Professional Motor Mechanic March 2024

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TOTHE TRADE

MARCH 2024

PMM

FREE

PROFESSIONAL MOTOR MECHANIC

ENTER THE CPD ZONE! YOU COULD EARN ONE CPD CREDIT THIS MONTH Also inside:

GARAGE SECTOR WINS MOT FIGHT ARE LED BULBS TOO BRIGHT? PMM PODCAST BEST BITS INSIDE

Let’s get technical: SA AB 9.5 CATALYTIC CONVERTER FAILURE EXAMINED NON-STARTING BMW AND A LEAKY LEXUS DIAGNOSED NISSAN JUKE CLUTCH REPL ACED ALL YOU NEED TO KNOW ABOUT TRANSMISSION OIL, LAMBDA SENSORS & ABS BELT ISSUES ON AUDI, SEAT, SKODA & VW ARTICLES ON MOT CONNECTED EQUIPMENT, ADBLUE, WINDSCREEN REPAIR AND MUCH MORE!

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Contents Regulars 7- 9

NEWS & VIEWS

10

TOP FIVE ARTICLES

13-29

CPD ZONE

28

PMM PODCAST: THE BEST BITS

31-32

BUSINESS & TRAINING

36

A LOOK ONLINE: AUDI A4

61

MYTHBUSTER: LED LAMPS

62-65

IN THE WORKSHOP

VOLUME 25 ISSUE 3 MARCH 2024

Features

39-48 EXHAUSTS & EMISSIONS

Editor’s Picks 26

GETTING INTO GEAR As part of this month’s CPD Zone, febi helps explain the role transmission oil plays in both manual and automatic cars. Make sure to read and scan the QR code at the end to claim your CPD point.

39

LAMBDA SENSORS NTK, a brand of Niterra, not only shares everything you need to know about lambda sensors but why you should know it, served with some technical advice on the side.

56

BETTER THAN NEW Sitting pride of place in this month’s remanufacturing feature, ACtronics gives PMM a history lesson on how the anti-lock braking system has evolved over the past decade and what this might mean for the future.

60

SOFTWARE SOLUTIONS Want to know all about the latest equipment and technology that could help you run a successful and modern garage? Look no further than page 60 of this issue, where Maverick Diagnostics, Garage Hive, TechMan and ClickMechanic give their advice.

49-55 TOOLS & GARAGE EQUIPMENT

56-59 REMANUFACTURING

Total Average Net Distribution 53,353 1st July 2022 – 30th June 2023

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VIEWPOINT

Editor KIERAN NEE News and Products Editor FREYA COLEMAN Digital Manager KELLY NEWSTEAD Group Manager ROBERT GILHAM Account Manager ALEX DILLEIGH Magazine Designer GEMMA WATSON Group Production Manager CAROL PADGETT Production Assistant CLAIRE SWENDELL Distribution Manager KARL CLARK

THE SUM OF PARTS

W

Subscriptions

PROFESSIONAL MOTOR MECHANIC is a business magazine for firms and individuals involved in all aspects of the motor trade. It is published eleven times a year and is available nationally FREE to the trade through leading motor factors. It is also available through the post at a cost of £30.

EUROPE and OVERSEAS UK £30 post paid Airmail £80 post paid Europe £50 post paid Printed by PCP Telford Published by HAMERVILLE MEDIA GROUP Regal House, Regal Way, Watford, Herts, WD24 4YF. Tel: Watford (01923) 237799 Fax: (01923) 246901 E-mail: pmm@hamerville.co.uk Sales enquiries: pmmsales@hamerville.co.uk Website: www.pmmonline.co.uk Copyright © 2024 The publishers and editor do not necessarily agree with the views expressed by contributors, nor do they accept responsibility for any errors of translation in the subject matter in this publication.

Associate member

e dedicated an episode of the PMM Podcast to the ongoing MOT debacle last year. We called it MOT Madness to reflect the commonly held view, in the aftermarket at least, that any plans to reduce the frequency of the test were just that: madness. What the episode (and our Striving for Success episode) showed, was that the reasoning behind the change was misplaced; whilst cars are mechanically more reliable, wear items and driver habits remain largely unchanged. What’s more, EVs surprised everyone by proving to be a bit of a lame duck at the MOT bay, with their extra weight chewing through tyres like marshmellows (or should that be marshmallows? An interesting discussion on, of all places, the Piston Heads forum suggests the country is bitterly divided on how to refer to the horrible, squidgy things. Southerners are apparently more likely to say it correctly [i.e. marshMELLOW] than our friends above the Watford Gap. If you agree with my spelling and pronunciation, please feel free to write in and let me know).

A year later and the Government has dropped its plans after all. Huzzah! Perhaps it was not much of a surprise, but it was exciting to watch a topic we had invested in play out before our eyes. We will be following up on the topic in this month’s episode, so be sure to tune in. It’s easy to feel isolated in this industry and to think that the issues you’re facing or the things that upset you are affecting you alone. Usually, that’s not the case. With the PMM Podcast we offer garages a platform to share their thoughts, to learn about what else is going on in the industry and to gain a sense of community – imagine if the postmasters had had their own podcast years ago in which they discussed their problems and shared advice!

Last month’s episode focussed on fake parts on the market. This idea originated from a couple of emails that were sent to me by readers of the magazine asking me whether fake parts were on the rise. They felt they had come across fraudulent parts more frequently since the cost of living started to rise and were worried this was becoming endemic. I won’t spoil it too much if you haven’t listened to it already, but I think some of the scenarios discussed in which fake or dubious parts threaten to enter the workshop will be familiar to most of you. What becomes clear in the episode is that the vast majority of UK workshops are vigilant and on the ball when it comes to quality parts. A drum we bang monthly, here at PMM. Whilst I’m on the topic of the podcast, I may as well discuss some of the conversations and topics we’ll be sharing over the coming months. We are adding a second podcast series, PMM ’s Aftermarket Chats, which will (hopefully) be released monthly. This means that every two weeks you will receive a shot of PMM – lucky you! In our Aftermarket Chats, Freya and I will be having a chat for half an hour with interesting people from the aftermarket. Longer than our normal podcast interviews, but not so long that you get bored. Oh and by the way, Freya and I are set to become TV stars soon after participating in the filming of The Paddock Speedshop, a show combining racing and classic car restoration, so now when you want to complain, you’ll have to call my agent!

Kieran Nee Editor

JOIN ME EACH MONTH ON THE PMM PODCAST Find every episode at www.pmmonline.co.uk/podcasts Also available: Listen on

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PMM NEWS

with Freya Coleman

NEWS IN

MOT test to remain at 3-1-1

BRIEF ■ USED CAR PRICES FALL According to SellYourCarInAFlash.com, EVs have on average lost a quarter of their buy-now value since last May, while petrol vehicles have lost nearly a third.

■ ADAS TRAINING COURSE SUCCESS Point S Tyre and Autocare, an independent tyre dealer and car maintenance network, has successfully delivered its first IMI Level 2 Award in ADAS calibration.

■ DRIVING BAN FOR TIPSY GARAGE OWNER A Southampton garage owner has been diqualisfied from driving after being caught over the legal limit in a customer’s car. He was pulled over after using the car to drive home from work, stopping at the pub to meet some friends on the way. He’s been disqualified from driving for 40 months and has been ordered to pay court fees totalling £785.

The Government has finally confirmed that MOTs will continue to be undertaken on the existing 3-1-1 pattern, rather than 4-1-1, following an industry consultation.

The consultation, which ran from January to March last year, sought the views of those in the aftermarket to ensure roadworthiness checks continue to balance the cost to motorists, road safety, advances in vehicle technology and tackling vehicle emissions.

To ensure MOTs are fit for the future, the government said it will further investigate how to better monitor diesel vehicle emissions through the DVSA. This is said to

include whether testing should do more to ensure that diesel vehicles comply with emissions regulations.

This is a huge victory for the automotive industry and motorists alike. For example, Hayley Pells, policy lead at the IMI commented: “We welcome the Government’s commitment to maintaining the first MOT at three years and annual testing thereafter. This aligns with our findings on the importance of regular checks for road safety and vehicle maintenance. The decision to further explore modernising tests for electric and automated vehicles is a positive step towards addressing the unique challenges and advancements in vehicle technology. We also appreciate the focus on diesel emissions, which is crucial for environmental concerns. The conclusion of the consultation also underscores the need for ongoing adaptations in MOT testing to keep pace with rapidly evolving vehicle technologies and environmental considerations.”

This decision has been celebrated widely within the automotive industry including organisations such as the SMMT, the IAAF, Garage Industry Trends and GSF car parts.

■ NEW DUCKHAMS OIL CEO APPOINTED Mike Bewsey, formerly of Moove Europe, has been appointed as CEO of the oil company. Bewsey, who is also president of the UKLA, commented that “Duckhams is a great brand with a rich heritage, well-loved by mechanics and motorists. It is an exciting time to be joining the Duckhams family.”

■ CASTROL CELEBRATES 125TH ANNIVERSARY To mark this, the oil company has unveiled a new ‘Onward, Upward, Forward’ strategy to meet the changing needs of customers.

Rising costs will be biggest test facing workshops Highlighting the main challenges workshops are set to face in 2024, the Motor Ombudsman’s annual service survey shows that three-quarters of vehicle repairers expect day-to-day running costs, energy bills, and taxes to have the biggest impact on their bottom line in 2024.

In addition, more expensive parts are likely to pose an additional concern for nearly two thirds of those questioned.

Recruiting qualified staff, which was a hurdle last year for 54 per cent of respondents, is set to remain a difficulty for 58 per cent of businesses, as demand for skilled technicians outstrips available supply in the labour market. This is especially true when it comes to those trained in the maintenance of electric vehicles.

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PMM NEWS

with Freya Coleman

DATES

Tackling the skills crisis

FOR THE DIARY

According to the IMI, there still remain more than 23,000 automotive job vacancies, despite figures improving.

To help tackle this, the institute has launched another report titled ‘Driving Auto Forwards’ which offers strategic recommendations and actions to combat the

■ Due to the success of the show at

top ten short-term drivers for skills change in the UK automotive sector. These drivers include the ongoing challenge of filling vacancies and green initiatives and sustainability.

WWW.RDR.LINK/ABG001

Sandown Park in surrey, Mechanex PMM Live, the UK’s longest-running trade show dedicated solely to the independent aftermarket, has added another show for 2024 taking place at the Yorkshire Events Centre in Harrogate on the 16th and 17th of May. This is on top of returning to Sandown Park in Surrey on the 12th and 13th of November.

The show is free to attend so register your attendance now.

■ The IMI annual dinner and awards 2024 is being held on Wednesday 13th of March at the InterContinental London, Park Lane. The annual event aims to offer an opportunity to celebrate with your peers, family and friends, recognising the incredible talent, commitment and passion driving the sector forward.

■ The IGA has announced the date and venue for the BIG Awards 2024. The awards will take place at the Hilton Metropole in Birmingham on Friday the 20th of September. Building on the success of the 2023 awards, where prizes to the value of £50,000 were awarded to category winners, this year’s event promises to be even bigger.

8 MARCH 2024 PMM

In pictures: The automotive charity Ben has unveiled its bus, a branded VW transporter campervan, to increase the charity’s visibility out on the road and raise awareness of its support.

Right to repair campaign launch The IAAF has launched its Right to Repair Campaign aimed at highlighting the mobility choices available to motorists through the automotive aftermarket of suppliers, motor factors and garages.

Following the successful lobbying by IAAF as part of UK AFCAR, now is the time to take on a longer-term approach to raising awareness of our trade and the benefits of choice the automotive aftermarket provides. Through legislation, the aftermarket has secured important gains in the reviewed MV-BEO ensuring effective competition and choice for millions of UK motorists, which includes full access and

recognition for independent garages, parts distributors, suppliers and manufacturers to full repair and maintenance information and data from vehicle manufacturers. There are now significant improvements for motorists to benefit from, which are detailed in law, and clearer definitions to support the way vehicles are repaired and maintained.

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MESSAGE ME YOUR NEWS AT FCOLEMAN@HAMERVILLE.CO.UK

On yer

bike!

In pictures: GSF Car Parts executive chairman Sukhpal Ahluwalia shown piloting the motor factor’s green solution to navigating London traffic: electric delivery bikes from VOK Bikes!

Over 180 TMD Friction workers walk out in strikes over pay

NEWS IN

Nearly 200 workers from TMD Friction’s Hartlepool factory have gone on strike following a dispute that started last June, when a below-inflation 4 per cent pay rise was rejected.

Unite regional officer Mike Routledge, who represents all of the striking workers, said: “This dispute will not end until an acceptable offer is put forward.”

of garages in the UK have an apprentice on their books. This is according to aftermarket data from GiPA, which also found that 90 per cent of respondents said they find recruiting apprentices very challenging.

Win EV work from dealers “Now’s the time for the independent sector to step-up, showcase their expertise, and position themselves as the go-to destination for EV services. The demand for reliable EV servicing and repairs is still on the rise, so there’s a unique opportunity for independent garages to match and even exceed the service levels offered by the franchise dealer network. We’re soaking up a lot of work from all over the country. The dealerships are slow-moving when it comes to EVs so there’s an open goal for independents to offer an attractive alternative.”

NUMBERS

23%

46 of the 119 motorway ervices reviewed by the RAC using Zapmap met the target number of chargers above 50kW by the end of 2023. This means the government missed its target of having six or more chargers at every motorway service area in England.

39% Matt Cleevely from Cleevely EV garage urges independent garages to win more work from dealers after SMMT figures show that BEV uptake has risen almost 20-fold in the last five years.

of motorist will only replace tyres if their car fails an MOT according to research by eBay, which also found that 15 per cent of motorists admitted to ignoring advisory for their tyres following an MOT.

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ONLINE ROUND UP

W

ith the PMM brand and content expanding onto YouTube and our podcast and social media continuing to thrive, we’re online now more than ever. So, those of you not taking advantage of our website are truly missing out. With an array of technical articles, breaking news, and helpful business tips, it’s a great source of information right at your fingertips. If you haven’t already, the PMM website is also a great place to listen to our monthly podcast (WWW.RDR.LINK/ABG002). If you’re not already convinced, this month, PMM’s news and products editor, Freya Coleman, takes a look back at the most popular articles on the website from the past month.

Digital Digest!

The internet’s top

5

2 Transmission replacement Making the list once again this month is diagnostics expert Ben Johnson, this time tackling a tricky transmission replacement on a BMW 13 REX. WWW.RDR.LINK/ABG004

biggest test facing workshops in 2024.

You might have already seen this in the news segment of the magazine or been a part of the many that read the article online.

WWW.RDR.LINK/ABG006

1 Part swapping warning

3 Classics made modern

Kicking off this month’s list of popular online articles is Autoelectro, underlining the necessity of technical proficiency amidst the surge of sophisticated vehicle components.

