Issue 54 Tech Nov/Dec www.tat.net.au Spotlight 2016 • Vehicle servicing • Electrical

Longer service intervals train Australian motorists to neglect their vehicles

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chnic e THE ia t n y INDEPENDENT s b NETWORK

f • Merc • Magna • Camry • Jaguar o s r n t ia On the blink TCL sucks Resists fans Not so cranky echnic

a year, but the network has grown far Also in this issue, there are stories about beyond the pages of the magazine. our expanded stable of writers, some UP FRONT new, some familiar, but all bringing a new In this issue, you will read stories about with Ken Newton global perspective to the everyday issue a new diagnostic program called Scan of fixing broken motor cars. Data, developed by Rod Maher at South hen Jeff Smit phoned me Grafton. This program consolidates TaT’s With the Aftermarket Expo in April, it’s almost a decade ago and online presence in a big way. going to be a very busy year. said, ‘Let’s start a magazine’, WI probably responded along the lines of The magazine will continue of course, but TaT is again heavily involved in Expo, ‘Find yourself another journo’. the real goodies are hidden behind the which is the biggest purely automotive website front page, accessible only to trade exhibition and seminar program in Magazines started with big ideas (and those who choose to pay the incredibly Australia. often little else), expecting advertising small fee by today’s standards and join up The TaT trainers will be conducting dollars to flood in the door just because as a member. the publishers thought they needed yet training sessions again – they packed another platform to promote their wares, There’s also the training. TaT is these them in at the last Expo in 2015. days in demand for both technical and rarely survive in Australia. Readers and members will see other business courses. Indeed, Australia is the biggest absorber changes during the year, all adding up to and demolisher of magazines in the Trainers Jeff Smit and Geoff Mutton an exciting, if not exhausting, 12 months. have conducted training events around world. As your foundation editor and TaT Australasia and are highly regarded for director, you will see a little less of me But back to Jeff’s call. ‘Calm down,’ their understandable, down-to-earth and next year as I’ll be moving into the slow he said. ‘It’s not just a magazine. It’s relevant training programs. a network of aftermarket technicians lane for a change. Rod Maher has also been accepted as sharing ideas, and I want to throw in a It’s certainly been an exhilarating and TaT’s fifth director and everyone in the TaT spot of training as well.’ sometimes exhausting few years helping team is delighted. So I gave in and the rest, as they say, is to build the TaT brand into the successful history. Rod brings new skills into the mix, and he and respected network that it is today. intends to keep expanding his Scan Data Stay loyal—it’s really worth it. The fact that the TaT magazine is about program for the good of the industry. to enter its ninth year is not a miracle. He has other diagnostic programs in his The magazine has been TaT’s shop ‘to do’ files just waiting for the right time window for 54 editions, at the rate of six to share them with his fellow technicians.

THE TAT TEAM • TaTassist • Tat share • TaT train CONTENTS • TaT’s a fact • Tips for TaT Publisher Jason Smith Changing landscape of vehicle servicing…4 • TaT Biz • TaT check • TaT find The Automotive Technician Anthony Tydd TaT’s new Scan Data program..……………6 Pty Ltd Rod Maher are all registered trade names of ABN 27 121 589 802 Maurice Donovan Strong new voice for the aftermarket……..7 30 Dale Street Wayne Broady The Automotive Technician TaT goes global with top technical writers…8 BROOKVALE NSW 2100 Clinton Brett Pty Ltd Rav 4 tank must come out [email protected] for fuel filter replacement…………………11 Columnists The Automotive Technician Pty Ltd publishes 1300 828 000 technical advice and actual case studies for Julian Hentze – Georgia USA Getting in contact with relays……………12 Fax 1300 828 100 the purpose of educating technicians. Geoff Mutton (Business) First death notice is posted Editor in chief These advices are given in good faith, and are for the combustion engine………………...16 Ken Newton Reader based on actual workshop repairs. DIY aftermarket sat nav……………………16 [email protected] Bron Robinson No guarantee is given, nor any liability 0438 569 517 Top Tools – Smart mini press……………18 Advertising inquiries accepted in respect to any published advice. Fax 1300 828 100 Janene Champion The Automotive Technician Pty Ltd is not Motorists have been Technical editor [email protected] responsible for the accuracy of any information trained to neglect their cars………………20 contained in material submitted by third parties Jeff Smit 03 5862 3090 The Autodocta……………………………..22 and published in this magazine and accepts [email protected] 0403 226 770 no liability in relation to such materials or their A 20 minute SAAB tip……………………...22 1300 828 000 content. Graphic design TaT’s a facts………………………………..23 General Manager Russell Jones Graphic Design Newsworthy articles or comments are Just give me a regas……………………..29 Geoff Mutton 0411 817 012 welcomed, and should be submitted to the [email protected] editor in chief. Putting Scan Data through its paces……30 Scan Data director www.rjgd.com.au All material appearing in The Automotive Rod Maher Fuel cleaning additive Technician is copyright. Reproduction in whole mixes with water, not with petrol…………30 Technical research Printing or in part is illegal without prior written consent Magna mayhem……………………………32 Deyan Barrie McPherson’s Printing Group from the editor in chief. 76 Nelson St [email protected] All advertisers agree to indemnify the Stuck without a sticker……………………34 Maryborough VIC 3465 publisher for all damages or liabilities arising Letter from America………………………..35 TaTassist traffic manager www.mcphersonsprinting.com.au from their published or unpublished material. Alex Cowie Faulty pressure switch……………………35 Affiliated associations The Automotive Technician is a member of the Burson Top Tech Tip………………………..36 Technical advisers VASA – [email protected] Circulations Audit Board. Jack Stepanian AAAA – [email protected] Audit period 1 October 2015 to 31 March 2016 TaT Training………………………………..38 Sam Nazarian Capricorn Society Alliance Average net distribution 9,944 Don’t be misled by the Gil Sher Supplier suction control valve fault…………………41

Pull-up resistor and two-wire sensor…….42

Tranny sleeve kit solves quill problem……45

Business training – clean up your act……46

The Automotive Technician 3 Changing landscape of

Cover StoryCover vehicle servicing by Jeff Smit and Ken Newton

he trend towards longer vehicle service intervals, Blind faith in oils driven to an almost unsustainable level by the car manufacturers and their compliant dealerships, is ‘The car makers seem to have this blind faith in the quality of the having a massive and detrimental impact on the new oils, and the engine the oil has to lubricate. The fundamental T Australasian vehicle fleet. principle is wrong. It makes no sense,’ Jeff said. New car sellers have successfully lulled the public into a sense ‘In the past, most vehicles, if not all, were serviced as regular of false security by claiming that the newer vehicles don’t need as clockwork every six months or 10,000 kilometres, whichever constant servicing like the good old cars. came first. We’ve gone from a society that once treasured and pampered ‘It’s the ‘whichever came first’ that most car owners don’t quite its vehicles, to one that now expects a vehicle to last only a understand.’ few years before tossing it away like an out-of-date kitchen This oil change interval was universally understood but has been appliance. tossed out the window, as car makers concoct their own service The new car dealers must be rubbing their hands with glee. It is schedule, and even threaten voided warranties if the oil they not in the interests of car makers for people to lovingly look after stipulate isn’t used. It’s a minefield out there, with ever changing their family car and keep them running for what, until recently, service schedules for different makes and models. was the average of 10 years before trading up. Complicating the issue is the reluctance of car makers to share The industry sector that understands this trend more than their service information with the people who do most of the car anybody is the aftermarket workshops. maintenance in the aftermarket workshops. They are battling a rear-guard action, trying to instill a sense of The manufacturers are attempting to keep the cost of car pride in car ownership, when all they see is almost criminal car ownership down by inferring that a new car needs servicing neglect, aided and abetted by the confusing advice in most new only every 12 months or 20,000 kilometers and even longer, car manuals. depending on the make or model. If the buyer of a new vehicle were to carefully read the owner’s manual they would soon The new car owner is the meat in the sandwich. The logbook discover that their driving pattern would fit the manufacturers’ says the vehicle doesn’t need frequent servicing. But after only a couple of years, when presented with a huge bill to clean definition of ‘severe’ driving, and for that kind of driving the the crap out of the engine, they try to blame their aftermarket service intervals must be reduced. workshop for the problem. Most driving could be ‘severe’ TaT Director and Technical Editor Jeff Smit doesn’t like what he sees limping into his workshops every day, ‘The thing that I It could be argued that the majority of driving on Australian roads fail to understand is that modern motor vehicles have smaller is ‘severe’ driving according to the car manufacrturers’ definition engines – less cylinder capacity, carry less oil in the engine – and that the only vehicle that could be safely serviced every 12 smaller sumps, are being worked harder than ever before – more months would be the vehicle ‘only driven by a little old lady on horsepower, yet their owners are being told that modern oils are Sundays’ – to reprise a corny and sexist old joke more likely to so great that there can be longer intervals between changes. be trundled out on used car lots. The Automotive Technician 4 But even that old adage no longer holds water, because if the Vehicle service data is available from quite a few sources, the ‘little old lady’ drives a diesel, she’s in for real trouble when the first being the owner’s manual (assuming there is one). A lot of filter and the engine clog up because the car isn’t driven hard owner’s manuals are difficult to understand and hard to work out enough to burn off the particulates. what is due when. There are a few well known data providers including Autodata (made available by Capricorn or Burson) ‘I am waiting for the day when a vehicle owner who has followed or Repco’s Autopedia. All of them charge fees and these vary the recommended service schedule with their dealership, is told depending on the amount of data required. that their car requires huge repairs or even an engine replacement, and that it will not be covered by warranty because the owner didn’t follow the ‘severe’ driving service schedule. I will be very surprised if it hasn’t happened already,’ Jeff added. Australian consumer law offers protection that guarantees certain consumer rights in the event of a premature failure of a product. The ACCC makes it clear that the consumer guarantees which apply, regardless of any warranties suppliers sell or give to you, apply for a reasonable time depending on the nature of the goods or services. This means consumer guarantees may continue to apply after the time period for the warranty has A page from Capricorn Service Data’s online service expired. This boils down to the fact that a car must last for a reasonable However, Capricorn Society has just launched Capricorn Service life, considering the money you paid for it. An engine should last Data, which is powered by Autodata’s unmatched coverage. This the life of the vehicle, and if it does not, the consumer has rights is available exclusively to Capricorn members as part of their under law to some form of warranty. But the new car supplier can membership. always fall back on their ‘severe’ driving service schedule. Under consumer law, the consumer’s responsibility is to understand the Capricorn Service Data gives Capricorn members instant access logbook service schedule. to the most comprehensive range of online service information covering thousands of vehicles. The data it provides supports the service and maintenance of almost any vehicle in line with Here’s an example that explains manufacturers’ warranty requirements. The content delivery is the confusion in the marketplace fast, easy and accurate. The repair times estimate and calculator enable more accurate quotes or estimates. It’s this up-to-date If a vehicle is in for a service and the timing belt is due for service information that workshops need more today than ever replacement, it’s the workshop’s obligation to inform the before to ensure that vehicles owners are informed about what vehicle owner that the timing belt is due for service and type of service or what part is due for replacement. spell out the consequences of ignoring the service should the timing belt break. If the workshop fails to advise of this service and the belt subsequently breaks, causing engine damage, the owner would have the right to claim the repairs from the workshop that last serviced the vehicle. So this is clear, the onus is on the workshop to report when things are due for replacement. Of course that doesn’t mean that the owner will follow the recommendation, but at least they are made aware. To safeguard the workshop, this information must be included on any invoice or correspondence. Other items that should be advised to the customer and noted on invoices are fuel filters, spark plugs, driveline oil replacements, brake fluids and coolant. They all can have a long term effect on vehicle safety and reliability.

