Import Car Magazine 2014 03

AMarch 2014

MAGAZINE

Fuel System Repair PCM Diagnostics Engine Noise At Cold Start

C1 Cover IC_03.14 3/13/14 12:35 PM Page C1

c2-1 toyotareman IC 3/13/14 12:42 PM Page c2

Reader Service: go to www.ICRapidResponse.com

c2-1 toyotareman IC 3/13/14 12:42 PM Page 1

CONTENTS

Publisher Jim Merle, ext. [email protected]

Editor Mary DellaValle, ext. [email protected]

Managing Editor Chris Crowell, ext. [email protected]

Technical Editor Larry Carley [email protected]

Graphic Designer Kelly Gifford, ext. [email protected]

Ad Services (Materials) Cindy Ott, ext. [email protected]

Circulation Manager Pat Robinson, ext. [email protected]

Subscription ServicesMaryellen Smith, ext. [email protected]

2 March 2014 | Import-Car.com

Volume 36, No. 3

16Diagnostic Solutions:PCM Diagnostics

Import Specialist ContributorGary Goms explains some tech-niques he uses to pin down an in-termittent or schizophrenicPCM malfunction, which typify thetypes of problems were begin-ning to see on OBD II vehicles.

A Publication

26

3816

26BMW Fuel SystemRepair Essentials

The BMW N54 fuel pump recallbrought to light the importance ofthe integrity of the fuel system,says Brake & Front End Editor Andrew Markel, who discusseshow to prevent fuel pump damageand costly comebacks that couldhurt your reputation.

38Tech Feature: RotorsPreventing Pulsation Comebacks

Its often been said that you shouldnever machine new rotors, but whatif the runout exceeds the manufac-turers specs when the new rotor isinstalled on the vehicle? Thats whyits critical to measure thickness andrunout in a brake rotor and wheelflange beforehand.

ImportCar Staff 330.670.1234

BMW Fuel System Essentials

02-04 Contents_March 3/13/14 12:14 PM Page 2


3 carquest IC 3/13/14 12:33 PM Page 3

DEPARTMENTS6 Editors Notebook

8 News Update

14 Gonzos Toolbox

21 Special Supplement: Maintenance Matters

34 Guest Editorial: Rich White,Car Care Council

42 Tech Update: Air Ride Systems

45 Import Tech Tips

49 Essentials (New Products)

51 RAPID RESPONSE

52 Classifieds

56 NASCAR Performance

A Publication


Columns

21

34

42

IMPORTCAR (ISSN 1069-4714)(March 2014, Volume 36, Number 3): Published monthly by Babcox Media, Inc., 3550 Embassy Parkway, Akron, OH 44333 U.S.A. Phone (330) 670-1234, FAX (330) 670-0874. Periodical postage paid at Akron, OH 44333 and additional mailing offices. POSTMASTER: Send address changes to IMPORTCAR, 3550 Embassy Parkway, Akron, OH 44333. IMPORTCAR is a trademark of Babcox Media, Inc. registered with the U.S. Patent and Trademark office. All rights reserved.A limited number of complimentary subscriptions are available to individuals who meet the qualification requirements. Call (330) 670-1234, Ext. 260, to speak to a subscriptionservices representative or FAX us at (330) 670-5335. Paid Subscriptions are available for non-qualified subscribers at the following rates: U.S.: $69 for one year. Canada: $89for one year. Canadian rates include GST. Ohio residents add current county sales tax. Other foreign rates/via air mail: $129 for one year. Payable in advance in U.S. funds. Mail payment to IMPORTCAR, P.O. Box 75692, Cleveland, OH 44101-4755. VISA, MasterCard or American Express accepted.

Member BPA International, Inc.Founded 1979. 2014 by Babcox Media, Inc.

Follow us on TwitterBecome a fan on Facebook

Contributing WritersBob Dowie, Village Auto Works, Chester, NY

Gary Goms, formerly of Midland Engine Electronics & Diagnostics, Buena Vista, CO

Bob Howlett, The Swedish Solution,Orange Village, OH

Scott Gonzo Weaver, Superior Auto Electric,Tulsa, OK

Bob Dowie, Village Auto Works, Chester, NY

Chris Klinger, Precision Incorporated, Tucson, AZ

Steve Louden, Louden Motorcar Services, Dallas, TX

Frank Scandura, Franks European Service,Las Vegas and Henderson, NV

Joe Stephens, Stephens Automotive, Palatine, IL

John Volz, Volz Bros., Grass Valley, CA

Babcox Media, Inc.

Editorial Advisory Board

3550 Embassy ParkwayAkron, OH 44333-8318

President Bill Babcox [email protected]

Vice President/ Greg CiraChief Financial Officer [email protected]

Vice President/ Jeff StankardGroup Publisher [email protected]

Controller Beth Scheetz [email protected]

In Memoriam

Founder of Edward S. BabcoxBabcox Publications (1885-1970)

Chairman Tom B. Babcox (1919-1995)

AUGMENTED REALITY CONTENT IN THIS ISSUE:

Auto-Video Inc. (AVI)...........................................................21

02-04 Contents_March 3/13/14 12:14 PM Page 4


5 mercedes IC 3/13/14 12:32 PM Page 5

By Mary DellaValle|EDITOR[EditorsNotebook


T he degree to which your employees can impactyour bottom line hingeson their level of engagementand sense of ownership in theshops success.

When engagement is high,performance follows, as doeskey business-building factorslike service excellence and outstanding customer service.

But, for many shop owners,tracking employee performanceoften falls by the wayside untila major problem arises*, saysGreg Sands, shop owner andCEO of direct mail providerMudlick Mail (www.mudlick-mail.com) in Acworth, GA.

Yet, when it comes to achiev-ing goals outside of work, weoften rely on metrics to deter-mine if were reaching our objec-tives. If you want to run amarathon, you track your time,he explains. If you want to loseweight, you measure your bodyfat. The same concept holds true

when it comes to evaluating em-ployees. You must set goals foreach position in your shop andthen establish a tracking mecha-nism to measure performance.

In Sands experience, he saysthat one of the main contribu-tors to lagging performance isthat employees dont knowhow to do their job, and thatswhere training proves to be essential.

So, to help boost engagement

and performance among yourteam, ensure that they are prop-erly trained, let them knowthey are appreciated, and thattheir daily contributions at theshop are recognized as being avital part of its success.

That way, youll help foster agreater sense of pride in theirwork, a commitment to repairexcellence and a customer serv-ice experience thats second tonone. IC

Boosts Pride And Performance

*To learn more about Greg Sands perspective on this topic, go to our sister publication Shop Owner magazines website,www.shopownermag.com, and search for his Improving Employee Performance article.

Mary DellaValle, [email protected]

Engagement & Ownership

ImportCar is pleased to announce the recent addition ofChris Crowell as Managing Editor, where he will play an integralrole in the brands print, digital, web and social media proper-ties and initiatives. Chris has a background in B-2-B publishing,having working as Editorial Director on magazines representingthe title insurance and settlement services industries.

