3660 HAND PUMP
Contents
1. FRONT COVER 3660 HAND PUMP Paragraph itle Page No I INTRODUCTION iscsicccsecstssiccocsscosssogobeceonnssedss saiia reari 1 II SAFETY PRECAUTIONS 000 eee eeeeseeseeeneeseeeneeeneens 1 HI VEHICLE SERVICE MANUALS 2 IV UNDERSTANDING VACUUM SYSTEMS 2 V AUTOMOTIVE VACUUM SYSTEMS wee 4 VI VACUUM MOTOR ACTUATOR OPERATION AND TESTING ois cssisscoscessevssasecostssnse ine eanna aN E 7 VII TESTING THE PCV SYSTEM esere 8 VIII TESTING THE EGR SYSTEM ww ee eeeeseeeeeeees 10 Ix DIAGNOSING MECHANICAL ENGINE CONDITIONS 1 0 eceeecceeseseeseeseeseeeneeeseees 13 X EXHAUST SYSTEM RESTRICTION TEST 15 XI FLUID EVACUATION ssoi raa iaieiiea ria 16 XII BLEEDING BRAKES 0000 doisin 18 XIII REPLACEMENT PARTS sissessesisississseniisidstasuseivrre niis 20 XIV SERVICE PROCEDURES ou eeeeeeeseeereeeeeeeeeees 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 3660 3660 INTRODUCTION Congratulations You have purchased a precision instrument manufactured to the highest quality standa2. change reservoir coolant A ASSEMBLING THE FLUID EVACUATION BRAKE BLEEDING KIT Use the following procedure to connect the fluid evacuation brake bleeding kit to the vacuum pump see Figure 10 3660 GAUGE HEAD 11 2 in 4cm tubing JAR LID m 3 5 9cm TUBING 24 in 21cm TUBING 80z 240ml RESERVOIR HOSE ADAPTERS es a PLUG m TEE FITTING Figure 10 Vacuum Pump Brake Bleeding and Fluid Evacuation Accessories 1 Attach the 3 1 2 9 cm length of tubing to the bottom fitting of the reservoir jar lid Tighten the reservoir jar lid onto the reservoir jar securely Connect the 1 1 2 4cm or the 24 inch 61cm length of tubing whichever is better suited for your application between the vacuum pump and the reservoir jar lid at the fitting marked PUMP NOTE To reduce the possibility of drawing fluid into the vacuum pump body make sure that the vacuum pump is only connected to the tubing that goes to the jar lid fitting marked PUMP 4 Attach a 24 inch 61cm length of tubing to the remaining fitting on the reservoir jar lid 3660 17 xII 18 FLUID EVACUATION PROCEDURES Assemble the fluid evacuation brake bleeding kit as described on page 16 NOTE Ifa large quantity of fluid is to be evacuated it is advised that a larger f
3. depends on the amount of vacuum that reaches the EGR valve At idle and at wide open throttle a negligible amount of vacuum reaches the valve and the valve stays closed As the throttle plates gradually open vacuum reaches the valve and the valve starts to open A low vacuum to the EGR valve will cause the valve to open slightly As the vacuum to the valve increases the EGR valve continues to open until it is fully opened e EGR Control System The control system monitors engine operation and modulates the amount of EGR based on engine operating conditions such as coolant temperature ambient air temperature exhaust back pressure and engine speed or load To improve drivability before the engine has reached normal operating temperature most vehicles use a thermal switching device which shuts off the EGR system while the engine is cold 11 B TROUBLESHOOTING NOTE EGR systems vary greatly between vehicle makes and models The following paragraphs provide general testing and troubleshooting procedures for EGR systems For specific tests for your vehicle refer to the manufacturer s service manual A defective EGR valve generally remains either fully closed or fully open An EGR valve which remains closed will increase NOx emissions An EGR valve which remains open will cause the engine to stall at idle to idle roughly to lose power or to run rough at full throttle An EGR valve may fail as a result of one or more of the fo
4. 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 GENER
5. sufficient vacuum in the reservoir jar If the vacuum is not holding retighten the lid on the jar 7 Open the brake bleeder screw slightly 1 4 1 2 turn to allow brake fluid to enter the reservoir jar The air that is bled from the brake lines will appear as large uneven bubbles in the 24 inch 61cm clear tubing 8 When the level of fluid in the reservoir jar reaches approximately 1 2 inches 2 5 5 cm tighten the brake bleeder screw DISPOSE OF THE USED BRAKE FLUID PROPERLY 9 Repeat steps I through 8 for all remaining wheels REPLACEMENT PARTS The following items are available as replacement parts or as optional accessories 1 Maintenance kit 2 Replacement gauge 3 Replacement handle 4 Replacement reservoir 8 oz 240 ml 5 Optional fluid evacuation kit Includes a 240z 720ml reservoir jar accessories 6 Replacement hose and fitting kit For ordering information and updates visit us on the web at www iequus com See SERVICE PROCEDURES on page 21 for more information 3660 XIV 3660 SERVICE PROCEDURES If you have any questions please contact your local store distributor or Manufacturer Department USA amp Canada 800 544 4124 7 00 4 00 Monday Friday PST All others 714 241 6802 7 00 4 00 Monday Friday PST FAX 714 432 7511 24 hr THE MANUFACTURER S ONE YEAR LIMITED WARRANTY The Manufacturer warrants to the original purchaser that this unit is free of defects in mat
