Autotechnician May23

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MAY 2023 ISSUE INSIDE Advertising cover wrap: your regular issue of Autotechnician is inside
MAY 2023 P14 VW Golf case study tech vs owner mindset P31 reman on the rise ingenius, not inferior P36 on the move mobile servicing & repairs it's Time to come together! Automechanika Birmingham is Back 6-8 June & we prepare for our workshop takeover in cheltenham Joinusatthisyear's AutomechanikaEventattheNEC GarageManagementSoftwareforCommercialVehicleWorkshops

MAY 2023

P4 Industry news

P8 autotechnician’s Workshop Takeover

P10 ALLDATA garage review

P12 KTS Diagnostics made ESI

P14 VW Golf case study

P20 Closed loop air suspension explained

P22 Bearings update

P24 Gasoline Direct Injection issues

P26 Human Resources 101

P31 Remanufacturing

P36 Mobile servicing & repair

P42 Automechanika Birmingham preview

P64 Parts, Tools & Tips

P70 New Car: Volvo EX90

P74 Support from Ben


07904 521 923


07808 077 611





Julia Crawford, Gareth Davies

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Over the past few years, we have had to adjust to communicating, learning, and conducting business online but the bene ts of meeting face-to-face with peers, suppliers and colleagues cannot be underestimated, especially in a trade that never stands still. If you are looking to strike a deal on your next investment in tools or garage equipment, want to prepare your career or workshop for the future, or learn about the latest technology and products to help give you the edge on your competitors, you cannot beat getting together in person to discuss what best suits your needs.

Automechanika Birmingham, the UK’s biggest trade event, is back after a four-year break and will run from 6-8 June at the NEC, providing an expected 12,000 visitors with access to 500 exhibitors, £50k of show discounts, product launches, giveaways, and 192 hours of free skills training. Organisers promise that ‘You’ll test, see and learn more in a few hours than you can in months from your garage.’ We have no doubt that a visit to Automechanika Birmingham will reap rewards for garages. We provide an event preview from p42 which highlights some of the show features that will justify some time out of your workshop.

We are also counting down to our Workshop Takeover in Cheltenham on Saturday 24th June, where three groups of technicians will tackle live faults on petrol, diesel, and electric vehicles to enhance their diagnostic skills –see page 8 for details and grab a subsidised ticket while you still can. Enjoy the issue – myself and the team hope to see you, in-person, very soon.



* View and download previous digital issues at:

Subscription to the magazine is free to those who ful l the publisher’s criteria. UK independent workshops can subscribe at Nine issues will be published throughout 2023 and will be mailed out free of charge to qualifying readers - you must work in a UK independent workshop, have buying responsibility and reside in the UK. Those who do not meet the qualifying criteria can request to receive a link to the digital issue free of charge or can opt to pay £25 for an annual subscription to receive an issue in the post. All material, unless otherwise stated, is the copyright of Aftermarket Media Solutions Ltd and reproduction in whole or in part of any text, photograph or illustration, without prior written permission of the publishers, is prohibited. While all due care is taken to ensure the content of Autotechnician is accurate, the publishers cannot accept liability for omissions or errors. Any written material or pictures supplied by contributors are published in good faith and on the understanding they are free from any copyright or other restrictions.

Published by: Aftermarket Media Solutions Ltd, The Joiners Shop, Historic Dockyard Chatham, Kent ME4 4TZ





With just over one month to go until Automechanika Birmingham 2023, the UK’s largest automotive trade exhibition event has highlighted its brand-new training hubs and popular show features for visitors.

The aim of the hubs is to support business owners, technicians, and specialists by providing insights into trends, technical information, practical sessions and the latest advice and tips to futureproof businesses.

Show features include Workshop, EV and Bodyshop Training Hubs providing technical training and demonstrations, plus conferences for Aftermarket, Supply Chain and Talent and Skills,


The nalists have been announced in the Automechanika Birmingham 2023 Garage Awards, hosted by the IAAF. The awards acknowledge the dedication independent garages and technicians have made to ensuring a ordable mobility in the UK over the past few years.

The winners will be announced at an awards evening on Wednesday 7 June at Hilton Metropole NEC.

Finalists of the Garage of the Year, sponsored by LKQ

o ering the latest news and advice from the sector. New for 2023 is a Detailing Hub, Collision Repair Live and Paint & Spray Live, providing practical demonstrations, and Modern Garage and EV Parc, looking at all things electric vehicles and garages of the future.

Take a look at our show preview starting on page 42 to see why the event running at the NEC from June 6-8 is a fantastic opportunity for technicians and workshop owners to get practical advice from the best suppliers, trainers, and experts in the trade.

Euro Car Parts, are: Coles Automotive, West Sussex; Hillclimb Garage, High Wycombe; Jackson & Phillips

Automotive Services, Leighton Buzzard; Lindleys

Autocentres, Nottingham; Old elds Garage Services, Leominster; Plantexpand, Wickford and Uck eld Motor Services, Uck eld.

The full list of nalists can be found at https://iaaf.

4 industry INDUSTRY


Year-end gures from the Institute of the Motor Industry (IMI) show that over 14,800 dedicated technicians undertook the training and quali cations required to obtain IMI TechSafe professional recognition in 2022. This boosted the total number of quali ed technicians able to safely work on electric vehicles in the UK to 39,000 by the end of last year.

The IMI welcomes the e ort by employers and individuals to upskill for decarbonisation but is calling for an acceleration of training to avoid the potential shortfall of 16,000 quali ed technicians currently predicted by 2032. The IMI is highlighting that previous market expectations of electric vehicles requiring less time for servicing may be misplaced, increasing pressure on a workforce already dealing with an ageing UK car parc.

“Despite a long-held belief that EVs – with less moving parts –will be quicker to service than their ICE counterparts, in-depth analysis conducted by the IMI for our response to the MOT

Consultation suggests otherwise”, explained Steve Nash, CEO of the Institute of the Motor Industry. “In particular, tyre wear on electric vehicles is heavier than on ICE models; according to Garage Industry Trends analysis of 2021 MOT test data, EVs had a failure rate of 11.43% for 2018 registered vehicles compared to 10.45% for petrol vehicles and the weak point was identi ed as tyres.

“The assumption that more EVs can be serviced by a single technician compared to non-EVs therefore no longer rings true. Garages and workshops can’t simply assume they will need fewer technicians to service EVs. Add to this the fact that the UK car parc is ageing rapidly, increasing the need for maintenance, and adding to the already sizeable workload of technicians, and it is easy to see how the training and deployment of technicians quali ed to work on EVs needs to shift up a gear.”


For peace of mind always use a Garage Equipment Association member.

GEA accredited engineers work to an industry code of conduct. Your assurance their skills and knowledge have been independently assessed.

Ask your engineer for his accreditation card ! The Upholders of Industry standards since 1945 The Garage Equipment Association GEA ACCREDITED ENGINEER Name Company Discipline Exp Date ID Number XX123456 XX123456 XX123456 XX123456 XX123456


The 2023 Star Awards, encompassing both the Garage Star and Customer Service Star accolades, are now open for customer nominations on The Motor Ombudsman’s Awards portal (www.

The annual competition recognises individual team members and businesses accredited to one or more of its four Motor Industry Codes of Practice, that have gone the extra mile in the eyes of consumers. Since the Star Awards were launched, around 3,500 nominations have been submitted, highlighting examples of excellence and remarkable acts of kindness and generosity to help motorists in their time of need.

More than 7,000 Motor Ombudsman-accredited franchise dealerships, independent garages and body repair centres across the UK are eligible to be put forward by motorists for one of the eight Garage Star trophies representing di erent regions of the UK, spanning Jersey in the south, to the Shetland Islands in the north.

Entries can be submitted by consumers up until the 15th October 2023, during which time, businesses can promote the contest, and be recognised in return by their customers. From the nominations received over the coming months, a shortlist of three names will then be compiled by The Motor Ombudsman for each of the 11 awards available in the competition.

The nalists will then be passed to a panel of judges to collectively decide the respective trophy winners for this year’s Garage Star and Customer Service Star Awards and the


Denso’s annual League of True Mechanic (LOTM) competition puts technicians through their paces with IMI accredited, online technical training and assessment. Prizes up for grabs included a DENSO WEC sports prototype model, laptop bag, Toyota Gazoo Racing polo shirt, a team racing jacket, Sonos One speaker, wireless Bose headphones and a Sonos Playbase. The seven high achieving technicians receiving these rewards were Jason Sprake, Brian Hurst, Darren Douglas, Sam Buettner, Andrew Tweedle, Roan Troy, and James Cauvain. In third place and winning a £500 Red Letter Day was Mark Lamont of Grasmere Garage, pictured, second with a £1,000 holiday voucher was Philip Scott of Robsons Motor Services and taking the top spot and winning the £2,000 luxury holiday rst prize, as well as taking the accolade of 2022 LOTM champion, was Edd Hunt of The Car Consultants.

“Our congratulations go out, not just to Edd, Philip and Mark, but to all the prize winners and everyone that entered the LOTM competition in 2022,” said DENSO Europe, Pan European Strategic Marketing Manager, Fatiha Laauich. “We launched the 2023 competition in

National Garage Star Award, chosen by the panel from eight regional winners.

This year, the Motor Ombudsman has partnered with the Chartered Trading Standards Institute’s Hero Awards. The National Garage Star Award will be presented in-person to this year’s winner at a ceremony within the Houses of Parliament in London’s Westminster. The business or team member will receive £2,000 worth of vouchers and marketing exposure; including a video lmed at their premises to highlight their achievement.

April, so we urge both previous entrants and technicians who’ve so far yet to enter, to register this year and aim to knock Edd o the top spot and take the prestigious title.” Registering for the e-Learning platform is free via the following link and you can also sign up to the LOTM competition.

WHO DO YOU THRUST TO HAVE YOUR BRAKE PARTS REPAIRED? Your expert in the remanufacturing of electronic car components Let’s keep it cost effec�ve & reliable together WWW.ACTRONICS.CO.UK 01206 849920

Bring it on!

Are you ready for autotechnician’s workshop takeover? We are counting down the days until we get together with readers and trainers once more at Autotech Live – our rst o cial Workshop Takeover!

Trust us, you cannot a ord to miss this – here’s the deal…

What is it? A full day of diagnostic troubleshooting side-byside with a great bunch of technician trainers within Matt Cleevely’s impressive workshop

When? From 9.30 to 4.30 on Saturday 24th June

Where? Cleevely EV, Cheltenham GL51 8PS

What’s the format? Small groups of technician/workshop owners will rotate around three workshop bays, focussing on diesel, petrol and EV/hybrid faults. There are no presentations,

just hands-on faultnding with justin-time learning thrown in by each guide trainer as and when required

How much will it cost me? Tickets are just £99+VAT

What! Why is it so cheap? Thanks to ACtronics, Alldata, Bosch Aftermarket and JLM Lubricants who support the campaign, we are able to o er cost-price tickets to ensure that everyone who is committed to upping their game can a ord to do so.

Sign me up! A limited number of subsidised tickets to the one-day event are available at www. training

Andy Crook of GotBoost will guide a team through diesel faults

Andy will be challenging technicians to stick to the process while ensuring the business has the systems in place to bene t from diagnostics. If the business wants to be e ective and the technician wants to be e cient, you need systems and processes. Andy will challenge you to diagnose the fault(s) e ciently and deal with the customer e ectively. Are your systems and processes robust enough? Come and nd out….

Gareth Davies of Euro Performance will help you tackle petrol vehicle issues

"I’m delighted to be involved in another autotechnician event where we get to meet like-minded industry professionals. This year the format is heading back to its roots and I’m looking forward to setting a broken car task for technicians and business owners to get their teeth into. As a small group, we’ll look at the real-world faults that have been presented, with some added customer twists and turns for good measure, and use a variety of dealer and aftermarket tools in combination

with shared knowledge and decision-making on how to attack the faults, from fault to x. We’ll cover all the meat and potatoes of the technical task, with opportunities for questions and pitstops for learning and development throughout the task. Above all we’ll have some fun while learning about the serious business of troubleshooting faults within the workshop. I look forward to seeing you all there!"

Host Matt Cleevely and Eliot Smith of Pro-moto will lead a team of techs through EV faults Matt says delegates will learn how to gain con dence repairing and diagnosing High Voltage circuits. Get a good understanding of what is required from a HV ready workshop and be inspired by working on EV’s within the busiest EV specialist workshop in the country.

Eliot will be tackling charging faults, so you can con dently attain whether you’re facing a faulty charger, charge lead or vehicle system. Learn how to diagnose common, and not so common, EV faults and get ahead of your competition.

In association with: Media Partner:


Don't miss out

Tickets to this event are limited to ensure a hands-on, valuable learning experience. A number of subsidised tickets to the one-day event are currently available at www. Email Nicola@ if you have any booking queries.

ACtronics are pleased to be continuing its sponsorship with Autotech for 2023

“As the market leaders in remanufacturing electronic automotive components, not only do we o er a rst-class solution for garages, but we also support rst-class training and technical support for the automotive trade. It’s more important than ever for technicians to have access to world-class training and ACtronics are very happy to work alongside autotech to provide this. It’s important that we all work together to futureproof garages ready for the changes ahead.”

Technicians to be supported by ALLDATA’s OEM repair data during autotech

“ALLDATA Europe is delighted to announce its partnership with autotech, a workshop training initiative that complements the OEM repair data provider’s strategy of supplying managers and technicians with accurate and up-to-date repair information.

With 89,000 make, model, engine and year vehicle combinations available on ALLDATA Repair, converting to 95% of vehicles on the road today, autotech participants can capitalise on this abundance of data while xing faults in the Autotech Live workshop arena. Consequently, they can boost their rst-time x rate when returning to the real-world garage environment.”

Bosch Aftermarket UK & Ireland are delighted to sponsor Autotech Live 2023 – an event where technicians work together and solve live vehicle faults

“Autotech Live gives workshops the opportunity to highlight any skill or knowledge gaps and provides the right tools and training to support them. The event on June 24th gives technicians the chance to work on both ICE vehicles and EVs.

To support workshops, Bosch’s training centre delivers a full range of technical training courses for all levels and roles in modern workshops, accredited by the IMI.

Bosch is a well-known supplier of workshop solutions, o ering a range of diagnostic testers such as the KTS series, and ESI[tronic] 2.0 Online software with ADAS Calibration, Air Conditioning, Emissions Testers, and Vehicle Systems Analysers, all EV compatible.”

JLM Lubricants UK are proud sponsors of Autotech

“The range of high quality JLM diesel and petrol additives is perfectly suited to the professional technician, including those who will be attending the Workshop Takeover. Attendees will receive an exclusive JLM goody pack including comprehensive information on the JLM product range. More and more professional technicians are choosing JLM products for their workshop because they realise that JLM produces top quality additives for both diesel and petrol engines that deliver excellent results, every time.”

Find out more at

Take a free online assessment now!

The latest autotech test joins the evolving bank of free knowledge assessments on www.autotechnician. and looks at troubleshooting fundamentals and best methods to tackle the real-world fault assessments within your workshop.

