Service Slants

Motor, Jun 2004 by Savasta, Bob

Lincoln

Cabin noise. Some 2003 Town Cars built before 6/2/03 may produce an intermittent fluttering or hooting sound in the passenger compartment. The noise is most pronounced when the vehicle is traveling at 65 to 75 mph, with the a/c system in the Recirc mode and a window or the moonroof slightly open.

According to Lincoln, the most likely source of the noise is the recirc/fresh air door vibrating against the air inlet opening in the heater core housing. The vibration is caused by the pressure difference that sets up between the outside air and the air in the cabin. Installing three self-adhesive foam strips (Part No. 3W1Z-19B739-BA) onto the inlet opening and cutting away the existing seal lip on the recirc/fresh air door should eliminate the noise permanently. Here's how to go about the fix:

Begin by turning the ignition on and selecting the Floor and Fresh Air modes on the climate control panel. Now take a peek under the dash, making sure the recirc/fresh air door has dropped into the Fresh Air position. Once it has, turn the ignition switch off and disconnect the battery ground cable. Next, remove the blower motor to gain access to the underside of the fresh air inlet opening in the heater core housing. Using the illustration shown here as a guide, clean around the opening, then apply the three foam strips in the areas indicated. Make sure you position the strips flush with the inside edge of the opening, and don't overlap it.

Now its on to the recirc/fresh air door. Reach into the opening left by the blower motor to gain access to the door. Using a razor blade or X-Acto knife, cut away the seal lip around the entire circumference of the door, making sure the door is flush with the inlet opening after the surgery. To complete the repair, install the blower motor, reconnect the battery cable, then take to the open road to ensure that the noise has been eliminated.

Note: Some Town Cars may already have the foam strips installed. If the noise persists on these vehicles, chances are the seal lip on the recirc/fresh air door was never removed. Cutting away the lip as outlined above should remedy the problem.

Chrysler

Engine damage from wrong oil filter use. Chrysler says it's very easy to cause engine damage when performing routine oil and filter changes on 2001-05 Sebring and Stratus models with the 2.4L inline Four. At the heart of the issue is the fact that the carmaker uses two different 2.4s on the Sebring and Stratus-a homebred DOHC setup and a SOHC design manufactured by Mitsubishi. Each engine takes a unique oil filter design, and the filters aren't interchangeable.

According to Chrysler, the bigger problem surfaces when you try to use the smaller Mitsubishi-style filter on the Chrysler-designed twin-cam engine. The gasket doesn't mate up properly to the homebred 2.4's filter housing, which causes massive oil leakage when the engine is started. It doesn't take lung for that leak to dry out the crankcase and wipe out the bottom end of the engine. Bottom line: Know which engine you're dealing with before ordering up an oil filter for a Sebring or Stratus.

For reference, the Chrysler-de- signed engine takes filter Part No. 04105409. Use Part No. MD360935 for the SOHC Mitsubishi fourbanger. If you use aftermarket filters, make sure your jobber does a good job of cross-referencing the filters to the correct applications.

GM Truck

Replacement fuel pressure regulator. GM has some good news for diesel specialists: The fuel pressure regulator on 2001-03 6.6L Duramax engines is now a serviceable item. Previous iterations of the engine required complete injection pump replacement if the pressure regulator went belly-up. No more. The replacement regulator can be had under Part No. 97728979.

Before ordering up the replacement fuel pressure regulator, however, GM recommends that you take out the old one and look carefully at its inner up. If its black or pitted, the regulator, as well as the injection pump, has been subjected to the corrosive effects of water. Replace the entire injection pump. If the tip of the old regulator is tan and smooth, corrosion isn't a factor and you're good to go with the replacement part.

Saab

Wet carpeting. Owners of some 9-3 models may complain of wet carpeting in either the driver- or passenger-side footwell. Saab says the water is most likely emanating from the lower a/c vents, and is due to the a/c system's inability to completely dehumidify the damp air that's prevalent in high-temperature, high-humidity conditions. Positioning a new air deflector (Part No. 53 32 358) on the lower portion of the blower housing should stem the tide of excess moisture and keep your customers feet dry.

Begin the installation of the new deflector by removing the blower motor. Now position the deflector on the blower housing so it rests on the radius of the front edge. Using the deflector as a template, drill two .060-in. holes in the housing. Limit the depth of the holes to .200 in., or you could go through the evaporator. Use a drill stop, if necessary. Now attach the deflector to the blower housing using the two screws provided. To complete the fix, reinstall the blower motor and check for proper fan operation.