Magazine - Car Mechanics - 03.2018

10 pages of your car problems solved by our experts
Cambelt
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Editorial Martyn Knowles, Editor
Email: [email protected]
Follow us on Facebook @ Car Mechanics
MOT no change
X Hooray! The Department of Transport 10 years, which was then reduced in
Gumtree and
eBay join forces
X Online car dealers can now reach
two big audiences with one advert
(DfT) has decided NOT to extend the 1967 to three years. Although the build
following a decision to merge
first MOT of cars and motorcycles to quality of modern vehicles has vastly
Gumtree’s motoring division with
four years due to safety concerns. improved since the 1960s, parts still
eBay. It also means punters will be
After a consultation period, the DfT wear out: tyre rubber slowly erodes or
able to choose from more vehicles
has listened to members of the public, suffers damage (sometimes unseen),
on one viewing platform.
motoring bodies and those working in suspension bits break or fall off,
According to the parent company,
the industry and decided that moving brakes leak fluid or wear down below
eBay Classifieds Group, Gumtree
the first MOT to four years, from three, recommended limits, etc. The majority
is currently the fastest-growing
is not a good idea. I agree that keeping of motorists never check over their
classifieds marketplace for selling
it at three years is the right decision vehicles regularly, so someone should
vehicles in the UK. Apparently, six
– moving it to four years would be be doing it annually, at least.
million users per month visit the
detrimental to road safety. Cars today rack up huge mileages in
motoring division on Gumtree, while
The MOT test is conducted to confirm a year and need to be tested at three
3.7 million users per month search
the roadworthiness of a vehicle, as well years. Take the 2015 Skoda Rapid 1.6
on eBay for a new vehicle.
as highlighting potential dangers in the TDI being sold on eBay recently. It had
Three packages with add-ons for
future through the advisory system. done 409,000 miles in less than three
all budgets will be offered to dealers
It was introduced in 1960, requiring years, but still wasn’t old enough to be
to list their stock.
all new vehicles to be checked after presented for its first MOT!
What marketplace works best for

you? Have you had success selling
After a consultation period,
or buying via eBay or Gumtree? Has
the Department for Transport
has decided to keep the first the experience been good or bad?
MOT at three years. We’d like to hear from you.
CM 60th at the NEC

X If you’d like to visit us at the NEC Birmingham
during the days of March 23-25 to celebrate the
magazine reaching 60, we’d be happy to see you.
You will find us as you go through the entrance to
Hall 4 – turn left and we are the first stand on the wall
line. Unfortunately, we won’t have room on the stand
to display any cars – we did have plans to do live
diagnostics demos – but we will be running exclusive
competitions and other activities during the show.
Myself and many of the familiar names from these
pages will be in attendance during the three days, so
you’ll be able to chat with us about your motoring
experiences. Dave Taylor has further details about
the show and ticket bookings on page 18, plus there’s
a chance to win a pair of entry tickets!
The April 2018 issue of CM will mark our 60th
anniversary and copies of the bumper-sized edition
will be available to buy at the NEC.
www.greatmagazines.co.uk/carmechanics March 2018 pCar Mechanics 3

Contents
56 Timing Belt Clinic:
FEATURES 90 Renault Clio 1.2 16v
6 Automatic gearboxes 64 DIY Servicing:
Troubleshooting and fixing
autobox problems. Jaguar XF 2.2D
61 Whatever happened 70 Help!

to the Reasonably
Priced Cars? One keen member 78 Diagnostics Doctor
The Suzuki Lianas from Top Gear. of the CM Brits
on Tour event is
seen rummaging
80 Electronic Diagnostics:
90 Brits on Tour amongst discarded Ford Focus 1.8 petrol
cigarette butts With Visteon System 7 type
CM’s latest road trip. trying to find an oil
leak on our BMW...
ESU 121 management system.
PROJECTS WORKSHOP REGULARS

30 Vauxhall Insignia 18 CM Insider
Part two: Swapping over the 22 Tales from
2.0 CDTi turbocharger. the Workshop
Unusual tips and fixes. 46 Your Letters
BUYING 38 BMW N-Series 48 Dealer’s Diary

Just how bad are the
50 Nissan Qashqai four-cylinder petrol engines? 86 Our Cars
Advice on buying the best. Rob Hawkins’ Audi A3 and
42 SRS trouble on Steve Hole’s RPS RPX.
54 Toyota Aygo the MGF & TF
Sourcing new and used parts. Fixing the seatbelts and airbags. 98 Ted Connolly
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4 Car Mechanics pMarch 2018 www.greatmagazines.co.uk/carmechanics

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Instant expert
Demystifying
AUTOMATIC
GEARBOXES
With automatic
gearboxes packing an
increasing number
of ratios, they can go
wrong with expensive
consequences. Rob
Marshall investigates
their inner secrets
and how their lives
can be prolonged.
B
efore US decadence is blamed
for the ‘lazy-man’ automatic
transmission, consider that
changing gear was not as easy
on 1930s manual cars compared to
those of today. While those early, bulky Automatic transmissions ware developed to has accelerated automatic transmission
be more responsive and efficient. Pictured is
automatic transmissions worked fine an eight-speed, rear-drive unit made by ZF.
development, with makers of the
with big American V8s being driven latest types boasting that they have
on wide open highways, they did not the outer ring gear of the appropriate caught-up in the efficiency stakes. As
translate well initially, when fitted to epicyclic gear set within the gearbox. automated manual gearboxes face their
sub-2.0-litre European four-cylinder The arrival of sophisticated own problems, chief among which
engines that had to make swift electronics, especially the self-learning are relatively poor reliability and high
overtakes on busy two-way roads. This ECUs that were pioneered by Japanese costs, it is believed that the traditional
explains the initial scepticism with manufacturers from the 1980s, made the torque converter clutch, coupled to an
which the ‘slushbox’ was met by British transmissions more responsive. Most electronically-controlled, epicyclic-geared
motorists, many of whom felt that they subsequent developments have focused transmission, on which this feature
not only robbed the driver of control, on making the unit lighter, less wasteful, focuses, will increase in popularity.
but were also uneconomical and sapped cheaper to produce and more compact,
power from the engine. especially for front-wheel drive vehicles.
In the late 1990s, when carbon dioxide
emissions and fuel economy figures were
Gaining acceptance chosen as the means by which car owners
Early automatic gearboxes were so bad and manufacturers could be taxed/
at deciding the appropriate moment for penalised, automatic gearboxes were
ratio shifts that some initial European still relatively inefficient, compared to
applications left the task of changing gear manuals. The arrival of single- and
to the driver. On certain types, such as twin-clutch automated manual gearboxes
the Wilson pre-selector, one could select
X Engine coolant can contaminate the gearbox
the next gear with a small hand lever fluid, causing it to congeal. This may be due
and the ratio change would be made by to either impact damage, or corrosion of the
depressing a foot pedal, which released water/oil heat exchanger (as pictured), caused
a brake band that was wrapped around by infrequent antifreeze changes.
6 Car Mechanics p March 2018 www.greatmagazines.co.uk/carmechanics

Demystifying AUTOMATIC GEARBOXES
PREVENTIVE MAINTENANCE
X Unlike many popular automatic transmissions of the 1950-1980s, on modern
systems, there is no need to adjust kickdown cables, or clean mechanical governors
(which prevent engine overspeeding) and to set brake bands periodically.
However, modern automatics rely still on the correct quantity of specific fluids
to maintain reliability. Always follow level check advice carefully, because it is
easy to make mistakes. Take extra care to ensure that you pour new fluid through
the correct aperture and do not dismantle part of the gearbox unintentionally, by
undoing an external bolt instead of a plug.
The oil should be clean. Dark-coloured fluid indicates a major internal problem,
due possibly to overheating, or deterioration of the clutch friction plates. While
many transmissions are described by the car manufacturers as being sealed for
life, it is accepted that periodic fluid changes are beneficial on an older vehicle.
Pay attention on a road-test, too. Any jerks, clunks, harsh changes, or a
sudden engine speed rise between gear changes (known as ‘flaring’) will need
investigating. It is possible that such issues might not illuminate a warning lamp
on the instrument panel.
into the torque converter housing. The

Topic 1
that it strikes the impellor in the same
engine’s crankshaft rotates an impellor direction of rotation, thus providing an
and the turbine sits opposite it, which is additional turning force, and creates a
The torque converter connected to the gearbox input shaft. As torque multiplication effect. This is why
The torque converter is attached to the the transmission fluid is forced outwards automatics can accelerate away relatively
engine flywheel (also called a ‘flexiplate’ from the impellor into the turbine’s quickly from a standstill, compared to a
– which, ironically, can crack) and acts blades, it encourages the turbine to manual, until a specific (albeit relatively
as an automatic clutch, torque multiplier rotate and power the gearbox. low) road speed is reached. A one-way
and a fluid flywheel. Pictures of which However, the fluid needs to return to clutch – referred to as a sprag – is fitted
are shown on pages 16/17. the impellor. It does this by flowing from to the stator, to enable fluid flow to be
While this sounds complex, its operating the outer blades of the turbine, into the reversed. At higher turbine speeds, the
principles are fairly straightforward. It’s centre, and back towards the impellor. sprag allows the stator to turn slightly,
best explained by this analogy: if you place Unfortunately, because it is travelling to enhance efficiency by not restricting
two desk fans face-to-face and switch-on in the opposite direction, it threatens the fluid flow as much. In theory, just as
one of them, the powered fan blades will to restrict the impellor’s movement with modern turbocharger technology,
force air into the blades of the other fan, and so its flow has to be diverted. To it would be possible to create a variable
causing it to rotate as well, albeit not at the resolve this, a stator is sandwiched vane torque converter, but designers
same speed. In an automatic transmission, between the middle of the impellor and have preferred to add extra gears within
an oil pump forces transmission fluid the turbine. This redirects the fluid so the transmission instead.
Despite the increase in the numbers of automated manual gearboxes, the traditional automatic
has a bright future. Pictured is a seven-speed unit for a BMW Active Hybrid model, which boasts
three internal electric motors, although the epicyclic gear sets are still obvious.
1 Electric motor A (67kW/260Nm)

2 Electric motor B (63kW/280Nm)
3 Electric oil pump for transmission
pressure during 'E Drive'
4 Power split transmission with
3 planetary gear seats, 7 speeds.

ROB’S TOP TIP
Never reuse a torque
As with the desk fans analogy, natural converter that has
inefficiencies mean that the impellor originated from a failed
and turbines never rotate at the same automatic gearbox.
speed, unless under deceleration. To
improve fuel consumption at higher
cruising speeds, a lock-up clutch is fitted
that ensures a direct-drive between the
stator and impellor. Lock-up operation
tends to be operated hydraulically by a
piston inside the torque converter, but it
is controlled electronically.
The torque converter, therefore,
has three operations. Stall is when the
turbine is locked solid, which may be
caused by the driver having applied
the brakes with the car stationary and
in gear. During acceleration, there is
a significant difference between the
impellor and turbine speeds, so an
infinitely variable torque multiplication
takes place. Last, when cruising, the
difference in speeds between the The packaging constraints of
impellor and turbine tends to be less a transverse automatic have
than 10% and this phase sees the torque not halted progress. Eight
converter act more like a fluid coupling gears are crammed into this
– the inefficiencies of which are negated compact casing fitted to
certain front-wheel drive Kias.
when the lock-up clutch is operational.
AUTOMATIC vs AUTOMATED MANUAL

X This subtle distinction matters
not only to the technically-minded Hydraulically-
but also to the average car buyer. Twin wet clutches controlled
shift mechanism
Many salespersons are unaware
of the differences, which has
come back to bite them, when Oil pump Gear position
angry customers complain sensor
“there’s something wrong with
my transmission”, because the
driving experience is not what
they expected. The truth is that
the most customers believe there High-
are two transmissions: automatic pressure
and manual. This is not this case. oil filter
While traditional automatic Inner input shaft
transmissions, as discussed in (1st, 3rd, 5th &
this feature, have been around in reverse gears)
their basic form for many years, Mechatronic
automated manual gearboxes Outer input shaft unit
are not only different inside but (2nd, 4th & 6th gears)
present different characteristics.
They were introduced in the early
2000s, mainly as an inexpensive answer to the efficiency resulting Direktschaltgetriebe (DSG) becoming the first
shortcomings of the traditional automatic gearbox, mass-produced system in 2003. Effectively, these are two
allowing car-makers to maximise fuel efficiency and reduce manual gearboxes linked together by a pair of clutches.
laboratory-calculated carbon dioxide emissions. Compared to the cheaper single-clutch alternatives, twin-
Of the two basic types, single-clutch automated manual clutch units tend to have a greater public acceptance.
transmissions are manual gearboxes with the clutch pedal Other manufacturers have developed their own units, with
and manual gearlever functions replaced by electric servo the most common alternative to the DSG being Ford’s
motors and an ECU. Early versions of these units can be Powershift (pictured). For more information on twin-clutch
very jerky to drive, especially on take-off and between transmissions, consult the February 2016 issue.
gearchanges, and you need to modify your driving technique Continuously Variable Transmissions (CVT) are not
to make smooth progress. We took an extensive look into automated manuals but an entirely different type of
single-clutch automated manuals in our March 2017 issue. automatic gearbox that relies on internal belts rather
Twin-clutch automated manual gearboxes were co- than epicyclic gears. For this reason, they are not within Continued
on page
developed by BorgWarner and Volkswagen, with the the scope of this feature.
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ROB’S TOP TIP
Replacing the traditional dry
Unfortunately for home mechanics, carrier acts as the output and interacts clutch, the torque converter
the torque converter is a sealed unit with both the sun and ring gears as is a sealed unit that evolved
that requires special equipment to the inputs (see illustration below). from the earlier fluid
allow dismantling. Unlike the clutches Theoretically, any one of these three flywheel concept.
in a manual, or automated, manual gears can be locked, which allows the
vehicle, the torque converter will not others to handle the output. By having body, which receives commands from
be damaged by holding the car on a hill several interlinked epicyclic gear sets the transmission control module (TCM),
using just the throttle, although this and a set of brakes, or clutches, a gearbox based on feedback from the various
will increase the temperature of the can be designed with a number of sensors on the transmission and vehicle.
transmission fluid markedly. While it different ratios.
is immensely reliable, faults can still RING GEAR
occur, with any contamination in the
gearbox damaging the torque converter.
(or ANNULUS)
Topic 3
To avoid ‘infecting’ a replacement
transmission, never reuse the torque
PLANETARY
CARRIER Electrics
converter from a failed unit. The arrival of sophisticated electronics
helped to reduce production costs of
SUN GEAR
Topic 2
automatic transmissions, by doing away
with earlier hydro-mechanical controls.
PLANETARY
It also overcame some of the auto’s
The epicyclic gearbox GEARS x 3
drawbacks. Self-learning ‘fuzzy logic’
While the actual automatic gearbox unit The clutch consists of a series of systems could not only be programmed
is quite daunting, the principles upon friction plates, each of which bears against with a wide range of complex
which it operates are also fairly simple. metal plates (called ‘steels’) and this algorithms but could also adapt to
The heart of the unit is the epicyclic arrangement provides a large working different driving styles. CANbus wiring
gear set, which creates two inputs and surface area. The friction plates and their technology advanced things further,
one output. At least several of these steels are housed within a clutch drum permitting the transmission’s ECU to
gear sets are installed within a typical that contains a piston, activated by oil communicate with other computer
automatic transmission. Named after pressure, which squeezes the clutch pack modules to provide additional functions,
ancient astronomy theory, a so-called together, locking the relevant component such as downshifting under braking.
sun gear is mounted in the centre and and permitting it to turn. Older In some of the latest models, drivers
meshing with its outer teeth is, usually, a transmissions tended to use adjustable can select ‘sports’ and ‘winter’ settings
trio of planetary gears that are supported brake bands, which are wrapped around manually, the former encouraging
by a planetary carrier frame. The ring the ring gear, literally holding it in higher engine speeds, while the latter
gear (or annulus) sits on the outer edge position. In most cases, modern wet allows the car to start in second or third
and its internal teeth run on those of clutch plates have replaced them. The gear, to minimise the risk of wheelspin
the planetary gears. Thus, the planetary oil pressure is provided by the valve from a standing start.
GEARBOX ASSESSMENT
W While there is a limited
1 number of transmission
manufacturers, automatic
gearboxes are tailored for each
application. Autobox repair
specialist, ATP Industries Group,
categorises remanufacturable core
stock into the different types.
X As cleanliness is critical,
2 ATP has designed its own jigs
for each transmission model. These
block-off any ports, so no dirt
that is loosened by the automated
cleaning and sandblasting
processes can enter the housings.
W The basic components

3 are then removed from the
gearbox. This transmission is
from a Chrysler Voyager. Pictured
is the oil pump that sits directly
behind the front sealing plate
(see also Steps 32 and 37).
X The input clutch hub is

4 then removed. Inside the
planetary assembly are the friction
clutch plates and the steels. These
are known to burn-out on this
particular transmission.

GEARBOX ASSESSMENT continued

W As this transmission
5 is a front-wheel drive
application, the gearbox is
tipped on its side and the
transfer gear is removed, after
the retaining nut is undone
and pulled from its shaft.
X The side casing cover

6 is unbolted, prior to
the differential gear and its
bearing being taken out. Note
that sealant paste was used
by the factory, not individual
paper gaskets.
W Some transmission
7 sumps boast a magnetic
filter – metal swarf saturation
indicates a major problem.
Note that a filter assembly is
located within the fluid pick-
up attached to the valve body.
X Numerous small bolts

8 hold the valve body in
place on this transmission.
When they are all unscrewed,
the valve assembly is
dismounted, ready to be
cleaned and dismantled.
With the valve body removed, the The output gear and its bearing are
9 accumulator components can also 10 removed using the same method as The second and fourth gear carrier
be extracted. These consist of a spring and that used to extract the input gear (see 11 pulls-out from the main gearbox – the
piston fitted with rubber seals – these tend Step 5). The bearings are replaced, damaged centre bush shows that severe
to be renewed post-cleaning. regardless of their condition. harm has resulted from a lack of lubrication.
W The clutch plates

12 can slip excessively,
because they overheat. This
is evident not just due to
deterioration of the friction
material, but also the
scoring and ‘blueing’ of the
metal steels.
X Severe damage
13 has also been done
to the outer ring gear’s
teeth (arrowed). It was
unsurprising to discover that
the epicyclic gear set had
chipped planetary gears, too.

ROB’S TOP TIP
Be very careful to always
GEARBOX ASSESSMENT continued

use the correct automatic
transmission fluid.
W As the tiniest grit particle

14 can destroy a remanufactured
gearbox, ATP puts the stripped
transmission, including the case
and all components, through a fully
automated cleaning procedure.
X From here, the transmission

15 is rebuilt in ATP’s giant
remanufacturing hall, which is divided
not only into automatic transmission
types but also into individual
components, each of which are rebuilt
separately, prior to being reunited.
VALVE BODIES
X Working in the strictest
16 cleanliness, every valve body
casting is stripped of its many
small parts. The inexperienced
rebuilder is at risk of either
losing parts, or fitting them in
the wrong order.
W Even if there
17 is no obvious
damage, ATP replaces After reassembly, the valve body is
all filters, check balls,
18 pressure-tested on the company’s
thermal valves and special rig so that a successful overhaul
rubber seals, regardless is confirmed, before it is refitted into the
of their condition. remanufactured transmission.
GEARBOX REASSEMBLY 19 W The bare

transmission case
awaits reassembly. Note
that some models are fitted
with a spin-on type of oil
filter. Should one of these
be present, always fit a
new replacement.
X On this six-speed
20 rear-wheel drive
transmission, made by
Chrysler, the low and reverse
gear clutch drum needs
assembling with a mixture
of examined and new parts,
before it is refitted.
W The component
21 parts of this clutch
drum are (top, left to right):
first and reverse drum,
piston, one-way housing and
one-way clutch; (bottom, left
to right): six clutch plates
and steels, diaphragm and
retaining circlips.
X Once the
22 clutch drum
for first and reverse
gears is assembled,
it is located into the
rear of the gearbox Continued
and held in place on page
with a large circlip. 14

We supply a
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Vehicle Wiring Products, 9 Buxton Court, Manners Ind.Est.,
Ilkeston, Derbyshire DE7 8EF
T IME T O S T E P OF F
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With so many demands from work, home and family,
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Demystifying AUTOMATIC GEARBOXES ROB’S TOP TIP
When replacing the fluid, it
is impossible to drain the
GEARBOX REASSEMBLY continued

gearbox fully – several fluid
changes may be required.
W Pictured are the components

23 within the reaction carrier/
output assembly (left to right): the
annulus (ring gear), output shaft
planetary assembly, reaction carrier
assembly and sun gear.
Once assembled, the output assembly

24 is located into the first and reverse
clutch drum assembly that is pictured being
fitted in Step 22.
W The planetary
25 gear set for fourth
gear is then inserted
into the case. Here, extra
Torrington-type bearings
are fitted to both sides of
the sun gear (one of them
is arrowed in the inset pic).
X A washer is
26 fitted to the ring
gear (annulus), before the
assembly is inserted into
the transmission casing
and the planetary gear set.
The second and fourth gear clutch

The thick metal reaction plate is 28 The clutch pack for first, second,
27 replaced next (pictured), on top of
assembly is fitted next. Note that it
is considerably smaller than the drum that
29 third, fourth and reverse ratios is a
which is fitted a pair of second gear friction houses reverse and first gears (pictured very hefty item, consisting of numerous
plates and steels, all of which are retained in Steps 20 and 21), because those ratios parts (pictured in Step 30). From the top,
by another large circlip. transmit less torque. left to right, the parts are…
W …the housing assembly,

30 the first, second and third
gear clutch pack, the reaction
plate and fourth gear clutch
pack. In the middle are the first,
second and third hub, the fourth
gear hub, the reverse hub and the
reverse clutch. On the bottom:
the pressure plate for reverse,
the pressure plate for fourth gear
and circlips.
X After the clutch pack
31 assembly is refitted into
the gearbox (as shown), the oil
pump – which has been rebuilt
with new seals and gears, if
necessary – is refitted.

The oil pump locates in front of the The transmission case is flipped
32 clutch pack and is secured to the 33 over on its jig. Note that, when the Final assembly sees the rear housing
case on this transmission by a series of selector is placed in the ‘Park’ position, the 34 refitted on this rear-wheel drive
bolts that will be tightened to their transmission is locked mechanically by a application. Any bushes, bearings, or oil
recommended torque. lever that acts on the output shaft (arrowed). seals are renewed, where necessary.
The fluid pick-up assembly is cleaned Moving to the front face/bellhousing

36 and given a new strainer, prior to being 37 section of the transmission, the front
The valve block assembly is reattached located onto the valve block. After the oil sealing plate is given new outer and inner
35 carefully into the transmission’s base filters are replaced, liquid gasket is applied rubber seals, then located in the casing,
and its securing bolts are torqued evenly. to the flange and the oil sump is refitted. prior to being secured with a circlip.
The various plugs and sensors are The testing includes running through
38 40
replaced, regardless of their condition,
because faulty electrical components can
39 ATP runs each of its rebuilt gearboxes
on a comprehensive test rig. The
all gears at extended engine speeds
and output loads. Computer algorithms,
create strange operating conditions that operator fills the unit with the appropriate written by ATP’s research team, dictate
can be blamed – often incorrectly – on the transmission fluid and subjects it to an the test cycle for each gearbox and which
transmission’s mechanical internals. intensive test cycle. parameters determine a pass, or fail.
DIY REPAIR PROPOSITION

X ATP Industries Group of Cannock, Staffordshire, started adapts them to each make and model’s requirements. These
repairing automatic gearboxes on privately-imported American companies include ZF, Jatco, Aisin AW, Renault/PSA and the
cars in the 1960s. Today, it remanufactures the latest gearboxes American carmakers General Motors (GM) and Chrysler. Car
for a number of car manufacturers. Being our technical assistant manufacturers tend not to stick with just one supplier, either.”
for this feature, the pictorial guide shows how to strip down a Mr Aston says that ATP’s remanufacturing process results
typical front/four-wheel drive transverse gearbox, followed by in a transmission that is better than new, because common
the reassembly of a rear-wheel drive layout. faults have been identified in real-world use, which has led to
“While car manufacturers say that they make their own ATP engineering its own solutions.
transmissions, the truth is that this is the exception rather He adds that the technically-aware car owner should
than the rule,” says Adrian Aston, ATP’s Technical Director. realise that DIY repairs are almost impossible to execute
“Each transmission tends to come from a specialist gearbox cost-effectively, meaning that they should prioritise correct
producer, which manufactures a series of gearboxes and maintenance and be swift to diagnose faults.

Demystifying AUTOMATIC GEARBOXES ROB’S
TOP TIP
Never engage
TORQUE CONVERTER CHECKS 'Park' when the
car is still moving.
Once split, the components can be

T3 assessed. The turbine is pictured being
ATP drills a hole into the torque Each torque converter is mounted held. Lying down is the other half cover that
T1 converter, to allow any lingering T2 onto a lathe, which cuts the weld that contains the inner stator (and its clutch), the
transmission oil to drain out. holds the two halves of the casing together. impellor, plus the lock-up clutch and piston.
While much of this work is The spigot that engages within the
T4 impossible for a DIYer, you can check T5 centre of the engine’s flexiplate
the tab that engages with the oil pump has flywheel can wear and the only repair The oil pump drive is checked for
not broken and that the internal bush is method is to build up its surface with weld
T6 scoring and the dimensions measured
not excessively scored. and machine it to the specified dimensions. with a set of Vernier calipers.
W The bronze bush on the

T7 inside of the back cover is
checked with a Go/No-Go gauge.
If outside of tolerance, the bush is
machined-out and a replacement
is pressed into position.
X Scoring on the input

T8 hub is caused by a failed
Torrington bearing, which is due
to contaminants in the fluid that
originate from the gearbox. The
solution is to drill out the rivets,
then remove the hub and renew it.
W The lock-up clutch is

T9 pictured being lifted away
from the turbine to check for
broken springs and other
physical damage to the clutch
diaphragm. A new friction lining
can be bonded to the back of the
piston, if required.
X New lock-up hub seals

T10 are fitted to the centre
hub, prior to the torque converter’s
front cover being located over the
one-way clutch assembly.

The stator is positioned between the The rear housing (the impellor is When reassembled, the unit is
T11 turbine and impellor and its one-way T12 located within it) is placed over the T13 tested for free rotation, to ensure
clutch is either replaced, or receives new other half. The drain hole that was drilled in that its internal tolerances are correct, prior
needles and rollers, depending on the design. Step T1 has been sealed by MIG weld. to the run-out being checked.
W Finally, the two

T14 torque converter
halves are reunited by
a fully automated MIG
welding machine.
X To leak-test the
T15 entire converter,
it is pressurised with
compressed air, prior to
being plunged into a tank
of water. Any pressure drop
is monitored electronically.
W After being welded,

T16 the torque converter
WITH THANKS TO
ATP Industries Group,
is checked for excessive run- Cannock Wood Industrial Estate,
out, prior to being balanced Cannock Wood Street, Cannock,
and any balance weights Staffordshire WS12 0PL. www.atp-group.com
added, if appropriate.
X Final checks
T17 involve assessing
if the internals rotate
smoothly. After this, the ends
are plugged to prevent any
contamination. The units
are now ready to be reunited
with the remanufactured
transmission.
TYPICAL PROBLEMS
X While space precludes listing common failures for every automatic gearbox produced
in the last 20 years, look out for five common symptoms that indicate potential problems.
1. Slipping gears and sudden rising engine revs between shifts (‘flare’)
This tends to be caused by low oil pressure, or incorrect or poor-quality fluid being used. Look for
incorrect fluid levels, as well as a blocked oil filter.
2. No clutch lock-up from the torque converter Usually caused by an electrical
problem and not the transmission. Check the brake pedal switch, as lock-up should cancel, when
the pedal is depressed. As lock-up functions only at normal operating temperatures, a faulty
coolant temperature sensor might be responsible, for example.
3. Delayed engagement after selecting ‘Drive’ or ‘Reverse’ Look for a worn, or

damaged, gear selector cable and loose linkages. Dropping food, or drink, into the gear selector
mechanism can affect the electrical contacts and may just need a degree of interior trim dismantling and a good clean.
4. Missing gears or no drive Usually caused by faulty gear-speed sensors mounted on the transmission. With some
gearboxes, it is possible to swap the connectors around by accident. Have a live diagnostic check conducted to evaluate the
readings before suspecting that the more expensive gearbox internals are the cause of your problems.
5. Noise Any new and unusual sounds indicate a problem and should be investigated immediately, not only to ensure safety,
but also to prevent catastrophic damage leading to expensive repairs.

CM Insider
Dave Taylor brings the latest news and product news
Join the celebration

X As mentioned in the February issue of CM, On the CM stand you'll have a www.caarparts.co.uk
the magazine will be celebrating its 60th chance to win a Sealey trolley jack.
anniversary next month with a special bumper-
sized edition and a stand at the Practical
Classics Classic Car and Restoration Show, with
FREE NEC
Discovery, at the NEC in Birmingham on March
23-25. We’d like to invite all of our readers to
tickets for
visit us on the stand and help celebrate this CM readers
milestone in the magazine’s history. X We have five pairs of tickets
You can find us at Stand 4-060, which is right for this year’s Practical
by the main entrance to Hall 4. Editor Martyn Classics Classic Car and
Knowles is looking forward to meeting readers Restoration Show, with
and you’ll hopefully be able to chat to our regular Discovery, at the NEC on
March 23-25 to give away to
writers and experts, including Andrew Everett,
X To book tickets, visit necrestorationshow.com CM readers. The tickets will
Kim Henson, Richard Gunn, Rob Hawkins, give free admission to any of
Rob Marshall, Steve Rothwell and Steven Ward. Adult tickets are just £18 for a day, or you the show days, with full access
We’ve also asked contributor John Ward to bring could upgrade to a weekend pass to make to all of the exhibitors’ halls.
along some of his wacky mechanical inventions, sure you don’t miss anything at the show. For a chance to win a pair
which have appeared on television across If you book in advance you could save up to of tickets please send an
Europe, America, Australia and Japan. 15%. By quoting the code PCRS18CMSR at email containing your name
As Sealey is celebrating its 40th anniversary the checkout, CM readers will get a £2.00 and postal address with the
in 2018, we have joined forces with them for discount. All ticket bookings are subject subject heading ‘Free NEC
to a single transaction fee of £1.50 (this is tickets’ to carmechanics@
a very special competition to win one of their
charged per booking, not per ticket) and bauermedia.co.uk
limited edition trolley jacks. Entry forms will be The deadline for all entries
available on the CM stand throughout the show, include a Show Guide to help you find your is March 12, 2018, after which
along with other surprises and giveaways. way around when you get to the NEC. the winners’ names will be
Hope you can make it and we look forward to Full terms and conditions can be found selected at random.
seeing you at the show. online at necrestorationshow.com
1
TO
Hitachi Combi Drill and GIVE
AWAY Morris 0W-30
Impact Wrench Twin Pack Engine Oil
X One of the world’s leading manufacturers of professional X Multivis ECO PC 0W-30
power tools and consumer electronics, Hitachi has combined from Morris Lubricants is a
its powerful DV18DGAL 18V combi drill and WH18DGL new generation passenger
18V impact driver in the KC18DGL(S)/JF Twin car engine oil formulated and
Pack to provide two garage essentials in one. developed for the latest PSA
Weighing in at 1.6kg, the DV18DGAL combi petrol and diesel engines,
drill has an impressive maximum tightening torque including hybrids. The low
of 70Nm (hard), and it can drill 13mm into brick and viscosity grade of 0W-30 not
steel and 38mm into wood. The WH18DGL impact driver only promotes fuel efficiency
weighs 1.4kg and has maximum tightening torque of 145Nm under a range of driving
(hard) and comes with a ¼in (6.35mm) hex bit holder. The conditions, but ensures rapid
Twin Pack also features two 5.0Ah Lithium-Ion batteries, circulation in stop-start engines,
compatible with each even when the engine is cold.
tool, and a UC18YFSL It is recommended for use
charger, all packed in a robust in the latest PSA engines,
carry-case. It is backed up with including BlueHDi
a three-year warranty. and Puretech
The Hitachi KC18DGL(S)/JF units and those
Combi Drill and Impact Wrench Twin We have one Hitachi employing
Pack has a list price of £420, but Combi Drill and Impact electronic stop-
always shop around for the best Wrench Twin Pack start technologies.
to give away to a CM Multivis ECO
deals and special offers. reader. For a chance to
For further details, visit PC 0W-30 can be
win it, please complete supplied in 1-, 5-
hitachi-powertools.co.uk the coupon on page 21.
and 25-litre bottles.
Click & Collect vehicle spares, workshop tools and leisure

equipment at over 400 independent member stores. www.caarparts.co.uk

CM Insider
2 NEWS IN BRIEF
TO
Ring Dual Power GIVE
AWAY
Preset Tyre Inflator
X At CM we are always highlighting the importance of tyre
maintenance, stressing how the correct tyre pressures
not only improve vehicle handling and economy but also
increase safety. The Ring RAC660 Dual Power Preset
Tyre Inflator can be used both at home and by the
roadside, inflating a 13in tyre from 0-35psi in under
2 minutes from either the 12V socket in your vehicle or S Fuzz Townshend and
a 230V mains plug. The preset function helps ensure Tim Shaw will be returning
accurate inflation and can be programmed to stop with the sixth series of the
automatically at the correct pressure. vehicle restoration series
The device also features a backlit digital screen, so Car SOS on National
you can set tyre pressures easily and accurately in even Geographic channel on
the lowest light conditions. It can be used for cars, caravans, motorhomes and 4x4 March 8. Special guest in
tyres, and comes with an eight-piece adaptor set to fit most inflatables from footballs to airbeds. the first episode will be
actor James Nesbitt from
The RAC660 Dual Power Preset Tyre Inflator comes complete with a sturdy carry-case and
hit shows such as Cold Feet,
has a recommended price of £79.99.
The Missing and Lucky Man.
X Walkers Garage in South
Otterington near Northallerton
is celebrating after being named
the national winner of the Ring
Golden Bulb Grand Prize, which
sees the company receiving
WIN We have two Ring
RAC660 Dual Power
more than £1000 worth of Preset Tyre Inflators to
workshop equipment and give away to CM readers.
accessories. Hosted by Ring, the prize package includes inspection For a chance to win one,
lights, battery care equipment, vehicle lighting and dashcams. please complete the
coupon on page 21.
NEW from CLARKE

S The 68-page Winter
Clarke AT133 ARC TIG/MMA Garage Essentials from
The Parts Alliance is now
Inverter Welder available. You can pick
up a copy at all branches
X This ultra-lightweight ARC TIG/MMA inverter welder is ideal for of Allparts, Bromsgrove
both automotive and general repairs. The efficient inverter Motor Factors, Car Parts
technology utilises a high switching frequency that typically & Accessories, CES, GMF,
allows the welder to be less bulky and better controlled than SAS Autoparts, SC Motor
traditional non-inverter transformer-type welders. Factors and Waterloo or
Specifications GSF Car Parts.
X Min/Max output current: 10A-130A X Electronically controlled output current
X Electrode diameter: 2.5/3.2mm X Thermal overload cut-out and LED indicator.
X Open circuit voltage: 85V X Hot Start, Anti Stick & Arc-Force
X Input voltage: 230V/50Hz X Dimensions: 300 x 132 x 212mm
X Maximum effective input current: 12.8A X Weight: 5.3kg
X Variable output current displayed on a The Clarke AT133 ARC TIG/MMA Inverter Welder
clear digital display is priced at £155.98.
S The vehicle repair and

Clarke Arc Activated Headshield maintenance website from
X Safety is paramount when you are welding and it’s important to Henkel was launched in
protect your face and eyes. This Arc Activated Grinding/Welding October 2014 to provide
Headshield provides a clear view when not welding, but instantly dedicated support to show
changes to the appropriate shade or filter when the arc is struck. how to use products from
Loctite, Teroson and Plastic
It is suitable for Arc, MIG and TIG welding.
Padding to carry out a
X Eye protection to EN379
repair. The portal has been
X Light shade Din 4
enhanced to give more rapid
X Manually adjusts from dark shade Din 9 to Din 13 access to information such
X Shade Din 15 UV protection as the new How To section
X Powered by lithium batteries and solar cells with easy-to-follow step-
The Clarke Arc Activated Headshield is priced at £47.98. by-step instructions. Visit
For further information about the Clarke range of products, carrepairsolutions.co.uk
please visit machinemart.co.uk

www.greatmagazines.co.uk/carmechanics March 2018pCar Mechanics 19

CM Insider
NEWS IN BRIEF NEW from LASER TOOLS

Laser Super-slim,
flexi-head ratchet
X You can see the fastener but you know you can’t get
S Avon Tyres has a socket or driver bit onto it without dismantling half
confirmed sponsorship of the engine? This super-slim flexi-head ratchet from
the Bloodhound Project, Laser (part number 6744) is the answer. One end has a
centred on Bloodhound standard ¼in square drive and the other a ¼in bit driver
SSC, a supersonic car – both heads are reversible and lockable, plus they can
that’s designed to go faster swivel through a full 180º at the press of the button and
than the speed of sound. lock into the required position. The fully-polished 300mm ratchet handle is slim enough to access
Avon is supplying tyres difficult areas, while the tool is beautifully balanced and fitted with a smooth ratchet mechanism.
suitable for desert use to The Laser super-slim flexi-head ratchet has a typical price of £44.86.
Bloodhound’s essential
support vehicles and is also
looking to produce a rubber
tyre for runway testing of
Laser Dedicated glow plug sockets
the land speed record car. X When it comes to unscrewing a faulty glow plug, you’ll be lucky to
even be able to see it, let alone get access to remove it. They’re invariably
X Carbon Clean, the hidden away in the hidden recesses around the cylinderhead and
engine decarbonising surrounded by metalwork and other components. These compact
solution that works with glow plug sockets (part number 6741) will fit into the tightest areas.
tap water, has launched The deep socket fits snugly over the glow plugs and the narrow
an affordable garage diameter and universal joint enables you to remove them efficiently
workshop offering, the and safely. Three sizes are included in the set – 8mm, 9mm and
DCS-16 DPF cleaning 10mm – all fitted with a universal joint. They are ¼in drive to keep the
system. Taking just size down and enable the use of slim, ¼in drive extension bars.
30 minutes or less to Each set of three glow plug sockets costs £27.12.
complete, the DCS-16
removes particulate matter
from the DPF after soaking
it in the cleaning solution
Laser Hose clamp removal tool
X This new hose clamp removal tool (part number 6938) is specifically
for 20 minutes, then uses
high pressure and water to designed to release to withdraw the spring clips used on Henn-type connec
remove the blockage. clamps commonly fitted to air, intercooler and cooling system hoses.
The compact design gives easy access in cramped conditions,
X Titan SuperSyn with the release head swiveling through 90º for maximum
F Eco-B SAE versatility. Pulling or rotating the T-handle neatly withdraws the
5W-20 ultra-high spring clip and releases the clamp, meaning there’s no need to
performance wrestle with screwdrivers or pliers.
engine oil from Applications include BMW, Citroën, Dacia, Fiat, Ford, Kia, Lexus,
Fuchs Lubricants Mazda, Mercedes-Benz, Nissan, Peugeot, Porsche, Renault,
now meets Toyota, VAG, Vauxhall/Opel and Volvo models.
the ACEA C5 The Laser hose clamp removal tool offers good value at £19.44.
specification. The new
spec was introduced by
the European Automobile
Manufacturers’ Association Haynes Owners Workshop Manuals
to reflect the worldwide Nissan Note 2006 to Sept 2013 Owners Workshop Manual & SEAT Leon
drive to improve fuel September 2005 to September 2012 Owners Workshop Manual
economy. The oil has been
proved to improve fuel These latest additions to the catalogue of authoritative workshop manuals
economy by more than from Haynes cover popular models from Nissan and SEAT.
3.5% in M111 FE testing.
X The Nissan Note 2006 to Sept 2013 Owners Workshop Manual includes
X Millers Oils, the the petrol and diesel versions of Nissan’s mini-MPV. Petrol engines covered
independent blender are the 1.4 (1386cc) and 1.6 (1598cc), along with the 1.5 (1461cc) diesel.
and supplier of advanced
W The SEAT Leon September 2005 to September
oils, lubricants and fuel
2012 Owners Workshop Manual covers the Leon Mk2 hatchback, including
treatments, has acquired
the Cupra and Cupra R with the 1.6 (1595cc) and 2.0 (1984cc) petrol
100% of the share capital
in Fuel Additive Science engines, as well as the 1.6 (1598cc), 1.9 (1896cc) and 2.0 (1968cc)
Technologies. By acquiring turbodiesels, plus models with DSG transmission. Note: this manual does
FAST, Millers Oils will also not include the 1.2, 1.4 or 1.8 petrol models or the 2.0 TSI petrol with engine
be taking ownership of code CCZB. It also excludes vehicles with fully-automatic transmission,
the established Exocet Flex-fuel models or the Mk3 introduced in October 2012.
brand of fuel additives Printed versions of each manual cost £22.99, or you can subscribe to the
and treatments. online version for £20.00 per manual per year.
Available from haynes.com, Amazon and other booksellers.


