autotechnician and sponsors provide an update on a new free test for technicians, announce the first round of speakers at the Big Weekend and provide Technical & training advice
AUTOTECH 2022 is sponsored by:
FEATURE contents P32 Big Weekend event update First round of speakers announced, and free hotel stay for guests who book a two-day pass!
P34 ACtronics: ECU issues & how to fix them ECU technology explained – faults and bespoke fixes
P36 Delphi: A future-proof diagnostic solution Hayley Pells of Avia Autos explains why she has chosen the DS180 BlueTech tool for its dedicated diagnostic ramp
P38 febi case study febi investigates some electrical gremlins affecting a Skoda Yeti in its workshop
P40 DPF Doctor Network Special Darren Darling interview: The DPF Doctor founder introduces his online training portal
P42 Varta: Start-Stop technology Varta provides an overview of Start-Stop technology & stresses the importance of vehicle checks to ensure fuel-saving measures are functioning correctly
P44 ZF [pro]Tech ZF Aftermarket discuss how its ZF [pro]Tech technical support and training is helping independents service & maintain the vehicles of today and tomorrow
AUTOTECH
p46 auto:resource and Automechanika UK update
31
Trainers gear up for Big Weekend event Our technician trainers are currently planning their sessions for Autotech’s Big Weekend taking place Friday 23rd and Saturday 24th September at Delphi Technologies workshop in Warwick. One and two-day tickets are available at a heavily subsidised rate, thanks to sponsors. • One day ticket: £79.00 plus VAT • Two day ticket: £129.00 plus VAT Grab a 2-day Big Weekend ticket and get a hotel room thrown in for free! Book a two-day pass to the event in July and we’ll take care of your accommodation on the Friday night at the team's hotel five minutes from the venue.
AUTOTECH 2022
Book your place online at https://autotechnician.co.uk/ training
32
Each day’s content is unique and will deliver a variety of practical advice to take back to your workshop, with a strong focus on promoting a first-time fix by strengthening the diagnostic process. Andy Crook of GotBoost, VAG specialist Gareth Davies, Matt Cleevely of Cleevely EV and Pete Melville of HEVRA are the first of the presenters to outline their sessions…
Andy Crook, GotBoost Andy will be delivering two sessions over the weekend. The first session on Friday 23rd September will investigate 'Framing the Problem.' • How processes and systems can help the business and the technician prevent diagnostic headaches • Covering effective communication, setting yourself up for success and keeping effective records This is a must-attend session if you find yourself giving away diagnostic time, or simply cannot charge for all of the time you take to diagnose complex faults. Andy’s Saturday session looks at ‘Closing the Loop.’ Andy will provide practical advice on how to improve customer satisfaction, your first-time fix rate and how to improve your diagnostic capability. • He will use case studies to illustrate how simple changes can transform how you deal with your customers
recognising good and bad data, and how to manipulate live data via sensor simulation to prove a fault/fault-free diagnosis. It will look to recap the day before in a brief summary, and then follow on using again a variety of tools, including sensor simulators, multimeters and oscilloscopes.
Matt Cleevely, Cleevely EV
• How a TV detective can improve your first-time fix rate, and how to identify the gaps in your diagnostic capability The session is aimed at technicians and business owners, based on Andy’s 'Business of Diagnostics' course.
Pete Melville, HEVRA Pete will demonstrate the multi-stage diagnostic process on a Renault Zoe that’s had faults installed on it – taking us through some basic problems and onto the more complex.
Gareth Davies, VAG specialist Day 1 Live case study – 5V reference troubleshooting Gareth's presentation will focus on the principle of a 5V reference circuit fault, how it can manifest in terms of DTC’s and symptoms/behaviours. It will cover both a dealer tool and aftermarket scan tools, show the differences in how the faults are represented and avenues to explore to get the information and data required to troubleshoot the fault accurately. The presentation will involve a ‘broken’ car live in the workshop and will require audience participation as a team in choosing the route to diagnosis and tests required to confirm the fault and fix. He aims to give the audience a few pointers in what to look for, and some take aways in new skills and tips to use back at their workshops.
Demystifying EV repair Matt Cleevely has created a bespoke rig containing all the high voltage elements of a Nissan Leaf present and he’ll discuss the problems he sees coming into the workshop, the kind of repairs an EV garage can expect over the next few years. He’ll also cover a couple of quirky faults he has seen that appear difficult but are in fact straightforward – he aims to dispel some myths surrounding EV & hybrid work.
Watch this space Keep an eye out on our Facebook page www.facebook. com/Autotechmagazine and our website www. autotechnician.co.uk for further announcements over the summer. Tickets are limited so book your pass now to avoid disappointment.
