Autotechnician magazine October 24

Includes: Oils, Turbo failure, Tooling, Automechanika Frankfurt & much more...

DIAGNOSTICS

TIPS & RESOURCES TO HELP YOU SEEK OUT THE UNDERLYING CAUSE OF FAULTS

Dear Reader,

Welcome to our October edition, which focuses on the tools, equipment and resources available to help you pinpoint underlying faults more e ciently – kicking o with a diagnostics feature from page 20, which includes the final article from Des Davies on voltage drop circuit testing.

From page 34, Rob Marshall investigates the role oil plays in providing diagnostic clues and how you can deduce additional issues after turbo failure, from page 45.

Amy Blick explains how mentoring will give your business a competitive edge on page 14 and we visit The Garage Warmington to find out what areas they have specialised in to stand out from the crowd, turn to page 54.

On page 6, we present highlights from Automechanika Frankfurt, which saw a return to great form post-pandemic with thousands of exhibitors showcasing products and training to support workshops with the latest technologies. We look ahead to 2025 on page 8 with news of how our autotech campaign will expand to better support technicians across the country.

Nicola St Clair Editor

Nicola@autotechnician.co.uk

facebook.com/Autotechmagazine x.com/autotech_mag

* View and download previous digital issues at: www.autotechnician.co.uk

And the winners of the 2024 British Independent Garage Awards are…

The 2024 British Independent Garage Awards took place 20 September, bringing together some of the best independent garages and trade professionals. This year’s award winners took home a share of £50,000 worth of prizes, with each award winner receiving a £1,000 cash prize from the Independent Garage Association (IGA).

Autotechnician would like to congratulate all the nominees and the worthy winners below:

Supplier of the Year: Euro Car Parts

Garage Management System of the Year: TechMan

Eco Garage of the Year: C R Allen and Sons

Marketing Strategy of the Year: CCM

Best Newcomer Award: Bear and Bee Garage

Business Improvement Award: Mechanic Man

Training and Development Award: Stourbridge Automotive

Community Hero Award: Westgate Tyres

Editorial correction

Customer Service Award: Mereworth Motors

Consumer Choice Award: Holmer Green Service Centre

Innovation Award: Shaikly Motor Company

Specialist Garage of the Year: The MINI Repair Shop

Independent Used Car Retailer of the Year: Available Car

Small Independent Garage of the Year: Oldfields Garage Services

Large Independent Garage of the Year: Hillclimb Garage

British Independent Garage of the Year: Shaikly Motor Company

Stuart James, CEO of the IGA, expressed his pride in the achievements of the winners and the importance of independent garages to the community. He remarked: “The level of talent and commitment displayed this year has been nothing short of exceptional. Independent garages play a vital part in the economy, and these awards highlight the crucial role they play in keeping the industry thriving. Congratulations to all the winners and finalists.”

Last issue's braking feature gave the impression that NAPA distributes Apec braking components. This is incorrect. They are two separate parts brands, both of which are distributed by the Alliance Automotive Group (AAG).

Ben invites automotive family to get involved in festive fundraising

Automotive industry charity, Ben, invites its automotive family to get involved in Christmas Jumper Day this December and has released its new Christmas card collection to raise funds to support those struggling or in crisis.

Ben’s Christmas Jumper Day fundraiser will take place on 13th December but can be organised for any day that month. To take part, participants simply sign up at https://bit.ly/ BenChristmas, share the date with colleagues/friends and wear their best (or worst) Christmas jumper on the day. Christmas Jumper Day is the ideal opportunity to get colleagues together in the workplace to have some festive fun and raise funds by donating £3 per person – the cost of a coffee.

This year, Ben is celebrating 35 years of Christmas cards designed by renowned motoring artist, Richard Wheatland, and is marking this special milestone by selling Richard’s first three card designs from 1989, 1990 and 1991 – now considered vintage, as well as a stunning new automotive design for this year’s card. You can purchase the cards at www.charitycardshop.com/ben.

Matt Wigginton, Director of Partnerships, Engagement & Income, said: “We hope our whole automotive family will get involved in Ben’s festivities this year! Christmas Jumper Day is such an easy one to get involved in and will help your company get into the festive spirit – you could even give away prizes for the best (and worst!) Christmas jumpers and raffle a Ben bear too. You can now also buy your Ben Christmas cards with a new and very special design by Richard Wheatland for 2024.”

“We are still seeing record numbers of people turning to Ben in desperation because they can’t afford the basics. It’s still really tough out there and many people in our automotive family urgently need us. Together, we can make a life-changing, often lifesaving, difference to the lives of our automotive family so please get involved today.”

Don’t suffer in silence, contact Ben’s helpline: 08081 311 333 or use the webchat at www.ben.org.uk. You can also access Ben’s out of hours text support line by texting BEN to 85258.

IAAF enhances support for garages

The Independent Automotive Aftermarket Federation (IAAF) has enhanced the support it provides to over 3,000 independent garage members by offering access to The Motor Ombudsman’s Alternative Dispute Resolution (ADR) service.

This additional benefit helps garages manage and resolve customer disputes more effectively through a structured and impartial process. IAAF members now have access to The Motor Ombudsman’s ADR services, enabling them to resolve disputes outside of court, which can save time, reduce costs and enhance a garage’s reputation for fairness and transparency. Additional benefit is enhanced

IS

credibility through the use of The Motor Ombudsman and CTSI Approved Code logos and increased visibility as members will be featured on The Motor Ombudsman’s popular online Garage Finder.

Mark Field, Chief Executive of IAAF, commented, “We are continuously developing our support offerings to better serve our members. By providing access to The Motor Ombudsman’s ADR services, we are equipping our garage members with a powerful tool to manage customer relations and uphold the high standards that our federation stands for."

EQUIPMENT ENGINEER

For peace of mind always use a Garage Equipment Association member. GEA accredited engineers work to an industry code of conduct. Your assurance their skills and knowledge have been independently assessed.

Automechanika Frankfurt showcases a wealth of innovation

Driving Transformation

The international trade fair returned to Frankfurt with gusto mid-September, attracting 108,000 visitors to take in 4,200 companies’ parts, equipment and workshop support services across 26 hall levels and explore the trends of electrification, vehicle connectivity, driver assistance systems and digitalisation.

Detlef Braun, Member of the Executive Board of Messe Frankfurt: “Even in the midst of the digital transformation, the industry once again demonstrated its wealth of innovation, providing countless highlights over the course of the fiveday event. Together with our exhibitors, we were able to find the right players to present the most important topics – including alternative drive systems, sustainability and the use of AI and robotics in the automotive aftermarket – on the stages and in the exhibition halls."

Five stages played host to discussions of trends and developments in various industry sectors. In the Future Mobility Park and the expert forum Innovation4Mobility, visitors had the opportunity to experience vehicles with alternative drive systems up close – including electric, hydrogen and hybrid and get behind the wheel themselves.

AT spent two days visiting many of the key suppliers, visit www.autotechnician. co.uk to find out what they are introducing into the UK in the coming months to support technicians and workshops.

Innovation Awards

Awards were held on the first evening of the show to honour suppliers who have created technologies that focus on digitalisation, new drive technologies and sustainability.

Smart solutions for vehicle technology as well as for workshops were honoured, including the AVILOO Flash Test, a plug and play battery test for EVs and hybrids, Snap-on’s Tru-Point 3D positioning ADAS calibration accessory that enables and monitors the precise placement of ADAS calibration mats, Schaeffler’s E-Drive Stator Lift for dismantling electric motors and GS27’s AIsupported training software with language customisation.

"More than almost any other sector, the automotive industry is at the beginning of a comprehensive transformation. We need new technologies to help us - on the way to digital, efficient and sustainable mobility."

THE FORMULA FOR EFFICIENCY

Outstanding quality in every detail.

Thanks to uncompromising quality, Schaeffler’s high-performance FAG steering and suspension parts are among the best in their class.

Leading quality in every detail

Careful selection of materials along with the use of advanced sealing and coating technologies ensure the highest levels of reliability and durability, guaranteeing market-leading quality across the entire range.

As always from Schaeffler, you also get everything you need in the box to guarantee a safe, professional and efficient repair.

Thanks to uncompromising quality, our high-performance FAG steering and suspension parts are among the best in their class. Careful material selection and the use of leading sealing and coating technologies ensure a consistently high level of quality. In this way, we guarantee market-leading quality across the entire product range. What workshop professionals particularly appreciate: Our customized solutions contain all relevant components in one box. That saves time when ordering and ensures safe, efficient, and effective repairs.

https://aftermarket.schaeffler.com/steering-parts

Test your skills and register for our 2025 training events

Test your technical knowledge online

There are 17 online multiple-choice assessments available, created to test technical knowledge and diagnostic procedures and are available FOC by logging on or quickly registering at www.autotechnician.co.uk/ registration/

Why not try Test 7 that consists of fifteen questions designed to test your knowledge of LIN Bus systems and your ability to analyse the data and waveforms provided to draw diagnostic conclusions?

Test 13 teases SCR system knowledge from users and presents the case of a VW Crafter, which has an illuminated AdBlue Malfunction Indicator, presenting code 'P202AReductant Tank Heating 2 circuit -open circuit'.

Test 16 is a logic check for the real-world fault assessments happening in workshops up and down the land. Questions centre around a real fault-to-fix scenario where a customer

presents an Audi A3 2005 8P model with several faults present.

Test 17 is a fuel pump case study involving a 2017 Land Rover Discovery Sport. The vehicle is fitted with the 204DT 2.0L Diesel common rail engine controlled by a BOSCH MEDC17.9 ECU and is presented with a start and cut-out fault. It has been recovered for diagnosis and the roadside recovery agent has included an explanation of the symptoms as follows, ‘The vehicle runs for approximately 20 seconds and then cuts out, after which, it does not start unless the Diagnostic Trouble Codes (DTCs) are cleared’. You will be required to direct the diagnosis through your analysis of test results and the technical information provided.

