The Garage - Friday 5th June 2015

New Blue 2 Post Ramp to increase lift capacity

Not much in the way of automotive maintenance today due to garage re-furbishment work. I have been away for the past week visiting family for half term, and I was most surprised to return and find an additional 2 poster in the Main Workshop.  Clever bit of space management!

After initially assisting Dave refit a front bumper and grill to a Jeep Cherokee, I was required to sit inside the vehicle to operate the throttle and bleed the cooling sytem - Due to the width of the vehicle, an access issue became apparant and a slim volunteer was therefore required!  With the Jeep satisfactorarily road tested it was then down to paint stripping, scraping, brushing and mopping in readiness for a new coat of paint.

Dan on the Mop

We were assisted by a favourable breeze which assisted with the floor drying process, and then it was down to a bit of trigonometry in marking out the bays ready to be painted.

Andy "Pythagoras"
Kirby at work

After confirming satisfactory alignment and tolerances, it was time to mark out the bays with masking tape.

Anyone for
Badminton?

With all three 2 Post Bays marked out it was time to bring out the roller and pole, and a tin of very red paint!  Extremely smart!

Bay 1 nearly done

You missed a bit Dan!

Professionally timed "Photo-bomb"
by Jim! Outstanding agility and
ability!

Bay 2 was almost complete when the big hand was on 12 and the little one was on 4, whereupon I was required to be elsewhere. Due to the imminent cessation of College Studies next Thursday (final exam), I will be putting in some additional hours at the garage as;

a. I would otherwise go off the boil and lose focus, and;

b. I enjoy being there!  Great crew and experiences forevermore - thanks guys,  See you all on Monday and Happy Friday!

The Garage - Friday 15th May 2015

1991 VW Transporter

Today I was assigned an electrical fault (lighting) task on a 1991 VW Transporter/Camper Van.  The vehicle has been at the garage for about 3 weeks, as the fault has proved very elusive to all who have attempted, and priority work loading has since prevented further progress.  This was my second attempt, as the first involved checking all the fuses and relays and the replacement of the left hand "Main Beam/Dip" column stalk, which was originally thought to be the cause of the fault.  There was originally evidence of a broken contact on the original component, however upon its re-assembly the fault of "no main beam/dip" remained.





Due to the level of work being undertaken inside, I was required to undertake the task outside in the bright and warm sunshine (ah well)! This also brought to the front of my mind the probable pining for the vehicle by the customer for the imminent Summer months, which spurred me on to solve the issue this time around!

Column Shroud
Removed

Having first removed the steering column shroud, I then 
proceeded to remove the horn switch to expose the steering wheel securing nut.  With the nut removed I was able to remove the steering wheel and expose the first of the 2 column stalks.  This was the component that was replaced last time around, and as far as any previous disassembly had gone.  Andy had instructed me to remove both stalks this time, and be particulalry vigilant in observing any broken or corroded wires and contacts in the process.

2nd Stalk exposed

Steering Wheel
Removed

Contact at 6 Oclock
originally damaged

Electrical Connector
Examined & Removed

It was at this stage I noticed that a connector on the 2nd stalk was only partially connected, which I duly noted on my Job Card for bringing to the attention of Andy at de-brief.  With all connections fully removed I was then able to remove the 2nd stalk, leaving the steering column stripped as far as the job required.

Partially engaged
connector

2nd Stalk Removed

Stripped Column

I then reported my findings to Andy who instructed me to re-assemble the components without attaching the steering wheel, ensuring all connectors were fully engaged, and then call him again to undertake another test of functions.

Happy Friday!
Which way to
Zone 2 please!

With all carefully completed Jim came out and observed a test of functions - which I am pleased to report was an outstanding success!!  With fault recorded as loose connector, it was then just a case of re-attaching the steering wheel with a high torque setting (ensuring that the road wheels were as straight as possible), and then reconnecting, inserting and testing the horn switch (which I did several times with a big smile)!  I was then requested to bring the vehicle to the front of the Workshop in order for it to undergo an MOT re-test and a subsequent front wheel allignment.  This was unfortunately the time that I was required to depart for my evening location, however it was a very satisfying and busy day which I enjoyed thoroughly!

The Garage - Friday 20th March 2015

Solar Eclipse as seen from Conwy

Today was a very special day at the garage, due largely to the number of natural phenomenon occurring.  We had a total Solar Eclipse, which also coincided with the Vernal Equinox and, from an astrological perspective, also saw the last of seven squares between Pluto and Uranus (which first began back in 2012 and usually mirror and reflect times of deep unrest and trouble).  Moments and events now finally passing!