"The presentation will involve a 'broken' car live in the workshop and will require audience participation in choosing the route to diagnosis and tests required to confirm the fault and fix"
Day 2 Live data and signals Greath’s presentation on the Saturday will use the same broken car from the day before but with a different fault imposed. It will look at interpretations of faults with and without DTC’s,
Book a two-day pass to the event in July and we’ll take care of your accommodation on the Friday night at the team’s hotel just down the road from the venue. • One day ticket: £79.00 plus VAT • Two-day ticket: £129.00 plus VAT Book your place online at https://autotechnician.co.uk/ training
AUTOTECH 2022
Grab a 2-day Big Weekend ticket & get a hotel room thrown in for free!
33
ECU issues and how to fix them The ECU is truly a wonderful piece of engineering. Not only does it contain a lot of functionality, but to reliably operate in a harsh environment with very variable conditions is a big achievement. However, the reliability still leaves something to be desired every now and then. Why can’t they solve these weaknesses?
by active components) dissipate quickly. Deformation and vibration therefore occur way less with ceramic printed circuit boards. It also prevents possible consequential damage due to these deformities. Cracks in solid connections are therefore also relatively rare. So, all-in-all, the use of ceramic material really has huge advantages. We even dare to say that the now somewhat older green printed circuit board is partly to blame for the varying reliability of some current ECUs.
It might be useful to start with some elaboration about the technology that’s used inside an ECU. Of course, the basis is formed by a processor, memory and a PCB (Printed Circuit Board), but there is really much more to tell.
Components on, and inside, the PCB
AUTOTECH
The PCB
34
We’ll start with the PCB itself: The well-known green printed circuit board, made out of fibreglass and epoxy resin, is still used regularly, but the arrival of ceramic material has made some manufacturers switch. Ceramic printed circuit boards can conduct and dissipate heat much better and are made of much finer and better structured material, which allows for very high precision manufacturing. This also has its advantages for printed circuit board design, as it also makes possible very small and complicated 3D structures. Car manufacturers are very eager to take advantage of these characteristics, as any form of space and weight saving is welcomed with open arms. We therefore expect to see the use of ceramic material in ECUs even more in the near future. Ceramic printed circuit boards are mostly glued to an aluminium base plate with a heat-conducting paste. This gives the circuit board its firmness and lets the heat (generated
It should come as no surprise that this difference in printed circuit boards also results in a different use of components. A conventional printed circuit board has a coarser structure in comparison to the ceramic variant. The components themselves are therefore logically somewhat more "robust" in design. Most contact points are therefore large enough to be seen without a microscope. You would therefore think that these components are also more reliable than the smaller fragile components on a ceramic printed circuit board, but strangely enough, this theory does not seem to hold true in reality. The larger components still regularly fail. Could low manufacturing costs play a role in this? Fortunately, with suitable (solder) equipment and sufficient skill, much is possible in repairing connections and replacing components on these conventional printed circuit boards, even if the contact points are located beneath the component, as is the case with processors such as BGAs. You’ll need special high-end equipment that can heat locally with extreme precision, but it’s doable for real experts. So, if something fails on a conventional printed circuit board, repair is possible in many cases. However, with components that are used on a ceramic printed circuit board, it suddenly
if you have the right (often expensive) equipment and use the correct methods. The thin aluminium wires cannot be soldered reliably, even if in theory there would be space for this option. But if soldering isn't the solution, how do you get these wire connections reattached to a contact point?
Ultrasonic wire bonding
An ECU with a modern ceramic printed circuit board.
becomes a lot more difficult. Because the overall design can be made smaller and more complex, it also becomes necessary to use smaller components. Fortunately, heat dissipation is not a huge problem due to the use of the ceramic material, even if these components are embedded. However, as soon as these delicate electronics fail, repair is not that easy. The components are difficult, if not impossible, to reach and they’ll damage quickly. In addition, the joints are often so small that they cannot be repaired without a microscope and some highly advanced equipment. It’s not impossible, but you must keep asking yourself in each individual case whether this is still economically justifiable.
Joint by wire Speaking of joints, due to the compact and complex design of a ceramic PCB, solder joints aren’t the obvious choice. Manufacturers often resort to wire connections, which can be microscopic. For example, the wire connections that run from the PCB to the ECU connectors are clearly visible, but the hundreds of gold wires connecting the square purple component in the centre of the PCB are only 50 microns thick and therefore almost invisible to the naked eye.
A possible solution is to opt for ultrasonic wire bonding, as ACtronics have also done. As the name suggests, ultrasonic vibrations are used (frequency: 60 kHz) to make two metals (in this case the contact surface and the bonding wire) flow into each other. We won't go into too much detail, but we can tell you that this way of bonding takes place quickly, accurately and without the addition of heat. The technique is therefore particularly suitable for use around delicate components. In addition, the new joint is particularly strong: the result is comparable to a welded joint.
