Viewing Officers, the Mercedes the Ageing Fleet of Land Rovers Was G-Wagon’S Biggest Claim to Fame Is Not Fitted with Air Conditioning, but This the Popemobile

June 2012 Issue 27 www.tat.net.au

The engine room is where Ford Performance begins

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call (02) 9905 8055 for your nearest Distributor for the love of work but only for money, is not likely to either with Ken Newton make money or find much fun in life.’ Charles M. Schwab, American steel magnate hat a busy few continue around Australia and months. The entire New Zealand for the rest of this ‘The first rule of any technology TaT team, Jeff Smit, year. used in a business is that WDeyan Barrie, Geoff Mutton automation applied to an and I found ourselves in Technical director Jeff Smit efficient operation will magnify Thailand at the Capricorn surprised us all when he trotted the efficiency. The second is Convention during May. out a quirky training session in that automation applied to any Phuket, based on his life story. inefficient operation will magnify Along with almost 500 other There was little Jeff in his bow the inefficiency.’ Bill Gates, co- Capricorn people, we ate, tie and long socks, and later with founder of Microsoft and one of founder of the Virgin Group of drank, trained and sweated at his shock of surfie hair – a far the world’s wealthiest people companies the Club Med in Phuket. Those cry from the wild party animal delegates who were able to hanging on to the back of a ‘I don’t pay good wages because ‘In the business world, everyone drag themselves away from the tuk-tuk in Thailand. (Thanks to I have a lot of money: I have is paid in two coins: cash and beach and the shopping loved Adam Cohen of Autodata for the a lot of money because I pay experience. Take the experience our two-day training program. evidence.) good wages.’ Robert Bosch, first; the cash will come later.’ There is little doubt that the German industrialist and founder Harold Geneen, American There was a powerful message business training program of Robert Bosch, innovative businessman famous as in his presentation, called Now Available! - an OEM generic scan devised by the TaT Biz side of maker of domestic and industrial president of the International our business is the best thing Life’s an adventure, but what equipment Telephone and Telegraph I particularly enjoyed was his tool for DIESEL, PETROL & HYBRID ever for many workshop owners. ‘I like thinking big. If you’re going Corporation TaT’s main training programs collection of quotations from to be thinking anything, you Now let one of our subscribers Electrical Vehicles! are traditionally based on famous people which he used might as well think big.’ Donald have the last word. This gem technical upskilling. Little did we to emphasise his message. I’ll Trump, American real estate of wisdom from Rob Gillies in realise that business training share some with you. mogul, TV personality and Ulladulla NSW. After finding a would become a priority, and ‘Whether you think you can or author. fault in a component which he that’s pretty much the theme whether you think you can’t, didn’t suspect as being faulty, he of all current training. The co- ‘Business opportunities are like you’re right!’ Henry Ford, founder quoted ‘Experience is something branded product with Capricorn, buses, there’s always another of the Ford Motor Company you get just after you need it.’ 9 steps to a better workshop, one coming.’ Richard Branson, fires up again this month and will ‘The man who does not work English business magnate and There endeth the lesson.

The TaT team Contents

Publisher Anthony Tydd Castrol oils the top engines……………4 •TaT Assist •TaT Chat •TaT Train The Automotive Technician Pty Ltd Gerry Marson Compressed air energy savings…………7 •TaT’s a fact •Tips for TaT • TaT Biz ABN 27 121 589 802 Maurice Donovan Non-genuine brake pads………………8 are all registered trade names of Diagnosis and waveforms………………10 The Automotive Technician Pty Ltd. 30 Dale Street Columnists The web can be useful…………………12 OEM Generic Automotive Scan Tool BROOKVALE NSW 2100 Julian Hentze – Georgia USA Volvo in electrics race…………………12 The Automotive Technician Pty Ltd Hayley Windsor – Australia Army’s Land Rover era ends……………14 publishes technical advice and [email protected] Reputation = the sum of your parts………16 actual case studies for the 1300 828 000 Reader purpose of educating technicians. How to lose friends and money…………18 Fax 1300 828 100 Bron Robinson These advices are given in good TaT’s a facts...…………………………20

faith, and are based on actual No fuel like a new fuel…………………22 Editor in chief Advertising inquiries workshop repairs. No guarantee is No codes, but still a sensor problem……23 Ken Newton Janene Champion given, nor any liability accepted in Denso announces driver-only a/c………23 [email protected] [email protected] respect to any published advice. Auto training boost at Kangan………24 0438 569 517 03 5862 3090 0403 226 770 Frosty times continue for Monroe………24 Fax 1300 828 100 Hottest new scan tool The Automotive Technician Pty Ltd Letter from America……………………26 Graphic design is not responsible for the accuracy Murphy’s Law – The good old days……27 Editorial and online Russell Jones Graphic Design on the market today! of any information contained in Older vehicles multiple symtoms………29 assistant 07 5532 2840 0411 817 012 material submitted by third parties Fixing it is one thing - ‘why’ is another……30 Tony Wragg [email protected] and published in this magazine and Training calendar..……………………...32 [email protected] accepts no liability in relation to Street Cred……………………………33 Printing such materials or their content. Top Tools – TA300 Smart Tach…………34 Trucks, Cars, Hybrids, Technical editor McPherson’s Printing Group Jeff Smit 5–7 Dunlop Rd Torsion dampers on the farm…………35 Newsworthy articles or comments Commercial innovation…………………36 [email protected] Mulgrave VIC 3170 are welcomed, and should be 1300 828 000 www.mcphersonsprinting.com.au TaT’s interesting……………………….38 4WD’s, Gasoline, Diesel submitted to the editor in chief. Business tips with Geoff Mutton………38 Technical research Affiliated associations All material appearing in The Deyan Barrie VASA [email protected] Automotive Technician is copyright. & Electrical models [email protected] AAAA member [email protected] Reproduction in whole or in part is The Automotive Technician is a member of the Circulations Audit Board. Capricorn Society Alliance Supplier illegal without prior written consent Audit period, 1 October 2011 to 31 March 2012. www.gscan.com.au Technical advisers from the editor in chief. Average net distribution 9,983. Jack Stepanian Sam Nazarian All advertisers agree to indemnify Nick Murphy the publisher for all damages or call (02) 9905 8055 Gil Sher liabilities arising from their published Jason Smith or unpublished material. for your nearest Distributor The Automotive Technician 3 The cover photograph, taken in the Engine The drivers Build Room of Ford Performance Racing in Melbourne provides a rare glimpse of the team at the coalface of high performance may be good, racing. The members are (from left) Justin Way – Engine Calibration Performance Manager, Ben Johnston – Engine Technician, but it’s the Ashley Campbell – Engine Building Technician in Charge and Simon Robinson – oil that gets Engine Technician. These team members are featured in other photographs in this cover story. Photography by Mark Horsburgh and them there Scott Wensley – VUE Images

ord Performance Racing has been at the top of its develop an oil which is light weight, with a viscosity thin enough to form in recent months, claiming its seventh straight do its job and move around the engine quickly. F win at the most recent Phillip Island race. ‘The oil holds the key to minimising the wear and tear on the While much of the credit for the wins must go to the team’s ace engine, and as a direct result, maximise the performance gain,’ he drivers Will Davison and Mark Winterbottom, the back-room team added. who prepare the engines, eking out every last bit of energy from Ford Performance Racing has been using Castrol oils since the the big 5.0 litre Ford V8s, deserve their share of praise. team was assembled almost 10 years ago. In a workshop simply labelled The Castrol chemists have developed the Engine Build Room at Ford a special synthetic and mineral blend Performance Racing, the engine Viscosity is a of oil, working in conjunction with building technician in charge, Ashley word you will hear Ashley and the Ford Performance Campbell, oversees the preparation Racing team. This combination of skills of every engine before every race. often in the back and dedication has managed to add Engines are stripped and rebuilt, parts room of V8 racing significant horsepower to the capability are put under the microscope for wear of the engines over a 10 - year period, inspection, and oils are drained and recovering some of the ground lost sent to chemists to analyse the contaminants they collect on their through ethanol fuel trials and the introduction several years ago way around the engine. of standardised camshaft profile in this racing category. It could be argued that apart from the fuel, it’s the oil in the engine After every race, a sample of the engine oil is sent to an that determines whether the race car reaches the chequered flag independent laboratory to test for contaminants such as metals first. from engine wear. Oils, as every technician would know, are now treated with The results go to the Castrol chemists and oil blender and they scientific reverence in the modern vehicle. In fact, some engines consult with Ashley’s team to get the best out of the lubricant. will reject oils that are not specifically designed for them. ‘Oils have changed dramatically through the years,’ said Ashley. Viscosity is a word you will hear often in the back room of V8 ‘The development of synthetic additives has had a massive effect racing. on wear factors, and so too have the new coatings, like graphite which is now applied to metals to reduce wear. As Ashley describes it, ‘The oil used in racing engines is constantly monitored and tested and it’s really all to do with ‘In a racing environment, you are trying to limit contaminants and viscosity. The less viscous the oil, the more smoothly it moves temperature related breakdowns of metal parts. All of this impacts through the engine and lubricates the moving parts. The trick is to on the engine’s performance.

The Automotive Technician 4 ‘We now rely on the correct combination of synthetic and mineral oil blended together. The oil is almost water-thin, and inside the engine, the synthetic additives and the mineral oil do separate jobs. ‘The mineral oil is vital to ensure a good seal between the rings and the bore while the synthetic component is able to better lubricate the various bearings. ‘So we expect the oil to do the job with minimum bearing fatigue, with less weight and friction,’ added Ashley. Oils have come a long way since Ashley’s involvement with the racing scene, which goes back to his days with Glenn Seton Racing, a top V8 Supercar team more than a decade ago. Glenn Seton Racing was subsequently bought by Prodrive and reinvented as Ford Performance Racing to promote the high performance road Falcons. Ashley was of course included in the sale. He recalls the days when the V8s relied on GP50, a now redundant high viscosity mineral oil.

