ImportCar, November 2013

A

November 2013

MAGAZINE

ABS Lamp On Engine Tech Tips Brake Service

C1 Cover IC_11.13 11/12/13 2:35 PM Page C1

C2-01 Toyota SPD IC 11/12/13 1:30 PM Page C2

Reader Service: go to www.ICRapidResponse.com

C2-01 Toyota SPD IC 11/12/13 1:30 PM Page 1

CONTENTS

Publisher Jim Merle, ext. [email protected]

Editor Mary DellaValle, ext. [email protected]

Managing Editor Jennifer Clements, ext. [email protected]

Technical EditorLarry [email protected]

Graphic Designer Kelly Gifford, ext. [email protected]

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

Circulation Manager Pat Robinson, ext. [email protected]

Subscription ServicesMaryellen Smith, ext. [email protected]

2 November 2013 | Import-Car.com

32Mazda DriveabilityCheck Engine Light DiagnosticsImport Specialist Bob Dowie takesa look at some of the more com-mon ailments that will bring yourMazda customers into your serv-ice bay with a check engine lightcomplaint, as he covers commonDTCs, stalling and ignition issuesand new technology.

18

4432

44Volkswagen RoutanBrake ServiceThe Routan has five different TSBsthat relate to addressing customerconcerns about brake noise, saysEditor of Brake & Front End mag-azine, Andrew Markel, as he cov-ers brake booster DTCs, front/rearbrake service and parking brakeadjustment.

ImportCar Staff

Volume 35, No. 11

Fuel Pump Diagnostics

330.670.1234

02-04 Contents 11.13 11/12/13 1:37 PM Page 2


03 Raybestos Chassis IC 11/12/13 1:07 PM Page 3

DEPARTMENTS6 Editor’s Notebook

8 News Update

14 Gonzo’s Tool Box

21 Special Supplement: Maintenance Matters

26 Tech Update: ESC/ABS

52 Tech Feature: Hyundai Engine Tech Tips

58 Import Tech Tips

62 Essentials (New Products)

63 WIX Tech of the Year Winner

66 RAPID RESPONSE

67 Classifieds

72 NASCAR Performance

A Publication


Columns

21

26

52

IMPORTCAR (ISSN 1069-4714)(November 2013, Volume 35, Number 11): Published monthly by Babcox Media, Inc., 3550 Embassy Parkway, Akron, OH 44333 U.S.A. Phone (330) 670-1234, FAX (330) 670-0874. Periodical postage paid at Akron, OH 44333 and additional mailing offices. POSTMASTER: Send address changes to IMPORTCAR, 3550 Embassy Parkway, Akron, OH 44333. IMPORTCAR is a trademark of Babcox Media, Inc. registered with the U.S. Patent and Trademark office. All rights reserved.A limited number of complimentary subscriptions are available to individuals who meet the qualification requirements. Call (330) 670-1234, Ext. 260, to speak to a subscriptionservices representative or FAX us at (330) 670-5335. Paid Subscriptions are available for non-qualified subscribers at the following rates: U.S.: $69 for one year. Canada: $89for one year. Canadian rates include GST. Ohio residents add current county sales tax. Other foreign rates/via air mail: $129 for one year. Payable in advance in U.S. funds. Mail payment to IMPORTCAR, P.O. Box 75692, Cleveland, OH 44101-4755. VISA, MasterCard or American Express accepted.

Member BPA International, Inc.Founded 1979. �2013 by Babcox Media, Inc.

Follow us on TwitterBecome a fan on Facebook

Contributing WritersBob Dowie, Village Auto Works, Chester, NY

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

Bob Howlett, The Swedish Solution,Orange Village, OH

Scott “Gonzo” Weaver, Superior Auto Electric,Tulsa, OK

Bob Dowie, Village Auto Works, Chester, NY

Chris Klinger, Precision Incorporated, Tucson, AZ

Steve Louden, Louden Motorcar Services, Dallas, TX

Frank Scandura, Frank’s European Service,Las Vegas and Henderson, NV

Joe Stephens, Stephens Automotive, Palatine, IL

John Volz, Volz Bros., Grass Valley, CA

Babcox Media, Inc.

Editorial Advisory Board

3550 Embassy ParkwayAkron, OH 44333-8318

President Bill Babcox [email protected]

Vice President/ Greg CiraChief Financial Officer [email protected]

Vice President/ Jeff StankardGroup Publisher [email protected]

Controller Beth Scheetz [email protected]

In Memoriam

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

Chairman Tom B. Babcox (1919-1995)

AUGMENTED REALITY CONTENT IN THIS ISSUE:

Diagnostic Solutions: Fuel Pumps........................................24SmartChoice™ Mobile App, powered by Federal-Mogul ......29(Open AVI Play and hold your smart device over the SmartChoice logo)

Tech Update: ESC/ABS........................................................30Auto-Video Inc. (AVI)...........................................................47

02-04 Contents 11.13 11/12/13 1:38 PM Page 4

05 Mercedes IC 11/12/13 1:06 PM Page 5

By Mary DellaValle|EDITOR[Editor’sNotebook


In case you haven’t noticed, female buying power is onthe rise. Women account for

about 85% of all automotivesales in U.S. households, and50-65% of customers at automo-tive service centers are women.

And you know what thatspells? Opportunity.

Bogi Lateiner gets it. She prob-ably would even if she weren’t afemale tech and shop owner. Heraward-winning full-service re-pair shop, 180 Degrees Automo-tive (www.180auto.com) inPhoenix, specializes in educatingfemale customers and creating apositive automotive repair expe-rience, and it has paid huge divi-dends in gaining and retainingcustomers. Bogi, also an ASEMaster-certified tech, was re-cently named winner of the WIXFilters 2013 Best Tech of the Yearcompetition (see ad on page 63).

Bogi is capitalizing on thetremendous opportunity to sether shop apart by successfullymarket to women, and offersthis advice*:

You Are In The RelationshipBusiness, Not The Car Business

People do business with peo-ple, not with businesses; andthis is especially true forwomen. Get out of the shopand be an active participant inyour community.

Don’t Just Fix Cars — CreateAn Experience

We need to go above and beyond to earn the trust of ourcustomers; we need to create“an experience.” From the moment a customer walks inthe door, to the follow-up callthey receive days after theirvisit, focus on providing a serv-

ice that is just as muchabout them as it is abouttheir car.

It’s All In The DetailsPeople will equate what

they see with how well youtake care of their car. Clutter,dirty counters, sloppily dressedemployees, worn furniture orneglected plants can reflectpoorly on your business, espe-cially among female customerswho are very detail-oriented.

Make It Easy To Do Business With Your Shop

Customers will feel respectedand cared for if you offer a vari-ety of ways for people to conve-niently do business with youand get on with their busy lives.Help your customers keep trackof upcoming service needs.

An Educated Customer Is ALoyal Customer

Women are more likely to trustyou (and therefore buy fromyou) if they see that you’re will-ing to be transparent and edu-cate them. Not only will it buildthe relationship and your cus-tomer’s trust in your shop, butthe repairs will sell themselves.

Many in the automotive indus-try are scrambling to market theirproducts and services specificallyto women. Are you? IC

*To read Bogi’s full story, go toour sister publication ShopOwner magazine’s website,www.shopownermag.com andsearch for the Marketing toWomen article written by Bogi.

Marketing To WomenShould Be One of Your Top Priorities

Mary DellaValle, [email protected]

06 Editor's Page_Nov 11/12/13 1:41 PM Page 6


07 NAPA Trac IC 11/12/13 1:06 PM Page 7


[NewsUpdate

Although the calendar may say November, it’s beginning to look alot like Christmas at many Federated Auto Parts stores. SeveralFederated members have started collecting toys and donations, aswell as holding special events, on behalf of the 2013 U.S. MarineCorps Reserve Toys for Tots campaign.

“We are thrilledthat so many Feder-ated members areparticipating in theToys for Tots cam-paign,” said MikeSchultz of Feder-ated Auto Parts. “What is really impressive is theircommitment throughout theyear to this worthy cause.Our members and their customers already startedcollecting toys and dona-tions for the coming holiday season, and we know that 2013 willbe even more successful than we could have imagined.”

Earlier this year, Federated members and suppliers raised$135,000 for Toys for Tots during the annual Federated Toys forTots auction held during the group’s annual awards dinner. Addi-tional funds were raised at hospitality events held at the recentFederated Auto Parts 400 NASCAR Sprint Cup race in Richmond.The donations were presented to retired Marine Lieutenant Gen-eral Pete Osman, president and CEO of the Marine Toys for TotsFoundation, Nov. 5 during the Automotive Aftermarket ProductsExpo (AAPEX) in Las Vegas.

Participating Federated Auto Parts stores will accept toy dona-tions at their locations. Financial contributions can also be made atwww.federatedautoparts.com/ToysforTots.aspx, which links directly to the Toys for Tots website. Donors can use their creditcard to securely make a monetary donation, or print out a formand mail it in with a check made out to Toys for Tots.

Federated Toys For Tots

Campaign in Full Swing

08-13 News 11/12/13 1:42 PM Page 8

09 Schaeffler IC 11/12/13 1:05 PM Page 9


[NewsUpdate

Federal-Mogul’s WagnerBrake brand is reaching outto automotive parts distrib-utors and service providersto increase awareness ofthe new packaging “Leaf-Mark” designation cover-ing “low copper”compliant brake pads. Recent legislation in California and Washington state has mandatedthe dramatic reduction of copper and other po-tentially hazardous substances in original equip-ment and replacement brake pads and shoes.

To help professional technicians and consumersdetermine whether brake pads comply with thelow copper requirements, the Automotive After-market Suppliers Association (AASA) and indus-try brake manufacturing registrar NSFInternational established a series of LeafMarkdesignations to be used on product packaging:

Level “A” designates compliance with require-ments concerning cadmium, chromium, lead,mercury and asbestos. Level “A” compliance isrequired by Jan. 1, 2014, in California and January2015 in Washington state.

Level “B” designates compliance with each ofthe aforementioned metals — all of the require-ments of Level “A”— as well as copper, whichmust be reduced to less than 5% of materialweight. Level “B” compliance is required by 2021.

