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1.800.4A.MOTOR
Magazine
Industry leading
content
Dan
Marinucci
dmarinucci@motor.com
Foreign Service
14 March 2012
S
ometimes we solve customers’ prob-
lems with a good memory, careful
visual inspection and old-fashioned
luck. Other times the jobs we tackle
require nearly every diagnostic tool,
tester and instrument we own.
This month’s saga reminds us that an accu-
rate vehicle history may be the single most
valuable tool at our disposal. What’s more, we
may have to pry this information out of the cus-
tomer. Finally, critical clues about vehicle histo-
ry may be right under our noses but we over-
look them and the fact that they beg answers
from the car owner.
This story concerns a first-rate shop I’ll call
“Pauly’s Garage” for the purposes of this col-
umn. A customer brought in a 2006 Toyota
Corolla, claiming that its brakes were locking
up. He said his wife drove the car most of the
time and the symptom occurred during her
routine commute to work. He also said he
smelled burning friction material.
Pauly verified the lady’s daily commute, then
one of his techs drove the Corolla over that
route again and again. Initially, no symptoms ap-
peared. Then the
tech put the car on a
lift and visually in-
spected the brakes.
He found some rela-
tively new-looking
brake parts, and the
brake fluid looked
and smelled new.
There weren’t any
obvious signs of
sticking or dragging
calipers and he
couldn’t find any
kinked or crimped
brake lines.
Hindsight, they
say, is always 20-20.
Here, the customer’s
comment about a
burnt-brake odor could have been the first red
flag about relevant vehicle history. How many
nontechnicians can identify the smell of over-
heated friction material? The second red flag
could have been the new brake parts. Who in-
stalled these parts? When and why?
Meanwhile, Pauly couldn’t locate any service
bulletins for the Corolla’s symptoms and a tech-
nical hotline service didn’t have any specific fixes
for it, either. Next, his tech tried recreating the
symptom by “driving” the car on the lift and re-
peatedly applying the brakes. That approach
failed, so he retraced the driving route—but this
time with many more brake applications along
the way. Finally, he smelled overheated friction
material and another symptom appeared. The
front wheels began dragging, the right front
seeming to drag slightly more than the left.
The tech flushed the hydraulic system with
fresh brake fluid and bled the system per Toy-
ota’s recommended procedure. However, the
front brakes still began dragging severely after
their established road test. When he raised the
car on a lift after each road test, the front wheels
barely turned. Loosening the front bleeder fit-
tings released the front calipers every time; then
the front wheels spun freely. But after each road
test, the front wheels would severely drag again.
By this time, Pauly told me, they began sus-
pecting a master cylinder problem. However,
confirming this suspicion required eliminating
everything outside the master cylinder—easier
said than done. They double-checked the car for
evidence of body/frame damage as well as bashed
brake lines. After all, a crimped metal line or in-
ternally flaking rubber brake hose could keep a
caliper applied. Pay attention here if you’ve never
seen this condition. A restriction inside a line or
hose may trap brake application pressure be-
tween the restriction and the caliper. Then the
caliper won’t release the pads after the driver ap-
plies and releases the brakes. However, opening
the caliper’s bleeder fitting will release the pads.
The tech connected a brake pressure gauge to
each front caliper and then operated the brakes
Whenyouserviceavehicle,howcertainareyouthatyou’retheonly
onewho’severworkedonit?Unlessyouknowyouare,questioning
thecustomertoobtainadetailedvehiclehistoryisamust.
Photo:DanMarinucci
If you suspect that a binding, corroded or
misadjusted brake pedal mechanism is
keeping the brakes partially applied, unbolt
the master cylinder and carefully pull it
forward just far enough to separate it from
the firewall or brake booster. See if this
trick releases the brakes.
continued on page 16
18 March 2012
C
armakers all over the world are
acutely aware of the model year
2016. The models to be sold in
the U.S. that year are on the
drawing boards right now. By
federal law, those vehicles must
meet a Corporate Average Fuel Economy
(CAFE) standard of 34.1 mpg. The 54.5 mpg
you’ve heard of doesn’t go into effect until 2025.
How are they going to do that?
The numbers are not as scary as they might
seem. Dan Edmunds, on the Edmunds.com
website, says: “The 34.1 mpg CAFE target for
2016 is actually equal to only 26 mpg on a win-
dow sticker. The talked-about 2025 CAFE stan-
dard—usually described as 54.5 mpg—amounts
to a figure of 36 mpg Combined [highway and
city driving] on a window sticker.”
