1900 MITSUBISHI DIAMANTE engine coolant

II-6 TROUBLESHOOTING
DIAGhUSTIC PROCEDURES
Gasoline Engines
1. Engine turns over, but wilt not start
a. Check fuel level in fuel tank, add fuel if empty.
b. Check battery condition and state of charge. If voltage and load test below specifica-
tion, charge or replace battery.
c. Check battery terminal and cable condition and tightness. Clean terminals and replace
damaged, worn or corroded cables.
d. Check fuel delivery system. If fuel is not reaching the fuel injectors, check for a loose
electrical connector or defective fuse, relay or fuel pump and replace as necessary.
e. Engine may have excessive wear or mechanical damage such as low cylinder cranking
pressure, a broken camshaft drive system, insufficient valve clearance or bent valves.
f. Check for fuel contamination such as water in the fuel. During winter months, the wa-
ter may freeze and cause a fuel restriction. Adding a fuel additive may help, however
the fuel system may require draining and purging with fresh fuel.
g. Check for ignition system failure. Check for loose or shorted wires or damaged igni-
tion system components. Check the spark plugs for excessive wear or incorrect elec-
trode gap. If the problem is worse in wet weather, check for shorts between the spark
plugs and the ignition coils.
h. Check the engine management system for a failed sensor or control module.
2. Engine does not turn over when attempting to start
a. Check the battery state of charge and condition. If the dash lights are not visible or
very dim when turning the ignition key on, the battery has either failed internally or
discharged, the battery cables are loose, excessively corroded or damaged, or the al-
ternator has failed or internally shorted, discharging the battery. Charge or replacethe
battery, clean or replace the battery cables, and check the alternator output.
b. Check the operation of the neutral safety switch. On automatic transmission vehicles,
try starting the vehicle in both Park and Neutral. On manual transmission vehicles, de-
press the clutch pedal and attempt to start. On some vehicles, these switches can be
adjusted. Make sure the switches or wire connectors are not loose or damaged. Re-
place or adjust the switches as necessary.
c. Check the starter motor, starter solenoid or relay, and starter motor cables and wires.
Check the ground from the engine to the chassis. Make sure the wires are not loose,
damaged, or corroded. If battery voltage is present at the starter relay, try using a re-
mote starter to start the vehicle for test purposes only. Replace any damaged or cor-
roded cables, in addition to replacing any failed components.
d. Check the engine for seizure. If the engine has not been started for a long period of
time, internal parts such as the rings may have rusted to the cylinder walls. The engine
may have suffered internal damage, or could be hydro-locked from ingesting water.
Remove the spark plugs and carefully attempt to rotate the engine using a suitable
breaker bar and socket on the crankshaft pulley. If the engine is resistant to moving, or
moves slightly and then binds, do not force the engine any further before determining
the problem.
3. Enpine stalls immediately when started
a. Check the ignition switch condition and operation. The electrical contacts in the run
position may be worn or damaged. Try restarting the engine with all electrical acces-
sories in the off position. Sometimes turning the key on an off will help in emergency
situations, however once the switch has shown signs of failure, it should be replaced
as soon as possible.
b. Check for loose, corroded, damaged or shorted wires for the ignition system and re-
pair or replace.
c. Check for manifold vacuum leaks or vacuum hose leakage and repair or replace parts
as necessary.
d. Measure the fuel pump delivery volume and pressure. Low fuel pump pressure can
also be noticed as a lack of power when accelerating. Make sure the fuel pump lines
are not restricted. The fuel pump output is not adjustable and requires fuel pump re-
placement to repair.
e. Check the engine fuel and ignition management system. Inspect the sensor wiring and
electrical connectors. A dirty, loose or damaged sensor or control module wire can
simulate a failed component.
f. Check the exhaust system for internal restrictions.
4. Starter motor spins, but does not engage
a. Check the starter motor for a seized or binding pinion gear.
b. Remove the flywheel inspection plate and check for a damaged ring gear.
5. Engine is difficult to start when Gold
a. Check the battery condition, battery state of charge and starter motor current draw. Re-
place the battery if marginal and the starter motor if the current draw is beyond specifi-
cation. b. Check the battery cable condition. Clean the battery terminals and replace corroded or
damaged cables.
c. Check the fuel system for proper operation. A fuel pump with insufficient fuel pressure
or clogged injectors should be replaced.
d. Check the engine’s tune-up status. Note the tune-up specifications and check for items
such as severely worn spark plugs; adjust or replace as needed. On vehicles with
manually adjusted valve clearances, check for tight valves and adjust to specification.
e. Check for a failed coolant temperature sensor, and replace if out of specification.
f. Check the operation of the engine management systems for fuel and ignition; repair or
replace failed components as necessary.