Get free, lifetime access to the full library simply by logging in or registering, by providing your email address at www.autotechnician.co.uk/registration/.

We will shortly be announcing our return to Cheltenham in 2025 for our Workshop Takeover and we are also planning to hold additional events in the South and East of the country. Email Nicola@ autotechnician.co.uk to hear the news first and gain early access to limited, cost-price tickets.

In association with:

REMANUFACTURING MAKES SENSE

For over 20 years ACTRONICS has been at the forefront of our industry developing sustainable remanufacturing solutions for you.

Our solutions are a cost effective, environmentally friendly alternative to replacement parts. Our Plug & Play solutions ensure a top-quality service backed by a 2-year warranty

Prevention, cure, and product performance

It’s frustrating visiting the doctor with your symptoms only for the prescribed treatment to fall short because the underlying issue is not resolved. The same principle holds true for repairs in your home. Stop the leak by patching up the ceiling but if the hole is still in the roof, you’ll pay the price when it rains. By contrast, as a top tier technician, diagnosing the root cause of any problem on a vehicle is second nature, part of your DNA. A customer brings a list of vehicle symptoms. You then deploy your expertise, experience and any required diagnostic tools to get to the root of the problem so you can deliver a first-time fix. This approach is just one of the many things that sets you apart from the DIY motorist enthusiast. Your knowhow plus that overriding objective to resolve underlying issues are the building blocks that your great reputation and brand rests on.

It is therefore crucial that the additives and lubricants you use in your workshop must also be up to the task – fixing the symptoms and resolving issues at the root, not just masking the problem. You must buy well, especially given the repeat purchase nature of these products and all this entails doing more than just looking at the marketing hype. Peer product reviews, independent testing, social comments from fellow

trade professionals – they all help build a true picture of the merits (or otherwise) of a product.

JLM Lubricants is a global trade trusted brand with a roster of products that have been road tested before launch with the most challenging customer of all – you, the professional technician. And not just one tech but several, in the workshop and on a wide range of vehicles. Because if top tier techs

A special feature from autotech sponsor, JLM Lubricants UK

have put a product through its paces to their own exacting standards and declared it fit for the rigours of the workshop it’s a sure sign you can use that product in your workshop too, confident you’re backing a winner.

If you’re new to JLM Lubricants, which products should you initially consider?

Let’s start with products that solve an immediate problem – in this case, a blocked DPF or general poor engine performance. These problems are tied in with the need to diagnose the underlying cause of the problem and not just clearing the symptom, to ensure there is no recurrence. DPF cleaning additives can help by introducing a catalyst into the filter that helps to burn off the particles, even if the vehicle is not being driven in optimal conditions. However, not all DPF additives are the same. There are significant differences, depending on the type of catalyst used as the base ingredient.

Ferrocene, or iron, is a commonly used catalyst which assists particle burn by artificially increasing the temperature in the DPF. Although this achieves the overall aim of reducing the particulate load in the filter, the downside is that the elevated temperatures of up to 800C risk damage, in some cases terminal damage, to the DPF core, particularly with overuse of this type of additive. Iron-based catalysts result in increased levels of ash deposits which can only be removed with an off vehicle physical clean of the DPF. So many of the DPF products promoted to technicians are iron based and simply not up to the job.

The alternative to iron is to use Cerium and Platinum. These precious metals, which are in the JLM Lubricants’ DPF Cleaner and DPF Regen Plus, help carbon deposits in the DPF to burn off at a lower temperature, around 400C. This lower temperature not only helps to protect and extend the life of the DPF core, but it also produces less ash which again extends the life of the DPF. Although JLM Lubricants DPF cleaning additives cost a little more than iron-based additives, the long-term benefits easily justify this premium, especially considering that the cost of replacing a damaged DPF can be in the thousands.

Which JLM DPF product to use?

At the first sign of the dashboard illuminating the DPF Cleaning Spray is the most likely candidate with the Diesel Particulate Filter Cleaner the next step up. If the engine or DPF are heavily contaminated, then the JLM DPF Cleaning Toolkit with the Cleaning Fluid and Flush pack is essential, see page 55 to see this in action. And a dose of the JLM Diesel Extreme Clean will restore performance and cut emissions. The critical point of note is that each one of these products and the professional DPF toolkit were evaluated by DPF specialists on dozens of vehicles before their global launch.

can be incorporated into routine servicing, and intervals between servicing, to help protect a customer’s vehicle. They also have the added benefit of a growing income stream for your workshop. The JLM Petrol and Diesel Injector Cleaners clean the entire fuel system, improving power and performance. For DPFs, soot deposits are reduced, improving power and fuel consumption, whereas for the petrol cleaner there is a reduction in harmful exhaust gases. The JLM Turbo Cleaner is economical, easy to use and very effective at removing soot and dirt.

One of the best ways of protecting the DPF is clean oil. So, regular servicing with a top tier engine flush such as JLM Engine Oil Flush is essential. And, using a professional fuel additive such as JLM Emission Reduction Treatment diesel and petrol helps to reduce the emissions’ load on the EGR and DPF. It is also a lot cheaper for your customer than using premium fuel.

Find out more

JLM Lubricants products are designed to support you, the professional technician, in your everyday work diagnosing and resolving underlying problems on increasingly older diesel and petrol vehicles. It is a powerful combination with the added benefit of long-term income streams from additive sales – at workshop visits and in between. If you are interested in trialing any of these products, or are simply curious to discover more, call 01273 891162, email info@kalimex.co.uk or visit www.jlmlubricants.co.uk

An Inside Job

Why mentoring will give your business a competitive edge, by autotechnician resident HR columnist, Amy Blick

I have noticed a shift in people’s perception of mentoring and how it can benefit not just the individuals being mentored, but also the business bottom line. In days of old, mentoring was regarded as the preserve of big businesses with big budgets. A mentor, often charging eyewatering sums, would come into the business and impart their skills and mentoring expertise, usually to the most senior people. Thankfully, today a growing army of small businesses are cottoning on to the many benefits of mentoring. For an SME like a workshop, it tends to happen organically and without a formal title – at its heart, mentoring is the professional and personal development of an employee by a more experienced colleague. So, you may already be a champion of mentoring but have not thought of it as such.

I would encourage any workshop to consider mentoring because it’s perfect for developing talent from within, for encouraging positive collaboration and for building on all the great things you have worked so hard to create.

And there’s more! Mentoring has the following benefits:

It fosters a culture of learning, curiosity and confidence

It actively encourages the sharing of knowledge

It helps you to retain good people

It helps you to streamline and improve processes

It improves business performance and profitability!

For your people, you are sending a clear signal that you care about their development and that although you do not have the budget of a plc, you are nevertheless investing in them. But, as with anything worth bringing into your business, if you are to commit to mentoring you must buy into it lock stock and barrel! That’s because although your mentors are home grown, they are likely to need some support beforehand if they are to flourish and if your business is to be rewarded for the time you have allowed for mentoring. Understandably, for a workshop most of the time is spent on the tools and training leans to the technical. However, there should always be space for personal development training, which mentoring can deliver.

When you are thinking of either being a mentor or nominating a mentor in your business, make sure the chosen person bears the hallmarks of what makes for a great mentor such as:

A genuine desire to help

Being approachable

Trustworthy

Respectful Patient

Happy to share their expertise

A good listener.

Are you thinking that the task of mentoring falls squarely on your shoulders as the workshop owner/manager? There may be others in your business that have much to impart, and they naturally draw people to them. They may also have more time than you. Crucially, for the person being mentored, it can be hard to open up to the boss, which is why I encourage you to step back and find your mentor from within the team.

How much time?

If the mentor and mentee are to derive significant value from the relationship you will need to free up time for both and book the sessions into the diary. How much time? A good starting point is to allow 60 minutes per session, once or

“I would encourage any workshop to consider mentoring because it’s perfect for developing talent from within, for encouraging positive collaboration and for building on all the great things you have worked so hard to create.”

febi Starters & Alternators

Wide Range – febi offer over 350 starter motors and alternators for popular passenger and light commercial vehicles, all in OE-matching quality for the performance and reliability its customers count on.

Range Expansion – febi constantly analyse the Independent Aftermarket and plan to add hundreds of new starter motors and alternators to its range in the next few years, including components for the latest 48v systems found in mild-hybrid vehicles.

Highest Quality – all febi starter motors and alternators are manufactured to OE specification, ensuring reliability and European regulations are met. As with OE, febi can supply alternators with or without the appropriate pulley.

100% New Parts – all febi starter motors and alternators are 100% new, with no old core surcharge or remanufactured parts; improving quality, efficiency, and eliminating the environmental cost of the logistics required to return the original.

A garage network prepared for the future

Why join 1TEC Auto Hub?

Something big is here and we want you to be part of it. Alongside seven of the automotive industry’s leading suppliers, including MPM, Pagid, Schaeffler, Shell, Valeo, VARTA UK, and ZF Aftermarket, we’ve launched a new and unique garage concept, 1TEC Auto Hub. Developed to provide independent workshops with all the tools, training, and business support you need to grow and thrive in the ever-changing automotive landscape, 1TEC Auto Hub also offers its members exclusive rewards to benefit you even further.

What you’ll get

• Access to a GMS to suit your workshop

• Access to the very latest Technical Data

• Marketing support to help your business grow

• Exclusive invites to events and workshops

• Training from Technical partners and the award winning LKQ Academy

• Business Support to unlock even more revenue streams

• Exclusive Rewards Platform housed in one easy to use digital platform.

twice a month, with more as momentum builds. The agenda can be fluid but focussing on knowledge transfer, explanation of key processes in your business and soft skills improvement is more than enough for several agendas. Preparation before each session should be scheduled in so that the mentor can be focussed and the mentee can see this is more than just a nice chat. Environment is a key consideration. If your workshop is noisy and busy pretty much all day long, have the sessions away from the shop floor, even at a local coffee shop.

