June 2008

Issue No 3

The hybrid heart

A tisket, a tasket, who

used this silly gasket on
the Falcon EF?
In the relay race, its
always the quality that
counts - ask this Toyota
Camry
On this Mazda 121 Metro,
too much flashing can get
you into big trouble $99 gives you:
Trust a failing resistor in
this Honda Civic to leave the 12 months subscription
lights on to TaT

Six magazines mailed

to your postal address

Access to illustrated
solutions on line

Problem solving service

APPLY ON PAGE 31
 The Hybrid Heart

T
here is little doubt Jeff delivered a trial training dealing with ABS
Pages 4 - 6
that appropriate day at CoolDrives Melbourne and traction control
training, in anything headquarters, to great acclaim. systems.
and everything to do
with keeping the modern car Since then, a number of At another workshop,
on the road and the customer training programs have been Gil Sher will introduce
happy, is going to become sketched out and the fruits of technicians to hybrid
Stepanian is appearing at
the cornerstone of every some of these labours will be cars and hybrid servicing. This Wire & Gas in his own right
successful business. seen by delegates at the Wire is a whole new ball game for as a director of his training
& Gas Convention 2008 on the most technicians, and one of company, Amazing Visions,
The technician who is skilled Gold Coast in June. those areas where a lack of TaT is working closely with
in at least some of the vital knowledge can be a disaster, Jack and is helping organise
areas of vehicle technology will For a company so young, it is in more ways than one. (Read his training requirements and
command a respect akin to that with some degree of pride that our feature story.) tools.
of a brain surgeon. TaT was able to deliver four top
trainers out of the 10 to Wire & Breaking away from the TaT will have a strong
Gas organisers. traditional on-car training presence at Wire & Gas, both
It was for these very reasons through its trainers and in the
routine, TaT technical director
that TaT decided, right at the trade show. TaTs at Booth 43.
Some of the topics will be firsts Jeff Smit will deliver an off-beat
beginning, that it would include
for Wire & Gas, recognising training session which is simply In this issue, TaT is proud to
training as one of its key
that while the convention is about giving technicians a far announce a huge rollout of
products.
essentially for AC and auto better sense of their own worth. TaT training programs, putting
electricians, todays technician some substance to its promise
TaT had barely received its needs to understand, or Guaranteed to be an of helping the technicians of
ABN when Technical Director at least have a working entertaining session, Jeff Australia improve their skills.
Jeff Smit, with a lot of help from knowledge of, the electronics has developed an interesting
training guru Jack Stepanian, of the entire vehicle. equation which can be applied ...and how timely is this issues
had developed the first of a feature on hybrid cars, just
to the selling of ones skills as
series of training modules when record fuel prices hit
For example, Nick Murphy, a technician.
based on an introduction to the headlines. Nobody could
who writes Murphys Law for accuse TaT of not being street
electrics and electronics. TaT will be running a workshop While electronics guru Jack wise.
The team
Publisher Editorial contributors TaT Assist TaT Space
CONTENTS
The Automotive Technician Hayley Windsor TaT Train TaTs a Fact
Pty Ltd Ashley Teitzel Tips for Tat Are you ready for hybrids 4-5-6
ABN 27 121 589 802 Mark Mitchell
PO Box 101 are all registered trade names TaT training begins 7
GYMEA NSW 2227 International correspondent of The Automotive Technician
Julian Hentze - USA Pty Ltd. GM Hybrids 8
1 Cleg Street Andrew Kavanagh - Europe
The Automotive Technician Pty Industry in the best of hands 9
ARTARMON NSW 2064
Copy proofing Ltd publishes technical advice
Ph 1300 828 000 and actual case studies for the Carbon build-up 10
Fax 1300 828 100 Bron Robinson purpose of educating technicians.
tat@tat.net.au Global Goss 11
Advertising inquiries These advices are given in good
Vicky Murphy faith, and are based on actual Street Cred - with Hayley 12
Editor in chief workshop repairs. No guarantee
Ken Newton vmurphy@tat.net.au
is given, nor any liability accepted Bulbs and auto transmission 12
knewton@tat.net.au 0419 284 246 in respect to any published
07 5591 6274 advice. The Chickadee Celica 13
Fax 07 5591 8172 Design
Allan Green The Automotive Technician Pty
0438 569 517 Ltd is not responsible for the CCN CoolWorld Awards 14
CEO Design accuracy of any information
ceodesigns@bigpond.com contained in material submitted Dealers in the firing line 14
Technical editor
Jeff Smit by third parties and published
Printing in this magazine and accepts TaTs a Fact 15 - 16 - 17 - 18
jsmit@tat.net.au no liability in relation to such
1300 828 000
Bones Print Solutions materials or their content. The Ant did it 19
128 Cope Street
WATERLOO NSW 2017 Newsworthy articles or comments Best to start with the basics 20
Technical research bonesps@optusnet.com.au are welcomed, and should be
Deyan Barrie submitted to the Editor in chief. Murphys Law - Poor vacuum 21
dbarrie@tat.net.au Affiliated associations
02 9476 6277 VASA inc AAAE All material appearing in The Top Tools 22
Automotive Technician is
Vehicle Air conditioning Specialists copyright. Reproduction in whole
Technical advisers of Australasia or in part is illegal without prior
And after hybrids - electric 23
Jack Stepanian inc Australian Association of written consent from the Editor
in chief. TaTs a fact 24
Automotive Electricians
Nick Murphy
secretary@vasa.org.au All advertisers agree to indemnify Sydney college goes hi-tech 27
nmurphy@tat.net.au
the publisher for all damages
or liabilities arising from their The Sheriff on in-house repairs 28
Wayne Broady published or unpublished
www.broadyauto.com.au material. The last word - Les Bennell 30

The Automotive Technician 3

 Are you ready for hybrid repair?
by Craig Van Batenburg, MAT L1 AAM
Automotive Career Development Center
Massachusetts USA
Hybrid Training Resources since 2000
Are you in the hybrid repair business?
What does that mean anyway? Isnt
everybody who considers themselves a
general repair workshop open for anything
with four wheels that comes in the door?
What if you are an import specialty
workshop? Or more specialised in Honda
or Toyota? The more we ask ourselves
What do we fix? the clearer the answer.
The day a hybrid is driven or towed to your
shop, you will have to have an answer
right then, so why not figure it out ahead
of time.
This year, the first hybrids will be 11
years old worldwide and nine years old in
Australia. Time is not on your side.
Today, driving around Australia, youll see
the Honda Insight (2000-2006), Honda
Civic Hybrid (2003-2008), Toyota Prius
(2001-2008), Lexus RX400h (2006-2008),
Lexus GS450h (2007-2008), and the new
Lexus LS 600h L. In the USA you can add
fourteen more versions of hybrids.
From the outset, because I was able to
ride on a wave of interest in the hybrid car,
plus the fact that we could work on them, I
was able to command a better labour rate
than anyone else. I was seen as a leader
in our industry.
The Automotive Technician 4
...or would you rather suffer the
ultimate embarrassment?
Quite simply, I saw this
technology as our future.
Some auto repair shops are
ahead of the wave, some ride the
wave, but many get washed over.
Those workshop operators who
have attended my hybrid training
are now adding hybrids to their
service menu.
Sydney technician Gil Sher
added hybrids to his service list
almost three years ago after
flying to the USA to do my four
day course.
Gil learned what he needed to
know to safely start up a new
stream of his Gil-Auto service.
Even if you are just thinking
about hybrid service as part of
your business plan, you had
better start planning now.
Go to a course, buy a hybrid
book or DVD, and maybe even
a hybrid vehicle. Start now, as
many of your competitors may be
ready to pounce.
There are three ways to get into this
market, and three levels of service you can
provide.
Level one hybrid service is the simple
stuff, primarily preventive maintenance and
simple 12 volt items that require few tools.
First off you need to know that any orange
colored cable, wire, plastic plug or switch
should be left alone. Then, especially on
the new Toyota Prius, you must know how
to start and shut off the car.
Hybrids made by Toyota and Lexus (I
expect you know that Lexus is a Toyota
product) can drive on electric power only.
That means it can be in your bay ready to
go, with the engine ready to start up, but
all the while it is perfectly silent.
Stealth mode is
eerie to the uninitiated.
More than one quick lube shop has had a
Prius on the rack with the oil drained when
the engine started up on its on.
How to prevent this? Just turn off the key
and remove it if you have one. Keyless
entry requires your foot on the brake pedal
while your right hand presses the power or
start/stop button for a second. (pic below)
If the dash is
dark, the car is
off. The top-of-
the-line Prius
does not require
the key fob to
be in the slot on
the dash, so look
at the dash, just
above the speedo read out. If the READY
light is not illuminated it is off and so is the
car.
It is not exactly
professional to ask your
customer how to start
their hybrid after they
drop it off. Sort of makes
them a little nervous.
One other simple service that can get
out of control is a coolant flush on a
2004-2008 Prius. On this hybrid a three
quart hot coolant storage tank is fitted just
under the left headlight. (pic below)
Five hours after the car is shut down, a 12
volt pump starts, a valve opens, and very
hot coolant is circulated into the cylinder
head to keep it warm for restarts. If you
are unlucky enough to have bad timing,
just after you open the cooling system for
a flush or minor service, this pre-heater
system could give you a face full of hot
water.
To be sure, disconnect the pump. One way
is to pull back the left front fender inner
plastic liner, then reach in and disconnect
the motor. It is the only pump bolted to the
stainless steel round can.
If you know, and follow, the proper
procedures, then minor service to hybrid
vehicles can be done with a reasonable
level of safety.
Note - the dashboard on all hybrids has a
very advanced readout for kilometres per
litre. Most owners take this read out pretty
seriously. If you do something to their
hybrid that makes a change for the worse
in fuel economy, I guarantee they will
complain and ask you to fix it.
So what should we be careful of that can
hurt fuel efficiency? The weight of the oil. I
stress this as the hybrid computer uses a
very powerful starter motor, one so strong
it could hurt the engine if it cranked over a
stuck engine.
Because of this, a highly sophisticated
sensor called a resolver watches the
starter motor upon start up and reports in
milli-seconds the effort required to spin the
crankshaft.
If the calculated amp draw is too high, it
commands the starter to shut down.
You now have a no start
with a code that has
a definition of broken
crankshaft. Yikes!
All of this hassle because you installed the
wrong weight of oil! Heavy oil will also give
you fewer kilometres per litre. Also watch
tyre pressure and wheel alignment, as
either one will upset the kilometres per litre
readings.
Level two service is what I describe as
getting the hybrid high voltage stuff out of
the way.
Panel shops require this level, as do air
conditioning shops, transmission shops
and others that arent going to fix the
hybrid system. But those high voltage
cables, inverters, DC-DC converters, and
HV battery packs just need a quick remove
and replace.
At this level, you will be working with high
voltages. There is no agreement on the
amount of voltage and amperage that can
burn or kill a technician.
Most agree it is 60 volts at 1/2 amp
sustained for 30 seconds, but it does
vary. No matter what you believe, all
hybrid systems have more than the most
optimistic numbers, so training to a higher
level of safety is required.
Level one is book training level, level two
is not. Some technical colleges may be
offering hybrid classes.
TaT technical editor Jeff Smit (top), with hybrid specialist Gil Sher
about to explore the hybrid heart
Do you need a hands-on safety class or
is a classroom lecture enough? This is
always a student driven question. It sure
makes me feel more confident when a car
is available to practice on.
A lot has been written about hybrid safety.
One guy said to me, No electrician I
know owns or uses a pair of high voltage
linemans gloves. They are trained to work
safely with high voltages so they dont
need them.
I dont disagree. But, we dont do this
every day. The gloves are easy to get,
easy to use, and
not needed at
every step, so why
not use them? Is
one more level of
safety too much?
Or will HV gloves
be on the list of
lift locks, safety
goggles, guards on grinders, and the other
safety items that are overlooked daily by
many techs looking for speed? Time will
tell.
One thing is for sure,
high voltage and current
in combination is lethal.
What should any technician insist on if
they are going to remove and replace high
voltage parts?
A CATIII certified DVOM (pic below)
or digital volt ohm meter, 1000 volt rated
Class O rubber gloves, training and
experience.
The first time I removed a high voltage
battery pack I was careful. I used my
gloves and meter, and was successful. It
was not hard to do. What was holding it in,
where were the hidden clips, how hard can
I tug at this and that? The usual questions
we have when we first encounter a new
part.
Testing for high voltage after you have
read the manual and taken all the steps
suggested is the best rule of thumb. Just
like a gun, always check to see of it is
loaded before handling.
A loaded hybrid system is one with high
voltage still present. The only high voltage
you cant reduce is the voltage in the
nickel metal hydride (NiMH) battery box.
The HV battery box is always removed as
an assembly, placed on a rubber covered
or wooden bench and handled carefully.
Every other part, especially the capacitors,
should be checked with your CATIII DVOM
with your rubber gloves on as you expose
HV parts before proceeding.
Level Two repair should be done by a
good electrical technician.
NiMH batteries do not store well for
long periods of time in hot climates, so
recycling yards should be carefully chosen
when buying a used battery pack. Electric
power steering (EPS) requires a scan tool
after replacement of the rack.
After a HV power-up dont be surprised if
you see warning lights and codes. If you
know you did everything right, a couple
of key on/off cycles or road tests may be
required to re-set the MIL and allow the
HV battery level indicator to be properly
displayed.
The Automotive Technician 5
 Start with working
on the high voltage
system. Proceed
cautiously, wear
those 1000 volt
linemans gloves and
use a CATIII DVOM.

