February 2010 Issue No 13 www.tat.net.au

Oz Top Gear’s top mechanic

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New Generation Scan Tools Call 02 9905 8055 www.hanatech.com.au for your nearest national distributor As our chief trainer Jeff Smit keeps What a fantastic notion that was, and with Ken Newton saying ‘nobody can know it all any this was one of the big ideas which more’. became part of the TaT philosophy, mainly because both Jeff Smit and any of us still persist Having been involved with a few auto It doesn’t take a Rhodes scholar to Deyan Barrie, the TaT technical with this ancient New conventions and training workshops quickly figure out that with all these team, headed up the AAAE in the Year’s resolution ritual in my time, I am regularly amazed new computer controlled systems early days. ofM promising ourselves to make that, year after year, you see the in the average family sedan, plus changes to our lives. same faces in front of the trainers. hybrids and electric cars about to flood the market, some extra training So if we now have you thinking about At a guess, 99% of those resolutions I’ve reached the conclusion and knowledge is going to be your own future in the industry, why that the world is equally divided are in the dustbin next day. That’s necessary if technicians are going to don’t you put this magazine aside for between those who appreciate the also part of the ritual. stay in the game. a few minutes and make a new set of value of training, and those who New Year’s resolutions. First allocate Regardless of whether we carry the believe they don’t need it. That need for knowledge is the an annual sum of money which resolution through to the end, the premise that drove the establishment you can afford to direct to training concept is supposed to be an annual I also know that once a technician of this magazine and our online help reflection on self improvement. I yourself and/or your technical staff. makes the big decision to and training programs. We arrived exclude from this story our Top Gear Then pack as many training events spend hundreds of dollars on the market at the right time, and mechanic featured in the cover story. (including registration, travel and into your year that you can possibly Hamish Allen is one of the 1% who it is inspiring to see the number of accommodation) to attend something attend. actually follows through with his New technicians who are enthusiastically as big and dynamic as the Wire Year resolution – read it on Page 4. tapping into our resources, and & Gas Convention, they usually sharing information with each other. Wire & Gas would be a must (there’s Working closely with many become addicted to training and a story in this issue). Watch out technicians and workshop owners conventions in the future. That’s why As a by-product of TaT, what we for the TaT training program when since this magazine first began we keep seeing the same faces – are really doing is establishing a it appears on our website, check in February 2008 has given our they wouldn’t miss it for quids. formidable database of experts out the other training opportunities technical team a good insight into in all fields of auto repair. The old through your wholesalers, including the state of readiness of most In case you haven’t noticed, the auto Australian Association of Automotive Bosch which runs excellent courses. technicians to face the problems that world is changing rapidly. Every area Electricians (AAAE), which merged will be wheeled into their repair bays of the modern vehicle is changing, with VASA, had this great idea years this year. and fast. ago, to ask its members if they had a There are many opportunities. Most Without detracting from the many speciality that they could share with are nights or weekends, so you are dedicated technicians who attend With each new wave of vehicles their fellow technicians. not throwing away work time. training and hone their skills at every comes a new wave of post-warranty problems for the aftermarket opportunity, we have to say that there They had a Merc specialist in Consider this your investment in your technician. The reality is that those are still too many people living in the Bendigo, an air conditioning wizard in own future. Other professionals do it, past, simply trusting that their years who think they can rely on their Brisbane, and a ECU guru in Perth… why not you. of experience will get them through. experience are deluding themselves. the list goes on.

The team Contents

Publisher International correspondents The zany Top Gear mechanic ……… 4,5 The Automotive Technician Pty Ltd Julian Hentze - Georgia USA •TaT Assist •TaT Chat •TaT Train Fantasy or future …………………… 5 •TaT’s a Fact •Tips for TaT ABN 27 121 589 802 Hayley Windsor - Peru Subaru ABS problem ……………… 7 - are all registered trade names of Volvo goes electric ………………… 7 1 Cleg Street Reader ARTARMON NSW 2064 Bron Robinson The Automotive Technician Pty Ltd. What is a job worth ………………… 8 The Automotive Technician Pty Ltd Concept - Twizy ZE …………………… 9 [email protected] Advertising inquiries publishes technical advice and A car with a screw loose …………… 11 Ph 1300 828 000 Jeff Smit actual case studies for the Fax 1300 828 100 Ford factory LP ……………………… 12 [email protected] purpose of educating technicians. Letter from America ………………… 15 Editor in chief Ph 02 9966 8600 These advices are given in good Ken Newton Wire & Gas registrations ………………15 faith, and are based on actual [email protected] Graphic design workshop repairs. No guarantee is It all begins with the battery ………… 15 0438 569 517 Russell Jones given, nor any liability accepted in Tat’s a facts ……………………… 16, 17 Fax 07 5591 8172 Russell Jones Graphic Design respect to any published advice. Top Tools - Durst charger ……………… 18 07 5532 2840 0408 123 287 Technical editor [email protected] The Automotive Technician Pty Ltd Top Tools - Projecta Intelli-Charge ….… 19 Jeff Smit is not responsible for the accuracy Charging extra for knowledge ………… 21 [email protected] of any information contained in 1300 828 000 Original TaT design standard New year - new cars ………………… 22 material submitted by third parties Allan Green It only takes a pinched wire ………… 22 Technical research CEO Design and published in this magazine and Street Cred - the Tuk-Tuk …………… 23 Deyan Barrie [email protected] accepts no liability in relation to [email protected] such materials or their content. Tat’s Interesting ……………………… 25 02 9476 6277 Printing Newsworthy articles or comments Murphy’s Law on training …………… 26 Technical advisers Immij NSW are welcomed, and should be Poor servicing to blame …………… 26 Jack Stepanian 3/12 Mars Road, submitted to the editor in chief. The last word - Stuart Charity ………… 30 Lane Cove Nick Murphy NSW 2066 All material appearing in The [email protected] Automotive Technician is copyright. The Automotive Technician is a member of www.immij.com.au the Circulations Audit Board. CAB Audited Reproduction in whole or in part is as at September 2009 - 9524 average net Wayne Broady distribution per issue. illegal without prior written consent Average copies mailed by post office or www.broadyauto.com.au Affiliated associations from the editor in chief. mailing house less returns - 7079 per issue. Gil Sher VASA (Automotive Air Conditioning, [email protected] Electrical & Cooling Technicians of All advertisers agree to indemnify Australasia) the publisher for all damages or Garry Reid [email protected] liabilities arising from their published [email protected] or unpublished material.

The Automotive Technician 3 – the zany mechanic behind Top Gear stunts

lateral thinkers. Hamish is very the production company which adopted his own annual challenge different. had put out the call for hosts of – a New Year’s resolution which the Australian show. He wasn’t he continues to adopt with gusto His customers, those who’ve interested in being a host, but every year. Most of us make entrusted him with their faulty reckoned he had a stack of resolutions and forget them next cars over many years, will interesting ideas which might be day. Hamish carries his through to Hamish vouch that he is a wizard of a useful for the show. the nth degree. Over the years, he mechanic. He’s been known to has become accomplished, if not call a customer at one o’clock in He was appointed mechanical expert, in astronomy, art history, the morning with the exciting news engineer to Top Gear Australia photography, journalism, flight – ou’ve heard of ‘Q’ that he’s just figured out the pesky series one and two and he had the the list goes on. surely? He was the problem with his vehicle. head of Q Branch (Q for YQuartermaster) in the James Hamish, a rally car builder and Bond movie series. driver in days gone by, confesses he never wanted to be a mechanic in the first place. His job – research and development. Provide James Bond with the gadgets and weaponry to “As an apprentice mechanic at defeat Spectre. college orientation, we were asked to stand in front of the class Now meet the man dubbed and reveal why we wanted to Australia’s ‘Q’ – he’s a Sydney become motor mechanics. My co- mechanic called Hamish Allen. apprentices gave the usual uplifting motives, but I just blurted out, ‘I His job – turn the auto tom-foolery don’t want to be a mechanic, but devised for the television show Top I want to be around machines’,” recalls Hamish. Hamish working to meet deadlines to manufacture a three engine Gear Australia Into reality. trike, at Jeff Smit’s McIver Engineering workshop in Sydney.

