Car Mechanics - February 2016

25 of your toughest car problems solved by our experts
Beginners’ guide to Timing

Multimeters belt
change
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Air filtration
upgrades
Increase your engine’s performance
SAVING YOU MONEY SINCE 1958
DIY Twin-clutch 10
PAGE
Service SPECIAL
Citroën DS3
e-HDi full check
GEARBOXES
How they work
What goes wrong
DIY repairs
Power Dismantling a
steering wet clutch system
pipe swap Mechatronics
BMW MINI 1.6 actuator stripdown
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Editorial Martyn Knowles, Editor
Email: martyn.knowles@bauermedia.co.uk
Follow us on Facebook @ Car Mechanics
End of the manual?

X Are the days of buying vehicles – I’m sure you’ll
Subscribe to
a digital CM
X To guarantee receiving a copy of
a traditional automatic find it a fascinating read.
your favourite magazine each month,
gearbox with a torque I doubt you’ll find any other
why not take out a subscription
converter finished? Is the publication offering such
– turn to page 96 for more details.
manual gearbox on the in-depth knowledge on If you prefer to read the magazine
verge of being consigned this subject. digitally on your mobile or computer,
to the history books? Having driven the DSG we can now offer every issue on the
A few years ago, twin-clutch transmission following platforms: iPad, iPhone,
I predicted car-makers will in VAG cars, I can say it is a Win8, PC/MAC, Android and ZR4.
stop fitting the conventional wonderful invention, giving To subscribe to an Android version
manual gearbox by 2020. sharp gear changes and of Car Mechanics, you’ll need to visit
That’s just four years away kickdown. I planted the this website: http://bit.ly/1N1v0bU
and it may take a bit longer throttle of a VW Golf GTI at
than I initially suggested. 50mph while it was cruising manual ’box, but with broadly similar
But I still think the days in 6th and it swiftly stepped fuel consumption figures.
of the self-shift manual down two gears, making One proviso: twin-clutch gearboxes
gearbox are numbered. overtaking effortless. have strict recommended service
That’s why our lead The benefit of these schedules and it’s essential to meet oil
article in this issue is a gearboxes is the lack of a and filter change intervals. So, if you’re
special 10-page feature on the subject torque converter (which makes the looking to purchase a used vehicle,
of twin-clutch gearboxes. Even if you’ve autobox slower and heavier than an make sure you check any service
never driven one – although they are equivalent-engined manual). You should history for maintenance mileages and
now fitted to a surprising variety of get stronger, faster acceleration than a invoices to indicate appropriate care.
Man to Man
X Over the festive period, I stayed with family on the Isle of
Man (IOM). If you’ve not been before, it’s worth a visit to this
island located in the Irish Sea, measuring just 14 miles wide
by 33 miles long. Some IOM motoring laws differ from the
UK: there are no annual roadworthiness examinations for
vehicles over three years old and the maximum speed isn’t
60mph, it’s whatever you consider safe! But what makes
the IOM a bit special for any petrolhead is its passion for
motorsport, classic cars and, of course, its legendary TT The Isle of Man
circuit, which annually hosts rapid-action motorcycle racing. Motor Museum.
Apart from the variety of vehicles you see on the open
road – the islanders seem to drive a lot of Japanese imports The owners also gave me an exclusive tour of the
– there’s a couple of motor-related museums to visit, both museum’s restoration area, which is not on public display,
located in Jurby at the north of the island. where the various exhibits are prepared for display.
The Transport Museum at Jurby airfield houses a vast The Cunninghams are also interested in alternative
display of predominantly old Manx-related buses and lorries, power. Denis is trying to run a Toyota Prius MkII into the
as well as a few classic cars. You can clamber aboard an old ground – and failing, as it keeps on delivering! He’s also just
Routemaster bus and enjoy its unique ambience. Admission taken delivery of a fully-electric Tesla Model S with a P90D
to the museum is free, and it’s open from 10am-4pm every badge on the rear. In case you don’t know, this means it has
Sunday from November to Easter, then on Saturday, Sunday a 90kWh battery for a 6% increase in range over the top
and Tueday from Easter until October. 85kWh model. It also means there’s a ‘Ludicrous’ button on
Within viewing distance from the Transport Museum is the dash, which, when activated, can blast the Tesla from
the impressive, newly-built (well, from May 2015) Isle of 0-60mph in 2.8 seconds! Sadly, I didn’t get to test this!
Man Motor Museum. This is a fascinating private collection The Cunninghams’ latest adventure, though, is to try
of vehicles and motorcycles that has been assembled by to break the land speed record for a steam-powered
father-and-son Denis and Darren Cunningham over 40 motorcycle. They’ve built a bespoke bike – which we
years. The Cunningham’s portfolio is impressive and varied. witnessed warming up and riding away for a test run on open
Over 100 vehicles are on display, including some models I’d road – to compete later this year at Bonneville, USA.
never seen before, like the 1954 Greyhound bus. There are Admission price to the Isle of Man Motor Museum is £9.50
cars, buses, trucks, transporters, fire engines, ambulances, per adult, and it’s open from 10am-5pm every Wednesday to
including one-offs and prototypes. Many of the exhibits were Sunday. You can watch an interesting video of the museum
acquired for their uniqueness and rarity. here: http://bit.ly/1K8sbBF
www.greatmagazines.co.uk/carmechanics February 2016 pCar Mechanics 3

Contents
66 Citroën DS3 e-HDi
FEATURES 62 Full step-by-step service guide.
6 Dual-Clutch 72 Help!
Transmissions Eight pages of your toughest
Everything you need to know motoring problems solved.
about automated manual ’boxes.
80 Diagnostics Doctor
32 Multimeter Masterclass Your diagnostics queries sorted.
A beginners’ guide to the
essential workshop tool. CM visits Philips 83 Renault Clio 1.2 16v
Automotive Lighting
in Germany.
Probing the Siemens SIM32
62 CM Visit: Philips management system.
Automotive Lighting
We tour the German plant. BUYING
REGULARS
90 Mechanex 50 VW Golf MkV
Report from the 2015 trade show. Find the finest example of the 20 CM Insider
perennial German best-seller. The latest tools and accessories.
93 2015 Index
54 BMW Z4 60 Dealer’s Diary
Sourcing new and used parts. Steven Ward inadvertently
PROJECTS washes some soundproofing.
36 Volvo S60 2.4D WORKSHOP 64 Your Letters

Part Three: A new cambelt, water
pump and tensionsers are fitted. 24 Tales from 88 Our Cars
the Workshop Rob Bradshaw’s Peugeot 205s.
44 MINI One 1.6
Part Six: Sorting the suspension, 56 Modifications: Filtration 98 Ted Connolly
power steering and droplinks. Fitting performance air filters. Ted tries out the Jaguar XF.
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4 Car Mechanics pFebruary2016 www.greatmagazines.co.uk/carmechanics

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Instant expert
Twin-clutch
transmissions
This automated manual Volkswagen Group’s
gearbox is referred to as six-speed wet
clutch DSG is the
a twin-, double- or dual- most common twin-
clutch transmission
clutch transmission. encountered on the
Rob Marshall looks at used car market.
how they evolved, how

they work and how the
technology is faring in
the real-world.
C
o-developed by BorgWarner
and the Volkswagen Group,
for the car-maker’s transverse
front- and four-wheel drive
applications, the compact Direct
Shift Gearbox or Direktschaltgetriebe
(DSG) was released in 2003 and was
the first mainstream twin-clutch
transmission. At its introduction, the market, and
twin-clutch units could swap ratios is approximately
more directly and more efficiently the same size as
than conventional epicyclic-geared a dual-clutch gearbox.
automatic transmissions. They were also after he left employment with André
more efficient, due to their direct drive Citroën. Kégresse’s main priority was
and lack of a torque converter. While A shaky start not efficiency, but to relieve the tedium of
revolutionary at the time, traditional Although many people associate the changing gear, in the days when manual
automatics have since caught up. For twin-clutch transmission with German transmission synchromesh was in its
example, ZF’s nine-speed transverse manufacturers, its working principles infancy. This necessitated the driver to
autobox is said to be more efficient than were patented by a French military double-declutch and match the engine
any other twin-clutch transmission on engineer, Adolphe Kégresse, in 1935, speed with that of the transmission,
W Twin-clutch units
tend to possess internal
wet clutches on more
powerful cars, such as
this Mitsubishi SST,
fitted to the Evolution X
as an optional extra.
X Historically, dry
twin-clutches tend
to be used on less
powerful cars and
replacement dictates
careful shimming prior
to fitting. While more
efficient, they tend not
to last as long as the
wet types.

Twin-Clutch Transmissions
CLUTCH 1
How they work CLUTCH 2 OUTPUT TO FRONT
INPUT SHAFT 2 INPUT SHAFT 1 AXLE DIFFERENTIAL
X While cross-sections make them
OUTPUT TO
appear to be incredibly complex, REAR AXLE
twin-clutch transmissions are fairly DIFFERENTIAL
straightforward. Although often
described as two gearboxes in one, in
fact they combine two input shafts,
with one shaft fitting inside the other,
each of which possesses a clutch. 5th GEAR
4th GEAR
Input Shaft 1 hosts the odd-numbered
gears (1st, 3rd, 5th and reverse) and 6th GEAR 7th GEAR CENTRE
1st GEAR DIFFERENTIAL
Input Shaft 2 the even-numbered
2nd GEAR REVERSE 3rd GEAR
gears (2nd, 4th and 6th). When one GEAR
shaft is being driven, the second
This is a four-wheel drive Audi S-tronic dual-clutch unit, used on the Q7 model, which shares
shaft is prepared with the next ratio.
Volkswagen Group’s DSG layout. Note how Input Shaft 1 is situated within Input Shaft 2.
When a change occurs, Input Shaft
1’s clutch, K1, disengages as Input Shaft 2’s clutch, K2, valves, through which pressurised fluid is pumped, to
engages to deliver a seamless, smooth and swift shift. operate both the clutches and gear shift selectors.
Additionally, two output shafts are in constant mesh with The transmission oil acts not only as a hydraulic medium
the differential. A single reverse shaft is fitted, too. but also cools the wet clutches. Consequently, the oil returned
Inside the six-speed DSG, the clutches are actuated from the clutch packs can reach 100°C in normal use. Cooling
hydraulically by the Mechatronics unit, a combined ECU and is achieved by pumping the oil into a heat exchanger on top
a gloriously-simple hydraulic valve circuit that’s activated of the gearbox, through which engine coolant flows. A pair
by solenoids; Mechatronics is derived from combining the of filters keeps the oil free of contaminants – one of them
terms ‘mechanics’ and ‘electronics’. In essence, its ECU is located in the base of the transmission; the other is a
(sealed to the Mechatronics body) receives information renewable filter that is situated within a dedicated housing
relating to not only internal speed, gear position and in the cooling circuit, on top of the casing. Volkswagen
temperature but also parameters that are taken from stipulates an oil change interval (typically, every 40,000
the car’s other sensors, including those relating with miles, but check your handbook to be sure), at which point
the engine ECU, ABS, shift lever module and instrument the removable filter must be replaced. Any warranty claim,
cluster. This information is passed to the Mechatronic’s incidentally, is void unless this work has been carried out
ECU, which controls the solenoids that activate hydraulic with the correct lubricant and an OE-specification filter.
to avoid the embarrassing crunch of How motorsport for its rally Quattros, possibly thanks to its
spinning gears. His AutoServe gearbox R&D director at the time, Dr Ferdinand
placed two manual gearboxes within a improved the breed Piech, being a grandson of Ferdinand
single casing, along with a pair of clutches; Porsche expressed a strong interest Porsche. Recalling the experiences of
one engaged the odd-numbered ratios, in the technology and transferred its the 530bhp Group B Audi Quattro being
the other one managed the even gears. development to Stuttgart. Not only was fitted with the PDK transmission in his
The now defunct Automotive the transmission’s low weight, super-fast book, Walter Röhrl Diary: Memories of a
Products of Leamington Spa, gear-changes and high efficiency ideally World Champion, the rally ace reminisced
Warwickshire, revisited the concept suited to economy-minded consumers, about the difference the transmission
40 years later, when it fitted various but the elimination of acceleration made: “The PDK made the acceleration
production cars (including the original lapse and the reduction in drivetrain even crazier… I could change gear at full
Ford Fiesta) with its experimental power losses made them a tantalising throttle, without any decrease in pulling
Hot-Shift gearbox in the 1980s. The proposition for motorsport. After two power, or any falling-off of turbo boost.”
work was overseen by Harry Webster, years’ intense refinement for racing Despite this, when Audi withdrew
former technical director of British purposes, the Porsche Doppelkupplung from Group B rallying a year
Leyland, just prior to his retirement. (PDK or ‘double clutch device’) was born. later, it also abandoned any
The Hot-Shift project intended to not At around the same time, the further PDK development
only address the inefficiencies of the technology was also being utilised by Audi programmes.
conventional automatic gearbox’s torque ROB’S
converters, especially when coupled to TOP TIP
low-powered, smaller capacity engines,
but also to create an automatic-type Never try to cure
an oil leak by using a transmission
transmission using manual gearbox stop-leak additive. The types
components, which would simplify containing glycol will swell all
mass production, because of increased rubber seals within the unit.
economies of scale. A main priority
was to ensure a seamless gear-change, Getting the oil level right
without disconnecting drive from the is essential. Follow any
instructions carefully if
engine, so, like the pre-WW2 AutoServe, doing the work at home.
the heart of the Hot-Shift system was Pictured is a cross-section of
two manual transmissions and a pair of the combined oil drain/level
clutches, housed within a single case. plug on the six-speed DSG.

clutch DSG is the most likely unit to both fuel economy and driving pleasure.
Entering the real world be encountered in the used car market Cramming more gears within the
Porsche appeared to lose interest, too, today, this article focuses on that variant. compact casing is also a possibility;
but the company’s road versions of the The ‘twin-clutch’ moniker references Volkswagen was developing a 10-speed
PDK were co-developed later with ZF a pair of wet clutches but, to make the DSG unit, which was shelved at the end of
Friedrichshafen AG. The production gearbox more efficient for engines last year, possibly due to other unexpected
reality debuted in 2008, over five years with lower outputs (initially less than factors that are making demands on the
after BorgWarner/Volkswagen Group 250Nm), dry clutch packs have been company’s cash resources.
introduced their six-speed DSG to the used. Most notably, Volkswagen Group Other car-makers also sell models
world, beneath the bonnet of the Audi introduced the twin dry clutch seven- with twin-clutch transmissions, but
TT 3.2-litre V6. While Audi had called speed DSG for its 1.4- and 1.6-litre the majority of them were developed in
its system S-tronic since 2006, it was petrol models. The reasoning behind collaboration with major transmission
basically the same as Volkswagen’s DSG, subsequent developments, which suppliers, such as ZF, LUK and Getrag.
although a seven-speed longitudinal include the use of less oil, electric (not Such units share the same operating
version was developed for some four- mechanical) oil pumps and clutch principles as DSG. The second most
wheel drive applications and varies only friction materials with improved heat popular version tends to be the six-speed
in internal details, the main difference transfer properties, has been to increase PowerShift unit, which can be fitted with
being two internal oil circuits. As efficiency even further, while driving either wet or dry twin-clutch packs, and
Volkswagen Group’s six-speed, wet down tailpipe emissions and enhancing is fitted to a variety of Volvos and Fords.
DSG: What goes wrong?

X Despite being a remarkable engineering feat that
has been mass-produced in millions of vehicles, many
unhappy customers have vented their ire at Volkswagen
for premature DSG failure. However, one issue might be
related to car salespersons failing to communicate the
subtle differences between automatIC and automatED
manual transmissions and that certain traditional
‘slush-box’ driving habits can damage a DSG.
Inside the wet-clutch DSG, the friction material, used on
the clutches’ multiple plates, is immensely resilient to wear.
Strangely, the steel plates on which they bear tend to suffer
more, such as developing high-spots and scores or ‘blueing’
with overheating. Therefore, many clutch problems can
be blamed on either excessive heat, an internal hydraulic
pressure problem (usually caused by the Mechatronics)
or poor driving, such as holding the car on a hill with just The latest dry twin-clutches handle more torque. Launched in late
the throttle. In the absence of lubricant, the dry clutches 2015, Suzuki’s six-speed, twin dry clutch TCSS can handle up to
320Nm, instead of the 250Nm of early units from other car-makers.
that are fitted to lower-powered models tend not to last as
long. Replacement parts appear to be restricted to trained is impossible. The Mechatronic’s 11 solenoids can fail but
specialists, because unless the initial adjustment is made a simple diagnostic test usually (but not always) pinpoints
correctly, which requires shimming to obtain the optimum the problem. Clever failsafe modes are also incorporated
clearance between the release bearing and pressure plate, within the Mechatronics. Should a problem be detected
it can destroy the twin-clutch unit very quickly. on Input Shaft 1, for example, the hydraulic pressure is
With wet-clutch types, increasing engine torque tends isolated from the faulty gear sets/clutch and the gears
to dictate that the internal hydraulic pressure is similarly on Input Shaft 2 will be used as a back-up. The opposite
increased, to reduce the chance of wet clutches slipping situation would occur if Input Shaft 2 developed an issue.
and overheating. Any weakness in the hydraulic system The transmission might still function in the event of an
reduces the clamping force of the clutches, causing them internal sensor failure and the resultant logging of a fault
to wear out prematurely. If an engine is tuned (or the car code. However, the transmission might select a single gear
is used frequently for towing), specialists recommend that only as an emergency measure. Yet, you can still identify
the transmission’s cooling system be upgraded, if possible. minor faults, which could develop into more serious issues.
If oil temperatures exceed 145°C, the DSG will shut down Judder is a common complaint, noticeable when moving off.
and will not select any ratio until it has cooled. If it occurs in normal operating temperatures, suspect an
The entire transmission can be ruined if a corroded heat internal pressure issue with the Mechatronics or the twin-
exchanger permits engine antifreeze/glycol to contaminate clutch pack, or else a pressure loss within the transmission
the hydraulic oil. Apart from destroying the lubricant’s case. Mechanically, the input shafts (one of which is hollow,
viscosity, it also strips the friction material from the clutches allowing the other one to pass through it) are reliable, other
and swells the many rubber components, including the seals than the rear end bearing that can deteriorate on the six-
on the pistons that activate the pair of clutches and those speed DSG. The two output shafts tend to be trouble-free.
within the hydraulic side of the Mechatronics. Even without However, due to the higher rotational speeds involved, 1st,
the ingress of antifreeze, the electric and hydraulic parts 2nd and 3rd gears are fitted with three-piece synchromesh;
of the Mechatronics unit are also prone to failing. Voltage the other forward gears utilise a simpler cone system.
spikes, caused by either a dying battery or careless jump- Crunching on the down-change is a well-known problem
starting, can damage the sealed ECU, DIY repair of which that afflicts the lower ratios.

DIY repair propositions Wet clutch or

dry clutch?
X Surprisingly, the DIY mechanic can over-complex, but that the non-availability X While both wet and
undertake certain repair tasks, including of certain components can restrict repair dry types of twin-clutch
oil and filter changes and removal of the options. The following procedure details the transmissions are operated
Mechatronics unit. To guide us through a dismantling exercise that is specific to the six- hydraulically, the friction
full strip-down of a Volkswagen Group six- speed wet clutch DSG, provides an overview surfaces of wet clutches are
speed DSG unit, we enlisted the services of of how the unit works and which components splashed with transmission
oil, while dry clutches are not
VMTP Midlands Limited of Staffordshire. The are known weak-spots. As the gear sets are
lubricated by gear oil, as with
company’s twin-clutch specialist explained similar to those fitted to conventional manual
conventional clutch plates.
that the main issue is not due to the unit being transmissions, they will not be stripped.
DSG WET CLUTCH DISMANTLE
Unbolt and remove the aluminium heat exchanger from the The Mechatronic’s electrical connector is delicate – even static
1 transmission, noting any oil seepage and inspecting the 2 electricity can damage the ECU – so wear gloves when
condition of the two rubber seals within the casting’s inlet and outlet. handling the unit and do not touch the electrical pins.
ROB’S
TOP TIP
If you suspect
input shaft bearing noise
on a six-speed DSG, be
wary as the resultant
excessive end-float can
damage the clutch drum
assembly, if ignored.
Use a 6mm Allen key to remove the flange. The bronze cone The aforementioned cones bear against the differential centre
3 should be inspected, once withdrawn from the casing. The 4 as a very simple limited slip differential of restricted capacity.
same process is repeated on the other flange. If a broken cone is discovered, check that the area is undamaged.
If you intend to separate the two casing Remove the Mechatronics unit, by Pictured is the sump removed and the
5 halves, remove the screws (as shown). 6 unbolting the sump bolts, prior to 7 oil drained, with the valve body half
They retain a plastic oil pipe within the prising the sump from the transmission. of the Mechatronics unit exposed. When it
transmission, which will otherwise be broken, Take great care not to damage the plastic fails, the diagnostic fault code relates to the
when the gearbox casing is separated. electrical socket. pressure adaptation being out of limit.

Twin-Clutch Transmissions ROB’S
TOP TIP
After rebuilding,
DSG WET CLUTCH DISMANTLE continued the transmission must be
calibrated electronically.
For more details, consult
http://bit.ly/1mBmuY2
Disconnect the wire from the Mechatronics unit to the input Remove the bolts that hold the Mechatronics unit to the main
8 speed sensor, which measures the speed of the clutch drum. 9 transmission case, noting their original locations, because
The drum attaches to the dual-mass flywheel. See Step 16. some of the holes drilled into the casting are unthreaded.
The Mechatronics unit must be If the reverse shaft’s speed sensor is Remove its securing bolts, lift off the
10 removed squarely, not at an angle, 11 snapped off, the Mechatronics unit is 12 end cover and its moulded gasket.
and handled as pictured. This is because scrap and new replacement costs start at Generally speaking, the pumps are very
the long, plastic reverse shaft speed sensor more than £600. See the separate section reliable – pressure drops tend to be the
extension reaches deep within the case. on DIY Mechatronics repairs. fault of the Mechatronics unit.
Beneath the cover, you will see the Unscrew its bolts, remove the oil pump Detach the circlip and retrieve the
13 oil pump and the reverse shaft 14 cover and gasket. Beneath it lies the 15 shim. Unfortunately, another circlip
sensor pick-up, the speed of which is input shaft bearing, which is known to wear holds the bearing in place behind the
measured by the Mechatronic’s long and become noisy, audible as the car moves casting, so the gearbox has to be split. The
plastic sensor extension. off from a standstill. splined oil pump driveshaft lifts out.
Now that the Mechatronics unit has Even if you are especially gentle, the Undo the bolts that hold the casing
16 been removed (see Step 10), the input 17 reverse speed sensor ring can distort. 18 halves together. Being made of steel,
speed sensor’s securing bolt can be undone Fortunately, new replacements are both they can corrode into the alloy casing, Continued
and the assembly withdrawn from the sump available and inexpensive – not replacing which makes them tricky to unscrew and on page
casting. Store the sensor in a safe place. it is a false economy. their Multi-Spline heads damage easily. 12

DSG WET CLUTCH DISMANTLE continued VW UK & DSG

warranties
X While continuous improvements
have been made to the
software and oil quality, official
manufacturer/importer warranties
on DSG gearboxes have increased
to 5-10 years in certain export
markets, possibly for those cars
that operate in warmer climates
(or territories with different legal
In this case, the rear housing is removed To access them, the main clutch cover
frameworks). While the transmission
19 from the gear set, necessitating the 20 has to be removed, by taking off the warranty has not been extended
unscrewing of the bolts located within the large snap-ring/circlip. Once the main cover beyond the standard three years for
bellhousing. However, further bolts are has been lifted away, the K1 and K2 wet clutch British cars, we have experience of
situated behind the K1 and K2 wet clutches. assembly is revealed. Volkswagen UK offering generous
goodwill payments for cars
outside of the importer’s statutory
ROB’S warranty period. The exact sum
TOP TIP is reviewed on a case-by-case
Removing the basis and depends on a number
Mechatronics unit can be done of parameters, including whether
with the ’box in situ, but access can or not the car has been serviced
be problematic. The original V6-
by a main dealer (this stipulation
powered Audi TT is a case in point.
does not break Block Exemption
After removing another regulations in non-warranty claims)
21 snap-ring, plus a centre circlip and its mileage.
(inset picture), the entire K1 and For example, the author was
K2 wet clutch assembly can be involved in a specific case which
withdrawn from the input shafts. concluded with VW UK backing
70% of a complete DSG gearbox
replacement cost on a seven-year-
old VW Golf 2.0 that had 80,000
miles recorded, which had suffered
from engine coolant contamination
that ruined the entire gearbox. The
owner funded the remaining cost
that totalled approximately £1000.
The main reason cited by VW UK
for its goodwill decision was that
the car in question possessed full
main dealership service history.
Therefore, buying a used car with
This is the other side of the clutch Each of these clutches consists of full franchised dealer service history,
22 drum, revealing the large K1 clutch 23 multiple friction plates (which are may give some safeguard if there
and the smaller K2 clutch inside. The friction directional) and ‘steels’. Inspect the friction is a suspicion about the health of
plates are directional and must not be refitted material for wear and the steels for high the twin-clutch transmission.
so that they rotate in the opposite direction. spots and evidence of overheating (‘blueing’).
Some types of dual-clutch gearboxes Once the remaining securing bolts Pictured here is the in-sump oil filter,
24 use a twin dry plate clutch assembly, 25 are removed, the two halves of the 26 which must be renewed every time the
which combines the clutch plates, release transmission can be separated, but take DSG transmission assembly is split, even if it
bearing and pressure plate in one. They tend care to ensure that the bottom half does looks clean and serviceable. Failure to do so
to wear more quickly and burn out faster. not topple over. is also a false economy.

Referring to Step 15, retrieve the input The input shaft bearing can be The gear sets’ lower ratios’ three-piece
27 shaft bearing’s other shim, which is 28 pressed from its shaft after removing 29 synchromesh also wears, causing a
situated on the inside of the casting. Do not its retaining circlip (as shown). It is a false notable gear crunch on downshifts. The
mix up the inner and outer shims, as they economy not to renew this fault-prone part dismantling procedure is very similar to
may be of a different thickness. when the gearbox is split. that of a conventional manual gearbox.
Obtaining spare parts for the gear sets is Pictured is the ‘Park’ mechanism, the The gear set cannot be removed from
30 likely to be problematic. For this reason, 31 internal lever of which locks against the 32 the transmission casing until, working
certain enterprising companies buy complete differential. Aside from damage caused by inside the bellhousing, the reverse shaft circlip
new gearboxes and dismantle them for parts. abuse, the mechanism is reliable. is removed with the washer plate and bearing.
The PowerShift HYDRAULICALLY

TWIN WET CLUTCHES CONTROLED SHIFT
X Launched in 2008, as result of the MECHANISM
Ford Motor Company and Getrag pooling
their resources, the PowerShift debuted
OIL PUMP GEAR POSITION
in a series of small-engined Volvos SENSOR
and Fords. It shares the same working
principles and general layout of the
DSG, including a dry twin-clutch variant
being used for the smaller engines from
approximately 2011. Those units tend HIGH
still to be under warranty. As a result, not PRESSURE
that many specialists have seen them, OIL FILTER
as yet. However, the wet clutch versions INNER
have their dual-mass flywheel housed INPUT SHAFT
(1st, 3rd, 5th &
within the gearbox casing, particles from Reverse gears)
which clog the internal filters when it MECHATRONIC
fails. Road-testers tend to report that the UNIT
OUTER
unit is not as enjoyable as Volkswagen’s INPUT SHAFT
(2nd, 4th & 6th gears)
versions and rebuilders claim that the
PowerShift is not as durable.
Known problems include the end plug coming out of the valve body on the
Mechatronics (pictured right on a 6DCT wet clutch version). Bearing failure tends
to strike on vehicles fitted with the 1.6-litre diesel (DV6) engine. PowerShift wet
clutch steels do not tend to last as well as DSG types either, possibly down to a
different lining composition. Its Mechatronics also tends to suffer from hydraulic
pressure failure and electrical spikes. Parts availability is restricted, meaning
certain faults can only be cured by a replacement gearbox.
It is alleged that some dealers did not inform owners that the unit had a specific maintenance interval, mainly involving
oil and filter changes, the subsequent omission of which voided the manufacturer’s warranty.

DSG WET CLUTCH DISMANTLE continued
Carefully withdraw the input, output and reverse shafts, Left-to-right is the output shaft hosting 1st, 3rd, 4th and 2nd
33 along with the differential and the gear selectors from the 34 gears, then the two-in-one input shaft and the other output shaft
transmission case. It is a fiddly operation! for reverse, 5th and 6th gears. Pictured far right is the reverse gear shaft.
Prevention is
better than cure
X Never forget that twin-clutch
transmissions are automated
manuals; certain practices that
are acceptable for conventional
transmissions might cause damage.
Holding the car on an incline with the
throttle, as well as erratic and violent
use of the controls, can shorten the
life of the internal components, as
Check the condition of the three speed Four magnetic gear position sensors
will sustained very high-speed and 35 pick-up rings. Two of them are situated 36 are mounted on the gear selectors,
full-throttle applications, which tend
to overheat the transmission fluid,
on the input shafts (as shown). The reverse sensed by the pick-up extension on the
especially in very hot weather.
shaft hosts another one. The clutch drum Mechatronics. The parts are positioned as if
housing is another pick-up. they were fitted within the case.
Never drive into water deep enough
to risk soaking the delicate electrical
connections and check the engine bay
for leaks. A failing dual-mass flywheel
(DMF) can shorten the life of the gear-
sets and their bearings. As with manual
transmissions, badly worn DMFs fall
apart in use and fragments can punch
holes into the transmission case.
In terms of the electrics, you
must maintain sound earth lead
connections. A healthy battery and
judicious jump-starting will reduce the
chance of damaging voltage spikes
that can corrupt the Mechatronic’s
ECU. Maintenance-wise, check the Working inside the case, remove the When reassembling the transmission,
engine coolant level regularly and be 37 piston assemblies, four of which are 38 replace all internal gaskets, which will
wary if it falls without an obvious leak; located within the front case (as pictured). reduce the risk not only of transmission oil
it could end up within the transmission. A further four are situated in the rear case. leaking out but also of an internal pressure
Change the coolant regularly Do not score the cylinder bores. leak affecting operation.
with fluid of the recommended
specification, to reduce the risk of the
heat exchanger corroding internally,
causing antifreeze to contaminate the
gearbox. Make sure that the radiator
does not become blocked internally.
Some companies, including VMTP
Midlands, possess glycol testing kits,
which will identify its presence.
Always adhere to any oil change
intervals, never skimping on lubricant
and filter quality. Ensure that your
transmission has the latest software
uploaded into its ECU and that any
relevant manufacturer Technical Service
Bulletins (and recalls) have been carried On fitting the clutch, shim kits are Always renew the front clutch cover, a
out. Finally, be wary that, as with any 39 available to control the input shafts’ end- 40 part that is included in a replacement
‘automatic’, an underperforming engine float, too much of which can damage the rear clutch kit. It is wise to also replace the Continued
will influence the gearbox’s behaviour. face of the clutch drum. Damage can also be dual-mass flywheel and the twin-clutch on page
caused by excessive input shaft bearing wear. assembly, plus the differential seals. 16

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Mechatronics DIY overhaul

SOLENOID GUIDE
CONDUCTIVE PLATE
N215 K1 clutch pressure control
N233
N216 K2 clutch pressure control
N217 Main line pressure control – N92
when faulty, the transmission
operates at maximum pressure
N91 4th and reverse gear
shift-solenoid
N88
N90 2nd and 6th gear shift-solenoid BLOW N89
N89 3rd and neutral shift-solenoid
N88 1st and 5th gear shift-solenoid N217
N371 Pressure control solenoid N218
– only 3rd and 1st gear of the
odd-numbered ratios can be
selected on failure
N371
N233 Pressure control solenoid – only N90
2nd gear of the even-numbered
ratios can be selected on failure
N91
N218 Clutch cooling pressure control
solenoid – failure causes N215
overheating of the clutches and
difficult gear selection when cold N216
N92 Multiplexer solenoid – allows the
shift solenoids to look after two WITH THANKS TO:
gears. Look for the gearbox being VMTP Midlands Ltd,
reluctant to shift out of gears, 10 Conduit Road, Cannock,
especially when cold, if this fails Staffordshire WS11 9TJ.
BLOW Pressure relief valve Tel: 01543 270555
www.vmtp-midlands.co.uk
(limit is approximately 33 bar)
X Typical faults that involve the Mechatronics include you might wish to investigate repairing the Mechatronics
a complete loss of drive, flashing PRNDS gear selector unit yourself, but you will need to balance the time/
lamps, violent engagement of 1st gear, hesitation on cost element of simply renewing the part with removing,
changing ratios and juddering, when pulling away as the dismantling and refitting the Mechatronics unit multiple
clutch engages. Accurate diagnostics must be carried out times using trial and error. As the ECU is sealed, DIY
before suspecting the unit. Yet, electrical interrogation electrical repairs are impossible, although some
does not always identify the source of hydraulic problems. specialists can replace the speed sensors. However, you
For example, a code indicating failure of the N217 can replace solenoids, providing that the replacements
pressure control solenoid might be correct, but the source match. Their resistance can also be checked.
could be a faulty pressure regulator hydraulic valve and The hydraulic block is also eminently serviceable and
not the solenoid. As the Mechatronics can be removed the following steps give an overview of the dismantling
from the car, in most cases with the transmission in situ, procedure and how to replace the filters and rubber seals.
MECHATRONICS DISMANTLE
Turn the unit over, remove the four

2
1 This is the ECU portion, which is sealed
to the case. It is advisable not to
T20 screws from the hydraulic side
and fold over the connections plate, being
3 Take off both the K1 and K2 clutch
pressure solenoids, one at a time, by
interfere with it. careful not to damage it. removing their securing screws.