Level “N” designates compliance with the “ZeroCopper” requirement, which takes effect in 2025.

Federal-Mogul recently introduced WagnerThermoQuiet Ceramic brake pads featuring thefirst full-line offering of 2021-compliant low- copper formulations. The Level “B” LeafMarkdesignation, indicating full compliance with 2021requirements, is now being added to Thermo-Quiet Ceramic packaging.

Visit www.WagnerBrake.com to learn moreabout the industry’s shift to low- and zero-copperbrake pads.

ANCO Wipers Proves ‘The Right Blades Matter’ With Consumer Rebates of Up to $10 Per Pair

Wagner Brake Helps Consumers and Installers RecognizeCertification Markings on Low-Copper Brake Pad Packaging

Federal-Mogul’s ANCO Wipers brand is proving“The Right Blades Matter” through a consumer pro-motion that offers rebates of up to $10 per pair onANCO premium wiper blades.

From Nov. 1 through Dec. 31, 2013, consumerswho purchase any pair of premium ANCO Contour,Profile or Transform wipers from a participatingdealer can qualify for a $10 mail-in rebate, while a$5 rebate is available on each pair of ANCOAeroVantage or Winter blades purchased. For pro-gram rules and restrictions and to complete the on-line rebate form, visit www.ANCORebate.com.

“Choosing the right wiper blade is a critical safetyconsideration, especially as we approach the winterdriving season,” said ANCO Brand Manager TracyNeil. “Our new promotion helps consumers getready for the season and save money while improv-ing their driving visibility with the latest technologyand world-class wiper designs.”

For more information about the ANCO “TheRight Blades Matter” rebate offer and any ANCOproduct, contact your ANCO distributor or Fed-eral-Mogul representative or visitwww.ANCOwipers.com.

08-13 News 11/12/13 1:42 PM Page 10


11 BMW IC 11/12/13 1:05 PM Page 11


[NewsUpdate

GOJO Industries announced thegrand-prize and first-prize win-ners in the “GOJO Tough Job.Sweet Deal. Giveaway” contestand sweepstakes.

“Tough Job. Sweet Deal” wascreated for those who work intough jobs and use industrialand automotive hand cleanerand conditioning products. Tobe eligible for the grand prize orone of six first prizes, entrantssubmitted a photograph orvideo, showing themselves andtheir dirty hands, through theentry form online or a photothrough Instagram (#GOJO-ToughSoils). In addition, theycould enter for a chance to win aweekly random prize drawing.Winners were determined byvotes received via social media.

“As the entries showed, our

customers take pride ingetting their hands dirtyon the job or in theirshops and they knowhow to get them cleanand conditioned,” said HaroldTyreman, GOJO sales & market-ing vice president in automo-tive, industrial and textile.“They are passionate aboutGOJO industrial and automo-tive hand cleaner and condition-ing products. Our Tough Job.Sweet Deal Giveaway rewardedthe seven winners for sharingtheir experiences.”

Grand-prize winner was BrianDugan of Sebring, FL. He won atrip for two to the 2014 BCSChampionship Game.* Duganhad the choice between theChampionship Game, a trip fortwo to the 2014 Daytona 500 or

2013 World Series Game 3. First prize iPad Mini winners

were Johna DeRosier of Greens-boro, NC; Crystal Gothe of Uni-versity Place, WA.; Lori Bowersof Chilton, WI; Michael Merryof Roy, UT; Andy Ruddock ofPrescott Valley, AZ; and LaurelKeating of Lumby, British Columbia.

The complete list of winners ispublished at www.GOJO.com/ToughJobSweetDeal.

*NASCAR, Major League Baseballand the BCS were not participants inthe giveaway and did not endorse thegiveaway.

The National Pronto Association has selectedDENSO Products and Services Americas, Inc. forits prestigious OE Supplier of the Year award forthe seventh time in the last eight years. Prontomembers rate suppliers on criteria such as prod-uct quality, profitability, delivery performance,service, support and marketing programs in orderto determine the winner each year.

DENSO was also awarded the 2013 Mexico Sup-plier of the Year Award. This was the first time thePronto Association has bestowed this award. Theaward was presented on Sept. 17, 2013, during

the Pronto Group’s Fall Conference in San Anto-nio, TX. The award states, “In grateful apprecia-tion of quality people, quality products andextraordinary service provided to the members ofthe National Pronto Association.”

“We are truly honored to be recognized for ourrelationships with Pronto’s members in the U.S.,Mexico and Latin America,” said Fran Labun, vicepresident sales group, DENSO Products and Serv-ices Americas, Inc. “All of us at DENSO are look-ing forward to continued success with Pronto andtheir members in the years ahead.”

National Pronto Association Awards DENSOWith OE Supplier of the Year Award

GOJO Announces Winnersin ‘Tough Job. Sweet Deal.Giveaway’

08-13 News 11/12/13 1:42 PM Page 12

NewsUpdate]

Import-Car.com 13

Trico Products reminds driversabout winter preparation withthe TRICO “Change YourClocks, Change Your Blades”campaign as Daylight SavingTime ends on Nov. 3. The cam-paign will help drivers as theyprepare their vehicles forchanging seasons.

“As a world leader in wiperblade technology, we want toencourage safe driving habitsby highlighting routine vehiclemaintenance with our bi- annual ‘Change Your Clocks,Change Your Blades’ cam-paign,” said Danielle Orlando,director of marketing, brandmanagement of Trico Prod-ucts. “Depending on location,the weather will soon bringrain, slush, ice and snow, sothis is the perfect time to pre-pare our vehicles for winter.We want drivers to take control of driving safety andavoid poor visibility in the upcoming winter months.”

For more information onTRICO product lines, contactTrico Products at 800-388-7426,or visitwww.TricoProducts.com.

Statement of Ownership, Management and Circulation(Act of August 12, 1970; Section 3685. Title 39. United States Code.)

Publication Title: ImportCar Publication Number: 1069-4714 Filing Date: Sept. 23, 2013Issue Frequency: Monthly Number of Issues Published Annually: 12 Annual Subscription Price:$69Complete Mailing Address of Known Office of Publication: 3550 Embassy Parkway, Akron, Ohio 44333-8318, Summit County. Contact Person: Pat Robinson Phone: 330-670-1234Complete Mailing Address of Headquarters of Publisher: Same as above.Publisher: Jim Merle (address same as above). Editor: Mary DellaValle (address same as above).Managing Editor: Jennifer Clements (address same as above).Owner: Babcox Media, Inc., William E. Babcox (Owner) 3550 Embassy Parkway, Akron, OH 44333.Known Bondholders, Mortgagees and Other Security Holders Owning or Holding 1 Percent or Moreof Total Amount of Bonds, Mortgages or Other Securities: None.Publication Title: ImportCar Issue Date for Circulation Data Below: August 2013.

Extent and Nature of Circulation: Average no. Actual no. copies each copies of issue during single issue preceding nearest to 12 months filing date

A. Total Number of Copies 30,080 30,228B. Paid and/or Requested Distribution

– Outside County Paid/Requested Mail Subscriptions Stated on PS Form 3541 28,913 29,173

C. Total Paid and/or Requested Circulation 28,913 29,173

D. Nonrequested Distribution – Outside County Nonrequested Copies Stated

on PS Form 3541 113 0– Nonrequested Copies Distributed Outside the Mail 791 795

E. Total Nonrequested Distribution 904 795F. Total Distribution 29,817 29,968G. Copies Not Distributed 263 260H. Total 30,080 30,228I. Percent Paid and/or Requested

Circulation 97.0% 97.3%

Publication of Statement of Ownership will be printed in the November 2013 issue of this publication.I certify that the statements made by me above are correct and complete.

Pat Robinson, Circulation Manager September 23, 2013

Trico Products Reminds Driversto ‘Change YourClocks, ChangeYour Blades’

ACDelco’s “Make a Deal with ACDelco” promotion, which runsthrough Nov. 30, provides service centers with virtual “play and win”games when they purchase eligible ACDelco products. Lucky winnerscan receive up to 150 earnPOWER points per game that can be usedtoward the purchase of more than 3,000 goods and services onACDelco360.com. ACDelco Professional Service Center program par-ticipants and independent service centers are eligible to participate.

For more information, see your participating distributor, visit acdelcotechconnect.com or call 1-800-ACDelco. Find and “like”ACDelco on Facebook at facebook.com/acdelco.

‘Make A Deal WithACDelco’ Promotion

08-13 News 11/12/13 1:42 PM Page 13

On one of many slow days atthe shop, I had a small jobcome in from one of the

local tire shops. This rather younggirl brought the car to me fromthe tire shop that’s just a fewblocks away.

She told me she was theowner and that the tire shopwas rude and wouldn’t helpher, so I called the tire shop to find out what wasthe deal.

Her problem was an occasional “no start.” Thetire shop didn’t want to get involved with this vehicle because it had a breath analyzer attachedto the starting system.

My opinion, if you get behind the wheel in acondition that would require having to blow intoa plastic tube to start your car, you really shouldtake stock of your life.

I needed to find out why this car won’t start.The first thing I did was disconnect the breathmachine to verify if the problem was the car orthe analyzer.

Once the unit was disconnected from the car, Ihad to call the 800 number on the device to letthem know that it’s an authorized disconnect,and not the driver trying to bypass the system.

It’s quite an ordeal. Not so much the physicaldisconnecting of the unit, but the informationyou have to provide to prove that you’re actuallya repair shop when it comes to properly discon-necting the unit.

With that accomplished, I got back to diagnos-ing the problem at hand. It turned out to be a badstarter motor. I called theparts warehouse and gotprices on a replacementstarter for the owner.Later that day, theowner calledback and

Driving, Drinking And GrandpaA Dangerous ‘Triangle’That Took Its Toll OnA No-Start Repair

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


[Gonzo’sToolbox

Scott “Gonzo” Weaver, gonzostoolbox.com

14-16 Gonzo's Toolbox 11/12/13 1:39 PM Page 14

15 Denso WB IC 11/12/13 1:04 PM Page 15

said they had just installed a starter so I must bemistaken.

It was a newer starter, not really a quality rebuiltunit, but it had a lifetime warranty. Against my bet-ter judgment, I removed the starter so they couldhandle the core and warranty.