This test has been created by VAG specialist, Gareth Davies, and presents the real data and investigation of faults on an Audi A3 within a multiple-choice format.

All you need to do is enter a few details at https:// click an automated email reply and you get instant, free access to the multiple choice tests focussing on various topics and scenarios, including: Energy requirements of similar vehicles; Case Study – P0303; The SCR system; Hybrid & EV; Common sensors used in spark ignition engine management systems; Oscilloscope Quiz; Testing electrical components; Electrical Test; LIN Bus; CAN-Bus; Diesel case study & Ignition case study!



ALLDATA UK pays Herefordshire-based Old elds Garage a visit after Tim Benson subscribed the workshop to ALLDATA Repair

Last November, ALLDATA Europe Marketing Manager, Julia Marra, struck a rapport with Old elds Garage Owner, Tim Benson, following a presentation of ALLDATA Repair at Mechanex Tim was persuaded to sign-up. Months later, Tim invited ALLDATA to his workshop to see how he and his colleagues have been getting on with ALLDATA Repair in the real world.

Old elds background

In 1991, Tim’s parents assumed control of a petrol station, with a built-in workshop at the rear. Tim’s dad was a mechanic, so his parents’ ambition was to forge a path to growing a successful workshop business – and so began the Old elds journey. Tim, though, took a di erent career path before returning to the family business a few years later.

He recalled: “Initially, I worked for a Volkswagen dealer, but I moved on to complete my national higher diploma and then a business management degree. I worked in IT, cosmetic surgery and two universities, then ended up back in the area. I was at a crossroads as to what I wanted to do, so I was slowly leveraged into the business.

“Unfortunately, we sustained a lot of damage from a re; however, that was the catalyst for some life-changing decisions. I decided to go all-in, and we moved to our current premises in 2011. My parents retired three years ago, so I now run the business exclusively.”

Tim is acutely aware of how vehicle technology and repair is becoming increasingly sophisticated. He is a business owner that wants to futureproof his business and be the best that Old elds can be – after-all, with a tight-knit community

of 12,000 people, word can spread fast and can make a huge di erence to businesses if it o ers a professional or unprofessional service.

Tim has invested signi cantly in Old elds’ facilities, infrastructure, training, tooling and equipment. He is an advocate of OE components too. That desire to improve the breadth of knowledge of Old elds sta and try to tackle every job that arrives in the workshop, not to mention the strive for OE quality, are just some of the reasons why Tim turned to ALLDATA Repair.

An annual subscription to ALLDATA Repair gives instant access to all repair data, as well as Technical Service Bulletins (TSBs), diagnostic trouble codes (DTCs) and electrical systems/wiring diagrams. The data is o ered with an intelligent search engine (o ering text string matching technology) to enable the technician to nd the data they need in seconds.

The portal o ers 91,950 make, model, engine, year (MMEY) vehicle combinations, which equates to 95% of vehicles on the road today. In the last 12 months alone, 301 models have been published. ALLDATA Repair possesses a library of six million technical drawings and wiring diagrams, including electrical connector views.

The connection between Tim, Old elds and ALLDATA Repair arose following an encounter at MECHANEX in 2022. Tim and ALLDATA Europe Marketing Manager, Julia Marra, met during the aftermath of a talk Tim was giving – about data!

Tim continued: “Julia approached me and asked if I’d heard of ALLDATA before, which I had, but the perception was that it was complicated to use; however, after explaining the product in more detail, Julia persuaded me to try it and see if my perception was wrong!

10 AUTOTECH 2023
ALLDATA’s Eric Ware and Annette Chamberlain with Old elds Garage Owner Tim Benson

“Obviously, using the original and unedited data from OEMs makes life a little challenging in that the manufacturers present and supply data di erently; however, that’s perfectly understandable. Vitally, it guarantees that the data supplied by ALLDATA, such as wiring diagrams or TSBs, hasn’t been reformatted or changed. We can have total con dence in what we’re being told.”

ALLDATA UK does o er training to subscribers, to help with setup, familiarisation of the software and suggest ‘tricks and tips’. And, indeed, Old elds has signed-up to receive training from ALLDATA Regional Sales Manager, Eric Ware. Tim described the added option of training as “bene cial and adds value” to ALLDATA Repair.

Tim added that ALLDATA Repair has also been useful on more complex jobs, which has allowed Old elds to go “further along with the process of the job”, thanks to “a test procedure, which is accurate, or a known problem on a particular vehicle that we wouldn’t have spotted previously”.

Perfect for diagnostic work

Tim has the philosophy of “there’s no such thing as too much data” and explained why ALLDATA Repair is a must for certain workshops. He said: “If a workshop is participating in any diagnostic work, I think it’d be foolish to not incorporate ALLDATA Repair into its overall package. Technical information, like testing procedures, TSBs and wiring diagrams, is easy to obtain.”

Focusing speci cally on TSBs, Tim pointed out that because ALLDATA Repair’s TSBs have come direct from OEMs, it means they can be relied upon – don’t need to be checked in fear of steps missing or incorrect.

Practical example

Tim illustrated how ALLDATA Repair works in the real-world. What should’ve been a straightforward task turned into a job for ALLDATA Repair’s data.

Tim picked up the story: “We had a fuel lter on a Volvo, a type that we’d never seen before. The tting was di erent to ones seen previously. It’s a job that we should be able to complete easily, but there was a particular clip that was unusual – it worked in a strange way: one pushes a bit up, then a bit down to unlock it. Logically, when one of our guys looked it, he pulled it but couldn’t undo the clip. Obviously, with the lter clip being made of plastic, there was the risk of it breaking when trying to force the issue.

“We logged onto ALLDATA Repair and found the exact procedure for replacing the fuel lter. It showed the type of clip and how it opened. Using ALLDATA Repair meant we were able to complete a 30-second job; whereas, before we invested in ALLDATA Repair, we probably would’ve broken the clip and ended up having to buy a fuel line. It’d be our fault and we’d have to explain that to the customer, which would likely be a tough conversation.”

He concluded: “The TSB element cuts down diagnostic time and testing time, and it sends users down a path which is the right one. It’s a useful partner. What’s more, certain repair procedures have also saved us and our customers time.”

Thank you to Tim Benson and the sta at Old elds for their hospitality and support.

Find out more

To learn more and discover how ALLDATA Repair works in practice, check out The website also o ers valuable information and the chance to request a free trial.

ALLDATA will be available for a chat during breaks at autotech’s workshop takeover in Cheltenham on 24 June. Tickets are available at

They will also be presenting at the Workshop Hub at Automechanika Birmingham, nd out more on page 47

11 AUTOTECH 2023
“For diagnostic work, I think workshops would be foolish to not incorporate Alldata Repair into their overall package”

KTS Diagnostics made ESI


Welcome to the second in a series of guides from Bosch to help your workshop make the most of its ESI[tronic] 2.0 software, designed to boost your know-how of the key features to maximise pro ts and enhance e ciency. This series of technical articles will break individual topics down and build all the way up from the basics to advanced expert tips.


In our last article, we covered how users of the software can easily and e ciently select the correct vehicle, and the importance of retrieving reliable information on the vehicle being worked on.

In this short guide, we’ll dive into the detail of how the System Overview feature can help you identify potential issues to arrive at the right diagnosis, faster than ever before. As well as how our Protocol Reports option can help you document the remediation action taken by your technician team in a professional report.


The ‘System Overview’ feature on the ESI[tronic] 2.0 works as the users ‘complete vehicle diagnostic check’, allowing you to carry out the necessary tasks e ciently for every vehicle that comes through your workshop doors for a service or repair. It helps to quickly and easily identify intermittent issues, pending technical problems and mechanical di culties that the driver or customer may not be aware of.

This feature will also run a systematic check on the vehicle, ensuring it has a clean bill of health for when it is handed back to the owner after a repair or service. Allowing you to know that you are delivering the best service possible to your customers, see Figure 1



Open the Diagnosis main tab.


Click on the ‘System search’ F12 soft key in the System Overview sub tab.


The KTS will then perform a full ‘Control unit search’ of all communicating systems.


Double click any of the system names in the categories for direct access to the ECU diagnostic functions for further information and testing. If a fault code is erased here, it will refresh when a user returns to it – enabling you to save and show the before and after status to show the vehicle owner.


Store the complete list in the job report with the F3 save button. You can also access a speci c list of Diagnostic Trouble Codes (DTC’s) and any available descriptions via the F5 fault details button. Again, this can be saved to the job protocol with a tap of the F3 save soft key.

Figure 1

When the system overview is complete, you will see a list of all ECU systems that are communicating and an indication if any fault codes are present. This is particularly bene cial when users are analysing a vehicle prior to any in-depth diagnostic testing as some faults, for example ESP problems, can log a DTC in more than one ECU.

Once you have retrieved the overview list, if necessary, any of the system names in the categories can be double-clicked. This will take the user straight to the ECU diagnostic functions for additional investigation and testing. From here, if the fault code no longer shows up, the overview list will refresh itself once you return to it.

Alternatively, you can also select the ‘Delete All Faults’ button to delete all DTC’s across multiple systems or ECU’s – in a single click. It’s worth noting that many newer vehicles will now support a fast CAN Bus search of all of the ECU’s on the vehicle system communication network. In some instances, a vehicle brand can have up to 60 ECU’S that can all be checked in under a minute, speeding up the technician’s task of assessing the diagnostic state of the vehicle. Yet, for other vehicle brands, this process may take a little longer, due to the KTS checking each ECU individually for presence and fault status of each group. The new generation of KTS (560/590) can communicate simultaneously over two communication channels in parallel to signi cantly speed up the time required for a complete vehicle scan.

to save or erase whichever information you choose to, which can be bene cial when you are justifying a lengthy repair process or operation time, see Figure 3


The System Overview function enables you to quickly and easily produce a professional and accurate vehicle report. The perfect tool to help you justify any repairs that you need to carry out on the vehicle to the owner, see Figure 2


Document the end-to-end process followed by your technicians during any diagnostic fault- nding work and share the before and after progress with your customers.


Choose to include a variety of di erent information in your reports – from ECU system names and identi cation details to the number of trouble codes stores and their descriptions.


The amount of information included in your protocol can be stored under ‘User settings’ in the main menu. This allows you

You can also choose to include your garage details that will appear in the report, alongside the option to include the job number, customer’s details, and any advisory comments to be communicated to the customer.

Importantly, the protocol le can be saved in a PDF format, which is useful for technicians to print and attach to an invoice, highlighting to customers what problems were found and repaired.

Each time a technician selects a di erent vehicle with the software and some information is saved, a new protocol report will be created.

A key new feature of the ESI[tronic] 2.0 is that you can continually save data to a previous protocol within the ‘last 30 vehicles’ list if you return to an un nished job, see Figure 4

In the next issue, discover how the Bosch ESI[tronic] software streamlines your everyday service tasks in the workshop.

Figure 2 Figure 3 Figure 4

Overview of the fuel system

Case study:

016 VW Golf R TSI 45,000 miles

Long Crank no DTC’s

Last year, we were presented with a 2016 VW Golf R TSI, and its issues were well documented by the customer in a ‘love letter’ as we call them in the workshop. It explained the symptoms, a large list of work conducted to date in a previous workshop and what they believed was responsible for the issues starting on a fairly low mileage, well-loved car.

Initially this was not my task to examine; there’s six of us on the workshop oor. Initially it was perceived the issue resided with the High-pressure fuel pump (HPFP) and was duly repaired with a new genuine item, tested under failing condition, and collected by the customer. My assistance was required for a di cult phone call from a disappointed customer two days later who reported that almost the same symptoms were back,

vs business owner mindset Testing led to concern with this section of fuel system
Legend G6 Fuel system pressurisation pump G247 Fuel pressure sender G410 Fuel pressure for low-pressure J538 Fuel pump control unit N276 Fuel pressure regulating valve N30-N33 Injectors, cylinders 1-4 N532-N535 Injectors 2, cylinders 1-4 AFuel lter BFuel tank CHigh-pressure fuel pump DFuel low-pressure rail EFuel high-pressure rail High-pressure system Fuel system / low pressure system Actuator / output signal Sensor / input signal
Location of clamp test

and that they weren’t best pleased given the amount of cash invested both with my garage and a previous garage, to be at the same point.

I listened to the customer issues and took the time to discuss how we could reach a mutually amicable position. We agreed to have the vehicle back in and carry out tests to try to understand how the symptoms were the same and provide an answer on what should be done to repair the issue. The customer was very sensible and relaxed about timescales, simply focused on the outcome of accurate diagnosis and recti cation of the issue. Furthermore, I had agreed I would spend as much time as needed, at my expense, to get to the route of the issue in testing charges. No pressure then!

I am sure we’ve all been in this position, xing a clear and present issue and being pleased the car is xed, only to nd, as Andy Crook describes, as peeling another layer from the onion. The heartache experienced by the customer of more problems and more expense magically then becomes your problem because the bit you xed was not it, or all of it. However it is dressed up, this phenomenon of the pressure being dialled up is a mental challenge that makes clear thinking and problem solving that much harder. Thankfully, unlike many customers who need their car back yesterday (I get it, it’s hard without wheels) this customer was magic and said they wouldn’t bother us, they’d hear from us when they hear from us – more of these please!

First port of call was to get the car into the workshop on the Friday afternoon in preparation for Monday morning. I wanted it to be in the workshop, in a position to connect any relevant tools and testing gear at the point at where the symptom occurs. What we were troubleshooting was a long crank, usually rst thing in the morning or when left for extended periods of rest. So, my point of testing to catch the fault is

extremely limited and I needed to make any of the tests I did count before having to do something else, for a few hours at least. The tech in question was also on annual leave for a week too, so the job narrative from its previous visit was all I had to go on.

Over the weekend, I read up on what the previous garage had done in terms of repairs and part changes and exactly what had been carried out in our workshop prior to my involvement. According to the customer, the vehicle had been lled up with ‘bad’ fuel that he had acquired ‘on the cheap’. It had caused a mis re and poor running with EPC and engine management light on which took him to his normal garage. They conducted tests and had replaced the spark plugs, ignition coils and four fuel injectors. The bad fuel was drained o , fresh fuel added, and an oil service conducted. The car appeared to work well for a week until the engine management light returned – it went back to said garage for further tests and was booked in with us around this point.

The vehicle was producing a DTC and engine management light but no mis ring at the point at which we rst saw the vehicle. The DTC being generated was P0087 – fuel pressure too low. It would take some time to return from clearing and pressure testing, including data logs, didn’t yield a huge number of clues to the problem area. The only anomaly found was with high fuel pressure being below the 50-bar required at idle, the scan tool reported a uctuating 43-46 bar. The technician removed the HPFP and found the spring and piston not to be quite square. This HPFP is driven o the camshaft on the engine, his theory being this could be a ecting that pressure reading. Before replacement, he straightened and lubricated the piston and re tted it. Coincidently, the pressure now resided at 50bar during idle testing and the actual and desired values when road testing under load showed almost identical in the logs. On this basis, and the bad fuel trauma, it was recommended to be replaced with a new genuine item. Not that it should matter as we try not to change parts because of whether they are common or not, but these pumps are fairly common on our brand base, noting that normal failure does display as a di erent failing symptom but similar DTC’s.

