fiˇ˘ˆ ˇ - automotive data | repair guides | shop solutions · pdf file• peterbilt...

One source for aftermarket info

PRODUCT CATALOG

In the format you need

solutionsInformatIon

that power business resultsMOTOR Information Systems is the leader in aftermarket information

solutions for vehicles. Founded in 1903, MOTOR products include targeted,

timely and accurate data to help its customers achieve their business

goals. Visit www.MOTOR.com.

www.motor.com

1.800.4A.MOTOR

Mechanical Repair

labor guiDe Manual

coverage: Multi-year coverage for domestic & imported cars, light trucks, vans & SUVs

contentS: • Labor times based on the original labor time database

by the Chilton Company• Divider tabs make finding the right data quick & easy• Detailed alphabetical labor operations index• Labor operations unique to the aftermarket

MeDiuM, heavy truck & van labor online

coverage: Multi-year coverage for domestic & imported medium & heavy duty trucks

contentS: • This module contains the mechanical labor times for

trucks, engines, trailers& transmission manufacturers. • Labor times may be searched stand-alone or correlated

to the Parts Catalog (MMY) search, creating a PARTS & LABOR look-up.

truck & van labor tiMe guiDe

coverage: Multi-year coverage for domestic & imported medium, light trucks, vans & heavy duty trucks

contentS: • Includes medium & heavy duty truck component

manufacturers• Labor times grouped by industry SYS code• Detailed labor operation alphabetical index

partS & labor electronic eStiMating


contentS: • Mechanical labor times, OE part numbers & prices in an

electronic format• Networkable• Searchable by category or system operation• Special table to enter supply costs, disposal charges &

canned jobs• Two tax rate percentages• Three labor rates• Printable custom greeting/message on the estimate• Authorization statement or disclaimer unique to your

business

4

www.motor.com

1.800.4A.MOTOR

Collision Repair

craSh eStiMating Data on DvD

DoMeStic craSh Data* & iMport craSh Data*

each DvD containS:• Crash Parts and Labor data• Black Book retail used car price information• Replacement assemblies time guide data• Guide to estimating• Illustrations – exploded component views

* DVDs are available individually or as a set. DVDs can be purchased as a yearly subscription (quarterly updates) or as individual DVDs.

craSh eStiMating Data online


contentS:• Crash Parts and Labor data• Black Book retail used car price information• Replacement assemblies time guide data• Guide to estimating• Illustrations – exploded component views

e-fraMe


• Precise frame & unibody measurement data on CD

• Capability to enter and retrieve customer information

• Universal symbols to locate measuring points quickly

• Fast access to data with clear, sharp images

• Zoom in function & capability to print exactly what you see on the monitor

contentS:

alSo available:

Crash Estimating Training Guide

5

www.motor.com

1.800.4A.MOTOR

Car/Truck Repair

Auto Repair Manuals: Vol 1&2

Light Truck & Van Repair Manuals: Vol 1&2

light truck & van repair Manual

voluMe 1: Mechanical repair

voluMe 2: abS/electrical

• Air conditioning maintenance• Cooling fans diagnosis & repair• Disc & drum brake service• Drive axle service• Electrical components R&R• Engine rebuilding specifications• Hydraulic brake system service & repair• Mechanical engine repair

• Power steering diagnosis & repair• Specification data• Starter & alternator diagnosis & repair• Steering column R&R• Suspension & steering components R&R• Tightening specifications• Tire pressure monitoring system • Wheel alignment

• Active suspension system• Anti-lock brake component locations• Anti-lock brake diagnosis & testing• Dash gauges diagnosis & testing• Dash panel service

• Passive restraint component locations• Speed control component replacement• Speed control diagnosis & testing• Warning lights diagnosis & testing • Wiper system diagnosis & testing

auto repair Manual

voluMe 1: Mechanical repair


• Air conditioning maintenance• Cooling fans diagnosis & repair• Disc & drum brake service• Drive axle service• Electrical components R&R• Engine rebuilding specifications• Hydraulic brake system service & repair• Machine shop specifications• Mechanical engine repair

• Power brake units• Power steering diagnosis & repair• Specification data• Starter & alternator diagnosis & repair• Steering column R&R• Suspension & steering components R&R• Tightening specifications• Tire pressure monitoring system • Wheel alignment

