Professional Motor Mechanic November 2023

PMM

PROFESSIONAL M OTOR M ECHANIC

MECHANEX SHOW PREVIEWINSIDE

WHAT MOT EQUIPMENT DO YOUNEED?

Q&A WITH GIPA’S QUENTIN LE HETET

Also inside:

BUSINESS & TRAINING

WINTER SERVICE & LIGHTING

DIAGNOSTICS & ENGINE MANAGEMENT

featuring

sponsored by

Editor’s Picks

16

43 SHOW PREVIEW

You could be reading this issue at our regional trade show Mechanex, or gearing up to travel to Sandown. Either way, you’ll want to get clued up with our show preview, featuring the full seminar line-up, interviews with key sponsors and a look at what some brands will be offering.

68 BRACING THE COLD

As the days get shorter and the weather gets colder, tools and equipment specialist Draper Tools is offering its top tips for dealing with the winter months.

63 UNLOCK EFFICIENCY

Ever thought about using dealer tools in automotive diagnostics? Andy Brooke, managing director of Maverick Diagnostics, is here to offer his top tips in doing so.

57-67 DIAGNOSTICS & ENGINE MANAGEMENT

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

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A ROAD tonowhere

It appears that our Prime Minister has been shaken by his own party’s recent surprise byelection victory in Uxbridge and South Ruislip – a contest which mostly centred around Labour London mayor Sadiq Khan’s planned extension of the ULEZ zone. The Ultra Low Emissions Zone, which effectively bans diesel vehicles of a certain age, and even some petrol cars, has now spread out to cover all London boroughs, meaning that if you are more than a few miles within the M25, it’s time to consider an upgrade – or given the price of used cars these days, simply a new-grade.

What has this got to do with the UK’s richest PM on record? Well Mr Sunak has brought the months of speculation on whether he will pull back on his own 2030 deadline for banning the sale of pure ICE vehicles (2035 for hybrids) to a screeching halt by admitting that his once firmly held beliefs were… not so firmly held after all.

Is this good news, though? As an aftermarket editor, I should probably be nodding enthusiastically and smugly proclaiming “I called it months ago” (which would be true, but so did everyone else). However, for a few reasons, the announcement leaves me anything but celebratory. Perhaps I should be thinking about the handful of garages which have publicly fretted about expanding ULEZ zones across the country threatening their business (customers aren’t going to pay 12 odd pounds to go to their usual garage, are they?). Maybe I should consider the older members of the aftermarket community who have no interest in working on EVs and who feel they’re too old to learn now. Should I, instead, be concerned about the very real threat EVs pose to the aftermarket.

I can’t, however, help but think that we shouldn’t be expending so much energy complaining about schemes to decarbonise transport and to make city air cleaner (as I write this, it occurs to me this might be the first time NIMBYs have wanted MORE pollution, not less…) and should instead be focussing on the real issues: labour rates, working conditions, the right to repair, the skills gap. For one, ICE vehicles will be around for a long, long time after the ban comes in (which it will, inevitably, at some point), meaning that there will be more than enough traditional work for those still around to take it. Secondly, discussions surrounding EV charging infrastructure, grid capacity etc. often feel like straw men set up to give the naysayers an easy win. Fix those problems and I have a nagging feeling that the stalwarts of the ICE brigade will simply find new windmills to tilt at. Yes, I struggle to see how EV charging across the UK will work, but I also would have struggled to see how mobile data could ever work, or digital radio, or self-service checkouts – these are all mad ideas which are now a part of daily life. I am not an expert on the “grid” and neither are you.

What is true is that battery capacity and range is going up, whilst price and charging times are coming down. Also true is that most cars on the road will still be ICE vehicles for a long time after the deadline, meaning there will be plenty of time to update infrastructure. Away from the logistics of the matter, if Sunak’s delay was motivated by anything other than next year’s election it would have happened a long time ago.

Kieran Nee Editor

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PMM NEWS with Freya

NEWSIN BRIEF

■ RISE IN NUMBER OF ILLEGAL ‘CHOP SHOPS’ Tracker Network and UK police forces have uncovered 34 illegal ‘chop shops’ nationwide so far in 2023, compared to an annual total of 32 for 2022.

■ EV TYRES ARE WEARING QUICKER THAN PETROL OR DIESEL Research from epyx’s 1link Service Network platform has found that EV tyres are lasting 6,350 miles fewer than petrol or diesel due to quicker wear because of the vehicle’s weight.

■ RECORD NUMBER OF STAR AWARD NOMINATIONS The Motor Ombudsman’s awards that recognise businesses accredited to the code of practice has seen 2300 nominations at time of writing one month before the awards, surpassing the 1500 from 2022.

■ FIRST LINE CELEBRATES ITS 40TH ANNIVERSARY Starting as Filter Internation in 1983, the First Line brand was introduced in 1987 and its steering and suspension programme was launched in 1992, now offering over 9,200 components and 40,000 references.

Coleman

MOT UPDATES

Emissions failures

An increasing number of MOT examiners are not conducting exhaust emission tests during an MOT, the DVSA has said.

On top of those, the government authority said other tests are also failing to produce records of these tests taking place during site visits. This raises speculation that there are even more cases of these tests not being conducted because if records are not available, the DVSA could consider that the emission test was not conducted.

Paperless MOTs

MOTs are set to go paperless within the year, as the DVSA looks to reduce fraud within the testing process.

The government agency wants to “massively reduce” the amount of paper used across the entirety of its remit, which includes plans to provide a digital-by-default option for the MOT certificate. This also aims to make the testing process more environmentally friendly.

This has led to numerous disciplinary cases resulting in testers and authorised examiners having their testing qualifications suspended or deleted.

“There is no excuse for not conducting emissions tests, and possible faulty equipment, or supposed lack of knowledge of equipment not storing information, will not be considered mitigation in any disciplinary case,” said the DVSA.

Surveys are set to be conducted to judge just how big of an impact this could make on the testing process, both for garages and drivers, especially for those that are less tech savvy. One big move could be to introduce a paperless MOT training log. Currently, they are recorded in many ways across different sites, with no standardised way to complete them and no centralised way to view them.

FOR UP-TO-DATE NEWS, SIGN UP FOR OUR WEEKLY E-NEWSLETTER. SIMPLY SCAN THE QR CODE

Wages on the rise

Data released as part of the IMI’s Automotive Labour Market Briefing has revealed that advertised wages in the industry are up 10 per cent.

However, more than 24,000 vacancies remain across the automotive sector, the advertised wages hoping to entice workers.

Training up

In response to the pressing demand for up-to-the-minute training amidst the rise of EVs, hybrids and intricate vehicle systems, Maverick Diagnostics has unveiled Automotive Training Academy’s online training platform.

But a slight drop since the end of 2022 (from 26,000) has been hailed promising by the IMI, but the institution is warning that more still needs to be done as the sector faces a vacancy rate 34 per cent higher than the average across all other industries.

NEWSIN QUOTES

Rishi Sunak pushes back ban on new petrol and diesel cars back 5 years to 2035. Here are some industry reactions:

“

It is imperative that we continue pushing forward with plans to upskill technicians and educate the wider public on EVs –this will not only lead to a stronger automotive sector but ensure that everyone has the right knowledge to make the transition safely and successfully.”

Simon King, interim CEO, Autotech Group.

“ Our business needs three things from the UK government: ambition, commitment and consistency,” said Ford’s UK chair Lisa Brankin ahead of Sunak’s announcement.“A relaxation of 2030 would unde-rmine all three.” But other carmakers openly welcomed the change, such as Toyota, the company said Sunak’s move “recognises that all low emission and affordable technologies can have a role to play in a pragmatic vehicle transition”. However, it is worth noting Toyota have been slower to rollout fully electric vehicles.

“

This platform is designed to cater to the educational needs of automotive technicians, encompassing 32 in-depth topics including electricity and electronics, engine management, air conditioning, diagnostics and hybrid and EV technology. This hopes to equip technicians with a well-rounded understanding of the industry landscape.

By shifting the goalposts, the government puts at risk the investments made by businesses in our sector who took early steps to adapt to a greener automotive landscape. These businesses now face an extended period before they can see a return on their investment, raising questions about the economic viability of their proactive efforts.”

Wayne Mason-Drust, NBRA’s board member said.

In pictures: Tony Lynch, driving his Lucas Oil sponsored Geriatric Toyota MR2, secured the 2023 Retro Rallycross Championship at the Pembrey Circuit in Wales

PMM NEWS

NEWSIN NUMBERS

4.1 %

The amount the used car market grew during the second quarter of 2023, with 1,832,267 vehicles being sold, according to the latest figure from the SMMT.

74 % of motorists say running costs are the most important factor when choosing a used car according the Startline Used Car Tracker.

with Freya Coleman

Is the ageing car parc good for independent garages?

In a recent episode of the Professional Motor Mechanic Podcast, host Kieran Nee spoke with Quentin le Hetet, country director UK at GiPA – also known as THE numbers man in the automotive aftermarket.

“In 2017, 38 per cent of the car parc was between less than one year old and four years old, now it is 26 per cent. So, it has already decreased by 11 points in just seven years’ time. This means that the younger share of the car population is shrinking, and this also means that the other side, after four years, is increasing. What we see is that the five to nine years old is particularly

To listen, scan the QR code

increasing at the moment, which is when generally drivers start to go independent garages... five to nine is really the sweet spot for any kind of workshop.”

In other words, cars on UK roads are getting older and this means more drivers could be turning to independent garages for repairs. This “sweet spot” for UK garages coupled with drivers continuing to spend money on their cars could mean that independent garages are in a position to thrive.

Online support and training

The automotive charity Ben launched a month-long campaign centred on suicide prevention.

This included a new section being launched on the website offering downloadable resources, contact details for further support and information on training and services for employers. This comes as its reported that 126 people die by suicide in the UK every week, 74 per cent of them being male. With the UK automotive industry being 80 per cent male, the sector could have a greater risk and vulnerability to suicide than in other industries.

DATES FORTHE DIARY Partnership success

MAM software has revealed its long-term partnership with Grooms Garage has assisted in the company’s longevity within the industry, the garage first being found in 1945. Grooms Garage has used products from MAM Software for over 25 years and are now utilising Autowork Online for its garage management needs.

■ Bookings are now open for the IAAF annual conference and awards dinner, taking place at DoubleTree by Hilton Milton Keynes on Thursday 7th December. The conference features a line-up of leading industry voices, and in the evening, delegates will be invited to the awards dinner, with Tom Allen, opening a show that recognises outstanding achievements across the automotive aftermarket.

With 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/ABC001). 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. 3

Digital Digest!

The internet’s top 5

practice tips such as making sure to follow the correct tightening procedure when reattaching the water pump cover, so is well worth a read.

WWW.RDR.LINK/ABC003

EGR valve replacement

Kicking off this month’s top online articles is Delphi, who have supplied PMM readers with a step-by-step exhaust gas recirculation valve replacement on a Nissan Micra. This comprehensive guide comes courtesy of its Masters of Motion hub for independent garage technicians.

the initial diagnosis being that there was excess wear at the clutch master cylinder to pedal connection.

WWW.RDR.LINK/ABC005

Suspension replacement

WWW.RDR.LINK/ABC002

Timing belt replacement

Up next is another guide, this one from Dayco on the replacement of a timing belt on a Škoda Octavia using its KTB819 Kit. This guide includes best

Another replacement guide follows from Febi, taking readers through the rear suspension on the trusty Ford Mondeo. Make sure to follow the link below to follow the step-by-step which is accompanied by helpful images.

WWW.RDR.LINK/ABC004

Clutch replacement

1 2 4 5

Replacement articles were very popular this month and so also making the list is a clutch replacement from REPXPERT Alistair Mason from Schaeffler on a 2014 Hyundai i30. The customer had report it was difficult to get into gear and

Battery draining causes

Rounding off this month’s top online articles, Ken Clark from Rotronics explains the difference between modern 12 V battery types and what causes lead to battery drain. Inside is the company’s top 10 things that are most likely to drain your customers’ batteries such as too many short trips, self discharge and cold weather

WWW.RDR.LINK/ABC006

PMM THE 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.

YOU ARE NOW ENTERING

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

Continuing 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!

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.

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Read ALL of the articles within this month’s CPD Zone

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Download your certificate for use as part of your annual CPD record

TROUBLESHOOTER

How to replace the transmission on a BMW i3 REX

Ihad always assumed the transmission on the BMW i3 was bomb proof. That was, however, until an i3 94 REX was towed into our front car park just last week. I took it for a spin around the car park and the symptoms were undeniable: a failing transmission. It’s hard not to be concerned when you witness firsthand the gearbox producing unsettling clunks and erratic jumps as I cautiously rolled along at a mere 10 km/h. Worse, this specific car has covered just shy of 50,000 miles. Not a considerable distance at all.

If we approach this complex machine as we would any unconventional vehicle, that is to say – a non-ICE vehicle, the initial step was to ensure the car was in a safe working condition. This involved opening the highvoltage battery safety connector, responsible for linking the battery cells, providing the dangerously high voltage required to power the i3’s 170-horsepower electric motor, often

referred to as “the electrical machine.”

Once a safe working environment had been established, the car reverts to nothing more than a conventional vehicle with a conventional if slimmed down transmission. An oil sample revealed the presence of metal swarf, a telltale sign of trouble: a new transmission was in order.

The REX variant of the i3 brings with it the weighty addition of a Rotax twincylinder engine, complete with its own highvoltage generator, aptly referred to as the “Range Extender Electrical Machine.” This additional engine introduces a layer of complexity, particularly when you're working within the confines of the i3’s compact rear engine bay.

One of the challenges posed by the i3 REX is the labyrinth of components that must be painstakingly disassembled just to gain access to the inner workings of the drivetrain.

The paramount concern in the removal process is to maintain the pristine condition of all electrical contacts. To achieve this, meticulous care is taken, evident in the application of tape to shield all exposed contacts. It's worth noting that the adhesive on the tape is delicately handled to ensure it never makes contact with the vital internal contact surfaces.

Close up of the crossbracing once the exhaust system and airbox were removed

Ben Johnson tackles a tricky transmission replacement on a BMW i3 REX.

Unconventionally, when stripping down, the EME – Electrical Machine Electronics –must be removed first, then the engine must be detached from the gearbox, and only then can the electrical machine be separated from the gearbox on the workbench. This unique order of operations is essential to avoid damage since the bolts that hold the transmission to the electrical machine are aluminium. Besides –trying to remove a heavy electrical motor from the gearbox first is counterproductive since removing the lightest component from the heaviest is the logical thing to do.

Now, let’s address a concerning issue that has cropped up in some reports. There have been cases of transmission repairs on the i3 failing prematurely, sometimes within just a few thousand miles. The culprit? Incorrect application of a special grease, often referred

to as “GE” grease, to the splines of the motor where it meshes with the gearbox input shaft. The root cause of this failure appears to be related to the brush-type seal located at the end of the motor bearing housing.

In these instances, too much grease or the wrong type of grease was used, leading to grease escaping from the splines. This escaping grease then found its way into the motor itself, resulting in catastrophic damage and premature failure. To illustrate the severity of this issue, I recently received images from someone who had seen evidence of a previous repairer liberally coat the motor splines with copper grease (which is highly conductive!). The consequences were dire, with the grease exiting at high velocity and infiltrating the motor casing and from there inside the motor itself. This unfortunate incident serves as a stark reminder of the importance of using the correct grease for specific applications.

The GE grease, as supplied by BMW, comes in a small package for a reason. It’s designed to apply precisely the right amount of grease to ensure that the hydraulic action during the mating of the gearbox to the electrical machine disperses the grease exclusively into the input shaft spline grooves and no further than that. This GE grease is, without a doubt, the stickiest and thickest substance I’ve ever encountered, resembling more of a glue than traditional grease. It serves as a compelling example of just how critical it is to select the appropriate grease

Rear lower subframe bracing removed. Time to remove the powertrain.

The gearbox casing removed revealed a failed lower differential bearing that had caused the diff, and other teeth to become damaged. A new gearbox was the only solution.

Close up of the differential crown wheel teeth damaged.

The Electrical Machine Service Cap removed exposes the 3 phase tails that must be removed prior to lifting off the Electrical Machine Electronics (EME) The circular component is the rotor position sensor.

thoroughly cleaned spline and correct application of a specific amount of GE grease to the base of the input shaft spline of the Electrical Machine.

for individual applications, underscoring the importance of attention to detail in our work.

Once the new gearbox arrived, I didn't waste any time in putting everything back together. You see, when you work quickly, you're less likely to forget where all the bits and pieces go. And with this car, there’s a lot to remember during reassembly.

The key here is precision. I had to make sure everything was put back exactly as it was when it rolled off the factory line. This isn't just about making the car look good; it’s about safety too. If you don’t install those high-voltage cables just right, you could end up with some serious problems, like them rubbing against something they shouldn’t. So, it's all about getting things back together perfectly to ensure safety on the road.