The repairs were actioned, and the same testing conducted after an overnight rest revealed no long crank and perfect performance, all appeared well.

Figure 2. Clamp attached to low pressure fuel feed to SRE plenum mounted injectors Figure 1. Testing and evaluation of the low-pressure pre supply fuel pump with an inline gauge

Monday came, as it always does, and I had to begin my testing. Prior to leaving the car I had left the driver’s door open but with the catch rolled as a lot of modern cars give a pre-squirt from the low-pressure fuel pump when the car is unlocked or driver’s door is opened. I didn’t want this to skew any tests I was about to carry out or diminish the chance of catching and experiencing the symptom for myself. Symptom experienced with scan tool live data showed that there was virtually nothing to go on. A very small dip in pre supply pressure but the window of opportunity to catch the issue was so small before starting and running without issue was minimal, a few seconds or so.

Contemplating what test(s) could be carried out to try and expose or promote the failure was tricky. I found myself standing at the front of the car looking at the engine bay for inspiration. I decided to think about what could be causing the symptom, without a running or performance issue. The fuel delivery unit or low-pressure fuel pump has an integrated lter that is part of the pump assembly. I elected to remove the LPFP for inspection. At the bottom of the pump is a strainer and it was badly blocked. I couldn’t be sure this was from the bad fuel or just normal build up, either way I cleaned it, repressurised the system and opted to try it the next morning. Before trying it I also had my scope set up to evaluate the pump itself during pressure build up and normal operation. All of this checked out and the two tests carried out were checking the command from the controller (pulse width modulated) and the 3-phase pump. All was good, but sure enough, it faulted the next morning.

The next step was to evaluate the low-pressure fuel pump pressure build up and decay. I used an inline pressure gauge adapted to measure the pressure from the pump up to the engine bay, see Figure 1, previous page . What I noticed before attempting to crank it the next morning was that although ‘leak free’ I had no residual pressure on my gauge. I was not sure whether this was correct, but truthfully, I had expected to see some remaining pressure here. Sure enough, the gauge rose quickly to approx. 5 bar when the ignition was turned on and upon cranking, the car faulted again. Getting thin on ideas for this mysterious phenomenon I found myself staring at the engine compartment once again. I had failed to notice this later variant of the EA888 engine has two sets of injectors.

I pulled up one of the very useful VAG self-study programs (SSP’s) and read up on how this type of dual injector system works. I remember dual injection systems from back in the day when you were looking to extract big power from Ford Sierra Cosworth’s and the old Turbo Technics converted MK2 VW Golfs but hadn’t personally seen them to this point on this engine. If I had, I clearly wasn’t paying enough attention! With this in mind, I updated the customer with the relevant test ndings. I also queried which injectors were replaced. The group of injectors that had been replaced for mis res were the High-pressure injectors mounted in the cylinder head.

With pressure decay being at the forefront of my mind, given pressure generation had been proven on low- and highpressure fronts, I elected for a very crude test before going home for the day. I used a set of clamps on the low-pressure feed hose to rail supplying the plenum-based injectors, see Figure 2. All my other test equipment, including low pressure

gauge was still in situ and I was keen to see the pressure reading on the gauge on my return the next morning. To my surprise it was still registering around half of the pressure (around 3 bar) on the gauge. Hmm I have a change here. With eyes tightly closed and techs for an audience I cranked the engine. To my amazement it started straight away, no long crank and no running problems. With these so called SRE injectors the last stop on this line I opted to set up a Columbo Test, of sorts.

I removed the clamp and ran the engine for a time. I then removed all xings securing the rail and injectors so I could remove them quickly and easily on my return in the morning. What I was able to prove is that the SRE injectors were working but leaking/decaying due to being faulty. Figure 3 shows wet injectors before the vehicle was even cranked, just ignition on and pre supply pressure built. With them removed, I was also able to see dampness on the piston crowns, which shouldn’t be there after a full 14 or so hours’ rest from combustion. The failure in this instance was only responsible for one perceived complaint and not other running issues and proved very tricky to accurately pin down. Having read the full SSP for this fuel injection system it's explainable and understandable how this fault could be overlooked and not revealed with average symptom-based testing.

I submitted my ndings to the customer, and a repair was actioned. Follow up testing the next day revealed the symptom was cured and the test equipment still connected showed that full decay in the low-pressure system is not normal and some should be retained.

I was pleased to get to the bottom of the issue, but xing this particular fault raised questions as a technician and business owner. Did the original fault get xed with the HPFP and that’s why there was no return of P0087 DTC? Should I have discounted our diagnostic testing when the vehicle returned, was I obligated to or was I taking ownership for the customers car problems? It’s a di cult quandary and the mindsets of technician vs business owner play o against one another in situations like this.

Figure 3. Injector face found to be wet after ignition on and fuel pressure priming system

Closed loop systems – A deeper look

Fun fact – not all automotive air suspension systems use the same working principle! Therefore, it is important for a professional workshop to know what system they are working on: a conventional open system or a so-called ‘closed loop’ air suspension system. The technical know-how for properly diagnosing possible system errors or defects, ensuring the correct working procedure is followed, correctly installing new air suspension components, and checking the system and making it operational again after an air spring leak is di erent from the conventional open air suspension system. In this article, Arnott will provide more insight into the alternative closed loop system.

In ation and de ation processes

Now that we know that speci c technical knowledge and understanding is required, let’s take a look at the general di erences between the two systems’ working principles before diving deeper into the subject.

compressing atmospheric air. When the system has a leak, it will try to retain its required operating pressure by opening the (ambient) air intake. However, it can only compensate for a small loss of nitrogen and when the compressed nitrogen mass gets too low the system will stop functioning.

Looking at the graph above, it shows the workings of the compressor are quite di erent in a closed loop system. In an open system the compressor compresses ambient air to ll the reservoir and/or air bellows, a closed loop compressor uses the pressurized nitrogen that is already existing in the system. Additionally, in a traditional air suspension system excessive air is released into the open but for a closed loop system the nitrogen stays inside the system and excessive pressure is led back to the reservoir. This is an important aspect to keep in mind when working on this system.

For in ation/additional pressure, the closed loop system uses two reversing valves that will open towards the valve block. The solenoid valve for the appropriate air spring opens and the additional pressure is transferred. When de ating, the excessive pressure is not discarded but cleverly routed back to the reservoir by opening the two reversing valves in the other direction. The excessive pressure is now transferred back into the reservoir. The pressure ow diagram below gives an indication of how the pressurized nitrogen is routed when an air spring is in ated or de ated.

The twist

Although it is called a ‘closed loop’ system and the diagram above shows how the compressed nitrogen is transferred from one area to another to in ate/de ate the system, don’t be fooled! A closed loop system does have the capability to make up for small amounts of nitrogen loss by drawing in and


Just like a conventional air suspension system, the system pressure will gradually drop when there is a big air leak present. Therefore, a symptom of an under-charged system is lack of operation. However, in a closed loop system, the ECU (Electronic Control Unit) continuously calculates the ‘nitrogen mass’ as an indication of normal operation. If too low, error messages like ‘max payload exceeded’ might appear on the dashboard (depending on the car manufacturer).

An indicator of an overcharged system is audible discharging of excess pressure. This only occurs when a mechanic has not followed the correct procedure when recharging the system after a leak repair. It goes without saying that an overcharged system can lead to damaged and defective components, alongside serious safety consequences.

This information is provided to you by Arnott – Suspension Products. With more than 30 years of experience in engineering, designing, and manufacturing high quality air suspension components for the aftermarket, Arnott is the technical expert when it comes to air suspension systems. Arnott’s products are produced with high-quality, OE components o ering exact form, t and function. Each product is extensively tested in our American and European facilities and custom-tuned to suit the speci c vehicle make and model before being produced.


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New bearing designs enhance e-mobility

Schae er strengthens chassis system business and details its latest bearings for electric mobility

Innovative bearing solutions can play a key role in sustainable electri ed mobility by making powertrains and chassis systems more energy e cient. Every watt of energy that can be saved in an electric vehicle translates into increased range. Vehicle producers are therefore looking closely at every single bearing application as they seek to optimise friction performance and enhance usability for the customer.

As a global automotive and industrial player, Schae er understands the major potential impact of innovative new technology and has recently announced a new wheel bearing designed speci cally for electric vehicles, featuring three rows of ball bearings.

“Schae er is looking to t its e cient and high-precision bearing solutions in chassis systems and electri ed powertrains to further enhance these systems and make them more sustainable” said Matthias Zink, CEO Automotive Technologies at Schae er AG.

“E-mobility represents a major opportunity for our bearings business,” said Dr Dieter Eireiner, the head of Schae er’s Bearing business division. “We are expecting strong growth over the next few years, with major sales potential particularly for ball, cylindrical roller and tapered roller bearings, and we are already involved in a number of promising development projects with big-name vehicle manufacturers. Innovative bearing technologies are also very important for LCVs and HGVs, because they can signi cantly increase vehicle range. Working with our customers, we intend to take bearings to a whole new level.”

TriFinity: Three rows of bearings for maximum adaptability

Schae er’s TriFinity product is a triple-row wheel bearing designed for use in electri ed powertrains that is no larger than standard two-row ball bearings but is able to transfer greater axle loads whilst also o ering signi cantly longer service life and improved rigidity.

The advanced ball bearing design provides an alternative to preloaded tapered roller bearing units. Switching from tapered rollers to balls leads to signi cant improvements in frictional torque and rigidity, which results in a 0.7 percent reduction in electricity consumption per vehicle in FTP75 test cycles.

Combining a TriFinity bearing with Schae er’s face spline technology allows downsizing solutions in the form of hub units with smaller diameters, which reduces bearing and seal

friction and optimises weight, resulting in a smaller carbon footprint. Clearance-free face spline technology can also transmit up to 50% more drive torque, reduces noise levels and is easier to install.

High-performance bearing applications for drivetrains

Schae er has also developed a new high-e ciency ball bearing with integrated centrifugal disc for electro-mobility applications. It is a high-performance, friction-optimised and sustainable product that combines the bene ts of both openbearing and sealed-bearing designs.

It is a smart yet simple solution that has a major impact on overall performance, producing 0.3 Nm less friction and reducing CO2 emissions by around 0.3 gms/km. Reducing losses of up to 30 watts per bearing can also improve the range of an electric vehicle by up to one percent. This advanced new product also increases on the service life of a traditional open bearing tenfold, o ering a signi cant cost reduction. Schae er received the Magna Supplier Award and the German Innovation Award in 2022 for this innovative new technology.


Bearing with Centrifugal Disc
Tri nity


Schae ler is a trusted technical partner of the automotive industry, delivering high-tech components and systems for OE tment by vehicle manufacturers around the world. We have used this OE know-how and engineering excellence to create our FAG steering and suspension range, which o ers a genuine quality alternative to independent workshops. It is also the perfect accompaniment to our leading range of FAG hub repair solutions, which o ers garages genuine OE quality at a competitive price. And, as always from Schae ler, everything a technician needs to carry out a professional wheel bearing repair or hub unit replacement is in just one box, so you can simply t and forget.

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Gasoline Direct Injection issues –what,

or who, is to blame?

Vehicle owners, workshops and vehicle manufacturers are seeing issues with Gasoline Direct Injected engines that cannot be put down to one fault. What’s behind the problems and what are the consequences? More importantly, what’s the solution? GDI specialist Phil Ellisdon of ASNU delivers his ndings within a three-part series of articles

Phil Ellisdon, CEO of ASNU, has been in this eld for nearly 50 years. Back in 1989, he became the ASNU distributor for Europe, gained Lucas and Bosch homologation, and eventually bought the ASNU business in 2000, shipping the manufacturing from Australia to Bushey in the UK.

The family business services thousands of ASNUs in over 60 countries worldwide through their distributor network and the equipment can be found in most vehicle manufacturer technical centres. In this article, Phil shares details of the symptoms, causes, consequences, and solutions on GDI issues that you need to be aware of...

Let’s start at the beginning. The concept of Gasoline Direct Injection, or GDI, is not new – the rst direct injection engine to use gasoline (amongst other fuels) to reach production was the 1925-1947 Hesselman engine, built in Sweden for truck and bus applications. As a hybrid between an Otto cycle

and a Diesel cycle engine, it could be run on a variety of fuels including gasoline and fuel oils.

So, if the design is perfect, the performance is fantastic and the reliability is outstanding, why are we seeing issues with GDI vehicles that cannot be allocated to anyone or any one thing? For those of you reading this and saying, “We don’t see problems with GDI”, you will understand more later in this article.

The GDI vehicle in use

The perfect driving conditions for a GDI engine are as follows: Using top grade fuel (as advised in the vehicle manual from the manufacturer) you start the engine and head out to the


motorway without tra c and without stopping. Drive 20 miles or whatever number of miles at the national speed limit up the motorway to your destination. Come o and drive without stopping, park up for the duration, then complete the same journey home.

The same scenario can be applied to the Diesel engine as well. If there were such a perfect condition, this would be it.

The reality is you start the engine and head out in the work/ school tra c to the M25 motorway in a Stop/Start enabled vehicle, so the engine automatically shuts o when stuck in the tra c and then starts and stops again 10 yards down the road when the tra c grinds to a halt again. This stop/start behaviour continues for the duration of the journey in the tra c. Then you hit the motorway and as its morning/evening the tra c is heavy and the stop/start process begins again. So, what is the problem we are seeing with GDI?

The answer is carbon build-up in the combustion chamber.

What causes carbon build-up?

It’s not any one entity, so let’s take a look at the contributing factors.

1. Fuel quality

The vehicle manufacturers stipulate that to maintain maximum engine e ciency with the minimum exhaust pollution a GDI engine must use the top-grade fuel. Now where fuel has an Ethanol content, the quality of fuel will vary from country to country, some owners prefer to use cheaper fuels as they have a cheaper car.

2. Driving conditions

The roads today are seeing more congestion than ever before, even clear roads have lower speed limits, and with engines encased in a much smaller location with smaller air ow access, the modern engine runs extremely hot, this heat quickly dries any residual fuel on the injector tip, it also dries any residual fuel in the combustion chamber creating the start of a carbon build-up.

3. Emission control

Emission control is the single one factor that EVERY vehicle manufacturer must comply with and although the GDI engine is by far the most emission-e cient produced, does produce more particulates than a Port Injected Engine. To ensure their vehicles produce a minimum carbon footprint, the VM’s Engine Management System, EMS, uses an automatic engine Stop/ Start system that switches o the engine when in tra c.

4. Fuel trim adjustment

In addition, the EMS also has Short- and Long-Term Fuel Trims that can add or reduce the amount of fuel the engine requires, controlled by various combustion performance sensors located on the engine. Unfortunately, this system has a aw – it cannot see the injectors’ spray pattern and therefore cannot determine if the spray is good or bad, which could result in bad combustion, leaving residual fuel in the combustion chamber.