We’d like to say that Hamish is “I’m not a people person. a quiet, unassuming, scientific Given time again I would do an time of his life working with the UK Here’s a sample: type - a younger version of the engineering degree.” team on their Australian live show humourless guy who played the last year. Q role in most of the early Bond He was employed at North Shore Resolution: This year I will fly. He movies. Nissan at the age of 18 and not only earned his licence to fly developed an interest in Nissan Hamish’s responsibility was to fixed and rotary wing aircraft, but build the vehicles required for the But we special vehicles – rally and race has also logged time in airships Top Gear stunts. “I assist the hosts can’t. cars. He was good at his job, (the Holdenburg) and corporate with their enthusiasm. They dream Hamish, becoming Repco apprentice jets. One of Hamish’s up these ideas, and my job was dubbed of the year. masterpieces – a fold-up to advise on whether they were ’Q’ by Resolution: This year I car in a suitcase. realistic or not. the Top He mucked around will become a professional Gear team, with motorbikes photographer. He’s now on the “The Top Gear hosts are fantastic is a motor and became a committee of the Mosman Camera and larger than life. We spend a mechanic technician Club, and late last year at the lot of time laughing. It is creative who, by with BMW Mosman festival, one of his images and outrageous.” his own Australia. was sold on the opening night. It admission, was a shot of the grave of Flight At It has been confirmed that suffers Lieutenant Keith Anderson at Liverpool there will be a third series of the from ‘non- Georges Heights in Mosman. linear brain he ran his Australian show on Channel 9 this own garage year, and the production company progression’. This year I want to for about four has indicated it wants Hamish on Resolution: We looked it up become a published journalist. – something to do years but ended up working their team. He started writing stories for the with chaos, or in on the tools as an employee at Australian Flying Magazine. His Hamish’s case, a bit Arcadia Motors in Crows Nest. His ability to meet the deadlines first attempts were unpublishable, of a mad genius. He would need He’s been there for the past 15 and the challenges of Top Gear is but he persevered and is now a to be to keep up with the likes of years. explained by Hamish’s quest to be Clarkson, Hammond and May. more than ‘just a mechanic’. regular contributor to flying and When it was announced that photography magazines and has Motor mechanics are not generally Top Gear was planning shows Long before Top Gear came along been published in the Sydney regarded as extroverts or even in Australia, Hamish looked up to brighten up his day, he had Morning Herald.

Hamish fulfils his New Year resolution All seems calm in this behind the scenes break in to go flying and here he is in USA skies. the Top Gear live show in Sydney. Hamish is in the brown hat and that’s Jeremy Clarkson on the right.

The Automotive Technician 4 – the zany mechanic behind Top Gear stunts Cover story by Ken Newton

We asked Hamish for his 2010 Hamish makes resolution and he whipped a last minute beautiful Hohner harmonica in the adjustments fantasy key of C out of his pocket. “This is to the it. I bought it in America and I will amphibious learn to play it this year. ”Hamish’s Audi at inquisitive nature sits well with the Hamilton Top Gear people. Island. or the future?

When given a challenge to f you think the modern produce a car which folds up into wide web and the a suitcase, or an amphibious car motor car is smart, information that will be which doesn’t look amphibious, you will be amazed at available will be endless. Hamish will forsake sleep and what’sI on the drawing meals to get the job done. board at the Swinburne Under pressure on one They are also working occasion, he didn’t sleep University of Technology on vehicle to vehicle for five days. in Melbourne. communication. Nothing seems impossible to him. He was asked in Top Gear The boffins there are First reports have this Australia series one if he could researching technologies system barely five years convert a Mercedes Smart car for a really smart car that away. The University has into a hearse. It was bizarre, but It’s part of the craziness of it all, Hamish borrowed a Smart from a but it does mean that I have to will tell you where and a couple of pilot cars and local car yard, attached funereal think of every possible eventuality when to refuel, remind hopes to have an on road adornments including flower before it leaves the workshop. you of things to be done trial fleet of up to 200 cars That’s a challenge,” says Hamish. vases, jammed a coffin through and direct you around car the back window with supporting soon. straps and the hosts paraded “I realise that what I do is outside accidents, road works and around Sydney to a disbelieving the brief of most mechanics. delays. This is just a sample of But it’s much more than being a public. “We converted it, filmed the changes technicians the segment, raced back and mechanic. Combustion engines put it back together better than haven’t changed much and a lot A number of companies can expect in the vehicles new. Nobody could tell we were of the faults we find today come are involved in the which will find their involved,” recalls Hamish. back to simple basics. I just apply research, including basic engineering principles to way into aftermarket At a production meeting in 2008, everything I make. And I walk Holden. workshops a decade from the hosts showed a desire to enter around with my eyes open, always now. an amphibious Audi convertible in looking for opportunities and crazy The object is to get the car the fun category of the Hamilton ideas. Island Prix d’Elegance. Hamish to assist the driver. It might be great “When I’m working for Top was given the job to make the car technology but, as we Gear, I’m simply coming up with waterproof and conceal sails and ordinary solutions to extraordinary Technology advancements all know, sooner or later, outboard motor so that nobody problems,” he adds. in wireless networks, could detect it as anything other these vehicles will break than a street vehicle. That’s what makes Hamish an satellite communication down. Who will be able to extraordinary motor mechanic. and the like will enable fix them? Depends who “It was fun producing the vehicle these vehicles to be has been paying attention. and to the horror of the crowd, to Wheelnote: For Top Gear connected to the world see it driven down the boat ramp Australia, Hamish needed an and off into the waves. It’s actually adaptable workshop which a lot of fun being crazy.” didn’t work only nine to five. He chose McIver Engineering And with this story, Hamish reveals in Artarmon, which happens one of the little secrets of Top to belong to TaT technical Gear. Once he completes a crazy editor and director Jeff Smit. Jeff and his team worked with vehicle or an otherwise improbable Hamish and crew around the gadget for the show, he is not clock to produce the suitcase allowed to test it. “Nothing can be car among other things. tested before the show goes live.

Hamish in serious briefing with host Richard Hammond.

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The Automotive Technician 6 YOU Hooray, we cried. rear ABS sensor was going out Then we did cry of sync with the rest and on SAID So Subarus don’t have ABS problems? because the noise removal of the wheel bearing IT! was gone but the there was a small imperfection in ABS error still the bearing seal area where the Reassembled and road tested. occurred. sensor reads from. ne for the never-to-be- Hooked up our scan tools and it forgotten files. would read data but not define A bit more research and a We replaced the driver’s rear the code. We lab scoped each Subaru specialist used his wheel bearing and the problem TheO vehicle is a 2005 Subaru individual wheel sensor and scan tool and reported it was was solved. Liberty. all read OK and the live data the driver’s rear wheel sensor showed them all working. malfunctioning so we changed This is where a four-channel lab The problem was a metallic, it. The problem was still there, scope would be useful. rotating ting-ting noise from the We decided to replace the keeping in mind we were driver’s side front. The noise driver’s front wheel bearing constantly thinking about the Hope this might save another stops at about 40 km/h and the as the ABS sensor looks at wheel bearings causing the technician some time and effort, ABS warning light comes on with the bearing seal so we also problem. But as we were told by not to mention the frustration. the error code 55. repacked the drive shaft. After the experts, “Mate, Subarus don’t that we actually pinpointed the have ABS problems”. Gary Homan ABS and cruise control does not noise to the ABS pump on start Nudgee Automotive QLD work. up with an increase in frequency So I have the only one in in comparison to the road Australia with the problem? (I guess we will soon find out if We removed and inspected the speed. When the noise stopped, yours was the only Subaru in driver’s front drive shaft, wheel the ABS light came on. We We then went to the Subaru Australia with this problem. A few hub and bearing and all looked replaced the pump and the noise dealer who used their scan technicians will be thanking you OK. disappeared. tool and discovered the driver’s Gary. Ed)

10.5 seconds and uses 280 kg Volvo joins the electric race of lithium ion batteries which are charged by a normal household nother of the classic car The C30EV has a range of 150 power socket in less than eight makers, Volvo, is close to kilometres on a single charge. hours. producing its first electric The vehicle first appeared as Avehicle. The electric motor uses a a concept at the beginning of 2009. It is based on the C30 quarter of the energy of a The plug-in C30 Electric Vehicle three door coupe and retains fossil fuel engine. Volvo hopes that when the vehicle is being (EV) is in production already four seats in the vehicle. recharged with renewable and was launched at the Detroit Fitted with a 82 kW motor, the power CO2 emissions will be motor show in January this year. vehicle can reach 100 km/h in almost zero.

