Service slants

Marcy, Thomas

Toyota

MIL on, false DTC stored. Some 1999 Avalon, Camry and Solara models (full list below) may experience MIL illumination accompanied by a false DTC P0446 in computer memory. According to Toyota, a new purge system vacuum control valve and hose assembly has been developed to correct the condition.

To begin the fix, first verify that the purge system is operating properly. If it is but the false code is stored, raise the vehicle on a lift to gain access to the purge canister. Next, remove the two vacuum lines at the canister, as shown in the illustration, save the metal clamps from the larger hoses for reuse, then install the new valve and hose assembly (Part No. 25852-- 20010).

To complete the fix, lower the vehicle, clear the code and make sure the gas cap is tight. The affected vehicles are:

Note that in these VINs, # may be either a 2 or an 8 and * may be any number from 0 to 9, or an X.

FOrd

Rough idle, exhaust noise. Some 1997-99 Crown Victorian, Mercury Grand Marquis and Lincoln Town Cars with the 4.6-liter V8 may experience a rough idle accompanied by exhaust ringing. Ford says this occurs on some single-exhaust vehicles due to the exhaust system resonance pressures that develop at idle. The fix is to install a mass damper on the righthand exhaust '"Y" pipe. Here's how:

After getting the vehicle up in the air, remove the two bolts and flag nuts that secure the right catalytic converter to the "Y" pipe and discard them. Next, remove the gasket between the converter and the "Y" pipe flanges. Clean the flanges thoroughly to make sure they're free of any leftover gasket material, then install a new gasket (Part No. E9AZ-5E241A) between the flanges. Next, install the mass damper (Part No. F2VY5F240-A), with the mass located toward the right side of the vehicle. Make sure the damper bracket attaches to the "Y" pipe using new bolts and nuts.

Tighten the bolts to 26 to 33 ft-lb. Now lower the vehicle a tad to gain access to the ignition key. Start the engine and verify that you've got a smoother idle and that no exhaust leaks exist. Finally, lower the car and take it out on the road to confirm the fix.

Chrysler

Porous transaxle case. Some owners of 1999 Avenger and Sebring, Cirrus, Stratus and Breeze, Sebring Convertible, and Town & Country/Caravan/Voyager models may experience transmission fluid leakage caused by case porosity in the cooler boss area. The leak can be misdiagnosed as leaks from the pan or the input speed sensor. The transaxles that exhibit this condition have a web of metal attaching the cooler bosses and the input speed sensor boss. This web forms a circular pocket in the area, and may be the source of the leak.

To check things out, start the engine and bring the tranny fluid to normal operating temperature. Clean the transaxle pan and the area around the input speed sensor, particularly the boss between the cooler lines in the area above the input speed sensor. With a helper in the vehicle, set the parking brake and apply the service brakes, then place the transaxle selector in Reverse. Raise engine speed to approximately 1100 rpm for at least three minutes, then inspect the cooler line boss area just above the input speed sensor. If a leak is evident from the pocket formed by the web of metal, Chrysler suggests that you try peening over the porous area with a punch. To do it, remove components as needed for a clear shot at the case. Using a suitable air hammer and blunt punch, insert the punch into the pocket fanned by the web of metal. Now operate the air hammer in 15- to 20-second bursts while moving the punch in a circular motion within the pocket. Continue massaging the metal at the center of the pocket and work outward in a circular motion until you think you've got the case sealed up.

Reassemble the components, check the transmission fluid level, then start the engine and check for leaks. If the leak hasn't stopped, a reman transaxle or new case is in order.

Saab

SRS lamp lit, false DTCs. Some 1999 9-3 models up to and including VIN X2027727 may experience an illuminated SRS light, with false trouble codes set. According to Saab, the trouble can likely be traced to insufficient crimping of the cable lugs in the SRS electrical harness, located between the control unit and the seat connector. As a result, DTC B2863 or B2868 can be generated.

