Tech Fuel October 2016 • Issue 53 www.tat.net.au Spotlight injection • Engine management • Cooling systems

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chnic e THE ia t n y INDEPENDENT s NETWORK Golf BMW Jag Ford Astra b • • • • • f o s r n Lock stock Cut and run In the dark Off balance Highly spun t ia echnic The Power of Knowledge

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Get the competitive Get the competitive edge and use Capricorn edge and use Capricorn Service Data today. Vehicle Videos today. capricorn.coop/servicedata capricorn.coop/vehiclevideos Regular readers will have noticed more and more TaT share stories creeping into our UP FRONT pages. This is going to increase next year with Ken Newton and you can expect to see a number of The Power other changes as well. he new TaT website and its You know how our technical writers are associated App is attracting a always saying, ‘Get back to the basics’. lot of attention if the number of Well that’s what this magazine intends to of Knowledge TaT shares is any guide. do, starting with the first edition in January WeT purposely designed the site to make 2017. it easier for technicians to tell their own In the fast-changing world of automotive service and TaT always intended to be a source of stories about fixes that worked well for technical know-how and stories that tell repair, knowledge is now one of your most powerful them. how problems are solved every day in tools. As we said from the beginning, TaT is all the workshop. The readership survey we about sharing of information, in an informal, conducted in 2015 showed beyond doubt Introducing two exclusive Member benefits: non-judgemental manner. that our readers crave such stories. We are sourcing technical writers in various We encourage readers, TaT member or Capricorn Service Data We don’t profess to be the ultimate gurus, but if you have been reading our technical aspects of engine management and the not, to submit their favourite fixes, repair Capricorn Vehicle Videos stories, you would have to admit we do drivetrain to augment our great TaT Tech stories, even horror stories. Never think that have some bright sparks among us. Team, and our pages are going to be filled what you write about might be common with new and interesting features covering knowledge. Somewhere in Australia or the whole vehicle. New Zealand, a reader will look at your contribution and say, ‘so that’s how One of TaT’s prime products, the it’s done’. If you help one person, your TaT’s a facts will cover more pages contribution will have been worthwhile. in the new year. You can make TaT the greatest resource These easy to follow case studies, network in the land, just by sharing your collected from TaT research ideas, your opinions, and your fixes. workshops and sent in by TaT members, are contained in a huge The technician you will help today will one online library that can be accessed day help you. Isn’t that the best kind of by TaT members. network there is?

THE TAT TEAM • TaTassist • Tat share • TaT train CONTENTS • TaT’s a fact • Tips for TaT Data and information……………………….4 Publisher Wayne Broady • TaT Biz • TaT check • TaT find Tea Gardens is the workshop of the future…5 The Automotive Technician Benjamin Perry Service know-how for Share technical knowledge are all registered trade names of So, what’s next?……………………………..7 Pty Ltd Faulty clockspring kept the light on………8 ABN 27 121 589 802 Columnists The Automotive Technician The plug wasn’t glowing……………………8 thousands of vehicles. with your customers. 30 Dale Street Julian Hentze – Georgia USA Pty Ltd Transmission limp modes in Magnas…….8 BROOKVALE NSW 2100 Geoff Mutton (Business) The fuel filter fixer almost meets his match..10 [email protected] The Automotive Technician Pty Ltd publishes Sealed unit bearing replacement…………11 Reader 1300 828 000 technical advice and actual case studies for Tumble valve system operation…………12 Bron Robinson Capricorn Service Data gives you instant access Capricorn Vehicle Videos clearly explains common Fax 1300 828 100 the purpose of educating technicians. Does a classier title allow you to the most comprehensive range of online service mechanical problems and procedures. When your Editor in chief Advertising inquiries These advices are given in good faith, and to put up your prices?……………………..14 are based on actual workshop repairs. No information covering thousands of vehicles. customers understand the reasons behind a service Ken Newton Janene Champion A good word for diesels…………………15 guarantee is given, nor any liability accepted in The Autodocta – Rear suspension noise…16 [email protected] [email protected] or repair, they’re more likely to spend the money respect to any published advice. Uni tests favour the genuine article………16 0438 569 517 03 5862 3090 Powered by Autodata’s unmatched required. Fax 1300 828 100 The Automotive Technician Pty Ltd is not Top tools G-Scan 2 multi-function tool……18 0403 226 770 responsible for the accuracy of any information Time, gentlemen and ladies, please…….20 coverage Technical editor contained in material submitted by third parties Are cars really just new age gadgets?…21 Graphic design Professionally-produced animations for the Jeff Smit and published in this magazine and accepts TaT’s Interesting……………………………22 Support the service and maintenance of Russell Jones Graphic Design [email protected] no liability in relation to such materials or their TaT’s a facts………………………………..23 automotive industry 0411 817 012 almost any vehicle in line with manufacturers’ 1300 828 000 content. TaT train…………………………………….29 warranty requirements Wide range of topics including engine, [email protected] Newsworthy articles or comments are USB kills the car……………………………29 Technical research www.rjgd.com.au steering system, suspension system, welcomed, and should be submitted to the Capricorn expands tech service…………30 Content delivery that is fast, easy and Deyan Barrie editor in chief. Drive your car off the production line……30 Printing tyres and automatic transmission [email protected] Waveform of Holden ethanol blend sensor.32 accurate McPherson’s Printing Group All material appearing in The Automotive Technician is copyright. Reproduction in whole Brake discs – is lighter better?…………34 Access videos any time on a computer, TaTassist traffic manager 76 Nelson St Repair time estimates and calculator Alex Cowie or in part is illegal without prior written consent Burson Top Tech Tip………………………35 for more accurate quotes laptop or tablet Maryborough VIC 3465 from the editor in chief. Letter from America……………………….36 www.mcphersonsprinting. Technical advisers All advertisers agree to indemnify the Toyota recalls the 89………………………38 Jack Stepanian com.au publisher for all damages or liabilities arising It’s here – UBER with no driver…………38 Sam Nazarian from their published or unpublished material. On your keyboards for a bug bounty……38 Gil Sher Affiliated associations Another fuel filter quirk……………………39 VASA – [email protected] A glow plug warning………………………41 Jason Smith The Automotive Technician is a member of the Anthony Tydd AAAA – [email protected] Circulations Audit Board. An investigation of an engine running rich..42 Capricorn Society Alliance Diagnostics can be a snap………………43 Rod Maher Audit period 1 October 2015 to 31 March 2016 Maurice Donovan Supplier Average net distribution 9,944 So who did the cop give the ticket to?…43 Get the competitive Get the competitive Video to combat ignorance edge and use Capricorn edge and use Capricorn about brake fluid…………………………..45 New batteries sealed and no maintenance.45 Service Data today. Vehicle Videos today. Potholes can cause much capricorn.coop/servicedata capricorn.coop/vehiclevideos more damage than you think………………45 Business training – turn on your headlights.46

The Automotive Technician 3 Data and information

Your most valuable spare part by Jeff Smit

ata and information have become the most valuable Good data also helps technicians on the floor to be more efficient spare parts in every aftermarket workshop. and productive – the less time wasted chasing information the D better. Sophisticated electronic systems can’t be diagnosed or repaired without both of those tools. But like any good tool set, there’s a cost attached to data and information. Data is needed for basic wheel bearing torque settings through to complex wiring diagrams for an engine electronic control module. Many workshop owners have come to realise that there are levels of data cost. The better the data, the higher the cost. It’s the Here are some of the everyday workshop repair same for all products. and service chores that once might have been done instinctively, but now can’t be attempted without The costs begin to add up in medium size workshops that find they will need to tap into more than one source to buy data and qualified data. information. But there is a perfectly logical way for workshops to recover Service – service schedules, illustrations, indicator these costs, and to generate a fund for future financing of data reset procedures, brake pad replacement procedures, air and specialised tools. conditioning information Think of data and information as products that are on the shelf Body and interior – airbag systems, key programming and on-sold to the customer. Oils and filters are charged out on Chassis – anti-lock brake systems, wheel alignment, tyre invoices without a murmur of concern from the customers. This is pressures, electric parking brake, tyre pressure monitoring quite legitimate. So data and information should also be listed as systems two parts that are required to service and repair vehicles. Powertrain – engine management, camshaft drive systems, Most workshops have adopted the notion of including scan tool auxiliary drive belts, clutches fees on invoices and, since scan tools are now required to begin the vast majority of diagnostic work, a small fee on every invoice General – technical specifications, repair times, known will mount up over a year, enabling the workshop to cover its fixes and bulletins, VIN plate location, warning lamps and updates and buy new scan tools without breaking the bank. symbols. There’s a story on the Autodata website that bears Electrical – battery disconnection and reconnection procedures, coloured wiring diagrams, diagnostic trouble repeating for those who might need more convincing codes, electrical component locations. for data acquisition and to justify data fees. ‘Since Ben commenced subscribing to Autodata in 2005 he Things to consider when looking for a data or information has never had a problem with data issues. Information is simply provider could include how the information is accessed, a mouse click away. On every invoice that Ben produces, he consistency of information layout and the extent of coverage includes a $2 data fee to offset the cost of his subscription of vehicles worldwide. It would be important to know how the to Autodata. Ben quickly worked out that if he didn’t have information is collected by the provider, and the extent of their immediate access to data, the time spent searching for it would world coverage. end up on the customer’s invoice as labour. Ben knew of other workshops that spent up to an hour searching the internet for The reason for the emphasis on coverage should be obvious. The information. If the average workshop was charging out labour at cars reaching Australia are, or soon will be, from somewhere else $80 per hour what would the customer think if that appeared on in the world. In fact, the majority of cars sold in Australia originate their invoice? in at least five other continents. ‘By charging a small data fee on each invoice, Ben is offsetting Probably the most critical area is that of support and updates. the cost of his subscription while being able to keep his labour With speed the driver of most business these days, technicians rates acceptable to his customers. He saw it as a win-win need to know the level and speed of support, and whether it is by situation, for himself and his customers. And he has never had phone, email or through internet portals. one customer question it. Those workshops that tap into the well of good data and ‘The other key to Ben’s success with charging a data fee is the information are in a far better position to take on more, and fact that he attaches printouts of the information he used for perhaps a bigger variety of, vehicles and to retain more repair the repair to the customer’s invoice, helping the customer to work in-house. understand what had to be done, and to appreciate the value.’ The Automotive Technician 4 Cover Story TEA GARDENS IS THE WORKSHOP OF THE FUTURE

he owners of Tea Gardens workshop. It doesn’t just look good, but ‘This is indeed the workshop of the Auto Electrics and it incorporates the best technologies, the future, and is a blueprint for the kind of Mechanical, Rod and best tools and is backed by the best data establishment that will be able to go head Melissa Blanch, are setting and knowledge services that money can to head with the dealership sector, and an aftermarket workshop buy. win public confidence in the aftermarket Tstandard that they believe will be services.’ mimimum to Rod and his staff survive, probably of six are already less than five years winning public from now. confidence and it Rod knows he shows on their daily is in competition job lists. with new car The staff are so proud dealerships, and his of the workshop, that long term mission they regularly invite is to ‘out-deal the customers in to the dealerships’. otherwise ‘out of He forecasts bounds’ workshop, to massive changes in discuss a repair issue the way workshops about their vehicle will need to operate and once inside, one within the next good look around is five years, and he enough to convince intends to be one of them that their car is the survivors. in the right place. ‘Anyone can It is worth noting that buy a scan tool Rod was inspired to and pretend invest in his workshop they understand and in constant diagnostic training for him and processes, but without knowledge, they His pride and joy is the diagnostic access his staff, partly as a result of a meeting will be hopeless in the future and the bench, powered by two computers, each with TaT’s Jeff Smit in the early 1990s, on motoring public will soon figure that out linked to three screens, all on the internet. a visit to Jeff’s Mosman Auto Electrical when they are exposed to professional and Air Conditioning in Sydney. TaT Technical Editor Jeff Smit drove the workshops such as ours,’ Rod says. 220km north of Sydney to Tea Gardens As a result Rod was one of the first to Phase one of their master plan is done. just to check out the workshop. ‘It’s the put his hand up to join the Australian They have built a model aftermarket best equipped I have ever seen,’ said Jeff. Association of Automotive Electricians and

