autotechnician magazine Nov/Dec 2022

More content. More quality. More reliability. More service. If time means money in your workshop, you can save on both with FAG. Our WheelSet complete hub repair solutions come with every genuine OE component you need to carry out a professional repair, right down to the last nut, bolt and washer - so no shopping around for missing parts. They also come with a 3 year unlimited mileage warranty, unrivalled service and training opportunities plus FREE downloadable fitting guides and RMI data at REPXPERT, the award-winning industry-leading knowledge portal and app for professional workshop technicians.

www.repxpert.co.uk

P4 Industry news

P10 The Mechanic’s Mentor

P13 Garage equipment wish list

P18 Hybrid & EV supplement

P20 Common faults & support from HEVRA

P28 Workshop visit: Cleevely Motors turns 60

P32 Training opportunities

P37 Picking EV parts partners

P42 Garage Management Systems

P44 Parts, Tools & Tips

P49 New Car: Suzuki Vitara Full Hybrid

NICOLA ST CLAIR, EDITORIAL DIRECTOR Nicola@autotechnician.co.uk 07904 521 923

PAUL DEARING, COMMERCIAL DIRECTOR Paul@autotechnician.co.uk 07808 077 611

ROB MARSHALL, TECHNICAL EDITOR

NATHAN WISE, DIGITAL BRAND MANAGER Nathan@autotechnician.co.uk

MIKE SMITH, EDITORIAL ASSISTANT admin@autotechnician.co.uk

CONTRIBUTORS:

Dee Blick, Pete Melville

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DEAR READER,

In our final issue of 2022, we focus on the need for investment to ensure you don’t get left out in the cold – from the perspective of training and continuous development for individuals and garage management software for workshop owners. Rob Marshall is already feeling festive and supplies a garage equipment wish list from page 13.

Electrified vehicles have received a lot of press in recent times and whether you like it or not, they will play their part in cleaner mobility in the coming years and early (ish) adopters are beginning to see the reward for making preparations before their competitors. From page 18, we talk to Pete Melville, who created the Hybrid and Electric Vehicle Repair Alliance (HEVRA), so that technicians could work out evolving issues together. He also provides case studies and outlines common EV faults his network has encountered. We visit Cleevely Motors as their business turns sixty, (trailblazers within EV repair), look at the training options available for those who want to add this string to their bow, and the parts suppliers to consider when sourcing products for hybrid and EV repair. Our New Car feature starting on page 49 outlines Suzuki’s first cost-effective highvoltage hybrid.

NICOLA ST CLAIR

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Published by: Aftermarket Media Solutions Ltd, The Joiners Shop, Historic Dockyard Chatham, Kent ME4 4TZ

industry

DON’T MESS WITH THE MOT

The Independent Automotive Aftermarket Federation (IAAF) has urged the new Secretary of State for Transport Mark Harper not to mess with the current MOT test frequency and strengthen the current 3-1-1 testing regime with the addition of testing electronically controlled safety systems (e.g., ADAS).

The Federation, along with UK AFCAR, has been highlighting the threat to road safety by conducting the first MOT when a vehicle becomes four years old and arguing that any extension to the test frequency will lead to an increase in road accidents as there will be no formal inspection of a vehicle’s road worthiness for a further 12 months.

MOT failures are disproportionately high for electric vehicles when they are first tested at three years, due to their increased tyre wear and there will be no official mileage or emissions checks for ICE vehicles recorded until after four years. In addition, delaying vehicle inspections may lead to higher repair costs for motorists who may not know that dangerous faults are developing with their vehicles. Mark Field, IAAF chief executive, said: “DVSA’s regulation of the MOT process and current testing frequency of 3:1:1 help to make the UK’s roads the second safest in Europe and while we look forward to working with the new ministers across

both Department for Business, Energy & Industrial Strategy (BEIS) and Department for Transport (DFT), we will fight any detrimental changes that threaten road safety and the automotive aftermarket.”

“Recent research from the RAC has shown that the majority of motorists consider that the UK MOT test is important for road safety and should not be changed and the wider industry is also firmly opposed to the idea of any changes to the 3-1-1 format.”

www.iaaf.co.uk

DVSA IMPROVES MOT REMINDERS AND HISTORY TOOLKIT

The DVSA has released its updated MOT reminders and MOT history toolkit for workshops, designed to make the process more efficient for users and help ease the workload for garages.

Managing MOT reminders has been made easier and a function has been added to amend or stop reminders for the vehicles registered. For the MOT history page, motorists and businesses now only need to enter a vehicle’s VC5 number once to view or print MOT certificates.

Since launching the MOT reminders, DVSA has reached four million sign-ups in total, and the MOT history

service has around two million visits per month. The new toolkit also includes advice and graphics for businesses to use on social media and emails to customers to help promote the MOT reminders and MOT history services and assist in managing workloads.

Workshops can find the updated toolkit on the link below.

https://mattersoftesting.blog.gov.uk/wpcontent/uploads/sites/19/2022/10/DVSA-MOTimprovements-toolkit.pdf

HELP SHAPE THE FUTURE FOR WORKSHOPS

The Independent Garage Association currently has a vacancy for a new member of the IGA Executive committee. If you are interested in making a difference to your fellow garage owners and becoming more involved in discussing new ideas to support the sector, whilst steering our industry through the challenges that are thrown at it on a daily basis, then get in touch. Email enquiries@rmif.co.uk.

RIGHT TO REPAIR: NEW BLOCK EXEMPTION PROPOSALS ARE BROADLY WELCOMED

The existing Motor Vehicle Block Exemption Regulation (MVBER) expires on 31 May 2023 and sets out automatic exemptions for certain categories of agreements related to the purchase, sale, and resale of spare parts for motor vehicles, and the provision of repair and maintenance services for vehicles. The Competition and Markets Authority (CMA) has recently reviewed the MVBER and has proposed revisions to government.

The UK Alliance for the Freedom of Car Repair (UK AFCAR) has welcomed the new proposals but has called for greater detail on how positive revisions of the regulation would be implemented to support motorists, workshops and parts suppliers.

On key areas outlined by UK AFCAR, the CMA has responded positively stating that “the definition of ‘spare parts’ should clearly include lubricants and encompass all software together with activation/configuration codes for replacement parts and components, which are strictly necessary to fit those parts or to replace or update components or systems of the vehicle, which are necessary for the use or operation of a motor vehicle, with the exception of fuel.”

The CMA’s recommendations also include a positive addition on the definition of ‘technical and vehicle information’ which will be treated as an ‘excluded restriction’ that would require self-assessment by a vehicle manufacturer so the wording in the guidance will be critical to its implementation. “The CMA finds that in-vehicle data should be included in this definition and acknowledges that the manner in which information is provided is relevant,” the report said.

Regarding vehicle warranties, the CMA proposes additional and updated guidance to clarify that the clauses contained in all documents proposed to consumers by OEM/authorised dealers or repairers should clearly state the consumer’s right to use the service of an independent repairer without losing the benefit of the warranty.

Another critical point made by the recommendation is the “recognition of new technologies and communication interface” with “access to technical and in-vehicle information” being a critical development. However, it is still referencing the workshop level as the basis for competition.

This new definition will include access to in-vehicle data but does not include independent and direct access to the vehicle remotely – only what must be made available once the vehicle is in the workshop. This, however, legitimises the VM’s ‘extended vehicle’ model and distorts the ability to compete.

Mark Field, IAAF Chief Executive and UK AFCAR Chairman, said: “We broadly welcome the top-line revisions to the MV-BEO. A key issue of the previous legislation was lack of enforcement of the regulation and its impact, particularly at garage level. We are only at the beginning of a long journey that seeks to ensure consumer choice – and the ability for the aftermarket to compete – is protected.”

Andy Hamilton, CEO LKQ Euro Car Parts, commented: “Fundamentally, competition is dependent on the existence of a level playing field between authorised and independent operators, which means fair and shared access to essential inputs such as spare parts and technical and vehicle information. The detailed wording of the guidance will therefore be critical. The CMA clearly acknowledges this and is taking steps to account for the technological developments of recent years –while building more flexibility into the guidance of the proposed new MV-BEO, which will also have a shorter duration, enabling another full review in six years - not ten as was the case under the previous EU regime.”

EBAY PREDICTS COST OF LIVING CRISIS WILL DRIVE SURGE IN DEMAND FOR RECYCLED ‘GREEN’ CAR PARTS

eBay says the cost-of-living crisis will see a growing number of motorists switch to ‘green’ recycled parts to help reduce motoring bills. The online marketplace found that 71% of 2,000 surveyed in May 2022 would consider switching from installing new car parts on their vehicle to ‘green’ recycled parts, to save money. Half of participants also said they’d like to opt for the reused parts to save on waste and help the environment.

Over the past three years, eBay has seen the supply of reused parts on its platform nearly double, with a green part now sold every seven seconds on eBay. Buyers can choose from more than 1.1 million green parts on the site and the reclaimed parts can be as much as 70% cheaper than new Original Equipment Manufacturer (OEM) parts. So-called ‘green’ items are typically undamaged and reusable recycled parts, but eBay

NGK

LAUNCHES

has partnered with the Vehicle Recyclers Association (VRA) to provide a certification process for automotive recyclers. All ‘Certified Recycled’ products listed on eBay come from VRACaccredited recyclers, are taken from end-of-life or written-off vehicles, and meet strict quality control standards.

To showcase its range of parts and accessories, eBay has partnered with MTV to remake the popular Pimp My Ride automotive makeover series. Available on MTV UK’s YouTube channel, the show’s most recent episodes feature vehicle makeovers incorporating green parts sourced by eBay.

For more information about Certified Recycled parts and accessories listings: https://pages.ebay.co.uk/2022/ certified-recycled/

TRAINING PORTAL WITH LOYALTY SCHEME MEMBER OFFER

NGK Spark Plugs has launched NGK Academy, a new online technical training portal.

The portal, aimed at supplying essential training primarily to workshops, includes 270 technical training videos covering various technical subjects/components by automotive training experts Our Virtual Academy (OVA) who have also created a suite of bespoke training videos on spark plugs.

