MMoottoorrssppoorrtt April 2013 www.tat.net.au Issue 32 wwiinnss wwiitthh tthhee AAnnddyy GGooooddaallll ffoorrmmuullaa A$130 (NZ$165) gives you: • 12 months subscription to TaT • Six magazines mailed to your address • Access to illustrated solutions online • Technical assist service Subscribe on page 43 • • ‘s a fact Holden Astra - not cranking BMW E46 - faulty ignition electrics • • Alpha Sprinter - battery not charging Audi 80 - windows don’t work problem solving MUCH MORE THAN A SCANTOOL Only Bosch can provide your workshop with a complete support package Bosch KTS Diagnostic Scanner Range and ESI[tronic] 2.0 ESI[tronic] Diagnostic Troubleshooting Mode Mode Includes: Diagnostic Software Information is now the most important diagnostic tool in the workshop and the KTS series, powered by ESI[tronic] - the world’s most comprehensive technical information software, provides the workshop with the guided analysis necessary for fast, accurate Error Code fault diagnosis for all components. 1. Functional Description Importantly for the diagnostic technician, ESI[tronic] 2.0 has the unique ability to ESI 2.0 makes Bosch KTS switch from the identified error code in more than just a scantool. Diagnostic Mode to repair information in the Troubleshooting Mode. 2. Component Locations 3. Wiring Diagrams 4. Pin Configuration & Set Data www.logicar.com.au 5. Component Waveforms HEAD OFFICE DINGLEY TULLAMARINE PHONE TOLL FREE 147 Rooks Road 15/42-44 Garden Blvd. 17a Carrick Dve. 1300 334 334 Vermont VIC 3133 Dingley VIC 3172 Tullamarine VIC 3043 PH: 1300 334 334 PH: (03) 9551 6222 PH: (03) 9338 7666 EFI EFI Fax: (03) 9873 7009 Fax: (03) 9551 6888 Fax: (03) 9338 4400 The Automotive Technician 2 UP with Ken after your customers has Here’s his four-point policy on they are in difficulty and be Newton already been written, but this subject: approachable and human. sometimes it’s the way it’s FRONT 1. Always be fair in your And probably the most expressed that makes an own dealings, unfairness pertinent advice for an auto impact. at the top can demoralise a workshop was never allow In one of my clean-outs workshop two people to do a job which recently, I came across some one could do. 2. Never hire relatives No matter how old you pages that I had copied or friends (don’t fire your When you are looking for are, you can do with many years ago from a little wife/partner who runs the staff, hire people who are a mentor. booklet, published in 1985, workshop office – that’s a bigger than you are. If you called Blood, Brains and Even though I am now in partnership) follow that policy, your Beer, the autobiography of the ‘experienced’ category David Ogilvy, the man Time 3. Sack incurable political workshop will become a of wordsmithing, I still feel a magazine called ‘the most types business of giants. great comfort to have a much sought-after wizard in today’s If you hire people who more experienced person advertising industry’. Ogilvy 4. Crusade against paper are less than you are, you looking over my shoulder. died in 1999. warfare. Encourage will become a business of your people to air their Let’s understand what a I would like to share some of disagreements face-to-face. midgets. mentor is: someone who his wisdom with you, not just And learn to have fun. imparts wisdom to and because it’s good to hear, David’s view was that if you David’s advice, ‘Get rid of sad shares knowledge with a less but it is incredibly simple and plan to give superior service dogs who spread gloom’. experienced colleague. You to your customers, you need understandable. I hope David can have many mentors. to make the most of your Finally, take heed of this old excuses me for changing own people. You do this Scottish proverb: Hard work These days, most of my [advertising] agency to auto by giving them challenging never killed a man. Men die mentors are unknown to me. workshop. opportunities, by recognising of boredom, psychological Their wisdom is mostly in His take on office politics their achievements, giving conflict and disease. The print. I absorb good advice, (read workshop politics)– them job enrichment and the harder people work the wherever I find it. work hard to minimise office maximum responsibility. happier they are. I’ve come to realise that all politics because they absorb Treat your young staff as Thanks David Ogilvy. I’ve the good advice about how energy which can better be grown-ups and they will passed it on. Does that make to run your business or look devoted to our clients. grow up. Help them when me a mentor? THE TAT TEAM • TaT Assist • TaT Chat • TaT Train CONTENTS • TaT’s a Fact • Tips for TaT • TaT Biz Publisher Gerry Marson Cover story – Andy Goodall..……………4 are all registered trade names of The Automotive Technician Maurice Donovan German cars head for CO..……………8 Pty Ltd Wayne Broady The Automotive Technician Pty Ltd 2 Tat assist...….…………………………9 ABN 27 121 589 802 Alex Cowie 30 Dale Street The Automotive Technician Pty Ltd publishes Some people don’t deserve a car………11 technical advice and actual case studies for the BROOKVALE NSW 2100 Columnists purpose of educating technicians. Volkswagen poltergeist?