Underhood Service by Babcox Media

■ Gonzo's Toolbox: Walking in My Shoes ■ A/C Update: Charging Too Much? ■ Don't Blow By PCV Service A

MAGAZINE

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ENGINE SERIES: FORD 4.0L SOHC SERVICE

CONTENTS 44

Service Solutions

A/C Update

Don’t Blow by PCV Inspections

Are Your Techs Overcharging?

Discover why on vehicles with more than 30,000 miles, technicians should begin making PCV valve checks a regular part of that vehicle’s maintenance inspection program.

While A/C performance problems due to too much refrigerant in the system have become an issue in recent years, its origins began many years ago by the practices of techs servicing largecapacity systems.

Editor Edward Sunkin, ext. 258 email: esunkin@babcox.com

Graphic Designer Dan Brennan, ext. 283 email: dbrennan@babcox.com

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

Publisher Jim Merle, ext. 280 email: jmerle@babcox.com

Technical Editor Larry Carley

Ad Services Director Cindy Ott, ext. 209 email: cott@babcox.com

Contributing Writers Gary Goms, Scott “Gonzo” Weaver, Bob Dowie and Randy Rundle

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

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DEPARTMENTS

Columns

6 Perspectives 8 Guest Editorial 14 Directions 16 Gonzo’s Toolbox 20 Talking Shop 50 Tech Tips 58 Shop 59 Rapid Response 60 Classifieds 64 Test Drive

Publication

advErtisiNG rEPrEsENtativEs

HOME OFFICE 3550 Embassy Parkway Akron, Ohio 44333-8318 330-670-1234 FAX 330-670-0874 www.babcox.com PRESIDENT Bill Babcox bbabcox@babcox.com 330-670-1234, ext. 217

VICE PRESIDENT Jeff Stankard jstankard@babcox.com 330-670-1234, ext. 282 Sales Representatives: Bobbie Adams badams@babcox.com 330-670-1234, ext. 238

Sean Donohue sdonohue@babcox.com 330-670-1234, ext. 206 Dean Martin dmartin@babcox.com 330-670-1234, ext. 225

John Zick jzick@babcox.com 949-756-8835

Editorial advisory Board Brent Crago, owner Top Tech Automotive Cleveland, Tennessee

Marvin Greenlee, owner Meade & Greenlee Inc. Salem, Oregon

Albert Duebber, owner Duebber’s Auto Service Cincinnati, Ohio

Anthony Hurst, owner Auto Diagnostics Ephrata, Pennsylvania

Audra Fordin, owner Great Bear Auto Repair Flushing, NY www.womenautoknow.com

Roger Kwapich, owner Smitty’s Automotive Toledo, Ohio

Rick O’Brien, technician Coachworks Portland, Maine Tom Palermo, general manager Preferred Automotive Specialists Jenkintown, Pennsylvania

Glenn Warner gwarner@babcox.com 330-670-1234, ext. 212

Paul Stock, owner Stock’s Underhood Specialists Belleville, Illinois Michael Warner, owner Suburban Wrench Pennington, New Jersey

Van Pedigo, owner Richfield Automotive Center Richfield, Ohio

List Sales Manager Don Hemming dhemming@babcox.com 330-670-1234, ext. 286 Classified Sales Tom Staab tstaab@babcox.com 330-670-1234, ext. 224

Underhood Service is a member of and supports the following organizations:

UNDERHOOD SERVICE (ISSN 1079-6177) (March 2013, Volume XVIII, Number 3): Published monthly by Babcox, 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: Please send address changes to UNDERHOOD SERVICE, 3550 Embassy Parkway Akron, OH 44333. UNDERHOOD SERVICE 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 UNDERHOOD SERVICE, P.O. Box 75692, Cleveland, OH 44101-4755. VISA, MasterCard or American Express accepted.

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» Publisher’s Perspective

By Jim Merle | PUBLISHER

EXPERIENCE THE MAGIC of AVI PLAY And Watch Me Come Alive!

rint is alive and well! However, advancements in technology with smart phones and tablets continue to amaze most of us and, with you in mind, we have taken advantage of these opportunities, hence the launch of our App; AVI PLAY! I could spend the next few paragraphs describing the value of AVI PLAY that will now unlock bonus content from select pages of each issue, but instead, I’m asking you to experience the magical technology of Augmented Reality by following these two easy steps:

1. From your Apple or Android smart

2. Open the AVI PLAY App once it’s

phone or tablet, visit www.AVIplayApp.com to download AVI PLAY.

downloaded and hold your device over this page to unlock a message from me, including some fascinating graphics that will appear on your device’s screen.

Look for the AVI PLAY App logo and callouts identifying technical features and advertisements powered by AVI PLAY beginning with this issue, and every issue of Underhood Service moving forward. It’s all about expanding the amount of relevant information for you with each issue of Underhood Service. Share your thoughts by contacting me at 330-670-1234 ext. 280, or by e-mail at jmerle@babcox.com. Onward! Jim

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» Guest Editorial By Rich White Executive Director, Car Care Council

April Is National Car Care Month What’s In It For You?

here is no better time than National Car Care Month in April to reach out to consumers to take better care of their vehicles. We caught up with Rich White, executive director, Car Care Council, to ask him about the advantages of getting involved with National Car Care Month to build loyalty with current customers and attract new ones.

Underhood Service: Please give us a brief overview of National Car Care Month and how the Car Care Council promotes the program. Rich White: National Car Care Month in April is the ideal time for the Car Care Council and the industry to work together to focus the attention of motorists on the benefits of routine and proper vehicle care, maintenance and repair, following winter and before the summer driving season. It’s also a chance to remind everyone that our industry keeps Americans

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on the road and makes a significant contribution to the economy, safety, performance, energy use, the environment and society overall. Central to celebrating National Car Care Month are community car care events hosted around the country by repair shops, parts stores and other aftermarket organizations that include free vehicle check-up events or inspections. Since the auto service and repair experience for the consumer is a local one, these types of community events are extremely popular with consumers and can be powerful business-building events, building loyalty and attracting new customers. The Car Care Council really goes “all out” to promote

Âť Guest Editorial National Car Care Month. While we believe that every month is car care month, we crank up intense media outreach for many weeks prior to April to ensure National Car Care Month is on the consumer mediaâ&#x20AC;&#x2122;s radar screen. We work with the trade media to publicize and encourage industry involvement and leverage the widespread public attention to vehicle care being driven by the council. We also conduct a robust social media campaign utilizing Facebook, Twitter, Pinterest and YouTube to reach motorists of all ages in a variety of ways.