In short… The shift to ceramic material has really benefited the ECU, as the older green circuit board has its drawbacks. Components appear to last longer due to better heat dissipation; solid connections suffer less from distortion and vibration and the design can be made much smaller, lighter and more complex. However, there is also a downside: wire connections. The ECU itself is by no means always to blame for the failure of these connections, but we cannot deny that this is clearly a weak spot. Fortunately, there are also companies such as ACtronics that have thoroughly studied this problem and can therefore provide a qualitative solution. www.actronics.co.uk
Note: These small gold wires are an excellent example to explain why you should never touch components with your fingers: The probability of pressing these gold wires together and thus cause a short circuit is very high.
Unlike the components themselves, the wire connections on a ceramic printed circuit board are often easily repairable. That is,
At ACtronics, a company that focuses on remanufacturing of electronic automotive components, they also use local heating to replace components. The machine has been programmed entirely in-house, creating a fast and precise solution for replacing BGAs. Programming this equipment does require a lot of specific knowledge and the equipment is very expensive. It is therefore not expected that other companies will follow quickly in these developments.
AUTOTECH
Let's be honest: These wire connections are clearly the weak spot of modern ECUs. They cannot withstand the continuous vibrations and temperature fluctuations for several years, circumstances that are common under the bonnet. This is mainly why a layer of silicone gel is applied, which should protect against this. However, this silicone gel does not prevent us from regularly encountering ECUs with faulty wire connections. And in our opinion, the chosen position of the ECU is also partly to blame. For example, on top of an intake manifold is not the most tactical position for a sensitive piece of technology such as an ECU. Yet some cars actually have the ECU placed right there!
35
A future-proof diagnostic solution for today’s workshop As vehicles become increasingly harder to access, investing in the right diagnostic solution has never been so important for independents. Hayley Pells, Director of Avia Autos, discusses why the award-winning business has chosen the Delphi Technologies DS180 BlueTech tool to help secure its future. With roots in race car preparation, 16 years’ experience of servicing all makes and models, plus in-house MOT, tyre replacement and full alignment facilities, Avia Autos can comfortably meet the maintenance requirements of a whole host of motorists.
AUTOTECH
However, rather than rely on its award-winning expertise and enviable reputation alone, the Bridgend-based independent recognises that while its past experience has allowed it to become firmly established, it is only by looking to the future that the family-run business can continue to prosper in a rapidly-evolving aftermarket.
36
“We’re a second-generation business and although my father spent decades building and working on single seaters and sports cars after originally starting out as a normal garage in the 1970s, we’ve come full circle to be a very traditional independent repairer,” said Hayley Pells, Director of Avia Autos. “Compared to the race cars my father worked on in the 1970s, the majority of what we do today is more routine, but there’s no doubt that the cars we are seeing are becoming more complex. Future-proofing the business is something of utmost importance to us, so embracing the technology and training
that will allow us to cater for the latest and most advanced vehicles is something we are always keen to explore.” To help ready itself for servicing a future vehicle parc that encompasses myriad powertrain options, and which is proving increasingly hard for the independent to access, Avia Autos has turned to Delphi Technologies for both training and equipment solutions. Pells completed the popular EV & Hybrid Level 3 IMI qualification via Delphi Technologies. Her father Andy and technician, Connor, also have the same qualification, meaning that the entire Avia Autos workshop can work on electrified vehicles. Connor is also studying for Master Technician status via the Delphi Technologies Academy e-learning platform, while, notably, the garage is an early adopter of Delphi Technologies’ next generation diagnostic tool, the DS180 BlueTech. Introduced in late 2021, the BlueTech tool is five times more powerful than its predecessor, delivers faster vehicle scan times than ever before, and boasts new integrations such as CAN FD, multiple CAN channels, and DoIP (Diagnostics over Internet Protocol) that offer garages cost-effective and intuitive access to the latest troubleshooting methods. The specification also includes Pass-Thru capability, which opens the door to services such as ECU programming that were previously the preserve of franchised dealers and their OE-specific tools, as well as the support and calibration of most modern ADAS features. Ease-of-use is also a key attribute of the BlueTech tool. For example, with the built-in Flight Recorder
mechanics can record a range of parameters during a solo road test, ready for review and analysis once safely back in the workshop. “We were certainly familiar with Delphi Technologies as we’ve fitted its products for 16 years, and I’d say the majority of what we install is made by the brand, mainly because of the coverage,” added Pells, who is also Council, Head of Garage section for the IAAF and a Technical Consultant to the IMI. “This was our first time with a diagnostic provision from the brand though, so it was a very new experience moving over to a Delphi Technologies system. “I was aware that the BlueTech tool existed on the market and had seen it utilised during the delivery of the Level 3 EV course, but it wasn’t until last year’s AutoInform event in Wolverhampton that I was able to gain a greater understanding of its capability. I was also presenting at the time, but my husband attended the Delphi Technologies briefing and simply said I needed it. That said, it’s a