Online Manual Jeep > Jeep Cherokee > Jeep Cherokee (XJ) > 1993 > ENGINE SYSTEMS UNIFORM INSPECTION GUIDELINES

1993 Jeep Cherokee

GENERAL INFORMATION

Engine Performance and Maintenance Motorist Assurance Program

Standards For Automotive Repair

All Makes and Models

INTRODUCTION TO MOTORIST ASSURANCE PROGRAM (MAP)

CONTENTS

Motorist Assurance Program (MAP)

OVERVIEW OF MOTORIST ASSURANCE PROGRAM

OVERVIEW OF SERVICE REQUIREMENTS AND SUGGESTIONS

Engine Assemblies

CYLINDER HEAD ASSEMBLIES LONG BLOCK ASSEMBLIES SHORT BLOCK ASSEMBLIES

Engine Components

ACCELERATOR PEDAL POSITION SENSORS

ACCESSORY BELTS

ACCESSORY PULLEYS

ACTUATORS

AIR CONDITIONING CYCLING SWITCHES

AIR CONDITIONING PRESSURE SENSORS

AIR DUCTS AND TUBES

AIR FILTER ELEMENTS

AIR FILTER GASKETS

AIR FILTER HOUSINGS AND GASKETS

AIR FUEL RATIO SENSORS

AIR INJECTION CONTROL SOLENOIDS

AIR PLENUMS

AIR PUMP BELTS

AIR PUMPS (ELECTRIC-DRIVEN)

AIR TUBES

ASPIRATOR, CHECK AND DECEL VALVES

BAFFLES

BALLAST PRIMARY SUPPLY RESISTOR WIRES

BALLAST RESISTORS AND PRIMARY SUPPLY RESISTOR WIRES

BAROMETRIC PRESSURE SENSORS

BATTERIES

BATTERY CABLES, WIRES AND CONNECTORS

BATTERY CONNECTORS

BATTERY TRAYS AND HOLD DOWN HARDWARE

BATTERY WIRES

BELT-DRIVEN AIR PUMPS

BELT IDLER ASSEMBLIES (ACCESSORY AND CAM BELTS)

BELT TENSIONERS (ACCESSORY AND CAM BELTS)

BOOST CONTROL MECHANISMS

CAMSHAFT POSITION SENSORS

CARBURETORS AND CHOKES

CASTING CORE PLUGS AND EXPANSION PLUGS

CHARGE AIR COOLERS "INTERCOOLERS" (CAC)

CHECK VALVES

CHOKES

CLUTCH PEDAL POSITION SWITCHES

COLD START INJECTORS

CONNECTORS

COOLANT

COOLANT RECOVERY TANKS

COOLING FAN MOTOR MODULES

COOLING FAN MOTOR RELAYS AND MODULES

COOLING FAN MOTOR RESISTORS

COOLING FAN MOTOR SENSORS AND SWITCHES

COOLING FAN MOTOR SWITCHES

COOLING FAN MOTORS

CRANKSHAFT POSITION SENSORS

DECEL VALVES

DEFLECTORS

DIP STICKS AND TUBES

DIP STICK TUBES

DISTRIBUTOR ADVANCES AND RETARDERS (MECHANICAL AND VACUUM)

DISTRIBUTOR BOOTS AND SHIELDS

DISTRIBUTOR CAPS

DISTRIBUTOR RETARDERS (MECHANICAL AND VACUUM)

DISTRIBUTOR ROTORS

DISTRIBUTOR SHIELDS

DISTRIBUTORS

EARLY FUEL EVAPORATION VALVES (HEAT RISER ASSEMBLIES)

EGR COOLERS

EGR EXHAUST MANIFOLD PASSAGES

EGR INTAKE AND EXHAUST MANIFOLD PASSAGES

EGR PLATES AND COOLERS

ELECTRONIC SPARK CONTROL MODULES

ELECTRONIC TRANSMISSION CONTROL DEVICES

ELECTRONIC TRANSMISSION FEEDBACK DEVICES

ENGINE COOLANT TEMPERATURE SENSORS

ENGINE COOLING SYSTEMS

ENGINE COVERS (OIL PAN, VALVE COVER, TIMING COVER)

ENGINE OIL

ENGINE OIL CANISTERS

ENGINE OIL COOLERS (EXTERNAL)

ENGINE OIL DRAIN PLUGS AND GASKETS

ENGINE OIL FILTERS AND CANISTERS

ENGINE OIL GASKETS

ENGINE OIL PRESSURE GAUGES (MECHANICAL)

EVAPORATIVE EMISSION (EVAP) CANISTER FILTERS

EVAPORATIVE EMISSION (EVAP) CANISTER PURGE DEVICES

EVAPORATIVE EMISSION (EVAP) CANISTERS

EVAPORATIVE EMISSION (EVAP) FEEDBACK DEVICES

EXHAUST GAS RECIRCULATION DEVICES

EXHAUST GAS RECIRCULATION FEEDBACK DEVICES

EXPANSION PLUGS

FAN CONTROL SENSORS

FUEL

FUEL ACCUMULATORS AND DAMPERS

FUEL AND COLD START INJECTORS

FUEL DAMPERS

FUEL DELIVERY CHECK VALVES

FUEL DISTRIBUTORS (BOSCH CIS)

FUEL FILLER NECKS AND RESTRICTORS

FUEL FILTERS

FUEL INJECTORS

FUEL LEVEL SENDERS7

FUEL PRESSURE REGULATORS

FUEL PUMPS (IN-TANK AND EXTERNAL, ELECTRICAL OR MECHANICAL)

FUEL RAILS

FUEL RESTRICTORS

FUEL TANKS

GAS CAPS

GASKETS

GROMMETS (VALVE COVER)

HARMONIC DAMPERS

HEATER CONTROL VALVES

HEATER CORES

HOSE AND TUBE COUPLERS, CONNECTORS AND CLAMPS

HOSE CLAMPS

HOSE CONNECTORS

HOSE COUPLERS

HOSES AND TUBES (FUEL LINES, RADIATOR, VACUUM, BY PASS,

HEATER, RECOVERY TANK AND OIL COOLERS) HOUSINGS

IDLE AIR CONTROLS IDLE SPEED CONTROL ACTUATORS IGNITION BOOTS IGNITION COIL TOWERS IGNITION COILS

IGNITION CONTROL MODULES (ICM) IGNITION SWITCHES IGNITION TERMINALS

IGNITION WIRES, BOOTS, COIL TOWERS AND TERMINALS (SECONDARY) IN-TANK FUEL STRAINERS INERTIA FUEL SHUT-OFF SWITCHES INTAKE AIR TEMPERATURE SENSORS INTAKE MANIFOLDS INTERCOOLERS KNOCK SENSORS LIQUID VAPOR SEPARATORS

MANIFOLD ABSOLUTE PRESSURE (MAP) SENSORS MASS AIR FLOW (MAF) SENSORS METAL AIR MANIFOLDS AND PIPES METAL AIR PIPES MIX CONTROL SOLENOIDS MOTOR MOUNTS

O-RINGS, GASKETS, SEALS AND SPRING LOCKS O2 SENSORS

OIL PRESSURE SENDING UNITS OIL PUMP PICK-UP SCREENS OIL PUMPS

PARK NEUTRAL POSITION SWITCHES PCV BREATHER ELEMENTS PCV ORIFICES PCV VALVES PICK-UP ASSEMBLIES (INCLUDES MAGNETIC, HALL EFFECT AND

OPTICAL)

POWER STEERING PRESSURE SENSORS POWERTRAIN CONTROL MODULES (PCM) AND PROM POWERTRAIN CONTROL PROM PRESSURIZED EXPANSION TANK CAPS

RADIATOR CAPS AND PRESSURIZED EXPANSION TANK CAPS RADIATOR FAN BLADES RADIATOR FAN CLUTCHES RADIATORS ROLL OVER VALVES SEALING COMPOUNDS SEALS

SECONDARY AIR INJECTION SYSTEM MANAGEMENT DEVICES SENSORS AND ACTUATORS SHROUDS, BAFFLES AND DEFLECTORS SPARK PLUGS SPRING LOCKS

SUPER CHARGERS

SWITCHES

THERMAL VACUUM VALVES

THERMOSTATIC AIR DOOR ASSEMBLIES

THERMOSTATS AND HOUSINGS

THROTTLE BODIES

THROTTLE CABLES

THROTTLE LINKAGES AND CABLES

THROTTLE POSITION SENSORS

THROTTLE POSITION SWITCHES

TIMING BELT SPROCKETS

TIMING BELTS

TORQUE STRUTS

TRANSMISSION RANGE SWITCHES

TUBE CLAMPS

TUBE CONNECTORS

TUBE COUPLERS

TUBES

TURBO CHARGERS

VACUUM CONNECTIONS

VACUUM HOSES, TUBES AND CONNECTIONS (NON-METALLIC)

VACUUM REGULATOR SOLENOIDS

VACUUM TUBES

VEHICLE SPEED SENSORS

VOLUME AIR FLOW SENSORS

WASTE GATE CONTROL SOLENOIDS

WASTE GATES AND BOOST CONTROL MECHANISMS

WATER PUMPS (ELECTRIC)

WATER PUMPS (NON-ELECTRIC)

WIRING HARNESSES AND CONNECTORS

INTRODUCTION TO MOTORIST ASSURANCE PROGRAM (MAP)

OVERVIEW OF MOTORIST ASSURANCE PROGRAM

The Motorist Assurance Program is the consumer outreach effort of the Automotive Maintenance and Repair Association, Inc. (AMRA). Participation in the Motorist Assurance Program is drawn from retailers, suppliers, independent repair facilities, vehicle manufacturers and industry associations.

Our organizationís mission is to strengthen the relationship between the consumer and the auto repair industry. We produce materials that give motorists the information and encouragement to take greater responsibility for their vehicles-through proper, manufacturer-recommended, maintenance. We encourage participating service and repair shops (including franchisees and dealers) to adopt (1) a Pledge of Assurance to their Customers and (2) the Motorist Assurance Program Standards of Service. All participating service providers have agreed to subscribe to this Pledge and to adhere to the promulgated Standards of Service demonstrating to their customers that they are serious about customer satisfaction.

These Standards of Service require that an inspection of the vehicleís (problem) system be made and the results communicated to the customer according to industry standards. Given that the industry did not have such standards, the Motorist Assurance Program successfully promulgated industry inspection communication standards in 1994-95 for the following systems: Exhaust, Brakes, ABS, Steering and Suspension, Engine Maintenance and Performance, HVAC, and Electrical Systems. Further, revisions to all of these inspection communication standards are continually re-published. In addition to these, standards for Drive Train and Transmissions have recently been promulgated. Participating shops utilize these Uniform Inspection & Communication

Standards as part of the inspection process and for communicating their findings to their customers.

The Motorist Assurance Program continues to work

cooperatively and proactively with government agencies and consumer groups toward solutions that both benefit the customer and are mutually acceptable to both regulators and industry. We maintain the belief that industry must retain control over how we conduct our business, and we must be viewed as part of the solution and not part of the problem. Meetings with state and other government officials (and their representatives), concerned with auto repair and/or consumer protection, are conducted. Feedback from these sessions is brought back to the association, and the program adjusted as needed.

To assure auto repair customers recourse if they were not satisfied with a repair transaction, the Motorist Assurance Program offers mediation and arbitration through MAP/BBB-CARE and other non­profit organizations. MAP conducted pilot programs in twelve states before announcing the program nationally in October, 1998. During the pilots, participating repair shops demonstrated their adherence to the Pledge and Standards and agreed to follow the UICS in communicating the results of their inspection to their customers. To put some "teeth" in the program, an accreditation requirement for shops was initiated. The requirements are stringent, and a self-policing method has been incorporated which includes the "mystery shopping" of outlets.

We welcome you to join us as we continue our outreach... with your support, both the automotive repair industry and your customers will reap the benefits. Please visit MAP at our Internet site www. motorist.org or contact us at:

1444 I Street, NW Suite 700

Washington, DC 20005

Phone (202) 712-9042 Fax (202) 216-9646 January 1999

MAP UNIFORM INSPECTION GENERAL GUIDELINES

OVERVIEW OF SERVICE REQUIREMENTS AND SUGGESTIONS

It is MAP policy that all exhaust, brake, steering, suspension, wheel alignment, drive-line, engine performance and maintenance, and heating, ventilation and air conditioning, and electrical services be offered and performed under the standards and procedures specified in these sections.

Before any service is performed on a vehicle, an inspection of the appropriate system must be performed. The results of this inspection must be explained to the customer and documented on an inspection form. The condition of the vehicle and its components will indicate what services/part replacements may be "Required" or "Suggested". In addition, suggestions may be made to satisfy the requests expressed by the customer.

When a component is suggested or required to be repaired or replaced, the decision to repair or replace must be made in the customerís best interest, and at his or her choice given the options available.

This section lists the various parts and conditions that indicate a required or suggested service or part replacement. Although this list is extensive, it is not fully inclusive. In addition to this list, a technician may make a suggestion. However, any suggestions must be based on substantial and informed experience, or the vehicle manufacturerís recommended service interval and must be documented.

Some conditions indicate that service or part replacement is

required because the part in question is no longer providing the function for which it is intended, does not meet a vehicle manufacturerís design specification or is missing.

Example:

An exhaust pipe has corroded severely and has a hole

in it through which exhaust gases are leaking. Replacement

of the exhaust pipe in this case is required due to

functional failure.

Example:

A brake rotor has been worn to the point where it measures less than the vehicle manufacturerís discard specifications. Replacement of the rotor is required because it does not meet design specifications.

Some conditions indicate that a service or part replacement is suggested because the part is close to the end of its useful life or addresses a customerís need, convenience or request. If a customerís vehicle has one of these conditions, the procedure may be only to suggest service.

Example:

An exhaust pipe is rusted, corroded or weak, but no leaks are present. In this case, the exhaust pipe has not failed. However, there is evidence that the pipe may need replacement in the near future. Replacement of the pipe may be suggested for the customerís convenience in avoiding a future problem.

Example:

The customer desires improved ride and/or handling,

but the vehicleís shocks or struts have not failed. In this

case, replacement may be suggested to satisfy the customerís

wishes. In this case, replacement of the shocks or struts may

not be sold as a requirement.

A customer, of course, has the choice of whether or not a shop will service his or her vehicle. He or she may decide not to follow some of your suggestions. When a repair is required, a MAP shop must refuse partial service on that system if, in the judgment of the service provider, proceeding with the work could create or continue an unsafe condition. When a procedure states that required or suggested repair or replacement is recommended, the customer must be informed of the generally acceptable repair/replacement options whether or not performed by the shop.

When presenting suggested repairs to the customer, you must present the facts, allowing the customer to draw their own conclusions and make an informed decision about how to proceed.

The following reasons may be used for required and suggested services. These codes are shown in the "Code" column of the MAP Uniform Inspection & Communications Standards that follow:

Reasons to Require Repair or Replacement

A - Part no longer performs intended purpose

–í - Part does not meet a design specification (regardless of

performance) –° - Part is missing

NOTE: When a repair is required, the shop must refuse partial service to the system in question, if the repair creates or continues an unsafe condition.

Reasons to Suggest Repair or Replacement

1 - Part is close to the end of its useful life (just above

discard specifications, or weak; failure likely to occur soon, etc.)

2 - To address a customer need, convenience, or request (to

stiffen ride, enhance performance, eliminate noise, etc.)

3 - To comply with maintenance recommended by the vehicleís

Original Equipment Manufacturer (OEM)

4 - Technicianís recommendation based on substantial and

informed experience

NOTE: Suggested services are always optional. When presenting suggested repairs to the customer, you must present the facts, allowing the customer to draw their own conclusions and make an informed decision about how to proceed.

ENGINE ASSEMBLIES

SERVICE PROCEDURES REQUIRED AND SUGGESTED FOR PROPER VEHICLE

OPERATION

CYLINDER HEAD ASSEMBLIES

NOTE: A Cylinder Head Assembly is a cylinder head fitted with valves, associated springs, retainers, and on overhead camshaft cylinder heads (OHC), camshaft, camshaft bearings, lash adjusters, tappets and rockers.

CYLINDER HEAD ASSEMBLY INSPECTION

Condition Code Procedure

Adjustable valve lash is

out of specification ... B Require repair.

Internal component failure

(any component) A (1) Require repair or

replacement of cylinder head assembly.

(1) - It is Required that all other failure related components

be inspected for cause and condition. Additional components or assemblies may be Suggested for repair or replacement, such as a water pump on a short block (reason code 4, technicianís recommendation based on substantial and informed experience).

Example:

If there is a failed head gasket with an external coolant leak, in addition to Requiring replacement of the head gasket, inspection of the following for cause and condition is Required: Block, Cooling System, Cylinder Head. It may be Suggested that additional inspections be performed, such as the other head gasket on a V-type engine.

LONG BLOCK ASSEMBLIES

NOTE: A Long Block Assembly is a short block assembly together with a cylinder head assembly and all those components fitted within the rocker or cam cover, and timing cover

(the whole presented as an assembly). A rebuilt or new oil pump, or kit shall be supplied or fitted as appropriate.

LONG BLOCK ASSEMBLY INSPECTION

Condition

Code

Procedure

Internal component failure

(any component) A (1) Require repair or

replacement of the long block assembly.

(1) - It is Required that all other failure related components

be inspected for cause and condition. Additional components or assemblies may be Suggested for repair or replacement such as a water pump on a short block (reason code 4, technicianís recommendation based on substantial and informed experience).

Example:

If there is a failed head gasket with an external coolant leak, in addition to Requiring replacement of the head gasket, inspection of the following for cause and condition is Required: Block, Cooling System, Cylinder Head. It may be Suggested that additional inspections be performed, such as the other head gasket on a V-type engine.

SHORT BLOCK ASSEMBLIES

NOTE: A Short Block Assembly is a cylinder block and all those components contained within the limits of the block deck or decks, the pan rail, the block rear face and the timing cover (where fitted), including the crankshaft.

SHORT BLOCK ASSEMBLY INSPECTION

Condition

Code

Procedure

Any internal component

failure A (1) Require repair or

replacement of the short block assembly.

(1) -

It is Required that all other failure related components be inspected for cause and condition. Additional components or assemblies may be Suggested for repair or replacement, such as a water pump on a short block (reason code 4, technicianís recommendation based on substantial and informed experience).

Example:

If there is a failed head gasket with an external coolant leak, in addition to Requiring replacement of the head gasket, inspection of the following for cause and condition is Required: Block, Cooling System, Cylinder Head. It may be Suggested that additional inspections be performed, such as the other head gasket on a V-type engine.

ENGINE COMPONENTS

ACCELERATOR PEDAL POSITION SENSORS

ACCELERATOR PEDAL POSITION SENSOR INSPECTION

Condition Code Procedure

Attaching hardware

missing C Require replacement of

hardware. Attaching hardware

threads damaged A ... Require repair or replacement

of hardware. Attaching hardware

threads stripped

(threads missing) A ... Require repair or replacement

of hardware.

Connector broken A .. Require repair or replacement.

Connector (Weatherpack

type) leaking A . . Require repair or replacement.

Connector melted A (1) Require repair or

replacement.

Connector missing C Require replacement.

Inoperative B (2) Require repair or

replacement. Further inspection required.

Missing C Require replacement.

Resistance out of

specification B .. Require repair or replacement.

Terminal broken A .. Require repair or replacement.

Terminal burned, affecting

performance A (1) Require repair or

replacement. Terminal burned, not

affecting performance .. 2 .. Suggest repair or replacement. Terminal corroded,

affecting performance .. A .. Require repair or replacement. Terminal corroded, not

affecting performance .. 2 .. Suggest repair or replacement. Terminal loose, affecting

performance B . . Require repair or replacement.

Terminal loose, not

affecting performance .. 1 .. Suggest repair or replacement. Threads stripped (threads

missing) A Require replacement.

Wire lead conductors

exposed B . . Require repair or replacement.

Wire lead corroded A .. Require repair or replacement.

Wire lead open A . . Require repair or replacement.

Wire lead shorted A .. Require repair or replacement.

(1) - Determine cause and correct prior to repair or

replacement of part.

(2) - Inoperative includes intermittent operation or out of OEM

specification. Some components may be serviceable; check for accepted cleaning procedure.

ACCESSORY BELTS

ACCESSORY BELT INSPECTION

Condition Code Procedure

Alignment incorrect B (1) Further inspection

required.

Cracked 1 Suggest replacement.

Frayed 1 Suggest replacement.

Missing C Require replacement.

Noisy 2 (2) Further inspection

required.

Plies separated A Require replacement.

Tension out of

specification B Require adjustment or

replacement. Worn beyond adjustment

range B Require replacement.

Worn so it contacts

bottom of pulley A Require replacement.

  1. - Determine cause of incorrect alignment and require repair.

  2. - Determine cause of noise and suggest repair.

ACCESSORY PULLEYS

ACCESSORY PULLEY INSPECTION

Condition Code Procedure

Alignment incorrect B .. Require repair or replacement.

Attaching hardware

broken A ... Require repair or replacement

of hardware. Attaching hardware

missing C Require replacement of

hardware. Attaching hardware not

functioning A ... Require repair or replacement

of hardware.

Bent A Require replacement.

Cracked A Require replacement.

Loose A . . Require repair or replacement.

Missing C Require replacement.

Pulley damaged, affecting

belt life A Require replacement.

ACTUATORS

See SENSORS AND ACTUATORS.

AIR CONDITIONING CYCLING SWITCHES

AIR CONDITIONING CYCLING SWITCH INSPECTION

Condition Code Procedure

Attaching hardware

missing C Require replacement of

hardware. Attaching hardware

threads damaged A ... Require repair or replacement

of hardware.

Attaching hardware

threads stripped

(threads missing) A ... Require repair or replacement

of hardware.

Connector broken A .. Require repair or replacement.

Connector (Weatherpack

type) leaking A .. Require repair or replacement.

Connector melted A (1) Require repair or

replacement.

Connector missing C Require replacement.

Contaminated A (2) Require repair or

replacement.

Inoperative B (3) Require repair or

replacement. Further inspection required.

Leaking A . . Require repair or replacement.

Missing C Require replacement.

Resistance out of

specification B .. Require repair or replacement.

Restricted, affecting

performance A . . Require repair or replacement.

Terminal broken A .. Require repair or replacement.

Terminal burned, affecting

performance A (1) Require repair or

replacement. Terminal burned, not

affecting performance .. 2 .. Suggest repair or replacement.
Terminal corroded,

affecting performance .. A .. Require repair or replacement.
Terminal corroded, not

affecting performance .. 2 .. Suggest repair or replacement.
Terminal loose, affecting

performance B . . Require repair or replacement.

Terminal loose, not

affecting performance .. 1 .. Suggest repair or replacement.

Threads damaged A . . Require repair or replacement.

Threads stripped (threads

missing) A Require replacement.

Wire lead conductors

exposed B . . Require repair or replacement.

Wire lead corroded A .. Require repair or replacement.

Wire lead open A . . Require repair or replacement.

Wire lead shorted A .. Require repair or replacement.

(1) - Determine cause and correct prior to repair or

replacement of part.

(2) - Determine source of contamination, such as engine

coolant, fuel, metal particles, or water. Require repair or replacement.