CM Insider
NEW from SEALEY NEWS IN BRIEF

Sealey Video Borescopes
X Sealey have launched a new range of high-
performance pistol-grip video borescopes with
85mm colour TFT screens, with a choice of S A cleaning service for
cameras ranging from 9mm (part no VS8230; DPFs is now available from
£239.94), 5.5mm (part no VS8231; £335.94) Halfords Autocentres in
or 3.9mm (part no VS8232; £317.94). conjunction with Ceramex.
Each model features video record and playback, still images and live-stream video via the AV out With the Ceramex patented
cleaning technology, known
connection, and they incorporate waterproof probe pods which have an IP67 rating. Videos and
as Xpurge, every filter is
images are stored on the supplied 4GB micro SD card, which allows up to 4.5 hours of video and
subjected to an internal
10,000 images that can easily be transferred to a computer via the USB connection. The borescopes and external inspection
also feature a digital zoom control and rotate/flip function of the image, and up to four hours of pre- and post-cleaning, also
continuous use is provided by a lithium-ion battery pack. comparing backpressure
In addition, Sealey can supply a range of replacement or alternative camera probes to the same readings and weight. This
IP67 rating and featuring super-bright LEDs for a clear image in dark areas. is compiled in a detailed
inspection report to ensure
the filter has been returned
Sealey V-Scan Pro Multi- to as-new condition.
Manufacturer Diagnostic Tool X Denso’s innovative

X This wireless multitasking operating system is a Standard Wiper Blade
professional-level device that offers the most extensive technology has been
coverage of OE-level diagnostics for cars, SUVs and vans adapted for use on the
Japanese Shinkansen, better
up to 3.5 tonnes. The V-Scan Pro Multi-Manufacturer
known as ‘bullet trains’!
Diagnostic Tool is supplied with two years of updates and
there’s no tool lockout when the update has expired.
Powered by an Intel Quad-Core Processor and running
X Sealey is on Android 4.4 operating system, it has a 32GB hard
celebrating its drive, is Wi-Fi compatible and has a touchscreen display.
40th anniversary The unit includes a 5.0 megapixel rear and 2.0 megapixel
in 2018 and has front facing camera and weighs just 0.7kg.
announced a The V-Scan Pro allows you to: COMPETITION
special promotion X Read and clear fault codes X Read live data WINNER
to celebrate. X Perform actuation tests
Running until April, it features X Perform ECU and key coding on certain vehicles TROLLEY JACK &
exclusive pricing on a special selection X Access special functions such as battery configuration, FOOT PUMP SET
of more than 200 of its most popular DPFs, electronic parking brakes, oil service resets,
R Gray, Lymington
products, including discounts of throttle reset, TPMS and more
up to 55%. These include X Access maintenance functions, technical information R Morris, Durham
special edition trolley and data management. Q What is the width of the
jacks, axle stands and gift- The Sealey V-Scan Pro Multi-Manufacturer Diagnostic trolley jack in millimetres?
boxed inspection lamps. Tool is priced at £1999.95, but is currently available for A 250
£1849.95 as part of Sealey’s Vehicle Service Promotion.
X Sealey's 48-page Vehicle Service Promotion will be running until May 31,
packed with hundreds of products specifically aimed at home maintenance
and servicing, offering savings of up 55% on selected items.
Visit your local Sealey stockist to pick up copies of these special promotion
catalogues or ring 01284 757500 to request delivery in the post.
For further details or to view Sealey’s entire range, visit www.sealey.co.uk
To be in with a chance of winning one of our FREE giveaways this issue, please indicate your preferred product below:
Hitachi Combi Drill and Impact Wrench Twin Pack
Ring Dual Power Preset Tyre Inflator *Please enter this information so that Car
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Tales from
the workshop
Finding & fixing advice from our garage proprietor eve o hwe
VAUXHALL COMBO The power

steering pump
An easy belt change bolts had

seized solid,
so the belt
X The owner of this 2000 Vauxhall Combo van booked it in was removed
for a drivebelt change, telling us it was an easy job. Needless by popping
to say, it did not go well. When fitting the two new drivebelts off the water
we found that every bolt that needed to be undone had pump pulley.
seized. The alternator belt had broken and was already off.
The first bolt to loosen off was the adjuster on the power
steering pump. Although the front of the bolt began to turn,
we noticed that the back portion of thread was staying put,
so continuing to turn the bolt would have sheared it off.
Next, we tried to loosen the pivot bolt in order to turn the
pump slightly from the top, but that bolt had also seized. This method worked, but putting on the new belts was a
The option now was to remove the belt by undoing the four challenge as the tension could not be correctly adjusted.
bolts holding the water-pump pulley in place. The pulley Informing the owner that we were not happy with the tension
could then be dropped forward, releasing the tension on of the new belts and charging only what we had originally
the power steering belt and allowing it to be removed. quoted for this ‘easy’ job, the vehicle was returned to him.
VOLKSWAGEN TOUAREG CHEVROLET MATIZ
Broken rear spring Failed wiper linkage

X Big vehicles require big On this 4x4, this is a X Driving through
Once the wiper arms and front scuttle
springs, which usually means straightforward task. The heavy rain is never
panel are removed there’s plenty of
it’s a harder job to replace spring is contained within pleasant, even less access to the wiper assembly.
them. This 2006 Volkswagen the rear strut assembly, so when the wipers
Touareg had just failed which can be removed from suddenly stop working.
the MOT due to a broken the vehicle by undoing the The owner of this
rear spring, so it was in the four bolts securing the top Chevrolet Matiz was
workshop for a replacement. bracket and the lower bolt in only a short distance
the strut bottom bush. from work at the time,
Once off the vehicle, the and with the forecast
top mount is unbolted to for better weather
reveal the strut securing later in the day,
nut, and once the spring is decided to wait a short
compressed, this nut can be while before bringing the crank section attached
undone and the broken spring the motor along to us. to the motor, meaning that
removed. Compressing the A lot of manufacturers the original balljoint had to
new spring before popping seem only to sell the be reused.
it into place and replacing wiper motor and linkage After removing the wiper
the strut top nut, the unit is as a complete unit, but arms and front scuttle panel,
then ready to fit back onto Chevrolet still supply the two the motor and linkage were
the vehicle. It is imperative to components separately, with removed and replaced as
The road spring is fitted into the take care when compressing the linkage a very reasonable one unit. Once all back
strut assembly, which is easily coil springs as a road spring £65. Strangely enough, the together, the wipers were up
removed from the vehicle.
under load can be lethal. new linkage did not include and running again.

The old tensioner was fully extended with the worn chain and
the difference with the new tensioner and chain was obvious.
VOLKSWAGEN GOLF
Sticky
boot catch
X We are often accused
of being fitters and not
mechanics because very
often a repair cannot be
carried out without fitting a
new part. This is not always
the case and quite often we
FIAT FIORINO do manage to carry out a
repair without the need to
Slapping timing chain simply fit a new component.

This 2001 VW Golf was in
X One of the small fleets we look after has job, requiring the sump to be dropped, along our workshop because the
a collection of Fiat Fiorino vans that were all with the engine mount and front cover being boot wouldn’t stay shut. The
registered in 2012 and have covered around stripped off. The water pump also needs to owner would slam it down
80,000 miles. The other thing they have in be removed, as well as quite a bit of stripping two or three times before
common is that they have now all had their down to allow the cam setting tools to be put the catch would eventually
timing chains replaced. in place. The crankshaft pulley bolt has a left- hold the boot hatch. His wife
This was a preventive measure against the hand thread and, just to keep things fun, the did not have the same ‘slam
loud clattering coming from their engines due sprockets are free-spinning with no keyway, power’ and couldn’t get the
to a stretched chain going beyond the limits relying on the pinching force of friction to keep hatch secured.
A sticky mechanism was
of the tensioner. This is not a five-minute them in place.
the problem and if we had
simply replaced the seized
part, it would have required
SKODA YETI us to purchase a complete
A short length of rubber hose is a cheap alternative
to fancy special tools for fitting spark plugs. handle to get the required
Spark plug mechanism. This would also

have needed painting to
match the vehicle’s colour.
replacement However, by removing the
hatch interior trim and
X When carrying out a service gaining access to the back
on this 2011 Skoda Yeti, we were of the mechanism, we
reminded of a problem that occurred were able to lubricate and
some years ago due to the closed- manipulate the sticking
up gap of a spark plug. On a lot of mechanism until it freed off.
vehicles, the spark plugs sit in a deep Now the boot hatch would
recess, and the problem occurred secure when simply pushed
because a trainee had been used into place and no new parts
to sliding the plugs into the recess, were required.
before slipping on the spark plug
socket and starting the thread by
hand. The little rubber retainer in the
spark plug socket quickly wears out with regular use and, after a short while, fails to grip
the plug. The danger of dropping the plug into the recess is that the end of the plug can
strike the head and close the gap. In this case, although no permanent damage was done
and the plug simply needed re-gapping, it was time-consuming and inconvenient.
Special tools are available to fit plugs, but like the insert in the spark plug socket, they
do wear out. Our answer is cheap and simple: a short length of rubber hose will slip over
the top of the spark plug and guide it into the recess. When it wears out, simply chop a The pendulum lever mechanism
short length off the end and it’s as good as new. was sticking and needed
manipulation and lubrication.
www.greatmagazines.co.uk/carmechanics pCar Mechanics

March 2018 23
Tales from the Workshop
BMW 5-SERIES
Blocked DPF
X Complaining that his BMW
520d was emitting a constant
sound of rushing air, the owner
was surprised to discover that the
problem was down to a blocked
diesel particulate filter (DPF).
The rush of air was the sound of
the exhaust gases fighting their
way out via a small leak in the
front flexi-pipe. The unit had long
since passed the stage where a
regeneration would have helped
and replacement was going to be
the only option.
In theory, this looked like a
quick and easy task. Bolted into
place with four nuts and bolts
at the square flange on either
end of the unit, it only needed
the bolts to be undone and the Once the DPF has been removed, the difference
DPF to be dropped out. But the between the new and old filters is obvious.
effects of rust had been at work,
so the nuts refused to come undone and the bolts were Once the new unit was fitted, the sound of rushing air
stuck fast in the holes, although the use of a grinder and was no longer audible and the vehicle’s performance was
an air saw helped ease the job a little. also increased.
CITROËN XSARA PEUGEOT 306
Gearbox oil leak Brake light switch swap

X Having recently allowed and it was likely the result X The brake light
Removing the air vent and
his brother-in-law to replace of a slight misalignment of switch on this 1998 switch panel still does not
the clutch on his wife’s 2005 the driveshaft. Peugeot 306 had give easy access to the
Citroën Xsara, this customer On the Xsara, the failed and the owner brake light switch.
discovered a few drips of oil driveshaft is held at the asked us to replace
on the driveway. Not wanting back of the engine by a it because access
to pester the brother-in- centre bearing that is to the switch is
law, who had done the job disconnected to remove the awkward. The switch
as a favour, he asked us to gearbox when replacing a is hidden from view
establish where the leaking clutch. Doing this allows the and, if you take
oil was coming from. driveshaft to be extracted the advice of the
We confirmed that the oil from the gearbox before internet, the dash
was coming from the gearbox the gearbox is dropped has to be stripped
down. Consequently, when out, along with the
The oil seal had been the gearbox is put back, driver’s air vent and
damaged, allowing
gear oil to leak out. the shaft can be guided in switch panel.
afterwards. If the centre Actually, even with
bearing is left attached, the the air vent and switch and lower the column
shaft can damage the oil panel removed, the brake slightly. Using this method,
seal as the gearbox is put light switch is still not easy the switch can be changed
back into place. to access. The quickest without fumbling around
After removing the way turns out to be what and any resulting scratches
driveshaft, a new oil seal originally seems to be the from trying to manoeuvre
stopped the leak and the longest: undo the two bolts through the obstacle course
gearbox oil was topped up. securing the steering column of dash brackets.

FORD FIESTA
MOT failure
on damaged
steering rack BMW 3-SERIES
X Sometimes the statements made
by customers are priceless. I’ve
lost track of the number of times
The subframe needs to
be dropped to remove
Window
a vehicle has come in for its MOT
and I’ve been told: “It should pass
everything OK.”
the steering rack,
which had blown off
one of the rack boots.
drop failure
X The soft-top on this
The owner of this 2008 Ford 2001 BMW 318Ci has a lip
Fiesta bought the car in because the around the top of the door’s
power steering had failed, saying drop glass to ensure it is as
“I don’t think it’s serious, because weatherproof as possible.
when I top up the fluid, it works.” When the car’s designers
This was true, but it only really introduced this feature
proved that the steering pump was they realised it could cause
operational. The reason the fluid a problem with the glass
wasn’t staying in the system was catching the roof as the door
because the power steering rack was opened and closed. As
had blown a seal, which, in turn, had a result, they introduced a
pushed the fluid out along the rack until it the excess oil had been mopped up from clever addition to the window
eventually blew off the rack boot. under the subframe, we could replace the motor that would drop the
On the Fiesta, although the subframe rack. It only remained for the steering to be glass fractionally when the
needs to be lowered to get the rack out of bled out and the tracking to be set up before door handle was pulled, then
position, the job itself isn’t too difficult. Once the owner could have their Fiesta back. close it up again when shut.
This system relies on a
small microswitch built into
the door lock. However, this
FIAT PANDA feature was not working on
this BMW because of a failed
Heated microswitch. Unfortunately
for the owner, spraying the
manifold switch with electrical cleaner

had no effect, so we fitted a
complete new lock (£140),
X The inlet manifold on
this 2006 Fiat Panda which remedied the problem.
was not designed to
be heated, but luckily
the experience didn’t
consign the unit to the
scrapheap. The Fiat had
been brought in due to
rough running and, when
listening to the note from The plastic manifold had sustained heat damage
the engine, we suspected on the joining face to the cylinderhead.
this was due to an air
leak. A quick spray around the manifold with a solvent while the engine was running
confirmed this by raising the revs slightly.
The complete lock assembly
When we removed the plastic manifold, it was discovered that the engine had needed to be replaced due to
overheated at some stage and this had resulted in the manifold softening and the rubber a faulty microswitch.
gaskets hardening. As the manifold is not difficult to remove and refit, we decided to
try fitting new gaskets to see if they would create a good enough seal. Fortunately, this Follow Steve on Twitter:
rectified the running problems. As a precaution we checked the cooling system, but www.twitter.com/cmtips
with no faults present we returned the vehicle to its owner with a note to watch the
temperature gauge more closely.
www.greatmagazines.co.uk/carmechanics March 2018pCar Mechanics 25

Win COMPETITION
PRIZES
3 £347 worth more than
packed with tools CHT859

1
to be
WON!
300-piece AF/metric
home garage repair kit
Î A massive selection of the most popular DIY hand tools
housed within a handy tool chest. Contents include:
X Assorted AF & metric socket sets
X ¼in, 3/8in & ½in ratchet handles
X Metric & SAE hex key sets X ½in & 3/8in extension bars
X Precision screwdrivers X Screwdriver bit handle
X Philips & slotted screwdrivers
X Combination, adjustable & locking wrenches
X Long nose, combination, slip joint & diagonal pliers
X Hammer X 3M tape measure
X Hacksaw X Knife X HSS drillbits & fasteners
X Dimensions LxWxH: 600x260x340mm X Weight 18kg
CHT859
RRP £155.98
inc VAT
CHT862
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HOW TO ENTER Entry is free. Employees of Bauer Media, Clarke International Ltd and their families are not
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Post to: CAR MECHANICS CLARKE TOOL CHEST COMP, Dept CM3, Bauer Media, Media House, Lynchwood, Peterborough PE2 6EA
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WBC240 45/240 £159.98 £191.98 MODEL CHARGE BATTERY EXC.VAT INC.VAT XEV11/100(OL)†* 9 2 100ltr £369.00 £442.80
#Turbo fan 190N 50-185 £99.98 £119.98 Efficient inverter XEV16/100†* 14 3 100ltr £399.00 £478.80
cooled 190TEN# 35-180 £147.99 £177.59 technology Variable BC520N 50/100 £179.98 £215.98 HFBC12 6 Amps 100Ah £44.99 £53.99
235TEN# 40-210 £156.99 £188.39 output current WBC400 60/350 £199.00 £238.80 HFBC12/24 20 Amps 200Ah £79.98 £95.98 XEV16/150†* 14 3 150ltr £429.00 £514.80
XEV16/200(OL)†* 14 3 200ltr £499.00 £598.80
CAR RAMPS MODEL MIN/MAX ELECTRODE GRINDERS XEV16/150(400V)†14 3 150ltr £499.00 £598.80
OUTPUT DIA. & STAND SPRAY GUNS XET19/200 (OL)* 18 4 200ltr £599.00 £718.80
CURRENT (MM) EXC.VAT INC.VAT Stands come XE18/200 (OL)* 18 4 200ltr £559.00 £670.80
• Lift cars AT133 10A-130A 2.5/3.2 £129.98 £155.98 complete with
6" & 8" BEST XEV26/200† 23 5.5 200ltr £699.00 £838.80
safely and AT135 10A-130A 2.5/3.2 £169.98 £203.98 AVAILABLE HUGE FROM ONLY SELLER
quickly bolt mountings XE37/270 (OL)* 36 2x 4 270ltr £1149.00 £1378.80
AT162 10A-160A 2.5/3.2/4.0 £149.98 £179.98 WITH LIGHT CHOICE £ 22
.99
EX.VAT
• Tough FROM ONLY and feet IN-STORE/ £
£ AT165 10A-160A 2.5/3.2/4.0 £199.98 £239.98 27
.59
ELECTRIC BELT
angled 26EX.VAT
.99 anchor holes
FROM ONLY STANDS FROM ONLY
ONLINE INC.VAT
steel £
32INC.VAT
.39
£ Super range of
DRIVEN AIR
construction PER PAIR
32EX.VAT
.99 £47.98 INC.VAT MODEL DESC EXC.VAT INC.VAT
belt driven air COMPRESSORS
£ PRO12C/ 1.2mm, £22.99 £27.59
MODEL CAPACITY EXC.VAT INC.VAT HYDRAULIC 39INC.VAT
.59
14C/18C 1.4mm, 1.8mm compressors, ideal for powering all commonly
CR2 2000kg £26.99 £32.39 BOTTLE JACKS PGF14/18 Pro, Gravity £26.99 £32.39 used air FROM ONLY
CRW25 2500kg £36.99 £44.39 FROM ONLY AP15 HVLP, 2.2mm £26.99 £32.39 PGF14 tools £
289EXC.VAT
.00
£ & spray
AXLE STANDS
7EXC.VAT
.99
# With
SP14/18C 1.4mm/ 1.8mm £27.99 £33.59
equipment.
£
346 .80
INC.VAT
£
Ratchet action for
9INC.VAT
.59
*Telescopic Range sanding belt WORKSHOP CAT117
JACK *8" whetstone
quick height adjustment HEIGHT EXC. INC. & 6" drystone CAT113 AIR TOOLS
Sold in pairs MODEL CAP. (mm) VAT VAT
FROM ONLY #per MODEL DUTY WHEEL
single CBJ2B 2 148-276 £7.99 £9.59 DIA. EXC.VAT INC.VAT
£
11EX.VAT
.99
stand CBJ3B 3 180-350 £11.99 £14.39 CBG6RP DIY 150mm £32.99 £39.59
£ CBJ5B 5 185-355 £14.99 £17.99 FROM ONLY HUGE CHOICE
14INC.VAT
.39
CTBJ5* 5 220-495 £49.98 £59.98
CBG6RZ
CBG6RSC
PRO 150mm £42.99 £51.59
HD 150mm £54.99 £65.99
£
18EXC.VAT
.99
IN-STORE/
MAX MIN/ CBJ8B 8 190-365 £17.99 £21.59 BOXER 14/150
MODEL TONS HEIGHT EXC.VAT INC.VAT CBG6SB# PRO 150mm £54.99 £65.99 £
22INC.VAT
.79 ONLINE
CBJ10B 10 195-375 £21.99 £26.39 CBG6RWC HD 150mm £59.98 £71.98
CAX2TF 2 235-360mm £11.99 £14.39 CTBJ10* 10 210-525 £69.98 £83.98 MODEL DESCRIPTION EXC.VAT INC.VAT MODEL
CAX-3TBC 3 300-430mm £21.99 £26.39 CBG8W* (wet) HD 150/200mm £56.99 £68.39 CAT110 ½" Impact Wrench £26.99 £32.39 CFM HP RCVR EXC.VAT INC.VAT
CBJ12B 12 200-380 £24.99 £29.99
CAX6TP 6 333-500mm £24.99 £29.99 CAT111 Air Orbital Sander £21.99 £26.39 RACER 9/50P* 9 2 50ltr £289.00 £346.80
CAX-6TBC 6 400-615mm £31.99 £38.39
CTBJ12* 12 235-580 £89.98 £107.98 FUEL TRANSFER CAT113 3" Cut Off Tool £18.99 £22.79 RACER 9/100P# 9 2 100ltr £339.00 £406.80
CBJ15B 15 205-390 £29.98 £35.98 PUMPS
CAX10TP# 10 450-750mm £79.98 £95.98 CBJ20B 20 217-407 £34.99 £41.99 CAT117 13 piece ½" £34.99 £41.99 BOXER 14/50P O/L* 14 3 50ltr £329.00 £394.80
Ideal for dispensing diesel, light Impact Wrench Kit BOXER 14/100P O/L 14 3 100ltr £389.00 £466.80
2/3 TONNE fuel oils or refueling vehicles
CAT120 43 Piece Air Tool Kit £99.85 £119.82 BOXER 14/150 O/L# 14 3 150ltr £399.00 £478.80
TROLLEY HYDRAULI Self-priming Includes 2m
CAT121 Dual Action Sander £24.99 £29.99 BOXER 14/200 O/L 14 3 200ltr £489.00 £586.80
FROM ONLY PRESSES cable with battery clips, 2m
£ JACKS FROM ONLY delivery hose, CAT123½" Reversible Air Drill £29.98 £35.98 * 110V model in stock # 400V model in stock
22EX.VAT
.99
£
139EX.VAT
.98
£
27INC.VAT
.59
£
167INC.VAT
.98 EST 2m suction hose
with foot valve/filter AUTOMOTIVE
SELLER assembly WHEEL DOLLY SET
JACKS ALSO PROFESSIONAL & nozzle FROM ONLY ENGINE AWD1
£
IN STOCK UP QUALITY FROM ONLY 44EXC.VAT
.99
STANDS
TO 5 TONNE Built for tough daily £
149EXC.VAT
.98 £
CTJ3000G
use in automotive/ 53INC.VAT
.99
MODEL TYPE TONNE EXC.VAT INC.VAT industrial workshops CSA10BB £

179INC.VAT
.98
CTJ2B DIY 2 £22.99 £27.59 Rotates £
CTJ2MB DIY + Case 2 £27.99 £33.59 * Available with/without MODEL MOTOR MAX FLOW EXC.VAT INC.VAT through 360˚ 44EXC.VAT
.99
CTJ2250LP* Low Profile 2 £39.98 £47.98 7 pce pin, bracket &

pressing plate kit ‡
DFT12
DFT24
12V
24V
40l/min £149.98
40l/min £149.98
£179.98
£179.98
CES680F Fully tested BIG £
53INC.VAT
.99
CTJ3000QL Quick Lift 3 £49.98 £59.98 to proof load 3" CASTORS PER PAIR
CTJ3000GB Pro Garage 3 £69.98 £83.98 Adjustable DFT230 230V 56l/min £189.98 £227.98
polycarbonate safety Four non-marking castors for easy
CTJ2001G NEW Pro Garage 2 £79.98 £95.98 LCD INSPECTION EXC. INC. movement in confined spaces Heavy duty steel
screen # Economy model
CTJ3000QLB Quick Lift 3 £79.98 £95.98
MODEL EXC.VAT INC.VAT CAMERA WITH MODEL CAPACITY VAT VAT *Folds for construction - load rating 500kg per dolly
CTJ3QLG NEW Pro Instant Lift3 £83.99 £100.79 Versatile tool for CES340 340kg £44.99 £53.99 storage
CTJ3000G Pro Garage 3 £99.98 £119.98 4 tonne bench# £139.98 £167.98 viewing objects in 9MM CES450 450kg £64.99 £77.99
10 tonne bench* £198.00 £237.60 BUY NOW
* CTJ2250LP has a 2.25 tonne capacity, has a inaccessible areas LENS CES560 560kg £79.98 £95.98
low entry of only 80mm and includes 2 sockets 12 tonne floor*# £249.00 £298.80 • 4 LEDs and 5 brightness £ SPREAD
6 SPEED
settings • 1m long, flexible £59EX.VAT
.98 CES680F* 680kg £99.98 £119.98
20 tonne floor £329.00 £394.80 THE COST
30 tonne floor‡ £649.00 £778.80 .98
71INC.VAT METAL LATHE
ALUMINIUM camera probe • Inc carry E
RACING JACKS
50 tonne floor‡ £1299.00 £1558.80 case, inspection mirror, CIC2410 PACKALG WITH 12 SPEED
MILL DRILL
Quick lift Non-marking
magnetic pick up and
hook attachments TOOL CHEST DEA - CL500M
nylon wheels Rubber
contact pad - helps AND TOOLS
protect vehicle CRANES FROM ONLY
£
undersides FROM ONLY 259EX.VAT
.98
£
CTJ1250AB
BEST
£
164EX.VAT .99
311INC.VAT
.98
VIDEO
£
ELECTRIC SELLER
.99
197INC.VAT 329 HAND CHT624 ON-LINE
IMPACT HUGE TOOLS

450NM MODEL DESC. EXC.VAT INC.VAT This great
FROM ONLY WRENCH CFC500F 1/2 ton fold £169.98 £203.98 FULL RANGE £
94EX.VAT
£ .99
Po CFC100 1 ton fold £164.99 £197.99
value set includes OF ACCESSORIES 995EXC.VAT
.00
CTC900B 9 drawer £
£
113INC.VAT
.99 1/2"
£
ONLY
CFC1000LR 1 ton £219.00 £262.80 IN STOCK 1194INC.VAT
.00
LOW
ENTRY *steel chassis duty 59EXC.VAT .98
long reach
chest & CTC500B
5 drawer cabinet 430mm between centres Compound slide
impa 71INC.VAT
£ .98
with 4 way tool post Power fed screw cutting
ONLY wre Folding and fixed Includes the
85MM most popular facility Forward/reverse lathe operation
Inc frames available Clutch for independent mill/drill operation
CTJ1250AB 1.25T £94.99 £113.99 & 22 Robust, rugged construction sockets, spanners,
CTJ1800A 1.8T £159.98 £191.98 Fully tested pliers, drivers,
& ca CEW1000 to proof load CFC100 Overload safety valve Floor Stand Including Suds Tray
CTJ2500QLG* 2.5T £149.98 £179.98 wrenches etc £169.00 Exc. VAT/£202.80 Inc. VAT
27189LH
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HEAVY £
FROM ONLY
TURBO FAN PRESSURISED
DUTY 59EX.VAT
.98
Offering low cost, GAS HEATERS SANDBLASTERS
PLS195 PETROL JETSTAR £
71INC.VAT
.98
PARTS
efficient heating Heavy duty steel construction
POWER PRESSURE WASHERS FROM ONLY WASHERS sandblasters for the quick
WASHERS Makes easy work for NEW £ removal of surface rust, paint,
washing vehicles, RANGE
79EXC.VAT
.98 PARTS WASHER
FLUID FROM dirt/grease etc. CPSB100
CAN DRAW Honda patios, stonework, £
£
FROM ONLY
OWN WATER & Diesel 95INC.VAT
.98 £5.99 INC.VAT
INCLUDES SANDBLASTING
219EXC.VAT
.00 etc. JET7500, 8500 &
engine models 9500 include h PROPANE £
FROM ONLY GUN, DELIVERY HOSE, 4
£
262INC.VAT
.80
in stock GAS FIRED 39EX.VAT
.98 CERAMIC NOZZLES AND
SAFETY HOOD
£
PRESSURE ENGINE EXC. INC.
*stainless steel
47INC.VAT
.98
FROM ONLY
MODEL BAR/PSI HP VAT VAT MODEL MOTOR MAX. PRESSURE EXC.VAT INC.VAT MODEL TANK CAP. TYPE EXC.VAT INC.VAT £
Tiger1800 110/1595 2.6 £219.00 £262.80 JS1850 1400W 1523psi £59.98 £71.98 MAX EXC. INC. CW2D 10Ltrs Bench £39.98 £47.98 139EX.VAT
.98
£
Tiger2600 170/2465 4 £289.00 £346.80 JS1950 1600W
Tiger3000 200/2900 6.5 £349.00 £418.80 Jet 7500 1600W
2030psi £89.98
2030psi £124.99
£107.98
£149.99
MODEL OUTPUT KW VAT VAT CW1D 45Ltrs Floor £99.98 £119.98 167INC.VAT
.98
Little Devil II 10 £79.98 £95.98 CWM20 22.5Ltrs Floor £139.98 £167.98
PLS195 186/2698 6.5 £439.00 £526.80 Jet8500 2100W 2610psi £149.98 £179.98 Little Devil SSII* 10.3 £84.99 £101.99 MODEL TANK FLOW RATE EX. VAT INC.VAT
CW40 75Ltrs Floor £159.98 £191.98 VOLUME REQ.
PLS265 260/3770 13 £669.00 £802.80 Jet9500 2400W 3045psi £179.98 £215.98 Devil 660 SS* 15 £99.98 £119.98
Devil 700 15 £99.98 £119.98 CPSB100 32 litre 6-19 cfm £139.98 £167.98
JUMP STARTS Devil 900 24.9 £139.98 £167.98
TAP & DIE SETS CPSB200 63 litre 12-20 cfm £169.98 £203.98
Provides essential home, High quality tungsten steel
Devil 910 SS* NEW 17.6-24.9£159.98 £191.98 Supplied in metal
FROM ONLY garage and roadside Devil 1600 36.6 £169.98 £203.98 ANGLE GRINDERS
£ storage case (except
59EX.VAT
.98 assistance Integral work Devil 2100 49.8 £259.00 £310.80 16pce) FROM ONLY
£
71INC.VAT light
.98 910 includes air
compressor Long life battery
Devil 4000 70-131 £398.00 £477.60 FROM ONLY
£
24EX.VAT.99
£
MODEL START PEAK 15EX.VAT
.99 £
29INC.VAT
.99
BOOST AMPS EXC.VAT INC.VAT ELECTRIC £FROM ONLY
19INC.VAT
£ .19 CAG800B
HEATERS £49EXC.VAT
.98
900 400A 900A £59.98 £71.98
BEST 59INC.VAT
.98 INC. DISC
910 400A 900A £69.98 £83.98 DEVIL TYPE EXC.VAT INC.VAT
SELLER & HANDLE
CLIPPJS NEW 200A 400A £74.99 £89.99 6003 CHT203 16pce Metric £15.99 £19.19
4000 700A 1500A £124.99 £149.99 CHT302 24pce UNC/UNF/NPT £19.98 £23.98 MODEL DISC (MM) MOTOR EXC.VAT INC.VAT
BEST EXTRA LONG 12/24 1000A@12V 2000A@12V £139.98 £167.98 CHT303 28pce Metric £23.99 £28.79 CAG800B 115 800W £24.99 £29.99
SELLE 500A@24V 1000A@24V CHT304 33pce Metric/UNF/BSP £32.99 £39.59 CON1050B 115 1050W £29.98 £35.98
1m LEADS CHT774 37pce Metric £38.99 £46.79 CON115 115 1010W £36.99 £44.39
CHT527 32pce Metric £46.99 £56.39 CAG2350C 230 2350W £52.99 £63.59
HEAVY DUTY IDEAL DEVIL 7003 CHT776 76pce Metric £64.99 £77.99 CON2600 230 2600W £79.98 £95.98
GARAGES/WORKSHOPS ALL-WEATHER MODEL VOLTAGE HEAT EXC.VAT INC.VAT
Ideal for use as a garage/workshop Extra tough triple PROTECTION
layer weatherproof fabric Heavy duty powder
OUTPUT KW BLAST CABINETS
DEVIL 6003 230V 1.5-3 £49.98 £59.98
coated steel tubing DEVIL 7003 230V 3 £59.98 £71.98 Blast away paint, DIAGNOSTICS
Ratchet tight tensioning DEVIL 6005 400V 2.5-5 £74.99 £89.99 surface rust, scale,
FROM ONLY DEVIL 7005 400V 5 £84.99 £101.99 burrs, carbon & dirt &
£ revitalise aluminium
229EXC.VAT
.00
DEVIL 6009 400V 4.5-9 £119.00 £142.80 £
FROM ONLY
ZIP CLOSE DOOR 274INC.VAT