Remove the battery

pack one evening
in your shop with a
helper (no beer that
night!), taking the
time to test each
connection as you
go. I removed a HV
NiMH battery pack in
a new Prius in about
one hour. The level
of comfort is always
higher as you move
up the learning curve. Gil Sher realised as long ago as his
Remember to tighten apprenticeship in a low level auto repair
all the connections shop, that if he didn't do something for
well, account for himself, he would never succeed. The
every bolt and question he asked himself when he
washer. No leftovers finished his apprenticeship was "Do I know
on this job. it all or do I want to know it all?"

The hybrid system is, in some ways, an
emission control system, so regulations
may play a big part in the hybrid drive
system. All 12 volt batteries located in the
trunk require a special charger as they are
advanced glass mat (AGM). Read up on
the exact model you will be handling so
you dont assume too much.
Level three is doing it all. No dealership
for this customer. Nope, I am going to fix
this hybrid right here, right now. The can
do attitude is a must.
After the safety part is understood and
practiced, simple maintenance becomes
easy, tyre pressures are set properly,
jump starting is a no brainier, and hybrids
seem so normal you want to own one, you
are ready to jump into the deep end of the
pool.
Now the factory scan tool is required and
good information is very important. Tech
support will most likely come into play
as you proceed. Life is more interesting
at this level, but not necessarily more
profitable.
In time it will be, but you may have to
develop a marketing plan as well as a
solid business plan.
Once past these stages it is time to
practice. Check with your local automotive
college and see if they have a hybrid
already that you can learn on. Buying your
own hybrid is not a bad idea and used
ones are out there. A new company car or
SUV can do a lot to motivate you. To learn
any new skill, it takes desire, time, good
information, equipment, and practice.
Drive these cars so you
know what normal is.
Learn how to put the hybrid into gas-only
or electric-only mode for a drivability road
test. This will prove helpful before you
get in too deep. Is it the electric drive or
the gasoline engine that is causing the
problem?
On the Honda system locate the hybrid
safety/de-powering switch, and shut it off.
Make sure the 12 volt lead acid battery
is OK and fully charged. Then take it for
a road test. The hybrid will be running as
a normal gas only car. If the problem is
gone, look at the electric drive as your
culprit. On the Toyota system it is not that
easy.
The Automotive Career Development
Center (ACDC) is researching a way to do
a similar process on these makes so that
you know which system your problem is
in. Scan tools are very helpful, but we all
know too well that they can send us down
the wrong road, if misread.
As we learn more about hybrid
technology, its quirks and problem areas,
more experiences will be shared by all
involved.
Hybrids will continue to be sold, serviced,
crashed, modified, and abused.
Our job, as it has always been, is to be
there with a helpful smile, a trusted tech,
and a solution to their problem.
For more information, or if you would like to visit
America and book into Craigs course, go to
www.auto-careers.org
He invested in an Allen engine analyser
and spent every Saturday morning, in his
own time, hooking it up to different cars
belonging to friends and family, learning
how to use it and to diagnose faults.
Gil's view is that anyone who thinks they
know it all, can probably exist in the trade
for another five years, moving to the
bottom of a steadily descending slope.
Those who intend being in the trade for
an indefinite number of years need to
be committed to pursuing continuous
life-long education which is not always
easy. It requires dedication, plus an
ongoing investment of time and money.
Gil personally invests hundreds of hours
and thousands of dollars each year
on education, training and practical
experience for himself and his technicians.
He has also learned how to persevere
against uncooperative vehicle
manufacturers who are reluctant to provide
technical information to independent
workshops. In many cases they deny them
access to even purchase their scan tools.
Persistence, ongoing interaction with like
minded mechanics, and attending as many
trade courses and conferences as they
can, is a way of life for Gil and his staff.
He says that flying his mechanics
interstate to attend courses, and sending
them to the USA to attend international
conventions is an essential investment for
his business.
Gil was the first Australian technician to
attend the ACDC hybrid training school in
the USA in 2006, and has given TaT the
inspiration for this special feature.

The Automotive Technician 6


The training programs, which
were always going to be an
essential product of TaT, will
begin rolling out nationally
through the second half of this
year.
The first program has been
put together by CoolDrive
Distribution, with TaT providing
the program, and VASA
providing some technical input
as well as its sponsorship
blessing.
TaT is negotiating with other
major manufacturers and
distributors to supply the
iSHOP
Your personal 24/7 online shop!
SAVE TIME
* No more waiting on hold
during busy times
* Order or browse after hours
SAVE MONEY
* iShops cost savings are passed
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* Regular iShop only specials
TATDec07.indd 1
training and content for a range
of training events. These will
be announced on www.tat.net.
au as soon as possible.
The CoolDrive program is
designed to be an ongoing
process for auto electrical and
air conditioning, to ensure that
industry specialists are brought
up to date with the latest
technologies and concepts.
As CoolDrives Trevor
Humphreys puts it, The first
course will be an introduction
to more complex issues to be
covered in future courses.
iSHOP
2008
19 July Melbourne
CoolDrive Box Hill
Contact:
Chris Bent 03 9896 7333
26 July Perth
Bel Eyre Hotel
Contact:
Gary Lings 08 9347 8333
9 August Darwin
CoolDrive Berrimah
Contact:
Adam Hudson 08 8944 3200
23 August Adelaide
Manhattan Motel
Contact:
Daryl Brougham 08 8347 1155
Registration fees are
deliberately being kept to a 4 October Townsville
low $175 for the day, including CoolDrive Garbutt
lunch. Contact:
Gary Powell 07 4755 2111
The training will not focus on
CoolDrive or its producs.
systems, multiplexing and
We know that CoolDrive
serial data communicaion,
benefits from a strong and well
principles of refrigeration and
trained industry, and we are
circuits, diagnostic procedures
enabling specialist trainers like
and techniques, and common
TaT and VASA to effectively
system faults and case studies.
and efficiently run the courses,
added Trevor.
All sessions are on Saturdays,
from 8.30am to 5pm, and
Course One will cover basic
include morning and afternoon
electrical and electronic theory,
teas, lunch and question and
power, charging and electronic
answer time.
CoolDrive iShop will even let you
check the status of your account or
search through previous orders.
To obtain a log in, simply call your nearest
CoolDrive Branch or visit the CoolDrive
website and well have you up and running
in no time.
The CoolDrive iShop web site can be found
by following the links at www.cooldrive.com.au
20/12/07 10:15:39 AM
The Automotive Technician 7
And you thought depending on engine and vehicle
application.