In my experience, tackling extensive jobs like this, particularly if it’s my first time, involves a tried-and-true strategy – capturing plenty of photos during the removal process and marking components with painted symbols. This systematic approach serves as a valuable memory aid when it comes to reassembly.

Moreover, during the installation phase, painting as each fastener is tightened is a practice I wholeheartedly endorse. It's a simple yet effective way to prevent any unintentional oversight, ensuring that nothing is left loose by mistake. However, I must emphasize the need for caution when wielding that paint pen. It’s vital never to paint equipotential bonding cables; doing so could introduce unwelcome resistance into this critical safety circuit. Safety always remains paramount in our line of work.

Once all the parts were back where they belonged in the vehicle, the next steps were straightforward. I began by double-checking and securing all the high-voltage connections, ensuring everything was in place before reconnecting the high-voltage battery connection.

A critical safety note here – when dealing with high-voltage systems, whether disconnecting, reconnecting, or handling Electrical Machine Electronics tails, I made sure to wear high-voltage gloves rated at over 1,000 V and a full shield face mask. This gear acts as a safeguard against any potential electrical discharge. It’s crucial to test these safety gloves before each use by blowing them up and checking for air leaks – you only have one chance when dealing with high voltages. As the saying goes, it’s always better to be safe than sorry. Even when the electricity is disconnected, it’s essential to consider the possibility of residual capacitance or surface charges. When in doubt, wearing gloves is the

wisest course of action. Safety remains our top priority in this line of work.

Checking the transmission oil on this car is a bit peculiar. Unlike newer gearboxes with both drain and fill plugs, this one had only a drain plug. To fill the oil, you have to go through the right output shaft opening; there’s no other way to do it.

Once that was done, it was a matter of reassembling the suspension and giving the car a quick test in the workshop. With the i3 back in action, installation of the bumper parts was undertaken and the fault codes cleared and re-checked. Before handing it over to the customer, the wheel alignment will be checked and corrected if required. Starting the REX engine using the diagnostic tool ISTA was necessary, just to ensure everything was working as it should – everything was okay.

One critical final step was to charge the high-voltage battery and to check for any potential issues that can crop up after such an extensive repair. The charging was flawless and no issues arose during or after the charging procedure. I sincerely hope that gearbox failures like this won't become a common occurrence. While this job was certainly interesting, it was a sizable one, and it’s not something I'm eager to tackle again anytime soon.

Oil filling to the gearbox demands the removal of the right driveshaft. Not a problem on this job but as a service task it would be a bit ridiculous.

The new transmission and drivetrain mated together and re-installed to the vehicle.

View from the rear of the Electrical Machine prior to removal of the engine (range extender), gearbox, Electrical Machine Electronics and the Electrical Machine. A complicated procedure to get this far.

HOW

TO Replace the clutch on a 2014 Range Rover Evoque

In this month’s Schaeffler LuK Clutch Clinic, REPXPERT Alistair Mason is replacing the clutch in a 2014 Range Rover Evoque 4X4 that is fitted with a 2.2 D engine and has covered just over 56,000 miles. The owner has reported that the clutch appears to be “slipping”, and a short road test confirmed the problem and clutch replacement was authorised.

Workshop equipment

■ Vehicle lift

■ Transmission jack

■ Engine support

■ Clutch alignment tool

■ Advised - driveshaft to hub removal tool.

Scheduled repair time: 6.4 hours.

Gearbox removal

With the vehicle placed on the vehicle lift, open the bonnet and remove the battery cover (Fig.1), air intake duct, front suspension cross brace, plenum chamber cover, battery and battery carrier. With access now available to the gearbox (Fig.2), remove the gearbox multiplugs, starter motor bolts, and ease the starter motor away from the bell housing, securing it in a rest position. Whilst in this area, remove the upper bell housing bolts, disconnect the hydraulic hose connection at the concentric slave cylinder (CSC) and plug hose connection to stop the fluid running out, also disconnect both gear change cables and stow in the bulkhead area.

Raise the vehicle lift to waist height, remove both front wheels and the N/S wheel arch liner, then raise the vehicle lift to gain access to the underside, remove the engine and gearbox undertrays and then drain the gearbox oil. Now remove the front subframe (Fig.3), which gives good access to the running gear that needs to be removed. So, remove both front driveshafts and centre support bearing (Note – a special removal tool may be required to push the driveshaft out of the hub assembly), followed by the air

charge pipe (Fig.4), disconnect the front prop shaft joint from the transfer box by removing the six bolts and remove the lower pendulum/torque mounting.

Remove the transfer box/driveshaft centre support bracket (Fig.5) and then unbolt the transfer box from the gearbox (Fig.6), remove the transfer box and then remove the lower bell housing bolts (Note – leave two easily accessible bolts to support the gearbox until the time of removal.) Support the engine using either an engine support or a second

transmission jack, gain access to the engine bay and remove the N/S gearbox mounting, lower the engine and gearbox slightly and remove the N/S gearbox mounting bracket (Fig.7). Support the gearbox with a transmission jack, remove the remaining bell housing bolts and ease the gearbox away from the engine, when clear, lower the transmission jack and remove the gearbox.

Fault diagnosis and clutch replacement

With the gearbox removed, it was clear to see that the clutch had been slipping badly as a lot of the clutch lining material was deposited in the bell housing and the release bearing on the CSC was blue in colour indicating constant contact and over-heating (Fig.8).

Remove the clutch assembly from the flywheel by unscrewing the six bolts (at this point we could see that the clutch lining had been subjected to a lot of heat as it was starting to break up and that the flywheel face was also “blued” (Fig.9). Due to the flywheel being subjected to excessive heat, replacement of the dual mass flywheel (DMF) was also advised, and the authorisation given.

After obtaining the torque values from Schaeffler’s REPXPERT, degrease the face using brake and clutch dust cleaner, and replace the DMF. Then turn your attention to the gearbox.

First remove any clutch dust (in this instance we used an industrial vacuum cleaner!) and the old CSC and then clean the bell housing using brake and clutch dust cleaner. Mount the new CSC and carefully tighten the bolts and torque to the manufacturer’s specification.

Apply a light smear of high melting point grease to the clutch plate splines on the gearbox input shaft and then mount the clutch plate onto the input shaft and move back and forth, this will ensure the clutch plate is of the correct fitment and evenly distribute the

grease. Then remove the clutch plate and wipe off any excess grease.

Now mount the new clutch onto the DMF, using a clutch alignment tool to position the clutch plate onto the DMF, ensuring the clutch plate is the correct way around as indicated by “Gearbox side”. Degrease the face on the clutch pressure plate and then install the pressure plate onto the DMF making sure it locates on the alignment dowels (Fig.10). Insert the six bolts, tighten them in an even and sequential process and then torque to the manufacturer’s specification.

Ensure all cables and hoses are clear of the bell housing area, so not to interfere with the gearbox installation and check that the engine to gearbox alignment dowels are correctly installed.

Gearbox installation

Position the gearbox onto the transmission jack and offer it up to the engine, but before rushing, it is always worth spending a little time aligning the gearbox correctly before mounting it onto the clutch and bolting to the engine. So, ease the gearbox into position and, when fully located onto the dowels, insert a couple of accessible bolts and tighten. Raise the engine and gearbox into position and secure with the installation of the N/S gearbox mounting.

Refit all the other components in reverse order of their removal and torque all bolts as required to the manufacturer’s specification, not forgetting to replenish the gearbox oil.

After the battery lead has been reconnected, reset all electrical consumers and carry out a full road test to ensure that the repair has been successfully completed.

BEST PRACTICE

Steering and suspension repairs

MOOG’s expert support team, the Garage Gurus, tells PMM about its latest advance in 3D schematics and offers up useful advice.

UPDATE YOUR TECHNICAL KNOWLEDGE

A quick scan of the QR code on any MOOG part is the gateway for mechanics to enhance their technical skills and keep up to date with the latest automotive developments and technologies. In addition to product authentication, fitting guides and advice and warranty information, scanning the QR code and tapping the relevant tab allows the user to enrol at the Garage Gurus® Online Training Centre, enabling them to access a comprehensive e-learning course library as well as live webinars and technical articles.

Some steering and suspension systems are incredibly complex and time consuming to diagnose and repair. This complexity can make it difficult to select the right part the first time, which not only slows things down, but can also lead to incorrect installations and ultimately, dissatisfied customers. To help combat this, the company’s 3D schematics aim to make it easy and quick to find the correct part for the job while providing a visual confirmation of the fitting position and the application criteria.

At the heart of the 3D schematics is an exploded view of the front/rear suspension system. This way, you can accurately see the fitting position of the parts that need replacement, eliminating the risk of incorrect installation due to any misunderstanding of how it fits into the system. The 3D schematics can also be used to identify surrounding parts that might need replacement as well in one single view.

Additionally, MOOG provides generic and specific fitting instructions to guide mechanics through the proper installation of the part. The specific fitting instructions are tailored to the exact part, while generic instructions cover standard practices that apply to all of the company’s parts. This ensures that the part is installed and functioning correctly.

The 3D schematics can be easily accessed

from the company’s parts finder, Driv e-cat and TecDoc catalogue, which is constantly being updated to include more parts and even more detailed images. This level of detail not only assists mechanics in selecting the correct part, but also makes repairs quicker and easier.

To find the 3D schematics in TecDoc, please, follow the steps below:

Select the vehicle in TecDoc

Click the part type, filter on MOOG and click any part number

Select the 3D Schematics link under the image (“circuit diagram”)

There are already 1200 3D Schematics available which cover more than 95 per cent of the European car parc.

In conclusion, 3D schematics provide mechanics with a unique visual confirmation that the correct part has been selected within complex steering and suspension systems. The ability to see the part in 360° rotating pictures and an exploded view of the system enables mechanics to easily select the correct part for the job, while fitting instructions reduce errors and repair time. WANT

KNOW YOUR PARTS

Toyota Prius Generation 3 brake system (2009-)

Blue Print offers its insight into the Toyota Prius Generation 3 brake system.

The Toyota Prius introduced in 1997, was the first full hybrid mass-produced car. Toyota have sold over 15 million hybrid vehicles globally since this date. With each model, comes evolution that affects each model mechanically and technically. In 2009, Toyota/Lexus changed the braking system fitted to the common Prius, Yaris, Auris/Corolla and CT200h models.

The brake system fitted to the Generation 3, Toyota Prius is different to a conventional hydraulic brake system and requires some background knowledge, before working on the system.

There are some commonalities between the old system fitted to the previous model Prius and the new system, but there are

some fundamental differences that are definitely worth knowing. As with conventional brake systems, the brake fluid replacement is part of the vehicle’s routine maintenance schedule, due to the hygroscopic nature of brake fluid. Therefore, this information is important when servicing or maintaining a Toyota or Lexus Hybrid vehicle.

The Hybrid System

In an ICE vehicle, fuel is used to increase road speed and then when pressure is taken off the accelerator, engine braking slows us down. Alternatively, the brake pedal is pressed, which applies the brake pads against the brake discs, which then creates friction and slows the vehicle down.

However, in a hybrid vehicle, the braking system is an integral part of the vehicle’s hybrid system. Fuel is used to accelerate to a speed and then when pressure is taken off the accelerator, the engine is disconnected from the drivetrain and the motor generator in the transmission generates electricity, to charge the high-voltage battery. This ‘regeneration’ is designed to cause the same rate of retardation as engine braking.

Slight pressure of the brake pedal simply increases the rate of charge and therefore the vehicle’s retardation, and it’s only when the driver’s demands on the braking system exceeds what the motor generator can provide, (about 30 per cent braking efficiency) that the hydraulic system comes into action.

The effect of this does two things; it improves your fuel consumption by around 60 per cent and increases the wear life of the brake friction components, with front brake pads normally lasting around 100,000

“In a hybrid vehicle, the braking system is an integral part of the vehicle’s hybrid system.”

km/60,000 miles or more.

A downside to this is that the brake calipers/sliders/pads are more prone to seizing through lack of use, especially if they are not inspected during routine maintenance.

So how does the system work?

The hydraulic braking system consists of:

■ An electrically driven pump and nitrogen filled accumulator to provide the operating pressure for the system.

■ A hydraulic brake booster, which controls the pressure relative to the driver’s demand.

■ A stroke simulator, which allows the brake pedal to stroke.

■ An active wheel speed sensor fitted to each wheel.

■ A brake pedal stroke sensor, which monitors pedal movement.

■ A hydraulic brake actuator (inside the dotted lines), containing 11 solenoid valves and two Pulse Width Modulated (PWM) linear valves.

So how does the system work?

The brake booster modulates the pressure in the brake line that goes to the SRC valve, which is closed with the system active, (shown when the field coil is red). The stroke simulator provides a degree of movement of the brake pedal by allowing brake fluid to displace the stroke simulator piston, when the brake pedal is pressed. Information from the pedal stroke sensor and master cylinder pressure sensor, about how far and how fast the brake pedal is pressed, and the pressure generated, is relayed to the brake electronic control module (ECM) and from the preprogrammed software in the ECM, a braking strategy is decided. Initially a small pressure is applied to the brake calipers, when the brake pedal is pressed. This is to precondition the brake discs and pads and to prevent the build-up of an oxide layer on the discs or water if driving in wet conditions.

Regenerative braking

Regeneration occurs when the hybrid control unit allows current to flow from the motor generators to the battery. The system is designed to recover as much energy as

possible. A combination of regenerative and hydraulic braking is used when the driver’s demand exceeds that, which can be provided by regeneration alone. Brake application is controlled by the two linear valves SLA (apply) and SLR (release) by using a balance of modulated current (PWM) to the valves, the pressure in the calipers can be controlled to produce the desired braking effect.

This system allows for the electronic control of the brakes to be independent of, but relative to, the drivers pedal application. The system also incorporates strategies for electronic brake distribution (EBD), the antilock braking system (ABS), Traction Control (TRC) and vehicle stability control (VSC).

ABS

The solenoid valves FLH and FLR control the pressure and flow to the front left caliper. In the event of a wheel slowing down as if to lock under braking, FLH (Front Left Hold) will be closed to prevent increasing pressure to the front left caliper and should the wheel then lock, FLR (Front left Release) will open, to release the pressure from the caliper to the reservoir allowing the wheel to turn; this action is repeated in quick succession until the wheel behaviour returns to normal. All four wheels can be controlled like this.

VSC/TRC

Controlling the hold valves will isolate parts of the circuit. Individual brakes can then be applied independently of the driver. TRC relies on being able to apply the brake of the driven wheel, which has lost traction under acceleration so as to apply drive to the opposite wheel across the differential. VSC works by applying the brakes to different wheels to correct excessive yaw caused by oversteer or understeer situations. Both systems also take control of the drive torque by controlling the engine throttle or drive motor.

Fail safe

In the event of an electrical failure, the valves revert to their un-energised position. SSC, SCC will close, conversely SMC and SRC will open. This allows a clear passage from the master cylinder to the front brakes, the pressure being generated by the driver pushing on the brake and pressurising the centre section of the brake booster.

Brake bleeding for routine maintenance

This has to be carried out using a suitable diagnostic tool and with an assistant. Due to the complexity of the system, the procedures must be strictly adhered to. There are two bleeding procedures; one for normal bleeding such as regular maintenance or after the replacement of a calliper or brake hose; and one for situations that will have involved letting air into the brake booster.

It is very important to follow the procedure lead by the software in the diagnostic tool; any deviation will cause the system to fail and the hybrid system to go into an emergency mode, logging fault code. ‘C1214 hydraulic control system malfunction’.

At the end of the process, the accumulator pressure is raised and lowered six times whilst the brake ECU opens and closes the internal valves in a sequence to circulate fluid.

If the brake booster, stroke simulator, hydraulic brake actuator, pump, accumulator or any of the pipes are to be replaced or if by accident air has entered the components mentioned, the second procedure is used. This procedure includes bleeding of the stroke simulator and initialisation of the linear valves.

Blue Print offer an extensive range of brake components for hybrid and electric vehicles which are fundamental to vehicles brake system, to decelerate and stop the vehicle. Its range focuses on meeting or exceeding ECE-R90 requirements, by lowering noise and vibration as well as reducing dust and emissions. This is done by using friction material, which contains less harmful metals such as copper.

The brake system fitted to the Generation 3 Prius is different to a conventional hydraulic system and requires some background knowledge.

DIAGNOSTIC GUIDE

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

A few years ago, PMM ran a guide from Bosch on its KTS diagnostics software, ESI[tronic] 2.0. We thought it would be a good idea to revisit the guide with Bosch and find out what’s changed. In this third instalment, Bosch explains how the software streamlines everyday service tasks in the workshop with the ‘service tasks’ feature.

In our previous issue we took a closer look at how technicians can quickly and easily run a complete vehicle diagnostic check with the ‘system overview’ tool. In this guide, we will take the next logical step with the ‘service tasks’ tool. By putting all the tasks you need to complete a service for a specific vehicle right at your fingertips, ‘service tasks’ is one of the easiest to-use timesaving features your Bosch ESI[tronic] 2.0 software has to offer. Here is how it works:

Accessing service tasks

The ‘service tasks’ tool on the ESI[tronic] 2.0 will guide you to precisely the right ECU for the chosen function – with no need for extensive searches or any prior knowledge about the make or model of the vehicle they are working on. This is a great time-saver for quickly identifying and executing the most common tasks, from maintenance resets and tyre changes to brake fluid and pad replacements.

