Volvo 850 troubleshoot guide

Volvo 850 service & repair manual

TROUBLE SHOOTING – BASIC PROCEDURES

1995 Volvo 850

GENERAL TROUBLE SHOOTING

* PLEASE READ THIS FIRST *

NOTE: This is GENERAL information. This article is not intended

to be specific to any unique situation or individual vehicle configuration. The purpose of this Trouble
Shooting information is to provide a list of common causes to
problem symptoms. For model-specific Trouble Shooting, refer to SUBJECT, DIAGNOSTIC, or TESTING
articles available in the section(s) you are accessing.

ACCESSORIES & ELECTRICAL

CHARGING SYSTEM TROUBLE SHOOTING

NOTE: This is GENERAL information. This article is not intended

to be specific to any unique situation or individual vehicle configuration. The purpose of this Trouble
Shooting information is to provide a list of common causes to
problem symptoms. For model-specific Trouble Shooting, refer to SUBJECT, DIAGNOSTIC, or TESTING
articles available in the section(s) you are accessing.
BASIC CHARGING SYSTEM TROUBLE SHOOTING CHART
CONDITION POSSIBLE CAUSE CORRECTION
Vehicle Will Not Dead battery Check battery cells, Start alternator belt tension and alternator output
Loose or corroded battery Check all charging connections system connections
Ignition circuit or switch Check and replace as malfunction necessary

condition, See Belt

Alternator Light Loose or worn alternator Check alternator drive

Stays On With drive belt tension and

Engine Running

Adjustment in TUNE-UP

article in the

TUNE-UP section
Loose alternator wiring
Check all charging

connections system connections

Short in alternator light See Indicator Warning wiring Lights in STANDARD
INSTRUMENTS in the ACCESSORIES & EQUIPMENT section
Defective alternator stator See Bench Tests in or diodes ALTERNATOR article
Defective regulator See Regulator Check in
ALTERNATOR article
Alternator Blown fuse See WIRING DIAGRAMS Light Stays Off
With Ignition
Switch ON
Defective alternator See Testing in
ALTERNATOR article
Defective indicator light See Indicator Warning bulb or socket Lights in STANDARD
INSTRUMENTS in the ACCESSORIES & EQUIPMENT section
Alternator Short in alternator wiring See On-Vehicle Tests Light Stays OFF in ALTERNATOR article With
Ignition
Switch ON
Defective rectifier bridge See Bench Tests in
ALTERNATOR article
Lights or Fuses Defective alternator wiring See On-Vehicle Tests Burn Out in ALTERNATOR article
Frequently
Defective regulator See Regulator Check in
ALTERNATOR article
Defective battery Check and replace as necessary

Check alternator drive belt

Ammeter
tension and condition. See Belt
Gauge
Loose or worn drive belt Adjustment in TUNE-UP article
Shows in the
Discharge
TUNE-UP section

Check all wires and wire

Defective wiring
connections

Defective alternator or See Bench Tests and On-Vehicle

regulator Tests in ALTERNATOR article

See Testing in STANDARD

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

Noisy Tighten drive pulley attaching

Loose drive pulley
Alternator nut

Tighten all alternator mounting

Loose mounting bolts
bolts

Worn or dirty bearings See Bearing

Replacement

ALTERNATOR article

Defective diodes or stator See Bench Test in

ALTERNATOR article
belt tension and

Battery Does Loose or worn drive belt Check alternator drive

Stay Charged

condition. See

Belt Adjustment in

appropriate TUNE-UP

article in the

TUNE-UP section

Loose or corroded battery Check all charging connections system connections

Loose alternator connections Check all charging system connections
Defective alternator or See On-Vehicle Tests battery and Bench Tests in
ALTERNATOR article
Add-on electrical accessories Install larger exceeding alternator capacity alternator
Battery Defective battery Check alternator Overcharged- output and repair as Uses Too Much necessary
Water
Defective alternator See On-Vehicle Test and Bench Tests in ALTERNATOR article
Excessive alternator voltage Check alternator output and repair as necessary

IGNITION SYSTEM TROUBLE SHOOTING

NOTE: This is GENERAL information. This article is not intended

to be specific to any unique situation or individual vehicle configuration. The purpose of this Trouble
Shooting information is to provide a list of common causes to
problem symptoms. For model-specific Trouble Shooting, refer to SUBJECT, DIAGNOSTIC, or TESTING
articles available in the section(s) you are accessing.
Ignition Secondary Trouble Shooting Chart
START: Visually inspect Spark Plug Wires, Coil Wires, Plug Wire Boots, Rotor, and Distributor Cap for
signs of damage.
OK NOT OK

damaged components

as necessary

* To test secondary ignition * Repair or replace

system, modify a Spark Plug

by attaching a ground wire

to the body of the plug and

widening the gap to 1/4-3/8″. Disconnect spark plug wire

and insert test plug. Ground plug, crank engine, and
check for spark.
GOOD SPARK NO SPARK
* If plug sparks, driveability * Remove coil wire from the problem is most likely NOT distributor and
attach the in the ignition system. modified spark plug. Ground
the plug and crank engine while checking for spark.

PRIMARY TROUBLE SHOOTING

CHECK CHART below in this

article.

GOOD SPARK NO SPARK

* *
If plug has a good spark, Proceed to the IGNITION

the problem is in the plug

wires, distributor cap, or

rotor. Replace components

as necessary.

Ignition Primary Trouble Shooting Chart

START: Visually inspect primary ignition wires for broken, frayed, split, or cut wires. Also check for loose,
corroded, or disconnected connectors.
OK NOT OK

components as necessary.

* Check that battery voltage * Repair or replace damaged

is at least 11.5 volts.

NOT OK OK
* Replace or recharge the * Check for battery voltage battery. at the positive terminal of
the coil.
OK NOT OK
* Check air Gap of the Pick-Up * Check resistance of ballast coil in the distributor. resistor (if used) for
the
correct resistance value.
OK NOT OK

necessary.

* Check Pick-Up coil for * Adjust or replace as

correct resistance value.

NOT OK OK
* Replace Pick-Up coil if * Check control module for not to specification. good ground connections.
OK
* If vehicle fails to run at this point, go to the appropriate article in the ENGINE PERFORMANCE section.
OK NOT OK
if the measured resistance

value is not within

specification.

* Check wires from the battery/ * Replace ballast resistor

ignition switch to the coil.

Also check the coil primary

and secondary resistance.

STARTER TROUBLE SHOOTING

NOTE: This is GENERAL information. This article is not intended

to be specific to any unique situation or individual vehicle configuration. The purpose of this Trouble
Shooting information is to provide a list of common causes to
problem symptoms. For model-specific Trouble Shooting, refer to SUBJECT, DIAGNOSTIC, or TESTING
articles available in the section(s) you are accessing.
BASIC STARTER TROUBLE SHOOTING CHART
CONDITION POSSIBLE CAUSE CORRECTION
Starter Fails Dead battery or bad Check battery charge to Operate connections between and all wires
and
starter and battery connections to starter
Ignition switch faulty Adjust or replace or misadjusted ignition switch
Open circuit between Check and repair wires starter switch ignition and connections as terminal on
starter relay necessary
Starter relay or starter See Testing in STARTER
defective article

See Testing in STARTER

Open solenoid pull-in wire
article

Charge or replace battery as

Weak battery or dead cell
Starter Does Not Operate and necessary
Headlights Dim Loose or corroded battery
Check that battery connections are
connections
clean and tight

Internal ground in starter See Testing in STARTER

windings article

Grounded starter fields See Testing in STARTERS

Armature rubbing on pole

See STARTER article
shoes

Starter Turns Starter clutch slipping See STARTER article

but Engine

Does Not Rotate

Broken clutch housing See STARTER article

Pinion shaft rusted or See STARTER article dry

Engine basic timing See Ignition Timing in incorrect TUNE-UP article
Broken teeth on engine Replace flywheel and flywheel check for starter pinion
gear damage
Starter Will Not Faulty overrunning See STARTER article
Crank Engine clutch
Broken clutch housing See STARTER article
Broken flywheel teeth Replace flywheel and check for starter pinion gear damage
Armature shaft sheared See STARTER article or reduction gear teeth
stripped
Weak battery Charge or replace battery as necessary

See On-Vehicle Tests inSTARTER article

Check all ground connections for tight and clean connections

Charge or replace

battery as necessary

Faulty solenoid

Poor grounds

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

Starter Cranks Battery weak or

Engine Slowly defective

Engine overheated See ENGINE COOLING SYSTEM article

Engine oil too heavy Check that proper viscosity oil
is used
Poor battery-to-starter Check that all connections between
battery and starter are clean and tight
Current draw too low or See Bench Tests in too high STARTER article
Bent armature, loose pole See STARTER article shoes screws or worn
bearings
Burned solenoid contacts Replace solenoid
Faulty starter Replace starter
Starter Engages Engine timing too far See Ignition Timing in Engine Only advanced TUNE-UP article
Momentarily
Overrunning clutch not Replace overrunning engaging properly clutch. See STARTER
article
Broken starter clutch See STARTER article
Broken teeth on engine Replace flywheel and flywheel check starter pinion
gear for damage
Weak drive assembly See STARTER article thrust spring
Weak hold-in coil See Bench Tests in
STARTER article
Starter Drive Defective point assembly See Testing in STARTER Will Not Engage article
Poor point assembly ground See Testing in STARTER
article
Defective pull-in coil Replace starter solenoid

Charge or replace battery as necessary

Check all wiring and connections leading to relay

switch

Starter Relay
Dead battery
Does Not Close

Faulty wiring

Neutral safety switch Replace neutral safety

faulty

Starter relay faulty Replace starter relay

Starter Drive Starter motor loose on Tighten starter

Will Not mountings attach bolts

Disengage

Worn drive end bushing See STARTER article

Damaged engine flywheel Replace flywheel and teeth starter pinion gear for
damage
Drive yolk return spring Replace return spring broken or missing
Faulty ignition switch Replace ignition switch
Insufficient clearance Replace starter between winding leads to solenoid solenoid terminal and main
contact in solenoid
Starter clutch not Replace starter clutch disengaging
Ignition starter switch Replace ignition switch contacts sticking
Starter Relay Faulty solenoid switch, Check all wiring Operates but switch connections or between relay
and Solenoid Does Not solenoid or replace
relay or solenoid as necessary
Broken lead or loose Repair wire or wire soldered connections connections as
necessary
Solenoid Plunger Weak battery Charge or replace Vibrates When battery as necessary Switch is Engaged
Solenoid contacts Clean contacts or corroded replace solenoid
Faulty wiring Check all wiring leading to solenoid
Broken connections inside Repair connections or switch cover replace solenoid
Open hold-in wire Replace solenoid
Low Current Draw Worn brushes or weak Replace brushes or brush springs as necessary
High Pitched Whine Distance too great Align starter or check During Cranking between starter that
correct starter Before Engine pinion and flywheel and flywheel are being Fires but Engine used
Fires and Cranks
Normally
High Pitched Distance too small between
Whine After Engine starter pinion and flywheel
Fires With Key Flywheel runout contributes released. Engine to the intermittent nature Fires and Cranks
Normally