It’s important to realize that this is an average
number for the whole fleet. It will include a lot
of thirsty trucks, big SUVs, some plug-in hybrids
and, of course, a whole slew of average vehicles.
Still, it leaves the carmakers right now
searching for ways to get roughly a 5-mpg in-
crease out of their vehicles. It would only be
fair to note that changing politics and changing
government rules go hand in hand. Depending
on what the government does, who winds up
getting elected and what the state of California
does, these rules
could be made ei-
ther easier or harder
to attain. That
doesn’t help the car
companies right
now; they really are
on the hook to do 5
mpg better and they
need all the ideas
they can get.
The basic formu-
las for calculating
fuel economy are
fairly straightfor-
ward. The force
needed to move a vehicle is equal to the mass
times the acceleration (weight includes gravity,
mass does not). Making a vehicle lighter or re-
ducing its acceleration are two ways to reduce
fuel consumption.
You can also work on waste factors. Improving
the efficiency of the engine and/or drivetrain, re-
ducing aerodynamic drag and reducing lost en-
ergy (exhaust, cooling and brakes) are all ways to
improve fuel economy. You can also work to re-
duce the energy associated with heating and
cooling the passenger compartment.
One particularly good area to look at is the
unsprung weight of the vehicle. Unsprung
weight is largely a function of the design of the
vehicle’s suspension and the materials used in its
components. This weight may be something of a
trade-off between the wheel’s ability to follow
bumps and the vibration isolation of those
bumps. Bumps and surface imperfections in the
road cause tire compression. This then puts a
force on the unsprung weight. The amount of
wheel movement is inversely proportional to the
unsprung weight.
What all this means is that a lighter wheel will
follow the bumps better and have more grip, as
well as a more constant grip, on the road surface.
When you’re trying to make improvements in
vehicle design, the sweet spot is when you can
not only improve the part, but improve overall
vehicle performance, too. Reducing unsprung
weight is a way to improve vehicle handling and
performance, and for designers to reduce weight
in other areas of the suspension and the vehicle
body because they have less impact and vibra-
tion to deal with.
Major development programs are going on
right now in terms of how to reduce the weight
of the tires and the wheels on which they’re
mounted. The HTAS Corp., part of the Euro-
pean tire company Vreedstein, is just one com-
pany that’s currently working on weight-reduced
tires. Gerlof Korte, who is in charge of the pro-
ject, says the target is to reduce the weight of
each tire by 4kg (9 lbs.), for a total vehicle weight
Mike
Dale
Fueleconomystandardsarerampingup,afteryearsofstability.
Asaresult,allrelatedsystemsmustbereevaluated.Weight-saving
innovationshelpthecause,whilebenefitingotherareasaswell.
mdale@motor.com
Eye On Electronics
PhotocourtesyBASF
The seat back for an automotive interior is
being simulated on-screen. The computer
simulation allows material substitution to
determine what will work best for the
stresses the application will undergo.
continued on page 20
• EDITOR’S REPORT by John Lypen
Provides expert opinions on key issues and concerns for shop
owners, technicians and the industry.
• TRADE SECRETS by Bob Cerullo
Bob uses case histories from his own shop to help show MOTOR
shop owners the right way to approach and fix mechanical
problems; right for both the customer and the shop.
• FOREIGN SERVICE by Dan Marinucci
ASE-certified, Dan uses hands-on experience to give readers
expert advice on finding and fixing hard-to-diagnose import
vehicle problems.
• DRIVEABILITY CORNER by Mark Warren
Mark is one of the nation’s leading experts on driveability. Every
other month he offers insightful, sometimes unconventional
diagnostic approaches to solving driveability problems.
• TROUBLE SHOOTER by Karl Seyfert
In a dialogue with technicians, Karl responds to questions
seeking expert advice on specific problems.
• PERFORMANCE PERSPECTIVES by Jim Gibson
This column covers the emerging performance enthusiast vehicle
service market.
• NEWSBREAK - Late-breaking news about technology, companies,
trends, legislation and regulations in the automotive industry.
• SERVICE SLANTS by Tom Rosario
OE Tech Service bulletins rank #1 on the list of information
technicians want.
• EYE ON ELECTRONICS by Mike Dale
Every other month, Mike Dale, an automotive design engineer,
covers the hot issues of electronic technology with a style that
demystifies complex service with practical advice.