How to identify relevant service tasks

STEP : Once you have selected the vehicle (see lesson 2) open the diagnosis menu and click on the Service Tasks button. (see fig.1).

STEP : By selecting ‘Service Tasks’ you will be presented with a list of possible service tasks for the selected vehicle (see fig.1).

STEP : Simply double click the service task you want to execute and the ESI[tronic] 2.0 will take you straight to the correct function in the corresponding ECU (see fig.2). Or alternatively, the service task that is required can also be entered by selecting it with one click, and then by pressing ‘start’ in the bottom righthand corner.

STEP : Users can also search for specific or desired tasks in the search bar (see fig.3). The ESI[tronic] 2.0 will let you easily search for any kind of available task and precisely tell which ECU to use – with no

need for extensive research or any prior knowledge about the make or model of the vehicle they are working on. Remember, ESI[tronic] 2.0 will also indicate if a specific service task does not require programming on the vehicle in question to make sure you do not waste time with any unnecessary searches or undertaking more work than needed (see fig.4).

Making the most of the mileage function

The ‘mileage function’ is another useful timesaving tool. By reading and consolidating all of the mileage data across the vehicle’s various control units – you can leverage this functionality to retrieve an accurate and efficient overview of all the mileage information stored in the vehicle. All in a single click (see fig.5).

This is particularly useful for understanding whether a vehicle’s mileage has been changed when carrying out work on behalf of insurance companies, experts and appraisers looking to prepare a valuation report, when returning cars to leasing companies or to give an accurate picture to car dealerships trading-in used cars.

Keeping your software updated is crucial

Remember, making sure your KTS/ ESI[tronic] 2.0 are running the very latest software updates is crucial for maximising the capabilities of the tools at your disposal.

When using our newest software, you can rest assured that any online software updates will be downloaded by the diagnostic download manager automatically in the background ( see fig.6 ).

With reduced maximum download sizes, it has never been easier to make sure you always have the very latest functional diagnostic coverage and are kept up to date with any enhancements to existing diagnostic systems.

However, to ensure you benefit from these online updates, you will need to manually apply any local system software updates and confirm the installation of the downloaded software updates.

If these updates are overlooked, you may end up with reduced functionality and incomplete or outdated information. To make sure you do not miss out, simply click once on the ‘Install now’ button and the DDM will do the rest – installing every available update on your computer (see fig.7).

Next month Join us for our next lesson to discover how the ‘known fixes’ feature could turn hours of Googling into seconds of searching.

The ‘service tasks’ tool on the will guide you to precisely the right ECU for the chosen function.

WILL HYDROGEN REPLACE

Proton-exchange membrane fuel cells, also known as polymer electrolyte membrane (PEM) fuel cells, are the type mainly used for vehicles. They produce electricity through the reaction of a fuel (hydrogen) with oxygen. Water is the only waste product from this type of fuel cell. The reaction between hydrogen and oxygen releases energy.

Fuel cells convert a substantial proportion of the chemical energy into electrical energy so are very efficient. All oxidations involve a transfer of electrons between the fuel and oxidant, and in a fuel cell this is employed to convert the energy directly into electricity.

The working temperature of fuel cells is 50-100°C, but some can be up to 200°C. High pressure is also used in the cell, in the region of 30 bar. A unit consisting of many fuel cells is referred to as a stack.

Individual cells are connected in series just like a normal battery. This forms a stack that meets the necessary voltage and current requirements. The theoretical open-circuit voltage of a hydrogen-oxygen fuel cell is 1.23V at room temperature, but

EVS ?

In part one I looked at how clean hydrogen is created. This time, we will examine briefly how a fuel cell converts hydrogen into electricity and then compare the efficiency of an EV and a FCEV.

For hydrogen to become a mainstream fuel, a new infrastructure will be required at fuel stations. The hydrogen will have to be created, compressed, delivered and stored.

Unfortunately, hydrogen consumes a huge amount of energy as it is being created and compressed. Delivering electricity to a charger via the national grid is very efficient.

For me, the key information that we need to be aware of is how much electricity is needed to run a hydrogen powered vehicle. This image shows that the BEV is much more efficient:

Grid capacity will need to expand to charge more BEVs, but to create enough hydrogen for the equivalent FCEVs, the expansion would need to be more than double.

in practice it is around 1V. Under load conditions, the cell voltage is between 0.5 and 0.8V. The stack voltage is usually 400-500V.

OPINION AND FACTS

As mentioned previously, in my opinion, hydrogen is not the future for cars, but it will be used for storage and on larger vehicles such as buses and trucks; perhaps even for shipping and aviation.

Something that is often overlooked is that a hydrogen car is a battery electric vehicle –but with considerable added complexity (and therefore cost). FCEVs have a lithium-ion battery and all the other components that a standard BEV has, but they also have a fuel cell stack, fuel storage tanks and associated delivery systems.

Creating and storing hydrogen when a wind turbine or solar farm is producing more electricity than is needed is an ideal solution. Truck refuelling stations could be located close to where this hydrogen is created to reduce delivery costs. However, to roll out a national network of hydrogen charging stations that rival petrol/diesel would be a huge task – some say we are struggling to roll out enough EV charge points, which is a much simpler process.

As a clean fuel, there is no doubt that hydrogen has exciting potential. The fact that big names like Bosch, VW, BMW, Toyota and others are investing in it definitely tells us something. However, there are a lot of technical challenges yet to solve, not least of which is the creation and distribution of hydrogen.

Hydrogen-powered cars have a lot going for them. They’re clean and offer good range. But on further examination, the amount of upstream electricity they use, makes them less attractive. Larger vehicles and local storage seem like good options, but we have all got a lot more to learn about the best way to use the benefits of hydrogen. Go BEVs!

FIG.2 Fuel cell stack from a Toyota Mirai

FIG.1 Proton-exchange (polymer electrolyte) membrane fuel cell operation

INSIDE INTELLIGENCE

Providing safe, accurate vehicle repairs and getting customers back on the road quickly means starting with the right tools: ALLDATA Repair offers exactly that by providing up-to-date OEM mechanical/body repair information and procedures for 91,950 unique vehicle combinations – more than 95 per cent of all vehicles on the road today. The portal comprises of six million technical drawings and wiring diagrams, including electrical connector views, which are available in five languages.

To show how ALLDATA Repair can be used in the real world, let’s look at two recent cases the team has dealt with.

2016 FORD TRANSIT

2.0L ECOBLUE

Experts at the ALLDATA Repair Info Centre Service recently received an enquiry from an independent workshop. The team were struggling to diagnose an issue on a 2016 Ford Transit 2.0L EcoBlue. The concern was a strange noise emanating from the vehicle’s engine compartment area and only appeared to sound when the vehicle was being driven – not stationary. Furthermore, the driver reported random starting issues. Despite a thorough diagnostic scan, no DTCs appeared, nor did any recorded issues. Perplexed, the workshop contacted ALLDATA Repair Info Centre Service for assistance.

Solution

Reassuringly, ALLDATA Repair’s professionals were able to come to the workshop’s aid! This issue pops up now and then, with the main suspect being the alternator pulley. In this case, the alternator needs to be removed, which then gives the technician access to the pulley.

The correct pulley can be acquired via local distributors or dealer, if the technician has the vehicle’s VIN number.

2018 JAGUAR F-PACE

Independent workshops and bodyshops rely on ALLDATA Repair; as such, it recently came to the assistance of a customer that was recently working on a 2018 Jaguar FPace, which had been experiencing issues which left a technician puzzled and scratching their head.

The lights, indicators and the wash wipe system worked intermittently. The technician scanned the vehicle’s systems, but no trouble codes were present – it was very odd and frustrating, as it was proving difficult to solve. Step forward, ALLDATA Repair.

Solution

Thankfully, ALLDATA Repair’s experts had come across this issue before and, indeed, it was tricky to solve! The root cause of the problem was down to a poor connection on the connector mounted on the PCB board within the lighting and/or wiper control switch.

The technician removed the control switches; in the example, it shows the left-hand control switch, but the right-hand side is the same.

Catch ALLDATA at Mechanex

Upon doing so, the technician connected and reconnected the control switches at least twice to clean the electrical contact points. They obtained some NyoGel electrical contact lubricant – a suitable equivalent is fine – and applied it to the connector on the PCB. For future reference, it’s vital that it’s not directly applied to the control switch connector.

Finally, they removed excess lubricant and refitted all components as required. The same method can be used, if required, to the right-hand control switch. This solved the issue and allowed the technician to complete a professional, correct and efficient repair, which meant their customer was a happy customer.

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 below or WWW.RDR.LINK/ABC013

A look inside:

Hi Quentin, could you give us a quick rundown of the state of play of the industry surrounding new cars coming into the UK at the moment? Obviously during the pandemic supply took a big hit. Where are we now?

Indeed it was a big hit and is still with us. The wave hasn't passed completely for new car sales. To put it into context, in the UK in 2019 there were 2.3 million new cars sold. In fact, this was quite a decrease when you go back and compare it to 2016. In 2016, 2.6 million new cars were sold. Looking at the figures for the years in between, we were roughly around 1.6 million each year, 2020-2022. I

So we can expect a slow recovery?

It’s the same everywhere. The recovery is underway; if you look at the first six months of 2023, the figures are relatively better in all, or at least the top five European countries, including the UK, compared to

don’t see any big earthquake in terms of recovery for 2023. Best case scenario we are looking at 1.8, but I think we will get to 1.7. All this means, then, that the UK has been facing an annual deficit in new cars coming onto the market of around 700,000 cars annually. For the three years leading up to 2023, this means the market is currently short of 2.1 million cars compared to pre-pandemic levels.”

This month we bring you a snippet of the chat between PMM editor and host of the PMM Podcast, Kieran Nee and country director for the UK at GiPA, Quentin Le Hetet. Here, the two discuss the ageing car parc.

Ageing cars - this is good news for garages, right?

It is, it is. Good news for most garages, that is. It is not, however, good news for dealerships. Let’s look at a stat that is very interesting: in 2017, 38 per cent of the car parc was less than four years old. Now, that figure is 26 per cent. So in just six years, that section of the car parc has decreased by 11 points. In other words, the younger share of the car population is shrinking. On the other side, the proportion of the car parc above four years old is growing. What we see is that the five to nine year old section is particularly increasing.

This is the point in a car’s life when drivers generally start to go to independent garages. Also particularly of interest is that the 15+ year old section is also increasing massively. If cars

are not being renewed with a new purchase, you don't just write off the car. You still need it. So people are holding onto their cars for longer.

So the two car age groups that are increasing are 5-9 years old and 15+. 5-9 is really the sweet spot for any kind of workshops. 15+ is still interesting for workshops, especially because you start to get very technical, mechanical failures. However at that age, owners are trying to limit the costs of car maintenance and might, for instance, go online to source parts or try and do a bit more themselves.

So there are two different profiles of drivers entering your workshop more frequently now. But all in all, this is definitely good news for the independent aftermarket.”

2022. But they are still much, much lower. The lack of new registrations means the UK car parc is aging a lot faster. Although, it must be said, the UK car parc was and still is one of the youngest in Europe.”

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

Catch Bilstein at Mechanex

BILSTEINB4–HANDLING AND SAFETY

JUST LIKE ON THE FIRST DAY

MOST DRIVERS DO NOT EVEN NOTICE THE GRADUAL WEAR TO WHICH IMPORTANT SUSPENSIONS COMPONENTS SUCH AS SHOCK ABSORBERS ARE SUBJECT. HOWEVER, HANDLING CAN CHANGE SERIOUSLY OVER TIME – OR EVEN MORE QUICKLY IN THE CASE OF PERMANENT EXTREME STRESS.

THE IMPORTANCE OF INTACT SHOCK ABSORBERS FOR A RELIABLE DRIVING EXPERIENCE

Handling becomes imprecise and the braking distance becomes longer without being noticed. Dangerous situations can quickly arise, especially in extreme situations when suddenly swerving in front of an obstacle, when shock absorbers are worn. It is therefore all the more important that a competent workshop regularly checks the safety-relevant components and, if necessary, replaces them with a reliable quality product.

If replacement is necessary, BILSTEIN shock absorbers from the B4 OE replacement range are the first choice. BILSTEIN has been fitting passenger car models from a wide range of manufacturers ex works for around 70 years and has played a key role in driving forward the development of suspension technology. In terms of technology and quality, they correspond exactly to the original equipment and thus fulfil exactly what most car drivers want – a driving experience like on the first day. What’s more, the first series-produced gas pressure shock absorbers also come from BILSTEIN. BILSTEIN can even meet brandspecific requirements for “intelligent”, semiactive suspensions in various Mercedes-Benz models with the B4 DampMatic®

OPTIMUM WORKSHOP SERVICE THANKS TO OEM EXPERTISE

It’s not only worthwhile for drivers to turn to the reliable and patented BILSTEIN technology, but also for workshops: The right B4 model is available for almost every car on the market, as a monotube and twintube gas pressure shock absorber, in the specification that exactly matches OE products. BILSTEIN is also a one-stop shop for the necessary accessories such as top mounts or bump stops and even springs. In addition, customers can revert to the BILSTEIN B4 OE replacement shock absorber with DampTronic® add-on for vehicles with active suspension systems. This reflects all the features of the OE shock absorbers and is just as easy to install using the plug-and-play method. The BILSTEIN B4 air suspension module is designed for vehicles with air suspensions. Rapid availability is also guaranteed thanks to production in Europe.

ANOTHER UPSIDE IS THAT THE EXPERT WILL HELP IF THERE ARE ANY QUERIES

BILSTEIN makes its extensive expertise as an OEM available to workshops quickly and without red tape. “Modern suspension technology is also making shock absorber replacement increasingly complex. Our team is always available for workshops to provide straightforward advice and practical support in the event of technical questions or problems. We pass on our consolidated knowledge of all aspects of the suspension system in special training courses, and at the same time prepare the workshop for future technologies”, explains Rainer Popiol, head of BILSTEIN Academy. In this way, the overall package of the B4 product range ensures a high level of customer satisfaction. After the shock absorbers have been replaced, perfect road grip and precise handling are restored. The result is maximum safety and a driving experience as if the car just came from the assembly line. A difference that the driver feels immediately and can experience over tens of thousands of miles.

EVTRAINING now available

The Varta team has announced a new suite of battery e-learning modules now live in the battery specialist’s online Partner Portal, designed to complement the company's more traditional face-to-face-training.

According to Varta, its goal is to always provide the best user experience during its training –both online and offline. “Our E-Learning offerings are aimed at everyone who deals with batteries in their daily business”, says Ulrich Germann, training and technical support manager at the Varta Training Academy. “We want technicians and sales advisors, wholesalers and retailers to be able to understand the new technologies and today’s complex vehicles. We want to share our profound knowledge in a user-centric approach so that our customers can be successful in their daily business.”

Start-stop

The first technology advancements around the battery came with the introduction of start-stop systems. Since then, fuel-saving functions have gone far beyond simply switching off the engine at traffic lights; many standard features are not even noticeable by the driver. For workshops to be able to repair these complex systems in the future, Varta will continually update the training modules to ensure technicians are prepared. In addition to general topics such as “Warehousing and Storage” or the “Varta brand and USPs”, there is also more in-depth technical material such as “Vibration Resistance” or “Deep Cycling Capabilities”.

And the next technological leap is already underway, as the role of the traditional 12V battery is more important than ever for hybrid and even pure electric vehicles. Additionally, with the latest developments in EFB and AGM batteries for heavy commercial vehicles, the technological landscape has become as complex as that of passenger cars, so well-educated employees become more and more important for a successful business.

After a successful launch, a new series on the topic of drivetrain electrification and the

role of the 12V battery in electric vehicles is ready for learners in the portal. The new modules focus on differing types of vehicle technology available in the market, and the role of the 12V battery for each of these. VARTA E-Learning courses are currently available within the VARTA Partner Portal. Registered users get access to a complete offering of digital trainings on: basic battery knowledge advanced passenger cars including modules on hybrids and EVs heavy commercial vehicles

Simply login and click the ‘menu’ in the top left of the screen, then you have free and unlimited access to the VARTA E-Learning.

“We are very pleased to be able to support the UK and Irish aftermarkets with these free-to-access Elearning courses, and hope that technicians and factor staff find them useful and informative.”

John Rawlins, marketing manager

SUSTAINABLE choicesforgrowth

As Europe sweltered under near-record temperatures this summer, the impetus for individuals to do their bit to help tackle the climate emergency by reducing their carbon footprint has become ever more compelling. Since transport is responsible for almost a quarter of the UK’s greenhouse gas emissions according to the Department for Transport, it’s important that drivers take environmental impact into account in their decisions about vehicle purchases and maintenance.