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The Automotive Technician 7 I will simply pass on some advice We could be talking about a by which may get you thinking about Jeff basic service, a tyre repair or a What is a job worth? Smit the issues you need to consider complex engine management when you value the job currently repair. on your hoist. n our last issue, I set out Workshop B is operated by a to convince workshop guy who attends every training I’m appealing to all of you to For a start, you really need to operators to add a ‘part session he can find, and has throw this hourly rate thinking know or have a very good idea Inumber’ to their invoices to developed good rapport with out the window. Start thinking about these basics, right at the cover technical information experts in a variety of fields. in terms of the complexity of start of the job. or data. I argued that the Same car, same problem, but each job, and the worth to constant collecting of he does the basic checks in 15 Does the customer need the the customer of your ability to technical data was now minutes, then looks up the latest vehicle back asap, or have you resolve complex repair issues. necessary to repair many of TaT solutions on the internet got the vehicle for a few days? the more complex jobs that because he paid to subscribe, Each repair should be treated reach workshops. and then rings an expert he What is the customer’s separately and priced and sold met at the last Wire & Gas expectation of the size of the job accordingly. At the end of the I was recommending just a small Convention for confirmation. He $ and therefore the cost of repair? day it’s an individual decision but consistent fee to offset the gets the answer in minutes and Is the customer a regular service money spent on data. Small fees the car is fixed and out of the that only you as a technician client or part of a company with a over a lot of jobs can add up to workshop within the hour. or as a workshop owner can quite a nest egg over a year. make. You really need to look in the mirror at your own But the bigger question remains - values, and try to determine how much is a repair worth? what price you think you would be comfortable with to sell You can get an argument going your expertise, experience, around any barbeque about the equipment, technical value of the job a person does. information and spare parts. There are so many variables Most true professionals in what that come into play, not the least many might see as ‘blue collar’ being that everyone seems to jobs under-sell themselves. have a different perception of value, and often this perception When discussing costings for has nothing to do with a person’s a job with the customer, price spending power. your labour as a dollar value, The measure of value is best not as hours worked. This explained in this time honoured would also apply to the invoice tale about the much maligned - only a dollar value for labour plumber doing a house call to with no mention of hours spent. attend to a blocked drain. In my big fleet or a large family with lots version, he walks to the kitchen The question is - should the If Workshop B has the of cars? sink, opens the cupboard doors, price of the job be pitched to the equipment, information and and gives the S-bend a good kick lowest common denominator – training to do a job quicker Believe it or not, knowing the with his boot. The drain clears the four hour effort? Should the and more efficiently than answers to these three questions and he charges the householder smarter of the workshops charge will help lead you to the value of Workshop A, then the labour $100. only for one hour? It doesn’t the job to the customer. charge should be the same for seem fair if Workshop A can fully the same repair. Workshop B justify a four hour job and charge Now for the vehicle is therefore rewarded, not for “But - but - you’ve been here for four hours. The point here hours spent on the job, but for two minutes and all you did is that if both workshops simply its knowledge, equipment and was kick the pipe.” charge by the hour, the invoices What is the service history? repair process. A technician would be vastly different for the How many things may be should not lose by being “Ah, yes, but I knew where same job. You could argue that required to get the vehicle back to kick it.” the smarter workshop has been to normal service standard? smarter. penalised by being smart and How complex is the repair or investing in knowledge. system to be worked on and will No technician can know In this classic case, the plumber it require ongoing servicing? everything. Years ago probably under-sold himself. What is a job really worth? most good technicians and The ‘knowing’ how to do things Most of us have been mechanics could repair just is the tradesman’s asset. My In an auto repair shop, there conditioned to charge out our about any vehicle that came basic contention is that you must are so many issues to consider. work at an hourly labour rate into the workshop. Those charge for ‘knowing’, not how There is no simple right or wrong and this system dominates the days are well and truly over. long the job took. answer to the question. aftermarket to this day. Technicians must become more professional and I pose this scenario for auto In presenting a case study to We still get the common share their knowledge and workshops. Workshop A has you, all I expect to achieve is to question from customers, experiences. good basic technicians on staff get you thinking about the value and good tools, but no internet of the job, and not just the hourly “What is your hourly labour access and they don’t attend rate plus parts. rate?” You never know, we could training courses and they have ?became even more profitable only basic data on hand. You So if you are expecting me Whenever I’m asked that because of information might say this is an average to come up with a formula for question I will always reply with sharing, just as many other workshop. They take four hours charging out this sample job, another question, “What type of professionals have been doing to do a tricky repair job. forget it. repair do you want me to do?” for years.

The Automotive Technician 8 concept - an abstract idea; a general notion; an idea or invention; (of a car or other vehicle) produced as an experimental model to test Concept the viability of new design features. Is it a bike? Is it a car?

wizy, by Renault, is designed to With a turning circle of just three bring a fresh new approach to metres and a footprint barely larger urban mobility. Its layout combines than that of a scooter it’s dead easy to Twizy ZE appears theT advantages of two and four wheeled park. Its agile handling ensures that it to glide gracefully and vehicles, offering maximum agility with rarely gets stuck in traffic, while the four silently along the road. stability. wheels and low centre of gravity provide excellent stability. It is powered by a 15 kW electric motor The Twizy ZE concept is an all-electric which develops 70 Nm of torque. Twizy ZE vehicle for city dwellers to pick their way As opposed to a conventional car, the body can accelerate at a similar rate to a 125 cc through the urban jungle. It has ultra- colour wheel fairings are not spherical but bike, and pulls away briskly from standstill. compact dimensions - 2.3 metres long and octagonal, and cover the tyres entirely. With a top speed of 75 km/h, Twizy ZE will 1.13 metres wide. Along with the pearlescent white and be in its element in suburban traffic. blue hub caps, they form a harmonious The four-wheel arrangement has open design in which the wheels can no longer It is the forerunner of the all-electric bodywork and a seat format which puts the be seen rotating. Instead, the only visible mobility solutions that Renault will passenger behind the driver. movement is that of the hub caps, so introduce to the market from 2011.

Wheelnote: Voiturette 1CV sold Producing cars since on Christmas Eve late 1897, the Renault 1899. The car was corporation was popular because of founded in 1899 as its incredible ability to Société Renault Frères climb streets without by Louis Renault, his any difficulty and its fuel brothers Marcel and economy. Fernand and other friends. The car mounted a De Dion-Bouton 1 cylinder The first Renault car engine, which allowed it was a stylish Renault to reach a top speed of 32 km/h.

cannot send wiring diagrams or written technical having data on hand is these days as essential as Help us information that may belong to a manufacturer your favourite shifting spanner. The TaT service Assist or a professional data service. It is TaT’s is designed to share information to help our to help you! recommendation that all workshops should have subscribers resolve tricky issues quickly. It works at least one subscription to a data provider. After on an old but proven theory – all, you are all supposed to be able to fix cars and ‘two heads are better than one’. here’s no doubt that the TaT Assist service we offer to subscribers is working its Tbutt off. It’s also working the butt off our technical AUSSIE MADE QUALITY JUMP advisers, but that’s what they are there for. However, the service would work a great deal STARTERS & BATTERY CHARGERS Eliminate Down Time and save money on batteries with our Jump Starters, Battery Chargers and genuine better if technicians would provide as much Carbon Pile Battery Load Testers. No matter what you are looking for, our entire product range features the information as possible on the TaT assist web strength, quality and reliability that Durst offers as proud Australian Manufacturers Since 1918. form before they press the submit button. We are getting forms with hardly any information filled in 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 but a one-line plea such as ‘here’s the problem, • Available in 12V or 24 Volt or combined • Larger models with Boost Start function tried a couple of things - help’. • 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 That’s not in the spirit of this service. • 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 You are really asking a lot of any adviser if he has Government, Mines, TAFE etc • Easy to use, instructions to second guess everything you have done on on front panel Durst SmartWasher • Used by the Australian the vehicle. It is time consuming and frustrating • Solvent free, no fumes Defence Forces, for both the subscriber and our technical team. to breathe in Government, Mines, TAFE etc • Don’t change solution • Minimal Maintenance The TaT Assist form has been designed to give • OH&S Compliant DURST INDUSTRIES • Fully Recycles our technicians a sporting chance to gather • Environmentally Friendly 189 St Johns Rd Glebe NSW 2037 information and get their heads around the • Won’t harm skin or lungs Ph 02 9660 1755 Email [email protected] problem. That way, they can give technicians Genuine Carbon Pile Battery Load Testers Sales, Service and Repairs. common sense advice that hopefully will lead to • Available in various models to cover 6, 12 & 24V Ask us about purchase • High Capacity models for all batteries including N200 size options including leasing. a rapid resolution. And we remind subscribers • Powder Coated Steel Case for Long Life again that TaT is not a data provider. Copyright • Carry or Trolley versions www.durst.com.au laws are strict about automotive data, so we The Automotive Technician 9 We know cars inside out Logicar electronics division embrace the challenges faced Like a surgeon our technicians pride themselves on with diagnosing today’s modern vehicles. Testing and correct diagnosis, quality workmanship and precision repairing automotive electronics has come a long way repairs that exceed original ECU specifications. since the inception of EFI in the mid 1980’s. In today’s fast With over 20 years experience, Logicar certainly know changing world we will go to great lengths to test, repair the challenges we all face with diagnosing electronics and re-test in the pursuit of continuous improvement. in modern vehicles. So if you are looking for personalised service, technical support, electronic testing and repairs choose Logicar. Our success is based on offering you premium service and support for all of your EFI needs, including Parts, ECU’s and Workshop Equipment ...making Logicar the logical choice!