……..…………12 [email protected] Julian Hentze – Georgia USA These advices are given in good faith, and are Street Cred with Hayley Windsor..………13 1300 828 000 Fax 1300 828 100 Hayley Windsor – Australia based on actual workshop repairs. No guarantee Choice of repairer moves closer..………14 is given, nor any liability accepted in respect to any published advice. Too many distractions…………………16 Reader Editor in chief Bron Robinson The Automotive Technician Pty Ltd is not Nissan didn’t like the cold……………18 Ken Newton responsible for the accuracy of any information Customer buys, but you pay……………21 [email protected] contained in material submitted by third parties 0438 569 517 Advertising inquiries and published in this magazine and accepts Where a/c technicians should spend winter..22 Fax 1300 828 100 Jcahnaemnpea [email protected] ncoon litaebnitl.it y in relation to such materials or their Conditions that set trouble codes………24 Editorial and online 03 5862 3090 0403 226 770 Newsworthy articles or comments are welcomed, TaT’s a facts...…………………………27 and should be submitted to the editor in chief. assistant The worthiness of the roadworthy………31 All material appearing in The Automotive Tony Wragg Graphic design Technician is copyright. Reproduction in whole or Training event a knock-out…………….32 [email protected] Russell Jones Graphic Design in part is illegal without prior written consent from Top Tools - battery charger…………….34 0411 817 012 the editor in chief. Technical editor [email protected] All advertisers agree to indemnify the publisher Letter from America with Julian Hentze…35 Jeff Smit for all damages or liabilities arising from their TaT at AAA Expo.………………………36 [email protected] Printing published or unpublished material. Brakes depend on good fluid intake……38 1300 828 000 McPherson’s Printing Group Top Tools – Smoking out the leaks……41 5–7 Dunlop Rd Technical research The trade getting a bad name…………44 Mulgrave VIC 3170 Deyan Barrie www.mcphersonsprinting. Knock, Click – who’s there?……………46 [email protected] com.au The Automotive Technician is a member of the Strong case for regular servicing………48 Circulations Audit Board. Technical advisers Magic wand that fixes cars……………50 Audit period 1 April to 30 September 2012. Jack Stepanian Affiliated associations Average net distribution 9,971. Motorised bathtub……………………..51 Sam Nazarian VASA [email protected] Nick Murphy AAAA member Commercial news……………………...53 Gil Sher [email protected] Tat’s interesting..………………………54 Jason Smith Capricorn Society Alliance Geoff Mutton’s business column………54 Anthony Tydd Supplier The Automotive Technician 3 Cover Picture: Andy Goodall with his 19 year-old daughter Michelle. Both have Michelle’s thesis for her motorsport qualifications is based written themselves into Australian motorsport history through their unique brand on her design and construction of a Formula Vee racing car, of training and qualifications. Michelle is believed to be Australia’s only female which is just six months away from going on a track. Checking motorsport manager, being in charge of Andy Goodall Racing and the Australian Institute of Motorsport racing teams. Michelle is also the curriculum writer for the her progress with the chassis of the racer is (from left) Andy Institute. Other uncaptioned photographs in this story are of racing cars being Goodall, Brett Dickie and Shaun Trounson built by students and supervised by Andy Goodall at the Institute of Motorsport. All photography by Dean Trounson Media Development, Andy Goodall Racing. Cover story Andy Goodall by Ken Newton Motorsport wins with the Andy Goodall formula A ndy Goodall was driving around the spacious paddocks in the Keilor district of Victoria in his own car at age 11. It was very rural back then and nearby Tullamarine airport hadn’t been thought of, so there was plenty of room and besides, these were the days when boys could be boys. We mention this only because it provides something of an explanation for a young country lad moving on to lead a fascinating life around motor cars and motor engineering and ultimately running one of Australia’s most prestigious academies of automotive technology and motorsport. But like all stories of Australian Institute of Motorsport, a rather unique Australian successful people, much of what happened to Andy was a bit of amalgam of a privately-owned automotive college and TAFE. sheer luck and a lot of hard work. He certainly had a talent, but His is a perfect partnership with Goulburn Ovens TAFE, one of the it helped being in the right place at the right time and being seen largest in regional Victoria. Andy has his own staff and so does and nurtured by the right people. And when doors opened, Andy Go TAFE, but students can share the facilities at both campuses usually stepped inside. and when specialist training of teachers is required for particular He recalls some of his great mentors who, he said, were ‘flat out motorsport and advanced automotive subjects, Andy can provide writing their own name’, but who could do amazing things with that too. their hands and their minds. It’s