6. En#ine is ditticutt to start when hot
a. Check the air filter and air intake system. Replace the air filter if it is dirty or contami-
nated. Check the fresh air intake system for restrictions or blockage.
b. Check for loose or deteriorated engine grounds and clean, tighten or replace as
needed.
c. Check for needed maintenance. Inspect tune-up and service related items such as
spark plugs and engine oil condition, and check the operation of the engine fuel and
ignition management system.
Diesel Engines
1. Engine turns over but won’t start
a. Check engine starting procedure and restart engine.
b. Check the glow plug operation and repair or replace as necessary.
c. Check for air in the fuel system or fuel filter and bleed the air as necessary.
d. Check the fuel delivery system and repair or replace as necessary.
e. Check fuel level and add fuel as needed.
f. Check fuel quality. If the fuel is contaminated, drain and flush the fuel tank.
g. Check engine compression. If compression is below specification, the engine may
need to be renewed or replaced.
h. Check the injection pump timing and set to specification.
i. Check the injection pump condition and replace as necessary.
j. Check the fuel nozzle operation and condition or replace as necessary.
2. Engine does
hot turn over when attempting to start
a. Check the battery state of charge and condition. If the dash lights are not visible or
very dim when turning the ignition key on, the battery has either failed internally or
discharged, the battery cables are loose, excessively corroded or damaged, or the al-
ternator has failed or internally shorted, discharging the battery. Charge or replace the
battery, clean or replace the battery cables, and check the alternator output.
b. Check the operation of the neutral safety switch. On automatic transmission vehicles,
try starting the vehicle in both Park and Neutral. On manual transmission vehicles, de-
press the clutch pedal and attempt to start. On some vehicles, these switches can be
adjusted. Make sure the switches or wire connectors are not loose or damaged. Re-
place or adjust the switches as necessary.
c. Check the starter motor, starter solenoid or relay, and starter motor cables and wires.
Check the ground from the engine to the chassis. Make sure the wires are not loose,
damaged, or corroded. If battery voltage is present at the starter relay, try using a re-
mote starter to start the vehicle for test purposes only. Replace any damaged or cor-
roded cables, in addition to replacing any failed components.
d. Check the engine for seizure. If the engine has not been started for a long period of
time, internal parts such as the rings may have rusted to the cylinder walls. The engine
may have suffered internal damage, or could be hydro-locked from ingesting water.
Remove the injectors and carefully attempt to rotate the engine using a suitable
breaker bar and socket on the crankshaft pulley. If the engine is resistant to moving, or
moves slightly and then binds, do not force the engine any further before determining
the cause of the problem.
3. Engine stalls afier starting
a. Check for a restriction in the fuel return line or the return line check valve and repair as
necessary.
b. Check the glow plug operation for turning the glow plugs off too soon and repair as
necessary.
c. Check for incorrect injection pump timing and reset to specification.
d. Test the engine fuel pump and replace if the output is below specification.
e. Check for contaminated or incorrect fuel. Completely flush the fuel system and replace
with fresh fuel.
f. Test the engine’s compression for low compression. If below specification, mechanical
repairs are necessary to repair.
g. Check for air in the fuel. Check fuel tank fuel and fill as needed.
h. Check for a failed injection pump. Replace the pump, making sure to properly set the
pump timing.

11-8 TROUBLESHOOTING
Ignition systems may be controlled by, or linked to, the engine fuel management sys-
tem. Similar to the fuel injection system, these ignition systems rely on electronic sen-
sors for information to determine the optimum ignition timing for a given engine speed
and load. Some ignition systems no longer allow the ignition timing to be adjusted.
Feedback from low voltage electrical sensors provide information to the control unit to
determine the amount of ignition advance. On these systems, if a failure occurs the failed
component must be replaced. Before replacing suspected failed electrical components,
carefully inspect the wiring and electrical connectors to the related components. Make
sure the electrical connectors are fully connected, clean and not physically damaged. If
necessary, clean the electrical contacts using electrical contact cleaner. The use of clean-
ing agents not specifically designed for electrical contacts should be avoided, as they
could leave a surface film or damage the insulation of the wiring.
1. Engine makes a knocking or pinging noise when accelerating
a. Check the octane rating of the fuel being used. Depending on the type of driving or
driving conditions, it may be necessary to use a higher octane fuel.
b. Verify the ignition system settings and operation. Improperly adjusted ignition timing
or a failed component, such as a knock sensor, may cause the ignition timing to ad-
vance excessively or prematurely. Check the ignition system operation and adjust, or
replace components as needed.
c. Check the spark plug gap, heat range and condition. If the vehicle is operated in se-
vere operating conditions or at continuous high speeds, use a colder heat range spark
plug. Adjust the spark plug gap to the manufacturer’s recommended specification and
replace worn or damaged spark plugs.