Are you now understanding where I am coming from?

5. Injector performance

The GDI Injector is the single most important component in the delivery and control of the fuel that is delivered directly into the combustion chamber; one of the harshest environments on the engine. It has the nest tolerance of any mechanical part on the vehicle, it has a 30-micron lter in the fuel inlet neck and it is required to deliver a very speci c amount of fuel in a very speci c spray format and droplet size in milli second durations. All this precision in one component and yet nowhere in the lifetime of the vehicle is the injector lter recommended to be replaced or the injector tested or serviced. We change the air lter, oil lters and fuel lters, but not injector lters, why not?

Individually, these contributing factors may cause issues in the long-term running of the vehicle, but only the petrol will cause the carbon build-up. An e cient engine driven in perfect conditions will prove to be trouble-free but collectively these contributing factors can cause short- and long-term problems that will require a diagnosis and x but, in some cases, damage the engine beyond economical repair.

Keep an eye out for Part Two in the June issue of Autotechnician where ASNU will be looking at the consequences.

For more information go to or email


Human Resources 101 for workshops

Within a series of articles, Human Resources expert Julia Crawford from People Pillar provides practical advice on all things people related – here, she focusses her attention on recruitment

Do you know how to attract the right people to your vacancies? Deciding to hire someone for the rst time is a big decision and you’ve probably been thinking about the bene ts, disadvantages, and costs for a while.

Can the business a ord to pay someone else? Will their value pay for their costs? Can I do all the work myself? Will I be stuck if I don’t hire someone? With a little forward planning, you can handle the whole recruitment process relatively easily, keeping your recruitment costs down, whilst showing your business o to its full potential. Here are my seven steps to e ective lowcost recruitment.

Step one: Identify your needs

Is it a new position? Are you replacing someone who is leaving? Or perhaps your business is growing so you are looking for additional help. Creating a list of skills, knowledge,

and experience that you want or need for your recruit to have is essential. For example, are there any skill gaps within the business that your new hire might be able to ll? Have you considered whether the workload is su cient to justify a new full-time member of sta ? Is there anyone in the business who will be looking to retire or leave the business soon?

Step two: Create a job description

It’s essential to have a job description for every role in your business. This way, when it comes to replacing a member of the team, or even creating new positions, you already know the responsibilities, quali cations, and skills needed for all. Why not ask your current employees to write their own job descriptions? This doesn’t have to be anything fancy. It could be a bulletpointed list of their responsibilities. This helps to make sure that no vital tasks are missed.

Each advertised job description should include the job title, responsibilities of the role, needed quali cations, skills, compensation, bene ts, and the location of the role. You could also consider writing a candidate pro le for each role within the business. These are designed to help you discover what kind of person you’re looking for to ll each role. It could also help you to know where to look for your next employee, as it will give you an insight into where they may look for a job, and therefore where you should consider advertising your role.


Step three: Plan your recruitment

How are you going to attract the best candidates? Is there someone within your business who could t the new role? Is there someone who is ready for the next step in their career? Do you have an apprentice who is nearing the end of their training, who would be looking for their rst quali ed role?

When it comes to advertising the job, how and where are you going to advertise it? Do your current employees know anyone who is looking for a similar role? Referrals are a great way of nding excellent candidates. You will need to decide who will be responsible for creating the job advert and eld responses, or any questions, you may receive. Will this be you? To keep everything consistent it would make sense to make this just one person.

Make sure the language you use isn’t discriminatory. For example, words like young, dynamic or mature could potentially be age discriminatory. Also, there is no reason to stipulate someone must hold a driving license if they are not going to be expected to drive for the job.

Step four: Screen and shortlist

You’ve received applications from people who want to work for you. Now it is time to lter out the good from the not-so-good.

1. Put aside any that don’t meet your essential criteria. That’s most likely to be skills and experience. Look at where they are geographically based too. If they need to be local, and aren’t, it may be that they are looking to relocate to your area.

2. Sort the remaining applications into two groups, those with the minimum quali cations, and those with preferred credentials. Those with ticks in both boxes become your short list.

Step ve: Interviews

Your candidates will want to impress you, but don’t forget that you also need impress them. Take the time to consider the candidate’s experience, if you want to attract and retain the best person for your business.

What will your process be? Will you chat on the phone rst, then in person? Will you be asking candidates to do a practical exercise? If you do, you need to also allow for nerves, as not everyone is at their best when under these conditions. How are you going to structure your interview process and document it?

Try to be as exible as you can with your candidates. They may be in roles that are tricky to take time away from, so insisting on a particular appointment, you may miss out on that outstanding candidate, because they cannot do the day or time you suggest.

Step six: Making an o er

Before you make an o er to your preferred applicant, there are a few things you need to consider:

a) Never turn down other candidates before you’ve o ered the job to your preferred candidate, and they’ve accepted (ideally in writing).

b) Choose a second favourite, in case your rst decides to take another job. If there are no other suitable candidates, you may have to go back to the start of the process.

c) Be clear what you are o ering the candidates because things said verbally can also form part of the contract.

d) Make any o ers conditional i.e., that the o er is made subject to…This could be quali cations, right to work documentation (this needs to be done BEFORE they start with you), DBS checks (if applicable) and references. That way, if something crops up in the coming weeks in relation to these, you can safely withdraw the o er of employment.

Once you have made the o er and they have accepted, you now need to prepare their contract of employment and send it to them before their rst day. When you have employees, you legally need to have 1) a disciplinary policy, 2) a grievance policy and 3) a data protection policy (including an Employee Privacy Notice). If you employ over ve people, you also need to have a Health and Safety Policy.

Also check references. Sometimes they aren’t much help. However, you’d be surprised at just how many businesses skip this step, only to be shocked when something goes awry. Do not contact their present employer unless they have given you permission to do so.

Step seven: Excellent on-boarding

This step is so often forgotten when it comes to the recruitment process, but it’s one of the most essential parts to get right when welcoming a new employee. You need a solid plan to help welcome a new employee into the business. What do they need to be able to start their new job easily? What will happen on their rst day? Who is going to do their induction, introductions to your employees, processes, training and development? Make sure you diarise to check regularly how they are doing. This may all seem like a lot of work to do for one recruit, but once you’ve created this plan, it can be used time and time again for each new hire you make.

BUT don’t forget about your current people, when employing new ones!

One thing to ensure you don’t do, when you are looking for a new employee, is alienate the ones that you already have. At the outset, share your plans and make them feel involved. If you shortlist candidates, why not show them around your business, so they can meet the rest of the team. Then, once you have started your new employee, make sure you take them around and introduce them, and arrange for them to spend time with all the team, as part of their on-boarding induction process. It really will make things easier for everyone to gel and become a great team!

If you would like to talk further about the above, or nd out more about how People Pillar can help your business with HR, please do get in touch.

 01303 769700



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HALL 19 • STAND R102

Automechanika Birmingham

Event preview Page 42-63

6-8 June | New product launches, demos, giveaways, show discounts and free training


Page 31-35

Parts, Tools & Tips

Page 64-69

New Car: Volvo EX90

Page 70-74

Mobile servicing & repair

Page 36-41

Running a mobile repair business presents di erent logistical challenges, compared to established garages with premises, leading Rob Marshall to ask leading tool suppliers how they can help.


Many green initiatives appear good for Mother Nature but come with the downside of performance and cost. With remanufactured car parts, the sceptical Rob Marshall is persuaded that garages and customers really can have it both ways.

Despite the motorcar having mud slung at it from every direction, it tends not to be realised that vehicles tend to be the most thoroughly recycled of all machines. While secondhand car parts have been available from various businesses for past decades, often on a cash-only basis and with a snarling Alsatian chained to the corner, salvaged parts' image is improving and are being viewed correctly as sustainable. With environmentally-friendly credentials to ful l on their company end-of-year reports, insurance companies and even the OEMs are taking an interest in salvaged components. Stellantis, the artist formally known as PSA and FCA, is one example of an OEM selling used parts as alternatives to new ones, through its platform.

What are remanufactured parts?

Remanufacturing is a preferred de nition over 'reconditioning', or 'repaired' for instance. Associations that include the European Association of Automotive Suppliers and the Automotive Parts Remanufacturers Association Europe have agreed on a formal de nition, which is:

“Remanufacturing is a standardised industrial process, by which cores are returned to same-as-new, or better, condition and performance. The process is in line with speci c technical speci cations, including engineering, quality and testing standards. The process yields fully warranted products.”

While remanufacturing makes repairing an older, lower-value car more viable economically, it also lowers repair costs for newer models. Pictured is a 48-volt combined starter alternator from Autoelectro's range. Global Remanufacturing Day fell on April 14th this year. Remanufactured parts help garages provide more competitive repair quotes. Yet, this is not the only advantage.

The remanufacturing di erence

Despite being related, used parts are very di erent to those that have been remanufactured. Autoelectro explains that, for rotating electrics, the case, castings and everything that mounts to the vehicle are, indeed, reused. Yet, to remanufacture a part, the remanufacturer must have a comprehensive technical understanding of how a part, such as a starter motor or alternator, operates and why it fails. Autoelectro says that this is how it can support a workshop with technical information that would not be possible from a spurious source that imports new units.

Carwood asserts that, by retaining both the material and valueadded from the original product, remanufacturing is a lot more cost-e ective than new OE. Carwood, for instance, prices its parts to be at least 25% cheaper than a new OE part.

Shaftec reasons that remanufacturing is not just a coste ective nicety but a necessity. It says that remanufacturing is often the only aftermarket alternative to keep older vehicles on the road, especially as our car parc is ageing. Shaftec says that, should a customer supply a part for remanufacturing that the company does not hold in stock, it will remanufacture the same component, turning the job around within a few days.

Workshop tips

Returning your undamaged faulty parts is a vital technician contribution to ensure the circular economy's viability. Without the core parts to remanufacture, the process cannot work. Through lack of knowledge, or even carelessness, technicians can damage parts on removal, rendering them scrap. Therefore, Carwood and Shaftec recommend the following precautions:

• Always remove the part using the correct tools/ equipment and processes only. When removing a fuel injector, especially if it is seized, a removal tool designed speci cally for that application will damage neither the body, nor electrical connector.

• Separate ancillary components from the unit beforehand. With turbochargers, for example, remove unions, adapters, banjo bolts and sensors.

• The unit should be removed in one piece, as a complete unit – do not dismantle it.

• Once removed, the unit should be handled with the same care and attention as a new unit and should not be considered scrap.

• Ideally, any product drillings and threads should be capped, where appropriate, to prevent contamination during transit.

• Ensure any castings and mounts are neither cracked, nor broken

• Any threaded bolts (including brake bleed nipples) must not be snapped o .

It may look like a crate of scrap but usable core is valuable, because it is vital to the remanufacturing process.
"Remanufactured parts help garages provide more competitive repair quotes. Yet, this is not the only advantage"

Why choose remanufactured parts?

While many new copy parts are on the market, which undercut new OEM parts in price, Shaftec advises that they are not always the best option. While they can be more expensive than remanufactured parts, in quality terms, these parts do not have the integrity of using OE core to o er OE performance levels.

Furthermore, the remanufactured part may boast a superior warranty than not just the copy parts but also the new OEM replacement. Shaftec highlights that one of its remanufactured driveshafts, for instance, carries a ve-year, or 60,000 miles warranty.

The environmental argument is also a strong pull, because the remanufacturing is sustainable environmentally. Autoelectro says that it strives to save as much original material from the old core as possible and to reduce the use of raw materials, where feasible. Not only does this save wastage but it also means that the remanufacturing process consumes less energy.

Remanufacturing: Putting right past wrongs

Autoelectro reports that the remanufacturing process allows quality companies to address inherent defects within the original design. The rotating electrics exponent comments that identifying patterns with parts that fail for the same reason and having experienced and knowledgeable personnel allows it to do this.

Remanufacturing Mythbusting

"Remanufactured products are a poor substitute for new"

Products from an OE-approved remanufacturer are designed, engineered and remanufactured to meet, or even exceed the vehicle manufacturer’s original factory speci cation, so are as good as new, if not better.

"Remanufactured, reconditioned, rebuild and refurbished mean the same"

A remanufactured part has been returned to the original speci cation through a highly-engineered, regulated process, which includes core inspection, product disassembly, cleaning, re-inspection, replacement of all wearable parts with like-for-like OE, followed by assembly and test and calibration. In contrast, a reconditioned, or refurbished, part is dismantled and cleaned but worn/damaged parts only are replaced.

"Saying that a remanufactured product is better than the OE is marketing hype"

Quality remanufacturers bring the very latest technology changes to older remanufactured products. It can also engineer out any design defects. More often than not, the remanufactured part outperforms the original component on which it is based.

"All remanufactured parts are the same"

Not at all. Remanufacturing is a sophisticated process that requires signi cant investment in capital equipment, processes and skills. Not every remanufacturer has the same capability levels.

"Remanufacturing uses old parts"

While the base OE-quality castings are renewed (or improved in the event of a defect) all wearing ones are replaced. Yet, if any other part of the unit does not pass the many performance or functional inspections, it will not be reused.

"Remanufactured products do not come with a warranty"

After all the work is completed, every single part is reassembled and individually tested for compliance with the vehicle manufacturer’s original factory speci cation. All remanufactured parts come with a warranty, which is at least the same as the OE, sometimes better.

The majority of components have no prescribed remanufacturing procedures. You must have faith in your manufacturing supplier to conduct the task properly. For instance, would many other fuel injector remanufacturers pay the same attention to prevent contamination from entering the workshop as Carwood does with its clean rooms?

Thorough testing is also a priority for quality remanufacturers. Pictured is Shaftec's Electric Power Steering rack test rig.

Carwood agrees. For instance, it has reverse-engineered the fuel injector nozzle capsule for Land Rover TD5 engines to improve both torque and fuel consumption. Its turbocharger remanufacturing department discovered that the integrated turbine and exhaust manifold casting was prone to cracking so badly that the exhaust manifold ports could detach. To eliminate this issue, its engineers have introduced a newly redesigned casting for a ected models, which include

the 2.0-litre versions of the Land Rover Freelancer 2/ Evoque and models using Ford's 2.0-litre Ecoboost engine. Other modi cations are less obvious but help to increase turbocharger life. A typical example is an improved thrust bearing, tted to certain 2.0-litre CDTi Vauxhall Astra J and Insignias, which is more wear-resistant, by increasing the surface retention of the oil, keeping it on the thrust bearing for longer. Furthermore, as certain seal plates are susceptible to failure around the compressor wheel diameter, Carwood engineers have introduced a new seal plate with strengthened ribs to reduce the failure rate.

Shaftec monitors wear and scrappage rates, too. It highlights that developments in oil seal technology, for instance, are incorporated within its remanufacturing process. It also enhances particular components where possible. For instance, Volkswagen Golf steering rack bars tend not to be suitable for remanufacturing, so Shaftec produces replacements.

