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Volvo 850 engine inspection

Volvo 850 service & repair manual

* ENGINE SYSTEMS UNIFORM INSPECTION GUIDELINES *

1995 Volvo 850

GENERAL INFORMATION
Engine Performance and Maintenance Motorist Assurance Program
Standards For Automotive Repair
All Makes and Models of the Volvo 850 series

INTRODUCTION TO MOTORIST ASSURANCE PROGRAM (MAP)

CONTENTS

Motorist Assurance Program (MAP) OVERVIEW OF MOTORIST ASSURANCE PROGRAM
OVERVIEW OF SERVICE REQUIREMENTS AND SUGGESTIONS
Engine Assemblies
CYLINDER HEAD ASSEMBLIES LONG BLOCK ASSEMBLIES SHORT BLOCK ASSEMBLIES
Engine Components
ACCELERATOR PEDAL POSITION SENSORS ACCESSORY BELTS
ACCESSORY PULLEYS ACTUATORS
AIR CONDITIONING CYCLING SWITCHES AIR CONDITIONING PRESSURE SENSORS AIR DUCTS AND TUBES
AIR FILTER ELEMENTS AIR FILTER GASKETS
AIR FILTER HOUSINGS AND GASKETS AIR FUEL RATIO SENSORS
AIR INJECTION CONTROL SOLENOIDS AIR PLENUMS
AIR PUMP BELTS
AIR PUMPS (ELECTRIC-DRIVEN) AIR TUBES
ASPIRATOR, CHECK AND DECEL VALVES BAFFLES
BALLAST PRIMARY SUPPLY RESISTOR WIRES
BALLAST RESISTORS AND PRIMARY SUPPLY RESISTOR WIRES BAROMETRIC PRESSURE SENSORS
BATTERIES
BATTERY CABLES, WIRES AND CONNECTORS BATTERY CONNECTORS
BATTERY TRAYS AND HOLD DOWN HARDWARE BATTERY WIRES
BELT-DRIVEN AIR PUMPS
BELT IDLER ASSEMBLIES (ACCESSORY AND CAM BELTS) BELT TENSIONERS (ACCESSORY AND CAM BELTS)
BOOST CONTROL MECHANISMS CAMSHAFT POSITION SENSORS CARBURETORS AND CHOKES
CASTING CORE PLUGS AND EXPANSION PLUGS CHARGE AIR COOLERS “INTERCOOLERS” (CAC) CHECK VALVES
CHOKES
CLUTCH PEDAL POSITION SWITCHES COLD START INJECTORS
CONNECTORS COOLANT
COOLANT RECOVERY TANKS COOLING FAN MOTOR MODULES
COOLING FAN MOTOR RELAYS AND MODULES COOLING FAN MOTOR RESISTORS
COOLING FAN MOTOR SENSORS AND SWITCHES COOLING FAN MOTOR SWITCHES
COOLING FAN MOTORS CRANKSHAFT POSITION SENSORS DECEL VALVES
DEFLECTORS
DIP STICKS AND TUBES DIP STICK TUBES
DISTRIBUTOR ADVANCES AND RETARDERS (MECHANICAL AND VACUUM) DISTRIBUTOR BOOTS AND SHIELDS
DISTRIBUTOR CAPS
DISTRIBUTOR RETARDERS (MECHANICAL AND VACUUM) DISTRIBUTOR ROTORS
DISTRIBUTOR SHIELDS DISTRIBUTORS
EARLY FUEL EVAPORATION VALVES (HEAT RISER ASSEMBLIES) EGR COOLERS
EGR EXHAUST MANIFOLD PASSAGES
EGR INTAKE AND EXHAUST MANIFOLD PASSAGES EGR PLATES AND COOLERS
ELECTRONIC SPARK CONTROL MODULES ELECTRONIC TRANSMISSION CONTROL DEVICES ELECTRONIC TRANSMISSION FEEDBACK DEVICES ENGINE COOLANT TEMPERATURE SENSORS
ENGINE COOLING SYSTEMS
ENGINE COVERS (OIL PAN, VALVE COVER, TIMING COVER) ENGINE OIL
ENGINE OIL CANISTERS
ENGINE OIL COOLERS (EXTERNAL) ENGINE OIL DRAIN PLUGS AND GASKETS ENGINE OIL FILTERS AND CANISTERS ENGINE OIL GASKETS
ENGINE OIL PRESSURE GAUGES (MECHANICAL) EVAPORATIVE EMISSION (EVAP) CANISTER FILTERS EVAPORATIVE EMISSION (EVAP) CANISTER PURGE DEVICES EVAPORATIVE EMISSION (EVAP) CANISTERS
EVAPORATIVE EMISSION (EVAP) FEEDBACK DEVICES EXHAUST GAS RECIRCULATION DEVICES
EXHAUST GAS RECIRCULATION FEEDBACK DEVICES EXPANSION PLUGS
FAN CONTROL SENSORS FUEL
FUEL ACCUMULATORS AND DAMPERS FUEL AND COLD START INJECTORS FUEL DAMPERS
FUEL DELIVERY CHECK VALVES FUEL DISTRIBUTORS (BOSCH CIS)
FUEL FILLER NECKS AND RESTRICTORS FUEL FILTERS
FUEL INJECTORS
FUEL LEVEL SENDERS7
FUEL PRESSURE REGULATORS
FUEL PUMPS (IN-TANK AND EXTERNAL, ELECTRICAL OR MECHANICAL) FUEL RAILS
FUEL RESTRICTORS
FUEL TANKS GAS CAPS GASKETS
GROMMETS (VALVE COVER) HARMONIC DAMPERS
HEATER CONTROL VALVES HEATER CORES
HOSE AND TUBE COUPLERS, CONNECTORS AND CLAMPS HOSE CLAMPS
HOSE CONNECTORS HOSE COUPLERS
HOSES AND TUBES (FUEL LINES, RADIATOR, VACUUM, BY PASS, HEATER, RECOVERY TANK AND OIL COOLERS)
HOUSINGS
IDLE AIR CONTROLS
IDLE SPEED CONTROL ACTUATORS IGNITION BOOTS
IGNITION COIL TOWERS IGNITION COILS
IGNITION CONTROL MODULES (ICM) IGNITION SWITCHES
IGNITION TERMINALS
IGNITION WIRES, BOOTS, COIL TOWERS AND TERMINALS (SECONDARY) IN-TANK FUEL STRAINERS
INERTIA FUEL SHUT-OFF SWITCHES INTAKE AIR TEMPERATURE SENSORS INTAKE MANIFOLDS
INTERCOOLERS KNOCK SENSORS
LIQUID VAPOR SEPARATORS
MANIFOLD ABSOLUTE PRESSURE (MAP) SENSORS MASS AIR FLOW (MAF) SENSORS
METAL AIR MANIFOLDS AND PIPES METAL AIR PIPES
MIX CONTROL SOLENOIDS MOTOR MOUNTS
O-RINGS, GASKETS, SEALS AND SPRING LOCKS O2 SENSORS
OIL PRESSURE SENDING UNITS OIL PUMP PICK-UP SCREENS OIL PUMPS
PARK NEUTRAL POSITION SWITCHES PCV BREATHER ELEMENTS
PCV ORIFICES PCV VALVES
PICK-UP ASSEMBLIES (INCLUDES MAGNETIC, HALL EFFECT AND OPTICAL)
POWER STEERING PRESSURE SENSORS
POWERTRAIN CONTROL MODULES (PCM) AND PROM POWERTRAIN CONTROL PROM
PRESSURIZED EXPANSION TANK CAPS
RADIATOR CAPS AND PRESSURIZED EXPANSION TANK CAPS RADIATOR FAN BLADES
RADIATOR FAN CLUTCHES RADIATORS
ROLL OVER VALVES SEALING COMPOUNDS SEALS
SECONDARY AIR INJECTION SYSTEM MANAGEMENT DEVICES SENSORS AND ACTUATORS
SHROUDS, BAFFLES AND DEFLECTORS SPARK PLUGS
SPRING LOCKS
SUPER CHARGERS SWITCHES
THERMAL VACUUM VALVES THERMOSTATIC AIR DOOR ASSEMBLIES THERMOSTATS AND HOUSINGS
THROTTLE BODIES THROTTLE CABLES
THROTTLE LINKAGES AND CABLES THROTTLE POSITION SENSORS THROTTLE POSITION SWITCHES TIMING BELT SPROCKETS
TIMING BELTS TORQUE STRUTS
TRANSMISSION RANGE SWITCHES TUBE CLAMPS
TUBE CONNECTORS TUBE COUPLERS TUBES
TURBO CHARGERS VACUUM CONNECTIONS
VACUUM HOSES, TUBES AND CONNECTIONS (NON-METALLIC) VACUUM REGULATOR SOLENOIDS
VACUUM TUBES
VEHICLE SPEED SENSORS VOLUME AIR FLOW SENSORS
WASTE GATE CONTROL SOLENOIDS
WASTE GATES AND BOOST CONTROL MECHANISMS WATER PUMPS (ELECTRIC)
WATER PUMPS (NON-ELECTRIC) WIRING HARNESSES AND CONNECTORS

INTRODUCTION TO MOTORIST ASSURANCE PROGRAM (MAP)

OVERVIEW OF MOTORIST ASSURANCE PROGRAM

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

It is MAP policy that all exhaust, brake, steering, suspension, wheel alignment, drive-line, engine performance and maintenance, and heating, ventilation and air conditioning, and electrical services be offered and performed under the standards and procedures specified in these sections.
Before any service is performed on a vehicle, an inspection of the appropriate system must be performed. The results of this inspection must be explained to the customer and documented on an inspection form. The condition of the vehicle and its components will indicate what services/part replacements may be “Required” or “Suggested”. In addition, suggestions may be made to satisfy the requests expressed by the customer.
When a component is suggested or required to be repaired or replaced, the decision to repair or replace must be made in the 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.

ENGINE ASSEMBLIES

SERVICE PROCEDURES REQUIRED AND SUGGESTED FOR PROPER VEHICLE

OPERATION

CYLINDER HEAD ASSEMBLIES

NOTE: A Cylinder Head Assembly is a cylinder head fitted with valves, associated springs, retainers, and on overhead camshaft cylinder heads (OHC), camshaft, camshaft bearings, lash adjusters, tappets and rockers.
CYLINDER HEAD ASSEMBLY INSPECTION
Condition Code Procedure
Adjustable valve lash is
out of specification … B …………….. Require repair. Internal component failure
(any component) …….. A ……….. (1) Require repair or replacement of cylinder head assembly.
(1) – It is Required that all other failure related components
be inspected for cause and condition. Additional components or assemblies may be Suggested for repair or replacement, such as a water pump on a short block (reason code 4, technician’s recommendation based on substantial and informed experience).
Example:
If there is a failed head gasket with an external coolant leak, in addition to Requiring replacement of the head gasket, inspection of the following for cause and condition is Required: Block, Cooling System, Cylinder Head. It may be Suggested that additional inspections be performed, such as the other head gasket on a V-type engine.

LONG BLOCK ASSEMBLIES

NOTE: A Long Block Assembly is a short block assembly together with a cylinder head assembly and all those components fitted within the rocker or cam cover, and timing cover
(the whole presented as an assembly). A rebuilt or new oil pump, or kit shall be supplied or fitted as appropriate.
LONG BLOCK ASSEMBLY INSPECTION
Condition Code Procedure
Internal component failure
(any component) …….. A ……….. (1) Require repair or replacement of the long block assembly.
(1) – It is Required that all other failure related components
be inspected for cause and condition. Additional components or assemblies may be Suggested for repair or replacement such as a water pump on a short block (reason code 4, technician’s recommendation based on substantial and informed experience).
Example:
If there is a failed head gasket with an external coolant leak, in addition to Requiring replacement of the head gasket, inspection of the following for cause and condition is Required: Block, Cooling System, Cylinder Head. It may be Suggested that additional inspections be performed, such as the other head gasket on a V-type engine.

SHORT BLOCK ASSEMBLIES

NOTE: A Short Block Assembly is a cylinder block and all those components contained within the limits of the block deck or decks, the pan rail, the block rear face and the timing cover (where fitted), including the crankshaft.
SHORT BLOCK ASSEMBLY INSPECTION
Condition Code Procedure
Any internal component
failure ……………. A ……….. (1) Require repair or replacement of the short block assembly.
(1) – It is Required that all other failure related components be inspected for cause and condition. Additional components or assemblies may be Suggested for repair or replacement, such as a water pump on a short block (reason code 4, technician’s recommendation based on substantial and informed experience).
Example:
If there is a failed head gasket with an external coolant leak, in addition to Requiring replacement of the head gasket, inspection of the following for cause and condition is Required: Block, Cooling System, Cylinder Head. It may be Suggested that additional inspections be performed,
such as the other head gasket on a V-type engine.

ENGINE COMPONENTS

ACCELERATOR PEDAL POSITION SENSORS

ACCELERATOR PEDAL POSITION SENSOR INSPECTION
Condition Code Procedure
Attaching hardware
missing ……………. C ………. Require replacement of hardware.
Attaching hardware
threads damaged …….. A … Require repair or replacement of hardware.
Attaching hardware threads stripped
(threads missing) …… A … Require repair or replacement of hardware.
Connector broken …….. A .. Require repair or replacement. Connector (Weatherpack
type) leaking ………. A .. Require repair or replacement. Connector melted …….. A ……….. (1) Require repair or replacement.
Connector missing ……. C ………… Require replacement. Inoperative …………. B ……….. (2) Require repair or replacement. Further
inspection required. Missing …………….. C ………… Require replacement. Resistance out of
specification ………. B .. Require repair or replacement. Terminal broken ……… A .. Require repair or replacement. Terminal burned, affecting
performance ………… A ……….. (1) Require repair or replacement.
Terminal burned, not
affecting performance .. 2 .. Suggest repair or replacement. Terminal corroded,
affecting performance .. A .. Require repair or replacement. Terminal corroded, not
affecting performance .. 2 .. Suggest repair or replacement. Terminal loose, affecting
performance ………… B .. Require repair or replacement. Terminal loose, not
affecting performance .. 1 .. Suggest repair or replacement. Threads stripped (threads
missing) …………… A ………… Require replacement. Wire lead conductors
exposed ……………. B .. Require repair or replacement. Wire lead corroded …… A .. Require repair or replacement. Wire lead open ………. A .. Require repair or replacement. Wire lead shorted ……. A .. Require repair or replacement.
(1) – Determine cause and correct prior to repair or replacement of part.
(2) – Inoperative includes intermittent operation or out of OEM specification. Some components may be serviceable; check for accepted cleaning procedure.

ACCESSORY BELTS

ACCESSORY BELT INSPECTION
Condition Code Procedure

Alignment incorrect …..

B

………. (1) Further inspection

required.

Cracked ……………..

1

………… Suggest replacement.

Frayed ………………

1

………… Suggest replacement.

Missing ……………..

C

………… Require replacement.

Noisy ……………….

2

………. (2) Further inspection

required.

Plies separated ………

A

………… Require replacement.

Tension out of

specification ……….

B

……….. Require adjustment or

replacement.

Worn beyond adjustment
range ……………… B ………… Require replacement. Worn so it contacts
bottom of pulley ……. A ………… Require replacement.
(1) – Determine cause of incorrect alignment and require repair. (2) – Determine cause of noise and suggest repair.

ACCESSORY PULLEYS

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

functioning …………

A

… Require repair or replacement

of hardware.

Bent ………………..

A

………… Require replacement.

Cracked ……………..

A

………… Require replacement.

Loose ……………….

A

.. Require repair or replacement.

Missing ……………..

C

………… Require replacement.

Pulley damaged, affecting

belt life …………..

A

………… Require replacement.

ACTUATORS

See SENSORS AND ACTUATORS.

AIR CONDITIONING CYCLING SWITCHES

AIR CONDITIONING CYCLING SWITCH INSPECTION
Condition Code Procedure
Attaching hardware
missing ……………. C ………. Require replacement of hardware.
Attaching hardware
threads damaged …….. A … Require repair or replacement of hardware.
Attaching hardware threads stripped
(threads missing) …… A … Require repair or replacement of hardware.
Connector broken …….. A .. Require repair or replacement. Connector (Weatherpack
type) leaking ………. A .. Require repair or replacement. Connector melted …….. A ……….. (1) Require repair or replacement.
Connector missing ……. C ………… Require replacement. Contaminated ………… A ……….. (2) Require repair or replacement.
Inoperative …………. B ……….. (3) Require repair or replacement. Further inspection required.
Leaking …………….. A .. Require repair or replacement. Missing …………….. C ………… Require replacement. Resistance out of
specification ……….. B .. Require repair or replacement. Restricted, affecting
performance ………… A .. Require repair or replacement. Terminal broken ……… A .. Require repair or replacement. Terminal burned, affecting
performance ………… A ……….. (1) Require repair or replacement.
Terminal burned, not
affecting performance .. 2 .. Suggest repair or replacement. Terminal corroded,
affecting performance .. A .. Require repair or replacement. Terminal corroded, not
affecting performance .. 2 .. Suggest repair or replacement. Terminal loose, affecting
performance ………… B .. Require repair or replacement. Terminal loose, not
affecting performance .. 1 .. Suggest repair or replacement. Threads damaged ……… A .. Require repair or replacement. Threads stripped (threads
missing) …………… A ………… Require replacement. Wire lead conductors

exposed …………….

B

.. Require repair or

replacement.

Wire lead corroded ……

A

.. Require repair or

replacement.

Wire lead open ……….

A

.. Require repair or

replacement.

Wire lead shorted …….

A

.. Require repair or

replacement.

(1) – Determine cause and correct prior to repair or replacement of part.
(2) – Determine source of contamination, such as engine coolant, fuel, metal particles, or water. Require repair or replacement.
(3) – Inoperative includes intermittent operation or out of OEM specification. Some components may be serviceable; check for accepted cleaning procedure.

AIR CONDITIONING PRESSURE SENSORS

AIR CONDITIONING PRESSURE SENSOR INSPECTION
Condition Code Procedure
Attaching hardware
missing ……………. C ………. Require replacement of hardware.
Attaching hardware
threads damaged …….. A … Require repair or replacement of hardware.
Attaching hardware threads stripped
(threads missing) …… A … Require repair or replacement of hardware.

Connector broken ……..

A

..

Require repair or replacement.

Connector (Weatherpack

type) leaking ……….

A

..

Require repair or replacement.

Connector melted ……..

A

………..

(1) Require repair or

replacement.

Connector missing …….

C

…………

Require replacement.

Contaminated …………

A

………..

(2) Require repair or

replacement.

Inoperative ………….

B

………..

(3) Require repair or

replacement. Further

inspection required.

Leaking ……………..

A

.. Require repair or

replacement.

Missing ……………..

C

………… Require

replacement.

Resistance out of

specification ……….

B

.. Require repair or

replacement.

Restricted, affecting
performance ………… A .. Require repair or replacement. Terminal broken ……… A .. Require repair or replacement. Terminal burned, affecting
performance ………… A ……….. (1) Require repair or replacement.
Terminal burned, not
affecting performance .. 2 .. Suggest repair or replacement. Terminal corroded,
affecting performance .. A .. Require repair or replacement. Terminal corroded, not
affecting performance .. 2 .. Suggest repair or replacement. Terminal loose, affecting
performance ………… B .. Require repair or replacement. Terminal loose, not
affecting performance .. 1 .. Suggest repair or replacement. Threads damaged ……… A .. Require repair or replacement. Threads stripped (threads
missing) …………… A ………… Require replacement. Wire lead conductors

exposed …………….

B

.. Require repair or

replacement.

Wire lead corroded ……

A

.. Require repair or

replacement.

Wire lead open ……….

A

.. Require repair or

replacement.

Wire lead shorted …….

A

.. Require repair or

replacement.

(1) – Determine cause and correct prior to repair or replacement of part.
(2) – Determine source of contamination, such as engine coolant, fuel, metal particles, or water. Require repair or replacement.
(3) – Inoperative includes intermittent operation or out of OEM specification. Some components may be serviceable; check for accepted cleaning procedure.

AIR DUCTS AND TUBES

AIR DUCT AND TUBE INSPECTION
Condition Code Procedure
Attaching hardware
broken …………….. A … Require repair or replacement of hardware.
Attaching hardware
missing ……………. C ………. Require replacement of hardware.
Attaching hardware not
functioning ………… A … Require repair or replacement

of hardware.

Leaking ……………..

A

.. Require repair or

replacement.

Missing ……………..

C

………… Require

replacement.

Restricted, affecting

performance …………

A

.. Require repair or

replacement.

AIR FILTER ELEMENTS

AIR FILTER ELEMENT INSPECTION
Condition Code Procedure

Leaking ……………..

A

………… Require replacement.

Paper filter element

oil-soaked …………

A

…….. (1) Require replacement.

Maintenance intervals …

3

… Suggest replacement to comply

with vehicle’s OEM recommended

service intervals.

Melted ………………

A

……….. Required replacement.

Missing ……………..

C

………… Require replacement.

Restricted, affecting

performance …………

A

………… Require replacement.

Water-contaminated ……

A

…….. (1) Require replacement.

(1) – Further inspection required to determine cause.

AIR FILTER GASKETS

See AIR FILTER HOUSINGS AND GASKETS.

AIR FILTER HOUSINGS AND GASKETS

AIR FILTER HOUSING AND GASKET INSPECTION
Attaching hardware
Attaching hardware not

AIR FUEL RATIO SENSORS

AIR FUEL RATIO SENSOR INSPECTION
Condition Code Procedure
Attaching hardware
missing ……………. C ………. Require replacement of hardware.
Attaching hardware
threads damaged …….. A … Require repair or replacement of hardware.
Attaching hardware

threads stripped

(threads missing) ……

A

Require repair or replacement

of hardware.

Connector broken ……..

A

..

Require repair or replacement.

Connector (Weatherpack

type) leaking ……….

A

..

Require repair or replacement.

Connector melted ……..

A

………..