If you want to tackle the job, order

To begin the repair, remove the seats and center console. Next, remove all scuff plates and the rear seat air vents on the left and right sides. Lift up the floor carpet and support it with a wooden block or something similar.

Now, open the covers of the cable conduit. Cut the cable tie at the control unit and unplug the connector from the controller. Next, cut off the cable tie from the cable outlet and unplug the connector there. Now, press away the locking tabs with a small screwdriver and extract the cable terminals from positions 10, 11, 13 and 14. Note that the tab may need to be pressed away a second time when the cable terminal is halfway out of the connector.

Clip off the cable terminals, then fold the cable back on the wiring harness and secure it with duct tape. Now, extract terminals from positions 7 and 9 in the 29-pin connector to the lefthand seat. Clip off the cable terminals, fold the ends back on the wiring harness and secure with duct tape once again.

Insert the orange cables to positions 7 and 9 in the 29-pin connector to the left-hand seat, then tape the new wiring harness to the old one toward the cable conduit. Lay the harness in the conduit and beneath the air duct. Be sure not to damage the cable terminals!

Make sure the cable is clear of any sharp edges, then close the conduit cover. Now, insert the cables in the control unit connector. The orange cables go into positions 10 and 11, the white cables into positions 13 and 14.

After plugging in the connector, fit a cable tie around the cable outlet. Now extract the cable terminals from positions 7 and 9 in the 29-pin connector to the right-hand seat.

Once again, clip off the cable terminals, fold the cable ends back on the wiring harness and secure them with duct tape. Insert the white cables in positions 7 and 9 in the 29-pin connector to the right-hand seat. Cut loose the cable ties (all three pieces) and tape together the new cable harness with the old one toward the cable conduit. Start with the 29-pin connector. Lay the harness in the cable conduit, fit new ties and close the conduit cover.

Now install a Tech 2 scanner or equivalent and connect the reference resistor to the driver's seat connector. Turn the ignition switch on and clear all DTCs in the SRS system. Turn the switch off, then back on, and look for DTCs. An open circuit should be indicated for the passenger seat.

Now turn off the ignition, transfer the reference resistor to the passenger seat and repeat the drill. If codes are generated other than those for an open circuit to the seat, check to see that the harness is connected properly.

Next, remove the resistor and reposition the carpet. Reinstall the scuff plates, air vents, center console and seats. Clear all DTCs and make sure the resistance in the SRS circuit for each seat is 2.5 .3 ohm. To complete the fix, disconnect your scanner, start the engine and make sure the SRS lamp goes out.

Volkswagen

Bogus wiper malfunction. What seems to be a wiper malfunction in 1999 GTI, Jetta GLX and Passat GLX models may actually be normal operation. Here's the deal: These vehicles are equipped with a rain sensor that causes the wipers to cease operation after one sweep if no rain is sensed on the windshield. The sensor then automatically shortens or lengthens the pause between sweeps according to the amount of moisture on the windshield. The wiper switch itself adjusts the sensitivity of the sensor.

If the ignition is switched off, however, the rain sensor must be reactivated. This is done by switching the wiper off, then back to the intermittent position. Explaining the operation of this system to customers could help prevent trouble down the road.

GM

Noisy rear brakes. Some 1998-2000 Chevrolet Camaros and Pontiac Firebirds built prior to VIN Y2111896 may give off a chirping sound when braking in Reverse. GM says the friction material is the most likely cause. Replacing the existing rear brake pads with a revised set (Part No. 18038575) should quell the noise for good.

Nissan

Hard cold-starting. Some 1996-99 Pathfinders built before 8/1/98 may be difficult to start at altitudes above 5000 feet and/or at low temperatures. Confined to vehicles with VIN JN8AR05Y*XW306090 or earlier, the problem usually occurs after a cold soak over four hours in duration.

Nissan says the problem can be traced to an insufficient volume of air flowing through the AAC valve while the engine cranks. A new AAC valve and attending ECM have been made available to fix the problem. Note, however, that the battery condition, oil viscosity, engine compression, fuel pressure, base idle speed and ignition timing should be checked before replacing the parts mentioned. The ECM replacements for manual and automatic transmissions are:

For the AAC valve assembly, replace the old unit with Part No. 237811W600. After you clear any DTCs set in computer memory, take the vehicle out for a road test.