While the adoption of EVs remains a key plank of the government’s net zero policy, the clean mobility agenda also relies on ensuring that the existing combustion-engine vehicles on the road are operating in the most ecoeffective manner. The question for garages is: how keen are motorists to choose more sustainable options where possible? What’s more: are they prepared to pay more for them, especially if the cost-of-living crisis puts pressure on their good intentions? The answer in many cases, according to YouGov research we commissioned, is very much in the affirmative.

Motorists are prepared to spend more to go green

For example, two in five UK drivers surveyed say that they would choose to go back to a garage or mechanic based on environmental factors – even if that meant paying a higher price for their services. A further one in seven would prefer to use a mechanic that was committed to environmental impact if the costs were equal.

What exactly do motorists mean by this? Digging deeper, those drivers indicated they are most interested in garages and mechanics who can recommend ways to improve the environmental impact of motoring, 21 per cent, and almost as many, 20 per cent, said a visible commitment to the environment, such as using renewable energy in the workshop, or recycling, is a factor.

That’s not to say that other considerations such as trust and confidence in the capability and pricing of garages, and their location, don’t remain key. However, it does illustrate that there are many ways for garages to attract more business from discerning customers.

Sustainability pays long term

One way to enable customers to make positive changes is to offer them simple solutions that are more eco-friendly than the alternatives – for instance by suggesting they switch to more sustainable engine oils. Environment is likely to trump cost here – we found that almost two-thirds of UK car or van owners would pay a higher price for vehicle maintenance products if they delivered environmental or sustainability benefits. Just 11 per cent of drivers said that they would not consider sustainability or environmental impact at all when making purchases for their vehicle.

However, it’s a misconception that better environmental performance costs more overall. In the long run, seeking out products that offer vehicle longevity should have economic and performance – as well as sustainability –benefits. After all, the longer customers can keep their car engines operating in peak condition, the better, and while some products may have a slightly higher upfront price, the long-term savings on maintenance or replacement costs are far greater. No wonder then that drivers indicated that they would be most heavily swayed by products that extend the lifespan of an engine (46 per cent) and improve fuel consumption (45 per cent). It was with these requirements in mind that we developed our Quartz range of engine lubricants to enhance engine cleanliness (and boost engine protection) while also improving fuel efficiency. It’s also why we designed our new eco-efficient ‘Quartz Box’ packaging to use less plastic and more recyclable cardboard, while reducing volume for optimised logistics. The case is clear. Motorists want to do what they can to become more environmentally friendly, and workshops have a key role to play in supporting that. Our research shows that delivering more sustainable products and services is often a competitive differentiator between garages, which should drive loyalty and business growth for those who demonstrate eco credentials. Going greener is win-win: not only can it help to save the planet – it can safeguard the viability and strength of your company’s operations too.

David

Valentyne, Business Development Manager

at

TotalEnergies

Marketing

UK discusses how focussing on sustainability can help drive business growth.

“One way to enable customers to make positive changes is to offer them simple solutions that are more eco-friendly.”

David Valentyne, TotalEnergies

Ask the EXPERTS first

2030 to 2035, while saying he still expected that by 2030 most new cars would still be electric due to advancements in technology and manufacturer investment.

IAAF says the five-year delay to the ban of internal combustion engine (ICE)-powered vehicle sales risks public enthusiasm for the Government’s Net Zero agenda, but that the implications on the aftermarket industry have not been fully considered as plans change.

As part of the Federation’s intensive lobbying activity, IAAF discussed with the Minister of State for Transport that the Government’s strategy remains zero exhaust emissions, but it was also confirmed that the ability to continue to use second hand vehicles that have internal combustion engines is also part of their strategy. IAAF has also suggested that future powertrain technology has not been fully considered amongst the discussion on banning new petrol and diesel vehicle sales, with hydrogen fuel cell technology also a viable option in the pursuit of a practical and

and allow it to play a greater role in the consultations on Net Zero. The aftermarket industry is the leading provider of service, maintenance, and repair of the 34 million vehicles on UK roads, so it needs to be part of the discussion.

“Everyone wants to do the right thing on climate change, but they don’t want to be unfairly penalised and faced with changing their mode of transport to a more expensive alternative at a time when the cost of living is so high,” Field adds.

“The issue is that without certainty and regular consultation, the automotive industry cannot appropriately plan for the future, whether that’s powered by petrol and diesel, electricity, or another alternative fuel. The delay proves that 2030 was simply a target, and in order to realistically achieve this then more discussion with the experts in service, maintenance and repair needs to happen.”

“Much has been made of the country’s triumphant road to an alternative-fuelled future, but the aftermarket, as the pinnacle of a circular economy that has been gearing up for a very diverse set of vehicles arriving on its shores for some time, yet again faces the goalposts being moved with little consultation.

As an independent trade body, IAAF advocates for the needs of the aftermarket supply chain including retained access to vehicle repair information, to ensure suppliers are on a level playing field with vehicle manufacturers, and earlier in the year campaigned for retention of the annual MOT.

The Independent Automotive Aftermarket Federation (IAAF) has urged the Government

“The issue is that without certainty, the automotive industry cannot appropriately plan for the future.” Mark Field, IAAF

TESTING TIMES

To perform MOT tests efficiently, it's important to have the right equipment in your MOT bay. JHM Butt delves into the various classes of MOT bays and the latest advancements that make MOT testing more accurate than ever before.

Regardless of the class, MOT bays require specific equipment to conduct inspections. Here are some essential tools and theiruses:

■ Roller Brake Tester (RBT): Measures the efficiency of a vehicle’s braking system, ensuring it meets safety standards.

■ Headlamp Beam Tester: Checks the alignment and intensity of a vehicle’s headlights to ensure proper visibility on the road.

■ Wheel Play Detector: Checks for excessive play in a vehicle’s steering components, ensuring proper control and safety.

■ Exhaust Gas Analyser: Analyses emissions to verify the vehicle’s compliance with environmental regulations.

When mechanics are buying or updating MOT equipment, there are several important considerations to keep in mind. Here are some factors they should be aware of and consider:

Quality and Durability: The quality and durability of the equipment should be a top priority. Investing in high-quality equipment ensures accurate and reliable test results and longevity of use. Look for reputable manufacturers and suppliers with a track record of producing reliable and robust equipment.

Technical Specifications: Mechanics should consider the specific technical specifications of the equipment they are purchasing or updating. It's important to ensure that the equipment meets the requirements for conducting MOT tests on the vehicles they service. Consider factors such as compatibility with vehicle models, measurement range, and precision of the equipment.

Compliance with Standards: Verify that the equipment meets all necessary standards and regulations for MOT testing. It should comply with relevant laws and requirements to ensure the accuracy and legality of the tests

conducted. Checking for certifications and adherence to industry standards is crucial.

Ease of Use: The equipment should be user-friendly and intuitive to operate. Complex and difficult-to-use equipment can lead to errors and inefficiencies during testing. Look for equipment with clear instructions, user-friendly interfaces, and features that simplify the testing process.

Maintenance and Support: Consider the availability of maintenance and support services for the equipment. Regular maintenance is crucial to ensure optimal performance and longevity. Ensure that spare parts are readily available, and consider the reputation and accessibility of the manufacturer or supplier for technical support and longevity of service in the industry.

New MOT technologies

Automated Test Lanes (ATL): ATLs have revolutionised MOT testing by automating various aspects of the process. These lanes utilise integrated testing equipment and software systems that streamline the testing process and reduce human error. Automated systems perform tests such as brake testing, emissions analysis, headlamp beam testing, and more, providing accurate results and minimising subjectivity.

Integrated Diagnostic Systems: New MOT equipment often comes with integrated diagnostic capabilities, allowing mechanics to conduct in-depth analysis and obtain detailed diagnostic information. This helps identify specific issues quickly and accurately, facilitating more effective repairs and adjustments.

Wireless Connectivity: Some modern MOT equipment offers wireless connectivity features, allowing seamless data transfer and integration with computer systems. This streamlines the testing process, increases efficiency, and reduces the risk of data entry errors.

When it comes to the durability and quality of MOT equipment, mechanics should pay attention to several aspects:

Build Quality: Look for equipment made using high-quality materials that can withstand regular use, including heavy-duty components wherever applicable. High-quality construction ensures durability and reliability.

Calibration and Accuracy: Verify that the equipment is accurately calibrated and recalibrated periodically. Accurate readings are vital for valid test results, and regular calibration ensures continued accuracy.

Manufacturer's Reputation: Research the reputation of the manufacturer or supplier. Consider their history, customer reviews, and feedback on the quality, durability, and reliability of the equipment. Reputable manufacturers with a solid track record are

likely to provide better-quality products.

Warranty and Service: Check for warranty options and the availability of service and support. A good warranty ensures protection against defects, and reliable service and support are crucial when assistance is needed.

Prioritising durability, quality, and accuracy will lead to a more efficient and reliable MOT testing process, benefiting both the mechanics and their customers.

In conclusion, consider the class-specific equipment required, and ensure quality, technical specifications, and durability when updating or purchasing new equipment. With advancements in technology, MOT testing has become more accurate than ever before.

Could REMANUFACTURING ease cost ofliving pressures?

The emotive topic of cost of living has triggered consumers to question – and change – their buying habits. The majority have become savvier; McKinsey’s September 2022 data, for example, reported that 81 per cent of consumers had changed their shopping behaviour in response to concerns and pressures faced – but what is the public’s attitude and perception when it comes to getting their vehicle repaired?

The remanufacturer of starter motors and alternators was founded in 1986, so it has operated during tough times before, but, thankfully, it has persevered through those challenging periods and is currently embarking on another successful chapter with sales at high levels.

The company prides itself on providing its customers with a quality product, comprehensive range, outstanding availability, and possessing premier knowledge, not to mention desirable remanufacturing facilities, all of which equate to an exceptional offering.

It is no secret: Autoelectro is a premium brand; however, given the aforementioned factors – and as he is about to explain – Harnek is adamant that the long-term value of the

company, and the products it offers, is priceless and reflects excellent value for money.

He said: “Though the initial impulse may be to go for cost over everything, the tradeoff for this may involve sacrificing quality, which can be a false economy, as it can lead to further issues down the road. It is human nature for price to contribute to decisionmaking, but if that decision leads to a product failing and, consequently, higher costs of fitment and removal – not to mention time, inconvenience and effort – for the customer, is that really much of a saving?”

The question of price

It’s in this context that the relevance and value of remanufacturing cannot be overstated. Remanufacturing requires a detailed and complex understanding of the product; this expertise allows Autoelectro’s engineers to disassemble, clean, inspect and remanufacture their units to meet or exceed OE specification.

Harnek added: “Copy products are unlikely to have the same level of engineering expertise, nor are they likely to underdo the rigorous testing for quality and reliability that our units are. This is also a key reason why we offer a standard two-year warranty on all of our products; we have such confidence in the quality and reliability of what we produce and where we believe we exceed, in comparison to those that can’t match the range coverage, warranty terms or technical understanding.”

On the latter point of technical understanding, Autoelectro has an archive of

technical documents, all of which are supplied with each individual part number, to support technicians when diagnosing and/or fitting a replacement part – irrespective of vehicle age or technology under the bonnet!

For example, on a Dacia Sandero and Logan 0.9 petrol (2013-2022), Autoelectro has heard of scenarios where the ignition switch/push to start button can remain in the start/on position and won’t release after the engine has started. Consequently, this means the starter is stuck in the ‘on’ position and remains engaged, which, in turn, causes the starter motor to burn out.

To support the technician, with every AEY3906 supplied, there is a warning notice included in the box. This advises and shows images of what a burnt out starter motor looks like, which can help technician determine the cause of failure. This is also a common fault on the Nissan Micra and Note 1.2 petrol (2010-2018) – AEY2687 is supplied with the best practice information too.

As a remanufacturer that gets to the heart of the issue and stands by the side of its customers, deciding to stick with a trusted, premium brand clearly has its advantages –why plump for the ‘value option’ when true value can be found in the unmistakable red box of Autoelectro?

Autoelectro’s Harnek Bhogal explores the cost-of-living crisis and whether remanufacturing could provide a partial solution.

WHERE: SANDOWN PARK, ESHER, SURREY

WHEN: TUESDAY 7TH AND WEDNESDAY 8TH NOVEMBER 2023 – 10AM TO 4PM

November means MECHANEX

2023 sees PMM once again rounding up the most important suppliers in the aftermarket to provide workshop owners and technicians with an engaging, informative day out of the workshop. The UK’s longest-running trade show dedicated solely to the independent aftermarket will once again be held at Sandown Park on Tuesday 7th and Wednesday 8th November. 2023’s show promises to be a

HOW DO I VISIT?

Getting to the show couldn’t be easier. The address for the show is:

SANDOWN PARK

PORTSMOUTH ROAD

ESHER SURREY

KT10 9AJ

If you’re coming by car head to the free car park. If you’re coming by public transport, the nearest train station is Esher, a 13 minute walk from the venue.

For the aftermarket, November means ONE thing: the Mechanex trade show at Sandown Park. This year, visitors will benefit from an even bigger show as we introduce the PMM LIVE brand to the show.

lively one, with even more exhibitors than last year signed up for the two day show.

MECHANEXis well known within the independent aftermarket for offering visitors a hands-on experience, bringing them the latest updates and expertise from across the industry and providing an exciting day away from the workshop.

Registration to visit the show is free and so is parking, so why not come and take a look at what the biggest names in the aftermarket have to show you. In such a competitive industry, MECHANEXis an opportunity you can’t afford to miss.

COME AND SAY HI!

As always, PMM will have a stand at the show, so come and say hi and let us know what you like (or dislike!) about the magazine. We may even be podcasting at the show, so please do come armed with your strongest opinions!

DID YOU KNOW?

Did you know you can claim CPD points for each seminar you attend at Mechanex? Simply scan the QR code at the stand at the end of each seminar, it couldn’t be easier.

If you like PMM, you’ll love MECHANEX– it’s simply the magazine in a live format.

PMM LIVE

2023 sees the introduction of the PMM LIVE brand. The trade’s favourite magazine is celebrating by bringing you the very best seminar content from exhibitors and industry experts. This year the show will feature TWO PMM LIVE branded seminar areas: the Learning Lounge and the Technical Talks area. These areas offer you the perfect opportunity to get involved and answer the questions you’ve been dying to know.

SANDOWN PARK ● 7-8TH NOVEMBER ● FREE ENTRY

Catch up with MECHANEX 2023’s Main Sponsor:

PMM ’s editor Kieran Nee catches up with Mann+Hummel’s Gary Winslow and Damian Milling to find out what makes Mechanex appealing to the brand and what they’ll be bringing to the show this year.

Morning guys, besides the free bacon roll, what's bringing you to the show this year?

Gary Winslow, product and marketing manager (GW): Well, the free bacon roll is always a plus. I think for a brand such as ourselves, we’ve got a big reputation and a big product in the market, so It's really good to actually touch base and talk to garages, meeting mechanics in person. It makes it a little bit more personable. Marketing is a wonderful thing, but it can be a little bit one dimensional. So to actually meet and greet, welcome people onto the stand is a real plus for us.

Is this your first time at Mechanex?

Damian Milling, national sales manager (DM): We’ve been before, back in the early days, certainly before COVID, and we felt it was time to get back out there and get to these fantastic regional events. You know, the big events that are central to the UK are great, but it’s also important that we’re in the place where our customers are actually working. We want to be as accessible to as many people as possible. So, you know, to get back and go down to Sandown, interacting with those people in that local vicinity and those that do travel is very exciting.

GW: I think what’s important as well, we don’t just take the sales team to exhibitions. We take product management. We take people from customer services. The whole aftermarket division gets represented. So the people that come to the show, they’re not just

having a sales pitch, they are having education, they are having training, they are talking to the people at the coalface every single day and I think that probably sets us apart. You literally get what’s in all the full experience and I think that benefits everybody.

Why do you think trade shows are so important?

DM: I mean, I think for us, we, it’s an opportunity to learn. So, you know, we're going to teach our customers and their customers about our product, but actually at the same time, they’re teaching us what they need, what they’re struggling with, what the concerns are, what their worries are, what their frustrations are, which then allows us to listen and to think and to learn and react and try and be better at what we do. You know, we are the premium filtration manufacturer globally, but it doesn't mean to say we haven’t got room to learn.

Why should visitors come over to the Mann+Hummel stand, then?

DM: We’re moving to a world of alternative fuel sales and electrification. Legislation is changing already. Recently, we’ve seen the change in UK government, internal combustion engine moving from 2030 to 2035. Will that change again? Come and talk

to us on our stand. We have a product that will be guaranteed to work for you and your customers, whether it be a vehicle straight off the production line into your workshop for its first service. The Mann-Filter, you can fit it, you can forget about it. It will not invalidate any block exemption regulations or manufacturer’s warranty whatsoever. We have a product in our range with Wix, a fantastic aftermarket quality product that’s really designed to give you that security, that quality, that confidence in fitting a product from a global manufacturer of filtration at a slightly lower price point for those more price conscious customers that you have.