"More often than not, the remanufactured part outperforms the original component on which it is based"

With tools and equipment available that make the mobile workshop a more realistic proposition, it is worth considering your options

Technicians taking to the road

Running a mobile repair business presents di erent logistical challenges, compared to established garages with premises, leading Rob Marshall to ask leading tool suppliers how they can help

Conducting vehicle repairs on the road is nothing new: breakdown operatives have done it for decades. Even so, like many industries, the trade has evolved and the exercise is not just becoming more viable but also more popular. Some of this is down to social reasons. Many people have products and services delivered to their door – so, why not those related to their motorcar? Other reasons may be due to necessity; it is not always straightforward to persuade a landlord to sign leases for garages, due possibly to historic prejudice about our industry.

With taking to the road becoming increasingly widespread, so too is the range of services o ered. While some businesses conduct general repairs and maintenance, others specialise. These include diagnostic professionals and bodywork smart repairers. Some businesses also go mobile as an extension to their garages, such as Cleevely EV adding a mobile division to its growing electric-vehicle business. Even so, whether you are on the road full-time, or a garage that is considering opening a mobile repair service to increase capacity but not reducing ramp space, it is worth keeping abreast of how wellestablished suppliers can support your business.

With a van becoming your workshop and store, every business will require di erent layouts



When you need to manage your diagnostics workflow from start to finish, you need the most advanced information-driven scan and scope handtool in the industry, with the storage, processing and communications capabilities to get you through every built specifically for the automotive industry from a company you’re absolutely sure you can trust.

designed and step

Driven by Fast-Track

A compressor that integrates with the van's engine saves weight and space. It also eliminates the need for a second engine with the associated noise and exhaust emissions. You can choose between a rotary screw-type compressor, tted under-bonnet and mounted to the engine, with the potential to house the receiver tank under the chassis. Alternatively, a more traditional 12v screw compressor is powered by a commercial alternator, driven via the FEAD drive. This ‘smart’ system ensures that engine revs drop only when more air is required, maximising fuel e ciency.

Keeping rolling

With so few cars being equipped with jacks and spare wheels, plus owners being either unable, or disinterested to do so, it is unsurprising that tyre de ations tend to feature in the top three reasons for roadside call-outs.

Hofmann Megaplan reports that it pioneered the mobile tyre tting concept, by producing the rst 12v tyre changer in the UK during the mid-1990s. When kitting-out vans for mobile tyre tting, the company reports that minimising the space needed for equipment is a priority, while maximising the range of tyres that a mobile technician can change. This explains why its mobile tting and balancing products are designed speci cally for the mobile professional. Its range of compressed air solutions, for instance, includes a space-saving petrol-powered unit and ingenious under-bonnet clutched compressor options, which bolt to the engine directly.

Hofmann Megaplan highlights that its 12v tyre changers provide the equivalent torque as a single-phase unit – an impressive feat. Additionally, its balancers use a dual 12v/240v supply. Naturally, the tyre tting equipment must be designed and built to survive being operated within a van environment. Therefore, all of the hardware must tolerate movement, vibration, temperature and humidity to be reliable and achieve a decent life expectancy.

The company has a dedicated tting centre to provide a wide variety of layouts and compressed air solutions. Accessories include LED lighting, plus supply and suitable storage options for ancillary items, from trolley jacks to hand cleaning equipment. Hofmann Megaplan emphasises that it is a specialist and the custom installations o ered can be as simple,

The ‘Pico’ is Hofmann Megaplan's space-saving wheel balancer option for the mobile tyre tting professional. The Pico can be xed to the side of a tyre changer, or on a workbench, enabling speedy and accurate balancing, while saving valuable space.

or as complex as they need to be. After all, technicians need their van to be their shop, o ce and workshop, which must be functional, professional and, above all, pro table.

Customers like the idea of repairs being conducted from home, or work, without involving them with the inconvenience of dropping their vehicle at the garage

One such professional to bene t from Castrol's Mobile Mechanic scheme is Daniel Curtin from Summers Shop, of St Ives, Cornwall. He shares his experiences with AT and tells us that: "The Race Group recognises mobile mechanics as professional motor technicians, who face the daily challenges of working from a van."

Topdon's Phoenix Mobile ADAS features a collapsible design for convenience, easy storage, and portability. With foldable arms and folding base legs, this tool can t in the boot of most vehicles.

Topdon reckons that its Mobile ADAS equipment can be set up and the calibration task started within half-and-hour.


Seeing where you are going

Like tyre tting, performing ADAS calibration on the move is virtually impossible, without equipment that is designed to save space. Topdon Diagnostics reckons that its Phoenix Mobile ADAS range provides the answer. Visit watch?v=bICmi7lkOuE or scan the QR code to view a Lane Departure Warning Calibration.

It comprises a foldable calibration frame that its makers state con dently o ers unmatched portability and convenience, making mobile technicians' businesses even more productive and pro table. Considering that ADAS calibration is becoming increasingly important to complete a safe and competent repair, especially with windscreen and suspension-related repairs, this development is worth considering.

Topdon o ers three packages, Basic, Deluxe or MAX, dependent on needs. Yet, the system has additional versatility, where single marque specialists (for instance) can purchase speci c calibration boards individually, should they so desire. Additionally, Topdon highlights its ability to allow mobile technicians the opportunity to brush up on their skills, with access to UK-based IMI-accredited trainers.

More than lube support on the go

Part of Certas Energy, the Race Group emphasises its tailored support packages that meet the extra challenges for technicians on the road. Even so, it does not matter whether technicians are based in one place, or not: selecting the correct lubricants for the appropriate vehicle remains just as important. Therefore, The Race Group supports mobile technicians with the same technical support as those with xed premises.

Yet, extra services are o ered. Through the Castrol Mobile Mechanic scheme, mobile technicians bene t from a product pro le, high-quality branded clothing, plus a pop-up gazebo that not only shelters the work area from the worst of the weather but also provides brand presence and a professional-looking work area.

Bearing Up

While Pichler Tools tends to focus more on supplying workshops, it highlights several compact o erings that have proven popular with mobile technicians. Speci cally, its wheel bearing removal kits permit Generation 1, 2 and 3 type wheel bearings to be pressed in and out on the vehicle within 15-20 minutes.

The core part of the system is the 22-tonne hydraulic cylinder ( Yet, when an airline is unavailable, the kit can be powered by an hydraulic foot pump ( article/home/80255560-hydraulic-foot-pump-to-beused-with-all-cylinders-spring-compressor/). Pichler tools says that the pump is both compact and portable, coming with a 2.2-metre length hose and drip-free quick release coupling for easy assembly.

Yet, the foot pump can power other tools within Pichler's range, such as equipment for pressing driveshaft from hubs, or ball joint extractors that apply 4.5 tonnes of pressure to ball stud, or aluminium wheel bearing carrier units.

Quick-erecting gazebos are now so good at protecting technicians from the weather allowing even smart repairers to paint a vehicle in pouring rain Topdon’s Phoenix Mobile ADAS equipment

The ultimate in precision engineering and strength - our Premier range is designed to last a lifetime and withstand the toughest work environments.
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6-8 June 2023, NEC

Free ticket, parking & breakfast!

• Gain free access to 500 suppliers including Bosch, Hella, NGK, Bilstein Group, Snap-On, Brembo, JLM Lubricants, Alldata, BM Catalysts & Delphi

• 192 hours of free skills training

• Modern Garage Live in Partnership with LKQ Euro Car Parts

• Thousands of pounds of exclusive show discounts, plus competitions & giveaways

First 500 visitors through the door will get a goodie bag, including a limited edition Automechanika hoodie or beanie hat, water bottles from Tunap and a gift from Tool Connection!

Scan the QR code to register for your free ticket, or visit



Automechanika Birmingham will welcome thousands of workshops and garage owners into the UKs largest aftermarket trade event from 9.30 on Tuesday 6 June, where visitors can try out the latest tools, access 192 hours of free skills training and hands-on demos, make valuable contacts, and take advantage of incredible show deals.

Within Hall 19, a focal point for garage owners and technicians, sits the Workshop Training Hub, in association with autotechnician magazine, Stand Q102. Delivering a packed programme of technical seminars each day, presented by respected specialists, and addressing the advancements and challenges facing automotive service, repair and maintenance. Covering a range of topics including engine


fault diagnostics, MOT, diesel, ADAS and much more. Read on to nd Hub timetables, exhibitor highlights, feature areas and some examples of the deals on o er at the 3-day event…


Halls 18-20 NEC Birmingham, B40 1NT

Opening times:

Tuesday 6 June 9.30am – 4.30pm, Wednesday 7 June 9.30am – 4.30pm, Thursday 8 June 9.30am – 4.00pm

Arrive before 10.30 to claim a FREE breakfast. Parking for workshop visitors is free of charge.

43 J02285 & J02280 Don’t Turn Away Diesel Business! J02230 & J02250 DPF Professional Clean & Flush Cleaned in 1 hour Keep the business in your workshop No need to remove DPF Diesel Intake Extreme Cleaning Two stage clean for maximum effect Add extra value to your service or MOT No expensive equipment required FormulaTradeProven For more information: Call: 01273 891 162 Email: EVENT PREVIEW
the QR code to register for your free ticket, or visit

What’s on guide

Automechanika Birmingham 2023, introduces brand-new training hubs and show features Three training hubs have been designed to support garage and bodyshop business owners and technicians by o ering insights into trends, technical information, practical sessions and the latest advice and tips to futureproof businesses. Workshop, EV and Bodyshop Training Hubs providing technical training and demonstrations, new for 2023 is a Detailing Hub, Collision Repair Live and Paint & Spray Live plus Modern Garage and EV Parc, looking at garages of the future and electric vehicles.

Automechanika Birmingham’s Workshop Training Hub, in association with autotechnician, has a diverse programme of technical seminars, covering topics such as fault diagnostics, MOT, diesel, and Advanced Driver-Assistance Systems (ADAS).

The EV Training Hub, sponsored by Alliance Automotive Group, will highlight the requirements and opportunities of hybrid and electric vehicle service and repair with topics such as how to prepare your garage to o er repair services, health and safety requirements, tools and equipment for high voltage operations, battery technology, plus hydrogen internal combustion.

The Bodyshop Training Hub will provide the latest updates, advice and technical innovations in collision repair, covering ADAS, body repair, EV repair, paint, re nishing and BS10125 standards.

Workshop Hub highlights, Stand Q130

6th June - 14:00 - 14:25

A Whistle-Stop problem-solving tour of vehicle uid systems including A/C by Richard Doran, Primalec Leak Control & Air Conditioning solutions

This short talk will cover the many di erent methods, tools and liquids available for better diagnosis and repair, including: New ways to x damaged pipes; The role of A/Cs and Climate Control systems in EVs and Hybrids; Making sure you nd x and prevent all the leaks, including invisible refrigerant micro leaks; The di erences between old and new refrigerants; plus, everything you need to know about A/C lubricants but didn’t know who to ask!

7th June - 13:15 - 13:55

Remove the guesswork – Why ALLDATA makes complicated repairs simple, by Hayley Pells – IMI, James Dillon – Technical Topics, Tim Benson

– Old elds Garage and Dave Shepherd – The Cognoscenti Partnership

Steve Derham, ALLDATA Technical Support Specialist leads a stellar panel as they each tackle the challenges associated with increasingly sophisticated vehicle technology and repairs. Learn how genuine and trustworthy OE data is a pivotal part of an independent technician’s day-to-day routine.

Technicians can get hands-on under the hood and inside the body of EVs at the EV Training Academy, in collaboration with the IMI, (Institute of Motor Industry), and gain guidance from EV experts. Modern Garage, in partnership with LKQ Euro Car Parts, will showcase how new technologies can be e ectively incorporated into a modern workshop, moving towards a digital future. There is also a Student Talent and Recharge programme in partnership with Autotech Group, o ering students CV writing tips and interview advice.

The Independent Automotive Aftermarket Federation (IAAF) has announced it will be hosting its rst Garage Awards in partnership with Automechanika Birmingham, celebrating the commitment and dedication independent garages and technicians have made to ensuring a ordable mobility in the UK over the past few years. This will be held on Wednesday 7 June at Hilton Metropole NEC.



HALL 19 • STAND R102

• Business peaks, annual leave, training days and sickness cover

• Fully qualified and vetted vehicle technicians and MOT testers

• Contracts lasting from one day to six months at a time

• UK-wide network of over 450 contractors

• Flexible work patterns: early, late, night & weekend shifts SHORT-STAFFED?


Contact us today to book your contractor!

Tel: 01234 432988

Email: Web:


• 6 to 12-month paid internships are a new, risk-free way of bringing new talent to your workshop

• Vetted candidates with a recent IMI Level 3 automotive qualification, equipped with a starter toolkit, basic safety workwear and uniform

• Assess your intern’s skills and work ethic before commiting to bringing them on as a permanent employee

• Over 200 candidates ready for an immediate start

We have interns ready to fill roles. Get in touch today!

Tel: 01234 432988



Workshop Training Hub schedule STand Q130

Tuesday 6 June | Day One

10:00 – 10:40 Workshop diagnostic tools strategy: To be, or not to be with dealer diag tools

James Dillon, Founder Technical Topics

10:45 – 11:10 Expert technical session, Bosch Automotive

11:15 – 11:40 Castrol’s response to OEM speci cations and hybridisation, Simon Gurney

11:45 – 12:10 ZF [pro]Tech: Technical Insights

12:15 – 12:40 Training mechanics to manage the changing face of vehicle repair head on, Solera Audatex

13:15 – 13:55 The modern garage, LKQ Euro Car Parts panel

14:00 – 14:25 A whistle-stop problem-solving tour of vehicle uid systems including A/C

Richard Doran, Primalec Leak Control and Air Conditioning solutions

14:30 – 14:55 Automated driving of the future, Pete Bradley, Hella's Head of International Technical Training and Ani Stepanyan, Head of Product Management

15:00 – 15:25 Oil basics, Drew Stinton, Shell UK

15:30 – 16:15 DPF do’s and don’ts, Barry Lawson, Lawson Autotech

Wednesday 7 June | Day Two

10:00 – 10:40 The challenges of hydrogen internal combustion for passenger cars

Andy Crook, Research Engineer, GotBoost

10:45 – 11:10 How to thrive in uncertain times: Insights, advice and actionable steps for success

Gavin Ruddick, Steer Automotive Group & Jessica Potts, BookMyGarage

11:15 – 11:40 Building a better future for the automotive aftermarket

Mark Ost & Tristain Hindle, Snap-on Diagnostics and Garage Equipment

11:45 – 12:10 TUNAP: The secret to EV aftersales pro t, Massimo Di Franco

12:15 – 12:40 DPF do’s and don’ts, Barry Lawson, Lawson Autotech

13:15 – 13:55 Remove the guesswork: Why ALLDATA makes complicated repairs simple

Hayley Pells, IMI; James Dillon, Technical Topics; Tim Benson, Old elds Garage; Dave Shepherd, Bodyshop Consultant

14:00 – 14:25 The MOT test: Today and tomorrow, Craig Scragg, RMI Technical Services Manager

14:30 – 14:55 How new vehicle technology will impact engine oil in 2023 and beyond

Mark Whitmill, Andrew Carter and Ed Gould, Comma

15:00 – 15:25 Running the shop: Driving value and e ciency throughout your business

Mike Bell, LKQ Euro Car Parts

15:30 – 15:55 Particulate measurement: Particulate number counting, Roy Prosser, Continental

Thursday 8 June | Day Three

10:00 – 10:40 The challenges of hydrogen internal combustion for passenger cars

Andy Crook, Research Engineer, GotBoost

10:45 – 11:10 Braking technology for EVs, Siti Abdullah, Brembo

11:15 – 11:40 Particulate measurement: Particulate number counting, Roy Prosser, Continental

11:45 – 12:10 How new vehicle technology will impact engine oil in 2023 and beyond

Mark Whitmill, Andrew Carter and Ed Gould, Comma

12:15 – 12:40 ZF [pro]Tech: Technical Insights

13:15 – 15:10 Talent and Skills Programme

MEYLE ORIGINAL oil change kits for automatic transmissions make changing transmission oil extremely easy: because each of the vehicle-specific kits in our range contain everything needed for the job. This saves time and enables a timely and competent service. Learn more at Everything you need for a complete gear oil change. MEYLE UK Ltd. 47 Dolphin Road, Shoreham-by-Sea, West Sussex, BN43 6PB, UK Phone: 01273 463686,,

Supporting the transition to EV service & repair

The EV Training Academy will practical advice on electric vehicles with demos and training delivered in partnership with the Institute of the Motor Industry and Our Virtual Academy. A series of 30-minute sessions will run throughout each day of the trade event.

