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Volvo 850 electrical system inspection

 

* ELECTRICAL SYSTEM UNIFORM INSPECTION GUIDELINES *

1995 Volvo 850

GENERAL INFORMATION
Electrical System Motorist Assurance Program
Standards For Automotive Repair
All Makes and Models

INTRODUCTION TO MOTORIST ASSURANCE PROGRAM (MAP)

CONTENTS

OVERVIEW OF MOTORIST ASSURANCE PROGRAM
OVERVIEW OF SERVICE REQUIREMENTS & SUGGESTIONS ACTUATOR MOTORS (SOLENOIDS) (ELECTRIC)
ACTUATOR MOTORS (VACUUM) AIR BAGS
ALTERNATORS AND GENERATORS AMPLIFIERS
ANTENNAS BATTERIES BATTERY CABLES BATTERY CABLES
BATTERY HOLD DOWN HARDWARE
BATTERY TRAYS AND HOLD DOWN HARDWARE BATTERY WIRES
BELTS
BULB SOCKETS
BULBS, SEALED BEAMS AND LEDS CD PLAYERS
CIGARETTE LIGHTER ASSEMBLIES CIRCUIT BREAKERS
CLUTCH SWITCHES CONNECTORS CONTROL MODULES
CRUISE CONTROL BRAKE SWITCHES CRUISE CONTROL CABLES
CRUISE CONTROL CLUTCH SWITCHES CRUISE CONTROL LINKAGES AND CABLES CRUISE CONTROL RESERVOIRS
CRUISE CONTROL TUBES
CRUISE CONTROL VACUUM DUMP RELEASE VALVES
CRUISE CONTROL VACUUM HOSES, TUBES AND RESERVOIRS CRUISE CONTROL VEHICLE SPEED SENSORS
DEFOGGERS DEFROSTERS DELAYS DIMMERS
ELECTRIC HEATERS EQUALIZERS
FUSE BLOCKS
FUSE BOXES AND BLOCKS
FUSES, FUSIBLE LINKS AND CIRCUIT BREAKERS FUSIBLE LINKS
GAUGES GENERATORS
GROUND CABLES AND STRAPS GROUND STRAPS
HEADLIGHT ADJUSTERS
HEATING ELEMENTS (DEFROSTERS, DEFOGGERS, ELECTRIC HEATERS AND SEATS) HORNS AND SIRENS
IGNITION SWITCHES INDICATOR LIGHTS
KEYLESS ENTRY KEYPADS AND TRANSMITTERS KEYLESS ENTRY TRANSMITTERS
LEDS LENSES MICROPHONES
MIRRORS (ELECTROCHROMATIC AND HEATED) MOTORS
NEUTRAL SAFETY SWITCHES ODOMETERS
ODOMETERS, SPEEDOMETERS AND TACHOMETERS (CABLE-DRIVEN) PULLEYS
RECEIVERS, AMPLIFIERS, EQUALIZERS AND SUB-WOOFER VOLUME CONTROLS RELAY BOXES
RELAYS
SEALED BEAMS SEAT HEATERS
SECURITY ALARM SENSORS SIRENS
SOLENOIDS
SPEAKERS AND MICROPHONES
SPEEDOMETER AND TACHOMETER LINKAGES AND CABLES SPEEDOMETER CABLES
SPEEDOMETERS STARTERS
SUB-WOOFER VOLUME CONTROLS SWITCHES
TACHOMETER CABLES TACHOMETERS
TAPE PLAYERS AND CD PLAYERS TENSIONERS
TIMERS
TIRE PRESSURE SENSORS TRANSCEIVERS TRANSDUCERS
VACUUM ACCUMULATORS (RESERVOIRS) VACUUM RESERVOIRS
VOLTAGE REGULATORS
WASHER FLUID LEVEL SENDERS WASHER PUMPS
WIPER ARMS AND BLADES WIPER BLADES
WIPER HOSES AND NOZZLES WIPER LINKAGES
WIPER NOZZLES
WIPER PUMP RESERVOIRS
WIRING HARNESSES AND CONNECTORS

INTRODUCTION TO MOTORIST ASSURANCE PROGRAM (MAP)

OVERVIEW OF MOTORIST ASSURANCE PROGRAM

The Motorist Assurance Program is the consumer outreach effort of the Automotive Maintenance and Repair Association, Inc. (AMRA). Participation in the Motorist Assurance Program is drawn from retailers, suppliers, independent repair facilities, vehicle manufacturers and industry associations.
Our organization’s mission is to strengthen the relationship between the consumer and the auto repair industry. We produce materials that give motorists the information and encouragement to take greater responsibility for their vehicles-through proper,
manufacturer-recommended, maintenance. We encourage participating service and repair shops (including franchisees and dealers) to adopt (1) a Pledge of Assurance to their Customers and (2) the Motorist Assurance Program Standards of Service. All participating service providers have agreed to subscribe to this Pledge and to adhere to the promulgated Standards of Service demonstrating to their customers that they are serious about customer satisfaction.
These Standards of Service require that an inspection of the vehicle’s (problem) system be made and the results communicated to the customer according to industry standards. Given that the industry did not have such standards, the Motorist Assurance Program successfully promulgated industry inspection communication standards in 1994-95 for the following systems: Exhaust, Brakes, ABS, Steering and Suspension, Engine Maintenance and Performance, HVAC, and Electrical Systems. Further, revisions to all of these inspection communication standards are continually re-published.
In addition to these, standards for Drive Train and Transmissions have recently been promulgated. Participating shops utilize these Uniform Inspection & Communication Standards as part of the inspection process and for communicating their findings to their customers.
The Motorist Assurance Program continues to work cooperatively and proactively with government agencies and consumer groups toward solutions that both benefit the customer and are mutually acceptable to both regulators and industry. We maintain the belief that industry must retain control over how we conduct our business, and we must be viewed as part of the solution and not part of the problem. Meetings with state and other government officials (and their representatives), concerned with auto repair and/or consumer protection, are conducted. Feedback from these sessions is brought back to the association, and the program adjusted as needed.
To assure auto repair customers recourse if they were not satisfied with a repair transaction, the Motorist Assurance Program offers mediation and arbitration through MAP/BBB-CARE and other non- profit organizations. MAP conducted pilot programs in twelve states before announcing the program nationally in October, 1998. During the pilots, participating repair shops demonstrated their adherence to the Pledge and Standards and agreed to follow the UICS in communicating
the results of their inspection to their customers. To put some “teeth” in the program, an accreditation requirement for shops was initiated. The requirements are stringent, and a self-policing method has been incorporated which includes the “mystery shopping” of
outlets.
We welcome you to join us as we continue our outreach… with your support, both the automotive repair industry and your customers will reap the benefits. Please visit MAP at our Internet site www. motorist.org or contact us at:
1444 I Street, NW Suite 700
Washington, DC 20005
Phone (202) 712-9042 Fax (202) 216-9646
January 1999

MAP UNIFORM INSPECTION GENERAL GUIDELINES

OVERVIEW OF SERVICE REQUIREMENTS & SUGGESTIONS

It is MAP policy that all exhaust, brake, steering, suspension, wheel alignment, drive-line, engine performance and maintenance, and heating, ventilation and air conditioning, and electrical services be offered and performed under the standards and procedures specified in these sections.
Before any service is performed on a vehicle, an inspection of the appropriate system must be performed. The results of this inspection must be explained to the customer and documented on an inspection form. The condition of the vehicle and its components will indicate what services/part replacements may be “Required” or “Suggested”. In addition, suggestions may be made to satisfy the requests expressed by the customer.
When a component is suggested or required to be repaired or replaced, the decision to repair or replace must be made in the customer’s best interest, and at his or her choice given the options available.
This section lists the various parts and conditions that indicate a required or suggested service or part replacement. Although this list is extensive, it is not fully inclusive. In addition to this list, a technician may make a suggestion. However, any suggestions
must be based on substantial and informed experience, or the vehicle manufacturer’s recommended service interval and must be documented.
Some conditions indicate that service or part replacement is required because the part in question is no longer providing the function for which it is intended, does not meet a vehicle manufacturer’s design specification or is missing.
Example:
An exhaust pipe has corroded severely and has a hole
in it through which exhaust gases are leaking. Replacement of the exhaust pipe in this case is required due to functional failure.
Example:
A brake rotor has been worn to the point where it measures less than the vehicle manufacturer’s discard specifications. Replacement of the rotor is required because it does not meet design specifications.
Some conditions indicate that a service or part replacement is suggested because the part is close to the end of its useful life or addresses a customer’s need, convenience or request. If a customer’s vehicle has one of these conditions, the procedure may be only to suggest service.
Example:
An exhaust pipe is rusted, corroded or weak, but no leaks are present. In this case, the exhaust pipe has not failed. However, there is evidence that the pipe may need replacement in the near future. Replacement of the pipe may be suggested for the customer’s convenience in avoiding a future problem.
Example:
The customer desires improved ride and/or handling, but the vehicle’s shocks or struts have not failed. In this case, replacement may be suggested to satisfy the customer’s
wishes. In this case, replacement of the shocks or struts may not be sold as a requirement.
A customer, of course, has the choice of whether or not a shop will service his or her vehicle. He or she may decide not to follow some of your suggestions. When a repair is required, a MAP shop must refuse partial service on that system if, in the judgment of the service provider, proceeding with the work could create or continue an unsafe condition. When a procedure states that required or suggested repair or replacement is recommended, the customer must be informed of the generally acceptable repair/replacement options whether or not performed by the shop.
When presenting suggested repairs to the customer, you must present the facts, allowing the customer to draw their own conclusions and make an informed decision about how to proceed.
The following reasons may be used for required and suggested services. These codes are shown in the “Code” column of the MAP Uniform Inspection & Communications Standards that follow:
Reasons to Require Repair or Replacement
A – Part no longer performs intended purpose
B – Part does not meet a design specification (regardless of performance)
C – Part is missing
NOTE: When a repair is required, the shop must refuse partial service to the system in question, if the repair creates or continues an unsafe condition.
Reasons to Suggest Repair or Replacement
1 – Part is close to the end of its useful life (just above discard specifications, or weak; failure likely to occur soon, etc.)
2 – To address a customer need, convenience, or request (to stiffen ride, enhance performance, eliminate noise, etc.)
3 – To comply with maintenance recommended by the vehicle’s
Original Equipment Manufacturer (OEM)
4 – Technician’s recommendation based on substantial and informed experience
NOTE: Suggested services are always optional. When presenting suggested repairs to the customer, you must present the facts, allowing the customer to draw their own conclusions and make an informed decision about how to proceed.

ELECTRICAL SYSTEMS

SERVICE PROCEDURES REQUIRED AND SUGGESTED FOR PROPER

VEHICLE OPERATION
NOTE: When working on electrical systems, if a potentially hazardous condition is observed, require repair or replacement of affected components prior to performing further work.

ACTUATOR MOTORS (SOLENOIDS) (ELECTRIC)

ACTUATOR MOTOR (SOLENOIDS) (ELECTRIC) INSPECTION
Attaching hardware
Attaching hardware not

Connector melted ……..

A

……….. (1) Require repair or

replacement.

Connector missing …….

C

………… Require replacement.

Inoperative ………….

A

…….. (2) Require replacement.

Linkage bent, affecting

performance …………

A

… Require repair or replacement

of linkage.

Linkage bent, not
affecting performance .. 2 … Suggest repair or replacement of linkage.
Linkage binding, affecting
performance ………… A … Require repair or replacement of linkage.
Linkage binding, not
affecting performance .. 1 … Suggest repair or replacement of linkage.
Linkage broken ………. A … Require repair or replacement of linkage.
Linkage loose, affecting
performance ………… A … Require repair or replacement of linkage.
Linkage loose, not
affecting performance .. 1 … Suggest repair or replacement of linkage.
Linkage missing ……… C ………… Require replacement.