But come and talk to us, speak to our product team, speak to our technical team, speak to our sales guys, we don’t bite, we are here to help you. And any concerns you’ve got that filtration is going to disappear, because filtration is bread and butter of your everyday business. I can tell you now, you’ve got nothing to fear. There are filtration products on alternative fuel cell vehicles, electric vehicles, full battery, plug-in hybrid.

GW: We will have an area for Q&A sessions where we will go through the technical aspects of the products. We will be taking products on the stand so you can actually hold it in your hand, you can talk about it.

Meet the speakers on the LEARNING LOUNGE

Ben’s health and wellbeing director, Rachel Clift

Neil Pattemore, UK AFCAR

Is there anything new coming down the MOT pipeline this year?

The DVSA are continually looking at ways to reduce errors and save time, even though this may require further investment from the testing stations. We are aware that the DVSA are currently trialling ways of testing nitrousoxide emissions, this was also part of the recent consultation, and they are undertaking a second round of trials using Automatic Number Plate recognition, (ANPR), via a smart phone or tablet, to aid vehicle identification and reduce errors.

In addition to this the DVSA are also trialling connected headlamp aim lamp equipment. If these trials are successful, it is likely we will see these introduced over the next couple of years. The last thing, that has been well publicised, is that training hours have been reduced from 16 hours over a five year period, to 15 hours over a five year period, in other words it is now simply three training hour per annum.

Is there anything new coming down the MOT pipeline this year?

Any source of relevant information is important, open forum seminars present those present with an opportunity to ask questions and gain better understanding of the some of the day-to-day challenges garages face. The benefits go far beyond what a speaker has to say, these are also networking opportunities, where shared experiences and solution can also provide huge benefit for those that attend.

What has Ben been up to this year?

We have been very busy supporting those who work, or have worked, in the automotive industry with their health and wellbeing. It’s a tough time for people right now with the cost-of-living crisis so we’re supporting people in many ways. We have a record number of people coming to us for support, not just about money worries, but also because of the knock-on effect that the costof-living crisis has had on their health and wellbeing, particularly mental health.

Why are events like Mechanex important to mechanics and to Ben?

It’s really important for us to attend events like Mechanex to raise awareness about the services and support that Ben provides. We want everyone in the automotive industry to know that Ben is there for them, providing support with their health and wellbeing through our free and confidential online selfhelp, helpline, support and specialist services. So, if you’re worried about your physical or mental health or concerned about your general wellbeing, we’re here to help.

Are you looking forward to the show?

I’m very much looking forward to the show, it will provide a great platform to share more about the support and services that Ben provides to those who may not already know about us.

What’s going on with competition legislation at the moment?

Following a welcome revision of the Motor Vehicle Block Exemption in the UK, the Competition and Markets Authority has recognised some of the important changes in the way that vehicles are diagnosed, serviced and repaired. However, there are still important aspects that require changes in other related UK legislation to ensure that independent operators can continue to have the ability to offer competitive services and consumer choice.

Why is access to data important?

The very basis of competition is enshrined in both EU and UK legislation, but as vehicle technologies have evolved, the devil is in the detail and it has also become more difficult for legislators to keep abreast of these technological changes. The ‘access to data’ is fundamental to being able to diagnose and repair a vehicle, but the ‘good old days’ of simply plugging into the OBD socket are fast disappearing.

Isn’t security of the utmost importance?

Of course, the security of the vehicle is very important, but this should not mean that competition should not, or cannot, exist. The process should not be ‘security by obscurity’, but should be a robust process with access and content set by legislation. However, by definition, who is working on the vehicle and for what purpose will need to be transparent.

IGA’s head of member services, Frank Harvey

PMM chats to some of the seminar speakers at this year’s event.

Darren Darling, DPF Doctor Network

Darren, we've spoken in the past about DPFs presenting problems for garages. Is there a lack of understanding in the industry?

Yeah, and I don't think it’s just a DPF problem to be honest. I went to college for three or four years and I was a qualified mechanic, but the world's moved on, you know, and we have to keep up with technology. Imagine an EV turns up at your workshop: do you have the knowledge base and are you equipped? Are you relying on a scan tool telling you what's wrong?

So yeah, there’s a lack of understanding, in my opinion. The information from manufacturers is not great either. So for us, we just developed our own process of working, understanding each individual vehicle, you know: how are the software strategies on a Toyota compared with a VW and so on and so on. It’s quite a painstaking process learning all these things, but without that, we would be stabbing in the dark a little bit and we would have a low success rate. On a local level we have a well-established workshop. I think that without a good process then you're just doing forced regenerations and having limited success.

A big risk comes with forced regenerations, right?

Yes, it’s something that’s not on the menu list at our workshop. It's not something that we do. There's no diagnostic value to it. Forcing it to do

something is not telling you that it's able to do it itself. They're two very, very different things. So doing its own routine regeneration during driving is completely different to you hitting the magic button and it forcing itself. You’re risking it getting too hot. Is it safe to do so?

What are your plans for Mechanex, then?

I want to share that the message that the pretty solid reputation for DPF repairs we’ve built up over the years is not the result of doing anything complicated. We've done it by spending a lot of time owning our mistakes. In the early days, if we made a mistake, that was my problem. How can I stop that happening again? It’s about building up a good process. I want to drive some points home regarding how important that process is because it reduces stress in the workshop: you're more efficient; you're more profitable.

Meet the seminar sponsors

PMM ’s news and products editor Freya Coleman caught up with the two sponsors of the PMM LIVE Technical Talks seminar stand to find out what brought them to the show.

Could you just start by introducing yourself and Alldata?

What are you bringing to the show this year, anything new?

We have a diverse range of products at Liqui Moly from our motor oils, additives, care range and service items. At the show, we intend to showcase a small selection of these so you can get a real feel for what we have to offer the trade. We’re not just motor oils and additives, we have a selection of top, high-quality products that can suit your workshop and garage needs.

Why should mechanics take time out to come to the show?

Mechanex is a great show to engage with the aftermarket. It’s a fantastic opportunity for us in the industry to get to know what problems you are facing day-today in the workshop and see if we can provide the solutions you need. Not only this, you may see technologies and products you weren’t aware of to diversify the services you can offer as well.

Why have you decided to

sponsor the NEW PMM Live Technical Talks?

The automotive industry is always changing and is different to what it was a couple of decades ago. Smaller capacity engines that require very specific oil grades is one example of changes in the automotive sector. So, with PMM Live, we at Liqui Moly feel that education is an important aspect to ensure the right information is out there for the industry. Visitors can gain great insights by attending these educational seminars, so they are able to give the best recommendations and prepare themselves for the future.

What are you most excited about for the show?

For us at Liqui Moly, we are excited to have a chance to discuss what we can offer as a partner for your garage or workshop. From our approvals on our oils, to seeing how our additives could save money. Trade shows, as a whole, provide a great avenue for discussions that sometimes aren’t possible in the work setting.

I’m Simon Frost, I’m the sales director for the UK for Alldata. Alldata is a company where we license the original repair data created by the vehicle manufacturers and we make it available to the independent garage sector.

This enables the independent garage to repair vehicles at the same level as the franchise dealer and we’re currently covering about 95 per cent of the vehicles on the road in the UK today.

So, you guys are sponsoring a seminar stand at Mechanex this year, why should mechanics come visit?

Well, the seminars are a great part of the show. There’s a lot of great content and it’s all massively relevant. There are all the top people in the industry presenting the latest knowledge and the latest findings and how to do business better and I think it’s really good for business owners to try and get away from their business for a short period of time, come and see what’s new, listen to what’s going on in the market and actually get to meet some of the people there and ask their own questions.

You’ll also have your own stand at the show, do you have any exciting things going on at your stand or any show deals for visitors?

We’ll be showing our repair product with all the data and looking at a recently launched product called Labor Times. So, customers can have a full demonstration with one of the sales team, they can spend some time on their own looking at the type of data we have just to make sure and see for themselves at their own leisure. They can also sign up for a two-week free trial. So, the best way to really test all data is in the workshop and see if it's helping you day to day to save some time or maybe take on a new repair you couldn't do previously.

Why do you think trade shows are important? Why should technicians take a day out of the workshop to come down?

Over the past few years, we’ve lost a bit of those face-to-face meetings and those interactions. That’s really coming back now. So, just meeting people face-toface is valuable. There’s an atmosphere there of openness, people showing what they have, a chance to see new stuff. It’s great to go and see how you can maybe implement something new to improve your business.

3D GROUP

Come and see 3D Group – the leading automotive locksmith suppliers in Europe, supplying replacement car keys, key cutting machinery, diagnostic tools and more with up to 50 per cent discount on stand.

BEN

Ben is the charity dedicated to supporting the people of the automotive industry, providing support for life for them and their family dependents. The charity supports individuals to navigate through life’s challenges, empowering them to make positive, lasting change.

Ben works with people to improve their lives through its free and confidential online selfhelp helpline and support services. It also provides those who work in the automotive industry with access to a free digital mental health and wellbeing platform.

CJ DIESEL

With all the latest equipment from Bosch, Hartridge, Merlin, Rabotti and Stardex, CJ Diesel remanufactures all makes of diesel injection equipment, including Bosch, Delphi, Denso, Siemens, VDO, Stanadyne, L’Orange and CAT. CJ Diesel remanufactures a huge range of fuel injection equipment: from the latest Euro 6 automotive applications through to Cummins, L’Orange and Bosch

large engine equipment for power generation marine installations. Remanufacture can improve inherent design flaws from initial production, thus prolonging part life and keeping costs down. Quality is sustained whilst taking ecological responsibility. So, for all your fuel diesel injection requirements, whether testing, remanufacturing or new, get in touch or come see the team at Mechanex!

DIAGNOSTIC CONNECTIONS CLICKMECHANIC

Are you ready to grow your business without hassle? Look no further than ClickMechanic! Since 2012, the company has connected thousands of garages and mobile mechanics across the UK with new local customers via our platform and app. At our stand, we are excited to showcase how we’re bringing trust, transparency, and convenience to the world of car

repair. With a range of exclusive show offers and the chance to connect with the team, don’t miss out on having a chat and signing up. Best of all it’s free to join and no monthly fees! In today’s environment staying ahead of the competition is crucial. Visit our stand and meet the team that is dedicated to helping you get more business and succeed, grab your exclusive show offers!

DUROFIX

Durofix is thrilled to be attending the show this year, where it’ll bringing discounts on its highly popular G12 Pro range, as well as showcasing other brands like Acdelco and DuroSense. Tools on offer incude the Durofix G12 range, the introduction of the RW1221 ratchet wrench and the stubby impact wrench RI12184. In addition to its Durofix range, we're also proud to feature Acdelco and DuroSense. Take this opportunity to explore the TPMS range, benefit from incredible discounts, and enhance your toolkits.

HICKLEYS

At Mechanex, Hickleys will be demonstrating units from diagnostic industry leaders such as Texa, Delphi and Bosch. It will also be presenting information on its comprehensive range of vehicle lifts. Also on display will be a range of aircon servicing units, many of which are kept in stock, ready to ship within a couple of days from the distribution centre in Somerset. Hickleys also stock

a vast range of tools for key and remote programming, and nondestructive vehicle entry. Speak to its team at the show to be shown how easy it is to add key programming as an extra revenue for your business. The company also has its own dedicated training centre that holds regular courses on vehicle entry and key programming, as well as a range of automotive training such as MOT testing and aircon servicing.

Diagnostic connections are looking forward to bringing all Mechanex visitors its extensive range of vehicle diagnostics equipment. It will have products on display from market leading brands such as Topdon, Autocom, Pico, Diagnose-Dan and Core Diagnostics to name just a few. The team on the stand are up for answering any questions you may have – the company’s mantra has and will also be to deliver approachable honest advice in a very confusing and misleading sector. It will also be launching brandnew products from

GROUPTYRE

Grouptyre is delighted to be exhibiting at the 2023 Mechanex show. The UK’s market leading independent national wholesaler of tyres, Grouptyre stocks a huge range of over 1.3m tyres with 455 delivery vans operating from 42 locations. Come and visit the team to see how Grouptyre can help you develop your business,

DCLubricants with its three-inone fuel additives for both petrol and diesel cars, alongside a two stage DPF cleaning solution and engine oil flush. Pop by to chat with Steve Scott from the simply diag network with a few guest appearances across the two days from Darren Darling, founder of The DPF Doctor.

with its business support, industry leading tools and market leading delivery service.

HUGH BOSWELL

Boswell Aftermarket is a Chartered insurance broker that has provided specialist insurance to the automotive aftermarket for over 40 years. We work with nationally

recognised automotive trade organisations and industryleading insurers, to provide insurance coverage to over 1,200 aftermarket businesses across the UK.

INFOPRO DIGITAL AUTOMOTIVE

Infopro Digital Automotive is a leading player in the businessto-business data, software and services for the automotive aftermarket. Our goal is to connect and inform all communities of the automotive aftermarket industry by

providing them with key information through full end-toend solutions that help them boost their business and work to their full potential.

LAUNCH TECH UK

Launch Tech UK will be showing its new range of EV diagnostic and workshop equipment to meet the future needs of the industry, plus the brand’s latest immobiliser and key programming tools. Technicians visiting the Launch Tech stand at Mechanex will also have the chance to see and get hands on with its leading product portfolio including workshop tools such as the ADAS Pro+ and ADAS Mobile and its diagnostics range, which features the brand new X431 Euro Turbo II, plus its popular X431 Euro Tab III and Immo

JHM BUTT

JHM Butt & Co Ltd is a leading garage equipment and workshop tools distributor with over 50 years of experience in the automotive and industrial markets. At Mechanex we will

be showcasing equipment such as tyre changers, wheel balancers, coil spring compressors and more. Come by our stand to discuss your garage needs.

KALIMEX

Alongside Kalimex’s permanent coolant leak repair K-Seal, it will also be demonstrating the bonding abilities of Quiksteel repair putty. Also on display will be the JLM range. JLM’s products are designed for the professional technician who wants to help their customers stay on the road for longer and save them money. JLM is known offering professional additives and tools for reducing emissions and improving performance for diesel, petrol and hybrid

engines. The product range includes powerful petrol products such as the emissions reduction treatment (ideal as a pre or post MOT insurance) and also dedicated and proven treatments for GDI (gasoline direct injection) engines. Plus, JLM offer a range of service products including an oil flush, oil treatments and powerful workshop sprays. To learn more and to pick up your limitededition goody pack visit the JLM stand.

On MAHA’s stand, exhibition attendees will have the opportunity to experience firsthand the capabilities of its equipment solutions that aim to enhance precision, efficiency, and compliance. The MLT 1000 and 3000 headlight testers will be featured on the stand, designed to meet stringent MOT testing standards while ensuring accurate headlight alignment. Additionally, the PMS 3.5 axle play detector will be on display, demonstrating its role in detecting axle-related issues efficiently and reliably. The MCD

Pro. Plus, the brand will be demonstrating the latest iterations of its popular smoke 1 and smoke 2 diagnostic leak detection product line, diagnostic tool add-ons.

2000 communication display cabinet will also be on display.

MERLIN DIESEL SYSTEMS

With 75 years of experience, Merlin Diesel Systems is one of the leading aftermarket suppliers of diesel fuel injection parts. As authorised distributors for Delphi, Bosch, Denso, Perkins,

Stanadyne, Hartridge, Yanmar and Continental, we drive the advancement of the global fuel injection landscape. Are you ready to discover diesel excellence?

MAHA UK

OPUS IVS

Opus IVS helps independent automotive workshops repair the most complex vehicles fast with diagnostics, programming and live repair guidance from OE brand-specific master technicians.

Opus IVS delivers beyond the scope of general scan tool diagnostic capabilities. Their IVS 360TM Live Repair Guidance support service provides unrivalled support to

workshops globally.

Join Opus IVS at MECHANEX 2023 and discover how their diagnostic solutions can help you to revolutionise your workshop repairs. On stand D52 experience hands-on demonstrations of the powerful in-depth diagnostics that DrivePro™ can provide, as well as how you can utilise the guidance of 100+ master technicians.

OSCA

Come and see a live demonstration of what OSCA can bring to your business. Whether you’re a mechanic, body shop repairer, or ADAS specialist. OSCA and its application list of over 10,000 jobs can provide accurate and efficient remote diagnostics via a network of live vehicle technicians removing the need to rely on the dealer network.

SUPERTRACKER

Take the opportunity to visit the Supertracker stand at this year's Mechanex for exciting product demonstration, technical advice, latest innovations and promotional pricing on its range of wheel alignment systems. The stand will also be launching an updated version of the laser wheel alignment

technology using green lasers to help improve visibility in bright sunlight. There is also an opportunity to meet some of the key Supertracker team including an experienced engineer who will be on the stand, readily available to ask any technical questions. Whether you already own one of its products and are looking for top tips, or if you’re interested in how its machines work, the engineer will be there to help. The directors of the company will also be there to meet with customers.