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The Automotive Technician 5 Castrol has now stipulated that as a result of the development work with a Ford Performance Racing sister company Ford Performance Vehicles, ‘Only one oil is recommended for the new range of supercharged BOSS 315 and 335 engines, Castrol Edge 5W-20.’ The oil, says Paul Cook, head of the Ford and Prodrive programs in Australia, is unique and a specific lubricant formulation to withstand the demands of the most powerful V8 engine ever offered by Ford. He went on to say that Edge was engineered to reduce friction and ensure maximum protection of all engine components, leading to better engine power and outstanding fuel economy. Like every mechanic or technician associated with car racing, Ashley Campbell gets his adrenalin rush from the never ending quest for performance improvement. ‘The program never stops and it’s made all the more interesting because we are dealing with the fundamental engine. We can’t call on any external technology to make it go faster. I have been developing the same fundamental engine for the past 15 years. ‘We run them on the Dyno three times to achieve a baseline performance rating, and then work out the average. Every Chemists examine oil samples in the laboratory at the Castrol improvement after that is measured against the baseline, so Technology Centre in China that we can constantly track which of our efforts is achieving the greater power and speed,’ Ashley said. of Australia (honouring the classic hand-built car made by the He is one of those special breed of technicians who seem to have Morgan family in the UK since 1899). Ashley restored his step- performance engines built into their own DNA from an early age. father’s 1976 Plus 8 narrow body Morgan, and his own hill climb car is a 1965 MGB. What he calls his humble beginnings in a Melbourne dealership kindled a passion for engine building and high performance racing Ashley’s maxim is that a good technician never stops learning, cars. He did many courses in performance engines and for after- and the sky’s the limit – precisely TaT’s philosophy and reason for hours amusement, got involved with the Morgan Owners’ Club being.

The Automotive Technician 6 Save money - try compressing your compressed air energy by Jeff Smit

pecialist compressed to reduce their costs and air company Southern maintain a high degree of Cross Compressors competitiveness. Renting specialty automotive workshop tools Shas pinpointed compressed The Clean Technology air as an easy target for Investment Program is being companies seeking to delivered by AusIndustry improve energy efficiency within the Department of and save a buck. Industry, Innovation, Science New variable speed drive and Tertiary Education and compressors that exactly delivery is supported by match the output to the Innovation Australia. Details volume demanded from the and a step-by-step guide are production line, can provide available from: typical energy savings www.ausindustry.gov.au, of more than 30 per cent phone 13 28 46 or email: compared with online/offline [email protected] demand machines with a linear reduction in power with Southern Cross Compressors demand. can provide guidance to workshops on measuring the Where these machines have predicted reduction in carbon been considered expensive emissions intensity and energy in the past with up to a 50 per savings over the effective life cent price premium, variable of equipment or plant. screw compressors command a lesser premium these days Experts at Southern Cross of around 15 per cent to 20 Compressors estimate per cent, and provide a faster that up to 50 per cent of payback on the initial capital energy used in producing investment. With energy costs compressed air is wasted. rising at an alarming rate, The company, which boasts these efficient machines are a team of highly qualified further reducing the payback technicians, has introduced period. a comprehensive program of air audits for all businesses, With the Australian large and small, and they Government’s current Clean report outstanding results. Technology Investment The audits measure airflow Program incentive, businesses requirements at every stage of can apply for up to 50 per usage, highlighting peaks and cent of the capital cost of low demand periods, leaks this equipment where it can in the reticulation lines or be proved that high energy- inappropriate uses. efficient measures are being They also assist in identifying introduced. the right compressor Emission reduction measures, equipment to be installed with particularly those related to particular emphasis on the improving energy efficiency, latest variable speed drive can greatly assist businesses machines. CALL US TODAY ON

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The Automotive Technician 7 Modern systems compensate for non-genuine brake pads

ctive cruise control now being quality non-genuine replacement fitted to some new cars will place brake pads.’ no more demands on the brake Active cruise control systems apply Asystem than a conventional driver- the brakes gently, and with much operated brake, according to Bendix faster feedback adjustment than any Brakes. human operator could ever do. If the When The company’s engineer, Tim Paton, brakes are more or less effective than an anti- was countering a market perception that what the system assumes, the system will lock braking OEM replacement pads must be fitted detect that the car is decelerating more or system is activated, the to vehicles equipped with active cruise less than expected, and will compensate computer determines what control – a driving aid operating the by adjusting brake pressure – within brake effect is required, then calculates accelerator and the brakes to maintain a milliseconds. and commands a brake pressure that distance from the car in front. The other driver aids function in the same would give that effect if the car was in Paton says cars fitted with active cruise way, but under much more demanding the same perfect factory condition as the control require no special consideration conditions. Anti-lock braking systems vehicles used to calibrate the computer. when selecting a replacement brake pad. have to compensate and re-calculate The system then monitors what actual for differences in traction between tyre brake effect it’s getting, re-calculates ‘If we compare it with other driver aids, and road, far more than they have what pressure should be delivered, and such as traction control, electronic stability to compensate for differences in pad commands it. control and anti-lock braking systems performance. which also perform computer-controlled Exactly the same applies to active cruise brake applications, they are all more These systems are very adaptable – they control. If the brake pads are non- sensitive to brake pad properties than function with new tyres on dry hotmix, standard, then the first pressure command active cruise control is,’ he said. ‘Extensive worn tyres on wet clay and even with one will need to be corrected slightly when testing and years of field experience have wheel on tarmac and one on ice and the the feedback kicks in. The effect of fitting shown that all of these systems function differences in pad friction are trivial in that aftermarket pads to a car equipped with properly when the vehicle is fitted with context. active cruise control is insignificant.

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The Automotive Technician 9 by Jack Stepanian and Sam Nazarian

hese days, Scan tool data list 1. diagnosticians are often faced with The data of every control vehicles that may require module was then scrutinised for scrutiny of a number of abnormal behaviour or abrupt probable causes in order to changes but none were noted. find the solution to a tricky Circuit diagram problem. Since fingers of accusation It’s possible that 10 cars of the were now pointing towards the same vintage, make and model engine management system, and with same symptom may rather than transmission or each need a different remedy. a CAN BUS issue, a circuit It follows then, that a diagram was accessed and every component was identified considerable amount of time along with their supply, and could be spent systematically ground and signal terminals. eliminating probable causes These components were until a definitive solution to the then prioritised according root cause reveals itself. Exposing the connector to idenfity the terminals to the criterion – should this One such vehicle, a Mercedes component fail, what will the Benz, 99 E-Class V6, was presented to TaT’s research centre. symptom be? After much cross-examination from the myriad On light acceleration the vehicle would accelerate, quite normally, components it was drilled down to a handful of sensors and but when a more aggressive acceleration was required, it would controls and, since the airflow meter (AFM) was on top of the list, hesitate, hold back, did not have any power and seemed to it was time to capture some waveforms on the oscilloscope. struggle as if it were starved of fuel or even suffering from blocked Diagnosis and oscilloscope catalytic converter. Yet, apart from this symptom, it was all working well. The next step was to expose and identify AFM terminals (pic 1) and capture waveforms of the following designated terminals The symptom begged for the following systematic approach. by reconnecting them and back probing AFM (pic 2) while the Simulate the symptom in a workshop environment ignition switch was off, then ignition on, then crank, engine run, snap throttle, let engine settle, then ignition off. Having test-driven the vehicle with the customer and confirmed the symptom, we attempted to simulate it in the workshop with the car stationary. While a similar symptom, in a much milder form, was observed, we were not sure whether this was due to free Pin 1 – yellow/green — intake air temperature sensor (pic 3) running unloaded high RPM cut-off coming into play or whether it Pin 2 – red/purple — supply to AFM (pic 4) was the real symptom. There were no shortcuts available, so we had to double our systematic effort. Pin 3 – brown — signal and AFM earth (pic 5) Check the basics Pin 4 – brown/yellow — reference constant voltage five volts (pic 6) Having checked the battery 2. supply, credibility of grounds Pin 5 – yellow/white — AFM between negative battery post output signal to control module to terminal, chassis and engine (pic 7) block, we then wiggled the wiring loom and connector while Examine waveform the engine was running and while we accelerated, but there All captured waveforms were was no obvious cause. OK. However, on closer Vacuum leaks, fuel pressure examination of pic 7, it seemed and fuel volume were that it did not really qualify for a measured. Back pressure true response trace of an AFM. from catalytic convertor was The voltage (Y axis) was assessed again with nil result. changed from 500 millivolts Diagnostic trouble code to 200 millivolts per division to amplify and allow closer Since a generic trouble code analysis of the waveform (pic search revealed nothing, 8). Traditionally, most AFM we accessed every control sensors when first switched on module that the scan tool could should exhibit a spike but this communicate with but all were Refitting the connector and backprobe to measure the waveforms was hardly evident. OK. The Automotive Technician 10 3. 4. 5. 6.

On almost full throttle, the AFM seemed to have failed to follow a 9. full voltage swing. Clean AFM

The sensor element was removed from its snorkel and cartridge and examined under a magnifying glass. While it seemed reasonably clean, the intake air temperature sensor (pic 9) and the AFM sensor film (pic 10) were cleaned with an airflow cleaning solvent. They were refitted and the waveform measurement repeated but there was no change. Replace AFM

After much consideration a new AFM sensor was fitted and the same waveform measurements repeated. Re-assess waveform with new AFM

As can be seen from pic 11 and pic 12, with the waveforms captured under the same conditions as pic 7 and pic 8 respectively, the new sensor not only exhibited a spike as expected on the initial ignition switch turn-on, but there was a much healthier trace representing an induction pulsation waveform of the airflow to the engine. Root cause

Initially, it was unclear whether the AFM output signal was a true reflection of airflow into the struggling engine or was the AFM signal making the engine struggle. Our familiarity with the look of Intake air temperature sensor after cleaning AFM signals led us to opt for the latter option. Lack of reported trouble codes 10. It was surmised that there were no codes reported since the AFM signal was varying and the voltage range was well and truly within the control module’s programmed parameters. The control module did not log a trouble code yet the output signal lacked fidelity. Synopsis

While waveform measurement and analysis form an essential part of systematic diagnosis, the ability to recognise proper or improper waveforms can only be attained by continually measuring waveforms of known good non-problematic sensors and components. And when faced with a vehicle that is The airflow sensor film can be seen between the gap problematic, all one has to ask is – what should the waveform look like? Then simply capture and compare the waveform with That’s how simple it is. what it is supposed to look like, or observe the abnormality of a Happy waveform capturing, waveform that is synchronised with the symptom. Sam and Jack

7. 8. 11. 12.

