April 2008

Issue No 2

CheyneBromfield
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UP FRONT
B
elieve it or not, this
magazine was not
born simply out
of a desire to get
rich or create a publishing
monument to ourselves.
We didnt expect to just sit
back while the advertisers
rushed in with open wallets.
We didnt think publishing
was just a matter of re-
cycling PR handouts.
We prefer to think that The
Automotive Technician is
the first cannon volley of
the technical knowledge
revolution.
The TaT team may well be
ahead of their time, but, as
one of the more passionate
of the directors noted, What
we are doing is a major shift
in the way things are done
and the way technicians
think.
In his words: The change
she is acomin, and it will
swell to an avalanche. We
are at the tipping point right
now.
The team
Publisher
The Automotive Technician
Pty Ltd
ABN 27 121 589 802
PO Box 101
GYMEA NSW 2227
1 Cleg Street
ARTARMON NSW 2064
Ph 1300 828 000
Fax 1300 828 100
tat@tat.net.au
Editor in chief
Ken Newton
knewton@tat.net.au
07 5591 6274
Fax 07 5591 8172
0438 569 517
Technical editor
Jeff Smit
jsmit@tat.net.au
1300 828 000
Technical research
Deyan Barrie
dbarrie@tat.net.au
02 9476 6277
Technical advisers
Jack Stepanian
Nick Murphy
nmurphy@tat.net.au
Editorial contributors
Hayley Windsor
TaT was born out of
necessity, combined with a
fair slab of inspiration and
commitment by people who
understand this industry,
who get their hands dirty in
it every day of their lives,
and who have spent most of
their working lives trying to
educate and motivate others.
Once, the progression from
an apprentice to a tradesman
was hard work, hours of
distress and dissatisfaction.
The training methods broke
the mind down and rebuilt
it into a kind of groove that
ran in a straight line, with
no deviations. In time, the
tradesman eventually earned
respect for his skills.
Today, there is little respect
for so many things.
The word tradesman has
changed forever. Todays
tradesman isnt quite
sure where he fits into a
world muddied by modern
ideologies. Too many
tradesmen have lost their
passion and their strength.
Ashley Teitzel
Mark Mitchell
International correspondent
Julian Hentze - USA
Andrew Kavanagh - Europe
Copy proofing
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Affiliated associations
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inc Australian Association of
Automotive Electricians
secretary@vasa.org.au
Even the authorities
dont know what a
tradesman is any
more. It seems
anyone can put up
a shingle and class COP THIS
themselves as an
expert in whatever Coil-on-Plug
they can get away explained P23
with (varies State
by State, which is
another problem). the subscribers to TaT which
makes it all work.
So its against this
confused background that Just as TaT has made its
Tat took on the challenge
commitment to improve the
to convert mechanics knowledge of technicians,
(tradesmen) into it requires a comparatively
technicians. We believe we smaller commitment by the
have a lot to offer. technicians to join up and
become involved in this new
It must come as a shock way of sharing information.
in this cynical world that
TaT actually wants to help One phone call from
people. And just as TaT has technician Graham Price
a lot to offer, so too do a lot (see P8) confirmed our entire
of technicians. strategy.
We are really establishing If just one TaTs a Facts
a knowledge network in helped solve one problem
which everyone shares and in a year, the time saved by
everyone benefits. the technician would more
than cover the cost of the
Which leads to the subscription to TaT.
subscription idea. It will be
TaT Assist TaT Space
CONTENTS
TaT Train TaTs a Fact
Tips for Tat In the fast lane 4&5
are all registered trade names Are you ready for hybrids 6&7
of The Automotive Technician
Pty Ltd Subscription form 7
The Automotive Technician Pty TaT sets new benchmarks 8
Ltd publishes technical advice
and actual case studies for the Global Goss 11
purpose of educating technicians.
Street Cred - with Hayley 13
These advices are given in good
faith, and are based on actual TaTs a Fact 14 - 18 - 19
workshop repairs. No guarantee
is given, nor any liability accepted
TaT Acronym project 15 - 16 - 17
in respect to any published
advice. Murphys Law - Mass air flow 21
The Automotive Technician Pty CAN test box 22
Ltd is not responsible for the
accuracy of any information
contained in material submitted Mitsubishis downfall 22
by third parties and published
in this magazine and accepts Coil-on-Plug 23 - 24
no liability in relation to such
materials or their content. Cheap cars - green cars 24
Newsworthy articles or comments Predictive Safety System 25
are welcomed, and should be
submitted to the Editor in chief. CAN technology 26 - 27
All material appearing in The Wire & Gas Convention 28
Automotive Technician is
copyright. Reproduction in whole More on Mass Meter Sensors 28
or in part is illegal without prior
written consent from the Editor The Sheriff wants a posse 29
in chief.
All advertisers agree to indemnify Turn skills to LPG conversion 29
the publisher for all damages
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published or unpublished
material.
The Automotive Technician 3
 IN THE FAST LANE
IN THE FAST LANE
Cheyne Bromfield is an inspiration to auto technicians everywhere. He is young
and passionate about motor sport, which has given him a dream career as a
leading technician at race events across the world. But success didn't just walk
in his door. He worked hard at it, and he lives by the mantra so often ignored by
those in the motor trade, 'to stop learning is to go backwards'. Editor Ken Newton
caught up with Cheyne before he leapt on a flight back to his UK base at the Team
Australia A1 racing headquarters.
some of the most significant powertrain The classroom (he only became a qualified
developments, including the first digital mechanic when he moved to the UK)
engine management system for Formula might have given him a piece of paper, but
One. Cheyne largely trained himself.

In this awesome world of advanced I just dont switch off. I spend as much
technology, Cheyne is in his element, but time as I can with the older guys with the

D
own Bowral way, some of the
locals will still remember the
mechanically-minded teenager
who fixed their motor mowers
and spent the rest of his time roaring
around the paddocks on his motocross
bike.
To talk to Cheyne Bromfield these days,
youd have to track him down to wherever
the A1 Grand Prix cars are racing could
be South Africa, Mexico or Europe.
Youll find Cheyne in the pits or at a
workbench, proudly kitted out in Alan
Docking Motorsport gear, preparing the
Team Australia race car for the next event
in the World Series.
Its a job all little boys dream about, being
appointed as sub-assembly technician for
Team Australia A1 Grand Prix.
Cheyne was accepted into the team late
in 2007, but came with already substantial
credentials as a racing car technician. In
2005 he had helped prepare and maintain
the legendary and gruelling Paris Dakar
Nissan Rally Raid Pick-up Trucks for multi
world champions Ari Vatanen and Colin
McCray while he was working with the
RJN Motorsport team.
Cheyne is well aware of his responsibility
as the technician who builds and maintains
the sub-assemblies of the Zytek-engined
racing cars with Lola chassis, from the
brake discs to the wheel uprights.
Lola Cars, established in 1958, is one
of the most successful manufacturers of
racing cars in the world. Zytek Systems
was founded in 1982 to develop and
manufacture innovative electronic
technologies for the exacting world of
motor racing.
They have been responsible for many
race-winning innovations, starting with
The Automotive Technician 4
without his dedication it might have turned
out differently.
Like all confident young men, Cheyne
readily admits there was a time soon after
he left Australia at the age of 19 to offer
himself to full time motor racing, that he
thought he knew it all.
After all, hed done his apprenticeship in
BMW workshops, and had crewed on a
few Australian racing teams.
Thinking I had all the skills that were
necessary to conquer the world was
almost my lifes huge mistake, recalls
Cheyne. It dawned on me pretty quickly
that my career wasnt moving at the speed
I expected and I realised then that I didnt
know it all, and would never know it all,
and that learning in the automotive game
just doesnt stop.
There is no closure in
vehicle technology.
"As quickly as something new is developed
and put on the market, someone else will
turn it around and do it better, make it
lighter or make it cheaper," says Cheyne.
Todays auto technicians must recognise
that they are in a technology fast lane in
the motor industry, and if they stop learning
for one minute, they are going backwards."
And he should know. Cheynes skills are
the result of listening and learning.
experience, and I listen and watch, and
absorb their knowledge like a sponge.
It is an accepted fact that many of the
advances in modern street vehicles flow
from the racing car industry.
The technology is so advanced in the
Team Australia cars that they cant even
be started unless the computer is plugged
in. The driver and crews then run through
computer screens of starting procedures
and system checking before being let
loose on the race circuit.
There are so many sensors on these
cars, covering every component, Cheyne
explains. People spend five years at
university just to be able to program a cars
damper system, so you can readily see
why technicians in the field must be totally
up to speed with how they work and how
they should be maintained.
As a youngster, he showed an early
aptitude for competitive racing. What
started in his later teenage years as
roaring around the paddocks in a ute or
on his motocross bikes soon developed
into a disciplined racing career. He was
successful in his age group for both
motocross and go-kart racing.
But his true love was always cars, and
after his apprenticeship with specialist
BMW workshops, he decided almost
immediately that race cars were the go.
After he settled down with RJN
Motorsports in the UK, he was virtually
thrown in at the deep end preparing
vehicles for the Paris Dakar rally (Cover
Pic). He regards these days as his
hardest, but most rewarding and character
building of his life.
Yes, he faced failures of physical
components through desert racing fatigue,
but the experience honed his skills as a
technician.

He had to be a problem solver, and soon
learnt to fabricate and machine parts to
keep the cars in the rally.
When RJN dropped the Nissan pick-ups,
they began extensive development of the
Nissan 350GT for Group N, or standard
production vehicle racing, and Cheyne
became head of the workshop, taking
responsibility for complete construction
and maintenance of a number of cars.
The 350s were raced in many countries
and in long distance races throughout
Europe.
After a number of years at RJN Motorsport,
the call of serious open wheeler race cars
was too strong, so Cheyne responded
to an advertisement from Alan Docking
Motorsport and was immediately accepted.
When asked if he regretted not being in
the racing helmet and behind the wheel,
he said, To me now, it is more satisfying
being involved in building the cars and
sending them on their way, than actually
driving them. Thats my passion, and
thats what keeps me motivated.
He regards A1 Grand Prix as a stepping
stone to the ultimate career for a motor
technician, Formula One.
I have made my way into World Series
racing through A1 Grand Prix, and I could
not think of a better way to advance a
technical career than being involved and
learning with these great people.
Wheelnote:
The A1 Grand Prix series, in which teams
representing 25 countries compete in
identical cars, began at the daunting Brands
Hatch circuit in Britain in 2005.
It was promoted as the fastest single-seater
race since the last Formula One Grand Prix
at the circuit in 1986.
The championship - touted as the world cup
of motor sport - is the concept of 28-year-
old Sheik Maktoum Hasher Maktoum Al
Maktoum, a member of Dubais ruling family.
The A1 Grand Prix is where all countries
compete on a level playing field with
deliberately equalised technology.
British firms Lola International and Zytek
Engineering were appointed to develop
the chassis and engine respectively, based
on the initial drawings of Sheikh Maktoum
himself while US company Cooper Tires was
chosen as the official A1 GP tyre supplier.
After an intense testing program, the final
A1GP race car was built and August 2005
saw the newly formed A1 Teams take to the
track for the first time.
Throughout five days of testing at both the
Silverstone Circuit in the UK and Paul Ricard
HTTT in the South of France, the cars proved
fast and reliable and an exciting spectacle
was assured as the time had come for the
first racing season to begin.
Prizemoney is $1.3 million at each round,
with a bonus of another $1 million to the
winning team at the end of the series.
Expatriate Australian team owner Alan
Docking, who runs his own formula three
operation in Britain, is responsible for the
engineering and European logistics of the
Australian team.
The national teams have attracted a number
of renowned front men as seat holders.
Australias is 1980 world F1 champion
Alan Jones, while the British effort is being
headed by former world motorcycle and
Formula One champion John Surtees.