THE MOT TRAINING AND COMPLIANCE GROUP

The MOT training and compliance group offer training for MOT testers and managers, site audit visits, and MOT AEC support, annual tester training, and MOT compliance folders, which will be available at the show for a discounted price. Other show offers include receiving 3 months AEC support when booking an MOT site audit

visit. So, visit this groups stand to talk everything MOT training and compliance and to look its comprehensive compliance folder in person, designed to make life easy for you and the DVSA inspector. If you have any questions or concerns about MOT training or compliance, come and talk to its team.

ROTRONICS

Rotronics will be showcasing the latest battery and charging technologies at Mechanex. Do you want to know more about the importance of testing EFB (enhanced flooded batteries) accurately, and how this can make a positive impact on your vehicle battery diagnosis? Want to understand more on how vehicle electrification, and both the EV pack and 12 V battery can be supported by your workshop going forward? Want to know more about the

industries first battery information portal ROBIS? Come along and see Rotronics ‘in action’ where they will be informing visitors on how AI and diagnostic ‘self-learning’ is being used to diagnose battery failure in the future. Also, visitors can expect to benefit from a host of show-time only preferential discounts and money saving deals during the show.

THINKCAR UK

Thanks to the overwhelming success experienced last year, Thinkcar UK is thrilled to announce its participation in Mechanex 2023. This year, its stand will feature a comprehensive display showcasing our entire product range, its flagship product, the ThinkCar Euro Max, now equipped with remote programming capabilities and accompanied by its full suite of accessories. Also being showcased is the Thinkcar UK

ADAS frame, highlighting its innovative space-saving features and value for independent workshops. The team looks forward to sharing the details of its special show offers and having many a conversation with exhibitors about their specific needs.

TURBOACTIVE

Turboactive will be showcasing the wide range of turbochargers it is able to offer for an assortment of applications, from passenger car and LCV, through to heavy-duty, plant and marine. Its sales rep and experienced technical advisor Alan will be available to provide technical advice, as well as tips and tricks regarding troubleshooting and fitment. The company will also be running a competition throughout the duration of the show in collaboration with key OEM supplier Garrett, offering a free sign up to Garrett’s installer connect training which provides

online training for turbo fitment and advice through a series of high-quality animations, culminating in a quiz which leaves the participant a certified Garrett turbo installer. Everyone who completes the training will be entered into a prize draw to win a prize pack of Garrett gear worth up to £120!

YOUNG AUTOMOTIVE DIRECT VIKA-DPA

As a world leading auto spare parts service supplier, Vika and DPA, offers top-level automotive parts for Volkswagen, ŠKODA, Audi, and SEAT models. Vika holds over 20,000 parts in its range focusing on mechanical and service parts. DPA-Diamond Performance Auto cover a comprehensive body parts workshop range.

We are specialist distributors of a comprehensive range of tyre repair, workshop consumables and servicing Products alongside Corghi tyre changing and wheel balancing equipment. Supplying high-quality brands such as Trax Wheel Balance Weights, Tech Tyre Repair Materials and Aircat Air Tools to meet all demands in the tyre industry. Please visit our stand to learn more and how best we can help you.

SEMINAR TIMETABLE

When to find your favourite seminar speakers each day on the Learning Lounge seminar stand.

DAYONE&DAYTWO

10.30 – THE IGA I MOT UPDATE

The IGA gives visitors the latest updates to the MOT regulations

11.30 – NEIL PATTEMORE

Today’s aftermarket faces increasingly challenging times, created by the changes in vehicle technology, the access to the vehicle and its data and the corresponding new business models for the diagnostics, repair and maintenance activities. Neil will explain what some of these challenges are and what is being done to ensure a vibrant UK aftermarket continues to exist.

12.30 – BEN

BEN’s head of wellbeing Rachel Clift explains the vital work the charity carries out and explains how you can get involved.

13.30 – DPF DOCTOR, DARREN DARLING

The DPF Doctor, aka Darren Darling, discusses with the Mechanex audience the importance of following set processes in the workshop when dealing with DPFs and beyond.

Who’s

THE KEYS TO SUCCESS

Autowave’s CEO Ravi Kotecha guides readers through some of the new products the autolocksmithing firm has recently released and will soon release.

Xhorse

There has recently been some speculation about a new XT27B transponder, let’s settle the truth. XT27A is the name given for the Global market Super Chip while XT27B is the name given for the China market Super Chip, there is still only one Superchip you can buy from Xhorse. We are bound to confidentiality on certain products but to give you a taster here are a few exciting things in the pipeline.

Xhorse is bringing out a powerful new programmer called ‘Multi Prog’ very soon, this device will have advanced programming functions on eeproms/MCUs, ECUs, airbag modules and much more. It will sit at a premium price point higher in the range than VVDI Prog. VVDI Prog will continue to be updated and stay current. Additionally, there will be a new cloud-based solution that will allow remote programming, already working successfully in China we expect to launch in the UK soon. Xhorse will also be bringing out high quality, competitively priced TPMS sensors and related equipment.

As a result of their growth in recent years Xhorse have become aware that it is sometimes difficult for dealers to service equipment and provide the level of after sales a brand like Xhorse requires. Autowave has been appointed the official UK repair centre for Xhorse. We are in the process of building a bespoke service centre to repair and service Xhorse products. This service is available to any customer, regardless of where you purchased your item from and Autowave will also be able to honour warranty repairs on behalf of Xhorse.

In order to protect the interests of local dealers, Xhorse plans to restrict IP for all

products with serial numbers from September 2023. This means that if you buy Xhorse products from China to use in the UK you will not have the ability to update Xhorse software. To retain the ability to update your products buy from Autowave, an Xhorse authorised dealer.

OBDstar

OBDstar have grown in presence in the UK and EU market over the last few years. They have focused on areas they specialise in and expanded product coverage accordingly. The amount of development that goes into their devices is second to none and their growth is testament to this. We saw firsthand what goes into producing their software and it would be fair to say they are innovators not imitators.

OBDstar is paving the way in development for motorcycle diagnostics and immobiliser programming, the UK and EU is a huge market for them which is proven by the number of devices out there. So, the demands of these territories remain a priority. They will be joining Autowave at MLA to launch a new flagship product so keep your eyes peeled.

OBDstar have also released products such as the DC706 ECU programmer/cloner and P50 airbag crash data device that are better than any competing European device I have

used throughout my time in the industry, also while not as relevant for the UK market they have also developed a marine scanner that just goes to show how forward thinking they are.

Xtool

Xtool is well known globally and considered one of the most popular brands in our industry across USA and South Asia. We work very closely with Xtool and over the last three years we have been helping develop their products for the UK market. A major point of discussion with Xtool is how we can adapt their devices and software to be more stable and reliable in the UK and EU. Xtool currently have UK specific devices, the immobiliser coverage for European manufacturers is far more advanced on these versions so in order to continue this distinction we agreed to have three Xtool engineers work from our UK office alongside Autowave technicians as a joint development project. Three engineers will spend at least two months in the UK so expect some major updates particularly on Renault, Fiat, Vauxhall, Peugeot, Citroen Ford and JLR.

Making your diagnostics tools work FORYOU

support behind the equipment.

Fcommunication interface (VCI) brings state-of-the-art OBD diagnostics to garages. Though they can choose to buy the DS180 BlueTech VCI only, most, according to Delphi, are now opting for the ‘Car Kit’ package, upgraded in the first quarter of 2023.

The ‘Car Kit’ combines the DS180 VCI hardware with a carry case – plus accessories including the USB hub needed to support J2534 ‘Pass-Thru’. The kit also includes a faster, larger and more powerful tablet to run the growing software resources quickly and reliably.

Delphi is urging garages looking at making investment in enhancing their diagnostics capabilities to do two things. The first is to take a long-term view and the second is to fully evaluate the resources and

“The challenge is to not just think about today but the vehicles you will see in three to five years’ time as you don’t want to discover you are restricted later,” said Marco Lagomarsini, Delphi. “The problem for technicians is more and more jobs on newer vehicles will require a modern diagnostic tool and connectivity is becoming more tightly controlled.

“Our BlueTech VCI offers a ‘future proof’ solution that works as seamlessly as possible with the latest vehicle manufacturer gateways with excellent coverage and capabilities too.”

Delphi suggests garages pay particular attention to work that they’ve done without diagnostics support that will require connectivity in future. They say the issue has been illustrated with EGR valves coming back as returns that ‘weren’t working’ simply

because garages hadn’t realised the part needed to be calibrated electronically after fitment in order to work properly.

This type of calibration is even required for some air filters on the latest vehicles. Delphi says they have the tools, technical data and training that the trade needs – with the facility for garages to check on a specific vehicle and job basis whether a diagnostics tool needs to be used.

Pass-Thru compliance and VM Security Gateways

The DS180 BlueTech device is J2534 PassThru enabled to ‘flash’ update ECUs effectively. It also offers an ‘integrated solution’ for easy connection through the security gateways of many vehicle manufacturers, saving technicians the time of completing multiple manual registrations for different VM portals.

readers on its BlueTech diagnostics package, pass thru and security gateways.

Delphi’s simple licensing model includes their full support package. This brings free access to the diagnostic e-learning content on Delphi Academy. The fee also ensures access to a technical hotline and ‘lifetime warranty’ on the VCI hardware where an uninterrupted licence is in place.

“The licence includes ADAS capabilities, security gateways and VRM look-up so there’s no ‘extras’ to pay later,” said Marco. “The e-learning resources are comprehensive to help garages set up and use the package, run procedures and better understand PassThru and security gateways.”

Pass-Thru is essential to access full diagnostics functionality, specifically updating (or ‘flashing’) ECUs. The BlueTech DS180 enables garages to simply plug in, access VM portals, download software and make updates. Security gateways serve an entirely different purpose. They exist to restrict and track who is accessing car ECUs for safety-related operations, aiming to protect cars and drivers. Historically, separate VM gateways have been time consuming to register with, pay for and use.

Delphi’s ‘integrated solution’ results from the global manufacturer’s agreement of commercial terms with a growing list of VMs and groups including FCA, VAG and Mercedes Benz/Smart. Delphi then implements the technical solutions to

streamline connectivity so licenced BlueTech users don’t have to log in to or register with individual VM portals.

“The process seems very simple because we’ve done a lot of complex work in the background to save technicians time,” said Marco. The DS180 BlueTech VCI sits firmly within the top tier of OE-level diagnostics solutions available to garages according to Delphi. It already supports key communications protocols like DoIP (used by Volvo and JLR) and CAN FD (Flexible DataRate) – a fast protocol currently used in highend vehicles that will become more widely adopted in future. “Many technicians are nervous,” said Marco. “Pass-Thru can be risky and you need to know what you're doing so that's why we’ve developed specific training.”

Delphi’s BlueTech licence can be purchased for anywhere from one to five years, with reduced rates for longer terms. It includes access to the extensive diagnostic e-learning content on Delphi Academy with training modules available on running procedures as well as Pass-Thru and security gateways too.

Delphi diagnostics configurator goes live

Delphi has this summer launched a new online ‘diagnostics configurator’ to further help independent garages quickly identify the diagnostic solution package best fitted to

their specific requirements. The diagnostics configurator, which can be accessed under ‘Diagnostics’ at WWW.RDR.LINK/ABC020,hasbeen developed to make it easier for technicians to understand the hardware, software and technical data options available to them. A simple step-by-step process makes it much easier to compare options and then make informed selections, ensuring the package quoted is best fitted to the specific workshop requirements according to Delphi.

Step : select by vehicle type - or by product as a ‘standard configuration’

Step : Select hardware options

The vehicle connection interface (VCI) can be selected on its own or as part of a solution package. Users then proceed to select any connection cables needed for older vehicles

Step : Choose the licence term, the vehicle technical information (VTI) level and e-learning access

Step : Review the ‘Bill of Materials’ The configuration process is completely transparent, so garages can quickly see the costs of different options and elements, as well as the substantial savings available with a longer licence

Step : Request a Quote

At the end of the process – which can be completed in just a couple of minutes – the chosen configuration can be saved and shared by email or a full quotation can be requested simply by completing a few details on the web form.

ELECTRIC EXPANSION

Autel UK are aiming to keep workshops up to date, so the diagnostic expert is throwing its hat into the electric and hybrid ring with the release of its EV expansion model.

With 51 per cent of vehicles sold in the UK in 2023 being either hybrid or 100 per cent electric, the demand for these vehicles to be serviced and maintained is growing at a rapid rate. Autel UK are committed to keeping workshops up to date with the latest developments in diagnostic technology.

New module

The company have recently released the EV expansion module which can be added to the MS909 / MS919 and MS Ultra. The EV expansion module says to allow workshops to quickly and efficiently diagnose battery faults on these vehicles. Currently it is general practice to strip a HV battery to diagnose which cells or modules are faulty, this is no longer required with the EV expansion module. The technician can connect directly to the high voltage battery monitoring system and display data like cell voltages, module voltage, state of charge and state of health. This not only saves time for the workshop but also makes it safer for technicians to diagnose.

Once the repair is approved by the user the relevant parts can be ordered and the battery pack is only stripped once the required parts are available for repair, speeding up the repair process while also making it safer for the technician.

Report facility

The EV expansion module is priced to offer a really quick return on investment for any tehcnician. It also offers a report facility so the workshop can show the end user the faults in an easy to understand format. Autel UK will also be launching more products around EV repair and maintenance later this year.

Deal me IN

Vehicle technology is moving at an enormous speed and for many businesses, the path ahead is unmistakably clear: embracing dealer tools and diagnostic platforms is no longer optional but essential. The launch of SERMI in 2023 has further eased the accessibility of these systems, offering a unified portal for accessing platforms from multiple manufacturers.

In this feature, I will spotlight the top-selling dealer tools in the UK and explore the enhanced profitability they offer, chosen as they cover a staggering 90 per cent of the vehicles currently on British roads.

The financial merits of using dealer tools come from the ability to charge a premium diagnostic rate when independent garages are using them. However, profitability naturally hinges on proficient use of these tools, which is why all independent workshops should take basic tool training as a minimum, with advanced training as the next step. Workshops that have embraced dealer tools, usually specialising in specific brands or vehicle

types, have enjoyed solid customer bases and increased hourly rates.

Tool Spotlight: ODIS

The off-board diagnostic and information system (ODIS) is a comprehensive application that covers Volkswagen, Audi, Seat, and Skoda. ODIS requires a high-specification laptop and a VAS 6154 VCI, although a rated passthrough dongle like the Mongoose VAS cable can also be used. Each brand has its unique identifying key and a stringent security process for tool application and usage. ODIS comes with an integrated suite of technical data and offers fully guided diagnostics specific to each brand and we’ve found that ODIS delivers an exceptional return on investment. Workshops typically charge significantly higher hourly rates when using ODIS, as it consistently and efficiently solves automotive issues. When used by properly trained technicians, ODIS not only covers a wide range of brands and models but is also userfriendly, making it an excellent investment. ODIS’s strong return on investment and expansive brand coverage make it a vital tool in any workshop’s arsenal.

Jaguar Land Rover: specialised but lucrative

By the nature of the beast, Jaguar Land Rover (JLR) is not for everybody, but for those who own these vehicles, keeping them running smoothly is a top priority. JLR offers two different software platforms running on a single laptop: For models up to 2017, SDD (Symptoms Drive Diagnostics software is used in conjunction with the JLR-VCI tool. TOPIX Cloud was introduced in 2022, for vehicles after 2018 and replaces the older Pathfinder platform. While the standard dealer tool goes by the name Bosch VCI, there are alternative options such as the DPD-U tool, which offers exactly the same functionality. When it comes to cost, JLR software is most economical when purchased on an annual basis. TOPIX also offers a separate subscription for documentation, allowing you to buy only the necessary documents on an hourly rate.

BMW ISTA: a comprehensive platform

BMW is probably the best value platform but can be frustrating as it’s so vast and many believe the whole car needs to be updated

Andy Brooke, managing director of Maverick Diagnostics, shares his types on unlocking profitability and efficiency in the workshop using dealer tools in automotive diagnostics.

“The launch of SERMI has further eased the accessibility of dealer systems.”

Andy Brooke, Maverick Diagnostics

with each module change. In this discussion, I'll focus on BMW's ISTA workshop platform and the Kasio key reading system, aiming to simplify their intricate functionalities.

Firstly, investing in a high-specification laptop for ISTA is crucial; better hardware leads to optimised system speed. The primary device used with this platform is known as ICOM A. Optional addons are available for older vehicles with 20-pin connectors and for most bus communication. It offers comprehensive features such as mapping, tyre pressure monitoring, and fully guided diagnostics through a system called AIR.

Kasio, on the other hand, is the key reading system. It enables technicians to extract all key data from a vehicle, upload service information to BMW's cloud, and then rewrite this information back into the vehicle. Once integrated into your workshop, Kasio can reduce BMW service time by 30 to 40 minutes.