£ .80 DEVIL 7009 400V 9 £139.98 £167.98 Min. air flow 10cfm
Bench & floor
37EX.VAT
.99
£
MODEL SIZE (LxWxH) EXC.VAT INC.VAT
DEVIL 6015 400V 5-10-15 £179.00
DEVIL 7015 400V 15 £199.98
£214.80
£239.98 standing models 45INC.VAT
.59
CIG1015 4.6 x 3 x 2.4M £229.00 £274.80 DEVIL 7025 400V 22 £299.00 £358.80 ALUMINIUM OXIDE MODEL EXC.VAT INC.VAT
CIG1216 4.9 x 3.7 x 2.6M £299.00 £358.80 DEVIL 7030 400V 30 £349.00 £418.80 POWDER FROM ONLY FROM ONLY EOBD Fault Code Reader £37.99 £45.59
CIG1020 6.1 x 3 x 2.4M £289.00 £346.80 £9.98 EX.VAT £ Engine EOBD/OBD2 £49.98 £59.98
CIG1220 6.1 x 3.7 x 2.5M £349.00 £418.80
10' RANGE NARROWER
WIDTH GREAT WHERE LENGTH DIESEL/PARAFFIN £11.98 INC.VAT 109
.98
EXC.VAT
CSB20B Fault code reader
£
CIG1224 7.3 x 3.7 x 2.5M £429.00 £514.80 SPACE IS TIGHT UP TO 24'
HEATERS 131INC.VAT
.98
Engine Diagnostic & £104.99 £125.99
FROM ONLY MODEL DESC. TYPE EXC.VAT INC.VAT EOBD/OBD 2 Fault Code Reader
INVERTER GENERATORS £
189EXC.VAT
.00
CSB20B Compact Cabinet Bench £109.98 £131.98
GENERATORS PG3800 £ CAR TRANSPORTER
Produces pure sine wave & stable power,
FROM ONLY
£
226INC.VAT
.80 SB30 Large Cabinet Floor £299.00 £358.80
LASHING
essential for computers 99EX.VAT
.98
Ideal for fast
& sensitive equipment £
119INC.VAT
.98
efficient heating STRUT
Low noise 12V Honda Extra-long run fuel SPRING COMPRESSOR £
battery charging engine tanks – up to 53 litres XR80 • Foot operated hydraulic 17EX.VAT
.99
5000KG
facility 4 stroke models Variable heat output with powered • Adjustable for £
21INC.VAT
.59 CAPACITY
engine IG1200 available thermostat control springs up to 350mm dia. &
FROM ONLY CHECK FRAME 254mm in length • Yoke travel:
£ MODEL MAX OUTPUT EXC.VAT INC.VAT SOCKET SETS
179EXC.VAT
.98
TYPE WHEN XR60 14.7kW £189.00 £226.80 340mm • Weight 31.5kg
ONLY
£ ORDERING
215INC.VAT
.98 XR80 20.5kW £239.00
XR110 29.3kW £289.00
£286.80
£346.80
SSC1000
£
109EXC.VAT .98 Top quality chrome £
24EX.VAT
.99
MAX WEIGHT EXC. INC. * was £346.80inc.VAT vanadium steel.
18 Sockets 8-32mm 29INC.VAT
XR160 46.9kW £349.00 £418.80 £ £ .99
MODEL OUTPUT KG VAT VAT MODEL KVA HP EXC.VAT INC.VAT XR210 61.5kW £399.00 £478.80
131INC.VAT
.98
IG950 800W 9.3 £179.98 £215.98 G720 0.7 - £99.98 £119.98 Reversible ratchet LIFETIME
IG1000 1000W 15 £229.98 £275.98 G1200 1.1 - £159.98 £191.98 Comfort grip handle GUARANTEE
IG1200 1200W 12.4 £259.98 £311.98 PG2500 2.2 6.5 £179.98 £215.98 BODY HUGE RANGE
IG3500F
IG2000
NEW 3400W 35 £329.98
2000W 19.4 £369.00
£394.80
£442.80
PG3800
PG3800DV*
3
3
7
7
£239.98
£269.00
£287.98
£322.80
DRILL PRESSES
Range of precision bench &
FROM ONLY
REPAIR
KITS CS10BRK
OF RATCHETS,
SPANNERS AND
NEW
£
IG2200 2200W 26.6 £389.00 £466.80 PG6500DVES 5.5 13 £499.00 £598.80 floor presses for enthusiast, 89EX.VAT .98
SOCKET SETS PRO360
£
CAR CREEPERS PRO 7" SANDER/ engineering & 107INC.VAT
.98
PRO389
industrial applications £FROM ONLY
B = Bench mounted £66EXC.VAT
.99
• Oil resistant vinyl covered padded POLISHER £ 62 PIECE
backs & headrests • Swivel castors
.98
69EX.VAT F = Floor standing 80INC.VAT
.39 1/2"&1/4"
£
for easy manoeuvrability
FROM ONLY
83INC.VAT
.98
MOTOR (W) EXC. INC.
Fast snap £
ONLY DRIVE
£
22EX.VAT
.99 CP185 MODEL SPEEDS VAT VAT
connector attachments for quick & easy assembly 59EX.VAT
.98
SOCKET
CDP5EB 350 / 5 £66.99 £80.39 £ & BIT SET
£
27INC.VAT
.59 CDP102B 350 / 5 £79.98 £95.98 Hydraulic pump, ram & hose with various tubes, 71INC.VAT
.98
• Includes hook & pieces & connectors Includes metal case 1/2"
loop backing pad CDP152B 450 / 12 £139.98 £167.98 TORQUE
MODEL DESCRIPTION EXC.VAT INC.VAT and hook & loop CDP202B 450 / 16 £185.00 £222.00 * Fast action pump WRENCH - CHT141
CMC36 Car creeper £22.99 £27.59 wool polishing CDP10B 370 / 12 £198.99 £238.79 MODEL CAPACITY EXC.VAT INC.VAT 5" Extension ONLY
£
CMC40 With tool storage £36.99 £44.39
CMC45 With adjustable headrest£29.98 £35.98
bonnet. • 1200W CDP352F 550 / 16 £229.00 £274.80
CDP452B NEW 550 / 16 £229.00 £274.80
CS4BRK
CS10BRK
4 tonne £89.98
10 tonne £149.98
£107.98
£179.98
bar 1/2" -
3/8"
23EX.VAT
.99
motor adaptor £
28INC.VAT
.79
CMC50 Folding car creeper £47.99 £57.59 CDP502F 1100 / 12 £499.00 £598.80 CS10SBRK* 10 tonne £154.99 £185.99 28-210 Nm
VISIT YOUR LOCAL SUPERSTORE OPEN MON-FRI 8.30-6.00,

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h a ll In s ig n ia 2 .0 C DT
Project Vaux
Turbocharger JOBS LIST

RENEW NEARSIDE
REAR WHEEL BEARING
PART 2
MAR 18
troubles
FIX AFL PART 2
FAULT MAR 18
FIT NEW PART 2
TURBOCHARGER MAR 18
INVESTIGATE LOW OIL PRESSURE
SERVICE ENGINE

PART TWO: Our Insignia is transported to
FIX LACK OF POWER
SERVICE BRAKES
our local garage to have the engine oil drained FOUR-WHEEL ALIGNMENT
Plus anything else that goes wrong in the coming months
and the turbo renewed in a bid to fix its low oil
pressure problem. Rob Hawkins reports.
W
e’ve had an anxious few weeks you take a look at Your Letters this month,
since buying and collecting you’ll find that several readers have
our Insignia before Christmas. already written in with advice – including
The low oil pressure warning a couple of useful methods of recognising
is the major cause for concern. According when a regen is occurring. Our sponsors,
to Vauxhall, if the engine oil is shown to Autovaux, have also been very helpful.
be overfull on the dipstick, this is often a Dan Smith at MJ Motors suggested
sign of an incomplete DPF regeneration. running the engine so that he could see
Allegedly, there’s no way of telling the problem for himself. Straight away,
when a regen is happening, so if the he could tell that the turbo was noisy. He
engine is switched off, the process isn’t detached the oil feed pipe to the top of
completed. The consequence of this is the turbo and no oil spurted out. It had
that diesel fuel is dumped into the engine clearly been starved of oil.
oil, resulting in the overfull reading. So the turbo definitely needed
During a DPF regen, the engine runs renewing. The engine oil pick-up pipe that through Vauxhall is £715.20). So a turbo
rich to heat up the exhaust system and we discussed last month should also be was delivered to MJ Motors along with
DPF. If the engine is switched off during replaced as it’s a common cause of low oil a selection of gaskets and several other
a regen, there may be excess diesel fuel pressure if it has perished. However, the parts that we will be fitting over the
inside the cylinders which hasn’t been Vauxhall technician we spoke to explained forthcoming months. We’ve managed to
combusted. This can seep past the piston that, if you’re lucky, changing the engine renew the turbo this month, but not fix
rings and into the oil, increasing the oil can fix the low oil pressure problem. the low oil pressure problem, yet. We have
volume of oil with fuel. We suspect this We weren’t so optimistic, but tried this however, managed to successfully renew
is the case with our Insignia’s engine. approach anyway. Sadly, it didn’t help. the nearside rear wheel bearing, although
We had our Insignia transported to A replacement turbo was needed. removing the old wheel bearing wasn’t as
our local garage, MJ Motors in Batley, for We contacted Autovaux, who were able easy as we had expected. Thankfully the
a second opinion and to devise a plan of to supply a remanufactured GM turbo replacement from Autovaux comes with
action for the low oil pressure problem. If for £438 (recommended retail price a two-year warranty.
RESOLVING LOW OIL PRESSURE

W With the
1 Insignia parked
on the driveway, we
needed to get it to
MJ Motors, who are
helping with this
project. They’re 12
miles away, but also
close to Autovaux, so Dan Smith at MJ Motors suggested
spares can be ordered 2 draining the overfilled engine oil. It
and delivered quickly. may be above the ‘Max’ mark due to a DPF
We used a local regeneration not being completed, dumping
transport company to diesel fuel into the engine oil and lowering
move our Insignia. the oil pressure.
Autovaux is the number one VAUXHALL specialist in the UK

CM project 2011 Vauxhall Insignia Tourer 2.0 CDTi
Contact
Autovaux
for all you
VAUXHALL
needs on
0333 358 3615
W After lifting the Insignia
3 on a two-post ramp, the
engine undertray was detached
by undoing a couple of quick-
release plastic fittings, then left The 13mm sump plug has a banjo-
suspended on its front mountings 4 style drain hole, which means it can
(it’s hinged across the front for be slackened to allow the engine oil to be
easy access to the sump). The steadily drained. This also avoids the risk
base of the sump was coated of oil surging out when the drain plug is
in oil and there were traces of removed and either missing the drain-pan or
engine coolant residue. running down your arms.
W Unfortunately,
5 the engine oil is
viscous. Realising it
could take the rest of the
day to drain, we decided
to remove the drain plug,
allowing the oil to drain
out much faster.
X After refitting
6 the drain plug, we
poured four litres of
5W-30 fully-synthetic low
ash oil into the engine,
then ran it to see if the
low oil pressure problem
had been resolved. It
hadn’t, and the turbo
was still sounding noisy,
suggesting it’s being
starved of oil.
REMOVING THE ORIGINAL TURBO
Judging by the noise from the turbo The turbo is located at the front of the The clamp proved difficult to detach.
1 and the lack of power from the engine, 2 engine bay. After detaching a small 3 Luckily, we had a new one from
we suspected the turbo needed replacing. heatshield, we made a start on removing the Autovaux, so we prised the old one open with
Autovaux manage to source a remanufactured 16mm bolt for the clamp that secures the a couple of pry bars. It still refused to budge,
GM turbo for a reasonable £438. exhaust downpipe to the turbine housing. so we resolved to try again later.
For genuine VAUXHALL parts visit www.autovaux.co.uk

REMOVING THE ORIGINAL TURBO CONTINUED
Despite the luxury of having easy access

6
4 The induction pipework between the
The pipe between the compressor
to the turbo, some of the fittings were
air filter housing and the compressor
housing of the turbo was undone. Both ends
5 housing and the intercooler is secured
not so straightforward to undo. For example,
the two 10mm bolts securing the oil drain pipe
are secured with Jubilee clips and there’s with two E12 bolts. There was just enough to the turbo have usually seized (penetrating
also a breather pipe and sleeving around the room to squeeze a socket and 3/8 in ratchet fluid was sprayed over them) and only the
compressor housing to detach. into position and undo them. frontmost bolt could be undone at this stage.
W We had been given

7 a new oil feed pipe
from Autovaux. It’s a short
metal pipe routed from the
top of the engine to the top
of the turbo and is known
to become blocked, thus
starving the turbo of oil.
Each end is secured with
a Torx T45 bolt.
X The turbo is
8 attached to the
exhaust manifold with three
11mm nuts. The easiest of
the three is accessed from
above, as shown here. Our
nut had seized, so the stud
came out with it, which
was a help when it came to
removing the turbo.
W The other two

9 11mm nuts that hold
the turbo onto the exhaust
manifold were not so easy
to undo. We sprayed them
with penetrating fluid, then
slowly wound them undone.
There’s not much room, so
this took several minutes.
X Finally, the turbo

10 was released. It was
lifted up to access and
undo the remaining 10mm
bolt for the oil drain pipe
(see Step 6) and detach
the plug connector for the
actuator. Now the old turbo
could be lifted free from
the engine bay.

CM project 2011 Vauxhall Insignia Sports Tourer 2.0 CDTi
FITTING THE REPLACEMENT TURBOCHARGER

W We had a selection
1 of clearly labelled
gaskets, nuts and a new oil
feed pipe from Autovaux to
fit to the replacement turbo.
These were all bagged-up
separately, making them easy
to match to the old parts.
X Before the turbo was

2 fitted, we cleaned the
mating surfaces for the oil
drain pipe, intercooler and
exhaust manifold. These are
coated in the old gasket, so
they needed to be cleaned to
ensure a good seal.
Fitting the turbo and making sure the Lowering the turbo into position proved A new firing ring was carefully inserted
3 new gaskets didn’t fall off wasn’t easy. 4 to be awkward. On the part of the turbo 5 between the turbine housing and the
Some of the gaskets have foldable tabs, that connects to the exhaust manifold, there exhaust downpipe. It should only be fitted
which can help to keep them in position, are two studs that need to be fed through one way round, with the raised edge against
such as the intercooler gasket shown here. mounting holes on the exhaust manifold. the exhaust downpipe.
The new oil feed pipe was fitted between

8 the top of the engine and the top of the
6 The oil drain pipe was reconnected,
followed by the intercooler pipe, as 7 Before the new oil feed pipe was fitted,
we poured fresh engine oil into the top turbo with new Torx T45 banjo bolts (notice
shown here. The edges of the gasket and its of the turbo to help prime it and ensure it the oil feed hole in the bolt for the engine
locating tabs can be seen in the photograph. didn’t run dry on the first start-up. side). All remaining parts were then refitted.

AFL TROUBLE
Dan Smith at MJ Motors plugged in his

2 Launch diagnostic equipment to help
1 The AFL lamp warning that appears
identify the AFL-related fault that had been The bulb in question was extracted
on the dashboard of our Insignia is an
MOT failure point. AFL stands for adaptive raised. The problem was narrowed down to 3 from the back of the headlight. It’s a
forward lighting, which helps to direct the the lighting circuit for the left (nearside) complete unit, including the bulb holder, so
headlights when turning at slow speed. We headlamp. We turned the steering to the left we ordered a new one from a local motor
needed to know more about the problem with the engine running and discovered a small factor. The AFL system also moves the
before we could resolve it. bulb inside the headlamp hadn’t illuminated. headlights in the direction of the steering.
RENEWING REAR WHEEL BEARING

W The nearside rear wheel
1 bearing was producing an
annoying rumble when driving
above 50mph. We suspected
the wheel bearing had failed,
so we ordered a new one from
Autovaux. It is supplied as a
complete assembly.
X After raising the Insignia
2 on a two-post ramp, we
removed the road wheel, then
undid the two 15mm bolts
securing the caliper carrier,
before detaching it along with the
brake caliper. Next, the brake disc
was taken off. At the last MOT the
rear discs/pads were renewed.
W The end of the

3 upper suspension
arm obstructs access to
some of the hub carrier
bolts, so we undid its
21mm nut and extracted
the 17mm bolt that’s
attached to the top of
the upright. The two can
then be separated.
X The hub carrier

4 is secured to
the upright with three
18mm bolts. There’s just
enough room to squeeze
in a deep socket and
½in ratchet to undo
them. Luckily, none of
them had seized.

PROJECT COSTS
PURCHASE
X Plenty of
5 penetrating fluid
OF CAR
was sprayed around
the area where the hub
carrier makes contact
with the upright. We
left it to soak in, then
tried releasing it with
a hammer, to no avail.
We also tried an air £2070.00
chisel, but no luck.
PARTS COSTS
Remanufactured GM turbo £438.00
Gaskets and fittings £20.51
Turbo oil feed pipe £46.33
AFL bulb £12.00
6 W A lump hammer
and a long bar was
Automega rear wheel bearing £68.64
5W-30 low ash engine oil (five litres) £25.98
tried next, using them to
hit the back of the wheel TOTAL £2681.46
bearing. We returned
to the air chisel and
penetrating fluid, but the
wheel bearing assembly
refused to budge.
NEXT ISSUE
We’ll be removing the engine sump
to check the oil pick-up pipe seal and
inspect the crankshaft bearings.
8 After cutting off the flange and the

three mounting lugs for the wheel USEFUL CONTACTS
bearing, we hit the back of it with a long Autovaux
Armed with a large angle grinder and metal bar and lump hammer. Eventually,
7 230mm cutting disc, we cut off the the wheel bearing flew out several metres
0333 358 3615
ends of the flange where the road wheel sits across the workshop! Here’s why it was so MJ Motors (Batley)
in an attempt to release the hub carrier. difficult to remove: corrosion. 01924 472404
W Dan Smith at MJ
9 Motors breathed
a sigh of relief because
he feared we’d have
to remove the upright
and press out the old
bearing. Before fitting
the new bearing, we
cleaned the hole in the
upright with a round file.
X The new hub

10 assembly fits
perfectly into the upright.
Corrosion will inevitably
strike again, but
hopefully we won’t have
to replace the bearing
again soon. This was a
tough job due to rust.

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Spotlight on BMW N-SERIES FOUR-CYLINDER PETROL ENGINES
F UR- YLINDER
It doesn’t have a glowing reputation in the
trade, but what makes the N-Series petrol
unit tick? Andrew Everett is your guide.
T
hose of you who read Steven Ward’s Dealer’s Diary
column may have seen his diatribe in the December 2017
issue about the N43 engine produced by BMW, used from
late 2007 in four-cylinder petrol 1- and 3-Series cars until
the replacement N20 and N13 units arrived around five years
ago. It has a well-deserved reputation for spelling trouble.
The N43 was the final development of the engine series
that began in 2001 with the N42. Back then, the N42 2.0 was
a revolutionary unit and was built in a brand-new factory in
Hams Hall, not a million miles away from the Rover plant at between the valves, inlet
Longbridge, where it was suggested it could be used in a future cam and rockers. A 12V
range of Rover cars – that didn’t happen, of course. electric motor bolted to the
The spec of the N42 was impressive for late 2001 and it would top of the head turned the
still be thoroughly modern if launched again today. It included eccentric shaft via a toothed
an all-alloy construction with a ladder-type block – a regular quadrant to increase or decrease valve lift, to allow the engine
alloy block but with the main bearing caps built into a frame to breathe more easily without the restriction of a throttle
for rapid assembly and extra strength – as well as Double Vanos body. The motor was controlled by a separate ECU that took
cam timing, 16 valves with Simplex chain-driven camshafts, information from the engine ECU, based on load, revs and a
double cam sensors (one for each cam) and Valvetronic. sensor on the front of the Valvetronic shaft. Further refinements
The last of these was BMW’s new concept where the lift of over the old iron block/alloy head M44 that preceded it (E36 and
the inlet valves – and thus engine speed and load – was variable Z3) included a plastic inlet manifold and cam cover – this helped
thanks to an eccentric shaft running the length of the head in keep the weight down, with the new engine weighing 87.5 kilos
as opposed to more than 100 kilos for the old unit.
The timing chain set-up was all new and was designed for rapid
assembly. This was a cassette-type chain assembly, lowered down
into the engine with the head fitted as a complete unit with the
chain, the plastic guide rail and pivoting tensioner blade, crank
sprocket and the two Vanos units. The N-Series crank had no
‘nose’ onto which the crank sprocket might slide because it was
all lowered in as one unit and the big crank end bolt tightened
to 300Nm. This immense torque meant there was no locating
keyway, relying on the torque of the bolt to keep it together.
The Vanos units were not keyed to the camshafts and stretch
bolts were fitted. The Vanos units also differed from previous
BMW practice – on the pre-2005 six-cylinder engines the
complete oil-pressure-fed Vanos unit was fitted to the front on
the head and located onto the front of the cams. On the N42,
though, separate Vanos units were built into the cam sprockets
themselves. They were activated by oil pressure and regulated
by the electronic solenoids in the front of the block that also
controlled the oil pressure going to the units.
The alternator, power steering pump and water pump all ran
off one auxiliary belt, with a spring tensioner fitted to the front
of the block. To save space and weight, the water pump was
combined with the power steering pump and bolted to the side
of the block. Due to the Valvetronic design, there was no inlet
manifold vacuum ( just like a diesel) and so a camshaft-driven
brake vacuum pump produced vacuum for the brake servo.
The oil pump was in the sump, integral with the balance shaft
assembly bolted to the block and driven by a second short chain
from the front of the crank. An ECU-controlled thermostat
regulated engine temperature.

N42 & N46 N43

X The N46 was a revised N42 introduced with the 118i and X The N43 arrived in late 2007 and was fitted to the 116i as
120i in late 2004 and fitted to the last year of E46 production. a 1600 (different bore and stroke to the previous N45), as
The N42 and N46 are so similar they can be interchanged if well as in 2.0-litre form to the 118i, 120i, 318i and 320i. The
the engine wiring loom has been swapped over – so an N42 main change was the introduction of direct-injection and
bare engine can be used in an E90 3-Series or 1-Series and the deletion of Valvetronic. This required an all-new head
vice versa. The Valvetronic ECU was discontinued on the N46, casting to accept the new type of Piezo injectors, as well
with Valvetronic control being taken care of by the engine as an exhaust-cam-driven high-pressure fuel pump – not a
ECU. The air injection emissions system was discontinued on rotary one on the back of the head as used on the MINI R56
the very last batch of N42 units in readiness for the N46. engine, but a pump action unit bolted to the top head face.
An electric coolant pump was used, along with a cam-
N45B16 & N45N driven brake vacuum pump, albeit of a different design.
Exhaust gas recirculation (EGR) was incorporated, along with
X The N45B16 was the 1.6-litre unit fitted to the 116i from mind-boggling exhaust gas sensors – as well as the main
2004 until early 2007 and was quite different to the N42/46. Lambda probe, there is a second regulating Lambda sensor
For a start, it didn’t have Valvetronic or balance shafts, and plus a Lambda monitor sensor. Automatic cars have an
due to the regular throttle body it didn’t need the brake extra temperature sensor and all N43s have a NOX (nitrogen
vacuum pump. The head was a unique design. The N45N oxide) sensor as well.
from early 2007 was almost identical and was fitted to cars While little is interchangeable, the basic block is very
after 2007 where the direct-injection N43 would not meet similar to before, with only an extra mounting lug for the
US emissions regulations. N45 engines had a small primary electric coolant pump. In 2009, the N43 1.6 was replaced by
catalytic converter fitted to the exhaust manifold. a lower output 2.0 unit for the 116i.
PROBLEMS, PROBLEMS
The N-Series unit has a catalogue of potential troubles, with the later N43 being by far the worst. Frequent oil
changes can help, but while the N42 and N46 can be kept plodding on, the N43 really is a disaster area.
TIMING CHAIN this and the stray bits will block the oil
pick-up and the engine will seize. If the
Use a 16mm socket on a breaker bar
and see if the Vanos units can be
X Chain issues are infamous. The links
guides are all in one piece then you can moved in relation to the camshaft (they
wear, causing chain stretch, resulting
do it with the sump still attached by should be locked), because they’re
in the chain thrashing against the rails
avoiding turning the oil pump chain and scrap if they do. With the timing chain
and eventually breaking them. Look into
thus disturbing the balance shafts. A tensioner plunger removed and the
the oil filler cap and if the guides are a
new chain kit from Febi Bilstein with new crank and cams timed up and locked in
dark brown or burnt orange colour (they
cam/crank bolts (you cannot reuse the place, it’s simple enough to fit a new or
were ivory coloured when new) then
old ones – they are stretch bolts) costs secondhand Vanos unit, but you must
they will be brittle and need changing.
around £120, but be careful with cheap fit a new bolt. Vanos units are the same
Replacing the chain isn’t difficult, but
locking tool kits as they can require for N42, N46 and N45 engines, as is the
involves locking tools and a ¾-inch
work with a file or a grinder to get them chain assembly; N43 ones are different.
breaker bar and socket to get the
to fit. For some reason N43 chain guides
300Nm crank bolt undone. It requires a
clean working area (not out in the road)
don’t last as long and we’ve heard of
them failing at as little as 30,000 miles.
VALVETRONIC
and patience – getting the locking pin X The eccentric shaft can wear on the
into the flywheel is very frustrating but tips of the lobes, affecting the amount
essential as you cannot time it up on VANOS of valve lift so that the engine misfires at
Top Dead Centre down a plughole. If the X Vanos units can fail, although N43 idle but smooths out over 1000rpm – if
guides have broken up, the sump needs ones are better. Bad ones can rattle the misfire reduces with the Valvetronic
to be dropped to get the bits out. Ignore and throw up cam timing fault codes. sensor unplugged, that’s the issue.
Here is an N42/45/46 timing tool set. Top Here we can see the reluctor plates and the
is the gold front locking bar and below that, The front locking tool located in situ. It has holes drilled in. When you remove the cam
on the right, are the black tools that lock the two dowels that lock into the small holes on cover and see this for the first time, the fact
back of the cam – my cheap set needed a the cam sensor reluctor plates fitted to the that the plates aren’t a mirror image of each
mod with a grinder! On the left are the crank front of the Vanos units. If these aren’t in the other makes you think the cam timing has
locking pin and chain tensioner. right place, cam sensor errors are unavoidable. jumped when it hasn’t.

This will cause an MOT fail on emissions. engine idling for two minutes before it down with the wishbones, but it’s
Unplugging the sensor can often scrape blipping the throttle. If a small cloud more involved on later cars. So do the
a pass, but repairing it is an involved of blue smoke issues from the tailpipe easy bits first, clean everything up and
job that is rarely worthwhile on a £500 then the engine hasn’t much of a future. maybe you’ll be lucky.
banger. The Valvetronic motors can fail Anything over 100,000 miles is prime
and, to be honest, are best replaced by for a bit of ring wear – not an issue
new units as they cost less than £100 on a £400 E46 winter hack, but not N43 DRAMAS
online. You will need proper diagnostics something you want on a £2500 car. X The N43 is notorious for running
to both reset the Valvetronic and Vanos faults and misfires. It’s not really BMW’s
adaptations, as well as to make sure it’s fault, as they were forced down the
the motor at fault and not the sensor. OIL LEAKS direct-injection route by emissions
Replacing the sensor requires extreme X The N-Series can really leak oil, laws and the bits that fail were made
care to avoid dropping the three 10mm particularly the N42, N45 and N46. by other companies. The original Piezo
bolts into the engine. The main leak points are the plastic injectors are dire and should have been
cam cover’s rubber gasket, the oil filter replaced by new ones by now – look
housing’s rubber seals, the vacuum to pay around £170 each, but forget
HEAD GASKET pump O-ring where it bolts to the head, used ones and remember that they
X Beware coolant leaks from the back the dipstick tube O-ring and the rubber will need coding to the car. Coil packs
of the head gasket. You might think it’s Vanos solenoid O-rings. By 100,000 were another problem area and four
leaking from the plastic coolant elbow, but miles you’ll find that they have all been new Bosch ones at around £30 each is
Sod’s Law says it won’t be. Alloy corrosion baked hard and become brittle and the solution, unless you enjoy chasing
of the block around the bore liners will crack-prone. Replacing the whole lot misfires. Once you’ve fitted new coils
cause gasket leaks and pressurising, but – it’s not worth skimping – will cost you and injectors, you then have the NOX
forget about repairing it – a good used £50 in parts and you’ll need to degrease sensor, which can fail and make the car
engine is the only way to go. the engine and undertray before blasting run massively rich. It costs £434 from
it with a serious pressure washer. But it’ll BMW with no aftermarket alternative,
transform a car that marks its territory, and used ones are rare – would you
OIL BURNING as well as stinking of burnt oil. The really want one anyway? Thankfully, the three
X The N42, N45 and N46 can get nasty one is the sump gasket, which Lambda probes are pretty reliable.
smoky in old age. It’s a combination requires removal of the front subframe. N43 plus points? Well, they don’t
of deteriorating valve guide oil seals On the E46 it’s not so bad, as once the suffer piston ring wear like the older
(rare) and, more commonly, worn piston engine is supported on a brace, you units and oil leaks are less of an issue,
rings. The acid test is to leave a warm can unbolt the steering rack and drop but overall the N43 is worth avoiding.
This is the rear exhaust cam locked – the Here’s the exhaust camshaft position On these units, there are Vanos control
inlet one slides in first, then the one sensor. Both inlet and exhaust sensors are solenoids mounted on the front of the head
pictured above. The cams are locked, then the same part number, but N43 ones do not to control the flow and pressure of oil to the
the chain is pre-tensioned with the threaded interchange with those from the older N52 Vanos units. These need periodic removal
tool and, once set up, the Vanos bolts (six-cylinder), N45, N46 engines. As with the and cleaning, along with new O-rings to stop
tightened and the locks removed. crank sensor, avoid cheap aftermarket items. annoying engine oil leaks.
This is the Valvetronic motor, a 12V unit

that spins at great speed to open and close On the N42 unit, the Valvetronic system Here is the N46 engine in a 2007 320i. While
the Valvetronic shaft. These can fail but was operated by this separate ECU that sits technically improved, the N46 seems more
often hamfisted mechanics break off the outside of the ECU box. On N46 engines, this prone to oil leaks – it has been said that
end when disconnecting the plug. New was discontinued and VVT control handled they run hotter for emissions and the rubber
aftermarket ones are £80. by the main engine ECU. gaskets have a harder time.

W Here is a new and old
timing chain kit from an
E90 320i – same parts for
N42 and N45. When new,
the plastic guides are a
light ivory colour, but end
up a grotty dark brown or
orange, at which point
they must be replaced.
X Here is a typical
shattered chain guide. By
the time it’s a dark brown
colour it’s absolutely
finished and must be
replaced. It will be brittle
and break up too easily.
The sump must be removed
to clean up the debris.
This yellow arrow shows the position of the

Here is an early N42 as fitted to the E46. It’s Oil filter housing leaks are common, but crankshaft position sensor and why the
been said that the N42 suffered less from later engines suffer more from this because manifold has to come off. Above the starter
oil burning than the later engine – possibly the rubber gaskets get hot and become too is the wiring junction box and the crankcase
due to running cooler? Regular 7000-mile oil brittle to seal effectively. Replacing all of the ventilation system, secured to the inlet
changes are the key to a long life. gaskets is a good day’s work. manifold by two 10mm nuts.
OTHER ISSUES the two bolts that secure the base of replace it. With crank sensors, only
X The crank sensor is positioned under the manifold to the steady bracket (not use a genuine part or one from Febi, as
the inlet manifold by the starter, making it fitted to the N45) are a pain to undo cheap ones rarely work for long, if at all.
impossible to see, let alone change, until and replace. The crankcase breather Also, the brake vacuum pump can fail
the inlet manifold is removed. Removing assembly lives under the manifold and, (the servo won’t work) and it’s not so
the manifold is not that bad, although if the engine uses oil, you might as well easy to replace.
CASE STUDY N42 NON-START

X We recently had a 2002 318Ci that wouldn’t start. It would
almost fire up, but it couldn’t quite manage it. The car had
been standing for some months following a non-start and the
garage couldn’t seem to fix it. A new crank sensor had been
fitted, which at least got the car to attempt starting, but didn’t
resolve the situation. Without a diagnostic reader to at least
drag up some fault codes, this was going to be a struggle.
A good battery is a start, so the engine can spin over good
and fast – if the battery is only average, it’ll never start. The For this, we held the throttle body plate open with a screwdriver
cam cover was removed to check the camshaft timing with handle to get some clean air and dry out the plugs and bores.
the locking toolkit, and although the chain and guides were A good five-second shot of Bradex Easy Start down the intake
original and due for replacement, the timing was near enough got it to run for a few seconds. Then, with the fuel pump fuse
and certainly good enough to start. refitted, it coughed into life and ran, albeit not very well. So the
Next, the plugs were replaced, but still no joy. Given that engine was switched off, restarted and the previously glowing
there was fuel at the injectors (you could smell it from the EML light went out and it sounded much better.
exhaust) and there was a miserable spark, attention was
turned to the crank sensor.
BMW handily buried this at the back of the block in such a The causes?
way that the inlet manifold needs to come off. Not too difficult, A Lucas crank sensor that just didn’t work properly (only ever use
albeit not very pleasant. A known good working sensor was a genuine BMW part), worn plugs and flooding. We later found
fitted, the car reassembled and tried again. This time it really out that an incorrect exhaust cam sensor was fitted, so with a
was trying to start, but just seemed to get bogged down. pair of good used ones fitted and the fault codes cleared (plus
We pulled out the fuel pump fuse and cleared its throat a bit. Valvetronic adaptions reset) it was running much, much better.

MGF & TF SRS TROUBLES
SRS trouble on
the MGF & TF
Rob Hawkins explains how to fix the
TOOLS
common seatbelt and airbag problems
X Breaker bar X Stereo removal
that can arise on the MGF and TF. X Ratchet: ½inch tools
X Spanners/ X Torque wrench
I
f the warning light for the At the heart of the SRS is a control unit,
supplemental restraint system which has been known to fail, although sockets: X Torx: T27, T30,
(SRS) illuminates on the dashboard not as frequently as the coupling and 10, 13 & 19mm T50
of an MGF or TF, there are a number seatbelt tensioners. The unit is hidden X Thread lock X Trim tools
of problems that could have arisen. away behind the centre console.
The components that make up the SRS Identifying the cause of an SRS fault is
include the seatbelt tensioners, where the possible with diagnostic equipment, but
wiring can get trapped or disturbed by the when we tried to pinpoint such a problem REPLACING
seat, especially if it’s moved forwards and
backwards repeatedly. Sometimes, the
on a 1996 MGF, there were no fault codes
logged for this system, so we had to rely on
AN AIRBAG &
SRS light only appears when the seat is in a process of elimination. Consequently, SRS COUPLING
a certain position, suggesting its wiring MGFnTF Bitz sell a used SRS pack
is damaged. If the seatbelt tensioner has for £20, which includes a control unit,
failed, they are straightforward to test seatbelt tensioners and an SRS coupling
and just as easy to replace. to help identify and fix the problem.
Another component that causes Disconnect the battery and leave it for
issues is a coupling that sits behind the at least 15 minutes before starting the
steering wheel. It provides the wiring job, to help keep static electricity away
for the airbag and can get worn over from wiring plug connectors.
time through use of the steering wheel.
If the horn doesn’t work, it’s likely the THANKS TO
coupling has failed. MGFnTF Bitz 01457 238202
According to marque specialists Website MGFnTFBITZ.co.uk
MGFnTF Bitz, the coupling is designed Email [email protected]
to last for 5-10 years, and while
New SRS coupling £35 Check the steering wheel is exactly
secondhand couplings can be bought for 1 central. This will make it easier to
£10-£12, a new one only costs £35 from Used seatbelt tensioner £5
remove, renew the coupling and reassemble
them. Steering wheel airbags appear to Used SRS control unit £5 everything. Disconnect the battery,
be a little more robust, so used ones are Used airbag £5 detaching the negative lead from the
plentiful and cost just £5. terminal, then leave it for 15 minutes.
Renewing a
seatbelt tensioner
X First, disconnect the battery and leave
it for 15 minutes before undoing any
plugs. Reach underneath the seat and
locate the connector plug for the seatbelt
tensioner, then disconnect it and plug in
another one. Reconnect the battery and
see if the replacement tensioner extinguishes the SRS light on the dashboard.
On MGFs and TFs with a square key-fob (pre-53-plate models), the tensioner’s plug
connector should be red. Later models with a round key-fob have a yellow connector.
Renewing a seatbelt tensioner requires the seat to be removed, by undoing the
four Torx T50 bolts holding it in place. The seatbelt tensioner is held to the side of First, the airbag has to be removed. It
the seat with a single Torx T50 bolt. Do not undo the bolt that holds the tensioner 2 is secured by two Torx T27 bolts. These
and seatbelt socket to the mounting bracket. bolts are accessed from behind the steering
When refitting the bolt with a replacement tensioner, apply a little thread lock. wheel and will require a reasonably long T27
tool to reach and undo them.