Concurrently, the staff of ImportCar would like to thank Jennifer Clements, former ImportCar Managing Editor, for morethan six years of dedicated service to the magazine. A key contributor to ImportCars editorial product, Jennifer also facilitated the production process each month. Jennifer remains editor of TechShop magazine, and also now serves as ManagingEditor of Babcox Medias newest publication, Northeast OhioParent magazine.

06 Editor's notebook 3/13/14 12:14 PM Page 6


7 boschotc IC 3/13/14 12:32 PM Page 7


[NewsUpdate

Federal-Moguls popular, free SmartChoice Mobile app for automo-tive service providers has been selected for the Frost & Sullivan NorthAmerican Customer Value Leadership Award. The Frost & Sullivan awardis presented annually to a company that has demonstrated excellence inimplementing strategies that proactively create value for its customers.Representatives of the Federal-Mogul Vehicle Components segment received the award earlier this year during the Frost & Sullivan Excel-lence in Best Practices Awards Gala in New Orleans.

The free Federal-Mogul SmartChoice Mobile app can be downloadedthrough the Apple App Store and Google Play as well as the companyswww.SmartChoiceApp.com website.

Federal-Mogul Mobile AppSelected for North American Customer Value Leadership Award

2014 AVI Sanibel TrainingConference Hits The MarkAutomotive Video Innovations (AVI)19th Annual Sanibel Training Con-ference, held Feb. 6-9 at the SanibelHarbour Marriott Resort, has be-come the annual gathering place forshop owners, techs, trainers and in-dustry leaders who are seriousabout training, and who also enjoythe camaraderie of industry friends.

The AVI Conference should bein the Guinness Book of WorldRecords, said Ron Bilyeu, a long-time educator, repair shop ownerand performance-tuning guru.There is no other conference thatattracts so many industry mastersin one place.

Attendees know first-hand thatthe AVI Conference is a unique experience. There youll find cutting-edge training presented byexpert trainers, who also take thetime to answer attendees ques-tions, and technicians who askpeers about impossible diagnosticissues theyve encountered, insearch of new answers.

Whether youre walking out ofWally Mouradians intense Power-stroke Diagnostics course, or laugh-ing hysterically as Becky Witt flingscream-filled pastries across theroom in her Service Writer Survivalclass, youll know youve experi-enced something different.

The technical forum is comple-mented by informal gatheringswhere industry acquaintances sharestories and best practices duringmealtime, and newcomers can jumpright in. And, despite how much theSanibel Conference has grown in recent years, that welcoming familyatmosphere is always evident.

The 2015 conference will be heldJan. 22-25, 2015, at the Sanibel Harbour Marriott Resort.

For more information on AVI training and events/sponsorship opportunities, go to: www.diagnos-ticnews.com or www.aviconfer-ence.com. AVI is the techniciantraining division of Babcox Media,founded in 1994.

08-13 News 3/13/14 12:17 PM Page 8

9 schaefflerina IC 3/13/14 12:34 PM Page 9


[NewsUpdate

As the winner of the Mitchell 1 Winter Escape to San Diegosweepstakes, Jeff Knapp, co-owner of his familys business,Knapps Service Center in Newburgh, IN, along with his wifeLaurel and son Colton, flew to San Diego on Feb. 6 to enjoy along weekend in San Diego, including a VIP tour of the Mitchell1 headquarters in Poway, CA.

As the sweepstakes winner, Knapp won round-trip airfare fortwo people to San Diego and three nights in a double occupancyroom at a four-star San Diego hotel, a rental car and $500 spend-ing money. He was selected randomly from a pool of customerswho used or upgraded to ProDemand during the contest period.

Knapps Service Center was founded in 1971 and continuestoday as a successful family-run business.

We offered the Winter Escape to San Diego sweepstakes asa way of showing our appreciation to our loyal customers,said Dave Ellingen, president of Mitchell 1. While Jeff may beonly one of our many thousands of subscribers, his family-runshop reflects our core customers small businesses that relyon our products and services to help them fix more cars andtrucks more efficiently.

Go to www.ICRapidResponse.com

Mitchell 1 Winter EscapeSweepstakes Winners EnjoyVIP Prize Package

The popular Federated Free Fuel Fridays contest isback. Every Friday through March 28, Federated will giveaway two free $50 gas cards on each of its Federated AutoParts and Federated Car Care Facebook pages.

Its been a cold, rough winter, so why not stay insideand visit Federated on Facebook? You could become afree fuel winner, said Phil Moore, senior vice presidentfor Federated Auto Parts.

Fans of Federated can enter for a chance to win and willreceive extra entries when sharing the contest with theirFacebook friends.

More Federated Free FuelFridays Ahead

08-13 News 3/13/14 12:17 PM Page 10


11 napatrac IC 3/13/14 12:31 PM Page 11


[NewsUpdate

Donations to the University of the After-market Foundation increased more thanthree-fold last year, according to JohnWashbish, MAAP, secretary of the Univer-sity of the Aftermarket Foundation andchairman of its contributions committee.

The foundations board of trusteesmade it a goal to significantly step up thefundraising efforts on behalf of the founda-tion. Based on the results, we have morethan exceeded expectations, Washbishsaid. We want to thank the many donors for their generous supportof the foundation and its scholarships and educational programs.

The following organizations contributed $100,000 or more to theUniversity of the Aftermarket Foundation in 2013: Aftermarket AutoParts Alliance, Automotive Distribution Network, Babcox Media,Brenton Productions, Dorman Products, Federated Auto Parts, National Pronto Association, and OReilly Auto Parts/OReilly andWooten Families. Donating $50,000 or more in 2013 were the ClayBuzzard Family, Dayco Products, Federal-Mogul and Tenneco.

ACDelco Professional Service Center (PSC) program participants cannow offer 24 months/24,000 miles (whichever comes first) of partsand labor coverage to consumers on qualified maintenance and repairs double the previous coverage.

Our customers trust us to help them maintain a competitive edgein the independent aftermarket, said Chris Brandt, ACDelco national marketing manager. A solid warranty that protects themand their customers is a statement that we stand behind our partsand the work performed by our PSC program participants.

The enhanced coverage applies to all levels of PSC participation. Some parts are exempt from the program, such as batteries with

established free-replacement periods and other products that may already offer longer warranties. Those warranties are still valid.


ACDelco Doubles Parts, Labor Coverage For All Professional ServiceCenter Program Participants

Record-Setting FundraisingYear for University of theAftermarket Foundation


08-13 News 3/13/14 12:17 PM Page 12

NewsUpdate]

Import-Car.com 13

Standard Motor Products (SMP) announced the Intermotor Parts Car Giveaway, available to profes-sional service technicians, counterpersons, motorists and all import car enthusiasts, is runningnow through April 15. The program will award onegrand prize winner a 2014 Subaru Impreza WRX,as well as first and second place prizes.