(3) - Inoperative includes intermittent operation or out of OEM

specification. Some components may be serviceable; check for accepted cleaning procedure.

AIR CONDITIONING PRESSURE SENSORS

AIR CONDITIONING PRESSURE SENSOR INSPECTION

Code

Condition

Attaching hardware
missing

Procedure

–° Require replacement of

hardware.

Attaching hardware

threads damaged A ... Require repair or replacement

of hardware. Attaching hardware threads stripped

(threads missing) A ... Require repair or replacement

of hardware.

Connector broken A .. Require repair or replacement.

Connector (Weatherpack

type) leaking A .. Require repair or replacement.

Connector melted A (1) Require repair or

replacement.

Connector missing C Require replacement.

Contaminated A (2) Require repair or

replacement.

Inoperative B (3) Require repair or

replacement. Further inspection required.

Leaking A . . Require repair or replacement.

Missing C Require replacement.

Resistance out of

specification B .. Require repair or replacement.

Restricted, affecting

performance A . . Require repair or replacement.

Terminal broken A .. Require repair or replacement.

Terminal burned, affecting

performance A (1) Require repair or

replacement. Terminal burned, not

affecting performance .. 2 .. Suggest repair or replacement.
Terminal corroded,

affecting performance .. A .. Require repair or replacement.
Terminal corroded, not

affecting performance .. 2 .. Suggest repair or replacement.
Terminal loose, affecting

performance B . . Require repair or replacement.

Terminal loose, not

affecting performance .. 1 .. Suggest repair or replacement.

Threads damaged A . . Require repair or replacement.

Threads stripped (threads

missing) A Require replacement.

Wire lead conductors

exposed B . . Require repair or replacement.

Wire lead corroded A .. Require repair or replacement.

Wire lead open A . . Require repair or replacement.

Wire lead shorted A .. Require repair or replacement.

(1) - Determine cause and correct prior to repair or

replacement of part.

(2) - Determine source of contamination, such as engine

coolant, fuel, metal particles, or water. Require repair or replacement.

(3) - Inoperative includes intermittent operation or out of

OEM specification. Some components may be serviceable; check for accepted cleaning procedure.

AIR DUCTS AND TUBES

AIR DUCT AND TUBE INSPECTION

Condition

Code

Procedure

Attaching hardware

broken A ... Require repair or replacement

of hardware. Attaching hardware

missing C Require replacement of

hardware. Attaching hardware not

functioning A ... Require repair or replacement

of hardware.

Leaking A . . Require repair or replacement.

Missing C Require replacement.

Restricted, affecting
performance A . . Require repair or replacement.

AIR FILTER ELEMENTS

AIR FILTER ELEMENT INSPECTION

Condition Code Procedure

Leaking A Require replacement.

Paper filter element

oil-soaked A (1) Require replacement.

Maintenance intervals ... 3 ... Suggest replacement to comply

with vehicleís OEM recommended service intervals.

Melted A Required replacement.

Missing C Require replacement.

Restricted, affecting

performance A Require replacement.

Water-contaminated A (1) Require replacement.

(1) - Further inspection required to determine cause. AIR FILTER GASKETS

See AIR FILTER HOUSINGS AND GASKETS.

AIR FILTER HOUSINGS AND GASKETS

AIR FILTER HOUSING AND GASKET INSPECTION

Condition Code Procedure

Attaching hardware

broken A ... Require repair or replacement

of hardware. Attaching hardware

missing C Require replacement of

hardware. Attaching hardware not

functioning A ... Require repair or replacement

of hardware.

Leaking A . . Require repair or replacement.

Missing C Require replacement.

AIR FUEL RATIO SENSORS

AIR FUEL RATIO SENSOR INSPECTION

Condition

Code

Procedure

Attaching hardware

missing C Require replacement of

hardware. Attaching hardware

threads damaged A ... Require repair or replacement

of hardware. Attaching hardware

threads stripped

(threads missing) A ... Require repair or replacement

of hardware.

Connector broken A .. Require repair or replacement.

Connector (Weatherpack

type) leaking A . . Require repair or replacement.

Connector melted A (1) Require repair or

replacement.

Connector missing C Require replacement.

Contaminated A (2) Require repair or

replacement.

Inoperative B (3) Require repair or

replacement. Further inspection required.

Leaking A . . Require repair or replacement.

Missing C Require replacement.

Resistance out of

specification B .. Require repair or replacement.

Restricted, affecting

performance A . . Require repair or replacement.

Terminal broken A .. Require repair or replacement.

Terminal burned, affecting

performance A (1) Require repair or

replacement. Terminal burned, not

affecting performance .. 2 .. Suggest repair or replacement. Terminal corroded,

affecting performance .. A .. Require repair or replacement. Terminal corroded, not

affecting performance .. 2 .. Suggest repair or replacement. Terminal loose, affecting

performance B . . Require repair or replacement.

Terminal loose, not

affecting performance .. 1 .. Suggest repair or replacement.

Threads damaged A . . Require repair or replacement.

Threads stripped (threads

missing) A Require replacement.

Wire lead conductors

exposed B . . Require repair or replacement.

Wire lead corroded A .. Require repair or replacement.

Wire lead open A . . Require repair or replacement.

Wire lead shorted A .. Require repair or replacement.

(1) - Determine cause and correct prior to repair or

replacement of part.

(2) - Determine source of contamination, such as engine

coolant, fuel, metal particles, or water. Require repair or replacement.

(3) - Inoperative includes intermittent operation or out of

OEM specification. Some components may be serviceable; check for accepted cleaning procedure.

AIR INJECTION CONTROL SOLENOIDS

AIR INJECTION CONTROL SOLENOID INSPECTION

Condition

Code

Procedure

Attaching hardware

missing C Require replacement of

hardware. Attaching hardware

threads damaged A .. Require repair or replacement

of hardware. Attaching hardware

threads stripped

(threads missing) A .. Require repair or replacement

of hardware.

Connector broken A . Require repair or replacement.

Connector (Weatherpack

type) leaking A . Require repair or replacement.

Connector melted A (1) Require repair or

replacement.

Connector missing C Require replacement.

Inoperative B (2) Require repair or

replacement. Further inspection required.

Leaking A . Require repair or replacement.

Missing C Require replacement.

Resistance out of

specification B . Require repair or replacement.

Restricted, affecting

performance A . Require repair or replacement.

Terminal broken A . Require repair or replacement.

Terminal burned, affecting

performance A (1) Require repair or

replacement. Terminal burned, not

affecting performance .. 2 . Suggest repair or replacement.
Terminal corroded,

affecting performance .. A . Require repair or replacement.
Terminal corroded, not

affecting performance .. 2 . Suggest repair or replacement.
Terminal loose, affecting

performance B . Require repair or replacement.

Terminal loose, not

affecting performance .. 1 . Suggest repair or replacement.

Threads damaged A . Require repair or replacement.

Threads stripped (threads

missing) A Require replacement.

Wire lead conductors

exposed B . Require repair or replacement.

Wire lead corroded A . Require repair or replacement.

Wire lead open A . Require repair or replacement.

Wire lead shorted A . Require repair or replacement.

(1) - Determine cause and correct prior to repair or

replacement of part.

(2) - Inoperative includes intermittent operation or out of

OEM specification. Some components may be serviceable; check for accepted cleaning procedure.

AIR PLENUMS

AIR PLENUM INSPECTION

Condition Code Procedure

Integrated air or fuel control components

inoperative A (1) Require repair or

replacement. Internal air or fuel

components damaged,

affecting performance .. A ... Require repair or replacement

of component. Internal air or fuel

components damaged, not

affecting performance No service suggested or

required. Internal air or fuel

components missing C Require replacement of

component.

Leaking A . . Require repair or replacement.

Restricted A .. Require repair or replacement.

Threads damaged A .. Require repair or replacement.

Threads stripped (threads

missing) A . . Require repair or replacement.

(1) - Inoperative includes intermittent operation or out of OEM specification.

AIR PUMP BELTS

AIR PUMP BELT INSPECTION

Condition Code Procedure

Alignment incorrect B (1) Further inspection

required.

Cracked 1 Suggest replacement.

Frayed 1 Suggest replacement.

Maintenance intervals ... 3 ... Suggest replacement to comply

with vehicle OEM recommended service intervals.

Missing C Require replacement.

Noisy 2 (2) Further inspection

required.

Plies separated A Require replacement.

Tension out of

specification B Require adjustment or

replacement. Worn beyond adjustment

range B Require replacement.

Worn so it contacts bottom
of pulley A Require replacement.

  1. - Determine cause of incorrect alignment and require repair.

  2. - Determine cause of noise and suggest repair.

AIR PUMPS (ELECTRIC-DRIVEN)

AIR PUMP (ELECTRIC-DRIVEN) INSPECTION

Condition Code Procedure

Attaching hardware

broken A ... Require repair or replacement

of hardware. Attaching hardware

missing C Require replacement of

hardware. Attaching hardware not

functioning A ... Require repair or replacement

of hardware.

Connector broken A .. Require repair or replacement.

Connector (Weatherpack

type) leaking A .. Require repair or replacement.

Connector melted A (1) Require repair or

replacement.

Connector missing C Require replacement.

Inoperative A (2) Require replacement.

Leaking A Require replacement.

Missing C Require replacement.

Noisy 2 Suggest replacement.

Terminal broken A .. Require repair or replacement.

Terminal burned, affecting

performance A (1) Require repair or

replacement. Terminal burned, not

affecting performance .. 2 .. Suggest repair or replacement.
Terminal corroded,

affecting performance .. A .. Require repair or replacement.
Terminal corroded, not

affecting performance .. 2 .. Suggest repair or replacement.
Terminal loose, affecting

performance B . . Require repair or replacement.

Terminal loose, not

affecting performance .. 1 .. Suggest repair or replacement.

Threads damaged A . . Require repair or replacement.

Threads stripped (threads

missing) A . . Require repair or replacement.

(1) - Determine cause and correct prior to repair or

replacement of part.

(2) - Inoperative includes intermittent operation or out

of OEM specification.

AIR TUBES

See AIR DUCTS AND TUBES.

ASPIRATOR, CHECK AND DECEL VALVES

ASPIRATOR, CHECK AND DECEL VALVE INSPECTION

Condition Code Procedure

Attaching hardware

broken A ... Require repair or replacement

of hardware. Attaching hardware

missing C Require replacement of

hardware.

Attaching hardware not
functioning A ... Require repair or replacement

of hardware.

Inoperative A (1) Require repair or

replacement.

Leaking A Require replacement.

Melted, affecting

performance A Require replacement.

Melted, not affecting

performance No service suggested or

required.

Missing C Require replacement.

Threads damaged A . . Require repair or replacement.

Threads stripped (threads
missing) A . . Require repair or replacement.

(1) - Inoperative includes intermittent operation or out of OEM specification.

BAFFLES

See SHROUDS, BAFFLES AND DEFLECTORS.

BALLAST PRIMARY SUPPLY RESISTOR WIRES

See BALLAST RESISTORS AND PRIMARY SUPPLY RESISTOR WIRES .

BALLAST RESISTORS AND PRIMARY SUPPLY RESISTOR WIRES

BALLAST RESISTOR AND PRIMARY SUPPLY RESISTOR WIRE INSPECTION
Condition Code Procedure

Attaching hardware

broken A ... Require repair or replacement

of hardware. Attaching hardware

missing C Require replacement of

hardware. Attaching hardware not

functioning A ... Require repair or replacement

of hardware.

Conductor exposed A Require replacement.

Connector broken A .. Require repair or replacement.

Connector melted A (1) Require repair or

replacement.

Connector missing C Require replacement.

Inoperative A (2) Require replacement.

Insulation overheated ... A Require replacement.

Terminal broken A . . Require repair or replacement.

Terminal burned, affecting

performance A (1) Require repair or

replacement. Terminal burned, not

affecting performance .. 2 .. Suggest repair or replacement. Terminal corroded,

affecting performance .. A .. Require repair or replacement. Terminal corroded, not

affecting performance .. 2 .. Suggest repair or replacement. Terminal loose, affecting

performance B . . Require repair or replacement.

Terminal loose, not

affecting performance .. 1 .. Suggest repair or replacement.

(1) - Determine cause and correct prior to repair or

replacement of part.

(2) - Inoperative includes intermittent operation or out

of OEM specification.

BAROMETRIC PRESSURE SENSORS

BAROMETRIC PRESSURE SENSOR INSPECTION

Condition Code Procedure

Attaching hardware

missing C Require replacement of

hardware. Attaching hardware

threads damaged A ... Require repair or replacement

of hardware. Attaching hardware

threads stripped

(threads missing) A ... Require repair or replacement

of hardware.

Connector broken A ... Require repair or replacement.

Connector (Weatherpack

type) leaking A . . Require repair or replacement.

Connector melted A (1) Require repair or

replacement.

Connector missing C Require replacement.

Contaminated A (2) Require repair or

replacement.

Inoperative B (3) Require repair or

replacement. Further inspection required.

Leaking A . . Require repair or replacement.

Missing C Require replacement.

Resistance out of

specification B .. Require repair or replacement.

Restricted, affecting

performance A . . Require repair or replacement.

Terminal broken A .. Require repair or replacement.

Terminal burned, affecting

performance A (1) Require repair or

replacement. Terminal burned, not

affecting performance .. 2 .. Suggest repair or replacement. Terminal corroded,

affecting performance .. A .. Require repair or replacement. Terminal corroded, not

affecting performance .. 2 .. Suggest repair or replacement. Terminal loose, affecting

performance B . . Require repair or replacement.

Terminal loose, not

affecting performance .. 1 .. Suggest repair or replacement.

Threads damaged A . . Require repair or replacement.

Threads stripped (threads

missing) A Require replacement.

Wire lead conductors

exposed B . . Require repair or replacement.

Wire lead corroded A .. Require repair or replacement.

Wire lead open A . . Require repair or replacement.

Wire lead shorted A .. Require repair or replacement.

(1) - Determine cause and correct prior to repair or

replacement of part.

(2) - Determine source of contamination, such as engine coolant,

fuel, metal particles, or water. Require repair or replacement.

(3) - Inoperative includes intermittent operation or out of

OEM specification. Some components may be serviceable; check for accepted cleaning procedure.

BATTERIES

Proper operation of any electrical system or component can be affected by battery condition. The battery(ies) must meet or exceed minimum specification for vehicle as equipped and test to that specific batteryís CCA.

Definition of Terms

* Battery Performance Testing

Testing that determines whether or not a battery meets both vehicle OEM and battery manufacturerís specifications.

* Cold Cranking Amp (CCA) Rating

The number of amperes a new, fully charged battery at 0 F (-17.8 C) can deliver for 30 seconds and maintain at least a voltage of 1.2 volts per cell (7.2 volts for a 12-volt battery).

* Cranking Amps (CA)

The number of amperes a new, fully charged battery, typically at 32 F (0 C) can deliver for 30 seconds and maintain at least a voltage of 1.2 volts per cell (7.2 volts for a 12-volt battery).

* OEM Cranking Amps

The minimum CCA required by the original vehicle manufacturer for a specific vehicle.

BATTERY INSPECTION

Condition Code Procedure

Battery frozen (1) Further inspection

required.

Case leaking A Require replacement.

Casing swollen A (2) Further inspection

required.

Circuit open internally . A Require replacement.

Electrolyte

contamination A (2) Further inspection

required. Electrolyte

discoloration A (2) Further inspection

required. Fails to accept and

hold charge A (3) Require replacement.

Fluid level low B (4) Further inspection

required.

Out of performance specification

for battery B (5) Require replacement.

Out of specification for
application B (5) Require replacement.

Post (top or side) burned,

affecting performance .. A (6) Require repair or

replacement.

Post (top or side) burned, not affecting

performance 2 (6) Suggest repair or

replacement. Post (top or side) corroded, affecting

performance A Require repair.

Post (top or side) corroded, not affecting

performance 2 Suggest repair.

Post (top or side)

loose A Require replacement.

Post (top or side) melted, affecting

performance A (6) Require repair or

replacement. Post (top or side) melted, not affecting

performance 2 (6) Suggest repair or

replacement.

Specific gravity low .... B (7) Further inspection

required.

State of charge low A (7) Further inspection

required.

Top dirty 2 Suggest cleaning battery.

Top wet A ... (8) Require cleaning battery.

Further inspection required.

Vent cap loose A ... Require repair or replacement

of vent cap.

Vent cap missing C Require replacement of vent

cap.

(1) - DO NOT attempt to charge a frozen battery. Allow

battery to warm thoroughly and then performance-test. If battery fails performance test, require replacement.

(2) - No service suggested or required unless the battery

fails performance test, in which case, require replacement.

(3) - This phrase refers to a battery that fails to either

accept and/or retain a charge using appropriate times listed in the Battery Charging Guide of the BCI Service Manual, battery charger operating manual, or battery manufacturerís specifications.

(4) - Determine cause of low fluid level. Refill to proper

level(s) with water (distilled water preferred). Recharge battery and performance-test.

(5) - The battery may meet battery manufacturerís

specifications but test below the minimum specification defined by the vehicleís OEM for that vehicle.

(6) - Determine cause and correct prior to repair or

replacement of part.

(7) - Recharge and test to manufacturerís specifications.

If battery fails performance test, require replacement.

(8) - Check fluid level and adjust to manufacturerís

specification. Suggest checking charging system for proper operation.

BATTERY CABLES, WIRES AND CONNECTORS

BATTERY CABLE, WIRE AND CONNECTOR INSPECTION

Condition Code Procedure

Application incorrect ... B .. Require repair or replacement.
Attaching hardware

broken A ... Require repair or replacement

of hardware. Attaching hardware

missing C Require replacement of

hardware. Attaching hardware not

functioning A ... Require repair or replacement

of hardware.

Connector broken A .. Require repair or replacement.

Connector melted A (1) Require repair or

replacement.

Connector missing C Require replacement.

Insulation damaged,

conductors exposed A (2) Require repair or

replacement. Insulation damaged,

conductors not exposed . 1 Suggest replacement.

Open A . . Require repair or replacement.

Protective shield

(conduit) melted 2 (1) Suggest repair or

replacement. Protective shield

(conduit) missing 2 .. Suggest repair or replacement.

Resistance (voltage drop)

out of specification ... A .. Require repair or replacement.

Routed incorrectly B Require repair.

Secured incorrectly B Require repair.

Shorted A . . Require repair or replacement.

Terminal broken A .. Require repair or replacement.

Terminal burned, affecting

performance A (1) Require repair or

replacement. Terminal burned, not

affecting performance .. 2 .. Suggest repair or replacement.
Terminal corroded,

affecting performance .. A .. Require repair or replacement.
Terminal corroded, not

affecting performance .. 2 .. Suggest repair or replacement.
Terminal loose, affecting

performance B . . Require repair or replacement.

Terminal loose, not

affecting performance .. 1 .. Suggest repair or replacement.
Voltage drop out of

specification A . . Require repair or replacement.

(1) - Determine cause and correct prior to repair or

replacement of part.

(2) - Exposed conductor at replacement (aftermarket) terminal

end does not require repair or replacement.

BATTERY CONNECTORS

See BATTERY CABLES, WIRES AND CONNECTORS.

BATTERY TRAYS AND HOLD DOWN HARDWARE

BATTERY TRAY AND HOLD DOWN HARDWARE INSPECTION

Condition Code Procedure

Battery improperly

secured 2 Suggest repair.

Bent, affecting

performance A . . Require repair or replacement.

Bent, not affecting

performance No service suggested or

required. Broken, affecting

performance A . . Require repair or replacement.

Broken, not affecting

performance No service suggested or

required. Corroded, affecting

performance A . . Require repair or replacement.

Corroded, not affecting

performance 2 . . Suggest repair or replacement.

Cracked, affecting

performance A . . Require repair or replacement.

Cracked, not affecting

performance 1 . . Suggest repair or replacement.

Missing C Require replacement.

Threads damaged A . . Require repair or replacement.

Threads stripped (threads

missing) A Require replacement.

Water drain clogged A Require repair.

BATTERY WIRES

See BATTERY CABLES, WIRES AND CONNECTORS.

BELT-DRIVEN AIR PUMPS

BELT-DRIVEN AIR PUMP INSPECTION

Condition Code Procedure

Attaching hardware

broken A ... Require repair or replacement

of hardware. Attaching hardware

missing C Require replacement of

hardware. Attaching hardware not

functioning A ... Require repair or replacement

of hardware.

Inoperative A (1) Require replacement.

Leaking A Require replacement.

Missing C Require replacement.

Noisy 2 Suggest replacement.

Pulley alignment

incorrect B .. Require repair or replacement.

Pulley bent A Require replacement.

Pulley cracked A Require replacement.

Pulley loose A .. Require repair or replacement.

Pulley missing C Require replacement.

Threads damaged A . . Require repair or replacement.

Threads stripped (threads

missing) A . . Require repair or replacement.

(1) - Inoperative includes intermittent operation or out of OEM specification.

BELT IDLER ASSEMBLIES (ACCESSORY AND CAM BELTS)

BELT IDLER ASSEMBLY (ACCESSORY AND CAM BELT) INSPECTION
Condition Code Procedure

Alignment incorrect B .. Require repair or replacement.

Attaching hardware

broken A ... Require repair or replacement

of hardware. Attaching hardware

missing C Require replacement of

hardware. Attaching hardware not

functioning A ... Require repair or replacement

of hardware.

Bearings worn 1 Suggest replacement.

Cracked 2 Suggest replacement.

Missing C Require replacement.

Noisy 2 Suggest replacement.

Seized A . . Require repair or replacement.

BELT TENSIONERS (ACCESSORY AND CAM BELTS)

BELT TENSIONER (ACCESSORY AND CAM BELT) INSPECTION

Condition Code Procedure

Alignment incorrect B .. Require repair or replacement.

Attaching hardware

broken A . . Require repair or replacement

of hardware. Attaching hardware

missing C Require replacement of

hardware. Attaching hardware not

functioning A ... Require repair or replacement

of hardware.

Bearings worn 1 Suggest replacement.

Belt tension incorrect .. B ... Require adjustment or repair.

Cracked 2 Suggest replacement.

Missing C Require replacement.

Noisy 2 Suggest replacement.

Pulley damaged, affecting

belt life A Require replacement.

Seized A . . Require repair or replacement.

BOOST CONTROL MECHANISMS

See WASTE GATES AND BOOST CONTROL MECHANISMS.

CAMSHAFT POSITION SENSORS

CAMSHAFT POSITION SENSOR INSPECTION

Condition

Code

Procedure

Attaching hardware

missing C Require replacement of

hardware. Attaching hardware threads

damaged A ... Require repair or replacement

of hardware. Attaching hardware

threads stripped

(threads missing) A ... Require repair or replacement

of hardware.

Connector broken A .. Require repair or replacement.

Connector (Weatherpack

type) leaking A .. Require repair or replacement.

Connector melted A (1) Require repair or

replacement.

Connector missing C Require replacement.

Contaminated A (2) Require repair or

replacement.

Inoperative B (3) Require repair or

replacement. Further inspection required.

Leaking A . . Require repair or replacement.

Missing C Require replacement.

Terminal broken A .. Require repair or replacement.

