ImportCar, October 2013 by Babcox Media

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Intermittent No Start

October 2013

MAGAZINE

❯❯ Parking Brake Service

Fuel Injector DTCs

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Mazda SKYACTIV Technology

CONTENTS

Volume 35, No. 10

Tech Feature

Diagnostic Solutions

Decoding DTCs Knowing how to interpret and break down the internal structure of DTCs will help determine how to make proper repairs, says Scott “Gonzo” Weaver. And, more correct diagnosis means less time spent on each job, and the quicker you can move onto the next.

Steering, Tire Wear Diagnostics Since many import manufacturers have eliminated adjustable camber and caster alignment angles, it’s doubly important to recognize signs of tire wear caused by bent struts, spindles, steering knuckles and control arms, says Import Specialist Contributor Gary Goms.

ImportCar Staff 330.670.1234 Publisher Jim Merle, ext. 280 jmerle@babcox.com Editor Mary DellaValle, ext. 221 mdellavalle@babcox.com

Managing Editor Jennifer Clements, ext. 265 jclements@babcox.com

Ad Services (Materials) Cindy Ott, ext. 209 cott@babcox.com

Technical Editor Larry Carley lcarley256@aol.com

Circulation Manager Pat Robinson, ext. 276 probinson@babcox.com

Graphic Designer Kelly Gifford, ext. 249 kgifford@babcox.com

Subscription Services Maryellen Smith, ext. 288 msmith@babcox.com

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DEPARTMENTS Columns 6 Editor’s Notebook 8 News Update 24 Gonzo’s Tool Box 30 Tech Update: Parking Brakes 62 Tech Training Offerings 74 Shop Profile: Curt’s Service,

Publication

Contributing Writers Bob Dowie, Village Auto Works, Chester, NY

Gary Goms, formerly of Midland Engine Electronics & Diagnostics, Buena Vista, CO Bob Howlett, The Swedish Solution, Orange Village, OH Babcox Blue

Scott “Gonzo” Weaver, Superior Auto Electric, Tulsa, OK

Inc., Oak Park, MI

Editorial Advisory Board Bob Dowie, Village Auto Works, Chester, NY Chris Klinger, Precision Incorporated, Tucson, AZ

80 Tech Update: Water Pumps 84 Import Tech Tips 94 Essentials (New Products) 98 RAPID RESPONSE 99 Classifieds 104 NASCAR Performance

Steve Louden, Louden Motorcar Services, Dallas, TX

Frank Scandura, Frank’s European Service, Las Vegas and Henderson, NV Joe Stephens, Stephens Automotive, Palatine, IL John Volz, Volz Bros., Grass Valley, CA

Babcox Media, Inc. 3550 Embassy Parkway Akron, OH 44333-8318

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AUGMENTED REALITY CONTENT

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Greg Cira gcira@babcox.com

IN THIS ISSUE:

Vice President/ Group Publisher

Jeff Stankard jstankard@babcox.com

Controller

Beth Scheetz bscheetz@babcox.com

SmartChoice™ Mobile App, powered by Federal-Mogul . .10 (Open AVI Play and hold your smart device over the SmartChoice logo)

Diagnostic Solutions: Steering, TPMS . . . . . . . . . . . . . . . .58 Mazda SKYACTIV Technology . . . . . . . . . . . . . . . . . . . . . .70 Auto-Video Inc. (AVI) . . . . . . . . . . . . . . . . . . . . . . . . . .83, 91 Become a fan on Facebook

In Memoriam Founder of Babcox Publications

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Chairman

Tom B. Babcox (1919-1995)

IMPORTCAR (ISSN 1069-4714) (October 2013, Volume 35, Number 10): Published monthly by Babcox Media, Inc., 3550 Embassy Parkway, Akron, OH 44333 U.S.A. Phone (330) 670-1234, FAX (330) 670-0874. Periodical postage paid at Akron, OH 44333 and additional mailing offices. POSTMASTER: Send address changes to IMPORTCAR, 3550 Embassy Parkway, Akron, OH 44333. IMPORTCAR is a trademark of Babcox Media, Inc. registered with the U.S. Patent and Trademark office. All rights reserved. A limited number of complimentary subscriptions are available to individuals who meet the qualification requirements. Call (330) 670-1234, Ext. 260, to speak to a subscription services representative or FAX us at (330) 670-5335. Paid Subscriptions are available for non-qualified subscribers at the following rates: U.S.: $69 for one year. Canada: $89 for one year. Canadian rates include GST. Ohio residents add current county sales tax. Other foreign rates/via air mail: $129 for one year. Payable in advance in U.S. funds. Mail payment to IMPORTCAR, P.O. Box 75692, Cleveland, OH 44101-4755. VISA, MasterCard or American Express accepted. Member BPA International, Inc. Founded 1979. 䊚2013 by Babcox Media, Inc.

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[ Editor’sNotebook

By Mary DellaValle|EDITOR

Tackle Unperformed Maintenance One Repair Job At A Time

ant to inject some enthusiasm into your marketing plan, deliver added value to your customers and even add some dollars to your bottom line? Then look no further than October Car Care Month. It’s not too late to host a car care event this month, or tie into an existing one, which will help drive business to your shop. Vehicle checkup lanes, a common component of car care month events, reveal unperformed maintenance issues involving check engine lights, filters and belts in need of replacement, low or dirty motor oil and low, leaky or dirty coolant. Power steering, transmission and brake fluids that were beyond their useful life, and improperly inflated tires and worn tread

Mary DellaValle, mdellavalle@babcox.com

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were also key findings. “Most Americans are busier than ever and they may not think twice about putting off vehicle maintenance. Yet, neglected auto care almost always means much higher costs down the road in the form of more extensive repairs or lost resale value,” says Rich White, executive director, Car Care Council. Helping your customers follow a routine maintenance schedule like the one found on the Car Care Council’s website (www.carcare.org) will help them save money, make informed vehicle repair decisions and keep their vehicles in safe, top-running condition. Further evidence of the “untapped” vehicle service market is a new report by AASA that reveals unperformed maintenance represents 27% of total aftermarket potential, but the larger

concern is vehicle safety, which can pose a threat to everyone traveling on U.S. roads and highways. “In 2012, unperformed and underperformed maintenance in the U.S. totaled $66 billion,” says Paul McCarthy, AASA vice president of industry analysis, planning and member services. “Although unperformed maintenance declined by approximately $1 billion year-over-year, it remained near a record high.” So advise your customers how to take a proactive role in regularly maintaining their vehicle. Educate them on the benefits of proper vehicle care. Your vehicle inspection efforts will make you a key player in tackling the vast amount of unperformed maintenance work that’s evidenced on every roadway in this country — an accomplishment that will pay big dividends for us all. IC

[ NewsUpdate Special Report: Healthier Hands Can Lead to Happier Techs GOJO Cites Science Of Hand Hygiene And Its Value In The Workplace Maintaining healthy hands on the job delivers important benefits in workplaces where employees encounter tough soils, said James W. Arbogast, Ph.D. and vice president of skin care science and product development for GOJO Industries, Inc., during GOJO’s “Science of Hand Hygiene” media education day held at the company’s headquarters in Akron, OH, in August. Dirt, grit, irritants and harsh chemicals combine with heat, cold and other environmental factors to create the perfect storm for occupational skin diseases. Contact dermatitis annually costs employers billions of dollars and costs another $500 million in productivity losses. Dr. Arbogast said the first line of defense is to become more aware of various hazards, including Chemical Irritants (lubricants, oils, greases, solvents, paints, fiberglass, acids and even poorly formulated hand cleansers that include surfac-

October 2013 | Import-Car.com

tants); Physical Agents (repeated exposure to heat, cold, water and friction); and Biological and Microbiological Agents (hand transmission of germs that may cause illness). “When dealing with tough soils day in and day out, workers need to use hand cleaners and conditioners made for the grease and grit they encounter on the job,” Dr. Arbogast said. “Quality handcleaning products are your main protection against skin dehydration and potential infection.” Developing a skin care regimen and good hand hygiene habits will lower costs (in terms of lost work time and absenteeism), increase productivity and efficiency, and allow technicians to “maximize the capability of the most important tools of their trade,” concluded Jim Brown, marketing director, manufacturing and automotive for GOJO. For more information about GOJO’s skin health and hygiene solutions, go to www.gojo.com.

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[ NewsUpdate Save On Monroe Ride Control Products This Fall Through ‘Spooktacular’ Shocktober Offer

The fall automotive maintenance season will include some “spooktacular” savings due to the Monroe “Shocktober” promotion that began Sept. 1 at participating service locations in the U.S. Through this promotion, consumers who purchase a combination of four qualifying shocks or struts will be eligible to receive a Visa prepaid card by mail equal to the lowest cost unit, up to Monroe’s and Rancho’s current published suggested list price. “This promotion is a very effective way to educate consumers about shocks and struts and how they can help provide safe steering, stopping and stability characteristics,”

October 2013 | Import-Car.com

said Sheryl Bomia, North American programs manager, Tenneco. “The fall maintenance season is a great time to have these components inspected. You’ll be shocked at the savings ‘Shocktober’ delivers if replacement is necessary.” The Shocktober promotion is available on several shock and struts series from Monroe and Rancho, including Monroe OESpectrum, Reflex, Sensa-Trac, Gas-Magnum, Max-Air and Quick-Strut replacement assemblies and Rancho RS5000 shocks. All submission forms must be postmarked by Dec. 2, 2013. For more information, visit www.Monroe.com.

AMI Announces 2013 Tom B. Babcox Memorial Scholarship Recipient The Automotive Management Institute (AMI), in conjunction with Babcox Media, recently announced Myles Dahlgren, director of mechanical operations, Lamettry’s Collision, Lakeville, MN, as the recipient of the “Tom B. Babcox Memorial Scholarship.” The scholarship recognizes a management-oriented member of the Automotive Service Association (ASA). The recipient receives $1,000 to be applied toward expenses to attend educational sessions and view the latest repair technologies and equipment during the Congress of Automotive Repair and Service (CARS), Oct. 16-18 in Las Vegas. Dahlgren has worked in the automotive service industry for 13 years. He holds several industry certifications and is currently completing the necessary requirements to earn the Institute’s Accredited Automotive Manager (AAM) designation. “I’m grateful to be selected as the recipient of the Tom B. Babcox Scholarship and to be given this opportunity to improve my management skills and share that knowledge with those I work with,” said Dahlgren. “I also look forward to meeting with owners, operators, techs and instructors who are the driving force in our industry. Building relationships with these key people will help keep me and those around me relevant in a constantly evolving industry.” For more information, contact AMI at 800-272-7467, ext. 129, or visit www.amionline.org.