MGF & TF SRS TROUBLES
SRS control unit
Carefully prise off the airbag from the Grip the steering wheel and use a 19mm
3 steering wheel, then detach the yellow 4 socket with a long ratchet or breaker
plug from it (note how it is fitted). The airbag bar to undo the centre nut. This should be
can now be removed and stored safely or tightened to 50-63Nm, so it may need a sharp
replaced. From inside the steering wheel, jolt at first to help shock and slacken it. Ask a
disconnect the plug with red wires for the horn. helper to hold the steering wheel if necessary.
X If the SRS control unit has to be
replaced, disconnect the battery
and leave it for 15 minutes before
undoing any wiring plugs. The front
of the centre console needs to be
detached to access the SRS control
unit, so this may mean the radio
has to be removed. Lever out the
lower switch panel using a trim tool,
then disconnect all the electrical
plugs behind it. Prise off the front
of the centre console with a plastic
trim tool, unscrew the gearknob
and detach the gearstick surround.
Carefully remove the steering wheel, Dismantle and remove the plastic
5 pulling it forwards to slide it off the 6 cowling around the steering column.
You should now be able to
splines on the end of the steering column. It consists of two halves and may have a access the three Torx T30
Take care not to damage the wiring, especially few securing screws keeping them together, mounting bolts for the control unit.
the red and black wires for the horn. along with some plastic clips.
Undo the four crosshead screws that The coupling can now be detached
7 secure the SRS coupling to the stalk Two wiring plugs are connected to the 9 from the end of the steering column.
switch assembly. The coupling will now feel
8 top of the coupling. Look for a release Pull it forwards to release and remove it.
loose, but it cannot be removed yet because tab on the top of each plug, push it in, then Note how the coupling is fitted with the plug
it’s still attached by its wiring. It will be ease the plug out of the coupling’s socket. connector at the top and the four holes for
removed in Step 9. Handle these electrical plugs with care. the mounting screws.
Compare the old coupling with the Fit the new coupling over the end of Refit the wheel, tightening the nut to
10 replacement you intend to fit. Check 11 the steering column. Replace the four 12 50Nm on pre-2000 MGFs and 63Nm
the wiring and plug sockets are the same. crosshead screws, attach the two wiring plugs on MY2000 and later models. Reconnect the
Do not rotate the inner ring of the new or at the top, then remove the plastic blue tag (if horn. Carefully refit the airbag, making sure the
replacement coupling or remove the plastic fitted). The blue tag will have to be snapped yellow plug is in the correct position. Reconnect
blue tag (if fitted) that prevents it moving. off, leaving a small piece of it remaining. the battery and switch on the ignition.

Your Letters
Your letters should
be addressed to
Martyn Knowles,
Car Mechanics,
Bauer Consumer Media Ltd,
Media House, Lynchwood,
Peterborough PE2 6EA
Email: martyn.knowles@
PROJECT PRAISE bauermedia.co.uk
Please include a postal
X My eyes lit up when I saw the new Insignia
address with letters
project in CM (February 2018 and onwards).
submitted by email.
I currently have a 2011 2.0 SRI CDTi hatchback in
the same colour as your project. This is my second
Insignia in 12 months – my first one came to a
nasty end two months ago, when a Volkswagen CHOCS AWAY
Golf hit it at 50mph from the rear. My current X Reading Dave Taylor’s CM
one is on 99,000 miles and runs great. However, Insider feature in the January
not everyone enjoys their car as much as me. 2018 issue, I couldn’t help but
As mentioned in your Editorial, engine chuckle after seeing you can
seizure is common on the 2.0 CDTi. Many fellow buy a chocolate toolkit online.
members of the Vauxhall Insignia Owners Group biggest talking points among members of the A while back, my wife covertly
and Vauxhall Insignia Misfits believe this problem owner groups is the dreaded DPF. Knowing how ‘stole’ a selection of my tools
is a result of interrupted DPF regenerations. If to spot a DPF regeneration is essential: 1000rpm one evening and made gel
you turn the engine off mid-regen, it’ll dump idle speed and a fuel consumption of 0.4 on the moulds from them to make
excess diesel into the sump and with 20,000 instant mpg screen, although you may not notice chocolate tools for my birthday
service intervals that diesel could be in the sump this at motorway speeds. You might consider cake. You can see her cake in
for many miles. Over time, this eats away at a fitting an LED to alert you of a DPF regen. the photo below. My wife even
small inexpensive seal on the oil pick-up pipe, Dave Hughes used edible paint to colour
causing a loss of oil pressure. Some owners get the tools and put grubby
the ‘oil pressure low’ message on the dash on X Glad to see you have a Vauxhall Insignia as fingermarks on the pliers!
the first cold start of the day, but ignore it as the your new project car. I own a 2010 model, but in Peter Clayton
it clears itself after a few seconds. That is the SRI trim and without the ecoFLEX engine. To be
first sign that the seal is letting go. Unfortunately, honest, there’s not a great difference between
the seal is not easy to replace on some vehicles, the two engines, although you have a final drive
requiring the gearbox to be split from the block ratio of 3.09 whereas my SRI has a ratio of 3.55.
to get access to two sump bolts, whereas in The 18-inch wheels with 245/45 R 18 tyres
some vehicles you can access the bolts by were standard for the Elite and 19-inch wheels
turning the engine over to reveal two slots in the with 245/40 R 19 tyres were an option. I don’t
flywheel. This might be worth covering in your think the stop-start was introduced into the
project as it could save the engine (Hopefully, Insignia until 2012. The overfilled sump may have
this will be covered in the next issue – Ed.) been a way to disguise the fact that the oil pick-
Other common faults are leaking EGR coolers up pipe seal has failed, increasing the level of the
– a replacement costs £40 from Vauxhall and oil above the seal to stop it sucking in air. Parking
takes about 1.5 hours to replace. Glow plugs on a slope may be enough to uncover the seal
can also cause issues – some are only a few again and allow air to be pulled into the pump.
quid to replace, but some are sensor units and
can cost £80 or more each. Discs and pads
The Elite is a lot of car for the money, but
the model can be a bit flaky at high mileages.
BEST
can cause some confusion – as a rule, manual
hatchbacks have the smaller 296 and 292 discs,
Thankfully mine has not suffered any serious
faults, except for needing a MAP sensor and
ADVICE?
X In his response to a reader
while automatic hatchbacks and most estates EGR clean about once a year, but then it only
query (‘Advice after collision’,
(manual or auto) have the bigger discs and the has 27,000 miles on it.
Help!, October 2017), I’m
rears are vented on some models. However, the Ray
surprised that Steve Rothwell
didn’t say that the reader
BRAKE DANCING should have reported the

accident to his insurance
X I had an MGB in my workshop recently with company, as in most Terms &
exactly the same problems as one of your Conditions there is a section
readers (Help!, October 2017). The brakes had saying that you must report
been serviced a few months previously – one “any incident which could
front caliper had been replaced, along with some result in a claim or not”. Plus,
metal brake pipes and the master cylinder when a policy is renewed, you
– but it still felt as if there was air in the system. are normally asked if you have
I bled the brakes in the normal way, then had any accidents.
pressure-bled them with Eezibleed, and even The other problem is what
reverse-bled them, all to no avail. I decided to would have happened if the
start from scratch with the rear brakes. It was replacement was not as good as the original other driver had no insurance?
only then that I discovered the handbrake cable (which he had kept). I asked for the original unit, It’s a legal minefield, because
was too tight and not fully releasing, so the slave fitted it and bled the brakes by normal method. if the driver did get any
cylinder never fully retracted. When I released Hey presto! Great brakes at last. compensation privately and
the handbrake cable, I was able to get quite a Incidentally, if the slave cylinder does not fully his insurance company found
few more notches on the adjuster. This helped retract, there is the possibility of air being left out, they could refuse to deal
quite a bit but was still not perfect. inside as the bleed nipple is at the bottom instead with it. The best advice would
Unlike your reader, the owner of the car of the top. Whoever designed this obviously be to report it and keep his
I was working on had changed the brake servo thought that brake fluid was lighter than air! fingers crossed.
as a precautionary measure and I suspect the Herbie Mitchell Peter Richardson

STAR
SALES DRIVE LETTER
X The popular press is constantly harping on
about low car sales, blaming the fall in sales on
environmentally-conscious buyers and the demand
for the latest technology in vehicles, etc. My view is
that this reasoning covers just a small proportion of
car buyers and that there are many other reasons
aside from cost affecting the current drop in sales,
especially among those of the older generation.
1) Scrappage schemes taking in cars that are anywhere from seven to 10 years old. Who on
earth is going to buy a car if the manufacturer gives the impression that it will potentially
be scrap in a few years? Any environmental improvement from the allegedly more efficient
STAR
engine will be outweighed by the environmental impact of manufacturing a brand-new car LETTER
every few years to replace a scrapper. The reader awarded the
2) Long-term unreliability of the most modern engines. Just look at the number of recent STAR letter will receive a
articles talking about the need to decoke inlet manifolds and the like after just a few tens SEALEY LED3601R lamp
of thousands of miles – and we are talking about four-stroke petrol engines here, not just X This Sealey 360° lamp can
dirty diesels or good old two-strokes – due mainly to direct-injection, seemingly required to illuminate your workspace no
meet emission regulations when the car is new, and the lack of a petrol/vapour wash of the matter where you are. It can
hang, attach and best of all, be
inlet components. Can anyone tell me that a modern engine that’s rapidly working its way set to any angle you need, from
towards this choked-up, coked-up state is any better for the environment than a flat-four any angle you want, thanks to
that’s still sweetly running after 15 years? its unique 360° rotating ball
3) Too much technology I don’t need or want, such as an integrated infotainment system, feature in the base.
parallel parking aids or a multitude of cameras and sensors, some of which will undoubtedly X The Sealey LED3601R is a mini
fail after a few years. One of my neighbours was quoted well over £200 to update his Audi and lightweight lamp with 2W
COB LEDs, which emit a purer
sat-nav system to cover the three years since he bought the car new. He politely declined. source of light compared to
Short-term fashionability and long-term environmental labels have been latched onto by the other LEDs. One single light
car industry and politicians, I suspect to support the economics of this particular industry at source means one shadow,
the expense of consumers. I just hope some common sense and practicality returns before unlike multiple SMD lights.
I need to buy my next car!
Colin Rienewerf
REVERSE ENGINEERING
X I read the letter entitled ‘Reversing sensors’
(Help!, October 2017) with interest. I have
would have meant inserting a wire in the flexible
rubber tube connecting the hatch to the body. In VISCOUS
installed a similar kit on several Vauxhall Corsas
– a 12-plate, 14-plate and 17-plate. I chose a
addition, Vauxhall had colour-coded all the wires
in the hatch as black. After a bit of exploration, CIRCLE
location for the sensor by looking at a factory- I located a connector behind the plastic panel on X I want to share something
fitted system on a car in a car park. the nearside of the car, on the C-post level with the I discovered about the oil
With the 12- and 14-plate, I placed the control top of the back seat. At this point Vauxhall changed viscosity in the 1.33-litre
unit behind the plastic surround at the offside back to normal coloured wiring and I could identify engine in my Toyota Yaris.
of the boot and connected a feed from the the feed to the reversing light, so once again I bought the car new from Hills
reversing light, putting a fuse in the feed. I fed I fed the control unit via a fuse behind one of the of Woodford, along with some
the cables from the sensors to the control unit plastic panels in the boot. All the subsequent Toyota top-up oil, which was
through the vents behind the bumper after wiring was as in the 12- and 14-plate cars. 5W-30 fully-synthetic. After
protecting them against sharp corners. The Before I installed the kit in the 17-plate car, a the first service, I queried
cables did not cause problems with either the friend suggested I fit a reversing camera instead why it had been serviced with
ventilation or road noise pick-up. The cable to the of sensors. I tried this, but found the display Toyota 0W-20 fully-synthetic
display was hidden behind the plastic trim on the that clips on the interior mirror to be useless rather than the 5W-30 that had
driver’s side of the floor until I could run it up the because the reflected daylight from the rear been recommended when I
trim on the inside of the A-post. The display was window makes it impossible to see the image bought the car a year before. All
then mounted with double-sided tape. clearly. At night, it worked OK. So if you want to I was told was that Toyota had
The 17-plate had the new body style, so it was fit a reversing camera, perhaps a dash-mounted changed the specification.
trickier to find a feed to the reversing light as display might be better. Last year, I took over
Vauxhall had put the light on the hatch, which Paul servicing the car myself and
went to another Toyota dealer
for engine oil, only to be
ROAD RAGE supplied with Toyota 5W-30,

which I queried with the dealer.
X I wholeheartedly agree with your readers regarding ‘smart’ A passing Toyota mechanic
motorways (‘Motorway Madness’, Your Letters, November overheard my query and asked
2017). The western bypass in Newcastle was ‘upgraded’, what I had been using. I said
resulting in more than two years of misery, jams and delays; Toyota 0W-20 and he confirmed
the project also overran. Now it is finally open and, thanks to that it was the correct oil for
a 50mph limit, there has been no improvement in transit times – if anything, they’ve got worse! that engine. I queried why
Meanwhile, the much vaunted A1M improvements are more than six months late and we have only it had changed and he said
just seen the speed limits removed from the 15-mile section of the road that has been finished for a that it was because Toyota
year. However, a part of this has now been restricted again while the ‘new’ carriageway is repaired. mechanics had been having to
On the subject of road repairs and potholes, these days any holes are patched, but the joint between change the pistons regularly
new and old is not sealed with bitumen. As a result, you end up with a larger pothole and another repair on engines run on 5W-30 due
job in very short order. I’d be interested in what the road repairers’ trade body thinks of this technique. to excessive carbon build-up.
Ed Dinning Ian Wallace

Dealer’s Diary
Our man in the trade, Steven Ward, comes across
a nightmare Range Rover and the car of his dreams.
Gone beyond
X My Land Rover specialist has had just
about enough of the new models. They’re
so complex to fix, he’s struggling to make
money on the troubleshooting. This
explained why he charged me £5500
to stop a Range Rover TDV8 going into
‘limp-home’ mode – that bill was for
two turbos and two EGRs. However, the
problem isn’t so much the big stuff as
things like the warning lights.
Now my specialist is a former auto
engineer, as opposed to a mechanic. But
he’s got a terrific mechanic as well, so
together they’ve got brains and common
sense. They’d taken on an Evoque
from a used car outfit that had its auto ‘The Evoque fix worked for just under two miles’
transmission failure warning light
illuminated; the car drove fine otherwise. correctly calibrated, the fix worked for one was ordered and fitted, which
Before the Evoque was booked in, just under two miles. finally fixed the problem.
they’d spent around five hours reading up Days had now been spent on this and In an effort to save some money,
on the possible causes for the fault code patience was wearing thin. Defeat was my specialist then asked if the old
logged by the ECU. The specialist has the admitted and it was sent to the local dealer. parts could be refitted to the car. After
Land Rover diagnostic kit – SDD, I think The local dealer also had a game with it. another two hours, they realised that
it’s called – that costs a fortune to license. He decided it also needed a new electronic they couldn’t refit and recode them
It was eventually decided the Evoque handbrake ECU, which was supplied and – the failed battery had spiked them.
needed a new transmission control coded. This fix lasted just a few miles. All in, and if you ignore the time my
module, so one was ordered. It made The dealer went to Land Rover specialist had spent on diagnostics and
no difference. After more hours poring Technical for help. Together they the like, the total bill was more than
over the diagnostics kit, it was decided realised that a small auxiliary battery £2800 on parts and LR dealer labour.
it also needed a position sensor for the buried deep within the dashboard must For these reasons, the trade is starting
shift mechanism in the cabin, so one have failed. Nobody knew about this to run a mile from new LRs. I’ll not even
was bought, fitted and coded-in. Once battery and it couldn’t be tested. A new get into the new Disco 5 and its issues…
Rolls over
covered 71,000 with eight RR
stamps in the service book.
It was in good nick, although
X It was supposedly a dealer part-ex I did find some cosmetic faults,
sale – an end-of-the-week sub-£2000 meaning the top book of £95,500
wash-up of swappers, finance repos was too salty for me. Bottom
and anything that had failed to sell book was £79,900. The fact it
earlier in the week. Not really the place had six registered keepers was
to bid on The Best Car In The World. also off-putting.
Why then was I standing in front But hey! Who am I kidding?
of a dark blue Rolls-Royce Phantom, The car was mortgage money to
a car more locomotive than lithe in me and, I dare say, to the trader
styling? Despite its discreet colour, standing next to me. So why
it still looked like a prop from The He had a valid point. Why on was I even taking note of its faults and
League of Extraordinary Gentlemen. earth would somebody with such a bits of missing trim?
The trader next to me muttered: magnificent car choose to sell it to The Phantom entered the hall
“What do you think they paid for that an online company which specialises quite majestically. The auctioneer
to make the gamble worthwhile?” in cash purchases? This particular had asked for £83,000 to get the ball
It was a question I’d not considered. establishment advertises via boards rolling. Reserve was set at £84,000
I was just taking in the details and its cable-tied to lamp posts. This – mid-book, I later found out.
incongruous presence at the sale. Phantom was on an 07-plate and had It failed to elicit a single bid.

Dealer’s Diary
New Romantic ‘Nobody else was going

to buy this car, so I gave
myself £3000’
The whole underbonnet area was
clean – not from steam blasting, but
from an easy, well-cared-for life.
Back inside, all the warning lights
illuminated as I hit the START button
and the car whirred and burst into life
– gloriously so. All the warning lights
extinguished and I could see there was
more than half-a-tank of fuel. This, dear
reader, usually signifies a car which has
been maintained regardless of cost.
Mileage was 74,361 and there were
eight service stamps. The car was
pre-reg plus one owner. Top book was
X It’s not often that I leave an auction nor the thinly-spoked alloys shod £3635, but this was late December
hall mournful for having missed out on with new Toyo tyres. There was a full and it was sub-zero outside. Nobody
a bid, but here I am, three weeks later, panoramic roof to contrast with the is going to buy this, I thought. So
still bitterly regretting my tightness. unusual Spandau Ballet hue. I gave myself £3000.
The car that’s got me despising myself Inside, the Alcantara was in black After a few slow bids, the hammer
for being a hard-nosed trader is, fairly with grey leather inserts and genuine gently fell at £3200. Not even mid-
predictably, an Alfa Romeo. floor mats, all as smart as the day they book and sadly not to me. There was
It’s rare to see a Brera in an auction left the factory. I settled myself in. The a representative of the dealer group
hall and I’d never seen one in metallic driving position adjusted spot-on – on the rostrum beside the auctioneer.
gold ever. So here I was, staring most un-Alfa like. I could see myself I suspect he feared the sale was
directly at the most beautiful car I’d in this, I really could. The clutch was going poorly, so he instructed the
seen for a very, very long time. light, the handbook pack was all there, auctioneer to sell it outright after he’d
The Alfa was a part-ex into the the reverse sensors worked. announced the provisional status of
Eastern Western Motor Group, so Before I hit the starter button, the bid – quite unusual.
straight away I knew it was likely to be I popped the bonnet to check under I’d gambled and lost and I’m gutted.
genuine. Indeed, the reg plates, rear there before disturbing the fluids. The It’s now for sale at a specialist for
window sticker and keyring all bore oil was clean and on the ‘Max’ mark, a smidgen under £6000. It’s not
the logo of the supplying Alfa dealer. likewise the coolant and brake fluid. outrageous money when you compare
Under the harsh white lighting of This was the 2.2, so it had a red rocker it to what else is out there. That’s a
the hall, I couldn’t fault the paintwork, cover, which was spotless and shiny. great margin on a great car.
happy people sell and happy people buy.
Steady on!
X It was an evening sale just before
The advent of internet bidding has, for
the most part, stemmed the flow of the
colourful phrases, dialect and banter
that were once part of the auctioneer’s
Christmas and nothing much was arsenal. The style, choice of words
happening. The public weren’t milling and even the tone of the auctioneer
around, for it was -2°C out in the yard. has changed to suit the anonymous
There were no internet bids flashing on the watcher and distant click-bidder. It’s all
monitors – I expect Amazon had replaced homogenous and exceptionally dull now
Auctionview in the nation’s web browsers. as the assembled audience can no longer
The Trade, weary from a difficult year, be exclusively captivated.
weren’t hedging bets by buying before No longer can a Skoda be routinely It was quite routinely described by the
Christmas. They therefore weren’t in referred to as a ‘Whisky & Soda’. No auctioneer as “A tidy thing…” As such,
anticipation of a strong start to the New longer can the auctioneer blatantly take I took no real notice. But I was then
Year. That’s significant in the scheme of the mickey out of those standing below tickled to hear the auctioneer follow this
things, but not relevant to this story. the rostrum or give nicknames to the with “…a bit like the driver”.
No, my story today revolves around regulars who bid in the shadows. The I did a double-take and saw the
the auctioneer and a rare lively moment internet buyer doesn’t get the joke and auctioneer give a cheeky wink to the
in an otherwise quiet sale. is distracted rather than amused. jockey. What was going on? These drivers
Back in the good old days, the Sobriety is the new flamboyancy. are miserable felons at the best of times.
auctioneer was the star turn in any sale Tonight, though, there was a rare I discreetly edged over to the misfiring 206
and their level of charisma and colourful moment of old-fashioned spontaneity to see a blonde driver behind the wheel.
patter encouraged bids. Remember, when a Peugeot 206 entered the ring. She was indeed fairly described as ‘tidy.’

: NISSAN QASHQAI
Used Car Focus
Worth
2007-2014
the Qash?
Nissan’s first crossover model was also one of
its most successful, with more than two million
sold in Europe, Japan, Australia and the US.
It’s a hugely popular secondhand choice. Rob
Bradshaw explains how to get the best deal.
W
hen it was first shown at 128bhp and 2.0 147bhp units, offered as
the 2006 Paris Motor Show, both two- and four-wheel drive.
the Qashqai was quite Interestingly, the Qashqai actually
a departure for Nissan. had less boot space than the Almera
Replacing both the Almera and the it replaced, but featured a number of
Almera Tino MPV, the newcomer was the hidden and clever storage areas, such
brand’s first so-called crossover model. as a secret cubby box beneath the main
It was also the first Nissan to be one in the armrest and, on some models,
fully designed, engineered and built in a modular boot floor with a separate
the UK, with most of the styling work compartment beneath.
carried out at the company’s design
studio in Paddington, the engineering
at the Nissan Technical Centre Europe More seats option
in Cranfield, Bedfordhsire, and the In 2008, Nissan extended the range
manufacturing at the company’s plant in further with the Qashqai+2. As the name
Washington, Tyne and Wear. suggests, this was a seven-seater, although
From the outset, it was a huge success. legroom in the rear was extremely
Keenly priced, well laid out and decent to cramped and only really suitable for
drive, it was the vehicle that kickstarted children. For most Qashqai buyers, that
a revolution in the new car market, was who would be sitting in them, so
with buyers abandoning traditional they serve a purpose.
five-door hatchbacks in pursuit of ever In terms of trim levels, the range
more lifestyle-based niches. kicked off with the Visia, which was
Three engines were offered at launch. pretty well catered for with aircon,
A 1.6 petrol with 115bhp and a 2.0-litre four electric windows, a trip computer, Production line at the Tyne and Wear plant.
with 138bhp, along with a 1.5-litre dCi Bluetooth, six airbags, alloy wheels
diesel, sourced from Renault. Both and a CD stereo. The door mirrors,
petrol models could be ordered with a handles and front grille were finished in
CVT automatic gearbox. With 109bhp, unpainted black plastic to remind you
the diesel was only good for steady that it was the base model, but it’s not a
progress, but was soon supplemented by bad package and is more generous than
a new family of engines developed in 1.6 most European rivals.
Specifications
Engine Power Average MPG 0-60mph Top speed CO2
1.6 petrol 115bhp 45mpg 11.5sec 113mph 144g/km
2.0 petrol 138bhp 36mpg 9.8sec 121mph 184g/km
1.5 diesel 108bhp 57mpg 12.3sec 110mph 129g/km

Used Car Focus Nissan Qashqai
Bodywork
X All Qashqais were sold with a
12-year anti-perforation warranty,
so any external corrosion other than
that caused by accident damage
should have been repaired under
warranty, if it has appeared at all.
However, Nissans don’t have the
best reputation for rust, and the
Qashqai, sadly, seems to be afflicted
by underbody corrosion, with
several reports of 2007 and 2008
models requiring welding to the
front subframe at MOT time.
The problem is engine-specific,
too. The 1.6- and 2.0-litre
diesels have bigger underbody
splashguards, which seem to protect
the vulnerable areas far better. The
problem is usually apparent around
the bulkhead, where the rear part of
the front subframe is mounted to
the bodyshell. It seems that there’s
a moisture trap here that’s worse on
petrol and 1.5 dCi models, causing
the subframe to rot from the top
downwards. When inspecting one,
shine a torch into the engine bay
behind the block and inspect for
advanced corrosion on the top part
of the subframe.
If you can be sure to find a solid
subframe, the best option is to clear
off any surface corrosion and drown
the area with rustproofing wax.
Otherwise, reports of body
problems are few and far between,
though some owners have reported
leaking tailgates. The problem here
is that the seals are easily damaged
Engine choice 1.6 petrol unit.

during loading and unloading. A
new seal – a 20-minute DIY fix
– normally resolves the problem.
X While the Qashqai is actually one of the better
cars in its class for reliability, there is still a
number of common faults you need to be aware
of. By far the most serious is occasional oil pump
failure on the 1.6- and 2.0-litre diesels. While it’s
not guaranteed to happen, you’re advised to not
drive the car as soon as you see the oil warning
lamp. A number of owners have discovered, after
driving their cars to the dealership for a diagnosis,
that it was the drive there with no oil circulating
that caused most of the engine damage.
Another common fault, which only tends to
affect pre-2008 cars, is related to the engine
stalling at random. This is due to a problem with
the aircon compressor, which can seize and cause
the drivetrain to jolt to a halt. If turning the aircon off stops Finally, 1.5 dCi diesels are prone to leaks from the diesel
it from happening, then you need a new compressor. injectors. This can occasionally be remedied by taking
The 1.6 and 2.0 diesels are among the best of the bunch them out, carefully cleaning the thread and where they sit
for reliability as far as modern diesels are concerned, in the block, and refitting them, though this will most likely
although they do need to be run on long journeys at least only be a temporary fix.
once a week to avoid a build-up of soot in the particulate If you have a Qashqai that simply refuses to turn over,
filter, which can lead to the engine going into ‘limp-home’ let alone start, this is more often than not a fault with the
mode. They do have another common fault that has ignition key. If these get wet or overheat, the transponders
similar symptoms to a DPF issue, though, which is caused can drop the signal. Try the spare and, if that works, you
by splits in the turbo hoses, leading to air escaping. When need to get your key fixed. Most high street key-cutters
it does, the power drops off quickly and the engine goes can do this, but you may then need to code it using
into ‘limp-home’ mode. diagnostic equipment, or else use an auto-locksmith.

Used Car Focus Nissan Qashqai
Valuations
X Such is the popularity of the Qashqai, resale values
are ridiculously steep. Unless you’re looking at a
particularly shabby or high-mileage example – and
they do exist – prices for well-maintained 2007 cars
are still upwards of £3000-£3500. You can spend less
on numerous 10-year-old cars that serve as perfectly
functional family vehicles, such as a Vauxhall Zafira or
Citroën C4 Picasso, but they don’t have the suburban
driveway appeal of the Qashqai. In many ways, the
Nissan has become the default choice of family car, as warranty period, but these are the market prices.
well as being the one that really sets the trend in the In terms of which model to go for, none is a bad choice,
burgeoning crossover market. with even the base model Visia having quite a few toys on
If you have around £6000 to spend, this covers the bulk board. That said, the Tekna is brilliantly well-equipped and,
of the used market and will get you a good 2010-2011 car, allowing for depreciation, either this or the n-tec+ make the
which is probably a better choice. Forewarned about the most sense today if you’re prepared to spend a couple of
potential for future corrosion, you can apply preventive hundred quid more than you would on a Visia or Acenta.
maintenance rather than end up with an expensive repair. Whichever one you go for, it should retain its value better
Top-end values are still north of £10,000, which is quite than most similar cars. The only real downside is that you
a lot to pay for a non-premium car that has come out of its will have had to pay more for it in the first place.
Next up was the Acenta, which got This sat between the Acenta and Tekna at a strange angle. You’ll still be able to
17-inch wheels in preference to the Visia’s and was style-focused, with 18-inch close the window if you’re the kind of
16-inchers, along with cruise control, alloys, a panoramic glass roof, satin silver frugal motorist who wants to wear it out
auto headlights and wipers, dual-zone roof rails and a standard-fit sat-nav, completely before replacing it, but you’ll
climate control, front fog-lamps, a CD along with a reversing camera. It quickly need to guide in the glass with your hand.
changer and a leather steering wheel and replaced the Acenta as the best-seller. Replacement is obviously the best
gearknob. There was also the option of a Nissan replaced the n-tec+ for the final course of action, but the problem is so
panoramic glass roof. Acenta was initially year of production with the 360 Edition, common that good used regulators are
the best-selling trim level in the UK. named after its pioneering Around View few and far between, meaning you’ll need
Tekna models added leather seats, camera system, which gave a birds-eye to pay £200 to get one from a Nissan
xenon headlamps, ‘intelligent key’ view of the car to help with manoeuvring dealer, unless you get lucky and find
automatic unlocking, larger alloy wheels in and out of tight parking spaces, along a low-mileage accident-damaged car
and a panoramic glass roof. In April with front and rear reversing cameras. at a breakers. The job is also tricky, as
2009, the Tekna trim was upgraded Other than piano black trim highlights you need to strip the door, which also
with more leather, heated front seats on the dashboard, the equipment was means taking out the window and mirror
and keyless entry and start. essentially the same as that of the n-tec+. controls before carefully removing the
The first Qashqai special edition, door trim, which is a very large moulding.
aimed squarely at retail buyers, came Another common problem is the
along in 2008. Called the Sound & Style, Interior Qashqai rattle, reported by many
it was only available with a choice of One of the most common faults with owners on the excellent Qashqai Forums
2.0-litre engines, either diesel or petrol, older Qashqais relates to ‘stuttering’ (www.qashqaiforums.co.uk). It
and was finished in a unique dark purple electric windows, which go up and down emanates from the rear of the cabin and
paint colour. Based on the Tekna, it with a jerky motion. This is caused by tends to occur if the rear seats have been
gained 18-inch alloy wheels, red-stitched worn joints in the regulators, which get folded flat to accommodate large loads.
part-leather trim, alloy pedals and a Bose slack and work loose. If left unrepaired, The cause is believed to be wear to the
premium audio system. the regulator will eventually break at clips that hold the seat base in place, which
In 2009, Nissan launched the n-tec+. one end, causing the window to go up makes the base itself rattle at low revs.

Verdict
X There’s a reason why the
Qashqai is such a popular car, and
even today the oldest examples
are still very much in demand.
That means there are other family
cars out there that you can buy for
less, but bear in mind that even
older Qashqais will hold their value
reasonably well.
Mechanically, they’re generally
pretty robust, and with many
modern cars becoming a
technological nightmare as they
get older, that can only be a good
thing. However, we do have our
reservations due to reports of
subframe corrosion, especially
on the back of Nissan’s highly
publicised recall of Navara pick-
If the steering feels at all slack or ups, which has led to many vehicles
Running gear seems to need turning too far, there under 10 years old being bought
The scourge of the modern diesel affects could be a problem with the steering back with fractured chassis legs.
the Qashqai as badly as – but no worse column. Wear at the pinion end of the It’ll be interesting to see if, three or
than – others. Listen for a light metallic steering column has been reported in a four years from now, older Qashqais
rattling when engaging and disengaging few cases, with an unusual steering feel start to disappear from UK roads.
the clutch. This is the first sign of wear being the most common cause. Luckily, In the meantime, they’re decent
to the dual mass flywheel, and the only the end of the column can be replaced family cars, extremely popular
way around the problem is an expensive from the universal joint downwards, and very practical. If those are
replacement. So don’t just pass the noise so you don’t need to extract the whole compelling enough reasons to buy
one, then you won’t go far wrong.
off as a slight rattle. thing, which would entail taking apart
A batch of early Qashqais were dashboards and airbags.
recalled due to a problem with the lower Qashqais also seem to eat rear shock bargaining point if viewing a car that
front suspension balljoints, which absorbers for breakfast, and Nissan was hasn’t had them replaced recently. The
were breaking free from the lower arm. once replacing them under warranty. front suspension bushes are also prone
The recall affects cars made between They’re no longer new enough for that, to wearing out, but unlike some cars
February and March 2007, so make sure though, so shocks need to be treated as they’re actually pretty easy to access.
the work has been carried out if you have a consumable that will need replacing Listen for clonking or light knocking
one of the affected vehicles. every 30,000 miles or so. Use it as a from the front end on rough surfaces.
Panoramic glass roof was fitted to Tekna and n-tec+ models.