AIR CONDITIONING & HEAT

AIR CONDITIONING TROUBLE SHOOTING

WARNING: This is GENERAL information. This article is not intended

to be specific to any unique situation or individual vehicle configuration. The purpose of this Trouble
Shooting information is to provide a list of common causes to
problem symptoms. For model-specific Trouble Shooting, refer to SUBJECT, DIAGNOSTIC, or TESTING
articles available in the section(s) you are accessing.
BASIC AIR CONDITIONING TROUBLE SHOOTING CHART CONDITION POSSIBLE CAUSE
Compressor Not Working Compressor clutch circuit open.
Compressor clutch coil inoperative. Poor clutch ground connection.
Fan belts loose.
Thermostatic switch inoperative. Thermostatic switch not adjusted. Ambient temperature switch open.
Superheat fuse blown.
Excessive Noise or Vibration Missing or loose mounting bolts.
Bad idler pulley bearings.
Fan belts not tightened correctly. Compressor clutch contacting body. Excessive system pressure.
Compressor oil level low.
Damaged clutch bearings. Damaged reed valves. Damaged compressor.
Insufficient or No Cooling;
Compressor Working Expansion valve inoperative.
Heater control valve stuck open. Low system pressure.
Blocked condenser fins. Blocked evaporator fins. Vacuum system leak.
Vacuum motors inoperative.
Control cables improperly adjusted. Restricted air inlet.
Mode doors binding.
Blower motor inoperative. Temperature above system capacity.

HEATER SYSTEM TROUBLE SHOOTING

NOTE: This is GENERAL information. This article is not intended

to be specific to any unique situation or individual vehicle configuration. The purpose of this Trouble
Shooting information is to provide a list of common causes to
problem symptoms. For model-specific Trouble Shooting, refer to DIAGNOSTIC, or TESTING articles
available in the section(s) you are accessing.
BASIC HEATER SYSTEM TROUBLE SHOOTING CHART CONDITION POSSIBLE CAUSE Insufficient, Erratic,
or No Heat Low Coolant Level
Incorrect thermostat.
Restricted coolant flow through heater core.
Heater hoses plugged. Misadjusted control cable. Sticking heater control valve. Vacuum hose leaking.
Vacuum hose blocked.
Vacuum motors inoperative. Blocked air inlet.
Inoperative heater blower motor. Oil residue on heater core fins. Dirt on heater core fins.
Too Much Heat Improperly adjusted cables.
Sticking heater control valve.
No vacuum to heater control valve. Temperature door stuck open.
Air Flow Changes During
Acceleration Vacuum system leak.
Bad check valve or reservoir.
Air From Defroster At All
Times Vacuum system leak.
Improperly adjusted control cables. Inoperative vacuum motor.
Blower Does Not Operate
Correctly Blown fuse.
Blower motor windings open. Resistors burned out.
Motor ground connection loose. Wiring harness connections loose. Blower motor switch inoperative.
Blower relay inoperative.
Fan binding or foreign object in housing.
Fan blades broken or bent.

BRAKES

BRAKE SYSTEM TROUBLE SHOOTING

NOTE: This is GENERAL information. This article is not intended

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

ENGINE MECHANICAL

COOLING SYSTEM TROUBLE SHOOTING

NOTE: This is GENERAL information. This article is not intended

to be specific to any unique situation or individual vehicle configuration. The purpose of this Trouble
Shooting information is to provide a list of common causes to
problem symptoms. For model-specific Trouble Shooting, refer to SUBJECT, DIAGNOSTIC, or TESTING
articles available in the section(s) you are accessing.
COOLING SYSTEM TROUBLE SHOOTING
CONDITION POSSIBLE CAUSE CORRECTION Overheating Coolant Leak Fill/Pressure Test
System
A/C Condenser Fins Clogged Remove/Clean Condenser
Radiator Fins Clogged Remove/Clean Radiator Thermostat Stuck Closed Replace Thermostat Clogged
Cooling System
Passages Clean/Flush Cooling
System
Water Pump Malfunction Replace Water Pump Fan Clutch Malfunction Replace Fan Clutch Retarded
Ignition Timing Reset Ignition Timing
Cooling Fan Malfunction Test Cooling Fan/ Circuit
Cooling Fan Motor
Malfunction Test Fan Motor
Cooling Fan Relay
Malfunction Test Fan Relay
Faulty Radiator Cap Replace Radiator Cap Broken/Slipping Fan Belt Replace Fan Belt Restricted Exhaust
Repair Exhaust System
Corrosion Impurities In Coolant Clean/Flush System
Coolant Leakage Damaged hose Replace Hose
Leaky Water Pump Replace Water Pump Damaged Radiator Seam Replace/Repair Radiator Leaky
Thermostat Cover Replace Thermostat
Cover
Cylinder Head Problem Check Head/Head Gasket
Leaky Freeze Plugs Replace Freeze Plugs
Recovery System Inoperative
Loose and/or Defective
Radiator Cap Replace Radiator Cap
Overflow Tube Clogged
and/or Leaking Repair Tube
Recovery Bottle Vent
Restricted Clean Vent
No Heater Core Flow
Collapsed Heater Hose Replace Heater Hose
Plugged Heater Core Clean/Replace Heater
Core
Faulty Heater Valve Replace Heater Valve

GASOLINE ENGINE – MECHANICAL TROUBLE SHOOTING

NOTE: This is GENERAL information. This article is not intended

to be specific to any unique situation or individual vehicle configuration. The purpose of this Trouble
Shooting information is to provide a list of common causes to
problem symptoms. For model-specific Trouble Shooting, refer to SUBJECT, DIAGNOSTIC, or TESTING
articles available
in the section(s) you are accessing.
BASIC GASOLINE ENGINE – MECHANICAL TROUBLE SHOOTING CHART CONDITION POSSIBLE CAUSE
CORRECTION

Incorrect ignition timing Reset ignition timing, See TUNE-UP

Leaking valves Replace valves, See

Worn fuel pump diaphragm or ENGINES

piston Replace diaphragm or piston

Improper ignition timing Reset ignition timing, See TUNE-UP

Intake Backfire
Faulty accelerator pump Replace accelerator

discharge
pump
Improper choke operation
Check choke and adjust as required
Defective EGR valve
Replace EGR valve
Fuel mixture too lean
Reset air/fuel mixture, See TUNE-UP
Choke valve initial clearance too
Reset choke valve initial clearance
large

Exhaust
Vacuum leak Inspect and repair vacuum system
Backfire
 Faulty vacuum diverter Replace vacuum diverter

valve valve

Faulty choke operation Check choke and adjust as required

Exhaust system leak repair exhaust system leak

Ignition timing too far advanced

Reset ignition timing, See TUNE-UP
Faulty ignition system
Check ignition timing, See TUNE-UP
Spark plugs loose or faulty
Retighten or replace plugs
Fuel delivery system clogged
Inspect lines, pump and filter for clog
Engine EGR valve inoperative
Replace EGR valve Inspect and/or replace hoses
Detonation PCV system inoperative or valve
Vacuum leaks Check vacuum system and repair leaks
Excessive combustion chamber Remove built-up deposits
deposits
Inspect and/or replace valves
Leaking, sticking or broken valves

External Oil Fuel pump improperly seated Remove pump, replace

Leakage or worn gasket gasket and seat

properly

Oil pan gasket broken or Straighten pan and

pan bent replace gasket

Timing chain cover gasket Replace timing chain

broken cover gasket

Rear main oil seal worn Replace rear main oil

seal

Oil pan drain plug not Remove and reinstall

seated properly drain plug

Camshaft bearing drain Remove restriction

hole blocked

Oil pressure sending Remove and reinstall

 switch leaking sending switch

Excessive Oil Worn valve stems or guides Replace stems or

Consumption guides, See ENGINES Valve “O” ring seals Replace “O” ring seals, damaged See ENGINES
Plugged oil drain back holes Remove restrictions Improper PCV valve Replace PCV valve operation
Engine oil level too high Remove excess oil Engine oil too thin Replace thicker oil Valve stem oil
deflectors Replace oil deflectors damaged
Incorrect piston rings Replace piston rings, See ENGINES
Piston ring gaps not Reinstall piston rings, staggered See ENGINES
Insufficient piston ring Replace rings, See tension ENGINES
Piston ring grooves or oil Replace piston rings, return slots clogged See ENGINES
Piston rings sticking in Replace piston rings, grooves See ENGINES
Piston ring grooves Replace piston and excessively worn rings, See ENGINES Compression rings installed
Replace compression upside down rings correctly, See
ENGINES
Worn or scored cylinder Rebore cylinders or walls replace block Mismatched oil ring Replace oil ring
expander and rail expander and rail, See
ENGINES
Intake gasket dowels too Replace intake gasket long dowels
Excessive main or connecting Replace main or rod bearing clearance connecting rod
bearings, See ENGINES
No Oil Pressure Low oil level Add oil to proper level Oil pressure sender or Replace sender or gauge
gauge broken
Oil pump malfunction Remove and overhaul oil pump, See ENGINES
Oil pressure relief valve Remove and reinstall sticking valve
Oil pump passages blocked Overhaul oil pump, See
ENGINES
Oil pickup screen or tube remove restriction blocked
Loose oil inlet tube Tighten oil inlet tube
Loose camshaft bearings Replace camshaft bearings, See ENGINES
Internal leakage at oil Replace block or passages cylinder head
Low Oil Pressure Low engine oil level Add oil to proper level
Engine oil too thin Remove and replace with thicker oil
Excessive oil pump Reduce oil pump clearance clearance, See ENGINES Oil pickup tube or screen
Remove restrictions blocked
Main, rod or cam bearing Replace bearing to clearance excessive reduce clearance, See
ENGINES
High Oil Improper grade of oil Replace with proper oil
Pressure Oil pressure relief valve Eliminate binding stuck closed
Oil pressure sender or Replace sender or gauge gauge faulty
Noisy Main Inadequate oil supply Check oil delivery to
Bearings main bearings
Excessive main bearing Replace main bearings, clearance See ENGINES
Excessive crankshaft end Replace crankshaft, See play ENGINES
Loose flywheel or torque Tighten attaching bolts converter
Loose or damaged vibration Tighten or replace damper vibration damper Crankshaft journals Re-grind
crankshaft out-of-round journals
Excessive belt tension Loosen belt tension
Noisy Connecting Excessive bearing clearance Replace bearing, See
Rods or missing bearing ENGINES
Crankshaft rod journal Re-grind crankshaft out-of-round journal
Misaligned connecting rod Remove rod or cap and or cap realign
Incorrectly tightened rod Remove and re-tighten bolts rod bolts
Noisy Pistons Excessive piston-to-bore Install larger pistons, and Rings clearance See ENGINES
Bore tapered or out-of-round Rebore block
Piston ring broken Replace piston rings, See ENGINES
Piston pin loose or seized Replace piston pin, See
ENGINES
Connecting rods misaligned Realign connecting rods Ring side clearance too Replace with larger or loose
or tight smaller rings
Carbon build-up on piston Remove carbon
Noisy Valve Worn or bent push rods Replace push rods, See
Train ENGINES
Worn rocker arms or bridged Replace push rods, See pivots ENGINES
Dirt or chips in valve Remove lifters and lifters remove dirt/chips Excessive valve lifter Replace valve
lifters, leak-down See ENGINES
Valve lifter face worn Replace valve lifters, See ENGINES
Broken or cocked valve replace or reposition springs springs
Too much valve stem-to-guide Replace valve guides, clearance See ENGINES
Valve bent Replace valve, See
ENGINES
Loose rocker arms Retighten rocker arms, See ENGINES
Excessive valve seat Reface valve seats, See run-out ENGINES