Intermotor is recognized as the import leaderin coverage and quality, with a commitment todelivering exact match fit, form and function,said Phil Hutchens, vice president of engine man-agement marketing, SMP. To drive Intermotorawareness and to reward our many Intermotorsupporters, were excited to give one luckygrand prize winner the opportunity to driveaway in the Intermotor Parts Car, a 2014 SubaruImpreza WRX.

In addition to the grand prize, five first prizewinners will receive a GoPro HERO3+ camera,and 10 second prize winners will receive aGarmin nvi LM with lifetime map updates.

Intermotor Parts Car Giveaway participantsmay enter by entry card or online atwww.IntermotorPartsCar.com.

The 2014 Expert Plus service dealer loyalty program from Tenneco createdto help automotive service businesses in-crease their share of the undercar servicemarket includes a complete marketingand promotional package.

This years Expert Plus Program certainly makes it easier to become aleader in ride and emission controlsales, said Sheryl Bomia, North Ameri-

can aftermarket programs manager forTenneco. The2014 pack-age includesa full year ofconsumer-drivenpromotions, sales incentives, training pro-grams and an array of attractive merchan-dising products that are only available tomembers.

The 2014 Expert Plus package, whichprominently includes a new Monroecounter stool highlighting the Monroe OE-Spectrum product line, has an increasedemphasis on training, incentives and consumer promotions.

The Expert Plus marketing package fea-tures an Expert Plus Preferred Customerrebate book that allows service professionalsto extend promotional offers for Tennecoproducts beyond the standard promotionalperiods and is available for premium rideand emission control products.

Each Expert Plus kit contains merchan-dising elements to drive sales and promote the Monroe and Walker brands,including a Walker catalytic converterproduct booklet, Monroe OESpectrummolded floor mat, an educational Walkeremissions control wall chart, branded appointment calendar and other keypoint-of-sale materials.

The enrollment fee for the annual program is $99. IC

Standard Motor ProductsDebuts Intermotor Parts

Car Giveaway

Tennecos Loyalty Program DesignedTo Serve UndercarService Market


08-13 News 3/13/14 12:17 PM Page 13

It was a picture-perfect day at the auto repair shop:the bays were full, the phone kept ringing, thefront door bell never seemed to stop, and every-one was humming a tune. Parts were ordered andcame in correctly the first time. There were nosnapped off bolts, no rusted parts, and no fuss abouthow long things were taking or how much it cost.

Somehow, I had the feeling there was going tobe a loose nut thrown into the activities of the day.

Two new jobs showed up at the same time. Anice, clean 2007 Ford F-350 4WD diesel with anABS light on, and a really dilapidated 1997 Kiawith charging system problems and no light on.

The F-350 owner was practically enthusiasticabout having his truck checked out. From there, itwas textbook diagnostics run a few tests,check the codes, hook up the scanner and watchthe speed sensor PIDs. Piece of cake.

The same explanation of the diagnostic chargeswas given to the owner of the Kia. That didnt goover as well at all. Seems the Kia had beenaround the block, and around again. The ownerhad it checked out at various shops, which allended up ticking him off and showed no positiveanswers about his cars problems.

The paint was faded, the clear coat was peeling,and the windshield was full of splinter cracks.The dull hood had greasy handprints all over thefront edge where people were grabbing it. Andthe interior of the car was a pit; the smell was oppressive. But I said Id look at it even if Ihad to wear a gas mask to do it.

The Kia had two problems: A faulty alternator anda strange problem with the instrument cluster.The charge light wouldnt come on. Since this carhas an alternator that is controlled by the PCM,the charge light is there only to indicate the condi-tion of the charging system to the driver. It cancharge just fine without a working charge light.

I made the call to the Kia owner and wentthrough all the steps needed to bring his little carback to life, including the part about needing to pullout the instrument cluster to see why the chargelight wasnt working. To my utter amazement, hesaid, Do it. Do it all. Youre the first person to makeany sense out of whats wrong, and I think yourethe man for the job. I was still in shock as I hungup the phone.

So, the owner of a grease-covered car I wouldntput a nickel into is having me do the whole thing;how about the enthusiastic owner of that exception-ally clean diesel? He ended up going on a rampageabout how Im a crook and how rotten all car repairpeople are (I spared the details because of this mag-azines import content). Go figure.

I guess it just goes to show, You cant judge abook by its cover, or an owner by his car. IC

Pride Of Vehicle Ownership Runs Deep, Aesthetics Aside

By Scott Gonzo Weaver, owner Superior Auto Electric, Tulsa, OK


[GonzosToolbox

Dont Judge A JobBy Its Cover

14 Gonzo's Toolbox 3/13/14 12:22 PM Page 14


15 mitchell1 IC 3/13/14 12:30 PM Page 15

Although post-1996 OBD II powertrain control modules (PCMs) are generally veryreliable, were beginning to see more fail-ures because the average age of our national vehicle fleet has now increased to about 11.5 years.Technically speaking, the PCM should store a DTC indicating some type of internal malfunction. But,in the real world, if your scan tool indicates nocommunication and asks if the ignition switch hasbeen turned on, you obviously have a communica-tions problem. Your first step is to verify that youhave entered the correct VIN and, if your scan tool

requires a vehicle personality key to communi-cate with the PCM, verify that the key is correct forthe application. Next, test the battery for a poorstate of charge (SOC) and state of health (SOH) before beginning any PCM diagnosis. If defective,the battery should be replaced or substituted beforecontinuing with the diagnosis.

In other cases of no communication, the scantool should have automatically identified the VINbut, for whatever reason, it did not. With that inmind, I usually begin a no-communications diag-nosis by testing the throttle position sensor or

Pinning Down Intermittent Malfunctionson OBD II Vehicles.

By Gary Goms, Import Specialist Contributor

PCM DIAGNOSTICS[DiagnosticSolutions


PCM/ECM Diagnostics

Photo 1: The throttle sensor is ahandy point at which to check forthe presence of reference voltage.

16-24 Diagnostic Solns_PCMs_ECMs 3/13/14 12:21 PM Page 16


17autelus IC 3/13/14 12:30 PM Page 17

other easily accessible sensors forthe presence of the 5-volt refer-ence signal that should be origi-nating from the PCM.

If the 5-volt reference is pres-ent, its likely that the PCM is atleast partially operational. If not,its possible that a shorted sensoris pulling the 5-volt reference toground, in which case the bestprocedure is to disconnect vari-ous sensors until the referencevoltage comes back on line. SeePhoto 1 on page 16.

Ive also had some PCMs failto communicate with the scantool because theyve been ruinedby excessive charging voltage,water intrusion or other cata-

strophic occurrences. If this is thecase, consult a PCM connectordiagram to determine the config-uration of the connector pins.

Most PCM connectors containa battery voltage (B+) pin, a key-on voltage pin and two redun-dant battery ground (B-) pins.The B+ pin, which is fused,maintains the PCMs keep-aliveand diagnostic memories whenthe ignition is turned off. Thekey-on pin supplies voltage tothe PCM and indicates when theignition is turned on. In some ap-plications, key-on voltage is sup-plied by a PCM relay.

