remove the product from the packaging and

examine it for any signs of damage that may have

occurred during shipment.

Before assembling the product, lay the contents out and

check them against the parts shown below. If any part is

damaged or missing, do not attempt to use the product.

Please contact the Draper Helpline; contact details can

be found at the back of this manual.

(A) (B)

(D)(E3)(E2)(E1)(F)

(C)

6. Operations

Important: Before preparing or adjusting this product,

read and understand all the safety instructions listed in

this manual.

ALWAYS refer to the manufacturer’s service manual to

ensure the correct testing procedures and specications

are followed. It is recommended that additional tests

such as compression tests, cylinder leakage tests,

ignition timing checks are carried out to conrm the

vacuum gauge readings.

6.1 Analysing Engine Mechanical

Conditions Using Manifold Readings

(Refer to the diagnostic chart for examples of readings

that may be observed).

• Important Notes:

− The action of the needle on the gauge during

testing is more important to note rather than the

actual reading.

− Engine types will run with dierent manifold

vacuum pressures, depending on camshaft

prole, valve overlap and timing. For reference the

needle reading should be steady and between 16

to 21inHg.

− Manifold vacuum is also aected by altitude and it

will drop approximately 1inHg for every 1000feet

above sea level so this should also be taking into

consideration when assessing the readings.

1 Fig.

6.2 Basic Diagnostic Test

1. Run the engine until the normal operating

temperature is reached. Then switch o the engine.

2. Connect the vacuum gauge to a port directly on the

manifold or on the carburettor/throttle body below

the throttle buttery.

3. Start the engine and allow to idle, observe the gauge

reading as shown in the diagnostic testing.

– 8 –

DiagnosticTesting

GaugeReading Cause

16 – 21inHg

Needle Steady

Normal

When throttle opened and

released, needle drops to

below 5inHg and then up to

25inHg. Then settles back

to original reading.

Normal

Steady but extremely low. Leaking intake manifold

system.

Faulty manifold or carburettor

base gasket.

Split vacuum hose.

EGR valve seized.

Steady but low. Retarded ignition timing.

Conrm using timing light

and reset to manufacturer’s

specication.

Slightly low and slowly

uctuating.

Over lean or rich mixture.

Check and reset as per

manufacturer’s specications.

Fluctuating between normal

and low readings.

Blown head gasket between 2

adjacent cylinders.

Carry out cylinder leakage

test.

Slightly lower than normal

even when throttle is

opened and released.

Worn piston rings.

Carry out compression test.

Regular drop between

normal and low reading.

Burnt Valve.

Normal until drops when

revs held at 3000rpm.

Restriction in exhaust system.

6. Operations

6.3 Ignition System Vacuum Advance

On standard points and some electronic ignition systems

there are two types of advance methods used, both of

which must function correctly to obtain maximum

performance and fuel economy.

• Mechanical/Centrifugal(Weightslocatedinthe

baseofthedistributor)- the weights move outwards

advancing the ignition timing as the engine RPM

increases. This is tested by disabling the system by

removing the vacuum advance line. Then with a

timing light connected, raise the engine RPM,

checking that the timing advances in accordance with

the manufacturer’s specication.

• VacuumAdvance(Engineloadsensedviamanifold

vacuum) - A vacuum diaphragm is mounted onto the

distributor and connected to a rotating internal base

plate which advances or retards timing as required to

suit varying engine loads.

a. To test this system for correct operation, connect a

timing light, raise the engine RPM and check the

timing advance against the manufacturer’s

specication. If the vacuum advance is not

operating, remove the vacuum line from the

distributor advance mechanism. Connect the

vacuum tester and create a 5-10inHg vacuum,

monitoring the timing at the same time. If a timing

advance is noted this conrms that the vacuum

diaphragm and mechanical links are in order and

that the fault is a vacuum supply.

b. To conrm this, connect the vacuum tester to the

vacuum supply line and check the gauge reading.

No vacuum should be noted at idle but when the

engine RPM is increased a vacuum increase should

be observed. If this does not occur, trace the

vacuum line back checking for restrictions and

breaks.

– 9 –

7. Fuel Systems Testing

The vacuum tester can be used to evaluate the condition

of a mechanical fuel pump by testing the vacuum that it

is able to create.

• Locate and remove the suction line from the pump.

Connect the vacuum tester to the suction port of the

pump, start and run the engine at idle.

• The vacuum reading observed will vary depending on

the make and model being tested but as a general rule

approximately 15inHg of vacuum should be created.

This should also be held for approximately 1 minute

after the engine shuts down. If this vacuum reading is

not achieved or the vacuum drops o immediately

with the engine shut down, the fuel pump requires

either an overhaul or replacement.