The Automotive Technician 5 that put him well and truly on a path Melissa Blanch, ‘because of her of learning and updating his skills. determination to succeed. She had the spark we were looking for.’ He later joined the Bosch network and has completed many of their Deborah works on a variety training courses. of equipment and has her air conditioning ticket. It’s more than The workshop is a full Bosch car likely she will continue on to get her service centre. auto electrical qualifications as well. Apart from the diagnostic bench, Rod and Melissa subscribe to most the company’s other pride and of the data and information services, joy is a young mechanic, Deborah including Autodata and TaT. Their Lilley, who is now finishing her third dream to establish a showplace year of apprenticeship with the Tea service and repair centre is not yet Gardens workshop and, for the past complete. two years, has been awarded Bosch Apprentice of the Year for the whole Rod sees a workshop that will of Australasia in the car service and have breakout rooms, specialising diesel categories. in diagnostic and repair services, and mobile work benches each Deborah was one of 20 applicants for equipped with an array of diagnostic an apprenticeship at Tea Gardens, equipment that can be wheeled from and she got the job, according to vehicle to vehicle.

The Automotive Technician 6 So, what’s

By Jeff next? Smit

utomotive research The next wave of motor and development vehicles are being designed centres around the and tested with new battery worldA are totally preoccupied chemistries and subsystems. with future advancements The hope is that batteries will in the average motor car. last longer, be lighter in weight There appears to be no end and cost less. to innovation and technology The next wave of engines improvement. will be lighter than currently, The prime focus seems to be reducing the overall vehicle on electric propulsion, energy weight and fuel consumption. storage systems, engines, alternative fuels, intelligent Improvements are being made transportation, communication to turbocharging, the system systems, autonomous that recovers the energy of vehicles, chassis systems and the exhaust gases to increase safety. the inducted charge, thereby increasing the power-to- Improving engine efficiency displacement ratio. and fuel economy are the current big ticket items Engine designers are trying and the principles guiding to improve the efficiency of these improvements include internal combustion engines downsizing, down-speeding, by developing advanced and direct fuel injection and combustion modes. boosting. One of these is called Transmissions are being homogeneous charge improved by adding more compression ignition whereby, gears. during combustion, a highly homogenised mixture of air, The load on a vehicle’s fuel, and combustion products energy reserves caused by accessories is being reduced from the previous cycle is through the intelligent energy auto-ignited by compression. management of other vehicle Other areas being looked components, electrification, at include ways to recover hybridisation, improved battery the energy that is normally management systems, new dissipated through the coolant battery chemistries and power and the exhaust gas systems electronics. of powertrains. Waste heat Reducing the overall vehicle recovery systems will be able weight will likely see new to convert thermal energy lightweight structures made into mechanical or electrical from alternative materials such energy. as aluminum, magnesium, Accessory loads from the composites, plastics and multi- alternator and power steering materials. are being investigated, The electrical and battery hopefully leading to better management systems are fuel economy. Coupled with being redesigned to improve stop-start technology, there performance of both the may be small increases in fuel batteries and their monitoring economy with minimum impact and management systems. on the total vehicle cost. The Automotive Technician 7 Faulty clockspring kept the light on

he traction control light was Live data was checked on the steering staying on. angle position and it read 3,267 degrees T fluctuating between both positive and The light appeared on start-up one 2011 Hyundai Elantra negative. morning and the owner was not able to turn the light out with the traction control Attempts were made to recalibrate the replace button. steering angle position sensor without with a genuine part and success. It just would not recalibrate. These codes appeared: recalibration was successful. A faulty steering angle position sensor C1260 – Steering angle sensor circuit- The code was cleared and a test drive was suspected and it looked like it signal proved the problem was solved. was part of the clockspring; this was C1283 – YAW rate and G sensor signal confirmed by the dealership. This was a 2.5 hour job. C1611 – CAN time out EMS C1612 – CAN time out ECM. So the fault was the faulty steering Zachary Meyer angle sensor built into the clockspring. Ultra Tune Mount Druitt The codes were cleared except that the The clockspring was not expensive to MOUNT DRUITT NSW C1260 would not clear. The plug wasn’t glowing

he check engine light had Injector returns were all equal. The low come on and the vehicle went fuel supply pressure was OK. into limp mode. T There was no air entering the system. The road test confirmed this occurred The suspect pressure regulator was 2012 2.2L Ford Ranger after prolonged acceleration. swapped to a known good vehicle and there was no fault. Code from the G-scan: The Two of the same model Rangers were in job would normally P067200 – #2 glow plug circuit for different faults at the same time. One entail installation of a new pump, injector P008900 – fuel pressure regulator needed a replacement engine so, after tests, a full set of glow plugs and a fresh performance consultation with the customer, the fuel fuel filter. P228C7B – fuel pressure regulator pumps and injectors were swapped over This engine had a ratcheting chain exceed control limit pressure. and the #2 glow plug was replaced. The tensioner so a timing cover removal was vehicle was to be pensioned off. also recommended. The codes cleared, but the glow plug fault code was a hard fault. Data was All fault codes were cleared, the injectors This was a 12 hour job. studied while driving and it showed that were coded and the vehicle extensively test driven. The fuel pressure was Jeff Thomasen the actual fuel pressure was dropping JR Automotive away from the desired pressure. holding, indicating the problem was solved. CAIRNS QLD Transmission limp modes in Magnas

here is a limp mode issue in the Because of this, installing a TL transmissions fitted to Magnas transmission into an earlier model, or from 1996 to 2005. an earlier model transmission into a TL T or TW, will cause the vehicle to go into When a new transmission is installed the 2003 Mitsubishi Magna limp mode as soon as the transmission vehicle goes into limp mode when the selects second gear. transmission selects second gear. for The cause of this is that the ECU is The Mitsubishi Magna had three different the correct model. programmed to look at the input shaft four-speed auto boxes. speed and compare it to the output shaft If not available, the TJ can be fitted with The TE had a unique box, the TF, TH and speed at a given speed and RPM. a TL ECU pack and the TL can be fitted TJ were all interchangeable. The TL and with a TJ ECU pack. Because of the different amount of teeth TW were different yet again. on the output shaft sensor ring, there is The TJ can run all transmissions from From the TL onwards, the speedo drive a different reading, thus the ECU locks TF to TJ and TL. The TW can only run a sensor was removed. the transmission into third gear and limp transmission from a TL or TW. In doing this, Mitsubishi added more mode to prevent damage. Mal Renneboogh teeth to the output shaft sensor pick-up The only solution is to ensure that you Rhiatech Automotive ring. have the correct series of transmission BAYSWATER VIC

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The Automotive Technician 9

AD_AUS_SEP16_TAT_FP.indd 1 16/08/2016 11:07 Honda Accord Euro The fuel filter fixer (Jason Smith) almost meets his match

’ve been replacing intank fuel filters The fuel system was primed by cycling the for a long time with 100 per cent key a few times. Honda Accord Euro success. I The car started and ran fine. In all the installations I’ve During the road test, the fuel restart done, there were never any trims came up fine. the engine. problems to speak of, and Back in the workshop the engine However, if the key was believe me, I’ve done some was started and stopped a few cycled to prime the system the pressure beauties. times during the final quality could be seen to be rising and the engine My standard approach is to control inspections. would start crisply. take my time, be observant It was then that I noticed the My conclusion was that there was and take photos of each car had become something wrong inside the fuel step to help with reassembly. difficult to start. It tank. I have become the fuel filter would crank over 2 After removing the fuel filter fixer in my part of the world. for five seconds module assembly again the Of the colleagues I have 1 before it would problem was very quickly helped, their problems are splutter into life. identified. The new fuel filter had almost always caused by This was not normal and become unclipped from the upper something being forgotten or reassembled had just started to happen some part of the module assembly (pic1). incorrectly. time after the final roadtest and during quality control. I clipped the unit back together and However, my 100 per cent success rate retested the car and it worked fine. was threatened recently by this Honda I noticed that if the key was cycled Accord Euro CL9, K24A3 engine and to prime the fuel system the car Wanting to avoid that problem re- 167,424 kilometres on the clock. would start and run crisply as it occuring, I threw the non-genuine should, so the fuel system analyser filter out and installed a genuine The car was in for a 160,000km scheduled was hooked up. unit (pic 2). service which meant it was due for its intank fuel filter replacement for the second A problem revealed itself quickly. The readings were rechecked and all time in the car’s life. I had replaced the The fuel pressure would bleed off was back to normal. filter at 80,000km with a genuine unit.So almost straightaway after the engine In choosing the genuine part, both the I replacedGearWrench the intake 120XP.pdf fuel filter1 19/08/2016 with 2:12:52a non- PM was stopped and then take more than owner and I avoided possible warranty or genuine unit. five seconds to rise to a pressure level to come-back issues, making us both happy.

The Automotive Technician 10 Sealed unit bearing replacement erman bearing manufacturer FAG has a new sealed It is supplied with a special tool for easy and convenient wheel bearing unit for commercial vehicles that is installation, ensuring reduced installation costs for the Gpre-assembled and lubricated for life at the factory. workshop. It means that workshops can now repair a wide range of There’s also no risk of incorrect or contaminated grease being different wheel hub types with a single repair insert unit. used. The unit consists of two tapered roller bearings, which are Three FAG repair insert units enable around 43 hubs for over connected after installation by means of a snap ring. The snap 2,100 different vehicle types to be repaired. ring ensures that the bearings are not damaged and are held in www.schaeffler.com.au position during installation on the axle shaft.