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2013_motor_catalog
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- 8. www.motor.com 1.800.4A.MOTOR Car/Truck Repair Auto RepairManuals: Vol 12 Light Truck Van Repair Manuals: Vol 12 light truck van repair MANUAL Volume 1: Mechanical Repair Volume 2: ABS/Electrical • Air conditioning maintenance • Cooling fans diagnosis repair • Disc drum brake service • Drive axle service • Electrical components RR • Engine rebuilding specifications • Hydraulic brake system service repair • Mechanical engine repair • Power steering diagnosis repair • Specification data • Starter alternator diagnosis repair • Steering column RR • Suspension steering components RR • Tightening specifications • Tire pressure monitoring system • Wheel alignment • Active suspension system • Anti-lock brake component locations • Anti-lock brake diagnosis testing • Dash gauges diagnosis testing • Dash panel service • Passive restraint component locations • Speed control component replacement • Speed control diagnosis testing • Warning lights diagnosis testing • Wiper system diagnosis testing auto repair manual Volume 1: Mechanical Repair Volume 2: ABS/Electrical • Air conditioning maintenance • Cooling fans diagnosis repair • Disc drum brake service • Drive axle service • Electrical components RR • Engine rebuilding specifications • Hydraulic brake system service repair • Machine shop specifications • Mechanical engine repair • Power brake units • Power steering diagnosis repair • Specification data • Starter alternator diagnosis repair • Steering column RR • Suspension steering components RR • Tightening specifications • Tire pressure monitoring system • Wheel alignment • Active suspension system • Air bag systems • Anti-lock brake component locations • Anti-lock brake diagnosis testing • Dash gauges diagnosis testing • Dash panel service • Passive restraint component locations • Speed control component replacement • Speed control diagnosis testing • Warning lights diagnosis testing • Wiper system diagnosis testing 6
- 9. www.motor.com 1.800.4A.MOTOR Car/Truck Repair Imported CarRepair Manuals: Vol 12 imported car repair MANUAL Volume 1: Mechanical Repair • Air conditioning maintenance • Cooling fans diagnosis repair • Disc drum brake service • Drive axle service • Electrical components RR • Engine rebuilding specifications • Hydraulic brake system service repair • Mechanical engine repair • Power steering diagnosis repair • Specification data • Starter alternator diagnosis repair • Steering column RR • Suspension steering components RR • Tightening specifications • Tire pressure monitoring system • Wheel alignment Volume 2: ABS/Electrical • Active suspension system • Anti-lock brake component locations • Anti-lock brake diagnosis testing • Dash gauges diagnosis testing • Dash panel service • Passive restraint component locations • Speed control component replacement • Speed control diagnosis testing • Warning lights diagnosis testing • Wiper system diagnosis testing ENGINE PERFORMANCE DRIVEABILITY ONLINE Coverage: Multi-year coverage for imported cars, light trucks, vans SUVs • Code accessing procedures • Computerized engine controls • Component locations • Drive cycles • Diagnostic flow charts • Emission application charts • Fuel system diagnosis service • Ignition system diagnosis repair • Sensor tune-up specifications • Service reminder warning lamp reset • Technical service bulletins • Vacuum hose routings • Wiring diagrams Contents: 7
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- 11. www.motor.com 1.800.4A.MOTOR EMISSION CONTROL VACUUMHOSE ROUTING COMPONENT LOCATION MANUAL Coverage: Multi-year coverage for domestic imported cars, light trucks, vans, SUVs, medium heavy duty trucks • Component locations • EGR diagnostic charts • EGR functional tests • Vacuum hose routings Contents: OBDII DRIVE CYCLES Coverage: Multi-year coverage for domestic imported cars, light trucks, vans SUVs Contents: • Drive cycle procedures • EPA highway urban procedures where OE does not publish data • Keyless ignition procedures • OBDII overview • Known readiness communications issues • Notes tips Emissions EMISSION CONTROL SYSTEMS APPLICATION Coverage: Multi-year coverage for domestic imported cars, light trucks, vans, SUVs, medium heavy duty trucks Contents: • Accessing clearing trouble codes • Charcoal canister locations • Data link connector locations • EGR functional test procedures • Emission system application charts • Federal state air quality standards • Ignition timing adjustment connector specifications • Lamp reset procedures • List of vehicles that cannot be tested on a dynamometer • Listing whether a vehicle is FWD, RWD, 4WD or AWD • MIL information • Service reminders • Visual inspection procedures 9