using a more powerful electric
motor to enhance engine

conventional
efficiency
The next-generation GM Hybrid System extending fuel cut-off during

technology was
will build upon the successful belt- deceleration
alternator-starter hybrid technology extending regenerative braking to
currently available in a number of current
moving fast
recapture more energy
GM models in America. By building on performing intelligent hybrid

stand back!
General Motors has announced a second-
generation version of the GM Hybrid
System with a new, more powerful lithium-
ion battery.
Hitachi Vehicle Energy Ltd will supply an
advanced lithium-ion battery which will
help make the next-generation GM Hybrid
System nearly three times more powerful
than the system it replaces.
Overall fuel economy improvements
for cars and trucks using the system
are expected to be up to 20 percent,
this proven technology, GM will be able to battery charging.
make the GM Hybrid System more cost-
effective. For additional energy savings, an
advanced six-speed automatic
The increased power from the lithium-ion
transmission also may be used, depending
battery will allow the next-generation GM
on the vehicle application.
Hybrid System to be used in a wide range
By the end of 2008, GM will offer nine
of global powertrains, including naturally
aspirated engines, new high-efficiency hybrid models on the worldwide market.
turbocharged engines, bio-fuel engines,
and diesels. GM will introduce 16 new hybrid vehicles
over the next four years. Here in Australia
The new GM Hybrid System helps we wont be far behind.
optimise fuel efficiency and reduce
emissions by: So if you are one of the newer breed of
technicians, you cant go wrong if you
turning the engine off at idle learn all about the new technologies as
offering brief electric-only they become available.
propulsion

Ferrari to drive next season A1 grand prix

London A1GP World Cup of
Motorsport has revealed the first image
of its brand new Powered by Ferrari car
for use in season four (2008/09). The
drawing was released ahead of the cars
inaugural shakedown test in England.
Formula One legend John Watson will
have the honour of driving the car for
the first time, powered by a V8 Ferrari
engine producing in the region of 600
bhp.
The chassis is based on the
design of the highly successful

Century makes F2004 chassis, incorporating

A1GPs core values to deliver

you more attractive...

close, exciting racing among
a competitive field where
overtaking is an essential part
of the entertainment.
The A1GPs sub-assembly
technician, Cheyne Bromfield
of Sydney, was featured in the
April edition of TaT. BELOW Roy
...to customers Hingston, Number 1 mechanic for
Team Australia, reads up on the
feature. The pic
was taken at
Customers are attracted to Century resellers because they sell Australias Brands Hatch in
leading battery brand. Resellers stock Century because it allows them to the UK where the
maximise margins, it increases the profile of their business and makes
selling batteries really easy. Century also has the most comprehensive
team is preparing
battery distribution network in Australia. for its next outing.

For more information call Century

1300 362 287

www.centurybatteries.com.au

The Automotive Technician 8

The industry is in the
very best of hands

From left to right: Andrew Berta (auto electrical teacher), Mitchell Madden,
winner of the Worldskills Award and TaT Encouragement Award, and TaT
Technical Director Jeff Smit. The other Worldskills winner, Justin Moore,
received a similar award.
I left with a great feeling that Auto Electrical -
our industrys future is in safe Stage Three
hands with the next group 1st Martin Rowling
of mechanical graduates 2nd Justin Moore
showing that they are up to the
challenges that lie ahead. Albert Durst Award
Auto Electrical - Highest
That was the enthusiastic over all three stages
reponse from TaT director Jeff Colin Evans
Smit, after he had presented
a complimentary subscription Worldskills Gold Medal
certificate to one of the up and winners, who will represent
coming leaders of tomorrow at their areas in the national
the 2008 awards presentation Worldskills later this year in
at Wetherill Park College in Sydney:
Sydney.
Mitchell Madden (Sydney)
The awards night was for Justin Moore (Sydney West)
automotive mechanics, light
mechanical and auto electrical Light Mechanical -
courses. Stage One
1st Christopher Hope
The South Western Sydney 2nd Vince Panuccio
Institute is the largest institute
in Australia with more than Light Mechanical -
74,000 enrolments across a Stage Two
range of subjects, from short 1st Tyrone Hadfield
courses through to advanced 2nd Tuan Nguyen
diploma and graduate certificate
courses. Light Mechanical -
Stage Three
The automotive department is 1st Tony Land
working hard to keep up with 2nd Adam Buhagiara
the rapid changes in vehicle
technology, even opening a Engine Reconditioning
new state of the art testing and 1st Michael Styles
training laboratory.
State Award
The award winners were:
For apprentice with highest
Auto Electrical - Stage One average mark on completion
1st Matthew Atkinson of the Certificate III in
2nd Matthew Xiberras
Automotive (Mechanical-engine A.D.R. A.D.R.
reconditioning) Course 2007: APPROVED APPROVED
Auto Electrical - Stage Two
1st Brad Bishop
2nd Mitchell Madden Michael Styles

The Automotive Technician 9

 A high price for new technology

M
ost technicians are
well aware of the
problems that are
caused by carbon build-up
within the inlet manifold
and especially around the
throttle body. Not only does
the carbon soak up fuel like
a sponge, but if the carbon
spreads it can even cause
a compression miss and
perhaps set a DTC.

As history has shown many

times before, new technology
brings about new problems.
One such problem is the
build-up of carbon. Take the
inlet manifold, for example.
In bygone years, we had a
carburetor (remember those?)
sitting on top of the engine.
Fuel was delivered above Deposit buildup from ordinary fuel After 10,000km on BP Ultimate Unleaded
the throttle plates which were
awash in petrol, one of the
BP Australia has even taken it The pic on the left, shows two clear up after the vehicle builds
worlds great solvents. There
a step further and conducted carburettors. The one on the heat. Diagnosis is relatively
were no carbon build-up
tests on engines with amazing left is from an engine after simple if the problem occurs for
problems because they were
results. continuous use of BP Ultimate you, but catching it may require
washed clean by a swirling flow
Unleaded and, as you can see, some cooperation between you
of fuel laden air.
The pics above show fuel it is significantly cleaner than and the customer.
intake valves before and the one on the right which was
after running on BP Ultimate taken from an engine that had You may need the car for a
Unleaded. The valve on the been running continuously on couple of nights to pin it down.
left is heavily coated in black, ordinary fuel. A quick inspection of the
carbonaceous deposits and throttle body will give you a
was taken from an engine The advanced cleaning good indication of the extent of
which had been running properties of BP Ultimate carbon build-up.
continuously on ordinary fuel. Unleaded can contribute
In sharp contrast, the one on to improvements in engine There are lots of products on
the right is the same valve performance such as power the market for cleaning throttle
Most technicians on the bodies, but again, which
after switching to BP Ultimate output, acceleration, fuel
workshop floor have already ones are safe to use on what
Unleaded and running for economy, and reduced exhaust
found vehicles with very dirty 10,000 km. emissions. systems?
inlet manifolds and throttle
bodies even to the point where
they cause some components Most of the The condition exhibits itself Send TaT your thoughts and

to stick and fail. Customers
complain of loss of power or
fuel economy.
We have all seen the
advertisements promoting
the use of high octane petrol,
because it keeps the inside
clean. The quality of the fuel
used has a big bearing on the
long term condition of the inlet
manifolds.
Most of the oil companies
have done their own research
and have proved that running
vehicles on higher octane fuel
has a great effect of keeping
new engines clean and even
has the ability to remove most
existing deposits that ordinary
fuels leave behind.
The Automotive Technician 10
existing deposits most dramatically when the
engine is cold. Customer
ideas and tell us what works
for you?
have been complaints will be along the
removed and the lines of crank, no-start, or starts TaT wishes to acknowledge
previously dirty but runs roughly and seems to and thank BP Australia for
information and photos.
valve is now
virtually as clean
as new.
The outstanding engine
cleaning properties of BP
Ultimate Unleaded cannot only
clean away existing deposits
to help achieve improved
performance but, in tests,
prevented an average 97%
of deposits from forming in
the engine. This means that
if your engine is new, fuelling
continuously with BP Ultimate
Unleaded can help keep it
clean.
Aint this new technology just
grand? Dont applaud yet!
from Julian Hentze, our man in Georgia, USA
snapped in a line-up with his new workmates
By now you would gather from watching
American television and movies that
there is a service called On Star that
is somehow related to American GM
vehicles.
It is quite ingenious. Apparently certain GM
vehicles are fitted with a GPS transponder
so, when your vehicle is involved in an
accident, enough to activate an airbag,
it sends a signal back to General Motors
where an operator contacts you in the
vehicle to see if you require assistance
and, if so, they contact all relevant
emergency services with your exact
location.
You can also contact On Star via a button
on your rearview mirror if you require
directions from point A to point B. It is
downloaded directly into your vehicles
entertainment system with point to point
directions to your destination. Pretty Cool
stuff.
From what I am told, its apparently the
start of OBDIII, where the vehicle has the
ability to report back to the manufacturer.
It can alert the local dealership when the
vehicle is due for a service, or when it
requires replacement parts through the
wireless network fitted to the vehicles
ECU. The dealership then contacts you,
tells you what your vehicle requires, and
organises a time for you to come in.
But it is creating a stir with the civil
libertarians. Why? All this is pretty good for
the vehicle owner, right?
Its the other things it can do that are
making people nervous. Rumour has it
that vehicle manufacturers are also trying
to keep on top of vehicle emissions.
Apparently the ECU could monitor
the vehicle emissions and, when out
of balance, send the data back to the
manufacturer or state emissions legislator
who then sends the vehicle owner a letter
or email with a demand to repair the
vehicle emissions within a certain time or
face a fine. One US state is talking about
making this law.
And if you are thinking of ignoring this
demand, the vehicle can be remotely shut
down so it can no longer pollute.
Fantastic technology, but imagine being
the technician at the receiving end of a
phone call from your customer when their
car failed to start because it was runnning
just a little rich.
the global goss
...now THIS is a
convention
from Andrew Kavanagh, our man in Antwerp,
Belgium, on guitar with daughter Claudia.
scales and a manifold set. They even set
While most of you in the southern
hemisphere are taking a breath after your
summer, ours is just heating up.
Last year Western Europe recorded one
of its coldest ever, with the average daily
temperature in Melbourne surpassing the
top here (and this was in July, supposedly
Belgiums hottest month). All I can ask is
that you cross your fingers and toes for our
mercury to climb above 20 this July!
Since Im the column writer, I intend to give
myself a plug. CPS Products has launched
a new automotive recovery machine,
four in one unit (AR2788E). This is pretty
revolutionary stuff using technologies
never seen in a machine of this calibre. I
have been personally busy launching this
in Russia, Denmark, United Kingdom and
Germany.
Did you know that every workshop here in
Europe possesses and uses equipment
like this recovery machine. I struggled with
the concept when I first arrived here.
No technician just buys a vacuum pump,
these large units up in the back of vans,
strange as it might seem to the Aussie
technician. I guess that is another feather
in the cap of the Australian way - versatility
at its best.
This month also sees me organising
and preparing for trade show season in
Europe, with Automechanika, European
Automotive Airconditioning Convention and
Chillventa. All three shows are within an
eight week period and I am beginning to
pull my hair out already.
Some interesting facts about these
conventions are mind boggling. For
example Automechanika in Frankfurt,
Germany is the worlds largest automotive
trade fair, with more than 4,600 exhibitors
spread over 10 halls and some of the halls
have three levels.
It is truly a trade fair to blow your mind.
If you were to visit every hall and every
booth, it would take more than a week just
to walk the show.
They have shuttle buses to take you from
hall to hall. Automechanika is held every
two years and in September 2006 nearly
160,000 people visited the show.
On reflection, exhibiting at VASA (Wire &
Gas) was a piece of cake.
However, if you are planning to visit
Germany for the show be sure to look me
up or send me an email and Ill give you
a tour (of the CPS booth and some local
watering holes).
The picture above is one of a few taken
for an article in an expatriate magazine
called (a)way, which features international
families living in Belgium.
Anyhow tot ziens - thats see ya later in
Flemish.
The Automotive Technician 11
 street cred with Hayley Windsor