As for costs, both ISTA and Kasio operate on an hourly token basis. However, we have found that tokens can often last longer, particularly if you are in the middle of programming. This also applies to ODIS; a one-hour token can potentially last all day.

Be prepared for frequent updates; BMW is known to update their systems as much as three times a month which can challenging for technical support teams. Despite frequent updates, its effectiveness and speed make it indispensable for BMW servicing.

Ford’s multiple options

Ford’s diagnostic landscape is somewhat complex, largely due to the vast number of models available globally. The primary tool is called the VCM3, with its dealer-specific variant being the VCMM which includes built

in measurement capabilities. It’s worth noting that VCMM isn’t used in the aftermarket; we’ve had a customer purchase only to realise they wasted their money.

Ford offers multiple software options, the details of which I am not going to delve into here. The most well-known is the IDS (integrated diagnostic software) which serves as the foundation for Ford’s other diagnostic software. IDS is most effective and provides a great return on investment. US licenses can be bought on a yearly or hourly basis, and this will also cover the FDR system which is generally the only other system independent operators in the UK and Europe would need. As you would expect for a global platform, it is user-friendly but should you require extra documentation or guided functions, you’ll need to use the PTS system and pay an hourly fee.

Vauxhall, Opel and the PSA Group

For Vauxhall, Opel, Peugeot, Citroën and DS, two tools are mainly in use sharing the same diagnostics box platform: the old Vauxhall GM MDI for programming and diagnostics of Vauxhall vehicles up to 2021, and the PSA XS core tool for PSA vehicles from 2004 to the present day. The PSA XS now includes Vauxhall which are all PSA based from 2021. To further complicate

things, Stellantis, who now own all the above, also owns Fiat jeep Europe which uses an entirely separate platform.

Mercedes Xentry: a premium offering

Mercedes offers three types of Xentry systems, each with its own set of features and access levels: Xentry PassThru, Xentry Lite, and Xentry Kit 4. The PassThru version is designed for diagnostics on vehicles compliant with Euro 5 standards and newer. Xentry Lite caters to a broader range, covering all vehicles back to those meeting Euro 4 standards. Xentry Kit 4 not only provides the same coverage as Lite but also includes additional information and add-ons. It's important to note that Mercedes maintains a stringent application process for these software versions. While the application process is stringent, the comprehensive functionalities of these systems justify the investment.

To conclude, dealer tools have transformed from being optional luxuries to essential investments for independent workshops aiming for profitability and efficiency. If you are contemplating adopting these tools, the financial incentives and technological advantages make them indispensable for your future success.

“Investing in a high-specification laptop for ISTA is crucial; better hardware leads to optimised system speed.”

Diagnosing an ENGINE MISFIRE

The vehicle, a 2014 plate, was presented with the engine warning light illuminated and the owner reporting long engine cranking, rough idling and exhaust smoke. Whilst these issues are typical of engine misfire, determining why is not always straightforward. Possible causes include a faulty high-pressure fuel pump or injector, problems in the fuel system, vacuum leaks and on rare occasions a compression drop in one or more cylinders, so it’s important to follow a methodical approach when diagnosing one.

Interrogate the vehicle’s fault code history with an EOBD diagnostic tool to get a clearer picture of what is happening. The Bosch KTS scan tool returned a P019100 fault code - fuel high pressure sensor.

Test the injector’s back leak on vehicle to pinpoint possible faults. With the test kit connected, start the engine, let it run at idle speed for a while, then stop the engine and measure the diesel fuel in the containers.

Unfortunately, there’s no simple pass/fail criteria, and this method relies on experience. However, as a rule of thumb, look for an imbalance between the injectors; a high backleak flow on one injector doesn’t necessarily mean this is at fault, and it’s possible that the three others with a much lower backleak, are to blame.

Check the high-pressure pump: most EOBD tools can display rail pressure demand and feedback during engine cranking and while the engine is running. If this test shows no rail pressure feedback during engine

cranking, then a sealed rail kit must be used to isolate the high-pressure hydraulic system, as a faulty rail pressure sensor could misdiagnose a faulty high-pressure pump, wasting valuable time and money.

In this case, the high-pressure pump generated the correct rail pressure during engine cranking and engine idling but was slow to do so. Furthermore, based on the EOBD fault codes stored in the vehicle ECU, plus the injector backleak check, two of the injectors were thought to be faulty. Although the simplest option would be to replace the high-pressure pump and all four injectors, it’s essential to determine why they failed, and address this, before doing so. If not, the replacement units could fail immediately, adding unnecessary cost and inconvenience to the vehicle owner.

Have a specialist test the injectors: after removing them from the vehicle, the injectors are put through a series of rigorous tests at Carwood’s fuel systems facility in Birmingham, to identify why they failed. This includes:

■ A surface level inspection to detect anomalies such as structural damage, missing components, evidence of tampering or gas blowby.

■ An electrical check, incorporating a dynamic actuation test where the piezo stack is charged and discharged for ten minutes to ensure it is not breaking down.

■ A basic hydraulic test at low pressure to check for correct spray pattern and fuel atomisation from the nozzle.

■ A bench test to OEM specification.

Two of the injectors failed the basic hydraulic test with no injection, and the other two failed the bench test due to low fuel delivery. So, to establish the exact failure mode, the parts are disassembled, and the individual components inspected under microscope. The analysis concluded that the injectors are contaminated with metal.

Remanufacturer and fuel systems specialist, Carwood, troubleshoots a common fault on a VW Caddy, equipped with CAYD engine.

Remove the pump: With evidence of contamination, the high-pressure pump is put through equally thorough checks. The tests confirmed that this too is contaminated with fine metal debris, caused by the high-pressure pump starting to fail.

Buy a genuine alternative to new: Since both the pump and all four injectors will need to be replaced, the technician has a choice. Fit new OE or a cost and eco-friendly unit, that’s just as-good-as new, from an OEapproved remanufacturer like Carwood.

Flush the system before the replacement parts are installed into the vehicle, to remove any trace of contamination. To do this, clean the fuel tank and low-pressure hydraulic pipework using traditional flushing methods and replace all high-pressure pipes, the rail assembly and fuel filters with new parts.

Fit the high-pressure pump, ensuring both the pump and rail fittings are clean. Remember to pressurize the fuel system by turning the ignition key on and check for leaks.

Recode the injectors into the vehicle ECU before installing them. This will ensure that the timing and quantity of fuel delivered is calibrated, in order to enable optimum performance. To do this, note both the newly generated calibration code on each injector,

and which cylinder it will be fitted to, and then enter the code into the correct cylinder, using an EOBD tool.

Perform a relearn: All Continental/VDO injectors have an ECU self-adaption process that needs to be performed after the injectors have been reprogrammed and fitted to the vehicle. This teaches the ECU the ideal pilot injection for the engine, in order to prevent engine knock. Although the procedures can vary by manufacturer (always check the handbook), as a guide:

■ Ensure no fault codes are present in the ECU.

■ Drive the vehicle until the engine coolant temperature is a minimum of 80˚C.

■ In third gear, increase the vehicle speed to 3000rpm and allow the engine to naturally deaccelerate to 1500rpm. Do not depress the brake pedal during this step as it will cancel the adaptation. Repeat this step two more times.

Reconnect the scan tool, clear all fault codes and take the vehicle for a short road test to confirm that the fault has been eliminated. Job done!

TOOLS forbracing thecold

Get help facing the winter months from tool and equipment specialist Draper, who is offering PMM readers its top tips for the colder and shorter days in the workshop.

The winter is a key time for vehicle maintenance, with temperatures dropping and driving conditions getting worse, it’s vital to prepare for the challenges the season brings. A few straightforward checks, together with having the right tools, can significantly reduce the risks that winter brings with it. It’s equally important to consider the conditions in the workshop during winter and plan ahead with the necessary equipment. Here’s a few recommendations from Draper:

Bringing batteries back to life

A great addition to the garage for busy times is battery charging station that can charge multiple vehicle batteries at once. Draper offers a microprocessor controlled 6V/12V bank charger station with capacity to charge and maintain three vehicle batteries simultaneously. It’s compatible with all

For those times when a vehicle really won’t start you need a big boost from a battery starter.

AGM and VRLA flooded batteries, making it suitable for range of vehicle batteries including motorbikes, vans and caravans. For those times when a vehicle really won’t start you need a big boost from a battery starter. A heavy-duty model capable of an 800-amp boost is ideal for professional workshops. For maximum safety and efficiency in the workshop look out for models with a fast-charging facility, terminal overload protection and polarity protection. Choosing a battery starter with wheels is also a good idea for easy portability.

Improving winter vision

It’s hard enough for drivers to see in winter, with the poor weather conditions and the darkness, so it’s especially important to keep lights and windscreens clean and clear at this time of year. When you have a vehicle in for a winter service, why not clean the windscreen inside and out, to offer best possible visibility for drivers?

Don’t forget to add the right anti-freeze additive into the vehicle’s screen wash too and check the condition of the windscreen wipers. It’s often the small jobs and simple checks like this that can make a significant difference to driver safety in winter.

Draper’s anti-freeze tester.

Identify electrical faults fast

Winter can play havoc with vehicle electrics, which can create additional workload at this busy time of year. It’s advisable to have a quality auto-ranging multimeter as part of your servicing kit – so that the next time you’re stood in front of a vehicle wondering, ‘is it the bulb, is it the fuse, is it the earth?’ –you’re able find the answer with speed and accuracy.

Well-lit working conditions

Seeing clearly under the bonnet or underneath a vehicle is not always easy at the best of times but with it getting dark so early in winter, having plenty of additional sources of light in the workshop is essential. Torches are great but for hands free working why not opt for an LED headtorch or an inspection lamp with magnetic base?

Draper Tools offers a 3W rechargeable

COB LED head torch that runs for two hours after charging on a micro-USB cable, making it a great option for winter working. Having a few LED work lamps can make a huge difference too if you workshop needs to boost brightness levels.

Keep warm and carry on Invest in some heavy duty thermal gloves to keep your hands warm during pre-drive vehicle inspections and during deliveries. It’s also a good idea to choose gloves with a latex coating to aid grip when everything is soaking wet in the inevitable winter rain.

If you’re considering a heater for the garage, an electric space heater is a worthwhile investment. Opt for an energyefficient PTC model, this means the heater is able to self-regulate in order to warm up your space (and keep it that way) quickly and efficiently.

WANT TO KNOW MORE? FOR MORE INFORMATION

WWW.RDR.LINK/ABC025

If you’re considering a heater for the garage, an electric space heater is a worthwhile investment.

Stepinto the LIGHT

The right lighting in the workplace is a prerequisite for effective and safe working. Large areas – such as workshops – often require specific lighting for individual areas and dark corners and it’s hard to get it right. Bad lighting at work leads to eyestrain and headaches, as well as to fatigue and concentration problems for those working in it.

But it goes further for, as well as being detrimental to the well-being of workshop personnel, it can drastically affect the productivity of workshop as a whole.

Proper lighting in the workplace is not only important for the health of workshop personnel, but is also a very real safety issue outside of the workshop as well. Without the right lighting it is much easier for a technician to overlook a defect, which in turn, has potential safety risks and consequences for motorists.

Workshops have more lighting requirements than might be imagined. Lighting does not have to simply provide light, but has to be at the correct light intensity. It needs to illuminate the right place and it also needs to provide as natural an atmosphere as possible for to be conducive to productivity.

The colour temperature of the light is particularly crucial here. Studies have shown that, in daylight, the midday sun has a colour temperature of approximately 6000 Kelvins and that human beings respond to this very positively. The best sort of lighting to satisify all these requirements in the workshop has for several years been LED-based, because they have a high Light Intensity and also offer white light that closest resembles daylight. In addition, LEDs offer low power consumption and an extremely long life.

Research

When it entered the workshop sector Philips looked carefully at the workshop environment and the specific needs it generates, in order to devise the optimal lighting solutions.

“We worked with experts to better understand how light affects worker performance in production environments. Then

PMM hears from Lumileds’ UK manager Richard Armstrong about the work that has gone into producing Phillips workshop lighting solutions and why warmer lights make for happier technicians.

we went to service professionals to see how our ideas worked in the workshop itself –after all who better to help develop a range of workshop lights than the people who will actually be using them,” explains Richard Armstrong, UK manager for Lumileds, which manufactures Philips Automotive Lighting products globally. “With these insights, we created lighting solutions for safer work environments, which reduced eyestrain by providing the right level of light – because when people can see clearer, they work better.”

Philips LED Inspection and work lights produce an intense natural white light, with a light colour of 6000-6500K. This light spectrum is optimal for fatigue-free, concentrated work. Lumileds works on the simple premise of having the right tool for the job, so it has a range of LED inspection and work lights to meet these differing requirements. They all, however, have several features in common.

Each workshop light is manufactured from high-quality materials and features light intensities which vary in strength, in order to provide perfect conditions at work within the workshop and even for use outdoors. Each has features which are aimed at enhancing either the experience of using the light, or its overall functionality. Research and use of products also showed that the treatment that lights are often subjected to in workshops can be tough, so Philips workshops lights all conform to high strength, dust resistance and chemical resistance standards.

“There are some incredibly clever ideas that we now have in action on the Xperion 6000 range. One has a UV beam to detect leaks and on others you can adjust the width of the beam. Several lights feature noncontact switching, so that you can turn the light on and off, without having to touch it, by simply waving to the light, using a gesture it is programmed to recognise,” enthuses Richard Armstrong. “As we know that people mislay their lights, several of them can be found using a special find-mylight system we have. One of our Xperion 6000 Flood Lights even features a bluetooth speaker system, so you can work to your favourite music!”

The Philips Xperion 6000 range includes wands, hand-helds and three flood lights as well as slim-lights, flexi-lights, a penlight and a head-worn lamp as well an under-bonnet light designed to illuminate across the entire width of any kind of car or truck. Some are extremely versatile and can be used in all sorts of different situations and others are for more specific tasks, where a specialist light beam or spread might be needed. There are 11 professional work lamps in total, as well as two smart accessories: a charging station and find-my-light system. All of these, like the lights themselves, are designed with the input of workshop technicians to that help make work life better for their fellow technicians every day.

WANT

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The treatment that lights are often subjected to in workshops can be tough...

Driving home for CHRISTMAS

Most of us would agree that winter journeys are often the worst of the year. There’s ice on the road. The mercury’s hitting zero. You’re stuck in traffic. And the radio has already played ‘Last Christmas’ six times this morning. The last thing you need is your car breaking down...

Well, don’t be fooled by the temperatures outside. Contrary to what you might think, vehicle overheating actually mainly occurs in the winter, often due to a fault with the cooling system such as a blocked thermostat, coolant leak or failing water pump. When overheating occurs, it can cause mid-journey driving issues and potentially expensive or even irreparable damage.

Spot the signs

To avoid these problems, it’s firstly important to be able to spot the signs. Hints that your engine is overheating include burning smells, engine noises, a temperature gauge in the red zone, and an excessively hot bonnet.

But what can we do to deal with these warnings once they present themselves? And how can we prevent them from occurring at all, so our festive journeys are as stress-free and pleasant as possible? Let’s take a look.

David Aldous, business development manager at Petronas, offers his advice to workshops and their customers this winter.

When overheating occurs, it can cause mid-journey driving issues.

Carry out a coolant flush

Over time, everyday dirt and debris from the road can build up and block your engine’s cooling system, preventing it from managing internal temperatures. A coolant flush drains these contaminants from your engine, making it a crucial procedure for maintaining a healthy vehicle and avoiding radiator clogs, engine corrosion, leaks, thermostat damage, and water pump issues.

Your car manufacturer’s manual should offer specialist advice on when and how to do a coolant flush for your model. Some new long-life coolants have a much longer life cycle, but for older vehicles, as a rule, you should try to carry out a flush every two years or every 40,000 miles— whichever comes first.

Regular coolant flushing should help your radiator regulate engine temperatures and nip overheating in the bud. However, we can’t always be this prepared or proactive. So, what should we do if we face an overheating vehicle mid-journey?

Switch on the heat

It sounds crazy, but it’s true: to cool your car’s engine, you may need to pump warm air into your passenger compartments.

Switching on your heating and blowers actually transfers heat away from the engine. It also opens up your heater core, a smaller version of the radiator that sits towards the front of your car, giving your engine the chance to draw in fresher, cooler air and operate at a safer temperature. So, the good news is you can blast those heat blowers to cool your frozen fingers on the steering wheel, safe in the knowledge that it’s also helping to keep your engine healthy.

Rev your engine or pull over

If your journey involves regular stops and starts due to traffic or stoplights, it’s a good

idea to rev your engine while stationary. Revving helps to pump water through the radiator and speed up the fan (if controlled by the engine), cooling internal temperatures.

But once you begin slowly moving again, try to avoid riding your brakes— brake drag further increases the load on your engine. Instead, let a larger gap open between you and the vehicle in front before you move forward.