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The Automotive Technician 11 At higher engine speeds and loads Tumble valve (RPM varies slightly depending on manufacturer requirements), the actuator moves the tumble valves to system operation Variable an unrestricted position allowing for an tumble increase in air volume for those high and common faults shutter demanding conditions. valve he tumble valve system on Note that some manufacturers use a actuator petrol engines is similar in partly restricted position for certain operation to the commonly used driving conditions. Variable swirl valves on diesel engines. tumble solenoid The vertically pivoted valves used on the Common faults T valve diesel system have been modified as Electric actuator system: tumble valves on the petrol engine. These generally use horizontally pivoted valves Due to the intake air stream location attached to a metal shaft that strategically of the tumble valves and shaft, carbon restricts part of the inlet port when build-up on many engine designs required. creates binding of the mechanical mechanism which results in incorrect This is common on some Mercedes V6 The activated or part-activated and non- tumble valve operation and excess load and V8 engines. activated movement of the shaft and on the electric actuator and levers. valves is controlled by the powertrain There may also be a rattle noise under control module (PCM) via an electric Disconnecting the actuator and testing light to moderate acceleration when the actuator system or pneumatic system for free movement of the shaft is engine is cold on some Mazda models, comprising actuator, vacuum valves and recommended before any major work due to air pulses acting on the actuated hoses and possibly a location sensor is carried out on this system. Wiring, (closed) tumble valves. actuator and sensors can all affect the or switch to identify the tumble valve A PCM software upgrade may assist on shaft rotation. These may be used on tumble valve operation and require thorough testing when a malfunction has some vehicles but only if the condition of conventional electronic fuel injection and the tumble valve assembly is acceptable. direct injection petrol engine systems. occurred.

Low RPM Low RPM Commonly replaced Mazda 3 and 6 Tumble flaps – tumble petrol applications valve and variable intake manifold solenoid valves

Pneumatic actuator Vacuum solenoid valve malfunctions can system: be more common on some vehicles. The carbon build-up Typical fault codes might be P2004 – Low RPM Low RPM problem still exists on Tumble control system stuck open, this system but other P2006 – Tumble control system stuck factors can affect closed, P2009 – Tumble control solenoid the operation. These valve circuit low input, or P2010 – Tumble Swirl flaps – include vacuum hose control solenoid valve circuit high input. diesel applications leakage from the Testing the solenoid operation is required vacuum source all the when the listed fault codes have been way to the pneumatic logged and in most common cases a Generally at lower RPM and torque actuator via the vacuum control solenoid simple solenoid replacement should rectify requirements the tumble valves are moved valve, or the condition of the pneumatic the condition, but only after all the pre- to the restricted position, causing the actuator diaphragm and any binding or tests have been carried out. intake airflow to increase in speed past damage. Disconnecting the vacuum hose the valve and create a tumble or swirl and connecting a hand vacuum pump action as the air enters the cylinder. This to the vacuum actuator can test for both TaT acknowledges the assistance of action allows the combustion chamber to diaphragm condition and operation. Premier Auto Trade in the preparation fill more efficiently and improves the air- of this article. Premier Auto Trade fuel mixture which is directed to the spark A mechanical linkage breakage or damage has one of the largest EFI and engine plug. is very common and can be costly management product portfolios in the on some models. Typically, fault code Australian aftermarket including this As a result, power and torque increases, P2004 – Tumble valve stuck in actuated new tumble valve solenoid. fuel consumption is lower and emissions position, will appear and also possibly www.premierautotrade.com.au decrease. codes P2005 and P2006. The Automotive Technician 12 Your motor trades insurance specialist. Deal with an insurance specialist who understands your business. Capricorn Risk Services understands your insurance needs. Our account managers have access to a wide range of general insurance products to assist in finding the insurance you need .

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o what do you call yourself – science or engineering. So, technically been trying to present ourselves as being a mechanic, a technician, a speaking, we are all technicians according better than the mechanic next door. I diagnostician? to that definition. suspect that the title “Master Technician” S out front, is more likely to draw customers You don’t hear ‘mechanic’ used as much ‘But if you were to survey your customers than the title “Mechanic”. But I agree, as it once was. Most auto workshops I bet that almost all would still call you a the name doesn’t make anyone a seem to have adopted the ‘technician’ mechanic. Let’s face it, we are mechanics. better person. It’s all to do with public label. Sure we can fit under the technician perception.’ umbrella. But do we really want to do A technician is, depending on which that? Anthony Tydd in Bendigo chimed in with, dictionary you use, an expert in the ‘I think the whole technician thing was practical application of a science. A ‘Do we really want to be just another one generated as a form of advertising, so if mechanic is a skilled worker who repairs of the many new self-titled technicians you want to attract more work than the and maintains vehicle engines and other that are appearing everywhere? other guy in town you need to create a machinery. ‘When we use a word too often it can lose better image. You can be a right royal dud So when does a mechanic become a its meaning, and this is what I believe but if your internet page and shop front technician? You could argue that everyone is beginning to happen with the word look good people will give you a go. who works under the bonnet of a modern ‘technician’. ‘We have tried to separate ourselves from vehicle could be called a technician, ‘Let’s stop trying to force the word being mechanics because everyone’s based on the description above. technician on our customers and be proud uncle or cousin knows a mechanic or is a But in some workshops there is a that we are mechanics.’ mechanic. The word has been distorted sensitivity attached to choice of job title, A good argument, said Maurice and abused by wannabes.’ as we found when the question flared into Donovan in Brisbane, but, ‘There is a So to cap off this debate, allow us to a rather animated debate within the TaT rather demeaning opinion abroad that a share some other newly coined job Tech Team. mechanic is just a grease monkey or a tyre descriptions that will only leave you This thoughtful argument, from Rod Maher kicker – somewhere down the bottom of with the conclusion that the mechanic/ in South Grafton, started it all. the job chain. technician debate is kid’s stuff. ‘I took great pride in the title of mechanic. ‘Not everyone would think like this, but I saw the title as a great reward for my there are still some who ignorantly think Barman efforts and an indicator of my skills and that way, and I believe that is why so many – Beverage Dissemination Officer abilities. In my mind, a mechanic was in our industry have chosen to adopt the somebody who could magically strip technician label. and rebuild almost anything. A mechanic Painter ‘I remember when the wreckers wanted had an almost wizard-like understanding – Colour Distribution Technician to clean up their industry and wanted to of the internal workings of mechanical be known as auto recyclers. But if we are components and machinery. Road sweeper honest, we still think of an auto recycler as – Highway Environmentalist Hygienist ‘What has confused and amused me over a wrecker, just as our customers think of recent years is the overuse of the word us as a mechanic. Factory worker ‘technician’. Why would a hairdresser ‘To be a mechanic in today’s world is a – Mass Production Engineer suddenly become a hair technician or a different job to the 70s era when I did garbage collector a waste management my time as an apprentice. It is a totally technician. Panel beater different trade today. – Vehicle Restoration Engineer ‘In my dictionary, a technician is a worker ‘A title doesn’t make us a better mechanic, trained with special skills, especially in but in today’s competitive world, we have Had enough?

The Automotive Technician 14 A good word

for diesels by Allan Gray

llan Gray has spent a lifetime around diesel engines and this magazine would not be the first to claim that Allan knows more about diesels than anybodyA else in the trade. He’s the face of Australian 4WD parts designer Terrain Tamer in Melbourne and the problems related to the quality of diesel fuel have dominated his thinking in recent years. When TaT ran a cover story (April 2016 issue) about the problems related to diesel fuel and the diesel particulate filter that can clog up and cost a fortune to replace, Allan was quickly on the phone with more good advice. But mainly, he just wanted to put in a good word for diesels, provided that the people who buy them understand the rules of the game. His take on diesels, an edited version of which we happily print below, suggests that diesel buyers are not fully briefed on how to look after their diesel engines, leading to the bad rap received by diesels and diesel fuel. That was the main point TaT made in its April story, in which we blamed the people who sell them for not being totally upfront about the special treatment diesel engines need to keep them alive and well.

oday’s high performance petrol and diesel engines Problems such as these are now with us in all modern vehicles are changing our expectations of performance and so don’t point the finger only at common rail diesels. economy. We now take comparatively low diesel engine Such problems should only be addressed by a professional, and Tnoise, instant starting and low emissions for granted. And so as the famous forest fire fighter Red Adair once said, ‘If you think long as car owners pay attention to some diesel operating a professional is dear, just wait until you hire an amateur’. procedures, we have come to expect longer engine life. Here’s my list of suggestions for maintaining a healthy diesel vehicle: We could never have imagined that a 2.8 litre engine could be installed in a double cab utility with a towing capacity of 3,500 kg. First fit a petrol stop fuel cap (according to most servos, you or someone else is going to refuel with petrol, sooner And who would have thought that you could purchase, off the or later). showroom floor, an economical, quiet, powerful, light commercial unit that could, with the right treatment, last far in excess of Use diesel fuel additives constantly as a sulphur anything in the past. replacement to lubricate the pump and keep injectors lubricated and clean. And most importantly, who would have thought that all this could be achieved while at the same time the engines were releasing Fit an extra fuel filter (an absolute must). very low, or even no killer emissions. Fit a good quality catch-can to grab the oil fumes from the But experience is revealing strong evidence of elephants in the tappet cover before contaminating the inlet manifold and room when it comes to diesel cars and maintenance. Regrettably, EGR system and fouling the intercooler. when Joe Public is in the showroom he is not told about these Run the vehicle at least twice a week for at least half an elephants. hour, non-stop. An unaware motoring public is not fully Don’t idle the engine for more than four minutes. Change the engine oil at least every 5,000km and closely informed about the care needed to get follow the oil specs in the owner’s handbook. the best out of their shiny new diesel. Ignore all of the above, and continue to drive as far as you like with any warning light on, at a cost of about $1,000 per kilometre. Diesel car owners, it seems, will just have to rely on their adopted local garage or workshop owner to tell them that paying attention to some low cost items will go a long way towards avoiding the To view more of Allan’s work visit main common rail diesel complaints. Such a discussion, if it ever terraintamer.tv happens, may not get rid of all the elephants in the room, but it would dramatically reduce their impact on a lot of wallets. We’ve all heard of weird problems with late model vehicles, like low rear tyre pressure causing limp mode; or incorrect light globe fitted; or a luxury vehicle stalled in the desert until someone was able to tell the driver by phone just to fill the washer bottle and drive home. Good advice, provided they don’t use the washers.