7.1 Carburettor Testing

The vacuum test kit allows quick and accurate testing of

many dierent types of vacuum control systems used on

carburettors. Examples of tests that can be carried out;

• TestingaChokeBreakDiaphragm.

− With the engine o and at normal operating

temperature, disconnect the vacuum line to the

diaphragm module. Connect the vacuum tester

and apply approximately 15inHg of vacuum

and wait for 30 seconds.

− No drop in gauge reading should be observed.

With the vacuum still applied ensure that the

choke buttery is pulled to the fully open position.

• TestingVacuumOperatedCarburettorSecondary

Barrel.

− With the engine o and at normal operating

temperature, remove the vacuum line from the

secondary diaphragm module. Connect the

vacuum tester, hold the throttle and secondary air

valve aps open.

− Operate the hand pump whilst observing whether

the secondary throttle buttery opens freely.

7.2 Fuel Injection Pressure

Regulator Testing

Multi-point fuel injection rail pressure varies to suit

changing engine loads and fuel delivery requirements.

This is done using a vacuum operated regulator which is

connected to the engine manifold vacuum to sense the

varying loads.

a. To test the fuel rail pressure, attach a gauge to the

rail, then the engine loads must be created to vary

the engine manifold vacuum.

b. Remove and block o the vacuum supply line to

the pressure regulator.

c. Then connect and operate the vacuum pump to

simulate vacuum pressures in accordance with the

manufacturer’s specication. Note: any variation in

fuel pressure reading.

7.3 Emission Control Exhaust Gas

Recirculation Valve (EGR)

• Start the engine and run at idle until normal operating

temperature is reached. Remove the vacuum line from

the EGR valve and attach the vacuum test kit.

• Operate the hand pump to apply approximately

15inHg of vacuum. If the EGR valve is working

correctly the engine idle will become rough. If the idle

remains unchanged the valve is possibly seized in the

closed position. If the vacuum is not held, the

diaphragm in the valve has failed.

7.4 One-Way Valve Testing

Many vacuum operated circuits use in-line one way

valves to apply vacuum in one direction only.

• To test the function of the valve remove it from the

circuit. Attach the vacuum tester and operate pump to

apply vacuum. The valve should only hold vacuum in

one direction.

– 10 –

7. Fuel Systems Testing

7.5 Electrically Operated Vacuum

Solenoid Testing

• Electrically operated vacuum solenoids are commonly

used in control circuits for air conditioning/ventilation

systems, emission control systems and idle step-up

systems.

1. Locate the solenoid to be tested and remove the line

that goes to the component.

2. Connect the vacuum tester to the solenoid port and

start the engine. With the system turned o the

gauge reading should be ‘0’.

3. Turn the system to the ‘on’ position and the gauge

reading should be equal to the manifold vacuum. If no

reading on the gauge, 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 not receiving a ‘switch on’ voltage (use a

multimeter to test this). If no vacuum exists trace the

supply line back to the vacuum source checking for

kinks and breaks.

7.6 Thermal Vacuum Switch Testing

• There are many vacuum controlled circuits that must

only operate when the engine reaches normal

operating temperature. This is done using thermal

switches that remain in an ‘o’ position until a given

temperature is reached.

1. To test this type of switch, remove the vacuum supply

line coming from the manifold to the switch and test

the manifold vacuum.

2. If this vacuum is correct ret the supply line to the

thermal switch and remove the opposing line from

the switch.

3. Attach the vacuum tester to the port and start the

engine. With a cold engine no reading should be

noted. When the engine reaches normal operating

temperature a manifold vacuum reading should be

noted.

7.7 Vacuum Operated Heater Tap Testing

Climate control ventilation systems commonly use

vacuum operated taps to control the heating modes and

to turn the heater tap ‘on’.

1. To test, remove the supply line from the tap vacuum

module and connect the vacuum tester.

2. With the engine at normal operating temperature

locate the heater return hose. With the heater tap

in the ‘o’ position, this hose should be cold.

3. Operate the vacuum pump to open the tap. The

gauge reading must hold steady. If the tap is working

the return hose will begin to heat. If the hose does not

begin to heat, this indicates that the tap is faulty.

7.8 Automatic Transmission Vacuum

Operated Modulator Valves Testing

• Automatic transmissions are normally equipped with

a vacuum operated modulator valve in order for the

automatic transmission to detect engine loads and

adjust shift points to suit.

• The vacuum tester can test both whether the

modulation valve diaphragm is serviceable and to

simulate varying engine loads so modulator pressure

readings can be recorded.

1. Totestthemodulatorvalvediaphragm - remove the

vacuum supply line from the valve and attach the

vacuum tester. Operate the vacuum pump until

approximately 15inHg is achieved and monitor the

gauge reading for approximately 30 seconds. No

vacuum drop should be noted.

