TROUBLESHOOTING INDEX 11-2 SECTION7:CLlMATECONTR(IL II-16

SECTION1: ENGINE 11-2 AIR CONDITIONER ll- -16

SECTION2: DRIVETRAIN 11-3 HEATER II-16
SECTION3:BRAKESYSTEM 11-3
SECTION4:WHEELS,TIRES,STEERING,
AND SUSPENSION II-4
SECTION5: ELECTRICAL
ACCESSORIES II-4
SECTION6:lNSTRUMENTSAND
GAUGES II-5
SECTION7:CLlMATE CONTROL II-5
DIAGNOSTIC PROCEDURES II-6
SECTION1: ENGINE II-6
ENGINESTARTINGPROBLEMS II-6
ENGINERUNNINGCONDITIONS II-7
ENGINENOISES,ODORSAND
VIBRATIONS II-8
ENGINEELECTRICALSYSTEM 11-8
ENGINECOOLINGSYSTEM II-8
ENGINEEXHAUSTSYSTEM II-9
SECTION2: DRIVETRAIN II-9
AUTOMATICTRANSMISSION II-9
MANUALTRANSMISSION II-10
CLUTCH II-10
DIFFERENTIALAND FINAL
DRIVE II-10
TRANSFERASSEMBLY II-10
DRIVESHAFT II-10
AXLES II-II
OTHERDRIVETRAIN
CONDITIONS II-II
SECTION3:BRAKESYSTEM II-II
BRAKESYSTEM
TROUBLESHOOTINGII-II
SECTION4:WHEELS,TIRES,STEERING
AND SUSPENSION II-12
WHEELSANDWHEEL
BEARINGS II-12
TIRES II-12
STEERING II-12
SUSPENSION II-12
DRIVINGNOISESAND
VIBRATIONS II-13
SECTION5:ELECTRlCAL
ACCESSORIES II-13 -
HEADLIGHTS II-13
TAIL, RUNNINGAND SIDEMARKER
LIGHTS II-13
INTERIORLIGHTS II-14
BRAKELIGHTS II-14
WARNINGLIGHTS II-14
TURNSlGNALAND4-WAYHAZARD
LIGHTS II-15
WINDSHIELDWIPERS II-15
SECTION6:lNSTRUMENTSAND
GAUGUES II-15 I
SPEEDOMETER(CABLE
OPERATED) II-15
SPEEDOMETER(ELECTRONICALLY
OPERATED) II-16
FUEL,TEMPERATUREAkJD OIL
PRESSURE GAUGES II-16
11-2 TROUBLESHOOTING
Condition Section/Item Number
Thefollowingtroubleshooting chartsaredividedinto7 sectionscoveringengine,drivetrain,brakes,wheels/tires/steering/suspension,
electricalaccessories,instrumentsandgauges,
andclimatecontrol.Thefirst portion(or index)consistsof a list of symptoms,alongwithsectionanditemnumbers.Afterselectingtheappropriatecondition,referto thecorresponding
diagnosticprocedurein thesecondportion’sspecifiedlocation.
INDEX

Gasoline Engines
Engineturnsover,but will not start I-A, 1
Enginedoesnotturnoverwhenattemptingto start l-A, 2
Enginestallsimmediatelywhenstarted I-A, 3
Startermotorspins,butdoesnotengage I-A, 4
Engineis difficultto startwhencold I-A, 5
Engineis difficultto startwhenhot I-A, 6

Diesel Engines
Engineturnsoverbutwon’tstart I-A, 1
Enginedoesnotturn overwhenattemptingto start l-A, 2
Enginestallsafterstarting I-A, 3
Startermotorspins,butdoesnotengage I-A, 4
Engineis difficultto start l-A, 5

Gasoline Engines
Enginerunspoorly,hesitates l-B, 1
Enginelackspower I-B, 2
Enginehaspoorfueleconomy l-B, 3
Enginerunson (diesels)whenturnedoff I-B, 4
Engineknocksandpingsduringheavyacceleration,andon steephills l-B, 5
Engineaccelerates
butvehicledoesnot gainspeed I-B, 6

Diesel Engines
Enginerunspoorly l-B,-1
Enginelackspower l-B, 2

Enginemakesa knockingor pingingnoisewhenaccelerating l-C, 1

Startermotorgrindswhenused l-C, 2
Enginemakesa screechingnoise l-C, 3
Enginemakesa growlingnoise I-C, 4
Enginemakesa tickingor tappingnoise l-C, 5
Enginemakesa heavyknockingnoise I-C, 6
Vehiclehasa fuelodorwhendriven l-C, 7
Vehiclehasa rotteneggodorwhendriven l-C, 8
Vehiclehasa sweetodorwhendriven I-C, 9
Enginevibrateswhenidling I-C, 10
Enginevibratesduringacceleration l-C, 11

Batterygoesdeadwhiledriving l-C, 1
Batterygoesdeadovernight I-C, 2

Engineoverheats I-D, 1
Enginelosescoolant I-D, 2
Enginetemperature
remainscoldwhendriving I-D, 3
Enginerunshot I-D, 4

Exhaustrattlesat idle speed l-F, 1

Exhaustsystemvibrateswhendriving l-F, 2
Exhaustsystemseemstoo low I-F, 3
Exhaustseemsloud I-F, 4
 I TROUBLESHOOTING
II-3
Condition Section/hem Number

Transmissionshiftserratically 2-A, 1
Transmissionwill notengage 2-A, 2
Transmissionwill not downshiftduringheavyacceleration 2-A, 3

Transmissiongrindsgoingintoforwardgearswhiledriving 2-B, 1 2-C, 2

Transmissionjumpsout of gear 2-B,2
Transmissiondifficultto shift 2-B,3 2-C, 2
Transmissionleaksfluid 2-B,4

Clutchslips on hills or duringsuddenacceleration 2-C,l

Clutchwill notdisengage,difficultto shift 2-c,2
Clutchis noisywhentheclutchpedalis pressed 2-c,3
Clutchpedalextremelydifficultto press 2-c,4
Clutchpedalremainsdownwhenpressed 2-c,5
Clutchchatterswhenengaging 2-C,6

Differentialmakesa lowpitchedrumblingnoise 2-D, 1

Differentialmakesa howlingnoise 2-D, 2

All Wheel and Four Wheel Drive Vehicles

Leaksfluid fromsealsor ventafterbeingdriven 2-E,1
Makesexcessivenoisewhiledriving 2-E,2
Jumpsout of gear 2-E,3

Rear Wheel, All Wheel and Four Wheel Drive Vehicles

Clunkingnoisefromcenterof vehicleshiftingfromforwardto reverse 2-F, l
,Excessive
vibrationfromcenterof vehiclewhenaccelerating 2-F,2

All Wheel and Four Wheel Drive Vehicles

, Frontor rearwheelmakesa clickingnoise 2-G,l
Frontor Rearwheelvibrateswith increasedspeed 2-G,2

Front Wheel Drive Vehicles

Frontwheelmakesa clickingnoise 2-G,3
Rearwheelmakesa clickingnoise 2-G,4

Rear Wheel Drive Vehicles

Frontor rearwheelmakesa clickingnoise 2-G,5
Rearwheelshuddersor vibrates 2-G,6

Burningodorfromcenterof vehiclewhenaccelerating 2-H, 1; 2-C, 1; 3-A, 9

Engineaccelerates,
butvehicledoesnotgainspeed 2-H, 2; 2-C, 1; 3-A, 9

Brakespedalpulsatesor shimmieswhenpressed 3-A-l

Brakesmakea squealingnoise CI 3-A, 2
Brakesmakea grindingnoise 3-A, 3
Vehiclepullsto onesideduring.braking 3-A, 4
Brakepedalfeelsspongyor hasexcessivebrakepedaltravel 3-A, 5
Brakepedalfeelis firm, butbrakeslacksufficientstoppingpoweror fade 3-A, 6
 11-4 TROUBLESHOOTING
Condition 2 Section/Item Number
^i Vehiclehasexcessivefrontenddiveor locksrearbrakestoo easily 3-A, 7
Brakepedalgoesto floorwhenpressedandwill not pumpup 3-A, 8
Brakesmakea burningodor 3-A, 9

All Wheel and Four Wheel Drive Vehicles

Frontwheelor wheelbearingloose 4-A. 1
Rearwheelor wheelbearingloose 4-A: 1

Front Wheel Drive Vehicles

Frontwheelor wheelbearingloose 4-A, 1
Rearwheelor wheelbearingloose 4-A, 2

Rear Wheel Drive Vehicles

Frontwheelor wheelbearingloose 4-A, 2
Rearwheelor wheelbearingloose 4-A, 1

Tireswornon insidetread 4-B, 1

Tireswornon outsidetread 4-B, 2
s Tireswornunevenly 4-B, 3

Excessiveplayin steeringwheel 4-c, 1

Steeringwheelshakesat cruisingspeeds 4-c, 2
Steeringwheelshakeswhenbraking 3-A, 1
Steeringwheelbecomesstiffwhenturned 4-c, 4

Vehiclepullsto oneside 4-D 1

Vehicleis verybouncyoverbumps 4-D, 2
Vehicleseemsto leanexcessivelyin turns 4-D, 3
Vehicleridequalityseemsexcessivelyharsh 4-D, 4
Vehicleseemslowor leansto oneside 4-D, 5

Noises
Vehiclemakesa clickingnoisewhendriven 4-E,1
Vehiclemakesa clunkingor knockingnoiseoverbumps 4-E,2
Vehiclemakesa lowpitchedrumblingnoisewhendriven 4-E,3
Vehiclemakesa squeakingnoiseoverbumps 4-E,4
\
Vibrations
Vehiclevibrateswhendriven 4-E,5

Oneheadlightonlyworkson highor lowbeam 5-A, 1

Headlightdoesnotworkon highor lowbeam 5-A, 2
Headlight(s)verydim 5-A, 3
/ .

Tail light,runninglightor sidemarkerlight inoperative 5-B, 1

Tail light,runninglightor sidemarkerlightworksintermittently 5-B, 2
Tail light,runninglightor sidemarkerlightverydim 5-B, 3

Interiorlightinoperative 5-c, 1
Interiorlightworksintermittently 5-c, 2
Interiorlightverydim 5-c, 3
 .
TROUBLESHOOTING
II-5
Condition Section/Item Number

Onebrakelightinoperative 5-D, 1
Bothbrakelightsinoperative 5-D,2
Oneor bothbrakelightsverydim 5-D,3

Ignition, Battery and Alternator Warning Lights, Check Engine

Light, Anti-Lock Braking System (ABS) Light, Brake Warning
Light, Oil Pressure Warning Light, and Parking Brake Warning
Light
Warninglight(s)remainson aftertheengineis started 5-E,1
Warninglight(s)flickersonandoff whendriving 5-E,2
Warninglight(s)inoperativewith ignitionon,andenginenotstarted 5-E,3

Turnsignalsor hazardlightscomeon, butdo notflash 5-F, 1

Turnsignalsor hazardlightsdo notfunctionon eitherside 5-F,2
Turnsignalsor hazardlightsonlyworkon oneside 5-F,3
Onesignallightdoesnotwork 5-F,4
Turnsignalsflashtoo slowly 5-F,5
Turnsignalsflashtoo fast 5-F,6
Four-wayhazardflasherindicatorlight inoperative 5-F,7
Turnsignalindicatorlight(s)do notworkin eitherdirection 5-F,8
Oneturnsignalindicatorlightdoesnotwork 5-F,9

Horndoesnotoperate 5-G,1
Hornhasan unusualtone 5-G,2

Windshieldwipersdo not operate 5-H, 1

Windshieldwipermotormakesa hummingnoise,getshot or blowsfuses 5-H,2
Windshieldwipermotoroperatesbutoneor bothwipersfail to move 5-H, 3
Windshieldwiperswill not park 5-H,4

Speedometer
doesnotwork 6-A, 1
Speedometer
needlefluctuateswhendrivingat steadyspeeds 6-A, 2
Speedometer
worksintermittently 6-A, 3

Speedometer
doesnotwork 6-B,1
Speedometer
worksintermittently 6-B,2

Gaugedoesnot register 6-C 1

Gaugeoperateserratically 6-C 2
Gaugeoperatesfully pegged ’ 6-C 3

Noair comingfromair conditionervents 7-A, 1

Air conditionerblowswarmair ’ 7-A, 2
Watercollectsonthe interiorfloor whentheair conditioneris used 7-A, 3
Air conditionerhasa moldyodorwhenused 7-A, 4