Missing valve lock Excessively worn

Install new valve lock Replace
camshaft lobes
camshaft, See ENGINES
Plugged valve lifter oil holes
Eliminate restriction or replace lifter
Faulty valve lifter check ball Replace lifter check ball, See ENGINES
Remove and reinstall correctly
Rocker arm nut installed upside down
Remove and replace valve lifters
Valve lifter incorrect for engine
Replace plunger or push rod
Faulty push rod seat or lifter plunger

Improper valve lash Re-adjust valve lash, See ENGINES

Worn or dirty valve lifters Clean and/or replace lifters

Noisy Valves
Worn valve guides Replace valve guides, See ENGINES

Excessive valve seat or Reface seats or valve

face run-out face

Worn camshaft lobes Replace camshaft, See

Loose rocker arm studs ENGINES

Bent push rods Re-tighten rocker arm studs, See

ENGINES Replace push rods, See
Broken valve springs ENGINES
 Replace valve springs, See ENGINES

Replace valves and/or springs, See

Weak valve springs or warped valves ENGINES

Improper lifter clearance Re-adjust clearance or replace lifters

Burned,Sticking or Worn guides or improper guide clearance Replace valve guides, See ENGINES
Broken Valves
Out-of-round valve seats or improper seat Re-grind valve seats
width Gum deposits on valve stems, seats
Remove deposits
or guides Improper spark timing
Re-adjust spark timing

Undersize pistons Replace with larger pistons, See

Broken ENGINES Replace with correct rings,
Wrong piston rings See ENGINES
Pistons/Rings
Out-of-round cylinder bore Re-bore cylinder bore

Improper connecting rod alignment Remove and realign connecting rods

Replace pistons, See ENGINES
Excessively worn ring grooves
Re-assemble pin-to
Improperly assembled piston pins
Insufficient ring gap clearance -piston, See ENGINES Install new
rings, See ENGINES
Engine overheating
Check cooling system Re-adjust
Incorrect ignition timing ignition timing, See TUNE-UP

Excessive Leaks at manifold to Replace manifold or

Exhaust Noise head, or to pipe pipe gasket

Exhaust manifold Replace exhaust

cracked or broken manifold, See ENGINES

ENGINE PERFORMANCE

CARBURETOR TROUBLE SHOOTING:

NOTE: This is GENERAL information. This article is not intended

to be specific to any unique situation or individual vehicle configuration. The purpose of this Trouble
Shooting information is to provide a list of common causes to
problem symptoms. For model-specific Trouble Shooting, refer to SUBJECT, DIAGNOSTIC, or TESTING
articles available in the section(s) you are accessing.
BASIC COLD START SYMPTOMS TROUBLE SHOOTING CHART
CONDITION POSSIBLE CAUSE CORRECTION

Check choke operation, see FUEL SYSTEMS

Check linkage, seeFUEL SYSTEM

Engine
Won’t Choke not closing
Start

Choke linkage bent

Engine Starts, Choke vacuum kick setting Check setting and

Then Dies too wide adjust see, FUEL SYSTEMS

Fast idle RPM too low Reset RPM to specif- ication, see TUNE-UP
Fast idle cam index Reset fast idle cam incorrect index, see FUEL
SYSTEMS
Vacuum leak Inspect vacuum system for leaks
Low fuel pump outlet Repair or replace pump, see FUEL SYSTEMS
Low carburetor fuel level Check float setting see FUEL SYSTEM

Engine Quits Choke vacuum kick setting Reset vacuum kick

Under Load incorrect setting,see FUEL

SYSTEMS

Fast idle cam index Reset fast idle cam incorrect index, see FUEL
SYSTEM
Incorrect hot fast idle Reset fast idle RPM, speed RPM see TUNE-UP

Engine Starts, Choke vacuum kick set too Reset vacuum kick,

Runs Up,Then narrow see FUEL SYSTEMS

Idles, Slowly

With Black Smoke Fast idle cam index Reset fast idle cam

incorrect index, see FUEL SYSTEMS

Hot fast idle RPM too low Reset fast idle RPM, see TUNE-UP
BASIC HOT START SYMPTOMS TROUBLE SHOOTING CHART
CONDITION POSSIBLE CAUSE CORRECTION Engine Won’t Engine flooded Allow fuel to
Start evaporate
BASIC COLD ENGINE DRIVEABILITY SYMPTOMS TROUBLE SHOOTING CHART CONDITION POSSIBLE CAUSE
CORRECTION

Defective choke control switchReplace choke control switch, see FUEL SYSTEMS

Plugged heat crossoverRemove restriction

system

Engine Stalls in Choke vacuum Reset choke vacuum kick,

setting
Gear kick incorrect see FUEL SYSTEMS
 Reset fast idle
Fast idle RPM incorrect
RPM, see TUNE-UP

Reset fast idle cam

Fast idle incorrect cam index
see FUEL SYSTEMS

Acceleration or Replace choke

Sag Defective switch choke control
Stall control switch

Choke vacuum kick Reset choke vacuum kick

setting incorrect see, FUEL SYSTEMS

Float level incorrect Adjust float level, FUEL

(too low) SYSTEMS

Accelerator pump Repair or replace pump

defective see FUEL SYSTEMS

Inspect lockout
Secondary throttles
adjustment,see FUEL
not closed
SYSTEMS

Sag or Stall

After Warmup

Defective Replace pump, see

accelerator pump FUEL SYSTEMS

Float level incorrect Adjust float level, see FUEL

(too low) SYSTEMS

Backfiring &

Black Smoke

BASIC WARM ENGINE DRIVEABILITY SYMPTOMS TROUBLE SHOOTING CHART

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

DIESEL ENGINE TROUBLE SHOOTING

NOTE: This is GENERAL information. This article is not intended

to be specific to any unique situation or individual vehicle configuration. The purpose of this Trouble
Shooting information is to provide a list of common causes to
problem symptoms. For model-specific Trouble Shooting, refer to SUBJECT, DIAGNOSTIC, or TESTING
articles available in the section(s) you are accessing.
NOTE: Diesel engines mechanical diagnosis is the same as gasoline engines for items such as noisy
valves, bearings, pistons, etc. The following trouble shooting covers only items pertaining to diesel
engines.
BASIC DIESEL ENGINE TROUBLE SHOOTING CHART

CONDITION POSSIBLE CAUSE CORRECTION

Engine Won’t Bad battery connections Check connections

Crank or dead batteries and/or replace

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

Cooling system leaksBelt slipping or damagedThermostat stuck closedHead gasket leakingCheck cooling
system and repair leaks Check tension and/or replace beltRemove and replace thermostat, see ENGINE
COOLING Replace head gasket

Injector pump fuel solenoidRemove and check

does not return fuel valvesolenoid and replace

Check pressure,
Incorrect injector pump see
housing pressure
FUEL SYSTEMS

Engine

Overheating

Low oil pump

Oil Light on Check oil pump operation, see ENGINES
at pressure
Idle Remove restriction
Oil cooler or line

restricted and/or replace cooler

Engine
Won’t

Shut Off

to OFF position if needed

VACUUM PUMP DIAGNOSIS

Excessive Noise Loose pump-to-drive Tighten screws assembly screws
Loose tube on pump assembly Tighten tube Valves not functioning Replace valves properly

Oil Leakage Loose end plug Tighten end plug

Bad seal crimp Remove and re-crimp

seal

FUEL INJECTION TROUBLE SHOOTING

NOTE: This is GENERAL information. This article is not intended

to be specific to any unique situation or individual vehicle configuration. The purpose of this Trouble
Shooting information is to provide a list of common causes to
problem symptoms. For model-specific Trouble Shooting, refer to SUBJECT, DIAGNOSTIC, or TESTING
articles available in the section(s) you are accessing.
BASIC FUEL INJECTION TROUBLE SHOOTING CHART

circuit

CONDITION POSSIBLE CAUSE CORRECTION

Engine Won’t Cold start valve inoperative Test valve and

Start (Cranks

Normally)
Poor connection;vacuum or Check vacuum and wiring electrical
connections
Contaminated fuel Test fuel for water or alcohol
Defective fuel pump relay Test relay and or circuit wiring
Battery too low Charge and test battery

Test pressure regul- ator and fuel pump, check for

Low fuel pressure
restricted lines and filters

No distributor reference
Repair ignition system as necessary
pulses

Open coolant temperature

Test sensor and wiring
sensor circuit

Shorted W.O.T. switch in

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

Defective ECM Replace ECM

Fuel tank residual pressure

Test for fuel pressure drop after shut down
valve leaks

Disconnected hot air tube to

Hard Starting Reconnect tube and test control valve
air cleaner

Defective Idle Air Control

Test valve operation and circuit
(IAC) valve

Shorted, open or misadjusted

Test and adjust or replace T.P.S.
T.P.S.