big investment and we won’t upgrade equipment unless we need to, so it had to fit our requirements.” Pells continued: “It was the first to be supplied by my local motor factor and it arrived just before Christmas, so we spent the shutdown period learning the system and loading it onto our PCs. Admittedly, we had a few teething issues, mostly due to diving straight in and not seeking assistance, and the transition from the tablet-based solutions that we were used to was a little strange at first, but it’s been a big catalyst in driving a cultural change in how we now approach vehicles when they enter the workshop. Previously, we’d just plug a tool in if there was a service light on the dashboard or we needed to take out a service light, but now a vehicle is immediately scanned before we do anything else. “We’ve reorganised the workshop to suit how important it is to us, with our first bay now serving as our dedicated diagnostic and service ramp. The BlueTech tool sits on its own computer at the front of the ramp and links up to a huge screen, so we can sit in the car and see what’s going on. We’ve put our PicoScope on the same computer and, noticeably, we’re using the tool’s guided diagnostics more and more. “Beforehand, if we were carrying out diagnostics we’d have to go to the storage cupboard, unlock it and take out the equipment. Now, the Delphi Technologies unit is as integrated
into the workshop as the ramp is. It’s helped us to go down the route that bigger independent garages and main dealers commonly adopt, where an area of the workshop is dedicated to a certain task. “At the moment, it’s serving primarily as a diagnostics tool and we’re building our familiarity first before we start to explore its full capabilities. Once we increase our understanding of it, we’ll start onboarding all the other functions, with ADAS recalibration likely to be first. We viewed it as a stepping stone to our ADAS investment and we plan to purchase the modular ADAS equipment from Delphi Technologies. That's why we went for this kit, as we wanted a special piece of equipment that would cover everything we wanted to do in the future. It’s this that really sets the BlueTech apart and I can’t think of anything else that currently matches it.” Once Pells and the Avia Autos team have mastered ADAS, the Security Gateway and Pass-Thru functions are likely to be the next that the garage will explore. “Connectivity is a real concern for the aftermarket. It does feel that independents are being walled out by the manufacturers and this is going to be one of the tools that makes vehicles still accessible to standalone garages,” added Pells. “The need to use dealer diagnostics software to access vehicles is becoming increasingly commonplace, but it’s something that’s easier to negotiate than many think, plus you’d be surprised how affordable the information can be. Paying for it may seem alien at first, but with the advent of consumer streaming services like Netflix, we’re now far more used to the idea of subscription-based access.
AUTOTECH
“Having the ability to now perform software updates is something we’re very excited about, and it’s having the relevant tools to perform these kind of tasks that will keep independents in business. Everything in the workshop of the future is going to be much more entwined, from parts stock to technical data to predicted labour costs to diagnostics, and with the BlueTech tool we have an integrated product that will grow with the business. That’s what I’m really looking forward to from Delphi Technologies and the tool, the integrated experience.” www.delphiautoparts.com/gbr/en/product/bluetechvci-diagnostics
37
Loss of communication febi investigates some electrical gremlins affecting a Skoda Yeti within its workshop
Diagnosing electrical faults can be challenging, but with the right tools, information, and knowledge, a fault can be tracked down and repaired. All vehicles have many built-in management systems which monitor and act on the information to make the vehicle safe, economic, and comfortable including many features which we think of as standard. The featured vehicle is the popular Škoda Yeti. The owner reported having issues with the right-hand rear door not locking and the electric window not working. After carrying out the initial check of all the door functions, it was confirmed that the central locking or door window controls were not operating in the right-hand rear door. Once the fault was established, information was checked to see how the central electric system worked. Each door has a control unit fitted which regulates the functions within the door. These control units are linked to each other from rear door to front door. These are then connected to the vehicle’s central electrics control unit. First, it was necessary to check if there were any fault codes logged. As suspected, a fault was recorded for the door control module: “right, rear, no signal/communication”. This confirms that the control module was not functioning correctly, but why?
Figure 1
units. After removing the right-hand front door trim panel and checking the wiring, the fault was found to be a broken wire between the ‘A’ pillar and the door. All wiring looms that connect between the vehicle’s body to the doors – or any other hinged point – are subject to a lot of movement, bending, and stretching to the point where the insulation cracks, therefore exposing the copper wire. This can lead to an open or a short circuit in the system. (Fig 1) With the fault identified, the option was to either repair or replace the wiring loom. A febi wiring repair kit was chosen, which comes supplied with a new multi-plug, connectors, and enough new silicone insulated wire to cover vehicles
Was this a case of a faulty control unit? It is very easy to replace a part based on a fault code description. However, it makes logical sense to confirm all findings before ordering any parts.
AUTOTECH
After the right rear door trim panel was removed, the 20-pin connector was identified at the control unit. This required testing before condemning the control unit. Terminals 18 & 19 are the power supply and terminal 30 is ground. These were checked and load tested and found to be in good working condition.
