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BASIC TROUBLE SHOOTING - GENERAL INFORMATION

HEADINGS
- * PLEASE READ THIS FIRST *
- ACCESSORIES & ELECTRICAL
  - CHARGING SYSTEM TROUBLE SHOOTING
  - IGNITION SYSTEM TROUBLE SHOOTING
  - STARTER TROUBLE SHOOTING
- AIR CONDITIONING & HEAT
  - AIR CONDITIONING TROUBLE SHOOTING
  - HEATER SYSTEM TROUBLE SHOOTING
- BRAKES
  - BRAKE SYSTEM TROUBLE SHOOTING
- ENGINE MECHANICAL
  - COOLING SYSTEM TROUBLE SHOOTING
  - GASOLINE ENGINE - MECHANICAL TROUBLE SHOOTING
- ENGINE PERFORMANCE
  - CARBURETOR TROUBLE SHOOTING:
  - DIESEL ENGINE TROUBLE SHOOTING
  - FUEL INJECTION TROUBLE SHOOTING
  - IGNITION SYSTEM TROUBLE SHOOTING
  - STARTER TROUBLE SHOOTING
  - TUNE-UP TROUBLE SHOOTING - GAS ENGINE VEHICLES
  - VACUUM PUMP - DIESEL TROUBLE SHOOTING
- MANUAL TRANSMISSION
  - MANUAL TRANSMISSION TROUBLE SHOOTING
- POWERTRAIN
  - CLUTCH TROUBLE SHOOTING
  - DRIVE AXLE - NOISE DIAGNOSIS
    - Unrelated Noises
    - Non-Drive Axle Noises
    - Gear Noise
    - Chuckle
    - Knock
    - Clunk
    - Bearing Whine
    - Bearing Rumble
    - Chatter On Turns
    - Axle Shaft Noise
    - Vibration
  - DRIVE AXLE - RWD TROUBLE SHOOTING
  - FWD AXLE SHAFTS & CV JOINTS TROUBLE SHOOTING
- STEERING & SUSPENSION
  - MANUAL STEERING GEAR TROUBLE SHOOTING
  - POWER STEERING TROUBLE SHOOTING
  - STEERING COLUMN TROUBLE SHOOTING
  - SUSPENSION TROUBLE SHOOTING
  - WHEEL ALIGNMENT TROUBLE SHOOTING
FIGURES
- Fig. 1: Ignition Secondary Trouble Shooting Chart
- Fig. 2: Ignition Primary Trouble Shooting Chart
- Fig. 3: Ignition Secondary Trouble Shooting Chart
- Fig. 4: Ignition Primary Trouble Shooting Chart
TABLES
- BASIC CHARGING SYSTEM TROUBLE SHOOTING CHART
- BASIC STARTER TROUBLE SHOOTING CHART
- BASIC AIR CONDITIONING TROUBLE SHOOTING CHART
- BASIC HEATER SYSTEM TROUBLE SHOOTING CHART
- BRAKE SYSTEM TROUBLE SHOOTING CHART
- COOLING SYSTEM TROUBLE SHOOTING
- BASIC GASOLINE ENGINE - MECHANICAL TROUBLE SHOOTING CHART
- BASIC COLD START SYMPTOMS TROUBLE SHOOTING CHART
- BASIC HOT START SYMPTOMS TROUBLE SHOOTING CHART
- BASIC COLD ENGINE DRIVEABILITY SYMPTOMS TROUBLE SHOOTING CHART
- BASIC WARM ENGINE DRIVEABILITY SYMPTOMS TROUBLE SHOOTING CHART
- BASIC DIESEL ENGINE TROUBLE SHOOTING CHART
- VACUUM PUMP DIAGNOSIS
- BASIC FUEL INJECTION TROUBLE SHOOTING CHART
- BASIC STARTER TROUBLE SHOOTING CHART
- BASIC SPARK PLUG TROUBLE SHOOTING CHARTS
- BASIC ELECTRONIC IGNITION TROUBLE SHOOTING CHARTS
- BASIC ELECTRONIC IGNITION TROUBLE SHOOTING CHARTS - USING OSCILLOSCOPE PATTERNS
- BASIC DRIVEABILITY PROBLEMS TROUBLE SHOOTING
- VACUUM PUMP (DIESEL) TROUBLE SHOOTING CHART
- MANUAL TRANSMISSION/TRANSAXLE TROUBLE SHOOTING
- BASIC CLUTCH TROUBLE SHOOTING CHART
- DRIVE AXLE (RWD) TROUBLE SHOOTING
- BASIC FWD AXLE SHAFTS & CV JOINTS TROUBLE SHOOTING CHART
- BASIC MANUAL STEERING GEAR TROUBLE SHOOTING CHART
- BASIC POWER STEERING TROUBLE SHOOTING CHART
- BASIC STEERING COLUMN TROUBLE SHOOTING CHART
- BASIC SUSPENSION TROUBLE SHOOTING CHART
- BASIC WHEEL ALIGNMENT TROUBLE SHOOTING CHART

GENERAL INFORMATION

Trouble Shooting - Basic Procedures

* PLEASE READ THIS FIRST *

NOTE: This is GENERAL information. This article is not intended to be specific to any unique situation or individual vehicle configuration. The purpose of this Trouble Shooting information is to provide a list of common causes to problem symptoms. For model-specific Trouble Shooting, refer to SUBJECT, DIAGNOSTIC, or TESTING articles available in the section(s) you are accessing.

ACCESSORIES & ELECTRICAL

CHARGING SYSTEM TROUBLE SHOOTING

BASIC CHARGING SYSTEM TROUBLE SHOOTING CHART

CONDITION & POSSIBLE CAUSE CORRECTION

Vehicle Will Not Start

Dead battery Check battery cells, alternator belt tension and alternator output

Loose or corroded battery connections Check all charging system connections

Ignition circuit or switch malfunction Check and replace as necessary

Alternator Light Stays On With Engine Running

Loose or worn alternator drive belt Check alternator drive tension and condition, See Belt Adjustment in TUNE-UP article in the TUNE-UP section

Loose alternator wiring connections Check all charging system connections

Short in alternator light wiring See Indicator Warning Lights in STANDARD INSTRUMENTS in the ACCESSORIES & EQUIPMENT section

Defective alternator stator or diodes See Bench Tests in ALTERNATOR article

Defective regulator See Regulator Check in ALTERNATOR article

Alternator Light Stays Off With Ignition Switch ON

Blown fuse See WIRING DIAGRAMS

Defective alternator See Testing in ALTERNATOR article

Defective indicator light bulb or socket See Indicator Warning Lights in STANDARD INSTRUMENTS in the ACCESSORIES & EQUIPMENT section

Alternator Light Stays OFF With Ignition Switch ON

Short in alternator wiring See On-Vehicle Tests in ALTERNATOR article

Defective rectifier bridge See Bench Tests in ALTERNATOR article

Lights or Fuses Burn Out Frequently

Defective alternator wiring See On-Vehicle Tests in ALTERNATOR article

Defective regulator See Regulator Check in ALTERNATOR article

Defective battery Check and replace as necessary

Ammeter Gauge Shows Discharge

Loose or worn drive belt Check alternator drive belt tension and condition. See Belt Adjustment in TUNE-UP article in the TUNE-UP section

Defective wiring Check all wires and wire connections

Defective alternator or regulator See Bench Tests and On-Vehicle Tests in ALTERNATOR article

Defective ammeter, or improper ammeter wiring connection See Testing in STANDARD INSTRUMENTS in the ACCESSORIES & EQUIPMENT section

Noisy Alternator

Loose drive pulley Tighten drive pulley attaching nut

Loose mounting bolts Tighten all alternator mounting bolts

Worn or dirty bearings See Bearing Replacement ALTERNATOR article

Defective diodes or stator See Bench Test in ALTERNATOR article

Battery Does Stay Charged

Loose or worn drive belt Check alternator drive belt tension and condition. See Belt Adjustment in appropriate TUNE-UP article in the TUNE-UP section

Loose or corroded battery connections Check all charging system connections

Loose alternator connections Check all charging system connections

Defective alternator or battery See On-Vehicle Tests and Bench Tests in ALTERNATOR article

Add-on electrical accessories exceeding alternator capacity Install larger alternator

Battery Overcharged-Uses Too Much Water

Defective battery Check alternator output and repair as necessary

Defective alternator See On-Vehicle Test and Bench Tests in ALTERNATOR article

Excessive alternator voltage Check alternator output and repair as necessary

CONDITION & POSSIBLE CAUSE	CORRECTION
Vehicle Will Not Start
Dead battery	Check battery cells, alternator belt tension and alternator output
Loose or corroded battery connections	Check all charging system connections
Ignition circuit or switch malfunction	Check and replace as necessary
Alternator Light Stays On With Engine Running
Loose or worn alternator drive belt	Check alternator drive tension and condition, See Belt Adjustment in TUNE-UP article in the TUNE-UP section
Loose alternator wiring connections	Check all charging system connections
Short in alternator light wiring	See Indicator Warning Lights in STANDARD INSTRUMENTS in the ACCESSORIES & EQUIPMENT section
Defective alternator stator or diodes	See Bench Tests in ALTERNATOR article
Defective regulator	See Regulator Check in ALTERNATOR article
Alternator Light Stays Off With Ignition Switch ON
Blown fuse	See WIRING DIAGRAMS
Defective alternator	See Testing in ALTERNATOR article
Defective indicator light bulb or socket	See Indicator Warning Lights in STANDARD INSTRUMENTS in the ACCESSORIES & EQUIPMENT section
Alternator Light Stays OFF With Ignition Switch ON
Short in alternator wiring	See On-Vehicle Tests in ALTERNATOR article
Defective rectifier bridge	See Bench Tests in ALTERNATOR article
Lights or Fuses Burn Out Frequently
Defective alternator wiring	See On-Vehicle Tests in ALTERNATOR article
Defective regulator	See Regulator Check in ALTERNATOR article
Defective battery	Check and replace as necessary
Ammeter Gauge Shows Discharge
Loose or worn drive belt	Check alternator drive belt tension and condition. See Belt Adjustment in TUNE-UP article in the TUNE-UP section
Defective wiring	Check all wires and wire connections
Defective alternator or regulator	See Bench Tests and On-Vehicle Tests in ALTERNATOR article
Defective ammeter, or improper ammeter wiring connection	See Testing in STANDARD INSTRUMENTS in the ACCESSORIES & EQUIPMENT section
Noisy Alternator
Loose drive pulley	Tighten drive pulley attaching nut
Loose mounting bolts	Tighten all alternator mounting bolts
Worn or dirty bearings	See Bearing Replacement ALTERNATOR article
Defective diodes or stator	See Bench Test in ALTERNATOR article
Battery Does Stay Charged
Loose or worn drive belt	Check alternator drive belt tension and condition. See Belt Adjustment in appropriate TUNE-UP article in the TUNE-UP section
Loose or corroded battery connections	Check all charging system connections
Loose alternator connections	Check all charging system connections
Defective alternator or battery	See On-Vehicle Tests and Bench Tests in ALTERNATOR article
Add-on electrical accessories exceeding alternator capacity	Install larger alternator
Battery Overcharged-Uses Too Much Water
Defective battery	Check alternator output and repair as necessary
Defective alternator	See On-Vehicle Test and Bench Tests in ALTERNATOR article
Excessive alternator voltage	Check alternator output and repair as necessary

IGNITION SYSTEM TROUBLE SHOOTING

Fig. 1: Ignition Secondary Trouble Shooting Chart

Fig. 2: Ignition Primary Trouble Shooting Chart

STARTER TROUBLE SHOOTING

BASIC STARTER TROUBLE SHOOTING CHART

CONDITION & POSSIBLE CAUSE CORRECTION

Starter Fails to Operate

Dead battery or bad connections between starter and battery Check battery charge and all wires and connections to starter

Ignition switch faulty or misadjusted Adjust or replace ignition switch

Open circuit between starter switch ignition terminal on starter relay Check and repair wires and connections as necessary

Starter relay or starter defective See Testing in STARTER article

Open solenoid pull-in wire Testing in STARTER article

Starter Does Not Operate and Headlights Dim

Weak battery or dead cell Charge or replace battery as necessary

Loose or corroded battery connections Check that battery connections are clean and tight

Internal ground in starter windings See Testing in STARTER article

Grounded starter fields See Testing in STARTERS

Armature rubbing on pole See STARTER article shoes

Starter Turns but Engine Does Not Rotate

Starter clutch slipping See STARTER article

Broken clutch housing See STARTER article

Pinion shaft rusted or dry See STARTER article

Engine basic timing incorrect See Ignition Timing in TUNE-UP article

Broken teeth on engine flywheel Replace flywheel and check for starter pinion gear damage

Starter Will Not Crank Engine

Faulty overrunning clutch See STARTER article

Broken clutch housing See STARTER article

Broken flywheel teeth Replace flywheel and check for starter pinion gear damage

Armature shaft sheared or reduction gear teeth stripped See STARTER article

Weak battery Charge or replace battery as necessary

Faulty solenoid See On-Vehicle Tests in STARTER article

Poor grounds Check all ground connections for tight and clean connections

Ignition switch faulty or misadjusted Adjust or replace ignition switch as necessary

Starter Cranks Engine Slowly

Battery weak or defective Charge or replace battery as necessary

Engine overheated See ENGINE COOLING SYSTEM article

Engine oil too heavy Check that proper viscosity oil is used

Poor battery-to-starter connections Check that all between battery and starter are clean and tight

Current draw too low or too high See Bench Tests in STARTER article

Bent armature, loose pole shoes screws or worn bearing See STARTER article

Burned solenoid contacts Replace solenoid

Faulty starter Replace starter

Starter Engages Engine Only Momentarily

Engine timing too far advanced See Ignition Timing in TUNE-UP article

Overrunning clutch not engaging properly Replace overrunning clutch. See STARTER article

Broken starter clutch See STARTER article

Broken teeth on engine flywheel Replace flywheel and check starter pinion gear for damage

Weak drive assembly thrust spring See STARTER article

Weak hold-in coil See Bench Tests in STARTER article

Starter Drive Will Not Engage

Defective point assembly See Testing in STARTER article

Poor point assembly ground See Testing in STARTER article

Defective pull-in coil Replace starter solenoid

Starter Relay Does Not Close

Dead battery Charge or replace battery as necessary

Faulty wiring Check all wiring and connections leading to relay

Neutral safety switch faulty Replace neutral safety switch

Starter relay faulty Replace starter relay

Starter Drive Will Not Disengage

Starter motor loose on mountings Tighten starter attach bolts

Worn drive end bushing See STARTER article

Damaged engine flywheel teeth Replace flywheel and starter pinion gear for damage

Drive yolk return spring broken or missing Replace return spring

Faulty ignition switch Replace ignition switch

Insufficient clearance between winding leads to solenoid terminal and main contact in solenoid Replace starter solenoid

Starter clutch not disengaging Replace starter clutch

Ignition starter switch Replace ignition switch contacts sticking

Starter Relay Operates but Solenoid Does Not

Faulty solenoid switch, switch connections or relay Check all wiring between relay and solenoid or replace relay or solenoid as necessary

Broken lead or loose soldered connections Repair wire or wire connections as necessary

Solenoid Plunger Vibrates When Switch is Engaged

Weak battery Charge or replace battery as necessary

Solenoid contacts corroded Clean contacts or replace solenoid

Faulty wiring Check all wiring leading to solenoid

Broken connections inside switch cover Repair connections or replace solenoid

Open hold-in wire solenoid

Low Current Draw

Worn brushes or weak brush springs Replace brushes or brush springs as necessary

High Pitched Whine During Cranking Before Engine Fires but Engine Fires and Cranks Normally

Distance too great between starter pinion and flywheel Align starter or check that correct starter and flywheel are being used

High Pitched Whine After Engine Fires With Key released. Engine Fires and Cranks Normally

Distance too small between starter pinion and flywheel Flywheel runout contributes to the intermittent nature

CONDITION & POSSIBLE CAUSE	CORRECTION
Starter Fails to Operate
Dead battery or bad connections between starter and battery	Check battery charge and all wires and connections to starter
Ignition switch faulty or misadjusted	Adjust or replace ignition switch
Open circuit between starter switch ignition terminal on starter relay	Check and repair wires and connections as necessary
Starter relay or starter defective	See Testing in STARTER article
Open solenoid pull-in wire	Testing in STARTER article
Starter Does Not Operate and Headlights Dim
Weak battery or dead cell	Charge or replace battery as necessary
Loose or corroded battery connections	Check that battery connections are clean and tight
Internal ground in starter windings	See Testing in STARTER article
Grounded starter fields	See Testing in STARTERS
Armature rubbing on pole	See STARTER article shoes
Starter Turns but Engine Does Not Rotate
Starter clutch slipping	See STARTER article
Broken clutch housing	See STARTER article
Pinion shaft rusted or dry	See STARTER article
Engine basic timing incorrect	See Ignition Timing in TUNE-UP article
Broken teeth on engine flywheel	Replace flywheel and check for starter pinion gear damage
Starter Will Not Crank Engine
Faulty overrunning clutch	See STARTER article
Broken clutch housing	See STARTER article
Broken flywheel teeth	Replace flywheel and check for starter pinion gear damage
Armature shaft sheared or reduction gear teeth stripped	See STARTER article
Weak battery	Charge or replace battery as necessary
Faulty solenoid	See On-Vehicle Tests in STARTER article
Poor grounds	Check all ground connections for tight and clean connections
Ignition switch faulty or misadjusted	Adjust or replace ignition switch as necessary
Starter Cranks Engine Slowly
Battery weak or defective	Charge or replace battery as necessary
Engine overheated	See ENGINE COOLING SYSTEM article
Engine oil too heavy	Check that proper viscosity oil is used
Poor battery-to-starter connections	Check that all between battery and starter are clean and tight
Current draw too low or too high	See Bench Tests in STARTER article
Bent armature, loose pole shoes screws or worn bearing	See STARTER article
Burned solenoid contacts	Replace solenoid
Faulty starter	Replace starter
Starter Engages Engine Only Momentarily
Engine timing too far advanced	See Ignition Timing in TUNE-UP article
Overrunning clutch not engaging properly	Replace overrunning clutch. See STARTER article
Broken starter clutch	See STARTER article
Broken teeth on engine flywheel	Replace flywheel and check starter pinion gear for damage
Weak drive assembly thrust spring	See STARTER article
Weak hold-in coil	See Bench Tests in STARTER article
Starter Drive Will Not Engage
Defective point assembly	See Testing in STARTER article
Poor point assembly ground	See Testing in STARTER article
Defective pull-in coil	Replace starter solenoid
Starter Relay Does Not Close
Dead battery	Charge or replace battery as necessary
Faulty wiring	Check all wiring and connections leading to relay
Neutral safety switch faulty	Replace neutral safety switch
Starter relay faulty	Replace starter relay
Starter Drive Will Not Disengage
Starter motor loose on mountings	Tighten starter attach bolts
Worn drive end bushing	See STARTER article
Damaged engine flywheel teeth	Replace flywheel and starter pinion gear for damage
Drive yolk return spring broken or missing	Replace return spring
Faulty ignition switch	Replace ignition switch
Insufficient clearance between winding leads to solenoid terminal and main contact in solenoid	Replace starter solenoid
Starter clutch not disengaging	Replace starter clutch
Ignition starter switch	Replace ignition switch contacts sticking
Starter Relay Operates but Solenoid Does Not
Faulty solenoid switch, switch connections or relay	Check all wiring between relay and solenoid or replace relay or solenoid as necessary
Broken lead or loose soldered connections	Repair wire or wire connections as necessary
Solenoid Plunger Vibrates When Switch is Engaged
Weak battery	Charge or replace battery as necessary
Solenoid contacts corroded	Clean contacts or replace solenoid
Faulty wiring	Check all wiring leading to solenoid
Broken connections inside switch cover	Repair connections or replace solenoid
Open hold-in wire	solenoid
Low Current Draw
Worn brushes or weak brush springs	Replace brushes or brush springs as necessary
High Pitched Whine During Cranking Before Engine Fires but Engine Fires and Cranks Normally
Distance too great between starter pinion and flywheel	Align starter or check that correct starter and flywheel are being used
High Pitched Whine After Engine Fires With Key released. Engine Fires and Cranks Normally
Distance too small between starter pinion and flywheel	Flywheel runout contributes to the intermittent nature

AIR CONDITIONING & HEAT

AIR CONDITIONING TROUBLE SHOOTING

WARNING: This is GENERAL information. This article is not intended to be specific to any unique situation or individual vehicle configuration. The purpose of this Trouble Shooting information is to provide a list of common causes to problem symptoms. For model-specific Trouble Shooting, refer to SUBJECT, DIAGNOSTIC, or TESTING articles available in the section(s) you are accessing.