Terminal burned, affecting

performance A (1) Require repair or

replacement. Terminal burned, not

affecting performance .. 2 .. Suggest repair or replacement. Terminal corroded,

affecting performance .. A .. Require repair or replacement. Terminal corroded, not

affecting performance .. 2 .. Suggest repair or replacement. Terminal loose, affecting

performance B . . Require repair or replacement.

Terminal loose, not

affecting performance .. 1 .. Suggest repair or replacement. Wire lead conductors

exposed B . . Require repair or replacement.

Wire lead corroded A .. Require repair or replacement.

Wire lead open A . . Require repair or replacement.

Wire lead shorted A .. Require repair or replacement.

(1) - Determine cause and correct prior to repair or

replacement of part.

(2) - Determine source of contamination, such as engine

coolant, fuel, metal particles, or water. Require repair or replacement.

(3) - Inoperative includes intermittent operation or out of

OEM specification. Some components may be serviceable; check for accepted cleaning procedure.

CARBURETORS AND CHOKES

NOTE: Proper operation of a carburetor includes the ability to control air/fuel mixtures during all phases or driving operation to comply with all federal and local emissions standards. Adjustments are to be considered repairs.

CARBURETOR AND CHOKE INSPECTION

Condition Code Procedure

Air/fuel control

incorrect B .. Require repair or replacement.

Application incorrect ... B .. Require repair or replacement. Attaching hardware

broken A ... Require repair or replacement

of hardware. Attaching hardware

missing C Require replacement of

hardware. Attaching hardware not

functioning A ... Require repair or replacement

of hardware.

Components binding A .. Require repair or replacement.

Components damaged, affecting operation or

performance A . . Require repair or replacement.

Components missing C Require replacement of

components.

Contaminated A (1) Require repair or

replacement. Further inspection required. Controlling linkages

binding A ... Require repair or replacement

of linkage.

Leaking A . . Require repair or replacement.

Mechanical operation

incorrect B .. Require repair or replacement.

Operating incorrectly ... B .. Require repair or replacement.

(1) - Some components may be serviceable; check for accepted cleaning procedure. Determine source of contamination, such as engine coolant, fuel, metal particles, or water. Require repair or replacement.

CASTING CORE PLUGS AND EXPANSION PLUGS

CASTING CORE PLUG AND EXPANSION PLUG INSPECTION

Condition Code Procedure

Leaking A Require replacement.

Material type
incorrect 2 Suggest replacement.

CHARGE AIR COOLERS "INTERCOOLERS" (CAC)

CHARGE AIR COOLER "INTERCOOLER" (CAC) INSPECTION

Condition Code Procedure

Air-to-air intercooler

leaking, affecting boost

performance A .. Require repair or replacement.

Attaching hardware

broken A ... Require repair or replacement

nf harriwa r<= .

Attaching hardware

missing C Require replacement of

hardware. Attaching hardware not

functioning A ... Require repair or replacement

of hardware.

Leaking coolant A .. Require repair or replacement.

Missing C Require replacement.

Restricted, affecting
performance A . . Require repair or replacement.

CHECK VALVES

See ASPIRATOR, CHECK AND DECEL VALVES.

CHOKES

See CARBURETORS AND CHOKES.

CLUTCH PEDAL POSITION SWITCHES

CLUTCH PEDAL POSITION SWITCH INSPECTION

Condition Code Procedure

Attaching hardware

missing C Require replacement of

hardware. Attaching hardware threads

damaged A ... Require repair or replacement

of hardware. Attaching hardware

threads stripped

(threads missing) A ... Require repair or replacement

of hardware.

Connector broken A .. Require repair or replacement.

Connector melted A (1) Require repair or

replacement.

Connector missing C Require replacement.

Inoperative B (2) Require repair or

replacement. Further inspection required.

Missing C Require replacement.

Resistance out of

specification B .. Require repair or replacement.

Terminal broken A .. Require repair or replacement.

Terminal burned, affecting

performance A (1) Require repair or

replacement. Terminal burned, not

affecting performance .. 2 .. Suggest repair or replacement. Terminal corroded,

affecting performance .. A .. Require repair or replacement. Terminal corroded, not

affecting performance .. 2 .. Suggest repair or replacement. Terminal loose, affecting

performance B . . Require repair or replacement.

Terminal loose, not

affecting performance .. 1 .. Suggest repair or replacement.

Threads damaged A . . Require repair or replacement.

Threads stripped (threads

missing) A Require replacement.

Wire lead conductors

exposed B . . Require repair or replacement.

Wire lead corroded A .. Require repair or replacement.

Wire lead open A . . Require repair or replacement.

Wire lead shorted A .. Require repair or replacement.

(1) - Determine cause and correct prior to repair or

replacement of part.

(2) - Inoperative includes intermittent operation or out of OEM

specification. Some components may be serviceable; check for accepted cleaning procedure.

COLD START INJECTORS

See FUEL AND COLD START INJECTORS.

CONNECTORS

See WIRING HARNESSES AND CONNECTORS.

COOLANT

COOLANT INSPECTION

Condition Code Procedure

Acidity (pH) incorrect .. 1 Suggest correction or

replacement.

Contaminated B (1) Require replacement or

recycling. Further inspection

required.

Level low B ... (2) Require filling to proper

level.

Maintenance intervals ... 3 (3) Suggest replacement.

Mixture incorrect B Require correction or

replacement.
Type incorrect B Require replacement.

(1) - Determine source of contamination and require

correction prior to coolant replacement.

  1. - Determine source of incorrect level and suggest repair.

  2. - The system should be drained and/or flushed and

refilled with correct coolant according to OEM recommended service interval and procedures.

COOLANT RECOVERY TANKS

COOLANT RECOVERY TANK INSPECTION

Condition Code Procedure

Attaching hardware

broken A . . Require repair or replacement

of hardware. Attaching hardware

missing C Require replacement of

hardware. Attaching hardware not

functioning A . . Require repair or replacement

of hardware.
Leaking A . Require repair or replacement.

Missing (if original
equipment)

–° Require replacement.

COOLING FAN MOTOR MODULES

See COOLING FAN MOTOR RELAYS AND MODULES.

COOLING FAN MOTOR RELAYS AND MODULES

COOLING FAN MOTOR RELAY AND MODULE INSPECTION

Condition Code Procedure

Attaching hardware

broken A ... Require repair or replacement

of hardware. Attaching hardware

missing C Require replacement of

hardware. Attaching hardware not

functioning A ... Require repair or replacement

of hardware.

Connector broken A .. Require repair or replacement.

Connector (Weatherpack

type) leaking A .. Require repair or replacement.

Connector melted A (1) Require repair or

replacement.

Connector missing C Require replacement.

Housing cracked 2 . . Suggest repair or replacement.

Malfunctioning A (2) Require repair or

replacement.

Missing C Require replacement.

Terminal broken A . . Require repair or replacement.

Terminal burned, affecting

performance A (1) Require repair or

replacement. Terminal burned, not

affecting performance .. 2 .. Suggest repair or replacement. Terminal corroded,

affecting performance .. A .. Require repair or replacement. Terminal corroded, not

affecting performance .. 2 .. Suggest repair or replacement. Terminal loose, affecting

performance B . . Require repair or replacement.

Terminal loose, not

affecting performance .. 1 .. Suggest repair or replacement. Wire lead conductors

exposed B . . Require repair or replacement.

Wire lead corroded A .. Require repair or replacement.

Wire lead open A . . Require repair or replacement.

Wire lead shorted A .. Require repair or replacement.

(1) - Determine cause and correct prior to repair or

replacement of part.

(2) - Includes inoperative, intermittent operation, failure

to perform all functions, or out of OEM specification.

COOLING FAN MOTOR RESISTORS

COOLING FAN MOTOR RESISTOR INSPECTION

Condition Code Procedure

Application incorrect ... B Require replacement.

Attaching hardware

broken A ... Require repair or replacement

of hardware. Attaching hardware

missing C Require replacement of

hardware. Attaching hardware not

functioning A ... Require repair or replacement

of hardware.

Connector broken A .. Require repair or replacement.

Connector (Weatherpack

type) leaking A .. Require repair or replacement.

Connector melted A (1) Require repair or

replacement.

Connector missing C Require replacement.

Missing C Require replacement.

Open A Require replacement.

Resistance out of

specification B . . Require repair or replacement.

Shorted A Require replacement.

Terminal broken A . . Require repair or replacement.

Terminal burned, affecting

performance A (1) Require repair or

replacement. Terminal burned, not

affecting performance ... 2 . Suggest repair or replacement.
Terminal corroded,

affecting performance ... A . Require repair or replacement.
Terminal corroded, not

affecting performance ... 2 . Suggest repair or replacement.
Terminal loose, affecting

performance B . Require repair or replacement.

Terminal loose, not

affecting performance ... 1 . Suggest repair or replacement.

(1) - Determine cause and correct prior to repair or replacement of part.

COOLING FAN MOTOR SENSORS AND SWITCHES

COOLING FAN MOTOR SENSOR AND SWITCH INSPECTION

Condition Code Procedure

Attaching hardware

missing C Require replacement of

hardware. Attaching hardware threads

damaged A ... Require repair or replacement

of hardware. Attaching hardware threads stripped

(threads missing) A ... Require repair or replacement

of hardware.

Connector broken A .. Require repair or replacement.

Connector melted A (1) Require repair or

replacement.

Connector missing C Require replacement.

Contaminated A (2) Require repair or

replacement.

Inoperative B (3) Require repair or

replacement. Further inspection required.

Leaking A . . Require repair or replacement.

Missing C Require replacement.

Resistance out of

specification B .. Require repair or replacement.

Terminal broken A .. Require repair or replacement.

Terminal burned, affecting

performance A (1) Require repair or

replacement. Terminal burned, not

affecting performance .. 2 .. Suggest repair or replacement.
Terminal corroded,

affecting performance .. A .. Require repair or replacement.
Terminal corroded, not

affecting performance .. 2 .. Suggest repair or replacement.
Terminal loose, affecting

performance B . . Require repair or replacement.

Terminal loose, not

affecting performance .. 1 .. Suggest repair or replacement.

Threads damaged A . . Require repair or replacement.

Threads stripped (threads

missing) A Require replacement.

Wire lead conductors

exposed B . . Require repair or replacement.

Wire lead corroded A .. Require repair or replacement.

Wire lead open A . . Require repair or replacement.

Wire lead shorted A .. Require repair or replacement.

(1) - Determine cause and correct prior to repair or

replacement of part.

(2) - Determine source of contamination, such as engine

coolant, fuel, metal particles, or water. Require repair or replacement.

(3) - Inoperative includes intermittent operation or out of

OEM specification. Some components may be serviceable; check for accepted cleaning procedure.

COOLING FAN MOTOR SWITCHES

See COOLING FAN MOTOR SENSORS AND SWITCHES .

COOLING FAN MOTORS

COOLING FAN MOTOR INSPECTION

Condition Code Procedure

Attaching hardware

broken A .. Require repair or replacement

of hardware. Attaching hardware

missing C Require replacement of

hardware. Attaching hardware not

functioning A . . Require repair or replacement

of hardware.

Connector broken A . Require repair or replacement.

Connector (Weatherpack
type) leaking A . Require repair or replacement.

Connector melted A (1) Require repair or

replacement.

Connector missing C Require replacement.

Hydraulic fan motor

leaking A . Require repair or replacement.

Inoperative A (2) Require replacement.

Missing C Require replacement.

Noisy 2 Suggest replacement.

Rotation incorrect for

application B . Require repair or replacement.

Terminal broken A . Require repair or replacement.

Terminal burned, affecting

performance A (1) Require repair or

replacement. Terminal burned, not

affecting performance .. 2 . Suggest repair or replacement.
Terminal corroded,

affecting performance .. A . Require repair or replacement.
Terminal corroded, not

affecting performance .. 2 . Suggest repair or replacement.
Terminal loose, affecting

performance B . Require repair or replacement.

Terminal loose, not

affecting performance .. 1 . Suggest repair or replacement.

Vibration 1 Suggest replacement.

Wire lead conductors

exposed B . Require repair or replacement.

Wire lead corroded A . Require repair or replacement.

Wire lead open A . Require repair or replacement.

Wire lead shorted A . Require repair or replacement.

(1) - Determine cause and correct prior to repair or

replacement of part.

(2) - Check fan motor/controls. Inoperative includes

intermittent operation or out of OEM specification.

CRANKSHAFT POSITION SENSORS

CRANKSHAFT POSITION SENSOR INSPECTION

Condition Code Procedure

Attaching hardware

missing C Require replacement of

hardware. Attaching hardware

threads damaged A ... Require repair or replacement

of hardware. Attaching hardware threads stripped

(threads missing) A ... Require repair or replacement

of hardware.

Connector broken A .. Require repair or replacement.

Connector (Weatherpack

type) leaking A . . Require repair or replacement.

Connector melted A (1) Require repair or

replacement.

Connector missing C Require replacement.

Contaminated A . . Require repair or replacement.

Inoperative B . . Require repair or replacement.

Further inspection required.
Leaking A . . Require repair or replacement.

Missing C Require replacement.

Resistance out of

specification B . . Require repair or replacement.

Terminal broken A . . Require repair or replacement.

Terminal burned, affecting

performance A (1) Require repair or

replacement. Terminal burned, not

affecting performance .. 2 .. Suggest repair or replacement. Terminal corroded,

affecting performance .. A .. Require repair or replacement. Terminal corroded, not

affecting performance .. 2 .. Suggest repair or replacement. Terminal loose, affecting

performance B . . Require repair or replacement.

Terminal loose, not

affecting performance .. 1 .. Suggest repair or replacement.

Threads damaged A . . Require repair or replacement.

Threads stripped (threads

missing) A Require replacement.

Wire lead conductors

exposed B . . Require repair or replacement.

Wire lead corroded A .. Require repair or replacement.

Wire lead open A . . Require repair or replacement.

Wire lead shorted A .. Require repair or replacement.

(1) - Determine cause and correct prior to repair or

replacement of part.

(2) - Determine source of contamination, such as engine

coolant, fuel, metal particles, or water. Require repair or replacement.

(3) - Inoperative includes intermittent operation or out of OEM

specification. Some components may be serviceable; check for accepted cleaning procedure.

DECEL VALVES

See ASPIRATOR, CHECK AND DECEL VALVES.

DEFLECTORS

See SHROUDS, BAFFLES AND DEFLECTORS.

DIP STICKS AND TUBES

DIP STICK AND TUBE INSPECTION

Condition Code Procedure

Application incorrect ... B Require replacement.

Bent 2 . . Suggest repair or replacement.

Broken, affecting

performance (for example,

fuel mixture) A . . Require repair or replacement.

Broken, not affecting

performance 2 . . Suggest repair or replacement.

Leaking, affecting

performance (for example,

fuel mixture) A .. Require repair or replacement.

Leaking, not affecting

performance 2 . . Suggest repair or replacement.

Missing –° Require replacement.

DIP STICK TUBES

See DIP STICKS AND TUBES.

DISTRIBUTOR ADVANCES AND RETARDERS (MECHANICAL AND VACUUM)

DISTRIBUTOR ADVANCE AND RETARDER (MECHANICAL AND VACUUM) INSPECTION
Condition Code Procedure

Attaching hardware

broken A ... Require repair or replacement

of hardware. Attaching hardware

missing C Require replacement of

hardware. Attaching hardware not

functioning A ... Require repair or replacement

of hardware.

Binding A . . Require repair or replacement.

Inoperative A (1) Require repair or

replacement.

Leaking A Require replacement.

Out of specification .... B .. Require repair or replacement.

(1) - Inoperative includes intermittent operation. DISTRIBUTOR BOOTS AND SHIELDS

DISTRIBUTOR BOOT AND SHIELD INSPECTION

Condition Code Procedure

Attaching hardware

broken A ... Require repair or replacement

of hardware. Attaching hardware

missing C Require replacement of

hardware. Attaching hardware not

functioning A ... Require repair or replacement

of hardware.

Deteriorated A Require replacement.

Leaking A Require replacement.

Missing A Require replacement.

Torn A Require replacement.

DISTRIBUTOR CAPS

DISTRIBUTOR CAP INSPECTION

Condition Code Procedure

Application incorrect ... B Require replacement.

Arcing A Require replacement.

Attaching hardware

broken A ... Require repair or replacement

of hardware.

Attaching hardware

missing C Require replacement of

hardware. Attaching hardware not

functioning A ... Require repair or replacement

of hardware.

Burned A Require replacement.

Carbon button missing ... A Require replacement.

Carbon button worn,

affecting performance . . A Require replacement.

Carbon button worn, not

affecting performance . . 1 Suggest replacement.

Carbon-tracked A Require replacement.

Cracked A Require replacement.

Loose 2 . . Suggest repair or replacement.

Terminal broken A .. Require repair or replacement.

Terminal burned, affecting

performance A (1) Require repair or

replacement. Terminal burned, not

affecting performance .. 2 .. Suggest repair or replacement. Terminal corroded,

affecting performance .. A .. Require repair or replacement. Terminal corroded, not

affecting performance .. 2 .. Suggest repair or replacement. Terminal eroded, affecting

performance A . . Require repair or replacement.

Terminal eroded, not

affecting performance No service suggested or

required. Terminal loose, affecting

performance B . . Require repair or replacement.

Terminal loose, not

affecting performance .. 1 .. Suggest repair or replacement.

(1) - Determine cause and correct prior to repair or replacement of part.

DISTRIBUTOR RETARDERS (MECHANICAL AND VACUUM)

See DISTRIBUTOR ADVANCES AND RETARDERS (MECHANICAL AND VACUUM) .

DISTRIBUTOR ROTORS

DISTRIBUTOR ROTOR INSPECTION

Condition Code Procedure

Application incorrect ... B Require replacement.

Attaching hardware

broken A ... Require repair or replacement

of hardware. Attaching hardware

missing C Require replacement of

hardware. Attaching hardware not

functioning A ... Require repair or replacement

of hardware.

Carbon-tracked A Require replacement.

Contact burned A Require replacement.

Corroded 1 Suggest replacement.

Eroded 1 Suggest replacement.

Loose A . . Require repair or replacement.

Out of specification .... B Require replacement.

DISTRIBUTOR SHIELDS

See DISTRIBUTOR BOOTS AND SHIELDS.

DISTRIBUTORS

DISTRIBUTOR INSPECTION

Condition Code Procedure

Attaching hardware

broken A ... Require repair or replacement

of hardware. Attaching hardware

missing C Require replacement of

hardware. Attaching hardware not

functioning A ... Require repair or replacement

of hardware. Bushings worn, affecting

performance A . . Require repair or replacement.

Bushings worn, not

affecting performance .. 1 .. Suggest repair or replacement. Cam lobes worn, affecting

performance A . . Require repair or replacement.

Cam lobes worn, not

affecting performance .. 1 .. Suggest repair or replacement.

Gear broken A .. Require repair or replacement.

Gear worn, affecting

performance A Require replacement.

Gear worn, not affecting

performance No service suggested or

required. Integrated pickup

triggering device

loose A . . Require repair or replacement.

Integrated pickup

triggering device

magnetism incorrect .... A .. Require repair or replacement. Leaking oil internally .. A .. Require repair or replacement.

Noisy 2 . . Suggest repair or replacement.

Pickup triggering device

(reluctor) broken A .. Require repair or replacement.

Pickup triggering device

(reluctor) loose A .. Require repair or replacement.

Pickup triggering device

(reluctor) weak A .. Require repair or replacement.

Reluctor (pickup

triggering device)

broken A . . Require repair or replacement.

Reluctor (pickup

triggering device)

loose A . . Require repair or replacement.

Reluctor (pickup

triggering device)

weak A . . Require repair or replacement.

Shaft bent A Require replacement.

Thrust washer broken .... A .. Require repair or replacement.

Thrust washer missing ... C .. Require repair or replacement. Thrust washer worn,

affecting performance .. A .. Require repair or replacement. Thrust washer worn, not

affecting performance .. 1 .. Suggest repair or replacement.

EARLY FUEL EVAPORATION VALVES (HEAT RISER ASSEMBLIES)

EARLY FUEL EVAPORATION VALVE (HEAT RISER ASSEMBLY) INSPECTION
Condition Code Procedure

Broken A . Require replacement of affected

parts.

Diaphragm inoperative ... A (1) Further inspection

required.

Leaking A . . Require repair or replacement.

Noisy 2 . . Suggest repair or replacement.

Seized A . Require replacement of affected

parts.

Spring broken B Require replacement of

spring(s).

Spring inoperative A (2) Require replacement of

spring(s).

(1) - Inoperative includes intermittent operation or out of

OEM specification. If the inoperative diaphragm is separate from the heat riser, then require replacement of the inoperative diaphragm. If the inoperative diaphragm is part of the heat riser, then replace the heat riser.

(2) - Inoperative includes intermittent operation or out of OEM

specification.

EGR COOLERS

See EGR PLATES AND COOLERS.

EGR EXHAUST MANIFOLD PASSAGES

See EGR INTAKE AND EXHAUST MANIFOLD PASSAGES.

EGR INTAKE AND EXHAUST MANIFOLD PASSAGES

EGR INTAKE AND EXHAUST MANIFOLD PASSAGE INSPECTION

Condition Code Procedure

Leaking A .. Require repair or replacement.

Restricted, affecting
performance A . . Require repair or replacement.

EGR PLATES AND COOLERS

EGR PLATE AND COOLER INSPECTION

Condition Code Procedure

Leaking A .. Require repair or replacement.

Missing C Require replacement.

Restricted, affecting
performance A . . Require repair or replacement.

ELECTRONIC SPARK CONTROL MODULES

ELECTRONIC SPARK CONTROL MODULE INSPECTION

Condition Code Procedure

Application incorrect ... B Require replacement.

Attaching hardware

missing C Require replacement of

hardware. Attaching hardware

threads damaged A ... Require repair or replacement

of hardware. Attaching hardware

threads stripped

(threads missing) A ... Require repair or replacement

of hardware.

Connector broken A .. Require repair or replacement.

Connector (Weatherpack

type) leaking A . . Require repair or replacement.

Connector melted A (1) Require repair or

replacement.

Connector missing A Require repair.

Contaminated A (2) Require repair or

replacement.

Leaking A . . Require repair or replacement.

Malfunctioning A (3) Require repair or

replacement.

Missing C Require replacement.

Terminal broken A . . Require repair or replacement.

Terminal burned, affecting

performance A (1) Require repair or

replacement. Terminal burned, not

affecting performance .. 2 .. Suggest repair or replacement. Terminal corroded,

affecting performance .. A .. Require repair or replacement. Terminal corroded, not

affecting performance .. 2 .. Suggest repair or replacement. Terminal loose, affecting

performance B . . Require repair or replacement.

Terminal loose, not

affecting performance .. 1 .. Suggest repair or replacement.

Threads damaged A . . Require repair or replacement.

Threads stripped (threads

missing) A Require replacement.

Wire lead conductors

exposed B . . Require repair or replacement.

Wire lead corroded A .. Require repair or replacement.

Wire lead open A . . Require repair or replacement.

Wire lead shorted A .. Require repair or replacement.

(1) - Determine cause and correct prior to repair or

replacement of part.

(2) - Determine source of contamination, such as engine coolant,

fuel, metal particles, or water. Require repair or replacement of source.

