WOODWORKING TIPS

HOME

DESERT

SPECIAL

Win98Tips

FAVORITE SITES

AUTOMOTIVE TIPS

REFERENCE

Small Engine Repair

HEALTH TIPS

McCLOUGHAN FAMILY

MISCELLANEOUS TIPS

INTERNET TIPS

SCANNING TIPS

XPTIPS

 

 

 

 

TABLE OF CONTENTS

       Just click on a topic to go to it!

CAN I DO MY OWN TUNEUP?
WHAT TO INCLUDE:   
TIMING
MY STEERING FEELS LOOSE 
SMELLY CAR
MY ENGINE WON'T START
WHAT CAUSES A NO SPARK CONDITION
LACKS POWER AT HIGH SPEED
DIRTY FUEL INJECTORS
INJECTOR CLEANING 
HARD STARTING WHEN COLD
HARD STARTING WHEN HOT
A SEASONAL PROBLEM 
STEADY MISS, BAD FUEL MILEAGE
IGNITION DIAGNOSIS
FUEL DIAGNOSIS
COMPRESSION DIAGNOSIS 
HOW DO I TELL IF I NEED A NEW FUEL FILTER
ENGINE STARTS THEN DIES
ELECTRIC COOLING FAN
SECTION TWO       
TIRE SIZE CALCULATOR
TIRE INFORMATION

 

 

 

Can I do my own tune-up to save money? 

Answer:

You can provided you know how to change spark plugs, check (and adjust, if necessary) the ignition timing, idle speed and idle mixture (carburetors only) on your engine. 

If you can reach the spark plugs on your engine, you should be able to change them yourself. All you need is a plug socket, ratchet wrench, extension, and feeler gauge to set the plug electrode gap. If you're working on an engine with adjustable timing, you'll need a timing light to make sure the timing hasn't changed (it shouldn't have unless somebody messed with it). And you'll need a tachometer to set the idle speed correctly. 

Engines that have electronic ignition and a sealed carburetor or fuel injection require very little maintenance beyond replacing the spark plugs every 30,000 miles, replacing the air and fuel filters annually (or as needed), changing the PCV valve (every 30,000 to 50,000 miles) and changing the oil and filter (every 3,000 miles or six months is usually recommended). 

When replacing these items, you should also give your engine a good "once over" to make sure there are no obvious problems such as fluid leaks, loose or damaged wires, belts, or hoses, etc. Checking things like compression and intake vacuum are not required, but can reveal a lot about the overall condition of your engine. 

WHAT TO INCLUDE: 

A comprehensive "tune-up" should probably include all of the following: 

     Replacing the spark plugs (be sure to gap to specs) 
     Inspect the rotor (replace only if necessary) 
     Inspect the distributor cap (replace only if necessary) 
     Check timing (adjust if necessary) 
     Inspect spark plug wires (replace only if necessary) 
     Check idle speed (adjust as needed) 
     Check choke (carbureted engines only) 
     Check compression (to monitor valve & ring wear, requires a compression gauge) 
     Check manifold intake vacuum (to check for leaks, or valve and ignition problems, requires a vacuum gauge) 
     Check battery/charging voltage (to detect charging system problems) 
     Inspect & clean battery posts and cable connections 
     Inspect air filter (replace if dirty) 
     Replace fuel filter (for preventative maintenance) 
     Replace PCV valve 
     Check vacuum hoses (replace only if cracked or loose) 
     Check all vital fluid levels (engine oil, transmission fluid, coolant, brakes and power
     steering) 
     Inspect belts & hoses (replace as needed) 
     Check safety items such as lights, wipers, tires (including inflation pressure), and horn. 
 
 
 TIMING

How do you check or adjust ignition timing on an engine with a distributor less ignition system? 

Answer:

You can't do either on many engines, but checks and adjustments are still possible on others. 

On some distributorless ignition systems, timing is fixed and cannot be adjusted. Nor are any timing marks provided on the crankshaft pulley for reference checks. If there are any problems (like a bad crankshaft position sensor), the onboard computer is supposed to pick it up and illuminate the Check Engine light. Otherwise, you have to assume everything is fine. 

On other engines without distributors, the crankshaft position sensor and/or cam position sensor allows a certain amount of adjustment. Loosening and rotating the sensor's position has the same effect on advancing and retarding timing as rotating a distributor. Timing marks on the crankshaft pulley are usually provided so a conventional timing light can be used to check timing. 

To check timing, attach a timing light to the number one spark plug wire. Use the light to illuminate the timing marks on the crankshaft pulley as the engine idles. Refer to the engine emissions decal or a shop manual for the timing specs. 

To adjust timing, loosen the crankshaft or camshaft sensor. Then rotate the sensor's position in the same direction as the crankshaft or camshaft turns to retard timing, or in the opposite direction to advance timing. 

On some engines timing can also be checked electronically through the computer system itself by plugging a "scan tool" into the computer's diagnostic connector. 
 

My steering feels loose. Any ideas why? 

Answer:

The most common causes of steering looseness include worn tie rod ends, a worn idler arm or center link (on vehicles without rack and pinion steering), a worn steering gear or a worn steering rack. 

Normally, your steering wheel should have no more than about a quarter inch of play. Any more means something is worn or loose and needs to be fixed. 

WARNING: Don't put off having your steering looked at because a failure of a critical component could cause loss of steering control! 

The inner and outer tie rod ends should have no perceptible looseness. Worn or loose tie rod ends are especially dangerous because if one pulls apart you'll lose steering control. Worn tie rod ends can also cause rapid tire wear. 

If you have a rear-wheel drive vehicle with conventional steering (not rack and pinion steering), the idler arm should have no more than the specified amount of maximum play. Refer to a manual for the specs and recommended procedure for checking it. Checking idler arm play usually involves pulling on the arm with a specified force and measuring how much the arm deflects. 

If your vehicle has a lot of miles on it, the steering gear or rack itself may be worn. On
conventional steering boxes, there's usually an adjustment screw that can be used to take some of the slack out of the system. With rack and pinion steering, though, adjustment is usually little help because the rack develops center wear. If the pinion is adjusted to compensate, the rack may bind when turned to either side. The only cure for a center wear condition is to replace the rack with a new one (an entire new rack assembly). 

OTHER CAUSES 

Sometimes the steering will feel loose because of a worn U-joint coupling in the steering column. Loose or worn wheel bearings can also make the steering wander and feel loose. 
 

My power steering feels stiff when I first start my car, but then feels normal after I've driven the car awhile. How come? 

Answer:

This is called "morning sickness" and has nothing to do with being pregnant. The condition is caused by wear in the spool valve housing on certain power steering racks -- notably GM front-wheel drive cars. 

When the car is first started, the rack is cold and clearances in the spool valve are at their greatest. Hydraulic pressure from the power steering pump leaks past grooves worn in the aluminum spool valve housing. This causes a loss of pressure and increases steering effort. The steering feels stiff with little or no power assist. As the car is driven, the rack warms up. This decreases the clearances inside the spool valve housing, which reduces the leakage past the grooves. More pressure goes to where it is supposed to go and the steering becomes easier as power assist returns. 