6. ATED 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 Ifthe 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 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 i
7. ated 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 FILTER MAIN BODY SPRING PUMP HANDLE VACUUM PORT p PISTON ASSEMBLY Figure 2 Hand Vacuum Pump Exploded View 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 D APPLYING VACUUM 1 Connect the vacuum pump s vacuum fitting to the component or system to be tested 2 Squeeze and releas
8. ceipt prepaid to TECHNICAL SERVICE 17291 Mt Herrmann St Fountain Valley CA 92708 Attn Service Department NOTE If sent by US mail be sure to insure the shipment Allow 3 4 weeks service time 21 FRONT COVER 3660 HAND PUMP
9. e Refer to your vehicle s service manual for procedures NOTE On some vehicles idle speed and air fuel mixture are not adjustable The on board computer makes adjustments based on sensor inputs and engine operating conditions ALWAYS consult the vehicle s service manual before making any adjustments TESTING THE EGR SYSTEM A SYSTEM OPERATION The Exhaust Gas Recirculation EGR system is used to reduce Oxides of Nitrogen NOx emissions NOx is created when nitrogen and oxygen in the atmosphere mix at temperatures above 2 500F 1371 During combustion temperatures in the cylinders can exceed 3 500 F 1927 C providing ideal conditions for the formation of NOx The EGR system reduces the formation of NOx by lowering the combustion temperature This is accomplished by recirculating exhaust gases through an EGR valve back into the combustion chambers 3660 3660 Depending on the make model and year of your vehicle the EGR valve may be controlled by one of two methods see Figure 5 VACUUM PORT SEALED ae HOUSING SPRING INTAKE FLOW ACTUATING ROD EGR FLOW THROTTLE PLATE DIAPHRAGM EXAUST FLOW qm Figure 5 Typical EGR System Operation e Ported Vacuum The EGR valve is actuated by ported vacuum from above the carburetor s throttle plates The amount of exhaust gas that is recirculated back into the combustion chamber
10. e manuals The following companies publish valuable repair manuals Haynes Publications 861 Lawrence Drive Newbury Park CA 91320 Phone CA 800 442 9637 TN 800 242 4637 Motor Publications 5600 Crooks Road Suite 200 Troy Michigan 48098 Phone 800 426 6867 Mitchell International 14145 Danielson Street Poway CA 92064 Phone 888 724 6742 FACTORY SOURCE Ford GM Chrysler Honda Isuzu Hyundai and Subaru Service Manuals Helm Inc 14310 Hamilton Avenue Highland Park Michigan 48203 Phone 800 782 4356 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 3660 3660 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
11. e 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 e Rough or uneven idle e Stalling e Pinging or knocking e Burned spark plugs e Burned exhaust valves e Faulty operation of vacuum operated devices F TESTING AND CHECKING VACUUM DEVICES AND COMPONENTS M
12. er load Use the following procedure to test for a restricted exhaust system NOTE In order for this test to be accurate make sure other engine problems as described in DIAGNOSING MECHANICAL ENGINE CONDITIONS are repaired first before the Exhaust System Restriction Test is performed 1 Connect the vacuum pump to an intake port and start the engine 2 With the engine at idle note the vacuum reading on the vacuum gauge e The vacuum reading should be within manufacturer s specifications 3 While observing the vacuum gauge slowly increase engine speed to 2500 3000 RPM At high RPM engine vacuum should be equal to the vacuum reading at idle 3 in 8 cm Hg e Ifthe vacuum decreases to zero or close to zero at high RPM there is probably a restriction on the exhaust system The most probable cause of a restricted exhaust system is a defective Catalytic Converter or muffler Consult the vehicle s service manual for further testing instructions 3660 15 xI 16 FLUID EVACUATION WARNING DO NOT USE THE HAND VACUUM PUMP TO EVACUATE GASOLINE OR ANY OTHER HIGHLY FLAMMABLE OR TOXIC FLUIDS CAUTION Some fluids brake fluid oils power steering fluid etc are very caustic corrosive and may damage painted surfaces Take precautions not to get them in contact with painted surfaces If you accidentally get them on a painted surface wash them off immediately The hand vacuum pump is an excellent tool to evacuate alm