The spark plug training videos, three of OVA’s core training videos and other existing NGK/NTK training content, will be free to access once enrolled on the portal, but there will be a charge for accessing the full suite.

To mark the launch, NGK is funding a three-month full access trial for hundreds of members of its BoxClever independent garage loyalty scheme. Mark Hallam, Marketing Manager, NGK Spark Plugs (UK) Ltd, said: “NGK Academy is designed to provide valuable, meaningful training that users can take on-board to help them each day at work.

“Our Virtual Academy has a host of incredibly useful training programmes on different aspects of a vehicle’s systems including comprehensive training videos on electric vehicles (EVs) and hybrids which we know our independent garage customers are extremely interested in.”

Ben Stockton, Managing Director of OVA, said: “In addition to the NGK training videos, NGK has purchased access to more than 270 training videos for hundreds of their customers. They’re on topics such as vehicle electrics, petrol and diesel engine management, chassis, hybrid and EV and HVAC.”

You can enrol for free limited access, paid full access or use your Promo Code for three months’ full access of NGK Academy at: ngkacademy.com To view the Academy promo video on YouTube go to https://youtu. be/F8gb5D6hh5s

GET ON TOP OF YOUR MOT CPD REQUIREMENT BEFORE THE MARCH DEADLINE

Nearly 700 MOT testers have been disqualified in the last two years, a rise of 49 per cent compared to the previous two. And while it’s right that driver safety has to be number one priority – not just for the DVSA, but for everyone who’s involved in vehicle servicing, maintenance and repair – according to LKQ Euro Car Parts, garages that lose just one tester could be missing out on around £670 in revenue per day.

Bob Wiffen, Workshop Solutions Director at LKQ Euro Car Parts, said: “The aftermarket has done phenomenally well to adapt to the shifts in seasonal MOT demand since the early days of the coronavirus pandemic. But effectively managing resource and inbound work volumes is just part of the challenge.

“Now that the autumn MOT wave is behind us, it’s time to for technicians to think ahead and get on top of their CPD before the 30th March 2023 deadline.”

The MOT CPD requirement has been in place for more than six years. Every year, hundreds of testers miss the deadline

to complete their three hours of training and subsequent assessment, which has a massive impact on garages’ ability to trade.

Each year’s training syllabus, set by the DVSA, is based on the latest MOT statistics, to determine the subject areas where it’s clear testers need to pay more attention, and that will make the biggest contribution to road safety.

Bob Wiffen added: “We work closely with the IMI and DVSA to ensure our customers have access to the approved annual training they need to run a successful and compliant MOT site. With our years of experience of offering training, and the partnerships we hold within the industry, the LKQ Academy is a one-stop shop for all the training requirements in the workshop.”

Light vehicle CPD – online assessment only – from £29 + VAT per candidate

Light vehicle CPD – online training and assessment – from £54 + VAT per candidate

Light vehicle CPD – classroom-based training and assessment – from £129 + VAT per candidate

All CPD courses from the LKQ Academy come with free IMI affiliate membership, worth £47.

LKQ Euro Car Parts has spoken out against the proposed move to change the MOT interval from annual to every two years and is committed to representing the best interests of both garages and drivers when the consultation starts. Bob Wiffen concluded: “Annual MOTs aren’t just an important revenue stream for garages – they protect road safety and help drivers stay on top of their vehicle maintenance in the most cost-effective way. Leaving problems to manifest over two years is likely to push up repair bills and make budgeting harder for drivers.”

https://lkqacademy.co.uk

Driven by TRUST

Bosch Braking Systems. Delivering safety since 1927 Bosch brake innovations have been ensuring road safety for more than 90 years. And we will continue to dedicate ourselves passionately to improving driving safety even further. In doing so, we benefit from decades of experience and comprehensive system expertise. For you, this means that you can fully rely on our products.

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What drives you, drives us.

ftermarket.co.uk

The Mechanic’s Mentor: Success starts in the Mind

By Dee Blick

The second article in an exclusive series where we look at how A&J Fleetcare are progressing on their mentoring journey with international bestselling small business author Dee Blick

The saying, ‘you are what you think’ is apt when it comes to running your own business. The power of positive thinking can do wonders for your bottom line, not least by empowering you to make decisions and take calculated risks – confident you can do it. And so began my second mentoring session with Alan and Jeanette Landale, the directors of Leeds based A&J Fleetcare. I was keen to find out what they thought about their business and the concept of the success mindset – did they embrace it or were they allowing self-limiting beliefs to crowd their thinking? It turned out that both of them, despite being passionate about their business, were unwittingly stopping short of allowing themselves to dream big and to believe they had what it takes to be even more successful.

For Alan, his working-class upbringing and lack of performance at school were the main reasons why he felt unworthy of headlight success. Likewise, Jeanette, who is one of the fiercest customer care champions I’ve worked with, had self-doubts too. Both of them were shying away from dreaming big because they were letting ‘stuff’ from the past get in the way of allowing themselves to think they not only deserved success, but they were more than capable of attaining it. They hadn’t stopped to look at how far they had come with their business on the smallest of budgets. That despite the global pandemic making trading tough they had taken the bold decision to move to a more centrally appointed location with more bays and a real chance of cracking some local fleet customers. Real entrepreneurial spirit on show, if proof were needed.

I had entered their business at just the right time because this session helped them to see what they had accomplished. It also gave them the impetus, or permission if you like, to change their thinking. We talked about self-limiting beliefs and how some experiences of the past can shape us in a positive way whereas others should be kicked to the kerb because they neither define nor help us. It mattered little how Alan had

The team at A&J Fleetcare

performed at school. What mattered now was how he and his team delivered a 100% first-time fix. Likewise, Jeanette, who didn’t need a string of qualifications to make customers feel happy, welcomed and reassured they were in the right hands.

During this session we explored what success meant to them. For Alan, it was about being able to increase the investment in training and development and take on new apprentices. For Jeanette, it was about being able to focus wholeheartedly on the business and not allow herself to become distracted with family issues. Both agreed they wanted to build their fleet customer base and to maintain their customer retention rate, despite increasing their charges to reflect the high value services they were offering; and the hike in business running costs.

We concluded our second session with the four elements of success mindset, namely:

• Thinking about success so any self-limiting beliefs could be replaced with positive thoughts

• Talking about success – decanting thoughts into regular discussions to bring them to life

• Planning success – making a list of what they wanted to accomplish

• Actioning success – setting timescales to implement what they had planned and getting on with the task of ticking off completed actions one by one.

I’ve had some people tell me this amounts to common sense. My response? Common sense is in short supply. It’s definitely uncommon. How many of us step outside our daily routine to explore what’s holding us back and to lay bare our bold plans and dreams for the future? Not enough of us! It’s easier to go

with what we’re doing day to day. And that’s no bad thing if we’re running a successful business. However, taking time out to reflect on how we think about ourselves, and where we would like to take our business, can only spur us on to accomplish even bigger and better things.

So, I’ll leave you with a few lines from an email Jeanette sent to me after our second session. They sum up what I hoped would happen.

“I feel so much more positive about our business and where we can take it under our own steam. Neither of us have ever spent time looking at our skills and abilities but I can see now that we deserve success because we work hard, and we do have what it takes to succeed. This isn’t something we acknowledged before we began our mentoring journey with you.”

Next month: Claiming your space as a time-served expert

You can get in touch with Dee at dee@themarketinggym. org.

Darren Darling conducts some on-site training at the workshop

Alan with DPF Doctor founder Darren Darling

Whether you are a garage owner seeking to make a radical investment, or a technician employee looking to fill a toolbox, Rob Marshall asks leading suppliers what you might wish to add to your festive wish lists

With the high street clamouring for your cash and Black Friday looming ever closer, the festive shopping period is the next hurdle that faces us before the holidays. Yet, do not forget purchases that either enhance your ability, or make work more comfortable. Should you be a garage owner, your needs (and budget) will be very different from those of an apprentice technician, for instance. Yet, it is always beneficial to consult your workshop team for opinions, which will help you make the right purchasing decision.

Hey, big spender!

Naturally, tool companies line up to tempt business owners –so let us dream first with some big ticket items. Naturally, ATLs represent a major investment and Snap-On reasons that its Sun Connected Automated One-Person Test Lane makes technician life easier, because the MOT procedure is made faster and simpler. The DGA 6000 Link also integrates the DVSA’s system with the Sun Emissions Tester, Brake Tester and Decelerometer. An intriguing feature for garages that wish to go a step further for their customers is the integrated OBD health-check function. This highlights vehicle faults before they pose an official problem, such as pending fault codes. This involves no

DREAMS UNDER THE TREE

Santa Baby:

"Think of all the cars that I have fixed, Think of all the defects that I haven't missed, Next year could be just as good, If you add some stuff to my Christmas list"

© Autotechnician Festive Lyrics Department

GARAGE EQUIPMENT

extra effort by the tester, because the checks are conducted automatically. While you (or your boss) might baulk at the £33,120 cost for a Class IV ATL, the pill is sweetened not just by the current finance promotion, of paying nothing for three months, but also a £5,296 emissions analyser (DGA6000) being included at no extra charge.

Like a modern ATL, up-to-date and intuitive diagnostics speed repair times and make technician lives far easier. Snap-on's answer is Zeus (EEMS342W), the top God of the company's

diagnostic offerings. Offering OEM repair information and guided component tests, its list price is £7,999.

Launch Tech UK’s diagnostic alternatives for multi-brand workshops focus on ease of use, wide vehicle coverage and extensive diagnostic capability across its range of smart tablets. Both the X-431 Euro Tab III (£5,700) and the X-431 Euro PRO 5 Link (£2,994) feature an integrated version of the Haynes PRO electronic module, along with a new Smartlink C VCI. Connecting to the OBD port and communicating wirelessly with the handset, Smartlink C facilitates fast ECU reprogramming, effective J2534 pass-thru and rapid OEM software downloads. Yet, should you get stuck, Launch's Super Remote Diagnosis can facilitate a service provider to access the vehicle remotely and perform diagnostics, recoding, or reprogramming functions, while you focus on another task.