The "fix" for this condition is to replace the rack with a new one (preferably with a cast iron spool valve housing) or a remanufactured rack that has a stainless steel sleeve pressed into the aluminum housing. 

  SMELLY CAR

Answer:

You probably have an oil leak on your engine that is dripping oil on an exhaust manifold or pipe. The most likely cause is a leaky valve cover gasket. 

Open the hood and visually inspect your engine (engine off, of course). Look for wet, oily streaks or a buildup of greasy deposits on the sides of your engine near the exhaust manifold. You may also have noticed some oil spots on your driveway, or a slight increase in oil consumption (check the oil level on the dipstick). 

If oil is leaking past the valve cover gasket, the gasket will have to be replaced. 

OTHER ODORS 

If you don't see an oil leak and continue to smell something unusual, it could signal something more serious. Overheated wiring may also produce a burnt smell, but one that has a sharper, more pungent or caustic odor. This is nothing to ignore because it may result in a fire. Have a professional inspect your wiring. 

An overheated automatic transmission or one that's filled with badly oxidized fluid (because nobody ever changed it) can also produce a burnt smell. To check the fluid, remove the transmission dipstick. If the fluid has a dark brown color or smells burnt, it is long overdue for a change. It might also mean your transmission is on the verge of calling it quits, too -- especially if it has been shifting erratically, slipping or otherwise acting up. Transmission repairs are very expensive and usually require replacing the transmission with a new or rebuilt unit. 

If you smell a "rotten egg" odor (hydrogen sulfide), it may mean your engine is running lean or that the catalytic converter may not be functioning properly. Some vehicles (Ford mostly) have had problems with persistent rotten egg odors from the converter. Apparently, it has something to do with the mix of catalysts used to manufacture the converters. Replacing the converter with a "revised" model usually cures the problem. 

MY ENGINE WON'T START 

Answer:

You may have an ignition, fuel delivery or compression problem. 

1. Check for spark first. If there's no spark, you may have a failed ignition module, ignition pickup, ignition coil or open in the ignition circuit (bad ignition switch or neutral safety switch). 

2. If you have spark, check for fuel. On carbureted engines, remove the air cleaner, hold the choke open, look down the carburetor throat and work the throttle linkage. If you don't see any fuel squirting into the carburetor, the problem may be a stuck needle inlet valve in the carburetor, a bad fuel pump, a plugged fuel filter, a plugged or frozen fuel line, an obstructed fuel tank pickup screen, or no fuel (or water contaminated fuel) in your tank. 

3. If you have spark and fuel, your timing chain or belt may have broken or slipped. If your engine has a distributor, remove the distributor cap and see if the rotor turns when the engine is cranked.
No movement would tell you the timing belt or chain (or possibly the cam itself) is broken.
Another alternative is to remove the valve cover to see if the valves are opening and closing. This too will show you if the cam drive or cam is broken. 

If a cam belt or chain has "slipped a tooth," throwing valve timing off, the valves will still open and close, and the rotor inside the distributor will still turn. But the engine won't develop enough compression to start. A compression check can help you find this kind of problem. 
             

  WHAT CAUSES A NO SPARK CONDITION

Answer:

The best way is to methodically check each component until you've isolated the fault. But many people start replacing things until they eventually stumble on whatever was causing their problem (which is a very expensive and time-consuming way to solve a no start problem). 

If you're certain the ignition system is not creating a spark (Further information is available on getting a spark.), you can assume that either the coil is defective or something in the electronic circuitry that controls the coil is defective. 

Most distributor type electronic ignition systems have either a magnetic pickup or "Hall effect" sensor that generates a signal as the distributor shaft rotates. On distributor less ignition systems, the trigger signal is generated by a Hall effect or magnetic crankshaft position sensor (and cam position sensor in many applications). The trigger signal goes to the ignition module, which switches the ignition coil on and off to fire the spark plugs. If the pickup or Hall effect switch is not producing a signal, or if the ignition module is not processing the signal, the coil won't fire. 

COIL CHECKS 

Ignition coils are pretty simple (just a set of copper windings around an iron core sealed in plastic), so there's not much that can go wrong with them. They do fail occasionally, but usually the part that fails is something more vulnerable like the ignition module, the pickup in the distributor or the wires that connect to the pickup or the module. 

The coil can be ruled out as a possible cause by checking it's "primary" and "secondary" resistance with an ohmmeter. Primary resistance is checked between the positive and negative coil terminals. As a rule, primary resistance should be two ohms or less. Secondary resistance is tested between the high voltage terminal and the negative terminal. Secondary resistance should be high, ranging anywhere from 8,000 to 20,000 ohms. The exact specs will vary from one application to another, so refer to a manual for the specifications for your vehicle. 

NOTE: On some distributor less ignition systems, the individual coils in the coil pack assembly can be replaced if only one coil is defective. On others, the coils cannot be replaced separately and the entire unit must be replaced if any coil, or the coil module, is bad. 

WIRING CHECKS 

CAUTION: Don't disconnect or unplug any connectors without first making sure the ignition is off. Breaking a connection while voltage is flowing in the circuit can create a voltage surge that may damage electronic components. 

Check all the connectors at the distributor, module and coil to make sure they're tight and
corrosion-free. It doesn't take much to disrupt the primary ignition circuit. A visual inspection won't necessarily reveal all such problems because "invisible" corrosion can create enough resistance to disrupt a low voltage circuit. You may have to back probe both sides of a connector with an ohmmeter to see if there is resistance in the link. 

Next, remove the distributor cap (if your engine has one) and inspect the wiring connections on the pickup (and module if the module is located inside the cap as is the case with most GM systems, or on the side of the distributor as is the case with many Ford systems). The flexing of the distributor can sometimes cause hairline cracks in the wires or their insulation creating an open in the circuit. 

PICKUP CHECKS 

If you don't find any problems here, check the resistance of the pickup in the distributor (refer to a manual for the exact specs). An open or short here can prevent the pickup signal from reaching the module. The exact test procedures are so varied that we'll summarize by saying that most checks involve using an ohmmeter to measure the resistance of a magnetic pickup or a voltmeter to check voltage readings in the Hall effect sensor circuits. If the readings are out of range, the pickup or sensor needs to be replaced. With Hall effect sensors, it's also important to make sure the sensor is receiving voltage because it can't generate a signal without voltage. Refer to a manual for the specific diagnostic procedure for your vehicle. 

NOTE: On engines with computerized controls, loss of the pickup signal will usually set a fault code in the computer. On vehicles with distributor less ignition systems, a bad crankshaft or camshaft sensor will also set a code. To check for such a code, you'll need a scan tool -- unless the computer has a "manual" diagnostic mode that displays "flash" codes (blinking lights) when certain terminals on the diagnostic connector are jumped or grounded. Refer to a manual for the code retrieval procedure. 

MODULE CHECKS 

Ignition modules frequently fail for three reasons: heat, vibration or voltage overload. Excessive heat can damage sensitive electronic chips. GM ignition modules and Ford TFI modules, in particular, rely on a layer of grease under the module to help carry heat away from the electronics. If someone replaced the module and forgot to apply the grease, the module may have failed due to overheating. The leads that connect the module to the wiring are also vulnerable to breakage, often as a result of vibration. Finally, a module can be destroyed if the high secondary voltage in the distributor somehow finds a path to the module. 