Green Eclipse

Viewing the Eclipse
AA Automotive Style!

AA Automotive did not pass the moment by either, as we all momentarily paused and downed tools and kettles at 0930 hrs to observe the event using a Welders Helmet accordingly.  Absolutely "brilliant" does not cover it!  This is the first one I have had the privilege to witness directly and it shall never be forgotten.

Master Tech on
the Welder

With Celestial events fading is was back to work.  First job for me was an exhaust removal and replacement on a Ford Car Transporter (no images due to full engrossment with task to hand)!  I required considerable assistance as it was "stubborn" to say the least!  Two of the bolts required removal via use of an angle grinder, where I got to feel the sensation of singeing hair and overalls for the first time!  I did one bolt just for the experience, for which I am most appreciative.  Once the middle section was replaced it was over to Jim for a bit of welding on another section, prior to satisfactory job completion.

Fire & Rescue Team
Required for Extraction (lol)!

We had a brief break for lunch, as work load suddenly picked up just as we were settling into our deck chairs ready for another mission on Boom Beach.  I managed to get my tub of salad down first though!  In came a Smart Car with a disconnected windscreen wiper mechanism.  This is the first time I had seen a Smart Car up close and personal, and to be honest, looking at the working space available, it appeared to be the equivalent of working through a letter box!  With a new part finally connected, Andy Kirby was duly coated in Vaseline and inserted into the "car" in order to test the mechanism for serviceability.  It was at this point I saw a humorous opportunity for a photo which I duly attach accordingly!  Andy re-gained the situation by asking me to top up the washer bottle, at the point of which he activated the washers unexpectedly - very refreshing!!

My final experience of the day was the observation of the undertaking of an Oil Pressure Test.  No ordinary car was this either!  A 1963 Ford Zodiac, pride and joy of Graham the Body Repair Shop man.  This was a task I previously had only theoretical knowledge of, so it was great to see it undertaken in "real time".

Beauty!!

Oil Pressure Tester

The oil warning light had previously illuminated and the oil pressure was duly required to be checked accordingly.  I checked the engine oil level which was perfectly OK.  Graham then proceeded to remove the Oil Pressure sensor and then insert the correct size adapter, onto which then connects the pressure test hose and gauge.  I struggled to find any information regarding sensor specifications, however I did obtain a positive reading with a Multimeter set to Ohms.  Andy and Graham then had to depart on a mission and left me to monitor the pressure gauge accordingly.  There was initially approximately 50 PSI Pressure which gradually settled at

Tester connected to Sensor Point

25 PSI.  Graham later ascertained from a phone call to a specialist that there should be at least 10 PSI per 1000 RPM, so the reading at idle was satisfactory, and a faulty sensor or connection was probably at fault.  Providing the pressure raised when the throttle was applied, and settled accordingly within the parameters previously described, all was well - with much relief to Graham!



With the time at 1610 hrs it was then time to depart for my evening location.  A very enjoyable and magical day - Thanks guys! - Happy Ecliptical, Equinoxial and Seventh Squared Friday to you!!!!

The Garage - Friday 6th March 2015

Manufacturer's Data

Arrived at just gone 9am and was immediately directed to Ramp 3 (by-passing the kettle) to undertake a service on a Honda Jazz 1.4.  Job Card stated Oil, Filter, Spark Plugs and Air Filter and it was straight to work!  Dan and Dave were also fully engaged on Ramps 1 and 2 and there was a proper buzz of busyness and focus in the air!

Filter R&R

I started by raising the vehicle and dropping the oil which had already had a flush added and been pre-warmed.  With the oil drained, filter changed it was back in with the sump plug and re-lowered to refill with manufacturer's specified quantity and grade of engine oil.

I then began on the spark plugs.  Upon removing the engine top cover I was somewhat bemused as to how the engine had been previously running, as there were 3 COP connectors already disconnected.  I called over Jim who was also initially perplexed, but very quickly pointed out there were actually 2 COP per cylinder (a row at the back I hadn't yet seen)! Ahem, anyway the forward 4 were relatively easy to access and remove, however the rearward 4 required a bit of lateral thinking with regards to the use of a variety of socket extensions, due to the available bodywork clearance available.  I also had to remove a throttle cable securing bracket, a vacumn pipe and an injector connection rail to gain full unhindered access.

Forward COP Removed

Rearward COP Removed

It was then out with the old spark plugs and back in with the new.  Upon removal of the plugs and COP I ensured that they were logically laid out in order for their correct reinstatement.