BASIC AIR CONDITIONING TROUBLE SHOOTING CHART

CONDITION POSSIBLE CAUSE

Compressor Not Working Compressor clutch circuit open.

..... Compressor clutch coil inoperative.

..... Poor clutch ground connection.

..... Fan belts loose.

..... Thermostatic switch inoperative.

..... Thermostatic switch not adjusted.

..... Ambient temperature switch open.

..... Superheat fuse blown.

Excessive Noise or Vibration Missing or loose mounting bolts.

..... Bad idler pulley bearings.

..... Fan belts not tightened correctly.

..... Compressor clutch contacting body.

..... Excessive system pressure.

..... Compressor oil level low.

..... Damaged clutch bearings.

..... Damaged reed valves.

..... Damaged compressor.

Insufficient or No Cooling; Compressor Working Expansion valve inoperative.

..... Heater control valve stuck open.

..... Low system pressure.

..... Blocked condenser fins.

..... Blocked evaporator fins.

..... Vacuum system leak.

..... Vacuum motors inoperative.

..... Control cables improperly adjusted.

..... Restricted air inlet.

..... Mode doors binding.

..... Blower motor inoperative.

..... Temperature above system capacity.

CONDITION	POSSIBLE CAUSE
Compressor Not Working	Compressor clutch circuit open.
.....	Compressor clutch coil inoperative.
.....	Poor clutch ground connection.
.....	Fan belts loose.
.....	Thermostatic switch inoperative.
.....	Thermostatic switch not adjusted.
.....	Ambient temperature switch open.
.....	Superheat fuse blown.
Excessive Noise or Vibration	Missing or loose mounting bolts.
.....	Bad idler pulley bearings.
.....	Fan belts not tightened correctly.
.....	Compressor clutch contacting body.
.....	Excessive system pressure.
.....	Compressor oil level low.
.....	Damaged clutch bearings.
.....	Damaged reed valves.
.....	Damaged compressor.
Insufficient or No Cooling; Compressor Working	Expansion valve inoperative.
.....	Heater control valve stuck open.
.....	Low system pressure.
.....	Blocked condenser fins.
.....	Blocked evaporator fins.
.....	Vacuum system leak.
.....	Vacuum motors inoperative.
.....	Control cables improperly adjusted.
.....	Restricted air inlet.
.....	Mode doors binding.
.....	Blower motor inoperative.
.....	Temperature above system capacity.

HEATER SYSTEM TROUBLE SHOOTING

NOTE: This is GENERAL information. This article is not intended to be specific to any unique situation or individual vehicle configuration. The purpose of this Trouble Shooting information is to provide a list of common causes to problem symptoms. For model-specific Trouble Shooting, refer to DIAGNOSTIC, or TESTING articles available in the section(s) you are accessing.

BASIC HEATER SYSTEM TROUBLE SHOOTING CHART

CONDITION POSSIBLE CAUSE

Insufficient, Erratic, or No Heat Low Coolant Level

..... Incorrect thermostat.

..... Restricted coolant flow through core.

..... Heater hoses plugged.

..... Misadjusted control cable.

..... Sticking heater control valve.

..... Vacuum hose leaking.

..... Vacuum hose blocked.

..... Vacuum motors inoperative.

..... Blocked air inlet.

..... Inoperative heater blower motor.

..... Oil residue on heater core fins.

..... Dirt on heater core fins.

Too Much Heat Improperly adjusted cables.

..... Sticking heater control valve.

..... No vacuum to heater control valve.

..... Temperature door stuck open.

Air Flow Changes During Acceleration Vacuum system leak.

..... Bad check valve or reservoir.

Air From Defroster At All Times Vacuum system leak.

..... Improperly adjusted control cables.

..... Inoperative vacuum motor.

Blower Does Not Operate Correctly Blown fuse.

..... Blower motor windings open.

..... Resistors burned out.

..... Motor ground connection loose.

..... Wiring harness connections loose.

..... Blower motor switch inoperative.

..... Blower relay inoperative.

..... Fan binding or foreign object in housing.

..... Fan blades broken or bent.

CONDITION	POSSIBLE CAUSE
Insufficient, Erratic, or No Heat	Low Coolant Level
.....	Incorrect thermostat.
.....	Restricted coolant flow through core.
.....	Heater hoses plugged.
.....	Misadjusted control cable.
.....	Sticking heater control valve.
.....	Vacuum hose leaking.
.....	Vacuum hose blocked.
.....	Vacuum motors inoperative.
.....	Blocked air inlet.
.....	Inoperative heater blower motor.
.....	Oil residue on heater core fins.
.....	Dirt on heater core fins.
Too Much Heat	Improperly adjusted cables.
.....	Sticking heater control valve.
.....	No vacuum to heater control valve.
.....	Temperature door stuck open.
Air Flow Changes During Acceleration	Vacuum system leak.
.....	Bad check valve or reservoir.
Air From Defroster At All Times	Vacuum system leak.
.....	Improperly adjusted control cables.
.....	Inoperative vacuum motor.
Blower Does Not Operate Correctly	Blown fuse.
.....	Blower motor windings open.
.....	Resistors burned out.
.....	Motor ground connection loose.
.....	Wiring harness connections loose.
.....	Blower motor switch inoperative.
.....	Blower relay inoperative.
.....	Fan binding or foreign object in housing.
.....	Fan blades broken or bent.

BRAKES

BRAKE SYSTEM TROUBLE SHOOTING

BRAKE SYSTEM TROUBLE SHOOTING CHART

CONDITION & POSSIBLE CAUSE CORRECTION

Brakes Pull Left or Right

Incorrect tire pressure Inflate tires to proper pressure

Front end out of alignment See WHEEL ALIGNMENT

Mismatched tires Check tires sizes

Restricted brake lines or hoses Check hose routing

Loose or malfunctioning caliper See DISC BRAKES or BRAKE SYSTEM

Bent shoe or oily linings See DRUM BRAKES or BRAKE SYSTEM

Malfunctioning rear brakes See DRUM, DISC BRAKES or BRAKE SYSTEM

Loose suspension parts See SUSPENSION

Noises Without Brakes Applied

Front linings worn out Replace linings

Dust or oil on drums or rotors See DRUM, DISC BRAKES or BRAKE SYSTEM

Noises With Brakes Applied

Insulator on outboard shoe damaged See DISC BRAKES or BRAKE SYSTEM

Incorrect pads or linings Replace pads or linings

Brake Rough, Chatters or Pulsates

Excessive lateral runout Check rotor runout

Parallelism not to specifications Reface or replace rotor

Wheel bearings not adjusted See SUSPENSION

Rear drums out-of-round Reface or replace drums

Disc pad reversed, steel against rotor Remove and reinstall pad

Excessive Pedal Effort

Malfunctioning power unit See POWER BRAKES or BRAKE SYSTEM

Partial system failure Check fluid and pipes

Worn disc pad or lining Replace pad or lining

Caliper piston stuck or sluggish See DISC BRAKES or BRAKE SYSTEM

Master cylinder piston stuck See MASTER CYLINDERS or BRAKE SYSTEM

Brake fade due to incorrect pads for linings Replace pads or linings

Linings or pads glazed Replace pads or linings

Worn drums Reface or replace drums

Excessive Pedal Travel

Partial brake system failure Check fluid and pipes

Insufficient fluid in master cylinder See MASTER CYLINDERS or BRAKE SYSTEM

Air trapped in system See BRAKE BLEEDING or BRAKE SYSTEM

Rear brakes not adjusted See Adjustments in DRUM BRAKES or BRAKE SYSTEM

Bent shoe or lining See DRUM BRAKES or BRAKE SYSTEM

Plugged master cylinder cap See MASTER CYLINDERS or BRAKE SYSTEM

Improper brake fluid Replace brake fluid

Pedal Travel Decreasing

Compensating port plugged See MASTER CYLINDERS or BRAKE SYSTEM

Swollen cup in master cylinder See MASTER CYLINDERS or BRAKE SYSTEM

Master cylinder piston not returning See MASTER CYLINDERS or BRAKE SYSTEM

Weak shoe retracting springs See DRUM BRAKES BRAKE SYSTEM

Wheel cylinder piston sticking See DRUM BRAKES or BRAKE SYSTEM

Dragging Brakes

Master cylinder pistons not returning See MASTER CYLINDERS BRAKE SYSTEM

Restricted brake lines or hoses Check line routing

Incorrect parking brake adjustment See DRUM BRAKES BRAKE SYSTEM

Parking Brake cables frozen See DRUM BRAKES BRAKE SYSTEM

Incorrect installation of inboard disc pad Remove and replace correctly

Power booster output rod too long See POWER BRAKE UNITS BRAKE SYSTEM

Brake pedal not returning freely See DISC, DRUM BRAKES BRAKE SYSTEM

Brakes Grab or Uneven Braking Action

Malfunction of combination valve See CONTROL VALVE or BRAKE SYSTEM

Malfunction of power brake unit See POWER BRAKE UNITS or BRAKE SYSTEM

Binding brake pedal See DISC, DRUM BRAKES or BRAKE SYSTEM

Pulsation or Roughness

Uneven pad wear caused by caliper See DISC BRAKES or BRAKE SYSTEM

Uneven rotor wear See DISC BRAKES or BRAKE SYSTEM

Drums out-of-round Reface or replace drums

CONDITION & POSSIBLE CAUSE	CORRECTION
Brakes Pull Left or Right
Incorrect tire pressure	Inflate tires to proper pressure
Front end out of alignment	See WHEEL ALIGNMENT
Mismatched tires	Check tires sizes
Restricted brake lines or hoses	Check hose routing
Loose or malfunctioning caliper	See DISC BRAKES or BRAKE SYSTEM
Bent shoe or oily linings	See DRUM BRAKES or BRAKE SYSTEM
Malfunctioning rear brakes	See DRUM, DISC BRAKES or BRAKE SYSTEM
Loose suspension parts	See SUSPENSION
Noises Without Brakes Applied
Front linings worn out	Replace linings
Dust or oil on drums or rotors	See DRUM, DISC BRAKES or BRAKE SYSTEM
Noises With Brakes Applied
Insulator on outboard shoe damaged	See DISC BRAKES or BRAKE SYSTEM
Incorrect pads or linings	Replace pads or linings
Brake Rough, Chatters or Pulsates
Excessive lateral runout	Check rotor runout
Parallelism not to specifications	Reface or replace rotor
Wheel bearings not adjusted	See SUSPENSION
Rear drums out-of-round	Reface or replace drums
Disc pad reversed, steel against rotor	Remove and reinstall pad
Excessive Pedal Effort
Malfunctioning power unit	See POWER BRAKES or BRAKE SYSTEM
Partial system failure	Check fluid and pipes
Worn disc pad or lining	Replace pad or lining
Caliper piston stuck or sluggish	See DISC BRAKES or BRAKE SYSTEM
Master cylinder piston stuck	See MASTER CYLINDERS or BRAKE SYSTEM
Brake fade due to incorrect pads for linings	Replace pads or linings
Linings or pads glazed	Replace pads or linings
Worn drums	Reface or replace drums
Excessive Pedal Travel
Partial brake system failure	Check fluid and pipes
Insufficient fluid in master cylinder	See MASTER CYLINDERS or BRAKE SYSTEM
Air trapped in system	See BRAKE BLEEDING or BRAKE SYSTEM
Rear brakes not adjusted	See Adjustments in DRUM BRAKES or BRAKE SYSTEM
Bent shoe or lining	See DRUM BRAKES or BRAKE SYSTEM
Plugged master cylinder cap	See MASTER CYLINDERS or BRAKE SYSTEM
Improper brake fluid	Replace brake fluid
Pedal Travel Decreasing
Compensating port plugged	See MASTER CYLINDERS or BRAKE SYSTEM
Swollen cup in master cylinder	See MASTER CYLINDERS or BRAKE SYSTEM
Master cylinder piston not returning	See MASTER CYLINDERS or BRAKE SYSTEM
Weak shoe retracting springs	See DRUM BRAKES BRAKE SYSTEM
Wheel cylinder piston sticking	See DRUM BRAKES or BRAKE SYSTEM
Dragging Brakes
Master cylinder pistons not returning	See MASTER CYLINDERS BRAKE SYSTEM
Restricted brake lines or hoses	Check line routing
Incorrect parking brake adjustment	See DRUM BRAKES BRAKE SYSTEM
Parking Brake cables frozen	See DRUM BRAKES BRAKE SYSTEM
Incorrect installation of inboard disc pad	Remove and replace correctly
Power booster output rod too long	See POWER BRAKE UNITS BRAKE SYSTEM
Brake pedal not returning freely	See DISC, DRUM BRAKES BRAKE SYSTEM
Brakes Grab or Uneven Braking Action
Malfunction of combination valve	See CONTROL VALVE or BRAKE SYSTEM
Malfunction of power brake unit	See POWER BRAKE UNITS or BRAKE SYSTEM
Binding brake pedal	See DISC, DRUM BRAKES or BRAKE SYSTEM
Pulsation or Roughness
Uneven pad wear caused by caliper	See DISC BRAKES or BRAKE SYSTEM
Uneven rotor wear	See DISC BRAKES or BRAKE SYSTEM
Drums out-of-round	Reface or replace drums

ENGINE MECHANICAL

COOLING SYSTEM TROUBLE SHOOTING

COOLING SYSTEM TROUBLE SHOOTING

CONDITION & POSSIBLE CAUSE CORRECTION

Overheating

Coolant Leak Fill/Pressure Test System

A/C Condenser Fins Clogged Remove/Clean Condenser

Radiator Fins Clogged Remove/Clean Radiator

Thermostat Stuck Closed Replace Thermostat

Clogged Cooling System Passages Clean/Flush Cooling System

Water Pump Malfunction Replace Water Pump

Fan Clutch Malfunction Replace Fan Clutch

Retarded Ignition Timing Reset Ignition Timing

Cooling Fan Malfunction Test Cooling Fan/Circuit

Cooling Fan Motor Malfunction Test Fan Motor

Cooling Fan Relay Malfunction Test Fan Relay

Faulty Radiator Cap Replace Radiator Cap

Broken/Slipping Fan Belt Replace Fan Belt

Restricted Exhaust Repair Exhaust System

Corrosion

Impurities In Coolant Clean/Flush System

Coolant Leakage

Damaged hose Replace Hose

Leaky Water Pump Replace Water Pump

Damaged Radiator Seam Replace/Repair Radiator

Leaky Thermostat Cover Replace Thermostat Cover

Cylinder Head Problem Check Head/Head Gasket

Leaky Freeze Plugs Replace Freeze Plugs

Recovery System Inoperative

Loose and/or Defective Radiator Cap Replace Radiator Cap

Overflow Tube Clogged and/or Leaking Repair Tube

Recovery Bottle Vent Restricted Clean Vent

No Heater Core Flow

Collapsed Heater Hose Replace Heater Hose

Plugged Heater Core Clean/Replace Heater Core

Faulty Heater Valve Replace Heater Valve

CONDITION & POSSIBLE CAUSE	CORRECTION
Overheating
Coolant Leak	Fill/Pressure Test System
A/C Condenser Fins Clogged	Remove/Clean Condenser
Radiator Fins Clogged	Remove/Clean Radiator
Thermostat Stuck Closed	Replace Thermostat
Clogged Cooling System Passages	Clean/Flush Cooling System
Water Pump Malfunction	Replace Water Pump
Fan Clutch Malfunction	Replace Fan Clutch
Retarded Ignition Timing	Reset Ignition Timing
Cooling Fan Malfunction	Test Cooling Fan/Circuit
Cooling Fan Motor Malfunction	Test Fan Motor
Cooling Fan Relay Malfunction	Test Fan Relay
Faulty Radiator Cap	Replace Radiator Cap
Broken/Slipping Fan Belt	Replace Fan Belt
Restricted Exhaust	Repair Exhaust System
Corrosion
Impurities In Coolant	Clean/Flush System
Coolant Leakage
Damaged hose	Replace Hose
Leaky Water Pump	Replace Water Pump
Damaged Radiator Seam	Replace/Repair Radiator
Leaky Thermostat Cover	Replace Thermostat Cover
Cylinder Head Problem	Check Head/Head Gasket
Leaky Freeze Plugs	Replace Freeze Plugs
Recovery System Inoperative
Loose and/or Defective Radiator Cap	Replace Radiator Cap
Overflow Tube Clogged and/or Leaking	Repair Tube
Recovery Bottle Vent Restricted	Clean Vent
No Heater Core Flow
Collapsed Heater Hose	Replace Heater Hose
Plugged Heater Core	Clean/Replace Heater Core
Faulty Heater Valve	Replace Heater Valve

GASOLINE ENGINE - MECHANICAL TROUBLE SHOOTING

BASIC GASOLINE ENGINE - MECHANICAL TROUBLE SHOOTING CHART

CONDITION & POSSIBLE CAUSE CORRECTION

Engine Lopes At Idle

Intake manifold-to-head leaks Replace manifold gasket, See ENGINES

Blown head gasket Replace head gasket, See ENGINES

Worn timing gears, chain or sprocket Replace gears, chain or sprocket

Worn camshaft lobes Replace camshaft, See ENGINES

Overheated engine Check cooling system, See COOLING

Blocked crankcase vent valve Remove restriction

Leaking EGR valve Repair leak and/or replace valve

Faulty fuel pump Replace fuel pump

Engine Has Low Power

Leaking fuel pump Repair leak and/or replace fuel pump

Excessive piston-to-bore clearance Install larger pistons, See ENGINES

Sticking valves or weak valve springs Check valve train components, See ENGINES

Incorrect valve timing Reset valve timing, See ENGINES

Worn camshaft lobes Replace camshaft, See ENGINES

Blown head gasket Replace head gasket. See ENGINES.