Linkage noisy ………..

2

.. Suggest repair or replacement.

Missing ……………..

C

………… Require replacement.

Terminal broken ………

A

.. Require

repair or replacement.

Terminal burned, affecting

performance …………

A

………..

(1) Require repair or

replacement.

Terminal burned, not
affecting performance .. 1 ……….. (1) Suggest repair or replacement.
Terminal corroded,
affecting performance .. A .. Require repair or replacement. Terminal corroded, not
affecting performance .. 1 .. Suggest repair or replacement. Terminal loose, affecting
performance ………… B .. Require repair or replacement. Terminal loose, not

affecting performance ..

1

.. Suggest repair or

replacement.

Missing ……………..

C

………… Require

replacement.

Noisy ……………….

2

.. Suggest repair or

replacement.

Out of adjustment …….

B

.. Require repair or

replacement.

(1) – Determine cause and correct prior to repair or replacement of part.
(2) – Inoperative includes intermittent operation or out of OEM
specification.

ACTUATOR MOTORS (VACUUM)

ACTUATOR MOTOR (VACUUM) INSPECTION
Condition Code Procedure
Attaching hardware
broken …………….. A … Require repair or replacement of hardware.
Attaching hardware
missing ……………. C ………. Require replacement of
Attaching hardware not
hardware.
functioning ………… A … Require repair or replacement of hardware.
Connector broken …….. A .. Require repair or replacement. Connector (Weatherpack
type) leaking ………. A .. Require repair or replacement. Connector melted …….. A ……….. (1) Require repair or replacement.
Connector missing ……. C ………… Require replacement. Inoperative …………. A …….. (2) Require replacement. Leaking (vacuum) …….. A .. Require repair or replacement. Linkage bent,
affecting performance .. A … Require repair or replacement of linkage.
Linkage bent, not
affecting performance .. 2 … Suggest repair or replacement of linkage.
Linkage binding,
affecting performance .. A … Require repair or replacement of linkage.
Linkage binding, not
affecting performance .. 1 .. Suggest repair or replacement of linkage.
Linkage broken ………. A … Require repair or replacement of linkage.
Linkage loose, affecting
performance ………… A … Require repair or replacement of linkage.
Linkage loose, not
affecting performance .. 1 … Suggest repair or replacement of linkage.
Linkage missing ……… C ………… Require replacement.

Linkage noisy ………..

2

.. Suggest repair or replacement.

Missing ……………..

C

………… Require replacement.

Noisy ……………….

2

.. Suggest repair or replacement.

Out of adjustment …….

A

.. Require repair or replacement.

(1) – Determine cause and correct prior to repair or replacement of part.
(2) – Inoperative includes intermittent operation or out of
OEM specification.

AIR BAGS

For all air bag components and conditions, refer to vehicle manufacturer’s specifications for diagnosis and parts replacement.

ALTERNATORS AND GENERATORS

NOTE: If components have been added that increase vehicle electrical load requirement (for example, sound systems, air conditioning, alarm systems, etc.), charging system output must meet the increased demand.
ALTERNATOR AND GENERATOR INSPECTION
Condition Code Procedure
Alternator output meets OEM specification but is insufficient for add-on
electrical load …….. 2 … Suggest upgrade of alternator or removal of excess electrical load.
Alternator’s rated output is below OEM
specification ………. B ………… Require replacement. Attaching hardware
broken …………….. A … Require repair or replacement of hardware.
Attaching hardware
missing ……………. C ………. Require replacement of hardware.
Attaching hardware non-
functioning ………… A … Require repair or replacement of hardware.
Connector broken …….. A .. Require repair or replacement. Connector (Weatherpack
type) leaking ………. A .. Require repair or replacement. Connector melted …….. A ……….. (1) Require repair or replacement.
Connector missing ……. C ………… Require replacement. Diode inoperative ……. A ……….. (2) Require repair or replacement.
Housing broken, affecting
performance ………… A .. Require repair or replacement. Housing broken, not
affecting performance .. .. …….. No service suggested or required.
Housing cracked, affecting
performance ………… A .. Require repair or replacement. Housing cracked, not
Terminal burned, not
affecting performance .. 2 .. Suggest repair or replacement. Terminal corroded,
affecting performance .. A .. Require repair or replacement. Terminal corroded, not
affecting performance .. 2 .. Suggest repair or replacement. Terminal loose, affecting
performance ………… B .. Require repair or replacement. Terminal loose, not
affecting performance .. 1 .. Suggest repair or replacement. Terminal resistance
(voltage drop) out of
specification ………. A .. Require repair or replacement. Threads damaged ……… A .. Require repair or replacement. Threads stripped (threads
missing) …………… A ………… Require replacement. Voltage drop out of
specification ………. A .. Require repair or replacement.
(1) – Determine cause and correct prior to repair or replacement of part.
(2) – Inoperative includes intermittent operation or out of OEM
specification.

AMPLIFIERS

See
RECEIVERS, AMPLIFIERS, EQUALIZERS AND SUB-WOOFER VOLUME CONTROLS .

ANTENNAS

ANTENNA INSPECTION
Condition
Code Procedure
Attaching hardware
broken …………….. A … Require repair or replacement of hardware.
Attaching hardware
missing ……………. C ………. Require replacement of hardware.
Attaching hardware not
functioning ………… A … Require repair or replacement of hardware.
Broken ……………… A ………… Require replacement. Bent ……………….. 2 .. Suggest repair or replacement. Binding …………….. 2 .. Suggest repair or replacement. Connector broken …….. A .. Require repair or replacement. Connector melted …….. A ……….. (1) Require repair or replacement.
Connector missing ……. C ………… Require replacement. Inoperative …………. A …….. (2) Require replacement. Insulation damaged,
conductors exposed ….. A .. Require repair or replacement. Insulation damaged,
conductors not exposed . 1 ………… Suggest replacement. Missing …………….. C ………… Require replacement. Motor runs continuously . A ……… Require or replacement. Power antenna noisy ….. 2 .. Suggest repair or replacement. Sticking ……………. 2 .. Suggest repair or replacement. Terminal broken ……… A .. Require repair or replacement. Terminal burned, affecting
performance ………… A ……….. (1) Require repair or replacement.
Terminal burned, not
affecting performance .. 2 .. Suggest repair or replacement. Terminal corroded,
affecting performance .. A .. Require repair or replacement. Terminal corroded, not
affecting performance .. 2 .. Suggest repair or replacement. Terminal loose, affecting
performance ………… B .. Require repair or replacement. Terminal loose, not
affecting performance .. 1 .. Suggest repair or replacement.
(1) – Determine cause and correct prior to repair or replacement of part.
(2) – Inoperative includes intermittent operation or out of specification.

BATTERIES

Proper operation of any electrical system or component can be affected by battery condition. The battery(ies) must meet or exceed
minimum specification for vehicle as equipped and test to that specific battery’s CCA.
Definition of Terms
* Battery Performance Testing
Testing that determines whether or not a battery meets both vehicle OEM and battery manufacturer’s specifications.
* Cold Cranking Amp (CCA) Rating
The number of amperes a new, fully charged battery at
0 F (-17.8 C) can deliver for 30 seconds and maintain at least a voltage of 1.2 volts per cell (7.2 volts for a
12-volt battery).
* Cranking Amps (CA)
The number of amperes a new, fully charged battery, typically at 32 F (0 C) can deliver for 30 seconds and maintain at least a voltage of 1.2 volts per cell (7.2 volts for a
12-volt battery).
* OEM Cranking Amps
The minimum CCA required by the original vehicle manufacturer for a specific vehicle.
BATTERY INSPECTION
Condition Code Procedure
Battery frozen ………. .. ……… (1) Further inspection required.
Case leaking ………… A ………… Require replacement. Casing swollen ………. A ………. (2) Further inspection required.
Circuit open internally . A ………… Require replacement. Electrolyte
contamination ………. A ……….. (2) Further inspection required.
Electrolyte
discoloration ………. A ………. (2) Further inspection required.
Fails to accept and hold
charge …………….. A …….. (3) Require replacement. Fluid level low ……… B ………. (4) Further inspection required.
Out of performance specification for
battery ……………. B …….. (5) Require replacement. Out of specification for
application ………… B …….. (5) Require replacement. Post (top or side) burned,
affecting performance .. A ……….. (6) Require repair or replacement.
Post (top or side) burned, not affecting
performance ………… 2 ……….. (6) Suggest repair or replacement.
Post (top or side)
corroded, affecting
performance ………… A …………….. Require repair. Post (top or side)
corroded, not affecting
performance ………… 2 …………….. Suggest repair.
Post (top or side)
loose ……………… A ………… Require replacement. Post (top or side) melted,
affecting performance .. A ……….. (6) Require repair or replacement.
Post (top or side) melted, not affecting
performance ………… 2 ……….. (6) Suggest repair or replacement.
Specific gravity low …. B ………. (7) Further inspection required.
State of charge low ….. A ………. (7) Further inspection required.
Top dirty …………… 2 ……. Suggest cleaning battery. Top wet …………….. A … (8) Require cleaning battery.
Further inspection required. Vent cap loose ………. A … Require repair or replacement of vent cap.
Vent cap missing …….. C ………. Require replacement of vent cap.
(1) – DO NOT attempt to charge a frozen battery. Allow battery to warm thoroughly and then performance-test. If battery fails performance test, require replacement.
(2) – No service suggested or required unless the battery fails performance test, in which case, require replacement.
(3) – This phrase refers to a battery that fails to either accept and/or retain a charge using appropriate times listed in the Battery Charging Guide of the BCI Service Manual, battery charger operating manual, or battery manufacturer’s specifications.
(4) – Determine cause of low fluid level. Refill to proper level(s) with water (distilled water preferred). Recharge battery and performance-test. If battery does not meet specifications, require replacement. If battery is sealed type (non-removable filler caps), require replacement.
(5) – The battery may meet battery manufacturer’s specifications but test below the minimum specification defined by the vehicle’s OEM for that vehicle.
(6) – Determine cause and correct prior to repair or replacement of part.
(7) – Recharge and test to manufacturer’s specifications. If battery fails performance test, require replacement.
(8) – Check fluid level and adjust to manufacturer’s specification. Suggest checking charging system for proper operation.

BATTERY CABLES

See BATTERY CABLES, WIRES AND CONNECTORS.

BATTERY CABLES, WIRES AND CONNECTORS

BATTERY CABLE, WIRE AND CONNECTOR INSPECTION
Condition Code Procedure
Application incorrect … B .. Require repair or replacement. Attaching hardware
broken …………….. A … Require repair or replacement of hardware.
Attaching hardware
missing ……………. C ………. Require replacement of hardware.
Attaching hardware not
functioning ………… A … Require repair or replacement of hardware.
Connector broken …….. A .. Require repair or replacement. Connector melted …….. A ……….. (1) Require repair or replacement.
Connector missing ……. C ………… Require replacement. Insulation damaged,
conductors exposed ….. A ……….. (2) Require repair or replacement.
Insulation damaged,
conductors not exposed . 1 ………… Suggest replacement. Open ……………….. A .. Require repair or replacement. Protective shield
(conduit) melted ……. 2 ……….. (1) Suggest repair or replacement.
Protective shield
(conduit) missing …… 2 .. Suggest repair or replacement. Resistance (voltage drop)
Terminal burned, not
affecting performance .. 2 .. Suggest repair or replacement. Terminal corroded,
affecting performance .. A .. Require repair or replacement. Terminal corroded, not
affecting performance .. 2 .. Suggest repair or replacement. Terminal loose, affecting
performance ………… B .. Require repair or replacement. Terminal loose, not
affecting performance .. 1 .. Suggest repair or replacement. Voltage drop out of
specification ………. A .. Require repair or replacement.
(1) – Determine cause and correct prior to repair or replacement of part.
(2) – Exposed conductor at replacement (aftermarket) terminal end does not require repair or replacement.

