TECH TIPS FOR AUGUST, 1996

A REVIEW OF THE CORE RETURNS, SHOW THAT MORE THAN 50% OF ALL THE PULLEYS WE SUPPLY ON ALTERNATORS ARE BEING RETURNED ON THE CORE. THIS INDICATES THAT OUR CUSTOMERS ARE HAVING TO CHANGE MOST OF THE PULLEY'S.  THIS PARTICULARLY RELATES TO FORD AND GM AUTOMOTIVE ALTERNATORS, I NOW UNDERSTAND WHY MOST OF THE LARGE REBUILDERS DO NOT INSTALL PULLEYS ON THESE ALTERNATORS. IN FUTURE WE WILL NOT SUPPLY PULLEYS ON THE COMMON FORD AND GM ALTERNATORS.  SINCE THE OLD ALTERNATOR HAS THE CORRECT PULLEY ON IT NOW, AND AT BEST WE ARE RELYING ON SOMEONE'S IDEA OF WHAT IS CORRECT, WE WILL SUPPLY AND INSTALL PULLEYS ONLY WHERE WE CAN BE ABSOLUTELY SURE THAT THE PULLEY IS THE CORRECT ONE.

AN ARTICLE I WAS READING GIVES SOME IDEA OF THE EFFICIENCY OF THE MODERN AUTOMOBILE ENGINE. THE ARTICLE SAID THAT IF THE AVERAGE ENGINE BURNED ONE (1) DROP OF ENGINE OIL PER REVOLUTION, THE SUMP WOULD BE EMPTY IN LESS THAN 20 MILES!

A FORD TSB REPORTS THAT ON 1990-92 FORD PROBES, THE MALFUNCTION INDICATOR LIGHT (MIL) MAY COME ON INTERMITTENTLY. THEY SAY THAT THIS MAY BE CAUSED BY OUTPUT VOLTAGE VARIATIONS FROM THE EGR VALVE POSITION SENSOR (EVP), AS A RESULT OF CARBON DEPOSITS ON THE EXHAUST GAS RECIRCULATION (EGR) VALVE. IF THE SYMPTOM SOUNDS FAMILIAR THE REPAIR PROCEDURE IS FOUND IN TSB 95-3-5. I HAVE A COPY OF THIS BULLETIN BUT IT IS TOO LENGTHY TO REPRODUCE HERE.

ACCORDING TO "MOTORS" MAGAZINE, SOME LATE MODEL FORDS, EQUIPPED WITH THE 3.0 & 3.9L ENGINES WITH THE DUAL OXYGEN SENSORS, MAY SEEM TO SET "KEEP ALIVE CODE 176 (FRONT O/2 SENSOR LEAN), BUT THE CUSTOMER WILL PROBABLY NOT NOTICE MUCH IN THE WAY OF DRIVEABILITY PROBLEMS, AND MAY REPORT THAT THE CHECK ENGINE LIGHT COMES ON SOMETIMES AND THEN GOES OUT.

FIRST DETERMINE THAT THE SENSOR'S HEATER CIRCUIT IS FUNCTIONING NORMALLY AND THAT THE OUTPUT VOLTAGE IS CROSS-COUNTING SWIFTLY, IF THIS IS CORRECT YOU ARE LEFT WITH ABOUT 20 POTENTIAL CAUSES, AND WHERE TO START. "MOTORS" SUGGESTS THIS LITTLE TRICK: SWAP THE O/2 SENSOR FRONT TO REAR. THEY ARE IDENTICAL EXCEPT FOR THE LENGTH OF THEIR HARNESSES.

IF THE ECA MEMORY NOW SHOWS A KEEP ALIVE CODE 172 (REAR O/2 SENSOR LEAN) THE PROBLEM HAS MOVED WITH THE SENSOR AND IT IS DEFINITELY POOCHED. IF THE CODE 176 COMES BACK, THERE IS AN INTERMITTENT LEAN CONDITION ON THE FRONT BANK.

ANOTHER FORD TSB, COVERING EARLY 90'S FULL SIZE FORD,LINCOLN & MERCURY PRODUCTS INDICATES THAT AN INTERMITTENT "NO START" MAY BE CAUSED BY CORROSION IN THE WIRE AT THE SWITCH TERMINAL AT THE SOLENOID. THIS IS THE SOLENOID ON THE STARTER NOT THE CONTROL SOLENOID ON THE FENDER. THERE IS A LONG DETAILED REPAIR PROCEDURE WHICH BASICALLY INVOLVES REMOVING THE SWITCH CONNECTOR & ABOUT 8" OF THE WIRE AND REPLACING IT WITH NEW. WE REPORTED THIS SEVERAL MONTHS AGO BUT SINCE THEN THE PROBLEM HAS SURFACED SEVERAL TIMES, MAKING A REVIEW A GOOD IDEA.

IT SEEMS A LITTLE EARLY TO BE THINKING ABOUT THIS, BUT, CHRISTMAS IS ON A WEDNESDAY THIS YEAR. UNDER NORMAL OPERATING CONDITIONS YOU WOULD EXPECT TO BE OPEN UNTIL ABOUT NOON ON THE TUESDAY, CLOSED WEDNESDAY & THURSDAY, AND EXPECTED TO REOPEN ON FRIDAY.

I WILL NOT GET ANY REAL VACATION THIS SUMMER AND AM CONSIDERING CLOSING FOR THE WEEK. OVER THE NEXT SEVERAL WEEKS PLEASE CONSIDER IF THIS WOULD ADVERSELY EFFECT YOU AND I WILL POLE YOU ABOUT THE END OF SEPTEMBER FOR SOME INPUT.