April 2011 Issue 20 www.tat.net.au

Where would the V8s be without the good oil?

$115 gives you: • 12 months subscription to TaT • Six magazines mailed to your postal address • Access to illustrated solutions on line • Technical assist service

Cover pics APPLY ON PAGE 36 Ross Gibb Photograpy • When capacitors • A throttle position sensor • Nothing like a few ‘s a fact leak, you’ve got had internal injuries on missing teeth on this problem solving trouble on this Mazda this Honda Jazz Merc to spoil your day Petrol/Diesel/Electric Engine Data

Advanced functions key programming, Key Coding/PCM/ module programming to 2011 levels Programming Bonus Rellim Code Book (2000 pages) - 20,000 GPS - SAT Nav PDQXIDFWXUHUVSHFL¿F'7&HQWULHVHPEHGGHG Data Ignition/Electrical/ Rugged high quality construction covers OBDII Systems Data 12V & 24V vehicles Easy user interface, advanced graph & record functions ABS/Brake Systems/ OQERDUG&$1SURWRFROVIRUFDUV:'¶V EPS Systems Data & Infotainment $VLDQWUXFNVWRPRGHOV Service/Reset Data HLJKTXDOLW\RXWGRRUUHDGDEOH colour touch screen SRS-Airbag Systems LDUJHVXSHUIDVWXSJUDGDEOH Data & Analysis 6'PHPRU\ Dual CPU super fast Transmission :LQGRZV&(SODWIRUP Data PCLQWHUIDFHYLD:L)L RUGLUHFW6'

Best Asian Scan Tool GLOBAL VEHICLE SCAN TOOL TECHNOLOGY

G-Scan the number one selling scan tool in Japan & Korea for quality & accuracy - now it’s Australia’s turn!

Genuine OEM Korean Scan Tool!

Japanese, Australian, European & USA based engineering teams!

Korean development team with over 100 engineers!

Offering the latest in high tech features & technologies!

Complete advanced truck coverage including DPF regeneration, injector coding, suction valve relearn

... and so much more!

2 Years FREE Updates - Update via Internet or CD call 02 9905 8055 www.gscan.com.au www.gscan.co.nz for your nearest G-Scan Distributor with Ken Newton in my business life about how a technician needs to have to make money was really only when a new customer arrives puff and nonsense. Some of with a broken down car in the opened my first private Can you technicians reading these motivational people are driveway. business a long time ago this hear yourself saying very entertaining but all they and, like far too many something like that? really leave you with is a warm Deyan says it’s often just the amateurI but enthusastic and fuzzy feeling that you can way you ask questions and entrepreneurs, I was satisfied These thoughts crossed my do anything if you try. Not very look at something when it that my talents were saleable, mind as I sat in the wings helpful, when you really want to is described to you that can that the world would beat at the opening night of our know how. determine whether the job will a path to my door and TaT Biz-Capricorn business be a breeze or a nightmare. that, provided I had a good improvement program in It’s the how of business that accountant, I would make suburban Melbourne. There’s got our first TaT Biz sign-ups Here’s his list, in Crownie order: a profit and build a great a review of the program in this going. One lady who runs the empire. edition. front office of an auto business • Tenacity is a necessity in Melbourne used the TaT Biz Yep. I built an empire. Well, a So where were the Geoff telephone answering scripts • Pig-headedness is a small empire. And I did make a Muttons of the world when I the very next day and was so plus profit. started my business. Geoff excited when it actually worked. • Logic is a bonus and Jeff Smit, who performed But looking back, I don’t need a great double act for opening • Lateral thinking helps She could almost feel the any accountant to tell me that night, got me so excited I • Confidence does unknown callers opening their I might have made a lot more wanted to rush out and start wonders for the client wallets as they realised they money had I understood a lot another new business, if only to were dealing with a hot shot and • Look for a possible more about invoicing and staff try out some of their strategies confident workshop that knew secondary cause of a management. And being able to for winning, holding and making what it was doing. fault read a profit and loss statement a nice profit out of clients. • Know where to get might have been handy. The Quite independently of this information or help thing is I trusted others to look Having been to quite a few great new program launch, after me. Big mistake. ‘Don’t of, what should I call them, • Ask why and how fellow director Deyan Barrie confound me with figures’, I business motivational lectures, things work was pondering the meaning of used to say. ‘I’m the creative over the years, I quickly realised • Don’t sell yourself life over a Crownie one evening one and I know how to satisfy after hearing the TaT Biz spiel short after work when he came the clients.’ that everything else I had heard up with his list of attributes

The TaT team Contents

Publisher International correspondents Cover story - V8s and oils……………4, 5 •TaT Assist •TaT Chat •TaT Train The Automotive Technician Pty Ltd Julian Hentze - Georgia USA TaT Biz gets them buzzing………………7 •TaT’s a Fact •Tips for TaT ABN 27 121 589 802 Hayley Windsor - Australia Beetle goes hybrid………………………8 are all registered trade names of You said it - the little blue wire…………8 The Automotive Technician 72 Holtermann Street Reader Sanity prevails in bull bars and bombs……8 Pty Ltd. CROWS NEST NSW 2065 Bron Robinson Aftermarket Expo a must-see event……10 The trouble with auto technicians………10 The Automotive Technician Pty Ltd [email protected] Advertising inquiries publishes technical advice and Research before you quote……………13 Ph 1300 828 000 Jeff Smit actual case studies for the Letter from America……………………15 Fax 1300 828 100 [email protected] purpose of educating technicians. The wonders of waveforms……………16 Ph 02 9966 8600 Diesel may yet dominate……………18, 19 Editor in chief These advices are given in good Tat’s a facts……………………20, 21, 22 Ken Newton Graphic design faith, and are based on actual Wire & Gas training……………………24 [email protected] Russell Jones workshop repairs. No guarantee is Competence before price ………..……26 0438 569 517 Russell Jones Graphic Design given, nor any liability accepted in You said it - what a hummer……………27 Fax 1300 828 100 07 5532 2840 0408 123 287 respect to any published advice. Blow that fuse…………………………28 Technical editor [email protected] Hybrid tools for hybrid servicing………28 The Automotive Technician Pty Ltd Honesty pays…………………………29 Jeff Smit is not responsible for the accuracy [email protected] TaT logo design You said it - airbag aftermath…………30 of any information contained in Diesel fix at Bosch training……………30 1300 828 000 Allan Green material submitted by third parties CEO Design Hygro not hydro………………..………30 Technical research and published in this magazine and [email protected] Street Cred with Hayley Windsor………31 Deyan Barrie accepts no liability in relation to Dual Mass Flywheels diagnostics………32 [email protected] such materials or their content. Murphy’s Law…………………………34 Printing 02 9476 6277 Where are the hybrids?…………………35 Immij NSW Newsworthy articles or comments Training calendar………………………36 Technical advisers 3/12 Mars Road, are welcomed, and should be Tat’s interesting………………………38 Jack Stepanian submitted to the editor in chief. Lane Cove NSW 2066 TaT Biz tips and tricks…………………38 Nick Murphy www.immij.com.au All material appearing in The [email protected] Automotive Technician is copyright. The Automotive Technician is a member of Affiliated associations Reproduction in whole or in part is the Circulations Audit Board. Wayne Broady VASA [email protected] illegal without prior written consent CAB Audited from 1 April to 30 Sept 2010 www.broadyauto.com.au AAAA member [email protected] from the editor in chief. Average net distribution per issue 9,928 Gil Sher Capricorn Society Alliance Supplier [email protected] All advertisers agree to indemnify the publisher for all damages or Garry Reid liabilities arising from their published [email protected] or unpublished material.

The Automotive Technician 3 Where would Gypsy Marshall, the V8s be top V8 mechanic without the

Cover story by Ken Newton good oil?

at Mazda when he volunteered nothing left to tweak? ‘It’s getting not the other way around. to help out the Allan Moffat team. hard to find any more power il, that slippery stuff He travelled around Australia in in an engine that’s already ‘Later model engines have that stops metal bits this role and enjoyed it so much been through every kind of smaller clearances because Ofrom seizing, has that when a job as a truck driver modification,’ says Gypsy. ‘So oil of the improvements in oil not been particularly front came up with Garry Rogers became the last resort.’ technology,’ Gypsy explains. of stage in the evolution of Motorsport, he grabbed it just to the motor vehicle. So much get in the door. If an oil could be developed that media attention is lavished was thin enough to be more on engine technology, but Sure enough, after a year economically pumped through oils rarely rate a mention. of driving trucks, Gypsy was the engine but still reduce the transferred to the engine room friction on moving parts, the V8s and he hasn’t looked back. By might have found a little more The days when one oil did his own admission, he is a power and performance. everything are long gone, for tinkerer. About three years ago, the team had its first major breakthrough when Valvoline came up with a synthetic oil 5W30.

‘It’s hard to imagine the pressures inside the engine when thick mineral oil is forced through it. We gained eight horsepower or more when we changed to the new and much thinner synthetic oil from the ‘Using a heavier oil in some mineral oil 25/60,’ Gypsy recalls. components means that when starting cold engines, Gypsy and his team are hoping the oils can’t move fast reasons that are only now ‘I’ve always played around with for even further advances in oil filtering through to the mechanics engines,’ he said. He’s been with technology to give them an edge enough to where they are and technicians. And if the failure the Garry Rogers team for the on the race track. needed. rate of components is any guide, past 13 years. there are still a lot of mechanics out there who think that one Until three years ago when they drum of good oil in a workshop is moved the workshop, they used enough for any job. Many seem their own engine Dyno testing to have forgotten that engine oil machine, but now, without a performs four rather important Dyno, the team leases their tasks — lubricate, protect, clean engines from Walkinshaw and cool. Performance, the GM Holden specialists. These people need to spend a few minutes with Geoff (better Gypsy’s job is to assemble the known as Gypsy – perhaps it’s engines for racing, adding the the ear-ring) Marshall, engine accessories and helping to fit builder and mechanical overseer them into the racing cars. for the Garry Rogers Motorsport team. For up to 16 weeks a year, Gypsy is at the track, eking out Gypsy is responsible for the every extra horsepower and engine preparation and ultimate economy through fuel mixtures performance of the Fujitsu V8s, and anything else that can be the team that finished third in the tweaked. The racing industry’s growing ‘Thick oils just can’t make it 2010 teams championship. reliance on thinner oils points up where, for example, cam shafts And therein lies the biggest the need for technicians working are running in the cylinder head. Gypsy’s progression to a job challenge for racing cars. What on street vehicles to understand The car makers have grasped that is the envy of other motor happens when everything that parts are now being the oil improvements to enhance mechanics began with his stint has been tweaked till there’s designed around specific oils – engine performance.

The Automotive Technician 4 ‘There are always going to ‘Piston life will be out the door Wheelnote: Garry Rogers began effort for the team not only to be improvements, even when and exhausts will run a lot racing Appendix J Holdens in run the V8 Supercar program you think that nothing more hotter than before. Crankshaft 1963. Garry Rogers Motorsport but also to design and build the could possibly be improved. maintenance will also be high,’ has become one of Australia’s Holden Monaro from the ground I’m guessing that people like Gypsy added. most professional and successful up. Valvoline are heading in the motorsport organisations. same direction. Some oils are as Translating the ethanol fuel After the success of the now light as water now – how far can research in the racing industry The team has had an enormous famous 427 Monaro in its first they go,’ asks Gypsy. to the consumer market, Gypsy impact on Australian motorsport, year, a second Monaro was warns technicians that as and Garry was instrumental in developed for the 2003 season. He expects oil improvements will ethanol fuel becomes more the development of many of This year was highlighted by lead to longer intervals between popular they will have to get Australia’s top drivers, including wins in Nation Cups events and oil changes because the new on top of the fuel system. Filter Steven Richards, Garth another Bathurst 24 Hour one/ synthetics will be capable of blockages occur a lot quicker Tander, Jason Bargwanna, two finish, with Peter Brock, Greg Jamie Whincup and Cameron Murphy, Jason Bright and Todd absorbing impurities inside the than usual and the injectors need McConville, along with their Kelly joining the existing team engine more effectively and for a to be cleaned more frequently. current drivers Lee Holdsworth and driving the race winning car. longer period of time. Better oils Because it’s a dry fuel, pumps and Michael Caruso. may have given V8 racing some wear out quicker and some In 2010 the Garry Rogers team One of the team’s greatest finished third in the teams successes was winning the championship. The team is 2000 Bathurst FAI 1000 with supported by Fujitsu, Valvoline, Garth Tander and Jason Cummins and Holden. Bargwanna behind the wheel of a VT Commodore. Bathurst has All photographs kindly supplied provided notable highlights for by Ross Gibb Photography the team including winning the [email protected] inaugural Bathurst 24 Hour in www.rossgibbphotos.com.au the Holden Monaro, with Garth Tander, Steven Richards, Nathan Pretty and Cameron McConville, during the 2002 season. AZThisHSY wasAutoparts a massive 92x135 eng V2:210 x 297 22.03.2011 12:01 Uhr Seite 1

Ignition Technology Diesel Cold-Start Technology Electronics Sensors power advantages but the same fuel lines, especially those with could not be said about green rubber content, are just not fuels. While going green by using compatible. Technicians will have ethanol fuels was, and still is, a to be careful about anything noble initiative, it caused major made of aluminium because BERU. Innovation headaches for the technicians ethanol fuel tends to corrode it. at Garry Rogers Motorsport and The car racing industry had to built in. what they went through serves spend a huge amount of money as a warning for technicians in to find out these things. Initially m o c the aftermarket repair sector. performance went backwards . u r

by as much as 20 and 30 e b .

horsepower. w

As Gypsy explains ‘We had to do w w extensive cylinder head work to BERU Ignition Coils BERU Ignition Cables BERU Ignition Parts suit ethanol fuel and we now find ‘As a result of our intensive work, we’re using 30% to 40% more we are now back to where we fuel than before to generate the were in pre-ethanol days,’ Gypsy same amount of power.’ said.

BERU ‘Certainly the emissions out of There are big plans ahead for Ultra Spark Plugs the exhaust pipe are much better the V8 supercars. Developments than before, but we’re using across the industry are pointing so much more fuel because of to a new breed of vehicle on the burn characteristics of the the track by 2013. They won’t ethanol, among other things. BERU Glow Plugs: go much faster but the cars and High market coverage and their technologies will be closer top-selling product lines. ‘It takes a couple of years to to one standard than ever before figure out how to produce the and this will translate to better same or more power with a new racing. Gypsy is forecasting that fuel and, in ethanol’s case, once V8s as road cars are on the you take away the environmental way out and even the days of For more information call 1300 133 129. rewards, it’s a lot of money for the petrol powered engine are very little gain. I forecast there numbered with diesel becoming A BorgWarner will be huge changes to engine more efficient and inroads being Business maintenance with E85 fuel. made by hybrids and electrics.