She came in for the old starter and sometime latershowed up with the replacement starter. I informedher that the quality of my diagnostics or thecharges had not changed. But, if the car failed tostart for any reason beyond the bolts falling out ofthe starter, it was coming out of her wallet. It wentin one ear and out the other.

A while later, Grandpa showed up to pick up thecar with one hell of a chip on his shoulder. (I thinkold Grandpa threw back a few before he showedup, too.)

“This is higher than the tire shop,” he said angrily, “I don’t think I should have to pay that

much for it if the other shop could have done it forless.”

I reminded him that the tire shop may have alower labor cost, but they also said they didn’thave the necessary skills to actually make theproper diagnosis and/or the repair. He rambledon about how he had fixed cars when he wasyounger and since he knew a lot about cars heasked if I could cut him some slack.

Sorry Grandpa, maybe I’m doing you a bigfavor; you spend a few bucks with me, that wayyou’ll be a few bucks shy of that next six pack.That might keep you or your alcoholic grand-daughter from getting behind the wheel drunk,and I might actually be preventing a future fatalaccident.

So do me a favor, save some of that hot air forthe breath machine. You’ll need it to start thecar. IC


[Gonzo’sToolbox

My opinion, if youget behind thewheel in a conditionthat would requirehaving to blow intoa plastic tube tostart your car, youreally should takestock of your life.

“”

14-16 Gonzo's Toolbox 11/12/13 1:39 PM Page 16


17 Carquest IC 11/12/13 1:03 PM Page 17

As I’ve discovered recently, times changeand so do the procedures for diagnosinginoperative fuel pumps. Just a few weeks

ago, I diagnosed a case in which the owner hadstarted his vehicle for several months by sprayingstarting fluid (ether) into his truck’s air intake before he cranked the engine.

The second case involved an old jobber storefriend who wanted a professional diagnosis before installing his own fuel pump. After thenew fuel pump was installed, his truck stillwouldn’t start.

Changing my diagnostic procedure quicklysolved both problems. With little more than aprofessional multimeter and a set of aftermarkettest accessories called “relay tester jumpers,” I’lltell you how I now approach diagnosing inopera-tive fuel pumps.

FUEL PUMP SYSTEMS

Before we begin, let’s take a look at the differ-ences between diagnosing a conventional dual-line, single-line, direct fuel injection or

pulse-modulated system. 1. The fuel pump in a conventional, dual-line

system supplies a fuel rail mounted on the engine, upon which a Schrader test port, the fuelinjectors and the fuel pressure regulator aremounted. A mechanical fuel pressure test is standard for these systems.

2. Fuel pumps in a single-line system aremounted inside an in-tank module that also contains the fuel filter, fuel level sensor and fuelpressure regulator. Since some single-line sys-tems don’t include a Schrader valve for fuel pressure testing, the mechanical pressure gaugemust be adapted to an open fuel line.

3. Direct fuel injection systems contain a con-ventional or pulse-modulated fuel supply pumpmounted inside the fuel tank and a mechanicalhigh-pressure pump mounted on the engine’scamshaft cover. Since a fuel pressure sensor mon-itors fuel pressure, a scan tool is more useful fordiagnosing fuel pump performance.

4. Pulse-modulated fuel pumps are becomingmore common because the PCM can establishbetter fuel control and reduce pump wear by


By Gary Goms, Import Specialist Contributor

FUEL SYSTEMS[DiagnosticSolutions[DiagnosticSolutions

Diagnosing Inoperative Fuel PumpsRelay Test Jumpers Prove Effective In Step-By-Step Fuel Pump Circuit Analysis

18-21,24 Diagnostic Solns_Fuel Sys 11/12/13 1:49 PM Page 18


19 TYC IC 11/12/13 1:03 PM Page 19

adjusting fuel pump speed to meet operating conditions. In contrast to variable-speed pumpsthat use a resistor in circuit to control pump speed,pulse-modulated systems control fuel pressure byrapidly pulsing or cycling the fuel pump on/off.

In any case, I’ll leave the diagnosis of direct fuelinjection and pulse-modulated systems for anotherday because they require a different diagnostic pro-cedure to measure and evaluate the relationship between fuel pressures and duty cycles.

SCAN TOOLS

A scan tool not only helps identify the type of fuelpump system used on the vehicle, it can also provide some very critical information. To illustrate,the Powertrain Control Module (PCM) must befunctioning before the fuel pump can operate. If thescan tool doesn’t communicate with the PCM, checkthe 16-pin OBD II connector for applicable power,ground and communications signals.

Then, check the PCM power and ground connec-tions before condemning the PCM. Remember, too,that communication can be interrupted if thePCM’s 5-volt reference is shorted to ground by afaulty sensor, or if the PCM’s bus communicationcircuits are shorted to ground by a defective bodycontrol module.

Consequently, it’s always a good practice to polleach on-board module to verify communicationsand to check for DTCs. Some newer-generation aftermarket scan tools will automatically performthis function, which is especially important for diagnosing modern controller area network (CAN)vehicles.

Depending upon the application, the vehicle security system might also disable the fuel pump ifit detects possible theft or tampering. One casecomes to mind in which the vehicle’s ignition keyhad lost its resistance pellet, causing the vehicle security system to disable fuel pump operation. Inmost cases, an appropriate DTC will be stored.


FUEL SYSTEMS[DiagnosticSolutions

The relay schematic is usuallyprinted on the relay case.

While the schematic can be con-fusing, it’s easy to determine pinfunction by using the test bulbmethod described in Photo 3.

The pump B+ is located onthe center pin, #87, of the

relay circuit tester. The key-on B+pin, #85, is located at far right.The fuel pump feed is pin #30, leftof center. Key-on B- to the PCMpin is #86, on the far left.

A test light made from a#194 bulb and holder can

be used for determining pinfunction and for grounding thekey-on relay pin without acciden-tally blowing a fuse.

Step-By-Step Analysis Of A Fuel Pump Circuit

1 2 3


In some applications, an inertia switch that’s deactivated by a sudden jarring of the vehicle candisable the fuel pump.

Last, remember that the PCM activates the fuelpump relay only if it receives a readable signalfrom the crankshaft (CKP) sensor. In many applica-tions, a good CKP will indicate cranking rpm onthe scan tool or on the instrument cluster tachome-ter. In other applications, the PCM will indicateCKP and camshaft position sensor (CMP) activityby counting the number of signals delivered to thePCM. Keep in mind that all of these tests can bedone without leaving the front seat of the vehicle.

PHYSICAL INSPECTIONS

When diagnosing any inoperative fuel pump, don’tforget to verify fuel level. To illustrate, a vehicle withjust a few gallons in the fuel tank will probably notstart on a steep incline. Similarly, a defective fuellevel sensor might indicate a higher-than-actual fuel

level, as will a fuel level sensor float that’s stuck onan improperly positioned fuel pump inlet screen.

A badly dented or damaged fuel tank might pushthe pump inlet out of the fuel or kink a fuel pumpoutlet hose. Worse still, a thief drilling a hole intothe tank might have drained the fuel.

Since the possibilities are endless, I often begin afuel pump diagnosis by adding a few extra gallonsof fuel to the tank just to make sure that the pumpinlet is adequately submersed in fuel.

RELAY CIRCUITS

Conventional fuel pumps are operated by a fuelpump relay that’s generally located in the underhoodfuse box. The relay has four important terminals:

1. The pump B+ terminal powers the fuel pumpthrough the relay contacts.

2. The pump B- terminal connects directly to thefuel pump and, more importantly, to the fuelpump ground.

Import-Car.com 21

FUEL SYSTEMS

Amperage draw is tested bymoving the positive test lead

on your DVOM to its 10-amp testport. The relay’s #30 and #87 pinscan be connected to the DVOMvia jumper test leads or by directlyholding the DVOM test probes onthe relay tester pins.

The key-on, engine-off amper-age flow through the pump-to-

ground pin is 5.892 amps. If therelay contacts close, the key-on, enginerunning amperage through pins #30 and#87 will decrease to about 0.38 amps.Higher amperages might indicate thatthe relay contacts have excessive resistance. Zero amperage indicatesthat the pump-to-ground is open-circuit.Lower-than-normal amperage indicatesan insufficient fuel supply to the pump.

This labscope waveform indi-cates about 6.5 amps of current

flowing through the fuel pump-to-ground pin. The ripples at the top indi-cate voltage fluctuations caused by thebrushes traveling over the pumpmotor’s commutator segments. Givenan eight-segment commutator, the indicated key-on, engine-off pumpspeed is about 6,000 rpm.

45 6

DiagnosticSolutions]


22-23 Airtex SPD IC 11/12/13 1:48 PM Page 22


22-23 Airtex SPD IC 11/12/13 1:48 PM Page 23

3. The key-on B+ terminal powers the relaysolenoid.

4. The key-on B- terminal is controlled bythe PCM.

When the ignition is first turned on, the PCMgrounds the key-on B- terminal for a few sec-onds to prime the system. When the engine iscranked, the PCM receives a signal from theCKP sensor and commands the relay closed foras long as the engine remains above crankingspeed. Some relays also contain an optionalfifth terminal that signals the PCM when therelay’s pump circuit is closed.

Although I’ve seen relay test jumpers at mylocal jobber stores and on tool trucks, I’venever given a lot of thought about how theycould improve fuel pump diagnosis. As it turnedout in the two cases mentioned at the outset, they became invaluable.

As mentioned above, B+ voltage should be avail-able at all times to one of the four adapter pins.Key-on voltage should be available at two pins, oneB+ and the other B- or ground. Of course, the ques-tion is knowing which is which. The answer is tofabricate a small test light from a #194 light bulband holder. The #194 bulb draws enough amperageto close the fuel pump relay, but not enough toblow the fuel pump fuse if a pin is mistakenlygrounded. The #194 test bulb can also be used toverify the integrity of the pump B+ and the pump-to-ground circuits.

MULTIMETER ANALYSIS

In this application, a direct amperage reading can beobtained by connecting a DVOM ammeter to pinnumbers 30 and 87. While not within the scope ofthis article, a fuel pump current ramp waveform canalso be obtained through pins 30 and 87. Althoughnot always true, a rule of thumb is that each ampereof current draw is approximately equal to 10 psi fuelpressure.