Survival Guide
Ian Cushway searches out new and used parts prices
Toyota Ay
Small is beautiful, but does that mean
parts costs are similarly minor?
S
ize obviously matters for Aygo Reliability of this Czech-made
buyers, but when Toyota joined miniature is good overall, but during its
ranks with Peugeot and Citroën nine-year lifespan it was subject to three
to launch its new city car in recalls. The first was to resolve a well-
2005, its diminutive proportions weren’t documented sticking accelerator pedal
its only asset. The firm suspension and that affected all cars built to the end of
nippy 68bhp three-cylinder 1.0-litre August 2009. Another recall concerning
VVT-i engine made it fun to drive, it the rear axle was issued in 2013 for
could do 65mpg on a run, and it also cars made in July and August that year,
qualified for free road tax. Available as followed by one in 2015 regarding faulty
both a three- and five-door, a 1.4 HDi front shock absorbers. Chances are the
turbodiesel was added in January 2006, necessary work will have already been
but this was sluggish and barely more done, but it’s worth checking.
economical than the petrol model. It also Regarding price, the Aygo was cheap
incurred road tax of £20, so it didn’t sell new and is even more affordable now, Most components for the Czech-made Aygo
well. There was also a MMT (Multimode with the cheapest we’ve seen advertised are shared with the Citroën C1 and Peugeot
Manual Transmission) auto, but this was at just £1000. The only tiny question 107. Reliability is generally good.
also disliked and is therefore rare today. mark hanging over what’s otherwise
In 2012, the Aygo received a front end considered a brilliant little car regards
makeover, as well as an improved interior build quality, because despite scooping and the occasional electrical gremlin.
with extra equipment. There was another numerous accolades in reliability As far as parts prices go, Toyota remains
revision in August 2013 before it was surveys, early examples are prone to competitive, but as always it pays to shop
replaced by the Mk2 in 2014. premature clutch failure, water leaks around for the best deals.
and filter on an annual basis or at least Clutches fail prematurely on early

Engines every 10,000 miles. And being a VVT-i, cars, sometimes after as little as 35,000
The VVT-i petrol units are virtually it’s worth keeping an eye on levels. The miles, so if it feel heavy or emits clunks,
bulletproof and, being chain-driven, only other real issue concerns water it could be about to let go. Cars made
there’s no cambelt interval to worry pumps on early models, which have after 2009 had the more robust Yaris
about. That said, the engines are worked been known to fail, so keep a lookout for clutch fitted and it’s possible to upgrade
hard so it makes sense to replace the oil tell-tale coolant leaks. an original to the 190mm diameter item.
Toyota Aygo
2005-2014
Model 1.0 1.4 HDi
Engine (cc) 998 1398
Power (bhp) 68 54
0-60mph (sec) 13.7 16.3
Top speed (mph) 98 96
Toyota’s three-cylinder 1.0 VVT-i is nippy, frugal and bulletproof. Average fuel (mpg) 65 68
F I X Y O U R C A R W I T H H AY N E S M A N U A L S

Survival Guide Toyota Aygo
USEFUL CONTACTS
BBA Reman 01634 687222

www.bba-reman.com
Euro Car Parts 020 8956 5000
www.eurocarparts.com
GSF Car Parts 0121 626 7981
www.gsfcarparts.com
Toyota Parts Direct 01793 412909
www.toyotadirectparts.co.uk
Steering component prices

PAS ECU
Main dealer £362.15
Remanufactured from £175.00
FRONT WHEEL BEARING
Main dealer £81.74
TOP TIP Independent from £59.99
Clutch problems
on the pre-2009
Aygo are common. Electrics
However, most
issues can be solved
The majority of the Aygo’s electrical
by fitting a 190mm components originated in France.
diameter clutch Whether that’s a good or bad thing is
plate in place of the
180mm original on open to debate, but suffice it to say that
earlier models. some owners have complained about
faulty airbag warning lights and other
Engine component prices Brake component prices spurious electrical glitches. Bear in mind,
ABS ECU
it’s a car that was built to a price and that
OIL FILTER
Main dealer £11.35 Main dealer £501.80 could be beginning to take its toll by now.
Independent from £4.69 Secondhand from £30.00
Electrical component prices
WATER PUMP FRONT BRAKE DISCS (PAIR)
Main dealer £95.54 WINDOW REGULATOR
Main dealer £101.00
Independent from £52.98 Main dealer £129.96
Independent from £48.99
CLUTCH PLATE FRONT BRAKE PADS
Main dealer £47.92 ALTERNATOR
Main dealer £76.31
Independent from £23.99 Main dealer £218.60
Independent from £116.99 (complete kit)
Brakes Steering/suspension Other problems

Front discs on the Aygo have been If the electric power steering becomes The rear door seals on the five-door
known to corrode and wear down after heavy, chances are the Koyo ECU has models, rear light clusters and the high-
as little as 20,000 miles, with some being developed a fault (it’s indicated by the level brake light can let in water. Rear
changed under warranty. As you’ll see fault code ‘C1554’). If you’re buying exhaust box baffles tend to rust and
from our price comparison, they’re not secondhand, it’s easier to replace the fail, so listen for blowing. Fortunately,
expensive to replace and it might be whole column (from around £60), Aygo parts prices are commensurate
worth fitting better aftermarket items if otherwise the ECU can be repaired by with its size, so replacements from an
you’re likely to do a high mileage. It’s been the likes of BBA Reman for around £175. independent won’t break the bank.
reported that rear brake cylinders leak, Being such a light car – it weighs just
so ensure regular fluid level checks and 820kg – suspension components last Other parts prices
be suspicious of any sponginess. Bosch well. However, tyre wear has been an REAR EXHAUST BOX
ABS control units can also sometimes issue, as have noisy wheel bearings – they Main dealer £225.48
fail, but it’s not a common fault. don’t seem to last very long on the Aygo. Independent from £59.99
F I X Y O U R C A R W I T H H AY N E S M A N U A L S

Timing Belt Clinic
Replacing the cambelt and water pump on a Renault
Clio 1.2 16v petrol looks as if it will be complicated
due to the right-hand engine mounting set-up. In fact,
the job’s not too daunting at all, says Kim Henson.
All references
TORQUE SETTINGS
to the ‘right and Cambelt tensioner
‘left’ sides of the
vehicle refer to locknut 24Nm (18lb ft)
the viewpoint of Crankshaft pulley
the driver, looking
retaining bolt (use a new bolt)
towards the front
of the car. 40Nm (30lb ft) plus 70° plus 5°
Water pump to engine bolts
9Nm (6.6lb ft)
Allow at least a full day to carry out

the job, particularly when tackling it for
the first time, although if things go well
you might accomplish the work in less
THANKS to
than half-a-day.
John Farrow of J&C The main steps are as indicated in our
Motors, Bournemouth photograph/caption sequence, but there
(Tel 01202 429420). are some extra points to note.
T
We deliberately tackled this job in the
he 2004 Renault Clio 1.2 16v is essential to check the manufacturer’s same way as a do-it-yourself mechanic,
hatchback brought into J&C advice relating to the specific model, as avoiding employing special tools and
Motors in Bournemouth was mileages and time change periods vary. possibly different book methods that a
suffering from coolant loss, With minor variations, the cambelt professional mechanic might employ.
suspected to be from an ailing water set-up on this car applies to Clios and It is necessary to raise the front of the
pump, and it was believed the engine other Renaults with similar engines car and support it on axle stands, and to
was still running on its original timing from 1998 to 2008. remove the right-hand front wheel. From
belt, well overdue for renewal. On this Clio, the water pump is driven within the wheelarch, the protective
For this model, it’s recommended by the cambelt, so it’s a good idea to renew inner wing cover panel can then be
the cambelt is renewed every five years both at the same time, even if the pump is detached, making it easier to access the
or 74,000 miles, whichever comes not yet leaking. Doing both jobs together cambelt/water pump areas.
first. The engine is regarded as an gives peace of mind and saves time in the For peace of mind, it is wise to install
interference type, which means piston long run, especially in view of the effort a complete camshaft belt kit, including
to valve contact is highly likely if the required to strip down components to a new tensioner assembly, rather than
cambelt breaks. For other Renaults, it reach the cambelt and water pump area. just the belt itself.
HELPFUL TIPS
X Before dismantling anything, disconnect the car’s battery. X The cambelt links the camshaft and crankshaft sprockets
X Store all nuts, bolts, clips, etc. in separate, labelled with a tensioner assembly towards the top of the rearmost
containers so that you can tell at once where they have belt run, with the water pump positioned halfway down the
come from when the time comes for reassembly. belt run towards the front of the engine. Normal direction
of rotation of the engine and the cambelt is clockwise
X Rotate the engine ONLY in the normal direction of
when viewed from the right-hand side of the car.
rotation when running (ie, clockwise when viewed from
X Before removing the water pump, place a bowl
the right-hand side of the vehicle) and never in the
underneath the car to catch the coolant as it escapes;
opposite direction. Note: If the spark plugs are removed,
dispose of it in an environmentally-friendly manner.
eliminating compression, it is easier to rotate the engine.
X On reassembly, apply torque settings as recommended
X When releasing/tightening the crankshaft pulley bolt,
by Renault. These vary according to the vehicle model,
the engine can be prevented from rotating by locking the
so refer to the manual specific to your particular car.
flywheel using a large flat-blade screwdriver or long bar,
X Note that, on completion of the job and having refilled
but take care that it doesn’t slip.
the cooling system with antifreeze, the system needs to
X Avoid turning the crankshaft and/or camshaft while the be bled of air. There’s a Schrader valve-type bleed point
cambelt is removed. at the air filter end of the cylinderhead, underneath the
X NEVER use the cam sprockets to rotate the engine. filter housing.

Timing Belt Clinic Renault Clio 1.2 16v
FITTING & TENSIONING THE NEW CAMBELT

The main steps for fitting and tensioning the cambelt timing pin/bolt (rotate the engine back and forth a little
are detailed in our photographs/captions, but there are to ensure that the pin/bolt is fully engaged). Reaffirm that
some extra points that need to be observed. the belt sprocket timing marks still align as intended.
X When fitting the new cambelt and guiding it onto the If all is well at this stage, remove the timing pin/bolt
drive sprockets/pulleys, ensure the belt is kept taut as you again, and release the tensioner assembly lock nut while
proceed. With the timing pin/bolt inserted in the flywheel, holding the Allen key. Now rotate the tensioner assembly
the belt sprocket timing marks must align as intended until the pointer is in its central position relative to the two
before and after fitting the new belt. prongs, then retighten the tensioner’s lock nut to 24Nm
X With the timing pin/bolt removed from the flywheel and (18lb ft). You must ensure that the tensioner assembly is
the tensioner lock nut slackened, use a 6mm Allen key NOT in contact with the cylinderhead; if it is, repeat the
to rotate the tensioner pulley anticlockwise, so that the tensioning procedure.
tensioner assembly’s pointer and prongs sit in the position X Reassemble the various components in reverse order
indicated in Step 32. Now fully tighten the tensioner to dismantling. Avoid starting the engine until the auxiliary
assembly’s locknut to 24Nm (18lb ft). drivebelt is fitted, to prevent possible damage to the
X With the crankshaft pulley and securing bolt refitted crankshaft pulley.
and torqued to 15Nm (11lb ft), rotate the engine clockwise X On completion fit a new crankshaft pulley bolt and
through six full revolutions, then reinsert the flywheel’s torque it to 40Nm (30lb ft) plus 70° plus 5°.
Renault Clio 1149cc four-cylinder
The right-hand end of the engine is what you need to access. The engine’s top cover panel (shielding the high-tension leads)
1 At first glance, there appears to be plenty of room around the 2 has to be released and removed. Store it safely where it cannot
engine, although the right-hand mounting assembly is in the way get dropped or trodden on – if you are feeling enthusiastic, now is a
– it’s easy to remove, though. good time to clean the cover.
W The air pipe serving the

3 carbon filter assembly needs
to be very carefully disconnected at
the rear of the engine compartment.
While it is detached, ensure that the
pipe is safely out of the way of all
following operations.
X The alternator drivebelt is

4 removed; very carefully check
its condition, watching especially
for cracks in the inside of the belt,
where they are not easy to see. On
reassembly, only reuse the belt if it
is in excellent condition.
W The engine mounting

5 assembly is unbolted from
the inner wing at its right-hand
end, and from the engine at its
left-hand end. It is secured by five
bolts (16mm spanner size) and is
not difficult to take out.
X Detach the aluminium

6 support for the right-hand
end of the engine; it doubles as the
upper cover for the cambelt. It is
secured by four long through-bolts
(13mm spanner size).

Renault Clio 1149cc four-cylinder continued
This is what the aluminium cover The plastic cover panel between the
7 8 There is no need to fully remove the
looks like when removed; for this
photograph, we left the four through-bolts
right-hand wheelarch and the engine bay
is secured by a series of plastic clips, which
9 plastic cover panel from the wheelarch.
in position. Check the condition of the cover need to be carefully eased out. These clips Simply rotate it upwards and out of the way,
and the threads on the bolts, storing them are easily damaged and it may be necessary leaving enough room to reach the lower end
carefully for reassembly. to buy replacements for reassembly. of the engine and cambelt.
W Use an 18mm socket

10 spanner to slacken the bolt
securing the crankshaft pulley.
Note: on this Renault engine,
this bolt is usually far easier to
release than on other vehicles.
Extract the bolt and detach the
pulley from the engine.
X Now turn to the lower

11 end of the cambelt area,
where there are two separate
plastic covers. Two small bolts
(10mm spanner size) secure the
first of these covers to the engine.
Take out both bolts, then…
W …detach the cover

12 panel. This is how this
panel appears when viewed from
the right-hand side of the engine
bay, with the camera held low
down within it, and at the front
of the engine compartment.
X Next to come off is this

13 additional plastic cover,
located at the bottom of the
cambelt area. It is held in place by
four bolts (10mm spanner size).
Remove the bolts, followed by the
cover, and store them safely.
W Slowly rotate the engine

14 clockwise viewed from the
right-hand (crankshaft pulley)
end of the motor, until the special
timing/locking pin (shown here)
slides through the aperture in the
bellhousing and into its hole in
the flywheel.
X Don’t worry if you

15 haven’t got the special
timing/locking pin. An alternative
is to use a suitable bolt (in this
case, with a head measurement
of 13mm across the flats).

Now release the cambelt tensioner The belt tensioner assembly is an

17 18
16 On this engine, there are no alignment
marks on the cambelt’s camshaft
assembly, relieving the belt of
tension and enabling it to be removed. We
eccentric design. To release tension
in the belt, the unit needs to be rotated
sprocket or engine. So, with the timing/ used a long 13mm ring spanner for this job, clockwise. If the tensioner assembly has
locking pin/bolt in position, as shown in enabling plenty of leverage to be applied to never been moved, it may be necessary to
Step 15, paint on your own alignment marks. loosen the securing nut. gently tap its body to encourage movement.
W Now it is an easy matter

19 to extract the old cambelt
from its sprockets and the
tensioner assembly. This engine
was still fitted with its original belt,
which had survived in remarkably
good condition, but it’s essential to
renew as recommended.
X Having moved the

20 alternator body outwards
to provide more room, unbolt the
water pump from the engine. The
pump is secured by a series of
bolts, easily removed using a 10mm
socket spanner (a universally-
jointed socket driver bar will help).
W Unbolt the coolant hose

21 union from the water pump
body (two bolts; 10mm spanner
size). If you haven’t already
drained the coolant, it will escape
now – so make sure you have a
suitable container underneath the
car to catch it.
X The pump is located on

22 two dowels. If it has been
in place for a long time, it may be
reluctant to separate from the
engine. Very carefully tap and/
or lever the pump away from the
cylinder block, taking care not to
damage the block face.
W There is plenty of room

23 around the right-hand side
of the engine in which to lift out
the old water pump. This one
looked very clean, but nevertheless
was suffering from a failed seal
and had been leaking coolant.
X We used a scraper to
24 remove old gasket material
and sealant from the cylinder
block’s face, against which the
new pump will sit. Check for
pitting. It’s a good idea to wipe the
block face with a clean rag dipped
in cellulose thinners.

Timing Belt Clinic Renault Clio 1.2 16v PARTS PRICES
Water pump
Renault Clio 1149cc four-cylinder continued and cambelt kit £72-£120
depending on make and supplier.
We applied sealant to the new water A bead of sealant applied to the gasket Fit the new pump, taking care to align
25 pump’s gasket face and the mating 26 face helps hold the gasket in position 27 the bolt holes in the pump body with
face on the engine. We suspect the pump while the new pump is installed. Wipe any those on the engine. Fit the bolts and tighten
had been weeping coolant from the gasket, excess sealant away from the inside of the a little at a time in diagonal sequence, until
in addition to leaking from the pump itself. gasket, so that it doesn’t stray into the pump. they are fully tightened.
W At the point of contact

28 between the water
pump and the hose union is a
rectangular rubber seal. Renew
this as a matter of course – a
new seal was provided in the
purchased water pump kit.
Next, refit the hose/union.
X The new tensioner
29 assembly (eccentric
profile) looks like this. The
large hole visible just to the
left of the centre of the unit is
to enable the assembly to be
slid onto the stud protruding
from the cylinder block.
W The tensioner
30 assembly is fitted to the
stud on the cylinder block, so
that it appears as shown just
before fitting the locking nut.
At this stage, the cambelt has
yet to be fitted.
X The new cambelt can

31 now be carefully guided
over and around its sprockets
and pulleys, ensuring that it is
taut on the non-tensioned side.
Take care not to strain the belt,
nor to contaminate it with oil,
grease, etc, during installation.
W When the
33 belt is correctly
tensioned, hold the
tensioner assembly
in this position using
the Allen key and
fully tighten the
assembly’s locknut
to 24Nm (18lb ft).
Re-check belt tension,
then reassemble
all components
in reverse order
Correctly setting the belt tension is very important. With the aid to dismantling
32 of a mirror, initially apply a 6mm Allen key (with the tensioner and observing the
locknut loose) to rotate the adjuster body anticlockwise so that the recommended
belt is tensioned and the tensioner assembly pointer and prongs align. torque settings.

Two Suzuki Lianas were
used by Top Gear. Car One
(on the left) was joined by a
back-up car, both of which
belong to Suzuki GB PLC.
Whatever happened to the Reasonably Priced Cars?

When the BBC series Top Gear was relaunched in 2016, the Suzuki Lianas used
in the Star in a Reasonably Priced Car segment were put out to pasture.
Rob Marshall tracks down the original cars to find out what happened to them.
X In October 2002, the production team had such confidence in his products’ “We didn’t realise what a much-loved
behind the BBC’s Top Gear TV series dependability that he is alleged to have member of the team it would become,”
was under pressure to deliver a revised put his job at risk, by sacrificing one of he said. “It stood up to the celebs’ lack
format that would modernise the show the freshly-launched Liana saloons in the of mechanical sympathy with fortitude.
for the 21st Century. One of the many name of light entertainment. The Liana It was plucky… an unlikely hero.”
problems involved finding a suitable was priced at £9999 – a whole quid As the new Top Gear format became
vehicle for a regular slot entitled Star beneath the target price dictated by the established, Suzuki’s PR boss had an
in a Reasonably Priced Car, in which production team – which Porter recalled easier time signing off a back-up car to
celebrities would drive competitively was perfect for the job. Nevertheless, take over in exceptional circumstances,
around a custom-made racetrack. he admits that, upon viewing it for the such as when a celebrity’s over-
As Top Gear’s former script editor, first time, his colleagues “howled with exuberance destroyed either a clutch,
Richard Porter, reminisced in his memoir, derisive laughter at this strange, gawky, or mangled part of the original car’s
And On That Bombshell, this presented odd little car”. bodywork. Or both.
a number of practical problems, quite
aside from putting celebs in a situation
that might be construed as being
beneath them. Expensive exotica was
out of the question, Porter explained,
lest the segment unintentionally become
known as Stars Soil Their Pants, Star in
a Very Tricky Insurance Claim, or Star in
a Tumbling Ball of Burning Wreckage.
Porter also revealed that sweet-
talking manufacturers into lending,
maintaining and repairing a new sub-
£10,000 car of modest performance
for regular mechanically-masochistic
torment was somewhat tricky,
especially as many public relations
departments deemed ‘Reasonably
Priced’ to be a euphemism for
something rather less desirable. Maybe
they had reservations about their cars’
ability to tolerate the abuse? Paul May (on the driver’s side) and Paul Buckman (foreground) look after Suzuki GB’s vehicle
Suzuki GB PLC was an exception fleet, including more than 50 press cars. They maintained the Lianas before, during and after
and the former head of Press and PR filming with the F1 drivers. The vehicle here is Car Two, wearing Car One’s registration plate.

Suzuki Special Report
Car One tended to be the vehicle driven by the celebrities appearing The back-up Liana can be identified by its front fog-lamps, while Car
on the show. To ensure continuity during editing, the back-up Liana, One has blanking plates fitted. Car Two also has narrower racing
occasionally, wore an identical numberplate. seats and slightly smaller Suzuki badges on its front wings.
fitted all-round every time the cars were technical modifications to be made to
One became two dispatched for filming, and the engine the cars during filming, which both the
Two Suzukis, therefore, shared the oil and filters were changed after every BBC and Suzuki refused.
limelight in Top Gear. The 52-plated other visit. Car One was fitted with a “The BBC was determined that both
original, Car One, spent most of its life roll-cage after Jay Kay’s ‘enthusiastic’ cars would be as near identical as
being ill-treated by celebrities, while the driving style almost caused it to flip possible,” recalls Paul M. “We even had
03-plated Car Two provided support over. When Lionel Richie and Trevor Eve to top-up fuel levels to ensure that the
duties, although it tended to be the understeered off the track, shearing kerb weights remained consistent.”
preferred choice of the F1 drivers. the wheel studs, Suzuki replaced the “With the F1 drivers especially,” adds
According to Alun Parry, current hub assembly and lower suspension Paul B, “car choice depended not on
head of Press and PR at Suzuki GB arm, prior to sending the car to the reliability, but which seat was fitted. Car
PLC, the publicity did not influence the bodyshop. Patrick Kielty, however, One possesses a wider racing seat than
Liana’s UK sales figures, but it lifted managed to bend the front suspension. its 03-plated sister – ultimately, the
the manufacturer’s brand profile, even The BBC instructed Suzuki that no decision came down to which seat the
after the model ceased production. uprated parts were to be fitted under driver preferred.”
The company retained both Lianas any circumstances; only racing seats, Suzuki’s master technicians also
used in the series, transporting them harnesses (which were replaced after recall how Kimi Räikkönen advised them
to the Dunsfold aerodrome for filming, their use-by dates had expired for safety that one car felt slightly more powerful
after being given the obligatory four reasons) and roll-cages were permitted. than the other. Suzuki GB PLC’s own
days’ notice from the BBC. At least one dynamometer confirmed his findings.
Suzuki master technician accompanied Not only were both cars’ engines
them on location, not only to provide The professionals producing greater outputs than their
technical support but also to ensure By the time Suzuki GB PLC master conservative factory figures stated (not
they were not sabotaged. technicians, Paul May and Paul Buckman, unusual with Japanese models), but Car
Parry corroborates Porter’s admission were charged with looking after the Lianas, Two was around three horsepower more
that Car One confounded engineers with the regular celebrity slot had been taken- potent. It was also found that the older
its tolerance to such repeated abuse, over by newer models, but the Lianas Liana’s rear suspension had become
especially as only consumable spare remained in demand for the F1 drivers’ softer with age, even though the
parts were replaced, crash damage leader board. The racing professionals dampers were not leaking. At this point,
excepted. He told CM that new original- were not only more competitive but the springs and dampers of both cars
specification Bridgestone Tyres were also tried to get permission for minor were renewed to restore the balance.
This tyre was new and survived just five

laps of Top Gear’s circuit when piloted by an
Despite spending most of their lives bouncing off the rev limiters for Top Gear, neither of the F1 driver. The high-speed cornering causes
cars’ engines has ever been dismantled and they both remain leak-free. excessive scrubbing on the sidewall.

Suzuki Special Report
“When the cars were being driven
by celebrities, it was not unusual for us
to see them being beaten around the
track for a full day,” says Paul B. “The
F1 drivers required fewer laps, because
they knew when their limits had been
reached. For example. on his second
Car One’s odometer reading of almost 11,000 track miles equates to between 150,000-200,000
visit, Lewis Hamilton required only 90 miles of everyday use, according to Suzuki engineers. Car Two displays just under 6000 miles.
minutes of filming time. While they were
less prone to off-track excursions, F1 normal driving, they have survived most notably on the sills, caused mainly
drivers were far more brutal to the cars’ in excellent mechanical order. The by the large drop between the track and
mechanicals, compared with the celebs. clutches are light, the gearchanges the airfield’s undergrowth.
Although both Lianas retained most of remain slick and the engines, which the Fifteen years after the first Liana TV
their original parts, I changed second master technicians admit have never loan, both Top Gear and Suzuki’s new
gear synchromesh several times on been taken apart, are rattle-free. Even models have evolved considerably.
Car Two, due to the vicious clutchless the air-conditioning works. However, Yet, should you require evidence that
changes meted out on the transmission neither would pass an MOT, because Suzukis – and Japanese cars in general
to obtain the fastest times.” the SRS (airbag) warning lamps are – are capable of surviving situations
illuminated, due to the racing harnesses that lie far outside their normal comfort
displacing the seatbelt pretensioners. zones, you need to look little further
CM’s assessment The most obvious clues to the than these Lianas.
Both cars had been stored outside at cars’ history are imprinted upon the It is worth noting, however, that newer
Suzuki GB PLC’s HQ in Milton Keynes bodywork. Car One displays obvious versions continue to trend. At the time
for nine months, prior to being moved upper panel damage, caused not only of writing, Suzuki is the second most
and cleaned for our photoshoot. We by being driven into a camera and reliable of present-day car brands
witnessed both engines starting from tripod (which smashed the original according to the most recent UK
cold without hesitation, admittedly windscreen), but also from Johnny Warranty Direct Reliability Index (which
after being coaxed with a battery Herbert jumping onto the roof. Several also factors repair costs), beaten only
booster, before settling promptly to slight colour variances are noticeable by Honda. For the shrewd car buyer
smooth and smoke-free idles. For old between panels, too, where bumpers, and home mechanic, these real-world
cars that have led such ruthless lives, doors and front wings suffered collateral findings are far more valuable than the
which Suzuki estimates to represent accident damage. The floorpans of both often hollow promises of dependability
between 150,000-250,000 miles of cars display a degree of battle scarring, that hide behind a prestigious badge.
NEXT MONTH hits

Anniversary issue Underbonnet
We celebrate 6 decades of CM
ON
NEW PROJECT FORD FIESTA
TEST
X 1958 Austin A35 DIY service
X Nissan electric van DIY service
X Excavating an inspection pit for
the perfect home garage
132 X Skoda Octavia buying guide
Top 20 most influential technical page X Honda Civic 1.6 diesel diagnostics
bumper
components of the last 60 years X History of Citroën hydraulics
X Cummins Railton bespoke build
Plus, we look back at some nostalgic moments in motoring history APRIL 2018
X The best & worst performing engines since the 1950s issue out
X 20 British cars on sale in 1958 X Major events from the late 50s March 15
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Overall difficulty rating
2011 Jaguar XF
2.2 turbodiesel
Executive
service
Rob Hawkins
finds out how Elite &
Performance Jags
services Jaguar’s mid-
range executive model.
J
aguar’s mid-range executive XF
first appeared in 2008. We’ve yet
to see their secondhand values
plummet as fast as many X- and
S-TYPEs, but it probably won’t be long
before they fall below the £5000 mark, in problems and failure of the rear Equipment required
which usually means owners will be camera, boot lights, numberplate lights i Jack i axle stands i oil tray i sockets/spanners
looking to maintain their cars themselves. and boot release. They are also fixing a lot (up to 27mm) i Allen keys (6-9mm) iTorx bits
The 2.2-litre diesel XF is a reliable of EGR/cooler-related issues at present. (T20-T30) i flat-head and crosshead screwdrivers
i wheel brace i pry bars i antifreeze hydrometer
and economical Jaguar to own, unlike Surface corrosion is seemingly an i electronic brake/clutch fluid strength checker
the larger 2.7- and 3.0-litre diesel models embarrassing problem on some XFs. We ibattery tester ihammers iimpact driver
that have been blighted with engine inspected a 2010 model back in 2014 and ibrake caliper windback tool iwire brush
failure. However, many of the common were horrified to find the suspension iabrasive paper ibrake grease ispray grease
ityre pump itorch itorque wrench irags for
problems associated with Jaguars can arms, rear subframe and one of the cleaning idisposable gloves idiesel primer pump
be found on the XF. The front bush on underbody brace bars were all looking
the front wishbone arms (known as very rusty. At that time, it was difficult
banana arms) wears, but can be renewed. to tell whether the corrosion would
Other suspension bushes are known to lead to structural problems, but holes in
wear, though new bushes and complete parts ranging from the shock absorbers
assemblies are available through many to subframes has long been a problem
independent spares specialists. associated with Jaguars.
Elite & Performance Jags have found The following pages follow Elite &
that the wiring loom routed into the boot Performance Jags servicing a couple of
can become damaged and worn, resulting 2.2-litre diesel engine XFs.
Underbonnet layout Thanks to:

Elite & Performance Jags
SCREENWASH BRAKE FLUID

www.eapj.com 01332 265826 Rob says
UNDER COVER COOLANT EXPANSION TANK The ‘Service Required’ warning
displayed between the speedo and tacho
can be reset. With the ignition switched
off, press and hold the rear fog-lamp
button, then switch on the ignition and
release the button. Press and hold in the
tripmeter button, then press and hold in
PAS FLUID the rear fog-lamp button (both buttons
RESERVOIR should now be held). Wait for a
reset service message to
appear on the instrument
display, but keep pressing
the two buttons until
a service mode
reset message
is displayed.
ENGINE OIL & FUEL FILTERS AIR FILTER ROB HAWKINS
UNDER COVER HOUSING Special Contributor

DIY Servicing 2011 Jaguar XF 2.2D
UNDERBONNET CHECKS
TOP TIP
Pinch the two
plastic tabs
together to
remove and fit
a wiper blade.
1 CHECK COOLANT
The coolant level can be checked via the 2 POWER STEERING FLUID 3 WASHER FLUID
expansion tank. Look at the side of the The power steering fluid reservoir is located The reservoir for the windscreen washer
plastic expansion tank to check the level. in front of the coolant expansion tank. fluid is on the offside rear of the engine
Test the strength of the coolant when it’s Shine a torch onto the side of the reservoir bay. Top it up with a mixture of washer fluid
cold (don’t release the pressure cap when to check the level, looking for the level and water (or a premix). Test the wipers
it’s hot). Elite find that the pink-coloured markers – clean the side of it if it’s covered and screenwashers to make sure they
G13 coolant lasts for up to 10 years, as long in dirt. If the level is low, top up with are correctly aimed and that there are no
as there are no leaks or coolant problems. Dexron III power steering fluid. blockages in the pipework and spray nozzles.
6 GREASE BONNET RELEASE

4 TEST BRAKE FLUID 5 LOOK FOR LEAVES Spray light grease over the two bonnet
The brake fluid reservoir is hidden under a Remove any leaves or debris from the scuttle catches along the front slam panel. Check
removable plastic flap. The XF uses DOT 4 panel cover; these could get drawn into the that the safety catch on the underside
fluid. This usually lasts for up to six years heater and air-conditioning system. There of the bonnet has not seized as it prevents
before it needs renewal. Use a brake fluid tester are also drain holes at the rear corners of the bonnet flying up when driving the car;
to check the moisture content in the fluid. If the engine bay which can get blocked with lubricate it if it’s stiff. Light grease can also
the fluid needs to be renewed, see Step 39. dirt, so make sure they are clear. be sprayed over the door and boot hinges.
OIL & FILTER TOP TIP

The sump
plug can be
reused two or
three times.
7 REMOVE UNDERTRAY 8 DRAIN ENGINE OIL

Access to the oil drain plug requires the engine undertray to be Have a six-litre container ready to collect the old engine oil. Undo
removed, which also helps with inspecting other areas of the underside. and remove the 13mm sump plug, then leave the oil to drain for 10
The undertray should be secured with a series of 10mm and Torx bolts minutes. Release the filler cap in the engine bay to help drain the
(T27-30), depending on whether they have been replaced in the past. engine oil. After draining, refit the sump plug.

OIL & FILTER (continued)
11 CHECK THE OIL LEVEL

Do not run the engine or switch on the
ignition for 15 minutes. To check the oil
9 RENEW OIL FILTER 10 TOP UP OIL level, switch on the ignition after this time
Undo the oil filter housing with a 27mm Measure out 5.8 litres of 5W-30 fully-synthetic (do not run the engine) and operate the
socket. Renew the filter and the rubber oil (low ash), then pour this into the engine. controls for the instrument display until a
O-ring on the thread of the housing – add Run the engine for a few seconds to make sure reading appears for the engine oil level. If
a smear of oil to the new O-ring to prevent the oil pressure warning light doesn’t remain the message refers you to the handbook,
it catching and tearing. Refit the housing, illuminated. Switch off, then inspect around wait another 15 minutes before checking the
tightening it to 25Nm. the drain plug and the oil filter for leaks. oil level again. Top up if necessary.
AIR & FUEL FILTERS
12 RENEW AIR FILTER

The air filter is located inside a plastic 13 ENGINE TOP COVER 14 FUEL FILTER PIPES
housing in the nearside front of the engine The fuel filter should be replaced every Undo three 6mm Allen key bolts that secure
bay. Undo seven Torx T20 screws to remove two years. It can be renewed from under the filter in position. Detach the four fuel
the top cover – lift this up to extract the the bonnet. First, prise off the engine’s top pipes from the top of the filter, as well as an
old air filter and fit the new one. Remove cover, which is clipped in position on the top. electrical plug at the top and another one
any debris from inside the air filter housing You will now be able to see the fuel filter on at the bottom. Lift up the filter a little to
before fitting the new filter. the nearside of the engine. access the lower electrical plug.
15 REMOVE OLD FUEL FILTER 16 PRIME THE FUEL FILTER

Extract the old fuel filter and check it’s identical to the new one. The new fuel filter needs to be primed before running the engine.
Remove the short drain pipe from the old fuel filter and transfer it to Use a hand pump to draw fuel into the new fuel filter. This can take
the new one. Lower the filter into position, reconnect the electrical several attempts, so it’s worthwhile test-starting the engine a few
plugs and refit the 6mm Allen key bolts and the four fuel pipes. times afterwards to make sure there are no air locks.

INTERIOR & BOOT CHECKS
17 RENEW POLLEN FILTER 18 CHECK VENTS & SEATBELTS 19 BOOT & BATTERY
The pollen filter is accessed via the Test that the motorised dashboard vents The battery is located inside the boot. Make
passenger footwell. Unclip a section of trim, open and close. These can fail and cost sure it’s secure and the terminals are firmly
then extract the filter, swap the plastic end around £150 each – Elite charges around fixed. Look for water inside the spare wheel
cover over to the new one and make sure the £250 to supply and fit a motorised vent, well and dry it out if there is any. There’s a
airflow arrows are in the correct direction. which involves dismantling part of the stop-start system installed next to the battery,
Finally, refit the plastic end cover with the dashboard. Check all seatbelts and the which must not get wet, so find and fix the
new filter and refit the trim. functions on the electric front seats. cause of the water leak (check the boot seal).
EXTERIOR CHECKS
22 WHEELS & TYRES

The XF is equipped with 17-19in steel or alloy
20 DOOR CHECKS 21 FRONT & REAR LIGHTS wheels. Check for kerb damage around the
Check all the doors can be opened from Check that the headlight and rear light bulbs inner and outer rims. Inflate the tyres to the
inside and outside, and that all of them illuminate. The headlights are secured with right pressure (31-34psi for under 100mph).
can be locked from the inside and with three 10mm bolts, accessed from under the There’s a label of recommended figures on
the remote key-fob (central locking). bonnet and behind the front wheelarch trim. the bottom of the nearside B-post – open
Problems with sticking exterior handles and Pull the headlight unit forward to access the passenger door to see it. Check the
malfunctioning locks are a common problem the bulbs. Renewing a rear bulb requires the tread depth on the tyres as uneven wear can
on the XF and many other Jaguars. boot trim to be detached. suggest worn suspension components.
SUSPENSION CHECKS
23 WIGGLE THE WHEELS
W Wiggle each raised road wheel at
the top and bottom and from side to
side to check for play in the wheel
bearings and upper wishbone bushes.
Do the same to each front road wheel
from left to right to check the track
rod ends. Hold each rear wheel at
ten-past-seven and ten-to-four and
wiggle it to check the frontmost and
rearmost suspension arms.
24 BANANA ARM
X Use a pry bar to check for excessive
play in the front bush for the front
lower wishbone (also known as
the banana arm due to its shape).
Wear is common on this arm’s large
suspension bush, which can be
renewed two or three times. A new
bush is around £30, although new
arms only cost around £85.

SUSPENSION CHECKS (continued)
25 STRUT BUSHES 26 REAR WISHBONE ARMS 27 TEST DROPLINKS

Use a pry bar to inspect the condition of the At the rear, use a pry bar to check the bushes There are anti-roll bars at the front and
front strut’s lower mounting bush. Excessive for each lower and upper wishbone. The lower rear of the XF, so inspect the balljoints of
play in this bush can result in a squeak from arm’s rearmost bush has a spherical bearing, the droplinks by wiggling each one. Worn
the front end. The same bush can be tested on which is known to wear and squeak. The droplinks can result in a knocking noise
the rear struts and wear is a common problem, other bushes are rubber and can also wear. when driving the XF. Also, wiggle the anti-roll
resulting in a hollow rattle when driving the New upper wishbones cost around £95 each bars to ensure their mounting bushes are
vehicle. New bushes cost £15-£30 each. and lower arms are priced at £120 or more. not worn.
RUST & UNDERSIDE CHECKS
29 LOOK FOR CORROSION 30 REAR DIFFERENTIAL OIL

Rust prevention is poor on the XF. Surface The rear diff has an inspection hole on the
28 INSPECT COIL SPRINGS corrosion on the suspension components, side, but if there are no signs of leaks – such
Visually inspect each coil spring for any underbody bracing and the rear subframe is as the one shown here that’s covered in
fractures in the coils. Don’t place your fingers common. Check that the lower mounts for surface corrosion – you may want to assume
between the coils in case you disturb anything the rear shock absorbers haven’t corroded the oil level is OK. If you want to check the
and the spring traps them. You may be able to and weakened. Clean and rust-protect level, undo the inspection hole and dip a finger
see more of the coil springs when the wheels the exposed areas of the rear subframe, inside. The level should be below the hole.
have been removed to service the brakes. detaching and cleaning any brace bars. Millers Oils recommend a range of 75W90 oils.
BRAKE CHECKS
33 EXTRACT FRONT PADS

31 AUTOBOX TROUBLE Prise off the brake caliper and suspend it
Most XFs have a ZF automatic gearbox with a 32 BRAKE SLIDER BOLTS aside with a metal hook. Extract the brake
plastic sump pan. The oil should be renewed With one of the front wheels removed, prise pads. On the nearside front, the inner brake
every 60,000 miles using ZF Lifeguard oil. The off the spring clip fitted against the rear of pad has a wear sensor and wiring attached
filter needs to be renewed at the same time. The the outer brake pad, extract two dust covers to it, so detach these. Check the thickness
plastic sump pan can crack and leak, but it’s at the back of the caliper, then undo two of the pads and clean them if there’s more
renewed at every oil service because the filter 9mm Allen key slider bolts. These can be than 3mm of friction material remaining;
and sump pan are supplied as one assembly. awkward to extract. otherwise, renew them (both sides).