L
ets face it we mere mortals
havent a clue whats going on
inside our vehicles and, with a
huge increase in computerisation,
electronic extras and hybridisation, the
chances of improving our understanding
are bleak.
We place a lot of trust in your hands when
we enter your workplace. And, from the
research, Ive gathered it seems were
unanimously sceptical of auto technicians
until they prove themselves.
This explains why I was fuming on the He explained that my next service would
way to collect my car after its last round of now be less costly and that my vehicle is
repairs.
The phone conversation, not 10 minutes
earlier, had ended with my abrupt
statement, but you only quoted me
$500-$700.
I resisted the temptation to carve my
initials with a key on the door of the dry and more styling and more product. If
technicians shiny, customised ute parked
out front, but later, I was glad I resisted.
On the counter, between
the cool, calm auto
tech and my seething,
frustrated self, lay an
assortment of parts as
familiar to him as they
were foreign to me.
They could have been the
innards of an industrial
kitchen sink for all I
knew; and the fact that
he recognised this,
maddened me more.
He began a show-and-tell
about the parts of my car,
what he had repaired,
what he had replaced and
his justification for the
extra costs.
now in top condition. He maintained eye
contact and as I listened intently, the heat
on my side of the counter subsided.
Its like a glamorous lady trying to explain a
$100 hair style to her balding man. Theres
the equipment, the hair product, the wash,
the massage, the styling, the cut, the blow
you laid all the products, utensils and the
before-and-after-shots on the counter, he
might have a better understanding.
With cars, as with haircuts, a greater
understanding doesnt make the cash
transfer any easier, but its reassuring to
know exactly what your money is being
spent on.
Its lucky that Im a rather carefree
and frugal hair-care consumer myself,
or I might have struggled to pay the
unexpected extra costs for my car upfront.
Either way, my auto tech had earned my
respect through patience and simplified
explanations. He had spared himself any
confrontation and secured himself a repeat
customer.
Hayley, and partner Todd Preston were
snapped in Thailand en route to settle in
London. Hayley will be writing from the old
country about things automotive.

We hear neutral at idle and lurching into

stories about gear on take off.
automatic

Diagnostic
transmissions Some repairers waste an
playing up in late extraordinary amount of time
model cars and the looking into transmission
causes are weird. problems, when the solution is
. quite simple.

Motorists with a gear
changing problem have been
caught out and so have some
repairers.
The answer could be as simple
as two blown stop light globes.
N16 Pulsars come to mind. The
latest was a 1999 TS Astra.
. on as possible. Try tail, stop,
The centre stop light worked,
but both outside globes were
out. The centre hi-level light is
a bunch of LEDs, therefore no
load and no signal to earth.
This was affecting the gear
changing - not going into
problems?
In our electrical training
program, one of the first steps
in our diagnostic procedure is a
full loaded light check, which is
now a must.
Turn on all the lights with the
engine running and as many
electrical circuits switched
hazards and reverse lights all
on at the same time, together
with AC, rear demisters and We have your solutions. Distributors for Launch,
even the front and rear wipers. AutoBoss, BulletPro, ADD, Boyce Publications,
Electrajet interactive, Electrajet Data, simply call
You are more likely to pick up
Terry on 0418 649894
an earth or wiring problem with
a loaded light check.
or Garry on 0417 023887. PROBLEM SOLVED.

The Automotive Technician 12

 Specifications:
Engine - 1968 cc twin overhead
cam Toyota engine with Yamaha
competition head, Cosworth pistons
and Carillo connecting rods and
otherwise modified to accommodate
a dry sump lubrication system.

Fuel injection - Lucas mechanical

injection with specially machined
slide throttle and inlet trumpets (set
up by Barry Seton and John Skola
together with Graham Wilkins who
still maintains its engine).

Power - 187 bhp (139kW) @ 7,500

rpm

Torque - 145 ft lbs (196 N.m) @

At the 2006 Australian Hill Climb Championship at Bathurst where the Chickadee Celica 6,000 rpm

T
won its class but did not break the class record which Beach had set back in 1988.
Weight - 960 kg
here would be few car raced the Chickadee Celica (See the race, including the
racing fans anywhere with considerable success. shots from the on-board camera Gearbox - 5 speed close ratio
in Australia who at http://www.youtube.com/ Toyota gearbox with Hollinger gears
havent heard of the According to watch?v=TvWFMOF7CWU)
Chickadee Celica. Toyota, the While Beach Thomas is
Clutch - Twin plate Borg & Beck
competition clutch
The most bizarre combination Chickadee Celica obviously enthusiastic about
of chicken food sponsor and is the most his cars performance in
Brakes - Four-piston disc brakes

successful Toyota
front and rear
incredibly gutsy historic circuit current historic motorsport,
racing car has captured the circuit racing car he recalls his first year of Wheels - 10 inch wide x 14 inch
imagination of racing fans at
all of Australias iconic race
in Australia. ownership in 1986 with diameter Simmons wheels
particular fondness.
tracks since the RA40 Toyota Fuel tank - 100 litre long range
Peter Williamson, a Toyota
Celica GT2000 was first raced In that year the Celica won
dealer at Liverpool, originally
in Australia in 1979. its class at the Australian
imported the car for racing in the Phillip Island, Queensland
1979. He modified it to meet Hill Climb Championship at Raceway and Wakefield Park
The Celica held the class Collingrove in SA (setting a
Australian Group C touring car circuits, proving that after
records at most Australian new class record for the hill
regulations and raced it under almost 30 years of competition
circuits during its long and breaking all other Group
the sponsorship of his Toyota it is still a top performer.
competition history as a C class records for the hill),
dealership.
Group C Touring Car and, was second in its class in the
as a consequence, became Beach expects to be racing the
Its second owner was Graeme NSW Hill Climb Championship
well known as the Chickadee (setting new class records at Celica at the Australian Muscle
Bailey, who acquired it in
Celica. Its then owner Graeme many of the hills, subsequently Car Masters at Eastern Creek
1980. He raced it successfully
Bailey was known as Chicken winning the class in 1987), on 7 September 2008 (Fathers
throughout 1980, 1981 and
Man and the car still carries and was a member of the Day) and at the V8 Supercar
1982, having upgraded its
his nameplate at the rear. outright winning team at the meeting at Oran Park on 6 and
engine to fuel injection in 1981.
6 hour relay race at Amaroo 7 December 2008.
Current owner and driver
The Celica is today presented Park Raceway (subsequently
Beach Thomas has retained If you want to see it in action
in the same specifications and repeated at Oran Park
the historic integrity of the you know where to go.
signage as raced at Bathurst in Raceway in 1987 and 1988).
car, restoring it to its original
the 1982 James Hardie 1000.
Chickadee Celica racing
As a current historic Group C Beach would be delighted to
signage.
In both circuit and hill climb touring car the Celica holds the say hello in the pits and show
events the Chickadee Celica under 2 litre class records at you over the Chickadee Celica.
Chickadee Chicken was a
proved many times it was no
substantial family run chicken
chicken on the track.
food company at Ourimbah
north of Sydney which is now
In its first year of racing, it
owned by Inghams.
was first in its class and a
remarkable 9th outright in the
The cars current sponsor is the
1979 Hardie Ferodo 1000 at
Sydney CBD law firm Thomas
Bathurst.
and Company of which Beach
Thomas is the principal.
It also made international
history in that race by
Beach Thomas himself has a
becoming the first racing car in
reputation in racing as long as
the world to carry an on-board
his beloved Chickadee Celica
television camera (designed
with an active involvement in
and installed by Channel 7),
motorsport since 1979. July 2004 during an historic race meeting at Queensland Raceway
with commentary by Peter Chickadee Celica was the quickest in the under 2000cc class and set a
Since 1986 he has owned and
Williamson. new historic class record for Group C Touring cars which still stands.
The Automotive Technician 13
 The pride of VASA
A rising star of Australias automotive air conditioning
industry was annointed at the inaugural CoolWorld
Industry Awards in Melbourne in April.

Steven Tiniakos, proprietor of Sydney-based Celsius Air

Conditioning and Refrigeration, was the first ever winner of
the Mobile Air Conditioning Technician of the Year award at
a glittering dinner at the Peninsular function centre in the
Docklands.

The judges, led by Mark Padwick, president of award

sponsor - the Vehicle Air Conditioning Specialists of
Australasia (VASA), called Tiniakos a an outstanding
ambassador for the mobile air conditioning industry.

The 27-year-old has gone to great lengths to train and

Above: VASA president Mark
Padwick presents Sydney
technician Steven Tiniakos,
proprietor of Celsius Air
Conditioning and Refrigeration,
with his CCN CoolWorld Mobile
Air Conditioning Technician of
the Year award. Left: Melbourne
finalist for the award was Steven
Manassa, technician at Kar Air
in Victorias Fern Tree Gully. At
right is workshop owner Andrew
Robertson, who nominated
Steve for the Award.
educate himself in all aspects of the trade as a licensed
technician in both mobile and stationary air conditioning
and refrigeration, a post-trade qualification and a teaching
qualification - Certificate IV in Training and Assessment.
The training required extensive overtime and voluntary
weekend work to get up the necessary hours. Steven has
also spread his wings, working on AC systems on buses,
coaches, trucks and cars in both Australia and Europe.
Steven is also to be particularly commended for pursuing
a part-time teaching role through TAFE, while staying on
the tools, added Mark Padwick.

