Equus 3660 User Manual

3660 © Innova 2001

FRONT

COVER

3660

HAND PUMP

i 3660

Paragraph Title Page No.

I INTRODUCTION............................................................ 1

II SAFETY PRECAUTIONS .............................................. 1

III VEHICLE SERVICE MANUALS................................... 2

IV UNDERSTANDING VACUUM SYSTEMS................... 2

V AUTOMOTIVE VACUUM SYSTEMS ........................... 4

VI VACUUM MOTOR/ACTUATOR OPERATION

AND TESTING................................................................ 7

VII TESTING THE PCV SYSTEM....................................... 8

VIII TESTING THE EGR SYSTEM....................................... 10

IX DIAGNOSING MECHANICAL

ENGINE CONDITIONS ................................................. 13

X EXHAUST SYSTEM RESTRICTION TEST ................. 15

XI FLUID EVACUATION ................................................... 16

XII BLEEDING BRAKES ..................................................... 18

XIII REPLACEMENT PARTS .............................................. 20

XIV SERVICE PROCEDURES ............................................. 21

WARNING:

This manual includes WARNINGS and CAUTIONS
identifying procedures and practices which, if not performed
properly, may result in personal injury or equipment damage.
However, this manual DOES NOT cover all possible uses or
methods of operation for the hand pump. It is the responsibility
of the user to determine that the method of operation and/or
servicing procedure used will not jeopardize personal safety or
vehicle safety. DO NOT USE THE VACUUM PUMP, IN ANY
MANNER, ON THE HUMAN BODY.

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I. INTRODUCTION

Congratulations. You have purchased a precision instrument
manufactured to the highest quality standards. This hand-operated
vacuum pump is a versatile tool that can be used in almost any
application where a vacuum must be generated, an existing vacuum
within a system must be measured or for fluid evacuation.

The vacuum pump is designed to aid in testing automotive vacuum
systems; testing vacuum actuated components and devices, and
bleeding brake systems.

The vacuum pump can also be used (in conjunction with a fluid
evacuation kit) as a fluid evacuation device to evacuate fluids from
various systems or locations.

II. SAFETY PRECAUTIONS

To avoid personal injury, instrument damage and/or damage to
equipment under test, DO NOT operate the hand pump before
reading this manual. ALWAYS use extreme caution when
working on an automobile.

This manual describes common test procedures used by experienced
service personnel and technicians. Many test procedures require
precautions to avoid accidents that can result in personal injury, and/or
vehicle or equipment damage. Always read your vehicle's service
manual and follow its safety precautions before any test or service
procedure is performed.

a. When an engine is running, it produces carbon monoxide )a toxic

and poisonous gas). To prevent serious injury or death from carbon
monoxide poisoning, operate a vehicle ONLY in a well-ventilated
area.

b. To protect your eyes from propelled objects as well as hot or caustic

liquids, always wear approved safety eye protection.

c. When an engine is running, several engine components rotate at a

very high rate of speed (coolant fan, pulleys, fan belt etc.). To avoid
serious injury, always be conscious of moving parts and keep a safe
distance from all these items as well as other potentially moving
objects.

d. Engine parts become extremely hot when the engine is running. To

prevent severe burns, avoid contact with hot engine parts.

e. Before starting an engine for troubleshooting, make sure the

parking brake is engaged. Put the transmission in "park" )for
automatic transmission) or "neutral" (for manual transmission).
Block the drive wheels with a suitable blocking device.

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f. To prevent damage to the on-board computer when taking vehicle

electrical measurements, always use a digital multimeter with at
least 10 Megohms of impedance.

g. The vehicle's battery produces highly flammable hydrogen gas. To

prevent an explosion, keep all sparks, high temperature items and
open flames away from the battery.

h. Don't wear loose clothing or jewelry when working on an engine.

Loose clothing can get caught on the fan, pulleys, belts, etc.
Jewelry is highly conductive to electricity, and can cause a severe
burn if it makes contact between a power source and ground.

III. VEHICLE SERVICE MANUALS

It is recommended that you consult the manufacturer’s service manual
for your vehicle before any test or repair procedures are performed.

Contact your local car dealership or auto parts store for availability of
these manuals. The following companies publish valuable repair
manuals.