Delphi highlights that diagnostics tools are for life, not just for Christmas. Its new DS180 (£2,440) is five times more powerful than its forebear and supports more contemporary challenges, such as those involving ADAS, security gateways and Pass-Thru technologies. We find its Flight Recorder system especially interesting (and beneficial for road safety), where test-drive results are available for review, after you return to the workshop. Should you be interested in repairing high-voltage vehicles, Delphi adds that the DS180 covers 85% of the hybrid and electric vehicle cars on UK roads.

Back to Earth

As worthy as they are, such purchases are major capital investments that a typical technician is unlikely to make,

For garages that are considering investing in their ADAS capabilities, consider

Boasting space-saving double-sided target boards, it offers coverage of 31 car and LCV brands, including 284 vehicles with cameras and 146 models with radar –numbers that are increasing. Naturally, it is compatible with new and existing Delphi Technologies DS diagnostic tools, thus streamlining the recalibration process. Prices start from £7,000.

Try getting this under your Christmas tree! Yet, ATLs are worth considering for garages looking to make a major investment in its facilities. Pictured is the Sun Connected Automated Test Lane (EEKT102A02).

Delphi's CRC-150 ADAS package.

Especially if you are just starting your career, seek out special offers on tools to start building your lifetime investment. Yet, look after them. This nine-drawer Sealey top box possesses ball-bearing slides and costs £155.94.

unless running their own businesses. Snap-On responds, quite reasonably, about how a decent-quality laser thermal imaging camera is invaluable for diagnosing anything from brakes to exhaust after-treatment systems, see below right. Yet, if that does not appeal, how about upgrading your battery-powered impact wrench? Snap-On's 18-volt, 12" CT9080 produces 1,423-newton metres of torque – which is over four times the twisting force produced by the engine fitted to the current generation (and soon to be culled) Ford Fiesta ST.

Yet, if the British Father Christmas is not quite as willing as the North American Santa Claus to gift you £865 for Snap-On's thermal imaging camera and £953 for the impact wrench, the £264 for Launch Tech's DPF Cleaning Gun and cleaning fluid may be tempting for garages, who are confronting a glut of particular filter blockage complaints. This tool facilitates technicians to spray cleaning fluid under pressure directly into the DPF through the pressure sensor tube.

However, what about all of those smaller but less valuable items that make technician lives so much easier? Sealey reckons that it has the answers – but only until the 31st of December, when its Christmas tool promotion ends. For instance, how about a 14-piece 3/8" metric socket set from the firm's Platinum range for £47.94? For the same money, you could have a rechargeable LED inspection light. Alternatively, if your workshop's doors are open permanently at this time of year, how about an infrared heater, which comes with a telescopic stand, for a shade under £150? Naturally, plenty of tools are available in the promotion; perhaps our favourite is the selection of ½" breaker bars, between 450 and 650mm long and produced in a variety of colours, priced between £16.74 and £28.74. For more information about these limited time offers, check out Sealey's digital catalogue via this link: https://bit.ly/SealeyDigitalCatalogue

(Prices quoted within this feature include VAT but should be checked with your supplier for accuracy.)

Tools, such as this Snap-On thermal imaging camera are extremely useful but, with the purchase cost nudging £1,000, garages should consider whether it should be financed by the garage, or technician.

Whether as a gift for yourself, or somebody else, do not forget training. An annual subscription to the Delphi Technologies Academy costs £220, which the company states is one of the most comprehensive and advanced online e-learning platforms available to anyone in the aftermarket. It covers traditional repair areas, such as brakes and suspension, through to negotiating complex electrical systems and getting to grips with electrification, Pass-Thru and Security Gateway technologies. Over 200 training courses and other technical materials are available. See Delphi Technologies (https://academyuk.delphiautoparts.com/#/publicdashboard) for more information.

To EV, or not EV –that is the question!

The question of whether garages should prepare now for electric vehicle repair has been a hot topic of debate over recent years but judging by the rate at which EV training is booking up, workshops are now appreciating the benefits of getting everything in place before EV adoption ramps up. Along with the significant numbers of hybrids entering the vehicle parc, it seems reasonable that the investment in training and equipment needed to take on this work will soon make significant returns – attracting new customers from competitors who are not prepared. AT’s local workshop has used its recent high-voltage training as a springboard for a new marketing campaign and they have discovered new customers who have come migrated from the main dealers and also directed from enquiries to the Hybrid and Electric Vehicle Repair Alliance (HEVRA).

Workshops who are seen to keep up with the times could also differentiate themselves from the competition when attracting new recruits. Offering training in the latest technologies is also a great way to retain existing staff.

Becoming EV-ready will not suit all – rural garages in an area with a poor charging infrastructure and low take-up are unlikely to see HV vehicles through the door anytime soon, but many urban workshops will only see more of them as time goes by. HV vehicles is unlikely to be the saviour of greener motoring but will certainly be part of the solution in the quest for more sustainable mobility, and the earlier you get on-board, the sooner you will become the go-to specialist in your area.

Training and investment

“How can the aftermarket get ready for tomorrow, today? It’s important to prepare,” says Neil Fryer, Vice President for the global Delphi Technologies Aftermarket business at BorgWarner. “Technicians won’t be left behind as long as they have the skills to cater to the new vehicle landscape. For now, the electric vehicle market presents the biggest opportunity, so it should be the focus.

Fryer continues: “EVs use high voltage components and cabling, which means technicians need to be sure a car is electrically safe before working on it. Even a job that an auto technician does daily on ICE vehicles, such as changing brake pads, could cause a serious incident if done incorrectly on an EV.

“It is not an option to simply ‘learn on the job’ or as and when customers request EV assistance. Specialist training is needed to ensure garages are equipped to handle any vehicle confidently and safely. Theory courses are available online to get to grips with the new systems. Then, accredited inperson training such as we offer at Delphi Technologies gives a practical opportunity to test and develop skills with expert support. As new EV brands and models enter the market, parts will evolve, so training should be undertaken regularly to ensure you have a holistic knowledge of EV systems.”

“The profits generated from maintenance, service, and investigation of current ICE vehicles can be invested into training and equipment needed for EVs. It will be no easy task, but becoming experts in repair and maintenance for both types of vehicle will be a must in the modern garage.”

EV skills gap

New data from the Institute of Motor Industry (IMI) reveals that the first six months of 2022 saw the highest number of technicians take an EV qualification that is eligible for IMI TechSafe accreditation, since its introduction in 2016. The number of technicians now qualified to work safely on electric vehicles is estimated to be 32,900; the equivalent of 15% of technicians in the UK.

Despite the rapid acceleration, the forecast of when the EV skills gap is likely to hit – the shortfall between electric vehicles on UK roads and enough approved technicians to service, repair and MOT them – has been dialled back by the IMI, from 2028 to 2027.

The new prediction draws on Auto Trader’s latest Alternative Fuel Vehicle (AFV) parc data which suggests that alternative fuel vehicles will make up 37% (12.6 million vehicles) of the total car parc by 2030 and that 26% (9 million vehicles) will be pure EV with adoption more rapidly than previously anticipated. The IMI forecasts that the number of TechSafe qualified technicians required to work with electric vehicles by 2030 is 90,000.

Peer support: Resolving EV repair issues as a team

Pete Melville tells AT why he felt the need to create the Hybrid and Electric Vehicle Repair Alliance (HEVRA), the technical support it provides workshops entering the world of Hybrid & EV repair, and describes typical vehicle faults HEVRA members encounter

I bought my first electric car back in 2015, and fairly quickly realised that these would become more popular, and that created a couple of potential problems – those who bought electric cars would need to get them serviced and repaired, and those who service and repair cars would need to adapt to working on them. Having done the hybrid and EV training myself, which was very useful and interesting, I wasn’t convinced the training offered would equip someone to repair every possible issue, and there wasn’t any way for the customers to know where to take their car. These ideas

developed to form HEVRA in 2017 – a service where customers could find good garages to look after their electric cars, and we’d make sure they were good by providing everything they needed to be good. HEVRA stands for the Hybrid and Electric Vehicle Repair Alliance, and also means “together” in Kurdish, which, although I don’t speak Kurdish, I thought summed it up quite well.

The issues I identified were:

• EV-trained mechanics saw EVs so rarely that they essentially forgot their training

•

• Mechanics were reluctant to take on work because of a lack of experience, therefore wouldn’t get any experience

• Parts were very expensive.

We’d solve the first issue by creating a network of trained and supported garages and promoting that network to the general public. The second issue would be fixed by publishing our own technical guide for each model. The third and fourth issues we’d fix by providing member garages with a regular newsletter and technical support. The newsletter would allow them to learn from the experience of others, and our support would mean garages could take on jobs with confidence. The issue of parts prices can be helped by accurate diagnosis but in some cases, it’s also possible to repair rather than replace.

Helping members get to the root of the problem

The support we provide is essentially split into two categories – marketing and technical. The two are of course linked, as our technical support maintains the reputation of the network and getting more cars in the door increases an individual technician’s experience.

On the marketing side, we promote the network with various owners’ clubs, with charging service providers, online and at in-person events. End users can then find garages in their area via our website and contact the garage directly to book their car in.

The garage then has their initial training (which they need to do elsewhere before signing up), their experience gained from previous repairs and from our newsletters and our vehicle-specific guides. If they need it, they can also call on our technical support service – a free and unlimited part of membership. We provide whatever help is necessary to get to the bottom of the problem. Obviously this benefits the customer as well as the garage, and it’s also important for us for two reasons: Firstly, every job done can have an effect on the whole network’s reputation, so it’s important for us and other members that a customer has a good experience. Secondly, for our own support team, we learn what we need to know by our members asking those questions.

Technical support case studies

The most recent fault I dealt with involved a Renault Kangoo that had been brought into a garage as a non-start. It’s over ten years old, which is about as old as you can get in the EV world at the moment, although we do support some hybrids older than this. The van had fault codes for the DC-DC converter (a solid-state component that performs the function that an alternator does on a traditional car) and a temperature sensor. Looking at the live data showed more anomalies – over a thousand volts reported in the inverter and some of the temperatures were over 500°C. The DCDC converter output was 31V and 63A, and yet only 11.8V at the 12V battery. Clearly something strange was going on.