UHS: Is it easy for a shop to participate in National Car Care Month? RW: The Car Care Council has a variety of resources and tools available at www.carcareindustry.com to make it easy for repair shops to celebrate National Car Care Month. For example, a repair shop could get a banner from the council to celebrate Car Care Month, hang it over a bay and then invite current

10 March 2013 | UnderhoodService.com

and prospective customers to come by for a free inspection and pick up a free Car Care Guide from the council. A shop could also partner with other shops or their jobber or distributor to host a larger event with free vehicle inspections. Community car care events can become more elaborate by including police safety seat demonstrations, custom/race/antique cars on display, a local radio station remote broadcast,

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» Guest Editorial refreshments from a nearby restaurant, a moon bounce for the kids and tables with educational materials such as worn-out wiper blades and hoses, dirty engine oil and fluids, dirty filters and worn tires. There is no one-size-fits-all template for participating. Businesses that get involved in National Car Care Month at any level can make their organization more visible to the vehicle owners in their community.

UHS: Can you tell us a little more about the council’s newly introduced online industry “ToolBox”? RW: Our new Industry ToolBox is available to the industry in advance of National Car Care Month at www.carcareindustry.com, and makes it quick and easy to get involved. It is a one-stop site designed to help shops, stores and other industry organizations reach out to customers in their communities. One popular feature of the ToolBox is the video titled “Drive Customers to Your Shop,” which highlights the benefits of participating in Car Care Month. The site also features “how to host” a community car care event instructions, printable materials, downloadable images and Car Care Clip videos. Ordering information to obtain “Be Car Care Aware” point-of-sale kits, brochures, merchandise and the popular Car Care Guides in English or Spanish can also be found there. UHS: You have said the Car Care Council’s website, www.carcare.org, is designed to fuel confidence regarding auto repair among vehicle owners. What are some of the most popular features of the site? RW: We make a concerted effort to ensure that our website is the “go to” place for preventive vehicle maintenance and repair information. With National Car Care Month upon us, the site’s Car Care Event Finder has a map feature to make it 12 March 2013 | UnderhoodService.com

easier for motorists to find a vehicle check-up event in their area. It’s quick and easy for a shop to enter its community car care event information. The site features a customized service interval schedule and an e-mail reminder service, a frequently updated blog to share the latest tips and advice and a comprehensive vehicle systems overview. The council’s popular Car Care Guide and the new “Ask a Tech” and “Go Green” sections offer insight and guidance for motorists. Among the many instructional videos housed on the site, we offer a new video titled “Auto Service and Repair: What to Expect” which takes the guesswork out of auto service by giving consumers a behind-the-scenes look at the repair shop experience. All in all, www.carcare.org is a one-stop site that shops can share with their customers to help them drive smart, save money and make informed vehicle repair decisions. ■

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» Directions

By Edward Sunkin |

EDITOR

Smart Devices That Make You Smarter

ure, there are endless fun things you can do with your smart phone and/or tablet — like keeping in contact with your friends, posting photos of you from the AAPEX/SEMA show or an industry training session, watching the latest car video “fails,” tweeting about the race on Sunday, you name it. But now, your smart device is the perfect complement to Underhood Service magazine for releasing exciting technical content, too.

Referred to as Augmented Reality, digital information content is presented in the form of videos, demonstrations or moving 3D programs. The content, in a way, “comes alive” for the viewer, making the informationsharing experience more engaging for our readers. For owners of smart devices, this type of content will be readily available at your fingertips, and can be viewed at any time along with Underhood Service magazine.

We have provided this exciting bonus Augmented Reality content throughout this issue. This bonus material is presented in short, concise, informative clips that accents the technical article in which it’s found. We at Babcox Media see this as the next step in the dissemination of technical and instructional content to shop owners and technicians. By pairing up the print version with today’s digital device, the connection to our reader

» Directions has never been better. Through AVI PLAY, we can provide demonstrations from advertisers, trainers and other technicians that give you a better understanding of a component, topic or repair. This is not just a one-time occurrence with this issue. The editorial staff, along with our advertisers and industry association supporters, pledge to bring you fresh, bonus content in each subsequent issue of Underhood Service. And when watching this bonus content, we invite you to share it with others in the shop. These are exciting times in the ways we can reach shop owners and technicians. We feel that bringing print and digital media together is the best way to increase the information distribution to our subscribers.

We also feel that it will add to their reading experience with each issue. Now, isn’t that smart? We would like your feedback on

this new medium. Please e-mail your questions, comments or suggestions for material for future AVI PLAY content to: esunkin@babcox.com. ■

As the number of professionals like yourself with smart devices continues to grow, we believe this is the future of information sharing. To unlock the “bonus” material from the magazine, simply download the AVI PLAY app at www.AVIplayApp.com. The app is available for both Apple and Android platforms.

AUGMENTED REALITY CONTENT IN THIS ISSUE: Content . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Page Publisher’s Perspectives . . . . . . . . . . . . . . . . . . . . . . . . .6 Delphi ad . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18-19 PCV Service feature . . . . . . . . . . . . . . . . . . . . . . . . . . .26 Auto-Video Inc. . . . . . . . . . . . . . . . . . . . . . . . . .41 and 57 A/C Equipment feature . . . . . . . . . . . . . . . . . . . . . . . .46

» Gonzo’s Toolbox By Scott “Gonzo” Weaver

WALK A MILE IN MY SHOES And You’ll Know Where I Get My Stories

was asked some time ago about why I write these peculiar articles about the vehicle repair business. Well, the only way I can explain it is to put yourself in the position that I’m in on a daily basis. I spend a better part of my day trying to understand what a customer is explaining to me, while using my training,

“Don’t do business with people you can’t get along with or ones you feel uncomfortable around.” background and basic common sense to come up with a logical answer to their vehicle’s problem. This is where these true-tolife stories begin. During an average day, a tech might work on vehicles spanning more than 20 different production years. Nothing is ever the same, from year to year, model to model, or manufacturer to manufacturer. These differences can be as varied as the people we meet. Knowing these changes in vehicle systems can be overcome with years of experience, but knowing how to deal with the attitudes and personalities of the consumer can take a lifetime. The

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varied ways people will explain their car problems to the tech can be baffling or even misleading. I try to never approach a situation with blinders on, so I don’t get lead down the wrong repair path. Sometimes, their explanations leave a lot of doubt as to what they really are trying to say. For some people, explaining things isn’t easy, so their way of getting their point across is to use an extremely long version of the story, or a complete biographical saga from their childhood to the present, just so I don’t miss any details. It’s hard to remind myself that I’m not going to make a customer out of every person who calls the shop, or patron who comes in the door, but I’m still stubborn enough to try anyway. As one long-time shop owner once told me years ago, “Don’t do business

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» Gonzo’s Toolbox with people you can’t get along with or ones you feel uncomfortable around.” I tend to believe that’s true after seeing the variety of people I’ve encountered over the years. But, those odd and different personalities and explanations about car problems are the best material for the next new story. You never know, the next one coming through the door might be a real winner. When it comes to educating the customer about what’s wrong with their vehicle, there’s only so far I can go. I usually try several different angles to bring the technical answer down to a level that is acceptable to the customer, but, sometimes, their comprehension is aided only by me using everything from charts, to graphs, to hand puppets. Sometimes, even explaining things to the customer is a show in itself. It can certainly be just as comical watching me try to explain something, as it is listening to their stories.

the potential outcome. In some small way, I hope people who read my stories not only see the humor in these situations, but also take away from them a bit of knowledge. I like to think of it as a life lesson that can’t be taught out of the automotive repair manual. But, it’s something everyone has or will experience.