The Automotive Technician 5 TaT’s new Scan Data program From will change the way you fix cars 1 January 2017

Rod Maher

eginning on 1 January 2017, leading them to repair solutions Features: TaT will introduce a brand that otherwise might take hours new online program that of researching or trial and error to Links to manufacturers’ service portals Bwill take a lot of the guess work solve. Information on manufacturers’ factory-level tooling out of diagnostics and provide a Scan Data operates in the way the Where to purchase factory equipment and OE dynamic new competitive edge for medical profession benchmarks their service subscriptions TaT members. patient’s performance. Doctors use Automotive software tools and calculators that are The program, called Scan blood tests and a range of scans, either standalone Apps that can be used without Data, is the result of years of ultra sounds and X-rays to establish the need for additional equipment, or that work gathering waveforms and values individual benchmarks for their in conjunction with specialist tooling such as from hundreds of vehicles and patients, so that when illness strikes, oscilloscopes or pressure transducers documenting them, with supporting they have an accurate record of calculators and other Apps, in an the patient’s baseline condition for Fault code definitions, currently explaining more easy to navigate online system comparison. than 8,000 codes available exclusively through the TaT Rod’s program has been hailed by Automotive abbreviations, currently explaining website. technicians as the most valuable more than 2,000 abbreviations or acronyms The cornerstone of the new Scan diagnostic tool on the market and A Wiki page, where members can add information Data program is the huge database better than anything else they have of value to fellow technicians and mechanics. of scan tool readings extracted seen anywhere in the world. It is already full of information about module through the on-board diagnostics But the program is a lot more than programming, key and FOB programming, module Parameter IDs (PIDS) from good good vehicle data. It is a one-stop reset and relearn procedures, timing belt and vehicles, or vehicles that are reference point for access to car service light resets and tips and tricks performing properly. manufacturers’ service portals, Forum and live chat containing gems of This data will provide a benchmark and for information about factory- information shared by members or to meet fellow for almost every vehicle with level tooling and subscriptions members for a simple chat performance problems that comes to original vehicle manufacters’ to a member workshop. service documents. It will be a ready Automotive links containing great website reference for fault code definitions, resources from around the world including The program is the brainchild currently covering more than 8,000 equipment suppliers, product catalogues, training of new TaT director Rod Maher, codes across most makes of vehicle. providers, workshop manuals, wiring diagram who explained that aftermarket resources, technical resources, service bulletins, workshops mostly only see broken Scan Data elevates the TaT factory service portals and a great deal more vehicles. And because vehicle networking philosophy to a manufacturers historically don’t whole new level. It will encourage Equipment reviews submitted by members – share new vehicle performance diagnostic sharing, covering this is the Trip Advisor of automotive and a values or other essental benchmark essentials such as module handy reference when considering buying data, workshops are often at a programming, key and FOB expensive scan tools, oscilloscopes and other disadvantage with very little or programming, module reset and diagnostic equipment. Each review contains nothing to show them what a good relearn procedures, timing belt and detailed information about the equipment, the vehicle’s performance data should service light resets. manufacturers’ website links and purchase look like. information. TaT members will be able to access Having access to a library of good the information on their computer or data for almost every make of car mobile device by simply clicking on Scan Data is an exclusive collaboration with TaT, and available in Australia will change the a vehicle badge icon to read online along with the popular TaT products, TaT’s a facts, repair landscape for workshops, and download for future reference. TaTassist and TaTshare, will be expanded continuously.

The Automotive Technician 6 Strong new voice for the aftermarket

Stuart Charity Deyan Barrie Maurice Donovan

aT director Deyan community and the economy,’ Barrie and senior TaT Stuart added. Tech Team member Government decision makers TMaurice Donovan have been in the past have not recognised appointed to the inaugural the value of the aftermarket Automotive Repairers sector to the Australian Council of Australia (ARCA), the national body set up to economy and to the safety and provide a strong voice for reliability of family cars. the independent repair and Independent service and repair service sector which is under businesses are the workshops significant threat from anti- of choice for more than seven competitive car company million Australian car owners – tactics and the rapid pace of more than half the vehicles on technology change. the road. The ARCA committee of 13 Among other things, ARCA includes industry leaders will generate input into drawn from independent community education about workshops and major service servicing of vehicles under and repair groups representing warranty, the pitfalls of dealer- all mainland states. offered extended warranties It is yet another initiative of and capped price service the Australian Automotive programs, and the myth of Aftermarket Association genuine parts. (AAAA), whose executive Their priority will be to director Stuart Charity protect consumer choice explained, ‘ARCA has been established to open doors and competition in the repair to increased automotive market. knowledge and business ARCA will also concern itself expertise, protect competition with creating and delivering and choice in the market, and technical training, and ensure a strong and unified addressing skills and training voice to government on behalf gaps. of Australia’s independent workshops. TaT general manager Geoff Mutton said the TaT team ‘Independent repairers have was delighted that Deyan realised that now more than Barrie and Maurice Donovan ever it is critical that this sector were selected on the new has a unified national voice committee. to influence key stakeholders and ensure that government ‘It indicates that TaT is recognition and support recognised as a worthwhile for these businesses is network in the aftermarket. proportionate to their important It’s a great feather in our cap,’ contribution to the Australian Geoff said. The Automotive Technician 7 his magazine turns nine It means that the skills of the aftermarket in the first edition of 2017, TaT goes global workshops have to match this plethora but the celebration being of car makes, each with their own planned is much bigger with top rated versions of modern technologies. than a birthday party. ‘The TaT directors and the technical TaT is going global in 2017, with a whole technical writers team who are the backbone of TaT’s Tnew look and a line-up of top technical many member services, decided that writers and trainers. it was time to tap into some of the Already regarded as the leading world’s best technical trainers to keep networking magazine and website for Australasian technicians at the peak of working technicians and mechanics, their game,’ said Geoff. TaT is lifting the bar even higher with the In every magazine next year, TaT will appointment of a stable of international publish technical articles written by and Australian writers who have been these trainers and authors, that relate to commissioned to produce a stream of each edition’s technical theme. relevant and timely technical stories to Some of the writers have already been prepare Australasian technicians for a featured in TaT, but never at the level challenging future. proposed for 2017 and into the future. As TaT General Manager Geoff Mutton Those listed below are just the beginning. explains, ‘Australia has always been a unique More discussions are under way with other automotive market because of the importation of writers, and they will be introduced during next probably the biggest range of car makes from around year. The flow of relevant editorial material will be the world. augmented by TaT’s own in-house writers, Jeff Smit, Deyan Barrie and Rod Maher. When the last Australian car maker pulls out, every single vehicle sold in Australia and New Zealand will have come from Here is the biggest clutch of high profile, diverse technical writers somewhere else. assembled in one aftermarket magazine.

Larry Carley He has published more than 2,500 with the Institute to develop technician Automotive technical articles in a range of popular magazines. certification tests. writer, editor and His articles for Babcox have earned him Areas of in-depth expertise include thirteen writing excellence awards from engine mechanical, electronics, fuel author the American Society of Business Press injection, ignition, emissions, onboard Illinois USA Editors and two from the Automotive diagnostics, air conditioning, brakes, www.AA1Car.com Media Conference. alignment, steering and suspension. CarleySoftware.com Larry has been certified by the He was also editor of Motor Service National Institute for Automotive magazine from 1979 to 1984. Larry has Larry is a technical writer for all the Service Excellence in seven areas of written scores of technical books and Babcox automotive trade magazines. automotive expertise, and has worked training courses. Insurance for

Frank Massey In the early years when no serial data Frank was rewarded for his efforts, the motor Automotive was available, he relied on pure logic and being presented with the Institute of the technical trainer circuit testing. Motor Industry (IMI) achiever of the year and writer award by the Duke of Kent, and shortly Frank developed an acute storehouse Lancashire England afterwards the first fellowship entry for trades industry. of knowledge of components and their www.autoinform.uk technical achievement. responsibilities in the automotive system. Frank began his automotive journey He established his independent tuning Get workshop and motor trades insurance that There were very limited diagnostic in the engine remanufacture industry, business in 1985, and that evolved into tools available so he made an early is right for you in your industry. spending 11 years as a precision his popular Auto Inform training platform assessment that the only way forward that has been adopted by almost every engineer. was the application of an oscilloscope – branch of the industry – independent Capricorn Risk Services understands your insurance needs. He acquired his diagnostic discipline not the tosh offered as tuners but a technicians, owners, college lecturers, Our account managers have access to a wide range of general from working on military aircraft for genuine bench lab scope with plenty of police, military, and some he can’t talk insurance products to find the protection you need. British Aerospace. bandwidth, sample rate and rise time. about.

Dan Sullivan authored two books on electrical theory segments. Dan has developed and Electrical and practice – Fundamental Electrical patented several electrical diagnostic tools Troubleshooting and Essentials of Electric and his YouTube channel contains more diagnostics trainer Find out how Capricorn can help you. North Carolina USA Power Generation. than 90 videos. brighterideas.com 1800 007 022 | [email protected] | www.capricornrisk.com RISK SERVICES He has trained more than 6,000 He has also written several documents Dan’s training is aimed specifically at technicians since 1996, and has trained detailing new theories on electrical Products sold through Capricorn Risk Services Pty Ltd are: (i) discretionary risk protection products issued by Capricorn Mutual Ltd; and (ii) general insurance For the best products issued by a range of insurers and brokered through Capricorn Insurance Services Pty Ltd. Before deciding to acquire any product you should consider the the transportation industry. He has for every major manufacturer in all industry diagnostics and management. interests of Product Disclosure Statement available from Capricorn Risk Services Pty Ltd to see if the product is appropriate for you. Capricorn Risk Services Pty Ltd (ABN 91 111 632 789) Authorised Representative (No. 460893) of Capricorn Mutual Ltd (AFSL 230038) and Capricorn Insurance our members Services Pty Ltd (AFSL 435197). The Automotive Technician 8 Insurance for the motor trades industry. Get workshop and motor trades insurance that is right for you in your industry. Capricorn Risk Services understands your insurance needs. Our account managers have access to a wide range of general insurance products to find the protection you need.