(1) Require repair or

replacement.

Connector missing …….

C

…………

Require replacement.

Contaminated …………

A

………..

(2) Require repair or

replacement.

Inoperative ………….

B

………..

(3) Require repair or

replacement. Further

inspection required.

Leaking ……………..

A

.. Require repair or

replacement.

Missing ……………..

C

………… Require

replacement.

Resistance out of

specification ……….

B

.. Require repair or

replacement.

Restricted, affecting
performance ………… A .. Require repair or replacement. Terminal broken ……… A .. Require repair or replacement. Terminal burned, affecting
performance ………… A ……….. (1) Require repair or replacement.
Terminal burned, not
affecting performance .. 2 .. Suggest repair or replacement. Terminal corroded,
affecting performance .. A .. Require repair or replacement. Terminal corroded, not
affecting performance .. 2 .. Suggest repair or replacement. Terminal loose, affecting
performance ………… B .. Require repair or replacement. Terminal loose, not
affecting performance .. 1 .. Suggest repair or replacement. Threads damaged ……… A .. Require repair or replacement. Threads stripped (threads
missing) …………… A ………… Require replacement. Wire lead conductors

exposed …………….

B

.. Require repair or

replacement.

Wire lead corroded ……

A

.. Require repair or

replacement.

Wire lead open ……….

A

.. Require repair or

replacement.

Wire lead shorted …….

A

.. Require repair or

replacement.

(1) – Determine cause and correct prior to repair or replacement of part.
(2) – Determine source of contamination, such as engine coolant, fuel, metal particles, or water. Require repair or replacement.
(3) – Inoperative includes intermittent operation or out of OEM specification. Some components may be serviceable; check for accepted cleaning procedure.

AIR INJECTION CONTROL SOLENOIDS

AIR INJECTION CONTROL SOLENOID INSPECTION
Condition Code Procedure
Attaching hardware
missing ……………. C ……… Require replacement of hardware.
Attaching hardware
threads damaged …….. A .. Require repair or replacement of hardware.
Attaching hardware threads stripped
(threads missing) …… A .. Require repair or replacement of hardware.
Connector broken …….. A . Require repair or replacement. Connector (Weatherpack
type) leaking ………. A . Require repair or replacement. Connector melted …….. A ………. (1) Require repair or replacement.
Connector missing ……. C ……….. Require replacement. Inoperative …………. B ………. (2) Require repair or replacement. Further
inspection required. Leaking …………….. A . Require repair or replacement. Missing …………….. C ……….. Require replacement. Resistance out of
specification ………. B . Require repair or replacement. Restricted, affecting
performance ………… A . Require repair or replacement. Terminal broken ……… A . Require repair or replacement. Terminal burned, affecting
performance ………… A ………. (1) Require repair or replacement.
Terminal burned, not
affecting performance .. 2 . Suggest repair or replacement. Terminal corroded,
affecting performance .. A . Require repair or replacement. Terminal corroded, not
affecting performance .. 2 . Suggest repair or replacement. Terminal loose, affecting
performance ………… B . Require repair or replacement. Terminal loose, not
affecting performance .. 1 . Suggest repair or replacement. Threads damaged ……… A . Require repair or replacement. Threads stripped (threads
missing) …………… A ……….. Require replacement. Wire lead conductors

exposed …………….

B

. Require repair or

replacement.

Wire lead corroded ……

A

. Require repair or

replacement.

Wire lead open ……….

A

. Require repair or

replacement.

Wire lead shorted …….

A

. Require repair or

replacement.

(1) – Determine cause and correct prior to repair or replacement of part.
(2) – Inoperative includes intermittent operation or out of OEM specification. Some components may be serviceable; check for accepted cleaning procedure.

AIR PLENUMS

AIR PLENUM INSPECTION
Condition Code Procedure
Integrated air or fuel control components
inoperative ………… A ……….. (1) Require repair or replacement.
Internal air or fuel components damaged,
affecting performance .. A … Require repair or replacement of component.
Internal air or fuel components damaged, not
affecting performance .. .. …….. No service suggested or required.
Internal air or fuel
components missing ….. C ………. Require replacement of component.
Leaking …………….. A .. Require repair or replacement. Restricted ………….. A .. Require repair or replacement. Threads damaged ……… A .. Require repair or replacement. Threads stripped (threads
missing) …………… A .. Require repair or replacement.
(1) – Inoperative includes intermittent operation or out of
OEM specification.

AIR PUMP BELTS

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

AIR PUMPS (ELECTRIC-DRIVEN)

AIR PUMP (ELECTRIC-DRIVEN) INSPECTION
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.

Threads damaged ………

A

..

Require

repair

or

replacement.

Threads stripped (threads

missing) ……………

A

..

Require

repair

or

replacement.

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

AIR TUBES

See AIR DUCTS AND TUBES.

ASPIRATOR, CHECK AND DECEL VALVES

ASPIRATOR, CHECK AND DECEL VALVE INSPECTION
Attaching hardware
Attaching hardware not
of hardware. Inoperative …………. A ……….. (1) Require repair or replacement.
Leaking …………….. A ………… Require replacement. Melted, affecting
performance ………… A ………… Require replacement. Melted, not affecting
performance ………… .. …….. No service suggested or required.
Missing …………….. C ………… Require replacement. Threads damaged ……… A .. Require repair or replacement. Threads stripped (threads
missing) …………… A .. Require repair or replacement.
(1) – Inoperative includes intermittent operation or out of OEM specification.

BAFFLES

See SHROUDS, BAFFLES AND DEFLECTORS.

BALLAST PRIMARY SUPPLY RESISTOR WIRES

See BALLAST RESISTORS AND PRIMARY SUPPLY RESISTOR WIRES.

BALLAST RESISTORS AND PRIMARY SUPPLY RESISTOR WIRES BALLAST RESISTOR AND PRIMARY SUPPLY RESISTOR WIRE INSPECTION Condition Code Procedure

Attaching hardware
broken …………….. A … Require repair or replacement of hardware.
Attaching hardware
missing ……………. C ………. Require replacement of hardware.
Attaching hardware not
functioning ………… A … Require repair or replacement

of hardware.

Conductor exposed

…….

A

………… Require replacement.

Connector broken

……..

A

.. Require repair or replacement.

Connector melted

……..

A

……….. (1) Require repair or

replacement.

Connector missing

…….

C

………… Require replacement.

Inoperative ………….

A

…….. (2) Require replacement.

Insulation overheated …

A

………… Require replacement.

Terminal broken ………

A

.. Require

repair or replacement.

Terminal burned, affecting

performance …………

A

………..

(1) Require repair or

replacement.

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

BAROMETRIC PRESSURE SENSORS

BAROMETRIC PRESSURE SENSOR INSPECTION
Condition Code Procedure
Attaching hardware
missing ……………. C ………. Require replacement of hardware.
Attaching hardware
threads damaged …….. A … Require repair or replacement of hardware.
Attaching hardware

threads stripped

(threads missing) ……

A

Require repair or replacement

of hardware.

Connector broken ……..

A

Require repair or replacement.

Connector (Weatherpack

type) leaking ……….

A

..

Require repair or replacement.

Connector melted ……..

A

………..

(1) Require repair or

replacement.

Connector missing …….

C

…………

Require replacement.

Contaminated …………

A

………..

(2) Require repair or

replacement.

Inoperative ………….

B

………..

(3) Require repair or

replacement. Further

inspection required.

Leaking ……………..

A

.. Require repair or

replacement.

Missing ……………..

C

………… Require

replacement.

Resistance out of

specification ……….

B

.. Require repair or

replacement.

Restricted, affecting
performance ………… A .. Require repair or replacement. Terminal broken ……… A .. Require repair or replacement. Terminal burned, affecting
performance ………… A ……….. (1) Require repair or replacement.
Terminal burned, not
affecting performance .. 2 .. Suggest repair or replacement. Terminal corroded,
affecting performance .. A .. Require repair or replacement. Terminal corroded, not
affecting performance .. 2 .. Suggest repair or replacement. Terminal loose, affecting
performance ………… B .. Require repair or replacement. Terminal loose, not
affecting performance .. 1 .. Suggest repair or replacement. Threads damaged ……… A .. Require repair or replacement. Threads stripped (threads
missing) …………… A ………… Require replacement. Wire lead conductors

exposed …………….

B

.. Require repair or

replacement.

Wire lead corroded ……

A

.. Require repair or

replacement.

Wire lead open ……….

A

.. Require repair or

replacement.

Wire lead shorted …….

A

.. Require repair or

replacement.

(1) – Determine cause and correct prior to repair or
replacement of part.
(2) – Determine source of contamination, such as engine coolant, fuel, metal particles, or water. Require repair or replacement.
(3) – Inoperative includes intermittent operation or out of OEM specification. Some components may be serviceable; check for accepted cleaning procedure.

BATTERIES

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

See BATTERY CABLES, WIRES AND CONNECTORS.

BATTERY TRAYS AND HOLD DOWN HARDWARE

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

BATTERY WIRES

See BATTERY CABLES, WIRES AND CONNECTORS.

BELT-DRIVEN AIR PUMPS

BELT-DRIVEN AIR PUMP INSPECTION
Condition Code Procedure
Attaching hardware
broken …………….. A … Require repair or replacement of hardware.
Attaching hardware
missing ……………. C ………. Require replacement of hardware.
Attaching hardware not

functioning …………

A

… Require repair or replacement

of hardware.

Inoperative ………….

A

…….. (1) Require replacement.

Leaking ……………..

A

………… Require replacement.

Missing ……………..

C

………… Require replacement.

Noisy ……………….

2

………… Suggest replacement.

Pulley alignment

incorrect …………..

B

.. Require repair or replacement.

Pulley bent ………….

A

………… Require replacement.

Pulley cracked ……….

A

………… Require replacement.

Pulley loose …………

A

.. Require repair or replacement.

Pulley missing ……….

C

………… Require replacement.

Threads damaged ………

A

.. Require repair or replacement.

Threads stripped (threads

missing) …………… A .. Require repair or replacement.
(1) – Inoperative includes intermittent operation or out of
OEM specification.

BELT IDLER ASSEMBLIES (ACCESSORY AND CAM BELTS)

BELT IDLER ASSEMBLY (ACCESSORY AND CAM BELT) INSPECTION
Condition Code Procedure
Alignment incorrect ….. B .. Require repair or replacement. Attaching hardware
broken …………….. A … Require repair or replacement of hardware.
Attaching hardware
missing ……………. C ………. Require replacement of hardware.
Attaching hardware not

functioning …………

A

… Require repair or replacement

of hardware.

Bearings worn ………..

1

………… Suggest replacement.

Cracked ……………..

2

………… Suggest replacement.

Missing ……………..

C

………… Require replacement.

Noisy ……………….

2

………… Suggest replacement.

Seized ………………

A

.. Require repair or replacement.

BELT TENSIONERS (ACCESSORY AND CAM BELTS)

BELT TENSIONER (ACCESSORY AND CAM BELT) INSPECTION
Condition Code Procedure
Alignment incorrect ….. B .. Require repair or replacement. Attaching hardware
broken …………….. A .. Require repair or replacement of hardware.
Attaching hardware
missing ……………. C ………. Require replacement of hardware.
Attaching hardware not
functioning ………… A … Require repair or replacement of hardware.
Bearings worn ……….. 1 ………… Suggest replacement. Belt tension incorrect .. B … Require adjustment or repair. Cracked …………….. 2 ………… Suggest replacement. Missing …………….. C ………… Require replacement. Noisy ………………. 2 ………… Suggest replacement. Pulley damaged, affecting
belt life ………….. A ………… Require replacement. Seized ……………… A .. Require repair or replacement.

BOOST CONTROL MECHANISMS

See WASTE GATES AND BOOST CONTROL MECHANISMS.

CAMSHAFT POSITION SENSORS

CAMSHAFT POSITION SENSOR INSPECTION
Condition Code Procedure
Attaching hardware
missing ……………. C ………. Require replacement of hardware.
Attaching hardware threads
damaged ……………. A … Require repair or replacement of hardware.
Attaching hardware

threads stripped

(threads missing) ……

A

Require repair or replacement

of hardware.

Connector broken ……..

A

..

Require repair or replacement.

Connector (Weatherpack

type) leaking ……….

A

..

Require repair or replacement.

Connector melted ……..

A

………..

(1) Require repair or

replacement.

Connector missing …….

C

…………

Require replacement.

Contaminated …………

A

………..

(2) Require repair or

replacement.

Inoperative ………….

B

………..

(3) Require repair or

replacement. Further

inspection required.

Leaking ……………..

A

.. Require r

epair or replacement.

Missing ……………..

C

…………

Require replacement.

Terminal broken ………

A

.. Require

repair or replacement.

Terminal burned, affecting

performance …………

A

………..

(1) Require repair or

replacement.

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

affecting performance

..

A

..

Require

repair

or

replacement.

Terminal corroded, not

affecting performance

..

2

..

Suggest

repair

or

replacement.

Terminal loose, affecting

performance …………

B

..

Require

repair

or

replacement.

Terminal loose, not

affecting performance ..

1

..

Suggest

repair

or

replacement.

Wire lead conductors

exposed …………….

B

..

Require

repair

or

replacement.

Wire lead corroded ……

A

..

Require

repair

or

replacement.

Wire lead open ……….

A

..

Require

repair

or

replacement.

Wire lead shorted …….

A

..

Require

repair

or

replacement.

(1) – Determine cause and correct prior to repair or replacement of part.
(2) – Determine source of contamination, such as engine coolant, fuel, metal particles, or water. Require repair or replacement.
(3) – Inoperative includes intermittent operation or out of OEM specification. Some components may be serviceable; check for accepted cleaning procedure.

CARBURETORS AND CHOKES

NOTE: Proper operation of a carburetor includes the ability to control air/fuel mixtures during all phases or driving operation to comply with all federal and local emissions standards. Adjustments are to be considered repairs.
CARBURETOR AND CHOKE INSPECTION
Condition
Code Procedure
Air/fuel control
incorrect ………….. B .. Require repair or replacement. Application incorrect … B .. Require repair or replacement. Attaching hardware
broken …………….. A … Require repair or replacement of hardware.
Attaching hardware
missing ……………. C ………. Require replacement of hardware.
Attaching hardware not
functioning ………… A … Require repair or replacement of hardware.
Components binding …… A .. Require repair or replacement. Components damaged,
affecting operation or
performance ………… A .. Require repair or replacement. Components missing …… C ………. Require replacement of components.
Contaminated ………… A ……….. (1) Require repair or replacement. Further inspection required.
Controlling linkages
binding ……………. A … Require repair or replacement of linkage.
Leaking …………….. A .. Require repair or replacement. Mechanical operation
incorrect ………….. B .. Require repair or replacement. Operating incorrectly … B .. Require repair or replacement.
(1) – Some components may be serviceable; check for accepted cleaning procedure. Determine source of contamination, such as engine coolant, fuel, metal particles, or water. Require repair or replacement.

CASTING CORE PLUGS AND EXPANSION PLUGS

CASTING CORE PLUG AND EXPANSION PLUG INSPECTION
Condition Code Procedure
Leaking …………….. A ………… Require replacement. Material type
incorrect ………….. 2 ………… Suggest replacement.

CHARGE AIR COOLERS “INTERCOOLERS” (CAC)

CHARGE AIR COOLER “INTERCOOLER” (CAC) INSPECTION
Condition Code Procedure
Air-to-air intercooler leaking, affecting boost
performance ………… A .. Require repair or replacement. Attaching hardware
broken …………….. A … Require repair or replacement of hardware.
Attaching hardware
missing ……………. C ………. Require replacement of hardware.
Attaching hardware not
functioning ………… A … Require repair or replacement of hardware.
Leaking coolant ……… A .. Require repair or replacement. Missing …………….. C ………… Require replacement. Restricted, affecting
performance ………… A .. Require repair or replacement.

CHECK VALVES

See ASPIRATOR, CHECK AND DECEL VALVES.

CHOKES

See CARBURETORS AND CHOKES.

CLUTCH PEDAL POSITION SWITCHES

CLUTCH PEDAL POSITION SWITCH INSPECTION
Condition Code Procedure
Attaching hardware
missing ……………. C ………. Require replacement of hardware.
Attaching hardware threads
damaged ……………. A … Require repair or replacement of hardware.
Attaching hardware threads stripped
(threads missing) …… A … Require repair or replacement of hardware.
Connector broken …….. A .. Require repair or replacement. Connector melted …….. A ……….. (1) Require repair or replacement.
Connector missing ……. C ………… Require replacement. Inoperative …………. B ……….. (2) Require repair or replacement. Further
inspection required. Missing …………….. C ………… Require replacement. Resistance out of
specification ………. B .. Require repair or replacement. Terminal broken ……… A .. Require repair or replacement. Terminal burned, affecting
performance ………… A ……….. (1) Require repair or replacement.
Terminal burned, not
affecting performance .. 2 .. Suggest repair or replacement. Terminal corroded,
affecting performance .. A .. Require repair or replacement. Terminal corroded, not
affecting performance .. 2 .. Suggest repair or replacement. Terminal loose, affecting
performance ………… B .. Require repair or replacement. Terminal loose, not
affecting performance .. 1 .. Suggest repair or replacement. Threads damaged ……… A .. Require repair or replacement. Threads stripped (threads
missing) …………… A ………… Require replacement. Wire lead conductors
exposed ……………. B .. Require repair or replacement. Wire lead corroded …… A .. Require repair or replacement. Wire lead open ………. A .. Require repair or replacement. Wire lead shorted ……. A .. Require repair or replacement.
(1) – Determine cause and correct prior to repair or replacement of part.
(2) – Inoperative includes intermittent operation or out of OEM
specification. Some components may be serviceable;
check for accepted cleaning procedure.

COLD START INJECTORS

See FUEL AND COLD START INJECTORS.

CONNECTORS

See WIRING HARNESSES AND CONNECTORS.

COOLANT

COOLANT INSPECTION
Condition Code Procedure

Acidity (pH)

incorrect ..

1

……….. Suggest correction or

replacement.

Contaminated

…………

B

…… (1) Require replacement or

recycling. Further inspection

required.

Level low ……………

B

… (2) Require filling to proper

level.

Maintenance intervals …

3

…….. (3) Suggest replacement.

Mixture incorrect ……. B ……….. Require correction or replacement.
Type incorrect ………. B ………… Require replacement.
(1) – Determine source of contamination and require correction prior to coolant replacement.
(2) – Determine source of incorrect level and suggest repair. (3) – The system should be drained and/or flushed and
refilled with correct coolant according to OEM
recommended service interval and procedures.

COOLANT RECOVERY TANKS

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

functioning …………

A

.. Require repair or replacement

of hardware.

Leaking ……………..

A

. Require repair or replacement.

Missing (if original
equipment) …………. C ……….. Require replacement.

COOLING FAN MOTOR MODULES

See COOLING FAN MOTOR RELAYS AND MODULES.

COOLING FAN MOTOR RELAYS AND MODULES

COOLING FAN MOTOR RELAY AND MODULE INSPECTION
Condition Code Procedure
Attaching hardware
broken …………….. A … Require repair or replacement of hardware.
Attaching hardware
missing ……………. C ………. Require replacement of hardware.
Attaching hardware not
functioning ………… A … Require repair or replacement of hardware.
Connector broken …….. A .. Require repair or replacement. Connector (Weatherpack
type) leaking ………. A .. Require repair or replacement. Connector melted …….. A ……….. (1) Require repair or replacement.
Connector missing ……. C ………… Require replacement. Housing cracked ……… 2 .. Suggest repair or replacement. Malfunctioning ………. A ……….. (2) Require repair or replacement.
Missing …………….. C ………… Require replacement. Terminal broken ……… A .. Require repair or replacement. Terminal burned, affecting
performance ………… A ……….. (1) Require repair or replacement.
Terminal burned, not
affecting performance .. 2 .. Suggest repair or replacement. Terminal corroded,

affecting performance

..

A

..

Require

repair

or

replacement.

Terminal corroded, not

affecting performance

..

2

..

Suggest

repair

or

replacement.

Terminal loose, affecting

performance …………

B

..

Require

repair

or

replacement.

Terminal loose, not

affecting performance ..

1

..

Suggest

repair

or

replacement.

Wire lead conductors

exposed …………….

B

..

Require

repair

or

replacement.

Wire lead corroded ……

A

..

Require

repair

or

replacement.

Wire lead open ……….

A

..

Require

repair

or

replacement.

Wire lead shorted …….

A

..

Require

repair

or

replacement.

(1) – Determine cause and correct prior to repair or replacement of part.
(2) – Includes inoperative, intermittent operation, failure to perform all functions, or out of OEM specification.

COOLING FAN MOTOR RESISTORS

COOLING FAN MOTOR RESISTOR INSPECTION
Condition Code Procedure

Application incorrect …

B

………… Require replacement.

Attaching hardware

broken ……………..

A

… Require repair or replacement

of hardware.

Attaching hardware
missing ……………. C ………. Require replacement of hardware.
Attaching hardware not
functioning ………… A … Require repair or replacement of hardware.
Connector broken …….. A .. Require repair or replacement. Connector (Weatherpack
type) leaking ………. A .. Require repair or replacement. Connector melted …….. A ……….. (1) Require repair or replacement.
Connector missing ……. C ………… Require replacement. Missing …………….. C ………… Require replacement. Open ……………….. A ………… Require replacement. Resistance out of
specification ………. B .. Require repair or replacement. Shorted …………….. A ………… Require replacement. Terminal broken ……… A .. Require repair or replacement. Terminal burned, affecting
performance ………… A ……….. (1) Require repair or replacement.
Terminal burned, not
affecting performance … 2 . Suggest repair or replacement. Terminal corroded,
affecting performance … A . Require repair or replacement. Terminal corroded, not
affecting performance … 2 . Suggest repair or replacement. Terminal loose, affecting
performance …………. B . Require repair or replacement. Terminal loose, not
affecting performance … 1 . Suggest repair or replacement.
(1) – Determine cause and correct prior to repair or replacement of part.