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[ NewsUpdate Wagner ThermoQuiet First Ceramic Full Line Brand Of Brake Pads To Achieve Low-Copper Certification Wagner ThermoQuiet Ceramic brake pads featuring Wagner OE21 formulations are the first full line of replacement ceramic pads to achieve low-copper certification. Approval was provided by NSF International, the independent registrar overseeing manufacturer compliance with copper legislation. The official industry “LeafMark,” indicating compliance with 2021 legislative requirements, will now appear on Wagner ThermoQuiet Ceramic boxes. Federal-Mogul has developed OE21 low-copper formulations specifically for the Wagner ThermoQuiet aftermarket product line. These new ThermoQuiet low-copper ceramic pads are 35% quieter, while providing 15% more stopping power and 40% greater fade resistance than previous formulations. “These low-copper certifications demonstrate that Wagner Brake is leading the way in addressing the latest environmental regulations. In addition,

our engineers have redefined the science of ceramic friction technology by developing eco-friendly formulations that provide across-the-board improvements in overall braking performance,” said Martin Hendricks, vice president and general manager, braking, Federal-Mogul. Reduction of copper content in vehicle friction materials is required with the recent passage of environmental legislation in California and Washington. This legislation mandates that the use of copper in new OE and replacement brake pads be reduced to less than 5% (“Low-Copper”) of material content by weight by Jan. 1, 2021. To learn more about the proprietary OE21 lowcopper friction formulations and Wagner ThermoQuiet Ceramic brake pads, visit www.WagnerBrake.com.

Fall Promotion Rewards Consumers For Walker Direct-Fit Catalytic Converter Purchases Consumers can receive a $40 Visa prepaid card for a Walker direct-fit catalytic converter purchased between Sept. 1 and Oct. 31, 2013, through Tenneco’s Walker “Ultra Rewards!” promotion. Available at participating automotive service locations nationwide, the Walker “Ultra Rewards!” incentive offers a $40 Visa prepaid card to consumers who purchase a qualifying Walker direct-fit catalytic converter or Walker CalCat direct-fit catalytic converter.

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“Through the ‘Ultra Rewards!’ promotion, consumers can get a significant savings on Walker direct-fit converters,” said Sheryl Bomia, North American programs manager, Tenneco. Engineered to meet CARB requirements, Walker CalCat converters are available for sale in all 50 states and Canada. For specific qualifying Walker products, go to www.WalkerExhaust.com. All submission forms must be postmarked by Dec. 2, 2013, to qualify.

NewsUpdate] Automotive Parts Associates Holds Inaugural Manufacturer Advisory Council Meeting Automotive Parts Associates (APA) wanted to see what could happen when they invited three key manufacturers to meet with some forward-thinking WDs for a couple of days of constructive discussions. While they didn’t solve all of the aftermarket industry’s problems in eight hours, they were successful in sending the manufacturers away as better suppliers, the shareholders away as better customers and APA as a better resource to both sides. As Mike Maloof, owner, World Auto Parts, put it, “It’s better to build a partnership rather than have just a good relationship.” This first-annual From left, front row: Ben Yelowitz, Dan Freeman, Roy Kent, Dale Devlin, Mike Fiorito. From left, back row: Gary Martin, Manufacturer Advisory Jeff VandeSande, Bill Cook, John Beale, Mike Maloof, Robert Council event was Duxler and T.J. Faley. hosted Sept. 10-11, 2014, at APA’s headquarters in Lenexa, KS. Manufacturers in attendance were Roy Kent, VP of Sales, Wholesale Channel for Federal-Mogul; Mike Fiorito, VP at KYB; and John Beale, VP, Traditional Aftermarket with UCI-Fram Group. APA’s Shareholders in attendance were Robert Duxler with A.I.M.S. in Simi Valley, CA; Dale Devlin and Jeff VandeSande representing BestBuy Distributors out of Canada; T.J. Faley for IWI Motor Parts, headquartered in Dubuque, IA; Ben Yelowitz representing Crest Auto Stores and POJA Warehouse in Philadelphia; and Mike Maloof of World Auto Parts in Cleveland, OH. The conversation was lively at times, but always circled back to a positive exchange of ideas. Boiled down, both sides are faced with similar issues including the shifting business on the Internet, swings in the global market and the constant need to stay ahead and on top. “While computers and phones are wonderful tools in business, nothing beats the spark of coming together in person to understand each other and explore new ideas,” said Gary Martin, executive vice president of APA. For more information about APA membership, contact Gary Martin or Bill Cook at 913-310-9250, or visit at www.professionalschoice.com.

Import-Car.com

[ NewsUpdate AIA To Hold 25th Annual Import Product & Marketing Awards Program The Auto International Association (AIA), a segment of AAIA, will present its 25th annual AIA Import Product and Marketing Awards Tuesday, Nov. 5 at 3 p.m. during AAPEX at the Sands Expo Center. The awards recognize manufacturers and marketers for excellence in products, packaging, websites, catalogs and marketing/advertising programs for import cars or trucks. Registrants listed by categories at press time include: Best Overall Import Aftermarket Product: DENSO Products and Services Americas, Inc.; Eurostar Industries Inc./Hamburg-Technic USA; Global Parts Distributors; GMB North America, Inc.; KYB Americas Corp.; MAHLE Clevite, Inc.; Nitoma, Inc. Best New Product for Import Cars or Trucks: AISIN World Corp. of America; Atlantic Automotive Enterprises, LLC; Dayco Products, LLC; DENSO Products and Services Americas, Inc.; Direct Market Access, Inc.; MAHLE Clevite, Inc.; ZF Services, LLC. Best Merchandising/Advertising of a Product for Import

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Cars or Trucks: CTEK Power, Inc.; DENSO Products and Services Americas, Inc.; Direct Market Access, Inc.; KYB Americas Corp.; Philips Automotive Lighting; ZF Services, LLC. Best New Packaging of a Product for Import Cars or Trucks: Beck/Arnley; Direct Market Access, Inc.; Philips Automotive Lighting; ZF Services, LLC. Best New Catalog of a Product Line for Import Cars or Trucks: AISIN World Corp. of America; DENSO Products and Services Americas, Inc.; KYB Americas Corp.; Permatex; Walker Products, Inc.; Wells Vehicle Electronics; ZF Services, LLC. Best Website Presentation of a Product Line for Import Cars or Trucks: AISIN World Corp. of America; DENSO Products and Services Americas, Inc.; ZF Services, LLC. Visit the AIA Import Product Awards display area at AAPEX, Level 1 Sands Expo Center, located adjacent to the AIA Booth/Lounge #9700.

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[ NewsUpdate New Federal-Mogul ‘SmartChoice Mobile’ App For Shops Speeds Repair Process Through Real-Time Connection To Parts And Customers Federal-Mogul has introduced a powerful, free mobile app designed to help automotive service providers dramatically increase operational efficiency, sales and customer satisfaction. The innovative, new “SmartChoice Mobile” app enables shop owners, service writers and professional technicians to use their iPhone or Android devices to instantly access the latest parts information for virtually any passenger car or light truck, and communicate detailed inspection findings, including photos of worn or broken parts and a repair estimate, directly to the vehicle owner. “SmartChoice Mobile is much more than a parts lookup tool — it helps speed the entire repair process by providing extensive parts and repair information and establishing a real-time connec-

tion with the vehicle owner,” said Brian Tarnacki, director, global market strategy, Federal-Mogul. The app includes VIN scanning technology that allows the user to instantly capture critical vehicle information and access all corresponding part and repair information via Federal-Mogul’s www.FMeCat.com applications database. The app also provides comprehensive lookup options such as specific part number/interchange search or traditional year, make and model. The service professional can use the app’s “Send Inspection Results” feature to compose and send a shop-branded email, featuring inspection results, repair estimate and images of worn parts, to the vehicle owner, and also includes instant-reply and

callback buttons to encourage the vehicle owner to ask questions and/or authorize the repair. To learn more and to download this free business-building tool, search for “SmartChoice Mobile” in the Apple App Store or Android Market or visit

CARDONE Announces ‘Enjoy Lunch On Us’ Promotion CARDONE Industries announces its “Enjoy Lunch on Us” promotion. Now through Dec. 31, 2013, service dealers and consumers can earn a $10 gift card to their choice of several popular restaurant chains with the purchase of one eligible A1 CARDONE Remanufactured Electronic Component. Up to five purchases per shop or household are permitted for a total of

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$50 in gift cards. Eligible parts include: Mass Air Flow Sensors, Transfer Case Control Modules, Electronic Throttle Bodies, Fuel Injector Control Modules and Electronic Automatic Transmission Control (EATX) Modules. Visit www.cardone.com/lunch for details and participating distributors. IC

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[ Gonzo’sToolbox

By Scott “Gonzo” Weaver, owner Superior Auto Electric, Tulsa, OK

Sometimes You Get More Than What You Pay For... But That’s Not Always A Plus

ne day, one of my customers called and said he just purchased a car from the police auction, but it had some sort of strange noise coming from the driver’s-side electric seat. It seems that every time he moved it, there was a strange electrical sound. He thought there was something wrong with the seat motor. He asked me, an auto electric technician, if I would take a look at it. “Sure,” I said. “What kind of car is it?” “It’s a Peugeot,” he answered. I’m not into Peugeots, but I told him I could take a quick look to see if I could help diagnose the problem. Within a few days, the car arrived at the shop, and after pulling it into a bay I tried the driver’s seat. Sure enough, as you moved the seat forward an inch or two, a horrible, loud buzzing sound emanated from under the seat. Rolling the seat backward would stop the noise. In disbelief, I rolled the seat forward to the spot that made the noise, but it seemed to be pretty consistent — same place, same noise. The second time I moved the seat to the spot that made the noise, I got out of the car and looked underneath. The noise immediately stopped…there was nothing, not a whisper of any strange noise or buzzing. The car had an all-black interior — black seats, black carpet and even the seat rails and brackets were solid black. It looked fine to me, but since I’m not accustomed to poking my head under Peugeot seats every day, I thought to myself that

I must have been missing something. I rolled the seat forward and backward several times to produce the noise, but to no avail. What in the world was going on? I called over my helper and asked him, “Listen to this and see what you think.” The noise was gone. I explained to my assistant what had happened and he was also at a loss. I climbed back in the car and, sure enough, as long as I was sitting in the seat, it would make the noise. But, when I got back out of the car and tried it again, there was nothing. This is ridiculous. I heard the sound myself but thought, “I’m not going crazy, am I?” I got out again, and this time I had my helper get in the car and move the seat. He moved the seat forward and, within a few inches, it starting making the noise. I told him to lift his butt out of the seat…and the noise stopped immediately. He tried several times, and then I tried a couple of times. Actually, we were having fun with it. One of us would sit in the seat and make a fake pistol with our fingers as if we were shooting each other. We would raise and lower our butts in and out of the seat and pretend we were Buck Rogers.