If voltage isnt available at theB+ pin, use a voltmeter to test

both legs of the PCM or enginecontrol module (ECM) fuse forbattery voltage. If testing doesntindicate nearly full battery volt-age, consult a wiring schematicfor areas that might affect thePCMs voltage supply. If key-onvoltage is say, two volts less thanbattery voltage at the key-on pin, suspect a bad ignition switch.

At least 9.5 volts should beavailable at the B+ and key-onpins during cranking to ensurethat the PCM is operating cor-rectly. With the key on, test the redundant PCM grounds for avoltage drop of more than 500 millivolts (mV) between the pinand battery ground.

DLC TESTING

The data link connector (DLC) isnumbered from left to right begin-ning at the upper left corner. Use aDVOM to check pin No. 16 on theDLC for battery voltage (B+). If B+is present, test pin Nos. 4 and 5with a 1.5-volt ohmmeter to ensurethat theyre connected to chassisground. I would not recommendusing a 12-volt continuity tester forchecking the DLC ground circuitsbecause the remaining 13 pins arelow-voltage communications buscircuits. See Photo 2 on page 20.

A better method for testing DLCpin activity is to use one of theseveral DLC breakout boxes(BOBs) now selling in the $200-$300 range on the general market.While Im only going to touch onthe application-specific topic ofbus communications, the DLCBOB will allow the technician to


PCM DIAGNOSTICS


[DiagnosticSolutions


19 oreilly IC 3/13/14 12:40 PM Page 19

instantly evaluate B+ at pin No. 16 and the integrityof ground pin Nos. 4 and 5.

In addition, the technician can use a labscope ormultimeter to monitor circuit activity on each communications bus pin. Remember that the remaining pins require a DLC connector diagramto complete an accurate bus communications diag-nosis. See Photo 3 on page 22.

POLLING THE MODULES

Here again, were touching on communications busdiagnostics, but if the scan tool is communicating,its time to poll all modules for both communica-tions and DTCs. In some cases, a no communica-tion message for a particular module mightindicate that the module is not present or not includ-ed in the scanner software. Remember that practical-ly all late-model vehicles contain, at the minimum,an engine/powertrain, anti-lock brake, theft deter-rent/vehicle security, safety restraint (air bag) andbody control module. Higher-end vehicles havemany more computers and modules, but here again,adequate training, database and OE-level scan toolcapability are required to evaluate these more com-plex systems.

BIDIRECTIONAL CONTROLS

In some cases, one portion of a PCM might become



PCM DIAGNOSTICS

Photo 2: This DLC breakout box connects between the scan tooland DLC. The LEDs indicate the correct functioning of pins 4, 5 and16 while the remaining pins allow the technician to monitor thevehicles communications bus system.


21 avitestprep IC 3/13/14 12:39 PM Page 21

non-operationaldue to a problemwith the PCMsprocessing capa-bility. Conse-quently, all suchcontrols and testsshould be activat-ed to ensure thatthe PCM is responding to bidirectional commands.

Bidirectional controls are also valuable for testingthe individual accessory drivers contained withinthe PCM, such as the ignition coil and fuel injectordrivers. The PCM, for example, might controlstarter engagement via a PCM-operated starterrelay. If the starter relay doesn't click when com-manded, the PCMs starter relay driver might notbe pulling the relay control circuit to ground.

INTERMITTENT FAILURES

In most cases, there is no definitive method for diagnosing an intermittently faulty or schizo-phrenic PCM. In my experience, most PCMs oper-ate at about 110-120 F temperature at 70 F ambientair temperature. When testing a suspected intermit-tent PCM failure, I use a small hair dryer set on lowheat to duplicate normal PCM operating temperatures.

But Ive also had PCMs reside in unusually hotareas, such as the engine firewall or over the heaterblower housing, so its possible that actual operat-ing temperatures might approach 150 F. As thePCM is warming up, tap the PCM case with ascrewdriver handle to simulate mild road andpowertrain vibration. In many cases, this test willdisclose temperature and vibration-sensitive circuitfailures within the PCM itself.

A final issue is moisture or fretting corrosion onthe PCM pins. Because pin corrosion is virtually invisible, I often use a small artists brush to applya conductivity enhancer like Stabilant 22 to thePCM pins. In some cases, this is a permanent repairfor a troublesome intermittent PCM malfunction.

PCM DIAGNOSTICS



Photo 3: Pin No. 16 at the DLC should always indicate battery voltage.



23 tycgenera IC 3/13/14 12:38 PM Page 23

RATIONALIZATION

Once in a great while, a PCMsimply wont display a correctvalue for a particular parameteridentification (PID). To illustrate, I

had a PCM disable an alternatorfield circuit because the voltagePID falsely indicated 17.5 volts,which is a threshold over-charg-ing condition. Most recently, Ifound another PCM that dis-

played 14.2 volts on the instrument cluster and on thescan tool display, which is wellwithin a normal charging voltagerange. But, despite the indicatedvoltage, the PCM wasnt ground-ing the alternator field circuit,which was causing the battery todischarge rather than charge.

As for trouble codes indicatingvoltage errors and similar PIDanomalies, remember that a diagnostic strategy might not beprogrammed into the PCMs digital logic for that purpose.

In some cases, the PCM veri-fies data inputs through aprocess called rationalization, inwhich the PCM compares thedata of one sensor with that ofother sensors. For example, thePCM might be comparing valuesfrom the engine coolant tempera-ture (ECT) with that of the intakeair temperature (IAT) sensor,both of which should indicatenearly the same temperaturesafter an overnight cold-soak.

In other cases, we might belooking at a software problemwith the scan tool itself. But thegreater point is to use a voltmeter,labscope or non-contact pyrome-ter to verify voltages, signals andtemperatures. Never take it forgranted that the PID value dis-played on the instrument clusteror scan tool is a correct value. IC


PCM DIAGNOSTICS[DiagnosticSolutions

Gary Goms is a former educator and shopowner who remains active in the after-market service industry. Gary is an ASE-certified Master Automobile Technician(CMAT) and has earned the L1 advancedengine performance certification. He alsobelongs to the Automotive Service Associ-ation (ASA) and the Society of AutomotiveEngineers (SAE).




25 advance IC 3/13/14 12:37 PM Page 25

The BMW N54 fuel pump recall a few yearsago brought to light the importance of theintegrity of the fuel system and how it cancontribute to the overall reliability of avehicle. While BMW never officiallystated what was causing thehigh-pressure fuel pumps tofail, some put the blame onlow-quality fuel that mighthave been contaminatedor had higher-than-nor-mal levels of ethanol.

These fuel quality issues apply to all BMW vehicles with either portor direct injection. The un-derlying message here is thatif the cleanliness and overall in-tegrity of the fuel tank is ignored,it will damage any fuel pump. This is

why addressing the fuel tank is essential duringany pump replacement to prevent costly come-backs that can also hurt your reputation.

If a vehicle gets 20 miles to the gallon,then more than 5,000 gallons of gas

(from many stations) will gothrough the tank in 100,000

miles. And, during thistime, sediment, rust anddebris from the pump canfind its way into the tank.