COOLING FAN MOTOR SENSORS AND SWITCHES

COOLING FAN MOTOR SENSOR AND SWITCH INSPECTION
Condition Code Procedure
Attaching hardware
missing ……………. C ………. Require replacement of hardware.
Attaching hardware threads
damaged ……………. A … Require repair or replacement of hardware.
Attaching hardware threads stripped
(threads missing) …… A … Require repair or replacement of hardware.
Connector broken …….. A .. Require repair or replacement.

Connector melted ……..

A

……….. (1) Require repair or

replacement.

Connector missing …….

C

………… Require replacement.

Contaminated …………

A

……….. (2) Require repair or

replacement.

Inoperative ………….

B

……….. (3) Require repair or

replacement. Further

inspection required.

Leaking ……………..

A

.. Require repair or replacement.

Missing ……………..

C

………… Require replacement.

Resistance out of

specification ……….

B

.. Require repair or replacement.

Terminal broken ………

A

.. Require repair or replacement.

Terminal burned, affecting

performance …………

A

……….. (1) Require repair or

replacement.

Terminal burned, not
affecting performance .. 2 .. Suggest repair or replacement. Terminal corroded,
affecting performance .. A .. Require repair or replacement. Terminal corroded, not
affecting performance .. 2 .. Suggest repair or replacement. Terminal loose, affecting
performance ………… B .. Require repair or replacement. Terminal loose, not
affecting performance .. 1 .. Suggest repair or replacement. Threads damaged ……… A .. Require repair or replacement. Threads stripped (threads
missing) …………… A ………… Require replacement. Wire lead conductors

exposed …………….

B

.. Require repair or

replacement.

Wire lead corroded ……

A

.. Require repair or

replacement.

Wire lead open ……….

A

.. Require repair or

replacement.

Wire lead shorted …….

A

.. Require repair or

replacement.

(1) – Determine cause and correct prior to repair or replacement of part.
(2) – Determine source of contamination, such as engine coolant, fuel, metal particles, or water. Require repair or replacement.
(3) – Inoperative includes intermittent operation or out of OEM specification. Some components may be serviceable; check for accepted cleaning procedure.

COOLING FAN MOTOR SWITCHES

See COOLING FAN MOTOR SENSORS AND SWITCHES.

COOLING FAN MOTORS

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

functioning …………

A

..

Require repair or replacement

of hardware.

Connector broken ……..

A

.

Require repair or replacement.

Connector (Weatherpack

type) leaking ……….

A

.

Require repair or replacement.

Connector melted ……..

A

………. (1) Require repair or

replacement.

Connector missing …….

C

……….. Require replacement.

Hydraulic fan motor

leaking …………….

A

. Require repair or replacement.

Inoperative ………….

A

……. (2) Require replacement.

Missing ……………..

C

……….. Require replacement.

Noisy ……………….

2

……….. Suggest replacement.

Rotation incorrect for

application …………

B

. Require

repair or replacement.

Terminal broken ………

A

. Require

repair or replacement.

Terminal burned, affecting

performance …………

A

……….

(1) Require repair or

replacement.

Terminal burned, not
affecting performance .. 2 . Suggest repair or replacement. Terminal corroded,
affecting performance .. A . Require repair or replacement. Terminal corroded, not
affecting performance .. 2 . Suggest repair or replacement. Terminal loose, affecting
performance ………… B . Require repair or replacement. Terminal loose, not

affecting performance ..

1

. Suggest repair or

replacement.

Vibration ……………

1

……….. Suggest

replacement.

Wire lead conductors

exposed …………….

B

. Require repair or

replacement.

Wire lead corroded ……

A

. Require repair or

replacement.

Wire lead open ……….

A

. Require repair or

replacement.

Wire lead shorted …….

A

. Require repair or

replacement.

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

CRANKSHAFT POSITION SENSORS

CRANKSHAFT POSITION SENSOR INSPECTION
Condition Code Procedure
Attaching hardware
missing ……………. C ………. Require replacement of hardware.
Attaching hardware
threads damaged …….. A … Require repair or replacement of hardware.
Attaching hardware

threads stripped

(threads missing) ……

A

… Require repair or replacement

of hardware.

Connector broken ……..

A

.. Require repair or replacement.

Connector (Weatherpack

type) leaking ……….

A

.. Require repair or replacement.

Connector melted ……..

A

……….. (1) Require repair or

replacement.

Connector missing …….

C

………… Require replacement.

Contaminated …………

A

.. Require repair or replacement.

Inoperative ………….

B

.. Require repair or replacement.

Further inspection required.

Leaking ……………..

A

.. Require repair or replacement.

Missing …………….. C ………… Require replacement. Resistance out of
specification ………. B .. Require repair or replacement. Terminal broken ……… A .. Require repair or replacement. Terminal burned, affecting
performance ………… A ……….. (1) Require repair or replacement.
Terminal burned, not
affecting performance .. 2 .. Suggest repair or replacement. Terminal corroded,
affecting performance .. A .. Require repair or replacement. Terminal corroded, not
affecting performance .. 2 .. Suggest repair or replacement. Terminal loose, affecting
performance ………… B .. Require repair or replacement. Terminal loose, not
affecting performance .. 1 .. Suggest repair or replacement. Threads damaged ……… A .. Require repair or replacement. Threads stripped (threads
missing) …………… A ………… Require replacement. Wire lead conductors

exposed …………….

B

.. Require repair or

replacement.

Wire lead corroded ……

A

.. Require repair or

replacement.

Wire lead open ……….

A

.. Require repair or

replacement.

Wire lead shorted …….

A

.. Require repair or

replacement.

(1) – Determine cause and correct prior to repair or replacement of part.
(2) – Determine source of contamination, such as engine coolant, fuel, metal particles, or water. Require repair or replacement.
(3) – Inoperative includes intermittent operation or out of OEM specification. Some components may be serviceable; check for accepted cleaning procedure.

DECEL VALVES

See ASPIRATOR, CHECK AND DECEL VALVES.

DEFLECTORS

See SHROUDS, BAFFLES AND DEFLECTORS.

DIP STICKS AND TUBES

DIP STICK AND TUBE INSPECTION
Condition Code Procedure
Application incorrect … B ………… Require replacement. Bent ……………….. 2 .. Suggest repair or replacement. Broken, affecting
performance (for example,
fuel mixture) ………. A .. Require repair or replacement. Broken, not affecting
performance ………… 2 .. Suggest repair or replacement. Leaking, affecting
performance (for example,
fuel mixture) ………. A .. Require repair or replacement. Leaking, not affecting

Requirereplacement.

performance …………

2

..

Suggest

repair or

replacement.

Missing

C

DIP STICK TUBES

See DIP STICKS AND TUBES.

DISTRIBUTOR ADVANCES AND RETARDERS (MECHANICAL AND VACUUM)

DISTRIBUTOR ADVANCE AND RETARDER (MECHANICAL AND VACUUM) INSPECTION
Attaching hardware
Attaching hardware not
(1) – Inoperative includes intermittent operation.

DISTRIBUTOR BOOTS AND SHIELDS

DISTRIBUTOR BOOT AND SHIELD INSPECTION
Attaching hardware
Attaching hardware not

DISTRIBUTOR CAPS

DISTRIBUTOR CAP INSPECTION
Condition Code Procedure
Application incorrect … B ………… Require replacement. Arcing ……………… A ………… Require replacement. Attaching hardware
broken …………….. A … Require repair or replacement of hardware.
Attaching hardware
missing ……………. C ………. Require replacement of hardware.
Attaching hardware not
functioning ………… A … Require repair or replacement of hardware.
Burned ……………… A ………… Require replacement. Carbon button missing … A ………… Require replacement. Carbon button worn,
affecting performance .. A ………… Require replacement. Carbon button worn, not
affecting performance .. 1 ………… Suggest replacement. Carbon-tracked ………. A ………… Require replacement. Cracked …………….. A ………… Require replacement. Loose ………………. 2 .. Suggest repair or replacement. Terminal broken ……… A .. Require repair or replacement. Terminal burned, affecting
performance ………… A ……….. (1) Require repair or replacement.
Terminal burned, not
affecting performance .. 2 .. Suggest repair or replacement. Terminal corroded,
affecting performance .. A .. Require repair or replacement. Terminal corroded, not
affecting performance .. 2 .. Suggest repair or replacement. Terminal eroded, affecting
performance ………… A .. Require repair or replacement. Terminal eroded, not
affecting performance .. .. …….. No service suggested or required.
Terminal loose, affecting
performance ………… B .. Require repair or replacement. Terminal loose, not
affecting performance .. 1 .. Suggest repair or replacement.
(1) – Determine cause and correct prior to repair or replacement of part.

DISTRIBUTOR RETARDERS (MECHANICAL AND VACUUM)

See
DISTRIBUTOR ADVANCES AND RETARDERS (MECHANICAL AND VACUUM).

DISTRIBUTOR ROTORS

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

functioning …………

A

… Require repair or replacement

of hardware.

Carbon-tracked ……….

A

………… Require replacement.

Contact burned ……….

A

………… Require replacement.

Corroded …………….

1

………… Suggest replacement.

Eroded ……………… 1 ………… Suggest replacement. Loose ………………. A .. Require repair or replacement. Out of specification …. B ………… Require replacement.

DISTRIBUTOR SHIELDS

See DISTRIBUTOR BOOTS AND SHIELDS.

DISTRIBUTORS

DISTRIBUTOR INSPECTION
Condition Code Procedure
Attaching hardware
broken …………….. A … Require repair or replacement of hardware.
Attaching hardware
missing ……………. C ………. Require replacement of hardware.
Attaching hardware not
functioning ………… A … Require repair or replacement of hardware.
Bushings worn, affecting
performance ………… A .. Require repair or replacement. Bushings worn, not
affecting performance .. 1 .. Suggest repair or replacement. Cam lobes worn, affecting
performance ………… A .. Require repair or replacement. Cam lobes worn, not
affecting performance .. 1 .. Suggest repair or replacement. Gear broken …………. A .. Require repair or replacement. Gear worn, affecting
performance ………… A ………… Require replacement. Gear worn, not affecting
performance ………… .. …….. No service suggested or required.
Integrated pickup triggering device
loose ……………… A .. Require repair or replacement. Integrated pickup
triggering device
magnetism incorrect …. A .. Require repair or replacement. Leaking oil internally .. A .. Require repair or replacement. Noisy ………………. 2 .. Suggest repair or replacement. Pickup triggering device
(reluctor) broken …… A .. Require repair or replacement. Pickup triggering device
(reluctor) loose ……. A .. Require repair or replacement. Pickup triggering device
(reluctor) weak …….. A .. Require repair or replacement. Reluctor (pickup
triggering device)
broken …………….. A .. Require repair or replacement. Reluctor (pickup
triggering device)
loose ……………… A .. Require repair or replacement. Reluctor (pickup

triggering device)

weak ……………….

A

.. Require repair or

replacement.

Shaft bent …………..

A

………… Require

replacement.

Thrust washer broken ….

A

.. Require repair or

replacement.

Thrust washer missing …

C

..

Require

repair

or

replacement.

Thrust washer worn,

affecting performance ..

A

..

Require

repair

or

replacement.

Thrust washer worn, not
affecting performance .. 1 .. Suggest repair or replacement.

EARLY FUEL EVAPORATION VALVES (HEAT RISER ASSEMBLIES)

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

Broken ………………

A

. Require replacement of affected

parts.

Diaphragm inoperative …

A

………. (1) Further inspection

required.

Leaking ……………..

A

.. Require repair or replacement.

Noisy

……………….

2

.. Suggest repair or replacement.

Seized

………………

A

. Require replacement of affected

parts.

Spring

broken ………..

B

………. Require replacement of

spring(s).

Spring

inoperative ……

A

…… (2) Require replacement of

spring(s).

(1) – Inoperative includes intermittent operation or out of OEM specification. If the inoperative diaphragm is separate from the heat riser, then require replacement of the inoperative diaphragm. If the inoperative diaphragm is part of the heat riser, then replace the heat riser.
(2) – Inoperative includes intermittent operation or out of OEM
specification.

EGR COOLERS

See EGR PLATES AND COOLERS.

EGR EXHAUST MANIFOLD PASSAGES

See EGR INTAKE AND EXHAUST MANIFOLD PASSAGES.

EGR INTAKE AND EXHAUST MANIFOLD PASSAGES

EGR INTAKE AND EXHAUST MANIFOLD PASSAGE INSPECTION
Condition Code Procedure
Leaking …………….. A .. Require repair or replacement. Restricted, affecting
performance ………… A .. Require repair or replacement.

EGR PLATES AND COOLERS

EGR PLATE AND COOLER INSPECTION
Condition Code Procedure
Leaking …………….. A .. Require repair or replacement.
Missing …………….. C ………… Require replacement. Restricted, affecting
performance ………… A .. Require repair or replacement.

ELECTRONIC SPARK CONTROL MODULES

ELECTRONIC SPARK CONTROL MODULE INSPECTION
Condition Code Procedure
Application incorrect … B ………… Require replacement. Attaching hardware
missing ……………. C ………. Require replacement of hardware.
Attaching hardware
threads damaged …….. A … Require repair or replacement of hardware.
Attaching hardware threads stripped
(threads missing) …… A … Require repair or replacement of hardware.
Connector broken …….. A .. Require repair or replacement. Connector (Weatherpack
type) leaking ………. A .. Require repair or replacement. Connector melted …….. A ……….. (1) Require repair or replacement.
Connector missing ……. A …………….. Require repair. Contaminated ………… A ……….. (2) Require repair or replacement.
Leaking …………….. A .. Require repair or replacement. Malfunctioning ………. A ……….. (3) Require repair or replacement.
Missing …………….. C ………… Require replacement. Terminal broken ……… A .. Require repair or replacement. Terminal burned, affecting
performance ………… A ……….. (1) Require repair or replacement.
Terminal burned, not
affecting performance .. 2 .. Suggest repair or replacement. Terminal corroded,
affecting performance .. A .. Require repair or replacement. Terminal corroded, not
affecting performance .. 2 .. Suggest repair or replacement. Terminal loose, affecting
performance ………… B .. Require repair or replacement. Terminal loose, not
affecting performance .. 1 .. Suggest repair or replacement. Threads damaged ……… A .. Require repair or replacement. Threads stripped (threads
missing) …………… A ………… Require replacement. Wire lead conductors

exposed …………….

B

.. Require repair or

replacement.

Wire lead corroded ……

A

.. Require repair or

replacement.

Wire lead open ……….

A

.. Require repair or

replacement.

Wire lead shorted …….

A

.. Require repair or

replacement.

(1) – Determine cause and correct prior to repair or replacement of part.
(2) – Determine source of contamination, such as engine coolant, fuel, metal particles, or water. Require repair or replacement of source.
(3) – Includes inoperative, intermittent operation, failure to
perform all functions, or out of OEM specification.

ELECTRONIC TRANSMISSION CONTROL DEVICES

ELECTRONIC TRANSMISSION CONTROL DEVICE INSPECTION
Condition Code Procedure
Attaching hardware
missing ……………. C ………. Require replacement of hardware.
Attaching hardware
threads damaged …….. A … Require repair or replacement of hardware.
Attaching hardware threads stripped
(threads missing) …… A … Require repair or replacement of hardware.
Connector broken …….. A .. Require repair or replacement. Connector (Weatherpack
type) leaking ………. A .. Require repair or replacement. Connector melted …….. A ……….. (1) Require repair or replacement.
Connector missing ……. C ………… Require replacement. Contaminated ………… A ……….. (2) Require repair or replacement.
Leaking …………….. A .. Require repair or replacement. Malfunctioning ………. A ……….. (3) Require repair or replacement.
Missing …………….. C ………… Require replacement. Resistance out of
specification ………. B .. Require repair or replacement. Restricted, affecting
performance ………… A .. Require repair or replacement. Terminal broken ……… A .. Require repair or replacement. Terminal burned, affecting
performance ………… A ……….. (1) Require repair or replacement.
Terminal burned, not
affecting performance .. 2 .. Suggest repair or replacement. Terminal corroded,
affecting performance .. A .. Require repair or replacement. Terminal corroded, not
affecting performance .. 2 .. Suggest repair or replacement. Terminal loose, affecting
performance ………… B .. Require repair or replacement. Terminal loose, not
affecting performance .. 1 .. Suggest repair or replacement. Threads damaged ……… A .. Require repair or replacement. Threads stripped (threads
missing) …………… A ………… Require replacement. Wire lead conductors

exposed …………….

B

.. Require repair or

replacement.

Wire lead corroded ……

A

.. Require repair or

replacement.

Wire lead open ……….

A

.. Require repair or

replacement.

Wire lead shorted …….

A

.. Require repair or

replacement.

(1) – Determine cause and correct prior to repair or replacement of part.
(2) – Determine source of contamination, such as engine coolant, fuel, metal particles, or water. Require repair or replacement.
(3) – Includes inoperative, intermittent operation, failure to perform all functions, or out of OEM specification.

ELECTRONIC TRANSMISSION FEEDBACK DEVICES

ELECTRONIC TRANSMISSION FEEDBACK DEVICE INSPECTION
Condition Code Procedure
Attaching hardware
missing ……………. C ………. Require replacement of hardware.
Attaching hardware
threads damaged …….. A … Require repair or replacement of hardware.
Attaching hardware

threads stripped

(threads missing) ……

A

..

Require repair or replacement

of hardware.

Connector broken ……..

A

..

Require repair or replacement.

Connector (Weatherpack

type) leaking ……….

A

..

Require repair or replacement.

Connector melted ……..

A

………..

(1) Require repair or

replacement.

Connector missing …….

C

…………

Require replacement.

Contaminated …………

A

………..

(2) Require repair or

replacement.

Inoperative ………….

B

………..

(3) Require repair or

replacement. Further

inspection required.

Leaking ……………..

A

.. Require repair or

replacement.

Missing ……………..

C

………… Require

replacement.

Resistance out of

specification ……….

B

.. Require repair or

replacement.

Restricted, affecting
performance ………… A .. Require repair or replacement. Terminal broken ……… A .. Require repair or replacement. Terminal burned, affecting
performance ………… A ……….. (1) Require repair or replacement.
Terminal burned, not
affecting performance .. 2 .. Suggest repair or replacement. Terminal corroded,
affecting performance .. A .. Require repair or replacement. Terminal corroded, not
affecting performance .. 2 .. Suggest repair or replacement. Terminal loose, affecting
performance ………… B .. Require repair or replacement. Terminal loose, not
affecting performance .. 1 .. Suggest repair or replacement. Threads damaged ……… A .. Require repair or replacement. Threads stripped (threads
missing) …………… A ………… Require replacement. Wire lead conductors

exposed …………….

B

.. Require repair or

replacement.

Wire lead corroded ……

A

.. Require repair or

replacement.

Wire lead open ……….

A

.. Require repair or

replacement.

Wire lead shorted …….

A

.. Require repair or

replacement.

(1) – Determine cause and correct prior to repair or replacement of part.
(2) – Determine source of contamination, such as engine coolant,
fuel, metal particles, or water. Require repair or replacement.
(3) – Inoperative includes intermittent operation or out of OEM specification. Some components may be serviceable; check for accepted cleaning procedure.

ENGINE COOLANT TEMPERATURE SENSORS

ENGINE COOLANT TEMPERATURE SENSOR INSPECTION
Condition Code Procedure
Attaching hardware
missing ……………. C ………. Require replacement of hardware.
Attaching hardware
threads damaged …….. A … Require repair or replacement of hardware.
Attaching hardware

threads stripped

(threads missing) ……

A

Require repair or replacement

of hardware.

Connector broken ……..

A

..

Require repair or replacement.

Connector (Weatherpack

type) leaking ……….

A

..

Require repair or replacement.

Connector melted ……..

A

………..

(1) Require repair or

replacement.

Connector missing …….

C

…………

Require replacement.

Contaminated …………

A

………..

(2) Require repair or

replacement.

Inoperative ………….

B

………..

(3) Require repair or

replacement. Further

inspection required.

Leaking ……………..

A

.. Require repair or

replacement.

Missing ……………..

C

………… Require

replacement.

Resistance out of

specification ……….

B

.. Require repair or

replacement.

Restricted, affecting
performance ………… A .. Require repair or replacement. Terminal broken ……… A .. Require repair or replacement. Terminal burned, affecting
performance ………… A ……….. (1) Require repair or replacement.
Terminal burned, not
affecting performance .. 2 .. Suggest repair or replacement. Terminal corroded,
affecting performance .. A .. Require repair or replacement. Terminal corroded, not
affecting performance .. 2 .. Suggest repair or replacement. Terminal loose, affecting
performance ………… B .. Require repair or replacement. Terminal loose, not
affecting performance .. 1 .. Suggest repair or replacement. Threads damaged ……… A .. Require repair or replacement. Threads stripped (threads
missing) …………… A ………… Require replacement. Wire lead conductors

exposed …………….

B

.. Require repair or

replacement.

Wire lead corroded ……

A

.. Require repair or

replacement.

Wire lead open ……….

A

.. Require repair or

replacement.

Wire lead shorted …….

A

.. Require repair or

replacement.

(1) – Determine cause and correct prior to repair or replacement of part.
(2) – Determine source of contamination, such as engine coolant, fuel, metal particles, or water. Require repair or replacement.
(3) – Inoperative includes intermittent operation or out of OEM specification. Some components may be serviceable; check for accepted cleaning procedure.

ENGINE COOLING SYSTEMS

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

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

Attaching hardware
incorrect ………….. B ………… Require replacement. Attaching hardware
loose ……………… A .. Require repair or replacement. Attaching hardware
missing ……………. C ………… Require replacement. Baffle loose ………… 2 .. Suggest repair or replacement. Baffle missing ………. C ………… Require replacement. Bent, affecting
performance ………… A .. Require repair or replacement. Bent, not affecting
performance ………… .. ……. No service suggested or required.
Cracked (not leaking) … 2 .. Suggest repair or replacement. Leaking externally …… A .. Require repair or replacement. Leaking internally,
causing fluid

contamination ……….