Both solenoids share a filter screen, which can be removed To access one of the securing bolts that holds the two halves of
4 and discarded – a new part must be fitted. 5 the unit together, remove the solenoids that are in the way.
Note that solenoids N217, N218, N233 Beneath some solenoids, note the The rubber parts can be renewed with
6 and N371 are fitted with O-rings on 7 O-ring and cap. Beneath the cap is a 8 those in the kit – don’t lose any parts,
their tips, which can be replaced. ball, spring and a smaller O-ring. nor damage the chamber’s internal surface.
Be wary that some solenoid internals might come apart as they Unscrew the remaining bolts that hold together the two halves of
9 are removed. Ensure they are reassembled correctly. 10 the hydraulic block; discard and renew the gasket.
Ensure that the three solenoid dampers Take out and clean the main multiplex
11 13
do not fall out and become lost. As
they are pulse width solenoids, the dampers
12 Lift out the filter blocks carefully and
check them for any residue. The gasket
valve. The pressure regulator and
clutch cooling valves are located in the two
cushion the oil flow. kit should include replacements. separate chambers above it.

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used with a microfibre cloth,
Clean, Dash & Glass and All Wheel Cleaner. For your chance to
it allows dirt particles to be win one, please complete the coupon on page 23. helping your
lifted into the cloth without vehicle to stay
damaging paintwork. as keeping the dashboard that actively removes heavy cleaner between
X Liquid Shine non-greasy and UV-protected. brake dust deposits and turns washes. Winter
(500ml; £9.99) Polymer technology traps red when it is ready to be Coat can be used
A synthetic polymer wax dirt in cloths to leave surfaces rinsed. The non-acidic formula on the entire
unlike any traditional car clean on the first pass. will not damage alloys, decals vehicle, including
waxes and which produces a X Fresh Shine or wheel nuts, and can be left glass, plastics,
long-lasting, mirror-like shine. (500ml; £5.99) on alloys for longer compared alloys, steel and
Contains no powders, so it will Spray liquid that quickly to more aggressive acidic or rubbers, and has
not leave a white residue, and and easily restores the alkaline cleaners. a durability of up
can be used on all exterior lustre to interior plastics. X Headlight Kit Restorer to six months,
surfaces except glass. Incorporates a pleasant air (£16.99) meaning it will last
X Dash & Glass freshener in five fragrances Includes fine sanding pads well into spring.
(500ml; £5.99) – Citrus, Strawberry, Vanilla, and an ultra-fine polish It is designed for simple
An innovative 2-in-1 product Outdoor and New Car – that that gives fast and effective application and will
that means you never need to last up to eight days. restoration of milky or guarantee stunning results.
worry about overspray! The X All Wheel Cleaner discoloured headlights, as It even comes with a Product
ClearVue formulation leaves (500ml; £6.99) well as protecting against Performance Money Back
windows streak-free, as well A unique PH-neutral cleaner future yellowing. Guarantee, so if you can
find a similar product that
performs better, you get
your money back.
Power Maxed Winter Coat
(500ml) retails at £14.99.
For more information, visit
www.powermaxed.com
Click & Collect vehicle spares, workshop tools and leisure

equipment at over 400 independent member stores. www.caarparts.co.uk
20 Car Mechanics pFebruary 2016 www.greatmagazines.co.uk/carmechanics

CM Insider
1
TO
AlcoSense GIVE
AWAY
NEWS IN BRIEF
Pro breathalyser and 20%
discount
X With over 18.6% of drink-drive for all
accidents happening the morning after, readers
when drivers may be unaware they still
have alcohol in their system from the night
before, an accurate personal breathalyser
is essential to tell you when alcohol has
cleared from your system.
AlcoSense recently visited the CM office
to give us an impressive demonstration of its
new AlcoSense Pro breathalyser, comparing X Any Country, Any Limit The AlcoSense
the results from the handheld unit and one Pro is the first breathalyser to work with any X The latest workshop
of the £13,000 professional breathalysers limit anywhere in the world. Just select from manuals from Haynes
used by the police. The Pro model uses an the pre-loaded list of overseas territories include volumes on the
Porsche 917 from 1969
121mm2 version of exactly the same sensor and the device will automatically set itself to
onwards and the Honda
as several police breathalysers, offering meet local legislation and measurements. Civic from 2006-2012.
levels of accuracy, reliability and consistency X Security The technology in the Pro Further details from
not previously available in a handheld device. unit ensures that you are never given an www.haynes.co.uk
In the side-by-side comparison, the incorrect under-reading.
AlcoSense Pro proved to be as accurate Designed in the UK, the AlcoSense Pro is X Sealey has launched its
New Year Sale, which runs
as the larger machine, as well as offering a available at a launch price of £129.99 until
until February 29. You can
number of innovations over other compact January 31, 2016, and £149.99 thereafter. It enjoy up to 60% discount
breathalysers. These include: is available from Halfords stores nationwide off selected tools,
X Estimated Time Until Sober or online at www.alcosense.co.uk accessories and workshop
As well as giving a detailed alcohol equipment. Visit www.
We have one AlcoSense
WIN
reading, the Pro will give an estimate sealey.co.uk or ask for a
Pro to give away to a CM special sale brochure from
of the time until you will be safe to reader. For a chance to your local Sealey stockist.
drive again. It can also be set up to win it, please complete
automatically alert you when you the coupon on page 23. X Engine care specialist
have reached this estimate. Cataclean has finalised
X You can take advantage of an exclusive 20% discount
X BlowCoach Gives live on any AlcoSense breathlyser for CM readers between
a major agreement that
on-screen feedback to ensure will see one of its flagship
January 15 and February 29. When you order from the products, Cataclean
that you are testing correctly alcosense.co.uk website, simply enter the code CC20 Diesel, being carried by
every time, and gives advice if at the checkout and the discount will be applied to your the RAC’s entire fleet of
you blow incorrectly. order. One unit per customer only. 1400 UK patrol vehicles.
V-Maxx Universal Machine Mart

Adjustable Droplink Kit shopping spree results
X Anyone who likes to properly set up X Back in the October issue of Car Mechanics we ran
their suspension will know that when you a competition to win five shopping sprees at Machine
lower a car, the resulting position of the Mart, worth up to £4000. The lucky winners have
anti-roll bar is moved from its optimum been announced as:
plane. With this kit, you can set the new 1st Prize £1500 Allan Huggins, Rochdale
links to take into account the precise drop 2nd Prize £1000 Darren Hawkins, Maidstone
you have made, or, if you prefer, replace 3rd Prize £750 Sandra Gould, Hull
your non-adjustable OEM versions on a 4th Prize £500 Bill Hamilton-Smith, Loughborough
standard ride-height vehicle. And the kit 5th Prize £250 Roger Docksey, Nantwich
fits 95% of the most popular tuned cars. A Machine Mart spokesperson said: “It has been
The kit contains three pairs of different with great pleasure speaking with all the competition
bodies, along with four high-precision winners and hearing about the projects they are
jointed ends. These will replace the OEM parts on many European and currently working on. A lot of the winners said they
Japanese cars, making for an easy swap. Using a convenient opposed ‘never win anything’, so it was nice to give them a good
thread design, these links can easily be adjusted once fitted to allow for selection of quality Clarke tools prior to Christmas.
real precision during chassis set-up. All parts are zinc-coated for a long The store managers welcomed each winner into
life, even on Britain’s salted roads. Machine Mart superstores across the country and
The V-Maxx Universal Adjustable Droplink Kit retails for helped choose the right tool for the job. We hope all the
£43.00 + VAT and can be ordered from www.v-maxx.co.uk winners enjoy their new tools for many years to come.”


CM Insider
NEWS IN BRIEF NEW from LASER TOOLS

Laser Circlip Pliers
X Designed to permit easy, safe and positive removal and
insertion or circlips on machinery and equipment, Laser circlip
pliers are available for either internal or external circlips, each
with either straight jaws for use where access is easy and bent
jaws where access is restricted. There are four sets of pliers
X Automotive tool brand in the range, all manufactured to DIN standard 5256 and all
Angry Jester has rolled 175mm in length and with a jaw width of 19mm-60mm.
out the first of six new Part no 6156: straight jaws for internal circlips Part no 6158: straight jaws for external circlips
liveried vans that will
act as mobile product Part no 6157: bent jaws for internal circlips Part no 6159: bent jaws for external circlips
showcases around the
Laser circlip pliers are priced at £14.33 each inc VAT.
UK. The VW Crafters are
kitted out with more than
160 items of equipment,
including the full Angry Laser Circuit Tester
Jester programme plus X This new circuit tester from Laser Tools (part no 6115)
a range from The Parts is suitable for 6-, 12- and 24-volt automotive systems.
Alliance’s leading tool
More than a standard circuit tester, it features a clear and
supply partners. It brings
the number of vans in the easy to read digital display that reads from 5-28 volts
fleet to eight, building up with an accuracy of plus or minus 3%, and bright LEDs to
initially to cover 82 of the indicate power (red) or ground (green). The coiled cable
151 branches that form stretches out to a useful three metres. The Laser circuit
The Parts Alliance Group. tester has an RRP of £45.58 inc VAT.
X German suspension
manufacturer Bilstein
is making its OEM- Laser Heavy-duty Hose Cutter
quality air suspension X This nifty new heavy-duty hose cutter from Laser
modules available to the Tools (part no 6135) may be small in size but it’s big
independent aftermarket.
on performance. Its compact size means that it’s ideal
The latest application is a
direct replacement for all for working in restricted
Mk4 models of the Land areas and the heat-treated
Rover Discovery, offering stainless steel blade gives
owners the chance to sharp, 90º cuts on hoses
replace failed units at less from 3-13mm. The soft
than main dealer prices.
grip handles have been
ergonomically designed for
maximum comfort. It is available
now for £7.15 inc VAT.
For further information about these
X VW Heritage and
products, as well as for details of the
Goodridge are re-
manufacturing stainless latest special offers and discounts,
steel K-Jetronic fuel tank please visit www.lasertools.co.uk
pipes suitable for all Golf
4
MkII 16v and early 8v TO
GTI models. The pipes
cost £99.95, with free UK
Laser Kneeling Pad with Worklights GIVE
AWAY
delivery if ordered online. X This handy Laser kneeling pad (part no 6407) includes the innovative
Visit www.vwheritage.com feature of two rows of 12 surface-mounted built-in LEDs, which
throw plenty of light upwards when underneath or at the side
X The Institute of Motor of a vehicle. The pad measures 460mm x 270mm and
Industry has appointed the
is manufactured from thick 30mm closed-cell foam.
Leather Training Centre
and College in Hull as the It is water- and oil-resistant, making it ideal for
only approved centre of its work either at the roadside or in the workshop.
kind in the UK. The college The LEDS are powered by three AA batteries.
enrols trainees from motor Laser kneeling pad with worklights costs £37 inc VAT.
vehicle manufacturers
and a variety of private We have four Laser Kneeling
WIN
businesses to undergo Pads with Worklights to give
specialist qualifications away to CM readers. For your
in working with leather chance to win one, please
products. complete the coupon on page 23.


CM Insider
NEW from CHICAGO PNEUM IC NEWS IN BRIEF

Wheel Dollies
X Chicago Pneumatic has introduced two new wheel
dollies for vehicle tyre changing and maintenance.
The CP87120 1.2-tonne dolly has two handles
for fast and easy manoeuvring, while the width
is adjustable to accept wheel diameters from
39.4-78.78in (1000-2200mm). It includes a
turnable wheel attachment to ensure wheels X Leicestershire industrial
are balanced safely, and eight large rollers with equipment supplier SIP
adjustable angles to handle tyres with deep treads. The CP87120 has launched its Get a
Grip on Winter promotion,
has a high quality steel frame that can be moved into position
with discounts across
easily, indoors or out, thanks to four swivel wheels with brakes. a wide range of air
On the other hand, the CP8770 twin-wheel dolly has a compressors, air tools,
lifting capacity of 1543lb (700kg), can be used with wheel heating equipment,
diameters of 21.4-50.5in (545-1280mm) and features a chargers and boosters,
chain attachment to provide safe wheel balancing pressure washers, welding
and metalwork, lifting and
during removal and transport.
automotive equipment.
Both wheel dollies are EC and ASME certified, The promotion runs
and include a double action hydraulic piston until April 30. Pick up a
smartly positioned on the side to enable easy copy from your local SIP
access to the operating area, making jobs distributor or contact
easier and quicker. www.sip-group.com
X Euro Car Parts has

Workshop Presses opened its 200th branch.
Manchester (Moss
X Chicago Pneumatic’s two new air-hydraulic Lane) is one of ECP’s
workshop presses bring 75 and 100 tonnes of new generation hubs,
pressure to the workshop, allowing users providing approximately
180 deliveries per day to
to bend and form metal to the desired Whitefield, Bury, Radcliffe,
shape and size easily. The two-step stroke Swinton and Cheetham Hill.
system provides high precision and the large
gauge (in short and metric tonnes) gives easy
and fast pressure control, while the sturdy
steel and iron frame guarantee high durability.
The presses also include many ergonomic
features which contribute to the comfort
of use and versatility of the equipment, COMPETITION
including a movable cylinder, a dedicated WINNERS
winch to easily adjust the bench, a set of
eight punches and v-blocks with high GAS HEATERS
K Harrison, Wisbech
capacity pistons. The presses are EC and
P Murden, Billericay
ASME certified and include an additional R Lee, Durham
adjustable safety cage for ASME markets.
Q What is the length of the
For further information on Chicago Little Devil II SS?
Pneumatic’s range of tools and workshop A 465 millimetres
equipment, please visit www.cp.co.uk
To be in with a chance of winning one of our FREE giveaways this issue, please indicate your preferred product below:
Turtle Wax car care packs AlcoSense Pro breathalyser *Please enter this information so that Car
Laser kneeling pad with worklights Mechanics can keep you informed of
newsletters, special offers and promotions
Simply fill in your details below and send to: Car Mechanics Giveaways February, via email. You may unsubscribe from
Bauer Media, Media House, Lynchwood, Peterborough PE2 6EA. Offer closes February 19, 2016. receiving these messages at any time and
we will never pass your email address to
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................................................................................................................................................................................ would also like to keep you informed of
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not wish to receive these from us or
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Tales from
the workshop
Finding & fixing advice from our garage proprietor eve o hwe
PEUGEOT 106 The failed bearing was the cause of the breakdown.
Sudden clutch failure

X The clutch on this 2001 Peugeot 106 had not given any
warning before breaking down. It had not been slipping
and the owner thought all was well until she heard a slight
squealing noise. The cause of the failure was not the clutch
pressure plate and cover, but the release bearing, which
had collapsed and begun to eat its way into the cover. The
plastic bearing carrier had then melted, speeding up the
release bearing failure. This is quite a common problem
on these vehicles. Very often, when replacing the clutch,
a new guide tube is needed for the release bearing.
Because of the owner’s quick action of not continuing
to drive when the clutch failed, this particular guide
tube was not damaged. After cleaning up and lightly
lubricating the new clutch, the replacement release
bearing could be fitted, leaving the car feeling much
lighter and smoother than before.
CITROËN FORD RANGER

BERLINGO
Cloudy clutch fluid
Worrying X Sometimes, car owners
will not believe we know the
We concluded that the
master cylinder rubbers
rattle answer to their problem.
The owner of this 2002
were perishing, causing the
blackness in the fluid and
X The owner of a 1997 Ford Ranger had suffered a the short-term failure being
Citroën Berlingo had sudden clutch pedal failure, experienced.
noticed strange noises but after pulling the pedal For the sake of a £30
being emitted from back up to the rest position cylinder, we recommended
the engine bay for a everything was once again the unit be replaced to
while. He ignored them, operating as it should. save a future breakdown.
probably hoping they He brought the vehicle in Eventually, the Ranger owner
would go away. By the to us for a look and it only agreed with us.
The rubber section of the pulley
time the strange noise had completely disintegrated. took one look at the state
had turned into an awful of the clutch fluid before we The colour of the
metallic rattle, the driver vibration, had broken free. clutch fluid said it all.
knew what had happened.
brought it to us to find out The continual spinning of the It then took us 20 minutes
what damage was being done. outer section had eventually to convince the owner to
The problem was not completely destroyed the take our advice.
as serious as the owner rubber until the two metal The fluid within the
had been dreading. The parts were rubbing against master cylinder reservoir
rubber section between each other. Fitting a new was thick and black, and
the centre and outer ring pulley and auxiliary drivebelt there were no signs of
of the crankshaft pulley, was all that was needed to external leaks in either the
which is there to absorb silence the engine again. master or slave cylinders.

Sponsored
The cable tie was replaced
with a metal securing clip. by
www.febi.com
VOLKSWAGEN GOLF
Clogged
VAUXHALL ASTRA cabin filter
Cable tie used on CV boot
X When servicing a vehicle
we haven’t seen before, we
like to start with a full service,
X Cable ties are a pretty neat to attach a CV boot to the Astra van came in for a changing all filters, etc, to
invention and are useful in driveshaft joint. We have service, we discovered one of ensure we have a clean start
many applications. They are seen quite a few of them fail the outer driveshaft gaiters and can set later services
great for fixing steering rack due to the pressure required had been replaced. Whoever according to time and
boots and securing slightly to fix a rubber CV boot had fitted the boot had used mileage. This 2008 Golf TDI
wobbly hubcaps. They are into position, and they’re a cable tie to secure it. Rather had covered 140,000 miles
also helpful for secure wiring nowhere near tough enough than let the clip fail in the and we had proof the cambelt
away from danger. However, for a neoprene boot. future, we decided to replace had been changed just before
they should not be used When this 1999 Vauxhall it with a proper metal fixing. the new owner took it over.
There was little else we could
be certain of and the owner
was in full agreement to give
With the car sitting higher on new springs, the old ones were scrapped. his new motor the works
from the outset.
Things didn’t look too
bad until we got to the cabin
filter. Removing it exposed
a cluster of leaves that had
undoubtedly been there for
a while. Although a blocked
pollen filter won’t cause a
breakdown or an engine
failure, it can cause strain on
BMW 320i
the heater motor and result in
Removing lowered suspension a poorly-performing climate

control system. Given the low
cost of a pollen filter, it makes
X The present owner of and with little clearance was sitting in a much better
this 2001 BMW 3-Series between the alloys and position, we moved on to sense to change it regularly.
had owned it for 11 years. the bodywork, the owner the slightly trickier fronts.
However, the previous decided it was time to put Once all four springs had
owner had lowered the the bounce back into his been replaced, the car sat at
suspension. Consequently, ageing Beemer. a far better height and the
over the years, the ride The rear springs are easy ride was much smoother.
had become a little soft to change on these vehicles, The springs that had
and the springs had lost so we decided to do them been replaced early in the
some of their bounce. The first. Once we could see Beemer’s life were now
vehicle now looked too low, that the rear of the vehicle consigned to the scrap heap. The pollen filter had not been
changed for quite some time.

Tales from the Workshop
CHRYSLER PT CRUISER The mounting

was eventually
Strange ticking noise released from

the engine bay.
X The owner of this recently-purchased 2004 2.0-litre

PT Cruiser brought in the motor after hearing a rhythmic
ticking noise from the front of the engine. Our first instinct
was to disconnect the auxiliary drivebelt before running up
the engine to listen for any change in the noise. However,
this was unnecessary, as once we had removed the inner
wheelarch cover to expose the drivebelt, we could see
evidence that the water pump had been leaking. This
meant that the cambelt would need to come off, which
is not a job for the fainthearted.
The coolant leak was spotted when

the inner wing panel was removed.
Here, the biggest problem is removing the engine mounting.

Sandwiched between the engine and inner wing, the mounting
is a very tight fit. Another problem is that the fixing bolts are
too long to remove without major contortions of the engine.
The exhaust needs to be disconnected to give enough up
and down movement of the engine to allow the bolts to clear
the inner wing panel for removal. Once all this was done, the
ticking noise – and the undetected water leak – were cured.
FORD Ka BMW 1-SERIES The pads were not low enough

to wear away the sensor.
Heater Brake
tap warning
horror wire
X The owner of X The brake pad
this 2002 Ford Ka warning light had
suddenly became been showing on this
aware of copious The heater valve 2008 BMW 1-Series for a fair was OK while the wheel was
pipe had simply
amounts of steam snapped off. while. The owner eventually off. With no problems there,
coming from decided to book the vehicle we moved on to the nearside
under the bonnet, coupled cooling fan was operating in for us to replace the brake front, where the front
with the illumination of the at the correct temperature pads. With warning light warning light wire attaches.
temperature warning light. (which it was) – for this, we wires front and back, he Although this appeared to
The plastic heater valve had had to plug in our scanner wasn’t sure which set would be in good condition, a quick
failed and one of the pipes had because the Ka does not need changing. check with a continuity
snapped off, allowing coolant have a temperature gauge. We started by removing tester showed us that there
to flow out of the system. This was not the end of the front offside wheel and was a break in the wire. The
When the vehicle arrived at the story – when the Ka was could see that the front brake pads still had a way to
our premises, we replaced the driven on the bypass, the brake pads appeared to go before they would need
£30 valve and ran the engine engine overheated again. be fine. Moving to the rear changing, so we repaired
to bleed out the cooling Further tests revealed that offside, the pads also looked the circuit and extinguished
system. Satisfied the system the head gasket had failed, to have plenty of life left in the light. The next time the
was bled out, we checked most likely the result of them. As the warning light owner sees the light should
the heater was getting warm continuing to drive the car system on the back is on the be when the brake pads have
(which it was) and that the after the initial hose failure. offside we checked that this actually worn down!

Tales from the Workshop
Available from
An attempt at repair had been
made to the cat bracket and your local
the flange was badly rusted.
motor factor…
…To find your

nearest stockist
call
01977 699777
www.febi.com
MERCEDES SLK
MAZDA 323F
Exhaust dismantling worry Mangled

X Sounding like a
combination of a drag racer
bracket had been subject to
a poor repair. Even though
recommendation. Replacing
the cat meant we didn’t have
mirror
and a bag of nails, this 2001 fitting a new cat was going to worry about attempting to X This 2000 Mercedes SLK
Mazda 323F was in for a new to bump up the price, we fit the new system onto the was owned by one of our
exhaust. The centre and rear advised the owner that it was old failing flange of the cat, regular customers and had
sections needed replacing, the best option. It would save reducing our labour costs been brought in for a coolant
but the catalytic converter future problems and ensure slightly. And once the job leak. We decided to also
was looking pretty shabby, the system remained silent. was completed, the owner attend to the mangled mirror
too. The tin heat shield had The owner was happy was pleased to receive back on the nearside, which was
broken free and the mounting to go along with our a much quieter motor. unusable due to the fact that
it was shattered.
A new mirror, complete
with backing, was available
FIAT FIORINO The chain tension was from our local factor for
at its maximum reach. under £17 and was popped
Timing into place in a few seconds.
The new mirror made driving
chain and reversing the vehicle far
easier and safer.
clatter
X In years gone by,
camshafts were driven
by a chain that normally
lasted the lifetime of the
engine. Then overhead
camshaft units began to
become more common,
but the duplex chain
usually fitted to these
was still fit for the life of When the owner picked
the engine. Now there is up the Merc, he was pleased
a new breed of engines that we had replaced the
which uses a chain to drive that suffers from stretched the sump and front cover, mirror glass and said he
the overhead camshafts, timing chains. The and the engine must be might even clean the inside
but because weight is now automatic adjuster does locked using special tools, of the motor!
such an issue the chain is not have enough travel to because, like many modern
normally a single link and take up all the slack and belt-driven units, the Follow Steve on Twitter:
too light for the job. the chain begins to sound crankshaft sprocket has www.twitter.com/cmtips
The engine fitted to this its death rattle. Fixing it no keyway and is held in
2010 Fiat Fiorino is one requires the removal of position purely by friction.

COMPETITION
Trolley jack, axle

stands & foot pump set
High-quality aluminium construction, ideal for sports and race cars.
Low-entry lifting range from only 85mm. Swivel castors for easy
manoeuvring and wide front roller for extra stability. Lightweight
design weighs only 11.65kg. Tough anodised finish.
X Lifting capacity: 1¼ tonnes (1250kg)
X Safe, simple-to-operate twist lock/unlock valve
X Saddle heights: min 85mm/max 375mm
X Dimensions (L/W/H): 580 x 250 x 210mm
CAX2TA
X Rubber pad on the saddle helps
to prevent vehicle damage
CTJ1250AB
AXLE
STANDS
A stylish pair of aluminium
axle stands which fit
alongside the Clarke
Racing range.
X Max weight load: 3 tonne
(3000kg) per pair
X Minimum height: 265mm
X Maximum height: 390mm
DOUBLE X Six height increments
FOOT PUMP
A heavy-duty foot pump with
a 650mm rubber hose and
thumblock car valve connector.
X Dual calibrated gauge
(0-100 psi/0-7 bar)
HOW TO ENTER: Entry is free. Employees of Bauer Media, Clarke International X Durable steel construction
Ltd and their families are not eligible. The original entry form must be used
(photocopies cannot be accepted). NB: Do not include subscriptions or any X Non-slip foot pedal
other correspondence with entries. Complete the entry form by answering the
simple question. The first TWO all-correct entries drawn will be the winners. No
X Includes four nozzles for
correspondence can be entered into. Closing date for entries is March 1, 2016. inflating vehicle tyres, sports
Results will be published in the April 2016 issue – due out March 17, 2016.
balls, airbeds, pedal bikes, etc. FP300
Post to: CAR MECHANICS CLARKE JACK, AXLE, PUMP COMP, Dept CM2, Bauer Media, Media House, Lynchwood, Peterborough PE2 6EA
Simply answer the following question for a chance to win one of these two prizes:
Telephone No: ..............................................................................................................
What is the maximum saddle height of the aluminium trolley jack in millimetres?
mail:* ..........................................................................................................................
ANSWER: 375 P 376 P 377 P (Tick one only)
Please enter this information so that Car Mechanics can keep you informed
Name: ........................................................................................................................................ f newsletters, special offers and promotions via email. You may unsubscribe
rom receiving these messages at any time and we will never pass on your
Address: ..................................................................................................................................... mail address to any third parties.
.................................................................................................................................................... auer Media (publishers of Car Mechanics) would also like to keep you informed
f special offers and promotions via post or telephone. Please TICK the box if
U
................................................................... Postcode: .............................................................. ou DO NOT wish to receive these from us or carefully selected partners
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WXDXH(MM) EXC.VAT INC.VAT 3 %#$+0'5 9 9 £169.98 £203.98

3 %*'45
3 %*'45
9 9
9 9
£78.99
£99.98
£94.79
£119.98
3 %#$+0'5 9 9 £199.98 £239.98 £
203INC.VAT
.98

3 45'2 62
9 9 £49.98 £59.98
3 %#$+0'5 9 9 £169.98 £203.98
3 %#$+0'5 9 9 £199.98 £239.98
£
239INC.VAT
.98
£
143INC.VAT
.98
EXTRA LARGE SIDE
HANDLE FOR EASY
MOVEMENT
GAS STRUTS FITS EITHER SIDE
Hold lid open
EXTRA
DEEP -
DRAWERS FULL DETAILS -
£
323INC.VAT
.98 SEE IN-STORE OR
VISIT WEBSITE
MAX. WEIGHT
RUBBER GRIP LOADING 500KG
SIDE HANDLES EVENLY DISTRIBUTED BLUE
YELLOW BLACK & GOLD
MODEL DESCRIPTION DIMS
RUBBER GRIP SIDE HANDLES WXDXH(MM) EXC.VAT INC.VAT

3 *'45 9
9 £99.98 £119.98
ALSO BLUE / YELLOW /
3 *'45 9 9
£119.98 £143.98
BLACK & GOLD
3 *'45 9 9 £139.98 £167.98

3 45'2 62 9 9
£69.98 £83.98

3 #$+0'5 99 £199.98 £239.98
EXTRA LARGE

3 #$+0'5 99 £169.98 £203.98
SIDE HANDLE
3 #$+0'5 99 £249.98 £299.98
FOR EASY
MOVEMENT
3 #$+0'5 9 9 £199.98 £239.98
FITS EITHER
SIDE £
299INC.VAT
.98 GREAT LOOKING, BIG 5" INDUSTRIAL CHROME
SPOKED WHEELS FOR EASY MOVEMENT
EXTRA LARGE
DRAWER PULLS
GREAT LOOKING,
BIG 5” INDUSTRIAL
215INC.VAT
£ .98
CHROME SPOKED
WHEELS FOR EASY
MOVEMENT*
£
550INC.VAT
.80
EXTRA LARGE
LOCKABLE FRONT
MODEL SIZE DESCRIPTION DIMS DRAWER PULLS
COVERS STORE
WxDxH(mm) EXC.VAT INC.VAT NEATLY WITHIN
3 *'45 9 9 £169.98 £203.98 CABINET

3 %*'45 9 9 £249.98 £299.98
3 #$+0'5
9 9 £299.98 £359.98

3 %#$+0'5
99 £399.00 £478.80

3 %*'45 9 9 £269.98 £323.98 DIMS.

3 %#$+0'5
99 £459.00 £550.80 MODEL DESCRIPTION LXWXH MM EXC.VAT INC.VAT

3 %*'45 9 9 £419.00 £502.80
3 %*'45 99
£129.98 £155.98

3 %#$+0'5 9
9 £649.00 £778.80 1.5M TALL

3 #$+0'5 99 £299.98 £359.98
3 %*'45 99
£179.98 £215.98
3 #$+0'5 99 £379.00 £454.80 LARGE 37" CABINET
NEW
ROLLED EDGE
UPRIGHTS GIVE: SAVE
EXTRA STRENGTH
SMOOTHER FINISH
SLEEK LOOK
PER SHELF
10%
WHEN YOU BUY
FROM ANY MIX OF 5
ASSEMBLE AS FROM THIS RANGE
SHELVING, BENCH SAVE AT LEAST
CORNER
UNIT
OR CORNER UNIT £
35INC.VAT
.98 350 KG
£17.99 INC.VAT
CHOICE OF 5 COLOURS
ONLY PER SHELF
265
PER SHELF
KG
RED, BLUE, BLACK,
SILVER & GALVANISED
£
95INC.VAT
.98
MODEL SHELF DIMS
STEEL
WxDxH(mm) EXC.VAT INC.VAT
£29.98 £35.98
WI BLUE, RED AND ALSO ASSEMBLES
£49.98 £59.98
48"/12 DE SILVER AVAILABLE AS BENCH
20mm
23975 ALL SIZES/SPECIFICATIONS ARE APPROXIMATE S X PAG OR OR

FROM ONLY
8/250
101INC.VAT
£ .99
FROM ONLY
NOW £
95INC.VAT
.98 HUGE CHOICE
SUPERSTORES OF SPRAY
GUNS &
BIG 2HP
Quick lift ":9
marking nylon wheels
NATIONWIDE 7.5CFM
AIRTOOLS
* steel Rubber contact pad - helps MODEL MOTOR CFM TANK EXC.VAT INC.VAT
chassis protect vehicle undersides Tiger 8/250 2Hp 7.5 24ltr £79.98 £95.98
MODEL EXC.VAT INC.VAT LOW Tiger 7/250 2Hp 7 24ltr £89.98 £107.98
1.25 tonne £84.99 £101.99 ENTRY
ONLY
WHERE QUALITY Tiger 11/250 2.5Hp 9.5 24ltr £119.98
Tiger 8/510 2Hp 7.5 50ltr £129.98
£143.98
£155.98
2 tonne £149.98 £179.98
2.5 tonne* £139.98 £167.98 85MM COSTS LESS Tiger 11/510 2.5Hp 9.5 50ltr £149.98 £179.98
H FROM ONLY H
FROM ONLY
H
£
53INC.VAT
.99
H
£
443INC.VAT.98
H H
FROM ONLY
JACKS ALSO H
H
IN STOCK UP H H
£
23INC.VAT
.98
TO 5 TONNE £
23INC.VAT
.98 FROM ONLY
MODEL TYPE EXC.VAT INC.VAT SADDLE HEIGHT EXC. INC.
CTJ2B DIY £19.98 £23.98 MODEL TYPE MIN-MAX MM VAT VAT £14.99 EX VAT £17.99 INC VAT H NEW
CTJ2MB DIY £24.99 £29.99 CTJ3000QL Quick Lift 195-520 £44.99 £53.99
£
47INC.VAT
.98
RANGE
CTJ2250LP * Low Profile £39.98 £47.98 CTJ3QLG Pro Instant Lift 145-520 £83.99 £100.79 MAX MAX
CTJ2QLG Pro Instant £69.98 £83.98 CTJ3000G Pro Garage 145-520 £84.99 £101.99 H MODEL CHARGE BATTERY EXC.VAT INC.VAT
FROM ONLY HFBC12 6 Amps 100Ah £39.98 £47.98
CTJ2001G Pro Garage £74.99 £89.99
CTJ2GLC Pro Long High Lift £169.98 £203.98 HFBC12/24 20 Amps 200Ah £69.98 £83.98
H FROM ONLY
£
65INC.VAT
.99
CFMMOTOR RCVR
H MODEL (HP) (LTR) EXC.VAT INC.VAT
32INC.VAT
£ .39
SEV11C* 9 2 100 £369.98 £443.98
SE16C100* 14 3 100 £399.00 £478.80
H SE16C150+14 3 150 *£429.00 FROM ONLY
MODEL CAPACITY EXC.VAT INC.VAT SE16C200+14 3 200 ‡£499.00
H CR2 2000KG £26.99 £32.39 MODEL MOTOR MAX. PRESSURE EXC.VAT INC.VAT SE18 18 4 200 £549.00
FROM ONLY
3 TON & CRW25 2500KG £36.99 £44.39 JS1750 1600w 1522psi £54.99 £65.99 SE26^ 23 5.5 200 £679.00
£
57INC.VAT
.59
6 TON JS1900 2000w 1957psi £79.98 £95.98 SE29+9† 28 2x3 270 £969.00£1162.80
MODELS Jet8000 2400w 2610psi £139.98 £167.98 SE36^ 30 7.5 270 £979.00£1174.80
23INC.VAT
£ .98 Jet9000 2600w 2900psi £159.98 £191.98 SE37+9† 36 2x4 270 £1099.00£1318.80 MODEL MAX AMPS
MAX MIN/ SE46#^ 40 10 270 £1449.00 CHARGE/BOOST EXC.VAT INC.VAT
MODEL TONS HEIG . I . FROM ONLY ‡ * + ‡ BC100N 15/100 £47.99 £57.59
CAX-3TBC 3 300-430mm £19.98 £23.98 NEW ^ M BC130C 15/120 £61.99 £74.39
CAX-6TBC 6 400-615mm £29.98 £35.98 9 BC190 38/180 £89.98 £107.98
£
9INC.VAT
.59
† # BC210C
BC410E*
15/120
/400
£94.99 £113.99
£119.98
MODEL EXC.VAT INC.VAT MODEL EXC.VAT INC.VAT
2 tonne £7.99 £9.59 8 tonne £17.99 £21.59 BC205 NEW 200 £169.98 £203.98
FROM ONLY
4 tonne £11.99 £14.39 10 tonne‡ £69.98 £83.98 BC520 510 £179.98
5 tonne‡ £49.98 £59.98 12 tonne £24.99 £29.99 HUGE CHOICE BC430 NEW 400 £369.00 £442.80
6 tonne £14.99 £17.99 20 tonne £34.99 £41.99 IN-STORE/ONLINE
£
23INC.VAT
.98 * ‡
MODEL DESCRIPTION EXC.VAT INC.VAT
CAT127 3" Cut off tool £22.99 £27.59 FROM ONLY
CAT128 1/4" Die Grinder £19.98 £23.98 FROM ONLY
H
CAT131 1/2" Impact Wrench £59.98 £71.98
BIG
H
CAT132 13Pc 1/2" Impact
£
263.98
INC.VAT
Wrench Kit £74.99 £89.99