(3) - Includes inoperative, intermittent operation, failure to

perform all functions, or out of OEM specification. ELECTRONIC TRANSMISSION CONTROL DEVICES

ELECTRONIC TRANSMISSION CONTROL DEVICE INSPECTION

Condition Code Procedure

Attaching hardware

missing C Require replacement of

hardware. Attaching hardware

threads damaged A ... Require repair or replacement

of hardware. Attaching hardware

threads stripped

(threads missing) A ... Require repair or replacement

of hardware.

Connector broken A .. Require repair or replacement.

Connector (Weatherpack

type) leaking A . . Require repair or replacement.

Connector melted A (1) Require repair or

replacement.

Connector missing C Require replacement.

Contaminated A (2) Require repair or

replacement.

Leaking A . . Require repair or replacement.

Malfunctioning A (3) Require repair or

replacement.

Missing C Require replacement.

Resistance out of

specification B . . Require repair or replacement.

Restricted, affecting

performance A . . Require repair or replacement.

Terminal broken A .. Require repair or replacement.

Terminal burned, affecting

performance A (1) Require repair or

replacement. Terminal burned, not

affecting performance .. 2 .. Suggest repair or replacement.
Terminal corroded,

affecting performance .. A .. Require repair or replacement.
Terminal corroded, not

affecting performance .. 2 .. Suggest repair or replacement.
Terminal loose, affecting

performance B . . Require repair or replacement.

Terminal loose, not

affecting performance .. 1 .. Suggest repair or replacement.

Threads damaged A . . Require repair or replacement.

Threads stripped (threads

missing) A Require replacement.

Wire lead conductors

exposed B . . Require repair or replacement.

Wire lead corroded A .. Require repair or replacement.

Wire lead open A . . Require repair or replacement.

Wire lead shorted A .. Require repair or replacement.

(1) - Determine cause and correct prior to repair or

replacement of part.

(2) - Determine source of contamination, such as engine coolant,

fuel, metal particles, or water. Require repair or replacement.

(3) - Includes inoperative, intermittent operation, failure to perform all functions, or out of OEM specification.

ELECTRONIC TRANSMISSION FEEDBACK DEVICES

ELECTRONIC TRANSMISSION FEEDBACK DEVICE INSPECTION

Condition Code Procedure

Attaching hardware

missing C Require replacement of

hardware. Attaching hardware

threads damaged A ... Require repair or replacement

of hardware. Attaching hardware

threads stripped

(threads missing) A .. Require repair or replacement

of hardware.

Connector broken A .. Require repair or replacement.

Connector (Weatherpack

type) leaking A . . Require repair or replacement.

Connector melted A (1) Require repair or

replacement.

Connector missing C Require replacement.

Contaminated A (2) Require repair or

replacement.

Inoperative B (3) Require repair or

replacement. Further inspection required.

Leaking A . . Require repair or replacement.

Missing C Require replacement.

Resistance out of

specification B .. Require repair or replacement.

Restricted, affecting

performance A . . Require repair or replacement.

Terminal broken A .. Require repair or replacement.

Terminal burned, affecting

performance A (1) Require repair or

replacement. Terminal burned, not

affecting performance .. 2 .. Suggest repair or replacement. Terminal corroded,

affecting performance .. A .. Require repair or replacement. Terminal corroded, not

affecting performance .. 2 .. Suggest repair or replacement. Terminal loose, affecting

performance B . . Require repair or replacement.

Terminal loose, not

affecting performance .. 1 .. Suggest repair or replacement.

Threads damaged A . . Require repair or replacement.

Threads stripped (threads

missing) A Require replacement.

Wire lead conductors

exposed B . . Require repair or replacement.

Wire lead corroded A .. Require repair or replacement.

Wire lead open A . . Require repair or replacement.

Wire lead shorted A .. Require repair or replacement.

(1) - Determine cause and correct prior to repair or

replacement of part.

(2) - Determine source of contamination, such as engine coolant,

fuel, metal particles, or water. Require repair or replacement.

(3) - Inoperative includes intermittent operation or out of OEM specification. Some components may be serviceable; check for accepted cleaning procedure.

ENGINE COOLANT TEMPERATURE SENSORS

ENGINE COOLANT TEMPERATURE SENSOR INSPECTION

Condition Code Procedure

Attaching hardware

missing C Require replacement of

hardware. Attaching hardware

threads damaged A ... Require repair or replacement

of hardware. Attaching hardware

threads stripped

(threads missing) A ... Require repair or replacement

of hardware.

Connector broken A .. Require repair or replacement.

Connector (Weatherpack

type) leaking A . . Require repair or replacement.

Connector melted A (1) Require repair or

replacement.

Connector missing C Require replacement.

Contaminated A (2) Require repair or

replacement.

Inoperative B (3) Require repair or

replacement. Further inspection required.

Leaking A . . Require repair or replacement.

Missing C Require replacement.

Resistance out of

specification B .. Require repair or replacement.

Restricted, affecting

performance A . . Require repair or replacement.

Terminal broken A .. Require repair or replacement.

Terminal burned, affecting

performance A (1) Require repair or

replacement. Terminal burned, not

affecting performance .. 2 .. Suggest repair or replacement. Terminal corroded,

affecting performance .. A .. Require repair or replacement. Terminal corroded, not

affecting performance .. 2 .. Suggest repair or replacement. Terminal loose, affecting

performance B . . Require repair or replacement.

Terminal loose, not

affecting performance .. 1 .. Suggest repair or replacement.

Threads damaged A . . Require repair or replacement.

Threads stripped (threads

missing) A Require replacement.

Wire lead conductors

exposed B . . Require repair or replacement.

Wire lead corroded A .. Require repair or replacement.

Wire lead open A . . Require repair or replacement.

Wire lead shorted A .. Require repair or replacement.

(1) - Determine cause and correct prior to repair or

replacement of part.

(2) - Determine source of contamination, such as engine

coolant, fuel, metal particles, or water. Require repair or replacement.

(3) - Inoperative includes intermittent operation or out of

OEM specification. Some components may be serviceable; check for accepted cleaning procedure.

ENGINE COOLING SYSTEMS

NOTE: Overheating, poor engine performance, and insufficient cabin heat can be affected by, but are not limited to, all of the components in the engine cooling system.

ENGINE COVERS (OIL PAN, VALVE COVER, TIMING COVER)

ENGINE COVER (OIL PAN, VALVE COVER, TIMING COVER) INSPECTION
Condition Code Procedure

Attaching hardware

incorrect B Require replacement.

Attaching hardware

loose A . . Require repair or replacement.

Attaching hardware

missing C Require replacement.

Baffle loose 2 . . Suggest repair or replacement.

Baffle missing C Require replacement.

Bent, affecting

performance A . . Require repair or replacement.

Bent, not affecting

performance No service suggested or

required.

Cracked (not leaking) ... 2 .. Suggest repair or replacement.

Leaking externally A .. Require repair or replacement.

Leaking internally,

causing fluid

contamination A . . Require repair or replacement.

Missing C Require replacement.

Restricted passage A .. Require repair or replacement.

Threads damaged A . . Require repair or replacement.

ENGINE OIL

ENGINE OIL INSPECTION

Condition Code Procedure

Contaminated A . . (1) Require replacement of oil

and filter.

Level high B ... Determine source of incorrect

level and require repair.

Level low B ... Determine source of incorrect

level and require repair.

Maintenance intervals ... 3 ... Suggest replacement to comply

with vehicleís OEM recommended service intervals.

(1) - Determine source of contamination, such as engine coolant, fuel, metal particles, or water when changing oil. Require

repair or replacement.

ENGINE OIL CANISTERS

See ENGINE OIL FILTERS AND CANISTERS.

ENGINE OIL COOLERS (EXTERNAL)

ENGINE OIL COOLER (EXTERNAL) INSPECTION

Condition Code Procedure

Air flow restriction .... A .. Require repair or replacement.
Attaching hardware

broken A ... Require repair or replacement

of hardware. Attaching hardware

missing C Require replacement of

hardware. Attaching hardware not

functioning A ... Require repair or replacement

of hardware.

Bypassed A . . Require repair or replacement.

Connection leaking A .. Require repair or replacement.

Corroded 1 . . Suggest repair or replacement.

Fins damaged, affecting

performance A . . Require repair or replacement.

Fins damaged, not

affecting performance .. 2 .. Suggest repair or replacement.

Fluid flow restrictions . A .. Require repair or replacement.
Internal restrictions,

affecting performance .. A .. Require repair or replacement.

Leaking A . . Require repair or replacement.

Missing A Require replacement.

Threads damaged A .. Require repair or replacement.

Threads stripped (threads

missing) A Require replacement.

ENGINE OIL DRAIN PLUGS AND GASKETS

ENGINE OIL DRAIN PLUG AND GASKET INSPECTION

Condition Code Procedure

Leaking A . . Require repair or replacement.

Missing C Require replacement.

Threads damaged A (1) Require repair or

replacement.

(1) - Some OEMs require replacement of drain plug gasket when

removing drain plug. Inspect threads in oil pan for damage.

ENGINE OIL FILTERS AND CANISTERS

ENGINE OIL FILTER AND CANISTER INSPECTION

Condition Code Procedure

Bulged A ( 1) Require replacement.

Further inspection required. Canister attaching

hardware broken A ... Require repair or replacement

of hardware. Canister attaching

hardware loose A Require repair.

Canister attaching

hardware missing C Require replacement.

Canister attaching hardware not

functioning A ... Require repair or replacement

of hardware.

Center tube collapsed ... A (2) Require replacement.

Further inspection required.

Contaminated A (3) Require replacement of

oil and filter.

Dented 2 (4) Suggest replacement.

Further inspection required.

Leaking A . . Require repair or replacement.

Maintenance intervals ... 3 ... Suggest replacement to comply

with vehicleís OEM recommended service intervals.

  1. - Inspect pressure relief valve.

  2. - Inspect bypass.

  3. - Determine cause of contamination, such as engine coolant,

fuel, metal particles, or water when changing oil. Require repair or replacement.

(4) - Determine cause, such as broken motor mount.

ENGINE OIL GASKETS

See ENGINE OIL DRAIN PLUGS AND GASKETS.

ENGINE OIL PRESSURE GAUGES (MECHANICAL)

ENGINE OIL PRESSURE GAUGE (MECHANICAL) INSPECTION

Condition Code Procedure

Indicates out of range . . B (1) Further inspection

required.

Inoperative A (2) Further inspection

required.

Leaking A . . Require repair or replacement.

Reads inaccurately 2 .. Suggest repair or replacement.

(1) - Gauge may indicate problem with contaminated oil, level,

pressure, or temperature, or problem with gauge.

(2) - Gauge may indicate problem with contaminated oil, level,

pressure, or temperature, or problem with gauge. Inoperative includes intermittent operation, out of OEM specification, or out of range. Further inspection required to determine cause.

EVAPORATIVE EMISSION (EVAP) CANISTER FILTERS

EVAPORATIVE EMISSION (EVAP) CANISTER FILTER INSPECTION

Condition

Code

Procedure

Attaching hardware

broken A ... Require repair or replacement

of hardware. Attaching hardware

missing C Require replacement of

hardware. Attaching hardware not

functioning A ... Require repair or replacement

of hardware.

Maintenance interval .... 3 ... Suggest replacement to comply

with OEM recommended service

interval.

Missing C Require replacement.

Restricted, affecting

performance A Require replacement.

Restricted, not affecting

performance 1 Suggest replacement.

Water-contaminated A Require replacement.

EVAPORATIVE EMISSION (EVAP) CANISTER PURGE DEVICES

EVAPORATIVE EMISSION (EVAP) CANISTER PURGE DEVICE INSPECTION
Condition Code Procedure

Attaching hardware

missing C Require replacement of

hardware. Attaching hardware

threads damaged A ... Require repair or replacement

of hardware. Attaching hardware threads stripped

(threads missing) A ... Require repair or replacement

of hardware.

Connector broken A .. Require repair or replacement.

Connector (Weatherpack

type) leaking A . . Require repair or replacement.

Connector melted A (1) Require repair or

replacement.

Connector missing C Require replacement.

Contaminated A (2) Require repair or

replacement.

Inoperative B (3) Require repair or

replacement. Further inspection required.

Leaking A . . Require repair or replacement.

Missing C Require replacement.

Resistance out of

specification B .. Require repair or replacement.

Restricted, affecting

performance A . . Require repair or replacement.

Terminal broken A .. Require repair or replacement.

Terminal burned, affecting

performance A (1) Require repair or

replacement. Terminal burned, not

affecting performance .. 2 .. Suggest repair or replacement. Terminal corroded,

affecting performance .. A .. Require repair or replacement. Terminal corroded, not affecting performance .. 2 .. Suggest repair or replacement.

Terminal loose, affecting

performance B . . Require repair or replacement.

Terminal loose, not

affecting performance .. 1 .. Suggest repair or replacement.

Threads damaged A . . Require repair or replacement.

Threads stripped (threads

missing) A Require replacement.

Wire lead conductors

exposed B . . Require repair or replacement.

Wire lead corroded A .. Require repair or replacement.

Wire lead open A . . Require repair or replacement.

Wire lead shorted A .. Require repair or replacement.

(1) - Determine cause and correct prior to repair or

replacement of part.

(2) - Determine source of contamination, such as engine coolant,

fuel, metal particles, or water. Require repair or replacement.

(3) - Inoperative includes intermittent operation or out of

OEM specification. Some components may be serviceable; check for accepted cleaning procedure.

EVAPORATIVE EMISSION (EVAP) CANISTERS

EVAPORATIVE EMISSION (EVAP) CANISTER INSPECTION

Condition Code Procedure

Inoperative A (1) Require repair or

replacement.

Leaking A Require replacement.

Missing C Require replacement.

Saturated A Require replacement.

(1) - Inoperative includes intermittent operation or out of OEM specification.

EVAPORATIVE EMISSION (EVAP) FEEDBACK DEVICES

EVAPORATIVE EMISSION (EVAP) FEEDBACK DEVICE INSPECTION

Condition Code Procedure

Attaching hardware

missing C Require replacement of

hardware. Attaching hardware

threads damaged A ... Require repair or replacement

of hardware. Attaching hardware threads stripped

(threads missing) A ... Require repair or replacement

of hardware.

Connector broken A .. Require repair or replacement.

Connector (Weatherpack

type) leaking A . . Require repair or replacement.

Connector melted A (1) Require repair or

replacement.

Connector missing C Require replacement.

Contaminated A (2) Require repair or

replacement.

Inoperative B (3) Require repair or

replacement. Further inspection required.

Leaking A . . Require repair or replacement.

Missing C Require replacement.

Resistance out of

specification B .. Require repair or replacement.

Restricted, affecting

performance A . . Require repair or replacement.

Terminal broken A .. Require repair or replacement.

Terminal burned, affecting

performance A (1) Require repair or

replacement. Terminal burned, not

affecting performance .. 2 .. Suggest repair or replacement.
Terminal corroded,

affecting performance .. A .. Require repair or replacement.
Terminal corroded, not

affecting performance .. 2 .. Suggest repair or replacement.
Terminal loose, affecting

performance B . . Require repair or replacement.

Terminal loose, not

affecting performance .. 1 .. Suggest repair or replacement.

Threads damaged A . . Require repair or replacement.

Threads stripped (threads

missing) A Require replacement.

Wire lead conductors

exposed B . . Require repair or replacement.

Wire lead corroded A .. Require repair or replacement.

Wire lead open A . . Require repair or replacement.

Wire lead shorted A .. Require repair or replacement.

(1) - Determine cause and correct prior to repair or

replacement of part.

(2) - Determine source of contamination, such as engine coolant,

fuel, metal particles, or water. Require repair or replacement.

(3) - Inoperative includes intermittent operation or out of

OEM specification. Some components may be serviceable; check for accepted cleaning procedure.

EXHAUST GAS RECIRCULATION DEVICES

EXHAUST GAS RECIRCULATION DEVICE INSPECTION

Condition Code Procedure

Attaching hardware

missing C Require replacement of

hardware. Attaching hardware

threads damaged A ... Require repair or replacement

of hardware. Attaching hardware threads stripped

(threads missing) A ... Require repair or replacement

of hardware.

Connector broken A .. Require repair or replacement.

Connector (Weatherpack

type) leaking A . . Require repair or replacement.

Connector melted A (1) Require repair or

replacement.

Connector missing C Require replacement.

Contaminated A (2) Require repair or

replacement.

Inoperative B (3) Require repair or

replacement. Further inspection required.

Leaking A . . Require repair or replacement.

Missing C Require replacement.

Resistance out of

specification B .. Require repair or replacement.

Restricted, affecting

performance A . . Require repair or replacement.

Restricted, not affecting

performance 1 .. Suggest repair or replacement.

Terminal broken A .. Require repair or replacement.

Terminal burned, affecting

performance A (1) Require repair or

replacement. Terminal burned, not

affecting performance .. 2 .. Suggest repair or replacement.
Terminal corroded,

affecting performance .. A .. Require repair or replacement.
Terminal corroded, not

affecting performance .. 2 .. Suggest repair or replacement.
Terminal loose, affecting

performance B . . Require repair or replacement.

Terminal loose, not

affecting performance .. 1 .. Suggest repair or replacement.

Threads damaged A . . Require repair or replacement.

Threads stripped (threads

missing) A Require replacement.

Wire lead conductors

exposed B . . Require repair or replacement.

Wire lead corroded A .. Require repair or replacement.

Wire lead open A . . Require repair or replacement.

Wire lead shorted A .. Require repair or replacement.

(1) - Determine cause and correct prior to repair or

replacement of part.

(2) - Determine source of contamination, such as engine coolant,

fuel, metal particles, or water. Require repair or replacement.

(3) - Inoperative includes intermittent operation or out of

OEM specification. Some components may be serviceable; check for accepted cleaning procedure.

EXHAUST GAS RECIRCULATION FEEDBACK DEVICES

EXHAUST GAS RECIRCULATION FEEDBACK DEVICE INSPECTION

Condition Code Procedure

Attaching hardware

missing C Require replacement of

hardware. Attaching hardware

threads damaged A ... Require repair or replacement

of hardware. Attaching hardware threads stripped

(threads missing) A ... Require repair or replacement

of hardware.

Connector broken A .. Require repair or replacement.

Connector (Weatherpack

type) leaking A . . Require repair or replacement.

Connector melted A (1) Require repair or

replacement.

Connector missing C Require replacement.

Contaminated A (2) Require repair or

replacement.

Inoperative B (3) Require repair or

replacement. Further inspection required.

Leaking A . . Require repair or replacement.

Missing C Require replacement.

Resistance out of

specification B .. Require repair or replacement.

Restricted, affecting

performance A . . Require repair or replacement.

Restricted, not affecting

performance 1 .. Suggest repair or replacement.

Terminal broken A .. Require repair or replacement.

Terminal burned, affecting

performance A (1) Require repair or

replacement. Terminal burned, not

affecting performance .. 2 .. Suggest repair or replacement.
Terminal corroded,

affecting performance .. A .. Require repair or replacement.
Terminal corroded, not

affecting performance .. 2 .. Suggest repair or replacement.
Terminal loose, affecting

performance B . . Require repair or replacement.

Terminal loose, not

affecting performance .. 1 .. Suggest repair or replacement.

Threads damaged A . . Require repair or replacement.

Threads stripped (threads

missing) A Require replacement.

Wire lead conductors

exposed B . . Require repair or replacement.

Wire lead corroded A .. Require repair or replacement.

Wire lead open A . . Require repair or replacement.

Wire lead shorted A .. Require repair or replacement.

(1) - Determine cause and correct prior to repair or

replacement of part.

(2) - Determine source of contamination, such as engine coolant,

fuel, metal particles, or water. Require repair or replacement.

(3) - Inoperative includes intermittent operation or out of

OEM specification. Some components may be serviceable; check for accepted cleaning procedure.

EXPANSION PLUGS

See CASTING CORE PLUGS AND EXPANSION PLUGS .

FAN CONTROL SENSORS

FAN CONTROL SENSOR INSPECTION

Condition Code Procedure

Attaching hardware

missing C Require replacement of

hardware. Attaching hardware

threads damaged A ... Require repair or replacement

of hardware. Attaching hardware

threads stripped

(threads missing) A ... Require repair or replacement

of hardware.

Connector broken A .. Require repair or replacement.

Connector (Weatherpack

type) leaking A . . Require repair or replacement.

Connector melted A (1) Require repair or

replacement.

Connector missing C Require replacement.

Contaminated A (2) Require repair or

replacement.

Inoperative B (3) Require repair or

replacement. Further inspection required.

Leaking A . . Require repair or replacement.

Missing C Require replacement.

Resistance out of

specification B .. Require repair or replacement.

Restricted, affecting

performance A . . Require repair or replacement.

Terminal broken A .. Require repair or replacement.

Terminal burned, affecting

performance A (1) Require repair or

replacement. Terminal burned, not

affecting performance .. 2 .. Suggest repair or replacement. Terminal corroded,

affecting performance .. A .. Require repair or replacement. Terminal corroded, not

affecting performance .. 2 .. Suggest repair or replacement. Terminal loose, affecting

performance B . . Require repair or replacement.

Terminal loose, not

affecting performance .. 1 .. Suggest repair or replacement.

Threads damaged A . . Require repair or replacement.

Threads stripped (threads

missing) A Require replacement.

Wire lead conductors

exposed B . . Require repair or replacement.

Wire lead corroded A .. Require repair or replacement.

Wire lead open A . . Require repair or replacement.

Wire lead shorted A .. Require repair or replacement.

(1) - Determine cause and correct prior to repair or

replacement of part.

(2) - Determine source of contamination, such as engine

coolant, fuel, metal particles, or water. Require repair or replacement.

(3) - Inoperative includes intermittent operation or out of

OEM specification. Some components may be serviceable; check for accepted cleaning procedure.

FUEL

FUEL INSPECTION

Condition Code Procedure

Contaminated B (1) Require repair or

replacement.

Fuel incorrect B (2) Require flushing of

system.

(1) - Determine of source of contamination. Require repair or

replacement.

(2) - If a fuel other than specification fuel is present in the

system, the required service is to flush and fill with the correct fuel.

FUEL ACCUMULATORS AND DAMPERS

FUEL ACCUMULATOR AND DAMPER INSPECTION

Condition Code Procedure

Attaching hardware

broken A ... Require repair or replacement

of hardware. Attaching hardware

missing C Require replacement of

hardware. Attaching hardware not

functioning A ... Require repair or replacement

of hardware.

Connections leaking A .. Require repair or replacement.

Inoperative A (1) Require replacement.

Leaking A Require replacement.

(1) - Inoperative includes intermittent operation or out of OEM specification.

FUEL AND COLD START INJECTORS

NOTE: You are not required to replace injectors in sets. However, you may suggest replacement of all injectors for preventive maintenance.

FUEL AND COLD START INJECTOR INSPECTION

Condition Code Procedure

Application incorrect ... B Require replacement.

Attaching hardware

broken A ... Require repair or replacement

of hardware. Attaching hardware

missing C Require replacement of

hardware. Attaching hardware not

functioning A ... Require repair or replacement

of hardware.

Connector broken A .. Require repair or replacement.

Connector (Weatherpack

type) leaking A .. Require repair or replacement.

Connector melted A (1) Require repair or

replacement.
Connector missing C Require replacement.