Blowermotordoesnotoperate 7-B, 1
Heaterblowscoolair 7-B,2
Heatersteamsthewindshieldwhenused 7-B,3
II-6 TROUBLESHOOTING
DIAGhUSTICPROCEDURES
Gasoline Engines
1. Engine turns over, but wilt not start
a. Checkfuellevelin fueltank,addfuel if empty.
b. Checkbatteryconditionandstateof charge.If voltageandloadtestbelowspecifica-
tion, chargeor replacebattery.
c. Checkbatteryterminalandcableconditionandtightness.Cleanterminalsandreplace
damaged,wornor corrodedcables.
d. Checkfueldeliverysystem.If fuelis not reachingthefuel injectors,checkfor a loose
electricalconnectoror defectivefuse,relayor fuelpumpandreplaceas necessary.
e. Enginemayhaveexcessivewearor mechanicaldamagesuchas lowcylindercranking
pressure,a brokencamshaftdrivesystem,insufficientvalveclearanceor bentvalves.
f. Checkfor fuelcontamination suchaswaterin thefuel.Duringwintermonths,thewa-
ter mayfreezeandcausea fuelrestriction.Addinga fueladditivemayhelp,however
thefuelsystemmayrequiredrainingandpurgingwithfreshfuel.
g. Checkfor ignitionsystemfailure.Checkfor looseor shortedwiresor damagedigni-
tionsystemcomponents. Checkthesparkplugsfor excessivewearor incorrectelec-
trodegap.If the problemis worsein wetweather,checkfor shortsbetweenthespark
plugsandthe ignitioncoils.
h. Checktheenginemanagement systemfor a failedsensoror controlmodule.
2. Engine does not turn over when attempting to start
a. Checkthebatterystateof chargeandcondition.If the dashlightsarenotvisibleor
verydimwhenturningthe ignitionkeyon,the batteryhaseitherfailedinternallyor
discharged,the batterycablesareloose,excessivelycorrodedor damaged,or theal-
ternatorhasfailedor internallyshorted,dischargingthebattery.Chargeor replacethe
battery,cleanor replacethe batterycables,andcheckthealternatoroutput.
b. Checkthe operationof theneutralsafetyswitch.Onautomatictransmissionvehicles,
try startingthevehiclein bothParkandNeutral.Onmanualtransmissionvehicles,de-
presstheclutchpedalandattemptto start.Onsomevehicles,theseswitchescanbe
adjusted.Makesuretheswitchesor wireconnectorsarenot looseor damaged.Re-
placeor adjusttheswitchesas necessary.
c. Checkthestartermotor,startersolenoidor relay,andstartermotorcablesandwires.
Checkthegroundfromtheengineto thechassis.Makesurethewiresarenot loose,
damaged,or corroded.If batteryvoltageis presentat thestarterrelay,try usinga re-
motestarterto startthevehiclefor testpurposesonly.Replaceanydamagedor cor-
rodedcables,in additionto replacinganyfailedcomponents.
d. Checktheenginefor seizure.If theenginehasnot beenstartedfor a longperiodof
time,internalpartssuchasthe ringsmayhaverustedto thecylinderwalls.Theengine
mayhavesufferedinternaldamage,or couldbehydro-lockedfromingestingwater.
Removethesparkplugsandcarefullyattemptto rotatetheengineusinga suitable
breakerbarandsocketon thecrankshaftpulley.If theengineis resistantto moving,or
movesslightlyandthenbinds,do notforcetheengineanyfurtherbeforedetermining
the problem.
3. Enpine stalls immediately when started
a. Checkthe ignitionswitchconditionandoperation.Theelectricalcontactsin the run
positionmaybewornor damaged.Try restartingtheenginewithall electricalacces-
soriesin theoff position.Sometimesturningthekeyon anoff will helpin emergency
situations,howeveroncetheswitchhasshownsignsof failure,it shouldbereplaced
assoonas possible.
b. Checkfor loose,corroded,damagedor shortedwiresfor the ignitionsystemandre-
pairor replace.
c. Checkfor manifoldvacuumleaksor vacuumhoseleakageandrepairor replaceparts
as necessary.
d. Measurethefuelpumpdeliveryvolumeandpressure.Lowfuelpumppressurecan
alsobenoticedasa lackof powerwhenaccelerating. Makesurethefuel pumplines
arenot restricted.Thefuelpumpoutputis notadjustableandrequiresfuelpumpre-
placementto repair.
e. Checktheenginefuelandignitionmanagement system.Inspectthesensorwiringand
electricalconnectors.A dirty,looseor damagedsensoror controlmodulewirecan
simulatea failedcomponent.
f. Checktheexhaustsystemfor internalrestrictions.
4. Starter motor spins, but does not engage
a. Checkthestartermotorfor a seizedor bindingpiniongear.
b. Removetheflywheelinspectionplateandcheckfor a damagedring gear.
5. Engine is difficult to start when Gold
a. Checkthebatterycondition,batterystateof chargeandstartermotorcurrentdraw.Re-
placethe batteryif marginalandthestartermotorif thecurrentdrawis beyondspecifi-
cation.
b. Checkthe batterycablecondition.Cleanthe batteryterminalsandreplacecorrodedor
damagedcables.
c. Checkthefuelsystemfor properoperation.A fuel pumpwith insufficientfuelpressure
or cloggedinjectorsshouldbereplaced.
d. Checktheengine’stune-upstatus.Notethetune-upspecificationsandcheckfor items
suchasseverelywornsparkplugs;adjustor replaceas needed.Onvehicleswith
manuallyadjustedvalveclearances,checkfor tightvalvesandadjustto specification.
e. Checkfor a failedcoolanttemperature
sensor,andreplaceif outof specification.
f. Checktheoperationof theenginemanagement systemsfor fuelandignition;repairor
replacefailedcomponentsas necessary.
6. En#ine is ditticutt to start when hot
a. Checktheair filterandair intakesystem.Replacetheair filter if it is dirty or contami-
nated.Checkthefreshair intakesystemfor restrictionsor blockage.
b. Checkfor looseor deterioratedenginegroundsandclean,tightenor replaceas
needed.
c. Checkfor neededmaintenance. Inspecttune-upandservicerelateditemssuchas
sparkplugsandengineoil condition,andchecktheoperationof theenginefueland
ignitionmanagement system.
Diesel Engines
1. Engine turns over but won’t start
a. Checkenginestartingprocedureandrestartengine.
b. Checktheglowplugoperationandrepairor replaceas necessary.
c. Checkfor air in thefuelsystemor fuelfilter andbleedtheair as necessary.
d. Checkthefueldeliverysystemandrepairor replaceas necessary.
e. Checkfuel levelandaddfuelas needed.
f. Checkfuelquality.If thefuel is contaminated, drainandflushthefueltank.
g. Checkenginecompression.If compressionis belowspecification,theenginemay
needto berenewedor replaced.
h. Checkthe injectionpumptimingandsetto specification.
i. Checkthe injectionpumpconditionandreplaceas necessary.
j. Checkthefuelnozzleoperationandconditionor replaceasnecessary.
2. Engine does hot turn over when attempting to start
a. Checkthe batterystateof chargeandcondition.If the dashlightsarenotvisibleor
verydimwhenturningthe ignitionkeyon,the batteryhaseitherfailedinternallyor
discharged, the batterycablesareloose,excessivelycorrodedor damaged,or theal-
ternatorhasfailedor internallyshorted,dischargingthe battery.Chargeor replacethe
battery,cleanor replacethe batterycables,andcheckthealternatoroutput.
b. Checktheoperationof the neutralsafetyswitch.Onautomatictransmissionvehicles,
try startingthevehiclein bothParkandNeutral.Onmanualtransmissionvehicles,de-
presstheclutchpedalandattemptto start.Onsomevehicles,theseswitchescanbe
adjusted.Makesuretheswitchesor wireconnectorsarenot looseor damaged.Re-
placeor adjusttheswitchesas necessary.
c. Checkthe startermotor,startersolenoidor relay,andstartermotorcablesandwires.
Checkthegroundfromtheengineto thechassis.Makesurethewiresarenot loose,
damaged,or corroded.If batteryvoltageis presentatthestarterrelay,try usinga re-
motestarterto startthevehiclefor testpurposesonly.Replaceanydamagedor cor-
rodedcables,in additionto replacinganyfailedcomponents.
d. Checktheenginefor seizure.If theenginehasnot beenstartedfor a longperiodof
time,internalpartssuchastheringsmayhaverustedto thecylinderwalls.Theengine
mayhavesufferedinternaldamage,or couldbehydro-lockedfrom ingestingwater.
Removetheinjectorsandcarefullyattemptto rotatetheengineusinga suitable
breakerbarandsocketonthecrankshaftpulley.If theengineis resistantto moving,or
movesslightlyandthenbinds,do notforcetheengineanyfurtherbeforedetermining
thecauseof the problem.
3. Engine stalls afier starting
a. Checkfor a restrictionin thefuel returnlineor the returnlinecheckvalveandrepairas
necessary.
b. Checkthe glowplugoperationfor turningtheglowplugsoff too soonandrepairas
necessary.
c. Checkfor incorrectinjectionpumptimingandresetto specification.
d. Testtheenginefuel pumpandreplaceif theoutputis belowspecification.
e. Checkfor contaminated or incorrectfuel.Completelyflushthefuelsystemandreplace
withfreshfuel.
f. Testthe engine’scompressionfor lowcompression.If belowspecification,mechanical
repairsarenecessaryto repair.
g. Checkfor air in thefuel.Checkfueltankfuelandfill as needed.
h. Checkfor a failedinjectionpump.Replacethepump,makingsureto properlysetthe
pumptiming.