Getting started

I have shared an entire suite of low-cost mentoring resources that I have created for SMEs with the aim of helping you to build a great mentoring programme without spending over the odds. I hope you feel inspired to explore further and don’t forget to quote AUTOTECH10 for your 10% discount!

The HR Playbook – Mentoring Skills Prompt Cards

This set of Prompt Cards for Mentoring is designed for small to medium sized businesses that want to build mentoring through the business with authentic and genuine conversations and relationships. It cultivates leadership abilities, enhances communication and builds a collaborative culture, increasing engagement, upskilling and professional development.

The Prompt Cards will:

Develop mentors to have confidence in building effective mentor relationships

Upskill mentors to confidently transfer knowledge and support growth

Build a driven culture of empowering others and collaboration success

Create well-rounded and comprehensive employee experience.

Ideal for:

Workshops that want to give structure to professional development and create genuine mentor pathways

Teams that need guidance on how to mentor and to confidently nurture these skills

Workshops that want to align current mentoring initiatives and build consistency and structure to create formal mentoring pathways.

https://thehrplaybook.co.uk/product/mentoring-skillsprompt-cards/

Performance Management

This suite of Performance Management documents is designed for small to medium sized businesses that require a

framework and the tools to set clear goals, provide real-time feedback and build professional and personal development for each employee throughout the year.

Includes:

Quick Guide to Performance Management (serves as Performance Management Policy)

Annual Review Form

Quarterly Review Form

Monthly Review Form

One-to-One Form

Personal Development Form

Probation Policy

Probation Form.

Results:

Drive consistency of performance management across the business

Upskill managers to confidently have discussions

Build a driven culture of objective setting and transparent success

Create well-rounded and comprehensive employee experience.

https://thehrplaybook.co.uk/product/performancemanagement-suite/

HR Power Hour

Message Amy if you would like to have a recruitment power hour – an online one-to-one packed with top tips and strategies for your business

* Amy@exhilhrate.co.uk

Since its inception in 1981, the Motaquip brand has been trusted by a legion of UK mechanics. With a rich heritage and over four decades of aftermarket expertise, each product bearing the unmistakable Motaquip ‘M’ fulfils a promise of quality and performance.

Available exclusively from Motor Factors across the UK.

FEATURES

Diagnostics

Searching for the root cause

Oil

Drained oil provides useful diagnostic clues

Talking Turbos & Beyond Using a turbo failure as a diagnostic tool

Hand tools

Getting the basics right

Searching for the root cause

We talk to the experts and outline the resources, tools and training to help you pinpoint underlying faults more effectively

Evolving content from the VMs

Bosch released its ESI[tronic] Evolution software back in January, providing users with a new Start Screen interface with direct links to in-depth service and maintenance information. Enhanced content accessed from the home screen includes OE Documents for Audi, VW, Fiat vehicles, BMW, Mini and Rolls-Royce, with Mercedes-Benz, Smart, Renault, Ford, Skoda and Seat also being added.

A new feature of the Evolution software simplifies vehicle identification – previously, identification was through manual selection criteria, VIN reading or RB Key but this can also be carried out via the number plate.

Software features to suit your level of diagnostic work

Maverick Diagnostics introduces the Autocom ICON diagnostic tool to the UK aftermarket, covering more than 40,000 systems for passenger vehicles. Developed in Sweden, it is a product of 30 years of diagnostic expertise, its capabilities include Intelligent Systems Identification, scanning and updates, and is fully compatible with modern technologies, such as CAN FD, DoIP, Pass-Thru J2534, and Secure Gateway.

The ICON has several software options to suit the level of diagnostic capability required. Autocom CARS Standard provides basic diagnostics, fault code management, essential service functions and real-time data. The Autocom CARS Plus software adds electric vehicle coverage, enhanced Secure Gateway support and guided diagnostics. The top-level CARS Pro software also provides advanced Secure Gateway features and flight recording.

www.maverickdiagnostics.com

DIAGNOSTICS

Access advanced diagnostics on your Android device

Hella introduces a device for advanced multi-brand diagnostics that can be accessed on Android devices. The mega macs S 20 has advanced features available on the mega macs X, including DoIP and selectable software modules, but in a scalable and more affordable option.

"We’re giving workshops the flexibility to use their own Android devices for advanced diagnostics, without compromising on performance,” said Julian Goulding, Head of Sales at Hella Gutmann. “It’s a powerful combination of affordability, efficiency, and cutting-edge technology that sets a new standard for modern vehicle diagnostics."

The mega macs S 20 is powered by Hella’s smart diagnostic interface, SDI, previously only available on its flagship devices and provides a quick, intuitive diagnostic process with support for DoIP and CAN-FD protocols.

“Technicians simply plug the mega macs S 20 dongle into the vehicle's OBD port and connect to it via their Android tablet or smartphone using Bluetooth or USB-C,” said Julian. “Two flexible software modules bring a choice of functions for workshops, from basic to advanced capabilities.”

The S2 license enables reading/clearing error codes, service resets, and adjusting settings. It also comes with regular

software updates and new vehicle model support.

Advanced functions such as mileage queries, coding, parameter viewing, actuator tests, and access to Hella Gutmann cyber security management (CSM) are also available. The device can unlock cyber security gateways within a fraction of a second for 17 brands, with BMW recently added.

An S3 license unlocks premium features like error codebased repair suggestions, access to the knowledge database, and HV battery diagnostics PRO. This enables the mega macs S 20 to assess EV traction batteries using ‘Battery Quick Check’, a feature once exclusive to the mega macs X. Find out more at https://bit.ly/HellaS20

ALLDATA Repair: Inside Intelligence

The ALLDATA Repair Info Centre Service team tackle a problem on a 2015 Porsche 981 Cayman S

Query

The owner of the car was experiencing a “strange noise” emanating from the engine compartment whilst driving –they described it as a “high-frequency, pulsating” noise. There was no pattern or specific conditions when the noise would be heard.

After various checks and road tests were carried out, and although the noise could be heard, there was no obvious reason for it or where it was being generated from.

Solution

The ALLDATA Repair Info Centre Service experts were able to come to the rescue. Although relatively uncommon, the team had encountered this issue before. The cause of the noise is from the vehicle’s oil separator.

If there is an excessive spring force tolerance from within the oil separator, it can cause that “high-frequency, pulsating” noise.

The solution is to first check the part number of the separator on the vehicle; if this is ‘9A1.107.042.01’, the part will need to be replaced with a later, modified one. Once fitted, the issue should be solved and the vehicle much quieter for the motorist.

ALLDATA Europe provides original vehicle manufacturer (VM), repair maintenance and diagnostic data via ALLDATA Repair, which includes more than 90 million articles, 8.5 million technical drawings and wiring diagrams with electrical connector views – that’s procedures for 144,000 year, make, model and engine combinations. It is the equivalent of 96% of vehicles on the road today.

The ALLDATA Repair Info Centre Service staffed by experienced technical support specialists can receive and answer requests within four hours – but will often respond quicker. Requests vary from users being unable to locate specific information for a job or because certain information is being processed for publication on ALLDATA Repair.

Compete with the main dealers

Maverick Diagnostics provides OEM diagnostic tools, the same ones the dealer workshops use, with full support and training for you and your workshop.

Our bundles pair a wide range of OEM tools with a rugged laptop or tablet, known to work perfectly with that brand’s diagnostic software.

This includes the software pre-installed and tested with your tool, 1-hour online initial training, sales support and help with OEM registration.

Dara Beck Vehicle Technician, Arwyns Garage

"They've been very helpful with the set up of the OEM tools, licensing and the training that they provided was second to none."

Visit:

THINKCAR ADAS

MAKE ADAS CALIBRATION SIMPLE AND ACCURATE

Accurate, Portable, Guided Calibration

The THINKCAR ADAS (Advanced Driving Assistance System) calibration unit is a portable device developed

instrumentation to assist in centering and positioning for high accuracy THINKCAR ADAS integrates with ACC, LDW, AVM, RCW, BSD system calibration functions.

Easy Installation Universal calibration components, different tools can be freely assembled to calibrate different car models.

High Accuracy

The calibration data reaches millimeter-level, for high accuracy

Guided Function Guided calibration for simple operation

Wide Coverage

Mercedes-Benz, BMW, Volkswagen, Audi, Land Rover, Jaguar, Porsche, Volvo, Fiat, Opel, SEAT, Skoda, Renault, Citroen, Peugeot, Alfa Romeo, SMART, MINI, GM, Buick, Cadillac, Chevrolet, Ford, Lincoln, Chrysler, Dodge, Jeep, Toyota, Lexus, Mitsubishi, Suzuki, Subaru and other models

Full System Support Lane Departure Warning (LDW), Adaptive Cruise Control (ACC), 360 Panoramic Monitoring (AVM), Rear Collision Warning (RCW), Blind Spot Monitoring (BSD) and more

THINKTOOL Euro 195 is a newly developed full system, full function diagnostic tool, supporting DOIP & CAN

protocols with the latest and more expansive passenger vehicle coverage.

Tools to support the repair of an ageing car parc

Aftermarket analysts GiPA have noted that one of the fastest growing parc segments is cars aged 10 years and above. “While this is obviously good news for the aftermarket” said Alex Gillbanks, MD of Impact Diagnostics, the specialist supplier behind Thinkcar UK, “vehicles from over 10 years ago were already very intricate. They feature an array of electronic systems, with packed-out engine bays leaving no room to work. This means garages need new tools to help them.”

Thinkcar UK has a range of diagnostic handsets available and is also bringing a range of taskspecific tools to help techs deal with this trend, among these is the ES401 Steering Endoscope, designed to support techs performing inspections in tight spaces, including combustion chambers and three-way catalytic sensors. Alex explains: “Used in tandem with Thinkcar UK devices, such as the Thinktool Euro Expert 195 diagnostic scan tool, the ES401 will help techs solve problems swiftly and cost-effectively.”

Its Euro Expert 195 gives users access to Thinkcar’s network of garages offering remote diagnostics, who can help to guide and program the vehicle with you.