Clutch slipping Adjust pedal and/or replace components, See ENGINES

Engine overheating Check cooling system, See COOLING

Auto. Trans. pressure regulator valve faulty Replace pressure regulator valve

Auto. Trans. fluid level too low Add fluid as necessary

Improper vacuum diverter valve operation Replace vacuum diverter valve

Vacuum leaks Inspect vacuum system and repair as required

Leaking piston rings Replace piston rings, See ENGINES

Faulty High Speed Operation

Low fuel pump volume Replace fuel pump

Leaking valves or worn Replace valves and/or springs, See ENGINES

Incorrect valve timing Reset valve timing,See ENGINES

Intake manifold restricted Remove restriction

Worn distributor shaft Replace distributor

Faulty Acceleration

Improper fuel pump stroke Remove pump and reset pump stroke

Incorrect ignition timing Reset ignition timing, See TUNE-UP

Leaking valves Replace valves, See ENGINES

Worn fuel pump diaphragm or piston Replace diaphragm or piston

Intake Backfire

Improper ignition timing Reset ignition timing, See TUNE-UP

Faulty accelerator pump discharge Replace accelerator pump

Improper choke operation Check choke and adjust as required

Defective EGR valve Replace EGR valve

Fuel mixture too lean Reset air/fuel mixture, See TUNE-UP

Choke valve initial clearance too large Reset choke valve initial clearance

Exhaust Backfire

Vacuum leak Inspect and repair vacuum system

Faulty vacuum diverter valve Replace vacuum diverter valve

Faulty choke operation Check choke and adjust as required

Exhaust system leak repair exhaust system leak

Engine Detonation

Ignition timing too far advanced Reset ignition timing, See TUNE-UP

Faulty ignition system Check ignition timing, See TUNE-UP

Spark plugs loose or faulty Retighten or replace plugs

Fuel delivery system clogged Inspect lines, pump and filter for clog

EGR valve inoperative Replace EGR valve

PCV system inoperative Inspect and/or replace hoses or valve

Vacuum leaks Check vacuum system and repair leaks

Excessive combustion chamber deposits Remove built-up deposits

Leaking, sticking or broken valves Inspect and/or replace valves

External Oil Leakage

Fuel pump improperly seated or worn gasket Remove pump, replace gasket and seat properly

Oil pan gasket broken or pan bent Straighten pan and replace gasket

Timing chain cover gasket broken Replace timing chain cover gasket

Rear main oil seal worn Replace rear main oil seal

Oil pan drain plug not seated properly Remove and reinstall drain plug

Camshaft bearing drain hole blocked Remove restriction

Oil pressure sending switch leaking Remove and reinstall sending switch

Excessive Oil Consumption

Worn valve stems or guides Replace stems or guides, See ENGINES

Valve "O" ring seals damaged Replace "O" ring seals, See ENGINES

Plugged oil drain back holes Remove restrictions

Improper PCV valve operation Replace PCV valve

Engine oil level too high Remove excess oil

Engine oil too thin Replace thicker oil

Valve stem oil deflectors damaged Replace oil deflectors

Incorrect piston rings Replace piston rings, See ENGINES

Piston ring gaps not staggered Reinstall piston rings, See ENGINES

Insufficient piston ring tension Replace rings, See ENGINES

Piston ring grooves or oil return slots clogged Replace piston rings, See ENGINES

Piston rings sticking in grooves Replace piston rings, See ENGINES

Piston ring grooves excessively worn Replace piston and rings, See ENGINES

Compression rings installed upside down Replace compression rings correctly, See ENGINES

Worn or scored cylinder walls Rebore cylinders or replace block

Mismatched oil ring expander and rail Replace oil ring expander and rail, See ENGINES

Intake gasket dowels too long Replace intake gasket dowels

Excessive main or connecting rod bearing clearance Replace main or connecting rod bearings, See ENGINES

No Oil Pressure

Low oil level Add oil to proper level

Oil pressure sender or gauge broken Replace sender or gauge

Oil pump malfunction Remove and overhaul oil pump, See ENGINES

Oil pressure relief valve sticking Remove and reinstall valve

Oil pump passages blocked Overhaul oil pump, See ENGINES

Oil pickup screen or tube blocked Remove restriction

Loose oil inlet tube Tighten oil inlet tube

Loose camshaft bearings Replace camshaft bearings, See ENGINES

Internal leakage at oil passages Replace block or cylinder head

Low Oil Pressure

Low engine oil level Add oil to proper level

Engine oil too thin Remove and replace with thicker oil

Excessive oil pump clearance Reduce oil pump clearance, See ENGINES

Oil pickup tube or screen blocked Remove restrictions

Main, rod or cam bearing clearance excessive Replace bearing to reduce clearance, See ENGINES

High Oil Pressure

Improper grade of oil Replace with proper oil

Oil pressure relief valve stuck closed Eliminate binding

Oil pressure sender or gauge faulty Replace sender or gauge

Noisy Main Bearings

Inadequate oil supply Check oil delivery to main bearings

Excessive main bearing clearance Replace main bearings, See ENGINES

Excessive crankshaft end play Replace crankshaft, See ENGINES

Loose flywheel or torque converter Tighten attaching bolts

Loose or damaged vibration damper Tighten or replace vibration damper

Crankshaft journals out-of-round Re-grind crankshaft journals

Excessive belt tension Loosen belt tension

Noisy Connecting Rods

Excessive bearing clearance or missing bearing Replace bearing, See ENGINES

Crankshaft rod journal out-of-round Re-grind crankshaft journal

Misaligned connecting rod or cap Remove rod or cap and realign

Incorrectly tightened rod bolts Remove and re-tighten rod bolts

Noisy Pistons and Rings

Excessive piston-to-bore clearance Install larger pistons, See ENGINES

Bore tapered or out-of-round Rebore block

Piston ring broken Replace piston rings, See ENGINES

Piston pin loose or seized Replace piston pin, See ENGINES

Connecting rods misaligned Realign connecting rods

Ring side clearance too loose or tight Replace with larger or smaller rings

Carbon build-up on piston Remove carbon

Noisy Valve Train

Worn or bent push rods Replace push rods, See ENGINES

Worn rocker arms or bridged pivots Replace push rods, See ENGINES

Dirt or chips in valve lifters Remove lifters and remove dirt/chips

Excessive valve lifter leak-down Replace valve lifters, See ENGINES

Valve lifter face worn Replace valve lifters, See ENGINES

Broken or cocked valve springs Replace or reposition springs

Too much valve stem-to-guide clearance Replace valve guides, See ENGINES

Valve bent Replace valve, See ENGINES

Loose rocker arms Retighten rocker arms, See ENGINES

Excessive valve seat run-out Reface valve seats, See ENGINES

Missing valve lock Install new valve lock

Excessively worn camshaft lobes Replace camshaft, See ENGINES

Plugged valve lifter oil holes Eliminate restriction or replace lifter

Faulty valve lifter check ball Replace lifter check ball, See ENGINES

Rocker arm nut installed upside down Remove and reinstall correctly

Valve lifter incorrect for engine Remove and replace valve lifters

Faulty push rod seat or lifter plunger Replace plunger or push rod

Noisy Valves

Improper valve lash Re-adjust valve lash, See ENGINES

Worn or dirty valve lifters Clean and/or replace lifters

Worn valve guides Replace valve guides, See ENGINES

Excessive valve seat or face run-out Reface seats or valve face

Worn camshaft lobes Replace camshaft, See ENGINES

Loose rocker arm studs Re-tighten rocker arm studs, See ENGINES

Bent push rods Replace push rods, See ENGINES

Broken valve springs Replace valve springs, See ENGINES

Burned,Sticking or Broken Valves

Weak valve springs or warped valves Replace valves and/or springs, See ENGINES

Improper lifter clearance Re-adjust clearance or replace lifters

Worn guides or improper guide clearance Replace valve guides, See ENGINES

Out-of-round valve seats or improper seat width Re-grind valve seats

Gum deposits on valve stems, seats or guide Remove deposits

Improper spark timing Re-adjust spark timing

Broken Pistons/Rings

Undersize pistons Replace with larger pistons, See ENGINES

Wrong piston rings Replace with correct rings, See ENGINES

Out-of-round cylinder bore Re-bore cylinder bore

Improper connecting rod alignment Remove and realign connecting rods

Excessively worn ring grooves Replace pistons, See ENGINES

Improperly assembled piston pins Re-assemble pin-to-piston, See ENGINES

Insufficient ring gap clearance Install new rings, See ENGINES

Engine overheating Check cooling system

Incorrect ignition timing Re-adjust ignition timing, See TUNE-UP

Excessive Exhaust Noise

Leaks at manifold to head, or to pipe Replace manifold or pipe gasket

Exhaust manifold cracked or broken Replace exhaust manifold, See ENGINES

CONDITION & POSSIBLE CAUSE	CORRECTION
Engine Lopes At Idle
Intake manifold-to-head leaks	Replace manifold gasket, See ENGINES
Blown head gasket	Replace head gasket, See ENGINES
Worn timing gears, chain or sprocket	Replace gears, chain or sprocket
Worn camshaft lobes	Replace camshaft, See ENGINES
Overheated engine	Check cooling system, See COOLING
Blocked crankcase vent valve	Remove restriction
Leaking EGR valve	Repair leak and/or replace valve
Faulty fuel pump	Replace fuel pump
Engine Has Low Power
Leaking fuel pump	Repair leak and/or replace fuel pump
Excessive piston-to-bore clearance	Install larger pistons, See ENGINES
Sticking valves or weak valve springs	Check valve train components, See ENGINES
Incorrect valve timing	Reset valve timing, See ENGINES
Worn camshaft lobes	Replace camshaft, See ENGINES
Blown head gasket	Replace head gasket. See ENGINES.
Clutch slipping	Adjust pedal and/or replace components, See ENGINES
Engine overheating	Check cooling system, See COOLING
Auto. Trans. pressure regulator valve faulty	Replace pressure regulator valve
Auto. Trans. fluid level too low	Add fluid as necessary
Improper vacuum diverter valve operation	Replace vacuum diverter valve
Vacuum leaks	Inspect vacuum system and repair as required
Leaking piston rings	Replace piston rings, See ENGINES
Faulty High Speed Operation
Low fuel pump volume	Replace fuel pump
Leaking valves or worn	Replace valves and/or springs, See ENGINES
Incorrect valve timing	Reset valve timing,See ENGINES
Intake manifold restricted	Remove restriction
Worn distributor shaft	Replace distributor
Faulty Acceleration
Improper fuel pump stroke	Remove pump and reset pump stroke
Incorrect ignition timing	Reset ignition timing, See TUNE-UP
Leaking valves	Replace valves, See ENGINES
Worn fuel pump diaphragm or piston	Replace diaphragm or piston
Intake Backfire
Improper ignition timing	Reset ignition timing, See TUNE-UP
Faulty accelerator pump discharge	Replace accelerator pump
Improper choke operation	Check choke and adjust as required
Defective EGR valve	Replace EGR valve
Fuel mixture too lean	Reset air/fuel mixture, See TUNE-UP
Choke valve initial clearance too large	Reset choke valve initial clearance
Exhaust Backfire
Vacuum leak	Inspect and repair vacuum system
Faulty vacuum diverter valve	Replace vacuum diverter valve
Faulty choke operation	Check choke and adjust as required
Exhaust system leak	repair exhaust system leak
Engine Detonation
Ignition timing too far advanced	Reset ignition timing, See TUNE-UP
Faulty ignition system	Check ignition timing, See TUNE-UP
Spark plugs loose or faulty	Retighten or replace plugs
Fuel delivery system clogged	Inspect lines, pump and filter for clog
EGR valve inoperative	Replace EGR valve
PCV system inoperative	Inspect and/or replace hoses or valve
Vacuum leaks	Check vacuum system and repair leaks
Excessive combustion chamber deposits	Remove built-up deposits
Leaking, sticking or broken valves	Inspect and/or replace valves
External Oil Leakage
Fuel pump improperly seated or worn gasket	Remove pump, replace gasket and seat properly
Oil pan gasket broken or pan bent	Straighten pan and replace gasket
Timing chain cover gasket broken	Replace timing chain cover gasket
Rear main oil seal worn	Replace rear main oil seal
Oil pan drain plug not seated properly	Remove and reinstall drain plug
Camshaft bearing drain hole blocked	Remove restriction
Oil pressure sending switch leaking	Remove and reinstall sending switch
Excessive Oil Consumption
Worn valve stems or guides	Replace stems or guides, See ENGINES
Valve "O" ring seals damaged	Replace "O" ring seals, See ENGINES
Plugged oil drain back holes	Remove restrictions
Improper PCV valve operation	Replace PCV valve
Engine oil level too high	Remove excess oil
Engine oil too thin	Replace thicker oil
Valve stem oil deflectors damaged	Replace oil deflectors
Incorrect piston rings	Replace piston rings, See ENGINES
Piston ring gaps not staggered	Reinstall piston rings, See ENGINES
Insufficient piston ring tension	Replace rings, See ENGINES
Piston ring grooves or oil return	slots clogged Replace piston rings, See ENGINES
Piston rings sticking in grooves	Replace piston rings, See ENGINES
Piston ring grooves excessively worn	Replace piston and rings, See ENGINES
Compression rings installed upside down	Replace compression rings correctly, See ENGINES
Worn or scored cylinder walls	Rebore cylinders or replace block
Mismatched oil ring expander and rail	Replace oil ring expander and rail, See ENGINES
Intake gasket dowels too long	Replace intake gasket dowels
Excessive main or connecting rod bearing clearance	Replace main or connecting rod bearings, See ENGINES
No Oil Pressure
Low oil level	Add oil to proper level
Oil pressure sender or gauge broken	Replace sender or gauge
Oil pump malfunction	Remove and overhaul oil pump, See ENGINES
Oil pressure relief valve sticking	Remove and reinstall valve
Oil pump passages blocked	Overhaul oil pump, See ENGINES
Oil pickup screen or tube blocked	Remove restriction
Loose oil inlet tube	Tighten oil inlet tube
Loose camshaft bearings	Replace camshaft bearings, See ENGINES
Internal leakage at oil passages	Replace block or cylinder head
Low Oil Pressure
Low engine oil level	Add oil to proper level
Engine oil too thin	Remove and replace with thicker oil
Excessive oil pump clearance	Reduce oil pump clearance, See ENGINES
Oil pickup tube or screen blocked	Remove restrictions
Main, rod or cam bearing clearance excessive	Replace bearing to reduce clearance, See ENGINES
High Oil Pressure
Improper grade of oil	Replace with proper oil
Oil pressure relief valve stuck closed	Eliminate binding
Oil pressure sender or gauge faulty	Replace sender or gauge
Noisy Main Bearings
Inadequate oil supply	Check oil delivery to main bearings
Excessive main bearing clearance	Replace main bearings, See ENGINES
Excessive crankshaft end play	Replace crankshaft, See ENGINES
Loose flywheel or torque converter	Tighten attaching bolts
Loose or damaged vibration damper	Tighten or replace vibration damper
Crankshaft journals out-of-round	Re-grind crankshaft journals
Excessive belt tension	Loosen belt tension
Noisy Connecting Rods
Excessive bearing clearance or missing bearing	Replace bearing, See ENGINES
Crankshaft rod journal out-of-round	Re-grind crankshaft journal
Misaligned connecting rod or cap	Remove rod or cap and realign
Incorrectly tightened rod bolts	Remove and re-tighten rod bolts
Noisy Pistons and Rings
Excessive piston-to-bore clearance	Install larger pistons, See ENGINES
Bore tapered or out-of-round	Rebore block
Piston ring broken	Replace piston rings, See ENGINES
Piston pin loose or seized	Replace piston pin, See ENGINES
Connecting rods misaligned	Realign connecting rods
Ring side clearance too loose or tight	Replace with larger or smaller rings
Carbon build-up on piston	Remove carbon
Noisy Valve Train
Worn or bent push rods	Replace push rods, See ENGINES
Worn rocker arms or bridged pivots	Replace push rods, See ENGINES
Dirt or chips in valve lifters	Remove lifters and remove dirt/chips
Excessive valve lifter leak-down	Replace valve lifters, See ENGINES
Valve lifter face worn	Replace valve lifters, See ENGINES
Broken or cocked valve springs	Replace or reposition springs
Too much valve stem-to-guide clearance	Replace valve guides, See ENGINES
Valve bent	Replace valve, See ENGINES
Loose rocker arms	Retighten rocker arms, See ENGINES
Excessive valve seat run-out	Reface valve seats, See ENGINES
Missing valve lock	Install new valve lock
Excessively worn camshaft lobes	Replace camshaft, See ENGINES
Plugged valve lifter oil holes	Eliminate restriction or replace lifter
Faulty valve lifter check ball	Replace lifter check ball, See ENGINES
Rocker arm nut installed upside down	Remove and reinstall correctly
Valve lifter incorrect for engine	Remove and replace valve lifters
Faulty push rod seat or lifter plunger	Replace plunger or push rod
Noisy Valves
Improper valve lash	Re-adjust valve lash, See ENGINES
Worn or dirty valve lifters	Clean and/or replace lifters
Worn valve guides	Replace valve guides, See ENGINES
Excessive valve seat or face run-out	Reface seats or valve face
Worn camshaft lobes	Replace camshaft, See ENGINES
Loose rocker arm studs	Re-tighten rocker arm studs, See ENGINES
Bent push rods	Replace push rods, See ENGINES
Broken valve springs	Replace valve springs, See ENGINES
Burned,Sticking or Broken Valves
Weak valve springs or warped valves	Replace valves and/or springs, See ENGINES
Improper lifter clearance	Re-adjust clearance or replace lifters
Worn guides or improper guide clearance	Replace valve guides, See ENGINES
Out-of-round valve seats or improper seat width	Re-grind valve seats
Gum deposits on valve stems, seats or guide	Remove deposits
Improper spark timing	Re-adjust spark timing
Broken Pistons/Rings
Undersize pistons	Replace with larger pistons, See ENGINES
Wrong piston rings	Replace with correct rings, See ENGINES
Out-of-round cylinder bore	Re-bore cylinder bore
Improper connecting rod alignment	Remove and realign connecting rods
Excessively worn ring grooves	Replace pistons, See ENGINES
Improperly assembled piston pins	Re-assemble pin-to-piston, See ENGINES
Insufficient ring gap clearance	Install new rings, See ENGINES
Engine overheating	Check cooling system
Incorrect ignition timing	Re-adjust ignition timing, See TUNE-UP
Excessive Exhaust Noise
Leaks at manifold to head, or to pipe	Replace manifold or pipe gasket
Exhaust manifold cracked or broken	Replace exhaust manifold, See ENGINES

ENGINE PERFORMANCE

CARBURETOR TROUBLE SHOOTING:

BASIC COLD START SYMPTOMS TROUBLE SHOOTING CHART

CONDITION & POSSIBLE CAUSE CORRECTION

Engine Won't Start

Choke not closing Check choke operation, see FUEL SYSTEMS

Choke linkage bent Check linkage, see FUEL SYSTEM

Engine Starts, Then Dies

Choke vacuum kick setting too wide Check setting and adjust see, FUEL SYSTEMS

Fast idle RPM too low Reset RPM to specification, see TUNE-UP

Fast idle cam index incorrect Reset fast idle cam index, see FUEL SYSTEMS

Vacuum leak Inspect vacuum system for leaks

Low fuel pump outlet Repair or replace pump, see FUEL SYSTEMS

Low carburetor fuel level Check float setting see FUEL SYSTEM

Engine Quits Under Load

Choke vacuum kick setting incorrect Reset vacuum kick setting,see FUEL SYSTEMS

Fast idle cam index incorrect Reset fast idle cam index, see FUEL SYSTEM

Incorrect hot fast idle speed RPM Reset fast idle RPM, see TUNE-UP

Engine Starts, Runs Up, Then Idles, Slowly With Black Smoke

Choke vacuum kick set too narrow Reset vacuum kick, see FUEL SYSTEMS

Fast idle cam index incorrect Reset fast idle cam index, see FUEL SYSTEMS

Hot fast idle RPM too low Reset fast idle RPM, see TUNE-UP

CONDITION & POSSIBLE CAUSE	CORRECTION
Engine Won't Start
Choke not closing	Check choke operation, see FUEL SYSTEMS
Choke linkage bent	Check linkage, see FUEL SYSTEM
Engine Starts, Then Dies
Choke vacuum kick setting too wide	Check setting and adjust see, FUEL SYSTEMS
Fast idle RPM too low	Reset RPM to specification, see TUNE-UP
Fast idle cam index incorrect	Reset fast idle cam index, see FUEL SYSTEMS
Vacuum leak	Inspect vacuum system for leaks
Low fuel pump outlet	Repair or replace pump, see FUEL SYSTEMS
Low carburetor fuel level	Check float setting see FUEL SYSTEM
Engine Quits Under Load
Choke vacuum kick setting incorrect	Reset vacuum kick setting,see FUEL SYSTEMS
Fast idle cam index incorrect	Reset fast idle cam index, see FUEL SYSTEM
Incorrect hot fast idle speed RPM	Reset fast idle RPM, see TUNE-UP
Engine Starts, Runs Up, Then Idles, Slowly With Black Smoke
Choke vacuum kick set too narrow	Reset vacuum kick, see FUEL SYSTEMS
Fast idle cam index incorrect	Reset fast idle cam index, see FUEL SYSTEMS
Hot fast idle RPM too low	Reset fast idle RPM, see TUNE-UP

BASIC HOT START SYMPTOMS TROUBLE SHOOTING CHART

CONDITION & POSSIBLE CAUSE CORRECTION

Engine Won't Start

Engine flooded Allow fuel to evaporate

CONDITION & POSSIBLE CAUSE	CORRECTION
Engine Won't Start
Engine flooded	Allow fuel to evaporate

BASIC COLD ENGINE DRIVEABILITY SYMPTOMS TROUBLE SHOOTING CHART

CONDITION & POSSIBLE CAUSE CORRECTION

Engine Stalls in Gear

Choke vacuum kick setting incorrect Reset choke vacuum kick, see FUEL SYSTEMS

Fast idle RPM incorrect Reset fast idle RPM, see TUNE-UP

Fast idle cam index incorrect Reset fast idle cam see FUEL SYSTEMS

Acceleration Sag or Stall

Defective choke control switch Replace choke control switch

Choke vacuum kick setting incorrect Reset choke vacuum kick see, FUEL SYSTEMS

Float level incorrect (too low) Adjust float level, FUEL SYSTEMS

Accelerator pump defective Repair or replace pump see FUEL SYSTEMS

Secondary throttles not closed Inspect lockout adjustment, see FUEL SYSTEMS

Sag or Stall After Warmup

Defective choke control switch Replace choke control switch, see FUEL SYSTEMS

Defective accelerator pump Replace pump, see FUEL SYSTEMS

Float level incorrect (too low) Adjust float level, see FUEL SYSTEMS

Backfiring & Black Smoke

Plugged heat crossover system Remove restriction

CONDITION & POSSIBLE CAUSE	CORRECTION
Engine Stalls in Gear
Choke vacuum kick setting incorrect	Reset choke vacuum kick, see FUEL SYSTEMS
Fast idle RPM incorrect	Reset fast idle RPM, see TUNE-UP
Fast idle cam index incorrect	Reset fast idle cam see FUEL SYSTEMS
Acceleration Sag or Stall
Defective choke control switch	Replace choke control switch
Choke vacuum kick setting incorrect	Reset choke vacuum kick see, FUEL SYSTEMS
Float level incorrect (too low)	Adjust float level, FUEL SYSTEMS
Accelerator pump defective	Repair or replace pump see FUEL SYSTEMS
Secondary throttles not closed	Inspect lockout adjustment, see FUEL SYSTEMS
Sag or Stall After Warmup
Defective choke control switch	Replace choke control switch, see FUEL SYSTEMS
Defective accelerator pump	Replace pump, see FUEL SYSTEMS
Float level incorrect (too low)	Adjust float level, see FUEL SYSTEMS
Backfiring & Black Smoke
Plugged heat crossover system	Remove restriction

BASIC WARM ENGINE DRIVEABILITY SYMPTOMS TROUBLE SHOOTING CHART

CONDITION & POSSIBLE CAUSE CORRECTION

Hesitation With Small Amount of Gas Pedal Movement

Vacuum leak Inspect vacuum lines

Accelerator pump weak or inoperable Replace pump, see FUEL SYSTEMS

Float level setting too low Reset float level, see,FUEL SYSTEMS

Metering rods sticking or binding Inspect and/or replace rods, see FUEL SYSTEMS

Carburetor idle or transfer system plugged Inspect system and remove restriction

Frozen or binding heated air inlet Inspect heated air door for binding

Hesitation With Heavy Gas Pedal Movement

Defective accelerator pump Replace pump, see FUEL SYSTEMS

Metering rod carrier sticking or binding Remove restriction

Large vacuum leak Inspect vacuum system and repair leak

Float level setting too low Reset float level, see FUEL SYSTEMS

Defective fuel pump, lines or filter Inspect pump, lines and filter

Air door setting incorrect Adjust air door setting, see FUEL

CONDITION & POSSIBLE CAUSE	CORRECTION
Hesitation With Small Amount of Gas Pedal Movement
Vacuum leak	Inspect vacuum lines
Accelerator pump weak or inoperable	Replace pump, see FUEL SYSTEMS
Float level setting too low	Reset float level, see,FUEL SYSTEMS
Metering rods sticking or binding	Inspect and/or replace rods, see FUEL SYSTEMS
Carburetor idle or transfer system plugged	Inspect system and remove restriction
Frozen or binding heated air inlet	Inspect heated air door for binding
Hesitation With Heavy Gas Pedal Movement
Defective accelerator pump	Replace pump, see FUEL SYSTEMS
Metering rod carrier sticking or binding	Remove restriction
Large vacuum leak	Inspect vacuum system and repair leak
Float level setting too low	Reset float level, see FUEL SYSTEMS
Defective fuel pump, lines or filter	Inspect pump, lines and filter
Air door setting incorrect	Adjust air door setting, see FUEL

DIESEL ENGINE TROUBLE SHOOTING

NOTE: Diesel engines mechanical diagnosis is the same as gasoline engines for items such as noisy valves, bearings, pistons, etc. The following trouble shooting covers only items pertaining to diesel engines.