• Active suspension system• Air bag systems• Anti-lock brake component locations• Anti-lock brake diagnosis & testing• Dash gauges diagnosis & testing• Dash panel service

• Passive restraint component locations• Speed control component replacement• Speed control diagnosis & testing• Warning lights diagnosis & testing• Wiper system diagnosis & testing

6

www.motor.com

1.800.4A.MOTOR

Car/Truck Repair

Imported Car Repair Manuals: Vol 1&2

iMporteD car repair Manual

voluMe 1: Mechanical repair• Air conditioning maintenance• Cooling fans diagnosis & repair• Disc & drum brake service• Drive axle service• Electrical components R&R• Engine rebuilding specifications• Hydraulic brake system service & repair• Mechanical engine repair• Power steering diagnosis & repair

• Specification data• Starter & alternator diagnosis & repair• Steering column R&R• Suspension & steering components R&R• Tightening specifications• Tire pressure monitoring system • Wheel alignment


• Active suspension system• Anti-lock brake component locations• Anti-lock brake diagnosis & testing• Dash gauges diagnosis & testing• Dash panel service• Passive restraint component locations

• Speed control component replacement• Speed control diagnosis & testing• Warning lights diagnosis & testing• Wiper system diagnosis & testing

engine perforMance & Driveability online

coverage: Multi-year coverage for imported cars, light trucks, vans & SUVs

• Code accessing procedures• Computerized engine controls• Component locations• Drive cycles• Diagnostic flow charts• Emission application charts• Fuel system diagnosis & service

• Ignition system diagnosis & repair• Sensor & tune-up specifications• Service reminder & warning lamp reset• Technical service bulletins• Vacuum hose routings• Wiring diagrams

contentS:

7

www.motor.com

1.800.4A.MOTOR

www.motor.com

1.800.4A.MOTOR

eMiSSion control vacuuM hoSe routing & coMponent location Manual

coverage: Multi-year coverage for domestic & imported cars, light trucks, vans, SUVs, medium & heavy duty trucks

• Component locations• EGR diagnostic charts

• EGR functional tests• Vacuum hose routings

contentS:

obDii Drive cycleS


contentS: • Drive cycle procedures• EPA highway & urban procedures where OE

does not publish data• Keyless ignition procedures

• OBDII overview• Known readiness & communications issues • Notes & tips

Emissions

eMiSSion control SySteMS application

coverage: Multi-year coverage for domestic & imported cars, light trucks, vans, SUVs, medium & heavy duty trucks

contentS: • Accessing & clearing trouble codes • Charcoal canister locations • Data link connector & locations • EGR functional test procedures • Emission system application charts • Federal & state air quality standards • Ignition timing adjustment connector

& specifications

• Lamp reset procedures• List of vehicles that cannot be tested on

a dynamometer• Listing whether a vehicle is FWD, RWD, 4WD

or AWD• MIL information• Service reminders• Visual inspection procedures

9

www.motor.com

1.800.4A.MOTOR

Medium/Heavy Trucks

Heavy Truck Repair Manuals: Vol 1&2

Heavy Truck Wiring Diagram Manuals: Vol 1&2

heavy truck Wiring DiagraM Manual

coverage: Multi-year coverage for medium & heavy duty trucks

• Autocar• Caterpillar• Chevrolet/GMC• Cummins• Detroit Diesel• Ford• Freightliner

• Hino• International• Isuzu• Kenworth• Mack• Mercedes-Benz• Mitsubishi-Fuso

• Nissan/UD• Peterbilt• Scania• Sterling• Volvo• Western Star

contentS:

heavy truck repair Manual

coverage: Multi-year coverage for medium & heavy duty trucks and components

vol. 1 chaSSiS repair• Air bags• Air conditioning, cooling,

electrical & exhaust• Brakes• Chassis, engine & electrical• Gasoline & diesel engines• Steering & suspension• Specification data

vol. 2 tranSMiSSion & aXle repair• Clutches & transfer cases• Drive axles• Fifth wheels• Transmissions

1987-2010

heavy truck DiagnoStic trouble coDeS

coverage: Multi-year coverage for medium & heavy trucks

contentS: • All codes for all commercial trucks• Description of sensors, their locations and how

they operate

MeDiuM & heavy truck engine perforMance & Driveability Manual

coverage: Multi-year coverage for engine performance & wiring information

contentS: • Component locations• Emission application charts• Emissions control system

