1986 MERCEDES BENZ ENGINE PERFORMANCE AND MAINTENANCE Inspection and Communication Standards

Uniform Inspection and Communication Standards
ENGINE PERFORMANCE AND MAINTENANCE
Overview

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, Electrical Systems, and Drive Train and Transmissions. Further, revisions to all of these inspection communication standards are continually re-published. 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 the Better Business Bureau 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:

7101 Wisconsin Avenue

Bethesda, MD 20814

Phone (301) 634-4955 - Fax (202) 318-0378

January 2002

Map@motorist.org
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 suggestedservice 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

1. A - Part no longer performs intended purpose
2. B - Part does not meet a design specification (regardless of performance)
3. 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. 1 - Part is close to the end of its useful life (just above discard specifications, or weak; failure likely to occur soon, etc.)
2. 2 - To address a customer need, convenience, or request (to stiffen ride, enhance performance, eliminate noise, etc.)
3. 3 - To comply with maintenance recommended by the vehicle's Original Equipment Manufacturer (OEM)
4. 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 Assemblies
Condition Code Procedure
Adjustable valve lash is out of specification B Require repair.
Combustion efficiency is reduced due to carbon deposits in the combustion chamber. 2 Suggest repair.
Combustion efficiency is reduced due to carbon deposits on the intake valve. 2 Suggest repair.
Internal component failure (any component) A Require repair or replacement of cylinder head assembly. See note below.
NOTE: 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).
For 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 Assemblies
Condition Code Procedure
Combustion efficiency is reduced due to carbon deposits in the combustion chamber. 2 Suggest repair.
Internal component failure (any component) A Require repair or replacement of the long block assembly. See note below.
NOTE: 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).
For 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 Assemblies
Condition Code Procedure
Combustion efficiency is reduced due to carbon deposits in the combustion chamber. 2 Suggest repair
Internal Component Failure (Any Component) A Require repair or replacement of the short block assembly. See note below.
NOTE: 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).
For 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

Service Procedures Required and Suggested for Proper Vehicle Operation
Accelerator Pedal Position Sensors

Accelerator Pedal Position Sensors
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 Require repair or replacement. See note below.
NOTE: Determine cause and correct prior to repair or replacement of part.
Connector missing C Require replacement.
Inoperative B Require repair or replacement. Further inspection required. See note below.
NOTE: Inoperative includes intermittent operation or out of OEM specification. Some components may be serviceable; check for accepted cleaning procedure.
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 Require repair or replacement. See note below.
NOTE: Determine cause and correct prior to repair or replacement of part.
Condition Code Procedure
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.
Accessory Belts

Accessory Belts
Condition Code Procedure
Alignment incorrect B Further inspection required. See note below.
NOTE: Determine cause of incorrect alignment and require repair.
Cracked 1 Suggest replacement.
Frayed 1 Suggest replacement.
Missing C Require replacement.
Noisy 2 Further inspection required. See note below.
NOTE: Determine cause of noise and suggest repair.
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.
Accessory Pulleys

Accessory Pulleys
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 Switches
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 Require repair or replacement. See note below.
NOTE: Determine cause and correct prior to repair or replacement of part.
Connector missing C Require replacement.
Contaminated A Require repair or replacement. See note below.
NOTE: Determine source of contamination, such as engine coolant, fuel, metal particles, or water. Require repair or replacement.
Inoperative B Require repair or replacement. Further inspection required. See note below.
NOTE: Inoperative includes intermittent operation or out of OEM specification. Some components may be serviceable; check for accepted cleaning procedure.
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 Require repair or replacement. See note below.
NOTE: Determine cause and correct prior to repair or replacement of part.
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.
Air Conditioning Pressure Sensors

Air Conditioning Pressure Sensors
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 Require repair or replacement. See note below.
NOTE: Determine cause and correct prior to repair or replacement of part.
Connector missing C Require replacement.
Contaminated A Require repair or replacement. See note below.
NOTE: Determine source of contamination, such as engine coolant, fuel, metal particles, or water. Require repair or replacement.
Inoperative B Require repair or replacement. Further inspection required. See note below.
NOTE: Inoperative includes intermittent operation or out of OEM specification. Some components may be serviceable; check for accepted cleaning procedure.
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 Require repair or replacement. See note below.
NOTE: Determine cause and correct prior to repair or replacement of part.
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.
Air Ducts and Tubes

Air Ducts and Tubes
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 Elements
Condition Code Procedure
Leaking A Require replacement.
Paper filter element oil-soaked A Require replacement. See note below.
NOTE: Further inspection required to determine cause.
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 Require replacement. See note below.
NOTE: Further inspection required to determine cause.
Air Filter Gaskets