Team Australia turned in its best A1 Grand Prix

result of the season in torrential rain at
Eastern Creek on 3 February this year.
Twenty-three year old John Martin, who replaced Ian Dyk as Performance:
Australia's lead driver in the New Zealand round in late 2007, Sprint starting in 9th, finishing 6th
finished sixth in the day's earlier sprint race before turning it on in Feature starting in 15th, finishing 5th
the Feature to climb from 14th to 5th, behind winner Adrian Zaugg
of South Africa. Best in Sector Times:
S1 6th, S2 8th, S3 3rd
The highlight came on Lap 23 for the 2006 Australian Formula
Ford champion when, with great courage, he passed another of Feature Race in the Wet
the stars of the day, Canadian 18-year-old Robert Wickens, on Average 256.9 kilometres per hour and that's quick in the
the inside to move into 6th. torrential wet rain!

South Africa's Zaugg won the feature with a faultless

performance, holding off Switzerland's Neel Jani by 19.56
seconds, with Great Britain's Robbie Kerr 3rd.
Thanks to Patrick
The results leave New Zealand and France equal on 96 points at Wedes A1 Team
the top of the standings, three points clear of Switzerland with six Australia Press
of 10 rounds now completed. PR
for racing stats
Australia jumped four places to 14th on 15 points. and pics
Team stats:

Placings:
14th overall with 15 points and a best ever result for
Team Australia at home with the 5th place finish in the
Feature.

Kilometres Raced: 1306.23

Kilometres Practiced: 2069, the most of all teams

Eastern Creek Maximum Speed: 271.4 on Lap 5 in

the Sprint
The Automotive Technician 5
 Are you ready to work on hybrids?
Make up your mind soon. Oh..and buy yourself a good pair of linesmans gloves because high voltage and current
in combination is lethal.

A TaT primer
hybrid, with the electric motor
acting as the primary power

on hybrids
by Jeff Smit
The next generation of
hybrid vehicles, the plug-in
hybrid, may be hitting the
streets sooner than some
of the manufacturers had
planned.
Toyota has announced it
will build its first plug-in
hybrid by 2010.
Hybrid vehicles available
today are closed systems,
and do not require plug-
in charging. A plug-in
hybrid vehicle expands
on the hybrid concept by
allowing for the battery
pack to be even further
recharged through plug-in
charging via a conventional
electric cord plugged into a
household 240 volt outlet.
While a conventional
hybrid vehicle may travel
short distances in pure
electric mode, plug-in
hybrids are designed to
travel extended distances
with little or no assistance
from the gasoline engine.
Even before the charge
is depleted, the gasoline
engine may be called on
to provide additional power for recharging
the battery, accelerating, passing, and
merging.
source, and the gasoline
engine providing supplemental
motivation.
In some designs, once the
initial charge is depleted,
it would operate just as a
conventional hybrid does, using
the gas engine.
The other concept is designed
to use only its electric motor,
using gasoline to aid in battery
recharging, not driving.
Testing has shown that plug-in
hybrids may be capable of up
TaTs USA correspondent Julian Hentze was a guest at the big to 40 kilometres to one litre
MACS Worldwide convention in Florida in February. Julian, a hybrid of fuel. Thats around 1,600
fanatic himself, was blown away by a presentation from Craig Van kilometres per 40 litre tank.
Batenburg (pictured), a top trainer in hybrids since 2000.
There is a growing interest for
With Julians help, TaT has secured a series of articles on hybrid plug-in hybrid vehicles as the
technology from Craig and, in the next issue, he will explore the next stepping stone towards
three entry levels for technicians wanting to cash in on hybrid full electrical vehicles.
aftermarket repair and maintenance.
Craig tells Australian technicians Time is not on your side anymore.
The tide of public
Some technicians are ahead of the wave, some ride the wave, but demand for the
many get washed over. next generation
of hybrids
His advice? If hybrid service makes a smart business plan, make has reached
up your own mind by attending a hybrid class, buy a hybrid book or
DVD, and maybe even a hybrid vehicle. So start now because many
a level that
of your competitors may be ready to pounce. manufacturers
around the world
The pic above shows Craig Van Batenburg with his beloved silver can no longer
Honda Insight hybrid car, which is still an attention getter. Craig ignore.
ordered it in 1999 so that he could understand more about this
technology he saw as our future. The most fuel efficient
2008 model cars available
to consumers are hybrids,
While operating on the additional according to new fuel economy numbers
plug-in charge, a plug-in hybrid more or issued by the EPA in America.
less works the opposite to a conventional (...more next page)

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TheTATDec07.indd
Automotive Technician
1 6 20/12/07 10:15:39 AM

...A TaT primer on hybrids
The Toyota Prius and the Honda Civic
Hybrid are the only vehicles to break the
40 miles per gallon mark.
Others in the top five most efficient
vehicles are also hybrids: the Nissan
Altima Hybrid, Toyota Camry Hybrid, the
two-wheel-drive Ford Escape Hybrid, the
only SUV in the list.
Despite the predictions that the new 2008
method for measuring fuel economy in
real life driving situations would bring
hybrids down a peg, it hasnt happened.
Hybrids were commonly criticised for
having exaggerated official miles per
gallon numbers on window labels, but
despite 20% lower fuel economy figures
compared to the previous year, the hybrid
gas-electric vehicles remain as leaders in
fuel efficiency.
In summary, current hybrid vehicles have
a gasoline engine that is assisted by an
electric motor, which helps it save gas. A
typical hybrid vehicle conserves fuel in a
few different ways. It recaptures energy
lost through braking and decelerating.
This recaptured energy is stored in a
battery pack as electricity. As demand
warrants, the stored electricity is used to
power an electric motor that assists the
vehicle's gasoline engine - usually during
acceleration.
Many hybrid vehicles conserve additional
fuel by incorporating a shut-off system
that shuts down the engine during stops.
In these cars and trucks the electric motor
alone may propel the vehicle for short
distances.

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The Automotive Technician 7

 Issue No 1 set a new benchmark -
according to our readers
I
n a nation with
reputedly the
highest number
of magazines per
head of population
in the world, it takes
a big leap of faith to
bring out yet another
title.
The key, of course, is to do
something nobody else has
done, and as far as we know,
weve done that.
We really arent in competition
with any other publication,
simply because no other
publication has ventured into
aftermarket problem solving
the way TaT has.
Theres a very dedicated team
behind TaT. Countless hours
are being spent documenting
vehicle problems.
Two of the directors of this
publication have turned
their already busy Sydney
service centres into technical
laboratories.
This is where the TaTs a fact
problems are tackled, solved,
tested and documented. The
technicians are pioneers
and innovators and the work
they are doing for their fellow
techicians, through this
publication, will go down in
Australian automotive history.
But dont take our word for it.
Our new
readers have
responded with an
enthusiasm even
we did not expect.
The phone has run hot with
calls from technicians wanting
to become subscribers.
Advertisers reported a strong
demand for their products
and industry leaders have
welcomed the new kid on the
block with best wishes for
continued publishing success.
For those of us outside the
big cities, its great to have
access to quality information
and assistance.
Greg Morris
Narrabri, NSW
The Automotive Technician 8
Well done and
congratulations getting
this massive project on
the road and doing such
a great job.
The whole magazine
concept is right for the
industry and the trade
will identify with this.
Good luck for the
continued success of the
publication. You have our
on-going support.
Clive Mount
Mount Auto Equip Pty Ltd.
Well you did it!
You overcame all the obstacles,
the knockers, the fear of failure
and just the plain outright stress
of doing another project in your
already busy lives.
You also had the vision to do
something very much needed in
your own industry, and enough
fortitude to carry it through.
You have set a new standard - a
new era has begun.
Mark Mitchell
SCA-Australia Pty Ltd
What a pleasant surprise to
receive a copy of The Automotive
Technician. An even bigger
surprise to see the quality of the
content of what will no doubt
become an industry must-read.
Ian Cradock
Sydney NSW
A great publication for
technicians, enabling us to learn
and stay ahead. Very refreshing
to see somebody giving something
back to the industry.
John Doherty
Melbourne VIC
Deal with Someone You Can Trust
Deal with Someone You Can Trust
43 - 51 Brisbane Street (Locked Bag 5012) Darlinghurst NSW 2010
Phone: 02 9213 4222 Facsimile: 02 9212 6889
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Dear Deyan
I am writing to congratulate you on your brilliant initiative in producing and publishing the TaT Magazine for
auto electricians and the motor industry at large.
I have read the first edition with considerable interest and have found it to be full of essential information for
the professional in our industry. I do hope that every auto electrician and motor trader in this State subscribes
to your magazine as it is only through high quality publications like this that they can keep ahead in this age of
constant change.
We wish you well with the magazine and will happily assist you in any way we can.
Kind Regards,
James McCall
Chief Executive
The main attraction - an ongoing
database of vehicle specific
solutions to everyday problems
I had been wrestling with
and time-wasting technical
this problem on a Holden
mysteries. Delivered in a
Astra with an intermittently consistent, well-illustrated format.
flashing oil light and had Designed for the computer terminal
spent an embarrassingly on your workbench - logged in to
long amount of time on it the biggest on-line problem solving
and it had me licked. database of its kind.
A mate in a workshop
nearby wandered in with
this new magazine and I
couldnt believe it when Training programs which can be
heres the same car, same
used by wholesalers, associations
problem with the solution or groups. Will eventually cover
on page 18. all sorts of vehicle training,
accompanied by actual workshop
I looked at the picture in experiences on DVD movies.
the magazine and it was
exactly what I was looking
at on the car sitting on my
hoist.
Specialised TaT workshops are
I couldnt believe that here
established and will eventually
was the solution, staring extend to a national network where
me in the face. I went and subscribers to the TaT program will
bought the recommended be able to contribute their problems
parts and it was done. AND their solutions.
My mates taken the
magazine back to his own
workshop, so how can I join
up? (Graham was referring of
course to the first issue of The A resource centre devoted to
collecting and publishing stories,
Automotive Technician and the
trends, research and profiles for
TaTs a fact HOLAS00110 and
yes, he did join up) sharing with TaT subscribers.
Graham Price
Thompsons Auto Service
Mayfield NSW A never-ending selection of
technical tips, aimed at helping
A great read, finally something technicians improve their
written by technicians, for diagnostic skills to save time
everyday technicians. and reduce frustration without
Michael Millner compromising the integrity of the
Sydney NSW job.
The Voice of the
Motor Industry
\
Value already from first edition. This can be a wealth of
experience and technical information which we all need to keep
up in an extremely fast moving industry. We need more and
more to be networking colleagues, not just competitors in this
industry.
Graham Patterson Apps Automotive Kirrawee, NSW
The Automotive Technician 9