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Products sold through Capricorn Risk Services Pty Ltd are: (i) discretionary risk protection products issued by Capricorn Mutual Ltd; and (ii) general insurance For the best products issued by a range of insurers and brokered through Capricorn Insurance Services Pty Ltd. Before deciding to acquire any product you should consider the interests of Product Disclosure Statement available from Capricorn Risk Services Pty Ltd to see if the product is appropriate for you. Capricorn Risk Services Pty Ltd (ABN 91 111 632 789) Authorised Representative (No. 460893) of Capricorn Mutual Ltd (AFSL 230038) and Capricorn Insurance our members Services Pty Ltd (AFSL 435197). Clinton Brett He is committed to improving the skills sound, smell, touch and taste are his Diesel fuel injection of the automotive trade, providing main tools. specialist common rail diesel diagnostics and Qunaba Queensland training throughout Australia. Diesel smoke, odour and colour can www.dieseldoat.com assist with diagnostics. White smoke, Clinton’s training focuses on the black smoke or both can point to more Clinton has concentrated on diesel fuel diagnostics of a diesel engine before than one faulty component. injection since completing his heavy wires, sensors and engine computers earthmoving apprenticeship at MTQ were added. Diagnosing electronic Knowing which one is correct the first Engine Systems in 1994. diesel vehicles mechanically, using sight, time is important.

Jack Stepanian An avid supporter of the TaT concept and oscilloscopes. of networking and sharing ideas, Jack’s Trainer and Originally an academic with the in-depth technical articles have been technical writer University of Sydney, involved in published in almost every TaT magazine TaT guru and communication and education, he later since inception. mentor became involved with General Motors In all of them, Jack has pushed Holden and the Institute of Automotive Collaroy NSW the envelope of training, enticing Engineering and went on to train large technicians to explore electronics and groups of people in motivational, Jack Stepanian is TaT’s mentor. sophisticated tools such as scan tools technical, sales and management areas.

Jason Smith With his inquiring mind, Jason sniffs in the 1980s in a small service station Automotive out the odd, difficult and unusual repair in Melbourne. Much later he worked at technician and problems and documents them for TaT. a Mitsubishi workshop and opened his own business in 1993. business owner He admits to absorbing auto knowledge Melbourne VIC like a sponge, and until a few years As well as his mechanical qualifications ago, had taken himself to night school to Certificate 4 level, Jason is a licensed

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The Automotive Technician 10 2007 Toyota Rav 4

Begin by disconnecting RAV 4 tank must the three pipes or hoses. Support the fuel tank with come out for a gearbox crane or similar, remove the three fuel tank fuel filter straps, unclip the hoses replacement and wiring saddles from the right side of by Jason Smith the tank near the rear using an 8mm socket and remove the fuel The tailshaft, then lower the fuel tank tank module assembly from the fuel tank. hile replacing the intank fuel original to allow access to the top middle Swap the numerous parts over, including filter on this Rav 4, I realised fi l t e r and top rear of the tank. the fuel pressure regulator and the fuel that many technicians Next unplug the fuel gauge sender pump including the top O-ring. Clean the Wmay not be aware that on this model wires near the center of the tank, (ACA33R, 07/2007 and 2AZ-FE engine) fuel pump strainer and continue swapping then at the rear of the tank unplug the fuel the fuel tank must be removed to the wiring harness and lower basket pump wiring harness and disconnect the replace the fuel filter. assembly. four hoses. It’s not like many other cars or even the Refit the assembled unit to the fuel tank, previous model Rav 4 that have inspection The fuel tank is now free to lower reconnect all wires and pipes, refit the fuel openings under the rear seat to access completely to a workable height. tank, refit all running gear, test and road test. the intank fuel filter. Clean around the top of the fuel filter This filter had to be replaced as part of an module assembly, remove all eight bolts The job should take around two hours. 80,000km service. I recommend the job be done with a low fuel tank level. The fuel filler inlet is located at the bottom of the tank and although the filler does have a trap door on it (sort of like a one way valve) there is the potential to spill fuel. Having the fuel level low also eliminates the need to decant the tank.

The fuel tank is rather long and awkward New filter installed Refitting the fuel tank to handle alone.

www.rycodpf.com.au

The Automotive Technician 11 TaT has published many articles Relays are also used when more on relays over the past eight Getting in contact than one circuit needs to be years. In three issues in 2009, activated by a single input. there were articles exploring the You can use a single input from different types of relays fitted with relays by Jeff Smit one part of an electrical system to vehicles and the danger of (such as a central locking output) getting them mixed up. to activate one or more relays It’s time to revisit this subject, that then complete one or more not because most technicians other circuits. don’t understand relays, but it is I would expect every technician obvious from feedback at many of has opened up and inspected the my training sessions, that many inside of a relay or two. are a little unclear about the role of the relay. In case of uncertainty about the parts in a relay, here is a closer The modern motor vehicle has look (pic 1). probably 20 or more relays within its electrical system, and that’s Inside a relay is a mounted coil only counting the external ones, wrapped around an iron core (the not ones built into components. electromagnet). Off this mount Relays come in many sizes, is a lever which is hinged. One ratings and configurations which end of this lever is connected to is why it’s important to understand 1 a tension spring which pulls the the differences as the wrong relay other end of the lever up. This is in certain applications can cause the relay in its de-energised state major damage to electronic components in or ‘at rest’ with no voltage applied. an instant. The braided bonding strap provides a good So what does a relay actually do? electrical connection between the lever and the mount, rather than relying on contact Relays are basically just an electromagnetic between the lever pivot points alone. switch, sometimes called a remote control electrical switch, but in the end relays are The coil and contact (or contacts) are then switches. connected to various terminals on the inside and outside of the relay body. Within every relay there are two separate 2 circuits – the coil circuit that is low current, Relay operation and an output switching circuit that is high All relays operate using the same basic current. principle. In our illustrations we will use There are many different relay designs a standard 5-pin relay with standard pin including 3-pin, 4-pin, 5-pin and 6-pin and all configuration. Relays have two separate have different internal design and therefore circuits – a coil circuit, low current, and an very different applications. output switching circuit, high current. What’s the difference between a When the coil circuit is supplied with voltage, a small magnetic field is created which relay and a solenoid? causes the hinged lever to be pulled down to A solenoid is an electromagnetic actuator. 3 close a set of contacts. Internally, a coil is wrapped around a This completes the ‘high’ current circuit moveable plunger, and when the coil is and the relay is said to be energised. When energised the plunger will move. voltage is removed from the coil terminal, Solenoids can be used to open a valve, move the spring pulls the armature back into its ‘at a lever or something else mechanical. In rest’ position and breaks the circuit between the case of a standard starter solenoid, the the terminals. solenoid will engage the starter drive into the So by applying or removing power to the ring gear as well as close the starter contacts coil (the low current circuit) the high current to feed power to the actual starter motor to circuit is switched on or off. It is important to start the engine turning over. In this case it is understand that the coil circuit and the output still a solenoid as the contacts are closed by switching circuit are electrically isolated from the moving plunger. 4 one another within the relay. The coil circuit Why are relays used? simply switches the high current circuit on (pic 2 and pic 3). A low current circuit is used to switch on or off a high current circuit. This is the most Relays are designed with either normally common reason for the use of relays. An open and/or normally closed contacts. The example of this would be if you were fitting most common relays on the market are spotlights to a vehicle and the extra current normally open type relays. In a changeover would be too high for the original circuit. relay there is one set of contacts normally open and one set which is normally closed Another reason they are popular in today’s (pic 4). cars is because of the cost savings. High current capacity wiring and components cost Other relay variations include 3-pin and 5-pin more than lower current capacity ones, so by relays. In the 3-pin, instead of two battery using relays the costs saved are substantial. 5 input sources, there is only one. (Continued)

The Automotive Technician 12 WORK. LEARN. INFORM.

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REPXPERT – a trademark of Schaeffler Automotive Aftermarket. (Continued) The input circuit It’s these two layouts which splits inside the relay supplying get technicians caught out both the coil circuit and the because using the wrong type output switching circuit (pic 5). in certain applications will cause instant ECU damage (pic 8). The Standardisation of automotive difference is that pin 30 and pin relays has been set by 86 are swapped over. the International Standard Organisation (ISO). The terminal widths used on 4-pin and 5-pin relays are almost ISO relays are currently used by always 6.3mm wide. However, all automotive manufacturers some of the more specialised around the world. Most of the relays can have terminal widths 4-pin and 5-pin relays used today of 2.8mm, 4.8mm and 9.5mm. are available in both standard The 9.5mm wide terminals tend mini and micro sizes. to be used for higher power Standard mini relays are a applications, such as thermos very popular relay which are fan operation, and the smaller a one-inch square cube and terminals tend to be used for 6a are available in 4-pin or 5-pin electronics signalling where only design, together with many pin very low currents are required. configurations. All widths will be compatible with Some examples can be seen in the standard female blade crimp pic 6a and pic 6b. terminals of the corresponding sizes. Micro relays have become popular to cope with the Spike protection decreasing amount of space When a coil circuit is energised, under the bonnet. These relays current flows through the coil are also available in 4-pin and from positive to negative (pic 9). 5-pin (pic 7 has two examples). This current flow causes a The terminal numberings found magnetic field around the coil. on a relay body are taken from When this circuit is de-energised, DIN 72552 which is a German switched off, current stops automotive industry standard flowing through the coil and the that has been widely adopted magnetic field collapses. As and allocates a numeric code the magnetic field is collapsing to various types of electrical 6b across the coil, it induces a terminals found in vehicles. voltage into itself. This voltage is created in reverse polarity and The terminals on the outside can spike at several hundred of a 4-pin or 5-pin mini relay volts. This voltage, 200 volts or are marked with numbers as more, can be dangerous to other shown below: circuits and components in a motor vehicle so most relays will Terminal/Pin number and now have some form of internal connection suppression. 85 - Coil, end of winding to Relay suppression can be ground or negative achieved by fitting a high ohm resistor, a diode or a capacitor 86 - Coil, start of winding to inside the relay. Diodes and power resistors are the most common 87 - Normally open (NO) (pic 10). 87a - Normally closed (NC) When a diode is used it is – not present on 4-pin connected in parallel, and in relays reverse bias with the relay coil. When the relay is switched on, 30 - Input or source 7 no current will flow through the diode. According to DIN 72552, the When the coil circuit is switched coil should be fed with +12V to off, current stops flowing through terminal 86 and grounded via the coil causing the magnetic terminal 85. However, in practice, field to collapse. The magnetic it makes no difference which lines of force cut through the coil way around they are wired, and induce a counter voltage (a unless you are using a relay voltage in reverse polarity) into with an integrated diode (more the winding. When the bottom on diodes later). ISO mini relays side of the diode sees 0.7 volts are available in two types of pin more positive voltage than the layout designated Type A and top, the diode becomes forward 8 Type B layouts. biased and allows the excess