See Air Filter Housings and Gaskets.
Air Filter Housings and Gaskets

Air Filter Housings and Gaskets
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.
Air Fuel Ratio Sensors

Air Fuel Ratio Sensors
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 Require repair or replacement. See note below.
NOTE: Determine cause and correct prior to repair or replacement of part.
Connector missing C Require replacement.
Contaminated A Require repair or replacement. See note below.
NOTE: Determine source of contamination, such as engine coolant, fuel, metal particles, or water. Require repair or replacement.
Inoperative B Require repair or replacement. Further inspection required. See note below.
NOTE: Inoperative includes intermittent operation or out of OEM specification. Some components may be serviceable; check for accepted cleaning procedure.
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 Require repair or replacement. See note below.
NOTE: Determine cause and correct prior to repair or replacement of part.
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.
Air Injection Control Solenoids

Air Injection Control Solenoids
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 Require repair or replacement. See note below.
NOTE: Determine cause and correct prior to repair or replacement of part.
Connector missing C Require replacement.
Inoperative B Require repair or replacement. Further inspection required. See note below.
NOTE: Inoperative includes intermittent operation or out of OEM specification. Some components may be serviceable; check for accepted cleaning procedure.
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 Require repair or replacement. See note below.
NOTE: Determine cause and correct prior to repair or replacement of part.
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.
Air Plenums

Air Plenums
Condition Code Procedure
Integrated air or fuel control components inoperative A Require repair or replacement. See note below.
NOTE: Inoperative includes intermittent operation or out of OEM specification.
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.
Air Pump Belts

Air Pump Belts
Condition Code Procedure
Alignment incorrect B Further inspection required. See note below.
NOTE: Determine cause of incorrect alignment and require repair.
Cracked 1 Suggest replacement.
Frayed 1 Suggest replacement.
Maintenance intervals 3 Suggest replacement to comply with vehicle OEM recommended service intervals.
Missing C Require replacement.
Noisy 2 Further inspection required. See note below.
NOTE: Determine cause of noise and suggest repair.
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.
Air Pumps (Electric-driven)

Air Pumps (Electric-driven)
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 Require repair or replacement. See note below.
NOTE: Determine cause and correct prior to repair or replacement of part.
Connector missing C Require replacement.
Inoperative A Require replacement. See note below.
NOTE: Inoperative includes intermittent operation or out of OEM specification.
Leaking A Require replacement.
Missing C Require replacement.
Noisy 2 Suggest replacement.
Terminal broken A Require repair or replacement.
Terminal burned, affecting performance A Require repair or replacement. See note below.
NOTE: Determine cause and correct prior to repair or replacement of part.
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.
Air Tubes

See Air Ducts and Tubes.
Aspirator, Check, and Decel Valves

Aspirator, Check, and Decel Valves
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 Require repair or replacement. See note below.
NOTE: Inoperative includes intermittent operation or out of OEM specification.
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.
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 Resistors and Primary Supply Resistor Wires
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 Require repair or replacement. See note below.
NOTE: Determine cause and correct prior to repair or replacement of part.
Connector missing C Require replacement.
Inoperative A Require replacement. See note below.
NOTE: Inoperative includes intermittent operation or out of OEM specification.
Insulation overheated A Require replacement.
Terminal broken A Require repair or replacement.
Terminal burned, affecting performance A Require repair or replacement. See note below.
NOTE: Determine cause and correct prior to repair or replacement of part.
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.
Barometric Pressure Sensors

Barometric Pressure Sensors
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 Require repair or replacement. See note below.
NOTE: Determine cause and correct prior to repair or replacement of part.
Connector missing C Require replacement.
Contaminated A Require repair or replacement. See note below.
NOTE: Determine source of contamination, such as engine coolant, fuel, metal particles, or water. Require repair or replacement.
Inoperative B Require repair or replacement. Further inspection required. See note below.
NOTE: Inoperative includes intermittent operation or out of OEM specification. Some components may be serviceable; check for accepted cleaning procedure.
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 Require repair or replacement. See note below.
NOTE: Determine cause and correct prior to repair or replacement of part.
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.
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.