38
However, testing the Local Interconnect Network (LIN) bus communication between the front door control unit and the rear at terminal 10 with an oscilloscope revealed that there was no signal. LIN is a low-speed, single-wire serial data bus used to control low-speed, non-safety-critical functions on a vehicle, especially windows, mirrors, door locks, etc. In this case, there was a loss of communication between the rear door and the front control
Figure 2
fitted with all options. The silicone insulation is more resistant against thermal stress and stays flexible at any temperature. This flexibility helps to prevent cable breaks in the future. The wires are tinned and are extra fine, making them more flexible and prevents corrosion for a reliable repair. (Fig 2)
Figure 3
Each wire was cut to size and the insulation stripped. Then, the joining connector was crimped into position, attaching the original loom to the new wire. After crimping, the crimp connector must be shrunk with a hot-air blower in order to prevent moisture from penetrating. Note: During each repair, ensure that the crimp connectors are not positioned immediately next to each other if there are multiple wires to be repaired. Arrange the crimp connectors slightly offset to ensure that the wiring loom does not become too big. When repairing CAN bus lines, they must have the same length when undertaking the repair and no cable piece should be longer than 50 mm without twisting the cables. After successfully joining all the wires and allocating them to the correct positions within the multi-plug, fabric insulation tape (107140) was applied to hold the loom together before being refitted to the vehicle. (Fig 3) With the repaired loom fitted, the integrity of the LIN communication was checked for a good quality signal (Fig 4) followed by the clearing of all fault codes and testing of the door functionality. All of the vehicle’s interior trim was refitted and the vehicle was ready to be handed back to the owner. Making this an economic repair, as there was just one part of the cable broken, there was no need to replace the complete wiring harness. Figure 4
febi Wiring Harness Repair Kits: The PLUS in Range febi Wiring Harness Repair Kits not only save time and money, they eliminate the need to replace the complete wiring harness when one part of the cable is broken. With over 115 references, febi has kits available for doors, rear doors, tailgate lamps and headlamps. One solution for one model covering all model variants.
Why febi? Economic Repair Solution • Save time • Cost effective
High Quality • I nsulation made of silicone, OE are normally made of PVC - Silicone is more resistant against thermal stress and stays flexible at any temperature. The flexibility helps to prevent cable breaks. •B raids of the wires are tinned* and the wires are extra fine-wired - Makes wires more flexible - Prevents corrosion on the braids due to contact with moisture
Rely on tested OE matching quality spare parts from febi. The entire range of wiring repair kits can be found at: partsfinder.bilsteingroup.com. The febi brand is part of the Bilstein group, the umbrella organisation for several other strong brands. Further information is available at: www.bilsteingroup.com.
All required components for the repair are included in the kit. You can find the complete overview of febi components at: partsfinder.bilsteingroup.com
AUTOTECH
*Tinned is a thin coating of the exposed end of the wire to prevent corrosion and can last 10 times longer than nontinned versions
39
JLM Lubricants founder Gilbert Groot, marketing expert Dee Blick, DPF Doctor Darren Darling and Mike Schlup MD of UK JLM distributor Kalimex
DPF Doctor Network Special A Day with the Doctors
AUTOTECH
A few weeks ago, an all-day event was hosted by Darren Darling, founder of The DPF Doctor Network, at DPF Doctor Network HQ in Ashington, Newcastle. Behind the event was Kalimex, the UK distributors of the JLM Lubricants’ product range. Gilbert Groot, founder of JLM Lubricants flew in for the day. Speakers included Gilbert, Mike Schlup (MD of Kalimex), Dee Blick, Barry Lawson (DPF Doctor), and Darren himself. 55 DPF Doctors turned up to share their experiences and learn more about marketing, sales and JLM Lubricants products.
40
Speaking of the day, Mike said: “Our goal was to meet as many DPF Doctors as possible and to highlight the products that have made JLM a trade trusted brand globally. It was great to have Dee sharing her marketing expertise given she is a global, bestselling marketing author with decades of experience helping small businesses to grow through effective shoestring marketing. Having Gilbert join us was a real bonus. He spoke about the JLM brand and why despite the company trading in 45 countries, he will never lose the close family feel JLM is renowned for. This was the first time many doctors had met Gilbert, so they were quick to ask questions. Barry Lawson,
a name readers of autotechnician will recognise as a longstanding contributor, talked about how he is building his business using the power of the DPF Doctor blueprint and by embracing new challenges and opportunities. It was a brilliant day, and we plan to return next year if Darren will have us!”
“Darren, thank you for organising a fantastic event at The DPF Doctor HQ. It was really nice to meet all the Doctors, to share ideas and knowledge and to experience some fantastic speakers including Dee Blick whose speech was mind blowing, Gilbert Groot and Barry Lawson. It was an excellent day for invested automotive technicians.” Adam Nowak, DPF Doctor (and the person behind the camera for the day)
Darren Darling’s Top of the Class DPF Training This event was held at Darren’s HQ where he delivers unique online and interactive DPF training to technicians in 40+ countries. In this special interview, we discover how Darren’s DPF training is revolutionising how training is delivered and why it is so powerful and popular.