2. Sfarter motor grinds when used
a. Examine the starter pinion gear and the engine ring gear for damage, and replace dam-
aged parts.
b. Check the starter mounting bolts and housing. If the housing is cracked or damaged
replace the starter motor and check the mounting bolts for tightness.
3. Engine makes a screeching noise
a. Check the accessory drive belts for looseness and adjust as necessary.
b. Check the accessory drive belt tensioners for seizing or excessive bearing noises and
replace if loose, binding, or excessively noisy.
c. Check for a seizing water pump. The pump may not be leaking; however, the bearing
may be faulty or the impeller loose and jammed. Replace the water pump.
4. Engine makes a growling noise
a. Check for a loose or failing water pump. Replace the pump and engine coolant.
b. Check the accessory drive belt tensioners for excessive bearing noises and replace if
loose or excessively noisy.
5. Engine makes a ticking or tapping noise
a. On vehicles with hydraulic lash adjusters, check for low or dirty engine oil and top off
or replace the engine oil and filter.
b. On vehicles with hydraulic lash adjusters, check for collapsed lifters and replace failed
components.
c. On vehicles with hydraulic lash adjusters, check for low oil pressure caused by a re-
stricted oil filter, worn engine oil pump, or oil pressure relief valve.
d. On vehicles with manually adjusted valves, check for excessive valve clearance or
worn valve train parts. Adjust the valves to specification or replace worn and defective
parts.
e. Check for a loose or improperly tensioned timing belt or timing chain and adjust or re-
place parts as necessary.
f. Check for a bent or sticking exhaust or intake valve. Remove the engine cylinder head
to access and replace.
6. Engine makes a heavy knocking noise
a. Check for a loose crankshaft pulley or flywheel; replace and torque the mounting
bolt(s) to specification.
b. Check for a bent connecting rod caused by a hydro-lock condition. Engine disassem-
bly is necessary to inspect for damaged and needed replacement parts.
c. Check for excessive engine rod bearing wear or damage. This condition is also asso-
ciated with low engine oil pressure and will require engine disassembly to inspect for
damaged and needed replacement parts,
7. Vehicle has a fuel odor when driven ’ a. Check the fuel gauge level. If the fuel gauge registers full, it is possible that the odor is
caused by being filled beyond capacity, or some spillage occurred during refueling.
The odor should clear after driving an hour, or twenty miles, allowing the vapor canis-
ter to purge.
b. Check the fuel filler cap for looseness or seepage. Check the cap tightness and, if
loose, properly secure. If seepage is noted, replace the filler cap.
c. Check for loose hose clamps, cracked or damaged fuel delivery and return lines, or
leaking components or seals, and replace or repair as necessary. d. Check the vehicle’s fuel economy. If fuel consumption has increased due to a failed
component, or if the fuel is not properly ignited due to an ignition related failure, the
catalytic converter may become contaminated. This condition may also trigger the
check engine warning light. Check the spark plugs for a dark, rich condition or verify
the condition by testing the vehicle’s emissions. Replace fuel fouled spark plugs, and
test and replace failed components as necessary.
5. Vehicle has a rotten egg odor when driven
a. Check for a leaking intake gasket or vacuum leak causing a lean running condition. A
lean mixture may result in increased exhaust temperatures, causing the catalytic con-
verter to run hotter than normal. This condition may also trigger the check engine
warning light. Check and repair the vacuum leaks as necessary.
b. Check the vehicle’s alternator and battery condition. If the alternator is overcharging,
the battery electrolyte can be boiled from the battery, and the battery casing may begin
to crack, swell or bulge, damaging or shorting the battery internally. If this has oc-
curred, neutralize the battery mounting area with a suitable baking soda and water
mixture or equivalent, and replace the alternator or voltage regulator. Inspect, service,
and load test the battery, and replace if necessary.
9. Vehicle has a sweet odor when driven
a. Check for an engine coolant leak caused by a seeping radiator cap, loose hose clamp,
weeping cooling system seal, gasket or cooling system hose and replace or repair as
needed.
b. Check for a coolant leak from the radiator, coolant reservoir, heater control valve or
under the dashboard from the heater core, and replace the failed part as necessary.
c. Check the engine’s exhaust for white smoke in addition to a sweet odor. The presence
of white, steamy smoke with a sweet odor indicates coolant leaking into the combus-
tion chamber. Possible causes include a failed head gasket, cracked engine block or
cylinder head. Other symptoms of this condition include a white paste build-up on the
inside of the oil filler cap, and softened, deformed or bulging radiator hoses.
