Car Mechanic Magazine

100 Pages·2017·27.867 MB·English

33 of your toughest car problems solved by our experts
Throttle
Body
UPGRADES
Increase power
and responsiveness
Make your own
REPAIR
PANELS
SAVINGYOUMONEYSINCE 1958
FREE
Timing PERFECT TICKETS
tothe
chain
Classic
PAINT
Motor
renewal
Nov
Show 10-12
PAGE
SPECIAL
REPAIRS
1.6 PSA engine
Assessing bodywork
damage accurately
Ford Fiesta
EcoBoost
Getting professional
DIY service
results with aerosol cans IN
Fixing chips and scrapes
9 scratch removal kits TESTED
ET9500
WIN
power
washer
see page20
orth
BUYING GUIDE FINDING PARTS DIAGNOSTICS
Jump smart Toyota
3 fortwo CeIica A4
prizes
worth over
Budgetrunabout Keenly-priceddeals 2.0TDIprobed
£305
October
28 Garage Guide – reader nominations 2017
SEE PAGE £4.00

Editorial
MartynKnowles,Editor
Email:[email protected]
Follow us on Facebook @ Car Mechanics
Scrapping
Mazdaispublicisingitsscrappageschemeusingamodelfromits
past. All its part-exchanged vehicles will be removed from the road.
roadworthy
vehicles
X It’s happening up and down the Vauxhallwasthefirsttostarta giventhesteadyriseinvalueofeven
country. Cars and vans with current scrappageschemeearlierthisyear, themostmainstreamcollectors’carsin
MOT certificates are being traded in I believe, having had them in place in recent years. But if we do see any, our
by the lure of recent manufacturer 2015 and 2016 for limited periods. In ‘safety-net’ will ensure that classic car
scrappage deals, offering vast money this year’s scheme, it scrapped more owners and clubs will benefit.”
off new ‘less polluting’ vehicles. than 5000 vehicles over a three-month Ford and Hyundai started a similar
Most of the manufacturers stipulate period, with 63% of that figure coming scrappage scheme in August. Ford have
that their scheme covers any vehicle from other marques. incentives of between £2000 (Fiesta)
registered on, or before, December31, One criticism of the 2009 UK and £7000 (Transit) off a variety of
2009 (pre-Euro 5) against a selectionof Government scrappage scheme models. But they aren’t concerned
latest Euro 6 petrol or diesel models. was that many classics and future about potential future classics being
OK, some of those motorists givingup classics were destroyed. Unlike most destroyed – the Ford scheme scraps all
on their vehicles are doing so because companies, Vauxhall recognised this as traded-in vehicles. Meanwhile, Hyundai
its current state of roadworthiness being bad publicity, so it instructed its will scrap Euro 1-3 emission vehicles
requires work to gain a new MOT, and approved recycling partner, Autogreen and Euro 4 models can be traded in.
others are perhaps finding it an easy of Daventry, to identify any vehicles With the new 67-reg coming out
route to off-loading their old motor manufactured prior to 1991 that in England, Scotland and Wales on
without the shock of ‘real’ trade-in values were presented through the scheme. September 1, other manufacturers have
or the potential hassle of selling privately. Vauxhall’s Luton HQ then informed any now instigated scrappage schemes.
Rock up at the dealer and come outafew relevant classic owners’ clubs giving Citroën, DS Automobiles and Peugeot
hours later with fresh new metal –your them the opportunity to purchase have changed the rules by taking in
old vehicle, no matter what its current potentially scarce parts. vehicles registered before December 31,
value (ie, much less than the given Simon Hucknall, PR manager for 2010; all vehicles will be recycled.
trade-in value), taken as down payment. Vauxhall Product and Heritage, says: On the other hand, Kia is offering a
That’s all well and good, but the “The Scrappage Allowance is designed £2000 scrappage bonus against any
vehicles traded in at dealerships aren’t to capture vehicles that are beyond car more than seven years old – this
being offered to anyone apart froma economic repair and, given the low value applies to a purchase of a Picanto or Rio
recycling centre. That means there’s of scrap metal, recycling of parts is vital model. The Kia dealer will arrange for
no chance of spare parts being made to the scheme’s viability. We’re also the old vehicle to be destroyed through
available to help keep other vehicleson confident that the number of genuine regulated channels. The scheme runs
the road and you lose aftermarket parts classics over 25 years old presented to until the end of December 2017.
sales for each vehicle that is scrapped. the scheme will be minimal, especially Renault offers incentives of up to
£7000, but the scheme excludes the
Twingo, ZE electric vehicles and the
all-new Koleos. All vehicles must have
been owned by the customer for more
than 90 days, and all vehicles will be
permanently destroyed.