A

.. Require repair or

replacement.

Missing ……………..

C

………… Require

replacement.

Restricted passage ……

A

.. Require repair or

replacement.

Threads damaged ………

A

.. Require repair or

replacement.

ENGINE OIL

ENGINE OIL INSPECTION Condition C

Contaminated …………

ode

A

..

Procedure

(1) Require replacement of oil

and filter.

Level high …………..

B

Determine source of incorrect

level and require repair.

Level low ……………

B

Determine source of incorrect

level and require repair.

Maintenance intervals …

3

Suggest replacement to comply

with vehicle’s OEM recommended

service intervals.

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

ENGINE OIL CANISTERS

See ENGINE OIL FILTERS AND CANISTERS.

ENGINE OIL COOLERS (EXTERNAL)

ENGINE OIL COOLER (EXTERNAL) INSPECTION
Condition Code Procedure

Air flow restriction ….

A

.. Require repair or replacement.

Attaching hardware

broken ……………..

A

… Require repair or replacement

of hardware.

Attaching hardware
missing ……………. C ………. Require replacement of hardware.
Attaching hardware not
functioning ………… A … Require repair or replacement of hardware.
Internal restrictions,

ENGINE OIL DRAIN PLUGS AND GASKETS

ENGINE OIL DRAIN PLUG AND GASKET INSPECTION
Condition Code Procedure
Leaking …………….. A .. Require repair or replacement. Missing …………….. C ………… Require replacement. Threads damaged ……… A ……….. (1) Require repair or replacement.
(1) – Some OEMs require replacement of drain plug gasket when removing drain plug. Inspect threads in oil pan for damage.

ENGINE OIL FILTERS AND CANISTERS

ENGINE OIL FILTER AND CANISTER INSPECTION
Condition Code Procedure
Bulged ……………… A …….. (1) Require replacement.
Canister attaching
Further inspection required.
hardware broken …….. A … Require repair or replacement of hardware.
Canister attaching
hardware loose ……… A …………….. Require repair. Canister attaching
hardware missing ……. C ………… Require replacement. Canister attaching
hardware not

functioning …………

A

… Require repair or replacement

of hardware.

Center tube collapsed …

A

…….. (2) Require replacement.

Further inspection required.

Contaminated …………

A

…… (3) Require replacement of

oil and filter.

Dented ………………

2

…….. (4) Suggest replacement.

Further inspection required.

Leaking ……………..

A

.. Require repair or replacement.

Maintenance intervals …

3

… Suggest replacement to comply

with vehicle’s OEM recommended

service intervals.

(1) – Inspect pressure relief valve. (2) – Inspect bypass.
(3) – Determine cause of contamination, such as engine coolant, fuel, metal particles, or water when changing oil. Require repair or replacement.
(4) – Determine cause, such as broken motor mount.

ENGINE OIL GASKETS

See ENGINE OIL DRAIN PLUGS AND GASKETS.

ENGINE OIL PRESSURE GAUGES (MECHANICAL)

ENGINE OIL PRESSURE GAUGE (MECHANICAL) INSPECTION
Condition Code Procedure

Indicates out of range ..

B

……….

(1) Further

inspection

required.

Inoperative ………….

A

……….

(2) Further

inspection

required.

Leaking ……………..

A

.. Require

repair or replacement.

Reads inaccurately ……

2

.. Suggest

repair or replacement.

(1) – Gauge may indicate problem with contaminated oil, level, pressure, or temperature, or problem with gauge.
(2) – Gauge may indicate problem with contaminated oil, level, pressure, or temperature, or problem with gauge. Inoperative includes intermittent operation, out of OEM specification, or out of range. Further inspection required to determine cause.

EVAPORATIVE EMISSION (EVAP) CANISTER FILTERS

EVAPORATIVE EMISSION (EVAP) CANISTER FILTER INSPECTION
Condition Code Procedure
Attaching hardware
broken …………….. A … Require repair or replacement of hardware.
Attaching hardware
missing ……………. C ………. Require replacement of hardware.
Attaching hardware not
Restricted, not affecting

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

Attaching hardware
missing ……………. C ………. Require replacement of hardware.
Attaching hardware
threads damaged …….. A … Require repair or replacement of hardware.
Attaching hardware

threads stripped

(threads missing) ……

A

Require repair or replacement

of hardware.

Connector broken ……..

A

..

Require repair or replacement.

Connector (Weatherpack

type) leaking ……….

A

..

Require repair or replacement.

Connector melted ……..

A

………..

(1) Require repair or

replacement.

Connector missing …….

C

…………

Require replacement.

Contaminated …………

A

………..

(2) Require repair or

replacement.

Inoperative ………….

B

………..

(3) Require repair or

replacement. Further

inspection required.

Leaking ……………..

A

.. Require repair or

replacement.

Missing ……………..

C

………… Require

replacement.

Resistance out of

specification ……….

B

.. Require repair or

replacement.

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

affecting performance

..

A

..

Require

repair

or

replacement.

Terminal corroded, not

affecting performance

..

2

..

Suggest

repair

or

replacement.

Terminal loose, affecting
performance ………… B .. Require repair or replacement. Terminal loose, not

affecting performance ..

1

.. Suggest repair or

replacement.

Threads damaged ………

A

.. Require repair or

replacement.

Threads stripped (threads

missing) ……………

A

………… Require

replacement.

Wire lead conductors

exposed …………….

B

.. Require repair or

replacement.

Wire lead corroded ……

A

.. Require repair or

replacement.

Wire lead open ……….

A

.. Require repair or

replacement.

Wire lead shorted …….

A

.. Require repair or

replacement.

(1) – Determine cause and correct prior to repair or replacement of part.
(2) – Determine source of contamination, such as engine coolant, fuel, metal particles, or water. Require repair or replacement.
(3) – Inoperative includes intermittent operation or out of OEM specification. Some components may be serviceable; check for accepted cleaning procedure.

EVAPORATIVE EMISSION (EVAP) CANISTERS

EVAPORATIVE EMISSION (EVAP) CANISTER INSPECTION
Condition Code Procedure

Inoperative ………….

A

……….. (1) Require repair or

replacement.

Leaking ……………..

A

………… Require replacement.

Missing ……………..

C

………… Require replacement.

Saturated ……………

A

………… Require replacement.

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

EVAPORATIVE EMISSION (EVAP) FEEDBACK DEVICES

EVAPORATIVE EMISSION (EVAP) FEEDBACK DEVICE INSPECTION
Condition Code Procedure
Attaching hardware
missing ……………. C ………. Require replacement of hardware.
Attaching hardware
threads damaged …….. A … Require repair or replacement of hardware.
Attaching hardware

threads stripped

(threads missing) ……

A

Require repair or replacement

of hardware.

Connector broken ……..

A

..

Require repair or replacement.

Connector (Weatherpack

type) leaking ……….

A

..

Require repair or replacement.

Connector melted ……..

A

……….. (1) Require repair or

replacement.

Connector missing …….

C

………… Require replacement.

Contaminated …………

A

……….. (2) Require repair or

replacement.

Inoperative ………….

B

……….. (3) Require repair or

replacement. Further

inspection required.

Leaking ……………..

A

.. Require repair or replacement.

Missing ……………..

C

………… Require replacement.

Resistance out of

specification ……….

B

.. Require repair or replacement.

Restricted, affecting
performance ………… A .. Require repair or replacement. Terminal broken ……… A .. Require repair or replacement. Terminal burned, affecting
performance ………… A ……….. (1) Require repair or replacement.
Terminal burned, not
affecting performance .. 2 .. Suggest repair or replacement. Terminal corroded,
affecting performance .. A .. Require repair or replacement. Terminal corroded, not
affecting performance .. 2 .. Suggest repair or replacement. Terminal loose, affecting
performance ………… B .. Require repair or replacement. Terminal loose, not
affecting performance .. 1 .. Suggest repair or replacement. Threads damaged ……… A .. Require repair or replacement. Threads stripped (threads
missing) …………… A ………… Require replacement. Wire lead conductors

exposed …………….

B

.. Require repair or

replacement.

Wire lead corroded ……

A

.. Require repair or

replacement.

Wire lead open ……….

A

.. Require repair or

replacement.

Wire lead shorted …….

A

.. Require repair or

replacement.

(1) – Determine cause and correct prior to repair or replacement of part.
(2) – Determine source of contamination, such as engine coolant, fuel, metal particles, or water. Require repair or replacement.
(3) – Inoperative includes intermittent operation or out of OEM specification. Some components may be serviceable; check for accepted cleaning procedure.

EXHAUST GAS RECIRCULATION DEVICES

EXHAUST GAS RECIRCULATION DEVICE INSPECTION
Condition Code Procedure
Attaching hardware
missing ……………. C ………. Require replacement of hardware.
Attaching hardware
threads damaged …….. A … Require repair or replacement of hardware.
Attaching hardware threads stripped
(threads missing) …… A … Require repair or replacement of hardware.
Connector broken …….. A .. Require repair or replacement. Connector (Weatherpack
type) leaking ………. A .. Require repair or replacement. Connector melted …….. A ……….. (1) Require repair or replacement.

Connector missing …….

C

…………

Require replacement.

Contaminated …………

A

………..

(2) Require repair or

replacement.

Inoperative ………….

B

………..

(3) Require repair or

replacement. Further

inspection required.

Leaking ……………..

A

.. Require repair or

replacement.

Missing ……………..

C

………… Require

replacement.

Resistance out of

specification ……….

B

.. Require repair or

replacement.

Restricted, affecting
performance ………… A .. Require repair or replacement. Restricted, not affecting
performance ………… 1 .. Suggest repair or replacement. Terminal broken ……… A .. Require repair or replacement. Terminal burned, affecting
performance ………… A ……….. (1) Require repair or replacement.
Terminal burned, not
affecting performance .. 2 .. Suggest repair or replacement. Terminal corroded,
affecting performance .. A .. Require repair or replacement. Terminal corroded, not
affecting performance .. 2 .. Suggest repair or replacement. Terminal loose, affecting
performance ………… B .. Require repair or replacement. Terminal loose, not
affecting performance .. 1 .. Suggest repair or replacement. Threads damaged ……… A .. Require repair or replacement. Threads stripped (threads
missing) …………… A ………… Require replacement. Wire lead conductors

exposed …………….

B

.. Require repair or

replacement.

Wire lead corroded ……

A

.. Require repair or

replacement.

Wire lead open ……….

A

.. Require repair or

replacement.

Wire lead shorted …….

A

.. Require repair or

replacement.

(1) – Determine cause and correct prior to repair or replacement of part.
(2) – Determine source of contamination, such as engine coolant, fuel, metal particles, or water. Require repair or replacement.
(3) – Inoperative includes intermittent operation or out of OEM specification. Some components may be serviceable; check for accepted cleaning procedure.

EXHAUST GAS RECIRCULATION FEEDBACK DEVICES

EXHAUST GAS RECIRCULATION FEEDBACK DEVICE INSPECTION
Condition Code Procedure
Attaching hardware
missing ……………. C ………. Require replacement of hardware.
Attaching hardware
threads damaged …….. A … Require repair or replacement of hardware.
Attaching hardware threads stripped
(threads missing) …… A … Require repair or replacement of hardware.

Connector broken ……..

A

.. Require repair or replacement.

Connector (Weatherpack

type) leaking ……….

A

.. Require repair or replacement.

Connector melted ……..

A

……….. (1) Require repair or

replacement.

Connector missing …….

C

…………

Require replacement.

Contaminated …………

A

………..

(2) Require repair or

replacement.

Inoperative ………….

B

………..

(3) Require repair or

replacement. Further

inspection required.

Leaking ……………..

A

.. Require repair or

replacement.

Missing ……………..

C

………… Require

replacement.

Resistance out of

specification ……….

B

.. Require repair or

replacement.

Restricted, affecting
performance ………… A .. Require repair or replacement. Restricted, not affecting
performance ………… 1 .. Suggest repair or replacement. Terminal broken ……… A .. Require repair or replacement. Terminal burned, affecting
performance ………… A ……….. (1) Require repair or replacement.
Terminal burned, not
affecting performance .. 2 .. Suggest repair or replacement. Terminal corroded,
affecting performance .. A .. Require repair or replacement. Terminal corroded, not
affecting performance .. 2 .. Suggest repair or replacement. Terminal loose, affecting
performance ………… B .. Require repair or replacement. Terminal loose, not
affecting performance .. 1 .. Suggest repair or replacement. Threads damaged ……… A .. Require repair or replacement. Threads stripped (threads
missing) …………… A ………… Require replacement. Wire lead conductors

exposed …………….

B

.. Require repair or

replacement.

Wire lead corroded ……

A

.. Require repair or

replacement.

Wire lead open ……….

A

.. Require repair or

replacement.

Wire lead shorted …….

A

.. Require repair or

replacement.

(1) – Determine cause and correct prior to repair or replacement of part.
(2) – Determine source of contamination, such as engine coolant, fuel, metal particles, or water. Require repair or replacement.
(3) – Inoperative includes intermittent operation or out of OEM specification. Some components may be serviceable; check for accepted cleaning procedure.

EXPANSION PLUGS

See CASTING CORE PLUGS AND EXPANSION PLUGS.

FAN CONTROL SENSORS

FAN CONTROL SENSOR INSPECTION
Condition Code Procedure
Attaching hardware
missing ……………. C ………. Require replacement of hardware.
Attaching hardware
threads damaged …….. A … Require repair or replacement of hardware.
Attaching hardware

threads stripped

(threads missing) ……

A

Require repair or replacement

of hardware.

Connector broken ……..

A

..

Require repair or replacement.

Connector (Weatherpack

type) leaking ……….

A

..

Require repair or replacement.

Connector melted ……..

A

………..

(1) Require repair or

replacement.

Connector missing …….

C

…………

Require replacement.

Contaminated …………

A

………..

(2) Require repair or

replacement.

Inoperative ………….

B

………..

(3) Require repair or

replacement. Further

inspection required.

Leaking ……………..

A

.. Require repair or

replacement.

Missing ……………..

C

………… Require

replacement.

Resistance out of

specification ……….

B

.. Require repair or

replacement.

Restricted, affecting
performance ………… A .. Require repair or replacement. Terminal broken ……… A .. Require repair or replacement. Terminal burned, affecting
performance ………… A ……….. (1) Require repair or replacement.
Terminal burned, not
affecting performance .. 2 .. Suggest repair or replacement. Terminal corroded,
affecting performance .. A .. Require repair or replacement. Terminal corroded, not
affecting performance .. 2 .. Suggest repair or replacement. Terminal loose, affecting
performance ………… B .. Require repair or replacement. Terminal loose, not
affecting performance .. 1 .. Suggest repair or replacement. Threads damaged ……… A .. Require repair or replacement. Threads stripped (threads
missing) …………… A ………… Require replacement. Wire lead conductors

exposed …………….

B

.. Require repair or

replacement.

Wire lead corroded ……

A

.. Require repair or

replacement.

Wire lead open ……….

A

.. Require repair or

replacement.

Wire lead shorted …….

A

.. Require repair or

replacement.

(1) – Determine cause and correct prior to repair or replacement of part.
(2) – Determine source of contamination, such as engine coolant, fuel, metal particles, or water. Require repair or replacement.
(3) – Inoperative includes intermittent operation or out of OEM specification. Some components may be serviceable; check for accepted cleaning procedure.

FUEL

FUEL INSPECTION
Condition Code Procedure

Contaminated …………

B

……….. (1) Require repair or

replacement.

Fuel incorrect ……….

B

……… (2) Require flushing of

system.

(1) – Determine of source of contamination. Require repair or replacement.
(2) – If a fuel other than specification fuel is present in the system, the required service is to flush and fill with the correct fuel.

FUEL ACCUMULATORS AND DAMPERS

FUEL ACCUMULATOR AND DAMPER INSPECTION
Attaching hardware
Attaching hardware not
(1) – Inoperative includes intermittent operation or out of
OEM specification.

FUEL AND COLD START INJECTORS

NOTE: You are not required to replace injectors in sets. However, you may suggest replacement of all injectors for
preventive maintenance.
FUEL AND COLD START INJECTOR INSPECTION
Condition Code Procedure

Application incorrect …

B

…………

Require replacement.

Attaching hardware

broken ……………..

A

… Require

repair or replacement

of hardware.

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

functioning …………

A

Require repair or replacement

of hardware.

Connector broken ……..

A

..

Require repair or replacement.

Connector (Weatherpack

type) leaking ……….

A

..

Require repair or replacement.

Connector melted ……..

A

……….. (1) Require repair or

replacement.

Connector missing …….

C

………… Require replacement.

Flow restricted ………

B

.. Require repair or replacement.

Inoperative ………….

B

……….. (2) Require repair or

replacement. Further

inspection required.

Leaking ……………..

A

.. Require repair or replacement.

Resistance out of

specification ……….

B

………… Require replacement.

Terminal broken ………

A

.. Require repair or replacement.

Terminal burned, affecting

performance …………

A

……….. (1) Require repair or

replacement.

Terminal burned, not
affecting performance .. 2 .. Suggest repair or replacement. Terminal corroded,
affecting performance .. A .. Require repair or replacement. Terminal corroded, not
affecting performance .. 2 .. Suggest repair or replacement. Terminal loose, affecting
performance ………… B .. Require repair or replacement. Terminal loose, not
affecting performance .. 1 .. Suggest repair or replacement. Threads damaged ……… A .. Require repair or replacement. Threads stripped (threads
missing) …………… A ………… Require replacement.
(1) – Determine cause and correct prior to repair or replacement of part.
(2) – Inoperative includes intermittent operation, out of
OEM specification. Some components may be serviceable.

FUEL DAMPERS

See FUEL ACCUMULATORS AND DAMPERS.

FUEL DELIVERY CHECK VALVES

FUEL DELIVERY CHECK VALVE INSPECTION
Condition Code Procedure

Inoperative ………….

A

…….. (1) Require

replacement.

Leaking externally ……

A

.. Require repair or

replacement.

Missing ……………..

C

………… Require

replacement.

Pressure leaking (bleeds

down) ………………

A

.. Require repair or

replacement.

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

FUEL DISTRIBUTORS (BOSCH CIS)

FUEL DISTRIBUTOR (BOSCH CIS) INSPECTION
Condition Code Procedure
Inoperative …………. A ……….. (1) Require repair or replacement. Further inspection required.
Leaking …………….. A .. Require repair or replacement. Out of specification …. B .. Require repair or replacement. Restricted, affecting
performance ………… A ……….. (2) Require repair or replacement. Further inspection required.
(1) – Inoperative includes intermittent operation.
(2) – Some components may be serviceable; check for accepted cleaning procedure.

FUEL FILLER NECKS AND RESTRICTORS

FUEL FILLER NECK AND RESTRICTOR INSPECTION
Attaching hardware
Attaching hardware not

FUEL FILTERS

FUEL FILTER INSPECTION
Condition Code Procedure
Attaching hardware
broken …………….. A … Require repair or replacement of hardware.
Attaching hardware
missing ……………. C ………. Require replacement of hardware.
Attaching hardware not
Restricted, not affecting

FUEL INJECTORS

FUEL INJECTOR INSPECTION
Condition Code Procedure
Attaching hardware
missing ……………. C ……… Require replacement of hardware.
Attaching hardware
threads damaged …….. A .. Require repair or replacement of hardware.
Attaching hardware threads stripped
(threads missing) …… A .. Require repair or replacement of hardware.

Connector broken ……..

A

.

Require repair or replacement.

Connector (Weatherpack

type) leaking ……….

A

.

Require repair or replacement.

Connector melted ……..

A

……….

(1) Require repair or

replacement.

Connector missing …….

C

………..

Require replacement.

Contaminated …………

A

……….

(2) Require repair or

replacement.

Inoperative ………….

B

……….

(3) Require repair or

replacement. Further

inspection required.

Leaking ……………..

A

. Require repair or

replacement.

Missing ……………..

C

……….. Require

replacement.

Resistance out of

specification ……….

B

. Require repair or

replacement.

Restricted, affecting
performance ………… A . Require repair or replacement. Restricted, not affecting
performance ………… 2 . Suggest repair or replacement. Terminal broken ……… A . Require repair or replacement. Terminal burned, affecting
performance ………… A ………. (1) Require repair or replacement.
Terminal burned, not
affecting performance .. 2 . Suggest repair or replacement. Terminal corroded,
affecting performance .. A . Require repair or replacement. Terminal corroded, not
affecting performance .. 2 . Suggest repair or replacement. Terminal loose, affecting
performance ………… B . Require repair or replacement. Terminal loose, not
affecting performance .. 1 . Suggest repair or replacement. Threads damaged ……… A . Require repair or replacement. Threads stripped (threads
missing) …………… A ……….. Require replacement. Wire lead conductors

exposed …………….

B

. Require repair or

replacement.

Wire lead corroded ……

A

. Require repair or

replacement.

Wire lead open ……….

A

. Require repair or

replacement.

Wire lead shorted …….

A

. Require repair or

replacement.

(1) – Determine cause and correct prior to repair or replacement of part.
(2) – Determine source of contamination, such as engine coolant, fuel, metal particles, or water. Require repair or replacement.
(3) – Inoperative includes intermittent operation or out of OEM specification. Some components may be serviceable; check for accepted cleaning procedure.

FUEL LEVEL SENDERS

FUEL LEVEL SENDER INSPECTION
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 conductors

exposed …………….

B

..

Require

repair

or

replacement.

Wire lead corroded ……

A

..

Require

repair

or

replacement.

Wire lead open ……….

A

..

Require

repair

or

replacement.

Wire lead shorted …….

A

..

Require

repair

or

replacement.

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

FUEL PRESSURE REGULATORS

FUEL PRESSURE REGULATOR INSPECTION
Condition Code Procedure

Contaminated

…………

2

………..