19. Engine vibraies when idling
a. Check for loose, collapsed, or damaged engine or transmission mounts and repair or
replace as necessary.
b. Check for loose or damaged engine covers or shields and secure or replace as neces-
sary.
11. Engine vibrates during acceleration
a. Check for missing, loose or damaged exhaust system hangers and mounts; replace or
repair as necessary.
b. Check the exhaust system routing and fit for adequate clearance or potential rubbing;
repair or adjust as necessary.
7. Battery goes dead while driving
a. Check the battery condition. Replace the battery if the battery will not hold a charge or
fails a battery load test. If the battery loses fluid while driving, check for an overcharg-
ing condition. If the alternator is overcharging, replace the alternator or voltage regula-
tor. (A voltage regulator is typically built into the alternator, necessitating alternator re-
placement or overhaul.)
b. Check the battery cable condition. Clean or replace corroded cables and clean the bat-
tery terminals.
c. Check the alternator and voltage regulator operation. If the charging system is over or
undercharging, replace the alternator or voltage regulator, or both.
d. Inspect the wiring and wire connectors at the alternator for looseness, a missing .
ground or defective terminal, and repair as necessary.
e. Inspect the alternator drive belt tension, tensioners and condition. Properly tension the
drive belt, replace weak or broken tensioners, and replace the drive belt if worn or
cracked.
2. Battery goes dead overnight
a. Check the battery condition. Replace the battery if the battery will not hold a charge or
fails a battery load test.
b. Check for a voltage draw, such as a trunk light, interior light or glove box light staying
on. Check light switch position and operation, and replace if defective.
c. Check the alternator for an internally failed diode, and replace the alternator if defec-
tive.
1. Engine overheats
a. Check the coolant level. Set the heater temperature to full hot and check for internal air
pockets, bleed the cooling system and inspect for leakage. Top off the cooling system
with the correct coolant mixture.
b. Pressure test the cooling system and radiator cap for leaks. Check for seepage caused
by loose hose clamps, failed coolant hoses, and cooling system components such as
the heater control valve, heater core, radiator, radiator cap, and water pump. Replace
defective parts and fill the cooling system with the recommended coolant mixture.

TROUBLESHOOTING 11-9
c. On vehicles with electrically controlled cooling fans, check the cooling fan operation.
Check for blown fuses or defective fan motors, temperature sensors and relays, and
replace failed components.
d. Check for a coolant leak caused by a failed head gasket, or a porous water jacket cast-
ing in the cylinder head or engine block. Replace defective parts as necessary.
e. Check for an internally restricted radiator. Flush the radiator or replace if the blockage
is too severe for flushing.
f. Check for a damaged water pump. If coolant circulation is poor, check for a loose wa-
ter pump impeller. If the impeller is loose, replace the water pump.
2. Engine loses coolant
a. Pressure test the cooling system and radiator cap for leaks. Check for seepage caused
by loose hose clamps, failed coolant hoses, and cooling system components such as
the heater control valve, heater core, radiator, radiator cap, and water pump. Replace
defective parts and fill the cooling system with the recommended coolant mixture.
b. Check for a coolant leak caused by a failed head gasket, or a porous water jacket cast-
ing in the cylinder head or engine block. Replace defective parts as necessary.
3. Engine temperature remains co/d when driving
a. Check the thermostat operation. Replace the thermostat if it sticks in the open posi-
tion.
b. On vehicles with electrically controlled cooling fans, check the cooling fan operation.
Check for defective temperature sensors and stuck relays, and replace failed compo-
nents.
c. Check temperature gauge operation if equipped to verify proper operation of the
gauge. Check the sensors and wiring for defects, and repair or replace defective com-
ponents.
4. Engine runs hot
a. Check for an internally restricted radiator. Flush the radiator or replace if the blockage
is too severe for flushing.
b. Check for a loose or slipping water pump drive belt. Inspect the drive belt condition.
Replace the belt if brittle, cracked or damaged. Check the pulley condition and prop-
erly tension the belt.
c. Check the cooling fan operation. Replace defective fan motors, sensors or relays as
necessary.
d. Check temperature gauge operation if equipped to verify proper operation of the
gauge. Check the sensors and wiring for defects, and repair or replace defective com-
ponents.
e. Check the coolant level. Set the heater temperature to full hot, check for internal air
pockets, bleed the cooling system and inspect for leakage. Top off the cooling system
with the correct coolant mixture. Once the engine is cool, recheck the fluid level and
top off as needed.
NOTE: The engine cooling system can also be affected by an engine’s me-
chanical condition. A failed head gasket or a porous casting in the engine
block or cylinder head could cause a loss of coolant and result in engine
overheating.