The Automotive Technician 15 The Autodocta Rear suspension noise Problem: A 2009 Hyundai i30 had an abnormal noise coming from the rear suspension. All the suspension Uni components were checked, but no excessive wear was found. tests favour the Solution: This problem has been reported by other i30 owners and it affects models from the start of production up to 31 May 2010. genuine article The problem was due to movement between the rear shock absorber damper rod cover and the rear suspension strut upper mounting delaide University’s The genuine bonnet absorbed bush. Centre for Automotive impact more evenly and didn’t Safety Research make contact with hard engine To fix, pull down the shock absorber A(CASR) have done a crash objects beneath, a major damper rod cover and thoroughly clean test that proves pretty cause of pedestrian injury. the damper rod cover top and upper conclusively that genuine mounting bush. Apply an appropriate The car makers’ body parts are much safer sealant to the upper outside edge of promoting the Genuine is Best than cheaper counterfeit the shock absorber damper rod cover awareness campaign says substitutes. and refit. the result warrants a call for Their test simulated a greater controls on the use of Carry out this procedure on both rear frontal collision with a child non-genuine components in shock absorber damper rod covers. pedestrian in a typical school vehicle repairs. Road test to confirm the noise is no zone of 40km/h. longer present. And if the safety test was not Leading technical information supplier They compared a genuine enough, the CASR concluded Autodata shares fixes to common Holden bonnet with a cheap that the counterfeit was so problems found in modern motor counterfeit. badly made you could almost fit a finger into the panel gap. vehicles. To learn more about their The genuine Holden bonnet innovative product visit: www.autodata-group.com won every time. www.genuineisbest.com.au

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The Automotive Technician 16 Background vortex (version 3) Silver base (version 2 - Skanem light silver) Titanium copy (Edge gold split) B

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he G-Scan 2 is a Korean-made The ability to connect the G-Scan 2 multi-function diagnostic unit to a wi-fi network not only makes a that powers up in seconds simple one touch update easy, but and feels snug in the hand. G-Scan 2 multi- also facilitates wireless printing of screen captures and captured data. It uses Samsung ARMII super-fast T Connectivity of G-Scan 2 is not limited processors, enabling technicians to function tool to wi-fi but can seamlessly connect to a select menus and enter the vehicle’s Windows based PC or Apple device or ECUs in the shortest possible time. This tablet for remote control access. is particularly evident when a system search is undertaken, where the The G-Scan 2 includes extensive, and G-Scan 2 searches for each and every easily accessible, exclusive listing of communicating electronic control unit Rellim trouble codes. This enables the that is on the BUS and lists them for technician to access tens of thousands perusal. of trouble code descriptions, possible causes and code setting parameters. Once communication is established with the vehicle the G-Scan 2, with The Rellim code book includes data its region specific software, allows written locally to support Australian bi-directional capabilities. These technicians. Another impressive option include actuation of components, DPF is the ability to access the online help regeneration, key programming and videos on the smart phone to scan QR module coding, to name a few, with great codes within the software. detail and accuracy. Other bonuses include accessing Whether it is a car, 4WD, petrol, diesel, automotive calculators and acronym lists hybrid or truck system, or 12V or 24V, the along with specific technical support files G-Scan 2 works for them with no need for within the software. additional hardware.

This tool is an OEM-based generic Another great feature is the inclusion system, covering the latest vehicle of control area network (CAN) activity systems including Flex-ray protocols. tests and J2534 support for flash programming. During diagnostics, the most important stage of prognosis is data analysis. That’s The impressive VMi2 high speed the ability to record an entire data list four-channel oscilloscope that piggy- during a test drive and mark the onset of backs onto the G-Scan 2, flawlessly interfaces with the main screen menu. an intermittent symptom by pressing the It not only displays colored waveforms, trigger button. each representing a specific input This enables the technician to play back channel, but also provides guided the recorded data list analysis and graph diagnostics, true RMS graphing and data in great detail. Using trigger points multimeter function. as a reference point, diagnosis is made As a complete hand-held unit with very simple. The saved data can easily the interconnected G-Scan 2 and be shared with fellow technicians. oscilloscope this scan tool brings to The 16GB SD memory provides more life features that have been long sought than a sufficient platform with room for after by the trade. future expansion. www.autoequipment.com.au

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www.bgprod.com.au The Automotive Technician 19 do some research and, instead of wasting money on parts that might not be needed, spend the same money on diagnostic Time, gentlemen and research. It will be a better result for the workshop and the car owner. Deyan Barrie ladies, please Deyan recalls his early training years in the RAAF, which no doubt explains why he understands the problem better than most. ccording to TaT research director Deyan Barrie, the ‘Under no circumstances did we ever jump onto an aircraft to do biggest mistake made by far too many workshops is a repair, never mind a diagnosis, without first hitting the books that they don’t allow technicians enough time to fix and looking at relevant information, circuit diagrams and specific anything.A repair procedures. It was only then that the tool bag was packed We’re not talking about straightforward mechanical and every relevant paragraph of information would be faults, but those complex issues that demand recorded on the job card and we had to sign off diagnostic time. that we had read it and understood it. Electrical and electronic faults just can’t be ‘So what’s so different in this highly complex fixed quickly. A proper diagnosis is required electronic and sophisticated multi-module before any attempt to fix the problem. automotive world?’ he asks. So any workshop that tries to promote the In the TaT research workshop, technicians fact that they can quickly and effectively are allowed as much time as they need diagnose complex electronic faults is to diagnose a problem, and that includes kidding itself. research time and thinking time. In fact, the word ‘quickly’ is taboo in Only this way will they become great Deyan’s book. diagnosticians and problem solvers. It’s a leftover from the old days, when some Many workshops don’t allow their technicians things could be fixed quickly and this notion enough time on the specialist tools required has now become entrenched in the automotive these days to read and analyse complex systems psyche. and components. But these days, when vehicle technology is changing faster than That often leads to repair by replacement, instead of repair by any workshop or technician can keep up with, even with the best diagnosis. of training, there are only two options with a problem vehicle – Lab scopes, Pico scopes and an array of scan tools should be guess and throw parts where you think the fault is or slow down, now as commonplace on the workbench as a set of wrenches.

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The Automotive Technician 20 ‘A hacker on a mission with an The first is the connection to the Internet endless supply of Redbull will break Are cars really just of Things and the second references into any secure vehicle network the future of the autonomous car where eventually.’ vehicles communicate with one another. new age gadgets? It doesn’t take a lot of imagination to That was one of the comments from the consider the implications of hacking into a TaT Tech Team during a recent debate vehicle-to-vehicle or worse, a vehicle-to- about hackers taking over vehicles that infrastructure network. are now bristling with electronics and communication systems. Fortunately, steps are being taken to ‘harden’ future vehicles from outside The story that kick-started the debate attacks, and keeping ahead of the hackers came from, of course, Las Vegas, where a has become another major industry in convention of the telematics industry was itself. Some TaT Tech Team members getting an update on the growing number scoff at any suggestion that hackers can of consumer features in cars that require be defeated, hence the opening sentence connection to the Internet of Things. in this story. ‘Hackers just don’t quit,’ Software and firmware updates could be Each consumer feature though opens a added the Tat Tech Team member. completed automatically without requiring new doorway for hackers to use to take the customer to schedule a service ‘Why have we allowed the manufacturers over and modify vehicle systems, even appointment. to turn the vehicle into another gadget,’ while the vehicle is in motion and under said another. ‘Of course, we throw But those same doorways are used by the driver’s control. gadgets away when we get tired of them hackers. To put this problem into perspective, a or they break. Which poses another big leading IBM engineer estimated that the Infotainment delivered by satellite or threat to those good technicians who like connected cars currently on the road are internet streaming, Bluetooth and onboard to fix things. WiFi hot spots are all potential access the second largest generator of data on ‘Manufacturers are banking on people points for hackers. And it’s not just the the Internet of Things. throwing away their cars when they ability to impact these onboard systems. Car makers are persisting with more break, so they can sell them another car. Imagine the personal data available to the and more connection points because by It is a conspiracy on two counts – the hacker – vehicle location, vehicle key and monitoring the thousands of data points first to access more of the consumer’s antitheft codes, email and text messages generated by the vehicle’s onboard money and the second to make cars so and other personal data. systems, problems affecting vehicle complicated and sealed that nobody will operation and safety could be predicted In an even bigger picture, consider that be able to fix them.’ the term ‘connected car’ has more than and attended to before they actually So where does that leave the aftermarket? occur. one meaning.

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The Automotive Technician 21 That new Black Magic Australian Auto Accessories has a new range of Black Magic products which feature a flawless black finish. Leading 4WD filters the range is the Cal Custom Hilborn CoolDrive Distribution stocks Sakura style short single air scoop that suits a 4WD filter service kits that include oil, dual carburettor application and the Cal air, fuel and cabin filters. The kits are Custom long street scoop that suits a for those who travel extensively and DP Chip dealer four-barrel carburettor. It’s the painting may be required to have their vehicles Piranha Off Road Products has technique to acquire that perfect black serviced when on the road. Kits will suit become a Premiere DP Chip dealer finish that is the big attraction. Electric vehicles such as the Toyota Hilux and and is located in the eastern suburbs current is used to adhere charged Landcruiser including Prado, Mazda BT- of Melbourne. DP Chip has created particles to make the paint stick and 50 and B2600 Bravo, Ford Ranger and a plug and play system using OEM renders the article rust resistant. the Volkswagen Amarok. They are also plugs that allow for more power and www.australianauto.com.au available for Holden, Isuzu, Mitsubishi torque to make driving much safer. 03 8560 2975 and Nissan 4WD and light commercial The DP Chip is used in conjunction models. with the vehicle’s computer to fine www.cooldrive.com.au tune its timing and fuel delivery. 03 9762 1200 Curvy lights www.piranhaoffroad.com.au CoolDrive Distribution has added Ignite’s curved lightbars to its range. They come in three sizes and feature three different beam patterns – spot, flood and a combination beam. The lightbars will withstand some of the harshest environments with protection against dust, moisture and long periods of immersion under pressure in water. www.cooldrive.com.au Interesting Back up view CoolDrive Distribution has a new New products and rear view mirror and reversing camera kit designed to be discreetly equipment for the mounted to the rear number plate. The camera can scan 120 degrees auto industry horizontally and 60 degrees vertically. Compatible with 12 volt plugs, the system includes two camera inputs with micro connectors for easier installation. Part No. GRV43MDT. Clutch video www.cooldrive.com.au Australian Clutch Services has released a ClutchTech video, adding to their Better back-up series of more than 40 technical videos Jaguar Land Rover is working on on YouTube. The new video looks at a semi-autonomous feature that the differences between Volkswagen they claim will make it dead easy to Golf and Audi A series clutch reverse a trailer without jack-knifing. assemblies. This is an important topic Using its own surround camera because the KSE21001 and KSE21003 system, the vehicle will steer itself to clutch kits have covers that can easily follow a path selected by the driver, be confused. compensating, one presumes, in 1800 CLUTCH (Australia) time to avoid the dreaded jack-knife. [email protected] Maybe next year. Light reading Narva’s 2016/17 catalogue is out – all 540 pages of it. It’s different though, with an interactive video capability. Sockets and sets Just run a mobile phone or tablet Kincrome has a new range of LOK-ON over the reader on the page and it socket sets and accessories, capable takes you to the product details or of loosening up to 85% of rounded or instructional video. Narva calls it damaged fasteners. LOK-ON ratchets visual learning. The new Ultima 215 have been designed in Australia and LED driving light is featured, and engineered to a world-class level. there’s plenty more. www.kincrome.com.au 1800 113 443 (Australia) www.narva.com.au