The Automotive Technician 5 The Automotive Technician 6 ‘What’s different great deal out of understanding Another first nighter, George gets them about this business the relationship of a well Naidu, who owns the Suntyre training program presented workshop to customer Brake & Front End Service at is that the TaT Biz satisfaction,’ said Adam. Sunbury, Victoria was more buzzing guys, because they impressed with getting access to are in the trade, have Feedback from Capricorn a network of like-minded people good insight into the area managers in Victoria willing to share ideas. ‘It was a issues facing small indicates that many of the pretty good night,’ he says ‘I got auto businesses and technicians who attended the some very useful information they deliver at a level introductory session to the 9 just out of the introductory we can relate to,’ steps program couldn’t wait to session, so I happily signed said David. start implementing changes to up for the 12-month program.’ their business techniques the George has run his own ‘I’ve done next day. Several have reported business for 13 years, but has management immediate improvements in their been 30 years on the tools. courses before and bottom line simply by adopting I come from a very the phone answering techniques Others who signed up in the first structured dealership outlined in the 9 steps. week of the program admitted background so I was that ‘a lot of the stuff they are in a good position As Steve Penney, an area telling us we already know’, but to judge this new manager for Capricorn in they joined up because ‘the training program. Victoria said, ‘A lot of people go trainers were able to put it into George Naidu signs on the dotted line to the 9 steps program, with a Capricorn area manager Steve Penney. to these improvement sessions words we could understand and ‘The fact that this and the next day, nothing they gave us achievable goals he TaT Biz business program has a changes. With this program to aim for.’ Others said that even improvement program strong auto industry base makes there is so much grass roots if they walked away with only has opened in Victoria to it very understandable and material which can be put into one or two good ideas in each Trave reviews. achievable. My wife Judy, who practice the very next day and month of the 12-month program, it would have paid for itself. The TaT and Capricorn Society move to introduce the co- Judy Flaimer decided to try out a couple of the TaT Biz branded 9 steps to a better phone answering templates workshop series of training the morning after the training events has caught the auto session. ‘It actually works,’ she aftermarket a little by surprise. said. ‘I could feel the attitude of the customer changing While there is no shortage of every time I asked a question business improvement ideas and I’m convinced that this floating around, this is the simple change will help us gain first one to be designed by new customers who trust our successful auto technicians for professionalism and expertise the Australasian auto workshop. and as a result it should impact on our profit levels.’ Geoff Mutton (back left) TaT Biz co-author and trainer and Jeff Smit, TaT technical director, The first-night audience at the celebrate the first signature to the 9 steps program from David and Judy Flaimer (seated at Melbourne suburb of Sunshine right). They were accompanied to the first night by Nathan Briffa . All technicians interested in this might have been small, but program, whether or not they the results were beyond the are Capricorn or TaT members, should contact their Capricorn expectations of the TaT Biz manages the front office at our the calls we are getting prove Area Manager or the Capricorn team and apparently also the business, and I got so much out that it works. Now that we Events team on Australia workshop owners who attended. of the introduction session that have attended a few sessions, freecall 1800 999 233, or New There were 11 in the class, we thought it wise to share these we will be able to sell it more new ideas with senior staff. enthusiastically to our members, Zealand freecall 0800 401 representing seven businesses. 444, or for more information, go Six of them enrolled in the They don’t need to understand because we all now have a it all, especially the financial better understanding of its online to: ongoing program which takes a www.capricorn.coop. year to complete. components, but at least it would effectiveness.’ help the business make changes The owners of the LPF to the way it operates if senior Automotive workshop in Bulla, staff took some ownership of the Victoria, David and Judy program and at least understood Flaimer, became the first in why we want to improve our Australasia to sign up for the business,’ added David. new business program and they began implementing some of the Their head mechanic, Adam TaT Biz ideas the very next day. Bau, who started at LPF Automotive as an apprentice They were so enthusiastic that at the age of 16 was just as they phoned their Capricorn enthusiastic as his employers. ‘It was really good and I picked area manager the next morning up a lot of good tips. Because to book their head mechanic I’m responsible for activities into the next available session, like opening and closing, staff which was later the same week Christian Norrish, Pepcar (seated left) was among the first to sign up to theTaT Biz uniforms and general upkeep program. With him is Neil Richards, Capricorn sales manager in Victoria, and behind in Epping, Melbourne. of the premises, I gained a them are Jeff Smit (left) and Geoff Mutton. The Automotive Technician 7 The beetle olkswagen, It uses a seven-speed direct-shift gearbox twin-clutch now the transmission. goes hybrid V world’s third largest car company, The compact electric motor is energised via a lithium-ion battery has unveiled a and being a plug-in hybrid it can be charged from a wall socket prototype two-seater when not in use. It’s good for a 35 kilometre distance before eco car concept needing to use the diesel engine. with gullwing doors, that uses less than VW claims the XL1 has a top speed of 160 km/h and a 0 to 100 one litre of fuel per km/h time of 11.9 seconds. The smoothly surfaced prototype 100 kilometres achieves its efficiency not only via its miserly travelled. engine, but also its light weight and aerodynamics. Its carbon-fibre body The Volkswagen XL1 prototype is the culmination work helps reduce overall of nine years research by the German company weight to just 795kg, and for an ultra efficient combustion engine car. it slices through the air Powered by a twin-cylinder 800cc turbo diesel thanks to a drag co- electric engine and electric motor that outputs efficient of just 0.186. a combined total of 55kW, the XL1 has a claimed fuel economy rating of just 0.9 litres per 100 kilometres while A production version of emitting 24 grams of CO2 per kilometre. the XL1 is not too far off.

YOU SAID IT! Watch out for the little blue wire

We investigated the wiring amplifier under the wiper Gary Homan he vehicle: Holden diagram and then traced the panel supplying the earth and Nudgee Automotive Commodore Calais problem to the blue wire at the bypassing the relay as the fan NORTHGATE QLD VS 1996 with a 3.8 V6 fan blower motor supplying the has a constant power supply. (Good job Gary. Sounds like you engine.T earth circuit for the blower fan. are nailing some of these problems. This is a climate control system This is a common fault and should The interior blower fan was The relay in the engine bay for so the fan amplifier we replaced go into the system for further constantly on, even with the the blower is a ground circuit. was $190. reference. Thanks for the feedback. keys out of the vehicle. We traced to a faulty fan Deyan)

Sanity prevails on bull bars and bombs

he federal government account of the safety needs of delivering no tangible benefit to has thrown out two millions of Australians living, the environment. They labelled Don’t forget to share obviously ridiculous working and holidaying in outer it another pink batts debacle Tpieces of legislation relating urban and regional areas. waiting to happen, but this one undreds of TaT to the car industry — the The feds recognised this and was on wheels. subscribers have used bull bar ban and cash for withdrew the proposal before the TaT assist service clunkers. the consultation period closed. The fundamental flaw in vehicle Hoffered at www.tat.net.au but scrappage schemes is that with a few exceptions we have Led by that tenacious Then there was the ‘cash they focus on vehicle age no idea whether the advice watchdog, the Australian for clunkers’ plan, a psuedo rather than actual emissions offered helped find the way to a Automotive Aftermarket environmentally happy scheme produced. This approach solution. Association (AAAA), the in which owners of old vehicles is based on the erroneous industry reared on its hind legs would be offered a guaranteed assumption that old cars are TaT director in charge of this to point out the stupidity of a and inflated price to get them dirty cars. However, the true service, Deyan Barrie, would like ban on bull bars on vehicles and their belching exhausts out culprits are gross polluters — to remind technicians that TaT is because of possible harm to of circulation. vehicles of any model year that a sharing network. In other words, pedestrians. The government are poorly maintained. we help you—you help us. was slavishly following a If only the feds read their European ban until they newspapers or did a modicum The AAAA asked ‘Do we grasped the fact that driving of research, they would need to give 200,000 people The whole idea is that TaT wants in most of Australia is very have discovered that similar $2000 of taxpayers money to share all of its fixes with other different to driving around programs were an abject failure to buy an imported car that TaT subscribers. If TaT assist gives Europe. in America and Europe. delivers average environmental you a lead to a solution and it performance, when the car works, we’d like you to send us an The AAAA submission pointed As the AAAA pointed out, the they own now could achieve email telling us how you solved the out that the European ban scheme was ill conceived, significant improvements in problem. Even if our ideas didn’t focused on pedestrian safety open to rorting and abuse and emissions performance after a lead to a solution, we would still in an urban context. It took no would have cost jobs while simple service.’ like to know the outcome.

The Automotive Technician 8

hsy add A4 FINAL OUTLINES.indd 1 21/3/11 9:40:47 PM The Automotive Technician 9 hsy add A4 FINAL OUTLINES.indd 1 21/3/11 9:40:47 PM f you’ve never been to a really big Among them will be exhibitors’ special trade show before, do yourself a offers, dynamic displays, product launches favour and make the time to attend Aftermarket and competitions. For the show car Ithe the 2011 Australian Automotive enthusiasts, there will be displays of award Aftermarket Expo to be held at the winning street and competition machines. Melbourne Exhibition Centre from Expo is a must- Thursday 12 May to Saturday 14 May. The Automotive Technician will be at You’ve got nothing to lose (because it’s see event the Expo and you will free) and a lot of new information on tools find Jeff Smit, Deyan and technology to gain. Barrie or Geoff Mutton on the Capricorn With 400 stands, this is the country’s stand (G54) where largest display of workshop equipment, you can bend their products and services, organised by ears on any aspect of the Australian Automotive Aftermarket the TaT network or the Association (AAAA). new TaT/Capricorn Jeff Smit from TaT co-branded training AAAA Executive Director, Stuart Charity, program 9 steps to a summed it up, ‘Trade visitors will enjoy better workshop. a feast of displays offering leading edge technology in diagnostic and repair Among the many demonstrations that equipment driven by sophisticated caught TaT’s eye was the mechanic’s electronics, the latest workshop tools clutch replacement challenge on the and equipment, and state of the art Schaeffler Automotive Aftermarket stand replacement parts and consumable (Q28), where its OE quality LuK, INA and products from all major manufacturers and FAG product range will be on show. resellers.’ So if you fancy yourself in the clutch replacement department, join in the The Expo will again have the separate mechanic’s challenge. It will be held on Collision Repair Expo next door. the stand and will be a competition to see who is the fastest to undertake a In addition to the equipment and challenging LuK clutch replacement. The products on display, the Expo offers The Mainline DynoLog AWD 1800 Chassis winner will roar around in a racing car at seminars featuring expert Australian and Dynamometer will be in action at Expo. the track day prize. There will also be live international speakers, who will provide demonstrations during each day of the an update on the progress of the Choice eliminating any technical or legal barriers show and experts will be on hand to help of Repairer campaign in Australia, Europe that have an impact on the car owners’ repairers understand the maintainance and and the USA. rights to have their vehicles maintained repair of their high tech gearboxes. and repaired at competitive prices in the This global campaign is fighting to protect workshop of their choice. A huge array of To book your attendance at the Australian consumer choice and competition in special attractions will also fill your Expo Automotive Aftermarket Expo, please visit the vehicle repair and service sector by day. www.aftermarketexpo.com.au

The trouble with auto technicians The G-scan fills a gap

– yes, it’s the money he G-scan (TaT Top Tools, in Australia. There are more than October 2010) has been 20,000 manufacturer specific uring a recent interview with ‘So doesn’t that tell us that the hourly getting good reviews since and generic codes enabling the Geoff (Gypsy) Marshall, rates being paid in the aftermarket Thitting the Australian market late technician to accurately find out engine builder and workshops are really quite low. The last year. why, and under mechanicalD overseer for the Garry mines are paying the right price but what conditions, Rogers Motorsport team, TaT asked the aftermarket repair industry is him if he felt a career in the auto simply not generating enough money It’s the genuine the fault codes repair business was worth pursuing to pay anywhere near the right price. Hyundai were set. The for young people with a penchant and KIA G-scan offers for motor cars. ‘The big dealerships chew up young OEM scan higher level people and spit them out and in the tool, offering software His answer, ‘Yes, but’. process they don’t really teach them extensive functions any additional skills. coverage of than According to Gypsy the biggest local and previously problem facing the aftermarket ‘As a result we have far too many imported available, automotive industry is lack of money. young people who really don’t know cars and making it a most suitable the fundamentals of how things work. trucks. It fills a piece of equipment to complete log ‘Workshops are complaining because And if you don’t understand how hole as a real truck and car scan book servicing in-house. they blame the mining industry for things work how can you fix anything’, tool option. stealing their staff using attractive he added. Also new is the optional WI-FI kit salary packages as an inducement,’ Gypsy says. ‘The industry may have a shortfall of The G-scan covers both 12v enabling a fast, reliable wireless skilled technicians for a while but I and 24v vehicles and supports interface to your computer for ‘The mines get the people because foresee the day when the industry will on-board CAN protocols for cars, diagnosis or training school they are prepared to pay the right have to get to a point where they are 4WDs and Asian trucks to 2011. applications. amount of money for those with the forced to pay more to those with the A feature exclusive to G-scan is skills they need. skills.’ Rellim data 2011, locally produced www.gscan.com.au

The Automotive Technician 10 See SACHS range at the ZF Services stand at the Australian Auto Aftermarket Expo, Melbourne, 12-14 May, Stand O28

The full range for the local market From Mini to Mack Shock Absorbers by SACHS

SACHS Shock Absorbers are trusted by leading vehicle manufacturers in both passenger and commercial vehicles. With the full aftermarket range for cars, utes, buses and trucks, SACHS has the application for your vehicle.

www.zf.com The Automotive Technician 11

SACHS_Ad_PC_ute_EN A4 TV.indd 1 11/03/2011 11:52:26 AM We pump fuel into the world’s leading engines As a supplier to the world’s leading car manufacturers VDO Fuel Pumps are true OEM.

When you fit VDO, you are fitting products which have been designed and manufactured for some of the top European car companies in the world. In Australia, VDO is one of the major OEM manufacturers supplying local car companies with their high tech electronic needs. As a direct supplier to the world’s best car manufacturers, VDO’s comprehensive range of engine management products are proven in both exceptional consistency and performance.