Jeep

Tailgate rattle. Some 1997-99 Wranglers may exhibit a rattling noise from the rear tailgate when the vehicle is driven over rough roads. The cure involves installing a revised tailgate latch, striker and cover.

To begin the fix, open the tailgate and remove the original latch cover and latch. Next, install the new latch and cover (Part Nos. 55074947AC and 55176533AC, respectively). After installation, tighten the latch screws to 98 in.-- lb and the cover screws to 50 in.-lb.

Now, mark the original striker position with a scriber, then remove the striker and trash it and its shims. Install the new striker (Part No. 55177243AB) and two new shims (Part No. 55033620) within your scribed marks.

Make sure the striker slot faces the front of the vehicle. Hold the flat sides of the striker flange to maintain alignment as you snug the bolts. Next, check to ensure that the striker has sufficient clearance to the jaws on the latch. Misalignment will cause binding. Add or remove shims from beneath the striker to obtain the needed clearance. Once the striker is properly positioned, tighten its bolts to 50 ft-lb. Finally, open and close the tailgate to confirm proper installation.

Ford

Coolant mixing precaution. A recent warning comes from Ford regarding the compatibility of its newest engine coolant with those already in service. A new long-life engine coolant, Motorcraft Premium Gold (yellow-colored), has been introduced in 2002 Excursion and Super Duty F Series vehicles. The initial-fill life for this new coolant is 100,000 miles/5 years. The replacement interval is 50,000 miles/3 years, due to variations in water quality.

Ford is currently testing to determine the backwards compatibility of Premium Gold with its conventional (green-colored) Motorcraft Premium. Until the final results are in, Ford advises that you not mix the two. Also, do not mix either Premium Gold or Premium (green) with Motorcraft Specialty Orange Engine Coolant, which is used in 1999-2002 Mercury Cougar and Ford Electric Vehicle Rangers.

GM Truck

New headlamp capsule. Technicians working on 1997-2000 Chevrolet Ventures, Oldsmobile Silhouettes and Pontiac Trans Sports should be aware that a new headlamp capsule is available. The capsules can now be purchased separately from the mounting frame and aiming assembly. Part numbers include:

The capsules come complete with a new bulb. If it becomes necessary to replace a capsule, first remove the one wing nut that secures the cornering lamp to the vehicle. Next, remove the cornering lamp and disconnect the two electrical connectors. Remove the two wing nuts that hold the unit to the vehicle.

Next, remove the headlamp and disconnect the electrical connector. Remove the two 10mm hex-head screws and the single 10mm nut that attaches the black frame to the headlamp.

Now remove the two 5.Smm hexhead screws attaching the headlamp to the black frame and carefully separate the headlamp from the frame. Then remove the two 7mm hex-head screws that attach the black horizontal aiming device to the headlamp.

To install the new unit, transfer the horizontal aiming device and two screws to the new headlamp. Tighten the screws to 18 in.-lb. Next, remove the two 7mm hex-head screws that attach the black pivot to the old headlamp. Transfer the black pivot and two screws to the new headlamp and tighten these screws to 18 in.-lb.

Now install the black frame to the new headlamp capsule. Install the two 5.5mm hex-head screws, tightening them to 18 in.-lb. Then install the two 10mm hex-head screws and tighten them to 45 in.-lb. Now install the single 10mm hex-head nut and tighten it to 55 in.-lb.

Connect the electrical connector to the new headlamp bulb, put on the two wing nuts and hand-tighten each. Connect the two electrical connectors to the cornering lamp and install the lamp in the vehicle. Hand-tighten the wing nut. Finally, inspect the lamp for proper operation and adjust the aiming as required.