EGR valve open Test EGR valve and control circuit

Poor Oxygen sensor signal Test for shorted or circuit

Incorrect mixture from PCV

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

Poor High
Speed Low fuel pump volume Faulty pump or restricted fuel lines or filters
Operation

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

Poor Oxygen sensor signal Test for shorted or open sensor or circuit
 Open coolant temperature
Test sensor and wiring
sensor circuit

Check wires for cracks or poor con- nections, test

Faulty ignition operation
secondary voltage with oscilloscope

Contaminated fuel Test fuel for water

or alcohol
Intermittent ECM ground Test ECM ground connection for resistance
Restricted air cleaner Replace air cleaner
Restricted exhaust system Test for exhaust manifold back pressure
Poor MAF sensor signal Check leakage between sensor and manifold

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

open sensor or

Poor VSS signal

Ping or Knock on Poor Knock sensor signal Test for shorted or

Acceleration

circuit

Poor Baro sensor signal Test for shorted or open sensor or circuit
Improper ignition timing See VEHICLE EMISSION CONTROL LABEL (where applicable)
Check for engine Low coolant, loose overheating problems belts or electric
cooling fan inoperative
NOTE: For additional electronic fuel injection trouble shooting information, see the appropriate article in
the ENGINE PERFORMANCE section (not all vehicles have Computer Engine Control articles). Information
is provided there for diagnosing fuel system problems on vehicles with electronic fuel injection.

IGNITION SYSTEM TROUBLE SHOOTING

NOTE: This is GENERAL information. This article is not intended

to be specific to any unique situation or individual vehicle configuration. The purpose of this Trouble
Shooting information is to provide a list of common causes to
problem symptoms. For model-specific Trouble Shooting, refer to SUBJECT, DIAGNOSTIC, or TESTING
articles available in the section(s) you are accessing.
Ignition Secondary Trouble Shooting Chart
START: Visually inspect Spark Plug Wires, Coil Wires, Plug Wire Boots, Rotor, and Distributor Cap for
signs of damage.
OK NOT OK

damaged components

as necessary

* To test secondary ignition * Repair or replace

system, modify a Spark Plug

 by attaching a ground wire

to the body of the plug and

widening the gap to 1/4-3/8″.

Disconnect spark plug wire

and insert test plug. Ground

plug, crank engine, and

check for spark.

GOOD SPARK NO SPARK

* If plug sparks, driveability * Remove coil wire from the problem is most likely NOT distributor and
attach the in the ignition system. modified spark plug. Ground
the plug and crank engine while checking for spark.

PRIMARY TROUBLE SHOOTING

CHECK CHART below in this

article.

GOOD SPARK NO SPARK

* *
If plug has a good spark, Proceed to the IGNITION

the problem is in the plug

wires, distributor cap, or

rotor. Replace components

as necessary.

Ignition Primary Trouble Shooting Chart

START: Visually inspect primary ignition wires for broken, frayed, split, or cut wires. Also check for loose,
corroded, or disconnected connectors.
OK NOT OK

components as necessary.

* Check that battery voltage * Repair or replace damaged

is at least 11.5 volts.

NOT OK OK
* Replace or recharge the * Check for battery voltage battery. at the positive terminal of
the coil.
OK NOT OK
* Check air Gap of the Pick-Up * Check resistance of ballast coil in the distributor. resistor (if used) for
the
correct resistance value.
OK NOT OK

necessary.

* Check Pick-Up coil for * Adjust or replace as

correct resistance value.

NOT OK OK

good ground connections.

* Replace Pick-Up coil if * Check control module for

not to specification.

OK
* If vehicle fails to run at this point, go to the appropriate article in the ENGINE PERFORMANCE section.
OK NOT OK

if the measured resistance

value is not within

specification.

* Check wires from the battery/ * Replace ballast resistor

ignition switch to the coil.

Also check the coil primary

and secondary resistance.

STARTER TROUBLE SHOOTING

NOTE: This is GENERAL information. This article is not intended

to be specific to any unique situation or individual vehicle configuration. The purpose of this Trouble
Shooting information is to provide a list of common causes to
problem symptoms. For model-specific Trouble Shooting, refer to SUBJECT, DIAGNOSTIC, or TESTING
articles available in the section(s) you are accessing.
BASIC STARTER TROUBLE SHOOTING CHART
CONDITION POSSIBLE CAUSE CORRECTION
Starter Fails Dead battery or bad Check battery charge to Operate connections between and all wires
and
starter and battery connections to starter

Ignition switch faulty or misadjusted Adjust or replace ignition switch

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

Starter relay or starter defective See Testing in STARTER

 article

See Testing in STARTER

Open solenoid pull-in wire
article

Charge or replace battery as

Starter Does Not Operate Weak battery or dead cell necessary
and Headlights Dim Loose or corroded battery connections Check that battery connections
are clean and tight

See Testing in STARTER

Internal ground in starter windings
article

Grounded starter fields See Testing in STARTERS

Armature rubbing on pole shoes See STARTER article

Starter Turns Starter clutch slipping See STARTER article

but Engine

Does Not Rotate

Broken clutch housing See STARTER article

Pinion shaft rusted or See STARTER article dry

Engine basic timing See Ignition Timing in incorrect TUNE-UP article
Broken teeth on engine Replace flywheel and flywheel check for starter pinion
gear damage

Starter Will
Not Faulty overrunning clutch See STARTER article
Crank Engine

Broken clutch housing See STARTER article

Replace flywheel and check for starter

Broken flywheel teeth
pinion gear damage

Armature shaft sheared or reduction gear

See STARTER article
teeth stripped

Weak battery Charge or replace battery as necessary

See On-Vehicle Tests in

Faulty solenoid
STARTER article

Poor grounds Check all ground

connections for tight and clean connections
Ignition switch faulty Adjust or replace or misadjusted ignition switch as
necessary
Starter Cranks Battery weak or Charge or replace
Engine Slowly defective battery as necessary
Engine overheated See ENGINE COOLING SYSTEM article
Engine oil too heavy Check that proper viscosity oil
is used
Poor battery-to-starter Check that all connections between
battery and starter are clean and tight
Current draw too low or See Bench Tests in too high STARTER article
Bent armature, loose pole See STARTER article shoes screws or worn
bearings
Burned solenoid contacts Replace solenoid
Faulty starter Replace starter
Starter Engages Engine timing too far See Ignition Timing in Engine Only advanced TUNE-UP article
Momentarily
Overrunning clutch not Replace overrunning engaging properly clutch. See STARTER
article
Broken starter clutch See STARTER article
Broken teeth on engine Replace flywheel and flywheel check starter pinion
gear for damage
Weak drive assembly See STARTER article thrust spring
Weak hold-in coil See Bench Tests in
STARTER article
Starter Drive Defective point assembly See Testing in STARTER Will Not Engage article
Poor point assembly ground See Testing in STARTER
article
Defective pull-in coil Replace starter solenoid
Starter Relay Dead battery Charge or replace

battery as necessary
Does Not Close Faulty wiring
Check all wiring and

connections leading to relay

Neutral safety switch faulty Replace neutral safety switch

Starter relay faulty Replace starter relay

Starter Drive Will Not Starter motor loose on mountings Tighten starter attach bolts
Disengage Worn drive end bushing See STARTER article

Replace flywheel and starter pinion

Damaged engine flywheel teeth
gear for damage

Drive yolk return spring broken or

Replace return spring
missing
 Faulty ignition switch Replace ignition switch

Insufficient clearance between winding

leads to solenoid terminal and main Replace starter solenoid
contact in solenoid

Starter clutch not disengaging Replace starter clutch

Ignition starter switch contacts sticking Replace ignition switch

Check all wiring between relay and

Starter Relay Operates Faulty solenoid switch, switch
solenoid or replace relay or solenoid
but Solenoid Does Not connections or
as necessary

Broken lead or loose Repair wire or wire

soldered connections connections as necessary

Solenoid Plunger Weak battery Charge or replace Vibrates When battery as necessary Switch is Engaged
Solenoid contacts Clean contacts or corroded replace solenoid
Faulty wiring Check all wiring leading to solenoid
Broken connections inside Repair connections or switch cover replace solenoid
Open hold-in wire Replace solenoid
Low Current Draw Worn brushes or weak Replace brushes or brush springs as necessary
High Pitched Whine Distance too great Align starter or check During Cranking between starter that
correct starter Before Engine pinion and flywheel and flywheel are being Fires but Engine used
Fires and Cranks
Normally
High Pitched Distance too small between Whine After Engine starter pinion and flywheel Fires With Key
Flywheel runout contributes released. Engine to the intermittent nature Fires and Cranks
Normally

TUNE-UP TROUBLE SHOOTING – GAS ENGINE VEHICLES

NOTE: This is GENERAL information. This article is not intended

to be specific to any unique situation or individual vehicle configuration. The purpose of this Trouble
Shooting information is to provide a list of common causes to
problem symptoms. For model-specific Trouble Shooting, refer to SUBJECT, DIAGNOSTIC, or TESTING
articles available in the section(s) you are accessing.
BASIC SPARK PLUG TROUBLE SHOOTING CHARTS
CONDITION POSSIBLE CAUSE CORRECTION Normal Spark Light Tan or Gray deposits No Action
Plug Condition
Electrode not burned or No Action fouled

mixture, see ENGINE PERFORMANCE section

Replace choke

Gap tolerance not changed No Action

Cold Fouling or
Overrich air/fuel mixture Adjust air/fuel

Carbon Deposits
 Faulty choke

assembly, see ENGINE

PERFORMANCE section

Clogged air filter Clean and/or replace air filter

Incorrect idle speed or Reset idle speed and/
dirty carburetor or clean carburetor
Faulty ignition wires Replace ignition wiring

pistons

Prolonged operation at idle Shut engine during long off idle

Sticking valves or worn valve guide seals Check valve train

Wet Fouling Worn rings and pistons Install new rings and

or Oil Deposits

Deposits in combustion chamber becoming fused to electrodeClean combustion chamber of deposits

Engine overheatingWrong type of fuelCheck cooling systemReplace with correct

Excessive cylinder wear Rebore or replace block

Excessive valve guide

Worn or loose bearing
clearance

Gap
Bridged

Blistered

Electrode

fuel

Loose spark plugs Retighten spark plugs

Over-advanced ignition Reset ignition timing see ENGINE

timing PERFORMANCE

Pre-
or Incorrect type of fuel Replace with correct
Ignition

Melted Electrodes fuel

Incorrect ignition timing Reset ignition timing see ENGINE PERFORMANCE

Burned valves Replace valves

Engine Overheating Check cooling system

 Wrong type of spark plug, Replace with correct

spark plug, see

too hot
ENGINE PERFORMANCE

Chipped
Severe detonation Check for over- advanced timing or combustion
Insulators