COP

Old Spark Plugs Fore and Aft

Having reconnected all connections and brackets previously removed, I then removed the old air filter from its housing and replaced it with the new one provided.  With job done in the engine bay it was then a case of restarting the engine to check engine oil settlement levels, and re-raise the vehicle to ensure a good seal at the filter.  With the Master Tech satisfied of a job completed to standard, I then completed and submitted my Job Card and removed the vehicle from the ramp ready for the customers' collection.

There immediately followed a Fiat Grand Punto (for which I have no photographic evidence), which required the R&R of a Vacumn Pipe (Air Filter Box to Cam Cover), which was completed with relative ease upon the replacement's arrival.  The original hose had "structurally collapsed" and appeared to be causing oil seepage from around the head gasket area. However after a good application of engine de-greaser, a change of engine oil and spin-on filter, it was then left running on the ramp over lunch, after which all appeared serviceable. Lunch was spent on "Boom Beach with the Boomtastic Boys", along with a tub of salad from Tracey's Butty Van earlier in the day!

Happy Friday!!!!!
Phone Thing I Just Found!

After lunch I then got to use the kettle and then began a round of housekeeping.  Awesome day and very thoroughly enjoyed!!!

The Garage - Friday 27th February 2015

Pads Worn

Arrived at the Garage at 0915 hrs and started at the kettle!  Andy was away at the College adjudicating at the World Skills Competition, which we monitored through a live stream throughout the day on a Workshop PC (inbetween retrieving manufacturer's data from Autodata)!  Jim assigned me to a Vauxhall Corsa at 1000 hrs in order to assess front pads. Due to all ramps being fully loaded, it was therefore necessary to undertake the operation on the shop floor with a jack and axle stands.

Piston Drawn Back

Having removed both front road wheels it became apparent that the front brake pads did indeed need replacement, so it was straight on the the phone to Euro Car Parts to source the replacements.  I also got to use the new Job Card and logged my first "official" job (solo).  Whilst waiting for the parts I took the opportunity to clean up the caliper sliders and dress them with Copper Grease.  I also wire brushed the pad seats on the caliper Mounts and also the centre wheel hubs, and applied a liberal amount of grease to those also. The wheel studs were also in need of a clean up so I gave them a "once over" with the rotary wire brush (safety goggles and gloves on).

The new pads arrived at 1025 hrs and having compared them to those currently fitted, I then proceeded to change the pads accordingly.  The job went smoothly and was only briefly suspended by the arrival of Tracey in the "Butty Van"!  One Bacon Roll later it was straight back to work, and the job was satisfactorily signed off as complete at 1100 hrs.

Happy Friday!!!
Thanks Dave!

I was then requested to attend to a bit of house keeping, which I gladly undertook, as the team were fully engaged with other ongoing tasks.  We broke for lunch at 1 pm, and then resumed at 2pm.  I left at 3.30pm (which is early for me), as I found I had attracted more garage debris to my external features than usual, and needed to have a wash up before attending work later!  Great day again and many thanks for the friendship and continued opportunities and experiences.

The Garage - Friday 30th January 2015

NSF Drop Link
for R&R

Work throughput status: "High"; Work for me to do status: "Plenty"; Friday Feeling status: "Happy"!

It was very much a case of "straight to work" assisting Dan with a VW Passat.  Dan was servicing OSR & NSR Discs and Pads and I was invited to assist, attending to OSF & NSF Drop Links and NSF CV Gaiter. Working alongside Dan is always a pleasure, as he is very task focussed, rather than chatter (more akin myself), and we had the total job calmly boxed off and back on 4 wheels, in about an hour and a half (considering off and on other minor assignments also)!   

Hub Nut Removed
and top bolts prepared
for Removal

With clear access to the CV Gaiter it was time to clean up and then locate the damage site, which was not easy to see at first glance.  As I intimated to Dave in a text later that evening;  I have learned "loads" since working with the team at AA Automotive, however today I learned something else; and that is: "NEVER" shout across the workshop "Jim! I've found the hole"!  Just one of those "immediate hindsight" moments! (LOL)!

Split CV Gaiter

Ahem! Anyway, having regained my composure I managed to R&R all components satisfactorily, prior to re-torquing all to Autodata specification.



There then followed a period of general housekeeping for about 30-40 minutes, and then, with all returned to a tidy and presentable order, it was time for lunch.

