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Tech Tips

212 Carroll St. • Ft. Worth, TX 76107
Monday - Friday 8 am to 6 pm CDT
Saturday 9 am to 2 pm CDT
(817) 335-9331 • FAX: (817) 335-5158


Please Choose Your Car:

Acura     Audi     BMW     Chrysler Imports     Daihatsu

Ford Imports     Geo     Honda     Hyundai     Infinity    

Isuzu     Jaguar     Kia     Lexus     Mazda     Mercedes

Mitsubishi     Porsche     Toyota     Volkswagen     Volvo


Acura

Q. Why does the LOW OIL PRESSURE light flicker when I'm waiting at
a red light after exiting the freeway? My mechanic says the engine is
fine but can't make the light go out. Can you help?


A. The flickering oil light usually indicates low engine oil pressure.
First, check the wiring connection for the oil pressure sensor for any
loose, corroded or frayed wires. Use a shop mechanical gauge to verify
oil pressure when the engine is at operating temp. Replace the sensor if
it is suspected to be defective. There are several other possible causes:
Worn bearings, crankshaft and internal engine parts (excessive oil clearance)
is the most common cause. The fix usually requires rebuilding the engine.
but first be sure the correct amount of oil is in the engine. Low oil levels are
the second mot common cause - but too much oil can cause the oil to 'foam',
resulting in low pressure. Another problem is using too light of viscosity oil
for the operating temperatures/conditions. Using 5w30 or 10w40 on a hot
summer day can spell disaster in some engines. Try using a heavier single
grade oil (40W instead of 10w40). Another common problem is extended oil
change intervals. Changing your oil and filter every 3000 miles can solve/prevent
a lot
of problems. The next most common problem is overheating. The engine's
cooling system is not working as well as it should (low or old coolant, loose or
worn out belts, sticky thermostat, corroded or blocked radiator cores, corroded
fan switch, etc). The excess heat thins out the oil. Also if the ignition timing is
wrong or if the fuel system isn't in 100% working condition the oil can be diluted
with fuel, thinning it out. On rare occasions the oil pump's relief valve will hang
after a fast trip on the freeway. The pumps valve may require a spring spacer or
stiffer spring. And sometimes a new oil pump is required. One last cause can be
a dented oil pan/blocked sump pickup tube.

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Audi

Late model AUDI 100 BRAKE NOISE: Rust build up on the rear ABS reluctor fins
will strike the ABS sensor, causing a squeal. Remove the caliper and carefully
scrape the rust off the fins
.

AUDI 90 and some 5000 models with 5 cyl engines. When replacing timing belt
or water pump, removing the front bumper cover will allow easier access to the
pulleys, etc. The minimal work needed to remove the bumper cover will save
more time in the long run.

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BMW

Engine oil / coolant leaks on 740i 740iL 530i 530iT 540i 840Ci all with M60 and
M62 engines. These V8 engines will develop leaks in the "valley" between the
cylinder heads. However they are often misdiagnosed as a leaking rear crank
seal or rear coolant channel leak due to the leak's misleading flow path. The
leak is usually caused by a bad valley cover gasket or cylinder head gasket.
The fluid will flow toward the rear of the engine and out the weep holes in
the rear of the block. It then flows down the rear of the block and into the bell
housing area, where it is often mistaken as coming from the crank seal or rear
coolant channel. If a leak appears here, remove the center valley cover and
visually inspect the valley area for leaks. This will help avoid very costly and
unnecessary transmission R&R to replace a perfectly good crank seal or channel
gasket, which may not be leaking.

TRANNY WON'T SHIFT TO HIGH:  BMW 735i  has a mechanical push button switch
(much like the old floor mounted headlight dimmer switch) located under the
accelerator pedal. This switch will get 'crudded up' and seize in the ON position,
preventing the transmission to shift into high. Use WD40 to free-up the switch.