If none of these steps help, and your engine temperature is climbing out of control, pull over to the side of the road. Then, open your car bonnet to let heat directly escape out of the engine bay. However, under no circumstances should your customers then touch any internal components, particularly the engine or radiator. A vehicle’s water and coolant mix is pressurised when hot, and opening the radiator cap can cause the coolant to spray out and cause serious skin burns. If you must open it, wait until your engine has completely cooled.

Choose a quality engine oil

Modern engines operate at higher temperatures and with more moving parts than ever before. To function properly, these moving parts need to be lubricated to reduce friction, while dissipating heat to protect the engine’s performance.

A high-quality engine oil for both cars and motorcycles can help to fight excessive engine temperature by regulating and absorbing heat, defending critical

components from damage, and reducing fuel consumption.

Fortunately, multi-viscosity oils can adapt to year-round temperatures by thinning out during the winter to flow faster through the engine and better lubricate its components. For instance, a 10W-40 oil has a viscosity grade of 10 in lower temperatures and 40 in higher ones.

Remember: you must choose the correct oil and viscosity for your model recommended by the manufacturer to avoid further vehicle issues. Before you buy, use tools such as a lubricant recommender to find a product that keeps your engine safe and running smoothly.

Stay cool this winter

Ultimately, the engine is the heart of your vehicle. So we must treat it with great care and attention. Regular overheating can limit its lifespan and major repairs can even exceed its entire value, resulting in an insurance write-off.

As the famous saying goes, ‘prevention is better than cure’. While you might not expect your engine to overheat in cool weather and feel you can fix it even if it does, this may not always be the case.

Instead, it’s best to carry out regular coolant flushes and invest in high-quality engine oils, regardless of how well your engine seems to be running. It might just save you stacks of time and cash—and help make your big drive home for Christmas as pleasant as you’d planned.

Under no circumstances should your customers then touch any internal components.

LCVs 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 shine a light on LCVs.

Taking the Ford 1.0-litre EcoBoost ‘Fox’ engine, which is used in multiple Ford applications including the BMax, C-Max, Ecosport, Fiesta, Focus and Mondeo, as an example, according to the manufacturer’s service schedule, the timing belt must be replaced at 150,000 miles or every 10 years, whichever comes soonest. When it comes to the Tourneo Connect and Courier however, the replacement mileage is slightly lower, at 140,000 miles.

Our customer had travelled from Dunfermline to our workshop in Larbert. Before this he had taken his vehicle to a local garage several times in a bid to get it out of limp mode. He collected the van after being told a DPF regeneration

had been conducted only for the engine management light to illuminate within a few miles.

■ P0671 Cylinder 1 glow plug circuit open

DISCOVER!

Find more technical articles on PMMOnline, scan the QR code below!

Frustrated he called us and booked the van in for a DPF assessment. He had come to the right people. We have been members of the DPF Doctor network for five years and draw freely on the wealth of knowledge which is being added to all the time. Darren Darling has been working behind the scenes on an excellent portal which makes it easy for us to look up faults and find testing advice. So, armed with comprehensive information gathered from the customer on the previous work on his van, we were able to start fault finding. There were seven logged fault codes:

■ P0673 Cylinder 3 glow plug circuit open

■ P0674 Cylinder 4 glow plug circuit open

■ P2002 Particulate filter efficiency below threshold

■ P2463 Particulate filter restriction soot accumulation

■ P246C Particulate filter forced limited power

■ P24A4 Particulate filter restriction soot accumulation too high

With this we were able to bring up some live data PIDs about where the problem lay. Not all the faults we find are listed as P codes. We were looking to see what state the DPF was in. Was it blocked? Could we clean it with the JLM Lubricants’ DPF cleaner or had it been blocked by too many forced regens and additives to the point that it had melted?

A 2.2l Ford Transit Custom with 145k miles on the clock enters DPF Doctor Barry Lawson’s workshop.

DPF troubles on a Ford Transit Custom

Weighing up the pros and cons of LCV lighting work

Ring Automotive argues it is labour time, not cost, that workshops should be considering when weighing up LCV lighting work.

Cost is always going to be a significant consideration when looking at components for LCVs. Work vans need to be resilient and efficient, while also meeting a budget to make them cost effective for the business using them. But going for the cheapest piece of kit is not always the best approach. As well as potentially being of poorer quality, if the installation time is not taken into consideration, then a lower price tag could end up costing a lot more in labour costs.

Staff time vs unit cost

For a skilled technician installing a warning light, work lighting or inverter, time is of the essence, as labour will be one of the biggest elements of any job. Therefore, for your customers, cutting down installation time is a no-brainer. Plus, with lower installation time, you can get more customers through the workshop in any given day. It’s a win-win to take installation time into account when choosing your supplier.

Installation options

A simple example could be looking at warning lighting. Look out for models with magnetic mounts, or single bolt fixings, rather than needing several holes drilled to be secured. Camera systems that have wireless elements may be more expensive than a conventional wired equivalent, but if it knocks an hour off installation, it can make it quicker for the installer and lower cost overall for the customer.

What’s new IN THE WORKSHOP?

with Freya Coleman

NEW TO RANGE

■ JURATEK has added 25 new references to its braking portfolio, including six brake discs, three brake pads and 16 calipers. In its brake discs range, the company has introduced part number HON162 to fit Honda Accord 12- and HR-V 15-, reference KIA144 for Hyundai Ioniq 16- and Kia Niro 16-, plus part number KIA151, which is suitable for the Kia Picanto 17-. Additional new brake disc references include MAZ158 for Mazda CX-3 15-, MGD100 for MG ZS 17,and VAG350, to fit popular passenger cars such as Audi A1 11-18, A1 Sportback 11-18, Seat Ibiza 09-16 and Volkswagen Polo 14-.

■ FIRST LINE’s 27 parts additions come across its steering and suspension, bearings, braking, clutch, cooling and filters ranges. In the steering and suspension range, 13 new parts are available, including left-hand and right-hand front suspension arms (part FCA8017/BCA8017 and FCA8018/BCA8018 respectively) for Ford Kuga 2019> cars. New left-hand and right-hand front tie rod ends (part FTR6261/BTR6261 and FTR6262/BTR6262 respectively) for Mercedes C-Class 2021> have been added. Also introduced is a front rack end for Suzuki Ignis 2016> (part FTR6264/BTR6264), and for Suzuki SX4 S-Cross 2013> and Suzuki Vitara 2015> (part FTR6267/BTR6267).

A Silverstone launch

PMM recently attended Silverstone to hear all about Motul’s new NGEN range, which uses high-quality regenerated raw materials in their formulations. This means it consists of oils that have already been used and recycled in a complex process, or oils from renewable biological sources. This not only reduces production-related CO2 emissions, but also saves fossil raw materials and enables more sustainable production.

The range consists of the NGEN 5 and 7 for motorbikes and the NGEN hybrid. The latter contains up to 25 per cent oil from renewable raw materials and aims to support better fuel efficiency as well as improve response and starting behaviour. In addition to the contents, the packaging of MOTUL NGEN products is also designed to be sustainable. All bottles consist of 50

A jump start

percent recycled plastics and are made to be 100 per cent recyclable.

WANT TO KNOW MORE?

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Ring has launched the RPPL1000 jump starter for 12V systems with 1000A starting capacity and 1500A peak current. This jump starter is said to be able to perform multiple starts from just one charge and can be used for all petrol vehicles and diesel engines up to 10-litre capacity. The starter is also lightweight (weighing just 2kg) and compact, making it easy to move around.

WANT TO KNOW MORE?

WWW.RDR.LINK/ABC029

Keeping clean

Leaks and spills are a regular occurrence, but the cleaning-up and disposal of these fluids involves little more than blue roll or rags, sand, granules and drip trays. These are affordable means of dealing with the problem, but they can be inefficient –neither cleaning nor absorbing particularly well. It is also worth noting that oily wipes are classed as hazardous materials and must be stored and disposed of as such and when people are busy, this can sometimes be overlooked.

Mewa’s Multitex absorbent mats are designed so that fluid is transported immediately from the outside into the absorbent inner core. A Multitex mat can absorb up to three litres of fluids before needing to be replaced – eliminating the need for sand, granules and drip trays. In

addition, cleaning wipes from Mewa are said to absorb up to 250 per cent of their own weight in fluid and are highly tear resistant. As such, they can soak up large volumes of liquids quickly.

Because the Mewa service includes pick up, wash and replacement, garages will never be without a mat or wipe to hand when they need it and there’s no wasted time reordering supplies. As part of its service, a safety container is also provided for the safe storage and transport of the wipes and mats. This means that oily wipes and mats, classified as hazardous waste, are simply and safely stored, ensuring garages remain compliant.

WANT TO KNOW MORE?

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LETTERS Writetotheexperts

Reader Marky Smith wrote to us recently to enquire about investing in dealer diagnostic tools. “I have a number of makes that regularly come through my workshop, particularly Fords.” explains Mr. Smith, “I have so far got by using aftermarket tools but am now thinking it’s

time to bite the bullet and spend some cash on the dealer tool. Any advice?”

Turn to page 63 of this very issue, that’s our advice!

Emails us with your questions at pmm@hamerville.co.uk

It’s said that hard-working craftsmen and women put more pressure on their knees than many top athletes. That’s why the risk of knee injuries is far higher among trade professionals and manual workers than other occupations. A great way to avoid knee problems is to wear Snickers workwear trousers with their innovative knee protection – KneeGuard.

Snickers Workwear has 86 different types of work trousers in multiple sizes to suit a host different trades and jobs on site, plus eight different types of kneepads. The design features of both the work trousers and kneepads aim to deliver flexibility when you walk, yet they close around your knees when you kneel down – to prevent your knees from sliding off the kneepad when moving around on the floor.

WANT TO KNOW MORE?

WWW.RDR.LINK/ABC031

Much ‘kneeded’ protection

Heat without flame

The use of induction heating in workshops and garages is said to be rapidly gaining popularity, replacing traditional oxyacetylene methods. Induction heating works by using electromagnets to heat metal instead of a flame torch. This method generates heat within the object itself, rather than relying on an external source like oxyacetylene. It's a safer and more efficient way to heat metal.

That’s why GYS have released the Powerduction 110LG, which is said to provide instant and efficient heating of metal parts. Whether you need to release seized components or warm up steel and aluminum, this product could be helpful in any workshop. It offers flameless technology aiming for precise, immediate heating which is said to not only ensure accuracy but also maintain a safe working environment.

WANT TO KNOW MORE?

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Coleman

IN THE WORKSHOP? with Freya

Coil spring compressor

Sealey has unveiled the Moden No. RE3000, a 3000kg air operated coil spring compressor, designed to provide fast and secure compression of suspension coil springs. Aiming to elevate efficiency and safety in the workshop. Key features include...

Fast and safe compression: The RE3000 claims to ensure swift and secure compression of suspension coil springs, saving valuable time during vehicle maintenance.

Robust construction: With a maximum load capacity of 3000kg, this air-operated unit is built to handle the toughest suspension coil spring jobs, aiming to provide durability.

Safety first: Equipped with a safety locking guard, the RE3000 offers peace of mind, aiming to reduce the risk of accidents during operation.

Versatile design: The compressor features adjustable swivel upper arm clamps and comes with a suspension strut clamp, making it compatible with a wide range of left and right-handed coil spring configurations and diameters.

Ease of use: The foot pedal actuation system simplifies operation, allowing for precise control over the compression process.

High-Pressure Performance: The RE3000 can handle a maximum air pressure of 145psi (10 bar), ensuring efficient and effective compression every time.

WANT TO KNOW

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

Leak free top ups

Designed to simplify the coolant filling process, this anti-spill coolant funnel set (part number 8638), includes a funnel with a shut-off valve and lid, along with five adaptor caps to fit various vehicles, including popular models from Ford and Vauxhall/Opel. The adaptors connect directly to the header or expansion tank, then the funnel is fitted onto the adaptor — this aims to enable fast, leak-free and effective coolant re-filling or topping-up. The funnel is fitted with a shut-off valve that enables precise control over the flow and helps prevent over-filling and coolant spillage.

Storage solutions

The set includes a threaded adaptor for GM group vehicles, a threaded adaptor for Ford vehicles and three bayonet-style adaptors, suitable for Chrysler, Honda, Hyundai, Mazda, Mitsubishi, Nissan, Opel, Subaru, Toyota, and Vauxhall. Also included is a useful extension pipe plus two 45-degree adaptors for accessing hard to reach filling points.

WANT TO KNOW MORE?

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A set for stubborn fixings

This pound-thru screwdriver set (part number 56148) from Kamasa contains a set of seven screwdrivers is designed to provide technicians with a convenient solution for releasing seized fixings effortlessly.

With the pound-thru feature, the screwdriver can be struck with a hammer, providing an additional force to help release

stubborn fixings during the application of torque. The strong polypropylene handles feature thermoplastic rubber (TPR) inserts that offer excellent grip. Crafted with user comfort in mind, these handles aim to allow for extended periods of use without causing discomfort or fatigue. Magnetic tips grip the screws securely for safe retrieval.

The set includes a range of sizes to cater to different fixing requirements. The PzDrive screwdrivers come in Pz1 x 80mm and Pz2 x 100mm sizes, while the Phillips screwdrivers are available in Ph1 x 80mm and Ph2 x 100mm sizes. For flathead screw applications, the set offers 4.5 x 90mm, 5.5 x 100mm, and 7 x 125mm screwdrivers.

WANT TO KNOW MORE?

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Kraftwerk is pleased to present its latest new addition to its workshop trolley collection, with the PT800. Tt comes as a five or seven drawer variant, is finished in satin matt black, has ABS/TPR protection on the edge of the trolley and drawers to mitigate any bodywork damage to customer vehicles in the workshop and offers anti-tilt technology to prevent tip over when the drawers are fully extended. It has a stainless-steel top with a chemical resistant finish and 2 unique pull-out drawers which slide out from underneath the top, for storing any personal effects.

The PT800 will also be available fully loaded with 143pcs or 283 pcs tools making a lineup of 6 new PT800 product offers and shortly the PT1000 will also be available as a 5 or 7 drawer option to go with the other 50 workshop trolley options available from Kraftwerk.

WANT TO KNOW MORE?

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Includes adaptors to fit models from Ford and Vauxhall, as well as Honda, Hyundai and others

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

JHM Butt & Co......................(loose insert) www.rdr.link/ABC100

AC Tronics Ltd ............................(page 61)

www.rdr.link/ABC101

Alldata ........................................(page 42) www.rdr.link/ABC102

Alliance Auto/APEC ............(page 83/IBC) www.rdr.link/ABC103

Bailcast ........................................(page 55) www.rdr.link/ABC104

Ben ..............................................(page 77) www.rdr.link/ABC105

Borgwarner Tech Ltd/Delphi ............................................(page 84/OBC) www.rdr.link/ABC106

Castrol (UK) Ltd ..................(pages 10,11) www.rdr.link/ABC107

ClickMechanic Ltd ......................(page 47) www.rdr.link/ABC108

Esprit ..........................................(page 71) www.rdr.link/ABC109

Ferdinand Bilstein UK Ltd ............(page 6) www.rdr.link/ABC110

GEA ............................................(page 69) www.rdr.link/ABC112

Jack Sealey Ltd ..........................(page 19) www.rdr.link/ABC113

Kalimex Ltd ................................(page 31) www.rdr.link/ABC114

Kalimex ......................................(page 45) www.rdr.link/ABC115

Karnetic Ltd/Autel ......................(page 65) www.rdr.link/ABC116

Launch UK ..................................(page 75) www.rdr.link/ABC117

Liqui Moly UK ..........................(page 26) www.rdr.link/ABC118

MAHA UK ..................................(page 45) www.rdr.link/ABC119

MAM Software ..........................(page 37) www.rdr.link/ABC120

Mann&Hummel (UK) Ltd ..........(page 23) www.rdr.link/ABC121

Maverick Diagnostics ..................(page 29) www.rdr.link/ABC122

Merlin Diesel Sys Ltd ................(page 49) www.rdr.link/ABC123

MS Motor Service ......................(page 29)

www.rdr.link/ABC125

Niterra UK Ltd/NGK ..................(page 62)

www.rdr.link/ABC126

OSCA (3D) ................................(page 40) www.rdr.link/ABC127

Pico Tech ....................................(page 56) www.rdr.link/ABC128

PMM Podcast ..............................(page 14) www.rdr.link/ABC129

Primalec ......................................(page 77)

www.rdr.link/ABC130

Ring Automotive ........................(page 72) www.rdr.link/ABC131

Robert Bosch Ltd ..........................(page 4)

www.rdr.link/ABC132

Schaeffler Auto ..............(pages 2/IFC,003)

www.rdr.link/ABC133

Straightset ..................................(page 53)

www.rdr.link/ABC134

Thermobile ..................................(page 45)

www.rdr.link/ABC135

Topdon UK ..................................(page 31)

www.rdr.link/ABC136

Ferdinand Bilstein UK Ltd ..........(page 13) www.rdr.link/ABC111

Motul ..........................................(page 72) www.rdr.link/ABC124

VLS ............................................(page 39) www.rdr.link/ABC137