Suzuki has a one-month scrappage
period until September 30, offering
up to £2000 on selected models. All
vehicles are sent to the Autogreen
recycling centre (as with Vauxhall).
Fiat/Chrysler Automobiles offer a
similar deal with vehicles registered
Youngdriversareconstantlytemptedfromtheiroldmodelsintonewbymanufacturerdeals,
before December 31, 2009.
includingPCPplans,cheaperinsuranceandfreeservicing.Thiscouldmeansomeyoungsters
Ironically, given the recent ‘dieselgate’
neverhavingtoliftthebonnettodomaintenancechecks–manufacturerwarrantiesand
servicingwillkeepthemontheroad.HavingaPCPonanewcarisawayofmakingcheaper scandal, VAG is offering incentives to
monthlypaymentsoverthreeyearsandeitherpayingofftheoutstandingfinalinstalment scrap all Euro 1-4 registered vehicles.
((known as a balloon ppayyment)) or else choppppingg in the vehicle for another new make/model. That’s one way of cutting emissions!
p
www.greatmagazines.co.uk/carmechanics October2017 Car Mechanics 3
Contents
68 DIY Servicing:
FEATURES
40
Ford Fiesta 1.0 EcoBoost
6 DIY paint repairs Full step-by-step DIY service plan.
Affordablerepairsforscuffs and 74 Help!
scratches,plustopadvice for
aerosol can resprays.
82 Diagnostics Doctor
65 Modifications:
Throttle bodies 84 Electronic Diagnostics:
Audi A4 2.0 TDI
The best upgrades for your car.
With the Siemens Simos PPD 1
WefitaWestfaliatowbarto our
management system.
project Mercedes-Benz estate.
PROJECTS
54 Toyota Celica
REGULARS
32 Peugeot207CC Sourcingnewandusedparts.
Parttwo:Changingthetiming
20 CMMInsider
chainisn’tashardas you might
think – if you have the right tools. WORKSHOP Newproductsandgiveaways.
40 Mercedes-Benz E320 CDI 24 Tales from 46 Dealer’s Diary
Part five: We fit a Westfalia the Workshop A damaged Micra at auction.
towbar to our estate.
56 Patches & repair panels 90 Our Cars
Martyn Knowles’s VW Beetle.
Replacing rotten bodywork in
BUYING
your home workshop.
92 Good Garage Guide
50 smart fortwo 60 Reviving a Ford Galaxy
98 Ted Connolly
Adviceonbuyingthebestof the An 180,000-mile model getsa
diminutivecity runabout. whole new lease of life. Ted looks at supercars.
Ifyouorsomeoneyouknowis MARKETING–Phone[phone] COMPLAINTS:BauerConsumerMediaLimitedis
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interestedinworkexperience MarketingExecutive ChanelBrown Organisation(www.ipso.co.ukk)andendeavoursto
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CONTACT US CarMechanics,BauerMedia, NewstradeMarketingManagerMark Webb bfoarueedrimtoerdiailaccoommppllaaiinnttss.ccoov.eurke.dObuyrtehmeaEidlaitdodrirael ss
MediaHouse,Lynchwood, [email protected]
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SUBSCRIPTIONS remainsthecopyrightofBauerandwereservetherighttocopyor
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iRobBradshaw iTedConnolly iIanCushway ManagingDirector/ConsumerCarsNiallClarkson htoauvesepeitramsisdseisocnrifbroemdianntyhoisnepaferaagturarepdh.oYroreufearlsreodptrooministheethsautbymoiutted
iAndrewEverett iRichardGunn iRobHawkins EditorialDirector JuneSmith-Sheppard materialtoitbeingusedbyBauer.IfBauerreceivesaclaimfroma
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DIY PAINT
REPAIRS
Scuffs and scratches
DIYspraypaintingcan
can really spoil the providedecentresults,
providedthatyouarepatient
appearance of a well- andpreparethesurface–but
therearealternativesbefore
maintained car. As a breaking-outtherattlecans.
professional repair, or
respray, can be pricey,
Rob Marshall looks
at more affordable
DIY options.