Removing all contami-nants is critical. If possi-ble, have the tank

steam-cleaned at a radia-tor shop that performs

these services. They can recondition a tank and check

for leaks that you may not be ableto spot. Your goal in cleaning the tank

Why A Clean Fuel Tank Is ImportantDuring Any Fuel Pump Replacement


[BMWFeature FUEL SYSTEMBy Andrew Markel, editor, Brake & Front End Magazine

26-32 BMW Fuel systems 3/13/14 12:20 PM Page 26

is to restore the environment inside the tank to itsoriginal state, before it moved off the assembly line.

If you think the new sock or strainer on the fuelpump will catch all of the bad stuff, youre wrong.The typical sock or strainer is designed to catch con-taminants that are between 50-100 microns in diam-eter. For comparisons sake, the size of a human hairis 40 microns. A typical inline fuel filter can catchparticles as small as 10 microns. The sock also has alimited capacity due to its small surface area.

Always install a new filter. Sounds simple, butits often forgotten. The old filter can restrict flowand cause the new pump to work harder. Thismakes for a hotter- running pumpthat fails sooner.

Bad

grounds and connections can also kill a new pump.Check the connector for any signs of thermal dam-age that may indicate there was a voltage drop or acircuit with high resistance. Do not assume the oldpump caused the thermal damage. Bad groundsand circuits will stay with thevehicle and damage the newpump.

Filter the fuel beforeyou put it back in thetank. If a fuelpump

Import-Car.com 27

BMWFeature]FUEL SYSTEM

1. Once thetank has been removed,

drain all fuel from the tank. Useonly an approved container or a fuelcaddy to filter and store the fuel.

2. Clean accumulated road debrisor rust from the top of the fueltank, especially around the moduleor hanger assembly to avoid con-taminating the fuel tank.

3. Remove the lock ring.

4. Remove the module or hangerassembly.

5. Clean and flush the tank withwater before installing the newmodule or hanger assembly.

6. Swirl the fuel tank around in acircular motion to collect any de-bris remaining in the fuel tank.

7. Slowly and carefully poor thefuel out of the tank into the ap-proved container or fuel caddy.

8. Turn the fuel tank over, then tapthe bottom to remove any debris.

9. If a tank can be cleaned, its im-portant to use high-pressure soapand water to remove the dirt. Late-model fuel tanks are difficult toclean because of their internalbaffling. The tank should then bethoroughly dried by circulating airthrough the tank or by simply plac-ing it in the summer sun. In manycases, a fuel tank replacement is

the most cost-effective and safestalternative.

10. If possible, take a lint-freeshop towel and wipe the inside ofthe fuel tank until it is clean.

11. Dry out the fuel tank com-pletely with compressed air.

12. Inspect the fuel tank carefully.If the tank is rusted inside orshows signs of physical damage, itmust be repaired or replaced.

13. After the tank has been driedwith compressed air, let it sit for30 minutes.

Courtesy of the Fuel Pump Manufacturers Council.

Fuel Tank Cleaning Procedures


28-29 airtex IC 3/13/14 12:37 PM Page 28


28-29 airtex IC 3/13/14 12:37 PM Page 29

went through a full meltdown,chances are pieces from the oldpump are still in the removedfuel. Many fuel caddies havebuilt-in filters.

Check the EVAP system beforereturning the car to the customer.It takes at least one drive cyclefor most vehicles to set an EVAPcode. A leak due to disturbingthe lines may not set a code dur-ing the initial test drive. Thecode may come on after the vehi-cle has been sitting for awhile orafter a certain temperature hasbeen reached.

Check the system with a scantool and/or smoke machine before delivering the car to thecustomer. Some scan tools andvehicles can perform a self-leakcheck. Fuel filler necks are espe-cially susceptible to leaks if thetank has been dropped.

In the Rust Belt states, corro-sion on the top of the tanks andon the fuel lines can become abig headache during fuel pump replacement. This comes frombrines that are used on roads toprevent icing. Brines stick to vehicles even the tops of fuel


FUEL SYSTEM[BMWFeatureBMW Fuel Pump Tech TipsHere are some recent tech-nical service bulletins re-lated to BMW fuel pumps.

#1. N20 Engine: Ticking NoiseFrom High-Pressure Fuel Pump

Situation: The customer com-plains of a high-frequency tick-ing noise from the enginecompartment. The noise can beheard inside and outside thevehicle.

Cause: Mechanical vibrationsinside the high-pressure fuelpump.

Correction: Install a high-pressure fuel pump cover (P/N13 51 7 629 129). The plasticacoustic cover will snap ontothe high-pressure fuel pump.

Do not remove the fuel linesor the high-pressure fuel pumpto install the acoustic cover.

#2. N14, N18 Engine: High-Pressure Pump Repair Instructions

The current version of the re-pair instruction Removing andinstalling or replacing high-pressure pump has a procedureerror. This current version of therepair instruction states to re-place the high-pressure supplyhose on the N14 engine and tonot replace the high-pressuresupply hose on the N18 engine.The N18 portion of the repair in-struction is incorrect.

As an interim solution, followthe procedure outlined below:

Continental High-Pressure

Pump: All vehicles equippedwith the N14 engine (all pro-duction); all N18 vehicles pro-duced up to March 2012 areequipped with a ContinentalHigh-Pressure Pump (see 1 inFig. 1).

When the N18 engine is fittedwith a Continental High-Pres-

sure Pump, the high-pressure supply hose (see 2 in Fig. 1)must be replaced when makingrepairs.

Bosch High-Pressure Pump:All vehicles equipped with theN18 engine and produced fromMarch 2012 and later.

When the engine is fitted witha Bosch High-Pressure Pump(see 1 in Fig. 2), the high-pres-sure supply hose (see 2 in Fig.2) must not be replaced whenmaking repairs.

Fig 1

Fig 2



31 napaaltrom Ic 3/13/14 12:36 PM Page 31

tanks long after the snowstorms have passed and eveninto summer. Then, every time itrains, the brines are reactivatedand start to corrode the tank.

Be sure to check the straps andthe tank mounting hardware. In2010, one automaker recalled 1.2million trucks due to corrosion ofthe straps that held up the gastank. Note: Its a good practice to

inspect the fuel lines for corrosionbefore starting the job. Nothing isworse than having to call the customer because a line collapseddue to corrosion during removalor installation. IC


FUEL SYSTEM[BMWFeature


Andrew Markel is the editor of Brake &Front End and Servicio Automotriz maga-zines. He has been with Babcox Media formore than 12 years. He is a technician andformer service writer and holds several automotive certifications from ASE and aftermarket manufacturers. He can bereached at [email protected].



33 walker IC 3/13/14 12:36 PM Page 33

Im tired of hearing about winter, talking aboutwinter and experiencing winter, and I bet youare, too. However, what has been the worstwinter in a generation may, in fact, be a blessingin disguise for independent repair shops acrossthe country.