- 12. www.motor.com 1.800.4A.MOTOR Medium/Heavy Trucks Heavy TruckRepair Manuals: Vol 12 Heavy Truck Wiring Diagram Manuals: Vol 12 HEAVY TRUCK WIRING DIAGRAM MANUAL Coverage: Multi-year coverage for medium heavy duty trucks • Autocar • Caterpillar • Chevrolet/GMC • Cummins • Detroit Diesel • Ford • Freightliner • Hino • International • Isuzu • Kenworth • Mack • Mercedes-Benz • Mitsubishi-Fuso • Nissan/UD • Peterbilt • Scania • Sterling • Volvo • Western Star CONTENTS: HEAVY TRUCK REPAIR MANUAL Coverage: Multi-year coverage for medium heavy duty trucks and components Vol. 1 CHASSIS REPAIR • Air bags • Air conditioning, cooling, electrical exhaust • Brakes • Chassis, engine electrical • Gasoline diesel engines • Steering suspension • Specification data Vol. 2 TRANSMISSION AXLE repair • Clutches transfer cases • Drive axles • Fifth wheels • Transmissions 1987-2010 Heavy Truck Diagnostic Trouble Codes Coverage: Multi-year coverage for medium heavy trucks Contents: • All codes for all commercial trucks • Description of sensors, their locations and how they operate MEDIUM heavy TRUCK ENGINE PERFORMANCE DRIVEABILITY MANUAL Coverage: Multi-year coverage for engine performance wiring information Contents: • Component locations • Emission application charts • Emissions control system repair • Fuel system diagnosis repair • Injection pumps • Specification data • Technical service bulletins • Vacuum hose routings 10
- 13. www.motor.com 1.800.4A.MOTOR When parts cross-referencesare required, people in the industry turn to FleetCross. From service locations to parts retailers and distributors to fleets and fleet management companies, FleetCross covers all facets of the truck industry. With hundreds of millions of original equipment and aftermarket part number crosses, FleetCross, by far, leads the industry in available cross reference parts information. The “All-Makes” data is: • available 24/7, providing the latest information when and where it’s needed • a complete system offering manufacturer catalogs in support of the cross references that contain manufacturer’s images, including off-highway and industrial equipment information • an intuitive system with advanced design that offers quick and thorough search results From aftermarket part numbers to illustrations, the system offers users a variety of selections to locate the parts information they need. Some of the options include: • Partial part number search • Manufacturer web site integrations • Tear away and duplicate tab technology • Advanced application installation, depending on environment • Web training and support with on site training available Visit www.motor.com for more information. ALL-MAKES FleetCross • Air bags • Air conditioning • Brakes • Computerized engine control system diagnosis • Drive axles transmissions • Emissions • Engine chassis • Engine electrical • Maintenance • Mechanical repair procedures • Performance... including trouble codes flow charts • Specifications • Steering suspension • Technical service bulletins • Wiring diagrams Contents: HEAVY TRUCK SERVICE dvd or online Coverage: Multi-year coverage for medium heavy duty trucks and components Medium/Heavy Trucks Users search by part number manufacturer’s name make-model-year 11
- 14. www.motor.com 1.800.4A.MOTOR SPECIFICATION GUIDE Coverage: Multi-year coveragefor domestic imported cars, light trucks, vans SUVs Contents: • A/C data • Ball joint specifications • Brake bleed procedures • Brake specification data • Cylinder head torques • Engine tightening specifications • Fluid capacities cooling system data • Front drive axle wheel lug nut tightening specifications • Lubricant data • Sensor specifications • Serpentine drive belt routing • Service reminder lamp reset • Tire inflation pressure data • Tune-up data • Valve timing marks • Wheel alignment data ALSO AVAILABLE: Specifications/Quick Reference HEAVY TRUCK SPECIFICATION GUIDE Coverage: Multi-year coverage for domestic imported medium heavy duty trucks Contents: • Brake data, sensor specificiations wheel alignment data • Cylinder head engine tightening specifications • Fluid capacities • Lubricant requirements • OE scheduled maintenance • Powertrain diagnostic trouble codes • Service reminder lamp reset procedures • Tune-up specifications • Valve timing marks Vintage Specification Guide WHEEL ALIGNMENT SPECIFICATIONS Coverage: Multi-year coverage for domestic imported cars, light trucks, vans SUVs Contents: • Adjustment procedures • Ball joint testing • Vehicle ride height tables BRAKE SPECIFICATIONS GUIDE AND BRAKE BLEED PROCEDURES Coverage: Multi-year coverage for domestic imported cars, light trucks, vans SUVs Contents: • Brake bleed sequence procedures • Brake rotor, drum machining service • Caliper mounting torque • Minimum lining thickness • Rotor parallelism, runout, thickness microfinish • Wheel bearing adjustment procedures • Wheel nut bolt torque 12