Batteries
Condition Code Procedure
Battery frozen Further inspection required. See note below.
NOTE: Do not attempt to charge a frozen battery. Allow battery to warm thoroughly and then performance-test. If battery fails performance test, require replacement.
Case leaking A Require replacement.
Casing swollen A Further inspection required. See note below.
NOTE: No service suggested or required unless the battery fails performance test, in which case, require replacement.
Circuit open internally A Require replacement.
Electrolyte contamination A Further inspection required. See note below.
NOTE: No service suggested or required unless the battery fails performance test, in which case, require replacement.
Electrolyte discoloration A Further inspection required. See note below.
NOTE: No service suggested or required unless the battery fails performance test, in which case, require replacement.
Fails to accept and hold charge A Require replacement. See note below.
NOTE: 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.
Fluid level low B Further inspection required. See note below.
NOTE: Determine cause of low fluid level. Refill to proper level(s) with water (distilled water preferred). Recharge battery and performance-test.
If battery does not meet specifications, require replacement.
If battery is sealed type (non-removable filler caps), require replacement.
Out of performance specification for battery B Require replacement. See note below.
NOTE: The battery may meet vehicle's OEM specifications for that vehicle but test below the minimum specifications defined by the battery manufacturer.
Out of specification for application B Require replacement.
NOTE: The battery may meet battery manufacturer's specifications but test below the minimum specification defined by the vehicle's OEM for that vehicle.
Post (top or side) burned, affecting performance A Require repair or replacement. See note below.
NOTE: Determine cause and correct prior to repair or replacement of part.
Post (top or side) burned, not affecting performance 2 Suggest repair or replacement. See note below.
NOTE: Determine cause and correct prior to repair or replacement of part.
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 Require repair or replacement. See note below.
NOTE: Determine cause and correct prior to repair or replacement of part.
Post (top or side) melted, not affecting performance 2 Suggest repair or replacement. See note below.
NOTE: Determine cause and correct prior to repair or replacement of part.
Specific gravity low B Further inspection required. See note below.
NOTE: Recharge and test to manufacturer's specifications. If battery fails performance test, require replacement.
State of charge low A Further inspection required. See note below.
NOTE: Recharge and test to manufacturer's specifications. If battery fails performance test, require replacement.
Top dirty 2 Suggest cleaning battery.
Top wet A Require cleaning battery. Further inspection required. See note below.
NOTE: Check fluid level and adjust to manufacturer's specification. Suggest checking charging system for proper operation.
Vent cap loose A Require repair or replacement of vent cap.
Vent cap missing C Require replacement of vent cap.
Battery Cables, Wires, and Connectors

Battery Cables, Wires, and Connectors
Condition Code Procedure
Application incorrect B Require repair or replacement.
Attaching hardware broken A Require repair or replacement of hardware.
Attaching hardware missing C Require replacement of hardware.
Attaching hardware not functioning A Require repair or replacement of hardware.
Connector broken A Require repair or replacement.
Connector melted A Require repair or replacement. See note below.
NOTE: Determine cause and correct prior to repair or replacement of part.
Connector missing C Require replacement.
Insulation damaged, conductors exposed A Require repair or replacement. See note below.
NOTE: Exposed conductor at replacement (aftermarket) terminal end does not require repair or replacement.
Insulation damaged, conductors not exposed 1 Suggest replacement.
Open A Require repair or replacement.
Protective shield (conduit) melted 2 Suggest repair or replacement. See note below.
NOTE: Determine cause and correct prior to repair or replacement of part.
Protective shield (conduit) missing 2 Suggest repair or replacement.
Resistance (voltage drop) out of specification A Require repair or replacement.
Routed incorrectly B Require repair.
Secured incorrectly B Require repair.
Shorted A Require repair or replacement.
Terminal broken A Require repair or replacement.
Terminal burned, affecting performance A Require repair or replacement. See note below.
NOTE: Determine cause and correct prior to repair or replacement of part.
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.
Battery Connectors

See Battery Cables, Wires, and Connectors.
Battery Trays and Hold Down Hardware

Battery Trays and Hold Down Hardware
Condition Code Procedure
Battery improperly secured 2 Suggest repair.
Bent, affecting performance A Require repair or replacement.
Bent, not affecting performance No service suggested or required.
Broken, affecting performance A Require repair or replacement.
Broken, not affecting performance No service suggested or required.
Corroded, affecting performance A Require repair or replacement.
Corroded, not affecting performance 2 Suggest repair or replacement.
Cracked, affecting performance A Require repair or replacement.
Cracked, not affecting performance 1 Suggest repair or replacement.
Missing C Require replacement.
Threads damaged A Require repair or replacement.
Threads stripped (threads missing) A Require replacement.
Water drain clogged A Require repair.
Battery Wires

See Battery Cables, Wires, and Connectors.
Belt-Driven Air Pumps

Belt-Driven Air Pumps
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 Require replacement. See note below.
NOTE: Inoperative includes intermittent operation or out of OEM specification.
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.
Belt Idler Assemblies (Accessory and Cam Belts)

Belt Idler Assemblies (Accessory and Cam Belts)
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 Tensioners (Accessory and Cam Belts)
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 Sensors
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 Require repair or replacement. See note below.
NOTE: Determine cause and correct prior to repair or replacement of part.
Connector missing C Require replacement.
Contaminated A Require repair or replacement. See note below.
NOTE: Determine source of contamination, such as engine coolant, fuel, metal particles, or water. Require repair or replacement.
Inoperative B Require repair or replacement. Further inspection required. See note below.
NOTE: Inoperative includes intermittent operation or out of OEM specification. Some components may be serviceable; check for accepted cleaning procedure.
Leaking A Require repair or replacement.
Missing C Require replacement.
Terminal broken A Require repair or replacement.
Terminal burned, affecting performance A Require repair or replacement. See note below.
NOTE: Determine cause and correct prior to repair or replacement of part.
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.
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.