Some cooling systems rely on electrically driven cooling fans to cool the radiator and
use electrical temperature sensors and relays to operate the cooling fan. When diagnos-
ing these systems, check for blown fuses, damaged wires and verify that the electrical
connections are fully connected, clean and not physically damaged. If necessary, clean
the electrical contacts using electrical contact cleaner. The use of cleaning igents not specifically designed for electrical contacts could leave a film or damage the insulation of
the wiring.
1. Exhaust rattles at idle speed
a. Check the engine and transmission mounts and replace mounts showing signs of
damage or wear.
b. Check the exhaust hangers, brackets and mounts. Replace broken, missing or dam-
aged mounts.
c. Check for internal damage to mufflers and catalytic converters. The broken pieces from
the defective component may travel in the direction of the exhaust flow and collect
and/or create a blockage in a component other than the one which failed, causing en-
gine running and stalling problems. Another symptom of a restricted exhaust is low
engine manifold vacuum. Remove the exhaust system and carefully remove any loose
or broken pieces, then replace any failed or damaged parts as necessary.
d. Check the exhaust system clearance, routing and alignment. If the exhaust is making
contact with the vehicle in any manner, loosen and reposition the exhaust system.
2. Exhaust system vibrates when driving
a. Check the exhaust hangers, brackets and mounts. Replace broken, missing or dam-
aged mounts.
b. Check the exhaust system clearance, routing and alignment. If the exhaust is making
contact with the vehicle in any manner, check for bent or damaged components and
replace, then loosen and reposition the exhaust system.
c. Check for internal damage to mufflers and catalytic converters. The broken pieces from
the defective component may travel in the direction of the exhaust flow and collect
and/or create a blockage in a component other than the one which failed, causing en-
gine running and stalling problems. Another symptom of a restricted exhaust is low
engine manifold vacuum. Remove the exhaust system and carefully remove any loose
or broken pieces, then replace any failed or damaged parts as necessary.
3. Exhaust system hangs too low
a. Check the exhaust hangers, brackets and mounts. Replace broken, missing or dam-
aged mounts.
b. Check the exhaust routing and alignment. Check and replace bent or damaged com-
ponents. If the exhaust is not routed properly, loosen and reposition the exhaust sys-
tern.
4. Exhaust sounds loud
a. Check the system for looseness and leaks. Check the exhaust pipes, clamps, flange
bolts and manifold fasteners for tightness. Check and replace any failed gaskets.
b. Check and replace exhaust silencers that have a loss of efficiency due to internally
broken baffles or worn packing material.
c. Check for missing mufflers and silencers that have been replaced with straight pipes
or with non-original equipment silencers.
NOTE: Exhaust system rattles, vibration and proper alignment should not
be overlooked. Excessive vibration caused by collapsed engine mounts,
damaged or missing exhaust hangers and misalignment may cause surface
cracks and broken welds, creating exhaust leaks or internal damage to ex-
haust components such as the catalytic converter, creating a restriction to
exhaust flow and loss of power.
1. Transmission shit& erratically
a. Check and if not within the recommended range, add or remove transmission fluid to
obtain the correct fluid level. Always use the recommended fluid type when adding
transmission fluid.
b. Check the fluid level condition. If the fluid has become contaminated, fatigued from
excessive heat or exhibits a burning odor, change the transmission fluid and filter us-
ing the recommended type and amount of fluid. A fluid which exhibits a burning odor
indicates that the transmission has been slipping internally and may require future re-
pairs.
c. Check for an improperly installed transmission filter, or missing filter gasket, and re-
pair as necessary.
d. Check for loose or leaking gaskets, pressure lines and fittings, and repair or replace as
necessary.
e. Check for loose or disconnected shift and throttle linkages or vacuum hoses, and re-
pair as necessary. ,
2. Transmission will not engage
a. Check the shift linkage for looseness, wear and proper adjustment, and repair as nec-
essary. b. Check for a loss of transmission fluid and top off as needed with the recommended
fluid.
c. If the transmission does not engage with the shift linkage correctly installed and the
proper fluid level, internal damage has likely occurred, requiring transmission removal
and disassembly.
3. Transmission will not downshift during heavy acceleration
a. On computer controlled transmissions, check for failed sensors or control units and
repair or replace defective components.
b. On vehicles with kickdown linkages or vacuum servos, check for proper linkage ad-
justment or leaking vacuum hoses or servo units.
NOTE: Mlany automatic transmissions use an electronic control module,
electrical sensors and solenoids to control transmission shifting. When
troubleshooting a vehicle with this type of system, be sure the electrical
connectors are fully connected, clean and not physically damaged. If nec-
essary, clean the electrical contacts using electrical contact cleaner. The
use of cleaning agents not specifically designed for electrical contacts
could leave a film or damage the insulation of the wiring.