- 15. www.motor.com 1.800.4A.MOTOR Specifications/Quick Reference quick lubricationGUIDE Coverage: Multi-year coverage for domestic imported cars, light trucks, vans SUVs Contents: • Chassis lubrication data • Cooling system capacities bleed procedures • Engine lubrication data • Resetting oil service indicators • Vehicle lift points Lubrication recommendations GUIDE Coverage: Multi-year coverage for domestic imported cars, light trucks, vans, SUVs, medium heavy duty trucks, tractors small engines Contents: • Fluid capacities • Lubricant type • Transmissions, transaxles differentials TRANSMISSION FLUID SERVICE GUIDE Coverage: Multi-year coverage for domestic imported cars, light trucks, vans SUVs Contents: • Lubrication fluid specifications • Fluid inspection procedures for transmissions that do not have a dipstick • Custom transmission illustrations • Transmission gasket illustrations • Injection pumps • Service intervals FARM TRACTOR LUBRICATION GUIDE Coverage: Multi-year coverage of farm tractor, medium heavy duty trucks other farm equipment Contents: • Crawler tractors • Lubrication fluid specifications • Lubrication service points • Self-propelled farm implements • Skid steer loaders chek-lube Coverage: Multi-year coverage for domestic imported cars, light trucks, vans SUVs Contents: • Engine component locations • Fluid capacities lubricant type • Part numbers for over 30 brands of aftermarket filters • Severe service maintenance intervals • Tire size specifications • Transmission, differentials transfer case fluid capacities type • Vehicle lift points 13
- 16. www.motor.com 1.800.4A.MOTOR Specialty Repair AIR BAGQUICK REFERENCE GUIDE Coverage: Multi-year coverage for domestic imported cars, light trucks, vans SUVs Contents: • Arming disarming procedures • Collision inspection • Component location service • Component replacement after deployment TECHNICAL SERVICE BULLETINS ONLINE Coverage: Multi-year coverage for domestic imported cars, light trucks, vans SUVs Contents: • Subscription provides access to over 100,000 TSBs at your fingertips, with the ability to quickly search for the one you need TIMING BELT AND CHAIN REPLACEMENT GUIDE Coverage: Multi-year coverage for domestic imported cars, light trucks, vans SUVs • Accessory drive belt tension • Free-wheeling or interference fit engine chart • OE scheduled recommendations • Step-by-step replacement procedures • Timing belt inspection fit procedures • Timing belt labor time Contents: 14
- 17. www.motor.com 1.800.4A.MOTOR Specialty Repair hybrid maintenanceGUIDE Coverage: Multi-year coverage for domestic imported cars, light trucks, vans SUVs Contents: • Cooling system service • ECM/PCM programming • Fuel system cleaning • Starting information TIRE PRESSURE MONITORING GUIDE Coverage: Multi-year coverage for domestic imported cars, light trucks, vans SUVs INTERIOR PANEL REMOVAL GUIDE Coverage: Multi-year coverage for domestic imported cars, light trucks, vans SUVs • Component locations • Component replacement • Description operation • Diagnosis testing • Reset re-learn procedures • Tire fitment data • Tire service procedures • Wiring diagrams Contents: • Replacement procedure panels, instrument panels floor consoles • Exploded views showing hidden fastener locations • Door handles • Door lock cylinders • Illustrations showing the type of fasteners • Air bag system precautions Contents: 15
- 18. www.motor.com 1.800.4A.MOTOR Specialty Repair VIN GUIDE Coverage: Multi-yearcoverage for domestic imported cars, light trucks, vans SUVs Contents: • Decoding of the first eleven VIN code positions SECTIONING GUIDE COVERAGE: 2006 – 2011 Domestic and Imported Cars and Light Trucks CONTENTS: • OEM-Authentic Sectioning Procedures and Illustrations outlines the process in which a sectioned component is required to be removed and replaced. • Air Bag Precautions allows user to disarm and arm air bag system as required to complete a safe sectioning procedure as required. • Hybrid Battery Service Precautions allows the user to disarm and arm the hybrid battery system as required to complete a safe sectioning procedure as required. • General Sectioning and Special Substrate Data allows the user to understand the different metals used by OEM’s in their vehicle builds and how they interact with each other. air conditionER heater online COVERAGE: Multi-year coverage for domestic imported cars, light trucks, vans SUVs CONTENTS: • Complete air conditioner, cooling system and heater diagnostics, repair procedures and specifications 16
- 19. www.motor.com 1.800.4A.MOTOR Wiring Diagrams/Component Locations wiringdiagrams online Coverage: Multi-year coverage for domestic imported cars, light trucks, vans SUVs Contents: • Over 2.5 million wiring diagrms • OE-drawn wiring diagrams searchable by system or component • Easy-to-use vehicle selection by year, make, model and engine Component Location online Coverage: Multi-year coverage for domestic imported cars, light trucks, vans SUVs Contents: • Nearly 2 million component locations • Easy-to-use vehicle selection by Year, Make, Model and Engine • Component locations searchable by system or component • Component images textual locations 17