The Automotive Technician 11 gone. The code for the knock sensor YOU Sometimes the web was still there, but the customer did SAID not want to go into this at the time IT! can be very useful because the acceleration problem was the main issue and that was he customer complained of poor I did fixed. acceleration and a flat spot. not have I try not to throw parts at problems, I road tested and there was indeed T access to my scope at the time but on this occasion, with no access to my very poor acceleration intermittently, and and because the code for scope and time being against me, I used no power. 2000 Ford KN Laser 1.8 ltr the knock sensor would the internet for research and TaT was a The only code was related to the knock clear and take a while to big help. (I’m getting better at identifying sensor. Looking at the live data, the timing come back, I felt the airflow rubbish on the web.) meter was giving the ECU seemed to be wrong and all over the incorrect signals. The job took me two place. I checked the airflow meter and hours. cleaned it, but the result was the same. I would have liked to have seen it on the Peter Hinds Pico, but a quick look Brisbane Mobile on the TaT website and Mechanics elsewhere on the web BRISBANE QLD confirmed that it was certainly a common (Good thinking Peter. problem. We’ve always said that A spare test unit was technicians should make tried and the problem greater use of internet resources. The was solved. A new airflow meter was fitted hardest part is sorting out the rubbish from and road tested and the problem was the good stuff. Ed)

Volvo joins the electric race

olvo has entered the electric The cars are leased to customers car race, with trials in China of in selected European countries and its C30 Electric cars. they are also currently operating in The Volvo C30 will be the first electric demonstration programmes in Sweden car from an international brand that will and Belgium. be presented, and involved in various The Volvo C30 Electric has a 20 kWh activities, in China. battery that is recharged from a regular Volvo Car Corporation started the household power socket. A full recharge production of the Volvo C30 Electric In takes about seven hours. The operating June 2011. The car is manufactured in range is up to 150 kilometres per full the Volvo Cars Ghent plant in Belgium charge. The top speed is 130 km/h and and finalised in the Torslanda plant in acceleration is 0–50 km/h takes four Sweden. seconds.

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The Automotive Technician 12 STRENGTH TO PERFORM FREEDOM TO DRIVE

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The Automotive Technician 13 replacement, the Mercedes G-Wagon, is in configurations of four or six wheels. With the army deployed in locations such as Afghanistan, air conditioning is no longer a luxury, but a necessity for mobile troops. Many of the vehicles in the old fleet, with the exception of the Bushmaster armoured troop carrier, ASLAV and new M1A1 Tankwere not air conditioned,’ Captain McCaskill added. Swinburne’s Adrian Lea said the Army technicians currently held mainly automotive heavy road transport qualifications, some even from the UK. Army’s Land Rover era ends – ‘We are offering a mix of skills recognition, credit transfer and additional gap training but now the troops are cool for the air conditioning subjects. ‘All programs are evaluated and courses he Australian Army’s love affair them to the training courses was a logistics were modified or improved to suit the with the Land Rover is coming to exercise of its own. feedback received from the technicians. a close. T Captain Ben McCaskill, head of the project ‘It has been a very worthwhile and successful exercise. Feedback has been This boxy little workhorse, which happens at the headquarters of the Army Logistic positive, especially relating to the expertise to be the second oldest four-wheel drive Training Centre in the Albury–Wodonga of the combined training team and the car brand in the world after Jeep, is Military Precinct, is pleased with progress, quality of the program. We can’t recall gradually being replaced by the Mercedes with an impressive 90 per cent attendance an equivalent snap training program of G-Wagon. rate across all courses. He said many of such a large number of students on one The Land Rover has been associated with the vehicle mechanics had to be called technology,’ Adrian added. the military vehicle scene in Australia, in back from other field work to do the one form or another, for more than half training at one of the three locations. While the Land Rover had its share of a century. The first one, a Series 2 short pomp and ceremony, often fitted with wheelbase model, was delivered to the a specially built-up rear body, perspex army in 1958. screens, chromed hubcaps and grab rails for reviewing officers, the Mercedes The ageing fleet of Land Rovers was G-Wagon’s biggest claim to fame is not fitted with air conditioning, but this the Popemobile. The Mercedes-Benz now essential vehicle climate control 230 G, painted in mother-of-pearl, comfort will come as standard in the new accompanied Pope John Paul II on many Mercedes vehicles. And the prospect journeys around the world. A powerful air of maintaining a fleet of air conditioned conditioning system in the rear ensured vehicles forced the army to upgrade the a comfortable temperature in the Holy skills of its mechanics and technicians, Father’s compartment when the sun all of whom are well qualified, but not was shining, while in rainy weather and necessarily in climate control technologies. high humidity the system prevented the In a rare move, even for the Australian windows from misting over. Defence Forces, a contract to train 600 ‘While vehicle mechanics looked after The Australian Army began taking delivery army vehicle personnel was let to the everything in the fleet, upskilling was of the all-wheel drive G-Wagon with three Swinburne University of Technology in required to deal with the technology of axles in 2009. First developed in the early Melbourne after the calling of national modern air conditioning systems and 1970s, the G-Wagon has undergone a tenders. automotive refrigerants,’ he said. number of modifications in its role first as a But, as Adrian Lea, Swinburne’s senior recreational vehicle, and then as a serious ‘The army’s wheeled fleet of around automotive educator in the School of military machine, particularly suited to off- 7,000 vehicles and trailers is being Engineering, Technology and Trades road travel, with a robust frame, rigid axles explained, the sheer logistics of meeting replaced in phases and the Land Rover’s and large coil springs. the Army’s deadline by the end of June this year meant that trainers from other colleges had to be roped in to help. ‘It was an extensive amount of training for our resources, within the timetable of only nine months,’ Adrian said. ‘So Swinburne partnered with the Barrier Reef Institute of Technology in Townsville, Charles Darwin University in Darwin and Wodonga TAFE in northern Victoria and between them, they are training groups of 12 students at a time, in one-week long intensive training camps, with up to three groups in training somewhere in Australia every week.’

Taking into account the physical Land Rover – moving the army since 1958 dislocation of Army technicians, getting The Automotive Technician 14 Audi recommends Castrol EDGE Professional

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The Automotive Technician 15 2002 Honda Civic The original hub showing 0.5mm gap New hub from the bad batch The new unit is the right one Your reputation equals the sum of your parts

by Jason Smith ow many times do you see I checked the price of a new genuine I got the vernier a problem with a car and the wheel bearing as well as a new non- calipers out and diagnosis leads you to human genuine assembly. The price of the did some measuring – my suspicions were error? non-genuine bearing was about half the confirmed. The diameter of the reluctor price of the genuine unit so of course the HI didn’t just make that up – at a course wheel on the new unit was smaller than customer picked the non-genuine option. called ‘Complex system fault diagnosis’ the one I had removed. Therefore the Note that this is a sealed wheel bearing I attended a few years ago, the only critical air gap between the reluctor wheel conclusion reached by the whole class and hub assembly. and the ABS sensor was a bit wider. was that a lot of faults are caused by Now I’m no electronics guru, but I know human intervention or human errors. if you change the air gap between the The biggest human error of them all, reluctor wheel and any sensor, this will believe it or not, is not checking the parts change the signal amplitude. I thought this that are about to be fitted. different air gap could potentially cause the ABS light to come on. As you get older you get a little bit wiser, so we are told. Perhaps that is why I’ve I decided to do some investigating into the found that it pays to take a little time to part that had been supplied. Not wanting check any replacement part, mechanical or any comeback and with my reputation at electronic, before you fit it. stake, I contacted my parts supplier who in turn put me in touch with their wholesaler, The following is a great example of why I’m offering this bit of sage advice. What’s who ultimately admitted there had been a in it for you – you save a lot of time, bad batch of that particular part number. The part arrived, the car went on the He also admitted there would have been headaches and, more importantly, your hoist and the brake caliper and pads reputation. a problem if it was fitted to the car, so my were removed. The centre axle nut was suspicions were justified. A few months ago, I was doing a minor removed as well so the wheel bearing and service on an 02/2002 Honda Civic ES1 hub assembly could be removed from the When the correct part arrived the next with 92,085 km on the clock. car. day, I checked it first, of course. All parts were fitted, the new center axle nut was On the road test I noticed the left rear When I mounted the new wheel bearing tightened to the correct torque of 181Nm and hub assembly to the stub axle, I wheel bearing was noisy. A replacement and the car road tested fine. bearing was not available that day so I noticed the air gap between the reluctor asked that the car be returned another day. wheel that came on the new unit and the This is just one example, but a good The customer asked for an approximate ABS sensor on the car was quite a bit enough one, to make all technicians adopt price, so an estimate was done. wider than the old one. my advice – check it before you fit it.