BATTERY HOLD DOWN HARDWARE

See BATTERY TRAYS AND HOLD DOWN HARDWARE.

BATTERY TRAYS AND HOLD DOWN HARDWARE

BATTERY TRAY AND HOLD DOWN HARDWARE INSPECTION
Condition Code Procedure
Battery improperly
secured ……………. 2 …………….. Suggest repair. Bent, affecting
performance ………… A .. Require repair or replacement. Bent, not affecting
performance ………… .. …….. No service suggested or required.
Broken, affecting
performance ………… A .. Require repair or replacement. Broken, not affecting
performance ………… .. …….. No service suggested or required.
Corroded, affecting
performance ………… A .. Require repair or replacement. Corroded, not affecting
performance ………… 2 .. Suggest repair or replacement. Cracked, affecting
performance ………… A .. Require repair or replacement. Cracked, not affecting
performance ………… 1 .. Suggest repair or replacement. Missing …………….. C ………… Require replacement. Threads damaged ……… A .. Require repair or replacement. Threads stripped (threads
missing) …………… A ………… Require replacement. Water drain clogged ….. A …………….. Require repair.

BATTERY WIRES

See BATTERY CABLES, WIRES AND CONNECTORS.

BELTS

BELT INSPECTION
Condition Code Procedure
Alignment incorrect ….. B ………. (1) Further inspection required.

Cracked ……………..

1

………… Suggest replacement.

Frayed ………………

1

………… Suggest replacement.

Missing ……………..

C

………… Require replacement.

Noisy ……………….

2

………. (2) Further inspection

required.

Plies separated ………

A

………… Require replacement.

Tension out of

specification ……….

B

……….. Require adjustment or

replacement.

Worn beyond adjustment

range ………………

B

…………

Require replacement.

Worn so it contacts bottom

of pulley …………..

A

…………

Require replacement.

(1) – Determine cause of incorrect alignment and require repair. (2) – Determine cause of noise and suggest repair.

BULB SOCKETS

BULB SOCKET INSPECTION
Condition Code Procedure
Attaching hardware
broken …………….. A … Require repair or replacement of hardware.
Attaching hardware
missing ……………. C ………. Require replacement of
Attaching hardware not
hardware.
functioning ………… A … Require repair or replacement of hardware.
Bulb seized in socket … A .. Require repair or replacement. Burned, affecting
performance ………… A ……….. (1) Require repair or replacement.
Burned, not affecting
performance ………… 2 ……….. (1) Suggest repair or replacement.
Broken ……………… A .. Require repair or replacement. Connector broken …….. A .. Require repair or replacement. Connector missing ……. C ………… Require replacement. Connector (Weatherpack
type) leaking ………. A .. Require repair or replacement. Connector melted …….. A ……….. (1) Require repair or replacement.
Corroded, affecting
performance ………… A .. Require repair or replacement. Corroded, not affecting
performance ………… 2 .. Suggest repair or replacement. Leaking …………….. A .. Require repair or replacement. Melted ……………… A …….. (2) Require replacement. Shorted …………….. A .. Require repair or replacement. Terminal broken ……… A .. Require repair or replacement. Terminal burned, affecting
performance ………… A ……….. (2) Require repair or replacement.
Terminal burned, not
affecting performance .. 2 .. Suggest repair or replacement. Terminal corroded,
affecting performance .. A .. Require repair or replacement. Terminal corroded, not
affecting performance .. 2 .. Suggest repair or replacement. Terminal loose, affecting
performance ………… B .. Require repair or replacement. Terminal loose, not
affecting performance .. 1 .. Suggest repair or replacement.
(1) – Determine cause and correct prior to repair or replacement of socket.
(2) – Determine cause and correct prior to replacement of part.

BULBS, SEALED BEAMS AND LEDS

NOTE: Does not include soldered-in components. BULB, SEALED BEAM AND LED INSPECTION
Condition Code Procedure
Adjustment out of
specification ………. B .. Require repair or replacement. Application incorrect … B …….. (1) Require replacement. Attaching hardware
broken …………….. A … Require repair or replacement of hardware.
Attaching hardware
missing ……………. C ………. Require replacement of hardware.
Attaching hardware not
functioning ………… A … Require repair or replacement of hardware.
Base burned, affecting
performance ………… A ……….. (2) Require repair or replacement.
Base burned, not affecting
performance ………… 2 ……….. (2) Suggest repair or replacement.
Base corroded, affecting
performance ………… A .. Require repair or replacement. Base corroded, not
affecting performance .. 2 .. Suggest repair or replacement. Base leaking ………… A .. Require repair or replacement. Base loose, affecting
performance ………… B .. Require repair or replacement. Base loose, not affecting
performance ………… 1 .. Suggest repair or replacement. Base melted …………. A …….. (2) Require replacement. Bracket bent, affecting
performance ………… A .. Require repair or replacement. Bracket bent, not
affecting performance .. .. …….. No service suggested or required.
Bracket broken, affecting
performance ………… A ………… Require replacement. Bracket broken, not
affecting performance .. .. …….. No service suggested or required.
Bracket corroded,
affecting performance .. A .. Require repair or replacement. Bracket corroded, not
affecting performance .. 2 .. Suggest repair or replacement. Bracket cracked, affecting
performance ………… A .. Require repair or replacement. Bracket cracked, not
affecting performance .. 1 .. Suggest repair or replacement. Bracket loose, affecting
performance ………… A .. Require repair or replacement. Bracket loose, not

affecting performance ..

1

.. Suggest repair or

replacement.

Bracket missing ………

C

………… Require

replacement.

Burned out …………..

A

………… Require

replacement.

Connector broken ……..

A

.. Require repair or

replacement.

Connector (Weatherpack

type) leaking ……….

A

.. Require repair or

replacement.

Connector melted ……..

A

……….. (2) Require repair or

replacement.

Connector missing …….

C

………… Require replacement.

Corroded, affecting

performance …………

A

.. Require repair or replacement.

Corroded, not affecting

performance …………

2

.. Suggest repair or replacement.

Cracked ……………..

A

………… Require replacement.

Intermittent …………

A

………… Require replacement.

Lamp base melted ……..

A

…….. (2) Require replacement.

Leaking ……………..

A

.. Require repair or replacement.

Missing ……………..

C

………… Require replacement.

Seized in socket ……..

A

.. Require repair or replacement.

Terminal broken ………

A

.. Require repair or replacement.

Terminal burned, affecting

performance …………

A

……….. (2) Require repair or

replacement.

Terminal burned, not

affecting performance .. 2 ……….. (2) Suggest repair or replacement.
Terminal corroded,
affecting performance .. A .. Require repair or replacement. Terminal corroded, not
affecting performance .. 2 .. Suggest repair or replacement. Terminal loose, affecting
performance ………… B .. Require repair or replacement. Terminal loose, not
affecting performance .. 1 .. Suggest repair or replacement. Threads damaged ……… A .. Require repair or replacement. Threads stripped (threads
missing) …………… A ………… Require replacement.
(1) – Application incorrect includes wrong bulb coating or color.
(2) – Determine cause and correct prior to repair or replacement of part.

CD PLAYERS

See TAPE PLAYERS AND CD PLAYERS.

CIGARETTE LIGHTER ASSEMBLIES

CIGARETTE LIGHTER ASSEMBLY INSPECTION
Condition Code Procedure
Attaching hardware
broken …………….. A … Require repair or replacement of hardware.
Attaching hardware
missing ……………. C ………. Require replacement of hardware.
Attaching hardware not
functioning ………… A … Require repair or replacement of hardware.
Inoperative …………. A ……….. (1) Require repair or replacement.
Loose ………………. A .. Require repair or replacement. Missing …………….. 2 ………… Suggest replacement. Sticking ……………. A .. Require repair or replacement. Terminal broken ……… A .. Require repair or replacement. Terminal burned, affecting
performance ………… A ……….. (2) Require repair or replacement.
Terminal burned, not
affecting performance .. 2 .. Suggest repair or replacement. Terminal corroded,
affecting performance .. A .. Require repair or replacement. Terminal corroded, not
affecting performance .. 2 .. Suggest repair or replacement. Terminal loose, affecting
performance ………… B .. Require repair or replacement. Terminal loose, not
affecting performance .. 1 .. Suggest repair or replacement.
(1) – Inoperative includes intermittent operation or out of OEM
specification.
(2) – Determine cause and correct prior to repair or replacement of part.

CIRCUIT BREAKERS

See FUSES, FUSIBLE LINKS AND CIRCUIT BREAKERS.

CLUTCH SWITCHES

See SWITCHES.

CONNECTORS

See WIRING HARNESSES AND CONNECTORS.

CONTROL MODULES

CONTROL MODULE INSPECTION
Condition
Code Procedure
Application incorrect … B ………… Require replacement. Attaching hardware
missing ……………. C ………. Require replacement of hardware.
Attaching hardware
threads damaged …….. A … Require repair or replacement of hardware.
Attaching hardware threads stripped
(threads missing) …… A … Require repair or replacement of hardware.
Code set
(if applicable) …….. A ………. (1) Further inspection required.
Connector broken …….. A .. Require repair or replacement. Connector melted …….. A ……….. (2) Require repair or replacement.
Connector missing ……. A …………….. Require repair. Contaminated ………… A ……….. (3) Require repair or replacement.
Inoperative …………. B ……….. (4) Require repair or replacement. Further inspection required.
Terminal burned, not
affecting performance .. 2 .. Suggest repair or replacement. Terminal corroded,
affecting performance .. A .. Require repair or replacement. Terminal corroded, not
affecting performance .. 2 .. Suggest repair or replacement. Terminal loose, affecting
performance ………… B .. Require repair or replacement. Terminal loose, not
affecting performance .. 1 .. Suggest repair or replacement. Threads damaged ……… A .. Require repair or replacement. Threads stripped (threads
missing) …………… A ………… Require replacement.
Wire lead conductors
exposed ……………. B .. Require repair or replacement. Wire lead corroded …… A .. Require repair or replacement. Wire lead open ………. A .. Require repair or replacement. Wire lead shorted ……. A .. Require repair or replacement.
(1) – Refer to manufacturer’s diagnostic trouble code procedure and require repair or replacement of affected component(s).
(2) – Determine cause and correct prior to repair or replacement of part.
(3) – Determine source of contamination, such as engine coolant, fuel, metal particles, or water. Require repair or replacement.
(4) – Inoperative includes intermittent operation or out of OEM specification. Some components may be serviceable; check for accepted cleaning procedure.

CRUISE CONTROL BRAKE SWITCHES

See SWITCHES.

CRUISE CONTROL CABLES

See CRUISE CONTROL LINKAGES AND CABLES.

CRUISE CONTROL CLUTCH SWITCHES

See SWITCHES.

CRUISE CONTROL LINKAGES AND CABLES

CRUISE CONTROL LINKAGE AND CABLE INSPECTION
Condition Code Procedure
Attaching hardware
broken …………….. A … Require repair or replacement of hardware.
Attaching hardware
missing ……………. C ………. Require replacement of hardware.
Attaching hardware not
functioning ………… A … Require repair or replacement of hardware.
Bent ……………….. A .. Require repair or replacement. Binding …………….. A .. Require repair or replacement. Bracket bent, affecting
performance ………… A .. Require repair or replacement. Bracket bent, not
affecting performance .. .. …….. No service suggested or required.
Bracket broken, affecting
performance ………… A ………… Require replacement. Bracket broken, not
affecting performance .. .. …….. No service suggested or required.
Bracket corroded,
affecting performance .. A .. Require repair or replacement. Bracket corroded, not
affecting performance .. 2 .. Suggest repair or replacement.
Bracket cracked, affecting
performance ………… A .. Require repair or replacement. Bracket cracked, not
affecting performance .. 1 .. Suggest repair or replacement. Bracket loose, affecting
performance ………… A .. Require repair or replacement. Bracket loose, not

affecting performance ..