Product range includes: • Fuel Injectors • Throttle Valves • Crankshaft Sensors • Fuel Supply Units (Modules/Carriers) • Air Mass Meters • MAP & Knock Sensors • Fuel Pumps • Idle-Speed Controllers • Digital Linear Actuators • Fuel Pressure Regulators • Camshaft Sensors

Distributor Name Location Suburb State Postcode Tel Premier Auto Trade Pty Ltd 36-40 Shearson Crescent Mentone VIC 3194 (03) 9581 9100 Hanvic South Yarra 3/650 Church Street Richmond VIC 3121 (03) 8416 8444 Imparts European 280 Hoddle Street Abbotsford VIC 3067 (03) 9417 4677 Logicar 147 Rooks Road Vermont VIC 3133 1300 334 334 Aznew Fuel Injectors 3/56 Smith Road Springvale VIC 3171 (03) 9558 5300 Automotive Service Solutions Unit 3/121 Newmarket Road Windsor QLD 4030 (07) 3857 9500 Australian Fuel Injection 20 Wentworth Street Granville NSW 2142 (02) 9897 9922

Continental Pty Ltd. 2 Scholar Drive Bundoora Victoria 3083 Australia Tel: 03 9468 1151 www.vdo.net.au

The Automotive Technician 12 t a rough guess, around one- Get the order right ‘I felt like a school kid who had just third of all vehicles brought in for cheated in a maths exam. But I had service or repair require a lot more – research before saved myself time and a lot of stress. Athan a robotic service routine. The customer was really happy to have you quote by Jeff Smit the problem solved and his car back Aftermarket workshops mainly sell with minimum time off the road. It was a solutions which can only come from a win–win situation and I made a good dollar lot of thinking. Like a medical specialist, out of the job as well,’ Jason added. technicians need to conduct tests to try to a Nigerian investment scam when they see it. get to the root cause of the problem. ‘On another occasion, a 2005 Ford Focus But don’t take TaT’s word for it came in for a service. I had been given From the enormous feedback TaT is strict instructions to do a minor service and getting from technicians, many of them keep the cost down because the customer seeking help or a second opinion through By now, regular readers will know who was sick of the car and wanted to sell it. the TaT assist service, it would appear Jason Smith is. He’s a technician, running that there are no hard and fast rules or a one-man business in Victoria, and ‘However, the customer had left a note guidelines which technicians follow — in he’s obviously a smart diagnostician. He in the car asking if I could check out a other words there is no diagnostic template attends training courses regularly and problem where the car seems to rev high or running sheet. Too many technicians prides himself on his ability to wrestle with when you first start it. Don’t you just love take a stab in the dark, give the customer a diagnostic problem until a solution is notes like that? They are really code for a quote and hope for the best. This is no found. He’s so good at his job that he often “fix my car but I don’t want to pay for it”. way to do business. finds himself dealing with problem vehicles that have long since been given up as lost ‘On the road test I could hear an air leak ‘Are we making it harder on ourselves causes by other aftermarket workshops coming from under the bonnet and after because of the way we tackle the and dealerships. many checks, I came to the conclusion challenging jobs? I think so,’ says TaT the air leak was more than likely coming technical director Jeff Smit. Jason is now one of TaT’s most from the inlet manifold area and even enthustiastic contributors, but this was not more likely to be from the gasket. This was As far as Jeff is concerned, there are only always so. going to be a costly exercise. two rules covering the diagnostic process. ‘About three years ago, I went to an Auto ‘Just before I called the owner, I hopped 1. Research the job before you take Partners trade night where Jeff Smit on to the TaT website and very much to my a guess and before you attempt a explained how the TaT system worked and surprise there was a case study that was quote. how the growing number of case studies very similar to the problem in the car that I on the TaT website could help technicians was working on. The outcome of that case 2. Communicate a lot more with your solve problems,’ recalls Jason. study was a cracked PCV hose under the customer and be brutally honest inlet manifold. in describing the time it’s going ‘I left that trade night with the attitude ‘I can to take and the checks that need fix my own problems buddy. I like to check ‘It’s in a very tight spot and only accessible to be made before a repair can be things out properly and repair them myself by removing the starter motor. Sure carried out. (See Jeff’s story in this so I don’t think you are going to be able to enough, the PCV hose on my customer’s issue about communication.) help me too much, especially by email. car was indeed badly cracked. Most of the TaT assist enquiries generated ‘The TaT magazines I took home by the subscribers’ form at www.tat.net.au contained a lot of useful information, just arrive after all the obvious repairs are done what we need in this trade. I became a and the quote has already been given to TaT subscriber and it wasn’t long before I the customer. The sequence is all wrong. began to see the benefits.

Technicians need to regard the TaT assist ‘I did get a few problem jobs that needed service and the TaT’s a fact solutions a second opinion, so I checked the web archive as part of the research process, site first and then sent off a quick email. not as a desperate last step to find a fix. Sure enough I did get a response and There are so many TaT’s a facts available it was great to get a second opinion on to TaT subscribers now that step one in some of those tricky jobs,’ said Jason. ‘The simple any diagnostic process should be to turn Since those early days, Jason lists action of checking the TaT web site case to the computer and start checking to see checking the TaT’s a facts as a first step in studies once again saved me a lot of time,’ if your particular problem has already been the diagnostic process and he has proof added Jason. documented. that it works. ‘TaT assist and the case studies on the But the TaT’s a facts or TaT assist are still ‘I was really busy. Booked out three weeks web site have been very useful to my only two of many resources you need to in advance. A Mitsubishi Lancer came in business. I still thoroughly check out all research. For example, if you are an Auto with some items of the instrument cluster faults properly myself first and most of the Data subscriber, see what they have to not working sometimes. I really did not time I have things under control, but for say. You will also be amazed at what you have time for this, so after a road test I those tricky jobs it helps to have a second can find if you just ‘Google’ it. There are hopped on to the TaT web site and sure opinion from TaT. The TaT membership code explanations and ideas galore on enough, there was a case study of exactly fee is money very well spent and being the web — the difficult part is identifying the same faults. I was able to go directly able to contribute to the magazine and the valid information from the rubbish. to the fault, pinpoint it as a broken circuit case studies myself has been a great But if you use a bit of common sense, behind the instrument cluster and I was experience. My best suggestion for all you should soon be able to recognise a able to repair the broken circuit very technicians is to check the web site as part genuine technical contribution in much the quickly with no time wasted. It was great. of your diagnosis.’ same way as most sensible people know

The Automotive Technician 13 SmartDriveTM technology. Clever enough to save you fuel and cut emissions^

Century’sCe new range of Ultra HI & Hi Performance batteries are the latest in new battery design and technology. FeaturingFe revolutionary SmartDrive™ technology this new range of environmentally friendly batteries can help reducered fuel consumption and vehicles emissions for the next generation of motor vehicles.

Suitable for petrol, diesel and gas powered vehicles, when used in vehicles  tted with regulated charge control systems; Century Batteries featuring SmartDrive™ technology can reduce fuel consumption and cut vehicle emissions by up to 2% Complemented with a new Flat Top design and an array of internal design improvements, Century Batteries featuring SmartDrive™ technology are The Smart Driver’s Choice! ^For more information call 1300 362 287 or visit www.centurybatteries.com.au CB123-1161 The Automotive Technician 14 Letter from by Julian  America  Some like it hot Hentze

t seems that the bitterly cold winter In the south we don’t have little luxuries we have experienced is coming to like public transport. I live in a city the an end and not soon enough for equivalent of Adelaide that has no public thisI Queenslander. bus or train system, but it has one hell of a freeway. Just before the start of spring, we started to reach temperatures of 28 to Petrol prices are rising to the same 30 degrees during the day, and since it’s levels of 2008, which at one stage was Julian with his dog Shiloh. spring time, it’s also time for me to start almost US$5 a gallon. With 3.78 litres to getting religious again. a gallon, that’s US$1.32 a litre, which to Americans is bloody expensive. And getting real personal, I spent The long range weather forecasts are US$550 and acquired a 1976 caravan predicting another good summer for Currently petrol is around $3.32 a gallon. that’s seven metres long and weighs two the US and as the old timers here in Petrol has gone up 20% since January. tonne. I plan, if the editor will allow me, the south keep telling me, a cold winter to write a technical page on how to seal means a hot summer. I hope they are We also expect that as summer hits, up leaks and rewire the electrical system. right. R134a has got to go up in price. At the Something like TaT tips for caravans. moment it’s running at its lowest price at The other issue facing our season here is US$250 for an 11kg (disposable) cylinder. So, hot summer plus high petrol prices the price of petrol and R134a. They both plus high refrigerant prices = who traditionally go up just before summer. There seems to be a real shortage here bloody knows. Best get off to church Summer time in the US means that it’s and they are predicting prices to hit and start my summer praying for higher family vacation time. Summer holidays US$290 as summer goes into full swing. temperatures. My dog Shiloh (an are in July (still very weird to me) and Australian Shepherd) loves the caravan families jump in the car and take off. On a personal note, I have been elected too. There is one thing that Americans and to the Board of Directors for NARSA (the (Caravan re-wiring guide heh? Could be Australians have in common, they love International Heat Transfer Association) a a best seller Jules. Ed) their cars. role I’m proud to undertake.

Thanks to our sponsors Why did I join Capricorn ?

Established in 1975 as a buying co-operative for the automotive service and repair industry in Australia, Capricorn Society Limited has grown to represent over 13,000 members in three countries. Together they purchased last year over AU $940 million in products and services from around 2,000 leading preferred suppliers. :LWKPHPEHUEHQH¿WVVXFKDV our own travel agency, our own BRAKES insurance alternative and PDQ\JUHDW¿QDQFLDOVHUYLFHV shouldn’t you be a member too?

www.capricorn.coop FREECALL 1800 EASIER (327 437)

CAPRICORN SOCIETY LIMITED - REGISTERED UNDER THE CORPORATIONS ACT 2001 ACN 008 347 313

The Automotive Technician 15 The wonders of waveforms by Jack Stepanian and Sam Nazarian

iven an opportunity to Diagnostically speaking, it is the And as the pintle reverts back to its diagnose, remove and leading and trailing edges of the rest position it bounces thus giving 5. replace a water pump square wave that truly reflect rise to a small hump at the end of Gon an unfamiliar vehicle, most the sensor’s status. It has to be the sharp back electromotive force technicians will do so with the as sharp as in this picture. This spike. utmost grace and precision sensor is OK. thanks to their visual and tactile 3. skills. Seeing and feeling are By contrast, a digital multimeter two of the greatest assets a will simply display an average of technician can possess. 6 volts. And should the output signal be switching from 10 to 2 A crank angle sensor fitted to a However, unlike mechanical volts (or even 8 to 4 volts) it will VW Golf engine will generate repairs, automotive electronics still be displaying 6 volts. Should an alternating current signal that differ due to the fact that electrons the sensor be dead and stuck on varies about zero volts base line. control engine management half way with no oscillation, it will While this is a crank sensor, it has systems. As electrons cannot again show 6 volts. Diagnostically a composite signal of revs per be seen or felt, unless you are speaking, not much help. Diagnostically speaking, it minute and top dead centre (see dabbling with secondary high is the supply, earthing, back pic 5). voltages of around 40,000 volts, a electromotive force and the pintle tool is needed to display them. 2. bounce that truly reflect the state The fast oscillation is that of revs of injector. Should there be no per minute and the stretched One such device is the good pintle bounce the chances are long pulse is that of top dead old humble and relatively cheap that the pintle is dirty and probably centre. Diagnostically speaking, option, the digital multimeter, stuck! This injector is OK not only the fidelity of the which measures and displays sinusoidal waveform truly reflects the quantity of electrons passing By contrast, a digital multimeter the sensor’s status, but the a given point in amps and the will simply display an average of changeover position of the long potential differences in voltages. 14 volts. And should there be no oscillation (from a positive to a Its downfall is, however, that the pintle bounce (dead injector) it will negative value) denotes the firing display in numeric form is the The supply of the primary still display 14 volts. of the spark (top dead centre). average of the measured quantity ignition coil of a Hyundai Getz is The crank shaft sensor is OK. of electrons. grounded and held grounded for 4. 4.5 thousandth of a second and By contrast, a digital multimeter In contrast, oscilloscopes will then released (see pic 2). At that will simply display an average not only display and allow the instant, secondary voltage builds varying voltage of between 4.5 to diagnostician to see electron up, electrons jump the gap across 5 volts. Again, should the sensor activity but also reveal the the spark plug for 1.5 thousandths be half dead? And should there be performance of a dance as of a second (reflected on the any abnormality on the measured electrons build at the tip of the primary coil) and then the signal signal? Again, it can be anything spark plug and fly off to the block reverts back to supply voltage. between 4.5 to 5 volts – not much with great clarity. It would seem help. that the oscilloscope has become Diagnostically speaking it is the Diagnostically speaking – not a must-have tool in the modern supply, earthing, back electro much help. An idle air control valve So how can any automotive tool box. motive force and spark duration fitted to a Suzuki Vitara engine diagnostician take the displayed that truly reflect ignition coil status. will vary the on and off time (duty voltages on a digital multimeter for The effectiveness of an Supply should not have ripples. cycle) to change pintle position granted!? oscilloscope over a digital Ground should be less than 0.1 thus maintaining a steady idle multimeter can be seen in volt and the back electro motive speed. In order to vary the engine Clearly, one needs to see what the examples of signal and control force should be more than 50 speed the pulse width is varied voltages are. An oscilloscope is the sensor voltages. See if you can tell volts. Spark duration should not (the on and off time). While the only commercially available tool the difference. have excessive oscillations. This frequency does not change, the that displays voltages in a graphic ignition coil is OK. pulse width will (see pic 4). form.

1. In contrast, a digital multimeter Diagnostically speaking, it is It now seems obvious that the will simply display an average of not only the leading and trailing oscilloscope has become a must- 14 volts. And should there be edges of the square wave that have tool. Next time you grab no back electro motive force (no truly reflect the valve’s status but a digital multimeter to carry out spark) it will still be displaying 14 also the degree of the pulse width diagnostic work, ask yourself if you volts! Diagnostically speaking – not modulation. This idle air control are really seeing all the intricate much help. valve is OK. details that an oscilloscope displays, as compared with a The supply of an injector pattern By contrast, a digital multimeter will steady/average voltage displayed of a Mazda MX5 is grounded and simply display an average varying in numeric form. A cam lobe sensor fitted to a held grounded for 3 thousandth of voltage between 2 and 10 volts. Mercedes Benz C180 engine will a second and then released (see Make the most of your generate an almost square wave pic 3). At that instant the magnetic And should there be any oscilloscope by hooking it up to signal that varies from zero to 12 field within the injector coil begins abnormality on the measured a component of a healthy vehicle volts. While the frequency varies to collapse a back electromotive signal, it can be anything between and watch the waveforms perform with engine speed, the on and off force of more than 50 volts is 2 and 10 volts – not much help. a dance before your eyes. It’s pure time does not (see pic1). induced. magic.

The Automotive Technician 16 Great repair service is only possible when you have great partners.

LuK INA FAG Products News

See us at Q28

Quality, innovation, trust and great teamwork. These are the things Clutch Change Challenge! that drive everything we do, because we know that long-lasting Take on the Clutch Change Challenge at the Schaeffler Automotive partnerships depend on them. From LuK clutch systems, to INA Aftermarket stand for your chance to win a track day! engine components, to FAG wheel bearings, it’s all brought to you by Schaeffler. For further information, please contact: T +61 (2) 8977 1038 Come to stand Q28 and see how we’re applying our innovative F +61 (2) 9452 4242 technology and great service to our partnerships with you. E LuK-AS.au@schaeffler.com See you there! W www.schaeffler-aftermarket.com

The Automotive Technician 17

   


  


 
 t’s 75 years since the first car achieve cult status as the first sporty powered by a diesel engine trundled diesel-powered passenger car. Idown a road. For many of those years, the diesel was regarded as an The mid-1980s saw the dawn of the oddity, despite the facts that diesel electronic era for diesel models. In 1986, engines had powered submarines and Bosch launched the first electronic control ships since 1910, pumped water from systems for its distributor and in-line farm wells around the world, and were pumps. capable of running non-stop for more than a decade between servicing. In 1987, Munich-based BMW became one of the first automakers to start using electronically controlled distributor pumps. ‘Sheer driving pleasure’ – as the sales blurb trumpeted – was now possible with After 75 years, the first turbo diesel engine made by BMW, which was available in the six-cylinder 524td.

diesel may yet In 1989, the first axial piston pump for diesel direct injection revolutionised the diesel engine. This innovation premiered in the Audi 100 TDI (turbodiesel direct dominate by Jeff Smit injection).