Q. How can I stop the A/C belt on my BMW (M50 engine) from making a droning
or rattling noise?
 
A. The noise is usually caused by too much axial play in the pitman arm and
base plate of the A/C belt tensioner. The following repair procedure should
solve the problem:

1. Remove the A/C tensioner from the A/C compressor
    bracket.

2. Remove the bolt that secures the tensioner to the base plate.

3. Clamp the base plate in a vice (use "soft jaws" to prevent damage to the
    aluminum casting). Use a brass hammer (or a piece of hardwood between
    hammer and part) to drive the pin though the base plate 5 mm (0.2"). Grind
    off about 0.5mm (0.020") from the back of the pin. Then drive the pin back in
    until flush with the back of the base plate.

4. Using the mount bolt that goes through the pin, a wide washer and several
    flat washers, temporarily bolt the pitman arm to the base. There should be no
    noticeable axial play and the pitman arm should turn freely. If the pitman arm
    binds, remove it and gently tap the outer bearing inward just enough to allow
    the arm to move free. Remount the arm washers, etc and check the axial play
    again and verify that the arm can turn freely.

 5. Reinstall the tensioner assembly and A/C belt.

 BMW 750iL 1990 Noisy rear brakes may be caused by the pads being put on wrong.
 The pads have  a "left and right" design. They have a bevel on one edge that must
 face downward, toward the normal rotation of the rotor. To fix simply put the pads
 in correctly.

 BMW 525i 1991 with M50 engine.  A rough idle or miss under heavy load may be
 due to a beak on the secondary side of the ignition coils. Most of the failures
 occur on models equipped with the "May und Christ" brand "ZUNDSPULE" coils.
 Remove the cylinder head cover and expose the coils. Identify the coil brand
 (either BOSCH or ZUNDSPULE). If Bosch, this tip does not apply. Next look for the
 coils production date (i.e. 91M06 is year=91, month=06,June). Coils made prior to
 91M01 (January 1991) should be replaced with p/n 178-8154. Automotive Machine
 stocks BMW parts and has the know-how to help you make proper repairs.

 For free BMW repair info e-mail us: ams@automotivemachine.com

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Chrysler Imports

 Please See Mitsubishi

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Daihatsu

Q. The Maintenance Req'd Lamp on my DAIHATSU came on.
My mechanic replaced a bad sensor and the car runs fine. But he said that since
I have over 75000 miles on the car, rather than reset the light, he will just remove
the bulb. Is this proper?


A. 
Daihatsu says to pull the bulb  after 80,000 miles.

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Ford Imports

Under Construction, Check Back Soon

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Geo

Under Construction, Check Back Soon

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Honda

Honda - here's a quick way to diagnose the cause of an overheated engine:
Check the coolant level. Drive the car until the gauges show its too hot, then
check the radiator's top tank. A normal temp is 180F - 210F. If its not any hotter
than 210F, the engine isn't overheating - instead the gauges, sender or wiring
is at fault. If its hotter than 210F, compare the upper radiator hose temp to the
lower hose temp. With the thermostat open and a good radiator, the lower
hose should only be 20 to 30 degrees cooler.On 84-90 Civics and 90 Accords,
where the thermostat is on the suction side of the flow, if the thermostat is
stuck closed, the lower hose will be cool to the touch or very much cooler
than the top hose. On earlier models with the t'stat on the pressure side, if the
t'stat is stuck closed, the top hose won't be hot when the gauge reads hot. If
both hoses are about the same temp then the radiator isn't transferring heat
or the fans are not operating properly. If the fans work OK, then the radiator
needs replacing or there are internal engine air/fuel combustion and ignition
tuning problems that are causing excess engine heat.

