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This chapter should cover all known mechanical failures that have occurred on the trail runs and any field repairs that can be made to get the vehicle off of the trail for proper repair. Also there should be a troubleshooting section containing a list of the vehicle codes displayed on the Scan guage.
 

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Discussion Starter · #2 · (Edited)
Working Copy

Title:
Mechanical

Subtitle:
Blah Blah Blah...

Heading 1:
Diagnostics

Heading 1 Body:

Heading 2:
Analysis Check

Heading 2 Body:
You will need to classify the problem you are experiencing to troubleshoot more systematically. use the following, etc... blah blabh

  • Engine does not start - Dead or low battery, no air flow, no fuel, no spark
  • Difficult to start - Low battery, poor air flow, poor fuel flow
  • Poor idling -
  • Poor drivability -
  • Engine Stall -
  • Others -
Heading 2:
Basic Inspection

Heading 2 Body:
1.) Is the battery voltage 11 Volts or more?
a.) No - Charge or replace battery
b.) Yes - Proceed to step 2
2.) Does the engine crank?
a.) No -
b.) Yes - Proceed to step 3
3.) Does the engine start?
a.) No -
b.) Yes - Proceed to step 4
4.) Check air filter
a.) Remove excess dirt by blowing w/compressed air or gentley tapping against a solid surface.
b.) Not Good - repair or replace
c.) Good - Proceed to step 5
5.) Check idle speed
a.) Warm up the engine to normal operating temperature.
b.) Switch off all the accessories.
c.) Switch off the air conditioning
d.) Shift transmission into N position.
e.) using an ODB II scan tool such as a ScanGauge II, verify that the idle speed is between 650 ~ 750 RPM
f.) No Good - Goto ....
g.) Good - Proceed to step 6
6.) Check ignition timing
a.)
b.)
7.) Check fuel pressure
a.) Be sure there is enough fuel in the tank.
b.) Verify the fuel pump is operational.
c.) Check for fuel pressure in the return hose when it is pinched off. You should hear a fuel flowing sound.
d.) No Good - proceed to .....
e.) Good - Proceed to step 8.
8.) Check for spark
a.)
b.)

Heading 2:
Dashboard Indicators


Heading 2 Body:
  • A-Trac - Indicates that the Active Control System is on
  • Check Engine -
  • Low Tire Pressure - Alerts operator that one or more of the 5 tires is low on pressure. This is normal if you've aired down however should go away when you air up.
  • Maintenance Required -
  • Slip Indicator - Flashes to indicate that A-Trac is engaged.
Heading 2:
Physical Indicators

Heading 2 Body:


Heading 2:
Operating the ScanGauge II

Heading 2 Body:

To identify areas of trouble in your vehicle perform the following steps on your ScanGauge II:
  • Press the button labled "More."
  • Press the button labeled "Scan" and take note of the error codes displayed.
Note: The Notes section of your Trail Log is a good area to note this information if the errors occur on a trail run.
  • Use the following ODB II Vehicle Codes to determine the problem area.
Heading 2:
ODB II Vehicle Codes