13. erials and workmanship under normal use and maintenance for a period of one 1 year from the date of original purchase whether or not actual use begins on that date User however is responsible for packaging and transportation of product to the service center If the unit fails within the one 1 year period it will be repaired or replaced during normal working hours at the Manufacturer s option at no charge when returned prepaid to the Service 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 or 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 rights which vary 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 Warranty service please call before sending item in for service send via U P S or US mail with a copy of sales re
14. everal 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 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 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 thes
15. h clean brake fluid Assemble the fluid evacuation brake bleeding kit as described on page 16 Select the appropriate bleed screw tapered adapter e Tapered adapters fit inside the brake bleeder screw and should be inserted tightly into the bleeder screw with a pushing twisting motion NOTE On some bleeder screws the clear tubing can be used directly on the bleeder screw without an adapter Push the tube over the top portion of the bleeder screw ensuring that a sealed condition exists If unable to achieve a sealed condition use a tapered adapter as described above Attach the selected adapter if used to the open end of the 24 inch 61cm piece of tubing Remove the bleeder screw Temporarily plug the bleeder screw hole use the plug supplied with the accessory kit or similar to prevent the leaking of brake fluid onto the brake assembly Wrap teflon tape on bleeder screw threads re install and tighten bleeder screw on brake assembly Take precaution not to cover the bleed hole on the side of the bleeder screw when wrapping it with Teflon tape 19 XIII 20 NOTE It is possible to bleed the brake system without using teflon tape on the bleed screw threads but air will be drawn from around the bleed screw threads and it may be difficult to tell if the air is coming from the brake system or from around the bleed screw threads 6 Squeeze and release the pump handle as necessary usually 8 12 times to create
16. hard acceleration or high speed operation heavy load condition low intake manifold vacuum allows the PCV valve spring to overcome the high crankcase pressure pushing the plunger out of the narrow end of the PCV valve and increasing the flow of crankcase gases into the engine for combustion 3660 TYPICAL PCV SYSTEM PCV VALVE OPERATION FRESH AIR CLOSURE TUBE PCV VALVE OIL FILLER CONTROLS SAB N lt AIR CLEANER FLOW RATE CARB INT MAN oleae peer ROCKER COVER Ni CRANK CASE gt gt gt gt gt y i N tt FRESH AIR OIL SEPARATOR FLOW AIR AND CRANKCASE VAPOR FLOW PCV VALVE OPERATING CONDITIONS NORMAL HIGH SPEED OR LOAD BACKFIRE DURING CRANKING HIGH VACUUM VACUUM BACKFIRE CAUSES PULLS VALVE Is Low HIGH PRESSURE TOWARD TOP SEAT IN MANIFOLD FLOW RATE INCREASES PLUNGER SPRING OPENS SEATSTO t It VALVE SEAL OFF FARTHER Pr CRANKCASE PRESSURE TENDS TO CLOSE VALVE FROM CRANKCASE Figure 4 Typical PCV System PCV Valve Operation B TEST PROCEDURES As a result of normal engine operation the PCV valve may become clogged and reduce the amount of crankcase ventilation Reduced ventilation can cause the formation of acids in the crankcase and a buildup of pressure which could force engine oil out past the engine seals To prevent these problem
17. ication of intake manifold system leak intake gasket carbu 76 cmHg retor base gasket vacuum devices or hoses etc Readings of 3 8 in 8 20cm Hg below normal may be an indication of late ignition valve timing or worn piston rings in Hg VACUUM 3 Ignition system problems or burned leaky and sticking valves Figure 8 If the gauge needle fluctuates very slowly over a range of approxi mately 2 in 3 cm Hg this may be an indication of an ignition problem spark plug gap ignition coil cables cap circuit If the valves are burned or leaking the vacuum reading will drop every time the defective valve or valves are inoperative An intermittent Figure 8 drop indicates sticking valves 14 3660 4 Leaking head gasket worn valve guides or weak broken valve springs Figure 9 If the gauge needle fluctuates regularly between a high and a low reading the cylinder head gasket may have a leak between two adjacent cylinders If the needle vibrates rapidly at idle inHg speed the intake valve guides are VACUUM probably worn If the needle SSS vibrates rapidly when the engine Figure 9 is accelerated the valve springs are weak EXHAUST SYSTEM RESTRICTION TEST The vacuum gauge is also a valuable tool to help in the troubleshooting of a restricted exhaust system An exhaust restriction usually allows normal engine performance at idle but causes poor performance at higher engine speed or with the engine und