A
ccidentshappen.Whether
brushingyourcaragainsta
hedge,makinglightcontact
withabollard,orwipinga
dusty panel innocently with a hand, allof
these seemingly innocuous actions can
damage the soft paint that is designed to orpresentunexpectedcosts,whenthe conciseinformationoncorrectpaint
enhance and protect the bodywork. Even timecomestohandbackaleasedvehicle. maintenance,consultourdetailing
using incorrect products and poor wash Naturally, prevention is better than seriesintheMayandJuly2016issuesof
techniques can result in swirl marks, the cure. For example, choosing parking CMM.Consideralsoapplyingaseparate
build-up of which causes a noticeable spots carefully will reduce the risk layer of wax, which is an inexpensive
dulling of the finish. Apart from looking of someone damaging the paintwork method of reducing the risk of light
unsightly, scruffy paint can also knock with their clothing, shopping bags, scratches, even though reapplication
hundreds of pounds from your car’s value, or a carelessly opened door. For tends to be required every few months.
WProblemsthat
afflictthemetal,
suchasrustbubbles
andscratchesthat
havebeencaused
bypoorpreparation
workbyabodyshop,
cannotberectified
withoutremoving
theppaintt.
XMetallicpaint
cansufferfrom
peelinglacquer,
whichrevealsthe
Scratchesonclearcoatsstandout,especiallyondarkcolours, dullerbasecoat
becausethemarksonthelacquerappearwhite.However, these beneathit.Theonly
scratches should reqquire no ppaintingg to remedyy. cureistoreppaintit.
p
6 CarMechanics October2017 www.greatmagazines.co.uk/carmechanics
DIY PAINT REPAIRS
DEALING WITH DEFECTS
XRegardlessofthepainttype,
Wet-and-drysandpaper,
scratchesandstone-chipspermeatethe
compoundingpastesand
toplayer.Thequestionis,howdeeply?
evenpolishallworkby
Dependingontheresponse,threerepair removingafinetoplayerof
methodscanbeconsidered. paint.Thisiswhyprofessional
Thefirstoptionistoreducethe detailersuseapaintdepth
levelofthesurroundingpaintuntilit’s gaugetoavoidtheriskof
equivalenttothelowestpointofthe abradingthrougheitherthe
scratch.Alternatively,layersofpaint base,orclearcoats.Yearsof
canbeaddedtothedefect,priortothe polishingcanresultinprimer
excessbeingremovedfromthesurface. beingexposed(seephoto),
Thefinaloptionisrespraying,whichcan necessitatingarespray.
beperformedeitherbyabodyshop,or
withDIYaerosolcansthatarereadily- DetailingofCirencester,ourtechnical advisethatyoucanperformasimple
availablethroughautomotiveaccessory partnerforthisfeature,saythedefect’s testbyslidingafingernailacrossthe
shopsandmotorfactors. depthandlocationwilldictatethe scratch:ifanotchcanbefelt,fresh
IanSealeyandRichMarchofUK mostappropriateactionandthey paintwillbeneeded.
optional extra for most carmakers. be applied with a rotary, or dual-action
The anatomy of paint
While clear coats offer a further layer of polisher, rather than a cloth, and may
Older cars, many of which reside within protection to the colour, the UV-resisting not be appropriate for domestic use.
the tax-exempt Historic classification, ingredients still degrade naturally, To save both time and effort, you might
were painted with single-pack top coats allowing the base coat to fade beneath. wish to work across the scratch with
from new. The coloured finish contains 3000-grit wet-and-dry sandpaper, using
solvents that evaporate after being a soap solution that provides a degree
Buffing-out
applied and it was this process that made of lubricity and reduces the danger of
the paint dry; manufacturers then sought The easiest option is to remove layers working through the paint completely.