Scott “Gonzo” Weaver, gonzostoolbox.com

October 2013 | Import-Car.com

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[ Gonzo’sToolbox “OK, enough fun, sit back down,” I said, “I’ll look underneath this time.” I got down to where I could look under the

seat, and at about the same time he was putting his weight back into the cushion, I spotted the problem. Oh my! I had to look

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again and again just to confirm what I was seeing. My helper asked: “What is it?” with great surprise and anticipation. As I looked underneath the seat, I could see a perfect bluishwhite lightning bolt glow about an inch or so long. It was pointed right at the bottom of the cushion, but only a fraction of an inch from the seat’s metal bracing. In a very calm voice I told him, “Now listen carefully, I want you to raise your butt out of the seat, and I’ll move the seat toward the rear. There is a police Taser pointing at your keister right now. Move very carefully, and I don’t think you’ll get shocked.” I think it shook him up a bit. But he carefully lifted his weight out of the seat. The Taser was the exact same color as the carpet and underside of the seat. It was so well camouflaged that it appeared to be a part of the seat mechanism. If it weren’t for the lightning bolt, I don’t think anyone could have spotted it. It really looked like a part of the seat brackets. After moving the seat backward, the Taser eased off of the button and came back to rest with the business end pointing harmlessly away from his “derriere.” I then reached under the seat and carefully pulled the Taser out. I called the customer and told him what I found, and, to say the least, he was shocked. So were we for that matter… well, almost. IC

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[ TechUpdate

PARKING BRAKES By Andrew Markel, Editor, Brake & Front End Magazine

Parking Brake System Checks Should Be A Part Of Routine Brake Service

he parking brake, also called the hand brake, emergency brake or ebrake, is a latching brake usually used to keep the vehicle stationary. It’s sometimes also used to prevent a vehicle from rolling when the operator needs both feet to operate the clutch and throttle pedals. Automobile hand brakes usually consist of a cable directly connected to the brake mechanism (often a hand-operated lever) on one end and to a lever or foot pedal at the driver’s position. Another variation, the electric parking brake, was first installed in 2001 and has since appeared in a number of import vehicles, including: • 2001-current Audi A4, A5, A6 and A8; • 2010 Subaru Legacy and Outback; • 2002-current BMW 7 Series and 5 Series; • Jaguar S-Type, XF and XJ; and • 2003-current Volkswagen models.

There are two variations of the system available. In the more-traditional “cable-pulling” type, an electric motor simply pulls the emergency brake cable rather than a mechanical handle in the cabin. A more complex unit uses two computer-controlled motors attached to the rear brake calipers to activate it.

It’s expected that these systems will incorporate other features in future versions. Some automakers already have a system in place where the emergency brake initiates when the car stops and then goes off as soon as the gas pedal is pressed, preventing the car from rolling downhill.

Andrew Markel

October 2013 | Import-Car.com

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[ TechUpdate

MULTI-PURPOSE MECHANISM Most electric parking brakeequipped vehicles work the same way most conventional systems work, except there is an electric motor actuating the cable or piston. Most motorists seldom use their parking brakes. But, it’s a required safety device that must work properly. The main function of the parking brake is to prevent the vehicle from rolling when it’s parked. PARK serves the same purpose in vehicles with automatic transmissions as leaving a manual transmission in gear. So, to many people, the parking brake seems redundant. Even so, it should be used, at least occasionally. When the parking brake is seldom used, one of two things can happen: it may stick and not release when it’s really needed,

PARKING BRAKES

or it may allow brake pedal travel to increase. Using the parking brake helps keep the cables freed up so corrosion can’t build up and cause them to bind. Applying the parking brake also works the self-adjusters in the rear brakes, and helps keep the linings in drum brakes properly adjusted for minimum pedal travel. On cars with four-wheel disc brakes and locking rear calipers, using the parking brake keeps the threaded self-adjusting mechanisms inside the rear caliper pistons working freely to compensate for pad wear. The parking brake also has a secondary purpose as an emergency brake. Should both hydraulic circuits fail, the driver can always yank on the parking brake to slow down the vehicle. The stopping power provided by the rear brakes is

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[ TechUpdate

PARKING BRAKES

marginal, but it’s better than nothing. The parking brake system is fairly simple. On vehicles with rear drum brakes, applying the parking brake pulls a pair of cables that are attached to arms on the secondary brake shoes. This forces both pairs of shoes outward against the drums to lock the brakes. On four-wheel disc brake applications, the disc brake pads are pushed against the rotor by the caliper pistons. This requires either a cam or screw mechanism inside the caliper piston that pushes the piston out and holds it there, or a mini-drum brake inside the rear rotor. On rear disc brake applications with locking calipers, the adjustment of the parking brake cable is

especially important. If the cable is adjusted too tightly, there may not be sufficient travel to work the self-adjusters and/or the brakes may drag. If the cable is adjusted too loosely, the parking brake may not hold the vehicle. As a rule, most hand levers should travel only about four or five “clicks” when properly adjusted.

SERVICE CONSIDERATIONS On rear disc brake applications with mini-drums in the rotors, the parking brake works like a conventional duo-servo drum parking brake. Pulling the cable forces the shoes outward against the drum to

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Article continues on page 38

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[ TechUpdate

PARKING BRAKES

Nissan Front Brake Caliper Fluid Residue Applied Vehicles: 2005-’07 Maxima (A34), 2005-’06 Altima (L31) and 2007 Altima (L32 and H32 Hybrid Electric Vehicles-HEV) If you confirm there is oil residue on the brake caliper (see Fig. 1) and it’s not assembly lubricant, refer to the Service Procedure as part of your normal brake diagnostic procedure. Note: Castor oil assembly lubricant is applied to the brake caliper when it’s built and some residue is normal. Do not replace the caliper for castor oil residue. Service Procedure: 1. Remove the lower pin bolt from the brake caliper, then pivot the brake caliper to the up position. See Fig. 2. 2. Remove the brake pads and hardware from the torque member. 3. Clean the brake caliper with Nissan Brake Cleaner. Make sure the brake caliper is fully dry before going to step 4. 4. Reinstall the brake pads and hardware in the torque member and pivot the brake caliper into position. 5. Insert the lower pin bolt to the brake caliper: Torque 22-31 Nm (17-22 in.-lb.) 6. Set the parking brake and place

Fig. 2

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October 2013 | Import-Car.com

Fig. 1 the gear selector in “P” or “N.” 7. Start the vehicle and leave it on during the next few steps. 8. Depress the brake pedal slightly (1/8 brake) for 10 seconds. 9. Depress the brake pedal as long as the pedal stroke for 60 seconds. 10. Repeat steps 8 and 9 three times. 11. Depress the brake pedal as long as the pedal stroke for 60 seconds. 12. Repeat step 11 three times. 13. Turn off the vehicle. 14. Visually check for oil residue on the caliper. • If the caliper is wet, replace it using normal warranty procedures. • If the caliper is dry, do not replace it. Courtesy of MotoLOGIC® Repair & Diagnostics: www.motoshop.com/motologic.

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[ TechUpdate

PARKING BRAKES

Continued from page 34

lock the wheel. But unlike a full-sized drum brake, there’s no self-adjuster mechanism for the star wheel to compensate for shoe wear. The only time the parking brake is applied is when the vehicle is at rest, so the shoes should last the life of the vehicle, unless the parking brake is not releasing and causing the shoes to drag. The thickness of the shoe linings doesn’t really matter, as long as there is enough lining left to hold the car on an incline with normal cable travel. On most vehicles, the left and right parking brake cables come together and are attached to a lever linkage called an “equalizer” yoke under the vehicle. The equalizer yoke balances, or equalizes, the amount of force that’s applied to both cables when the parking brake is applied. The equalizer linkage, in turn, is connected to a single cable that runs to the parking brake lever or pedal. An adjustment screw may be located on the front cable where it connects to the equalizer, or where the cable attaches to the parking brake lever. On conventional systems and electric systems, the

October 2013 | Import-Car.com

equalizer linkage can also rust up, interfering with proper application and release. Also, inspect the hinge pivot because it can break loose, rendering the parking brake useless. When doing a brake job, therefore, always check the operation of both parking brake cables and the equalizer linkage. Apply the parking brake to see if the linkage is working properly and that the brakes will hold the vehicle. Then, check that the brakes fully release. If there are any binding issues and/or corrosion, clean and lubricate the cables (if possible) or replace them. In addition, lubricate the pivot point on the equalizer linkage. On electric systems, the actuator will adjust for cable stretch over time. But, it can only compensate so far. A scan tool is required to service electric parking brake systems. Don’t try jumping 12 volts to the various connector pins to extend or retract the piston or cables. Chances are you’ll set a malfunction code and turn on the brake light when the EBCM exercises the unit for the first time. Worst-case scenario: you could damage the unit. IC

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[ TechFeature

DIAGNOSTIC CODES By Scott “Gonzo” Weaver, Contributing Writer

like to take full advantage of the codes offered by the vehicle manufacturers. One of the ways to do that is to understand what all those letters and numbers in a diagnostic trouble code represent. Each of the five digits actually has a purpose and can make the job of diagnosing a vehicle’s problem much easier if you understand the breakdown of the code’s letters and numbers. I don’t want to even begin to try and remember each individual code, there are just too many of them, but rather what section of the car to which the code is referring. Let’s say you’re on the phone with a prospective customer and they mention a code number. While you’re talking to the customer, they are usually looking for some confidence in what you’re telling them. So, knowing how to break down the code and explain it to them could make the difference in whether or not they’ll call the next shop on their list.

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Keep in mind that codes are designed to help identify a particular problem with an area of the vehicle. They are a “guide” not a cure. Codes should be used in conjunction with proper diagnostic procedures, scanner readings and technical information. All circuits and components should be thoroughly tested before the replacement of any component.

BREAKING DOWN THE CODE The first character of the five-digit code is a letter that defines the section or system in the vehicle to which the rest of the code refers. The letter codes are: P, B, C and U. (There are a few older models with an “E” code, too. Treat those like a “P” code.) The letter “P” represents the powertrain (engine and transmission).

DIAGNOSTIC CODES

TechFeature]

The letter “B” represents the body systems. This is a rather large list of systems, including HVAC, interior lighting, exterior lighting, air bag and seat belt systems, wipers, dash and instrument panel, and electric seats. There are more added all the time. The letter “C” represents the chassis systems. This generally consists of the anti-lock brake system and its numerous speed sensors. You can find steeringrelated codes and emergency brake codes here as well. The “U” represents network codes. These are the codes related to the internal communication between different modules in the vehicle. These codes will also lead you to the other major sections of the car by way of the bus line information. You may also find some codes that will overlap into other areas such as the “P” codes and “C” codes. The next digit of the code is for OBD II or direct manufacturer codes. You’ll most likely see “P0XXX” or “P1XXX.” However, there are some rarely seen codes with a 2 or a 3 after the letter codes. The third position is for the sub-system based on the first letter of the code, for example: 1: Fuel and Air Metering; 2: Fuel and Air Metering (injecThe “P” indicates it’s a powertrain code. The first “1” indicates it’s manufacturer specific. The second “1” indicates it’s related to fuel or air metering. tor circuit malfunction only); 3: Ignition System or Misfire; 4: Auxiliary Emission Control System; 5: Vehicle Speed Control and Idle Control System; Import-Car.com

[ TechFeature

DIAGNOSTIC CODES

The advantage of a full-feature scan tool is the ability to decode the DTC and give possible causes.