Strange faults are nothing unusual on cars that are controlled by software and you may have come across this even if you don’t deal with electric cars. If you work on diesels, have you

Different makes and models work in very different ways

ever noticed that some cars won’t start when a common rail injector is leaking back, and yet others start perfectly but then suffer problems when under load? It’s thanks to one value in the ECU’s software that sets the required fuel pressure to start. That’s all it is. We don’t generally repair software, but it’s important to understand how it works on that particular car to repair the electrical and mechanical parts.

The inverter was not correctly initialising. When this happens, the various parts of its memory fill up with 11111111… rather than the correct binary numbers. The software then reads these values as those crazy figures you saw above, and decides the temperature values and DCDC output are the problem. It also won’t let the vehicle start as the inverter voltage isn’t the same as the battery voltage (in fact it doesn’t even get to that point because it will check for plausibility before connecting the traction battery).

So how did we deal with this Kangoo? I attached a pre-written test plan to an email and clicked send. We know there’s a relatively small number of things that will cause this incorrect initialisation, so it’s just a case of doing a few multimeter checks to determine which it is. These pre-written test plans not only allow us to offer the service we can at the price we do, but they also make the service better – just like a mass-produced car, making something the same every time means it’s not only easier, it means you can make it consistent and, if necessary, tweak it to make it even better. We can make sure all the information needed to deal with that fault is in that guide and if the garage follows the guide and it’s still not clear, it’s our job to make the guide better next time.

Of course, there’s always a first time you see a fault, so I’ll give you a very different example. A 2018 Jaguar I-Pace, again towed in to a garage as a non-start. Needless to say, we’re much more familiar with the Kangoo above, than a car that has only started falling out of warranty in the last year. This particular example was totally dead, requiring the car to be accessed using the emergency mechanical key. Once both 12V batteries had been charged, it presented a huge number of fault codes and had lost significant coolant in both the drivetrain and battery circuits.

The garage decided to perform a visual inspection and also noticed a bolt missing from one of the front motor mounts. Getting more information from the customer revealed the car had already been apart – a franchised dealer had actually removed the entire front powertrain assembly to try to locate the problem. They had then quoted the customer to replace the motor, inverter and wiring harness at a cost of over £8,000. Unfortunately, we often see this type of ‘diagnosis’ where a garage will quote to replace everything in the hope the customer will either take the car away or hope that one of the new parts might fix it. Even more worryingly, when we end up fixing cars like this, often the fault is something else entirely, so these bills are not only very expensive, but won’t even fix the vehicle. The customer had declined the repair and taken the car for a second opinion, so the dealer had refitted everything. Well, refitted mostly everything.

The new information certainly helped, it explained a lot of the fault codes and it also meant the car probably hadn’t suffered a coolant loss, it had just not been refilled after being apart. The best option was now to clear all the codes and see what the current issues were.

We found most of the fault codes cleared, the few left were “missing data” type codes which are pretty vague, and a few more relating to the electric parking pawl actuator, which had the emergency release pulled in order to get the car to the garage.

“This change is no different to electronic fuel injection becoming mainstream in the 1990s or diesel becoming mainstream in the 2000s –there will always be those who get involved and get a name for themselves and can do a good job and make money, and others who drag their feet.”

The park pawl was then set back to its normal position, surprisingly the fault codes did not clear, so perhaps this was a different issue and the most likely was that it hadn’t been reconnected when it was apart before, so the first job was to look and see if it was plugged in.

Unfortunately, it’s probably easier to see secret files on the government’s next U-turn than it is to see an I-Pace parking lock when the car’s reassembled, so it was time for another idea. By accessing the wiring from further up we could do a few tests to see if it was likely to have a parking actuator on the other end of it, which might reveal a different problem, or at least give us some evidence that it was worth stripping the car down a bit. This revealed a missing 12V supply to the actuator, which turned out to be a broken wire in a fairly accessible location. And just like that, it was fixed. Obviously, there was some more work to do to bleed the cooling systems and put right some of the previous garage bodges, but the car was driveable and the fault codes were cleared.

Next time we see a similar issue, it won’t involve so many messages back and forth, and this is how we build the expertise that makes assisting in the Kangoo case above so straightforward. Not only does it help with that particular fault, but we’ve learnt a little more about the workings of the car –which control units use which messages, and other little details that will help us fix unrelated faults on other cars of the same type.

Of course, when one of our members gets in touch with an issue, they don’t know whether they’ll get a straightforward “here’s all the info” or a long-winded “let’s work this out together”, but one way or another, we’ll do what we can to help.

Common brand-related faults

Renault is the brand we deal with the most, followed by Nissan, Tesla and then BMW. All of these manufacturers have been making electric vehicles for many years and therefore have far larger numbers outside of warranty than some other brands. I think another reason we see so many Renaults is because they use a more modern, software-driven design and rather than having certain common faults you see again and again, the problems tend to be more random. Both of these factors make them harder to diagnose so it’s more likely a garage will get in touch.

One fault we are seeing again and again though is the DCDC converter on some Renault Zoe models, which does the same job as an alternator on a traditional car. It’s a good job for garages as it involves quite a bit of labour without too much spend on parts or programming requirements. We’re also seeing quite a few hybrid battery problems on the Range Rover Sport and heating issues across all makes and models as we head into winter.

Do you think there is a need for all garages to prepare for Hybrid & EV repair?

I think it’s important to be able to repair the cars your customers drive, and it’s also important to take on new customers to replace those who inevitably move away or give up driving. This change is no different to electronic fuel injection becoming mainstream in the 1990s or diesel becoming mainstream in the 2000s – there will always be those who get involved and get a name for themselves and can do a good job and make money, and others who drag their feet.

Plug-in vehicles currently account for about 3% of all the cars on the road – about the same number of Land Rovers on the road, and the trend is only going one way. In 2022, more fully electric cars have been sold new than diesel cars, and a third of new cars have a high voltage system.

The work you need to do and when you need to do it depends on the customers you have and the customers you want to attract, but I think it will be essential in the future.

membership@hevra.org.uk www.hevra.org.uk

Is your business in Electric Vehicle Ready Mode

It doesn’t have to be of course, but if you intend to do EV work then it needs switching on. Automotive author, Tom Denton, says there are a few steps you need to take now, or at least be seriously preparing for them. In the next issue of AT, Tom will outline the qualifications you and/or the team will need, what equipment will be essential, and how will you market and price EV repair and maintenance.

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Cleevely Motors celebrates sixty years

Evolving an established local garage into a national pioneer does not happen overnight but what next? Rob Marshall reports from Cleevely Motors' 60th anniversary to discover the latest news in its journey

Few regular readers of AT would not have heard of Cleevely Motors of Cheltenham. This busy independent Gloucestershire family garage is now in its third generation, with Matt and Claire Cleevely overseeing a busy workshop, serving its local community, while nurturing its national repute.

Looking forward but not losing focus

For the Cleevely family, the future is very much electric. This journey started officially just five years ago, when Cleevely Electric Vehicles was incorporated as a new sister company, with co-directors David and Samantha Smith. It was a brave move. With the pre-existing Cleevely Motors having to

customer waiting lists of at least several weeks, it would have been logical to have simply expanded to cater for the immediate workload. Instead, Cleevely EV introduced more radical thinking, which has grabbed nationwide attention. Yet, traditional repairs have not been abandoned. Since the pandemic, Cleevely Motors has moved from its original site to the Lansdown Industrial Estate and remains as busy as ever.

Cleevely Motors, Cleevely EV and Cleevely Mobile provided guests with insight into its past, present and future

“Naturally, most of the focus was on Cleevely EV, although nods to the family's past took centre stage, including the presence of Matt's grandfather's longretired Land Rover Series One recovery truck”

Cleevely EV thinks that zero direct emission taxis should not be limited solely to the capital, hence it forging a relationship with the LEVC as an approved seller and service centre for its high-voltage plug-in hybrid taxi.

implement

Even so, subsequent expansion into adjoining units has been due to increasing interest in the electric vehicle business. While EV hire and sales remain, the increased interest in high-voltage propulsion has led to Matt becoming one of the leading voices in the EV aftermarket. Instead of keeping hard-earned repair techniques close to his chest, Matt is disarmingly altruistic in his approach. As with any technician, his chief objective is to keep vehicles on the road, by making repairs as viable economically for owners as possible. His attitude extends to the aftermarket community, for whom he offers his premises as a base in which Pro-Moto delivers technician high-voltage training, as well as being a HEVRA member, where technicians assist each other with repair advice.

Time for celebration

To commemorate 60 years of Cleevely Motors, the companies hosted a birthday celebration, twinned with an EV meet. Naturally, most of the focus was on Cleevely EV, although nods to the family's past took centre stage, including the presence of Matt's grandfather's long-retired Land Rover Series One

recovery truck and the immaculate Mini Mayfair that belongs to Shaun Cleevely, Matt's Father.

The event also provided the businesses with a chance to highlight how they have evolved, post-pandemic. Aside from all Cleevely-related companies now being based at the same site for the first time, it also heralded a new company. Cleevely EV Mobile was established last year to bring repair services that Cleevely EV offers to customers directly and is enjoying strong demand. It also introduced a major new partnership. While Cleevely EV is not the first Castrol Service Agent, it is the first aftermarket garage to utilise Castrol ON EV fluids, which benefit the customer and vehicle, by enhancing range, permitting faster charging and extending the lifespan of high-voltage powertrains. Naturally, representatives from the Race Group were kept busy throughout the day to answer questions.

It was especially reassuring to discover that owners of certain latest models, such as this Hyundai Ioniq 5 that was launched only last year, prefer to entrust this aftermarket EV specialist with repairs and maintenance, rather than main dealers.

“Instead of keeping hardearned repair techniques close to his chest, Matt is disarmingly altruistic in his approach”

While potential and current customers were greeted with open arms, in typical Cleevely fashion, technicians from other garages were also welcome, including those curious about training and working on high-voltage vehicles for the first time. The event was also supported strongly by EV enthusiasts, in particular members of the Southwest EV Group, Dorset EVs and model-specific clubs, such as the Renault Zoe & E-Tech & Z.E. Owners Club.

Clearly, the celebrations of all things Cleevely could be described as nothing more than a success but what next for the businesses? Matt insists that training never ends and so expanding his team's numbers and skills is a priority. He is practising what he preaches and is focussing on improving customer experience, before, during and after the vehicle leaves the workshop.

