INTERMITTENT SIMULATION
To reproduce the conditions that create an intermittent fault so it may be identified during testing, some of the following methods may be used
- Applying light vibration to components.
- Heating a component.
- Wiggling or bending a wiring harness.
- Applying humidity to a component.
- Removing or applying a vacuum supply source.
Monitor circuit/component voltage or resistance while attempting to simulate intermittent. If vehicle is running, monitor for self-diagnostic codes. See TESTS W/CODES article. Use the results of these tests to identify a faulty component or an area that should be closely checked for the problem.
Note. For additional information on connecting test equipment and operating Continuous Monitor Mode test procedures, see TESTS W/CODES article.
ROUTINE 200 - NO CRANK & NO START
| SYSTEM & Component(s) | GO TO |
|---|---|
| STARTING: Battery, Starter Relay, Starter, Neutral Drive Switch/ Clutch Switch/Brake Interlock Switch, Ignition Switch, Transmission Linkage Adjustment | Charge or replace battery, check charging and starting systems |
| EEC: Neutral Drive Switch/ Clutch Switch | See TESTS W/CODES article |
| BASIC ENGINE: Flywheel, Engine Seized | Check engine mechanical condition |
| FUEL DELIVERY: Injectors | See SYSTEM/COMPONENT TESTS article |
ROUTINE 200 - NO CRANK & NO START
ROUTINE 201 - CRANKS NORMALLY BUT WON'T START
Note. Extended cranking due to a "NO START" condition, can load exhaust system with raw fuel. This can ruin the catalytic converter after engine is started. After a "NO START" condition has been repaired, disconnect the thermactor air supply, run the engine until surplus fuel is used up and reconnect the thermactor air supply.
| SYSTEM & Component(s) | GO TO |
|---|---|
| EEC: Quick Test | See TESTS W/CODES |
| IGNITION (ALL TYPES): Electrical Connections, Secondary Ignition Wires, Spark Plugs Fouled, Ignition Switch | See SYSTEM/COMP TESTS |
| IGNITION (DSII & TFI IV): Ignition Coil or Module, Rotor Alignment, Distributor Cap, Adapter, Rotor & Stator | See SYSTEM/COMP TESTS |
| IGNITION (DIS/EDIS): Single or Dual Hall Crank Sensors, Hall Camshaft Sensor Ignition Module & Coil pack(s) | See SYSTEM/COMP TESTS |
| FUEL DELIVERY: Filter, Pump, Contamination in Fuel Lines, Tank (Fuel Supply), Dual Tank Selector Switch, Sender Filter, PFI & TBI Pressure regulator, Injectors & Inertia Switch | See SYSTEM/COMP TESTS |
| FUEL CHARGING ASSY: Electrical Connections, Throttle Linkages | See SYSTEM/COMP TESTS |
| BASIC ENGINE: Camshaft Timing, Compression | Check engine mechanical condition |
| EGR: Valve | See SYSTEM/COMP TESTS |
| EXHAUST: Catalyst Exhaust | Visually inspect for blockage |
ROUTINE 201 - CRANKS NORMALLY BUT WON'T START
ROUTINE 202 - CRANKS NORMALLY BUT WON'T RUN (STALLS)
| SYSTEM & Component(s) | GO TO |
|---|---|
| FUEL CHARGING ASSY: Curb or Fast Idle Speed, Electrical & Vacuum Connections | See SYSTEM/COMP TESTS |
| EEC: Quick Test | See TESTS W/CODES |
| FUEL DELIVERY: Filter, Pump, Contamination in Fuel Lines, Tank (Fuel Supply), Dual Tank Selector Switch, Sender Filter, Fuel Pressure Regulator, Injectors & Inertia Switch | See SYSTEM/COMP TESTS |
| IGNITION (DSII & TFI IV): Ignition Coil or Module, Rotor Alignment, Dist. Cap, Adapter, Rotor & Stator | See SYSTEM/COMP TESTS |
| IGNITION (DIS/EDIS): Single or Dual Hall Crank Sensors, Hall Camshaft Sensor Ignition Module & Coil pack(s) | See SYSTEM/COMP TESTS |
| EXHAUST: Component (Restricted) | Inspect exhaust system |
| EGR: Valve | See SYSTEM/COMP TESTS |
| BASIC ENGINE: Camshaft & Valve Train | Check engine mechanical condition |
ROUTINE 202 - CRANKS NORMALLY BUT WON'T RUN (STALLS)
ROUTINE 203 - CRANKS NORMALLY BUT SLOW TO START
Note. It is a good practice to confirm that the correct starting procedure was being used by the customer proceeding with diagnosis.