to speed-up the process by using heat to of surrounding paint, but Ian Sealey of The resulting dull haze can be polished
maximise productivity. UK Detailing advises caution: “While to a sheen with abrasive pastes – either
Two-pack paints became more modern car paint is very resilient, it lacks rubbing compound, or scratch remover,
popular from the 1980s. These cure depth and DIY users must be careful not followed by a polish – before the area is
chemically, by using a hardener additive to break through either the clear coat, or protected with a coat of wax.
that is mixed with the paint, again being the base coat and into the primer.”
sped-up with ovens. This results in a Should you make this mistake,
Filling the gap
far hardier finish that is less resistant the only way to rectify the damage is
to oxidisation (colour fade), caused through repainting, which can be very Dealing with deeper defects is riskier
by ultraviolet rays breaking down the expensive. Ian says: “Very often, to and it is important to manage your
pigments within the colour coat. To make a seamless blend between new and expectations accordingly. “Such repairs
protect and enhance this coloured paint old paint, a small defect on a car’s flank are not of bodyshop quality,” says
(which is called ‘base coat’ in the trade), might mean that the entire side of the UK Detailing's Rich March. “While
a 'clear coat' translucent protective car would need a respray.” everything depends on the nature of
layer started to be offered by car Both DIY rubbing compounds of the damage and where on the vehicle
manufacturers. Metallic and pearlescent varying grades, as well as scratch it has occurred, paints that are safe
paint finishes involve adding reflective remover products, are available to for DIY use are not as long-lasting as
colour flecks into either the base, or DIYers and professionals alike. Many professional products, largely because
clear coats (or both) – a profitable trade products, however, are designed to of safety aspects.”
XPoorcarwashing
techniquescausemany
finescratches,calledswirl
marks,inthefinish.Usea
mobilephonetorchtolook
forthem.Afinerubbing/
cuttingcompoundand
polishshoulderadicatethe
marks–notethedifference
betweenleftandrigghtt.
WTheseattempts
totouch-upthe
scratchesonanAlfa
RomeoSpider’srear
bumperhavemade
thingslookworse,
nothelpedbythe
poorcolourmatch
andexcesspaint Shouldyouchoosetopaintyourvehicle,ensurethatanyreplacement
thathasspilledover painthasbeenmixedproperly.Pre-mixedaerosolcanstendtooffera
thereppairareass. fairlyy ggood colour match, but ensure yyou shake them before spprayyingg.
p
www.greatmagazines.co.uk/carmechanics October2017 CarMechanics 7
DIY PAINT REPAIRS ROB’S TOP TIP
Assesscarefullywhich
repairtechniqueisbest
Laden with isocyanates, bodyshop- DIY SPRAYING forthetypeofdamage
grade two-pack paints are dangerous when anditslocation.
inhaled and should not be used outsideofa
filtered, air-fed paint booth, which is outof XThefinalDIYoptionissuitableforlargerareas
the typical DIYer’s reach. The only option andiscloserinmethodologytothoseusedbya
is to rely on air-drying solvent-based bodyshop.Aswithallrepairs,thelocationofthe
paints, but you are still required to wear damagewilltellyouhowfaryoushouldextendthe
a breathing mask and all painting must workareabeyondtheflaw.Shouldyoubeconfronted
be carried-out in a well-ventilated area. withasmallpanel,suchasafuelfillercap,itwould
beeasiertopainttheentirething.However,painting
In our non-spraying examples
acompletedoorskin,forexample,tendstonotbe
(see Steps 37-47), we used the Chipex
feasiblewithanaerosolcan.
system, which is a comprehensive kit
Ifpossible,onealternativeforalargerpanelis
costing £29.99. While you could spray
topaintasectionedge-to-edge.Thisexplainsour
cheaper aerosol paint into a clean
decisiontopaintanembossedbumperpanelinourexample(seeSteps1-36),whichhas
receptacle and dab it on with a small definedboundaries.Thealternativeismuchhardertoachieve,whichistopaintalocalised
brush, such paints are very thin. The areaandblend-inthenewcolourwitholdafterthepainthasdried–thenewerthecar,the
Chipex formula is thicker and faster- betterthecolourmatchwillbeofthereplacementpaint.Anotheroptionistoblendthenew
drying. Not only is no primer required paintintoacurve,wherethechangeincontourwilldisguiseanyminorcolourdifferences.