BASIC DIESEL ENGINE TROUBLE SHOOTING CHART

CONDITION & POSSIBLE CAUSE CORRECTION

Engine Won't Crank

Bad battery connections or dead batteries Check connections and/or replace batteries

Bad starter connections or bad starter Check connections and/or replace starter

Engine Cranks Slowly, Won't Start

Bad battery connections or dead batteries Check connections and/or replace batteries

Engine oil too heavy Replace engine oil

Engine Cranks Normally, But Will Not Start

Glow plugs not functioning Check glow plug system, see FUEL SYSTEMS

Glow plug control not functioning Check controller, see FUEL SYSTEMS

Fuel not injected into cylinders Check fuel injectors, see FUEL SYSTEMS

No fuel to injection pump Check fuel delivery system

Fuel filter blocked Replace fuel filter

Fuel tank filter blocked Replace fuel tank filter

Fuel pump not operating Check pump operation and/or replace pump

Fuel return system blocked Inspect system and remove restriction

No voltage to fuel solenoid Check solenoid and connections

Incorrect or contaminated fuel Replace fuel

Incorrect injection pump timing Re-adjust pump timing, see FUEL SYSTEMS

Low compression Check valves, pistons, rings, see ENGINES

Injection pump malfunction Inspect and/or replace injection pump

Engine Starts, Won't Idle

Incorrect slow idle adjustment Reset idle adjustment, see TUNE-UP

Fast idle solenoid malfunctioning Check solenoid and connections

Fuel return system blocked Check system and remove restrictions

Glow plugs go off too soon See glow plug diagnosis in FUEL SYSTEMS

Injection pump timing incorrect Reset pump timing, see FUEL SYSTEMS

No fuel to injection pump Check fuel delivery system

Incorrect or contaminated fuel Replace fuel

Low compression Check valves, piston, rings, see ENGINES

Injection pump malfunction Replace injection pump, see FUEL SYSTEMS

Fuel solenoid closes in RUN position Check solenoid and connections

Engines Starts/Idles Rough W/out Smoke or Noise

Incorrect slow idle adjustment Reset slow idle, see TUNE-UP

Injection line fuel leaks Check lines and connections

Fuel return system blocked Check lines and connections

Air in fuel system Bleed air from system

Incorrect or contaminated fuel Replace fuel

Injector nozzle malfunction Check nozzles, see FUEL SYSTEMS

Engines Starts and Idles Rough W/out Smoke or Noise, But Clears After Warm-Up

Injection pump timing incorrect Reset pump timing, see FUEL SYSTEMS

Engine not fully broken in Put more miles on engine

Air in system Bleed air from system

Injector nozzle malfunction Check nozzles, see FUEL SYSTEMS

Engine Idles Correctly, Misfires Above Idle

Blocked fuel filter Replace fuel filter

Injection pump timing incorrect Reset pump timing, see FUEL SYSTEMS

Incorrect or contaminated fuel Replace fuel

Engine Won't Return To Idle

Fast idle adjustment incorrect Reset fast idle, see TUNE-UP

Internal injection pump malfunction Replace injection pump, see FUEL SYSTEMS

External linkage binding Check linkage and remove binding

Fuel Leaks On Ground

Loose or broken fuel line Check lines and connections

Internal injection pump seal leak Replace injection pump, see FUEL SYSTEMS

Cylinder Knocking Noise

Injector nozzles sticking open Test injectors, see FUEL SYSTEMS

Very low nozzle opening pressure Test injectors and/or replace

Loss of Engine Power

Restricted air intake Remove restriction

EGR valve malfunction Replace EGR valve

Blocked or damaged exhaust system Remove restriction and/or replace components

Blocked fuel tank filter Replace filter

Restricted fuel filter Remove restriction and/or replace filter

Block vent in gas cap Remove restriction and/or replace cap

Tank-to-injection pump fuel supply blocked Check fuel lines and connections

Blocked fuel return system Remove restriction

Incorrect or contaminated fuel Replace fuel

Blocked injector nozzles Check nozzle for blockage, see FUEL SYSTEMS

Low compression Check valves, rings, pistons, see ENGINES

Loud Engine Noise With Black Smoke

Basic timing incorrect Reset timing, see FUEL SYSTEMS

EGR valve malfunction Replace EGR valve

Internal injection pump malfunction Replace injection pump, see FUEL SYSTEMS

Incorrect injector pump housing pressure Check pressure, see FUEL SYSTEMS

Engine Overheating

Cooling system leaks Check cooling system and repair leaks

Belt slipping or damaged Check tension and/or replace belt

Thermostat stuck closed Remove and replace thermostat, see ENGINE COOLING

Head gasket leaking Replace head gasket

Oil Light on at Idle

Low oil pump pressure Check oil pump operation, see ENGINES

Oil cooler or line restricted Remove restriction and/or replace cooler

Engine Won't Shut Off

Injector pump fuel solenoid does not return fuel valve to OFF position Remove and check solenoid and replace if needed

CONDITION & POSSIBLE CAUSE	CORRECTION
Engine Won't Crank
Bad battery connections or dead batteries	Check connections and/or replace batteries
Bad starter connections or bad starter	Check connections and/or replace starter
Engine Cranks Slowly, Won't Start
Bad battery connections or dead batteries	Check connections and/or replace batteries
Engine oil too heavy	Replace engine oil
Engine Cranks Normally, But Will Not Start
Glow plugs not functioning	Check glow plug system, see FUEL SYSTEMS
Glow plug control not functioning	Check controller, see FUEL SYSTEMS
Fuel not injected into cylinders	Check fuel injectors, see FUEL SYSTEMS
No fuel to injection pump	Check fuel delivery system
Fuel filter blocked	Replace fuel filter
Fuel tank filter blocked	Replace fuel tank filter
Fuel pump not operating	Check pump operation and/or replace pump
Fuel return system blocked	Inspect system and remove restriction
No voltage to fuel solenoid	Check solenoid and connections
Incorrect or contaminated fuel	Replace fuel
Incorrect injection pump timing	Re-adjust pump timing, see FUEL SYSTEMS
Low compression	Check valves, pistons, rings, see ENGINES
Injection pump malfunction	Inspect and/or replace injection pump
Engine Starts, Won't Idle
Incorrect slow idle adjustment	Reset idle adjustment, see TUNE-UP
Fast idle solenoid malfunctioning	Check solenoid and connections
Fuel return system blocked	Check system and remove restrictions
Glow plugs go off too soon	See glow plug diagnosis in FUEL SYSTEMS
Injection pump timing incorrect	Reset pump timing, see FUEL SYSTEMS
No fuel to injection pump	Check fuel delivery system
Incorrect or contaminated fuel	Replace fuel
Low compression	Check valves, piston, rings, see ENGINES
Injection pump malfunction	Replace injection pump, see FUEL SYSTEMS
Fuel solenoid closes in RUN position	Check solenoid and connections
Engines Starts/Idles Rough W/out Smoke or Noise
Incorrect slow idle adjustment	Reset slow idle, see TUNE-UP
Injection line fuel leaks	Check lines and connections
Fuel return system blocked	Check lines and connections
Air in fuel system	Bleed air from system
Incorrect or contaminated fuel	Replace fuel
Injector nozzle malfunction	Check nozzles, see FUEL SYSTEMS
Engines Starts and Idles Rough W/out Smoke or Noise, But Clears After Warm-Up
Injection pump timing incorrect	Reset pump timing, see FUEL SYSTEMS
Engine not fully broken in	Put more miles on engine
Air in system	Bleed air from system
Injector nozzle malfunction	Check nozzles, see FUEL SYSTEMS
Engine Idles Correctly, Misfires Above Idle
Blocked fuel filter	Replace fuel filter
Injection pump timing incorrect	Reset pump timing, see FUEL SYSTEMS
Incorrect or contaminated fuel	Replace fuel
Engine Won't Return To Idle
Fast idle adjustment incorrect	Reset fast idle, see TUNE-UP
Internal injection pump malfunction	Replace injection pump, see FUEL SYSTEMS
External linkage binding	Check linkage and remove binding
Fuel Leaks On Ground
Loose or broken fuel line	Check lines and connections
Internal injection pump seal leak	Replace injection pump, see FUEL SYSTEMS
Cylinder Knocking Noise
Injector nozzles sticking open	Test injectors, see FUEL SYSTEMS
Very low nozzle opening pressure	Test injectors and/or replace
Loss of Engine Power
Restricted air intake	Remove restriction
EGR valve malfunction	Replace EGR valve
Blocked or damaged exhaust system	Remove restriction and/or replace components
Blocked fuel tank filter	Replace filter
Restricted fuel filter	Remove restriction and/or replace filter
Block vent in gas cap	Remove restriction and/or replace cap
Tank-to-injection pump fuel supply blocked	Check fuel lines and connections
Blocked fuel return system	Remove restriction
Incorrect or contaminated fuel	Replace fuel
Blocked injector nozzles	Check nozzle for blockage, see FUEL SYSTEMS
Low compression	Check valves, rings, pistons, see ENGINES
Loud Engine Noise With Black Smoke
Basic timing incorrect	Reset timing, see FUEL SYSTEMS
EGR valve malfunction	Replace EGR valve
Internal injection pump malfunction	Replace injection pump, see FUEL SYSTEMS
Incorrect injector pump housing pressure	Check pressure, see FUEL SYSTEMS
Engine Overheating
Cooling system leaks	Check cooling system and repair leaks
Belt slipping or damaged	Check tension and/or replace belt
Thermostat stuck closed	Remove and replace thermostat, see ENGINE COOLING
Head gasket leaking	Replace head gasket
Oil Light on at Idle
Low oil pump pressure	Check oil pump operation, see ENGINES
Oil cooler or line restricted	Remove restriction and/or replace cooler
Engine Won't Shut Off
Injector pump fuel solenoid does not return fuel valve to OFF position	Remove and check solenoid and replace if needed

VACUUM PUMP DIAGNOSIS

CONDITION & POSSIBLE CAUSE CORRECTION

Excessive Noise

Loose pump-to-drive assembly screws Tighten screws

Loose tube on pump assembly Tighten tube

Valves not functioning properly Replace valves

Oil Leakage

Loose end plug Tighten end plug

Bad seal crimp Remove and re-crimp seal

CONDITION & POSSIBLE CAUSE	CORRECTION
Excessive Noise
Loose pump-to-drive assembly screws	Tighten screws
Loose tube on pump assembly	Tighten tube
Valves not functioning properly	Replace valves
Oil Leakage
Loose end plug	Tighten end plug
Bad seal crimp	Remove and re-crimp seal

FUEL INJECTION TROUBLE SHOOTING

BASIC FUEL INJECTION TROUBLE SHOOTING CHART

CONDITION & POSSIBLE CAUSE CORRECTION

Engine Won't Start (Cranks Normally)

Cold start valve inoperative Test valve and circuit

Poor connection;vacuum or wiring Check vacuum and electrical connections

Contaminated fuel Test fuel for water or alcohol

Defective fuel pump relay or circuit Test relay and wiring

Battery too low Charge and test battery

Low fuel pressure Test pressure regulator and fuel pump, check for restricted lines and filters

No distributor reference pulses Repair ignition system as necessary

Open coolant temperature sensor circuit Test sensor and wiring

Shorted W.O.T. switch in T.P.S. Disconnect W.O.T. switch, engine should start

Defective ECM Replace ECM

Fuel tank residual pressure valve leaks Test for fuel pressure drop after shut down

Hard Starting

Disconnected hot air tube to air cleaner Reconnect tube and test control valve

Defective Idle Air Control (IAC) valve Test valve operation and circuit

Shorted, open or misadjusted T.P.S. Test and adjust or replace T.P.S.

EGR valve open Test EGR valve and control circuit

Poor Oxygen sensor signal Test for shorted or circuit

Incorrect mixture from PCV system Test PCV for flow, check sealing of oil filter cap

Poor High Speed Operation

Low fuel pump volume Faulty pump or restricted fuel lines or filters

Poor MAP sensor signal Test MAP sensor, vacuum hose and wiring

Poor Oxygen sensor signal Test for shorted or open sensor or circuit

Open coolant temperature sensor circuit Test sensor and wiring

Faulty ignition operation Check wires for cracks or poor con- nections, test secondary voltage with oscilloscope

Contaminated fuel Test fuel for water or alcohol

Intermittent ECM ground Test ECM ground connection for resistance

Restricted air cleaner Replace air cleaner

Restricted exhaust system Test for exhaust manifold back pressure

Poor MAF sensor signal Check leakage between sensor and manifold

Poor VSS signal If tester for ALCL hook-up is available check that VSS reading matches speedometer

Ping or Knock on Acceleration

Poor Knock sensor signal Test for shorted or open sensor or circuit

Poor Baro sensor signal Test for shorted or open sensor or circuit

Improper ignition timing See VEHICLE EMISSION CONTROL LABEL (where applicable)

Check for engine overheating problems Low coolant, loose belts or electric cooling fan inoperative

CONDITION & POSSIBLE CAUSE	CORRECTION
Engine Won't Start (Cranks Normally)
Cold start valve inoperative	Test valve and circuit
Poor connection;vacuum or wiring	Check vacuum and electrical connections
Contaminated fuel	Test fuel for water or alcohol
Defective fuel pump relay or circuit	Test relay and wiring
Battery too low	Charge and test battery
Low fuel pressure	Test pressure regulator and fuel pump, check for restricted lines and filters
No distributor reference pulses	Repair ignition system as necessary
Open coolant temperature sensor circuit	Test sensor and wiring
Shorted W.O.T. switch in T.P.S.	Disconnect W.O.T. switch, engine should start
Defective ECM	Replace ECM
Fuel tank residual pressure valve leaks	Test for fuel pressure drop after shut down
Hard Starting
Disconnected hot air tube to air cleaner	Reconnect tube and test control valve
Defective Idle Air Control (IAC) valve	Test valve operation and circuit
Shorted, open or misadjusted T.P.S.	Test and adjust or replace T.P.S.
EGR valve open	Test EGR valve and control circuit
Poor Oxygen sensor signal	Test for shorted or circuit
Incorrect mixture from PCV system	Test PCV for flow, check sealing of oil filter cap
Poor High Speed Operation
Low fuel pump volume	Faulty pump or restricted fuel lines or filters
Poor MAP sensor signal	Test MAP sensor, vacuum hose and wiring
Poor Oxygen sensor signal	Test for shorted or open sensor or circuit
Open coolant temperature sensor circuit	Test sensor and wiring
Faulty ignition operation	Check wires for cracks or poor con- nections, test secondary voltage with oscilloscope
Contaminated fuel	Test fuel for water or alcohol
Intermittent ECM ground	Test ECM ground connection for resistance
Restricted air cleaner	Replace air cleaner
Restricted exhaust system	Test for exhaust manifold back pressure
Poor MAF sensor signal	Check leakage between sensor and manifold
Poor VSS signal	If tester for ALCL hook-up is available check that VSS reading matches speedometer
Ping or Knock on Acceleration
Poor Knock sensor signal	Test for shorted or open sensor or circuit
Poor Baro sensor signal	Test for shorted or open sensor or circuit
Improper ignition timing	See VEHICLE EMISSION CONTROL LABEL (where applicable)
Check for engine overheating problems	Low coolant, loose belts or electric cooling fan inoperative

NOTE: For additional electronic fuel injection trouble shooting information, see the appropriate article in the ENGINE PERFORMANCE section (not all vehicles have Computer Engine Control articles). Information is provided there for diagnosing fuel system problems on vehicles with electronic fuel injection.