4. Startermotorspins,butdoesnotengage
a. Checkthestartermotorfor a seizedor bindingpiniongear.
b. Removetheflywheelinspectionplateandcheckfor a damagedring gear.
Gasoline Engines
1. Engine runs poor/y, hesiiates
a. Checktheengineignitionsystemoperationandadjustif possible,or replacedefective
parts.
b. Checkfor restrictedfuel injectorsandreplaceas necessary.
c. Checkthefuelpumpoutputanddelivery.Inspectfuel linesfor restrictions.If thefuel
pumppressureis belowspecification,replacethefuelpump.
d. Checktheoperationof theenginemanagement systemandrepairas necessary.
2. Enfline lacks power
a. Checktheengine’stune-upstatus.Notethetune-upspecificationsandcheckfor items
suchasseverelywornsparkplugs;adjustor replaceas needed.Onvehicleswith
manuallyadjustedvalveclearances, checkfor tightvalvesandadjustto specification.
b. Checktheair filter andair intakesystem.Replacetheair filter if it is dirtyor contami-
nated.Checkthefreshair intakesystemfor restrictionsor blockage.
c. Checkthe operationof theenginefuelandignitionmanagement systems.Checkthe
sensoroperationandwiring.Checkfor lowfuelpumppressureandrepairor replace
componentsas necessary.
d. Checkthethrottlelinkageadjustments. Checkto makesurethe linkageis fully open-
ingthethrottle.Replaceanywornor defectivebushingsor linkages.
e. Checkfor a restrictedexhaustsystem.Checkfor bentor crimpedexhaustpipes,or in-
ternallyrestrictedmufflersor catalyticconverters.Compareinletandoutlettempera-
turesfor theconverteror muffler.If the inletis hot,butoutletcold,thecomponentis
restricted.
f. Checkfor a looseor defectiveknocksensor.A loose,improperlytorquedor defective
knocksensorwill decreasesparkadvanceandreducepower.Replacedefectiveknock
sensorsandinstallusingthe recommended torquespecification.
g. Checkfor enginemechanicalconditionssuchas lowcompression,wornpistonrings,
wornvalves,worncamshaftsandrelatedparts.An enginewhichhasseveremechani-
calwear,or hassufferedinternalmechanicaldamagemustberebuiltor replacedto re-
storelostpower.
h. Checktheengineoil levelfor beingoverfilled.Adjusttheengine’soil level,or change
theengineoil andfilter,andtop off to thecorrectlevel.
i. Checkfor anintakemanifoldor vacuumhoseleak.Replaceleakinggasketsor worn
vacuumhoses.
j. Checkfor draggingbrakesandreplaceor repairas necessary.
k. Checktire air pressureandtire wear.Adjustthe pressureto the recommended set-
tings.Checkthetire wearfor possiblealignmentproblemscausingincreasedrolling
resistance,decreased accelerationandincreasedfuelusage.
I. Checktheoctaneratingofthefuel usedduringrefilling,andusea higheroctanerated
fuel.
3. Poor fuel economy
a. Inspecttheair filter andcheckfor anyair restrictionsgoingintotheair filter housing.
Replacetheair filter if it is dirty or contaminated.
b. Checktheenginefor tune-upandrelatedadjustments. Replacewornignitionparts,
checktheengineignitiontimingandfuelmixture,andsetto specificationsif possible.
c. Checkthetire size,tire wear,alignmentandtire pressure.Largetirescreatemore
rollingresistance,smallertiresrequiremoreenginespeedto maintaina vehicle’sroad
speed.Excessivetire wearcanbecausedby incorrecttire pressure,incorrectwheel
alignmentor a suspensionproblem.All of theseconditionscreateincreasedrolling
resistance,causingtheengineto workharderto accelerateandmaintaina vehicle’s
speed.
d. Inspectthe brakesfor bindingor excessivedrag.A stickingbrakecaliper,overlyad-
justedbrakeshoe,brokenbrakeshoereturnspring,or bindingparkingbrakecableor
linkagecancreatea significantdrag,brakewearandlossof fueleconomy.Checkthe
brakesystemoperationandrepairas necessary.
4. Engine runs on (diesels) when turned off
a. Checkfor idlespeedsettoo highandreadjustto specification.
b. Checktheoperationof the idlecontrolvalve,andreplaceif defective.
c. Checkthe ignitiontimingandadjustto recommended settings.Check for defective
sensorsor relatedcomponentsandreplaceif defective.
d. Checkfor a vacuumleakat theintakemanifoldor vacuumhoseandreplacedefective
gasketsor hoses.
e. Checktheenginefor excessivecarbonbuild-upin thecombustionchamber.Usea
recommended decarbonizing fueladditiveor disassemblethecylinderheadto remove
thecarbon.
f. Checktheoperationof theenginefuel management systemandreplacedefectivesen-
sorsor controlunits.
g. Checktheengineoperatingtemperature for overheatingandrepairas necessary.
TROUBLESHOOiNG
11-7
5. Engine knocks and pinfls during heavy accele/ation, and on steep hills
a. Checkthe octaneratingof thefuel usedduringrefilling,andusea higheroctanerated
fuel.
b. Checktheignitiontimingandadjustto recommended settings.Checkfor defective
sensorsor relatedcomponentsandreplaceif defective.
c. Checktheenginefor excessivecarbonbuild-upin thecombustionchamber.Usea
recommended decarbonizing fueladditiveor disassemble thecylinderheadto remove
thecarbon.
d. Checkthesparkplugsfor thecorrecttype,electrodegapandheatrange.Replaceworn
or damagedsparkplugs.Forsevereor continuoushighspeeduse,installa sparkplug
thatis oneheatrangecolder.
e. Checkthe operationof theenginefuelmanagement systemandreplacedefectivesen-
sorsor controlunits.
f. Checkfor a restrictedexhaustsystem.Checkfor bentor crimpedexhaustpipes,or in-
ternallyrestrictedmufflersor catalyticconverters.Compareinletandoutlettempera-
turesfor theconverteror muffler.If the inletis hot,butoutletcold,thecomponentis
restricted.
6. Engine atxelerates, but vehicle does not gain speed
a. Onmanualtransmissionvehicles,checkfor causesof a slippingclutch.Referto the
clutchtroubleshooting sectionfor additionalinformation.
b. Onautomatictransmissionvehicles,checkfor a slippingtransmission”Checkthe
transmissionfluid levelandcondition.If thefluid levelis too high,adjustto thecor-
rectlevel.If thefluid levelis low,top off usingthe recommended fluidtype.If thefluid
exhibitsa burningodor,thetransmissionhasbeenslippinginternally.Changingthe
fluid andfilter mayhelptemporarily,howeverin this situationa transmissionmayre-
quireoverhaulingto ensurelong-termreliability.
Diesel Engines
1. Engine runs pOOr!y
a. Checkthe injectionpumptimingandadjustto specification.
b. Checkfor air in thefuel linesor leaks,andbleedtheair fromthefuelsystem.
c. Checkthefuelfilter,fuelfeedandreturnlinesfor a restrictionandrepairas necessary.
d. Checkthefuelfor contamination, drainandflushthefueltankandreplenishwithfresh
fuel.
2. Enfline lacks power
a. Inspecttheair intakesystemandair filterfor restrictionsand,if necessary, replacethe
air filter.
b. Verifythe injectionpumptimingandresetif out of specification.
c. Checktheexhaustfor an internalrestrictionandreplacefailedparts.
d. Checkfor a restrictedfuelfilterand,if restricted,replacethefilter.
e. Inspectthefuelfiller capvent. Whenremovingthefiller cap,listenfor excessivehiss-
ing noisesindicatinga blockagein thefuelfiller capvents,If thefiller capventsare
blocked,replacethe cap.
f. Checkthefuelsystemfor restrictionsandrepairas necessary.
g. Checkfor lowenginecompressionandinspectfor externalleakageat theglow plugs
or nozzles.If noexternalleakageis noted,repairor replacetheengine.
ENGINEPERFORMANCE
TROUBLESHOOTING
HINTS
Whentroubleshooting anenginerunningor performance condition,the mechanical
conditionof theengineshouldbedeterminedbeforelengthytroubleshooting procedures
areperformed.
Theenginefuel management systemsin fuel injectedvehiclesrelyon electronicsen-
sorsto provideinformationto theenginecontrolunitfor precisefuelmetering.Unlike
carburetors, whichusethe incomingair speedto drawfuelthroughthefuelmeteringjets
in orderto providea properfuel-to-airratio,a fuel injectionsystemprovidesa specific
amountof fuelwhichis introducedby thefuel injectorsintothe intakemanifoldor intake
port,basedon the informationprovidedby electronicsensors.
Thesensorsmonitortheengine’soperatingtemperature, ambienttemperature andthe
amountof air enteringtheengine,enginespeedandthrottlepositionto provideinforma-
tionto theenginecontrolunit,which,in turn,operatesthefuel injectorsby electrical
pulses.Thesensorsprovideinformationto theenginecontrolunitusinglowvoltage
electricalsignals.As a result,an unpluggedsensoror a poorelectricalcontactcould
causea poorrunningconditionsimilarto a failedsensor.
Whentroubleshooting a fuelrelatedengineconditiononfuel injectedvehicles,care-
fully inspectthewiringandelectricalconnectorsto therelatedcomponents. Makesure
theelectricalconnectorsarefully connected, cleanandnotphysicallydamaged.If neces-
sary,cleantheelectricalcontactsusingelectricalcontactcleaner.Theuseof cleaning
agentsnotspecificallydesignedfor electricalcontactsshouldnot beused,astheycould
leavea surfacefilm or damagethe insulationof thewiring.
Theengineelectricalsystemprovidesthe necessaryelectricalpowerto operatetheve-
hicle’selectricalaccessories,electroniccontrolunitsandsensors.Becauseengineman-