18. iner s vacuum port a partial vacuum lower than atmospheric pressure is created in the sealed section of the container As a result atmospheric pressure exerts a force on the side of the piston or diaphragm that is open to the atmosphere causing it to move in the direction of the applied vacuum This mechanical action is is utilized to activate whatever is attached to the shaft or lever on the diaphragm see Figure 3 Figure 3 Typical Vacuum Motor Actuator The amount of force applied by atmospheric pressure to the diaphragm is calculated by multiplying the pressure difference between atmospheric pressure and the pressure within the container times the surface area of the diaphragm or piston Atmospheric Pressure Container Pressure X Surface area Force The hand vacuum pump can be used to perform a wide range of tests such as measuring the amount of vacuum in a system or device detecting a leak in a system or a fluctuating vacuum supply The pump can also be used for testing the function of a variety of vacuum operated devices Vil B VACUUM MOTOR ACTUATOR TESTING PROCEDURES The following procedure shows how the vacuum pump might be used to check a vacuum motor actuator for a leaking diaphragm 1 Connect the vacuum pump s vacuum hose to the vacuum port of the motor actuator 2 Operate the handle to apply 8 10 inches 20 25 cm Hg of vacuum to the motor actuator as shown on the vacuum gauge NOTE Co
19. llowing causes 12 Loss of vacuum or control vacuum Mechanical defect such as a ruptured diaphragm Contamination of or damage to the valve seat restricted by carbon buildup Restrictions in the exhaust tube TESTING EGR VACUUM EGR CONTROL SYSTEM Connect the vacuum pump s vacuum port to the EGR valve s vacuum supply line use the vacuum tee included in the accessory kit if necessary Start and run the engine until it reaches normal operating temperature Increase engine speed to approximately 2000 2500 RPM and observe the vacuum gauge e The EGR valve vacuum supply should be at least 4 6 in 10 15 cm Hg of vacuum e If no vacuum is present check the vacuum hoses and connections that supply vacuum to the EGR valve for any abnormality or defect Repair as necessary e If vacuum hoses are in good condition test the control system that modulates and controls the vacuum to the EGR valve Control systems and testing procedures vary widely depending on the make year and model of the vehicle Consult the manufacturer s service manual for testing procedures 3660 D TESTING THE EGR VALVE DIAPHRAGM 1 Turn the engine off Disconnect the vacuum hose at the EGR valve Connect the vacuum pump to the EGR valve use the clear hose and adapter included in the accessory kit as necessary 4 Squeeze and release the pump handle until 10 12 in 26 30 cm Hg of vacuum is indicated on the gauge Observe
20. luid reservoir jar be used A fluid evacuation kit that includes a 24 ounce 720 ml reservoir jar and longer tubing is available as an option See page REPLACEMENT PARTS on page 20 for more information Insert the open end of the clear tubing into the item from which fluid is going to be evacuated Make sure the evacuation kit is assembled properly and the jar lid is properly tightened Squeeze and release the pump handle as needed until the desired amount of fluid is evacuated CAUTION To prevent fluid from being drawn into the pump body only evacuate fluid until the reservoir container is half full When the container is half full use the relief valve on the pump to release the vacuum then empty the container and repeat the procedure until the desired amount of fluid is evacuated BLEEDING BRAKES WARNING Most Anti Lock brake systems use a high pressure pump to maintain system pressure ALWAYS observe the following precautions when servicing Anti Lock brake systems A ALWAYS refer to the manufacturer s service manual for service and repair procedures for your vehicle s Anti Lock brake system ALWAYS wear safety goggles when performing servicing procedures ALWAYS depressurize the system before adding brake fluid or performing servicing procedures ALWAYS use manufacturer recommended brake fluids ONLY Unless directed to by the manufacturer s service procedure NEVER open a bleeder valve or loosen a hydraulic li