£
27INC.VAT
.99
3" CASTORS £
53INC.VAT
.99
FROM ONLY
CAT133 3"Cut Off Tool & 1/4" £47.99 £57.59 H INC. DISC
NEW & HANDLE
Die Grinder
26INC.VAT
£ .39 CAT134
CAT136
1/2" Reversible Ratchet
6" Dual Action Sander
£34.99 £41.99
£34.99 £41.99
MODEL I MM)MOTOR EXC.VAT INC.VAT
MODEL DESCRIPTION EXC.VAT INC.VAT 3/8" Keyless Reversible
CAG800B NEW 800w £22.99 £27.99
CAT137 CON1050 NEW 1050w £27.99 £33.59
CMC36 Car creeper £21.99 £26.39 Drill £34.99 £41.99
CMC45 With adjustable headrest£28.99 £34.79 B&D CD11 710w £29.98 £35.98
CAT139 150mm Air Hammer CAG2350 2350w £49.98 £51.59
CMC50 Folding car creeper £44.99 £53.99 inc 4 Chisels £19.98 £23.98 AIR AIR EXC. INC.
MODEL RECEIVERDISPLACEMENT VAT VAT
Tiger 16/510 50 litre 14.5 cfm £219.98 £263.98
Tiger 16/1010 100 litre 14.5 cfm £269.98 £323.98
£
47INC.VAT
.98
H H
H 6" & 8"
H AVAILABLE
H WITH LIGHT H
H STAND AVAILABLE FROM MODEL EXC.VAT INC.VAT
FROM ONLY FROM ONLY ONLY £39.98 EX.VAT 4 ton bench‡ £129.98 £155.98
H 10 ton bench* £189.98 £227.98
H
£
53INC.VAT
.99
£
131INC.VAT
.98
* £47.98 INC.VAT
12 ton floor* £239.98 £287.98
‡ £
35INC.VAT
.98
£36.99 EXC.VAT 20 ton floor* £399.00 £478.80
MODEL MIN/MAX AMPS EXC.VAT INC.VAT 50 ton floor‡# £1598.00
MIG 102NG* 35/90 £109.98 £131.98 £44.39 INC.VAT
# FROM ONLY
NEW £
53INC.VAT
.99 MIG 145
MIG 152‡
35/135
40/140
£149.98
£164.98
£179.98
FROM ONLY *
‡
MIG 180 40/160 £179.98 £215.98 £
155INC.VAT
.98
MIG 196 40/180 199 98 239 98 #
£
20INC.VAT
.39
FROM ONLY
MODEL DUTY WHEEL
H DIA EXC.VAT INC.VAT
59INC.VAT
£ .98
CBG6RP DIY 150mm £29.98 £35.98
FROM ONLY
CBG6RZ PRO 150mm £39.98 £47.98 H
FROM ONLY
CBG6RSC HD 150mm £49.98 £59.98
CBG6SB#
CBG6RWC
PRO 150mm £49.98
HD 150mm £54.99
£59.98
£65.99
H
£
215INC.VAT
.98
H
£
203INC.VAT
.98
CBG8W (wet) HD 150/200mm £55.99 £67.19
MODEL AMPS EXC.VAT INC.VAT H
90EN 24-90 £169.98 £203.98 H
105EN 30-100 £184.99 £221.99
SEE THE
FULL MODEL AMPS EXC.VAT INC.VAT
£
23INC.VAT
.98
MODEL BED WIDTH EX VAT INC VAT
151EN 30-150 £209.98 £251.98 EA110 40-100 £49.98 £59.98 £179.98 £215.98
RANGE £359.00 £430.80
160EN 30-150 £259.98 £311.98 EA165 65-160 £64.99 £77.99
ONLINE &
IN-STORE 115N 30-110 £64.99 £77.99
£
83INC.VAT
.98
MIG WELDERS # EA200‡ 60-200 £87.99 H

E
‡
160N
190N
40-150 £67.99
50-185 £94.99
£81.59
£113.99 PACKALG
Quality machines from
Britain’s leading 190TEN# 35-180£139.98 £167.98 DEA 4
supplier 235TEN# 40-210£149.98 £179.98 H TOOL CHES
See online for
AND TOOLS
included ENGINE
accessories CRANES
4V
FROM ONLY
ORDLESS FROM ONLY ALL THIS ONLY
329
MPACT CIR220 ONLY HAND
RENCH
£
179INC.VAT
.98 £
311INC.VAT
.98 TOOLS
£
215INC.VAT
.98
9.
£107INC.VAT
.98 MODEL DESC. EXC.VAT INC.VAT H (34> 2=0,?
MODEL MIN-MAX AMPS EXC.VAT INC.VAT 23mm chro CFC500F 1/2 ton folding £149.98 £179.98 value set includes FULL RANGE
anadium CIR220 CTC900B 9 drawer OF ACCESSORIES
£179.98 £215.98 CFC100 1 ton folding £154.99 £185.99
£214.99 £257.99 ockets HEAVY
C A "4 / DUTY
CFC1000LR 1 ton £199.98 £239.98 chest & CTC500B
5 drawer cabinet
IN STOCK 1018INC.VAT
£ .80
£239.98 £287.98 long reach

£269.98 £323.98 Batteries & H9.7@/0>?30
£339.00 £406.80 1 hour fast cha H :7/492 ,9/ FC0/ most popular
‡ £399.00 frames available sockets, spanners,
# £429.00 OTHER MODELS MAX TORQUE EXC.VAT INC.VAT Fully tested H &:-@>? =@220/ .:9>?=@.?4:9 pliers, drivers,
£56.99 £68.39 to proof load H #A0=7:,/ >,10?D A,7A0 wrenches etc
‡ # NEW £119.98 £143.98 CFC100
£699.00
24640LH
JUMP
OR OVER GET
Provides essential
home, garage and
roadside assistance
Integral work light
START
, FREE CATALOGUE
500
PAGE
YOUR
FREE
910 includes air
compressor
FROM ONLY
Over COPY
Long life battery £
MODEL START
63INC.VAT
PEAK
.59
NOW!
BOOST AMPS EXC.VAT INC.VAT EXTRA LONG IN-STORE
£52.99 £63.59 1m LEADS
£59.98 £71.98
NEW PRICE CU S & ONLINE
£114.99 £137.99 HEAVY NEW PRODUCTS PHONE
£129.98 £155.98
DUTY 17KG SPECIALIST TOOLS & MACHINERY
visit machinemart.co.uk 0844 880 1265
IDEAL
ALL-WEATHER FROM ONLY
K K PROTECTION
HUGE CHOICE FROM ONLY
K IN-STORE/ FROM ONLY
£
47INC.VAT
.98
ONLINE
K
£
23INC.VAT
.98
PARTS WASHER FLUID
FROM £4.99 EX.VAT
FROM ONLY MODEL DESC EXC.VAT INC.VAT
£
238INC.VAT
.80
£5.99 INC .VAT
PRO12C/ 1.2mm, £19.98 £23.98 GREAT FOR REMOTE
14C/18C 1.4mm, 1.8mm MODEL TANK CAP. TYPE EXC.VAT INC.VAT
ZIP CLOSE DOOR
£
262INC.VAT
.80
PGF14 ‡ Pro, Gravity £24.99 £29.99
LOCATIONS CAN
DRAW OWN WATER £39.98 £47.98
MODEL SIZE (LxWxH) EXC.VAT INC.VAT SP14/18C 1.4mm/ 1.8mm £27.99 £33.59 £99.98 £119.98
£219.00 £262.80 HVLP AP15 2.2mm £27.99 £33.59 NEW £144.99 £173.99
£259.00 £310.80 ‡ RANGE RESSURE ENGINE EXC. INC.
£159.98 £191.98
£269.00 £322.80 10' RANGE NARROWER
WIDTH GREAT WHERE LENGTH MODEL BAR/PSI HP VAT VAT
£299.00 £358.80 UP TO 24' £199.00 £238.80
£379.00 £454.80 SPACE IS TIGHT
£259.98 £311.98
FROM ONLY £329.98 £395.98
£399.00 £478.80
FROM ONLY £
17INC.VAT
.99 £599.00 £718.80
£
47INC.VAT
.98
£
275.98
INC.VAT
INCLUDES SANDBLASTING
GUN, DELIVERY HOSE, 4
TYPE EXC.VAT INC.VAT CERAMIC NOZZLES AND
£14.99 £17.99 SAFETY HOOD
MODEL EXC.VAT INC.VAT £19.98 £23.98
£39.98 £47.98 # £23.99 £28.79 FROM ONLY
£54.99 £65.99 # £31.99 £38.39
£99.98 £119.98
£41.99 £50.39 £
167INC.VAT
.98
# 19INC.VAT
£ .19
MODEL TANK FLOW RATE EX. VAT INC.VAT
PRICE CUT VOLUME REQ.
CPSB100 32 litre 6-19 cfm £139.98 £167.98
£
467.98
INC.VAT
CPSB200 63 litre 12-20 cfm £169.98 £203.98
£
29INC.VAT
.99
FROM ONLY
£
107INC.VAT
.98
K
CHECK FRAME TYPE K
WHEN ORDERING
MODEL KVA HP EXC.VAT INC.VAT
Huge range of quality electric models – £89.98 £107.98
From DIY, trade to Industrial ONLY
£149.98 £179.98 K
£189.98 £227.98
PROPANE NOW FROM
PRICE CUT
ONLY
£
23INC.VAT
.98
£239.98 £287.98 K £ .98
119INC.VAT
GAS FROM ONLY £369.00 £442.80
FIRED £479.00 £574.80
£
77INC.VAT
.99 71INC.VAT
£ .98
£569.00 £682.80
47INC.VAT
£ .98
*
#
CZ-2104
MODEL MAX EXC. WAS NOW K 5000KG
MODEL VOLTAGE HEAT EXC.VAT INC.VAT FROM ONLY
OUTPUT KW
Little Devil II 10.3
VAT INC.VAT INC.VAT
£64.99 .99 OUTPUT KW
£
20INC.VAT
.39
CAPACITY
CZ-2104 230v 2.5 £39.98 £47.98
Little Devil SSII* 10.3
Devil 650 15
£79.98
£74.99 £
.98
.99 DEVIL 6002 230V 0.7-2 £39.98 £47.98 95.98
£
INC.VAT
K INCLUDES
Devil 660 SS* 15 £109.98 .98 DEVIL 6003 230V 1.5-3 £49.98 £59.98 REMOTE
DEVIL 7003 230V 3 £54.99 £65.99 K ONLY
Devil 850 12.4 –31 £129.98 £ 98 FROM ONLY MODEL CABLE MAX LOAD LIFT CONTROL
Devil 860SS*# 31 £149.98 98 DEVIL 6005 400V 2.5-5 £74.99 £89.99 £19.98 £23.98
DEVIL 7005 400V 5 £79.98 £95.98 (KG) HEIGHT EXC.VAT INC.VAT
Devil 1850# 26.9 – 58 £299.98 98
DEVIL 6009* 400V 4.5-9 £119.00 £142.80
£24.99 £29.99 £
23INC.VAT
.98 CH2500B Single 125 12M £79.98 £95.98
£
27INC.VAT
.59
Devil 3000# 35.8 – 82 £339.98 — £407.98 £29.98 £35.98 Double 250 6M
Devil 4000 70–131 £399.98 — £479.98 DEVIL 7009 400V 9 £137.99 £165.59 LIFETIME
DEVIL 6015‡ 400V 5-10-15 £179.00 £214.80 CH4000B Single 200 12M £99.98 £119.98 GUARANTEE
Devil 3150# 46 – 100 £469.98 — £563.98 Double 400 6M
* ‡ FROM ONLY
HUGE RANGE OF RATCHETS,
SPANNERS AND SOCKET SETS
£
57INC.VAT
.59
FROM ONLY
ONLY
*
NEW £
95INC.VAT
.98
RANGE 83INC.VAT
£ .98
K
FROM ONLY
FROM ONLY
59INC.VAT
£ .98
* K
MODEL CAPACITY EXC.VAT INC.VAT
£
215INC.VAT
.98
K
CES340 NEW 340kg £49.98 £59.98 MODEL MAX OUTPUT EXC.VAT INC.VAT MODEL MOTOR CAPACITY EXC. INC.
CES500A 227kg £54.99 £65.99 XR60 14.7kW £179.98 £215.98 WET/DRY VAT VAT K
CES450 NEW 450kg £69.98 £83.98 XR80 20.5kW £229.98 £275.98 £47.99 £57.59 MODEL CAPACITY EXC.VAT INC.VAT
CES750A 340kg £79.98 £95.98 XR110 29.3kW £279.98 £335.98 CVAC20SS* 1400W 16/12ltr £59.98 £71.98 CS4BRK 4 tonne £79.98 £95.98
CES560 NEW 560kg £84.99 £101.99 XR160 46.9kW £329.98 £395.98 * £64.99 £77.99 CS10BRK 10 tonne £139.98 £167.98
CES680F* NEW 680kg £119.98 £143.98 XR210 61.5kW £369.98 £443.98 CVAC30SS* 1400W 24/21ltr £86.99 £104.39 CS10SBRK* 10 tonne £149.98 £179.98
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Instant expert
Multimeter
Masterclass
Part One: A multimeter
is an invaluable tool
for working on a car’s
electrics, but how
do you use them and
what can they tell you?
Dave Rogers offers
expert advice.
Safety first
M
ultimeters are an essential
tool for electrical fault- X Never use a multimeter on mains
equipment or other electrical
finding around vehicles. You systems or components where
can pick one up quite cheaply
these days, but in order to get the best
high voltages occur unless you are
experienced or qualified to do so.
Getting started
out of it you do need to have some X As a general rule, if you are If you are not familiar with multimeters
idea of how to use it. You also need to inexperienced you should only then they can look a bit confusing at
measure systems below 50 volts AC
understand how to apply a measurement or DC. If you are in any doubt, don’t!
first. However, they are all quite similar
correctly and to interpret the readings. X Only use the correct meter leads to
in user layout and controls. Broadly
All multimeters measure volts, amps execute measurements. speaking there are three main areas to
and ohms, and many can do much more. X If the fuse blows in the meter then consider on the front panel.
However, this capability could lead to replace it with one of the same rating. The display – normally an LCD
confusion if you are not familiar with the X Check and double-check the leads – shows the value that you are
principles of electricity. So, in this first and dial setting before measuring. measuring. It is usually a 3½- or 4-digit
part of the feature, we will explain what display, meaning that the decimal
a multimeter actually does and how to In the next issue, we’ll look at some point will move depending upon the
use it. We will also outline some of the typical measurement scenarios using a magnitude of the measured value (ie,
electrical theory you need to know to multimeter. In addition, we’ll offer some higher values have lower precision, thus
make basic measurements. And we’ll look tips to help you get the best out of your less decimal places). In addition, the
at some additional features that could be meter, as well as a mini buyer guide to display will indicate the current selected
available depending upon your meter. finding the ideal device. mode: volts, ohms and amps, plus if you
Functions X At its most basic, a multimeter allows you to accurately measure the voltage,
current and resistance present in an electrical system or circuit.
VOLTAGE The unit of measurement is volts. You have CURRENT The unit of measurement is amps. This will
probably heard the terms AC (Alternating Current) and DC need to be measured less often on a vehicle compared
(Direct Current) with respect to electricity – multimeters to the voltage, but it is sometimes useful. A current
are able to handle both types. DC means the current and measurement is intrusive, so you need to connect it into the
polarity of the circuit is uni-directional (for example, as circuit in order to take a measurement.
would be the case with a battery), while AC means it is bi- RESISTANCE The unit of measurement is ohms. It is
directional, continuously reversing in a cyclic manner (as is often necessary to measure the resistance of a component
normally the case for mains power supplies). AC systems to compare it with a known value (perhaps from technical
are generally not used in vehicle systems, although some data, or just to check for continuity in a part of a circuit or
sensors can generate an AC signal (for example, a crank component). This is another intrusive measurement, as
position sensor). For auto electrics you will be looking at DC the circuit or component must be fully disconnected and
voltage in the range 5-15 volts for a 12-volt system. isolated in order to make the measurement.

Multimeter Masterclass Part 1
These are typical sockets where the leads are

connected. COM is ‘Common’ and is normally
the socket for the black ‘negative’ lead. The
other ‘positive’ sockets (connected to the
red lead) are selected according to the signal
being measured. You can see that voltage,
ohms and other signals requiring a high input
resistance use the same socket, whereas
current measurements use different socket
inputs with low resistance (depending on
whether you are measuring amps or milli-
Three different digital multimeters, but all are actually quite similar from a user perspective. amps); these low resistance current inputs are
The display, control selector and sockets are the areas on which the user should concentrate. normally fused to protect the meter circuit.
are using the milli or micro range for
very small value signal measurements.
Multimeter
The control/selector switch allows measurement basics
you to specify the mode and range for With vehicle electrics, there are a
the measurement. This knob can have number of different aspects of a system
many selection options or relatively that you may want to measure or
few depending upon the type of meter. monitor. For example, measuring the
Better-quality meters have a feature voltage of an electrical system indicates
called ‘autoranging’ – this means, for the electrical ‘pressure’ that pushes the
example, that if you want to measure current around against the resistance
volts, you just select volts and the meter in the system in order to work (for
will automatically set itself to the correct example, the amount needed to make
range according to the input signal. This a bulb filament become white hot and
makes the meter much easier to use. Also, emit light). In addition, you may want
the selector dial is much easier to read. to know the level of the current itself,
The lead sockets are where the leads as current is effectively the amount
are connected to the meter. Depending on of electron flow in the system. The
what mode you are in – volts, amps, ohms, pressure and flow are linked: more
These are typical displays you will see on a etc – you need to select the correct socket. pressure and more flow against a given
digital multimeter. Note that on the upper In general, the high resistance part of resistance means more work is done.
meter display you can also see a bar graph the meter circuitry is used for volt and In the past, mechanics would use
underneath the main digits, to assist the ohm measurements (connected to one different meters to take different
user in reading the meter and seeing signal input socket), whereas the low resistance measurements – a voltmeter to read
trends. You can also see the mode displayed
– on the upper display we’re reading DC
part of the meter circuit is used for volts or an ammeter to measure current.
millivolts, while on the lower display we’re current/amp measurement (a different The beauty of a multimeter is that it’s
seeing DC volts in Autoranging mode. socket often protected by a fuse). a single meter that is capable of taking
a range of different measurements.
Typically, multimeters will always be
able to measure volts, amps and ohms,
but often they also incorporate other
features that allow the user to do much
more analysis and measurement of an
electrical circuit.
Originally, multimeters were
analogue devices with a needle and dial,
however these have now been almost
universally superseded by digital units
(also referred to as a DMM; analogue
meters were also known as AVO meters,
standing for Amps-Volts-Ohms). DMMs
are much more robust than analogue
Selector dials are generally quite intuitive on autoranging multimeters – note that both
meters as they don’t incorporate an
meters pictured above are set in the DC volts mode. On the left-hand dial, reading clockwise easily damaged needle/dial, however
from the Off position, the selections are AC volts, DC volts, AD/DC milli-volts, Ohms, some users prefer to look at a dial as it
Capacitance, AC/DC amps. AC/DC milli-amps, AC/DC micro-amps. is easier to process visually.

Analogue and current, the resistance of the meter a circuit, and you may want to establish
digital multimeters circuit is very low. This prevents the resistance without powering up the
(www.draper.com) meter from creating an additional circuit – for example, measuring a
circuit resistance and affecting the component out of the circuit. For this
accuracy of the reading. Figure 3 application, you can use the multimeter
shows how the meter is connected. The like an ohmmeter, which measures
important thing to remember is that resistance by applying a small current
the meter itself will have a limit as to the through the component/circuit and
amount of current it can measure. Most establishing resistance by measuring
multimeters are limited to 10 amps voltage and current. The current is tiny,
maximum, so you must be careful not to supplied by a dry cell battery inside the
overload the meter circuit, which is often meter, so there is no danger of damage
What protected by a fuse inside the meter itself. to the system under test. Also, it is
can you removed from the circuit completely for
the measurement, so the circuit does
measure with Ohms not need to be activated.
a multimeter? Apart from voltage and current, it’s The circuit for measuring resistance
When looking at volts (pressure), amps often useful to be able to measure the is shown in Figure 4 and always
(flow) and resistance (resistance to resistance of a circuit or a component involves complete removal of the
flow), the measurement principle is – that is, the restriction that the circuit/ component, or isolation of the circuit,
different for each. So is the way that the component provides to the flow of in order to make a measurement.
meter is connected in the circuit. current. According to Ohm’s Law, the Note that it often makes sense to
resistance (in ohms) multiplied by the check or calibrate the meter before a
current (in amps) equals the voltage. resistance measurement is made. To
Volts So by knowing the current and voltage do this, you connect the test leads of
To measure the voltage, you need across a component, you can calculate the meter together and check that the
to connect the meter ‘across’ the its resistance (resistance = volts ÷ amps). reading is zero ohms. Also, note that the
component or circuit section of However, it’s not always convenient component or circuit must be completely
interest, effectively in parallel. The to measure both voltage and current in isolated or you will get false readings.
meter then reads the same pressure
as the component and can measure
and display the value. Note that a
Figure 1
Connection of the multimeter (DMM) for
multimeter has a very high resistance to
voltage measurement (www.autoelex.co.uk)
ensure that no additional load is applied
to the circuit by the meter, and hence
the circuit itself is not disturbed by the
meter while performing a reading. Take
a look at the circuit diagram Figure 1:
most vehicle circuits will be earth
return, hence one side of the voltmeter
may often be connected to a convenient
earth point when taking a reading.
Another common, but perhaps
underused, technique when measuring
voltage on vehicle circuits where
the voltage is low but the current is
high, is to measure the voltage drop
across part of the circuit. This is useful
particularly if a high resistance is
suspected to be causing a problem Figure 2
– for example, across a switch or Connection of the
connector. Measuring the voltage drop multimeter (DMM)
highlights a resistance in a working, for voltage drop
loaded circuit and can easily show up measurement
bad connections. Figure 2 shows the (www.autoelex.co.uk)
meter connection – a typical value
is that the voltage drop should be no
more than 10% on any part of the
wiring circuit to the component.
Amps
To measure current, the meter has to
be connected into the circuit in series.
Note that the meter is connected
in circuit so it can measure the flow
around the circuit when in operation.
When using a multimeter to measure

What else can before they will switch on and conduct.
you measure?
Most multimeters will not provide this
minimum voltage in resistance test
Troubleshooting
Most multimeters have additional mode, as they tend to use very low Here is a quick guide to help you
measurement modes or features, some voltages to prevent circuit or component quickly establish if you are using the
of which can be quite useful and are damage. In diode test mode, a small multimeter correctly.
worth understanding. current is supplied by the meter, which X Do I know what I want to measure
is used to test the diode in forward and with the meter?
Typical extra measurements that you
may see, dependwing on the meter, are: reverse directions (by reversing the lead X Is the selector dial in the correct
connections manually). For a healthy position for what I am measuring?
Continuity test
Very similar to a resistance test, often diode, one way should conduct, the other X Are the leads connected to the
incorporating an audible signal to give should block. When the diode conducts, correct sockets?
a ‘Go’ or ‘No Go’ indication. Very useful the voltage drop across the diode is X Do I know what value to expect
for testing bulbs, fuses, switches, etc shown on the display, generally about from the meter when I take a
0.5-0.7 volts depending on the diode measurement?
– components that are generally either
open or closed circuit – and giving a quick type. If the diode is blocking, no current
indication if they are OK or not. The meter flows and the display shows zero. that thermocouples are not incredibly
generally gives an audible signal if the accurate at around ± 1°C.
resistance is below a certain value. Can In addition, special features are often
also be used on wiring and connectors added to multimeters aimed at specific Transistor test
to detect open circuits, as long as the applications. For example, electronics This is an electronic component test
circuit is not live and is isolated. laboratory test meters may include: feature, similar to a diode test, but to
Temperature test the gain factor of a transistor (ie,
Diode test An additional connector to allow the amplification ability of the transistor,
Another type of resistance check, but temperature measurement via a also known as hFE). Unless you’re an
used specifically for diodes, which are thermocouple is generally supplied electronics engineer or technician, you
an electrical one-way valve. They are with the meter. The tip of this is the are unlikely to need this.
semi-conductor junctions and need a sensing element and the temperature
is displayed on the meter display – note Capacitor test
minimum voltage applied across them
Similar to a transistor test, but specifically
for measuring the capacitance value
Figure 3 of a capacitor. Again, unless you are an
Multimeter (DMM) connected electronic engineer, you won’t need this.
for current measurement
(www.autoelex.co.uk)
Multimeters aimed at automotive
diagnostics are also popular. These
may include the following features:
Electronics tacho
This mode allows measurement of
engine speed via an inductive clamp
usually supplied with the meter. The
clamp picks up ignition pulses from
the HT lead, with the meter calculating
the time difference between the pulses
and converting this to engine speed.
Sometimes the meter can be adjusted
for four-stroke or two-stroke engines
to give the correct reading, otherwise
the reading has to be halved for a two-
stroke or wasted spark ignition system.
Figure 4
Multimeter (DMM) connected Dwell/pulse width
across the component for resistance This mode allows you to measure the
measurement (www.autoelex.co.uk)
width or the duty factor of a pulse (ie,
how long the pulse is active within a
switching cycle). Typical automotive
applications would be for measuring
points dwell (ie, how long the points are
closed – normally given as an angle in
degrees or %), injector opening time (in
milliseconds) and idle speed control valve
operation (% on/off of the driver circuit),
along with some less common functions.
FEATURE AUTHOR
Dave Rogers is a trained master technician
and auto electrician, as well as a technical
author. Find out more at www.autoelex.
co.uk or follow Dave on Twitter @Autoelex

Project Volvo S6
Replacing
the cambelt
PART THREE: Although our project had a service
JOBS LIST
REPAIR REAR BODY
AND BUMPER DAMAGE
PART 2
JAN 16
history, there was no invoice for a cambelt change. ENGINE PART 3
SERVICE FEB 16
Andrew Everett guides us through the task of CAMBELT, TENSIONERS PART 3
replacing the belt, water pump and tensioners. AND WATER PUMP FEB 16
CHECK/CHANGE GEARBOX OIL
C
ambelt Roulette is not a game – very tight. He advised buying a new nut
CHECK AND OVERHAUL BRAKES
you want to play on a Volvo S60. from Volvo for a few quid. Often this nut
While the cambelt replacement is on so tight that not even a serious air- CHECK AND OVERHAUL
STEERING AND SUSPENSION
interval is something daft like gun will get it off. The only option is to
100,000 miles, you really want to be drill into it and split it with a cold chisel FIND AND REPAIR PAS FLUID LEAK
replacing it before then. We had no idea before refitting a new one. REPAIR DRIVER’S ELECTRIC WINDOW
when the belt had last been changed on REPAIR DRIVER’S SEAT
our S60 and, at 157,000 miles, what was AND INTERIOR PLASTICS
the water pump like? Was it the original? Impressive stuff Plus anything else that goes wrong in the coming months
As with our Laguna dCi project a The job itself is pretty easy because
couple of years ago, we gingerly drove Volvo engineers actually thought about run is simple. One thing: always draw a
our S60 back to base and prised the cover how the car would be serviced and diagram of the cambelt and the auxiliary
back to have a quick look. Sure enough, repaired in its lifetime – we have to say belt runs – the latter has a complex run.
the belt’s outer surface did look a bit we’re very impressed with the standard The other general rules apply:
tired. So once the bodywork was done, of design and build of the S60. There are cleanliness, washing off all antifreeze
we took the car to Parkside Autos in a few oddities like the plastic arch liner and oil spills, and spending time
Worksop (01909 506555) to have the belt, being riveted to the bodywork, but, apart cleaning up the block face where the
tensioners and water pump replaced. from that, it’s all straightforward. water pump fits because bits of the old
Referring to the Haynes manual, The timing marks are fairly easy to gasket will be left behind. While a belt
the S60 five-cylinder diesel belt didn’t see and no locking tools are needed. change is quite a simple job, don’t be
look bad. Parkside’s Gary Cooke had The belt tension is not difficult to set, tempted to skimp on the water pump. It
one reservation and that was that the and because the injection pump runs might seem OK now, but what about in
crankshaft nut is done up to 300Nm off the other end of the cam, the belt 50,000 miles? It’s not worth the gamble.
CAMBELT & WATER PUMP RENEWAL
This is what the S60 2.4D looks like under the bonnet: lots of The first task is to remove the top engine cover. There are no
1 plastic covers but nothing very daunting and there’s enough 2 nuts, bolts or screws involved as there are two plastic lugs on
room on the cambelt end of the engine to access everything. the top of the engine that locate into the rubber plugs on the cover
Changing the belt on a five-cylinder petrol engine isn’t very different. itself. Clean it up before refitting and fit the belt change sticker.

CM project 2007 Volvo S60 2.4D
The next job is to remove the engine steady bar – you can do To remove the cambelt cover there is a single 10mm bolt in the
3 the belt with it fitted, but removing it takes five minutes and 4 centre (you can see the boss for it here) and then the cover
gives you a lot of extra room. There are four 16mm bolts to remove, unclips from the top edge and lifts out. Watch out for a lot of oil here
plus another nut and bolt on the centre mount. – an indication that the cam oil seal is leaking badly. Ours was fine.
Most manufacturers would be content Next, remove the plastic arch liners. Remove the auxiliary belt by
5 to let the tyre rub through the plastic 6 These are secured to the body by alloy 7 detensioning the belt with a T20 Torx
arch liner, but Volvo fitted this neat little rivets that are easy enough to drill out, as on a ratchet, as shown here. Make a clear
steel plate to prevent this from happening. shown here. Make sure you have a supply drawing of the belt run around the various
It is secured by a couple of 10mm plastic of new ones to go back on, or you could use pulleys and idlers – do not rely on diagrams
nuts and then just lifts off. plastic blind rivets as a replacement. because the chances are they’ll be wrong!
Here’s the crank pulley centre nut that secures the pulley and A far better idea is to use an air-gun capable of easily undoing
8 hub to the crank. The four 18mm bolts secure the pulley to the 9 a nut this tight, as shown here. If it really will not shift, you can
hub. The nut is tight at 300Nm. On manuals, put the car in gear and grind a flat on one side and split it with a cold chisel. Note how dry
have a helper apply the brakes while you use a big breaker bar. the engine is – no oil leaks on this 157,000-mile car.

CAMBELT & WATER PUMP RENEWAL continued
Undo the four bolts that hold the pulley to the hub – the hub The crank pulley can now be detached, leaving the crank hub
10 stays on the crank and must not be removed. The bolts are 11 behind, as shown here. Our pulley came off fairly easily with
tightened to 35Nm first, then angle tightened by another 50° some releasing fluid around the locating dowel, plus careful use of a
– apply a decent strong thread lock as well. pry bar and a copper mallet to gradually draw the pulley off.
Now we need to set the cam and crank It’s not easy to see – and even harder to Now we need to remove the old cambelt.
12 timing. Start by finding the marks on the 13 photograph – but there is a lug on the 14 With a 6mm Allen key in the adjuster
cam pulley and cylinderhead, as highlighted crank pulley hub and this must line up with the hole, hold it steady while you slacken the
here – the crank is actually before top dead cast line on the oil pump housing (circled). 13mm lock nut. The tension will release and
centre. Refit the crank nut with a suitable When the crank and cam pulley marks are you can slide off the cambelt. The cam will
spacer so you can turn the engine over easily. lined up, we can start taking off the belt. not spring around and a lock is not needed.
Here are the

16 new pulleys:
the tensioner
on the left and
idler on the right.
The idler uses a
10mm bolt and a
new threadlocked
bolt is supplied.
Pulley nuts/bolts
are torqued to
25Nm and 27Nm
Extract the tensioner and the idler pulleys, followed by the water respectively. The
15 pump – there’s very tight access, but you can see the bolt holes in old rollers were
the photo. Our pump was an original Aisin Volvo and still looked in fine still in very good
fettle. Place a washing up bowl underneath to catch escaping coolant. condition.

