TM 9-2320-361-34 MECHANICAL SYSTEMS TROUBLESHOOTING SYMPTOM INDEX MALFUNCTION TROUBLESHOOTING NO. MALFUNCTION PROCEDURE PAGE 1. 2. 3. 4. 5. 6. 9. 10, 11. 12. 13. 14. 15. 16. 17. 18. 19. 20. 21. 22. 23. 24. 25. 26. 27. 28. 29. 30. 31 32. 33. 34. 35. 36. ENGINE Engine will not crank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6 Starter cranks engine slowly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7 Engine cranks but will not start . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7 Engine starts but stops when accelerator is operated . . . . . . . . . . . . . 2-8 Engine stops when accelerator is returned to idle position. . . . . . . . . . 2-8 Poor acceleration and/or lack of power. . . . . . . . . . . . . . . . . . . . . . . . 2-8 Engine delivers excessive black exhaust smoke . . . . . . . . . . . . . . . . . 2-8 Engine surges . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8 Engine misfires during operation. . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9 Engine stops during normal operation. . . . . . . . . . . . . . . . . . . . . . . . 2-9 Exhaust color blue during normal operation . . . . . . . . . . . . . . . . . . . 2-9 Exhaust color white during normal operation and idle . . . . . . . . . . . . 2-10 Engine oil pressure low or zero at normal operating temperature. . . . . 2-11 Engine oil pressure extremely high at normal operating temperature. . 2-12 Engine oil loss during normal operation . . . . . . . . . . . . . . . . . . . . . . 2-13 Engine noise abnormal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-13 Engine vibration abnormal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-14 FUEL SYSTEM No fuel at fuel injectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-14 Low fuel supply at injector nozzles.. . . . . . . . . . . . . . . . . . . . . . . . . 2-16 Fuel injectors inoperative . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-16 Fuel injectors deliver excess fuel into engine . . . . . . . . . . . . . . . . . . . 2-16 COOLING SYSTEM Coolant loss during normal operation . . . . . . . . . . . . . . . . . . . . . . . . 2-17 Coolant temperature excessive.. . . . . . . . . . . . . . . . . . . . . . . . . . . 2-17 CLUTCH Vehicle will not move or engine stalls with clutch engaged. . . . . . . . . . 2-17 Burning odor evident with clutch engaged. . . . . . . . . . . . . . . . . . . . . 2-18 Clutch noisy during engagement and disengagement . . . . . . . . . . . . . 2-18 Vibration during clutch engagement. . . . . . . . . . . . . . . . . . . . . . . . . 2-19 Clutch pedal will not travel depress . . . . . . . . . . . . . . . . . . . . . . . 2-19 TRANSMISSION Transmission oily. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-19 Transmission leaks oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-19 Transmission grinds and/or pops out of gear during shifting . . . . . . . . 2-20 TRANSFER CASE Transfer case will not operate front differential . . . . . . . . . . . . . . . . . 2-20 Transfer case will not operate rear dfierential. . . . . . . . . . . . . . . . . . 2-20 Transfer case leaks oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-20 Transfer case noisy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-21 Transfer case grinds or pops out of gear during normal vehicle operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-21 2-3