| SYSTEM & Component(s) | GO TO |
|---|---|
| IGNITION (DSII & TFI IV): Distributor Cap, Adapter & Rotor | See SYSTEM/COMP TESTS |
| IGNITION (DIS/EDIS): Single or Dual Hall Crank Sensors, Hall Camshaft Sensor Ignition Module & Coil Pack(s) | See SYSTEM/COMP TESTS |
| EEC: Quick Test | See TESTS W/CODES |
| FUEL DELIVERY: Filter, Pump, Contamination in Fuel lines, Tank (Fuel Supply), Dual Tank Selector Switch, Sender Filter, Fuel Pressure Regulator, Injectors | See SYSTEM/COMP TESTS |
| FUEL CHARGING ASSY: Curb or Fast Idle speed, Electrical & Vacuum Connections | See ADJUSTMENTS |
| EXHAUST: Component (Restricted) | Check exhaust system |
| INDUCTION & VACUUM DISTRIBUTION: Vacuum leaks, Air Cleaner Element Restricted | Perform a visual inspection |
| COOLING: Electric Fan (Hot Start Only) | Check cooling system |
| EGR: Valve | See SYSTEM/COMP TESTS |
| PCV: Valve | See SYSTEM/COMP TESTS |
| EVAP: Components | See SYSTEM/COMP TESTS |
ROUTINE 203 - CRANKS NORMALLY BUT SLOW TO START
ROUTINE 204 - ROUGH IDLE
| SYSTEM & Component(s) | GO TO |
|---|---|
| COOLING: Fan or Electric Fan (Loose or Cracked) | Perform a visual inspection |
| IGNITION: Scope Engine for: Spark Plug, Coil, Secondary Wires, Distributors Cap, Adapter, Rotor & Ignition Timing | See SYSTEM/COMP TESTS |
| EEC: Quick Test | See TESTS W/CODES |
| FUEL CHARGING ASSY: Curb or Fast Idle Speed, Electrical & Vacuum Connections | See SYSTEM/COMP TESTS & ADJUSTMENTS |
| FUEL DELIVERY: Fuel Pressure Regulator, Injectors, Fuel Rail | See SYSTEM/COMP TESTS |
| VACUUM DISTRIBUTION: Vacuum Leaks | Perform a visual & audible inspection |
| EGR: Valve, Vacuum Regulator | See SYSTEM/COMP TESTS |
| COOLING: Thermostat | Check cooling system |
| BASIC ENGINE: Compression, Valve Train, Camshaft, Intake Manifold Gaskets | Check engine mechanical condition |
| PCV: Valve | See SYSTEM/COMP TESTS |
| EVAP: Components | See SYSTEM/COMP TESTS |
| EXHAUST: Pipes, Muffler, Catalyst Resonator, Heat Control Valve | Check exhaust system |
ROUTINE 204 - ROUGH IDLE
ROUTINE 205 - MISSES UNDER LOAD
| SYSTEM & Component(s) | GO TO |
|---|---|
| IGNITION: Scope Engine for: Spark Plug, Coil, Secondary Wires, Distributors Cap, Adapter, Rotor & Ignition Timing | See SYSTEM/COMP TESTS |
| EEC: Quick Test | See TESTS W/CODES |
| FUEL DELIVERY: Filter, Pump, Lines, Fuel Pressure Regulator Sender Filter, Injectors | See SYSTEM/COMP TESTS |
| FUEL CHARGING ASSY: Electrical andVacuum Connections | See I SYSTEM/COMP TESTS and ADJUSTMENTS |
| EGR: Valve | See SYSTEM/COMP TESTS |
ROUTINE 205 - MISSES UNDER LOAD
ROUTINE 206 - LOW IDLE (STALLS ON DECEL OR QUICK STOP)
| SYSTEM & Component(s) | GO TO |
|---|---|
| FUEL CHARGING ASSY: Curb or Fast Idle speed, Electrical & Vacuum Connections, Throttle Devices | See SYSTEM/COMP TESTS |
| EEC: Quick Test | See TESTS W/CODES |
| EGR: Valve | See SYSTEM/COMP TESTS |
| BASE TRANSMISSION (E40D ONLY): Transmission Oil Level, Converter Clutch Control Solenoid | Check transmission |
ROUTINE 206 - LOW IDLE (STALLS ON DECEL OR QUICK STOP)
ROUTINE 207 - HESITATES OR STALLS ON ACCELERATION