EV & HYBRID

Selling the EV – five years on Matt believes that expansion into other areas should not be to the detriment of other parts of the business. Naturally, with more EVs entering the marketplace, high-voltage sales have grown organically. Yet, Cleevely EV could have been satisfied solely with its stock comprising primarily of used Nissan Leafs and Renault Zoes, with a smattering of Teslas. This is not the case.

Considering the beneficial role that EVs play in reducing urban air pollution levels, Cleevely EV has researched how Cheltenham could benefit from more local support with electric hackney carriages. As a consequence, it has since become an approved seller and service centre with the London Electric Vehicle Company (LEVC), a firm owned by Geely Automotive (a Chinese firm that has a principal stake in Volvo, for instance) and which assembles the vehicles in Coventry.

Yet, this is not all. An interesting development is Cleevely EV becoming a distributor and reseller of Carver electric tricycles. Apart from offering means of zero localised emission transport for last-mile trips especially, such vehicles can be driven on a motorcycle licence and tilt under cornering. Furthermore, they offer a relatively low-priced means of electric transportation – something that is worth considering in today's cost-conscious times.

Four wheels good, two wheels bad? Not so – EV bikers also joined in

Several repair displays were present, such as this spilt Nissan Leaf transmission. Other presentations included Cleevely EV's modified Tesla Model 3 and its stripped-out Nissan Leaf high-voltage exhibit.

“Cleevely EV Mobile was established last year to bring repair services to customers directly and is enjoying strong demand”

Does electric herald the three-wheeler's return as an affordable alternative to increasingly expensive cars?

Training review: EV Troubleshooting with Pro-Moto

I recently attended a new 2-day Electric Vehicle Troubleshooting Course created by Pro-Moto’s founder Eliot Smith at his HQ in Aldershot, Surrey. Eliot has notched up 40 years of experience in the trade, on the workshop floor as a BMW technician before moving into technical support for Honda. This saw him travelling around the globe, experiencing the latest hybrid and electric vehicle technology. He left to start an independent training business and Pro-Moto was born. One of his first tasks was to develop and write the national qualification for the UK aftermarket alongside the IMI and since then has been involved in educating not only technicians but many from outside the trade, including research and development companies, the police and fire rescue services.

The Pro-Moto training centre in Ash Vale is a recognised national training provider with IMI Awards. Eliot has developed three new courses to complement the Level 1 to 4 EV training he provides (he also offers courses on CAN-Bus, fuel injection, air con, electrics, and effective scoping.) ‘HV Battery Repair’, ‘HV Charging Systems’ and ‘EV Troubleshooting’ have been designed to keep up with the common faults identified within EV vehicle systems.

I went on the 2-day EV Troubleshooting Course, which addresses how to best diagnose, troubleshoot problems, and repair the systems and components. It covers insulation issues, battery degradation, HV battery imbalance, non-start battery faults, charging problems, and more.

I found Eliot very flexible with his approach to the course content and would tailor the course to your needs. The first day of the course began with a discussion on troubleshooting process – preferred methods, tools used and any experience we had on EV system faults. We were advised to take our time, use our instincts, be confident in what we did, make notes, take pictures, and then review our work.

Up for the task

Over the two days, we were guided through six scenarios. I do not want to give away too much detail and spoil it for future attendees so will give a glimpse into the content and teaching methods. One task involved a non-start Lexus Is300h, which did not have a ‘ready mode’ symbol displayed on the dashboard. Eliot would let you carry on with the diagnosis but would ask why you chose a particular tool or test method. We would review our methods and results and discuss what would we have done differently to help find the faults and fix the vehicles.

We were presented with a non-start Nissan Leaf, which had the high voltage warning light on. This task highlighted the need to always use the correct safety workwear and tools, to disconnect the auxiliary battery and the interlock service plug and wait until the capacitors had depleted the high voltage. The group then practised checking the voltages of the main

By Des Davies AAE MIMI of Top Gear Motor Services

cables to the HV battery (max 5V is safe to work on). We were then shown the correct procedures to remove the battery from the vehicle. Eliot explained in detail how to rebuild the battery and replace it then onto the vehicle frame.

Other tasks involved a Renault Zoe, which would not charge properly and checking the individual battery cells on a Toyota for imbalance.

Summary:

An excellent course with lots of activities and handouts given to enhance our learning journey on Electric vehicle systems, with real-world faults. Eliot is a very knowledgeable, approachable, and clever instructor who lets you diagnose the vehicles yourself but observes and closely monitors your progress and guides your diagnostic plans and methods.

I thoroughly enjoyed the experience having gained a wealth of knowledge on completing this course. Highly recommended!

www.pro-moto.co.uk

Eliot discussing the battery cells and blocks

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Training resources

Your place or mine?

Autotech Training, a division of the Autotech Group who provides recruitment services to the trade, delivers various training programmes, including Electric Vehicle courses, within its training centre in Milton Keynes – upcoming dates are listed on the right.

Training can also be delivered onsite at a customer’s workshop, eliminating travel expenses and disruption to the business (courses can be booked over weekends and bank holidays). This option provides great value for money and in addition, the experienced trainer will also use, when appropriate, a workshop’s own equipment so employees are trained on the kit they use day-to-day.

Reader feedback

Josh Whittemore, Training & Development Co-ordinator at the Elite Garages network of independent garages, took the Level Two training at Autotech’s EV training suite in Milton Keynes, saying: “I thought they were really professional and that's when I decided to get our whole team trained by them.” Josh selected the number of vehicle technicians from each site to receive the EV training, based on the density of EV sales within their local area – smart thinking! Because of the high number of Tesla sales within Bournemouth, four vehicle technicians from Elite Garage Bournemouth were EV trained by Autotech. Josh saw this training as a much needed and logical step: “We need to be prepared. Not only to be able to create a new

revenue stream and meet customer demand, but to safeguard our employees and equip them with the relevant skills to work safely on these high voltage vehicles.”

Autotech Training dates coming up in Milton Keynes

IMI Level 2 award in Electric/Hybrid Vehicles Routine Maintenance Activities

November 21, 30

December 5,19, 21

January 9, 16, 23, 30

February 6, 13, 20, 27

IMI Level 3 award in Electric/Hybrid Vehicle Systems Repair and Replacement

November 21 & 22, 30 & 01

December 5 & 6, 19 & 20, 21 & 22

January 9 & 10, 16 & 17, 23 & 24, 30 & 31

February 6 & 7, 13 & 14, 20 & 21, 27 & 28

IMI Level 4 award in the Diagnosis, Testing and Repair of Electric/Hybrid vehicles and components

November 23 & 24

December 7 & 8

For further information from Autotech Training, call 01234 240503, or visit www.autotechtraining.co.uk

Plugging-in to the aftermarket’s need for EV servicing solutions

Using its OEM expertise, Delphi Technologies provides independents with the tools and training required to compete with franchised dealers for EV servicing.

Delphi’s DS180 BlueTech diagnostic tool is compatible with over 85% of the mainstream electric vehicle parc and covers more than 60 hybrid and electric vehicle models, giving technicians the ability to read fault codes and view live data for key modules such as the invertor, charger, motor and battery management system. There’s also the capability to perform special functions, such as recalibration following reduction gear or motor replacement. The tool also boasts new integrations over its predecessor, such as CAN FD, multiple CAN channels, and DoIP (Diagnostics over Internet Protocol).

Of course, having the right tool for the job also requires the right knowledge to use it. While the DS180 BlueTech is designed to be simple to use, there are a series of video tutorials on the Delphi Technologies Academy – the brand’s comprehensive e-learning platform. A dedicated EV/hybrid section includes a wide selection of courses and tutorials on everything from working with voltage and having the correct PPE/CPE to testing high-voltage insulation and the safety steps that must be adhered to when working on an electrified vehicle.

Subsidised Level 3 Hybrid/EV course

The Independent Garage Association will continue to heavily subsidise Hybrid/Electric Vehicle Repair Level 3 courses for IGA members at a rate of £250 + VAT until the end of the year, as it prepares to launch a Level 4 Award in Diagnosis, Testing and Repair of Hybrid/Electric Vehicles and Components. This

The training course are designed to be part of a ‘blended’ learning approach that combines online and practical learning, with each earning credits towards the Institute of the Motor Industry’s Continuing Professional Development (IMI CPD) programme. Technical Services Manager, Luke Garratt, says: “Helping independents adapt their service offering to include electrified vehicles is something we take very seriously. Our size and expertise allow us to efficiently bring to market OE-spec service parts and other components for EVs, while customer feedback has enabled us to shape our EV diagnostic and training solutions to ensure that they meet the varied requirements of garages and technicians.”

qualification covers working on live HEV high voltage vehicle systems and components. Contact the IGA to join the waiting list for the new course or enquire about available spaces on the Level 3.

01788 225 908

Now is the time to upskill

“ While there are undoubtably challenges to deal with in the present, aftermarket operators have to have one eye on the future. And critically, the future has arrived,” says Bob Wiffen, Workshop Solutions Director at LKQ Euro Car Parts.

“Hybrids are increasingly commonplace in the independent aftermarket, and EVs won’t be far behind, once they start coming out of warranty at scale. Independent garages are already widely acknowledged to be ahead of the dealerships on quality of service and value for money. Now is the time to upskill, so that they can keep pace with a customer base that’s evolving. Those that move first will enjoy a competitive advantage locally, at least for the time being.”

According to LKQ Euro Car Parts, effective marketing is key, to all garages, but especially those with a point of difference when it comes to maintaining vehicles with zero-emission capability. As well as retaining existing customers that trade up to the latest, cleanest, greenest technologies – workshops that promote their expertise in working with battery-powered vehicles can win business from their competitors.

The LKQ Academy has committed to training more than 2,000 technicians in EV and hybrid service, maintenance and repair in 2023, and is launching two new courses: EV troubleshooting and HV Battery Repair.

For more information, visit www.lkqacademy.com. Individual annual memberships start at £649 + VAT, and garage memberships are also now available.

“As well as retaining existing customers that trade up to the latest, cleanest, greenest technologies –workshops that promote their expertise in working with batterypowered vehicles can win business from their competitors.”