TYPES OF CODES 6: Computer Output Circuits (theft codes;) 7: Transmission; and 8: Transmission. Manufacturers are not required to follow the generic numbering system above but most will follow the same code identifications. The last two numbers refer to the actual component or area the first three digits represent. Example: P0301, the “P” represents the “powertrain,” the “0” represents that it’s a generic code (OBD II), the “3” represents that it’s an ignition misfire, and the last two digits indicate on which cylinder the misfire has been detected. In this example, the “01” would represent cylinder #1.

When we refer to codes, there are two types that are of interest: current codes and history codes. Current codes are codes that the internal monitoring system of the computer has deemed necessary for attention. History codes are codes that have had a fault that either has been repaired or is no longer considered “important” to the overall vehicle condition by the computer. But, the computer program still feels it’s necessary to leave a trace for the technician to follow for any needed evaluations. History codes are extremely helpful in diagnosing intermittent failures. These history codes become a “bread crumb trail” back

Deciphering DTCs has become a regular part of a technician’s daily job. Knowing how to interrupt and break down the internal structure of the code will help in determining how to make the proper repairs. Go to www.ICRapidResponse.com

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[ TechFeature

DIAGNOSTIC CODES

scanner does run across a code that it doesn’t understand, a message will be displayed across the screen: “Manufacturer Only Code” or “Unreadable Code.” What it’s actually telling you is, it’s a “1” code (second digit of the code, or more to the point, a manufacturer-specific code). You’ll have to step up to a better scanner to read that particular code. Several manufacturers have added additional information to the five-digit “C” or chassis codes are some of the most difficult to decode. Often, the codes are more dependent on the manufacturer of the ABS system rather than the OEM. codes that are “Symptom Categories.” The DTC symptom is made up of an additional two-digit code that is placed after the to the source of a problem. I would advise against five-digit code (usually a space between the two clearing history codes, unless you have written them codes). The first digit following the DTC indicates down and thoroughly checked them out. the symptom category, while the second digit refers to the subsystem or more in-depth information CODE READING WITH A SCANNER about the symptom. There are 16 possible symptom categories availAs far as reading a code, as long as we are talking able for 0 to 9 and A to F. Currently, there are only about generic codes, any OBD II-compliant scanner will more than likely be able to read those codes. If a eight categories in use, 0 through 7. Article continues on page 47

Audis Experience Delayed Engagement With DTCs P2700, P2701, P2702, P2703 or P0730 Models affected:

09L 321 371 A . . . .Gasket for oil pan

Model Year Vehicle-Specific Equipment A4 Cabriolet . .2008-’09 . . .09L gearbox A5, S5 . . . . . . .2008-’10 . . . .0B6 gearbox A6 . . . . . . . . . .2008-’10 . . . .09L gearbox A8 . . . . . . . . . .2008-’10 . . . .09L or 09E gearbox A4 . . . . . . . . . .2010 . . . . . . .0B6 gearbox Q5 . . . . . . . . . .2010 . . . . . . .0B6 gearbox

09E Gearbox 09E 325 429 . . . . .Oil Strainer 09E 321 371 . . . . .Gasket for oil pan

Required Parts and Tools Part Number . . . .Part Description 0B6 Gearbox 0B6 325 429 . . . . . .Oil Strainer 0B6 398 747 . . . . .1 set hexagon socket flat head . . . . . . . . . . . . . . .bolts 09E 321 371 A . . . .Gasket for oil pan 09L Gearbox 09L 325 429 . . . . . .Oil Strainer

Customer may report: • At startup, the vehicle experiences intermittent no-drive when the driver selects driving mode D or R; or • The vehicle can be driven only in third gear (limp home mode). Shop findings: • In rare circumstances, if the vehicle was in motion and the ATF strainer becomes loose, the transmission may go into Limp Mode and can be driven in only third gear. • In cold conditions, the gearbox shifts with a delay. In hot conditions, suction noises occur. Tech Tip continues on page 46

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[ TechFeature Continued from page 44

• The following DTCs may be stored in the transmission control unit: DTC P0730 (Transmission monitoring incorrect gear ratio) DTC P2700 (Clutch A implausible) DTC P2701 (Clutch B implausible) DTC P2702 (Clutch C implausible) DTC P2703 (Clutch D implausible) Because of a design change, the ATF strainer can come loose from the guide of the ATF pump intake duct. As a result, air can be drawn in, which causes the oil to foam, which prevents the clutches from closing completely. Service Procedure: If the complaint can be reproduced, proceed as follows: 1. Check the gearbox control unit for the above entries and create a diagnos-

DIAGNOSTIC CODES

tic protocol. If there are no faults stored, but the concern can be duplicated, proceed to step 2. If one or more of the above DTCs are stored, proceed to step 3. 2. Check the ATF level per ELSA instructions. If the fluid level seems too high and foamy due to air mixed with the ATF, proceed to step 3. 3. Drain the ATF into a clean container and remove the ATF pan. Tip: Catch the ATF in a clean container and reuse it after the repair. 4. If the filter was found in the bottom of the pan, proceed to step 6. 5. If the filter is still seated in the valve body, try to remove it with light force. • When removed, if the filter seal

remained behind in the valve body or is not fully installed on the neck of the filter, proceed to step 6. 6. Replace the ATF filter with a new filter according to the repair manual. Note: Make sure that the magnets in the oil sump are not stuck on the underside (metal side) of the loose ATF filter and are not removed with the old strainer. The magnets must be reinstalled in the pan in their correct original location to protect the transmission from metallic particle abrasion. 7. If there are complaints of gear shift quality after replacing the ATF filter, clear the adaptations in the test plan and then perform the Guided Functions Adaptation Drive (GFF). Courtesy of MotoLOGIC® Repair & Diagnostics: www.motoshop.com/motologic.

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DIAGNOSTIC CODES Continued from page 44

0: General electrical fault (standard wiring failures). 1: Additional electrical failures (overflow from the “0” code). 2: Frequency/pulse width (frequency and pulse modulated inputs and outputs of the PCM). 3: PCM internal failures (memory, software, internal electrical failures of the PCM). 4: PCM programming failures (operational software). 5: Algorithm failures, PCM failures or input comparison failures. 6: Mechanical failures (faults detected by inappropriate

TechFeature]

motion in response to a PCMcontrolled output). 7: Bus signal failures (signal integrity or bus hardware failures). 8: Reserved codes (reserved for future use). The second digit of these “symptom” codes refers to a specific problem area. For example: 01: Represents a code for “short to battery.” 02: Represents a code for “short to ground.” As you can see, the first digit represents the general area of the

code, while the second digit is more precise in directing you where to look. I’ve counted more than 80 subsystem codes currently in use. Deciphering DTCs has become a regular part of a technician’s daily job. Knowing how to interpret and break down the internal structure of the code will help in determining how to make the proper repairs. The more time we spend doing the correct diagnosis means the less time we’ll spend on the job, and the quicker we can move onto the next. IC

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[ DiagnosticSolutions

STEERING, TIRE WEAR By Gary Goms, Import Specialist Contributor

Modern tire construction has generally trended toward low aspect ratio tire casings with more flexible sidewalls and rigid treads. Although this type of construction has made tires less sensitive to negative camber angles used in many current steering geometry designs, many types of tire wear patterns continue to indicate problems in a vehicleâ&#x20AC;&#x2122;s steering geometry. To illustrate, many import manufacturers have eliminated adjustable camber and caster alignment angles from their suspensions. Consequently, itâ&#x20AC;&#x2122;s doubly important to recognize signs of tire wear caused by bent struts, spindles, steering knuckles and control arms. See Photo 1 on page 50.

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[ DiagnosticSolutions STEERING, TIRE WEAR

CAMBER ANGLES

Photo 1: Although this tire is worn slightly at the center from over-inflation, the tread is worn evenly with no feathering at the edges of the tread ribs.

To better understand how bent steering components affect tire wear, letâ&#x20AC;&#x2122;s draw an imaginary line front to rear, through the center of the vehicle chassis. Positive camber is represented by the top of the tire leaning away from the centerline, while the top of the tire leaning toward the centerline represents negative camber. Thanks to advanced tire designs, many modern vehicles improve handling by incorporating negative camber into their suspension designs. When diagnosing steering-pull complaints, remember that camber pulls toward the front tire with the most positive camber angle. Remember, too, that changes in camber angle are most affected by changes in the vehicleâ&#x20AC;&#x2122;s ride height. See Photo 2.

STEERING AXIS INCLINATION (SAI)

Photo 2: This tire illustrates classic camber angle wear because the tread is worn smoothly with no rough, feather edges.

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SAI reduces steering effort and improves steering response by allowing the tire to pivot at the centerline of the tire tread. SAI, along with caster angle, also helps center the steering wheel after

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48-60 Diagnostic Solns_Steering 10/18/13 11:08 AM Page 54

[ DiagnosticSolutions Photo 3: This tire illustrates extreme camber angle wear with some feathering on the tread blocks. Extreme camber wear as shown can be caused by a bent spindle.

STEERING, TIRE WEAR

tread, off-road tires because the camber change through a turn is often sufficient to wear the corners off the tread blocks. This condition often can’t be avoided with some types of 4WD vehicles equipped with solid front axles. Since SAI is a fixed angle built into the spindle, SAI-related tire wear complaints are generally caused by offset wheels and bent spindles. See Photo 3.

CASTER ANGLE Positive caster angle is represented when the upper pivot point or ball joint of the steering knuckle trails behind the lower pivot point or ball joint. To better clarify, always remember that any bicycle has positive caster built into its steering fork. In most cases, modern vehicles incorporate relatively large amounts of positive caster to help center the steering wheel during forward driving, and to also enhance steering geometry when driving around a corner. Unlike camber, caster angle isn’t significantly changed by vehicle ride height and, except in the most extreme cases, does not affect tire wear. cornering. SAI is best represented by drawing a line through the upper and lower pivot points (ball joints) of the steering knuckle through the approximate center of the tire tread. To improve steering response as the vehicle navigates a corner, SAI also operates in concert with caster angle to increase the inside wheel positive camber and decrease the outside wheel positive camber. When diagnosing a camber-related tire wear complaint, it’s also important to know that incorrect SAI caused by a bent spindle or strut will negatively affect camber angle during cornering. SAI is most affected by offset wheel rims because offset wheels move the tires away from their normal pivot centers. Many undesirable issues are therefore created by offset wheels, including excessive negative camber wear, increased steering effort and increased steering sensitivity to road surface irregularities. The effects of SAI are most notable on open-

TOE ANGLE Positive toe angle is represented when the front wheels point to the forward centerline of the vehicle. Positive toe is commonly used on rear-wheel-drive (RWD) vehicles to compensate for the outward deflection in the steering linkage created by the rolling resistance of the tires. In contrast, negative toe angle is used on many front-wheel-drive (FWD) vehicles to compensate for the positive toe angle created by the forward driving thrust of the front wheels. Assuming either toe angle is correct, either will “zero out” under average driving conditions. The indicator of excessive positive or negative toe angle is a feathering or scuffing that can be detected by stroking the fingertips across the edge of each tread bar or tread block. A feather edge on the inside of the tread bar indicates excess toe-in, Article continues on page 58

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[ DiagnosticSolutions

STEERING, TIRE WEAR

Tire Pressure Monitoring Systems Because tire pressure monitoring systems (TPMS) became standard equipment in 2008, itâ&#x20AC;&#x2122;s currently estimated that about 40% of our vehicle population will be equipped with TPMS by the end of the 2014 model year. The basic concept of TPMS includes replacing the conventional valve stem with a miniature battery-powered pressure sensor and radio transmitter held in place by a special anodized aluminum nut sealed by special rubber grommets. Each sensor has an OEM part number, which is required for sensor replacement. The TPMS sensor begins transmitting tire pressure to the TPMS module as soon as the wheel begins to rotate. The TPMS module itself is programmed to recognize the wheel location of each TPMS sensor and will illuminate a warning on the instrument cluster or message center if the air pressure is incorrect in one or more tires. Depending upon miles driven, the sensorâ&#x20AC;&#x2122;s integral battery is designed to last between five and 10 years. Many TPMS sensors need to be replaced due to worn batteries. Domestic, European and Asian auto manufacturers use different methods for servicing tire pressure monitoring systems on their various platforms. When the tires are rotated, the new location of each wheel must be re-learned by the TPMS module.