Dealership service back in the firing line

The independent consumer
watchdog, Choice, has claimed
somethings going wrong with
car dealership service centres,
which performed quite poorly in a
Choice shadow shop conducted in
Sydney.
Choice hired a top mechanic to introduce
four basic faults into various makes of
cars, and then sent a female shadow
shopper to 28 Sydney dealerships with the
faulty vehicles.
The results, in anyones
terms, were devastating.
Only three of the dealership service
centres picked up all four basic faults, with
Choice telling its readers and any member
of the public who would like to read it on
their website, that motorists cannot rely on
the quality of service they will get from a
dealers service centre.
Despite the fact that the car makers
reinforce the customer expectation in their
own literature, it appears that for every
dealer that delivers a competent service,
theres another that will take the motorists
money and give second rate advice. In
this case, they missed vital and obvious
faults which needed fixing for safety and
road worthiness.
For a full report on this state of affairs with
dealerships, visit www.choice.com.au
TaTs view is that a similar study of the
aftermarket workshops would probably
turn up the same result.

. . . you'll just have to get the

new UNICLA catalogue
- now available
With new 14 cylinder technology, UNICLA has
taken the grunt and sweat out of installing big
compressors for big jobs. Weighing in at 24
kilos, our 600cc compressor can chill out a big
coach.and our other 28 new models cover
everything else.

Call now for the new

catalogue - 1800 628 133 Australian
Distributor

See the latest models at Stand 28 Wire & Gas

The Automotive Technician 14
 FOREF96112
FORD
FALCON EF
06/1996
6 cylinder
Customer complaint
Poor running. Flat spot on take
off. Vehicle has had recent
cylinder head work.
Problem summary
Vehicle worse when cold and
improved slightly when normal
operating temperature was
reached.
Vehicle had recent head work
and problem was evident since
then.
Diagnostic sequence
First checked fuel pressure and
flow. OK.
Check engine timing.
Remove rocker cover
and check internal
engine timing.
On four gas analyser at idle and
at cruise, Lambda 1. Good.
Hard acceleration and it
hesitates and pops back as if
lean.
Removed the injectors and
found that incorrect inlet
manifold gasket was fitted.
Fault description
Gasket was covering half the
hole of the injector effecting the
spray.
When previous work was done,
the incorrect inlet manifold
gasket was fitted. There are
a couple of different gaskets
available for different engine
types.
Fault solution
Replacement of the inlet
manifold gasket with the correct
one.
Recommended time
Labour time was 3 hours, taking
into account research time,
location of parts and actual
time spent fixing the problem.
Whenever replacing gaskets
always size up against the
old gasket if possible and
against the two mating
surfaces.
When faced with a vehicle with engine or running problems, TaT
recommends that you start with the basics.
1. Check engine oil for quantity and quality
2. Check battery, quantity of electrolyte, terminal condition and charge
rate(more on this in the next issue)
3. Check air intake system, air filter, security and condition of ducting and
condition of throttle body
4. Check spark plugs, check condition, gap and deposits
5. Check all vacuum hoses and connections
6. Check all wiring looms and connectors
After all these basic checks are done, then proceed to access the ECU fault
codes.
The Automotive Technician 15
 HONCI00440
Honda
Civic
04/2000
Customer complaint
Airbag light staying on (SRS
Light).
Problem summary
SRS light illuminated about
one week prior and has been
on whenever vehicle has been
operated.
Diagnostic sequence
General inspection of vehicle
and SRS components, wiring,
airbags, seat belt tensioners
and wiring. All ok.
Connect aftermarket or factory
scan tool and check for fault
codes our scanner came up
with two codes :-
PAB open in inflation circuit
Increased resistance in
PAB
Both of these codes imply a
fault in the passenger airbag
system (PAB).
On further investigation it was
noticed that the vehicle was not
fitted with a passenger airbag,
only a drivers side airbag
system.
Note: As with most airbag
systems, the SRS Electronic
control module (ECM) fitted, is
a full system, multiple airbags
module.
Therefore there must be a
dummy connector, or resistor
to replace the PAB.
The Automotive Technician 16
Fault description
The car has a problem with
the resistance shown to the
computer in the passenger side
airbag circuit due to the resistor
failing.
Fault solution
Locate and inspect the wiring
and connections at SRS
ECM. The ECM in this model
is located behind the centre
console mounted on the raised
floor pan to the right of the
glove box.
Trace wiring to locate dummy
resistor. In this model it is
located near the ECM in a
yellow connector.
The dummy resistor is blue
and measures two ohms in
resistance.
Source a replacement resistor
from Honda
Part number H
32146-SV4-013 dummy
resistor
Replace the resistor, then
re-scan the car and clear any
existing fault codes. Road test
and recheck the faults in the
SRS ECM.
Recommended time
Labour time for this job was
2.5 hrs, taking into account
research time, location of parts
and the actual time spent fixing
the problem.
All airbag systems and
wiring and connectors
are identified by yellow
connectors, yellow harness
clips and taping.
Always consult owners or
workshop manuals before
disconnection of any
connections or modules.
Once an airbag system has
TaT will soon have hundreds of technical solutions,
been deployed, the entire just like this one, at www.tat.net.au
system must be replaced. For subscribers only
 HONAC03420
ACCORD
2003
4 CYLINDERS
Customer complaint
Drivers side headlight not
operating.
Problem summary
All other lights working
correctly. Drivers side park light
working. No headlight or high
beam on drivers side.
Diagnostic sequence
Care should be taken when
working on this vehicle as the
headlights are a high voltage
system.
Started by testing all fuses,
battery power and earth
connections. Both front
headlights separately fused.
Drivers headlight fuse blown.
Connected short tester/light
to drivers headlight fuse.
Disconnected drivers side
headlight globe. Short still
present.
Disconnected main headlight
assembly plug - short goes
away.
Removed complete headlight
assembly and front bumper
bar.
High voltage control unit
mounted directly under
headlight assembly.
After removal of the
control unit, water damage was
noticed. Opened control unit
and found water inside.
Fault description
The high voltage control unit
is mounted directly under the
headlight.
Water was entering the
headlight unit and then leaking
into the control unit via the
wiring harness hole.
The water had
caused corrosion within the
control unit and the moisture
was also causing the electrical
short.
Fault solution
In this case, drying out the
control unit and resealing the
headlight enabled the repair.
In worse circumstances,
the control unit may
need to be replaced.
Recommended time
Labour time was 2.5 hours,
taking into account research
time, location of parts and
actual time spent fixing the
problem.
Because of the high voltage
used in late model vehicles,
extra care must be taken
when diagnosing problems
in these systems.
Good quality rubber gloves
should be worn when
working with high voltage
systems.
Something bugging you
technically?
Email your technical
questions to TaT, and
we will find the answer
or solve the
problem and print it for
all to share.
info@tat.net.au
The Automotive Technician 17
 TOYCA02421
TOYOTA CAMRY
Diagnostic sequence
12-2002 Checked A/C system
2AZ-FE 4 cyl refrigerant gas pressures -
found to be good.

Back probed and tested

voltage supply to A/C
compressor. Voltage was
intermittently low.

Located compressor micro

Customer complaint
Air conditioning not working.
Problem summary
Air conditioning compressor
not switching on intermittently
and A/C switch light flashing
when system not working.
relay, labeled as MG CLT, in
fuse box under bonnet
next to battery.
Removed and checked
voltage supply to relay - good.
Opened up relay and inspected
contacts which were badly
burnt and damaged. Checked
current flow of compressor
clutch.
Should be 3.3 amps, 14 volts
divided by 4.2 ohms = 3.3
amps.
Fault description
The compressor relay cycles
while driving to maintain the
desired cabin temperature,
so the contacts are open and
closing regularly.
The built in relay suppression
is insufficient to prevent the
contacts from arcing.
Fault solution
Replacement of A/C relay
with good quality relay is
recommended.
Recommended time
Labour time was 2 hours,
taking into account research
time, location of parts and
actual time spent fixing the
problem.
Whenever replacing an A/C
compressor, we recommend
testing for any voltage drop
across relays.
If unsure of internal condition,
we recommend a new relay be
fitted.

VVWGO00215
VW GOLF Fault description
2000
Due to high resistance in main
4 cylinder transmission plug, across a
number of pins, the vehicle
Customer complaint was experiencing transmission
problems.

ECM light coming on.

Problem summary
ECM light coming on
intermittently. Strange gear
changes on road test.
Diagnostic sequence
Scan the engine and
transmission system.
Fault solution
Replacement of plug from both
engine and transmission sides.
Recommended time
Labour time was 2.5 hours,
taking into account research
time, location of parts and
actual time spent fixing the
problem

Transmission had a lot of

history. Clear codes and road
test.

ECM light came back on after

short road test. Inspection of
wiring harness and connectors
to gearbox.

Main connection to gearbox

badly corroded and one pin
broken due to corrosion.