“Reality check” You could call it a “reality check” for the automotive world. I write about the everyday events that occur in an automotive repair shop, not some contrived managementimprovement idea that’s going to boost your bottom line. Techs from all over the world e-mail me, and have no trouble relating to my stories, and you can tell they’re smiling while they write those e-mails. It helps everyone realize they are not alone in this incredible and challenging

world of automotive repair. And that’s what these stories are really all about. But, these stories not only apply to just automotive techs; they’re something anyone who deals with the general public will enjoy reading. I know doctors, lawyers, bank executives, roofers and a whole lot of other professionals who read and relate to my stories. You just never know where the next interesting story will come from. When you take the time to really think about it, somewhere in our family tree we all have that crazy relative who has done something weird, or a co-worker whose elevator has skipped a few floors. It might even be something you’ve noticed on the news or on the drive home. No matter where we are, something out of the ordinary is going to happen, sooner or later. And, as long as that keeps happening, I’ll keep writing. ■

“Sixth Sense” After many years of standing behind the counter, I tend to have a “sixth sense” about the upcoming repair, either from the reactions of the customer, or from the condition of the car. I tend to go back through my memory files and find a situation that is comparable to the latest one. After all of these years, there’s no doubt there are some comparisons to a story I’ve already put onto paper. Writing these stories down also makes it easier to think of a better way to handle it in the future, or be aware of

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» Talking Shop

TAX SAVINGS

OVER THE FISCAL CLIFF FOR TAX SAVINGS By Mark Battersby

he so-called “Fiscal Cliff” tax package, recently passed by Congress and signed into law, renewed more than 50 temporary tax breaks through 2013, saving individuals and businesses about $76 billion. Admittedly, single individuals with incomes above the $400,000 level and married couples with income higher than $450,000 will pay more in taxes in 2013 because of a higher 39.6% income tax rate and a 20% maximum capital gains tax. In fact, employees will find less in their paychecks in 2013 because the American Taxpayer Relief Act did not extend the payroll tax holiday that had reduced Social Security payroll deductions from 6.2% to 4.2% on earned income up to the Social Security wage base ($113,700 for 2013). It is a similar story for the self-employed. There is good news and bad news contained in the fiscal cliff tax laws for the owners and operators of small- and mediumsized automotive repair shops and businesses. First, the good news: Greater certainty in taxes. The owners and operators of many businesses have grown used to a number of longstanding tax breaks, but they also have had to get used to the uncertainty of whether they will be renewed each year. While many tax breaks were allowed to expire at the end of 2011, the new tax law renews them retroactively, allowing shop owners to claim them on both their 2012 and 2013 tax returns.

ONE MAN’S LOOPHOLE A unique provision in the new law involves — and is limited to — so-called “Motorsports Entertainment Complexes.” Nicknamed the “NASCAR Loophole,” the seven-year recovery period for motorsports entertainment complexes has been extended for capital expenditures made before Dec. 31, 2013. The amendment applies to property placed in service after Dec. 31, 2011. Among the less-targeted business provisions in the new law are: THE WORK OPPORTUNITY TAX CREDIT (WOTC) — a tax credit that rewards employers that hire individuals

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» Talking Shop

TAX SAVINGS

from targeted groups. It has been extended to Dec. 31, 2013, and applies to individuals who begin work for the employer after Dec. 31, 2011. Under the revised WOTC, auto repair businesses hiring an individual from within a targeted group are eligible for a credit generally equal to 40% of first-year wages up to $6,000. WAGE CREDIT FOR ACTIVE DUTY SERVICE MEMBERS: The employer wage credit for employees who are active-duty members of the uniformed services now applies to payments made after Dec. 31, 2011, and before Dec. 31, 2013. EMPLOYER-PROVIDED EDUCATIONAL ASSISTANCE: The new tax law extends permanently the exclusion from income and employment taxes of employer-provided education assistance up to $5,250. The shop or business may also deduct up to $5,250 annually for qualified education assistance paid on behalf of an employee. QUALIFIED IMPROVEMENTS: This allows shop owners who had given up on the prospect of recovering the cost of improvements made to leased property (as well as restaurant or retail improvements) payback over a shorter 15-year period. The new law extends the 15-year straight-line recovery for qualified improvements made to leased property, qualified restaurant buildings and qualified retail improvements for expenditures made before Jan. 1, 2014. Best of all, the write-off applies to all property placed in service after Dec. 31, 2011.

TOOL & EQUIPMENT UPGRADES THE SECTION 179 EXPENSING WRITE-OFF: The American Taxpayer Relief Act extended through 2013 the Tax Code’s Section 179, first-year expensing write-off. Now, the higher expensing limits in effect in 2011 have been reinstated for 2012 and extended for expenditures made before Dec. 31, 2013. Thus, an auto repair shop can expense or immediately deduct up to $500,000 of expenditures 22 March 2013 | UnderhoodService.com

in 2012 and 2013, subject to a phase-out if total capital expenditures exceed $2,000,000. The maximum amount that can be expensed in years beginning after 2013 will, without amendment, drop to $25,000. COMPUTER SOFTWARE: The election to expense and immediately deduct rather than depreciate the off-the-shelf computer software used by so many shops under the tax law’s Section 179 has also been extended and applies to expenditures made before Dec. 31, 2013. QUALIFIED UNDER SECTION 179: Those shops and businesses with expenditures in 2012 and 2013 for qualified real property such as land and whatever is erected on it — including the already-mentioned leasehold improvements, restaurant property,and retail improvements — can elect to claim Section 179 expensing treatment for such expenditures. BONUS DEPRECIATION: The tax break that allows profitable auto service and repair businesses to write-off large capital expenditures immediately — rather than over time — has long been used as an economic stimulus. One-hundred-percent “bonus” depreciation expired at the end of 2011. Today, the new law allows 50% bonus depreciation for property placed in service through 2013. Some transportation and longer-lived properties are even eligible for bonus depreciation through 2014. To be eligible for bonus depreciation, property must be depreciable under the standard MACRS system, and have a recovery period of less than 20 years. Code Section 179 first-year expensing remains a viable alternative especially for small businesses, since under the Section 179 write-off, property may be either used or new, in contrast to the bonus depreciation requirement that the taxpayer be the “first to use.” The portion of the tax laws that imposes dollar limits on the annual depreciation deductions for cars

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» Talking Shop and light trucks used in the auto repair business is also impacted by the new bonus depreciation rules. If bonus depreciation had not been extended, the 2012 tax year would have been the final year in which substantial firstyear write-offs for buyers of business automobiles would be available.