Autosessive supplied a new Graf pump The cambelt tensioner is spring loaded Here’s the tensioner bolted on, with
17 for £55 and it’s important to replace it 18 and in normal running the peg should 19 the V groove properly seated on the
when the belt is renewed because the pump sit in the centre of the V, as shown here. dowel in the block. You can now adjust the
forms part of the belt tensioner arrangement. After you’ve spent a bit of time with brake tensioner so it’s fully retracted and lock it
So if the pump bearings fail, the belt will go cleaner making sure the crank pulley is nice in place before carefully feeding on the new
slack. An OE Volvo pump costs around £100. and clean, bolt on the new tensioners. belt – start at the crank pulley.
The new belt has been fitted here. Start at the crank pulley and Release the tensioner and the belt will go tight. Using an Allen
20 make very sure the belt teeth have fully engaged with the teeth 21 key, adjust the tensioner until the peg is centralised, as seen
on the crank hub. Feed it around the idler pulley, the cam sprocket, in Step 19. Rotate the engine twice and recheck the timing and belt
around the water pump and finally the tensioner pulley. tension. All OK? Then you can torque the tensioner nut to 25Nm.
Pulley Bolts
35Nm + 50°
Hub Nut
300Nm
Pulley Bolts
35Nm + 50°
Now double-check the belt timing and tension, and if all is still Now add the coolant – we used a Bluecol-type solution. Fill it
22 OK, refit the crank pulley. Use a good strong thread lock on the 23 to the brim, as the level will drop once the engine starts and it
main nut and bolts, and tighten the bolts to 35Nm and 50°. As said, the will require a top-up after a few miles. This is a good time to check
pulley crank nut is 300Nm, requiring a serious torque wrench. for leaks from the pump body gasket.

BELT & WATER PUMP RENEWAL continued PROJECT COSTS

PURCHASE
OF CAR
£1497.00
PARTS & RUNNING COSTS
Annual road tax £205.00
Repairs to offside rear wing £960.00
Bonnet respray £190.00
24 The power steering pump cover will

need to be cleaned before refitting. 25 Now fire up the engine and check it
sounds OK. Allow it to idle while you
Water pump £55.00
There are only two bolts, despite there rivet the wheelarch liner back on. Set the Gates cambelt £45.72
being three bolt holes! We also fitted a new heater to hot and keep an eye on the coolant INA tensioner kit £99.59
auxiliary belt at a reasonable £39.54 as our level. Ours needed no bleeding at all and
old one was starting to show its age. required only one top-up. Oil & filter change (inc materials) £94.00
Labour to replace belt & water pump £72.00
USEFUL CONTACTS Antifreeze £12.00
Autosessive 0844 736 9933 Auxiliary belt £39.54
www.autosessive.com
TOTAL COSTS £3269.85
Parkside Autos (Worksop) 01909 506555
OIL & FILTER CHANGE
Once the engine has fully warmed up after a five-mile run, With a suitable bowl underneath, slacken and remove the 18mm
1 drop the front undertray. This is secured by 10mm bolts, but 2 sump plug nut and drain the oil until it’s just slowly dripping.
you may find the retaining bolts are a bit rusty and could possibly Use a new sump plug washer – most filters will have one in the packet
have seized. Ours came out with the help of penetrating fluid. – and tighten the sump plug to 35Nm. Don’t overtighten it.
We used a Mann oil filter as they’re of very good quality and The oil filter housing is positioned at the front of the engine
3 only cost £6.52 from Autosessive. Parkside used the correct oil: 4 and to the right of the alternator. The screw-on cap has a 36mm
a low ash 0w30 fully-synthetic. As our car has a DPF fitted and sump Hex requiring the correct socket. The Mann oil filter also includes a
levels can raise after a regen, the oil level is set at just over halfway. new rubber sealing O-ring, which takes a few seconds to fit.

GO
HANDS
ringautomotive.co.uk
MAGflex RANGE
The MAGflex range of
LED inspection lamps has been LED MULTI
POSITIONAL
designed for hands free usage.
You can twist, hang, flex and fix
the lamps to make sure you can Li-ion MAG
BATTERY
NET
position the light precisely
where you need it.
Visit our website www.ringautomotive.co.uk

for details of your nearest RING stockist.
UV
TORCH
250 440
LUMENS LUMENS
RIL3600HP RIL4000 RIL3100HP

MAGflex Twist MAGflex MAGflex UV
t M I N I On e R 5 0 1 .6
Projec
Pipes, bushes
& a windscreen
Part Six: In the penultimate instalment, a JOBS LIST PART 2-4
FIX NON-RUNNING ENGINE OCT-DEC 15
new windscreen is fitted to our MINI, along INVESTIGATE
PART 2
with new power steering pipes, suspension ENGINE OIL LEAK OCT 15
bushes and droplinks. Rob Hawkins reports. SERVICE

ENGINE
PART 4
DEC 15
RENEW
T
his windscreen has been steering pipe connection where space is PART 4
changed before,” commented too tight for a standard socket. Instead, RADIATOR DEC 15
Chris Leathley of Afford A they machined down a socket to ensure it SERVICE/RENEW BRAKE PART 5
DISCS & PADS JAN 16
Screen, as he carefully prised fits. They even had a special set of drifts
off the trim from the A-panels, only manufactured by a local engineering FIX BOTCHED BRAKE PAD PART 5
WEAR SENSOR WIRING JAN 16
to discover it was hanging on by a few company to help remove the steel outer
remaining plastic clips. Thankfully, casing from the rearmost suspension RENEW BRAKE PIPES PART 5
& FLEXI-HOSES JAN 16
removing the old, cracked windscreen bush on the front lower arms.
and fitting a new one wasn’t any more INVESTIGATE PAS PART 6
FLUID LEAK FEB 16
difficult than expected, but we did
decide to renew the pillar trims as well. PAS foibles FIT A NEW
WINDSCREEN
PART 6
FEB 16
We also dropped the front subframe These suspension and power steering
FIT NEW FRONT PART 6
from our MINI and renewed a few parts, issues are some of the typical problems LOWER ARM BUSHES FEB 16
including some leaking power steering associated with the MINI. Power
TREAT RUST ON TAILGATE
pipes and worn suspension bushes. steering difficulties are often caused
With new parts supplied by Blue Print, by corroded or water-damaged wiring, FIT A NEW ROOF AERIAL
everything went smoothly, but that was which is sometimes wrongly diagnosed
also down to the fact that Mad4MINI, as pump failure. The pump has been Common front suspension problems
which completed all of the work shown known to continue working even after include all of the areas we’ve repaired.
in our photographs, is able to do this sort the engine is switched off, which results The rear inner bush on the front lower
of work blindfolded. They’ve also thought in it burning out. General pump failure arms, the anti-roll bar D-bushes and the
around problems and come up with their is common, too. Our power steering droplinks are all worthwhile replacing,
own solutions, such as working out a pump is in good working order, so we especially after disturbing the front
way to undo a particular 19mm power refrained from renewing it. subframe to work on the PAS pipes.
POWER STEERING PIPES & SUSPENSION BUSHES
The front subframe needs to be removed

1 to be able to change the power steering The end of the steering column has to The power steering fluid reservoir is
pipes. It also makes it a lot easier to renew
2 be detached from the steering rack. 3 located at the back of the engine bay
the anti-roll bar and lower arm bushes. First, The two are joined together with a 13mm bolt. and is clamped in position. After undoing a
we needed to detach the bumper, which we Once undone, we prised them apart using a 10mm nut, we released the clamp and made
covered in detail in the November 2015 issue. pry bar. They were dry and corroded. sure the reservoir was free to drop down later.

CM project 2004 MINI One 1.6
To drop the subframe, we had to

4 separate the track rod ends, droplinks A lollipop-style lower engine mount There are two electrical plugs on the
and outer balljoints on the front lower arms. 5 had to be detached where it’s 6 power steering pump, which had to be
We had already separated the lower arms and connected to the engine sump. This is detached. They are a push-fit type, but quite
track rod ends during the engine swap, but secured with a 16mm bolt. Once undone, the awkward to release. We disconnected the
the droplinks were a little more troublesome. mount remained on the subframe. battery as one of them is a live feed.
We’re now ready to drop the subframe, Using a transmission jack to support Both of the lower arms’ rear bushes
7 so we slackened and removed the ten 8 the subframe, we raised the MINI on a 9 were worn, so we had to remove each
16mm bolts that secure it. There are also two-post ramp. The subframe was released lower arm. There’s a balljoint for the front
two 10mm bolts at the front that hold the and we could lift it off the transmission jack mount, secured with two 16mm bolts. These
subframe extensions to the front panel. and place it on the floor. can seize and shear, but we were lucky.
We didn’t think we’d be quite so lucky With both lower arms detached, we A steel outer casing remained inside
10 with the 18mm bolts for the rear 11 tore off the housing and old rear 12 each bush housing, so we pressed it
mounts, which also secure the anti-roll bar. bushes using a pry bar, leaving behind the out. For this, Mad4MINI has a special set of
Three of them were too much for the impact remains of the rubber inner, which were drifts that were manufactured for them by a
driver, but we succeeded with a breaker bar. removed with water pump pliers. local engineering company.

POWER STEERING PIPES & SUSPENSION BUSHES continued
The new bush should have a triangular Each new bush is carefully pressed into After cleaning and applying copper
13 marking to show how it’s fitted, but 14 the respective housing. These housings 15 grease to the hexagonal spindle on
our Blue Print bushes didn’t have one. are sided and have a part number stamped the lower arm where the new bush sits,
Instead, we could tell which way they should on them to help identify them – 6757561 for the housing was refitted. There’s only one
be fitted by the shape of the bush. the nearside and 6757562 for the offside. position in which it should be fitted.
We’re fitting new anti-roll bar mount After renewing the suspension The pipework is secured in three places.
16 bushes from Blue Print. These are 17 bushes, we turned to the power 18 The most awkward to remove is a 19mm
tapered to match the shape of the bar, so steering pipework. We have a new set banjo bolt, which is obstructed by another
they should only be positioned one way of pipes from Blue Print. First, there’s a banjo bolt for the return pipe to the fluid
round. We inserted them when refitting the heatshield to remove, which is held on by reservoir. Luckily, Mad4MINI has a socket that
lower arms onto the subframe. a 10mm nut and a 10mm bolt. has been machined to undo the bolt.
A 13mm banjo bolt at the pump must be undone, along with a After fitting the new pipework and tightening the 19mm banjo
19 10mm nut for a mounting, to extract the old pipework. The new 20 bolt to 34Nm, we cleaned the steering rack, then refitted the
pipes are a straight swap. We renewed any washers with genuine parts. lower arms, applying copper grease to the 16mm and 18mm bolts.

We renewed the droplinks with components from Blue Print. There’s a locating lug on the underside of each front chassis
21 These have a 5mm Allen keyhole in the end of each balljoint 22 leg, which must match up with a hole in the subframe.
stud and are supplied with a new 17mm locking nut. There are no We manoeuvred the subframe into position, supported it on a
flats on the stud to grip when tightening the nut. transmission jack, then lowered the MINI onto it.
NEW WINDSCREEN
The MINI’s windscreen is bonded in The trim along the base of the A length of rubber trim is fitted across
1 position. We asked Leeds-based Afford 2 windscreen had similarly been 3 the top of the windscreen and was
A Screen to fit a new one. They started by removed before, but we managed to salvage relatively straightforward to remove. With
carefully prising off the A-pillar trim, but it, despite some of the fittings falling off. all of the trim taken off, we could then start
found someone had been there before and This trim consists of two halves and is also to cut through the sealant holding the
had broken off most of the fittings. secured with screws inside the A-pillars. windscreen in position.
Afford A Screen used a knife with a guide tool attachment to cut Having cut all the way around the perimeter of the windscreen,
4 around the perimeter of the windscreen and through the sealant. 5 the glass started to feel loose, but it still needed some gentle
It’s all too easy to slip if cutting through with a normal Stanley knife. leverage from inside the car to help release it.

NEW WINDSCREEN continued
PROJECT COSTS
PURCHASE
OF CAR
£972.00
Eventually the old windscreen could be Sealant remained all the way around
6 safely lifted away from the MINI. The 7 the windscreen surround, so most of PARTS COSTS
crack down the driver’s side that was present it had to be removed before fitting the new Replacement 44K engine £510.00
when we bought the car hadn’t got any worse, windscreen. There’s no quick solution here Air filter ADG02285 £6.98
although we’ve not driven it that much since. – just a scraper, a knife and patience. Oil filter ADG02124 £2.96
Clutch kit ADG030148 £95.59
Clutch release bearing ADB113303 £10.68
USEFUL CONTACTS Thermostat ADG09225 £26.32
Blue Print www.blue-print.com Thermostat housing £48.00
Mad4MINI 0113 276 1636 Radiator ADG09840C £178.38
www.mad4mini.co.uk Auxiliary drivebelt
tensioner ADB119601 £52.50
Afford A Screen 0113 268 0334 Auxiliary drivebelt AD06R870 £10.33
www.affordascreen.co.uk
Used water pump from Mad4MINI £25.00
Spark plugs £24.80
Thread repair for spark plug hole £144.00
NEXT ISSUE BMW MINI crankshaft pulley £185.03
In the final
instalment, MINI steel water pipe £148.80
we’ll be Gaskets and seals £5.50
taking our HT leads ADG01630 £40.54
MINI One Engine and gearbox oil £36.40
Eventually, we were ready to fit our project for
8 its MoT, Sump plug £5.50
replacement windscreen. First, some
renewing a Front brake discs (pair) ADG04374 £38.64
fresh sealant was applied around the entire
windscreen surround. Afford A Screen uses a sticking gear lever, treating the corroded Rear brake discs (pair) ADG04375 £40.30
tailgate and fitting a new roof aerial. £26.40
battery-operated gun for this. Front brake pads ADG04243
Rear brake pads ADG04244 £19.65
Front flexi-hoses (pair) ADG05359 £38.44
Rear flexi-hoses (pair) ADG05356 £38.44
Handbrake cables
ADB114601 & ADB114602 £55.28
Brake pad wear indicator ADB117202 £13.97
Copper pipe £12.00
Exhaust system,
gasket and new clamp £86.40
Front lower arm bush (pair)
ADG080146 £46.24
Droplinks (pair) ADG08525 £27.84
Anti-roll bar mount bushes
ADB118005 £6.80
Windscreen renewal (fitted) £140.00
A-pillar trim panels £84.00
TOTAL COSTS £3203.71
Note: BLUE PRINT PRICES ARE
The new windscreen was then carefully lowered into position and held in place with a pair RECOMMENDED RETAIL, BUT MAY BE
9 of suction pads. After checking that there was an even gap all the way round, the old trim CHEAPER THROUGH SOME STOCKISTS
was refitted, along with two new pieces for the A-pillars.

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olkswagen Golf MkV
Used Car Focus: V
A whole
in one
Posh, practical and a huge step on from the MkIV,
the still fresh-looking Golf MkV might just be the
answer to all your motoring needs. Ian Cushway
explains how to spot the best examples.
W
ithout wishing to sound too luxuries, but the extra weight ruined
much like a Volkswagen ad, it’s the driving experience. Thankfully, the
the car other manufacturers MkIV from 1998 was a step back in the
tried untiringly to mimic, but right direction. It had sharper handling,
never quite managed to equal. more space and a more generous spec
Unbelievably, it’s been 40 years since list, but soon looked dated both in terms
the now iconic Golf emerged and the of styling and technology.
model has continued to grow in status, That’s where the more rounded MkV
each generation offering more space, from 2004 comes in. As well as its rakish
more refinement and a wider range of styling, the new Golf was bigger in the
engines. Yet throughout its life, solid back, safer, came with a wider range of
German engineering, practicality and
the attraction of that classy VW badge on
engines and transmissions, and, best
of all, was much more sophisticated
Engine choice
the grille have remained constant, which underneath, thanks to a new platform, X There’s a wide choice of engines to
is why the Golf continues to attract electric steering, multi-link rear choose from, ranging from the somewhat
buyers. Due to the instantly recognisable suspension and direct injection for most flaccid 74bhp 1.4 up to the 16v 197bhp 2.0
shape of the panel just behind the rear of the petrol and diesel engines. TFSI in the GTI. In between, there’s also
side window, you can trace the design The MkV remained untouched a 1.6 FSI (fuel stratified injection), a fast
lineage right through from the first visually during its lifetime, although and flexible 148bhp 2.0-litre normally-
model to the current offering. a limited run of 1500 Edition 30 cars aspirated petrol, and a punchy 138bhp
That said, the Golf success story hasn’t were released in October 2006 and 2.0 TDI turbodiesel. The pick of the
been without its hiccups. The MkIII there was another limited edition bunch is the GT TDI with its talented
from 1991 was a huge let-down after Pirelli model, both of which used a DSG transmission or the lively 1.6 FSI
the much-loved and now iconic MkII. 230bhp version of the GTI engine with petrol. The staggeringly quick but frugal
Bloated looking and bland, with roly-poly beefier turbos and camshafts. Needless 2.0 TDI 170 is also an excellent choice.
handling, it was safer and boasted more to say, both are sought after. A range of new engines appeared in the
summer of 2006, including the 140bhp
Specifications 1.4 TSI/TFSI twincharger (turbocharged
and supercharged) petrol that appeared
Engine (petrol) Power Average 0-60 VED Insurance in the MkV GT. From 2007 there was
Output Consumption mph Band Group also the highly fuel efficient BlueMotion,
1.4 74bhp 38.7mpg 14.2sec H 6 which could eke out 62.8mpg. In late
1.4 TSI 138bhp 44.8mpg 8.5sec H 18 2007, the 1.6 FSI petrol engine was
replaced by the new chain-driven
1.6 FSI Sport 113bhp 38.2mpg 10.5sec H 14
122bhp 1.4 TSI fitted with just a turbo.
2.0 GTI 197bhp 35.8mpg 6.9sec J 34 As you would expect, all units should
Engine (diesel) prove reliable if looked after, but it would
1.9 TDI 105bhp 53.0mpg 10.9sec F 14 be a mistake to be complacent when
2.0 TDI 138bhp 47.9mpg 8.9sec F 19 buying cars with missing history or
Reserve products online at eurocarparts.com and collect instore at a time that suits
you with our CLICK & COLLECT service. Now with over 180 branches nationwide.

Used Car Focus Volkswagen Golf MkV
IN ASSOCIATION WITH
Running gear
X You’ll find the Golf MkV to be
sharp, stable and controlled, if just a
little too firm on the worst potholed
surfaces. The multi-link rear
suspension is a big step on from
the old MkIV and the chassis feels
taut and agile, allowing corners
to be taken at speed without any
drama whatsoever.
There have, however, been reports
of the rear springs breaking, so
ensure that the car’s sitting evenly
at the back. Meanwhile, check for
uneven tyre wear; at the front it
will indicate worn front suspension
components, namely the wishbone
bushes, while at the rear it
might mean that the multi-link
arrangement is out of adjustment.
There was a problem on early cars
concerning the steering rack and
some were replaced under warranty;
if it clunks on full lock, suspect
problems. Front wheel bearings on
the MkV don’t last long so listen out
for any suspicious humming.
Brakes on the MkV should feel
strong, but make sure there is
no ABS warning light showing as
pumps and modules have been
known to fail.
obvious running problems. The plastic TDI BMN, are less reliable and 2.0 FSI engine.
timing belt tensioner on the 1.4 16v can there was a recall in 2012.
fail, so confirm that it was replaced at Lift pumps can let go and the
the same time as the timing belt, due earliest 2.0 PD engines had a
for replacement every 60,000 miles. complicated fuel cooling system
On the GTI it’s not an easy job. While that is also troublesome. Any
still on the GTI watch for boost leaks MkV that doesn’t run perfectly
– as the cars get older this is becoming should be viewed with suspicion.
more common. The 140 and 170bhp TDI was
A common issue on FSI engines fitted with a Diesel Particulate
concerns worn cam followers for the Filter (DPF) from 2007, so watch for
high-pressure fuel pump. If a car cuts any warning lights. Thankfully, the
out for no reason, or the engine check late-2008 common rail 2.0-litre diesel
light is illuminated, it could be on its way (identified by its four-digit engine code
out. If it does fail, the damage can be and angled manifold mouldings on
expensive to remedy. A receipt showing the plastic engine cover) is largely
that the cam follower and seal have trouble-free and very smooth.
been replaced will offer peace of mind. PD engines require oil that meets
The 1.4 TSI had a timing chain, and if VAG specifications – namely 505.01
it’s not been treated to fresh, quality oil it (fixed servicing) or 507.00 (variable)
can stretch and rattle, so listen for this. – so search through receipts to ensure
The PD diesels are reliable, but if you it’s been used, otherwise the car might
notice a distinct lack of power or, worse, have suffered camshaft wear. A sign of 3.2-litre V6 from its predecessor, albeit
if it goes into ‘limp-home’ mode while a fastidious previous owner is if they’ve with an extra 10bhp (246). It could do
on a test drive it could be suffering from changed the oil and filter every 7000 0-60mph in a tad over six seconds
a clogged variable vane turbo. miles and used a long-life brew. and featured four-wheel drive, stiffer
The 2006-2009 Siemens Piezo The storming R32 model went on sale suspension and beefier brakes to cope
injector engines, as fitted to the 2.0 in late 2005 and inherited the same with its supercar-like performance.

A revelation in many respects, the Golf GTI achieves 0-60
MkV instantly put the Golf back into in under seven seconds.
contention as the world’s best hatchback.
But since the arrival of the MkVI in
2008, MkV values have taken a hit, which
means you can buy one for significantly
less than you might have thought.
Transmission
VW manual transmissions should
feel silky, but be wary of rattles on very
high-mileage examples that could point
to a worn dual mass flywheel. If there’s
any doubt, haggle hard on price because
it’s not cheap to replace once you’ve
included a new clutch and labour.
The direct-shift DSG gearbox is
excellent and should be smooth and
effortless in operation, so be wary if Trim & equipment
it’s jerky or hangs on to gears, because Standard equipment, even on entry-
repairs are expensive. DSG oil changes level models, is generous, with all MkVs
are due every 40,000 miles, so check the getting dust and pollen filters, remote
service records to confirm that this has central locking and heated mirrors,
been carried out. as well as comprehensive safety kit in
Also see our twin-clutch transmission the form of front, side and full-length
feature starting on page 6. curtain airbags, along with hydraulic
brake assist and an ESP system with an
electronic differential lock. No wonder,
Electrics then, that it scored an impressive five
As when buying any used car, it’s a stars in the EuroNCAP crash tests. Plush SE trim with alloys and cruise control
case of systematically making sure The S trim added standard air- was renamed ‘Match’ in 2007.
everything works as it should and that conditioning, while the SE (later Match)
there are no warning lights showing. has alloys, cruise control, automatic
There have been reports of coil pack lights and wipers, and body coloured
issues on some models, possibly as a bumpers and trim. The GTs got front
result of oil ingress, as well as radiator fogs, dual zone climate control, bigger
fans failing, so it’s worth being aware of alloys and a firmer suspension. GTIs
rough running, Lambda warnings and will either have leather or the traditional
signs of overheating. tartan check interiors.
Condensation in the rear lenses is Some owners complained that the
a common MkV foible. Make sure the MkV didn’t feel quite as well screwed
light unit hasn’t suffered long-term together as past Golfs, and there have
soaking, otherwise the connections are been reports of annoying rattles from the
likely to be corroded. dash and switchgear on early examples. DSG transmission is a popular choice,
especially on sporty GT models.
Six-cylinder R32
offers a different It’s worth avoiding cars with scruffy
driving experience cabins and frayed seat bolsters, as it’s
to the four-pot GTI.
never as easy as you think to make
them look smart. Also, check that the
air-conditioning is blowing cold air,
because the compressors are a known
weak spot and replacing one with the
cost of specialist labour could cost the
best part of £1000.
Corrosion shouldn’t be a huge issue,
although some cars are showing signs
of rust around the front and rear
wheelarches, the tailgate lip, the sills,
the rear chassis box areas and the front
and rear roof seams, so it’s important to
give these areas a thorough inspection.

Verdict What about the MkIV?

X Dynamically, the MkV was
arguably the best Golf ever when X Despite looking its age,
it arrived in 2004 and it still looks the MkIV is still an excellent
and feels great. The fact that prices car. So if you’re on a limited
have softened to very affordable budget, you shouldn’t rule
levels adds to the attraction. it out. Superior build quality
means reliability is still good,
Apart from the few niggles
and an excellent supply of
mentioned elsewhere, build is top
aftermarket and secondhand
drawer, which means cars last well
spares means keeping one in fine fettle won’t be that expensive.
and provide years of trouble-free
When viewing cars for sale, look for proof that the cambelt has been
motoring. There’s a caveat, though: changed every 50,000-60,000 miles and that there’s been regular oil and
the financial penalty for missed filter changes. Where a new cambelt has been fitted, check to see whether a
regular servicing will be high, so it’s water pump went on at the same time as the impellers have a horrid tendency
crucial to place proof of scrupulous to come loose on their spindles.
and continuous maintenance high With turbodiesels, beware of any potential VNT (Variable Nozzle
on your buying criteria. Turbocharger) problems. If lacklustre performance isn’t down to the turbo, it
Which model to go for depends will be due to one of the solenoids that controls it.
on type of use and budget. We Early small engine petrol models can cost as little as a few hundred
like the 1.4 FSI, but the best value pounds, but your money will be better spent on an honest 1.9 TDI with lots of
probably lies in the early 1.9 TDI. workshop bills proving it’s been looked after – as little as £1500 will get you
If you can afford it, go for the behind the wheel of one of these.
common rail diesel from late 2008 GTIs feel sluggish but still have kudos, and while scruffy high-mileage
because it’s just much smoother. examples start at £800, spending a bit more on a nice car makes sense. The
The GTI is brilliant, being hidden gem is the eager 1.8T. A clean, historied one of these will easily cost
remarkably quick and impressively less than £2000. A soon-to-be-collectable limited edition Anniversary GTI
frugal thanks to that TFSI engine. might be as much as £6000.
Valuations ALSO CONSIDER

X The cheapest MkVs Ford Focus
you’ll find will be something X Brilliant dynamics is
like a 2004 1.4 or 1.6 petrol what gave the Focus the
model with lower spec, edge over its rivals originall
and we’re pleased to confirm
which begin at around
the model from 2004 continues this
£1500. A high-mile low- tradition. It’s well screwed together, too.
spec early 1.9 TDI will be Image-wise it’s still not even close to the
slightly more – £2000 is a Golf, but it’s likely to be a fraction of the
realistic starting price, with price. Pick of the bunch is the 2.0-litre
really nice SE examples Duratorq TDCi and a tidy 2006-era car
with full history and just could be yours for as little as £1500.
50,000-60,000 miles more likely £3000-£3500. A high-mile common
to be £4500. GTIs of the same era rail diesel will begin at £3500, but BMW 1-Series
but lots of miles will start at around you’ll need to pay at least £4500 for X Just as classy as the
the same price, and expect to pay a nice, lower mileage model. Golf, the 1-Series is great
to drive, with the gutsy
£3500+ for a sporty 2.0 TDI GT – at The first of the 1.4 TSI Golfs start
120d producing 163bhp a
this money, it will be a 2004 or 2005. at £5000, while a car that’s done rush from 0-62mph in under 8 seconds,
Average mileage examples of the 50,000 with a history is likely to be a while returning close to 50mpg. SE
1.4 FSI begin at £2000, but one with grand more. At a main dealer, the last trim is the one to go for, but they’re not
as little as 70,000-80,000 miles cars made will be nudging £7000 for cheap – £7000 is the starting price for
and a good history will be more like a low-mileage example. a 2006 car with average mileage.
Citroën C4
X If you like your gadgets
the characterful C4 will
be right up your street.
The common rail 2.0-litre
turbodiesel is a gem, but for all
round versatility the 1.6 HDi makes the
Click & Collect most sense. It will do 60mpg without
within 15 minutes from even trying, yet it still feels nippy.
Considerably cheaper than a Golf and
a choice of over 180 perhaps a bit more idiosyncratic, you
can buy a 2008 car with under 50,000
branches nationwide miles in sporty VTR+ trim for £3500.

Survival Guide
Ian Cushway searches out new and used parts prices
BMW Z4
The talented German roadster still looks
good, and if you shop around for parts it’s
a viable alternative to less posh two-seaters.
T
hanks to its controversial
Chris Bangle ‘flame surfacing’ Engines
contours, the Z4 always looked The Z4’s M54 engine, lifted from the E46
ahead of its time – and a lot more 3-Series, is reliable enough, although
modern than its Porsche Boxster rival. the 3.0-litre has a tendency to consume
Built in BMW’s Spartanburg, USA, plant, oil – up to one litre per 1000 miles is
the Z4 was launched in Europe in 2002 not unheard of and the engine drinks
and arrived here a year later. more when used for short trips where
Being aimed squarely at the higher the engine doesn’t warm up properly. A
end of the open-top market, there were clogged crankcase breather valve or hose
just two engine options at launch: the on the underside of the manifold will
M54 straight-six in 2.5- and 3.0-litre make consumption higher. It’s an easy
forms. These were mated to a five- and and relatively inexpensive fix, but you’ll
six-speed manual gearbox respectively, need to remove the manifold.
although a Steptronic automatic was A common issue that affects the M54 A clogged crankcase breather will increase
optional. The firm’s sequential manual concerns the variable intake manifold the six-cylinder engine’s thirst for oil. It’s
(SMG) system was also offered from (DISA). The single plastic flap and its relatively straightforward to replace.
launch in the UK, but was a rare option. steel pin workings can fail, allowing it
A 2.2i joined the line-up in 2003, to drop into the engine. You’ll notice a Engine component prices
featuring a 170bhp six-cylinder engine lack of top-end power or low-end torque, OIL FILTER
from the 320i and 520i. Sadly, it was depending on the position in which it Main dealer £12.53
replaced by a somewhat flaccid 150bhp has failed, and possibly a rattle from the Independent from £4.19
four-cylinder 2.0i unit in May 2005. manifold itself and valve gear damage if RADIATOR
A facelift took place in 2006, at the it makes it into the engine itself. Main dealer £262.01
same time as the arrival of the potent A service indicator will tell you when Independent from £52.30
3.2-litre Z4 M coupé. to make the necessary oil and filter DUAL MASS FLYWHEEL
Having cost £31,480 for the 3.0-litre at changes, however sticking to an 8000- Main dealer £793.09
launch, you can now pick up the same car mile regime is advisable. Make sure the Independent from £466.79
for as little as £4000. That said, shrewd correct specification 5w30 oil is used
buyers will need to be aware of some – although on cars that drink more than
mechanical glitches and also be willing most, a thicker 10w40 is preferable. Electrics
to shop around for parts. Prices quoted Head gasket failure is normally As the Z4 gets older, it is likely to suffer
here are for a 2003 2.5-litre model. caused by problems with the cooling a number of electrical issues, specifically
system, such as a duff radiator or broken problems with the camshaft position
BMW Z4 plastic water pump impeller. If you
end up having to replace the gasket and
sensor, with symptoms being a flat
spot or hesitation while accelerating.
2003-2008 intend keeping the car, it’s worth fitting Coil pack and MAF failures are also a
Model 2.0i 2.2i 2.5i 3.0i 3.2i a new radiator, water pump, header tank common occurrence.
Engine (cc) 1995 2171 2494 2979 3246 and drivebelt at the same time. The roof on the Z4 with its glass rear
Power (bhp) 150 170 192 231 343 The six-speed transmission can feel window is able to go from fully open to
0-60mph (sec) 8.2 7.7 7.0 5.9 5.0
somehwat notchy when compared to fully closed in just 10 seconds and was
the five-speed, but otherwise problems billed as the fastest folding lid at launch.
Top speed (mph) 137 140 146 155 155
should be few and far between. Ditto the That said, they can prove troublesome
Average fuel (mpg) 38 32 32 31 28
auto and SMG set-up. with age as the various microswitches
Follow us on: HAYNES: T H E F I R S T T O O L www.haynes.co.uk

YOU SHOULD REACH FOR See Haynes See How

Survival Guide BMW Z4
TOP TIP SP O NSO RE D BY

Six-cylinder Z4s tend to consume
oil, so keep a close eye on the levels. www.haynes.co.uk
It’s wise to replace the crankcase See Haynes See How
breather If it hasn’t been changed
already, because consumption will
increase dramatically when it clogs.
Using a thicker 10w40 oil may help
curb its drinking habit. USEFUL CONTACTS
Black Circles www.blackcircles.com
BM Town Performance Centre
0151 281 9077 www.bmtown.com
BMW Car Club (GB) 01225 709009
www.bmwcarclubgb.co.uk
Euro Car Parts 020 8956 5000
www.eurocarparts.com
FAB Recycling Ltd 01594 827333
www.fabdirect.com
GSF Car Parts 0121 626 7981
www.gsfcarparts.com
Motormec, Suffolk 01603 485163
www.motormec.co.uk
been known to suffer problems with the

and interlocks develop problems. If the £250), bear in mind it may need recoding. electric power steering, which can become
hood fails to operate at all, suspect a dead With Euro Car Parts selling Pagid front stiff around the central position when the
motor. It’s prone to being water damaged brake pads for as little as £24.42 car gets hot. A replacement rack is the
if the drain tubes which exit via the a set, you can’t go wrong. official remedy, although lubrication in
wheelarches get blocked. Secondhand the correct places on the column will help.
ones cost £200 from FAB Recycling. Brake component prices
Central locking can be problematic, FRONT BRAKE DISCS (PAIR) Suspension/steering
with the most likely culprit being the Main dealer £133 component prices
transponder unit in the key or the GM5 Independent from £52.68 REAR SUSPENSION SPRING
module, the latter is £435.88 new from a FRONT BRAKE PADS Main dealer £117.00
main dealer or £75 secondhand. Main dealer £81 Independent from £44.89
Independent from £24.42 STEERING RACK
Electrical component prices Main dealer £570.00
CAMSHAFT SENSOR Independent from £179.94
Main dealer £104.75 Suspension Secondhand from £395.00
Independent from £49.78 Most components here are taken from
COIL PACK the E46 3-Series, so any problems are
Main dealer £52.48 well documented, notably worn front Miscellaneous
Independent from £22.06 lower wishbone bushes, duff anti-roll If a Z4 smells musty inside, suspect
bar droplinks, worn balljoints, leaky damp carpets due to water ingress via
dampers and iffy rear trailing arm outer the doorcards. Usually this happens
Brakes bushes. Top mounts can also let go on if the membrane has been disturbed.
Brake issues are rare on the Z4 beyond the high milers. Suspension springs have Water in the boot is most likely due to
occasional ABS sensor problem or, in the been known to snap, especially at the water getting in via the rear light lenses.
worst case scenario, a failed ABS ECU, rear, so if a car’s sitting down on one side The Z4 was designed to use runflat tyres,
which is built into the ABS block. If you at the back this could be why. so there’s nowhere to keep a spare. Runflat
manage to find a secondhand unit (from Early cars made prior to 2004 have technology has moved on considerably
since its introduction, so they are nowhere
near as noisy or unpredictable as they once
Z4 M coupé were – or as expensive. If you do want to
Approved for production in 2005, the potent make the swap to standard tyres, a can
M coupé borrowed the E46 M3’s 3.2-litre
343bhp straight-six, as well as components of foam sealant and an inflator will have
from its brakes and suspension. The M’s to be your spare.
limited slip differential completed the
package. Vanos units are more reliable than Misc component prices
in the M3, with problems mainly limited to TYRES
electronic failures such as ignition coils and Cheapest standard tyre
throttle position sensors. Ride is firm, but at least the conventional hydraulic set-up (225/45 R17, Black Circles) £43.40
offers better feel and reliability than the Z4’s electro-hydraulic affair. Brakes are
taken from the M3 CSL, using 348mm front and 328mm rear compound discs. Cheapest runflat
(225/45 R17, Black Circles) £77.10
Follow us on:
www.haynes.co.uk
See Haynes See How

Modification Series: FILTRATION
mance
PART THREE:
TERS
Can a performance
air filter really make
a difference and is it
worth the extra expense
over a standard
disposable filter? Rob
Hawkins investigates
and also looks into
what’s involved in fitting
an aftermarket kit.
A
ftermarket air filters are a
popular upgrade for improving
engine performance. Don’t
expect masses more bhp, but
many of the performance panel filters, So how does an aftermarket filter It’s easy to design an aftermarket
open cones and closed induction kits can improve the performance of an engine? induction system that generates more
help an engine breathe better, resulting And if they are that good, why don’t car engine performance. Strangulation of
in a few more horses and a noticeable manufacturers use them as standard? airflow because a filter or its pipework
improvement in power delivery. A standard panel filter is designed is too restrictive can have a negative
Budget for between £30 and £50 to to trap dirt and be renewed. It’s usually effect. The positioning of the filter and
buy a performance panel filter, around contained within an induction system the distance between it and a throttle
£100 or more for an open cone kit, and that keeps induction noise to a minimum body, for instance, is important. There
upwards of £200 for a closed induction through hard plastic pipework and are also problems with drawing warm
kit (usually comprising a cone inside a resonator boxes. Performance filters engine air into the induction system. The
housing). In most cases, expect 3-4 extra let the engine breathe better and the following pages deal with many of these
bhp from a panel filter, whereas we’ve filtration material used is more expensive issues, including a step-by-step guide to
seen gains of up to around 10bhp with a to manufacture than a renewable paper fitting an open cone induction system in
closed induction kit. However, when it element air filter. The pipework for open a Mazda MX-5 MkII, complete with test
comes to value for money, the panel filter cones and closed induction systems isn’t results and our findings when we tried to
is often the most cost effective. concerned about noise. make our own induction system.
FAQ
Q: Do I need to inform my insurance company before fitting a performance air filter?
A: It’s worthwhile checking with them to make sure they allow such modifications,
especially if they increase the performance of the engine.
Q: Could I run my engine with no air filter?