Flow restricted B .. Require repair or replacement.

Inoperative B (2) Require repair or

replacement. Further inspection required.

Leaking A . . Require repair or replacement.

Resistance out of

specification B Require replacement.

Terminal broken A . . Require repair or replacement.

Terminal burned, affecting

performance A (1) Require repair or

replacement. Terminal burned, not

affecting performance .. 2 .. Suggest repair or replacement.
Terminal corroded,

affecting performance .. A .. Require repair or replacement.
Terminal corroded, not

affecting performance .. 2 .. Suggest repair or replacement.
Terminal loose, affecting

performance B . . Require repair or replacement.

Terminal loose, not

affecting performance .. 1 .. Suggest repair or replacement.

Threads damaged A . . Require repair or replacement.

Threads stripped (threads

missing) A Require replacement.

(1) - Determine cause and correct prior to repair or

replacement of part.

(2) - Inoperative includes intermittent operation, out of

OEM specification. Some components may be serviceable.

FUEL DAMPERS

See FUEL ACCUMULATORS AND DAMPERS.

FUEL DELIVERY CHECK VALVES

FUEL DELIVERY CHECK VALVE INSPECTION

Condition Code Procedure

Inoperative A ( 1) Require replacement.

Leaking externally A .. Require repair or replacement.

Missing C Require replacement.

Pressure leaking (bleeds

down) A . . Require repair or replacement.

(1) - Inoperative includes intermittent operation or out of OEM specification.

FUEL DISTRIBUTORS (BOSCH CIS)

FUEL DISTRIBUTOR (BOSCH CIS) INSPECTION

Condition Code Procedure

Inoperative A (1) Require repair or

replacement. Further inspection required.

Leaking A . . Require repair or replacement.

Out of specification .... B .. Require repair or replacement.

Restricted, affecting

performance A (2) Require repair or

replacement. Further inspection required.

  1. - Inoperative includes intermittent operation.

  2. - Some components may be serviceable; check for accepted

cleaning procedure.

FUEL FILLER NECKS AND RESTRICTORS

FUEL FILLER NECK AND RESTRICTOR INSPECTION

Condition Code Procedure

Attaching hardware

broken A ... Require repair or replacement

of hardware. Attaching hardware

missing C Require replacement of

hardware. Attaching hardware not

functioning A ... Require repair or replacement

of hardware.

Leaking A . . Require repair or replacement.

Missing C Require replacement.

Restricted 2 .. Suggest repair or replacement.

FUEL FILTERS

FUEL FILTER INSPECTION

Condition Code Procedure

Attaching hardware

broken A ... Require repair or replacement

of hardware. Attaching hardware

missing C Require replacement of

hardware. Attaching hardware not

functioning A ... Require repair or replacement

of hardware.

Leaking A . . Require repair or replacement.

Maintenance interval .... 3 ... Suggest replacement to comply

with OEM recommended service

interval.

Missing C Require replacement.

Restricted, affecting

performance A Require replacement.

Restricted, not affecting

performance 1 Suggest replacement.

Water-contaminated 2 Suggest replacement.

FUEL INJECTORS

FUEL INJECTOR INSPECTION

Condition Code Procedure

Attaching hardware

missing C Require replacement of

hardware. Attaching hardware

threads damaged A .. Require repair or replacement

of hardware. Attaching hardware threads stripped

(threads missing) A .. Require repair or replacement

of hardware.

Connector broken A . Require repair or replacement.

Connector (Weatherpack

type) leaking A . Require repair or replacement.

Connector melted A (1) Require repair or

replacement.

Connector missing C Require replacement.

Contaminated A (2) Require repair or

replacement.

Inoperative B (3) Require repair or

replacement. Further inspection required.

Leaking A . Require repair or replacement.

Missing C Require replacement.

Resistance out of

specification B . Require repair or replacement.

Restricted, affecting

performance A . Require repair or replacement.

Restricted, not affecting

performance 2 . Suggest repair or replacement.

Terminal broken A . Require repair or replacement.

Terminal burned, affecting

performance A (1) Require repair or

replacement. Terminal burned, not

affecting performance .. 2 . Suggest repair or replacement.
Terminal corroded,

affecting performance .. A . Require repair or replacement.
Terminal corroded, not

affecting performance .. 2 . Suggest repair or replacement.
Terminal loose, affecting

performance B . Require repair or replacement.

Terminal loose, not

affecting performance .. 1 . Suggest repair or replacement.

Threads damaged A . Require repair or replacement.

Threads stripped (threads

missing) A Require replacement.

Wire lead conductors

exposed B . Require repair or replacement.

Wire lead corroded A . Require repair or replacement.

Wire lead open A . Require repair or replacement.

Wire lead shorted A . Require repair or replacement.

(1) - Determine cause and correct prior to repair or

replacement of part.

(2) - Determine source of contamination, such as engine coolant,

fuel, metal particles, or water. Require repair or replacement.

(3) - Inoperative includes intermittent operation or out of

OEM specification. Some components may be serviceable; check for accepted cleaning procedure.

FUEL LEVEL SENDERS

FUEL LEVEL SENDER INSPECTION

Condition Code Procedure

Attaching hardware

broken A ... Require repair or replacement

of hardware. Attaching hardware

missing C Require replacement of

hardware. Attaching hardware not

functioning A ... Require repair or replacement

of hardware.

Inoperative A (1) Require repair or

replacement.

Leaking A . . Require repair or replacement.

Terminal broken A .. Require repair or replacement.

Terminal burned, affecting

performance A (2) Require repair or

replacement. Terminal burned, not

affecting performance .. 2 .. Suggest repair or replacement. Terminal corroded,

affecting performance .. A .. Require repair or replacement. Terminal corroded, not

affecting performance .. 2 .. Suggest repair or replacement. Terminal loose, affecting

performance B . . Require repair or replacement.

Terminal loose, not

affecting performance .. 1 .. Suggest repair or replacement. Wire lead conductors

exposed B . . Require repair or replacement.

Wire lead corroded A .. Require repair or replacement.

Wire lead open A . . Require repair or replacement.

Wire lead shorted A .. Require repair or replacement.

(1) - Inoperative includes intermittent operation or out of

OEM specification.

(2) - Determine cause and correct prior to repair or

replacement of part.

FUEL PRESSURE REGULATORS

FUEL PRESSURE REGULATOR INSPECTION

Condition Code Procedure

Contaminated 2 (1) Suggest repair or

replacement. Further inspection required.

Inoperative B (2) Require repair or

replacement. Leaking (internally or

externally) A .. Require repair or replacement.

Pressure out of

specification B .. Require repair or replacement.

Vapor bypass restricted . A .. Require repair or replacement.

(1) - Some components may be serviceable; check for accepted cleaning procedure. Determine source of contamination. Require repair or replacement.

(2) - Inoperative includes intermittent operation or out of OEM specification.

FUEL PUMPS (IN-TANK AND EXTERNAL, ELECTRICAL OR MECHANICAL)

FUEL PUMP (IN-TANK AND EXTERNAL, ELECTRICAL OR MECHANICAL) INSPECTION
Condition Code Procedure

Attaching hardware

broken A ... Require repair or replacement

of hardware. Attaching hardware

missing C Require replacement of

hardware. Attaching hardware not

functioning A ... Require repair or replacement

of hardware.

Connector broken A .. Require repair or replacement.

Connector (Weatherpack

type) leaking A .. Require repair or replacement.

Connector melted A (1) Require repair or

replacement.

Connector missing C Require replacement.

Contaminated A (2) Require replacement.

Inoperative A (3) Require repair or

replacement. Leaking externally

(includes pulsator) .... A .. Require repair or replacement.
Leaking internally

(includes pulsator) .... A .. Require repair or replacement.

Noisy 2 . . Suggest repair or replacement.

Out of specification .... B .. Require repair or replacement.

Terminal broken A .. Require repair or replacement.

Terminal burned, affecting

performance A (1) Require repair or

replacement. Terminal burned, not

affecting performance .. 2 .. Suggest repair or replacement.
Terminal corroded,

affecting performance .. A .. Require repair or replacement.
Terminal corroded, not

affecting performance .. 2 .. Suggest repair or replacement.
Terminal loose, affecting

performance B . . Require repair or replacement.

Terminal loose, not

affecting performance .. 1 .. Suggest repair or replacement.

Threads damaged A . . Require repair or replacement.

Threads stripped (threads

missing) A Require replacement.

Wire lead conductors

exposed B . . Require repair or replacement.

Wire lead corroded A .. Require repair or replacement.

Wire lead open A . . Require repair or replacement.

Wire lead shorted A .. Require repair or replacement.

(1) - Determine cause and correct prior to repair or

replacement of part.

(2) - Determine source of contamination. Require repair or

replacement.

(3) - Inoperative includes intermittent operation.

FUEL RAILS

FUEL RAIL INSPECTION

Condition Code Procedure

Attaching hardware

broken A ... Require repair or replacement

of hardware. Attaching hardware

missing C Require replacement of

hardware. Attaching hardware not

functioning A ... Require repair or replacement

of hardware.

Contaminated A (1) Require replacement.

Leaking A . . Require repair or replacement.

Restricted A . . Require repair or replacement.

Rust-pitted 1 Suggest replacement.

(1) - Determine source of contamination. Require repair or replacement.

FUEL RESTRICTORS

See FUEL FILLER NECKS AND RESTRICTORS.

FUEL TANKS

FUEL TANK INSPECTION

Condition Code Procedure

Attaching hardware

broken A ... Require repair or replacement

of hardware. Attaching hardware

missing C Require replacement of

hardware. Attaching hardware not

functioning A ... Require repair or replacement

of hardware.

Baffles loose A .. Require repair or replacement.

Contaminated A (1) Require repair.

Corroded internally A .. Require repair or replacement.

Distorted, affecting

performance B Require replacement.

Distorted, not affecting

performance No service suggested or

required.
Leaking A . . Require repair or replacement.

(1) - Determine source of contamination. Require repair or replacement.

GAS CAPS

GAS CAP INSPECTION

Condition Code Procedure

Application incorrect ... B Require replacement.

Fails to maintain proper

pressure A Require replacement.

Gaskets missing C Require replacement.

Leaking A Require replacement.

Missing C Require replacement.

Plugged (vacuum and

pressure relief) A Require replacement.

Seals missing C Require replacement.

GASKETS

GASKET INSPECTION

Condition Code Procedure

Leaking A ( 1) Require repair or

replacement.

(1) - Require inspection of mating and sealing surface and repair or replace as necessary.

GROMMETS (VALVE COVER)

GROMMET (VALVE COVER) INSPECTION

Condition Code Procedure

Leaking 2 (1) Suggest repair or

replacement.

(1) - Require inspection of mating and sealing surface and repair or replace as necessary.

HARMONIC DAMPERS

HARMONIC DAMPER INSPECTION

Condition Code Procedure

Application incorrect ... B Require replacement.

Attaching hardware

broken A . . Require repair or replacement

of hardware. Attaching hardware

missing C Require replacement of

hardware. Attaching hardware not

functioning A . . Require repair or replacement

of hardware.

Cracked A Require replacement.

Dented (fluid

type only) A Require replacement.

Keyway distorted A . Require repair or replacement.

Leaking (Fluid damper

only) A Require replacement.

Loose A Require replacement.

Noisy A Require replacement.

Outer ring slipped out of

position A Require replacement.

Positioned incorrectly .. A . Require repair or replacement. Rubber damping material

deteriorated 1 Suggest replacement.

Seal surface worn, causing

a leak A . Require repair or replacement.

Threads damaged A . Require repair or replacement.

Threads stripped (threads

missing) A Require replacement.

HEATER CONTROL VALVES

HEATER CONTROL VALVE INSPECTION

Condition Code Procedure

Attaching hardware

broken A ... Require repair or replacement

of hardware. Attaching hardware

missing C Require replacement of

hardware. Attaching hardware not

functioning A ... Require repair or replacement

of hardware.

Bypassed A Require replacement.

Coolant leak A .. Require repair or replacement.

Malfunctioning A (1) Require repair or

replacement.

Missing C Require replacement.

Restricted A . . Require repair or replacement.

Vacuum leak A . . Require repair or replacement.

(1) - Includes inoperative, intermittent operation, or failure to perform all functions.

HEATER CORES

HEATER CORE INSPECTION

Condition Code Procedure

Air flow restriction .... A .. Require repair or replacement. Attaching hardware

broken A ... Require repair or replacement

of hardware. Attaching hardware

missing C Require replacement of

hardware. Attaching hardware not

functioning A ... Require repair or replacement

of hardware.

Bypassed A . . Require repair or replacement.

Connection leaking A .. Require repair or replacement.

Corroded 1 . . Suggest repair or replacement.

Fins damaged, affecting

performance A . . Require repair or replacement.

Fins damaged, not

affecting performance .. 2 .. Suggest repair or replacement.

affecting performance .. A .. Require repair or replacement.

Leaking A . . Require repair or replacement.

Missing C Require replacement.

HOSE AND TUBE COUPLERS, CONNECTORS AND CLAMPS

NOTE: When replacing fuel lines and hoses, replace with product that meets or exceeds OEM design specifications.

HOSE AND TUBE COUPLER, CONNECTOR AND CLAMP INSPECTION

Condition Code Procedure

Application incorrect ... B Require replacement.

Connected incorrectly ... A Require repair.

Corroded, not reusable .. 1 Suggest replacement.

Cracked A Require replacement.

Insufficient clamping

force, allowing hose to

leak A . . Require repair or replacement.

Leaking A . . Require repair or replacement.

Missing C Require replacement.

Safety clip missing (not

leaking) C ... Require replacement of safety

clip.

Stripped A Require replacement.

HOSE CLAMPS

See HOSE AND TUBE COUPLERS, CONNECTORS AND CLAMPS .

HOSE CONNECTORS

See HOSE AND TUBE COUPLERS, CONNECTORS AND CLAMPS .

HOSE COUPLERS

See HOSE AND TUBE COUPLERS, CONNECTORS AND CLAMPS.

HOSES AND TUBES (FUEL LINES, RADIATOR, VACUUM, BY PASS,

HEATER, RECOVERY TANK AND OIL COOLERS)

HOSE AND TUBE (FUEL LINE, RADIATOR, VACUUM, BY PASS, HEATER, RECOVERY TANK AND OIL COOLER) INSPECTION

Condition Code Procedure

Application incorrect ... B Require replacement.

Connected incorrectly ... A Require repair.

Corroded, not reusable .. 1 Suggest replacement.

Cracked A Require replacement.

Dry-rotted 1 .. Suggest repair or replacement.

Hard 1 . . Suggest repair or replacement.

Inner fabric (webbing)

damaged A Require replacement.

Insufficient clamping

force, allowing hose to

leak A . . Require repair or replacement.

Leaking A . . Require repair or replacement.

Maintenance intervals ... 3 Suggest replacement.

Melted 1 . . Suggest repair or replacement.

Missing C Require replacement.

Outer covering damaged .. 1 Suggest replacement.

Outer covering damaged to

the extent that the inner

fabric is visible A Require replacement.

Protective sleeves

damaged 2 . Suggest replacement of sleeves.

Protective sleeves

missing 2 . Suggest replacement of sleeves.

Restricted, affecting

performance A .. Require repair or replacement.

Restricted, not affecting

performance 2 . . Suggest repair or replacement.

Routed incorrectly 2 .. Suggest repair or replacement.

Safety clip missing C Require replacement.

Spongy 1 . . Suggest repair or replacement.

Stripped A Require replacement.

Swollen B Require replacement.

Threads damaged A .. Require repair or replacement.

Threads stripped (threads

missing) A Require replacement.

Type incorrect 1 .. Suggest repair or replacement.

HOUSINGS

See THERMOSTATS AND HOUSINGS.

IDLE AIR CONTROLS

IDLE AIR CONTROL INSPECTION

Condition Code Procedure

Attaching hardware

missing C Require replacement of

hardware. Attaching hardware

threads damaged A ... Require repair or replacement

of hardware. Attaching hardware threads stripped

(threads missing) A ... Require repair or replacement

of hardware.

Connector broken A .. Require repair or replacement.

Connector (Weatherpack

type) leaking A . . Require repair or replacement.

Connector melted A (1) Require repair or

replacement.

Connector missing C Require replacement.

Contaminated A (2) Require repair or

replacement.

Inoperative B (3) Require repair or

replacement. Further inspection required.

Leaking A . . Require repair or replacement.

Missing C Require replacement.

Resistance out of

specification B .. Require repair or replacement.

Restricted, affecting

performance A . . Require repair or replacement.

Terminal broken A .. Require repair or replacement.

Terminal burned, affecting

performance A (1) Require repair or

replacement. Terminal burned, not

affecting performance .. 2 .. Suggest repair or replacement. Terminal corroded,

affecting performance .. A .. Require repair or replacement. Terminal corroded, not

affecting performance .. 2 .. Suggest repair or replacement. Terminal loose, affecting

performance B . . Require repair or replacement.

Terminal loose, not

affecting performance .. 1 .. Suggest repair or replacement.

Threads damaged A . . Require repair or replacement.

Threads stripped (threads

missing) A Require replacement.

Wire lead conductors

exposed B . . Require repair or replacement.

Wire lead corroded A .. Require repair or replacement.

Wire lead open A . . Require repair or replacement.

Wire lead shorted A .. Require repair or replacement.

(1) - Determine cause and correct prior to repair or

replacement of part.

(2) - Determine source of contamination, such as engine coolant,

fuel, metal particles, or water. Require repair or replacement.

(3) - Inoperative includes intermittent operation or out of

OEM specification. Some components may be serviceable; check for accepted cleaning procedure.

IDLE SPEED CONTROL ACTUATORS

IDLE SPEED CONTROL ACTUATOR INSPECTION

Condition Code Procedure

Attaching hardware

missing C Require replacement of

hardware. Attaching hardware

threads damaged A ... Require repair or replacement

of hardware. Attaching hardware threads stripped

(threads missing) A ... Require repair or replacement

of hardware.

Connector broken A .. Require repair or replacement.

Connector (Weatherpack

type) leaking A . . Require repair or replacement.

Connector melted A (1) Require repair or

replacement.

Connector missing C Require replacement.

Contaminated A (2) Require repair or

replacement.

Inoperative B (3) Require repair or

replacement. Further inspection required.

Leaking A . . Require repair or replacement.

Missing C Require replacement.

Resistance out of
specification B .. Require repair or replacement.

Terminal broken A .. Require repair or replacement.

Terminal burned, affecting

performance A (1) Require repair or

replacement. Terminal burned, not

affecting performance .. 2 .. Suggest repair or replacement. Terminal corroded,

affecting performance .. A .. Require repair or replacement. Terminal corroded, not

affecting performance .. 2 .. Suggest repair or replacement. Terminal loose, affecting

performance B . . Require repair or replacement.

Terminal loose, not

affecting performance .. 1 .. Suggest repair or replacement.

Threads damaged A . . Require repair or replacement.

Threads stripped (threads

missing) A Require replacement.

Wire lead conductors

exposed B . . Require repair or replacement.

Wire lead corroded A .. Require repair or replacement.

Wire lead open A . . Require repair or replacement.

Wire lead shorted A .. Require repair or replacement.

(1) - Determine cause and correct prior to repair or

replacement of part.

(2) - Determine source of contamination, such as engine coolant,

fuel, metal particles, or water. Require repair or replacement.

(3) - Inoperative includes intermittent operation or out of

OEM specification. Some components may be serviceable; check for accepted cleaning procedure.

IGNITION BOOTS

See IGNITION WIRES, BOOTS, COIL TOWERS AND TERMINALS (SECONDARY) .

IGNITION COIL TOWERS

See IGNITION WIRES, BOOTS, COIL TOWERS AND TERMINALS (SECONDARY) .

IGNITION COILS

IGNITION COIL INSPECTION

Condition Code Procedure

Arcing A Require replacement.

Attaching hardware

broken A ... Require repair or replacement

of hardware. Attaching hardware

missing C Require replacement of

hardware. Attaching hardware not

functioning A ... Require repair or replacement

of hardware.

Connector broken A .. Require repair or replacement.

Connector (Weatherpack

type) leaking A .. Require repair or replacement.

Connector melted A (1) Require repair or

replacement.

Connector missing C Require replacement.

Corroded, affecting

performance A Require replacement.

Corroded, not affecting

performance 2 Suggest replacement.

Distorted (2) No service suggested or

required.

Inoperative A (3) Require replacement.

Oil leaking A Require replacement.

Out of specification .... B Require replacement.

Terminal broken A . . Require repair or replacement.

Terminal burned, affecting

performance A (1) Require repair or

replacement. Terminal burned, not

affecting performance .. 2 .. Suggest repair or replacement.
Terminal corroded,

affecting performance .. A .. Require repair or replacement.
Terminal corroded, not

affecting performance .. 2 .. Suggest repair or replacement.
Terminal loose, affecting

performance B . . Require repair or replacement.

Terminal loose, not

affecting performance .. 1 .. Suggest repair or replacement.
Wire lead conductors

exposed B . . Require repair or replacement.

Wire lead corroded A .. Require repair or replacement.

Wire lead open A . . Require repair or replacement.

Wire lead shorted A .. Require repair or replacement.

(1) - Determine cause and correct prior to repair or

replacement of part.

(2) - Distortion may be the result of overheating; coil should

be tested.

(3) - Inoperative includes intermittent operation.

IGNITION CONTROL MODULES (ICM)

IGNITION CONTROL MODULE (ICM) INSPECTION

Condition Code Procedure

Application incorrect ... B Require replacement.

Attaching hardware

missing C Require replacement of

hardware. Attaching hardware

threads damaged A ... Require repair or replacement

of hardware. Attaching hardware threads stripped

(threads missing) A ... Require repair or replacement

of hardware. Code set

(if applicable) A (1) Further inspection

required.

Connector broken A .. Require repair or replacement.

Connector (Weatherpack

type) leaking A .. Require repair or replacement.

Connector melted A (2) Require repair or

replacement.

Connector missing A Require repair.

Contaminated A (3) Require repair or

replacement.

Leaking A . . Require repair or replacement.

Malfunctioning A (4) Require repair or

replacement.

Missing C Require replacement.

Terminal broken A . . Require repair or replacement.

Terminal burned, affecting

performance A (2) Require repair or

replacement. Terminal burned, not

affecting performance .. 2 .. Suggest repair or replacement.
Terminal corroded,

affecting performance .. A .. Require repair or replacement.
Terminal corroded, not

affecting performance .. 2 .. Suggest repair or replacement.
Terminal loose, affecting

performance B . . Require repair or replacement.

Terminal loose, not

affecting performance .. 1 .. Suggest repair or replacement.

Threads damaged A . . Require repair or replacement.

Wire lead conductors

exposed B . . Require repair or replacement.

Wire lead corroded A .. Require repair or replacement.

Wire lead open A . . Require repair or replacement.

Wire lead shorted A .. Require repair or replacement.

(1) - Refer to manufacturerís diagnostic trouble code

procedure and require repair or replacement of affected component(s).

(2) - Determine cause and correct prior to repair or

replacement of part.

(3) - Determine source of contamination, such as engine

coolant, fuel, metal particles, or water. Require repair or replacement.

(4) - Includes inoperative, intermittent operation, or failure to

perform all functions.