Testing Relay using Jump Pack
across terminals 86 & 87

After lunch we then had a Vauxhall Corsa in with a potentially catastrophic failure, caused by the owner attempting to jump the battery with 24 Volts! Remarkably the wiring loom appeared intact, and I initially observed as Dan probed all the fuses for continuity, using a multimeter. These also all proved OK, and then using Autodata, we both checked the operation of all the Relays for proper functioning.  Andy and Dave then departed with a handful of tools on a mission to "Jacksons", for a spare Control Module and a replacement Relay.  Upon their return, and further elevated inspection, it became apparent that the Starter Motor was "singed", to say the least, and possibly the Alternator also, although this was unfortunately the point where I was required to bail out for my evening job, and I very much look forward to an update from Dan and Dave next Thursday.  Thanks again for a "very" humorous and fruitful day guys!

The Garage - Friday 23rd January 2015

Work throughput remains "high" at AA Automotive, who appear to have bucked an otherwise "slow start" trend to the year (according to information gathered from other local automotive service providers), and long may it continue.  I started the day with the obligatory round of brews, and then started on finishing the cleaning of the inside of the Porsche Bell Housing from last Friday.  Andy Kirby then came through to the back and requested if I could remove and refit 2 new tyres for a Vauxhall Zafira.  Dan was engrossed with a Gearbox removal from a motor home, and Dave was engaged with the sorting of a Saab boot lock, so I was only too happy to muck in and bridge a gap.

OSF Drop Link
Refitted

Having retrieved the relevant vehicle information from Autodata, regarding pressures and torques, I then set about the removal, replacement and re-balancing accordingly, which went very well indeed.  I cleaned up the hubs with a wire brush, applied a light coat of low fling lubricant and then re-fitted the NSF wheel and tyre. Andy had removed a drop link on the OSF so I was instructed to hold fire on that side.  At this point Andy was required elsewhere and then left me with instructions for the careful refitting of the drop link OSF (due to the close proximity of currently rotating pulleys).  Once fitted I was then able to re-attach the OSF road wheel, and then lower the beam jack, in order to torque both road wheels to manufacturer's specification.

New Oil Filter
Installed

I was then informed that a Minor Service was also required.  Having lowered the ramp, in order to switch off the ignition, I then re-raised the vehicle and then gathered a floor post with suitable container, and all the other required tools, before dropping the (HOT) engine oil accordingly.  With the oil drained and Sump Plug (& washer) replaced, I then removed and replaced the Spin-On Oil Filter already provided.  At the point of the Oil Filter removal, I made a point of notifying Andy that there was considerable evidence of oil leakage from the old filter, which had "clearly" not been replaced for some time.  Prior to replacement therefore, I applied copious amounts of engine de-greaser to the underside of the engine and surrounding areas, in order to to ensure a good finish to the job.

I was also required to improvise a repair to a  rear-end exhaust shroud, which had become completely detached, due to "rotting" around its' securing bolts.  Notwithstanding liberal application of rust penertrator and brushing, two of the remaining five viable securing bolts sheared upon their tentative removal. Thankfully there is a very large tub of spare nuts, bolts and washers held within the Workshop, within which I managed to source 3 suitably over-sized washers to re-pin the shroud to a satisfactory standard.  Satisfied so far, I then lowered the vehicle in order to refill with the Manufacturer's specified grade and quantity of engine oil, and then also removed and replaced the Air Filter accordingly.

Re-filling Engine
Oil

With the fresh oil in and level checked, I then conducted a start in order to allow the oil level to re-settle accordingly.  I then switched off the engine and re-checked accordingly (including beneath for any leakage) - of which there was none currently apparent.  I then topped up to 5.5 litres and moved swiftly on to the Air Filter, which went without a hitch. I then de-greased and cleaned off the engine top cover to ensure a "job done" finish (or so I thought)!

Air Filter
Replacement

Andy duly removed the vehicle from the ramp and on came another motor home for a service.  By this time it was round about 1545 hours (30 minutes to go for myself) and all I had to do was drop the engine oil and re-seal realistically.  Before I had chance to find the correct size tool to remove the sump plug, I was asked by Jim if I recalled removing the washer from the old Oil Filter on the Zafira, as it was leaking oil!  (Shoot)!  I did however, remain confident that I had done all correctly and professionally, as is required, and duly attended Ramp 1, where the vehicle had been re-raised for inspection (now with customer waiting)! The filter I had previously just installed was re-removed and duly re-inspected accordingly.

After confirming all appeared "OK", I was asked to sit in the vehicle while it was raised higher, in order to re-run the engine upon re-fitment, which did "thankfully" prove to be OK. It was subsequently suggested that the level of contamination from the previous leakage (despite my best-est cleaning efforts), was probably the cause, as upon re-fitment all was indeed well, and was gracefully informed - "it could have happened to anyone" (Big inner sigh of relief)!  With vehicle lowered I was then requested to reverse the vehicle to the entrance of the workshop in readiness for the customers' retrieval, upon his payment for services professionally rendered of course!