The Automotive Technician 18


The ant did it!
T
his is not the first time that weve
met the kamikaze ant. These little
chaps like the warm and cozy
surrounds of the humble relay.
In this case it was a Holden Astra TS
which had broken down a couple of
times and had some parts like the throttle
body and the main engine control unit
(ECU) replaced, not to mention the
reprogramming.
The original problem was that the vehicle
would intermittently not start. The vehicle
would always throw up a number of
different fault codes.
This is the important part - trust your
instinct. Logic says go back to basics.
Is there fuel and spark? Are the injectors
pulsing and most important of all are all the
power and earth supplies OK?
After a number of checks, it was
discovered there was no power
intermittently to the injectors, so the hunt
was on. The wiring diagram was checked
and the power supply to the injectors was
found to come from an EFI relay located
on the passenger side near the fire wall.
The relay was found to be switching but
there was no power output. When the
cover was removed there was some black
debris in between the main contacts.
A closer look revealed that it was mushy.
The kamikaze ant family had set up home
inside the relay.
Unfortunately for some of the ants, they
were directly between the contacts when
the relay was energised and subsequently
were squashed.
Their remains were intermittently stopping
the contacts from closing completely.
.
The moral of this story is - dont forget the
basics.
TaT workshops are finding quite a few
cases where faulty or incorrect relays are
causing some diagnostic challenges.
Watch for coverage of the 2008 Wire
& Gas Training Convention and Trade
Show in the next issue of TaT.
Only TaT and VASAs own newsletter,
Hot Air, will bring you news on
important industry events -
because we are part of the industry.
Reliable products are
better for business
Adelaide UltraTune service centre owner
David Banning and his technicians have
adopted Bendix brake pads as first choice
on customers cars because, apart from the
many good technical reasons, it enhances
our business reputation.
David has seen brake pads go through a
lot of change especially with the removal
of asbestos. He says many manufacturers
have struggled to find the right compounds
to replace asbestos but Bendix has got it
right. When our clients are not happy with
their pads, we confidently replace them
with Bendix because we have proved the
reliability of the product. I have done that
at my own expense to maintain good faith
with my clients.
The technicians who deal with them also
feel good about Bendix pads because they
know that customers are not going to come
back complaining of noise or dust.
As the owner of UltraTune Modbury and
UltraTune Golden Grove, in Adelaides
north-eastern suburbs, David knows
that customers dont necessarily come
back saying they had a good experience
with a purchase but if they have a bad
experience, they never come back.
David tested Bendix pads on his own
vehicle and found that the wear ratio
versus dust and noise was very good.
www.bendix.com.au
Brake Advice Centre 1800 819 666
brakeadvicecentre@bendix.com.au
Caption for the pics should be as follows:
Ultra Tune Golden Grove staff from left to
From left: David Banning, Richard
Lloyd, Andrew Wilson and Brian
Clow at Ultra Tune Golden Grove
The Automotive Technician 19
Fundamentals of Electrical Testing and Diagnosis
Best to start with the basics
Checking the basics
Having listened to and verified the
customers complaint, it will be time to
check the basics, and basics means visual
as well electrical checks.
The visual is pretty simple. You would
visually check to see if there are any
obvious abnormalities that could contribute
to the problem - things you could pick up
with the naked eye.
For the electrical checks you will need a
digital multi meter (DMM). But what do we
really check with DMM during these initial
stages?
Supply and ground
It is prudent to confirm that the battery
supply (charging) and battery grounds
(earths) be as near perfect as possible.
But how do we confirm this?
One way is by simply disabling the vehicle
from start and cranking the engine. While
it is being cranked, that is, while the
vehicle is drawing maximum possible
current without switching accessories
ON, you then measure the voltage drop
from battery post to clamp, then battery
post to chassis, and finally, battery post
to the block. All should measure less than
0.3 of a volt. If not, it will need further
investigation. This may be the cause of the
problem.
Now that you are sure that the vehicle has
a good battery ground, the next logical
step would be to check battery supply.
This can easily be done by checking
the voltage of the battery from post to
post while the engine is running (with all
accessories ON).
With the DMM set on DC range, it
should, naturally, display optimal charge
The Automotive Technician 20
voltage between 13.5v and 14.5v. This
measurement, however, does not indicate
any noises on the DC supply.
In order to measure noises (if there are
any) all you need to do is switch DMM
from DC range to AC. As a rule of thumb,
it should be less than 0.3v (as can be seen
from the pic below).
Scan tool
The next step in diagnostics is to decipher
Diagnostic Trouble Codes (DTC) - if any.
Should there be any DTC, do a DTC
search on the internet. Ascertain the
conditions of setting DTC.
Sensor
Should the DTC relate to, say, Mass
Air Flow Sensor (MAF) then simply
carry out supply and ground voltage
checks as stipulated earlier (AC and DC
while cranking and running) and check
parameters as well as the output signal
voltage.
Confirm diagnosis
Having confirmed the cause of the DTC
which may range from supply, ground,
component, wiring and or even Electronic
Control Module (ECM) the next process
in electrical testing and diagnosis is
confirming that the customers concern has
been resolved.
Synopsis
In order to carry out proper electrical
testing and diagnosis, it is imperative that
initially the supply and ground voltages are
checked (AC and DC) at battery, ECM and
component level.
It is only then that an informed
decision can be made for a
proper diagnosis, a trivia that is
often overlooked.
In the next issue of TaT, I will
examine the anatomy of DTC
and what it really means!
Till then, happy diagnosis!
Jack Stepanian
Handy reference:
http://www.scangauge.net/DTC/
Toyota.html
Jack Stepanian will be one of
the top trainers at Wire & Gas
Training Convention and Trade
Show 27-29 June 2008 at the Gold
Coast Convention Centre.
Murphys Law The good oil on bad vacuum
Most people, when diagnosing poor engine
idle and performance complaints, tend to
overlook one small thing - does the engine
have enough airflow in the intake.
A vacuum gauge is one of the most
powerful diagnostic tools you can have in
your toolbox. Many hours are lost looking
for a problem that could have easily been
sorted within a few minutes. A simple hook
up may save your customer a lot of money
and you a lot of time.
I have heard many war stories where the
vacuum gauge would have saved a lot of
red faces.
Low vacuum may be the result of many
faults such as low compression, burnt
valves, incorrect ignition timing, incorrect
valve timing, inlet manifold leaks and so
on.
Low vacuum could also be due to sticky
compression rings resulting in air escaping
around the rings thus pulling crank case
pressure past the side of the piston walls.
Generally this is caused by carbon build
-up in the first and second ring grove.
There are several methods for reducing
this build-up.
The best way is to use a decarbon
machine, a process which takes about an
hour using a decarb fluid together with
petrol.
The carbon clean is connected to the cars
fuel rail by means of a supply and return.
Using the pump in the machine, the cars
fuel supply is taken out of the system.
Shows vacuum before this process.
Indicates that vacuum
increased after the cleaning.
The carbon clean fluid soaks down through
the upper compression rings, dissolving
carbon and turning it into a thick oil to be
burnt in the combustion chamber once the
30 minute soak cycle is completed.
Bad fuel can cause vacuum problems,
such as incomplete combustion and
poorly seating valves
as in this example.
Most low vacuum symptoms are a result of
engine condition.
Valve timing can be one of those problems
that can cause even those with a full head
of hair to go bald. Connect the vacuum
gauge. It should have pride of place in
your toolbox.
This is a classic
case where a
car arrived at
our door with
no mention of
a timing belt
replacement
only a week
earlier.
The symptoms were poor idle and no
power up to 3500 rpm. Variable cam timing
can have a strange effect on the running of
a car if the timing is incorrect.
Another dead giveaway is that the engine
control module will log a code for either
exhaust or inlet cam sensor.
The ECM looks at the crank position
sensor (CKP) signal in sequence with
the cam position sensor (CPS). If these
two signals are out of their operating
parameter, the code will be logged.
I hope this advice will help in your quest
to find problems quickly and correct
them. I run a very busy workshop and
down time on fault finding can become
very expensive. Ive proved many times
that vacuum can unearth many engine
performance hiccups.
Happy diagnosing
Nick Murphy
A new stand alone Blue Components
catalogue released by Australias leading
steering specialist includes more than 50
new product lines.
With more than 40 pages of easy to use
reference material it provides coverage in
excess of 300 new vehicle applications,
illustrating just how far the range of
steering pumps and accessories has
developed since its launch in 2007.
The expanded APS Blue Components
program not only covers popular steering
pumps but also now includes high
pressure steering pump hoses, plus a
range of rack and pinion boot kits.
The new Blue Components catalogue is
available throughout Australia by calling
Toll Free 1800 335 634 or online at
www.bluecom.com.au
The Automotive Technician 21
 Jeff Smit road test
op
The original SXE-Probe
(Dont mix up the letters)
As time becomes more and more valuable
to technicians and vehicles become more
advanced, any new tools or equipment that
help us are always welcome.
I think the SXE-Probe will be one of those
must haves in the tool box of technicians
of all levels.
The SXE-Probe is a logic probe combining
features of a Digital Multi Meter (DMM)
and oscilloscope but simplifying the display
for technicians who want to find the pulse
but dont need to see the trace signal.
At the switch of a button you can change
between voltage, frequency and duty
cycle.
The applications where the SXE-Probe
could be used are just about endless.
Some of the areas include:
Starting and charging systems
Electric relay and actuator
controls
Pulse generators
Injectors
Map sensors
...in fact anything that has wires connected
to it can be tested with the SXE-Probe.
We all know now that the humble old test
light, using an incandescent globe, say
three watt, is a no-no, especially around
electronic circuits.
In the top picture, we are testing the
switching side of an injector on a 03/99
Daewoo Lanos.
The SXE-Probe is switched to % Duty
Cycle, and at idle it is telling us that the
injector is on for 5% of the time or, as
shown, 95% of the time there is no earth
switching to the injector.
In the middle picture we are testing the
MAP sensor on the same vehicle. This
time we are switched to voltage and the
output signal is showing 1.6 volts.
Changing the vacuum supply to the MAP
sensor instantly showed up with a change
in the output voltage. When checking the
The Automotive Technician 22
ools
other two wires, the SXE
-Probe showed instantly
that we had a good 5
volt supply and, more
importantly, a good 0.0
voltage at the ground
wire.
In both of these
examples, we are using
the very convenient
probe tip lead extender.
This extender changes
the probe from a test
light type probe into a
dual lead multi meter
type tester.
When using the probe
as a test probe, the LED
light at the tip is very useful for under dash
work or wherever the light is limited.
We put the SXE-Probe into the hands of
some top technicians and the responses
were nothing but very good.
Ian from Balgowlah Automotive was
enthusiastic, Fantastic, very practical and
the first tool I grab when testing anything
electrical now.
The LED light is also very handy and Im
finding more and more ways of using the
SXE-Probe every day on the workshop
floor.
Manufacturers and wholesalers
For great interactive uses for the SXE
probe, go to www.sxeprobe.com.au If you have a tool that you believe
is the answer to every technicians
Where: Available from Mount Auto dream, TaT would love to do a road
Equipment 02 9905 8055 at an test to back it up.
introductory price of $159 plus GST.
Great value for our Top Tool.
Call Jeff Smit at 1300 828 000
Also available from:
(Road tests are free of charge -
this means we retain our
editorial integrity)
At www.tat.net.au, Subscribers can track every technical article
published in this magazine, categorised for easy navigation. For ex-
ample, if you want to read every article weve published about hybrid
technology...easy, one click and up comes a list of all articles and the
dates published. You can read them on-line or print them out as PDFs.
...and after hybrids - ELECTRIC
S
ince its introduction at the North
American International Auto
Show, the Chevrolet Volt Concept
sedan powered by GMs E-Flex
electric propulsion system has energised
car enthusiasts around the world with its
potential to greatly reduce trips to the petrol
station, as well as greatly reduce CO2
emissions.
The Chevrolet Volt Concept is a battery-
powered, four-passenger extended-range
electric vehicle with approximately 65 kms of
electric drive range, with a petrol FlexFuel on-
board engine to create additional electricity to
extend the vehicles range.
Hybrid vehicles are already making their
presence felt and the future is going to be in
electric vehicles like the Volt. Battery electric
technologies will radically alter the landscape
for personal transportation for decades to come.
Simply put, the E in E-Flex stands for
electricity; Flex for the many ways to make and
store it. In fact, three E-Flex variants have been
introduced this year, including the FlexFuel Volt
in the US, hydrogen fuel cell Volt in China and
the bio-diesel Opel Flextreme in Europe.
When its lithium-ion battery is fully charged,
the FlexFuel Volt will be expected to deliver up
to 65 kms of pure electric vehicle range. When
the battery is depleted, a 1L, three-cylinder
turbocharged engine will be designed to create
enough additional electricity to provide excellent
restricted conditions. I am looking
fuel economy. The Volt also can be fully
charged by plugging it into a 240-volt outlet for
approximately three hours a day.
Some of the technology behind the Volt draws
from GMs previous experience in starting
the modern electric vehicle market when it
launched the EV1 in 1996. Many of the same
engineers who worked on the EV1 are working
on the Volt and E-Flex System.
If you lived within 40 kms of work and charged
your vehicle every night when you came
home or during the day at work, you could
conceivably never burn a drop of gas on your
daily commute.
If you forget to charge the vehicle or it travels
too far, the Volt would still get good fuel
economy by using the engine to produce
electricity and extending its range comparable
to that of todays conventional vehicles.
Key to making the E-Flex System a reality is a
large, reliable, lithium-ion battery.
It uses nanophosphatebased cell technology,
which, compared to other
lithium-ion battery chemistries,
provides higher power output,
longer life and safer operations.
GMs E-Flex System will enable
multiple propulsion systems to fit
into a common chassis. Another
benefit of most electrically driven
vehicles is that there are no
emissions when they operate in
all-electric mode.
The fan belt tightening
debate - adapted from a
real on-line blog in USA
Dear Jeff
I do most of my fan belt
replacements and adjustments
myself. I am frustrated as to how
much flex a belt should have. Is
there a V belt tensioning gauge
that will show me at a glance
when I have the proper tension.
I tried using a ruler, but its hard
to see the measurement when
you are lying on your back in
for a tool that is easy to use and
doesnt cost a lot.
The short answer is firm, not
too loose and not too tight.
The fan belt tension is more by
feel than by measure. Perhaps
go to a car lot and feel different
tensions of belts to get the
feel. Only a loose belt will
squeal and shout out for help.
Thanks for the answer Jeff. But
my service manual describes the
procedure of correct tightness
in the amount of flex in inches
between designate pulleys at
approximately 20 lbs of pressure.
Do you know of a tool that will
give me the exact measurement,
other than a straight edge or
ruler?
There is a tool available for
viewing at the Virtual Mechanic
International Automotive
Museum (VMIAM). Its in
Tashkent, Uzbekistan but it
only opens once every 100
years and it has a licence
to open for only one day. It
just so happens that it was
yesterday it was open.
Apart from that I remember
20 years ago using one as
a hammer at trade school at
Richmond TAFE. We had to
stay back that day until the
teacher found out who did it. I
stayed at school for days until
I got hungry. They gave us only
KFC but with no salt it was
horrible.
I dont know of any person
who would use such a tool as I
think we have all lost the art of
being spot on. Jeff
The Automotive Technician 23
 MAZ1201422
Problem summary
MAZDA
121 METRO After testing, found that
02-2001 occasionally, both right and
left indicator lights flash when
B3 4cyl 1300 using either left or right.

