Service manual

Electrical System
10-87
Model 3606 • Origin 10/99
19. Intake manifold remains
abnormally hot during
normal engine operation.
1. Thermo-start plug is ON
continuously due to a defective
ignition switch or a short circuit in
the wiring.
2. Thermo-start plug leaks fuel into
intake manifold.
1. Remove and test the ignition key
switch in all positions. Replace a
defective switch.
2. Replace thermo-start plug.
20. Charging System/GENERAL
VISUAL CHECK
1. Check for loose or corroded
connections.
2. Check the condition and
adjustment of the alternator belt.
3. Check the condition of the battery.
1. Repair as required.
2. Install a new belt if necessary.
3. Refer to
Section 10.7.2 Battery
.
21. ALTERNATOR
Noisy Alternator.
1. Damaged or worn drive belt.
2. Worn alternator bearings or shaft.
1. Install new drive belt.
2. Install new alternator.
22. BATTERY
Battery doesn't perform sat-
isfactorily.
1. Damaged or defective battery. 1. Test battery; refer to
Section
10.7.2 Battery
.
23. Discharged battery. 1. Short circuit in battery cell(s).
2. Loose or dirty battery cable
connections.
3. Electrical draw on battery.
4. Dirty battery top.
5. Low output or no output from
alternator.
6. High resistance in the positive (+)
battery cable.
7. High resistance in the negative (-)
battery cable.
1. Conduct battery load test.
2. Clean and tighten connections.
3. Test and correct draw on battery.
4. Clean the top of the battery.
5. Test the alternator.
6. Check the positive cable.
7. Check the negative cable.
24. Switches and Solenoids
IGNITION KEY SWITCH
Key binds in switch.
1. Sticky, dirty, or bent key. 1. Clean, remove sticky substance
or dirt, burrs, etc. from key and
sprinkle powdered graphite on
key. Insert, turn and withdraw
several times from ignition switch.
IMPORTANT: Use only graphite or a
liquid lock deicer within the lock.
25. Key cannot enter switch or
be turned once inside.
1. Defective switch.
2. Ice has formed in switch.
1. Replace the switch.
2. Warm the switch with warm air or
use liquid lock deicer to thaw the
lock.
26. Ignition switch fails to func-
tion in one or more posi-
tions.
1. Loose or broken wiring or blown
fuse.
2. Trouble in the starting circuit.
3. Defective ignition key switch.
1. Replace wiring and fuse.
2. Refer to starting circuit
troubleshooting.
3. Test and repair or replace the
ignition key switch.
Electrical System Troubleshooting
Problem Possible Cause Remedy