In 1989, Audi was the first The diesel stationary engine is now a automobile manufacturer to collectable and huge field days around utilize the electronically Australasia every year pay homage to controlled axial this seductively throbbing machine which piston distributor injection pump oozes confidence and reliability. VP34 from Bosch. Some auto historians say the main reasons for the dominance of petrol The direct injection system appplied engines over diesel were the smell of In 1936 Bosch’s in-line pump also came into by Audi marked an diesel fuel and the famous diesel ‘knock’, use in automobiles. The Mercedes-Benz 260D important milestone in particularly when idling. was the first mass-produced diesel powered diesel development. passenger car in the world. Diesel engines in the modern vehicle are now accepted and have become Thanks to their cost-effectiveness, diesel- synonymous with fuel efficiency. powered passenger cars were growing in The new Bosch technology allowed popularity, particularly as taxis, which had the diesel to be injected directly into But does diesel, with all of its grand history to withstand harsh driving conditions. the cylinder at a high pressure of some on the sea and land, represent any kind of 1,000 bar, resulting in particularly efficient threat to the petrol engine? As early as 1960, Bosch unveiled the first combustion. This meant much better distributor pump. It was lighter and more power output and smoothness coupled Industry experts are predicting that 20 compact than existing in-line pumps, with low fuel consumption and emissions. years into the future, diesel engines will be paving the way for the use of diesel one of the most important power trains in engines in smaller passenger cars. Direct injection was to become the norm passenger cars. a few years later in diesel passenger In 1975, the VW Golf became the first car and truck engines. In the late 1990s, Companies like Bosch, along with compact-class diesel model to have a the uptake of diesel engines received vehicle manufacturers, see enormous high-speed diesel engine, which delivered a major boost with the development of development potential in diesel. high revs but was also economical thanks another three different high-pressure to the Bosch distributor-type injection injection products – the radial piston Developers at Bosch Diesel Systems are pump. With a turbocharger and lightning distributor pump (1996), the common predicting fuel consumption of just 3.6 fast looks, the Golf GTD version would rail system (1997), and the unit injector litres per 100 kilometres for a compact- (1998) that was used in vehicles such as class diesel-powered passenger car by Volkswagen’s 3-litre Lupo. 2015. Of all the alternatives available in the late The world’s first series-produced diesel 1990s, common rail injection technology passenger car, a Mercedes-Benz 260D, ultimately established itself as the leading was shown at the Berlin Automobile solution. Exhibition in 1936. It used a third less fuel than a gasoline model for the same power Starting in 1997, the Mercedes-Benz output. Sales were initially disappointing 220 CDI and the Alfa Romeo 156 JTD since the diesel car was no match for its became the first cars to use the innovation. gasoline-powered counterparts that could It provided constantly high injection boast better performance and smoothness. Bosch was the first company to offer vehicle pressures of up to 1,350 bar for all the By 1950, Bosch had manufactured one manufacturers an injection system which made cylinders served by the common rail. possible the economic production of diesel million diesel pumps for passenger cars engines for use in vehicles. A 1927 automobile The common rail system made multiple and trucks. diesel engine with an experimental Bosch injections possible for the first time. The Automotive Technician 18 injection pump. engines will grow in the US from the current 5% to 10% in 2015.

Targets for reducing fuel consumption have been tightened substantially over the past few years, with the transition from the Euro 5 to Euro 6 emissions standard meaning that NOX emissions will need to be cut by more than half.

To this end, Bosch engineers are increasing exhaust-gas recirculation rates, charge-air pressures for combustion air, and injection pressures over the greater part of the engine map, thus reducing nitric oxide levels in the combustion process.

Bosch engineers are also applying exhaust-gas treatment to further improve diesel-engine efficiency. They have taken the Denoxtronic for SCR (Selective Bosch’s introduction of common rail injection Catalytic Reduction) NOX reduction, in 1997 was a world first. Injectors were which is already tried and tested in the Manufacture of in-line pumps for diesel injection manufactured at this Bamberg factory. commercial-vehicle segment, and modified systems in the Feuerbach factory, 1954. it to passenger-car requirements. Diesel In 2003, Bosch unveiled the third cars have been fitted with this technology generation of common rail injection in the US since 2009, specifically to Diesel passenger-cars of the future will featuring piezo electric in-line injectors. comply with the particularly stringent run even more efficiently. A diesel-powered Compared with its predecessors, this exhaust emissions legislation there. These car in 2015 will consume just 3.6 litres to system further reduced the diesel diesel vehicles are now also available in drive 100 kilometres, some 30% less fuel engine’s fuel consumption and exhaust Europe as Euro 6 models. than a 2009 equivalent diesel model uses. emissions, while also reducing the associated running noise. Over 66 million With hybridisation, the fuel consumption of engines have been fitted with Bosch’s The future is diesel diesel engines will be reduced by as much common rail systems to date. as 40%. Bosch diesel technology will pave the way Bosch common rail technology once again over the next few years for even more propelled the diesel boom at the start of Bosch engineers are already working on efficient passenger-car driving based on systems for future engine concepts being the new millennium. the internal-combustion engine. planned by car makers and will continue

While in 1997 only 22% of all passenger Taken together, the individual technical to promote the refinement of internal- cars sold in western Europe ran on diesel, developments associated with the internal combustion engines. this figure was over 50% in 2006. Common combustion engine are giving rise to rail technology still offers a great deal of engine concepts that will be ready for the Many thanks to Bosch for historical data technical potential, even the most stringent market in 2015. and technical details for this article. emissions limits in California can be met Additional information can be accessed at using common rail. The diesel engines of the future will have www.bosch.com.au just three cylinders and a displacement Over the past few years, several of some 1.1 litres, thanks to extreme European, US and Asian manufacturers downsizing, and yet they will offer have initiated a major diesel campaign in dynamic, refined driving characteristics the US. The two premium automakers, with an output of roughly 100 kilowatts. Audi and BMW, joined the ranks of Mercedes-Benz in increasingly opting for They will be fitted with a range of diesel engines in the US. Bosch expects additional products, all of which will that the proportion of diesel-powered combine to increase the efficiency of the powertrain:

• a start-stop system to automatically switch the engine on and off when the vehicle comes to a stop, for instance at lights or in traffic jams

• thermal management to get the engine quickly up to the optimal operating temperature and keep it there

• a highly efficient alternator which uses brake energy as one source Final quality inspection of in-line pumps for diesel Manufacture of injectors at the Feuerbach injection systems at the Feuerbach factory, 1939. factory, 1950. for charging the battery. The Automotive Technician 19 HONJA03116 HONDA JAZZ ‘s a fact 2003 problem solving 4 Cylinders

Customer Fault Description Complaint The TPS was Engine check light on. internally faulty. This was causing the flat Problem spot and the engine check Summary light to come on. On road test the check Fault Solution engine light came on. Removed the Also noticed the vehicle throttle body had a slight flat/dead spot assembly. from time to time. Even though Diagnostic the TPS can be removed the only Sequence part available is the complete Retrieved fault codes. throttle body. Code 07-01 in memeory New throttle body relating to the TPS supplied and fitted. voltage low. Cleared fault code and Scanned and scoped road tested. the TPS output. The TPS voltage dropped intermittently. It went Recommended below set voltage of 0.51 Time volts. Labour time was 3 hours, While applying taking into account accelerator on a research time, location few ocassions the of parts and actual time RPM went up but spent fixing the problem. TPS voltage did not rise.

TPS Switch

ISC Motor

The Automotive Technician 20 MAZ6292215 MAZDA 626 ‘s a fact GE 2.0L problem solving 1992 4 Cylinders

Customer Complaint

Automatic transmission (AT) light flashing intermittently and not firing up.

Problem Summary

AT light flashing and on the road test the vehicle was lacking power.

There were also gear changing problems.

Noticed the engine fan coming on when the vehicle was dead cold and hard to fire up.

Diagnostic Sequence

Checked for fault codes – no codes.

Checked wiring and sensors using workshop manual as reference. All supplies, circuits and sensors appeared correct.

Fault Description

Isolated the fault to the engine ECU/AT.

Removed the ECU and inspected internal circuits.

Definite circuit board damage in a number of areas and can see some capacitors had leaked, damaging the circuit board and components.

Fault Solution

Supplied and fitted a replacement ECU.

Reassembled and road tested.

Now starting well, gear changing OK and engine fan function correct.

Recommended Time

Labour time was 2.5 hours, taking into account research time, location of parts and actual time spent fixing the problem.

The Automotive Technician 21 MERCC01619 :hl\a8>K98l^kb^l8¦8La^8\hfie^m^8 MERCEDES ‘s a fact C200 W203 ]bZ`ghlmb\8lhenmbhg problem solving 2001 6 Cylinders

Customer Complaint As we found out later it was the secondary air bypass that directs Loud clicking and crunching sound air through the special pollen filter from rear of dash on start up. after the fresh recirculation flap and filter.

Problem Summary The motor is screwed in on top of the box and the gear meshes with Every time the vehicle ignition is the gear on the door flap and has turned on and started there is a a stopper end protruding outwards loud gear crunching sound at the so as to stall the motor and control rear left of dash. ECU picks up the higher current and switches it off. Diagnostic Sequence In the last double image Removed the glove box area and you can see how the gear isolated the noise to a blend door has been damaged and a not working correctly. few teeth are missing. Also you get an idea of how it A small blend door motor operates sits in place. every time the vehicle is turned on to find its position. There is no Fault Solution separate switch to turn it off. When we rang the dealer we We had to get the assembly out. were told that we had to buy the In this instance we were able to complete box. remove the complete assembly without disassembling all of dash. After ringing around and getting a parts break down we found that We did have to there was a separate spare parts disassemble the centre kit available that covered a few section and part of the sets of plastic gears. console. This linkage and plastic gears kit The fact is there is a sort of was replaced, dash and the vehicle clip arrangement and slide were reassembled. No problem at the top right corner area refitting and resecuring the box and that is impossible to get to made sure there were no rattles. without removing the top section of dash. Another happy owner who only paid for what was required. In this instance we were lucky Linkage kit P/No 203 830 00 32 that someone else had been here (for this model) before us and obviously did not put it back in. Looking at it I would say by giving it a bit of a twist and Recommended Time a good pull it would come out anyway. Labour time was 7 hours, taking into account research time, location of parts and actual time spent fixing Fault Description =_y\b^gm8 o^ab\e^8 ]bZ`ghlmb\l8 bl8 ^ll^gmbZe8 _hk8 Z8 ln\\^ll_ne8 Znmhfhmbo^8 phkdlahi’8 La^8 fh]neZk8 the problem. :hl\a8>K98Krlm^f89gZerl^k8ikhob]^l8]bZ`ghlbl—8mkhn[e^lahhmbg`8Zg]8f^Zlnk^f^gm8m^\agheh`r8bg8hg^8 This blend door motor and flap bgm^`kZm^]8iZ\dZ`^’8;hf[bg^8Zg8hl\beehl\hi^8pbma8Z8CLK8l\Zgg^k8Zg]8^o^g8Z8`Zl8ZgZerl^k8fh]ne^—8 is part of the main fan and air mh8_hkf8Z8\hfik^a^glbo^8]bZ`ghlmb\8ieZm_hkf8¦8lZobg`8rhn8mbf^8Zg]8fhg^r’8888 distribution box. tips for ideas division >hk8_nkma^k8bg_hkfZmbhg8hg8ma^8:hl\a8>K98kZg`^8\Zee8ma^8:hl\a8

The Automotive Technician 22 9

210x297 TAT FSA Adv.indd 1 29/3/11 10:34:30 AM :hl\a8>K98l^kb^l8¦8La^8\hfie^m^8 ]bZ`ghlmb\8lhenmbhg

=_y\b^gm8 o^ab\e^8 ]bZ`ghlmb\l8 bl8 ^ll^gmbZe8 _hk8 Z8 ln\\^ll_ne8 Znmhfhmbo^8 phkdlahi’8 La^8 fh]neZk8 :hl\a8>K98Krlm^f89gZerl^k8ikhob]^l8]bZ`ghlbl—8mkhn[e^lahhmbg`8Zg]8f^Zlnk^f^gm8m^\agheh`r8bg8hg^8 bgm^`kZm^]8iZ\dZ`^’8;hf[bg^8Zg8hl\beehl\hi^8pbma8Z8CLK8l\Zgg^k8Zg]8^o^g8Z8`Zl8ZgZerl^k8fh]ne^—8 mh8_hkf8Z8\hfik^a^glbo^8]bZ`ghlmb\8ieZm_hkf8¦8lZobg`8rhn8mbf^8Zg]8fhg^r’8888

>hk8_nkma^k8bg_hkfZmbhg8hg8ma^8:hl\a8>K98kZg`^8\Zee8ma^8:hl\a8

The Automotive Technician 23 9

210x297 TAT FSA Adv.indd 1 29/3/11 10:34:30 AM VASA turns on full weekend of hard core training

ASA is breathing new around Australia and New life into its training Zealand have enjoyed for program with a very years, to deliver hard hitting, Vdifferent Wire & Gas Training concentrated training for two Convention at the Novotel solid days. Dave Melbourne St Kilda Beach on Townley 11 and 12 June 2011. Entry prices are $440 for non- VASA members and $385 for It will be just two solid days VASA members. Full details of serious training, mini trade are at www.vasa.org.au Grant show and few frills - but a much Hand lower cost. The training program:

It might be winter in Melbourne, Grant Hand but what better place to spend Cert IV air conditioning and refrigeration it than right on the beach at St advanced course Kilda. If the sun is going to shine anywhere in Melbourne in June, Dave Townley it’s here, where you can see the Climate control systems to Cert IV level sea. on late model vehicles Jack Stepanian Unlike offerings of multiple Advanced engine management to Cert IV training options at previous level on vehicles three to six years old conventions, this time, nobody Geoff Mutton will miss out. VASA has selected Business training with specific relevance four of Australia’s top trainers, to aftermarket automotive workshops some of whom technicians Jack Stepanian Geoff Mutton

BOYCE’S Endorsed by... autolibrary Australia’s most comprehensive and affordable software www.autolibrary.com.au See you at the AAAA Trade Show (IAME Stand E31, May 12-14) Timing Belt R & R Component Locations Electrical Wiring Diagrams

Service Light Resetting Diagnostic Trouble Codes Terminal Voltages

ANNUAL SUBSCRIPTION: $869 INCL. GST FOR YOUR FREE 30 DAY DVD DEMO CONTACT US TODAY ON (02) 9319 7484 2 UPDATES PER YEAR +FREE TECHNICAL SUPPORT COMPARE THE DIFFERENCE!

The Autolibrary users are your guarantee of Quality $OVRLQFOXGHV6HUYLFH4XRWLQJ6HUYLFH6FKHGXOHV5HSDLU7LPHV6SHFL¿FDWLRQVDQGORDGVPRUH

TATThe Mar Automotive 2011.indd 1 Technician 24 11/03/2011 2:48:54 PM Vehicle exhaust pollution and its effect on both employees health and the environment is now on every workshops agenda. Australian legislation on workplace OH&S continues to tighten.