The Automotive Technician 14 voltage to pass, completing the circuit to the other end of the coil. This induced current flows around the coil and diode until the voltage is dissipated. When a resistor, which is more durable, is used for suppression, it can suppress voltage spikes similar to a diode. A resistor will allow current to flow through it whenever the relay is on. Therefore the resistance of the resistor must be high, around 700 ohms, in order to prevent too much current flow in the circuit. High ohm resistors are not as good at suppressing voltage as diodes. 12 There are many different opinions about testing relays. I have a fairly strong point of view, rightly or wrongly, that the best way and place to test a relay is in the vehicle and connected to the circuit that it was designed for. Normally when you get to the stage of testing a relay it is because something is not working. I will admit that accessing the wiring of many relays in modern motor cars is not easy, and 9 indeed sometimes impossible. That’s where equipment like the deluxe relay test kit (part number 60660 Burson Auto Parts) comes into its own (pic 11). This great kit was featured in Top Tools (issue 37, February 2014). It allows you to maintain the original circuit with the original relay in place but now you have direct 13 access to all pins of the relay via the relay test pods. This piece of equipment is one of the most valuable in my toolbox. With this testing piece in place you can check all voltages, both power and earths to the relay (pic 12, pic 13 and pic 14). This way, an accurate and precise diagnosis can be made on the relay’s integrity as well as the relay’s circuits. Relays have been around for a long time and they are here to stay. Upskilling yourself to really understand them and test them is vital. But be very particular when replacing any relay. Make sure it’s the 10 right one for the job, otherwise you might be 14 looking at an expensive repair.

11

The Automotive Technician 15 First death notice is posted for the combustion engine

ignals are coming The resolution from the Do It Yourself out of Germany that German states is linked to electric cars may calls on the European Union aftermarket sat nav herald the beginning to consider ending the lower of the end of the levels of tax on diesel fuel combustion engine. ove the work of the Dumb and Dumber. across Europe. TaT team. I have It is reported that the federal The vehicle’s owner could A move in recent years been a member since council of all 16 German not understand why his towards more diesel Lthe early days and have states has agreed that petrol vehicle would not pass the production has apparently attended many of your and diesel engines should be Roadworthy. backfired now that the workshops. off the streets by as early as I am not sure that he made 2030. stories have emerged Your vision and insights are it strong enough either about companies cheating second to none and my Reviewers of this momentous because he used 6mm bolts their emissions tests and a business partner and I have decision hasten to add that and 6mm plate. growing awareness of the benefited greatly from the this is not a binding decision TaT team’s information and I thought it was worth on car makers, but there health implications of diesel teachings. sharing with your many seems no doubt that the fuel particulates. readers. inexorable move towards We run our business a lot Individual countries in Europe cleaning up world pollution is differently now to what we Campbell Waters are already passing tougher being driven by Germany. did years ago. Ace Automotive Repairs emissions laws and are BUNDOORA VIC The photos were taken from The auto industry is one moving to restrict the use of a vehicle that came into my (Sure was worth sharing of the largest sectors of fossil fuel powered vehicles. workshop. Campbell. He obviously the German economy. The The big three German car cares a lot about his car. And country makes more vehicles They don’t qualify for TaT’s a thanks for your kind words... than any other in Europe, and makers have recently been facts but perhaps you could it’s guys like you who keep us is the third largest vehicle ramping up their commitment have a new category called focused. Editor Ken) maker in the world. to producing electric cars.

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The Automotive Technician 16 The KYB range of shock absorbers and struts is continuing to expand, with more car applications added to the large range of European car makes and models. The premium quality KYB products are a direct replacement for many of the European vehicles on Australia’s roads.

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he debate concerning and anticipate brake wear and service intervals for new been trained to replacement intervals for brake cars is raging in the systems. If I have to judge if brakes T aftermarket world. need replacing at a service and the neglect their cars customer has adopted 15,000km, This is where most of the country’s 20,000km or even 25,000km sick cars are taken for repair service intervals, the brakes will and service, not the dealerships. SERVICE need replacing earlier and that’s Aftermarket technicians and OVERDUE not value for money. mechanics are shaking their heads in disbelief that car owners can be If the car hits a pot hole 5,000km so gullible, that dealerships can after a service, throwing it out of be so uncaring. Why is it that the alignment, I could save the tyres majority of car owners seem to be at a 10,000km service interval. no longer interested in looking after Any longer interval will result in their expensive vehicles. And why is it that those who do care premature new tyres. about their vehicles are so often fobbed off by service managers Mercedes Vito advises 20,000km service intervals, but the in dealerships who so obviously know little about the need for oil must be topped up at 15,000km because it uses it. Why? more regular servicing. Simply because the oil has degraded so much. I challenge my customers to show me a mechanic anywhere who goes beyond Here’s a story that’s typical of the dealership attitude: a 10,000km service interval on their own car. The owner of a 12 month old Land Rover Discovery, with The biggest thing that may hurt the aftermarket are extended 18,500km on the clock, was on a weekend trip when the car’s warranties like Kia’s seven-year warranty but when you read the computer flashed a warning that a service was due within small print, it is difficult to figure out what is actually covered by the next 1,000km. He gets three years free servicing from the their warranty. dealer. Anthony Tydd At the first opportunity, he took the vehicle to the Land Rover TaT Tech Team dealer and asked for the service to be carried out. Bendigo VIC ‘No’ said the service manager, the service wasn’t due until the The service intervals are too long. Customers have been back to vehicle had done 26,000km – 7,500km into the future. This BMW dealerships in some cases for two services and their cars was contrary to what the car’s computer was saying. haven’t yet had an oil change. Then the dealer tried to sell him the line that with today’s The dealer has a line entry normally at five years – modern oils cars don’t need to be serviced as frequently. The de-sludge service. car’s owner refused to accept that advice, and insisted the Gil Sher service be done that day. Sensible man. TaT Tech Team The TaT Tech Team was invited to provide their views about Sydney NSW modern service intervals, and the potential pitfalls for the Caring for cars is old hat unwary. Read on for a scary ride. Vehicles will never last as long as they once did because people Many problems result from extended just don’t know how to look after them. Subsequent huge repair bills don’t seem to faze them. They just service intervals pay up and most do not learn from the experience. The trouble is that many vehicle owners will naturally extend their The brain-washing began soon after the old 12 month or service times anyway, often going many thousands of kilometres 20,000km warranties were abandoned for longer service beyond the service time. Combine that attitude with the extended intervals. Some folk are still driving those vehicles serviced under service period and the end result is usually not a good one. the old regime, and they are working fine. Good quality synthetic oils might be up to the task of extended Look around and you will find that quite a number of later services but if low grade oils are used, the level of protection vehicles are actually extinct, but the old FC, EK, and EH Holdens would be greatly compromised. and the old Fords live on in numbers. Extended service intervals equals a neglected vehicle in my Customers regularly miss services by as much as 10,000km. book. I have had many vehicles come in with driveability Vehicles come to us with so-called electrical issues, but we find complaints that turn out to be oil pressure and variable valve they have no oil, no coolant and the owner had absolutely no timing issues that almost always were caused by extended idea. service intervals. In other words, a neglected vehicle. Deyan Barrie All my customers are on 10,000km or 12 months service intervals TaT Research Director and some have asked for 5,000km intervals. Sydney NSW Rod Maher Car makers don’t want you to keep Scandata and TaT Director South Grafton NSW your car too long 10,000km is the magic interval Those of us in the aftermarket could be excused for thinking that car manufacturers have calculated how long a car will last 10,000km is the right interval for checking for early tyre wear on their extended service schedules, with the aim of artificially or wheel alignment problems and the right interval to judge stimulating new car sales. The Automotive Technician 20 The typical vehicle used around the city in short trips where the Mineral based oils like Castrol XL were commonly used and the oil cannot reach its proper operating temperature, should have an service schedule was three months or 3,000 miles. oil change and service every six months or 5,000 km. In the 1980s manufacturers moved to six months or 10,000km The damage we see as a result of extended service intervals is servicing. The change seemed subtle and we liked what we mainly engine sludge that causes oil starvation to cam gears heard – lower servicing costs. and rockers to the point where cams and rockers have to be Some of the cabbies were old school and they did most of their replaced. own servicing to keep costs down but they stood by the 5,000km Then there are turbo failures, variable valve timing solenoids service interval. sticking, timing chains stretching and engine breathing blocked. In the early 2000s, 15,000km and higher service intervals were Maurice Donovan introduced. The public embraced this as a cost saving and it TaT Tech Team become a selling point for many models. Brisbane QLD But it backfired. The engines now are fuming with premature Services should match driving style turbo failures, oil leaks, timing chain and cam wear. The industry has never before seen anything like this, with failures in vehicles The minimum service requirements as set by the vehicle with as low as 70,000km on the clock. manufacturer are designed to keep the vehicle in good running Many Japanese models have remained on six months or order while under new car warranty, but they do not take into 10,000km servicing. Toyota, Mazda and Honda in particular are account the different driving styles and driving conditions for outstanding in engine reliability, as opposed to some European each vehicle. makes such as BMW, Mercedes, and many others on extended Servicing requirements need to be adapted to suit driving oil change periods. styles and types of use and customers need to be advised that The logbooks are not very clear about the need for more frequent additional servicing is needed if their vehicle use doesn’t fit the oil changes depending on your driving conditions. norm. It would make life a lot simpler for car owners if service items that are time related are itemised, and the same for those In reality, they are saying that if you drive in what they call service items that are kilometre based. ‘severe’ or ‘harsh’ conditions, cars should be serviced just like they used to be. But this is the bit never explained when the This way, the vehicle is not getting over-serviced for vehicle is sold, or if it is, it is rarely reinforced at the service outlet. some items. What is described as ‘severe or harsh’ by the manufacturers is Wayne Broady how most Australians drive. TaT Tech Team Sydney NSW In the typical school and shopping family vehicle, oil never reaches operating temperature, and a certain amount of the fuel Are cars appliances or sophisticated has made its way to the engine sump. machines? Because the oil is not at around 80°C it is not kept as a vapour and sent off through the PCV system to be dealt with in normal Some service schedules appear to be written by the marketing combustion. Instead it is absorbed into the oil. department rather than engineers. How can a Jeep and a Mazda sharing the same engine, have blatantly different service This process is repeated day after day, until the viscosity of the schedules on a whole range of things from engine oil to filters? oil has become compromised, and begins to lose its capacity as a lubricant. Often the big ticket items will conveniently require servicing just as the car finishes its capped price servicing period. Fuel is not a good lubricant, and it is also not good at lubricating oil seals. Fuel contaminated oil has become thinner and more And how can a car built in January have a distinctly different volatile, and now begins to burn at a faster rate, causing the service schedule from an identical model built in February? sludge build-up in many areas of the engine. This reduces the There are ridiculous oddities like a manual transmission car ability to deliver oil to many areas of the engine, especially on having an external fuel filter but the automatic variant uses a non- cold start-up. replaceable specified in-tank filter. Graham Patterson Of course oil sludging is the main culprit. Customers simply don’t Apps Automotive understand that 15,000km of primarily long distance driving is Kirrawee NSW worlds away from 15,000km of stop-start short distance city driving. Motorist education is needed We currently still operate on a 10,000km or six months service Oil companies pride themselves on the superb inherent qualities schedule for the vast majority of our customers. of their manufactured oils, such as magnetic oils. Brendan Sorensen However (and it is a big however), it is not the quality of the oil Steve Sorensen Mechanical but rather the unfiltered impurities from the engine during its Browns Plains QLD operating period that does most damage, with the impurities Trips to shops and school are no good floating in the oil. As a rule of thumb, if engine life needs to be prolonged, my for cars past experience tells me that the engine filter and oil should be replaced every 10,000km (synthetic or otherwise). I have spent more than 45 years in the industry, having started in the era of the HQ Holden. Taxis were the litmus test of vehicle Jack Stepanian performance, and cabbies would complain if their engines did TaT Research Centre not last more than one million kilometres. Sydney NSW The Automotive Technician 21 2005 SAAB The Autodocta A 20 minute Whining above 90km/h SAAB tip by Anthony Tydd Problem: A 2012 BMW 1 Series had a whining type read where a technician spent four hours trying to noise coming from under the vehicle when driving above diagnose a SAAB that would not crank and intermittently 90km/h. not fire up. The noise was experienced on the road test but its source I There were no fault codes, and inputs and outputs at the ECU could not be found in the workshop. All the screws holding the were scoped to trace and locate the problem. underbody shields were checked to the correct torque. There was nothing obvious that would cause the noise. The fault was in the crank angle sensor. The signal voltage was not high enough for the ECU to register what cylinder it was Solution: Autodata has seen this fault on several BMW looking at, but not low enough for a fault code to log. models. It is due to excessive clearance between the front I have worked on SAABs for many, many years, and with this and centre underbody shields. kind of fault, it is almost always one of three things and the The centre underbody shield must be removed and the underbody diagnosis should take 20 minutes, not hours. thoroughly cleaned in the area indicated in the illustration. Fuel pump – check for rail pressure at valve on rail (three Fit a foam pad, available from BMW parts departments, to the minutes) cleaned area and then refit the centre underbody shield. Road test Crank angle sensor – crank the engine and 9.9 times out of 10 to ensure the noise has been eliminated. if the tacho does not flinch it’s the crank sensor. A dead crank Leading technical information provider Autodata share fixes to sensor won’t even bump the tacho common problems found (three seconds) in modern motor Check for spark at the vehicles. coil pack (maybe 15 To learn more minutes) about their This routine innovative new applies to all online product SAAB 900s, the visit: www. 9-3 and the 9-5 autodata- from 1998 onwards. group.com/au