Many vehicles display TPMS warnings on their message centers.

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[ DiagnosticSolutions

STEERING, TIRE WEAR

Most applications can be relearned by using electronic tooling designed specifically for TPMS service. Currently, the aftermarket is supplying relatively inexpensive TPMS sensors that can be “cloned” to replace OE sensors by using special tooling to program the OEM part number to the replacement sensor. While TPMS repairs aren’t required by law, remember that it’s illegal for any service professional to intentionally disable a tire pressure monitoring system. If the TPMS is working when it enters a service bay, it must be working when it leaves. The hex nut retainer indicates that this is a TPMSequipped wheel.

while a feather edge on the outside of the tread bar indicates toe-out. Because toe angle is affected by changes in camber and caster angles, it’s always the last angle to be adjusted during the wheel alignment process. In addition, any change in camber or caster angles will immediately change the toe angle. Toe angle geometry can also be greatly affected by changes in suspension height.

ACKERMAN GEOMETRY Ackerman geometry reduces tire scuffing by allowing the inner tire to turn through a shorter radius than the outer tire. The Ackerman angle is represent-

October 2013 | Import-Car.com

ed by drawing a line from the center of the lower ball joint through the center of the outer tie rod end. In general, each of these lines should intersect near the center of the rear axle. Correct Ackerman geometry is indicated when the outer wheel turns through a 20-degree radius from centerline and the inner wheel turns through approximately a 22-degree radius from centerline. Because it’s a fixed angle, incorrect Ackerman geometry is usually caused by a bent steering arm. Incorrect Ackerman geometry generally scuffs the tires when driving through sharp corners and might cause tire squeal during sharp turns in parking lots. In any case, Ackerman geometry should always be checked as part of any routine wheel alignment.

TIRE INFLATION Incorrect tire pressure can aggravate any steering geometry-related tire wear complaint. The tire pressure monitoring systems required as standard equipment for the 2008 model year have gone a long way to reduce tire wear complaints. With that said, under-inflation still tends to wear both outer edges, while over-inflation tends to wear the center of the tire tread. See Photo 4 on page 60.

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[ DiagnosticSolutions

STEERING, TIRE WEAR

ROAD CROWN ISSUES Most highways are built higher at the center to expedite drainage of rainwater and melting snow. This angled road surface, commonly called road crown, will cause a RWD vehicle aligned with equal side-to-side camber and caster angles to drift to the outer edge of the roadway. In contrast, most FWD and all-wheel-drive (AWD) vehicles are not nearly as sensitive to differences or “splits” in side-to-side camber and caster angles because the driving thrust transmitted through the front wheels pulls the vehicle along the road crown. Nevertheless, many alignment techs often “tweak” camber and caster angles on RWD vehicles to reduce steering pull on crowned roads. Keep in mind that camber angles in RWD vehicles tend Photo 4: Since the outside tread ribs are largely intact, this tire has obviously suffered from over-inflation.

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to pull toward the most positive camber, while caster angles in RWD vehicles tend to pull toward the most negative caster angle. If the front wheels have insufficient toe angle, the driver’s-side front tire will tend to wear on the inside edge, since it’s trying to steer the vehicle toward the center of the road. Conversely, if the front wheels have excessive toe angle, the right front or passenger-side front tire will tend to wear at the outer edge because it’s trying to steer the vehicle toward the center of the road. In summary, the diagnosis of any tire wear complaint requires a thorough interview with the customer concerning the history of the vehicle and any unusual driving conditions, including how the vehicle is routinely loaded. The diagnostic process also requires a thorough knowledge of how the fixed angles, including steering axis inclination and Ackerman Effect, can affect tire wear. In most cases, unusual tire wear patterns are the result of collision damage that can’t be detected unless the steering axis inclination and turning radius or Ackerman Effect are accurately measured. IC

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[ TrainingUpdate

NEW Technical Training Opportunities

• Advanced Auto Parts Training Solutions

• SKF: Book an SKF Tech Training Truck

Basic automotive concepts to advanced technical diagnostic training. Visit eservices.advancecommercial.com or call 855-222-1632.

Nothing beats a face-to-face training session with a technical expert. SKF technical training trucks can deliver hands-on technical training right to your location. Contact your SKF representative or call 800-882-0008 for details.

• ALLDATA Training Garage Comprehensive web-based training. For more information, visit www.alldata.com/alldatatraining-garage.

• AVI Training Conference Nov. 4-5 in Las Vegas. For information, visit www.aviconference.com or contact AVI at 800718-7246.

• Dill Air Controls TPMS Educational Videos To view the videos, go to www.dillvalves.com.

• Standard Motor Products TechSmart Tech Session Training Videos Available for viewing at www.youtube.com/ TechSmartParts and www.facebook.com/ TechSmartParts by clicking on the video channel button.

• VDO REDI-Sensor TPMS Training Video Shows technicians the proper procedure for maintaining and replacing damaged VDO clampin TPMS sensor valve stems. Watch the video along with other REDI videos here: youtube.com/user/redisensor.

• Elite Shop Management Training Seminars/Webinars For more information, visit www.eliteworldwidestore.com/automotive-seminars-and-webinars.html.

• Federal-Mogul Technical Education Center To register for a Federal-Mogul TEC training workshop and to access any archived webinar, follow the “Aftermarket” and “Technical” links at www.federalmogul.com or call 888-771-6005. To register for any Federal-Mogul TEC live webinar, go to www.federalmoguletec.com.

• MAP Web-Based Training The Automotive Maintenance and Repair Association’s (AMRA) Motorist Assurance Program (MAP) has added a new MAP-qualified training program and assessment test to its online offerings. For more information, contact AMRA/MAP at amra@amra.org.

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• WORLDPAC Advanced Technical Training Program Dates The WORLDPAC technical training program provides advanced level diagnostic training for independent repair technicians. • October 19-20: BMW Chassis Dynamics III, Houston, TX • October 19-20: Modern Diagnosis and Service Techniques, Milpitas, CA • October 26-27: Mini R56, Milpitas, CA • October 26: Volvo Engine Management, Raleigh, NC • November 2: Volvo VIDA Diagnostics and Networking Systems, San Francisco, CA • November 9: VW and Audi Engine Management and Scan Data Diagnostics, Portland, OR • November 9: BMW Motorsport II, Milpitas, CA • November 9: MINI R56 Complete Vehicle, Cambridge, MA Register at www.worldpac.com under Technical Training Seminar or call your WORLDPAC associate at 800-888-9982 ext. 5470. IC

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64-73 Mazda SKYACTIV Engine 10/18/13 11:05 AM Page 64

[ MazdaFeature

SKYACTIV ENGINE By Larry Carley, Technical Editor

Mazda isn’t one of the high-volume automakers. With only 1.9% of the automotive market, they are smaller than Subaru, BMW and Mercedes-Benz (each of which has about a 2% market share). But lately, Mazda has been making big waves in the automotive world with its SKYACTIV technology. Introduced in 2011 in the Japanese market, Mazda’s ultra high-compression, direct injection gasoline engines are achieving fuel economy numbers that rival many hybrids — and at much less cost. These engines include the SKYACTIV-G 1.3L engine in the 2012 Mazda 2, the 2.0L in the 2012 Mazda 3 and 2013 CX-5, and the 2.0L and 2.5L engines in the 2014 Mazda 6 and CX-5. The secret to Mazda’s fuel economy gains with its SKYACTIV-G engines is in its approach to combustion management. Diesel engines are typically about 30% more efficient than gasoline engines partly because of their significantly higher compression ratios (16:1 or higher for diesels versus 9:1 or 10:1 for most gasoline engines). Raising the compression ratio of a gasoline engine also improves its thermal efficiency, power output and fuel economy.

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SKYACTIV ENGINE

MazdaFeature]

But as compression goes up, so do the octane requirements of the fuel to resist detonation. If the fuel lacks enough octane to handle a higher compression ratio, it will detonate, knock and cause a loss of power â&#x20AC;&#x201D; and possible engine damage, too! So how can Mazda SKYACTIV-G engines burn regular 87 octane gasoline with a static compression ratio of 13:1? Itâ&#x20AC;&#x2122;s Mazda magic! Many high-performance racing engines run compression ratios of 14:1 or higher, but not on ordinary pump gas. These engines are burning super high-octane racing gas or some type of alcohol (methanol or E85 ethanol) and have rich air/fuel mixtures. Leaded racing fuel rated at 107 pump octane can usually handle compression ratios in the 12:1 range. With 112-octane racing gas, the compression ratio can be bumped up to 14 or 15:1. However, most racing engines are carbureted or port injected and do not have direct injection or Variable Valve Timing (VVT). Consequently, they have to burn some type of high-octane racing fuel to minimize the risk of detonation. Mazda engineers knew this when they designed their new SKYACTIV-G engines. They knew that a higher compression ratio would increase fuel efficiency and economy, but that detonation would be a problem if the temperature and pressure in the combustion chamber was too high for regular gasoline or even premium pump gas. Their solution was to reduce the temperature and pressure inside the combustion chamber by carefully managing the running compression of the engine via VVT, by precisely timing and aiming the direct fuel injection pulses into the combustion chamber, and by extracting heat as quickly as possible from the engine with a long tube 4-2-1 exhaust manifold.