By controlling exhaust emissions at source with the use of filters fitted directly to the vehicle exhaust outlet the problem is quickly and effectively controlled.

Each MF-100 filter comes complete with one replaceable filter cartridge. Filter cartridges are replaced approximately every 280 uses for petrol vehicles and 120 uses for diesel vehicles. A foil rupture disc inside the canister unit indicates when the cartridge filter is due for replacement. Tested and certified in MF-100 shown fitted with optional dual exhaust cone the European Union at over 99% filter efficiency. BOYCE’S Endorsed by... autolibrary Australia’s most comprehensive and affordable software www.autolibrary.com.au See you at the AAAA Trade Show (IAME Stand E31, May 12-14) Timing Belt R & R Component Locations Electrical Wiring Diagrams Rid Odor Pro is a new technology that fights air conditioning • Permanently destroys tobacco, food and malodours, bacteria, germs, moulds, fungus and spores at beverage, body and dampness odours. • Full point of sale promotional support for the molecular level. Allergic symptoms such as sore throat, participating service centres. weeping eyes, and streaming nose are common as a result of untreated air conditioning systems, as well as an increase in Streptococcus pyogenes 100% kill respiratory system and chest infections. Asthma sufferers can Ulocadium chartarum 100% kill Aspergillus niger 100% kill also experience increased discomfort. Rid Odor Pro is used Penicillum purporogenum 100% kill extensively throughout the U.S. by car dealerships, used car Staphylococcus aureus 100% kill Service Light Resetting Diagnostic Trouble Codes Terminal Voltages sales departments, crash repairers, hire car and fleet operators, MRSA 99% kill emergency services, airlines, etc. Trichophyton metagrophytes 99% kill

ANNUAL SUBSCRIPTION: $869 INCL. GST )RUDYLGHRGHPRQVWUDWLRQRIWKH5LG2GRU3URVHUYLFHSOHDVHYLVLWZZZULGRGRUFRPYLGHRVSKS FOR YOUR FREE 30 DAY DVD DEMO CONTACT US TODAY ON (02) 9319 7484 2 UPDATES PER YEAR +FREE TECHNICAL SUPPORT Authorised and exclusive Australian distributors of: COMPARE THE DIFFERENCE! Essential Service Programs The Autolibrary users are your guarantee of Quality $OVRLQFOXGHV6HUYLFH4XRWLQJ6HUYLFH6FKHGXOHV5HSDLU7LPHV6SHFL¿FDWLRQVDQGORDGVPRUH Ph: 02 8084 1745 Email: [email protected] www.espro.com.au

TAT Mar 2011.indd 1 11/03/2011 2:48:54 PM The Automotive Technician 25 are price driven. Competence before price In fact, the survey revealed something that TaT has suspected for a while, that says ATE survey today’s motorists are far more concerned about the ability and competence of workshops than they are about the cost of repairs.

The survey results were shared with technicians who attended training sessions arranged by Frank Maergner, HSY’s National Sales/Branch The ATE presenters (from left) Michael Meerboth, Operations Manager and his Frank Maergner and Bert Lembens. teams throughout Australia, and conducted by two top nternational brake supplier guns from ATE in Germany. ATE has revealed the They were Bert Lembens, head of the ATE results of a major motorist training centre and Michael Meerboth, surveyI which has blown sales manager aftermarket for the Far another hole in the populist East, Australia and New Zealand. theory held by far too many service centres that car owners The training sessions which attracted an average of 65 technicians each were held in Melbourne, Adelaide, Perth, Product Range Brisbane and Sydney. For the survey, motorists were asked What you and your car need is right here - What’s Stopping you? what they looked for in choosing a workshop. Brake Discs Brake Drums RDA Clutch While most workshops believed price would be top of the list, surprisingly it came fifth on a seven-point list.

Largest and most The RDA Clutch range In number one spot was competence. Over 2000 applications from Alfa comprehensive range in comprises the top selling clutch Motorists wanted to feel that the to Volvo Australia-wide. Australia to complement our applications in Australia. RDA Discs & Pads - made for extensive range of brake shoes. Including standard, RPM, 4WD workshop or technician had the and commercial clutch kits. each other! confidence and skill to solve their problems. Slotted Disc Turbo Grooved GP MAX Rotors Sports Rotors Brake Pads Bert explained that the modern motorist looked for solutions once they satisfied themselves of the workshop’s Most extensive range of standard disc pads and competence. For Increased dissipation of With all the benefits of slotted shoes in Australia, with over water, dust and road grime from rotors plus they’re zinc plated 600 applications. Our pads Friendly staff was the second most the contact area of braking and gold passivated to avoid are asbestos free, good value system. Available for all current corrosion. Available for all RDA for money, excellent operating important thing motorists looked for, performance. RDA vehicle applications. vehicle applications. followed by location, availability, price, invoice explanation and image of the Extreme Ultimax Pads Greenstuff Brake Pads service centre.

ATE is the automotive arm of Continental and is a pioneer of technical innovation. It invented the hydraulic Heavy duty brake pads, with Produce minimal dust, have low brake system and is the development a shimmed backing plate. rotor wear and universal heat Road sport upgrade brake Ideal for those who brake range abilities, meeting original pad for vehicles up to 750kg. partner for driver assistance and braking Higher quality than original heavily, carry heavy loads or tow equipment standards. systems. boats/trailers often. equipment.

Redstuff Yellowstuff Commodore Ninety-five per cent of the company’s Upgrade Kits current business is original equipment in a large range of vehicles.

ATE has more than 190 manufacturing sites in 39 countries and plans to open A brake pad upgrade for Upgrade earlier Commodore highly tuned sedans or A brake pad upgrade for race models to VE brakes. brake centres in Australia in the next six performance cars, the best cars or performance cars that Standard or slotted rotors to eight months. choice for fast road use and are used regularly on the track. available. Includes everything occasional track use. you need for fitment. www.rdabrakes.com.au The Automotive Technician 26 The Automotive Technician 26 The Brakes That Stop A Nation YOU SAID IT! What a Hummer

he vehicle was a Hummer H2, Fuel injectors were running at 5.3 2006 model with a 6.0 litre petrol IS2 Vortec engine and milliseconds and when accelerated we T63,000 kilometres on the clock. had 30% duty cycle. The complaint was lack of performance. The timing would retard to about 15 Lack of performance? It was lucky to go after top dead centre on stall test (we faster than 40 km/h. It would idle but not made a mark) and the knock sensors accelerate. were reading nothing on one sensor and 0.9 volts on the other (they do These have virtually the same engine have problems with these on the management system as the 5.7 litre Commodores). We checked the fuel Gen III VX Commodore. The test list as well because we have had diesel- read codes PO175, system too rich; contaminated petrol lately but the spark PO300, random misfire detected; and plugs are usually still wet. These were PO438, catalyst system efficiency good. below threshold. Cleared the codes and only the random misfire code PO300 Compression test was 180 psi. We did returned. scope the coils and drove the coils and they were great. So after working down Live data showed multiple misfire the tick list we finally got to the exhaust. history on cylinders 4 and 6 on the right We tested the exhaust pressure before bank. Gas analysis showed Lambda 1 the catalytic converters. The left bank and no real sign of running lean or rich. was 2 psi and right bank went to 20 psi.

Started the list of tests in the engine Removed the engine pipe and catalytic bay — fuel pressure good at 60 psi assembly which is a two-into-one and (non-return system but we did remove it sounded normal at the rear. Cut the the Shrader valve and checked flow and catalytic converters out and there was yes, it seems to aerate the fuel but that the right hand converter blocked and the was not the problem). Full 12 volts at left OK. I still have a concern about the knock the fuel pump as well, alternator ripple sensors but they are under the inlet and charge circuit fine; earths good, Replaced both catalytic converters and manifold and at Holden it was common air mass meter works correctly but now it goes like a Hummer. to have to change them. This is a hesitation on acceleration in neutral and low volume import and has no dealer would not stall test over 1500 rpm. There is always a concern if there is a support and info was a bit hard at first. fuelling issue and whether this would Anyway I am off to Ashley and Martin on There are no vacuum ports in the have caused the converter to fail, or Monday. manifold so we drilled and tapped a if it did so as a result of being hot and small fitting into the manifold to connect driving through flood waters. Gary Homan a vacuum gauge (fitting is an LPG Nudgee Automotive injection fitting). The diagnosis and testing was really a NUDGEE QLD training exercise. It took the best part of Manifold vacuum was 15 inches of seven hours and the removal and refit of (Do we read into this that you lost a lot mercury (Hg) which is not flash but turns the exhaust was another seven hours as of hair over this problem? We’ve got to out they seem to be only about 16 to 17 some of the bolts were seized. hand it to you for perseverence. Ed) Hg when good.

The Automotive Technician 27 ow many times has someone The answer to this was no. The fuse asked you to fix their car sometimes had been replaced a number of times because their stop lights you just and everything worked OK for a while Hwere not working or they lost their Blow can’t trust with the same end result followed by headlights suddenly. And they add your eyes the same question, the same problem ‘but I checked the fuses and the and fuse changes. The vehicle came globes and they looked OK’. that to our TaT workshop after the owner and his mechanic had looked at the Then you find that the fuses are blown problem fuse yet again. ‘The fuse is and you have to restrain yourself from fuse! not blown’, they agreed. Sure enough, making the owner out to be a goose. by Deyan Barrie it looked OK at a quick glance. The I usually use the ‘you can’t always trusty old LED test light shows it just trust your eyes’ approach and it is open circuit. A good hard look does make them more comfortable. I revealed the fuse had separated due try to explain that this is why we have Once the fuse was removed it was to heat rather than blown. test equipment, to help us verify the obvious that the fuse was problem and the cause. fractured on both ends and Pic 2 shows this fuse which on was floating around in its first visual inspection looked Even technicians get cover. OK. We found that the owner caught sometimes, lived on a property out of especially if Pic 1 is the blade fuse town and some of the roads they are in a in question. There were very rough. A good look hurry when is nothing unusual at the trailer wiring revealed checking about a fuse that is a section of harness that had things and they open circuited but just rubbed through due to a bit may take the looks OK until, at of flexing, plus the fact that the visual inspection a closer inspection, trailer plug harness had been for granted. They you see the hairline pulled close to a section of the may also get fracture. But a fuse that tow bar frame. caught out if the fault resets when it feels like it, is odd to is intermittent. say the least. You can see how a simple wire that rubbed through can have a lot Here are two separate problems and The second problem was an of people running round in circles. both are intermittent in some ways. intermittent blinker circuit on a Doesn’t it prove yet again that four-wheel drive Nissan Navara. technicians need to devote a bit The first was a problem with an engine This blinker fuse had been replaced more time and effort when faced with fan control operation. The fans were recently and other technicians had intermittent problems. working at the time of testing but with been chasing an intermittent short vehicle movement mainly over bumps for some time. All they could do was The customer will appreciate your the circuit would make and break. The to keep replacing it. All the right effort and your expertise. Again I circuit was tested and deemed OK. It questions had been asked, such as stress ‘cause and effect’. Don’t dismiss was only when the test light was used ‘have you towed anything recently the basics and use everything at your and the fuse tapped while testing that because there may be a short in the disposal when testing circuits and it open circuited. trailer’. analysing intermittent problems.

specifically designed for Hybrid Tools for Hybrid Servicing hybrid vehicles but has the complete range of automotive echnicians planning on hybrid vehicles are no and the MMD 540H Hybrid functions. to work on hybrid different to those any other Automotive Multimeter. Tcars will need to know vehicle, others will be vastly Bosch phone 1300 783 031 a few things about handling different. Safe handling of The FSA 050 is a hand-held up to 650 volts — enough a system with up to 650 device that can also be linked to kill you. volts will require specialist wirelessly to the FSA740 knowledge and tools. This Motor Tester Software to If you haven’t seen a hybrid is not all bad news. Smart document the measurement vehicle in your workshop yet, workshops will do the training results. it won’t be long. When it does and establish themselves as arrive, you will be faced with skilled specialist centres for This new product is designed new technology for which you hybrid vehicles. for quick use and offers a need to prepare with training means of testing insulation and new equipment. To cope with some of the and high voltage on electric working requirements on and hybrid electric drive These emerging power train hybrids, Bosch has launched systems as a stand-alone technologies and high voltage two products that relate option. assemblies will pose new specifically to hybrid vehicle challenges for any workshop. diagnosis – the Hybrid The MMD 540 Hybrid While some operations Vehicle Tester FSA 050 Automotive Multimeter is

The Automotive Technician 28 hy do so many give you a quote because schedule be the first and the way they always were, workshop owners until we test a few things, logical thing to do? I know but perhaps they are feeling Wand managers feel I will not be sure where these challenging jobs take more frustrated when they lift personally responsible for the problem lies’, best you time — not hours, but days, the bonnet of a modern car the problem vehicles in practice in front of a mirror. sometimes weeks. Be up because they have no idea their workshops? front and honest with your what they’re looking at. You think I’m being harsh? customer. ‘Leave it with me We didn’t design the vehicle, Follow me and you’ll thank and I will look at it tomorrow You can’t expect your we didn’t make the vehicle, me later. and give you a report. customer to keep up with we didn’t buy the vehicle, we the advancement of car are just the person left to fix technology. the problems. Honest is not only the Given the growing separation I know from my own between motorists and their experience that there’s cars’ technology, I believe it’s nothing quite as daunting best policy – it pays our responsibility to educate as a frustrated motorist by Jeff Smit them. That’s the only way we demanding an instant fix at can ensure we receive the the lowest possible price. fees appropriate for the effort If you believe that a new ‘After that we’ll talk about involved. But before you fall into the distributor, leads and plugs how we need to go about trap of commiserating with will solve that missing repairing the vehicle.’ If you Again I think the key to them and pushing yourself engine, let your customer are not up-front and honest ensuring every job that and your workshop to know that’s where you about the time it’s going to enters your workshop leaves ridulous lengths to find the have to start. It may require take, they will presume you’ll with little or no stress, some fix and then lose money on additional repairs but you fix it today and they will be profit in the till, a happy it because you didn’t see the can’t proceed any further able to pick it up tonight. customer and a proud size of the problem in the until those initial repairs are workshop is communication. first place, just take a deep done. You have to make sure We know more breath and tell yourself ‘I’m they understand that point. So next time a problem Ford in charge here and I know a about fixing cars arrives at your door, tell the damn sight more about how Customers will often interpret than the customer. customer up-front that this to fix this car than the angry things differently to the way Communicate. is going to be a challenge to person standing in front of we say it, so make very sure fix. Let them know that you me’. that they fully understand. Think about your last visit to are going to have to do some You should also have done the doctor or specialist. Did research and spend some How you deal with these your homework and made you demand your broken leg time on the vehicle and that situations will determine sure that the customer’s be fixed by this afternoon this will all cost money. if it turns into a pleasant car doesn’t have a common because you need to walk and profitable experience problem somewhere the dog tomorrow. Of course Establish a budget to the or another unprofitable else that could cause or not. You waited for X-rays point of the research before nightmare. contribute to the symptoms. and other tests and up till getting too involved in the That’s called research before now, you are relying on your vehicle fix. Communication is the the first diagnosis. health fund to back up your key. If you are not a good credit card. In my experience, customers communicator, learn to be If a vehicle is overdue like honesty, and it pays to one or stay out the back of for service and it’s in the Did you get a quote on that be honest even if the news is the workshop. If you can’t workshop for a hesitation or leg first. Of course you didn’t. not what they want to hear. look a customer in the eye miss, wouldn’t getting the I don’t think our customers and say ‘Mr Jones, I can’t vehicle to its proper service today are any different to