In any case, this test can be done without attaching a fuel pressure gauge or testing for volt-

age at the tank connection. As for the vehicle thatwould start on ether, the pump relay was closing,but the presence of B+ at both pump terminals in-dicated that pump itself was open-circuit. Whenether was sprayed into the air intake, the enginewould start and the alternator would generateenough voltage to bridge the worn brushes in thefuel pump.

The second case was fairly simple. Since I had B+on both key-on pins, I knew the key-on pin wasn’tbeing grounded by the PCM. Checking the fuse box,I found a PCM fuse that had been accidentallyburned. With that, I’ll leave you with a step-by-stepprocedure for diagnosing a fuel pump (see pages 20and 21) by using a relay test jumper kit available atyour local jobber store or tool truck dealer. IC


FUEL SYSTEMS[DiagnosticSolutions

Gary Goms is a former educator and shop ownerwho remains active in theaftermarket service industry.Gary is an ASE-certifiedMaster Automobile Techni-cian (CMAT) and has earnedthe L1 advanced engine per-formance certification. Healso belongs to the Automo-tive Service Association(ASA) and the Society of Automotive Engineers (SAE).


25 OReilly IC 11/12/13 1:02 PM Page 25

Electronic stability control (ESC) was intro-duced in 1995 and touted as the second mostimportant advancement in auto safety, after

seat belts, becoming standard equipment on every2012 passenger vehicle.

ESC is supposed to help drivers maintain safe control of their vehicles and prevent accidents.

However, it’s the tires that determine the effectiveness of ESC for every vehicle. Simply

put, ESC is on-board computer technologythat helps improve a vehicle’s steadiness onthe highway by detecting and minimizingskids and maintaining steering control.

It works whether a vehicle is braking, accelerating or coasting by detecting under-steer from front-end slides, oversteer fromrear-end slides and hydroplaning. It per-forms in any driving condition, such as dry,wet or icy pavement, and at any speed.

In general, ESC systems monitor a vehi-cle’s stability 25 times per second to detectimminent skidding. It uses sensor signalsthat compare the intended direction in whichthe driver wants the vehicle to move, withthe vehicle’s actual direction. If there is a discrepancy, the system makes adjustmentsto help prevent skidding and keep the vehi-

cle on its planned path.During normal driving, ESC works in the

background and continuously monitors steeringand vehicle direction. The driver’s intentions are

determined through the measured steering wheelangle. The actual direction is determined by measured

lateral acceleration, yaw or vehicle rotation, and each

Electronic Stability Control System Effectiveness Depends On WhereThe Rubber Meets The Road


By Skip Scherer, Contributing Writer

ABS/ESC[TechUpdateTechUpdate

26-30 Tech Update_ESC_ABS 11/12/13 1:47 PM Page 26


27 KYB IC 11/12/13 1:02 PM Page 27

wheel’s road speed.When a loss of

steering control isdetected, ESC au-tomatically — andin the blink of aneye — uses the vehicle’s brakingsystem to correctits path, literallysteering the vehicleback on course. Braking is auto-matically applied to individualwheels.

For example, braking a frontwheel on the outside of a skidwould counter oversteer, whilebraking an inner rear wheelwould counter understeer. Somesystems combine select brakingwith reduced engine power tohelp regain control of a vehicle.

The corrections happen soquickly that without a dashboardwarning light, the driver mightnot know the vehicle’s on-boardcontrols just helped avoid a poten-tially serious accident and injuries.

SAFETY STATISTICS

ESC and ABS are not the samething. ABS prevents wheel lockupduring braking. Speed sensors on avehicle’s wheels detect developingproblems and the on-board controlunit sends signals that pump thebrakes rapidly to prevent individ-ual wheels from locking.

Every year ABS/ESC hydrauliccontrol units get smaller andlighter. They are also becomingmore functional with the abilityto connect with more sensors to

add featureslike automatic braking, adaptivecruise control and even regenera-tive braking control for hybrids.

NHTSA concluded that ESC reduces passenger car crashes by35% and SUV crashes by 63%. Italso determined that ESC was effective in reducing accidents ofsingle vehicles that ran off theroadway and rolled over orstruck a stationary object.

A similar study by the Insur-ance Institute for HighwaySafety reported that ESC pre-vents 56% of fatal single-vehiclecrashes and almost 80% of fatalsingle-vehicle rollovers.

THE ROLE OF TIRES

In spite of all the high-tech electronics controlling a vehicle’shandling capabilities and stability,its four tires provide the contactpoints on a roadway’s surfacethat ultimately control theamount of slipping and slidingthat can take place. ESC is only asgood as the available traction.

So, what do tire manufacturersconsider when designing a tire


ABS/ESC[TechUpdate

Go to www.ICRapidResponse.com



29 Wagner SmartChoice IC 11/12/13 1:01 PM Page 29

that taps into ESC’s full potential? A spokespersonfor one of the three largest tire companies, who askednot to be identified, said there is no special considera-tion given to ESC when tires are being developed.

At first, the response may seem surprising. How-ever, tire dealers know that properly designed tiresprovide optimal traction for specific vehicles. Acar’s design, weight, center of gravity, speed, direc-tion and many other traits, as well as road condi-tions, add up to its overall balance, while the tirescontribute to the vehicle’s overall stability.

Since ESC is safety technology and not a performance enhancement, it can’t improve on traction attributes already built into a tire. ESC doesn’t improve the inherent traction of tires, butgood tires can maximize the safety maneuvers pro-vided by ESC, such as better-controlled cornering.

The conclusion: ESC can only work when tractionis available. Bald tires render ESC ineffective inrain. Likewise, hard tire compounds render ESCalmost useless on ice.

A technician’s role in maintaining a fully func-tioning ESC starts with understanding the technol-ogy and educating his or her customers. Informingdrivers about proper tire maintenance, as well as

using appropriate tires for the winter season, en-sures that on-board ESC, ABS and Traction Controltechnology improve the safety of the driver andothers. Consistent tire wear is important to ESC’scomplex electronics. Conflicting tire diameters andair pressures can fool the sensors.

Technicians must know if a vehicle that has undergone wheel alignment service requires itsESC steering angle sensor to be reset or not. Failure to perform an OEM’s required SAS resetprocedure after an alignment could create ESC performance issues. IC


ABS/ESC[TechUpdate

When a loss of steering control is detected, ESCautomatically — and in the blink of an eye —uses the vehicle’s braking system to correct itspath, literally steering the vehicle back on course.



31 Parts Plus IC 11/12/13 1:01 PM Page 31

The usual complaint is a big stumble or stall on initial acceleration. As the engine torques on the mounts, thecrack in the hose will open, allowing unmetered airinto the manifold, while, at the same time, reduc-ing airflow through the mass air flow sensor. Ofcourse, when the engine stumbles, the crackcloses, allowing the engine to accelerate, start-ing the entire process all over again.

Although it’s simple to diagnose with a visual inspection, I’ve seen some good techni-cians tricked by this one. These hoses becomehard and brittle over time, and you may notfind the fault simply by squeezing the hose. Besure to inspect the hoses closely for cracks that


By Bob Dowie, Contributing Writer

DRIVEABILITY [MazdaFeature

This article will look at Mazda driveability issues as well as some ofthe more common ailments that will bring a car into your bay with acheck engine lamp complaint. The most common failure wesee on Mazda models is a torn air intake hose betweenthe airflow sensor and the throttle body. The symptoms that result from this failure are hard tomiss, but fool the customer into mistakenlythinking that the transmission is the problem.

32-34, 38-42 Mazda Driveability 11/12/13 1:46 PM Page 32

won’t be obvious but will become evident whenthe engine is loaded against the mounts.

Another issue is a P0400 code, excessive EGRflow. The first problem is the fact that an “excessiveflow” code will be thrown, when the actual prob-

lem is “insufficient flow.” The excessive report is the result of the ECU command-ing more EGR when the engine doesn’trespond as expected to the EGR valve

being opened. The most common cause forthis lack of response is plugged EGR passages

in the manifold. By removing the throttle body andEGR valve, the passages can be cleaned using a liberal amount of carbon cleaner and a piece ofspeedometer or hand brake cable and a drill.

On some models, it will be necessary to removethe upper plenum. Be sure the vacuum line and

manifold nipple areclear going into the

MAP-type sensorthat serves as

the EGR boostsensor. Don’tlet the termboost sensorconfuseyou; it’s amanifoldpressuresensor

that’s usedto monitor the

pressure changewhen the EGR is

commanded open. On the later models that use

an electrically controlled EGR,there have been instances where

the valve has caused issues with athrottle tip-in stumble, stalling or rough

idle. These complaints may be accompaniedby a system lean code. If the rough idle is

caused by a partially open EGR valve it’s easy to

diagnose: Just let the engine warm up and look forflow through the valve by checking to see if the valveis excessively warm. We know there shouldn’t be anyflow through the valve at idle; if so, the high temp indicates that the spring-loaded valve is not seating.

STALLING ISSUE

A stalling issue can be a bit more challenging, sinceit could be an intermittent problem with the valvenot closing. In this case, we check other possibilitiesfor stalling; if we find no problems there, we gowith our experience and replace the valve. The samescenario applies with a throttle tip-in stumble. Inthis case, the weak return spring in the valve is allowing more flow than the ECU is commanding. Ifyou suspect this problem, a road-test with the valvedisconnected will quickly confirm it.

While a sticking EGR can cause a system leancode, it’s not the most common cause. The first stepwhen faced with a lean code is to be sure to look atthe freeze-frame data. Look at the fuel trims andthe conditions when the code was set. You’ll proba-bly find a long-term trim number near 25. This isthe result of the short-term trim adding fuel anddriving up the long-term number. If you’re lookingat a multi-bank engine, take note if both banks areshowing a similar number or if it’s just one bank.

Freeze frame will also tell you when the limit wasreached. Armed with this information, you canmake some decisions. If the limit was reached atidle, it would have you looking for unmetered airfinding its way into the engine. It could be the EGRvalve, but could also be an intake manifold gasketleak, or the O-ring seals on the V6.