(1) Suggest repair or

replacement. Further

inspection required.

Inoperative

………….

B

………..

(2) Require repair or

replacement.

Leaking (internally or
externally) ………… A .. Require repair or replacement. Pressure out of

specification ……….

B

.. Require

repair or replacement.

Vapor bypass restricted .

A

.. Require

repair or replacement.

(1) – Some components may be serviceable; check for accepted cleaning procedure. Determine source of contamination. Require repair or replacement.
(2) – Inoperative includes intermittent operation or out of
OEM specification.

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

Attaching hardware
broken …………….. A … Require repair or replacement of hardware.
Attaching hardware
missing ……………. C ………. Require replacement of hardware.
Attaching hardware not

functioning …………

A

Require repair or replacement

of hardware.

Connector broken ……..

A

..

Require repair or replacement.

Connector (Weatherpack

type) leaking ……….

A

..

Require repair or replacement.

Connector melted ……..

A

……….. (1) Require repair or

replacement.

Connector missing …….

C

………… Require replacement.

Contaminated …………

A

…….. (2) Require replacement.

Inoperative …………. A ……….. (3) Require repair or replacement.
Leaking externally
(includes pulsator) …. A .. Require repair or replacement. Leaking internally
(includes pulsator) …. A .. Require repair or replacement. Noisy ………………. 2 .. Suggest repair or replacement. Out of specification …. B .. Require repair or replacement. Terminal broken ……… A .. Require repair or replacement. Terminal burned, affecting
performance ………… A ……….. (1) Require repair or replacement.
Terminal burned, not
affecting performance .. 2 .. Suggest repair or replacement. Terminal corroded,
affecting performance .. A .. Require repair or replacement. Terminal corroded, not
affecting performance .. 2 .. Suggest repair or replacement. Terminal loose, affecting
performance ………… B .. Require repair or replacement. Terminal loose, not
affecting performance .. 1 .. Suggest repair or replacement. Threads damaged ……… A .. Require repair or replacement. Threads stripped (threads
missing) …………… A ………… Require replacement. Wire lead conductors
exposed ……………. B .. Require repair or replacement. Wire lead corroded …… A .. Require repair or replacement. Wire lead open ………. A .. Require repair or replacement. Wire lead shorted ……. A .. Require repair or replacement.
(1) – Determine cause and correct prior to repair or replacement of part.
(2) – Determine source of contamination. Require repair or replacement.
(3) – Inoperative includes intermittent operation.

FUEL RAILS

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

functioning …………

A

… Require repair or replacement

of hardware.

Contaminated …………

A

…….. (1) Require replacement.

Leaking ……………..

A

.. Require repair or replacement.

Restricted …………..

A

.. Require repair or replacement.

Rust-pitted ………….

1

………… Suggest replacement.

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

FUEL RESTRICTORS

See FUEL FILLER NECKS AND RESTRICTORS.

FUEL TANKS

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

functioning

…………

A

… Require repair or replacement

of hardware.

Baffles loose

………..

A

.. Require repair or replacement.

Contaminated

…………

A

…………. (1) Require repair.

Corroded internally …..

A

.. Require repair or

replacement.

Distorted, affecting

performance …………

B

………… Require

replacement.

Distorted, not affecting
performance ………… .. …….. No service suggested or required.
Leaking …………….. A .. Require repair or replacement.
(1) – Determine source of contamination. Require repair or replacement.

GAS CAPS

GAS CAP INSPECTION
Condition Code Procedure

Application incorrect …

B

………..

Require

replacement.

Fails to maintain proper

pressure ……………

A

………..

Require

replacement.

Gaskets missing ………

C

………..

Require

replacement.

Leaking ……………..

A

………..

Require

replacement.

Missing ……………..

C

………..

Require

replacement.

Plugged (vacuum and

pressure relief) …….

A

………..

Require

replacement.

Seals missing ………..

C

………..

Require

replacement.

GASKETS

GASKET INSPECTION
Condition Code Procedure
Leaking …………….. A ……….. (1) Require repair or replacement.
(1) – Require inspection of mating and sealing surface and repair or replace as necessary.

GROMMETS (VALVE COVER)

GROMMET (VALVE COVER) INSPECTION
Condition Code Procedure
Leaking …………….. 2 ……….. (1) Suggest repair or replacement.
(1) – Require inspection of mating and sealing surface and repair or replace as necessary.

HARMONIC DAMPERS

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

functioning …………

A

.. Require

repair or replacement

of hardware.

Cracked ……………..

A

………..

Require replacement.

Dented (fluid

type only) ………….

A

………..

Require replacement.

Keyway distorted ……..

A

. Require repair or replacement.

Leaking (Fluid damper

only) ………………

A

……….. Require replacement.

Loose ……………….

A

……….. Require replacement.

Noisy ……………….

A

……….. Require replacement.

Outer ring slipped out of

position ……………

A

……….. Require

replacement.

Positioned incorrectly ..

A

. Require repair or

replacement.

Rubber damping material

deteriorated ………..

1

……….. Suggest

replacement.

Seal surface worn, causing

a leak ……………..

A

. Require repair or

replacement.

Threads damaged ………

A

. Require repair or

replacement.

Threads stripped (threads

missing) ……………

A

……….. Require

replacement.

HEATER CONTROL VALVES

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

functioning …………

A

… Require repair or replacement

of hardware.

Bypassed …………….

A

………… Require replacement.

Coolant leak …………

A

.. Require repair or replacement.

Malfunctioning ……….

A

……….. (1) Require repair or

replacement.

Missing ……………..

C

………… Require replacement.

Restricted …………..

A

.. Require repair or replacement.

Vacuum leak ………….

A

.. Require repair or replacement.

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

HEATER CORES

HEATER CORE INSPECTION

Condition C

ode

Procedure

Air flow restriction ….

A

.. Require repair or replacement.

Attaching hardware

broken ……………..

A

… Require repair or replacement

Attaching hardware
of hardware.
missing ……………. C ………. Require replacement of hardware.
Attaching hardware not
functioning ………… A … Require repair or replacement of hardware.
Bypassed ……………. A .. Require repair or replacement. Connection leaking …… A .. Require repair or replacement. Corroded ……………. 1 .. Suggest repair or replacement. Fins damaged, affecting
performance ………… A .. Require repair or replacement. Fins damaged, not
affecting performance .. 2 .. Suggest repair or replacement. Internal restrictions,
affecting performance .. A .. Require repair or replacement. Leaking …………….. A .. Require repair or replacement. Missing …………….. C ………… Require replacement.

HOSE AND TUBE COUPLERS, CONNECTORS AND CLAMPS

NOTE: When replacing fuel lines and hoses, replace with product that meets or exceeds OEM design specifications.
HOSE AND TUBE COUPLER, CONNECTOR AND CLAMP INSPECTION
Condition Code Procedure
Application incorrect … B ………… Require replacement. Connected incorrectly … A …………….. Require repair. Corroded, not reusable .. 1 ………… Suggest replacement.

Cracked ……………..

A

………… Require replacement.

Insufficient clamping

force, allowing hose to

leak ……………….

A

.. Require repair or replacement.

Leaking ……………..

A

.. Require repair or replacement.

Missing ……………..

C

………… Require replacement.

Safety clip missing (not

leaking) ……………

C

… Require replacement of safety

clip.

Stripped …………….

A

………… Require replacement.

HOSE CLAMPS

See HOSE AND TUBE COUPLERS, CONNECTORS AND CLAMPS.

HOSE CONNECTORS

See HOSE AND TUBE COUPLERS, CONNECTORS AND CLAMPS.

HOSE COUPLERS

See HOSE AND TUBE COUPLERS, CONNECTORS AND CLAMPS.

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

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

Application incorrect

B

………… Require replacement.

Connected incorrectly

A

…………….. Require repair.

Corroded, not reusable ..

1

………… Suggest

replacement.

Cracked ……………..

A

………… Require

replacement.

Dry-rotted …………..

1

.. Suggest repair or

replacement.

Hard ………………..

1

.. Suggest repair or

replacement.

Inner fabric (webbing)

damaged …………….

A

………… Require

replacement.

Insufficient clamping force, allowing hose to

leak ……………….

A

.. Require repair or

replacement.

Leaking ……………..

A

.. Require repair or

replacement.

Maintenance intervals …

3

………… Suggest

replacement.

Melted ………………

1

.. Suggest repair or replacement.

Missing ……………..

C

………… Require replacement.

Outer covering damaged ..

1

………… Suggest replacement.

Outer covering damaged to

the extent that the inner

fabric is visible ……

A

………… Require replacement.

Protective sleeves
damaged ……………. 2 . Suggest replacement of sleeves. Protective sleeves
missing ……………. 2 . Suggest replacement of sleeves. Restricted, affecting
performance ………… A .. Require repair or replacement. Restricted, not affecting

performance …………

2

.. Suggest repair or

replacement.

Routed incorrectly ……

2

.. Suggest repair or

replacement.

Safety clip missing …..

C

………… Require

replacement.

Spongy ………………

1

.. Suggest repair or

replacement.

Stripped …………….

A

………… Require

replacement.

Swollen ……………..

B

………… Require

replacement.

Threads damaged ………

A

.. Require repair or

replacement.

Threads stripped (threads

missing) ……………

A

………… Require

replacement.

Type incorrect ……….

1

.. Suggest repair or

replacement.

HOUSINGS

See THERMOSTATS AND HOUSINGS.

IDLE AIR CONTROLS

IDLE AIR CONTROL INSPECTION
Condition Code Procedure
Attaching hardware
missing ……………. C ………. Require replacement of hardware.
Attaching hardware
threads damaged …….. A … Require repair or replacement of hardware.
Attaching hardware

threads stripped

(threads missing) ……

A

Require repair or replacement

of hardware.

Connector broken ……..

A

..

Require repair or replacement.

Connector (Weatherpack

type) leaking ……….

A

..

Require repair or replacement.

Connector melted ……..

A

………..

(1) Require repair or

replacement.

Connector missing …….

C

…………

Require replacement.

Contaminated …………

A

………..

(2) Require repair or

replacement.

Inoperative ………….

B

………..

(3) Require repair or

replacement. Further

inspection required.

Leaking ……………..

A

.. Require repair or

replacement.

Missing ……………..

C

………… Require

replacement.

Resistance out of

specification ……….

B

.. Require repair or

replacement.

Restricted, affecting

performance …………

A

.. Require repair or

replacement.

Terminal broken ………

A

.. Require repair or

replacement.

Terminal burned, affecting
performance ………… A ……….. (1) Require repair or replacement.
Terminal burned, not
affecting performance .. 2 .. Suggest repair or replacement. Terminal corroded,
affecting performance .. A .. Require repair or replacement. Terminal corroded, not
affecting performance .. 2 .. Suggest repair or replacement. Terminal loose, affecting
performance ………… B .. Require repair or replacement. Terminal loose, not
affecting performance .. 1 .. Suggest repair or replacement. Threads damaged ……… A .. Require repair or replacement. Threads stripped (threads
missing) …………… A ………… Require replacement. Wire lead conductors

exposed …………….

B

.. Require repair or

replacement.

Wire lead corroded ……

A

.. Require repair or

replacement.

Wire lead open ……….

A

.. Require repair or

replacement.

Wire lead shorted …….

A

.. Require repair or

replacement.

(1) – Determine cause and correct prior to repair or replacement of part.
(2) – Determine source of contamination, such as engine coolant, fuel, metal particles, or water. Require repair or replacement.
(3) – Inoperative includes intermittent operation or out of OEM specification. Some components may be serviceable; check for accepted cleaning procedure.

IDLE SPEED CONTROL ACTUATORS

IDLE SPEED CONTROL ACTUATOR INSPECTION
Condition Code Procedure
Attaching hardware
missing ……………. C ………. Require replacement of hardware.
Attaching hardware
threads damaged …….. A … Require repair or replacement of hardware.
Attaching hardware threads stripped
(threads missing) …… A … Require repair or replacement of hardware.
Connector broken …….. A .. Require repair or replacement. Connector (Weatherpack
type) leaking ………. A .. Require repair or replacement. Connector melted …….. A ……….. (1) Require repair or replacement.
Connector missing ……. C ………… Require replacement. Contaminated ………… A ……….. (2) Require repair or replacement.
Inoperative …………. B ……….. (3) Require repair or replacement. Further inspection required.
Leaking …………….. A .. Require repair or replacement. Missing …………….. C ………… Require replacement. Resistance out of
specification ………. B .. Require repair or replacement.

Terminal broken ………

A

.. Require

repair or replacement.

Terminal burned, affecting

performance …………

A

………..

(1) Require repair or

replacement.

Terminal burned, not
affecting performance .. 2 .. Suggest repair or replacement. Terminal corroded,
affecting performance .. A .. Require repair or replacement. Terminal corroded, not
affecting performance .. 2 .. Suggest repair or replacement. Terminal loose, affecting
performance ………… B .. Require repair or replacement. Terminal loose, not
affecting performance .. 1 .. Suggest repair or replacement. Threads damaged ……… A .. Require repair or replacement. Threads stripped (threads
missing) …………… A ………… Require replacement. Wire lead conductors

exposed …………….

B

.. Require repair or

replacement.

Wire lead corroded ……

A

.. Require repair or

replacement.

Wire lead open ……….

A

.. Require repair or

replacement.

Wire lead shorted …….

A

.. Require repair or

replacement.

(1) – Determine cause and correct prior to repair or replacement of part.
(2) – Determine source of contamination, such as engine coolant, fuel, metal particles, or water. Require repair or replacement.
(3) – Inoperative includes intermittent operation or out of OEM specification. Some components may be serviceable; check for accepted cleaning procedure.

IGNITION BOOTS

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

IGNITION COIL TOWERS

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

IGNITION COILS

Attaching hardware
Attaching hardware not

replacement.

Connector missing …….

C

…………

Require replacement.

Corroded, affecting

performance …………

A

…………

Require replacement.

Corroded, not affecting
performance ………… 2 ………… Suggest replacement. Distorted …………… .. …. (2) No service suggested or required.
Inoperative …………. A …….. (3) Require replacement. Oil leaking …………. A ………… Require replacement. Out of specification …. B ………… Require replacement. Terminal broken ……… A .. Require repair or replacement. Terminal burned, affecting
performance ………… A ……….. (1) Require repair or replacement.
Terminal burned, not
affecting performance .. 2 .. Suggest repair or replacement. Terminal corroded,

affecting performance

..

A

..

Require

repair

or

replacement.

Terminal corroded, not

affecting performance

..

2

..

Suggest

repair

or

replacement.

Terminal loose, affecting

performance …………

B

..

Require

repair

or

replacement.

Terminal loose, not

affecting performance ..

1

..

Suggest

repair

or

replacement.

Wire lead conductors

exposed …………….

B

..

Require

repair

or

replacement.

Wire lead corroded ……

A

..

Require

repair

or

replacement.

Wire lead open ……….

A

..

Require

repair

or

replacement.

Wire lead shorted …….

A

..

Require

repair

or

replacement.

(1) – Determine cause and correct prior to repair or replacement of part.
(2) – Distortion may be the result of overheating; coil should be tested.
(3) – Inoperative includes intermittent operation.

IGNITION CONTROL MODULES (ICM)

IGNITION CONTROL MODULE (ICM) INSPECTION

Condition C

ode

Procedure

Application incorrect …

B

………… Require replacement.

Attaching hardware

missing …………….

C

………. Require replacement of

hardware.

Attaching hardware
threads damaged …….. A … Require repair or replacement of hardware.
Attaching hardware threads stripped
(threads missing) …… A … Require repair or replacement of hardware.
Code set

(if applicable) ……..

A

……….

(1) Further inspection

required.

Connector broken ……..

A

.. Require

repair or replacement.

Connector (Weatherpack

type) leaking ……….

A

.. Require

repair or replacement.

Connector melted ……..

A

………..

(2) Require repair or

replacement.

Connector missing …….

A

…………….. Require repair.

Contaminated …………

A

……….. (3) Require repair or

replacement.

Leaking ……………..

A

.. Require repair or replacement.

Malfunctioning ……….

A

……….. (4) Require repair or

replacement.

Missing ……………..

C

………… Require replacement.

Terminal broken ………

A

.. Require repair or replacement.

Terminal burned, affecting

performance …………

A

……….. (2) Require repair or

replacement.

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

affecting performance

..

A

..

Require

repair

or

replacement.

Terminal corroded, not

affecting performance

..

2

..

Suggest

repair

or

replacement.

Terminal loose, affecting

performance …………

B

..

Require

repair

or

replacement.

Terminal loose, not

affecting performance ..

1

..

Suggest

repair

or

replacement.

Threads damaged ………

A

..

Require

repair

or

replacement.

Wire lead conductors

exposed …………….

B

..

Require

repair

or

replacement.

Wire lead corroded ……

A

..

Require

repair

or

replacement.

Wire lead open ……….

A

..

Require

repair

or

replacement.

Wire lead shorted …….

A

..

Require

repair

or

replacement.

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

IGNITION SWITCHES

See SWITCHES.

IGNITION TERMINALS

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

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

NOTE: You are not required to replace ignition wires in sets.
However, you may suggest replacement of the entire secondary wire set for preventive maintenance.
IGNITION WIRE, BOOT, COIL TOWER AND TERMINAL (SECONDARY) INSPECTION Condition Code Procedure Application incorrect … B ………… Require replacement.
Attaching hardware
broken …………….. A … Require repair or replacement of hardware.
Attaching hardware
missing ……………. C ………. Require replacement of hardware.
Attaching hardware not
functioning ………… A … Require repair or replacement of hardware.
Carbon-tracked ………. A ………… Require replacement. Corroded ……………. 1 .. Suggest repair or replacement. Insulation leaking
(shorted) ………….. A .. Require repair or replacement. Metal heat shield bent .. 2 .. Suggest repair or replacement. Missing …………….. C ………… Require replacement. Oil-soaked (spongy) ….. 1 ………… Suggest replacement. Resistance incorrect …. B ………… Require replacement. Routed incorrectly …… 2 …………. (1) Suggest repair. Terminal broken ……… A .. Require repair or replacement. Terminal burned, affecting
performance ………… A ……….. (2) Require repair or replacement.
Terminal burned, not
affecting performance .. 2 .. Suggest repair or replacement. Terminal corroded,
affecting performance .. A .. Require repair or replacement. Terminal corroded, not
affecting performance .. 2 .. Suggest repair or replacement. Terminal loose, affecting
performance ………… B .. Require repair or replacement. Terminal loose, not
affecting performance .. 1 .. Suggest repair or replacement.
(1) – If improper routing affects the performance of other systems, require repair. Proper routing, hardware, heatshields, etc., are intended to prevent premature failure of secondary ignition components.
(2) – Determine cause and correct prior to repair or replacement of part.

IN-TANK FUEL STRAINERS

IN-TANK FUEL STRAINER INSPECTION
Condition Code Procedure
Missing …………….. C ………… Require replacement. Restricted ………….. A .. Require repair or replacement. Torn ……………….. A ………… Require replacement.

INERTIA FUEL SHUT-OFF SWITCHES

INERTIA FUEL SHUT-OFF SWITCH INSPECTION
Attaching hardware
Attaching hardware not

of hardware.

Connector broken ……..

A

.. Require repair or replacement.

Connector melted ……..

A

……….. (1) Require repair or

replacement.

Connector missing …….

C

………… Require replacement.

Contaminated …………

A

…….. (2) Require replacement.

Inoperative ………….

A

……….. (3) Require repair or

replacement.

Missing ……………..

C

………… Require replacement.

Terminal broken ………

A

.. Require repair or replacement.

Terminal burned, affecting

performance …………

A

……….. (1) Require repair or

replacement.

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

affecting performance

..

A

..

Require

repair

or

replacement.

Terminal corroded, not

affecting performance

..

2

..

Suggest

repair

or

replacement.

Terminal loose, affecting

performance …………

B

..

Require

repair

or

replacement.

Terminal loose, not

affecting performance ..

1

..

Suggest

repair

or

replacement.

Wire lead conductors

exposed …………….

B

..

Require

repair

or

replacement.

Wire lead corroded ……

A

..

Require

repair

or

replacement.

Wire lead open ……….

A

..

Require

repair

or

replacement.

Wire lead shorted …….

A

..

Require

repair

or

replacement.

(1) – Determine cause and correct prior to repair or replacement of part.
(2) – Determine source of contamination, such as engine coolant, fuel, metal particles, or water. Require repair or replacement.
(3) – Inoperative includes intermittent operation or out of
OEM specification.

INTAKE AIR TEMPERATURE SENSORS

INTAKE AIR TEMPERATURE SENSOR INSPECTION
Condition Code Procedure
Attaching hardware
missing ……………. C ………. Require replacement of hardware.
Attaching hardware
threads damaged …….. A … Require repair or replacement of hardware.
Attaching hardware

threads stripped

(threads missing) ……

A

Require repair or replacement

of hardware.

Connector broken ……..

A

..

Require repair or replacement.

Connector (Weatherpack

type) leaking ……….

A

..

Require repair or replacement.

Connector melted ……..

A

………..

(1) Require repair or

replacement.

Connector missing …….

C

…………

Require replacement.

Contaminated …………

A

………..

(2) Require repair or

replacement.

Inoperative ………….

B

………..

(3) Require repair or

replacement. Further inspection required.
Leaking …………….. A .. Require repair or replacement. Missing …………….. C ………… Require replacement. Resistance out of
specification ………. B .. Require repair or replacement. Restricted, affecting
performance ………… A .. Require repair or replacement. Terminal broken ……… A .. Require repair or replacement. Terminal burned, affecting
performance ………… A ……….. (1) Require repair or replacement.
Terminal burned, not
affecting performance .. 2 .. Suggest repair or replacement. Terminal corroded,
affecting performance .. A .. Require repair or replacement. Terminal corroded, not
affecting performance .. 2 .. Suggest repair or replacement. Terminal loose, affecting
performance ………… B .. Require repair or replacement. Terminal loose, not
affecting performance .. 1 .. Suggest repair or replacement. Threads damaged ……… A .. Require repair or replacement. Threads stripped (threads
missing) …………… A ………… Require replacement. Wire lead conductors

exposed …………….