not that he thought any less of Andy Goodall as a brand name first appeared in 1979, when people who could articulate and pump out great documents, but he was barely 18 years old. He was already forging ahead in a he quickly learnt that it was a well-balanced combination of the factory-backed team as a team member, but took the plunge to two that worked best. become a privateer as well. In Andy’s classrooms today, you will find that same philosophy. As His training career started much later, after he had already one of his students, Craig Shepley from Adelaide, said recently accumulated his own impressive set of qualifications, which he (TaT cover story Issue 31, February 2013), ‘Andy doesn’t believe spends a lot of time upgrading to retain his teaching status. He in a lot of bookwork. He believes you learn by practice and that holds diplomas in Motorsport, Automotive Mechanical Technology, you have to do it until it is perfect.’ Automotive Management and Education. He is an automotive Andy Goodall is the owner of Andy Goodall Training and the engineer and holds a Graduate Certificate in Management. Andy Goodall encourages motorsport talent through his Institute of Motorsport scholarships. Two of his stars are in this picture (from left) Shaun Trounson, team driver and trainer, Andy Goodall, and Brett Dickie, team development test driver and trainer and a national sports sedan champion driver. Both were previous students of the motorsport program who gained Diplomas in Motorsport and are currently scholarship recipients of full-time drives in the racing team. The Automotive Technician 4 But back to the beginning As a teenager he couldn’t get enough of hotted-up cars. So he ‘It was a significant thing to be able to do,’ Andy said. ‘We were up started tinkering. ‘I had a great ability to pull things apart, but I against some pretty professional teams, but we had our share of didn’t have much talent putting them back together. Let’s say I success.’ was inquisitive,’ he recalls. Andy not only owned the team, but was one of its drivers as well. At secondary school, now aged 15, Andy joins a mechanical They raced in the Group C class of touring cars in the junior appreciation class. One of his teachers senses talent and advises categories. Andy to sit for a Victorian Automobile Chamber of Commerce ‘I had many great sponsors back then. I worked with a factory (VACC) scholarship, which he wins. team by day and prepared our own race cars in my spare time. It So he becomes a VACC student and this is where coincidences gave me a good insight into how things worked in motorsport.’ begin to fashion his career. With his racing team still ticking away in the background, Andy Part of the VACC deal was that he spends four years working freelanced for a number of years, mainly building historic vintage alternately with the four Australian car makers of the time. and racing cars for clients who he said had more money than sense. His first role is helping out on an engine assembly line. One of the people in charge of the line also senses his talent, and asks ‘I think they treated these cars like jewellery because some of Andy if he would like a job working with the race team. ‘It turns my creations cost more than a million dollars. That was a lot of out he was more than the foreman I thought he was. He was the money in those days,’ Andy said. production manager and he had some influence,’ Andy says. ‘I ‘One of the most famous I rebuilt from scratch was a Bugatti Type told him I was interested in engineering and race cars.’ 40 racing car which should have won the first Australian Grand Andy was offered a role as a trainee trade-qualified engineer Prix back in 1928, but didn’t because of a fuel issue. It took 6,000 working with the race team. hours to build and I started with very little but a pile of original drawings. It had been left to rot for about 60 years and what the The job included an active involvement in what was then one of rodents didn’t eat, the rust did.’ the most successful racing teams in Australian motorsport. He was now only 16 years old. That started in 1977 and Andy worked on the motorsport program until 1984. He recalls his great mentors. ‘I was taught by men whose philsophy was – bite off more than you can chew and chew like hell. ‘It was about this point that I realised my career had taken shape. This is where it all really started,’ Andy recalls. He was then invited to be a trainer, training apprentices and dealership mechanics from time to time, and that experience whetted his appetite for education. But his taste for his own business was when he started Andy Goodall Racing in 1979. The Automotive Technician 5 The economic downturn of the late 1980s put a stop to that type Institute of Motorsport a special place in automotive education of work, so Andy became a manager with the RACV in road after only a few years. service, as part of the team with the responsibility of training and The completion and retention rate at his college is one of the technical support for the club’s 230 patrolmen. highest of any school in Australia. Students complete many This lasted about eight years, and Andy reverted to his first love, qualifications in a year, and while it’s not a large number building racing cars. compared with most of the big colleges, his institute does not lose any along the way. ‘Back then, I designed and manufactured the whole car. I built everything from open-wheelers to prototype sports cars and The institute covers the entire automotive curriculum, but is best touring cars and several that were built for Asian and European known for its motorsport and automotive technology qualifications. championships. These are cars that needed multi-million dollar ‘The students design and build all of our racing cars, and they budgets to keep on the track.’ have just completed a huge project to turn a 25 year old truck It’s now almost the turn of the century and Andy finds himself into a state-of-the-art motorsport transporter. Three racing cars back with a vehicle manufacturer for another four years working in are currently in various stages of completion, two will be on the the experimental department. Andy Goodall Racing was still alive track in Formula Vee events later this year, racing in both the New and well. South Wales and Victorian state championships and the national championship and title. In 2005, Andy Goodall Training became a fully fledged education consultancy. He worked with schools, was an education ‘Our education formula succeeds because, unlike other attempts consultant and in a short time had established seven automotive to run a motorsport college, we have current resources and our colleges. own racing team. Our students produce cars that actually race, so we are able to offer the total experience of engineering, engine Andy’s unique training style, a flexible blend of theory and performance, building, racing and business management,’ Andy practice, has earned Andy Goodall Training and the Australian says. The Automotive Technician 6 Visit the SACHS stand at the Australian Automotive Aftermarket Expo, Sydney, 11-13 April Stand D26 The full range for the local market From Mini to Mack Shock Absorbers by SACHS SACHS Shock Absorbers are trusted by leading vehicle manufacturers in both passenger and commercial vehicles. With the full aftermarket range for cars, utes, buses and trucks, SACHS has the application for your vehicle. www.zf.com The Automotive Technician 7 undercar.indd 1 20/02/2013 11:04:58 AM Stalemate as T he saga of the world’s new They cite safety concerns resulting from refrigerant for mobile air a possible leak, claiming that enough German cars conditioning systems has taken CO escaping into the passenger 2 a dramatic turn, although it won’t cabin could cause drowsiness among come as a big surprise to many. occupants, increasing the risk of an head for CO accident. All of the major German car makers have now banded together to oppose 2 They also point to indirect carbon the adoption of HFO-1234yf on safety emissions. Because more petrol or grounds, flagging that they are now diesel fuel is needed to power a CO 2 determined to go straight to CO based a/c system it requires more 2 systems. They’ve told the European Union they need two years to energy to maintain sufficient internal pressure to keep carbon design and change over to CO. It was common knowledge that dioxide contained and in a liquid state. 2 the German factories put a lot of money and effort into developing At press time, there had been no official EU response to the CO systems some years ago, but they abandoned this when 2 current situation, but back in November the Climate Action news that a new refrigerant that met the emissions criteria and Commission took a tough stance, insisting that all member states would be a safe drop-in for R134a was announced. Another factor comply with their refrigerant directive immediately. was that the new alternative did not require a comprehensive and costly redesign of air conditioning systems. Commissioner Connie Hedegaard was reported as saying that car makers had had enough time to get their act together on the But in their new act of defiance of the EU directive that all vehicles directive. must stop using R134a from this year, they now have the support of the German environmental authority UBA, which has made an The EU passed its directive governing the phase-out of the application to the EU to grant an extension to 2015. automotive air conditioning refrigerant R134a in 2006. The phase- out began this year. The EU, until now, has stood firm and threatened the car makers, particularly Daimler, with heavy fines if they did not comply. A Driving the death of R134a was its known potential to warm the previous application to delay the directive had failed. Whether climate 1,400 times more than normal carbon dioxide. the EU position will weaken now under the combined onslaught The world’s car makers agreed to adopt HFO-1234yf which was from all German car makers as well as the German environmental jointly developed and produced by Honeywell and DuPont. authority remains to be seen. Earlier this month, BMW joined Daimler and Volkswagen’s Daimler originally challenged the safety of HFO-1234yf with tests Audi and resigned from an industry research group looking into of its own which, the car maker said, proved beyond doubt that in the safety of HFO-1234yf, due to concerns over the scientific a real-life crash scenario, the refrigerant would ignite and release thoroughness of the investigation. toxic hydrogen fluoride gas. Daimler has been joined now by BMW, Volkswagen, Audi and Mercedes Benz brands in the move Daimler said its own tests not only proved the company’s fears towards CO systems. were justified, but that they may have underestimated the risks. 