D
isneyworld in
Orlando, Florida
was where Julian
met up with his two
pals (above) at the MACS
(Mobile Air Conditioning
Society) Worldwide
Convention.
The subjects covered by the
speakers were broad and
varied, but I got hooked on
a personal interest of mine,
the hybrid vehicle. To me,
the hybrid is symbolic of how
innovative the car industry
can be when confronted with
environmental imperatives.
I listened to Craig Van
Batenburg, who specialises
in hybrid cars and just loves
Hondas. He is self taught and
really knows his stuff. Take it
from me, hybrids are coming
and in a big way.
We know of the Prius, but
here there is not only a
Camry hybrid, but also a
hybrid version of the Kluger,
the Nissan Ultima, the Ford
Escape and just released is
a General Motors hybrid SUV
which is a little smaller than the
Suburban.
The one big thing that Craig
zeroed in on was the role of
the air conditioning system to
keep the electrical components
cool in the cabin. There are
enough electronics in each
vehicle to keep a sparky busy
for a month, so theres no
doubt in my mind that knowing
your stuff on hybrids is likely to
make you very rich.
Safety is a priority when
working on these vehicles,
although Craig revealed that
the global goss
no one had yet been killed
working on a hybrid. This is
more than likely due to the
multiple safety measures built
into the vehicle, such as the
ECU constantly monitoring for
voltage drop to the body.
Why is safety an issue? Here
are some startling statistics:
60 volts at half an amp can
kill you. The smallest hybrid
system runs at 1,440 volts and
125 amps.
Its no wonder that a set of
electrical linesmans gloves are
the minimum safety essentials.
The hybrid compressors are
manufactured by Sanden for
Honda, Denso makes them
for Toyota and Ford, and
Mitsubishi has just entered the
hybrid pump market with the
new GM hybrid SUV.
The compressors are a
scroll design and come in
two sections. Generally one
end is 12 volt belt driven and
the other end is driven by
high voltage electricity. They
are two independent scroll
compressors within the same
housing.
The Ford and Mazda hybrids
air conditioning systems use
an evaporator in the rear boot
section and is there solely for
the electronics that are hidden
in the back, usually where the
spare tyre would be.
The air conditioning has priority
on the ECU circuit to keep the
vehicles multiple electronic
components cool.
MACS this year showcased
products from 130 exhibitors
from Julian Hentze
Georgia, USA
from around the world, and
it was a real pleasure to see
them all under one roof.
I spoke with Elvis Hoffpauir, the
Worldwide President of MACS,
who is passionate about the
industry and ensures that it has
a strong voice.
I appreciate not everyone has
a spare ten thousand dollars
to visit this great annual event
in the US, but the Gold Coast
event in June this year is
driven by people with similar
passion to Elvis and it will be a
grand event in its own right.
(Julian is referring to Wire & Gas
2008. He and Andrew Kavanagh
served on the Wire & Gas
Committee for several years)
...and Andrew Kavanagh
CPS Products N.V.
Belgium
European news and views
relating to the automotive
industry are surprisingly very
similar to the topics which are
high on the Australian agenda,
except that in Belgium, Im a
great deal closer to the centre
of the design action.
When approached to write
this column on the state of the
nation here in Europe, I was a
little perplexed about what to
write, but for those fortunate
(or unfortunate) to have made
my acquaintance, they should
know that I am never short of
words.
Present hot topics in the
European market are the
same as last year and the year
before, and the year before
that what refrigerant are
we going to use in the near
future?
As the time line creeps forward
and Europe has to ban R134a
in the not to distant future,
we still have no conclusive
replacement - and I find that
quite comical.
What is it going to be? R-777
(CO2), R152a , or the new
kid on the bock HFO-1234yf
(the refrigerant DuPont and
Honeywell propose to replace
R134a).
If I were a bookmaker I would
have my money on the last,
actually something like this:
HFO-1234yf $1.25
R-777 (CO2) $7.00
R152a $11.00
A three horse race - you take
your pick?
Writing about this got me into a
reflective mood.
I remember penning a speech
and delivering it at the opening
of the VASA convention in
Sydney 2001 and I mentioned
technology like 36/42 volt
systems and CO2 refrigerant.
I even recall some scoffing at
the mere mention of CO2. Isnt
it funny how quickly technology
progresses. Back then it was
just speculation, now this could
very much be a reality.
To remain at the cutting
edge of the vehicle industry,
information and education has
become more important now
than ever.
Six years ago who would have
predicted the remarkable
changes our industry is going
through.
Six years ago we were just
getting over retrofitting and
now it is another refrigerant,
another system and more
advanced technology.
Congratulations for staying in
a trade that has progressed
further than any other I can
recollect in the last decade.
The Automotive Technician 11
 #4

Maintenance and Diagnosis is crucial for a Fuel Pump to perform in the correct manner in which it was intended.
Fact 1 Fact 2
All ACA Fuel Pumps are 100% tested at time of manufacturer. Obviously, Over 70% of pumps tested were found to have failed or suffered
this is why it is crucial to perform testing before suspecting the pump. performance problems due to contamination of fuel & or foreign
In fact, over 25% of Fuel Pumps returned for warranty consideration particles within the fuel system.
meet all manufacturers specifications when tested. Therefore, we have provided a simple Fuel System Overview for your
viewing...
Note: No cutting or modification of the fuel system is required when installing a genuine ACA replacement Fuel pump Kit.
All ACA Fuel Pumps are 100% tested at time of manufacturer.
Ensure a correct diagnosis of the entire fuel system is done before replacing the fuel pump. Remember to practice caution, due care must be taken.
Always refer to the manufacturers service & technical handbooks before removal or installation of any fuel or electrical components.

1.
4. 5. 6.
10. 3.
8.
2.
9.
7.

1. Fuel Filler Cap -

Ensure a proper fuel
delivery, evaporative
emission control system
operation, and avoid any fuel
contamination. Make sure that the
filler cap has a uniform seal, if not
then replace the filler cap.
2. Fuel tank - The leading cause of
all fuel pump failure is caused misdiagnosed
through fuel tank contamination. as a fuel pump
problem. Check or 9. Fuel Filter - A restricted in-line
Thorough in-tank cleaning is tank or externally fuel filter creates significant
strongly recommended before replace as a part of the fuel pump
service. mounted, the strainer is the amounts of back pressure on the
every fuel pump replacement. first line of defence against fuel delivery, causing premature
3 & 4. Supply and Return Lines - 6. Fuel System Wiring - Inspect premature pump failure. This is pump failure.
Restricted or blocked lines force all the wiring harness carefully for why a new strainer is supplied in Protect your investment, replace
the fuel pump to work harder in loose, frayed or damaged wiring, every ACA Replacement Fuel Pump your inline fuel filter every time you
delivering a sufficient quantity of melted or blistered terminal Kit (where possible). Note: The carryout an oil change, and or as
fuel. connector, loose spade terminals correct location/positioning of the a part of a fuel pump service.
To avoid any fuel delivery on fuel pump relay/fuse, loose strainer is important for a perfect
terminal connector on the fuel 10. Fuel Injectors - Faulty injectors
problems, it is strongly seal. Failure to observe this can
can create drivability issues that
recommended that the fuel supply pump. Faulty wiring is easily cause the strainer to fall off and
are often misdiagnosed as a fuel
& return lines are blown free of any misdiagnosed as a fuel problem cause premature pump failure.
pump problem.
contaminated fuel. and can create potentially a
dangerous condition. 8. Fuel Pump - All ACA
5. Fuel Pressure Regulator - A replacement Fuel pump kits have
faulty regulator can contribute to 7. Fuel Pump Strainer - No matter been designed & built to meet or
fuel pump failure or be easily if it is a fuel pump mounted in the exceed the OE specifications.
Copyright 2007 Enforced ABN 78 003 653 183
 street cred
W
as I taking a big everyone mocked. What more
risk? I booked does a rookie consumer need
my car in for a to check before we hand over
new clutch based our car and a large portion of
on only one professional our savings?
recommendation, a good
quote, and the gushing Finding the right guy for the
assurance from Rob who ran job is like sourcing a good
the workshop - trust me, we restaurant but with far more
will do a good job. serious consequences if the
Well, that will be a surprise, wrong choice is made.
If the food tastes
bad, or the waiter
never looks your
way, or youve
spotted one too
many cockroaches
scurrying under the
kitchen door, you
have every right to
complain without
delay and you may
even recoup your
expenses before
the bill is presented.
But a poor
investment in
an automotive
technician may
leave you with a
very empty feeling
in your stomach
not to mention your
wallet.
continental cockpit for the new ford
Continental Pty Ltd, formally Siemens VDO Automotive has
opened a cockpit manufacturing plant to supply complete
modules to Ford.
Costing more than $7 million, the purpose built Campbellfield
plant in Melbournes North East, will supply the interior cockpit
assemblies for the latest Ford Falcon FG.
The plant will pump out around 70,000 cockpit assemblies per
year over the life of the vehicle.
The Continental Group is a leading supplier worldwide of brake
systems, powertrain and chassis systems and components,
instrumentation, infotainment solutions, vehicle electronics, tyres
and engineering elastomers.
Lucky for me, Rob (the poor
bugger) under-estimated
the amount of time and
effort required for my clutch
replacement, and after a
10-hour day in which he says
his employee almost walked
out on me, I paid the agreed
price and drove smoothly out
of the parking lot feeling much
better than he did.
My smugness at having, for
once in my life, chosen the
right man for the job without
being sent to the poor house,
didnt go unnoticed by my ute-
driving partner.
His most recent repair story
didnt have a happy ending.
After paying his repair bill, he
drove his car away in the same
condition it had started the day.
Boys being boys, he wouldnt
concede hed made a wrong
choice of workshop or
technician because he didnt
want to appear to be a fool.
Pride, I think its called.
He didnt go back to that
workshop ever again.
Diagnostic
problems?
We have your solutions. Distributors for Launch,
AutoBoss, BulletPro, ADD, Boyce Publications,
Electrajet interactive, Electrajet Data, simply call
Terry on 0418 649894
or Garry on 0417 023887. PROBLEM SOLVED.
with Hayley Windsor
So when we collected my car
with its new clutch, my partner
quite naturally quizzed our new
and trusted repairman about
where he should take his car
for a specific kind of repair.
You know how to tell a good
repairer from a bad one?
confided Rob.
If their parking lot is full early
in the morning, then you can
almost guarantee theyll do a
good job on your car.
Well, that little bit of hometown
wisdom flies in the face of
all my other advice, like
looking for a wall full of
training certificates, or a clean
workshop, or cheap prices, or
proximity to home.
Robs advice was noteworthy,
but cruising industrial estates
and counting the cars in the
parking lots at the crack of
dawn means Id have to get up
pretty early.
I think Ill stick to the more
traditional method of picking a
good repairman. Young, blue
eyes, clean fingernails...you
know the stuff.
The Automotive Technician 13
 BMW3997421
BMW E39
04-1997
6 cylinder
Customer complaint
No interior fan on any setting.
Problem summary
Climate control, interior fan
motor not operating on any
speed. All climate control
functions working and LCD
display for fan control working
correctly showing variable
speeds, as the system has a
variable speed fan.
Diagnostic sequence
Test all fuses and circuit
breakers in the fuse box to
check power supply to fan
control system.
Then scan the electronic
control systems with an
appropriate scan tool.
Remove the under dash
panels on the drivers side to
access the fan variable speed
controller.
Holden Commodore
VT -VT 11
1997 to 2000
1 Turn ignition Off
2 Hold down both up and 6
down arrow buttons on the up and down buttons until
trip computer.
The Automotive Technician 14
Find the variable fan speed
resistor and check the wiring
connections for power.
Fault description
The fault on this car is in the
variable resistor that controls
the fan speed for the internal
ventilation system.
[1]
Fault solution
First you need the
replacement part from BMW
Resistor part no.
64116923204.
Make sure that you check
the chassis no. with BMW on
ordering because they do vary
between models.
Fit the new resistor into the
[2]
hole with the two required
screws, install the wiring and
then test the fan operation.
All should again be working [3]
correctly.
You may also want to check
that there are no error codes
stored in the computer, using
an appropriate scan tool.
Recommended time
Labour time was two and a
half hours, taking into account
research time, location of parts
and the actual time spent
fixing the problem.
Service light
reset
3 Switch on ignition while 7 Release both buttons and
holding down both buttons. turn ignition off.
4 The trip computer will
beep, release buttons.
Something bugging you
Figures should now be
flashing. technically?
5 Press the mode button Email your technical questions to TaT, and
until another beep is we will find the answer or solve the
heard.
problem and print it for all to share.
Again hold down both the info@tat.net.au
a final beep is heard.
 (Figure Out What This
One Stands For)
TaT AUTO ACRONYM PROJECT

I
Welcome to the

f youve been forced to
read an official letter lately,
youll quickly discover that
letter writers suffer from
acronymophilia.
The overuse of acronyms is
endemic, and most agree its a
trend we just have to learn to
live with.
Theres even an organisation
called ASS (Acronym Sense
Society) which opposes
the widespread overuse of
acronyms (WOA).
What started out as a need for
highly specialised technical
shorthand (HSTS) for scientists
and engineers has now
infiltrated all parts of society.
The automotive industry
has its own particular brand
of shorthand in the form of
acronyms and abbreviations.
If technicians dont know
what they mean, they will
find themselves at a great
disadvantage.
To complicate life even further,
the car manufacturers have
developed acronyms for their
own makes of vehicles, so
WOT in a Holden manual,
might mean something entirely
different in a Mazda manual.
So, in this issue, The
Automotive Technician
is launching its own
AUTO ACRONYMS AND
ABBREVIATIONS PROJECT
(TAAAP).
This project is aimed at helping
technicians figure out technical
journals, articles and even the
instructions for how to use new
readers to send in their
products, so keep it handy for
acronyms as they fall over
reference.
them (FOT - ouch) and well
add them to the list.
Later in the year, TaT will print
a wall chart of acronyms and
this will be sent free to all
So to start the ball rolling
subscribers.
(BR), heres our first wave
of auto acronyms and
In the meantime, we invite abbreviations (FWAA).