& repair• Fuel system diagnosis & repair

• Injection pumps• Specification data• Technical service bulletins• Vacuum hose routings

10

www.motor.com

1.800.4A.MOTOR

heavy truck repair Manual


When parts cross-references are required, people in the industry turn to FleetCross. From service locations to parts retailers and distributors to fleets and fleet management companies, FleetCross covers all facets of the truck industry. With hundreds of millions of original equipment and aftermarket part number crosses, FleetCross, by far, leads the industry in available cross reference parts information. The “All-makes” data is:

• available 24/7, providing the latest information when and where it’s needed • a complete system offering manufacturer catalogs in support of the cross references that contain

manufacturer’s images, including off-highway and industrial equipment information• an intuitive system with advanced design that offers quick and thorough search results

From aftermarket part numbers to illustrations, the system offers users a variety of selections to locate the parts information they need. Some of the options include:

• Partial part number search• Manufacturer web site integrations• Tear away and duplicate tab technology• Advanced application installation, depending on environment• Web training and support with on site training availableVisit www.motor.com for more information.

ALL-mAkesFleetCross

• Air bags• Air conditioning• Brakes• Computerized engine control

system diagnosis• Drive axles & transmissions• Emissions• Engine & chassis• Engine electrical

• Maintenance• Mechanical repair procedures• Performance... including trouble codes &

flow charts• Specifications• Steering & suspension• Technical service bulletins• Wiring diagrams

contentS:

heavy truck Service DvD or online


Medium/Heavy Trucks

Users search by > part number > manufacturer’s name > make-model-year

11

www.motor.com

1.800.4A.MOTOR

Specification guiDe


contentS: • A/C data• Ball joint specifications• Brake bleed procedures• Brake specification data• Cylinder head & torques• Engine tightening specifications• Fluid capacities & cooling system data• Front drive axle & wheel lug nut

tightening specifications• Lubricant data• Sensor specifications• Serpentine drive belt routing• Service reminder lamp reset• Tire inflation pressure data• Tune-up data• Valve timing marks• Wheel alignment data

alSo available:

Specifications/Quick Reference

heavy truckSpecification guiDe

coverage: Multi-year coverage for domestic & imported medium & heavy duty trucks

contentS: • Brake data, sensor specificiations & wheel

alignment data• Cylinder head & engine tightening

specifications• Fluid capacities• Lubricant requirements• OE scheduled maintenance• Powertrain diagnostic trouble codes• Service reminder lamp reset procedures• Tune-up specifications• Valve timing marks

Vintage Specification Guide

Wheel alignMent SpecificationS


contentS: • Adjustment procedures• Ball joint testing• Vehicle ride height tables

brake SpecificationS guiDe anD brake bleeD proceDureS


contentS: • Brake bleed sequence procedures• Brake rotor, drum machining & service• Caliper mounting torque• Minimum lining thickness• Rotor parallelism, runout, thickness &

microfinish• Wheel bearing adjustment procedures• Wheel nut & bolt torque

12

www.motor.com

1.800.4A.MOTOR

Specifications/Quick Reference

quick lubrication guiDe


contentS: • Chassis lubrication data• Cooling system capacities & bleed

procedures• Engine lubrication data • Resetting oil service indicators• Vehicle lift points

lubrication recoMMenDationS guiDe

coverage: Multi-year coverage for domestic & imported cars, light trucks, vans, SUVs, medium & heavy duty trucks, tractors & small engines

contentS: • Fluid capacities• Lubricant type• Transmissions, transaxles &

differentials

tranSMiSSion fluiD Service guiDe


contentS: • Lubrication & fluid specifications• Fluid inspection procedures for

transmissions that do not have a dipstick

• Custom transmission illustrations• Transmission gasket illustrations• Injection pumps• Service intervals

farM tractorlubrication guiDe

coverage: Multi-year coverage of farm tractor, medium & heavy duty trucks & other farm equipment

contentS: • Crawler tractors• Lubrication & fluid specifications• Lubrication service points• Self-propelled farm implements• Skid steer loaders

chek-lube


contentS: • Engine component locations• Fluid capacities & lubricant type• Part numbers for over 30