Model upgrades

TOPDON released the Phoenix Lite 3 earlier this year, improving upon the popular Lite 2 and includes an upgrade to the VCI to a CANFD compatible MDCI. It now includes a DoIP adaptor cable, topology view included and is now compatible with its Phoenix Mobile ADAS

The equipment supplier has also introduced the Phoenix XLink to its Professional line of tooling, shown here. The tool has DoIP and CAN-FD protocol communication, cloud-based programming and coding, for an investment of

The RAM and Rom have been doubled in the improved ArtiDiag Pro, the operating system has been upgraded to Android 10 and DoIP and CANFD has been added.

https://www.topdondiagnostics.co.uk/

Address knowledge gaps with how-to videos

Delphi is encouraging technicians to take advantage of its growing library of ‘how-to’ videos, which aim to help workshops tackle increasingly complex jobs.

A video is released each Thursday as part of its Masters of Motion programme, providing cost-free, step-by-step guidance and expert tips.

“We’re strong believers in the power of knowledge and the importance of ongoing learning,” said Luke Garratt, Technical Services Manager at Delphi. “These videos are created by technicians, for technicians. It means this content is relevant, practical, and immediately applicable in the workshop.”

The latest videos include ‘How to adapt a low-pressure EGR valve’, walking technicians through the correct procedure, from checking for fault codes in the exhaust gas recirculation valve to a final road test, and ‘How to perform real-time data recording’, covering everything from understanding vehicle symptoms to settling on a diagnosis and proceeding with a repair. Recent topics include videos on AdBlue, tyre pressure monitoring systems and several Tesla-specific guides.

The Masters of Motion hub can be found online here: https://bit.ly/DelphiMOM. For more advanced learning resources, technicians are directed to the Delphi Academy at: https://bit.ly/Delphiacademy.

1TEC rolls out remote diagnostic service

1TEC Auto Hub garages can now undertake more complex coding and programming jobs without having to invest in their own manufacturer-specific equipment by using a new remote diagnostic service from LKQ Euro Car Parts.

LKQ is also working to incorporate coding into its parts cataloguing system, offering parts which come with a coded solution.

The 1TEC Auto Hub is celebrating its first year in the market and has attracted more than 275 garages. LKQ Euro Car Parts launched the network in conjunction with MPM Oil, Pagid, Schaeffler, Shell, Valeo, Varta and ZF Aftermarket – each bringing unique perks and rewards to the network, from access to the latest technical and diagnostic data, tools, marketing and business support, access to training via LKQ Academy, plus events.

As well as the new Remote diagnostics support, Slicker Recycling has also come on-board as a partner –offering sustainable workshop waste collections, drainage services and site clearance. www.1tec.co.uk

Check vehicle software and ECU comms to avoid misdiagnosis

Every one of Autoelectro’s starter motors and alternators is built and tested to meet or exceed OE specifications and during this process, the team has identified that newer alternators, which communicate with the vehicle’s ECU to determine charge rate and warning light controls, can encounter communication issues if the vehicle’s software is outdated. This can lead to misdiagnosed charging faults, where the alternator is mistakenly blamed.

Autoelectro’s Harnek Bhogal said: “We have identified several ECU-controlled – and even 48V – part numbers for new Ford, Range Rover and Audi models, of which the technical support is exclusive to us in the aftermarket. Our first piece of technical advice for these parts is to ensure that the vehicle software is up to date before conducting any diagnostic or repair work. This step is crucial to avoid misdiagnosis and unnecessary replacement of functioning alternators.”

www.autoelectro.co.uk

Plug and go diagnostic bundle

A1 Remote Diagnostics introduces its A1 Remote Mega Bundle, a complete package of equipment needed to perform remote diagnostic work, for under £1k and aims to make life simpler for busy workshops by being able to go from the bundle delivery to coding and programming in less than ten minutes.

Adam Molloy, operations director, said: “We’re making it super simple and cost-effective to reduce key-tokey times and eliminate the need to take vehicles to a main dealer for coding. We’re seeing workshops turn jobs around in 15 minutes instead of 15 days. Keeping vehicles in the workshop is key to getting them back to the customer quicker, controlling workflow and invoicing the job sooner.

The bundle includes an A1 Remote Diagnostics interface, mobile router with cable, GYS battery support unit, SIM card, 20m cable, simple set-up instructions, unlimited technical support and express delivery.

https://bit.ly/A1bundle

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Voltage drop circuit testing –

Part Four

This is the final article on voltage drop circuit testing, following on from the fundamentals of the circuit testing method, explained in Part One, Two and Three

By Des Davies AAE MIMI, Top Gear Motor Services

My previous articles covered the basics and rules of these circuits and components. This example demonstrates a test to identify and locate a fault in the positive/live side of the circuit of a 2 resistor/bulb circuit.

Connect the multimeter across the 2 resistor/bulbs in the circuit, it should read battery voltage of 12.6V. The left side multimeter M1 indicates a 10V drop across the circuit, which should display a reading of 12.6V on this multimeter. We must have an unwanted resistance somewhere in the circuit, which could be in the positive/live side or the ground/earth side.

Place the red lead of your multimeter on the battery positive terminal and the black lead to the input terminal of the first resistor/bulb. If the multimeter M2 now reads 2.60V as in Figure 1, we must have a voltage drop somewhere in this part of the circuit.

Move your black lead backwards towards the battery at different points in this part of the circuit until your multimeter displays a maximum reading of 0.5V, in between where you previously had the reading of 2.60V and the reading of 0.5V max is the point where your high resistance or voltage drop is in the circuit.

Figure 2 shows how you check for the unwanted resistance in the circuit by placing the red multimeter lead on the battery positive terminal and leaving it connected to this terminal, whilst then placing the black lead at various points in the cable that goes from the battery positive to the input of the first resistor/bulb. Meter M1 now reads 2.60V, indicating a resistance before meter M1.

Move the black lead only and back track towards the battery positive terminal taking your multimeter readings. Meter M2 reads 2.60V, therefore the resistance is still in that part of the circuit, before this meter reading. Again, move the black lead only, and back track towards the battery positive terminal taking your next multimeter reading. Keep back tracking with the black lead until the meter now reads 0V (0.5V max) (M3).

Where the meter now displays 0V (0.5V max) (M3) and the previous meter reading of 2.60V (M2), in between these 2 readings is the unwanted resistance in that cable.

0V reading on positive side of the load indicates an open circuit in the live side of the circuit.

Note: A 0V reading on your meter can also indicate a short circuit or very high resistance in that circuit and these will not display a reading on the multimeter so be aware of this!

Again, back track with your red lead back to the positive battery terminal at different points until your multimeter reads 12.6V and in between these 2 readings of 0.00V and 12.6V, will be the open circuit in that location of the positive cable.

A reading of 12.60V on your multimeter indicates an open circuit in the ground circuit, no current flow and therefore it is not completing the circuit.

Remember wherever the voltage or current comes from, it must return to that source, to complete the circuit and function correctly.

Backtrack moving your red lead back towards the battery negative terminal until the reading on your multimeter displays a maximum of 0.5V, in between the readings of 12.60V and the 0.5V maximum is the fault in this circuit.

Three resistors in a series circuit

Let's now look at an electrical circuit with three resistors and test using a basic digital multimeter, Figure 7 overleaf. It does not matter how many resistors/bulbs you have in the circuit; they all must add up to battery/system voltage if the system is operating correctly. which is 12.6V.

This is a 3 bulb/resistor circuit, which is tested in the same way as the other series circuits. Remember they all share the total voltage in the circuit.

Don't forget the 4 important rules when using a multimeter to test any electrical circuit or components: Current is the same in all parts of the circuit; the applied voltage equals the sum of the volt drops around the circuit; the total resistance of the circuit (Rt) equals the sum of the individual resistance values (R1 + R2 + R3…); always check the vehicle battery first for system voltage, a fully charged battery will provide 12.6V.

Figure 2

Figure 3

Figure 4

Figure 5

Figure 6

DIAGNOSTICS

All the individual resistors/bulbs must add up to battery/ system voltage, Figure 8, in this circuit each resistor/bulb has the same resistance and therefore has a voltage drop of 4.2V, adding the 3 together, 4.2V + 4.2V +4.2V = 12.6V, which is the battery/source voltage, this circuit is functioning correctly and to its full potential.

If they do not add up to battery/system voltage, then you must test the circuit using the multimeter to locate the unwanted voltage drop, which could be on the live side of the circuit or the earth/ground side.

With the black lead now connected to battery negative, earth/ground terminal and red lead connected around the circuit of this series circuit, Figure 9, we can test the individual inputs of these bulbs/resistors. The black lead must always be connected to the battery earth/ground terminal for these tests.

Meter M4 tests the input voltage of the first bulb/resistor in this circuit, 12.3V is a good reading. Meter M3 tests the input voltage of the second bulb/resistor in this circuit, 8.1V is a good reading. Meter M2 tests the input voltage of the third bulb/resistor, 4.2V is good. Meter M1 is testing the earth/ ground voltage of this circuit, 0.3V is a good reading.

Remember, if they all have the same resistance values, the voltage drops will be equal, 3 resistors X 4.2V volt drop =12.6V as they all share the system or battery voltage of 12.6V. If they did not have the same resistances, then they should all add up to battery or source voltage.

Having the correct knowledge of how the circuits operate correctly is essential, and having a good reliable source of technical information and the manufacturer’s data and circuit diagrams will help you to diagnose the electrical faults and fix the vehicle. This testing technique can be used on any circuit on the vehicle, but you may have to adapt the testing methods.

The easiest thing to do is fry an ECM or electronic component that costs a lot of money or starts a fire, the hardest thing is to tread carefully and only test what your knowledge and experiences have taught you. Think before you leap, it's a long way down!

Knowledge is power!

Because we cannot visually see the electrons move in a circuit it is more difficult to diagnose and understand. If you are not sure of your test result readings then you must have access to the manufacturer's data to proceed and work safely, test don't guess!