FINANCING, MONEY AND TAXES GAIN FROM SMALL BUSINESS STOCK: The new law extends the rule allowing 100% of the gain realized on the so-called “small business stock” used by so many businesses to attract investors to be ignored. In general, an investor can exclude from

TAX SAVINGS

his or her income 100% of any gain realized on the sale or exchange of “small business stock” acquired prior to Jan. 1, 2014, and held for more than five years. The amount of gain that can be ignored is limited to the lower of $10 million or 10 times the basis or book value of the small business stock disposed of during the tax year. To be eligible, small business stock must have been issued after Aug. 10, 1993, and acquired by the investor at its original issue. The small business stock must also have been issued by a regular domestic, incorporated shop or business, with gross assets of less than $50 million. AN ‘S’ CORPORATION’S BUILT-IN GAINS have new rules. Although an S corporation is a pass-through entity and not usually subject to income taxes, it is liable for the tax imposed on built-in gains or capital gains. The tax on built-in gains is a corporate level tax on S corporations that dispose of assets that appreciated in value during the years when the operation was a regular “C” corporation. The new law provides for a five-year holding period for the sale of property with built-in gain for taxable years beginning in 2012 or 2013.

LIVING WITH ESTATE TAXES

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Always of significant interest to family-owned businesses, the estate tax has long been a bit of a mixed bag. The $5 million dollar per person exemption was kept in place (and indexed for inflation continued). However, the top rate is increased to 40% and effective Jan. 1, 2013. This change to 40% increased revenues from 2012

policy by $19 billion dollars. Other good news for estate planning — portability is kept in place and estate and gift remains unified, i.e., the $5 million stays in place for gift tax purposes as well. And, it is all permanent.

PLANNING OPPORTUNITIES ABOUND The majority of auto repair shops and businesses operate as pass-through entities, such as partnerships and S corporations. Profits are passed through to the individual owners and, therefore, are taxed at the individual’s income tax rates. A regular “C” corporation, with its current tax rate of 35%, may become more attractive with rates rising to 39.6% for some individuals. Many popular but temporary tax extenders relating to businesses are included in the American Taxpayer Relief Act, although it is not the grand bargain as envisioned by lawmakers. Despite the Code Section 179 small business expensing, bonus depreciation and the Work Opportunity Tax Credit, the new law is effectively only a stop-gap measure designed to prevent the onus of the expiration of the Bush-era tax cuts from falling on middleincome taxpayers. Congress must still address spending cuts and may even tackle tax “reform.” The time is now — hopefully before filing your auto repair operation’s 2012 tax returns — for every shop owner, operator and manager to consult with their accountants and/or tax professionals to focus on the potential savings offered by these newly revised, extended and expanded business credits, deductions and tax write-offs. ■

» Service Solution Don’t

PCV

Blow By

PCV Inspections by Underhood Service staff

nyone who services vehicles like yourself knows that the positive crankcase ventilation (PCV) valve prevents crankcase blowby vapors from escaping into the atmosphere by siphoning the vapors back into the intake manifold so they can be reburned in the engine. They’ve been around since 1968 on most vehicles, and the main component is a springloaded PCV valve that meters airflow. Mounted in the valve cover and connected to the intake manifold, carburetor or throttle body with a large vacuum hose, the PCV valve plays an important role in vehicle performance.

PCV VALVE OPERATION

that causes sludge. If the PCV valve or hose becomes clogged, moisture can rapidly accumulate in the crankcase causing engine-damaging sludge to form. A plugged PCV may also allow pressure to build inside the engine causing oil leaks. A quick check of the PCV valve is to shake it and listen for a rattle (no rattle would indicate a blockage). Another is to pull the valve from the valve cover and feel the end for vacuum while the engine is idling (no vacuum would indicate a blockage). The recommended replacement interval is typically 50,000 miles. Some engines do not use a PCV valve for crankcase ventilation, but have a breather box that serves the same purpose.

PCV USE Intake vacuum pulls fresh air into the crankcase through a second breather hose. As the air passes through the engine, it picks up blowby vapors and moisture before it is pulled through the PCV valve and back into the engine. The PCV valve changes the flow rate according to engine load and throttle position. PCV helps extend oil life by removing moisture

All PCV valves are not created equal. They have different flow characteristics that are specific to each engine application and may even be specific to particular platforms using the same engine. UnderhoodService.com

» Service Solution

PCV

On some older vehicles, a small PCV air filter is mounted inside the air cleaner. This filter should always be inspected and cleaned or replaced as needed on a regular basis.

If the engine has an external air leak you will not have an effective PCV system. This could be a leaking front cover, rocker cover, oil pan gasket, manifold end gaskets or any other host of potential leaks. Most emission control parts like the PCV valve require little if any scheduled maintenance, but replacement may be necessary if the Check Engine light is on, the vehicle has failed an emissions test or is experiencing a driveability problem. Other emission control components include the exhaust gas recirculation (EGR) valve, the evaporative emission control system (EVAP) vapor canister and purge valves, the catalytic converter, oxygen sensors and all of the engine’s other engine management sensors. The PCV valve should be inspected and cleaned every 50,000 miles, or replaced as needed (if clogged or malfunctioning).

TESTING A PVC VALVE Testing the PCV system is relatively easy and can be done a number of different ways:

• Pinching: After running the engine up to operating temperature and allowing it to stabilize at

PCV-INTEGRATED ROCKER COVERS One of the most distinctive features of the new LS1 Corvette engine is its domed rocker covers, which house the patent-pending, integrated positive crankcase ventilation system designed to enhance oil economy and oil life, while reducing oil consumption and contributing to low emissions. GM designers said the rocker covers also hold the direct-mount ignition coils for the coil-near-plug ignition system. Between the individual coil packs, the domed sections of the covers contain baffles that separate oil and air from the crankcase gases — about three times the oil/air separation capability of previous engines. 26 March 2013 | UnderhoodService.com

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» Service Solution

PCV

idle, pinch or block off the hose between the vacuum source and the PCV valve. The engine should typically drop 50-80 rpm. If the engine does not change, check the PCV valve and system hoses for blockage. Replace components as necessary and retest. • Vacuum with gauge: Run the engine up to operating temperature. Shut the engine off and block off the fresh air source to the engine. This would typically be the hose coming from the air cleaner to the rocker cover. Remove the dipstick tube and connect a vacuumpressure gauge to the dipstick tube. Restart the engine and allow it to stabilize at idle. Then take a reading of your vacuum-pressure gauge. You should read 1-3” of vacuum with a normally operating PCV. If you have 0” of vacuum or even pressure, you have problems.

• Vacuum without a gauge: Another way to perform a vacuum test on a PCV valve is to start the engine and bring it to normal operating temperature. Next, disconnect the hose from the remote air cleaner or air outlet tube.