In some applications, modules can be checked by using a high impedance (10 megohms) digital ohmmeter to measure resistance between various terminals. If any of the measurements are out of spec, the module is defective and needs to be replaced. But on most applications, a process of elimination is used to isolate a bad module. Or, a "known good module" is substituted for the old one to see if it cures the problem. If the engine starts, the old module must have been bad. If it still doesn't start, then it's something else. The problem with this technique is that the new module may be damaged if there's a short in the wiring that caused the old module to fail. 

COMPUTER CHECKS 

Most electronic ignition systems will start even if the computer is defective or disconnected. The computer plays an "intervening" role and modifies spark timing by delaying or advancing the pickup trigger signal or module switching of the coil. In spite of the fact that many people blame the computer for anything that goes wrong, the fact is the computer is pretty reliable. Most problems can be traced to opens in the wiring harness or loose or corroded connectors. 

A scan tool is required to check the computer for ignition-related fault codes, unless the system provides a manual flash codes. Refer to a manual for the diagnostic procedure for your vehicle. 
 

                     LACKS POWER AT HIGH SPEED

Answer:

You most likely have one of two problems: a fuel line restriction or an exhaust restriction. 

FUEL RESTRICTION 

A plugged fuel filter, crushed fuel line or clogged pickup screen inside the fuel tank can all starve your engine for fuel. Enough fuel may get through for the engine to start and run at low speed, but when more fuel is needed it can't get through resulting in loss of power at high speed. The same kind of problem can also be caused by a weak fuel pump. But fuel pumps usually quit altogether when they fail. 

Inspect the fuel line from the tank to the engine. If you don't see any obvious damage, try replacing the fuel filter. If that doesn't help, blowing out the fuel line with compressed air from the engine towards the fuel tank may help dislodge a blockage and debris from the pickup screen. If the pickup screen in the tank is clogged with rust and debris, the tank will have to be removed so the screen can be replaced and the tank cleaned. 

Fuel pressure can also be checked by teeing a suitable gauge into the fuel line. If pressure is very low (refer to a manual for the specs), the pump probably will need to be replaced. 

EXHAUST RESTRICTION 

As for an exhaust restriction, the easiest way to check for this condition is to hook up a vacuum gauge to a vacuum port on the intake manifold or throttle body. If vacuum is low and continues to drop as the engine runs, it's telling you pressure is backing up because of a restriction in the exhaust. The most likely culprit is a clogged catalytic converter. 

If the converter has overheated, it may have melted internally. This would restrict the flow of gases through the converter and create a serious backpressure problem that would cause a loss of power at high speed. If the blockage is complete, the engine may start then die and not run at all. 

Other causes here may include a crushed exhaust pipe (a visual inspection should find this easy enough), a double-walled pipe that has collapsed internally, or a muffler that has become clogged with rust (rare, because they usually blow out). If you suspect an exhaust restriction, temporarily disconnect the head pipe from the catalytic converter (which is no easy task because the bolts will probably be rusted solid). If the engine now runs normally, you have an exhaust restriction. Inspect the converter and replace it if needed. 

NOTE: If the converter is plugged, it failed because something else caused it to overheat. Causes include misfiring spark plugs and leaky exhaust valves. The underlying problem needs to be identified and corrected before the converter is replaced otherwise the new converter will suffer the same fate. 

  DIRTY FUEL INJECTORS

Answer:

"Dirty" is actually a misnomer. Rarely are injectors clogged with dirt. Rather, they are usually clogged or restricted by a buildup of fuel varnish deposits. This reduces the amount of fuel that the injector sprays, which in turn may cause the engine to run lean and misfire, hesitate or stall. 

A fuel injector is nothing more than spray nozzle. With mechanical injectors, a spring loaded valve allows fuel to squirt out of the nozzle when line pressure overcomes spring tension that holds the valve shut. With electronic injectors, a spring-loaded solenoid pulls open a pintle valve or ball type valve when the injector is energized by the computer. This allows the pressurized fuel in the fuel rail to flow through the injector and squirt out the nozzle. 

Injectors come in a variety of styles. Early Bosch style injectors have a pintle valve and are the ones most prone to clogging. In 1989, General Motors introduced its new "Multec" style injectors which have a ball valve design and are claimed to be more resistant to clogging. Other injectors have a disc-valve design that is also said to resist clogging. 

The truth is ANY injector can clog. Nobody's injectors are immune to this kind of problem, but some are obviously better than others. 

Problems can occur even with a slight buildup of deposits. Because the injector orifice is so small, it doesn't take much crud to restrict the flow of fuel or to disrupt the spray pattern. For good combustion, the injectors must produce a fine cone-shaped mist of fuel vapor. Wear or deposits in the nozzle can create "streamers" of liquid fuel that vaporize and burn poorly. This, in turn, can cause hesitation, emissions and performance problems. 

INJECTOR CLEANING 

The cure for a set of clogged injectors is cleaning -- or replacement if they're too badly clogged to respond to cleaning. Injectors are expensive to replace. New domestic injectors sell for $60 to $100 each, with new import injectors fetching $125 to $175 each. Injectors should only be replaced as a last resort. 

If your injectors are clogged, they can be cleaned with pressurized solvent, or removed for off-car cleaning. There are also fuel tank additives that claim to clean clogged injectors, but the cleaning such products do is usually minimal. So save your money and put it towards a professional cleaning. 

There are do-it-yourself on-car injector pressure cleaning kits that are similar to the equipment professionals use. But some of these kits can be tricky or even dangerous to use. Our advice is to let a professional do it. 

On-car injector cleaning involves feeding solvent under pressure into the injector fuel rail or supply line. The concentrated solvent passes through the injectors and loosens and washes away the accumulated varnish deposits. The results are usually good, and make a noticeable difference in idle smoothness, emissions and fuel economy. 

If your injectors are really clogged and fail to respond well to on-car cleaning, off-car cleaning using special fuel injection cleaning equipment would be the next logical option. Some of this equipment is designed to "reverse" flush the injectors so any debris that's trapped inside the injector or above the inlet screen will also be removed. Off-car cleaning also allows a mechanic to observe the spray pattern of the injectors to make sure there aren't any streamers or problems. Off-car cleaning is more expensive because of the labor involved to remove the injectors, but the results are usually better. 

KEEPING INJECTORS CLEAN 

The best way to minimize or eliminate the need for injector cleaning is to use a quality brand of gasoline that contains sufficient detergent to prevent varnish buildup. Most brand name gasolines today have enough detergent to do this. As a rule, premium grades usually contain a somewhat higher concentration of cleaners. 

You can also use fuel tank additives to keep your injectors clean. Such products really aren't necessary if you're using quality gasoline. But if you're buying the cheapest gas you can find, using an additive might be good insurance. 
 
