Service Slants

Ford Truck

Slow power window travel. Owners of 2005-07 Ford F-150s and 2006-07 Lincoln Mark LTs may come into your shop with a complaint that the power windows take a very long time to close when they're in their fully open position. Ford attributes the slow travel to misalignment between the window glass and the glass run(s). Realigning the glass should eliminate further troubles.

Before removing the door panel, however, get the truck in your bay, lower the window fully, then time how long it takes to go from the fully open to fully closed position. If the interval is less than six seconds, that's acceptable by Ford's standards-return the vehicle to the customer. If the time required to close the window is more than six seconds, inspect the glass runs to make sure they're not wavy, which will place additional resistance on the glass. Correct the runs as required. Now remove die door panel. Using the illustration on the upper left, locate the front and rear glass clamps. Loosen both with a ¼-in.-drive T-30 Torx socket. Next, push the glass fully upward into the door header, shift it rearward until it stops against the window run seal, then lower it back into the glass clamps, as shown in the illustration on the lower right. To complete the fix, tighten both clamps and check for proper window operation. If there's still a problem, repeat the procedure. If the window travel time is acceptable, reinstall the door panel.

GM

Clunk or chatter from rear. Some 2004-07 Cadillac XLRs and 2005-07 Chevy Corvettes may give off a clunk or chatter from the rear while the car is making turns. After careful analysis, GM engineers have determined that a slip/stick condition in the clutch plates of the limited-slip rear differential is the root cause of the noise. Swapping out the conventional rear cliff fluid for a new synthetic lube (Part No. 89021677), then adding a special limited-slip additive (Part No. 1052358) should help quell the noise quite nicely.

Start the lube swap off by getting the two-seater up on a lift. Now remove the drain & fill plugs from the differential. Drain the fluid, then reinstall the drain plug and washer and tighten the plug to 25 ft.lbs.

Continue by shaking the can of the limited-slip additive for at least one minute to mix it thoroughly, then add 8 oz. of the stuff to the diff. Follow that up by filling the differential with the synthetic lube until it's even with the bottom of the fill plug. Now reinstall the fill plug and washer and torque the plug to the same spec as the drain plug. To complete the job, lower the vehicle, drive to a parking lot and make eight to ten figureeights to allow the additive to work itself thoroughly into the clutch plates.

Nissan

Variable valve timing DTCs stored, engine noise. All 19962007 Nissan models with variable valve timing (WT) systems may illuminate the MIL and store one or more of the following DTCs in computer memory: POOIl, P0014, P0021, P1110 and P1135. All of these codes signify problems with the WT control function, and may be accompanied by a rattle or similar noise from under the hood.

Before getting into more compli- cated diagnoses of the WT system, such as the solenoid valve or sprockets, cover the basics and check the engine oil level and pressure. Nissan says that a low oil level or abnormally low oil pressure can have negative effects on the proper function of the WT system. Engines that are especially susceptible to the lube issues are the VQ35, QR25, QG18, GA16, VQ40, VK56, MR18 and MR20.

Honda

Inoperative air conditioning. An owner of a 1998 Passport built through VIN 4S6C.58W.W4423374 may come into your shop complaining that the air conditioning system in the truck is blowing warm air. If he does, head immediately to the underhood fuse box and check the 10-amp No. 5 fuse. If it's blown, chances are good that the lead wire for the compressor clutch coil has shorted out on the power steering pump or compressor pulley, reports Honda. Replacing the clutch coil, pulley, drive plate and related hardware from a special repair kit (Part No. 8-97183-481-0) should get the a/c system up and running again. After the new parts are installed, use a mini wire tie to secure the clutch coil lead wire away from all rotating components to prevent a repeat performance.

Saturn

Inaccurate fuel gauge. The owner of a 2007 ION may arrive at your shop one day complaining that the fuel gauge reads Empty, even though there's plenty of fuel remaining in the tank. The problem may be accompanied by a Low Fuel message on the dash, with DTC P0461 stored in computer memory. According to Saturn, if no other codes are stored, you're probably just dealing with software snafus between the fuel gauge and the PCM. Reprogramming the module with revised software should take care of the situation immediately. You'll find the new service calibration on TIS2WEB.