I used to practice by experimenting and testing known good circuits and components. I would do this as often as I could in my own time, to help me develop better skills by making lots of mistakes and learning from them.

I hope that I have helped to make it easier to understand the basic functionality of electrical circuits, and this helps you to better understand basic testing for voltage drops and faults in an electrical circuit, by using the correct equipment. Remember, practice makes perfect!

It is not that difficult, but it can be time consuming. That's life – nothing is easy, but it can also be rewarding!

Your multimeter is your best friend when testing and diagnosing circuit faults, buy a good make and look after it and this will last a very long time. You don't need expensive oscilloscopes to identify basic circuit or component faults.

Good luck with your diagnosing and testing!

Figure 7

Figure 8

Figure 9

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With non-compliant oils entering the market, and oil diagnostics becoming more sophisticated and popular, workshops need to take extra care to ensure that they are using the correct lubricants

OIL DIAGS

Just as doctors tell us that stools indicate issues with our bodies, Rob Marshall reasons that drained oil provides useful diagnostic clues – but ones that could get you into trouble

The increased fussiness of modern mechanical components' lubrication needs poses a problem for workshops. As febi explains, tailpipe emissions have dominated engine and drivetrain development. This has caused oil viscosities to decrease, necessitating an increasing cocktail of sophisticated additive packs to provide adequate anti-wear protection. Liqui Moly elaborates that, whereas the base oil used to be the most important performance ingredient in engine oil, today, it is the additive package. Surprisingly, almost a third of modern oils comprise additive packages to ensure cleaning, corrosion protection, cooling and lubrication. The actual oil content in these low-viscosity lubricants tends to just be the carrier for those remarkable chemicals.

While garages cannot perform accurate oil diagnostics, it is a good idea to check the filter pleats and housing for any potentially worrying contaminations, such as metal fragments. Even if none is found, clean the housing of any old oil, or sludge, before fitting a new element.

How can you use oil as a diagnostic tool?

Technicians can examine drained oil and make judgements, based on experience. Engine oil, possessing a strong smell of fuel, should be taken seriously. Blame could lie with the driver making an excessive number of short trips; alternatively, a faulty fuel injector might be the cause. A very high oil level on diesels might indicate a DPF problem. A potential follow-up may be to check diagnostically how many successful regenerations have taken place; all that may be needed is a fuel additive, or more detailed analysis, such as boost leak, all of which are upgrade services. Yet, be wary of being tempted into snap-diagnosis. The resultant 'mayonnaise' under the oil filler cap might well be caused by coolant and oil mixing, but should not be confused by the natural condensation that can occur on some engines, especially as the weather cools. While a little messy, and not forgetting to wear gloves to protect from carcinogenic used oil, inspect used filter pleats for any contaminations that they have trapped. It is also wise to clean out any plastic filter housings thoroughly, prior to installing a fresh filter element.

Therefore, Duckhams' assertion that modern lubricants are, "highly engineered solutions that play a vital role... in vehicle performance and longevity," is no exaggeration. Yet, with so many different manufacturer specifications, what should you use and is it really that important? As the VLS explains, such non-compliant products risk causing damage to customer vehicles, so how do you know which products to use? The VLS says that the online lubricant databases, operated by most lubricant companies, will provide a recommendation for the correct oil but they should be used only as a starting point. Technicians should verify any recommendation afterwards by referencing the vehicle's manual and checking the product claims in marketing literature, technical data sheets and product labelling. Looking beyond the viscosity to specific performance claims, such as the ACEA sequences and OEM standards, should ensure that the lubricant is fit for purpose in that specific vehicle. The VLS also warns that not all claims, made by lubricant blenders, are true. To help,

As our turbocharger feature explains, most failures are caused by the lubrication system. Pictured is a sludge within a failed turbocharger core, caused by the oxidising.

What can laboratories find in engine oil?

“No longer will a stock of two, or three, large drums of engine oil suffice and most aftermarket garages realise this"

the VLS publishes guidance leaflets: https://ukla-vls.org. uk/publications/. Additionally, should you be suspicious about a product's claims, you can report it to VLS by calling 01442 875922. Taking extra care to ensure that you are using the correct lubricant is vital. As Liqui Moly highlights, the workshop would be responsible if mechanical damage resulted due to incorrect filling.

Price pressures

No longer will a stock of two, or three, large drums of engine oil suffice and most aftermarket garages realise this. As Duckhams admits, workshops are moving towards smaller pack sizes to keep inventory down, yet, it warns about quality. With rapid increases in labour, parts, fuel and insurance costs, lubricant prices have become even more relevant. With new engines come new oil specifications, which Duckhams says is leading to a further proliferation of brands, making choices even more difficult for garages.

Yet, Duckhams urges caution, when it comes to engine oil, in particular. While using non-compliant oil might not cause obvious damage immediately, it can cause increased wear to critical parts as time elapses. This, Duckhams explains, creates knock-on costs for vehicle owners and potential damage to a garage’s reputation.

To justify its views, Duckhams shares its aftermarket experiences. The firm sees plenty of 5W30 ACEA C3 used in workshops and yet very few OEMs recommend that specification alone. Most of them require an additional OEM specification, such as MB 229.51, BMW LL-04, Volkswagen standard 504 00, or 507 00. Meeting these specifications dictates many more enhanced tests beyond those needed

It can be tempting to use a lubricant that is not to the exact specification, either to cut cost, or time. Who will find out, right? The problem with this stance is the growing trend of car manufacturers, warranty companies and even car owners engaging specialist laboratories to test engine oil, to identify who is liable to pay for repairs. The main purpose is to find whether neglect is the reason for mechanical failure, instead of a manufacturer defect. If a garage has used incorrect oil, for example, then this evidence could be used against you, should a customer decide to take legal action against you for negligence.

The laboratory will know the chemical makeup of the oil, from the manufacturer's specifications. Mechanical wear can also be assessed. Naturally, an engine, or transmission, will shed metal fragments. These are analysed by the laboratory and it is established if the quantity within the sample is excessive, which is denoted by particles being larger than 15 microns. It also establishes which metals are present. Aluminium fragments tend to originate from pistons, whereas molybdenum and chromium tend to stem from the piston rings. Iron emanates usually from the cylinder liners, or the timing chain, where one is fitted. Soft metal deposits, such as lead, copper, or even tin, tend to originate from crankshaft bearings. Non-metallic contamination will also be present on affected engines. Fragments from Belt In Oil timing belts and plastic pips from failing timing belt tensioners are also possibilities. All of these contaminations will be identified in the final report, which tend to be prepared in a format that can be used as evidence in the county court.

Assessing the oil can also reveal elements that originate neither from the engine, nor the oil itself. Silicon suggests dirt, for instance, unless potassium and sodium are also found, which suggests the presence of coolant.

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to meet the standard C3. While most garages understand that 5W30 C3 is one of the most popular engine oils in the aftermarket, we all should consider that OEM specifications are more important than the viscosity and the ACEA (or API) grades.

Duckhams reemphasises the VLS's advice: if a product sounds too good to be true, challenge and check it. Request that the supplier provide Technical Data Sheets to confirm that the product has the correct approvals. Look closely at the language used. Is it approved by an OEM, or just 'suitable for use in xxx,' or 'meets the requirements of xxx'? While the wording is very subtle, there is a big difference. By investing in OEM approval, including hours of testing at a significant cost, an oil blender has proven that its formulation is suitable for the application.

Should you be unsure about a particular brand, especially if it is relatively new in our crowded marketplace, Duckhams says that you can check online if it has registered with European lubricants organisations, ATIEL and Sail Europe. Any lubricant marketer, claiming any ACEA performance standards, must be a signatory of the European Engine Lubricant Quality Management System marketers' Letter of Conformance, even if they sell products only in the UK. This can be checked at www.sail-europe.eu/registrations/lubricant-marketers

Castrol has announced that it is the official supplier of transmissions for a pair of Chinese manufacturers. The Castrol ON EV Transmission Fluid W2 is compatible with the MG HS Plug-in Hybrid and MG ZS EV. Its ON EV Transmission Fluid W5 has been developed for BYD, used in the wet e-motors found in the Seal saloon, as well as the upcoming Seal U DM-I Plug-in Hybrid SUV. The W5 formulation is also compatible with BYD models that feature a dry e-motor, including the Atto 3 and Dolphin models.

Why bother?

Naturally, this extra bureaucratic load adds to workshop time and cost. However, with inflation placing extra pressures on costs and with the motoring public tightening their belts still further, it seems as though cheaper but non-compliant blends are creeping into the market and, potentially, into your workshop.

The VLS reports that 2024 has seen a dramatic increase in its workload. This year, the organisation opened 19 cases. While this might not sound like many, this compares with a total of 33 over a previous five-year period! As the VLS’s objective is to bring products into compliance following investigation, it is pleasing to see that many cases have concluded with oil blenders taking action to put things right.

Yet, it seems as though there is a worrying increase in blenders not bringing their products back into compliance, meaning that these lubricants are still available in the marketplace, for garages to use. The VLS told AT that it has reported several cases to Trading Standards this year. Once such product even turned solid at low temperatures, which remained on UK sale even following the VLS's sixmonth review, because the lubricant marketer had not taken effective action to recall it.

www.ukla-vls.org.uk

Extra, Extra.

As an oil blender and additive producer, Liqui Moly recommends additives as preventative measures. By using the company's additives in conjunction with its lubricants, there is no chance of chemical incompatibility, which is a reason given by some blenders, who do not sanction additives. Yet, the use of high-quality additives have proven beneficial to keep modern engines clean.

Liqui Moly recommends its Pro-Line Engine Flush is used prior to draining, followed by its Cera Tec additive, which is dosed into the new oil. It highlights, however, that the maximum oil level must not be exceeded.

Verification of Lubricant

Specifications is an independent trade body here to protect you by investigating performance claims made on lubricant products so that you and your customers can be assured that the oils you use are what they say and can do what is claimed.