| SYSTEM & Component(s) | GO TO |
|---|---|
| EEC: Quick Test | See TESTS W/CODES |
| IGNITION: Scope Engine for: Spark Plug, Coil, Secondary Wires, Distributor Cap, Adapter, Rotor & Ignition Timing | See SYSTEM/COMP TESTS |
| FUEL CHARGING ASSY: Curb or Fast Idle speed, Electrical & Vacuum Connections | See ADJUSTMENTS and SYSTEM/COMP TESTS |
| FUEL DELIVERY: Filter, Pump, Contamination in Fuel lines, Switch, Sender Filter, Fuel Pressure Regulator, Injectors | See ADJUSTMENTS and SYSTEM/COMP TESTS |
| VACUUM DISTRIBUTION: Vacuum Leaks | Perform a visual & audible inspection |
| INDUCTION: Air Cleaner Duct, Stove Pipe & Valve Inter-Cooler Tube (Air Leaks) | See SYSTEM/COMP TESTS |
| EGR: Valve | See SYSTEM/COMP TESTS |
| PCV: Valve | See SYSTEM/COMP TESTS |
| EXHAUST (RESTRICTION): With Back Pressure EGR System | See SYSTEM/COMP TESTS |
| BASE TRANSMISSION (E40D & A4LD): Converter Clutch, Control, Solenoid Override | See TESTS W/CODES |
ROUTINE 207 - HESITATES OR STALLS ON ACCELERATION
ROUTINE 208 - BACKFIRE (INTAKE OR EXHAUST)
| SYSTEM & Component(s) | GO TO |
|---|---|
| IGNITION: Scope Engine for: Spark Plug, Coil, Secondary Wires, Distributor Cap, Rotor Ignition Timing, crossed Wires | See BASIC TESTING |
| VACUUM DISTRIBUTION: Vacuum hoses, or Connections Leak(s) | Perform a visual & audible inspection |
| EEC: Quick Test | See TESTS W/CODES |
| THERMACTOR: Thermactor System Components | See SYSTEM/COMP TESTS |
| PULSE Air: Pulse Air System Components | See SYSTEM/COMP TESTS |
| BASIC ENGINE: Compression, Valve Train, Camshaft, Intake Manifold Gaskets | Check engine mechanical condition |
| EXHAUST: Components (Restricted) | Check exhaust system |
| Fuel DELIVERY: Filter, Pump, Contamination in Fuel lines, Sender Filter, Fuel Pressure Regulator, Injectors | See ADJUSTMENTS and SYSTEM/COMP TESTS |
ROUTINE 208 - BACKFIRE (INTAKE OR EXHAUST)
ROUTINE 209 - LACK OF POWER
| SYSTEM & Component(s) | GO TO |
|---|---|
| IGNITION: Timing | See G - ADJUSTMENTS |
| EEC: Quick Test | See TESTS W/CODES |
| FUEL DELIVERY: Filter, Pump, Lines, Sender Filter, Fuel Pressure, Regulator Injectors | See SYSTEM/COMP TESTS |
| FUEL CHARGING ASSY: Curb or Fast Idle Speed, Electrical & Vacuum Connections | See BASIC TESTING and SYSTEM/COMP TESTS |
| IGNITION: Scope Engine for: Spark Plug, Coil, Secondary Wires, Distributor Cap, Rotor & Ignition Timing, Crossed Wires | See BASIC TESTING |
| EXHAUST: Components (Restricted) | Check exhaust system |
| COOLING: Thermostat | Check cooling system |
| VACUUM DISTRIBUTION: Vacuum Leak(s) | Perform a visual & audible inspection |
| INDUCTION: Air Cleaner Duct, Valve & Element | See SYSTEM/COMP TESTS |
| EGR: Valve | See SYSTEM/COMP TESTS |
| BASIC ENGINE: Compression Check, Camshaft, Valve | See BASIC TESTING |
| DRIVE TRAIN: Clutch, Automatic Transmission, Brakes | Check transmission & drive train components |
ROUTINE 209 - LACK OF POWER
ROUTINE 210 - SURGES AT STEADY SPEED
| SYSTEM & Component(s) | GO TO |
|---|---|
| EEC: Quick Test | See TESTS W/CODES |
| FUEL DELIVERY: Filter, Pump, Lines, Sender Filter, Fuel Pressure Regulator | See SYSTEM/COMP TESTS |