agementsystemsaresensitiveto voltagechanges,analternatorwhichoveror under-
chargescouldcauseenginerunningproblemsor componentfailure.Mostalternators
utilizeinternalvoltageregulatorswhichcannotbeadjustedandmustbereplacedindi-
viduallyor asa unitwiththealternator.
11-8 TROUBLESHOOTING
Ignitionsystemsmaybecontrolledby,or linkedto, the enginefuelmanagement sys-
tem.Similarto thefuel injectionsystem,theseignitionsystemsrelyon electronicsen-
sorsfor informationto determinetheoptimumignitiontimingfor a givenenginespeed
andload.Someignitionsystemsno longerallowthe ignitiontimingto beadjusted.
Feedback from lowvoltageelectricalsensorsprovideinformationto thecontrolunitto
determinetheamountof ignitionadvance.Onthesesystems,if a failureoccursthefailed
componentmustbereplaced.Beforereplacingsuspectedfailedelectricalcomponents,
carefullyinspectthewiringandelectricalconnectorsto therelatedcomponents.Make
suretheelectricalconnectorsarefullyconnected,cleanandnot physicallydamaged.If
necessary, cleantheelectricalcontactsusingelectricalcontactcleaner.Theuseof clean-
ing agentsnotspecificallydesignedfor electricalcontactsshouldbeavoided,as they
couldleavea surfacefilm or damagethe insulationof thewiring.
1. Engine makes a knocking or pinging noise when accelerating
a. Checktheoctaneratingof thefuelbeingused.Depending on thetypeof drivingor
drivingconditions,it maybenecessaryto usea higheroctanefuel.
b. Verifythe ignitionsystemsettingsandoperation.Improperlyadjustedignitiontiming
or a failedcomponent,suchas a knocksensor,maycausethe ignitiontimingto ad-
vanceexcessivelyor prematurely. Checkthe ignitionsystemoperationandadjust,or
replacecomponentsas needed.
c. Checkthesparkpluggap,heatrangeandcondition.If thevehicleis operatedin se-
vereoperatingconditionsor at continuoushighspeeds,usea colderheatrangespark
plug.Adjustthesparkpluggapto the manufacturer’s recommended specificationand
replacewornor damagedsparkplugs.
2. Sfarter motor grinds when used
a. Examinethestarterpiniongearandtheenginering gearfor damage,andreplacedam-
agedparts.
b. Checkthestartermountingboltsandhousing.If the housingis crackedor damaged
replacethestartermotorandcheckthe mountingboltsfor tightness.
3. Engine makes a screeching noise
a. Checktheaccessorydrivebeltsfor loosenessandadjustas necessary.
b. Checktheaccessorydrivebelttensionersfor seizingor excessivebearingnoisesand
replaceif loose,binding,or excessivelynoisy.
c. Checkfor a seizingwaterpump.Thepumpmaynot beleaking;however,thebearing
maybefaultyor the impellerlooseandjammed.Replacethewaterpump.
4. Engine makes a growling noise
a. Checkfor a looseor failingwaterpump.Replacethe pumpandenginecoolant.
b. Checktheaccessorydrivebelttensionersfor excessivebearingnoisesandreplaceif
looseor excessivelynoisy.
5. Engine makes a ticking or tapping noise
a. Onvehicleswith hydrauliclashadjusters,checkfor lowor dirtyengineoil andtop off
or replacetheengineoil andfilter.
b. Onvehicleswith hydrauliclashadjusters,checkfor collapsedliftersandreplacefailed
components.
c. Onvehicleswithhydrauliclashadjusters,checkfor lowoil pressurecausedby a re-
strictedoil filter,wornengineoil pump,or oil pressurereliefvalve.
d. Onvehicleswithmanuallyadjustedvalves,checkfor excessivevalveclearanceor
wornvalvetrainparts.Adjustthevalvesto specificationor replacewornanddefective
parts.
e. Checkfor a looseor improperlytensionedtimingbeltor timingchainandadjustor re-
placepartsas necessary.
f. Checkfor a bentor stickingexhaustor intakevalve.Removetheenginecylinderhead
to accessandreplace.
6. Engine makes a heavy knocking noise
a. Checkfor a loosecrankshaftpulleyor flywheel;replaceandtorquethemounting
bolt(s)to specification.
b. Checkfor a bentconnectingrodcausedby a hydro-lockcondition.Enginedisassem-
bly is necessaryto inspectfor damagedandneededreplacement parts.
c. Checkfor excessiveenginerod bearingwearor damage.Thisconditionis alsoasso-
ciatedwith lowengineoil pressureandwill requireenginedisassemblyto inspectfor
damagedandneededreplacement parts,
7. Vehicle has a fuel odor when driven ’
a. Checkthefuelgaugelevel.If thefuelgaugeregistersfull, it is possiblethattheodoris
causedby beingfilledbeyondcapacity,or somespillageoccurredduringrefueling.
Theodorshouldclearafterdrivingan hour,or twentymiles,allowingthevaporcanis-
ter to purge.
b. Checkthefuelfiller capfor loosenessor seepage.Checkthecaptightnessand,if
loose,properlysecure.If seepageis noted,replacethefiller cap.
c. Checkfor loosehoseclamps,crackedor damagedfueldeliveryandreturnlines,or
leakingcomponentsor seals,andreplaceor repairas necessary.
d. Checkthevehicle’sfueleconomy.If fuelconsumptionhasincreaseddueto a failed
component,or if thefuel is not properlyigniteddueto an ignitionrelatedfailure,the
catalyticconvertermaybecomecontaminated. Thisconditionmayalsotriggerthe
checkenginewarninglight.Checkthesparkplugsfor a dark,richconditionor verify
theconditionby testingthevehicle’semissions.Replacefuelfouledsparkplugs,and
testandreplacefailedcomponentsas necessary.
5. Vehicle has a rotten egg odor when driven
a. Checkfor a leakingintakegasketor vacuumleakcausinga leanrunningcondition.A
leanmixturemayresultin increasedexhausttemperatures, causingthecatalyticcon-
verterto run hotterthannormal.Thisconditionmayalsotriggerthecheckengine
warninglight.Checkandrepairthevacuumleaksas necessary.
b. Checkthevehicle’salternatorandbatterycondition.If thealternatoris overcharging,
the batteryelectrolytecanbeboiledfromthe battery,andthebatterycasingmaybegin
to crack,swellor bulge,damagingor shortingthebatteryinternally.If this hasoc-
curred,neutralizethe batterymountingareawitha suitablebakingsodaandwater
mixtureor equivalent,andreplacethealternatoror voltageregulator.Inspect,service,
andloadtestthebattery,andreplaceif necessary.
9. Vehicle has a sweet odor when driven
a. Checkfor anenginecoolantleakcausedbya seepingradiatorcap,loosehoseclamp,
weepingcoolingsystemseal,gasketor coolingsystemhoseandreplaceor repairas
needed.
b. Checkfor a coolantleakfromtheradiator,coolantreservoir,heatercontrolvalveor
underthedashboardfromtheheatercore,andreplacethefailedpartas necessary.
c. Checktheengine’sexhaustfor whitesmokein additionto a sweetodor.Thepresence
of white,steamysmokewitha sweetodorindicatescoolantleakingintothecombus-
tion chamber.Possiblecausesincludea failedheadgasket,crackedengineblockor
cylinderhead.Othersymptomsof this conditionincludea whitepastebuild-upon the
insideof theoil filler cap,andsoftened,deformedor bulgingradiatorhoses.
19. Engine vibraies when idling
a. Checkfor loose,collapsed,or damagedengineor transmissionmountsandrepairor
replaceas necessary.
b. Checkfor looseor damagedenginecoversor shieldsandsecureor replaceas neces-
sary.
11. Engine vibrates during acceleration
a. Checkfor missing,looseor damagedexhaustsystemhangersandmounts;replaceor
repairas necessary.
b. Checktheexhaustsystemroutingandfit for adequateclearanceor potentialrubbing;
repairor adjustas necessary.
7. Battery goes dead while driving
a. Checkthe batterycondition.Replacethe batteryif the batterywill notholda chargeor
failsa batteryloadtest.If the batterylosesfluid whiledriving,checkfor anovercharg-
ing condition.If thealternatoris overcharging, replacethealternatoror voltageregula-
tor. (A voltageregulatoris typicallybuilt intothealternator,necessitatingalternatorre-
placementor overhaul.)
b. Checkthe batterycablecondition.Cleanor replacecorrodedcablesandcleanthebat-
teryterminals.
c. Checkthealternatorandvoltageregulatoroperation.If thechargingsystemis overor
undercharging, replacethealternatoror voltageregulator,or both.
d. Inspectthewiringandwire connectorsatthealternatorfor looseness,a missing .
groundor defectiveterminal,andrepairas necessary.
e. Inspectthealternatordrivebelttension,tensionersandcondition.Properlytensionthe
drivebelt,replaceweakor brokentensioners,andreplacethedrivebeltif wornor
cracked.
2. Battery goes dead overnight
a. Checkthe batterycondition.Replacethe batteryif the batterywill notholda chargeor
failsa batteryloadtest.
b. Checkfor a voltagedraw,suchasa trunklight,interiorlightor gloveboxlightstaying
on. Checklightswitchpositionandoperation,andreplaceif defective.
c. Checkthealternatorfor an internallyfaileddiode,andreplacethealternatorif defec-
tive.
1. Engine overheats
a. Checkthecoolantlevel.Setthe heatertemperature to full hotandcheckfor internalair
pockets,bleedthecoolingsystemandinspectfor leakage.Topoff thecoolingsystem
withthecorrectcoolantmixture.
b. Pressuretestthecoolingsystemandradiatorcapfor leaks.Checkfor seepagecaused
by loosehoseclamps,failedcoolanthoses,andcoolingsystemcomponentssuchas
theheatercontrolvalve,heatercore,radiator,radiatorcap,andwaterpump.Replace
defectivepartsandfill thecoolingsystemwiththe recommended coolantmixture.