Mitsubishi

Engine block beater installation. Owners of Mitsubishi vehicles may want you to install an engine block heater, which is used to maintain coolant fluidity inside the engine during cold weather. It consists of a heating element, an electrical connector and an electrical cord that can be connected to standard 110-volt AC house current. The block heater is the same diameter and shape as an engine's core plug, and it permanently replaces a designated plug on the engine.

Before installing the heater, make sure the coolant has cooled and pressure has been safely released. Next, drain the coolant. Find the appropriate core plug location for the engine as outlined in the instructions that come with the heater, then punch or drill a hole in the center of it and pry or pop the plug from the core hole. Note: Do not attempt to install the block heater in a core plug location other than that specified.

Lubricate the heater's O-ring with fresh coolant, insert the heater into the core hole with the element pointed in the proper direction, then tighten its retaining screw to the exact torque specified in the installation instructions. To complete the installation, refill the cooling system with clean, properly mixed coolant, start the engine and check for leaks. Caution: Do not operate the heater element while it's not immersed in coolant or it will quickly bum out, and may burn you. Also, Mitsubishi does not recommend using cooling system additives designed to prevent system leaks with the new heater.

Acura

Extension shaft sealing bolt recall. Acura advises us concerning a safety recall on its 1996-99 3.5RL and 199698 3.5TL vehicles. The vehicles affected include all 1996-98 models, and 1999 models through VIN JH4KA9 ...XC012694. In these, the extension shaft sealing bolt on the transmission housing could loosen and come out. If this happens, the shaft can back out and disconnect from the differential. If this malady occurs while the customer is driving, the vehicle loses power to the drive wheels. Or, if the vehicle is stopped with the transmission in Park (with the parking brake not engaged), the vehicle could move unexpectedly. Acura says that owners of the affected vehicles should receive mail notification of this recall.

To determine if the recall has been performed, look at the engine compartment VIN. If the fifth character from the left has a center punch mark above it, the service has been completed. If it hasn't, send your customer to the dealer for the free fix.

Chrysler

Intermittent cruise control loss. Owners of certain 1989-99 Chrysler vehicles having a 41TE/AE transaxle built before 8/8/98 (MDH 080831) or 42LE transaxle built through the 1997 model year may experience loss of the cruise control function.

According to Chrysler, the anomaly may occur after either the transaxle input speed sensor or output speed sensor has been replaced. If either is the case, check the sensor connectors for terminal spreading.

Note that the input or output speed sensor design changed effective with the 1998 model year for LH models, and 8/8/98 for 41TE/AE-equipped vehicles. In the change, the terminals are slightly different between the old and new sensors. When you install a new sensor on an early sensor-equipped vehicle, the connector terminals may spread and cause an intermittent cruise control condition. Therefore, anytime you install a later model sensor on an early-model vehicle, the connector must also be replaced. For the repairs, use the Input Speed Sensor Wiring Repair Package (Part No. 05014409AA) and Output Speed Sensor Wiring Repair Package (Part No. 05014471AA).

Mazda

Binding, noisy or inoperative sunroof. Some sunroof operating mechanisms of 1998-99 626s have problems that may be traced to broken or missing sunroof glass panel bumper clips becoming lodged in the track. This could result in broken front and rear guides. Also, the rear guide may be improperly secured to the front guide. Improper sunroof drive cable and motor timing settings from the factory can also be a cause.

To fix the problem, first obtain new bumper clips (Part No. GD7B 69 828). Remove the broken clips and loose pieces. Install the new clips and recheck for proper operation of the sunroof glass. If timing adjustments are needed, follow the procedures from a good shop manual.

Saturn

MIL light on, DTC P0133 stored. Some 1999 Saturn S-Series vehicles may have an illuminated MIL with DTC P0133 (02 sensor slow response) stored in computer memory. Apparently, the response times (lean to rich/rich to lean) of the oxygen sensor may exceed the values set within the current PCM calibration. The fix is to install a revised 02 sensor (Part No. 21022987), followed by a reprogramming of the EEPROM.

Copyright Hearst Business Publishing Dec 2001
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