Improper gapping procedure Re-gap spark plugs

Rust Colored
Additives in unleaded fuel Try different fuel brand
Deposits

Water In Combus- Blown head gasket or Repair or replace

tion Chamber cracked head head or head gasket

NOTE: Before diagnosing an electronic ignition system, ensure that all wiring is connected properly
between distributor, wiring connector and spark plugs. Ignition problem will show up either as: Engine
Will Not Start or Engine Runs Rough.
BASIC ELECTRONIC IGNITION TROUBLE SHOOTING CHARTS
CONDITION POSSIBLE CAUSE CORRECTION Engine Won’t Open circuit between Repair circuit

ignition switch
Repair circuit
Open circuit between

ignition switch and starter

solenoid

Engine Runs
Fuel lines leaking or clogged Tighten fitting, remove restriction
Rough

Reset ignition timing see ENGINE

Initial timing incorrect
PERFORMANCE

Centrifugal advance malfunction Repair distributor advance

Defective spark plugs or wiring Replace plugs or plug wiring

Component Spark arc-over on cap, rotor or

Replace cap, rotor or or coil
Failure coil

Defective pick-up coil Replace pick-up coil

Defective ignition coil Replace ignition coil

Defective vacuum unit Replace vacuum unit

 Defective control module Replace control module

BASIC ELECTRONIC IGNITION TROUBLE SHOOTING CHARTS – USING OSCILLOSCOPE PATTERNS

CONDITION POSSIBLE CAUSE CORRECTION Firing Voltage Retarded ignition timing Reset ignition
Lines are the Same, timing, see ENGINE
but Abnormally High PERFORMANCE section
Fuel mixture too lean Readjust carburetor, see ENGINE PERFORMANCE
High resistance in coil Replace coil wire wire
Corrosion in coil tower Clean and/or replace terminal coil
Corrosion in distributor Clean and/or replace coil terminal distributor cap
Firing Voltage Fuel mixture too rich Readjust carburetor, Lines are the Same see ENGINE PERFORMANCE
but Abnormally Low
Breaks in coil wire causing Replace coil wire arcing
Cracked coil tower causing Replace coil arcing
Low coil output Replace coil
Low engine compression Determine cause and
repair
One or More, But Carburetor idle mixture Readjust carburetor, Not All Firing not balanced see ENGINE
PERFORMANCE Voltage Lines are
Higher Than Others EGR valve stuck open Clean and/or replace valve
High resistance in spark Replace spark plug plug wires wires

Cracked or broken spark

Replace spark plugs
plug insulator

Intake vacuum leak Repair leak

Defective spark plugs Replace spark plugs

Corroded spark plug

Replace spark plugs
terminals

Curb idle mixture not

Readjust carburetor, see ENGINE
One or More, But Not All Firing Voltage balanced
PERFORMANCE
Lines Are Lower Than Others Breaks in plug wires
Replace plug wires
causing arcing

Cracked coil tower causing

Replace coil
arcing

Low compression Determine cause and repair

Defective spark plugs Replace spark plugs

Corroded spark plugs Replace spark plugs

Cylinders Not Cracked distributor cap

Replace distributor cap
Firing terminals
 Shorted spark plug wire Determine cause and repair

Mechanical problem in
Determine cause and repair
engine

Defective spark plugs Replace spark plugs

Spark plugs fouled Replace spark plugs

BASIC DRIVEABILITY PROBLEMS TROUBLE SHOOTING TABLE CONDITION POSSIBLE CAUSE CORRECTION
Hard Starting Binding carburetor linkage Eliminate binding Binding choke linkage Eliminate binding
Binding choke piston Eliminate binding
Restricted choke vacuum Check vacuum lines for blockage

see ENGINE PERFORMANCE

Worn or dirty needle valve and Clean carburetor, see

seat ENGINE PERFORMANCE

Readjust or replace float see the ENGINE

Float sticking
PERFORMANCE section

Incorrect choke adjustment Reset choke adjustment see ENGINE PERFORMANCE

Defective coil Replace coil

Improper spark plug gap Regap spark plugs

Incorrect ignition timing Reset ignition timing see ENGINE PERFORMANCE

Detonation Over-advanced ignition timing Reset ignition timing see ENGINE PERFORMANCE

Defective spark plugs Replace spark plugs

Fuel lines clogged Clean fuel lines

Check and repair EGR

EGR system malfunction
system

PCV system malfunction Repair PCV system

Vacuum leaks Check and repair vacuum system

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

Restricted airflow Remove restriction

Vacuum advance malfunction Check distributor operation

Dieseling Binding carburetor linkage Eliminate binding

Binding throttle linkage Eliminate blinding

Binding choke linkage or fast idle

Eliminate binding
cam

Defective idle solenoid Replace idle solenoid see ENGINE PERFORMANCE

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

Incorrect ignition timing Reset ignition timing see ENGINE PERFORMANCE

Reset idle mixture,

Incorrect idle mixture setting
see ENGINE PERFORMANCE

Faulty Incorrect ignition timing Reset ignition timing

Acceleration

Engine cold and choke too Adjust choke and

lean allow engine to warm- up
Defective spark plugs Replace spark plugs
Defective coil Replace coil

slots, see FUEL

Faulty Low Speed Clogged idle transfer slots Clean idle transfer

Operation

Restricted idle air bleeds Disassemble and clean and passages carburetor, see FUEL
Clogged air cleaner Replace air filter Defective spark plugs Replace spark plugs Defective ignition wires
Replace ignition wire
see ENGINE PERFORMANCE
Defective distributor cap Replace distributor cap
Faulty High Speed Incorrect ignition timing Reset ignition timing
Operation see ENGINE PERFORMANCE
Defective distributor Replace advance

centrifugal advance mechanism

Defective distributor Replace advance unit

vacuum advance

Check gap and/or replace spark

Incorrect spark plugs or plug gap
plugs

Check choke and repair as

Faulty choke operation
required
 Clogged vacuum passages Remove restrictions

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

Check filter and replace as

Restricted air cleaner
necessary

Defective distributor cap, rotor or

Replace cap, rotor or coil
coil

Misfire
at All Defective spark plugs Replace spark plugs
Speeds

Replace spark plug

Defective spark plug wires
wires

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

coil coil

Cracked or broken vacuum Replace vacuum hoses

hoses

Vacuum leaks Repair vacuum leaks

Fuel lines clogged Remove restriction
Hesitation Cracked or broken vacuum Replace vacuum hoses hoses
Vacuum leaks Repair Vacuum leaks Binding carburetor linkage Eliminate binding Binding throttle linkage
Eliminate binding Binding choke linkage or Eliminate binding
fast idle cam
Improper float setting Readjust float setting, see FUEL
Cracked or broken ignition Replace ignition wires wires
Rough idle, Incorrect curb idle or fast Reset idle speed, see Missing or idle speed see ENGINE
PERFORMANCE Stalling
Incorrect basic timing Reset ignition timing see ENGINE PERFORMANCE
Improper idle mixture Reset idle mixture, adjustment see ENGINE PERFORMANCE
Improper feedback system Check feedback system operation see ENGINE PERFORMANCE
Incorrect spark plug gap Reset spark plug gap, see ENGINE PERFORMANCE
Moisture in ignition Dry components components
Loose or broken ignition Replace ignition wires wires
Damaged distributor cap or Replace distributor or rotor cap or rotor
Faulty ignition coil Replace ignition coil Fuel filter clogged or worn Replace fuel filter Damaged idle
mixture screw Replace idle mixture
screw, see FUEL
Improper fast idle cam Reset fast idle cam adjustment adjustment, see TUNE-
see ENGINE PERFORMANCE
Improper EGR valve operation Replace EGR valve Faulty PCV valve air flow Replace PCV valve Choke
binding or improper Reset choke or
choke setting eliminate binding
Engine Vacuum leak Repair vacuum leak
Surges Improper float bowl fuel Reset float

Engine
level adjustment, see FUEL
Surges

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

Engine
Clogged or worn air cleaner filter Replace air filter
Surges

Engine Replace diaphragm,

Faulty choke vacuum diaphragm
Surges see ENGINE PERFORMANCE

Engine
Exhaust manifold heat valve inoperative Replace heat valve
Surges

Engine
Improper distributor spark advance Check distributor operation
Surges

Engine
Leaking valves or valve components Check and repair valvetrain
Surges

Engine
Improper carburetor mounting Remove and remount carburetor
Surges

Engine
Excessive play in distributor shaft Replace distributor
Surges

Engine
Loose or corroded wiring connections Repair or replace as required
Surges

Engine
Improper PCV valve airflow Replace PCV valve
Surges

Engine
Vacuum leaks Repair vacuum leaks
Surges

Engine
Clogged air bleeds Remove restriction
Surges

Engine
EGR valve malfunction Replace EGR valve
Surges

Engine
Restricted air cleaner filter Replace air filter
Surges
Engine
Cracked or broken vacuum hoses Replace vacuum hoses
Surges

Engine
Cracked or broken ignition wires Replace ignition wires
Surges

Engine
Vacuum advance malfunction Check unit and replace as necessary
Surges

Engine
Defective or fouled spark plugs Replace spark plugs
Surges

Ping or
Spark Reset ignition timing see ENGINE
Incorrect ignition timing
PERFORMANCE
Knock

Distributor centrifugal or vacuum advance

Check operation and replace as necessary
malfunction

Carburetor setting too lean Readjust mixture

setting, see ENGINE PERFORMANCE

Vacuum leak Eliminate vacuum leak

EGR valve malfunction Replace EGR valve

Poor Gasoline
Cracked or broken vacuum hoses Replace vacuum hoses
Mileage

Vacuum leaks Repair vacuum leaks

Defective ignition wires Replace wires

Readjust setting, see

Incorrect choke setting
ENGINE PERFORMANCE

Defective vacuum advance Replace vacuum advance

Defective spark plugs Replace spark plugs

Binding carburetor power piston Eliminate binding

Dirt in carburetor jets Clean and/or replace jets

Incorrect float adjustment Readjust float setting, see FUEL

Defective power valve Replace power valve, see ENGINE PERFORMANCE

 Incorrect idle speed Readjust idle speed

Engine Stalls Improper float level Readjust float level

Leaking needle valve and seat Replace needle valve and seat

Vacuum leaks Eliminate vacuum

leaks

VACUUM PUMP – DIESEL TROUBLE SHOOTING

NOTE: This is GENERAL information. This article is not intended

to be specific to any unique situation or individual vehicle configuration. The purpose of this Trouble
Shooting information is to provide a list of common causes to
problem symptoms. For model-specific Trouble Shooting, refer to SUBJECT, DIAGNOSTIC, or TESTING
articles available in the section(s) you are accessing.
NOTE: Diesel engines mechanical diagnosis is the same as gasoline engines for items such as noisy
valves, bearings, pistons, etc. The following trouble shooting covers only items pertaining to diesel
engines.
VACUUM PUMP (DIESEL) TROUBLE SHOOTING CHART
CONDITION POSSIBLE CAUSE CORRECTION