 

HARD STARTING WHEN COLD 

Answer:

If your engine has a carburetor, the hard starting problem is most likely choke related. If the engine cranks normally and the spark plugs are not worn or dirty, the choke probably needs to be repaired or adjusted. 

The choke may be set too rich or too lean. Either way can cause hard starting. Inside the choke housing is a bimetal spring that regulates the tension on the choke according to temperature. If this spring is broken, the choke will not operate. If the choke linkage is rusty or jammed with varnish deposits or dirt, it may stick or not operate smoothly. Cleaning with carburetor spray or solvent may help alleviate a sticking problem. 

On older fuel injected engines, a separate "cold start" injector is used to spray additional fuel into the intake manifold when a cold engine is first started. If this injector is not working, the engine can be hard to start. The injector is controlled by a timer and relay, so if either of these components is defective it can prevent the cold start injector from doing its job, too. 

If your engine cranks slowly, your cold starting problem is not fuel related, but may be due to a weak battery, loose or corroded battery cables, or a weak starter. 

Check for obvious problems first. Remove, clean and inspect the battery cables (both ends). Then check battery charge and condition. (More information on the condition of your battery and battery recharging is available.) If the battery charge is low, recharging the battery may temporarily solve your problem. But there's a reason why your battery is low. You probably have a charging system problem that requires further diagnosis. (More information on alternators is also available.)
If your battery is more than four or five years old, it is probably near the end of its service life and needs to be replaced. A "load test" will tell you if it still has sufficient cranking capacity to provide reliable cold starting. 

Slow cranking during cold weather (below freezing) can also be caused by oil that is too thick. A high viscosity oil such as straight 30 or 40 weight oil in the crankcase can make an engine very difficult to crank when the temperature drops. Switching to a lighter multi viscosity oil such as 10W-30 or 10W-40 should solve this problem. 
 

 HARD STARTING WHEN HOT

Answer:

Hot starting problems are usually fuel related. When a hot engine is shut off, the temperature of the engine and everything on it continues to rise for awhile as the engine undergoes a period of "heat soak." This can cause fuel to boil inside the carburetor bowl, fuel lines and fuel filter. When you attempt to restart the engine, "vapor lock" obstructs the flow of fuel and the engine doesn't want to start. 

This is much less of a problem on fuel injected engines because the fuel is usually under much higher pressure inside the injectors and fuel line. Even so, a fuel line routed near an exhaust manifold or a fuel rail that's exposed to a lot of heat may still suffer the same kind of problems. 

Heat soak problems such as these can sometimes be cured by wrapping insulation around affected fuel lines, and/or installing an insulating spacer or heat shield under the carburetor. 

A SEASONAL PROBLEM 

Hard starting tends to be a seasonal problem, but may be worse in the early months of spring when refiners are switching fuel blends. Gasoline refiners produce fuel with a slightly lower volatility rating (called "Reed vapor pressure") during hot summer months because lower volatility fuel is less likely to boil and cause hot starting problems. During the winter, they switch to a higher volatility fuel because it makes cold starting easier. But if you still have "winter" grade fuel in your tank when warm spring weather arrives, you may experience some hot starting problems. The problem will go away, however, as soon as the refiners in your area switch to their summer grade fuel. 

OTHER CAUSES 

Hot starting problems can also be caused by cooling problems that allow your engine to run too hot (the pistons swell up and may scuff the cylinder walls), or excessive resistance in the starter motor that causes the engine to crank slowly. A starter "amp draw" test can be used to check the condition of your starter. Also, many starters have small "heat shields" to protect them from heat radiating from nearby exhaust pipes or manifolds. If the shield is missing, the starter may get too hot and bind up. 

STEADY MISS, BAD FUEL MILEAGE

Answer:

A steady miss indicates one of three things: a cylinder that isn't firing because of an ignition problem, a cylinder that isn't firing because it isn't receiving fuel (multipoint fuel injected engines only), or a cylinder that has lost compression. 

The first step in diagnosing this kind of problem is to identify the dead cylinder. A professional mechanic can do this quickly by hooking the engine up to an ignition oscilloscope and displaying an ignition raster pattern. The dead cylinder will show a firing voltage that is significantly higher or lower than its companions depending on the nature of the problem. He might also do a "power balance" test and/or a compression test to find the dead cylinder. 

One way you can find a weak or dead cylinder is to momentarily disconnect each of your engine's spark plug wires one at a time while the engine is running. When the plug wire is removed from the spark plug, there should be a big drop in idle speed and idle smoothness. When you pull a wire and there's little or no change in idle speed or quality, you've found the bad cylinder. 

It makes no difference whether you remove each plug wire from the spark plug or the distributor (or coil pack on distributor less ignition systems). The idea is to simply disconnect each cylinder for a moment to see if it makes any difference in the way the engine runs. The one that makes no difference is the problem cylinder. 

CAUTION: Disconnecting spark plug wires while the engine is dangerous because you risk
getting shocked. You can minimize this danger one of several ways. One is to wear rubber gloves and use insulated spark plug wire pliers to momentarily disconnect each plug wire. Another is to make sure no part of your body is touching or leaning against any metal surface on the vehicle (the fender, hood, grille, etc.). Or, you could turn the engine off, remove a plug wire, restart the engine, note any change in idle, then repeat for each of the remaining spark plugs. 

IGNITION DIAGNOSIS 

If you disconnect the plug wire from the spark plug and hold the end of the wire close to the plug terminal or other metal surface, you should see a spark and/or hear a crisp snapping noise if voltage is getting through the wire. No spark would tell you the plug wire is bad, voltage is arcing inside the distributor cap (remove and inspect the cap for cracks and carbon tracks -- replace if any are found) or a dead coil on a distributor less ignition system (Note: on most distributor less ignition systems, each coil fires two cylinders. So if both cylinders are dead, you know for sure the coil is not working. If only one cylinder is dead, however, it's not the coil). 

If all of the plug wires seem to be sparking okay, the next step would be to remove the spark plug in the problem cylinder. Fouling is a common cause of ignition misfire. Examine the end of the plug. If the electrode is covered with deposits, clean or replace the spark plug. Also, note the type of deposits on the plug. Thick, black, wet or oily-looking deposits would tell you the cylinder is burning oil (probably due to worn valve guides, rings and/or cylinder wall). If the deposits are a powdery black, the cylinder is running too rich (probably due to a leaky injector on a multipoint fuel injected engine). If the deposits are brown or gray, it indicates a normal buildup. However, the plug may be fouled because it hasn't been changed for a long time, because it is the wrong "heat range" for your engine application (you need a hotter plug), or because of frequent short trip stop-and-go driving. 

In any event, if the plug is fouled you should probably remove, inspect and clean or replace all of the spark plugs. 

FUEL DIAGNOSIS 

If the dead cylinder is receiving spark through the plug wire and the spark plug itself appears to be okay (not wet or fouled), and your engine has multipoint fuel injection you may have a dead fuel injector. 