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The Automotive Technician 22 MART8738A New Ranges AD TAT 190x137.indd 1 11/08/16 11:09 AM MITVE00121 MITSUBISHI VERADA ‘s a fact 2000 diagnostic solutions 6 Cylinders

Customer TCL vacuum control solenoid and valve that works the complaint vacuum to operate the TCL The vehicle’s engine vacuum diaphragm and pull check light was coming on the throttle linkage to on intermittently and the stop it from working. traction control (TCL) light Under normal operating would come on. conditions the only time Problem summary the TCL light should come on (indicating that traction The previous repairer could control has been turned off) not get the vehicle to play is when the override switch up. is turned to the off position 1 which the driver might prefer Diagnostic in snow or wet conditions. sequence In this instance the faulty Road tested on the freeway. component caused the It played up during cruise throttle malfunction whether only but not if driven hard. the main TCL switch was on or off. The vehicle would lose accelerator pedal control and The reason it occurred only if more power was needed, it at cruise was because that was unable to accelerate. It was when the engine had made no difference whether maximum engine vacuum. the traction control switch This would build up, was on or off. sneaking through the faulty valve and build up in the The engine check light and diaphragm and eventually TCL light were on, and stop the throttle mechanism 2 accelerator response was from going further. lost. When driven hard the Code: vacuum could not build up 72 – TCL solenoid. quickly enough to affect acceleration as much, due to The TCL system function less engine vacuum. affects the throttle body operation. 1 Fault solution The vacuum control valve A new generic vacuum was checked and appeared control valve was fitted. to work electrically. This This valve is located on the valve works the TCL vacuum left side of centre on the diaphragm that affects the firewall. 4 accelerator operation when the TCL is engaged, by The code was cleared, the restricting the opening of the vehicle road tested and the 3 throttle plate mechanism. 2 problem solved. Fault description Recommended When checking the control time valve vacuum, it was not Labour time was 2 hours, shutting the vacuum off taking into account research completely when it was time, location of parts and turned off. 3 actual time spent fixing the This was causing the engine problem. vacuum to bleed through into the diaphragm, pulling Tips for TaT onto the throttle body lever Another stupid abbreviation. and affecting throttle control. TCL is the abbreviation for traction control, and not The TCL system has a 4 traction control module, a traction control light. The Automotive Technician 23 JAGXJ97410 JAGUAR XJ SPORTS ‘s a fact 1997 diagnostic solutions 8 Cylinders

Customer complaint The vehicle would sometimes crank, but other times not at all. Problem summary The owner had the battery replaced, but the problem continued to occur. Diagnostic sequence The battery was tested at the battery posts. It passed the electronic load test, but when the same test was carried out further up the line at the main cable/junction point it failed the load test. 1 2 The reading showed ‘Replace battery (259 CCA)’. Fault description This reading led us believe there was a bad connection, causing a large enough voltage drop to make the starter motor play 1 up. We isolated the problem to the main positive cable lug and battery terminal. Fault solution A new positive cable was made up and fitted. It went from the battery terminal positive to the main junction that houses the mega fuse links (500amp). 3 The same test was carried out again and this time it passed. 4 The reading showed ‘Good battery (622 CCA)’. Of course the same test could have been done using the digital volt meter and measuring the voltage drop between different points while cranking the engine over. Recommended time Labour time was one hour, taking into account research time, location of parts and actual time spent fixing the problem. Tips for TaT This problem is quite common with many European models. Always carry out voltage drop tests as one of your first steps in 2 the diagnostic process.

3 4

The Automotive Technician 24 MER1603422 MERCEDES A160 ‘s a fact 2003 diagnostic solutions 4 Cylinders

Customer Not wishing to confuse everyone, but when the complaint cluster reads the system When the left blinker is voltage it probably has turned on in this vehicle, some sort of internal preset the right blinker sometimes parameters and internal flashes. It is intermittent, matching resistors that help but always occurs at a bad in distinguishing which way time. was selected by the voltage eg. if you have the key on Problem summary but the engine is off, the This problem was ongoing voltage could be as low as and intermittent and could 11.5 volts. happen hot or cold. It still knows what you Warning. The instrument are selecting because the cluster is very sensitive and system’s selection voltage central display can fail just is the same. by manipulating it. When the system played Please refer to TaT assist up, we had the left blinker 1 MER1603430 (A160 on selected but it was flashing instrument problem). to the right. The voltage was one volt Diagnostic more than the voltage sequence recorded when it was We acquired some circuit working correctly. diagrams and found that Fault solution the circuit is controlled by the instrument cluster. 1 We tried to manipulate the connection points in case it The trigger circuit is a was a bad pin or connector. single wire circuit from the It was not. It was not a blinker switch up to the blinker switch either. cluster. The problem appeared The blinker switch has an to be an internal cluster inbuilt resistance on the left resistance circuit problem indication side and direct where it was not pulling the switching from the right voltage down far enough. side. A good second-hand It supplies a positive 2 cluster was located and voltage up the line to the fitted. All functions worked cluster. The cluster looks at okay and the problem was the voltage and makes the solved. Right selection Left selection indicators flash according to the selection. Recommended The input signal was time monitored by back probing the back of the plug while Labour time was 3.5 hours, it was still connected to the taking into account instrument cluster. 2 research time, location of parts and actual time spent Fault description fixing the problem. When the right indicator Tips for TaT was selected, we had vehicle system voltage 3 Make sure the customer but when the left indicator is advised of possible was selected, we had a problems with the much lower input voltage at instruments when a cluster the same point. 4 is manipulated. 3 4

The Automotive Technician 25 TOYCA99425 TOYOTA CAMRY ‘s a fact 1999 diagnostic solutions 6 Cylinders

Customer complaint The fan speed control circuit is positioned across the single resistor. The interior fan was not working correctly. By varying the signal voltage to the control Problem summary unit, it varies current across the resistor, The interior fan speed operated on low thereby controlling the speed of the fan motor. speed only. There was no variation with the Fan fan switch operation. Fault solution resistor Diagnostic sequence The old fan speed control module was 4 There was power to the fan motor, but it removed from the evaporator housing Fan control only worked at low speed. so that the resistor could be inspected and module the fan motor current draw checked. The voltage input varied with switching at 1 the fan speed control unit, but there was The old module was pulled apart, but no speed increase. 1 there was nothing to see and no signs of overheating. 5 Fault description It was replaced with a new fan control The fan control speed module was back module. 6 probed and voltages checked. 2 A performance test was carried out, and Both components are located above the the fan operated correctly. driver’s left foot in the HVAC box on the side. 3 Recommended time Labour time was 2.5 hours, taking into Fan control The resistor is located above the fan speed module control unit. The resistor is a large single account research time, location of parts circuit used for the lowest fan speed as and actual time spent fixing the problem. well as sharing the load of the control 2 circuit for higher speeds.