The Automotive Technician 25

Old sensor ring 79.05mm The replacement sensor ring was 77.15mm

The Automotive Technician 16 ŠKODA recommends Castrol EDGE Professional recommends Castrol EDGE Professional

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The Automotive Technician 17 ith apologies to Humphrey with Geoff revealed there had been Bogart and his classic line an issue with the glow plug operation. Win Casablanca ‘Of all the gin Sometimes the vehicle would be hard to joints, in all the towns, in all the world, start and would run poorly until the engine she walks into mine’, we present ‘Of all ran for a while. Geoff was apparently the repair workshops in all the world, a advised by a service workshop not to car owned by top TaT Biz trainer Geoff worry too much because it was just one Mutton rolls into mine’. that had failed. Bad advice. Geoff Mutton’s key message in all of How to lose All the glow plugs were removed, his business training sessions is that inspected and tested. They did not look workshop staff must maintain constant burnt or spent. There was only one communication with the customer in friends and faulty one and it was more of an internal cases of critical repair. If they fail to manufacturing fault so it was replaced. communicate, the customer will walk away. money – Reassembled, the vehicle was started and In this case, Geoff was the customer, and there was no engine or diesel particulate he did walk, and the workshop missed out filter (DPF) light on. on what turned out to be a $2,000 job. a horror story Scan tool showed code P0403 for EGR Geoff was doing Capricorn training in control circuit. Thailand and his family back in Australia give it to 1pm and they would call to let her know. They didn’t call. were driving in the family car, a Suzuki When the car was driven around the block Vitara 2008 diesel, when it suddenly 2pm – Another call to the workshop. They white plumes of smoke poured out. Back stopped and would not restart. say the wreckers did not send the part in the workshop, hooked up through the extraction system and the vehicle was run Here’s what happened. because it was damaged. They can get another second-hand part but now want up to about 1800 RPM so that the DPF Sunday May 6 – The NRMA towed the $3,000 – it seems the wrecker has woken would clear totally. After about three- broken-down car to the nearest workshop. up to what it’s worth. The workshop is told quarters of an hour the exhaust was clear. it’s not to proceed, and that the car will be Monday May 7 Another road test, at constant RPM for 10 towed back home. kilometres, and it was clear after about one 8am – Geoff’s wife calls the workshop. Monday May 14 kilometre. No forced burn needed on this Service person advises they will look at the one. car first thing this morning and give her an Car is towed to a TaT workshop in Sydney. update by about 10.30am. They didn’t call. An oil flush was done and the oil and filter An inspection revealed the exhaust was changed just in case the oil had been 11am – She calls again. Service person not as bad as expected, with normal contaminated. The vehicle was scanned said the car would be looked at later and exhaust heat-related marks. and got the all clear. It was about 10 hours they would give her a call. They didn’t call. The diesel particulate filter was blocked work. 3pm – TaT technical director Jeff Smit, who and badly carboned up. A carbon cleaning This is one of those times when the vehicle is with Geoff Mutton in Thailand, phones mixture was used and back-flushed with a owner has to help make the decision the workshop to see if he can help with the gerni and then a large volume of air. to go outside the square and allow the diagnosis. Technical talk is exchanged and workshop to attempt a carbon clean and Jeff advises the car’s history, including a Some stud threads had to be repaired as back flush. Considering the cost of a new glow plug issue. He is advised nobody has they had been stripped when the exhaust filter at $8,000, the risk was worth taking, yet looked at the car. Jeff Smit provides his was taken off by the first workshop. based on the TaT workshop’s experience mobile number and asks if someone could The cause? TaT technicians had already and assessment. Only full and frank call him once the car has been inspected. worked it out before the vehicle reached communication with the owner will cope They didn’t call. the TaT workshop. A long conversation with situations like this. Tuesday May 8 Retail cost of the job was $1,900. 3pm – Geoff Mutton calls the workshop Notice anything about the above story? from Thailand to be told that the diesel particulate filter is broken and all burnt out. The workshop which received the car a Could be around $1,000, so they ask if week earlier committed the cardinal sin they should ring around and locate a used of initiating not one call to the customer. part. Geoff agrees. They said they would All communications were initiated by the give him a call tomorrow to let him know customer, mostly out of frustration. how they were going. They didn’t call. Even worse, their phone manner at times Wednesday May 9 was unprofessional. Sometimes the phone was answered with a curt ‘hello’. No 3pm - Geoff Mutton calls again from Contaminated inlet business name and little else. Thailand, to be told that a genuine part is $8,000, but they have located a used As Geoff rightly sums up, ‘Our trust was one for $300. They were taking photos to wavering with this workshop when they confirm it is the correct part. Geoff says failed to honour their first promise to call to go ahead and order the part if it is the back on the Monday morning. It just got correct one. Geoff is also told the car won’t worse after that. Once that trust is lost, you be fixed by Friday. They need more time, are reluctant to spend money with them.’ and it depends on the arrival of the part. Wheelnote: Workshop name and Thursday May 10 location have been supressed to protect the guilty. They are certainly 11am – Geoff’s wife calls the workshop for prime candidates for the next available an update. The part had not arrived – but Cleaned inlet Capricorn business training session.

The Automotive Technician 18 STRENGTH TO PERFORM FREEDOM TO DRIVE

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The Automotive Technician 19 HOLBA97811 HOLDEN ‘s a fact BARINA SB problem solving 1997 4 Cylinders

Customer Complaint We either had poor circulation of the water pump or an internal radiator The vehicle had overheated in problem. traffic, losing its coolant. The way the high fan thermo switch Problem Summary came on at the right temperature (but not the low) – plus the fact that The vehicle was checked at a mechanical shop for coolant leaks. the radiator would not dissipate the A pressure test revealed that there heat quickly enough even when fan was a leaking heater tap, and a new speeds were manipulated – made h/tap was fitted. us look more closely at the radiator. It was checked again and a system The coolant was removed coolant flush performed, with new and we noticed a strange coolant added. mixture of colours and a crusty red material. It was noted that the engine fan was not starting at operating We removed the radiator and the temperature. two thermo switches in the lower driver’s side of the radiator. Diagnostic Sequence We found that the lower The vehicle was brought to us section blocked up badly. This to check the engine cooling fan was stopping the hot coolant operation (no low speed fans). hitting the low speed thermo We checked it and found the fan switch base, resulting in circuit was OK, but the low fan the low fan speed. speed sensor on the radiator was not switching below 100 degrees This was also the reason for the Celsius. lack of flow through the radiator, causing the heat build-up and the By bridging out the switch circuit on radiator’s inability to cope. the bottom of the radiator we could get the fan working at low speed. Fault Solution The low fan speed would not reduce A new radiator was supplied, thermo the temperature below 95˚degrees switches were refitted and the Celsius. If left to rise above 110 assembly was refitted. degrees Celsius, the high speed fan would kick in, but it still took time for The system had new coolant, and the temperature to come down. we tested to ensure there was a Blockage good flow. The engine temperature We discussed the problem with the worked as it should. owners who advised us they had been having issues for some time – The low fan speed was cycling at losing coolant (but not visibly). They the correct temperature (regularly had been adding water only. and quickly downwards between 90 Low fan switch HIgh fan switch and 100 degrees Celsius). position position Fault Description We suspected a volume/flow Recommended Time problem. Labour time was 5.5 hours, taking The thermostat was removed into account research time, location from the equation because of the of parts and actual time spent fixing temperature of both main hoses. the problem.

‘s a fact problem solving TaT’s a facts are real life fixes, collected from TaT workshops and from our subscribers, covering a variety of vehicles, old and new. It is a constantly growing resource with hundreds of fixes to known vehicle problems.Available for subscribers only at www.tat.net.au

The Automotive Technician 20 JEECH00311 JEEP ‘s a fact CHEROKEE problem solving 2000 6 Cylinders

Customer Complaint Brakes locked on. Problem Summary Brakes locked on after completing front pads and rotors. Diagnostic Sequence The diagnostic sequence was as follows: a) Inspected the brake system. b) Released the bleeder nipple. No pressure, front brakes still locked on. c) Removed the brake caliper assembly and pulled it apart, removing the pistons and inspecting the housings. Fault Description Further research revealed that the vehicle had ceramic pistons that absorb brake fluid and swell. The result was obvious once a section of the piston was broken away. After new pads were fitted, the swollen pistons didn’t retract after application – causing brakes to stay on. Fault Solution The vehicle required new callipers – genuine, part number 05093328AD. The old callipers were ATE type with a coat hanger style retaining spring. Once the new callipers were fitted, the brakes bled as normal. Recommended Time Labour time was 3 hours, taking into account research time, location of parts and actual time spent fixing the problem.