The Automotive Technician 29 YOU SAID Big bills in airbag aftermath IT! He said the noise was top of a new passenger front his incident with a unbelievable when the air bag seat which will be required. It customer’s vehicle deployed and it had scared won’t be a cheap fix. proves how powerful the hell out of him. airT bags are and how it’s There was no one in the probably not a good idea It appears the plank has hit passenger seat, nor was to be near them when they the sill under the passenger there anything on the seat to go off. front door right next to the make the system think that side air bag sensor — how someone was sitting there. My customer was driving his unlucky is that. It’s likely that 2007 Ford Ranger when he the near direct hit on the Jason Smith saw a large brickie or painter sensor, the ABS operating, JDS Automotive scaffold plank on the road. the car swerving and MOOROOLBARK VIC He took last minute evasive decelerating has caused the action, swerving and braking airbag to deploy. (From my knowledge, the to miss the plank, but it hit passenger side airbags, the car on the passenger side The deployment broke the be they front or side bags, underneath. door trim and the “B” pillar should not go off unless trim, the left hand front door someone is in the passenger As you can see, the sticks out now at the top, the front seat. It should have a passenger side air bag went tint on the glass has been sensor to inform the system off. When I spoke to the damaged and the rear door when someone or something driver about 45 minutes later hinges and front striker have is on the seat. Interesting. I’ll his hearing was still impaired. slightly moved. All that is on keep looking into it. Jeff Smit)

Get your Hygro, not hydro – there’s a big difference n eagle-eyed reader, Mark Callinan, director of the diesel fix British and European Motor Works in Castle Hill, NSW, emailed ‘Sorry to be picky mate, but brake at Bosch Afluid ishygroscopic not hydroscopic!’ He was referring to the Top Tools review of the ATE brake training bleeding unit FB 30s (TaT December 2010). The story read, ‘Technicians should know that brake fluid osch training for 2011 exceptional knowledge into its is very hydroscopic and once it has absorbed moisture it will focus on diesel training programs. becomes very corrosive.’ The facts are correct, but the choice and direct injection. of the word hydroscopic was way off. B During 2010, Bosch trained The company is responding to more than 60,000 people In fact, depending on what dictionary you pick up, you might the growing number of diesel worldwide. discover the word hydroscopic doesn’t even exist. cars on the road. It wasn’t that long ago that only trucks used This year’s focus will be on The right word, hygroscopic, means the tendency of some diesel. Now the most desired diesel common rail systems materials to absorb moisture from humid air and that’s exactly marques have many diesel and gasoline direct injection what brake fluid does. options – look at BMW’s line- systems, starting with up. instruction on the system and For the word purists out there, there is such a thing as a principles, through to fault hydroscope, an optical apparatus which allows you to peer at The introduction of so many finding and diagnostics. objects under the sea. Really not related to brake fluid at all. diesel vehicles has not slowed the development of systems for Attendees are provided with An internet search also petrol powered cars with direct training, course books, manuals revealed that the Canadian injection gasoline systems and a participation certificate. technology manufacturer developing very quickly. Technical courses run over two PICA, has named its days, and technical information new tool for inspecting Workshops now need to be sessions are three-hour pipelines for defects, able to service both diesel and evening programs. the Hydroscope. petrol vehicles to ensure that they survive into the future. For enrolments or information, (Well done and thanks call 03 9541 5553 between for letting us know Bosch is an original equipment 9am and 2pm on weekdays or Mark. Jeff Smit) supplier of diesel, gasoline and email: automotive.training@ hybrid systems and brings this au.bosch.com These are hydroscopes as well…

The Automotive Technician 30 Monroe re-signs Mark Winterbottom

8 Supercar star driver, Mark He has taken part in several Monroe ‘Frosty’ Winterbottom, will supported road safety and trade events, continue to be the face of the road including Fatality Free Friday and The Vsafety initiatives being rolled out by World’s Biggest Driving Lesson. Monroe shock absorbers. A Monroe Safety Specialist The company has signed Winterbottom for Program is also being planned, another two years. to encourage more independent workshops to capitalise on their Winterbottom was placed third in the 2010 safety efforts through timely V8 Supercar Championship Series, gaining intervention on shock absorber three victories and five pole positions. replacement.

STREET Green is still rather pale CRED And, they announced, environmental Design, style, brand and safety all protection considerations are increasingly rated ahead of a car’s environmental with Hayley Windsor influencing our decision when we purchase considerations. Clearly, the earth’s quakes, a car. tornados, floods, heat waves, landslides and extreme weather conditions aren’t doing t the 81st Geneva Motor Show, But according to another major survey, our too much to sway those of the opinion that held in March 2011, the organisers curiosity and interest in green trends and global warming is a conspiracy. decided to expand the Green technologies is quite removed from our car PavilionA and teamed up with the likes of buying decisions. And for those who see these catastrophes Chevrolet, Mercedes, Mitsubishi and Tata, as a sure sign of global warming, apparently among others, to offer green test drives Research released in November 2010 by they are not prepared to give up space, during the event. Bosch showed that despite 69% affordability and style in favour of a green of drivers claiming tick of approval. Yet. The ten-day event placed more emphasis to do their best for than ever on the Green Pavilion, moving it to the environment, According to Automotive a central and heavily trafficked location. only 5% of News Australia, only in new car the first half of 2011 will The Geneva people reckoned that, because buyers there be some indication green cars and alternative drive systems had would be of which forecasts of been popular with the public and the media influenced electric vehicle market during 2010, their interest would be aroused by a penetration are most given the opportunity to experience them car’s green likely to prove true. close-up. credentials. Assuming that, like myself, In the lead-up to the show, the organisers Bosch had sampled more than you won’t all be racing out to also revealed that surveys had 1,000 UK car buyers. When asked to purchase the £345 Definitive 2011 demonstrated that visitors to the show are rank their main influence behind their Electric Vehicle Research Report, I not only interested in new models, they also purchase decision, 63% of motorists said suggest we just keep our eyes on the road, want to learn about the technologies of the that price was the most important factor, where the trends will sooner or later reveal future. closely followed by vehicle size (at 56%). themselves.

The Automotive Technician 31 Diagnostics made easy Free poster on Dual Mass Flywheels for our readers!

ore of the smaller vehicles Here’s a sample: are coming out with manual Fig 3 transmission and as a result Friction surface (see Fig 1) techniciansM will see more dual mass flywheels (DMF) giving problems or Description: Localised, dark hot spots, wearing out. also in massive number Effect: None The international specialist in drive Remedy: No remedial measure required train technology, LuK, has produced an informative diagnostic poster with Fig 2 illustrations and descriptions for 18 different faults.

Included is a cause and effect chart and, most importantly, a remedy.

The poster stresses the importance of a visual inspection of the DMF in order to evaluate whether it needs to be replaced. Balance weights (see Fig 4)

The poster offers expert advice on Description: Loose or missing (indicated evaluating and repairing the DMF. by clearly visible welding spots) and loud humming noise Effect: DMF out of balance – engine runs Fig 1 uneven Remedy: Replace DMF Friction control disk (see Fig 2) Fig 4 Description: Friction control disk melted Cause: High thermal load inside the DMF Effect: Limited operational reliability of DMF Remedy: Replace DMF

Grease stains (see Fig 3)

Description: Slight trails of grease leaking from the openings or seal caps Effect: None Remedy: No remedial measure required IN EVERY BRAKE PAD CHANGE -V,
%VBM
.BTT
'MZXIFFM
°
This is one of those useful posters that WITH BENDIX HIGH PERFORMANCE &YQFSU
"EWJDF
PO
'BJMVSF
%JBHOPTJT deserves a place on every workshop wall. 4FSWJDF
1PXFS
1BSUOFSTIJQ
4
D
I
B
F
G
G
M
F
S


(
S
P
V
Q


"
V
U
P
N
P
U
J
W
F


"
G
U
F
S
N
B
S
L
F
U SYNTHETIC LUBRICANT *OCFUXFFO
QSJNBSZ
BOE In the next edition of TaT you will find the $MVUDI
ESJWFO
QMBUF TFDPOEBSZ
¿ZXIFFM 'SJDUJPO
TVSGBDF 'SJDUJPO
TVSGBDF 'SJDUJPO
TVSGBDF #BMM
CFBSJOH 1MBJO
CFBSJOH 1MBJO
CFBSJOH -PX
UIFSNBM
MPBE 7JTVBM
TZNQUPNT
TVDI
BT
HSFBTF
MFBLBHF
TDPSFT
BOE
complete install procedure for a DMF on a EJTDPMPVSBUJPO
BSF
PGUFO
UIF
TZNQUPNT
PG
GVSUIFS
EBNBHF
UP
JOEJWJEVBM
%.'
DPNQPOFOUT
"MXBZT
DPOEVDU
B
Ford Transit, including photos. As a special DPNQSFIFOTJWF
WJTVBM
JOTQFDUJPO
PG
UIF
%.'
UP
BTTFTT
UIF
QBSUµT
PQFSBUJPOBM
SFMJBCJMJUZ service to TaT readers and subscribers, LuK %FTDSJQUJPO %FTDSJQUJPO %FTDSJQUJPO %FTDSJQUJPO %FTDSJQUJPO %FTDSJQUJPO %FTDSJQUJPO %FTDSJQUJPO %FTDSJQUJPO $MVUDI
EJTD
CVSOU #VSOU
SFTJEVFT
PG
BCSBEFE
DMVUDI
GBDJOH
BU
4DPSJOH -PDBMJTFE
EBSL
IPU
TQPUT $SBDLT
(SFBTF
FHSFTT %BNBHFE
PS
EFTUSPZFE 8PSO
PVU
'SJDUJPO
TVSGBDF
TMJHIUMZ
EJTDPMPVSFE
UIF
%.'µT
PVUFS
FEHF
PS
JO
UIF
WFOUJMBUJPO

4PNFUJNFT
JO
WFSZ
IJHI

OVNCFST
#FBSJOH
TFJ[FE
*O
SFMBUJPO
UP
UIF
EJBNFUFS
UIF
NBYJNVN
HPMEZFMMPX
and TaT have joined forces to offer a free IPMFT
4FBMJOH
DBQ
NJTTJOH
PS
EJTDPMPVSFE
SBEJBM
CFBSJOH
DMFBSBODF
GPS
B
OFX
QBSUJT

/P
UBSOJTI
BU
UIF
PVUFS
FEHFT
PG
UIF
Available in 10 x 6g sachet Trade Pack and 255g bottles CSPXO
EVF
UP
UIFSNBM
MPBE 
NN
XJUI
BO
BENJTTJCMF
JODSFBTF
%.'
PS
JO
UIF
SJWFU
BSFB UISPVHIPVU
JUT
TFSWJDF
MJGF
VQ
UP

NN poster exclusively to TaT subscribers and $BVTF $BVTF $BVTF $BVTF $BVTF $BVTF $BVTF $BVTF $BVTF 5IFSNBM
PWFSMPBE
PG
UIF
DMVUDI
ESJWFO
5IFSNBM
PWFSMPBE
PG
UIF
DMVUDI
ESJWF
QMBUF 8PSO
PVU
DMVUDI  5IFSNBM
PWFSMPBE 5IFSNBM
PWFSMPBE
PS
NFDIBOJDBM

8FBS
BOEPS
NFDIBOJDBM
JNQBDU 8FBS
BOE
UFBS 5IFSNBM
MPBE QMBUF
PDDVSSJOH
FH
JG
UIF
XFBS
MJNJUT

$MVUDI
MJOJOH
SJWFUT
TDPSF
PO
EBNBHFPWFSMPBE readers. XFSF
FYDFFEFE
GSJDUJPO
TVSGBDF Bendix Ceramic High Performance Synthetic Lubricant is designed specifically &GGFDU &GGFDU &GGFDU &GGFDU &GGFDU &GGFDU &GGFDU &GGFDU &GGFDU 5IFSNBM
MPBE
BQQMJFE
PO
UIF
%.' 3FTJEVFT
PG
UIF
BCSBEFE
GSJDUJPO
NBUFSJBM
-JNJUFE
QPXFS
USBOTNJTTJPO
DBQBCJMJUZ
/POF -PTT
PG
UIF
%.'µT
PQFSBUJPOBM
SFMJBCJMJUZ *OTVG¾DJFOU
CFBSJOH
MVCSJDBUJPO %.'
JT
EFGFDUJWF
’
NN
/POF
/POF DBO
QFOFUSBUF
JOUP
UIF
BSD
TQSJOH
DIBOOFM


5IF
DMVUDI
JT
VOBCMF
UP
HFOFSBUF

%.'
GBJMT

NN
*ODSFBTFE
UJMUJOH
PG
UIF

> BOE
DBVTF
NBMGVODUJPO UIF
SFRVJSFE
UPSRVF TFDPOE
¿ZXIFFM
%BNBHF
UP
UIF
%.'
GSJDUJPO
TVSGBDF To get your free poster send your request for brake parts metal to metal and metal to rubber contact areas. 3FNFEZ 3FNFEZ 3FNFEZ 3FNFEZ 3FNFEZ 3FNFEZ 3FNFEZ 3FNFEZ 3FNFEZ 1FSGPSN
B
WJTVBM
JOTQFDUJPO
GPS
TJHOT
PG
3FQMBDF
%.' 3FQMBDF
%.' /P
SFNFEJBM
NFBTVSFT
SFRVJSFE 3FQMBDF
%.' 3FQMBDF
%.' 3FQMBDF
%.' 3FQMBDF
%.'
JG
CFBSJOH
DMFBSBODF
FYDFFET
/P
SFNFEJBM
NFBTVSFT
SFRVJSFE *O
BEEJUJPO
UP
UIF
WJTVBM
JOTQFDUJPO
UIF
-V,
%.'
TQFDJBM
UPPM
UIFSNBM
EJTDPMPVSBUJPO
PO
UIF
%.'