If you have concerns about a lubricant, report

Oil for EVs

As we all know, the arrival of EVs means no more oil changes and no more maintenance. So would certain EVangelists have us believe! Naturally, this is complete nonsense but it is encouraging that not only are many garages looking to upskill but also they are supported by quality aftermarket specialists. One such example

is MEYLE, which introduced a drive oil change kit for Tesla Models S, X, 3 and Y, as part of its expanding eSolutions portfolio. This contains all of the parts that garages need to conduct the procedure, which the manufacturer recommends every two years. (Image courtesy of Tesla, Inc.)

Specialist fluids

You do not necessarily have to rely on the OEMs for specialist fluids. febi, for instance, supplies products not only for automatic transmissions but also gear oil for Dual Clutch automated manual gearboxes. It also supplies Hydraulic Fluid for Haldex Couplings, such as that pictured. The bilstein group highlights that

these products can be supplied as complete service kits, which include filters, gaskets, drain plugs and oil pans, if required. For more information and to confirm compatibility, check out the firm's updated 'fluidfinder', on its parts finder site: https://fluids.febi.com/en/ car/# .

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TALKING TURBOS AND BEYOND

As the turbocharger has a significant influence on the entire engine, consider it as an integral part of the power-plant and emission control systems, not as a bolt-on component.

Few automotive components work as hard as the humble turbocharger but how can you use its failure as a diagnostic tool, while effecting quality but profitable repairs? Rob Marshall, therefore, looks at the latest information for professional workshops.

Once the preserve of expensive, high-performance exotica, the modern turbocharger has managed to square so many engineering circles. It offers high performance with low emissions, the economy of a small displacement engine with the power of a larger one and relative cost-effectiveness that pleases carmakers. No wonder it has become almost ubiquitous.

The precision shaft and turbine/compressor wheels are subjected to extremes of temperatures, pressures and speeds. Unsurprisingly, they cannot tolerate extended periods of neglect and it tends to be these parts within the turbocharger's core, which fail first.

The quantity of carbon that can build on and around the variable vane mechanism is surprising. Pictured is a turbo from a JLR 2.0-litre Ingenium diesel engine.

Yet, the turbocharger is a precision component. Its shaft spins many times faster than the crankshaft and its exposure to compressed air, flowing exhaust gases, plus having the exhaust manifold acting as a heat sink, means that it faces extremely high temperatures. In many ways, it is remarkable that turbochargers can last for the life of an engine.

What goes wrong?

Naturally, turbochargers have a finite life, one that reduces significantly under neglect. Being such a stressed component, failure should be viewed as a symptom of another problem. This is why suppliers of remanufactured turbochargers insist that extra parts be renewed. As it is so reliant on the lubrication system, any weakness in the oil supply tends to be indicated by the turbocharger being the first component to suffer. Some companies highlight that, even after replacing parts and conducting multiple oil flushes in quick succession, a small risk remains of carbon particles damaging the turbocharger's soft bearings.

These bearings develop an audible whine, when worn, and the resultant play causes the shaft to wobble. This can promote the fast-spinning compressor, or turbine wheels, to strike the internal housings, rendering them as scrap. This movement can also result in oil leaking into both the intake and exhaust systems. Should the catalytic converter, particulate filter and NOx catalysts need to be replaced due to engine oil contamination, the repair cost will rise considerably.

Excessive back pressures, from blocked DPFs, can also cause oil consumption. Exhaust gases can be forced from the turbine through into the compressor side, distorting the rubber and metal oil seals/piston rings in the process.

Diesel variable vane systems (of which there are a variety of anachronisms, including VVT/VGT/VNT) can seize due to carbon accumulation. This damages the actuators, fooling technicians into suspecting the actuator instead of the underlying cause. Thankfully, various fuel additives are available that are designed to clear this carbon from the VVT, such as JLM Lubricant's Diesel Turbo Cleaner, available through Kalimex.

Extra parts

To ensure you are quoting accurate prices and ensuring maximum reliability from a remanufactured turbocharger, study the parts that the supplier states should be changed. Should you decide to take a shortcut, or your customer pressurises you to do so to shave costs, consider that the turbocharger supplier may ask for evidence that these components were changed if it is to honour a warranty claim.

While variable vane mechanism actuators tend to be bolted to the turbocharger, even slight variations in their positions can prevent full boost from being achieved at certain engine speeds. Turbocharger remanufacturers use specialist test rigs to determine the correct positon, so bear this in mind, should you replace the actuator and a new boost problem appears.

Finally, the driver might be to blame, so sensitive communication might help resolve the problem. Short trips can promote carbon build and seize the vanes. Despite the insistence of car makers, professional turbocharger remanufacturers remain adamant that a turbocharged engine should never be raced on start-up and, preferably, not until the oil has warmed. Similarly, the throttle should not be blipped, prior to engine shutdown. This exercise cuts the oil supply to the bearings, while the shaft remains spinning at high speed. Allowing the engine to idle for a while, before switching the engine off, not only lets the shaft slow and cool but it also helps to prevent harmful heat-soak that can carbonise the oil and damage the soft bearings further. In the name of mechanical sympathy, you might wish to advise your high-mileage customers to deactivate start-stop systems, especially if they have to stop immediately after a high-speed motorway run.

Case study: PSA/Ford 1.6-litre diesel (DV6)

One would have thought that cars, fitted with this engine, are too elderly to be worth repairing. Yet, turbocharger suppliers report that there is still a healthy demand for replacement turbochargers. In particular, Nissens Automotive (Nissens) reminds workshops that repair remains profitable.

The aftermarket specialist says that, despite negative views held within the repair industry, the DV6 is a reliable unit. Yet, it is especially vulnerable to turbocharger failure, caused by the incorrect specification lubricant, or if it has become overly contaminated with debris/diesel fuel. Neglected servicing is one reason but mechanical problems can also degrade the oil prematurely. This includes blown fuel injector seals, identified by 'chuffing', or a black coal-type deposit building around the injector bases. Alternatively, intake leaks promote rapid DPF filling and turbocharger over-speeding.

This is why Nissens explains that carrying out an oil and filter change and replacing the turbocharger on a faulty car, without finding the underlying cause, risks further turbo failure. While oil degradation tends to be a popular root cause of turbocharger failures, Nissens

highlights oil flow as an additional but related reason. The aftermarket supplier explains that these situations are related, because contaminations within the oil, such as sludge, or soot deposits, oil can restrict, or block, the oil galleries.

Therefore, to help workshops conduct a thorough repair, Nissens Automotive has also produced four replacement turbo kits for the various versions of this engine. It explains that both the 'basic' and 'plus' versions of the kits are available for both DPF and non-DPF variants. The basic kits (Nissens' part numbers 9300908 and 9300909) contain the oil pick up/strainer, oil feed line, oil return line, oil return line flange and two banjo fitting bolts. The 'plus' kits (part numbers 9300910 and 9300911) add a pair of oil filters, their assembly gaskets, plus vacuum pump and oil cooler gaskets.

When the appropriate kit is combined with one of the two replacement turbo options (Nissen's part numbers 93037, or 93061) workshops have a straightforward OE-quality repair solution. Full details can be found through the Nissens online catalogue at: https://nissens.com/catalogue

Belt in Oil considerations

Even if they have not yet shredded their teeth, fine particles of the timing belt end up in the oil. AT has witnessed fine belt particles contaminating the oil pump strainers of PSA/ Stellantis and Ford 1.0-litre Ecoboosts, even on cars that have received regular oil and filter changes, before the official belt change interval. As the turbocharger tends to be the first component that fails as a result of lubrication system issues, you should inspect it for wear and damage. This includes checking for excessive play in the turbocharger shaft, as well as listening for audible whining that indicates all is not well with the bearings.

While the BIO replacement procedure recommends strongly that the sump is removed and the oil pump strainer cleaned, at the very least, we have noticed an omission from some of the repair procedures for the 1.0-litre Ecoboosts. The turbocharger is protected by another filter in the oil line, positioned behind a plug within the turbo's oil gallery, adjacent to the BIO belt drive. While replacement filters are available from Ford, workshops are suffering severe delays in genuine parts deliveries, due to asbestos being found in its UK distribution centre, meaning that components are being shipped from Europe, for the time being.

Tools degrade with the rigours of workshop life, although a lack of maintenance and incorrect use (such as that demonstrated) will reduce their lives markedly

Hand tools –getting the basics right

Despite the proliferation of exciting electronic tooling, basic hand tools remain fundamental backbones of your workshop and are easy to take for granted. Rob Marshall liaises with Laser and Sealey tools to find out how a busy technician can best look after them.

Unlike hard and software-driven equipment, hand tools tend not to go out of date. This explains why many technicians treat them as lifetime investments. Regardless of whether you have adopted a cost-is-no-object attitude to tools, or whether you plump for more value-orientated mid-range offerings, it pays to look after them.

Shelling out

Sealey says that, should hand tools not perform well, they will make the job harder and waste time. Therefore, prioritise tools that are well-made and designed to make complex tasks simpler, dangerous tasks safer and strenuous tasks easier, by being comfortable and easy to use. To reduce fatigue, consider hand tools with ergonomic grips, or power tools with vibration-reducing housings. When selecting sockets, Sealey recommends that technicians look at its Lock-onTM models, which feature machined flutes in the walls of the socket to enable use with fasteners that are up to 85% rounded.

Striking the plastic handle of the screwdriver risks forcing the metal shaft upwards and breaking the plastic moulding. Yet, you can buy' Pound-thru' screwdrivers that are designed to tolerate this kind of treatment, although it is prudent to use a copper-headed mallet to reduce the chance of 'mushrooming' the end.

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Many quality suppliers stock ratchet repair kits to fix broken mechanisms. Broken ratchets can cause the tool to slip, risking injury. Yet, they require only a smear of grease. So never pack the void with lubricant.