IF LEFT UNATTENDED…. A neglected or poorly operating PCV system will quickly contaminate the engine oil and heavy sludge accumulations will begin to form. Imagine dumping water and acid into your engine oil on a daily basis: how do you think that would impact the bearings, pistons and oil characteristics? For that matter, how long do you think the engine would last by doing that? That is exactly what an improperly functioning PCV system will do because that is what the combustion process blowby contains. Place a stiff piece of paper over the nipple or hose end and wait 1 minute. If vacuum holds the paper in place, the system is okay; reconnect the hose. If the paper is not held in place, the system is plugged or the evaporative emission valve (if equipped) is leaking. Inspect the PCV valve and grommet for deterioration, and replace if necessary.

VW Drivers Complaining of Power Loss While servicing a 2002 Volkswagen Jetta (or any 1998-2006 VW vehicle equipped with the 1.8L turbo engine) because the customer complains of a loss of power when accelerating, you may come across stored P codes due to an air intake issue. If a DTC P1297 (17705) or P1557 (17965) are stored in DTC memory, VW reports that this may be caused by intake hoses leaking (during

28 March 2013 | UnderhoodService.com

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Âť Service Solution

PCV

boost conditions) due to incorrect torque on clamps or improper placement, or worn or torn intake hoses, etc.

SERVICE PROCEDURES: Perform an intake system pressure test to detect leaks in the intake system as follows: 1. Separate the intake hose from the mass air flow sensor (MAF) assembly. 2. Remove the crankcase ventilation hose from the PCV valve and close off the crankcase side of the valve with the plug (orange arrow, Figure 1), hose and clamps (supplied with the turbocharger tester, P/N VAG 1687). TiP: This will disconnect the engine crankcase from the intake system. 3. Insert the air pressure adaptor, P/N VAG 1687/1 (blue arrow, Figure 1) into the intake hose between the MAF sensor and the intake system (clamp using the existing hose clamp). TiP: The hose at the throttle assembly will stay connected during the test.

Figure 1

PRESSURE TEST: 1. Attach the outlet hose of the turbocharger tester to the fitting on the air pressure adaptor (blue arrow, Figure 2). 2. Close the outlet valve after the gauge. 3. Back off the pressure regulator knob of the 30 March 2013 | UnderhoodService.com

Figure 2

turbocharger tester fully to protect the gauge when shop air supply pressure is applied to the assembly. 4. Attach an air line to the inlet fitting on the turbocharger tester. 5. Open the valve between the regulator valve and gauge. 6. Adjust the test pressure up to 0.5 bar by turning the regulator valve. Note: Do not pressurize the system above the 0.5 bar! Doing so will force oil into the intake through the throttle body assembly, causing damage to the engine. 7. Slowly open the outlet valve (after the gauge) to test the hose connections. 8. Observe the pressure gauge for a drop in pressure. TiP: Some pressure will be lost past the throttle plate. 9. Apply soapy water or leak-check liquid to all intake system connections to check for leaks. TiP: An ultrasonic tester may also be used to locate leaks. 10. Repair any leaks that are found. 11. Remove the plug from the crankcase ventilation hose. 12. Remove the air pressure adaptor and reinstall the hoses. Courtesy of Mitchell 1. â&#x2013;

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Âť Engine Series

FORD 4.0L V6

By Larry Carley, technical editor

he Ford 4.0L SOHC engine is the successor to the 60-degree V6 pushrod OHV 4.0L engine, and is the latest in a long series of engines produced at Fordâ&#x20AC;&#x2122;s plant in Cologne Germany. The SOHC version went into production in 1997 for use in the Explorer and Mercury Mountaineer, and later became an optional engine for the 2001 to 2011 Ford Ranger, 2001 to 2010 Mazda B4000, 2005 to 2010 Ford Mustang and 2005 to 2009 Land Rover LR3. Rated at a rather anemic 210 horsepower, the

March 2013 | UnderhoodService.com

4.0L SOHC V6 is not exactly a high output engine. It also has an unusual overhead cam drive setup. Unlike most other OHC V6 and V8 engines that drive both overhead cams directly from the crankshaft with a belt or chain, this engine has an intermediate jackshaft in the middle of the block where a pushrod cam would normally be located. A short timing chain on the front of the engine connects the crankshaft to the intermediate jackshaft. A second, longer timing chain

» Engine Series behind the first chain connects the front of the jackshaft to the overhead cam on the left side of the engine. A third timing chain in the back of the engine connects the rear of the jackshaft to the overhead cam in the right cylinder head. There is also a balance shaft in the crankcase of engines used in 4x4 trucks, which is driven by a fourth chain directly off the crankshaft. Why Ford designed the cam drives this way is anyone’s guess. It probably allowed the engine to be shorter and more compact. But one of the unintended consequences of this fore-and-aft split cam drive arrangement is that it makes the timing chains, guides and tensioners VERY difficult to replace — which makes for an expensive repair when a chain guide or tensioner fails on one of these engines (a common problem on high mileage engines, especially if the owner has neglected regular oil changes).

TIMING CHAIN PROBLEMS Some of the early engines up through 2002 in the Ranger and Explorer have had a timing

FORD 4.0L V6

chain rattle problem due to the poor design of the original teflon chain guides. The noise is most noticeable when a cold engine is first started, and is usually loudest from 2400 to 3000 rpm. The same noise problem can also develop in 2003 and newer high-mileage engines as a result of chain guide wear. In some instances, the guide may break and disintegrate and spew debris into the oil pan. This may also cause one of the timing chains to break (typically the front left chain). Fortunately, the 4.0L SOHC is not an interference engine so a timing chain failure won’t bend the valves. But it does create an expensive repair for the vehicle owner. Ford issued a TSB for the timing rattle problem and released a redesigned “‘cassette”‘ (the timing chain, gears, guide and tensioner assembly) for the left front timing chain. This timing chain cassette can be replaced without having to pull the engine out of the vehicle. But, if the engine has a bad rear chain or guide, or a chain guide has failed and throws debris into the crankcase, you will have to remove the engine to make the

The 4.0L SOHC engine was found under the hood of many Ford and related SUVs and light trucks, as well as 2005-’10 Mustangs.

UnderhoodService.com 33

» Engine Series

FORD 4.0L V6

required repairs. That includes removing the flywheel and flexplate so that the rear cam drive cassette can be replaced, and pulling the oil pan so any debris in the oil pan and oil pickup screen can be cleaned out. You’ll also need a special tool kit (Ford or aftermarket) to hold the cams and tension the timing chains, and to prevent the crankshaft from rotating while you’re doing the cam drives. You’ll also need the proper puller to get the harmonic balancer off the crankshaft. The redesigned Ford primary timing chain service kit includes an improved chain tensioner and chain guide, chain, jackshaft and sprockets. Kit number 2U3Z-6D256-AA is for balance shaft engines in 1999 to 2001 4x4 Explorer/Mountaineer, 2001 to 2002 4x4 Sport/Sport Trac and all 2002 Explorer/Mountaineer (except engine codes 2G-960-AA and 2G-964-AA). Kit number 2U3Z6D256-BA is for non-balance shaft engines in 1999 to 2001 2WD Explorer/Mountaineer and 2001 to 2002 2WD Sport/Sport Trac, and all 2001 to 2002 Ranger.

