Equus 5660 User Manual

Table of Contents

i

Title Page No.

INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

SAFETY PRECAUTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

VEHICLE SERVICE MANUALS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

UNDERSTANDING VACUUM SYSTEMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

What is Vacuum? . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

How is Vacuum Measured? . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

How is Vacuum Created/Generated? . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

AUTOMOTIVE VACUUM SYSTEMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

How an Engine Generates Vacuum . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

Vacuum Distribution Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

Using the Vacuum Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

Applying Vacuum . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

Troubleshooting Vacuum Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

Testing and Checking Vacuum Devices and Components . . . . . . . . . . . . . 7

VACUUM MOTOR/ACTUATOR OPERATION AND TESTING . . . . . . . . . . . . . . 8

Vacuum Motor/Actuator Description and Operation . . . . . . . . . . . . . . . . . . 8

Vacuum Motor/Actuator Testing Procedures . . . . . . . . . . . . . . . . . . . . . . . 9

TESTING THE PCV SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

System Description and Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

Test Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

TESTING THE EGR SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

System Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

Testing EGR Vacuum/ EGR Control System . . . . . . . . . . . . . . . . . . . . . . . . 13

Testing the EGR Valve Diaphragm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

Checking EGR Valve Seat/Restrictions in Exhaust Tube . . . . . . . . . . . . . . 14

DIAGNOSING MECHANICAL ENGINE CONDITIONS . . . . . . . . . . . . . . . . . . . 15

EXHAUST SYSTEM RESTRICTION TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

FLUID EVACUATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

Assembling the Fluid Evacuation/Brake Bleeding Kit . . . . . . . . . . . . . . . . . 18

Fluid Evacuation Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

BLEEDING BRAKES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

Bleeding Automobile Brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

REPLACEMENT PARTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

WARRANTY AND SERVICING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

Warranty and Servicing

25

LIMITED ONE YEAR WARRANTY

The Manufacturer warrants to the original purchaser that this unit is free of
defects in materials and workmanship under normal use and maintenance for a
period of one (1) year from the date of original purchase.

If the unit fails within the one (1) year period, it will be repaired or replaced, at
the Manufacturer’s option, at no charge, when returned prepaid to the Ser vice
Center with Proof of Purchase.The sales receipt may be used for this purpose.
All replacement parts, whether new or re-manufactured, assume as their war­ranty period only the remaining time of this warranty.

This warranty does not apply to damage caused by improper use, accident,
abuse, improper voltage, service, fire, flood, lightning, or other acts of God, or if
the product was altered or repaired by anyone other than the Manufacturer’s
Service Center.

The Manufacturer, under no circumstances shall be liable for any consequential
damages for breach of any written warranty of this unit.This warranty gives you
specific legal rights, and you may also hav e rights which v ary from state to state.
This manual is copyrighted with all rights reserved. No portion of this document
may be copied or reproduced by any means without the express written per­mission of the Manufacturer. THIS WARRANTY IS NOT TRANSFERABLE. For
service, send via U.P.S .(if possible) prepaid to Manuf acturer. Allow 3-4 weeks for
service/repair.

SERVICE PROCEDURES

Products requiring service should be returned as follows:

1. Call the Technical Service Center to obtain a Return Reference Number:
USA & Canada = 1-800-544-4124
Other = 714-241-6805

2. Package the product carefully to prevent shipping damage

3. Include your name, return address, and a day contact phone

4. Enclose a copy of the dated sales receipt

5. Describe the problem

6. Ship prepaid to: Technical Service Center, 17291 Mt. Herrmann Street, Fountain

Valley, CA 92708 U.S.A.
Phone: [phone] or 714-241-6805

Fax: [phone]
Web: www

.iEQUUS.com Email: [e-mail]

www.iEQUUS.com

®

Innova Electronics Corp.

17291 Mt. Herrmann Street
Fountain Valley, CA 9270

Instruction MRP #93-0082

PRODUCT DESIGN & COPYRIGHT

© 2005