To check for this kind of problem, start the engine and place your finger on the injector. You should feel a buzzing vibration if the injector is working. No buzz means the injector is either defective or it is not receiving a voltage signal through its wiring harness. You can check for the presence of voltage with a 12 volt test light or voltmeter. Disconnect the injector wiring connector and attach the test light or voltmeter between the injector and connector. If the light doesn't flash or you don't see a voltage reading when the engine is running, it indicates a wiring or computer problem that will require further diagnosis. If voltage is getting through but the injector isn't working, then the injector is defective and needs to be replaced. 

Sometimes the injector will appear to be working but really isn't. It will be receiving voltage and buzzing as normal, but because it is clogged up with varnish deposits little or no fuel is actually being squirted into the cylinder. If ignition and compression are both okay in the bad cylinder, therefore, it would tell you the injector is clogged. On-car cleaning may reopen the clogged injector is the varnish isn't built up too thick. But a completely clogged injector usually doesn't respond well to this type of cleaning. It either has to be removed for off-car cleaning (which may or may not succeed id reopening it) or be replaced. 

COMPRESSION DIAGNOSIS 

If the dead cylinder is getting spark and fuel, the only thing that's left is a compression problem.
The most likely causes here would be a leaky valve (probably an exhaust valve since they run much hotter than intake valves and usually fail or "burn" first), a blown head gasket (this usually involves two adjacent cylinders, however), or a rounded or badly worn cam lobe. 

A compression check will verify if the cylinder is developing its normal compression. Little or no compression would verify any of the above problems. A leakage test could also be used to further diagnose and identify the nature of the problem (valves, head gasket or cam). Air leakage through the exhaust port would indicate a bad exhaust valve. Air leakage back through the intake manifold would indicate a bad intake valve. Air leaking into an adjacent cylinder would indicate a blown head gasket. Minimal leakage would indicate a rounded cam lobe. 

Leaky valves would require removing the cylinder head and having a valve job performed. A leaky head gasket would require removing the head and replacing the gasket (and probably resurfacing the head to restore flatness). A cam problem would require removing and replacing the camshaft and lifters (old lifters should never be reused with a new cam). 
 
 

HOW DO I TELL IF I NEED A NEW FUEL FILTER

Answer:

The only way to tell for sure is to remove the filter and blow through it. If there's little resistance, the filter is still okay and does not need to be replaced. But if there's more than minimal resistance, the filter is dirty and should be replaced. 

CAUTION: Gasoline is poisonous, does not taste very good and may burn sensitive lips. So don't hold the filter to your mouth to blow through it. Instead, attach a short piece of clean rubber hose to the filter and then blow through the hose to test the filter. 

FILTER PROBLEMS 

A completely plugged fuel filter will stop your engine cold by choking off the flow of fuel to the carburetor or injectors. The engine may not start, or it may start, then stall and die. 

Some filters have a spring-loaded bypass, however, that allows fuel to bypass the filter element if it becomes clogged. Fuel continues to flow, but it may carry dirt to the carburetor or injectors, which can create additional problems. 

A partially restricted filter will usually pass enough fuel to keep the engine running at idle or low speed, but may starve the engine for fuel at higher speeds or loads. So your engine may run fine putting around town, but sputter and lack power when you try to drive at highway speeds or pass someone. 

TANK FILTER 

Located inside the fuel tank is a screen or mesh sock that acts like a prefilter to keep big pieces of dirt and rust from being drawn into the fuel pickup tube or tank-mounted electric fuel pump. If the screen becomes clogged with debris, it can have the same effect as a plugged or dirty fuel filter. Therefore, if you've been experiencing a fuel starvation problem and have replaced the fuel filter --and it didn't help -- the screen in the tank is probably the culprit. To clean or replace it, the fuel tank usually has to be removed. 

WARNING: The fuel tank must be drained prior to removal. The fuel must be stored in a sealed "approved" container. The battery should also be disconnected to prevent any accidental sparks from an in-tank electric fuel pump connection from igniting the vapors. Do not smoke when working on the fuel tank, filter or fuel lines, and keep all other sources of ignition away (electric heaters, pilot lights, etc.) from the work area. 

FILTER REPLACEMENT 

Replacing the fuel filter periodically (every year or so) for preventative maintenance can reduce the risk of filter-related driveability problems. Most vehicle manufacturers, however, no longer specify a replacement interval for the fuel filter. Or, if they do it's some incredibly long interval like once every five years or 50,000 miles. Many mechanics feel this is unrealistic. Waiting that long to change the filter is asking for trouble, especially if you drive on gravel or dirt roads, buy the cheapest gas you can find from "cut-rate" stations, use gas with alcohol in it, or your vehicle is more than six or seven years old and may have rust in the tank. 

The fuel filter on carbureted engines is usually located at the inlet fitting of the carburetor, or an "in-line" filter is used between the fuel pump and carburetor. 

When replacing a filter that screws into the inlet fitting on the carburetor, be careful not to
over tighten the filter. The threads in the carburetor are relatively soft and can be easily stripped. But also make sure the filter is snug so that it doesn't leak. It's okay to apply some gasket sealer to the filter threads to assure a leak-free connection. But do not use RTV silicone sealer (which gasoline dissolves) or teflon tape (pieces of which can flake loose and end up in the carburetor). 

When replacing an in-line filter, most filters come with two new rubber hoses that go on either side of the filter. Use them. Don't reuse the old hoses because rubber hoses deteriorate over time and can leak or shed small flakes or rubber that can end up in the filter or carburetor. Also, make sure the hose clamps are properly positioned and tight. 

Replacing an in-line fuel filter -  

NOTE: Most in-line filters have an arrow showing the direction fuel should flow through the filter. Install the filter so the arrow points toward the carburetor. 

FUEL INJECTION FILTERS 

Fuel filters on fuel injected engines are usually larger and have a finer filter element than those on carbureted engines. Consequently, they are usually more expensive. 

The filter may be located anywhere between the fuel tank and injector fuel supply rail or throttle body. On many cars, light trucks and minivans, the filter is located underneath the vehicle along a frame rail. On some, the filter is part of the electric fuel pump assembly inside the fuel tank! Refer to a shop manual for your fuel filter's location. 

CAUTION: Fuel injected engines usually have a lot of residual pressure in the fuel line, even when a vehicle has sat overnight. So either follow the manufacturer's recommended procedure for relieving pressure in the line prior to removing the filter (applying vacuum to the fuel pressure regulator manifold fitting, or cranking the engine with the ignition disabled), or wrap a rag around the hose connections and slowly loosen them. 

If the filter has an arrow indicating the direction of flow, it should be installed with the arrow pointing toward the engine and away from the fuel tank. 

If the filter is located inside the tank, the tank will probably have to be removed. Follow the same precautions as previously described for replacing a plugged pickup screen. 
 

 ENGINE STARTS THEN DIES

Answer:

It sounds like the classic symptom of an exhaust blockage, probably due to a clogged catalytic converter. The converter can overheat and be damaged if excessive amounts of unburned fuel enter the exhaust system. This can happen if the engine has one or more fouled spark plugs or leaky exhaust valves. When this unburned fuel hits the converter, it sends temperatures soaring. The ceramic substrate or pellets that support the catalyst can melt and partially or completely block the flow of exhaust through the converter. 