Haynes Publications, 861 Lawrence Drive, Newbury Park, CA
91320, Phone: CA [phone], TN [phone]

Motor Publications, 5600 Crooks Road, Suite 200, Troy, Michigan
48098, Phone [phone]

Mitchell International, 14145 Danielson Street, Poway, CA 92064,
Phone [phone]

FACTORY SOURCE (Ford, GM, Chrysler, Honda, Isuzu, Hyundai
and Subaru Service Manuals

Helm Inc., 14310 Hamilton Avenue, Highland Park, Michigan 48203,
Phone [phone]

IV. UNDERSTANDING VACUUM SYSTEMS

In order to properly test and diagnose faults in automotive vacuum
systems, it is important to understand what vacuum is, how it is
measured, and how engines create, distribute and use vacuum.

A. WHAT IS VACUUM?

The earth’s atmosphere (the air that we breathe) is not really empty
space, but is filled with air molecules. Vacuum is the partial or
complete absence of atmosphere (an empty space where no molecules of
any sort exist). Interstellar space is an almost a perfect vacuum.

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B. HOW IS VACUUM MEASURED?

The earth’s atmosphere exerts a force on all surfaces it contacts. This
force is called “atmospheric pressure”. There is a direct relationship
between atmospheric pressure and vacuum. In order to understand
vacuum, we need to understand what atmospheric pressure is and how
it's measured.

Air is composed of tiny particles called molecules. Air molecules have
weight. Atmospheric pressure is defined as the force exerted by the
total weight of the air above a specific area at any elevation. At sea
level, the total weight of a column of air (air molecules) above an area
of one square inch equals 14.7 pounds (1030g/cm2). At higher
elevations there are fewer air molecules, and the weight of the air
above a comparable surface area is lower than at sea level. This is why
the air pressure at higher elevations is lower than at sea level.

Atmospheric pressure is measured using an instrument called a
Manometer/Barometer. A Manometer/Barometer is a hollow glass tube
with one end sealed and the other end immersed in a container of
mercury.

At sea level, the force of the surrounding air pressure (atmospheric
pressure) of 14.7 psi (1030g/cm2) acting on the mercury in the
container forces the mercury up the glass tube to a measured height of
30 inches (76 cm).

Vacuum can be defined as a pressure that is less than the surrounding
air pressure (atmospheric pressure). Vacuum gauges base their
readings on atmospheric pressure as indicated on a Manometer/
Barometer. The “0” indication on a vacuum gauge is calibrated to
represent "atmospheric pressure"; the “30” indication represents "zero
pressure" or a "perfect vacuum". Any reading between these two
indications (“0” and “30”) represents a pressure that is less than the
surrounding air pressure (atmospheric pressure).

C. HOW IS VACUUM CREATED/GENERATED?

Vacuum (a low pressure area) can be created in a sealed container in
one of two ways:

1. If part of the air is removed from a sealed container, there will be

fewer air molecules per square inch inside the sealed container
than in the surrounding outside air. Fewer air molecules within a
constant area equates to a lower air pressure.

2. If the area inside a sealed container is increased but the amount of

air inside the container stays the same. The area inside the
container will have fewer air molecules per square inch than the
surrounding outside air. Increasing area while maintaining a
constant volume of air equates to a lower air pressure.

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V. AUTOMOTIVE VACUUM SYSTEMS

A. HOW AN ENGINE GENERATES VACUUM

Gasoline engines create vacuum as a byproduct of normal operating.
During engine operation, when the pistons inside the cylinders move
down on the intake stroke, the combustion chamber area (volume)
inside the cylinders is greatly increased (see Figure 1). This action
decreases the pressure inside the combustion chamber creating a
partial void or vacuum (an area with fewer air molecules per square
inch than the surrounding outside air.) A mixture of air and fuel from
the carburetor/fuel injectors and intake manifold rushes into the
cylinders through the intake valve to fill this partial void. The
continuous movement of the pistons within the cylinders creates a need
for a constant supply of air and fuel to fill the partial void created
inside the cylinders on the intake strokes. The continuous flow of air
and fuel through the intake manifold creates a low pressure (vacuum)
inside the manifold. The low pressure (vacuum) in the intake manifold
exists as long as the engine is in operation. This is how vacuum is
generated in an internal combustion (gasoline) engine.