As featured on the PMM Podcast, this next article is from Fellten talking about its kits (and assistance) available to workshops taking on a classic car-to-EV conversion. If you have any questions or curiosity on how this works, this article is the perfect place to start!

WWW.RDR.LINK/ABG003

WWW.RDR.LINK/ABG005

4 Rising costs Next up is The Motor Ombudsman’s annual service and repair survey, revealing that rising costs will be the

10 MARCH 2024 PMM

5 Clutch replacement Rounding off this month’s list of popular online articles is Schaeffler, providing us with another great clutch replacement guide. This time, a 2014 Range Rover Evoque 4X4 that is fitted with a 2.2 D engine.

WWW.RDR.LINK/ABG007

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READ ME TO COLLECT YOUR CPD POINT

CPD ZONE

W O N E R A U O Y ENTERING

PMM has teamed up with the CPD Group to offer you the chance to gain CPD points while you read every issue!

C

ontinuing professional development (CPD) can be broadly defined as any type of learning you undertake which increases your knowledge, understanding and experience of a subject area and your role within it. To help professionals to better document and prove this process, our new CPD Zone features articles that have been checked, verified and accredited by a thirdparty specialist organisation.

The content within the CPD Zone will provide you with 1 CPD Credit, or 1 hour’s worth of continuous professional development.

Once you have read through the articles contained within, you will be able to scan the QR code at the end of the last article. This will provide you with a downloadable certificate, personalised to you. This can then be used as part of your ongoing CPD record, as needed to satisfy various organisations and schemes. Regular readers of PMM, therefore, could earn 11 CPD points just by reading the magazine each month.

DO NOT SCAN THE QR CODE UNLESS YOU HAVE READ ALL OF THE CONTENT WITHIN THIS SECTION!

NEW USERS –

ACCESS YOUR BESPOKE CPD CERTIFICATE IN FIVE STEPS

CPD relies on self-certification, which in turn relies on professionalism and honesty from those who participate. We have great faith in the diligence and professionalism of our readers – we are called Professional Motor Mechanic, after all. It is fairly safe to assume that if you are picking up PMM each month, then you are already interested in reading and understanding technical content. Indeed, we are a lifeline for many in the industry who rely on us to spread the word on the latest changes and developments originating with the OEMs.

THIS PROCESS IS COMPLETELY FREE Don’t worry – you won’t have to pay a penny to gain your CPD points each month. It’s on us!

All certificates are valid for one year from the issue date. If you have any issues downloading the certificate or using the system please email us at: pmm@hamerville.co.uk

��� Read ALL of the articles within this month’s CPD Zone ��� Scan the QR code or enter the RDR.Link in your web browser – both are found at the end of the last article in this section ��� Enter your email address ��� Fill out your details on the contact form ��� Download your certificate for use as part of your annual CPD record

PREVIOUS USERS –

ACCESS YOUR CPD CERTIFICATE IN FOUR STEPS ��� Read ALL of the articles within this month’s CPD Zone ��� Scan the QR code or enter the RDR.Link in your web browser – both are found at the end of the last article in this section ��� Enter your name and email address ��� Download your certificate for use as part of your annual CPD record

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TROUBLESHOOTER Why was the BMW 635 not starting?

PMM ’s diagnostic dynamo Ben Johnson breaks out the Pearl Jam tapes and indulges in a gleaming BMW 635 in its twilight years.

A

s I dramatically skidded into the Schmiedmann car park last month, battling the elements like a gladiator in an automotive arena, little did I anticipate the spectacle that awaited me. In a sea of predictable BMWs, one machine dared to break the monotony—a regally defiant 1980s metallic brown classic, arrogantly staking its claim over two parking spaces.

Behold, not the mythic M635 CSI but the slightly less haughty 635 (sans M badge). It is a relic from an era when cars had character, not just cup holders. The sheer audacity of this vintage 6 series, lounging in all its 80s glory, left me more astonished than a caveman discovering fire and of course I dared to hope that the job, whatever that may be, would be given to me.

Getting started My anticipation only grew as I circled this automotive time capsule. It may not have been the rockstar M variant, but this handsome machine had a swagger and that shark nosed front end that whispered tales of open roads, cassette tapes and questionable fashion choices. The weather may have been miserable, but that classic BMW was a beacon of automotive splendour, daring anyone to defy its aura. In that moment, the mundane car park transformed into a stage and the 635 CSI, my unwitting co-star, stole the show.

I didn’t need to wait long for the afternoon to roll around when the job card was handed to me containing a more slimmed down key than the usual chunky key-fobbed variants – clearly this meant that I had been given the chance to repair something that I had no idea about or had ever worked on before. Little did I know what sort of rollercoaster this old car would send me on.

14 MARCH 2024 PMM

��� One of the finest cars ever made: The amazing BMW 635 CSI

With the determination of a conductor coaxing a symphony from an antique orchestra, my first order of business was to charm the venerable M30 engine into grumbling to life. The lazy starter, in protest, moaned like a worn-out troubadour, signalling a battery on life support – a clear consequence of the owner’s persistent attempts to kickstart the ageing heart of the machine. A tale as old as car ownership itself. To the car’s credit, she did start every time but sadly would cut out immediately. As for revving it – forget it.

Not happening. So, there we had it – it starts then stops. What a mystery.

Given its vintage stature in the realm of 1985, the absence of a lambda sensor, not even a rudimentary single-wire version, was glaring. As for fault codes, well, that's a pipe dream unless you happen to possess a Sun 2013 tester, a beast that was half of the length of the 635, weighing upwards of 200 kilos and dwarfing the vehicle it aimed to

diagnose. No high-tech shortcuts here—just the cold reality that my skills, untouched for nearly 28 years since I first wielded the spanners, were about to be summoned from their mechanical slumber. Time to roll up the sleeves and embrace the challenge, for this was a dance with the vintage, a tango with the past (Fig.1).

With the car reluctantly shoved into the workshop, my comrades grumbling in a symphony of discontent, I wasted no time slapping the battery charger onto the tired veins of the vintage lady. A surge of electrical vitality was just what the old girl needed.

In the spirit of desperate optimism, I attempted the “stomp test,” a term that I loathe but, alas, fits the motley scene. Much like the missing lambda sensor, reading flash codes seemed like chasing a unicorn. Disaster! No shortcuts here—time to roll up the sleeves and let the thinking cap work its rusty magic. It was a battle of wits with this wheeled enigma.

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Facing an automotive puzzle that transported me back to the days when flannel shirts were cool and grunge was all the rage – yes, the 90s – I found myself in the presence of an enigma last encountered during my college escapades in the department of motor vehicle engineering. Back then, it was an old Porsche that puzzled me; today, it's a different vintage beast with an engine bay that’s practically a nostalgia trip.

Among the familiar yet oddly distant components, the air flow meter stood out – a curious, over-engineered contraption that hinted at the complexities lying beneath the bonnet. Memories of college days flooded back, and I pondered the potential magnitude of the task at hand. This was no ordinary job; it was a journey back in time, a plunge into the depths of mechanical intricacies.

In my mind’s eye, I envisioned myself transforming into one of those seasoned lecturers from the past – those who, with a hint of oil-stained wisdom, could sniff tailpipes and adjust mixtures to stoichiometric perfection. The ghosts of old-school techniques from my early 90s education whispered in the recesses of my memory.

Uncertain if I could summon those lessons, I decided it was time to channel my inner vintage mechanic and give it a nostalgic go.

��� Unless you have a machine the size of a garden shed, you may as well forget about connecting anything to this diagnostic socket

Upon diving into the heart of the matter, my first gaze fell upon the fuel pressure, seemingly holding steady at 3 bar. Yet, the real revelation came when, armed with plastic hose clamp pliers and the indispensable assistance of a colleague, I clamped down on the return line from the pressure regulator on the injector rail. Lo and behold, the idle perked up, but alas, the throttle response remained anaemic, as if it had taken a vow of non-existence.

These engines, usually content with a cozy 3-bar fuel pressure, decided to throw a classic tantrum, bleeding off occasionally to a lacklustre 2 bar. Sensing the need for a sage move, I opted for the surgical replacement of the fuel pressure regulator, swapping in a Pierburg type. A decision that

paid dividends, for post-transplant, the old girl grudgingly settled into an idle. Yet, the spectre of troublesome idling and a throttle response on life support lingered, as persistent as an unwanted guest. The mechanical saga continued.

In the uproarious symphony of our workshop, an hour into the relentless quest for engine enlightenment, I nearly overlooked the subtle yet grating hiss of unwanted air.

While feverishly toying with the throttle cable and the engine armed with the freshly sourced fuel pressure regulator, my ears finally tuned into the disconcerting sound.

In the quirky realm of these cars, air flow meters display a chameleon-like flexibility, working contentedly in either orientation— aluminium side up or the more conventional plastic-side-up arrangement. Imagine my disbelief when, probing beneath where I assumed an aluminium base should be, my hand encountered nothing but the exposed inner machinations of the mechanical air flow flap. The bottom of the air flow meter had vanished without a trace! (Fig.4).

��� Not something you see every day: The bottom missing from an air flow meter

��� I hadn’t fault-finded an engine housed in a vintage bay such as this since the 1990s, when they were far from vintage.

I was out of my comfort zone but one night spent on Google armed me with as much information as I needed to tackle this troublesome M30 engine

Despite a thorough search in the engine bay's deepest recesses yielding nothing, I took matters into my own hands. Crafting a makeshift base for the airflow meter from laminated cardboard, generously coated with silicone glue, seemed like a dubious yet necessary endeavour. Installing this jerryrigged contraption, I was met with astonishment as the engine now revved with newfound gusto! However, the celebration was short-lived, for the emissions declared war on decency. Running richer than a top fuel dragster and idling more chaotically than a cammed café racer, the raw fuel spewing from the tailpipe transformed our workshop

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CPD ZONE

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��� Undeterred I decided to make a temporary bottom just to see if the car would at least rev up normally.

Thankfully, my handiwork paid off

into a symphony of combustion chaos. The saga continued, now with a touch of cardboard ingenuity (Fig.5).

Having crafted a rather nifty new bottom panel for our sorry-looking airflow meter, I was delighted as the engine roared to life.

Yet, the spectre of a dismal idle still haunted the proceedings. Upon yanking out the airflow meter once more, I discovered the culprit—a flap scraping against the casing.

With time breathing down our necks, the decision was swift: source a used unit.

A week later, the used arrival looked more like a relic from a vehicular graveyard than a saviour. Undaunted, I slapped it on, and the car begrudgingly sputtered to life, still drowning in an excess of richness. In my quest to unravel the mysteries of emissions on this vintage beauty, an online archive safari ensued.

Jackpot! A document from the ‘80s revealed that the “new” air flow meter CO adjustment screw had been cranked clockwise, settling at the richest mixture setting possible. A few, three to be precise, anticlockwise turns and we found ourselves in the middle position.

Now, it was a dance of fine-tuning until stoichiometric bliss. But lacking a fancy emissions tester, my nose became the reluctant judge and the car still exuded the pungent aroma of unburnt fuel.

Removing the oil cap on this engine, if it was running perfectly would make it run lean and it would start to hunt. Removing the oil cap on this engine actually made it run perfectly – a tell-tale sign that it was indeed running super rich. Removing the oil cap (Fig.6) had allowed enough post air flow meter air to make the mixture closer to stoichiometric.

16 MARCH 2024 PMM

��� Stoichiometric-like running smoothness achieved by removing the oil cap

��� Old school meters require old school solutions – a turn from the base position marked in blue marker pen around six teeth clockwise solved this problem

���

Undeterred, I pulled out the airflow meter once more, realising the flap was so slack it hardly bothered to return. Armed with ancient wisdom from online archives, I tightened the spring tension on the elusive dial inside the air flow meter. The results were pure magic— super-smooth idle, and the noxious cloud of raw petrol at the rear dissipated into the ether.

Overjoyed and over the moon, I revelled in the triumph of employing old-school techniques that worked like an absolute charm! (Fig.7).

With the old girl now idling like a beauty and the exhaust less likely to upset a climate activist it was time to hand her back to the owner. Sadly, the car came on a trailer with summer tyres on so the usual post-repair road-test would be out of the question. I have to say that I will really miss this wonderful car with its quirky character and fine leather interior (Fig.8). It was testament to a bygone era that we will never see again and that fills me with a tinge of sadness. However, next spring I will service her after a deep winter’s slumber so I may finally get the chance to take her on that elusive test-drive after all.

WANT TO KNOW MORE? FOR MORE INFORMATION WWW.RDR.LINK /ABG008

They don’t make interiors this cool anymore!

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COMMON FAULTS Issues with accurate engine timing Contitech discusses the need for electronic timing setting when installing the CT1167 timing belt as well as all associated kits for Audi, Seat, Skoda and VW. Various 1.0–1.6L TSI and EA211 models with electronic camshaft adjustment.

Problem When fitting the timing belt, the bolts for the camshaft adjustment (Fig.1) must be loosened. After belt replacement the timing and lead angle for the electronic camshaft adjustment are not set accurately enough with the mechanical locking tools.

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Cause A new combustion process means that the intake valves can be closed very early on with this engine while the intake stroke is still in progress. Loosening the bolts for the camshaft adjustment can cause the timing to be set incorrectly or inaccurately, which has a major effect on mixture preparation.

The VAS 611 007 tool is capable of setting the camshaft angle so that it is accurate to one tenth of a degree (Fig.3).

Additional time allowance for the setting work: approx. 2.5h.

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Solution The basic setting needs to be programmed and adjusted electronically using testing tool VAS 611 007 (Fig.2).

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��� “The VAS 611 007 tool is capable of setting the camshaft angle so that it is accurate to one tenth of a degree.”

18 MARCH 2024 PMM

There are two different adapters for the tool (Fig.4): ■ Tool VAS 611 007/8 for three- and fourcylinder TSI units without Active Cylinder Technology ■ Tool VAS 611 007/4 for four-cylinder TSI units with Active Cylinder Technology WANT TO KNOW MORE? FOR MORE INFORMATION WWW.RDR.LINK /ABG009

019_PMM_MAR24_Layout 1 01/02/2024 11:11 Page 1

COMMON FAULTS Where was water entering the 2016 Lexus RX? Autodata rescues a garage all at sea over a mysterious case of water ingress in a customer’s Lexus RX’s load area.

The problem:

What does Autodata recommend?

“We are having a problem finding the source of a water ingress on a 2016 Lexus RX. The load area carpet is wet after heavy rain. We have checked the tailgate weather seal for any signs of damage and checked the tailgate drain holes for blockages but all seems OK. We have carried out several water tests but cannot see how the water is entering the vehicle. Have you got any advice for us?”

The problem you have described has been reported by other Lexus RX owners with models built up to 09/18. The water ingress is through the rear spoiler weather seal which is deformed due to excessive vibration. Remove the rear spoiler and fit new rear spoiler weather seals. To prevent re-occurrence of the fault, fit modified rear spoiler vibration damper pads, available from Toyota parts department, positioned as shown. Refit the rear spoiler, ensuring the weather seals are not deformed during fitment. Dry out the vehicle as necessary.