NN >
'PS
EBNBHF
BTTFTTNFOU
SFGFS
UP and postal address to the technical team at FOBCMFT
XPSLTIPQT
UP
DIFDL
UIF
CBTJD
GVODUJPOT
PG
UIF
%.'
²-PX
UIFSNBM
MPBE³ ².FBO
UIFSNBM
MPBE³ Why use Lubricant? Reduces wear, corrosion & noise XIJMF
UIF
QBSU
JT
NPVOUFE
5IF
TQFDJBM
UPPM
NFBTVSFT
UIF
SPDL
²)JHI
UIFSNBM
MPBE³ ²7FSZ
IJHI
UIFSNBM
MPBE³ Schaeffler Automotive Aftermarket. BOE
UIF
GSFFQMBZ
XIJDI
JT
UIF
BOHMF
BU
XIJDI
UIF
QSJNBSZ
BOE
TFDPOEBSZ
¿ZXIFFMT
DBO
CF
SPUBUFE
BHBJOTU
FBDI
PUIFS
CFGPSF
.FBO
UIFSNBM
MPBE )JHI
UIFSNBM
MPBE 7FSZ
IJHI
UIFSNBM
MPBE 'SJDUJPO
DPOUSPM
EJTD 1SJNBSZ
¿ZXIFFM 4UBSUFS
SJOH
HFBS 4FOTPS
SJOH (SFBTF
FHSFTT #BMBODF
XFJHIUT • 7RSURWHFWPHWDOWRPHWDODQGPHWDO MPBE
JT
FYFSUFE
PO
UIF
BSD
TQSJOHT • Non-melting • Insoluble & waterproof Phone: 02 8977 1038  WRUXEEHUFRQWDFWDUHDV 5IF
SFTVMUT
BSF
DPNQBSFE
UP
UIF
SBUFE
WBMVFT
PG
UIF

• Extreme temperature protection to 1650°C • Chemical resistant DPSSFTQPOEJOH
%.'
QBSU
OVNCFS
XIJDI
DBO
CF
GPVOE
FJUIFS

Fax: 02 9452 4242 • 7RHQVXUHVPRRWKRSHUDWLRQ PO
UIF
%.'µT
JOEJWJEVBM
%BUB
8IFFM
PO
UIF
*OUFSOFU
VOEFS

• Lasts the life of the brake job • Silences calipers XXX3FQ9QFSUDPN
PS
XXX4DIBFG¿FS"GUFSNBSLFUDPN

%FTDSJQUJPO %FTDSJQUJPO %FTDSJQUJPO %FTDSJQUJPO %FTDSJQUJPO %FTDSJQUJPO %FTDSJQUJPO %FTDSJQUJPO %FTDSJQUJPO Email: [email protected] 'SJDUJPO
TVSGBDF
EJTDPMPVSFE
CMVF
EVF
UP
5BSOJTI
JO
SJWFU
BSFB
BOEPS
BU
UIF
PVUFS

%.'
EJTDPMPVSFE
CMVFQVSQMF
BU
UIF

'SJDUJPO
DPOUSPM
EJTD
NFMUFE 4FDPOEBSZ
¿ZXIFFM
TDPSFT
UIF
4UBSUFS
SJOH
HFBS
IFBWJMZ
XPSO 4FOTPS
SJOH
UFFUI
EJTUPSUFE
.JOPS
HSFBTF
FHSFTT -PPTF
PS
NJTTJOH • BOE
PO
UIF
$%
TVQQMJFE
XJUI
UIF
TQFDJBM
UPPM
UFNQPSBSZ
UIFSNBM
MPBE

$ EJBNFUFS
/P
UBSOJTI
PO
UIF
GSJDUJPO
TVSGBDF TJEFT
PS
CBDL
BOEPS
WJTJCMZ
EBNBHFE

QSJNBSZ
¿ZXIFFM

4MJHIU
USBJMT
PG
HSFBTF
MFBLJOH
GSPN


*OEJDBUFE
CZ
DMFBSMZ
WJTJCMF
7RH[WHQGWKHOLIHRIEUDNHSDGVDQGURWRUV
/P
EJTDPMPVSBUJPO
JO
UIF
SJWFU
BSFB
5IF
%.'
XBT
JO
DPOUJOVFE
PQFSBUJPO
FH
DSBDLT
UIF
PQFOJOHT
PS
TFBM
DBQT XFMEJOH
TQPUT • Prevents rust & corrosion
BGUFS
IJHI
UIFSNBM
IBE
PDDVSSFE
)FBWZ
HSFBTF
MFBLBHF

H

)PVTJOH
DPWFSFE
XJUI
H
SFBTF 0O
UIF
CBTJT
PG
UIF
SFTVMUT
PG
CPUI
UIF
WJTVBM
JOTQFDUJPO
BOE
UIF
• $BVTF $BVTF $BVTF $BVTF $BVTF $BVTF $BVTF $BVTF $BVTF 7RUHGXFHQRLVHIURPEUDNHFRPSRQHQWV NFBTVSFNFOUT
UIF
NFDIBOJD
IBT
UP
EFDJEF
XIFUIFS
PS
OPU
UIF
%JTDPMPVSBUJPO
PG
UIF
GSJDUJPO
TVSGBDF
JT
B
)JHI
UIFSNBM
MPBE
$ 7FSZ
IJHI
UIFSNBM
MPBE )JHI
UIFSNBM
MPBE
JOTJEF
UIF
%.' 'SJDUJPO
SJOH
PG
UIF
QMBJO
CFBSJOH
XPSO
PVU %FGFDUJWF
TUBSUFS .FDIBOJDBM
EBNBHF   You can also pick up your free poster from the OPSNBM
PDDVSSFODF
EVSJOH
PQFSBUJPO %.'
OFFET
UP
CF
SFQMBDFE
8IFO
JO
EPVCU
XF
SFDPNNFOE
UIBU
&GGFDU &GGFDU &GGFDU &GGFDU &GGFDU &GGFDU &GGFDU &GGFDU &GGFDU UIF
%.'
CF
SFQMBDFE
BT
QBSU
PG
B
QSPGFTTJPOBM
DMVUDI
SFQBJS TaT team on the Capricorn Society stand at /POF %FQFOEJOH
PO
UIF
EVSBUJPO
PG
UIF
UIFSNBM
%.'
JT
EFGFDUJWF -JNJUFE
PQFSBUJPOBM
SFMJBCJMJUZ
PG
UIF
%.' /PJTF
FNJTTJPO /PJTF
PDDVSSJOH
EVSJOH
FOHJOF
TUBSU &OHJOF
SVOT
VOFWFO
/POF
GPS
NJOPS
HSFBTF
FHSFTT %.'
PVU
PG
CBMBODF MPBE
BQQMJFE
UIF
%.'
JT
EFGFDUJWF
*OTVG¾DJFOU
MVCSJDBUJPO
PG
UIF
BSD
TQSJOHT

-PVE
IVNNJOH DBVTFE
CZ
IFBWZ
HSFBTF
MFBLBHF

3FNFEZ 3FNFEZ 3FNFEZ 3FNFEZ 3FNFEZ 3FNFEZ 3FNFEZ 3FNFEZ 3FNFEZ the Australian Automotive Aftermarket Expo /P
SFNFEJBM
NFBTVSFT
SFRVJSFE 3FQMBDF
%.' 3FQMBDF
%.' 3FQMBDF
%.' 3FQMBDF
%.'
3FQMBDF
%.' 3FQMBDF
%.'
-JUUMF
HSFBTF
FHSFTT
SFRVJSFT

3FQMBDF
%.' FOR MORE INFORMATION
1FSGPSN
TUBSUFS
NPUPS
GVODUJPO
UFTU
BOE
OP
DPVOUFS
BDUJOH SFQMBDF
TUBSUFS
NPUPS
JG
OFDFTTBSZ

3FQMBDF
%.'
JG
HSFBTF
MFBLBHF
JT
IFBWZ from 12 to14 May at the Melbourne Exhibition Freecall the Bendix Brake Advice Centre on Centre, Southbank. 1800 819 666 (8am-5pm Monday to Friday EST) 'VSUIFS
JOGPSNBUJPO
JT
BWBJMBCMF
BU
XXX4DIBFG¿FS"GUFSNBSLFUDPN or +61 3 5327 0211 from overseas. ]
XXXUBUOFU 4DIBFGGMFS
"VTUSBMJB
1UZ
-UE

]

"VUPNPUJWF
"GUFSNBSLFU

]

10
#PY


]

'PSFTUWJMMF
/48


]

"VTUSBMJB

]

1IPOF






]

'BY





]

&NBJM

-V,"4BV!TDIBFGGMFSDPN Or visit bendix.com.au or bendix.co.nz Bendix is a trademark of Honeywell International Inc.

The Automotive Technician 32 YOU SAID Case study of ML 350 aircon fault IT! ambient temperature and coolant system, and used four litres of his Mercedes ML 350 temperature readings but still no flush to clean out the evaporator. came to us from a operation. We replaced the condenser and franchisee who had filter drier. The ‘new’ cleaned and Treplaced a compressor in the After locating the old compressor tested compressor was refitted compressor replacement without belief that the clutch had failed and checking that it was faulty and the system recharged. checking the system integrity, tell and disengaged the shaft on (assuming the new one must be them to get a new job. the front pulley. good), we then began to look After reassembling and thinking for a possible control module or all problems would be solved, Thanks for your ear at late hours (TaT technical director Deyan electrical fault. we still had no operation. Scan and with your fantastic editing this Barrie explains that this is a tool data of the compressor may become a case study in TaT, constant drive, variable speed The white flag went up so we remained at 4% and it was still which we have found very helpful. compressor that had a safety sent it to our local Mercedes able to manually operate through limiter as part of the front hub that dealership. Still no joy and they the scan tool but it still registered Greg Moore snaps if the compressor seizes were still coming back with the a compressor fault. After phone Pelusey and Newell and then the pulley free-wheels.) same faults and the belief that the calls to TaT, we ordered a control OSBORNE PARK WA compressor was at fault. valve. The next day it was fitted, They had replaced the the system re-gassed and the (Well done Greg and thanks for the compressor only, recharged the After going down the same track problem was solved. feedback. Yes this is a good report system, but the air con system as the previous guys, all the fault and great to ponder about how this still would not work. They had codes came back pointing to a If we had believed our scan tool sort of problem should be dealt scanned it and scan tool-operated faulty compressor. We decided to and our gut feeling, quite apart with from the start. Never take the system but still it would not de-gas the system and remove from all the flush requirements, a someone else’s word as gospel. If work normally. the compressor. Upon removal replacement of the control valve others say tests are all good, don’t we noticed contaminated oil. (solenoid) would have solved the regard this as our starting point. Looking at live data, we had problem. Googling Nippon Denso We have to assess and evaluate every detail, especially when it engine coolant at minus 40C and We sent the compressor to our control valve it was clear that we has been handballed down the ambient temperature was the repairer who cleaned and flushed weren’t the first and probably line. Nothing should be taken for same. Bingo — a faulty alarm it and said that the compressor won’t be the last to come across granted without a lot of personal acknowledgement module (AAM). and control valve were all OK. a control valve issue. Finally, investigation. This story proves this Changing the AAM now gave us We carried out a total flush of the if you find anyone who does theory in so many ways. Deyan)

IN EVERY BRAKE PAD CHANGE WITH BENDIX HIGH PERFORMANCE SYNTHETIC LUBRICANT

Available in 10 x 6g sachet Trade Pack and 255g bottles Bendix Ceramic High Performance Synthetic Lubricant is designed specifically for brake parts metal to metal and metal to rubber contact areas. Why use Lubricant? Reduces wear, corrosion & noise • 7RSURWHFWPHWDOWRPHWDODQGPHWDO • Non-melting • Insoluble & waterproof  WRUXEEHUFRQWDFWDUHDV • Extreme temperature protection to 1650°C • Chemical resistant • 7RHQVXUHVPRRWKRSHUDWLRQ • Lasts the life of the brake job • Silences calipers • 7RH[WHQGWKHOLIHRIEUDNHSDGVDQGURWRUV • Prevents rust & corrosion • 7RUHGXFHQRLVHIURPEUDNHFRPSRQHQWV

FOR MORE INFORMATION Freecall the Bendix Brake Advice Centre on 1800 819 666 (8am-5pm Monday to Friday EST) or +61 3 5327 0211 from overseas. Or visit bendix.com.au or bendix.co.nz Bendix is a trademark of Honeywell International Inc.

The Automotive Technician 33 Murphy’s Law – We think we have it tough

recently travelled the So how do we compare with length of Vietnam and was our work ethic and the way Isurprised to see a country we communicate with each steeped in tradition, and other? I think in some cases where some of their day-to- the under-developed countries day chores could only be have it over us. I’m not talking described as primitive. about work conditions, because who would want to work in the What caught my attention was situations I’ve described. the way the Vietnamese work, with no fuss, in situations that I think it’s more to do with the an Australian motorist would fact that they see the future as never tolerate. a pot of information. Some may have knowledge in one aspect What first caught my attention and some in another and when was a truck parked on the side many heads come together of a road and the driver had there is nothing that can’t be crawled underneath to fix it, Where do all these motorbikes There was also a noticeable achieved. right where it had broken down. and cars get fixed? Apparently, lack of workshops and in some they get fixed where they break there were kids as young as We tend to have the attitude I’m not talking about some down, on the side of the road, 12 working away on a dirt that if we share information, it quiet side street, this was on a in very dangerous situations. floor or on the footpath. The will be used to take customers main road with motorbikes by Somehow the rest of the traffic funniest thing I saw was a very away, but does that really the thousands and cars driving seems to find its way around it, late model Volvo XC90 with happen? on the wrong side. Organised with the mechanic occasionally rear differential completely chaos. dodging out of the way of a removed, sitting fair smack in truck or a glut of motorbikes. the middle of the road. My first thought was that this poor bugger is going to get his The drive into Hanoi was Elsewhere, people were legs run over, but then out of horrendous but interesting. applying window tinting to a nowhere he had a few more Weaving its way through the new car — you guessed it, in helpers. Next thing you know, mass of cars and bikes was the middle of the road. the tail shaft comes rolling out some kind of half bike, half from under the truck. trike arrangement, on which Motor cars, other than some was balanced a two-metre-high Russian models, have not that Travelling back on that same tree fully laden with cumquats. long been common in Vietnam, road the following day, there It was a funny sight because so where do they get their was the same truck, but you couldn’t see the bike, only service and repair information the team working on it had a cumquat tree passing by the from? swelled. I noticed the tail shaft window. still on the ground, along with They are not using hoists and the gearbox in pieces and In Hanoi I noticed more and the use of any form of scan tool something that resembled the later model vehicles, and would be out of the question. In Vietnam there seems to be a flywheel. expensive vehicles at that. standard pricing system across BMW, Volvo, Mercs and the I had a conversation with a the country and that’s based I had to leave this amazing like all had to be serviced repairer, or rather it was a lot of on however long it takes to do spectacle of roadside repair, and repaired. There are a few head nodding and arm waving. the job. There seems to be no thinking that I would never see dealers in Vietnam but nothing He told me ‘If you in trouble under-cutting to win customers. that again. Wrong. to what we’re used to. and can’t fix, call friend and It doesn’t matter where you go, if friend can’t fix call another the price is the same, unless friend.’ you are a tourist.

Eventually the network is put There’s a lesson for our in place and someone can business in this story. The usually come to the rescue. Vietnam experience is perhaps This is a very tight-knit a primitive form of what TaT community and in a large city is trying to achieve — a they all seem to know each sharing of information rather other. How, I wondered. than jealously guarding our expertise or under-cutting our The answer seems to lie in neighbours. the fact that their work is their life, seven days a week. They Happy diagnosing make the time to sit with fellow mechanics and have a beer. Nick Murphy It’s a ritual you see everywhere and this is the basis of their networking.