H EAD OFFICE DINGLEY TULLAMARINE PHONE 147 Rooks Road 15/42-44 Garden Blvd. 17a Carrick Dve. Vermont VIC 3133 Dingley VIC 3172 Tullamarine VIC 3043 334 334 PH: 1300 334 334 PH: (03) 9551 6222 PH: (03) 9338 7666 Fax: (03) 9873 7009 Fax: (03) 9551 6888 Fax: (03) 9338 4400 EFI EFI 1300 The Automotive Technician 10 YOU check and see if there was Turned on dash and park lamp A car with a screw loose? wiring going to the front doors. switch after replacement of the SAID I checked the driver’s side 10 amp fuse and, hey presto, IT! behind and above the kick everything worked and no of tail, dash and headlights panel. I located a wiring fuses blowing. and ended up at the Holden harness running to the front his was a dash lamp fault dealership where we were able door, unplugged it and the Time spent – two seconds to in a Holden Rodeo RA to download them off a CD. short was still there. remove the problem screw, six T2004 Diesel 4WD. hours to find the fault, taking The circuit diagram shows that Checked the passenger side, into account obtaining the The customer complained of dash light bulbs have a positive found the main harness plug wiring diagram. dash lamp fuse and radio 12 12 volt supply from the tail there facing upwards behind volt power supply fuse blowing, lamp relay, through a fuse, then the glove box, but no female The screw must have slightly probably caused by grounded it goes to ground through the end. moved against other pins wiring or switch somewhere dash lamp dimmer or rheostat inside the plug as the vehicle in the dash or the surrounding switch. travelled over unsealed roads front panel. and this was causing the radio The funny thing is that when I fuse to blow sometimes. The Removed the instrument got the vehicle back the second colour of dash lamp wire is cluster, centre and lower time, the fuse on the radio green with red trace. panels and all the switch wiring supply was not blowing when off the back of hazard, 4WD, the dash lamp control switch Gary Smith unlock-lock, dash dimmer, was plugged in. Only the dash Innisfail Auto Electrical Pty blower motor, heater control lamp fuse was blowing. Ltd switches, cigarette lighter and I decided to have a closer also removed the radio/CD. I studied the wiring diagrams inspection of the plug. Looked (Sometimes you just can’t The fuses were still blowing! again and noticed that the dash inside the plug and bingo! fathom where the trouble light circuit includes the electric There in the middle of the multi lies. All the more reason for We put everything back window switches which would plug, among the wiring pins thorough visual inspections of together so the customer could be mounted in the front doors. was a self-tapping screw. We all components in a situation drive the vehicle. Spent a few This vehicle had no power just turned the plug upside like this. Thanks for sharing days getting circuit diagrams windows so I thought I’d better down and out it popped. Gary. Ed)

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."%& 1300 The Automotive Technician 11 Ford Factory LPG - the Vialle Venturi systems By Wayne Broady used to assist with the starting by introducing some vapour directly into the manifold via the vapour he Vialle Venturi systems are fitted on the hose when the vehicle is being cranked over and six cylinder AU, BA-BF and FG sedans, while the engine is under certain conditions. As wagons and utes. for previous models, when LPG changes from a BA Ford wagon tank T liquid to a vapour inside the converter, it requires AU1 Vialle dual fuel is similar to earlier Ford EF-EL. heat taken from the cooling system heater water sensor changing rich/lean and the stepper motor A major difference is that it is controlled by a Ford hoses to prevent the converter from freezing. A count, ideally around 160. The higher the number ECU. Ford possibly changed to dedicated LPG problem with the cooling system could also cause the more the stepper motor is closing and the richer due to warranty issues with petrol injectors and the the converter to freeze up which then could cause the vehicle. The lower the number the leaner the owners of these vehicles not wanting to maintain a damage to the diaphragms in the converter. This vehicle and more open. The stepper motor is similar petrol system when running on LPG. The following would cause water to be drawn into the motor via to an idle speed motor with four wires. vehicles are dedicated LPG fuel systems. the LPG vapour hose. Draining the converter will show up this problem. Common problems with these vehicles include AU11-111 Vialle LPG - uses Ford ECU computer backfiring caused by problems in the ignition - mounted LH kick panel Scan tools, as well as a specific Vialle stepper system. Coils (AU) and COP (BA-BF-FG) units BA Vialle LPG - uses Ford ECU computer - motor tester, can now be used to check the are common causes for backfiring . There are also mounted LH engine bay operation of the stepper motor and closed loop converter issues due to water problems and idling BF Vialle LPG - uses Ford ECU computer - operation. The scan tool can give the stepper motor issues due to the idle jet being blocked. Major mounted LH engine bay count which on average should read approximately sludge or contamination in the converter slows FG Vialle LPG - uses Ford ECU computer - 160 steps at idle and under throttle condition remain the reaction time of the diaphragms and can also mounted LH engine bay close to this figure. Under heavy throttle conditions it cause lean mixtures and backfiring. This sludge can FG Vialle LPG - uses Ford computer - mounted will be slightly on the rich side. The stepper motor is also stick plungers inside both gas lock off and idle LH engine bay, now has stability control mounted to the outlet of the convertor and controls lock causing a no-start situation especially in cold Future - Liquid injection main gas flow via a pintle opening and closing weather. vapour hose. The scan tool is also able to read In the AU11 (BA, BF, and FG) sedans and wagons LPG tank gauge resistances and specific engine LPG sender units can also go open circuit and this a twin manifold tank arrangement is fitted. Tank is ECU fault codes for LPG. causes problems with the fuel gauge, bringing up two tanks joined together by a manifold – only one fault codes. Be sure to check resistance number set of valves. The tank is mounted under the floor Prior to setting up the ECU, make sure the ignition against originals when replacing these senders as section of the boot. Ford modifies the floor so that system is in optimum condition, the air filter is clean, there are many options. Utes use two gauges in it is flat with no spare tyre well. A space saver type there are no vacuum air leaks and the O2 sensor is series to match the dash gauge. Stepper motors spare is provided which sits in the boot and takes in working order. Check for ECU fault codes. There can jam due to water intrusion and can also cause some of the luggage space in the sedan. As for the can be some ghost codes for the O2 sensor and the drivers in the ECU to blow. wagon, the spare wheel is relocated into the rear start valve can be normal. If in doubt note the codes luggage compartment and mounted upright using down, cancel the codes and recheck after road test. An additional LPG fuse is located in the engine bay a bracket. With the ute, separate twin tanks are behind the inlet manifold. On some earlier models mounted either side of the tail shaft with exhaust Spark plugs are normally a colder heat range with the fuse is located inside the cabin, underneath the modifications. The spare tyre remains in its normal a reduced gap and shorter change intervals than glove box. This fuse can blow when the solenoid position. in a petrol fuelled vehicle. AU series 1 and 11 use coils overheat and crack. standard type plugs with a change interval of 20,000 The Vialle system uses Venturi or a donut ring to kilometres. The later models AU, BA-BF and FG When checking the vehicle for RTA registrations, introduce LPG at the throttle body. A Vialle complex use a specific long life plug with a change period disconnect each tank solenoid (AFSOD valve) converter is mounted on the driver’s side inner of 105,000 kilometres. It is imperative to keep the and run the vehicle until the engine stops to verify guard with the Ford computer controlling the LPG ignition system at its optimum on these vehicles. operation. A harness connector is fitted close to system functions such as the safety switch control, each AFSOD. Remember to disconnect both tanks petrol injector disable, stepper motor mixture control Drain the LPG converter through two 6 mm drain on the ute while the twin manifold tanks on sedans and fuel gauge operation (which reads to existing bolts at the base of the converter. A little sludge can and wagons have only one AFSOD as the tanks dash gauge) as well as Ignition system operation come out but no water. If water is in the converter are joined together by large tubes and treated as similar to a petrol vehicle, but has no injectors or it would require an overhaul and stepper motor one tank. petrol system fitted. replacement due to water contamination. Also remember to check LPG tank dates. This can Venturi based systems are prone to backfiring due Clean the LPG idle jet found beneath the solenoid. be tricky as access is sometimes difficult. to faults in the ignition system. Spark plugs, leads, Remove the coil and plunger housing, watch for coil packs and coil on plugs (COP) can cause the brass jet and ensure the spring doesn’t fly out. The system has been well engineered over the backfiring as can lean mixtures. Beneath these is a small jet which can be removed years, but is now out of date. Ford has been testing using the manufacturer’s removal tool. This is a a new liquid injection system which will bring power The operation and servicing of the system is similar small long screw with the removable spark plug closer to the petrol levels and also negate backfiring to earlier versions. A stepper motor is also fitted screw cap that uses the spark plug thread to pull issues as the LPG is introduced into the manifold to the vapour output hose of the converter. The out the jet. Clean the jet with compressed air and close to the inlet valves. These new systems ECU controls this stepper motor to open or close reinstall. are under development, and not all that far from the vapour outlet which then enriches or leans the completion. I will cover more about these newer mixtures depending on oxygen sensor readings. To set up the ECU, disconnect the battery or ECU systems in future TaT issues. fuses. Connect a scan tool and bring up the stepper An additional start solenoid valve is mounted on top motor and O sensor parameters. Bring the vehicle I hope my fellow technicians had a wonderful 2 Christmas and enjoyable and safe new year. of the converter and is controlled by the ECU. It is up to operating temperature and watch the O2

BA Ford engine bay

The Automotive Technician 12 The Automotive Technician 13 Julian :hl\a8>K98l^kb^l8¦8La^8\hfie^m^8 Hentze ]bZ`ghlmb\8lhenmbhg

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The Automotive Technician 14 9

210x297 TAT FSA Adv.indd 1 30/9/09 2:07:39 PM Julian :hl\a8>K98l^kb^l8¦8La^8\hfie^m^8 Hentze Letter from America Toyota – I forgive you