BRAKE CHECKS (continued)
34 CLEAN CALIPER 35 REAR SERVICE MODE

Clean inside the caliper and carrier, apply a Before any work can be conducted on the
smear of brake grease (not copper grease) rear brakes, the electronic park brake must 36 REAR DIFFERENCES
to the top and bottom edges of the brake be put into ‘service’ mode. This must be The XF’s rear brakes are similar to the
pads, then refit them, followed by the caliper. completed using diagnostic equipment fronts. There’s a smaller spring clip fitted
Reattach the brake pad wear sensor (NSF). to avoid damaging any parts on the XF by for each outer brake pad. The slider bolts
Tighten the slider bolts to 28Nm for 326mm activating the handbrake when working on require a 7mm Allen key to undo them and
discs or 58Nm for 355mm discs. the rear brakes. there’s a wear sensor on the offside rear.
37 BRAKE DISC RENEWAL 38 RETRACTING A PISTON

If a brake disc has to be renewed, the If new brake pads or new discs and pads
caliper carrier has to be removed first. This are fitted, the piston inside the caliper will 39 RENEWING BRAKE FLUID
is secured with two 15mm bolts, which are need to be retracted. Check the level in the If the brake fluid needs to be renewed (it was
tightened to 115-135Nm. The old brake disc brake fluid reservoir to ensure it won’t spill tested in Step 4), there’s a bleed nipple on
may require a few taps with a hammer to over. On the rear, a windback tool is required, each brake caliper. Start at the NSR, followed
release it – they are prone to getting stuck, whereas on the front the piston can be by the OSR, then the NSF and finally the OSF.
especially on early XFs. pushed in with a G-clamp. Keep the fluid topped up in the reservoir.
Don’t forget to also SERVICE SCHEDULE X Check battery

Elite & Performance Jags recommended X Lubricate all locks and hinges
service schedule for the XF 2.2D. X Check steering and suspension
components
EVERY 12,000 MILES or 12 MONTHS X Check brakes; strip and clean or renew
X Change oil and filter as necessary
X Renew air filter X Check handbrake operation
X Check coolant level and test X Check auxiliary drivebelt
concentration
X CHECK WHEEL NUTS Tighten them to X Check brake fluid level and test EVERY 24 MONTHS
102Nm for alloy wheels and 88Nm for water content
steel wheels. X Renew fuel filter
X Check tyre condition, pressure
X CHECK AUXILIARY DRIVEBELT Inspect and tread
the ribs for cracks and damage. It X Top up screenwash fluid EVERY 100,000 MILES
should be renewed every 100,000 miles. X Renew auxiliary drivebelt
X Check all instruments and controls
X CHECK THE FUSES AND RELAYS
Located on the offside of the engine X Check wiper blades and washer jets
bay. Unscrew three plastic plugs and X Check all engine bay hoses and EVERY 144,000 MILES or 120 MONTHS
remove the top lid to inspect them. pipework for condition and leaks X Renew timing belt and water pump

Help! Your non-diagnostic
vehicle-related problems
solved by Steve Rothwell
age, it will be interesting to see how for £49.94 will read and clear all fault
GENERAL they fare. As far as handbrake operation codes from EOBD-compliant vehicles,
goes, there is no substitute for a proper but will not reset your service lights or
Stop-start hand-operated parking brake which
you can release mechanically when you
read the ABS or airbag systems.
For something which will cover more
motoring wish. Driving a manual vehicle with an
electrically-operated handbrake does
systems on both vehicles, the Foxwell Pro
NT624 ALL System Scan Tool at £299
My last car, a Volkswagen Golf, take quite a bit of practice. should be just about all you will need.
had an electronic handbrake All are available from gendan.co.uk
and stop-start technology. Being
old-school, I hated this, as I could imagine GENERAL
the starter and starter ring engaging so GENERAL
frequently that sooner or later something
would break. Am I missing something?
Fault code reader Oil specification
Have manufacturers come up with a way Can you recommend a fault code
to avoid this happening? I asked the VW reader for a 2015 BMW 520d F11 I maintain all of the cars in my
and SEAT service departments and they Touring and a 2005 Corsa SXi 1.2 family and many of them are
just shrugged and said the manufacturers petrol, although there is a good chance the made by Vauxhall and Ford. The
knew what they were doing! latter vehicle will be swapped in the future Ford cars require 5W-30 engine oil to
Mike Nurse for something a lot newer and probably specification WSS-M2C913-A, while the
petrol? I am not expecting too much to Vauxhalls use 5W-30 engine oil to Dexos
One would hope that vehicle go wrong, so I don’t need anything too 2 specification. I am looking to buy the
manufacturers knew what they professional – maybe a device that will engine oil in bulk, so is it acceptable to use
were doing, but one can’t help read and reset fault codes and perhaps Dexos 2 engine oil in both makes?
but wonder if stop-start systems were reset service lights. Bruce Selby
simply introduced to lower emissions to Melvyn Allen
meet targets! I would need the exact details of
There are a few variations of starter There are a few options and the each vehicle to be certain, but
motor used in stop-start systems. main factors to consider are the Ford-specified 5W-30 oil is
These vary from the standard type whether you wish to reset the possibly ACEA A5/B5, while the Vauxhall
which has been strengthened to cope service lights on your BMW and, of course, oil may be ACEA C3. Even though both
to permanently-engaged systems which which vehicle will replace your Corsa. are 5W-30, this only refers to the viscosity
also act as an alternator. The battery The Foxwell NT510 Full Systems of the oil, not its performance qualities.
also needs to be improved to handle Scanner at £169 will cover all systems Despite the difference in price, it would
stop-start driving and has to prevent the on your BMW and will reset the service be far better to buy the correct oil for
system operating if the battery voltage lights, but its all-round abilities are each vehicle than to compromise on a
drops too low. Most of these systems restricted to BMW and MINI. It will read one-size-fits-all alternative.
can be – and often are – disabled. off codes from any EOBD-compliant This is a problem we come across in
I have yet to see any extensive wear vehicle, which will cover any petrol the workshop. Whereas years ago a bulk
on the ring gear from such systems vehicle from 2001 onwards and any delivery of 20W-50 would satisfy most
and so far have not come across any diesel from 2004 onwards. Alternately, vehicles, we now carry around six drums
starter motor failures. But as vehicles the Foxwell NT204 Diagnostic Scan Tool of different oils to varying specifications.
not again for the next 50 miles. It is more By removing the induction pipe from
noticeable in cold weather; in warm the air filter to the inlet manifold, you
weather it seems to disappear. should be able to see the electronically-
At first I wondered if it was a sticking controlled butterfly. I would spray this
FORD MONDEO throttle, but I understand this car has an with a carb cleaner – such as this one
electronic throttle. The car is regularly http://bit.ly/2jbiiyY – to dislodge
Split-second serviced, but as the fault is so random
and infrequent it never occurs when
any carbon deposits and free up the
operation of the spindle.
surging it’s at the garage and the car runs fine
otherwise. Any thoughts about what the
The other possibility is that the
surging is actually a slight misfire. As
I have a 2009 Ford Mondeo problem could be? this happened not long after the last
2.0 petrol with 70,000 miles. G Marriott service, I would check that you do not
Following a major service two have a spark plug or coil pack that is
years ago, the engine occasionally seems The problem may be the throttle failing or poorly connected.
to surge for a split-second – this is most body, which incorporates the Even though you have no EML
noticeable when cruising. Acceleration butterfly and control motor. showing, if you can gain access to a
and cruising is otherwise fine. This Sometimes the butterfly will stick scanner then you may find that a fault
surging occurs randomly, sometimes a slightly on the spindle, meaning the has been logged in the ECU, which will
couple of times over 20 miles and then throttle will not react as it should. guide you to the source of the problem.

Help!
FORD FOCUS
Power steering leak

I have a 2006 Ford Focus 1.6 petrol with 41,000 miles. It has developed
a slight weep from the steering rack. Is there any suitable additive to the
power steering fluid that could be used to fix the leak or is it
time to replace the rack?
David Gardiner A Focus power steering rack.
According to the data

I have, your Focus
should be equipped with
electro-hydraulic power steering. This uses a thinner CHF fluid and an electric
motor to supply the pressure. Although there are additives – such as this one
http://bit.ly/1SgBt6q – which are suitable for this system, my concern is always
more frequently and the warning nearly
possible contamination in the rest of the system. You do not mention where the
always comes on sometime during a
steering rack is weeping from, but I have seen these racks leak from the steering
journey. The fault is apparently not unique
input shaft and soak the driver’s carpet.
to my car and there are vague suggestions
It is most likely time to replace the steering rack. This will require the subframe
on the internet about it being due to the
to be lowered, and you will need alignment pins 205-880 for the subframe when
connector to the steering pump and an
reassembling. The cost of the steering rack should be around £200, whereas the
earth connection.
additive will cost around £8.50.
The vehicle is in excellent condition
and free from rust. I don’t think it would
and connections. First, I would ensure that be suffering from corroded connections,
FORD FOCUS there are no breaks in the loom and that although I haven’t tried to clean these
the connecting plugs to both the valve connections yet because access under
Error code and PCM are in a good, clean condition.
The terminal from the PCM is number
the headlight is rather difficult. My village
garage has no clue and I cannot find a
I had the error code ‘PO444’ on my F16. Looking at the PCM with the plug power steering specialist near Cambridge.
2006 Ford Focus 1.6 Ghia five- removed, you will see two distinct banks When it first occurred, I topped up the
door, so I changed the purge valve of terminals: one has 52 terminals and sealed-for-life reservoir with about 70cc of
under the bonnet and cleared the code, but the other 42. With the smaller bank of Ford’s special oil, which seemed to keep it
the warning light is still illuminated. I am terminals to your right, there should be at bay for a few weeks. Mind you, I did not
unclear how the evaporative control system four larger terminals at the top right. know how high the reservoir should be filled.
works, but I understand there must be a Starting at the left and counting from Andrew Webb
pressure sensor somewhere, presumably the top row of the left bank, terminal F16
along with a one-way valve to allow air to will be around the centre of the second The light will illuminate when it
take the place of the used fuel. Any help row down. Having located the terminal, detects a fault in the CAN-bus
you can give with the locations of these you can use an ohmmeter to check the system and should also retain a
components would be much appreciated. continuity between this and the valve. If fault code, which should be retrievable
Joe Sykes no wiring problems are found, the fault using the Ford diagnostic system.
may be within the PCM. There are some simple checks that can
The fuel vapour evaporation be done using a meter and these do
system is quite simple, concern the integrity of the connections.
consisting of the purge valve FORD C-MAX Even though your vehicle may be in good
(which you have already replaced) and condition, there may be corrosion within
an evaporation emission canister. The
canister is connected to the fuel tank Power steering the electrical plugs.
As I am sure you have already
via a combination of rubber and plastic For several months, my 2008 Ford discovered, the reservoir is easily filled
hoses, and the purge valve is connected C-MAX 1.8 petrol with the Zetec once the offside headlamp has been
to the inlet manifold. The valve is engine and 65,000 miles has had removed. To access the pump, the
controlled directly by the Powertrain an intermittent fault with the electro- undershield must also be detached.
Control Module (PCM) using a set hydraulic power steering. A warning beep Once you have access to the unit, undo
calibrated table of operation. The normal goes off and gives the dashboard warning the electrical plugs and check the
position for the purge valve is closed ‘Power Steering Malfunction’, followed by condition of the terminals, then using a
and the fuel tank vents through the the dashboard warning light going orange. continuity meter ensure the resistance
canister, which absorbs the hydrocarbon The warning then goes away, but the is less than 5 ohms to the earth
emissions from the fuel tank. When the amber light stays on. There is no change to connection and that the voltage from
valve is open, the canister is subjected to the steering, although I think it sometimes the supply side is greater than 10V.
the manifold depression and the vapour changes itself to ‘Comfort’ mode. This As you have also had to top up the
deposits are drawn into the inlet manifold warning occurs when you start the car or steering fluid, I would carefully check
to mix with the combustion mixture. after 10-30 minutes. It does not seem to for any leaks. I have seen these steering
The code ‘P0444’ indicates that the be connected with cold, heat, wetness, racks leak from the steering column
purge control circuit is open. As you have dryness, road gradient, braking or even shaft, allowing the fluid to be soaked up
replaced the valve, this leaves the wiring steering, although it has been occurring by the driver’s underfloor matting.

Help!
LAND ROVER FREELANDER
Plastic trim valeting

I read your excellent article on Valeting on a Budget in the July 2017 issue. Has your team any
advice on cleaning/refurbishing the grey plastic mouldings and bumpers that were used on
early Land Rover Freelanders? The plastic tends to become discoloured, pale and patchy and
I have been unable to find any product that will restore it.
Michael Owen Black Wow Exterior Trim Restorer.
The product Black Wow as used in the article is actually suitable for any colour of plastic trim.
After first cleaning the trim with Pre Wow, then using the Black Wow, you should be able to
bring back the original colour. If the trim is severely faded, the first application may bleed into
the plastic and appear to have not made a difference. If this happens use a second coat and, once the
plastic is saturated, the original colour should be returned and should last for months. There are other
products on the market such as Back For Good, made by Spautopia, but this is not one I have tested.
With any treatment of this type, it is very important that the plastic is thoroughly cleaned and dried
before applying the restorer. Any dirt left on the plastic will cause the end result to be patchy.
and stored in a dry place away from Up until this problem, the vehicle was
sunlight should be good for around five running fine and not showing any faults on
years. As the oil ages, the first sign of the dash. It has always started first time,
ageing is usually deposits at the base of hot or cold, and has never been run low
the liquid. This is the residue of additives on fuel. It is well maintained and always
that have begun to separate. garaged when not in use.
Russ Bedford
ROVER 45
ROVER 75 You will appreciate that if a
Gearbox oil Non-starting 75
mechanic who has had the benefit
of actually testing the vehicle has
change I have a 2001 Rover 75 with the
BMW 2.0 CDT diesel engine, now
not been able to remedy the problem, then
it can be a difficult task from a distance.
I was going to refresh the oil in my As you have had a mobile diagnostic firm
Rover 45 as the Haynes manual showing 111,000 miles. It was out, I am assuming the codes were read,
recommends changing it every running fine when I last used it, but a week but none was present. I'm also assuming
60,000 miles. However, I have found that the later it would not start – it was cranking that the fuel lines up to the high-pressure
drain and refill plugs are blanked off. How over well on the starter, but would not fire. pump were full and that the electric low
do I check the oil level or refill the gearbox I checked what I could – such as the fuses pressure pump was working.
if the driveshafts have to be removed and – and operated the door locks with the From the information you have
refitted? Also, does engine oil have a shelf ignition key several times, but the engine supplied, there are two possible causes.
life, as I have five litres in storage? would not fire. A mobile diagnostics team The first is that an injector is allowing
Michael Kent checked it, but didn’t find anything wrong. the fuel to bypass it, preventing
I checked for fuel in the line – ie, under sufficient pressure from building up in
As your Rover 45 is a late model, the bonnet, fuel pump and filter, etc – all of the common rail. However, if this were
I am assuming it was built around which seemed OK, but no fuel was being the case you would have an engine
2005 and has a manual gearbox. delivered to the common rail. I changed management light caused by a low
The drain and level plugs should be the camshaft sensor, but this made no pressure in the fuel rail. Nevertheless,
situated at the nearside of the differential, difference. I have since talked to a couple I would carry out a leak-off test on the
just below and beside the nearside of Rover mechanics and they said it could injectors to ensure this is not the case.
driveshaft. The filler and level plugs be the Bosch injection pump, although The leak-off test is done by placing the
should not be blanked off, but may have this a pretty reliable unit. I believe there is leak-off pipe from each injector into a
a recessed hex. The plugs do become a valve on the injection pump body that receptacle. The leak-off return should be
very tight over time and it is always may benefit from cleaning, but I have not blocked off, then, by cranking the engine
advisable to check the filler plug can be touched this yet. for a couple of minutes, the fuel coming
removed before draining the gearbox oil. from the leak-off pipes can be measured.
In addition, the IB5 unit will have a filler The level in all receptacles should be
plug, but may not have a drain plug. equal, so if one is much higher than the
The type of oil depends on whether others, this indicates a faulty injector.
you have the PG1 or R65 unit fitted. Both As you have had no previous problems
were used in the Rover 45, as well as the and the fault appeared without any
IB5 gearbox. Thus, the oil will either be prior warning, I would be surprised if the
MTF94 or 10W-40. problem was an injector. The most likely
The shelf life of oil depends on the cause is the high-pressure fuel pump.
temperature and conditions of storage. As you point out, there is a fuel pressure
A sealed container that prevents A non-starting 2001 Rover 75 may have sensor and inlet filter on the Bosch
airborne moisture entering the liquid problems with the injectors or fuel pump. pump, which may benefit from cleaning.

Help!
OPEL KADETT
Screeching noise
Using my Pico NVH kit, I tracked down a screeching noise
VAUXHALL CORSA on a 1990 Opel Kadett E to the THM125C automatic transmission. It is
coming from the transaxle end, rather than the sidepan, valve body end.
First oil change From the ATSG General Motors manual on the 125C, I eliminated the possibility
that the speedo-driven gear needs lubrication – it’s well lubricated and does it with
My daughter bought a brand-new the car static – but it does sound as if it’s coming from the governor/speedo-gear
Corsa 1.2 and has now covered body. I thought it might be an alternator lack-of-bearing-lubrication noise or a loose
6500 miles. I was wondering if, alternator fan rattling and contacting the alternator body, but the NVH kit showed
in your opinion, it would be OK to do an that not to be the case. I’ve attached the original Pico.
oil and filter change? The reason I ask is The noise only occurs at one engine speed, with the car moving or static. I can
I have read that some cars have running-in get it in neutral and in gear, although it’s easier to achieve and stay at the exact revs
oil from new and I am not sure if Vauxhall when in gear, which is about 1200rpm. I wasn’t able to measure the revs precisely
employ this system. In the past I have because all four channels on the PicoScope were in use.
always changed the oil and filter every six I’ve dosed the transmission with Wynn’s ATF Flush and extracted all the oil from
months regardless of mileage. the sump and refilled it three times while collecting the waste fluid from the return
James Shaw oil-cooler pipe. I used AC Delco Dexron III ATF. I have some Wynn’s Automatic
Transmission Treatment, but I’m reluctant to add this to a proprietary lubricant that
As you say, some engine meets the gearbox manufacturer’s standards, especially if it’s going to start swelling
manufacturers use a different seals that are fine at the moment.
Drive chain sits
oil for the first fill than what With it being a resonant noise, I’m between flywheel
is recommended for the balance of not too worried, but I wonder if you and gearbox in this
can shed any light on it? Looking on section of casing
the vehicle’s life. At 6500 miles, your
daughter’s Corsa will have bedded in YouTube at a teardown of a THM125C,
the necessary components and I would I have a mental image of a set of
be quite happy for the oil and filter to plates loosely vibrating at resonance.
be changed. The oil capacity should be Martin Rubenstein
four litres and the recommended oil is a
fully-synthetic 5W-30 low saps oil such With noise vibration
as Comma Syner-Z 5W-30. harshness (NVH) issues,
it can be very difficult to
pinpoint the source. One of the
VAUXHALL ASTRA BERTONE problems in tracing such problems
is that noise and vibrations can
Gearbox/ travel and isolating them may not

always be straightforward, even
clutch problem with the sophisticated kit you

have. Because of this, and because
The 125C gearbox layout showing the drive line.
you mentioned that at one point you suspected the alternator bearing, I would
I recently bought an Astra Bertone
remove the alternator belt just to be sure that one of the driven pulleys is not the
with the Z18XE engine that is
cause of the vibration. You can then be confident this area is not to blame.
possibly suffering from gearbox/
The Turbo-Hydramatic 125C gearbox is quite a complex unit, but the earlier
clutch failure. When starting the car
units contained a torque converter clutch that locked up at around 50mph using
from cold, there is a whirring sound that
vacuum and temperature sensing; later units use a solenoid activated by the ECU
instantly goes away when you put your
to lock up the impeller. As the noise occurs at only 1200rpm, it may be due to the
foot down on the clutch. It also seems to
impeller vibrating within the torque convertor, although I appreciate that this is
go away after a few minutes of running.
not near the area you suspect. One other possibility is that the chain driving the
When I was reversing the car, the
main shaft has stretched slightly and vibrating through the output shaft, which
nearside front wheel felt like it was seizing
would travel the length of the gearbox.
up or going to fall off. The nearside lower
balljoint on the wishbone had a lot of play
in it, which was also causing play on the depressed. The input shaft that will be With the driveshaft removed from the
wheel. It did occur to me that, given the spinning at engine speed will slow down hub, you should be able to feel any
amount of play, the driveshaft may not be and stop when the clutch is depressed. problems with the outer joint by rotating
sitting in the gearbox correctly. As the noise goes as the vehicle it in a circular motion. This should be
Could this be the case or do you think warms up, this may indicate that warm smooth and, if any notches can be felt,
the balljoint is the culprit? oil is reaching the bearing and silencing this would confirm a failure of the joint.
Paul Mccully the noise. It may be worth checking the oil
It is unlikely that play in the balljoint level of the gearbox to ensure that the
If the noise goes away when the is preventing the driveshaft from sitting problem is not down to lack of oil. Of
clutch is pressed, it is most likely correctly in the gearbox, but you may course, given the balljoint/driveshaft
to be the input shaft bearing. If it have an outer CV joint which is worn and issue, it would be difficult to test-drive
was the release bearing, the noise would locking up, which would give very similar the vehicle to ensure that you have no
normally increase as the clutch was symptoms to the ones you describe. further gearbox problems.

Help!
VAUXHALL ZAFIRA
BMW 3-SERIES
Runaway diesel Switched live circuit
I need advice on resolving issues
following a runaway diesel engine My vehicle is a 2012 BMW 320i Sport.
on a 2006 Zafira 1.7 CDTi. The I recently purchased a dashcam and
circumstances were that I was driving hardwire kit, which I’ve routed through
along normally, then plumes of thick white to the engine bay fusebox. The trouble I’m having
smoke came from the exhaust. I dipped is finding a switched live circuit to use, as they all
the clutch, but the engine raced even stay live when the ignition is switched off. Apparently
higher. I coasted to a halt and turned off most circuits do stay live for a while, so I would
the ignition, but the engine continued appreciate some guidance on how to find one.
to run, until eventually it stopped of its I have attached a fusebox diagram.
own accord, before self-destructing. John Bond
The fusebox layou
The garage recovered it and said it could
have been caused by an attempted The systems used in the modern vehicle
regeneration following a blocked DPF. do keep certain circuits live for a period
So far, they have done an oil and filter after the ignition has been switched off.
change, emptied out all the induction As you have found, it is difficult with the CANbus
components of the engine oil/diesel fuel system to locate a directly switched 12V circuit.
mixture, and checked the timing belt, In the boot fusebox, fuse number 162 is a switched
timing and camshaft sensor, but the accessory circuit and should do the job. Alternately,
engine will not fire up. They have found the circuit to either the heated seats (fuses 141 & 164 in your picture) should
multiple error codes relating to over- power down within a short period.
revving. They tried Easy Start, just to see If neither of these options works, I suggest using a relay taking its power from
if they could get it to run, but it refused a permanent live. With the switch side of the relay wired into the rear of the EOBD
to start. There are no nasty noises when socket using pin number 1, this should be switched on and off with the ignition.
it turns over and it appears to have good
compression. It feels normal on cranking.
The injectors cannot be removed for a test. but when the car has warmed up a little bit
Eddy Hurst the selector becomes stiff to move. The
stiffness occurs before the temperature
One of the more common at which the transmission ‘thump’ occurs.
problems with the 1.7 CDTi engine I’ve greased the selector joints underneath
is a failure of the turbo seals, the car but this hasn’t helped.
which allows engine oil to enter the inlet BMW 5-SERIES R Darvill
system. Once in the cylinders, the oil will
begin to burn and can feed the engine,
causing the runaway effect you have
Banging gearbox Answering your last point first,
provided the engine idle speed is
experienced. This is far more likely than I would appreciate some help with correct, it is quite normal for the
a failed regeneration being the cause. an issue I have with the automatic vehicle to creep forward if left in gear
You mention that the induction gearbox in my 2002 BMW 540i with and unchecked. As long as the engine is
components were emptied of oil (there the ZF 5HP24 transmission. When coming not labouring when pressing the brake
should be no fuel in the induction to a stop, the gearbox bangs down into to prevent this movement then there is
components) and this would back up first gear. It can be controlled with a very, nothing to worry about.
the idea that the turbo was the cause very gradual stop, but in normal driving As the vehicle has covered 133,000
of the failure. The multiple codes found it happens at every stop. The issue only miles without any evidence of having
should be cleared to allow any further occurs when the gearbox has warmed up. had the gearbox oil changed, I would
returning codes to show up. I have a C110 code scanner and have start by doing an oil change to see if
You say that the engine stopped of noted that the problem starts when the any improvement is made. If there is no
its own accord, before self-destructing. gearbox reaches around 90°C and I have improvement, the problem may be due
If this is the case, any damage to the seen the gearbox reach 107°. The car has to a faulty speed sensor in the gearbox.
pistons, bores or valves may also have done 133,000 miles and, as far as I know, There are two sensors that detect input
damaged the injectors. It would be has never had a gearbox oil and filter and output speeds, and you should be
interesting to know how much oil was change. I’ve checked the fluid level with able to check these using your C110
left in the engine when it finally stopped. the car running and it is fine. Every other scanner to read off the live data. I would
A very low level would confirm that the aspect of the gearbox works well, including list the transmission temperature sensor
engine was running on engine oil when kickdown and manual selection mode. as another possibility, but you have
the failure happened, but if the level was One other point that may be relevant already checked this and ruled it out.
still high then the failure may have been is that the car will drive at around 5mph Another problem which can occur on
due to a fuel injection fault. on the flat in forward and reverse without the 5HP 24 gearbox is that the valve
As the engine will not fire up with pressing the accelerator pedal. I have body can crack, releasing pressure from
Easy Start, this suggests that there is never owned a car with an automatic the seals. This normally only occurs
insufficient compression. The next step gearbox before, so I’m not sure if this is when the ’box is warm and the valve
would be to remove the injectors to test normal. I’d also like to add that the gear body slightly expanded by the heat. I am
the compression of the cylinders and to selection between Park, Neutral, Reverse not sure if this would affect the actual
check the injectors for damage. and Drive is fine when the car is stone cold, gearchange, but it is a possibility.

Help!
removed the instrument cluster, which cluster. I can only find one fuse in the SAM
was when the cable connection dropped for the cluster and that is obviously OK.
out of its seating position. I refitted the Simon Wright
cluster, making sure it was correctly
SMART ROADSTER connected, reattached the battery and Provided the plug to the
turned on ignition. This time everything lit
Tachometer up, but the tachometer wasn’t working.
Is there any way of checking the cluster
tachometer wasn’t misaligned or
inadvertently placed in the wrong
position, it is unlikely that any damage
trouble without creating more problems? I have
inspected the cables leading to the
should have occurred to the unit, given
that you took adequate precautions by
The instrument cluster tachometer cluster and noted some fusible links on disconnecting the battery. However, it
doesn’t function at all in my 54-plate some of the wires, but I’m not sure how is possible that even though you believe
smart roadster with 107,000 miles. to test them without disturbing the SAM the plug is now correctly located, a poor
The car is fitted with the optional extra trip unit below. I’m not sure how to check the connection is still present. With this in
computer which still shows the correct cluster circuit for the tacho stepper motor, mind, my first move would be to remove
RPM, so I’m assuming the RPM signal/ or if the tacho stepper motor can be the plug again and spray the plug and
sensor is functioning properly. replaced easily and what problems would connection with an electrical switch
Unfortunately, I caused this problem arise if I tried to replace it. cleaner spray, then firmly reconnect
by swapping the instrument cluster I have managed to get hold of a the plug in the socket and check the
dial face from white to black, although secondhand instrument cluster – I’m operation of the tachometer.
the procedure went exactly as per the unsure of its mileage and other settings As the second rev counter function is
Evilution website instructions. The stored in it – but I’m not too confident operating, you can discount the possibility
problem arose when I reattached the about fitting it as I have read that the that the tachometer circuit is at fault.
instrument cluster connection plug, as mileage stored in the cluster EEPROM As you mentioned the evilution.co.uk
I unknowingly failed to seat and connect it could overwrite the ECU/SAM mileage. website, I presume that you are a
properly. I then connected the battery and I have also got the correct wiring diagram member of the site, in which case
turned on the ignition, but nothing lit up on for the car, but I’m unsure what to look for excellent instructions are available for
the cluster. I disconnected the battery and as everything else is working fine on the cloning the ECU. From the details I have,
the ECU will override the cluster and not
the other way round.
SMART FORTWO Other problems that can occur include
water damage to the SAM unit, but
Servicing tips as everything was working before the
disconnection, this is unlikely. One option
I have a 2002 smart fortwo 599cc with only 51,000 miles on the clock and may be to let a company such as this
would like to service it myself. I have changed the oil and filter, and fitted one http://bit.ly/2uPIEdu check and,
new tyres and a battery. In its life, it has been serviced nine times if required, repair the unit. Prices start
(according to the paperwork), but I can’t be sure what was done, as the items at around £40, but as I've not personally
are not mentioned, only the mileage of service. It seems impossible to find a used this company this is only a
manual. Perhaps you could advise me how I check the known faults and suggestions and not a recommendation.
problems? Even a small book on servicing would be useful.
Terence J Gwin
The plug lead removal tool. SMART FORTWO
As with many modern vehicles, a
workshop manual is available but
only via an internet download. As you
Programming
have written to me using paper and pen, I will
assume that you do not have access to the internet.
remote key
The smart’s three-cylinder engine, as you have no doubt discovered, does not My granddaughter received two
have a sump drain bung (although conversions were available) and the oil must keys with the 2005 smart fortwo
be drawn out with a syringe when it requires changing. The engine also has six cabriolet she bought recently.
spark plugs, and while the top three are quite accessible, the other three sit at the One remote works fine, but the other
back of the engine and require the removal of the rear bumper to allow sufficient one probably needs a new battery. If we
access. The spark plug leads also have a metal cap which is prone to sticking onto replace the battery will the remote need to
the plug. A special removal tool is available, but I just use a length of flattened be synchronised with the car?
brake pipe with a small hook formed at the end. Dave Fisher
Provided regular oil changes are performed, the smart is a reliable vehicle.
Sometimes the door handle can stick, causing the door to not latch. This is a As the system does work with
common problem, caused by a sticky cable in the handle, which is easily removed one key, replacing the battery on
by undoing the screw from inside the door handle and fixing this can be quickly the second key should restore
remedied by lubrication. its operation. If the problem is more
Another area sometimes prone to failure is the clutch actuator, which can than a failed battery, the keys can only
become sticky and require cleaning. This will be apparent by a failure of the unit be reprogrammed using diagnostic
to select a gear and three bars displaying in the gear display window. equipment. Before replacing the battery,
There is a smart car owners club that offers an offline membership and the ensure that the second key will operate
contact details are: thesmartclub Ltd, Offline Membership, 1 Corbiehill Park, the ignition and start the engine, which
Edinburgh EH4 5EQ; Tel 0845 299 0332. will confirm whether the immobiliser
chip has been affected.

Help!
loss from the sump gaskets on the MINI position, so I manually opened it with the
One, but as the gasket sits above the emergency cable. This has left her with
oil level, the loss only occurs when the a boot that remains shut, but can’t be
vehicle is on the move. opened without lifting the rear seat. I have
One litre of oil every 450 miles is confirmed that the solenoid is working.
MINI ONE excessive and the allowed limit according Do you know of any common faults with
to BMW is one litre every 1000 miles. these cars? I guess a break in one of the
cables from the opening and closing of
Oil consumption With this in mind, I would definitely
bring it to the attention of the warranty
company in the first instance, although
the tailgate is the most likely cause, but
I have been unable to track down a wiring
My daughter bought a 2007 MINI
One in May 2015. It goes well, if this is an aftermarket and not a diagram to identify each wire.
doesn’t appear to have any oil BMW warranty they may not cover Chris
leaks and doesn’t burn oil. The mileage is this problem. If this is the case and
approximately 86,000. your daughter’s MINI has a full service Although the vehicle has been
I have read on websites that the oil history, I would bring it to the attention re-registered, it is normal to put a
consumption can be quite high, but after of your local BMW dealer, although as the registration number on the vehicle
careful monitoring I am finding that the vehicle is now out of the manufacturer’s which reflects the year of manufacture.
vehicle is only achieving around 450 miles to warranty it is unlikely they will be able to Working on this basis, I am assuming the
one litre of oil. Do you think I should inform carry out any repair under warranty if the MINI is a 2007 (R50-N12) model.
the warranty company of this situation vehicle was not purchased through them. As you correctly say, the most likely
before the warranty expires? Are you aware source of the problem is a broken wire
of any BMW response to the problem of MINI COOPER between the body and rear hatch. The
high oil consumption in the MINI? wires to the solenoid should be green/
Eddie Gracia Boot lock grey and green/brown; there are also
two earth wires on the solenoid, both
The first thing I would check I wonder if you could help me of which are brown. By pulling back the
is the PCV (positive crankcase with my sister’s 57-plate MINI sheathing between the body and the
ventilation) valve; this is located Cooper D, although I understand rear hatch, it is very likely that any break
at the top of the cam cover on the left that the car has been re-registered, so in the wire will become visible.
as you look at the car from the front. I can’t confirm its actual age. The problem Autodata also informs me that water
This valve does wear, causing excessive started when she found she was unable ingress through the rear wiper spindle
crankcase pressure, which can lead to oil to shut the boot. When she asked me to can also cause problems by entering
use. There have also been reports of oil look at it, I found the latch in the locked the harness.
the reversing light switch. Loosening off ran OK, but the engine light remained
the back bracket is simple enough, but illuminated, so I took it to a local garage to
accessing the bellhousing top bolt is have the codes read. I was told it was an
difficult without dropping the gearbox EGR problem, but the garage reset the light.
slightly. This requires the gearbox to be So now I have a car with no real fault and
supported and the crossmember lowered. no engine light, although it still stutters
MITSUBISHI SHOGUN
The top bolt does not need to be removed occasionally, particularly at a steady speed
when I lift the throttle slightly. I decided to
Fitting a reverse totally, just loosened off enough to allow
the bracket to move sufficiently. Rubber
hoses connect the vacuum pipe at either
try EGR cleaner spray and also ran some
fuel system cleaner with a full tank of fuel,
light switch end, so once the metal pipe has been
loosened, it can be put aside to access
and this appeared to make a difference.
The engine idles smoothly, seems to pull
I’m trying to figure out how to the reversing light switch. As the box has OK, the fuel consumption is pretty good at
replace the reverse light switch also been dropped slightly, access to the 30-35 mpg, and there’s no smoke or signs
on a 56-reg Shogun Sport 2.5 TD. switch is easier. of a problem. However, it still occasionally
I can see where the switch is located, but This may seem like a lot of work to stutters when I lift the throttle.
how do you remove it? There’s almost no replace a switch, but sometimes the Is this still a symptom of an EGR
space between it and the car floor and long way round is the quickest. This way problem or is there something else likely
there is a solid vacuum line on top of it, it is also easier to start the thread on the to be causing it?
plus the vacuum line bracket is in the way new switch, avoiding the possibility of Thomas Hills
and it almost appears to be recessed. Do cross-threading.
you know if a special tool is required? The symptoms you have do
Matthew Fliege suggest a sticking EGR valve,
MITSUBISHI OUTLANDER especially given the information
As far as I am aware, there is no from the fault code and the fact that
special tool for the job. Here’s
the method I use to replace it.
EGR problem things have improved after using an EGR
cleaner. If the valve has gummed up, it
As you have seen, the switch is located I have a Spanish-registered 2010 may require another treatment with the
on the offside of the gearbox. The vacuum Mitsubishi Outlander 2.2 DI. cleaning spray to fully shift the carbon
line that runs alongside is secured in two Recently, the vehicle stalled and, that builds up and restricts its operation.
places on the gearbox – the front fixing when it was restarted, went into ‘limp- In severe cases, it’s possible the unit will
is through the bellhousing top bolt and home’ mode and showed the engine fault need to be completely removed to clean it
the back fixing is on a bracket just behind light. Next day, the vehicle started and effectively or may even need replacement.