Carburetors and Chokes
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 Require repair or replacement. Further inspection required. See note below.
NOTE: 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.
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.
Casting Core Plugs and Expansion Plugs

Casting Core Plugs and Expansion Plugs
Condition Code Procedure
Leaking A Require replacement.
Material type incorrect 2 Suggest replacement.
Charge Air Coolers "Intercoolers" (CAC)

Charge Air Coolers "Intercoolers" (CAC)
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 Switches
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 Require repair or replacement. See note below.
NOTE: Determine cause and correct prior to repair or replacement of part.
Connector missing C Require replacement.
Inoperative B Require repair or replacement. Further inspection required. See note below.
NOTE: Inoperative includes intermittent operation or out of OEM specification. Some components may be serviceable; check for accepted cleaning procedure.
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 Require repair or replacement. See note below.
NOTE: Determine cause and correct prior to repair or replacement of part.
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.
Cold Start Injectors

See Fuel and Cold Start Injectors.
Connectors

See Wiring Harnesses and Connectors.
Coolant

Coolant
Condition Code Procedure
Acidity (pH) incorrect 1 Suggest correction or replacement.
Contaminated B Require replacement or recycling. Further inspection required. See note below.
NOTE: Determine source of contamination and require correction prior to coolant replacement.
Level low B Require filling to proper level. See note below.
NOTE: Determine source of incorrect level and suggest repair.
Maintenance intervals 3 Suggest replacement. See note below.
NOTE: The system should be drained and/or flushed and refilled with correct coolant according to OEM recommended service interval and procedures.
Mixture incorrect B Require correction or replacement.
Type incorrect B Require replacement.
Coolant Recovery Tanks

Coolant Recovery Tanks
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 Relays and Modules
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 Require repair or replacement. See note below.
NOTE: Determine cause and correct prior to repair or replacement of part.
Connector missing C Require replacement.
Housing cracked 2 Suggest repair or replacement.
Malfunctioning A Require repair or replacement. See note below.
NOTE: Includes inoperative, intermittent operation, failure to perform all functions, or out of OEM specification.
Missing C Require replacement.
Terminal broken A Require repair or replacement.
Terminal burned, affecting performance A Require repair or replacement. See note below.
NOTE: Determine cause and correct prior to repair or replacement of part.
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.
Cooling Fan Motor Resistors

Cooling Fan Motor Resistors
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 Require repair or replacement. See note below.
NOTE: Determine cause and correct prior to repair or replacement of part.
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 Require repair or replacement. See note below.
NOTE: Determine cause and correct prior to repair or replacement of part.
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.
Cooling Fan Motor Sensors and Switches

Cooling Fan Motor Sensors and Switches
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 Require repair or replacement. See note below.
NOTE: Determine cause and correct prior to repair or replacement of part.
Connector missing C Require replacement.
Contaminated A Require repair or replacement. See note below.
NOTE: Determine source of contamination, such as engine coolant, fuel, metal particles, or water. Require repair or replacement.
Inoperative B Require repair or replacement. Further inspection required. See note below.
NOTE: Inoperative includes intermittent operation or out of OEM specification. Some components may be serviceable; check for accepted cleaning procedure.
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 Require repair or replacement. See note below.
NOTE: Determine cause and correct prior to repair or replacement of part.
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.
Cooling Fan Motor Switches

See Cooling Fan Motor Sensors and Switches.
Cooling Fan Motors

Cooling Fan Motors
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 Require repair or replacement. See note below.
NOTE: Determine cause and correct prior to repair or replacement of part.
Connector missing C Require replacement.
Hydraulic fan motor leaking A Require repair or replacement.
Inoperative A Require replacement. See note below.
NOTE: Check fan motor/controls. Inoperative includes intermittent operation or out of OEM specification.
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 Require repair or replacement. See note below.
NOTE: Determine cause and correct prior to repair or replacement of part.
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.
Crankshaft Position Sensors