The Automotive Technician 21 s more companies jump conditions. This makes it difficult to on the green wagon, many ascertain the right amount of ethanol Anew products emerge that There’s no fuel that goes in to petrol as an incorrect are intended to save the planet and amount can adversely affect the reduce the human carbon footprint. balance and performance of a vehicle. The study said that car manufacturers All very noble, but in the flurry to get like a new fuel have claimed that ethanol content green things to market, it becomes by Jeff Smit and Ken Newton higher than 10 per cent in petrol convenient to overlook any downsides, engines could cause decreased engine especially when many people are performance and driveability, corrosion genuinely keen to do the right thing of metallic fuel system compounds and are in receptive frames of mind for such as the fuel line, premature anything green. degradation of plastic or rubber For the automotive industry, ethanol components, and troubles with cold fuel is the big green thing and for start and vapour lock. some years now, various governments The car makers, of course, keen and automotive associations have to be seen to be doing the right not quite been able to issue iron- thing, claim their new vehicles are clad guarantees about the efficacy ethanol compatible. Late last year, of ethanol fuel. The green marketers Holden released the updated MY12 would have us believe that a certain Commodore range of VE Series II percentage of ethanol is a good thing vehicles. ‘Now, all Commodore sedan, for modern cars. Others say don’t put it sportwagon and utes are factory fitted anywhere near an older vehicle. with E85 capability,’ crows the Holden Human health is highly dependent website, without really addressing what on what we put in our mouths and moves they made to overcome the similarly, what goes into a modern car’s tank must impact on the known issues of ethanol component damage. Holden uses what it health of the vehicle. calls a flex-fuel engine, capable of running on anything from 100 per cent petrol right up to E85, a shandy of 15 per cent petrol and The debate on ethanol fuel has become as muddied as the 85 per cent ethanol. debates on carbon tax and global warming. Support and outright abuse can be found in equal proportions by just typing ‘ethanol’ The website also goes on about the use of ethanol in the V8 into Google. Like this Sydneysider in a recent blog, ‘E10 is a ripoff racing fleet, but as TaT discovered in interviews with fleet engine and a conjob by big fuel companies. It’s rubbish and will damage builders, the switch to ethanol put the racing industry back your engine’. considerably. Many workshops are now seeing more ethanol-fueled cars and Gypsy Marshall, engine builder and mechanical overseer for most of them would probably agree with the above blogger. the Garry Rogers Motorsport team said ethanol caused major headaches for the technicians, and what they went through Studies on ethanol are coming thick and fast from around the serves as a warning for technicians in the aftermarket repair world, and while readers need to be circumspect about studies sector. by people with vested interests, there would seem to be sufficient workshop evidence to suggest that caution should be exercised. ‘We had to do extensive cylinder head work to suit ethanol fuel and we now find we’re using 30 per cent to 40 per cent more One study, released this year, conducted by a consultant to the fuel than before to generate the same amount of power. Once US Environmental Protection Agency, has forecast a rise in auto you take away the environmental rewards, it’s a lot of money for repair costs due to adverse effects of fuel containing up to 15 per very little gain. I forecast there will be huge changes to engine cent ethanol blends. Compared with typical petrol, issues found maintenance with E85 fuel. Piston life will be out the door and in the study included damaged valves and valve seats, misfires, exhausts will run a lot hotter than before. Crankshaft maintenance lower performance, engine damage, poor fuel economy and will also be high,’ Gypsy added. (See TaT Issue 20, April 2011.) increased emissions. The lab manager at international auto Car makers, they said, did not build parts manufacturer BG Products Inc, vehicles to handle the more corrosive Ken Shriner, investigated the effects ethanol fuel. of ethanol on engine parts, and also Australian legislation imposes a 10 concluded that ‘the average driver will per cent cap on the concentration of notice a difference in the thickness fuel ethanol blends, hence the blend of their wallet after switching from of 90 per cent unleaded petrol and 10 conventional to E85 fuel.’ per cent fuel ethanol are commonly Here are the main study findings: referred to as E10. Older vehicles have fuel systems A study attributed to a collaboration containing plastics, elastomers of Tasmanian colleges concluded and metal alloys that may not be that the disadvantage of ethanol is compatible with ethanol. In order to that the majority of cars in Australia be compatible with ethanol-containing are designed to run on petrol. Petrol fuel, special fuel system hardware, consists of over one thousand sensing mechanisms and algorithms in chemical compounds which are mostly Source: Carsguide.com.au the on-board computer are necessary petroleum based. Petrol fuels require to make adjustments to the fuel to air an extensive range of operating A Sydney service station reported a boost in sales after putting out this sign. Many motorists are rejecting ratio. conditions and the properties must ethanol fuels, perhaps because of uncertainty about be balanced to give a satisfactory their effect on engines. Most later model vehicles can use performance over a range of driving up to E10. On older vehicles, if the The Automotive Technician 22 fuel is switched from conventional unleaded to E10, much of One positive effect of ethanol-containing fuel is the reduction in the sediment, oxidation residue and other contaminants in emissions. the fuel tank and lines are dissolved or suspended in the new Older boats, small engines and recreational vehicles were not fuel. These contaminants may find their way to the filter until a engineered to use ethanol-containing fuel. Problems are not sufficient amount of the ethanol-containing fuel has been turned inevitable but there’s a much greater chance of issues such as over. Ethanol-containing fuel also contains water, which carries corrosion of fuel system components and deterioration of fuel dissolved salts and contaminants, and can cause premature filter lines and gaskets. plugging and injector fouling. Adding an additive like BG 44K will help But, if the fuel tank and delivery One positive effect of to remove the deposit formations caused system are clean and well maintained, by the use of E10 fuel. no additional filter plugging should ethanol-containing fuel is occur—outside of what is typical for E10 fuel accelerates deposit formation conventional unleaded. the reduction in emissions on rings. And stuck rings not only cause excessive oil consumption, but also allow E10 fuel is the worst blend in terms of oil to enter the combustion chamber and deposit formation in the engine. It can create significantly more soil spark plugs and sensors. BG’s compression performance deposits than conventional unleaded. Ethanol-containing fuel can restoration (part no. 109) at oil changes is designed to prevent corrode the fuel system. Ethanol is a mildly acidic molecule which ring sticking and improve effectiveness of emission control can cause corrosion. Acids accelerate the corrosion process, systems. particularly in iron-based alloys, but it can accelerate corrosion to aluminium, brass, bronze, silver, lead and other alloys found in TaT acknowledges the assistance of BG Products for research on the fuel system. ethanol effects on engines.

sensors. Everything seemed to be giving the correct signals, so we back-probed YOU No codes, but still the ECU and found the coils were losing SAID a sensor problem signals sometimes. We rechecked all IT! earths and battery voltages and all were good.

2002 Suzuki Jimny was towed In the end, after much searching, someone in. The customer had a problem at Autodata remembered having a similar 2002 Suzuki Jimny with the vehicle after driving it for problem with a Suzuki which turned out to 10A to 20 minutes. It would start surging be a crank angle sensor. Armed with that straight away and drove OK for another 10 and sometimes die out on the side of information together with our suspicions, minutes and then started bunny hopping, the road. we installed a new crank sensor and it surging and backfiring. This had happened since another fixed the problem. As soon as the ignition was turned off and workshop had replaced the catalytic This is worth passing on to others because then started up again, the engine would convertor with an aftermarket one. They of the importance of sharing experiences – run fine. There were no fault codes logged had also fitted a new cam angle sensor but in this case even though it was seemingly in the ECU, fuel pressure and flow rate still had the same problem. putting out a good signal and there were were good, so we removed the fuel tank to no fault codes, the crank angle sensor was We checked out the exhaust and found see if there was anything floating around still the problem. pieces of the old cat stuck in the exhaust covering the tank pickup. Everything was pipe and rear muffler. We cut open and fine. Thanks to TaT and Autodata. cleaned out the muffler and exhaust and then took it for a test run. But after 25 We took it for another drive and when it Paul Young minutes the engine died. It started again started to play up we started scoping the RIDGLEY TAS

DENSO announces driver-only air conditioning

ENSO Corporation has launched what it says is the world’s first automotive a/c system capable of heating Dand cooling the driver’s area only. The new system can separately control the climate in three different cabin zones – the driver, front passenger and rear seat areas. This can help improve overall fuel economy when the a/c is on. According to DENSO, when only the driver’s side a/c is being used, the a/c system can save up to 20 per cent of annual energy consumption compared with conventional models. DENSO’s new system only uses outside air for the dashboard and front window vents on each side. When compared with conventional products, this reduces by half the amount of warm cabin air lost, and this also helps to reduce the amount of energy Internal structure of HVAC Unit needed to operate the a/c. for right handled vehicles

The Automotive Technician 23 Auto training gets major he southern hemisphere’s largest and most advanced automotive testing and training facility is being boost at Kangan Institute established at the Kangan Institute in Melbourne’s Docklands. More than $20 million alone has been invested in a suite of testing technology from international equipment manufacturer, Froude Hofmann. With expertise in the engine testing industry dating back to the late 19th century, Froude Hofmann will supply their world-renowned dynamometers and associated control and data acquisition systems. As well as the standard AG500 dynamometer for testing engines for passenger cars and light commercial vehicles, dynamometers will also be installed for testing heavy trucks, coaches, all-wheel drive vehicles and motorcycles. The company has also supplied an emissions integration and test automation package, and an automated brake tester. AZ HSY Autoparts 92x135 eng neu: 08.02.12 16:51

Ignition Technology Diesel Cold-Start Technology Electronics Sensors Frosty times continue BERU. Innovation for Monroe

built in for 100 years. ord Performance Racing (FPR) V8 Supercar driver Mark ‘Frosty’ Winterbottom has announced he will continue as Monroe ShockF Absorbers’ Safety Ambassador during the 2012 V8 Supercar Season. His third year with Monroe, Frosty has represented the company at several major www.beru.com events, including the 2011 Australian Automotive Aftermarket Expo. The V8 Supercar Championship will visit 15 venues this year before reaching the finals at Sydney’s Olympic Park on 1–3 December. Frosty is competing in his sixth V8 Supercar season with FPR this year. During this time he has raced to 17 wins, 46 podium (top three) finishes and 21 pole positions. He finished third For more in the 2011 V8 Supercar Championship. information Notably, he has never finished outside call 1300 133 129. the Championship top five since joining Ford’s team. Last year Winterbottom became the first Australian sportsman to star in a Disney/ Pixar movie when he voiced his own character A BorgWarner Business ‘Frosty’ in the Australian and New Zealand versions of the film Cars 2.