Customer complaint
When using indicators,
intermittently both sides flash.
ESTABLISHED 1977
Diagnostic sequence
Started by testing all fuses
and battery power and earth
connections.
Located the flasher unit/control
relay, under dash on drivers
side below the engine control
unit.
Inspected connections. The
flasher unit is not the traditional
type, but rather a control unit
A DIVISION OF J.C. FRY & SONS PTY LTD
that has separate left and right operation.
circuits and switching.
Fault solution
Remove and inspect hazard
switch. Internal corrosion found
on contacts. Replacement of the hazard
light switch was required.
Fault description Part number
MZ-B25D-66-4H000
The internal corrosion of the
hazard switch was causing Recommended time
tracking and activation of the
hazard lights but only when the
left or right indicators were in Labour time was two hours,
taking into account research
time, location of parts and
actual time spent fixing the
NSW (02) 9438 4588 problem.
VIC (03) 9646 0994
QLD (07) 3373 8099
sales@frysspares.com

Nationwide Distributors of Because of the positioning of

many hazard light switches,
Wiper Systems and Components they collect dirt and often
Rocker Switches cleaning solutions when dash
boards are cleaned.
Column Switches
Together with the contact
Mirrors and Arms with direct sunshine, this can
have a harsh effect on hazard
Handles, Locks and Latches switches.
Gas Struts Because of the type of circuit
used in this vehicle, sight
Filters Air, Fuel and Oil tracking inside the hazard
15 inch Motorised Televisions switch causes the activation of
the hazard lights by the flasher
Brooms, Brushes and Squeegees unit/control unit.

Brake Systems
Thermostat Control If you havent yet joined
the growing number of
technicians who have become
Subscribers to TaT, please
visit our stand (43) at the
2008 Wire & Gas Training
Convention and Trade Show,
27-29 June at the Gold Coast
Convention Centre.
SWF s Trico s Bosch s Teknoware s Mekra sZimmermansBehr
(www.wireandgas.com.au)
BD-FP-5164976-08

The Automotive Technician 24

The Automotive Technician 25
 Suspension system based on
Hi, Thanks for producing this great
technical magazine here is a little
guide I made for the VW Golf. Cheers
famed Bose speaker technology
John After 24 years research, Bose Corporation has created a unique
electromagnetic suspension system for cars.
I make no claim that this is a perfect
method but it worked for me. Prototypes of the Bose suspension have been installed in standard
production vehicles which have been tested on a wide variety of roads and
The Golfs plasticintake manifold obscures on durability courses with apparently good reviews.
the spark plugs and makes their removal
an arduous task. I hope this may help
some poor soul attempting to replace the
spark plugs on this German masterpiece.

John Smedley, Lockleys Auto Repairs SA

Spark Plug Removal V.W. Golf

1.6 Litre Petrol

Remove wiring harness (LHS),

plug leads (leave on coil) and lead
bracket

A linear electromagnetic motor is installed at each wheel of a Bose equipped

vehicle. Inside the motor are magnets and coils of wire. When electrical
power is applied to the coils, the motor retracts and extends, creating motion
between the wheel and car body.

The linear electromagnetic motor responds quickly enough to counter the

effects of bumps and potholes, maintaining a comfortable ride.
Use screwdriver in end of tube to
Additionally, the motor has been designed for maximum strength in a small
guide plug straight on to #3 cylinder package, allowing it to put out enough force to prevent the car from rolling
and pitching during aggressive driving maneuvers.
Remove plug - socket,
then rubber remover The power amplifier delivers electrical power to the motor in response to
signals from the control algorithms.

The amplifiers are based on switching amplification technologies pioneered

by Dr. Bose in the early 1960s technologies that led to the founding of Bose
Corporation in 1964.

The goal of the control algorithms is to allow the car to glide smoothly over
roads and to eliminate roll and pitch during driving.

A new range of parts washers from
Kincrome has been released for large
and small workshops with a model also
ideal for the home workshop.
The three models include two permanent
stand models of 150 and 90 litre
capacities plus a 75 litre mobile unit.
All are constructed of heavy sheet
metal finished in tough scratch resistant
hammer tone enamel and each complies
with Australian Standards.
The largest in the range has a 75 litre
detergent capacity with a submersible
pump operating at 10-12 litres per minute
through a flexible metal hose. Each
washer also includes a replaceable filter,
removable parts tray and bottom storage
shelf.
The portable model comes complete with
heavy duty lockable castors plus a parts
draining shelf and drain tub.