II-16 TROUBLESHOOTING
c. Gauge sending unit defective. Replace gauge sending unit.
d. Gauge or sending unit improperly installed. Verify installation and wiring, and repair
1. Speedometer does not work
a. Check the speed sensor pickup and replace as necessary.
b. Check the wiring between the speed sensor and the speedometer for corroded termi-
nals, loose connections or broken wires and clean or repair as necessary.
c. Install a known good speedometer to test for proper operation. If the substituted
speedometer functions properly, replace the speedometer assembly.
2. Speedometer works intermittently
a. Check the wiring between the speed sensor and the speedometer for corroded termi-
nals, loose connections or broken wires and clean or repair as necessary.
b. Check the speed sensor pickup and replace as necessary. as necessary.
2. Gauge operates enatica//y
a. Checkfor ioose, shorted, damaged or corroded electrical connections or wiring and
repair as necessary.
b. Check gauge sending units and replace as necessary.
3. Gauge operates fully pegged
a. Sending unit-to-gauge wire shorted to ground.
b. Sending unit defective; replace sending unit.
c. Gauge or sending unit not properly grounded.
d. Gauge or sending unit improperly installed. Verify installation and wiring, and repair
as necessary.
I. Gauge does not register
a. Check for a missing or blown fuse and replace as necessary.
b. Check for an open circuit in the gauge wiring. Repair wiring as necessary.
I. No air coming from air conditioner vents
a. Check the air conditioner fuse and replace as necessary.
b. Air conditioner system discharged. Have the system evacuated, charged and leak
tested by an MVAC certified technician, utilizing approved recovery/recycling equip-
ment. Repair as necessary.
c. Air conditioner low pressure switch defective. Replace switch.
d. Air conditioner fan resistor pack defective. Replace resistor pack.
e. Loose connection, broken wiring or defective air conditioner relay in air conditioning*
electrical circuit. Repair wiring or replace relay as necessary.
2. Air conditioner blows warm air
a. Air conditioner system is discharged. Have the system evacuated, charged and leak
tested by an MVAC certified technician, utilizing approved recovery/recycling equip-
ment. Repair as necessary.
b. Air conditioner compressor clutch not engaging. Check compressor clutch wiring,
electrical connections and compressor clutch, and repair or replace as necessary.
3. Water collects on the interior floor when the air conditioner is used
a. Air conditioner evaporator drain hose is blocked. Clear the drain hose where it exits
the passenger compartment.
b. Air conditioner evaporator drain hose is disconnected. Secure the drain hose to the
evaporator drainage tray under the dashboard.
4. Air conditioner has a moldy odor when used
a. The air conditioner evaporator drain hose is blocked or partially restricted, allowing
condensation to build up around the evaporator and drainage tray. Clear the drain
hose where it exits the passenger compartment.
,
1. Blower motor does not operate
a. Check blower motor fuse and replace as necessary.
b. Check blower motor wiring for loose, damaged or corroded contacts and repair as
necessary.
c. Check blower motor switch and resistor pack for open circuits, and repair or replace
as necessary.
d. Check blower motor for internal damage and repair or replace as necessary.
2. Heater blows cool air
a. Check the engine coolant level. If the coolant level is low, top off and bleed the air
from the cooling system as necessary and check for coolant leaks.
b. Check engine coolant operating temperature. If coolant temperature is below specifica-
tion, check for a damaged or stuck thermostat.
c. Check the heater control valve operation. Check the heater control valve cable or vac-
uum hose for proper installation. Move the heater temperature control from hot to cold
several times and verify the operation of the heater control valve. With the engine at
normal operating temperature and the heater temperature control in the full hot posi-
tion, carefully feel the heater hose going into and exiting the control valve. If one
heater hose is hot and the other is much cooler, replace the control valve.
3. Heater steams the windshield when used
a. Check for a loose cooling system hose clamp or leaking coolant hose near the engine
firewall or under the dash area, and repair as necessary.
b. Check for the existence of a sweet odor and fluid dripping from the heater floor vents,
indicating a failed or damaged heater core. Pressure test the cooling system with the
heater set to the fully warm position and check for fluid leakage from the floor vents. If
leakage is verified, remove and replace the heater core assembly.
NOTE: On some vehicles, the dashboard must be disassembled and re-
moved to access the heater core.

II-20 GLOSSARY
SECONDARY CIRCUIT: The high voltage side of the ignition system, usu-
ally above 20,000 volts. The secondary includes the ignition coil, coil wire,
distributor cap and rotor, spark plug wires and spark plugs.
SENDING UNIT: A mechanical, electrical, hydraulic or electromagnetic de-
vice which transmits information to a gauge.