IGNITION SYSTEM TROUBLE SHOOTING

Fig. 3: Ignition Secondary Trouble Shooting Chart

Fig. 4: Ignition Primary Trouble Shooting Chart

STARTER TROUBLE SHOOTING

BASIC STARTER TROUBLE SHOOTING CHART

CONDITION & POSSIBLE CAUSE CORRECTION

Starter Fails to Operate

Dead battery or bad connections between starter and battery Check battery charge and all wires and connections to starter

Ignition switch faulty or misadjusted Adjust or replace ignition switch

Open circuit between starter switch ignition terminal on starter relay Check and repair wires and connections as necessary

Starter relay or starter defective See Testing in STARTER article

Open solenoid pull-in wire See Testing in STARTER article

Starter Does Not Operate and Headlights Dim

Weak battery or dead cell Charge or replace battery as necessary

Loose or corroded battery connections Check that battery connections are clean and tight

Internal ground in starter windings See Testing in STARTER article

Grounded starter fields See Testing in STARTERS

Armature rubbing on pole shoes See STARTER article

Starter Turns but Engine Does Not Rotate

Starter clutch slipping See STARTER article

Broken clutch housing See STARTER article

Pinion shaft rusted or dry See STARTER article

Engine basic timing incorrect See Ignition Timing in TUNE-UP article

Broken teeth on engine flywheel Replace flywheel and check for starter pinion gear damage

Starter Will Not Crank Engine

Faulty overrunning clutch See STARTER article

Broken clutch housing See STARTER article

Broken flywheel teeth Replace flywheel and check for starter pinion gear damage

Armature shaft sheared or reduction gear teeth stripped See STARTER article

Weak battery Charge or replace battery as necessary

Faulty solenoid See On-Vehicle Tests in STARTER article

Poor grounds Check all ground connections for tight and clean connections

Ignition switch faulty or misadjusted Adjust or replace ignition switch as necessary

Starter Cranks Engine Slowly

Battery weak or defective Charge or replace battery as necessary

Engine overheated See ENGINE COOLING SYSTEM article

Engine oil too heavy Check that proper viscosity oil is used

Poor battery-to-starter connections Check that all between battery and starter are clean and tight

Current draw too low or too high See Bench Tests in STARTER article

Bent armature, loose pole shoes screws or worn bearings See STARTER article

Burned solenoid contacts Replace solenoid

Faulty starter Replace starter

Starter Engages Engine Only Momentarily

Engine timing too far advanced See Ignition Timing in TUNE-UP article

Overrunning clutch not engaging properly Replace overrunning clutch. See STARTER article

Broken starter clutch See STARTER article

Broken teeth on engine flywheel Replace flywheel and check starter pinion gear for damage

Weak drive assembly thrust spring See STARTER article

Weak hold-in coil See Bench Tests in STARTER article

Starter Drive Will Not Engage

Defective point assembly See Testing in STARTER article

Poor point assembly ground See Testing in STARTER article

Defective pull-in coil Replace starter solenoid

Starter Relay Does Not Close

Dead battery Charge or replace battery as necessary

Faulty wiring Check all wiring and connections leading to relay

Neutral safety switch faulty Replace neutral safety switch

Starter relay faulty Replace starter relay

Starter Drive Will Not Disengage

Starter motor loose on mountings Tighten starter attach bolts

Worn drive end bushing See STARTER article

Damaged engine flywheel teeth Replace flywheel and starter pinion gear for damage

Drive yolk return spring broken or missing Replace return spring

Faulty ignition switch Replace ignition switch

Insufficient clearance between winding leads to solenoid terminal and main contact in solenoid Replace starter solenoid

Starter clutch not disengaging Replace starter clutch

Ignition starter switch contacts sticking Replace ignition switch

Starter Relay Operates but Solenoid Does Not

Faulty solenoid switch, switch connections or relay Check all wiring between relay and solenoid or replace relay or solenoid as necessary

Broken lead or loose soldered connections Repair wire or wire connections as necessary

Solenoid Plunger Vibrates When Switch is Engaged

Weak battery Charge or replace battery as necessary

Solenoid contacts corroded Clean contacts or replace solenoid

Faulty wiring Check all wiring leading to solenoid

Broken connections inside switch cover Repair connections or replace solenoid

Open hold-in wire Replace solenoid

Low Current Draw

Worn brushes or weak Replace brushes or brush springs as necessary

High Pitched Whine During Cranking Before Engine Fires but Engine Fires and Cranks Normally

Distance too great between starter pinion and flywheel Align starter or check that correct starter and flywheel are being used

High Pitched Whine After Engine Fires With Key released. Engine Fires and Cranks Normally

Distance too small between starter pinion and flywheel Flywheel runout contributes to the intermittent nature

CONDITION & POSSIBLE CAUSE	CORRECTION
Starter Fails to Operate
Dead battery or bad connections between starter and battery	Check battery charge and all wires and connections to starter
Ignition switch faulty or misadjusted	Adjust or replace ignition switch
Open circuit between starter switch ignition terminal on starter relay	Check and repair wires and connections as necessary
Starter relay or starter defective	See Testing in STARTER article
Open solenoid pull-in wire	See Testing in STARTER article
Starter Does Not Operate and Headlights Dim
Weak battery or dead cell	Charge or replace battery as necessary
Loose or corroded battery connections	Check that battery connections are clean and tight
Internal ground in starter windings	See Testing in STARTER article
Grounded starter fields	See Testing in STARTERS
Armature rubbing on pole shoes	See STARTER article
Starter Turns but Engine Does Not Rotate
Starter clutch slipping	See STARTER article
Broken clutch housing	See STARTER article
Pinion shaft rusted or dry	See STARTER article
Engine basic timing incorrect	See Ignition Timing in TUNE-UP article
Broken teeth on engine flywheel	Replace flywheel and check for starter pinion gear damage
Starter Will Not Crank Engine
Faulty overrunning clutch	See STARTER article
Broken clutch housing	See STARTER article
Broken flywheel teeth	Replace flywheel and check for starter pinion gear damage
Armature shaft sheared or reduction gear teeth stripped	See STARTER article
Weak battery	Charge or replace battery as necessary
Faulty solenoid	See On-Vehicle Tests in STARTER article
Poor grounds	Check all ground connections for tight and clean connections
Ignition switch faulty or misadjusted	Adjust or replace ignition switch as necessary
Starter Cranks Engine Slowly
Battery weak or defective	Charge or replace battery as necessary
Engine overheated	See ENGINE COOLING SYSTEM article
Engine oil too heavy	Check that proper viscosity oil is used
Poor battery-to-starter connections	Check that all between battery and starter are clean and tight
Current draw too low or too high	See Bench Tests in STARTER article
Bent armature, loose pole shoes screws or worn bearings	See STARTER article
Burned solenoid contacts	Replace solenoid
Faulty starter	Replace starter
Starter Engages Engine Only Momentarily
Engine timing too far advanced	See Ignition Timing in TUNE-UP article
Overrunning clutch not engaging properly	Replace overrunning clutch. See STARTER article
Broken starter clutch	See STARTER article
Broken teeth on engine flywheel	Replace flywheel and check starter pinion gear for damage
Weak drive assembly thrust spring	See STARTER article
Weak hold-in coil	See Bench Tests in STARTER article
Starter Drive Will Not Engage
Defective point assembly	See Testing in STARTER article
Poor point assembly ground	See Testing in STARTER article
Defective pull-in coil	Replace starter solenoid
Starter Relay Does Not Close
Dead battery	Charge or replace battery as necessary
Faulty wiring	Check all wiring and connections leading to relay
Neutral safety switch faulty	Replace neutral safety switch
Starter relay faulty	Replace starter relay
Starter Drive Will Not Disengage
Starter motor loose on mountings	Tighten starter attach bolts
Worn drive end bushing	See STARTER article
Damaged engine flywheel teeth	Replace flywheel and starter pinion gear for damage
Drive yolk return spring broken or missing	Replace return spring
Faulty ignition switch	Replace ignition switch
Insufficient clearance between winding leads to solenoid terminal and main contact in solenoid	Replace starter solenoid
Starter clutch not disengaging	Replace starter clutch
Ignition starter switch contacts sticking	Replace ignition switch
Starter Relay Operates but Solenoid Does Not
Faulty solenoid switch, switch connections or relay	Check all wiring between relay and solenoid or replace relay or solenoid as necessary
Broken lead or loose soldered connections	Repair wire or wire connections as necessary
Solenoid Plunger Vibrates When Switch is Engaged
Weak battery	Charge or replace battery as necessary
Solenoid contacts corroded	Clean contacts or replace solenoid
Faulty wiring	Check all wiring leading to solenoid
Broken connections inside switch cover	Repair connections or replace solenoid
Open hold-in wire	Replace solenoid
Low Current Draw
Worn brushes or weak	Replace brushes or brush springs as necessary
High Pitched Whine During Cranking Before Engine Fires but Engine Fires and Cranks Normally
Distance too great between starter pinion and flywheel	Align starter or check that correct starter and flywheel are being used
High Pitched Whine After Engine Fires With Key released. Engine Fires and Cranks Normally
Distance too small between starter pinion and flywheel	Flywheel runout contributes to the intermittent nature

TUNE-UP TROUBLE SHOOTING - GAS ENGINE VEHICLES

BASIC SPARK PLUG TROUBLE SHOOTING CHARTS

CONDITION & POSSIBLE CAUSE CORRECTION

Normal Spark Plug Condition

Light Tan or Gray deposits No Action

Electrode not burned or fouled No Action

Gap tolerance not changed No Action

Cold Fouling or Carbon Deposits

Overrich air/fuel mixture Adjust air/fuel mixture, see ENGINE PERFORMANCE section

Faulty choke Replace choke assembly, see ENGINE PERFORMANCE section

Clogged air filter Clean and/or replace air filter

Incorrect idle speed or dirty carburetor Reset idle speed and/ or clean carburetor

Faulty ignition wires Replace ignition wiring

Prolonged operation at idle Shut engine off during long idle

Sticking valves or worn valve guide seals Check valve train

Wet Fouling or Oil Deposits

Worn rings and pistons Install new rings and pistons

Excessive cylinder wear Rebore or replace block

Excessive valve guide clearance Worn or loose bearing

Gap Bridged

Deposits in combustion chamber becoming fused to electrode Clean combustion chamber of deposits

Blistered Electrode

Engine overheating Check cooling system

Wrong type of fuel Replace with correct fuel

Loose spark plugs Retighten spark plugs

Over-advanced ignition timing Reset ignition timing see ENGINE PERFORMANCE

Pre-Ignition or Melted Electrodes

Incorrect type of fuel Replace with correct fuel

Incorrect ignition timing Reset ignition timing see ENGINE PERFORMANCE

Burned valves Replace valves

Engine Overheating Check cooling system

Wrong type of spark plug, too hot Replace with correct spark plug, see ENGINE PERFORMANCE

Chipped Insulators

Severe detonation Check for over-advanced timing or combustion

Improper gapping procedure Re-gap spark plugs

Rust Colored Deposits

Additives in unleaded fuel Try different fuel brand

Water In Combustion Chamber

Blown head gasket or cracked head Repair or replace head or head gasket

CONDITION & POSSIBLE CAUSE	CORRECTION
Normal Spark Plug Condition
Light Tan or Gray deposits	No Action
Electrode not burned or fouled	No Action
Gap tolerance not changed	No Action
Cold Fouling or Carbon Deposits
Overrich air/fuel mixture	Adjust air/fuel mixture, see ENGINE PERFORMANCE section
Faulty choke	Replace choke assembly, see ENGINE PERFORMANCE section
Clogged air filter	Clean and/or replace air filter
Incorrect idle speed or dirty carburetor	Reset idle speed and/ or clean carburetor
Faulty ignition wires	Replace ignition wiring
Prolonged operation at idle	Shut engine off during long idle
Sticking valves or worn valve guide seals	Check valve train
Wet Fouling or Oil Deposits
Worn rings and pistons	Install new rings and pistons
Excessive cylinder wear	Rebore or replace block
Excessive valve guide clearance	Worn or loose bearing
Gap Bridged
Deposits in combustion chamber becoming fused to electrode	Clean combustion chamber of deposits
Blistered Electrode
Engine overheating	Check cooling system
Wrong type of fuel	Replace with correct fuel
Loose spark plugs	Retighten spark plugs
Over-advanced ignition timing	Reset ignition timing see ENGINE PERFORMANCE
Pre-Ignition or Melted Electrodes
Incorrect type of fuel	Replace with correct fuel
Incorrect ignition timing	Reset ignition timing see ENGINE PERFORMANCE
Burned valves	Replace valves
Engine Overheating	Check cooling system
Wrong type of spark plug, too hot	Replace with correct spark plug, see ENGINE PERFORMANCE
Chipped Insulators
Severe detonation	Check for over-advanced timing or combustion
Improper gapping procedure	Re-gap spark plugs
Rust Colored Deposits
Additives in unleaded fuel	Try different fuel brand
Water In Combustion Chamber
Blown head gasket or cracked head	Repair or replace head or head gasket

NOTE: Before diagnosing an electronic ignition system, ensure that all wiring is connected properly between distributor, wiring connector and spark plugs. Ignition problem will show up either as: Engine Will Not Start or Engine Runs Rough.

BASIC ELECTRONIC IGNITION TROUBLE SHOOTING CHARTS

CONDITION & POSSIBLE CAUSE CORRECTION

Engine Won't Start

Open circuit between distributor and bulkhead connector Repair circuit

Open circuit between bulkhead connector and ignition switch Repair circuit

Open circuit between ignition switch and starter solenoid Repair circuit

Engine Runs Rough

Fuel lines leaking or clogged Tighten fitting, remove restriction

Initial timing incorrect Reset ignition timing see ENGINE PERFORMANCE

Centrifugal advance malfunction Repair distributor advance

Defective spark plugs or wiring Replace plugs or plug wiring

Component Failure

Spark arc-over on cap, rotor or coil Replace cap, rotor or or coil

Defective pick-up coil Replace pick-up coil

Defective ignition coil Replace ignition coil

Defective vacuum unit Replace vacuum unit

Defective control module Replace control module

CONDITION & POSSIBLE CAUSE	CORRECTION
Engine Won't Start
Open circuit between distributor and bulkhead connector	Repair circuit
Open circuit between bulkhead connector and ignition switch	Repair circuit
Open circuit between ignition switch and starter solenoid	Repair circuit
Engine Runs Rough
Fuel lines leaking or clogged	Tighten fitting, remove restriction
Initial timing incorrect	Reset ignition timing see ENGINE PERFORMANCE
Centrifugal advance malfunction	Repair distributor advance
Defective spark plugs or wiring	Replace plugs or plug wiring
Component Failure
Spark arc-over on cap, rotor or coil	Replace cap, rotor or or coil
Defective pick-up coil	Replace pick-up coil
Defective ignition coil	Replace ignition coil
Defective vacuum unit	Replace vacuum unit
Defective control module	Replace control module

BASIC ELECTRONIC IGNITION TROUBLE SHOOTING CHARTS - USING OSCILLOSCOPE PATTERNS

CONDITION & POSSIBLE CAUSE CORRECTION

Firing Voltage Lines are the Same, but Abnormally High

Retarded ignition timing Reset ignition timing, see ENGINE PERFORMANCE section

Fuel mixture too lean Readjust carburetor, see ENGINE PERFORMANCE

High resistance in coil wire Replace coil wire

Corrosion in coil tower terminal Clean and/or replace coil

Corrosion in distributor coil terminal Clean and/or replace distributor cap

Firing Voltage Lines are the Same but Abnormally Low

Fuel mixture too rich Readjust carburetor, see ENGINE PERFORMANCE

Breaks in coil wire causing arcing Replace coil wire

Cracked coil tower causing arcing Replace coil

Low coil output Replace coil

Low engine compression Determine cause and repair

One or More, But Not All Firing Voltage Lines are Higher Than Others

Carburetor idle mixture not balanced Readjust carburetor, see ENGINE PERFORMANCE

EGR valve stuck open Clean and/or replace valve

High resistance in spark plug wires Replace spark plug wires

Cracked or broken spark plug insulator Replace spark plugs

Intake vacuum leak Repair leak

Defective spark plugs Replace spark plugs

Corroded spark plug terminals Replace spark plugs

One or More, But Not All Firing Voltage Lines Are Lower Than Others

Curb idle mixture not balanced Readjust carburetor, see ENGINE PERFORMANCE

Breaks in plug wires Replace plug wires causing arcing

Cracked coil tower causing arcing Replace coil

Low compression Determine cause and repair

Defective spark plugs Replace spark plugs

Corroded spark plugs Replace spark plugs

Cylinders Not Firing

Cracked distributor cap terminals Replace distributor cap

Shorted spark plug wire Determine cause and repair

Mechanical problem in engine Determine cause and repair

Defective spark plugs Replace spark plugs

Spark plugs fouled Replace spark plugs

CONDITION & POSSIBLE CAUSE	CORRECTION
Firing Voltage Lines are the Same, but Abnormally High
Retarded ignition timing	Reset ignition timing, see ENGINE PERFORMANCE section
Fuel mixture too lean	Readjust carburetor, see ENGINE PERFORMANCE
High resistance in coil wire	Replace coil wire
Corrosion in coil tower terminal	Clean and/or replace coil
Corrosion in distributor coil terminal	Clean and/or replace distributor cap
Firing Voltage Lines are the Same but Abnormally Low
Fuel mixture too rich	Readjust carburetor, see ENGINE PERFORMANCE
Breaks in coil wire causing arcing	Replace coil wire
Cracked coil tower causing arcing	Replace coil
Low coil output	Replace coil
Low engine compression	Determine cause and repair
One or More, But Not All Firing Voltage Lines are Higher Than Others
Carburetor idle mixture not balanced	Readjust carburetor, see ENGINE PERFORMANCE
EGR valve stuck open	Clean and/or replace valve
High resistance in spark plug wires	Replace spark plug wires
Cracked or broken spark plug insulator	Replace spark plugs
Intake vacuum leak	Repair leak
Defective spark plugs	Replace spark plugs
Corroded spark plug terminals	Replace spark plugs
One or More, But Not All Firing Voltage Lines Are Lower Than Others
Curb idle mixture not balanced	Readjust carburetor, see ENGINE PERFORMANCE
Breaks in plug wires	Replace plug wires causing arcing
Cracked coil tower causing arcing	Replace coil
Low compression	Determine cause and repair
Defective spark plugs	Replace spark plugs
Corroded spark plugs	Replace spark plugs
Cylinders Not Firing
Cracked distributor cap terminals	Replace distributor cap
Shorted spark plug wire	Determine cause and repair
Mechanical problem in engine	Determine cause and repair
Defective spark plugs	Replace spark plugs
Spark plugs fouled	Replace spark plugs

BASIC DRIVEABILITY PROBLEMS TROUBLE SHOOTING

CONDITION & POSSIBLE CAUSE CORRECTION

Hard Starting

Binding carburetor linkage Eliminate binding

Binding choke linkage Eliminate binding

Binding choke piston Eliminate binding

Restricted choke vacuum Check vacuum lines for blockage

Worn or dirty needle valve and seat Clean carburetor, see ENGINE PERFORMANCE

Float sticking Readjust or replace float see the ENGINE PERFORMANCE section

Incorrect choke adjustment Reset choke adjustment see ENGINE PERFORMANCE

Defective coil Replace coil

Improper spark plug gap Regap spark plugs

Incorrect ignition timing Reset ignition timing see ENGINE PERFORMANCE

Detonation

Over-advanced ignition timing Reset ignition timing see ENGINE PERFORMANCE

Defective spark plugs Replace spark plugs

Fuel lines clogged Clean fuel lines

EGR system malfunction Check and repair EGR system

PCV system malfunction Repair PCV system

Vacuum leaks Check and repair vacuum system

Loose fan belts Tighten or replace fan belts, see ENGINE PERFORMANCE

Restricted airflow Remove restriction

Vacuum advance malfunction Check distributor operation

Dieseling

Binding carburetor linkage Eliminate binding

Binding throttle linkage Eliminate blinding

Binding choke linkage or fast idle cam Eliminate binding

Defective idle solenoid Replace idle solenoid see ENGINE PERFORMANCE

Improper base idle speed Reset idle speed, see see ENGINE PERFORMANCE

Incorrect ignition timing Reset ignition timing see ENGINE PERFORMANCE

Incorrect idle mixture setting Reset idle mixture, see ENGINE PERFORMANCE

Faulty Acceleration

Incorrect ignition timing Reset ignition timing see ENGINE PERFORMANCE

Engine cold and choke too lean Adjust choke and allow engine to warm-up

Defective spark plugs Replace spark plugs

Defective coil Replace coil

Faulty Low Speed Operation

Clogged idle transfer slots Clean idle transfer slots, see FUEL

Restricted idle air bleeds and passages Disassemble and clean carburetor, see FUEL

Clogged air cleaner Replace air filter

Defective spark plugs Replace spark plugs

Defective ignition wires Replace ignition wire see ENGINE PERFORMANCE

Defective distributor cap Replace distributor cap

Faulty High Speed Operation

Incorrect ignition timing Reset ignition timing see ENGINE PERFORMANCE

Defective distributor centrifugal advance Replace advance mechanism

Defective distributor vacuum advance Replace advance unit

Incorrect spark plugs or plug gap Check gap and/or replace spark plugs

Faulty choke operation Check choke and repair as required

Clogged vacuum passages Remove restrictions

Improper size or clogged main jet Check jet size and clean, see FUEL

Restricted air cleaner Check filter and replace as necessary

Defective distributor cap, rotor or coil Replace cap, rotor or coil

Misfire at All Speeds

Defective spark plugs Replace spark plugs

Defective spark plug wires Replace spark plug wires

Defective distributor cap, rotor, or coil Replace cap, rotor, or coil

Cracked or broken vacuum hoses Replace vacuum hoses

Vacuum leaks Repair vacuum leaks

Fuel lines clogged Remove restriction

Hesitation

Cracked or broken vacuum Replace vacuum hoses hoses

Vacuum leaks Repair Vacuum leaks

Binding carburetor linkage Eliminate binding

Binding throttle linkage Eliminate binding

Binding choke linkage or fast idle cam Eliminate binding

Improper float setting Readjust float setting, see FUEL

Cracked or broken ignition wires Replace ignition wires

Rough Idle, Missing or Stalling

Incorrect curb idle or fast idle speed Reset idle speed, see see ENGINE PERFORMANCE

Incorrect basic timing Reset ignition timing see ENGINE PERFORMANCE

Improper idle mixture adjustment Reset idle mixture, see ENGINE PERFORMANCE

Improper feedback system operation Check feedback system see ENGINE PERFORMANCE

Incorrect spark plug gap Reset spark plug gap, see ENGINE PERFORMANCE

Moisture in ignition components Dry components

Loose or broken ignition wires Replace ignition wires

Damaged distributor cap or or rotor Replace distributor cap or rotor

Faulty ignition coil Replace ignition coil

Fuel filter clogged or worn Replace fuel filter

Damaged idle mixture screw Replace idle mixture screw, see FUEL

Improper fast idle cam adjustment Reset fast idle cam adjustment, see TUNE- see ENGINE PERFORMANCE