As with parts suppliers, trust in a tools provider that will not supply fakes, has decent aftersales support and can respond quickly. It is also prudent to rely on established brands with decent long-term guarantees and those with the ability to supply spare parts, such as replacement ratchet mechanisms. Should you choose not to perform the work yourself, Sealey highlights its service centre, where a tool can be repaired within 48 hours of receipt. Furthermore, the company's spare parts inventory stretches to over 120,000 components, including those for discontinued tools.

Look after your tools...

Naturally, with tools being used every day within a busy workshop environment, an efficient storage system avoids time being wasted by searching. Yet, it also extends tool lifespans. Quality tool suppliers have a variety of storage options, from traditional rails, racks and dividers to cut-out foam inserts that fit inside toolbox drawers.

Hand tools also benefit from being kept clean. Any chemical contamination that risks damaging protective anti-corrosion coatings should be removed immediately. Try to inspect your tools after each use. For instance, sharp damaged/peeling plating might cause you an injury the next time you pick it up, whereas loose fixings/joints risk the tool failing as you apply force to it. Cracks on power tool handles, or damaged wiring/ bulging battery packs, should also be remedied as soon as possible. As Sealey highlights, defective tools are major causes of technician workplace injuries.

Avoiding abuse

Understandably, situations arise, where technicians use tools in a way not intended by their designers. Tools can be damaged by incorrect use but this is not always obvious. With pullers, applying force at an angle risks applying force to the tool, rather than the component. It is also worth noting that two-legged pullers are harder to keep aligned than one with more legs.

Sealey's Top Five Tool Abuse Findings

Screwdrivers being used on incompatible fasteners

Screwdrivers being used as pry bars, chisels, or hammers

Ratchets and spanners being used with a hollow tube to give extra leverage

Wire cutters being used to cut anything but wire

Standard sockets being used with impact wrenches

Pullers fail by not being installed correctly. The threads on the mandrel can also strip but you can reduce the chance of this happening, by giving it a light smear of extreme-pressure grease, containing molybdenum disulphide (i.e. CV joint grease).

Overheating a stubborn fixing, using an induction tool until it is cherry red, also damages the tool, by burning away the coil's insulation. Overheating stresses the internal electronics as does not fitting the correct replacement coils.

Increasing the force applied to a fixing, by using an extension bar on a tool handle, may work but it exposes the tool to greater forces than it is designed to handle. This is a major cause of ratchet mechanisms breaking, although a repair kit might be available to salvage the tool.

Lack of maintenance is one consideration. For instance, torque wrenches require recalibrating periodically, so they remain within tolerance. Yet, how often is this done? Sticky ratchets may need periodic lubrication - but this is quite

Specialist hand tools

Some jobs dictate that general hand tools are unsuitable, no matter how much they cost you. A typical example of this is a range of tools introduced by Schaeffler for modern clutches, designed to make your work easier, quicker and simpler.

The DMF Special Tool (400008010) measures bearing rock and rotational free play angles, so you can assess whether, or not, the DMF needs replacing.

The SAC Special Tool (400023710) permits accurate self-adjusting clutch installation, without activating the internal mechanism.

Finally, the basic Double Clutch Special Tool (400041810) is the basis of a modular tool system and can be combined with vehicle-specific supplementary tool kits, dependent on make and model. More Information on Schaeffler tools can be accessed via the REPXPERT app, downloadable for free for all iOS and Android devices, or at www.repxpert.co.uk

different from swamping the mechanism with grease. Any colleagues, responsible for health and safety, would be wise to check any handheld tool for damage and natural wear and tear, particularly if it is powered by electricity, or air pressure.

The Garage Warmington –Small but mighty

I visited the father and son team of The Garage Warmington, a small roadside workshop in Oxfordshire, back in August, to see the proactive pair in action, having enjoyed their company at several of our training events over the years. Training and their enthusiasm for the trade has been key to their success – being firmly committed to keeping up with evolving technologies as well as growing their connections within the trade to share best practice advice with peers.

The family business was set up by Martin Smith in 1974, with son Adrian helping out at the garage from the age of 8. Adrian worked alongside his father for over 20 years and took over in 2017 when his father retired. Adrian’s son Joshua is now the third generation of the family to join the business. The garage has built up a great reputation over the last 50 years of trading, with a strong focus on providing a friendly excellent customer service, transparent pricing and quality repairs.

They provide a full range of repairs and servicing on ICE and electric vehicles and have made a name for themselves for their diagnostic expertise, and more recently, DPF issues –receiving many recommendations and referrals from other garages who are yet to tool up and train in this lucrative and growing arena.

Although they recognise they are good at what they do, they sensibly acknowledge there are people out there who are better and they benefit from their expertise by being part of various networks and have enjoyed meeting like-minded folk at autotechnician’s Workshop Takeovers. Josh has been one of our youngest delegates and has taken much away from these fault-finding sessions and has also had incredible luck with the raffle we hold, winning great prizes on a couple of occasions. Two years ago, Josh’s name was pulled out of the hat and won a JLM Lubricants prize bundle from distributors Kalimex. Having used them back in the workshop, they have now switched over to the range of repair and preventative treatments for engine, fuel system and exhaust components.

Adrian was unblocking a DPF on an Audi A6 when I arrived, using the JLM Diesel DPF Cleaning Toolkit, a task he undertook last year – frustratingly, the car has an underlying injector issue that should be addressed but the owner is the type of customer who doesn’t want to spend any money. So, it’s back to address the symptoms rather than the true fault.

It’s a straightforward process that takes under one hour to clean the diesel particulate filter, without the filter having to be dismantled. The toolkit comprises a spray gun, a highly concentrated cleaner and a flush fluid. The first is a presoaking cleaner that loosens the soot and grease and the rinsing fluid flushes the filter until it is thoroughly clean.

“Before cleaning the DPF, at idle the pressure read 107.2 mbar and at 2,700 rpm the reading was 646.8 mbar. After using the JLM toolkit we performed a road test, at idle the pressure now read 8.01 mbar and at 2,700 rpm was 43.92 mbar – a great result and the customer says it is still driving well.”

It was the first time Adrian had used the toolkit on such a blocked filter, so he called Mike Schlup from the UK distributor Kalimex for some technical reassurance before he began. He connected the spray nozzle to the rubber hose on the front pressure sensor on the DPF and squirted the fluid in onesecond intervals then left it to soak for 30 minutes as it was badly blocked. Usually, you would need to leave for just a few minutes.

The JLM Diesel DPF Flush was then applied to clear out the substrate and redistribute the accumulated soot within the soot trap. Adrian placed the collector under the exhaust pipe to collect the plentiful foam.

Preventing Problems…

Adrian finds that JLMs preventative treatments, such as the Petrol Emission Reduction Treatment, are an easy sell to customers, as it cleans the entire fuel system and gives an immediate improvement in engine combustion, which is reflected in lower emissions – particularly useful before a vehicle heads for an MOT test.

Adrian is particularly happy with the support he receives from JLM, in addition to branded merchandise and signage, he welcomes the fact they have a UK-based technical helpline to call when he wants to check the application of their products on a particular vehicle.

PARTS, TOOLS & TIPS

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

A fast fix for broken pipes and hoses

The Smart Splice system, available from Primalec, enables speedy repairs and modifications to pipes and hoses – ideal for repairing or reconfiguring AC pipework, providing a permanent or temporary fix.

The line connectors, developed in the USA for General Motors, provide airtight seals in just a few minutes and can withstand over 150bar pressure.

It can be used to repair leaks, connect metal pipes to flexible hoses, block off malfunctioning sections of A/C systems, add or replace a service port, using a range of angle connections.

Primalec has created a video to show how simple it is to use Smart Splice, demonstrating the process of fixing a line and hose.

Visit https://bit.ly/smartsplice or scan the QR code above to view. www.primalec.co.uk

Streamline your workshop

Straightset’s latest Workshop Furniture brochure highlights the range of storage and benching it offers to create an organised, efficient workspace.

Its Workbench System is modular so you can create a bespoke working area, with single and double tool benches with drawers, storage and dispensing cabinets.

The brochure details a range of customisation options, including drawer configurations, worktop depths, and additional features such as integrated power systems and foam inlays.

Download the brochure at https://bit.ly/Straightset or scan the QR code above.

New 0W-20 oil for popular models

Castrol has a new low-viscosity engine oil for use in a wide range of Peugeot, Citroen, DS and Vauxhall vehicles introduced from 2018 where the manufacturer recommends PSA B71 2010.

Castrol MAGNATEC 0W-20 FE will enable garages to service vehicles powered by the 1.2 PureTech and 1.5 BlueHDi engines and is also compatible for Vauxhall models featuring the 1.2 Turbo and 1.5 Diesel.

The oil clings to critical engine parts for better wear protection, safeguarding components such as the valvetrain, timing chain, pistons and bearings.

Brake fluid considerations

Brake fluid is a vital, safety-critical component within the braking system with several factors affecting its effectiveness. Here, febi outlines its characteristics and advises on best practice.

febi DOT 4, DOT 4 LV (low viscosity), DOT 4 Plus, DOT 5.1 and DOT 5.1 EHV (electric and hybrid vehicle) are fully-synthetic brake fluids based on glycols, containing oxidation and corrosion inhibitors with excellent dry and wet boiling point properties, which also prevent vapour bubble formation.

Friction during the braking process generates heat and some of this heat is absorbed by the brake fluid. The boiling point of a brake fluid is a temperature at which gas bubbles form. As soon as a gas bubble forms, the pressure in the brake system can no longer be maintained because the gas can be compressed. The consequence is a sudden reduction in braking effectiveness, which can lead to an accident.

The hygroscopic property of brake fluid is required so that any water present distributes itself evenly throughout the liquid. If water is collected in a specific area, the boiling point would lower to approximately 100 °C. However, if the water is dissolved in the brake fluid up to a proportion of 3% (for example), the boiling point would remain significantly higher than 100 °C, where the risk of bubble formation is much lower. Several factors affect and accelerate the absorption of water. These include the storage of brake fluid in open, unsealed

packaging for longer periods, non-compliance with brake fluid service intervals, damaged brake system elements (e.g. cracks or splits in the outer layers of flexible brake hoses), or damaged seals/gaskets.