brands of aftermarket filters• Severe service maintenance intervals• Tire size & specifications• Transmission, differentials &

transfer case fluid capacities & type• Vehicle lift points

13

www.motor.com

1.800.4A.MOTOR

Specialty Repair

air bag quick reference guiDe


contentS: • Arming & disarming procedures• Collision inspection• Component location & service• Component replacement after deployment

technical Service bulletinS online


contentS: • Subscription provides access to over 100,000 TSBs at your fingertips, with the ability to

quickly search for the one you need

tiMing belt anD chain replaceMent guiDe


• Accessory drive belt tension• Free-wheeling or interference fit

engine chart• OE scheduled recommendations

• Step-by-step replacement procedures• Timing belt inspection fit procedures• Timing belt labor time

contentS:

14

www.motor.com

1.800.4A.MOTOR

Specialty Repair

hybriD Maintenance guiDe


contentS: • Cooling system service• ECM/PCM programming• Fuel system cleaning• Starting information

tire preSSure Monitoring guiDe


interior panel reMoval guiDe


• Component locations• Component replacement• Description & operation• Diagnosis & testing

• Reset & re-learn procedures• Tire fitment data• Tire service procedures• Wiring diagrams

contentS:

• Replacement procedure panels, instrument panels & floor consoles

• Exploded views showing hidden fastener locations

• Door handles• Door lock cylinders• Illustrations showing the type of fasteners• Air bag system precautions

contentS:

15

www.motor.com

1.800.4A.MOTOR

Specialty Repair

vin guiDe


contentS: • Decoding of the first eleven VIN code positions

Sectioning guiDe

coverage:2006 – 2011 Domestic and Imported Cars and Light Trucks

contentS:• OEM-Authentic Sectioning Procedures and Illustrations outlines the process in

which a sectioned component is required to be removed and replaced.• Air Bag Precautions allows user to disarm and arm air bag system as required to

complete a safe sectioning procedure as required.• Hybrid Battery Service Precautions allows the user to disarm and arm the hybrid

battery system as required to complete a safe sectioning procedure as required.• General Sectioning and Special Substrate Data allows the user to understand the

different metals used by OEM’s in their vehicle builds and how they interact with each other.

air conDitioner & heater online

coverage:Multi-year coverage for domestic & imported cars, light trucks, vans & SUVs

contentS:• Complete air conditioner, cooling system and heater diagnostics, repair procedures

and specifications

16

www.motor.com

1.800.4A.MOTOR

Wiring Diagrams/Component Locations

Wiring DiagraMS online


contentS: • Over 2.5 million wiring diagrms• OE-drawn wiring diagrams searchable by system or component• Easy-to-use vehicle selection by year, make, model and engine

coMponent location online

coverage:

Multi-year coverage for domestic & imported cars, light trucks, vans & SUVs

contentS: • Nearly 2 million component locations• Easy-to-use vehicle selection by Year, Make, Model and Engine • Component locations searchable by system or component• Component images & textual locations

air conDitioner & heater online

coverage:Multi-year coverage for domestic & imported cars, light trucks, vans & SUVs

contentS:• Complete air conditioner, cooling system and heater diagnostics, repair procedures

and specifications

17

www.motor.com

1.800.4A.MOTOR

Shop Management

Motor Shop DirectortM letS you:• Improve shop productivity • Increase production output • Enhance profits • Maximize resources • Eliminate financial waste

With the click of a MouSe you can:• Write work orders• Manage your inventory • Network• Maintain service histories • Export accounting data to Quicken, QuickBooks, Pro, Peachtree• Interface with MOTOR™/Alldata®, Alldata, MOTOR Electronic Estimating, Quick Quote, Real Time, WorldPac, Wrenchead Catalog, and Mighty Auto Parts!

• PLUS MOTOR Parts & Labor Guide

* our upcoMing preMiuM eDition aDDS:• Internet Auto Parts (IAP) integration that will enable

importing from O’Reilly, AutoValue, Bumper to Bumper, Car Quest, and many more.