HARD CLUTCH PEDAL: 1984-1987 HONDA Civic, CRX. These models had an
additional brace welded to the accelerator pedal bracket. This brace has a
guide tube on it for the clutch cable. Sometimes the brace will break off,
letting the unguided clutch cable to bind and result in a very hard to push
clutch pedal. The bracket and brace are up under the dash and hard the see.
Some of the braces have been unwittingly left off when replacing accelerator
cables. This problem is many times incorrectly diagnosed as a bad clutch.

Honda Accord and Prelude 1993-94.  Premature rear brake wear may be caused
by a binding parking brake handle. to fix remove the console, brake rod and
handle. Laying the handle assembly on its side, place an 8mm socket under the
rivet. Using a 3/16" punch on the topside of the rivet, tap it with a hammer a few
times. this will free up the handle / rod. After refitting in the car, re-adjust the
equalizer rod and check the parking brake's operation.

HONDA Accord 94-95.  A buzzing noise at 1800 RPM or when accelerating may be
caused by defective gaskets each end of the mid exhaust pipe, in front of the
catalytic converter. The fix requires replacing the gaskets with new ones - but first
coat the gaskets with anti-seize. Use new nuts and bolts with the original springs.
Torque to 16 ft-lbs.

1990 Honda Civic. Horn may randomly sound when driving. Seems to occur more
often during cold weather. The horn's slip ring retaining screws under the steering
wheel come into contact with metal burrs on the steering wheel frame. This completes the horn's ground circuit. Remove the steering wheel, remove the lower cover (4 screws) and file off any burrs. Reassemble.

Q. Why does the LOW OIL PRESSURE light flicker when I'm waiting at a red light
after exiting the freeway? My mechanic says the engine is fine but can't make the
light go out. Can you help?


A. The flickering oil light usually indicates low engine oil pressure. First, check
the wiring connection for the oil pressure sensor for any loose, corroded or frayed
wires. Use a shop mechanical gauge to verify oil pressure when the engine is at
operating temp. Replace the sensor if it is suspected to be defective. There are
several other possible causes: Worn bearings, crankshaft and internal engine
parts (excessive oil clearance) is the most common cause. The fix usually
requires rebuilding the engine. but first be sure the correct amount of oil is in
the engine. Low oil levels are the second mot common cause - but too much oil
can cause the oil to 'foam', resulting in low pressure. Another problem is using too
light of viscosity oil for the operating temperatures/conditions. Using 5w30 or 10w40
on a hot summer day can spell disaster in some engines. Try using a heavier single
grade oil (40W instead of 10w40). Another common problem is extended oil change
intervals. Changing your oil and filter every 3000 miles can solve/prevent a lot
of
problems. The next most common problem is overheating. The engine's cooling
system is not working as well as it should (low or old coolant, loose or worn out
belts, sticky thermostat, corroded or blocked radiator cores, corroded fan switch,       etc). The excess heat thins out the oil. Also if the ignition timing is wrong or if
the fuel system isn't in 100% working condition the oil can be diluted with fuel, thinning it out. On rare occasions the oil pump's relief valve will hang after a fast trip on the freeway. The pumps valve may require a spring spacer or stiffer spring. And sometimes a new oil pump is required. One last cause can be a dented oil pan/blocked sump pickup tube.

HONDA Accord and Civic 1992-93.  A low RPM (1100), warmed up engine, may make
a humming noise, often mistakenly diagnosed as a bad alternator bearing. The noise
is usually caused by the normal friction between the water pump shaft and seal. The
simple fix is to add 6 - 12 ounces of water pump lube to the coolant.  For more info
see an import specialist, like Automotive Machine & Supply, with over 27 years of
Honda know-how.

HONDA Accord 199-92. A surge or miss at 1800-2200 RPM may be caused by a
missing (burnt-off) oxygen sensor cover. Remove and inspect the oxygen sensor.
If the cover is missing, replace the sensor.