c. Onvehicleswithelectricallycontrolledcoolingfans,checkthecoolingfanoperation.
Checkfor blownfusesor defectivefanmotors,temperature sensorsandrelays,and
replacefailedcomponents.
d. Checkfor a coolantleakcausedby a failedheadgasket,or a porouswaterjacketcast-
ing in thecylinderheador engineblock.Replacedefectivepartsas necessary.
e. Checkfor an internallyrestrictedradiator.Flushtheradiatoror replaceif the blockage
is too severefor flushing.
f. Checkfor a damagedwaterpump.If coolantcirculationis poor,checkfor a loosewa-
ter pumpimpeller.If the impelleris loose,replacethewaterpump.
2. Enginelosescoolant
a. Pressuretestthecoolingsystemandradiatorcapfor leaks.Checkfor seepagecaused
by loosehoseclamps,failedcoolanthoses,andcoolingsystemcomponentssuchas
the heatercontrolvalve,heatercore,radiator,radiatorcap,andwaterpump.Replace
defectivepartsandfill thecoolingsystemwiththerecommended coolantmixture.
b. Checkfor a coolantleakcausedby a failedheadgasket,or a porouswaterjacketcast-
ing in thecylinderheador engineblock.Replacedefectivepartsas necessary.
3. Engine temperature remains co/d when driving
a. Checkthethermostatoperation.Replacethethermostatif it sticksin the openposi-
tion.
b. Onvehicleswithelectricallycontrolledcoolingfans,checkthe coolingfan operation.
Checkfor defectivetemperaturesensorsandstuckrelays,andreplacefailedcompo-
nents.
c. Checktemperature gaugeoperationif equippedto verifyproperoperationof the
gauge.Checkthesensorsandwiringfor defects,andrepairor replacedefectivecom-
ponents.
4. Engine runs hot
a. Checkfor an internallyrestrictedradiator.Flushthe radiatoror replaceif the blockage
is too severefor flushing.
b. Checkfor a looseor slippingwaterpumpdrivebelt.Inspectthedrivebeltcondition.
Replacethe beltif brittle,crackedor damaged.Checkthepulleyconditionandprop-
erlytensionthebelt.
c. Checkthecoolingfanoperation.Replacedefectivefan motors,sensorsor relaysas
necessary.
d. Checktemperature gaugeoperationif equippedto verifyproperoperationof the
gauge.Checkthesensorsandwiringfor defects,andrepairor replacedefectivecom-
ponents.
e. Checkthecoolantlevel.Settheheatertemperature to full hot,checkfor internalair
pockets,bleedthecoolingsystemandinspectfor leakage.Topoff thecoolingsystem
withthecorrectcoolantmixture.Oncetheengineis cool,recheckthefluid leveland
top off as needed.
NOTE:The engine cooling system can also be affected by an engine’s me-
chanical condition. A failed head gasket or a porous casting in the engine
block or cylinder head could cause a loss of coolant and result in engine
overheating.
Somecoolingsystemsrelyon electricallydrivencoolingfansto cooltheradiatorand
useelectricaltemperaturesensorsandrelaysto operatethecoolingfan.Whendiagnos-
ingthesesystems,checkfor blownfuses,damagedwiresandverifythattheelectrical
connectionsarefullyconnected,cleanandnot physicallydamaged.If necessary, clean
theelectricalcontactsusingelectricalcontactcleaner.Theuseof cleaningigents not
1. Transmission shit& erratically
a. Checkandif notwithinthe recommended range,addor removetransmissionfluid to
obtainthecorrectfluid level.Alwaysusethe recommended fluidtypewhenadding
transmissionfluid.
b. Checkthefluid levelcondition.If thefluid hasbecomecontaminated, fatiguedfrom
excessiveheator exhibitsa burningodor,changethetransmissionfluid andfilter us-
ingthe recommended typeandamountof fluid.A fluid whichexhibitsa burningodor
indicatesthatthetransmissionhasbeenslippinginternallyandmayrequirefuturere-
pairs.
c. Checkfor an improperlyinstalledtransmissionfilter,or missingfilter gasket,andre-
pairas necessary.
d. Checkfor looseor leakinggaskets,pressurelinesandfittings,andrepairor replaceas
necessary.
e. Checkfor looseor disconnected shiftandthrottlelinkagesor vacuumhoses,andre-
pairas necessary. , use of cleaning agents not specifically designed for electrical contacts
2. Transmission will not engage
a. Checktheshift linkagefor looseness,wearandproperadjustment,
andrepairas nec-
essary.
TROUBLESHOOTING
11-9
specificallydesignedfor electricalcontactscouldleavea film or damagethe insulationof
thewiring.
1. Exhaust rattles at idle speed
a. Checktheengineandtransmissionmountsandreplacemountsshowingsignsof
damageor wear.
b. Checktheexhausthangers,bracketsandmounts.Replacebroken,missingor dam-
agedmounts.
c. Checkfor internaldamageto mufflersandcatalyticconverters.Thebrokenpiecesfrom
thedefectivecomponentmaytravelin thedirectionof theexhaustflowandcollect
and/orcreatea blockagein a componentotherthantheonewhichfailed,causingen-
ginerunningandstallingproblems.Anothersymptomof a restrictedexhaustis low
enginemanifoldvacuum.Removetheexhaustsystemandcarefullyremoveanyloose
or brokenpieces,thenreplaceanyfailedor damagedpartsas necessary.
d. Checktheexhaustsystemclearance,routingandalignment.If theexhaustis making
contactwiththevehiclein anymanner,loosenandrepositiontheexhaustsystem.
2. Exhaust system vibrates when driving
a. Checktheexhausthangers,bracketsandmounts.Replacebroken,missingor dam-
agedmounts.
b. Checktheexhaustsystemclearance,routingandalignment.If theexhaustis making
contactwiththevehiclein anymanner,checkfor bentor damagedcomponentsand
replace,thenloosenandrepositiontheexhaustsystem.
c. Checkfor internaldamageto mufflersandcatalyticconverters.Thebrokenpiecesfrom
thedefectivecomponentmaytravelin thedirectionof theexhaustflowandcollect
and/orcreatea blockagein a componentotherthanthe onewhichfailed,causingen-
ginerunningandstallingproblems.Anothersymptomof a restrictedexhaustis low
enginemanifoldvacuum.Removetheexhaustsystemandcarefullyremoveanyloose
or brokenpieces,thenreplaceanyfailedor damagedpartsas necessary.
3. Exhaust system hangs too low
a. Checktheexhausthangers,bracketsandmounts.Replacebroken,missingor dam-
agedmounts.
b. Checktheexhaustroutingandalignment.Checkandreplacebentor damagedcom-
ponents.If theexhaustis not routedproperly,loosenandrepositiontheexhaustsys-
tern.
4. Exhaust sounds loud
a. Checkthesystemfor loosenessandleaks.Checktheexhaustpipes,clamps,flange
boltsandmanifoldfastenersfor tightness.Checkandreplaceanyfailedgaskets.
b. Checkandreplaceexhaustsilencersthathavea lossof efficiencydueto internally
brokenbafflesor wornpackingmaterial.
c. Checkfor missingmufflersandsilencersthathavebeenreplacedwithstraightpipes
or with non-originalequipmentsilencers.
NOTE:Exhaust system rattles, vibration and proper alignment should not
be overlooked. Excessive vibration caused by collapsed engine mounts,
damaged or missing exhaust hangers and misalignment may cause surface
cracks and broken welds, creating exhaust leaks or internal damage to ex-
haust components such as the catalytic converter, creating a restriction to
exhaustflow and loss of power.
b. Checkfor a lossof transmissionfluid andtop off as neededwiththe recommended
fluid.
c. If thetransmissiondoesnotengagewiththeshift linkagecorrectlyinstalledandthe
properfluid level,internaldamagehaslikelyoccurred,requiringtransmissionremoval
anddisassembly.
3. Transmission will not downshift during heavy acceleration
a. Oncomputercontrolledtransmissions,checkfor failedsensorsor controlunitsand
repairor replacedefectivecomponents.
b. Onvehicleswith kickdownlinkagesor vacuumservos,checkfor properlinkagead-
justmentor leakingvacuumhosesor servounits.
NOTE:Mlanyautomatic transmissions use an electronic control module,
electrical sensors and solenoids to control transmission shifting. When
troubleshooting a vehicle with this type of system, be sure the electrical
connectors are fully connected, clean and not physically damaged. If nec-
essary, clean the electrical contacts using electrical contact cleaner. The
could leave a film or damage the insulation of the wiring.
II-10 TROUBLESHOOTING
1. Transmission grinds going into forward gears while driving
a. Checktheclutchreleasesystem.Onclutcheswitha mechanicalor cablelinkage,
checktheadjustment. Adjusttheclutchpedalto have1 inch(25mm)of free-playat
the pedal.
b. If theclutchreleasesystemis hydraulicallyoperated,checkthefluid leveland,if low,
top off usingthe recommended typeandamountof fluid. ,
c. Synchronizers worn.Removetransmissionandreplacesynchronizers.
d. Synchronizer slidingsleeveworn.Removetransmissionandreplaceslidingsleeve.
e. Gearengagement dogswornor damaged.Removetransmissionandreplacegear.
2. Transmission jumps out of gear
a. Shiftshaftdetentspringsworn.Replaceshiftdetentsprings.
b. Synchronizerslidingsleeveworn.Removetransmissionandreplaceslidingsleeve.
c. Gearengagement dogswornor damaged.Removetransmissionandreplacegear.
d. Crankshaftthrustbearingsworn.Removeengineandcrankshaft,andrepairas neces-
sary.
3. Transmission difficult to shift
a. Verifytheclutchadjustmentand,if notproperlyadjusted,adjustto specification.
b. Synchronizersworn.Removetransmissionandreplacesynchronizers.
c. Pilotbearingseized.Removetransmissionandreplacepilot bearing.
d. Shiftlinkageor bushingseized.Disassembletheshift linkage,replacewornor dam-
agedbushings,lubricateandreinstall.
4. Transmission leaks fluid
a. Checkthefluid levelfor anoverfilledcondition.Adjustthefluid levelto specification.
b. Checkfor a restrictedtransmissionventor breathertube.Clearthe blockageas neces-
saryandcheckthefluid level.If necessary,top off withthe recommended lubricant.
c. Checkfor a porouscasting,leakingsealor gasket.Replacedefectivepartsandtop off
thefluid levelwiththerecommended lubricant.
1. Clutch slips on hills or during sudden acceleration
a. Checkfor insufficientclutchpedalfree-play.Adjustclutchlinkageor cableto allow
about1 inch(25mm)of pedalfree-play.
b. Clutchdiscwornor severelydamaged.Removeengineor transmissionandreplace
clutchdisc.
c. Clutchpressureplateis weak.Removeengineor transmissionandreplacetheclutch
pressureplateandclutchdisc.
d. Clutchpressureplateand/orflywheelincorrectlymachined.If theclutchsystemhas
beenrecentlyreplacedandrebuilt,or refurbishedpartshavebeenused,it is possible
thatthemachinedsurfacesdecreased theclutchclampingforce.Replacedefective
partswith newreplacement parts.
2. Clutch will not disengage, difficult to shift
a. Checktheclutchreleasemechanism.Checkfor stretchedcables,wornlinkagesor
failedclutchhydraulicsandreplacedefectiveparts.Onhydraulicallyoperatedclutch
releasemechanisms, checkfor air in the hydraulicsystemandbleedas necessary.
b. Checkfor a broken,crackedor fatiguedclutchreleasearmor releasearmpivot.Re-
placedefectivepartsandproperlylubricateuponassembly.
c. Checkfor a damagedclutchhubdamperor damperspring.Thebrokenpartstendto
becomelodgedbetweentheclutchdiscandthepressureplate.Disassemble clutch
systemandreplacefailedparts.
d. Checkfor a seizedclutchpilot bearing.Disassemble theclutchassemblyandreplace
the defectiveparts.
e. Checkfor a defectiveclutchdisc.Checkfor warpageor liningthicknesseslargerthan
originalequipment.
3. Clutch is noisy when the clutch pedal is pressed
a. Checktheclutchpedalstopandpedalfree-playadjustmentfor excessivemovement
andadjustas necessary.
b. Checkfor a wornor damagedreleasebearing.If thenoiseceaseswhenthepedalis re-
leased,thereleasebearingshouldbereplaced.
c. Checktheenginecrankshaftaxialplay.If thecrankshaftthrustbearingsarewornor
damaged,thecrankshaftwill movewhenpressingtheclutchpedal.Theenginemust
bedisassembled to replacethecrankshaftthrustbearings.
4. Clutch pedal extremely difficult to press
a. Checktheclutchpedalpivotsandlinkagesfor binding.Cleanandlubricatelinkages.
b. Oncableactuatedclutchsystems,checkthecableroutingandcondition.Replace
kinked,frayed,damagedor corrodedcablesandcheckcableroutingto avoidsharp
bends.Checktheenginegroundstrapfor poorconductivity.If thegroundstrapis
marginal,theenginecouldtry to grounditselfvia theclutchcable,causingpremature
failure.
c. Onmechanicallinkageclutches,checkthe linkagefor bindingor misalignment.Lubri-
catepivotsor linkagesandrepairas necessary.
d. Checkthe releasebearingguidetubeandreleaseforkfor a lackof lubrication.Installa
smoothcoatingof hightemperature greaseto allowsmoothmovementof therelease
bearingovertheguidetube.
5. Clutchpedalremainsdownwhenpressed
a, Onmechanicallinkageor cableactuatedclutches,checkfor a looseor disconnected
link.
b. Onhydraulicallyactuatedclutches,checkthefluid levelandcheckfor a hydraulicleak
atthe clutchslaveor mastercylinder,or hydraulicline.Replacefailedpartsandbleed
clutchhydraulicsystem.If no leakageis noted,theclutchmastercylindermayhave
failedinternally.Replacetheclutchmastercylinderandbleedtheclutchhydraulicsys-
tem.
6. clutch chatters when engaging
a. Checktheengineflywheelfor warpageor surfacevariationsandreplaceor repairas
necessary.
b. Checkfor a warpedclutchdiscor damagedclutchdamperhub.Removetheclutch
discandreplace.
c. Checkfor a looseor damagedclutchpressureplateandreplacedefectivecomponents.
NOTE:The clutch is actuated either by a mechanical linkage, cable or a
clutch hydraulic system. The mechanical linkage and cable systems may
require the clutch pedal free-play to be adjusted as the clutch disc wears. A
hydraulic clutch system automatically adjusts as the clutch wears and, with
the exception of the clutch pedal height, no adjustment is possible.
1. Differential makes a low pitched rumbling noise
a. Checkfluid leveltypeandamount.Replacethefluidwiththerecommended typeand
amountof lubricant.
b. Checkthedifferentialbearingsfor wearor damage.Removethe bearings,inspectthe
driveanddrivengearsfor wearor damage,andreplacecomponentsas necessary.
2. Differential makes a howling noise
a. Checkfluid leveltypeandamount.Replacethefluid withthe recommendedtypeand
amountof lubricant.
b. Checkthedifferentialdriveanddrivengearsfor wearor damage,andreplacecompo-
nentsas necessary.
All Wheel and Four Wheel Drive Vehicles
1. Leaks fluid from seals or vent after being driven
a. Fluidleveloverfilled.Checkandadjusttransfercasefluid level.
b. Checkfor a restrictedbreatheror breathertube,clearandcheckthefluid levelandtop
off as needed.
c. Checksealconditionandreplaceworn,damaged,or defectiveseals.Checkthefluid
levelandtop off as necessary.
2. Makes excessive noise while driving
a. Checkthefluid for thecorrecttypeof lubricant.Drainandrefill usingthe recom-
mendedtypeandamountof lubricant.
b. Checkthefluid level.Topoff thefluid usingtherecommended typeandamountof lu-
bricant.
c. If thefluid levelandtypeof lubricantmeetspecifications,checkfor internalwearor
damage.Removeassemblyanddisassemble to inspectfor worn,damaged,or defec-
tive components.
3. Jumps out of gear
a. Stopvehicleandmakesuretheunit is fullyengaged.
b. Checkfor worn,looseor an improperlyadjustedlinkage.Replaceand/oradjustlink-
ageas necessary.
c. Checkfor internalwearor damage.Removeassemblyanddisassemble to inspectfor
worn,damaged,or defectivecomponents.
Rear Wheel, All Wheel and Four Wheel Drive Vehicles
1. Clunking noise from center of Vehicle shifting from forward to reverse
a. Wornuniversaljoint. Removedriveshaftandreplaceuniversaljoint.
2. Excessive vibration from center of vehicle when accelerating
a. Wornuniversaljoint. Removedriveshaftandreplaceuniversaljoint.