Crankshaft Position Sensors
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 Require repair or replacement. See note below.
NOTE: Determine cause and correct prior to repair or replacement of part.
Connector missing C Require replacement.
Contaminated A Require repair or replacement. See note below.
NOTE: Determine source of contamination, such as engine coolant, fuel, metal particles, or water. Require repair or replacement.
Inoperative B Require repair or replacement. Further inspection required. See note below.
NOTE: Inoperative includes intermittent operation or out of OEM specification. Some components may be serviceable; check for accepted cleaning procedure.
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 Require repair or replacement. See note below.
NOTE: Determine cause and correct prior to repair or replacement of part.
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.
Decel Valves

See Aspirator, Check, and Decel Valves.
Deflectors

See Shrouds, Baffles, and Deflectors.
Dip Sticks and Tubes

Dip Sticks and Tubes
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 performance 2 Suggest repair or replacement.
Missing C Require replacement.
Dip Stick Tubes

See Dip Sticks and Tubes.
Distributor Advances and Retarders (Mechanical and Vacuum)

Distributor Advances and Retarders (Mechanical and Vacuum)
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 repair or replacement.
Inoperative A Require repair or replacement. See note below.
NOTE: Inoperative includes intermittent operation.
Leaking A Require replacement.
Out of specification B Require repair or replacement.
Distributor Boots and Shields

Distributor Boots and Shields
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.
Deteriorated A Require replacement.
Leaking A Require replacement.
Missing A Require replacement.
Torn A Require replacement.
Distributor Caps

Distributor Caps
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 Require repair or replacement. See note below.
NOTE: Determine cause and correct prior to repair or replacement of part.
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.
Distributor Retarders (Mechanical and Vacuum)

See Distributor Advances and Retarders (Mechanical and Vacuum).
Distributor Rotors

Distributor Rotors
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

Distributors
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 Valves (Heat Riser Assemblies)
Condition Code Procedure
Broken A Require replacement of affected parts.
Diaphragm inoperative A Further inspection required. See note below.
NOTE: 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.
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 Require replacement of spring(s). See note below.
NOTE: 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 Passages
Condition Code Procedure
Leaking A Require repair or replacement.
Restricted, affecting performance A Require repair or replacement.
EGR Plates and Coolers

EGR Plates and Coolers
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 Modules
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 Require repair or replacement. See note below.
NOTE: Determine cause and correct prior to repair or replacement of part.
Connector missing A Require repair.
Contaminated A Require repair or replacement. See note below.
NOTE: Determine source of contamination, such as engine coolant, fuel, metal particles, or water. Require repair or replacement of source.
Leaking A Require repair or replacement.
Malfunctioning A Require repair or replacement. See note below.
NOTE: Includes inoperative, intermittent operation, failure to perform all functions, or out of OEM specification.
Missing C Require replacement.
Terminal broken A Require repair or replacement.
Terminal burned, affecting performance A Require repair or replacement. See note below.
NOTE: Determine cause and correct prior to repair or replacement of part.
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.
Electronic Transmission Control Devices

Electronic Transmission Control Devices
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 Require repair or replacement. See note below.
NOTE: Determine cause and correct prior to repair or replacement of part.
Connector missing C Require replacement.
Contaminated A Require repair or replacement. See note below.
NOTE: Determine source of contamination, such as engine coolant, fuel, metal particles, or water. Require repair or replacement.
Leaking A Require repair or replacement.
Malfunctioning A Require repair or replacement. See note below.
NOTE: Includes inoperative, intermittent operation, failure to perform all functions, or out of OEM specification.
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 Require repair or replacement. See note below.
NOTE: Determine cause and correct prior to repair or replacement of part.
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.
Electronic Transmission Feedback Devices

Electronic Transmission Feedback Devices
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 Require repair or replacement. See note below.
NOTE: Determine cause and correct prior to repair or replacement of part.
Connector missing C Require replacement.
Contaminated A Require repair or replacement. See note below.
NOTE: Determine source of contamination, such as engine coolant, fuel, metal particles, or water. Require repair or replacement.
Inoperative B Require repair or replacement. Further inspection required. See note below.
NOTE: Inoperative includes intermittent operation or out of OEM specification. Some components may be serviceable; check for accepted cleaning procedure.
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 Require repair or replacement. See note below.
NOTE: Determine cause and correct prior to repair or replacement of part.
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.
Engine Coolant Temperature Sensors

Engine Coolant Temperature Sensors
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 Require repair or replacement. See note below.
NOTE: Determine cause and correct prior to repair or replacement of part.
Connector missing C Require replacement.
Contaminated A Require repair or replacement. See note below.
NOTE: Determine source of contamination, such as engine coolant, fuel, metal particles, or water. Require repair or replacement.
Inoperative B Require repair or replacement. Further inspection required. See note below.
NOTE: Inoperative includes intermittent operation or out of OEM specification. Some components may be serviceable; check for accepted cleaning procedure.
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 Require repair or replacement. See note below.
NOTE: Determine cause and correct prior to repair or replacement of part.
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.
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 Covers (Oil Pan, Valve Cover, Timing Cover)
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
Condition Code Procedure
Contaminated A Require replacement of oil and filter. See note below.
NOTE: Determine source of contamination, such as engine coolant, fuel, metal particles, or water when changing oil. Require repair or replacement.
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.
Engine Oil Canisters