The Automotive Technician 26

Sydney college
goes very
hi-tech to
teach auto
technicians
W
etherill Park College, part of
TAFE NSW -South Western
Sydney Institute, is about
to open its new automotive
electrical training laboratory.
The room is set up with the Degem
training system which has been used in
other training centres around Australia.
The system comprises 16 student stations
and one teachers master station. Each
station has a computer linked to an
electronic control board together with a
digital multi-meter.
All 16 stations are then linked to the
teachers master station which can
set and monitor all student stations.
Their progress can be followed as they
undertake training and diagnostic modules
on a range of subjects.
Some of the interactive simulator boards
include DC circuits, magnetism, motors,
semi conductors, ABS, EFI, distributor-
less ignition systems and many more.
The college is also looking into added
simulator boards such as air conditioning
and common rail diesel.
Andrew Berta, auto electrical teacher in
charge of setting up the new facility said
All the teachers and students are very
keen to get stuck into this new technology
and expand their own knowledge and
understanding of electronics.
Providing students with the latest
equipment and complying with current
training package requirements is
becoming exceedingly difficult to achieve
both physically and financially.
Industry expectations
are that graduating
students will have high
level employability
skills including IT,
communication and
customer service skills.
IT-based learning systems are a viable
option for an effective training solution
that meets industry requirements, aids
student learning and develops teachers
professional skills.
Brighter work lights
Narvas Senator work lamps are a
lot brighter with the addition of High
Intensity Discharge (HID) versions.
Using the latest European D1 globes,
coupled with the compact internally
mounted Gen 5 ballasts, the new
lamps come as a total package pre-
wired with 300mm of cable.
TAFEs new automotive integrated
learning centre at Wetherill Park College
combines theory with real-life practical
experience in the same classroom.
Faculty director Trevor Smith said
students will be able to use multi-meters,
oscilloscopes and other test gear linked
through automotive specific software for
learning and assessment and can work on
physical vehicle components without the
fear of damaging them.
By inserting malfunctions, the fault is
presented to the student in the form of a
real-life simulation. The software guides
the student towards a solution by showing
them how to identify, diagnose and repair
complex malfunctions in motor vehicles.
Students are tested on their depth of
learning and diagnostic skills by the
teacher tracking and recording an
individuals progress.
The centres modularity allows flexibility
of use for different audiences from
apprenticeship courses to specialist
advanced training for experienced
mechanics.
The system is linked to online learning
and assessment resources that can also
allow students to study from home or at
the workplace.
They are available in 12 and 24 volt in
both flood and pencil beam options.
The benefit of the HID version is the
pure bright white light output which
at a Kelvin rating of 4150 is close to
daylight. The D1 globe and Gen 5
ballast produce a fast ignition and
warm up time when compared with the
older D2 technology. HIDs resistance
to vibration gives up to five times
greater life compared with standard
halogen globes.
The Automotive Technician 27
 In-house repair?
...more like in-house
obsolescence
S
heriff Ashley Teitzel
has just returned
from ridin the range
out Roma way.
And as usual, hes come
back with some horror
stories about vehicle repairs,
which somehow are more
dramatic when told against
the background of the great
outback.
Out west,
everyones an
expert.
The tyranny of distance means
that machinery has to be held
together with number eight
fencing wire or dumped until
a real expert arrives on the
scene.
But today, the Sheriff has his
six-guns pointed at all those
companies and organisations
which mistakenly believed
they were going to save heaps
of money by taking all their
repairs in-house.
Have you got your 2008 ADAIR catalogue?
The Automotive Technician 28
A noble idea, but
there is plenty of
proof that it can
end up costing the
company a fortune
in assets which
lose their re-sale
value because poor
workmanship has
literally repaired
them to death.
Ashley is a tad angry because,
as an independent and highly
skilled operator, he and others
like him lose another customer
every time a shire council,
or a provincial fleet operator
decides to take their repairs
Nice piece of in-house repair
in-house, as they seem to be
doing lately.
But you know what happens?
They put on someone they
believe is competent, and
maybe they are. But the whole
idea is to save money right?
So do you think the employer is
going to put their hand in their
pocket to send the technician
to courses, or to conventions,
to maintain their skills on
Do you want to purchase one compressor
and hope its right? Or purchase a
compressor kit and know it fits!
Unique to ADAIR, a range of compressor kits that
suit popular vehicles.
modern technical equipment?
Not likely.
Or if the technician decides
to upskill himself to stay in the
game, it wont be long before
he gets a whiff of the money
and opportunity in the mining
industry and he takes the next
stage out of town, says the
Sheriff.
Now heres the punch line to
this story. Ashley is called to
the west to get an ailing AC in
a big passenger coach back
into service.
You should have seen it. It
had been hacked and patched
so often that the company
would have had to spend a
small fortune to get it going
again, and even if they had the
money, I didnt have the two
weeks I would have needed to
do the job. So that was pretty
smart, wasnt it?
They saved big money getting
AUTO AIR PRODUCTS THAT GO THE DISTANCE
Call 1800-1-ADAIR website adair.net.au
patch-work done in-house for
years, only to end up with an
expensive piece of equipment
with a resale value somewhere
on the bottom side of ten
bucks.
Even basic electronics is over
the heads of a lot of people in
these jobs. The bottom line is
that with the shortage of well
trained technicians because of
the resources boom, there just
arent enough people with the
knowledge to look after every
fleet in every town in Australia.
So the message is that
companies need to do their
research properly, find a very
competent specialist in their
region and engage them for a
regular maintenance program
instead of trying to patch things
up themselves.
More work for us experts, and
ultimately fewer costly repairs
and equipment write-downs for
the companies.
And one last thing. With
vehicle technology running at
high speed, all OEMs should
take over all training. A radical
idea, but not silly.
Colleges may be able to teach
the fundamentals, but what we
need here in the aftermarket
are crash courses on the
technology which came out last
week, not five years ago.
 #3
Fuel System Troubleshooting & Electrical Checks
Often fuel system repairs are performed without correct diagnosis, Ground
-
resulting in many components being sourced & replaced before the +
problem is found, thus turning a relative small job into a large, very
costly experience.
This also causes an inconvenience to the customer due to the down
time and higher labour costs than necessary.
A simple solution is to perform basic fuel system troubleshooting and Battery

diagnosis checks with a digital voltmeter and some knowledge of the

vehicles electrical system.
Digital Voltmeter
When diagnosing a vehicle that will not start...
Check the fuel gauge level in the tank Fuel Pump Relay
Check to see if power is available at the pump fuse & relay. MRA - Fuel Pump
Once having done this, the vehicles voltage system should be Fuel Pump Voltage Drop Test Assembly

tested... Firstly, we will look at the negative side of the electrical

Connect a digital voltmeter to the positive and negative battery
terminals
System voltage should read between 11.8 - 12.6v DC or higher
with no electrical load on the system. If the voltage reads less, the
starting and charging system should be investigated before looking at
testing the electrical side of the fuel system.
Ground
Battery
circuit, then the positive side.
1. Connect the digital voltmeter test lead to the negative battery
terminal and the other to the negative terminal at the pump.
2. The pump circuit must be energised (note: the majority of fuel
pumps will run for a few seconds once the relay is energised, this is
only long enough to prime the system, until an RPM signal is
generated.
3. If the negative circuit is in good condition, the voltage drop
measured should be 0.1v DC or less. A larger voltage drop reading
indicates a problem. Damaged or corroded vehicle wiring or harness
connectors are likely sources of this problem.
4. If the voltage drop is within 0.1v DC or less, repeat the same test
on the positive side.

Ground - +

Digital Voltmeter

MRA - Fuel Pump

MRA - Fuel Pump Assembly Assembly
Testing the electronics within a fuel system...
Battery
Fuel Pump Voltage Test
1. Connect a digital voltmeter to the fuel pump connector - this
checks for any voltage drop or loss caused by damaged wires or
poor connections. Digital Voltmeter

2. Turn the ignition key to On (the fuel pump will only receive the
battery voltage for a few seconds, this is to allow the fuel pump to
prime the fuel system before start)
3. Measure the voltage at the pump. The reading should be within
0.5vDC of the system voltage. (Battery Voltage).
Copyright 2007 Enforced ABN 78 003 653 183 The Automotive Technician 29
Page 1

Source: Les Bennell
Les Bennell Auto Air and
Electrics - Cleveland Qld
I
n the picturesque Brisbane
bayside suburb of
Cleveland, Les Bennell
had built up the perfect
auto repair business, a
combination of auto electrical
and air conditioning, with
special equipment for working
on heavy machinery, doing a
range of truck repairs and retail
vehicles.
He had a diverse customer
base including a lot of
locals whod built a trusting
relationship with Les and his
team through the years, and
farmers and big equipment
owners who knew that Les had
that special expertise to solve
their problems quickly, and on
site.
With such a long and
chequered background, one
would have thought that
here was a business worth
something.
But when Les and Jan, his wife
and business partner, locked
the doors on Les Bennell Auto
Air and Electrics at Trade
Street, Cleveland on 28 March
2008, he realised
Les entered the air conditioning
industry 20 years ago, following
a background in heavy trucks.
He trained through courses
and self application and began
a mobile service for all types
of vehicles, but specialised in
heavy equipment.
He developed systems, one
being adopted by Massey
Ferguson UK for heavy
equipment used in harsh
tropical conditions. Because
of his strong design skills he
was often called on to modify
imported systems to better suit
the tropics.
His work has taken him to
extremesfrom the Tasmanian
forests in mid winter and to
the Cape York gold fields
and Groote Island in the
Territory and he earned a
strong reputation in the
south Queensland outback
for his ability to get the most
impossible job done.
He is a foundation member of
VASA, the association which
presented Les with a VASA
Pioneer Award in 2002.
The Automotive Technician 30
Les Bennell (left), with his key staff at the peak. Next to Les is Garry Russell, a mechanical specialist on
AC in European cars, apprentice Luke Millar, auto electricians Shayne Longman and Jacques Dognibene.
that his beloved business
wasnt worth a cracker, but not
for the reasons one might think.
Les had tried to sell the
business as a going concern,
but he quickly found that
the business was a bit too
big for an entrepreneurial
technician or mechanic, a lot
too diversified for perhaps
an auto electrician...in other
words, there was nobody on
the market with either enough
staff or enough skills to justify
the purchase of such a well
equipped workshop.
In a way, it points up the
dire shortage of multi-skilled
tradesmen in the auto
aftermarket industry.
At the end of the day, Les and
Jan did a massive stocktake,
and disposed of their workshop
possessions in an auction.
I found it difficult even to
find auto electricians with AC
experience, said Les.
In a general discussion on the
state of the industry, Les was
uncharacteristically pessimistic.
More and more work is being
won back by the dealerships,
he laments. Not like the
A pioneer shuts the doors
the industry is the loser
old days, when dealerships
had basic skills for the
simple service, but needed
aftermarket specialists to solve
the real repair problems.
Plus, people are not keeping
the cars as long as they used
to, warranties are much longer,
and it became noticeable
that we were not getting cars
into the workshop until they
were five years old and older,
recalls Les.
Its a far cry from the days
when Les and his workshop
were kept flat out doing
warranty work for the OEMs.
It was expertise that kept us
going, he says. The public will
soon figure it out - no expertise,
no work. Simple as that.
Attitudes have reversed, says
Les. To be in this business
today, you must be more of
a business person than a
technician, whereas in earlier
days, a good tradesman
could virtually set up business
anywhere and survive.
For Les, and many VASA
members like him, the secret to
survival was knowledge.
As experienced as Les and
his staff were, you would find
him at every VASA and Wire &
Gas Convention and training
workshops. His theory was
that no technician could stand
still - to do so would eventually
lead to the new technologies of
the motor car outstripping the
technicians knowledge, and
once that happens, you revert
to being one of the industry
cowboys.
VASAs senior training
coordinator and acknowledged
Australian AC expert, Grant
Hand, of Automotive Training
Solutions considered Les
Bennell to be one of the
most experienced men in the
business.
Grant remarked in a recent
phone call I need to have a
good chat to Les Bennell at
convention about a few issues.
When told that Les had just
closed his doors, the phone
went silent.
Les, you are going to be
missed.
But dont worry about us - you
just go out and have some well
deserved fun.
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Are you: Accessory fitting
Panel beating
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Self employed Marine Other Australian Refrigerant
Handling Licence (ARC)?
Please tick those boxes Spray painting Your age range:
which describe the areas Under 20 Yes No
in which you regularly Radiator repair
work: 20-30
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The Automotive Technician 31