Guests can get hands-on with two demo vehicles and ask EV experts anything about hybrids and EVs. The EV Training Academy programme will cater for all technicians with both beginner and advanced-level tuition on o er. The free sessions, delivered alongside training vehicles, include Essential EV Training; HV System Isolation (low-voltage service disconnect) for beginners and Advanced EV Training; as well as Plug-in Charging (proximity pilot circuit).

Essential EV Training will demonstrate the high-voltage isolation process using a low-voltage service disconnect, which is becoming an increasingly popular solution used by vehicle manufacturers. The Advanced EV Training session o ers businesses the opportunity to learn about the proximity pilot circuit used in Type 2 plug-in charging system.

Steve Nash, CEO of the IMI added: “This focus on EV skills is great news because our latest data shows that by 2030, 103,000 IMI TechSafe quali ed technicians will be needed to work with electric vehicles in the UK alone. However, we are currently predicting a potential shortfall of 4,500 quali ed technicians by 2029, increasing to a massive skills gap of 16,000 by 2032.”

Nash adds: “It is critical that consumer con dence in electric vehicles is not eroded by a lack of ability of garages to service, maintain, and repair the new drivetrain.”

A discounted one-year subscription to ALLDATA Repair with Labour Times is available to visitors who register their interest or sign up for a 14-day free trial on Stand R120 in Hall 19

As vehicle technology becomes increasingly sophisticated, access to data – and accurate data at that –is paramount. Correct testing procedures, DTCs, TSBs and wiring diagrams are all must-haves in today’s workshops; ALLDATA Europe is con dent that having this data at your ngertips will boost business e ciency, strengthen both knowledge and con dence in taking on complex repairs, and widen the menu of services.

ALLDATA Sales Director, Simon Frost, and Technical Support Specialist, Steve Derham, invite you to an in-depth discussion that comprises Old elds Garage Owner, Tim Benson, former garage owner and now IMI Policy Manager, Hayley Pells, renowned technical expert, James Dillon, and experienced bodyshop specialist, Dave Shepherd.

Each automotive professional will bring their unique, considered, and comprehensive experiences and

opinions to the fore – from repairing a vehicle in the garage to analysing current legislative challenges and pronounced industry trends – meaning all bases will be covered.

The 45-minute session will take place at 1:15pm on Wednesday 7th June at the Workshop Hub.

See us at Stand L140 6-8 June 2023 NEC, Birmingham

Giveaways & competitions

COMMA will be holding its biggest ever point giveaway on Stand F90 –giving every visitor to the stand the chance to earn points that can be redeemed for prizes after the show. Prizes include iPads, Bluetooth speakers, co ee machines, a team go-karting experience, and more.

Maverick Diagnostics will give away on-the-spot prizes on Stand L140, including discount vouchers worth up to £200, beanies and mugs.

Come and see the full-size WRC rally car on the CastrolStand S130 and each day there will be a barrel table and chairs set given away.

Take a spin on the wheel at the Bilstein Group StandP100 to win a bag of goodies.

Hands-on demos & training

Bosch on StandQ102 will highlight the latest developments for the DAS 3000 platform and experts will be on-hand to provide demonstrations at 10.30am, 13:30 and 15:30 every day and answer any questions visitors may have.

Merlin Diesel Systems will be showcasing the Hartridge Sabre Diesel test bench on Stand X100

Tyre changing and wheel balancing demonstrations will highlight the time and laboursaving bene ts of both Hofmann and Balco equipment on the ISN Europe Stand R70 Maverick Diagnostics will be demonstrating the AVILOO FLASH test on a Tesla Model 3 car on their Stand L140 – the rst independent EV battery tester available in the UK automotive aftermarket.

Be the rst to get hands-on with the latest additions to the Snap-on Fast-Track Intelligent Diagnostic Scan Tool Family on Stand P130

Visitors to Brembo’s Stand R102 can expect to see all its new products displayed and can take part in a quiz to test their knowledge to be in with the chance to win some gadgets

Its replacement braking programme is divided into four di erent product groups. Brembo Essential o ers the rst approach to replacement opportunities, including brake drums, shoes, hydraulic components and remanufactured calipers. Its premium line Brembo Prime is designed for customers seeking the best t for their car, LCV or truck and provides brake discs, brake pads, calipers, brake uid and additional brake accessories. Brembo Beyond is

dedicated to electric vehicles and includes the Brembo Beyond EV kit – a range of coated discs and pads that are quieter and more resistant to oxidation and corrosion. Brembo Xtra includes drilled and slotted brake discs, high friction pads, coloured aluminium calipers, and a new brake uid.

From 10:45 to 11:10 at the Workshop Training Hub on the 8th June, Brembo will present ‘Braking Technology for EVs.’ This will outline the braking system in EVs, trends and solutions so that workshops can prepare for the peculiarities for a professional service that is continuously updated with the evolution of vehicles.


Seegreat NEW products on StandR60

SmartSplice -thecrimp-free,solder-free secureleakrepairmethodforfluidand refrigerantcarryingpipesandhosesincluding A/Cs,TransmissionsandPowerSteering. Eye-See SightglassFilteredA/CDiagnostic set.Showsupimpuritiesandcontamination, lubricantandrefrigerantbreakdown.

Purifier-2 -thelatestadditiontotheAirco Shielddeodorising/sanitisingrangewith addedpowertocleansetheevaporator chamber,airchannels,cabinair,cabin surfacesandfabrics.

Glo-LeakFlash -Newsingledosesystem thatletsyouflashGlo-LeakUVintothe A/Cusingthesystem’sownrefrigerantfor fasterresults.

Testyourskillsandknowledgeinourdaily competitiononthestand.Andjoinusin theWorkshopHub - Hall19standQ130at 2pmonTuesday6thJune foraWhistle-Stop problem-solvingtourofvehiclefluidsystems includingA/Cs.

FluorescentLeak Detection Pressureleaktesting &sensingsystem Leaksealants forHV-AC&R Purifier:Sanitise &Deodorise ElectronicRefrigerant &NitroTracedetection HighPerformanceA/C Lubricants&Additives Leaksfound&fixedtodaysaves moreexpensiverepairstomorrow LeakControl ContactyourPrimalecdistributororFactororcallusfordetailson 01622816955 | Primalec,NettlesteadGreen,Nr.Maidstone,KentME185HD,England.
automechanika BIRMINGHAM NEC,6-8June2023
Choose the aftermarket partner who’s here to help keep you ahead, today and tomorrow. Whether it’s parts, tools, support or training... we’ve got your back! Partner with Delphi Technologies Visit the Masters of Motion hub for more information Delphi Technologies is a brand of BorgWarner Inc. Masters of Motion currently available only in EMEA.

Exhibitor news

We highlight some of the product launches, demos and handson training planned across the three days of the show

LKQ Euro Car Parts will present its extensive product range, training platform and other garage solutions across four stands at the show. Its product range will be presented on its largest Stand N100 including its in-house component brands –Starline, MPM Oils, Pagid and Eicher.

The LKQ Academy will be inviting attendees to experience the garage of the future at stand N125, with live demos on air conditioning, wheel alignment, diagnostics, and garage management software. Expert advice for bodyshops will be available on Y100

It will introduce a unique new garage concept – 1Tec Auto

Primalec will debut several new products at the show on stand R60, which is located right by the entrance to Hall 19.

Visitors will be able to watch or participate in demonstrations including a working A/C unit and see how easy the products are to use, including the new EyeSee Refrigerant Inspector.

Smart Splice is the canny connector system that facilitates speedy repairs and modi cations to pipes and hoses, enabling repairs to leaks in vehicle transmissions, power steering and air conditioning systems – typical repairs take just ve minutes. Smart Splice parts include straight, 45°- and 90°-line ttings, as well as hose to pipe, hose to hose, and line block-o ttings. You can even use Smart Splice to add a service port connector to an A/C line.

Primalec’s unique vacu-can injection system has been repairing micro A/C leaks with Airco Seal Pro for over 20 years and now you can use it to inject ExtraCool A/C rejuvenator, and Glo-Leak Flash UV leak detector dye as well. Primalec’s system mixes with the system’s own refrigerant before injection, giving faster circulation and avoiding any risk of clogging the compressor.

Puri er-2 – the latest addition to Primalec’s deodorising/

Hub – alongside seven other aftermarket suppliers, including MPM Oil, Pagid, Schae er, Shell, Valeo, Varta, and ZF, and subject experts will be sharing their knowledge within the interactive hubs.

Opus IVS, will have a vehicle on stand W70 for a live demonstration of their remote services. The Remote Assist Program (RAP) enables customers to use their DrivePro device with the support of OEM-trained master technicians. The Opus IVS DrivePro Elite diagnostic tablet o ers a remote services VCI and coverage for 64 brands. It comes with IVS 360 live support included.

sanitising range is on show too, along with Nitro-Trace, Leaktronic and the sought after Snow Leopard oils.

If you’re at the Show on Tuesday afternoon, join them on the Workshop Hub (Q130) at 2pm for a whistle-stop problem-solving tour of vehicle uid systems.


MEYLE’s stand will be in Hall 20, E60, where the focus will be on their HD product line and their new eSolutions. Among the highlight products, visitors will nd automatic transmission service kits as well as the new and MEYLE HD control arm for Tesla Model 3 & Model Y, which provides a durable solution. A comfortable meeting area invites visitors to sit down and chat with experts over a cup of co ee to learn more about how its spare part solutions make car repair and maintenance easier and more e cient.

The KalimexStand K107 will feature new product launches, giveaways and show deals throughout the three days. The team invite readers to nd out about cost-e ective DPF cleaning solutions from JLM Lubricants plus the latest additives for AdBlue, GDI engines and emissions reduction. Visitors can also pick up an exclusive goody bag, including a limited edition mug stu ed with sweets. The rst 50 visitors to its stand each day will also get a free stick of Quiksteel Epoxy Putty.

Maverick Diagnostics o ers to help visitors modernise their workshops on Stand L140, providing practical advice on OEM tooling, technical support, training, and EV battery diagnostics. Whether you are just considering specialising or are already experienced in using dealer diagnostics, its team of experts will be on hand to o er advice and business support. It will showcase its range of OEM tooling and technical support, while its sister company, Automotive Training Academy will present its comprehensive training program, including dealer tool and EV training.

It will also launch its new EV battery diagnostics products from AVILOO, carrying out live demonstrations on a Tesla Model 3. Visitors can enter a competition to win a £7,000 JLR dealer diagnostics and support bundle (preregistration is required, simply email, as well as giving away IMI EV training for two technicians. Plus, special discounts will be o ered to existing and new customers.

Niterra UK – owner of the NGK and NTK vehicle electronic brands – will have a host of attractions on Stand E90 and will focus on its NGK Academy training initiative and its EGR valves range.

Garage visitors will also be able to test their skills on a race car simulator when the fastest competitor will win the Niterra Trophy, walk away with a BoxClever gift bag, and have the chance of meeting some of the company’s motorsport ambassadors.

British racing driver Nic Hamilton, who has con rmed he is to drive Team HARD. Racing’s Cupra Leon in the 2023 Kwik Fit British Touring Car Championship (BTCC) season, will be on the stand on Tuesday, June 6. Hamilton, the brother of seven-time World Formula 1 champion Lewis Hamilton, has a long-standing relationship with the NGK brand and will be available to meet visitors as will North Yorkshire based racing car driver Max Coates, who will be on the stand on Thursday, June 8.

British racing driver Nic Hamilton will be on the NGK Stand E90 on Tuesday June 6
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OSRAM and Ring will be sharing Stand M111 in Hall 19 with an extensive display of their products, including a focus on the original equipment lighting solutions OSRAM provides, and Ring’s aftermarket battery care, workshop tools, and inspection lamps.

New product highlights include the Osram Night Breaker 200, its Professional Series of working lights and Ring’s coloured inspection lamps, cordless tyre in ator, pro jump starter and RWL400, RWL600 and RWL1000 work lamps.

The stand will host interactive features and experts from both Ring and OSRAM will be on hand throughout the show to discuss products, o er advice and perform product demonstrations if needed, and there will also be the chance for visitors to win prizes on the stand.

Henry Bisson, Marketing Director at Ring, said: “Automechanika Birmingham is always an excellent show for us to communicate with current and new customers about what we can help them with, whether that’s lighting solutions or one of our other ranges… for workshops, it’s vital that technicians have the best tools to hand at all times, if a vehicle has a battery/starter system fault, they need to diagnose and identify it quickly and e ciently to be able to get on with their job for instance.”

TOPDON UK on Stand N62 will provide answers to your questions on its range of diagnostic products, whether it be ADAS, Diagnostic tools, Remote diagnostics solutions or the newly introduced Thermal Imaging and battery range of products.

Steve Scott from the renowned Simply Diag Network and Diagnose Dan will also be on the stand to chat with visitors. Three prizes will be given away in a competition to win a Phoenix Lite 2, T30000 Battery Charger and TC005 Handheld Thermal Camera. Goodie bags will also be handed out!

Visit Stand S90 to view a huge range of Sealey products, their current promotions and the latest 1,432 page edition of The Tool

Catalogue, containing over 12,000 products designed for use in the trade with 1,100 brand new products. There will also be some show deals to take advantage of.

The Independent Garage Association (IGA) supports members with the day-to-day challenges and complexities of running a garage business and ensures the sector’s voice is heard at Government level.

IGA members have access to a wealth of services, advice and resources; including a dedicated member helpline, legal and HR advice, technical training, MOT QC and Health & Safety schemes, online technical forum and helpline, customer conciliation and arbitration, exclusive commercial services and o ers, preferential training rates at the RMI Academy of Automotive Skills, and more.