IGNITION SWITCHES

See SWITCHES.

IGNITION TERMINALS

See IGNITION WIRES, BOOTS, COIL TOWERS AND TERMINALS (SECONDARY) .

IGNITION WIRES, BOOTS, COIL TOWERS AND TERMINALS (SECONDARY)

NOTE: You are not required to replace ignition wires in sets. However, you may suggest replacement of the entire secondary wire set for preventive maintenance.

IGNITION WIRE, BOOT, COIL TOWER AND TERMINAL (SECONDARY) INSPECTION
Condition Code Procedure

Application incorrect ... B Require replacement.

Attaching hardware

broken A ... Require repair or replacement

of hardware.

Attaching hardware

missing C Require replacement of

hardware. Attaching hardware not

functioning A ... Require repair or replacement

of hardware.

Carbon-tracked A Require replacement.

Corroded 1 . . Suggest repair or replacement.

Insulation leaking

(shorted) A . . Require repair or replacement.

Metal heat shield bent .. 2 .. Suggest repair or replacement.

Missing C Require replacement.

Oil-soaked (spongy) 1 Suggest replacement.

Resistance incorrect .... B Require replacement.

Routed incorrectly 2 (1) Suggest repair.

Terminal broken A .. Require repair or replacement.

Terminal burned, affecting

performance A (2) Require repair or

replacement. Terminal burned, not

affecting performance .. 2 .. Suggest repair or replacement.
Terminal corroded,

affecting performance .. A .. Require repair or replacement.
Terminal corroded, not

affecting performance .. 2 .. Suggest repair or replacement.
Terminal loose, affecting

performance B . . Require repair or replacement.

Terminal loose, not

affecting performance .. 1 .. Suggest repair or replacement.

(1) - If improper routing affects the performance of other

systems, require repair. Proper routing, hardware, heatshields, etc., are intended to prevent premature failure of secondary ignition components.

(2) - Determine cause and correct prior to repair or

replacement of part.

IN-TANK FUEL STRAINERS

IN-TANK FUEL STRAINER INSPECTION

Condition Code Procedure

Missing C Require replacement.

Restricted A . . Require repair or replacement.

Torn A Require replacement.

INERTIA FUEL SHUT-OFF SWITCHES

INERTIA FUEL SHUT-OFF SWITCH INSPECTION

Condition Code Procedure

Attaching hardware

broken A ... Require repair or replacement

of hardware. Attaching hardware

missing C Require replacement of

hardware.

Attaching hardware not
functioning A ... Require repair or replacement

of hardware.

Connector broken A . . Require repair or replacement.

Connector melted A (1) Require repair or

replacement.

Connector missing C Require replacement.

Contaminated A (2) Require replacement.

Inoperative A (3) Require repair or

replacement.

Missing C Require replacement.

Terminal broken A . . Require repair or replacement.

Terminal burned, affecting

performance A (1) Require repair or

replacement. Terminal burned, not

affecting performance .. 2 .. Suggest repair or replacement.
Terminal corroded,

affecting performance .. A .. Require repair or replacement.
Terminal corroded, not

affecting performance .. 2 .. Suggest repair or replacement.
Terminal loose, affecting

performance B . . Require repair or replacement.

Terminal loose, not

affecting performance .. 1 .. Suggest repair or replacement.
Wire lead conductors

exposed B . . Require repair or replacement.

Wire lead corroded A .. Require repair or replacement.

Wire lead open A . . Require repair or replacement.

Wire lead shorted A .. Require repair or replacement.

(1) - Determine cause and correct prior to repair or

replacement of part.

(2) - Determine source of contamination, such as engine coolant,

fuel, metal particles, or water. Require repair or replacement.

(3) - Inoperative includes intermittent operation or out of

OEM specification.

INTAKE AIR TEMPERATURE SENSORS

INTAKE AIR TEMPERATURE SENSOR INSPECTION

Condition Code Procedure

Attaching hardware

missing C Require replacement of

hardware. Attaching hardware

threads damaged A ... Require repair or replacement

of hardware. Attaching hardware threads stripped

(threads missing) A ... Require repair or replacement

of hardware.

Connector broken A .. Require repair or replacement.

Connector (Weatherpack

type) leaking A . . Require repair or replacement.

Connector melted A (1) Require repair or

replacement.

Connector missing C Require replacement.

Contaminated A (2) Require repair or

replacement.
Inoperative B (3) Require repair or

replacement. Further inspection required.

Leaking A . . Require repair or replacement.

Missing C Require replacement.

Resistance out of

specification B .. Require repair or replacement.

Restricted, affecting

performance A . . Require repair or replacement.

Terminal broken A .. Require repair or replacement.

Terminal burned, affecting

performance A (1) Require repair or

replacement. Terminal burned, not

affecting performance .. 2 .. Suggest repair or replacement.
Terminal corroded,

affecting performance .. A .. Require repair or replacement.
Terminal corroded, not

affecting performance .. 2 .. Suggest repair or replacement.
Terminal loose, affecting

performance B . . Require repair or replacement.

Terminal loose, not

affecting performance .. 1 .. Suggest repair or replacement.

Threads damaged A . . Require repair or replacement.

Threads stripped (threads

missing) A Require replacement.

Wire lead conductors

exposed B . . Require repair or replacement.

Wire lead corroded A .. Require repair or replacement.

Wire lead open A . . Require repair or replacement.

Wire lead shorted A .. Require repair or replacement.

(1) - Determine cause and correct prior to repair or

replacement of part.

(2) - Determine source of contamination, such as engine coolant,

fuel, metal particles, or water. Require repair or replacement.

(3) - Inoperative includes intermittent operation or out of

OEM specification. Some components may be serviceable; check for accepted cleaning procedure.

INTAKE MANIFOLDS

INTAKE MANIFOLD INSPECTION

Condition Code Procedure

Corroded, affecting

sealability A . . Require repair or replacement.

Integrated air or fuel

control components

inoperative A (1) Require repair or

replacement. Internal air or fuel

components damaged,

affecting performance .. A ... Require repair or replacement

of component. Internal air or fuel

components damaged, not

affecting performance No service suggested or

required. Internal air or fuel

components missing C Require replacement of

component.

Leaking A . . Require repair or replacement.

Out of specification .... B Require replacement.

Restricted A . . Require repair or replacement.

Threads damaged A . . Require repair or replacement.

Threads stripped (threads

missing) A . . Require repair or replacement.

Warped B . . Require repair or replacement.

(1) - Inoperative includes intermittent operation or out of OEM specification.

INTERCOOLERS

See CHARGE AIR COOLERS "INTERCOOLERS" (CAC).

KNOCK SENSORS

KNOCK SENSOR INSPECTION

Condition Code Procedure

Attaching hardware

missing C Require replacement of

hardware. Attaching hardware threads

damaged A ... Require repair or replacement

of hardware. Attaching hardware

threads stripped

(threads missing) A ... Require repair or replacement

of hardware.

Connector broken A .. Require repair or replacement.

Connector (Weatherpack

type) leaking A .. Require repair or replacement.

Connector melted A (1) Require repair or

replacement.

Connector missing C Require replacement.

Inoperative B (2) Require repair or

replacement. Further inspection required.

Leaking A . . Require repair or replacement.

Missing C Require replacement.

Resistance out of

specification B .. Require repair or replacement.

Terminal broken A .. Require repair or replacement.

Terminal burned, affecting

performance A (1) Require repair or

replacement. Terminal burned, not

affecting performance .. 2 .. Suggest repair or replacement. Terminal corroded,

affecting performance .. A .. Require repair or replacement. Terminal corroded, not

affecting performance .. 2 .. Suggest repair or replacement. Terminal loose, affecting

performance B . . Require repair or replacement.

Terminal loose, not

affecting performance .. 1 .. Suggest repair or replacement.

Threads damaged A . . Require repair or replacement.

Threads stripped (threads

missing) A Require replacement.

Wire lead conductors

exposed B . . Require repair or replacement.

Wire lead corroded A .. Require repair or replacement.

Wire lead open A . . Require repair or replacement.

Wire lead shorted A .. Require repair or replacement.

(1) - Determine cause and correct prior to repair or

replacement of part.

(2) - Inoperative includes intermittent operation or out of

OEM specification. Some components may be serviceable; check for accepted cleaning procedure.

LIQUID VAPOR SEPARATORS

LIQUID VAPOR SEPARATOR INSPECTION

Condition Code Procedure

Inoperative A (1) Require repair or

replacement.

Leaking A Require replacement.

Missing C Require replacement.

Restricted A . . Require repair or replacement.

(1) - Inoperative includes intermittent operation or out of OEM specification.

MANIFOLD ABSOLUTE PRESSURE (MAP) SENSORS

MANIFOLD ABSOLUTE PRESSURE (MAP) SENSOR INSPECTION

Condition Code Procedure

Attaching hardware

missing C Require replacement of

hardware. Attaching hardware

threads damaged A ... Require repair or replacement

of hardware. Attaching hardware threads stripped

(threads missing) A ... Require repair or replacement

of hardware.

Connector broken A .. Require repair or replacement.

Connector (Weatherpack

type) leaking A . . Require repair or replacement.

Connector melted A (1) Require repair or

replacement.

Connector missing C Require replacement.

Contaminated A (2) Require repair or

replacement.

Inoperative B (3) Require repair or

replacement. Further inspection required.

Leaking A . . Require repair or replacement.

Missing C Require replacement.

Resistance out of

specification B .. Require repair or replacement.

Restricted, affecting

performance A . . Require repair or replacement.

Terminal broken A .. Require repair or replacement.

Terminal burned, affecting

performance A (1) Require repair or

replacement. Terminal burned, not

affecting performance .. 2 .. Suggest repair or replacement. Terminal corroded,

affecting performance .. A .. Require repair or replacement. Terminal corroded, not

affecting performance .. 2 .. Suggest repair or replacement. Terminal loose, affecting

performance B . . Require repair or replacement.

Terminal loose, not

affecting performance .. 1 .. Suggest repair or replacement.

Threads damaged A . . Require repair or replacement.

Threads stripped (threads

missing) A Require replacement.

Wire lead conductors

exposed B . . Require repair or replacement.

Wire lead corroded A .. Require repair or replacement.

Wire lead open A . . Require repair or replacement.

Wire lead shorted A .. Require repair or replacement.

(1) - Determine cause and correct prior to repair or

replacement of part.

(2) - Determine source of contamination, such as engine coolant,

fuel, metal particles, or water. Require repair or replacement.

(3) - Inoperative includes intermittent operation or out of

OEM specification. Some components may be serviceable; check for accepted cleaning procedure.

MASS AIR FLOW (MAF) SENSORS

MASS AIR FLOW (MAF) SENSOR INSPECTION

Condition Code Procedure

Attaching hardware

missing C Require replacement of

hardware. Attaching hardware threads

damaged A ... Require repair or replacement

of hardware. Attaching hardware threads stripped

(threads missing) A ... Require repair or replacement

of hardware.

Connector broken A .. Require repair or replacement.

Connector (Weatherpack

type) leaking A .. Require repair or replacement.

Connector melted A (1) Require repair or

replacement.

Connector missing C Require replacement.

Contaminated A (2) Require repair or

replacement.

Inoperative B (3) Require repair or

replacement. Further inspection required.

Leaking A . . Require repair or replacement.

Missing C Require replacement.

Resistance out of
specification B .. Require repair or replacement.

Restricted, affecting

performance A . . Require repair or replacement.

Terminal broken A .. Require repair or replacement.

Terminal burned, affecting

performance A (1) Require repair or

replacement. Terminal burned, not

affecting performance .. 2 .. Suggest repair or replacement. Terminal corroded,

affecting performance .. A .. Require repair or replacement. Terminal corroded, not

affecting performance .. 2 .. Suggest repair or replacement. Terminal loose, affecting

performance B . . Require repair or replacement.

Terminal loose, not

affecting performance .. 1 .. Suggest repair or replacement.

Threads damaged A . . Require repair or replacement.

Threads stripped (threads

missing) A Require replacement.

Wire lead conductors

exposed B . . Require repair or replacement.

Wire lead corroded A .. Require repair or replacement.

Wire lead open A . . Require repair or replacement.

Wire lead shorted A .. Require repair or replacement.

(1) - Determine cause and correct prior to repair or

replacement of part.

(2) - Determine source of contamination, such as engine

coolant, fuel, metal particles, or water. Require repair or replacement.

(3) - Inoperative includes intermittent operation or out of

OEM specification. Some components may be serviceable; check for accepted cleaning procedure.

METAL AIR MANIFOLDS AND PIPES

METAL AIR MANIFOLD AND PIPE INSPECTION

Condition Code Procedure

Attaching hardware

broken A ... Require repair or replacement

of hardware. Attaching hardware

missing C Require replacement of

hardware. Attaching hardware not

functioning A ... Require repair or replacement

of hardware.

Broken A Require repair of injection

tube or replacement of manifold. Corroded, affecting

structural integrity ... 1 Suggest replacement of

injection tube or manifold.

Leaking A Require repair of injection

tube or replacement of manifold.

Loose A Require repair.

Missing C Require replacement.

Restricted A Require replacement of

injection tube or manifold.

Threads damaged A Require repair.

Threads stripped (threads
missing) A Require replacement.

METAL AIR PIPES

See METAL AIR MANIFOLDS AND PIPES.

MIX CONTROL SOLENOIDS

MIX CONTROL SOLENOID INSPECTION

Condition Code Procedure

Attaching hardware

missing C Require replacement of

hardware. Attaching hardware

threads damaged A ... Require repair or replacement

of hardware. Attaching hardware

threads stripped

(threads missing) A ... Require repair or replacement

of hardware.

Connector broken A .. Require repair or replacement.

Connector (Weatherpack

type) leaking A . . Require repair or replacement.

Connector melted A (1) Require repair or

replacement.

Connector missing C Require replacement.

Contaminated A (2) Require repair or

replacement.

Inoperative B (3) Require repair or

replacement. Further inspection required.

Leaking A . . Require repair or replacement.

Missing C Require replacement.

Resistance out of

specification B .. Require repair or replacement.

Restricted, affecting

performance A . . Require repair or replacement.

Terminal broken A .. Require repair or replacement.

Terminal burned, affecting

performance A (1) Require repair or

replacement. Terminal burned, not

affecting performance .. 2 .. Suggest repair or replacement. Terminal corroded,

affecting performance .. A .. Require repair or replacement. Terminal corroded, not

affecting performance .. 2 .. Suggest repair or replacement. Terminal loose, affecting

performance B . . Require repair or replacement.

Terminal loose, not

affecting performance .. 1 .. Suggest repair or replacement.

Threads damaged A . . Require repair or replacement.

Threads stripped (threads

missing) A Require replacement.

Wire lead conductors

exposed B . . Require repair or replacement.

Wire lead corroded A .. Require repair or replacement.

Wire lead open A . . Require repair or replacement.

Wire lead shorted

A

Require repair or replacement.

(1) - Determine cause and correct prior to repair or

replacement of part.

(2) - Determine source of contamination, such as engine

coolant, fuel, metal particles, or water. Require repair or replacement.

(3) - Inoperative includes intermittent operation or out of

OEM specification. Some components may be serviceable; check for accepted cleaning procedure.

MOTOR MOUNTS

MOTOR MOUNT INSPECTION

Condition Code Procedure

Attaching hardware

broken A ... Require repair or replacement

of hardware. Attaching hardware

missing C Require replacement of

hardware. Attaching hardware not

functioning A ... Require repair or replacement

of hardware.

Broken A Require replacement.

Leaking (hydraulic

mount) A Require replacement.

Mounting hole worn,

affecting performance . . A Require replacement.

Mounting hole worn, not

affecting performance No service suggested or

required. Rubber deteriorated,

affecting performance . . A Require replacement.

Rubber deteriorated, not

affecting performance No service suggested or

required.

Threads damaged A . . Require repair or replacement.

Threads stripped (threads

missing) A Require replacement.

O-RINGS, GASKETS, SEALS AND SPRING LOCKS

O-RING, GASKET, SEAL AND SPRING LOCK INSPECTION

Condition Code Procedure

Leaking A ( 1) Require repair or

replacement.

(1) - Require inspection of mating and sealing surface and repair or replace as necessary.

O2 SENSORS

O2 SENSOR INSPECTION

Condition Code Procedure

Attaching hardware

missing C Require replacement of

hardware. Attaching hardware

threads damaged A ... Require repair or replacement

of hardware. Attaching hardware

threads stripped

(threads missing) A .. Require repair or replacement

of hardware.

Connector broken A .. Require repair or replacement.

Connector (Weatherpack

type) leaking A . . Require repair or replacement.

Connector melted A (1) Require repair or

replacement.

Connector missing C Require replacement.

Contaminated A (2) Require repair or

replacement.

Inoperative B (3) Require repair or

replacement. Further inspection required.

Leaking A . . Require repair or replacement.

Missing C Require replacement.

Resistance out of

specification B .. Require repair or replacement.

Restricted, affecting

performance A . . Require repair or replacement.

Terminal broken A .. Require repair or replacement.

Terminal burned, affecting

performance A (1) Require repair or

replacement. Terminal burned, not

affecting performance .. 2 .. Suggest repair or replacement. Terminal corroded,

affecting performance .. A .. Require repair or replacement. Terminal corroded, not

affecting performance .. 2 .. Suggest repair or replacement. Terminal loose, affecting

performance B . . Require repair or replacement.

Terminal loose, not

affecting performance .. 1 .. Suggest repair or replacement.

Threads damaged A . . Require repair or replacement.

Threads stripped (threads

missing) A Require replacement.

Wire lead conductors

exposed B . . Require repair or replacement.

Wire lead corroded A .. Require repair or replacement.

Wire lead open A . . Require repair or replacement.

Wire lead shorted A .. Require repair or replacement.

(1) - Determine cause and correct prior to repair or

replacement of part.

(2) - Determine source of contamination, such as engine

coolant, fuel, metal particles, or water. Require repair or replacement.

(3) - Inoperative includes intermittent operation or out of

OEM specification. Some components may be serviceable; check for accepted cleaning procedure.

OIL PRESSURE SENDING UNITS

OIL PRESSURE SENDING UNIT INSPECTION

Condition Code Procedure

Connector broken A .. Require repair or replacement.

Connector (Weatherpack

type) leaking A .. Require repair or replacement.

Connector melted A (1) Require repair or

replacement.

Connector missing C Require replacement.

Inoperative A (2) Require repair or

replacement.

Leaking A Require replacement.

Output signal incorrect . B .. Require repair or replacement.

Terminal broken A .. Require repair or replacement.

Terminal burned, affecting

performance A (1) Require repair or

replacement. Terminal burned, not

affecting performance .. 2 .. Suggest repair or replacement.
Terminal corroded,

affecting performance .. A .. Require repair or replacement.
Terminal corroded, not

affecting performance .. 2 .. Suggest repair or replacement.
Terminal loose, affecting

performance B . . Require repair or replacement.

Terminal loose, not

affecting performance .. 1 .. Suggest repair or replacement.

Threads damaged A . . Require repair or replacement.

Threads stripped (threads

missing) A Require replacement.

(1) - Determine cause and correct prior to repair or

replacement of part.

(2) - Inoperative includes intermittent operation or out of

OEM specification.

OIL PUMP PICK-UP SCREENS

OIL PUMP PICK-UP SCREEN INSPECTION

Condition Code Procedure

Attaching hardware

broken A ... Require repair or replacement

of hardware. Attaching hardware

missing C Require replacement of

hardware. Attaching hardware not

functioning A ... Require repair or replacement

of hardware.

Bypass stuck A .. Require repair or replacement.

Cracked A . . Require repair or replacement.

Loose A . . Require repair or replacement.

Missing C Require replacement.

Positioned incorrectly .. A .. Require repair or replacement.

Restricted A .. Require repair or replacement.

Screen torn A Require replacement.

OIL PUMPS

OIL PUMP INSPECTION

Condition Code Procedure

Attaching hardware

broken A ... Require repair or replacement

of hardware. Attaching hardware

missing C Require replacement of

hardware. Attaching hardware not

functioning A . . Require repair or replacement

of hardware.

Broken A . . Require repair or replacement.

Housing cracked A .. Require repair or replacement.

Leaking A .. Require repair or replacement.

Pressure relief valve

stuck A . . Require repair or replacement.

Seized A . . Require repair or replacement.

Worn beyond

specifications B .. Require repair or replacement.

PARK NEUTRAL POSITION SWITCHES

PARK NEUTRAL POSITION SWITCH INSPECTION

Condition Code Procedure

Attaching hardware

missing C Require replacement of

hardware. Attaching hardware

threads damaged A ... Require repair or replacement

of hardware. Attaching hardware threads stripped

(threads missing) A ... Require repair or replacement

of hardware.

Connector broken A .. Require repair or replacement.

Connector (Weatherpack

type) leaking A . . Require repair or replacement.

Connector melted A (1) Require repair or

replacement.

Connector missing C Require replacement.

Contaminated A (2) Require repair or

replacement.

Inoperative B (3) Require repair or

replacement. Further inspection required.

Leaking A . . Require repair or replacement.

Missing C Require replacement.

Resistance out of

specification B .. Require repair or replacement.

Terminal broken A .. Require repair or replacement.

Terminal burned, affecting

performance A (1) Require repair or

replacement. Terminal burned, not

affecting performance .. 2 .. Suggest repair or replacement. Terminal corroded, affecting performance .. A .. Require repair or replacement.

Terminal corroded, not

affecting performance .. 2 .. Suggest repair or replacement. Terminal loose, affecting

performance B .. Require repair or replacement.

Terminal loose, not

affecting performance .. 1 .. Suggest repair or replacement.

Threads damaged A .. Require repair or replacement.

Threads stripped (threads

missing) A Require replacement.

Wire lead conductors

exposed B . . Require repair or replacement.

Wire lead corroded A .. Require repair or replacement.

Wire lead open A . . Require repair or replacement.

Wire lead shorted A .. Require repair or replacement.

(1) - Determine cause and correct prior to repair or

replacement of part.

(2) - Determine source of contamination, such as engine

coolant, fuel, metal particles, or water. Require repair or replacement.

(3) - Inoperative includes intermittent operation or out of

OEM specification. Some components may be serviceable; check for accepted cleaning procedure.

PCV BREATHER ELEMENTS

PCV BREATHER ELEMENT INSPECTION

Condition Code Procedure

Attaching hardware

broken A ... Require repair or replacement

of hardware. Attaching hardware

missing C Require replacement of

hardware. Attaching hardware not

functioning A ... Require repair or replacement

of hardware.

Leaking A Require replacement.

Maintenance intervals ... 3 ... Suggest replacement to comply

with vehicleí s OEM recommended service intervals.

Melted A Required replacement.

Missing C Require replacement.

Restricted, affecting

performance A Require replacement.

Restricted, not affecting

performance 1 Suggest replacement.

Water-contaminated A Require replacement.

PCV ORIFICES

PCV ORIFICE INSPECTION

Condition Code Procedure

Leaking A Require replacement.

Maintenance interval .... 3 ... Suggest repair or replacement

to comply with OEM recommended service intervals.

Missing C Require replacement.

Restricted A . . Require repair or replacement.

PCV VALVES

PCV VALVE INSPECTION

Condition Code Procedure

Application incorrect ... B Require replacement.