In a gasoline-operated engine/vehicle the vacuum that is generated in
the intake manifold is used to operate a number of vacuum-actuated or
vacuum-controlled devices.

NOTE:

Diesel engines, because of their design, produce less vacuum than
gasoline engines. The vacuum produced by a diesel engine is insufficient
to operate vacuum devices. If vacuum devices are added to a diesel
system, an electrical or mechanical vacuum pump is used to operate these
devices. Regardless of how vacuum is generated, the principle of operation
of vacuum devices is the same. The hand vacuum pump can be used to
test vacuum operated devices on both gasoline and Diesel systems.

Figure 1. Piston Intake Stroke

FUEL INJECTOR

VACUUM PORT

EXHAUST

INTAKE MANIFOLD

COMBUSTION
CHAMBER

PISTON

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B. VACUUM DISTRIBUTION SYSTEMS

In order to supply vacuum from the intake manifold to the various
vacuum-operated devices found on an automobile, a vacuum
distribution system is needed. Vehicle manufacturers install vacuum
ports and/or vacuum distribution blocks in the intake manifold. Most
vacuum-operated devices are connected to these vacuum ports/vacuum
distribution blocks using vacuum hoses, lines and fittings.

NOTE:

Some vacuum ports are located above the throttle plates of the
throttle body and only supply vacuum when the throttle plates open.
This type of connection is called "Ported Vacuum". On some vehicles,
emission-related devices such as EGR valves or distributor vacuum
actuators are designed to operate only when the vehicle is driven under
certain conditions. Ported vacuum is used to operate these devices.

C. USING THE VACUUM PUMP

The vacuum pump consists essentially of a pump body, a moveable
handle, a spring-loaded piston rod, a vacuum gauge, a vacuum fitting
and a vacuum release system (see Figure 2).

The vacuum pump can be used in almost any application where
vacuum must be generated, or where existing vacuum within a system
must be measured. In most cases, the vacuum pump is connected
directly to the vacuum port of a component, or is connected into a
vacuum hose in the system using a tee connector. The following
paragraphs outline the basic modes of operation for the vacuum pump.
Specific uses for the vacuum pump are provided later in this manual.

Figure 2. Hand Vacuum Pump - Exploded View

GAUGE

VACUUM
PORT

VACUUM
RELIEF
VALVE

FILTER

MAIN BODY

PISTON ASSEMBLY

SPRING PUMP HANDLE

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D. APPLYING VACUUM

1. Connect the vacuum pump's vacuum fitting to the component or

system to be tested.

2. Squeeze and release the pump handle, and read the amount of

vacuum indicated on the vacuum gauge.

3. Continue squeezing and releasing the pump handle until the

desired amount of vacuum is shown on the vacuum gauge.

E. TROUBLESHOOTING VACUUM SYSTEMS

NOTE:

This manual describes common general test procedures used by
service personnel and technicians. Use the test procedures described in
this manual only as a guide. Always consult the vehicle's service
manual for more detailed testing instructions and specifications before
any diagnostic test or procedure is performed.

The intake manifold is a sealed system, and the air that enters the
system must be metered to maintain a balanced air/fuel mixture. On a
gasoline engine, this metering is controlled by the throttle plates. A
leak in any part of the vacuum system, including the intake manifold,
introduces unmetered air into the intake manifold, resulting in a
leaner air/fuel mixture (too much air/not enough fuel). A lean air/fuel
mixture can result in higher combustion temperature and engine
misfires. A vacuum leak will also reduce the total amount of vacuum
available to all vacuum-operated devices, and may severely effect their
operation.

The following are some possible symptoms/results of a vacuum leak:

• Rough or uneven idle

• Stalling

• Pinging or knocking

• Burned spark plugs

• Burned exhaust valves

• Faulty operation of vacuum-operated devices

F. TESTING AND CHECKING VACUUM DEVICES AND COMPONENTS

Most problems in automobile vacuum systems result from disconnected
or leaking hoses, bad connectors, defective motor diaphragms or valves.
Pinched vacuum hoses or clogged valves may also restrict vacuum flow.

The first step in checking a vacuum system is to visually check all
vacuum hoses, lines and connectors for cuts, cracks and splits. Check for
collapsed or pinched vacuum hoses. Vacuum hoses have a tendency to
deteriorate because of harsh conditions within the engine compartment.