A: That would improve airflow in many cases, but there would be nothing to stop
dirt getting into your engine. Large pieces of dirt and debris could cause internal
damage, so always use an air filter.
Q: There are lots of cheap, non-branded universal air filters available on eBay. Are they
just as good as those from K&N, Pipercross and other specialists?
A: The materials used in air filters and the design of the cones and panel filters all
contribute to how an air filter performs. Specialists such as K&N, Pipercross, Closed air induction kits, such as this Viper
Green and many others have found the best methods for filtration and this has system from Pipercross, usually offer the
been demonstrated in group tests. You may be saving money by buying a non- best performance gains of any performance
branded universal air filter, but it’s a gamble as to whether it will make a difference. air filtration upgrade, but are also the most
expensive due to their complex design.

DO THEY MAKE A DIFFERENCE?

X The Mazda MX-5 has a closed induction system with a
panel filter concealed in a plastic box and a feed pipe that
takes air from around the nearside front of the engine bay.
The air is then drawn through a pipe that is fitted across
the front of the engine to a single throttle body on the
offside of the engine bay. After checking the condition
of the standard panel filter to make sure it was clean, we
conducted a power run on the rolling road at Roadrunner
Racing (www.roadrunnerracing.net) and, much to our
amazement, found our MX-5’s 1.8-litre twin-cam produced
an impressive 141.2bhp. At the time, the car had 112,000
miles on the clock and should produce around 140bhp.
Next, we fitted a K&N panel filter, which retails for
£51.60. Unlike a standard air filter, the K&N unit doesn’t
need to be renewed at the recommended service intervals
and only needs to be cleaned after 50,000 miles.
On the rolling road, the K&N panel filter only produced
1bhp more than the standard filter. The power curve is
similar, although we did notice a spike, which may suggest
an emerging ignition problem, but nothing that affects the
overall performance of the engine.
The 57i open cone
produced an additional
4.5bhp over the
standard induction
system and panel
filter. The kit is
supplied with a
cold air feed pipe, Power output increased
which helps to draw air over standard when the
from the lower front of K&N 57i kit was installed
the car and feed it up and rolling road tested.
to the cone. This may
help to produce more
performance, but all of the air filters in this case were tested
with the bonnet raised to help draw in a mixture of air. panel filter and 4618rpm with the K&N panel.
Looking at the power curve chart, there are a couple Priced at £156.90, the 57i kit costs almost £35 per extra
of spikes, which suggest a possible ignition problem, but bhp, which in this case makes it better value for money
the overall performance can still be measured. The torque than the K&N panel, which costs £51.60 and only produced
remains similar to a standard air filter and the K&N panel, an additional 1bhp – had it produced 2bhp, it would have
peaking at 4875rpm instead of 4591rpm with a standard represented better value for money.
FITTING A K&N CONE AIR FILTER TO A MAZDA MX-5 MkII
Remove the induction pipework that The MX-5’s standard air-box needs to be The MX-5’s MAF meter is also retained,
1 feeds air into the standard air-box. This 2 extracted. In the case of the MX-5 MkII, 3 but needs to be detached. First, its
is secured to the inner wing with a couple of an air temperature sensor is fitted to the side electrical plug must be disconnected. Pinch
10mm bolts. The pipework slots into the air- of the air-box, so this needs to be pulled out the tab on the side of the plug to release it,
box, so it should be straightforward to remove. and will be later fitted into the cone. then carefully slide it off.

FITTING A K&N CONE AIR FILTER TO A MAZDA MX-5 MkII continued
Undo the clip that secures the Release the metal clips that secure the Undo the two 10mm bolts that secure
4 induction hose to the MAF meter. 5 air filter box’s lid in position. Remove 6 the MAF meter to the lid of the air filter
This may be a large jubilee clip or, as shown the lid and detach the induction hose from box. Carefully remove the MAF meter along
above, a clip with a 10mm nut and bolt – the the MAF meter. The lid can now be extracted with the rubber seal, which will probably fall
nut is supposed to remain secure, but not from the engine bay, but don’t discard it as off. Don’t discard the two 10mm bolts as they
in this case. the MAF meter is required. will be needed later.
STANDARD
SYSTEMS
The K&N 57i
7 open cone can
sit inside the base of
the standard air filter
box, but it’s best to
remove the base and
create more space.
It’s secured with a
couple of bolts that
require a socket and
long extension bar to
undo. Once undone,
lift the base of the air
filter box out of the
engine bay.
X The standard induction system
on most vehicles is designed within
specific parameters and is often
COLD AIR
difficult to improve upon. It needs X One of the essential aspects
to be quiet, so it usually includes of engine induction is the
a resonator box, which helps to temperature of the air being
muffle induction noise. It may have drawn or forced in. The cooler
some form of cold air feed, to draw the temperature of the air, the
cool air from outside the engine greater its density, which means
bay; this may be from within a it contains more oxygen, and
wheelarch, through or below the oxygen is the essential ingredient
front grille or via a dedicated air for combustion.
scoop. We’ve seen some problems So when it comes to fitting a
with such designs, such as Alfa performance air filter, an open
Romeos that hoover up water from cone fitted inside the engine bay,
a cold feed pipe located below the for instance, may result in a drop
front bumper. The MGF has a side in power because the induction
air scoop to draw induction air, system is drawing in warm engine
but wind tunnel tests have proven air from under the bonnet. We
there’s very little pressure in this found this when we fitted an open
area, so it has limited benefit. cone on an MG ZS, positioning the
With the exception of cone right next to the radiator.
performance panel filters, The cone may have been less
aftermarket open cones and restrictive than the standard induction system and panel filter that drew air
induction kits usually require the from the nearside front wheelarch, but the warmer air didn’t help with
standard system to be removed. increasing the performance of the engine.

CAN YOU MAKE YOUR OWN?

X We experimented with several approaches to making your
own induction system. The simplest of these is to remove the
standard panel filter from the air filter housing and replace it
with the universal air filter foam that’s available for motorbikes
– some bracing may be required across the induction pipe if
there’s a risk of sucking the thin foam filter through.
Most people fit a universal open cone onto the end of the
throttle body, extending it with some rubber pipework, if
necessary. However, problems can often arise with this
set-up, including finding the room to fit the cone and
ensuring it can be fed with cold air.
The most ambitious DIY air filter is to construct your own
closed induction system. We tried making our own using a
new paint tin to store an open cone, along with several pipes
including some from an old vacuum cleaner. The results
look terrible, the noise from the tin is awful and the airflow
may be too restrictive, but if you’re prepared to invest
a lot of time into such a project, anything is possible.
An angled bracket is supplied with the

8 57i kit and this has to be secured to a Attach a large jubilee clip (supplied in Carefully feed the air temperature
mounting bracket near the power steering 9 the K&N 57i kit) around the base of the 10 sensor that was removed in Step 2
pump. It will be attached to the side of the new open cone air filter. Next, fit the end of (this shouldn’t apply to the MX-5 MkI) into the
MAF meter later. First, undo the 12mm bolt the MAF meter (the end that was attached to hole in the base of the 57i open cone air filter.
above the power steering pump pulley, then the standard air-box) into the open cone and This will be a reasonably tight fit and there
refit it with the angled bracket. tighten the jubilee clip. isn’t any other means of keeping it secure.
Refit one of the 10mm bolts

12 for the MAF meter (see Step 6)
through the top hole in the angled
bracket that was fitted in Step 8
and into the side of the MAF meter.
This helps to keep it steady. Tighten
all the jubilee clips.
USEFUL CONTACTS
Green 01928 581284
www.green-filter.co.uk
ITG 024 7630 5386
www.itgairfilters.com
K&N 01925 636950
www.knfilters.co.uk
Pipercross 01604 707750
Reattach the MAF meter’s electrical plug
11 that was removed in Step 3, then fit the www.pipercross.net
air filter and MAF meter back onto the induction Powertec 01933 685840
pipe. Make sure the wiring for the MAF meter www.powertecfilters.co.uk
and air temperature sensor are not stretched.

Dealer’s Diary
Our man in the trade, Steven Ward, washes some
soundproofing and sees a cop car being incinerated.
Flood Severe rain had caused flooding, then the skies cleared
and a sharp frost produced an unwelcome surprise.
damage e witnessed a somewhat bizarre
W phenomena in our showroom

over the winter. Not so much
spiritual, but definitely very physical.
We had taken in an old swapper and
decided to tax it to run over the winter.
I’d driven this car extensively on a very
wet weekend in Hawes, North Yorkshire.
The standing water on all those country
lanes meant I surfed my way around the
Dales. When I got home, the skies were
crystal clear, heralding a sharp frost.
What happened next came as a surprise.
The car’s offside front wing was now
twisted badly: misshapen, ill-fitting between wing and inner chassis was
and catching the leading edge of the usually vacuum-sealed in a polythene
door when it was opened. I had clearly bag, but this bag had been ripped to ‘I’d pressure-washed the
damaged the vehicle while in my shreds, presumably at the same time as sound-deadening material’
possession, but through no real fault of someone had butchered the wheelarch
my own. The damage looked to be coming liner. Now I’m guessing this was done during the drive home in sub-zero
from the inside out, as the only flaw in by a home mechanic to get to a failed temperatures. Furthermore, I had left
the paint was a crack resulting from washer pump without using a ramp. Or it to stand outside as the temperature
the bulging metal. Under the bonnet, tools. Or common sense. dropped even further and the wing
everything was in order, but, admittedly, Whatever the reason, the result was twisted and cracked when the combined
somewhat dirty from the road trip. that I’d essentially pressure-washed water and foam expanded.
Unbolting the wing, the cause of the the sound-deadening material over the So is this classed as an Act of God or is it
damage became apparent. The moulded course of the weekend, then subjected the unintended consequence of a shoddy
sound-deadening material in the space the sodden foam to a fast-freeze mechanic? Just for the books, like?
Euro 6 farce ‘The Euro 6

s the ‘65-plate’ came into fashion on September 1,
A 2015, there were around 20 types of passenger car

that did not meet this new emissions target. That
meant they couldn’t legally be registered on or after that date.
laws are a
headache’ From Sept 1, 2015
all new vehicles
had to be Euro 6
How then have I seen some of these vehicles being sold with compliant.
whopping great discounts on dealer forecourts?
Believe it or not, you could register these cars on the
65-plate provided they were ‘sold’ on that plate BEFORE
September 1. That’s not a problem for most dealers, as they
have an allocated bunch of registrations way in advance.
I still cannot get my head around this or the point of the
emissions cut-off date. I’ll not even go into the fact that if the
car sells for less than a certain number per annum, dealers
can continue to retail them.
My point is this: Euro 6 is a headache involving a post-
burn clean-up exercise that costs a fortune in kit and adds
to woeful reliability. If you are in the market for such a car,
then give one of these pre-reg Euro 5 dinosaurs some serious
consideration. They’ll be cheap to buy, cheaper to run and
more reliable than their cleaner counterparts.

Dealer’s Diary
Police, camera, action ‘Repairing a police car

ack in the day, when I was a thought the sight of a very high- in a civilian environment
B serving police constable, the
cop cars were maintained in
our own workshops. That is, except for
performance car in the distinctive
‘Battenburg’ livery with ‘the blues’ on
top would look good outside the front
has strict guidelines’
the air-sprung Land Rover used by the of their premises – and it did. I mean, it I’ll point out now that this traffic car
inspector of the firearms division, but was a very well-heeled area of town and was secure in the front of the premises
then that was a complicated, unreliable just down the road from the local nick. and wasn’t about to be stolen. However,
bit of kit that led a hard life. As a boy who grew-up on a council locked barriers, CCTV and sturdy
Sadly, dedicated police workshops estate and who enjoyed hearing the tall security posts are no impediment to a
as we knew them were closed due to tales of the local traffic division’s Sierra well-aimed series of Molotov cocktails.
relentless budget cuts. These days, as the Sapphire Cosworth being joy-ridden to The car may well have been repaired
vehicles have got ever more complicated death, while the Pandas were ‘bricked’, that day, but by the evening it was a
to repair while paradoxically requiring both you and I know what is coming next. smouldering shell.
less routine servicing, it’s the retail
network that has stepped in. Leaving a Police patrol vehicle outside a
bodyshop premises, it ended up like this.
As you can appreciate, repairing a
police vehicle in a civilian environment
is not without very strict guidelines.
Keys must kept locked away in
a separate office, there are rules
regarding road tests and the cars must
be secure at all times. As a result, only
very select retail premises are entrusted
to carry out servicing and repairs.
One very well respected garage
I know did such a repair by the
(accreditation) book. Bullishly, they
out. I started to open the supercharger
Bin-end Benz
s I put the gearbox into 6th, the
up, slotting it into 6th at 70mph and the
Merc flew, not that it ever felt potent
A
Benz had received a fair bit of fettling; pottering around Peterborough. The
King came onto the radio and, a front spring and some other odds and MPG climbed from low 30s to high 30s.
at that point in the proceedings, ends for the MoT test (they are notorious And this was how it remained all the
the car made some sense to me. It is a for springs) and an engine smoke test. way home. Had Car Mechanics cured the
good motorway car and it has a terrific The smoke test highlighted a certain troublesome Stuttgart car?
stereo. I still didn’t care for this model lack of air-tightness around the EGR My faith in these cars is non-existent.
of M-B however. That’s because they valve and this had been resealed. Would They were bought by people who strived
have previously caused me so much this cure the constant Engine Warning themselves into debt to buy a Benz
grief in the garage. Light? Or would the Mercedes main when what they had, in reality, was
This then, was the collection and agent have the last laugh? Focus finances. Ambition is all well and
delivery of CM’s recently-completed Well, 200 miles was duly exceeded not good, but when the car has less integrity
project car – The Mercedes-Benz C180 long after I had pointed the Benz’s bonnet than a Maestro, but with the costs and
Kompressor hatchback/coupé thingy. star north. The warning light remained complication of a Prestige, you can
I’d taken the train down to Peterborough see where the trouble lay. Customers
to meet Editor Martyn for the handover. couldn’t and wouldn’t pay for all their
I’d also used the meet to have a tour of faults and the required maintenance.
Bauer Media Mansions and, naturally, So why am I flogging this thing up the
a Chinese buffet for lunch. A1 when its sale will be a tale of grief ?
Martyn was late and he Well, if you cast you mind way
had crippled the car’s average back to CM’s Project Micra,
MPG due to the traffic around The ex-project Mercedes C180K completed you will recall how I sold that
the M25. Crucially, however, nearly 400 miles in 8hrs, returning 38mpg. to a schoolfriend? This M-B
the amber stare of the Engine was now going to her husband,
Warning Light had not whom I also went to school
illuminated. This was despite with. No CM reader had the
the lack of advice taken by faith to buy it, but my mate did.
the Mercedes main agent (ie, To date, the dreaded
throw thousands of pounds at Management Light has remained
it). To date, the Merc had never extinguished. My mate Trev is
exceeded 200 miles before over the moon with it. Nobody is
setting the warning light aglow. more surprised than me with this
Prior to my collection, the news. Except maybe Martyn!

CM Visit We call in on those businesses making
a difference to the motoring world,
for an insight into their operations.
Philips Automotive
Lighting (Lumileds)
In a quest to discover Quality is paramount to Philips, an OE supplier.
Humans augment computer checks, examining
how many people bulbs under UV light to find any imperfections.
it takes to change a
headlight bulb, Rob
Marshall ventures
to Germany and
discovers that it is
more than he thought.
T
hanks to developing and
manufacturing such a diverse
range of products, from electric
shavers to dictaphones, Philips
has become a difficult company to define.
Yet, it remains uncommon knowledge resulted in one of the most advanced headlight, can not only reduce visibility
that the Dutch firm took its first steps car lamp development, testing and but also increases glare for other
to become one of the largest electronics manufacturing hubs in the world. drivers, which can be dangerous.”
companies in the world, by manufacturing The testing rig projects a dipped-
light filaments in 1891, prior to making beam pattern of several different lamp
its first car lightbulb in 1914. Philips All down to accuracy units onto a measurement screen, 25
has split the lighting division from My tour of the Philips facility begins at metres away, which demonstrates that
its consumer lifestyle and healthcare the Application Centre, a testing nucleus all headlamps are far from equal, even
interests and today employs more than that evaluates not only the effectiveness though they all comply with the same
1200 people at its automotive lighting of bulbs (including their luminance and European Type Approval legislation.
centre, Lumileds Germany GmbH, light emission) but also the performance Similarly, not all light sources are the
situated in Aachen, the country’s most of headlight optics. same. If a bulb was badly made – with
westerly-based city, close to Cologne. “An effective and safe headlight is a misaligned filament, for example
Based on a giant industrial site, shared a combination of a good-quality – the headlamp optics will be unable
with the company’s research hub, headlight and a well-made bulb,” to make efficient use of the light. The
automotive bulb production commenced explains Lukas Küpper, Philips’ senior result might be excessive glare in
at the Philips Lighting Business Centre application engineer. “A poor bulb, some parts of the beam pattern and
in 1962. Continuous development has fitted to an ill-designed or damaged insufficient illumination in others.
Lichtverteilung Straße Lichtverteilung Straße
[m] [m]
-12.0 -12.0
-10.0 -10.0
-8.0 -8.0
-6.0 -6.0
-4.0 The difference in -4.0
-2.0
light distribution, -2.0
0.0
2.0
between a poorly- 0.0
2.0
4.0
made bulb (left) 4.0
6.0 and a well-made 6.0
8.0 alternative (right), is 8.0
10.0
substantial, as shown 10.0
12.0
14.0
on these charts 12.0
14.0
10 20 30 40 50 60 70 80 90 100 110 [m]

for bulbs that were 10 20 30 40 50 60 70 80 90 100 110 [m]
2 3 5 7 10 14 20 24 32 40 50 60 70 80 100 [lx]
tested in the same 2 3 5 7 10 14 20 24 32 40 50 60 70 80 100 [lx]
headlight unit.

Car Mechanics Visit Philips Automotive Lighting
All Philips headlight Philips manufactures all of the bulb’s component

bulbs start their parts in-house, excluding the metal bases, which are
lives as long quartz fitted only after their alignment is checked in relation
glass tubes, which to the filament. This applies to every halogen bulb.
are loaded manually
into a machine at the
start of the process.
The tip of the halogen bulb is placed into paint,

which is baked on. On imitation or badly-made
bulbs, the paint can burn away, causing light Cameras and
scatter and damage to the headlight’s internals. computers
maintain the tight
dimensions required
throughout the
production process.
Here, a filament’s
dimensions have to
fit within the green
box, in order to
meet the company’s
0.1mm tolerance.
Research at Philips has uncovered that the infant technology cannot match over 2000 on-and-off cycles. Needless to
approximately one in four aftermarket HID headlamps for effectiveness, at the say, the large room was rather warm!
bulbs are built to a poor standard. time of my visit, being to the standard
Excessive glare is also a reason why of a poor H7 halogen bulb. Ironically,
fitting either HID (High Capacity with today’s obsession to reduce weight In production
Discharge) or LED (Light Emitting and power consumption, the LEDs The trip culminated in a tour around
Diode) aftermarket conversion kits get so hot that the headlight has to be both the halogen and HID bulb-making
into a halogen lamp housing is a bad fitted with cooling mechanisms. More facilities. Both processes commence with
idea, because the lamp optics cannot worryingly, the lamp unit’s internals are long, glass tubes being fed into specialist
work with an incompatible light source. inaccessible, meaning that the entire cutting and moulding machinery, prior
There is also a possibility of damaging headlamp will require renewal should to progressing across the production
the headlight’s reflectors, through either a long-lasting LED fail. For any reader area. The whole procedure is highly
excessive heat (HID bulbs generate that remembers sealed beam headlights, mechanised, from the making of the
heat in different regions of the bulb) or it appears that LED headlight delicate halogen filaments to the
excessive ultraviolet radiation. Fitting technology might be a retrograde step, impressive way that the HID bulbs are
such kits also contravenes European for the time being. filled with salt and gas, as one end is
Type Approval and British Normal IVA frozen with liquid nitrogen, while the
tests, as well as various other laws. opposite side is super-heated and sealed.
Testing, testing However, it is the accuracy of
As Philips serves original equipment production that impressed the most. The
‘One in four aftermarket suppliers, all of its bulbs, including filaments, for example, are produced to a
bulbs are sub-standard’ those for the aftermarket, have a 0.1mm tolerance, with numerous cameras
failure rate that cannot exceed one per on both the halogen and HID production
Instead of using a filament, HID bulbs million. Although every bulb is tested, lines continuously monitoring the quality
are mini arc lights, with the light source approximately one in seven is extracted control procedure. Humans support the
emanating from a mixture of salts and from the production lines and placed hardware with regular visual checks and
gases. Just like conventional strip- through exhaustive trials in a laboratory this production precision not only allows
lights, they require a ‘jump start’ to get that operates 24 hours a day. These Philips to achieve the strict reliability
them running, but as the bulb heats up include vibration tests, chemical tests targets but also its bulbs last longer, while
and the gases vaporise, they draw less and cold water spray exposure. Philips’ permitting the headlamp’s optics to
power than conventional halogen bulbs, Halogen bulbs, incidentally, are made work at their most efficient rate.
while being considerably brighter. Due from quartz glass, making them less “While our bulbs are more expensive
to this, both ballast and starter units prone to explode if soaked. than both counterfeit Philips products
are required. Self-leveling optics and As a voltage increase of 5% can almost or inexpensive replacements that
external washers are requirements on half the life of a halogen bulb, the tests also tend to be found online,” says Jürgen
the majority of HID lamps, to reduce the include over-voltage tolerance, as well as Melzer, Philips’ automotive lighting
risk of dazzling oncoming motorists. ensuring that the bulb’s output does not technical consultant, “they give superior
While LED headlamps are all the drop below 20% throughout its life. performance, last longer and, of course,
rage with new car buyers, Lukas’s As HID bulbs tend to suffer more from comply with the legal directives of the
demonstrations led me to believe that repeated switchings, these are tested to European ECE regulation.”

Your letters should
Your Letters
be addressed to
Martyn Knowles,
Car Mechanics,
Bauer Consumer Media Ltd,
Media House, Lynchwood,
Peterborough PE2 6EA
Email: martyn.knowles@
KEY FACTS
X I found the article on
bauermedia.co.uk
Please include a postal
address with letters
refurbishing VW key fobs (CM, submitted by email.
July 2015) extremely useful. Of
the two fobs I have for my 2002 After my initial success with
VW Golf GTI 2.0, one had non- the first fob, I ordered another
functioning buttons, while the with plans to refurb the
other had a broken attachment second key. However, I ordered
for a keyring. After reading from a different company
your article, I immediately car. A knowledgeable friend top left of the fob in the first and this new fob was only
ordered a replacement case suggested that I had failed picture, in the small capsule- compatible with the key that
online for around £4. to swap over the immobiliser shaped pocket of the fob; came with it, not my original
Thanks to your article, I was element from the original fob. the second photo shows key. There does appear to
able to dismantle one of the I dismantled the refurbished it removed from the fob. be some variation between
fobs and reassemble it with fob and, sure enough, there I prised the element out with a the refurb kits being offered
the new case. I kept my key, was the element he described. spudger and temporarily held online. Of course, getting the
as there was nothing wrong It is very small and easy to it in the new fob with Blu-Tack key cut was inexpensive, but
with it. When I tested the fob, miss, but I have attached in case it needed removing meant the second refurb was
it opened the doors with no some photos to show readers again. The Golf started and not as cheap as the first one.
problem, but wouldn’t start the what it looks like. It is in the everything worked fine. Patrick White
SWEDISH CHAIN OF EVENTS

DEFENDER X I was interested in the recent feature on
timing chains (CM, October 2015) and on the
With this engine, you can buy a new spring and a
seal for the plunger-type tensioner for a few quid
X After reading your Survival problems with longevity. I have had two chain- from BMW, which I did. Again, the difference was
Guide for the Volvo XC90 (CM, driven BMWs and the problems I’ve experienced noticeable and the engine is now up to 140,000
Sept 2015) and Steve Darbin’s have been related to the plunger-type tensioners miles on it’s original chain, with no known issues.
reaction to it in Your Letters rather than anything else. If my 330i had a belt-driven engine then it
(Oct 2015), I feel I must point The first was an E46 318i with the N42 engine, would either already be on it’s second belt or
out a few errors given my which started to develop a chain rattle on fast approaching a belt change, so even if the
experience of this superb car. cold starts at about 70,000 miles. I did some chain went now it would have far outlasted a
First, you mention the “weak” research and found out that there had actually cambelt. It’s probably worth mentioning that
gearbox – this was, in fact, the been a recall on the tensioner and that my car I change the oil every 7500 miles and I only use
GM autobox that was only fitted hadn’t had the replacement. BMW sold me the quality engine oil and filters, so my chain rattle
to the T6 versions and has a upgraded part for peanuts as it was a recall part wasn’t due to poor maintenance.
life expectancy of only 85,000 and I fitted it straight away. The difference was Given my experiences, I wonder if it’s not the
miles. The five- and six-speed very noticeable and I put another 25,000 miles chains that are the problem, but the tensioners
Aisin Warner units are much
on that engine with no further chain rattle. that need to be seen as consumable parts? In the
tougher, with lives of more
My second experience was with an E46 330i case of these BMW engines, they are cheap and
than 200,000 miles being the
with the M54 unit. At around 120,000 miles, it also only take 10 minutes to replace at an oil change.
norm. You also point out, quite
started producing a bit of a rattle on cold start. Ben Jones
rightly, the failure of the swirl
flap arm, but Volvo do sell a fix
for less than a tenner!
I bought my 2006 185
Geartronic in 2010, with 80,000
NEW GENERATION
X I have been buying your magazine for the past
FULL CHARGE
X In my experience, cars with a stop-start
miles and a full service history three months after being told about it by a young function that are used only for town driving
plus a recent cambelt change. DIY mechanic who fixed my Skoda Fabia diesel. have batteries where the power level is
The car has now covered The Fabia had a running fault where the engine always just above the minimum needed for
150,000 miles. Apart from the would cut out if you didn’t keep blipping the the stop-start to work.
usual service items, it has only throttle and two garages had failed to fix it. Then The battery never gets a good charge,
needed a new swirl flap arm, a friend recommended this mechanic, saying said even though the alternator is working hard
both rear wheel bearings, rear he was very good. to put power in the battery and the engine
discs/pads. Over this time, the The mechanic listened to the car running, then is using a bit more fuel. Each time the car
XC90 has averaged 32mpg told me that it was a common problem that he stops, the engine stops and it will take about
(I do avoid short trips) and had seen on other Fabia diesels. It was due to a 2000 watts to restart and this power has to
taken four adults and two kids fault in the wiring from the fuel pump to a wiring be put back into the battery
on several holidays without a connector, caused by two or three wires fraying, I recommend using a smart charger to
hiccup. In the 45 years since resulting in a poor connection to the fuel pump. He fully charge the battery every few months
I started driving, this is definitely had it fixed and running perfectly in 25 minutes. on cars that never get a good run. This
the best car I’ve ever owned. It is great to see your magazine encouraging applies to cars that have little use or only
That’s my experience and young people to take an interest in cars. I am sure do short trips. Often the engine runs better
judging by the comments by there must be a lot more very good young DIY afterwards, because the force needed to spin
Volvo owners club members, mechanics out there and I am sure your magazine the alternator has been reduced.
I believe it is typical. is a great encouragement to them. The battery needs charging, not replacing!
Dave Head William Ponsford Jonathan Willis

CHEAP AUDI FIX
X I have some useful information for any Audi
LETTER
turbo owners. I own a 57-plate Audi A4 2.0 TFSI
and had been having problems with my turbo,
which would cut out when accelerating and
remain out of use until the ignition switch was
turned off then back on again. The problem
seemed to manifest itself after the engine
was warm and the diagnostics indicated
there was a turbo overboost problem.
All the online forums suggested that the
problem was due to a sticking wastegate

valve and that a replacement turbo was
needed, at a cost of £450-£1500 depending
LETTER
The reader awarded the
on whether it was a reconditioned or new
letter will receive a
unit – this was without labour charges. One
member of a forum had tried replacing the
SEALEY LED3601G lamp
MAP sensor, to no avail. He then replaced This Sealey 360° lamp can
illuminate your workspace no
the N75 valve, which controls the wastegate matter where you are. It can
actuator, and the problem went away. hang, attach and best of all, be
An N75 valve from Audi costs just £25. It’s set to any angle you need, from
very fiddly to replace, as it is bolted to the any angle you want, thanks to
its’ unique 360° rotating ball
side of the turbo, but once the two bolts are If I had fitted a new turbo or a refurbished feature in the base. This unique
undone and the three pipe clips removed, unit, my problem would have gone away as feature, along with its’ powerful
it comes out easily. Inspection of the old all refurbished turbos have the N75 valve magnets, mean that you can
unit revealed a small split at the top of the replaced as part of the refurbishment and position it in the most awkward
of spaces, leaving you with both
housing, probably caused by excessive heat new turbos come with it pre-fitted. So if your hands free to work.
due to its close proximity to the exhaust turbo suffers from an over-boost problem, try The Sealey LED3601G is a mini
manifold – you couldn’t think of a worse replacing the N75 valve first. You could save and lightweight lamp with 2W
place to fit a plastic-bodied unit! When fitting yourself a small fortune. COB LEDs, which emit a purer
the new N75 valve, I placed two small fibre David John source of light compared to
other LEDs. One single light
washers between the mounting plate and source means one shadow,
the unit, to try to reduce heat transfer. The Martyn Knowles responds: Great tip, David. unlike multiple SMD lights. The
car now runs like it should, with the turbo This will also apply to other VAG cars using lamp also has the addition of a
working at full engine temperature. the TFSI unit in various power outputs. micro USB charging port.
THE BIG CHILL

X Regarding CM Insider in the December 2015 The radiator and thermostat work together to
issue, I must refute the point about wind chill maintain coolant at the desired temperature
factor and that driving at 50mph into a head
wind when the ambient temperature is -1°,
and there will be no chance of it freezing.
Problems might arise if a vehicle is left
FAN MAIL
X Some time ago, you
results in air passing through your radiator at standing in wind at very low temperatures,
published an item about a
a much cooler temperature. where the coolant will cool down more rapidly
common problem on the Ford
Wind chill is a Met Office expression designed than in still air (but still only to the ambient
Fusion and Focus 1.6Ds where
to indicate that standing in a breeze makes one temperature). If the coolant concentration has
the coolant fan was coming on
feel colder than standing in still air at any given been allowed to fall then freezing could occur,
intermittently when not needed.
temperature. That is because the heat is taken but that would not be a problem in any vehicle
Recently, my own Fusion began
away from your body at a faster rate in wind or a with a properly maintained cooling system.
permanently running the fan
draught. When you are driving, whatever speed John Cookson
day and night.
you are doing, the air passing through your
The temporary answer was
radiator will remain at -1°. Martyn Knowles responds: We did ask the
to disconnect the fan. At the
Since that is how a radiator is designed to work, Pro Panel team to comment on the chill
back of the battery is a black
it cannot and will not cause the coolant in the factor statement made by ATS Euromaster,
box with three relays inside.
radiator to fall below the ambient temperature. but it failed to respond.
Removing the grey relay (part
no 5M5T 14B 192 EA), I found
EVERY VOLT COUNTS