WANT TO KNOW MORE? FOR MORE INFORMATION WWW.RDR.LINK /ABG010

020_PMM_MAR24_Layout 1 01/02/2024 11:12 Page 20

CPD ZONE

READ ME TO COLLECT YOUR CPD POINT

HOW TO Replace the clutch on a Nissan Juke 1.5 dCl In this month’s Schaeffler LuK clutch feature, REPXPERT Alistair Mason is replacing the clutch and dual mass flywheel (DMF) on a 2011 Nissan Juke 1.5 dCI. The vehicle has been booked in due to a very heavy clutch pedal, after some initial diagnosis, gearbox removal was advised and authorisation given.

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��� VEHICLE INFORMATION

Workshop equipment ■ Vehicle lift – (two post is ideal).

■ Engine support.

■ Transmission jack.

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20 MARCH 2024 PMM

Nissan

Model:

Juke

Year:

2011

Engine:

1.5

Schedule time:

4.9 hours

■ Clutch alignment tool.

Note – Prior to the repair, ensure you have the locking wheel bolt key if required.

Gearbox removal

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Manufacturer:

With the vehicle placed on the lift, open the bonnet and remove the following items – engine cover, battery and battery carrier (Fig. 1), air filter assembly and air filter ducting, this now gives better access to the top of the gearbox. Remove the gear position switch multiplug and gear change cables (Fig. 2), there is now better access to remove the upper bell-housing bolts. Remove the hydraulic clutch pipe from the concentric slave cylinder (CSC) connection and if possible blank the pipe to stop the fluid running out.

Raise the vehicle lift to gain access to the underside and remove the engine under-tray, this is a good time to remove the gearbox oil drain plug and allow the oil to drain, lower the vehicle to waist height, remove both front wheels and both front hub nuts (Fig. 3), remove the N/S wheel arch liner; this now gives access to remove the gearbox earth lead (Fig. 4) and unclip the wiring loom.

We now need to remove or lower the front subframe to give clearance to remove the gearbox, disconnect the anti-roll bar links, bottom ball joints, remove the driveshafts, remove the steering rack to subframe bolts and support the steering rack, remove the engine to subframe pendulum mount, remove the starter motor bolts, support the engine, remove the four subframe bolts and lower the front sub-frame.

020_PMM_MAR24_Layout 1 01/02/2024 11:14 Page 21

With the aid of a ladder, remove the gearbox mounting accessed from the engine bay, support the gearbox with a transmission jack, remove the lower bell housing bolts, lower the engine and gearbox slightly, ease the gearbox off the clutch and away from the engine, when clear lower the gearbox and remove from the vehicle.

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Clutch removal and replacement Remove the nine clutch bolts from the pressure plate and remove the clutch assembly. At this point the clutch was examined and it could be seen that the clutch was near the end of its service life as the clutch lining had worn close to flush with the lining rivets (Fig. 5), due to this the clutch diaphragm fingers would not be operating in their optimum position and therefore giving a heavier feeling clutch pedal.

The customer had authorised replacing the dual mass flywheel as advised as best practice, so a LuK RepSet DMF was the chosen repair solution as it contains all parts required for the repair.

Remove the six DMF retaining bolt and remove the DMF, inspect the rear of the engine for any leaks, rectify as required and then clean the back of the engine with clutch and brake dust cleaner to avoid any contamination of the new clutch and DMF assembly.

Mount the new DMF onto the crankshaft and insert the new bolts, tighten in an even and sequential manner and torque to the manufacture’s specification and when correctly torqued, degrease the DMF face with clutch and brake dust cleaner (Fig. 6).

We now turn our attention to the gearbox and the release system, remove the two CSC retaining bolts and remove the CSC, check for any leaks, also check for any play in the gearbox input shaft and then clean the bellhousing with clutch and brake dust cleaner.

Carefully mount the new CSC taking note of the service information with reference to the clutch pipe grommet, insert the two CSC retaining bolts and torque as required (Fig. 7).

Apply a light smear of high melting point grease to the splines on the gearbox input shaft and then mount the new clutch plate onto the input shaft, this will confirm the

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clutch plate is correct and also evenly distribute the grease, remove the clutch plate and wipe off any excess grease.

Now fit the new clutch onto the DMF, mount the new clutch plate onto the DMF ensuring “gearbox side” is visible (Fig. 8) and then align using a clutch alignment tool, degrease the clutch pressure plate surface with clutch and brake dust cleaner, position the clutch pressure plate onto the DMF alignment dowels, fit and tighten the nine clutch bolts in an even and sequential manner, torque to the manufacturer’s specification and then finally remove the clutch alignment tool.

Before fitting the gearbox, ensure the engine to gearbox alignment dowels are positioned correctly and that all cables etc. are clear of the bellhousing area to aid gear-box fitment.

It is always best practice to flush the old clutch fluid out of the hydraulic system and refill with new fluid of the correct specification.

Gearbox installation Place the gearbox onto the transmission jack, raise the jack; when the gearbox is close to the engine, spend a little time aligning the gearbox, ease into position and then onto the alignment dowels. Insert and tighten a couple of easily accessible bellhousing bolts. Using the jack, raise the gearbox and install the gearbox mounting, the engine support and transmission jack can now be removed and then all parts can be fitted in reverse order of removal. When bleeding the clutch, the bleed system has a two position CSC connection (Fig. 9), position one opens the bleed nipple and when the connection is pushed against the gearbox casing the bleed nipple is closed, in this instance the connection was eased back to position one and the hydraulic system was vacuum bled. Remember to refill gearbox oil with the correct grade and amount of oil and to reset all affected electrical consumers, always carry out a full road test to ensure a quality repair.

WANT TO KNOW MORE? FOR MORE INFORMATION WWW.RDR.LINK/ABG011

PMM MARCH 2024 21

FULL PAGE_Layout 1 31/10/2022 17:05 Page 1

THE

PMM PODCAST WHAT DO CHANGING A BATTERY, CHANGING A BABY (JUST THE NAPPY) AND CHANGING YOUR MORNING RADIO STATION ALL HAVE IN COMMON? THEY OFFER THE PERFECT OPPORTUNITY TO LISTEN TO THE PROFESSIONAL MOTOR MECHANIC PODCAST WITH KIERAN NEE. HEAR ADVICE ON PRICING JOBS, MANAGING PARTS SUPPLY, ELECTRIFICATION, RECRUITMENT AND MUCH MORE.

LISTEN NOW ON YOUR PODCAST PLATFORM OF CHOICE

Listen on

Listen on

Listen on

Listen on

Google Podcasts

Amazon Podcasts

Spotify Podcasts

Apple Podcasts

023_PMM_MAR24_Layout 1 01/02/2024 11:16 Page 23

READ ME TO COLLECT YOUR CPD POINT

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CPD ZONE

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DIAGNOSTIC GUIDE Using Bosch’s ESI[tronic] 2.0 software: a monthly guide

Your path to diag success !

Last month in our guide to Bosch’s KTS diagnostics software, ESI[tronic] 2.0, we looked at RMI manuals, this month we look at the benefits available when evaluating the ‘actual values’ of a system. An essential source of information for automotive system diagnosis and analysis, ‘actual values’ (AVs) are the variable data parameters that have been processed by the ECU.

A

ctual Values offer a useful representation of the state of an ECU system based on data collected from the sensors or switch input signals and the component outputs on the vehicle. You can use Bosch ESI[tronic] 2.0 to display the information in a variety of formats while also saving the results for benchmarking and comparison.

Once you have connected the Bosch KTS to the vehicle and selected the relevant system, ESI[tronic] 2.0 will offer you ‘actual values’ in the function selection screen if the ECU in question supports this type of data transfer (Fig.1). Remember, an AV can either be a numerical value of measurement, such as ‘control module supply voltage: 12.9 volts’, or alternatively an input or output condition

like ‘drivers door status: door open’. The system continually refreshes the on-screen data stream to make viewing any changes in condition that are recognised by the ECU and visible in ESI[tronic] 2.0 simple.

Finding the right AV faster Modern vehicles’ ECUs can support hundreds of AV parameters. ESI[tronic] 2.0 simplifies the process of selecting the right AV by providing an ‘actual value group’ selection screen in some cases, and notably these ‘actual value groups’ help you to find exactly what you need, faster (Fig.2).

The ‘actual value’ search bar is another quick and easy way to efficiently search the list of AVs by key word. Simply type straight into the search field to filter the AV list to

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only show values that contain the text you have entered instantly (Fig.3).

Following your search, you can choose any of the required AVs to be displayed for comparison purposes. Up to eight different AVs can be displayed together and a ‘tick’ symbol in the box on the left confirms your selected values.

If you are using a computer with a keyboard, a handy tip for selecting values from the list is to use the up and down cursor keys to scroll through the list and the space bar or left/right cursor keys to select or deselect the highlighted value name.

Once you have made your selection, clicking ‘continue’, pressing F12 or hitting the enter key, will show you the values on screen in a text format. Each AV will have

��� PMM MARCH 2024 23

023_PMM_MAR24_Layout 1 01/02/2024 11:17 Page 24

CPD ZONE

READ ME TO COLLECT YOUR CPD POINT

��� the name, value, unit and possibly a hint such as “allow engine to idle” displayed. At this point, you will see the value changing as the parameter data is refreshed (Fig.4).

Using the ‘save F2’ soft key at any time will add the data on screen to the job protocol.

After some time has elapsed, pressing the F3 soft key when viewing the AVs will allow you to cycle through the maximum, Minimum and current values collected since the data stream was started – a very helpful tool if you are looking for a value that is operating outside of its expected threshold.

For example, if the turbo of an engine system was over-boosting on a road test then you will see, via the F3 maximum key, that the tolerance boost value was exceeded at some point. Without having to constantly monitor the changing value stream you may identify a momentary value that could have otherwise been missed.

You will also notice that there are up and down arrows on the right side of the screen that will enable you to scroll to the next or previous values from the AV list.

The time base can also be adjusted between 5 to 60 seconds to zoom in or out of the graph on screen. Pressing the ‘pause’ key will stop the data collection at that point and the buffer memory will store up to approximately the last six minutes, depending on how many values were selected (Fig.5). Allowing you to play back the capture in a sequence – or scroll through the data screen-by-screen – and then zoom into millisecond detail if needed (Fig.6).

The information you need Benchmarking against expected values Sometimes when investigating a fault on a vehicle there is a physical symptom present, but no diagnostic trouble codes stored. If you decide to investigate the AVs of the system for any anomalies and you have a valid licence for ESI[tronic] 2.0 manuals, you can now click on the blue underlined AV name to see the functional description of the associated component and any expected values for the conditions. A favourite AV feature included in ESI[tronic] 2.0 is the ‘F6 - time profile’ soft key. By changing the display of AVs to a colourful graphical format that plays across the screen you can configure the data presented to best suit your requirements.

It is easier to identify a problem when you can clearly see the relationship between components in operation together. Depending upon the system and fault that you’re investigating, the applicable values can be viewed together in one graph. For example, the accelerator pedal position, air mass meter flow, EGR valve actuation and boost pressure on a common rail diesel engine during acceleration.

Clicking ‘F4 save’ during an AV time profile will take a static screen capture of the data graphing on screen and add it onto the protocol report which can be saved and printed off for reference.

Along the bottom you will notice an icon that looks like a floppy disk symbol, called ‘data recording’, which will save a flight

recorder style file of the current time profile data collection. You can save, open, review and play back the data recording at any time.

A useful feature if you are searching for an intermittent fault and wanted to first record the event occurring out on the road and later view and analyse the results back in the workshop. The file at that point will be saved in the ‘recordings’ tab (found in the ‘main menu’ under the ‘protocols’ section) (Fig.7).

Finally, you can also add important information, such as customer and vehicle reference, to be able to later identify the job associated with the file. The ‘actual value’ display features described in this article can be highly useful in automotive system diagnostics by allowing you the versatility to view and store the data from the vehicle in different ways.

Next month we’ll be discovering how ESI[tronic] 2.0 can help you overcome stringent and commonplace secured diagnostic outputs to provide customers with a full service.

WANT TO KNOW MORE? FOR MORE INFORMATION WWW.RDR.LINK /ABG012

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24 MARCH 2023 PMM

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CPD ZONE

READ ME TO COLLECT YOUR CPD POINT

KNOW YOUR PARTS Transmission Oil febi explores the important role transmission oil plays in manual and automatic vehicles.

T

he engine creates the energy of the vehicle, which is used by the transmission to power the wheels.

Every transmission type relies on the quality of the oil designed to fulfil the most extreme requirements, allowing the driver to be confident that all the power of the engine is transferred to the road.

With the continuous evolution of automotive technology, transmissions have become more complex and, in turn, require more technologically-advanced fluids to ensure they operate with efficiency and reliability.

The transmission is one of the vehicle’s most vital components, with numerous finelyengineered precision parts making it one of the most complex and expensive units to repair or replace. Using the correct oil and replacing it at the correct time is key to preventing transmission problems such as ‘shudder’, gear stiffness and axle whining.

Damaging components before these issues occur can result in possible premature and expensive transmission failure.

Manual transmissions Manual transmission oil plays an extremely important role in the correct operation of the transmission as it will keep it lubricated and protected from heat and wear. The additives are combined with the base oil during the production process to increase the following main functions: Thermal Stability: Operating at high temperatures, gear oil must remain thermally stable to reduce the build-up of sludge and maintain efficiency. A gear oil that cannot withstand the temperature of the application it is used in will have decreased power and wear and tear will occur much sooner.

Extreme Pressure (EP) additives: These help protect the gearbox in conditions where extreme pressure and shock-loading will occur.

26 MARCH 2024 PMM

Choosing the correct oil

Contamination and Corrosion: This is to combat any contaminants that may enter the system. Gear oil will need to contain anticorrosive, anti-oxidation or anti-foaming agents. These additives perform best in environments with high speeds and low loads.

Automatic transmissions The various automatic transmission types are designed to control and optimise gear-shift quality and ‘feel’, with transmission oil playing a major part in this.

This allows the gear shift to operate completely smoothly and efficiently – made possible by using sophisticated ‘additive packs’ within the base oil.

Direct-shift, continuously variable, automated manual and traditional torqueconverter automatic transmissions are engineered to give seamless gear changes to make driving easier. By not having to make the decision of when to change gear, the driver can concentrate on traffic and road conditions. These sophisticated transmissions require quality oil to keep the operating systems running smoothly and its computercontrolled control unit operating within very fine engineering tolerances.

Transmission oil is not just a lubricant – it is a vital component which optimises gear-shift quality and ‘feel’, providing excellent friction behaviour thanks to its thermal stability. It also gives ageing resistance – ensuring wear protection in all operating conditions and guaranteeing the best possible corrosion defence.