Bob Wiffen, Workshop Solutions Director at LKQ Euro Car Parts

EV & HYBRID

Become an EV Master

Our Virtual Academy offers technicians who have the Level 3 Award, the chance to supercharge their electric vehicle diagnostic skills with its EV Masters Roadshow, developed in partnership with HEVRA.

autotechnician joined six technicians on the last day of their EV Masters course within an RAC workshop near Brands Hatch back in March. Over four days, technicians are fully immersed in the practical diagnosis of hybrid and electric vehicles, giving candidates the skills, knowledge, and confidence to efficiently diagnose then carry out subsequent repairs of electrified vehicles, achieving the IMI Level 4 Award.

It’s very much a hands-on experience, with perhaps just three or four hours of the course within the classroom discussing theory. Peter told us: “Technicians do their job on their feet and work with their hands and the best place for training is in the workshop. Like a lot of people, learning through action and application cements knowledge in their minds. It’s about developing the skills as well, getting them comfortable working around the high voltage systems.”

Climate Comfort System in New Energy Vehicles

As more new energy vehicles (NEVs), which include hybrid and electric vehicles, take to the roads, more will come into the workshop for routine climate system service, maintenance, or repair. Technicians need to be aware that they require special handling and safety procedures, as well as specialist knowledge to complete it successfully. Many NEVs rely on a heat pump solution, which is an advanced system compared to a standard air conditioning (AC) loop.

Nissens

High-voltage vehicles include not just battery electric vehicles but also hybrids that move using an electric-only mode, when the combustion engine is deactivated, see video at footer of this page

EVs: PICKING PARTS PARTNERS

While you may have invested in tools and training, Rob Marshall finds that it is worth spending some time not just researching which components are relevant but also knowing on whom you can rely

Whatever you think about the wisdom of exchanging Arabian/ Russian oil for Chinese minerals, high-voltage transport remains a growing and intriguing proposition for all of us. Naturally, most new sales have come from businesses, keen to benefit from the tax incentives that compensates them (to an extent) for having to switch from the convenience of diesel. The fact that Synetiq, a leading vehicle recycling company, reports that demand for EV scrapping has increased tenfold within the last two years shows that the push for electrification is very much relevant for the aftermarket.

Avoiding preconceptions

Again, whatever you think of the motivations behind the decisions, electrified transport has accelerated the rate of technological change. Unlike in previous years, where a new car model could inherit virtually all of the mechanical entrails of a generation or two previously, manufacturers are forced to upgrade and develop the running gear faster than before. Even model facelifts, which appear to be little more than a bonnet and bumper change, tend to harbour more substantial mechanical changes underneath. This situation is even more

true of battery EVs and plug-in Hybrids, as the race between manufacturers to increase range is especially aggressive.

Therefore, when looking at a high-voltage vehicle, consider the challenges that manufacturers have faced. When looking at steering and suspension components, for instance, heavier high-voltage vehicles are likely to possess different shock absorber/damper specifications. Therefore, while dampers from conventional petrol/diesel models may bolt-on, they will be to the wrong specifications. This can lead to under damping, which prejudices both handling and braking distances. Other changes may be more obvious, such as different suspension designs. You may find additions, such as an extra rear-mounted Panhard rod. We have come across manufacturers fitting lighter suspension components to their EV models, such as castings manufactured from aluminium alloy, rather than iron. BMW 740e plug-in hybrid e-drive mode

When looking at high-voltage vehicles, consider that weight concerns are not limited to Battery Electric Vehicles. Plug-in Hybrids comprise not just hefty battery packs and motors but also the combustion engine and associated transmissions.

When working on these exciting new technologies, consider that identifying the correct parts is another complication that you face.

Supplier considerations

Many garages have prioritised other services from their parts suppliers over price alone. Availability and range are typical examples. You may decide to align yourself with one main supplier, or several of them, but there are plenty of options.

LKQ Euro Car Parts provides an overview of the current situation: While the company says that it is dedicated to

doing everything that it can to support workshops through the current difficult environment, it encourages businesses to consider their futures. It reports that hybrid models are common among independent aftermarket workshops already and it foresees that additional high-voltage vehicles (including Battery Electric Vehicles) will not be far behind, once their manufacturer warranties expire.

Another parts supplier, Meyle, agrees. It states that, to keep up with the rising demand for electrified vehicles, expanding the expertise in the safe handling of high-voltage vehicles will make automotive workshops more competitive.

While we will not repeat our separate article on EV training, consider that some parts suppliers provide such opportunities to further your understanding. This is especially relevant with specialists. Take Nissens Automotive as an example, which concentrates on thermal management. Clearly, understanding the function of thermal management systems in modern highvoltage vehicles is essential, considering it differs considerably from the traditional cabin-only HVAC systems that have been employed for many decades. Nissens can provide you with not just this knowledge but also valuable diagnostic information.

Talent but not the tools...

Upskilling and being aware of the safety implications presented by high-voltage is all well and good but not very useful if you do not have the appropriate physical tools at your disposal. LKQ Euro Car Parts highlights that it has a full suite of equipment that contains everything that a technician needs to service high-voltage vehicles without suffering harm. Its safety pack, for instance, includes high-voltage floor matting,

Make no presumptions, even with popular models that possess high-voltage models. Vauxhall's fully electric Corsa-e, for instance, has different subframes and suspension components, compared to its combustionengined sisters.

Can we come and say hello?

Ben’s Outreach Team is on the road delivering free on-site visits to micro, small and mediumsized automotive employers. It’s our chance to tell you more about the many ways we can help you and your team – like our free and confidential helpline, extensive range of health and wellbeing resources and employer partnership programmes.

Learn more and request your free on-site visit at ben.org.uk/ben-on-the-road

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Scan to request a visit from Ben

an insulated rescue pole and safety clamp, safety signage, an insulated face shield and gloves, extra-long hex keys and a 22-piece insulated toolkit. Yet, the company reports that it has paid special attention to ensure that its offerings are 'budget friendly'.

The company also reports that high-voltage vehicles place a greater emphasis on software. LKQ Euro Car Parts reassures us that it is striving to ensure that vehicle manufacturers neither lock independent garages out of their gateways, nor fit parts that can be activated only through the manufacturer’s server.

Yet, the firm argues that diagnostic investment is only one part of the software investment strategy and garages should also embrace garage management systems that enhance customer service provision, while streamline quoting, invoicing, resourcing and parts ordering. It reveals that LKQ Euro Car Parts customers also benefit from exclusive access to CarSys, a cloud-based GMS application, which includes digital job cards, integrated HaynesPro data, job clocking, quick quoting and parts ordering.

The right parts for the right job

Try to keep abreast of how suppliers are keeping ahead of the game. Naturally, this magazine strives to keep you informed with the latest developments. For instance, Meyle reports that its approach to improve OE quality has expanded to give birth to a fresh new range of components for high-voltage vehicles. This has resulted in its portfolio for these vehicles tripling within three years – impressive stuff. Yet, some parts incorporate the company's philosophy of its HD range where OE parts are enhanced. Its latest addition is the introduction of a complete top suspension wishbone for Tesla's 3 and Y models, which eradicates the annoying squeak that plagues the OE part.

Nissens also reports that it is preparing for future aftermarket demands. This includes expanding its radiator and air conditioning condenser ranges. For instance, it can satisfy 74% of the EU high-voltage car parc for high-voltage condensers. Understandably, these cover the most popular models, from Tesla Models S, 3 and X, through to Toyota/Lexus hybrids, Mitsubishi Outlander PHEVs and Nissan Leaf Battery Electric Vehicles. The company reports that it is poised to introduce

Delphi has launched a range of new components for the Tesla Model S, which include control arms, drop links, track rod ends and ball joints. It has also addressed several of the OEM part's shortcomings, such as its heattreatment manufacturing process enhancing these parts' robustness even further.

The MEYLE HD control arm for Tesla Model 3 and Y models will be introduced early next year. It is being added to a range that comprises more than 3,300 products in the Meyle portfolio for high-voltage vehicles.

components for recently introduced models, which comprise Audi's e-tron, the BMW iX and the Mercedes-Benz EQC. The firm emphasises that workshops should have no concerns about quality, because its advanced test, validation and development capabilities are at the company's core. These operations are carried out worldwide, including at a dedicated technology centre in Germany and an advanced in-house test centre in Denmark.

Even so, when considering components, it is easy to be distracted by high-voltage vehicle differences, rather than the similarities. High Voltage hybrids combine the best and worst of both electric and ICE technologies and, arguably, are the most complex technically. At service time, LKQ Euro Car Parts remind us that, like all other ICE cars, they still require the standard lubrication and filtration attention, although these operations can be conducted only when the high-voltage system is deactivated. Similarly, do not overlook consumable items, such as wipers and lighting. LKQ Euro Car Parts reminds us that it supplies these parts to its trade customers through the ordering platform, Omipart.

Finally, do not forget the value of aftermarket trade bodies, such as the Hybrid and Electrical Vehicle Repair Alliance (HEVRA). Some of its members may also advise you on their experience of certain parts, some of whom may have engineered their own products that are unavailable elsewhere, which are well worth considering.

What is a high-voltage vehicle? Technology is changing quickly; so are definitions. AT defines a low-voltage hybrid as one that employs a sub 48-volts architecture that cannot move under its own power. Therefore, highvoltage hybrids comprise more than 48-volts and can drive under electric-only power. Yet, exceptions exist even to our classifications.

Most notably, certain Stellantis (mainly former Fiat Chrysler Automobile) models utilise a 1.5-litre GDI petrol engine, combined with a 48-volt drive motor within the pictured dualclutch transmission. This architecture permits electric-only propulsion. These vehicles include hybrid versions of Fiat's 500X and Tipo, the Jeep Renegade/Compass and Alfa-Romeo's Tonale. Yet, their low-voltage systems and small batteries limit the EV-only range considerably but at least repair procedures do not involve high-voltage technician safeguards.

Garage Management: Take the reins and get ahead

The fallout from the six-month MOT extension has played havoc with many workshops’ workloads so it makes sense to get the garage, and customers, as organised as possible – to release the pressure during peak times and boost business in quieter months. Here, we look at garage management systems and the importance of online marketing.