B

.. Require repair or

replacement.

Wire lead corroded ……

A

.. Require repair or

replacement.

Wire lead open ……….

A

.. Require repair or

replacement.

Wire lead shorted …….

A

.. Require repair or

replacement.

(1) – Determine cause and correct prior to repair or replacement of part.
(2) – Determine source of contamination, such as engine coolant, fuel, metal particles, or water. Require repair or replacement.
(3) – Inoperative includes intermittent operation or out of OEM specification. Some components may be serviceable; check for accepted cleaning procedure.

INTAKE MANIFOLDS

INTAKE MANIFOLD INSPECTION
Condition Code Procedure
Corroded, affecting
sealability ………… A .. Require repair or replacement. Integrated air or fuel
control components
inoperative ………… A ……….. (1) Require repair or replacement.
Internal air or fuel components damaged,
affecting performance .. A … Require repair or replacement of component.
Internal air or fuel components damaged, not
affecting performance .. .. …….. No service suggested or required.
Internal air or fuel
components missing ….. C ………. Require replacement of
component. Leaking …………….. A .. Require repair or replacement. Out of specification …. B ………… Require replacement. Restricted ………….. A .. Require repair or replacement. Threads damaged ……… A .. Require repair or replacement. Threads stripped (threads
missing) …………… A .. Require repair or replacement. Warped ……………… B .. Require repair or replacement.
(1) – Inoperative includes intermittent operation or out of
OEM specification.

INTERCOOLERS

See CHARGE AIR COOLERS “INTERCOOLERS” (CAC).

KNOCK SENSORS

KNOCK SENSOR INSPECTION
Condition Code Procedure
Attaching hardware
missing ……………. C ………. Require replacement of hardware.
Attaching hardware threads
damaged ……………. A … Require repair or replacement of hardware.
Attaching hardware threads stripped
(threads missing) …… A … Require repair or replacement of hardware.
Connector broken …….. A .. Require repair or replacement. Connector (Weatherpack
type) leaking ………. A .. Require repair or replacement. Connector melted …….. A ……….. (1) Require repair or replacement.
Connector missing ……. C ………… Require replacement. Inoperative …………. B ……….. (2) Require repair or replacement. Further
inspection required. Leaking …………….. A .. Require repair or replacement. Missing …………….. C ………… Require replacement. Resistance out of
specification ………. B .. Require repair or replacement. Terminal broken ……… A .. Require repair or replacement. Terminal burned, affecting
performance ………… A ……….. (1) Require repair or replacement.
Terminal burned, not
affecting performance .. 2 .. Suggest repair or replacement. Terminal corroded,
affecting performance .. A .. Require repair or replacement. Terminal corroded, not
affecting performance .. 2 .. Suggest repair or replacement. Terminal loose, affecting
performance ………… B .. Require repair or replacement. Terminal loose, not
affecting performance .. 1 .. Suggest repair or replacement. Threads damaged ……… A .. Require repair or replacement. Threads stripped (threads
missing) …………… A ………… Require replacement.
Wire lead conductors
exposed ……………. B .. Require repair or replacement. Wire lead corroded …… A .. Require repair or replacement. Wire lead open ………. A .. Require repair or replacement. Wire lead shorted ……. A .. Require repair or replacement.
(1) – Determine cause and correct prior to repair or replacement of part.
(2) – Inoperative includes intermittent operation or out of OEM specification. Some components may be serviceable; check for accepted cleaning procedure.

LIQUID VAPOR SEPARATORS

LIQUID VAPOR SEPARATOR INSPECTION
Condition Code Procedure

Inoperative ………….

A

………..

(1) Require repair or

replacement.

Leaking ……………..

A

…………

Require replacement.

Missing ……………..

C

…………

Require replacement.

Restricted ………….. A .. Require repair or replacement.
(1) – Inoperative includes intermittent operation or out of OEM
specification.

MANIFOLD ABSOLUTE PRESSURE (MAP) SENSORS

MANIFOLD ABSOLUTE PRESSURE (MAP) SENSOR INSPECTION
Condition Code Procedure
Attaching hardware
missing ……………. C ………. Require replacement of hardware.
Attaching hardware
threads damaged …….. A … Require repair or replacement of hardware.
Attaching hardware

threads stripped

(threads missing) ……

A

Require repair or replacement

of hardware.

Connector broken ……..

A

..

Require repair or replacement.

Connector (Weatherpack

type) leaking ……….

A

..

Require repair or replacement.

Connector melted ……..

A

………..

(1) Require repair or

replacement.

Connector missing …….

C

…………

Require replacement.

Contaminated …………

A

………..

(2) Require repair or

replacement.

Inoperative ………….

B

………..

(3) Require repair or

replacement. Further

inspection required.

Leaking ……………..

A

.. Require repair or

replacement.

Missing ……………..

C

………… Require

replacement.

Resistance out of

specification ……….

B

.. Require repair or

replacement.

Restricted, affecting

performance …………

A

.. Require repair or

replacement.

Terminal broken ………

A

.. Require repair or

replacement.

Terminal burned, affecting
performance ………… A ………… (1) Require repair or replacement.
Terminal burned, not
affecting performance .. 2 .. Suggest repair or replacement. Terminal corroded,
affecting performance .. A .. Require repair or replacement. Terminal corroded, not
affecting performance .. 2 .. Suggest repair or replacement. Terminal loose, affecting
performance ………… B .. Require repair or replacement. Terminal loose, not
affecting performance .. 1 .. Suggest repair or replacement. Threads damaged ……… A .. Require repair or replacement. Threads stripped (threads
missing) …………… A ………… Require replacement. Wire lead conductors

exposed …………….

B

.. Require repair or

replacement.

Wire lead corroded ……

A

.. Require repair or

replacement.

Wire lead open ……….

A

.. Require repair or

replacement.

Wire lead shorted …….

A

.. Require repair or

replacement.

(1) – Determine cause and correct prior to repair or replacement of part.
(2) – Determine source of contamination, such as engine coolant, fuel, metal particles, or water. Require repair or replacement.
(3) – Inoperative includes intermittent operation or out of OEM specification. Some components may be serviceable; check for accepted cleaning procedure.

MASS AIR FLOW (MAF) SENSORS

MASS AIR FLOW (MAF) SENSOR INSPECTION
Condition Code Procedure
Attaching hardware
missing ……………. C ………. Require replacement of hardware.
Attaching hardware threads
damaged ……………. A … Require repair or replacement of hardware.
Attaching hardware threads stripped
(threads missing) …… A … Require repair or replacement of hardware.
Connector broken …….. A .. Require repair or replacement. Connector (Weatherpack
type) leaking ………. A .. Require repair or replacement. Connector melted …….. A ……….. (1) Require repair or replacement.
Connector missing ……. C ………… Require replacement. Contaminated ………… A ……….. (2) Require repair or replacement.
Inoperative …………. B ……….. (3) Require repair or replacement. Further inspection required.
Leaking …………….. A .. Require repair or replacement. Missing …………….. C ………… Require replacement. Resistance out of
specification ………. B .. Require repair or replacement.
Restricted, affecting
performance ………… A .. Require repair or replacement. Terminal broken ……… A .. Require repair or replacement. Terminal burned, affecting
performance ………… A ……….. (1) Require repair or replacement.
Terminal burned, not
affecting performance .. 2 .. Suggest repair or replacement. Terminal corroded,
affecting performance .. A .. Require repair or replacement. Terminal corroded, not
affecting performance .. 2 .. Suggest repair or replacement. Terminal loose, affecting
performance ………… B .. Require repair or replacement. Terminal loose, not
affecting performance .. 1 .. Suggest repair or replacement. Threads damaged ……… A .. Require repair or replacement. Threads stripped (threads
missing) …………… A ………… Require replacement. Wire lead conductors

exposed …………….

B

.. Require repair or

replacement.

Wire lead corroded ……

A

.. Require repair or

replacement.

Wire lead open ……….

A

.. Require repair or

replacement.

Wire lead shorted …….

A

.. Require repair or

replacement.

(1) – Determine cause and correct prior to repair or replacement of part.
(2) – Determine source of contamination, such as engine coolant, fuel, metal particles, or water. Require repair or replacement.
(3) – Inoperative includes intermittent operation or out of OEM specification. Some components may be serviceable; check for accepted cleaning procedure.

METAL AIR MANIFOLDS AND PIPES

METAL AIR MANIFOLD AND PIPE INSPECTION
Condition Code Procedure
Attaching hardware
broken …………….. A … Require repair or replacement of hardware.
Attaching hardware
missing ……………. C ………. Require replacement of hardware.
Attaching hardware not

functioning …………

A

… Require repair or replacement

of hardware.

Broken ………………

A

….. Require repair of injection

tube or replacement of

manifold.

Corroded, affecting

structural integrity …

1

………. Suggest replacement of

injection tube or manifold.

Leaking ……………..

A

….. Require repair of injection

tube or replacement of

manifold.

Loose ……………….

A

……………. Require repair.

Missing ……………..

C

………… Require replacement.

Restricted …………..

A

………. Require replacement of

injection tube or manifold.

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

METAL AIR PIPES

See METAL AIR MANIFOLDS AND PIPES.

MIX CONTROL SOLENOIDS

MIX CONTROL SOLENOID INSPECTION
Condition Code Procedure
Attaching hardware
missing ……………. C ………. Require replacement of hardware.
Attaching hardware
threads damaged …….. A … Require repair or replacement of hardware.
Attaching hardware

threads stripped

(threads missing) ……

A

Require repair or replacement

of hardware.

Connector broken ……..

A

..

Require repair or replacement.

Connector (Weatherpack

type) leaking ……….

A

..

Require repair or replacement.

Connector melted ……..

A

………..

(1) Require repair or

replacement.

Connector missing …….

C

…………

Require replacement.

Contaminated …………

A

………..

(2) Require repair or

replacement.

Inoperative ………….

B

………..

(3) Require repair or

replacement. Further

inspection required.

Leaking ……………..

A

.. Require repair or

replacement.

Missing ……………..

C

………… Require

replacement.

Resistance out of

specification ……….

B

.. Require repair or

replacement.

Restricted, affecting
performance ………… A .. Require repair or replacement. Terminal broken ……… A .. Require repair or replacement. Terminal burned, affecting
performance ………… A ……….. (1) Require repair or replacement.
Terminal burned, not
affecting performance .. 2 .. Suggest repair or replacement. Terminal corroded,
affecting performance .. A .. Require repair or replacement. Terminal corroded, not
affecting performance .. 2 .. Suggest repair or replacement. Terminal loose, affecting
performance ………… B .. Require repair or replacement. Terminal loose, not
affecting performance .. 1 .. Suggest repair or replacement. Threads damaged ……… A .. Require repair or replacement. Threads stripped (threads
missing) …………… A ………… Require replacement. Wire lead conductors

exposed …………….

B

.. Require repair or

replacement.

Wire lead corroded ……

A

.. Require repair or

replacement.

Wire lead open ……….

A

.. Require repair or

replacement.

Wire lead shorted ……. A .. Require repair or replacement.
(1) – Determine cause and correct prior to repair or replacement of part.
(2) – Determine source of contamination, such as engine coolant, fuel, metal particles, or water. Require repair or replacement.
(3) – Inoperative includes intermittent operation or out of OEM specification. Some components may be serviceable; check for accepted cleaning procedure.

MOTOR MOUNTS

MOTOR MOUNT INSPECTION
Condition Code Procedure
Attaching hardware
broken …………….. A … Require repair or replacement of hardware.
Attaching hardware
missing ……………. C ………. Require replacement of hardware.
Attaching hardware not
functioning ………… A … Require repair or replacement of hardware.
Broken ……………… A ………… Require replacement. Leaking (hydraulic
mount) …………….. A ………… Require replacement. Mounting hole worn,
affecting performance .. A ………… Require replacement. Mounting hole worn, not
affecting performance .. .. …….. No service suggested or required.
Rubber deteriorated,
affecting performance .. A ………… Require replacement. Rubber deteriorated, not
affecting performance .. .. …….. No service suggested or required.
Threads damaged ……… A .. Require repair or replacement. Threads stripped (threads
missing) …………… A ………… Require replacement.

O-RINGS, GASKETS, SEALS AND SPRING LOCKS

O-RING, GASKET, SEAL AND SPRING LOCK INSPECTION
Condition Code Procedure
Leaking …………….. A ………… (1) Require repair or replacement.
(1) – Require inspection of mating and sealing surface and repair or replace as necessary.

O2 SENSORS

O2 SENSOR INSPECTION
Condition Code Procedure
Attaching hardware
missing ……………. C ………. Require replacement of hardware.
Attaching hardware
threads damaged …….. A … Require repair or replacement of hardware.
Attaching hardware

threads stripped

(threads missing) ……

A

..

Require repair or replacement

of hardware.

Connector broken ……..

A

..

Require repair or replacement.

Connector (Weatherpack

type) leaking ……….

A

..

Require repair or replacement.

Connector melted ……..

A

………..

(1) Require repair or

replacement.

Connector missing …….

C

…………

Require replacement.

Contaminated …………

A

………..

(2) Require repair or

replacement.

Inoperative ………….

B

………..

(3) Require repair or

replacement. Further

inspection required.

Leaking ……………..

A

.. Require repair or

replacement.

Missing ……………..

C

………… Require

replacement.

Resistance out of

specification ……….

B

.. Require repair or

replacement.

Restricted, affecting
performance ………… A .. Require repair or replacement. Terminal broken ……… A .. Require repair or replacement. Terminal burned, affecting
performance ………… A ……….. (1) Require repair or replacement.
Terminal burned, not
affecting performance .. 2 .. Suggest repair or replacement. Terminal corroded,
affecting performance .. A .. Require repair or replacement. Terminal corroded, not
affecting performance .. 2 .. Suggest repair or replacement. Terminal loose, affecting
performance ………… B .. Require repair or replacement. Terminal loose, not
affecting performance .. 1 .. Suggest repair or replacement. Threads damaged ……… A .. Require repair or replacement. Threads stripped (threads
missing) …………… A ………… Require replacement. Wire lead conductors

exposed …………….

B

.. Require repair or

replacement.

Wire lead corroded ……

A

.. Require repair or

replacement.

Wire lead open ……….

A

.. Require repair or

replacement.

Wire lead shorted …….

A

.. Require repair or

replacement.

(1) – Determine cause and correct prior to repair or replacement of part.
(2) – Determine source of contamination, such as engine coolant, fuel, metal particles, or water. Require repair or replacement.
(3) – Inoperative includes intermittent operation or out of OEM specification. Some components may be serviceable; check for accepted cleaning procedure.

OIL PRESSURE SENDING UNITS

OIL PRESSURE SENDING UNIT INSPECTION
Condition Code Procedure
epair
or replacement.
epair
or replacement.
(1) Require repair or replacement.
Require replacement. (2) Require repair or replacement.
Require replacement.
epair epair
or replacement. or replacement.
Terminal burned, not
(1) Require repair or 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. Threads damaged ……… A .. Require repair or replacement. Threads stripped (threads
missing) …………… A ………… Require replacement.
(1) – Determine cause and correct prior to repair or replacement of part.
(2) – Inoperative includes intermittent operation or out of
OEM specification.

OIL PUMP PICK-UP SCREENS

OIL PUMP PICK-UP SCREEN INSPECTION
Condition Code Procedure
Attaching hardware
broken …………….. A … Require repair or replacement of hardware.
Attaching hardware
missing ……………. C ………. Require replacement of hardware.
Attaching hardware not
functioning ………… A … Require repair or replacement

of hardware.

Bypass stuck …………

A

.. Require repair or replacement.

Cracked ……………..

A

.. Require repair or replacement.

Loose ……………….

A

.. Require repair or replacement.

Missing ……………..

C

………… Require replacement.

Positioned incorrectly ..

A

.. Require repair or replacement.

Restricted …………..

A

.. Require repair or replacement.

Screen torn ………….

A

………… Require replacement.

OIL PUMPS

OIL PUMP INSPECTION
Condition Code Procedure
Attaching hardware
broken …………….. A … Require repair or replacement of hardware.
Attaching hardware
missing ……………. C ………. Require replacement of hardware.
Attaching hardware not
functioning ………… A .. Require repair or replacement of hardware.
Broken ……………… A .. Require repair or replacement. Housing cracked ……… A .. Require repair or replacement. Leaking …………….. A .. Require repair or replacement. Pressure relief valve
stuck ……………… A .. Require repair or replacement. Seized ……………… A .. Require repair or replacement. Worn beyond
specifications ……… B .. Require repair or replacement.

PARK NEUTRAL POSITION SWITCHES

PARK NEUTRAL POSITION SWITCH INSPECTION
Condition Code Procedure
Attaching hardware
missing ……………. C ………. Require replacement of hardware.
Attaching hardware
threads damaged …….. A … Require repair or replacement of hardware.
Attaching hardware

threads stripped

(threads missing) ……

A

Require repair or replacement

of hardware.

Connector broken ……..

A

..

Require repair or replacement.

Connector (Weatherpack

type) leaking ……….

A

..

Require repair or replacement.

Connector melted ……..

A

………..

(1) Require repair or

replacement.

Connector missing …….

C

…………

Require replacement.

Contaminated …………

A

………..

(2) Require repair or

replacement.

Inoperative ………….

B

………..

(3) Require repair or

replacement. Further

inspection required.

Leaking ……………..

A

.. Require r

epair or replacement.

Missing ……………..

C

…………

Require replacement.

Resistance out of

specification ……….

B

.. Require

repair or replacement.

Terminal broken ………

A

.. Require

repair or replacement.

Terminal burned, affecting

performance …………

A

………..

(1) Require repair or

replacement.

Terminal burned, not
affecting performance .. 2 .. Suggest repair or replacement. Terminal corroded,
affecting performance .. A .. Require repair or replacement.
Terminal corroded, not
affecting performance .. 2 .. Suggest repair or replacement. Terminal loose, affecting
performance ………… B .. Require repair or replacement. Terminal loose, not
affecting performance .. 1 .. Suggest repair or replacement. Threads damaged ……… A .. Require repair or replacement. Threads stripped (threads
missing) …………… A ………… Require replacement. Wire lead conductors

exposed …………….

B

.. Require repair or

replacement.

Wire lead corroded ……

A

.. Require repair or

replacement.

Wire lead open ……….

A

.. Require repair or

replacement.

Wire lead shorted …….

A

.. Require repair or

replacement.

(1) – Determine cause and correct prior to repair or replacement of part.
(2) – Determine source of contamination, such as engine coolant, fuel, metal particles, or water. Require repair or replacement.
(3) – Inoperative includes intermittent operation or out of OEM specification. Some components may be serviceable; check for accepted cleaning procedure.

PCV BREATHER ELEMENTS

PCV BREATHER ELEMENT INSPECTION
Condition Code Procedure
Attaching hardware
broken………………. A … Require repair or replacement of hardware.
Attaching hardware
missing ……………. C ………. Require replacement of hardware.
Attaching hardware not
functioning ………… A … Require repair or replacement of hardware.
Leaking …………….. A ………… Require replacement. Maintenance intervals … 3 … Suggest replacement to comply with vehicle’s OEM recommended
service intervals. Melted ……………… A ……….. Required replacement. Missing …………….. C ………… Require replacement. Restricted, affecting
performance ………… A ………… Require replacement. Restricted, not affecting

performance …………

1

…………

Suggest

replacement.

Water-contaminated ……

A

…………

Require

replacement.

PCV ORIFICES

PCV ORIFICE INSPECTION
Condition Code Procedure
Leaking …………….. A ………… Require replacement. Maintenance interval …. 3 … Suggest repair or replacement to comply with OEM recommended
service intervals.
Missing …………….. C ………… Require replacement. Restricted ………….. A .. Require repair or replacement.

PCV VALVES

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

functioning …………

A

… Require repair or replacement

of hardware.

Grommet broken ……….

A

… Require repair or replacement

of grommet.

Grommet missing ………

C

. Require replacement of grommet.

Grommet not

functioning …………

A

… Require repair or replacement

of grommet.

Inoperative ………….

A

…….. (1) Require replacement.

Leaking ……………..

A

………… Require replacement.

Maintenance interval ….

3

… Suggest replacement to comply

with vehicle’s OEM recommended

service intervals.

Missing ……………..

C

………… Require replacement.

Restricted …………..

A

………… Require replacement.

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

PICK-UP ASSEMBLIES (INCLUDES MAGNETIC, HALL EFFECT AND

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

Adjustment incorrect ….

B

…………….. Require repair.

Attaching hardware

broken ……………..

A

… Require repair or replacement

of hardware.

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

functioning …………

A

… Require repair or replacement

of hardware.

Connector broken ……..

A

.. Require repair or replacement.

Connector (Weatherpack

type) leaking ……….

A

.. Require repair or replacement.

Connector melted ……..

A

……….. (1) Require repair or

replacement.

Connector missing …….

C

………… Require replacement.

Inoperative ………….

B

…….. (2) Require replacement.

Oil-soaked …………..

A

………… Require replacement.

Terminal broken ………

A

.. Require

repair or replacement.

Terminal burned, affecting

performance …………

A

………..

(1) Require repair or

replacement.

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

affecting performance

..

A

..

Require

repair

or

replacement.

Terminal corroded, not

affecting performance

..

2

..

Suggest

repair

or

replacement.

Terminal loose, affecting

performance …………

B

..

Require

repair

or

replacement.

Terminal loose, not

affecting performance ..

1

..

Suggest

repair

or

replacement.

Wire lead conductors

exposed …………….

B

..

Require

repair

or

replacement.

Wire lead corroded ……

A

..

Require

repair

or

replacement.

Wire lead open ……….

A

..

Require

repair

or

replacement.

Wire lead shorted …….

A

..