HONDA Accord and Civic '80-'84. When changing air filters be careful that you get
the correct filter. To reduce their inventory investment, many auto supply chain
stores have incorrectly combined '79 and earlier filters with the '80 and later filters
(they are the same size). The '80-'84 filters are made of a finer filtering media. If
thecheaper earlier filter is used your carburetor may plug up and your piston rings
will suffer premature wear. If the later filter is used on the early cars, the gas mileage
will be lower and emissions will be higher as the filter does not flow air as freely as
the carb was designed for. The tip here is to buy your parts from Import Specialists
who know Hondas.
Call AUTOMOTIVE MACHINE (1-800-210-8675) for any parts your
Honda may need.

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Hyundai

HYUNDAI TRIBURON and ELANTRA clutch pedal squeak or squawk is usually
caused by a lack of grease on the upper plastic support bushing for the clutch
release lever / shaft. Disconnect the clutch slave cylinder's pushrod from the lever.
Remove the nut and washer, then remove the lever. Pull the upper plastic support
bushing and grease liberally.  Refit the bushing, lever, nut and washers, and the
pushrod.

Cheap Insurance for HYUNDAI EXCEL ??? 
When replacing the clutch on 1986-94 Hyundai Excels look carefully at the throw-out
bearing fork and pivot shaft. They are usually held together in alignment with a small
pin. After many miles of use this pin likes to crack and bend. With the increase spring
pressure of a new clutch, a weak pin will either bend rapidly or shear off. This causes the clutch to "lose adjustment" or not work at all. So, while you're installing a new clutch, eyeball this pin or better yet, just replace the pin with a new one. At a cost of less than a $1.50, it's cheap insurance.

Hyundai Excel '89 - 9/91 and Scoupe '89-11/91.  Intermittent No-Cranks. The solenoid
only clicks when the key is in start position, yet other times car cranks ok. Solenoid
is not getting enough voltage to fully connect battery to starter motor. To repair
install relay p/n 111.937.503  Call our Hyundai sales team for details.

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Infinity

Please see Nissan
 

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Isuzu

Under Construction, Check Back Soon

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Jaguar

Under Construction, Check Back Soon

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Kia

SQUEALING ALTERNATOR BELT: 94-95 Kia Sephias require 32 ft-lbs of tension on
new belts and 27 ft-lbs on used belts... which is gonna take a pry bar and some
muscle if you don't have special tool # K94A-3200-E. Use a big pry bar to tighten the
belt, then torque the slider bolt to 18 ft-lbs and the alternator mount bolt to 35 ft-lbs.


Kia
- many models will experience valve lifter clatter upon start-up. The cause
is aerated oil trapped in the lifters. The air can usually be purged by doing the
following: Warm up the engine to normal operating temp. Rev the engine to
3000 rpm for 5 minutes to bleed the air from the lifters. This should solve the
problem, however if a lifter still makes noise at start up, replace it with a new
one.

Kia - Amanti, Sedona, Optima, Rio and Cinco models have "interference" engines - meaning that if the timing belt breaks, the valves will hit the pistons and bend....which is very costly to repair. So it is very important to check the condition of the timing belt during routine mantenance. It is recommended the timing belt be replaced at 60,000 miles.
 
 
Kia - V6 engines. many Techs get confused about the location of cylinder bank #1. Unlike most car makers, which designates the cylinder bank closest to the front of the vehicleas bank #1, Kia designates the rear-most bank as bank #1

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Lexus

Please see Toyota

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Mazda

MAZDA B2200 trucks 84-90 Sometimes have a valve train noise that lasts for at
least a minute after start up. While the noise doesn't seem to hurt anything,
Mazda has some replacement rocker arms with larger oil passages.
P/N F240-12-130B & 131B for cylinders #1 & #3. P/N F240-12-150B & 151B for
cylinders #2 & #4.

Mazda Millenias 1995.  If your battery goes dead even when alternator is working
properly, look in the trunk for the problem. It seems the factory incorrectly installed
the trunk light switch on many cars. The light stays on - draining the battery. the
clearance between the lights terminals is too narrow. Loosen (but do not remove)
the screw that secures the switch. Then use a screw driver in the latch to simulate
a closed lid. Adjust the switch by turning the body of the switch until the light goes
out. Retighten the screw.