The TaT Auto Acronyms & Abbreviations Project (TAAAP)

A amperes Aux auxiliary CCD computer controlled dwell
a/c air conditioning Avg average CCEI coolant controlled idle enrichment
A/F air/fuel ratio AWD all-wheel drive (Chrysler)
A/T automatic transmission or transaxle B/P backpressure CCEV coolant controlled engine vacuum
AAC auxiliary air control B+ battery positive voltage switch
AAP auxiliary acceleration pump BAC by-pass air control CCM central control module
AAV anti-afterburn valve (Mazda) BAP barometric absolute pressure sensor CCO converter clutch override
AB air bleed BARO barometric pressure CCOT clutch cycling orifice tube
ABCV air bleed control valve BAT battery CCP controlled canister purge (GM)
ABDC after bottom dead centre BBDC before bottom dead centre CCV canister control valve
ABRS air bag restraint system BCM body control module CCW Counterclockwise
ABS antilock brake system BDC bottom dead centre CDI capacitor discharge ignition
Abs absolute BHP brake horsepower CEAB cold engine air bleed
ABSV air bypass solenoid valve (Mazda) BID breakerless inductive discharge(AMC) CEC crankcase emission control system
AC air cleaner BLK black (Honda)
AC alternating current Blst ballast CECU central electronic control unit
ACC a/c clutch compressor BLU blue (Nissan)
ACCS a/c cycling switch Blwr blower CESS cold engine sensor switch
ACCUM accumulator BMAP barometric pressure sensor CFC chlorofluorocarbons
ACCY accessory BOO brake on-off switch CFI cross fire injection (Chevrolet)
ACT air charge temperature BP back pressure CFI central fuel injection
ACV thermactor air control valve BPS barometric pressure sensor CFI continuous fuel injection
ADJ adjust or adjustable BPS bits per second cfm cubic feet per minute
ADV advance BPT back pressure transducer Chrg charging
AEAT air conditioning evaporator air temp Brkr breaker CID cubic inch displacement
AFM air flow meter BRN brown CID cylinder identification sensor
AFS air flow sensor BTC before top center Circ circuit
AHL automatic headlight leveling BTDC before top dead center CIS continuous injection system
AI air injection Btu British thermal unit CIS-E continuous injection system - electric
AIR air injection reactor BUS circuit providing communication path CKP crankshaft position sensor
AIS automatic idle speed motor (Chrysler) BVSV bimetallic vacuum switching valve CKP REF crankshaft reference
AIS air injection system C celsius CKT circuit
ALCL assembly line communications link C3 computer command control system CL closed loop
ALDL assembly line data link C3I computer controlled coil ignition CLR clear
Alt alternator or altitude C4 computer controlled catalytic cm2G square centimetre gauge
Amp ampere converter system CMP camshaft position sensor
APS atmospheric pressure sensor (Mazda) CALPAK calibration pack CMP REFcamshaft reference
APS absolute pressure sensor (GM) CAN controller area network CNG compressed natural gas
ARC automatic ride control CANP canister purge solenoid valve Cntrl control
ASCD automatic speed control device Carb carburetor CO carbon monoxide
ASCS air suction control solenoid CAS clean air system (Chrysler) CO2 carbon dioxide
ASD automatic shutdown CAS crank angle sensor Comp compressor or compartment
ASDM airbag system diagnostic module CAT catalytic converter Conn connector
Assy assembly CB Circuit Breaker Cont. continued
ASV air suction valve CBD Closed Bowl Distributer CONV convertible
ATC automatic temperature control CBVV Carburetor Bowl Vent Valve COP coil on plug ignition
ATDC after top dead center CC catalytic converter CP canister purge
ATF automatic transmission fluid CC cubic centimeters CPA connector position assurance
ATS air temperature sensor cc/rev cubic centimetre per revolution CPI central port injection (GM)
Auto automatic CCC computer command control system CPP clutch pedal position

The Automotive Technician 15

 The TaT Auto Acronyms & Abbreviations Project (TAAAP)
CPS crankshaft position sensor EFC electronic feedback carburetor HSO high specific output
CPU central processing unit (Chrysler) HTR heater
CSC coolant spark control (Ford) EFCA electronic fuel control assembly (Ford) HVAC heating ventilation and air
CSSA cold start spark advance (Ford) EFE early fuel evaporation conditioning system
CSSH cold start spark hold (Ford) EFI electronic fuel injection HVS high voltage switch
CTAV cold temperature actuated vacuum EGO exhaust gas oxygen sensor (see Hz hertz (cyles per second)
(Ford) HEGO) I/M inspection/maintenance
CTB CAN test box EGR exhaust gas recirculation system I/P instrument panel
CTO coolant temperature override switch EGRC EGR control solenoid or system IA intake air
(AMC) EGRPS EGR valve position sensor (Mazda) IAC idle air control
CTP closed throttle position EGR-SV EGR solenoid valve (Mazda) IACV idle air control valve
CTS coolant temperature sensor EGRT EGR temperature IAT inlet air temperature sensor (Ford)
CTS charge temperature switch (Chrysler) EGRTV EGR thermo valve (Chrysler) IAT intake air temperature
CTVS choke thermal vacuum switch EGRV EGR vent solenoid or system IATS intake air temperature sensor (Mazda)
Cu. In. cubic Inch EI electronic ignition IC integrated circuit
CVC constant vacuum control ELB electronic lean burn (Chrysler) ICM ignition control module
CVCC compound vortex controlled EM engine modification ICS idle control solenoid (GM)
combustion system (Honda) EMI electromagnetic interference ID inside diameter
CVR control vacuum regulator (Ford) EMR emission maintenance reminder ID Identification
CVx2 check valve or constant velocity module IDM ignition diagnostic monitor
CW clockwise EPA environmental protection agency IFI indirect fuel injection
CYL cylinder EPROM erasable programmable read only IGN ignition
D drive memory ILC idle load compensator
dB decibels ESA electronic spark advance In inches
DBV dual bed catalyst ESC electronic spark control In Hg inches of mercury
DC direct current ESP electronic stability program INJ injector or injection
DDD dual diaphragm distributer ESS electronic spark selection (Cadillac) IP instrument panel
Def defogger or defroster EST electronic spark timing IPC instrument panel cluster
DEFI digital electronic fuel injection ETR emergency tensioning retractor IRC integrated radio chasis
DERM diagnostic energy reserve module EVAP evaporative emission system ISA idle speed actuator
DFI direct fuel injection EVIC electronic vehicle information centre ISC idle speed control
DFS deceleration fuel shutoff (Ford) EVO electronic variable orifice ISS idle stop solenoid
Diag diagnostic EVP EGR valve position sensor ITCS ignition timing control system (Honda)
DIC driver information centre EVR EGR valve regulator ITS idle tracking switch
DIS distributorless ignition system (Ford) EVRV electronic vacuum regulator valve for IVSV idle vacuum switching valve
DIS direct ignition system (GM) F fahrenheit J/B junction block
DIST distribution F/B fuse block K kelvin
DK BLU dark blue FBC feedback carburetor k kilo
DK GRN dark green FBCA feedback carburetor actuator (Ford) KAM keep alive memory
DLC data link connector FC fan control KAPWR keep alive power
DME digital motor electronics (Motronic FCA fuel control assembly (Chrysler) KBPS 10,000 bits per second
System) FCS fuel control solenoid (Ford) kcal kilocalories
DOHC dual overhead cams FDC fuel deceleration valve (Ford) kg kilograms
DP dashpot FEEPROM flash electrically erasable kg/cm kilograms per square centimetre
DRB-II diagnostic readout box programmable read only memory kgf kilogram-force
DRCV distributor retard control valve FI fuel injection kgm kilograms per metre
DSO digital storage oscilloscope FICD fast idle control device kHz kilohertz
DSSA dual signal spark advance (Ford) FIPL fuel injector pump lever KISS keep it simple stupid!
DTC diagnostic trouble code FLS fluid level sensor (GM) Km kilometers
DTM diagnostic test mode FP fuel pump Km/h kilometers per hour
DVDSV differential vacuum delay and FPM fuel pump monitor KOEC key on, engine cranking
separator valve FPROM flash erasable programmable read KOEO key on, engine off
DVDV distributor vacuum delay valve only memory KOER key on, engine running
DVOM digital volt ohm meter ft lb foot pound kPa kilopascals
EAC electric assist choke FWD front-wheel drive kPaG kilopascal gauge
EACV electronic air control valve g grams KS knock sensor
EBCM electronic brake control module GCM governor control module KSM knock sensor module
EBM electronic body module (GM) GEN generator KV kilovolts
EBTCM electronic brake traction control GND ground kW kilowatts
module GRN green L litres
EC engine control GRY gray L/D light duty
ECA electronic control assembly H/D heavy duty LAN local area network
ECAT electronically controlled automatic H20 water lb ft pound feet
transaxle HAC high altitude compensation Lbs pounds
ECCS electronic concentrated control HAIS heated air intake system (Chrysler) LCD liquid crystal display
system (Nissan) HC hydrocarbon LED light emitting diode
ECL engine coolant level HEDF high speed electro drive fan relay or LH left hand
ECM engine control module circuit LOS limited operation strategy
ECM electronic control module HEGO heated exhaust gas oxygen sensor LT BLU light blue
ECS evaporation control system (Chrysler) HEI high energy ignition LT GRN light green
ECT engine coolant temperature Hg mercury Lt(s) light(s)
ECU electronic control unit Hgt height LTFT long term fuel trim
EDF electric drive fan relay assembly HLDT headlight Lugg luggage
EDIS electronic distributorless ignition HO high output LUS lock-up solenoid
system HO2S heated oxygen sensor M/T manual transaxle or transmission
EEC evaporative emission controls HO2S1 upstream heated oxygen sensor mA milliamps
EEC electronic engine control HO2S2 up or downstream heated oxygen MA PFI mass air sequential port fuel injection
EECS evaporative emissions control system sensor system
(GM) HO2S3 downstream heated oxygen sensor MAF mass airflow sensor
EEPROM electronically erasable programmable HP high performance MAP manifold absolute pressure
read only memory chip hp horsepower MAT manifold air temperature
EFC electronic fuel control HSC high swirl combustion MC mixture control
The Automotive Technician 16
 The TaT Auto Acronyms & Abbreviations Project (TAAAP)
MCM mirror control module PIP profile ignition pickup STI self-test input circuit
MCS mixture control solenoid (GM) Pkg package STO self-test output
MCT manifold charge temperature (Ford) PNK pink SUB-02 sub oxygen sensor
MCU microprocessor controlled unit PNP park/neutral switch Susp suspension
MCV mixture control valve PPL purple Sys system
MDP manifold differential pressure PPM parts per million t tonne (Note: ton is not abbreviated)
MEM-CALmemory calibration chip PRNDL park reverse neutral drive low TA temperature air (Honda)
mfd microfarads PROM program read only memory TAB thermactor air by-pass
MFI multiport fuel injection PS metric horsepower TAC thermostatic air cleaner
MIL malfunction indicator lamp PS power steering TACH tachometer
MLP manual lever position PSA pressure switch assembly TAD thermactor air diverter
mm millimeters PSI pounds per square inch TAV temperature actuated vacuum
MPFI multi point fuel injection psig pounds per square inch gauge TB throttle body
MPG miles per gallon PSP power steering pressure TBI throttle body injection
MPH miles per hour PSPS power steering pressure switch TC turbocharger
MPI multi port injection Psuc suction pressure TCC torque converter clutch
ms millisecond PTC positive temperature coefficient TCCS Toyota computer controlled system
MST manifold surface temperature PTO power take-off TCM transmission or transaxle control
mV millivolts PVA ported vacuum advance module
MVZ manifold vacuum zone PVC positive crankcase ventilation TCS transmission controlled spark (GM)
NDS neutral drive switch PVS ported vacuum switch TCS traction control system
NGS neutral gear switch PWR GD power ground circuit TDC top dead center
NIM navigation interface module QS9000 quality assurance standard for OEM TDCL total diagnostic communication link
Nm Newton meters part suppliers TDM theft deterrent module
No number Qts quarts TELE telematics
Nos numbers RABS rear anti-lock brake system Temp temperature
NOX oxides of nitrogen RAC remote accessory control TFI thick film ignition system
NPS neutral pressure switch RAM random access memory TFP throttle fluid pressure
NVRAM nonvolatile random access memory RAP retained accessory power TGS top gear switch (cancels SIL in top
O oxygen RECIRC recirculation gear)
O/S oversize RED red THS transmission hydraulic switch
O2 oxygen RFA remote function actuator TIC thermal ignition control (Chrysler)
O2S oxygen sensor RFI radio frequency interference TP throttle position
OBD onboard diagnostics RH right hand TPI tuned port injection
OBD I onboard diagnostics generation one ROM read only memory TPP throttle position potentiometer
OBD II onboard diagnostics, second RPM revolutions per minute TPS throttle position sensor
generation RPO regular production option TPT throttle position transducer (Chrysler)
OC oxidation catalyst RSE rear seat entertainment TRS transmission regulated spark (Ford)
OCC output circuit check RVB rear vacuum break TS temperature sensor
OD overdrive RWAL rear wheel snti-lock brake TSB technical service bulletin
OD outside diameter RWD rear-wheel drive TSP throttle solenoid positioner (Ford)
ODM output device monitor SAP accelerator pedal TTS transmission temperature switch
ODO odometer SAS steering angle sensor TV thermovalve
OE original equipment SAVM spark advance vacuum modulator TV throttle valve
OEM original equipment manufacturer SAW spark angle word TVS thermal vacuum switch
OHC overhead cam SBC single bed converter TVV thermal vacuum valve
OL open loop SBEC single board engine controller TWC three-way catalyst
Opt option or optional SC sub cooling V valve
ORG orange SC supercharger V volts
OS oxygen sensor SCB supercharger bypass Vac vacuum
OSAC orifice spark advance control SCC spark control computer VAC volts alternating current
(Chrysler) SCS air suction control solenoid VAF vane airflow sensor
OSC output state check SDI SAAB direct ignition VAF volume airflow
oz ounce SDM sensing diagnostic module VAPS vane air flow sensor or circuit
ozs ounces SEN sensor VAT variable assist power steering
P park SES service engine soon indicator VATS vehicle anti-theft system
P/B power brakes SFI sequential fuel injection VBATT vehicle battery voltage
P/C printed circuit SH super heat VCC viscous converter clutch
P/N park/neutral SIC secondary information centre VCM vehicle control module
P/N part number SIG RTN signal return circuit VDC volts direct current
Pa pascals SIL shift indicator light VDV vacuum delay valve
PA pressure air (Honda) SIM seat interface module VIN vehicle identification number
PAFS pulse air feeder system (Chrysler) SIR supplemental inflatable restraint VIO violet
PAIR pulsed secondary air injection system (air bag) VLR volt loop reserve
(GM) SMEC single module engine controller VM vane meter
PAIR pulsed secondary air injection SOHC single overhead cam VOM vehicle power supply voltage (10-14
PAV pulse air valve SOL solenoid volts)
PCM powertrain control module SPFI sequential port fuel injection VR voltage regulator
PCS purge control solenoid SPK spark control VREF voltage reference (ECA supplied
PCSDM passenger compartment SPOUT spark output signal reference voltage)
sensor/diagnostic module SRDV spark retard delay valve VRV vacuum regulator valve
PC-SOL purge control solenoid SRI service reminder indicator VS vehicle sensor
PCV positive crankcase ventilation SRS supplemental restraint system VSC vehicle speed control sensor or signal
Pdis discharge pressure (air bag) VSS vehicle speed sensor
PFE pressure feedback EGR sensor or SRT system readiness test VSV vacuum switching valve
circuit SS speed sensor W watts
PFI port fuel injection SS3/4-4/3 shift solenoid circuit WHT white
PGM-FI programmed gas management fuel SSI solid state ignition WOT wide open throttle
injection (Honda) STAR self-test automatic readout WSS wheel speed sensor
PGM-FI programmed fuel injection STFT short term fuel trim YEL yellow