On the four-cylinder, a leaking intake gasket willusually set a misfire code, along with the systemlean code, letting you know where to concentrateyour inspection. Usually all it takes is a shot of in-take cleaner at the manifold flange and stethoscopeto confirm the diagnosis. The six-cylinder’s uppermanifold O-ring leaks can be a bit more challeng-ing, and if you’re in doubt, a smoke test will con-

Article continues on page 38

MazdaFeature]DRIVEABILITY



Late-Model

There have been some reports of wiring har-ness failure in the popular Tribute modelthat could shut down an injector or coil on

acceleration and set the appropriate misfire code.The failure is usually within a couple of inches ofthe ECU; a shake and wiggle test will confirm theproblem. But with the wire breaking inside the in-sulation, it would be time well spent to check apin chart to better identify the suspected wires.

The problem with system lean codes hasn’tgotten any better, but the possible causes havechanged. There are still problems with contami-nated mass air flow sensors, and intake hosesthat can be diagnosed as previously discussed.

We’re seeing some new problems that will leadto lean codes at idle. Like the sticking EGRvalves on the earlier cars, the purge valves arenot closing causing vacuum leaks most prevalentat idle. You’ll see a high reading on long-termfuel trim as the ECU tries to add enough fuel tocompensate. It’s an easy problem to confirm;with the engine running there should be no vac-uum on the vent line side of the valve. Like theEGR valves, this can be an intermittent problem.

If you’re in doubt, remove the valve and tap theinlet side on a clean bench. If any debris comesout of the valve, you can be pretty sure you’vefound the problem and should consider replac-ing the charcoal canister.

Another problem we’re seeing with the 2.3L engines is a bit more serious and will lead to poorperformance and a no-start complaint. These tim-ing chain-equipped engines have been having aproblem with the cam timing shifting when the oillevel gets extremely low. In a perfect world, every-one checks the oil and gets timely oil changes,but we all know that’s not always the case.

These engines use friction washers (that mustbe replaced when removed) to hold the cam andcrank gears in place after using special tools toestablish the cam timing. While this system allows more precise timing, it has to be consid-ered while you’re diagnosing a no-start, lowpower or crank and cam sensor codes. It’s appar-ent the cams are momentarily seizing due to thelack of lubrication and the gears are slipping. It’salso important to keep this system in mind ifyou’re going to replace a crank seal.

MAZDA ISSUES



35 Standard IC 11/12/13 1:00 PM Page 35

36-37 Autolite SPD IC 11/12/13 1:44 PM Page 36

36-37 Autolite SPD IC 11/12/13 1:44 PM Page 37

firm you’re on the right track.On the other hand, if the freeze-

frame information is telling youthat the code was set at speed, theidle is smooth and the driver re-ports no additional symptoms,you would have to think aboutwhat makes it lean under thoseconditions. My first thoughtwould be the mass air flow sensoris not reporting all the air flow to

the ECU; by now we should all beaware of how debris finds its wayto the hot wire sensor.

If you’re going on an initialroad-test after checking and clear-ing the codes and memory, set thescanner up to monitor the fueltrims, front O2 and calculatedload. Before you hit the road,make sure the O2 and short-termtrim is switching as expected. On

the road, do a couple of wide-open accelerations, making noteof the calculated load; it should a90-plus percentage. If not, take aclose look at the mass air flowsensor for contamination.

The sensors can be carefullycleaned — and we’re havinggood luck with some of the prod-ucts designed for the job — butbe gentle as they are fragile. Welook at cleaning the sensor aspart of the diagnostic processand recommend a new sensor toensure a successful repair, so besure to note that on the invoice toprevent any misunderstanding.

Once the problem is diagnosedand repaired, make sure that thebolts holding the sensor to the airfilter housing are tight, that the airfilter box is not allowing unfilteredair into the sensor, and that the airfilter element is of high qualityand in good condition. There havealso been reports of the sensorhousing bolts coming loose, lettingdirt into the air stream, so be sureall the air is being filtered.

IGNITION SYSTEM

A P0300 series code indicatingmisfires has us moving to the ignition system. Many times, amisfire code will have a driveabil-ity complaint associated with it,but either way the diagnosticstrategy is similar. If the miss isalways evident, it shouldn’t takeyou long to figure it out. Be surethe engine is mechanically soundwith good compression and sparkplugs that are in good condition.


DRIVEABILITY[MazdaFeature




39 Cardone IC 11/12/13 1:00 PM Page 39

While you’re there, take a goodlook at the wires for any crackingor indication of carbon tracking;look closely for pinholes burntthrough the plug boots thatwould let the spark get to ground.If any oil is evident, replace thevalve cover gasket with sparkplug tube seals. If the oil is deepenough, that could very well bethe cause of your problem. Grabyour stethoscope and be sure theinjectors are opening and closingby listening for that distinctiveclick with the tool in the same location on each injector; theyshould all sound the same.

With Mazda’s distributorlessignition (DIS), using waste spark,coil pack and coil-on-plug sys-tems, as the miles add up, noneof the systems have been im-mune to problems. Plug wireshave been the most common fail-ures, but we’ve seen some coilsfail as well. In the best case, theOBD II system is reporting theoffending cylinder, sending youin the right direction. If not, itcan be tough to pinpoint the offending cylinder, especially ifit’s an intermittent problem.

While you can use a low-ampprobe to look at the coils, it can be

difficult to catch the problem. Ona higher mileage, four-cylindercar that uses two coils and twowires, I would tend to replace allthe components. On coil-packcars, history tells us wires are themore common failure.

With six-cylinder, coil-on-plugcars where the cylinder can’t bepinpointed, you have to decide ifyou should change them all orwait for the failure to becomemore evident. That decisionwould require a discussion

between you and your customer.On the models that require mani-fold removal for access, we always recommend replacing allthe coils and plugs while we’rethere.

The other weak link in the igni-tion system is the distributor it-self. You may have a complaintthat the car cut out, but when itwas started back up, it seemedfine. Or maybe it just cut out andwouldn’t start. There are no serv-iceable parts in the Mazda distributor, so if you have a no-spark condition that is traced toone of the components housed in

the distributor, the unit will haveto be replaced.

Actually, on some models, the igniter is available, but it costs asmuch as a rebuilt distributor. Theaftermarket offers high-quality re-built units, but they don’t all comewith the O-ring. You may be ableto carefully replace the old one, butit’s much safer to have a new oneon hand. When the time comes toput on the timing light, be sure tocheck your service information forany special procedure required to


DRIVEABILITY[MazdaFeature


On the four-cylinder, a leaking intake gasket will usually set a misfire code,

along with the system lean code, lettingyou know where to concentrate your

inspection. Usually all it takes is a shot ofintake cleaner at the manifold flange and

stethoscope to confirm the diagnosis.



41 NAPA Oil Filter IC 11/12/13 12:59 PM Page 41

set thebase timing.

If you ignore amisfire code for anylength of time, you will befaced with a P0420 catalytic con-verter efficiency code. Again,using the data side of the scan-ner, we want to take a look at thefront and rear O2 sensors to seeif the “cat” is doing its job. Un-fortunately for the customer, weusually see the sensors mirroringeach other, telling us the misfirehas damaged the converter. If thefront sensor were switchingnicely while the rear remainedsteady, we’d know the cat’sdoing its job. Keep in mind thatthe cats are covered with aneight-year, 80,000-mile warranty.

LATEST TECHNOLOGY

While Mazda has long enjoyed areputation for high-performance, affordable cars, the engineershaven’t stopped looking for improvements. The latest is itsSKYACTIV technology. Its SKY-

ACTIV-D engine, for example,touts the world’s lowest diesel- engine compression ratio: 14.0:1, producing 20% better fuel efficien-cy. Mazda accomplishes this usinga sequential twin turbocharger induction system setup to crammore air into the cylinders whenthe engine is running. There is asmaller turbo and a larger turbothat can work together or inde-pendently. The smaller turbo helpsreduce turbo lag at low rpm,while the larger turbo supplies in-creased boost pressure for high-speed power.

Mazda engineers also workedhard to reduce parasitic drag inthe engine, as well as the trans-mission, resulting in better fuelmileage and increased perform-ance. Go to www.mazda.comand click on the SKYACTIV tabfor more details. IC

42 November 2013 | Import-Car.com Go to www.ICRapidResponse.com

[MazdaFeature DRIVEABILITY



43 Speedville IC 11/12/13 12:58 PM Page 43

The 2008-’12 VolkswagenRoutan is a re-badged variant of

the Chrysler minivanplatform with revisedstyling, suspension tun-ing and brake serviceprocedures. So this vanhas a bit of a split personalitywhen it comes to servicing the brakes.

The customers who drive the Routan and theChrysler minivan are two different customers,judging by the TSBs. The Routan has five differ-ent TSBs that relate to addressing customer con-cerns about brake noise. The Chrysler minivanhas zero. The two vans have almost identicalbrake systems and are assembled in the sameplant. So you’ll have to give the Routan driver alittle special attention.

BRAKE FLUID

Volkswagen requires SAE J1703 or DOT 4 brakefluid for the Routan. This type of brake fluid isrecommended because of the kinematic viscosityrequirements of ABS and ESC systems.

BRAKE BOOSTER

The 3.6L engine-equipped Routan uses a vacuumpump to augment normal engine vacuum. Controlof the vacuum pump is provided by the PCM. Atwo-wire electrical connector is used to receivepower and ground for the vacuum pump. Operat-ing voltage is between 9V-16V.

Some vehicles with the auxiliary vacuum pumpmay store a DTC P1479 (17887) for a brake vacuum system malfunction. Sometimes, thiscode can be set erroneously due to suddenchanges in engine vacuum, or as a result of condensation buildup. Checking the vacuumpump will require the use of a scan tool that canperform the bi-directional test for the pump.

FRONT & REAR BRAKES

As stated previously, the Routan driver is moresensitive to brake-related noise. Always use a premium pad setwith new hard-ware when thebrake friction material needs tobe replaced.