| FUEL CHARGING ASSY: Curb or Fast Idle Speeds Electrical & Vacuum Connections | See ADJUSTMENTS |
| IGNITION: Scope Engine for: Spark Plug, Coil, Secondary Wires, Distributor Cap, Rotor Ignition Timing, Crossed Wires | See BASIC TESTING |
| VACUUM DISTRIBUTION: Vacuum Leak(s) | Perform a visual & audible inspection |
| EGR: Valve | See SYSTEM/COMP TESTS |
| INDUCTION: Air Cleaner Duct & Valve & Element | See SYSTEM/COMP TESTS |
| EVAP: Components | See SYSTEM/COMP TESTS |
| BASIC ENGINE: Valve Train & Camshaft Intake Manifold Gaskets | See BASIC TESTING |
| THERMACTOR: Thermactor System Components | See SYSTEM/COMP TESTS |
ROUTINE 210 - SURGES AT STEADY SPEED
ROUTINE 211 - HIGH IDLE, ENGINE "DIESELS"
Note. If engine Idles smoothly after key is turned off, trouble is likely to be in the Ignition Switch, Ignition harness, starter solenoid "IGN" tap, or EEC relay
| SYSTEM & Component(s) | GO TO |
|---|---|
| FUEL CHARGING ASSY: Curb or Fast Idle Speed, Electrical & Vacuum Connections, Throttle Positioner, Throttle Plate & Linkage | See BASIC TESTING and SYSTEM/COMP TESTS |
| VACUUM DISTRIBUTION: Vacuum Leak(s) | Perform a visual & audible inspection |
| EEC: Quick Test | See TESTS W/CODES |
| INDUCTION: Vacuum Leaks | Perform a visual & audible inspection |
| COOLING: Overheating | Check cooling System |
ROUTINE 211 - HIGH IDLE, ENGINE "DIESELS"
ROUTINE 213 - POOR FUEL ECONOMY
Note. Since Fuel consumption is drastically increased for city driving, short-run operation, stop and go driving, trailer towing, extended winter warm-up periods, etc., as opposed to "trip", mileage, an attempt should be made to determine these factors when confronted with "poor mileage" conditions. However, since the operator is not always at fault, the following is appended.
| SYSTEM & Component(s) | GO TO |
|---|---|
| FUEL CHARGING ASSY: Electrical & Vacuum Connections | See ADJUSTMENTS |
| FUEL DELIVERY: Fuel Return Line Blocked, Fuel Pressure Regulator | See BASIC TESTING |
| INDUCTION: Air Cleaner Duct & Valve, Air Cleaner Element (Restricted) | Perform a visual inspection |
| IGNITION: Scope Engine for: Spark Plug, Coil, Secondary Wires, Distributor Cap, Rotor & Adapter Ignition Timing, Crossed Wires | See BASIC TESTING |
| EEC: Quick Test | See TESTS W/CODES |
| COOLING: Thermostat | Check cooling System |
| FACTORS EXTERNAL TO THE ENGINE: Tire Pressure & Type, Clutch Operation, Converter Clutch Override, Automatic Transmission Shift Pattern & Fluid Level, Brake Drag, Exhaust System, Speedometer/Odometer Gear & Axle Ratio, Vehicle Load, Road & Weather Conditions, Aftermarket Add-Ons | Perform a manual and visual inspection |
| BASE Transmission (E40D ONLY): Converter Clutch Control Solenoid | See TESTS W/CODES |
ROUTINE 213 - POOR FUEL ECONOMY
ROUTINE 214 - HIGH OIL CONSUMPTION
Note. If the condition can not be verified, clean engine, if necessary, change oil and Filter (at customer expense), seal and have customer drive 500 miles (804.5 Km) or enough Distance to consume two quarts before returning for re- examination.