• NAPA ProLink integration

• Activant part integration

Shop operationS• Customer Search - By name, phone, plate, VIN, make, fleet number • •

• Drag & drop scheduling and appointment system • •

• Service history/recommendations • •

• Four labor rates • •

• Bar code reader & mechanical cash drawer ready • •

• Up to 9800 standard tasks with labor, parts, comments & menu pricing • •

• Integrates with: MOTORTM/ALLDATA®, Alldata, MOTOR E-Estimating • •

• Surcharges/Standard surcharges, automatic shop supplies charge • •

• Direct editing of parts & labor from work order view • •

• Split labor capability for multiple technicians working on one job • •

• On-the-fly editing of customer, vehicle and part information • •

• Reminder message- service recommendations and account balance • •

• Automatically create standard tasks (canned jobs) • •

• Target profit indicator- Graphic indicator shows work order profitability • •

• Work order print preview- Standard layout • •

• Security system with 16 different security rights per user •

• Automated time sheet system •

• Ten level parts matrix pricing •

• Modem based auto dialer •

• Spell check with user definable customer dictionary •

• Auto Text System- Automatically enter a sentence using three letters •

• Vehicle specific standard tasks •

management/marketing• Over 30 management reports • •

• Technician productivity analysis by job • •

• Compatible with Microsoft Office products • •

• Work order customization • •

• Over 100 customizable options • •

• Automatic export to Customer Link • •

• Upgradable to multi-user network • •

• MOTOR marketing module •

• Inventory management system •

• Parts catalog integration with Wrenchhead, WorldPac & Mighty •

• Archive utility to transfer 300 work orders to archives •

financial management• Profit analysis by type of service, work order, service writer & technician • •

• Track marketing sources for each customer • •

• Un-post/Re-post utility to correct closed work order information • •

• Export accounting data to Quicken, Quick books & Peachtree •

•

• A/R billing terms, aging, interest charging & payment Allocation •

• Viewabl management Reports •

• Warranty system with receivable billing •

gS pro

* eDitionfeature

take control of your ShopWith Motor Shop Director™

18

www.motor.com

1.800.4A.MOTOR

Shop Management

Starter Service Writing SoftWarethe perfect Solution for SMall ShopS

• Seamless integration with MOTOR’s e-EstimatingTM

• Import MOTORTM/ALLDATA® estimates & convert to work orders

• Great starter software for small shops

• Basic work order, customer invoice & service history shop management program

• Quick Books interface available

• Financial reports

• Seamless upgrade to Shop Director™

eZ-Writer featureS:

Marketing iS eaSy With Motor Shop Director™ Marketing

• By type• Using structured query language• By vehicle type or options

• Labels• E-mail notification• Printed reports

• Postcards• Data files

chooSe your cuStoMerS:

• By zip code• Needing specific type of service• Last time they were in for service

SenD Maintenance reMinDerS & proMotional offerS by generating:

• TechLink automated time sheet system: record time at the task level for complete profit analysis

• Technician productivity analysis

• Vehicle search by plate, VIN, make & fleet number

• Transfer vehicles from one customer to another

aDDitional featureS:

• Over 100 custom options to tailor Shop Director to your needs

• Drag & drop scheduling & appointment system

• Built in accounts receivable billing

• Toll–free technical support help line (1 year included with all updates)

Ten-level Matrix Pricing: Automatically apply different margins

based on part cost! Here you see a part cost of $6.50 selling for

$19.70; a 67% margin and 203% mark-up.

19

www.motor.com

1.800.4A.MOTOR

Magazine

conSiStent circulation quality• #1 circulated magazine among all service & repair

magazines

• #1 in total units delivered among all audited service & repair magazines

• #1 in first-year qualified circulation among all service & repair magazines

conSiStent eDitorial quality• #1 in average individual readership time per issue at

1 hour, 24 minutes

• 90% of MOTOR Magazine recipients read MOTOR on a regular basis

• Winner of numerous journalism and automotive media awards

• Jesse H. Neal Award (2010-2009, Finalist 2011)

• International Automotive Media Award (1999-2011)

• APEX Awards for Publication Excellence (2001-2009)

• TABBIE Awards (2006-2011)

• Azbee Excellence Award (2007-2010)

• 1.7 years: Average length of issue retention

• 18.5 years: Average subscriber to MOTOR

your #1 Source for autoMotive afterMarket inforMation

20

www.motor.com

1.800.4A.MOTOR

Magazine

inDuStry leaDingcontent

DanMarinucci

[email protected]

Foreign Service

14 March 2012

Sometimes we solve customers’ prob-lems with a good memory, carefulvisual inspection and old-fashionedluck. Other times the jobs we tacklerequire nearly every diagnostic tool,tester and instrument we own.