How does the training portal work? Our world class training portal is a fantastic resource for any workshop committed to growing through focussed learning. We have three main sections, ‘Live Training’ where we broadcast in full HD from our training academy so delegates can ask questions and have them answered live; ‘Training Reruns’ where we upload every training session so it can be viewed 24/7. This enables members to catch up on training and keep up to date at their own convenience. There are currently 80 2-hour training sessions. And finally, a ‘Video Guides’ section – a searchable series with 100+ short training videos offering ‘just in time’ training for when you have a job in your workshop. Members have unlimited access to our training portal - 24 hours a day, 365 days a year. They can attend as many live training sessions as often as they like so no pressure to learn everything to perfection first time around. It’s the ultimate ‘all you can eat, super healthy buffet’ for DPF training!
How do you keep your training fresh and relevant? It’s based on real-world experience - real faults, real fixes in our own workshop. So, when we see new faults, we create new training content. The beauty of live sessions is the flow of new questions from attendees which keeps things doubly interesting! Having the content online enables us to add new content to the Video Guides section. If we cover a ‘fix’ in training, you can be sure it’s been proven in our workshop.
How is the training structured? Initial training is a 12-part course delivered over 3 weeks; four two-hour sessions per week. It’s the ultimate bite sized learning for easy integration in the working day. The live sessions start at 9am UK time. We encourage workshops to attend refresher training at least once every six months so they can remain up to date with everything DPF related and at the top of their game. Our Video Guides section helps in this. All the resources we offer ensure that workshops continue to work in an efficient, lean and customer focused way with their first-time fix rate a glowing testament to this.
What does all this cost? The subscription which is a business investment is incredible value for money. Just £1,500 a year which should be covered by approximately 7 DPF cleans/repairs. It’s worth pointing out this fee covers the whole team, including the front of house staff. I will repeat this! One flat rate of £1,500 means that every single person in the business, all the technicians and other team members, can attend our training as many times as they like in a year. Within weeks, sometimes days, the cost is more than recouped with the business forging ahead as a DPF specialist with a superb first-time fix rate. We usually find that the technicians attend all the live training sessions and the front of house choose the ones that enhance their understanding of DPFs. I will stick my neck out and say there is no other provider delivering DPF training to this standard, at this value with such an incredible return on investment.
Your training is popular with technicians in countries including Australia and America… We address the issues that workshops face globally. We also teach technicians a robust process that can be applied to ANY vehicle, so regional differences in vehicles are not an issue. The huge win/win is that this industry leading training is accessible from the comfort of your own workshop or home without the need to travel and with no hotel bills to bump up the cost!
Tell us about your recent trip to Australia where you spoke at the AAAA show… Being invited as a keynote speaker by the organisers of the AAAA Expo, the largest Automotive trade event in the southern hemisphere was a real privilege. There was a buzz around the room and many delegates stayed on afterwards so they could pick my brains and find out more about our DPF training. After experiencing jet lag from a 36-hour delay I was fuelled by coffee and adrenalin and the fact that many of the audience had travelled some distance to meet me. The conversations we had were similar to those at European and USA events. Technicians realise they need DPF training so when I tell them about the content on our training portal and provide a sneak preview to show them what they can access it usually leads to a sign up. The feedback from our international members has been fantastic with our first annual subscribers already signing up for an additional 12 months as they have benefitted so much from the first year of training. World class training, available anytime, anywhere! Contact Darren on www.the-dpf-doctor.com to find out more about DPF training. For more on JLM Lubricants, please visit www.jlmlubricants.co.uk.
AUTOTECH 41
Check Your Customer’s Car Battery To Ensure Fuel-Saving Measures On-Board Their Vehicle Operate Correctly As fuel prices continue to rise and the costof-living crisis takes full effect, drivers will be looking for measures to reduce outgoings and make their vehicles run as efficiently as possible.
AUTOTECH
Saving fuel was, and continues to be, an important aspect of driving – not only in terms of environmental protection, but also as a benefit in limiting expenditure. Technology helps provide support in the form of the Start-Stop system, which has been long-established standard equipment in modern cars; nearly all cars with an internal combustion engine produced today have a Start-Stop system on-board, over 98% in fact.
42
A brief history of Start-Stop Today, saving fuel is considered sensible not only for financial but also for ecological reasons. But when the idea of the automatic Start-Stop system was born, it was rather the oil price crisis of the time that provided the need for fuel saving measures. Toyota invented the first automatic Start-Stop system in the mid-1970s.