| SYSTEM & Component(s) | GO TO |
|---|---|
| EXTERNAL LEAKS: Rocker Cover Gasket, Crankshaft Seals, Engine Assembly | Perform a visual inspection |
| PROPER DIPSTICK: Overfilling (sometimes accomplished by the "short stick" gas station procedure) | Perform a manual and visual inspection |
| INDUCTION: Air Cleaner Element (Sealing) | Perform a visual inspection |
| PCV: Valve | See SYSTEM/COMP TESTS |
| INTERNAL LEAKS (BLUE SMOKE FROM TAILPIPE): Valve Guides & Stem Seals, Intake Manifold & Gasket, Cylinder Head Drain Passages, Piston Rings | Check engine mechanical condition |
ROUTINE 214 - HIGH OIL CONSUMPTION
ROUTINE 215 - SPARK KNOCK (PINGS)
| SYSTEM & Component(s) | GO TO |
|---|---|
| IGNITION: Timing | See ADJUSTMENTS |
| EEC: Quick Test | See TESTS W/CODES |
| VACUUM DISTRIBUTION: Vacuum Leaks PVS | Perform a visual & audible inspection, See SYSTEM/COMP TESTS |
| COOLING: Overheating | Check cooling System |
| BASIC ENGINE: Oil Level, Compression Check, Intake Manifold Gasket | See BASIC TESTING |
| FUEL DELIVERY: Injectors | See SYSTEM/COMP TESTS |
| PCV: Valve | See SYSTEM/COMP TESTS |
| EGR: Verify Correct Application, Then Diagnose | See SYSTEM/COMP TESTS |
| INDUCTION: Air Cleaner Duct & Valve Assembly | See SYSTEM/COMP TESTS |
| THERMACTOR: Thermactor System Components | See SYSTEM/COMP TESTS |
| BASE Transmission (E40D NON-DIESEL ONLY): Transmission Controls | See TESTS W/CODES |
ROUTINE 215 - SPARK KNOCK (PINGS)
Note. If the above fails to correct the condition, it is recommended that the owner change his source of Fuel and use higher octane Fuel.
ROUTINE 216 - ENGINE VIBRATES AT NORMAL OR HIGH SPEED
| SYSTEM & Component(s) | GO TO |
|---|---|
| ENGINE ACCESSORIES: Fan, Belt Driven Components, Engine Mounts & Engine Vibration Damper | Perform a manual and visual inspection |
| OTHERWISE: Non-Engine Components: Drive Line, Tires, Wheel Balance | Perform a manual and visual inspection |
ROUTINE 216 - ENGINE VIBRATES AT NORMAL OR HIGH SPEED
ROUTINE 217 - ENGINE RUNS COLD
| SYSTEM & Component(s) | GO TO |
|---|---|
| GAUGE System: Gauge, Sender | See appropriate article in the ACCESSORIES & EQUIPMENT section |
| COOLING: Thermostat | Check cooling System |
ROUTINE 217 - ENGINE RUNS COLD
ROUTINE 218 - ENGINE RUNS HOT
| SYSTEM & Component(s) | GO TO |
|---|---|
| COOLING: Thermostat, Coolant Level, Radiator or A/C Condenser, Pressure Cap & Overflow System, External Leaks, Belts & Belt Tension, Fan & Fan Clutch, Electric Fan (if so equipped) | See BASIC TESTING |
| GAUGE System: Gauge, Sender | See appropriate article in the ACCESSORIES & EQUIPMENT section |
| EEC: Quick Test | See TESTS W/CODES |
| IGNITION: Timing | See ADJUSTMENTS |
| BASIC ENGINE: Oil Level, Internal Leak(s), Core Sand in Head/Block, Water Pump | Check engine mechanical condition |
| BRAKE: Brakes (Dragging) | Check brake system |
ROUTINE 218 - ENGINE RUNS HOT
ROUTINE 219 - EXHAUST SMOKE
Note. White smoke is normal during warm-up.