X The other week I could not Bizarrely, I have been told of the Trades Description Act?
that terminals 3 and 5 were
closed circuit, but should have
been open circuit. I purchased
start my car. The dashboard that the car’s ignition system This got me thinking: why two used relays very cheaply
lights were not functioning, the requires the battery to have a don’t car manufacturers use and, before fitting them,
lights would not come on and charge of 12.66 volts to crank 14-volt batteries instead? A I connected 12 volts to
even the central locking failed. the engine. This meant that 14-volt battery would provide terminals 1 and 2 to ensure
I measured the charge in the because my battery’s charge the extra oomph to start the car, the relay was functioning.
battery, which read 12.16 volts. had 0.5 volts less than this with back-up capacity, although, I have now taken apart the
So why wasn’t the car’s battery magic figure, it would not obviously, the vehicle’s 12-volt original relay and the contact
operating the starter motor? start. So manufacturers are electrical circuits would require points show considerable
Logically, a 12-volt battery installing 12-volt systems, yet semi-conductors to protect the burning of the contacts. I hope
reading more than 12 volts the batteries they fit need an individual circuits from damage. this is not to be the next car to
should have sufficient charge additional charge in excess In the end, I bought a follow the mysterious fires in
to turn over the engine until of the rating printed on the replacement battery. Vauxhall Zafiras!
the alternator kicks in. Wrong! casing. Surely this is a breach PJ Bott AA Steel

DIY Servicing
2011 CITROËN DS3
DStyle + e-HDi
Treat your
DS3 to a
full service
The stylish DS3 is perceived
as being quite complex.
However, servicing is relatively
straightforward, so long as you
don’t mind a little dismantling, Overall difficulty rating
explains Richard Gunn.
T
rivia time: did you know that, in overcome any issues. As these Citroëns
ZF SERVICES PROTECH: 2011, the Citroën DS3 became were only launched in 2010, most will
THE WORKSHOP CONCEPT FOR
DRIVELINE AND CHASSIS.
the first car to be ‘product only just have emerged from the period
placed’ in a British pop video, of main dealer servicing, which means
Q
Q
Engineer on-site garage visits
Dedicated first class training
when it appeared alongside a snakeskin you have the opportunity to check if
Q Direct contact to expert transmission specialists leotard-clad Pixie Lott in her promo for they have been doing a proper job!
Access to extensive technical know-how
Q
Q Online portal providing you with a complete

What Do You Take Me For? The DS3’s bold and handsome looks,
resource of technical information What will be of more significance to with lots of funkiness thrown in for
www.zf.com/uk/protech CM readers is that, despite appearing good measure, have made the model
to have a complicated mechanical very successful in Europe, with the
set-up, the French supermini shouldn’t diesel versions being particularly
present too many problems when it popular. The 1.6-litre engine of our
comes to DIY servicing. Although a lot e-HDi example puts out 90bhp, giving it
is squeezed under the bonnet – which quite frisky performance despite being
Equipment required does make some things difficult to capable of around 80mpg. That makes
i Jack i axle stands i oil tray i sockets and
access, especially the fuel filter – some it very economical to run, and if you
spanners i flat-blade, crosshead & Torx screwdrivers patience and a decent set of tools should service it yourself, the savings stack up.
i wheel brace i antifreeze hydrometer ielectronic
brake/clutch fluid strength checker iwire brush
i abrasive paper i copper grease ispray grease
ityre pump itorch itorque wrench irags for
Underbonnet layout BRAKE & CLUTCH
FLUID RESERVOIR
cleaning idisposable gloves
POLLEN FILTER FUEL FILTER AIR FILTER
(under trim cover) (under cover) (under cover)
Richard says
There have been instances of the rear wheelarch
liners coming loose on DS3s, which will mean
they collapse towards the wheels. Not only does
this look unsightly, but if they collapse too far, it’s ENGINE OIL
a safey issue and not something FILLER CAP BATTERY
you want to have happen at (under cover)
speed. So a service is a good
time to check the security of
the liners and, if it looks like
things are starting to wear
out, take steps to secure them.
Silicone sealant inside the arch
lip, with the liner held in place with
clothes pegs until it sets, works
surprisingly well.
COOLANT
RICHARD GUNN EXPANSION SCREENWASH ENGINE OIL FILTER
Special Contributor TANK RESERVOIR OIL DIPSTICK (under pipework)
www.zf.com/uk/protech

DIY Servicing 2011 Citroën DS3 DStyle + e-HDi
UNDER THE BONNET
1 REMOVE ENGINE COVER 2 REMOVE AIR FILTER COVER 3 CHANGE AIR FILTER
It’s no surprise that Citroën, one of the Once the engine cover is out of the way, it’s With the old air filter out of the way, clean
most style-conscious of all car companies, time to change the air filter. It’s held on by the inside of the box with a cloth, getting
should try to beautify its engine by sticking a three Torx screws; undo these and the top can rid of any old leaves, debris, etc. Then drop
cover over the top of the engine. It shouldn’t be lifted off. Remove the paper element from in the new filter. The element is sculpted to
discourage the DIY-er though, as it simply inside – this one looked like a mouse had the shape of the box, so there’s no chance of
pulls off, allowing access underneath. been living inside! putting it in the wrong way.
4 CHECK COOLANT 5 TOP UP SCREENWASH 6 CHECK BRAKE FLUID

The coolant expansion tank is transparent, Right next door to the coolant expansion tank The combined brake and clutch fluid reservoir
so the level can be checked with reference is the screenwash reservoir. As its contents is tucked underneath the bulkhead. If the
to the marks on the side. However, we get more rapidly used up during the winter exterior is grimy, a torch will help verify
recommend using a hydrometer to test the months, make sure it’s full. You can’t see the fluid is at the level it should be. Use an
strength, to ensure the mixture will make it much more than the neck of the reservoir, so electronic fluid checker to check strength. If
through winter without freezing. It should be just add the correct mixture of screenwash any topping-up is needed, use DOT 4 fluid. Be
renewed every two years. and water until it reaches the top. careful not to spill any as it’s corrosive.
7 REMOVE FUEL FILTER PIPES 8 REMOVE OLD FUEL FILTER 9 CHANGE FUEL FILTER
The fuel filter is also up near the bulkhead, There are two 8mm bolts that hold the fuel Put the new fuel filter in a vice, and, if not
towards the right-hand side of the engine filter in place. Take the casing over to a already in place, fit the rubber O-ring around
bay. It’s rather buried by pipework, so the suitable work surface. Twisting the centre the top hole. Put a smear of oil around the
first thing is to remove these. The in-pipe tap will allow you to drain off the fuel inside, top to aid with sealing. Although there’s
(on the left as you face it) has a tab you pull from underneath. Then, keeping it upright, a hand primer pump that you can use, it’s
up to release it, while the other two have undo the three T20 Torx screws so the probably easier to pre-prime the filter with
tags that need to be pushed in. plastic top can be removed. diesel or fuel additive before it goes back on.
ZF SERVICES PROTECH: THE WORKSHOP CONCEPT FOR


UNDER THE BONNET (continued)
TOP TIP
Once the fuel filter
is back in place and
the service finished,
it may take a few
turns of the engine
before it fires up. If
it refuses to start,
use the hand primer
pump button again,
to help to draw in
more fuel.
10 PRIME & RE-FIT FUEL FILTER 11 CHECK BATTERY 12 REMOVE OIL FILTER
To prime the filter, connect a length of fuel There’s a very complex battery arrangement Citroën hasn’t made it easy to get at the
pipe to the inlet pipe of the filter assembly, on these cars, with multiple connections oil filter – it’s tucked away underneath the
then pour in an amount of diesel or additive lurking underneath the hinged plastic top flap. turbocharger. Start by moving aside the air
via a funnel. Use the pump button on the There’s no option to check the acid level inside inlet plastic casing (next to the battery) by
top to help draw it in. When the filter is the battery, so just make sure all the terminals removing its trim clip, then push one of the
full, put it back on the engine and then are secure and give them a coating of plastic tabs up so the retaining clip can be
reconnect everything. protective grease to help stave off corrosion. slid back. This releases the casing.
TOP TIP
There’s a
prominent peg
on top of the
filter element
that will need
to be properly
located in the
cap when you clip
it on. When the
whole assembly
goes back on the
car, it should be
torqued to 25Nm.
13 REMOVE TURBO PIPEWORK 14 REMOVE OIL FILTER 15 CHANGE OIL FILTER

Next, you need to unbolt the pipework that There’s still not a lot of room to get at the The old oil filter element simply unclips from
goes into the turbocharger. Fortunately, it’s oil filter, thanks to the other surrounding its top and can then be discarded. Fit the new
only held in place by a 10mm bolt, although pipes, but it should just about be accessible, filter element in its place. Also make sure you
it may still be difficult to twist off. You’ll also assuming you take care and use a long remove the old rubber sealing ring from the
need to disconnect the mass air meter wiring socket; you’ll need a 27mm item. Try to top’s thread and put in the replacement that
plug before you can finally get the pipework have some old rags around to soak up the should come with the new element, with a
out of the way. inevitable splatter as you take it out. light skim of oil to help sealing.
UNDER THE VEHICLE – FRONT
16 CHECK DRIVEBELTS 17 CHANGE POLLEN FILTER 18 DRAIN ENGINE OIL

Clearance to see the drivebelts is quite The filter is behind a plastic trim cover in the Before you drain the oil, you’ll need to remove
restricted, so it’s a good idea to check them right-hand side bulkhead. The trim simply the engine undershield. It’s held on by seven
from beneath the car as well. You should keep pulls away, after which you can reach in and 10mm bolts. The sump drain plug requires an
an eye out for signs of fraying and tearing, remove the filters. And yes, we do mean filters, 18mm socket to remove it. The old oil should
and ensure there’s not too much slack because for some reason, the DS3 has two be emptied when warm. System capacity is
between pulleys. The belts shouldn’t be able fitted. Make sure you extract both and, when 4.25 litres, so make sure you have something
to be twisted any more than half-a-turn. you replace them, put them in the right way. underneath to hold this amount.

TOP TIP
The copper
washer on the
sump plug should
be replaced when
the oil is changed,
otherwise the
sump could
start leaking.
19 REFILL ENGINE OIL 20 CHECK UNDERBODY 21 CHECK GEARBOX OIL

Use 5w30 fully-synthetic engine oil. Although Look underneath for any signs of corrosion or The transmission oil level check plug is on
official capacity is 4.25 litres, it’s unlikely damage, especially where the metal brake and the end of the gearbox, where access is tight.
you’ll be able to fit this in due to old stuff left fuel lines are exposed, and look along the entire Nevertheless, you should be able to get in a
in the system. We suggest putting in about exhaust for any rust or damage from bumps. 19mm socket to undo it. Then dip in a finger
three litres, then starting and stopping the Also make sure the mountings are secure or cable tie, to make sure the fluid is up to
engine briefly, before topping up further and and won’t allow the exhaust to knock against the level of the neck. Fluid shouldn’t be too
making reference to the dipstick. the bodywork or even drop off completely. dark or smell burnt.
TOP TIP
Tyre pressures
on this car are
35psi all around,
although they will
vary depending on
what wheels are
fitted. Pressures
for your model will
be on a label inside
the passenger door
shut. Road wheel
bolts should be
torqued to 110Nm.
22 CHECK WHEELS & TYRES 23 REMOVE WHEELS 24 CHECK STEERING

Check all road wheels for anything stuck The wheels can now be removed. Each nut is Before you dismantle the brakes, check
in the tyres, as well as cracking, kerbing or covered by a plastic cover. There’s a proper the suspension and steering components.
bulging. Also ensure they’re road legal, with tool to take them off, which should be in the Lookout for perished rubber bushes, broken
at least 2mm of even tread left. Rock the spare wheel toolkit in the back of the car, but road springs and leaks from dampers and
wheels top to bottom; significant play points it’s just as easy to extract them using pliers. brake lines, usually around unions. Also
to suspension issues. Finally, spin the wheels; Also in the toolkit in the back should be the check the CV boots to make sure there are no
a low drone points to worn wheel bearing. locking wheelnut tool. gaps letting in dirt, which will lead to wear.
25 REMOVE BRAKE CALIPERS 26 FURTHER CLEAN BRAKES 27 CLEAN BRAKE PADS

Clean up the brake assembly using a wire With the pads and calipers out of the way, The pads on this DS3 needed replacing, but
brush, then use a 13mm socket or spanner continue to clean with both a wire brush and assuming yours have 2mm of friction material
to remove the two bolts on the rear of the proprietary spray cleaner. Scrape any grime left, they can be reused. Rub their fronts
caliper. The caliper can then be lifted away, and corrosion from the mountings where the against abrasive paper and apply copper grease
although you’ll probably need to prise it away pads sit using a flat-blade screwdriver. Also to their rears and mounting lugs, as well as
with a screwdriver. The pads should stay in turn the rim of the disc against a screwdriver the clips on the caliper where they mount.
place around the disk, so prise them out, too. to scrape off loose corrosion. The caliper bolts will also need lubrication.
ZF SERVICES PROTECH: THE WORKSHOP CONCEPT FOR


UNDER THE VEHICLE – REAR OTHER ITEMS
28 CLEAN REAR BRAKES 29 FURTHER CLEAN BRAKES 30 CHECK SPARE WHEEL

The rear brakes are also discs, so clean them Carry out more cleaning on the inside of the The spare wheel is under the boot floor, held
with a wire brush. You’ll need a 13mm spanner calipers – use a flat-blade screwdriver to in by a rather fiddly yellow plastic screw.
or socket for the outer rear caliper bolts, scrape out any stubborn, compacted dirt. Undo this and take out the spacesaver type
and a 15mm one to hold the inner sliders, as Continue with the same cleaning and copper wheel to check its condition and pressure;
shown, while you undo them. The pads should grease lubrication regime on the pads and it should be 60psi. Also have a look at the
remain around the disc when you remove the calipers as on the fronts, before you put toolkit that sits in the top of the wheel, to
caliper, so extract them afterwards. everything back together again. make sure it’s complete.
31 LUBRICATE ALL LOCKS 32 CHECK ALL INSTRUMENTS 33 RESET SERVICE INDICATOR

All the locks, hinges and catches on the Run through all the instruments and controls Resetting the illuminated service indicator
car require a dose of oil or spray grease. to make sure they function as they should. warning reminder is quite straightforward. With
This is specified as a service job but often Check the operation of all lights – including the ignition off, push in and hold the right-hand
gets missed. To get right into locks, use an the tail lamps by seeing if they ‘reflect’ trip button adjacent to the speedometer/
extension tube if it helps. Don’t forget to in a nearby handy wall – and inspect the rev counter. Now turn the ignition on and
lubricate less obvious items such as the seatbelts for any damage, ensuring they keep the button pressed in until the service
petrol filler cap hinge. ‘grab’ properly when pulled hard. indicator counts down to zero. Voila!
SERVICE SCHEDULE X Check fuel lines, hoses and tank

X Drain diesel fuel filter of water
X Clean any body and door drain holes with
a small screwdriver or bit of wire, to make EVERY 12,500 MILES or TWO YEARS X Replace pollen filter
sure they’re not blocked. Also clear any X Change engine oil and filter X Reset service interval indicator
leaves out of nooks and crannies – they X Check all lights, instruments and controls
could end up obstructing drainage. EVERY 25,000 MILES
X Check windscreen wipers and washer jets
X Replace diesel fuel filter
X If the handbrake needs adjusting X Lubricate all locks, catches and hinges
(because it’s not holding or there’s too much X Check battery EVERY 37,500 MILES
travel before it engages), you’ll find the X Check body and underbody for corrosion/damage X Replace air filter
adjustment nut underneath the rear cubby X Check exhaust system and mountings condition
hole in the centre console. X Check all hoses for leaks and condition EVERY 60,000-62,500 MILES
X Check coolant level and concentration X Check HDi particle filter system additive level
X Make sure that the wipers can perform
X Top up screenwash
their job properly by checking that the rubber EVERY 75,000-80,000 MILES
X Check suspension and steering components
isn’t perished or torn (which could lead to X Replace ancillary drivebelt (stop & start engines)
scratched glass). In addition, try out the X Check auxiliary drivebelt condition
screen washers and make sure they work and X Check tyre pressures and condition
X Check spare wheel pressure and condition
EVERY 100,000 MILES
aim properly. Adjust with a pin as necessary. X Check particle filter
X Check brake and clutch fluid level and strength
Thanks to Ellingworth’s Garage of Fengate in Peterborough,

X Check front brakes; clean or renew as necessary EVERY 150,000 MILES or 10 YEARS
X Check rear brakes; clean or renew as necessary X Replace timing belt (this is Citroën’s recommendation,
Cambridgeshire, for its help with this feature. This friendly, long-
X Check all brake lines for leaks but if you use your car a lot around town, we
established and family-run business is happy to work on practically
anything with an engine. For further details, Tel: 01733 343941. X Check transmission fluid level suggest changing it well before this interval).

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Help! Your vehicle-related problems
solved by Steve Rothwell
GENERAL GENERAL
Brake fluid Jump pack option

reservoir cap I was hoping to get a starter pack for the winter. Along
with the familiar packs there is the new type of small
Having had many problems square battery charger units, like the one shown on
with brake fluid reservoir caps page 18 of CM Insider in the May 2015 edition of CM. Have you
over the years, I have decided seen these work and would they start a car with a really flat
to seek your advice. Many companies battery or would it be best to stick to the old-style jump-starter
seem to offer a pan-European cap packs? My vehicle has a 51 Amp Hour battery.
that is supposed to fit the majority J Mitchell
The Ring RPP900 Power Pack
of European-made cars. Experience
has made me very suspicious of such The unit shown in the May issue is the Ring RPP900,
claims as there is never a specification which uses a lithium-ion battery instead of the traditional lead acid
given for the thread (ie, the thread unit. The advantage of this new type of power pack is the small size
type, pitch, major/minor diameters). and low weight, and the only disadvantage is the slightly higher price.
Is it a commercial secret? It is usually Personally, I have not yet used one of these packs, but I have heard very
described as being a ‘Universal E20 favourable reports through the trade and do know that they have been used to
Standard Connector’. What does this successfully start diesel engines with a flat battery. The 51 Amp Hour capacity
mean? Where does it come from? What of your battery should be well within the capabilities of such a device.
is the diameter of the male thread?
SP Tools describes it as a ‘Reservoir
Adaptor 46.5mm x 3.5mm’ but it is at Institut für Normung eV or German Ford, Volvo and European vehicles. The
variance with other supplier specs. Institute for Standardisation). E20 does not refer to the dimensions.
I suspect this thread is non-standard as What most screw threads do but is just the manufacturer’s part
I can find no DIN/ISO standard anywhere. have is an ISO standard number number. A quick check revealed that
Trevor Smithson 68-1 (International Standard for at least 10 different variations of
Organisation). This controls the brake fluid reservoir cap are fitted to
The brake fluid reservoir is a pitch of the thread in relation to the the range of vehicles available.
part that’s manufactured for diameter. It should also be noted that The standard that does universally
a vehicle in the same way as not all brake reservoir caps use a cover the fitting of the cap is SAE
a door handle, so although it can be thread – some have a bayonet fixing J1605. This specifies the standard
fitted to different vehicles it does not and some have a rubber cover. that must be met to maintain the
have a DIN standard. DIN is actually a The E20 connector is not a universal performance of the seal in protecting
German standard listing (Deutsches connector, but it will fit versions of against water and dirt ingress.
have been changed, as has the fuel filter. Do you know of any companies in the
I have run it with the turbo disconnected Guildford area that test injectors?
to see if oil was getting past seals, but this Dave Goulty
FORD TRANSIT made no difference. I have also blanked
off the EGR valve with no change. I have As your engine starts without
Excess smoking used Ametech Engine Restore in case
there was a problem with bore wear and
any difficulties, I would not
suspect that the bores are
I have a 2001 Ford Transit 2.4 have also used a fuel injector cleaner. worn. And the fact that there is no
turbodiesel with 51,000 miles. There is no smoke on overrun and the smoke on start-up or overrun would
I have known the vehicle since oil level is correct without signs of oil seem to rule out the valve stem oil
new, so the mileage is genuine and it use. One thought was that there was a seals. The most likely scenario is
has a full service history. problem with the valve oil seals, although, that the injectors are overfuelling, so
The problem I have is excessive in that case, I would have expected smoke getting them tested would be my first
smoking when moving off after a period on start-up. I believe the most likely fault move. I have no personal experience
of idling. The smoke is white/blue. This is a leaky injector – is there any way to of a company in the Guildford area,
only occurs after idling and the van check injectors in situ to try and identify but after a quick search I did find a
doesn’t smoke on start-up – the engine the faulty one, as to get them all out I think garage that may be able to help and
starts and runs well. The oil and oil filter the head would need to be removed? have forwarded its details to you.

Help!
FORD FUSION
Timing belt renewal

Could you give me instructions on how to renew the timing belt on a
2004 Ford Fusion 1600cc petrol engine? Are any special tools required?
Eric Nicholson
The tools to set the valve timing
I will start with a warning that the

crankshaft pulley on your Ford is
free-running on the crankshaft
and not held in position with a keyway. This
means that extra care must be taken and the
crankshaft pulley bolt must always be replaced
and torqued up to the required settings. FORD FIESTA
Special tools are required to swap the timing
belt and they consist of a camshaft locking plate
(part no 303-376B) and a crank setting pin (part no
Aircon removal
303-748). Also recommended but not essential for I have a 2006 Ford Fiesta Zetec
the job are a flywheel locking tool (part no 303-393) 1.2 petrol. The air-conditioning
and a crankshaft pulley locking tool (part no 205-072). in the car does not work
The procedure is as follows: anymore and there is no gas in the
1) Disconnect the battery and remove the engine cover. Jack up the vehicle system. The bearing on the aircon
and support the offside on a stand with the road wheel off the ground. compressor is starting to get noisy, so
Remove the offside road wheel. it would seem the compressor/bearing
2) Unbolt and move the coolant expansion tank; this should shift out of the is on its way out. I am not too bothered
way without disconnecting any hoses. Next, remove the air intake; this about having air-conditioning and
should be bolted down with three fixings from the top. was wondering if there is some sort of
3) Before removing the auxiliary drivebelt, loosen off the four bolts securing conversion kit so I could take out the
the water pump pulley. Once these are loose, the auxiliary belt can be compressor and replace it with just a
detached and the pulley bolts can then be fully undone and the pulley pulley and bearing to keep the drivebelt
removed. Also remove the upper timing belt cover. working correctly?
4) Next you will need to extract the starter, to enable the flywheel to be locked. On this Fiesta the stretch belt
Support the engine using a block of wood and a jack, then remove the drives the alternator and the aircon
alternator and engine mounting. Next, the cam cover needs to be detached. compressor and a double pulley; the
5) The engine now needs to be rotated until it is approximately 10° before double pulley then drives the power
Top Dead Centre on cylinder one. Then fit the crank setting pin after steering via another small stretch belt.
removing the blanking plug; this can be found to the left of the crankshaft Dave Gilfoyle
pulley as you look at it and a few centimetres along the block. Now turn
the engine slowly until the crankshaft comes into contact with the setting I know of no specific kit to
pin and then lock the flywheel/crankshaft and extract the crankshaft replace the air-conditioning
pulley bolt – this will be tight! pump pulley, and because of
6) Now loosen off the camshaft pulley bolts and tap the back of the pulleys the route the belt takes, it would not
to free them from the taper. Lock the camshafts using the locking plate, be possible to use a shorter belt that
attaching it in the recesses at the end of the camshafts. Now detach the misses out the aircon pump. However,
lower timing belt cover. a quick look on eBay revealed that
7) Next, remove the tensioner and old belt. Fitting the new belt into position there are quite a few secondhand
is easy as the timing is set by the locking pin and plate. Fit and adjust the units available for under £20.
tensioner, then lock and tighten the camshaft pulleys to 60Nm. Refit the As the air-conditioning pumps
lower timing belt cover and the crankshaft pulley. There are three different have a magnetic clutch, provided
pulley bolts available for the engine and you must establish which one the outer pulley freewheels then
you require. Measure the depth of the thread in the end of the crankshaft there is no reason for the pump to
– if this is 42mm, you will require a M12x29 bolt, if it is 52mm you will be operational. I am assuming that
require a M12x44 bolt and if it is 81mm you will need the M14x80 bolt. The your pump is noisy even with the air-
torque settings for the M12 bolts are 40Nm + 90° and for the M14 bolt are conditioning disengaged, indicating
100Nm + 90° plus a further 15° after a five-minute rest. that the freewheeling mechanism is
8) Now remove all locking tools and turn the engine 355° and refit the failing. Having the air-conditioning
crankshaft setting pin. Turn the engine until the crankshaft sits against system evacuated and then fitting a
the pin and ensure that the camshaft setting plate fits into position. secondhand pump which can be left
Provided the timing is correct then reassembly can take place. disconnected should ensure that the
auxiliary pulleys are all driven.

Help!
FORD ESCORT RS2000

TRIUMPH TR7
Restoration Wiper motor lubrication
project I have a bit of a problem with the wiper self parking on my
I am undertaking the restoration Triumph TR7. I think it is probably a bad connection as a bit of pushing
of a Ford Escort MkII RS2000 and tugging on the wiring normally gets it going again for a month or so.
and would appreciate your When I park it up for the winter, I was intending to take out the wiper motor
advice on having the shell chemically to check it properly. My question is what type of oil/grease should I use on the
stripped (eg, like the service offered by various components? The Leyland manual says Ragosine Listate grease and
SPL). I am concerned by some reports Castrol Turbo 41 oil, neither of which are now available. Looking online, there
that indicate that the chemicals used seems to be quite a variation in opinions as to which is best, with
are sometimes difficult to flush from warnings of dire consequences if you use the wrong stuff.
box sections and joints. I have removed Martin Marsland
The aerosol white lithium grease
90% of the paint and underseal from the
floorpan, which is in very good condition, The best equivalent for the Ragosine Listate is white lithium
but want to ensure all rust is eliminated. grease. As you will need very little, I would recommend an
If I complete the work manually, aerosol, such as this one http://bit.ly/1MvHF2U at £3.59.
I intend to use rust converter on any You will also be able to use it in other applications.
pits and then paint the floor in primer The modern equivalent of the Turbo 41 oil is Shell Turbo T-68.
before undersealing. Do your colleagues As this is an industrial product, it does not seem to be sold in
in the trade prefer the manual approach quantities less than 20 litres, which would make its purchase for
rather than the chemical dip? your uses prohibitive. Using a standard synthetic engine oil to
Eddie Gracia lubricate these points should not cause any harm.
I believe the warnings of dire consequences that you have read
refer to using an LM type grease in the cable/rack mechanism. This
can dry out and cause friction, putting a strain on the motor and burning it out.
controlled thermal process to remove

all paint and contamination (eg,
underseal) from components without
any stress damage or warping.
What is the best way to strip the bodyshell of However, having not used this
a Ford Escort MkII RS2000 project? company, this is only a suggestion and VAUXHALL COMBO
not a recommendation.
This has long been one
of those decisions made FORD FOCUS
Low temperature
on individual merit. The I have a 2003 Combo 1.6 8v
alternative to chemical dipping is to
sand- or grit-blast the bodyshell. The
Fuel filter dual-fuel van (ie, petrol and
LPG). The engine is Z16SE I think.
advantage of blasting is that it will
leave no residue; the disadvantage
location I have two problems. The first is that
the temperature gauge stays on the
is that it will not reach into the areas My car is a 2005 Ford Focus floor unless in traffic; as soon as any
that dipping will. MkII 1.6 Ti-VCT. Where is the fuel speed is reached, it falls back.
If using the dipping process, you must filter located and could you give I have fitted a new genuine Vauxhall
be sure the chemicals are thoroughly me any advice on changing it? I have a thermostat, which I have tested and it
washed out of the box sections and Haynes manual, but having searched it opens and shuts normally. The top rad
difficult to access areas, then you thoroughly, there is no mention of a fuel hose and bottom hose are running hot.
must protect these areas to prevent filter. Rather than search for it, I have The other problem is that the heater
premature rusting from the inside out. taken the easy option and asked you! is very poor. I did make the mistake a
Looking at the SPL website, it George Woodward couple of years ago by pouring in some
appears it also offers electrophoretic rad weld to cure a small water leak,
coating. The advantage of this is that, From the information I have, but I have since fitted a new radiator.
although the process will cost more this model does not have a Both hoses to the heater are hot where
than you doing the job manually, it separate fuel filter and relies they go through the bulkhead. At the
should save you many hours of work on the fine mesh filter located in point where these hoses connect to the
and give you a long-lasting result. the fuel tank prior to the fuel pump heater pipes, there is a pull-up clip on
There is also a third option, which pick-up. This is standard on many each rubber hose – I did pull these up,
is thermal stripping. This is offered vehicles and the filter does not require but could not remove the rubber pipe
by www.paint-strip.co.uk and uses a changing during normal service. as it seemed too tight. I thought about

Help!
putting a power washer (lower pressure) top hose does not warm up before before removing. Gently twisting the
into the heater pipes to try and clear the engine gets up to operating pipe backwards and forwards, and
any crud. If these hoses can be forced temperature. The hose should remain rocking up and down while pulling,
off, are there any sealing issues when cold until the thermostat opens; by should eventually free off the hose.
putting them back? I did try various checking this, you can ensure the stat When refitting, there should be no
radiator flushing liquids, but to no avail. is not opening too early. problem resealing the joint. I find that
Nigel Gibb If the thermostat is operating using a silicone lubricant spray helps
correctly then you may have two ease the reconnecting process. Refit
The two problems sound very different problems. First, the the clip before attaching the pipe and
much as if they are related. temperature sender may not be always ensure you hear the clip snap
You mention that both the operating correctly, meaning that the back into place.
top and bottom hoses, along with gauge is not indicating the correct As the temperature of the engine
the heater hoses, are all running hot, temperature. Second, the air mixer drops when on a clear run, this
indicating that the coolant is flowing flap in the heater may not be moving indicates that there is no problem
freely around the engine. The first correctly, preventing the hot air from with the flow through the radiator.
question I would ask is how hot do being directed into the van.
the hoses feel? Once up to running If the problem is a poor flow through
temperature, the coolant should be the heater, removing the hoses and VAUXHALL CORSA
around 90°C. This is, of course, not far flushing the heater matrix should help.
short of boiling point, meaning that
the hoses should be too hot to hold.
The hose connectors do tend to stick
in position, making them difficult to
Brake pipe
Although you have fitted a new
thermostat, I would check its
remove, and I normally try to ease the
connector away from the pipe. Remove
replacement
operation by ensuring that the the metal ‘C’ clip from the connector Do you know of any company
in the UK that manufactures
complete brake pipe kits – the
VAUXHALL VECTRA rigid brake pipes, not flexible hoses? They
are for my son’s 2005 Vauxhall Corsa,
Towbar electrics which received a couple of advisories

during its recent MoT. I know you can buy
I have a 2007 Vectra 1.8 SRi hatchback without the built-in sat-nav. kits on eBay to make up your own pipes,
I have fitted a towbar and was told that if I bought a plug-in wire loom at but I have never done this and do not
£80 from Vauxhall it would work without having to have it accepted by feel overly confident in trying it.
using Tech 2. I did this and it didn’t work, so now the indicators flash fast, among James Shaw
other things. I rang Vauxhall and they confirmed that I would have to have Tech 2
at a further cost of £70 and that the previous advice I’d received was incorrect. I will start by saying that
So, at a cost of £150, I took it off and got a refund. making brake pipes is
I then bought a Ring multiplex relay and I’m looking for the best way to wire probably not as difficult as you
it (eg, scotch locks filled with silicon). Where can I run a live feed, as there is a might imagine. The tools sold to form
fusebox on the left-hand side of the boot? I don’t really want to run a fused wire the end flares are easy to operate
all the way back to the battery. and do a good job. Having said that, if
Paul Lewis you do not feel confident making up
the brake pipes, it would be best to
The confusion on the coding issue has The WT16 & 59 terminals purchase ready-made items.
probably arisen because – technically – I do not know of any company
the direct fit loom will operate without any that sells the pipes ready-formed.
coding, but it will not operate correctly. I have looked This is most likely because many
at various aftermarket direct fit units and all of them brake pipes need to be shaped when
say that they require no coding, yet when you look at the fitting instructions fitted as they are routed around and
one stage of the operation is to use Tech 2 to reset the functions. through other components.
You do not mention the part number of the Ring multiplex relay you have Shaping brake pipe is not difficult
purchased, but I am assuming it is a bypass unit. The feed for this can be and using gentle pressure it can be
taken from the fusebox in the rear of the vehicle and you should be able to shaped to fit. There is a company at
tap into a live feed at fuse location number 16. This is for the heated seat, this website http://bit.ly/1H72oMB
which should not be in use as your vehicle is the basic model. that sells a complete range of brake
Using a male connector, such as a WT59, to plug into the live side of the pipes in cupro-nickel (my preferred
fuse fitting, you will need to fit a fuse inline to protect the circuit. Although material) in differing lengths and
scotch locks are perfectly acceptable to connect the wires, the contact at very reasonable prices. These
area is small and the connection can fail over time, even after filling it with will need shaping, but the ends are
silicone to protect the wire. The better option would be to cut and splice the pre-formed. However, never having
loom with the added wire into a butt connector such as a WT16. used this company myself, this is a
suggestion not a recommendation.