b. Driveshaftmisaligned.Checkfor collapsedor damagedengineandtransmission
mounts,andreplaceas necessary.
c. Driveshaftbentor out of balance.Replacedamagedcomponentsandreinstall.
d. Driveshaftout of balance.Removethedriveshaftandhaveit balancedby a competent
professional,or replacethedriveshaftassembly.
NOTE:Most driveshafts are linked together by universal joints; however,
some manufacturers use Constant Velocity (CV) joints or rubber flex cou-
plers.
All Wheel and Four Wheel Drive Vehicles
1. Front or rear wheel makes a clicking noise
a. Checkfor debrissuchasa pebble,nail or glassin thetire or tire tread.Carefullyre-
movethedebris.Smallrocksandpebblesrarelycausea puncture;however,a sharp
objectshouldberemovedcarefullyat a facilitycapableof performingtire repairs.
b. Checkfor a loose,damagedor wornConstantVelocity(CV)joint andreplaceif defec-
tive.
2. Front or rear wheel vibrates wlth Increased speed
a. Checkfor a bentrim andreplace,if damaged.
b. Checkthetiresfor balanceor internaldamageandreplaceif defective.
c. Checkfor a loose,wornor damagedwheelbearingandreplaceif defective.
d. Checkfor a loose,damagedor wornConstantVelocity(CV)joint andreplaceif defec-
tive.
Front Wheel Drive Vehicles
3. Front wheel makes a c&kin@ noise
a. Checkfor debrissuchasa pebble,nail or glassin thetire or tire tread.Carefullyre-
movethedebris.Smallrocksandpebblesrarelycausea puncture;however,a sharp
objectshouldberemovedcarefullyat a facilitycapableof performingtire repairs.
b. Checkfor a loose,damagedor wornConstantVelocity(CV)joint andreplaceif defec-
tive.
1. Brake pedal pulsates or shimmies when pressed
a. Checkwheellug nuttorqueandtightenevenlyto specification.
b. Checkthe brakerotorfor truenessandthicknessvariations.Replacetherotorif it is
too thin,warped,or if thethicknessvariesbeyondspecification.Somerotorscanbe
machined:consultthe manufacturer’s specificationsandrecommendations beforeus-
ing a machinedbrakerotor.
c. Checkthebrakecaliperor caliperbracketmountingbolttorqueandinspectfor loose-
ness.Torquethe mountingboltsandinspectfor wearor anylooseness,including
wornmountingbrackets,bushingsandslidingpins.
d. Checkthewheelbearingfor looseness.If the bearingis loose,adjustif possible,oth-
erwisereplacethe bearing.
2. Brakes make a squealing noise
a. Checkthe brakerotorfor the presenceof a ridgeontheouteredge;if present,remove
the ridgeor replacethebrakerotorandbrakepads.
b. Checkfor debrisin the brakeliningmaterial,cleanandreinstall.
c. Checkthe brakeliningsfor wearandreplacethe brakeliningsif wearis approaching
the liningwearlimit.
d. Checkthe brakeliningsfor glazing.Inspectthe brakedrumor rotorsurfaceandre-
place,alongwiththe brakelinings,if thesurfaceis notsmoothor even.
e. Checkthe brakepador shoemountingareasfor a lackof lubricantor thepresenceof
surfacerust.Cleanandlubricatewitha recommended hightemperaturebrakegrease.
3. Brakes make a flrindinfl noise
a. Checkthebrakeliningsandbrakesurfaceareasfor severewearor damage.Replace
wornor damagedparts.
b. Checkfor a seizedor partiallyseizedbrakecausingprematureor unevenbrakewear,
excessiveheatandbrakerotoror drumdamage.Replacedefectivepartsandinspect
thewheelbearingcondition,whichcouldhavebeendamageddueto excessiveheat.
4. Vehicle pulls to one side during braking
a. Checkfor air in the brakehydraulicsystem.Inspectthebrakehydraulicseals,fluid
linesandrelatedcomponentsfor fluid leaks.Removetheair fromthebrakesystemby
TROUBLESHOOTlNGll-11
4. Rear wheel makes a clicking noise
a. Checkfor debrissuchas a pebble,nail or glassin thetire or tire tread.Carefullyre-
movethedebris.Smallrocksandpebblesrarelycausea puncture;however,a sharp
objectshouldberemovedcarefullyat a facilitycapableof performingtire repairs.
Rear Wheel Drive Vehicles
5. Front or rear wheel makes a clicking noise
a. Checkfor debrissuchas a pebble,nail or glassin thetire or tire tread.Carefullyre-
movethedebris.Smallrocksandpebblesrarelycausea puncture;however,a sharp
objectshouldberemovedcarefullyat a facilitycapableof performingtire repairs.
6. Rear wheel shudders or vibrates
a. Checkfor a bentrearwheelor axleassemblyandreplacedefectivecomponents.
b. Checkfor a loose,damagedor wornrearwheelbearingandreplaceas necessary.
1. Burning odor from center of vehicle when accelerating
a. Checkfor a seizingbrakehydrauliccomponentsuchasa brakecaliper.Checkthe
caliperpistonfor surfacedamagesuchas rust,andmeasurefor out-of-roundwear
andcaliper-to-pistonclearance.Foradditionalinformationon brakerelatedodors,re-
ferto section3-A, conditionnumber9.
b. Onvehicleswitha manualtransmission,checkfor a slippingclutch.Forpossible
causesandadditionalinformation,referto sectionZ-C,conditionnumber1.
c. Onvehicleswithanautomatictransmission,checkthefluid levelandcondition,Top
off or changethefluidandfilter usingthe recommendedreplacementparts,lubricant
typeandamount.If theodorpersists,transmissionremovalanddisassemblywill be
necessary.
2. Engine accelerates, but vehicle does not gain speed
a. Onvehicleswith a manualtransmission,checkfor a slippingor damagedclutch.For
possiblecausesandadditionalinformationreferto sectionZ-C,conditionnumber1.
b. Onvehicleswithanautomatictransmission,checkthefluid levelandcondition.Top
off or changethefluid andfilter usingtherecommendedreplacement
parts,lubricant
typeandamount.If theslippingcontinues,transmissionremovalanddisassemblywill
benecessary.
bleedingthe brakes.Besureto usefreshbrakefluidthatmeetsthemanufacturers rec-
ommendedstandards.
b. Checkfor an internallyrestrictedflexiblebrakehydraulichose.Replacethehoseand
flushthe brakesystem.
c. Checkfor a seizingbrakehydrauliccomponentsuchasa brakecaliper.Checkthe
caliperpistonfor surfacedamagesuchas rust,andmeasurefor out-of-roundwear
andcaliper-to-pistonclearance.Overhaulor replacefailedpartsandflushthe brake
system.
d. Checkthevehicle’salignmentandinspectfor suspensionwear.Replacewornbush-
ings,balljointsandsetalignmentto themanufacturers specifications.
e. If thebrakesystemusesdrumbrakesfrontor rear,checkthebrakeadjustment.Inspect
for seizedadjustersandcleanor replace,thenproperlyadjust.
5. Brake pedal feels spongy or has excessive travel
a. Checkthebrakefluid levelandcondition.If thefluid is contaminated
or hasnot been
flushedeverytwoyears,cleanthe mastercylinderreservoir,andbleedandflushthe
brakesusingfreshbrakefluidthatmeetsthe manufacturers recommended standards.
b. Checkfor a weakor damagedflexiblebrakehydraulichose.Replacethehoseand
flushthebrakesystem.
c. If the brakesystemusesdrumbrakesfrontor rear,checkthebrakeadjustment.Inspect
for seizedadjustersandcleanor replace,thenproperlyadjust.
6. Brake pedal feel is firm, but brakes lack sufficient stopping power or
fade
a. Checkthe operationof the brakeboosterandbrakeboostercheckvalve:Replaceworn
or failedparts.
b. Checkbrakeliningsandbrakesurfaceareasfor glazingandreplacewornor damaged
parts.
c. Checkfor seizedhydraulicpartsandlinkages,andcleanor replaceas needed.
7. Vehicle has excessive front end dive or locks rear brakes too easily
a. Checkfor worn,failedor seizedbrakeproportioningvalveandreplacethevalve.
b. Checkfor a seized,disconnectedor missingspringor linkagefor thebrakepropor-
tioningvalve.Replacemissingpartsor repairas necessary.
 11-12 TROUBLESHOOTING
8. Brake pedal goes to floor when pressed and will not pump up
a. Checkthebrakehydraulicfluid levelandinspectthefluid linesandsealsfor leakage.
Repairor replaceleakingcomponents, thenbleedandflushthe brakesystemusing
freshbrakefluid thatmeetsthemanufacturer’s recommended standards.
b. Checkthe brakefluid level.Inspectthe brakefluid levelandbrakehydraulicseals.If
thefluid levelis ok,andthe brakehydraulicsystemis freeof hydraulicleaks,replace
thebrakemastercylinder,thenbleedandflushthe brakesystemusingfreshbrake
fluidthatmeetsthemanufacturer’s recommended standards.
9. Brakes produce a burning odor
a. Checkfor a seizingbrakehydrauliccomponentsuchasa brakecaliper.Checkthe
caliperpistonfor surfacedamagesuchas rust,andmeasurefor out-of-roundwear
andcaliper-to-pistonclearance.Overhaulor replacefailedpartsandflushthebrake
system.
b. Checkfor an internallyrestrictedflexiblebrakehydraulichose.Replacethe hoseand
flushthebrakesystem.
c. Checktheparkingbrakereleasemechanism,seizedlinkageor cable,andrepairas
necessary.
IJront Wheel or Wheel Bearing Loose
All Wheel and Four Wheel Drive Vehicles
a.Torquelug nutsandaxlenutsto specificationandrecheckfor looseness.
b. Wheelbearingwornor damaged.Replacewheelbearing.
FrontWheelDriveVehicles
a. Torquelug nutsandaxlenutsto specificationandrecheckfor looseness.
b. Wheelbearingwornor damaged.Replacewheelbearing.
Rear Wheel Drive Vehicles
a. Wheelbearingoutof adjustment. Adjustwheelbearingto specification;if still loose,
replace.
b. Torquelugnutsto specificationandrecheckfor looseness.
c. Wheelbearingwornor damaged.Replacewheelbearing.
2. Rear Wheel or Wheel Bearing Loose
All Wheel and Four Wheel Drive Vehicles
a.Torquelug nutsandaxlenutsto specificationandrecheckfor looseness.
b. Wheelbearingwornor damaged.Replacewheelbearing.
Front Wheel Drive Vehicles
a.Wheelbearingout of adjustment. Adjustwheelbearingto specification;if still loose,
replace.
b. Torquelugnutsto specificationandrecheckfor looseness.
c. Wheelbearingwornor damaged.Replacewheelbearing.
Rear Wheel Drive Vehicles
a.Torquelugnutsandto specificationandrecheckfor looseness.
b. Wheelbearingwornor damaged.Replacewheelbearing.
1. Tires worn on inside tread
a. Checkalignmentfor a toed-outcondition.Checkandsettire pressuresandproperly
adjustthetoe.
b. Checkfor worn,damagedor defectivesuspensioncomponents.Replacedefective
partsandadjustthealignment.
2. Tires worn on outside tread e 1. Vehicle pulls to one side
a. Checkalignmentfor a toed-incondition.Checkandsettire pressuresandproperly
adjustthetoe.
b. Checkfor worn,damagedor defectivesuspensioncomponents. Replacedefective
partsandadjustthealignment.
3. Tires worn unevenly
a. Checkthetire pressureandtire balance.Replacewornor defectivetiresandcheckthe
. alignment;adjustif necessary.
BRAKEPERFORMANCE
TROU5LESHOOTINc;
HIIVTS
Brakevibrationsor pulsationcanoftenbediagnosedona safeandcarefultestdrive.
A brakevibrationwhichis felt throughthe brakepedalwhilebraking,butnotfelt in the
steeringwheel,is mostlikelycausedby brakesurfacevariationsin therearbrakes.If
boththe brakepedalandsteeringwheelvibrateduringbraking,a surfacevariationin the
frontbrakes,or bothfrontandrearbrakes,is verylikely.
A brakepedalthatpumpsupwith repeatedusecanbecausedbyair in thebrakehy-
draulicsystemor, if thevehicleis equippedwith reardrumbrakes,the brakeadjusters
maybeseizedor out of adjustment.A quicktestfor brakeadjustmentonvehicleswith
reardrumbrakesis to pumpthebrakepedalseveraltimeswiththevehicle’senginenot
runningandthe parkingbrakereleased.Pumpthe brakepedalseveraltimesandcon-
tinueto applypressureto the brakepedal.Withpressurebeingappliedto thebrake
pedal,engagethe parkingbrake.Releasethebrakepedalandquicklypressthebrake
pedalagain.If thebrakepedalpumpedup,the rearbrakesarein needof adjustment.Do
notcompensate for the rearbrakeadjustmentbyadjustingtheparkingbrake,thiswill
causeprematurebrakeliningwear.
To testa vacuumbrakebooster,pumpthe brakepedalseveraltimeswiththevehicle’s
engineoff.Applypressureto the brakepedalandthenstarttheengine.Thebrakepedal
shouldmovedownwardaboutoneinch(25mm).
b. Checkfor wornshockabsorbers.Replacedfailedcomponents, wornor defectivetires
andcheckthealignment;adjustif necessary.
c. Checkthealignmentsettings.Checkandsettire pressuresandproperlyadjustthe
alignmentto specification.
d. Checkfor worn,damagedor defectivesuspensioncomponents.Replacedefective
partsandadjustthealignmentto specification,
1. Excessive play in steering wheel
a. Checkthesteeringgearfree-playadjustmentandproperlyadjustto removeexcessive
play.
b. Checkthesteeringlinkagefor worn,damagedor defectiveparts.Replacefailedcom-
ponentsandperforma frontendalignment.
c. Checkfor a worn,damaged,or defectivesteeringbox,replacethesteeringgearand
checkthefrontendalignment.
2. Steering wheel shakes at cruising speeds
a. Checkfor a bentfrontwheel.Replacea damagedwheelandcheckthetirefor possible
internaldamage.
b. Checkfor anunevenlywornfronttire. Replacethetire,adjusttire pressureandbal-
ance.
c. Checkthefronttiresfor hiddeninternaldamage.Tireswhichhaveencountered large
pot holesor sufferedotherhardblowsmayhavesustainedinternaldamageand
shouldbereplacedimmediately.
d. Checkthefronttiresfor anout-of-balancecondition.Remove,spinbalanceandrein-
stall.Torqueall thewheelboltsor lugnutsto therecommended specification.
e. Checkfor a loosewheelbearing.If possible,adjustthe bearing,or replacethe bearing
if it is a non-adjustable
bearing.
3. Steering wheel shakes when braking
a. Referto section3-A, conditionnumber1.
4. Steering wheel becomes stiff when turned
a. Checkthesteeringwheelfree-playadjustmentandresetas needed.
b. Checkfor a damagedsteeringgearassembly.Replacethesteeringgearandperforma
frontendalignment.
c. Checkfor damagedor seizedsuspensioncomponents.Replacedefectivecomponents
andperforma frontendalignment.
a. Tire pressureuneven.Adjusttire pressureto recommendedsettings.
b. Tireswornunevenly.Replacetiresandcheckalignmentsettings.
c. Alignmentout of specification.Alignfrontendandcheckthrustangle.
d. Checkfor a draggingbrakeandrepairor replaceas necessary.
2. Vehicle is very bouncy over bumps
a. Checkfor wornor leakingshockabsorbersor strutassembliesandreplaceas neces-
sary.
b. Checkfor seizedshockabsorbersor strutassembliesandreplaceas necessary.