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The Automotive Technician 25 It’s manufactured in Australia, the GM world headquarters for rear wheel drive rphy’s vehicles. It looks like a Commodore, u smells like a Commodore so I’m thinking M it may be a rebadged Commodore. The interesting thing, apart from the SS bit, is that it will be the first rear-wheel drive model Chevrolet has offered since the 1996 Impala. The other big news is that Chevrolet will Letter from be using the SS body style as their vehicle  America  of choice for NASCAR. Which is a big deal. Using the old ‘win on Sunday, sell it by Julian Hentze Monday’ mentality – if you want to sell, you put it on a NASCAR track. Car makers jostle Next year looks like a big year for most car for pole position makers in the US with many announcing model line-ups for 2013. Ford will change Julian in work mode at MACS Convention a couple of months back. Ahh – memories. ummer technically starts here 26 vehicles which account for 46% of in June, but the weather pattern their volume. The vehicles facing change What’s a C-Max? It’s Detroit’s answer to has changed since I last wrote are the Edge, Mustang and the F series S pickups. the Toyota Prius. The C-Max will sell in to you. If you recall, I was dancing in the US for US$25,995 where the Prius the streets as the heat had hit with a General Motors has also announced that is currently selling at US$27,310. Ford vengeance. It didn’t last that long. they will change 25 vehicles which account also says it will get better fuel economy for 41% of their lineup. All are US-based Although it’s been pleasant weather, it than the Prius, but no figures have been vehicles, and their pickup series is also hasn’t been the sort of heat that breaks released. Will Ford make an impact with facing a change. For GM and Ford, the things, like air conditioners. According to the C-Max? I’ll be honest with you, there pickup or truck, as it’s known here, is a has been a definite big shift in the US the long range weather forecast, that’s all large profit earner and volume mover. I’m going to change very soon. I hope they’re towards fuel economy vehicles, but GM sure both will be sweating on the model recently had to temporarily shut down right! changes turning heads. production of the Chevrolet Volt because The news in the US that will bring a smile Fiat will be pushing further into Chrysler there were too many sitting on dealers’ to most Australians, is that General Motors in 2014 with their models starting to be lots. Sure, price has something to do with has finally announced a new model with rebadged. The pickup and commercial it, but have the Big Three yet convinced the Chevrolet brand. The Chevrolet SS segment are the first to be infused with the general public that these are as is a rear-wheel drive, four-door sedan, Fiats. Ford has announced that the C-Max reliable as the car they already have in powered by a V8. is ready for orders. their driveway?

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Phone 03 9416 7077 Fax 03 9416 7096 email [email protected] urphy’s Bring back the good old days and the good old thinking M rely on constant depression to raise the dash to an air leak by richening the mixture. This Law pot piston. This in turn changes the shape of will cause the RPM to increase and the idle the needle in the main jet. Without this, the air control will try to bring the RPM back to air to fuel ratio will be adversely affected. the desired idle level. with Nick Murphy The carburetors for the E type had to be When an engine’s RPM decreases below removed and rebuilt. This is something I like the desired idle, the ECU overcompensates, to do in-house as it keeps me in touch with causing the engine to idle higher through one are the days where fixing a the past, and in control of the job. Doing one the idle air control. In some extreme cases, car with an engine problem was a carby is bad enough, so doing four the RPM will increase so much Gsimple task. becomes a big task – new that the ECU will see the How things have changed. Now an engine spindles and butterflies, increase with the throttle problem can be caused by almost anything. pressing out the main closed, treating the Even the transmission can impact on the jet and replacing way it runs. it, replacing the circumstances needle and seats, as overrun and These days the first thing a technician replacing the shouting the does is connect the scan tool and see what diaphragms and, injectors off. trouble codes appear. If there is nothing of course, cleaning logged it can become a laborious task, The carburetor days everything. checking and rechecking without a result. may be behind us, However, it is very So what has really changed then? Life as a but not the reciprocating satisfying to take on a job technician has become harder that’s what! engine. The engine still needs that requires so much attention, Carburettor There are a lot more things that can go fuel, spark and air. Refining the way and of course you get to do the test drive at wrong these days. these elements are delivered has been a the end of it! progressive path over the years. When I serviced a 1972 E type V12 recently What have we learned from the days when people were commenting on how hard it Remember the Ford XF? It had a very basic we had no highly sophisticated equipment to must be to work on older cars these system, but it worked. help us deal with problems? days. But, it is only an engine with carburetors. Sadly, it seems we have learned more about the way electronics work and I initially thought the car had an forgotten that the engine still operates ignition fault, because of the misfire in the same way. on throttle response. However, after hooking up the oscilloscope to check When you think about it, at least the secondary ignition, I confirmed 50 per cent of problems we that was not the problem. deal with are mechanical. How do you check if the fuel is a problem? Low compression can create The gas analyser will confirm what the low air speed – this can Injector A late model Commodore emissions are doing, although dealing with cause an engine to run lean multiple cylinders can be difficult, particularly as the airflow meter sends a with a V12. A lean misfire can give the same low signal back to the ECU. With no trimming device and an ECU impression as a faulty ignition system – it Low vacuum can cause an array of that had no way to compensate for takes a lot more energy to deliver a spark problems, mainly with manifold absolute shortcomings, if the XF had an air leak across the gap of a spark plug when the pressure (MAP) sensors – a low vacuum (even through the rear main seal), the mixture is lean. reading will result in a rich reading from the engine would run rough. With the addition MAP sensor. Low vacuum can also be the With a modern system the ignition has a lot of variable valve timing and variable cam lift more energy, so a lean misfire is a lot less cause of valve timing, variable valve timing (combined with multiple valves) the engine evident. correction and low swept volume. has become a highly technical device. A mechanical problem can be masked by a Today’s engine computers are capable of Engine oils running at correct temperatures very efficient engine management system. overcoming small faults and will adjust the have become critical for the modern engine. fuel trim to suit. A carburetor simply can’t do For example, exhaust blockages might this. not be a mechanical fault but can cause A correct diagnosis is based on the path you choose. Remember that sometimes In the case of the E type, the CD strombergs similar problems – including back pressure (reducing airflow) and air speed through the basics can be overlooked. This tends to the inlet manifold. Blocked air filters have make your diagnosis harder. the same effect, with the higher vacuum The condition of the engine should play under load causing the MAP to give a richer a big part – checking the oil, vacuum and reading to the ECU. even engine noises first can lead to an Manifold air leaks, causing engine misfires, early decision. I don’t know how many lean readings and rough idling, have been times I have been caught out though, not to one of the most misunderstood problems for mention my colleagues! the mechanic. These days I tend to go for the basics first, A closed loop fuel trim with an air leak can but it hasn’t always been that way. overcompensate with the idle air control Happy diagnoses V12 Jaguar engine valve. Hunting and erratic throttle responses are typical of air leaks. An ECU will respond Nick Murphy The Automotive Technician 27 No Future? Or Bright Future?

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BCS A4 TAT Ad Mechanic.indd 1 7/07/11 1:37 PM So I guess the condenser (Great work Peter. We have YOU was playing games with me seen many cases where there No Future? Or Bright Future? Older vehicles will often because, at first, everything is more than one problem, SAID seemed to work but later did especially in older vehicles that IT! have multiple symtoms not want to work. may not have been looked after as well as they should have been. he car would drive and it seemed to be a main The ECU was damaged in two Always remember to inform your normally but after power feed to the injectors, spots – one was the leaking customers that you have found being switched off, it distributor, a/c system and capacitor and the other was a a problem, but that may not be Trefused to start. ECU. I unplugged everything burnt track which happened the end of the issues. You won’t while checking to see if the to be where the white wire/red know until you repair that problem I was called out on a Sunday trace went in. and retest. TaT has covered that

short went away. Camry 5S-FE 2.2 ltr 1994 Toyota afternoon and there condenser problem in TaT’s a It took three hours for this job. were some international The only thing left was the fact TOYCA93112 on our web Now I can sleep at night. students who just kept ECU. I unplugged that and site. We are currently working on cranking the engine the short went away. Opening Peter Hinds on improvements to our systems till it could crank no more. up the ECU I found a leaking Brisbane mobile mechanics including the TaT’s a fact data I tried to start it with jumper capacitor as well as other BRISBANE QLD base to make these problems leads and sure enough it damage. easier to find. Jeff Smit) cranked over, but wouldn’t The students of course now fire. expected a two dollar fix for The first thing I noticed was their five dollar car. no check engine lamp, A reasonable second- no spark or injector hand ECU was located pulse and no scan tool and fitted. The fuse communication. The fuses under the bonnet was fixed but the car were all OK. Under still would not start. the dash I found a 7.5 Somebody had left the amp fuse blown. The distributor unplugged Didn’t become a replacement fuse also in the dark. MECHANIC to do blew as soon as the key was But when it was plugged in – PAPERWORK? turned on. ...let Capricorn bang – blown fuse yet again. I make your life This fuse goes to the ignition pulled out the distributor again a lot easier. switch and then out to a white and retested. This time there wire with a red trace. I noticed was no spark. the same wire at the distributor so I removed it as I wanted to try my new toy, the ignition consolidated monthly billing | access to a vast tester. supplier network | instant credit | exclusive rewards Are you; Joining the Bosch Car Service Network can help Everything worked and I had program | busines protection equipment finance and MUCH more... • Keeping pace with technology? you fill the gaps in your current business model spark as well as two signals from the crank angle and top Capricorn helps people in the automotive industry save time and • Accessing world class technical training? and put you in touch with a rapidly growing dead centre sensor. There was money. We’re a key player in the automotive parts buying sector still the short on the same wire. with the power of more than 14,000 members across Australia, New • Improving business practices? network of like-minded professionals. Zealand and South Africa. Best of all we’re owned by our members Being a Sunday afternoon so they share in our success. • Getting support with technical issues? in the hot sun with no wiring Want to know how we can make your life easier? Ask us now www.capricorn.coop • Supported by a strong brand? With 15,000 workshops worldwide the Bosch diagram and the students Looking right in the bottom looking over my shoulder, I left of the distributor I found a • Utilising the latest diagnostic equipment? Service Network is clearly doing something right. it at that and had the car towed condenser that appeared to my workshop. www.capricorn.coop to have melted. After After acquiring a wiring replacement, the car finally Capricorn Society Limited - Registered under the Corporations Act 2001 ACN 008 347 313 diagram I traced this wire started.