- 20. www.motor.com 1.800.4A.MOTOR Shop Management MOTOR SHOPDIRECTORTM LETS YOU: • Improve shop productivity • Increase production output • Enhance profits • Maximize resources • Eliminate financial waste with the click of a mouse you can: • Write work orders • Manage your inventory • Network • Maintain service histories • Export accounting data to Quicken, QuickBooks, Pro, Peachtree • Interface with MOTOR™/Alldata®, Alldata, MOTOR Electronic Estimating, Quick Quote, Real Time, WorldPac, Wrenchead Catalog, and Mighty Auto Parts! • PLUS MOTOR Parts Labor Guide *Our upcoming Premium Edition adds: • Internet Auto Parts (IAP) integration that will enable importing from O’Reilly, AutoValue, Bumper to Bumper, Car Quest, and many more. • NAPA ProLink integration • Activant part integration Shop Operations • Customer Search - By name, phone, plate, VIN, make, fleet number • • • Drag drop scheduling and appointment system • • • Service history/recommendations • • • Four labor rates • • • Bar code reader mechanical cash drawer ready • • • Up to 9800 standard tasks with labor, parts, comments menu pricing • • • Integrates with: MOTORTM /ALLDATA®, Alldata, MOTOR E-Estimating • • • Surcharges/Standard surcharges, automatic shop supplies charge • • • Direct editing of parts labor from work order view • • • Split labor capability for multiple technicians working on one job • • • On-the-fly editing of customer, vehicle and part information • • • Reminder message- service recommendations and account balance • • • Automatically create standard tasks (canned jobs) • • • Target profit indicator- Graphic indicator shows work order profitability • • • Work order print preview- Standard layout • • • Security system with 16 different security rights per user • • Automated time sheet system • • Ten level parts matrix pricing • • Modem based auto dialer • • Spell check with user definable customer dictionary • • Auto Text System- Automatically enter a sentence using three letters • • Vehicle specific standard tasks • management/marketing • Over 30 management reports • • • Technician productivity analysis by job • • • Compatible with Microsoft Office products • • • Work order customization • • • Over 100 customizable options • • • Automatic export to Customer Link • • • Upgradable to multi-user network • • • MOTOR marketing module • • Inventory management system • • Parts catalog integration with Wrenchhead, WorldPac Mighty • • Archive utility to transfer 300 work orders to archives • financial management • Profit analysis by type of service, work order, service writer technician • • • Track marketing sources for each customer • • • Un-post/Re-post utility to correct closed work order information • • • Export accounting data to Quicken, Quick books Peachtree • • • A/R billing terms, aging, interest charging payment Allocation • • Viewabl management Reports • • Warranty system with receivable billing • GS PRO * EDITIONFEATURE Take control of your shop with MOTOR Shop Director™ 18
- 21. www.motor.com 1.800.4A.MOTOR Shop Management Starter SERVICEWRITING Software The perfect solution for small shops • Seamless integration with MOTOR’s e-EstimatingTM • Import MOTORTM /ALLDATA® estimates convert to work orders • Great starter software for small shops • Basic work order, customer invoice service history shop management program • Quick Books interface available • Financial reports • Seamless upgrade to Shop Director™ EZ-WRITER FEATURES: Marketing is Easy with MOTOR Shop Director™ Marketing • By type • Using structured query language • By vehicle type or options • Labels • E-mail notification • Printed reports • Postcards • Data files CHOOSE YOUR CUSTOMERS: • By zip code • Needing specific type of service • Last time they were in for service SEND MAINTENANCE REMINDERS PROMOTIONAL OFFERS BY GENERATING: • TechLink automated time sheet system: record time at the task level for complete profit analysis • Technician productivity analysis • Vehicle search by plate, VIN, make fleet number • Transfer vehicles from one customer to another ADDITIONAL FEATURES: • Over 100 custom options to tailor Shop Director to your needs • Drag drop scheduling appointment system • Built in accounts receivable billing • Toll–free technical support help line (1 year included with all updates) Ten-level Matrix Pricing: Automatically apply different margins based on part cost! Here you see a part cost of $6.50 selling for $19.70; a 67% margin and 203% mark-up. 19
- 22. www.motor.com 1.800.4A.MOTOR Magazine Consistent Circulation Quality • #1circulated magazine among all service repair magazines • #1 in total units delivered among all audited service repair magazines • #1 in first-year qualified circulation among all service repair magazines Consistent Editorial Quality • #1 in average individual readership time per issue at 1 hour, 24 minutes • 90% of MOTOR Magazine recipients read MOTOR on a regular basis • Winner of numerous journalism and automotive media awards • Jesse H. Neal Award (2010-2009, Finalist 2011) • International Automotive Media Award (1999-2011) • APEX Awards for Publication Excellence (2001-2009) • TABBIE Awards (2006-2011) • Azbee Excellence Award (2007-2010) • 1.7 years: Average length of issue retention • 18.5 years: Average subscriber to MOTOR Your #1 Source for Automotive Aftermarket Information 20
