FRONT COVER 3660 HAND PUMP 3660 © Innova 2001
Paragraph I II III IV V VI VII VIII IX X XI XII XIII XIV Title Page No. INTRODUCTION............................................................ SAFETY PRECAUTIONS .............................................. VEHICLE SERVICE MANUALS................................... UNDERSTANDING VACUUM SYSTEMS ................... AUTOMOTIVE VACUUM SYSTEMS ........................... VACUUM MOTOR/ACTUATOR OPERATION AND TESTING................................................................ TESTING THE PCV SYSTEM .....
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.
III. 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.
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.
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.
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.
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.
VI. 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.
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: Consult the vehicle’s service manual for specifications. 3. Observe the vacuum gauge for approximately one minute.
TYPICAL PCV SYSTEM / PCV VALVE OPERATION FRESH AIR (CLOSURE) TUBE OIL FILLER CAP 3 AIR CLEANER CARB. INT. MAN.
1. Inspect the PCV system for worn, kinked or plugged hoses. Make sure all hoses are properly and securely connected. 2. Connect the hand vacuum pump to an intake manifold vacuum port. (use the hose and a suitable adapter from the accessory kit, as needed). 3. Start and run the engine until it reaches normal operating temperature. 4. Run the engine at idle and observe the vacuum gauge. 5. • The vacuum gauge should indicate between 16 ~ 22 in. (41 ~ 56 cm) Hg.
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 HOUSING SPRING INTAKE FLOW ACTUATING ROD DIAPHRAGM EGR FLOW THROTTLE PLATE EXAUST FLOW Figure 5. Typical EGR System Operation • Ported Vacuum - The EGR valve is actuated by ported vacuum from above the carburetor's throttle plates.
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.
D. TESTING THE EGR VALVE DIAPHRAGM 1. Turn the engine "off" 2. Disconnect the vacuum hose at the EGR valve. 3. 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 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.
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.
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 speed, the intake valve guides are probably worn.If the needle vibrates rapidly when the engine is accelerated, the valve springs are weak. X.
XI. 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 almost any type of fluid.
JAR CAP GAUGE HEAD 11/2 in (4cm) tubing JAR LID PUMP 3.5" (9cm) TUBING 24 in (21cm) TUBING 8oz ( 240ml) RESERVOIR HOSE ADAPTERS PLUG 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. 2. Tighten the reservoir jar lid onto the reservoir jar securely. 3.
B. FLUID EVACUATION PROCEDURES 1. Assemble the fluid evacuation/brake bleeding kit as described on page 16. NOTE: If a large quantity of fluid is to be evacuated, it is advised that a larger fluid 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. 2. Insert the open end of the clear tubing into the item from which fluid is going to be evacuated.
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.
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 sufficient vacuum in the reservoir jar. If the vacuum is not holding, retighten the lid on the jar. 7.
XIV. SERVICE PROCEDURES If you have any questions, please contact your local store, distributor or Manufacturer Department. USA & 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.
FRONT COVER 3660 HAND PUMP © Innova 2001 3660