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BCS A4 TAT Ad Mechanic.indd 1 7/07/11 1:37 PM YOU SAID Fixing it is one thing – ‘why’ is another IT! problem was confirmed. A new alternator was Alternator connected - short light on his case study may look easy, but it fitted, the circuit was again tested for a short required a correct diagnosis, more and it was OK. so because the parts were very Next a new main fuse block assembly was Texpensive. fitted, with all connections swapped over The vehicle was a Toyota Hilux 10/2006, carefully. The codes were checked with a KUN26 with 146,031 km on the clock and a scan tool and none were found. 1KD-FTV turbo diesel engine. Alternator disconnected 2006 Toyota Hilux 2006 Toyota The engine was started and the systems The problem was a major electrical one – tested OK. However, I found the alternator basically nothing worked on the car. output was 36 amps at idle with no The engine would run and the headlights accessories on and about 70 amps with some worked, but that’s about it. No parkers, brake accessories running. lights, radio or a/c and the ‘check engine’, ABS and 4WD lights were on all the time. This vehicle had two batteries and although both batteries had been tested and checked I performed the basic checks of lights, fuses, battery connections and charge rate. No lights out OK, I decided to properly charge both to were working except headlights and almost make sure there was no other problem that all fuses in the fuse box near the steering caused the alternator to fault in the first place. column had no power to them. The battery After charging both batteries, the alternator connections were OK but the battery was not charging. output was down to about 9 amps at idle with no accessories on, which is a much better The fuse box under the bonnet was checked reading. next, and there it was found that the main 100 amp fuse or breaker was blown for the The car was road tested and all was OK. alternator circuit. As the pictures show, the fuse block is a complete assembly, with all Time taken was approximately 2.5 hours. fuses joined together. The one question I really wanted answered Power was entering the fuse box, but the was why the alternator faulted in the first circuit was open to the alternator main wire. place. I asked the customer many questions about how this problem first occurred, but I connected up a short light between the open circuit and found a short on that circuit. I nothing was obvious. The only thing that was recommend that a short light not be used on a unusual was that this vehicle was used to circuit this big with a lot of load – I did not run attempt to jump start a stranded turbo diesel the engine or accessories. Prado the week before. The Prado wouldn’t Because the blown fuse was marked ‘100 amp start, so the Hilux had been used for jump ALT’, that’s where I decided to start looking starting for some minutes, all to no avail. Did for the short. With the short light connected this contribute to the problem? I don’t know. I and on, I disconnected the main wire on the have yet to strip the alternator and look inside. alternator and the short light went out. This is not the first time I have fitted a new This indicated a possible short in the alternator to find the current output a bit high, alternator. That wire and the other wires to the even when the batteries test OK. From now alternator were checked for damage but all on I will just charge the battery anyway to checked out OK. avoid the high output, especially with calcium At this stage I was sure it was an alternator type batteries. problem, but just to be on the safe side, and because the parts were going to be very Jason Smith expensive, I decided to send in a TaT assist JDS Automotive just to get a second opinion and to make sure MOOROOLBARK VIC New alternator fitted - short light off I hadn’t missed anything. TaT assist director Deyan Barrie agreed Broken fuse in the fuse block with my diagnosis and also gave me a tip to test the alternator when I had removed it. When I did that and tested it for Close up of the blown circuit The short light off Connections for the short light a dead short the The Automotive Technician 30 ONE WORKSHOP. ONE ATF.

The Automotive Technician 31 train training division 2012 Business training calendar

he Capricorn/Tat Biz business training program for 2012 begins in June, with a planned rollout of 44 evening workshops across Australia and New Zealand. TTaT Biz trainer Geoff Mutton has devised a brand new course, called Maximising Labour Output, in which he addresses the fact that under-performing and disengaged staff cost businesses thousands of dollars every year. For full details phone your local Capricorn area team or visit www.capricorn.coop

Zone Date Location QLD 8 Aug Maroochydore WA 27 Sept Victoria Park NZ 18 June Kamo, Whangarei QLD 9 Aug Brisbane, Northside WA 28 Sept Victoria Park NZ 19 June Hobsonville, Auckland QLD 21 Aug Brisbane, Southside NZ 15 Oct South Island, TBA NZ 20 June Ellerslie, Auckland QLD 22 Aug Toowoomba NZ 16 Oct South Island, TBA NZ 21 June Hamilton West, Hamilton QLD 23 Aug Tweed Heads NZ 17 Oct South Island, TBA VIC 3 July Preston SA 28 Aug Stepney NZ 18 Oct South Island, TBA TAS 4 July Bellerive SA 29 Aug Mawson Lakes NSW 24 Oct Bathurst VIC 10 July Ballarat SA 30 Aug Glenelg NSW 25 Oct Liverpool VIC 11 July Bendigo WA 4 Sept Albany NSW 30 Oct Canberra VIC 12 July Albury WA 5 Sept Bunbury NSW 31 Oct Wagga Wagga VIC 17 July Frankston WA 6 Sept Mandurah QLD 13 Nov Mackay VIC 18 July Moorabbin NZ 10 Sept North Island, TBA QLD 14 Nov Townsville VIC 19 July Dorset Gardens NZ 11 Sept North Island, TBA QLD 15 Nov Cairns QLD 6 Aug Bundaberg NZ 12 Sept North Island, TBA NSW 20 Nov Lismore QLD 7 Aug Hervey Bay NZ 13 Sept North Island, TBA NSW 21 Nov Maitland

TaT Biz Training Dates Booking Australia - Call Nicola Pine 1800 EASIER (327 437) or email [email protected] New Zealand – Call 0800 401 44

For the training night calendar and registration forms go to www. AutoPartners training autopartners.com.au or call 1300 650 048 Technicians should keep their eyes peeled for the AutoPartners Brands interested in taking part should also make contact. free training nights, where automotive experts give informative presentations covering a range of brands and parts, including Monroe, EXEDY, Champion, Ferodo, Fuelmiser, Tecalemit and SuperPro. This year’s events will be held at some great locations including Herrod Motorsport, Lucas Dumbrell Racing and Team Bray Racing. Technicians will have a rare opportunity to check out some impressive workshops and meet with racing celebrities. The nights are fun and engaging, and it’s easy for mechanics to learn about new or improved products.

understand that unless the team hours are getting billed to Business training the customers, their wages are being paid out of profit, or the earns praise owner’s own pocket,’ the audience was told. Among the many strategies suggested, the setting of labour TaT Biz trainers Geoff Mutton and Jeff Smit ‘road tested’ revenue targets was considered essential before any other the 2012 training series, 9 steps to a better workshop, moves were adopted to achieve 100 per cent of the business’s during May’s Capricorn Convention at Club Med in Phuket, potential. Thailand. Capricorn members should get in touch with their area manager Over two intensive days, the duo did a reprise of the 9 steps for more details and a registration form. introduction of 2011 followed by a comprehensive session based on maximising labour output. This course will be rolled out in 2012, beginning in New Zealand in mid-June and then continuing around Australia. Workshop owners who attended the Phuket training praised the labour output course, with a near perfect 10-out-of-10 score, and suggested that the TaT Biz trainers consider more courses related to staff recruitment, benchmarking and training just for staff members. The trainers stressed that labour in a workshop is the main commodity bought and sold. To generate a fair return on investment, the return on labour needed to be maximised. Not only was maximising labour output a mind-shift for the business owner, but a wake-up call for the team members in the workshop. ‘In the final analysis, workshop owners need to clearly

The Automotive Technician 32 customising our car space to suit our Click goes the individual needs and comforts? handbag, click, STREET I searched the Automotive Interiors Expo website for a picture or story on what I click, click! believe is an essential in the modern car – CRED a cockpit with handbag space. ho would have thought it — an To my disappointment, it looks as though exhibition devoted entirely with Hayley Windsor they’ve not yet cottoned on to the to design concepts and demands of the industry’s fastest-growing Waccessories inside the cabin of the car. customer group, the females. From speaker systems to fastening motorist a say at a mini-expo where the Here’s another good idea. How about an systems, sat navs to floor mats, the public can make suggestions and air their online drop down menu for the popular Automotive Interiors Expo in Germany is in-car frustrations. brands, where, with the click of the mouse, where our future in-car experience and we can customise our personal space in environment is created. We love to personalise our lives – our the cabin. homes and gardens, ourselves and I’ve done a few columns on car ‘Click’ and a handbag hook is added. our possessions. Our houses can be accessorising in the past, but this takes ‘Click’ and a cup holder is added. ‘Click’ personalised from scratch, of course, and the internal design possibilities to another and empty spaces have storage options, level – or at least it would if it were open even those within a standard housing for my handbag. to the general public. It’s a closed shop for estate usually get a choice of colour car designers, manufacturers and interior scheme and curtains to distinguish them You could click your way through the upholstery design and colour, add a waste suppliers. from the neighbours. bin and finally ‘submit’ and your request But why leave all the design detail to Many of us spend a lot of our time in the goes to the production line. Customer these so-called experts? Why not give the car so why can’t we have more say about satisfaction guaranteed!

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The Automotive Technician 33 of the piezoelectric sensor signal in order to adapt to a variety of with Jeff Smit engines and measurement conditions. The tool is supplied with a 1.8 metre long sensor cable and universal piezoelectric sensor clamp suitable for one-quarter inch and 6 mm diameter fuel injection lines. Other sizes of piezoelectric sensor clamps are also available. TA300 Smart Tach TA300 features: • For 1 to 12 cylinders and 2 or 4 cycle engines otorists are embracing diesel powered cars at a fast pace, so quickly in fact that the time has arrived when • Measures from 200 to 20,000 RPM on a 4.5 digits LCD the average aftermarket workshop will need all the display helpM it can get to properly diagnose problems, even in older • Advanced microcontroller technology yields 0.1 per type diesel vehicles. cent accuracy One common issue with working on some diesel engines is how • Universal transducer clamp attaches quickly to fuel to determine the engine RPM. This is where the TA300 can come injection lines in very handy. • 1.8 metre cable allows RPM readings to be taken well The TA300 is a tachometer specially designed for use on diesel away from hot or moving parts in the engine engines equipped with fuel injection pump and individual fuel • User adjustable signal threshold level from 20 per cent injection lines. It uses a piezoelectric transducer clamp which is to 80 per cent placed on one of the fuel lines for sensing • 10 levels of user adjustable signal sensitivity the pulses caused Simple and easy to use by the surge of fuel pressure inside. It • Tachometer – place the piezoelectric sensor on a fuel then uses these injection line of the diesel engine pulses to measure the • Minimum and maximum display – two secondary RPM of the engine. displays show in real time the maximum and minimum readings For maximum flexibility, the TA300 • Adjustable threshold and sensitivity level – allow for allows the user to compensation of weak or noisy signal adjust the sensitivity AD_AUS_MAY12_TAT:AD_AUS_MAY12_TAT_HPand 24/05/2012 threshold level 09:59 Page Durst1 industries 02 9660 1755 www.durst.com.au

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The Automotive Technician 34 agle-eyed Cooldrive Tasmania branch Some manager, Mark Lynch, took this pic in a Tasmanian workshop, which shall remain technicians Enameless to protect its stupidity. ‘Worse still,’ said Mark, ‘is that I had to actually explain will never to the tech working on the car what the problem was.’ Said TaT technical director Jeff Smit, ‘It’s hard to believe that with the current licensing system in place, learn a vehicle like this could be on the road and that a so- called licensed technician could do something so very wrong.’ For those readers not familiar with vehicle air conditioning, the problem was that the accumulator has both a low side and a high side fitting attached to it which makes servicing this air conditioning system impossible.