- 23. www.motor.com 1.800.4A.MOTOR Magazine Industry leading content Dan Marinucci dmarinucci@motor.com Foreign Service 14March 2012 S ometimes we solve customers’ prob- lems with a good memory, careful visual inspection and old-fashioned luck. Other times the jobs we tackle require nearly every diagnostic tool, tester and instrument we own. This month’s saga reminds us that an accu- rate vehicle history may be the single most valuable tool at our disposal. What’s more, we may have to pry this information out of the cus- tomer. Finally, critical clues about vehicle histo- ry may be right under our noses but we over- look them and the fact that they beg answers from the car owner. This story concerns a first-rate shop I’ll call “Pauly’s Garage” for the purposes of this col- umn. A customer brought in a 2006 Toyota Corolla, claiming that its brakes were locking up. He said his wife drove the car most of the time and the symptom occurred during her routine commute to work. He also said he smelled burning friction material. Pauly verified the lady’s daily commute, then one of his techs drove the Corolla over that route again and again. Initially, no symptoms ap- peared. Then the tech put the car on a lift and visually in- spected the brakes. He found some rela- tively new-looking brake parts, and the brake fluid looked and smelled new. There weren’t any obvious signs of sticking or dragging calipers and he couldn’t find any kinked or crimped brake lines. Hindsight, they say, is always 20-20. Here, the customer’s comment about a burnt-brake odor could have been the first red flag about relevant vehicle history. How many nontechnicians can identify the smell of over- heated friction material? The second red flag could have been the new brake parts. Who in- stalled these parts? When and why? Meanwhile, Pauly couldn’t locate any service bulletins for the Corolla’s symptoms and a tech- nical hotline service didn’t have any specific fixes for it, either. Next, his tech tried recreating the symptom by “driving” the car on the lift and re- peatedly applying the brakes. That approach failed, so he retraced the driving route—but this time with many more brake applications along the way. Finally, he smelled overheated friction material and another symptom appeared. The front wheels began dragging, the right front seeming to drag slightly more than the left. The tech flushed the hydraulic system with fresh brake fluid and bled the system per Toy- ota’s recommended procedure. However, the front brakes still began dragging severely after their established road test. When he raised the car on a lift after each road test, the front wheels barely turned. Loosening the front bleeder fit- tings released the front calipers every time; then the front wheels spun freely. But after each road test, the front wheels would severely drag again. By this time, Pauly told me, they began sus- pecting a master cylinder problem. However, confirming this suspicion required eliminating everything outside the master cylinder—easier said than done. They double-checked the car for evidence of body/frame damage as well as bashed brake lines. After all, a crimped metal line or in- ternally flaking rubber brake hose could keep a caliper applied. Pay attention here if you’ve never seen this condition. A restriction inside a line or hose may trap brake application pressure be- tween the restriction and the caliper. Then the caliper won’t release the pads after the driver ap- plies and releases the brakes. However, opening the caliper’s bleeder fitting will release the pads. The tech connected a brake pressure gauge to each front caliper and then operated the brakes Whenyouserviceavehicle,howcertainareyouthatyou’retheonly onewho’severworkedonit?Unlessyouknowyouare,questioning thecustomertoobtainadetailedvehiclehistoryisamust. Photo:DanMarinucci If you suspect that a binding, corroded or misadjusted brake pedal mechanism is keeping the brakes partially applied, unbolt the master cylinder and carefully pull it forward just far enough to separate it from the firewall or brake booster. See if this trick releases the brakes. continued on page 16 18 March 2012 C armakers all over the world are acutely aware of the model year 2016. The models to be sold in the U.S. that year are on the drawing boards right now. By federal law, those vehicles must meet a Corporate Average Fuel Economy (CAFE) standard of 34.1 mpg. The 54.5 mpg you’ve heard of doesn’t go into effect until 2025. How are they going to do that? The numbers are not as scary as they might seem. Dan Edmunds, on the Edmunds.com website, says: “The 34.1 mpg CAFE target