2008-’12 Volkswagen RoutanBrake Service


By Andrew Markel, Editor, Brake & Front End Magazine

BRAKE JOB[TechUpdate

Andrew Markel

44,46,50 Tech Update_VW brakes 11/12/13 2:40 PM Page 44


45 Advics IC 11/12/13 1:34 PM Page 45

The stock front disc brakes are equipped with anaudible wear indicator only on the left-side inboardbrake pad. The right-side pads do not include anaudible wear indicator. Rear disc brakes areequipped with audible wear indicators on both theleft- and right-side inboard brake pads.

The rear calipers have an integrated parkingbrake in the caliper. Turning the caliper piston willretract the caliper.

PARKING BRAKE ADJUSTMENT

The parking brake lever is an automatic-adjusting type that continuously applies minimal tension to the parking brake cables tokeep them in adjustment at all times.

1. Wipe the front parking brake cable strand clean at the interme-diate bracket area. Do not use any type of sharp instrument directlyon the cable strand to hold it in place. Damage to the cable strand or


BRAKE JOB

[TechUpdate


The vacuum pump is controlledby the PCM.

Article continues on page 50



47 AVI Test Prep IC 11/12/13 1:34 PM Page 47

48-49 FM Wagner SPD IC 11/12/13 2:39 PM Page 48


48-49 FM Wagner SPD IC 11/12/13 2:39 PM Page 49

coating canoccur.

2. Clamp an appropriate pair of pliers on only thefront parking brake cable button and pull the cablestrand rearward until it stops. Grasp the front cablestrand and hold it in this position, and then removethe pliers from the button.

3. While holding the front cable in this position,install the equalizer (attached to both rear cables)on the front parking brake cable.

4. Release the grasp on the front parking brakecable.

5. Apply and release the parking brake lever onetime. This will seat the parking brake cables andallow the auto adjuster in the parking brake levermechanism to correctly tension the parking brakecables.

Torque Specs:FrontGuide Pin: 26 ft./lbs.Caliper Bracket Bolt:

125 ft./lbs.RearGuide Pin: 26 ft./lbs.Caliper Bracket Bolt:

100 ft./lbs.

Runout Limit:0.002”

Bleeding Sequence:Left rear, Right front,

Right rear, Left front. IC


BRAKE JOB

[TechUpdate


The equalizer bar forthe parking brake.

The Routan with the 3.6L engine was the only model tocome with a vacuum pump forthe booster.

The parking brake lever is anautomatic-adjusting type thatcontinuously applies minimaltension to the parking brakecables to keep them in adjustment at all times.



51 NAPA Chassis IC 11/12/13 1:33 PM Page 51

For the past three years, Hyundaihas managed to sell more than halfa million vehicles each year. Being

able to service them can add dollars toyour bottom line. Here are some top techtips to aid your diagnostic efforts.

No Spark, No Injector Pulse on2002 Sonata 2.4L Models

You may get a customer complaintthat the vehicle died while in Drive,then wouldn’t start. There is no sparkand no injector pulse, no engine rpmon the scanner while cranking, and it’ssetting a crankshaft position sensor(CKP) code P0335. CKP sensor failureis common.

Tests/Procedures: 1. Verify the battery voltage to the

CKP sensor on the pink wire.2. Verify that the ground for the CKP sensor is

good on the black wire — look for 0.05 volts orless.3. Scope the CKP sensor on the yellow wire for a

consistent 0-5 volt square wave signal.4. Check for possible timing belt shredding

that’s affecting the CKP sensor. Courtesy of Identifix.

Hyundai 2.4L: Belt Debris Damages Trigger Wheel

In the case of “no start” problems, it pays toknow the service history. If the car has suffered abroken timing belt, it’s a good possibility thatsome debris from the broken belt has found itsway to the crankshaft position sensor (CKP),causing damage to both the sensor and triggerwheel. On 2.4L engines, the balance shaft belts


HYUNDAI TECH TIPS[TechFeature[TechFeature

[

[

52-56 Tech Feature_Hyundai engine 11/12/13 2:38 PM Page 52

53 Denso CAF IC 11/12/13 1:33 PM Page 53

have been known to fail and gounnoticed until the pieces finallytake out the CKP sensor, result-ing in a “poor run” or “no start.”

Hyundai Engine Stumble:Check Coolant and AirTemps Another common driveabilityproblem that may or may nothave an associated code is astumble or cutting out on throt-tle tip in. If the check enginelight is lit, hook up your scan-ner and retrieve the code; themost common will be a systemlean code. While you have the

scanner installed, take a coupleof minutes to look at the otheravailable parameters. Are thetemp sensors reading correctlywith a cold engine? The coolantand air temps should be close.

2004-’06 Elantra: CheckEngine Light On With FuelSystem Lean CodeVehicle Application:2004-’06 Hyundai Elantra GLS

2.0L and 2004 Hyundai ElantraGT 2.0LThe check engine light is on

with a post catalyst fuel systemlean code P2096, an O2 sensor


HYUNDAI TECH TIPS


[TechFeature[TechFeature

[

Hyundai 1.6-2.4L: Checkthe Weights on the ShaftsBefore Installing BeltsHyundai also uses balance andoil pump shafts driven by thetiming belt. In the early 1990s,balance shafts were used onthe small displacement 1.6Land 1.8L DOHC engines foundin the popular Elantra and thesporty Tiburon, as well as thelarger displacement 2.0L and2.4L engines used in theSonata.

The addition of the balancebelt won’t cause any problemsas long as it’s timed correctlyand the counterweights are inthe proper position when the belts are installed. There are accessholes in the block that allow you to insert a punch or screwdriverto ensure the weights are at the bottom of the shaft, but they arenot always necessary. It isn’t difficult to "feel" that the weights areat the bottom of the shaft. Later 1.8L and 2.0L engines went witha timing chain tying the cams together, while a belt was used onthe opposite end of the exhaust cam to drive both. No balanceshafts are used on these engines but remain necessary on thelarger displacement four-cylinder engines.

[



55 Harbor Freight IC 11/12/13 1:32 PM Page 55

stuck lean B1/S2 code P2270,and an O2 sensor no activityB1/S2 code P0140.

Potential Causes:Air/fuel ratio sensor, exhaust

flex pipe, fuel pump, heated oxy-gen sensor, mass air flow sensor.

Tests/Procedures: 1. Monitor the front air/fuel

ratio sensor for about 2 volts atidle. Voltage should go down alittle (rich) under heavy accelera-tion and up a little (lean) on deceleration. Voltage should increase to about 3.2 volts in fuelcut. (Hard deceleration from 4,000rpm).2. Monitor the rear O2 sensor to

be about 0.4 to 0.6 volts andsteady. Voltage should go up(rich) under heavy accelerationand down (lean) on deceleration.3. Check the fuel trims to be

close to 0%, add fuel and create avacuum leak to see if the air/fuelratio sensor reacts and the fueltrim changes.4. Check the mass air flow

sensor voltage at the pink wire tobe about 1.4 volts at idle andabout 2.5 volts at 3,000 rpm.5. Have a helper partially plug

the tailpipe while you check forexhaust leaks.6. Check fuel pressure to be

about 49.8 psi.Courtesy of Identifix.

Hyundai Voltage Drop DiagnosticsExcessive resistance in high-

amperage circuits may result inone or more of the followingsymptoms:• Blower motor speed slows downand the radio cycles off and on.

• Intermittent headlight dim-ming during deceleration.This bulletin provides the pro-

cedure to diagnose and repairthe vehicle wiring grounds.

Service Procedure:1. Start the vehicle and turn on

the headlights (including highbeam), air conditioning and setthe blower to maximum speed.2. Using a digital volt-ohm meter

(DVOM), perform a voltage droptest on the positive battery cable,paying particular attention to theleads to the underhood junctionbox. If the voltage drop is morethan 0.2 volts on any of the leads,replace the positive battery cable.3. Perform the voltage drop test

on the negative battery cable. Ifthe voltage drop is more than 0.2volts, repair or replace the nega-tive battery cable.4. Perform the voltage drop

check to all body ground loca-tions in the engine compartment.Check with the positive DVOMlead on the negative battery ter-minal and the negative lead to theground locations. If the voltagedrop is more than 0.2 volts, repairor replace the body ground termi-nal and/or wiring assembly.5. Perform the voltage drop

test on all Engine and Transmis-sion ground straps. Check withthe voltmeter positive lead onone end of the strap and thenegative lead to the oppositeend. If the voltage drop is morethan 0.2 volts, repair or replacethe ground terminal and/orground strap. ICCourtesy of ALLDATA.


HYUNDAI TECH TIPS


[TechFeature[TechFeature

[



57 Wix IC 11/12/13 1:32 PM Page 57

NISSANMAXIMA’S ABS ACTIVATESON NORMAL BRAKING, ABSWARNING LAMP IS ON

Applied VINs:2004-’06 all VINs2007 built before 1N4BA41

E(*)7C 806900

Confirm:The ABS light is on with one

or more of the following DTCstored,

- C1105 - RR RH Sensor 2- C1110 - Controller Failure- C1124 - RR LH IN ABS SOL- C1126 - RR RH IN ABS SOLand/orThe ABS system activates

with normal braking.

Service Procedure: 1. Remove only the right rear

(passenger side) brake rotor,wheel hub assembly and baffleplate (see Fig. 1).

2. Remove the plastic hubcap (see Fig. 2).

3. Remove the right rear ABSwheel sensor as follows:

a. Apply corrosion pene-trant to the sensor bolt.

b. Use a punch and hammerto lightly tap the sensor bolt.

c. Remove the sensor boltand sensor (see Fig. 3).

4. Clean any corrosion off ofthe knuckle, baffle plate andwheel hub assembly.

– Use a non-metal brush onthe wheel hub assembly. Ametal brush may damage com-ponents.

– A wire wheel or metalbrush can be used on theknuckle and baffle plate.

5. Grind or file a notch in thelocating hole (see Fig. 4).

Before grinding – see Fig. 5After grinding – see Fig. 6

on page 60.6. Install the new plastic hub

cap.7. Reassemble all parts

removed in reverse order.Make sure to use a new ABSwheel sensor.