The Automotive Technician 17

 HOLVY03424
HOLDEN
COMMODORE VY
2003
3.8 litre V6
Customer complaint
Vehicle alarm going off
intermittently while driving or
when parked.
Problem summary
After testing found that
vehicle horn was going off
intermittently. The alarm
system was not affecting the
horn operation.
Diagnostic sequence
It took some time to isolate the
problem to the horn and not the
alarm.
After questioning the owner at
length, we worked out that the
indicators were not flashing
when the horn was sounding.
This enabled us to eliminate
the alarm at this point.
No codes were present relating
to horn or alarm system.
Fault description
After removal of the air bag it
was found that a
metallic sticker
on the steering
wheel was peeling up and
shorting to the horn contact on
the air bag unit.
This was causing the horn
to sound when contact was
made.
The Automotive Technician 18
Fault solution
The horn system on this model
was wired through a micro
relay mounted in the main fuse
box under the bonnet.
Because there is a relay in
the system, only a very small
current draw is required to
activate the horn relay and
sound the horn.
Removal of the offending
sticker was all that was needed
to rectify the problem.
We suspect that the small
current draw through the
sticker caused the sticker to
change shape, like a thermal
circuit breaker, and stop
shorting out the contact.
This made the process of
diagnosing the problem very
difficult due to the problem only
occurring infrequently and for
only a very short time.
Recommended time
Labour time was 1.5 hours,
taking into account research
time, location of parts and
actual time spent fixing the
problem.
This was a classic situation
where as much information
as possible was required
from the customer.
Once we were able to
determine that the indicators
were not flashing at the
same time, it made the job of
isolating the problem easier.
Metallic stickers can cause
problems to electrical The TaT website www.tat.net.au will be a
circuits, so keep your eyes constant source of information for
and minds open to possible subscribers to TaT.
causes of intermittent faults.
There will be hundreds of solutions like this
one plus technical information from experts
Share your technical solutions
on all manner of subjects.
with us. TaT will give away an
annual subscription to the best
Many technical articles will appear on the
solution every issue. Send to
info@tat.net.au
website before being published...but only
subscribers will be able to access these.
 HOLVT00112
HOLDEN
COMMODORE VT
2000
5.7 litre Gen 3
Customer complaint
Vehicle running rough and
poorly.
Problem summary
After road testing found that
vehicle was running poorly and
very rough at idle.
Diagnostic sequence
1) General inspection of engine
components especially the
air intake pipes and vacuum
hoses around inlet manifold.
2) Extract codes - codes P0171
and P0174. Both indicating
system too lean on banks one
and two.
Fault description
Due to codes indicating lean
running on both banks, further
inspection of all inlet manifold
hoses.
Remove air intake to throttle
body and inspect positive
crankcase ventilation (PCV)
pipes.
Found perished breather hose
to PCV valve.
This was allowing air to enter
the engine without passing
though the air mass meter
and therefore logging codes
for system running too lean on
both banks.
Fault solution
Source new hose set from
Holden.
Part no. 12590632 TUBE PCV
VLV(4)
Fit new tubes as required.
We recommend removal of
idle speed control motor and
cleaning of throttle body and
inlet manifold with a suitable
throttle body cleaner.
Recommended time
Labour time was two hours,
taking into account research
time, location of parts and
actual time spent fixing the
problem.
Whenever codes are relating
to engines running too lean,
a good place to start is to
look and check for air or
vacuum leaks.
A thorough inspection of
the air mass meter is also
recommended.
www.tat.net.au
can save you the cost of
your annual subscription
with just one job
the odometer. The light can be the reset button for approx
Service light reset by following this eight seconds
reset procedure after servicing.
3 Wait until the word InSp is
Holden Barina XC 1 While holding down the replaced by ----
2001 to 2005 odometer reset button, turn
on the ignition 4 Release the reset button
The service light is located in
the instrument cluster within 2 Continue to hold down 5 Turn off the ignition.
The Automotive Technician 19