for 2016 is actually equal to only 26 mpg on a win- dow sticker. The talked-about 2025 CAFE stan- dard—usually described as 54.5 mpg—amounts to a figure of 36 mpg Combined [highway and city driving] on a window sticker.” It’s important to realize that this is an average number for the whole fleet. It will include a lot of thirsty trucks, big SUVs, some plug-in hybrids and, of course, a whole slew of average vehicles. Still, it leaves the carmakers right now searching for ways to get roughly a 5-mpg in- crease out of their vehicles. It would only be fair to note that changing politics and changing government rules go hand in hand. Depending on what the government does, who winds up getting elected and what the state of California does, these rules could be made ei- ther easier or harder to attain. That doesn’t help the car companies right now; they really are on the hook to do 5 mpg better and they need all the ideas they can get. The basic formu- las for calculating fuel economy are fairly straightfor- ward. The force needed to move a vehicle is equal to the mass times the acceleration (weight includes gravity, mass does not). Making a vehicle lighter or re- ducing its acceleration are two ways to reduce fuel consumption. You can also work on waste factors. Improving the efficiency of the engine and/or drivetrain, re- ducing aerodynamic drag and reducing lost en- ergy (exhaust, cooling and brakes) are all ways to improve fuel economy. You can also work to re- duce the energy associated with heating and cooling the passenger compartment. One particularly good area to look at is the unsprung weight of the vehicle. Unsprung weight is largely a function of the design of the vehicle’s suspension and the materials used in its components. This weight may be something of a trade-off between the wheel’s ability to follow bumps and the vibration isolation of those bumps. Bumps and surface imperfections in the road cause tire compression. This then puts a force on the unsprung weight. The amount of wheel movement is inversely proportional to the unsprung weight. What all this means is that a lighter wheel will follow the bumps better and have more grip, as well as a more constant grip, on the road surface. When you’re trying to make improvements in vehicle design, the sweet spot is when you can not only improve the part, but improve overall vehicle performance, too. Reducing unsprung weight is a way to improve vehicle handling and performance, and for designers to reduce weight in other areas of the suspension and the vehicle body because they have less impact and vibra- tion to deal with. Major development programs are going on right now in terms of how to reduce the weight of the tires and the wheels on which they’re mounted. The HTAS Corp., part of the Euro- pean tire company Vreedstein, is just one com- pany that’s currently working on weight-reduced tires. Gerlof Korte, who is in charge of the pro- ject, says the target is to reduce the weight of each tire by 4kg (9 lbs.), for a total vehicle weight Mike Dale Fueleconomystandardsarerampingup,afteryearsofstability. Asaresult,allrelatedsystemsmustbereevaluated.Weight-saving innovationshelpthecause,whilebenefitingotherareasaswell. mdale@motor.com Eye On Electronics PhotocourtesyBASF The seat back for an automotive interior is being simulated on-screen. The computer simulation allows material substitution to determine what will work best for the stresses the application will undergo. continued on page 20 • EDITOR’S REPORT by John Lypen Provides expert opinions on key issues and concerns for shop owners, technicians and the industry. • TRADE SECRETS by Bob Cerullo Bob uses case histories from his own shop to help show MOTOR shop owners the right way to approach and fix mechanical problems; right for both the customer and the shop. • FOREIGN SERVICE by Dan Marinucci ASE-certified, Dan uses hands-on experience to give readers expert advice on finding and fixing hard-to-diagnose import vehicle problems. • DRIVEABILITY CORNER by Mark Warren Mark is one of the nation’s leading experts on driveability. Every other month he offers insightful, sometimes unconventional diagnostic approaches to solving driveability problems. • TROUBLE SHOOTER by Karl Seyfert In a dialogue with technicians, Karl responds to questions seeking expert advice on specific problems. • PERFORMANCE PERSPECTIVES by Jim Gibson This column covers the emerging performance enthusiast vehicle service market. • NEWSBREAK - Late-breaking news about technology, companies, trends, legislation and regulations in the automotive industry. • SERVICE SLANTS by Tom Rosario OE Tech Service bulletins rank #1 on the list of information technicians want. • EYE ON ELECTRONICS by Mike Dale Every other month, Mike Dale, an automotive design engineer, covers the hot issues of electronic technology with a style that demystifies complex service with practical advice. 21
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