| SYSTEM & Component(s) | GO TO |
|---|---|
| BLACK SMOKE (RICH MIXTURE): Air Cleaner Element (Restricted), Fuel Pressure Regulator Injectors, EEC Components | Perform a visual inspection, See SYSTEM/COMP TESTS , see TESTS W/CODES |
| BLUE SMOKE (BURNING OIL): PCV Valve, Valve Guides/Stems/Seals, Oil Drain Passages in Head Rings (not seated, seized, gummed up, worn), Cylinder Bores (scuffed) | See BASIC TESTING , see engine mechanical condition |
| WHITE SMOKE (COOLANT IN COMBUSTION): Thermactor Vacuum Delay Valve (restricted), EGR Cooler, Intake Manifold (cracked/porous), Cylinder Head/Gasket (Leaks), Block (cracked/porous) | See I - SYSTEM/COMP TEST |
ROUTINE 219 - EXHAUST SMOKE
ROUTINE 220 - GAS SMELL
| SYSTEM & Component(s) | GO TO |
|---|---|
| FUEL DELIVERY: Injectors (Leaking), Fuel Filter, Fuel Pump, Fuel Line, Fuel Pump to Tank, Fuel Tank, Fuel Tank filler neck/Cap (Leaks), Fuel Return Line (Blocked), Fuel Pressure Regulator | See SYSTEM/COMP TESTS |
| EVAP: Carbon Canister, Solenoid, Hoses (Leaks) | See SYSTEM/COMP TESTS |
ROUTINE 220 - GAS SMELL
ROUTINE 221 - "CHECK ENGINE" OR "SERVICE ENGINE SOON" LIGHT ALWAYS OR NEVER ON "CHECK ENGINE"/"CHECK DCL" MESSAGE ON
| SYSTEM & Component(s) | GO TO |
|---|---|
| EEC: Quick Test | See TESTS W/CODES |
ROUTINE 221 - "CHECK ENGINE" OR "SERVICE ENGINE SOON" LIGHT ALWAYS OR NEVER ON "CHECK ENGINE"/"CHECK DCL" MESSAGE ON
ROUTINE 223 - IMPROPER SHIFT
| SYSTEM & Component(s) | GO TO |
|---|---|
| BASE, TRANSMISSION (E4OD, A4LD, AXOD ONLY): Converter Clutch, Control Solenoid, Electronic Pressure Control Solenoid, Shift Solenoid #1 & #2, 4WD low Switch | See TESTS W/CODES |
| EEC (E4OD, A4LD ONLY): Quick Test | See TESTS W/CODES |
ROUTINE 223 - IMPROPER SHIFT
ROUTINE 224 - SHIFT INDICATOR LIGHT (SIL) & AUDIBLE CHIMES "ON"
Note. Verify that the customer has read the owners manual on the new 3.8L SC overheat protection feature.
The 3.8L SC is equipped with a Shift indicator light and audible chime that warns the customer when the engine oil or coolant overheats while the vehicle is operated at high Speeds (above 100 MPH) for extended periods of time. The Shift indicator light and chime will also warn the customer when the engine has reached too high an RPM for that gear.
The EEC-IV processor will reduce vehicle Speed by limiting Fuel to the engine when one of these overheat conditions has been reached. The customer may then notice a loss of power and/or a slight vibration. The Shift indicator light will illuminate and the audible chime will produce a steady tone, alerting the customer to upshift at this time. Full power will be restored and the Shift indicator light and chimes will turn off when the vehicle returns to normal operating temperatures.
| SYSTEM & Component(s) | GO TO |
|---|---|
| EEC: Shift Indicator Light Bulb "SIL" Dimmer Relay Top Gear Switch | See TESTS W/CODES |
| 3.8L SC ONLY: Audible Chime System | See appropriate article in the ACCESSORIES & EQUIPMENT section |
ROUTINE 224 - SIL & AUDIBLE CHIMES "ON"