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» Engine Series ENGINE SERVICE If the head gasket is leaking, replacing the left head gasket can be done with the engine in the vehicle (assuming there is enough room to pull the head). But if the right head has to come off, the only way to remove the head is with the engine out of the vehicle because of the rear cam drive on the right head. At this point, some might argue that it’s cheaper and easier to simply find a good used engine and replace the old motor rather than repair it. This might be a viable alternative IF you can find a good used low-mileage 4.0L SOHC V6 that can be swapped into your customer’s vehicle. But by the time many of these engines end up in a salvage yard, they don’t have a lot of miles left in them. A better option if your customer is willing to spend the money would be to install a remanufactured engine. A reman

FORD 4.0L V6

engine from a reputable supplier should be completely reconditioned to original specifications and come with an extended warranty. Some suppliers offer a three-year or 36,000-mile warranty with their reman engines. That’s a better deal than the 30 day guarantee many salvage yards offer (which doesn’t include labor!). If the engine in your customer’s vehicle has a timing chain rattle problem, and the engine has less than 100,000 miles on it, doing an oil change and using a light viscosity, pure synthetic oil can sometimes quiet the noise. The lighter oil will flow to the timing chain more quickly following a cold start and reduce the noise somewhat. However, if the engine has a lot of miles on it (more than 100,000) or changing motor oils makes no difference, replacing the timing chain cassette(s) will likely be necessary to quiet the engine.

One of the unintended consequences of the 4.0L’s fore-and-aft split cam drive arrangement is that it makes the timing chains, guides and tensioners VERY difficult to replace and an expensive repair when a chain guide or tensioner fails. Courtesy: Cloyes Gears Go to www.uhsRAPIDRESPONSE.com

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» Engine Series

FORD 4.0L V6

As we mentioned earlier, mostat housing and coolant this is a rather involved sensors. You may have to repair procedure so always remove the thermostat refer to the Ford service lithousing if you can’t get the erature for the step-by-step tensioner out with a wrench details. If you try to wing or deep socket. it as you go, you’ll likely The left (front) and right be in for some unpleasant (rear) cam drive cassettes surprises along the way. for this engine are differThe jackshaft drive gear ent, and the design and and cam drive gear retainquality of the parts can ing bolts are TTY (torquevary depending on the supto-yield) and should not be plier. Some aftermarket reused. If you don’t suppliers buy their cam A short timing chain on the front of the replace these bolts with drive cassettes from the engine connects the crankshaft to the new ones, there’s a risk of same original equipment intermediate jackshaft. breakage. The rear jacksupplier that Ford uses, shaft bolt is also covered by a small circular plug while others do not. Since this is a labor-intensive on the back of the engine. It looks like a freeze repair that should only have to be done once, plug but isn’t. don’t try to save money on a no-name part. Go The front left chain tensioner can be tricky to with the genuine Ford replacement parts or parts extract because of its close proximity to the therfrom a quality-brand aftermarket company.

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38 March 2013 | UnderhoodService.com

» Engine Series

FORD 4.0L V6

Other “fun” parts to replace on this engine include the heated PCV valve on the back of the left valve cover. It’s out of sight and hard to reach with little clearance between the engine and firewall.

DIAGNOSTICS If the Check Engine light is on and you’re doing misfire diagnostics on a 2006 and up Explorer, a new scan tool PID that’s available on these models is the actual burn time of each individual spark plug. By comparing the spark durations, you can quickly see if a spark plug is fouled or a cylinder has low compression because the burn time for that cylinder will be longer. If you see a cylinder with a shorter burn time, it would tell you that cylinder is running lean or the spark plug gap in that cylinder is worn or set too wide. On some 2005-’10 Mustangs with automatic transmissions, there can be an annoying vibration at idle, especially when the A/C is on. The problem is not the engine, but an exhaust vibration. Ford TSB 05-8-6 says the cure is to install a damper kit to dampen the annoying vibration. The kit is P/N 5R3Z-5F240-A.

MAINTENANCE The original equipment spark plugs are platinum with a 100,000-mile service interval. Make sure 40 March 2013 | UnderhoodService.com

you install the correct replacement plugs because the ones for the 4.0L OHV pushrod engine are shorter and won’t position the electrode the correct distance into the combustion chamber. Though Ford diehards tend to stick with the original Motorcraft brand spark plugs, any brand of spark plug will work in these engines provided the plug manufacturer has a listing for the engine application. The plug gap is 0.054” on most applications. The crankcase oil capacity on the 4.0L SOHC V6 is 5 quarts, usually 5W-30 for the older vehicles and 5W-20 for the newer ones. Refer to the vehicle owner’s manual for the recommended viscosity. ■

» A/C Update

OVERCHARGING

ARE YOUR TECHS OVERCHARGING? I By Bob Pattengale, aftermarket trainer

n the world of public opinion, if you were asked if your technicians were overcharging your customers, you might interpret that as an issue pertaining to the customer’s repair bill. However, in the world of mobile air conditioning service, we’re referring to the problem of some vehicle A/C systems being (unknowingly) charged with too much refrigerant. While A/C performance problems due to too much refrigerant in the system have basically become an issue in recent years, its origins began many years ago. When we look at the refrigerant demands on older R-12 vehicles, A/C systems operated on as much as 55 to 60 ounces!

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In fact, back when I first started as a technician, we used to have stacks of cans in cases, and you put two to three cans in the car and then you’d toss the leftover refrigerant in the trashcan. You didn’t care about it. It was cheap, and there was a lot to go in there. Today’s R134-a systems have 12 to 16 ounces of refrigerant to deal with. Now, what are the changes? What are the differences there? Remember, back in the old days, you had a very large air conditioning compressor. That thing took three to four pounds of refrigerant, and when you pushed the button to turn the air conditioning on, you felt a decrease in performance of the

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» A/C Update

OVERCHARGING

vehicle. That’s because it took a lot of horsepower to push that refrigerant through the air conditioning system. Today, it’s a much smaller deal; the smaller compressor takes a lot less energy. Now, in most cases today, if you’re running around in a Toyota Corolla or maybe a little Nissan Sentra or small vehicle, when you turn on the air conditioning, you don’t even feel the effects. Why is that? There’s a lot less refrigerant in the system that we have to deal with. Now, global warming is certainly a concern, which is one reason why OEMs began reducing the size of A/C systems. The other concern is mileage. If I have a large compressor, and I’m trying to get more gallons per mile out of the vehicle, what you have to do is decrease the size of that compressor. So, if I have an extremely large compressor, I’m going to use more gas. If I have a very small compressor, I’m going to be able to get more gas mileage out of the vehicle. And, I’m going to put less load on the engine itself. So that’s why we see a transition to these smaller systems, primarily to get that gas mileage taken care of.