Excessive Noise Loose pump-to-drive Tighten screws

assembly screws

Loose tube on pump assembly Tighten tube

Valves not functioning Replace valves

properly
Oil Leakage Tighten end plug
Loose end plug

Bad seal crimp Remove and re-crimp seal

MANUAL TRANSMISSION

MANUAL TRANSMISSION TROUBLE SHOOTING

NOTE: This is GENERAL information. This article is not intended

to be specific to any unique situation or individual vehicle configuration. The purpose of this Trouble
Shooting information is to provide a list of common causes to
problem symptoms. For model-specific Trouble Shooting, refer to SUBJECT, DIAGNOSTIC, or TESTING
articles available in the section(s) you are accessing.
MANUAL TRANSMISSION/TRANSAXLE TROUBLE SHOOTING Condition Possible Cause
Noisy In Forward Gears .Low gear oil level,
.Loose bell housing bolts,
.Worn bearings or gears
Clunk On Deceleration
(FWD Only) .Loose engine mounts,
.Worn inboard CV joints,
.Worn differential pinion shaft,
.Side gear hub counterbore in case worn oversize
Gear Clash When Shifting
Forward Gears .Clutch Out Of Adjustment,
.Shift linkage damaged or out of adjustment,
.Gears or synchronizers damaged,
.Low gear oil level
Transmission Noisy When
Moving (RWD Only) Quiet In
Neutral With Clutch Engaged .Worn rear outputshaft bearing
Gear Rattle .Worn bearings,
.Wrong gear oil,
.Low gear oil,
.Worn gears
Steady Ticking At Idle
(Increases With RPM) .Broken tooth on gear
Gear Clash When Shifting
Forward Gears .Worn or broken synchronizers
Loud Whine In Reverse .Normal condition (1)
Noise When Stepping On Clutch .Bad release bearing,
.Worn pilot bearing
Ticking Or Screeching As
Clutch Is Engaged .Faulty release bearing,
.Uneven pressure plate fingers
Click Or Snap When Clutch
Is Engaged .Worn clutch fork,
.Worn or broken front bearing retainer
Transmission Shifts Hard .Clutch not releasing,
.Shift mechanism binding,
.Clutch installed backwards
Will Not Shift Into One
Gear, Shifts Into All
Others .Bent shift fork,
.Worn detent balls
Locked Into Gear,
Cannot Shift .Clutch adjustment,
.Worn detent balls
Transmission Jumps Out
Of Gear .Pilot bearing worn,
.Bent shift fork,
.Worn gear teeth or face
.Excessive gear train end play
.Worn synchronizers
.Missing detent ball spring
.Shift mechanism worn or out of adjustment
.Engine or transmission mount bolts loose or out of adjustment
.Transmission not aligned
Shift Lever Rattle .Worn shift lever or detents
.Worn shift forks
.Worn synchronizers sleeve
Shift Lever Hops Under
Acceleration .Worn engine or transmission mounts
(1) – Most units use spur cut gears in reverse and are noisy

POWERTRAIN

CLUTCH TROUBLE SHOOTING

NOTE: This is GENERAL information. This article is not intended

to be specific to any unique situation or individual vehicle configuration. The purpose of this Trouble
Shooting information is to provide a list of common causes to
problem symptoms. For model-specific Trouble Shooting, refer to SUBJECT, DIAGNOSTIC, or TESTING
articles available in the section(s) you are accessing.
BASIC CLUTCH TROUBLE SHOOTING CHART

Oil, grease or glaze onDisassemble and clean

Oil or grease on clutchClean or replace clutch

facingsclutch disc

CONDITION POSSIBLE CAUSE CORRECTION

or
Chattering Incorrect clutch adjustment Adjust clutch

Grabbing

facings or replace

See DRIVE AXLES

Loose “U” joint flange
article

Worn input shaft spline Replace input shaft

Binding pressure plate Replace pressure plate

Binding release lever See CLUTCH article

Binding clutch disc hub Replace clutch disc

Unequal pressure plate contact Replace worn/misaligned components

Loose/bent clutch disc Replace clutch disc

Incorrect transmission alignment Realign transmission

Worn pressure plate, disc or flywheel Replace damaged components

Broken or weak pressure springs Replace pressure plate

Lubricate clutch pedal

Sticking clutch pedal
& linkage
 Incorrect clutch disc facing Replace clutch disc

Engine loose in chassis Tighten all mounting bolts

Failure to

Release

Incorrect release lever or See CLUTCH article pedal adjustment

Worn or broken clutch Replace clutch disc facings
Bent clutch disc or Replace damaged pressure plate components
Clutch disc hub binding on Clean or replace clutch input shaft disc and/or input shaft
Binding pilot bearing Replace pilot bearing
Sticking release bearing Replace release bearing sleeve and/or sleeve
Binding clutch cable See CLUTCH article
Defective clutch master Replace master cylinder Defective clutch slave Replace slave cylinder Air in
hydraulic system Bleed hydraulic system
Dry or binding clutch Lubricate and align pedal hub components
Floor mat interference Lay mat flat in proper with pedal area

switch

Dry or pivots binding ball/fork Lubricate and align components

Faulty clutch cable Replace clutch cable

Noisy Clutch Faulty interlock switch Replace interlock

Pedal

Self-adjuster ratchet Lubricate or replace noise self-adjuster

Speed control interlock Lubricate or replace switch interlock switch
Clutch Pedal Binding clutch cable See CLUTCH article
Sticks Down
Springs weak in pressure Replace pressure plate plate
Binding in clutch linkage Lubricate and free linkage

Noisy Dry release bearing Lubricate or replace release bearing

Noisy Dry or worn pilot bearing Lubricate or replace bearing

Noisy Worn input shaft bearing Replace bearing

Transmission
Weak springs in pressure plate Replace pressure plate
Click

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

Oil on clutch disc damper Replace clutch disc

Broken spring in slave Replace slave cylinder

 cylinder

DRIVE AXLE – NOISE DIAGNOSIS

Unrelated Noises
Some driveline trouble symptoms are also common to the engine, transmission, wheel bearings, tires,
and other parts of the vehicle. Ensure cause of trouble actually is in the drive axle before adjusting,
repairing, or replacing any of its parts.
Non-Drive Axle Noises
A few conditions can sound just like drive axle noise and have to be considered in pre-diagnosis. The 4
most common noises are exhaust, tires, CV/universal joints and wheel trim rings.
In certain conditions, the pitch of the exhaust gases may sound like gear whine. At other times, it may
be mistaken for a wheel bearing rumble.
Tires, especially radial and snow, can have a high-pitched tread whine or roar, similar to gear noise. Also,
some non-standard tires with an unusual tread construction may emit a roar or whine.
Defective CV/universal joints may cause clicking noises or excessive driveline play that can be
improperly diagnosed as drive axle problems.
Trim and moldings also can cause a whistling or whining noise. Ensure none of these components are
causing the noise before disassembling the drive axle.
Gear Noise
A “howling” or “whining” noise from the ring and pinion gear can be caused by an improper gear
pattern, gear damage, or improper bearing preload. It can occur at various speeds and driving
conditions, or it can be continuous.
Before disassembling axle to diagnose and correct gear noise, make sure that tires, exhaust, and vehicle
trim have been checked as possible causes.
Chuckle
This is a particular rattling noise that sounds like a stick against the spokes of a spinning bicycle wheel. It
occurs while decelerating from 40 MPH and usually can be heard until vehicle comes to a complete stop.
The frequency varies with the speed of the vehicle.
A chuckle that occurs on the driving phase is usually caused by excessive clearance due to differential
gear wear, or by a damaged tooth on the coast side of the pinion or ring gear. Even a very small tooth
nick or a ridge on the edge of a gear tooth is enough the cause the noise.
This condition can be corrected simply by cleaning the gear tooth nick or ridge with a small grinding
wheel. If either gear is damaged or scored badly, the gear set must be replaced. If metal has broken
loose, the carrier and housing must be cleaned to remove particles that could cause damage.
Knock
This is very similar to a chuckle, though it may be louder, and occur on acceleration or deceleration.
Knock can be caused by a gear tooth that is damaged on the drive side of the ring and pinion gears. Ring
gear bolts that are hitting the carrier casting can cause knock. Knock can also be due to excessive end
play in the axle shafts.
Clunk
Clunk is a metallic noise heard when an automatic transmission is engaged in Reverse or Drive, or when
throttle is applied or released. It is caused by backlash somewhere in the driveline, but not necessarily in
the axle. To determine whether driveline clunk is caused by the axle, check the total axle backlash as
follows:
1) Raise vehicle on a frame or twinpost hoist so that drive wheels are free. Clamp a bar between axle
companion flange and a part of the frame or body so that flange cannot move.
2) On conventional drive axles, lock the left wheel to keep it from turning. On all models, turn the right
wheel slowly until it is felt to be in Drive condition. Hold a chalk marker on side of tire about 12″ from
center of wheel. Turn wheel in the opposite direction until it is again felt to be in Drive condition.
3) Measure the length of the chalk mark, which is the total
axle backlash. If backlash is one inch or less, drive axle is not the source of clunk noise.
Bearing Whine
Bearing whine is a high-pitched sound similar to a whistle. It is usually caused by malfunctioning pinion
bearings. Pinion
bearings operate at drive shaft speed. Roller wheel bearings may whine in a similar manner if they run
completely dry of lubricant. Bearing noise will occur at all driving speeds. This distinguishes it from
gear whine, which usually comes and goes as speed changes.
Bearing Rumble
Bearing rumble sounds like marbles being tumbled. It is usually caused by a malfunctioning wheel
bearing. The lower pitch is because the wheel bearing turns at only about 1/3 of drive shaft speed.
Chatter On Turns
This is a condition where the entire front or rear of vehicle vibrates when vehicle is moving. The
vibration is plainly felt as well as heard. Extra differential thrust washers installed during axle repair can
cause a condition of partial lock-up that creates this chatter.
Axle Shaft Noise
Axle shaft noise is similar to gear noise and pinion bearing whine. Axle shaft bearing noise will normally
distinguish itself from gear noise by occurring in all driving modes (Drive, cruise, coast and float), and
will persist with transmission in Neutral while vehicle is moving at problem speed.
If vehicle displays this noise condition, remove suspect axle shafts, replace wheel seals and install a new
set of bearings.
Re-evaluate vehicle for noise before removing any internal components.
Vibration
Vibration is a high-frequency trembling, shaking or grinding condition (felt or heard) that may be
constant or variable in level and can occur during the total operating speed range of the vehicle.
The types of vibrations that can be felt in the vehicle can be divided into 3 main groups:
* Vibrations of various unbalanced rotating parts of the vehicle.
* Resonance vibrations of the body and frame structures caused by rotating of unbalanced parts.
* Tip-in moans of resonance vibrations from stressed engine or exhaust system mounts or driveline
flexing modes.