This month’s saga reminds us that an accu-rate vehicle history may be the single mostvaluable tool at our disposal. What’s more, wemay have to pry this information out of the cus-tomer. Finally, critical clues about vehicle histo-ry may be right under our noses but we over-look them and the fact that they beg answersfrom the car owner.

This story concerns a first-rate shop I’ll call“Pauly’s Garage” for the purposes of this col-umn. A customer brought in a 2006 ToyotaCorolla, claiming that its brakes were lockingup. He said his wife drove the car most of thetime and the symptom occurred during herroutine commute to work. He also said hesmelled burning friction material.

Pauly verified the lady’s daily commute, thenone of his techs drove the Corolla over thatroute again and again. Initially, no symptoms ap-

peared. Then thetech put the car on alift and visually in-spected the brakes.He found some rela-tively new-lookingbrake parts, and thebrake fluid lookedand smelled new.There weren’t anyobvious signs ofsticking or draggingcalipers and hecouldn’t find anykinked or crimpedbrake lines.

Hindsight, theysay, is always 20-20.Here, the customer’scomment about a

burnt-brake odor could have been the first redflag about relevant vehicle history. How manynontechnicians can identify the smell of over-heated friction material? The second red flagcould have been the new brake parts. Who in-stalled these parts? When and why?

Meanwhile, Pauly couldn’t locate any servicebulletins for the Corolla’s symptoms and a tech-nical hotline service didn’t have any specific fixesfor it, either. Next, his tech tried recreating thesymptom by “driving” the car on the lift and re-peatedly applying the brakes. That approachfailed, so he retraced the driving route—but thistime with many more brake applications alongthe way. Finally, he smelled overheated frictionmaterial and another symptom appeared. Thefront wheels began dragging, the right frontseeming to drag slightly more than the left.

The tech flushed the hydraulic system withfresh brake fluid and bled the system per Toy-ota’s recommended procedure. However, thefront brakes still began dragging severely aftertheir established road test. When he raised thecar on a lift after each road test, the front wheelsbarely turned. Loosening the front bleeder fit-tings released the front calipers every time; thenthe front wheels spun freely. But after each roadtest, the front wheels would severely drag again.

By this time, Pauly told me, they began sus-pecting a master cylinder problem. However,confirming this suspicion required eliminatingeverything outside the master cylinder—easiersaid than done. They double-checked the car forevidence of body/frame damage as well as bashedbrake lines. After all, a crimped metal line or in-ternally flaking rubber brake hose could keep acaliper applied. Pay attention here if you’ve neverseen this condition. A restriction inside a line orhose may trap brake application pressure be-tween the restriction and the caliper. Then thecaliper won’t release the pads after the driver ap-plies and releases the brakes. However, openingthe caliper’s bleeder fitting will release the pads.

The tech connected a brake pressure gauge toeach front caliper and then operated the brakes

When you service a vehicle, how certain are you that you’re the only

one who’s ever worked on it? Unless you knowyou are, questioning

the customer to obtain a detailed vehicle history is a must.

Phot

o: D

an M

arin

ucci

If you suspect that a binding, corroded ormisadjusted brake pedal mechanism iskeeping the brakes partially applied, unboltthe master cylinder and carefully pull itforward just far enough to separate it fromthe f irewall or brake booster. See if thistrick releases the brakes.

continued on page 16

18 March 2012

Carmakers all over the world areacutely aware of the model year2016. The models to be sold inthe U.S. that year are on thedrawing boards right now. Byfederal law, those vehicles must

meet a Corporate Average Fuel Economy(CAFE) standard of 34.1 mpg. The 54.5 mpgyou’ve heard of doesn’t go into effect until 2025.How are they going to do that?

The numbers are not as scary as they mightseem. Dan Edmunds, on the Edmunds.comwebsite, says: “The 34.1 mpg CAFE target for2016 is actually equal to only 26 mpg on a win-dow sticker. The talked-about 2025 CAFE stan-dard—usually described as 54.5 mpg—amountsto a figure of 36 mpg Combined [highway andcity driving] on a window sticker.”