Wallet - "check", Mobile Phone - "check", E-Cig, fluid & Charger - "check", Specs & Case - "check", TNT Woolly Hat "check", off to work I went, departing at 1615 hrs, and still with a very Happy Friday feeling indeed! Thanks guys - brilliant blur of another day at AA Automotive!

The Garage - Friday 16th January 2015 - Porsche 911 Restoration Task

Porcshe 911
Restoration Task

I had an absolutely fantastic day at AA Automotive today - happy as a pig in the proverbial doo-doo I was!  Andy Kirby was away on a well deserved holiday so it was all hands to the pumps.  I started with the usual moral sustaining activity and then proceeded to attend to a bit of housekeeping, which also resulted in the workshop sink being returned to its' pristine chrome appearance.  Jim, the Master Tech, returned from a mission just as I was finishing off, and promptly introduced me to the engine and transmission of a Porsche 911, which had been removed from its carcass on Ramp 1, and was now on a pallet at the rear of the workshop waiting to be separated, and then the clutch removed ready for a replacement.  This was virgin territory for me yet again and the opportunity was readily accepted and seized accordingly.  This was a paying customer's restoration project car, so no time was to be wasted.  Dan was doing measurements for a few of the vehicle panel replacements, and then later even doing some Mig Welding, which was "fantastic" to see (well done Dan), and Dave was flat out doing servicing on a couple of diesel fleet vehicles (well done also) - Teamwork in motion!

Releasing Clutch
Release Mechanism

At the point of my introduction, the 4 bell housing bolts had already been removed, but the transmission unit was refusing to separate from the engine.  After checking YouTube and Google for any hints without success, I had to call in Jim for some guidance.  After an explanation of the clutch operation being the reverse to the conventional method, ie, pull as opposed to push, it became clear that the clutch release mechanism needed to be removed in order to allow the internal fork to be able to swing free of the release bearing within - thus allowing the separation to occur.  With copious amounts of rust penertrator applied, removal of a bottom circlip, and a couple of well aimed firm blows of a copper and hide persuasion device with flat punch, the mechanism came nicely off.  The transmission and the engine were then separated - which was a very nice feeling!

Old and new units
compared

Evidence of
leaking rear Crankshaft
Seal

Things from hereon in became a lot more familiar, as now the dog could see the rabbit so to speak.  After a closer look at what I was seeing, I could see that the "ring gear" of the fly wheel was in fact a separate component, and wasn't actually "part of the flywheel" as such.  I duly removed the bolts securing the pressure plate to the flywheel, and then removed the bolts securing the ring gear to the assembly already removed - clever engineering and completely new to me!  It was at this point a familiar face from Coleg Cambria arrived at the Garage (Karl Andrews) who was invaluable in my further guided assistance, especially considering the current Garage workload!  He suggested further removal of the flywheel in order to inspect for oil leakage from behind, which proved to be sound advice indeed!

Cleaning and leveling
surface of Flywheel

Serviceable
Flywheel ready for
Re-installation

I then set about cleaning up the flywheel (front & rear), first with a course sandpaper and then with a finer one, interspersed with liberal applications of brake cleaner.  The result was very satisfying indeed!  With both a hard and a soft wire brush with brake cleaner, I then addressed the face of the transmission behind the flywheel, which produced the same satisfying results.

Cleaned face of
Transmission

Seal drilled & Screws
Inserted

At this point it was time for the removal of the leaking Rear Crankshaft Oil Seal, of which I had "No" idea how to do.  Karl explained it was basically an "interference fit", which translated as - it needs pulling out!  After repeated attempts with various picks, it was finally suggested that the seal needed to be drilled "very carefully" with a fine drill bit, and then screws inserted - onto which the universal tool of "mole grips" could then be attached and then priesed out accordingly.  This did eventually work with considerable patience, and with the additional leverage of a suitably sized flat head screw driver applied at the correct place and angle!  Happy days and thank you Karl - much learned indeed!

"Out you Come"

Thanks Karl!

As can be seen from image left, there was immediately evidence of emulsification, and as this engine is air cooled (as reminded by Dave), the contamination can only be caused by fuel ingestion into the oil itself (Cylinder Head(s) and/or Piston Rings)?...... to be eagerly resumed at a later date!







With the big hand of the clock at number 3 and the little hand at 4, it was time to bail out for work "rapid style" and off I went with a "Very" Happy Friday feeling indeed!

At work 20 Minutes
Later!