]bZ`ghlmb\8lhenmbhg an anyone tell me where 2009 went? ceased production of the affected vehicles. Remembering the quality issues GM has It was a crazy year for me. I flew Three quarters of the total US sales for had over the years as well as their journey Cenough miles to go around the Toyota are of vehicles manufactured at into Chapter 11, I thought that one was a world twice. I have been fortunate to see Toyota plants in US and Canada. bit rich! almost every state in the US with my job. The Avalon and Camry are made in Has this defect affected sales for Toyota? The big MACS Convention was in ‘Sin Kentucky, the Prado and Landcruiser in Not for me, I’d have one any day. Nothing City’ - Las Vegas. The company I work for Indiana, the Hilux in Texas and the Corolla, could kill my old HJ60, and lets face it, was exhibiting. Echo and RAV 4 are made in Canada. Toyota hardly ever gets it wrong so a little forgiveness is what they need right now. I am always impressed by the size of The recall issue is a sticking accelerator MACS, the training was spot on and peddle. At first they thought it was the floor Below: Julian poses with his children Zac, the tradeshow featured companies from mats but it seems now that it may be the aged eight and Bailey, around the world. The only disappointment mechanism as well as the mats. There are four. The car in the was that I could find only one Aussie at the 2.3 million vehicles affected by the recall. background is a show. rat rod – cool, Unfortunately for Toyota, a few news noisy and It’s not often in America that TV news can cameras caught customers driving into fast. stop you in your tracks. At my house I dealerships with their engines revving out have 117 channels and that’s called the of control. Toyota reacted quickly and new basic package. peddles for production vehicles were being installed by 28 January. The bad news In this highly competitive environment, the is that any modifications or repairs to the TV news falls into camps like hard right, existing vehicles currently on the road will hard left or entertainment dressed up as need to be approved by the US Transport news. I honestly gave up watching it, along Safety Board before being released as a with many other people I know. repair.

Anyway I was in a hotel when I caught the GM was quick to capitalise on Toyota’s news that Toyota had stopped selling eight misfortune by running a campaign offering models and was starting a massive recall. a $1000 discount and zero interest if they What, Toyota? It went on to say it had also traded in their Toyota.

The big drawcard which differentiates Wire common rail diesel, European engine Registrations & Gas from any other event is the intensive management, air conditioning on a variety now open for training sessions conducted on vehicles. of cars, radiators and scan tool reading. Wire & Gas The trade show is already a near sellout, Incentives being offered to delegates with a record number of 50 booths booked include a cut price deal for second and so far. subsequent technicians from a workshop echnicians can now register for the with a fully paid delegate, and a $95 big Wire & Gas Training Convention Delegates can nominate to attend their registration fee for an apprentice. and Trade Show, to be held at the RoyalT Pines Resort, Gold Coast from June choice of 50 training sessions over a 11 to 14 this year. three day period, conducted by ten of the The Wire & Gas Training Convention leading trainers in Australia. They will and Trade Show is hosted by VASA This convention, held only every two years, cover business management through to (Automotive Air-conditioning, Electrical and is the showcase of the auto electrical, air conditioning repair on earth moving Cooling Technicians of Australasia). air conditioning and heat exchange equipment. aftermarket and the biggest event of its Registration forms and full program are at kind in Australasia. Hybrid vehicles will be covered along with www.wireandgas.com.au

without a good, stable power supply and acid battery in use in today’s cars. Imagine It all begins with don’t forget the earth supplies. the battery and alternator as the heart of =_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 vehicle. It needs to be strong, with :hl\a8>K98Krlm^f89gZerl^k8ikhob]^l8]bZ`ghlbl—8mkhn[e^lahhmbg`8Zg]8f^Zlnk^f^gm8m^\agheh`r8bg8hg^8 the battery TaT workshops are seeing an increasing good power as well as good flow of power bgm^`kZm^]8iZ\dZ`^’8;hf[bg^8Zg8hl\beehl\hi^8pbma8Z8CLK8l\Zgg^k8Zg]8^o^g8Z8`Zl8ZgZerl^k8fh]ne^—8 number of vehicles where faults are either to keep the vehicle alive. mh8_hkf8Z8\hfik^a^glbo^8]bZ`ghlmb\8ieZm_hkf8¦8lZobg`8rhn8mbf^8Zg]8fhg^r’8888 s vehicles become more electronic battery or charging system related. we need to remember the electrical TaT subscribers can check previous >hk8_nkma^k8bg_hkfZmbhg8hg8ma^8:hl\a8>K98kZg`^8\Zee8ma^8:hl\a8

210x297 TAT FSA Adv.indd 1 30/9/09 2:07:39 PM TOYLA98316 TOYOTA LANDCRUISER ‘s a fact FZJ105 1998 problem solving 6 Cylinders

Customer Complaint Fault Description

The vehicle was towed in. It had almost no Checked under the pump (easier brake pedal pressure. It had 153,500 km on said than done) and found two the clock. large red and blue wires that went from the base of the ABS module to the Problem Summary pump.

The ABS warning light was on and there Peeled back the cover at both ends and was an audible buzzer was sounding. found bad corrosion on two of the terminals under the ABS module end. The brake system on these Landcruisers does not have a vacuum booster. They With the ignition on and the ABS relay have a very elaborate hydraulic pump cycling in and out, I checked for power - it assembly mounted together with master was OK. At the other end of the wires, cylinder and ABS module. where they go into the pump it was OK as well. The corroded wires were not the problem, but they may have contributed to Diagnostic Sequence the pump failing.

Hooked up the scan tool. Had two DTCs - C1256 accumulator low pressure Fault Solution malfunction and C1252 hydro booster pump malfunction. A second-hand complete assembly was sourced at the request of the Cleared the codes and they returned owner and fitted to the vehicle. immediately, with ABS light and buzzer. Rear brakes were bled. Ignition Performed basic checks on fuses, on, open one rear bleeder, press relays and related wiring and brake pedal about one inch, pump harnesses. All checked out OK. operates and fluid comes out. Repeat on the other side. Front brakes While doing this I noticed that I were bled with vacuum bleeder. could hear the ABS relays clicking Note: About two litres of fluid are used on and off cycling every few in the system and it is recommended to seconds and I also noticed I could not hear use Toyota DOT3 fluid as there can be the master cylinder pump working, as I problems if the wrong fluid is used. remembered should happen. The DTCs were cleared and the car road Opened one rear bleeder, turned the tested, rechecked for DTCs - all clear and ignition on and pressed the brake pedal all OK. down about an inch. No fluid was pumped out and could not hear the brake pump working. This is the correct way to bleed Recommended Time the rear brakes on these vehicles. Labour time was 4.5 hours, taking into account research time, location of parts and actual time spent fixing the problem.

tips for ideas division

Thanks to Jason from JDS Auto for this great report.

The Automotive Technician 16 MAZM605118 MAZDA ‘s a fact MAZDA 6 problem solving 2005 4 Cylinders

Customer Complaint

Problems starting cold, poor performance. Idle hunting intermittently. Problem Summary Cranks and fires up when cold but stalls a few times Fuel damper unless accelerator is used. Also has poor acceleration and idle becomes erratic when the vehicle reaches operating temperature.

When the vehicle is switched off hot, it will not restart always. Diagnostic Sequence

There were no fault codes on scan tools and the spark was OK.

Hooked up fuel pressure gauge and found the pressure to be extremely low and very slow to rise.

Acquired some technical information. The fuel pump and fuel pressure regulator are inside the fuel tank and so is the fuel filter assembly.

The device on the fuel rail is a fuel damper and not a pressure control regulator.

Fault Description

The fuel pressure would only get to 2.5’bar at most and when switched off it would drop to less than 1.5’bar. When the engine was hot the pressure would not even get to 2’bar. Fault Solution Fuel pressure The fuel pump assembly is accessed by moving the rear regulator seat top section and removing the access panel. Fuel pump location Remove the complete fuel pump assembly and after inspecting it order a complete assembly as best option. Filter body Main housing New assembly comes complete minus the fuel sender that we had to swap over by sliding the old one onto the side of assembly.

Vehicle started and now the fuel pressure is around 4’bar while running, and at rest it remains at 2.4’bar. Recommended Time

Labour time was 4 hours, taking into account research time, location of parts and actual time spent fixing the problem.

At the time of this report the assembly was around tips for ideas division $260. Due to the way it is put together and considering the cost we would not recommend changing just one part or even just the filter if available. Re-securing the hoses and refitting the pressure regulator looks like a real mission to push back in place and seal.