Selecting the correct replacement oil specification is vitally important to safeguarding transmission operation as designed, and to maintain its performance throughout the lifetime of the vehicle. All febi transmission oils have the oil viscosity rating and vehicle manufacturer specifications, plus recommended applications, written on the label to identify the suitability of each oil.

To ensure a transmission’s long life and smooth operation, febi recommends that regular transmission oil servicing is carried out to the vehicle manufacturer’s recommended intervals, subject to the operating conditions of the vehicle.

WANT TO KNOW MORE? FOR MORE INFORMATION WWW.RDR.LINK /ABG013

REDEEM YOUR CPD CREDIT Congratulations, you have reached the end of the CPD Zone! To access your CPD credit from The CPD Group, scan the QR Code or WWW.RDR.LINK /ABG014

Project4_Layout 1 11/02/2020 09:29 Page 1

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A look inside:

THE

PMM PODCAST

the best bits

The PMM Podcast is back this month with an in-depth look at fake parts on the market. It’s a hot topic right now with the cost-of-living crisis refusing to go away and we expect the episode to be essential listening for workshops up and down the country. While we’ve been busy beavering away on that episode (and future episodes of course), we thought we’d share with you some of the best bits of the podcast so far. Enjoy!

Tina Drayson, CCM

Episode two: How to Price Jobs Right Trade rate discounts: Don’t give them. As a garage, what we sell is our labour. You’ve got to consider also that some garages out there specialise in certain things like diagnostics, so a lot of what they do is for other garages and not necessarily for the general public. If 80 per cent of their work is for other garages, that means they’re discounting 80 per cent of their work.”

Bob Rollins,

garage owner Episode two: How to Price Jobs Right Going to a garage, you’re paying for years of experience.

If you’re a doctor, for example, you do so many years’ training.

If you’re a solicitor, you do so many years’ training. But we don't charge anywhere near like a solicitor or a doctor, but we’re still mending cars.”

28 MARCH 2024 PMM

Gavin White, Autotech Recruit Episode three: Finding the car technicians of the future Interestingly, asked them a very simple question, which was Why did you leave your previous job? If you ask the same question to an employer, the response is ‘they're moving for 50p an hour more’ but actually of the technicians we were talking to, about 74 per cent of them said the reason they left their previous job was broken promises around training.

I still walk into garages every day and it is like stepping back in time. It's like 20, 30 years ago when I was in a dealership, and you think, really? We're sitting here with cars that can drive themselves, talk to satellites, be controlled from anywhere in the world and we can't even be bothered to print off an employment contract for someone?”

TO LISTEN TO ALL OF THE EPISODES SO FAR ON THE PLATFORM OF YOUR CHOICE, SIMPLY SCAN THE QR CODE

028_PMM_MAR24_Layout 1 01/02/2024 14:36 Page 29

Neville Smith, garage owner Episode five: Fighting for the Right to Repair

Nigel Bottom, Witham Group Episode nine: All About Oil

It’s a competitive market and I feel that if the dealers were to exclude us from the repair sector, they would not manage to repair the cars on the road. Already we are finding that with some vehicles, customers are getting upset

because they can’t get logged in with a dealer for weeks. In some cases, that’s months. They have the right to choose who repairs their car and when it’s repaired, they shouldn’t be strung out and held to ransom by a dealer.”

Nick Lyes, RAC Episode ten: MOT Madness The government’s line is that the vehicles we drive today are completely different from vehicles we drove, say, 30, 40 years ago. Vehicles generally are more reliable, but that’s mechanically more reliable.

When you look at the aspects of the MOT you are looking at things like suspension, brakes, tyres... and all of those things haven't really changed in the last

30, 40 years. Those are still big areas that can be affected by things like the weight of the vehicle, the state of the road and, of course, the way people drive.

So it’s really vital that those components are continually tested as we do today. When you look at the failure rates of MOTs, for example, lighting, suspension, brakes, tyres all make up the biggest proportion of failures.”

Chris Hazell, Fellten Episode thirteen: Classic Cars: The Comeback The whole thought process behind it is that classic cars are here to stay. They’re getting older and they're going up in value continually, becoming works of art. However, people never drive them because they're worried they’re going to break down. We’ll take a classic vehicle, remove the engine and gearbox after it’s been

쑿 PMM Editor Kieran Nee channelled his inner Clarkson at Fellten last summer with CEO Chris Hazell

weighed and then we’ll design and develop a battery and a drivetrain that drops into the original space.

The main focus is to maintain the weight as close as possible and keep the weight distribution the same, but also make it so it’s bolt-in so it can be put back to original in the future.”

The cost is relatively small in the grand scheme of a vehicle now costing 30, 40, 50,000 pounds. Realistically it's probably got 50 pounds’ worth of oil in it, which will last up to two years. Selfishly, the one commodity that again, moves the vehicle on, helps with its fuel economy, keeps it quiet, reduces its temperature, does all the other wonderful things that lubricants do, is less than the rubber mats

that keep the carpet clean, which only lasts two years as well.”

Alex Lindley, Garage Hive Episode twelve: Striving for Success When you look at the data from a high level view without drilling down, and when I say drilling down, I mean like splitting between fuel types and registration years, in that case what the government has suggested makes perfect sense. That combined with what European countries do – it’s all very sensible for the

public. And, yes it’s true that cars are getting more reliable. I appreciate that. However, you’re wearing out items like brake pads and tyres – they're always going to wear out at the same rate, but the fact is that first time cars coming for their first MOT test are passing more than they were a few years ago.

But when you look at the data taking into account the year a vehicle was registered, EVs fail more than petrols,

which I personally didn’t expect to see. Not by a lot, but they are failing more.”

Louise Baker, Womanic Episode fifteen: Women in the Workshop When I first started out, let’s say I’ve done a lower arm on a car. I’ve been known to sneak out at like two, three o’clock in the morning back to my customer’s house and got on the floor, under the car. I’d just double check that I’ve pinched the wheel box up.

It’s just pure paranoia.”

PMM MARCH 2024 29

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031_PMM_MAR24_Layout 1 01/02/2024 16:41 Page 31

BUSINESS

& TRAINING

MOT Standards and compliance focus With the DVSA clamping down on poor performing MOT stations, maintaining a high standard has never been more important. Autotech Training’s Rob Walsh discusses.

T

he pressure on MOT testing stations is reaching unprecedented levels with the DVSA reporting an average of 642 vehicles per MOT test station in the UK and projections suggesting that, by 2045, there could be a staggering 45 million cars on British roads.

This surge in vehicle numbers intensifies the need for more MOT testing centres across the UK. The other challenge is ensuring the industry upholds stringent standards, thus ensuring the safety and roadworthiness of the ever-expanding fleet of vehicles on UK roads and motorways.

Data from the DVSA’s recent freedom of interest request also revealed an increase in the number of rogue MOT testers in the UK. In total, 687 MOT testers were disqualified in 2020 to 2022 financial years, a rise of 49 per cent compared to the two years previous (2018 to 2020).

AI-driven inspections The DVSA is increasingly adopting technology, and more specifically, artificial intelligence, to conduct intelligent inspections of authorised garages. This datadriven approach aims to identify and eliminate rogue testers and sites that fall short of the required standards. The result has been a noticeable increase in the banning of poor-performing testers over recent years, indicating a more proactive stance from regulatory bodies.

MOT testing stations should be using technology to streamline compliance processes and monitor data.

Rob Walsh, head of MOT Autotech Training

“This surge in vehicle numbers intensifies the need for more MOT testing centres across the UK. The other challenge is ensuring the industry upholds stringent standards.”

Amidst these developments, the significance of maintaining high standards within MOT testing stations cannot be overstated. The recent crackdown by the DVSA on testers failing to complete their annual assessments on time is a clear signal that compliance is non-negotiable. MOT testers must remain current and on top of their continuous professional development (CPD) to meet the evolving demands of their profession and contribute to a safer road environment.

This responsibility doesn't rest solely on the shoulders of individual testers but extends to garage owners, especially those managing multiple sites. They must scrutinise MOT data meticulously to identify skills gaps and manage processes effectively. Complacency in this regard could have severe consequences, including potential financial losses and, in extreme cases, the closure of businesses.

Online solution With so much advanced technology at their fingertips, MOT testing stations now have the opportunity to leverage the tools available to streamline compliance processes and monitor data effectively to spot and react to any red flags early.

A good illustration can be found in Autotech Training’s MOTsafe, which not only meets the increasing industry demand for complete compliance but also aims to goes beyond by offering a proactive solution to mitigate potential risks.

WANT TO KNOW MORE? FOR MORE INFORMATION WWW.RDR.LINK /ABG014

PMM MARCH 2024 31

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BUSINESS

& TRAINING

Website, booking and management in ONE place MAM Software now offers workshops the opportunity to streamline online booking within Autowork Online.

M

They’ll set up your new website, configure the services and pricing, then connect it to Autowork Online. They manage any website changeovers from existing providers and provide hosting and ongoing support. Garages can rest assured that help is available to them throughout every step of their new website journey.

AM software has announced a collaboration with Vitara Commerce, introducing Autowork Online customers to its online booking solution, “Bookar”. This partnership provides Autowork Online users with access to enhanced capabilities within their garage and workshop management software. The collaborative solution allows customers to benefit from online appointment scheduling whilst providing a comprehensive approach to garage and workshop management.

Advantages

Website help By integrating Autowork Online with Bookar, garage customers can access instant online pricing and appointment scheduling for services such as MOTs, common repairs, maintenance and tyre services. Bookar replaces the business’ existing website and is adaptable to the specific needs of each garage. Web design and content customisation options ensure that every garage’s online presence is personalised. Websites are search engine optimised, whilst supplementary digital marketing plans are offered as add-ons to enhance visibility and reach.

This integration enables real-time display of appointment dates and time-slot availability on the website. Moreover, it automates the creation of online bookings in Autowork Online, streamlining the entire process for businesses and customers alike.

Getting started with Bookar is easy.

32 MARCH 2024 PMM

By integrating Autowork Online with Bookar, garage customers can access instant online pricing and appointment scheduling for services such as MOTs, common repairs, maintenance and tyre services.

The introduction of Vitara’s Bookar tool with Autowork Online demonstrates MAM Software’s dedication to delivering advanced solutions for the automotive market.

Businesses looking to enhance customer experience and stay ahead of competition can take advantage of the “futureproof” system.

“We’re thrilled to bring this integration to our Autowork Online customers,” explains Nathan Fothergill, sales manager at MAM Software. “Our goal is always to streamline operations for our customers and keep them ahead of the curve in the automotive industry.

The features Bookar offers, such as real-time scheduling and online booking options, will allow them to optimise processes to their greatest potential. This will give garages and workshops an opportunity to fully embrace the online market.”

WANT TO KNOW MORE? FOR MORE INFORMATION WWW.RDR.LINK /ABG015

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ADVERTORIAL

Themed “Merch Up Your Store”, BILSTEIN aims to create an attractive workshop.

MERCH UP YOUR STORE! HIGH-QUALITY BILSTEIN MERCHANDISE FOR THE WORKSHOP BILSTEIN stands for vehicle dynamics and optimum driving experience. Now workshops can benefit from the passion for perfect shock absorbers with an exclusive merchandise package. The limited packages are free of charge and include: ● Unique BILSTEIN metal sign with a retro look ● Large BILSTEIN workshop banner in the size 300x100cm ● Striking counter display with an informative brochure

Themed “Merch Up Your Store”, BILSTEIN aims to create an attractive workshop – for a professional customer experience and to cheer up the staff.

Next to top-of-the-line merchandise, the updated brochure helps in consultations and in generating additional business.

It does not only provide a good overview of the various BILSTEIN products, but also illustrates why it is worth opting for premium suspension technology.

MORE INFORMATION THE NUMBER OF MERCHANDISE PACKAGES IS LIMITED, SO INTERESTED WORKSHOPS SHOULD BE QUICK. THE LINK FOR FREE REGISTRATION LEADS DIRECTLY TO THE PROMOTION PAGE: WORKSHOP.BILSTEIN.COM/EN/ MERCH-UP/

1 BWWW.FACEBOOK.COM/BILSTEIN.UK D WWW.INSTAGRAM.COM/BILSTEIN_OFFICIAL FWWW.YOUTUBE.COM/BILSTEINDE ICAMPER.BILSTEIN.COM IWORKSHOP.BILSTEIN.COM PMM MARCH 2022

PMM grid_Layout 1 27/11/2023 16:20 Page 1

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ONLINE REPORT

Audi A4 covered on

Online Thanks to PMMOnline, technical guides have never been easier for technicians to access. With no need to sign in, pay or subscribe, PMMOnline offers an invaluable and simple-to-use resource for the aftermarket. Let’s take a look at some technical guides in our extensive digital archive.

This month, we do a spot of fault-finding on the Audi A4.

Scantec resolves an Audi power fault Scantec’s Ross Kemp is on the case to solve an ongoing problem concerning an Audi A4 FSi frequently losing power, with the engine even cutting out completely at times.

Recently, a customer brought into us a slightly ageing, but much loved, Audi A4 FSi. The owner reported symptoms of intermittent but frequent engine malfunction warning lamp with subsequent loss of power and, on occasion, the engine cutting out.

Unusually, this job was accompanied by a very long and detailed letter from the owner outlining the history of the problem over the last 12 months.

Detailed attempts to rectify this issue included multiple fuel filters, fuel system flushing, replacement throttle pedal, spark plugs and they had even had the engine control module sent away for bench testing.

Investigating the fuel pressure As with the beginning of every diagnostic assessment, we started with a full systems fault scan and visual inspection. Initial diagnostic results showed a generic noncylinder specific misfire fault

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code (16698) and a fuel pressure regulation fault (17428). Visual inspection also confirmed a nongenuine fuel filter.

Knowing that any possible fuel pressure issue could alter the cylinder’s air/fuel ratio (therefore affecting combustibility and having the potential to cause a misfire), we decided to investigate the fuel system first.

Initial checks via live data confirmed the high-pressure fuel system’s demanded and actual pressures matched. Cracking out the low-pressure fuel gauges and being conscious of the non-OE fuel filter, we checked the fuel supply pressures before and after the fuel filter. This confirmed that not only was the pressure delivered from the in-tank electric fuel pump within specification but there was almost no drop in pressure across the fuel filter.

So far so good, however as it stands all the testing has taken

place in the workshop and as such we really haven’t put the engine under any real load. As we still suspected a fuel pressure and/or delivery issue we opted next for a really quick but effective test.

Checking the O2 sensors We initially monitored both O2 sensors’ operation (in the workshop) to confirm both sensors were operational and correct and could therefore be relied upon to report the actual fuelling state of the engine. We proceeded with monitoring those sensors whilst driving the vehicle and within seconds we noted that when demanding full throttle, both sensors switched lean, confirming as suspected that we had a definite fuel delivery issue.

Interestingly the fuel pressure appeared to still be within the required specification.