but, for modern finishes, no clear-coat Youshouldacceptthatyourobjectiveistomakeanydamagelookbetterandthata
is needed afterwards. However, you perfectrepairmightnotbepossiblewithoutprofessionalassistance.Aerosolcanpaintis
notonlymuchsofterthantwo-packprofessionalblends,makingitmorepronetofuture
must lower your expectations with such
scratches,butitisalsomorevulnerabletofading.Nevertheless,onehugeadvantage
repairs. The final result should improve
withDIYpaintingisthat,shouldyoumakeamistake,youcansimplywipeawaythepaint
the cosmetic appearance of a car froma
withcellulosethinnersandstartagain.
distance but you may be disappointedif
you are expecting a truly flawless repair.
In some cases, that may be achievable Thanks to:
only after an expensive visit to a The Professional Valeters and Detailers’ Trade Association www.pro-valets.co.uk
paintshop. Yet, a number of professional Chipex www.chipex.co.uk
companies, such as Chips Away, can UKDetailingLimitedUnit2,PurlieusBarn,Ewen,CirencesterGL76BY.
carry-out localised repair work without 01285770090 www.ukdetailing.com
resorting to extensive repainting. RichMarch,JohnPainter,IanSealeyandBertYouell
DIY PAINTLESS LIGHT SCRATCH REMOVAL
A WThesesmall
scratches on a rear
wheelarch are typical of
minor damage, caused
possibly by a coat button,
or a rivet from a pair
ofjeans.
B XDeeper scratches
can be buffed with
3000-grit wet-and-dry
sandpaper, prior to an
abrasive paste being
applied either to a polisher
or a microfibre cloth.
C Afterbeingappliedevenlytothepad, D Afterthecompoundhasdriedand E Applying wax will not only enhance Continued
professionalsmovearotatingdual-action buffed-offwithanothermicrofibrecloth, the colour but also protect the paint on page
10
polisher head evenly around the damagedarea. sufficient clear coat should have been removed. against further damage and UV degradation.
p
8 CarMechanics October2017 www.greatmagazines.co.uk/carmechanics
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DIY PAINT REPAIRS ROB’S TOP TIP
oucanusenewspaper
maskyourcar,
thoughbodyshop
DIY AEROSOL CAN REPAIRS askingpapercostsless
an £10 per small roll.
2 Fortunately, most of the damage had 3 To remove any contamination,
1 This car had suffered from a scrape been confined to the indented part of including polish and old wax, the
that had not only penetrated the paint the bumper that, on this car, is a moulded damaged area and surroundings require
but also gouged the plastic deeply. portion that couldn’t be unclipped. wiping down with a panel-wipe solvent.
4 As it is easier to paint the entire bumper 5 The tape provides protection to the 6 Moving to 400-grit wet-and-dry, used
portion, its edges were masked after surrounding paintwork. Starting with wet with cold water, the rest was rubbed
thesolventhadevaporated.Usegoodquality 320-gritwet-and-dry,thedamagedsection down,toprovideakeysothatnewpaintwill
maskingtapefromabodyshopsupplier. wasflattedtoremoveanyprotrudingplastic. adheresatisfactorilytothepanel.
7 Once the surface was level, a distinct 8 An air-drying 'stopper' can be used, 9 Prior to applying the filler to the
gouge remained that had to be filled. or a two-pack body filler, as pictured. surface (pictured), ensure that it is
First, however, the sanded area was cleaned Follow the instructions to mix the filler and mixed to an even colour and is not streaked,
with a panel-wipe solvent. its hardener to an even-coloured paste. or else it will not cure entirely.
10 You can use a flat block with 320-grit 11 This is the repair smoothed down; if 12 As it is easier to paint the entire
wet-and-dry sandpaper to rub down a the scrape is deep, you might decide to section, rather than blend the new paint
small area like this. Note that excess filler apply a further filler layer. Small marks canbe with the old, the surface was rubbed down
remains at the top of this repair. filled with filler primer paint, or stopper paste. again with 400-grit wet-and-dry (used wet).
p
10 CarMechanics October2017 www.greatmagazines.co.uk/carmechanics