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EQUIPMENT TEST When the Mobile Air Conditioning Society Worldwide (MACS) conducted its studies in 2007 on J2788, the SAE standard that deals with A/C recovery and recharge equipment, it led to some interesting results. In its findings, MACS concluded that even with the best machines out there, you were not going to pull all of the refrigerant out of an A/C system during service. According to MACS’ research, the organization went out and purchased just standard run-of-themill air conditioning machines from shops. Some of these had been well maintained, while others were poorly maintained. The MACS team brought the equipment together and began a testing process to determine how well they worked. Depending upon the ambient temperature, some of the machines could not pull out more than 50% of the refrigerant. So, let this sink into your head: If you only pulled 50% of the remaining refrigerant in the system out, you left 50% behind. If you add another full charge on top of that, you have added full refrigerant on top of left-behind refrigerant. Now, I’m talking about a car that was blowing cool, not cold. And, I’m not talking about one that had the A/C compressor replaced, where it was empty. This is a customer that came in and said, “Hey, it’s not blowing as cold as it was last year, I want it cold this year.” So, to address the customer’s needs, what your tech does is roll the machine up, and perform a complete cycle — recover it, recycle it, do a vacuum and a recharge to get the customer going. And, that’s the scenario where the chances are highly likely that your tech left refrigerant behind. Let’s take a look at a couple more items. Even the best machine that they could find would only pull 70% of the refrigerant out at a 50° temperature range. Now, why 50° temperature? This is based upon

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» A/C Update

OVERCHARGING

average temperature around the country, and they use that as a standard for testing. We’re going to look at a couple of examples where the car was warmed up and the temperature (ambient temperature) was higher. So, even in good climate control, even the best machine that they could find, the equipment

operator is still going to leave some refrigerant behind. Now, that surprised me. I was shocked, really, when I looked at the differences between J2810 and J2788. Here is another real-world example. A customer comes into the shop with the complaint that the A/C’s blowing cool, but not cold. Checking under the hood, we find that it’s a 16ounce system. And, I suspect, that it’s at least four to six ounces low, because the performance has reached the point where the temperature is increasing. This is an expansion valve car, so we predict that when it gets about 30% to 40% low on charge, that we’re going to have an issue with the air conditioning performance. Now, let’s take this example a little bit further. Let’s say you had a machine that is poorly maintained, resulting in you only removing about half of the remaining refrigerant in the system. So, using the example of a system of 16 ounces, and based on my experience, I estimate that the system is four ounces low. This would take the refrigerant in the system to be about 12 ounces. With the older, poorly maintained recover machine, only 50% of that amount is recovered. That would mean that there’s six ounces remaining in the system. And, we’ll say I then did a charge of 15 ounces refrigerant. When the service is completed, we see that the system is actually five to six ounces overcharged. That’s a lot of refrigerant. Again, I was surprised. I didn’t know that this was happening in the field, and after doing research over the last couple of years, I find that more and more shop owners have discovered that they have vehicles that are overcharged and it’s actually creating some issues. ■ Reader Service: Go to www.uhsRAPIDRESPONSE.com

48 March 2013 | UnderhoodService.com

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» TechTips

Ford / Lincoln / Mercury

This month is sponsored by:

Coil-On-Plug Misfire Diagnostic Tips for Engine That Misfires or is Running Rough Ford: 1996-’99 Taurus SHO 1998-2006 Crown Victoria, Mustang 2000 Taurus 2002-’05 Thunderbird 2003-’06 Focus 2004-’06 Taurus 2005-’06 Five Hundred, Freestyle 1997-2006 E-Series, Expedition, F-150 1999-2006 F-Super Duty 2000-’05 Excursion, F-53 2001-’06 Escape 2002-’05 Explorer 2005-’06 Escape Hybrid

Lincoln: 1997-’98 Mark VIII 1998-2002 Continental 1998-2006 Town Car 2000-’06 LS 1998-2006 Navigator 2002-’03 Blackwood 2003-’05 Aviator

Mercury: 1998-2006 Grand Marquis 2000 Sable 2004-’05 Sable 2005-’06 Montego 2002-’05 Mountaineer 2005-’06 Mariner 2006 Mariner Hybrid

March 2013 | UnderhoodService.com

Note: Follow this TSB procedure only if there are no specific misfire TSBs/ SSMs released for the vehicle symptom being experienced.

Issue: Approximately 50% of coil on plug (COP) coils returned for warranty do not have a problem.

Action: The misfiring cylinder must be identified through Self-Test misfire codes or through WDS Power Balance. Rule out base engine problems; rule out fuel problems; and then look at ignition problems (be sure to rule out coil primary circuit issues). Once the above steps have been completed, and the issue is in the secondary part of the ignition system, the oscilloscope procedure outlined in this TSB can isolate the difference between a coil or spark plug problem.

Service Procedure: The optional WDS COP Kit available through Rotunda

will provide more accurate diagnosis and help reduce replacement of non-defective parts. The Kit (418-F5528) can be purchased through 1-800ROTUNDA. The following material will detail the diagnostic steps on WDS to take the guesswork out of misfire diagnosis using the COP kit. The following procedure is for cylinderspecific misfires and not random misfires. Random misfires have a different root cause and are not covered by this TSB.

Misfire Definition: A misfiring cylinder is lacking power relative to the other cylinders. The causes for a cylinder-specific misfire could be fuel, spark or mechanical problems. Perform a thorough visual inspection. If no visible concerns are found, use the following WDS tools for misfire diagnosis: - Self-Test (Check for codes first); - Power Balance (Identify the

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Ford / Lincoln / Mercury

Figure 2

Figure 1

cylinder of concern); - Relative Compression (Rule out a possible mechanical issue); - Fuel (Make sure fuel injectors are not restricted); - Ignition (Make sure spark plugs and coils are working properly); and - Oscilloscope (Detailed signal analysis).

If there is a self-test code identifying a particular cylinder, then you just need to determine if it is a fuel, ignition or even a mechanical problem. Proceed to Step 2 on page 54 after running Relative Compression to rule out any mechanical issues. If there is no self-test code and the customer concern is a miss, proceed to Step 1, also on page 54.

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Ford / Lincoln / Mercury

Step 1: (Select Toolbox Icon, then Powertrain, then Power Balance) The cylinder-specific misfire has to be identified as shown in the example in Figure 1 in order to proceed with the remaining steps. If the miss does not occur at idle (in the bay), try to brake-torque the engine. This extra loading should reproduce the miss in the bay. If the miss cannot be reproduced during brake torque, select Relative Compression under Powertrain on WDS before going on a road test to rule out mechanical problems. If Relative Compression shows a problem then the base engine issue must be serviced. If Relative Compression results are good (see Figure 2), road-test under as many different driving conditions as possible until the miss occurs on Power Balance. Some misses may be very intermittent, so be patient and concentrate on steadyload conditions. Once a cylinder dropout is identified, proceed to Step 2.