Require

repair

or

replacement.

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

POWER STEERING PRESSURE SENSORS

POWER STEERING PRESSURE SENSOR INSPECTION
Condition Code Procedure
Attaching hardware
missing ……………. C ………. Require replacement of hardware.
Attaching hardware
threads damaged …….. A … Require repair or replacement of hardware.
Attaching hardware

threads stripped

(threads missing) ……

A

Require repair or replacement

of hardware.

Connector broken ……..

A

..

Require repair or replacement.

Connector (Weatherpack

type) leaking ……….

A

..

Require repair or replacement.

Connector melted ……..

A

………..

(1) Require repair or

replacement.

Connector missing …….

C

…………

Require replacement.

Contaminated …………

A

………..

(2) Require repair or

replacement.

Inoperative ………….

B

………..

(3) Require repair or

replacement. Further

inspection required.

Leaking ……………..

A

.. Require repair or

replacement.

Missing ……………..

C

………… Require

replacement.

Resistance out of

specification ……….

B

.. Require repair or

replacement.

Restricted, affecting
performance ………… A .. Require repair or replacement. Terminal broken ……… A .. Require repair or replacement. Terminal burned, affecting
performance ………… A ……….. (1) Require repair or
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. Threads damaged ……… A .. Require repair or replacement. Threads stripped (threads
missing) …………… A ………… Require replacement. Wire lead conductors

exposed …………….

B

.. Require repair or

replacement.

Wire lead corroded ……

A

.. Require repair or

replacement.

Wire lead open ……….

A

.. Require repair or

replacement.

Wire lead shorted …….

A

.. Require repair or

replacement.

(1) – Determine cause and correct prior to repair or replacement of part.
(2) – Determine source of contamination, such as engine coolant, fuel, metal particles, or water. Require repair or replacement.
(3) – Inoperative includes intermittent operation or out of OEM specification. Some components may be serviceable; check for accepted cleaning procedure.

POWERTRAIN CONTROL MODULES (PCM) AND PROM

POWERTRAIN CONTROL MODULE (PCM) AND PROM INSPECTION
Condition Code Procedure

Application incorrect …

B

………… Require replacement.

Attaching hardware

missing …………….

C

………. Require replacement of

hardware.

Attaching hardware
threads damaged …….. A … Require repair or replacement of hardware.
Attaching hardware threads stripped
(threads missing) …… A … Require repair or replacement of hardware.
Code set

(if applicable) ……..

A

……….

(1) Further inspection

required.

Connector broken ……..

A

.. Require

repair or replacement.

Connector (Weatherpack

type) leaking ……….

A

.. Require repair or replacement.

Connector melted ……..

A

……….. (2) Require repair or

replacement.

Connector missing …….

A

…………….. Require repair.

Contaminated …………

A

……….. (3) Require repair or

replacement.

Leaking ……………..

A

.. Require repair or replacement.

Malfunctioning ……….

A

……….. (4) Require repair or

replacement.

Missing ……………..

C

………… Require replacement.

Terminal broken ………

A

.. Require repair or replacement.

Terminal burned, affecting
performance ………… A ……….. (2) Require repair or replacement.
Terminal burned, not
affecting performance .. 2 .. Suggest repair or replacement. Terminal corroded,
affecting performance .. A .. Require repair or replacement. Terminal corroded, not
affecting performance .. 2 .. Suggest repair or replacement. Terminal loose, affecting
performance ………… B .. Require repair or replacement. Terminal loose, not
affecting performance .. 1 .. Suggest repair or replacement. Threads damaged ……… A .. Require repair or replacement. Threads stripped (threads
missing) …………… A ………… Require replacement. Wire lead conductors

exposed …………….

B

.. Require repair or

replacement.

Wire lead corroded ……

A

.. Require repair or

replacement.

Wire lead open ……….

A

.. Require repair or

replacement.

Wire lead shorted …….

A

.. Require repair or

replacement.

(1) – Refer to 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) – Includes inoperative, intermittent operation, failure to perform all functions, or out of OEM specification.

POWERTRAIN CONTROL PROM

See POWERTRAIN CONTROL MODULES (PCM) AND PROM.

PRESSURIZED EXPANSION TANK CAPS

See RADIATOR CAPS AND PRESSURIZED EXPANSION TANK CAPS.

RADIATOR CAPS AND PRESSURIZED EXPANSION TANK CAPS

RADIATOR CAP AND PRESSURIZED EXPANSION TANK CAP INSPECTION Condition Code Procedure

Application incorrect …

B

………..

Require replacement.

Coolant recovery check

valve inoperative ……

A

……. (1)

Require replacement.

Fails to maintain proper

pressure ……………

B

……….. Require replacement.

Gasket missing ……….

C

. Require replacement of gasket.

Missing ……………..

C

……….. Require replacement.

Seal missing …………

C

… Require replacement of seal.

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

RADIATOR FAN BLADES

RADIATOR FAN BLADE INSPECTION
Condition Code Procedure

Application incorrect …

B

……….. Require replacement.

Attaching hardware

broken ……………..

A

.. Require repair or replacement

of hardware.

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

functioning …………

A

.. Require repair or replacement

of hardware.

Bent ………………..

A

……….. Require replacement.

Broken ………………

A

……….. Require replacement.

Cracked ……………..

A

……….. Require replacement.

Loose ……………….

A

. Require repair or replacement.

Missing ……………..

C

……….. Require replacement.

RADIATOR FAN CLUTCHES

NOTE: Some lateral movement, measured at the fan blade tip, may be normal.
RADIATOR FAN CLUTCH INSPECTION
Condition Code Procedure
Attaching hardware
broken …………….. A … Require repair or replacement of hardware.
Attaching hardware
missing ……………. C ………. Require replacement of hardware.
Attaching hardware not
functioning ………… A … Require repair or replacement of hardware.
Bearing noisy ……….. A ………… Require replacement. Bearing worn ………… A ………… Require replacement. Fastener loose ………. A … Require repair or replacement of fastener.
Inoperative …………. A …….. (1) Require replacement. Leaking …………….. 1 ………… Suggest replacement. Seized ……………… A ………… Require replacement. Slips (insufficient fan
speed) …………….. A ………… Require replacement. Thermal control
incorrect ………….. B .. Require repair or replacement.
(1) – Inoperative includes intermittent operation or out of
OEM specification.

RADIATORS

RADIATOR INSPECTION
Condition Code Procedure
Air flow restriction …. A …………….. Require repair.

Application incorrect …

B

………… Require replacement.

Attaching hardware

broken ……………..

A

… Require repair or replacement

of hardware.

Attaching hardware
missing ……………. C ………. Require replacement of hardware.
Attaching hardware not
functioning ………… A .. Require repair or replacement of hardware.
Connection leaking …… A .. Require repair or replacement. Corroded ……………. 1 .. Suggest repair or replacement. Fins damaged, affecting
performance ………… A .. Require repair or replacement. Fins damaged, not
affecting performance .. 2 .. Suggest repair or replacement. Internal oil cooler
leaking ……………. A .. Require repair or replacement. Internal restrictions,
affecting performance .. B .. Require repair or replacement. Internal restrictions, not
affecting performance .. 2 .. Suggest repair or replacement. Leaking …………….. A .. Require repair or replacement. Threads damaged ……… A .. Require repair or replacement. Threads stripped (threads
missing) …………… A .. Require repair or replacement. Tubes damaged, affecting
performance ………… A .. Require repair or replacement. Tubes damaged, not
affecting performance .. .. …….. No service suggested or required.

ROLL OVER VALVES

ROLL OVER VALVE INSPECTION
Condition Code Procedure
Inoperative …………. A ……. (1) Require replacement. Leaking …………….. A ……….. Require replacement. Missing …………….. C ……….. Require replacement.
(1) – Inoperative includes intermittent operation or out of
OEM specification.

SEALING COMPOUNDS

SEALING COMPOUND INSPECTION
Condition Code Procedure
Leaking …………….. A ……….. (1) Require repair or replacement.
(1) – Require inspection of mating and sealing surface and repair or replace as necessary.

SEALS

SEAL INSPECTION
Condition Code Procedure
Leaking …………….. A ……….. (1) Require repair or replacement.
(1) – Require inspection of mating and sealing surface and repair or replace as necessary.

SECONDARY AIR INJECTION SYSTEM MANAGEMENT DEVICES SECONDARY AIR INJECTION SYSTEM MANAGEMENT DEVICE INSPECTION Condition Code Procedure

Attaching hardware
missing ……………. C ………. Require replacement of hardware.
Attaching hardware
threads damaged …….. A … Require repair or replacement of hardware.
Attaching hardware

threads stripped

(threads missing) ……

A

..

Require repair or replacement

of hardware.

Connector broken ……..

A

..

Require repair or replacement.

Connector (Weatherpack

type) leaking ……….

A

..

Require repair or replacement.

Connector melted ……..

A

………..

(1) Require repair or

replacement.

Connector missing …….

C

…………

Require replacement.

Contaminated …………

A

………..

(2) Require repair or

replacement.

Inoperative ………….

B

………..

(3) Require repair or

replacement. Further

inspection required.

Leaking ……………..

A

.. Require repair or

replacement.

Missing ……………..

C

………… Require

replacement.

Resistance out of

specification ……….

B

.. Require repair or

replacement.

Restricted, affecting
performance ………… A .. Require repair or replacement. Terminal broken ……… A .. Require repair or replacement. Terminal burned, affecting
performance ………… A ……….. (1) Require repair or replacement.
Terminal burned, not
affecting performance .. 2 .. Suggest repair or replacement. Terminal corroded,
affecting performance .. A .. Require repair or replacement. Terminal corroded, not
affecting performance .. 2 .. Suggest repair or replacement. Terminal loose, affecting
performance ………… B .. Require repair or replacement. Terminal loose, not
affecting performance .. 1 .. Suggest repair or replacement. Threads damaged ……… A .. Require repair or replacement. Threads stripped (threads
missing) …………… A ………… Require replacement. Wire lead conductors

exposed …………….

B

.. Require repair or

replacement.

Wire lead corroded ……

A

.. Require repair or

replacement.

Wire lead open ………. A .. Require repair or replacement. Wire lead shorted ……. A .. Require repair or replacement.
(1) – Determine cause and correct prior to repair or replacement of part.
(2) – Determine source of contamination, such as engine coolant, fuel, metal particles, or water. Require repair or replacement.
(3) – Inoperative includes intermittent operation or out of OEM specification. Some components may be serviceable; check for accepted cleaning procedure.

SENSORS AND ACTUATORS

NOTE: Conditions pertaining to the sensors and actuators listed in this section may be found under the name of the sensor or actuator.
SENSOR ABBREVIATION TABLE
Sensor Abbreviation
Accelerator Pedal Position Sensor ……………………. APP Air Conditioning Cycling Switch ………………………. AC Air Conditioning Pressure Sensor ……………………… .. Air Fuel Ratio Sensor ……………………………….. .. Barometric Pressure Sensor …………………………. BARO Camshaft Position Sensor ……………………………. CMP Clutch Pedal Position Switch ………………………… CPP Cooling Fan Motor Sensors and Switches ………………… .. Crankshaft Position Sensor ………………………….. CKP Electronic Transmission Feedback Devices ………………. .. Engine Coolant Temperature Sensor ……………………. ECT Evaporative Emission feedback devices …………………. .. Exhaust Gas Recirculation feedback devices …………….. .. Fan Control Sensor ………………………………….. FC Intake Air Temperature Sensor ……………………….. IAT Knock Sensor ……………………………………….. KS Manifold Absolute Pressure Sensor ……………………. MAP Mass Air Flow Sensor ……………………………….. MAF O2 Sensor …………………………………………. O2S Park Neutral Position Switch ………………………… PNP Power Steering Pressure Sensor ………………………. PSP Thermal Vacuum Valve ……………………………….. TVV Throttle Position Sensor ………………………. TP Sensor Throttle Position Switch …………………………….. .. Transmission Range Switch ……………………… TR Switch Vehicle Speed Sensor ……………………………….. VSS Volume Air Flow Sensor ……………………………… VAF
ACTUATOR ABBREVIATION TABLE
Actuator Abbreviation
Air Injection Control Solenoid ……………………….. .. Electronic Transmission control devices ……………….. .. Evaporative Emission Canister ………………………. EVAP Purge Device ……………………………………….. .. Exhaust Gas Recirculation Device …………………….. EGR Fuel Injector ………………………………………. .. Idle Air Control …………………………………… IAC
Idle Speed Control Actuator …………………………. ISC Mix Control Solenoid ………………………… MC Solenoid Secondary Air Injection System Management Device …. AIR, PAIR Vacuum Regulator Solenoid ……………………………. .. Waste Gate Control Solenoid ………………………….. ..

SHROUDS, BAFFLES AND DEFLECTORS

SHROUD, BAFFLE AND DEFLECTOR INSPECTION
Condition
Code Procedure
Application incorrect, affecting cooling system
performance ………… A . Require repair or replacement. Attaching hardware
broken …………….. A .. Require repair or replacement of hardware.
Attaching hardware
missing ……………. C ……… Require replacement of hardware.
Attaching hardware not
functioning ………… A .. Require repair or replacement of hardware.
Bent, affecting cooling
system performance ….. A . Require repair or replacement. Blocked, affecting cooling
system performance ….. A . Require repair or replacement. Broken, affecting cooling
system performance ….. A . Require repair or replacement. Cracked, affecting cooling
system performance ….. A . Require repair or replacement. Loose, affecting cooling
system performance ….. A ……………. Require repair. Loose, not affecting
cooling system
performance ………… 2 ……………. Suggest repair. Missing, affecting cooling
system performance ….. C ……….. Require replacement.

SPARK PLUGS

NOTE: You are not required to replace spark plugs in sets.
However, you may suggest replacement of the other plugs for preventive maintenance.
SPARK PLUG INSPECTION
Condition Code Procedure

Application incorrect … B

…………

Require

replacement.

Electrode eroded …….. 1

…………

Suggest

replacement.

Fouled ……………… A ……….. (1) Require repair or replacement.
Gap incorrect ……….. B .. Require repair or replacement. Insulation broken ……. A …………. Require replacement Insulator cracked ……. A ………… Require replacement. Leaking compression ….. A .. Require repair or replacement. Maintenance interval …. 3 ………… Suggest replacement. Threads damaged ……… A .. Require repair or replacement. Threads stripped (threads
missing) …………… A ………… Require replacement. (1) – Determine cause of fouling and suggest repair.

SPRING LOCKS

SPRING LOCK INSPECTION
Condition Code Procedure
Leaking …………….. A ……….. (1) Require repair or replacement.
(1) – Require inspection of mating and sealing surface and repair or replace as necessary.

SUPER CHARGERS

SUPER CHARGER INSPECTION
Condition Code Procedure
Attaching hardware damaged, affecting operation or
performance ………… A … Require repair or replacement of hardware.
Attaching hardware
missing ……………. C ………. Require replacement of hardware.
Bearing noisy ……….. A ………… Require replacement. Bearing worn ………… A ………… Require replacement. Boost pressure
incorrect ………….. A ……….. (1) Require repair or replacement.
Clearance out of

specification ……….

B

..

Require

repair or

replacement.

Leaking ……………..

A

..

Require

repair or

replacement.

Noisy ……………….

2

..

Suggest

repair or

replacement.

Threads damaged ………

A

..

Require

repair or

replacement.

Threads stripped (threads

missing) ……………

A

..

Require

repair or

replacement.

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

SWITCHES

SWITCH INSPECTION
Condition Code Procedure
Attaching hardware
broken …………….. A … Require repair or replacement of hardware.
Attaching hardware
missing ……………. C ………. Require replacement of hardware.
Attaching hardware not
functioning ………… A … Require repair or replacement
Binding, affecting
of hardware.
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.

THERMAL VACUUM VALVES

THERMAL VACUUM VALVE INSPECTION
Condition Code Procedure

Connector broken ……..

A

.. Require repair or replacement.

Connector (Weatherpack

type) leaking ……….

A

.. Require repair or replacement.

Connector melted ……..

A

……….. (1) Require repair or

replacement.

Connector missing …….

C

………… Require replacement.

Contaminated …………

A

……….. (2) Require repair or

replacement.

Inoperative ………….

B

……….. (3) Require repair or

replacement. Further

inspection required.

Leaking ……………..

A

.. Require repair or replacement.

Missing ……………..

C

………… Require replacement.

Resistance out of

specification ……….

B

.. Require repair or replacement.

Restricted, affecting
performance ………… A .. Require repair or replacement. Terminal broken ……… A .. Require repair or replacement. Terminal burned, affecting
performance ………… A ……….. (1) Require repair or replacement.
Terminal burned, not
affecting performance .. 2 .. Suggest repair or replacement. Terminal corroded,
affecting performance .. A .. Require repair or replacement. Terminal corroded, not
affecting performance .. 2 .. Suggest repair or replacement. Terminal loose, affecting
performance ………… B .. Require repair or replacement. Terminal loose, not
affecting performance .. 1 .. Suggest repair or replacement. Threads damaged ……… A .. Require repair or replacement. Threads stripped (threads
missing) …………… A ………… Require replacement. Wire lead conductors

exposed …………….

B

.. Require repair or

replacement.

Wire lead corroded ……

A

.. Require repair or

replacement.

Wire lead open ……….

A

.. Require repair or

replacement.

Wire lead shorted …….

A

.. Require repair or

replacement.

(1) – Determine cause and correct prior to repair or replacement of part.
(2) – Determine source of contamination, such as engine coolant, fuel, metal particles, or water. Require repair or replacement.
(3) – Inoperative includes intermittent operation or out of OEM specification. Some components may be serviceable; check for accepted cleaning procedure.

THERMOSTATIC AIR DOOR ASSEMBLIES

THERMOSTATIC AIR DOOR ASSEMBLY INSPECTION
Condition Code Procedure
Attaching hardware damaged, affecting operation or
performance ………… A … Require repair or replacement of hardware.
Attaching hardware

missing …………….

C

………. Require replacement of

hardware.

Binding ……………..

A

.. Require repair or replacement.

Leaking ……………..

A

.. Require repair or replacement.

Missing ……………..

C

………… Require replacement.

Seized ………………

A

.. Require repair or replacement.

THERMOSTATS AND HOUSINGS

THERMOSTAT AND HOUSING INSPECTION
Condition Code Procedure
Application incorrect … B ………… Require replacement. Attaching hardware
broken …………….. A … Require repair or replacement of hardware.
Attaching hardware
corroded …………… A … Require repair or replacement of hardware.
Attaching hardware
missing ……………. C ………. Require replacement of hardware.
Attaching hardware not

functioning …………

A

… Require repair or replacement

of hardware.

Housing corroded ……..

1

.. Suggest replacement of housing.

Inoperative ………….

A

…….. (1) Require replacement.

Installation incorrect ..

B

.. Require repair or replacement.

Leaking ……………..

A

.. Require repair or replacement.

Thermostat missing ……

C

………. Require replacement of

thermostat.

Threads damaged ………

A

.. Require repair or replacement.

Threads stripped (threads

missing) ……………

A

.. Require repair or replacement.

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

THROTTLE BODIES

THROTTLE BODY INSPECTION
Condition Code Procedure

Connector broken ……..

A

.. Require repair or replacement.

Connector (Weatherpack

type) leaking ……….

A

.. Require repair or replacement.

Connector melted ……..

A

……….. (1) Require repair or

replacement.

Connector missing …….

C

………… Require replacement.

Contaminated …………

A

……….. (2) Require repair or

replacement.

Leaking ……………..

A

.. Require repair or replacement.

Restricted …………..

A

…………. (3) Require repair.

Terminal broken ………

A

.. Require repair or replacement.

Terminal burned, affecting

performance …………

A

……….. (1) Require repair or

replacement.

Terminal burned, not
affecting performance .. 2 .. Suggest repair or replacement. Terminal corroded,
affecting performance .. A .. Require repair or replacement. Terminal corroded, not
affecting performance .. 2 .. Suggest repair or replacement. Terminal loose, affecting
performance ………… B .. Require repair or replacement. Terminal loose, not
affecting performance .. 1 .. Suggest repair or replacement.

Threads damaged ………

A

..

Require

repair

or

replacement.

Threads stripped (threads

missing) ……………

A

..

Require

repair

or

replacement.

Throttle shaft binding,

affecting performance ..

A

..

Require

repair

or

replacement.

Throttle shaft worn,

affecting performance ..

A

..

Require

repair

or

replacement.

Throttle shaft worn, not

affecting performance ..

1

..

Suggest

repair

or

replacement.

Wire lead conductors

exposed …………….

B

..

Require

repair

or

replacement.

Wire lead corroded ……

A

..

Require

repair

or

replacement.

Wire lead open ……….

A

..

Require

repair

or

replacement.

Wire lead shorted …….

A

..

Require

repair

or

replacement.

(1) – Determine cause and correct prior to repair or replacement of part.
(2) – Determine source of contamination, such as engine coolant, fuel, metal particles, or water. Require repair or replacement.
(3) – Some components may be serviceable; check for accepted cleaning procedure.

THROTTLE CABLES

See THROTTLE LINKAGES AND CABLES.

THROTTLE LINKAGES AND CABLES

THROTTLE LINKAGE AND CABLE INSPECTION
Attaching hardware
Bracket bent, not
affecting performance .. .. ……. No service suggested or required.
Bracket broken, affecting
performance ………… A Require replacement. Bracket broken, not
affecting performance .. .. ……. No service suggested or required.
Bracket corroded,
affecting performance .. A .. Require repair or replacement. Bracket corroded, not

affecting performance ..

2

..

Suggest

repair

or

replacement.

Bracket cracked, affecting

performance …………

A

..

Require

repair

or

replacement.

Bracket cracked, not

affecting performance ..

1

..

Suggest

repair

or

replacement.

Bracket loose, affecting
performance ………… A .. Require repair or replacement. Bracket loose, not

affecting performance ..

1

.. Suggest repair or replacement.

Bracket missing ………

C

………… Require replacement.