Attaching hardware

broken A ... Require repair or replacement

of hardware. Attaching hardware

missing C Require replacement of

hardware. Attaching hardware not

functioning A ... Require repair or replacement

of hardware.

Grommet broken A ... Require repair or replacement

of grommet.

Grommet missing C . Require replacement of grommet.

Grommet not

functioning A ... Require repair or replacement

of grommet.

Inoperative A ( 1) Require replacement.

Leaking A Require replacement.

Maintenance interval .... 3 ... Suggest replacement to comply

with vehicleís OEM recommended service intervals.

Missing C Require replacement.

Restricted A Require replacement.

(1) - Inoperative includes intermittent operation or out of OEM specification.

PICK-UP ASSEMBLIES (INCLUDES MAGNETIC, HALL EFFECT AND

OPTICAL)

PICK-UP ASSEMBLY (MAGNETIC, HALL EFFECT AND OPTICAL) INSPECTION
Condition Code Procedure

Adjustment incorrect .... B Require repair.

Attaching hardware

broken A ... Require repair or replacement

of hardware. Attaching hardware

missing C Require replacement of

hardware. Attaching hardware not

functioning A ... Require repair or replacement

of hardware.

Connector broken A .. Require repair or replacement.

Connector (Weatherpack

type) leaking A .. Require repair or replacement.

Connector melted A (1) Require repair or

replacement.

Connector missing C Require replacement.

Inoperative B (2) Require replacement.

Oil-soaked A Require replacement.

Terminal broken A .. Require repair or replacement.

Terminal burned, affecting

performance A (1) Require repair or

replacement. Terminal burned, not

affecting performance .. 2 .. Suggest repair or replacement. Terminal corroded,

affecting performance .. A .. Require repair or replacement. Terminal corroded, not

affecting performance .. 2 .. Suggest repair or replacement. Terminal loose, affecting

performance B . . Require repair or replacement.

Terminal loose, not

affecting performance .. 1 .. Suggest repair or replacement. Wire lead conductors

exposed B . . Require repair or replacement.

Wire lead corroded A .. Require repair or replacement.

Wire lead open A . . Require repair or replacement.

Wire lead shorted A .. Require repair or replacement.

(1) - Determine cause and correct prior to repair or

replacement of part.

(2) - Inoperative includes intermittent operation or out of

OEM specification. Refer to OEM recommended serviceí procedures.

POWER STEERING PRESSURE SENSORS

POWER STEERING PRESSURE SENSOR INSPECTION

Condition Code Procedure

Attaching hardware

missing C Require replacement of

hardware. Attaching hardware

threads damaged A ... Require repair or replacement

of hardware. Attaching hardware threads stripped

(threads missing) A ... Require repair or replacement

of hardware.

Connector broken A .. Require repair or replacement.

Connector (Weatherpack

type) leaking A . . Require repair or replacement.

Connector melted A (1) Require repair or

replacement.

Connector missing C Require replacement.

Contaminated A (2) Require repair or

replacement.

Inoperative B (3) Require repair or

replacement. Further inspection required.

Leaking A . . Require repair or replacement.

Missing C Require replacement.

Resistance out of

specification B .. Require repair or replacement.

Restricted, affecting

performance A . . Require repair or replacement.

Terminal broken A .. Require repair or replacement.

Terminal burned, affecting
performance A (1) Require repair or

replacement. Terminal burned, not

affecting performance .. 2 .. Suggest repair or replacement. Terminal corroded,

affecting performance .. A .. Require repair or replacement. Terminal corroded, not

affecting performance .. 2 .. Suggest repair or replacement. Terminal loose, affecting

performance B . . Require repair or replacement.

Terminal loose, not

affecting performance .. 1 .. Suggest repair or replacement.

Threads damaged A . . Require repair or replacement.

Threads stripped (threads

missing) A Require replacement.

Wire lead conductors

exposed B . . Require repair or replacement.

Wire lead corroded A .. Require repair or replacement.

Wire lead open A . . Require repair or replacement.

Wire lead shorted A .. Require repair or replacement.

(1) - Determine cause and correct prior to repair or

replacement of part.

(2) - Determine source of contamination, such as engine

coolant, fuel, metal particles, or water. Require repair or replacement.

(3) - Inoperative includes intermittent operation or out of

OEM specification. Some components may be serviceable; check for accepted cleaning procedure.

POWERTRAIN CONTROL MODULES (PCM) AND PROM

POWERTRAIN CONTROL MODULE (PCM) AND PROM INSPECTION

Condition Code Procedure

Application incorrect ... B Require replacement.

Attaching hardware

missing C Require replacement of

hardware. Attaching hardware

threads damaged A ... Require repair or replacement

of hardware. Attaching hardware threads stripped

(threads missing) A ... Require repair or replacement

of hardware. Code set

(if applicable) A (1) Further inspection

required.

Connector broken A .. Require repair or replacement.

Connector (Weatherpack

type) leaking A .. Require repair or replacement.

Connector melted A (2) Require repair or

replacement.

Connector missing A Require repair.

Contaminated A (3) Require repair or

replacement.

Leaking A . . Require repair or replacement.

Malfunctioning A (4) Require repair or

replacement.

Missing C Require replacement.

Terminal broken A . . Require repair or replacement.

Terminal burned, affecting

performance A (2) Require repair or

replacement. Terminal burned, not

affecting performance .. 2 .. Suggest repair or replacement. Terminal corroded,

affecting performance .. A .. Require repair or replacement. Terminal corroded, not

affecting performance .. 2 .. Suggest repair or replacement. Terminal loose, affecting

performance B . . Require repair or replacement.

Terminal loose, not

affecting performance .. 1 .. Suggest repair or replacement.

Threads damaged A . . Require repair or replacement.

Threads stripped (threads

missing) A Require replacement.

Wire lead conductors

exposed B . . Require repair or replacement.

Wire lead corroded A .. Require repair or replacement.

Wire lead open A . . Require repair or replacement.

Wire lead shorted A .. Require repair or replacement.

(1) - Refer to manufacturerís diagnostic trouble code

procedure and require repair or replacement of affected component(s).

(2) - Determine cause and correct prior to repair or

replacement of part.

(3) - Determine source of contamination, such as engine coolant,

fuel, metal particles, or water. Require repair or replacement.

(4) - Includes inoperative, intermittent operation, failure to

perform all functions, or out of OEM specification.

POWERTRAIN CONTROL PROM

See POWERTRAIN CONTROL MODULES (PCM) AND PROM.

PRESSURIZED EXPANSION TANK CAPS

See RADIATOR CAPS AND PRESSURIZED EXPANSION TANK CAPS.

RADIATOR CAPS AND PRESSURIZED EXPANSION TANK CAPS

RADIATOR CAP AND PRESSURIZED EXPANSION TANK CAP INSPECTION
Condition Code Procedure

Application incorrect ... B Require replacement.

Coolant recovery check

valve inoperative A (1) Require replacement.

Fails to maintain proper

pressure B Require replacement.

Gasket missing C . Require replacement of gasket.

Missing C Require replacement.

Seal missing C ... Require replacement of seal.

(1) - Inoperative includes intermittent operation or out of OEM specification.

RADIATOR FAN BLADES

RADIATOR FAN BLADE INSPECTION

Condition Code Procedure

Application incorrect ... B Require replacement.

Attaching hardware

broken A . . Require repair or replacement

of hardware. Attaching hardware

missing C Require replacement of

hardware. Attaching hardware not

functioning A . . Require repair or replacement

of hardware.

Bent A Require replacement.

Broken A Require replacement.

Cracked A Require replacement.

Loose A . Require repair or replacement.

Missing C Require replacement.

RADIATOR FAN CLUTCHES

NOTE: Some lateral movement, measured at the fan blade tip, may be normal.

RADIATOR FAN CLUTCH INSPECTION

Condition Code Procedure

Attaching hardware

broken A ... Require repair or replacement

of hardware. Attaching hardware

missing C Require replacement of

hardware. Attaching hardware not

functioning A ... Require repair or replacement

of hardware.

Bearing noisy A Require replacement.

Bearing worn A Require replacement.

Fastener loose A ... Require repair or replacement

of fastener.

Inoperative A ( 1) Require replacement.

Leaking 1 Suggest replacement.

Seized A Require replacement.

Slips (insufficient fan

speed) A Require replacement.

Thermal control

incorrect B . . Require repair or replacement.

(1) - Inoperative includes intermittent operation or out of OEM specification.

RADIATORS

RADIATOR INSPECTION

Condition Code Procedure

Air flow restriction .... A Require repair.

Application incorrect ... B Require replacement.

Attaching hardware

broken A ... Require repair or replacement

of hardware. Attaching hardware

missing C Require replacement of

hardware. Attaching hardware not

functioning A . . Require repair or replacement

of hardware.

Connection leaking A .. Require repair or replacement.

Corroded 1 .. Suggest repair or replacement.

Fins damaged, affecting

performance A . . Require repair or replacement.

Fins damaged, not

affecting performance .. 2 .. Suggest repair or replacement. Internal oil cooler

leaking A . . Require repair or replacement.

Internal restrictions,

affecting performance .. B .. Require repair or replacement. Internal restrictions, not

affecting performance .. 2 .. Suggest repair or replacement.

Leaking A . . Require repair or replacement.

Threads damaged A . . Require repair or replacement.

Threads stripped (threads

missing) A .. Require repair or replacement.

Tubes damaged, affecting

performance A .. Require repair or replacement.

Tubes damaged, not

affecting performance No service suggested or

required.

ROLL OVER VALVES

ROLL OVER VALVE INSPECTION

Condition Code Procedure

Inoperative A (1) Require replacement.

Leaking A Require replacement.

Missing C Require replacement.

(1) - Inoperative includes intermittent operation or out of OEM specification.

SEALING COMPOUNDS

SEALING COMPOUND INSPECTION

Condition Code Procedure

Leaking A ( 1) Require repair or

replacement.

(1) - Require inspection of mating and sealing surface and repair or replace as necessary.

SEALS

SEAL INSPECTION

Condition Code Procedure

Leaking A ( 1) Require repair or

replacement.

(1) - Require inspection of mating and sealing surface and repair or replace as necessary.

SECONDARY AIR INJECTION SYSTEM MANAGEMENT DEVICES

SECONDARY AIR INJECTION SYSTEM MANAGEMENT DEVICE INSPECTION
Condition Code Procedure

Attaching hardware

missing C Require replacement of

hardware. Attaching hardware

threads damaged A ... Require repair or replacement

of hardware. Attaching hardware

threads stripped

(threads missing) A .. Require repair or replacement

of hardware.

Connector broken A .. Require repair or replacement.

Connector (Weatherpack

type) leaking A . . Require repair or replacement.

Connector melted A (1) Require repair or

replacement.

Connector missing C Require replacement.

Contaminated A (2) Require repair or

replacement.

Inoperative B (3) Require repair or

replacement. Further inspection required.

Leaking A . . Require repair or replacement.

Missing C Require replacement.

Resistance out of

specification B .. Require repair or replacement.

Restricted, affecting

performance A . . Require repair or replacement.

Terminal broken A .. Require repair or replacement.

Terminal burned, affecting

performance A (1) Require repair or

replacement. Terminal burned, not

affecting performance .. 2 .. Suggest repair or replacement. Terminal corroded,

affecting performance .. A .. Require repair or replacement. Terminal corroded, not

affecting performance .. 2 .. Suggest repair or replacement. Terminal loose, affecting

performance B . . Require repair or replacement.

Terminal loose, not

affecting performance .. 1 .. Suggest repair or replacement.

Threads damaged A . . Require repair or replacement.

Threads stripped (threads

missing) A Require replacement.

Wire lead conductors

exposed B . . Require repair or replacement.

Wire lead corroded A .. Require repair or replacement.

Wire lead open A . . Require repair or replacement.

Wire lead shorted A .. Require repair or replacement.

(1) - Determine cause and correct prior to repair or

replacement of part.

(2) - Determine source of contamination, such as engine coolant,

fuel, metal particles, or water. Require repair or replacement.

(3) - Inoperative includes intermittent operation or out of

OEM specification. Some components may be serviceable; check for accepted cleaning procedure.

SENSORS AND ACTUATORS

NOTE: Conditions pertaining to the sensors and actuators listed in this section may be found under the name of the sensor or actuator.

SENSOR ABBREVIATION TABLE

Sensor Abbreviation

Accelerator Pedal Position Sensor APP

Air Conditioning Cycling Switch AC

Air Conditioning Pressure Sensor

Air Fuel Ratio Sensor

Barometric Pressure Sensor BARO

Camshaft Position Sensor CMP

Clutch Pedal Position Switch CPP

Cooling Fan Motor Sensors and Switches

Crankshaft Position Sensor CKP

Electronic Transmission Feedback Devices

Engine Coolant Temperature Sensor ECT

Evaporative Emission feedback devices

Exhaust Gas Recirculation feedback devices

Fan Control Sensor FC

Intake Air Temperature Sensor IAT

Knock Sensor KS

Manifold Absolute Pressure Sensor MAP

Mass Air Flow Sensor MAF

O2 Sensor O2S

Park Neutral Position Switch PNP

Power Steering Pressure Sensor PSP

Thermal Vacuum Valve TVV

Throttle Position Sensor TP Sensor

Throttle Position Switch

Transmission Range Switch TR Switch

Vehicle Speed Sensor VSS

Volume Air Flow Sensor VAF

ACTUATOR ABBREVIATION TABLE

Actuator Abbreviation

Air Injection Control Solenoid

Electronic Transmission control devices

Evaporative Emission Canister EVAP

Purge Device

Exhaust Gas Recirculation Device EGR

Fuel Injector

Idle Air Control IAC

Idle Speed Control Actuator ISC

Mix Control Solenoid MC Solenoid

Secondary Air Injection System Management Device .... AIR, PAIR

Vacuum Regulator Solenoid

Waste Gate Control Solenoid

SHROUDS, BAFFLES AND DEFLECTORS

SHROUD, BAFFLE AND DEFLECTOR INSPECTION

Condition Code Procedure

Application incorrect,

affecting cooling system

performance A . Require repair or replacement.

Attaching hardware

broken A . . Require repair or replacement

of hardware. Attaching hardware

missing C Require replacement of

hardware. Attaching hardware not

functioning A . . Require repair or replacement

of hardware. Bent, affecting cooling

system performance A . Require repair or replacement.

Blocked, affecting cooling

system performance A . Require repair or replacement.

Broken, affecting cooling

system performance A . Require repair or replacement.

Cracked, affecting cooling

system performance A . Require repair or replacement.

Loose, affecting cooling

system performance A Require repair.

Loose, not affecting

cooling system

performance 2 Suggest repair.

Missing, affecting cooling

system performance C Require replacement.

SPARK PLUGS

NOTE: You are not required to replace spark plugs in sets.

However, you may suggest replacement of the other plugs for preventive maintenance.

SPARK PLUG INSPECTION

Condition Code Procedure

Application incorrect ... B Require replacement.

Electrode eroded 1 Suggest replacement.

Fouled A ( 1) Require repair or

replacement.

Gap incorrect B . . Require repair or replacement.

Insulation broken A Require replacement

Insulator cracked A Require replacement.

Leaking compression A . . Require repair or replacement.

Maintenance interval .... 3 Suggest replacement.

Threads damaged A . . Require repair or replacement.

Threads stripped (threads

missing) A Require replacement.

(1) - Determine cause of fouling and suggest repair.

SPRING LOCKS

SPRING LOCK INSPECTION

Condition Code Procedure

Leaking A ( 1) Require repair or

replacement.

(1) - Require inspection of mating and sealing surface and repair or replace as necessary.

SUPERCHARGERS

SUPER CHARGER INSPECTION

Condition Code Procedure

Attaching hardware

damaged, affecting

operation or

performance A ... Require repair or replacement

of hardware. Attaching hardware

missing C Require replacement of

hardware.

Bearing noisy A Require replacement.

Bearing worn A Require replacement.

Boost pressure

incorrect A (1) Require repair or

replacement. Clearance out of

specification B . . Require repair or replacement.

Leaking A . . Require repair or replacement.

Noisy 2 . . Suggest repair or replacement.

Threads damaged A .. Require repair or replacement.

Threads stripped (threads

missing) A . . Require repair or replacement.

(1) - Boost pressure problems may be caused by other systems or components.

SWITCHES

SWITCH INSPECTION

Condition Code Procedure

Attaching hardware

broken A ... Require repair or replacement

of hardware. Attaching hardware

missing C Require replacement of

hardware.

Attaching hardware not
functioning A ... Require repair or replacement

of hardware. Binding, affecting

performance A . . Require repair or replacement.

Binding, not affecting

performance 2 . . Suggest repair or replacement.

Broken A .. Require repair or replacement.

Burned, affecting

performance A (1) Require repair or

replacement. Burned, not affecting

performance 2 (1) Suggest repair or

replacement. Cracked, affecting

performance A . . Require repair or replacement.

Cracked, not affecting

performance 1 . . Suggest repair or replacement.

Leaking A . . Require repair or replacement.

Malfunctioning A (2) Require repair or

replacement. Melted, affecting

performance A (1) Require repair or

replacement. Melted, not affecting

performance 2 (1) Suggest repair or

replacement.

Missing C Require replacement.

Out of adjustment B .. Require repair or replacement.

Terminal broken A .. Require repair or replacement.

Terminal burned, affecting

performance A (1) Require repair or

replacement. Terminal burned, not

affecting performance .. 2 .. Suggest repair or replacement. Terminal corroded,

affecting performance .. A .. Require repair or replacement. Terminal corroded, not

affecting performance .. 2 .. Suggest repair or replacement. Terminal loose, affecting

performance B . . Require repair or replacement.

Terminal loose, not

affecting performance .. 1 .. Suggest repair or replacement.

Wonít return A .. Require repair or replacement.

Worn 1 Suggest replacement.

(1) - Determine cause and correct prior to repair or

replacement of part.

(2) - Includes inoperative, intermittent operation, or failure

to perform all functions.

THERMAL VACUUM VALVES

THERMAL VACUUM VALVE INSPECTION

Condition Code Procedure

Connector broken A .. Require repair or replacement.

Connector (Weatherpack

type) leaking A .. Require repair or replacement.

Connector melted A (1) Require repair or

replacement.

Connector missing C Require replacement.

Contaminated A (2) Require repair or

replacement.

Inoperative B (3) Require repair or

replacement. Further inspection required.

Leaking A . . Require repair or replacement.

Missing C Require replacement.

Resistance out of

specification B .. Require repair or replacement.

Restricted, affecting

performance A . . Require repair or replacement.

Terminal broken A .. Require repair or replacement.

Terminal burned, affecting

performance A (1) Require repair or

replacement. Terminal burned, not

affecting performance .. 2 .. Suggest repair or replacement.
Terminal corroded,

affecting performance .. A .. Require repair or replacement.
Terminal corroded, not

affecting performance .. 2 .. Suggest repair or replacement.
Terminal loose, affecting

performance B . . Require repair or replacement.

Terminal loose, not

affecting performance .. 1 .. Suggest repair or replacement.

Threads damaged A . . Require repair or replacement.

Threads stripped (threads

missing) A Require replacement.

Wire lead conductors

exposed B . . Require repair or replacement.

Wire lead corroded A .. Require repair or replacement.

Wire lead open A . . Require repair or replacement.

Wire lead shorted A .. Require repair or replacement.

(1) - Determine cause and correct prior to repair or

replacement of part.

(2) - Determine source of contamination, such as engine coolant,

fuel, metal particles, or water. Require repair or replacement.

(3) - Inoperative includes intermittent operation or out of

OEM specification. Some components may be serviceable; check for accepted cleaning procedure.

THERMOSTATIC AIR DOOR ASSEMBLIES

THERMOSTATIC AIR DOOR ASSEMBLY INSPECTION

Condition Code Procedure

Attaching hardware

damaged, affecting

operation or

performance A ... Require repair or replacement

of hardware. Attaching hardware

missing C Require replacement of

hardware.

Binding A .. Require repair or replacement.

Leaking A . . Require repair or replacement.

Missing C Require replacement.

Seized A .. Require repair or replacement.

THERMOSTATS AND HOUSINGS

THERMOSTAT AND HOUSING INSPECTION

Condition Code Procedure

Application incorrect ... B Require replacement.

Attaching hardware

broken A ... Require repair or replacement

of hardware. Attaching hardware

corroded A ... Require repair or replacement

of hardware. Attaching hardware

missing C Require replacement of

hardware. Attaching hardware not

functioning A ... Require repair or replacement

of hardware.

Housing corroded 1 .. Suggest replacement of housing.

Inoperative A (1) Require replacement.

Installation incorrect .. B .. Require repair or replacement.

Leaking A . . Require repair or replacement.

Thermostat missing C Require replacement of

thermostat.

Threads damaged A .. Require repair or replacement.

Threads stripped (threads
missing) A .. Require repair or replacement.

(1) - Inoperative includes intermittent operation or out of OEM specification.

THROTTLE BODIES

THROTTLE BODY INSPECTION

Condition Code Procedure

Connector broken A .. Require repair or replacement.

Connector (Weatherpack

type) leaking A .. Require repair or replacement.

Connector melted A (1) Require repair or

replacement.

Connector missing C Require replacement.

Contaminated A (2) Require repair or

replacement.

Leaking A . . Require repair or replacement.

Restricted A (3) Require repair.

Terminal broken A . . Require repair or replacement.

Terminal burned, affecting

performance A (1) Require repair or

replacement. Terminal burned, not

affecting performance .. 2 .. Suggest repair or replacement.
Terminal corroded,

affecting performance .. A .. Require repair or replacement.
Terminal corroded, not

affecting performance .. 2 .. Suggest repair or replacement.
Terminal loose, affecting

performance B . . Require repair or replacement.

Terminal loose, not

affecting performance .. 1 .. Suggest repair or replacement.

Threads damaged A . . Require repair or replacement.

Threads stripped (threads

missing) A . . Require repair or replacement.

Throttle shaft binding,

affecting performance .. A .. Require repair or replacement. Throttle shaft worn,

affecting performance .. A .. Require repair or replacement. Throttle shaft worn, not

affecting performance .. 1 .. Suggest repair or replacement. Wire lead conductors

exposed B .. Require repair or replacement.

Wire lead corroded A .. Require repair or replacement.

Wire lead open A . . Require repair or replacement.

Wire lead shorted A .. Require repair or replacement.

(1) - Determine cause and correct prior to repair or

replacement of part.

(2) - Determine source of contamination, such as engine coolant,

fuel, metal particles, or water. Require repair or replacement.

(3) - Some components may be serviceable; check for accepted

cleaning procedure.

THROTTLE CABLES

See THROTTLE LINKAGES AND CABLES.

THROTTLE LINKAGES AND CABLES

THROTTLE LINKAGE AND CABLE INSPECTION

Condition Code Procedure

Attaching hardware

broken A ... Require repair or replacement

of hardware. Attaching hardware

missing C Require replacement of

hardware. Attaching hardware not

functioning A . . Require repair or replacement

of hardware.

Bent A . . Require repair or replacement.

Binding A . . Require repair or replacement.

Bracket bent, affecting

performance A .. Require repair or replacement.