The Automotive Technician 22 HOLAS08611 HOLDEN AH ASTRA ‘s a fact 2008 diagnostic solutions 4 Cylinders

Customer This was a bit high. All the components were cleaned and treated, the The fan speed resistor and complaint bush was lubricated and fan motor were removed The interior blower fan was the fan motor for inspection. working on high speed reassembled. 6 only. Fault description The sticker was removed Problem summary The fan speed resistor off the base of the fan harness was disconnected motor, revealing the All three lower speed fans and the assembly removed. opening, so if moisture were lost at the same time. It clips into the housing. 2 does occur it will not pool. Diagnostic The fan motor and housing The thermal fuse was sequence assembly were removed, 3 bypassed by fitting a and the fan speed resistor 25 amp circuit breaker in 1 The glove box assembly circuit checked. the supply line. 7 was removed to access the After reconnecting the fan motor assembly and The thermal fuse, situated current clamp, the current the fan speed resistor. 1 between fan speed three and four, had blown. 4 draw on start-up and full When the circuit was speed had dropped to checked, the fan speed The fan motor was very 18 amps and settled down resistor circuit was open on stiff to spin by hand, so a to 14 amps running. all three lower speeds. tight bush was suspected. The problem was solved. A current clamp was Fault solution hooked up and the current Recommended With the fan motor pulled draw of the fan motor was time monitored. apart, the end plate, bush and brush gear end of the Labour time was 2.5 hours, On start-up the current motor had some moisture taking into account peaked at 25 amps and or water damage. 5 research time, location of 2 then settled at around parts and actual time spent 18 amps. fixing the problem.

3 4 5

6 7

The Automotive Technician 23 FORNL99112 FORD NL FAIRLANE ‘s a fact 1999 diagnostic solutions 8 Cylinders

Customer complaint The vehicle was running rough and missing. A coil problem was suspected. Problem summary The owner called roadside assist and the vehicle’s alternator was replaced because of a strange noise. On a second callout the owner was advised that the leads should be replaced, so he arranged this through his mechanic. Diagnostic sequence 1 The vehicle was in a TaT workshop to have the coils checked when it became obvious that the new leads did not fix the problem. The new alternator and new set of leads were obvious. 1 2 Quizzing the owner to find out why the alternator had been replaced he advised that road service was called because his engine was vibrating and occasionally making strange knocking noises. Road service fitted the alternator and advised that the vehicle be taken to his own repairer to have new leads fitted. It was obvious that the problem was more mechanical and not electrical, because it felt like an uneven miss and rumble. Fault description With the engine off, the fan was pulled around by hand and it was noticed that the harmonic balancer moved prior to the engine crank turning. The old harmonic balancer was removed and its 2 failure was verified. 3 The centre rubber sleeve had let go, so the shock absorption effect was gone, causing the pulley to move either way off centre, in turn causing the knocking and imbalance. Fault solution A new harmonic balancer was fitted and the unbalanced running and idle was gone. Recommended time Labour time was 2 hours, taking into account research time, location of parts and actual time spent fixing the problem. Tips for TaT Technicians should never take for granted third-hand information. Nothing beats a proper investigation and diagnosis. Coupled with doing an independent diagnosis, time should always be made to discuss the problem with the owner. 3

The Automotive Technician 24 JAGSP97420 JAGUAR S TYPE ‘s a fact 1997 diagnostic solutions 8 Cylinders

Customer complaint verified, but the relay was not being triggered at the relay. 4 The tail lights were not working. A full 12V negative was Problem summary measured on the volt meter at The dash lights were working, the base of the plug, but only but not the tail or park lights. 5V at the relay. Diagnostic sequence Fault solution The circuit at the headlight A replacement module was not switch was checked. All the available so it was decided to circuits were earth switching locate the fault and try to repair circuits that turn the relays on. the circuit. The circuit diagram showed A bad solder joint was a multifunction module in the suspected, but what was lighting circuit. This was located found was a diode that looked in the boot under the battery overheated and cracked. 5 panel cover. 1 The volt meter verified that the diode was crook so it was Fault description replaced and the circuit started The module was removed. 2 working again. The sticker showed the module The problem was solved. controls and the switches for a number of circuits. Recommended time The printed circuit board was a Labour time was 3.5 hours, double sided board and housed taking into account research seven micro relays. 3 time, location of parts and actual time spent fixing the The connector plug was back problem. 1 probed and switching was

2

3 4 5 Blown diode (D10)

The Automotive Technician 25 BMW8705111 BMW E87 ‘s a fact 2005 diagnostic solutions 4 Cylinders

Customer Fault solution complaint 2 To access the CAS, the The vehicle cut out while inlet manifold assembly driving and was towed in. was unbolted and moved up out of the Problem summary way. This was a BMW 120i 3 The CAS is located model and when brought under the starter motor in, it ran without cutting (about half way along) out. and sits in a bit of a gully inside the engine Diagnostic block. sequence 4 When the sensor was unplugged, unbolted, A large number of fault removed and inspected codes were found in the the sensor housing was lighting system, engine full of engine oil. start, starter operation, footwell module, junction The oil had somehow 1 box electronics, auxiliary pushed its way in. This is water pump and A0B4 (car not the first time this had access system). been seen, but it usually has a fault code. Fault description A new CAS was fitted and Nothing from the scans the intake reassembled. related to the issues of The problem was solved. crank or firing. A similar problem with a Recommended 320i 2001 model showed time codes for throttle control, Labour time was 5.5 hours, emergency operation, cam taking into account shaft, crank shaft speed research time, location of and cam control and it parts and actual time spent turned out to be an issue fixing the problem. with the crank angle sensor (CAS). Tips for TaT 1 With this in mind, and It just goes to show how the fact that sometimes care is needed when 2 a crank sensor code relying on scan tools and may not appear, this fault codes. There have was inspected first. been some horrific stories relating to the A0B4 code.

4 3

The Automotive Technician 26 VWGO04432 VOLKSWAGEN GOLF ‘s a fact 2004 diagnostic solutions 4 Cylinders

Customer complaint A central locking problem with the driver’s door. Problem summary The driver’s front door would lock only manually and not remotely. 1 Diagnostic sequence The fault was isolated to the door lock module in the driver’s door. This unit is a complete latch and solenoid control module. Fault description To access the module inside the door the outer door skin must be unscrewed and removed. 1 3 2 This provides access to the internals of the door including the window motor, regulator and wiring harness. 2 The faulty door lock assembly was unbolted and removed. 3 In this instance, the wiring harness was removed and replaced. 4 Some wires had started to crack the insulation and break up at the hinging point. 5 This harness problem can cause a variety of issues, including a flat battery if a specific wire is broken that stops the systems going to 4 sleep. Fault solution A new wiring harness module and door lock module were fitted. 6 All codes were rechecked and confirmed as cleared. Recommended time Labour time was 3 hours, taking into account research time, location of parts and actual time spent fixing the problem. 5 6

The Automotive Technician 27 WORK. LEARN. INFORM.

The new service dimension for garages and retailers Our online portal offers everything to make the day-to-day work of garage professionals even easier. Whether you need information about our product groups transmission, engine or chassis: A clear structure and intelligent search process deliver the desired results quickly and reliably.

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aT head trainer Jeff Smit will present a practical and topical training session during the afternoons prior to 10 September – Sydney Hilton Hotel the Capricorn dinners and trade displays in Australia and New Zealand. 15 October – Adelaide Convention Centre THe will be exploring the process of diagnosing problems on late model vehicles. 22 October – West Australia Crown Casino The training sessions are free of charge to Capricorn members 29 October – Jupiter’s Casino Gold Coast who attend the dinner and display event. Each session will run from 2.30pm to 4pm. The trade show will be 12 November – Melbourne Crown Casino open from 4pm to 7pm, followed by the dinner. This is quality technical training for members and their staff, free of 26 November – Auckland Sky City Convention Centre charge. Visit www.capricorn.coop/events to reserve your place.

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13 September – Port Macquarie NSW 27 September – Adelaide SA 19 October – Ballarat VIC 14 September – Coffs Harbour NSW 28 September – Footscray VIC 20 October – Bendigo VIC 15 September – Wollongbar NSW 18 October – East Geelong VIC

TaT diagnostics training Subjects: OBD-II PIDs (onboard diagnostics parameter IDs) – codes workshops used to request data from a vehicle, used as a diagnostic WORK. LEARN. INFORM. These workshops, conducted by TaT head trainer and technical tool editor, Jeff Smit, are 2.5 hours long and include a workbook. Using scan tools and live data, enabling technicians to see The subject is diagnostics using live data, a topical and practical what’s happening inside the vehicle’s electronic systems The new service dimension for garages and retailers session that will explore the process of and new approach to A comprehensive approach to diagnosing drivability issues diagnosing problems in vehicles. These are essential training nights using computer data Bookings at: 1300 650 048 Our online portal offers everything to make the day-to-day work of garage professionals even easier. Whether for technicians working with scan tools and problem vehicles. Real life case studies. www.autopartners.com.au you need information about our product groups transmission, engine or chassis: A clear structure and intelligent search process deliver the desired results quickly and reliably. 20 September – North Perth WA 13 October – Wollongbar NSW 10 November – Bendigo VIC 21 September – South Perth WA 25 October – Adelaide SA 22 November - Cairns QLD › Product range › Product knowledge 22 September – Bunbury WA 26 October – Footscray VIC 23 November - Townsville QLD › TecDoc online catalogue › Training opportunities and training content 11 October – Port Macquarie NSW 8 November – Geelong VIC 24 November - Mackay QLD › Repair instructions › How-to videos 12 October – Coffs Harbour NSW 9 November – Ballarat VIC › Product advantages › Latest product updates and service information › Failure diagnosis

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cigarette lighter accessory socket and, presto, the car started no problem. he car would not crank over once The car would not start when a USB plug turned off. FROM EXPERT TO EXPERT T was inserted into the output. The battery tested OK, but while trying If using the mains power supply section Support Hotline (Mon -Fri, 8.30 am - 5 pm) 2008 Holden Colorado RC 4JJ1 to crank the engine over we saw no of the inverter, the car worked fine. Australia: 1300 585 462 signal to the starter and no voltage drop New Zealand: 0800 585 462 on the starter main feed wire. Same thing happened when we tried it in the second cigarette lighter accessory problem As we were unplugging the starter relay socket. in the Colorado. www.repxpert.com to test for feed to it, the owner was Brendan Sorensen taking some equipment out to put in A little forum browsing showed others Steve Sorensen Mechanical another ute. He unplugged an inverter with various components plugged into BROWNS PLAINS QLD and work torch charger from the main the accessory socket having the same REPXPERT – a trademark of Schaeffler Automotive Aftermarket. The Automotive Technician 29 Drive your car off the production line

n enterprising Kiwi has convinced Swedish car maker Volvo that its factory delivery experience, available only to US buyers, should be made available to other Capricorn countries,A including New Zealand and Australia. It works like this. You buy a Volvo off the plan and then opt to expands tech service travel to Sweden to see your car come off the production line at the factory in Gothenburg. You can take the car for a drive around apricorn, features 29,000 vehicles Sweden or further afield before bringing it back to the factory for Australasia’s largest from 80 manufacturers, packing up to send home. cooperative in the 85,000 diagrams, 500,000 automotiveC parts buying step-by-step procedures Volvo offers a package that includes flights, accommodation, industry, has introduced and thousands of monthly insurance, airport transfers and a tour of the Volvo factory, itself two new essential tools updates. a hugely popular attraction. There’s also a range of packaged for automotive workshops. holiday tours designed to help its customers get the most out of Another part of the new their trip to Sweden. Available only to Capricorn service, Capricorn Vehicle members, the new tools Videos, is designed to help The US has been the only country in the world offered this service contain access to a workshop owners share for the past 60 years. This year, around 1,400 Americans will comprehensive range of technical knowledge with combine a Scandinavian holiday with their new car purchase. online service information their customers and clearly They’ll be joined by one Kiwi who convinced his Volvo dealer that covering thousands of explain common mechanical he should be offered the same experience. vehicles. problems and procedures. Volvo took the bait, and are making the offer global. It’s powered by Autodata, www.capricorn.coop or There’s only one snag – new cars must be shipped out of Sweden whose global database [email protected] within six months of purchase to avoid paying local taxes.