Step 2: (Select Toolbox Icon, then Powertrain, then Fuel System Test) Run the Fuel System Test on WDS to determine if there may be a fuel problem. After complet-

ing the Fuel Pressure/Leakdown Test, select Injector Flow to isolate a restricted injector as shown in Figure 3. If all of the injectors are within specification, proceed to Step 3.

Step 3: (Select Toolbox Icon, then Powertrain, then Ignition System Test) Run the Ignition System Test on WDS to determine if there is an ignition problem. Look at both duration (DUR) and kilovolts (KV), and look for values that standout from the rest as shown in Figure 4 and Figure 5. Note: Live display has to average ignition values because there is too much data to display. Make a capture to view each engine event without averaging. This can be helpful when the problem is intermittent. If the miss is extremely intermittent and does not show up in ignition, proceed to step 4. If either spark duration or peak KV on the red probe (suspect cylinder) are offset from the values displayed on the black probe (known-good cylinder), then the problem is in the ignition system. Rule out coil primary circuit issues before proceeding to coil secondary issues such as the spark plug, coil boot or possibly the coil. Use the WDS oscilloscope with the COP kit to determine if the issue is the coil or the spark plug.

Step 4: (Select Toolbox, then Oscilloscope)

Figure 3 Go to www.uhsRAPIDRESPONSE.com

Warning: Secondary ignition voltages are very high. Keep hands and tools

Âť TechTips

Figure 4

Figure 5

away from the end of the coil that supplies the spark.

Set-up: With the engine off, pull the suspect coil from the cylinder well and turn it upside down so the coil cannot spark to any other surface. Wrap a clean

shop cloth around the hard shell of the coil to help keep the coil propped up and stable. Caution: The coil boot can be damaged if the coil sparks to another surface during this procedure. Keep the coil connected to the harness and leave the WDS COP clip attached to the coil. Route the coil clip wire and cable away from the coil being tested,

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Ford / Lincoln / Mercury

as well as other coils, to avoid noise interference. Disconnect the injector of the cylinder being tested so raw fuel is not washing the cylinder. This is a stress test for the coil. The type of waveform displayed on the oscilloscope will show whether a coil or the plug is the problem, if all previous steps have been followed. Keep hands and tools away from the end of the coil that supplies the spark.

COP Stress-Test Procedure: Go to the Oscilloscope Tool and select Channel 3, then select Auto, then select COP_STRESS_TEST_RED. This pre-configured setting will zoom-in on the peak firing of the coil being tested. Start the engine and be sure the coil is not sparking to any surface. If the coil is sparking to other surfaces, turn off the engine immediately and readjust the coil so it cannot spark to any other surface. Restart the engine and touch the Red Man icon to start the oscilloscope. All settings

are pre-configured and no adjustments are necessary. Compare the waveform you get with the examples provided in Figures 6, 7 and 8). Figure 6 is a good waveform. If your waveform is similar to Figure 6, the coil is working correctly and the spark plug is suspect. Figures 7 and 8 are examples of problem coils. Replace the coil if the waveform is similar to Figures 7 or 8. The coil is causing the misfire when the peak firing appears like those shown. Notice the difference in the peak-firing signal when compared to the good peak signal in Figure 6. Figure 8 shows a more dramatic fault in the peak failure. Most root causes of misfire issues can be identified quickly using the steps outlined above. Some misfire issues can be difficult making the oscilloscope an important part of your diagnostic toolbox. â&#x2013; Courtesy of Identifix

Figure 8 Figure 6

Figure 7

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Spectra Premium recently launched a new line of oxygen sensors. To complement its ecofriendly approach of digitizing print material, the company is launching a digital flipbook format of the Oxygen Sensor Catalog. This format will enhance customers’ viewing experience with a slick and easy-to-navigate online tool, while being mobile compatible. Bring your traditional print experience to new levels by combining the simplicity of reading a book with today’s modern multimedia technologies. Try it at www.spectrapremium.com. Reader Service: Go to www. uhsRAPIDRESPONSE.com

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Delphi announces seven new sensors that cover almost 6 million North American Audi, Volkswagen and Mercedes-Benz vehicles from 1985 to present (P/Ns TS10236, TS10245, TS10251, TS10269, TS10278, TS10279 and TS10281). Delphi’s one-piece design and automated production process eliminates internal connectors and failure points. A rugged plastic shell and thermistor pre-mold subassembly prevent stress, ensuring accurate measurements and vibration resistance. The thermistor is separate from the outer shell and is surrounded by thermally conductive fluid. Reader Service: Go to www.uhsRAPIDRESPONSE.com

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62 March 2013 | UnderhoodService.com

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» Test Drive The Complete Book of Camaro This is a Camaro book like no other. The Complete Book of Camaro covers the entire production history of Chevrolet’s iconic pony car, from the original concept car, code-named Panther, to the latest and greatest fifth-generation sensation. The Complete Book of Camaro showcases in photos, text and technical specifications every model since 1967. If Chevrolet built it, it is here. This lavishly illustrated book, weighing nearly four lbs., details all five generations of the Camaro’s production run: the original models developed to fight the Mustang in the pony car wars of the late 1960s; the second-generation cars that became icons of American automotive styling in the 1970s; the third-gen cars that helped to lead the muscle car renaissance of the 1980s; the refined fourth-generation models that continued to demonstrate GM’s engineering prowess through the 1990s; and finally, the blockbuster new fifth-generation Camaro that has taken the world by storm. Muscle car enthusiasts and auto historians alike will revel at the book’s in-depth data and details on the body, interior and engines that created this American driving icon. In addition to the production vehicles, prototypes, show cars, anniversary editions and pace cars are also covered. With extensive details, specifications, hundreds of photographs and a trick book cover featuring an RS-model headlight door that slides open when the book is opened, The Complete Book of Camaro is the ultimate resource on Chevrolet’s legendary pony car. The book makes a perfect gift for a technician or shop owner whose heart for the Camaro runs deep. BOOK NOTES: Author: David Newhardt Format: Hardcover, 288 Pages ISBN: 9780760339619 Price: $50 plus S & H To order: www.qbookshop.com/motorbooks.com

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GUESS THE CAR! WIN $50! #12

What vehicle MAKE does the picture on the left represent? Submit your guess with our online contest form by visiting www.UnderhoodService.com/guessthecar or scan the QR code to the right with your smart phone. The winner will be randomly selected from correct entries and awarded $50. Entries must be received by March 31, 2013.

#11

December Solution: (Ford) Focus Solved by: Zach Nowaczyk, technician at Walbridge Automotive, Walbridge, OH

CONGRATULATIONS Zach! Employees of Babcox Media, industry manufacturers and Underhood Service advertisers are not eligible to enter.

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