Help!
MAZDA5 Have a
problem vehicle?
Bad vibrations GET IN TOUCH...
My 2007 Mazda5 2.0 Sport is experiencing a vibration through the steering
wheel and the body of the car. The problem is most noticeable when If you have a problem vehicle,
accelerating between 60-70mph. Car Mechanics has the answer in
The problem started after I had some work done on the nearside driveshaft the shape of our technical editor
– there was perhaps a slight vibration before the work, but nothing like it is now. STEVE ROTHWELL. Contact Steve,
The car failed the MOT due to the outer CV boot being split and, when it went in for as detailed below, for FREE advice
repair, the garage found the inner joint was corroded and required replacement. on all car-related problems. Please
There is now what looks like a rubber sleeve fixed to the driveshaft with cable ties, help Steve to help you by giving as
which I presume is a balance weight that was removed in order to replace the much information on the symptoms
gaiter/CV joint and was put back in the wrong place. as you can.
I have had all four wheels balanced and also had a full four-wheel alignment check As Help! is a free service, some
and adjustment. Do you know if it is possible to have the driveshaft properly balanced complex questions may require more
while it is on the car and, if so, can you advise me of any companies in or near Kent time and resources than we can
who could do this work? If not, is it possible to have the shaft removed, balanced and reasonably allow – when this is the
replaced somewhere locally? A last resort would be to replace the entire driveshaft case we will let you know.
– would that need to be a manufacturer’s original part to guarantee good balance
Steve will reply to all queries as
or would an aftermarket item be fine?
quickly as possible, but please allow
Tim Collins up to 28 days for a reply. Difficult/
complex questions or those requiring
From your description and the fact that research may take a little longer –
the vibration started after the remedial please be patient.
work for the MOT, it does sound as though
the balance of the driveshaft is the problem. Neither Bauer Media nor Steve
Cable ties are not really adequate to ensure that The driveshaft Rothwell can accept any liability for
showing the centre loss, damage or injury resulting from
the balance weight does not move on the shaft
balance weight. replies to readers’ queries.
and I would replace these with wormdrive clips.
I know of no company that can balance the shaft on the vehicle. I would first To access web addresses starting
try to adjust the balance weight – it’s less likely to have been put in the wrong with http://bit.ly just type these into
position than it is to have been rotated incorrectly. By marking the shaft and the your browser address line, rather
weight, it should be possible to rotate it 90° at a time, then road-test the vehicle than the search engine and they
to assess the effect. If this reduces the vibration, further fine-tuning by rotating should work as intended.
10° or so at a time may alleviate the problem. The other option would be a
replacement shaft, but, as you have already paid out for a replacement joint, this
should not really be necessary.
WRITE (enclosing a SAE):
HELP! PAGES
CAR MECHANICS
and the needle stayed at the top no BAUER CONSUMER MEDIA LTD
matter the throttle position and it was still MEDIA HOUSE, LYNCHWOOD,
stuck there when I returned home.
PETERBOROUGH PE2 6EA
The following day, the rev counter went
wild for the first mile or two, then it started
to relate to the throttle position and over E-MAIL:
NISSAN ALMERA the next half-hour operated normally. [email protected]
Since then, on most days it always starts Please include your postal address
Rev counter off wild and later calms down. I am sure

that the needle responds to the throttle
position as it calms down, which led me problem with the Almera rev counter
reading to think inlet track depression was

involved as the response of the needle to
and some owners have been successful
in fixing it by removing the dash,
I have a 1995 Nissan Almera 1600 throttle is instantaneous. However, as it stripping out the rev counter and re-
GX auto petrol with engine GA16 DE. improves, one realises that it is the RPM soldering the joints. This will take just
It has 73,000 miles on the clock. controlling the needle. Whatever the rev a short touch with a hot soldering iron
About a week ago, I was in heavy traffic counter says, the engine always responds on each visible joint on the circuit board
and needed to get over to the right to flawlessly to throttle. and will rectify the problem if it is due
take a right-hand turn at the next lights. Ken Wilkinson to a dry or cracked solder joint.
I indicated right and floored the throttle, Before trying this, however, I would
pulling into a gap. I glanced at the rev The operation of the vehicle rev first check and ensure the connecting
counter and the needle was up against the counter is electronic and driven plugs are making a good contact with
maximum stop. By then, I had feathered by the information received the dash and that none of the plugs are
the throttle as I had all the speed I from the ECU. Given that the engine loose. A poor connection or bad earth
needed, the kickdown had operated as performs correctly and the throttle may be to blame for the fault.
per usual and everything except the rev response is good, the fault is most If the problem is more severe, a
counter was fine. I got held at the lights likely in the gauge itself. This is a known replacement rev counter will be needed.

Steve Rothwell answering your ENGINE MANAGEMENT queries
AUDI A3 The one-way non-return valve.
Difficult starting
My car is a 2008 Audi A3 2.0 TDI (engine code BKD) costs around £60, but when
showing 100,000 miles on the clock. It is serviced and this problem occurs it does
gets new oil, fuel and air filters regularly. normally trigger a fault code.
Over the past year, it has developed a strange fault. It starts Other common faults
up first thing when hot or cold, regardless of the outside include the failure of the injector rubber seals and problems
temperature, for a day or two, but after 3-4 days it behaves with the camshaft operating system. If either of these
as if there isn’t diesel coming through the system. It will are present I would expect to see smoke when the vehicle
eventually start on the second or third try. started and/or a slight misfire. As you report neither of these
Apart from this, all systems are OK and there are no warning problems, we can hopefully discard these possibilities.
lights. Audi has tested it for hidden faults, too. Aside from this, This leaves the fuel pressure system. One possibility is
the car runs like new, cold or hot. that the fuel pump at the end of the camshaft (tandem
George Patelaros pump) is draining when left for a period of time, meaning no
fuel is initially supplied to the injectors.
The engine in your Audi is the Pumpe Düse unit. With this in mind, I would examine the fuel pipes and
The injection pressure is delivered by the injector connections on the fuel filter. Also inspect the fuel pipes
itself, using the cam lobe to operate the injector and between the fuel filter and pump. There is a non-return
provide the pressure. The injection timing is still electronic valve built into this pump, but it can fail over time. A
and a wiring loom runs within the cam carrier housing to cheaper alternative to replacing the tandem pump, which
trigger the injectors. also supplies the vacuum to the braking system, is to fit a
One problem that is very common on this engine is for the separate non-return valve in the system. VAG manufacture
loom that runs within the cam carrier housing to fracture. such a valve (part number 165201542B) and it costs around
This will give an intermittent connection and can cause a £18. Fitting one of these in the return feed from the tandem
problem such as you are experiencing. A replacement loom pump to the fuel filter should remedy the problem.
X The throttle
potentiometer and
throttle body have
been replaced.
JAGUAR XJ6 X The ECU has been
replaced, along with the
Sudden MAF sensor, Lambda
sensor and spark plugs.
cutting-out X The water temperature

sensor was replaced.
I am tearing my hair out with None of this has failed
my 1995 Jaguar XJ6 X300 3.2 to eliminate the fault, which still occurs diagnosis difficult, but I am assuming
auto, with full service history and at between 55-60 minutes whether the you have replaced all the above items
88,000 miles. It will start and run from cold vehicle is driven or stationary. with either new or tested components.
perfectly for 55-60 minutes, then it stops As a last resort, the car was booked into If not, the problem still sounds like the
without any prior warning, bringing up the the main agent for a full diagnostic check. crankshaft sensor has issues.
EML and battery lights. The engine will They had the vehicle for five days but were Taking it that all the replacement parts
restart immediately, but the fault will then unable to come up with anything. are good and not a concern, this leads me
reoccur at ever-shorter intervals. There is I am sure the problem is heat-related, to believe the problem must lie within the
now some irregular running and misfiring. but what could it be? wiring system, with the most likely source
The following items have been checked: Peter Tomkins being either the loom from the crankshaft
X All earth and electrical connections. sensor or the multi-plug on the ECU.
X Fuel pump, fuel pump relay and fuel filter. Given the circumstances of the Testing the system with an ohmmeter
The fuel pressure regulator has been failure, the problem does appear one wire at a time will be a laborious
replaced and the fuel pressure tested. to be associated with the heat task, but may highlight the fault.
X All relays and the fuseboard. The of the engine. You also seem to have You have not mentioned connecting
battery has also been replaced. replaced just about every component the vehicle up to a scanner and your XJ6
X The cam sensor, crank sensor and six that could be the source of the problem. should have a 16-pin data connector
coil packs have been replaced. There is always the possibility that one under the dashboard. This may help
X The collision cut-out switch was tested of the components you have replaced retrieve a code that could point you in
and found to be OK. is also faulty and this can really make the right direction.
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Diagnostics Doctor
VOLKSWAGEN PASSAT
Diagnostics Doctor
Exhaust First, I should say that all
vehicles with a DPF should be Diagnostics Doctor is a FREE helpline
pressure sensor using a low ash oil to extend the
life of the DPF. It should be noted that
service for CM readers – including
trade readers – who are struggling with
The EML in my 2009 Volkswagen ash and soot are two different products. diagnostic/engine management related
Passat 2.0 CR TDI came on after Soot will burn off from a DPF during faults. Steve Rothwell will answer all
93,000 miles. My Foxwell NT500 regeneration, whereas ash will not, as it your queries. He will need as much
is made up of inert inorganic metals and detail as possible:
scanner – which I am not very good
MAKE, MODEL, YEAR and ENGINE
at using! – is giving the codes ‘001137 mineral compounds from lubricants and CODE of your vehicle, and the type
exhaust pressure sensor 1 (G450) the result of engine wear. This will build of management system installed
implausible signal’ and ‘009299 DPF filter up to a point where the DPF will become Obviously, Steve will not be able to
differential pressure sensor implausible blocked. The regeneration will continue assess the vehicle up close, so his
signal’. The scanner gave the code info: to take place but will not reduce the answer will be on the basis solely of
‘01137 Fault status 11100000; priority 2; back pressure. The maximum oil ash your description. This is a FREE service
freq 1; pressure -82mbar and -77mbar’ and volume of the DPF should be around and it may take some time to respond
‘09299 Fault status 11100000; priority 2; 380ml and, using the recommended to certain problems. If you would like
low ash oil or low SAPs (Sulphated Ash, to receive a personal response via post,
freq 1; pressure -87mbar and -77mbar’.
please enclose an SAE.
I have cleared the codes and driven 30 Phosphorous, Sulphur), it would be
Write to:
miles so far without bringing on the EML expected that the engine should have
again. I assume that it is the same sensor? covered nearly 400,000 miles before DIAGNOSTICS DOCTOR
If so, I suppose this could be a faulty sensor this was achieved. CAR MECHANICS
or problems with hoses or wiring. Given The ‘G450’ implausible signal codes BAUER MEDIA, MEDIA HOUSE
that I have had the differential pressure do indicate a fault with the sensor, but LYNCHWOOD
sensor replaced on a Peugeot 307 2.0 at it is also very likely that the problem is PETERBOROUGH
100,000 miles, it would seem likely to be in the wiring loom between the sensor PE2 6EA
the same thing. However, I understand it and the ECU. Pay particular attention to e-mail:
would need adaptation/calibration once the loom where it intersects with other [email protected]
fitted, and to do this I need a channel sets of wires just above the gearbox. It
number and value to code it. I know that has often been found that where the
two part numbers were used, but mine is loom then connects to the vehicle body,
the later one – part no 076 906 051B. the plastic insulation trunking can chafe
Common abbreviations
Also, the DPF has 108ml of ash and it through the wires internally. If no faults ATS Air Temperature Sensor
has been 530 kilometres since its last are found with the wiring, then the AFM Air-Flow Meter – not a MAF type (see below).
regeneration. How much ash can the DPF sensor will most likely need replacing It could be, for example, a vane type
hold before it needs to be cleaned? – this does not need calibrating, but just CAS Crank Angle Sensor
Ian Hildrew requires fitting into place. CPS Crank Position Sensor
CTS Coolant Temperature Sensor
ECT Engine Coolant Temperature
ECU Electronic Control Unit
SUBARU IMPREZA EGR Exhaust Gas Recirculation – meters exhaust
gas back to the intake manifold
EML light The idle

air control
EML Engine Management Light
EMS Engine Management System
My car is a 2002 Subaru Impreza valve. FCR Fault Code Reader
2.0 DOHC non-turbo with
HT High Tension – ignition output to the spark plugs
105,000 miles. The EML light
IAV Idle Air Valve
came on, but only downhill with throttle
ISCV Idle Speed Control Valve – usually operated by
closed, then went out again. The fault a motor controlled by the ECU
code left behind was ‘P1507’, which I control system. The most likely cause
LOS Limited Operating Strategy – if the ECU detects
was told indicates the neutral interlock of this is the idle air control valve a malfunction, it runs a programme to allow the
switch in the gearbox is faulty. This was (IAV). It is possible that the wiring or car to still go, but at reduced efficiency
replaced with a new one, but now the connection is at fault, but given the MAF Mass Air-Flow meter
EML light is on all the time and the ‘P1057’ fact that the EML only comes on during MAP Manifold Air Pressure
code has returned. The engine seems downhill runs with the throttle closed MIL Malfunction Indicator Lamp
to start and run OK, albeit with some and the light then goes go out, I would PCV Positive Crankcase Ventilation – takes crankcase
hesitation pulling away at junctions. expect the problem to be a sticking gases and recycles back to the inlet system
Dave Leslie IAV. I would first try removing the TBPS Turbo Boost Pressure Sensor – used by the
valve and cleaning it, but use a new ECU to regulate turbo output
The ‘P1057’ code actually gasket as a failed gasket will also cause TPS Throttle Position Sensor
indicates that there is a issues. If this does not rectify the VSS Vehicle Speed Sensor
malfunction within the idle problem, I would fit a new IAV. WOT Wide Open Throttle
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Electronic FORD
FOCUS
Diagnostics
Tracing and fixing faults in electronic engine management systems
1.8-LITRE
PETROL
The Ford Focus has always been a family favourite.

Kim Henson and Edward Haggar delve into
the management system of a 1.8-litre
petrol example from 2010.
M
aking its European debut petrol units,
in 1998, Ford’s Escort first dating
replacement, the Focus, from 2001 (and
NOTES:
initially received mixed part of the Mazda All references in our text and
reviews for its idiosyncratic styling, L engine family). This is captions to ‘left’ and right’ sides are
yet was almost universally praised for the engine in the Focus featured here, a from the point of view of someone sitting
in the car and looking ahead.
its dynamism and comfort. Successive second-generation, 1.8-litre (engine code
generations have become more QQDB) petrol model registered in March while the plug on another cylinder fires
conventional in appearance and, 20 2010. This model features a combined simultaneously on the exhaust stroke,
years down the line, the Focus remains igniton and fuel Engine Control Module this has no effect on engine power and is
a family and fleet favourite, for both (ECM) from Visteon. thus said to be ‘wasted’.
new and used examples. At various Our guide to this model’s engine and In addition, this Focus features a
times during the last decade it has its system is Edward Haggar. Smart Charge alternator, which varies
been the best-selling car in Britain, and the level of battery charging according to
sometimes the best-seller globally, too. the temperature of the engine, delivering
Second-generation models arrived for Preparation a higher rate of charging at lower
2005, with mildly-restyled body panels, At the outset it is worth mentioning temperatures. It is important to never
lamps and front grille introduced late in that this engine operates under a parts- jump-start a car with a Smart Charge
2007. The Focus MkIII arrived in 2011. saving wasted-spark ignition system. set-up if the battery is discharged. This is
Over the years, a wide variety of petrol In this, two spark plugs are fired at the
and diesel engines have powered the same time in pairs: one plug fires on
Focus, including direct-injection, twin the compression stroke, igniting the
overhead camshaft, four-cylinder Duratec fuel mixture and producing power,
1798cc 4-cylinder 16v petrol PRE- & POST-CAT

OXYGEN SENSOR
CONNECTORS
EXPANSION
TANK IGNITION COILS x 4
BATTERY (EFB)
UNDER COVER
AIRCON FUEL INJECTORS x 4

FUSEBOX
PRESSURE
SENSOR AIR
FILTER
HOUSING
Thanks to Rhydian Edwards for driving
his Focus 1.8 about 500 miles from north THROTTLE BODY
Wales and back for our photo session.

Electronic Diagnostics Ford Focus MkII 1.8 petrol
because the system may supply up to 18 pressure (MAP) sensor carrying out
volts, potentially causing major damage
to electrical components/modules on Tool of choice this task. Again, the information is fed
through to the ECM as a vital part of
the vehicle. It is also important to note the fuel requirements equation.
that vehicles with Smart Charge systems Note that, in Ford terminology,
require special enhanced flooded types the ECM is known as the Powertrain
of battery (EFB); normal lead-acid types Control Module (PCM).
will not do the job.
Note that there is no cambelt to
renew on this engine, as it features a Fault 1
chain-driven camshaft.
This Focus employs an accelerator X For this Focus, the Snap-on Verus IGNITION COIL FAILURE
position sensor mounted on the throttle Pro diagnostic tool is user-friendly Symptoms of our first fault on this Focus
and comprehensive in coverage. It
pedal. Like most recent vehicles, it has include misfiring, poor running and
can also be used with many other
a fully electronic link between the pedal vehicle makes and models.
possible cutting-out of the engine. The
and the throttle body, as opposed to the car will be undriveable and the engine
mechanical connection on older cars. The warning light will be illuminated, with
information gathered by the sensor is sent how warm the engine is and delivering fault codes stored for relevant cylinder
to the ECM so the required level of fuel/ this information to the ECM, which can misfires. This could be due to failure of
air mixture can be supplied to the engine. then calculate and control appropriate/ one or more of the four separate ignition
The inlet manifold incorporates optimum fuel delivery (see Fault 3). coils – with this engine one individual
throttle flaps that move in response to The mass air flow (MAF) sensor in coil serves each spark plug.
the accelerator pedal position. Throttle this Ford assesses the rate of air flowing The first diagnostic step should be a
flap cleaning is possible if performed through the intake system. The data is fault code check. Fords are really good
with care using a non-aggressive passed electronically to the ECM, which from a diagnostic point of view and a basic
cleaning agent and a small brush. then uses the information to calculate EOBD reader will show codes. You will see
Another vital component of the and adjust the required levels of fuelling. fault codes relevant to the failed cylinder.
management system on this Focus is the It is essential that the pressure Examples of these engines that are
coolant temperature sensor. This assesses within the inlet manifold is precisely poorly maintained can suffer from valve
the temperature of the coolant, indicating assessed, with the mass absolute or piston ring issues. Always remove the
Typical Ford Focus components
The sticker attached to the right-hand end of the cam cover This Focus needs an enhanced flooded battery (EFB), not a
1 can provide invaluable information about the engine. If the 2 conventional lead-acid type. Before carrying out diagnostic
sticker on your Focus is still in place and legible, it is worth taking procedures, check the battery to ensure it is of the correct type/
a photograph of it and saving it for the future. specification (see Preparation).
The Smart Charge alternator set-up

3 This vital main earth connection for the Four pencil-type ignition coils are
delivers a higher rate of charging
when the battery needs it most (eg, when
4 battery is attached to the left-hand front 5 used, one serving each spark plug.
the engine is cold). However, if the 12V suspension tower. Examine the connection Coil failure can result in a variety of running
battery is fully discharged, never jump- for corrosion. For future protection, it’s wise problems. We recommend renewing all four
start the car (see Preparation). to apply a silicone protectant. coils and the spark plugs at the same time.

Engine management The Visteon System 7 type ESU 121 management system
used on this Focus incorporates these primary components:
X Smart charge alternator X Inductive crank sensor X Knock sensor mounted
X EFB battery to engine block
X Brake position sensor mounted
to brake pedal X Coolant temperature
X 4 x fuel injectors
sensor, monitoring coolant
X 4 x pencil-type ignition coils X Accelerator position sensor temperature
(one serving each spark plug) mounted to pedal
X Fuel pump in tank,
X Wasted-spark ignition coil X Pre- and post-cat oxygen sensors with level sensor
spark plugs and check for arcing, but the rear of the coil plug. In some cases, coils at the same time – remember that
also pay attention to the tip for signs of damage occurs to the seal, allowing the other three are the same age and will
oil and excessive carbon build-up. moisture ingress and corrosion. have covered the same mileage as the
If suitable test equipment is available, If a new plug is required, a secondhand one that has failed.
carry out a cylinder leakage check or connector is inexpensive, but it will need
compression test – in each case you are
looking for obvious drops. If all is OK
to be soldered in. Don’t be tempted to use
normal connections because, over time,
Fault 2
on this front, you can then inspect the
ignition coils. A quick check is to swap
moisture will find its way in. Where
available, always use solder in conjunction
DEFECTIVE
the coil from one cylinder to another, with heat shrink for an air-tight seal. OXYGEN SENSOR
noting if the misfire moves to that Due to the high volumes produced, When our next fault arises, most of the
cylinder. A more in-depth test involves genuine Ford parts are usually relatively time the driver will only be aware that
using an oscilloscope to check primary inexpensive – a decent branded coil can the engine warning light is on, but that
and secondary circuits. be bought for around £20. If finances the car is driving faultlessly. In this
A less common fault is corrosion in allow, it is advisable to renew all four situation, the first thing to do is carry
Typical Ford Focus components (continued)
We advise carrying out careful checks Located just in front of the cam cover, These are the connectors for the
6 of the plug/socket connectors 7 along the front of the engine, are the 8 Lambda/oxygen/O2 sensors (pre-
serving the ignition coils. These are prone four fuel injectors. The good news is that the and post-cat). Check condition/security and
to corrosion due to the long-term ingress injectors are usually long-lasting. If fitting cable connections. The sensors determine
of moisture. Separate the connections and new injectors, the rubber O-rings on the the amount of oxygen present in the exhaust
scrutinise the plugs/sockets. ends of the injectors require renewal as well. system, advising the ECM to adjust fuelling.
The exhaust gas recirculation (EGR) The inlet manifold assembly The throttle body with idle control
9 valve is bolted to the left-hand end 10 incorporates throttle flaps which 11 system is situated within the intake
of the cylinderhead. The function of the move in response to the driver’s demands trunking and incorporates a flap valve that
EGR system is to recirculate exhaust via the accelerator pedal and accelerator allows fuel/air mixture to pass to the engine.
gases back through the engine, helping position sensor (see Preparation), to vary The flap and the interior of the throttle body
to minimise emissions. the fuel/air mixture entering the engine. must be clean to ensure correct operation.

out a diagnostic investigation and read Fault 3

the stored fault codes – you will see a Technical specs
code related to ‘oxygen sensor heater AILING COOLANT
Actual values
circuit open circuit’.
The next step should be to remove the
TEMPERATURE Component Value
connector – it is only clipped in place SENSOR Coolant temperature
– and inspect it for corrosion. We’ve come The symptoms relating to our third sensor pins 1 and 2 20°C,
across a Focus where the clip was broken fault are extended cranking times and 28,000 ohms;
and the connector was left hanging, a strong, fuel-rich smell coming from 80°C,
allowing water to enter and sit within the exhaust – plus, if it’s MOT time, 25,000 ohms
the connector, corroding away the pins. a failure due to excessively high CO Crank sensor 500 ohms
If all is OK so far, use a multimeter to readings. Diagnosing this without a bit
check the heater wires for resistance of experience can lead people down the Ignition coil 12 volts
– you will likely find an open circuit, wrong path and they’ll fit new parts that Oxygen sensor 3.5-4.5 ohms
meaning a new sensor is required. aren’t required. Injector resistance 12 ohms
Before installing the replacement Carry out a full diagnostic check. It’s Fuel pressure idling 3.8 bar
sensor, ensure the threads are clean to unlikely this will show any faults with
ensure a tight fit – a sensor that doesn’t the coolant temperature sensor, because
sit flush can allow air to be drawn in, the way the sensor works means it will but the reading will be high or vice versa
causing other issues. still be operating within its parameters, – it’s possible that it can fail either way.
Note that a special oxygen sensor so the ECM won’t trigger a fault. You will The coolant temperature sensor is
socket is a essential to aid fitting and probably find codes relating to ‘oxygen located on the right-hand side of the
removal, but they can be bought cheaply. sensors rich mixture’, which is where the cylinderhead in the coolant housing
If finances allow, change both pre- and inexperienced would fit a new oxygen – it goes without saying that you need to
post-cat sensors – the other sensor sensor. Live data now can be a real help, ensure that the cooling system is drained
might be the same age and mileage, thus if available. Look up coolant temperature before attempting to renew the sensor. It’s
could be on borrowed time. and you will find that the engine is cold not uncommon for this housing to leak as
The underbonnet fuse and relay box This Focus is comparatively unusual The air filter assembly is easy to
12 is found on the left-hand side of the 13 for a recent model in that the layout, 14 access and is positioned on the
engine bay, just behind the headlamp and function and electrical rating of the fuses in left-hand side of the engine bay, just
ahead of the suspension strut tower. Unlike the underbonnet fuse/relay box are marked ahead of the battery. Inspect the trunking
many modern vehicles, this fuse/relay box is on the underside of the lid, which also holds and ensure that all the securing clips are
easily accessible. a tool for removing and refitting the fuses. sound and securely tightened.
The bonnet latch assembly, linked Found adjacent to the coolant tank In this Focus, the diagnostic socket
15 to the key slot within the front grille, 16 on the right-hand side of the engine 17 is located low down on the right-
is located in a vulnerable position and can bay is the air-conditioning pressure sensor, hand side of the fascia. It is shown here
suffer from seizure unless it is regularly which measures pressure within the system with a bluetooth connector plug for the
lubricated. It’s worth applying fresh grease so the ECM can control operation of the Snap-on Verus Pro tool already plugged
at every service. aircon. This sensor is a three-wire type. in and ready to supply information.

Typical Ford Focus components (continued)
The Snap-on Verus Pro is a versatile tool that works well on

18 This screenshot on the Verus Pro is indicating live data
the Focus, as well as many other cars. This screenshot is
showing the general set-up/system list. From here the operator can
19 from our Focus, covering a full range of components and
choose which area of the management system to interrogate. operating systems. This is invaluable in terms of diagnosis.
As an example of the type of information the Verus Pro can Actuator tests are available using the Verus Pro. These help
20 provide, this screenshot shows live data relating to the coolant 21 to determine the source of problems with the dash gauges,
temperature and its sensor. Malfunctions resulting in calculations etc. Some owners find that pressing and holding down the fascia-
that are too high or low will adversely affect fuelling levels. mounted reset button can help with instrument panel diagnostics.
well, so it might be worth replacing it at

the same time as the sensor.
Always ensure that red long-life
USEFUL PREPARATION DATA
Below are the official recommended renewal intervals for the various components.
coolant is used. These systems don’t However, we strongly advise that the change intervals are at least halved.
require any special bleeding and usually Service intervals Every 12,500 miles or annually, whichever comes first.
bleed out OK. To start with, always fill Air filter Every 37,500 miles or three years.
the system to the ‘Max’ mark. Set the Fuel filter At least every 37,500 miles or three years.
heater controls inside the car to ‘Hot’, Spark plugs NGK TR6AP-13 or equivalent, renewed every 37,500 miles or three years.
start the engine and run it until the Coolant Every 10 years.
top and bottom hoses are hot; a digital Auxiliary drivebelt Every 125,000 miles or 10 years. Note that there is no belt
thermometer can make temperature tensioner; officially, renewal involves cutting off the old belt and using a special tool to
assessment easier. fit the new one, however the job can be done using a couple of well-placed screwdrivers
Once both hoses are hot, put on the so long as you’re careful not to damage the belt.
pressure cap and wait for the cooling fan Brake fluid Every two years.
to operate. After this, stop the engine, Engine oil 5W-20 Castrol Magnatec (or equivalent)
allow the engine to cool and re-check the Capacity Service fill, 4.3 litres; dry fill, 4.6 litres.
coolant level. It goes without saying to
never remove the cap when hot.
were just three grades of engine oil in after the car has been serviced. In fact, it
Fault 4 the workshop: 10W-40, 15W-40 and is the tappets sticking that causes these
20W-50. Now garages typically stock 10 problems. If the trouble is identified at
INCORRECT different types, with extended change an early stage, a good engine flush and
SPECIFICATION intervals and lower emissions, so using
the right oil is crucial.
oil change using the correct oil can sort
things out. However, if the engine is left
ENGINE OIL With regards the Focus, we have running with the wrong oil, internal
Using the wrong engine oil doesn’t encountered examples where the driver scoring and excessive wear will arise.
just affect Fords, but vehicles from complains of poor acceleration and what Lack of the correct lubrication will
every manufacturer. At one time there might be described as a misfire not long result in hefty repair bills.

VISTEON SYSTEM 7 TYPE ESU 121 CIRCUIT DIAGRAM www.autodata-group.com

30
15
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gn ws
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rt
X28-I B A B
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27 36 22
rt
X28-II
K20
F132 F138 1 3 F111
K4 2 5 K46 K79-II K256 15A 10A 15A
F33 F35 F9 F36 F34
10A 10A 20A 10A 10A A11
2 5
1 3 2
31 36 13 16 32 7 38 37 17
B F F G G F B F F
gn ws
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sw ge
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sw bl
gn bl
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sw rt
rt sw
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gn rt
br rt
br rt
gr rt
gr rt
VAN
VAN
VAN
VAN
sw ge
ws
ge
br
gr
bl
CAN-H
CAN-H
CAN-L
CAN-L
gn ws
gn sw
gn sw
A5
gn ge
gn og
gn ge
gn ge
gn bl
gn bl
gn rt
gn rt
gn rt
gn rt
gn rt
gr
bl
22 23 13 14 31 10
sw ge
gn ge
rt sw
ws
ge
br
H63 P9
Y3-I Y3-II Y3-III Y3-IV Y179 B33 Y102 Y151 Y104 T1-I T1-II T1-III T1-IV S13-II X1 S258-I
2 2 2 2 1 3 1 2 5 2 2 2 2 2 2 11 3 km/h 2 1 2 3 6 1 S39
A75
B138
18 17
1 1 1 1 2 1 2 2 1 3 4 6 1 1 1 1 1 1 6 14 3 5 4 2
gn ws
sw og
sw ge
sw ge
br rt
br rt
gr rt
gr rt
CAN-H
sw bl (sw rt)
CAN-L
sw ws
sw ws
ws gn
sw ge
sw og
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sw gn
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gn og
ws bl
ws bl
sw bl
sw bl
ws rt
sw rt
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ws
gn ws
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br rt
gr rt
gr
A A B B B B C C C C C C C A A A B B B B A A A A A A A
l2 g1 d1 d2 e1 e2 d2 b3 d1 b1 b2 c1 c2 h1 m2 m3 h1 h4 h2 h3 b2 a4 b4 e3 d2 g2 k2
A=48 B=32 C=32 A35 A35
c1 e1 d1 e2 m1 b2 b3 a1 d4 f1 e4 f3 g1 h3 h4 b1 a2 a2 c3 c4 f1 e1 f2 d4 c2 e4 e3 l4 g1 h1 m4 e2 a4
A A A A A B B C C C C C C C C B B A B C A C A B A B B A B C A C C
ws sw
ws gn
ws gn
sw og
sw gn
sw gn
sw og
sw ge
sw og
sw ge
sw ge
sw ge
sw ge
ge gn
br ws
br ge
ws bl
ws bl
ws bl
ws vi
ws vi
ws vi
ws rt
ge bl
ge vi
gn rt
br bl
br rt
sw ge
gn og
ws
br
br
gr
bl
bl
2 4 2 4 1 2 1 2 5 6 3 1 1 3 2 1 2 3 2 1 4 1 2 1 2 1
M6
M89 B169 B25
1 3 1 3 4 2 4 2 1 1 5
B54 B132 A177 B83 A95 B69 G1
B72-I B72-II B24 B161 S153 S389 M12
sw og
gn ge
br ws
br gn
sw rt
gn rt
br bl
br bl
br rt
sw
sw ws
br
sw bl
sw
31
EP3 1154837 EP1 EP3 1154837 EP9 EP16
EP10 = LHD
CODE COMPONENT DESCRIPTION CAN-H CONTROLLER AREA NETWORK S389 ENGINE OIL PRESSURE SWITCH
(DATA BUS) HIGH
A5 INSTRUMENT PANEL T1-I IGNITION COIL | 1
CAN-L CONTROLLER AREA NETWORK
A11 MULTIFUNCTION CONTROL MODULE T1-II IGNITION COIL | 2
(DATA BUS) LOW
A35 ENGINE CONTROL MODULE (ECM) T1-III IGNITION COIL | 3
EP EARTH POINT
A75 INSTRUMENTATION CONTROL MODULE T1-IV IGNITION COIL | 4
F FUSE
A95 ENGINE COOLANT BLOWER MOTOR VAN VEHICLE AREA NETWORK (DATA BUS)
G1 ALTERNATOR
CONTROL MODULE
X1 DATA LINK CONNECTOR (DLC)
H63 ENGINE MALFUNCTION INDICATOR
A177 THROTTLE CONTROL UNIT
LAMP (MIL) X28-I FUSEBOX/RELAY PLATE,
B24 ENGINE COOLANT TEMPERATURE ENGINE BAY | 1
K4 STARTER MOTOR RELAY
(ECT) SENSOR
X28-II FUSEBOX/RELAY PLATE,
K20 FUEL PUMP (FP) RELAY
B25 INTAKE AIR TEMPERATURE ENGINE BAY | 2
(IAT) SENSOR K46 ENGINE CONTROL (EC) RELAY
Y3-I INJECTOR | 1
B33 VEHICLE SPEED SENSOR (VSS) K79-II IGNITION MAIN CIRCUITS RELAY | 2
Y3-II INJECTOR | 2
B54 CRANKSHAFT POSITION K256 WIDE OPEN THROTTLE (WOT) RELAY
Y3-III INJECTOR | 3
(CKP) SENSOR
M6 ENGINE COOLANT BLOWER MOTOR
Y3-IV INJECTOR | 4
B69 KNOCK SENSOR (KS)
M12 FUEL PUMP (FP)
Y102 INTAKE MANIFOLD AIR CONTROL
B72-I HEATED OXYGEN SENSOR (HO2S) | 1
M89 THROTTLE MOTOR SOLENOID
B72-II HEATED OXYGEN SENSOR (HO2S) | 2
P9 VEHICLE SPEEDOMETER Y104 EVAPORATIVE EMISSION (EVAP)
B83 MANIFOLD ABSOLUTE PRESSURE CANISTER PURGE VALVE
S13-II BRAKE PEDAL POSITION (BPP)
(MAP) SENSOR
SWITCH | 2 Y151 EXHAUST GAS RECIRCULATION (EGR)
B132 CAMSHAFT POSITION (CMP) SENSOR VALVE ACTUATOR
S39 INERTIA FUEL SHUT-OFF (IFS) SWITCH
B138 ACCELERATOR PEDAL POSITION Y179 INTAKE MANIFOLD AIR CONTROL
S153 AC REFRIGERANT LOW PRESSURE
(APP) SENSOR ACTUATOR
SWITCH
B161 AC REFRIGERANT PRESSURE SENSOR 15 IGNITION SWITCH – IGNITION ON
S258-I CLUTCH PEDAL POSITION (CPP)
B169 THROTTLE MOTOR POSITION SENSOR SWITCH | 1 30 BATTERY + 31 BATTERY –

Our ars
Rob
Hawkins
Special Contributor
Still going
strong
I
n 2016, CM bought a 2005 Audi
A3 2.0 TDI with 101,581 miles and
ran it as a project car from April
to October that year. Despite the
magazine having paid a reasonably high
price of £3284 for the car, when some
A3s in good condition were selling
for less than £3000, the 11-year-old
Sportback still seemed a bargain given
it was loaded with toys, including a And don’t even mention insurance… had access to at Town Garage in Leeds
panoramic glass roof and six-speed Being a journalist means it isn’t cheap, when the A3 was a project. It took me
gearbox. I bought it when the project despite me having a squeaky-clean track almost 15 minutes to undo the fittings
series ended – after all, the car had been record, so there’s no change out of £500 for the undertray and slide it out from
with me from the start and everyone per year for a fully comprehensive policy. underneath. Space was equally tight when
in my family loved the ride quality, Fortunately, that’s all of the major it came to draining the oil. I used a shallow
performance and standard of equipment. expenses covered, for now. The project drainer that only just managed to squeeze
It’s approaching two years since the series in CM meant most of the big underneath. Time quickly seemed to
A3 was bought by CM and there are now jobs were completed, ranging from the disappear as I renewed the oil filter, which
116,000 miles on the clock. Similar-aged glow plugs to the timing belt and water is accessed from the top of the engine,
models with low mileages are being pump. And the dual mass flywheel and air filter. The whole job from start to
advertised on autotrader.co.uk for less was renewed for Clutch Clinic in the finish took a bewildering one-and-a-half
than £2000, so I’ve lost a fair amount of September 2017 issue. hours. I can complete an oil change on
money in depreciation, especially when So aside from checking the tyres and my Mazda MX-5 in 20 minutes.
the mileage is taken into consideration. underbonnet fluids every week, the A3
You could say that losing £1284 over hasn’t needed any attention for several
around 15,000 miles equates to 8.5 pence months. However, it wasn’t long before Brake pad inspection
per mile, and that’s before fuel, tax, I started thinking about renewing the All of the A3’s brake discs and pads
insurance, servicing and repairs. engine oil, oil filter and air filter. The were renewed in 2016, along with the
I’ve spent almost £1600 on fuel Febi engine oil we used in the June 2016 brake fluid. So while I was confident
(including the time when the A3 was issue should be changed every 20,000 they wouldn’t be excessively worn after
a project car) and, in that time, the miles or 12 months. So I waited for a 15,000 miles, I wanted to make sure they
2.0-litre BKD engine has returned an discount offer at Euro Car Parts and weren’t dragging and that all of the slider
average of 46mpg (long runs generally bought five litres of fully-synthetic bolts were free to move.
return 50-55mpg, but urban driving 5W-30 Triple QX, along with an oil filter. A service of the brakes at a garage is
drops to 40mpg). I recently renewed the Renewing the oil on my driveway at quite straightforward, especially with a
tax on the A3 and paid £150 for a year. home made me appreciate the ramps we two-post ramp. Simply raise the vehicle,
All of the A3’s brake discs and pads were Engine oil service on Rob’s driveway was
The air filter was 12 months old and was changed in June 2016. An annual strip and time-consuming without the benefit of a
showing signs of needing renewal. clean ensured they’re working properly. ramp or inspection pit.