If a complete blockage occurs, the engine will start normally but the exhaust has no place to go. Backpressure quickly builds up and within a couple of minutes the engine quits running. Eventually, the pressure will seep out and allow the engine to restart after it has sit for some time. But the blockage will prevent it from running for long. 

The cure here would be to replace the converter. But first, the underlying problem that caused the converter to overheat and fail needs to be diagnosed and corrected -- otherwise the new converter will suffer the same fate. 

Other possible causes of this kind of condition include a crushed exhaust pipe, some prankster shoving a potato up your tailpipe, a collapsed inner wall in a double-walled head pipe, or a muffler that's obstructed with rust debris. 
 

 ELECTRIC COOLING FAN

Answer:

Yes. The cooling fan is only needed when engine temperature rises above a predetermined level --or when there is an increased load placed on the cooling system (as when running your air conditioner). The rest of the time, running the fan would be a waste of electrical energy so it is turned off. 

Electric cooling fans are found on most front-wheel drive vehicles with transverse mounted engines as well as many late model rear-wheel drive vehicles. Electric fans are used on FWD cars because the fan doesn't require a belt drive and can be mounted independent of the engine's location. What's more, electric fans require less power to operate (for improved fuel economy and performance), they're quieter, and they allow more precise control over cooling. 

By comparison, a mechanical belt-driven fan can require anywhere from 5 to 15 horsepower depending on engine speed and the size of the fan. Even with a fan clutch to reduce the drag at higher speeds, it's still a lot of wasted power. 

FAN OPERATION 

At highway speeds, there is usually enough airflow through the radiator that a fan isn't needed. So the fan usually only operates when the vehicle is sitting in traffic or driving at slower speeds. 

On older applications, the electric fan is controlled by a temperature switch located in the radiator or engine. When the temperature of the coolant exceeds the switch's rating (typically 195 to 235 degrees F), the switch closes and energizes a relay that supplies voltage to run the fan. The fan then continues to run until the coolant temperature drops back below the opening point of the switch. Most electric fans are also wired to come on when the A/C is on. Many vehicles also have a separate fan for the A/C condenser (dual fan systems). One or both fans come on when the A/C is on. 

In newer vehicles with computerized engine controls, fan operation is regulated by the engine control module. Input from the coolant sensor, and in many cases the vehicle speed sensor too, is used to determine when the fan needs to be on. 

CAUTION: Many electric fans are wired to come on anytime the engine is above a certain
temperature, regardless of whether the engine is running or not. This means the fan may come on after the engine has been shut off. So keep your fingers away from the fan at all times unless the battery or fan motor wires have been disconnected. 

CHECKING THE FAN 

Four things can prevent a fan from coming on when it should: a bad temperature switch or coolant sensor (or problem in the switch or sensor wiring circuit); a bad fan relay; a wiring problem (blown fuse, loose or corroded connector, shorts, opens, etc.); or a failure of the fan motor itself. Only the latter would require replacing the fan motor. 

One way to check the operation of the fan motor is to jump it directly to the battery. If it spins, the motor is good, and the problem is elsewhere in the wiring or control circuit. Another check is to test for voltage with a voltmeter or test light at the fan's wiring connector. There should be voltage when the engine is hot and when the A/C is on. 

 

SECTION TWO
FRONT WHEEL DRIVE CLICKING SOUND
CLUTCH SLIPPAGE
CHECK ENGINE LIGHT IS ON
HOW CAN I TELL IF CATALYTIC CONVERTER IS OK
CAUSES OF CONVERTER FAILURES 
VEHICLE TROUBLESHOOTING
 EXTRA ITEMS TO KEEP IN VEHICLE  
 

FRONT WHEEL DRIVE CLICKING SOUND

Answer:

Yes. A clicking sound when turning is one of the classic symptoms of a worn or damaged
"constant velocity" (CV) joint. Your car has four such joints on the two front axles: two inboard joints and two outboard joints. The outboard joints are the ones that make a clicking sound when they go bad. 

Inside the joint are six steel balls, positioned in grooves between an inner race and an outer
housing. The balls are held in position by a cage that looks something like a wide bracelet with windows or slots cut in it. When the joint is new, the balls fit tightly into the cage windows. But as the joint accumulates miles, the cage windows become worn and allow the balls to rattle around. The grooves in the inner race and outer housing also wear, which further contributes to noise. 

When driving straight, a worn CV joint is usually quiet (constant noise would indicate a bad wheel bearing or other problem). But when the wheels are turned to either side, the joint bends causing the balls to click as they slide around in their cage windows and grooves. The noise is usually loudest when backing up with the wheels turned. Repacking the joint with grease won't help because the joint is worn and needs to be replaced. 

The "normal" life of a CV joint is usually 100,000 miles or more. But a joint can fail prematurely if the rubber boot that surrounds it is damaged or develops a leak. 

CV JOINT BOOTS 

The boot, which is made of rubber or hard plastic, serves two purposes: it keeps the joint's vital supply of special grease inside, and it keeps dirt and water out. After five or six years of service, it's not unusual for the boot to develop age cracks or splits. Boots can also be damaged by road hazards or a careless tow truck operator who uses J-hooks to tow your vehicle. 

Once the boot seal is broken, the inside grease quickly leaks out. Starved for lubrication, the CV joint soon fails. Dirt and water can also enter the boot and contaminate any grease that's left inside. Either way, a damaged boot is bad news for the joint. 

CV joint boots should be inspected periodically (when the oil is changed is a good time) to make sure they are not cracked or torn, and that the clamps are tight. If you see grease on the outside of the boot, it is leaking and needs to be replaced (the sooner the better). If a clamp is loose and the boot is leaking grease at one end, the clamp needs to be replaced. 

Original equipment boots are a one-piece design, which means the drive shaft and CV joint have to be removed from the vehicle and disassembled to replace a bad boot. However, there are aftermarket "split-boots" designed for easy do-it-yourself installation. The split-boots eliminate the need to remove and disassemble the joint and driveshaft. You simply cut off the old boot, clean out as much of the old grease as possible from the joint, pack the joint with fresh high temperature CV joint grease (never ordinary chassis grease), then install the new boot. Most split-boots have a seam that is glued together. The seam must not have any grease smeared on it and the glue must be applied carefully for a good seal. Also, the vehicle must not be driven until the glue has cured (about an hour or so). 

NOTE: Most professional mechanics do not use split-boots because (1) they don't think a
split-boot is as reliable or as long-lived as a one-piece original equipment style boot, and (2) they don't like the idea of installing a new boot on a questionable joint. 

By the time a damaged or leaky boot is noticed, the joint has usually lost most of its grease and/or been contaminated by dirt. Unless the joint is removed, disassembled, cleaned and inspected, there's no way to know if it is still in good enough condition to remain in service. If it's making noise, replacing the boot would be a waste of time because the joint is bad and needs to be replaced (most new joints come with a new boot, clamps and grease). But even if the joint isn't making any noise, it may still have wear or internal damage that will soon cause it to fail. 

WARNING: A CV joint failure can cause loss of steering control under certain circumstances. If the joint locks up, it can prevent the wheels from being turned. 