The harsh elements will leavemany vehicles in need of serviceand National Car Care Month inApril is the ideal time to captureyour share of these service and repair opportuni-ties. Its also a chance to improve relationshipswith customers and attract new ones, leading tomore long-term business.

Having a proper plan in place to capitalize onNational Car Care Month is the first step. The CarCare Council website features a toolbox of infor-mation, promotional materials and suggestions tohelp you get started (www.carcare.org/industry-tool-box). Since there is no one-size-fits-all template for participating in National Car CareMonth, the toolbox also offers a variety of ideason how to incorporate National Car Care Month

activities into your plans, whether you choose tohost an event or participate on a smaller scale.

Hosting a free community car care event duringNational Car Care Month is an inexpensive andhighly successful way to enhance customer rela-

tionships, capture more businessfrom current customers and generate new business.

For a larger community event,you could partner with other busi-

nesses in your area, as well as a local radio station.For a smaller event, you could offer free vehicle in-spections right at your business location. The pos-sibilities are endless. Whatever you decide to do,this is a tremendous opportunity to increase thegoodwill and trust among your customer base.

If you decide to conduct an event, the Car CareCouncil has a point-of-sale kit available for useduring National Car Care Month and throughoutthe year (www.carcare.org/pos-starter-kit). Thekit includes consumer education brochures,posters, bay banners, mirror hangers, vehicle in-spection forms, an English/Spanish countermat

Brutal Winter Can MeanProfitable SpringDuring National Car Care Month


By Rich White, Executive Director, Car Care Council

NATIONAL CAR CARE MONTH[GuestEditorial

34,36 Guest Editorial, Rich White 3/13/14 12:19 PM Page 34


35 mahle IC 3/13/14 12:35 PM Page 35

and the very popular Car Care Guide.In addition, the free digital version of the

Car Care Guide is available as a reference foryou and your customers. It can be found atwww.carcare.org/car-care-resource/car-care-guide/.

Free resources for your customers dont end withthe Car Care Guide. The council has a free personal-ized service schedule and email reminder service tohelp consumers remember to be car care aware.By sharing the link, www.carcare.org/car-care-ser-vice-schedules/custom-service-schedule/, yourcustomers can become more proactive in maintain-ing their vehicle and following a service schedulewith your help.

Does your shop have a social media presence? Ifso, why not like and follow the Car Care Councilon Facebook (facebook.com/CarCareCouncil) andTwitter (twitter.com/CarCareCouncil). The council

frequently posts helpful tips, videos and information,such as its new Maintenance Mondays posts, thatcan easily be shared with your own fans and follow-ers.

Participating in National Car Care Month is timewell spent and gives you a chance to build aware-ness of your business, increase car counts and edu-cate consumers on how much of their vehiclesmaintenance is going unchecked. Dont sit out thisNational Car Care Month. Start planning today forwhat could be the start of a real game changer foryour business. For more information on NationalCar Care Month and the Be Car Care Aware campaign, visit www.carcare.org. IC


[GuestEditorial


NATIONAL CAR CARE MONTH

34,36 Guest Editorial, Rich White 3/13/14 12:19 PM Page 36


37 gmb IC 3/13/14 12:43 PM Page 37

Lets say a vehicle had 0.003of lateral runout whenmeasured at the outsideface of the rotor. If this vehicle isriding on 205/55R16 tires, in justone mile, the high-spot with0.003 of runout goes past thecaliper approximately 836 times.Over the course of 6,000 miles,that spot on the rotor will go pastthe pads more than five milliontimes. Every time this spot passesthe pads, a little bit of the rotorsmaterial is removed.

Thats why its critical to measure thickness and runout ina brake rotor and wheel flange,even if new rotors are going tobe installed.

Before getting started and removing the rotor, mark itsoriginal position with a paint orgrease marker .

1. Inspect the rotors surfacefor defects, corrosion or cracks.

2. Find the discard measure-ments on the rotor. On some aftermarket rotors, they will belaser-etched into the sides ofthe plates. If a discard meas-urement cant be found, look itup along with the specificationfor thickness variation or parallelism.

3. Using a micrometer, meas-ure the thickness of the rotor inat least six spots that are oppo-site from each other.

4. Record the results. Varia-tions in thickness should be between 0.001 and 0.003.

MEASURING RUNOUT

1. Mount the dial indicator to arigidly secure portion of the sus-pension, like the knuckle. Do notmount the arm to the tie rodends or the control arms. Posi-tion the indicator tip perpendi-cular to the rotors surface and0.5 from the edge of the rotor.

2. Tighten down the rotor withthe correct conical washers to the

Stop PulsationComebacksBefore They Start


By Andrew Markel, Editor,Brake & Front End Magazine

ROTOR RUNOUT AND DTV[TechFeature


38-40 Tech Feature_Brake Rotors 3/13/14 12:29 PM Page 38


39 partsmaster IC 3/13/14 12:43 PM Page 39

recommended lugnut spec.3. Set the dial to zero and turn

the rotor.4. Mark the high and low spots

of the runout. For most cars, thespecification will be 0.002 or less.

5. Remove the rotor. Inspect themounting surface inside the hat.Remove any corrosion or debris.

WHEEL FLANGE RUNOUT

1. Rotate the hub bearing assembly by hand. Any rough-ness, play or noise from the bear-ing is an indication of damage.Verify that the condition is nor-mal or requires replacement.

2. The dial indicator baseshould be placed or clampedrigidly on a secure portion of thesuspension. Position the indica-tor tip as perpendicular to thewheel flange as possible.

3. Set the dial indicator to zero.Next, turn the flange at leasttwice and observe the high andlow spots of runout.

4. Mark the high and low spotsof runout on the flange.

5. If the flange has more than0.002, or the readings are incon-sistent, further corrective actionsmight need to be taken.

MATCHING THE HUB TOTHE ROTOR

By measuring and marking thehigh and low spots of runout inthe hub and rotor, its possible tomatch the high spot of runout inthe hub with the low spot ofrunout in the rotor. This tech-nique can be used to minimize

the amount of material removedwith an on-the-car brake lathe.

Flange runout can be correctedwith tapered shims that areavailable to correct a runout of0.003 (0.075 mm) to 0.009(0.230 mm). A runout of morethan 0.005(0.125 mm) at thebearing flange cannot be cor-rected by the use of a shim.

The combination of the rotorand bearing flange could preventthe rotor from being turned.Check the bearing flange runoutafter checking friction surfacerunout, and then check flangerunout by changing the rotor po-sition 180 on the bearing. If thehigh spot changes 180, the rotorcould be OK or ready to turnafter the bearing is shimmed.

Components should bemarked as you perform an in-spection of the assembly. Checkthe bearing endplay. Mark the relation of the rotor to the bear-ing flange. Then, mark the rotorhigh and low runout spots on therotor friction surface, as follows:the low spot marked as zero andthe high spot as 0.XX. Mark thehigh and low runout spots on the

bearing flange with the samemethod as the rotor friction surface.

If the endplay exceeds themanufacturers specifications, replace the bearing and recheckrunout.