NOTE:When one shock fails, ft is recommended to replace front or rear
units as pairs.
3. Vehicle leans excessively in turns
a. Checkfor wornor leakingshockabsorbersor strutassembliesandreplaceas neces-
sary.
b. Checkfor missing,damaged,or wornstabilizerlinksor bushings,andreplaceor in-
stallas necessary.
4. Vehicle ride quality seems excessively ha&h
a. Checkfor seizedshockabsorbersor strutassembliesandreplaceas necessary.
b. Checkfor excessivelyhightire pressuresandadjustpressuresto vehiclerecommen-
dations.
5. Vehicle seems low or leans to one side
a. Checkfor a damaged,brokenor weakspring.Replacedefectivepartsandcheckfor a
neededalignment.
b. Checkfor seizedshockabsorbersor strutassembliesandreplaceasnecessary.
c. Checkfor wornor leakingshockabsorbersor strutassembliesandreplaceas neces-
sary.
Noises
1. Vehiclemakesa clickingnoiseswhendriven
a. Checkthe noiseto seeif it varieswith roadspeed.Verifyif the noiseis presentwhen
coastingor withsteeringor throttleinput.If theclickingnoisefrequencychangeswith
roadspeedandis notaffectedby steeringor throttleinput,checkthetiretreadsfor a
stone,pieceof glass,nail or anotherhardobjectimbeddedintothetire or tire tread.
Stonesrarelycausea tire punctureandareeasilyremoved.Otherobjectsmaycreate
anair leakwhenremoved.Considerhavingtheseobjectsremovedimmediatelyat a
facilityequippedto repairtire punctures.
b. If theclickingnoisevarieswiththrottleinputandsteering,checkfor a wornConstant
Velocity(CV-joint)joint, universal(U- joint) or flexjoint.
2. Vehicle makes a clunking or knocking noise over bumps
a.A clunkingnoiseoverbumpsis mostoftencausedbyexcessivemovementor clear-
ancein a suspensioncomponent.Checkthesuspensionfor soft,cracked,damagedor
wornbushings.Replacethe bushingsandcheckthevehicle’salignment.
b. Checkfor loosesuspensionmountingbolts.Checkthetightnessonsubframebolts,
pivot boltsandsuspensionmountingbolts,andtorqueto specification.
c. Checkthevehiclefor a loosewheelbearing.Somewheelbearingscanbeadjustedfor
looseness,whileothersmustbereplacedif loose.Adjustor replacethe bearingsas
recommended bythe manufacturer.
d. Checkthedoorlatchadjustment.If the dooris slightlyloose,or the latchadjustment
is notcentered,thedoorassemblymaycreatenoisesoverbumpsandroughsurfaces.
Properlyadjustthedoorlatchesto securethedoor.
1. One headlight only works on high or low beam
a. Checkfor batteryvoltageat headlightelectricalconnector.If batteryvoltageis present,
replacethe headlightassemblyor bulbif availableseparately.If batteryvoltageis not
present,referto theheadlightwiringdiagramto troubleshoot.
2. Headlight does not work on high or low beam
a. Checkfor batteryvoltageandgroundat headlightelectricalconnector.If batteryvolt-
ageis present,checkthe headlightconnectorgroundterminalfor a properground.If
batteryvoltageandgroundarepresentat theheadlightconnector,replacethehead-
lightassemblyor bulbif availableseparately.If batteryvoltageor groundis not pre-
sent,referto the headlightwiringdiagramto troubleshoot.
b. Checkthe headlightswitchoperation.Replacetheswitchif theswitchis defectiveor
ooeratesintermittentlv.
w
3. Headlight(s) very dim
a. Checkfor batteryvoltageandgroundat headlightelectricalconnector.If batteryvolt-
ageis present,tracethegroundcircuitfor theheadlampelectricalconnector,then
cleanandrepairas necessary.If thevoltageat theheadlightelectricalconnectoris
significantlylessthanthevoltageat thebattery,referto the headlightwiringdiagram
to troubleshootandlocatethevoltagedrop.
TROUBLESHOOTING
11-13
3. Vehicle makes a low pitched rumbling noise when driven
a. A lowpitchedrumblingnoiseis usuallycausedby a drivetrainrelatedbearingandis
mostoftenassociatedwitha wheelbearingwhichhasbeendamagedor worn.The
damagecanbecausedby excessivebraketemperatures or physicalcontactwitha pot
holeor curb.Sometimesthe noisewill varywhenturning.Lefthandturnsincreasethe
loadonthevehicle’srightside,andrightturnsloadthe leftside.A failedfrontwheel
bearingmayalsocausea slightsteeringwheelvibrationwhenturning.A bearing
whichexhibitsnoisemustbereplaced.
b. Checkthetire conditionandbalance.An internallydamagedtire maycausefailure
symptomssimilarto failedsuspensionparts.Fordiagnosticpurposes,try a known
goodsetof tiresandreplacedefectivetires.
4. Vehicle makes a squeaking noise over bumps
a. Checkthevehicle’sballjointsfor wear,damagedor leakingboots.Replacea balljoint
if it is loose,thebootis damagedandleaking,or theballjoint is binding.Whenre-
placingsuspensionparts,checkthevehiclefor alignment.
b. Checkfor seizedor deterioratedbushings.Replacebushingsthatarewornor dam-
agedandcheckthevehiclefor alignment.
c. Checkfor thepresenceof swaybaror stabilizerbarbushingswhichwraparoundthe
bar.Inspecttheconditionof the bushingsandreplaceif wornor damaged.Remove
the bushingbracketandapplya thin layerof suspensiongreaseto theareawherethe
bushingswraparoundthe barandreinstallthe bushingbrackets. ~
5. Vehicle vibrates when driven
a. Checkthe roadsurface.Roadswhichhaveroughor unevensurfacesmaycauseun-
usualvibrations.
b. Checkthetire conditionandbalance.An internallydamagedtire maycausefailure
symptomssimilarto failedsuspensionparts.Fordiagnosticpurposes,try a known
goodsetof tiresandreplacedefectivetires immediately.
c. Checkfor a wornConstantVelocity(CV-joint)joint, universal(U- joint) or flex joint
andreplaceif loose,damagedor binding.
d. Checkfor a loose,bent,or out-of-balance
axleor driveshaft.Replacedamagedor
failedcomponents.
NOTE:Diagnosing failures related to wheels, tires, steering and the sus-
pension system can often times be accomplished with a careful and thor-
ough test drive. Bearing noises are isolated by noting whether the noises
or symptoms vary when turning left or right, or occur while driving a
straight line. During a teft hand turn, the vehicle’s weight shifts to the
right, placing more force on the right side bearings, such that if a right side
wheel bearing is worn or damaged, the noise or vibration should increase
during light-to-heavy acceleration. Conversely, on right hand turns, the ve-
hicle tends to lean to the left, loading the left side bearings.
Knockingnoisesin thesuspensionwhenthevehicleis drivenoverroughroads,rail-
roadtracksandspeedbumpsindicatewornsuspensioncomponentssuchasbushings,
balljoints or tie rodends,or a wornsteeringsystem.
1. Tail light, running light or side marker light inoperative
a. Checkfor batteryvoltageandgroundat light’selectricalconnector.If batteryvoltageis
present,checkthe bulbsocketandelectricalconnectorgroundterminalfor a proper
ground.If batteryvoltageandgroundarepresentat thelightconnector,butnot in the
socket,cleanthesocketandthegroundterminalconnector.If batteryvoltageand
groundarepresentin the bulbsocket,replacethe bulb.If batteryvoltageor groundis
notpresent,referto thewiringdiagramto troubleshootfor an opencircuit.
b. Checkthe lightswitchoperationandreplaceif necessary.
2. Tall light, running light or side marker light works intermittently
a. Checkthebulbfor a damagedfilament,andreplaceif damaged.
b. Checkthebulbandbulbsocketfor corrosion,andcleanor replacethebulband
socket.
c. Checkfor loose,damagedor corrodedwiresandelectricalterminals,andrepairas
necessary.
d. Checkthe lightswitchoperationandreplaceif necessary.
3. Tail light, running light or side marker light very dim
a. Checkthe bulbandbulbsocketfor corrosionandcleanor replacethe bulband
socket.
II-14 TROUBLESHOOTING
b. Checkfor lowvoltageat thebulbsocketpositiveterminalor a poorground.If voltage
is low,or thegroundmarginal,tracethewiringto, andcheckfor loose,damagedor
corrodedwiresandelectricalterminals;repairasnecessary.
c. Checkthe lightswitchoperationandreplaceif necessary.
1. Interior light inoperative
a. Verifythe interiorlightswitchlocationandposition(s),andsettheswitchin thecor-
rectposition.
b. Checkfor batteryvoltageandgroundatthe interiorlightbulbsocket.If batteryvoltage
andgroundarepresent,replacethe bulb.If voltageis notpresent,checkthe interior
lightfusefor batteryvoltage.If thefuseis missing,replacethefuse.If thefusehas
blown,or if batteryvoltageis present,referto thewiringdiagramto troubleshootthe
causefor anopenor shortedcircuit.If groundis notpresent,checkthe doorswitch
contactsandcleanor repairas necessary.
2. Interior light works intermittent/y
a. Checkthe bulbfor a damagedfilament,andreplaceif damaged.
b. Checkthebulbandbulbsocketfor corrosion,andcleanor replacethebulband
socket.
c. Checkfor loose,damagedor corrodedwiresandelectricalterminals;repairas neces-
sary.
d. Checkthedoorandlightswitchoperation,andreplaceif necessary.
3. Interior light very dim
a. Checkthe bulbandbulbsocketfor corrosion,andcleanor replacethe bulband
socket.
b. Checkfor lowvoltageat the bulbsocketpositiveterminalor a poorground.If voltage
is low,or thegroundmarginal,tracethewiringto, andcheckfor loose,damagedor
corrodedwiresandelectricalterminals;repairas necessary.
c. Checkthedoorandlightswitchoperation,andreplaceif necessary.
1. One brake light inoperative
a. PressPressthe brakepedalandcheckfor batteryvoltageandgroundat thebrakelight
bulbsocket.If present,replacethebulb.If eitherbatteryvoltageor groundis notpre-
sent,referto thewiringdiagramto troubleshoot.
2. Both brake lights inoperative
a. Pressthe brakepedalandcheckfor batteryvoltageandgrou’ndat thebrakelightbulb
socket.If present,replacebothbulbs.If batteryvoltageis not present,checkthe brake
lightswitchadjustmentandadjustasnecessary.If thebrakelightswitchis properly
adjusted,andbatteryvoltageor thegroundis not presentat thebulbsockets,or atthe
bulbelectricalconnectorwiththe brakepedalpressed,referto thewiringdiagramto
troubleshootthecauseof an opencircuit.
3. One or both brake lights very dim
a. Pressthebrakepedalandmeasurethevoltageat thebrakelightbulbsocket.If the
measuredvoltageis closeto thebatteryvoltage,checkfor a poorgroundcausedby a
loose,damaged,or corrodedwire,terminal,bulbor bulbsocket.If thegroundis
boltedto a paintedsurface,it maybenecessaryto removetheelectricalconnectorand
cleanthemountingsurface,so theconnectormountson baremetal.If batteryvoltage
is low,checkfor a poorconnectioncausedby eithera faultybrakelightswitch,a
loose,damaged,or corrodedwire,terminalor electricalconnector.Referto thewiring
diagramto troubleshootthecauseof a voltagedrop.
1. Warning light(s) stay on when the engine is started
Ignition, Battery or Alternator Warning light
a. Checkthealternatoroutputandvoltageregulatoroperation,andreplaceas necessary.
b. Checkthewarninglightwiringfor a shortedwire.
Check Engine Light
a. Checktheenginefor routinemaintenance andtune-upstatus.Notethe enginetune-up
specificationsandverifythesparkplug,air filterandengineoil condition;replace
and/oradjustitemsas necessary.
b. Checkthefueltankfor lowfuel level,causingan intermittentleanfuelmixtur
e.Topoff fueltankandresetcheckenginelight.
c. Checkfor a failedor disconnectedenginefuelor ignitioncomponent,sensoror con-
trol unitandrepairor replaceas necessary.
d. Checktheintakemanifoldandvacuumhosesfor air leaksandrepairas necessary.
e. Checktheengine’smechanicalconditionfor excessiveoil consumption.
Anti-Lock Braking System (ABS) Light
a. Checkthewheelsensorsandsensorringsfor debris,andcleanas necessary.
b. Checkthe brakemastercylinderfor fluid leakageor sealfailureandreplaceas neces-
sary.
c, ChecktheABScontrolunit,pumpandproportioningvalvesfor properoperation;re-
placeas necessary.
d. CheckthesensorwiringatthewheelsensorsandtheABScontrolunitfor a looseor
shortedwire,andrepairas necessary.
brake Warning Light
a. Checkthe brakefluid levelandcheckfor possibleleakagefromthe hydrauliclinesand
seals.Topoff brakefluidandrepairleakageas necessary.
b. Checkthe brakeliningsfor wearandreplaceas necessary.
c. Checkfor a looseor shot-tedbrakewarninglightsensoror wire,andreplaceor repair
as necessary.
Oil Pressure Warning Light
a. Stoptheengineimmediately.Checktheengineoil levelandoil filter condition,and
top off or changetheoil as necessary.
b. Checktheoil pressuresensorwirefor beingshortedto ground.Disconnectthewire
fromtheoil pressuresensorandwiththe ignitionin theONposition,butnot running,
theoil pressurelightshouldnot beworking.If the lightworkswiththewirediscon-
nected,checkthesensorwirefor beingshortedto ground.Checkthewire routingto
makesurethewire is notpinchedandcheckfor insulationdamage.Repairor replace
thewireas necessaryandrecheckbeforestartingtheengine.
c. Removetheoil panandcheckfor a cloggedoil pick-uptubescreen.
d. Checktheoil pressuresensoroperationbysubstitutinga knowngoodsensor.
e. Checktheoil filterfor internalrestrictionsor leaks,andreplaceas necessary.
WARNING: If the engine is operated with oil pressure below the manufac-
turer’s specification, severe (and costly) engine damage could occur. Low
oil pressure can be caused by excessive internal wear or damage to the en-
gine bearings, oil pressure relief valve, oil pump or oil pump drive mecha-
nism.
Beforestartingtheengine,checkfor possiblecausesof rapidoil loss,suchas leaking
oil linesor a loose,damaged,restricted,or leakingoil filter or oil pressuresensor.If the
engineoil levelandconditionareacceptable, measuretheengine’soil pressureusinga
pressuregauge,or determinethecausefor theoil pressurewarninglightto function
whentheengineis running,beforeoperatingtheenginefor anextendedperiodof time.
Anothersymptomof operatinganenginewith lowoil pressureis thepresenceof severe
knockingandtappingnoises.
Parking Brake Warning Light
a. Checkthebrakereleasemechanismandverifythe parkingbrakehasbeenfullyre-
leased.
b. CheckCheck the parkingbrakelightswitchfor loosenessor misalignment.
c. CheckCheck for a damagedswitchor a looseor shortedbrakelightswitchwire,and
replaceor repairas necessary.
2. Warning light(s) flickers on and off when driving
Ignition, Battery or Alternator Warning Light
a. Checkthealternatoroutputandvoltageregulatoroperation.An intermittentcondition
mayindicatewornbrushes,an internalshort,or a defectivevoltageregulator.Replace
thealternatoror failedcomponent.
b. Checkthewarninglightwiringfor a shorted,pinchedor damagedwireandrepairas
necessary.
Check Engine Light
a. Checktheenginefor requiredmaintenance andtune-upstatus.Verifyenginetune-up
specifications,aswellas sparkplug,air filter andengineoil condition;replaceand/or
adjustitemsas necessary.
b. Checkthefueltankfor lowfuel levelcausingan intermittentleanfuelmixture.Topoff
fueltankandresetcheckenginelight.
c. Checkfor an intermittentfailureor partiallydisconnected
enginefuelandignition
component,sensoror controlunit;repairor replaceas necessary.
d. Checkthe intakemanifoldandvacuumhosesfor air leaks,andrepairas necessary.
e. Checkthewarninglightwiringfor a shorted,pinchedor damagedwireandrepairas
necessary.
Anti-Lock Braking System (ABS) Light
a. Checkthewheelsensorsandsensorringsfor debris,andcleanas necessary.
b. Checkthebrakemastercylinderfor fluid leakageor sealfailureandreplaceas neces-
sary.
c. ChecktheABScontrolunit,pumpandproportioningvalvesfor properoperation,and
replaceas necessary.