Bracket bent, not

affecting performance . . . . No service suggested or

required. Bracket broken, affecting

performance A Require replacement.

Bracket broken, not

affecting performance . . . . No service suggested or

required. Bracket corroded,

affecting performance .. A .. Require repair or replacement. Bracket corroded, not

affecting performance .. 2 .. Suggest repair or replacement. Bracket cracked, affecting

performance A . . Require repair or replacement.

Bracket cracked, not

affecting performance .. 1 .. Suggest repair or replacement.

Bracket loose, affecting

performance A .. Require repair or replacement.

Bracket loose, not

affecting performance .. 1 .. Suggest repair or replacement.

Bracket missing C Require replacement.

Broken A Require replacement.

Cracked A . . Require repair or replacement.

Disconnected A .. Require repair or replacement.

Kinked A . . Require repair or replacement.

Melted A .. Require repair or replacement.

Missing C Require replacement.

Noisy 2 . . Suggest repair or replacement.

Out of adjustment B (1) Require repair or

replacement.

Routed incorrectly 2 Suggest repair.

Seized A . . Require repair or replacement.

(1) - Follow OEM recommended adjustment procedures. Require repair or replacement if out of specification.

THROTTLE POSITION SENSORS

THROTTLE POSITION SENSOR INSPECTION

Condition Code Procedure

Attaching hardware

missing C Require replacement of

hardware. Attaching hardware

threads damaged A ... Require repair or replacement

of hardware. Attaching hardware

threads stripped

(threads missing) A ... Require repair or replacement

of hardware.

Connector broken A .. Require repair or replacement.

Connector (Weatherpack

type) leaking A . . Require repair or replacement.

Connector melted A (1) Require repair or

replacement.

Connector missing C Require replacement.

Contaminated A (2) Require repair or

replacement.

Inoperative B (3) Require repair or

replacement. Further inspection required.

Missing C Require replacement.

Resistance out of

specification B .. Require repair or replacement.

Terminal broken A .. Require repair or replacement.

Terminal burned, affecting

performance A . . (1) Require repair or replacement.

Terminal burned, not

affecting performance .. 2 .. Suggest repair or replacement. Terminal corroded,

affecting performance .. A .. Require repair or replacement. Terminal corroded, not

affecting performance .. 2 .. Suggest repair or replacement. Terminal loose, affecting

performance B .. Require repair or replacement.

Terminal loose, not

affecting performance .. 1 .. Suggest repair or replacement.

Threads damaged A .. Require repair or replacement.

Threads stripped (threads

missing) A Require replacement.

Wire lead conductors

exposed B . . Require repair or replacement.

Wire lead corroded A .. Require repair or replacement.

Wire lead open A . . Require repair or replacement.

Wire lead shorted A .. Require repair or replacement.

(1) - Determine cause and correct prior to repair or

replacement of part.

(2) - Determine source of contamination, such as engine coolant,

fuel, metal particles, or water. Require repair or replacement.

(3) - Inoperative includes intermittent operation or out of

OEM specification. Some components may be serviceable; check for accepted cleaning procedure.

THROTTLE POSITION SWITCHES

THROTTLE POSITION SWITCH INSPECTION

Condition Code Procedure

Attaching hardware

missing C Require replacement of

hardware. Attaching hardware

threads damaged A ... Require repair or replacement

of hardware. Attaching hardware

threads stripped

(threads missing) A .. Require repair or replacement

of hardware.

Connector broken A .. Require repair or replacement.

Connector (Weatherpack

type) leaking A . . Require repair or replacement.

Connector melted A (1) Require repair or

replacement.

Connector missing C Require replacement.

Inoperative B (2) Require repair or

replacement. Further inspection required.

Missing C Require replacement.

Resistance out of

specification B .. Require repair or replacement.

Terminal broken A .. Require repair or replacement.

Terminal burned, affecting

performance A (1) Require repair or

replacement. Terminal burned, not

affecting performance .. 2 .. Suggest repair or replacement. Terminal corroded,

affecting performance .. A .. Require repair or replacement. Terminal corroded, not

affecting performance .. 2 .. Suggest repair or replacement. Terminal loose, affecting

performance B . . Require repair or replacement.

Terminal loose, not

affecting performance .. 1 .. Suggest repair or replacement.
Threads damaged A . . Require repair or replacement.

Threads stripped (threads

missing) A Require replacement.

Wire lead conductors

exposed B . . Require repair or replacement.

Wire lead corroded A .. Require repair or replacement.

Wire lead open A . . Require repair or replacement.

Wire lead shorted A .. Require repair or replacement.

(1) - Determine cause and correct prior to repair or

replacement of part.

(2) - Inoperative includes intermittent operation or out of

OEM specification. Some components may be serviceable; check for accepted cleaning procedure.

TIMING BELT SPROCKETS

TIMING BELT SPROCKET INSPECTION

Condition Code Procedure

Alignment incorrect B Require repair.

Attaching hardware

broken A ... Require repair or replacement

of hardware. Attaching hardware

missing C Require replacement of

hardware. Attaching hardware not

functioning A ... Require repair or replacement

of hardware.

Bent A Require replacement.

Cracked A Require replacement.

Key damaged A Require replacement.

Loose A . . Require repair or replacement.

Missing C Require replacement.

Pulley damaged, affecting

belt life A Require replacement.

Sprocket damaged,

affecting belt life .... A .. Require repair or replacement.

Sprocket loose B .. Require repair or replacement.

Sprocket-to-shaft

alignment incorrect B . . Require repair or replacement.

TIMING BELTS

TIMING BELT INSPECTION

Condition Code Procedure

Adjustment incorrect .... 2 (1) Suggest adjustment.

Alignment incorrect B (2) Further inspection

required.

Broken A Require replacement.

Cam timing out of

specification B Require repair.

Cracked 1 Suggest replacement.

Fluid-soaked 1 ... Suggest replacement. Further

inspection required.

Frayed 1 Suggest replacement.

Maintenance intervals ... 3 ... Suggest replacement to comply

with vehicle OEM recommended

service intervals.

Missing C (3) Require replacement.

Noisy 2 (4) Further inspection

required. See note below.

Plies separated A Require replacement.

Tension out of

specification B Require adjustment or

replacement.
Teeth missing A Require replacement.

  1. - Inspect belt tensioners, pulleys, and cover.

  2. - Determine cause of incorrect alignment and require repair.

  3. - CAUTION: Internal engine damage may result from timing

belt damage/failure.

(4) - Determine cause of noise and suggest repair.

TORQUE STRUTS

TORQUE STRUT INSPECTION

Condition Code Procedure

Attaching hardware

broken A ... Require repair or replacement

of hardware. Attaching hardware

missing C Require replacement of

hardware. Attaching hardware not

functioning A ... Require repair or replacement

of hardware.

Binding A Require replacement.

Body dented A (1) Further inspection

required.

Body punctured A Require replacement.

Bushing deteriorated,

affecting performance .. A Require replacement.

Bushing deteriorated, not

affecting performance No service suggested or

required.

Bushings missing C Require replacement.

Bushings separated from

mounting eye 1 Suggest replacement.

Damping (none) A Require replacement.

Leaking oil, enough for

fluid to be running down

the body A Require replacement.

Missing C Require replacement.

Noisy 2 (2) Further inspection

required.

Piston rod bent A Require replacement.

Piston rod broken A Require replacement.

Seized A Require replacement.

Threads damaged A . . Require repair or replacement.

Threads stripped (threads

missing) A Require replacement.

(1) - Require replacement of units where dents restrict strut

piston rod movement. If dents donít restrict movement, no service is suggested or required.

(2) - If noise is isolated to shock or strut, suggest replacement.

TRANSMISSION RANGE SWITCHES

TRANSMISSION RANGE SWITCH INSPECTION

Condition Code Procedure

Attaching hardware

missing C Require replacement of

hardware. Attaching hardware

threads damaged A ... Require repair or replacement

of hardware. Attaching hardware

threads stripped

(threads missing) A ... Require repair or replacement

of hardware.

Connector broken A .. Require repair or replacement.

Connector (Weatherpack

type) leaking A . . Require repair or replacement.

Connector melted A (1) Require repair or

replacement.

Connector missing C Require replacement.

Contaminated A (2) Require repair or

replacement.

Inoperative B (3) Require repair or

replacement. Further inspection required.

Leaking A . . Require repair or replacement.

Missing C Require replacement.

Resistance out of

specification B .. Require repair or replacement.

Terminal broken A .. Require repair or replacement.

Terminal burned, affecting

performance A (1) Require repair or

replacement. Terminal burned, not

affecting performance .. 2 .. Suggest repair or replacement. Terminal corroded,

affecting performance .. A .. Require repair or replacement. Terminal corroded, not

affecting performance .. 2 .. Suggest repair or replacement. Terminal loose, affecting

performance B . . Require repair or replacement.

Terminal loose, not

affecting performance .. 1 .. Suggest repair or replacement.

Threads damaged A . . Require repair or replacement.

Threads stripped (threads

missing) A Require replacement.

Wire lead conductors

exposed B . . Require repair or replacement.

Wire lead corroded A .. Require repair or replacement.

Wire lead open A . . Require repair or replacement.

Wire lead shorted A .. Require repair or replacement.

(1) - Determine cause and correct prior to repair or

replacement of part.

(2) - Determine source of contamination, such as engine coolant,

fuel, metal particles, or water. Require repair or replacement.

(3) - Inoperative includes intermittent operation or out of

OEM specification. Some components may be serviceable;

check for accepted cleaning procedure.

TUBE CLAMPS

See HOSE AND TUBE COUPLERS, CONNECTORS AND CLAMPS .

TUBE CONNECTORS

See HOSE AND TUBE COUPLERS, CONNECTORS AND CLAMPS.

TUBE COUPLERS

See HOSE AND TUBE COUPLERS, CONNECTORS AND CLAMPS.

TUBES

See HOSES AND TUBES (FUEL LINES, RADIATOR, BY PASS, HEATER, RECOVERY TANK AND OIL COOLERS).

TURBO CHARGERS

TURBO CHARGER INSPECTION

Condition Code Procedure

Attaching hardware

broken A ... Require repair or replacement

of hardware. Attaching hardware

missing C Require replacement of

hardware. Attaching hardware not

functioning A ... Require repair or replacement

of hardware. Boost pressure

incorrect A (1) Require repair or

replacement.

Leaking A . . Require repair or replacement.

Noisy 2 . . Suggest repair or replacement.

Oil seal (internal)

leaking A . . Require repair or replacement.

Vibrates A .. Require repair or replacement.

(1) - Boost pressure problems may be caused by other systems or components.

VACUUM CONNECTIONS

See VACUUM HOSES, TUBES AND CONNECTIONS (NON-METALLIC) .

VACUUM HOSES, TUBES AND CONNECTIONS (NON-METALLIC)

VACUUM HOSE, TUBE AND CONNECTION (NON-METALLIC) INSPECTION
Condition Code Procedure

Leaking A . . Require repair or replacement.

Melted A Require replacement.

Missing C Require replacement.

Oil-soaked (spongy) 1 Suggest replacement.

Restricted A .. Require repair or replacement.

Surface cracks (dry-
rotted) 1 Suggest replacement.

VACUUM REGULATOR SOLENOIDS

VACUUM REGULATOR SOLENOID INSPECTION

Condition Code Procedure

Attaching hardware

missing C Require replacement of

hardware. Attaching hardware

threads damaged A ... Require repair or replacement

of hardware. Attaching hardware

threads stripped

(threads missing) A ... Require repair or replacement

of hardware.

Connector broken A .. Require repair or replacement.

Connector (Weatherpack

type) leaking A . . Require repair or replacement.

Connector melted A (1) Require repair or

replacement.

Connector missing C Require replacement.

Contaminated A (2) Require repair or

replacement.

Inoperative B (3) Require repair or

replacement. Further inspection required.

Leaking A . . Require repair or replacement.

Missing C Require replacement.

Resistance out of

specification B .. Require repair or replacement.

Restricted, affecting

performance A . . Require repair or replacement.

Terminal broken A .. Require repair or replacement.

Terminal burned, affecting

performance A (1) Require repair or

replacement. Terminal burned, not

affecting performance .. 2 .. Suggest repair or replacement. Terminal corroded,

affecting performance .. A .. Require repair or replacement. Terminal corroded, not

affecting performance .. 2 .. Suggest repair or replacement. Terminal loose, affecting

performance B . . Require repair or replacement.

Terminal loose, not

affecting performance .. 1 .. Suggest repair or replacement.

Threads damaged A . . Require repair or replacement.

Threads stripped (threads

missing) A Require replacement.

Wire lead conductors

exposed B . . Require repair or replacement.

Wire lead corroded A .. Require repair or replacement.

Wire lead open A . . Require repair or replacement.

Wire lead shorted A .. Require repair or replacement.

(1) - Determine cause and correct prior to repair or replacement of part.

(2) - Determine source of contamination, such as engine coolant,

fuel, metal particles, or water. Require repair or replacement.

(3) - Inoperative includes intermittent operation or out of

OEM specification. Some components may be serviceable; check for accepted cleaning procedure.

VACUUM TUBES

See VACUUM HOSES, TUBES AND CONNECTIONS (NON-METALLIC) .

VEHICLE SPEED SENSORS

VEHICLE SPEED SENSOR INSPECTION

Condition Code Procedure

Attaching hardware

missing C Require replacement of

hardware. Attaching hardware

threads damaged A ... Require repair or replacement

of hardware. Attaching hardware

threads stripped

(threads missing) A ... Require repair or replacement

of hardware.

Connector broken A .. Require repair or replacement.

Connector (Weatherpack

type) leaking A . . Require repair or replacement.

Connector melted A (1) Require repair or

replacement.

Connector missing C Require replacement.

Contaminated A (2) Require repair or

replacement.

Inoperative B (3) Require repair or

replacement. Further inspection required.

Leaking A . . Require repair or replacement.

Missing C Require replacement.

Resistance out of

specification B .. Require repair or replacement.

Terminal broken A .. Require repair or replacement.

Terminal burned, affecting

performance A (1) Require repair or

replacement. Terminal burned, not

affecting performance .. 2 .. Suggest repair or replacement. Terminal corroded,

affecting performance .. A .. Require repair or replacement. Terminal corroded, not

affecting performance .. 2 .. Suggest repair or replacement. Terminal loose, affecting

performance B . . Require repair or replacement.

Terminal loose, not

affecting performance .. 1 .. Suggest repair or replacement.

Threads damaged A . . Require repair or replacement.

Threads stripped (threads

missing) A Require replacement.

Wire lead conductors

exposed B . . Require repair or replacement.

Wire lead corroded A .. Require repair or replacement.

Wire lead open A . . Require repair or replacement.

Wire lead shorted A .. Require repair or replacement.

(1) - Determine cause and correct prior to repair or

replacement of part.

(2) - Determine source of contamination, such as engine coolant,

fuel, metal particles, or water. Require repair or replacement.

(3) - Inoperative includes intermittent operation or out of

OEM specification. Some components may be serviceable; check for accepted cleaning procedure.

VOLUME AIR FLOW SENSORS

VOLUME AIR FLOW SENSOR INSPECTION

Condition Code Procedure

Attaching hardware

missing C Require replacement of

hardware. Attaching hardware

threads damaged A ... Require repair or replacement

of hardware. Attaching hardware

threads stripped

(threads missing) A ... Require repair or replacement

of hardware.

Connector broken A .. Require repair or replacement.

Connector (Weatherpack

type) leaking A . . Require repair or replacement.

Connector melted A (1) Require repair or

replacement.

Connector missing C Require replacement.

Contaminated A (2) Require repair or

replacement.

Inoperative B (3) Require repair or

replacement. Further inspection required.

Leaking A . . Require repair or replacement.

Missing C Require replacement.

Resistance out of

specification B .. Require repair or replacement.

Restricted, affecting

performance A . . Require repair or replacement.

Terminal broken A .. Require repair or replacement.

Terminal burned, affecting

performance A (1) Require repair or

replacement. Terminal burned, not

affecting performance .. 2 .. Suggest repair or replacement. Terminal corroded,

affecting performance .. A .. Require repair or replacement. Terminal corroded, not

affecting performance .. 2 .. Suggest repair or replacement. Terminal loose, affecting

performance B . . Require repair or replacement.

Terminal loose, not

affecting performance .. 1 .. Suggest repair or replacement.

Threads damaged A . . Require repair or replacement.

Threads stripped (threads

missing) A Require replacement.

Wire lead conductors

exposed B . . Require repair or replacement.

Wire lead corroded A .. Require repair or replacement.

Wire lead open A . . Require repair or replacement.

Wire lead shorted A .. Require repair or replacement.

(1) - Determine cause and correct prior to repair or

replacement of part.

(2) - Determine source of contamination, such as engine coolant,

fuel, metal particles, or water. Require repair or replacement.

(3) - Inoperative includes intermittent operation or out of

OEM specification. Some components may be serviceable; check for accepted cleaning procedure.

WASTE GATE CONTROL SOLENOIDS

WASTE GATE CONTROL SOLENOID INSPECTION

Condition Code Procedure

Attaching hardware

missing C Require replacement of

hardware. Attaching hardware

threads damaged A ... Require repair or replacement

of hardware. Attaching hardware

threads stripped

(threads missing) A ... Require repair or replacement

of hardware.

Connector broken A .. Require repair or replacement.

Connector (Weatherpack

type) leaking A . . Require repair or replacement.

Connector melted A (1) Require repair or

replacement.

Connector missing C Require replacement.

Contaminated A (2) Require repair or

replacement.

Inoperative B (3) Require repair or

replacement. Further inspection required.

Leaking A . . Require repair or replacement.

Missing C Require replacement.

Resistance out of

specification B .. Require repair or replacement.

Restricted, affecting

performance A . . Require repair or replacement.

Terminal broken A .. Require repair or replacement.

Terminal burned, affecting

performance A (1) Require repair or

replacement. Terminal burned, not

affecting performance .. 2 .. Suggest repair or replacement. Terminal corroded,

affecting performance .. A .. Require repair or replacement. Terminal corroded, not

affecting performance .. 2 .. Suggest repair or replacement. Terminal loose, affecting

performance B . . Require repair or replacement.

Terminal loose, not

affecting performance .. 1 .. Suggest repair or replacement.

Threads damaged A . . Require repair or replacement.

Threads stripped (threads

missing) A Require replacement.

Wire lead conductors

exposed B . . Require repair or replacement.

Wire lead corroded A .. Require repair or replacement.

Wire lead open A . . Require repair or replacement.

Wire lead shorted A .. Require repair or replacement.

(1) - Determine cause and correct prior to repair or

replacement of part.

(2) - Determine source of contamination, such as engine coolant,

fuel, metal particles, or water. Require repair or replacement.

(3) - Inoperative includes intermittent operation or out of

OEM specification. Some components may be serviceable; check for accepted cleaning procedure.

WASTE GATES AND BOOST CONTROL MECHANISMS

WASTE GATE AND BOOST CONTROL MECHANISM INSPECTION

Condition Code Procedure

Boost pressure

incorrect A (1) Require repair or

replacement. Further inspection required.

Leaking A . . Require repair or replacement.

(1) - Incorrect boost pressure includes intermittent operation or out of OEM specification.

WATER PUMPS (ELECTRIC)

WATER PUMP (ELECTRIC) INSPECTION

Condition Code Procedure

Attaching hardware

broken A ... Require repair or replacement

of hardware. Attaching hardware

missing C Require replacement of

hardware. Attaching hardware not

functioning A ... Require repair or replacement

of hardware.

Connector broken A .. Require repair or replacement.

Connector (Weatherpack

type) leaking A .. Require repair or replacement.

Connector melted A (1) Require repair or

replacement.

Connector missing C Require replacement.

Inoperative A (2) Require replacement.

Leaking A . . Require repair or replacement.

Missing C Require replacement.

Noisy 2 Suggest replacement.

Rotation incorrect for

application B .. Require repair or replacement.

Terminal broken A .. Require repair or replacement.

Terminal burned, affecting

performance A (1) Require repair or

replacement. Terminal burned, not

affecting performance .. 2 .. Suggest repair or replacement. Terminal corroded,

affecting performance .. A .. Require repair or replacement. Terminal corroded, not

affecting performance .. 2 .. Suggest repair or replacement. Terminal loose, affecting

performance B . . Require repair or replacement.

Terminal loose, not

affecting performance .. 1 .. Suggest repair or replacement.

Vibration 1 Suggest replacement.

Wire lead conductors

exposed B . . Require repair or replacement.

Wire lead corroded A .. Require repair or replacement.

Wire lead open A . . Require repair or replacement.

Wire lead shorted A .. Require repair or replacement.

(1) - Determine cause and correct prior to repair or

replacement of part.

(2) - Check fan motor/controls. Inoperative includes

intermittent operation or out of OEM specification.

WATER PUMPS (NON-ELECTRIC)

WATER PUMP (NON-ELECTRIC) INSPECTION

Condition Code Procedure

Attaching hardware

broken A ... Require repair or replacement

of hardware. Attaching hardware

corroded A ... Require repair or replacement

of hardware. Attaching hardware

missing C Require replacement of

hardware. Attaching hardware not

functioning A ... Require repair or replacement

of hardware. Corrosion (internal) is excessive, affecting

performance A Require replacement.

Corrosion (internal) is excessive, not affecting

performance 2 . Suggest cooling system service.

Inoperative A (1) Require replacement.

Leaking A Require replacement.

Noisy A Require replacement.

Rotation incorrect for

application B .. Require repair or replacement.

Shaft bent A Require replacement.

(1) - Inoperative includes intermittent operation or out of OEM specification.

WIRING HARNESSES AND CONNECTORS

WIRING HARNESS AND CONNECTOR INSPECTION

Condition Code Procedure

Application incorrect ... B .. Require repair or replacement. Attaching hardware

broken A ... Require repair or replacement

of hardware. Attaching hardware

missing C Require replacement of

hardware. Attaching hardware not

functioning A ... Require repair or replacement

of hardware.

Connector broken A .. Require repair or replacement.

Connector (Weatherpack

type) leaking A .. Require repair or replacement.

Connector melted A (1) Require repair or

replacement.

Connector missing C Require replacement.

Insulation damaged,

conductors exposed A .. Require repair or replacement.

Insulation damaged,

conductors not exposed . 1 Suggest replacement.

Open A . . Require repair or replacement.

Protective shield

(conduit) melted 2 (1) Suggest repair or

replacement. Protective shield

(conduit) missing 2 .. Suggest repair or replacement.

Resistance (voltage drop)

out of specification ... A .. Require repair or replacement.

Routed incorrectly B Require repair.

Secured incorrectly B Require repair.

Shorted A . . Require repair or replacement.

Terminal broken A .. Require repair or replacement.

Terminal burned, affecting

performance A (1) Require repair or

replacement. Terminal burned, not

affecting performance .. 2 .. Suggest repair or replacement. Terminal corroded,

affecting performance .. A .. Require repair or replacement. Terminal corroded, not

affecting performance .. 2 .. Suggest repair or replacement. Terminal loose, affecting

performance B . . Require repair or replacement.

Terminal loose, not

affecting performance .. 1 .. Suggest repair or replacement. Voltage drop out of

specification A . . Require repair or replacement.

(1) - Determine cause and correct prior to repair or replacement of part.