Compare the bearing flangeto rotor runout position.

If the shim cannot correct therunout, the bearing should be replaced.

Check the rotors thickness.The minimum dimension shouldbe stamped or cast into the rotor.There has to be enough thicknessto cover the runout without goingbelow the minimum thickness.

RUNOUT MINIMIZATION

Today, you can purchase an on-the-car brake lathe that, after ithas been attached to the vehicle,will automatically compensate forrunout quick and easy.

In some cases with excessiverunout, a new rotor should bemachined to match the vehicle,which helps to match the rotorsto the hub flange.

The main advantage of an on-the-car lathe is that it is able tocut a rotor in its operating plane.This means that the rotor is machined to match the hub.

It has often been said that youshould never machine new rotors,but what if the runout exceeds themanufacturers specificationswhen the new rotor is installed onthe vehicle? This situation makes itpermissible to machine a new rotorwith an on-the-car brake lathe. IC


ROTOR RUNOUT AND DTV[TechFeature

38-40 Tech Feature_Brake Rotors 3/13/14 12:29 PM Page 40


41 gaas IC 3/13/14 12:43 PM Page 41

A ll air ride systems can fail and requireservice, and there are several repair pathsyou can go down to offer the best optionfor your customers needs and budget.

The start of any repair path is diagnostics. Withmodern air ride systems, failures can occur inmultiple areas including the control modules, solenoids and even the vehicle network. A failure

may appear to be a leaking air bag,but it could also be a control mod-

ule that cant communicate, astuck solenoid or a worn

out compressor. Insome cases, the con-trol module will re-quire reprogrammingto resolve a problem.

Some of these fixescan be very expen-

sive. But

before any air ride system is scrapped for passivecoil spring units, consider the resale value of thevehicle. A functioning air ride system can addthousands to the price of some vehicles. On othervehicles, the price has depreciated to the pointwhere a functioning system makes little difference.

Always advise the customer that not repairingthe air ride system removes some functionalityfrom the vehicle like adjustable ride control andload leveling.

With more and more air-ride-equipped vehiclesaccumulating miles, you can expect to see asteady stream of these vehicles in your bays. Youalso have more options than ever before when itcomes to replacement parts and conversion kits.Below is a forecast of current and future air ridevehicles and replacement options.

BMW

The 5 Series received a rear air leveling suspensionin 1999 as an option. The X5 was the first to get airride in 2000. In 2002, the 7 Series received an adjustable air suspension. New models like the X6have air ride as standard. Replacement parts andconversion kits are available.

JAGUAR

The 2004-10 Jaguar XJ8 and XJR have air rideunits at all four corners. Replacement units fromthe dealer can be very expensive. Coil conversionkits are available, as well as replacement sensors,compressors and complete air ride units.


By Andrew Market, Editor, Brake & Front End Magazine

AIR RIDE SYSTEMS[TechUpdate

Air Ride ReplacementOptions:Give You The Ability To Repair Or Convert A Variety Of Makes And Models

42,44 Tech Update_Air Ride Systems 3/13/14 12:28 PM Page 42


43 kyb IC 3/13/14 12:42 PM Page 43

LAND ROVER

Air ride suspensions were stan-dard on all Discovery and RangeRover models since the mid-1990s. These models have com-mon pattern failures that canleave the suspension flat or insafe mode. There are many replacement and service optionsavailable for these vehicles fromspecialists. Coil conversion kitsare available as a solution for acost-conscience customer, but before considering this option,consider the resale value of thevehicle, as mentioned earlier.

LEXUS

From the start, Lexus offered airride at all four corners as an op-tion with the 1990 LS400. Sincethen, air ride has become optionalor standard equipment on mostmodels including the RX and GXSUVs. Aftermarket repair and conversion options are available.

MERCEDES-BENZ

Mercedes-Benz has offered sever-al air ride and hydraulic systemssince the early 1990s, includingAirmatic and ABC. Some of thesesystems can also have ActiveDampening Control (ADC).When ordering replacement partsfor these vehicles, make sure youknow which system it has andwhether the vehicle is all-wheeldrive. The greatest opportunityfor shops is the S-Class for replacement air ride componentsand coil conversion kits.

TOYOTA

The 2003-11 Toyota 4Runner withthe X-REAS system is not an airride system, but its a system thatcan fail. The X-REAS system linksall four shock absorbers to a cen-ter control absorber. The aftermar-ket does offer service parts as wellas passive conversion kits. IC


[TechUpdate AIR RIDE SYSTEMS


With more and more air-ride-equipped vehicles accumulating miles, you can expect to see a steady stream of thesevehicles in your bays.


42,44 Tech Update_Air Ride Systems 3/13/14 12:28 PM Page 44

HONDA ACCORD MAKES THUMPINGNOISE AT COLD START

Applies To: 1998-2002 AccordL4 all models with A/T andcruise control

Symptom:A thump as the ignition

switch is released from the startposition or as the engine starts.This noise sounds similar to arubber mallet striking theframe and occurs only on acold start (the vehicle has beensitting for some time, usuallyovernight).

Probable Cause:The vacuum-actuated engine

mount does not work properlybecause of insufficient intakemanifold vacuum at start-up.

Corrective Action:To increase vacuum, reroute

the vacuum hose for the enginemount control solenoid valve tothe cruise control vacuum tank.

Diagnosis:Ask your customer if the

noise happens only on a coldstart, after the vehicle has beensitting for some time, usuallyovernight.

If the noise happens onlyon a cold start, go to RepairProcedure A - 1998-2000 Accordbelow or Repair Procedure B -2001-02 Accord on page 46.

If the noise happens at everystart, disregard this bulletin,and look for other possiblecauses (exhaust hangers, rearengine mount, etc.).

Repair Procedure A: 1998-2000 Accord

1. Look at the three vacuumports on the top of the intakemanifold. See Fig. 1. Is vacuumport C capped?

If port C is not capped,replace the fuel pressure regu-lator and hose (see S/B 00-018,MIL Comes On With DTCsP0171 and/or P0172, filedunder Fuel and Emissions).Then go to step 2.

If port C is capped, go tostep 2.

2. Disconnect the three vacu-um hoses from the Y-fitting. SeeFig. 2. Save the Y-fitting.

3. Remove the hose from vacuum port A and discard it.

4. Remove and discard thelong vacuum hose going to thefuel pressure regulator. Savethe double hose clip.

5. Unclip the cruise controlvacuum hose from the intakeair duct. Measure 4-1/2 in.from the check valve on thecruise control vacuum tank,then remove a 1/2-in. sectionof the hose beyond this pointwith a utility knife. See Fig. 3.

6. Connect the ends of the vac-uum hose you just cut to theopposite ends of the Y-fitting youremoved in step 2. See Fig. 4.

7. Connect the engine mountcontrol solenoid valve vacuumhose to the open port on the Y-fit-ting. Push the hose into the clipon the side of the intake air duct.