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K An assembly of bits Waveform of Holden The Flex Fuel ethanol content sensor is a complex assembly of bits that comprises ethanol blend sensor an electrical connecting terminal, a fuel sensing element and a microprocessor in by Sam Nazarian and Jack Stepanian one complete unit (pic 6).

ou may have seen the VE Commodore series II with its green wavy line eco-friendly emblem and the striking insignia of Ethanol Flex Fuel E85 (pic 1). Inside the petrol filler cap door, another sticker reads ‘Up to 85% ethanol fuel suitable’ (pic 2). 3

Flex Fuel E85, as the name implies, can be any proportion of ethanol to petrol, thus demanding a continuous correction 6 of the spark timing. To cater for this, continuously altering ignition spark timing Fuel is directed to the sensing element (A) via the metal tubing that has a GM-style 1 with that of engine input parameters, a Flex Fuel sensor (FFS) is used to inform fuel quick connector. This sensing element measures the capacity permittivity of the and enable the ECM to fluid passing through the two conducting adapt to the fuel mix. circular metal electrodes (permittivity being a measure of the response of a substance to an electric field) and measures the temperature of fuel with its inbuilt negative temperature co-efficient thermistor. 2 The microprocessor (B), attached to the side of the measuring cell, then processes These symbols and signs suggest that a this information and generates a square blend of unleaded fuel, ranging from the wave with the following characteristics: standard 91 RON petrol to a mix of E85 (85% ethanol and 15% unleaded petrol) The microprocessor alters the frequency of the generated waveform, would not alter the vehicle’s driveability, thus representing the blend of the whether or not they have V6 or V8 fuel (change in frequency) and also engines. changes the width of the negatively- How can this be? E85 ethanol fuel has going pulse of the same waveform, a RON rating of about 104. The altered representing the temperature of the lambda for stoichiometric combustion fuel (change in pulse width). from 14.7:1 to 9.8:1 would surely render either of these engines inadequate. These changes are all encapsulated in the one waveform – pure brilliance. Yet the vehicle performs on any 4 combination of fuel blends. The electrical connector of FFS (C) provides Often referred to as the physical connections to a supply, a ground How does the engine control management sensor assembly, GM part and the output signal, inputing the ECM (ECM) unit know what blend of fuel is in number 1357739 (pic 4) that monitors the change in frequency and the tank? An ethanol sensor perhaps? is located as close to the the negative pulse width. This signal is And if there is such a sensor that can fuel tank’s outlet fuel hose attained via a 5V regulated voltage with a give the ECM the correct blend of fuel, as possible, as shown on pull-up resistor from the ECM. let alone the fuel temperature, where is it, a Holden V8 SS V ute (pic 5). Anatomy of a sensor (pic 7) and how does it work? How does this Holden measure and 1 – outer electrode of the analyse its ethanol content in real time, measurement cell as you drive, and what does the sensor 2 – inner electrode of the measurement output waveform look like? cell Flex fuel E85 3 – negative temperature co-efficient Ethanol E10 is a blend of 10% ethanol and thermistor 90% unleaded petrol. E85 is commonly 4 – microprocessor known as racing fuel (pic 3) with its high percentage of biofuel to petrol. 5 – supply This mix drastically alters the volatility of 6 – ground the fuel, demanding a constant change in 5 7 – sensor signal output waveform spark timing. The Automotive Technician 32 Anatomy of the waveform To convert the base reading of the wavelength to frequency, simply calculate The change of blend in the ethanol the inverse of the time base reading, for content is reflected in the change in example: frequency of the sensor output signal. frequency = 1/wavelength, Similarly, the change of fuel temperature is reflected in the negative pulse width of or the waveform. And again, an oscilloscope wavelength = 1/frequency. can see the negative pulse width, in In this particular scenario, frequency milliseconds (ms). 7 will be = 1/12.5ms = 1,000/12.5 = 80Hz, The frequency and negative pulse width retrospectively representing an ethanol Measuring output sensor signal are both encapsulated in the same one content percentage of 30%. waveform (pic 8). The FFS is the cop that controls your Improper operation of the FFS will result The temperature of the fuel is reflected car’s alcohol consumption (give or take a in ignition timing faults and excessive in the following negative pulse width chemical formula or two, ethanol is in the fuel use. Should you be interested in the calibrations: same family as vodka). amount of ethanol in the blend of fuel, use a digital multimeter and measure the 1ms pulse width = -40°C It makes sure that the ECM’s program frequency of the sensor output signal matches the alcohol content, or the 5ms pulse width = +150°C ethanol blend, making sure it is just using these benchmarks: This captured waveform has a time base right for maximum performance (an auto 50Hz (cycles per second) = 0% of 5ms and 1V per division and is of a breathaliser perhaps). ethanol simulated fuel blend (and not an actual 150Hz (cycles per second) = 100% fuel measurement reading from fuel tank), ethanol yielding: 180Hz and 190Hz = contaminated a negative pulse width (NPW) of 2.4ms rendering a fuel temperature of 25°C, The contaminated benchmark means there is a limited amount of and onboard diagnostics from the smart a wavelength of 12.5ms rendering a microprocessor. frequency of 80Hz and retrospectively An oscilloscope must be used to see the representing an ethanol content 8 sensor signal output waveform. percentage of 30%.

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The Automotive Technician 33 Yes, a rotating disc does have a certain amount of rotating inertia or a flywheel Brake discs – is effect which requires power to accelerate and decelerate. lighter better? It takes approximately 24Nm of torque to get a 9.5kg disc spinning up to 134 km/h re lighter brake rotors worth the A disc rotor consists of the mounting bell and back down to zero when braking. effort. It’s a question asked a lot which attaches to the axle and the braking The lighter 8.5kg disc requires in the performance domain. band or ring, to which the brake torque is approximately 20.5Nm which is a little A applied via the caliper. better than a ten per cent saving in energy There’s no simple answer but some facts might help to allow educated decisions to The braking band or ring in this disc rotor required to accelerate and decelerate the be made. weighs approximately 6kg. same vehicle. A typical large sedan weighing 1,690kg is In the above scenario, this 9.5kg disc will Generally a car manufacturer will traveling at 134km/h and it has to brake increase in temperature by approximately determine the ideal disc mass or weight quickly. Assume the average tyres can 125 degrees Celsius in less than five for the vehicle and it certainly isn’t in handle a G-force of 0.85 before they lose seconds. If the same 300mm disc their best interests to add weight to traction. weighed 8.5kg with a braking band of their vehicles or give away unnecessary kilograms of metal. The car will decelerate at 0.81Gs to 5.5kg the temperature increase would avoid skidding. It comes to a stop in be closer to 137 degrees Celsius. A ten By thinking smarter, DBA has developed approximately 87 metres and generates per cent increase in temperature doesn’t opportunities to reduce weight without approximately 1170kW (1569hp or sound all that much but unfortunately heat reducing performance by using higher 1110BTU/sec) of kinetic energy doing so. transfer isn’t all that simple. quality disc rotor materials in their performance range or by replacing stock This energy has to be transferred through What happens in performance driving is rotors with two-piece designs such as the braking system in order stop the a series of brake applications at regular DBA’s 5000 series discs which reduce vehicle. When this much energy is intervals. The time between brake weight from the mounting bell while pumped into the disc rotors in a matter of applications is rarely enough to allow the BY maintaining the optimal weight on the seconds (4.7s)DESIGNED it generates a lot of heat disc to recover to the optimal braking temperature so you end up with an braking band. and the amountENGINEERED of mass or weight in the disc rotor is critical in order to cope with accumulation of temperature build-up over & PRODUCED this load. a period of time. TaT acknowledges the assistance of IN THE USA A typical front disc rotor on a large sedan The other side of the coin is unsprung DBA in the preparation of this article. is approximately 300mm in diameter and weight or rotating inertia, a favoured www.dba.com.au weighs around 9.5kg. subject of performance fanatics. TM ™

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The Automotive Technician 34 TOP Even the very best spanner set doesn’t TECH TIP cut it any more in the modern workshop. If finding the money for equipment is efore even thinking about new a real issue for the workshop, greater tools, or what scan tool or intervention is required from an outside B oscilloscope to buy, the top consultant like TaT’s Geoff Mutton, a priority for staying in business, and business trainer who has helped many being successful, is to update your Australian workshops to get back on neck-top computer and update your their feet and become profitable again. approach to diagnostics. Only then can you start thinking about Budgets must be found every year to the right equipment to enable you and update old equipment and purchase your technicians to diagnose efficiently. new equipment. Workshops can no longer afford The best way to find out what equipment to quibble about investing in good The real cost of equipment has dropped would work best in your workshop is to equipment if the plan is to stay in the dramatically in recent times and the ask around. game and be competitive. excuse that a workshop can’t afford it is Join a network, talk to fellow technicians And by ‘good equipment’, we mean up no longer valid. Without the equipment, and you will be surprised what you can to date equipment. you can’t fix cars – end of story. learn.