Help!
VAUXHALL CORSA My second problem is that every time

I go to open the car, nothing works as it is
Intermittent LADA RIVA
in Economy Mode. This is very frustrating
when doing the weekly shop and not
misfire being able to get into the boot due to
I bought my daughter a 2001 Oil requirements the motorised tailgate not functioning
when the car is in Economy Mode.
Corsa 1.2 16v petrol and it’s got I have a 1996 Lada Riva which The C5 is nearly five years old, so
an intermittent misfire. has been converted to run a I have replaced the original battery with a
It was running fine, then one day it 2.0-litre twin-cam 16v engine VARTA E44 12V 77Ah 780A. When fitting
would not start, so I plugged in my ACR4 from a late 1970’s Fiat 132 Mirafiori it, I made sure both terminal clamps were
and read the code for a faulty crank Sport. I’ve no service history for the clean and have put lithium grease on the
sensor. I replaced the crank sensor and engine, but I know that the mechanic terminals. I have checked the battery
the engine started up straight away. who fitted it changed the cambelt and voltage when the car is running, which is
However, once it’s been running for 20- serviced it. Can you tell me what oil it 14.6 volts; when the engine is not running,
30 minutes, it will misfire and the check runs on and the intervals for oil changes it’s 12.6 volts. I could understand why
engine light comes on. If you switch initially and throughout its life? the car would remain in Economy Mode
it off and start it up again, there’s no Also, what oil should I use in the if it only did short journeys, but I took it
misfire and no engine check light. Then associated Fiat five-speed gearbox? on a 30-mile motorway run and, even
the same scenario occurs again. And finally, the vehicle uses an Escort then, it remains in Economy Mode when
If you plug in the ACR4, it indicates MkII rear axle – what oil should that I restart it. The car always starts first time.
a multiple misfire. I have given it a full use? Do you have any other tips for Does the ECU monitor the battery
service, to no effect. recommissioning/running in? voltage level and, if so, do you know
This must have been an issue Ashley Wensak what voltage level triggers the Economy
previously, as the person I bought it Mode? Or does it use a timer to monitor
from had fitted a new Bosch coil pack The recommended oil I have your driving time and voltage level? If
and new plugs just a few days before listed for the Fiat 132 engine it uses a timer, can you reset this by
I bought it. The engine is tappety, as is 10w40 semi-synthetic, with removing a fuse?
I believe all these engines are, and I have a change interval of 6000 miles or six Carl Jones
done a compression test, but all was OK. months. The recommended oil for the
There was an article in Professional five-speed gearbox is Tutella ZC-90. A technical manual for your
Motor Mechanic saying that if you don’t Many Fiat owners recommend using vehicle is available for £9.99
fit a Lucas SEB485 and use a cheap one 15w40 oil in the gearbox because it from www.emanualonline.com.
instead (I got mine off eBay) the car will eases gear changing when cold, but This is a very comprehensive manual
probably send an incorrect signal to the the important thing is not to use an and covers all aspects of your C5. It is
ECU, resulting in an intermittent misfire EP oil which will damage the brass a large download and requires running
and stalling when the engine heats up. components in the gearbox. The rear in a virtual player on your computer. Full
What are your thoughts on this, as a axle oil for the Ford unit is EP80w90. instructions are included. Unfortunately
Lucas SEB485 crank sensor is £30 and physical paper manuals are no longer
genuine Vauxhall part is £42+VAT. readily available for modern vehicles.
Stephen Haywood Regarding your running fault, as you
have checked the battery voltage, which
The fact that the misfire appears to be within the tolerance
begins once the engine allowed, the most likely reason for the
warms up may indicate a vehicle prematurely entering Economy
problem with the sensor due to slight CITROEN C5 Mode is a failure in the BSI (body
distortion when warm. Unfortunately, control). The unit may simply need
I have also experienced problems with
cheap aftermarket sensors and, given
Economy mode resetting and I would try this first:
O Open the driver’s window and
the symptoms you have, I would agree I am looking to carry out some ensure the bonnet is open
that it may be prudent to fit either a maintenance on my 2009
O Ensure everything is switched off
Lucas or genuine unit. Citroën C5 2.2 HDi, but I have
and all doors are closed
The new spark plugs and coil pack been unable to find any technical
manuals for the car. I tried Haynes, but O Remove the key from the ignition
indicate that the previous owner
it only covers the MkII, which is OK for and wait for three minutes
may have had similar problems. It
may also be worth checking the suspension, etc, but does not cover the O Disconnect the battery for 15
continuity of the wiring loom between correct engine. I did think about trying seconds then reconnect
the sensor and ECU, and between the Peugeot 407 manual, as I know the O After a further 10 seconds and
the coil pack and ECU, to ensure this car has the same engine, but it was no without opening the door, reach
is not the problem. As a matter of use. I was told that the Ford Mondeo through the driver’s open window
course, I would also check the earth uses the same engine, but, again, the and turn on the sidelights
connections of the ECU. Haynes manual only covers the 2.0 unit. O Switch on the ignition

Help!
O Hold down the lock button on the

key for 10 seconds RENAULT CLIO
O Remove the key from the ignition,
then open and close the driver’s door
O Lock and unlock central locking
Heater blower failure
using the key The heater blower module has failed on my Renault Clio 182,
O Enter the vehicle and start the engine which I believe is quite a common problem. A new module from Renault
costs £120, however entering part number 7701051272 into eBay brings
Following this procedure, if the
up a plethora of them for between £25-£40. The thing is, I’m pretty sure they
system still goes immediately into
are all Chinese copies. I say that because Valeo doesn’t supply the module to
Economy Mode then it is most likely
anyone other than Renault, making it a dealer-only part, which I assume means
that the BSI will need repairing. BBA
Valeo won’t be able to sell the pattern to other companies until the tie-in is up.
Reman (www.bba-reman.com) can
What’s your take on Chinese parts? I can’t help but feel that the quality control
check this for you, although it may be
just isn’t up to the same standard as it is in Europe – and that’s with parts that aren’t
worth getting the dealer to check the
illegal copies. Do you think I’d be OK to fit one of these parts? My worry is with it
software first.
being an electrical part – if, for instance, it can’t cope with the nominal current draw
of the circuit and starts to get to hot, is it likely to send my car up in flames?
Most of the parts on eBay do seem to come with a 12-month guarantee and
I can get one from a large UK-based, VAT-registered company called RSC
Europe. Have you ever had any dealings with this company?
Your help on this is much appreciated as really don’t
want to go another winter without heat.
PEUGEOT BOXER Anthony Pattinson
Bad starting Starting with your last question,

I have had no dealings with RSC
I have had my 1997 Peugeot Europe, although looking at their
Boxer XUD9TE motorhome for website they appear to be a reputable,
16 years. After a while, I found UK-based business. As you say, the part
starting very difficult. If I wait for a count does come with a 12-month guarantee and
The heater blower module
of four after the glow plugs go out, it I would expect you to have no problems with it.
starts first time. After a service at my I would shy away from the Chinese copies, not because they are Chinese,
local garage, they flattened the battery. but mainly because of the problems you would encounter with any warranty
I changed the plugs on two occasions, issues dealing with an overseas company. I would not expect any problems
but this hasn’t resolved the issue. with the unit being unable to deal with the current draw as the unit is basically
This may have no bearing on the a resistor and is built to deal with the consequential heat produced. The only
problem, but the cylinderhead blew area I would check if you were to fit such a unit is that the connections are
on me during a trip to France. The good. A poor connection between the plug and unit will cause the current to
garage did not just replace the gasket, arc across the connections; this will then produce heat and possibly result in
but fitted a complete head assembly an electrical fire. Provided the connections are good, this will not occur.
including pipes, etc, but this didn’t help
with the bad starting issues.
I have seen queries online complaining a first time start, I would not suspect As you suspect, your Peugeot
of the same problem. Have you any that it is the fuel injection system does have torsion bar
ideas what might be causing it? that is at fault. suspension at the rear. There
Brian Walters is no way to adjust it and replacing the
PEUGEOT 205 two torsion bars is quite a complex
As the engine starts well after job. Given the age of the vehicle, you
you wait for a short period
after the glow plug light goes Low suspension may also find the job of replacing
the torsion bars will be hampered
out, I would suggest checking the My 1992 Peugeot 205 1.8 by corrosion on the parts. However,
glow plug timer unit. A quick check non-turbo diesel hatchback sits before considering replacing the rear
with a test light will confirm when the a little lower at the rear than torsion bars, I would check the two
glow plugs are actually operating. It the front. I have changed the two rear flexible mountings securing the rear
may be the case that the plugs are shock absorbers, but it hasn’t made any suspension to the body. If the mounts
either being operated for too short a noticeable difference. I believe the car have collapsed, this could be the
period or that the light is prematurely has a torsion bar system. If this is the cause of the lower ride height. The
extinguishing. It could be that the case, can it be adjusted and secondly part number is 5151 10.
latent heat in the plugs supplying the could I do this myself? According to my data, the best
extra heating the engine requires to I would also like to know what grade oil for your 205 would be a 5w40
start first time. As the short wait after of engine oil would be best for this car. fully-synthetic complying with
the light has extinguished will ensure Peter Walmsley ACEA A3/B4; API SM CF.

Help!
According to the data I have, the petrol V70 which will do for the rest of
rear ABS sensors are incorporated the car, but it’s the engine and gearbox
into the hub bearing. I would check I’m not sure about.
the resistance of the sensors first and Also, the car has a habit of starting-
this should show up a faulty unit. A up and then dying when you put it into
SAAB 9-5 correctly operating sensor should give reverse and sometimes into drive, then
a reading of around 1130Ω ± 115Ω. it cranks over but has a job to start.
ABS problems Having said all that, the ABS ECU
has been a common problem on the
After doing this two or three times, it
is all right until the next day. The glow
My 2004 Saab 9-5 Aero with Saab 9-5 and may well turn out to be plugs are working fine as it starts up
78,000 miles has suffered an the source of the problem. first time from cold and the glow plug
intermittent ABS problem for a light comes on.
number of months. The dashboard ABS Daryl Rogers
warning light will illuminate, followed by
the EPS/TCS warning light, although The D5252T engine was used
the car drives normally even with these in the Audi 100 prior to being
warnings. I cleaned the wheel hub toothed fitted in the Volvo. The engine
rings and the ABS plugs/connections, VOLVO V70 management is carried out using a
etc, but the problem persists. Bosch MSA 15.8 system. This system
Recently, the problem has got
worse and the warnings lights can V70 information is not readable with EOBD equipment
and requires a Volvo-dedicated
illuminate even from start-up. Also, the I was wondering if you could system to retrieve the error codes.
speedometer can stop working when help me with my dad’s 1999 As you say, the only Haynes manuals
the fault appears – the rev counter is Volvo V70 2.5 turbodiesel available cover the petrol engines or
OK. Sometimes restarting the car can automatic. I am struggling to find a the later 2.4 diesel version. There is an
extinguish the lights, but not always. Haynes manual for it. It has the D5252T online version available on this website
The car does not show an ‘engine fault’ engine which is used by VW and Audi, http://bit.ly/1eIG0et, although
light and my Autel FCR says no fault but I am unsure of what models they I must warn you that this is a large file
codes are stored. use it for. I have a Haynes manual for the and could take a while to download.
I assumed the problem was probably
a faulty ABS wheel sensor. However,
the non-functioning speedo might VOLVO V70 T5
also suggest an ECU problem. The car
has a small ABS ECU attached to the
front of the ABS pump and my guess is
DSTC service required
I have a 2001 Volvo V70 T5, an ex-police car. I have owned
this ECU is malfunctioning and should
the car for eight years and never had a problem. However, last week,
be replaced/refurbished.
after it had been parked up for a week, I started it up and the ‘DSTC
Gerald Reeves
Service Required’ message came up on the dashboard, along with the DSTC
warning light. The ABS or brake warning lights have not come on.
If a fault has occurred in the I read on some forums that the yaw rate sensor can get wet, so I took it out,
ABS, a fault code should but the floor and sensor were totally dry and the sensor is a sealed unit. If I use
be stored in the ABS ECU. the switch to turn off the DSTC, the warning message remains. I have had the
To retrieve the codes from the ABS fault codes read and they are: ‘OOB2 – yaw rate sensor signal faulty intermittent
unit you will need to get the vehicle fault’ and ‘OOA2 – yaw rate sensor signal 1 & 2 outside permitted range’.
examined using the Tech II or similar As there are no other warning lights for the brakes or ABS, will the problem be
diagnostics equipment. Although all with the yaw rate sensor or could it be something else? Also, if I fit a used sensor,
modern vehicles have to comply with will it need to be calibrated to the car?
EOBD specification on engine systems, Dave Hogan The YAW sensor
this does not apply to ABS systems.
Some Autel fault code readers do As you have already removed and
support the Saab ABS diagnostics, checked the sensor, I am assuming
but without knowing the model you you have also checked the
are using it is difficult to check. connecting plug and terminals – another
The fact that the speedometer is also of the common problems with these
playing up may indicate that the fault is sensors. If this is not the case, I would first
with the nearside rear sensor, as this is remove and clean the plug and terminals
where the signal for the speedometer using an electrical cleaning spray. If this
is taken from. This sensor also supplies does not rectify the problem, then the most likely fault will be the sensor.
information to the engine ECU with After replacing the sensor, the system will have to be recalibrated using the
regards to speed, so when it is faulty Volvo VIDA software. You may be able to locate an independent workshop
it often results in uneven running and with this equipment, which should be cheaper than using a main agent.
possibly stalling at junctions.

Help!
The starting issue could be due to the seatbelt pretensioners and seat
to a few issues. Given the fact that squabs. After checking the connections, Have a
once the car is started then all is OK
until the next day, I would check the
you should reset the airbag memory.
Follow the sequence below: problem vehicle?
fuel supply system for any tiny leaks
that may be allowing air to enter the
1. Turn on the ignition until the airbag
light goes off briefly; this will be a
GET IN TOUCH...
system. Possibly replacing the fuel few seconds. If you have a problem vehicle,
filter would be a good first move. 2. Immediately after the airbag light Car Mechanics has the answer in
I would also check for any excessive goes out, turn off the ignition for the shape of our technical editor
smoking when starting-up, which three seconds. STEVE ROTHWELL. Contact
could indicate incorrect fuelling. 3. Turn the ignition back on, turning Steve, as detailed below, for FREE
Even though the glow plug light off again as soon as the airbag light advice on all car-related problems.
seems to work, this is not an goes out, as in Step 1. Repeat this Please help Steve to help you by
indication that the glow plugs are for three cycles in total. giving as much information on the
operating correctly. The best way to 4. Then turn the ignition on for one symptoms as you can.
check the glow plugs is to disconnect second and immediately turn off As Help! is a free service, some
the feed wires and then test the the ignition, then back on again complex questions may require
resistance of each glow plug with an and start the car. more time and resources than we
ohmmeter. You should be looking at a If this does not cure the problem, can reasonably allow – when this is
resistance of under 5Ω. you will need to find someone with the case we will let you know.
a Nissan-compatible code reader Steve will reply to all queries as
who can read off the fault codes for quickly as possible, but please
you. This will point you in the right allow up to 28 days for a reply.
direction as to the reason for the light Difficult/complex questions or
illuminating. Although some airbag those requiring research may take
problems could land you with a repair a little longer – please be patient.
bill of £500, such faults would normally Neither Bauer Media nor Steve
NISSAN ALMERA result in a permanent warning light. Rothwell can accept any liability
for loss, damage or injury resulting
Flashing NISSAN NOTE from replies to readers’ queries.
To access web addresses starting
airbag light Some notes with http://bit.ly just type these
into your browser address line,
I have recently purchased a
2003 Nissan Almera Pulse.
The car is mechanically sound,
on the Note rather than the search engine and
they should work as intended.
Please could you tell me if
however it seems to have a worrying
electrical problem. The airbag warning
CM has ever run a feature on WRITE (enclosing a SAE):
servicing the Nissan Note 1.4? HELP! PAGES
light keeps flashing on and off. It was Could you advise where I could pick
like this when I bought it and I have CAR MECHANICS
up a workshop manual? Haynes does BAUER CONSUMER MEDIA LTD
since heard that this is a MoT failure not publish one, but I am not sure if the
point. I have also been told that this MEDIA HOUSE, LYNCHWOOD,
engine is used in other Nissan models.
could cost £500-£600 to repair. Is it correct that Nissan are putting
PETERBOROUGH PE2 6EA
Is this something I can fix myself and
how should I go about it?
Mick Baker
Renault engines in some of their cars?
Also, I was told that the body is used by E-MAIL:
other vehicle manufactures. Is this true? carmechanicshelp@yahoo.co.uk
S Little Please include your postal address
As the light flashes on and then
goes off again, it means that We carried out a Service Bay These Help! pages are dedicated to the
the fault is not being logged feature on the Nissan Note in late RODNEY JACQUES, who answered
as a permanent code. For this reason, the August 2014 edition. Q&As here from 1995 to 2012.
I would suspect that the source of the There are workshop manuals
problem is nothing more serious than available in CD format on eBay. since the March 27, 1999. The alliance
a bad connection to the underseat I would advise getting one that is in worked initially by using Nissan-
connection. This is quite a common PDF format, as I believe this will be developed petrol engines and Renault-
problem on many vehicles and often easier to follow and individual pages developed diesel engines. Your petrol
comes to light when the vehicle can be printed out if required. engine in the Nissan Note was jointly
changes hands and the new owner The Nissan Note shares its base developed by Renault and Nissan.
moves the seat into a different position. frame (platform type B) with the The advantage of this is the ability for
With the ignition off, my first move Renault Modus, along with eight other vehicle manufacturers to share design
would be to disconnect and reconnect Nissan and Renault vehicles. There costs and knowledge, enabling them to
the plugs under the front seats that go has been a Renault/Nissan alliance produce a vehicle for a lower initial cost.

Dave Peacock answering your engine management queries
Should I have it reset to 1800cc
fuelling or can’t that be done? The
problem is it’s a fairly recent ECU (there
were tickover problems on the original!)
and I understand my local garage
doesn’t have the equipment to fix the
old-style ECU.
ROVER 214 The only place around here is a Renault
main dealer who used to be a Rover
Engine transplant agent and can still reprogramme older
Rovers. I know this expenditure sounds
Rover 214SEi cabriolet begins suffering a
My 1995 Rover 214SEi cabriolet madness on an old Rover, but it is used mystery misfire after an engine rebuild.
has the MEMS 2J type ECU, for pleasure and for Rover Club events.
with engine code K16. I have Karl Sheridan the ECU-programmed fuelling map
just had the engine rebuilt after takes over, which could cause a weak
diagnosing piston slap. However, the 1.4 Some more info please. Is the mixture misfire if it is under-fuelling.
pistons and liners were not available, hunting within an 100rpm, On the other hand, it could be
plus they would have cost £500. 200rpm or 300rpm rev range? due to something else. To confirm
The supplier, who is also an engine At idle, the mixture is controlled by the you have a weak mixture misfire, try
reconditioner, advised that the 1.8 Lambda sensor. If the hunting at idle fooling the ECU into going a bit richer
K-Series piston and liners would do the you refer to is a slight rev change at to see if this cures it. The easiest way
job using the original conrods. This is around once a second, then it is caused to do this is by adding resistance
the route I went down and duly bought by the Lambda sensor switching. If it is to the coolant temperature sensor
them, then passed them on to my more than just a slight hunting, check circuit to make the ECU think the
garage who were doing the job. for inlet air leaks and clean out the engine is colder than it is. Add about
The engine seems to run OK on throttle body and butterfly, and if it’s 1000 ohms. If this works then so long
medium journeys, but I went on a long still a problem then the management as this modification doesn’t cause
journey and could feel the car slightly system needs checking over. the ECU to enter ‘open loop’ Lambda
missing under load. It also used more The fuelling map for cruising is control (which would fail the MoT
fuel than before and hunted at tickover. controlled by the Lambda sensor emissions testing), then you can then
In the old days you could adjust the carb going into closed-loop control when find the minimum extra resistance
to get a richer setting and I’m assuming cruising, so the fact that the ECU needed to prevent lean mixture
that the mixture being set by the ECU is for a slightly smaller engine size misfire and your problem is solved.
is obviously for the 1396cc engine, shouldn’t matter. However, under Other more costly alternatives are
whereas of course I’ve given it a slight heavy load, the Lambda sensor output to have your existing ECU remapped
increase in bore size. is ignored (open-loop control) and or to use the 1.8-litre ECU.
MAZDA3
High warm-up idling

I enjoyed the article on the on the clutch discs in the autobox.
Mazda3 in the July 2014 issue Otherwise, the car is excellent, with no
of CM. I own a 2009 1.6 Takara engine malfunction lights.
auto with Z6 engine, 2004-2009 Jim
model. What engine management
system is installed in this car and The management system Are the high revs at idle putting too much
has there ever been a feature in the is a Mazda one with the of a strain on the Mazda3 engine?
magazine about it? designation of Mpi-s. A
On start-up from cold, the revs at wiring diagram is published by charge, at http://qcwo.com/
idle are approximately 1700rpm, falling Autodata, but this is available by otherdeal/Wiring-Diagrams
back to 1200rpm after three minutes subscription only. However, you The idle speed you get from cold
and eventually to 700rpm, during can find one-off downloads for looks normal. Don’t worry about
which time I am reluctant to engage management systems, some for engaging drive during warm-up as
drive as I feel this puts a severe strain free and some for a small download the system is designed to handle it.

Diagnostics Doctor
I have taken the car for another spin and Theory being that the main dealer
I would say it’s a slight hesitancy when cannot alter the existing set-up, so that
pushing on. I would really define the would be £70 wasted.
hunting as an erratic tickover, but not Karl
like when the original ECU failed and the
tickover soared between 800-1300rpm. I fitted the 1.8 injectors, but the MG ECU
I have booked it into the garage that has a wasn’t an easy fit. I ran it with the injectors Diagnostics Doctor
T4 diagnostics kit and see what they say. fitted and it seemed to cure the problem
of misfire under load, but the stepper Diagnostics Doctor is a FREE helpline
My other thought is that if they service for CM readers – including
can’t solve it – and me not being into motor wouldn’t settle below 950rpm at trade readers – who are struggling with
measuring resistances on the Lambda idle. I re-booked it into the ex-Rover dealer diagnostic/engine management related
sensor – is that I could buy a matched to get it checked out, but they explained faults. Dave Peacock of the Nottingham-
that the additional kit that goes with the based diagnostic company ECU Testing
set off eBay consisting of an ECU and the Ltd will answer all your queries. We
various immobiliser and central locking T4 had been damaged and therefore need as much detail as possible:
boxes and key fobs from an MGF 1800cc they couldn’t help. Would have been nice MAKE, MODEL, YEAR and ENGINE
for around £70. Might this be the better if they’d discovered that before I went! CODE of your vehicle, and the type
Found that another ex-Rover dealer still of management system installed
option? Would I also need to change Obviously, Dave will not be able to
any of the sensors, such as the Lambda had the equipment to reset the car. They
assess the vehicle up close, so his
sensor, etc, or are they the same? My reset the airflow and brought the revs answer will be on the basis solely of
theory is that if I get the full kit off the down to about 850rpm, which seems OK. your description. This is a FREE service
MGF, I shouldn’t have to do anything else. I’m not sure about fuel consumption, and it may take some time to respond
but it’s certainly happier going up hills! to certain problems. If you would like
One other thing that occurred to me is to receive a personal response via post,
to change the silencer from the 1400cc Karl please enclose an SAE.
to the 1600cc, because I know the engine Write to:
management system might take into DIAGNOSTICS DOCTOR
account the back pressure from the CAR MECHANICS
exhaust. The 1.4 has a small tailpipe, while BAUER MEDIA, MEDIA HOUSE
the 1.6 model has larger twin bore pipes, LYNCHWOOD
although that might merely be cosmetic. PETERBOROUGH PE2 6EA
Karl NISSAN MICRA e-mail: dpeacock760@gmail.com
website: www.ecutesting.com
In theory, the MGF management
transplant is an excellent solution.
Micra CVT
All of the ECU pin in/pin outs match, I’ve a 2001 Nissan Micra with a Common abbreviations
although the MGF uses a few extra CVT gearbox which sometimes
ATS Air Temperature Sensor
ones for power steering, instrument sticks in first gear. If I turn
AFM Air-Flow Meter – not a MAF type (see below).
panel and cooling fan relay, but these the engine off and back on again, the It could be, for example, a vane type
will not matter. The Lambda sensor problem goes away. I went to Nissan CAS Crank Angle Sensor
will be the same, but you do need to today and they said there were problems CPS Crank Position Sensor
check other critical components – the with the aircon control, line pressure CTS Coolant Temperature Sensor
crank position sensor, MAP sensor, sensor and line pressure control function. ECT Engine Coolant Temperature
CTS and TPS are the same. Sinead ECU Electronic Control Unit
Injectors are likely to be different. EGR Exhaust Gas Recirculation – meters exhaust
In fact, if you do find the injectors to gas back to the intake manifold
be different, it is worth just changing EML Engine Management Light
these, because the increased fuel EMS Engine Management System
may cure your fault. Or fit an uprated FCR Fault Code Reader
fuel pressure regulator – Malpassi HT High Tension – ignition output to the spark plugs
does a product called the FSE boost IAV Idle Air Valve
valve, which is an adjustable pressure ISCV Idle Speed Control Valve – usually operated by
a motor controlled by the ECU
regulator, which should give you the
LOS Limited Operating Strategy – if the ECU detects
extra fuel you need to cure a weak flat a malfunction, it runs a programme to allow the
spot. The management system does car to still go, but at reduced efficiency
Nissan Micra’s CVT gearbox is intermittently
not measure exhaust back pressure, so sticking in first – is it the stepper-motor? MAF Mass Air-Flow meter
it isn’t affected by the smaller diameter MAP Manifold Air Pressure
exhaust, although if you are looking for It’s probably the stepper-motor, MIL Malfunction Indicator Lamp
maximum power it should be changed. which determines the distance PCV Positive Crankcase Ventilation – takes crankcase
gases and recycles back to the inlet system
between the pulleys on the
TBPS Turbo Boost Pressure Sensor – used by the
I’ve decided to go down the MGF CVT, that will have to be replaced. ECU to regulate turbo output
route. I’ve cancelled the main dealer Nissan has just read off the fault TPS Throttle Position Sensor
appointment and have ordered a used codes and told you the results, but they VSS Vehicle Speed Sensor
but matched ECU and 5AS box and a don’t seem to relate to your problem. WOT Wide Open Throttle
set of injectors. I will advise how I get on. Clear them and see if they return.

THEY LOOK GREAT
ON PAPER
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someone who already owns the model you’re considering?
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Electronic RENAULT
CLIO
Diagnostics
Tracing and fixing faults in electronic engine management systems
1.2 16v
NOTE: All references in our text

Ever popular among buyers, and captions to ‘left’ and right’
sides are from the point of view of
Renault Clios have been someone sitting in the car
and looking ahead.
with us for a quarter-
of-a-century now.
Kim Henson and
Dean Birch delve into
the diagnostic aspects
of a 2005 MkII 1.2 16v.
T
he Renault Clio arrived in the engine. This was one of the last MkII
UK in 1991, fresh-faced but models from 2005, powered by a 75PS
with much of its underbody four-cylinder engine.
and running gear based on the Our guide to this Renault’s engine and Preparation
Renault 5. The model was notable for its Siemens SIM32 management system Underbonnet access all around the
being advertised on television with the is Dean Birch of Onboard-Diagnostics engine is improved by first removing the
help of ‘Nicole’ and ‘Papa’ (aka actors (info@onboard-diagnostics.co.uk). air-box assembly, after detaching the
Estelle Skornik and Max Douchin). Less Note that Clios of this era could be fitted various hoses connected to it.
angular second-generation Clios were either with the Siemens system or with If the servicing history of the Clio
introduced in 1998, with a restyle and a Magneti Marelli set-up. In addition to being examined is not documented,
other upgrades being carried out in 2001. inlet manifold differences, the easiest carry out a full service on the vehicle
Third-generation models (sharing their way to tell which system is fitted to a to start with, before carrying out
chassis with the Modus and the Nissan particular Clio is to establish where the diagnostic operations.
Micra and Note) appeared in 2005. A ECU is located; if it is adjacent to the This engine features adjustable valve
variety of petrol engines were offered, battery this indicates a Siemens system, clearances, so ensure that these are
plus 1.5-litre diesel units. whereas on Magneti Marelli-equipped correctly set. Also check that the valve
Our guinea pig vehicle is a 16-valve versions the ECU is buried at the back of cover gasket is in good condition, with
1.2-litre petrol version, with a D4F the engine bay. no oil leaks evident.
1.2-litre 4-cylinder petrol PRE O2 SENSOR ENGINE ECU
IGNITION COIL
SYSTEM
RELAYS
MAP SENSOR
CRANKSHAFT
SENSOR
TANK VENT KNOCK

SOLENOID SENSOR

Electronic Diagnostics RENAULT CLIO 1.2 16v
Check that the throttle body assembly

is clean. If required, the unit is quite
Engine management easily removed for cleaning, once the
The Siemens SIM32 management system used on this Clio incorporates trunking has been detached.
these primary components: Note that poor running of the vehicle
in terms of accelerator response can
X A three-harness Siemens control unit. X A push-fit MAP sensor.
sometimes be incorrectly attributed to
X Four pencil-type injectors. X Separate main and fuel pump relays. the throttle pedal circuitry, whereas it
X A pedal-mounted accelerator sensor.
X Twin oxygen/O2/Lambda sensors. could simply be due to contamination of
X A fully electrically-activated throttle the throttle flap/assembly. Gently apply
body module. X An NTC-style coolant temperature carburettor/fuel system cleaner spray and
sensor. remove all dirt/debris once it has been
X A single coil block with attached HT
leads. X A diagnostic socket, mounted softened/dissolved by the cleaning agent.
X An inductive type crankshaft sensor. underneath the ashtray.
Fault 1:
It’s essential that the engine always usually due to dodgy connections, corroded FAILED AIRCON
runs with clean oil and filter. It’s also
imperative that the spark plugs are of the
cables, poor earthing or a combination
of these issues. Many such faults are
SYSTEM PRESSURE
type recommended by Renault, and that relatively straightforward to rectify. SWITCH
they are clean and correctly gapped. On the section of the wiring loom Symptoms of our first fault on this Clio
Inspect the wiring within the engine adjacent to the left-hand front inner include extremely rough running (if the
bay, assessing the state of all cables, wing, there should be a trumpet-shaped engine can be persuaded to start at all),
connections and earths – as with other shield around the group of cables. This with a very unstable idle. In addition, it
Renaults of this age, it is known to be is designed to deflect water away from will be difficult for the driver to rev the
fragile, so breakages are not unknown. the electrical junctions/relays in the motor or even to keep it running.
Always treat the cables with great forward left-hand corner of the engine Fault codes may be stored, relating
respect, never straining the wiring or the bay, so ensure that it is present, correctly to throttle pedal reference voltage or
connectors. A multitude of faults can arise, installed and undamaged. sensor reference voltage shorting to
Typical Clio 1.2 faults
Highlighted here is an important The bundle of electrical cables shown This connecting plug/socket assembly
1 system earth connection on our Clio 2 here is part of the main wiring loom, 3 links the engine bay wiring to the car’s
MkII. This earth cable/connector is located found just behind the left-hand headlamp. loom. The two halves are just a push-fit, but
close to the left-hand side of the engine The cables are normally hiding within the complete unit locks into a special recess
compartment and bolted to the gearbox. insulation. These cables are prone to on the fusebox; ensure the assembly is fully
Make sure it’s secure and undamaged. breaking, resulting in a variety of ailments. engaged, so it can’t work loose.
We carry out initial voltage checks on Immediately adjacent to the left-hand The fuel injector circuit resistance
4 the accelerator pedal circuit (Fault 1). 5 front inner panelwork are these 6 (Fault 2) can be checked by connecting
For convenience these can be carried out important system relays. Ensure that their the test meter via the socket found at the
at the multi-plug/socket assembly shown connectors are clean and sound, and that left-hand end of the fuel rail, after detaching
in Photo 3. The row of cables closest to the the relays are all pressed fully home on the the five cable wiring harness plug from the
camera serves the accelerator circuit. mounting board if you’ve removed any. socket. This test can be very helpful, but…

ground. These codes refer to the five- time. Although the switch has not been
volt output from the engine ECU to the
accelerator pedal circuit. However, other
operational, it is still connected within
the circuit, effectively dragging down the
Technical specs
components also receive their five-volt reference voltage for the other sensors Actual values
reference supply from the ECU, and and giving very poor running. Renewal Component Value
although they are not directly linked, of the switch would ensure normal Crankshaft sensor 200-400 ohms
any component sharing this supply can running, as well as operation of the air- Injector resistance 13-15 ohms
affect other components/sensors in the conditioning system.
Fuel pressure 2.4-2.7 bar
same chain. Any problem with the wiring
with vacuum
(for example, a short to ground/earth) or
within a sensor (sometimes an internal
Fault 2: Coolant temperature
sensor 300-400 ohms
short to ground) in the chain may result
in the symptoms described.
FUEL INJECTOR @ 80°C
One component that often gives trouble PROBLEMS
in such cases is the air-conditioning Another problem makes itself known The Bosch injectors may also be at
system pressure switch, which can suffer by what seems to be a pronounced, fault – they are prone to failure, either
from an internal short circuit. Before cylinder-specific misfire, which may going open circuit or providing very
getting too deeply involved in other be intermittent in its early stages. It low resistance readings. Testing for
aspects of the car’s wiring, it is worth may also be more prevalent in ‘heat resistance readings is shown in Photo 6,
disconnecting the switch by detaching sink’ situations – for example, when the with a multimeter being used to check
the harness plug connector and seeing engine is stopped and allowed to stand each individual injector, measured at
whether the five-volt reference supply for a while, then restarted. Fault codes the multi-plug/socket assembly at the
returns, together with disappearance of relating to ‘Injector circuit fault or error’ left-hand end of the fuel rail. Injector
the symptoms described and the fault or similar may be stored. renewal is straightforward, as it is
codes, in which case the cause of the If the above symptoms are occurring, fairly easy to extricate the fuel rail and
trouble has been found. first carry out routine checks of the injectors without the need to remove
Often in such instances, it will be electrical circuitry, including all the inlet manifold. If it is unclear which
discovered that the air-conditioning connections, ensuring that the fuel injector is at fault, the units can be tested
system has been inoperative for some supply system is operating as it should. individually by a specialist. Occasionally
…it is also vital to ensure that the The single coil assembly that serves The front or upstream oxygen/O2/
7 contacts within the plug/socket 8 all four high-tension leads/spark plugs 9 Lambda sensor is located within
assembly are clean, sound and free from is located behind the engine on the right- the exhaust pipe, right at the back of the
corrosion. Also watch for loose or widely- hand side of the vehicle. Check the harness engine bay. Although partly hidden from
spread contact pins, which may adversely connections here, as loose pins that result view when looking into the underbonnet
affect electrical continuity. in misfiring are often encountered. compartment, it is not too bad to reach.
This component is the air-conditioning