DRIVE AXLE – RWD TROUBLE SHOOTING

NOTE: This is GENERAL information. This article is not intended

to be specific to any unique situation or individual vehicle configuration. The purpose of this Trouble
Shooting information is to provide a list of common causes to
problem symptoms. For model-specific Trouble Shooting, refer to SUBJECT, DIAGNOSTIC, or TESTING
articles available in the section(s) you are accessing. For definitions
of listed noises or sounds, see DRIVE AXLE – NOISE DIAGNOSIS
under POWERTRAIN.
DRIVE AXLE (RWD) TROUBLE SHOOTING
CONDITION POSSIBLE CAUSE CORRECTION
Knocking or Clunking
Differential Side Gear
Clearance Check Clearance
Worn Pinion Shaft Replace Pinion Shaft Axle Shaft End Play Check End Play Missing Gear Teeth Check
Differential/
Replace Gear
Wrong Axle Backlash Check Backlash
Misaligned Driveline Realign Driveline
Clinking During Engagement
Side Gear Clearance Check Clearance
Ring and Pinion Backlash Check Backlash Worn/Loose Pinion Shaft Replace Shaft/Bearing Bad “U” Joint
Replace “U” Joint Sticking Slip Yoke Lube Slip Yoke
Broken Rear Axle Mount Replace Mount
Loose Drive Shaft Flange Check Flange
Click/Chatter On Turns
Differential Side Gear
Clearance Check Clearance

Change Lubricant

Wrong Turn On Plates (1) Replace Clutch Plates

Wrong Differential

Lubricant (1)

Knock Or Click Flat Spot on Rear

Wheel Bearing Replace Wheel Bearing

Low Vibration At All Speeds
Faulty Wheel Bearing Replace Wheel Bearing
Faulty “U” Joint Replace “U” Joint Faulty Drive Shaft Balance Drive Shaft Faulty Companion Flange
Replace Flange Faulty Slip Yoke Flange Replace Flange
(1) – Limited slip differential only.

FWD AXLE SHAFTS & CV JOINTS TROUBLE SHOOTING

NOTE: This is GENERAL information. This article is not intended

to be specific to any unique situation or individual vehicle configuration. The purpose of this Trouble
Shooting information is to provide a list of common causes to
problem symptoms. For model-specific Trouble Shooting, refer to SUBJECT, DIAGNOSTIC, or TESTING
articles available in the section(s) you are accessing.
BASIC FWD AXLE SHAFTS & CV JOINTS TROUBLE SHOOTING CHART CONDITION POSSIBLE CAUSE
Grease Leaks CV boot torn or cracked
Clicking Noise on Cornering Damaged outer CV Clunk Noise on Acceleration Damaged inner CV
Vibration or Shudder Sticking, damaged or worn CV
on Acceleration Misalignment or spring height

STEERING & SUSPENSION

MANUAL STEERING GEAR TROUBLE SHOOTING

NOTE: This is GENERAL information. This article is not intended

to be specific to any unique situation or individual vehicle configuration. The purpose of this Trouble
Shooting information is to provide a list of common causes to
problem symptoms. For model-specific Trouble Shooting, refer to SUBJECT, DIAGNOSTIC, or TESTING
articles available in the section(s) you are accessing.
BASIC MANUAL STEERING GEAR TROUBLE SHOOTING CHART
CONDITION POSSIBLE CAUSE CORRECTION

Rattle or Chucking Noise in Rack Rack and pinion mounting bracket

Tighten all mounting bolts
and Pinion loose
 Lack of/or incorrect lubricant Correct as necessary

Rattle or Chucking Noise in Rack Steering gear mounting bolts

Tighten all mounting bolts
and Pinion loose

Front wheel bearing improperly See FRONT SUSPENSION

Excessive Play
adjusted article

See STEERING LINKAGE

Loose or worn steering linkage
article

See MANUAL STEERING GEAR

Loose or worn steering gear shift
article

See MANUAL STEERING GEAR

Steering arm loose on gear shaft
article

Steering gear housing bolts loose Tighten all mounting bolts

Steering gear adjustment too See MANUAL STEERING GEAR

loose article

Steering arms loose on Tighten and check

knuckles steering linkage

Rack and pinion mounting Tighten all mounting

loose bolts

See adjustment in
Rack and pinion out of adjustment
STEERING article

Tie rod end loose Tighten and check steering linkage

Excessive Pitman shaft-to- ball nut

Repair as necessary
lash

Poor Lack of lubricant in ball joint or

Lubricate and service systems
Returnability linkage

See STEERING LINKAGE

Binding in linkage or ball joints
and SUSPENSION article

See WHEEL ALIGNMENT

Improper front end alignment
article
 Improper tire pressure Inflate to proper pressure

Tie rod binding Inflate to proper pressure

See STEERING COLUMN

Shaft seal rubbing shaft
article

Excessive
Improper tire pressure Inflate to proper pressure
Vertical Motion

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

Worn or faulty shock absorbers Check and replace if necessary

Loose tie rod ends or steering Tighten or replace if necessary

Loose or worn wheel bearings See SUSPENSION article

Steering Pulls to One

Improper tire pressure Inflate to proper pressure
Side

Front tires are different sizes Rotate or replace if necessary

Wheel bearings not See FRONT SUSPENSION

adjusted properly article

Bent or broken suspension See FRONT SUSPENSION

components article

Improper wheel alignment See WHEEL ALIGNMENT

article

Brakes dragging See BRAKES article

pressure

Instability Low or uneven tire Inflate to proper

pressure

Loose or worn wheel See FRONT SUSPENSION

bearings article
Loose or worn idler arm See FRONT SUSPENSION
bushing article
Loose or worn strut See FRONT SUSPENSION
bushings article
Incorrect front wheel See WHEEL ALIGNMENT
alignment article
Steering gear not See MANUAL STEERING
centered GEARS article
Springs or shock Check and replace if necessary
Improper cross shaft See MANUAL STEERING GEARS article

POWER STEERING TROUBLE SHOOTING

NOTE: This is GENERAL information. This article is not intended

to be specific to any unique situation or individual vehicle configuration. The purpose of this Trouble
Shooting information is to provide a list of common causes to
problem symptoms. For model-specific Trouble Shooting, refer to SUBJECT, DIAGNOSTIC, or TESTING
articles available in the section(s) you are accessing.
BASIC POWER STEERING TROUBLE SHOOTING CHART
CONDITION POSSIBLE CAUSE CORRECTION Rattle or Pressure hoses touching Adjust to proper

Tighten and check, replace if necessary

fluid

See STEERING COLUMN

Worn shaft serrations
article

Growl in
Excessive pressure in Restricted hoses, see POWER
Steering hoses STEERING GEAR article
Pump

See POWER STEERING GEAR

Scored pressure plates
article

Scored thrust plates or See POWER STEERING GEAR

rotor article

Extreme wear of cam See POWER

STEERING GEAR
ring article

Rattle in
See POWER
Steering Vanes not installed STEERING PUMP
article
Pump

See POWER
Vanes sticking in rotor STEERING PUMP
article

Swish noise
in Defective flow control See POWER
STEERING PUMP
valve article
Pump

Groan in Air in fluid See POWER STEERING PUMP

Steering article
Pump

Poor pressure hose

connection

Squawk See POWER

When Damper “O” ring on STEERING PUMP
valve
spool cut
Turning article

Moan or
Pump shaft bearing scored Replace bearing and
Whine

in Pump

Air in fluid or fluid See POWER STEERING PUMP

level low article
Hose or column grounded Check and replace if necessary
Cover “O” ring missing See POWER STEERING PUMP
or damaged article
Valve cover baffle See POWER STEERING PUMP
missing or damaged article
Interference of See POWER STEERING PUMP
components in pump article
Loose or poor bracket Correct or replace if alignment necessary

article

Hissing When
Internal steering leakage in gear Check valved assembly first
Parking

Chirp in
Loose or steering worn power belt Adjust or replace if necessary
Steering Pump

Buzzing When Noisy pump See POWER STEERING PUMP

Not Steering

Free play in steering See STEERING COLUMN

shaft bearing article
Bearing loose on shaft See STEERING COLUMN
serrations article

Clicking Noise Pump slippers too See POWER

STEERING PUMP
in Pump long article

Broken slipper See POWER

STEERING PUMP
springs article
 Excessive wear or See POWER
STEERING PUMP
nicked rotors article

Damaged cam See POWER

STEERING PUMP
contour article

Poor Return Wheel rubbing against See STEERING COLUMN

of
Wheel turn signal SWITCHES article

Flange rubbing steering See STEERING COLUMN

gear adjuster article

Tight or frozen steering See STEERING COLUMN

shaft bearing article

Steering gear out of See POWER STEERING GEAR

adjustment article

Sticking or plugged spool See POWER STEERING PUMP

valve article

Improper front end See WHEEL ALIGNMENT

alignment article

Wheel bearings worn or See FRONT SUSPENSION

loose article

Ties rods or ball joints

Check and replace if necessary
binding

Intermediate shaft joints See STEERING COLUMN

binding article

Kinked pressure hoses Correct or replace if necessary

Loose housing head See POWER STEERING GEAR

spanner nut article

See POWER STEERING GEAR

Damaged valve lever
article

Sector shaft adjusted too See ADJUSTMENTS in POWER

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

Reaction ring sticking See POWER STEERING GEAR

in cylinder article

See POWER STEERING

Reaction ring sticking in housing GEAR
head
article

See POWER STEERING

Steering pump internal leakage PUMP

article

Steering gear-to-column See STEERING COLUMN

misalignment article

Lack of lubrication in linkage Service front suspension

Lack of lubrication in ball joints Service front suspension

See POWER STEERING

High internal pump leakage PUMP
Increased Effort When Turning Wheel
Fast Power steering pump belt article