8. Cut a 34-in. length of 3.5 mmID vacuum hose, then connect

ImportTechTips]

Import-Car.com 45

Fig. 1

Fig. 2

Fig. 3

Fig. 4


45-48 Tech tips 3/13/14 12:28 PM Page 45

one end to vacuum port A andthe other end to the fuel pressureregulator. Push the new hose intothe clips at the locations shownin Fig. 5.

Repair Procedure B: 2001-02Accord

1. Disconnect the enginemount control solenoid valvevacuum hose from vacuumport A. See Fig. 6. Unclip thehose from the double hose clipand from the side of the intakeair duct. Remove and discardthe double hose clip.

2. Measure 3 in. from theopen end of the hose, andremove that section of hosewith a utility knife. See Fig. 7.

3. Unclip the cruise controlvacuum hose from the top of theintake air duct. Measure 4-1/2in. from the check valve on thecruise control vacuum tank, then

remove a 1/2-in. section of thehose beyond this point with a utility knife. See Fig. 8.

4. Connect the ends of thevacuum hose you just cut tothe opposite ends of the newY-fitting. See Fig. 9.

5. Connect the enginemount control solenoid valvevacuum hose to the open port

on the Y-fitting. Push the hoseinto the clip on the side of theintake air duct.

6. Push the cruise control vacuum hose into the clip onthe top of the intake air duct.

7. Push the new cap onto vacuum port A.

Courtesy of ALLDATA.

FLUSHING THESTEERING SYSTEM

Fine particles can enter a hydraulic system because of mechanical stress on the steeringcomponents. As a consequence,its recommended to flush the entire hydraulic system when re-placing the power steering pump.

A few vehicle manufacturershave installed a drain bolt in thearea of the steering gear. The disadvantage is that it is not possible to drain all the hydraulicfluid here. A residual quantity


[ImportTechTipsFig. 5 Fig. 6 Fig. 7

Fig. 8 Fig. 9


45-48 Tech tips 3/13/14 12:28 PM Page 46

47 SolvTec IC 3/13/14 12:27 PM Page 47

always remains in the system.

Repair Procedure:1. Raise the vehicles front

wheels off the ground. Raisingthe wheels will allow for lowerresistance (in steps 9 and 12)when turning the wheels backand forth while flushing the system. It will also prevent thehydraulic fluid from foaming.

2. Remove the power steeringreservoir cap.

3. Remove the return line onthe reservoir, making sure to collect all the fluid being drainedout. Be sure to properly disposeof the old fluid.

4. Disconnect the feed linefrom the reservoir and removethe reservoir from the vehicle.

5. With the reservoir removed,clean the inside with a suitablecleaner. Brake cleaner is recom-mended. If the vehicle isequipped with an in-line filter, besure to clean or replace the filter.

6. Reinstall the reservoir andattach the fluid feed line, but donot attach the return line. With asuitable plug, plug off the loca-tion on the reservoir where thereturn line should be connected.

7. Fill the reservoir with thecorrect fluid, allowing the fluidlevel to stabilize. Once the fluidhas stabilized, start the vehicle.

8. With the engine running,collect the fluid that will beflowing out of the return line.

9. Keeping the engine run-ning, turn the wheel back andforth from stop to stop. Do thisapproximately 10 to 12 timesuntil the fluid runs clean.

Very important: Always makesure to keep the reservoir full. Donot allow the reservoir to run dryas this will damage the pumpand create air in the system.

10. Once the system is flushed,turn off the engine. Remove theplug on the reservoir and recon-nect the return line. (Collect thefluid that will run out of the reser-voir when the plug is removedand dispose of it properly.)

11. Top off the reservoir withadditional, clean fluid and allowthe fluid level to stabilize.

12. Once complete, start theengine and turn the wheel stop tostop 20 times to bleed air from thesystem. While the system is beingbled, make sure the fluid leveldoes not go below the fill line.

13. Lower the vehicle, verifythe fluid is at the correct operat-ing level, then reinstall thepower steering reservoir cap.

14. Check for any leaks and testdrive to verify proper operation.

Important! Its essential tocomply with the vehicle manu-facturers installation instruc-tions and to use only thehydraulic fluids approved forthe respective vehicle. The speci-fication is found in the ownersmanual for the vehicle.

Important! Hydraulic fluidmay not enter the soil. Disposalmust take place via the supplierof the materials or a specialrefuse collection point. IC

Courtesy of Schaeffler GroupUSA Inc.


[ImportTechTips


45-48 Tech tips 3/13/14 12:28 PM Page 48

Import-Car.com 49

Brought to you by Essentials]


The PlatinumNAPAFilter offers tech-nology for the latest advancements insynthetic oil and performance oil filters.Featuring a host of oil filter innova-tions, including wire re-enforced fullysynthetic media and an ultra-durable Hydrogenerated Nitrile compound anti-drain back valve(where applicable), this oil filter pro-vides the ultimate protection in theNAPA Family of oil filters. Visit www.napafilters.com for more information.Reader Service: Go to www.icRAPIDRESPONSE.com

Ranger Products, a division of Bend-Pak Inc., is bringing a new tire changerto market. The R980ATF is equippedwith a powerful variable-speed motorand gear box that work systematically

at multi-speeds, allowing operatorsto match turntable rotation-al speed with varied tire

and wheel combinations. Ergonomic controls aresensibly placed to mini-mize excessive reachingor bending, resulting inmore jobs per day. The

R980ATF workswith a wide variety of wheels, including virtuallyall OEM and per-

formance tire andwheel configurations.

Reader Service: Go towww.icRAPIDRESPONSE.com

ZF Services, LLC, theaftermarket busi-ness unit of ZFFriedrichshafenAG in NorthAmerica, announced thelaunch of 49 newparts added to theSachs passenger carand light truck clutch product line during 2013.The new part numbers added throughout the year includ-ed 24 new complete clutch kits, 11 flywheels and 14 hydraulic SKUs. These clutch kits released during the pastyear fit the 2006-13 Audi A3 and VW CC, EOS, GTI, Jettaand Passat. Reader Service: Go to www.icRAPIDRESPONSE.com

Advance Auto Parts Professional offersquality fuel pumpsfrom Airtex, the U.S.aftermarket leadersince 1935. Airtexfuel pumps are designed and builtwith the latest ad-vances in fuel deliv-ery technology and

are used by the automotive aftermarket, OEMs andspecialty manufacturers. For more information on Air-tex products, call your local Advance delivery location.Reader Service: Go towww.icRAPIDRESPONSE.com

Solv-Tec reports that sales of its K-Sealone-step permanent coolant leak repairare rocketing both in the U.S. and over-seas. A recent independent market survey in the U.K. reported that K-Seal isnow the No. 1 best-selling total coolantleak repair, recommended by nine out of10 K-Seal distributors. One concentrated8-oz. bottle (P/N ST5501) will perma-nently fix head, head gasket, block, radi-ator, heater core and water pump leaksin engines up to 12 cylinders.Reader Service: Go towww.icRAPIDRESPONSE.com

Documents

Import Car Magazine 2014 03