8. If code C1124 and/orC1126 was stored, replace theABS actuator.


[ImportTechTips

Fig. 1: Nissan

Fig. 2: Nissan

Fig. 3: Nissan

Fig. 4: Nissan

Fig. 5: Nissan

58-61 Tech Tips 11/12/13 2:37 PM Page 58


59 U of Aftermarket IC 11/12/13 1:31 PM Page 59

9. If you did not replace the ABS actuator instep 8, do the following:

a. Use CONSULT-II to clear all ABS DTCs.b. Test-drive the vehicle.c. Recheck for code C1110.d. If code C1110 is stored, replace the ABS

actuator.10. Test-drive the vehicle; make sure the incident

is fixed and the ABS light does not come back on.Courtesy of ALLDATA.

FUEL TRIM DIAGNOSISAND O2 SENSOR PERFORMANCE

To better understand how fuel trim numbers aregenerated, the ECM/PCM uses the oxygen sensoror air/fuel sensor input signal to adjust fuel injectorpulse-width values. If a longer-than-normal injectorpulse width is required to maintain the desired oxygen sensor signal, the ECM/PCM displays an increased fuel trim value in its datastream.

Of course, accurate fuel trim values are basedon a properly functioning oxygen sensor. So,when diagnosing any fuel injection malfunction,it’s important to make sure that the oxygen sensor is accurate and responsive to fuel trimchanges. Other areas that may affect fuel trimsare poorly functioning MAF sensors, MAP sensors, low fuel pressures and vacuum leaks.

Some general guidelines for diagnosing fuel

trim and the potential causes for failure can befound on page 61.

A useful diagnostic tool is to determine if thefuel trim problem exists in more than one engineoperating range. Fuel trim should be checked atidle, at 1,500 rpm and at 2,500 rpm. In addition tothese no-load checks, drive the vehicle at varioussteady load conditions and watch for fuel trimvariation. If long-term fuel trim (LTFT) for bank 1is 25% at idle, but corrects to 4% at 1,500 and2,500 rpm, focus on factors that cause a lean con-dition at idle, such as a vacuum leak. If the condi-tion exists in all rpm ranges, the cause is morelikely a fuel supply issue caused by low fuel pres-sure, a restricted injector or a defective sensorinput from a MAF or engine temperature sensor.

Fuel trim can also be used to identify whichbank of cylinders is causing a problem. If theLTFT for bank 1 is 20% and the LTFT for bank 2is 3%, the source of the problem is associatedwith bank 1 cylinders only. The diagnosis shouldfocus on factors related to bank 1.

If an engine vacuum leak is suspected, inspectthe intake manifold and vacuum hoses for leaks.If none are found, connect a vacuum gauge tosee if engine vacuum readings are steady at idleand within a normal range. A low reading couldindicate a vacuum leak or possibly a leakingEGR valve.

The performance of the O2 sensors can bemeasured using a scan tool, a DVOM or a labscope. Check to see if the O2 sensor respondscorrectly to rich and lean fuel conditions. A richcondition can be temporarily created with apropane enrichment tool and a lean conditioncan be temporarily created by removing a vacu-um line. If the engine control system is in closedloop (check loop status with the scan tool), moni-tor the injector pulse-width changes in responseto changes to the O2 sensor readings. If thesevalues are normal, you can assume the feedbackfuel control system is doing its job.

Check vehicle fuel pressure by connecting afuel pressure gauge to the fuel rail and monitor-


[ImportTechTips

Fig. 6: Nissan

58-61 Tech Tips 11/12/13 2:55 PM Page 60

ing fuel pressure. Does the pressure changewhen you disconnect the regulator vacuum lineor restrict the fuel return line? Low-pressurereadings could indicate a restricted fuel filter orstrainer, excessive resistance in the fuel pumpwiring or a failing fuel pump. High fuel pressurereadings would point toward a faulty fuel pres-sure regulator or a restricted fuel return line.

If fuel pressure is normal, monitor the injectorpatterns with a labscope. The injector pulse-width should increase and decrease with rapidincreases and decreases in throttle position andincreases and decreases in engine load.

Use the labscope to look at the engine’s second-ary ignition pattern. If one or more of the sparkfiring lines are excessively high with short firingtime, it’s a good indicator of a lean fuel conditionin the affected cylinders. Lean mixtures are lessconductive than rich mixtures and require highervoltages to initiate a spark. A lean condition couldbe a symptom of a dirty, clogged or inoperativefuel injector. The premature loss of the spark canalso be caused by poor volumetric efficiency dueto a worn cam lobe or a leaky exhaust valve.

If the fuel mixture is running rich because theO2 sensor is inoperative, or the feedback controlsystem is staying in open loop, the firing volt-ages will likely be lower than normal with longerfiring lines.

Possible Causes of Fuel Trim FailuresMechanical Conditions:

• False air/vacuum leaks• Saturated charcoal canister• Leaking fuel pressure regulator

• Fuel pressure and volume• Engine operating temperature• Exhaust leaks• Engine compression• PCV system• Sticking injectors

Electrical Components:• Fuel injectors

• Ignition system• Battery and charging systems• Powertrain Control Module• Wiring harness/connectors

Sensor Failures: • Upstream O2 sensors (HO2S)• Manifold Absolute Pressure (MAP)• Mass Air Flow (MAF)• Vane Air Flow (VAF)• Engine Coolant Temperature (ECT)• Throttle Position Sensor (TPS)• Intake Air Temperature (IAT)

Courtesy of Delphi Product & Service Solutions.

HEATER CORE LEAK REPAIRA classic sign of a heater core problem is when theinside of the vehicle windshield persistently keepsmisting. Warm coolant is leaking out of the coreinto the vents and then condensing against thecooler surface of the windshield. The automatic response is to turn up the blowers to try and clearthe mist, but this only compounds the problem.

The solution is usually to remove and eitherrepair or replace the heater core. However, this isa particularly time-consuming task, which onolder vehicles is often not cost-effective. An alter-native solution is to treat the cooling system witha total coolant leak repair additive. These aredesigned to flow throughout the cooling system,including through the heater core, to make aquick and low-cost repair. Look for a ceramic-based, coolant-friendly product, ideally one thatconforms to ASTM D-3147.

This solution is courtesy of K-Seal www.kseal.com. IC

Import-Car.com 61

ImportTechTips]

58-61 Tech Tips 11/12/13 2:55 PM Page 61


[EssentialsFederal-Mogul Corporationand its Wagner Brake brandare shifting to environmen-tally friendly low-copperbrake pads. Federal-Mogulrecently introduced WagnerThermoQuiet Ceramicbrake pads featuring thefirst full-line offering of2021-compliant low-copperformulations. Now featured in ThermoQuiet Ceramicpads, the Wagner OE21 low-copper formulations are35% quieter and offer 15% more stopping power andup to 40% greater fade resistance than previous for-mulations. Visit www.WagnerBrake.com. ReaderService: Go to www.icRAPIDRESPONSE.com

This holiday season getthe DIYer in your life a gift youknow they will love. Head ondown to NAPA and get yourchoice of three tool sets foronly $19.99 each: GearWrenchfive-piece ratcheting wrenchset, Carlyle 19-in-one ratchet-ing driver bit set or EVER-CRAFT nine-piece Screwdriver

Set. At participating NAPA AUTO PARTS stores, whilesupplies last. Offer valid Nov. 17 through Dec. 31, 2013. Reader Service: Go to www.icRAPIDRESPONSE.com

When performing a clutch repair on select Subaru applications, including theBaja, Forester, Impreza, Legacy andOutback models, you may observe excessive damage sustained to thethrow-out bearing retainer. Schaeffleroffers two LuK RepSet clutch kits, 15-030 and 15-031, which resolve this situ-ation. Every LuK RepSet contains a newclutch, disc, release bearing, pilot bear-ing, spline and lubricant. These two kitscontain a release bearing and repairsleeve designed to slide over the throw-out bearing retainer, thereby protectingand lengthening the life of the clutchand drivetrain system. Reader Service:Go to www.icRAPIDRESPONSE.com

Ranger Products, a division of BendPak,recently unveiled its new QuickJackportable jack system that makes vehiclemaintenance — on the track and off —convenient and lightning fast. The3,500-lb. capacity, lightweight Quick-Jack can be easily stowed in the trunkor back seat of most cars. Bring it tothe track or drop it on your garagefloor to perform routine maintenance,all in seconds. The QuickJack collapsesto a low 3-in. profile so it fits whereother jacks don’t. Call 805-933-9970 orvisit www.quickjack.com. Reader Service: Go towww.icRAPIDRESPONSE.com

<<

<<

Brought to you by


<<

<<

Identifix has unveiled its newest feature in Direct Hit:vehicle search by VIN. Subscribers can now access information by simply typing at least 10 digits of a vehicle’s 17-digit VIN when creating a new vehiclewithin the online tool. There’s also an auto-suggestfeature that offers a list of applicable vehicles once atechnician enters model and year information. Direct-Hit allows techs to diagnose and repair vehicles withgreater speed, accuracy and confidence without leaving the vehicle. Reader Service: Go towww.icRAPIDRESPONSE.com

<<

62,65 Essentials 11/12/13 2:36 PM Page 62

WIX® Filters, a member of the Affinia Group family of brands, in conjunction with Brake & FrontEnd, ImportCar and Underhood Service magazines, named Bogi Lateiner of 180 DegreesAutomotive in Phoenix the third-annual Best Tech at the AWDA conference on Nov. 4 in Las Vegas.

“Bogi’s vision for the automotive service industry seeks toempower consumers through knowledge of automotive basics,”

said Mike Harvey, brand manager for WIX Filters. “Her approachto consumer education also includes outreach to women on

how they can pursue careers as auto mechanics. She represents the future of automotive technicians and is anexceptional choice for this year’s ‘Best Tech’ award.”

Lateiner, a 13-year veteran in the automotive service industry, is an ASE-certified technician. She teaches basiccar care classes for women and appears on a national TVshow called “All Girls Garage,” targeting female viewers.

“I started a repair shop in my driveway with little morethan a strong passion for educating my customers

and a commitment to the highest quality ofservice and repair,” Lateiner said. “I wanted

to create a shop where everyone couldfeel comfortable and where I could be a

part of elevating the reputation of theautomotive industry.”