A LOOK INSIDE A SKYACTIV-G engine is pretty similar to any other engine. Import-Car.com

64-73 Mazda SKYACTIV Engine 10/18/13 11:05 AM Page 66

[ MazdaFeature It has an aluminum block and cylinder head, with a pair of chain-driven overhead cams. There are four pistons, 16 valves (four per cylinder) and one platinum spark plug per cylinder with a coil-on-plug ignition system. Nothing unusual here. However, the pistons are domed like a performance piston to raise compression, and have a small cup in the top similar to a diesel piston. The cup acts like a minicombustion chamber and allows the flame front to spread quickly when fuel is injected directly into this recessed cup in the top of each piston. The cup allows faster combustion and shortens the time any unburned air/fuel mixture in the rest of the cylinder is exposed to high temperatures, thus reducing the risk of detonation. These engines also use a continuously variable, dual sequential valve timing (S-VT) system to constantly vary the amount of

SKYACTIV ENGINE

valve overlap as well as the timing of the intake and exhaust valves. This effectively reduces compression during the intake stroke, as well as pumping losses that would normally occur when the throttle is nearly closed at idle and under light load. During the intake stroke, the throttle and intake valves are held open while the piston moves down the cylinder. But the intake valves donâ&#x20AC;&#x2122;t close when the piston reaches bottom dead center and reverses direction. Rather, the intake valves remain open for a brief period as the piston starts back up on its compression stroke. This forces excess air back out of the cylinder and allows the engine to behave as if it has a lower compression ratio than it actually does. It seems counterproductive, but it actually improves combustion efficiency while lowering the octane requirements to prevent detonation.

High compression without knocking

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[ MazdaFeature

SKYACTIV ENGINE

The 2.5L SKYACTIV-G engine in the 2014 Mazda 6 is no slouch. Rated at 184 horsepower, the engine can push this car from zero to 60 mph in seven seconds flat. But, top speed is electronically limited to 135 mph. To extract as much residual heat from the combustion chamber following each power stroke, the SKYACTIV-G engines are equipped with a special long

tube, four-into-two-into-one exhaust manifold. It looks like an aftermarket performance exhaust header and serves essentially the same purpose. The long tubes

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help extract the exhaust more efficiently so that no exhaust is sucked back into adjacent cylinders during their intake strokes. The long exhaust tubes also help increase engine torque and power. The 2.5L SKYACTIV-G engine in the 2014 Mazda 6 is no slouch. Rated at 184 horsepower, the engine can push this car from zero to 60 mph in seven seconds flat. But, top speed is electronically limited to 135 mph. As for fuel economy, SKYACTIV-G technology delivers significant gains with EPA ratings that are 15% better than Mazda’s previous engines of similar displacement. The 2.5L engine in the Mazda 6 is rated at 26 mpg city and 38 mpg highway with the six-speed automatic transmission. There is also a special Grand Touring edition available with a “tech package” that adds all kinds of electronic gadgets that include active grille shutters for improved high-speed aerodynamics. This version is EPA rated at 40 mpg highway.

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64-73 Mazda SKYACTIV Engine 10/18/13 11:05 AM Page 70

[ MazdaFeature

SKYACTIV ENGINE

DIESEL VERSION Mazda also has a SKYACTIV-D diesel engine that will be available in the Mazda 6 and possibly other models for 2014. Unlike other diesel engines, the 2.2L SKYACTIV-D has an unusually low static compression ratio for a diesel: only 14:1. The idea here was to reduce pumping losses by using a lower compression ratio, but still maintain high thermal efficiency by using a sequential twin turbocharger induction system setup to cram more air into the cylinders when the engine is

running. There is a smaller turbo and a larger turbo that can work together or independently. The smaller turbo helps reduce turbo lag at low rpm, while the larger turbo supplies increased boost pressure for highspeed power. The SKYACTIV-D engine is also more than 50 lbs. lighter than the previous diesel engine it replaces, and has 20% less internal friction. These improvements allow the new SKYACTIV-D engine to get 20% better fuel economy. The engine also meets all U.S. and

So how can Mazda SKYACTIV-G engines burn regular 87 octane gasoline with a static compression ratio of 13:1? Itâ&#x20AC;&#x2122;s Mazda magic!

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64-73 Mazda SKYACTIV Engine 10/18/13 11:05 AM Page 72

[ MazdaFeature

SKYACTIV ENGINE

European exhaust emission requirements without needing an expensive and cumbersome exhaust aftertreatment system. The engine runs cleaner with virtually no soot and minimal NOx emissions. Cold starts are assisted by ceramic glow plugs and variable exhaust valve timing (which helps retain heat).

SKYACTIV piston

MAINTENANCE REQUIREMENTS The maintenance requirements for Mazda’s SKYACTIV-G engines are similar to that of other late-model imports. The scheduled oil change intervals for “normal” service is every 7,500 miles. Mazda recommends using 0W-20 motor oil to

maximize fuel efficiency. Spark plugs are long-life platinum with a replacement interval of 150,000 miles. The recommended service interval for chang-

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64-73 Mazda SKYACTIV Engine 10/18/13 11:05 AM Page 73

SKYACTIV ENGINE

ing the coolant, however, is only 60,000 miles. Because the SKYACTIV-G applications are still so new, you probably won’t see any engine-related repair work until the cars are out of warranty. Like any relatively new technology, there may be some teething problems down the road, which will provide service opportunities for the aftermarket. For now, the SKYACTIV technology appears to be working quite well. Mazda has released at least one TSB for the 2.0L SKYACTIV-G engine in the 2012-’13 Mazda 3 and 2013 CX-5. Bulletin 01-003/13 covers a rough-idle condition with an illumined MIL and DTCs P0015 and P0524. The DTC code P0015 is exhaust cam timing over-retarded, and the code P0524 is for low engine oil pressure.

MazdaFeature]

The possible cause may be debris in the oil pump pressure relief valve or the oil control valve causing a drop in oil pressure. The recommended fix is to check oil pressure, and if it’s less than specifications (7 psi or more at idle, and 43 to 62 psi at 4,500 rpm), replace the oil pump and clean the oil pan. Mazda also has a TSB out warning of contaminated mass airflow sensors on some of these engines. Bulletin 01-009/12 says MAF sensor problems can be caused by debris on the sensor element. Check the condition and fit of the air filter (replace as needed), and clean or replace the MAF sensor, as needed, if the maximum static voltage reading for the MAF sensor exceeds 0.65 to 0.68 volts. IC

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[ ShopProfile Curt’s Service Inc. Taking Customer Service To The Next Level

t Curt’s Service Inc. what you see is truly what you get. Recently, a photo submitted by Curt Massoll’s 15-bay shop in Oak Park, MI, won a contest sponsored by Robert Bosch LLC. Curt’s Service is a Bosch Car Service center (BCS) — part of an exclusive network of shops whose standards meet the Bosch criteria for excellence in the services they provide. Designed exclusively for BCS participants, the contest called for a photo that would best reflect the values of the Bosch brand, including a clean, professional and up-to-date business environment. Not surprisingly, Curt’s Service proved itself to be a winner. They were taken for an exclusive behind-the-scene look at Hendrick Motorsports in Concord, NC. “Being a Bosch Car Service center has set the bar higher for us in terms of the quality of repair and service that we offer to our customers,” said shop owner, Curt Massoll. Massoll is assisted by his sons, Keith and Andy Massoll, who are co-owners. Keith helps out on the technical side, and Andy is in charge of customer service and marketing. The Massolls utilize as much of the Bosch Car Service program as possible — technician training, diagnostics and tools, the Bosch “image” program, the nationwide warranty, which enhances customer confidence, and the Bosch

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“Being a Bosch Car Service center has set the bar higher for us in terms of the quality of repair and service that we offer to our customers.” – Owner, Curt Massoll

Shop Owner Curt Massoll with son and co-owner, Andy Massoll.

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[ ShopProfile

Curt’s serviCe inC.

Service credit card that allows them to offer their customers convenient, deferred interest payment terms on repairs and maintenance.

Excellence In Customer Care

“The point is, we always strive to be honest, trustworthy, friendly and understanding of an individual customer’s needs.” For example, if a customer has moved out of state, their car needs some work and they wish to contact a shop, Curt’s Service helps them find a local service center, preferably a Bosch Car Service center. Curt checks out the service center’s website to determine its suitability to the customer’s needs, and sometimes even gets on the phone to discuss the repair. Curt’s Service keeps all service records, and can supply any information that’s needed to complete the repair efficiently and successfully at another BCS facility. So, it all boils down to catering to your customers’ needs, Curt advises.

“Overall, the program has supported us in our efforts to embrace the relationship between the customer and the repair facility,” said Andy. “The partnership with Bosch has been pivotal in helping realize my father’s belief, which is to ‘take care of the customer first.’ If we can do that, the customer will not want to go anywhere else.” So what exactly does Curt mean when he says, “the customer comes first”? “If I focus on catering to my customer’s needs, I’ll probably be taking care of all the cars he or she will How Curt’s Service Came To Be own, including those several years down the road,” Curt started out as an experimental build-up technician Curt explained. In his 30-plus years in the business, at Chrysler Engineering in Detroit. Years later, he was Curt’s customer service acumen has led him to take laid off during the recession and attempted to get a job care of several generations within a family. at one of several local repair centers, but had no luck. “Some of my current customers were in baby seats Curt started workwhen I first began Highly trained technicians handle sophisticated repairs on vehicles ing on family and working on their such as this red Corvette with advanced technology systems. friends’ vehicles parent’s car,” he out of his home says with some until it became degree of pride much more than and amusement. what a side busiA spotless shop floor ness could support. reflects the quality of In February work at Curt’s Service. 1981, he leased a Sunoco, then a Mobil gas and service station, where he worked for five years. When Mobil Oil Corp. wanted to get out of the service side of the business and convert service bays to a Mini Mart store, Curt saw it as a perfect opportunity to make a career change. It was in 1986 that Curt’s Service made the move to its current location in Oak Park, MI. It was here

October 2013 | Import-Car.com

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[ ShopProfile

Curt’s serviCe inC.

Dedication and efficiency are the driving force behind the team at Curt’s Service.

that an existing building was converted into a six-bay repair shop. A year later, Curt realized that if he wanted to grow his business, he needed a strong partner that could provide him with the tools they needed, and he joined the Bosch Car Service network.

Driving Into The Future When Curt joined the Bosch Car Service program in August 1987, he was one of the first shops to see the benefits associated with it. The technical information and training package, in particular, was very attractive. Many years later, when Bosch introduced the Bosch Service credit card, Curt’s Service saw how deferred interest financing would help customers opt to have more services done in a single visit, and would increase repair and maintenance efficiency for the shop. Knowing he had the help and support of his sons, Keith and Andy, in March 2012 Curt purchased the property next door and built an 8,000-sq.-ft. addition, to give him a total of 15 service bays including two alignment Go to www.ICRapidResponse.com

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racks. Currently, he employs seven full-time, certified technicians and a total of 15 people. The shop services all makes and models and has three divisions — European Import, Asian Import and Domestic/Fleet. “No matter what you drive or what your fleet is comprised of, we have the specialized tools and technicians that allow us to efficiently take care of your vehicle,” Andy said confidently.