Improper EGR valve operation Replace EGR valve

Faulty PCV valve air flow Replace PCV valve

Choke binding or improper choke setting Reset choke or eliminate binding

Vacuum leak Repair vacuum leak

Improper float bowl fuel level Reset float adjustment, see FUEL

Clogged air bleed or idle passages Clean carburetor passages, see FUEL

Clogged or worn air cleaner filter Replace air filter

Faulty choke vacuum diaphragm Replace diaphragm, see ENGINE PERFORMANCE

Exhaust manifold heat valve inoperative Replace heat valve

Improper distributor spark advance Check distributor operation

Leaking valves or valve components Check and repair valvetrain

Improper carburetor mounting Remove and remount carburetor

Excessive play in distributor shaft Replace distributor

Loose or corroded wiring connections Repair or replace as required

Engine Surges

Improper PCV valve airflow Replace PCV valve

Vacuum leaks Repair vacuum leaks

Clogged air bleeds Remove restriction

EGR valve malfunction Replace EGR valve

Restricted air cleaner filter Replace air filter

Cracked or broken vacuum hoses Replace vacuum hoses

Cracked or broken ignition wires Replace ignition wires

Vacuum advance malfunction Check unit and replace as necessary

Defective or fouled spark plugs Replace spark plugs

Ping or Spark Knock

Incorrect ignition timing Reset ignition timing see ENGINE PERFORMANCE

Distributor centrifugal or vacuum advance malfunction Check operation and replace as necessary

Carburetor setting too lean Readjust mixture setting, see ENGINE PERFORMANCE

Vacuum leak Eliminate vacuum leak

EGR valve malfunction Replace EGR valve

Poor Gasoline Mileage

Cracked or broken vacuum Replace vacuum hoses hoses

Vacuum leaks Repair vacuum leaks

Defective ignition wires Replace wires

Incorrect choke setting Readjust setting, see ENGINE PERFORMANCE

Defective vacuum advance Replace vacuum advance

Defective spark plugs Replace spark plugs

Binding carburetor power piston Eliminate binding

Dirt in carburetor jets Clean and/or replace jets

Incorrect float adjustment Readjust float setting, see FUEL

Defective power valve Replace power valve, see ENGINE PERFORMANCE

Incorrect idle speed Readjust idle speed

Engine Stalls

Improper float level Readjust float level

Leaking needle valve and seat Replace needle valve and seat

Vacuum leaks Eliminate vacuum leaks

CONDITION & POSSIBLE CAUSE	CORRECTION
Hard Starting
Binding carburetor linkage	Eliminate binding
Binding choke linkage	Eliminate binding
Binding choke piston	Eliminate binding
Restricted choke vacuum	Check vacuum lines for blockage
Worn or dirty needle valve and seat	Clean carburetor, see ENGINE PERFORMANCE
Float sticking	Readjust or replace float see the ENGINE PERFORMANCE section
Incorrect choke adjustment	Reset choke adjustment see ENGINE PERFORMANCE
Defective coil	Replace coil
Improper spark plug gap	Regap spark plugs
Incorrect ignition timing	Reset ignition timing see ENGINE PERFORMANCE
Detonation
Over-advanced ignition timing	Reset ignition timing see ENGINE PERFORMANCE
Defective spark plugs	Replace spark plugs
Fuel lines clogged	Clean fuel lines
EGR system malfunction	Check and repair EGR system
PCV system malfunction	Repair PCV system
Vacuum leaks	Check and repair vacuum system
Loose fan belts	Tighten or replace fan belts, see ENGINE PERFORMANCE
Restricted airflow	Remove restriction
Vacuum advance malfunction	Check distributor operation
Dieseling
Binding carburetor linkage	Eliminate binding
Binding throttle linkage	Eliminate blinding
Binding choke linkage or fast idle cam	Eliminate binding
Defective idle solenoid	Replace idle solenoid see ENGINE PERFORMANCE
Improper base idle speed	Reset idle speed, see see ENGINE PERFORMANCE
Incorrect ignition timing	Reset ignition timing see ENGINE PERFORMANCE
Incorrect idle mixture setting	Reset idle mixture, see ENGINE PERFORMANCE
Faulty Acceleration
Incorrect ignition timing	Reset ignition timing see ENGINE PERFORMANCE
Engine cold and choke too lean	Adjust choke and allow engine to warm-up
Defective spark plugs	Replace spark plugs
Defective coil	Replace coil
Faulty Low Speed Operation
Clogged idle transfer slots	Clean idle transfer slots, see FUEL
Restricted idle air bleeds and passages	Disassemble and clean carburetor, see FUEL
Clogged air cleaner	Replace air filter
Defective spark plugs	Replace spark plugs
Defective ignition wires	Replace ignition wire see ENGINE PERFORMANCE
Defective distributor cap	Replace distributor cap
Faulty High Speed Operation
Incorrect ignition timing	Reset ignition timing see ENGINE PERFORMANCE
Defective distributor centrifugal advance	Replace advance mechanism
Defective distributor vacuum advance	Replace advance unit
Incorrect spark plugs or plug gap	Check gap and/or replace spark plugs
Faulty choke operation	Check choke and repair as required
Clogged vacuum passages	Remove restrictions
Improper size or clogged main jet	Check jet size and clean, see FUEL
Restricted air cleaner	Check filter and replace as necessary
Defective distributor cap, rotor or coil	Replace cap, rotor or coil
Misfire at All Speeds
Defective spark plugs	Replace spark plugs
Defective spark plug wires	Replace spark plug wires
Defective distributor cap, rotor, or coil	Replace cap, rotor, or coil
Cracked or broken vacuum hoses	Replace vacuum hoses
Vacuum leaks	Repair vacuum leaks
Fuel lines clogged	Remove restriction
Hesitation
Cracked or broken vacuum	Replace vacuum hoses hoses
Vacuum leaks	Repair Vacuum leaks
Binding carburetor linkage	Eliminate binding
Binding throttle linkage	Eliminate binding
Binding choke linkage or fast idle cam	Eliminate binding
Improper float setting	Readjust float setting, see FUEL
Cracked or broken ignition wires	Replace ignition wires
Rough Idle, Missing or Stalling
Incorrect curb idle or fast idle speed	Reset idle speed, see see ENGINE PERFORMANCE
Incorrect basic timing	Reset ignition timing see ENGINE PERFORMANCE
Improper idle mixture adjustment	Reset idle mixture, see ENGINE PERFORMANCE
Improper feedback system operation	Check feedback system see ENGINE PERFORMANCE
Incorrect spark plug gap	Reset spark plug gap, see ENGINE PERFORMANCE
Moisture in ignition components	Dry components
Loose or broken ignition wires	Replace ignition wires
Damaged distributor cap or or rotor	Replace distributor cap or rotor
Faulty ignition coil	Replace ignition coil
Fuel filter clogged or worn	Replace fuel filter
Damaged idle mixture screw	Replace idle mixture screw, see FUEL
Improper fast idle cam adjustment	Reset fast idle cam adjustment, see TUNE- see ENGINE PERFORMANCE
Improper EGR valve operation	Replace EGR valve
Faulty PCV valve air flow	Replace PCV valve
Choke binding or improper choke setting	Reset choke or eliminate binding
Vacuum leak	Repair vacuum leak
Improper float bowl fuel level	Reset float adjustment, see FUEL
Clogged air bleed or idle passages	Clean carburetor passages, see FUEL
Clogged or worn air cleaner filter	Replace air filter
Faulty choke vacuum diaphragm	Replace diaphragm, see ENGINE PERFORMANCE
Exhaust manifold heat valve inoperative	Replace heat valve
Improper distributor spark advance	Check distributor operation
Leaking valves or valve components	Check and repair valvetrain
Improper carburetor mounting	Remove and remount carburetor
Excessive play in distributor shaft	Replace distributor
Loose or corroded wiring connections	Repair or replace as required
Engine Surges
Improper PCV valve airflow	Replace PCV valve
Vacuum leaks	Repair vacuum leaks
Clogged air bleeds	Remove restriction
EGR valve malfunction	Replace EGR valve
Restricted air cleaner filter	Replace air filter
Cracked or broken vacuum hoses	Replace vacuum hoses
Cracked or broken ignition wires	Replace ignition wires
Vacuum advance malfunction	Check unit and replace as necessary
Defective or fouled spark plugs	Replace spark plugs
Ping or Spark Knock
Incorrect ignition timing	Reset ignition timing see ENGINE PERFORMANCE
Distributor centrifugal or vacuum advance malfunction	Check operation and replace as necessary
Carburetor setting too lean	Readjust mixture setting, see ENGINE PERFORMANCE
Vacuum leak	Eliminate vacuum leak
EGR valve malfunction	Replace EGR valve
Poor Gasoline Mileage
Cracked or broken vacuum	Replace vacuum hoses hoses
Vacuum leaks	Repair vacuum leaks
Defective ignition wires	Replace wires
Incorrect choke setting	Readjust setting, see ENGINE PERFORMANCE
Defective vacuum advance	Replace vacuum advance
Defective spark plugs	Replace spark plugs
Binding carburetor power piston	Eliminate binding
Dirt in carburetor jets	Clean and/or replace jets
Incorrect float adjustment	Readjust float setting, see FUEL
Defective power valve	Replace power valve, see ENGINE PERFORMANCE
Incorrect idle speed	Readjust idle speed
Engine Stalls
Improper float level	Readjust float level
Leaking needle valve and seat	Replace needle valve and seat
Vacuum leaks	Eliminate vacuum leaks

VACUUM PUMP - DIESEL TROUBLE SHOOTING

VACUUM PUMP (DIESEL) TROUBLE SHOOTING CHART

CONDITION & POSSIBLE CAUSE CORRECTION

Excessive Noise

Loose pump-to-drive assembly screws Tighten screws

Loose tube on pump assembly Tighten tube

Valves not functioning properly Replace valves

Oil Leakage

Loose end plug Tighten end plug

Bad seal crimp Remove and re-crimp seal

CONDITION & POSSIBLE CAUSE	CORRECTION
Excessive Noise
Loose pump-to-drive assembly screws	Tighten screws
Loose tube on pump assembly	Tighten tube
Valves not functioning properly	Replace valves
Oil Leakage
Loose end plug	Tighten end plug
Bad seal crimp	Remove and re-crimp seal

MANUAL TRANSMISSION

MANUAL TRANSMISSION TROUBLE SHOOTING

MANUAL TRANSMISSION/TRANSAXLE TROUBLE SHOOTING

Condition Possible Cause

Noisy In Forward Gears Low gear oil level, Loose bell housing bolts, Worn bearings or gears

Clunk On Deceleration (FWD Only) Loose engine mounts, Worn inboard CV joints, Worn differential pinion shaft, Side gear hub counterbore in case worn oversize

Gear Clash When Shifting Forward Gears Clutch Out Of Adjustment, Shift linkage damaged or out of adjustment, Gears or synchronizers damaged, Low gear oil level

Transmission Noisy When Moving (RWD Only) Quiet In Neutral With Clutch Engaged Worn rear outputshaft bearing

Gear Rattle Worn bearings, Wrong gear oil, Low gear oil, Worn gears

Steady Ticking At Idle (Increases With RPM) Broken tooth on gear

Gear Clash When Shifting Forward Gears Worn or broken synchronizers

Loud Whine In Reverse Normal condition ⁽¹⁾

Noise When Stepping On Clutch Bad release bearing, Worn pilot bearing

Ticking Or Screeching As Clutch Is Engaged Faulty release bearing, Uneven pressure plate fingers

Click Or Snap When Clutch Is Engaged Worn clutch fork, Worn or broken front bearing retainer

Transmission Shifts Hard Clutch not releasing, Shift mechanism binding, Clutch installed backwards

Will Not Shift Into One Gear, Shifts Into All Others Bent shift fork, Worn detent balls

Locked Into Gear, Cannot Shift Clutch adjustment, Worn detent balls

Transmission Jumps Out Of Gear Pilot bearing worn, Bent shift fork, Worn gear teeth or face, Excessive gear train end play, Worn synchronizers, Missing detent ball spring, Shift mechanism worn or out of adjustment, Engine or transmission mount bolts loose or out of adjustment, Transmission not aligned

Shift Lever Rattle Worn shift lever or detents, Worn shift forks, Worn synchronizers sleeve

Shift Lever Hops Under Acceleration Worn engine or transmission mounts

⁽¹⁾ Most units use spur cut gears in reverse and are noisy

POWERTRAIN

CLUTCH TROUBLE SHOOTING

BASIC CLUTCH TROUBLE SHOOTING CHART

CONDITION & POSSIBLE CAUSE CORRECTION

Chattering or Grabbing

Incorrect clutch adjustment Adjust clutch

Oil, grease or glaze on facings Disassemble and clean or replace

Loose "U" joint flange See DRIVE AXLES article

Worn input shaft spline Replace input shaft

Binding pressure plate Replace pressure plate

Binding release lever See CLUTCH article

Binding clutch disc hub Replace clutch disc

Unequal pressure plate contact Replace worn/misaligned components

Loose/bent clutch disc Replace clutch disc

Incorrect transmission alignment Realign transmission

Worn pressure plate, disc or flywheel Replace damaged components

Broken or weak pressure springs Replace pressure plate

Sticking clutch pedal Lubricate clutch pedal & linkage

Incorrect clutch disc facing Replace clutch disc

Engine loose in chassis Tighten all mounting bolts

Failure to Release

Oil or grease on clutch facings Clean or replace clutch clutch disc

Incorrect release lever or pedal adjustment See CLUTCH article

Worn or broken clutch facings Replace clutch disc

Bent clutch disc or pressure plate Replace damaged components

Clutch disc hub binding on input shaft Clean or replace clutch disc and/or input shaft

Binding pilot bearing Replace pilot bearing

Sticking release bearing sleeve Replace release bearing and/or sleeve

Binding clutch cable See CLUTCH article

Defective clutch master Replace master cylinder

Defective clutch slave Replace slave cylinder

Air in hydraulic system Bleed hydraulic system

Rattling

Weak or broken release lever spring Replace spring and check alignment

Damaged pressure plate Replace pressure plate

Broken clutch return spring Replace return spring

Worn splines on clutch disc or input shaft Replace clutch disc and/or input shaft

Worn clutch release bearing Replace release bearing

Dry or worn pilot bearing Lubricate or replace pilot bearing

Unequal release lever contact Align or replace release lever

Incorrect pedal free play Adjust free play

Warped or damaged clutch disc Replace damaged components

Slipping

Pressure springs worn or Release pressure plate

Oily, greasy or worn facings Clean or replace clutch disc

Incorrect clutch alignment Realign clutch assembly

Warped clutch disc or pressure plate Replace damaged components

Binding release levers or clutch pedal Lubricate and/or replace release components

Squeaking

Worn or damaged release Replace release bearing

Dry or worn pilot or release bearing Lubricate or replace assembly

Pilot bearing turning in crankshaft Replace pilot bearing and/or crankshaft

Worn input shaft bearing Replace bearing and seal

Incorrect transmission alignment Realign transmission

Dry release fork between pivot Lubricate release fork and pivot

Heavy and/or Stiff Pedal

Sticking release bearing sleeve Replace release bearing and/or sleeve

Dry or binding clutch pedal hub Lubricate and align components

Floor mat interference with pedal Lay mat flat in proper area

Dry or binding ball/fork pivots Lubricate and align components

Faulty clutch cable Replace clutch cable

Noisy Clutch Pedal

Faulty interlock switch Replace interlock switch

Self-adjuster ratchet noise Lubricate or replace self-adjuster

Speed control interlock switch Lubricate or replace interlock switch

Clutch Pedal Sticks Down

Binding clutch cable See CLUTCH article

Springs weak in pressure plate Replace pressure plate

Binding in clutch linkage Lubricate and free linkage

Noisy

Dry release bearing Lubricate or replace release bearing

Dry or worn pilot bearing Lubricate or replace bearing

Worn input shaft bearing Replace bearing

Transmission Click

Weak springs in pressure Replace pressure plate plate

Release fork loose on ball stud Replace release fork and/or ball stud

Oil on clutch disc damper Replace clutch disc

Broken spring in slave cylinder Replace slave cylinder

CONDITION & POSSIBLE CAUSE	CORRECTION
Chattering or Grabbing
Incorrect clutch adjustment	Adjust clutch
Oil, grease or glaze on facings	Disassemble and clean or replace
Loose "U" joint flange	See DRIVE AXLES article
Worn input shaft spline	Replace input shaft
Binding pressure plate	Replace pressure plate
Binding release lever	See CLUTCH article
Binding clutch disc hub	Replace clutch disc
Unequal pressure plate contact	Replace worn/misaligned components
Loose/bent clutch disc	Replace clutch disc
Incorrect transmission alignment	Realign transmission
Worn pressure plate, disc or flywheel	Replace damaged components
Broken or weak pressure springs	Replace pressure plate
Sticking clutch pedal	Lubricate clutch pedal & linkage
Incorrect clutch disc facing	Replace clutch disc
Engine loose in chassis	Tighten all mounting bolts
Failure to Release
Oil or grease on clutch facings	Clean or replace clutch clutch disc
Incorrect release lever or pedal adjustment	See CLUTCH article
Worn or broken clutch facings	Replace clutch disc
Bent clutch disc or pressure plate	Replace damaged components
Clutch disc hub binding on input shaft	Clean or replace clutch disc and/or input shaft
Binding pilot bearing	Replace pilot bearing
Sticking release bearing sleeve	Replace release bearing and/or sleeve
Binding clutch cable	See CLUTCH article
Defective clutch master	Replace master cylinder
Defective clutch slave	Replace slave cylinder
Air in hydraulic system	Bleed hydraulic system
Rattling
Weak or broken release lever spring	Replace spring and check alignment
Damaged pressure plate	Replace pressure plate
Broken clutch return spring	Replace return spring
Worn splines on clutch disc or input shaft	Replace clutch disc and/or input shaft
Worn clutch release bearing	Replace release bearing
Dry or worn pilot bearing	Lubricate or replace pilot bearing
Unequal release lever contact	Align or replace release lever
Incorrect pedal free play	Adjust free play
Warped or damaged clutch disc	Replace damaged components
Slipping
Pressure springs worn or	Release pressure plate
Oily, greasy or worn facings	Clean or replace clutch disc
Incorrect clutch alignment	Realign clutch assembly
Warped clutch disc or pressure plate	Replace damaged components
Binding release levers or clutch pedal	Lubricate and/or replace release components
Squeaking
Worn or damaged release	Replace release bearing
Dry or worn pilot or release bearing	Lubricate or replace assembly
Pilot bearing turning in crankshaft	Replace pilot bearing and/or crankshaft
Worn input shaft bearing	Replace bearing and seal
Incorrect transmission alignment	Realign transmission
Dry release fork between pivot	Lubricate release fork and pivot
Heavy and/or Stiff Pedal
Sticking release bearing sleeve	Replace release bearing and/or sleeve
Dry or binding clutch pedal hub	Lubricate and align components
Floor mat interference with pedal	Lay mat flat in proper area
Dry or binding ball/fork pivots	Lubricate and align components
Faulty clutch cable	Replace clutch cable
Noisy Clutch Pedal
Faulty interlock switch	Replace interlock switch
Self-adjuster ratchet noise	Lubricate or replace self-adjuster
Speed control interlock switch	Lubricate or replace interlock switch
Clutch Pedal Sticks Down
Binding clutch cable	See CLUTCH article
Springs weak in pressure plate	Replace pressure plate
Binding in clutch linkage	Lubricate and free linkage
Noisy
Dry release bearing	Lubricate or replace release bearing
Dry or worn pilot bearing	Lubricate or replace bearing
Worn input shaft bearing	Replace bearing
Transmission Click
Weak springs in pressure	Replace pressure plate plate
Release fork loose on ball stud	Replace release fork and/or ball stud
Oil on clutch disc damper	Replace clutch disc
Broken spring in slave cylinder	Replace slave cylinder

DRIVE AXLE - NOISE DIAGNOSIS

Unrelated Noises

Some driveline trouble symptoms are also common to the engine, transmission, wheel bearings, tires, and other parts of the vehicle. Ensure cause of trouble actually is in the drive axle before adjusting, repairing, or replacing any of its parts.

Non-Drive Axle Noises

A few conditions can sound just like drive axle noise and have to be considered in pre-diagnosis. The 4 most common noises are exhaust, tires, CV/universal joints and wheel trim rings.

In certain conditions, the pitch of the exhaust gases may e gear whine. At other times, it may be mistaken for a wheel bearing rumble.

Tires, especially radial and snow, can have a high-pitched tread whine or roar, similar to gear noise. Also, some non-standard tires with an unusual tread construction may emit a roar or whine.

Defective CV/universal joints may cause clicking noises or excessive driveline play that can be improperly diagnosed as drive axle problems.

Trim and moldings also can cause a whistling or whining noise. Ensure none of these components are causing the noise before disassembling the drive axle.