Today, 180 Degrees Automotiveis an 8,000-square-foot, state-of-the-art facility with the look and feel ofa coffee shop and designed withthe customer in mind. Amenitiesinclude a children’s play area, artgallery, comfortable couches and

free Wi-Fi.WIX Filters and Babcox Media also

named two finalists for the Best Techaward – Jeff Florey of The Auto Shop in

Santa Cruz, CA, and Audra Fordin of GreatBear Auto Repair in Flushing, NY.

63 BestTech IC_Layout 1 11/12/13 1:31 PM Page 63

64 APJ Reach IC 11/12/13 1:30 PM Page 64

Import-Car.com 65

Centric Parts has intro-duced StopTech BigBrake Kits for the 2013Lexus GS350 sedan. Thekit uses floating direc-tional AeroRotors (front355 x 32 mm; rear 345x 28 mm), as well as bil-let aluminum mountingbrackets with stainless-steel studs, DOT-compli-ant stainless steel braid-ed Teflon brake lines,StopTech’s Street Performance brake pads, plus six-piston ST-60 calipers for front and four-piston ST-40 calipers for rear. Reader Service: Go to www.icRAPIDRESPONSE.com

Robert Bosch LLC is broadening its coverage ofgasoline fuel injectors for domestic, Asian and Euro-pean applications with 11 new gasoline direct injector (GDI) part numbers and 12new gasoline port fuel injector part num-bers. Bosch is now bringing its advancedOE technology to the aftermarket to ensure that technicians can replace afailed part with the same OE part.The expanded coverage includes Audi, VW, BMW, Infiniti, Mazda, Mercedes-Benz, Mini Cooper andPorsche. Reader Service: Go towww.icRAPIDRESPONSE.com

Arnott Inc. has released its 2014product catalog, which provides detailed information on more than260 air suspension replacement prod-ucts including new product offeringsfor BMW, Mercedes-Benz, Audi andmore. The 36-page catalog featuresArnott’s entire product line brokendown by application and providespart numbers correlated by year andmodel. A PDF download is availableat www.arnottindustries.com. Reader Service: Go towww.icRAPIDRESPONSE.com

Honeywell Friction Materials announces the arrival of Stop, itsnewest brake pad line. The Stopbrand offers a high-value brake padwith a competitive price. Stop brakepads are designed to meet OE specifications for fit, form and function. Honeywell includes all therecommended brake hardware in thebox for Stop to reduce installationtime, improve bay efficiency and restore OE performance. Reader Service: Go towww.icRAPIDRESPONSE.comRaybestos brand chassis parts – an Affinia brand – announces

that listings for 25 makes and 61 models covering the 2014model year have been added to the Raybestos chassis cata-log. Ball joints and control arms have been added for the fol-lowing 2013-’14 models: Honda Odyssey: P/N 502-1296, LeftUpper, P/N 502-1297, Right Upper; Acura RDX and 2013Honda CRV: P/N 505-1386, Lower; and Toyota 4Runner: P/N507-1725, Left Lower, P/N 507-1724, Right Lower, P/N 502-1267, Left Upper and P/N 502-1268, Right Upper. Reader Service: Go to www.icRAPIDRESPONSE.com

<<

<<

<<

Brought to you by Essentials]


<<

<<

62,65 Essentials 11/12/13 2:36 PM Page 65

It’s Fast, Easy and Accurate!Get FREE PRODUCT AND SERVICE INFO from the companies featured in this issue of ImportCar.

>> VISIT www.icRapidResponse.com and click on the company from which you want information.

>> OR, go to www.Import-Car.com and click on the ImportCar Rapid Response Logo.

Post your job for just $50 a month!Visit AutoProJobs.com to get started today!

Contact: Karen Kaim p) 330.670.1234 ext. 295 f ) 330.670.7153 [email protected]


Reader Service: Go to www.icRapidResponse.com

WANT DETAILS ON THE PRODUCTS & SERVICES YOU SEE IN

ADVICS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .45Airtex Corporation . . . . . . . . . . . . . . . . . . . . . . . . . . . .22, 23Auto Value/Bumper to Bumper . . . . . . . . . . . . . . . . . .Cover 4Autolite . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .36, 37BendPak . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Insert, 40BMW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11CARDONE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .39CARQUEST Auto Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . .17DENSO Products and Services America, Inc. . . . . . . . .15, 53Harbor Freight Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .55Idemitsu Lubricants America Corp. . . . . . . . . . . . . . . . . . .46Intermotor by SMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .35KYB Americas Corp. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .27Mercedes-Benz USA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5Moog Steering & Suspension . . . . . . . . . . . . . . . . . . . . . . .28

NAPA . . . . . . . . . . . . . . . . . . . . . . . .Cover Call Out, 7, 41, 51Nucap Industries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .50O’Reilly Auto Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .25Parts Plus . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .31Raybestos Chassis . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3, 54Schaeffler Group USA . . . . . . . . . . . . . . . . . . . . . . . . . . . .8, 9SmartChoice by Federal-Mogul . . . . . . . . . . . . . . . . . . . . .29Tenneco/Walker . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .42Toyota . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Cover 2, 1TYC/Genera Corp. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .19University Of The Aftermarket . . . . . . . . . . . . . . . . . . . . . .59Wagner Brakes/Federal-Mogul . . . . . . . . . . . . . . . . . . .48, 49Wix Filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .56, 57, 63WORLDPAC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Cover 3

Advertiser Page Advertiser Page

66 rapid response IC_Nov_Layout 1 11/12/13 2:36 PM Page 66

DI R E C T C L A S S I F I E D S

Import-Car.com 67

Call now to order or to receive a free 2012 catalog 1-800-434-5141www.autobodysuppl ies.com

Why switch to PDQ? PRICES. Low prices. High Quality. Always.1st time buyer? Order from this ad and receive these special prices.

67-71 Classifeds IC_Nov_75-79 UHS May classifieds 11/12/13 2:42 PM Page 67




Import-Car.com 69


ERIKSSON INDUSTRIES • 800-388-4418Old Saybrook, CT • FAX 860-395-0047 • www.zftranspart.com

Audi • BMW Jaguar • Porsche

Range Rover • VW

Filters Mechatronics

Kits Oils

Hard Parts Manuals

Torque Converters

Authorized Distributor

Transmissions/Parts




Import-Car.com


Import-Car.com 71


Track Talk

Ever think about 1 millionmiles of racing?

That equates to over tworound trips from the Earth tothe moon and 40 trips aroundthe Earth. In every NASCARrace, spark plugs and fuelinjectors fire about 3.6 mil-lion times in each racecar.One million miles of racing?That’s over 10 billion times.

When Dale Earnhardt Jr.crossed the start/finish line atCharlotte Motor Speedway tolead lap 34 in October’s Bankof America 500, he loggedthe one-millionth mile ofelectronic fuel injection (EFI)in NASCAR Sprint Cup Series(NSCS) competition sincethe transition from tradition-al carburetors to EFI in 2012.

It should come as no sur-prise that the milestone wasunder the radar, given that theswitch to EFI itself has beensmooth, almost seamless andvirtually invisible.

Reliability in race cars,just as in passenger cars, hasimproved considerably overthe last several decades. Butthe old adage remains true— racing is the ultimate testof a machine. If you want tofind out what’ll break, take acar to a racetrack and push itto the absolute limit for afew hundred miles. Then dothat every week for 36 weeks.

When Freescale enteredNSCS competition as thesole-source supplier of auto-motive semiconductors, therewas certainly enough concernto go around. Not just takingout carburetors, which havebeen used reliably fordecades, but installing anentirely new system whichincluded an engine computer,sensors, injectors and wiring.

But not once in a mil-lion miles has the brain ofthe EFI system, the electroniccontrol unit (ECU), failed,

from the electronics sup-plied by McLaren to thecomputing power suppliedby chip maker Freescale.

“The good news is, whenit’s a non-event, we tip our hatto it because that means thatit’s done its job,” NASCARVice President of Competitionand Racing DevelopmentRobin Pemberton said of thesuccessful transition to EFI. “Amillion racing miles is onething, but it’s probably almostequaled in test miles, and tomy knowledge, we haven’thad any failures.”

With its frequency andlength of races, NSCS racingarguably puts more stress onthe engine and the EFI sys-tem than any other competi-tive series.

“Our short races are 250miles, which is what otherseries run as their big races,”continued Pemberton. “Withthe full-bodied cars, with theminimal tires that we have,the brake heat and the(engine) heat that’s generated,we put everything to the test.”

As a NSCS driver puts aracecar through its paces, theECU records a wealth of data

that can be downloaded andanalyzed via the banks oflaptop computers teamshave in their garage stalls.

“I think the big benefithas really been for the teams,because they’ve been able topinpoint times when there’sbeen a failure (in the engine)and understand that,” saidSteve Nelson, director ofmarketing for Freescale. “Andit’s helped them when theygo back and look at data tobuild engines that are morereliable. They can identifyover-revs, missed shifts, alltypes of things.”

Interestingly, the com-puter chips Freescale sup-plies for the EFI systemsaren’t custom-made for thehigh-test level of racing.You’ll find the exact samething in your street car.

“The little chips we putinto those engine computersare the exact same ones we putinto passenger cars,” Nelsonexplained. “We don’t special-test them. They come right offthe shelf. To do a millionmiles with zero failures withnon-racing-specified parts is areally nice story for us.”

Follow NASCAR Performance on Twitter and Facebookwww.twitter.com/NASCARauto

www.facebook.com/NASCARPerformance

Electronic Fuel Injection MarksMillionth Milestone

Leading lap 34 in last month’s Bank of America 500 at CharlotteMotor Speedway, Dale Earnhardt Jr. logged the one-millionth mile ofEFI in NASCAR Sprint Cup Series competition. Photo Credit: Getty Images

A game-changer: EFI has provided NASCAR teams with a new wayto gather information to win races via an electronic control unitthat records a wealth of data. Photo Credit: Getty Images

72 NASCAR_IC_Nov_Layout 1 11/12/13 2:35 PM Page 72


C3 Worldpac IC 11/12/13 1:29 PM Page C3


C4 Alliance IC 11/12/13 1:29 PM Page C4

Documents

ImportCar, November 2013