My mechanic tells me my front-wheel drive (FWD) car has a bad outer CV joint. He says the shaft has to be replaced. Isn't there a less expensive way to fix it? 

Answer:

Time is money in the auto repair business. It's much faster and easier for a mechanic to replace the entire driveshaft assembly with both joints on it than to mess around replacing a CV joint on your old driveshaft. Removing the old CV joint from the shaft, disassembling and inspecting the other CV joint on the shaft to make sure it is still good, reassembling and repacking both joints with grease and installing the boots and clamps is a messy and time-consuming job. So that's why your mechanic is trying to give you the "shaft." He isn't trying to cheat you. He's only trying to save himself some time and effort. 

The cost of replacement shafts for most FWD cars today has dropped to the point where a
complete shaft assembly with new or remanufactured CV joints costs little more (or in some cases no more!) than a brand new replacement joint. That's why most mechanics have gone to swapping shafts instead of replacing individual CV joints. 

When the shaft is changed, your old shaft and joints are exchanged for the replacement shaft. Your old shaft is then returned to a company that specializes in shaft rebuilding. Your old shaft is then rebuilt using new or remanufactured joints. The shaft then goes back into the parts distribution pipeline and is sold to the next person who needs one. That's how the system works. It's recycling in action, and it actually saves consumers a lot of money. 

If you're pinching pennies and/or don't plan to keep your car for a long time, you can save some money by asking for a shaft with remanufactured, rather than new, joints. The warranty won't be as good, and the joints may not last as long as brand new ones, but you get what you pay for. 

Shafts for import vehicles typically cost about 30% more than those for domestic vehicles because there are more different designs of import shafts and joints (some of which can be very difficult and expensive to obtain). 
 

CLUTCH SLIPPAGE

Answer:

It depends. If your clutch has low miles on it (40,000 or less), chances are the slippage is due to one of two things: oil contamination or a misadjusted clutch linkage. If your clutch has a lot of miles on it (60,000 or more), chances are it's worn out and you need to replace it. 

To rule out oil contamination as a possible cause of slippage, check under the rear of the engine and the bell housing for oil leaks. If you see oil on the oil pan or bell housing, the rear main oil seal is probably leaking. Other leak points include manifold and valve cover gaskets at the back of the engine, and the transmission input shaft seal. 

If you've got an oil leak, don't replace the clutch until you've fixed the leak. Once the clutch linings have been contaminated by oil, there's no way to clean them. Replacing the clutch disk is the only way to restore proper clutch operation. 

If you don't have a leak, check the linkage adjustment. Most cars with a cable linkage have an automatic adjusting mechanism that's supposed to maintain proper clearances. If anything, the cable would be too loose rather than too tight. But if someone has been playing around with the linkage adjustment, they may have gotten it too tight. The same goes for vehicles with hydraulic linkages. There's no way this type of linkage can cause slippage unless it is misadjusted by someone. 

That leaves the clutch itself. Slippage can be caused by two things: worn facings or loss of spring tension in the pressure plate. Unless the clutch really has been abused or has a lot of miles on it, it's unlikely the pressure plate is weak. Normal wear reduces the thickness of the facings on the clutch disk, which in turn reduces the clamping force the pressure plate can apply to squeeze the disk against the flywheel. Replacing the clutch disk should cure the problem. 

Even so, the clutch and flywheel should be carefully inspected when the parts are removed. If the pressure plate is worn or damaged, you'll need to replace that, too. Most experts recommend having the flywheel refaced to restore the friction surface. You can probably get by without refacing the flywheel -- but only if the flywheel is flat, smooth, clean and un cracked. Any grooves, heat discoloration, cracking or other damage would call for resurfacing or replacing the flywheel. 
 

CHECK ENGINE LIGHT IS ON

Answer:

It means your vehicle's onboard computer system has self-diagnosed some kind of problem. The "Check Engine" light, which is also called a "Malfunction Indicator Lamp" (MIL) or "Service Engine Soon" (SES) lamp, is there to signal you when a problem occurs that may require attention.
This can include anything from a momentary hiccup that has has little or no noticeable affect on engine performance or driving safety to a failure of a major electronic component. There's no way to know what the light means without running a diagnostic scan on the system to determine the nature of the fault. 

As a rule, a continuous Check Engine light usually signals a "hard fault" or failure that has occurred. If the light comes on and off, or only blinks momentarily, the problem may be minor or intermittent in nature. 

To help identify the problem, it helps to make a mental note of the conditions that occurred when the light came on. Where you driving at a certain speed? Accelerating or slowing down? Shifting gears? 

Onboard diagnostic systems are very complex and require a fair amount of expertise as well as special tools to troubleshoot. To find out what's wrong, a technician has to "get into" your system through a diagnostic connector which may be located under the dash, under the driver's seat or in the engine compartment. The diagnostic connector serves as a port of entry for accessing information and/or for putting your vehicle's computer system into a special diagnostic mode for further testing or displaying "fault codes". 

Fault codes are numeric codes that are generated when a problem is detected. If a sensor circuit reads out of range or some electronic component fails to respond to a command from the computer, the computer recognizes it as a fault and records a number that corresponds to the nature of the problem. The technician must then retrieve the code and refer to specific diagnostic chart or "fault tree" that gives him the step-by-step checks he has to perform to isolate the failed component. It can be a very time-consuming process depending on the nature of the problem. Usually the process works but sometimes it doesn't. An intermittent fault can be very difficult to track down, and may require repeated attempts to repair it. 
 

 HOW CAN I TELL IF CATALYTIC CONVERTER IS OK

Answer:

The catalytic converter is our main line of defense against air pollution, so it's important to make sure it is functioning efficiently and passing exhaust without creating undue restrictions that might reduce performance, fuel economy or emissions. That's one of the reasons for periodic vehicle emissions testing. If the converter isn't working, you won't pass the test. 

If the your converter is plugged, it will create a restriction in your exhaust system. The buildup of backpressure will cause a drastic drop in engine performance and fuel economy, and may even cause the engine to stall after it starts if the blockage is severe. 

The easiest test for converter plugging is done with a vacuum gauge. Connect the gauge to a
source of intake vacuum on the intake manifold, carburetor or throttle body. Note the reading at idle, then raise and hold engine speed at 2,500. The needle will drop when you first open the throttle, but should then rise and stabilize. If the vacuum reading starts to drop, pressure may be backing up in the exhaust system. 

You can also try to measure backpressure directly. If your engine has air injection, disconnect the check valve from the distribution manifold, and connect a low pressure gauge. Or, remove the oxygen sensor and take your reading at its hole in the manifold or headpipe. Refer to the backpressure specs for the application. Generally speaking, more than 1.25 psi of backpressure at idle, or more than 3 psi at 2,000 rpm tells you there's an exhaust restriction. 

If there appears to be an exhaust restriction, disconnect the exhaust pipe just aft of the converter to relieve pressure and recheck the readings. CAUTION: The pipes will be hot so wait awhile for things to cool down. If vacuum goes up and/or backpressure drops, the problem isn't not a plugged converter but a plugged muffler or collapsed pipe. If there's little or no change in readings, the converter is plugged. 