2 The UBA, in its pitch to the EU for an extension of time, claimed If Daimler stands firm and refuses to use the new refrigerant that a switch to CO would reduce the global warming potential it risks losing its ability to sell the cars in the EU, including the 2 by 75 per cent over HFO-1234yf, and that this alone would Mercedes A-Class. justify allowing a longer transition time for those car makers that Volkswagen patriarch Ferdinand Piech told Auto Bild magazine committed to the switch. in November that a CO based air conditioning system was the 2 Opponents of carbon dioxide as a refrigerant, however, argue it better solution since it is inherently non-flammable. He said VW is not just the comprehensive and costly redesign of a/c systems would continue to use the existing R134a refrigerant until it can that needs to be taken into account. make the technological jump on an industrial scale. German car makers in Here is a list of the top ten countries Zooming in on Germany, the third perspective and their production of vehicles for the highest car-producing country in the top ten car makers in 2011 (per cent) world, here are the 2011 production On a world scale, the German car figures for the companies that have industry is a massive force. It is the China 24 defied the order to change over to third largest car-producing country Japan 11.9 HFO-1234yf: on earth, beaten only by China Germany 9.7 Volkswagen, with 8,157,058 cars is and Japan, and German company, the second biggest car maker on the Volkswagen, is the second biggest South Korea 7 planet (eclipsed by General Motors). car maker. India 5 BMW, with 1.7 million cars produced in In 2012, for the first time ever, the car USA 4.9 2011 was the world’s 13th biggest car makers of the world produced more Brazil 4.2 maker while Daimler, with 1.5 million than 60 million passenger cars. France 3.2 was the 14th. That’s 165,000 new cars off assembly Spain 3 (Source: International Organisation of lines every day. Russia 2.9 Motor Vehicle Manufacturers) Australia was 29th on the list with 0.3 per cent The Automotive Technician 8 assist technical support The TaT assist service is a valuable benefit for TaT magazine subscribers. TaT assist is an internet based service for subscribers to provide detailed information about their problem using an online form. TaT technical specialists will research the problem and perhaps seek advice from other experts on the TaT Tech Team. Here are the 10 Commandments of TaT assist. 1. The online form is the only way to lodge a TaT assist request. 2. You must be a TaT magazine subscriber to request help through TaT assist. We will talk only to the person whose name is listed as the TaT subscriber, and that person is expected to be the one working on the problem vehicle. 3. TaT assist is just one of your research tools. As trained technicians, subscribers are expected to follow a logical diagnostic sequence and do some homework before seeking help from TaT. Sources of data may be car makers’ websites or the extensive TaT’s a facts files on the TaT website – your problem may already have been solved and documented there. 4. TaT assist can help you develop sound diagnostic principles. We cannot help you through a routine service or installation. 5. Wiring diagrams cannot be provided by TaT assist. All workshops are expected to have access to a data provider and wiring diagrams are part of your tools of trade. We would be breaching copyright if we passed on any OEM or data provider’s printed information. 6. To lodge an online form, click on the TaT assist link. Follow the prompts and give as much information as possible – all fields are mandatory. 7. If a form is incomplete it cannot be sent. You will get an email asking for more information. So please provide all the information correctly the first time. 8. TaT assist requests are usually handled on the day they are received but timing cannot be guaranteed. If your request requires discussion, we will send you an email or a phone call. 9. Be patient. Problem vehicles can be frustrating and time consuming. Note that on the TaT assist form, we ask if your problem is really urgent. That helps us prioritise the calls for help. 10. Please let us know how you finally resolved your repair problem so that we can share your solution with your fellow technicians. The Automotive Technician 9 VERY VALVOLINE LIMITED OFFER WORKSHOP FLUID CENTRE THE EXPERTS IN FLUID MANAGEMENT CLEANER WORKSHOP - 20L drums in a single location. 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