Our attention then turned to fuel delivery, as although we had

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already established the fuel pressure was correct, we were conscious of one of the owner’s statements: “in total [the vehicle] had four new fuel filters. Each time [it] seemed to help for a bit, then the issue would return”.

Luckily, being a German brand, not only did we have access to all OE documentation and data but the required information regarding fuel delivery was very well documented – this is something that is sadly missing with many other brands.

A quick check confirmed the following expected minimum delivery when the system was set to 4 Bar and run for 15 seconds: Noting the different minimum delivery based on supply voltage we opted to support the battery at

monitor the current as that way we could Find more technical also be sure the articles on pump had a PMMOnline, scan sufficient power and the QR code below! ground. We then proceeded to run the pump for exactly 15 Monitoring the pump seconds at 14v and 4 We removed the highBar while monitoring pressure pump’s (low current flow (pump pressure) supply line integrity) and the alland attached a fuel important resulting pressure transducer delivery amount. and manual tap, ran The results showed quite the electric pump manually by clearly that we had no electrical feeding the pump’s supply fuse and supply and/or pump integrity slowly adjusted the tap until the issues (as shown by the pump’s system was running stably at a current draw), yet we barely fixed 4 Bar. As we were already achieved 250cm3 – being not far using the scope to monitor the fuel pressure and manually powering off half the expected delivery... the supply pump, we also opted to exactly 14v, our theory being we should more than exceed the minimum specifications for delivery.

DISCOVER!

Whistling windscreen on Audi A4 Autodata’s Technical Team share their fixes to common problems raised through Autodata’s technical helpline, available to all UK customers.

The customer reported a severe vibration from the engine when starting from cold. This was accompanied by a fuel smell from the exhaust and the engine MIL illuminated in the instrument panel.

Verifying the customer’s complaint is an essential step in the diagnostic process. On this occasion, the customer’s complaint performed right on cue and we quickly identified that the engine was misfiring from cold.

Free revving the engine would allow the engine to run smoothly and on return to idle the misfire had improved. At this stage, it is worth mentioning that the vehicle in question was a two-cylinder design, and so losing one cylinder had a detrimental effect on engine

vibration and performance levels.

The video uses NVH to capture the misfire condition during cold start, where we obtained a clear E0.5 engine vibration order during the initial start-up. Note that a two-cylinder engine has one combustion event every revolution of the crankshaft, therefore, a misfire introduces one disturbance every two revolutions of the crankshaft (one disturbance/two crankshaft revolutions = E0.5).

With the customer’s complaint verified, we confirmed the vehicle’s ID and specification.

The inspection confirmed no fluid leakages, no visible signs of damage to hoses, connections, wiring harnesses or accident repair.

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EXHAUSTS

& EMISSIONS

KNOW YOUR PARTS Lambda sensors NTK, a brand of Niterra, explains what garages need to know about lambda sensors, why they need to know and offers some technical advice.

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otorists today can turn to the workshop as a fantastic source of knowledge and services for their increasingly complex vehicle. They require their vehicles to be more economical and environmentally friendly than ever without compromising performance, so the pressure is on garages to be more emissions savvy than ever.

One way to help optimise the car’s engine management when entering the workshop for service or maintenance work, is by fitting a new lambda (oxygen) sensor, as they slowly degrade over time.

This is often the simplest step to breathing new life into tiring engines with the benefits of fitting a new lambda being immediate and measurable as they are said to support optimum egine efficiency, reduced emissions and increased economy.

go-to solution for the car on the ramp.

“Many part numbers are brought into the aftermarket from the OE side of our business so motorists can be confident that their engines are fitted with components which meet or exceed vehicle manufacturers’ specifications. By choosing NTK they are not only selecting performance parts for their customers but also lots of support for the technician and the workshop.”

The company also advises garages should always fit an OE-quality lambda sensor for the vehicle and application they are working on, and steer well clear of ‘universal’ sensors.

Wide coverage Garages need to be able to fit high-quality parts to their customers’ vehicles safe in the knowledge they are providing their customers quality and performance they can rely on. With a range of more than 400-part numbers from OE to IAM giving 76 per cent coverage of European vehicles in operation, NTK is said to be the number one lambda choice of most of the world’s leading vehicle manufacturers.

Becca Knight, marketing manager for NTK brand owner Niterra UK, said: “As the leading supplier of lambda sensors both for OEMs and the aftermarket, Niterra is continually providing sensors which help to make engines cleaner, more efficient, and our wide application coverage makes NTK the

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EXHAUSTS

& EMISSIONS

TECHNICAL TIPS:

Niterra advises garages to fit a new NTK lambda sensor whenever they replace a vehicle’s catalytic convertor as a worn or failed sensor can result in drastically reduced control of the fuelling system which could result in increased fuel consumption, uneven running, generally poor performance or failure of a MOT emission test.

The company also advises garages should always fit a bespoke OE-quality lambda sensor for the vehicle and application they are working on, and steer well clear of ‘universal’ sensors. A ‘universal’ lambda sensor is designed to cover as many applications as possible by splicing in the old connector from the unit being replaced. In theory, this sounds like a good idea. In practice, the potential for a mismatch with the vehicle's system or subsequent premature failure is very high.

Power of ceramic Niterra’s long pedigree in producing NTK oxygen sensors dates back to the 1980s since when the reduction of harmful emissions has made significant advances, not least thanks

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to the development of new technologies and extensive research.

Today, highly efficient ceramic heaters in lambda sensors ensure that the sensors start measuring sooner and respond faster.

To achieve more accurate measurements to meet the ever more stringent Euro emissions regulations, huge efforts are being made in the continuous improvement of the ceramic components. In addition, a variety of sensor types have been developed catering to specific applications. They include broadband sensors and lambda sensors whose electric resistance changes depending on the air-fuel ratio.

With this dedicated engineering background, Niterra has the technical expertise to help technicians solve many problems they face in the workshop for lambda sensors.

Lambda sensors are part of the NTK portfolio of vehicle electronics that includes NOx, MAF/MAP, camshaft/ crankshaft, EGT sensors, EGR valves, along with the recently introduced exhaust pressure sensors, comprising of differential, absolute and highpressure type sensors.

■ Often a fault code can be read that correctly relates to an issue with the lambda sensor and replacing it can clear the code.

However, upon the removal of the sensor, closely inspect the inside of the connector for any oil contamination – however slight. Some vehicle models are known for an engine oil leak to allow oil to enter the wiring loom, migrating to other areas of the loom via capillary action – which is the root cause of the fault code.

■ Fault codes recorded for lambda ‘sensor 2’ (rear) can lead to the query that ‘the sensor required has more wires than the one supplied’. NOx sensors always have more wires than a Lambda sensor and outwardly are very similar in appearance, the lambda sensor will be close by!

WANT TO KNOW MORE? FOR MORE INFORMATION WWW.RDR.LINK /ABG016

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ADBLUE assistance AdBlue is becoming an increasing problem for workshops, with diagnostics provider Autel UK observing a 200 per cent increase in support calls relating to AdBlue systems and resets. To help combat this, the company is sharing its tips.

M “Once the fault has been diagnosed and corrected it is normally required to initiate a forced DPF regeneration as in a lot of cases the soot level has built up due to the inefficiency of the ad-blue system.”

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any faults in the SCR system start a countdown until no engine start, there can be several faults that activate this countdown from as simple as low AdBlue fluid all the way to in-depth efficiency faults.

Once the vehicle counter has reached zero, the engine can no longer be started and it will then require a diagnostics tool to reset the SCR system to get the vehicle started and diagnosed. Typically, this reset adds around 30 miles to the counter, giving the workshop chance to diagnose the system.

With the in-depth diagnostics functions available on Autel’s range of tools, technicians can integrate the SCR system with the use of live data, active test and special functions.

Once the fault has been diagnosed and corrected it is normally required to initiate a forced DPF regeneration as in a lot of cases the soot level has built up due to the inefficiency of the AdBlue system. The Autel range aims to offer a wide coverage of vehicles and features for this.

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It can also be the case that a component with the SCR system needs to be replaced, normally if this is done then a reset or adaptation needs to take place. Again, the Autel range offers a lot of in-depth functionality for tasks such as this.

Along with the wide coverage and mass of features within the diagnostics tool Autel UK offers a full tech support service for use of UK registered tools. This helps technicians

find the functions and data they need, giving them the best chance of a first-time repair.

The Autel range is available through motor factors and tool distributors nationwide, with onsite demos available to enable workshops to select the best for their business.

WANT TO KNOW MORE? FOR MORE INFORMATION WWW.RDR.LINK /ABG017

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Keeping it NEW How important is it for parts suppliers to be proactive when it comes to bringing new part numbers to market?

Well, according to exhaust specialist Klarius, it’s what makes a supplier a tried and tested workshop partner.

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n an evolving automotive landscape teeming with a variety of makes and models, the challenge for aftermarket support is not just keeping pace but staying ahead. The key to success lies in a proactive and responsive approach to product development. But how can this be achieved effectively?

The first step in successful product development is a deep understanding of market trends. This requires dedicated specialists who continually analyse the diversity of vehicles and customer needs. By reviewing various makes and models, companies can ensure their product

catalogues reflect the most current and demanded aftermarket needs. This strategic approach enables the development and launch of products at the best possible time, meeting market demands precisely when needed.

While many companies may start with a focus on local markets, expanding their vision to include global trends can provide a competitive edge. This doesn’t mean losing sight of local needs but rather integrating them into a more comprehensive understanding of global demands. Such a holistic approach ensures products on offer are relevant and available across diverse markets, reinforcing a supplier’s position as a leader in its industry.

& EMISSIONS

Being first to market with new products is a significant advantage in the competitive automotive aftermarket. A high rate of new product releases can set a company apart.

This rapid development cycle is key to staying on top of demand, offering the latest solutions before anyone else.

A wide product range must also meet the highest quality standards to ensure reliability and customer satisfaction. Certifications and endorsements, like those from the VCA in the UK or the TÜV in Germany, are vital as they attest to stringent quality control measures and enhance trust in a company’s products.

Klarius Products aims to espouse these principles through its new to range programme.

By adhering to these strategies, it anticipates the needs of the automotive aftermarket. By focusing on these core principles, the company is aiming to ensure that garages always have the right parts when they need them.

Kings of León Klarius has broadened its range of aftermarket emissions components, including full exhaust systems for a couple of variants of the SEAT León. The release includes 14 new additions that are tailored to various vehicles.

Since its debut in 1999, the SEAT León has not only carved a niche for itself as a hot hatch in the compact car market but has also etched its name in the automotive industry.

Emerging as a symbol of Spanish flair in design, coupled with the engineering precision of the Volkswagen Group, the León is based on the revered VW Golf platform. This fusion has birthed a vehicle that’s not only visually striking but a joy to drive, appealing to a broad spectrum of car enthusiasts.

WANT TO KNOW MORE? FOR MORE INFORMATION WWW.RDR.LINK /ABG018

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How can you help your customers’ cars run MORE EFFICIENTLY? This is the question we posed to companies recently, let’s see what they had to say.

CASTROL “An oil-based engine flush can be an effective remedy for neglected engines” “Many of today’s customers are finding themselves more disconnected from car maintenance, with many not aware of the importance of ensuring their vehicles are lubricated on a regular and appropriate basis. If substandard or incorrect oil is used, vehicles will run less efficiently, with the potential for costly repairs further down the line.

“Workshops should take the opportunity to consult with their customers about the best oil to use for their vehicle. A nationwide survey of 1,000 UK car owners commissioned by Castrol found that 53 per cent of those questioned wanted to hear about premium lubricants that might maximise the performance, efficiency and overall life of their car’s engine.

“An oil-based engine flush can be an effective remedy for neglected engines, or engines that have experienced a build-up of sludge. Regular maintenance with high quality engine oil will prevent this from occurring, but when a second-hand car is purchased, the new owner may only have the choice of flushing the oil or stripping down the engine to clean it.”

A new product launched by Castrol is engine shampoo, a pre-oil change treatment that contains solvent-free powerful cleaning agent (PCA) additive technology to deliver a deep yet gentle clean.

WANT TO KNOW MORE?

WWW.RDR.LINK /A BG019

BM CATS “It’s important that garages have effective procedures in place to alert motorists of MOT and servicing schedules, particularly through a cost-of-living crisis” “Ensuring a vehicle runs efficiently starts with adhering to regular servicing and maintenance schedules. Failure to adhere to routine maintenance not only potentially costs the motorists more money in the long run with worsening problems, but also contributes to air pollution if factors relating to vehicle emissions remain unchecked. It’s important that garages have effective procedures in place to alert motorists of MOT and servicing schedules, particularly through a cost-of-living crisis.

“Key to efficient motoring is also the use of highquality replacement parts. In our own product category of hot end emissions products, we recommend that garages opt for best-in-class quality when selecting these products and stress the importance of ensuring that the vehicle is fitted with a quality product that meets the legal requirements in terms of type approval.

“We’ve been encouraging motor factors and garages to embrace new opportunities to not only keep up with demand of an ever-evolving vehicle parc, but also to be able to service vehicles that incorporate an expanding array of emissions-reducing technology. Since the coronavirus pandemic, we have noticed that garages have significantly increased their communication with motorists and some garages now offer training workshops for drivers on the ‘self-care’ they can carry out on their vehicle to ensure it remains roadworthy.”

WANT TO KNOW MORE?

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WWW.RDR.LINK /A BG020

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KLARIUS FUELTONE PRO “DPFs are needing more attention but aren’t getting the regenerative cycles they need to clear the pollutant”

“Offering an AdBlue check and top-up service is another opportunity for garages to keep their customers cars running efficiently”

Fueltone Pro DPF Foam Burst is applied to the DPF via a sensor port when the filter is blocked. The foam expands though the filter and burns away particulates, saving time and costs on expensive repairs.

“For the vehicle owner, poor quality components can easily harm fuel economy, and can cause engine wear and damage from excess back pressure. It’s often that poor quality parts can cause warning lights on the dashboard, due to the operational parameters on backpressure or emissions not matching the original device. For the vehicle technician it can also be a costly and frustrating error, increased fitting time or wasting ramp time.

“The smart solution is to source parts that are rigorously designed by a reputable manufacturer, who takes the time to make OE equivalent parts. Simply choosing a trusted brand will ensure the parts are both easy to fit and provide long term value for the owner.

“Offering an AdBlue check and top-up service is another opportunity for garages to keep their customers cars running efficiently. Klarius’ AdBlue distribution is backed by the world’s leading manufacturer of AdBlue, and garages should be aware that sourcing a trusted brand of will help to ensure a quality product is supplied to the customer and meets ISO 22241 standards.”

WANT TO KNOW MORE?

WANT TO KNOW MORE?

“Generally we’re finding that more garages are turning to fuel additives, engine flush products and DPF cleaning foams, to keep engines running cleaner and to remove pollutants from DPFs. The trend we’re seeing is that DPFs are needing more attention but aren’t getting the regenerative cycles they need to clear the pollutant.