Members receive regular communication via email, post, and telephone about important industry updates, and are sent straightforward advice when new issues a ecting the sector emerge.

IGA members can also join Trust My Garage, the IGA’s nationwide consumer assurance scheme that acts as a badge of quality for independent garages. The scheme is approved by the Chartered Trading Standards Institute and backed by extensive nationwide advertising, giving local garages a national pro le.

You can talk to the IGA team at the show on Stand G122 about the bene ts of IGA membership, to ask any industry questions you may have or to discuss the issues they are lobbying for on your behalf.

As one of the event’s Platinum partners, on Stand Q90 in Hall 19, HELLA will exhibit its workshop equipment for vehicle diagnostics and advanced driver assistance systems, as well as its OE replacement parts programme, that includes a wide range of vehicle electrics and electronics.

“With the complexity of modern vehicle technology aligned with the vehicle manufacturer’s drive to lockout independents,


workshops need diagnostic equipment that not only tackles the technology, but also provides a solution for the cyber security management (CSM) barriers they encounter,” explains HELLA’s Ian Boyle.

“So, to both highlight these issues and demonstrate that there are viable, cost-e ective solutions to them, is why we’re exhibiting and this means that the Hella Gutmann mega macs X and the macsRemote, as well as the latest CSC Tool-Digital for ADAS calibration that we o er, will take centre stage during the event.

HELLA will also deliver ‘Automated driving of the future’ and ‘High voltage expertise’ presentations from both the Workshop Training Hub (Q130) and EV Hub.

BM Catalysts’ will highlight the latest Selective Catalyst Reduction (SCR) references alongside its already established range of catalytic converters, diesel particulate lters and front pipes in Hall 19, Stand M70

Mark Blinston, commercial director at BM Catalysts, said: “Demand for SCRs is only going to increase, as many of the newer Euro 6 vehicles feature this technology and will be entering the vehicle parc over the next few years. It is therefore imperative that the aftermarket is fully informed and has readily available access to high-quality SCRs.”

The team will share information on changes to emissions legislation, including the proposed changes to MOT testing on

diesel vehicles, and the opportunities that are appearing within the aftermarket as a result.

Technicians visiting the stand will have the opportunity to get a practical insight into the company’s manufacturing processes, assembling a catalytic converter using a demonstration jig.

Delphi Technologies, a brand of BorgWarner, invites visitors to get hands-on with its latest innovations on Stand R64 in Hall 19. New-to-range parts, including a Tesla suspension arm, a raft of rst-to-market brake components, and new bi-metallic, highcarbon alloy brake discs will be set out, alongside a complete programme of workshop support in the form of Masters of Motion and Delphi Academy.

“Automechanika is a golden opportunity for garages to see what’s happening in our industry,” said Nigel Du eld, UK Country Director at Delphi. “We’ll be demonstrating how we’re helping garages service increasingly complex vehicle systems through the supply of premium quality parts, OE-level diagnostic equipment, technical support and training.”

To celebrate its Alpine sponsorship, visitors will be invited to compete for the best lap time on an Alpine F1 simulator and reaction time on a Batak machine, with daily prizes for the top performers. Elsewhere at the exhibition, Delphi’s Technical Services Manager Luke Garratt will be presenting ‘Hydrogen Internal Combustion – Is this the future?’ as a keynote speaker on Wednesday 7th June.


“The simple fact is nothing beats showing garages our products,” said Steve Prince, MD at Pichler Tools. “They then instantly see for themselves not only the manufacturing quality and professional durability of Pichler Tools but also understand exactly what speci c jobs particular products do and how they work so well.”

Steve explains that Pichler’s tools are designed to improve safety, speed, and quality of work, or simply help retain jobs that otherwise couldn’t be done on site. “Pichler Tools was rst known for specialist injector and glow plug removal kits,” said Steve. “There’s now a lot more products in our range to help garages grow their pro ts.”

Pichler Tools, on Stand S88, will bring their best-selling heavy duty heat inductor, the workshop coil spring compressor, an automatic brake bleeder and their wheel bearing removal kits –for all main generations of vehicle wheel bearings.

The Veri cation of Lubricant Speci cations (VLS) will celebrate ten years of protecting lubricants users at Automechanika Birmingham this year on Stand S60

Back in 2013, VLS was formed amid concerns that some lubricant products were being sold with claims that did not seem believable. Closer inspection found that substandard formulations were occasionally passed o as the latest speci cations or even failed to perform e ectively. Most lubricants sold in the UK market at the time were fully compliant. However, out of this concern, reputable lubricant blenders and manufacturers came together to launch VLS. Since then, VLS has investigated 86 di erent lubricant complaints from cold weather properties to compliance with industry standards and market regulations. The work is ongoing, with eight cases currently under review.

The Motor Ombudsman will be operating a case clinic on Stand F117 in Hall 20 each day of the event. Members of the organisation’s Dispute Resolution and Business Services team will be on-hand to discuss the bene ts of being accredited to its Chartered Trading Standards Institute (CTSI)-approved Motor Industry Codes of Practice, and to provide information and guidance on best practice for resolving consumer disputes fairly and quickly without having to resort to legal action.

At Automechanika, CDTi will present its new pre- lled PatFluid Bag Range for the rst time, speci cally designed for vehicles that use on-board DPF additive (Fuel Borne Catalyst) dosing systems. Some of these vehicles require a exible bag or pouch to hold the additive which can be quickly replaced with a new one when it runs out. Find out more in Hall 20, Stand G78

Ecobat Battery will be exhibiting on G90 in Hall 20, which will be divided into ve areas: Automotive, leisure, mobility/ motorcycle, chargers/invertors, with a fth being dedicated to sister company Ecobat Solutions, which o ers an integrated EV battery logistics, re-engineering and recycling service to manufacturers.

“Alongside best practice battery advice, such as to check the battery of every vehicle that enters the workshop and to make sure the battery is supported when carrying out diagnostic tests for the installers present,” says Ecobat Battery’s Commercial Director, Paul Payne. “We’ll also be presenting charging and solar solutions for the leisure sector, products to cater for the motorcycle and mobility sectors and even addressing the EV market with an EV lithium battery pack."

Community-driven garage management software, Garage Hive will be encouraging stand visitors to interact with the software during live demonstrations Stand P60 in Hall 19. There will also be plenty of freebies up for grabs including a chance to win a free ticket worth £100 for The Blend 2023, its annual conference and networking event for independent garage owners taking place on Saturday 7th October in Birmingham.

Garage Hive director Alex Lindley, alongside other team members, will be on-hand to issue expert advice for independent garages keen to boost business performance. “We’re really looking forward to the return of Automechanika Birmingham,” said Alex. “It’s an excellent opportunity to meet like-minded garage owners, re ect on shared challenges and discuss garage growth potential. We’ll also be launching a new parts supplier integration at the show, which will bring further timing-bene ts for workshops.”

WHEN THE SOLUTION EXISTS BEFORE THE PROBLEM APPEARS. Visit our stand for a chance to win 12 months FREE HGS data! AUTOMECHANIKA BIRMINGHAM 6 - 8 JUNE 2023 | STAND Q90 HELLA - THE ELECTRONICS EXPERT FOR E-MOBILITY. Join the rest of the aftermarket community at the BIG UK reunion to influence industry-wide change 6-8 June 2023 | NEC, Birmingham TRAINING | TOOLS | TECHNOLOGY Book your FREE ticket today

Parts, Tools & Tips

New products, tting tips & technical advice to ease fault- nding and installation


The range of NTK exhaust gas temperature sensors (EGTS) has been expanded to include 98 new parts for tens of thousands of vehicles on the UK and Ireland’s roads. The NTK range from Niterra UK now comprises 113 parts.

NTK EGT sensors are a popular choice for vehicle manufacturers as they provide extreme resilience against heat and vibrations, have high measuring accuracy, fast light-o times and an exceptionally wide measuring range. Mark Hallam, Marketing Manager, Niterra UK Ltd, said: “The EGT sensors range has proven to be very popular since launch and the new additions make it even more attractive as it caters for a wide range of popular vehicles from many of the World’s leading marques including Mercedes Benz, Audi, Volkswagen, Volvo and Vauxhall.”

The NTK EGT sensors range was introduced to the UK market in 2014 by NGK Spark Plugs (UK) which in April o cially changed the name of its UK operations to Niterra UK Ltd.

The NTK range also includes Lambda sensors, camshaft & crankshaft sensors and MAF & MAP sensors.

Double your points!

In other news, members of the BoxClever independent garage loyalty scheme will receive double points for all precious metal spark plug boxes banked between April and June 2023. They will also get a free prize draw entry every time they bank any NGK or NTK branded product boxes from now until the end of June 2023 giving multiple chances to win an additional 10,000 points bonus.

Garages can check out what engine types can bene t from an upgrade to NGK Laser Iridium and Platinum spark plugs by visiting the website uk and going to the NGK Part Finder sub-site.


Castrol has launched a new formulation of its MAGNATEC lubricant, which has been designed to meet the speci c needs of Fiat GS1 and DS1-compatible engines, found in models such as the Fiat Panda and 500, Jeep Compass and Jeep Renegade, and Alfa Romeo Mito. Castrol MAGNATEC 0W-30 GS1/DS1 features a patented DUALOCK Technology, designed to provide engines with 50% better protection from warm-up wear and re-start wear.

Castrol MAGNATEC 0W-30 GS1/DS1 is designed for use across all Fiat petrol and diesel vehicles where Fiat recommends an ACEA C2 or earlier speci cation 0W-30 lubricant. The new product is the rst Castrol engine oil to meet Fiat 9.55535-GS1 and Fiat 9.55535-DS1 speci cations.

The product clings to vulnerable metal surfaces and moving parts, to providing protection during warm-up. The unique molecules in DUALOCK Technology lock together with the other MAGNATEC molecules to protect against engine wear.

Find out more about Castrol’s MAGNATEC product range at:

• Legal Advice • HR Support • MOT Quality Control Schemes • Health & Safety Programmes • Technical Support Helpline • MOT & Technical Training • Implementing Legislation • Digital Service Records • Trust My Garage • Utilities Management • Industry Scam Information • Access to ADR for consumer disputes • Exclusive Member Offers & Services • Lobbying for issues affecting your garage ...and any other issues you need help with We can support you with: DO YOU OWN OR RUN AN INDEPENDENT GARAGE? The Independent Garage Assocation has been your trade body since 1913. Join us to receive everything you need to run a successful garage business, all in one place at an unbeatable price. Contact our friendly team today to find out how your independent garage can benefit from membership: 01788 225 908 Scan here to visit the IGA website


BM Catalysts shares some useful insight into the importance of using new ttings when replacing an emissions control product

The manufacturer ensures that, where required, technicians have access to accompanying mounting components, with tting kits being launched as standard with most new-to-range products. Kits can include anything from gaskets and clamps to washers and springs, as well as specialist nuts and bolts.

Mark Blinston, commercial director at BM Catalysts, says: “Fitting kits are a small but important factor to take into consideration when buying or tting a replacement emissions control product. It recommends using a new tting kit wherever possible and there are several bene ts to using them that are often overlooked.

“The bene ts of using a tting kit outweigh the costs and we encourage technicians to utilise the kits in our range to help prevent invalidating warranties and the complications that can arise from trying to reuse old or existing ttings.”

Over time, gaskets can su er wear and tear which could cause them to break. Fitting new gaskets at the time of replacing the unit itself helps eliminate this risk and creates a better, tighter seal. With manifold catalytic converters, this means that gases are less likely to leak.


TEXA offers a complete series of products dedicated to the Car/ LCV market. Our solutions include our latest multibrand diagnsotic tablet, AXONE Voice, our top of the range vehicle interface TXT MULTIHUB and our Advanced Driver Assistance Systems.

“As manifold gaskets are compression gaskets, it’s unlikely even the most skilled of technicians will be able to get them in the exact same position again if they intend on reusing them”, Blinston comments.

Much like gaskets, support rubbers can deteriorate and break over time, with rubber known to perish with age. Failure to replace worn support rubbers or hangers can allow too much movement in the exhaust, which could cause damage to the replacement unit. Should an under oor unit become detached and make impact with the ground, it could potentially destroy the internal monolith, meaning a costly further replacement would be required.

Rusty nuts and bolts can sometimes lose threads, meaning they may not be long enough to t the new unit – something usually not discovered until the unit is about to be tted onto the vehicle. Purchasing replacements in advance may help avoid delays or unnecessary complications when it comes to tting. What’s more, springs can lose their strength and so cannot hold joints together e ectively, thus allowing the joints to blow.

The company is also warning against the use of exhaust paste, as when used in front of a catalytic converter to try and rectify tting issues, it will invalidate the unit’s warranty. The company recommends using a kit designed speci cally to t the unit to the vehicle to avoid complications and possible warranty failures.

Scan for more information. PARTS, TOOLS & TIPS


First Line has issued advice to technicians looking to solve a diesel particulate lter (DPF) regeneration issue on popular Ford vehicles caused by failing OE pressure hoses.

The third-generation, 2.0 litre TDCi–engined Ford Mondeo, and associated S-Max and Galaxy derivatives produced from 2007 to 2014, feature a DPF coated with a platinum-based catalyst. The catalyst lowers the temperatures needed to start burning the carbon build-up in the DPF and is designed to last about 120,000 miles.

The Ford DPF is monitored by a Di erential Pressure Sensor that checks for conditions where the lter may become overloaded. However, the sensor is attached with rubber hoses that can fail due to high temperature uctuations and cause incorrect sensor readings.

By exceeding the threshold for conditions in which the DPF may become overloaded, a Diagnostic Trouble Code (DTC) of P2002: Particle Filter E ciency Below Limit may be thrown, causing technicians to consider expensive and potentially unnecessary DPF replacement.

If the rst DTC is cleared by the technician and the car is driven away, but then exceeds the threshold at which the pressure sensor deems the DPF to be overloaded for a second time, this can disable the EGR valve and put the car in limp home mode, as the DPF is likely full and may now need to be replaced along with the any other components that have led to the failure.

Global Sales Director at First Line, Kevin Neaverson, said: “It is extremely unusual that a DPF will simply fail on its own, as it is just a lter. As with many issues that appear to be caused by a DPF that is full or not regenerating, it’s often a symptom rather than the cause. At this stage, the true fault needs to be identi ed so that the DPF can regenerate itself and continue to do its job.”

First Line strongly recommends that if the vehicle is reporting engine codes relating to the DPF or Di erential Pressure Sensor, for example: P2002, P2453, or P2452, then there is a possibility that the Di erential Pressure Sensor Hoses are the cause and require replacement.

The OE rubber hoses can become fatigued, hardened, brittle or scorched, which leads to the hoses failing, causing incorrect readings to the Di erential Pressure Sensor.

“By inspecting the pressure hoses rst, technicians can save the vehicle owner timely and costly repairs. This is simply a 45-minute job that requires the vehicle to be high on a ramp, so that access to the Di erential Pressure Sensor can be gained via removing the sub-frame cross brace as it is located just behind the engine,” Neaverson comments.