A subscription
to TaT just got a
whole lot easier
Established in 1974,
Capricorn Society Limited
is one of the largest
automotive buying groups
in the world, with more
than 10,000 members and
1,200 suppliers operating
in Australia, New Zealand
and the Republic of South
Africa.
When you have an account
with Capricorn you get
instant credit with hundreds
of top name suppliers, all at
competitive prices, on one
30 day account for easy
book-keeping.
You also earn Reward
Points on every dollar you
spend that can be used for
great gift cards from leading
retailers, making payments
towards your Capricorn
account, booking holidays
with Capricorn Travel or
even shopping online with
the Rewards on the Web
program.
For more information on how
Capricorn can benefit your
business, please visit the
Capricorn website at www.
capricorn.com.au or FreeCall
1800 999 233.
Finer points of the Code
Grant Hand,
head of
Automotive
Training
Solutions (ATS),
issues a timely
warning about
interpretation of the new
auto Code of Practice which
will apply to all handling of
vehicle refrigerants (R134a)
The Automotive Technician 20
ar
lls
Perths e the perfect
hi
proving ground - for brakes!
S
ome of the steep hills around Perth
have become the testing ground
for the heavy duty brake pads from
Bendix.
Designed to work under heavy loads and
at high temperatures, Bendix Heavy Duty
consistently performs on load carrying work
vehicles like courier vans, horse floats,
caravans and trailers.
Mark Wilson, who runs a service centre at
Walliston, said one of his customers, a taxi
owner, had achieved remarkable mileage out
of his heavy duty pads.
We replaced the first rotors after he had
done 350,000 km. We change the brake
pads before they are down too low so the
surface temperature doesnt increase too much.
Bendix Heavy Duty is a brake pad designed
If you keep the maintenance up and dont let the
to run at high temperatures in vehicles carrying
brake pads get down too low, you generally get
loads or making lots of stops in heavy traffic.
better mileage out of your discs and your pads,
Mark explained.
The challenge was to provide positive high
temperature performance without unnecessary
Eddie Worsnop, a Roleystone service centre
rotor wear.
owner, said the steep hills around Perth made
Bendix Heavy Duty pads a first choice even for
The friction material lasts a long time, up to
regular cars.
twice as long as typical brake pads, he said.
Theres one particular hill that a lot of customers
The purpose of brakes is to transform kinetic
of mine use called Canning Mills Road East.
energy into heat. The insulation layer between
the pad and the backing plate inhibits the
They obviously ride the brakes all the way
transfer of heat to the backing plate to stop heat
down. Its a bit of a killer that hill. Brake fade with
damaging the caliper, Tim said.
ordinary pads was never normally an issue but
over-heating and rapid wear was, he said.
The Insulayer assists the adhesion of friction
material to the backing plate and prevents heat
You might as well stick transfer which stops brake fluid from boiling and
something proper on in the ensures a positive pedal feel at high operating
beginning, he claimed.
temperatures.
Bendix Applications Engineer, Tim Paton, said Bendix Heavy Duty pads now also have
the compound used in Heavy Duty pads was the Bendix Titanium Stripe which means no
originally sourced from an OE application in the bedding-in and less down time. With the
US. Titanium Stripe you get instant pedal feel from
the first stop.
The pads were developed for Australian use on
the Bendix dynamometer at Ballarat and then Want more?
road tested. Brake Advice Centre: 1800 819 666
Catalogue: www.bendix.com.au
The long awaited automotive the automotive air conditioning you determine that air may be
Code of Practice is in its final Code of Practice is to minimise pulled into the system it will be
stages of ratification. the emissions of harmful necessary to lightly purge the
synthetic greenhouse gases applicable hose of air. This is
The important point to consider and ozone depleting gases. desirable over allowing air to
when you refer to the Code is enter a system, where it may
that it is a minimum standard Minimise is the key word. cause acid formation and thus
document. When working on air an emission of the full system
conditioning systems it charge.
In simple terms all work is sometimes difficult to
Many volumes of Grants
must MEET or EXCEED the completely stop emissions.
technical papers are available to
standards laid down in the As an example, if you connect VASA members.
document. The overall aim of a hose that has air in it and www.vasa.org.au
Murphys Law
D
iagnoses of a Mass Air Flow (MAF)
meter can be very deceptive,
particularly if there are no
Diagnostic Trouble Codes (DTC) recorded.
Symptoms of a faulty MAF are usually
poor performance. In some cases it can
cause a whole range of problems, most
commonly flat spots throughout the rev
range.
The MAF has several different functions.
Its main function is to measure the air
volume. This information goes back to
the Engine Control Module (ECM); the
ECM then determines the engine load in
conjunction with the other major sensors
such as the Throttle Position Sensor,
Engine Coolant Temperature, Crankshaft
Position Sensor and Vehicle Speed
Sensor.
With this information the ECM can
calculate a load. This load signal is used
in conjuction with the information from
the O2 sensor to calculate fuel trim.
The load signal calculated by the ECM is
sent to the Transmission Control Module, Note the voltage after cleaning
which will then calculate shift patterns
and valve body pressure.
In some European cars with coil over
plug it can cause a DTC indicating
random misfire. It is tempting to replace
coils and HT leads, so its better that you
check the MAF first before making an
expensive mistake.
With this information you can see how
a faulty MAF sensor can cause a whole
range of problems, and how important
it is to diagnose this fault before you go
wasting time looking elsewhere.
It will be unusual for the ECM to record a
DTC for the MAF sensor because the
MAF will still be running within its
operating parameters. It will only log a
code if the MAF is open/short circuit.
Testing Procedures
Most MAF sensors send a voltage signal.
In the case of the Holden Commodore it
will be a frequency signal but in both
cases they can be tested without too
much trouble.
Tools required will be a digital storage
oscilloscope (DSO), set of long test leads
and a faulty car (preferably).
The settings on the scope should be 0.2
Avoid expensive mistakes
check the Mass Air Flow first
- 0.5 volts per division and 200 ms time
base. The voltage range may have to be
altered depending on the signal output.
You have to use a wide time base to
capture the drop out in the signal.
Note the voltage before cleaning
The position of the insert and the
sensors
The diagram above is a typical signal from a
MAF before cleaning
The insert removed and the location
of the air intake temperature sensor.
Testing and measuring a faulty
MAF is the same procedure as
before. On a faulty MAF the
signal will fall to 0 volts. We
have to test the sensor with a
wide time base in order to catch
the drop in voltage. If you use
your curser and scroll across
the signal, you can measure the
This is the same MAF sensor after cleaning
with a cotton bud and solvent. I use brake clean drop out area.
because it evaporates quickly.
Remove the MAF from the car, if you
look down through the MAF you can
see two fine wires with heat variable
Note the voltage
resistors on them. One resistor is for
air temperature and the other is the
air flow measurement. You can clean
both of them. Removing the insert
from the housing will make it easier
to clean but in some cases it may not
be possible to remove the insert. Note the signal
going to ground
Remember when using a DSO, its
better to record any information.
The DSO has more time to gather
data in record mode than looking at The signal recorded from a MAF sensor that has
live info. failed; the only fix for this one is to replace it.
It is more economical to purchase the MAF Happy diagnosing
insert instead of buying the whole housing.
All testing of MAF sensors is performed
with engine running on snap throttle or Nick Murphy
when the problem occurs.
The Automotive Technician 21
 did an ugly duckling
really bring
mitsubishi down
Mitsubishis demise as one of
the remaining four Australian car
manufacturers was, according to many
motoring writers, inevitable when the
company produced just one ugly duckling
in an otherwise handsome line of motor
cars.

The 380 was the front wheel drive family

...so whats in the blue box?

sedan which was supposed to give the
market an alternative to the standard
Holden, Toyota and Ford sedans.

T
his small blue box gives the
technician easy and instant
access to the modern motor
vehicles electronic systems via
the OBD II connector.
The CAN Test Box (CTB) incorporates
a 2.5 metre cable with a 16 pin DLC
connector and a 16 pin pass through
connection for scan tools (OEM or
aftermarket).
Once connected to the vehicle via the
OBD II connector, instant testing of
the power and earth circuits gives
the technician a very quick and easy
reference.
The CTB also identifies what protocols the
particular vehicle is running such as low
and high CAN bus.
All technicians have faced the situation
where you plug your trusty scan tools into
a vehicle, only to find you cant establish
communication.
This is where a simple device like the
CTB is great. Once the CTB is in place, it
instantly tests power and earth points as
well as indentifying the type of systems
that are active.
You also have instant and safe access to
all the 16 pins of the OBD II connector.
Once the CTB is in place you can have
your scan tool working away as well and
will be able to use your oscilloscope on
any of the 16 pins.
LEDs are connected to all 16 pins and
again give the technician a quick reference
to whats happening.
The CTB is a great
learning tool to
allow technicians
at all levels to
further understand
the modern motor
vehicles electronic
communications.
One car buff described the 380 as a
shocker and reckoned it was designed
by a disjointed mob of designers who then
took their designs to a welder in the hope
that a car would pop out the end of the
production line.
This was to be Mitsubishis salvation in
Australia, but the car buyers rejected it.
Its a shame that a perceived poor design
of a car can lead to a shut down with such
devastating results for the workforce.
So, following the principle that the
customer is always right, TaT has little
choice but to nominate the 380 for the Ugly
Oscars, up there alongside the early 4
cylinder Torana, the Leyland P76 and the
Morris Marina (described by Wikipedia as
one of the worst cars of all time).
But dont write off Mitsubishi. They are still
a major car supplier on a world scale.

LEFT: Using the

CTB together with
a new hand held
electronic tester
which will be Leyland P76
explained in more
detail in the next
issue of TaT.

Where: Mount Auto

Equipment. (see P10
advertisement)
SMILE
A mechanic was removing a cylinder head from a So how come I get a pittance and you get the really
famous heart surgeons car. The surgeon came in to big money, when you and I are doing basically the
check on progress. The mechanic shouted across same work?"
the garage, "Hey Doc, look at this engine. I can The surgeon smiled and leaned over, and whispered
open hearts, take valves out, fix'em, put in new parts to the mechanic, "Try doing it with the engine
and when I finish this will work just like a new one. running!
Morris Marina
The Automotive Technician 22
Cop this if you really
want to start something
The humble old conventional ignition system, comprising a distributor,
the points, a coil, the ballast resistor and ignition leads made way for the
coil packs, but now it's a Coil-on-Plug (COP) ignition system.
Todays technician will need to keep up to
speed with the current generation of COP
ignition systems, which are in response to
the call on car makers to reduce emissions
from these fuel guzzling, belching,
polluting machines which are dominating
our lives, and our planet.
Its not only environmental responsibility
which is to blame for the march of
technology. Car makers really do want
to improve ignition performance and
reliability.
High tension leads have always been a
weak link, especially since the introduction
of ignition systems minus the distributor.
The high tension leads must carry high
voltages to fire the spark plugs. They have
to be heavily insulated and they must have
the ability to suppress electromagnetic
interference (EMI). The wires
must also be able to withstand
high temperatures in the engine
compartment.
To overcome the problems that high
tension leads have caused over
many years, the Coil-on-Plug ignition
system has entered the market and
can be found on a growing number of
late model engines.
Design technicians say the COP
ignition systems can deliver around
30% more electrical energy than
earlier systems. Using individual coils
for each spark plug also means the
coils have more time between each
firing.
Increasing the coil saturation time
(coil on time) increases the coil output
voltage at high rpm when misfiring is most
likely to occur. This improves combustion
and reduces the risk of misfire with lean
fuel mixtures (lean mixtures require more
voltage to ignite).
The spark plugs are accessed from the top
of the conventional four cylinder, east-west
motor, so the mounting of the COP was in
most cases an easy task.
As with all new electrical systems like
COP, the designers have to start at the
drawing board to ensure proper fitment.
In most applications the Engine Control
Unit (ECU) determines which and when
each coil is fired.
After receiving all necessary inputs from
sources like the crank angle sensor, the
ECU will fire each coil at precisely the
right time.
The fundamental set-up of each coil
is basically the same as the earlier
conventional coils. Each coil has a primary
resistance of approx 0.4 to 0.6 ohms and
steps up the primary system voltage from
12 volts to as high as 40,000 volts to
produce a spark for the spark plug.
The only real difference between COP and
other ignition systems is that each COP
coil is mounted directly atop the spark
plug so the voltage goes directly to the
plug electrodes without having to pass
through a distributor or wires. It is a direct
connection that delivers the hottest spark
possible.
MISFIRES
COP systems can suffer from many of the
ailments which dogged the earlier ignition
systems such as misfiring, hard starting or
a no start.
Spark plugs can still be fouled by oil or
fuel deposits as well as pre-ignition and
detonation, so COP ignition systems are
not immune from trouble.
If the crankshaft position sensor fails, the
loss of the basic timing signal will prevent
the system from generating a spark and
the engine will not start or run. A failed
driver circuit within the ECU can kill an
individual coil and prevent that cylinder
from firing. But with COP, an individual
coil failure will cause misfiring in only one
cylinder.
It is important to remember that ignition
misfire can also be caused by other
factors such as worn or fouled spark
plugs, loose or damaged coil connectors
or terminals, dirty fuel injectors, low fuel
pressure, intake vacuum leaks or loss
of compression in a cylinder. All these
possibilities need to be considered when
looking into a misfiring problem.
The most common trouble codes you may
encounter with COP systems on OBD II
equipped vehicles are P0300 series codes
such as P0301 or P0302, which indicate a
misfire in a particular cylinder.
The important point to remember here
is that a general misfire code (P0300)
is probably not ignition related but is
due to a vacuum leak or fuel delivery
problem.
A code that indicates a misfire in a
single cylinder (such as P0304), on
the other hand, will usually be due
to a fouled spark plug, weak coil,
dirty or dead fuel injector, or loss of
compression from a burned valve or
leaky head gasket.
If a misfire is due to a bad coil,
you should find a coil code that
corresponds to the same cylinder
(P0351 to P0358).
A COP engine that cranks but fails to start,
in many cases will have a problem in the
crankshaft position sensor circuit (code
P0320). Loss of the camshaft position
sensor signal (code P0340) may prevent
the ECU from properly synchronising the
fuel injectors, but may still allow the engine
to start and run in a limp-in mode.
When checking coils, pay close attention
to the tube that wraps around the spark
plug. Cracks can allow voltage to jump to
ground causing a misfire.
The spark plug terminal should also fit
tightly.
(continued next page)
The Automotive Technician 23
 (COP continued)
More cheap cars - terrific! Just what we need

If a COP coil
tests bad and is
replaced, future
problems can
often be avoided
by cleaning the
COP connector
and wiring
harness terminals. Corrosion at either
place can cause intermittent operation and
loss of continuity, which may contribute to
component failure.
SPARK PLUGS
A
s technicians battle to keep ahead
of the models available in Australia,
a Chinese car manufacturer is
planning an assault on the Australian
market.
The company, Geely, plans to present its
cars at the Sydney International Motor
Show in October 2008.
Outside the four majors which dominate
the world market, independent makers in
China, Korea, India, Malaysia, Slovakia,
the Czech Republic, Italy and Russia are
Sensible technicians
would never consider
buying a budget car,
even if they thought they
could use their skills to
keep it on the road.
So now is a good time to start warning
family and friends not to succumb to
budget buying of something as important
as a car, especially if they are using it as a
family vehicle.