Just because a converter is passing gas doesn't mean it is okay. If the catalyst inside is
contaminated or worn out, high carbon monoxide (CO) and/or hydrocarbon (HC) readings will be present in the exhaust. If you have access to a high temperature digital pyrometer (or an oven thermometer will do), check the converter's temperature fore and aft. A good converter will usually run 100 degrees F hotter at its outlet than its inlet. Little or no temperature change would indicate low efficiency, or a problem with the converter's air supply. Converters need supplemental oxygen in the exhaust to re-burn pollutants, so if the air injection system or aspirator valve isn't doing its job the converter can't do its job either. 

Check the air injection pump, belt and check valve. If you suspect that the check valve is allowing exhaust to flow backwards, remove it and blow through both ends. It should let air pass in one direction, but not in the other. Examine the air injection manifold, too, because it tends to rust out and leak air. Check the diverter valve to make sure it is working correctly, too. It should be routing air to the converter when the engine is at normal temperature. 

On engines with aspirator valves instead of air pumps, you should hear and/or feel the fluttering of the internal flapper as the engine is idling. 

CAUSES OF CONVERTER FAILURES 

Fouling, clogging, melt-down and breakage of the ceramic substrate inside a converter are
common conditions that can cause problems. Plugging is usually the end result of a melt-down, which occurs because the converter gets too hot. This happens because the engine is dumping unburned fuel into the exhaust. The excess fuel lights off inside the converter and sends temperatures soaring. If it gets hot enough, the ceramic substrate that carries the catalyst melts. 

The unburned fuel may be getting into the exhaust because of a bad spark plug or valve, but an overly rich air/fuel mixture is another possibility. In older carbureted engines, a heavy or misadjusted carburetor float may be the underlying cause. But on newer engines with "feedback" carburetion or electronic fuel injection, the engine may not be going into "closed loop" (the normal mode where the computer regulates the air/fuel mixture to minimize emissions). 

A bad oxygen sensor or coolant sensor may be giving the computer bogus information. A sluggish or dead O2 sensor will make the computer think the exhaust is running lean, so the computer will try to compensate by making the fuel mixture rich. A coolant sensor that always indicates a cold engine will also keep the system in open loop, which means a steady diet of excess fuel. But it might not be the sensor's fault. A thermostat that's stuck open or is too cold for the application can prevent the engine from reaching its normal operating temperature. So if your converter has failed and needs to be replaced, the engine should be diagnosed for any underlying problems before the new converter is installed. 

Another cause of converter clogging and contamination is excessive oil consumption. Worn valve guides or seals can allow oil to be sucked into the engine's combustion chambers. The same goes for worn or damaged rings or cylinders. Oil can form a great deal of carbon, and metals present in the oil can contaminate the catalyst. A compression check or leak-down test will tell you if the rings are leaking, while a fluttering vacuum gauge needle will help you identify worn valve guides. 
 

    VEHICLE TROUBLESHOOTING

1.------------------- Check gas is it getting to carburetor?
2.------------------- Check Wiring is it all connected?
3.------------------- Check Starter is it cranking fast enough?
4.------------------- Check Points are they burned, rubbing block worn?

            Vehicle Stalls

1.-------------------Idle speed too slow?
2.-------------------Air leaks in hoses or manifold?
3.-------------------Check Points
4.-------------------Burnt Valve, do compression test.
5.-------------------Vapor lock overheated fuel.
6.-------------------Flooding, needle valve, choke, float setting, float damage or sticking?

           Engine Misfires at all speeds

1.------------------Fouled or broken plug
2.------------------Bad spark plug cables
3.------------------Low battery
4.------------------Low alternator voltage
5.------------------Bad points
6.------------------Incorrect gap on points
7.------------------Bad coil condenser or connections
8.------------------Bad distributor cap or Rotor
9.------------------Loose or corroded connections in ignition circuit.
10.----------------Blown Head Gasket do compression test.
11.----------------Sticking Valves
12.----------------Leak at intake manifold
13.----------------Preignition

            Engine Misfires at high speed

1.--------------------Wrong type spark plugs
2.--------------------Point gap too wide.
3.--------------------Sticking Valves
4.--------------------Weak Valve Springs
5.--------------------Fuel delivery inadequate
6.--------------------Mild vapor lock, check routing of fuel lines
7.--------------------Weak spark
8.--------------------Improper timing
9.--------------------Restricted exhaust
10.------------------Vacuum advance not working, check hose
11.------------------Dirty air cleaner
12.------------------Choke not opening completely
13.------------------pre-ignition

Lack of power or high speed performance

1.---------------------Incorrect timing
2.---------------------Check Vacuum advance
3.---------------------Burnt points or weak spring
4.---------------------Check spark plugs
5.---------------------Check plug wires
6.---------------------Check carburetor
7.---------------------Low Compression
8.---------------------Bad carb accelerator pump
9.---------------------Bad fuel pump

                         Rough Idle

1.--------------------Dirty jets in carb
2.--------------------Improper Idle setting
3.--------------------Float level
4.--------------------Choke not opening enough
5.--------------------Air leaks
6.--------------------Burnt Valve
7.--------------------Improper fuel pump pressure

 

                       Backfire

1.-----------------------Lean fuel mixture
2.-----------------------Engine cold and choke open too far.
3.-----------------------Bad Valve or spring
4.-----------------------Bad wiring or Distributor cap.
5.-----------------------Bad Plugs
6.-----------------------Incorrect timing, check timing chain

                      Engine Overheats

1.----------------------Slipping fan belt
2.----------------------Needs water
3.----------------------Incorrect timing
4.----------------------Blown head gasket
5.----------------------Dirty Radiator, engine water passages
6.----------------------Defective thermostat
7.----------------------Bad hoses
8.----------------------Bad Water pump
9.----------------------Outside of Radiator clogged or blocked
10.---------------------Weak hose, can be sucked closed when motor speeded up.
11.---------------------To clean engine and radiator put in can of lye in COLD WATER  run for a few days then flush.
  Don't Use Lye On Aluminum Blocks or heads.

                    Timing Chain

Check by grasping lower pulley, rotate back and forth to check for excessive play.

                    Clogged Fuel Filter 

Will cause engine to die, hesitate, lose power, will usually act up when going uphill or under hard acceleration, will come and go, these same symptoms can be caused by a loose wire connection. Or defective ignition switch. 

        EXTRA ITEMS TO KEEP IN VEHICLE
 

1.---------------------4 ft of radiator hose, knife to cut it with.
2.---------------------top and bottom radiator hoses
3.---------------------Drive belt
4.---------------------Screwdriver, visegrips, crescent wrench
5.---------------------2 ft baling wire
6.---------------------Blanket, pillow, matches
7.---------------------$50 in cash and change
8.---------------------3 qts oil, brake fluid, windshield washer fluid
9.---------------------Can of tire inflator
10.-------------------Spare tire, jack, lug wrench, flashlight, flares
11.-------------------Electrical tape, 4 ft electric wire
12.-------------------Paper towels, windex, ice scraper
13.-------------------Spare wiper blades
14.-------------------Spare light bulbs fuses