Volkswagen and Audi introduced their versions of the StartStop system in the 1980s. Together with a 5-speed gearbox, aerodynamic bodywork, and electronic fuel consumption indicator, these improvements were intended to significantly reduce fuel consumption. A new generation of Start-Stop systems followed in the 2000s. This sophisticated and robust technology marked the beginning of the Start-Stop success story.
Depending on the style of driving, Start-Stop technology can achieve fuel savings of up to 15%. However, the effectiveness of the system depends on many factors, including the area of use. During urban use, the automatic Start-Stop system causes the engine to switch off at standstill. Naturally, it is less effective on long motorway journeys.
High demands on the battery The reliable supply of electrical consumers while the engine is switched off, is very demanding. That is why an advanced lead acid battery is the heart of every well-functioning Start-Stop system. The only battery technologies which can withstand the challenges of automatic Start-Stop systems are AGM and EFB (find out more here https://batteryworld.varta-automotive. com/en-gb/efb-or-agm-which-battery-do-i-need).
EFB batteries – for entry level Start-Stop systems EFB batteries (EFB stands for “Enhanced Flooded Battery”) are suitable for the power supply of cars with entry-level automatic Start-Stop systems. The design of EFB batteries is a further development of conventional lead acid batteries. Several enhancements on component level help to extend the life of the battery. EFB batteries' low internal resistance guarantee a strong cycle durability and improve the stability in challenging applications such as Start-Stop – they can withstand two times more charging cycles* compared to conventional starter batteries. * Test standard EN 50342-1 and for EFB and AGM, additionally EN 50342-6
AGM batteries – for advanced Start-Stop systems When it comes to vehicles with automatic Start-Stop systems with braking energy recovery (recuperation), or cars with premium equipment and sophisticated accessories, AGM batteries (AGM stands for “Absorbent Glass Mat”) offer a higher capability to withstand these high-power demands compared to regular starter batteries.
Checking your customer’s start-stop is working? If you service a car with an automatic Start-Stop System, there are a few things you need to be aware of. When replacing the
If an AGM battery is already installed in the vehicle, it must always be replaced with another AGM battery. An upgrade from an EFB to an AGM battery is possible though and can increase the efficiency of the automatic Start-Stop system resulting in more efficient fuel consumption. VARTA highly recommend not to downgrade the battery or try to fit a traditional flooded battery to a vehicle with Start-Stop; they simply were not designed to deal with the recurring stop and then start again type journeys. On the other hand, an ageing battery is susceptible to reduce the number of Start-Stop events taking place. Therefore, it is recommended to check the battery on a regular basis as part of the service and replace before it fails to ensure maximum fuel efficiency. So, to guarantee your customer’s vehicle gets the most out of its fuel saving measures, VARTA encourage technicians to test every car’s battery entering the workshop, and if in a weak state, suggesting to the customer it is replaced, using the fuel saving benefits as rationale. To ensure you keep your customers satisfied, recommend VARTA the battery brand trusted by the trade, the world’s leading original equipment battery. To find out more, visit the VARTA team during Autotech’s Big Weekend in September, or contact varta-support@clarios.com.
AUTOTECH
AGM batteries have excellent cold-start characteristics. They enable a powerful engine start which supports a reduced operation time of the starter. Thanks to their good recharge capability and high power in lower states of charge, a warm engine can be switched off and started again several times at short intervals, without the risk of difficulties when restarting. Regarding their service life, AGM batteries also have significant advantages over traditional starter batteries. They can withstand three times more charging cycles* than conventional starter batteries. Because the electrolyte in an AGM battery is bound in an absorbent glass fleece, it makes them resilient to hard conditions, leak-proof and maintenancefree.
car’s battery, the new battery must be able to be recognized by the battery sensor (IBS) of the Start-Stop system, so that the vehicle can track the battery status accurately, therefore programming/registering of the new battery is necessary. This allows the vehicle’s energy management to closely monitor the battery parameters in order to leverage the highest fuel savings. If an incorrect battery is installed in the vehicle or it is not correctly registered, this can result in some on-board functionality (e.g. electric windows) ceasing to work or even premature battery deterioration and another breakdown.
43
AUTOTECH
ZF [pro]Tech offering takes centre stage at UK Garage and Bodyshop Event
44
ZF Aftermarket illustrated how the company delivers cutting-edge technical support, information and training to the independent aftermarket through its ZF [pro]Tech garage workshop at the June event, in order to service and maintain the vehicles of today and tomorrow.
training, the business made a decision long ago that this initiative would be about people, not profit.
ZF [pro]Tech delivers independent workshops two industry programmes, Plus & Start, providing a comprehensive, personalised technical support and information hub for the independent garage network.
New technologies mean that new skills are needed. Those who master the high degree of system networking and the different functions of mild hybrid, hybrid and electric vehicles can play a leading role in the business of the future.
Membership includes access to ZF's technical knowledge, discounted training courses and free access to OEM service campaign information across all systems, not just ZF. This operates via an online portal and technical helpline.