SENSOR: Any device designed to measure engine operating conditions or
ambient pressures and temperatures. Usually electronic in nature and designed
to send a voltage signal to an on-board computer, some sensors may oper-
ate as a simple on/off switch or they may provide a variable voltage signal
(like a potentiometer) as conditions or measured parameters change.
SHIM: Spacers of precise, predetermined thickness used between parts to es-
tablish a proper working relationship.
SLAVE CYLINDER: In automotive use, a device in the hydraulic clutch sys-
tem which is activated by hydraulic force, disengaging the clutch.
SOLENOID: An electrically operated, magnetic switching device.
SPARK PLUG: A device screwed into the combustion chamber of a spark ig-
nition engine. The basic construction is a conductive core inside of a ceramic
insulator, mounted in an outer conductive base. An electrical charge from the
spark plug wire travels along the conductive core and jumps a preset air gap
to a grounding point or points at the end of the conductive base. The resul-
tant spark ignites the fuel/air mixture in the combustion chamber.
SPLINES: Ridges machined or cast onto the outer diameter of a shaft or in-
ner diameter of a bore to enable parts to mate without rotation.
TACHOMETER: A device used to measure the rotary speed of an engine,
shaft, gear, etc., usually in rotations per minute.
THERMOSTAT: A valve, located in the cooling system of an engine, which
is closed when cold and opens gradually in response to engine heating, con-
trolling the temperature of the coolant and rate of coolant flow.
TOP DEAD CENTER (TDC): The point at which the piston reaches the top
of its travel on the compression stroke.
TORQUE: Measurement of turning or twisting force, expressed as foot-pounds
or inch-pounds.
TORQUE CONVERTER: A turbine used to transmit power from a driving
member to a driven member via hydraulic action, providing changes in drive
ratio and torque. In automotive use, it links the driveplate at the rear of the en-
gine to the automatic transmission. TRANSDUCER: A device that changes energy from one form to another. For
example, a transducer in a microphone changes sound energy to electrical en-
ergy. In automotive air-conditioning controls used in automatic temperature
systems, a transducer changes an electrical signal to a vacuum signal, which
operates mechanical doors.
TRANSISTOR: A semi-conductor component which can be actuated by a
small voltage to perform an electrical switching function.
TUNE-UP: A regular maintenance function, usually associated with the re-
placement and adjustment of parts and components in the electrical and fuel
systems of a vehicle for the purpose of attaining optimum performance.
TURBOCHARGER: An exhaust driven pump which compresses intake air
and forces it into the combustion chambers at higher than atmospheric pres-
sures The increased air pressure allows more fuel to be burned and results
in increased horsepower being produced.
.
VACUUM ADVANCE: A device which advances the ignition timing in re-
sponse to increased engine vacuum.
VACUUM GAUGE: An instrument used for measuring the existing vacuum
in a vacuum circuit or chamber. The unit of measure is inches (of mercury in
a barometer).
VALVE: Devices that can open or close fluid passages in a hydraulic system
and are used for directing fluid flow and controlling pressure.
VALVE CLEARANCE: The measured gap between the end of the valve stem
and the rocker arm, cam lobe or follower that activates the valve.
VISCOSITY: The ability of a fluid to flow. The lower the viscosity rating, the
easier the fluid will flow. 10 weight motor oil will flow much easier than 40
weight motor oil.
VOLTMETER: An instrument used for measuring electrical force in units
called volts. Voltmeters are always connected parallel with the circuit being
tested.
WHEEL CYLINDER: Found in the automotive drum brake assembly, it is a
device, actuated by hydraulic pressure, which, through internal pistons, pushes
the brake shoes outward against the drums.