As for spark plugs, long life platinum plugs
are used with most COP ignitions.
Such plugs are capable of going 100,000
kilometres under ideal conditions, but keep
in mind that any plug can still fail due to
fouling and misfire if an engine burns oil,
develops an internal coolant leak or runs
too rich.
Many technicians are changing spark
at 60,000 kilometres instead of 100,000
kilometres.
ESTABLISHED 1977 A DIVISION OF J.C. FRY & SONS PTY LTD
Nationwide Distributors of
Wiper Systems and Components
Rocker Switches
Column Switches
Mirrors and Arms
Handles, Locks and Latches
hoping to appeal to budget conscious
drivers already stressed over high fuel
prices, with rock bottom, no frills, cut price
cars.
Some are likely to be so cheap that these
cars will be throw-aways, or disposables,
when something major goes wrong.
Like many cheap goods, they can be more
trouble than they are worth when they stop
working.
NSW (02) 9438 4588
VIC (03) 9646 0994
QLD (07) 3373 8099
sales@frysspares.com
on the earth.
Take note of recent reports that one of
hundreds of Chinese car makers scored
the worst result in 20 years of safety
testing at the European crash testing
centre.
Green cars? sure!
but youd better read
the small print
If the hits on the Australian Governments
green vehicles guide are any indication,
the Australian motorist is finally seriously
looking at environmentally friendly, greener
ways to get about.
The motorists are looking at any vehicles
which have a greener nature, be it a
diesel, hybrid or ethanol compatible so that
they leave a minimum size carbon imprint
This might be so, but dont expect the oil
companies to suddenly realise the folly of
their ways and stop producing petrol.
Like refrigerant gas producers, car makers
will be looking at more efficient ways of
using nasties like fuel.

Gas Struts Remember the great 42 volt idea, which

boasted an engine which shut down when
Filters Air, Fuel and Oil the vehicle was stationary. It was hoped
15 inch Motorised Televisions to improve fuel ecomomy by up to 30% in
city driving.
Brooms, Brushes and Squeegees
The Proton Jumbuck half ton ute has just
Brake Systems been named the most economical ute on
Thermostat Control the Australian market, recording the best
greenhouse and air pollution rating.

Many thanks to all of the technicians

who sent in their subscription forms
to TaT.

All subscribers are contacted

personally and given their passwords
SWF s Trico s Bosch s Teknoware s Mekra sZimmermansBehr to access the new website and its
many technical treasures. If you
have any suggestions or questions,
BD-FP-5164976-08

please email info@tat.net.au

The Automotive Technician 24
No more rear-enders
with technology that can
foresee the accident
I
magine your car being able
to alert you of an imminent
crash or apply emergency
braking in unavoidable
collisions. If humans cant
avoid hitting other vehicles or
objects on the road, maybe
smart technology can.
Theres been a lot of interest in
safety systems lately, moreso
after an adventurous motoring
writer challenged himself to
drive the new BMW fitted with
Active Cruise Control and Stop
& Go function from Sydney to
Newcastle and back without
once touching either the
accelerator or the brake.
In most of the top European
cars now, the Active Cruise
Control comes as standard.
It can maintain both your speed
and a set distance from the car
in front, so you never need to
touch the pedals.
Bosch reckons about one
third of all car accidents are
collisions with other vehicles
or objects and in almost 50
percent of such accidents, the
driver does not brake at all or,
at best, is much too hesitant.
Many of these rear-end
crashes might be prevented
by Boschs Predictive Safety
Systems, or they will at least
be reduced in impact.
Based on the information
received by the sensors on
distance, relative speed and
size of the vehicle you are
about to hit, the systems are
capable of activating the safety
functions even before the
imminent crash, says Bosch.
Bosch is marketing the
Predictive Safety Systems in
three steps.
The system gets the brake
unobtrusively ready for a
possible emergency braking.
The Predictive Safety System
of the second generation also
alerts the driver to critical traffic
situations. To achieve this, the
system triggers, for example, a
short and powerful brake jolt.
The third step will exercise
automatically an emergency
braking with maximum
deceleration of the vehicle.
Studies show that about
half of all collisions could
be prevented with driver
assistance systems.
A.D.R. A.D.R.
APPROVED APPROVED
The Automotive Technician 25
CAN do technology:
Youd better not miss the bus
Y
By Jeff Smit
oull never have to work on
that, I remember my boss
telling me back in the 1970s,
when, as an apprentice, I
found myself staring unbelieving at the
wonders of the VB Commodore and XD
Falcon electronic ignition systems.
I quickly learned that if we dont accept the
fact that we will all have to work on that
whatever that is we will never keep up
in our industry.
Not only do we have to repair these things,
but the reality is that even that will be
difficult unless we understand how they
work.
Lets look more closely at the technology in
the new VE Holden Commodore series.
Along with the now old hat systems like
satellite navigation and trip computer,
controlled by a scroll wheel and buttons on
the steering wheel, the VE comes with two
priority keys which store individual driver
information.
Some of the stored detail includes
personalised settings for trip computer,
seat and mirror settings, radio stations and
even the drivers favourite instrumentation
settings and illumination.
At night, the interior lighting can be set
to illuminate only the speedometer.
To continue to deter the theft of radio
systems, the radio, instrument cluster and
other key components are electronically
linked to the vehicle and will not operate in
any other vehicle.
The audio system is Blue Tooth compatible
and also will accept MP3 players via an
input jack on the face of the radio. A rear
DVD player folds down to keep the kids
happy on those long trips.
The greatest advancement is in the Holden
Assist telematics. This new system allows
the vehicle to receive and send data.
For example, if any of the air bags have
been deployed, the system notifies an
operator who will attempt to speak to the
driver via the radio system. If the operator
does not receive a response, emergency
services are notified and told the vehicles
exact position by the on-board satellite
navigation system.
If you lock yourself out of the vehicle, an
operator can confirm that youre the owner,
then unlock the vehicle remotely. For road
side assistance, a press of a button and
they will know exactly where you are.
The Automotive Technician 26
Holdens VE Lumina
The VE Commodore has up to 30
computers or modules that control
functions like engine operation,
transmission, power steering, anti lock
brakes, telematics, instrument cluster,
climate control and theft deterrent.
Here are just some of the control modules.
Those in red are part of the high speed
system and the rest are on the low speed
system.
Engine control module (ECM)
Transmission control module (TCM)
Steering wheel angle sensor (SAS)
Electronic brake control module (EBCM)
including Electronic stability program (ESP)
Traction control system (TCS)
Antilock braking system (ABS)
Telematics (TELE)
Instrument panel cluster (IPC)
Heating, ventilation, air conditioning (HVAC)
Body control module (BCM).
Theft deterrent module (TDM)
Integrated radio chassis (IRC)
Remote function actuator (RFA)
Rear seat entertainment (RSE)
Automatic headlamp levelling (AHL)
Navigation interface module (NIM)
Remote function actuator (RFA)
So how do you get all
these electronic modules
to talk to each other?
Since about 2003, a growing number
of vehicles have been built with a new
onboard communications protocol called
CAN (Controller Area Network).
CAN is essentially an engineering
standard for how computers and modules
talk to one another via the serial data bus
in a vehicles wiring system.
The CAN protocol was created by Bosch in
anticipation of future advances in onboard
electronics. The first production application
was on several Mercedes-Benz models.
If youre not up to speed on the latest
electronics and dont know a data bus from
a commuter bus, diagnosing CAN systems
will be a challenge.
Even so, you dont have to be an engineer
to perform basic diagnostics on CAN
GM Corp
equipped vehicles because the diagnostics
are essentially the same as OBD II
vehicles.
The only difference is that you need a
CAN-compliant scan tool to read the
vehicle serial data.
Like many current vehicles, information in
a CAN-equipped vehicle is shared over a
serial data bus.
The bus is the circuit that carries all the
electronic chatter between modules.
The new VE commodore requires a high-
speed data bus to handle the volume of
information going back and forth between
some of the more important safety related
modules.
In 1995, GM introduced its own data bus to
handle communication between modules.
The system ran at a speed of approx
10,000 bits per second (10 Kbps), which
was more than adequate for vehicles a
decade ago.
For the VE, GM moved to their next
generation data bus system which
they called GM LAN (GM Local Area
Network). Holden has added the capability
to operate at two speeds on two separate
buses; a low speed 33 Kbps bus and a
high speed 500 Kbps bus.
The low speed side of the GM LAN system
operates on a single wire bus to handle
body-related control functions, while the
high speed bus uses two wires to carry
data between the powertrain, transmission
and antilock brake modules.
A gateway node connects the high
speed bus and low speed bus and allows
information to be shared back and forth.
For example, the radio (which is connected
to the low speed bus) may adjust volume
based on engine speed and vehicle speed
(from the high speed bus) to offset road
noise.
(More on controller area networks and
diagnostics on these systems in future editions
of TaT).
The diagram on the next page shows the
basic configuration of the high and low
speed GM LAN.
 Latest technology in GMs VE
BCM TCM SAS EBCM AHL ECM

120 120
8 16
High speed
GM LAN
Link
to low X40 diagnostic plug
speed 1 9

MCM SIM RFA

HVAC TDM SIC IPC RSE IRC TELE NIM SDM

Low speed GM LAN

Glossary of abbreviations GM Corp

BCM body control module EBCM electronic brake control module

TCM transmission control module AHL automatic headlight levelling
SAS steering angle sensor ECM engine control module

HVAC heating, ventilation, a/c TELE telematics

TDM theft deterrent module
SIC secondary information centre
IPC instrument panel cluster
RSE rear seat entertainment
IRC integrated radio chassis
NIM navigation interface module
SDM sensing diagnostic module
MCM mirror control module
SIM seat interface module
RFA remote function actuator
The Automotive Technician 15
The Automotive Technician 27
 More on air
mass meter
sensors
This is a common
problem but the Reader adds
issue being missed to debate
is - where does - P15 last
the carbon deposit issue
come from? Can we
minimise it?
pure fuel back through the PCV