“Modern diesel-powered vehicles all feature a DPF as part of the vehicle’s exhaust system. If partially clogged with particulate, it increases back pressure in the engine, affecting fuel economy and reducing power, and over time can cause serious issues.”

WWW.RDR.LINK /A BG021

WWW.RDR.LINK /A BG022

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EXHAUSTS

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Technical training coordinator for EEC, Stuart Still, comes to the aid of a customer faced with the prospect of a catalytic converter whose nine lives were up. A killer coil turned out to be the main culprit.

Who (What) Killed the Cat?

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great deal of my time is spent fault finding and diagnosing emission faults, some of which potentially could result in a damaged catalytic converter or DPF, even though the faulty component was unrelated and would not normally be associated with a damaged cat.

One of the most effective emissions diagnostic tools is the 4-gas analyser; understanding and reading the four gas values correctly will enable you to locate and rectify many possible faults. Some of these failed components, especially ignition related ones, could have inadvertently damaged the catalytic converter, even though you would not initially have identified the link, but are often interpreted as an ineffective cat.

It is extremely important that when a faulty component has been located, repaired, or replaced, you check that damage has not been caused to any other related component.

To enforce this scenario I was recently contacted by a customer who explained that the Saab 9.5 he was working on had failed its MOT due to the emissions, he diagnosed the problem was the cat, as it was way below its threshold, the 4 gas values backed this up with readings of: CO: 1.2 per cent CO2: 14.3 per cent HC: 79PPM O2: 1.2 per cent Lambda: 1.04 These are typical values of a damaged cat that is not working efficiently.

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He could not understand this as the car belonged to one of his loyal customers, which is serviced regularly with him, he had also replaced the catalytic converter just five months previously, this was due to external impact damage, which caused the monolith to collapse.

He was so convinced it was the cat, that he agreed for me to visit him the following day to assist him with his diagnosis, this would give me an opportunity to give the car a once over before he replaced the cat.

It is extremely important that when a faulty component has been located, repaired, or replaced, you check that damage has not been caused to any other related component.

It is extremely unusual for a cat to fail within a two year period, the ones that do fail are usually associated with an emissions failure or a related faulty component, e.g.

EGR valve, air mass meter, injectors etc.

Arrangements were made for me to visit the garage and examine the Saab, the first thing I checked was the coil pack, knowing that they are a constant problem on Saab 9.5s; my concerns were correct, as a new coil pack had been fitted, the invoice in the service book, showed that it had been fitted three months ago, so backing up my theory.

My customer agreed that this could have been

the source of the problem. We replaced the damaged cat, followed up by a 4 gas emissions test, the results were perfect: CO: <0.20 CO2: > 13.5 HC: <15PPM O2: < 0.20 Lambda: 1 I explained that the damaged cat was a direct result of the failed coil pack, and that it was good practice to carry out a 4 gas emissions test directly after replacing any failed ignition component, especially coil packs.

Recently, I was talking to two major auto electrical manufacturers who explained the UK market for coil pack is immense.

There is an opportunity for us all, to be more effective when repairing customers’ vehicles, by reporting possible damaged related component as a consequent of the original problem.

Carrying out this practice will not only reduce catalytic converter problems, it will also help with continued customer satisfaction by being proactive, thorough and conscientious.

I am convinced that failed coil packs are resulting in a large number of cat warranties, to help reduce this industry problem we have compiled a warning flyer advising that an emissions test is done after replacing a coil pack or ignition related components.

WANT TO KNOW MORE? FOR MORE INFORMATION WWW.RDR.LINK /ABG023

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TOOLS

& EQUIPMENT

CHARGING customers

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he recent Motor Ombudsman’s annual service and repair sector survey highlighted the main challenges workshops are set to face in 2024. Increased day to day running costs, recruitment and more expensive parts were all cited as issues together with customers putting off routine maintenance as well as essential repairs as the effects of the cost of living crisis continue to bite.

With a need to balance additional costs and profitability against possibly reduced footfall, customer retention is going to be a critical factor. Maximising revenue per customer is an increasingly important aspect and an easy win exists by offering battery service – testing, charging, and replacing batteries where necessary.

This of course is not new, and plenty has been written about the value of testing batteries. It’s unlikely any workshop does not possess a battery tester of some description.

Despite this though a recent survey undertaken by Rotronics indicated that almost half of workshops do not routinely test batteries as part of a vehicle service.

Three steps to success When it comes to battery testing, there are three issues to address if workshops are to maximise revenues and customer trust.

Rotronics is reminding PMM readers that when it comes to passenger car batteries, testing can open the door to an easy win.

Provide your customers with an easy-to-read report

■ Make testing part of the service process.

The tester is a workshop tool that should be as visible as a socket set and not kept in a drawer deployed only in emergencies.

Bring it to the front of the workshop and adjust the service routine to include it.

Once the routine is established our research shows the benefits will flow.

not been easy. While some testers can come with printout facilities it’s still not plain sailing. The information is not presented in a clear to understand way and if the ‘till roll’ runs out and there is no more paper to hand the potential to engage is gone. Fortunately, there is another way...

Reliable tester ■ Use up to date equipment that provides reliable, consistent results.

A quick google search on ‘12V battery tester’ will reveal pages and pages of possibilities and prices. How to choose? We are biased of course, but choosing equipment from suppliers that work with the vehicle manufacturers for their – increasingly complex – battery needs is a good start.

They demand ease of use, consistent results, robustness, and good technical back up service. Why settle for less?

■ Engage the customer with results of the test and any recommendations.

It’s vital to share test results with the customer. It can build trust and may lead to an additional revenue opportunity.

Unfortunately, communicating results has

The latest CPX900 tester from Midtronics is easy to use, compatible with all 12V lead acid starter batteries including EFB and features Wi-Fi communication. That means that it is compatible with ROBIS – Rotronics own reporting system that for the first time allows you to share an easy to understand battery condition report to your customer.

Using a ‘traffic light’ system ROBIS explains the key measurements in symbols and language everyone can understand and provides reassurance that a thorough test has been undertaken and that the results can, if necessary, be actioned easily.

WANT TO KNOW MORE? FOR MORE INFORMATION WWW.RDR.LINK /ABG024

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& EQUIPMENT

Victoria Evans, director of Esprit Windscreen Repair Equipment talks to PMM about the firm’s Elite Windscreen Repair Kit and what it offers to independent workshops.

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re you offering windscreen repair to your customers yet? If not, you’re missing out on a great opportunity to offer an add-on service, helping their vehicles pass their MOT, at the same time as creating an extra line of income for your business.

Our repair kit is simple to learn to use and we offer training with every Elite kit, free if you visit our premises in Staffordshire. We also have options to train you at your premises, either individually or in a group.

The Elite kit can carry out around 40 repairs and after that you only have to replace the consumables, like the resin. Some of our customers have had their kits for over 20 years!

Within the kit, firstly you have the Elite Bridge. This is designed to comfortably fit in the hand, and the moveable arm means that you can position it perfectly over the damage and inspect the repair before curing. The sucker should be used with a small amount of the gel and it’ll stick fast to the screen.

Turning to the injectors, we offer plastic or stainless steel. The latter come with a lifetime guarantee and are part of our constant drive to make our kit more sustainable. They can be used again and again and cleaned with our ESpray to keep them in tip top condition. The resin can be used on all types of breaks, including cracks. We offer a UV proof syringe as standard, but we also offer the transparent syringes too – we tried to phase them out but our customers asked for them back so we couldn’t say no! The UV proof syringes are ideal if you’re repairing outside in sunlight, or

SCREEN TIME if you ever have issues with resin curing prematurely in the syringe.

We sell resin in 2, 5, 10 and 50ml bottles so you can purchase whatever works best for your business. The kit comes with four resin packs each containing a 2ml bottle. Once the resin has been introduced to the break and the on/off cycle started, you can also use the Esprit heater. This is also manufactured in-house and ensures the screen can be heated to the perfect temperature to allow the best ingress of resin throughout the break. Once you’re ready to cure the break, the Esprit LED lamp is used.

Again, manufactured by Esprit, it’s the perfect size for breaks and also cracks. After 75 seconds, the repair is cured and all you need to do to perfect the repair is scrape off the excess resin and give it a little polish.

Turning a profit We recommend charging around £25-40 per repair and we calculate the cost of the repair at around £2-3, so you can see, they’re a great way to increase your profit. Plus, a happy customer with a repaired windscreen, passing the MOT, is probably a repeat customer. We know there are lots of repair kits on the market these days, so why should people choose our one? Well, the Elite kit has passed the prestigious TUV accreditation and we’ve been in business for over 40 years. We’ll train you, so you can see the kit working. We offer IMIaccredited training as well as refresher training.

We’re based in Britain and our kit is manufactured in Britain, so you know that if you have questions, you can pick up the phone and speak to one of our experienced staff.

If you’re reading this and you would like to know more, I suggest giving us a ring and speaking to our head of technical and training, Dean, or our key account manager, Sam. Take a look at our website – it’s got our free training videos, customer testimonials, demo videos and all the information on which is the right kit for you.

WANT TO KNOW MORE? FOR MORE INFORMATION WWW.RDR.LINK /ABG025

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Get CONNECTED Snap-On discusses the MOT and how it is evolving to meet environmental demands.

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esponding to public demand for cleaner air, the government and industry are driving the automotive industry towards an ever greater commitment to environmental sustainability. For the manufacturers, this means producing cleaner, more efficient vehicles. For the service and repair sector, emissions testing and diagnostics have become critical processes. To meet these changing demands, independent garages need to stay ahead of the curve. One way to do this is by investing in connected emissions equipment, which can offer numerous benefits and help secure the future of your business.

The MOT Test is continually evolving to improve safety and the environment and connected equipment enables you to keep up with the latest updates and futureproofs your business. Connected equipment has revolutionised the testing process since its introduction in 2019 with connected roller brake testers and has expanded to include brake decelerometers and emissions analysers including petrol gas analysers and diesel smoke meters. Plans involve particulate number emissions testing, MOT bay camera technology, electronic assessment of headlights and ADAS systems.

What is connected equipment?

Connected MOT equipment streamlines communication with the DVSA's MOT testing system (MTS) through a single button press, eliminating data entry errors.

The primary objective is to enhance testing efficiency, save time, increase accuracy and reduce manual input by instantly accessing vehicle information from the DVSA database and automatically transmitting test results. Connected equipment eliminates manual data entry, reducing the risk of

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human error, ultimately saving time and ensuring higher MOT testing standards.

Governments worldwide are tightening emissions regulations to combat air pollution and reduce the environmental impact of vehicles. Stricter emissions standards are being enforced in some European regions, such as Belgium, the Netherlands, and Germany, that are already implementing particulate number (PN) testing, with the UK also conducting small-scale trials. To stay compliant and futureproof your business, independent garages should invest in the latest emissions equipment, ensuring they can adapt to evolving regulations seamlessly.

Making the investment Upgrading old equipment to a connected MOT system such as an automated or oneperson test lane offers significant productivity enhancements, cost savings, and revenueboosting benefits. Integration with the MTS saves time, eliminates input errors, and eliminates the need for physical result printouts. Just think about the number of MOT tests you do in a day, potentially saving time and money on each will pay big over a year, after all, time is money!

The SUN DGA6000 LINK aims to streamline MOT testing for speed and reliability. This system integrates your MOT equipment into the DVSA's MTS enhancing efficiency and reducing errors. Its software simplifies the testing process, saving time in training, setup, and daily workload. The SUN DGA6000 LINK also integrates with the SUN roller brake tester further streamlining your MOT processes. It is also compatible with John Bean wheel alignment systems, enabling affordable expansion beyond emissions testing to include profitable wheel alignment functionality.

WANT TO KNOW MORE? FOR MORE INFORMATION WWW.RDR.LINK /ABG026

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Jump for

JOY Ring’s latest jumpstarter ensures there is no vehicle too big for garages to help out of a jam.

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utomotive lighting and auto electrics supplier, Ring, is kicking off its 50th birthday year with a flurry of activities, the first of which is the launch of a new product for the market.

While the RPPL1000 jumpstarter for 12V systems has only been on the market for six months, Ring, which is always upgrading and evolving its range for further uses, has introduced the RPPL3000 to accommodate 12V and 24V systems, so that technicians can have an even greater range of options.

The RPPL3000 lithium professional jump starter is suitable for workshops and recovery vehicles, as it’s ideal for all petrol vehicles and 24V diesel vehicles up to 13-litre due to its high power and auto voltage detection.

This jumpstarter can be used on 4x4s, cars, vans, motorcycles, commercial vehicles and even boats. Helpfully, it has a built-in LED work light, allowing users to work in darker conditions, it is also lightweight, only

weighing 5.6kg, which is 75 per cent lighter than equivalent lead acid jumpstarters, making it more mobile and easy to use.

Other features include a 12V DC port and USB port to charge mobile devices, as well as reverse polarity protection and overvoltage protection. The over-voltage protection means that when the jumpstarter is being recharged, the unit will disconnect from the charger and stop allowing charge to flow in once it’s fully charged and it will also stop adding charge if the voltage in the battery starts to increase too much.

Who is it suitable for?

Marketing director for Ring, Henry Bisson, said: “We think it’s important to provide technicians with as much choice as possible: if they work in a workshop that only sees cars, then the new RPPL3000 will still get use, but they will not be using all of the features available, so perhaps we’d suggest the RPPL1000, which is specifically for 12V

vehicles. However, if they are unsure of what vehicle they’ll be working on from one day to the next, maybe working in a mixed fleet depot, then the RPPL3000 gives them the flexibility they need when they need to jumpstart a vehicle.

“We’re extremely pleased with all of the features the RPPL3000 offers technicians.

Being lightweight, it can be easily carried around a forecourt and will do multiple jumpstarts before needing to be recharged.

For personal and practical reasons, the RPPL3000 provides the ability to charge a phone or light up an area, if they are out on the road, for example. As it’s likely that all these key features will be needed, we make sure our products are able to provide a multitude of benefits, not just one.”

WANT TO KNOW MORE? FOR MORE INFORMATION WWW.RDR.LINK /ABG027

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TOOLS

& EQUIPMENT

ELEVATE your workshop Equipment specialists Maha UK provides PMM with explains why investing in high-quality MOT equipment is worthwhile for garages.

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hile the government continuously deliberated the frequency of the MOT, there is no deliberation needed in terms of the importance of high-quality MOT garage equipment. From potential return on investment to quality, support, and connectivity, Maha UK provides a comprehensive insight that explains why investing is the correct formula.

In the pursuit of efficiency and profitability, independent workshops can find a valuable ally in Maha UK’s MOT workshop equipment, the firm claims. The potential return on investment is evident by streamlining processes, reducing downtime, and increasing throughput. The incorporation of innovative but simple-to-use technology says to ensure that each piece of equipment is an asset that pays dividends over time.