Our Cars Rob Hawkins
The annual MOT
for the A3 saw it
pass with ease. Rob’s youngest
son, Joel, was
bribed with a
pocket money
bonus if he
washed, dried,
polished and
waxed all four
alloy wheels.
remove the wheels and work around all were lubricated with multi-purpose
four brakes. On my driveway, it’s a two- grease, although I have recently acquired In Rob’s garage
hour job, requiring each corner of the a tube of brake grease, which I will be
car to be raised in turn with a trolley jack using on the next service. 2005 Audi A3 2.0 TDI
and supported by an axle stand before We MOT-tested the A3 during the Ex-project car from CM, which replaced the
removing the respective road wheel project series, but it soon came around deceased Ford Focus as the family transport.
and working on the brake. Thankfully, again. I had nothing to worry about. With
this was a good opportunity to ask my lots of new components fitted and no 1998 Mazda MX-5 1840cc
Another ex-project car from CM. Budget
youngest son, Joel, if he wanted to earn signs of corrosion, it sailed through. respray is the next major job.
some extra pocket money. He couldn’t
refuse, so I gave him a bucket of soapy 1976 VW Transporter 1584cc
water, a wash-mitt, a large old towel, Rear wiper motor Family accommodation for the summer
some polish and wax, and several clean In the October 2016 issue, we looked into holidays since 2010, travelling regularly to
France, Holland, Germany and Belgium.
cloths. The A3’s alloy wheels are in why the rear wiper motor wasn’t working
reasonably good condition, so I’m hoping and concluded that the motor had failed.
that a thorough wash, polish and wax A secondhand replacement was fitted occurred. I was driving home and was
will help to keep corrosion away. after the project series had finished, only a few minutes away when I heard
While Joel was sprucing up the wheels, so the wiper motor was alive once a strange whoosh-like noise from
I could take my time servicing the brakes. more. Sadly, it only lasted six months. the engine bay. At the same time, the
I removed the caliper and brake pads, I inspected the fuses and they seemed nearside front brake seemed to start
cleaned around the carrier and edges of fine, so I’ll have to check there’s a supply squealing. I made it home and looked
the brake pads, made sure the slider bolts to the motor. The last time the wiper under the bonnet and through the spokes
were free, then reassembled everything motor failed, it would squirt washer fluid of the wheel for any signs of trouble.
with a tiny smear of copper grease across the rear glass but refused to wipe. There was nothing. I even spoke to a few
applied to the top and bottom edges of This time, it won’t even squirt washer mechanics and Audi specialists who
the brake pads, where they make contact fluid. Maybe the stalk switch has failed. probably thought I’d lost the plot. To
with the caliper carrier. The slider bolts An equally confusing problem recently date, the noise hasn’t returned.
Access to the oil filter is from the top of the

engine. It’s less back-breaking than from Secondhand replacement wiper motor
underneath, but a little fiddly, especially if Febi torque wrench came in useful for lasted six months before it stopped
you want to avoid oil drips. tightening the oil filter housing to 25Nm. working, along with the rear washer.

Steve
Hole
Special Contributor
MG TF
into a
RPS RPX
Part 2
L
ast month I related how
I replaced the body panels on a
2002 MG TF X Power 160 with
glassfibre replacements from
RPS Ltd of Lowestoft to transform it into
an RPS RPX. Having trailered the part-
completed car to MG K-Series experts
Mike and Martin at MJS Auto and that he’d just fixed and sent off for a spot cornering. Unfortunately, I forgot that
Marine in Littlehampton, they phoned of porting and polishing. the dampers and springs lowered the ride
with the bad news a few days later. MJS also fitted new underfloor height by 1.5in, thus when reloading the
I thought the engine sounded a bit stainless steel coolant pipes which fitted MG onto the trailer, I fractured the front
‘endy’ when I loaded it onto the trailer and well with the aluminium radiator. On went splitter. Another job for the paintshop.
Mike’s verdict confirmed my suspicions: EBC discs and Yellowstuff pads all-round,
the little ends were kaput, but he had a along with Automec brake pipes and brake
decent secondhand block in his stores. fluid. I also upgraded to ProTech dampers, Back on the road again
A couple of days later, I got another specially adapted for the TF by a On the morning of its MOT, as
phone call from Mike. Having built modification firm; being a fan of Nitron, I started the engine, the Brown &
the bottom end up, he was turning his I went for their turquoise springs (350lb Gammon low coolant level kit began
attention to the cylinderhead, only to fronts with 850lb rears). emitting a warning buzz. I suspected an
notice it had been skimmed too many I had been apprehensive about overly airlock and went through the MG TF
times to be of any use. VVC heads, stiffening the springs over standard, process of eliminating trapped air from
particularly Trophy 160 ones, cost silly but the Nitrons transformed the TF’s the system. This seemed to sort it and the
money, even on eBay and Gumtree. often jarring ride and it now does a car duly flew through the MOT.
Luckily, Mike had a spare cylinderhead decent impression of a Lotus Elise when However, next time I started up, the
buzzer went off again. This problem
This Brown & Gammons stumped MJS for weeks until, by
kit emits a buzz if the chance, Mike noticed a minuscule
coolant level drops pinprick in one of the internal coolant
below a certain level.
pipes that was causing problems
when the system was pressurised.
A call to XPart and new pipes were
The replacement Protech Shocks dampers.

These have been re-valved specifically for
the MG TF and greatly improve ride quality.

Our Cars Steve Hole
Finished at last and fully road-legal.
The colour is a Citroën shade called
Karma Purple. The colour has split
opinion, but everyone seems to like the Our car is the second RPX
yellow stripe across the front splitter. to be completed. Here’s
the original demonstrator
at RPS Ltd in Lowestoft.
In Steve’s garage
2015 smart forfour
prime I felt the need to try and
do my bit for the environment
and decided on a small city car.
In the two months I’ve had it, it’s
on their way. Fitting them is quite proven trouble-free and a willing
involved and requires half of the car’s little companion with the two extra
interior to be removed, but it solved the seats in the rear (it’s more of a 2+2
problem instantly. Mike also adjusted than full-on four-seater) proving
the handbrake to stop the dash-light useful at times. I’ve also been
illuminating – another common MG TF seeing 60mpg around town.
issue. And he fitted a neat sump plug 2010 BMW X5 E70
replacement called an EZ Oil Drain Have made several upgrades
Valve, a clever ‘tap’ that means you don’t and mods. The odometer clicked
need to remove a sump plug ever again. past 118,000 miles recently,
Finally, the car was taken to Kingswell although the engine is strong and
Coachworks in East Sussex for respraying. feels healthy, pulling strongly all
I went for a Citroën colour called Karma The EZ Oil Drain Valve replaces the sump plug through the range without leaving
Purple with a glittery enhancer – a and releases the oil at the turn of the tap. smoke trails behind her. Sadly,
a neighbour recently reversed
Marmite colour, but it certainly sparkles
into my driver’s door and this got
in sunlight – plus a yellow painted
me thinking that a change was
pinstripe on the front splitter. Now needed. As I write this I’m about to
I just have to inform DVLA of the colour- collect my new X5 F15 XDrive 3.0d.
change and complete the re-registration
process by filling out a V627/1 (built-up 1996 JAKABI ABSTER
vehicle report) and I’m all set. Formerly known as an MGF! The
project car is nearly finished after a
Next time I’ll discuss another recent
major transformation. More soon...
bodykit conversion, turning an MGF
into a Jakabi Abster.
I went for Nitron

springs, softening the
front springs while
going stiffer at the rear.

Brits on Tour
Martyn Knowles plans a four-day run to France (and back)
CM’s 16-year-old
PART TWO E46 on French soil.
X With just a day to test the wind-up. Eventually he said: “Can I bring
roadworthiness of our 2001 BMW Vic? He’s a mobile mechanic.”
3-Series E46 before heading off on a “Of course”, I said. “There’s loads of
1000-mile trip to the Continent, I was room in a 3-Series.”
feeling a little less nervous. The German The car was ready, my passengers
four-door saloon was now performing were here... and so was Gavin, a CM
better than it did before it went into the reader driving with us to France in his
garage for a few repairs. With a fresh 1990 Mazda MX-5 Eunos. We set off in
MOT certificate, a new radiator and convoy at midday on Friday, heading
coolant, a fixed leaking downpipe, fresh towards the Port of Dover.
oil and filter, a new cam cover gasket The BMW six-pot was purring along
and revitalised front suspension, it nicely and we hit the M20 for some
was driving perfectly. The only warning faster road speeds. All good so far.
issued by the garage was that it might The DFDS ferry crossing service was
still be leaking engine oil. smooth and both cars were parked up
S My two passengers helping drive the BMW
Two weeks previously, I had no in Calais for the night while we refuelled across France: Ken Lowe (top) and Vic Smith.
passengers in the BMW with me. So ourselves at the local food outlet/ What had they let themselves in for?
I made contact with my old mate Ken, shopping centre at Cité Europe.
whom I’d known from previous French You can cover many miles on the
tours involving Jaguars – lots of them – ultra-quiet French road system – we
and had been part of a breakdown crew Where are we going? were averaging over 60mph. Ken had
who could orchestrate roadside repairs The next morning – in what was to the accelerator firmly planted as we hit
if (when) they broke down. become a daily ritual – we checked a steady incline on the dual carriageway,
At first, Ken thought my invitation to the BMW dipstick before firing up the before: “Oh shit, we’ve lost power.”
join me on an all-expenses trip was a engine. It needed a top-up at Calais. As Ken spoke, the orange EML
Was there a visible leak underneath? illuminated, but the engine was still
Not really. No worries then. firing, albeit not on all cylinders. The
We headed south-west onto the next rest area was two miles away.
French motorway system towards our It was only Day One and we’d
overnight stop in Rennes, 320 miles travelled just 100 miles from Calais, so
away. Our first stop would be the port I was fearing the worst for a few sweaty
A bottle of of Honfleur for lunch. I did the first stint minutes. But as we slipped the gearstick
Cataclean went of driving, clicking on the cruise control into neutral while taking the slip-road
into the BMW at 80mph. The E46 computer was into the rest area and coasting to a stop,
fuel tank to showing an ever-increasing average fuel the EML went out. Phew! I had loaded
help clean the
fuel system.
consumption, getting into the mid-30s my code reader in the boot with my
before it was time for Ken to take over. luggage, so plugged it in for a diagnosis.

Brits on Tour
The ECU had cut power to cylinder 3
CM reader Donald Stickland (second Volvo from left) and his friend
for some reason, but now it was back Jason (first Volvo on left) met us in the car park of the Lohéac motor
running on all six. museum. Both have immense knowledge of motoring matters.
We built up speed again and all
was well as we arrived at Honfleur for
lunch. With the sat-nav now set to ‘no
tolls’, we enjoyed some non-motorway
driving down to Domfront for a quick
refeshment stop, before arriving at
Rennes in the late afternoon, where we
had arranged dinner with CM reader
Don Stickland, who was touring France.
Drinking to excess car museum at Lohéac. The previous next overnight stay. The BMW was
Our now regular engine oil check the evening, we had made arrangements behaving itself and we felt the engine
next morning revealed that the BMW to join Donald Stickland and his friend was actually becoming more responsive
was down to the minimum mark on the Jason on a tour of the museum. After during acceleration. With only 150 miles
dipstick. Where was the oil going? Gavin half-a-day looking at the splendid to reach Bayeux, all was well.
reported seeing a bit of blue from the exhibits (turn to page 92 for photos of The next morning, we started heading
exhaust occasionally while following us, some of the highlights), we made our for home, dropping by the coastal
but the amount the engine was using, departure, saying we’d be back one day town of Arromanches-les-Bains, one of
you’d think a cloud of smoke would be for a longer look. the sites of the Normandy landings in
visible. Not to us, it wasn’t. Donald and Jason were heading off 1944. We had breakfast in a small café,
Twenty-odd miles south-west of in different directions, while we were and reflected back on the historical
Rennes is the Manoir de L’Automobile turning north towards Bayeux for our importance of this small town.
If you’ve owned or driven a Mazda MX-5 you’ll

understand how great they sound and handle.
I think Ken and Vic were bored not fixing
anything, so they started taking the BMW
The EML appeared out of the blue on the E46 engine apart in a lay-by to try and work out
dash at speed. It went out again, fortunately. why we were losing so much engine oil.
Gavin Tarrant’s 1.6 MX-5 is a great drive. It’s 27 years old and still likes the
occasional 7000rpm gearchange. This engine required just an egg-cup of
oil during our 1000-mile jaunt, whereas the BMW needed just a bit more.

Brits on Tour
Situated 22 miles SW of Rennes at Lohéac is the Manoir De

Lohéac Motor Museum L’Automobile museum. Well worth a visit if you are in the area.
A rare
Citroën BX
4TC entered
into Group
B rallying in
the 1980s.
The hanging
A 1928 Citroën C4 Torpedo illuminated
with a four-cylinder engine signs are
and no door handles! brilliant.
It’s not all French vehicles on display. Here’s a LHD A few Fords, including a Lotus Cortina Mk1,
Austin Mini Cooper Mk1 alongside a Lotus Elan. Escort RS2000 Mk1 and a Capri RS2600 Mk1.
Lurking in the background is a Sinclair Model re-enactment gives you an The mocked-up old-timer workshop is
C5. You really need to visit at least insight into how they made certain fantastic. This early diagnostics centre
twice to spot everything on show. components back in the old days. had a timing light attached to it.
Driving out of Arromanches, we These six-cylinder BMWs have a

stopped off at the 360° Circular complex breather hose system that
Cinema on the cliff-top, which shows a requires complete renewal at this age.
documentary film about D-Day. It’s loud It’s not expensive to buy the pipework,
and sad at the same time. so I’m hoping this will help the engine
We now had to head back to Calais. breathe a little better.
Both cars were running superbly and The BMW on-board computer said
we arrived back quicker than expected, we had averaged 35.8mpg – not
enabling us to catch an earlier DFDS unreasonable calculations, as I’d worked
ferry. Once back on UK soil, we bade out an average of 35.1mpg from
farwell to Gavin and all agreed it had tank-to-tank top-ups. Rather good for a
been a good few days of motoring. heavily-laden saloon of 2200cc. In fact,
The BMW did drink all five litres of it probably used more oil than fuel!
engine oil I’d stored in the boot. That’s a Two days after arriving home, the
litre every 200 miles – not good. While BMW showed itself up: the coolant
For being the only CM reader to join us for
some of this could be blamed on engine header tank decided to split. Luckily, the full tour (and being a top car nut), we
leakage, I can’t believe it lost that much. Febi sell the part to fix it. I just need to gave Gavin Tarrant a Sealey LED inspection
So where did it go? find time to do the job. lamp to remember his time with us.

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MITSUBISHI GALANT V6 Genuine rear boot floor
24v ESTATE. Auto. Cruise, MAZDA EUNOS 1992. 110,000 miles. Includes matching
with carpet + inflation kit
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(foam block, sealant and
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CLASSIFIED DEADLINE FOR APRIL 2018 ISSUE: February 28

W A Y
OTORING
H E
E
T
R
W
EE
ET
W
SC
E R
EN
E
ES OF Y ES T ERY EAR!
FROM THE
MAKERS OF
42 NOSTALGIC ST CLASSIC
CAR
WEEKLY
S PE C I A L
BUYING Q SELLING Q NEWS
EDITION
MAGAZINE!
The Way We Were Volume One, is a special

edition magazine brought to you by Classic Car
Weekly. It is a chance to immerse yourself in five
decades of British motoring nostalgia. It brings
together historic images of the country’s towns
and cities from the 1950s through to the 1990s
– and the expert views of Classic Car Weekly’s
writers on each year’s cars and culture. No matter
when your childhood was or where you spent it,
you’re bound to find a street scene in this special
magazine packed with the cars you grew up with.
THE WAY WE WERE
THE WAY WE WERE

ATES OPEN
MARCH 1 7
DOUGLAS, ISLE OF MAN
Ford 100E Anglia just nudging its
the picture, differentiated from
Prefect sibling by its less ornate
grille, which also marks it out as
1957 example It’s next to one of
way into
its four door
three bar
a 1953
CAR OF 1967 ASTON MARTIN
DBS
CAR OF 1979 VW’S FLOODG
some Rootes’ Aston Martin may have been
Moving to the middle rows (with
MAY 1979
commercial derivatives of the Series blunt instrument persona it
CAERNARFON,
AA and a Hillman the marque that Britain’s rich
subliminal advertising for the Minx, a Commer Express delivery
van was intended to be fitted with
lifebelt in case the owner of the
Morris
engine version of the LT It’s a short hop to the Isle of Man Next in line are a couple of Morris and famous all wanted a piece
Aston Martin’s new 5340cc V8
GWYNEDD, WALES
A notchback version of the
Minors
Traveller gets in difficulty), there’s
a Vauxhall
van, and a
The 1970s was a remarkable
Polo – the Derby – made
was introduced. Karmann for this shot,
where everybody seems to have vanished
The green one is a 1954 1956 Series
II still
of during the 1960s but those
pieces were looking a little
But this wasn’t ready in time
Viva HC estate, a Bedford HA decade for VW as it turned started work on the Golf
retaining the original split front
windscreen so the DBS ‘made do’ with the
yellow Capri. The HA van could
possibly be its debut in 1977. In 1978 the dated Enter the DBS in 1967
around its business – and convertible in February 1979, that would be dropped for the 1000
variant, DB6’s 4 0 litre straight six until
ons vehicle final German-built Beetle
W
e know that seaside holiday resorts looking much more modern
shadow of the town’s castle walls
a Post Office Telecommunicati its vehicles – to feature the third-gen T3 Transporter as typified by the white model adjacent
This 1969 The six cylinder DBS was
yellow paint left the Emden production
A host of classics shelter in the
as that company used a lot of front-end, water-cooled vehicles were introduced
aren’t usually that busy during car would have been built after 1962,
as it has
than its predecessors
dropped in 1972 while the V8
recall their line with manufacture
RICHARD GUNN
– many readers will doubtless engines. It had begun winter, but Douglas, the Isle of the larger combined indicators/sideligh Its larger proportions gave it
in August and production became the non DB prefixed
used in their continuing in Mexico until ts up
DAVID BROWN
Buzby cartoon bird character with VW’s takeover of Man s capital, seems to be front The bumper overriders suggest vaguely American muscle car
Helen’s Road (to the right of our
photograph) of the Jetta began the AM V8 instead built right the
advertising campaigns from 1976
onwards. 2003 The VAG brand name strangely deserted, even for the off that looks As f to underline this
ooking at this splendid view of of heritage on NSU and the launch of following month season it’s a DeLuxe version A Minivan way through until 1989
So, there was and is plenty
L
in the appeared and a diesel rests next
Caernarfon, I would suggest that town and the You’d expect to find Japanese cars the K70, to be overtaken Aside from the solitary, shadowy
figure has been writing for CCW since 2000, and in that door, not that much of it can be seen
offer to attract tourists to the
was cutting his teeth as a cub reporter are at least thanks
the slide was taken just before and visitors picture by this time and there by the first Passats from walking past the scaffolding clad
Villiers time has spent most of his wages repairing the to the inconveniently parked bus
demand for car parking for locals the blue car One of only
down in London in the late 1970s, and went three Datsuns in the mix, with
have Hotel on the left, it s almost like
mid day on 25 May 1979 No, I 1973 From 1974 the FWD the zombie
various beige 1970s cars he’s ended up buying. two foreign vehicles both of which,
of the sun and alike remains a priority at the front of the next row being
a 1200 apocalypse has struck this corner perhaps
Scirocco opened new
on to interview many of the decade’s stars.
this 220bhp leviathan to 120mph
not been calculating the angle Stepping back into our picture
of May 1979 Datsun of Loch unsurprisingly, are Volkswagens
is the last Its bulk
four door saloon The bright red doors for the firm while on Promenade and Victoria Street in
LOSE YOURSELF IN 1967
that the almost completely obscures a red
shadows cast, as the date and time the Slate Quay car park certainly
offered row and the UK s identifiable vehicle in this row, in
the form Mini A
photograph was taken is dutifully
recorded on
cars Being a complete Sunny 120Y stands out in the back 1 July that year the last of closest off shore tax haven There
isn t even of a Beetle An Austin A35 and BMC Rover P4, BMC 1800, two more Minors,
a good variety of Unfortunately on the island and dating from the 1100 can two
the unknown photographer’s slide
mount As an orange there s a 180B Bluebird nearby almost 12 m llion Beetles anyone on board the No 10 bus which, mid 19th just be made out nearer the sea behind Minis, another red Cortina and the
Volkswagen ‘divi’ I instantly detect You might expect to find a Princess
in such
corrosion killed many of these
imports off because century was demolished in 1996/97 second
an avid collector of old slides,
this is a real
left distance and a left the assembly ine in public service vehicles are often
better The Over on the other side of the road, Volkswagen, an 11 window Type
1 bus in two BE NICE IN SPACE
and white T2 in the close proximity to a castle so a
four cylinder,
prematurely, and unlike their
British rivals Royal Bank of Scotland now occupies a white
bonus as it cuts out the guesswork row of cars Wolfsburg Germany The chronicled than private ones, we its spot Ford Cortina MkI four door saloon, tone green and white, complete the replaced by a lookalike
news that Scirocco lurking among the back twin headlight example does not
look out
these 1970s trailblazers for Japan
s carmaking can tell you In the distance, the Promenade Methodist black chain The UK USA and Soviet
While the nation reeled from the two appearance of the Golf s a 1949 Douglas Corporation Transport Morris Minor and grey Triumph However, it’s another two tone vehicle Album covers and song
Much more in yer face is a ‘Brenda’ of place It is keeping a safe distance
from
giants are now a rare sight at today’s
classic AEC Church has been replaced by a modern Herald are Union sign the Outer Space
the price of milk was about to
rise by 10 per steels in 1974 marketed as the Regent III with Northern Counties place that stands out most the yellow lyrics supposedly hold hide
door 1 3 Ford Escort MkII on standard a Hillman Imp, a two door saloon
that I did
car shows, with values on the up
bodywork. of worship. But apart from these parked outside the Villiers A red
Austin 1100 and white Treaty Among its principles
cent to 15p a pint from the start
of April, metal Rabbit in the US produced Out of service in 1976, it went to losses, this Metropolitan coupé, BMC s idiosyncratic clues including this year’s
(cue Saxon’s Wheels of Steel heavy have some experience of earlier
in the 1970s
Further along the back row you’ll
find a the London Victorian terrace remains largely sits beyond the bus Occupying the
centre are no placing of weapons
motorists were still recovering
from other With its Vo kswagen’s real cha lenger Bus Preservation Group in Cobham, unbroken. compact collaboration with its US Sgt Pepper’s Lonely Hearts
Thatcher s anthem from the following year) A friend had one and each time
we went on
Rover SD1, a typical beige Maxi,
a Citroën Surrey, Sadly, the same probably can’t be ground of this wide promenade (and
blocking equivalent, of mass destruction in
rises introduced since Margaret the MkII, a joint to the Beetle s long held before ending up in Germany, where said for the lines of the summer only Douglas the American Motors Corporation, Club Band
modern square cut lines, holiday it broke down and I had
to contribute
GS in Pallas trim, a CX Safari,
Rover P6, it most of the cars here. Although this sold in space close to Earth and no
Conservative government won
power three and Germany, crown The famous hot disappeared The buildings on the may Bay the UK from 1957 Although never
development between Ford UK to running repairs Perhaps surprisingly,
he is
Morris Minor 1000, and a Harvest
Gold be 1967, many of the machines hail Horse Tramway, saved from closure badged as sneak ly putting them on the
weeks earlier The price of bread,
gas and it came to hatch GTI followed in 1976 from an in 2016 an Austin here, the car became informally FIT FOR A SAINT
petrol was up offered a simplistic purity when still a friend We later toured parts
of central
1100/1300 Plenty to keep the
peak capped left have also gone The
earlier era, with Morris Minors being after more than 2000 supporters Moon either Conventional
electricity had all risen, while There were The Polo supermini joined most signed known as one, while ‘Metropolitan’ St Pancras Station
driving, but they just rotted away and north Wales in his Maxi The
Renault 12 is
car park attendant occupied
Villiers Hotel largest prevalent - obviously much appreciated a petition supporting it) is a regal was weapons are fine though NO STRINGS
by 6p per gallon (it averaged 79p per gallon such as the fleet in 1975 as did a Golf, Passat, Polo and Scirocco. looking often shortened to ‘Metro’ thus that towering Victorian
motoring had updates in the mid to late 1970s, a reminder of another good looking,
fastback
The car park s still being used
to host the The VW range had the Derby, by Daimler Majestic Major, with its making it No probs there ATTACHED
that year) However, the cost of with the third light truck called the LT Mann-kind. Starting on the right,
there’s a huge an Austin Metro 20 years before Gothic cathedral to the
people from visiting square headlights for L models, style mid sized saloon Among
the vehicles
cars of North Wales’ tourists to
this day, but boot and 4 6 litre V8 capable of propelling the better Britain wins the Eurovision
obviously not deterred when there known holder of this title came along railways is made a Grade
still spaces generation appearing in 1980, beyond the Mini is seen a Bedford
CF and its
we wish a few more had Imps and
Escorts PAUL IS DEAD Song Contest with
Caernarfon, though there were were more than 600,000 MkIIs
on the roads Transit I isted building following
Quay car park fans earlier competitor the MkI Ford (HONESTLY) Sandie Shaw’s Puppet
LOSE YOURSELF
available on the Slate Ford a campaign led by Poet
They’re in big demand with today’s
As the name suggests, the still
thriving car
BIG PICTURE GERMANY MINIATURE
A rumour starts going Laureate John Betjeman
on a String The UK also
park occupies the old quayside
where slate
FIT FOR A IMPORT HIT CALLING MINOR around that Beatle Paul starts negotiations to join
IN 1979
Just in time too it was only
was transferred from railway wagons
to boats The C troën MARVEL MEETING McCartney has been the European Economic
By 1979, the harbour was mainly used by PRINCESS The Datsun 1200
B110 was the first CX’s room and Bizarrely, this AEC
The M ni’s tiny killed in a car crash and
ten days away from being
demolished in November
Community So how’s that
of Caernarfon Hydropneumatic Regent ended up Is this a gathering working out these days?
pleasure craft though a couple Four-cylinder Japanese motor dimensions are
be found Princess models imported into suspension meant The good news for in Germany. Does of the nascent
(CO) registered fishing boats can were given round it was a favourite anyone know
well illustrated Isle of Man Morr s
was the UK in large anyone wishing not alongside a small’
in this view The current castle headlamps. numbers. for UK fi m crews. where it is now? Minor Owners’
to hear the voice Beetle and Minor
ROOTES
English
built from 1283 by order of the Club branch?
King Edward I and occupies a
strategic of the UK’s first ANGLIA
position overlooking the southern
end lady Prime Minister
was that the Sony
DELIVERY UP FRONT
Isle
of the Menai Strait opposite the Commer’s M nx Nudging into view
Wa kman personal
of Anglesey The castle and medieval based light van is th s 1953 1957
cassette player
town walls are part of a World competed n the Anglia A cross
was introduced 8 10cwt market
Heritage Site Don’t look now, Gary, mesh grille was
this year in the through to 1957
Though Caernarfon lost its last but you’ve forgotten introduced in 1957
a US The bad news your car. You said you
BR station in 1970 (there’s now
site) was that it cost feel safest of all in it!
Morrison’s supermarket on the
$200 We needed Luckily the song itself
the town has been the northern the UK.
some good music was a big hit in
terminus of the Welsh Highland
to put us off our
Railway narrow gauge line since running at
in St woes in the UK as inflation was
October 1997, with its station economy was in a bad shape and
17% the
of the
acts of terrorism were rarely out
world head ines But f you could afford a
play on it?
new fangled Walkman what to
months a lot of people
Come the summer
debut
were grooving to Michael Jackson’s
spawned
solo album Off The Wall, which
You Get
hits singles such as Don’t Stop ‘til
school
Enough and Rock With You. Old
The
rock fans could get into Pink Floyd’s
Wall, The Clash had us singing along to RTINA MAJOR, NOT AN AUSTIN
London Calling, and Squeeze took
us Up
their RAP MINOR METRO
The Junction. Led Zeppelin played a brave owner
The
last ever UK gig at Knebworth, while o parks h s car
To balance out all No not that kind!
on drums the Minors here’s
Who returned with Kenney Jones ont of some a more potent
We bet this bright
following the death of Keith Moon. ffolding Hope Metro(politan)
WORK HACK felt with and apt y named
VANTASTIC
looked more at
Electro-pop made its presence hing fell on it Majestic Major home in summer
Friends
This Hillman Imp the likes of Tubeway Army’s Are
Transit MkI had
been replaced looks l ke it’s led a Electric, then their lead singer Gary
the previous year pretty tough life, Numan’s Cars, while M had everybody
by the MkII, but judging by the talking about Pop Muzik. SIC CAR WEEKLY The Way We Were
still built by Ford corrosion on both
in Southampton. its wheel arches.
WEEKLY | 73
The Way We Were CLASSIC CAR The Way We Were CLASSIC CAR
WEEKLY | 49
Way We Were
72 | CLASSIC CAR WEEKLY The
p to 5
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Ted Connolly
Ted sees red... but manages to keep his temper.
happened, but some of the contains solvents. It is ultraviolet rays and results in
Take it stuff I turned out wasn’t bad. difficult for my feeble brain bleaching. Another is that red
as red Anyhow, it got to the stage

where I’d look at a car and
to come to terms with water-
based paints – I still think of
paint is based on red oxide,
which goes on to oxidise even
X Whereas I once reckoned try to identify the colour using a brush and palette to further. My panel-beating
I was well-versed on the – just like you probably create pictures as a lad, not next-door-neighbour had
subject of automotive paint, spotted numberplates painting cars. another explanation: red
I am now somewhat lost. as a kid. To this day, I can contains more pigments
I suppose it’s rather stupid remember loads of them. than any other hue, therefore
to say that paint technology A few stuck in my mind,
Where is all it is unstable and loses its
has moved on, because even back then, and they this leading? colour very quickly.
that’s what technology is were Aubergine, Silver Fox, Well, nowhere, really. It’s So take your pick. I prefer
supposed to do and, equally, Saluki Bronze and Blue Mink. just that I received a missive to believe my neighbour,
us dinosaurs are meant to Those with good recall and from CM contributor Jeremy because he was in the game
remark on the situation with absolutely nothing better to Haworth, who sent in a for a very long time and had
a mixture of bewilderment do in life will identify them as photo of a Mitsubishi with neither the facility of Uncle
and disdain. Ford colours, most popularly noticeably faded paint. He Google for reference nor the
The reason I seize on this used on the Cortina Mk2, observed that somebody need to prove himself online
particular subject is that, at especially the 1600E. had tried to polish in an with fancy words. In truth,
one stage in my tacky little I noted that, after a while, adjoining panel with a I don’t think anybody quite
life, I spent many, many all of these paint finishes degree of success and then knows the answer, nor how
hours doing bodywork. It started flaking. It was appeared to have given up. to prevent it from happening.
was never a profession, just explained to me that the paint It has always been To close, I might add that
a means of making beer itself was OK, but there was common for red paint to red does hold intrigue in
money (as some bloke said a problem with the lacquer. fade – just check out the other circles. You will be
when he visited my workshop At the time, Ford – along number of ex-Royal Mail familiar with the expression
and saw the amount of paint with other manufacturers vans running around with ‘holding a red rag to a bull’.
hanging around: “Blimey, you – used cellulose lacquer and pink panels and marks on This is fantasy, because
must drink a lot!” Yes, I know, it really wasn’t much cop. the sides where the original bulls are colour-blind and
the old ones are the best). I haven’t forgotten acrylic decals have been removed. it is not the red of the rag
I had the good fortune to paints, by the way, but they But why does red fade far that irritates them but the
live next door to a panel- never caught on in the same more than any other colour? flapping of the material.
beater for more than a fashion as cellulose. Well, there are a number Fortunately, at a certain age,
decade and he taught me As time progressed, of theories and some border a columnist can get away
a great deal about paint cellulose gradually began to on being rather too scientific with writing irrelevant tripe,
spraying. He was what go out of vogue and two-pack for this puny column. One drawing comments like:
I would regard as old-school, became the system to use. It is that red paint reflects red “Bless him, he can’t help it.”
having served his time at was super-tough and shone light, which then absorbs Well, I can, so don’t bother.
a Vauxhall-Bedford main like a shilling in a sweep’s
dealership when coach armpit. The only snag was
enamel was still in regular that it contained isocyanates, ‘Why does red fade more than other hues?’
use. Part of his job involved a derivative of cyanide, so
hand-painting the chassis you needed an air-fed mask
of Bedford trucks. Each and plenty of ventilation to
chassis was then sold and remain safe. I couldn’t afford
the customer either took that sort of gear and, by this
it as it was or specified a stage, I’d cut down on my
certain type of body to be beer consumption, so
fitted. Cellulose was around, I didn’t need to do as much
of course, but had still not bodywork. In the event,
reached wide popularity. I stopped spraying altogether
I never used coach enamel and chucked away my guns
– I’m not quite that old – and (madness, on reflection,
have sprayed using cellulose, because they were all
which was considered the DeVilbiss – top-drawer gear).
industry standard when I got Paint systems have moved
into painting. The subject on since the 2K days and
became almost an obsession now the trade uses water- CM contributor Jeremy Haworth
with me and I’d work all based paint, which is quite sent in this photo to demonstrate
hours trying to achieve clean, although, ironically, that even relatively modern red
that perfect finish. It never car paint has a tendency to fade.
the lacquer generally still

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What is the article mainly discussing?

What is the article mainly discussing?

What decision has the Department of Transport made regarding extending the first MOT?

What decision has the Department of Transport made regarding extending the first MOT?

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www.greatmagazines.co.uk/carmechanics March 2018 pCar Mechanics 7

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CAR LIFTS AND CAR TILTERS

GT01B FULL RANGE

W The basic components

X The input clutch hub is

10 Car Mechanics p March 2018 www.greatmagazines.co.uk/carmechanics

GEARBOX ASSESSMENT continued

X The side casing cover

X Numerous small bolts

W The clutch plates

www.greatmagazines.co.uk/carmechanics March 2018 pCar Mechanics 11

GEARBOX ASSESSMENT continued

W As the tiniest grit particle

X From here, the transmission

GEARBOX REASSEMBLY 19 W The bare

12 Car Mechanics p March 2018 www.greatmagazines.co.uk/carmechanics

Also suppliers CA FRE

To find out more about Press Pause, visit;

GEARBOX REASSEMBLY continued

W Pictured are the components

Once assembled, the output assembly

The second and fourth gear clutch

W …the housing assembly,

14 Car Mechanics p March 2018 www.greatmagazines.co.uk/carmechanics

The fluid pick-up assembly is cleaned Moving to the front face/bellhousing

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www.greatmagazines.co.uk/carmechanics March 2018 pCar Mechanics 15

Once split, the components can be

W The bronze bush on the

X Scoring on the input

W The lock-up clutch is