Heading 2 Body:
P0100 Mass Air Flow Circuit.
P0101 Mass Air Flow Circuit Range/Performance.
P0105 Manifold Absolute Pressure Circuit.
P0106 MAP/BARO Circuit Range/Performance.
P0110 Intake Air Temperature Circuit.
P0115 Engine Coolant Temperature Circuit.
P0116 Engine Coolant Temperature Range/Performance.
P0120 Throttle Pedal Sensor Switch "A" Circuit.
P0121 Throttle Pedal Sensor Switch "A" Circuit Range/Performance.
P0125 Insufficient Coolant Temperature for Closed Loop Fuel Control.
P0130 Heated Oxygen Sensor Circuit - Bank 1 Sensor 1.
P0133 Heated Oxygen Sensor Circuit Slow Response Bank 1 Sensor 1.
P0135 Heated Oxygen Sensor Circuit - Bank 1 Sensor 1.
P0136 Heated Oxygen Sensor Circuit - Bank 1 Sensor 2.
P0141 Heated Oxygen Sensor Circuit - Bank 1 Sensor 2.
P0150 Heated Oxygen Sensor Circuit - Bank 2 Sensor 1.
P0153 Heated Oxygen Sensor Circuit Slow Response Bank 2 Sensor 1.
P0155 Heated Oxygen Sensor Circuit - Bank 2 Sensor 1.
P0156 Heated Oxygen Sensor Circuit - Bank 2 Sensor 2.
P0161 Heated Oxygen Sensor Circuit - Bank 2 Sensor 2.
P0170 Fuel Trim malfunction.
P0171 System too Lean.
P0172 System too Rich.
P0201 Injector Circuit - Cyl. 1.
P0202 Injector Circuit - Cyl. 2.
P0203 Injector Circuit - Cyl. 3.
P0204 Injector Circuit - Cyl. 4.
P0205 Injector Circuit - Cyl. 5.
P0206 Injector Circuit - Cyl. 6.
P0300 Random Misfire.
P0301 Misfire Detected - Cyl. 1.
P0302 Misfire Detected - Cyl. 2.
P0303 Misfire Detected - Cyl. 3.
P0304 Misfire Detected - Cyl. 4.
P0305 Misfire Detected - Cyl. 5.
P0306 Misfire Detected - Cyl. 6.
P0325 Knock Sensor 1 Circuit.
P0330 Knock Sensor 2 Circuit.
P0335 Crankshaft Position Sensor "A" Circuit.
P0336 Crankshaft Position Sensor "A" Circuit Range/Performance.
P0340 CMP Sensor Circuit malfunction.
P0385 Crankshaft Position Sensor "B" NE2 Circuit.
P0401 EGR Flow Insufficient.
P0402 EGR Flow Excessive.
P0420 Catalyst System Efficiency below Threshold.
P0430 Catalyst System Efficiency below Threshold Bank 2.
P0440 EVAP Control System.
P0441 EVAP Control System Improper Purge Flow.
P0446 EVAP Control System Vent Control.
P0450 EVAP Control System Pressure Sensor.
P0451 EVAP Control System Pressure Sensor Range/Performance.
P0500 Vehicle Speed Sensor.
P0505 Idle Speed Control System.
P0510 Close Throttle Position Switch.
P1100 BARO Sensor Circuit.
P1120 Accelerator Pedal Position Sensor Circuit.
P1121 Accelerator Pedal Position Sensor Range/Performance Problem.
P1125 Throttle Control Motor Circuit.
P1126 Magnetic Clutch Circuit.
P1127 ETCS Actuator Power Source Circuit.
P1128 Throttle Control Motor Lock.
P1129 Electric Throttle Control System.
P1130 Air-Fuel Sensor Circuit Range/Performance.
P1133 Air-Fuel Sensor Circuit Response.
P1135 Air-Fuel Sensor Heater Circuit Response.
P1150 A/F Sensor Circuit Range/Performance.
P1153 A/F Sensor Circuit Response.
P1155 A/F Sensor Heater Circuit.
P1200 Fuel Pump Relay Circuit.
P1300 Igniter Circuit - No. 1.
P1310 Igniter Circuit - No. 2.
P1335 No Crankshaft Position Sensor Signal - Engine Running.
P1349 VVT System.
P1400 Sub-Throttle Position Sensor.
P1401 Sub-Throttle Position Sensor Range/Performance Problem.
P1405 Turbo Pressure Sensor Circuit.
P1406 Turbo Pressure Sensor Range/Performance Problem.
P1410 EGR Valve Position Sensor Circuit.
P1411 EGR Valve Position Sensor Circuit Range/Performance.
P1500 Starter Signal Circuit.
P1510 Boost Pressure Control Circuit.
P1511 Boost Pressure Low.
P1512 Boost Pressure High.
P1520 Stop Lamp Switch Signal.
P1565 Cruise Control Main Switch Circuit.
P1600 ECM.
P1605 Knock Control CPU.
P1630 Traction Control System.
P1633 ECM.
P1652 Idle Air Control Valve Control Circuit.
P1656 OCV Circuit.
P1658 Wastegate Valve Control Circuit.
P1661 EGR Circuit.
P1662 EGR by-pass Valve Control Circuit.
P1780 Park/Neutral Switch.