Since voltage peaks of up to 1,000 volts occur in electric drives, it is extremely important to know how to adeptly handle high voltage systems. To meet these requirements, we offer fundamental vocational education and training in the field of Electromobility, offering the qualification of High Voltage Expert.
A one-off affordable payment offers garages membership to this. The online personalised information hub allows access to ZF's technical knowledge, together with all-makes, all systems OEM service campaign information, traditionally available only through main dealers at considerable cost. The ZF [pro]Tech concept was born of a genuine desire to support the independent aftermarket in an age of advancing and changing mobility. A firm believer in the importance of futureproofing the aftermarket through knowledge and
The road to electrification From low voltage technologies and hybrid systems to purely electric drives, ZF are developing pioneering innovations and offer a broad portfolio for electric mobility.
Become the expert e-mobility contact with ZF Technical Training You will learn everything you need to know about integrated, (partially) electrified drive concepts, such as hybrid and fuel cells, as well as their high capacity for system integration; the practical training is in-depth and easy-to-understand. The
seminar, which is based on the blended learning principle, offers maximum effectiveness and flexibility to all participants. “Blended learning” refers to the ideal combination of e-learning and classroom sessions. The advantages for you: • E-learning gives you complete flexibility when it comes to time management: individual modules ranging from 25 to 50 minutes can be selected according to your level of knowledge • Identical training content that saves as much time as possible: 40 percent faster than conventional training • Perfect transfer of theory into practice: The practical section
Darren Lloyd, Network, Technical and Training Manager “In my new role as Network, Technical and Training Manager UK, one of my core focuses will be to highlight the importance of training at garage level. Embracing training is key if the automotive aftermarket is to continue to be able to repair, service and maintain vehicles that feature the very latest technology. This technology is evolving at a rapid pace, which is creating a clear skills gap within the industry. ZF [pro]Tech is aimed at equipping vehicle technicians with the support, technical knowhow and necessary expertise to upskill and work on a diverse vehicle parc to ensure they can provide customers with quality solutions.
“I’d highly recommend the ZF course,” says Dale Terry, Sales Director at HGV Direct. “It was a valuable learning experience. The knowledge of components within a HV vehicle, along with understanding the function and potential problems as systems age will prove invaluable to our business in the future. I feel confident now offering advice to our customer base on this technology, and I’m glad to be involved at this early stage for our industry.” For more information, or to book a place onto one of the ZF High Voltage Expert training courses, email: protech. zf-aftermarket.uk@zf.com.
while considering professional association standards. “It’s an exciting time to be a forwarding-thinking and enthusiastic vehicle technician, as there are plenty of opportunities to thrive.” Louise Tobin, Field Technical Sales Engineer “I have been in the automotive industry for more than 10 years, gaining experience in both the aftermarket and manufacturing. Since recently joining ZF, I have now become IMI-level trained on electric vehicles and I’m looking forward to engaging more directly with ZF’s network of experienced vehicle technicians and sharing the technical information and knowledge that I’ve acquired over the years.” William Orridge, Product Support Technician “ZF [pro]Tech has a reputation for quality and professionalism and I’m excited to be part of a growing technical team that works closely with experienced technicians to ensure they have the support and tools necessary to futureproof their businesses and work on an ever-changing and developing vehicle parc.”
AUTOTECH
“Electric vehicles and hybrids are no longer the future; they’re very much the present, as we’re already seeing this type of technology in the aftermarket. The thirst for knowledge was evident at the recent UK Garage and Bodyshop Event, as one of the most popular questions asked was about EV and hybrid training. ZF [pro]Tech has an extensive programme on this topic, including our High Voltage Expert qualification, which covers the complete range of topics needed for the technology of the future,
demonstrates how to use the necessary special tools, shows you how to optimally organize your repair shop and how to work with electrical equipment.
45
Free access to comprehensive resource auto:resource is a digital platform for the UK automotive aftermarket, created by Automechanika UK, organisers of the recent UK Garage & Bodyshop Event in Birmingham* Turn to page 64 for details of last month’s event
Automechanika UK returns to NEC in 2023! Its aim is to help inform people from all areas of the aftermarket, whilst connecting them to suppliers online. The hub’s resources cover product, training, promotions, business advice and insights, plus industry news. You can become a member to access exclusive content, training, promotions and more. With a free user account, you can browse and search for free training videos, articles, tutorials and how-to guides from leading suppliers and experts.
AUTOTECH 2022
Find out more at www.autoresource.co.uk.
46
Automechanika UK, the UK’s largest gathering for the automotive industry, will once again open its doors at the NEC Birmingham 6-8 June 2023. Technicians and workshop owners can expect direct access to hundreds of the leading equipment, parts, software and training suppliers over the three-day event, which has experienced a hiatus in recent years due to the pandemic. Keep up to date with news of the event on www. autoresource.co.uk.