2. Tocheckmodulatorpressurereadings - attach a

pressure gauge to the appropriate port on the

transmission. Remove the vacuum supply line from

the modulator and attach the vacuum tester. Start

and run the engine and apply vacuum pressures.

Monitor readings and conrm that they conform with

the manufacturer’s specications.

– 11 –

8. Braking Systems

8.1 Brake Servo Diaphragm Testing

1. Remove the vacuum supply line from the brake servo

tting.

2. Attach the vacuum tester to the vacuum supply port

on the servo. Operate the pump to create

approximately 15inHg of vacuum and wait for 30

seconds. No drop in the vacuum reading should be

observed. If the vacuum drops this indicates that the

brake servo diaphragm is faulty. In this case the servo

should be removed for overhaul or replaced by an

authorised repairer.

8.2 Brake And Clutch Bleeding Procedure

 WARNING!Familiariseyourselfwiththehazards

ofbrakeuid-readandfollowthe

manufacturer’sinstructionsonthecontainer.

• DO NOT touch the vehicle’s brake pedal whilst

bleeding the brakes.

• Ensure that the vacuum pump is connected to the

brake bleeder reservoir in accordance with the car

manufacturer’s recommendations. Failure to do so will

result in brake uid being drawn into the vacuum

pump.

• Refer to the specic vehicle manufacturer’s

instructions for brake bleeding and wheel sequence

procedure before proceeding. If no specic

instructions from the vehicle manufacturer exist,

follow the instructions detailed below:-

1. Remove the cap of the vehicle’s master brake uid

reservoir. If the uid level is not at maximum, top it up.

2. Attach the appropriate size bleeding adaptor (A) to (E)

to the bleed nipple on the brake calliper of the rst

wheel, normally farthest from the master brake uid

reservoir.

3. Operate the vacuum pump until approximately

21inHg vacuum is created.

4. Apply copper grease to the brake bleeding nipples

before and after the brake bleeding procedure to

reduce the possibility of seized or broken nipples

when the brakes are next bled.

5. Open the bleed nipple about a quarter of a turn. Allow

brake uid to be drawn until no air bubbles are visible

in the brake uid in the clear hose.

6. Tighten the bleed nipple and remove the adaptor

from the brake nipple.

7. Repeat the process as necessary.

− NOTE! Check the master brake uid reservoir

regularly to ensure that the level does not drop too

far, and top up as necessary.

− Empty bleeder container regularly and do not

allow container to overll as brake uid will be

drawn into vacuum pump.

 WARNING!Whenbrakebleedingand/oruid

changingiscomplete,testtheactionofthe

brakepedaltoensurethatthebrakesare

workingbeforeattemptingtodrivethevehicle

ontheroadandtestthevehicleforsatisfactory

performanceofthebrakingsystem.

– 12 –

• After use, clean and store in the storage case in a cool,

dry, childproof area.

10. Spares, Returns and Disposal

For spare parts, servicing, and repair and replacement

options, please contact the Draper Tools Product

Helpline for details of your nearest authorised agent.

Any servicing or repairs carried out by unauthorised

personnel or installation of spare parts not supplied by

Draper Tools will invalidate your warranty.

At the end of its working life, dispose of the product

responsibly and in line with local regulations. Recycle

where possible.

• Dispose of waste liquids in accordance with local

authority regulations.

11. Warranty

Draper Tools products are guaranteed for 12months to

be free from defective materials and workmanship. Full

details of the warranty period can be found on the Draper

Tools Website.

Should the tool develop a fault within the warranty

period, return the complete tool to the place of purchase

or contact Draper Tools directly. Proof of purchase must

be provided.

This warranty does not apply to any consumable parts or

normal wear and tear.

It also does not cover any damage caused by misuse,

careless or unsafe handling, modications, or repairs

carried out by any personnel other than an authorised

Draper Tools repair agent.

Please note that this guarantee is in addition to and does

not aect your statutory rights.

9. Maintenance

– 13 –

Notes

– 14 –

Notes

– 15 –

Delta International

Delta International BV

Oude Graaf 8

6002 NL

Weert

Netherlands

Contact Details

Draper Tools

Draper Tools Limited

Hursley Road

Chandler’s Ford

Eastleigh

Hampshire

SO53 1YF

Website: drapertools.com

Email: [email protected]

Product Helpline: +44 (0) 23 8049 4344

TelephoneSalesDesk: +44 (0) 23 8049 4333

GeneralEnquiries: +44 (0) 23 8026 6355

GeneralFax: +44 (0) 23 8026 0784

Please contact the Draper Tools Product Helpline for repair and servicing enquiries.

DRAPER 35891 Vacuum Test Kit (19 Piece)

Product's Documents

Other

Specifications

DRAPER 35891 Questions and Answers