Heading 1:
Engine



Heading 1:
Body



Heading 1:
Chassis

Heading 2:
Tires and Wheels

Heading 2 Body:
A wheel is made up of a tire that is mounted on a rim. On the trail, there are several issues that can arise in this area as it is the one and only part of the car that contact the rough terrain you are driving on, well most of the time, that is.

Heading 3:
Rim Damage

Heading 3 Body:
Pound pack bent steel rims with a hammer.

Heading 3:
Tire Punctures

Heading 3 Body:
Tire punctures can be repaired in a variety of ways depending on the severity and intention of the repair. In most cases, you will either change the wheel or repair the tire right on the car. You may want to only get the vehicle moving again long enough to get it to the main road where tow services can pick you up.

Tire Plugs - plugs are the fastest and most common.....

Patches - Patching is rarely ever done on the trail but what kind of field guide would this be if we didn't tell you how? 1.) Remove wheel from vehicle 2.) remove tire from rim by.......

Rudimentary Repairs - here is your last resort methods you might need to use in order to get back off of the trail. Duct tape is your friend here. After locating the hole in the tire, be innovative. Search around for anything you can use to 1.) smooth out the shape of the hole to something more round 2.) jam into the hole to reduce the rate at which air will leak 3.) If needed, wrap the wheel in duct tape, a whole roll if necessary.

Heading 3:
Wheel Weights

Heading 3 Body:
Wheel weights are strategically placed on the wheel at the time of balancing them in the tire shop. These wheel weights, either stick on or crimp on may become dislodged and cause the wheel to be off balance. Of balance wheels will result in vibrations, uneven tire wear and even reduce the life of other suspension/steering components.

You should take inventory of what weights each wheel has and check that they are still there after a trail run. If you mark the rim or cheat sheet of their location, you can carry spares or take it to a tire shop if they are missing.

Heading 2:
Front Axles & CV Joints

Heading 2 Body:


Heading 3:
CV Joint Damage

Heading 3 Body:
Blah Blah Blah

Heading 3:
CV Boot Damage

Heading 3 Body:
Bagging the boot, etc..., blah blah blah

Heading 2:
Front Differential

Heading 2:
Front Shocks, Springs and Sway-Bar

Heading 2:
Front Upper and Lower Control Arms

Heading 2:
Rear Axles

Heading 2:
Rear Differential

Heading 2:
Rear Shocks, Springs and Sway-Bar

Heading 2:
Rear Upper and Lower Links

Heading 1:
Electrical
 

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Discussion Starter · #3 · (Edited)
Heading 1:
Vehicle Specifications

Heading 2:
Dimensions and Capacities

Heading 2:
Torque Specifications

Heading 3:
Engine

Spark Plug Coil Bolt - 8 ft./lbs.
Spark Plugs - 14 ft./lbs.

Drive Shaft - 65 ft./lbs.

Heading 3:
Body

Body Mounts - 35 ft./lbs.

Heading 3:
Chassis

Spindle Nut - 175 ft. lbs.
Sway Bar Link Nut - 52 ft. lbs.
Brake Caliper Bolts: 91 ft. lbs.
Lower Control Arm Knuckle Nuts: 118 ft. lbs.

Rear Shock Upper Nut: 18 ft. lbs
Rear Shock Lower Bolt: 72 ft. lbs
Rear Anti-swaybar Nut, Upper Link Assy. (frame): 11 ft. lbs
Rear Anti-swaybar Bolt, Bracket Cover (over bushing): 22 ft. lbs
Rear Anti-swaybar Nut, Lower Link Assy. (swaybar): 52 ft. lbs
 

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