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Find out more at www.newtrueblue.com.au ost motorists don’t have a ‘A lot of people will be just looking for a clue about their vehicle’s air price, but don’t play that game. I never take conditioning system or what Just give on a job without going through all these Mkeeps it alive. preliminaries, because it will most likely end in an argument about the cost of the service There are still a few workshops that insist on me a regas – displaying those once ubiquitous sandwich and the aircon may still not be working. boards on the footpath, with messages like Nobody wins,’ Deyan said. ‘Regas - only $99’ or ‘REGAS WHILE YOU yeah, right! To finish on this air conditioning theme, WAIT’. Their motives perhaps are pure, but Deyan gives his opinion about dye in air The next chapter in Australian battery what they are effectively doing is keeping conditioning systems. alive the myth that there’s a mysterious ‘I am not a fan of using it on a regular basis. substance in the car that is used by the engine and it needs filling The only time we may use it is when we have done a full system up when your aircon stops running cold. manufacturing has arrived. flush and new components or the system are totally clear of dye. These are the same workshops that either don’t know, or don’t ‘We do not use it as a leak finder on the day but only for future take the time to explain that if a car needs ‘topping up’ it means reference. the refrigerant is leaking and this is a federal offence. The Our first sealed maintenance free battery designed workshop is indeed breaking the law if they attempt to refill the ‘If you read the code of practice carefully it states that a vehicle refrigerant without locating the leak and fixing it. We are talking should not be recharged and put back on the road if a leak is and manufactured in Australia for Australia. about the common and only approved refrigerant (R134a) for suspected. So my interpretation is that you are looking for a leak, vehicles in Australia that cannot be released because it is a you can’t find it, so you add dye. greenhouse gas and dangerous to the environment. ‘Now here is the clincher – if you let the car go because you can’t Such old myths make it difficult for the good aircon repairers who find the leak, but you know there must be a leak somewhere, you have to spend inordinate lengths of time explaining the law and the are not doing the right thing. That’s the NO! NO! I’m astounded so repair process and cost (which can be expensive). More often than many workshops do that as a first option instead of having a good not, a car owner who doesn’t want to listen to anything to do with look, spending the time and charging the time out for the correct the law will end up going to the cheaper regas place. What do they answer. care, as long as their vehicle’s aircon is cold. ‘A good electronic leak detector and Big Blu will pick up most As the owner of one good workshop in Brisbane said after leaks. losing yet another job because the car owner thought it was too ‘My view is that if you have gone all over the system and still don’t complicated and expensive, ‘The public has no understanding or pick up the leak, then it will be in the evaporator. I have a 99 per respect for the a/c regulations and think all we have to do is put a cent success rate with that theory. little bit of gas in their system and all is fixed.’ ‘I like to think that our workshop is the ‘yes’ workshop – yes, we TaT put the question of how to handle these situations to can fix it given the time and proper remuneration.’ TaT director Deyan Barrie, who probably has done more air conditioning repairs in his day than most auto technicians. ‘I usually begin by answering their question with another question, such as: What makes you think your car needs a regas? ‘I want to get them engaged, so here’s a stack of other questions ENGINE and my own answers that I may fire into the conversation: So where do you think the gas is gone? PARTS www.etponline.com.au There is no such thing as just a regas, in fact it’s not even a word. You mean a system recharge? ®(03) 9357 0854 A recharge is only the last part of the service or repair of an air conditioning system. NEW PARTS: What do you do when you get a flat tyre? Surely you don’t just pump it up and drive off at 100km/h? Cylinder Heads First you’d look for a leak, right? Same thing applies to your a/c system. VRS Gaskets We will do a pre-inspection, then a close investigation and diagnosis to determine what your a/c system really needs, then we’ll let you know what the problem is and an Camshafts estimate of the cost of repair – because it will be a repair. Plus a range of Small Parts The diagnosis will be around $100 and if you don’t take our advice after that, you still owe us around $100. www.etponline.com.au Is there a history of previous work? What was it and what The easiest way to stay up to was the result? datewith ETP’s product range ‘The main thing is not to even talk about a price of repair. How can you know if you haven’t diagnosed the system?’ Deyan added. New Cylinder Head Kits ‘Don’t over-quote or under-quote, but seek their permission to take Bare Head - VRS - Valves - Head Bolts* the diagnosis a further step to remove the compressor and inspect *Head bolts are only supplied for some applications Find out more at www.newtrueblue.com.au the oil inside first. And yes, this is an extra charge even if we have 72 Killara Rd, Campbellfield Vic 3061 to pull the pin because of the black death. So the customer will know exactly where they stand, and they will not have wasted several hundred dollars without finding out what is wrong with their system. 03 9357 0854 The Automotive Technician 29 Volkswagen Bora V5

One is that the MAF sensor sensor was telling the truth Putting Scan Data was faulty and was lying to us. and there was a mechanical by Rod The other was that the engine breathing problem. was not breathing as well as through its paces Maher In this instance both LTFT and it should and the MAF sensor STFT were almost maxed out was telling the truth. This faulty mass airflow (MAF) road test, together with engine into the positive, so it was would be from something like sensor was suspected. size, IAT and BARO data clear that the MAF sensor an intake or exhaust restriction A were entered into the MAF was lying and it was under- Let’s do some driver’s seat or a mechanical breathing calculator. reporting. The MAF sensor was diagnostics to test the problem like valve timing. examined for contamination operation of this MAF sensor The calculator determined So which was it? and was clean. using a few live data PIDS on that with the given engine size a road test and plugging the and conditions the MAF value Easy, we used fuel trims. If the A new MAF sensor was results into the Volumetric should have been around fuel trims were heavily into the installed and the road test Efficiency and MAF Sensor 117.05 grams per second (g/s) positive, we would know that was repeated, recording new Calculator from the Scan Data. (pic 1). But we achieved only the MAF sensor was lying and test data. The new test data (Calculations are inbuilt into the 82.5 g/s, showing that the MAF the engine was breathing well, was entered into the MAF dynamic new TaT/Scan Data sensor was reporting 34.63% but the MAF sensor wasn’t calculator (pic 2). reporting it. product for TaT members only) under the expected value. Success. The MAF calculator On the scan tool, the following So the reported MAF value On the other hand, if the fuel showed a great result with the were selected: Intake air was way down. Did that trims were normal, the MAF new MAF sensor. temperature (IAT), barometric mean a new MAF sensor was pressure (BARO), MAF sensor, needed? short term fuel trim (STFT), No. All this test revealed so far long term fuel trim (LTFT) and was that according to the MAF engine speed (RPM). I hit sensor test results the engine record and drove around the wasn’t breathing as much air block revving the engine close as it should have under those to redline at wide open throttle conditions. (WOT) through the first two gear changes. But there are two possible scenarios that could cause this Then, the highest MAF and result. 1 2 RPM values during the WOT

he people behind the Inter-Ject Other photos show the remarkable ability fuel tank additives have been able of the Inter-Ject chemical to neutralise to demonstrate how fuel additives Fuel cleaning sulphuric acid contamination that occurs Tcan suspend water, neutralise acids in all fuel systems due to moisture and remove carbon from fuel systems. additive mixes and heat. In tests, contamination was reproduced by adding sulphuric acid to In all hydrocarbon fuels, including petrol a fuel sample and shaking the test tube and diesel, small amounts of sulphur with water, not to get the stain on the glass. The folded dioxide are present and when it comes tissue shows the subsequent carbon stain into contact with moisture, unavoidable in (pic 3 and pic 4). any fuel system, it combines to produce with petrol minute quantities of sulphurous acid. There are chemicals on the market that will mix with water, but have an affinity to This is what forms corrosion, resin and The suspended water is eliminated in the petrol and will drop the water back out of carbon, leading to restricted airflow and normal combustion process. suspension when added to the mix. lower engine performance. Recent tests on their formula show how TaT acknowledges the technical assistance Inter-Ject chemicals neutralise acid, the additive suspends and neutralises of Harry Holzmann at Blue Mountains Fuel suspend water, and remove resin and sulphurous acid. Injection & Brad’s Garage Lithgow NSW in carbon. Being an organic solvent, the formulation the preparation of this article. in Inter-Ject allows the chemical to mix with the water and not the petrol. The first photo shows 10ml of water on the bottom, with 20ml of petrol on top (pic 1). In the second photo, 20ml of the additive has been added to the mix, but instead of raising the level of petrol, the additive and the water are now 30ml of homogenised liquid (pic 2). This mixture will burn in the combustion chamber. Inter-Ject will not allow the 2. Petrol, water 4. Acid cleaned by 1. Petrol and water water to come out of suspension and will 3. Petrol and acid and Inter-Ject always be expelled during combustion. Inter-Ject The Automotive Technician 30 NEW & IMPROVED VALVOLINE FILTERS • Excellent filtration, efficiency and dirt holding capacity. • Inclusion of six Multi-Fit spin-on filters to the Valvoline range. • An oil filter range that suits most popular vehicles within the Australian market. • Manufactured with Cellulose-Glass Polyester Synthetic Blend filter media which is designed to improve efficiency without sacrificing performance.

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Magna mayhem Mitsubishi Magna 3 his vehicle was previously brought in for an engine miss. After carrying out a cylinder Tbalance test, the fault was isolated 1 2 to No. 3 cylinder. 4 Being a V6 the intake manifold had to be removed to gain access to the rear The faulty lead was replaced and by this time the rotor had arrived. After analyser readings were sent for analysis plugs. However, when the spark plugs were (pic 3 and pic 4). It was agreed that the coil removed, the fault became obvious. The fitting it and carrying out a road test, it ran like a dog, backfiring with a general lack was breaking down under load and the platinum spark plugs had not been replaced waveforms supported this diagnosis. for some time (160,000km) and tracking had of power. It was discovered that even though become an issue (pic 1). the new rotor was the correct part number, When voltage drop tests of power and all other brands, apart from Bosch, were ground circuits as well as captured All spark plugs, plug leads, rotor button and incorrect for this particular vehicle (pic 2). waveforms of the igniter proved the ECU distributor cap were replaced, minus the Finally all the parts were sorted out and the was functioning correctly, the ignition coil rotor that was on order. After reinstalling the was condemned. inlet manifold, the engine still had a miss. customer drove away happy – for about a month. The next complaint was that the A second-hand distributor which included After another balance test it was established vehicle suffered from a miss under load. After the coil was installed, and during a lengthy that the fault lay in No. 5 cylinder, under the testing with a five gas analyser and finding and strenuous road test, the car ran like a inlet manifold. This thing needed wing-nuts. the readings within range, a static resistance dream and according to the happy owner, When the manifold was removed again, it test on the ignition coil proved to be within continues to do so. specifications. The primary current and was discovered that the new No.5 plug lead Thanks again for all the help from the TaT secondary voltage waveforms were captured had been manufactured incorrectly and Tech Team. even though it was a deep reach lead, the on a Pico oscilloscope. Mark Rabone connector had been placed right at the top of After following the TaTassist basic checklists, Part time automotive lecturer the bend, creating a massive spark gap and we asked TaT for help. Captured waveforms Goulburn TAFE NSW an engine miss. together with G-Scan live data and gas

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The Automotive Technician 32 Is your workshop ready for extended service intervals?