1

.. Suggest repair or replacement.

Bracket missing ………

C

………… Require replacement.

Broken ………………

A

………… Require replacement.

Cracked ……………..

A

.. Require repair or replacement.

Disconnected …………

A

.. Require repair or replacement.

Kinked ………………

A

.. Require repair or replacement.

Melted ………………

A

……….. (1) Require repair or

replacement.

Missing ……………..

C

………… Require replacement.

Noisy ……………….

2

.. Suggest repair or replacement.

Out of adjustment …….

B

……….. (2) Require repair or

replacement.

Routed incorrectly ……

2

…………….. Suggest repair.

Seized ………………

A

.. Require repair or replacement.

(1) – Determine cause and correct prior to repair or replacement of part.
(2) – Follow OEM recommended adjustment procedures. Require repair or replacement if out of specification.

CRUISE CONTROL RESERVOIRS

See CRUISE CONTROL VACUUM HOSES, TUBES AND RESERVOIRS.

CRUISE CONTROL TUBES

See CRUISE CONTROL VACUUM HOSES, TUBES AND RESERVOIRS.

CRUISE CONTROL VACUUM DUMP RELEASE VALVES

CRUISE CONTROL VACUUM DUMP RELEASE VALVE INSPECTION
Condition Code Procedure
Attaching hardware
broken …………….. A … Require repair or replacement of hardware.
Attaching hardware
missing ……………. C ………. Require replacement of hardware.
Attaching hardware not

functioning …………

A

… Require repair or replacement

of hardware.

Broken ………………

A

.. Require repair or replacement.

Inoperative ………….

A

…….. (1) Require replacement.

Leaking ……………..

2

………… Suggest replacement.

Out of adjustment …….

B

………. (2) Further inspection

required.

(1) – Inoperative includes intermittent operation or out of OEM
specification.
(2) – Follow OEM recommended adjustment procedures. Require repair or replacement if out of specification.

CRUISE CONTROL VACUUM HOSES, TUBES AND RESERVOIRS CRUISE CONTROL VACUUM HOSE, TUBE AND RESERVOIR INSPECTION Condition Code Procedure

Leaking …………….. A .. Require repair or replacement. Melted ……………… A ………… Require replacement. Missing …………….. C ………… Require replacement. Oil-soaked (spongy) ….. 1 ………… Suggest replacement. Restricted ………….. A .. Require repair or replacement. Surface cracks (dry-
rotted) ……………. 1 ………… Suggest replacement.

CRUISE CONTROL VEHICLE SPEED SENSORS

CRUISE CONTROL VEHICLE SPEED SENSOR INSPECTION
Condition Code Procedure
Air gap incorrect ……. B ……. (1) Require adjustment to vehicle manufacturer’s specifications.
Attaching hardware
broken …………….. A … Require repair or replacement of hardware.
Attaching hardware
missing ……………. C ………. Require replacement of hardware.
Attaching hardware not

functioning …………

A

… Require repair or replacement

of hardware.

Broken ………………

A

………… Require replacement.

Housing cracked ………

A

………… Require replacement.

Internal resistance

does not meet

specifications ………

B

…….. (2) Require replacement.

Lead routing incorrect ..

B

.. Require rerouting according to

vehicle manufacturer’s

specifications.

Loose ……………….

B

……. (3) Require adjustment to

vehicle manufacturer’s

specifications.

Missing ……………..

C

………… Require replacement.

Output signal incorrect .

B

……….. (2) Require repair or

replacement.

Surface contaminated ….

2

.. Suggest cleaning; identify and

correct source.

Tip bent …………….

B

………… Require replacement.

Tip broken …………..

B

………… Require replacement.

Tip missing ………….

B

………… Require replacement.

Wire lead burned ……..

A

………… Require replacement.

Wire lead conductors

exposed …………….

B

………… Require replacement.

Wire lead corroded ……

A

………… Require replacement.

Wire lead open ……….

A

………… Require replacement.

Wire lead shorted …….

A

………… Require replacement.

(1) – If a sensor is not adjustable, further inspection is required to identify and correct cause.
(2) – Component failure may be caused by water intrusion into the wiring harness. Always check insulation for damage
and wiring for excessive resistance.
(3) – Some integral bearing assemblies with sensors may require replacement.

DEFOGGERS

See
HEATING ELEMENTS (DEFROSTERS, DEFOGGERS, ELECTRIC HEATERS AND SEATS) .

DEFROSTERS

See
HEATING ELEMENTS (DEFROSTERS, DEFOGGERS, ELECTRIC HEATERS AND SEATS) .

DELAYS

DELAY INSPECTION
Condition Code Procedure
Attaching hardware
broken …………….. A … Require repair or replacement of hardware.
Attaching hardware
missing ……………. C ………. Require replacement of hardware.
Attaching hardware not
functioning ………… A … Require repair or replacement of hardware.
Binding, affecting
performance ………… A .. Require repair or replacement. Binding, not affecting
performance ………… 2 .. Suggest repair or replacement. Broken ……………… A .. Require repair or replacement. Burned, affecting
performance ………… A ……….. (1) Require repair or replacement.
Burned, not affecting
performance ………… 2 ……….. (1) Suggest repair or replacement.
Cracked, affecting
performance ………… A .. Require repair or replacement. Cracked, not affecting
performance ………… 1 .. Suggest repair or replacement. Inoperative …………. A ……….. (2) Require repair or replacement.
Melted, affecting
performance ………… A ……….. (1) Require repair or replacement.
Melted, not affecting
performance ………… 2 ……….. (1) Suggest repair or replacement.
Missing …………….. C ………… Require replacement. Terminal broken ……… A .. Require repair or replacement. Terminal burned, affecting
performance ………… A ……….. (1) Require repair or replacement.
Terminal burned, not
affecting performance .. 2 .. Suggest repair or replacement. Terminal corroded,
affecting performance .. A .. Require repair or replacement. Terminal corroded, not
affecting performance .. 2 .. Suggest repair or replacement. Terminal loose, affecting
performance ………… B .. Require repair or replacement. Terminal loose, not
affecting performance .. 1 .. Suggest repair or replacement.
(1) – Determine cause and correct prior to repair or replacement of part.
(2) – Inoperative includes intermittent operation or out of OEM
specification.

DIMMERS

DIMMER INSPECTION
Condition Code Procedure
Attaching hardware
broken …………….. A … Require repair or replacement of hardware.
Attaching hardware
missing ……………. C ………. Require replacement of hardware.
Attaching hardware not
functioning ………… A … Require repair or replacement of hardware.
Binding, affecting
performance ………… A .. Require repair or replacement. Binding, not affecting
performance ………… 2 .. Suggest repair or replacement. Broken ……………… A .. Require repair or replacement. Burned, affecting
performance ………… A ……….. (1) Require repair or replacement.
Burned, not affecting
performance ………… 2 ……….. (1) Suggest repair or replacement.
Cracked, affecting
performance ………… A .. Require repair or replacement. Cracked, not affecting
performance ………… 1 .. Suggest repair or replacement. Inoperative …………. A ……….. (2) Require repair or replacement.
Melted, affecting
performance ………… A ……….. (1) Require repair or replacement.
Melted, not affecting
performance ………… 2 ……….. (1) Suggest repair or replacement.
Missing …………….. C ………… Require replacement. Terminal broken ……… A .. Require repair or replacement. Terminal burned, affecting
performance ………… A ……….. (1) Require repair or replacement.
Terminal burned, not
affecting performance .. 2 .. Suggest repair or replacement. Terminal corroded,
affecting performance .. A .. Require repair or replacement. Terminal corroded, not
affecting performance .. 2 .. Suggest repair or replacement. Terminal loose, affecting
performance ………… B .. Require repair or replacement.
Terminal loose, not
affecting performance .. 1 .. Suggest repair or replacement.
(1) – Determine cause and correct prior to repair or replacement of part.
(2) – Inoperative includes intermittent operation or out of OEM
specification.

ELECTRIC HEATERS

See
HEATING ELEMENTS (DEFROSTERS, DEFOGGERS, ELECTRIC HEATERS AND SEATS) .

EQUALIZERS

See
RECEIVERS, AMPLIFIERS, EQUALIZERS AND SUB-WOOFER VOLUME CONTROLS .

FUSE BLOCKS

See FUSE BOXES AND BLOCKS.

FUSE BOXES AND BLOCKS

FUSE BOX AND BLOCK INSPECTION
Attaching hardware
Attaching hardware not
Broken, affecting
performance ………… A ………… Require replacement. Broken, not affecting
performance ………… .. …….. No service suggested or required.
Burned, affecting
performance ………… A ……….. (1) Require repair or replacement.
Burned, not affecting

performance …………

2

………..

(1) Suggest repair or

replacement.

Connector broken ……..

A

.. Require

repair or replacement.

Connector (Weatherpack

type) leaking ……….

A

.. Require repair or replacement.

Connector melted ……..

A

……….. (1) Require repair or

replacement.

Connector missing …….

C

………… Require replacement.

Cover missing ………..

C

… Require replacement of cover.

Cracked, affecting

performance …………

A

.. Require repair or replacement.

Cracked, not affecting

performance ………… 1 .. Suggest repair or replacement. Melted, affecting
performance ………… A …….. (1) Require replacement.
Melted, not affecting
performance ………… 2 …….. (1) Suggest replacement. Terminal broken ……… A .. Require repair or replacement. Terminal burned, affecting
performance ………… A ……….. (1) Require repair or replacement.
Terminal burned, not
affecting performance .. 2 .. Suggest repair or replacement. Terminal corroded,
affecting performance .. A .. Require repair or replacement. Terminal corroded, not
affecting performance .. 2 .. Suggest repair or replacement. Terminal loose, affecting
performance ………… B .. Require repair or replacement. Terminal loose, not
affecting performance .. 1 .. Suggest repair or replacement.
(1) – Determine cause and correct prior to repair or replacement of part.

FUSES, FUSIBLE LINKS AND CIRCUIT BREAKERS

FUSE, FUSIBLE LINK AND CIRCUIT BREAKER INSPECTION
Condition Code Procedure
Application incorrect … B ………… Require replacement. Blown ………………. A …….. (1) Require replacement. Corroded, affecting
performance ………… A .. Require repair or replacement. Corroded, not affecting
performance ………… 2 .. Suggest repair or replacement. Cracked, affecting
performance ………… A .. Require repair or replacement. Cracked, not affecting
performance ………… 1 .. Suggest repair or replacement. Inoperative …………. A …….. (2) Require replacement. Insulation damaged,
conductors exposed ….. A .. Require repair or replacement. Insulation damaged,
conductors not exposed . 1 ………… Suggest replacement. Missing …………….. C ………… Require replacement. Routed incorrectly …… B …………….. Require repair. Secured incorrectly ….. B …………….. Require repair. Terminal broken ……… A .. Require repair or replacement. Terminal burned, affecting
performance ………… A ……….. (1) Require repair or replacement.
Terminal burned, not
affecting performance .. 2 .. Suggest repair or replacement. Terminal corroded,
affecting performance .. A .. Require repair or replacement. Terminal corroded, not
affecting performance .. 2 .. Suggest repair or replacement. Terminal loose, affecting
performance ………… B .. Require repair or replacement. Terminal loose, not
affecting performance .. 1 .. Suggest repair or replacement.
(1) – Determine cause and correct prior to repair or replacement of part.
(2) – Inoperative includes intermittent operation.

FUSIBLE LINKS

See FUSES, FUSIBLE LINKS AND CIRCUIT BREAKERS.