The Automotive Technician 17 With Nick Murphy Keeping up the voltage with the op ools Durst PPS-1270 & BCD-1225

ears ago it was the original version of software acceptable to try to start and an upgrade will fix it, or there a car even if the battery could be a hardware fault and that Ylevel was low and if it was too component has to be replaced. low, a push start was in order. If that’s the case, the new component will need to be coded Car electrics have changed, or to the ECU. should I say car electronics have changed. On board computers Because of critical voltage levels and modules have a lot to do with of late model cars, the battery that, requiring a minimum amount has to be kept at a high level of of battery charge of no less than charge. The Durst BCD-1225 10.5 volts. with its unique switching process is available in 12 volt (15, 25, 50 Now, with the introduction of BUS systems, software plays a big Amp) or 24 volt (15 and 25 Amp) part in how the system operates. versions. Voltage and current are very important in the performance of The BCD range is available in the system, to a point where a flat single, dual or triple channel battery will cause software glitches versions, depending on the and loss of program memory. model. Multiple channel versions come with a lead set for each Durst Industries recognised channel. As with the BCS range, this problem and has designed a remote control panel and a and manufactured a power battery temperature sensor are supply to cater for any testing or available as options. programming that may have to be performed. The uses and applications for these premium chargers are Durst is no newcomer to the endless. The BCD range can industry. The business has up to six to eight hours to do a full This allows the manufacturers been passed down through the be used to maintain full battery system upgrade. Any battery or to build in active idle control and generations from as far back as voltage while testing the car or power drop while this process is cruise control without the need for 1918. According to Basil Smith, downloading information similar happening could mean you have other mechanical components who has been with the company to the PPS but with the capability to start over again. All these additional functions are for 20 years, it still manufactures of supplying a battery charge. controlled by the vehicle’s ECU. most of its equipment in house including the circuit board design The BCD chargers release a and even the winding of the small amount of amperage to battery chargers. start with so as to not spike any electronic components of the The PPS-1270 (70 amp) uses car. They are ideal for charging a unique multi stage switching calcium batteries where system that allows the power amperage has to be delivered in supply to maintain the correct small amounts. voltage at 14.6 volts, or other voltage requirements for as long as needed. Why do we need to I found the Durst PPS and BCD maintain this voltage? All modern products to be of good quality. systems are designed to operate The units are finished in a heavy between battery rest voltage (fully duty powder coat so they will charged battery) and charge take all the workshop treatment voltage (14 volt). If this voltage you would expect. drops below battery rest voltage the system may log a code for low The leads and connections are battery and that makes it hard to Why do we have to carry out The ECU has to decide if it needs all very solid and would stand diagnose any faults. software upgrades? Modern to close the throttle down as in the test of time. vehicles have a lot of the the case of traction control, or it mechanical actions taken out Programming is paramount to may have to control idle when and replaced with stepper motors Happy Diagnosing maintain sustainable voltage at a or actuators. For example, the different loads are applied. All this correct range. Any variation could drive-by-wire throttles on most late happens with the aid of software cause software glitches in the models have taken the place of a programs. Sometimes there might Nick Murphy process. Some makes can take throttle cable. be an underlying problem with

The Automotive Technician 18 Jeff Smit looks at the op ools Projecta Intelli-Charge

ick Murphy is spot on We always charge customer’s Wet and Calcium. all types of batteries. The first with the many reasons batteries overnight if we two stages, ‘de-sulphation’ and for needing a good suspect that the battery may By selecting the battery ‘soft start’ prepare the battery Nbattery supply in the modern be a little down on charge. The chemistry type, Intelli-Charge for charging. motor car. The importance of Projecta 12 volt 10 amp model adjusts the charge to precisely a sound, fully charged battery is ideal for this purpose. match the battery, extending ‘Bulk’ then delivers a fast cannot be underestimated. charge followed by ‘absorption’ You all know the sort of which ensures the battery is problems that can be caused fully charged. The ‘analysis’ by flat or faulty batteries. I mode is designed to ensure the believe it’s our job to test each battery is fully charged. and every battery in every car that comes into our workshops. If the battery fails the analysis If some of your customers are stage the charger will begin to like mine, they don’t drive their ‘recondition’ the battery, testing cars very often, or very far. after each stage up to three times. This type of driving pattern has a draining effect on the battery. Once past the analysis stage, So even though the car still the battery is maintained ready starts OK, the battery may be for use. Some of the features only half charged, and that’s of this charger are the easy to not good for either the battery read LED display which allows or the car. you to quickly customise the charge settings and monitor Wherever possible we should the charger’s performance. be recharging the batteries in our customer’s vehicles if they The chargers also remember need it – as a matter of routine the last settings even when the vehicle maintenance. That’s This charger goes through battery life and performance. power has been turned off. where a good battery charger seven stages to ensure that The fully automatic nature of comes in handy. the battery is given the best this charger makes using this Always remember to test the chance of returning to a full for overnight battery charging battery after charging and In one of the TaT workshops charge. very handy. recommend a replacement we have been giving the battery if you don’t get the Projecta Intelli-Charge battery It is engineered and designed The charging technique, known results that you are looking for. charger C1000 model, a good in Australia for use on all types as seven stage charging, has workout. of battery including Gel, AGM, been engineered for use on Cheers, Jeff

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The Automotive Technician 19 On road to a cleaner future.

The Century Yuasa Battery Recycling program is a total battery management solution designed to provide businesses with a reliable scrap battery collection service and alleviate the environmental issues and regulatory requirements associated with the handling and storage of used lead acid batteries.

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The Automotive Technician 20 Charging for Data TAT AD Jan 2010:Charging for DATA TAT Ad Jan 2010 29/01/2010 16:18 Page 1

YOU Our trade really does need educating in SAID Charging extra for knowledge order that we do not sell ourselves short. IT! Thanks again for an enthusiastic entitled ‘Vehicle Information and Data presentation. ” ddie Worsnop of A Grade Fee’. This will help distinguish for the Mechanical Services in Roleystone customer the costs involved for technicians Cheers, WA is glad he enrolled for Jeff to be acquainted with the technical ESmit’s Perth training session towards the knowledge to service and repair their Eddie Worsnop end of last year. vehicles. It will also allow me to recoup the ever increasing costs of obtaining (Thanks Eddie. Good to hear that Jeff’s “Thanks for your training presentation last information and doing the training. advice is often followed. I note you night. This morning, I did what I had been I appreciate the strong emphasis you advertise yourself as ‘Service at its putting off doing for some time - I added place on identifying and charging for these Best’. With your attitude, the claim is fully a part number to my invoicing program essential costs. justified. Ed.)

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The Automotive Technician 21 to see what market share Aftermarket technicians should they can wrestle from Toyota take more than just a passing New Year, New Cars who have had a complete interest in this wave of new stranglehold on the hybrid vehicles. ere’s a preview of the Geely MK market up until new cars likely to hit the now. What we don’t know is how the market during 2010. 2010 will Australian public will embrace H see an influx Toyota Camry some of these very new and Holden Commodore E85 of Chinese- Hybrid very different technologies. made motor Holden has been making vehicles. The The engines for some time that can Geely is one Toyota of them. It Camry comes as hybrid is a hatch due to or a Geely MK hit the sedan and showrooms in early should be on sale 2010. The Camry is early this year. The based on the world’s top Great Wall Motors selling hybrid, the Toyota Toyota Camry Hybrid passenger cars Prius. The 2.4 litre petrol are coming in engine and the electric The answer to that question the first motor combine for will determine how much our quarter. a total of 140 technicians will need to know in kW. Toyota the future to be able to service Holden Commodore E85 Honda claims and repair these vehicles. Hybrid that the run on ethanol. These Insight Camry Some will prosper while others engines have been for export, hybrid are bound to flounder. These especially to Brazil. The uses are interesting times for the Insight at least auto aftermarket. This year will see them in the will be priced 35% less fuel Commodore that will run on the under $30,000. Honda Hybrid Insight than its Australian- new blend of 85% ethanol and This makes it an attractive made six cylinder 15% petrol. That would be first proposition for those looking to competitors. for an Australian car maker. do their bit for the environment. Honda claims Mitsubishi iMiEV Great Wall Motors that the This fully electric Insight offers production car will family sized be the first for mass accommodation release in Australia. A with the fuel full ‘tank’ will take you 160 efficiency of a kilometres and Mitsubishi small car. It will claims an 80% charge from a be interesting 30 minute quick charge. Mitsubishi iMiEV

YOU switches. As Fault Solution the cruise and Replaced switch assembly with SAID It only takes a pinched wire horn share genuine unit due to broken and IT! three wires at previously repaired switches. covers to check clock spring the steering A cheaper fix would have been EF FALCON 1996 and steering column wiring wheel, the problem appeared to repair the damaged wire and harness to see if there were to be related to the switches insulate to prevent the problem Customer Complaint any bridged or damaged wires themselves. returning. Cruise control not working. causing cross-over feed from the horn wiring to the cruise Replaced switches and the Recommended Time Problem Summary wiring. problem was solved. A closer Labour time was one hour, On the road test, we noticed look at wiring for the switches taking into account research when switching cruise on, the Disconnected cruise control found a pinched wire between time, location of parts and horn sounds. module and noticed the horn the cruise switches and the actual time fixing the problem. would not sound with horn steering wheel. Roy Chapman Diagnostic Sequence switches but would still sound Dandenong VIC Obtained wiring diagram to with cruise on switch. As Fault Description locate common points of the horn earth circuit goes Checked wiring and located (Many thanks for your case interest. through the cruise control unit, pinched wire causing cruise study Roy, very interesting. I’m I then joined the in/out earth on switch to sound the horn as sure that you are not the first Removed air bag from steering connections to confirm that they share wires at the steering to come across this complaint. wheel and the column the horn still worked with horn wheel. Jeff Smit)