The hygroscopic properties of the brake fluid stem from the glycol content. This allows the fluid to gradually absorb more and more water, which also means that it needs to be changed on a regular basis. Vehicle manufacturers generally recommend changing the brake fluid every 30,000 to 50,000 kilometres or every two years, subject to operating conditions.

febi brake fluids are developed in accordance with the quality standards of vehicle and brake system manufacturers to meet the requirements for current brake systems, including electronically-controlled brake systems which need to perform reliably and within fractions of a second.

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Diagnose faults on the latest BMWs

Technicians can now work on the latest BMWs protected by cyber security systems without having to go through the OE portal as Hella Gutmann adds BMW to the list of supported brands for its Cyber Security Management (CSM) product.

VM security gateways restrict access to certain diagnostic features to protect connected vehicles from potential hacking.

“Mega macs users can bypass the hassle of registering individually on OE portals, undergoing tests, and paying fees,” said Julian Goulding, Hella’s Head of Sales. “Instead, by simply authenticating once with Hella Gutmann free of charge, security gateways are automatically unlocked.”

The latest range of mega macs diagnostic devices instantly detect if a vehicle is secured upon connection, or via a VIN search. When detected, Hella Gutmann CSM automatically unlocks the gateway within a fraction of a second, giving technicians easy access to all the usual diagnostic functions including reading/deleting error codes, viewing parameters, basic settings, calibrations, coding, actuator tests and service resets.

Using Hella’s CSM, workshops currently get largely unhindered diagnostic access for recently launched models

from Abarth, Alfa Romeo, Audi, BMW, Chrysler, Cupra, Dacia, Dodge/RAM, Fiat, Hyundai, Jeep, Kia, MercedesBenz, Renault, Seat, Skoda and Volkswagen. In addition, cyber security hurdles on Ford, Polestar and Volvo can be overcome with most mega macs devices via a ‘Seed-Key’ procedure.

https://bit.ly/HellaCSM

Water pump for Volvo engines

Schaeffler’s range of INA electric auxiliary water pumps now includes a new reference for the popular Volvo XC60, alongside several other models.

Electric water pump ‘538 1018 10’ covers Volvos equipped with the B4204 engine, including variants of the S60, S90, V40, V60, V70, V90, XC40, XC70 and XC90. The most popular vehicle covered is the Volvo XC60 Hybrid AWD, in production since 2018.

“This new pump is notable for its precise controllability,” said Maik Evers, Head of Product Management Powertrain Systems at Schaeffler.

“Because it is powered by the vehicle electrical system, not the belt drive, the delivery rate is continuously regulated.”

For vehicles equipped with Volvo’s B4204 engine, Schaeffler also offers several other INA engine

Remanufactured braking range expands

Brake Engineering has introduced more than 60 new brake calipers this year for multiple VMs, including Audi, BMW, Fiat, Ford, Vauxhall, and VW. The new additions cover more than 150 passenger car and light commercial applications and have also been added for electric vehicles Nissan Leaf and Tesla Model 3.

system repair solutions, including ‘530 0746 10’

Timing Belt kit, ‘529 0554 10’ FEAD kit, ‘535 0367 10’

Overrunning Alternator Pulley (OAP) and ‘529 0548 10’, another FEAD kit.

www.repxpert.co.uk

Each of its calipers are remanufactured according to an ISO international quality standard, which includes a 10-stage process that begins from the moment core arrives at the Brake Engineering Centre in Wrexham and proceeds through inspection, breakdown, cleaning, plating, rebuild, testing, packing, shipment and finally fitment of the caliper to vehicles.

All Brake Engineering calipers are fitted with new pistons and sliders made on-site using the latest CNC multi-spindle machines. Accepted core units are fully dismantled and all wearing parts are completely replaced with brand new components including pistons, seals, sliders and circles. Each unit is also given an electroplating finish, ensuring a longer lasting caliper, which causes less damage to the environment.

www.brake-eng.com

Renault's 5 E-Tech takes over from the popular Zoë, taking the French firm back to the future with some interesting premium technical features

RENAULT 5 E-Tech

Leaning heavily on retro nostalgia, Rob Marshall looks at the latest R5, reimagined as an EV after almost thirty years of absence from UK sales charts

You could not have failed to notice that Battery Electric Vehicles have received a pasting recently - not all of it fair. Even so, the BEV honeymoon, in particular, is over. While the 2035 target is looking increasingly unachievable (for now), even the most sceptical technician cannot deny that electric propulsion is becoming increasingly popular.

In the new car scene, all is also not well. BEVs are seen as too expensive, hence why demand among private motorists is flatlining. A host of low-cost Chinese BEV brands are flooding the UK market to resolve the issue, causing established brands, which have committed themselves to a pure EV future, more than a few headaches. Whether these Sino-cars have suitable spare parts and data support for the aftermarket remains to be seen. Yet, their limited brand cachet means that established car manufacturers, at least, have one upper hand.

Enter Renault's 5 E-Tech, an all-electric retro car that is being hyped by its manufacturer as being a new European Star, being built in France using EU components. Perhaps a reason for hammering home this message is not solely for national pride but because another Renault Group BEV, the Dacia Spring, has lost access to French 'bonus écologique' subsidy payments, due to it being a rebadged Chinese-built Dongfeng.

The denim upholstery, used on the seats, fascia and door panels, is produced from 100% recycled plastic (PET) water bottles. As is the modern trend, dual horizontal screens dominate the dashboard. The central 10-inch multimedia touchscreen is powered by the OpenR Link system, with Google built-in, dependent on the trim level.

Unsurprisingly, Renault has leaned heavily on its heritage, from the 5 E-Tech's bright retro paint palette and interior colour schemes to '1972' graphics inside, referencing the launch of the original cinq. Yet, beneath the superficialities, the 5 E-Tech is Renault's first car to be underpinned by the company's AmpR small chassis, indicating that more small BEVs are to come, including those from Nissan. This new floor pan has helped restrict dimensions to just under four metres and enhances available interior space. Above all, the 5 E-Tech weighs less than 1.5 tonnes.

Power Tech

The 52kWh battery possesses four modules, each containing 48 cells within its floor-mounted casing, compared with the 12 smaller modules found on Mégane E-Tech electric and Zoë models. It also utilises Nickel Manganese Cobalt chemistry, which Renault says offers the best energy density for its size and 220kgs weight. Providing a 248-miles range between charges, it also can facilitate 100kW DC fast charging, in which case only 30 minutes are needed to boost battery charge levels from 15% to 80%. A smaller 40-kWh battery (186 miles range), of similar construction, is planned later. A liquid thermal management system regulates battery temperatures but Renault advises that the coolant does not circulate within the battery pack but through the extruded floor. A heat pump is employed in conjunction with a high-voltage 8 kW coolant heater, which can pre-heat the interior and be controlled remotely through the MyRenault App.

The motor, transmission and battery pack are based on those fitted to other Renault E-Tech models but are not interchangeable. The inverter and charging systems have been upgraded to facilitate V2G and VTL charging. Renault says that all of the electrical components developed for the 5 E-Tech will feature on future Renault Group B-segment BEVs.

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The electric motor (rated at 150 horsepower, providing a 0-60mph time of sub 8 seconds, although a 120 horsepower version will follow after the car's launch) is based on those used on the existing Mégane and Scénic E-Tech electric models, although the rotor has been shortened by 3cm and is 15kgs lighter, meaning that the motors are not interchangeable. These types do not employ rare earth magnets but copper coils, instead. Yet, the AC/DC converter (which transforms 400V to 12V) has seen more radical changes, by being integrated with the charger; the reasons given for this decision are weight and space-saving.

Perhaps the most notable feature under the 5 E-Tech's skin is 11kW AC bidirectional charging. This means that the car battery can run a 220V domestic appliance, demanding up to an impressive 3,700 watts. Aside from this Vehicle To Load (V2L), Vehicle To Grid (V2G) recharging is also possible, where the owner can save on domestic energy bills, by the car feeding electricity back into the grid.

Safety tech

Again, to shed weight and save space, the master cylinder, ABS and ESP are combined into one module. There is also no physical connection between the pedal and master cylinder, although Renault promises that the 'decoupled' braking system delivers a consistently strong pedal feel, with the switch between regenerative braking and hydraulic braking taking place seamlessly. Naturally, the driver can use the gear lever to adjust regeneration levels, as required. The brakes also lock on post-impact, to reduce the risk of another impact, caused by a secondary collision.

Renault has also crammed the little 5 E-Tech with ADAS features that you might expect to see on larger vehicles. This includes automatic emergency braking that works with reverse gear selected and emergency lane-keeping technology. Intriguingly, a steering wheel-mounted button permits the driver to deactivate up to five ADAS features at the same time, should it be desired.

This BEV also boasts several Level 2 autonomous driving features, which combine adaptive cruise control with Stop & Go and lane centring assist to keep the car's positioning biased to the nearside, to help two-wheeled vehicles overtake in urban traffic. Hands-free parking features, too.

Is it here?

Renault's 5 E-Tech will replace the Zoë and is expected to arrive on UK shores early next year. While prices have not been announced formally at the time of writing, it costs 25,000 Euros in France. The biggest battery and motors will arrive first, followed by the lesser spec models in due course.

The seat cross-members protect the battery without the need for extra bodyshell reinforcements, freeing up more space for the battery

The rear suspension boasts multi-link geometry to benefit handling, stability and noise levels. Its compact nature ensures that the suspension does not encroach into space needed for the battery.

The steering system possesses a high 13.7:1 gearing ratio and Renault has strived to suppress the turning circle to 10.3m. Special attention was paid to the damping to compensate for battery weight. The 18-inch alloy rims are standard equipment.

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