MAZDA 323 And Protege 1990-93.  Rear brake squeal while applying the brakes
may be caused by a small amount of grease on the brake drums. Mazda originally
put the grease on the drum's dust seal to keep dirt out of the wheel bearings. The
factory put too much grease on these models and the excess was flung onto the
drum and brake shoes. To fix: Remove and clean drums, but do not remove
remaining grease from dust seals . Remove shoes and clean backing plates. Have
an omni-directional finished machined on the drums. Replace the shoes. Refit
drums and reassemble. For more info call our Mazda team at 1-800-210-8675.

MAZDA Miata or 323. Be sure to properly install the drain plug when changing
motor oil. These cars have a slight recess in the oil pan into which the drain plug's
sealing washer must fit. It is easily possible to tighten the plug with the washer
misaligned; resulting in an oil leak.

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Mercedes

1992-1995 Mercedes 300D, 300SD, E300, and  S350 models may exhibit some of
the following symptoms caused by a stretched timing chain: rough running, loss
of power, ticking noises from the engine, oil consumption, and/or hard starting.

1. Q. My MERCEDES 300E has a small amount of antifreeze/coolant weeping from
the vent hole of the water pump. Do I need a new water pump?


A. It is normal for a small drop or two of coolant to weep at the vent hole. Coolant
that is used to lubricate the water pump's seal is allowed to weep out the vent
hole. Usually it evaporates, leaving only a white crusty residue. But on cars that are
used for only short distances liquid drops will be present. The best thing to do is to
have your cooling system flushed and refilled annually. Be sure to use
antifreeze/coolant that is specifically designed for aluminum engines.

2. Q. The Maintenance Req'd Lamp on my Mercedes came on. My mechanic
replaced a bad sensor and the car runs fine. But he said that since I have over
75000 miles on the car, rather than reset the light, he will just remove the bulb.
Is this proper?

A. 
Mercedes says to yank the Oxy Sensor Service bulb after 60,000 miles.

Back to Index


Mitsubishi

Mitsubishi - 2001-03 V6 powered Galant and Eclipse and some 2002-03 four cylinder models may make a sharp ringing noise when lightly braking. The noise is often caused by a poorly designed caliper support. Mitsubishi now offers new supports (p/n MN102821) that are supposed to cure the high pitched noise.

Q. The Maintenance Req'd Lamp on my MITSUBISHI came on.
My mechanic replaced a bad sensor and the car runs fine. But he said that since I
have over 75000 miles on the car, rather than reset the light,  he will just remove
the bulb. Is this proper?

A.
Mitsubishi recommends removing the bulb on many high milage cars/trucks.
Mercedes says to yank the Oxy Sensor Service bulb after 60,000 miles and Daihatsu
says to pull theirs after 80,000 miles. And
Nissan says to disconnect the bulb at 90,000
miles for most 80-87 model cars and trucks.

Q.Why does my MITSUBISHI V6 make a slapping noise when it is first started? The
noise is worse on cold mornings.

A. The noise you hear is probably piston slap.
Mitsubishi has released some
improved pistons for the left or even numbered cylinders on many model V6's. The
new pistons are p/n MD152563. The new pistons also have an "L" on top. Use these
pistons in cylinders #2, 4, and 6 only. Install them on the conn rod with the "L" on
the same side of the rod as the "front" mark on the rod. Install the piston/rod into
the engine so that the "L" is facing the toward the crank pulley end of the engine.
For more information, contact Automotive Machine at 1-800-210-8675.

MITSUBISHI 1988 Starion. Mitsubishi made an error on the service information for
'88 Starions. If you install the plugs the book calls for, the car will probably run rough.
The correct plug is an
NGK BPR5ES-11 copper core or an NGK BPR5EVX-11
platinum.