It’s important to realize that this is an averagenumber for the whole fleet. It will include a lotof thirsty trucks, big SUVs, some plug-in hybridsand, of course, a whole slew of average vehicles.

Still, it leaves the carmakers right nowsearching for ways to get roughly a 5-mpg in-crease out of their vehicles. It would only befair to note that changing politics and changinggovernment rules go hand in hand. Dependingon what the government does, who winds upgetting elected and what the state of California

does, these rulescould be made ei-ther easier or harderto attain. Thatdoesn’t help the carcompanies rightnow; they really areon the hook to do 5mpg better and theyneed all the ideasthey can get.

The basic formu-las for calculatingfuel economy arefairly straightfor-ward. The force

needed to move a vehicle is equal to the masstimes the acceleration (weight includes gravity,mass does not). Making a vehicle lighter or re-ducing its acceleration are two ways to reducefuel consumption.

You can also work on waste factors. Improvingthe efficiency of the engine and/or drivetrain, re-ducing aerodynamic drag and reducing lost en-ergy (exhaust, cooling and brakes) are all ways toimprove fuel economy. You can also work to re-duce the energy associated with heating andcooling the passenger compartment.

One particularly good area to look at is theunsprung weight of the vehicle. Unsprungweight is largely a function of the design of thevehicle’s suspension and the materials used in itscomponents. This weight may be something of atrade-off between the wheel’s ability to followbumps and the vibration isolation of thosebumps. Bumps and surface imperfections in theroad cause tire compression. This then puts aforce on the unsprung weight. The amount ofwheel movement is inversely proportional to theunsprung weight.

What all this means is that a lighter wheel willfollow the bumps better and have more grip, aswell as a more constant grip, on the road surface.

When you’re trying to make improvements invehicle design, the sweet spot is when you cannot only improve the part, but improve overallvehicle performance, too. Reducing unsprungweight is a way to improve vehicle handling andperformance, and for designers to reduce weightin other areas of the suspension and the vehiclebody because they have less impact and vibra-tion to deal with.

Major development programs are going onright now in terms of how to reduce the weightof the tires and the wheels on which they’remounted. The HTAS Corp., part of the Euro-pean tire company Vreedstein, is just one com-pany that’s currently working on weight-reducedtires. Gerlof Korte, who is in charge of the pro-ject, says the target is to reduce the weight ofeach tire by 4kg (9 lbs.), for a total vehicle weight

MikeDale

Fuel economy standards are ramping up, after years of stability.

As a result, all related systems must be reevaluated. Weight-saving

innovations help the cause, while benefiting other areas as well.

[email protected]

Eye On Electronics

Ph

oto

cou

rtes

y B

ASF

The seat back for an automotive interior isbeing simulated on-screen. The computersimulation allows material substitution todetermine what will work best for thestresses the application will undergo.

continued on page 20

• eDitor’S report by John Lypen Provides expert opinions on key issues and concerns for shop owners, technicians and the industry.

• traDe SecretS by Bob Cerullo Bob uses case histories from his own shop to help show MOTOR shop owners the right way to approach and fix mechanical problems; right for both the customer and the shop.

• foreign SerVice by Dan Marinucci ASE-certified, Dan uses hands-on experience to give readers expert advice on finding and fixing hard-to-diagnose import vehicle problems.

• DriVeaBilitY corner by Mark Warren Mark is one of the nation’s leading experts on driveability. Every other month he offers insightful, sometimes unconventional diagnostic approaches to solving driveability problems.

• troUBle Shooter by Karl Seyfert In a dialogue with technicians, Karl responds to questions seeking expert advice on specific problems.

• performance perSpectiVeS by Jim Gibson This column covers the emerging performance enthusiast vehicle service market.

• neWSBreak - Late-breaking news about technology, companies, trends, legislation and regulations in the automotive industry.

• SerVice SlantS by Tom Rosario OE Tech Service bulletins rank #1 on the list of information technicians want.

• eYe on electronicS by Mike Dale Every other month, Mike Dale, an automotive design engineer, covers the hot issues of electronic technology with a style that demystifies complex service with practical advice.

21

fiˇ˘ˆ ˇ - automotive data | repair guides | shop solutions · pdf file• peterbilt...

Documents