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www.bgprod.com.au The Automotive Technician 33 customer wanted the air Lo and behold, they had done the original conditioning compressor Stuck without sticker for the Sanden compressor – my on a 1987/8 VL Walkinshaw lucky day. Commodore a sticker Jeff Smit The sticker was ordered over the reconditioned. internet at a cost of $35.00 and it This Sanden compressor, TR70 turbo was in the workshop within days rotary,A was in fair condition but had (pic 4). been sitting around for about 10 years The customer was most while the owner was painstakingly impressed (pic 5). restoring the vehicle back to its original condition (pic 1 and pic 2). 2 I pass on the details of Stick This 1 because they have produced The compressor was sent to our most of the decals and stickers for regular reconditioner, Ben Perry the VL Walkinshaw as well as many at Australian Auto Compressors other older Australian vehicles. in Milton in Brisbane. When the compressor came back the customer www.stickthisdecals.com.au was unhappy that the original [email protected] compressor identification label was gone (pic 3). A little research resulted in finding a South Australian company called Stick This, that can reproduce decals.

5

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The Automotive Technician 34 Letter from I hope it’s all over by the time America you read this by Julian Hentze

s a pseudo journalist, unwavering loyalty you would I never thought I see on the side of the Bathurst Faulty would be filing a story track. But unlike after those underA a desk like a war races, when we all pick up pressure correspondent, right in the our eskys and say ‘good race’ thick of it on the front lines. and go home in peace, this switch 1999 Holden Frontera political race we are having will OK, so I’m exaggerating, but continue to spew vitriol. there are days when it feels like his vehicle the front line. Only the bullets It’s like the race never stops was idling very tested are missing. and whatever you do, never high, at 1,800RPM for vacuum leaks. get caught wearing the wrong andT sometimes up to Everything else has faded into brand on your shirt. 3,000RPM with the foot It was the pressure switch insignificance while the world off the accelerator. on the power steering watches on in awe, or is that I am sure you’re all sitting at pump that was at fault. dismay, at the US general home, watching the news and The engine light did not elections. wondering if everyone has come on and there were no The switch was gone bonkers over here? codes. disconnected (a As I write this to meet my replacement was deadline, the election is weeks Most Americans I talk to are Replaced the idle air unavailable). away. Hopefully, when you pick watching the calendar and not control motor but no up this magazine, it will all be the news, just waiting for 9 difference. The idle speed was over and we will be spared the November, and wondering how checked when cold and at When the battery was operating temperature and constant flow of bullsh*t. two very unpopular candidates disconnected, it idled OK can be tripping from scandal while using powersteering. The best analogy I can give for a few minutes of driving to scandal, yet still be the only you for this election is you’re and then returned to the It was now idling OK. ones left that can possibly either a Ford man or a Holden same symptoms. Damien Coutts become our president. man. Tested the coolant sensor Active Autos Regardless who wins, it’s This election has exhibited and mass airflow and WHALAN NSW going to be a very interesting the same kind of stubborn, year.

The Automotive Technician 35 TOP offerings are worried that customer TECH Educate your education will drive potential customers away. But the research revealed that TIP customers clients appeared to be less concerned if education initiatives revealed to them t’s difficult enough for technicians the lack of differentiation on service to keep up with changing outcomes. Better yet, they were more I technologies, so how do you think likely to trust the workshop as a result of the customer is coping? a customer education initiative. Customer education is not advertising or The truth is that in the automotive marketing. industry, where marketing ploys and advertisements are continuously pushed While components may tie in with on consumers, customers are looking for advertising or marketing, they are genuine insights. In most cases, a well- certainly not the same. Advertising For years, conventional wisdom was developed customer education strategy and marketing attempt to persuade on that teaching customers too much about can be enough to influence buying an emotional level, whereas customer a product or service would give them decisions. education aims to make the consumer added leverage. TaT is producing customer focused aware of all relevant information about However, according to research, there educational brochures for TaT members the product or service being planned are actually considerable advantages to use. The first one, The good oil about for their car. So it follows that customer in improving customers’ service oils educates the customer about the education refers to a workshop’s knowledge. importance of regular servicing while role in providing customers with the The research suggested that efforts to the second, The risks of driving a diesel information, skills and abilities to in the city is about modern diesels and enhance customer knowledge were tied become a more informed buyer. how to keep them healthy and free of directly to trust in the services being carbon build-up. Historically, workshops have been provided. When coupled with a positive hesitant to educate customers for many attitude and outgoing personality from Make education a deliberate part of the reasons. Many believed that the more the educating workshop, the results are workshop routine. There’s plenty to be knowledgeable a consumer became, magnified even more. Despite these gained by educating your customers the more likely they might be to shop revelations, many workshops with about the how and the why of what we around and choose an alternative. average or middle-of-the-road product know.

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The Automotive Technician 36 , ,.... ,,, .. 1, . --..., --

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linton Brett brings more than 20 years of experience Here is his current course program: to diesel fuel injection. A fifth generation mechanic, All training sessions include dinner, booklet and three months Clinton diagnoses diesel faults around the world trial to Diesel Help phone assistance. Cby phone, email or video link and conducts live common Prices quoted are per person and all courses are limited to 15 rail diesel diagnostics training courses for all automotive attendees. repairers and the fleet servicing industry.

Saturday 12 November 2016, Six hours over two evenings of common Offline bookings: $440 by bank transfer, 8.30am to 3.30pm rail diesel fuel systems diagnostics. with 10% discount for groups of three Brisbane QLD, All Autos Advanced Online bookings: $395 Diesel Help Members: $352 Tuning, Geebung Offline bookings: $440 by bank transfer, ------Six hours common rail diesel fuel with 10% discount for groups of three Tuesday 6 December 2016, systems diagnostics. Diesel Help Members: $352 6pm to 9:30pm Online bookings: $395 ------Whittlesea VIC Offline bookings: $440 by bank transfer, Saturday 26 November 2016, Three hours training course for common with 10% discount for groups of three 8:30 am to 3:30 pm rail diesel air intake, VGT Turbo & EGR Diesel Help Members: $352 Ferntree Gully VIC systems diagnostics. ------Six hours training course for common rail Online bookings: $143 Tuesday 15 November 2016, diesel fuel systems diagnostics. Offline bookings: $165 by bank transfer 6pm to 9.30pm Online bookings: $395 Diesel Help Members: $132 Brisbane QLD, All Autos Advanced Offline bookings: $440 by bank transfer, Tuning, Geebung with 10% discount for groups of three Three hours common rail diesel air Diesel Help Members: $352 More information: intake, VGT Turbo and EGR systems ------www.dieseldoat.com diagnostics. Saturday 3 December 2016, [email protected] Online bookings: $165 8:30am to 3:30pm Clinton Brett 0432 738 003 ------Whittlesea VIC Training courses for 2017 begin in Wednesday 16 and Thursday 17 Six hours training course for common rail February. November 2016, 6pm to 9:30pm diesel fuel systems diagnostics. Check website for dates. Wyong Central Coast NSW TAFE Online bookings: $395

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TheAD_AUS_MAR16_TAT_HP.indd Automotive Technician 38 1 10/02/2016 08:13 The TaT Team takes networking very seriously – but what fun!

TaT’s newest director Rod Maher introduces the team to his Scan Data website, a new member product starting 1 January 2017

embers of the TaT Tech Team, new slant on our approach to our business Comments from others: with some invited guests, meet and personal lives,’ Jeff added. ‘Mark Mitchell’s examples of solving big a couple of times a year for Team member Rod Maher was the big transport issues was a great lesson in how Mwhat they call their ‘play day’. surprise of the weekend. His passion for to avoid over-complicating an issue, and They share experiences, fix problem cars, the Pico pressure transducer, the overlay instead, stand back and look for simple put new tools through their paces and visit program and volumetric efficiency was answers.’ exciting new auto facilities.It’s the best inspiring. networking weekend there is, and they ‘It’s encouraging to see that others have have a lot of fun doing it. The TaT Team at Mark the same passion as me for fixing a car’s Mitchell’s SuperTest fault properly the first time.’ The September weekend in Brisbane facility at Ormeau was organised by senior TaT Tech Team Maurice Donovan summed up: ‘When member Maurice Donovan who owns All you bring together a bunch of diagnostic States Advance Tuning. technicians who thrive on the challenges we all face when fixing the modern As TaT director Jeff Smit commented, motor car, we have a recipe for a good ‘It’s amazing what happens when you time. If I had to choose one highlight of get like-minded technicians together in a workshop.’ the weekend, it would be that our team member Rod Maher is not only a gifted The weekend began with an inspection of diagnostic technician, but a gifted trainer Mark Mitchell’s SuperCool and SuperTest as well.’ facility at Ormeau, between Brisbane and the Gold Coast. ‘Terrain Tamer’s senior engineer and arguably Australia’s foremost 4WD diesel ‘Mark’s stories related to his astounding expert, Allan Gray, is a great TaT supporter business journey were something I’ll and he enjoyed the Brisbane play day.’ remember for a very long time. His What makes the TaT network work so passion for getting whatever job done, well is that the team has formed firm ‘I feel as a mechanic we are fortunate to and done right, was brilliant. It turned out friendships, and ideas are quickly and have such an organisation of dedicated, to be a top rate mentoring session and easily bounced off each other in a non- knowledgeable people who are willing to his words of wisdom have given all of us a competitive environment. share their experiences,’ he said.

