Service slants

Motor, Jan 1999 by Juran, Ken

Chrysler

Flickering headlights. Usually it's just a bad sealed beam, bulb or socket-no big deal. But if you ever come across a 1995-96 Dodge or Plymouth Neon with this symptom, the problem may lie in the circuitry itself. Apparently, some of these cars may flicker the headlights when the radiator fan(s) or a/c system cycles on. So a Headlamp Flicker Package (Part No. 4856386) has been developed to address this condition.

The it contains one solid-state relay, a PIM module, a wiring overlay harness and two relay attaching screws. What you'll do is install the new relay in the radiator fan circuit and the PWM control module in the Power Distribution Center (PDC) in place of the radiator fan relay. Before beginning, disconnect the negative battery cable and get the car up on a lift for access to the lower left crossmember/radiator support area. Then proceed as follows:

If the car has cruise control, unscrew the splash shield and fold it out of the way. Then, measure 2 3/4 inches in from the left side of the crossmember and 2 inches up from the lower edge. At that point, drill a 1/4-inch hole to accept the guide pin on the solid-state relay (see top illustration). Hold the relay in position to mark the two mounting hole locations. Drill a 9/64-inch hole at each location and mount the relay flush on the crossmember with the two screws provided. Then disconnect the radiator fan connector.

Be careful on two-fan setups. Make sure you're performing this rewiring procedure to the primary fan, not the second fan motor. Connect the Y end of the kit's wiring overlay harness between the fan and the vehicle harness, then hook the remaining connector to the new relay. Route the single red wire up the body's left side rail to the PDC. Tie off all the wiring, as necessary.

Put the splash shield back in place and drop the car to ground level to work at the PDC. Pull the relays for the starter, radiator fan, a/c clutch and fog lights (if so equipped). Then pry up and remove the orange terminal locking strip. Unlatch the entire PDC from the battery tray and flip it over on the fender. Pop the bottom cover to get to the connectors (see bottom illustration).

Grab the red wire you routed and insert its terminal into cavity No. 39 under the PDC. This is the center position of the radiator fan relay socket. Lay the red wire in with the rest of the bundle and put the PDC's bottom cover back. Then remount the PDC itself and replace everything you took out except the radiator fan relay. In that slot, insert the PWM module from the kit. Replace the PDC cover and hook up the battery.

Finally, start the engine and make sure the radiator fan turns on with the a/c or defroster, in recirculation mode.

GM & GM-Powered Trucks

Stumble/stall/hard start/DTCs. Air getting into the fuel system when the tank is below X level causes some 199697 6.5-liter (VINs F and S) diesel-powered GM trucks and those supplied with this GM diesel to stumble, stall, take a long time to start and store history DTCs P0251, P0370 and P1216. Of course, the MIL also lights intermittently. The affected models are Chevy and GMC C/K-, G- and P-bodies, the AM General Hummer and the Reumech A-Wagon.

It's unlikely you'll be able to duplicate the symptoms, but the codes are a good tip-off to the problem. The only thing you can do in the form of a fix is to fill the tank at least halfway, purge the air using the procedure in a service manual, erase the DTCs and inform the customer not to let the tank run down so far. It'll probably take you about a half-hour to burp the system.

Ford

MIL on/DTC 0411. A 1995 Lincoln Continental built before 8/6/96 may show up some day with the MIL lit and DTC 0411 stored in memory. The probable cause will be corroded terminals on the air injection management relay located on the driver's side of the engine bay directly above the transaxle. Pull connector C144 to check things out. If there's no corrosion, follow Ford's troubleshooting procedure. If you find a mess inside the connector, Ford says to replace any damaged terminals. If they're female and in the connector, that makes sense, but if the relay's terminals are eaten away, it makes more sense to just replace the relay. Pack the new connection with silicone dielectric grease.

Volkswagen

Front wheel bearing clunk. VW wants you to install new wheel bearings up front on a 1993-96 Golf III, GTI or Jetta III that makes a clunk when accelerating or braking for a sharp turn, especially after backing out of a parking space and when rolling forward with the wheel turned in the opposite direction. This is apparently caused by a lack of grease between the bearings and their housings. There are two wheel bearing kits to choose from. Those cars with the 2-liter four-cylinder take Part No. 357 498 625B; models with the 2.8-liter V6 take Part No. IHO 498 625.

Apply plenty of molybdenum grease to the outer diameter of the bearing and the inner diameter of the housing before pressing the new unit into place.

Nissan