What It Takes To a young entrepreneur who wants to break into the auto repair business, Curt’s advice is, “Fixing cars today is not what it was 20 years ago. Modern vehicles are rolling computers and modules that require an immense amount of training and specialized tools to perform standard repairs. To be successful you have to deliver the complete package of customer care and find a partner like Bosch that can give you the support you will need. If done well, it can be immensely gratifying.” For information on the Bosch Service network, visit www.boschcarservice.us. IC

[ TechUpdate

WATER PUMPS By Larry Carley, Technical Editor

Water Pumps Keep It Cool Inspect Related Parts During Replacement When a water pump reaches the end of its road, don’t hesitate to replace it. The water pump circulates coolant between the engine and radiator to manage the engine’s waste heat and prevent the engine from overheating. Though the pump turns continuously while the engine is running, coolant flow is actually controlled by the thermostat. A thermostat that is stuck shut will block coolant flow and cause the engine to overheat. A good thermostat also can be damaged by overheating, so if you’re replacing a water pump because the engine overheated, it’s a good idea to replace the thermostat as well. A water pump consists of a cast iron,

October 2013 | Import-Car.com

aluminum or stamped steel housing, a shaft mounted “impeller” that moves the coolant through the pump, a shaft seal (usually ceramic) and ball or roller bearings to support the shaft. Seal failure will allow coolant to leak out of the pump, while bearing failure will often make the pump noisy. Most water pumps are belt-driven off the crankshaft, but, on some engines, the pump is driven by the timing belt. On most engines, the pump pulls coolant in through the lower radiator hose and routes it into the block and heads. On “reverse flow” systems, the pump first routes the coolant into the head(s) and then to the block. Some pumps have additional inlet and

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[ TechUpdate

WATER PUMPS

outlet ports for heater hose and bypass connections. Many OEM water pumps are capable of going 100K to 150K miles or more, but may fail sooner for a variety of reasons. Cooling system neglect can shorten the life of the shaft seal. Fan imbalance on applications where a mechanical cooling fan is mounted to the front of the water pump also can shorten the life of the water pump shaft bearings and seal. Because of the many differences in OEM water pump designs, make sure the replacement pump has the same mounting configuration, bolt locations and hose connections as the original. Likewise, itâ&#x20AC;&#x2122;s important to compare pump heights, as these may also vary depending on the dimensions of the

timing cover or other belt-driven engine accessories. When a water pump is replaced, the cooling system should be drained, flushed and refilled with a fresh mixture of antifreeze and water to restore

[

Many OEM water pumps are capable of going 100K to 150K miles or more, but may fail sooner for a variety of reasons.

]

proper cooling performance and corrosion protection. Merely draining the radiator can leave up to half of the old coolant in the block. Belts and hoses should all be carefully inspected and replaced if any are found to be worn, cracked, damaged or in poor condition. Hoses that are brittle, aged, cracked, bulging or chaffed must be replaced. New hose clamps are also recommended. High-mileage belts should also be replaced, regardless of their appearance. IC

Larry Carley has more than 30 years of experience in the automotive aftermarket, including experience as an ASE-certified technician, and has won numerous awards for his articles. He has written 12 automotiverelated books and developed automotive training software, available at www.carleysoftware.com.

October 2013 | Import-Car.com

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[ ImportTechTips 2004-’05 NISSANS HAVE MIL ON WITH DTC P0300-P0306, P1273 OR P1283

Applied vehicles: 2004 Maxima (A34) 2004 Quest (V42) 2004-’05 Altima (L31) with VQ35 only Concern: An MIL “On” with one or more of the following DTCs stored: • P0300, P0301, P0302, P0303, P0304, P0305, P0306 (cylinder misfire); or • P1273, P1283 (A/F ratio lean). Action: Injector resistance may cause one or more of the above listed DTCs to be set. • Check the resistance of the injectors against the values in this bulletin. Note: Incident injectors will have resistance values: – outside of the specified range indicated in this bulletin and – will be significantly different from the non-incident injectors at the other cylinders. Important: The purpose of the Action is to give you a quick idea of the work you will be performing. You must closely follow the entire Service Procedure as it contains information that is essential to successfully completing this repair. Service Procedure: Use Chart 1 below to determine which injectors to inspect.

Fig. 1: Nissan

DTC 1273 = Bank 1 (requires checking only that bank) 1. Locate and separate the F44 engine harness connector from the F101 injector sub-harness connector. See Fig. 1. 2. Using Chart 1 and the pin location in Fig. 2 on page 86, measure the resistance of the injector(s).

DTC 1283 = Bank 2 (requires checking only that bank) Important: • Replace an injector only if its resistance is outside of the above range and the resistance is much different from the resistance of the other injectors. – A single injector DTC Cyl Connector location Connector Between usually causes this # # pins incident. If more than P0301 1 Injector sub-harness F101 5&6 one injector has resistP1273 P0303 3 Injector sub-harness F101 5&2 ance values out of P0300 P0305 5 Injector sub-harness F101 5&1 specification: - there might be a P0302 2 Injector F18 of injector general problem with P1283 P0304 4 Injector F20 of injector P0306 6 Injector F22 of injector the accuracy of the resistance measurement, or Chart 1: Resistance: 11.5 to 15.5 Ω at 50-190° F (10-88° C) [room temperature to engine warm temperature] - component (injec-

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[ ImportTechTips

Fig. 2: Nissan Fig. 3: Power Steering Fluid

tor) temperature condition may be high or low, or - the vehicle is not of the applicable range. DTC P0301-P0306 requires checking a single injector. (refer to Chart 1 and the procedures used in DTC P1273 or P1283)

DTC P0300 (requires checking all injectors) (refer to Chart 1 and the procedures used in DTC P1273 and P1283). Note: It’s possible that a single injector incident: – can affect the air/fuel sensor control for a bank of cylinders, and – this can result in a P0300 code. If the resistance of all the injectors is within 11.5 to 15.5 Ohms at 50-190° F (10-88° C), and the engine temperature is in the room temperature to engine warm temperature range, return to ASIST for further diagnosis. Courtesy of Mitchell 1.

POWER STEERING FLUID IS JUST POWER STEERING FLUID, RIGHT? NOT NECESSARILY, ESPECIALLY WHEN IT COMES TO IMPORTS…

Long gone are the days when a can of ATF was all

October 2013 | Import-Car.com

you needed to top off a power steering reservoir. For years now, savvy technicians have known to use dedicated power steering fluids for the many models, both import and domestic, that call for them. There are still many cars on the road for which ATF is appropriate. However, in recent years, some European automakers including Audi, Volvo and Mercedes-Benz, have specified a more advanced synthetic fluid for use in power steering systems. This fully synthetic blend is designed with selected esters and certain anti-wear characteristics to assure longevity of the various alloys used in the sophisticated power rack-and-pinion units in these vehicles. See Fig. 3. It maintains a very stable viscosity over a particularly wide range of operating conditions, assuring proper lubricity in the extremes of high desert temperatures, as well as remaining free flowing in extreme cold, even down to -40 to -50° F. In addition, the advanced chemistry of these new blends allows for effective lubrication and protection, even with the extended fluid change intervals as specified by these automakers. Mixing this new blend with previous petrole-

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[ ImportTechTips um-based fluids is not recommended. However, replacing the petrochemical fluid in older models with this new synthetic fluid is a viable upgrade, and is easily accomplished with a thorough flushing of the old fluid. Do note, however, that Honda-specific power steering fluid is recommended for Honda and Acura models. The new synthetic fluid is often identified as CHF11S in owners’ manuals and service manuals. It is also readily identified by its distinctive green color. So while it’s always best to refer to manufacturers’ reference data, as a general rule, you’ll be safe adding “green to green.” Note that while fluids may be described as compatible with CHF11S, some fluids are blended to exceed the standards of such fluid, sometimes by a wide margin. So, it’s best to check the specs of a given fluid, or choose

a brand you trust to meet or exceed OE recommendations. Contributed by Steve Muth, chief chemist, The Penray Companies.

ADJUSTABLE CLUTCH MASTER CYLINDERS Following a new clutch installation, there is nothing worse than experiencing slipping or release problems. Many times technicians even begin to believe that the new clutch kit is defective. This is not correct, in most cases. The majority of the time a simple, quick adjustment will alleviate any problems. Most Japanese/ Korean imports utilize an adjustable clutch master cylinder (Fig. 4). When a new clutch kit is installed, the master cylinder needs to be re-adjusted to work properly with this new kit and avoid release and

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Fig. 4

slipping problems. The steps listed below demonstrate the proper way to adjust the master cylinder and avoid potential release problems with the new clutch. Preventing No Release: 1. Verify that the hydraulic fluid is clean and that the correct fluid was used. 2. Locate the master cylinder push rod that attaches to the clutch pedal. Fig. 5

3. Using Fig. 5 as reference, extend the push rod to allow for more throw. After the rod has been extended, tighten the locking nut. Caution: Do not extend the rod out too far. Extending it too far out can block the compensating port in the master cylinder. Preventing Slipping: 1. Verify that the hydraulic fluid is clean and that the correct fluid was used. 2. Locate the master cylinder push rod that attaches to the clutch pedal.

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[ ImportTechTips Fig. 6

3. Using Fig. 6 on page 90 as reference, shorten the push rod to allow for less throw. After the rod has been shortened, tighten the locking nut. Note: In a slipping situation, the rod is too long, causing the compensating port to be blocked off, not allowing fluid to return to the fluid reservoir. Courtesy of Schaeffler Aftermarket, www.Schaeffler-Aftermarket.us

BMW INTERMITTENT NO-START PROBLEM WITH A DEAD BATTERY

Affected vehicle: 2006 BMW 550i Base 4.8L, V8, MFI, DOHC Customer Concern: Vehicle has an intermittent no-start problem and the battery has gone dead. Potential Causes: Incorrect battery or the

comfort access module. Battery Tests: 1. This vehicle uses a glass mat type battery and requires reprogramming if a conventional lead-acid battery is used as a replacement. 2. Glass mat batteries can be damaged if charging voltage goes above 14.8 volts. Quick charge strategies are not recommended as they will damage the glass mat battery. 3. Battery replacement needs to be registered in the power module regardless of battery type. After eight battery replacement procedures, the power module will require replacement as well. 4. Using a scan tool to interrogate the power module and comfort access module will often help explain battery/starting problems. Confirmed Fix: Initialized Battery: After battery replacement, the energy management system needs to be notified of a new battery. Initialize the battery to the vehicle with a BMW-compatible scan tool. Tech Tips: The comfort access module performs the functions of the ignition switch. It controls all ignition switch functions and is diagnosable with a BMWcompatible scan tool. Courtesy of Identifix’s “Five Fast Fixes” IC

October 2013 | Import-Car.com

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[ Service&Repair

Put ACDelco-Licensed Tools to Work on Your Next Repair Every job worth doing is worth using the right parts, as well as the right tools. In addition to more than 100,000 aftermarket parts, you’ll find the trusted ACDelco name on a growing portfolio of reliable, award-winning tools designed and built for technicians who don’t have time for downtime. The entire ACDelco-licensed lineup of more than 80 tools and accessories includes impact, ratchet and torque wrenches, drills/drivers, polishers, grinders, work lights and inspection cameras. From powerful pneumatic tools to innovative and lightweight Lithium-ion batterypowered cordless and digital products, there’s an ACDelco-licensed tool for every job. Recent product introductions include: • Two 18V 3-in1 combo kits provide a convenient, reliable and compatible solution for technicians’ needs. The ARZ18CSP1 18V combo kit includes the ARI2061 Li-ion ½-inch impact wrench, drill/driver (ARD2081) and foldable

LED light (ARL2025). The ARZ18CSP4 combo kit includes the ARI2060 Li-ion ½-inch super-torque impact wrench with digital clutch, ½-inch drill/driver and foldable LED light. • A Li-ion 12V impact driver (ARI1265) makes 105 ft.-lbs. (1,265 in. lbs. / 140 Nm) of torque, 5 percent to 58 percent more maximum torque than its leading competitors. It comes with two battery packs, a quick charger with Air-Forced Cooling System (AFCS) design and a carrying case.