Being a member of VASA

In many cases we see thicker system as intended.
slimy contamination, which

doesnt cost - it pays

can often be linked with poor
maintenance history, wrong
oil, heavy fuel contamination
Organisers of the biggest training convention and trade show in the oil, or an excessively
dedicated to the auto electrical and air conditioning industry have worn engine combined with a
introduced a bold initiative to get new blood to the biennial event, neglected PCV valve.
scheduled for the Gold Coast Convention Centre from 27 - 29
June 2008. The result is crankcase vapour
entering the intake area and
Already considered by regular exhibitors as the highest quality fouling the throttle body and air
audience in Australasia, there is a determined move to interest flow meters.
the younger generation to conventioneering.
After a road test, bring the
If workshops are members of VASA, they can bring their car to operating temperature,
apprentices to the convention free, and additional technical staff remove the oil filler cap and
from the same workshop get a full registration at half price. look for oil vapour.
One member from North Queensland has already registered and If the mist is there, I can
is bringing six apprentices with him. guarantee the PCV valve has
been neglected.
Organisers see this as a means of growing VASA as well as
turning the next generation into knowledge junkies. The vehicle produces this
vapour because the oil
Convention chair Mark Padwick, who is also President of VASA, has failed. Poor oil quality
says that once hooked, delegates to the Wire & Gas Training especially in a vehicle used
Convention and Trade Show keep coming back, year after year. as a shopping trolley - short
daily trips to shops and school
The initial decision might be a little hard, considering that there - results in deposits of enriched
are fares and accommodation costs to meet as well as the fuel mix into the sump. The
registration fee, but veteran conventioneers will tell you that engine oil never reaches
the knowledge and contacts they gain at the convention gives operating temperature long
them a return on their investment which far outstrips the initial
enough to dissipate this as
investment, said Mr Padwick.
Diagnosing this is simple, and
can also be a very good tool in
helping you sell servicing. The
oil needs to be changed more
frequently in short distance
vehicles and maybe the oil
quality needs to be better.
Areas such as injectors
and oxygen sensors are
consumables with a huge
effect on both economy and
premature engine wear.
In general, a more regular
service will at least reduce this
vapour issue even in an older,
worn engine.
Also be very wary of falcon
throttle bodies marked with a
yellow tag, do not clean.
If you do clean this, computer
re-learning will occur in about
one to two weeks and in the
meantime expect stalling and
rev fluctuation.
With thanks to
Graham Patterson,
Apps Automotive,
Kirrawee NSW 2232

For registration
details, email
wireandgas2008@ Century makes
ozaccom.com.au or
phone 07 3854 1611 you more attractive...
Australias top trainers and
speakers will be at the convention
this year, covering topics such
as scan tools and A/C advanced
servicing. ...to customers
A keynote speaker is Wayne
Gardner, World 500cc motorcycle
racing champion and Australian V8 Customers are attracted to Century resellers because they sell Australias
Supercar Champion. leading battery brand. Resellers stock Century because it allows them to
maximise margins, it increases the profile of their business and makes
selling batteries really easy. Century also has the most comprehensive
battery distribution network in Australia.

For more information call Century

1300 362 287

www.centurybatteries.com.au

The Automotive Technician 28

 Sure looks
like some-
body let
that gas out
allright...,
the Sheriff
(paraphrasing
John Wayne)
Our intrepid sheriff Ashley Teitzel is
volunteering to raise a posse to run some
gas jockeys out of town.
Ashley, who travels far and wide into the
wild outback of Queensland has yet to be
convinced that many bush workshops are
doing the right thing by the new national
refrigerant licensing laws.
I know the auditors from ARCTICK cant
be everywhere, but the big question
is, how would they ever know if some
backyarder let go a full charge of R134a
into the atmosphere?
For those with the right skills, LPG conversion can be a profitable diversion
By Wayne Broady
LPG conversions may well
be profitable for those who
know how to do it properly, but
meeting the demand since the
introduction of the governments
$2,000 rebate in mid 2006 has
not been a walk in the park.
Workshops in the LPG
conversion market have been
swamped with inquiries. When
petrol prices rise, there is a fresh demand
for conversion quotes.
Equipment supply problems coupled
with workshops booked out for months
in advance are giving the industry its
challenges.
The industry has been on a roller coaster
ride, from the highs of the government
rebate to the lows of the tax review which
almost killed the industry in 2003-4.
Not only do vapour injection
systems meet emission
requirements but they eliminate
backfiring issues associated with
mixer or venturi based systems.
They also provide a seamless
changeover from petrol to LPG,
as well as better performance
and economy. They start on
petrol and swap over when the
required engine temperature is
reached.
The industry needs to keep the standards
high and ensure conversions are done to
the strict Australian Standard AS 1425.

The Sheriffs big beef is against some
gung-ho panel beaters hes visited as he
rides the western ranges.
I went to one panel shop and actually
copped this guy letting the gas go from a
cars a/c so he could work on it.
I said Oy, you shouldnt be doing that.
A dirty look was the response.
Then, as an afterthought, I asked him if
he had a Refrigerant Handling Licence.
When he said no, I handed him an ARC
letter explaining why he needed to be
licensed and why he shouldnt be letting
gas into the atmosphere, and he grabbed
the letter, turned it over and scrawled the
following message on the back.
Yeah, right, Ashley muttered to himself as
he rode into the sunset.
Gone are the days of converting new
vehicles by adding an LPG converter,
mixer and some wiring and then doing
some minor mixture adjustments with
a gas analyser or dedicated hand held
device.
Stringent emission testing requirements
are in force for vehicles manufactured after
January 2004.
Kehlin vapour injectors
Newer technology, the vapour injection
system, helps to meet these requirements.
The system comprises a set of
injectors, converter or regulator, and a
programmable ECU which is accessed via
laptop with specific software.
Ford Falcon AU Impco Mixer
based under bonnet conversion
Some vehicle manufacturers now have
factory approved kits such as Toyota
Hiace, Holden Rodeo 3.5, Toyota Camry
2003-2004, Mitsubishi Magna and 380.
Ford has an LPG kit only for Falcons and
Holden has VZ/VE dual fuel vehicles.
The shortage of auto mechanics and LPG
installers is critical. New skills must be
introduced into the trade, and bolstered
with support and training.
Prime candidates for LPG skills are
existing mechanics with EFI and tuning
skills. They will probably adapt to vapour
injection technology more readily than
others.
Wayne Broady trained in LPG and began
conversions in the early 1990s. He operates
Broady Automotive Repairs in Sydney, is a
member of the Gas Injection Group and LPG
Australia. www.broadyauto.com.au
Go to www.lpgautogas.com.au for info

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The Automotive Technician 29

THE LAST WORD
Source: Bevan Carrick
Director
CoolTemp Pty Ltd
The Brisbane manufacturing plant
of CoolTemp is one of the success
stories of the Australian car parts
manufacturing industry.
After June 2008, CoolTemp, or at
least its incredible expertise and
all of its specialised equipment for
making complex evaporators and
heat exchangers, will disappear
from Australian shores.
CoolTemp is not going to the wall,
but its directors saw the writing
on the wall before becoming yet
another victim of the globalisation
of products and the cold hard fact
that the only way to meet budgets
is to send manufacturing to Asia.
One of the founders of CoolTemp,
Bevan Carrick, has spent most
of his life designing specialised
equipment to ensure a
manufacturing standard for their
aftermarket and OEM products.
Theres probably no better person
on the Australian landscape to
explain why we are hard pressed
to find anything made in Australia
on our shelves any more, from
everyday food items to vehicle
B
parts.
evan Carrick
doesnt regret
the years spent
pandering to the
stringent demands of vehicle
manufacturers and while he
very much regrets the loss of
talent from his manufacturing
plant as his beloved machinery
is shipped off to a new owner
in Thailand, he admits the
decision to quit came at the
right time.
I would have liked to carry
on to another level, but global
forces shattered that dream
and besides, I dont want to live
overseas. But Ive really had
enough of dealing with OEMs
and its time for a change. This
business has done more than
its share of gut-busting hard
work, and being screwed on
every price, he laments.
He was happy to divulge a
few, almost disturbing figures.
Only the customers names
are deleted to avoid their
embarrassment, a human
condition not often found
among car manufacturers.
The Automotive Technician 30
We did all the hard work on
the design and manufacturing
process, and then got $48
each for condensers. The
dealers were selling them for
$700. Some of those new
headlights bringing more than
$1,000 at a dealership, would
have been bought from the
guy who made them for around
$25, if he was lucky. You cant
blame the consumer for being
sceptical.
Made in
And to demonstrate why so
much money and effort was put
into a fault-free production line,
Asia - get
Bevan produced figures which
explain why only the extremely
used to it!
bold and confident would ever
go into OEM production.
If an evaporator core which we
had sold to a car maker for $48
pricing is quite often ridiculous, than ever, with parts lasting
was returned as a warranty but this is where they make a lot longer. Cars are really
claim, we had to buy it back for
their real money not from cheap for the technology they
around $500, plus a loading of selling the car in the first place. contain, so thats why many
17%. Lucky for us, out of the Its obvious that it pays them to motorists will happily dispose
one million plus evaporators keep the prices high on OEM of a vehicle when it comes out
we produced, only six or so parts. of warranty.
were returned, he said.
But even the OEM parts Theres not much good news
Technicians working at the market is changing gradually, for any high volume local
coalface of the aftermarket
with more and more manufacturing in Australia
should remember this about wholesalers, who might have any more. It will continue to
legitimate manufacturers. We once offered the market a diminish.
just could not afford to aim for cheap alternative product,
anything less than a nil reject boasting that they only have Bevans summing up - The
rate. Even then, if a problem original parts for a particular manufacturing sector in
was reoccurring with a product, purpose. Whats happening Australia is now so non-
the car maker would mount a is that car manufacturers are existent that if the backside
full investigation and the fault designing parts which are so fell out of the resources boom
would be isolated and fixed. complex in their engineering tomorrow, we would be flat out
that it just doesnt pay for an buying a pair of thongs next
This applies to all original aftermarket plant to tool up for week.
products made for the big car it.
(Subscribers to TaT can read the
makers. In the majority of
whole interview on our website,
cases, warranty claims can be The parts market is also
along with a background story
traced back to poor installation diminishing because todays of the CoolTemp manufacturing
by the repairer, said Bevan. vehicles are of higher quality facility with pictures.)
Generally speaking, ADVERTISERS INDEX
Australians do not
The Automotive Technician appreciates the support of the pioneer
appreciate quality
advertisers in The Automotive Technician. Please support them where
anywhere near as much
youo can.
as the Europeans or the
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Japanese.
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If I had a choice, I
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I agree that OEM parts
 From one
professional to
ANOTHER Our workshop is an
Sometimes, in a
Injection Correction
busy workshop,
specialist and
professional
Yamaha injector
technicians need to
preferred service
call in a specialist
specialist for
with the expertise
outboard dealers.
and equipment
That gives us the
to clean the
capacity to
injectors which
service most late
are the very heart
model outboards
of a cars engine.
and motorbikes.

The advantages of using an Injection Correction specialist

As you know, injectors clog, just
like arteries, and can seriously
damage engines.
Your client will appreciate your
attention to the detail of cleaning
injectors because if ignored, it
will affect their wallet, their fuel
consumption and the environment.
Because we burn organic fuels and
because organic fuels do not burn
clean, injectors become blocked.
We remove the injectors from the
vehicle.
We test and record results for all
injectors, with attention to:
Leakdown, atomisation,
timed open flow, timed
pulsed flow
We ultrasonically clean the
injectors
We backflush the injectors at
operating pressure
We repeat the tests to verify
the effectiveness of the entire
operation
We return clean and properly
operating injectors
We provide a meaningful and
accurate report, together with an
explanation of the report
While we do this, you can be
looking after more clients

Injection Correction Service Centre

1800 INJECT (1800 465328)
For information and trade quotes