21. ne while the system is pressurized BLEEDING AUTOMOBILE BRAKES CAUTION Brake fluid is very caustic corrosive and will damage painted surfaces Take precautions to prevent brake fluid from contacting these surfaces If brake fluid contacts a painted surface wash it off immediately 3660 3660 Air in the brake system hydraulic lines can result in a low or soft brake pedal To remedy this problem the air must be bled from the hydraulic lines The vacuum pump provides a simple and effective method of bleeding air from the brake system Use the following procedure to bleed air from automobile brake lines NOTES Make sure all brake bleeding nuts are clean prior to beginning the brake bleeding procedure Bleed the brake system in the following order for most vehicles a Master cylinder If the master cylinder needs to be bled consult the vehicle s service manual and follow the manufacturer s instructions for procedures b Combination valve bleeder screws if equipped c Wheel cylinders and calipers Procedures and sequences for bleeding wheel cylinders and calipers very widely from one manufacturer to the next Always consult the vehicle s service manual and follow the manufacturer s recommendations for the proper procedure or sequence to follow when bleeding wheel cylinders and calipers Check the fluid level in the master cylinder frequently during brake system bleeding and top off as needed with fres
22. nside 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 FUEL INJECTOR VACUUM PORT EXHAUST tome MANIFOLD COMBUSTION CHAMBER Figure 1 Piston Intake Stroke 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 3660 3660 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 oper
23. nsult the vehicle s service manual for specifications 3 Observe the vacuum gauge for approximately one minute e If the vacuum gauge reading remains steady for one minute the diaphragm is not leaking e If the vacuum gauge reading falls a leaking diaphragm is indicated TESTING THE PCV SYSTEM A SYSTEM DESCRIPTION AND OPERATION The Positive Crankcase Ventilation PCV system helps reduce air pollution by aiding in the scavenging and burning of harmful engine crankcase vapors and gases before they can enter the atmosphere The PCV system consists essentially of an intake filter PCV valve and interconnecting hoses see Figure 4 Fresh air is drawn through the intake filter located in the air cleaner through the valve cover and into the crankcase to be mixed with the crankcase gases From the crankcase the gases are drawn to the opposite valve cover through the PCV valve and into the intake manifold The intake manifold vacuum draws these crankcase gases where they are mixed with incoming intake air to be burned during engine combustion Airflow through the PCV system adds to the airflow through the carburetor or throttle body during engine operation During cruising and light acceleration intake manifold vacuum and the pressure inside the crankcase are relatively high The strong manifold vacuum draws the PCV valve plunger into the narrow end of the valve restricting most of the flow of gases into the intake manifold During
24. ost any type of fluid The following are typical areas where the hand vacuum pump can be very useful for evacuating fluids e Automatic transmissions transaxle If the transmission is accidentally overfilled with transmission fluid Most vehicles are not equipped with a drain plug and the only way to drain excess fluid is to remove the pan A more effective and easier method is to use the vacuum pump with the fluid evacuation kit to siphon the extra fluid out through the filler tube NOTE On some transmissions transaxles the distance from the top of the filler tube to the transmission oil pan is quite long A longer tubing sold separately than the one supplied with the fluid evacuation kit may be needed to evacuate transmission fluid from these units e Power steering pump fluid to correct an overfilled condition to replace the pump reservoir fluid with new power steering fluid e Master cylinder to correct an overfill condition to replace the master cylinder brake fluid with new fluid e Differential 4WD and rear wheel drive vehicles some 4WD and rear wheel drive vehicles need to be serviced periodically by changing the differential fluid but are not equipped with a drain plug With the vacuum pump and the fluid evacuation kit the fluid can be siphoned out through the fill hole without removing the differential cover e Coolant overflow reservoir remove coolant from overflow reservoir to correct an overflow condition or to
25. ost 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 3660 Vi 3660 VACUUM MOTOR ACTUATOR OPERATION AND TESTING A VACUUM MOTOR ACTUATOR DESCRIPTION AND OPERATION A vacuum motor actuator is a device that uses vacuum to perform a mechanical function An automobile engine uses vacuum motors actuators to perform many functions Typical functions performed by vacuum motors actuators are e Opening and closing the heater and air conditioning duct doors e Raising the EGR valve pintle off it s seat to recirculate exhaust gas back into the system e Activating the vacuum advance unit to advance distributor spark advance timing A vacuum motor actuator is a partially sealed container on VACUUM PORT most vehicles container is cylindrical in shape One side of the container is sealed and is equipped with a vacuum port The other side of the container is covered by a rubber diaphragm or a piston D DIAPHRAM a spring with an attached shaft or a lever When engine vacuum is applied to the conta