TechMan highlights the importance of having a Garage Management System, especially during MOT peak times. The company launched in 2015 to help garages and technicians boost efficiency, improve customer service, increase productivity and grow profitability.

It offers garage owners, managers, technicians and front-ofhouse staff intuitive garage management tools and features to make life easier and remain competitive.

Key features of TechMan include job scheduling, reporting, service assist, a customer portal, purchase orders, Haynes Pro and Euro Car Parts catalogue integrations. A popular feature is the MOT expiry date refresh, which offers TechMan customers a return on investment, or their money back. This gives workshops an analysis of their entire customer vehicle data,

producing a report and then updating the MOT dates in bulk, as necessary. This feature is in addition to the MOT expiry date lookup integration it already offers. The objective is to update any expired or ‘not recorded’ MOT expiry dates. The system will start to send text and/or email reminders to drivers when their MOT expiry date nears, encouraging them to book.

TechMan analyses the current state of MOT dates within its customer data for dates that are current, expired and not recorded. A comprehensive report is generated, detailing the findings, which includes a forecast of how many bookings they will need to make to get a return on the investment of carrying out the MOT dates refresh. If the MOT refresh has not resulted in additional MOT bookings to cover the original refresh cost, TechMan will give customers the value of the refresh back in credits.

For more information about the TechMan Garage Management System or to arrange a demonstration, call 01604 666 720 or visit www.techmangms.com

Recent projects at Haynes Motor Museum

Integrate accounts and provide electronic vehicle health checks for customers

AT spoke to Chris Waterhouse, Workshop & Restoration Manager at Haynes Motor Museum, who has experience of various management systems, to find out what he is currently using to keep restoration projects on track

“I joined the New Zealand Army in 1976 and started an Apprenticeship as a Vehicle Mechanic. I completed my Advanced Trade Certificate qualification as an Automotive Engineer in 1982. After various promotions and postings around New Zealand and overseas, I left the Army in 2002 and moved to the UK. I was initially employed on the tools working for Mercedes-Benz and then moved into management and was a Service Manager for Mercedes-Benz for 12 years. I took up employment at Haynes Motor Museum five years ago and have been the Service Manager for the Workshop and Restoration Centre for the last year. I have worked with various Garage Management Systems from the basic T Card and handwritten diary in the Army to the very detailed and technical system Kerridge at Mercedes-Benz. I have worked with GDS (Garage Data Systems) at the Museum and found it very user friendly. We carry out repair, restoration, servicing and MOTs on veteran, vintage and Classic motorcars for a wide variety of clients. We also prepare cars for the Museum to attend various shows and events. Some of our recent restorations have included Maserati Sebring, Ferrari Dino, Mercedes 300SE, Rolls Royce 20/25, and Series 1 Land Rover.

“GDS is ideal for our use as we need to ensure all parts purchased are put on to the system and times are accurately recorded to ensure correct invoicing. GDS is also used by our Accounts Department to integrate with SAGE. As a charity, we are always conscious of costs and have found GDS to be great value for money. I have no hesitation in recommending this product.”

Workshop Manager, from GDS, features HMRC-recognised digital VAT Software and is designed to be simple to use for managing daily workshop activities, creating invoices, and maintaining accurate workshop service records.

It enables users to book and manage jobs, manage supplier POs and returns, track staff hours, an Electronic Vehicle Health Check System enabling picture uploads on the go, sends customer texts for car collection & service and MOT reminders, supports postal, email & SMS marketing, connects to your account platform, has an integrated payments system, and imports data from most other management systems.

Would you like a demo? Register your interest at www.gds. co.uk/get-demo

‘Garages need a predictable flow of online enquiries to convert into work’ Workshop owner and trainer Andy Crook, says that the majority of independent garages either don’t have an online presence, or don’t maximise the one they have. As creator of the Atomic Success Training Programme and founder of the fast-growing Facebook group, Garage Owners Network, Andy says he’s shocked by the lax attitude garage owners have towards being found online.

He said: “In my experience, garage owners don’t seem to think a website and other online platforms are that important. They also tend to have an inflated value of their business. The thing is, if the business only works when the owner works, it actually has very little value at all. Garages can add value and make more profit by attracting customers that are the right fit for their business. They need a predictable flow of enquiries to convert into work – and most of those enquiries start life with an online search.

“Traditional word-of-mouth has been largely replaced by social media but Facebook, for example, isn’t enough on its own. Garages won’t be found for their general services there. What’s needed is a presence across various platforms, with a website being the central core of where customers are driven to. It’s here that they’ll read about how you can help them, look at your reviews and find information at 9pm when you’re not there to answer the phone.”

Andy estimates that out of approximately 35,000 independent garages in the UK, the majority are leaving huge amounts of work on the table for main dealers and fast fits; simply because they haven’t got their head around how easy it is to intercept those enquires online. “Customers buy everything differently now and it’s inevitable that, at some point, they’ll go online. Garage services are no exception. You need to be found easily, provide helpful information and build trust –before they even drive into your workshop.”

Jim Lang, founder of website specialist, Garage Services Online concurs. He said: “Lots of garages come to us because they know they should have some form of online presence, even if they feel indifferent to it to start with. It’s not until the website is live that they truly appreciate and reap the value to their business, from an increase in quality enquiries to a healthier bottom line.”

https://www.facebook.com/groups/garageownersnetwork https://garage-services-online.co.uk

Parts, Tools & Tips

New products, fitting tips & technical advice to ease fault-finding and installation

SUPPORTING

A MOVE INTO EV SERVICING

First Line continues to expand its electric vehicle product offering, with over 1,000 references for fully electric vehicles across over 60 product lines.

Figures released by the Society of Motor Manufacturers and Traders (SMMT) earlier in 2022 revealed that electric plug-in vehicles now account for more than one in six new car registrations, while battery electric (hybrid) cars alone rise to one-in-nine, with more registered in 2021 than the previous five years combined.

Jon Roughley, Global Marketing Director, said: “As the used vehicle parc expands each year, and electric vehicles are making up more of new car sales, the aftermarket should expect to see an increasing number of EVs requiring maintenance and repairs turning up at independent workshops across the country.

Its total number of catalogue applications for EVs now tops over 5,400, fitting over 150 different vehicles. Product groups covered include Steering and Suspension, Braking, Wheel Bearings, and Cabin Filters.

All of its new-to-range products can be found in the online catalogue WebCat, https://webcat.firstline.co.uk/Home

200

NIGHT BREAKER ® 200 is OSRAM’s brightest halogen headlight bulb ever. With up to 200% more brightness1 to guide the way, this high-performance halogen bulb range is a valuable addition to any workshop or garage. A far-reaching beam up to 150m and up to 20% whiter light provide excellent vision and visibility –enabling drivers to see farther and react sooner. Enhance your customers’ safety and offer a modern look with a simple halogen upgrade that is globally approved for road use. Combining quality, performance and style, the new NIGHT BREAKER ® 200 will make your customers see halogen bulbs in a whole new light.

Insist on OSRAM - the No. 1 in Automotive Lighting.

Light is OSRAM

Darker nights are ahead Upgrade your service offering with NIGHT BREAKER®

GO PLATINUM WITH YOUR TRAINING

LKQ Euro Car Parts has launched a new Platinum membership tier for its LKQ Academy, offering workshop customers access to 20 training days – across 25 locations – and 20 eLearning courses annually for £2,499 a year, with no limit to the number of staff who can be trained.

This membership covers the full LKQ Academy training catalogue – resources range from technical education to business support and management courses. All courses are IMIapproved and are updated regularly.

For individual technicians, LKQ Academy also offers Gold, Silver and Bronze tier memberships, which begin at £649 for a 12-month period.

Bob Wiffen, Workshop Solutions, said: “Workshops need to evolve and adapt to meet the ever-changing demands of motorists and their vehicles, so it’s important that everyone on the team has affordable access to quality training.

“As well as covering everything technicians need to know for a first-time fix from ADAS to hybrids/EV and everything in between, the business management courses we offer to garages’ support staff are proving increasingly popular. “We’re helping independent workshops tighten up their backoffice processes, their marketing capabilities and the experience

they offer at front-of-house, to ensure they continue to compete with the dealerships.”

LKQ Academy Platinum membership is available to customers across the UK and can be paid for via direct debit.

https://lkqacademy.co.uk

PARTS, TOOLS & TIPS

SUPPORTING GASOLINE HYBRID REPAIR

The majority of the manufactured hybrid vehicles have a gasoline engine on board. In the future, the most dominant system for hybrids will be gasoline direct injection (GDI), where Bosch boasts a leading position in OE for both injectors and pumps. GDI plays a key role in engine efficiency, reducing fuel consumption and emissions due to direct injection of the fuel into the combustion chamber.

The quality of the engine management parts in hybrids is highly important due to Start/Stop systems instant starting capabilities in cold weather as well. Only parts having an OE level quality can ensure the benefit of hybrid technology in terms of fuel efficiency and Bosch offers a wide range of components for hybrids. For the most sold European hybrid vehicles Bosch provides several gasoline parts, such as: Toyota Yaris 1.5 HSD ignition coils and electric fuel pumps; VW Passat 1.4 GTE Hybrid Variant and Golf VII 1.4 GTE ignition coils, high-pressure injectors GDI, knock sensor, pressure sensor, rotation speed sensor; BMW 225 xe Active Tourer ignition coil, high pressure injector GDI, high-pressure pump GDI, oxygen and knock sensors. www.boschaftermarket.com/gb/en/parts

IN THE NEXT ISSUE OF AUTOTECHNICIAN MAGAZINE…

Within the Jan/Feb issue, we will be highlighting the repair issues, latest systems and products within Lighting, Batteries & Chargers, Clutch, Steering & Suspension. In addition to our usual features, VAG specialist Gareth Davies will provide a Case Study and video descriptions detailing an Audi A3 2005 with a random alarm problem and we’ll also have the next instalment from The Mechanic’s Mentor Dee Blick, plus another thought-provoking article from Andy Crook. We will also be kicking off Autotech 2023, with new online content to help fix faults faster and announce our next training event!