Diesel trainer Clinton Brett talks about common diesel problems

TaT Team member Gil Sher leads a diagnostic discussion

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The Automotive Technician 39 SPARK PLUGS For Most Makes & Models

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For your nearest ACDelco Stockist call 1800 ACDelco or visit acdelco.com.au Air is one of the biggest enemies in a diesel fuel system and it can enter a fuel Sucked in? system undetected. The scan tool won’t Don’t be misled by the tell you the system has air in the fuel. Air SPARK will not compress in a diesel fuel system. suction control valve fault Entire fuel systems have been replaced, by Clinton Brett only to discover that a $2 fuel filter drain 2 tap O-ring was the cause. Vehicles: All common rail diesel (CRD) I run the clear tube around the side mirror Diagnose to replace, not which keeps it secure without obstructing PLUGS Suspected failure: Suction control vision. valve (SCV) replace to diagnose You will be driving and looking for large air For Most Makes & Models Symptoms: Stalling, runs rough, surges I hear this all the time: ‘I’m going to bubbles when the fault occurs. or does not start and when it does start replace the SCV because it’s a common it stalls again. fault, they’re not expensive and it Running clear tube in and out of the pump will probably be due for one.’ Wrong will help diagnose the two possibilities. I Fault codes: Yes and no. If they are diagnosis. demonstrate this procedure in my training present it could be a variety, such as courses around Australasia. P0087, P0088, P0089, P0090, P0091, Workshops are trusted to diagnose P0092, P0093, P0094 and P1089. correctly the first time, so here’s how Air entering on the low pressure side to perform one of the easiest, low cost between high pressure pump and tank: diagnostic procedures that will help This could be caused by: n my early days of common rail determine if it really is a failed SCV. diagnostics, mechanics often sent Diagnostic procedure for detecting air fuel filter seals a European common rail diesel in a fuel system: fuel filter drain tap O-ring that should I(CRD) to us after they had replaced be replaced every second service the rail sensor, with the same fault re- Option 1- Install ‘The Eliminator’, a occurring. separate fuel supply (pic 1). perished fuel hose Before the introduction of the SCV on Option 2- Replace the existing fuel hose quick release fitting seals failure with clear tubing (pic 2). the Denso CRD such faults didn’t exist. cracked fuel tank pickup The European manufacturers, Bosch, blocked fuel tank pickup or dislodged Siemens and Delphi, used inlet metering internal tank hose. valves, fuel control valves and pressure regulation valves that had a low failure Air is visible on the return clear tube but rate. The Denso CRD system was different no air is entering the pump: to that of the European designed common The radial seal/drive shaft in high pressure rail systems and came with a new set of pump is worn. guidelines to diagnosing. This failure often occurs once the vehicle Around 2005 there were never-ending 1 has been at operating temperature for SCV faults which often were a result of the more than 30 minutes. Fuel viscosity plays different fuel quality from state to state, a big part in this fault. The hotter the fuel meaning the manufacturers had to make Use enough length of tubing to route the less viscosity, therefore less sealing some modifications to suit the different outside the engine bay between the fuel ability between the seal and the shaft. * conditions. Eventually the manufacturers SPARK PLUG TYPE APPLICATION PRICE filter assembly and the high pressure fuel The failure is likely in engines using timing got it right, yet there were recurring SCV pump so that it is visible while driving. Run chain or gear driven, and that have often REGULAR Coverage for most older vehicles on the road today faults that were not the actual valve failing. done more than 180,000km. and robust design, ACDelco Regular Spark Plugs are an $1.95 another clear tube to replace the return of SPARK PLUGS economical choice for solid performance. A fault would re-occur after the SCV the pump to either the tank or fuel filter, Bonus fault diagnosis when the fuel had been replaced. Yes, they do fail and depending on the engine design. in the tubes is clear (no air entering or Designed for today’s most popular vehicles, ACDelco’s you need to be sure your diagnosis was PLATINUM If the system contains ‘quick fittings’, I leaving the high pressure pump): Platinum Rapidfire® Spark Plug fits engines using regular correct the first time. Some vehicles, (RAPIDFIRE®) $3.25 have my ‘Optimus Primer’ kit, which has plugs, as well as newer vehicles requiring platinum FIT WITH after a new SCV is fitted, will leave the Timing chain is stretched. SPARK PLUGS performance 35 different fittings for diesel fuel filter workshop, travel a couple of days or a few This can be determined by using a scope, replacement and diagnostics. The kit hundred kilometers and the same fault scan tool, or audible or physical checking An ideal plug for vehicles requiring platinum performance CONFIDENCE includes a bulb type hand primer which DOUBLE PLATINUM or older vehicles calling for regular plugs, ACDelco’s would occur again. of the chain for stretching. SPARK PLUGS Double Platinum Spark Plugs can give up to $4.45 you may have to install to prime the 100,000 kms# of service in some applications. Air in the fuel system is one of the system when using the clear lines (pic 3 www.dieseldoat.com contributing factors. and pic 4). [email protected] DOUBLE PLATINUM Designed to last up to 100,000 kms# in most FINEWIRE applications, ACDelco Double Platinum Finewire Plugs $5.25 SPARK PLUGS are the ideal replacement for today’s newer vehicles

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For your nearest ACDelco Stockist call 1800 ACDelco or visit acdelco.com.au 3 4 The Automotive Technician 41 Clearly, we need to be able to temperature coefficient (NTC) Pull-up resistor see inside the ECM (shaded in devices that exhibit an unusual and two-wire blue). characteristic in the following ECM and 5.0 volts manner: as the temperature sensor regulated supply of the engine block increases, by Sam Nazarian and Jack Stepanian the resistance will reduce and Puzzled by your finding consequently the voltage at the ave you ever wondered that, whenever the plug is S terminal will also drop. why, whenever you disconnected from the sensor Temperature increases are measuring a connector, that the signal, S – = reduction in resistance sensor signal voltage such white wire, jumps to 5.0 volts, value = voltage decreases (at as a two-wire engine coolant you naturally suspect that there terminal S). temperature (ECT) sensor, has to be a pull-up resistor in series from the regulator to the and the sensor connector Open circuit ECT voltage 1 sensor (pic 4). is disconnected from the Whenever a voltage sensor, the voltages seem to This follows the mechanic’s measurement is taken with high jump up from, say, 1.7 volts the measured voltages are simple logic that if there was impedance digital multimeters to 5.0 volts? This story is for 1.7 volts (grey) and 0.15 volts no series resistor (with the 5.0 that normally range between 1.0 those who are puzzled by this (brown). The engine is warm but volt internal regulator) then the and 10 mega ohms, the voltage phenomenon. you decide to disconnect the voltage at the sensor signal connector at the sensor (pic 2) terminal (S) should remain measured in an open circuit If you already know the answer, and again measure the voltage constant whether the connector condition (pic 6) will almost keep reading because this story in an open circuit condition. is connected to the sensor or always be very close to that will be the first of a series of not. So you decide to redraw of the actual voltage regulator, articles that will probe not only the circuit diagram in a manner 5.0 volts. This diagram, so a three-wire sensor (pull-up and that is more alluring (pic 5). inexplicably redrawn from pull-down voltage swing) but a mechanic’s perspective also transistor to transistor logic ECT acting as voltage divider (based on Autodata’s original (TTL), driver circuits and more. diagram), illustrates how a This, and the mysteries of Following your previous high impedance measuring future circuits will be explained 2 deduction, this logical thinking device will have extremly low not from the pure electronic by default renders the ECT current draw, hence extremely sensor to be acting as a voltage engineer’s perspective, To your surprise, you measure low voltage drop. Thus, high but rather from a humble 5.0 volts on the grey signal divider (pic 5). impedance measuring devices mechanic’s perspective. Unlike voltage and no change on the Simply put, two resistors will have minimal effect on the any electronic dissertation, this brown at 0.15 volts. Puzzled are now in series acting as a voltage being measured while and the following articles will by your findings, you decide to voltage divider and, as can pull resistors are in situ. explain circuit principles and consult the circuit diagram. be seen, E being the sensor Most two-wire sensors will the mysteries that lie behind signal, earth will always reside In the diagram (pic 3) the either have a pull-up or pull- observed voltages, through the on a voltage of 0.15 volts. component on the left down resistor. Following the eye of a mechanic. (B30 – mass air flow sensor) Based on these deductions, the mechanic’s perspective and We begin with the simplest of and the component on the right resistance of the ECT sensor (B147 – throttle position sensor) (shaded in yellow) should be with logical deduction from the the scenarios and assume that share the same signal ground the same as the pull-up resistor circuit diagram (and with some ECT sensor voltages are under (brown wire) with that of the ECT (marked in blue). This then will voltage measurements) one can interrogation. (B24 - engine coolant form a voltage divider, equally easily ascertain the parameters ECT and pull-up resistors temperature sensor) centrally dividing the regulated voltage of a given configuration. placed and shaded yellow. So you decided to measure of 5.0 volts. So, the S signal The next article will explore the the voltage of the ECT sensor However, as the connector at voltage now becomes 2.5 volts three-wire sensors along with at the thermostat housing of a the sensor is disconnected from whenever the connector is their pull-up and pull-down connected. 1AZ- FE, 2002 Rav4, ACA21R, that of the sensor, the signal resistor configurations. voltage (S – white wire) is pulled ECT with NTC 2.0L. The authors thank Autodata for up to 5.0 volts and the signal characteristics While the connector is earth (E – brown wire) remains allowing reproduction of their connected to the sensor (pic 1) at 0.15 volts. ECT sensors are negative circuit diagram.

3 4 5 6

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4 Ensuring the sleeve is correctly fitted Lyontek 07 3624 9990 7b Close-up of the finished job PH 1300 BURSON (1300 28 77 66) www.burson.com.au www.pdmusa.com The Automotive Technician 45 ‘You want your car fixed, or not?’

ome would argue that technical skill and experience should count more than office or workshop Clean up your act Spresentation. That might be true for those customers who have known you for Concentrate on those things that are immediately apparent to a years, but if you are looking for new customers – and who isn’t customer, such as street appeal, staff uniforms, grooming and – their impression of you and your business will begin to form in non-verbal communication. the car park and the moment they walk in your front door. Combined, how these areas are presented can form an opinion And when times are tough, as they are now with consumer of your workshop as competent and your staff as knowledgeable. spending tight, workshops need every trick in the book to make an impression on customers and that means workshop appeal, Social psychologists who study the impact of image have determined that it takes just 30 seconds for someone meeting beginning at the street front, and employee image. you for the first time to form a whole laundry list of impressions There’s no great science attached to presentation. Everyone can about your character and abilities. do it, and it doesn’t need to cost a fortune. Now 30 seconds doesn’t give you time to pull out all your Sometimes, workshop owners have become so used to the way trade certificates, showcase your resume, or present character their business presents itself, that they can’t see the wood for references. It doesn’t allow any time to explain that you have the trees. In these cases, the best idea is to invite some friends years of experience, training and a substantial list of truly who you can count on to tell you the truth, to drive up to your satisfied customers. workshop and note those things which look bad and could be It’s in those first thirty seconds that customers form all those improved. different impressions based almost entirely on what they see – Start at the most visible places, like the front of your building, the your workshop, uniform, smile, and the rest of your non-verbal car park, the main entry and the front office or waiting room. communications. Appearances do count. You will be amazed at what a difference a coat of paint and a These first impressions will be lasting ones. When your visual good clean-up can do in the front office and a by-product you appearance and message is positive, the potential customer might not have expected will be an improvement in staff attitude you’ve just met will tend to assume that other aspects about you and morale. are equally positive.

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The Automotive Technician 46