The Automotive Technician 22 of money for vehicles with four environmental reasons and Street Cred wheels. pilot projects have sprung up with Hayley Windsor Tuk-tuk tales around the world to test their Since then, tuk-tuks have efficiency and eco-friendliness. become a popular form of aving spent more than scooter in the front, with handle-bar controls, and a two- urban and tourist transportation In Dhaka, Bangladesh, they’re 100 hours and 4500 the world over. India’s Bajaj affectionately called ‘CNGs’ kilometres on buses wheeler, two-seater passenger Auto Limited churn out most and are symbolically painted Hduring a three week journey compartment in the rear. Most of them. This company is now green. across the Andes from have a sheet metal body Argentina to Chile I reckoned covered with canvas and roll- the largest exporter of the I had earned a quality down sides but the style does three-wheeler to more than 50 And if you don’t know the afternoon of wave-riding in the vary a lot from place to place. countries. origin of the name tuk-tuk, you Ecuadorian town of Montanita. obviously have never heard In Angkor Wat, Cambodia, I Many have been converted one. The word ‘bus’ conjures all- recall seeing tourists being from petrol to compressed too-fresh images of unhygienic towed in a cart behind a natural gas (CNG) for Happy New Year, bathrooms, dingy roadside regular motorbike, while I Hayley. canteens and altitude sickness. preferred riding side saddle on One immigration queue took the back of an uncomfortable from 4 am to 7 am to get motorcycle. through, with the immigration police individually keying two In Port Blair, Sri Lanka, three bus-loads of passengers into of us plus our surf boards, their unreliable system. jammed into the back of an already shaky rickshaw on I’d much rather talk-talk about three incredibly small wheels. the tuk-tuk. No wonder we busted a tyre.

I thought this practical people- The tuk-tuk design is said mover was found only in to have spawned from the South-east Asia, but here they Piaggio Ape C, a three- are in Peru. wheeled light commercial vehicle first produced in Italy in These motorised rickshaws 1948. It was a practical answer are called ‘moto’ in Peru. by the inventor of the iconic All tuk-tuks are typically a Vespa to post-war shortages tuk-tuk!

It provides research, design and development the second half of 2010, will be an extension Orbital to gas up next services for the world’s producers of of OAGS’ long-running relationship with Ford, powertrains and engine management under which it supplies the LPG system for Ford LPG system systems for application in motorcycles, cars, the current Falcon E-Gas model. trucks and marine and recreational vehicles. rbital Autogas Systems (OAGS) The E-Gas models are factory-fitted LPG- Orbital’s principal operations in Perth, dedicated vehicles and represent more than has been appointed as the OEM Western Australia, provide a world- 25% of total Falcon sales. supplier of a new-generation LPG class facility with capabilities in design, system for Ford Falcon models. O manufacturing, development and testing of OAGS is about to release liquid injection engines and powertrains. conversion kits to suit up to 40 different Orbital is an international developer of engine models including the BA, BF and FG Fords and related technologies. The new contract with Ford, which begins in and the V6 VE Commodores.

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The Automotive Technician 23 “You can tell a good tradesman by the tools he uses” …and you can tell a good tool maker by their years of experience YELLOW JACKET® celebrates 60 years in the business this year and automotive Australian distributor, SCA Australia has a great prize for a lucky customer!

RecoverXLTTM Refrigerant Digi-Alarm Thermometer Recovery Machine A cost-effective This compact unit measures from alternative to big systems, this -50° to 200°C and triggers an alarm machine is lightweight, low cost and at the high and low programmed easy to use and maintain. temperatures.

SAE J2788 Compliant Series The YELLOW JACKETTM Refrigerant Management System (RMS) is the simplest, easiest to use a/c service centre, helping technicians meet today’s tough service standards. The RMS 37880 Automatic provides full cycle recovery/recycle/ evacuate/ recharge to bring the vehicle back to factory specifications with the press of one button.

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The new YELLOW JACKET™ refrigeration system analyser Features a full color graphics display and color-coded diagnostics for intuitive, easy reading.

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Competition conducted by SCA Australia Pty Ltd. Prize part numbers are 69239 and 69790 and retail value is $269. The Automotive Technician 24 The Automotive Technician 11 Draw will be held on 5 April 2010 and the winner notified by phone and/or email. Results will be posted at www.sca-australia.com.au Limit is one entry per customer Thanks to our advertisers…

‘s interesting

2010 Bosch Spark Plug Catalogue The 2010 Bosch Spark Plug Catalogue is now available. It utilises the New Autodata modules world’s largest vehicle Three brand new modules have been added database to provide to the Autodata Premium Package. Autodata workshops with a Socket set for the stubborn ones researchers have delivered modules on air comprehensive guide A practical socket set has been released by conditioning services connectors, electric to replacement Kincrome. Branded under the ‘LOK-ON’ name, parking brakes and battery disconnection spark plugs for the the Kincrome 39 piece socket set is ideal for and reset procedures. The new modules Australian market. removing stubborn fasteners. The sockets drive satisfy a growing need for detailed drawings It features 60 the side of the fastener using a unique subtle and explanations of service procedures for new vehicle applications, cam found in the six point socket design. This emerging technologies like the electric parking providing comprehensive range coverage unique design not only provides increased brake. One of the most popular modules will be of over 96%. The Bosch Spark Plug Catalogue strength but also avoids the rounding of rusted the one which lifts the lid on the often obscure includes a simple part number cross reference and damaged fasteners. The cam design also hiding places for air conditioning connectors and table. The rationalised range of Good, Better, enables the user to effectively loosen fasteners service ports. The battery disconnection and Best spark plug part numbers allows workshops which have rounded by up to 85%. The ‘LOK- reset procedures module explains how many of to offer maximum coverage with only a minimum ON’ design helps reduce stress concentration the comfort features of the modern vehicle can inventory investment. when torqued, preventing the fastener from be restored through the ‘relearning’ process. rounding whilst offering better torque than Ph 07 3245 3282 Contact your local Bosch distributor or Bosch conventional sockets.www.kincrome.com.au [email protected] Customer Service Centre on 1300 30 70 40.

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The Automotive Technician 25 Who trains the trainers while Murphy’s Law the trainers are training you? ’ve been attending some called up one day when really before they contact us. Then short technical courses needed.Training can be general there is the small percentage recently and they not or specific, even to a particular who tend to struggle with the Ionly added to my technical model and make of vehicle. procedure and sometimes knowledge but they also Is the specific course even getting to the starting made me realise that some of informative? Yes. Is it going to point. Our advantage as our practices and procedures improve your diagnostic skills? trainers is that through handling could be improved. Probably not. these problems every day from subscribers, we tend to So my theme is the importance General courses are more likely know which type of training of training. Training does a lot to improve your skills to attack will be more beneficial for the more than cram facts down our any job. technician. throats. Now here comes the plug! Training underpins your It certainly educates us, but it TaT will be running a series of knowledge. The only way can give us more confidence in training courses this year (dates anyone is going to learn is from our approach and reinforce our yet to be announced). The experience or from their own or basic knowledge so that we can current popular course is on other people’s mistakes. best judge where this problem scan tools and basic diagnostic job is going to lead us. procedures. These courses are The training events conducted designed to improve skills by by TaT in conjunction with Gut feeling should never using real life examples, taken wholesalers or OEMs are be ignored because with from our extensive TaT files. usually very reasonably priced experience comes an intuition because they are subsidised by that can lead you in the right At TaT we answer on average the commercial partner. direction. eight questions a day dealing with problem jobs faced by I hope to see you at one of the The more training sessions you our subscribers. Most of them courses. attend, the more little pieces are good in-depth faults where of information are stored in the subscribers have had a Happy Diagnosing the back of your mind, to be decent crack at solving them Nick Murphy

“Has a history of issues and it is to be sold This scenario usually turns around and bites The tale of the as soon as we repair it.” the repairer. Why would a technician or a workshop compromise their work ethic and Deyan’s response is worth noting for all possibly risk a comeback from an angry new quickie $ale technicians asked to fix something quickly and cheaply for sale. owner. You must always make sure that TaT subscriber recently sought the customer understands that your time is technical director Deyan Barrie’s “I always get worried when the customer money and that there is no such thing as a A advice on a vehicle which he said, says he just wants a quick fix for a sale. cheap shortcut.”