54 MARCH 2024 PMM

The company’s MBT 2250 EUROSYSTEM, approved by the DVSA, aims to reflect the company’s dedication to precision and durability. From robust motor assemblies to the ability to withstand extreme torque and stress, its equipment is said to guarantee a longer lifespan, delivering consistent and reliable results.

Beyond the equipment A strategic investment involves not only the equipment itself but also the support and training that comes with it. The company offers technical support and comprehensive training programs – given the equipment is manufactured by Maha, who better to offer training than its engineers? Workshops can maximise the potential of their equipment, minimise downtime and stay ahead of industry advancements.

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Legal obligation Connectivity is not just important, it’s a legal requirement: new MOT equipment needs to be able to connect to the DVSA MOT testing service. Workshops considering a new roller brake tester, for example, need to ensure it's a model that can connect to the MOT testing service.

The company’s MOT garage equipment, including the MBT 2250 EUROSYSTEM software, aims to allow seamless integration with other modules, transforming the brake tester into an all-encompassing workshop platform. This connectivity is said to improve efficiency and futureproofs the workshop for evolving industry demands.

Furthermore, independent workshops face increasing scrutiny in meeting DVSA specifications. Its collaboration with the Garage Equipment Association aims to ensure that its equipment consistently meets

Maha’s garage equipment aims to allow seamless integration with other modules, transforming the brake tester into an all-encompassing workshop platform.

the stringent criteria for being ‘green coded’ – a marker of equipment that is current and fully compatible for use in MOT sites. This partnership showcases the company’s commitment to upholding industry standards and providing workshops with reliable and compliant solutions.

For independent workshops seeking a strategic edge in the competitive automotive landscape, investing in quality MOT garage equipment from Maha UK is a shrewd choice. The potential return on investment, coupled with quality, support, and connectivity, positions it as a trusted partner in elevating workshop efficiency, ensuring compliance, and future-proofing operations.

WANT TO KNOW MORE? FOR MORE INFORMATION WWW.RDR.LINK /ABG028

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REMANUFACTURING

ANTI-LOCK BRAKING SYSTEMS: A history

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he anti-lock braking system (ABS) has become a crucial (and mandatory) part of the modern car. This isn’t surprising because the ABS significantly improves braking performance and safety. Over the last 10 years, ABS units have undergone a significant evolution, driven by technological advancements and higher safety standards. In this article, we examine the changes and innovations in ABS units over the past 10 years and take a look at what they might look like in the future.

ACTronics talks PMM through how the anti-lock braking system unit has evolved over the past 10 years and what this means for the future. conditions and steering input. As a result, the optimum braking force can be determined in every situation and loss of grip is minimized.

To complete the major change, ABS units have become smaller and lighter over the last 10 years. Manufacturers have adopted new materials and design techniques to reduce the size and weight of the ABS. Practical and efficient!

The future

Schematic representation of how regenerative braking works

Evolution of ABS units Over the past 10 years, ABS units have increasingly been integrated with other safety systems, such as traction control (TCS), electronic stability control (ESC/ESP), and emergency braking assist. These integrations have significantly improved braking performance and vehicle stability. This has been made possible by high-tech sensor technology of the ABS unit. Modern ABS units use very sophisticated sensors to detect and analyse the vehicle's movements. This allows faster and more accurate response to changes while driving the car.

Another change that has contributed to the above is the improvement in the computing power of the ABS system. The control algorithms used in ABS units have become more complex and sophisticated.

They can now take into account different variables, such as speed, grip, road

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Now that we’ve looked back in time, let’s take a look ahead as there are several developments and innovations coming up that will change the ABS in the near future.

One of the most obvious is integration with advanced braking systems for electric vehicles. With the continued growth of electric vehicles, ABS units will be more closely integrated with advanced braking systems specifically designed for electric propulsion. This includes regenerative braking, which recovers kinetic energy and converts it into electricity, and electrically controlled brake actuators that provide faster and more precise braking response.

In addition, ABS units will increasingly benefit from the continued development of connected and autonomous vehicle technologies. The ABS system will be able to exchange information with other vehicle sensors and systems, allowing them to respond even faster and more accurately to traffic situations and potentially dangerous scenarios. This will further improve the safety of the vehicle and help prevent accidents. An extension of this is an increasingly intelligent brake control. With advanced AI algorithms and machine learning, ABS units can provide intelligent braking control in the future. The system will

adapt to the driver's driving style and different driving conditions. This allows for personalised braking performance that is tailored to the driver's preferences and driving style. Finally, ABS will increasingly find its way into new vehicle types. ABS units are gradually becoming commonplace in electric bicycles and scooters, for example. The demand for a safe braking system will also grow for other means of transport to prevent slipping and locking wheels.

ABS systems are also increasingly being used on e-bikes

Over the past 10 years, ABS units have undergone significant changes and innovations, such as integration with other safety systems, advanced sensor technology, improved algorithms and weight savings. In the future, ABS units will continue to evolve, with further integration into electric vehicles, connected/autonomous vehicles, intelligent braking control and expansion into new vehicle types. These developments will contribute to an even higher level of braking performance, safety and driving experience in the vehicles of tomorrow.

WANT TO KNOW MORE? FOR MORE INFORMATION WWW.RDR.LINK /ABG029

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REMAKING the planet Oliver Stahnke, sales manager, Borgwarner, discusses what sustainability means to the company and explains the part that remanufacturing plays in achieving those goals.

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efore explaining how remanufacturing contributes to our sustainability goals, it’s perhaps useful to summarise how we go about the process. We separate the individual components of a used part into those that must always be replaced – such as bearings – and those that can potentially be reused. The latter are cleaned, then checked against original specifications to ensure they are within tolerance for remanufacturing. We replace components that don’t meet the criteria with new OE items and combine them with the reusable components to complete the parts list for a remanufactured assembly.

We’ve been remanufacturing parts for nearly 30 years, including turbochargers,

alternators, generators, electronic unit injectors, and EGR valves. During that time, we’ve reused more than 24,500 metric tonnes of cast iron and aluminum. Our turbocharger remanufacturing program alone has saved some 5.2 million turbines, compressor housings and bearings from landfill. Across our product lines, approximately 36 per cent of our input in 2022 came from recycled or remanufactured material.

We’ve made significant progress towards our sustainability goals over the past two years, despite significant headwinds and market volatility. In 2021, we announced our Charging Forward strategy, designed to increase production of electric and other vehicle parts that enable zero- and lower-

emissions transportation – and in 2023 we invested approximately 19 per cent of net eProducts sales into eProducts research to maintain our position at the forefront of electric technology. We now expect to achieve our 2025 goals ahead of schedule, so we’ve evolved our strategy to Charging Forward 2027, which aims to achieve 49 per cent of sales revenue from eProducts by 2027. Our ultimate goal is to achieve carbon neutrality – Net Zero – by 2035.

WANT TO KNOW MORE? FOR MORE INFORMATION WWW.RDR.LINK /ABG030

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REMANUFACTURING

A CHANGE of idea Autoelectro is telling garages the tide has turned: part swapping is out, understanding the system is in.

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utoelectro, a remanufacturer with nearly four decades of experience, is underlining the necessity of technical proficiency amidst the surge in sophisticated vehicle components. In an era dominated by innovation, the rotating electrics specialist stands as an advocate for education and proactive problem-solving.

Despite Autoelectro still selling dynamos, inertia starter motors and ACR alternators today, both the sector and the professionals it services find themselves amidst a technological revolution where electronic control units (ECUs) direct water-cooled, reversible alternators, stop/start systems, hybrid configurations, and a plethora of advanced starters, including tandem and dual solenoid varieties.

This change in direction requires a departure from the traditional approach of simply swapping out parts to address issues.

Instead, the focus needs to shift towards understanding the intricacies of these modern components to diagnose and resolve the root causes of problems.

Autoelectro is approaching four decades and, therefore, recognises the significance of technical understanding in the current

58 MARCH 2024 PMM

automotive landscape. It is particularly concerned about switches from quality remanufactured parts towards mass-produced alternatives from the Far East, forfeiting the technical expertise within the industry.

The heart of the matter For Autoelectro, one of the core issues is the tendency to replace suspected faulty parts without delving into the underlying causes of the problem. This approach, addressing symptoms rather than causes, can lead to recurring issues and fails to provide a sustainable solution. It’s a short-term fix, not a long-term solution.

Autoelectro’s Harnek Bhogal said: “Our commitment to technical excellence sets us apart. Unlike the trend of batch testing, every part released by us undergoes two rounds of testing – first at the component level and then as a complete unit on OE-spec test equipment. This meticulous testing process ensures that our parts meet the highest standards before reaching the market.”

Harnek also highlighted Autoelectro’s engineers; they play a crucial role in this process. By working with old cores and identifying common themes among specific part numbers, Autoelectro’s ability to strip, inspect, and test exchange parts gets straight to the root causes of recurring faults. This proactive approach allows the company to go beyond merely supplying parts, offering invaluable insights into potential issues associated with specific engines or vehicle makes and models, remanufacturing a part to meet, or even exceed, OE-specification.

An important “factor” Furthermore, Autoelectro believes the importance of collaboration between motor factors and technicians is critical. Blindly swapping parts without addressing the true problem could lead to an erosion of trust between garages and factors.

Harnek added: “We recognise this challenge and actively support garage technicians by providing part-specific technical bulletins.

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These offer guidance on common faults, best practices, and key indicators to look for in the old cores they remove from vehicles.”

One such example is if a pattern emerges where every returned old core is contaminated with fluid: Autoelectro issues a technical bulletin advising technicians to investigate and correct leaks before installing replacement parts; in fact, below are two examples of Autoelectro using its ability of testing, stripping down and investigating old cores to find common issues: AEG1472 (Ford Transit 2.0 diesel alternator (2016-onwards)): possible tensioning or belt issue that causes premature failure of the clutch pulley and, thus, the premature failure of the alternator. Autoelectro recommends changing the belt and tensioner at the same time as replacing the alternator to avoid the same pulley issue happening again. Failing to do so may lead to the same fault occurring on replacement parts.

AEY2803 (Chevrolet Captiva and Cruze/Vauxhall Antara 2.02.2 diesel starter motor (20112016)): a common fault where the wiring insulation on the vehicle is not correctly heat shrunk, which causes the B+ terminal on the solenoid to overheat and melt, leading to the premature failure of the starter motor. Therefore, inside every AEY2803 box supplied, Autoelectro provides a warning notice, advising the technician and showing images of what damage to the solenoid and terminals looks like, to avoid the same issue happening again.

Harnek said: “Both of the faults on these part numbers can often be intermittent due to the nature of them; the tensioning issue, for instance, may cause the belt to slip, which can cause sporadic charging faults, while the incorrectly heat shrunk wiring insulation may cause intermittent starting issues on the vehicle, which will get worse over time.

“It is easy to see how a technician may think this is just due to wear and tear on the unit, when in reality, that is not the case, and the root cause must be fixed.”

By sharing these types of insights into common issues, as well as the likes of belt slippage or dust/fluid contamination, Autoelectro allows technicians to diagnose and rectify problems at the source: “They should be more confident and comfortable,” Harnek concluded.

As a long-standing, award-winning remanufacturer and a business that enjoys consistent year-on-year growth, Autoelectro champions the need for technical expertise in an era increasingly dominated by complex and sophisticated vehicle components.

WANT TO KNOW MORE? FOR MORE INFORMATION WWW.RDR.LINK /ABG031

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THE MODERN WORKSHOP

Can DIGITAL SOLUTIONS improve the running of your garage?

Digital platforms have an essential role to play in the modern workshop. We asked some of the leading providers of software solutions to offer their advice to garages looking to beat the dealers at their own game.

Bringing together customers and workshops ClickMechanic updates the traditional repair quoting process by automatically generating price quotes based on the vehicle’s make and model, along with the customer’s location.

This not only streamlines the quoting process but also ensures consistent and fair pricing, benefiting both garages and customers alike.

The platform further simplifies operations by streamlining the booking process through an easy-to-use online website. Standout features include handling all admin, payment, and customer service tasks. This allows garages to devote their full attention to car repairs, covering everything from customer

interactions to invoicing seamlessly.

ClickMechanic also facilitates customer feedback and reputation management, helping garages build a strong reputation and efficiently address any concerns. The platform also plays a crucial role in expanding a garage’s market reach, connecting them with a wider customer base actively seeking car repair services.

Streamline the workday Garage Hive can significantly enhance the efficiency and operations of a busy workshop. The award-winning, communitydriven garage management software allows garage owners and technicians to manage workflows with ease.

“At the heart of Garage Hive is an intuitive service schedule,” said Ray Dilsons, Managing Director of Garage Hive. “Acting as a central hub for all workshop activities, it provides instant access to essential information such as bookings, workload, and staff availability.”

Designed to be efficient even under pressure, creating and managing job sheets is a straightforward process in Garage Hive.

Checklists and vehicle health checks, mean technicians can perform inspections and provide updates as work progresses. Garage Hive notifications, meanwhile, ensure front-of-house staff are kept updated of pending checklists, promoting timely approval and action.

“It’s about streamlining the entire process,” said Ray. “Garage Hive ensures a smooth flow of information, allowing for prompt customer communication and approval processes.”

Garages can customise items, descriptions, and categories, as well as import supplier part numbers, adding flexibility and convenience to inventory management. It also supports the creation of default labour lines and categories.

It means job sheets are automatically populated with predefined data, particularly beneficial for fixed-priced servicing.

Reducing downtime In a world of advancing technology, digitisation in the automotive industry has well and truly landed. Whether it’s EVs, diagnostics or a garage management system, today’s workshops should embrace new software and digital platforms to stay ahead of the game and ensure the most efficient daily operations.

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Mythbusters

060_PMM_MAR24_Layout 1 01/02/2024 15:59 Page 61

Sorting out fact from fiction in the workshop

WHAT YOU’VE HEARD:

LED headlamps are too bright for UK roads.

WHAT WE’VE HEARD: We put this to OSRAM’s Kristin Tränka who kindly “illuminated” the topic for us. Kristin rightly pointed out that firstly LED retrofits are illegal in the UK, (and will result in a failed MOT, we might add) so we should only be considering factory-fitted headlights, which are subject to the same anti-glare requirements as halogen lights. Case closed? Well, not quite. Kristen did provide an answer to the problem: “After some time, it can happen that the headlights are no longer adjusted and oncoming traffic is dazzled as a result. Uneven roads and speed bumps can cause the light distribution to become misaligned and therefore not function as intended. However, this is not due to the headlamp design or the LED technology, but to the given circumstances.”

WHAT WE SAY: Perhaps it’s glaringly obvious that brighter lights result in more dazzling performances on our roads, but it’s unlikely they’ll be going anywhere anytime soon. It’s time to look on the bright side and acknowledge that when adjusted correctly, they can make the roads a lot safer. So spread the word with your customers.

GET IN TOUCH

Heard something interesting in the workshop (or even the pub) lately and wonder how much truth is in it?