GAUGES

NOTE: Includes odometers, speedometers and tachometers (except cable-driven).
GAUGE INSPECTION
Attaching hardware
Attaching hardware not
replacement. Lens cloudy …………. 2 ……….. (2) Suggest repair or replacement.
Lens missing ………… C ……….. (2) Require repair or replacement.
Malfunctioning ………. A ……….. (3) Require repair or replacement.
Mechanical head noisy … 2 .. Suggest repair or replacement. Terminal broken ……… A .. Require repair or replacement. Terminal burned, affecting
performance ………… A ……….. (1) Require repair or replacement.
Terminal burned, not
affecting performance .. 2 .. Suggest repair or replacement. Terminal corroded,
affecting performance .. A .. Require repair or replacement. Terminal corroded, not
affecting performance .. 2 .. Suggest repair or replacement. Terminal loose, affecting
performance ………… B .. Require repair or replacement. Terminal loose, not
affecting performance .. 1 .. Suggest repair or replacement.
(1) – Determine cause and correct prior to repair or replacement of part.
(2) – If lens is available as a separate part, require replacement of lens only.
(3) – Includes inoperative, intermittent operation, failure to perform all functions, out of OEM specification,
or out of range.

GENERATORS

See ALTERNATORS AND GENERATORS.

GROUND CABLES AND STRAPS

GROUND CABLE AND STRAP INSPECTION
Attaching hardware
Attaching hardware not
Corroded, affecting
performance ………… A .. Require repair or replacement. Corroded, not affecting
performance ………… 2 .. Suggest repair or replacement. Insulation damaged,
exposing conductors …. 2 ………… Suggest replacement. Loose ………………. A …………….. Require repair. Missing …………….. C ………… Require replacement. Open ……………….. A .. Require repair or replacement. Resistance high ……… A .. Require repair or replacement. Terminal resistance
(voltage drop) is out of
specification ………. B .. Require repair or replacement. Voltage drop out of
specification ………. B .. Require repair or replacement.

GROUND STRAPS

See GROUND CABLES AND STRAPS.

HEADLIGHT ADJUSTERS

HEADLIGHT ADJUSTER INSPECTION
Condition Code Procedure
Attaching hardware
broken …………….. A … Require repair or replacement of hardware.
Attaching hardware
missing ……………. C ………. Require replacement of hardware.
Attaching hardware not
functioning ………… A … Require repair or replacement of hardware.
Bent, preventing

adjustment ………….

A

.. Require repair or replacement.

Broken ………………

A

.. Require repair or replacement.

Indicator broken ……..

A

………… Require replacement.

Indicator missing …….

C

………… Require replacement.

Missing ……………..

C

………. Require replacement of

adjusters. Seized ……………… A .. Require repair or replacement. Threads damaged ……… A .. Require repair or replacement. Threads stripped (threads
missing) …………… A ………… Require replacement.

HEATING ELEMENTS (DEFROSTERS, DEFOGGERS, ELECTRIC HEATERS AND

SEATS)
HEATING ELEMENT (DEFROSTER, DEFOGGER, ELECTRIC HEATER AND SEAT) INSPECTION
Condition Code Procedure
Attaching hardware
broken …………….. A … Require repair or replacement of hardware.
Attaching hardware
missing ……………. C ………. Require replacement of hardware.
Attaching hardware not

functioning …………

A

Require repair or replacement

of hardware.

Connector broken ……..

A

..

Require repair or replacement.

Connector (Weatherpack

type) leaking ……….

A

..

Require repair or replacement.

Connector melted ……..

A

……….. (1) Require repair or

replacement.

Connector missing …….

C

………… Require replacement.

Inoperative …………. A ……….. (2) Require repair or replacement.
Terminal broken ……… A .. Require repair or replacement. Terminal burned, affecting
performance ………… A ……….. (1) Require repair or replacement.
Terminal burned, not
affecting performance .. 2 .. Suggest repair or replacement. Terminal corroded,

affecting performance

..

A

..

Require

repair

or

replacement.

Terminal corroded, not

affecting performance

..

2

..

Suggest

repair

or

replacement.

Terminal loose, affecting

performance …………

B

..

Require

repair

or

replacement.

Terminal loose, not

affecting performance ..

1

..

Suggest

repair

or

replacement.

Wire lead burned ……..

A

..

Require

repair

or

replacement.

Wire lead conductors

exposed …………….

B

..

Require

repair

or

replacement.

Wire lead open ……….

A

..

Require

repair

or

replacement.

Wire lead shorted …….

A

..

Require

repair

or

replacement.

(1) – Determine cause and correct prior to repair or replacement of part.
(2) – Inoperative includes intermittent operation or out of OEM
specification.

HORNS AND SIRENS

HORN AND SIREN INSPECTION
Condition Code Procedure
Attaching hardware
broken …………….. A … Require repair or replacement of hardware.
Attaching hardware
missing ……………. C ………. Require replacement of hardware.
Attaching hardware not
functioning ………… A … Require repair or replacement of hardware.
Terminal burned, not
affecting performance .. 2 .. Suggest repair or replacement. Terminal corroded,

affecting performance

..

A

..

Require

repair

or

replacement.

Terminal corroded, not

affecting performance

..

2

..

Suggest

repair

or

replacement.

Terminal loose, affecting

performance …………

B

..

Require

repair

or

replacement.

Terminal loose, not

affecting performance ..

1

..

Suggest

repair

or

replacement.

Wire lead burned ……..

A

..

Require

repair

or

replacement.

Wire lead conductors

exposed …………….

B

..

Require

repair

or

replacement.

Wire lead open ……….

A

..

Require

repair

or

replacement.

Wire lead shorted …….

A

..

Require

repair

or

replacement.

(1) – Determine cause and correct prior to repair or replacement of part.
(2) – Inoperative includes intermittent operation.

IGNITION SWITCHES

See SWITCHES.

INDICATOR LIGHTS

INDICATOR LIGHT INSPECTION Condition C

Does not come on during

ode Procedure

bulb check ………….

..

………

(1)

Further

inspection

required.

Fails to function properly

during test mode …….

..

………

(1)

Further

inspection

required.

On constantly ………..

..

………

(1)

Further

inspection

required.

On intermittently ……. .. ……… (1) Further inspection required.
(1) – See service manual for further information.

KEYLESS ENTRY KEYPADS AND TRANSMITTERS

KEYLESS ENTRY KEYPAD AND TRANSMITTER INSPECTION
Attaching hardware
Attaching hardware not
Terminal burned, not
affecting performance .. 2 .. Suggest repair or replacement. Terminal corroded,
affecting performance .. A .. Require repair or replacement. Terminal corroded, not
affecting performance .. 2 .. Suggest repair or replacement. Terminal loose, affecting
performance ………… B .. Require repair or replacement. Terminal loose, not
affecting performance .. 1 .. Suggest repair or replacement. Wire lead burned …….. A .. Require repair or replacement. Wire lead conductors
exposed ……………. B .. Require repair or replacement. Wire lead open ………. A .. Require repair or replacement. Wire lead shorted ……. A .. Require repair or replacement.
(1) – Determine cause and correct prior to repair or replacement of part.
(2) – Malfunctioning includes inoperative, intermittent operation, or failure to perform all functions.

KEYLESS ENTRY TRANSMITTERS

See KEYLESS ENTRY KEYPADS AND TRANSMITTERS.

LEDS

See BULBS, SEALED BEAMS AND LEDS.

LENSES

LENSE INSPECTION
Condition
Code Procedure
Adjustment out of
specification ………. B …………….. Require repair. Application incorrect … A ………… Require replacement. Attaching hardware
broken …………….. A … Require repair or replacement of hardware.
Attaching hardware
missing ……………. C ………. Require replacement of hardware.
Attaching hardware not
functioning ………… A … Require repair or replacement of hardware.
Broken, affecting
performance ………… A ………… Require replacement. Broken, not affecting
performance………….. .. …….. No service suggested or

required.

Cracked ……………..

A

…………

Require

replacement.

Discolored …………..

A

…………

Require

replacement.

Leaking ……………..

A

.. Require repair or

replacement.

Melted, affecting

performance …………

A

………… Require

replacement.

Melted, not affecting

performance …………

2

………… Suggest

replacement.

Missing ……………..

C

………… Require

replacement.

MICROPHONES

See SPEAKERS AND MICROPHONES.

MIRRORS (ELECTROCHROMATIC AND HEATED)

MIRROR (ELECTROCHROMATIC AND HEATED) INSPECTION
Attaching hardware
Attaching hardware not
Terminal burned, not
replacement.
affecting performance .. 2 .. Suggest repair or replacement. Terminal corroded,

affecting performance

..

A

..

Require

repair

or

replacement.

Terminal corroded, not

affecting performance

..

2

..

Suggest

repair

or

replacement.

Terminal loose, affecting

performance …………

B

..

Require

repair

or

replacement.

Terminal loose, not

affecting performance ..

1

..

Suggest

repair

or

replacement.

Wire lead burned ……..

A

..

Require

repair

or

replacement.

Wire lead conductors

exposed …………….

B

..

Require

repair

or

replacement.

Wire lead open ……….

A

..

Require

repair

or

replacement.

Wire lead shorted …….

A

..

Require

repair

or

replacement.

(1) – Determine cause and correct prior to repair or replacement of part.
(2) – Inoperative includes intermittent operation.

MOTORS

MOTOR INSPECTION
Condition Code Procedure
Amperage draw out of
specification ………. A .. Require repair or replacement. Attaching hardware
broken …………….. A … Require repair or replacement of hardware.
Attaching hardware
missing ……………. C ………. Require replacement of hardware.
Attaching hardware not
functioning ………… A … Require repair or replacement of hardware.
Bracket bent ………… A .. Require repair or replacement. Bracket broken ………. A .. Require repair or replacement. Bracket cracked ……… A .. Require repair or replacement. Bracket holes elongated,
affecting performance .. A .. Require repair or replacement. Bracket holes elongated,
not affecting
performance ………… .. ……. No service suggested or required.
Bracket missing ……… C ………… Require replacement. Connector broken …….. A .. Require repair or replacement. Connector (Weatherpack
type) leaking ………. A .. Require repair or replacement. Connector melted …….. A ……….. (1) Require repair or replacement.

Connector missing …….

C

…………

Require replacement.

Drive mechanism damaged,

affecting performance ..

A

………..

(2) Require repair or

replacement.

Drive mechanism damaged, not affecting

performance …………

Fails to disengage ……

2

A

……….. (2) Suggest repair or replacement.

.. Require repair or replacement.

Housing broken, affecting
performance ………… 2 .. Suggest repair or replacement. Housing broken, not
affecting performance .. .. ……. No service suggested or required.
Housing cracked, affecting
performance ………… A .. Require repair or replacement. Housing cracked, not
affecting performance .. 1 .. Suggest repair or replacement. Inoperative …………. A ……….. (3) Require repair or replacement.
Linkage bent, affecting
performance ………… A … Require repair or replacement of linkage.
Linkage bent, not
affecting performance .. .. …….. No service suggested or required.
Linkage binding, affecting
performance ………… A … Require repair or replacement of linkage.
Linkage binding, not
affecting performance .. 2 … Suggest repair or replacement of linkage.
Linkage broken ………. A … Require repair or replacement of linkage.
Linkage loose, affecting
performance ………… A … Require repair or replacement of linkage.
Linkage loose, not
affecting performance .. 1 … Suggest repair or replacement of linkage.
Linkage missing ……… C ………… Require replacement.

Linkage noisy ………..

2

.. Suggest repair or replacement.

Missing ……………..

C

………… Require replacement.

Noisy ……………….

2

.. Suggest

repair or replacement.

Out of adjustment …….

B

……….

(4) Further inspection

required.

Resistance out of

specification ……….

A

.. Require

repair or replacement.

Terminal broken ………

A

.. Require

repair or replacement.

Terminal burned, affecting

performance …………

A

………..