Gear Noise

A "howling" or "whining" noise from the ring and pinion gear can be caused by an improper gear pattern, gear damage, or improper bearing preload. It can occur at various speeds and driving conditions, or it can be continuous.

Before disassembling axle to diagnose and correct gear ke sure that tires, exhaust, and vehicle trim have been checked as possible causes.

Chuckle

This is a particular rattling noise that sounds like a stick against the spokes of a spinning bicycle wheel. It occurs while decelerating from 40 MPH and usually can be heard until vehicle comes to a complete stop. The frequency varies with the speed of the vehicle.

A chuckle that occurs on the driving phase is usually caused ive clearance due to differential gear wear, or by a damaged tooth on the coast side of the pinion or ring gear. Even a very small tooth nick or a ridge on the edge of a gear tooth is enough the cause the noise.

This condition can be corrected simply by cleaning the gear tooth nick or ridge with a small grinding wheel. If either gear is damaged or scored badly, the gear set must be replaced. If metal has broken loose, the carrier and housing must be cleaned to remove particles that could cause damage.

Knock

This is very similar to a chuckle, though it may be louder, and occur on acceleration or deceleration. Knock can be caused by a gear tooth that is damaged on the drive side of the ring and pinion gears. Ring gear bolts that are hitting the carrier casting can cause knock. Knock can also be due to excessive end play in the axle shafts.

Clunk

Clunk is a metallic noise heard when an automatic transmission is engaged in Reverse or Drive, or when throttle is applied or released. It is caused by backlash somewhere in the driveline, but not necessarily in the axle. To determine whether driveline clunk is caused by the axle, check the total axle backlash as follows:

Raise vehicle on a frame or twinpost hoist so that drive wheels are free. Clamp a bar between axle companion flange and a part of the frame or body so that flange cannot move.
On conventional drive axles, lock the left wheel to keep it from turning. On all models, turn the right wheel slowly until it is felt to be in Drive condition. Hold a chalk marker on side of tire about 12" from center of wheel. Turn wheel in the opposite direction until it is again felt to be in Drive condition.
Measure the length of the chalk mark, which is the total axle backlash. If backlash is one inch or less, drive axle is not the source of clunk noise.

Bearing Whine

Bearing whine is a high-pitched sound similar to a whistle. It is usually caused by malfunctioning pinion bearings. Pinion bearings operate at drive shaft speed. Roller wheel bearings may whine in a similar manner if they run completely dry of lubricant. Bearing noise will occur at all driving speeds. This distinguishes it from gear whine, which usually comes and goes as speed changes.

Bearing Rumble

Bearing rumble sounds like marbles being tumbled. It is usually caused by a malfunctioning wheel bearing. The lower pitch is because the wheel bearing turns at only about 1/3 of drive shaft speed.

Chatter On Turns

This is a condition where the entire front or rear of vehicle vibrates when vehicle is moving. The vibration is plainly felt as well as heard. Extra differential thrust washers installed during axle repair can cause a condition of partial lock-up that creates this chatter.

Axle Shaft Noise

Axle shaft noise is similar to gear noise and pinion bearing whine. Axle shaft bearing noise will normally distinguish itself from gear noise by occurring in all driving modes (Drive, cruise, coast and float), and will persist with transmission in Neutral while vehicle is moving at problem speed.

If vehicle displays this noise condition, remove suspect parts, replace wheel seals and install a new set of bearings. Re-evaluate vehicle for noise before removing any internal components.

Vibration

Vibration is a high-frequency trembling, shaking or grinding condition (felt or heard) that may be constant or variable in level and can occur during the total operating speed range of the vehicle.

The types of vibrations that can be felt in the vehicle can d into 3 main groups:

Vibrations of various unbalanced rotating parts of the vehicle.
Resonance vibrations of the body and frame structures caused by rotating of unbalanced parts.
Tip-in moans of resonance vibrations from stressed engine or exhaust system mounts or driveline flexing modes.

DRIVE AXLE - RWD TROUBLE SHOOTING

DRIVE AXLE (RWD) TROUBLE SHOOTING

CONDITION & POSSIBLE CAUSE CORRECTION

Knocking or Clunking

Differential Side Gear Clearance Check Clearance

Worn Pinion Shaft Replace Pinion Shaft

Axle Shaft End Play Check End Play

Missing Gear Teeth Check Differential/Replace Gear

Wrong Axle Backlash Check Backlash

Misaligned Driveline Realign Driveline

Clinking During Engagement

Side Gear Clearance Check Clearance

Ring and Pinion Backlash Check Backlash

Worn/Loose Pinion Shaft Replace Shaft/Bearing

Bad "U" Joint Replace "U" Joint

Sticking Slip Yoke Lube Slip Yoke

Broken Rear Axle Mount Replace Mount

Loose Drive Shaft Flange Check Flange

Click/Chatter On Turns

Differential Side Gear Clearance Check Clearance

Wrong Turn On Plates ⁽¹⁾ Replace Clutch Plates

Wrong Differential Lubricant ⁽¹⁾ Change Lubricant

Knock Or Click

Flat Spot on Rear Wheel Bearing Replace Wheel Bearing

Low Vibration At All Speeds

Faulty Wheel Bearing Replace Wheel Bearing

Faulty "U" Joint Replace "U" Joint

Faulty Drive Shaft Balance Drive Shaft

Faulty Companion Flange Replace Flange

Faulty Slip Yoke Flange Replace Flange

⁽¹⁾ Limited slip differential only.

FWD AXLE SHAFTS & CV JOINTS TROUBLE SHOOTING

BASIC FWD AXLE SHAFTS & CV JOINTS TROUBLE SHOOTING CHART

CONDITION POSSIBLE CAUSE

Grease Leaks CV boot torn or cracked

Clicking Noise on Cornering Damaged outer CV

Clunk Noise on Acceleration Damaged inner CV

Vibration or Shudder on Acceleration Sticking, damaged or worn CV Misalignment or spring height

STEERING & SUSPENSION

MANUAL STEERING GEAR TROUBLE SHOOTING

BASIC MANUAL STEERING GEAR TROUBLE SHOOTING CHART

CONDITION & POSSIBLE CAUSE CORRECTION

Rattle or Chucking Noise in Rack and Pinion

Rack and pinion mounting bracket loose Tighten all mounting bolts

Lack of/or incorrect lubricant Correct as necessary

Steering gear mounting bolts loose Tighten all mounting bolts

Excessive Play

Front wheel bearing improperly adjusted See FRONT SUSPENSION article

Loose or worn steering linkage See STEERING LINKAGE article

Loose or worn steering gear shift See MANUAL STEERING GEAR article

Steering arm loose on gear shaft See MANUAL STEERING GEAR article

Steering gear housing bolts loose Tighten all mounting bolts

Steering gear adjustment too loose See MANUAL STEERING GEAR article

Steering arms loose on knuckles Tighten and check steering linkage

Rack and pinion mounting loose Tighten all mounting bolts

Rack and pinion out of adjustment See adjustment in STEERING article

Tie rod end loose Tighten and check steering linkage

Excessive Pitman shaft-to-ball nut lash Repair as necessary

Poor Returnability

Lack of lubricant in ball joint or linkage Lubricate and service systems

Binding in linkage or ball joints See STEERING LINKAGE and SUSPENSION article

Improper front end alignment See WHEEL ALIGNMENT article

Improper tire pressure Inflate to proper pressure

Tie rod binding Inflate to proper pressure

Shaft seal rubbing shaft See STEERING COLUMN article

Excessive Vertical Motion

Improper tire pressure Inflate to proper pressure

Tires, wheels or rotors out of balance Balance tires then check wheels and rotors

Worn or faulty shock absorbers Check and replace if necessary

Loose tie rod ends or steering Tighten or replace if necessary

Loose or worn wheel bearings See SUSPENSION article

Steering Pulls to One Side

Improper tire pressure Inflate to proper pressure

Front tires are different sizes Rotate or replace if necessary

Wheel bearings not adjusted properly See FRONT SUSPENSION article

Bent or broken suspension components See FRONT SUSPENSION article

Improper wheel alignment See WHEEL ALIGNMENT article

Brakes dragging See BRAKES article

Instability

Low or uneven tire pressure Inflate to proper pressure

Loose or worn wheel bearings See FRONT SUSPENSION article

Loose or worn idler arm bushing See FRONT SUSPENSION article

Loose or worn strut bushings See FRONT SUSPENSION article

Incorrect front wheel alignment See WHEEL ALIGNMENT article

Steering gear not centered See MANUAL STEERING GEARS article

Springs or shock Check and replace if necessary

Improper cross shaft See MANUAL STEERING GEARS article

POWER STEERING TROUBLE SHOOTING

BASIC POWER STEERING TROUBLE SHOOTING CHART

CONDITION & POSSIBLE CAUSE CORRECTION

Rattle or Chucking Noise

Pressure hoses touching engine parts Adjust to proper clearance

Loose Pitman shaft Adjust or replace if necessary

Tie rods ends or Pitman arm loose Tighten and check system

Rack and pinion mounts loose Tighten all mounting bolts

Free play in worm gear See POWER STEERING GEAR article

Loose sector shaft or thrust bearing adjustment See POWER STEERING GEAR

Free play in pot coupling See STEERING COLUMN article

Worn shaft serrations See STEERING COLUMN article

Growl in Steering Pump

Excessive pressure in hoses Restricted hoses, see POWER STEERING GEAR article

Scored pressure plates See POWER STEERING GEAR article

Scored thrust plates or rotor See POWER STEERING GEAR article

Extreme wear of cam ring See POWER STEERING GEAR article

Rattle in Steering Pump

Vanes not installed See POWER STEERING PUMP article

Vanes sticking in rotor See POWER STEERING PUMP article

Swish noise in Pump

Defective flow control valve See POWER STEERING PUMP article

Groan in Steering Pump

Air in fluid See POWER STEERING PUMP article

Poor pressure hose connection Tighten and check, replace if necessary

Squawk When Turning

Damper "O" ring on valve spool cut See POWER STEERING PUMP article

Moan or Whine in Pump

Pump shaft bearing scored Replace bearing and fluid

Air in fluid or fluid level low See POWER STEERING PUMP article

Hose or column grounded Check and replace if necessary

Cover "O" ring missing or damaged See POWER STEERING PUMP article

Valve cover baffle missing or damaged See POWER STEERING PUMP article

Interference of components in pump See POWER STEERING PUMP article

Loose or poor bracket alignment Correct or replace if necessary

Hissing When Parking

Internal leakage in steering gear Check valved assembly first

Chirp in Steering Pump

Loose or worn power steering belt Adjust or replace if necessary

Buzzing When Not Steering

Noisy pump See POWER STEERING PUMP article

Free play in steering shaft bearing See STEERING COLUMN article

Bearing loose on shaft serrations See STEERING COLUMN article

Clicking Noise in Pump

Pump slippers too long See POWER STEERING PUMP article

Broken slipper springs See POWER STEERING PUMP article

Excessive wear or nicked rotors See POWER STEERING PUMP article

Damaged cam contour See POWER STEERING PUMP article

Poor Return of Wheel

Wheel rubbing against turn signal See STEERING COLUMN SWITCHES article

Flange rubbing steering gear adjuster See STEERING COLUMN article

Tight or frozen steering shaft bearing See STEERING COLUMN article

Steering gear out of adjustment See POWER STEERING GEAR article

Sticking or plugged spool valve See POWER STEERING PUMP article

Improper front end alignment See WHEEL ALIGNMENT article

Wheel bearings worn or loose See FRONT SUSPENSION article

Ties rods or ball joints binding Check and replace if necessary

Intermediate shaft joints binding See STEERING COLUMN article

Kinked pressure hoses Correct or replace if necessary

Loose housing head spanner nut See POWER STEERING GEAR article

Damaged valve lever See POWER STEERING GEAR article

Sector shaft adjusted too tight See ADJUSTMENTS in POWER STEERING GEAR article

Worm thrust bearing adjusted too tight See ADJUSTMENTS in POWER STEERING GEAR article

Reaction ring sticking in cylinder See POWER STEERING GEAR article

Reaction ring sticking in housing head See POWER STEERING GEAR article

Steering pump internal leakage See POWER STEERING PUMP article

Steering gear-to-column misalignment See STEERING COLUMN article

Lack of lubrication in linkage Service front suspension

Lack of lubrication in ball joints Service front suspension

Increased Effort When Turning Wheel Fast Foaming, Milky Power Steering Fluid, Low Fluid Level or Low Pressure

High internal pump leakage See POWER STEERING PUMP article

Power steering pump belt slipping Adjust or replace if necessary

Low fluid level Check and fill to proper level

Engine idle speed to low Adjust to correct setting

Air in pump fluid system See POWER STEERING PUMP article

Pump output low See POWER STEERING PUMP article

Steering gear malfunctioning See POWER STEERING GEAR article

Wheel Surges or Jerks

Low fluid level Check and fill to proper level

Loose fan belt Adjust or replace if necessary

Insufficient pump pressure See POWER STEERING PUMP article

Sticky flow control valve See POWER STEERING PUMP article

Linkage hitting oil pan at full turn Replace bent components

Kick Back or Free Play

Air in pump fluid system See POWER STEERING PUMP article

Worn poppet valve in steering gear See POWER STEERING PUMP article

Excessive over center lash See POWER STEERING GEAR article

Thrust bearing out of adjustment See POWER STEERING GEAR article

Free play in pot coupling See POWER STEERING PUMP article

Steering gear coupling loose on shaft See POWER STEERING PUMP article

Steering disc mounting bolts loose Tighten or replace if necessary

Coupling loose on worm shaft Tighten or replace if necessary

Improper sector shaft adjustment See POWER STEERING GEAR article

Excessive worm piston side play See POWER STEERING GEAR article

Damaged valve lever See POWER STEERING GEAR article

Universal joint loose Tighten or replace if necessary

Defective rotary valve See POWER STEERING GEAR article

No Power When Parking

Sticking flow control valve See POWER STEERING PUMP article

Insufficient pump pressure output See POWER STEERING PUMP article

Excessive internal pump leakage See POWER STEERING PUMP article

Excessive internal gear leakage See POWER STEERING PUMP article

Flange rubs against gear adjust plug See STEERING COLUMN article

Loose pump belt Adjust or replace if necessary

Low fluid level Check and add proper amount of fluid

Engine idle too low Adjust to correct setting

Steering gear-to-column misaligned See STEERING COLUMN article

No Power, Left Turn

Left turn reaction seal "O" ring worn See POWER STEERING GEAR article

Left turn reaction seal damaged/missing See POWER STEERING GEAR article

Cylinder head "O" ring damaged See POWER STEERING PUMP article

No Power, Right Turns

Column pot coupling bottomed See STEERING COLUMN article

Right turn reaction seal "O" ring worn See POWER STEERING GEAR article

Right turn reaction seal damaged See POWER STEERING GEAR article

Internal leakage through piston end plug See POWER STEERING GEAR article

Internal leakage through side plugs See POWER STEERING GEAR article

Lack of Effort in Turning

Left and/or right reaction seal sticking in cylinder head Replace, see POWER STEERING GEAR article

Wanders to One Side

Front end alignment incorrect See WHEEL ALIGNMENT article

Unbalanced steering gear valve See POWER STEERING GEAR article

Low Pressure Due to Steering Pump

Flow control valve stuck or inoperative See POWER STEERING PUMP article

Pressure plate not flat against cam ring See POWER STEERING PUMP article

Extreme wear of cam ring Replace and check adjustments

Scored plate, thrust plate or rotor See POWER STEERING PUMP article

Vanes not installed properly See POWER STEERING PUMP article

Vanes sticking in rotor slots See POWER STEERING PUMP article

Cracked/broken thrust or pressure plate See POWER STEERING PUMP article

STEERING COLUMN TROUBLE SHOOTING

BASIC STEERING COLUMN TROUBLE SHOOTING CHART

CONDITION & POSSIBLE CAUSE CORRECTION

Noise in Steering

Coupling pulled apart See STEERING COLUMNS article

Column not correctly aligned See STEERING COLUMNS article

Broken lower joint Replace joint

Horn contact ring not See STEERING COLUMN article

Bearing not lubricated See STEERING COLUMN article

Shaft snap ring not properly seated Reseat or replace snap ring

Plastic spherical joint not lubricated See STEERING COLUMN article

Shroud or housing loose Tighten holding screws

Lock plate retaining ring not seated See STEERING COLUMN article

Loose sight shield Tighten holding screws

High Steering Shaft Effort

Column assembly misaligned See STEERING COLUMN article

Improperly installed dust shield Adjust or replace

Tight steering universal joint See STEERING COLUMN article

High Shift Effort

Column is out of alignment See STEERING COLUMN article

Improperly installed dust shield Adjust or replace

Seals or bearings not lubricated See STEERING COLUMNS article

Mounting bracket screws too long Replace with new shorter screws

Burrs on shift tube Remove burrs or replace tube

Lower bowl bearing assembled wrong See STEERING COLUMN article

Shift tube bent or broken Replace as necessary

Improper adjustment of shift levers See STEERING COLUMN article

Improper Trans. Shifting

Sheared shift tube joint Replace as necessary

Sheared lower shaft lever Replace as necessary

Improper shift lever adjustment See STEERING COLUMN article

Improper gate plate adjustment See STEERING COLUMN article

Excess Play in Column

Instrument panel bracket bolts loose Tighten bolts and check bracket

Broken weld nut on jacket See STEERING COLUMN article

Instrument bracket capsule sheared See STEERING COLUMN article

Column bracket/jacket bolts loose Tighten bolts and check bracket

Steering Locks in Gear

Release lever mechanism See STEERING COLUMN article

SUSPENSION TROUBLE SHOOTING

BASIC SUSPENSION TROUBLE SHOOTING CHART

CONDITION & POSSIBLE CAUSE CORRECTION

Front End Noise

Loose or worn wheel See Wheel Bearing Adjustment in SUSPENSION

Worn shocks or shock mountings Replace struts or strut mountings

Worn struts or strut mountings Replace struts or strut mountings

Loose or worn lower control arm See SUSPENSION

Loose steering gear-to-frame bolts See STEERING

Worn control arm bushings See SUSPENSION

Ball joints not lubricated Lubricate ball joints & see Ball Joint Checking in SUSPENSION

Front Wheel Shake, Shimmy, or Vibration

Tires or wheels out of balance Check tire balance

Incorrect wheel alignment See WHEEL ALIGNMENT

Drive shaft unbalanced Check drive shaft balance

Loose or worn wheel bearings See WHEEL ALIGNMENT

Loose or worn tie rod ends See SUSPENSION

Worn upper ball joints See Ball Joint Checking in SUSPENSION

Worn shock absorbers Replace shock absorbers

Worn strut bushings Replace strut bushings

Car Pulls to One Side

Mismatched or uneven tires Check tire condition

Broken or sagging springs See SUSPENSION

Loose or worn strut bushings See SUSPENSION

Improper wheel alignment See WHEEL ALIGNMENT

Improper rear axle alignment Check rear axle alignment

Power steering gear unbalanced See STEERING

Front brakes dragging See BRAKES

Abnormal Tire Wear

Unbalanced tires Check tire balance & rotation

Sagging or broken springs See SUSPENSION

Incorrect front end alignment See WHEEL ALIGNMENT

Faulty shock absorbers Replace chock absorbers

Scuffed Tires

Toe-In incorrect See WHEEL ALIGNMENT

Suspension arm bent or twisted See appropriate SUSPENSION article

Springs Bottom or Sag

Bent or broken springs See SUSPENSION

Leaking or worn shock absorbers Replace shock absorbers

Frame misalignment Check frame for damage

Spring Noises

Loose "U" Bolts See SUSPENSION

Loose or worn bushings See SUSPENSION

Worn or missing interliners See SUSPENSION

Shock Absorber Noise

Loose shock mountings Check & tighten mountings

Worn bushings Replace bushings

Air in system Bleed air from system

Undercoating on shocks Remove undercoating

Car Leans or Sways on Corners

Loose stabilizer bar See SUSPENSION

Faulty shocks or mountings Replace shocks or mountings

Broken or sagging springs See SUSPENSION

Shock Absorbers Leaking

Worn seals or reservoir tube crimped See SUSPENSION

Broken Springs

Loose "U" bolts See SUSPENSION

Inoperative shock absorbers Replace shock absorbers

WHEEL ALIGNMENT TROUBLE SHOOTING

BASIC WHEEL ALIGNMENT TROUBLE SHOOTING CHART

CONDITION & POSSIBLE CAUSE CORRECTION

Premature Tire Wear

Improper tire inflation Check tire pressure

Front alignment out of tolerance See ALIGNMENT SPECS in WHEEL ALIGNMENT section

Suspension components worn See SUSPENSION section

Steering system components worn See STEERING section

Improper standing height See WHEEL ALIGNMENT

Uneven or sagging springs See SUSPENSION section

Bent wheel See WHEEL ALIGNMENT

Improper torsion bar adjustment See SUSPENSION section

Loose or worn wheel bearings See WHEEL BEARING ADJ. in SUSPENSION section

Worn or defective shock Replace shock absorbers

Tires out of balance Check tire balance

Pulls to One Side

Improper tire inflation Check tire pressure

Brake dragging See BRAKE section

Mismatched tires See WHEEL ALIGNMENT

Broken or sagging spring See SUSPENSION section

Broken torsion bar See SUSPENSION section

Power steering valve not centered See STEERING section

Front alignment out of tolerance See WHEEL ALIGNMENT section

Defective wheel bearing See WHEEL BEARINGS in SUSPENSION section

Uneven sway bar links See SUSPENSION section

Frame bent Check for frame damage

Steering system bushing worn See STEERING section

Hard Steering

Idler arm bushing too tight See STEERING LINKAGE in STEERING section

Ball joint tight or seized See SUSPENSION section

Steering linkage too tight See STEERING LINKAGE in STEERING section

Power steering fluid low Add proper amount of fluid

Power steering drive belt loose See STEERING section

Power steering pump defective See STEERING section

Steering gear out of adjustment See STEERING section

Incorrect wheel alignment See WHEEL ALIGNMENT

Damaged steering gear See STEERING section

Damaged suspension See SUSPENSION section

Bent steering knuckle or supports See SUSPENSION section

Vehicle "Wanders"