See Engine Oil Filters and Canisters.
Engine Oil Coolers (External)

Engine Oil Coolers (External)
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.
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.
Fluid flow restrictions A Require repair or replacement.
Internal restrictions, affecting performance A Require repair or replacement.
Leaking A Require repair or replacement.
Missing A Require replacement.
Threads damaged A Require repair or replacement.
Threads stripped (threads missing) A Require replacement.
Engine Oil Drain Plugs and Gaskets

Engine Oil Drain Plugs and Gaskets
Condition Code Procedure
Leaking A Require repair or replacement.
Missing C Require replacement.
Threads damaged A Require repair or replacement. See note below.
NOTE: 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 Filters and Canisters
Condition Code Procedure
Bulged A Require replacement. Further inspection required. See note below.
NOTE: Inspect pressure relief valve.
Canister attaching 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 Require replacement. Further inspection required. See note below.
NOTE: Inspect bypass.
Contaminated A Require replacement of oil and filter. See note below.
NOTE: Determine cause of contamination, such as engine coolant, fuel, metal particles, or water when changing oil. Require repair or replacement.
Dented 2 Suggest replacement. Further inspection required. See note below.
NOTE: Determine cause, such as broken motor mount.
Leaking A Require repair or replacement.
Maintenance intervals 3 Suggest replacement to comply with vehicle's OEM recommended service intervals.
Engine Oil Gaskets

See Engine Oil Drain Plugs and Gaskets.
Engine Oil Pressure Gauges (Mechanical)

Engine Oil Pressure Gauges (Mechanical)
Condition Code Procedure
Indicates out of range B Further inspection required. See note below.
NOTE: Gauge may indicate problem with contaminated oil, level, pressure, or temperature, or problem with gauge.
Inoperative A Further inspection required. See note below.
NOTE: 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.
Leaking A Require repair or replacement.
Reads inaccurately 2 Suggest repair or replacement.
Evaporative Emission (EVAP) Canister Filters

Evaporative Emission (EVAP) Canister Filters
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.
Maintenance interval 3 Suggest replacement to comply with OEM recommended service interval.
Missing C Require replacement.
Restricted, affecting performance A Require replacement.
Restricted, not affecting performance 1 Suggest replacement.
Water-contaminated A Require replacement.
Evaporative Emission (EVAP) Canister Purge Devices

Evaporative Emission (EVAP) Canister Purge Devices
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 Require repair or replacement. See note below.
NOTE: Determine cause and correct prior to repair or replacement of part.
Connector missing C Require replacement.
Contaminated A Require repair or replacement. See note below.
NOTE: Determine source of contamination, such as engine coolant, fuel, metal particles, or water. Require repair or replacement.
Inoperative B Require repair or replacement. Further inspection required. See note below.
NOTE: Inoperative includes intermittent operation or out of OEM specification. Some components may be serviceable; check for accepted cleaning procedure.
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 Require repair or replacement. See note below.
NOTE: Determine cause and correct prior to repair or replacement of part.
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.
Evaporative Emission (EVAP) Canisters

Evaporative Emission (EVAP) Canisters
Condition Code Procedure
Inoperative A Require repair or replacement. See note below.
NOTE: Inoperative includes intermittent operation or out of OEM specification.
Leaking A Require replacement.
Missing C Require replacement.
Saturated A Require replacement.
Evaporative Emission (EVAP) Feedback Devices

Evaporative Emission (EVAP) Feedback Devices
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 Require repair or replacement. See note below.
NOTE: Determine cause and correct prior to repair or replacement of part.
Connector missing C Require replacement.
Contaminated A Require repair or replacement. See note below.
NOTE: Determine source of contamination, such as engine coolant, fuel, metal particles, or water. Require repair or replacement.
Inoperative B Require repair or replacement. Further inspection required. See note below.
NOTE: Inoperative includes intermittent operation or out of OEM specification. Some components may be serviceable; check for accepted cleaning procedure.
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 Require repair or replacement. See note below.
NOTE: Determine cause and correct prior to repair or replacement of part.
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.
Exhaust Gas Recirculation Devices