Ford

ABS light on, codes set. The owner of a 2005 Ford Freestar or Mercury Monterey minivan built from 3/1/05 through 5/31/05 may come into your shop with an illuminated ABS light. If he does, immediately connect your scanner to the DLC and start poking around for codes. If DTCs C1165/C1235 or C1175/C1236 are logged, chances are one or both of the rear wheel speed sensors are contaminated with moisture or corrosion. The source of the water intrusion, says Ford, is a bum rear hub/bearing assembly. Installing an upgraded, bettersealed bearing assembly (Part No. 6F2Z-1100-A, right; 6F2Z-1 KX)-B, left) along with a new speed sensor should take care of the situation permanently.

GM/GM Truck

A/C blows warm air. Owners of some 2001-02 GM minivans and SUVs (complete list below) may complain that their vehicle's a/c system is blowing warm air. If you're thinking low refrigerant charge here, you'd be right. If you're thinking leak, you'd be right again. But this is no ordinary leak; the condenser likely has a large crack in the area of the lower right attachment bracket, says GM. Fortunately, the General has come up with a new-design, better quality condenser (Part No. 10339103, black; 10339104, unpainted) to address the leakage issue. When installing the new heat exchanger, install bolts at both upper retaining brackets, as well as the lower left bracket. The lower right bracket doesn't have a hole, so it goes unused.

Vehicles that are susceptible to the refrigerant leak and can benefit from the upgraded condenser are 2001-02 Chevy Ventures, Olds Silhouettes and Pontiac Azteks & Montanas, as well as 2002 Buick Rendezvous.

Acura

Wind noise. All 1998 3.5RLs, as well as 1999 models built through VIN JH4KA9...XC008991, are susceptible to interior wind noise when driven at speeds above 50 mph. According to Acura, the air is most likely coming into the passenger cabin at the base of the windshield, and is the result of a large gap in the a/c recirculation housing. To make a definitive diagnosis, get the car to 50 mph, then press the RECIRC button on the climate control panel. Once you hear the rush of air, press the FRESH AIR button on the panel (or the RECIRC button again if the vehicle has a navigation system) to switch operating modes. If the wind noise is still there, this fix doesn't apply; continue the search. If the noise goes away, replace the recirculation housing with an updated design (Part No. 79303-SZ3-A01).

Mazda

Clutch noise, vibration. Some 2001-02 Miata sports cars built before 12/1/01 may produce a chattering noise or vibration when the clutch is released on cold takeoff. According to Mazda, the probable cause for either complaint is a compatibility problem between the pressure plate and flywheel surfaces. Installing a new-design pressure plate (Part No. BP11-16-410A-9U) and flywheel (Part No. BPR7-11-500A) should resolve the clutch issue immediately. The clutch disc itself remains the same (Part No. BP07-16-460C-9U).

Ford Truck

Brake warning lights on, humming noise. Owners of 2005-06 Ford Escape hybrid or 2006 Mercury Mariner hybrid SUVs may come into your shop one day complaining that the yellow ABS and red brake warning lights are illuminated on the dash. They may also comment that they hear a humming noise from the engine bay every time the brake pedal is depressed.

When one of these trucks does find its way in, immediately hook up your scanner and start checking for DTCs. If a C 1475 pops up in the ABS module, it means the Electronic Hydraulic Control Unit (EHCU) has taken a turn for the worse, which is why the warning lights are on and the code is set. The humming noise, by the way, is the result of the hydraulic pump running to help maintain power brake assist in the face of the bum control unit. Installing a revised EHCU (Part No. 7M6Z-2C286-A) should bring all braking functions back to normal.

Note: Mark all brake lines prior to removing the defective control unit to ensure that they're properly installed on the new EHCU. When bleeding the hydraulic system, install a battery charger to maintain adequate system voltage. After the hydraulic bleed, you'll have to perform an air bleed and an ACU check. The replacement EHCU conies with an embedded C 1525 DTC. You won't be able to clear it until air is completely bled from the system. If you get an OE or 01 error message during the service bleed, it means the brake reservoir was probably low on fluid. Fill the reservoir, then repeat the bleeding procedure. If an 06 error message pops up, make sure the pressure at the brake bleeder is set to 35 psi. If the pressure is correct, either the float is stuck or there's an internal leak in the bleeder. Finally, if DTC C 1524 sets after the system bleeds have been performed, the new EHCU will have to be calibrated to the pedal travel sensor. To do this, push the brake pedal to the floor and release it. The code should clear.