d. CheckthesensorwiringatthewheelsensorsandtheABScontrolunitfor a looseor
shortedwireandrepairas necessary.
Brake Warninu Liaht
a. Checkthe brakefluid~evelandcheckfor possibleleakagefromthe hydrauliclinesand
seals.Topoff brakefluidandrepairleakageas necessary.
b. Checkthe brakeliningsfor wearandreplaceas necessary.
c. Checkfor a looseor shortedbrakewarninglightsensoror wire,andreplaceor repair
as necessary.
Oil Pressure Warning Light
a. Stoptheengineimmediately.Checktheengineoil levelandcheckfor a suddenand
rapidoil loss,suchasa leakingoil lineor oil pressuresensor,andrepairor replaceas
necessary.
b. Checkthe oil pressuresensoroperationby substitutinga knowngoodsensor.
c. Checktheoil pressuresensorwirefor beingshortedto ground.Disconnectthewire
fromtheoil pressuresensorandwiththeignitionin theONposition,butnot running,
the oil pressurelightshouldnot beworking.If the lightworkswiththewirediscon-
nected,checkthesensorwirefor beingshortedto ground.Checkthewire routingto
makesurethewire is not pinchedandcheckfor insulationdamage.Repairor replace
thewireas necessaryandrecheckbeforestartingtheengine.
d. Removetheoil panandcheckfor a cloggedoil pick-uptubescreen.
Parking Brake Warning Light
a. Checkthe brakereleasemechanismandverifytheparkingbrakehasbeenfully re-
leased.
b. Checkthe parkingbrakelightswitchfor loosenessor misalignment.
c. Checkfor a damagedswitchor a looseor shortedbrakelightswitchwire,andreplace
or repairas necessary.
3. Warning li#ht(s) inoperative with iflnition on, andengine not started
a. Checkfor a defectivebulbby installinga knowngoodbulb.
b. Checkfor a defectivewireusingtheappropriatewiringdiagram(s).
c. Checkfor a defectivesendingunit by removingandthengroundingthewireatthe
sendingunit.If the lightcomesonwiththe ignitionon whengroundingthewire,re-
placethesendingunit.
1. Turn siflnais or hazard iiflhts come on, but do not flash
a. Checkfor a defectiveflasherunitandreplaceas necessary.
2. Turn signals or hazard iiflhts do not function on either side
a. Checkthefuseandreplace,if defective.
b. Checktheflasherunit by substitutinga knowngoodflasherunit.
c. Checktheturnsignalelectricalsystemfor a defectivecomponent,opencircuit,short
circuitor poorground.
3. Turn siflnais or hazard lights only work on one side
a. Checkfor failedbulbsandreplaceas necessary.
b. Checkfor poorgroundsin bothhousingsandrepairas necessary.
4. One siflnai light does not work
a. Checkfor a failedbulbandreplaceasnecessary.
b. Checkfor corrosionin thebulbsocket,andcleanandrepairas necessary.
c. Checkfor a poorgroundatthe bulbsocket,andcleanandrepairas necessary.
5. Turn signals flash too slowly
a. Checksignalbulb(s)wattageandreplacewith lowerwattagebulb(s).
1. Speedometer does not work
a. Checkandverifythatthe speedometer cableis properlyseatedintothespeedometer
assemblyandthespeedometer drivegear.
b. Checkthespeedometer cablefor breakageor rounded-offcableendswherethecable
seatsintothespeedometer drivegearandintothe speedometer assembly.If damaged,
brokenor thecableendsareroundedoff, replacethecable.
c. Checkspeedometer drivegearconditionandreplaceas necessary.
d. Installa knowngoodspeedometer to testfor properoperation.If thesubstituted
speedometer functionsproperly,replacethespeedometer assembly.
TROUBLESHOOTING
1145
6. Turn signals flash too fast
a, Checksignalbulb(s)wattageandreplacewith higherwattagebulb(s).
b. Checkfor installationof thecorrectflasherunitandreplaceif incorrect.
7. Four-way hazard flasher indicator iiflhi inoperative
a.Verifythattheexteriorlightsarefunctioningand,if so, replaceindicatorbulb.
b. Checktheoperationof thewarningflasherswitchandreplaceif defective.
0. Turn signal indicator ii#ht(s) do not work in either direction
a. Verifythattheexteriorlightsarefunctioningand,if so, replaceindicatorbulb(s).
b. Checkfor a defectiveflasherunit by substitutinga knowngoodunit.
9. One turn signal indicator liflht does not work
a. Checkfor a defectivebulbandreplaceas necessary.
b. Checkfor a defectiveflasherunit by substitutinga knowngoodunit.
1. Horn does not operate
a. Checkfor a defectivefuseandreplaceas necessary.
b. Checkfor batteryvoltageandgroundat hornelectricalconnectionswhenpressingthe
hornswitch.If voltageis present,replacethehornassembly.If voltageor groundis
not present,referto ChassisElectricalcoveragefor additionaltroubleshooting
tech-
niquesandcircuitinformation.
2. Horn has an unusual tone
a. Onsinglehornsystems,replacethehorn.
b. Ondualhornsystems,checkthe operationof thesecondhorn.Dualhornsystems
havea highandlowpitchedhorn.Unplugonehornat a timeandrecheckoperation.
Replacethe hornwhichdoesnotfunction.
c. Checkfor debrisor condensation
build-upin hornandverifythehornpositioning.If
the hornhasa singleopening,adjusttheopeningdownwardto allowfor adequate
drainageandto preventdebrisbuild-up.
1. Windshield wipers do not operate
a. Checkfuseandreplaceas necessary.
b. Checkswitchoperationandrepairor replaceas necessary.
c. Checkfor corroded,loose,disconnected
or brokenwiresandcleanor repairas neces-
sary.
d. Checkthegroundcircuitfor thewiperswitchor motorandrepairasnecessary.
2. Windshield wiper motor makes a humming noise, gets hot or blows
fuses
a.Wipermotordamagedinternally;replacethewipermotor.
b. Wiperlinkagebent,damagedor seized.Repairor replacewiperlinkageasnecessary.
3. Windshield wiper motor operates, but one or both wipers fail to move
a.Windshieldwipermotorlinkagelooseor disconnected.
Repairor replacelinkageas
necessary.
b. Windshieldwiperarmslooseonwiperpivots.Securewiperarmto pivotor replace
boththewiperarmandpivotassembly.
4. Windshield wipers will not park
a. Checkthewiperswitchoperationandverifythattheswitchproperlyinterruptsthe
powersuppliedto thewipermotor.
b. If thewiperswitchis functioningproperly,thewipermotorparkingcircuithasfailed.
Replacethewipermotorassembly.Operatethewipermotorat leastonetimebefore
installingthearmsandbladesto ensurecorrectpositioning,thenrecheckusingthe
highestwiperspeedon a wetwindshieldto makesurethearmsandbladesdo not
contactthewindshieldtrim.
to minimizesharpbendsor kinks.If thesheathinghasbeendamaged,replacetheca-
bleassembly.
b. Checkthespeedometer cablefor adequatelubrication.Removethecable,inspectfor
damage,clean,lubricateandreinstall.If thecablehasbeendamaged,replacetheca-
ble.
3. Speedometer works intermittently
a. Checkthecableandverifythatthecableis fully installedandthefastenersaresecure.
b. Checkthecableendsfor wearandrounding,andreplaceas necessary.
II-16 TROUBLESHOOTING
1. Speedometer does not work
a. Checkthespeedsensorpickupandreplaceas necessary.
b. Checkthewiringbetweenthespeedsensorandthespeedometer for corrodedtermi-
nals,looseconnectionsor brokenwiresandcleanor repairas necessary.
c. Installa knowngoodspeedometer to testfor properoperation.If thesubstituted
speedometer functionsproperly,replacethespeedometer assembly.
2. Speedometer works intermittently
a. Checkthewiringbetweenthespeedsensorandthespeedometer for corrodedtermi-
nals,looseconnectionsor brokenwiresandcleanor repairas necessary.
b. Checkthespeedsensorpickupandreplaceas necessary.
I. Gauge does not register
a. Checkfor a missingor blownfuseandreplaceas necessary.
b. Checkfor anopencircuitin thegaugewiring.Repairwiringas necessary.
I. No air coming from air conditioner vents
a. Checktheair conditionerfuseandreplaceas necessary.
b.Air conditionersystemdischarged.Havethesystemevacuated, chargedandleak
testedby anMVACcertifiedtechnician,utilizingapprovedrecovery/recycling equip-
ment.Repairas necessary.
c. Air conditionerlowpressureswitchdefective.Replaceswitch.
d. Air conditionerfanresistorpackdefective.Replaceresistorpack.
e. Looseconnection,brokenwiringor defectiveair conditionerrelayin air conditioning*
electricalcircuit.Repairwiringor replacerelayas necessary.
2. Air conditionerblowswarmair
a.Air conditionersystemis discharged.Havethesystemevacuated, chargedandleak
testedby an MVACcertifiedtechnician,utilizingapprovedrecovery/recyclingequip-
ment.Repairas necessary.
b. Air conditionercompressorclutchnot engaging.Checkcompressorclutchwiring,
electricalconnectionsandcompressorclutch,andrepairor replaceas necessary.
3. Water collects on the interior floor when the air conditioner is used
a. Air conditionerevaporatordrainhoseis blocked.Clearthedrainhosewhereit exits
thepassengercompartment.
b.Air conditionerevaporatordrainhoseis disconnected.Securethedrainhoseto the
evaporatordrainagetrayunderthedashboard.
4. Air conditioner has a moldy odor when used
a. Theair conditionerevaporatordrainhoseis blockedor partiallyrestricted,allowing
condensationto buildup aroundtheevaporatoranddrainagetray.Clearthedrain
hosewhereit exitsthepassengercompartment.
c. Gaugesendingunitdefective.Replacegaugesendingunit.
d. Gaugeor sendingunit improperlyinstalled.Verifyinstallationandwiring,andrepair
as necessary.
2. Gauge operates enatica//y
a. Checkforioose,shorted,damagedor corrodedelectricalconnectionsor wiringand
repairas necessary.
b. Checkgaugesendingunitsandreplaceas necessary.
3. Gauge operates fully pegged
a. Sendingunit-to-gaugewireshortedto ground.
b. Sendingunitdefective;replacesendingunit.
c. Gaugeor sendingunit not properlygrounded.
d. Gaugeor sendingunit improperlyinstalled.Verifyinstallationandwiring,andrepair
as necessary.
1. Blower motor does not operate
a. Checkblowermotorfuseandreplaceas necessary.
b. Checkblowermotorwiringfor loose,damagedor corrodedcontactsandrepairas
necessary.
c. Checkblowermotorswitchandresistorpackfor opencircuits,andrepairor replace
as necessary.
d. Checkblowermotorfor internaldamageandrepairor replaceas necessary.
2. Heater blows cool air
a. Checktheenginecoolantlevel.If thecoolantlevelis low,top off andbleedtheair
fromthecoolingsystemas necessary andcheckfor coolantleaks.
b. Checkenginecoolantoperatingtemperature. If coolanttemperature is belowspecifica-
tion, checkfor a damagedor stuckthermostat.
c. Checktheheatercontrolvalveoperation.Checkthe heatercontrolvalvecableor vac-
uumhosefor properinstallation.Movetheheatertemperature controlfromhotto cold
severaltimesandverifythe operationof theheatercontrolvalve.Withtheengineat
normaloperatingtemperature andtheheatertemperature controlin thefull hotposi-
tion, carefullyfeeltheheaterhosegoingintoandexitingthecontrolvalve.If one
heaterhoseis hotandtheotheris muchcooler,replacethecontrolvalve.
3. Heater steams the windshield when used
a. Checkfor a loosecoolingsystemhoseclampor leakingcoolanthoseneartheengine
firewallor underthedasharea,andrepairas necessary.
b. Checkfor theexistenceof a sweetodorandfluid drippingfromtheheaterfloorvents,
indicatinga failedor damagedheatercore.Pressuretestthecoolingsystemwiththe
heatersetto thefullywarmpositionandcheckfor fluid leakagefromthefloorvents.If
leakageis verified,removeandreplacetheheatercoreassembly.
NOTE:On some vehicles, the dashboard must be disassembled and re-
moved to access the heater core.