Exhaust Gas Recirculation Devices
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 Require repair or replacement. See note below.
NOTE: Determine cause and correct prior to repair or replacement of part.
Connector missing C Require replacement.
Contaminated A Require repair or replacement. See note below.
NOTE: Determine source of contamination, such as engine coolant, fuel, metal particles, or water. Require repair or replacement.
Inoperative B Require repair or replacement. Further inspection required. See note below.
NOTE: Inoperative includes intermittent operation or out of OEM specification. Some components may be serviceable; check for accepted cleaning procedure.
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 Require repair or replacement. See note below.
NOTE: Determine cause and correct prior to repair or replacement of part.
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.
Exhaust Gas Recirculation Feedback Devices

Exhaust Gas Recirculation Feedback Devices
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 Require repair or replacement. See note below.
NOTE: Determine cause and correct prior to repair or replacement of part.
Connector missing C Require replacement.
Contaminated A Require repair or replacement. See note below.
NOTE: Determine source of contamination, such as engine coolant, fuel, metal particles, or water. Require repair or replacement.
Inoperative B Require repair or replacement. Further inspection required. See note below.
NOTE: Inoperative includes intermittent operation or out of OEM specification. Some components may be serviceable; check for accepted cleaning procedure.
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 Require repair or replacement. See note below.
NOTE: Determine cause and correct prior to repair or replacement of part.
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.
Expansion Plugs

See Casting Core Plugs and Expansion Plugs.
Fan Control Sensors

Fan Control Sensors
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 Require repair or replacement. See note below.
NOTE: Determine cause and correct prior to repair or replacement of part.
Connector missing C Require replacement.
Contaminated A Require repair or replacement. See note below.
NOTE: Determine source of contamination, such as engine coolant, fuel, metal particles, or water. Require repair or replacement.
Inoperative B Require repair or replacement. Further inspection required. See note below.
NOTE: Inoperative includes intermittent operation or out of OEM specification. Some components may be serviceable; check for accepted cleaning procedure.
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 Require repair or replacement. See note below.
NOTE: Determine cause and correct prior to repair or replacement of part.
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.
Fuel

Fuel
Condition Code Procedure
Contaminated B Require repair or replacement.
NOTE: Determine of source of contamination. Require repair or replacement.
Fuel incorrect B Require flushing of system. See note below.
NOTE: 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 Accumulators and Dampers
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.
Connections leaking A Require repair or replacement.
Inoperative A Require replacement. See note below.
NOTE: Inoperative includes intermittent operation or out of OEM specification.
Leaking A Require replacement.
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 Injectors
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 Require repair or replacement. See note below.
NOTE: Determine cause and correct prior to repair or replacement of part.
Connector missing C Require replacement.
Flow restricted B Require repair or replacement.
Inoperative B Require repair or replacement. Further inspection required. See note below.
NOTE: Inoperative includes intermittent operation, out of OEM specification. Some components may be serviceable.
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 Require repair or replacement. See note below.
NOTE: Determine cause and correct prior to repair or replacement of part.
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.
Fuel Dampers

See Fuel Accumulators and Dampers.
Fuel Delivery Check Valves

Fuel Delivery Check Valves
Condition Code Procedure
Inoperative A Require replacement. See note below.
NOTE: Inoperative includes intermittent operation or out of OEM specification.
Leaking externally A Require repair or replacement.
Missing C Require replacement.
Pressure leaking (bleeds down) A Require repair or replacement.
Fuel Distributors (Bosch CIS)

Fuel Distributors (Bosch CIS)
Condition Code Procedure
Inoperative A Require repair or replacement. Further inspection required. See note below.
NOTE: Inoperative includes intermittent operation.
Leaking A Require repair or replacement.
Out of specification B Require repair or replacement.
Restricted, affecting performance A Require repair or replacement. Further inspection required. See note below.
NOTE: Some components may be serviceable; check for accepted cleaning procedure.
Fuel Filler Necks and Restrictors

Fuel Filler Necks and Restrictors
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 2 Suggest repair or replacement.
Fuel Filters

Fuel Filters
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.
Maintenance interval 3 Suggest replacement to comply with OEM recommended service interval.
Missing C Require replacement.
Restricted, affecting performance A Require replacement.
Restricted, not affecting performance 1 Suggest replacement.
Water-contaminated 2 Suggest replacement.
Fuel Injectors

Fuel Injectors
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 Require repair or replacement. See note below.
NOTE: Determine cause and correct prior to repair or replacement of part.
Connector missing C Require replacement.
Contaminated A Require repair or replacement. See note below.
NOTE: Determine source of contamination, such as engine coolant, fuel, metal particles, or water. Require repair or replacement.
Inoperative B Require repair or replacement. Further inspection required. See note below.
NOTE: Inoperative includes intermittent operation or out of OEM specification. Some components may be serviceable; check for accepted cleaning procedure.
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 Require repair or replacement. See note below.
NOTE: Determine cause and correct prior to repair or replacement of part.
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.
Fuel Level Senders