10 system’s pressure sensor (a trinary Hidden from view underneath the Attached to the front face of the
pressure switch – see Fault 1), mounted on 11 thermostat housing at the left-hand 12 cylinder block, just behind the
the left-hand side at the front of the car end of the engine is the crankshaft position engine oil dipstick tube, is the knock
and within the pipework threaded into the sensor. In this shot the twin cable (green and sensor – the brown component visible
system’s condenser. orange) harness plug is connected. in the centre of this photograph.

such symptoms are caused by control (UCH) or Body Control Module (BCM) on the fascia will not illuminate and/or
unit faults, but in most cases an injector that governs the operation of a host communications to the module will not
will be found to be the culprit. of electrical circuits, including those be available, and the engine will not start.
mentioned above, and immobiliser This is because a request from the engine
authorisation. This unit is prone to failure, ECU to the UCH to permit starting of the
Fault 3: often due to the ingress of moisture engine will not be carried out. Normally,
following a rainwater leak past a deficient the UCH receives data from the engine
AILING UCH (UNITÉ windscreen seal. The unit is not sealed ECU, and if all is well it will release the
CENTRALE HABITACLE against moisture ingress and is mounted immobiliser. It is worth removing the
beneath the glovebox. As the water enters UCH from the vehicle and looking closely
or BODY CONTROL over time, corrosion sets in gradually and at the circuit board – see Photo 16.
MODULE) eats into the board-mounted components, In terms of dealing with a damaged
This is the most complex, or at least eventually destroying the board assembly UCH, there are several options. First,
potentially challenging, fault. The car and rendering it inoperative. a new module can be purchased via
can suffer from a variety of strange When the car and the UCH/BCM is a Renault dealership. This will be an
electrical malfunctions, including behaving normally, the red LED on the unprogrammed unit and its price will
erratic or unpredictable operation of the dashboard illuminates when the ignition depend on the level of equipment fitted
lighting, locking system, windows and key is turned on and glows steadily for to the vehicle in question; the lower
relays (clicking/operating randomly) a few seconds before extinguishing, specification module works out at around
and/or the vehicle may refuse to start. and the engine will start as designed. £200, whereas the more sophisticated
As with other Renaults, this Clio However, if the UCH is suffering from assembly (capable of controlling
incorporates a Unité Centrale Habitacle moisture ingress/corrosion, the red LED automatic headlamps, for example) costs
Typical Clio 1.2 faults (continued)
This shot is taken from the right- This is one of the Clio’s exposed The UCH/Body Control Module (BCM)
13 hand side of the engine bay. Behind 14 key fobs. These keys (each of which 15 is located beneath the left-hand side
the coolant expansion tank’s upper hose includes a transponder – the small gold- of the fascia and controls the operation
can be seen the heavy-duty steel security coloured component towards the top right of many of the Clio’s systems, including
cage that accommodates the ECU, which is in this shot) are very fragile and need to be the immobiliser, electric windows, etc. It
difficult to access and remove/refit. treated with care. contains information unique to the car.
The in-car fusebox is positioned at the This screenshot, generated by the

17 left-hand end of the fascia assembly 18 Renault Clip dealer tool, shows the
and is accessible with the door open and various functions available to the operator,
the fusebox cover panel removed. The fuses once the equipment has been linked to the
within protect a multitude of circuits. vehicle via the Clio’s diagnostic socket.
Important information
is a Clio’s UCH/BCM (see Fault 19
16 Here
3) on the bench. These units suffer
regarding key/correct
immobiliser function can
from water ingress due to leaking screen be seen in this screenshot
seals, etc. A new one from Renault costs from the Renault Clip tool. As
£200-£300. A used unit cannot be fitted indicated in our text, this area
on its own, but ‘cloning’ of the requisite can be fraught with difficulties
information is possible at around £100. on the Clio (see Fault 3).

approximately £300. The new module confirm that the part numbers on the
will need to be introduced to the vehicle, two modules are compatible.
for which close to dealer level equipment A third method of getting over the Tool of choice
will be required. In addition, it will be UCH problem is to engage a specialist
For this feature, Dean is using
necessary to have the 16-digit PIN code to supply a secondhand module. He or
the Renault CAN Clip dealer tool,
unique to the car, which may be difficult she can read and ‘clone’ the information
which provides full functionality
to obtain from Renault. from the faulty module onto the
with this Clio.
A second option is to buy a used replacement. If this route is chosen, it is
module. You cannot simply buy and fit essential that the part numbers on the
a UCH assembly on its own, but instead new and original modules match. the original module for refurbishment
have to purchase a kit comprising the The typical price of a used module is by a specialist, provided it is not
engine ECU, the key and the UCH/ between £70 and £100, in addition to the irreparable, which can be the case if
Body Module, all from the same donor cost of cloning the information. moisture ingress has been taking place
car. Prior to purchase, it is necessary to A further alternative is to send away over an extended period of time.
SIEMENS SIM32 CIRCUIT DIAGRAM Diagram drawn by

Keith Ravenhill
15 IGNITION SUPPLY
30 BATTERY SUPPLY
31 GROUND SUPPLY
A40 ENGINE MANAGEMENT ECU
B10 CRANKSHAFT
POSITION SENSOR
B20 KNOCK SENSOR
B41 INTAKE AIR

TEMPERATURE SENSOR
B50 COOLANT
TEMPERATURE SENSOR
B60 MANIFOLD ABSOLUTE

PRESSURE SENSOR (MAP)
B71 PRE-CAT OXYGEN SENSOR
B73 POST-CAT OXYGEN SENSOR
E1-4 SPARK PLUGS
F1- FUSEBOX 1
F2- FUSEBOX 2
K30 MAIN RELAY
K35 FUEL PUMP RELAY
K261 RADIATOR FAN RELAY 1
K262 RADIATOR FAN RELAY 2
M30 FUEL PUMP
M110 RADIATOR FAN MOTOR
R31 THROTTLE VALVE POSITON

SENSOR (DUAL)
R111 THROTTLE PEDAL POSITION

SENSOR (DUAL)
S402 BRAKE PEDAL SWITCH
S302 CLUTCH PEDAL
T2 WASTED SPARK
IGNITION PACK
X16 J1962 DIAGNOSTIC

CONNECTOR
Y30 MULTI-POINT INJECTOR
Y50 PURGE VALVE

Our a
Rob
Bradshaw
Special Contributor
205s are
like buses
I
’ve always been a big fan of Peugeot
205s. I love the simple, clean
Pininfarina styling that still looks
fresh and modern. Considering
it’s now 32 years since the car made
its debut, it has aged better than most
vehicles of its era and it’s also still
tremendous fun to drive.
Then there’s the build quality. French
cars of the 1970s weren’t renowned for
being the best in the world, but the 205 To cut a long part-exer, available to me for its stand-in
was the car that pretty much fixed that. story short, I have a number of friends in value of £250, it seemed a shame to let it
Not only were the engines generally the motor trade who know I’m a sucker get shipped off to auction. Not only that,
reliable, both the early Simca-derived for anything old and unusual. So when but the car was identical to one owned by
‘Suitcase’ unit and the later TU, but the I got a call from a contact about a my mate Paul during our late teens, and
bodywork was a revelation, too. Gone Peugeot 205 Trio that had come in as a I have many happy memories of driving
were the days of flaky French steel
that would corrode with almost the
same alacrity as Italian metal, Instead
there was a galvanised shell and body
panels that proved immune to natural
destruction. I genuinely believe the 205
is one of the best-made cars of all time
and have put my money where my mouth
is on five previous occasions, none
of which has disappointed.
The most recent of those was
a 1989 205 CJ convertible in
silver, which I bought in 2009 as
a short term project and finally
parted with this summer after a
friend convinced me he’d use it more
than I did. But as the 205 departed for
pastures new, I knew I’d get another. Peugeot 205 Number 1 drove dreadfully
What I hadn’t banked on was being until Rob realised that the tyre pressures
varied from 9psi to 34psi. A day’s detailing
205-less for less than a month. As is will have it looking like a million dollars.
often the way, my next 205 found me.
The original dealer sticker is a nice period

Interior in the Trio is pretty tidy. Check out touch, especially as the car was bought from The tailgate panel is single skinned, so it may
those 1990s turquoise seatbelts! the neighbouring village to where Rob lives. not be too difficult to repair.

Our Cars Rob Bradshaw
unit has packed up. A suitably retro

Left… or right?
early 1990’s CD player is top of the wish In Rob’s garage
list, but I’ll see what I can turn up in
the car boot sales, rather than pay the 2000 Land Rover Discovery
silly prices such units tend to fetch on Td5 ES auto My wife’s car, chosen for its
auction websites. seven-seat capacity rather than offroad ability.
Extremely handy for towing the caravan.
1995 Jaguar XJ6 3.2 Sport
Acquisition No 2 Luxury on a shoestring.
That’s acquisition No One dealt with,
but the story isn’t finished. In order
1995 Rover 820 Vitesse turbo
My childhood dream car. It takes all sorts!
to accommodate my new purchase,
both space- and time-wise, I decided it 1993 Rover Metro Rio Grande
Recently bought this. In lovely condition.
was time to sell my Hyundai XG30. The
3.0-litre Korean luxury barge came to me 1992 Rover 214Si
as a whimsical part-exchange against my Replaced my 214SEi. Basic trim, but
Rover Sterling, covered in these pages sensational timewarp condition.
last year. But I didn’t really bond with it, 1989 Rover 820e Absolutely mint early
so I advertised it for sale via Facebook. It Rover 800 Fastback – an acquired taste.
took less than a day to find it an owner, 1988 Land Rover 110 station
but the deal was incumbent on me taking wagon Worked hard for a living. About the
his existing car as part-payment. The car only 1988 components are the numberplates.
in question? A Peugeot 205.
in convoy with it through the adventures So, less than two days after taking
1988 Rover Metro Clubman
Gathering dust in a lock-up. Rare survivor in
of my misspent youth. custody of the white 205, it was joined excellent condition, but needs a new clutch
Forty-eight hours after the call, having by a blue one, this time a 1.6 automatic of and I’ve been meaning to fit one for four years.
convinced my long-suffering wife that the 1995 vintage. If the white one’s a cracker,
kids would enjoy an evening stroll in the then this one’s an absolute peach.
1984 Mini City Everyone loves a Mini.
countryside, I was driving back from rural With just 65,000 miles on the clock, a
Northants in a white 205 three-door comprehensive service history and almost for a supermini of that vintage and the
with turquoise seatbelts, white hubcaps unmarked Miami Blue bodywork, the auto power steering, central locking and
and a half-length sunroof. And I love it. bears all the hallmarks of a well-loved car. plush velour seats give it a much more
The 1.1-litre Trio has covered just It’s interesting to see how two almost upmarket feel.
under 99,000 miles. It starts and drives identical cars can be so very different in Like the 1.1, it’s not devoid of jobs to do.
really well, save for a wheel wobble at terms of character. The white 1.1, with First on the list is to investigate the cause
60mph, which I’m convinced is down its manual gearbox and buzzy TU engine, of mayonnaise under the oil filler cap to
to the wheels needing balancing. I’ll is a typical French supermini: loud and ensure it’s not the head gasket. TUs are
address that issue with some budget lively, with no power steering, it begs prone to condensation build-up under the
rubber, as the current tyres are clearly to be driven in a spirited manner and plastic cap, not helped by the design of the
advanced in years. There’s also a dent responds well to such behaviour. The cap itself, which expands and contracts
in the tailgate, caused by a ladder falling auto, on the other hand, feels altogether with temperature changes. But there’s
over in the previous owner’s garage, and more civilised – the 1.6 engine gives rather a lot of it and I’d rather pressure-
other things for the to-do list include much more even acceleration, the test the head to be sure. It also has a blow
sourcing a radio, as the original Peugeot four-speed ’box is surprisingly smooth from the exhaust midsection and the
remote central locking has packed up.
Peugeot 205 auto Over the next few weeks, I’ll be
is in excellent working my way through the job list on
overall condition.
both cars and trying to find a dent-free
tailgate for the white one, as I reckon
it’ll be easier than trying to repair the
existing panel.
Later high-line interior

is significantly posher!

Mechanex 2015
Mechanex
The free-to-attend
annual Mechanex shows
are provided at different
locations around the
country for people
working in the motor
trade. Kim Henson
visited the Sandown Park
event in Esher, Surrey in
November 2015.
F
or those working in the motor charge technical seminars, each lasting James gave some useful hints regarding
trade who are in need of up to about 45 minutes, comprising a logical approach to fault finding in the
information, tools/equipment, talks, slides and videos presented by complex electronic/electrical systems
finance or insurance, or who specialists knowledgeable in their employed in modern vehicles. Again,
just want to keep abreast of current respective fields. In many cases, the emphasis was on practical methods
trends in car maintenance and repairs, attendees are also able to take advantage of working to help ensure a speedy and
the Mechanex shows are just the of special show offers and discounts. accurate outcome for the benefit of both
ticket. Organised by Professional Motor the operator and the customer.
Mechanic magazine, the Mechanex Further seminars covered subjects
shows are described as “the regional Gaining knowledge including direct petrol injection
trade show for auto repair professionals”, CM attended two seminars on the technologies, remanufacturing
encompassing garage proprietors, day. The first, put on by Delphi, was developments, hybrid vehicles,
mechanics and independent operators. entitled The Connected Car and covered profiting from the latest battery
The shows feature a diverse range of the expected growth in the future of technology, common rail diesel engines
companies and individuals selling internet/WiFi-based diagnostics, and the intricacies of electrically-
vehicle-related components, equipment various aspects of Ecall legislation operated handbrake systems.
and tools, as well as financial services. and the probable implications for the We went to the show in the company
Many of the technical equipment independent aftermarket. of two motor trade professionals, both
displays are set up so the firm’s wares The second seminar was a talk by James of whom agreed that attending was well
could be demonstrated in practical Dillon of Technical Topics in Somerset, worthwhile, although both also admitted
terms (for example, vehicle steering describing how it is still possible for hard- that they could easily have spent ‘a
system tracking equipment, special pressed garages and mechanics to survive fortune’ on new equipment, if they had
tools for running gear overhaul, etc). and even thrive when carrying out time- bought all the gear that would have been
There is also a wide variety of free-of- consuming diagnostic work. In addition, helpful to their respective businesses!
Demonstrations of purpose-designed pullers Klann brought along a diverse selection

to safely remove hub bearings were being The KYB shock absorber stand incorporated of specialist automotive tools and gave
given by Pichler on its stand. a fabulous Scalextric circuit. showgoers hands-on experience.

Mechanex 2015
W Delphi held
a technical
seminar on the
subject of The
Connected Car.
X The Autodata
stand at the
Sandown
Mechanex show.
Schaeffler/LUK’s stand
offered help with dealing
2016 EVENTS
with dual mass flywheels. For those wishing
to attend any of the
Mechanex shows, the
2016 schedule includes:
Alexandra Palace, April
London 19/20
Eventcity, May
Manchester 17/18
Donington Park, October
Derbyshire 11/12
Sandown Park, November
Surrey 8/9
For further information
and to register, visit
Mechanex.info Sykes-Pickavant Ltd displayed a wide
variety of its trade equipment.
Booster
NEXT MONTH packs
on test
Decoking MARCH 2016 issue
out FEBRUARY 18
modern engines O Alfa Romeo 147 parts guide

O Chevrolet Captiva buying tips
O Project MINI gear linkage renewal
O CM Visit: Shell Hamburg Tech Centre
O Multimeter Masterclass Part 2
O Tea Break: History of the 12V battery
Follow CM as we find out why some engines are clogging up internally

X Intake walnut shell blasting X Combustion chamber Terraclean X EDT lubrication detox
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A J RENAULT
Clio: 2005 1.2 16v MkII, DIY Servicing, Sep 15, p66-70
ALFA ROMEO JAGUAR
Modus: 2004-2012, Survival Guide, Oct 15, p56-57
147: 2001-2009 Used Car Focus, Jun 15, p50-54 XJ6: 3.2 Sport, DIY Servicing, Jan 15, p64-69
ROVER
Alternators: Reconditioning, Jun 15, p6-13 X-TYPE 2.0D project:
75: Diesel thermostat budget repair, Jul 15, p48
Anti-lock Braking Systems: ABS faults, Nov 15, p6-12 Pt1: Assessing our latest £1000 purchase,
Feb 15, p28-32 827: Sterling, Our Cars, Apr 15, p90-91
AutoInsider Live! 2015, Aug 15, p69
Pt2: Engine servicing and rear-end D-bush renewal, 827: Sterling, Our Cars, May 15, p90-91
Auxiliary Drivebelts: Typical troubles, Jul 15, p58-60
AUDI Mar 15, p26-30
A2: 2000-2005, Survival Guide, Feb 15, p56-57 Pt3: New brakes, window seal strips & rear drop links, S
Apr 15, p30-34 Screen Mounts, on test, Oct 15, p42-45
Pt4: Cold starting issues & a noisy rear wheel SEAT
B bearing, May 15, p40-44
Ibiza: 2006 1.2 12v, DIY Servicing, Dec 15, p66-70
Battery Care: Jan 15, p6-11 Pt5: New suspension & MoT test, Jun 15, p28-32
Toledo: 1999-2005, Survival Guide, Apr 15, p56-57
BENTLEY Pt6: Soundproofing & rustproofing, Jul 15, p30-34
SKODA
Continental GT: 2003-2010, Survival Guide, Pt7: Clutch, DMF & release bearing, Aug 15, p30-34
Aug 15, p56-57 Octavia: 1.9 TDI PD 105, Electronic Diagnostics,
May 15, p84-88
BMW K Small Component Storage: on test, Feb 15, p58-61
1-Series: DPF disaster, Sep 15, p55
Key Fob Refurbishment, Jul 15, p46-47 SUZUKI
3-Series: E46 Rear wheel bearing swap, Jan 15, p32-35
KIA Splash: 2012 1.2 auto, DIY Servicing, Jul 15, p66-70
3-Series: Differential swap, May 15, p46-47
Picanto: 2010 1.1-litre, DIY Servicing, May 15, p68-72
3-Series: E90, 318i Electronic Diagnostics,
Dec 15, p83-86 T
3-Series: E90, Survival Guide, Jun, p56-57 L Tea Break:
Brake Hydraulics: Maintaining, Jul 15, p6-14 LPG Disasters: Dec 15, p42-46 Pt4: Exhausts, Feb 15, p86-87
Pt5: Air-conditioning, Aug 15, p62-63
C M Timing Belt Clinic
Car Creepers, on test, Jul 15, p42-45 MAZDA Honda Civic 1.4, May 15, p58-61
CHRYSLER 2: 1.5-litre petrol, Electronic Diagnostics, Nov 15, p82-86 Timing Chains: Understanding, Oct 15, p6-14
300C: 2006-2011 Used Car Focus, Oct 15, p50-54 6: 2002-2007, Used Car Focus, Apr 15, p50-54 Timing Lights: on test, Jun 15, p58-61
CITROËN Mechanex 2014, Mar 15, p64 Torx Kits, on test, Aug 15, p42-45
C1: 2011 VTR 998cc, DIY Servicing, Nov 15, p66-70 MERCEDES-BENZ Toyota Land Cruiser 4.2 diesel, Mar 15, p66-67
C3: 1.6 petrol, Electronic Diagnostics, Jun 15, p83-87 C180K Sports Coupe project: Tracking Gauge, Build your own:
C4: 2004-2010, Used Car Focus, Aug 15, p50-54 Pt4: Central locking & column stalk, Jan 15, p36-40 Pt1: Make the frame, Mar 15, p58-60
C6: 2005-2012, Used Car Focus, Jan 15, p50-54 Pt5: Suspension, brakes & thermostat, Feb 15, p34-38 Pt2: Preparing the vehicle, Apr 15, p36-37
Climate Control: Fixing, May 15, p6-14 Pt6: Wheels, tyres, rust & finishing touches, Pt3: Taking accurate measurements, May 15, p62-64
Clutch Clinic: Mar 15, p36-40 Trim: Renovating lacquered wood veneer, recoating plastic
ML: 280 CDi, Electronic Diagnostics, Sep 15, p84-88 mouldings, Mar 15, p6-11
Ford Escort 1.6 Zetec, Apr 15, p44-48
MG Tour de Germany:
Peugeot 306 1.9D, Nov 15, p40-45
F/TF: 1995-2005, Survival Guide, May 15, p56-57 Fixing our 1996 VW Passat, Nov 15, p90-91
Cordless Inspection Lamps: on test, May 15, p30-33
MINI Pt1: Driving to Stuttgart, Dec 15, p90-92
CM Visit:
One Project: TOYOTA
Bridgestone Europe, Nov 15, p46-48
Pt1: Purchasing non-runner from auction, Corolla: 1.6 petrol E12/E120, Electronic Diagnostics,
Lincon Batteries, Mar 15, p32-33 Jan 15, p80-84
Sept 15, p30-34
MG at Longbridge, Apr 15, p60-62 Land Cruiser: 4.2 diesel, Timing Belt Clinic,
Pt2: Checking over the non-running engine,
Oct 15, p30-34 Mar 15, p66-67
D Pt3: Taking out original engine, Nov 15, p28-32 Prius Series:
Dashcams, on test, Dec 15, p58-62 Pt4: Fitting a replacement engine, Dec 15, p36-40 Pt3: Is the Hydrid a DIY proposition? Jan 15, p26-30
MITSUBISHI Pt4: Looking at Mk1, Mk2 & Mk3 models,
F Feb 15, p40-44
Shogun: 2000-2006, Survival Guide, Jan 15, p56-58
Prius: 2000-present, Survival Guide, Dec 15, p56-57
FIAT Modification Series:
Starlet Project:
Stilo: 2002-2006 Used Car Focus, Mar 15, p50-54 Pt1: Suspension upgrades, Sep 15, p42-46
Pt1: Budget purchase, Aug 15, p58-61
Punto: 2001 CVT autobox change, Jun 15, p40-44 Pt2: Polyurethane bushes, Nov 15, p58-61
Pt2: Cooling system fix and servicing, Sep 15, p58-60
FORD
Pt3: Cambelt swap, Oct 15, p58-61
Escort: Clutch Clinic 1.6 Zetec, Apr 15, p44-48 N Turbocharging: Rebuilding, Sept 15, p6-15
Fiesta: 2003 1.3 Finesse, DIY Servicing, Apr 15, p66-70 NISSAN TVR
Focus: 2008 2.0-litre petrol, DIY Servicing, Oct 15, p66-70 Micra K12 Project: Chimaera: 1993-2003, Survial Guide, Mar 15, p56-57
Ka 1.3 project: Pt7: Suspension springs & awkward glovebox fix, Tyres: Buying and maintaining, Feb 15, p6-12
Pt1: Assessing our 2007 car, May 15, p34-38 Jan 15, p42-46
Pt2: Changing heater unit, Jun 15, p34-38 Micra: K12 C+C 1.6 petrol, Electronic Diagnostics,
Pt3: New brakes & rear wheel bearings, Jul 15, p36-40 Jul 15, p82-86 V
Pt4: New dampers & full service, Aug 15, p36-40 Patrol: 1987-2009, Used Car Focus, Feb 15, p50-54 VAG Coolant Expansion Bottle Swap, Mar 15, p48-49
Pt5: Fuel flap area rust repair, Sep 15, p36-40 Primera: 2002-2007, Used Car Focus, Nov 15, p50-54 VAG Drum Brake Renewal, Oct 15, p46-48
Pt6: Rust repairs and full paint, Oct 15, p36-40 VAUXHALL
Pt7: Rustproofing body, Nov 15, p34-38 P Tigra: B 1.4, Electronic Diagnostics, Apr 15, p83-86
Mondeo: 2000 1.8 MkII, DIY Servicing, Aug 15, p64-68 Vectra C/Signum: 2002-2008 Used Car Focus,
PEUGEOT
Jul 15, p50-54
Fluid Dynamics: Complete guide to fluids, Dec 15, p6-15 306: Clutch Clinic, 1.9D, Nov 15, p40-45
VOLKSWAGEN
Fuel Injectors: Looking after your. Apr 15, p6-14 407: 2007 1.6 HDi, DIY Servicing, Jun 15, p66-70
Eos: 1.4 TSI 122PS, Electronic Diagnostics, Oct 15, p83-87
407: 1.6 HDi, Electronic Diagnostics, Feb 15, p81-85
Golf: MkIV 1.6 auto, Diagnostics Case Study, Aug 15, p78
H Product Tests:
Passat: 2001-2010, Survival Guide, Nov 15, p56-57
HONDA Car Creepers, Jul 15, p42-45
Transporter T5: Our Cars, Jun 15, p88-89
Accord: Readers’ Motors, Feb 15, p92-93 Cordless Inspection Lamps, May 15, p30-33
VOLVO
Accord: 2.0-litre petrol i-VTEC, Electronic Diagnostics, Dashcams, Dec 15, p58-62
S40: 2.0 non-turbo first-series, Electronic Diagnostics,
Mar 15, p84-88 Screen Mounts, Oct 15, p42-45 Aug 15, p83-86
Accord: 1998-2008, Used Car Focus, Dec 15, p50-54 Small Component Storage, Feb 15, p58-61 S60 Project:
Civic: 1.4-litre four-cylinder, Timing Belt Clinic, Timing Lights, Jun 15, p58-61 Pt1: Purchasing 2007 2.4D for £1500, Dec 15, p30-33
May 15, p58-61 Torx Kits, Aug 15, p42-45 S60: 2005 D5 2.4, DIY Servicing, Feb 15, p64-68
HYUNDAI
S80: 1998-2006, Used Car Focus, May 15, p50-54
Getz: 2005 1.1-litre, DIY Servicing, Mar 15, p68-72 R XC90 T6 project:
Matrix: 2001-2010 Used Car Focus, Sep 15, p50-54
RANGE ROVER Pt1: Fitting a towbar & engine service, Mar 15, p42-46
Range Rover: Body and chassis part company, Pt2: Oil leak & locking wheel bolt disaster,
I Sep 15, p62-65 Apr 15, p40-43
Instrument Clusters: Repairing, Aug 15, p6-15 Sport: 2005-2013, Survival Guide, Jul 15, p56-57 XC90: 2002-2014, Survival Guide, Sep 15, p56-57

FREE ADS Car Mechanics offers a FREE classified service FOR PRIVATE
SELLERS ONLY who want to sell-on their UNWANTED CARS
and PARTS, or for those who need a specific item.
Simply jot down the details, a contact telephone
number and, for our reference only, your home
address. We will even print a PHOTOGRAPH
(subject to space). Plus whether you want the
advert to run one or two issues?
WE REGRET WE CANNOT TAKE ADVERTS OVER THE PHONE. THIS
CLASSIFIED SECTION IS STRICTLY FOR CAR-RELATED ITEMS.
MGF. 2001, 59,000 miles,

CARS Very good bodywork, head
gasket and cambelt been
FOR SALE done, lots of history. Car drives
beautifully. Viewing highly
recommended. £1550 ono.
Tel: 07920 236852. Solihull.
PARTS
FOR SALE
RENAULT CLIO 1.2. 1997.
VOLKSWAGEN POLO 1.4. 2001. 100,001 miles. 3-door
73,000 miles, Excellent runner SKODA FABIA BONNET.
hatchback, MoT October 2016, E/W, P/S, electric mirrors,
and driver. MoT June. non- Pick up only or arrange your
aircon, airbags, C/L. Good runner, clean body, needs
power steering model, good own postage. £30 or best
water pump, can be driven away, easy project, P/EX for
condition for the year. Please offer. Tel: 07724 103751.
Mk2 Golf/Polo. £495 ono. Tel: 01233 640372. Kent.
call for more details and more Warwickshire.
pictures. £299. Tel: 07950
338604. South London.
GARAGE
HONDA ACCORD. 2002.
83,980 miles. Excellent
KIT
condition, two former keepers, SIM 115mm ANGLE
sunroof, alloys, quick sale GRINDER. Hardly used.
required. £420. Tel: 07976 Needs a new black handle –
938173. East Yorkshire. PORSCHE BOXSTER 3.2S. ,·YHWULHGWRJHWRQHIRULWEXW
2000. 67,500 miles, New had no joy. Would like £60
SMART CAR. 2002. 68,000 MoT, red leather and black cash, but am open to offers.
miles. Passion, Black. Auto. roof, service history, new Please call Richard on 01432
Good condition generally. alternator and air mass 274663. Herefordshire.
6-speed. 74mpg. Top 75mph. meter, many other new parts,
£30 tax per year. Long MoT. good tyres. £5750. Tel: 07702
AUDI A4. 1999. 140,000

£1100. Tel: 07931 238911.
Powys.
828351. East Sussex. WANTED
miles. 1.8 petrol, full service MG MAESTRO 2.0i 1991 rear
history, immaculate, drives SUBARU WRX. 1995. engine to gearbox mounting.
as it should, MoT July 2016. Bodyshell c/w doors, boot, Tel: 01438 311781. Herts.
£695 ono. Tel: 07464 135941. bonnet and glass, no rust, with
North Yorkshire. V5. Buyer collects, sensible HAYNES MANUAL to cover
offers please. Tel: Peter on Renault Megane 1.5 dCi
MERCEDES-BENZ CLK 07775 616569. Essex. 2006 model. Tel: 0151 520
200K. 2000. 131,000 miles, KIA SORRENTO 2.5 DIESEL. 3212 evening only.
My daily driver, 2-litre XJ SPORT PREMIUM TD 2005. 130,000 miles. Black
supercharged with 5-speed 2.7. 2005. Metallic black with with full grey leather interior.
automatic gearbox. Black
leather interior with cruise
ivory leather interior. Special
edition. Diesel Sport. 12
Top of the range model with
chrome bumpers and side
MISC
and aircon. Full MoT, good months MoT. Excellent all- steps. Just had full service OIL CAN. Half pint size,
mechanics but does need round condition. New engine including new discs and made by Sutcliffe in 1942,
minor paint. £750 ono. fitted at 80,000 miles at cost pads. MoT Oct 16. Excellent nice period accessory, hard
Tel: 0786 6137816. of £5500. £5500 ono. Tel: workhorse. £2,800 ono. Tel: to find. £19 plus P&P. Tel:
West Midlands. 01270 528012. Cheshire. 01270 528012. Cheshire. 01761 470607. Somerset.
CLASSIFIED DEADLINE FOR MARCH 2016 ISSUE: February 2

FEDERATION OF ENGINE REMANUFACTURERS
Classified
.&.#&34 Please mention
%*3&$503: LPG you saw their

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Ted Connolly
Ted is slightly disappointed by a drive in the Jaguar XF.
Driving Future classic?
The Jaguar XF.
a dream
IF money were no object,
which car would you buy?
A Lamborghini? Porsche?
Ferrari? Rolls-Royce (mustn’t
say Roller, I copped a right
telling-off for using that
expression a while back)?
Everyone has their dream
machine, but most of us don’t
have the dream finances.
I have been lucky
over the years, because
masquerading as a motoring
journalist has allowed me One that particularly can see 60mph in around
to get behind the wheel of
most of the world’s good
stuck in my mind was the
Jaguar XJ6. I had one to fling
‘The Jaguar XF is a eight seconds. That might
not sound quick in absolute
stuff. Actually, my scribbling around in 1983 and it was truly fabulous car, terms, but it’s the way it gets
pretensions have seen me a wonderful blend of wood, there. The mid-range punch
checking out a whole variety leather, silence, power and
but it just didn’t is phenomenal and it’s all
of vehicles when they were general opulence. I have do it for me’ achieved in near-silence.
new, including the Reliant always loved Jags – having A truly fabulous car, but
Rialto, Toyota Starlet, the owned an S-Type in the it’s easy to fall behind with it just didn’t do it for me.
first of the XR2 and XR3 1970s and drooled over technology and the general I still craved the ambience of
Fords (before they got fuel various Mk2s that were feel of new cars. Therefore, leather seats, a walnut dash
injection), Saab 9000 Turbo, floating around – and the I was appreciative when a and rows of wonderfully-
Fiat Argenta (remember that XJ carried on the tradition friend, who has made it in confusing switches and dials.
one? Bet you don’t!), Audi of (if you will kindly excuse business, took me for a spin So having been out in what
100, Suzuki Alto, Hyundai the totally worn-out phrase) in his new Jaguar XF. He’s many would consider to be
Pony, Rolls-Royce Corniche, grace, pace and space. got the 2.2-litre diesel, and a dream car, what would
Ford Sierra, Citroën BX, As a result of the sort with all of the toys, such as I choose if cash was not
MG Metro Turbo and Audi of stuff I do now – I feebly a mini-television, probably a problem? Quite simply,
Quattro. Many are old hat refer to it as work – road- set him back around the I don’t know, mainly because
now, but, as I said, they were tests aren’t generally part £40,000 mark, maybe more. I prefer to have dreams
new at the time. of my itinerary and, thus, With 200bhp available, it rather than money.
That caps
it all
YOU may (or may not)
recall that I reported on the
activities of some piece of
low-life in my neighbourhood
who kindly nicked the valve
caps off the Connolly MX-5. A
real pity, because they were anodised red, and were not only observations and items of interest – says the theft of
sourced and specially bought, but also looked the business. valve caps is not confined to the kerbside outside my
The thief was quite brazen, because three of the caps hovel. He writes: “You ain’t alone. I visited the new Haynes
disappeared overnight and the fourth a day later. He (or International Motor Museum not long after it was opened
she) had obviously been disturbed the first time round and and what did I see? Or not see, depending on how you view
returned to finish the job. I am not a man to seek revenge it. New, old, it mattered not. Missing valve caps all over the
and immediately put thoughts of connecting the car to the place. Always on cars sided next to the walkways, of course.”
mains out of my head. Well, maybe not immediately, but Jeremy sent three photos (above) taken at the museum
I eventually got round to a reasonable way of thinking. to illustrate the point. Is nothing sacred? It makes you
Anyhow, CM contributor Jeremy Haworth – who wonder what goes through the minds of people who steal
occasionally gets in touch with snippets of information, for the sake of it. Or, indeed, just steal. Probably nothing.

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