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t might be a litte known name right You see, Velodyne makes LiDAR now, but pretty soon, Velodyne equipment. LiDAR or ‘light detection and LiDAR Inc. may be up there in lights ranging technology’ is basically a laser with the likes of Intel or Bosch. that rotates like a radar, mapping the surrounding area in 3D. IWhy the sudden interest in a name I’ve never heard of? Oh, and guess what? Every vehicle manufacturer working on self-driving cars, It’s hard to ignore the fact that Ford and with the exception of Tesla, uses LiDAR. China’s version of Google, Baidu, have just sunk $75 million each into Velodyne With this massive cash injection, Velodyne The most interesting thing in this LiDAR Inc. is projecting that it can lower the announcement for me was that Velodyne manufacturing cost and shrink the size uses its own proprietary software and of the LiDAR equipment to the size of a algorithms for interpreting the data. hockey puck (25mm x 76mm). According to LiDAR, its sensors can All vehicles run on different software, produce 2.2 million data points per as we know, but if one company second with a range up to 200 metres. is supplying almost all of the manufacturers, it surely must help that Complete European Brake Pad Kit LiDAR is used in conjunction with cameras the vehicles can talk to each other in to help with the vehicle’s autonomous traffic and of course this means that driving capabilities. individual manufacturers won’t need to Cameras these days are tiny and can cough up their own software to run on be placed anywhere. one single platform. It looks like the self-driving car of the Interesting times ahead because from + future will not only incorporate some great worldwide reports (including Australia) we + technology, but will look pretty cool as may yet be driving – sorry, not driving – in + opposed to a Noddy car going to a B&S an autonomous car sooner rather than + ball. later.

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Find out more at www.newtrueblue.com.au This driverless Volvo is already being Toyota recalls the 86 It’s here – tested in South Australia UBER with oyota Australia illuminate on the dashboard has recalled 15,000 along with a short audible no driver Toyota 86 vehicles warning whilst manual steering Tbuilt between April 2012 would be maintained. ar makers and will be a human driver sitting and March 2015 due to a companies that behind the wheel, although he To rectify this condition, the use lots of cars are or she won’t be driving. potential loss of power power steering steering assist. Cstepping up the pace in the electronic The cars are coming from race to see who gets the first control Volvo, who teamed up with The recall autonomous car fleet on the impacts unit and UBER in a US$300 million road doing real transport partnership to bring 100 right- wire work. self driving Volvo XC90s to hand drive harness Pittsburgh. vehicles that will be And bless their innovative are equipped replaced little souls, it could be that And cars are not all UBER is with driver’s knee in all renegade UBER. interested in. According to the impacted vehicles. airbags. News comes from TaT’s US US financial press, UBER has A letter will then be sent by acquired a company that has Due to an improper wire columnist Julian Hentze, that registered mail to all owners developed a US$30,000 self harness layout, there is a UBER was planning to put of the impacted vehicles to drive technology kit to retrofit possibility that the electric self-drive cars on the streets request that they make an commercial semis. power steering harness in Pittsburgh before the end of appointment at their preferred August. UBER now seems to be may interfere with the Toyota dealer. instrumental panel lower cover In time, they say, people who leading a number of big which contains the driver’s The repair work will take dial up a UBER could see a names, including Google, knee airbag on Australian just over an hour and will be driverless car at the front gate. Apple and Ford, in the race to bring self drive cars into specification vehicles. carried out free of charge. It knows where you want to go, the everyday market. If their There have been 62 reports in so you just jump in and watch If this happens, there could Pittsburgh experiment works, Australia with no accidents or TV or read the paper. be an electrical contact failure the future of ride-hailing cars injuries reported as a result of which may result in the loss UBER say they have a fleet will be no private owners, this condition. of power steering assist. A of driverless cars at the ready no drivers and very few warning light would then www.toyota.com.au but, for the time being, there employees. On your keyboards ENGINE PARTS for a bug bounty www.etponline.com.au ®(03) 9357 0854 NEW PARTS: nformation technology bill in front of their noses will nerds in the US are being encourage them to share what Cylinder Heads paid a ‘bug bounty’ for they find in cyberspace so that Ialerting car makers to potential vulnerabilities can be VRS Gaskets potential cybersecurity fixed before they cause havoc attacks on vehicle software. on the freeway. Camshafts The bounty will be paid by Depending on how good the FCA, one of the big three car shared information is, the Plus a range of Small Parts makers in the US. nerds can collect between US$150 and US$1,500 They acknowledge per report. www.etponline.com.au that there are a The easiest way to stay up to lot of people FCA reckon that tinkering with by offering datewith ETP’s product range vehicle IT the cash systems, incentives, New Cylinder Head Kits so they are they are Bare Head - VRS - Valves - Head Bolts* hoping that ‘engaging the *Head bolts are only supplied for some applications dangling community of 72 Killara Rd, Campbellfield Vic 3061 the dollar hackers’. 03 9357 0854 The Automotive Technician 38 2005 Toyota Corolla 1ZZ-FE

Eager to confirm my diagnosis, I Another fuel fitted the Denso pump to the module assembly and fitted it to the Corolla. The fault was the same.So the intank Jason filter quirk Smith module assembly was removed again. This time I connected the engine t’s not often I have problems with The system must see the engine crank cylinder leak-down tester to the pump a car after replacing an intank fuel before it starts to prime. module assembly fuel line outlet at the top filter, but two in and applied 20psi of pressure. On cranking the engine, the Irecent months has Air could be heard leaking from the fuel needle on the fuel system got to be worth analyser would slowly start pressure regulator (pic 3). talking about. to rise and after three to five I unclipped the It seems that, seconds, when the needle bottom cover from recent calls hit about 250Kpa, the to confirm to myself and engine would start and run the exact Ryco filters, I have fine. The running pressure location, unearthed a problem was about 310Kpa. which was that can happen But when the engine was the pressure to anyone, so pay switched off, the fuel regulator. attention. pressure would bleed The pressure This car had back to 0 within about five regulator was 158,336 kilometres seconds.The car was then removed and on the clock and 1 difficult to start again. leak tested was in for its With the car running and and air was 160,000km major the system at running definitely service which included pressure, I quickly clamped the flexible leaking (pic 4). replacing the intank fuel filter under the fuel line on the fuel system analyser and back seat (pic 1). I used a top brand 5 just as quickly turned the car off. aftermarket filter. This held pressure in the rail and But after the replacement, the injectors. The car would start engine was started and as quickly and crisply with usual it cranked for a few no problem, proving that seconds more than normal there was no problem to prime the fuel system. forward of the fuel tank Then it started, so module assembly. that’s not unusual. The regulator was submerged to show the Thinking it might be leak. During the service a fuel pump check work, the car was valve issue, I took After checking prices and started a few times with the pump out, the availability I opted for an no problem. engine cylinder aftermarket Goss intank 2 leak-down tester fuel filter module After some time, however, was hooked up and assembly (pic 5). it would crank abnormally for air pressure was three to five seconds before 6 As soon as it added. it would start, regardless of was fitted the when it was last started. Air could be heard car started escaping from the crisply and All work was rechecked and nothing odd bottom of the fuel pump quickly. was found. until 20psi was reached and The running Going back over the fuel filter replacement then the leak would stop. pressure was I decided to fit a genuine fuel checked at This was filter but the 350Kpa and the confusing. problem was resting pressure was still present. I did the same test on a checked over a period of 45 minutes and The old filter Denso fuel pump from a didn’t go below about 20psi (pic 6). assembly went Mazda 323 and it did not Volume remained in the line so after road back in – same leak air at all. testing, everything seemed to be working result. well. The fuel system It is suspected that while changing the analyser was intank fuel filter, somehow debris had hooked up where caused the fuel pressure regulator to the first clue stick slightly open, enough to cause this was evident – no 3 problem. residual pressure or fuel volume in Attempts had been made to clean the the line (pic 2). regulator with compressed air, to no avail. With the ignition switched on, the system did not prime and the fuel analyser gauge Thanks to Ryco GUD and Goss for did not start to rise. It is important to 4 their technical input. mention this as it is normal for this car. The Automotive Technician 39

Workshop Mate… more than just a press! The safest most versatile A glow plug undercar workstation NEW MODEL 2016 WORKSHOP MATE warning Australia’s leader in research & his is a development of undercar equipment! cautionary tale about 2005 Jeep Cherokee KJ  NEW FEATURE - the only press with a changingT glow plugs. hanger to press wheel bearings in rear There was a voltage change on the glow plugs from hubs without disassembling the brakes 7V to 5V requiring a whole new set of glow plugs and a (Patent pending exclusive to Workshop Mate) new glow plug module.  MORE TOOLING - 62 pieces of specialised After diagnosing one faulty glow plug on this 2.8L CRD Jeep the system had to be converted to a 5V system tooling to fit Australian model cars instead of 7V.  TALLER & WIDER - with a larger bed for This meant replacing all four glow plugs and a glow plug module. This was the information received from the parts easier use interpreter.  FREE undercar porta power So after purchasing four new glow plugs and a new module at $1,200 and taking four hours to access,  FREE oil filter crusher diagnose and then replace them, one very vital piece of information was left out.  FREE four swivel castors with brakes A software upgrade must be done when converting to 5V at the time of replacing the glow plugs and module.Lack of this information resulted in failure of the new glow plugs just one day after fitting and possibly the module as well. The vehicle was on its way to the dealership for a software upgrade and we may be up for another $1,200 in parts and their labour to fit. I hope this story helps to prevent others from falling into the same trap. Chad Condipodero Auto Response HIGH WYCOMBE WA (Thanks for this great warning Chad. We investigated a little further and found that the original glow plugs were a ceramic type, no longer available through the manufacturer, but they have been superseded by a metallic glow plug. The ceramic glow plugs are coloured white and the metallic are grey. Emery paper should be used to scratch the oxidation of the sensor to see which type you are dealing with. A new module must be installed and programmed at the same time as the replacement of the ceramic glow plugs Don’t be fooled by cheap imitations! with the metallic plugs. TaT Tech Team Call 1300 766 050 for your free DVD to view this unique piece of equipment www.acvautotools.com.au

The Automotive Technician 41 2002 PEUGEOT 307

his car had a misfire and there had The front O2 sensor controls the short been new plugs, new ignition coils An investigation of an term fuel trim and when the sensor is and you name it thrown at this car. engine running rich showing a rich condition, the short term T fuel trim will go negative and the engine It would run well and all of a sudden start by Maurice control module (ECM) will shorten the on to misfire. It did not take me long to work Donovan time of the injector and vice versa if the out No. 2 injector was at fault. It was O is reading lean. But few of us realise replaced and it fixed the misfire. 2 that in some vehicles the manufacturer’s