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Porsche

Under Construction, Check Back Soon

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Toyota

KNOCKING NOISE Coming from under the valve cover on a 22R Toyota may be
caused by a rocker arm hitting the valve cover. Reusing the valve cover gasket and
then over tightening the four acorn nuts to keep the cover from leaking seems to be
the root cause. The fix: install a new gasket and retighten the four acorn nuts to
factory specs.

FRONT CRANKSHAFT OIL SEAL LEAKS: Toyota 20R and 22R  engines that
appear to have a front crank seal leak may need more than a new seal. Be sure to
inspect / replace the oil pump o-ring.   Also look for a groove worn on the pulley's
seal area.  If it is worn fit a repair sleeve over this area.  Call Automotive Machine
at 1-800-210-8675 for all the parts and info.

OIL BURNING, SMOKE BELCHING TOYOTA PREVIA VAN: Complaints of oil
consumption 90-93 may be caused by a faulty oil level sender. Seems the bad
sender automatically  pumps oil from the reservoir tank even though the engine
isn't low on oil. This over fills the engine, which burns off the excess oil. double
check the oil level with the dipstick and replace the low oil sensor.

CLUTCH CHATTER: Some Toyota pick-ups and 4-runners with 2.4L engines may suffer
from clutch chatter caused by excessive flywheel and / or clutch run-out.  Pull the
pressure plate and disc. Measure the flywheel run-out with a dial gauge. Maximum
is 0.004" If over spec, mark the high point on flywheel . Remove flywheel and check
crank flange run-out. mark its low point. Reassemble the flywheel on the crank with
the two marks aligned as closely as possible. Recheck the flywheel run-out. If still
not within spec have the flywheel resurfaced.  Before installing the disc be sure its
run-out doesn't exceed 0.031"  Torquing the pressure plate bolts, in a star pattern, to
14 ft-lbs. Maximum run-out for the pressure plate's diaphragm spring lip (where the
release bearing contacts it) is 0.020" For more details or info on parts or machining
the flywheel,   please call us at 1-800-210-8675.

Q. How can I test the rear shocks on my US built TOYOTA Corolla? My mechanic says
they're not the same as the shocks on a Japanese Corolla.

A. Your mechanic is right. Your US built Corolla uses Delco shocks that require a
different test procedure. The Japanese shocks can be tested by pushing the piston
rod in while feeling for smooth even resistance and no hard spots or noise. Then after the rod is fully compressed, the released rod should return at a constant rate. Your US Corolla's Delco shocks can be tested the same way, except instead of fully
compressing the rod, it is only pushed in until the notch on the piston rod stops even
with the top of the collar. Then when released the rod should return at a constant rate. If the shock piston rod is pushed in beyond the notch, the inner seal may be damaged and oil and gas may leak out.

TOYOTA Camry With 2.0L 2S-E engine. Low RPM stalling (usually while shifting)
may be caused by the distributor's pickup coil air gap being too wide.
The spec is .008" - .016".

Toyota 2VZFE, 3VZE, 5SFE engines. Connecting rod bolts tend to rotate in the rod
and can give false torque to yield movement.   Follow the initial torque steps in
manual. then use an awl to scribe two lines 90 degrees apart (A at 12 o'clock & B
at 3 o'clock) on the tip end of the rod bolt sticking thru the nut. Next scribe a third
line (C) on the edge of the nut in line with A. Now when turning the final
torque-to-yield 90 degrees, just turn the nut clockwise until line C aligns with line
B. this will ensure that the nut really turned 90 degrees on the bolt, even if the bolt
turned in the rod.

Q. Why does the LOW OIL PRESSURE light flicker when I'm waiting at a red light
after exiting the freeway? My mechanic says the engine is fine but can't make the
light go out. Can you help?