BIG CHRISTMAS GIVEAWAY

OE wiper blade manufacturer, TRICO, has launched a Christmas themed scratchcard competition through its five UK & Ireland distributors, running from 7th November until 16th December, with every single TRICO wiper blade purchased.

The manufacturer has over £10,000 worth in prizes to be won and a top prize of a £2,000 holiday voucher to beat those winter blues. There are more than 500 prizes to be won including hotel stays, Christmas hampers, luxury spa days, Amazon gift vouchers, wine and craft beer gifts.

To be in with the chance to win, customers simply need to purchase TRICO wipers from one of the five distributors taking part. They’ll receive one scratchcard for every TRICO wiper purchased, and will have until 31st January 2023 to claim their prizes.

TRICO’s main UK and Ireland distributors will take part in this promotion, including A1 Motor Stores and UKS in the UK, and Carcessories, Qualvecom and Wiper Services in Ireland.

First Brand’s Group Brand & Marketing Manager (Europe), Sam Robinson, said: “We’ve run these promotions around Christmas

before and they’re always a hit with distributors and their customers as they vie to win a prize. As the harsh weather kicks in and drivers look to change their wipers, there couldn’t be a better time to stock up on TRICO wiper blades ready to take advantage of the extra sales opportunities the winter brings.”

CASTROL LEARNING CAMPUS CREATED TO SHARPEN SKILLS

Castrol has launched the new Castrol Learning Campus, a digital learning platform designed for workshops and distributors. A wide range of modules are tailored to the individual user, from technical tutorials for technicians and workshop managers, to video sessions for front-of-house staff that help to improve customer service and facilitate upselling.

Gavin Collis, Future Skills and Learning Lead at Castrol, said: “Whether it’s improving customer service levels, building product knowledge, or enhancing technical capability, users

can be assured of benefitting from expert online tuition from a partner they can trust.”

The Castrol Learning Campus is a development of the existing Castrol Academy learning platform. All existing modules and user information, including user progress and certification details, have been automatically transferred over to the Castrol Learning Campus. Castrol’s Oil Essentials, iLearning and Castrol Zoom websites have also been incorporated into the new e-learning platform, enabling users to access all learning materials in one place.

Further information about the Castrol Learning Campus can be found within this video: https://www.youtube.com/ watch?v=1vCQKXBFRpI.

ADAS FOR THE AFTERMARKET

The current market for ADAS can broadly be divided into two sections: camera and radar. One of DENSO’s major forthcoming product developments is to make its ADAS available for retrofit, not just as equipment for new vehicles.

“DENSO is working on an approach that takes account of both the depth and width of the task", explains European Marketing Manager, Fatiha Laauich. “The definition of 'depth' is the full pursuit of cutting-edge technologies that will enable DENSO to make mobility users safer. One example of this is how DENSO is using AI technology to predict potential hazards by, for instance, detecting pedestrians, in a non-distracting way, when visibility conditions are poor. In addition, at junctions with poor visibility and other situations where blind spots pose a threat, V2X and map functions provide infrastructure-related information, which, together with sensor information, can help prevent many accidents.

“The 'width' means ensuring that products and technologies are used in as many vehicles as possible, including in the aftermarket. Pursuing this goal will require safe products with the highest level of quality and reliability, at competitive prices.

“DENSO has supplied various OE ADAS equipment such as LiDAR devices, millimetre-wave radar, and vision sensors, since

RECHARGE THOSE BATTERIES

the 1990s. Introducing ADAS to the aftermarket not only gives a boost to aftermarket businesses, but it also makes life-saving technology more widely available."

“It is this advanced technology that levels the playing field between independent workshops and their vehicle manufacturer franchised dealer counterparts, enabling professional technicians to access the most technically advanced vehicles parts, thus increasing customer confidence and loyalty.”

PARTS, TOOLS & TIPS

Apec has announced a new range of aftermarket electric vehicle charging cables in the UK. The launch is the latest in a series, expanding on its 50 years of automotive expertise beyond braking to stay on pace with the electric future.

Apec’s EV Charging Cables provide an aftermarket solution suitable for most electric vehicles on the market and are supplied with a durable storage case for safe transportation and storage. All cables in the range are designed to be long lasting, VDC tested, waterproof to IP54, and fully certified.

https://apecautomotive.co.uk

CREATE YOUR DREAM WORKSHOP

Sealy has created a new design tool to help users create their ideal workshop from the wide range of storage systems it provides. Their modular design means the systems are truly customisable; each range allows you to purchase a simple base unit or create a complete storage system.

The Workshop Designer tool helps users create their perfect combination of drawers, cabinets and back panels. The Superline Pro and Premier ranges can be customised further by selecting traditional pressed wood or contemporary stainlesssteel worktops.

Users can specify room dimensions, drag and drop chosen units into place then review the design in 3D view. Once happy with the final design, it can generate an itemised quote.

www.sealey.co.uk/workshop-designer-intro

Suzuki Vitara Full Hybrid

As its brand enters its 101st year, Suzuki has developed its first cost-effective high-voltage hybrid, with a technical specification dictated firmly by market forces, as Rob Marshall discovers

It is very easy to misunderstand Suzuki's car division. While it may be a relatively small player in the UK, the company has a vast presence in other markets. Notably, Maruti Suzuki has close to a 50% market share in India. Yet, in the British Isles, Suzuki is neither a budget brand, nor one chasing fleet sales, but it focusses on value and dependability. Operating mainly through family-owned dealerships, most of its sales are to private individuals, who cannot benefit from significant tax incentives to offset the high-purchase price of an EV. Interestingly, Suzuki GB PLC states that its customers are two part-exchanges away from going fully electric.

Why the rush?

These reasons may explain why the brand has been comparatively conservative and relatively slow to embrace electrification, compared with other carmakers. Instead, the company has preferred a simpler approach, focussing on efficiency savings as a means of slashing CO2 emissions, including cutting weight, instead of adding technical complexity. Colin Chapman would be proud. Admittedly, the mild-hybrid Smart Hybrid Vehicle by Suzuki (SHVS) made some difference but its effectiveness was limited by being a 12-volts system, which was necessary to keep asking prices down. It took until 2020 for the system to be uprated to 48-volts architecture.

The Vitara has been on the UK market for seven years and still looks fresh but its technical credentials are enhanced by the new Full Hybrid system

The GDI 1.5-litre engine is used instead of the old 1.0-litre turbocharged Boosterjet unit. This makes sense, as turbochargers do not benefit from sudden engine shutdowns, due to lubrication starvation and localised overheating. Considering Suzuki's experience with developing its own motorcycle, marine and motorcar petrol engines, this cam chain unit is likely to be reliable.

"Suzuki GB states that its customers are two partexchanges away from going fully electric"

Suzuki's Full Hybrid is a parallel hybrid system, in which an electric motor is positioned between the ICE and the transmission. Both systems drive the road wheels. Highlighted are the battery pack and the drive motor but note that the Full Hybrid also employs a belt-driven ISG.

NEW CAR FOCUS

Yet, to keep development costs low, Suzuki has leaned on Toyota for its high-voltage expertise as a stop-gap. The Suzuki Across is a badge-engineered Toyota RAV4 Plug-In Hybrid, whereas the British-built Swace is a Corolla Touring Sports. This decision has bought Suzuki sufficient time to develop its first high-voltage architecture, which appears beneath the bonnet of the familiar, capable, attractive but ageing Hungarian-built Vitara, a model that was introduced in 2015.

Efficiency up but costs down The New Vitara Full Hybrid sells alongside the Vitara Mild Hybrid but utilises a 140-volts drivetrain. Compared to other high-voltage hybrids, this is comparatively low but is still high enough to dictate that technicians are EV qualified. Another curiosity is the AGS (Auto Gear Shift) gearbox, which is neither an epicyclical transmission, nor a DCT/twin-clutch unit. It is a manual gearbox, with selectors and clutch operated by robotics, dictated to suppress manufacturing costs. Using high-voltages and more sophisticated transmissions means more expensive and heavier parts, risking Full Hybrid Suzukis becoming too expensive in western markets, let alone in the growing east.

As expected with Suzuki, while its hands are tied with its driveline hardware, its engineers have succeeded in minimising the downsides. Driveline shunts have been virtually eliminated, having the high-voltage drive motor/generator powering the AGS gearbox's output shaft via a chain drive, which Suzuki says fills the torque gap during gear shifts and provides a smoother transition of power. A reduction gear also reduces motor speeds, enhancing torque. The system also incorporates

"Suzuki's first full hybrid may be misunderstood but its execution is sound"

The main drive motor/generator and its chain drive are integral within the compact ASG manual transmission. The car also boasts three batteries. An Enhanced Flooded lead-acid Battery (EFB) for the 12-volt electrics beneath the bonnet, a 12-volt lithium-ion battery for the ISG is beneath the passenger seat and the high voltage battery pack and inverter are situated towards the rear.

a 'coast' mode, where the engine stops running completely on the overrun. A dual mass flywheel also absorbs the associated driveline forces, as the engine shuts down and restarts.

As with Suzuki's mild-hybrid SHVS, a belt-driven Integrated Starter Generator (ISG) also features. Not only does this provide the smart alternator function but it also restarts the engine. However, a conventional pre-engaged starter motor is also employed for the initial cold start. Yet, the ISG does not provide any engine torque assist, because this task is performed by the high-voltage motor/generator.

In summary:

Suzuki's first full hybrid may be misunderstood but its execution is sound. The company may not pack its cars with the latest technology but, in a world where other manufacturers are scrambling to outdo each other in the EV stakes, sometimes, being more circumspect is the wiser approach.

As with most of the latest models, it takes time for the aftermarket to establish the engine oil specifications. The latest formulations boast extra timing chain protection

The manual gearbox has its gears and clutch controlled electro-hydraulically. These single-clutch automated manuals are becoming less popular in western markets. Suzuki has succeeded in reducing most of the associated disadvantages with well-engineered software but it remains neither as quick (nor as complex and expensive) as a DCT, such as Volkswagen Group's DSG. Pictured is the electro-hydraulic control unit, mounted on top of the transmission.

Again, to keep the vehicle price down, the Vitara Full Hybrid employs an EFB starter battery, rather than a more expensive AGM

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