Give us a shout and we’ll do our best to sort out the fact from the fiction. Email us at pmm@hamerville.co.uk

As a forward-thinking garage management software company, TechMan built its system from the ground up, using its real-time frustrations and knowledge to identify suitable digital solutions to assist technicians, thus creating a digital platform that enables garages and workshops to gain a tighter grip on the day-to-day running of a modern workshop.

One of the main advantages of a garage management system is that it can help businesses to become more efficient. With real-time data available, workshops can monitor their operations and identify areas for improvement. This means that businesses can reduce downtime, improve productivity, and increase turnover.

Another advantage of a garage management system is that it can help businesses to provide a better customer experience. With electronic job cards and EVHCs, workshops can provide customers with a detailed breakdown of the work that has been done on their vehicle. Additionally, customers can receive updates on the progress of their vehicle and be alerted when it is ready for collection.

“The backbone of any modern workshop is robust technical support.”

Operations Manager at CCM Garage, Tina Drayson, hails TechMan as something her workshop couldn’t function without. She comments: “Being digital and embracing new technologies has allowed us, as a business, to be able to track and measure data that enables us to be more efficient, improve productivity, generate more turnover, provide a better customer experience, and have better consistency across all of our sites.”

Diagnostics support, dealer style The backbone of any modern workshop is robust technical support. With comprehensive online resources and guides, technicians can access a wealth of information at their fingertips. For more pressing issues, a dedicated hotline can offer real-time problemsolving, ensuring minimal downtime in a workshop’s operations. Moreover, a proactive approach to software management, including

remote updates, keeps workshops’ diagnostics systems up-to-date and ready to use at all times. At Maverick Diagnostics, we have partnered with Grup Eina, which has access to almost two million known fixes and an expert helpdesk that could save technicians hours of labour.

In the heart of the modern toolbox lies a selection of OEM tools, crucial for precise and efficient diagnostics and repairs. These tools are continually updated with the latest software, ensuring compatibility with new vehicle models and technologies. This fusion of precision and technology is what sets independent workshops equipped with dealer tooling apart. These are professional tools made to be used at dealerships and provide the best-supported functions for the specific brand. We provide these diagnostic tools to independent workshops, to provide the same capabilities as the main dealers.

WANT TO KNOW MORE? FOR MORE INFORMATION WWW.RDR.LINK /ABG032

PMM MARCH 2024 61

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What’s new

IN THE WORKSHOP? with Freya Coleman

NEW TO

RANGE ■ JURATEK has revealed 25 new additions for the start of the year, including one wheel cylinder, 20 calipers, and four brake pads for enhanced vehicle performance and safety. The brand’s new part number in its wheel cylinders line is JCY1210 designed for Nissan models such as Bluebird 12-, Juke 10-19, Sentra 06-, and Tiida 12-. Highlights in the new caliper part numbers include JCA1639L and JCA1639R for Fiat 500 07-, Punto 93-12 and Ford Ka 08-16.

■ The latest additions to the DENSO ignition range come with 14 coils that are linked to 21 original equipment part numbers and cater for 1,649 passenger car applications, covering almost 33 million vehicles across the European car parc, including Nissan Micra III (k12), NOTE (E11) (06-12) and Hyundai Elantra (05-11), i20 I (08-15), i30 (FD) (07-12), Cee'd (06-12), Pro Cee'd (08-13)

■ FIRST LINE has added 32 new references to its product lines, the latest additions include 13 steering and suspension parts covering 18 vehicle references, two cooling components covering 16 references, 10 cabin filters suitable for 58 references, an oil filter relevant for four references, three fuel filters for 14 references, and finally, three steering gaiter kits to cover seven references.

■ Key additions to First Line’s BORG & BECK range include top strut mounting kit, part number BSM5599, for the Volvo XC40 E, 1.5, 2.0, 2.0D and 2.0H model lines (2017) and new cabin filter, BFC1369, for Toyota's innovative CH-R, spanning from 1.2 to 2.0H variants (2016).

■ Mercedes Benz, Lamborghini, Hyundai and MG units are just some of eclectic new-to-range references recently brought to market by AUTOELECTRO. Focusing on alternators first, the brand now stocks a Mercedes Benz AMG A45, CLA45 2.0 petrol 2020-onwards (AEG1640), Hyundai i10 1.0 Blue Drive petrol 2018-onwards (AEG1645), Honda Civic 1.6 diesel 2018onwards (AEG1648) and Alfa Romeo Stelvio 2.9 V6 petrol (2018-onwards). Switching to starter motors, the remanufacturer’s stock has been bolstered with units for a Lamborghini Countach, Diablo 5.2 V12 1985-1990 (AEX1498), MG ZS 1.0 petrol 2017-onwards (AEX1499), Vauxhall Astra 1.5 diesel automatic 2019-onwards (AEX1500) and Nissan X-Trail 1.3 petrol 2019-onwards (AEX1501).

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Wind-protective jackets and hoodies Snickers Workwear’s new range of lightweight mid-layers are crafted for full flexibility on site and optimal comfort. Built for active work, they’re said to be fully flexible and can be worn as an outer layer when it’s warmer or a mid-layer when it’s a bit cooler.

They’re full of handy technical features and innovative fabrics to tame the wind, plus energising colours to assist in brightening your spring-time workday. Choose from new street-smart styles such as the wind blocker half-zip hoodie or the lightweight flexiwork midlayer jacket. There’s also a new windproof soft-shell jacket for women. Whatever mid-layer you choose, Snickers claim that they all have body-mapping designs for a great fit, outstanding functionality and long-lasting comfort.

WANT TO KNOW MORE?

WWW.RDR.LINK /A BG033

Diagnostics tool Launch Tech’s CRP MOT 4 is a development of its CRP MOT 3 diagnostic tool. With new hardware and diagnostic functions, the CRP MOT 4 is a entry-level device for those looking to enter into diagnostics and is also ideal as a second device for technicians in the workshop. Key benefits include 31 powerful service functions including actuator tests, covering a range of car models. It also comes equipped with a high-performing 2.0 GHz Quad-Core processor, Android 10.0 OS, 4GB RAM, 64GB storage, and a vibrant 10.1" display for superior efficiency. It also features the DBS Car V11 VCI for fast Bluetooth connection, supporting diverse protocols, including DOiP and CAN FD, aiming for seamless and comprehensive diagnostics, as well as featuring a practical soft carry case crafted for durability and convenience for optimal protection in the workshop and on-the-road.

WANT TO KNOW MORE?

WWW.RDR.LINK /A BG034

062_PMM_MAR24_Layout 1 02/02/2024 10:59 Page 63

MESSAGE ME YOUR PRODUCT RELEASES OR YOUR FAVOURITE PRODUCTS AT FCOLEMAN@HAMERVILLE.CO.UK

New from Laser Tools Star socket This extra-long slim-fit star E12 socket (part number 8718) is specifically designed for the PSA EB2 series of engines that use E12 Torx cylinder head bolts. On these engines, access to the cylinder head bolts is very restricted — even after removal of the camshafts a standard E12 socket cannot be used.

The socket’s slim fit design and length allow the user to easily access the head bolts. This 1/2" drive socket is 200mm long to give you the required access; it is manufactured from chrome-vanadium steel (CRV 6150) for toughness and shock resistance and finished with black phosphate.

Applications include: PSA and BMW group vehicles. Engines include: PSA EB0 (1.0L) and EB2 (1.2L), and BMW M50, M52, M54, S52, M42, and M44.

WANT TO KNOW MORE?

WWW.RDR.LINK /A BG035

Adjustable wrench This adjustable wrench features a spring-loaded jaw, serrated teeth, and a flexible head for which is said to allow for easy access to hard-to-reach fixings (part number 8729). With its simple pull-back action, it aims to provide a fast and secure grip on fixings ranging from 8mm to 17mm in diameter. Manufactured from chrome vanadium steel for toughness and shock resistance, this wrench is said to be particularly good on damaged or rounded-off fasteners. Other features include a lockable flexi-head for greater access and its quick-adjustment head’s serrated teeth grip firmly on even the most rounded fixings. The tool’s overall length is 187mm with a jaw range of 8 - 17mm. For use on all types of bolts, including single hex (6pt), bi-hex (12pt), Star/Torx, spline, and square, etc.

WANT TO KNOW MORE?

WWW.RDR.LINK /A BG036

Wash bucket This wash bucket features an integrated dirt trap from (part number 8737), designed to streamline your cleaning and detailing tasks.

This bucket aims to ensure that sediment settles at the bottom and prevents dirt and grit from remixing with the water. Key features include: ■ Dirt trap: Allowing particles and debris to settle at the base, keeping your cleaning water cleaner.

■ Easy handling: With two comfortable soft-grip handles, this bucket offers ease of use and portability.

■ Pouring Spout: Making it convenient to pour water precisely where you need it .

■ Durable construction: Manufactured from tough polypropylene plastic (PP).

■ Wide, open shape: The wide, open design of the bucket easily accommodates a long-handle wash brushes.

WANT TO KNOW MORE? WWW.RDR.LINK /A BG037

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What’s new

IN THE WORKSHOP? with Freya Coleman

Cleanliness tips:

Why should garages care about seat covers?

Leading seat cover manufacturer, Town and Country Covers, explains why you should invest in the seat covers used while working on a customer’s car.

Being a technician can be a messy job, you have to reach into the engine bay which results in oily hands or remove tyres that are normally covered in dirt – either way, your hands and clothing are usually somewhat grimy. So, when getting in and out of a customer’s car, you don’t want to transfer that dirt into the vehicle, which is where fast fit seat covers come into play.

While some workshops may choose to opt for paper or plastic covers to put in vehicles to protect the interior, there is a sturdier and more sustainable option available – Town and Country covers’ fast fit universal seat covers that can be fitted

and removed in seconds.

The cover is designed with two things in mind, speed of fitting and removal, while aiming to provide excellent protection to the seat. It is in one piece, which slips over the headrest and covers the front of the seat.

Helpfully, this seat cover can be quickly rolled up and stored into a bag, so that it’s neatly put away and can be used at a moment’s notice.

The cover is made from the company’s signature heavy-duty polyester, aiming to ensure it’s of premium quality, waterproof and hard-wearing for the tough environment and for the many uses it will have.

To ensure it maintains high production standards when manufacturing its seat covers, it checks the durability of its products through conducting tests, such as

tear strength by falling pendulum apparatus, seam strength and abrasion resistance amongst others.

The covers are made from a 600-denier polyester with a waterproof polyurethane backing and are designed in the UK. This means the company has total control over the process. Town and Country Covers also uses overlocked seams for extra strength and durability.

The company even offers an embroidery service, so if a workshop would like to brand its fast fit seat covers, then Town and Country Covers is able to do this for them for a more professional look.

WANT TO KNOW MORE? WWW.RDR.LINK/ABG038

Brake pads Bettaparts has introduced an expanded

as Opell and Vauxhall. models including

brake pad range with 16 new part numbers

Corsa 19- and Mokka 20-, and various

designed to cater to a vast array of

Peugot applications such as 208 12- and

vehicle models. Among the new entries is

3008 11-16.

reference PLU1290 and is tailored for several CITROËN models like the C4 Grand Picasso 06-13 and DS5 11-16, as well

64 MARCH 2024 PMM

WANT TO KNOW MORE? WWW.RDR.LINK/ABG039

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MESSAGE ME YOUR PRODUCT RELEASES OR YOUR FAVOURITE PRODUCTS AT FCOLEMAN@HAMERVILLE.CO.UK

Product spotlight: The DY2300 locking wheel nut remover tool from Dynomec This locking wheel nut remover tool is a blend of decent engineering and patented solutions.

The patent not only aims to underscore the tool's uniqueness but also highlights Dynomec's commitment to what they term “pushing the boundaries”.

The impact driver, where rigidity takes centre stage, is used as a single assembly, featuring fewer joints to maximise rigidity and adaptors that firmly screw in place.

This streamlined construction not only enhances the tool's overall durability but also instils user confidence, resulting in a more successful and efficient operation.

A feature within the DY2300 is the peak drive c blade range which is specifically designed to tackle the Mcgard-style wheel nuts, but excelling particularly against the aggressive patterns and large track widths.

WANT TO KNOW MORE?

WWW.RDR.LINK /A BG040

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ADVERTISEMENT INDEX

Here is a useful summary of all the adverts that appear in this issue of Professional Motor Mechanic.

Each is listed with its page number and a direct URL that will get you straight to the relevant online information

AC Tronics .................................................................. (page 19)

Kalimex Ltd ................................................................ (page 65)

www.rdr.link/ABG100

www.rdr.link/ABG116

Aisin Europe .............................................................. (page 25)

Klarius Products Ltd ....................................................(page 43)

www.rdr.link/ABG101

www.rdr.link/ABG117

Autotech Recruit ........................................................ (page 37)

Liqui Moly UK ............................................................ (page 59)

www.rdr.link/ABG102

www.rdr.link/ABG118

Bailcast ........................................................................ (page 50)

Lucas Oil Prods Ltd ...................................................... (page 4)

www.rdr.link/ABG103

www.rdr.link/ABG119

Ben .............................................................................. (page 41)

MAHA UK .................................................................... (page 9)

www.rdr.link/ABG104

www.rdr.link/ABG120

BM Cataslysts ............................................................ (page 38)

MAM Software ............................................................ (page 63)

www.rdr.link/ABG105

www.rdr.link/ABG121

Bonaprene Products Ltd .............................................. (page 30)

Mann & Hummel (UK) Ltd ........................................ (page 12)

www.rdr.link/ABG106

www.rdr.link/ABG122

Borg Automotive ........................................................ (page 33)

Maverick Diagnostics .................................................. (page 44)

www.rdr.link/ABG107

www.rdr.link/ABG123

Bowmonk .................................................................... (page 53)

Mechanex .................................................................... (page 35)

www.rdr.link/ABG108

www.rdr.link/ABG124

Castrol .................................................... (IBC - OBC Gatefold)

PMM Online ................................................................ (page 27)

www.rdr.link/ABG109

www.rdr.link/ABG125

Comline Autoparts Ltd ................................................ (page 11)

Ring Automotive ........................................................ (page 44)

www.rdr.link/ABG110

www.rdr.link/ABG126

Contitech Power Trans Grp ........................................ (page 33)

Ryme UK .................................................................... (page 57)

www.rdr.link/ABG111

www.rdr.link/ABG127

DC Lubricants Ltd ...................................................... (page 55)

Schaeffler Automotive ...................................................... (IFC)

www.rdr.link/ABG112

www.rdr.link/ABG128

Dynomec .................................................................... (page 57)

The IMI ...................................................................... (page 30)

www.rdr.link/ABG113

www.rdr.link/ABG129

Ferdinand Bilstein UK Ltd ............................................ (page 6)

Topdon UK .................................................................. (page 47)

www.rdr.link/ABG114

www.rdr.link/ABG130

Jack Sealey Ltd .......................................................... (page 17) www.rdr.link/ABG115

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