Broken ………………

A

………… Require replacement.

Cracked ……………..

A

.. Require repair or replacement.

Disconnected …………

A

.. Require repair or replacement.

Kinked ………………

A

.. Require repair or replacement.

Melted ………………

A

.. Require repair or replacement.

Missing ……………..

C

………… Require replacement.

Noisy ……………….

2

.. Suggest repair or replacement.

Out of adjustment …….

B

……….. (1) Require repair or

replacement.

Routed incorrectly ……

2

…………….. Suggest repair.

Seized ………………

A

.. Require repair or replacement.

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

THROTTLE POSITION SENSORS

THROTTLE POSITION SENSOR INSPECTION
Condition Code Procedure
Attaching hardware
missing ……………. C ………. Require replacement of hardware.
Attaching hardware
threads damaged …….. A … Require repair or replacement of hardware.
Attaching hardware

threads stripped

(threads missing) ……

A

Require repair or replacement

of hardware.

Connector broken ……..

A

..

Require repair or replacement.

Connector (Weatherpack

type) leaking ……….

A

..

Require repair or replacement.

Connector melted ……..

A

………..

(1) Require repair or

replacement.

Connector missing …….

C

…………

Require replacement.

Contaminated …………

A

………..

(2) Require repair or

replacement.

Inoperative ………….

B

………..

(3) Require repair or

replacement. Further

inspection required.

Missing ……………..

C

…………

Require replacement.

Resistance out of

specification ……….

B

..

Require repair or replacement.

Terminal broken ………

A

..

Require repair or replacement.

Terminal burned, affecting

performance …………

A

..

(1) Require repair or replacement.

Terminal burned, not
affecting performance .. 2 .. Suggest repair or replacement. Terminal corroded,
affecting performance .. A .. Require repair or replacement. Terminal corroded, not
affecting performance .. 2 .. Suggest repair or replacement. Terminal loose, affecting
performance ………… B .. Require repair or replacement. Terminal loose, not

affecting performance ..

1

.. Suggest repair or

replacement.

Threads damaged ………

A

.. Require repair or

replacement.

Threads stripped (threads

missing) ……………

A

………… Require

replacement.

Wire lead conductors

exposed …………….

B

.. Require repair or

replacement.

Wire lead corroded ……

A

.. Require repair or

replacement.

Wire lead open ……….

A

.. Require repair or

replacement.

Wire lead shorted …….

A

.. Require repair or

replacement.

(1) – Determine cause and correct prior to repair or replacement of part.
(2) – Determine source of contamination, such as engine coolant, fuel, metal particles, or water. Require repair or replacement.
(3) – Inoperative includes intermittent operation or out of OEM specification. Some components may be serviceable; check for accepted cleaning procedure.

THROTTLE POSITION SWITCHES

THROTTLE POSITION SWITCH INSPECTION
Condition Code Procedure
Attaching hardware
missing ……………. C ………. Require replacement of hardware.
Attaching hardware
threads damaged …….. A … Require repair or replacement of hardware.
Attaching hardware threads stripped
(threads missing) …… A .. Require repair or replacement of hardware.
Connector broken …….. A .. Require repair or replacement. Connector (Weatherpack
type) leaking ………. A .. Require repair or replacement. Connector melted …….. A ……….. (1) Require repair or replacement.
Connector missing ……. C ………… Require replacement. Inoperative …………. B ……….. (2) Require repair or replacement. Further
inspection required. Missing …………….. C ………… Require replacement. Resistance out of
specification ………. B .. Require repair or replacement. Terminal broken ……… A .. Require repair or replacement. Terminal burned, affecting
performance ………… A ……….. (1) Require repair or replacement.
Terminal burned, not
affecting performance .. 2 .. Suggest repair or replacement. Terminal corroded,
affecting performance .. A .. Require repair or replacement. Terminal corroded, not
affecting performance .. 2 .. Suggest repair or replacement. Terminal loose, affecting
performance ………… B .. Require repair or replacement. Terminal loose, not

affecting performance ..

1

..

Suggest

repair

or

replacement.

Threads damaged ………

A

..

Require

repair

or

replacement.

Threads stripped (threads
missing) …………… A ………… Require replacement. Wire lead conductors
exposed ……………. B .. Require repair or replacement. Wire lead corroded …… A .. Require repair or replacement. Wire lead open ………. A .. Require repair or replacement. Wire lead shorted ……. A .. Require repair or replacement.
(1) – Determine cause and correct prior to repair or replacement of part.
(2) – Inoperative includes intermittent operation or out of OEM specification. Some components may be serviceable; check for accepted cleaning procedure.

TIMING BELT SPROCKETS

TIMING BELT SPROCKET INSPECTION
Condition Code Procedure
Alignment incorrect ….. B …………….. Require repair. Attaching hardware
broken …………….. A … Require repair or replacement of hardware.
Attaching hardware
missing ……………. C ………. Require replacement of hardware.
Attaching hardware not
functioning ………… A … Require repair or replacement of hardware.
Bent ……………….. A ………… Require replacement. Cracked …………….. A ………… Require replacement. Key damaged …………. A ………… Require replacement. Loose ………………. A .. Require repair or replacement. Missing …………….. C ………… Require replacement. Pulley damaged, affecting
belt life ………….. A ………… Require replacement. Sprocket damaged,
affecting belt life …. A .. Require repair or replacement.

Sprocket loose ……….

B

..

Require

repair

or

replacement.

Sprocket-to-shaft

alignment incorrect …..

B

..

Require

repair

or

replacement.

TIMING BELTS

TIMING BELT INSPECTION Condition C

Adjustment incorrect ….

ode

2

Procedure

……… (1) Suggest adjustment.

Alignment incorrect …..

B

……….. (2) Further inspection

required.

Broken ………………

A

………… Require replacement.

Cam timing out of

specification ……….

B

…………….. Require repair.

Cracked ……………..

1

………… Suggest replacement.

Fluid-soaked …………

1

… Suggest replacement. Further

inspection required.

Frayed ………………

1

………… Suggest replacement.

Maintenance intervals …

3

… Suggest replacement to comply

with vehicle OEM recommended

service intervals.

Missing ……………..

C

…….. (3) Require replacement.

Noisy ……………….

2

………. (4) Further inspection

required.

See note below.

Plies separated ………

A

………… Require replacement.

Tension out of

specification ……….

B

……….. Require adjustment or

replacement.

Teeth missing ………..

A

………… Require replacement.

(1) – Inspect belt tensioners, pulleys, and cover.
(2) – Determine cause of incorrect alignment and require repair. (3) – CAUTION: Internal engine damage may result from timing
belt damage/failure.
(4) – Determine cause of noise and suggest repair.

TORQUE STRUTS

TORQUE STRUT INSPECTION
Condition Code Procedure
Attaching hardware
broken …………….. A … Require repair or replacement of hardware.
Attaching hardware
missing ……………. C ………. Require replacement of hardware.
Attaching hardware not
functioning ………… A … Require repair or replacement of hardware.
Binding …………….. A ………… Require replacement. Body dented …………. A ………. (1) Further inspection required.
Body punctured ………. A ………… Require replacement. Bushing deteriorated,
affecting performance .. A ………… Require replacement. Bushing deteriorated, not
affecting performance .. .. …….. No service suggested or
Leaking oil, enough for
(1) – Require replacement of units where dents restrict strut piston rod movement. If dents don’t restrict movement, no service is suggested or required.
(2) – If noise is isolated to shock or strut, suggest replacement.

TRANSMISSION RANGE SWITCHES

TRANSMISSION RANGE SWITCH INSPECTION
Condition Code Procedure
Attaching hardware
missing ……………. C ………. Require replacement of hardware.
Attaching hardware
threads damaged …….. A … Require repair or replacement of hardware.
Attaching hardware

threads stripped

(threads missing) ……

A

Require repair or replacement

of hardware.

Connector broken ……..

A

..

Require repair or replacement.

Connector (Weatherpack

type) leaking ……….

A

..

Require repair or replacement.

Connector melted ……..

A

………..

(1) Require repair or

replacement.

Connector missing …….

C

…………

Require replacement.

Contaminated …………

A

………..

(2) Require repair or

replacement.

Inoperative ………….

B

………..

(3) Require repair or

replacement. Further

inspection required.

Leaking ……………..

A

.. Require r

epair or replacement.

Missing ……………..

C

…………

Require replacement.

Resistance out of

specification ……….

B

.. Require

repair or replacement.

Terminal broken ………

A

.. Require

repair or replacement.

Terminal burned, affecting

performance …………

A

………..

(1) Require repair or

replacement.

Terminal burned, not
affecting performance .. 2 .. Suggest repair or replacement. Terminal corroded,
affecting performance .. A .. Require repair or replacement. Terminal corroded, not
affecting performance .. 2 .. Suggest repair or replacement. Terminal loose, affecting
performance ………… B .. Require repair or replacement. Terminal loose, not
affecting performance .. 1 .. Suggest repair or replacement. Threads damaged ……… A .. Require repair or replacement. Threads stripped (threads
missing) …………… A ………… Require replacement. Wire lead conductors

exposed …………….

B

.. Require repair or

replacement.

Wire lead corroded ……

A

.. Require repair or

replacement.

Wire lead open ……….

A

.. Require repair or

replacement.

Wire lead shorted …….

A

.. Require repair or

replacement.

(1) – Determine cause and correct prior to repair or replacement of part.
(2) – Determine source of contamination, such as engine coolant, fuel, metal particles, or water. Require repair or replacement.
(3) – Inoperative includes intermittent operation or out of
OEM specification. Some components may be serviceable;
check for accepted cleaning procedure.

TUBE CLAMPS

See HOSE AND TUBE COUPLERS, CONNECTORS AND CLAMPS.

TUBE CONNECTORS

See HOSE AND TUBE COUPLERS, CONNECTORS AND CLAMPS.

TUBE COUPLERS

See HOSE AND TUBE COUPLERS, CONNECTORS AND CLAMPS.

TUBES

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

TURBO CHARGERS

TURBO CHARGER INSPECTION
Condition Code Procedure
Attaching hardware
broken …………….. A … Require repair or replacement of hardware.
Attaching hardware
missing ……………. C ………. Require replacement of hardware.
Attaching hardware not
functioning ………… A … Require repair or replacement of hardware.
Boost pressure
incorrect ………….. A ……….. (1) Require repair or replacement.

Leaking ……………..

A

..

Require

repair or replacement.

Noisy ……………….

2

..

Suggest

repair or replacement.

Oil seal (internal)

leaking …………….

A

..

Require

repair or replacement.

Vibrates …………….

A

..

Require

repair or replacement.

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

VACUUM CONNECTIONS

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

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

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

VACUUM REGULATOR SOLENOIDS

VACUUM REGULATOR SOLENOID INSPECTION
Condition Code Procedure
Attaching hardware
missing ……………. C ………. Require replacement of hardware.
Attaching hardware
threads damaged …….. A … Require repair or replacement of hardware.
Attaching hardware

threads stripped

(threads missing) ……

A

Require repair or replacement

of hardware.

Connector broken ……..

A

..

Require repair or replacement.

Connector (Weatherpack

type) leaking ……….

A

..

Require repair or replacement.

Connector melted ……..

A

………..

(1) Require repair or

replacement.

Connector missing …….

C

…………

Require replacement.

Contaminated …………

A

………..

(2) Require repair or

replacement.

Inoperative ………….

B

………..

(3) Require repair or

replacement. Further

inspection required.

Leaking ……………..

A

.. Require repair or

replacement.

Missing ……………..

C

………… Require

replacement.

Resistance out of

specification ……….

B

.. Require repair or

replacement.

Restricted, affecting
performance ………… A .. Require repair or replacement. Terminal broken ……… A .. Require repair or replacement. Terminal burned, affecting
performance ………… A ……….. (1) Require repair or replacement.
Terminal burned, not
affecting performance .. 2 .. Suggest repair or replacement. Terminal corroded,
affecting performance .. A .. Require repair or replacement. Terminal corroded, not
affecting performance .. 2 .. Suggest repair or replacement. Terminal loose, affecting
performance ………… B .. Require repair or replacement. Terminal loose, not
affecting performance .. 1 .. Suggest repair or replacement. Threads damaged ……… A .. Require repair or replacement. Threads stripped (threads
missing) …………… A ………… Require replacement. Wire lead conductors

exposed …………….

B

.. Require repair or

replacement.

Wire lead corroded ……

A

.. Require repair or

replacement.

Wire lead open ……….

A

.. Require repair or

replacement.

Wire lead shorted …….

A

.. Require repair or

replacement.

(1) – Determine cause and correct prior to repair or replacement of part.
(2) – Determine source of contamination, such as engine coolant, fuel, metal particles, or water. Require repair or replacement.
(3) – Inoperative includes intermittent operation or out of OEM specification. Some components may be serviceable; check for accepted cleaning procedure.

VACUUM TUBES

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

VEHICLE SPEED SENSORS

VEHICLE SPEED SENSOR INSPECTION
Condition Code Procedure
Attaching hardware
missing ……………. C ………. Require replacement of hardware.
Attaching hardware
threads damaged …….. A … Require repair or replacement of hardware.
Attaching hardware

threads stripped

(threads missing) ……

A

Require repair or replacement

of hardware.

Connector broken ……..

A

..

Require repair or replacement.

Connector (Weatherpack

type) leaking ……….

A

..

Require repair or replacement.

Connector melted ……..

A

………..

(1) Require repair or

replacement.

Connector missing …….

C

…………

Require replacement.

Contaminated …………

A

………..

(2) Require repair or

replacement.

Inoperative ………….

B

………..

(3) Require repair or

replacement. Further

inspection required.

Leaking ……………..

A

.. Require r

epair or replacement.

Missing ……………..

C

…………

Require replacement.

Resistance out of

specification ……….

B

.. Require

repair or replacement.

Terminal broken ………

A

.. Require

repair or replacement.

Terminal burned, affecting

performance …………

A

………..

(1) Require repair or

replacement.

Terminal burned, not
affecting performance .. 2 .. Suggest repair or replacement. Terminal corroded,
affecting performance .. A .. Require repair or replacement. Terminal corroded, not
affecting performance .. 2 .. Suggest repair or replacement. Terminal loose, affecting
performance ………… B .. Require repair or replacement. Terminal loose, not
affecting performance .. 1 .. Suggest repair or replacement. Threads damaged ……… A .. Require repair or replacement. Threads stripped (threads
missing) …………… A ………… Require replacement. Wire lead conductors

exposed …………….

B

.. Require repair or

replacement.

Wire lead corroded ……

A

.. Require repair or

replacement.

Wire lead open ………. A .. Require repair or replacement. Wire lead shorted ……. A .. Require repair or replacement.
(1) – Determine cause and correct prior to repair or replacement of part.
(2) – Determine source of contamination, such as engine coolant, fuel, metal particles, or water. Require repair or replacement.
(3) – Inoperative includes intermittent operation or out of OEM specification. Some components may be serviceable; check for accepted cleaning procedure.

VOLUME AIR FLOW SENSORS

VOLUME AIR FLOW SENSOR INSPECTION
Condition Code Procedure
Attaching hardware
missing ……………. C ………. Require replacement of hardware.
Attaching hardware
threads damaged …….. A … Require repair or replacement of hardware.
Attaching hardware

threads stripped

(threads missing) ……

A

Require repair or replacement

of hardware.

Connector broken ……..

A

..

Require repair or replacement.

Connector (Weatherpack

type) leaking ……….

A

..

Require repair or replacement.

Connector melted ……..

A

………..

(1) Require repair or

replacement.

Connector missing …….

C

…………

Require replacement.

Contaminated …………

A

………..

(2) Require repair or

replacement.

Inoperative ………….

B

………..

(3) Require repair or

replacement. Further

inspection required.

Leaking ……………..

A

.. Require repair or

replacement.

Missing ……………..

C

………… Require

replacement.

Resistance out of

specification ……….

B

.. Require repair or

replacement.

Restricted, affecting
performance ………… A .. Require repair or replacement. Terminal broken ……… A .. Require repair or replacement. Terminal burned, affecting
performance ………… A ……….. (1) Require repair or replacement.
Terminal burned, not
affecting performance .. 2 .. Suggest repair or replacement. Terminal corroded,
affecting performance .. A .. Require repair or replacement. Terminal corroded, not
affecting performance .. 2 .. Suggest repair or replacement. Terminal loose, affecting
performance ………… B .. Require repair or replacement. Terminal loose, not
affecting performance .. 1 .. Suggest repair or replacement. Threads damaged ……… A .. Require repair or replacement. Threads stripped (threads
missing) …………… A ………… Require replacement.
Wire lead conductors
exposed ……………. B .. Require repair or replacement. Wire lead corroded …… A .. Require repair or replacement. Wire lead open ………. A .. Require repair or replacement. Wire lead shorted ……. A .. Require repair or replacement.
(1) – Determine cause and correct prior to repair or replacement of part.
(2) – Determine source of contamination, such as engine coolant, fuel, metal particles, or water. Require repair or replacement.
(3) – Inoperative includes intermittent operation or out of OEM specification. Some components may be serviceable; check for accepted cleaning procedure.

WASTE GATE CONTROL SOLENOIDS

WASTE GATE CONTROL SOLENOID INSPECTION
Condition Code Procedure
Attaching hardware
missing ……………. C ………. Require replacement of hardware.
Attaching hardware
threads damaged …….. A … Require repair or replacement of hardware.
Attaching hardware

threads stripped

(threads missing) ……

A

Require repair or replacement

of hardware.

Connector broken ……..

A

..

Require repair or replacement.

Connector (Weatherpack

type) leaking ……….

A

..

Require repair or replacement.

Connector melted ……..

A

………..

(1) Require repair or

replacement.

Connector missing …….

C

…………

Require replacement.

Contaminated …………

A

………..

(2) Require repair or

replacement.

Inoperative ………….

B

………..

(3) Require repair or

replacement. Further

inspection required.

Leaking ……………..

A

.. Require repair or

replacement.

Missing ……………..

C

………… Require

replacement.

Resistance out of

specification ……….

B

.. Require repair or

replacement.

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

Threads damaged ………

A

.. Require repair or

replacement.

Threads stripped (threads

missing) ……………

A

………… Require

replacement.

Wire lead conductors

exposed …………….

B

.. Require repair or

replacement.

Wire lead corroded ……

A

.. Require repair or

replacement.

Wire lead open ……….

A

.. Require repair or

replacement.

Wire lead shorted …….

A

.. Require repair or

replacement.

(1) – Determine cause and correct prior to repair or replacement of part.
(2) – Determine source of contamination, such as engine coolant, fuel, metal particles, or water. Require repair or replacement.
(3) – Inoperative includes intermittent operation or out of OEM specification. Some components may be serviceable; check for accepted cleaning procedure.

WASTE GATES AND BOOST CONTROL MECHANISMS

WASTE GATE AND BOOST CONTROL MECHANISM INSPECTION
Condition Code Procedure
Boost pressure
incorrect ………….. A ……….. (1) Require repair or replacement. Further inspection required.
Leaking …………….. A .. Require repair or replacement.
(1) – Incorrect boost pressure includes intermittent operation or out of OEM specification.

WATER PUMPS (ELECTRIC)

WATER PUMP (ELECTRIC) INSPECTION
Attaching hardware
Attaching hardware not
Terminal burned, affecting
performance ………… A ……….. (1) Require repair or replacement.
Terminal burned, not
affecting performance .. 2 .. Suggest repair or replacement. Terminal corroded,
affecting performance .. A .. Require repair or replacement. Terminal corroded, not
affecting performance .. 2 .. Suggest repair or replacement. Terminal loose, affecting
performance ………… B .. Require repair or replacement. Terminal loose, not

affecting performance ..

1

.. Suggest repair or

replacement.

Vibration ……………

1

………… Suggest

replacement.

Wire lead conductors

exposed …………….

B

.. Require repair or

replacement.

Wire lead corroded ……

A

.. Require repair or

replacement.

Wire lead open ……….

A

.. Require repair or

replacement.

Wire lead shorted …….

A

.. Require repair or

replacement.

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

WATER PUMPS (NON-ELECTRIC)

WATER PUMP (NON-ELECTRIC) INSPECTION
Condition Code Procedure
Attaching hardware
broken …………….. A … Require repair or replacement of hardware.
Attaching hardware
corroded …………… A … Require repair or replacement of hardware.
Attaching hardware
missing ……………. C ………. Require replacement of hardware.
Attaching hardware not
functioning ………… A … Require repair or replacement of hardware.
Corrosion (internal) is excessive, affecting
performance ………… A ………… Require replacement. Corrosion (internal) is

excessive, not affecting performance …………

Inoperative ………….

2

A

. Suggest cooling system service.

…….. (1) Require replacement.

Leaking ……………..

A

………… Require

replacement.

Noisy ……………….

A

………… Require

replacement.

Rotation incorrect for

application …………

B

.. Require repair or

replacement.

Shaft bent …………..

A

………… Require

replacement.

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

WIRING HARNESSES AND CONNECTORS

WIRING HARNESS AND CONNECTOR INSPECTION
Condition Code Procedure

Application incorrect …

B

.. Require repair or replacement.

Attaching hardware

broken ……………..

A

… Require repair or replacement

of hardware.

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

functioning …………

A

Require repair or replacement

of hardware.

Connector broken ……..

A

..

Require repair or replacement.

Connector (Weatherpack

type) leaking ……….

A

..

Require repair or replacement.

Connector melted ……..

A

……….. (1) Require repair or

replacement.

Connector missing …….

C

………… Require replacement.

Insulation damaged,

conductors exposed …..

A

.. Require repair or replacement.

Insulation damaged,
conductors not exposed . 1 ………… Suggest replacement. Open ……………….. A .. Require repair or replacement. Protective shield
(conduit) melted ……. 2 ……….. (1) Suggest repair or replacement.
Protective shield
(conduit) missing …… 2 .. Suggest repair or replacement. Resistance (voltage drop)
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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