26. peration and sealing integrity of these devices before an engine vacuum test is performed 1 Start and run the engine until it reaches operating temperature 2 Connect the vacuum gauge to the intake manifold Whenever possible connect the gauge hose directly to a vacuum port on the intake manifold in order to avoid any leaks that might exist in other connections 3 Evaluate the test results 3660 13 NOTE Use the following illustrations only as a guide These drawings are examples based on manufacturer s specifications of 18 in 51 cm Hg of vacuum at idle at sea level The idle specifications for your vehicle may be higher or lower as specified by the vehicle s manufacturer than the ones shown The purpose of these examples is to show the action or fluctuations of the needle which are indicative of engine condition 1 Normal engine Figure 6 An engine at idle at sea level should show a steady needle and a vacuum of 15 22 in 38 56 cm Hg depending on manufacturer s specifications Quickly opening and closing the throttle should cause the vacuum to momentarily drop to below 5 in 12 cm Hg followed by a momentary rebound to approx imately 25 in 64 cm Hg before returning to normal 15 22 in 38 56 cm Hg 2 Intake system leak late ignition valve timing or low compression Figure 7 If the gauge reading at idle is steady but much lower than normal 5 13 in 12 25 cm Hg this may be an ind
27. rds 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 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 s
28. s the PCV valve should be replaced periodically NOTE A slow or rough idle can be caused by a clogged PCV valve Check the PCV system BEFORE adjusting engine idle 3660 9 VIII 10 Inspect the PCV system for worn kinked or plugged hoses Make sure all hoses are properly and securely connected Connect the hand vacuum pump to an intake manifold vacuum port use the hose and a suitable adapter from the accessory kit as needed Start and run the engine until it reaches normal operating temperature Run the engine at idle and observe the vacuum gauge e The vacuum gauge should indicate between 16 22 in 41 56 cm Hg e The gauge needle should remain steady little or no movement e Note the engine speed RPM and vacuum at idle Clamp the vacuum supply hose to the PCV valve e Engine speed should decrease by approximately 100 RPM as a result of loss of air flow from the PCV system e Vacuum should increase slightly indicating vacuum flow through the PCV system has been plugged e IfBOTH a decrease in engine RPM and an increase in vacuum are not observed replace the PCV valve and or any damaged or plugged hoses NOTE Be sure to install the correct PCV valve for your vehicle Installing the wrong PCV valve can result in either excessive or insufficient air flow through the PCV system After replacing the PCV valve ALWAYS readjust the engine s idle speed and if possible the idle air fuel mixtur
29. the vacuum gauge for one minute minimum e Verify the vacuum gauge reading of 10 12 in 26 30 cm Hg remains steady for at least one minute If the vacuum drops the diaphragm is defective E CHECKING EGR VALVE SEAT RESTRICTIONS IN EXHAUST TUBE The only way to accurately check the EGR valve seat for contamination or damage and the exhaust tube for restrictions is to remove the EGR valve Consult the manufacturer s service manual for procedures The EGR valve may also operate properly with the engine at normal operating temperature but remain open when the engine is cold This usually occurs when a faulty thermal switching device fails to shut off the vacuum supply when the engine is cold IX DIAGNOSING MECHANICAL ENGINE CONDITIONS When used properly a vacuum gauge can provide a considerable amount of information about the internal condition of an engine However it is easy to misinterpret the readings of the instrument and thereby reach false conclusions When using a vacuum gauge on an engine it is far more important to note the action and the general location of the needle rather than the actual vacuum reading NOTE Vacuum leaks or improper operation of any of the external vacuum operated devices EGR valve vacuum operated solenoids EVAP system vacuum valves etc and hoses may interfere with proper engine diagnosis by giving a false indication of current engine condition Always perform a preliminary check for proper o
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