The Automotive Technician 34 TaT subscriber from Dandenong Hybrid course been running his own business for the in Victoria, Nigel Tilley of Aussie past five years. ATune, was so inspired by the worth doing - hybrid stories that are published from He has invested heavily in diagnostic time to time in this magazine, that he but where are equipment including diagnostic computer took himself off to Massachusetts in scanners, and he and his staff regularly the US to spend a week at Craig Van the hybrids? attend training courses on modern vehicle Batenburg’s famous hybrid course. systems.

Craig is a regular contributor to this He is also a great believer in joining magazine and the first Australian automotive information networks and data technician to do his course, Gil Sher from providers. Sydney, is now a hybrid trainer in the TaT stable. Nigel Tilley is typical of the growing breed of younger technicians who Nigel took his US trip a little more than subscribe to TaT’s view that training a year ago and since then, despite his and skills development are the essential new-found and valuable knowledge, he’s ingredients for a successful aftermarket still wondering where all the hybrids are repair workshop. hiding. Nigel Tilley: ‘I have no regrets about doing the course, www.aussietune.com.au and I never expected to make a killing Craig Van Batenburg: immediately with my hybrid knowledge,’ Nigel Tilley of Aussie Tune www.auto-video.com Nigel admits. just didn’t want to touch them. ‘In fact most of the hybrid work I’ve captured ‘I see the training more as a long-term has been straightforward servicing but investment in my own future. I did Craig’s even that requires specialist knowledge course because I wanted to be ahead of that I would not have had if I didn’t do a the game in my own community and I am comprehensive course. a great believer in value-adding to your knowledge so that you can continue to be ‘The experience of simply attending competitive. Craig’s course was worth every bit of the financial outlay.’ ‘Maybe it’s too soon for hybrid breakdowns and maybe the Dandenong Craig and his wife are an awesome team area is not typical hybrid country. and there is no doubt that Craig is one of the best hybrid teachers around.’ ‘However, my reputation with hybrids has spread to the point where several other Nigel has spent most of his working life in workshops in the district have sent me the auto workshop environment and has problem hybrids to repair because they

This magazine is just AUSSIE MADE QUALITY JUMP the tip of the iceberg! STARTERS & BATTERY CHARGERS Eliminate Down Time and save money on batteries with our Jump Starters, Battery Chargers and genuine Carbon Pile Battery Load Testers. No matter what you are looking for, our entire product range features the strength, quality and reliability that Durst offers as proud Australian Manufacturers Since 1918.

Market Leading Jump Starters Battery Chargers that Stand the Test of Time • From small carry to massive trolley units • Available from 6V to 36V and 3A to 100A • Available in 12V or 24 Volt or combined • Larger models with Boost Start function • Fuse Protected for OH&S Compliance • Powder Coated Steel Case • Anti Spike protected to protect electronics for Long Life • Reverse Polarity Warning buzzer • Carry or Trolley versions • Powder Coated Steel Case for Long Life • All components are Heavy • Long leads for easy access Duty for years of trouble free • Used by the Australian Defence Forces, operation Government, Mines, TAFE etc • Easy to use, instructions on front panel Durst SmartWasher • Used by the Australian • Solvent free, no fumes Defence Forces, to breathe in Government, Mines, TAFE etc • Don’t change solution • Minimal Maintenance • OH&S Compliant DURST INDUSTRIES • Fully Recycles 189 St Johns Rd Glebe NSW 2037 www.tat.net.au • Environmentally Friendly • Won’t harm skin or lungs Ph 02 9660 1755 This is where you find the database of repair Email [email protected] solutions, stories from all TaT issues, training Genuine Carbon Pile Battery Load Testers Sales, Service and Repairs. • Available in various models to cover 6, 12 & 24V programs and much more. Ask us about purchase • High Capacity models for all batteries including N200 size options including leasing. This is where you reap the real benefits of your • Powder Coated Steel Case for Long Life • Carry or Trolley versions subscription to TaT. www.durst.com.au

The Automotive Technician 35 Capricorn and TaT Biz training rolls out

he 2011 training The business training workshops program will are open to all, whether or not Capricorn Events team: concentrate for most you are a Capricorn member, Australia freecall ofT this year on the co- a TaT subscriber or a VASA 1800 999 233 branded 9 steps to a better member, so if you see a date New Zealand freecall workshop, being managed below that suits you, don’t Training for 0800 401 444 by Capricorn Society and hestitate to get in touch with better business www.capricorn.coop delivered by TaT Biz. the Capricorn Society.

April 2011 Thursday 23, Adelaide Hills SA September 2011 Monday 27, Tauranga NZ Monday 11, Ringwood VIC Tuesday 28, New Plymouth NZ Thursday 1, Geelong VIC Tuesday 12, Ferntree Gully VIC Wednesday 29, Palmerston North NZ Monday 5, Sale VIC Thursday 14, Dandenong VIC Thursday 30, Wellington NZ Tuesday 6, Traralgon VIC Wednesday 7, Warragul VIC May 2011 July 2011 Thursday 8, Cranbourne VIC Monday 12, Mildura VIC Tuesday 3, Sumner Park QLD Tuesday 13, Echuca VIC Tuesday 5, Southport QLD Wednesday 4, Slacks Creek QLD Wednesday 14, Bendigo VIC Wednesday 6, Tweed Heads NSW Thursday 5, Fortitude Valley QLD Thursday 15, Ballarat VIC Tuesday 10, Brendale QLD Thursday 7, Toowoomba QLD Tuesday 20, Geraldton WA Wednesday 11, Nambour QLD Tuesday 12, Griffith ACT Wednesday 21, Melville area WA Thursday 12, Noosa Heads QLD Wednesday 13, Wollongong NSW Thursday 22, Bunbury WA Tuesday 17, Penrith NSW Thursday 14, Miranda NSW Wednesday 18, Parramatta NSW Tuesday 19, Gosford NSW October 2011 Thursday 19, Kogorah NSW Wednesday 20, Hornsby NSW Tuesday 24, Coffs Harbour NSW Thursday 21, Brookvale NSW Monday 3, Sunbury VIC Wednesday 25, Newcastle NSW Tuesday 4, Shepparton VIC Thursday 26, Campbelltown NSW August 2011 Wednesday 5, Wangaratta VIC Tuesday 31, Burnie TAS Thursday 6, Albury VIC Tuesday 11, Adelaide central SA Monday 8, Nelson NZ June 2011 Wednesday 12, Adelaide south SA Tuesday 9, Christchurch NZ Thursday 13, McLaren Vale SA Wednesday 1, Launceston TAS Wednesday 10, Dunedin NZ Tuesday 18, Perth nth suburbs WA Thursday 2, Hobart TAS Thursday 11, Invercargill NZ Wednesday 19, Perth nth suburbs WA Tuesday 7, Port Lincoln SA Tuesday 16, Vic Park area WA Thursday 20, Midland area WA Wednesday 8, Port Pirie SA Wednesday 17, Vic Park area WA Thursday 9, Gawler SA Thursday 18, Point Kennedy WA November 2011 Tuesday 14, Berri SA Wednesday 24, Auckland NZ Wednesday 15, Murray Bridge SA Thursday 25, Auckland NZ Monday 14, Greensborough VIC Thursday 16, Mt Gambier SA Monday 29, Horsham VIC Tuesday 15, South Melbourne VIC Tuesday 21, Adelaide Outer West SA Tuesday 30, Hamilton VIC Wednesday 16, Carlton VIC Wednesday 22, Adelaide West SA Wednesday 31, Warrnambool VIC Thursday 17, Darrebin VIC

YES! Please sign me up for my $115 magazine subscription and access to your technical solutions!

Mr Ms Mrs Miss (circle) First name: ______Surname: ______Postal address: ______State: ______PC:______Work phone number: (_____)______Mobile number: ______Email: ______Method of payment CHEQUE: Payable to The Automotive Technician The Automotive Technician $115 covers 12 months access to technical CAPRICORN ACCOUNT: Account No:______solutions and six issues of this magazine Want more information? Account Name:______In Australia, call 1300 828 000 In New Zealand, call +61 2 9966 8600 Signature:______

CREDIT CARD: Mastercard Visa Card Number: Name on Card:______Expiry Date:____/____ Amount: $115 AUD $130 NZD Signature: ______Date: ______

PLEASE FAX OR COPY AND SEND WITH YOUR REMITTANCE TO: The Automotive Technician 72 Holtermann Street, CROWS NEST NSW 2065 or FAX TO 1300 828 100. From New Zealand, please fax your form to +61 2 9438 3213

The Automotive Technician 36 Capricorn and TaT Biz training rolls out

1ST BRAND... 1ST IN INNOVATION

VALVOLINE - THE GUARANTEED PERFORMER Contact Valvoline for more information regarding the Customer Service Van and Valvoline Professional Series. www.valvoline.com.au The Automotive Technician 37 Try selling your ‘s interesting best stock Geoff Mutton New products and equipment for the auto industry

1. Kincrome file set comes with the two quality VDO gauges, sender units, Kincrome has released three new ranges of file sets adaptors, wiring loom extension and cable ties. featuring a three-piece 200mm bastard cut set, a three- piece 250mm 2nd cut set and a five-piece 250mm 6. Belt wear gauge with a combination of bastard and 2nd cut files. All sets With research showing that one in five vehicles include hand file, half round and round file types with needs at least one new belt it’s timely that Gates has common strategy used by the five-piece set also including a square file. developed a belt wear gauge to take the guesswork just about every business to boost profitability is to try to www.kincrome.com.au out of belt replacement decisions. Traditional belts, Asell more of the stock that has a normally made from neoprene, show signs of wear higher gross margin. 2. A brake-through through cracking, pilling, glazing or misalignment A new generation of brake pads 1. damage. Modern belts, made from EPDM (a For example, if you had a fruit store and linings plus OEM quality synthetic rubber), do and bought an apple for 40c and sold brake shoe sets for the not show the same it for $1 you would make a gross profit latest heavy commercial characteristics so of 60c with a gross margin of 60%. If vehicles, prime movers belt wear is harder to you were then able to source a better tasting apple for 45c but could sell it for and trailers has been determine. $1.20 you would make 75c gross profit released by Bendix. with a gross margin of 62.5%. Marketed as PROTRANS the For the Gates belt new generation of disc brake wear gauge display 4. In our industry we are lucky enough to pads are designed in Australia unit or a free Gates have two different types of inventory to withstand harsh operating belt wear gauge to sell — parts and labour. The gross conditions. 3. go to the website profit on parts will generally range from www.bendix.com.au southpacsales@ 10% on large items up to 80% on small www.bendix.co.nz gates.com parts and consumables. By contrast, labour has a 100% gross profit margin. brakeadvicecentre@bendix. That’s because you have already paid com.au 7. New products from for the labour. It’s a fixed cost that you Fuelmiser will incur regardless of whether or not 3. Wiper blade Fuelmiser’s new products you sell your staff hours. catalogue include transmission Trico has released 5. neutral start (inhibitor) From this it is clear that labour is the 8. its 2011 product switches, EGR valves most valuable inventory you have catalogue and and speed sensors. More for sale and because of this it makes sense to focus on selling as much of it application than 220 part numbers have as possible. guide for wiper been added to the range blades and refills including extensions in all The reality of our industry is that too covering the four Trico 2. sensors and ignition coils many workshops focus on trying to ranges, from high categories. Technical and make money by selling parts. There performance to budget. vehicle application: are plenty of workshops that employ A special wiper blade Phone 1800 245 748 someone solely for the purpose of fault diagnosis section Customer service: ringing different suppliers to try to save is included to help 6. 1800 605 673 a few dollars here and there. They do this at the cost of not selling their most identify blades that www.motospecs. valuable stock — labour — which is need replacing. com.au sitting idle out the back waiting for the Phone: parts to arrive. 1300 698 742 8. Lamps almost Essential 7. like daylight. In the fruit store scenario it’s like the Service Heavy duty high green grocer trying to flog his ageing Programs: powered LED stock at the expense of his fresh 02 8001 6120 9. lighting offers produce that is still sitting out the back unrivalled white in the cool room.

4. Diesel fuel light output and There is nothing wrong with keeping stabiliser performance, reliability, maintenance-free operational your suppliers competitive but if it Trico Products life of more than 50,000 hours, plus a greater ability comes at the expense of selling less has added Gold Eagle’s Diesel Formula STA-BIL Fuel to withstand shock and vibration. Narva has released labour then it is doing more damage Stabiliser to its additives line-up. Diesel fuel stored a new range of work lamps with flood beams up to an than good. in bulk tanks, drums or in a fuel tank, can deteriorate amazing 15,000 Lumens output. Due to the low current rapidly for a variety of reasons. The addition of Diesel draw, wiring up these lamps is simple so on-site staff From our experience, highly profitable Formula STA-BIL Fuel Stabiliser to a full tank of can do the job without specialised training. workshops just want the most reliable supplier and are happy to pay a fresh diesel will keep it fresh for around 12 months, Phone 1800 113 443 [email protected] premium for it because they know preventing the formation of sludge and sediment and the quicker the parts arrive the better at the same time helping to remove water from the 9. Gates timing kits chance they have of selling all their system. Gates has released an additional nine timing labour hours. component kit part numbers covering 22 new 5. VDO gauges applications, suitable for the Lexus range, Toyota Apply this principle to your workshop. An original equipment style instrument pod carrying Landcruiser, Mitsubishi Mirage and Lancer. Gates Ensure that you are doing everything an oil pressure gauge and voltmeter designed to fit timing component kits provide the necessary in your power to sell as much labour as VY to VZ Holden Commodores is now available from components so that you can service the entire timing possible.

VDO. The pod comes with a complete ‘plug and play’ system. The kits contain seals, tensioners, idlers, Stay tuned for more tips and tricks. installation kit with clear instructions. No cutting or springs, bolts, washers and water pumps. drilling is required to complete the installation as the kit Ph: 03 9797 9688 www.gatesaustralia.com.au Geoff Mutton TaT Biz trainer The Automotive Technician 38

WN VE KNO RESOL TO ES SOLUTIONINEEREDA L ISSU KITS ENG TION OPERA

From belt jump off (such as that experienced in the Chrysler Voyager) to chronic belt noise (such as that in the Toyota Corolla & Rav4) and cooling system enhancements, these precision-engineered Solution Kits have been developed to resolve a variety of engine operational issues.

Gates Solutions Kits enhance original equipment drive designs so that customer’s vehicles are better than when they left the showroom. In some cases, Gates Solution Kits are used to eliminate troublesome noise, or in other more severe cases, can prevent roadside breakdown. They address a range of applications and are tailored for specific models to include specially-constructed belts, upgraded pulleys and tensioners, and other belt drive and cooling system components.

At Gates, we understand what you need to make your customers satisfied - no comebacks!

For a full application listing of the Solution Kits available visit: www.gatesaustralia.com.au/solutionkits The Automotive Technician 39 Don’t miss out, contact Autodata today on 1300 764 432 www.autodata.com.au

See us at

Thur 12 - Sat 14 May 2011 Melbourne Exhibition Centre Stand N6

AD_AUS_MAR11_TAT_FP