TORSION DAMPERS ON THE FARM

any technicians servicing drive train under all operating conditions, agricultural mobile machinery including engine idling, full load and during incorrectly diagnose torsion over-running. damperM problems as faults within the gearbox, but, after the gearbox is removed, Simple axial dampers use a series of small it becomes clear that the torsion damper coil springs mounted within a clutch disc needs to be replaced. centre which are compressed by each torque peak to smoothen the torque flow into the Schaeffler says many workshops are unaware transmission. The use of two or three different that LuK torsion dampers, or powershift strengths of springs services the full torque dampers, commonly fitted to tractors, are a output of the engine between idling and full service item with a scheduled service life so engine output. This type of damper frequently they require regular replacement. has an articulation between 10 and 25 Torsion dampers are designed to reduce degrees. At the other end of the scale is the torsional vibration between the engine and long travel damper which uses arc springs to the transmission while maintaining engine provide exceptional damping ability under all inertia and strong power output through the operating conditions. This damper design is transmission system. particularly suited to higher powered engines LuK engineers have designed application and can have an articulation in excess of 40 specific torsion dampers that are a part of degrees. the clutch disc or, in the case of clutchless Schaeffler recommends that repairers should transmissions, mounted directly into the always check the condition and service life flywheel. timeframe of torsion or power shift dampers These torsion dampers are able to ‘damp out’ before sending customers back to dealers. all of the torque peaks, thereby eliminating Pierre Marshall, Manager Automotive 1300 excitation in the transmission. The genius 585 462 of the LuK design is that the torsion damper must be able to eliminate excitation in the [email protected]

The Automotive Technician 35

Dayco’s out to belt Don’t mask odours – the squeals, squeaks kill them and chirps verybody knows that if a cat pees in your car, the smell will linger for a long time. Now there’s a new ayco claims its new W odour-eating product which will absorb the stench Profile Poly-Rib engine Eof cat’s pee and every other noxious smell. belt is one of the most The ClenAir products, in tubs and sprays, are based on a Dinnovative advancements in proprietary blend of activated carbon, capable of removing engine belt design for the past 25 volatile organic compounds and pollutants. years. Importers, Supercool Asia Pacific, were drawn to the product The company says its patented design ensures the belt remains because of its ease of handling on the job as well as its stable and accurate over a longer service life and imperative abilities to convert the most pungent of smells into clean air. to maintain the silent, responsive and economical performance The tubs are simply uncovered and placed inside air handlers required in modern day engines and their auxiliary systems. or return ducts in air conditioning systems in homes, offices Because there is no single engine belt design that will work and apartment blocks. For a vehicle, mini tubs can be slid with every application, the Dayco belts have been designed under the seat to do their silent air cleaning work. specifically around each application’s drive system. The ClenAir gel formula treats This new design has been developed and tested to deal with all internal air by reacting with common aftermarket application issues such as ‘squeals’ caused the airborne odour-causing by relative slip between the engine belt and a pulley, ‘squeaks’ compounds and other pollutants caused by a momentary slip and ‘chirps’ caused by the relative on a molecular level and misalignment by pulleys in a drive system. eliminating them. Dayco’s initial range of W Profile Poly-Rib engine belts covers SuperCool has tested a tub on almost 300 vehicle applications for Holden, Toyota, Mitsubishi cat’s urine and has an enthusiastic and Nissan models that have problem noisy drives. testimonial to prove that it actually does work. Repairers also have access to Dayco’s Engine Belt Wear Awareness Gauge that allows them to check engine belt wear ClenAir is available through Actrol levels and recommend replacements when necessary. These Parts outlets. gauges are available from Dayco distributors nationwide. [email protected] PC-VCi Wireless Diagnostics

• Australian, Asian and European coverage • Automatic software updates • Order parts and information at the engine bay • Wireless vehicle connection • Integrated speakers and 180° swivel camera • Semi-ruggedised • Water resistant • Internet connectivity • Up to 8 hour battery life • 10.1” touch screen Web Parts and Data Optional • Wireless OTC (4/5) gas analyser • Wireless OTC smokemeter • USB OTC 2 channel scope Phone for a free demo

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The Automotive Technician 36 Gates simplifies its part numbering system

n a move to simplify the identification process for timing system components, Gates Australia has changed the part numbering system for its Timing IComponent Kit (TCK) program. The new system helps buyers to indentify the right kit for each application, as they more closely reflect the numbers of the timing belts included in each kit. For example, part number VKMA91003S has been changed to TCK199, and the timing belt in this kit is T199. This helps to quickly identify the components included in each kit. Suffix characters are used to identify any additional components. For example, H = Hydraulic Tensioner, WP = Water Pump, SF = Stretch Fit Belts. In cases where timing belts are used in multiple applications and kits, there will be a suffix of A, B, or C preceding the TCK Gates Customer Service 03 9797 9688 number. [email protected]

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The Automotive Technician 37 Communication is the key ‘s interesting by Geoff Mutton The New products and equipment for the auto industry level of customer service you provide will 1. Gates pumps out new 4. New motorsport lubricant determine how catalogue 1. range many of your customers will return to your business. And Gates has released its latest Motul has launched a new range a key part of customer service is water pump catalogue, of 300V motorsport oils that communication. featuring 730 new applications. combine synthetic base oils with Included are images of major premium chemical compounds. If your communication is effective, you will consolidate the customer’s products and a cross-reference Eight formulations are on offer, perception that they received value section for easy identification featuring two new viscosities – for money in your workshop. How you and replacement. To download a super fine OW15 for power communicate will have more of an a PDF version of the catalogue potential and OW40 for power impact on a customer’s satisfaction visit www.gatesaustralia. with reliability. Available through level than the actual repair or service work. The industry needs to understand com.au/autocatalogues Autobarn, Repco that giving a discount, no matter how or email and major large, will not make up for bad customer southpacsales@ automotive service. gates.com for a hard workshops. Communication is the only way to sell copy. 5. Show your workmanship to your customers. 2. Narva shows us off your To ensure the biggest return for your efforts, you must inform your customer the light 2. tools as much as possible about the work Narva has released its Kincrome has undertaken. Most customers are totally unaware of the extent of work you Model 34 and 36 trailer launched its new do during a service or during a more slimline LED lamps in 9-33V multi- 3. starter range of complex repair. voltage format. Featuring Contour tool kits. tough polycarbonate These are the critical communication Available in four stages: lenses, stop and tail light colours, the kits indicators, direction 1. Car drop-off – confirm the expected step away from the indicators and pick up time and the scope of repairs traditional square- and ask if there are any specific areas retro reflectors, edge toolbox of concern the 24 mm deep design and feature lamps come with Explain to the customer the diagnosis contoured lined stainless steel and repair process so they have a drawers, chamfered clear understanding of what is going to screws and angular sides and happen a five-year heavy duty plastic warranty. 2. Sales call – after confirming with 5. tops. your customer what is going to happen, They are always follow it through. If you say you also fitted with 0.5 Designed in Australia, the will ring by 1pm, make sure you do. metres of hard-wired tinned cable to keep kits are aimed at the trade You will plant seeds of mistrust in the out dust and water. The new lamps are ideal professional or enthusiast looking for a customer’s mind if you don’t call when for boats, trailers and campervans and are ‘stylish’ storage or tool kit solution. you said you were going to call. So you available from leading automotive, transport need to confirm: The Kincrome range is available from and marine outlets. • the repairs to be carried out automotive, hardware and industrial stores. 3. New drive belt tool helps relieve www.kincrome.com.au • the total cost tension HELLA Australia is now an original • time of completion Optibelt has released a mounting tool equipment supplier to Proton Cars 3. Vehicle pickup - If you have that allows trouble free installation of new Malaysia. covered everything in the sale call, the generation elastic EPK ribbed drive belts. pickup should go without a problem. It already has decades of experience If not properly tensioned, the belt can be You need to ensure that their invoice supplying all three Australian car makers is prepared and ready for them. The severely compromised, causing premature – Toyota, Ford and Holden and their invoice should always include all the failure. According to Optibelt, the mounting predecessors – with headlights, rear lamps repairs undertaken and cover everything tool allows these tightly tensioned belts discussed during the phone calls. and a range of other lighting products. to be fitted with ease, avoiding possible Always offer to go through the invoice HELLA has invested heavily in its Australian damage to the sensitive tie beam. with them and show them any replaced manufacturing capabilities. Founded in or damaged parts. [email protected] 1899, the privately owned German company As a rule of thumb if your customers operates in more than 100 countries. are calling you to find out what is going on with their vehicle then your 4. communication is poor and I can guarantee they are getting frustrated with your service. So get on the phone and start keeping your customers in the loop on the progress of work on their vehicle. More tips and tricks next issue. The Automotive Technician 38 The Automotive Technician 39 Quality on hand through the generations.

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