First Line’s pressure pipe (part FEH1000) replaces the OE reference 1440559 or 6G915H241AA and o ers a durable pressure hose that can withstand the highly uctuating temperatures and harsh working conditions, helping prevent failure and DTCs relating to DPF failure.

For more information, visit First Line Ltd.’s WebCat resource: https://webcat.

Take on the BIG Comma Workshop Challenge

Hear from our oil experts at Comma Talks Book in a free Comma Workshop Workout

Get ready for our Professional Partner Programme 2.0

To find out more, visit or scan the QR code. You’ll find details of the Big Comma Workshop Challenge and how to register for tickets to the show. T&Cs apply.




Denso says that despite the growth in hybrid and electric vehicles, diesel powered cars and light commercial vehicles still make up a huge part of the European vehicle parc, so original equipment replacement components remain of great importance. To ensure diesel engines run as e ciently and reliably as possible, many rely on highly engineered and incredibly precise diesel injectors, served by equally hightech fuel pumps.

DENSO Aftermarket has introduced an additional seven common-rail injectors, as well as seven common-rail diesel fuel pumps, into its range. These 14 items cater for 114 applications, including the Mazda 2/3/CX-3, Mitsubishi L200 and Toyota Hilux. These additions can be found in the company’s E-catalogue catalog/pv and via TecDoc.


Snap-on says that when technicians update their diagnostic tools with the latest software release, they can be con dent that their diagnostic tool will perform smarter xes that lead to complete repairs and satis ed customers.

New coverage highlights include: 2022 model year updates for all available makes; expanded code scan and clear codes for the model year 2023; new 2022 models including BMW 2 Series Active Tourer, HR-V-EV (Electric), PSA C5X, Renault Zoe Ph2 and Vitara Hybrid; coverage highlights include 2021 and newer Hyundai Elantra, Santa Fe and Sonata front-view camera calibration; Mazda 2022 MX-30 functional tests and special functions for

the powertrain control module, instrument cluster and adaptive front lights; Ford 2021 and newer, over 35 new variants with added special functions including ADAS and many more.

Snap-on claim to be the rst to provide access to Nissan’s secured vehicles in Europe, direct from the scan tool. The 23.2 software bundle has also added Ford to their portfolio providing access to the vehicle right from the scan tool.

For speci c coverage and features by platform, refer to the vehicle coverage guide at

More features & enhancements are highlighted in this short video:

Motul Additives: Performance and Value Added for the Workshop and the End User. Trusted lubricant innovator, Motul has developed an extensive range of additive products for professional use – and now for consumer use as well.

Our wide range provides users e ective solutions for many technical issues, with the resultant improvement in overall performance and an accompanying service o er that brings added value for workshops and their customers.

Motul PROFESSIONAL Additive Range

For Motul Sales, Product information and Technical enquiries contact:

Enhance your additive service with Motul’s 2-in-1 and 3-in-1 Inject system for workshops

Trade enquiries: 01905 676819 I Club Motul: 01905 676818 I


Delphi Technologies introduces new bi-metallic, high-carbon alloy brake discs, delivering a 15% weight reduction compared to a single, fully cast-iron disc – helping to improve fuel e ciency and reduce vibration and noise.

The parts feature its new component coating, Magni, engineered to deliver superior corrosion protection from a single layer and is said to further enhance the appearance of the nondrilled, drilled and slotted discs sporting the coating.

Applications included in the initial launch have focused on some of the most popular BMW models. The range is planned to expand soon with applications currently in development for Toyota, Mercedes, Tesla, VAG, Jaguar Land Rover.

Workshop bene ts

By choosing these coated discs with many bene ts for their customers, the workshop can improve servicing upsells and increase average invoice values. The discs have no oil- lm; therefore, they do not require cleaning before installation, and they come with xing screws for a fast- t solution out of the box.

“We chose this coating for its ability to enhance corrosion protection while not compromising the other high performing aspects of these brake discs.” comments Laurence Batchelor, Delphi Technologies Global Chassis Lead. “This new range


immediately impresses upon tment and in the long term, as the driver experiences optimum safety and MPG bene ts at a time when managing vehicle costs has never been so important.”

In a corrosion stress-test, comparing a BMW OE coated disc vs a Delphi Technologies disc with the Magni coating, the Delphi Technologies disc far outperformed the OE disc; taking 240 hours to show evidence of corrosion compared to the 120 hours of the OE disc.

We focus on Business Support, Training, Tooling & Technical Data – all of which underpin success within a workshop, as well as our usual features. If you would like to contribute your news or views, email

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NEW CAR: Volvo EX90

Volvo reports that its all-electric, seven-seater EX90 marks the start of something new, yet all it wants to talk about is safety – so what has changed? Rob Marshall looks into the car's technical aspects to nd out.

In years past, we looked upon this Swedish legend as the very epitome of conservatism. Volvos were sensible, heavy, square and safe (just like their owners, which we would never dare to suggest). Yet, Ovlov realised it needed more than loyalty from the twin-set and pearls brigade to survive and past models heralded new directions for the company. The P1800, 480, 850 and the rst generation S80 and XC90 were genuine pivotal cars that ushered fresh ways of thinking and Volvo wants the EX90 to join this list of comparatively radical alumnae.

Yet, Volvo is not abandoning its core principle and is keen to highlight the model's safety credentials. This is not entirely surprising, because there is not much new to reveal about its running gear, which, according to several reports, has been unveiled already, powering the Polestar 3 SUV. With Volvo

aiming to become an all-electric brand by the end of the decade, we should view the EX90 as a replacement for the current XC90, which is still looking fresh after eight years.

Electrical power

Being bidirectional, like that tted to the Hyundai's Ioniq 5, the onboard 11kW charger not just facilitates charging but also discharging. Unfortunately, the EX90 takes almost 60 hours to charge fully from 'empty' with a 13-Amp plug. However, as shrewd EV owners appreciate that charging from home is

The EX90 SUV's blu front end highlights its all-electric prowess, as the brand powers forward with its aim to produce EVs solely by 2030 Organic LEDs (OLED) are the latest developments in rear lamp technology. As they require no re ectors, the lamp unit can be up to 90% smaller than traditional lament types, o ering designers exibility that Volvo has used to full e ect.

the least expensive way to 'refuel', as well as being kinder to the battery than fast charging, at least they can use the car as a giant power-pack to power their whole house. At least, that is the plan – Volvo has yet to con rm if this system will be available on UK cars. We shall nd out, when the rst examples hit our shores in September. More costly DC fast-charging cuts this time considerably, achieving a 20% to 80% state-of-charge in just over half an hour. The 111kWh battery, incidentally, provides a maximum 373 miles of range.

Perhaps understandably, Volvo does not reveal many details about the battery. All we know is that it is made by Contemporary Amperex Technology Ltd. (CATL), a Chinese company that is barely a decade old, yet is supplying almost most European and North American EV manufacturers. According to TIME magazine, the company has created more billionaires than either Google or Facebook, and is worth more than the Volkswagen Group. Like many EVs, the battery assembly is mounted to the oor pan's underside and incorporates the thermal management system. Being especially digital-tech heavy, the Volvo mobile phone 'app can be used by the owner to warm, or cool, the battery manually.

Volvo's rst large EV SUV is four-wheel-drive, with a single-drive motor mounted to each axle. The result is 408PS, or 770Nm of torque. If this is not enough, a performance version raises output to 517PS/910Nm and provides a 0-62mph dash of 4.7 seconds. The front motors between the two versions are the same, whereas the output of that tted to the rear axle rises from 163PS to 272PS for the higher-powered model. The rear motors also combine not just torque vectoring but can also be decoupled to reduce drag under overrun/coasting conditions to optimise valuable range. All new Volvos have their top speed pegged at 112mph and the EX90 is no exception.

Strength is power but intelligence is better

So, the new Volvo is powerful. It needs to be, for this 5m x 2m SUV weighs more than a current generation Range Rover 3.0-litre plug-in hybrid, tipping the scales at over 2.8 tonnes.

Naturally, its sheer bulk places it at a signi cant advantage in a collision. Yet, Volvo's ambitious safety vision of nobody being killed inside and around a new model has led to the company taking a particularly close interest in advancing existing ADAS technology. Incidentally, we understand that Volvo's rst Level 3 autonomous system, Ride Pilot, will appear in the EX90, although possibly not for the UK market.

The rst new ADAS system is driver monitoring, using two cameras that are positioned to the left and centre of the fascia, plus a capacitive steering wheel. These systems observe and sense not just the driver's posture but they also detect when attention is diverted from driving. An additional infrared sensor captures eye movements and evaluates blink and pupil dilution rates. The car can respond with a simple warning that is ampli ed, dependent on the situation's severity. Should the driver become unresponsive, the car will manoeuvre to a safe standstill and warn surrounding tra c with its hazard warning lamps. It will be interesting to see if such technology from a Chinese-owned manufacturer will be viewed by drivers as a positive safety feature, or an unreasonable intrusion.

Being one of the rst cars to feature daytime running lamps, the EX90 has full LED matrix units, as an update to Volvo's 'Thor Hammer' lamp styling cues.
Unlike Tesla, Volvo's giant 14.5-inch centre screen is portrait orientated. Volvo promises that the Snapdragon Cockpit platform from Qualcomm (which supplies Renault and Honda) provides lightning-fast computing power and high-quality graphics on the screen. While Google's Android Auto is standard, the system is also compatible with Apple CarPlay and boasts 5G connectivity.

The EX90 features the rst interior radar system on a production car, although this activates only when the car is locked. Designed to be sensitive enough to detect the tiniest movements, the intention is to prevent hypothermia, or heatstroke situations, when people and/or animals are left inside a locked vehicle, using sensors mounted on the cabin roof. Volvo says that the car will remain unlocked, should it detect movement inside the car. The climate control system may also not deactivate. Again, it remains to be seen if this system proves a genuine lifesaver, or an irritating inconvenience in the real world.

Unsurprisingly, the EX90 features the full suite of exterior ADAS hardware that you would expect, from ultrasonic (parking) sensors, to cameras, radar and LiDAR. The new close-tomedium range LiDAR is mounted on the roof and Volvo says it decreases severe accidents by up to 20%. The system is the fruit of a ve years-long collaboration between Volvo and the North American Luminar corporation, which states that the technology does not aim to replace human driving but enhances it.

Fitted to the EX90, the Lumiunar Iris LiDAR operates on the 1550 nanometre wavelength, with an Nvidia Orin processor providing the necessary computing power. The main advantages include higher resolution and superior processing power that allows the system to spot smaller objects faster than before. Volvo claims that the EX90's system can detect

pedestrians up to 1/4 of a mile away and can distinguish a tyre on a dark road that is 120 metres ahead. Naturally, this ADAS system is integrated with the other ECUs, including those that provide emergency backup for the steering and braking.

So, there you have it. A very safe, very big, very fast (if you ignore the top speed) and a very heavy Volvo. It is also not especially cheap, with prices starting at just under £96,000, although this appears to be a relative bargain, when compared with some of its competitors. The EX90 is available to pre-order now, with the rst deliveries expected in September.

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The 17 battery modules are mounted beneath the centre portion of the oor pan.
Luminar's Iris is tted to the new EX90, mounted to the roof outside the car.

Survey reveals that stress is the biggest issue for automotive workers

Automotive industry charity, Ben, has revealed results from its latest health and wellbeing survey, in which most automotive workers identi ed stress as the biggest issue they are struggling with.

Over 1,000 automotive employees took part in the survey from all UK regions, ages, gender and working environments. A total of 66% of respondents said stress had most a ected their health and wellbeing, followed by poor sleep and low mood, both at 62%.

The survey also revealed that the proportion of people su ering from stress in the workplace has increased by 8% year on year, with ‘high workloads’, ‘pressure to meet targets’ and ‘not enough sta ’ driving this. The survey also reveals that there has been an increase in people a ected by ‘poor work-life balance’ and ‘not taking enough time to rest and relax’.

The survey also revealed that poor sleep has increased from 49% to 62% – which perhaps isn’t surprising given the increase in stress levels of those surveyed. Around 92% of people also reported their cost-of-living had increased compared with a year ago and those struggling to make ends meet has increased by 10% to 28%. In addition, worryingly, 1 in 10 people said they have skipped meals in response to the rising cost of bills.

Respondents were also asked to highlight the issues most likely to impact them over the next 12 months. The top three issues mentioned were the cost-of-living crisis (52%), supply chain shortage e.g. chips – semiconductors (33%) and sta shortages

(31%). These issues are likely to be contributing to the stress levels of those working in the automotive industry.

The survey is in its sixth year, with the aim of uncovering the key health and wellbeing issues currently a ecting the automotive industry workforce so Ben can continue to provide relevant support now and in the future.

Rachel Clift, Health & Wellbeing Director at Ben, said: “With it being Stress Awareness Month, it is very timely that we’re sharing our latest survey results, especially as the ndings tell us that stress is presenting as a real area of concern for our automotive workforce. Through our annual surveys, we listen to our automotive family so we can fully understand the health & wellbeing issues they are facing, enabling us to provide the support they need.

“In addition to stress being the biggest issue, it’s clear to see that automotive workers are also under more pressure and aren’t taking enough time to rest and relax outside of work. There are also some worrying trends relating to the cost-ofliving crisis, such as skipping meals. In light of these results, we want everyone who works, or has worked, in the automotive industry to know that we’re there for them, so please get in touch if you’re struggling.

“We’re also here for employers too, so if you’re worried about stress in your workplace, please do reach out and connect, emailing to discuss how Ben can support your organisation and the health and wellbeing of your employees.”

If you’re feeling stressed and would like some tips and advice, visit



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NGK Spark Plugs (UK) Ltd


All successful companies evolve over time to meet the challenges of the future.

NGK Spark Plugs is no exception. But rest assured, we remain firmly committed to servicing the needs of the automotive aftermarket upon which our hard won reputation has been built. That’s why the NGK and NTK brand names will remain loud and proud on the products you have come to know and trust. But from April 2023, standing on the shoulders of those giants, will be the name Niterra. The new corporate face of NGK Spark Plugs worldwide.


Articles inside


pages 77-78

Survey reveals that stress is the biggest issue for automotive workers

page 76

NEW CAR: Volvo EX90

pages 72-75


pages 69-71


page 68

Parts, Tools & Tips

pages 66-68

Exhibitor news

pages 59-65

Workshop Training Hub schedule STand Q130

pages 49-58

What’s on guide

pages 46-48


pages 44-45


pages 39-43

Technicians taking to the road

page 38


pages 33-38

Human Resources 101 for workshops

pages 28-29

or who, is to blame?

pages 26-27


pages 25-26

New bearing designs enhance e-mobility

page 24

Keeping it Rolling febi Wheel Bearing Kits

page 23

Closed loop systems – A deeper look

page 22

KTS Diagnostics made ESI

pages 14-16, 18-21


pages 12-13

Bring it on!

pages 10-11


pages 8-9


page 7


page 6


page 5
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