Volvo

A/C compressor operates continuously, or not at all. Volvo reports that the a/c compressor clutch on some 1998 C70, V70, S70 and 850 models may stay engaged continuously, or may not cycle on at all. The Swedish carmaker has traced the problem to an open or short in the linear pressure sensor. A new-design pressure sensor (Part No. 9171701-7) is now available to restore proper a/c function.

To help out with diagnosis, Volvo points out that the linear pressure sensor shares the same ground in the PCM with the altitude sensor, accelerometer sensor and tank pressure sensor. So when the linear sensor goes bye-bye, it may set DTCs for one or more of these sensors in PCM memory. One final point: Before installing the updated pressure sensor, disconnect the negative battery lead for a minimum of two minutes. That'll clear the PCM memory of past "disturbances" caused by the faulty sensor and get everything off to a fresh start.

Pontiac

SRS recall. GM wants you to be aware that some 2007 G6 models built from VIN breakpoints 74102732 through 74108835 have been recalled for problems with the passenger seat sensing system. In a nutshell, the sensing system is designed to deactivate the passenger-side air bag when a young child is in the seat. Unbeknownst to GM, there was a problem at the factory while the system s module was being calibrated. That problem can result in the air bag deploying during a frontal impact, seriously injuring or killing a child.

GM will replace the entire passenger seat sensing system (including the module) as part of the recall. In the meantime, if a customer with a G6 happens to come in and you notice a young child in the front seat, take a minute to look at the air bag status light. It should indicate that the air bag is deactivated. If it isn't, have the child moved to the back seat. Your alertness just may save the kid's life!

GM/GM Truck

No-crank, no-start. Owners of all 2001-07 GM cars and light trucks may complain of a no-crank, no-start condition. According to GM, theres a good chance the problem will be intermittent in nature, and is most likely the result of stripped or damaged threads at the side-post battery terminals and/or bolts. Retapping both battery terminals with a 3/8-16 bottom tap and replacing both cable terminal bolts with new parts is the easy, permanent fix.

Toyota

Passenger compartment leaks. Owners of 2004-07 Solaras, 2005-07 Avalons and 2007 Camrys may come into your shop complaining of a water leak at the headliner or footwell area. One possible cause for the condition, says Toyota, is one or more of the moon roof drain hoses working their way loose from the roof drain pan nipples. Securing the hoses to the nipples with newly developed retaining clamps (Part No. 90467-14001, four required) should put a quick end to the leak.

To do the job, start by peeling back the headliner. Now install one clamp onto each of the four drain hoses and push the hoses onto the nipples. Using a pair of pliers, position the ears of the clamps so they're facing the outside of the vehicle and are slightly above the lower surface of the sliding roof housing. Next, grab a hose and spray the outside of the moon roof to check for leaks. If everything is sealed up inside, reinstall the headliner, then road-test the vehicle to make sure you've got no wind noise issues from the moon roof.

Jaguar

Rattling or knocking noise. Owners of some 1998 XJR models built from VIN breakpoints 812256 through 853935 may come into your shop with a complaint of a loud rattle or knock from the engine compartment that manifests itself under heavy engine loads. According to Jaguar, a likely cause of the noise is fuel pulsation that tends to be amplified by the rigidity of the fuel return line between the rail and the return pipe. Installing a new-design return line (Part No. NNC 6054FB) should muffle the noise to your customer's satisfaction.

Acura

Pedal pulsation and/or vibration. Some 1999-2003 3.2TL models, as well as 2001-03 CL vehicles, may produce a pedal pulsation and/or steering wheel vibration when the brakes are applied at road speed. Not surprisingly, Acura attributes the condition to excess thickness variation in the front, and possibly rear, rotors.

Start the repair by measuring the front rotors with a micrometer to make sure there's enough meat left for a cut. Now attach an on-car brake lathe and machine both rotors, making sure you apply a nondirectional finish to the surface. Install new front pads, then take the car on the road and get it up to speed. If the pulsation and/or vibration is still there, repeat the drill at the rear of the car.

Copyright Hearst Business Publishing Oct 2007
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