(1) Require repair or

replacement.

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

affecting performance

..

A

..

Require

repair

or

replacement.

Terminal corroded, not

affecting performance

..

2

..

Suggest

repair

or

replacement.

Terminal loose, affecting

performance …………

B

..

Require

repair

or

replacement.

Terminal loose, not

affecting performance ..

1

..

Suggest

repair

or

replacement.

Wire lead burned ……..

A

..

Require

repair

or

replacement.

Wire lead conductors

exposed …………….

B

..

Require

repair

or

replacement.

Wire lead open ……….

A

..

Require

repair

or

replacement.

Wire lead shorted …….

A

..

Require

repair

or

replacement.

(1) – Determine cause and correct prior to repair or replacement of part.
(2) – Further inspection required to determine cause. (3) – Inoperative includes intermittent operation.
(4) – Follow OEM recommended adjustment procedures. Repair or replace if out of specification.

NEUTRAL SAFETY SWITCHES

See SWITCHES.

ODOMETERS

See GAUGES.

ODOMETERS, SPEEDOMETERS AND TACHOMETERS (CABLE-DRIVEN) ODOMETER, SPEEDOMETER AND TACHOMETER (CABLE-DRIVEN) INSPECTION Condition Code Procedure

Attaching hardware
broken …………….. A … Require repair or replacement of hardware.
Attaching hardware
missing ……………. C ………. Require replacement of hardware.
Attaching hardware not
functioning ………… A … Require repair or replacement of hardware.
Connector broken …….. A .. Require repair or replacement. Connector (Weatherpack
type) leaking ………. A .. Require repair or replacement. Connector melted …….. A ……….. (1) Require repair or replacement.
Connector missing ……. C ………… Require replacement. Drive cable broken …… A ………… Require replacement. Drive cable noisy ……. 2 .. Suggest repair or replacement. Inoperative …………. A ………. (2) Further inspection required.
Leaking …………….. A ………… Require replacement. Lens broken …………. A ……….. (3) Require repair or replacement.
Lens cloudy …………. 2 ……….. (3) Suggest repair or replacement.
Lens missing ………… C ……….. (3) Require repair or replacement.
Noisy ………………. 2 .. Suggest repair or replacement. Terminal broken ……… A .. Require repair or replacement. Terminal burned, affecting
performance ………… A ……….. (1) Require repair or replacement.
Terminal burned, not
affecting performance .. 2 .. Suggest repair or replacement. Terminal corroded,
affecting performance .. A .. Require repair or replacement. Terminal corroded, not
affecting performance .. 2 .. Suggest repair or replacement. Terminal loose, affecting
performance ………… B .. Require repair or replacement. Terminal loose, not
affecting performance .. 1 .. Suggest repair or replacement.
(1) – Determine cause and correct prior to repair or replacement of part.
(2) – If lens is available as a separate part, require
replacement of lens only.
(3) – Includes inoperative, intermittent operation, failure to perform all functions, out of OEM specification,
or out of range.

PULLEYS

PULLEY INSPECTION
Condition Code Procedure
Alignment incorrect ….. B .. Require repair or replacement. Application incorrect … B ………… Require replacement. Attaching hardware
broken …………….. A … Require repair or replacement of hardware.
Attaching hardware
missing ……………. C ………. Require replacement of hardware.
Attaching hardware not

functioning …………

A

… Require repair or replacement

of hardware.

Bent ………………..

A

………… Require replacement.

Cracked ……………..

A

………… Require replacement.

Loose ……………….

A

.. Require repair or replacement.

Missing ……………..

C

………… Require replacement.

Pulley damaged, affecting

belt life …………..

A

………… Require replacement.

RECEIVERS, AMPLIFIERS, EQUALIZERS AND SUB-WOOFER VOLUME

CONTROLS
RECEIVER, AMPLIFIER, EQUALIZER AND SUB-WOOFER VOLUME CONTROL INSPECTION
Condition Code Procedure
Attaching hardware
broken …………….. A … Require repair or replacement of hardware.
Attaching hardware
missing ……………. C ………. Require replacement of hardware.
Attaching hardware not
functioning ………… A … Require repair or replacement of hardware.
Connector broken …….. A .. Require repair or replacement. Connector melted …….. A ……….. (1) Require repair or replacement.
Connector missing ……. C ………… Require replacement. Malfunctioning ………. A ……….. (2) Require repair or replacement.
Missing …………….. C ………… Require replacement. Sound quality poor …… A ……….. (3) Require repair or replacement.
Terminal broken ……… A .. Require repair or replacement. Terminal burned, affecting
performance ………… A ……….. (1) Require repair or replacement.
Terminal burned, not
affecting performance .. 2 .. Suggest repair or replacement.
Terminal corroded,
Terminal corroded, not
Terminal loose, affecting
(1) – Determine cause and correct prior to repair or replacement of part.
(2) – Malfunctioning includes inoperative, intermittent operation, or failure to perform all functions.
(3) – Make sure poor sound quality is not caused by ignition/charging system or other forms of electrical interference.

RELAY BOXES

RELAY BOX INSPECTION
Condition Code Procedure
Attaching hardware
broken …………….. A … Require repair or replacement of hardware.
Attaching hardware
missing ……………. C ………. Require replacement of hardware.
Attaching hardware not
functioning ………… A … Require repair or replacement of hardware.
Broken, affecting
performance ………… A ………… Require replacement. Broken, not affecting
performance ………… .. …….. No service suggested or required.
Burned, affecting
performance ………… A ……….. (1) Require repair or replacement.
Burned, not affecting

performance …………

2

………..

(1) Suggest repair or

replacement.

Connector broken ……..

A

.. Require

repair or replacement.

Connector (Weatherpack

type) leaking ……….

A

.. Require repair or replacement.

Connector melted ……..

A

……….. (1) Require repair or

replacement.

Connector missing …….

C

………… Require replacement.

Cover missing ………..

C

… Require replacement of cover.

Cracked, affecting

performance …………

A

.. Require repair or replacement.

Cracked, not affecting
performance ………… 1 .. Suggest repair or replacement. Melted, affecting
performance ………… A …….. (1) Require replacement. Melted, not affecting
performance ………… 2 …….. (1) Suggest replacement. Terminal broken ……… A .. Require repair or replacement. Terminal burned, affecting
performance ………… A ……….. (1) Require repair or replacement.
Terminal burned, not
affecting performance .. 2 .. Suggest repair or replacement. Terminal corroded,
affecting performance .. A .. Require repair or replacement. Terminal corroded, not
affecting performance .. 2 .. Suggest repair or replacement. Terminal loose, affecting
performance ………… B .. Require repair or replacement. Terminal loose, not
affecting performance .. 1 .. Suggest repair or replacement.
(1) – Determine cause and correct prior to repair or replacement of part.

RELAYS

Attaching hardware
Attaching hardware not
of hardware. Housing broken ………. A ……….. Require replacement. Housing cracked ……… 2 ……….. Suggest replacement. Inoperative …………. A …….. (1) Require replacement. Missing …………….. C ……….. Require replacement. Terminal broken ……… A .. Require repair or replacement. Terminal burned, affecting
performance ………… A ……….. (2) Require repair or replacement.
Terminal burned, not
affecting performance .. 2 .. Suggest repair or replacement. Terminal corroded,
affecting performance .. A .. Require repair or replacement. Terminal corroded, not
affecting performance .. 2 .. Suggest repair or replacement. Terminal loose, affecting
performance ………… B .. Require repair or replacement. Terminal loose, not
affecting performance .. 1 .. Suggest repair or replacement.
(1) – Inoperative includes intermittent operation or out of OEM
specification.
(2) – Determine cause and correct prior to repair or replacement of part.

SEALED BEAMS

See BULBS, SEALED BEAMS AND LEDS.

SEAT HEATERS

See
HEATING ELEMENTS (DEFROSTERS, DEFOGGERS, ELECTRIC HEATERS AND SEATS) .

SECURITY ALARM SENSORS

SECURITY ALARM SENSOR INSPECTION
Condition Code Procedure
Attaching hardware
missing ……………. C ………. Require replacement of hardware.
Attaching hardware threads
damaged ……………. A … Require repair or replacement of hardware.
Attaching hardware threads stripped (threads
missing) …………… A … Require repair or replacement of hardware.
Connector broken …….. A .. Require repair or replacement. Connector melted …….. A ……….. (1) Require repair or replacement.
Connector missing ……. C ………… Require replacement. Inoperative …………. B ……….. (2) Require repair or replacement. Further
inspection required. Missing …………….. C ………… Require replacement. Resistance out of
specification ………. B .. Require repair or replacement. Terminal broken ……… A .. Require repair or replacement. Terminal burned, affecting
performance ………… A ……….. (1) Require repair or replacement.
Terminal burned, not
affecting performance .. 2 .. Suggest repair or replacement. Terminal corroded,
affecting performance .. A .. Require repair or replacement. Terminal corroded, not
affecting performance .. 2 .. Suggest repair or replacement. Terminal loose, affecting
performance ………… B .. Require repair or replacement. Terminal loose, not
affecting performance .. 1 .. Suggest repair or replacement. Threads damaged ……… A .. Require repair or replacement. Threads stripped (threads
missing) …………… A ………… Require replacement. Wire lead conductors
exposed ……………. B .. Require repair or replacement. Wire lead corroded …… A .. Require repair or replacement. Wire lead open ………. A .. Require repair or replacement. Wire lead shorted ……. A .. Require repair or replacement.
(1) – Determine cause and correct prior to repair or replacement of part.
(2) – Inoperative includes intermittent operation or out of OEM
specification.

SIRENS

See HORNS AND SIRENS.

SOLENOIDS

See ACTUATOR MOTORS (SOLENOIDS) (ELECTRIC).
NOTE: For starter solenoids that are integral to the starter assembly, see STARTERS.
NOTE: For starter relays, see RELAYS.

SPEAKERS AND MICROPHONES

SPEAKER AND MICROPHONE INSPECTION
Condition Code Procedure
Application incorrect … A ………… Require replacement. Attaching hardware
broken …………….. A … Require repair or replacement of hardware.
Attaching hardware
missing ……………. C ………. Require replacement of hardware.
Attaching hardware not
functioning ………… A … Require repair or replacement of hardware.
Connector broken …….. A .. Require repair or replacement. Connector (Weatherpack
type) leaking ………. A .. Require repair or replacement. Connector melted …….. A ……….. (1) Require repair or replacement.
Connector missing ……. C ………… Require replacement. Inoperative …………. B ……….. (2) Require repair or replacement. Further
inspection required. Membrane torn ……….. A ………… Require replacement. Missing …………….. C ………… Require replacement. Polarity reversed ……. A …………….. Require repair. Sound quality poor …… A ……….. (3) Require repair or replacement. Further
inspection required. Terminal broken ……… A .. Require repair or replacement. Terminal burned, affecting
performance ………… A ……….. (1) Require repair or replacement.
Terminal burned, not
affecting performance .. 2 .. Suggest repair or replacement. Terminal corroded,
affecting performance .. A .. Require repair or replacement. Terminal corroded, not
affecting performance .. 2 .. Suggest repair or replacement. Terminal loose, affecting
performance ………… B .. Require repair or replacement. Terminal loose, not
affecting performance .. 1 .. Suggest repair or replacement.
(1) – Determine cause and correct prior to repair or replacement of part.
(2) – Inoperative includes intermittent operation or out of
OEM specification.
(3) – Make sure poor sound quality is not caused by ignition/charging system or other forms of electrical
interference.