A. The flickering oil light usually indicates low engine oil pressure. First, check the
wiring connection for the oil pressure sensor for any loose, corroded or frayed wires.
Use a shop mechanical gauge to verify oil pressure when the engine is at operating
temp. Replace the sensor if it is suspected to be defective. There are several other
possible causes: Worn bearings, crankshaft and internal engine parts (excessive
oil clearance) is the most common cause. The fix usually requires rebuilding the
engine. but first be sure the correct amount of oil is in the engine. Low oil levels are
the second mot common cause - but too much oil can cause the oil to 'foam',
resulting in low pressure. Another problem is using too light of viscosity oil for
the operating temperatures/conditions. Using 5w30 or 10w40 on a hot summer day
can spell disaster in some engines. Try using a heavier single grade oil (40W instead
of 10w40). Another common problem is extended oil change intervals. Changing your
oil and filter every 3000 miles can solve/prevent a lot
of problems. The next most
common problem is overheating. The engine's cooling system is not working as well
as it should (low or old coolant, loose or worn out belts, sticky thermostat, corroded
or blocked radiator cores, corroded fan switch, etc). The excess heat thins out the oil.
Also if the ignition timing is wrong or if the fuel system isn't in 100% working condition the oil can be diluted with fuel, thinning it out. On rare occasions the oil pump's relief valve will hang after a fast trip on the freeway. The pumps valve may require a spring spacer or stiffer spring. And sometimes a new oil pump is required. One last cause can be a dented oil pan/blocked sump pickup tube.

TOYOTA Pickups. Low clutch pedal complaint may be caused by a broken pedal
bracket (under dash) instead of the usual worn clutch disc and pressure plate.

TOYOTA Most Models. If the alternator charge light is ON with the engine running,
try tapping on the alternator's case with a small hammer. If the light flickers or goes
OFF, it is most likely the brushes are worn out. Tapping on the case causes the
brush springs to extend, making the brush contact the slip ring. Instead of replacing
an expensive alternator, simply replace the brush set.

For further ways to save money repairing and maintaining your Toyota,
call
Automotive Machine at 1-800-210-8675.

TOYOTA  Most late models. If your turn signals don't work, first check the fuses and
bulbs. Still no signals? Here's a real money saver. The circuit for the turn signals go
thru the four-way emergency flasher switch on most models. If the four-ways don't
get much use, the turn signal contact in the four-way switch may corrode. Simply
turning the four-ways on and off several times may cure the turn signal problem.

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Volkswagen

Volkswagen - Golf Jetta. Starter motor fails to engage when engine is hot.
The problem can occur when voltage to the starter solenoid terminal 30 drops
below 10 volts. To fix the problem, first check the battery's condition. Next clean
and tighten the + battery cable and ground cable connections, as well as the
ground strap connection at the engine/transmission. Lastly, install a relay to route
full battery voltage to the solenoid. Automotive Machine has the relay and wiring instructions availabe. Call 1-800-210-8675.

 

VOLKSWAGEN water pumps are designed to "leak". They intentionally leak a
small amount of coolant to coat the seal during pump operation. This coolant then
exits thru a weep hole when the engine cools down. Minute gray-green traces of
coolant residue at the weep hole is normal - it doesn't mean the pump is bad.
However if this residue is building up or has spread beyond the weep hole the
pump is defective.  Also if any white powder is forming the pump should be
replaced.

Q. Why won't my VOLKSWAGEN FOX  (87-93) start?!  My mechanic has replaced the
battery, the starter and checked all the connections. He even replaced the ignition
switch!  What gives?

A. The
VW Fox has a nasty little habit of "out foxing" even the best mechanics. Have
your mechanic check the fuse box for a loose bridge wire that connects terminals 36
and 38. Be sure the bridge wire is securely seated and making good contact.