ACDelco-licensed power tools and accessories are available from authorized distributors. For more information on the full lineup and purchasing information, please visit www.acdelco-tools.com.

92 October 2013 | Import-Car.com

Service&Repair]

Good Timing is Everything Just one CRP P/N delivers all you need to do it right When you want your labor hours to be as profitable as possible, it’s key to have everything ready and at hand. A good timing belt service calls for much more than just the belt replacement. That’s why CRP’s ContiTech Timing Belt Kits have all the wear components you’ll need for that vehicle, in one box, with ONE part number. Depending on the version of the ContiTech Timing Belt Kit you choose, you’ll be able to service timing belts, idlers, tensioners, hydraulic dampers, and a water pump without searching for multiple part numbers. Our Pro Series Plus kits even include camshaft and balance shaft seals for the most comprehensive service offered. Every ContiTech Timing Belt Kit is assembled with only OE-quality parts. In addition, ContiTech kit coverage extends to almost every make and

model car you’ll be working on. CRP has over 125 Pro Series Timing Belt Kits with coverage for over 1,600 vehicles and over 230 standard Timing Belt Kits to help you handle over 2,000 applications. CRP Automotive developed its ContiTech Timing Belt Kits program to give professional repair technicians a convenient solution that helps them eliminate the need to spend unnecessary time and effort searching and ordering multiple part numbers from different distributors, all for the same job. When dealing with critical engine system components, it pays to have good timing. ContiTech Timing Belt Kits are the only part you’ll need to complete your timing belt service right the first time, every time. Get more information at www.contibelts.com or for detailed parts information go to www.showmetheparts.com/crp.

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[ Essentials

Brought to you by

All-New ANCO Profile Wipers — The all-new line of ANCO Profile beam blades combines best-in-class performance with an exclusive low-profile connector system that covers more than 98% of vehicles with just 12 SKUs. Each Profile blade also features the ANCO brand’s patented Articulated Contact Technology, which permits unrestricted flexing for more uniform pressure distribution and improved conformance to curved windshields. Visit www.ANCOWipers.com. Reader Service: Go to www.icRAPIDRESPONSE.com

Tenneco continues to expand its Walker emissions control line, with nearly 270 new catalytic converter, muffler and exhaust assembly part numbers now available for popular domestic and import models. The new parts include Walker Ultra EPA-compliant converters, Walker CalCat CARB-compliant converters and premium QuietFlow SS stainless steel mufflers and assemblies. Among the new parts are several Walker Ultra manifold converters, designed to be installed directly onto the engine cylinder head. Reader Service: Go to www.icRAPIDRESPONSE.com

Gain Customers and a Great Reputation with OEM Branded Products from NAPA — NAPA Import Auto Parts supplies globally sourced parts for import cars from the most respected original equipment manufacturers and aftermarket suppliers in the industry. With more than 6,000 NAPA Auto Parts stores, we provide availability in virtually every market nationwide. Original equipment supplier products in the original brand packaging have never been this accessible until now! Reader Service: Go to www.icRAPIDRESPONSE.com

Bosch’s EuroLine Disc Brake Pads were developed as an OE replica line, to match the look, feel and performance of the OE brake pads on European vehicles. Rigorously tested, validated and certified to meet or exceed European ECE R90 standards for performance and durability, EuroLine brake pads feature a consistently high coefficient of friction in severe braking conditions and high shear strength that stands up to heat without separating. Reader Service: Go to www.icRAPIDRESPONSE.com

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Autolite XP Xtreme Performance Iridium enhanced spark plugs are one of Autolite’s most technologically advanced spark plugs ever. With an iridium-enhanced 0.6 mm finewire design and proprietary V-trimmed platinum sidewire technology, these spark plugs provide better durability* and a more focused ignition for better overall ignitability** and optimal performance. *Compared to 0.8 mm finewire, multielectrode design and standard plugs. **Compared to average of other premium brands.

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Essentials]

Brought to you by

<< When performance matters,

The Gates Corporation recently announced the addition of 394 new parts to its catalog of quality automotive products. The new parts include turbocharger hose for VW and Audi applications, branched radiator hose, timing component kits with water pump, and small I.D. and molded hose. Gates is expanding the largest range of OE exact branch radiator hose coverage with 23 new branched assemblies. Visit www.gates.com/automotive. Reader Service: Go to www.icRAPIDRESPONSE.com

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StopTech, the high performance and racing brand from Centric Parts, has introduced front axle StopTech Big Brake Kits for the all-new 2013 Acura ILX and 2012-â&#x20AC;&#x2122;13 Honda Civic Si sedan and coupe. These big brake kits offer stiffer calipers, larger rotors, higher friction pads, stainless steel braided lines and all of the necessary mounting hardware and brackets to complete the job. Reader Service: Go to www.icRAPIDRESPONSE.com Standard Motor Products, Inc. (SMP) has added 388 new part numbers to its Standard brand and Intermotor line of genuine import parts. This expansion features more than 150 new switches including multi-function, combination, cruise control, hazard warning, power seat memory, torque converter lock-up and more. SMP has also added cloneable TPMS sensors, airbag clocksprings, camshaft and crankshaft sensors, ABS speed sensors, exhaust gas temperature sensors and more. Reader Service: Go to www.icRAPIDRESPONSE.com

The Innova PRO 31603 expert diagnostic tool allows technicians to quickly retrieve vital information in order to diagnose OBD II, ABS and SRS issues. Extended Asian and European ABS and SRS coverage is available so technicians can complete more repairs more efficiently. Shop management software reports manage vehicle diagnostics. Visit www.pro.innova.com. Reader Service: Go to www.icRAPIDRESPONSE.com

count on ACDelco Rapidfire Spark Plugs â&#x20AC;&#x201D; ACDelco Rapidfire Platinum Performance Spark Plugs are designed for import owners who want to get more out of their vehicle. They feature reduced sparking voltage, greater corrosion protection, longer life and improved efficiency over conventional plugs. They also feature a three-year limited warranty and broad coverage. Learn more at www.acdelco.com.

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It’s Fast, Easy and Accurate! Get FREE PRODUCT AND SERVICE INFO from the companies featured in this issue of ImportCar. >> VISIT www.icRapidResponse.com and click on the company from which you want information. >> OR, go to www.Import-Car.com and click on the ImportCar Rapid Response Logo.

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104 NASCAR_Oct.13 IC_Layout 1 10/18/13 11:02 AM Page 104

Track Talk Where There’s a Weld, There’s a Way NASCAR racecars require hundreds of welds — and every single one of them has to be perfect. At 200 miles per hour and around every corner, racecars are pushed to their very limits. They have to be strong for safety, but light for performance. The cars built at Stewart Haas Racing are no exception. Back at the shop, master fabricators like Daniel Smith spend hours making sure every weld is just right. For Smith, simply put, it’s his passion. “I’ve always wanted to weld,” said Smith, a native of Concord, NC, born and raised in the heart of motorsports country. After graduating from NASCAR Technical Institute and 5 Off 5 On Pit Crew U in 2004, 19-year old Smith landed a full-time position at what was then Haas CNC Racing. Being a typical adventurous teen, Smith quickly earned the nickname “Danger” among his

peers at the shop, but that didn’t stop him from putting in long hours of hard work and sacrifice to perfect his craft. “In the beginning, I spent a lot of time in the shop,” Smith reminisced. “I would stay after work on my own time to pick up pointers from other welders. I was welding anything and everything I could get my hands on in the shop.” Smith began his racing career in the teardown department, but soon earned a promotion to the fab shop. Today, the 29-year-old veteran juggles both pit crew and shop duties. “On Sundays, I go over-the-wall as the rear tire changer on the No. 14,” explained Smith. “On Monday mornings at 7 a.m. sharp, I’m back at the shop, welding and building suspension pieces, upper control arms, oil tanks, spindles and exhaust pipes.” Smith’s day job is critical. About 95% of NASCAR racecars are TIG-welded by hand. Long before the racecar hits the track, welding and fabrication consume roughly 950 man hours on each racecar back at the shop. Lincoln Electric, which has provided Stewart Haas Racing with welding machines, consumables and apparel since 2008, says welding plays an important role in NASCAR keeping drivers safe first and foremost. “Critical components such as the roll cage, seat and chassis need to withstand forceful impacts at speeds of 200+ mph,” said Mickey Holmes, sports marketing manager for Lincoln Electric. “Quality welds help achieve this.” Most welds join intersecting tubes that make up the frame and roll cage. These components are fabricated from mild steel, which allows the racecar to

absorb the forces of a crash in a bendbefore-break mode. When drivers walk away from highspeed crashes unhurt, it can be attributed to overall safety improvements in the chassis design — and weld quality. Smith works with a variety of Lincoln equipment at the shop, including Invertec V311-T AC/DC, Precision TIG375, Invertec V205-T AC/DC, Power MIG 350MP, Power MIG 256 and Power MIG 180Cs. The team’s transports (or crash carts as they’re commonly called) are equipped with Power MIG 180Cs and Invertec V205s. “The welding technology is really amazing,” said Smith. “They’re solid machines. You can kind of get spoiled working with all the nice equipment at the shop.” Smith understands if a part breaks on the track, it cannot break at the weld. “My standards are a little higher from working in NASCAR — the welds have to look nice and be clean and sound,” continued Smith. “The steering shaft has to hold up at every turn. Holding all of the suspension components together is very vital in racing.” He knows the importance of a sound weld, and that a driver’s life is on the line. By Kimberly Hyde, NASCAR

Double-duty: Daniel Smith is a welder/fabricator at Stewart Haas Racing and rear tire changer on the No. 14 Mobil 1/Bass Pro Shops Chevrolet. Do you have a passion for welding, too? Start your project today with help from Lincoln Electric at lincolnelectric.com/moneymatters. Follow NASCAR Performance on Twitter and Facebook www.twitter.com/NASCARauto www.facebook.com/NASCARPerformance

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