SPEEDOMETER AND TACHOMETER LINKAGES AND CABLES

SPEEDOMETER AND TACHOMETER LINKAGE AND CABLE INSPECTION
Condition Code Procedure
Attaching hardware
broken …………….. A … Require repair or replacement of hardware.
Attaching hardware
missing ……………. C ………. Require replacement of hardware.
Attaching hardware not
functioning ………… A … Require repair or replacement of hardware.
Bent ……………….. A .. Require repair or replacement. Binding …………….. A .. Require repair or replacement. Bracket bent, affecting
performance ………… A .. Require repair or replacement. Bracket bent, not
affecting performance .. .. …….. No service suggested or required.
Bracket broken, affecting
performance ………… A ………… Require replacement. Bracket broken, not
affecting performance .. .. …….. No service suggested or required.
Bracket corroded,
affecting performance .. A .. Require repair or replacement. Bracket corroded, not
affecting performance .. 2 .. Suggest repair or replacement. Bracket cracked, affecting
performance ………… A .. Require repair or replacement. Bracket cracked, not
affecting performance .. 1 .. Suggest repair or replacement. Bracket loose, affecting
performance ………… A .. Require repair or replacement. Bracket loose, not
affecting performance .. 1 .. Suggest repair or replacement. Bracket missing ……… C ……….. Require replacement. Broken ……………… A ……….. Require replacement. Cracked …………….. A .. Require repair or replacement. Disconnected ………… A .. Require repair or replacement. Kinked ……………… A .. Require repair or replacement.

Melted ………………

A

……….. (1) Require repair or

replacement.

Missing ……………..

C

………… Require replacement.

Noisy ……………….

2

.. Suggest repair or replacement.

Routed incorrectly ……

2

…………….. Suggest repair.

Seized ………………

A

.. Require repair or replacement.

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

SPEEDOMETER CABLES

See SPEEDOMETER AND TACHOMETER LINKAGES AND CABLES.

SPEEDOMETERS

See GAUGES.

STARTERS

NOTE: To prevent misdiagnosis, care should be taken to eliminate the possibilities of mechanical problems or high resistance in power and/or ground circuits.
STARTER INSPECTION
Condition Code Procedure
Amperage draw does not
meet OEM specifications . B .. Require repair or replacement. Attaching hardware
broken …………….. A … Require repair or replacement of hardware.
Attaching hardware
missing ……………. C ………. Require replacement of hardware.
Attaching hardware not
functioning ………… A ……….. (1) Require repair or replacement of hardware.
Bracket bent, affecting
performance ………… A .. Require repair or replacement. Bracket bent, not
affecting performance .. .. …….. No service suggested or required.
Bracket broken, affecting
performance ………… A ………… Require replacement. Bracket broken, not
affecting performance .. .. …….. No service suggested or required.
Bracket corroded,
affecting performance .. A .. Require repair or replacement. Bracket corroded, not
affecting performance .. 2 .. Suggest repair or replacement. Bracket cracked, affecting
performance ………… A .. Require repair or replacement. Bracket cracked, not
affecting performance .. 1 .. Suggest repair or replacement. Bracket holes elongated,
affecting performance .. A .. Require repair or replacement. Bracket holes elongated,
not affecting
performance) ……….. .. …….. No service suggested or required.
Bracket loose, affecting
performance ………… A .. Require repair or replacement. Bracket loose, not
affecting performance .. 1 .. Suggest repair or replacement. Bracket missing ……… C ………… Require replacement. Drive gear damaged,
affecting performance .. A ……….. (2) Require repair or replacement.
Drive gear damaged, not
affecting performance .. 2 ……….. (2) Suggest repair or replacement.
Fails to disengage …… A .. Require repair or replacement. Housing broken, affecting
performance ………… 2 .. Require repair or replacement. Housing broken, not
affecting performance .. .. …….. No service suggested or required.
Housing cracked, affecting
performance ………… A … Require repair or replacement. Housing cracked, not
Starter shaft bushing worn, affecting
performance ………… A ………… Require replacement. Starter shaft bushing
worn, not affecting
performance ………… 1 ………… Suggest replacement. Terminal broken ……… A .. Require repair or replacement. Terminal burned, affecting
performance ………… A ……….. (5) Require repair or replacement.
Terminal burned, not
affecting performance .. 2 .. Suggest repair or replacement. Terminal corroded,
affecting performance .. A .. Require repair or replacement. Terminal corroded, not
affecting performance .. 2 .. Suggest repair or replacement. Terminal loose, affecting
performance ………… B .. Require repair or replacement. Terminal loose, not
affecting performance .. 1 .. Suggest repair or replacement.
(1) – Inspect block or bell housing mounting surface.
(2) – Further inspection required to determine cause. Require inspection of ring gear.
(3) – Inoperative includes intermittent operation. (4) – Bushing may be in bell housing.
(5) – Determine cause and correct prior to repair or replacement of part.

SUB-WOOFER VOLUME CONTROLS

See
RECEIVERS, AMPLIFIERS, EQUALIZERS AND SUB-WOOFER VOLUME CONTROLS .

SWITCHES

SWITCH INSPECTION
Condition Code Procedure
Attaching hardware
broken …………….. A … Require repair or replacement of hardware.
Attaching hardware
missing ……………. C ………. Require replacement of hardware.
Attaching hardware not
functioning ………… A … Require repair or replacement of hardware.
Binding, affecting
performance ………… A .. Require repair or replacement. Binding, not affecting
performance ………… 2 .. Suggest repair or replacement. Broken ……………… A .. Require repair or replacement. Burned, affecting
performance ………… A ……….. (1) Require repair or replacement.
Burned, not affecting
performance ………… 2 ……….. (1) Suggest repair or replacement.
Cracked, affecting
performance ………… A .. Require repair or replacement. Cracked, not affecting
performance ………… 1 .. Suggest repair or replacement. Leaking …………….. A .. Require repair or replacement. Malfunctioning ………. A ……….. (2) Require repair or replacement.
Melted, affecting
performance ………… A ……….. (1) Require repair or replacement.
Melted, not affecting
performance ………… 2 ……….. (1) Suggest repair or replacement.
Missing …………….. C ………… Require replacement. Out of adjustment ……. B .. Require repair or replacement. Terminal broken ……… A .. Require repair or replacement. Terminal burned, affecting
performance ………… A ……….. (1) Require repair or replacement.
Terminal burned, not
affecting performance .. 2 .. Suggest repair or replacement. Terminal corroded,
affecting performance .. A .. Require repair or replacement. Terminal corroded, not
affecting performance .. 2 .. Suggest repair or replacement. Terminal loose, affecting
performance ………… B .. Require repair or replacement. Terminal loose, not
affecting performance .. 1 .. Suggest repair or replacement. Won’t return ………… A .. Require repair or replacement. Worn ……………….. 1 ………… Suggest replacement.
(1) – Determine cause and correct prior to repair or replacement of part.
(2) – Includes inoperative, intermittent operation, or failure to perform all functions.

TACHOMETER CABLES

See SPEEDOMETER AND TACHOMETER LINKAGES AND CABLES.

TACHOMETERS

See GAUGES.

TAPE PLAYERS AND CD PLAYERS

TAPE PLAYER AND CD PLAYER INSPECTION
Condition Code Procedure
Attaching hardware
broken …………….. A … Require repair or replacement of hardware.
Attaching hardware
missing ……………. C ………. Require replacement of hardware.
Attaching hardware not
functioning ………… A … Require repair or replacement of hardware.
Connector broken …….. A .. Require repair or replacement. Connector melted …….. A ……….. (1) Require repair or replacement.
Connector missing ……. C ………… Require replacement. Malfunctioning ………. A ……….. (2) Require repair or replacement.
Missing …………….. C ………… Require replacement. Skips ………………. A .. Require repair or replacement. Sound quality poor …… A ……….. (3) Require repair or replacement.
Speed incorrect ……… A .. Require repair or replacement. Terminal broken ……… A .. Require repair or replacement. Terminal burned, affecting
performance ………… A ……….. (1) Require repair or replacement.
Terminal burned, not
affecting performance .. 2 .. Suggest repair or replacement. Terminal corroded,
affecting performance .. A .. Require repair or replacement. Terminal corroded, not
affecting performance .. 2 .. Suggest repair or replacement. Terminal loose, affecting
performance ………… B .. Require repair or replacement. Terminal loose, not
affecting performance .. 1 .. Suggest repair or replacement. Wire lead burned …….. A .. Require repair or replacement. Wire lead conductors
exposed ……………. B .. Require repair or replacement. Wire lead open ………. A .. Require repair or replacement. Wire lead shorted ……. A .. Require repair or replacement.
(1) – Determine cause and correct prior to repair or replacement of part.
(2) – Malfunctioning includes inoperative, intermittent operation, or failure to perform all functions.
(3) – Make sure poor sound quality is not caused by ignition/charging system or other forms of electrical interference.

TENSIONERS

TENSIONER INSPECTION
Condition Code Procedure

Alignment

incorrect …..

B

..

Require repair or replacement.

Attaching

hardware

broken …………….. A … Require repair or replacement of hardware.
Attaching hardware
missing ……………. C ………. Require replacement of hardware.
Attaching hardware not
functioning ………… A … Require repair or replacement
of hardware. Bearings worn ……….. 1 ………… Suggest replacement. Belt tension incorrect .. B … Require adjustment or repair. Cracked …………….. 2 ………… Suggest replacement. Missing …………….. C ………… Require replacement. Noisy ………………. 2 ………… Suggest replacement. Pulley damaged, affecting
belt life ………….. A ………… Require replacement. Seized ……………… A .. Require repair or replacement.

TIMERS

TIMER INSPECTION
Condition Code Procedure
Attaching hardware
broken …………….. A … Require repair or replacement of hardware.
Attaching hardware
missing ……………. C ………. Require replacement of hardware.
Attaching hardware not
functioning ………… A … Require repair or replacement of hardware.
Broken ……………… A .. Require repair or replacement. Burned, affecting
performance ………… A ……….. (1) Require repair or replacement.
Burned, not affecting
performance ………… 2 ……….. (1) Suggest repair or replacement.
Cracked, affecting
performance ………… A .. Require repair or replacement. Cracked, not affecting
performance ………… 1 .. Suggest repair or replacement. Inoperative …………. A ……….. (2) Require repair or replacement.
Melted, affecting
performance ………… A ……….. (1) Require repair or replacement.
Melted, not affecting
performance ………… 2 ……….. (1) Suggest repair or replacement.
Missing …………….. C ………… Require replacement. Terminal broken ……… A .. Require repair or replacement. Terminal burned, affecting
performance ………… A ……….. (1) Require repair or replacement.
Terminal burned, not
affecting performance .. 2 .. Suggest repair or replacement. Terminal corroded,
affecting performance .. A .. Require repair or replacement. Terminal corroded, not
affecting performance .. 2 .. Suggest repair or replacement. Terminal loose, affecting
performance ………… B .. Require repair or replacement. Terminal loose, not
affecting performance .. 1 .. Suggest repair or replacement.
(1) – Determine cause and correct prior to repair or replacement of part.
(2) – Inoperative includes intermittent operation or out of OEM
specification.

TIRE PRESSURE SENSORS

TIRE PRESSURE SENSOR INSPECTION
Condition Code Procedure
Attaching hardware
broken …………….. A … Require repair or replacement of hardware.
Attaching hardware
missing ……………. C ………. Require replacement of hardware.
Attaching hardware not

functioning …………

A

… Require repair or replacement

of hardware.

Inoperative ………….

A

……….. (1) Require repair or

replacement.

Loose ……………….

A

.. Require repair or replacement.

Missing ……………..

C

………… Require replacement.