Q. Why does my VOLKSWAGEN ('91 & later Fox, '85 & later Golf, Vanagon, or Jetta)
Stall, cut-out, jerk, or lack power after driving at a constant highway speed for an
hour? Even after it stalls it will restart. Sometimes it will only do this once or twice
a month.My VW mechanic can't find anything wrong. What gives?

A. Some VW cars have a mass air flow sensor that vibrates the potentiometer arm
during extended driving at constant speeds. The resonance causes the mass air
flow sensor to send an intermittent signal to the ECU. The ECU will default to a no
load signal and reduce injector open time.
To remedy this problem install a damper/converter (p/n 025-906-302A) between
the wiring harness and the mass air flow sensor connector.

VOLKSWAGEN Jetta, Rabbit, Scirocco. A quick and easy way to fix worn alternator
mount holes: drill out the hole to 7/16", press an old bronze Rabbit valve guide into
the hole and remount the alternator. Even a new guide is an inexpensive repair
p/n 056-103-419A costs about $1.

Q. Why does the LOW OIL PRESSURE light flicker when I'm waiting at a red light
after exiting the freeway? My mechanic says the engine is fine but can't make the
light go out. Can you help?


A. The flickering oil light usually indicates low engine oil pressure. First, check the
wiring connection for the oil pressure sensor for any loose, corroded or frayed wires.
Use a shop mechanical gauge to verify oil pressure when the engine is at operating
temp. Replace the sensor if it is suspected to be defective. There are several other
possible causes: Worn bearings, crankshaft and internal engine parts (excessive
oil clearance) is the most common cause. The fix usually requires rebuilding the
engine. but first be sure the correct amount of oil is in the engine. Low oil levels
are the second mot common cause - but too much oil can cause the oil to 'foam',
resulting in low pressure. Another problem is using too light of viscosity oil for
the operating temperatures/conditions. Using 5w30 or 10w40 on a hot summer day
can spell disaster in some engines. Try using a heavier single grade oil (40W instead
of 10w40). Another common problem is extended oil change intervals. Changing your
oil and filter every 3000 miles can solve/prevent a lot
of problems. The next most
common problem is overheating. The engine's cooling system is not working as well
as it should (low or old coolant, loose or worn out belts, sticky thermostat, corroded
or blocked radiator cores, corroded fan switch, etc). The excess heat thins out the oil.
Also if the ignition timing is wrong or if the fuel system isn't in 100% working condition the oil can be diluted with fuel, thinning it out. On rare occasions the oil pump's relief valve will hang after a fast trip on the freeway. The pumps valve may require a spring spacer or stiffer spring. And sometimes a new oil pump is required. One last cause can be a dented oil pan/blocked sump pickup tube.

VOLKSWAGEN Golf Jetta Rabbit Scirocco water cooled engines. A loud noise in the
top end of the engine which may be mistaken as coming from the valve train or near
the top of the valve cover nearest the timing belt, is usually caused by a bad bearing
in the timing belt tensioner.

Volkswagen Golf, Jetta, GTI, Cabrio  1993 and later models with 2.0L engines.  Ignition miss and/or poor performance may be caused by a bad coil wire or incorrect coil wire routing. Replace the plug/coil wire set and route the coil wire away from the heater hose.

VOLKSWAGEN Water cooled models. Instead of spending hours removing carpet,
pedals, etc to reweld a broken clutch cable guide sleeve - find a metal sleeve, of the
same diameter and about an inch longer. Weld or braze a large washer whose ID    fits the sleeve's OD to one end of the sleeve. Drill two holes 180 degrees apart in the
washer, and from under the hood slip the sleeve thru the cable's hole in the firewall
and attach it with two sheet metal screws thru the holes in the washer. Install the
cable.

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Volvo

VOLVO Turbo models. A bad turbo seal can cause excessive oil consumption - but
before you condemn the turbo or piston rings, check for a sludge restricted oil
separator. Similar to the older models' flame trap the oil separator box can get
clogged, causing oil to be sucked into the turbo and burned.

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