Adjust or replace if

Foaming, Milky Power Steering Fluid, slipping necessary

Low Fluid Low fluid level Check and fill to

Level or Low proper level

Engine idle speed to low
Pressure Adjust to correct

setting

See POWER STEERING

Air in pump fluid system PUMP

article

See POWER STEERING

Pump output low PUMP

article

See POWER STEERING

Steering gear malfunctioning
GEAR
 article

Check and fill to proper

Wheel Surges or Jerks Low fluid level
level

Adjust or replace if
Loose fan belt
necessary

See POWER STEERING

Insufficient pump pressure PUMP

article

See POWER STEERING

Sticky flow control valve PUMP

article

Linkage hitting oil pan at full turn Replace bent components

See POWER STEERING

Kick Back or
Air in pump fluid system PUMP
Free Play
article

See POWER STEERING

Worn poppet valve in steering PUMP
gear
article

See POWER STEERING

Excessive over center lash GEAR

article

See POWER STEERING

Thrust bearing out of
GEAR

adjustment article

Free play in pot coupling See POWER STEERING PUMP

article
Steering gear coupling See POWER STEERING PUMP
loose on shaft article
Steering disc mounting Tighten or replace if bolts loose necessary
Coupling loose on worm Tighten or replace if shaft necessary
Improper sector shaft See POWER STEERING GEAR
adjustment article
Excessive worm piston See POWER STEERING GEAR
side play article
Damaged valve lever See POWER STEERING GEAR
article
Universal joint loose Tighten or replace if necessary
 See POWER
Defective rotary valve STEERING GEAR
article

No Power See POWER

When Sticking flow control valve STEERING PUMP
Parking article

See POWER
Insufficient pump pressure output STEERING PUMP
article

See POWER
Excessive internal pump leakage STEERING PUMP
article

Excessive internal gear See POWER STEERING PUMP

leakage article

Flange rubs against gear See STEERING COLUMN

adjust plug article
Loose pump belt Adjust or replace if necessary
Low fluid level Check and add proper amount of fluid
Engine idle too low Adjust to correct setting
Steering gear-to-column See STEERING COLUMN
misaligned article

Left turn reaction seal See POWER

No Power, Left Turn STEERING GEAR
“O” ring worn article

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

Cylinder head “O” ring See POWER STEERING PUMP

damaged article

No Power, Column pot coupling See STEERING COLUMN

Right Turns bottomed article

Right turn reaction seal See POWER STEERING GEAR “O” ring worn article
Right turn reaction seal See POWER STEERING GEAR
damaged article
Internal leakage through See POWER STEERING GEAR
piston end plug article
Internal leakage through See POWER STEERING GEAR
side plugs article

incorrectarticle
Lack of Effort in Left and/or right reaction seal Replace, see POWER
Turning sticking in cylinder head STEERING GEAR article

See
Wanders to One Front end alignment ALIGNMENT
WHEEL

Side

Unbalanced steering See POWER STEERING GEAR

gear valve article
Low Pressure Due Flow control valve stuck See POWER STEERING PUMP
to Steering Pump or inoperative article
Pressure plate not flat See POWER STEERING PUMP
against cam ring article
Extreme wear of cam ring Replace and check adjustments
Scored plate, thrust See POWER STEERING PUMP
plate or rotor article
Vanes not installed See POWER STEERING PUMP
properly article
Vanes sticking in rotor See POWER STEERING PUMP
slots article
Cracked/broken thrust or See POWER STEERING PUMP
pressure plate article

STEERING COLUMN TROUBLE SHOOTING

NOTE: This is GENERAL information. This article is not intended

to be specific to any unique situation or individual vehicle configuration. The purpose of this Trouble
Shooting information is to provide a list of common causes to
problem symptoms. For model-specific Trouble Shooting, refer to SUBJECT, DIAGNOSTIC, or TESTING
articles available in the section(s) you are accessing.
BASIC STEERING COLUMN TROUBLE SHOOTING CHART
CONDITION POSSIBLE CAUSE CORRECTION

article

Noise in Coupling pulled apart See STEERING COLUMNS

Steering

Shifting
Improper gate plate See STEERING COLUMN
adjustment article
Excess Play in Instrument panel bracket Tighten bolts and check
Column bolts loose bracket
Broken weld nut on jacket See STEERING COLUMN
article
Instrument bracket capsule See STEERING COLUMN
sheared article
Column bracket/jacket Tighten bolts and check bolts loose bracket
Steering Locks Release lever mechanism See STEERING COLUMN
in Gear article
SUSPENSION TROUBLE SHOOTING

NOTE: This is GENERAL information. This article is not intended

to be specific to any unique situation or individual vehicle configuration. The purpose of this Trouble
Shooting information is to provide a list of common causes to
problem symptoms. For model-specific Trouble Shooting, refer to SUBJECT, DIAGNOSTIC, or TESTING
articles available in the section(s) you are accessing.
BASIC SUSPENSION TROUBLE SHOOTING CHART
CONDITION POSSIBLE CAUSE CORRECTION
Front End Noise Loose or worn wheel See Wheel Bearing Adjustment in SUSPENSION
Worn shocks or shock Replace struts or strut mountings mountings
Worn struts or strut Replace struts or strut mountings mountings
Loose or worn lower control See SUSPENSION
arm
Loose steering gear-to- See STEERING
frame bolts
Worn control arm bushings See SUSPENSION
Ball joints not lubricated Lubricate ball joints & see Ball Joint Checking in SUSPENSION
Front Wheel Tires or wheels out of Check tire balance
Shake, Shimmy, balance or Vibration
Incorrect wheel alignment See WHEEL ALIGNMENT
Drive shaft unbalanced Check drive shaft balance
Loose or worn wheel See WHEEL ALIGNMENT
bearings
Loose or worn tie rod ends See SUSPENSION
Worn upper ball joints See Ball Joint Checking in SUSPENSION
Worn shock absorbers Replace shock absorbers
Worn strut bushings Replace strut bushings
Car Pulls to Mismatched or uneven tires Check tire condition
One Side
Broken or sagging springs See SUSPENSION
Loose or worn strut See SUSPENSION
bushings
Improper wheel alignment See WHEEL ALIGNMENT Improper rear axle Check rear axle
alignment alignment
Power steering gear See STEERING
unbalanced
Front brakes dragging See BRAKES
Abnormal Tire Unbalanced tires Check tire balance & Wear rotation
Sagging or broken springs See SUSPENSION Incorrect front end See WHEEL ALIGNMENT
alignment
Faulty shock absorbers Replace chock absorbers
Scuffed Tires Toe-In incorrect See WHEEL ALIGNMENT Suspension arm bent or See appropriate
twisted SUSPENSION article
Springs Bottom Bent or broken springs See SUSPENSION
or Sag
Leaking or worn shock Replace shock absorbers absorbers
Frame misalignment Check frame for damage

Spring Noises Loose “U” Bolts See SUSPENSION

 Loose or worn bushings See SUSPENSION

Worn or missing interliners See SUSPENSION

Shock Absorber
Loose shock mountings Check & tighten mountings
Noise

Worn bushings Replace bushings

Air in system Bleed air from system

Car Leans or Undercoating on shocks Remove undercoating

Loose stabilizer bar See SUSPENSION

Sways on Corners

Faulty shocks or mountings Replace shocks or mountings

Broken or sagging springs See SUSPENSION

Shock Absorbers
Worn seals or reservoir tube crimped See SUSPENSION
Leaking

Broken Springs Loose “U” bolts See SUSPENSION

Inoperative shock absorbers Replace shock absorbers

WHEEL ALIGNMENT TROUBLE SHOOTING

NOTE: This is GENERAL information. This article is not intended

to be specific to any unique situation or individual vehicle configuration. The purpose of this Trouble
Shooting information is to provide a list of common causes to
problem symptoms. For model-specific Trouble Shooting, refer to SUBJECT, DIAGNOSTIC, or TESTING
articles available in the section(s) you are accessing.
BASIC WHEEL ALIGNMENT TROUBLE SHOOTING CHART
CONDITION POSSIBLE CAUSE CORRECTION
Premature Tire Improper tire inflation Check tire pressure
Wear
Front alignment out of See ALIGNMENT SPECS in tolerance WHEEL ALIGNMENT section
Suspension components worn See SUSPENSION section
Steering system components See STEERING section worn
Improper standing height See WHEEL ALIGNMENT Uneven or sagging springs See SUSPENSION section
Bent wheel See WHEEL ALIGNMENT Improper torsion bar See SUSPENSION section
adjustment
Loose or worn wheel See WHEEL BEARING ADJ. bearings in SUSPENSION section
Worn or defective shock Replace shock absorbers
Tires out of balance Check tire balance
Pulls to One Improper tire inflation Check tire pressure
Side
Brake dragging See BRAKE section
Mismatched tires See WHEEL ALIGNMENT Broken or sagging spring See SUSPENSION section Broken
torsion bar See SUSPENSION section
Power steering valve not See STEERING section centered
Front alignment out of See WHEEL ALIGNMENT
tolerance section
Defective wheel bearing See WHEEL BEARINGS in
SUSPENSION section
Uneven sway bar links See SUSPENSION section Frame bent Check for frame damage Steering system
bushing See STEERING section
worn
Hard Steering Idler arm bushing too tight See STEERING LINKAGE
in STEERING section
Ball joint tight or seized See SUSPENSION section
Steering linkage too tight See STEERING LINKAGE in
STEERING section
Power steering fluid low Add proper amount of fluid
Power steering drive belt See STEERING section loose
Power steering pump See STEERING section defective
Steering gear out of See STEERING section adjustment

Incorrect wheel alignment See WHEEL ALIGNMENT

Damaged steering gear See STEERING section

Damaged suspension See SUSPENSION section

Bent steering knuckle or supports See SUSPENSION section

Vehicle
Strut rod or control arm bushing worn See SUSPENSION section
“Wanders”

Loose or worn wheel See WHEEL BEARINGS in

bearings SUSPENSION section

Improper tire inflation Check tire pressure
Stabilizer bar missing or See SUSPENSION section defective
Wheel alignment out of See Adjustment in tolerance WHEEL ALIGNMENT section
Broken spring See SUSPENSION section Defective shock absorbers Replace shock absorbers Worn
steering & suspension See SUSPENSION section
components
Front End Shimmy Tire out of balance/round Check tire balance Excessive wheel runout See WHEEL
ALIGNMENT Insufficient or improper See WHEEL ALIGNMENT
caster section
Worn suspension or steering See SUSPENSION section components
Defective shock absorbers Replace shock absorber
Wheel bearings worn or See WHEEL BEARING ADJ. loose in SUSPENSION section
Power steering reaction See STEERING section
Bracket loose
Steering gear box (rack) See STEERING section mounting loose
Steering gear adjustment See STEERING section loose
Worn spherical joints See SUSPENSION section
Toe-In Not Lower control arm bent See SUSPENSION section
Adjustable
Frame bent Check frame for damage
Camber Not Control arm bent See SUSPENSION section
Adjustable
Frame bent Check frame for damage
Hub & bearing not seated See SUSPENSION section properly