Strut rod or control arm bushing worn See SUSPENSION section

Loose or worn wheel bearings See WHEEL BEARINGS in SUSPENSION section

Improper tire inflation Check tire pressure

Stabilizer bar missing or defective See SUSPENSION section

Wheel alignment out of tolerance See Adjustment in WHEEL ALIGNMENT section

Broken spring See SUSPENSION section

Defective shock absorber Replace shock absorbers

Worn steering & suspension components See SUSPENSION section

Front End Shimmy

Tire out of balance/round Check tire balance

Excessive wheel runout See WHEEL ALIGNMENT

Insufficient or improper caster See WHEEL ALIGNMENT section

Worn suspension or steering components See SUSPENSION section

Defective shock absorbers Replace shock absorber

Wheel bearings worn or loose See WHEEL BEARING ADJ. in SUSPENSION section

Power steering reaction Bracket loose See STEERING section

Steering gear box (rack) mounting loose See STEERING section

Steering gear adjustment loose See STEERING section

Worn spherical joints See SUSPENSION section

Toe-In Not Adjustable

Lower control arm bent See SUSPENSION section

Frame bent Check frame for damage

Camber Not Adjustable

Control arm bent See SUSPENSION section

Frame bent Check frame for damage

Hub & bearing not seated properly See SUSPENSION section

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CONDITION	POSSIBLE CAUSE
Grease Leaks	CV boot torn or cracked
Clicking Noise on Cornering	Damaged outer CV
Clunk Noise on Acceleration	Damaged inner CV
Vibration or Shudder on Acceleration	Sticking, damaged or worn CV Misalignment or spring height

CONDITION & POSSIBLE CAUSE		CORRECTION
Rattle or Chucking Noise in Rack and Pinion
Rack and pinion mounting bracket loose		Tighten all mounting bolts
Lack of/or incorrect lubricant		Correct as necessary
Steering gear mounting bolts loose		Tighten all mounting bolts
Excessive Play
Front wheel bearing improperly adjusted		See FRONT SUSPENSION article
Loose or worn steering linkage		See STEERING LINKAGE article
Loose or worn steering gear shift		See MANUAL STEERING GEAR article
Steering arm loose on gear shaft		See MANUAL STEERING GEAR article
Steering gear housing bolts loose		Tighten all mounting bolts
Steering gear adjustment too loose		See MANUAL STEERING GEAR article
Steering arms loose on knuckles		Tighten and check steering linkage
Rack and pinion mounting loose		Tighten all mounting bolts
Rack and pinion out of adjustment		See adjustment in STEERING article
Tie rod end loose		Tighten and check steering linkage
Excessive Pitman shaft-to-ball nut lash		Repair as necessary
Poor Returnability
Lack of lubricant in ball joint or linkage		Lubricate and service systems
Binding in linkage or ball joints		See STEERING LINKAGE and SUSPENSION article
Improper front end alignment		See WHEEL ALIGNMENT article
Improper tire pressure		Inflate to proper pressure
Tie rod binding		Inflate to proper pressure
Shaft seal rubbing shaft		See STEERING COLUMN article
Excessive Vertical Motion
Improper tire pressure		Inflate to proper pressure
Tires, wheels or rotors out of balance		Balance tires then check wheels and rotors
Worn or faulty shock absorbers		Check and replace if necessary
Loose tie rod ends or steering		Tighten or replace if necessary
Loose or worn wheel bearings		See SUSPENSION article
Steering Pulls to One Side
Improper tire pressure		Inflate to proper pressure
Front tires are different sizes		Rotate or replace if necessary
Wheel bearings not adjusted properly		See FRONT SUSPENSION article
Bent or broken suspension components		See FRONT SUSPENSION article
Improper wheel alignment		See WHEEL ALIGNMENT article
Brakes dragging		See BRAKES article
Instability
Low or uneven tire pressure		Inflate to proper pressure
Loose or worn wheel bearings		See FRONT SUSPENSION article
Loose or worn idler arm bushing		See FRONT SUSPENSION article
Loose or worn strut bushings		See FRONT SUSPENSION article
Incorrect front wheel alignment		See WHEEL ALIGNMENT article
Steering gear not centered		See MANUAL STEERING GEARS article
Springs or shock		Check and replace if necessary
Improper cross shaft		See MANUAL STEERING GEARS article

CONDITION & POSSIBLE CAUSE		CORRECTION
Rattle or Chucking Noise
Pressure hoses touching engine parts		Adjust to proper clearance
Loose Pitman shaft		Adjust or replace if necessary
Tie rods ends or Pitman arm loose		Tighten and check system
Rack and pinion mounts loose		Tighten all mounting bolts
Free play in worm gear		See POWER STEERING GEAR article
Loose sector shaft or thrust bearing adjustment		See POWER STEERING GEAR
Free play in pot coupling		See STEERING COLUMN article
Worn shaft serrations		See STEERING COLUMN article
Growl in Steering Pump
Excessive pressure in hoses		Restricted hoses, see POWER STEERING GEAR article
Scored pressure plates		See POWER STEERING GEAR article
Scored thrust plates or rotor		See POWER STEERING GEAR article
Extreme wear of cam ring		See POWER STEERING GEAR article
Rattle in Steering Pump
Vanes not installed		See POWER STEERING PUMP article
Vanes sticking in rotor		See POWER STEERING PUMP article
Swish noise in Pump
Defective flow control valve		See POWER STEERING PUMP article
Groan in Steering Pump
Air in fluid		See POWER STEERING PUMP article
Poor pressure hose connection		Tighten and check, replace if necessary
Squawk When Turning
Damper "O" ring on valve spool cut		See POWER STEERING PUMP article
Moan or Whine in Pump
Pump shaft bearing scored		Replace bearing and fluid
Air in fluid or fluid level low		See POWER STEERING PUMP article
Hose or column grounded		Check and replace if necessary
Cover "O" ring missing or damaged		See POWER STEERING PUMP article
Valve cover baffle missing or damaged		See POWER STEERING PUMP article
Interference of components in pump		See POWER STEERING PUMP article
Loose or poor bracket alignment		Correct or replace if necessary
Hissing When Parking
Internal leakage in steering gear		Check valved assembly first
Chirp in Steering Pump
Loose or worn power steering belt		Adjust or replace if necessary
Buzzing When Not Steering
Noisy pump		See POWER STEERING PUMP article
Free play in steering shaft bearing		See STEERING COLUMN article
Bearing loose on shaft serrations		See STEERING COLUMN article
Clicking Noise in Pump
Pump slippers too long		See POWER STEERING PUMP article
Broken slipper springs		See POWER STEERING PUMP article
Excessive wear or nicked rotors		See POWER STEERING PUMP article
Damaged cam contour		See POWER STEERING PUMP article
Poor Return of Wheel
Wheel rubbing against turn signal		See STEERING COLUMN SWITCHES article
Flange rubbing steering gear adjuster		See STEERING COLUMN article
Tight or frozen steering shaft bearing		See STEERING COLUMN article
Steering gear out of adjustment		See POWER STEERING GEAR article
Sticking or plugged spool valve		See POWER STEERING PUMP article
Improper front end alignment		See WHEEL ALIGNMENT article
Wheel bearings worn or loose		See FRONT SUSPENSION article
Ties rods or ball joints binding		Check and replace if necessary
Intermediate shaft joints binding		See STEERING COLUMN article
Kinked pressure hoses		Correct or replace if necessary
Loose housing head spanner nut		See POWER STEERING GEAR article
Damaged valve lever		See POWER STEERING GEAR article
Sector shaft adjusted too tight		See ADJUSTMENTS in POWER STEERING GEAR article
Worm thrust bearing adjusted too tight		See ADJUSTMENTS in POWER STEERING GEAR article
Reaction ring sticking in cylinder		See POWER STEERING GEAR article
Reaction ring sticking in housing head		See POWER STEERING GEAR article
Steering pump internal leakage		See POWER STEERING PUMP article
Steering gear-to-column misalignment		See STEERING COLUMN article
Lack of lubrication in linkage		Service front suspension
Lack of lubrication in ball joints		Service front suspension
Increased Effort When Turning Wheel Fast Foaming, Milky Power Steering Fluid, Low Fluid Level or Low Pressure
High internal pump leakage		See POWER STEERING PUMP article
Power steering pump belt slipping		Adjust or replace if necessary
Low fluid level		Check and fill to proper level
Engine idle speed to low		Adjust to correct setting
Air in pump fluid system		See POWER STEERING PUMP article
Pump output low		See POWER STEERING PUMP article
Steering gear malfunctioning		See POWER STEERING GEAR article
Wheel Surges or Jerks
Low fluid level		Check and fill to proper level
Loose fan belt		Adjust or replace if necessary
Insufficient pump pressure		See POWER STEERING PUMP article
Sticky flow control valve		See POWER STEERING PUMP article
Linkage hitting oil pan at full turn		Replace bent components
Kick Back or Free Play
Air in pump fluid system		See POWER STEERING PUMP article
Worn poppet valve in steering gear		See POWER STEERING PUMP article
Excessive over center lash		See POWER STEERING GEAR article
Thrust bearing out of adjustment		See POWER STEERING GEAR article
Free play in pot coupling		See POWER STEERING PUMP article
Steering gear coupling loose on shaft		See POWER STEERING PUMP article
Steering disc mounting bolts loose		Tighten or replace if necessary
Coupling loose on worm shaft		Tighten or replace if necessary
Improper sector shaft adjustment		See POWER STEERING GEAR article
Excessive worm piston side play		See POWER STEERING GEAR article
Damaged valve lever		See POWER STEERING GEAR article
Universal joint loose		Tighten or replace if necessary
Defective rotary valve		See POWER STEERING GEAR article
No Power When Parking
Sticking flow control valve		See POWER STEERING PUMP article
Insufficient pump pressure output		See POWER STEERING PUMP article
Excessive internal pump leakage		See POWER STEERING PUMP article
Excessive internal gear leakage		See POWER STEERING PUMP article
Flange rubs against gear adjust plug		See STEERING COLUMN article
Loose pump belt		Adjust or replace if necessary
Low fluid level		Check and add proper amount of fluid
Engine idle too low		Adjust to correct setting
Steering gear-to-column misaligned		See STEERING COLUMN article
No Power, Left Turn
Left turn reaction seal "O" ring worn		See POWER STEERING GEAR article
Left turn reaction seal damaged/missing		See POWER STEERING GEAR article
Cylinder head "O" ring damaged		See POWER STEERING PUMP article
No Power, Right Turns
Column pot coupling bottomed		See STEERING COLUMN article
Right turn reaction seal "O" ring worn		See POWER STEERING GEAR article
Right turn reaction seal damaged		See POWER STEERING GEAR article
Internal leakage through piston end plug		See POWER STEERING GEAR article
Internal leakage through side plugs		See POWER STEERING GEAR article
Lack of Effort in Turning
Left and/or right reaction seal sticking in cylinder head		Replace, see POWER STEERING GEAR article
Wanders to One Side
Front end alignment incorrect		See WHEEL ALIGNMENT article
Unbalanced steering gear valve		See POWER STEERING GEAR article
Low Pressure Due to Steering Pump
Flow control valve stuck or inoperative		See POWER STEERING PUMP article
Pressure plate not flat against cam ring		See POWER STEERING PUMP article
Extreme wear of cam ring		Replace and check adjustments
Scored plate, thrust plate or rotor		See POWER STEERING PUMP article
Vanes not installed properly		See POWER STEERING PUMP article
Vanes sticking in rotor slots		See POWER STEERING PUMP article
Cracked/broken thrust or pressure plate		See POWER STEERING PUMP article

CONDITION & POSSIBLE CAUSE		CORRECTION
Noise in Steering
Coupling pulled apart		See STEERING COLUMNS article
Column not correctly aligned		See STEERING COLUMNS article
Broken lower joint		Replace joint
Horn contact ring not		See STEERING COLUMN article
Bearing not lubricated		See STEERING COLUMN article
Shaft snap ring not properly seated		Reseat or replace snap ring
Plastic spherical joint not lubricated		See STEERING COLUMN article
Shroud or housing loose		Tighten holding screws
Lock plate retaining ring not seated		See STEERING COLUMN article
Loose sight shield		Tighten holding screws
High Steering Shaft Effort
Column assembly misaligned		See STEERING COLUMN article
Improperly installed dust shield		Adjust or replace
Tight steering universal joint		See STEERING COLUMN article
High Shift Effort
Column is out of alignment		See STEERING COLUMN article
Improperly installed dust shield		Adjust or replace
Seals or bearings not lubricated		See STEERING COLUMNS article
Mounting bracket screws too long		Replace with new shorter screws
Burrs on shift tube		Remove burrs or replace tube
Lower bowl bearing assembled wrong		See STEERING COLUMN article
Shift tube bent or broken		Replace as necessary
Improper adjustment of shift levers		See STEERING COLUMN article
Improper Trans. Shifting
Sheared shift tube joint		Replace as necessary
Sheared lower shaft lever		Replace as necessary
Improper shift lever adjustment		See STEERING COLUMN article
Improper gate plate adjustment		See STEERING COLUMN article
Excess Play in Column
Instrument panel bracket bolts loose		Tighten bolts and check bracket
Broken weld nut on jacket		See STEERING COLUMN article
Instrument bracket capsule sheared		See STEERING COLUMN article
Column bracket/jacket bolts loose		Tighten bolts and check bracket
Steering Locks in Gear
Release lever mechanism		See STEERING COLUMN article

CONDITION & POSSIBLE CAUSE		CORRECTION
Front End Noise
Loose or worn wheel		See Wheel Bearing Adjustment in SUSPENSION
Worn shocks or shock mountings		Replace struts or strut mountings
Worn struts or strut mountings		Replace struts or strut mountings
Loose or worn lower control arm		See SUSPENSION
Loose steering gear-to-frame bolts		See STEERING
Worn control arm bushings		See SUSPENSION
Ball joints not lubricated		Lubricate ball joints & see Ball Joint Checking in SUSPENSION
Front Wheel Shake, Shimmy, or Vibration
Tires or wheels out of balance		Check tire balance
Incorrect wheel alignment		See WHEEL ALIGNMENT
Drive shaft unbalanced		Check drive shaft balance
Loose or worn wheel bearings		See WHEEL ALIGNMENT
Loose or worn tie rod ends		See SUSPENSION
Worn upper ball joints		See Ball Joint Checking in SUSPENSION
Worn shock absorbers		Replace shock absorbers
Worn strut bushings		Replace strut bushings
Car Pulls to One Side
Mismatched or uneven tires		Check tire condition
Broken or sagging springs		See SUSPENSION
Loose or worn strut bushings		See SUSPENSION
Improper wheel alignment		See WHEEL ALIGNMENT
Improper rear axle alignment		Check rear axle alignment
Power steering gear unbalanced		See STEERING
Front brakes dragging		See BRAKES
Abnormal Tire Wear
Unbalanced tires		Check tire balance & rotation
Sagging or broken springs		See SUSPENSION
Incorrect front end alignment		See WHEEL ALIGNMENT
Faulty shock absorbers		Replace chock absorbers
Scuffed Tires
Toe-In incorrect		See WHEEL ALIGNMENT
Suspension arm bent or twisted		See appropriate SUSPENSION article
Springs Bottom or Sag
Bent or broken springs		See SUSPENSION
Leaking or worn shock absorbers		Replace shock absorbers
Frame misalignment		Check frame for damage
Spring Noises
Loose "U" Bolts		See SUSPENSION
Loose or worn bushings		See SUSPENSION
Worn or missing interliners		See SUSPENSION
Shock Absorber Noise
Loose shock mountings		Check & tighten mountings
Worn bushings		Replace bushings
Air in system		Bleed air from system
Undercoating on shocks		Remove undercoating
Car Leans or Sways on Corners
Loose stabilizer bar		See SUSPENSION
Faulty shocks or mountings		Replace shocks or mountings
Broken or sagging springs		See SUSPENSION
Shock Absorbers Leaking
Worn seals or reservoir tube crimped		See SUSPENSION
Broken Springs
Loose "U" bolts		See SUSPENSION
Inoperative shock absorbers		Replace shock absorbers

CONDITION & POSSIBLE CAUSE		CORRECTION
Premature Tire Wear
Improper tire inflation		Check tire pressure
Front alignment out of tolerance		See ALIGNMENT SPECS in WHEEL ALIGNMENT section
Suspension components worn		See SUSPENSION section
Steering system components worn		See STEERING section
Improper standing height		See WHEEL ALIGNMENT
Uneven or sagging springs		See SUSPENSION section
Bent wheel		See WHEEL ALIGNMENT
Improper torsion bar adjustment		See SUSPENSION section
Loose or worn wheel bearings		See WHEEL BEARING ADJ. in SUSPENSION section
Worn or defective shock		Replace shock absorbers
Tires out of balance		Check tire balance
Pulls to One Side
Improper tire inflation		Check tire pressure
Brake dragging		See BRAKE section
Mismatched tires		See WHEEL ALIGNMENT
Broken or sagging spring		See SUSPENSION section
Broken torsion bar		See SUSPENSION section
Power steering valve not centered		See STEERING section
Front alignment out of tolerance		See WHEEL ALIGNMENT section
Defective wheel bearing		See WHEEL BEARINGS in SUSPENSION section
Uneven sway bar links		See SUSPENSION section
Frame bent		Check for frame damage
Steering system bushing worn		See STEERING section
Hard Steering
Idler arm bushing too tight		See STEERING LINKAGE in STEERING section
Ball joint tight or seized		See SUSPENSION section
Steering linkage too tight		See STEERING LINKAGE in STEERING section
Power steering fluid low		Add proper amount of fluid
Power steering drive belt loose		See STEERING section
Power steering pump defective		See STEERING section
Steering gear out of adjustment		See STEERING section
Incorrect wheel alignment		See WHEEL ALIGNMENT
Damaged steering gear		See STEERING section
Damaged suspension		See SUSPENSION section
Bent steering knuckle or supports		See SUSPENSION section
Vehicle "Wanders"
Strut rod or control arm bushing worn		See SUSPENSION section
Loose or worn wheel bearings		See WHEEL BEARINGS in SUSPENSION section
Improper tire inflation		Check tire pressure
Stabilizer bar missing or defective		See SUSPENSION section
Wheel alignment out of tolerance		See Adjustment in WHEEL ALIGNMENT section
Broken spring		See SUSPENSION section
Defective shock absorber		Replace shock absorbers
Worn steering & suspension components		See SUSPENSION section
Front End Shimmy
Tire out of balance/round		Check tire balance
Excessive wheel runout		See WHEEL ALIGNMENT
Insufficient or improper caster		See WHEEL ALIGNMENT section
Worn suspension or steering components		See SUSPENSION section
Defective shock absorbers		Replace shock absorber
Wheel bearings worn or loose		See WHEEL BEARING ADJ. in SUSPENSION section
Power steering reaction Bracket loose		See STEERING section
Steering gear box (rack) mounting loose		See STEERING section
Steering gear adjustment loose		See STEERING section
Worn spherical joints		See SUSPENSION section
Toe-In Not Adjustable
Lower control arm bent		See SUSPENSION section
Frame bent		Check frame for damage
Camber Not Adjustable
Control arm bent		See SUSPENSION section
Frame bent		Check frame for damage
Hub & bearing not seated properly		See SUSPENSION section