MASTER INDEX 11-23
GENERALINFORMAITON 3-65
INSPECTION 3-65
REFINISHING 3-67
ENGINE FAN 3-19
REMOVAL & INSTALLATION 3-19
ENGINE MECHANICAL 3-1
ENGINE OVERHAUL TIPS 3-58
CLEANING 3-58
OVERHAUL TIPS 3-58
REPAIRING DAMAGEDTHREADS 3-59
TOOLS 3-58
ENGINE PREPARATION 3-59
ASSEMBLY 3-64
DISASSEMBLY 3-60
INSPECTION 3-
REFINISHING & REPAIRING 3-63
ENGINE RECONDITIONING 3-57
ENGINE START-UP AND BREAK-IN
3-69
BREAKING IT IN 3-69
KEEP IT MAINTAINED 3-69
STARTING THE ENGINE 3-69
ENGINE 'l-33
OIL& FILTER CHANGE 1-34
OILLEVELCHECK 1-33
ENGINE 3-1
REMOVAL&INSTALLATION 3-l
ENGlNECONTROLUNIT/POWERTRAINCONTROLMODULE(ECU/PCM)
4-7
OPERATION 4-7
REMOVAL&INSTALLATION 4-7
ENGINECOOLANTTEMPERATURESENSOR
4-10
OPERATION 4-10
REMOVAL&INSTALLATION 4-10
TESTING 4-10
ENGINECOOLANTTEMPERATURESENDING
UNIT 2-11
REMOVAL&INSTALLATION 2-11
TESTING 2-11
ENGINE IDENTIFICATION NUMBER l-10
ENTERTAINMENT SYSTEMS 6-14
EVAPORATIVECANISTER I-16
SERVICING 1-16
' EVAPORATIVEEMISSIONCONTROLS 4-2
COMPONENTTESTING 4-3
OPERATION 4-2
REMOVAL&INSTALLATION 4-4
EXHAUST MANIFOLD 3-14
REMOVAL & INSTALLATION 3-14
EXHAUST SYSTEM 3-55
EXHAUSTGASRECIRCULATION SYSTEM
4-5
COMPONENTTESTING 4-5
OPERATION 4-5
REMOVAL&INSTALLATION 4-6
EXTERIOR 1 O-2
FASTENERS, MEASUREMENTS AND CONVERSIONS 1-6
. FENDERS 10-4
REMOVAL &INSTALLATION IO-4
FIRING ORDERS 2-7
FLASHERS 6-28
REPLACEMENT 6-28
FLOOR CONSOLE IO-6
REMOVAL& INSTALLATION IO-6 1
FLUID PAN 7-10
FLUID DISPOSAL 1-33
FLUIDS AND LUBRICANTS 1-33
FLYWHEEVDRIVEPLATE 3-55
REMOVAL & INSTALLATION 3-55
FRONT CRANKSHAFT SEAL 3-48
REMOVAL & INSTALLATION 3-48
FRONT SUSPENSION 8-4 FRONTWHEELDRIVEMODELS 1-44
FUELANDENGINEOILRECOMMENDATIONS 1-33
ENGINEOIL l-33
FUEL 1-33
OPERATION IN FOREIGN COUNTRIES
1-33
FUEL LINE FITTINGS 5-2
REMOVAL&INSTALLATION 5-2
FUEL RAIL AND INJECTORS(S)
5-4
REMOVAL &INSTALLATION 5-4
TESTING 5-8
FUELSYSTEM SERVICE PRECAUTIONS 5-3
FUELFILTER 1-15
REMOVAL&INSTALLATION l-15
FUEL LINES AND FITTINGS 5-2
FUELPRESSUREREGULATOR 5-9
REMOVAL & INSTALLATION 5-9
FUEL TANK 5-10
FUSES 6-27
REPLACEMENT 6-27
FUSIBLE LINKS 6-27 #
RESETTING AND/OR REPLACEMENT 6-28
GAUGES 6-18
REMOVAL & INSTALLATION 6-18
GENERAL INFORMATION 5-3
GENERAL INFORMATION 6-7
DISARMING 6-7
REARMING 6-7
SERVICE PRECAUTIONS 6-7
GENERAL INFORMATION 9-24
PRECAUTIONS 9-24
GENERALINFORMATION 2-10
GENERALINFORMATION 2-2
CYLINDER DROPTEST 2-2
SECONDARYSPARKTEST 2-2
GENERALINFORMATION 2-5
GENERALINFORMATION 2-8
REMOVAL &INSTALLATION 2-9'
TESTING 2-8
GENERALINFORMATION 4-26
CHECKENGlNE/MALFUNCTlONlNDlCATOR LIGHT 4-26
SERVICE PRECAUTIONS 4-26
GENERALINFORMATION 4-27
G-SENSOR 9-29
REMOVAL &INSTALLATION 9-29
HALFSHAFTS 7-13
HALFSHAFTS 7-3
CV-JOINTS OVERHAUL 7-5
REMOVAL&INSTALLATION 7-3
HATCH/TAILGATE/TRUNKLID LOCKCYLINDER lo-10
REMOVAL & INSTALLATION IO-IO
HATCH IO-3
ALIGNMENT IO-3
REMOVAL & INSTALLATION IO-3
HEADLIGHT SWITCH 6-19
REMOVAL 81 INSTALLATION 6-19
HEADLIGHTS 6-19
AIMING THE HEADLIGHTS 6-20
REMOVAL& INSTALLATION 6-19
HEATER CORE 6-9
REMOVAL&INSTALLATION 6-9
HEATING AND AIR CONDITIONING 6-7
HOOD IO-2
ALIGNMENT IO-3
REMOVAL & INSTALLATION IO-2
HOSES I-20
INSPECTION I-20
REMOVAL&INSTALLATION I-21
HOW TO USE THIS BOOK 1-2
HUB & BEARINGS 8-25