Fuel Level Senders
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 Require repair or replacement. See note below.
NOTE: Inoperative includes intermittent operation or out of OEM specification.
Leaking A Require repair or replacement.
Terminal broken A Require repair or replacement.
Terminal burned, affecting performance A Require repair or replacement. See note below.
NOTE: Determine cause and correct prior to repair or replacement of part.
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.
Fuel Pressure Regulators

Fuel Pressure Regulators
Condition Code Procedure
Contaminated 2 Suggest repair or replacement. Further inspection required. See note below.
NOTE: Some components may be serviceable; check for accepted cleaning procedure. Determine source of contamination. Require repair or replacement.
Inoperative B Require repair or replacement. See note below.
NOTE: Inoperative includes intermittent operation or out of OEM specification.
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.
Fuel Pumps (In-Tank and External, Electrical, or Mechanical)

Fuel Pumps (In-Tank and External, Electrical, or Mechanical)
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 Require repair or replacement. See note below.
NOTE: Determine cause and correct prior to repair or replacement of part.
Connector missing C Require replacement.
Contaminated A Require replacement.
NOTE: Determine source of contamination. Require repair or replacement.
Inoperative A Require repair or replacement. See note below.
NOTE: Inoperative includes intermittent operation.
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 Require repair or replacement. See note below.
NOTE: Determine cause and correct prior to repair or replacement of part.
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.
Fuel Rails

Fuel Rails
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 Require replacement. See note below.
NOTE: Determine source of contamination. Require repair or replacement.
Leaking A Require repair or replacement.
Restricted A Require repair or replacement.
Rust-pitted 1 Suggest replacement.
Fuel Restrictors

See Fuel Filler Necks and Restrictors.
Fuel Tanks

Fuel Tanks
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 Require repair. See note below.
NOTE: Determine source of contamination. Require repair or replacement.
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.
Gas Caps

Gas Caps
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

Gaskets
Condition Code Procedure
Leaking A Require repair or replacement. See note below.
NOTE: Require inspection of mating and sealing surface and repair or replace as necessary.
Grommets (Valve Cover)

Grommets (Valve Cover)
Condition Code Procedure
Leaking 2 Suggest repair or replacement. See note below.
NOTE: Require inspection of mating and sealing surface and repair or replace as necessary.
Harmonic Dampers

Harmonic Dampers
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 Valves
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 Require repair or replacement. See note below.
NOTE: Includes inoperative, intermittent operation, or failure to perform all functions.
Missing C Require replacement.
Restricted A Require repair or replacement.
Vacuum leak A Require repair or replacement.
Heater Cores

Heater Cores
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.
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 Couplers, Connectors, and Clamps
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)

Hoses and Tubes (Fuel Lines, Radiator, Vacuum, By Pass, Heater, Recovery Tank, and Oil Coolers)
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 C Require replacement of sleeves.
Restricted, affecting performance A Require repair or replacement.
Restricted, not affecting performance 2 Suggest repair or replacement.
Routed incorrectly, where failure is likely to occur B Require 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 Controls
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 Require repair or replacement. See note below.
NOTE: Determine cause and correct prior to repair or replacement of part.
Connector missing C Require replacement.
Contaminated A Require repair or replacement. See note below.
NOTE: Determine source of contamination, such as engine coolant, fuel, metal particles, or water. Require repair or replacement.
Inoperative B Require repair or replacement. Further inspection required. See note below.
NOTE: Inoperative includes intermittent operation or out of OEM specification. Some components may be serviceable; check for accepted cleaning procedure.
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 Require repair or replacement. See note below.
NOTE: Determine cause and correct prior to repair or replacement of part.
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.
Idle Speed Control Actuators

Idle Speed Control Actuators
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 Require repair or replacement. See note below.
NOTE: Determine cause and correct prior to repair or replacement of part.
Connector missing C Require replacement.
Contaminated A Require repair or replacement. See note below.
NOTE: Determine source of contamination, such as engine coolant, fuel, metal particles, or water. Require repair or replacement.
Inoperative B Require repair or replacement. Further inspection required. See note below.
NOTE: Inoperative includes intermittent operation or out of OEM specification. Some components may be serviceable; check for accepted cleaning procedure.
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 Require repair or replacement. See note below.
NOTE: Determine cause and correct prior to repair or replacement of part.
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.
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

Ignition Coils
Condition Code Procedure
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.
Connector broken A Require repair or replacement.
Connector (Weatherpack type) leaking A Require repair or replacement.
Connector melted A Require repair or replacement. See note below.
NOTE: Determine cause and correct prior to repair or replacement of part.
Connector missing C Require replacement.
Corroded, affecting performance A Require replacement.
Cor