But this car had a secondary problem. I software also looks at the rear O2 sensor was unhappy with what I was seeing on when calculating fuel trims. the scan tool. There was way too much Now it was time to think With this in mind could the rear sensor fuel being taken away from the fuel trims, outside of the box be affecting the fuel trims? So again indicating a rich engine condition (pic 1). A variable resistor (pic 2) was hooked thinking outside the box, I removed the

up to the MAP sensor signal wire and a front O2 sensor and ran the car with good ground. Watching the scan tool, I the sensor sitting outside the exhaust

adjusted the variable resistor until 32kpa system. My thinking was that the front O2 appeared on the scan tool MAP parameter sensor would read a low voltage due to identification (PID). not being in the exhaust system and the extra oxygen that would be entering the With the engine idling and the MAP PID cat through the open hole where the front now sitting on 32kpa, I was expecting the O sensor screws in, will cause the rear fuel trims to come down to a reasonable 2 sensor to also run lean. value, but they didn’t, so I knew my abnormal MAP value was not This is exactly what happened, but 1 Car idling with negative fuel trims and causing the negative fuel the fuel trims remained negative, high MAP value trims (pic 3). 3 so I have now proven that the O sensors were not the The carbon canister Good engine 2 Fuel trims indicate the overall condition vacuum at idle reason for the negative fuel evaporative vacuum of the fuel delivery and the electronic fuel trims (pic 4). injection (EFI) system. purge line was disconnected, If there was a mechanical Fuel trims need to be checked at different to rule out the problem there would not be RPM under load conditions. A vehicle that possibility of a the correct engine vacuum. is adding excessive fuel at idle and comes leaking purge valve. Considering all external back into normal control above 2,000RPM Fuel pressure was possibilities were covered, it is indicating a vacuum leak. Where the checked to ensure there was time to turn to the ECM fuel trims are good at idle but add fuel was no excessive fuel that manages the fuel trim. under load indicates poor fuel delivery pressure. The pressure gauge or dirty mass air flow (MAF) sensor. Fuel The powers and grounds were was left on in the car for an extended confirmed OK, so it was time to question trims reveal a lot of valuable diagnostic time to make sure the gauge did not drop information. the health of the software. The Peugeot off pressure too quickly – that would have dealer confirmed there was no updated I go along with the school that says up to indicated a leaking injector. software for this car, so it would seem to or below 10% fuel trim value is acceptable. be an ECU issue. The car owner opted Others say anything over 5% is not normal What else can cause an to take the car as it was because, after or acceptable. I find that as vehicles engine to run rich? all, the original misfire problem had been age, with higher mileage on them, 10% fixed. compensates for normal deterioration of The engine breather was OK. If the EGR the EFI system. valve was stuck open and because Conferring with the TaT Tech Team, I was this engine was a speed density told that just because the fuel pressure This Peugeot had a total engine (meaning it is a MAP wasn’t dropping rapidly, it did not rule out fuel trim of –14 up to sensor fuel controlled that it was the injector – and there was a –24 at times, and it was engine) it could be case study to prove it. the same throughout expected to show a The Peugeot was recalled and for no all RPM and load vacuum drop if the 2 charge, the injectors were removed and conditions. This was EGR was opened flow tested, but they were OK. indicating a rich at idle. But there condition that would was no drop in Everything was checked one more time trigger the malfunction vacuum when with no new conclusion. The customer indicator lamp (MIL). the engine vacuum was was happy to drive the car knowing full The other abnormality tested, and the MAP had well that the MIL could come on. was the manifold absolute already been manipulated to I can’t say my time was wasted. I had pressure (MAP) sensor that read a normal value at idle. covered myself for when the MIL does was reading 40kpa at idle when it should It did not fix the fuel trims, so come on, and I spent the time to relay all have been around 32kpa. This was a this ruled out the EGR being the moves to the car owner. real concern and most likely the reason the cause of the problem. for the rich condition. The engine vacuum was sitting on 20In Hg (inches of mercury), The O2 sensors were properly checked indicating a good breathing engine and and I felt confident they were not my therefore not the reason for the high MAP issue, but also noted was that the rear O2 reading. MAP powers and grounds were sensor was following the front O2 sensor when hot. good and there was a signal voltage, but 4 Using the variable resistor to manipulate I was unsure of what the correct signal Obviously the catalytic convertor was no the MAP sensor value on the scan tool and voltage should have been at idle. longer effective. there are still negative fuel trim readings

The Automotive Technician 42 Diagnostics can be a snap The Automotive Technician

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“Tech-Centre is not only

Times Guide Times able to help you with your VACC Times Guide Eleventh Edition ry The Times Guide for Mechanical Repairs Eleventh Edition was o is researched and published by the Victorian Automobile Chamberv of Commerce technical repair issues d Times Guide -A For Mechanical Repairs h but is able to provide the c e T most relevant and accurate de ui G s information every single time.” e im Mark Purnell T M & J Auto Electrics Merrylands, NSW

For Mechanical Repairs Eleventh Edition

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trusted, tailored products and services. ourauto.com.au 16-031 OA_TaT The Automotive Technician 44 ar owners are reducing its boiling point by 75 e generally ignorant degrees. lin about the role played Video to combat market n O Once the brake fluid has been - by brake fluid and neither do h C c changed it is important to e they understand why fluid T ignorance about brake bleed the system to remove levels should be checked lk any air bubbles trapped in the a and the fluid changed -T line which may cause a spongy h c regularly. fluid e brake pedal and in extreme T This research finding has cases, brake failure. prompted brake manufacturer Automotive information at your fingertips Bendix DOT 3 High Bendix to produce a video Performance Brake Fluid is that might help in workshop suitable for use in ABS/non communications with ABS disc and drum brakes customers. and hydraulic clutch systems “Tech-Centre is not only Brake fluid is designed with a pooling and corrosion on metal into an estimated boiling point in cars, trucks, buses and high boiling point to withstand components in the system. and, since brake fluids vary motorcycles where FMVSS

Times Guide Times able to help you with your Elevated moisture levels over in formula, such a test will VACC Times Guide Eleventh Edition ry the extreme temperatures DOT 3 fluids are specified. This The Times Guide for Mechanical Repairs Eleventh Edition was o is researched and published by the Victorian Automobile Chamberv of Commerce technical repair issues time reduce the boiling point not provide a result unless d Times Guide generated during braking and fluid is straw in colour. -A For Mechanical Repairs of the fluid, resulting in a the tester is calibrated to the h but is able to provide the needs to be checked to ensure c reduction in effectiveness of manufacturer’s product when Bendix DOT 4 High e it meets the exact temperature T most relevant and accurate Performance/Heavy Duty de requirements. the brake fluid. new. ui Brake Fluid is suitable for use G s information every single time.” In hot weather or under The tester recommended by e Both DOT 3 and DOT 4 are in ABS/non ABS disc and heavy braking, moisture can Bendix is one that heats the im Mark Purnell hydroscopic fluids which drum brakes and hydraulic T M & J Auto Electrics absorb moisture when vapourise, causing the system brake fluid to determine the clutch systems in cars, trucks, Merrylands, NSW exposed to air in instances to lock, and leading to a soft correct boiling point. buses and motorcycles. DOT 4 brake pedal or complete brake where the reservoir cap is Such a test takes less than a fluid is blue in colour. failure. opened or through brake lines minute to accurately measure where the moisture level can Two common tools are used to the boiling point and confirm Brake advice 1800 819 666 (Aust) build up over time through test brake fluid – a conductivity if the brake fluid has absorbed +61 3 5327 0211 (NZ) microscopic pores in the line. tester or a boiling point tester. too much moisture to be safe. [email protected]

For Mechanical Repairs Eleventh Edition This is a normal process of Conductivity testers estimate In just twelve months, brake www.bendix.com.au the brake fluid’s life cycle and the moisture content by fluid will have absorbed www.youtube.com/bendixtv moisture absorption prevents converting the conductivity approximately 2% water,

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maintenance requent driving over VACC 464 St Kilda Road, Melbourne VIC 3004 rough roads full of T: 03 9829 1111 W: vacc.com.au entury Batteries © 2013 Eleventh Edition Website and marketing solutions potholes, or even the has launched the Fubiquitous speed bumps can next generation of have serious consequences “I would recommend CAustralian-made batteries for vehicle suspension, tyres that are sealed and maintenance-free. OurAuto to all automotive and steering components, vehicle suspension movement businesses that are looking The batteries are a perfect balance between cranking according to suspension at safe limits, helping the performance and battery life. They incorporate a labyrinth experts at Monroe. brakes and steering to do their for a professional service, lid system and heat sealed double lid to reduce water loss job by maintaining traction Cumulative damage can occur a website that looks great while increasing electrolyte levels. with the road at all times. The over a period of months and shock absorbers, struts and and achieves solid results.” Their cutting edge plate designs and special paste braking distances may not associated components also Stuart Hunter formulations combine to deliver superior cranking become evident until there’s distribute the vehicle’s weight Stuart Hunter Motors performance, corrosion resistance and heat tolerance. an emergency. Workshops across all four wheels, limiting Moorabbin VIC In designing these batteries, Century is keeping up with in country areas particularly the transfer of weight from the complex vehicle technology that is placing greater demands should do their customers a front to the rear when braking on the battery. Century invests significantlyin research and favour by adding inspections and from side to side when development to keep pace with the of shock absorbers, strut turning. next generation of vehicles. mounts, steering components The popularity of low profile and wheel alignment to service The latest sealed and tyres in modern cars has also visits. maintenance-free batteries took increased the rate of tyre two years to perfect, plus a A vehicle can only stop in the and wheel damage caused Book a consultation before September 30, and present this ad to receive a FREE Samsung tablet if you purchase a website multi-million dollar investment shortest time and steer at its by rough roads. Monroe in their Queensland based optimum levels of safety when recommends that shock manufacturing facility. its shock absorbers, struts, absorbers should be checked strut mounts and bearings are particularly when there are At OurAuto, we protect, inform and help automotive not worn or damaged. The obvious signs of tyre and businesses around Australia grow, by providing 1300 687 288 1300 362 287 damping action performed by wheel damage caused by www.centurybatteries.com.au these components maintains potholes. trusted, tailored products and services. ourauto.com.au 16-031 OA_TaT The Automotive Technician 45 Business training – turn on your headlights

on’t you wish your business had a good set of A financial dashboard is not dissimilar to a car’s dashboard headlights, enabling you to see a long way ahead, and which is covered in gauges and warning lights. You would hardly even around corners, so that you could be cashed up recommend to your customers that it’s OK for them to drive Dand prepared for any emergency. around in their new car with only the speedo working and every other gauge and warning light turned off. And don’t give me the old ‘I was trained to fix cars, not balance the books’ excuse. If running your business feels like driving your business with the headlights off, it’s time to build your financial dashboard. Alone, Fixing cars is a trade, for sure, but once you step over the line it won’t make your business more profitable but it will help you to become a business owner as well, it follows that you are now make better decisions that will lead to a more profitable business. really involved in two trades – fixing cars, and running a business to make a profit. By setting up a financial dashboard, a business can monitor and track critical numbers, called key performance indicators. The financial dashboard will contain a number of these indicators, such as the number of jobs invoiced, staff time invoiced, number of complaints and re-works, cash balance, debtors and creditors due, total sales, cost of goods sold. Most of these numbers should be in your point of sale system. A financial dashboard means that all key performance indicators are on one page – easier to see the whole picture and easier to track performance. It means the business owner gets early warnings of problem areas. For example, the dashboard may flash the warning that debtors are on the rise. Something can be done about this before the money in the bank dries up.

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