YOU spark plugs in poor condition due to lack of servicing. Oil damage was caused by a SAID Poor servicing to blame? leaking rocker cover. IT! show. The problems did not emerge until it We replaced the rocker cover gasket, spark he car is a 2006 TK Barina was driven more than 20 minutes. plugs and ignition leads and cleaned the oil automatic. damage. Road tested for 40 minutes to verify In the workshop we connected the scanner the repair. TheT customer was complaining about the and checked fault codes, finding codes vehicle surging, hesitating and generally P2610 (ECM timing failure), P0300 This vehicle had only done 73,000 kilometres running poor but only after having been (multiple missfire malfunction), and P0700 and was supposedly serviced regularly by the driven for more than 25 minutes. He also (transmission control failure). Noted and dealer. reported poor fuel economy. Also the cleared the codes. Road tested again and malfunction indicator lamp came on and rechecked fault codes. The same codes I spent about three and a half hours fixing the stayed on. returned. Checked the information on codes, problems. looking for connection of all codes. Repair sequence: Nigel Tilley Checked the following: lights, battery, Aussie Tune We drove the vehicle for about 30 minutes terminals, fuses, key, fuel level and engine Dandenong VIC and found it was surging and lacking power oil level. Codes P2610/P0300 relate to the under medium to heavy acceleration. It also ignition system so a check of the ignition (Proof positive yet again that poor servicing is showed intermittent rough idle and felt like system was performed. We found ignition at the root of many a problem. Thanks for the lack of fuel, such as a weak fuel pump might leads to be severely oil soaked and the tip Nigel. Ed)

The Automotive Technician 26 ACA Master Ignition Catalogue A new and extended range of ignition coils

The new and extended range of ignition coils from ACA (Automotive Components & Accessories) is now released in a new technical catalogue. As with all ACA catalogue extensions, the range has been carefully researched and the applications are extensive. When you supply your customer with an ACA product you can be confident it is an exact replacement product. Contact ACA for a copy of the new Master Ignition Catalogue.

Automotive Components & Accessories Pty Ltd Ph: (02) 9938 8700 Fax: (02) 9907 1860 Email: [email protected] Web: www.aca-auto.com.au

The Automotive Technician 27 7742 Burson Adv A4 21/11/08 3:12 PM Page 1

The Equipment Specialists All enquiries: VICTORIA / TASMANIA SCAN TOOLS, GAS ANALYSERS, EFI CLEANING AND AIR CONDITIONING ROB CAMERON 0412 959 348 IAN BATEMAN 0412 517 673 HOISTS JOHN WILKINS 0412 925 587 WHEEL SERVICE (Incl. ALIGNERS, BALANCERS, TYRE CHANGERS, BRAKE LATHES) BRIAN BUCK 0447 391 819

NEW SOUTH WALES ALL EQUIPMENT BEN CROCKETT 0409 540 808

QUEENSLAND ALL EQUIPMENT ERNIE LINNING 0429 020 781

The Automotive Technician 28 This magazine is just the tip of the iceberg! training

new TaT training program TaT and head trainer Jeff Smit for 2010 is close to being have received heaps of praise from released. technicians who said they enjoyed www.tat.net.au A the format, and were able to take Following last year’s highly successful ideas from the training into the This is where you find the databaseof training roadshow, the plan is to have workshop the very next day, saving repair solutions, stories from all TaT night workshops throughout Australia them time and money on the job. and New Zealand with the support of issues, training programs and much more. our partners which last year included When the training program is Burson, Autodata, Motor Traders, available, it will be posted at: This is where you reap the real benefits of Coventry and the Capricorn Society. www.tat.net.au your subscription to TaT.

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

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The Automotive Technician 29 by Ken THE LAST WORD Newton Stuart leads the fight for choice

hichever way you read information that limits consumer we have received from various it, Stuart Charity is choice and the legitimate business quarters within government and taking on the big end of growth of the independent from the whole independent Wauto-town. workshops. industry sector,” added Stuart.

The AAAA is the David. The entire “It is our position that much of the He knows it’s going to be a long automotive manufacturing industry negative consumer experience campaign and he’s ready for of the world, and by extension all of with product warranties has been it. “It’s a journey, and we have their dealerships, is the Goliath. caused by the increased practice of motor vehicle dealers offering really only started out. But Stuart is not using a sling with extended warranties at the point a sizeable stone in the pouch – of sale. These warranties are “We expect the OEMs to fight not yet anyway. He’s using logic, often offered at no additional hard to retain their market consultation and negotiation to cost to the consumer. However, position, but there’s also a gradually wear away the veneer of these warranties have restrictive large slice of the dealership protectionism which has enveloped provisions on the choice of repairer industry which does recognise tuart Charity is the the car industry since Henry Ford and parts used, contain ambiguous that sharing information with face at the coalface of decided that black was the only language and do not clearly aftermarket independents is the mission to restore car colour you could buy. If an specify the additional benefits in not a bad thing, and that quite Sfull rights to Australian car aftermarket had existed back the contract over and above the often, excellent and profitable owners to be able to make then, an enterprising independent consumer’s basic statutory rights,” relationships can be built their own choice of car workshop might have made a says Stuart. between specialised independent repairer, rather than feeling fortune re-painting Henry’s Fords in operators and the dealerships,” any other colour than black. obliged to lock into a long He points to other questionable he said. term warranty period with practices by motor vehicle Stuart and the AAAA are not manufacturers in their use of the car dealership. mavericks and nor are they without “Dealerships will never be in a statements in vehicle handbooks situation to service the entire friends in their quest to seek that imply that using a repairer He is the Executive Director legislative backing to force car Australian fleet and there other than the accredited of the Australian Automotive makers and their dealers to share are some who feel that the Aftermarket Association Ltd their product data with independent network of the particular aftermarket only deserves the (AAAA) so in that context workshops, and so deliver a choice manufacturer may affect the scraps.” he represents every auto of repairer to the car owners of vehicle’s performance or void the workshop which operates as Australia. statutory warranty. “We are trying to convince an independent, outside the dealership and OEM network. the OEMs that they and their Australia has picked up on “These statements are designed dealerships have an obligation campaigns in Europe and America to influence the vehicle owner In reality, the AAAA, established to their car buyers to allow them which have been running for years, to purchase a specified brand in 1980, represents the the choice of repairer and not with varying degrees of success. of part for the entire life of the dictate through obscure warranty interests of manufacturers, A couple of American states have re-manufacturers, importers, vehicle. We submit that this provisions that they have no legislation which effectively breaks distributors, wholesalers, practice could be viewed as a the dealership stranglehold on other choice but to bring their resellers and retailers of breach of the exclusive dealing new car buyers while in Europe vehicle back to the dealership. automotive parts, accessories, provisions of the Trade Practices there are now EU regulations That can only perpetuate the tools and equipment in Act and yet this is common which support the concept, but high prices and long waits which Australia. practice in the industry,” he it’s a limited win for independent typify the dealership model of operators. added. looking after customers,” Stuart It has more than 1200 said. members. The technicians of Australia, So all Stuart hopes to achieve working in a range of independent is a fair and transparent market Stuart joined AAAA in “Right now, customers cannot workshops in every country for vehicle consumers. If the February 2006. He was make informed decisions, and whistle-stop and capital city, are formerly Executive Director car makers and the industry that’s what our campaign is all facing daily information issues. of the Society of Automotive groups which represent them about.” Some are as simple as having Engineers Australasia and aren’t prepared to take a more to take a customer’s car to an prior to that worked as equitable position in the repair “The best outcome I can hope for appropriate dealership to have a the automotive industry industry, then it might take a is an industry round table which fault code removed and an engine specialist with Austrade in national consumer law that will management system reset. It might reach a new agreement Melbourne. During his two legislate clearly on the definitions can only be done, the dealers on how the industry does its years at Austrade, Stuart claim, with their own dedicated between voluntary, statutory and business. If we can’t get the helped to promote Australian equipment. extended warranties and ensure power back into the motorists’ automotive industry capability clarity in the terminology they hands through consensus, internationally and disseminate According to Stuart Charity, this is use. then we must continue the fight information on opportunities in anti-competitive behaviour. through to legislation.” overseas markets to the local This is a good time to repeat the “I’ve got no issue with industry. Choice of Repairer mantra. “The dealerships offering any length Technicians can add fuel to the aim of the Choice of Repairer From 1998 to 2001, Stuart of warranty they like to try to AAAA campaign by providing Campaign is to protect choice worked for the Victorian retain their customers. I believe details of instances where and competition in vehicle repair, Department of State in a competitive marketplace, repairs have to be referred to the servicing, replacement parts and Development in a range of but at the moment, once a new dealership because technical accessories sector by eliminating international investment and car hits the road, it’s heavily data has been withheld. Any any technical or legal barriers major event attraction roles weighted in the dealers’ favour vehicle that an independent that impact on the Australian covering South East Asia and consumers right to have their with inducements which we claim repairer has to send back to the North Asia. vehicle serviced, maintained and are anti-competitive. What is in dealership for diagnosis, parts repaired at competitive prices in our favour is that governments or re-coding is a case study that For ten years prior to that he the workshop of their choice.” around the world will usually AAAA needs for its submission to was a franchising and marketing There are significant side issues, react against anti-competitive government. consultant and purchasing not the least being what the behaviour and so far, in our manager for a large insurance AAAA sees as new car warranty Australian campaign, we have Emails should be sent to: group. terminology abuses and misleading been pleased with the reactions [email protected]

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