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

TRANSCEIVERS

TRANSCEIVER INSPECTION
Condition
Code Procedure
Attaching hardware
broken …………….. A … Require repair or replacement of hardware.
Attaching hardware
missing ……………. C ………. Require replacement of hardware.
Attaching hardware not
functioning ………… A … Require repair or replacement of hardware.
Connector broken …….. A .. Require repair or replacement. Connector melted …….. A ……….. (1) Require repair or replacement.
Connector missing ……. C ………… Require replacement. Malfunctioning ………. A ……….. (2) Require repair or replacement.
Missing …………….. C ………… Require replacement. Sound quality poor …… A ……….. (3) Require repair or replacement.
Terminal broken ……… A .. Require repair or replacement. Terminal burned, affecting
performance ………… A ……….. (1) Require repair or replacement.
Terminal burned, not
affecting performance .. 2 .. Suggest repair or replacement. Terminal corroded,
affecting performance .. A .. Require repair or replacement. Terminal corroded, not
affecting performance .. 2 .. Suggest repair or replacement. Terminal loose, affecting

performance …………

B

..

Require

repair

or

replacement.

Terminal loose, not

affecting performance ..

1

..

Suggest

repair

or

replacement.

Wire lead burned ……..

A

..

Require

repair

or

replacement.

Wire lead conductors

exposed …………….

B

..

Require

repair

or

replacement.

Wire lead open ……….

A

..

Require

repair

or

replacement.

Wire lead shorted …….

A

..

Require

repair

or

replacement.

(1) – Determine cause and correct prior to repair or replacement of part.
(2) – Malfunctioning includes inoperative, intermittent operation, or failure to perform all functions.
(3) – Make sure poor sound quality is not caused by ignition/charging system or other forms of electrical interference.

TRANSDUCERS

TRANSDUCER INSPECTION
Condition Code Procedure
Attaching hardware
broken …………….. A … Require repair or replacement of hardware.
Attaching hardware
missing ……………. C ………. Require replacement of hardware.
Attaching hardware not

functioning …………

A

Require repair or replacement

of hardware.

Connector broken ……..

A

..

Require repair or replacement.

Connector (Weatherpack

type) leaking ……….

A

..

Require repair or replacement.

Connector melted ……..

A

………..

(1) Require repair or

replacement.

Connector missing …….

C

…………

Require replacement.

Drive mechanism damaged,

affecting performance ..

A

………..

(2) Require repair or

replacement.

Drive mechanism damaged, not affecting
performance ………… 2 ……….. (2) Suggest repair or replacement.
Inoperative …………. A ……….. (3) Require repair or replacement.
Leaking
(vacuum/fluid/air) ….. A ………… Require replacement. Linkage bent, affecting
performance ………… A … Require repair or replacement of linkage.
Linkage bent, not
affecting performance .. .. …….. No service suggested or required.
Linkage binding, affecting
performance ………… A … Require repair or replacement of linkage.
Linkage binding, not

affecting performance ..

2

Suggest

repair

or replacement

of linkage.

Linkage broken ……….

A

Require

repair

or replacement

Linkage loose, affecting
of linkage.
performance ………… A … Require repair or replacement of linkage.
Linkage loose, not
affecting performance .. 1 … Suggest repair or replacement of linkage.
Linkage missing ……… C ………… Require replacement. Linkage noisy ……….. 2 .. Suggest repair or replacement. Out of adjustment ……. B ………. (4) Further inspection required.
Terminal broken ……… A .. Require repair or replacement. Terminal burned, affecting
performance ………… A ……….. (1) Require repair or replacement.
Terminal burned, not
affecting performance .. 2 .. Suggest repair or replacement. Terminal corroded,
affecting performance .. A .. Require repair or replacement. Terminal corroded, not
affecting performance .. 2 .. Suggest repair or replacement. Terminal loose, affecting
performance ………… B .. Require repair or replacement. Terminal loose, not
affecting performance .. 1 .. Suggest repair or replacement.
(1) – Determine cause and correct prior to repair or replacement of part.
(2) – Further inspection required to determine cause.
(3) – Inoperative includes intermittent operation or out of specification.
(4) – Follow OEM recommended adjustment procedures. Repair or replace if out of specification.

VACUUM ACCUMULATORS (RESERVOIRS)

VACUUM ACCUMULATOR (RESERVOIR) INSPECTION
Condition Code Procedure
Attaching hardware
broken …………….. A … Require repair or replacement of hardware.
Attaching hardware
missing ……………. C ………. Require replacement of hardware.
Attaching hardware not
functioning ………… A … Require repair or replacement of hardware.
Leaking …………….. A .. Require repair or replacement.

VACUUM RESERVOIRS

See VACUUM ACCUMULATORS (RESERVOIRS).

VOLTAGE REGULATORS

VOLTAGE REGULATOR INSPECTION
Condition Code Procedure
Attaching hardware
broken …………….. A … Require repair or replacement of hardware.
Attaching hardware
missing ……………. C ………. Require replacement of hardware.
Attaching hardware not
functioning ………… A … Require repair or replacement of hardware.
Connector broken …….. A .. Require repair or replacement. Connector (Weatherpack
type) leaking ………. A .. Require repair or replacement. Connector melted …….. A ……….. (1) Require repair or replacement.
Connector missing ……. C ………… Require replacement. Inoperative …………. A …….. (2) Require replacement. Terminal broken ……… A .. Require repair or replacement. Terminal burned, affecting
performance ………… A ……….. (1) Require repair or replacement.
Terminal burned, not
affecting performance .. 2 .. Suggest repair or replacement. Terminal corroded,
affecting performance .. A .. Require repair or replacement. Terminal corroded, not
affecting performance .. 2 .. Suggest repair or replacement. Terminal loose, affecting
performance ………… B .. Require repair or replacement. Terminal loose, not
affecting performance .. 1 .. Suggest repair or replacement.
(1) – Determine cause and correct prior to repair or replacement of part.
(2) – NOTE: Inoperative includes intermittent operation or out of OEM specification.

WASHER FLUID LEVEL SENDERS

WASHER FLUID LEVEL SENDER INSPECTION
Attaching hardware
Attaching hardware not
Terminal burned, not
affecting performance .. 2 .. Suggest repair or replacement. Terminal corroded,
affecting performance .. A .. Require repair or replacement.
Terminal corroded, not
Terminal loose, affecting
Terminal loose, not
(1) – Inoperative includes intermittent operation or out of OEM
specification.
(2) – Determine cause and correct prior to repair or replacement of part.

WASHER PUMPS

WASHER PUMP INSPECTION
Condition Code Procedure
Attaching hardware
broken …………….. A … Require repair or replacement of hardware.
Attaching hardware
missing ……………. C ………. Require replacement of hardware.
Attaching hardware not
functioning ………… A … Require repair or replacement of hardware.
Connector broken …….. A .. Require repair or replacement. Connector melted …….. A ……….. (1) Require repair or replacement.
Connector missing ……. C ………… Require replacement. Inoperative …………. A ……….. (2) Require repair or replacement.
Leaking externally …… A .. Require repair or replacement. Leaking internally …… A .. Require repair or replacement. Noisy ………………. 2 .. Suggest repair or replacement. Resistance out of
specification ………. B .. Require repair or replacement. Terminal broken ……… A .. Require repair or replacement. Terminal burned, affecting
performance ………… A ……….. (1) Require repair or replacement.
Terminal burned, not
affecting performance .. 2 .. Suggest repair or replacement. Terminal corroded,
missing) …………… A ………… Require replacement. Wire lead conductors
exposed ……………. B .. Require repair or replacement.
Wire lead corroded …… A .. Require repair or replacement. Wire lead open ………. A .. Require repair or replacement. Wire lead shorted ……. A .. Require repair or replacement.
(1) – Determine cause and correct prior to repair or replacement of part.
(2) – Inoperative includes intermittent operation.

WIPER ARMS AND BLADES

NOTE: Windshield coatings or waxes can cause blades to not function as intended. Clean surface before making final judgment about blade replacement.
WIPER ARM AND BLADE INSPECTION
Condition Code Procedure
Attaching hardware
broken …………….. A … Require repair or replacement of hardware.
Attaching hardware
missing ……………. C ………. Require replacement of hardware.
Attaching hardware not
functioning ………… A … Require repair or replacement of hardware.
Attaching socket
stripped …………… A ………… Require replacement. Bent ……………….. A .. Require repair or replacement. Loose ………………. 2 .. Suggest repair or replacement. Missing …………….. C ………… Require replacement. Noisy ………………. 2 .. Suggest repair or replacement. Size incorrect ………. 2 ………… Suggest replacement. Tension insufficient …. B .. Require repair or replacement. Torn ……………….. A ………… Require replacement. Worn, affecting
performance ………… A ………… Require replacement. Worn, not affecting
performance ………… 1 ………… Suggest replacement.

WIPER BLADES

See WIPER ARMS AND BLADES.

WIPER HOSES AND NOZZLES

WIPER HOSE AND NOZZLE INSPECTION
Condition Code Procedure
Attaching hardware
broken …………….. A … Require repair or replacement of hardware.
Attaching hardware
missing ……………. C ………. Require replacement of hardware.
Attaching hardware not

functioning …………

A

… Require repair or replacement

of hardware.

Blocked ……………..

A

.. Require repair or replacement.

Leaking …………….. A .. Require repair or replacement. Missing …………….. C ………… Require replacement. Oil-soaked (spongy) ….. 1 ………… Suggest replacement. Spray pattern incorrect . 2 .. Suggest repair or replacement. Surface cracks (dry-
rotted) ……………. 1 ………… Suggest replacement.

WIPER LINKAGES

WIPER LINKAGE INSPECTION
Condition Code Procedure
Attaching hardware
broken …………….. A … Require repair or replacement of hardware.
Attaching hardware
missing ……………. C ………. Require replacement of hardware.
Attaching hardware not
functioning ………… A … Require repair or replacement of hardware.
Attaching stud stripped . A ………… Require replacement. Bent ……………….. A .. Require repair or replacement. Inoperative …………. A …….. (1) Require replacement. Loose ………………. 2 .. Suggest repair or replacement. Missing …………….. C ………… Require replacement. Noisy ………………. 2 .. Suggest repair or replacement. Tension insufficient …. B .. Require repair or replacement. Worn, affecting
performance ………… A ………… Require replacement. Worn, not affecting
performance ………… 1 ………… Suggest replacement.
(1) – Inoperative includes intermittent operation.

WIPER NOZZLES

See WIPER HOSES AND NOZZLES.

WIPER PUMP RESERVOIRS

WIPER PUMP RESERVOIR INSPECTION
Attaching hardware
Attaching hardware not

WIRING HARNESSES AND CONNECTORS

WIRING HARNESS AND CONNECTOR INSPECTION
Condition Code Procedure

Application incorrect …

B

.. Require repair or replacement.

Attaching hardware

broken ……………..

A

… Require repair or replacement

of hardware.

Attaching hardware
missing ……………. C ………. Require replacement of hardware.
Attaching hardware not

functioning …………

A

Require repair or replacement

of hardware.

Connector broken ……..

A

..

Require repair or replacement.

Connector (Weatherpack

type) leaking ……….

A

..

Require repair or replacement.

Connector melted ……..

A

……….. (1) Require repair or

replacement.

Connector missing …….

C

………… Require replacement.

Insulation damaged,

conductors exposed …..

A

.. Require repair or replacement.

Insulation damaged,
conductors not exposed . 1 ………… Suggest replacement. Open ……………….. A .. Require repair or replacement. Protective shield
(conduit) melted ……. 2 ……….. (1) Suggest repair or replacement.
Protective shield
(conduit) missing …… 2 .. Suggest repair or replacement. Resistance (voltage drop)
Terminal burned, not
affecting performance .. 2 .. Suggest repair or replacement. Terminal corroded,
affecting performance .. A .. Require repair or replacement. Terminal corroded, not
affecting performance .. 2 .. Suggest repair or replacement. Terminal loose, affecting
performance ………… B .. Require repair or replacement. Terminal loose, not
affecting performance .. 1 .. Suggest repair or replacement. Voltage drop out of
specification ………. A .. Require repair or replacement.
(1) – Determine cause and correct prior to repair or replacement of part.

 

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