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Monday, September 22, 2014

Dr. Gizmo Column

"Dr. Gizmo"
By Phil Arendt

$1150 Repair Estimate Completed For $88  
Question 1
I am a senior citizen snowbird who lives in Arizona during the winter months and Wisconsin during the summer.  My son stores my 2006 Buick La Crosse indoors while I’m away.  When I returned this summer the air conditioner was not working.

I went to my local dealership where I paid $34.82 for diagnostic work.  The service person said the a/c was so bad that the mechanic could see the trouble from across the shop.  I received an estimate for major repairs totaling nearly $1,200.  They said I should return in a week to have the work completed. 

I went to another shop for a second opinion.  Two hours later my local independent shop had repaired the air conditioner for $88.  It’s been seven weeks since the repair and the a/c works perfectly.  My shop said that if there are any problems to return to have the issue repaired under warranty.

I was going to speak with the dealer owner about the encounter but I did not want to cause problems for the other shop so I refrained from doing so.  I thought you could comment on this issue.  Can you?  J.N., email

Answer 1
I certainly appreciate your letter.  Thanks for sharing your experience.  You made the right decision by seeking a second opinion.  Any time there is a large repair estimate it’s a good idea to get a second opinion.

As a certified arbitrator and mediator for decades, I’ve heard hundreds and hundreds of cases in which I made decisions based upon the evidence from the parties in my hearings.  With your letter there was a partial copy of the dealer shop estimate.  I did not see a repair receipt from the second shop that did the repair so I have only a partial picture of what needed repair and why. 

Be this as it may, your dealer representative obviously used poor judgment in saying his technician could see the trouble from across the shop.  His technician must have x-ray vision.  For $34.82 that’s about all he used to diagnose the trouble while condemning expensive parts such as a compressor and refrigerant line for a leak.  The estimate was accurate for replacing those parts but since your car was repaired for much less, those parts were not needed.  I wish I could pat you on the back for making a sound decision on whom to award the repair.

Another important aspect of this episode is that your second shop repaired the issue to your satisfaction at a fraction of the cost of the original dealership estimate without needing to replace previously condemned parts.  His x-ray vision is even more acute and probably backed up his diagnosis with a few tests.  Consider visiting his shop for future preventive maintenance and repairs.    

Wear And Tear Taking Toll On Transmission
Question 2
I have a 4L80E transmission in my 2002 Chevrolet Crew Cab 4x4 HD truck.  It has a slight hesitation going into overdrive once in a while going up a gradual incline.  It doesn't do it all the time.  I think third gear is just a little too grabby.

The truck and transmission have 135,000 miles.  The trans has been flushed twice and the filter has been changed once.  I also had the shift solenoids changed, but the trouble continues. 

Do you have any ideas? A.B., email

 
Answer 2
It’s time to dump the truck.  All kidding aside, at this mileage and age the transmission is a candidate for replacement or overhaul.  The trans in your truck is pretty expensive so an overhaul might be less expensive.  Having said this, if the hesitation is not too much of an annoyance, and you can live with it, consider waiting until the concern becomes worse or the transmission gives up.  If this doesn’t suit your fancy visit a transmission specialist.  An adjustment might resolve the issue.  Also, it is possible there is a programming issue that is causing the problem.  However, from what you describe there likely is an issue with internal wear.

 
Noise At Front Of Engine Due To Excessive Wear
Question 3
The check engine light turned on in my 2004 Nissan Maxima with 176,000 miles.  Also, the engine idle is not smooth.  I went to my local shop that has been servicing the car for many years.  One of the technicians did a number of tests.  He said that there is excessive noise at the front of the engine which is an indication that it needs a timing chain.  He also said that the camshaft sensor tests good but it might be bad but he thinks the trouble might be caused by the timing chain. 

The shop manager says the timing chain repair is expensive.  He will write an estimate for that work but he won’t know until the work is completed if the car will need sensors or other work.  I’m hesitant to do any work to the vehicle since it is 10 years old and has so many miles.  It’s in great shape and has never giving me a bit of trouble since it was new but I don’t want to sink a lot of money into it. 

Does what they told me make sense to you?  Should I keep the car?  N.D., email

 
Answer 3
Certainly repairing the car although is expensive is much less expensive than purchasing a car but that decision is up to you. 

Your technician appears to be on the right track.  It’s entirely possible that the noise from the front of the engine is caused by excessive wear of the timing chain and related parts.  It’s also possible that the check engine light illuminated due to timing issues of the camshaft relative to the crankshaft.  This also causes issues with the camshaft sensor.  The sensor reports timing to the engine control module.  If the timing is off, the light illuminates and sets a code indicating possible trouble with the sensor.

It’s time to take into consideration the repair estimate.  Then you can decide to fix the condition or replace the car.

 
No Need To Yank Out Engine
Question 4
I have a 1999 Suzuki Grand Vitara with a 2.5 engine.  It’s in great condition although it has 140,000 miles.  There is noise from the front of the engine.  My shop says the timing chain is the cause of the noise.  They said they have to take out the engine to replace it.  It’s an expensive job.

How much is it to replace the timing chain?  Do they have to take out the engine?  G.R., email

 
Answer 4
I’m sorry but we don’t provide repair estimates.  It is an expensive repair and it does take a lot of effort. 

It’s not necessary to remove the engine.  A technician removes everything from the front of the engine to gain access to the timing chain.  It’s a tight space, but once accessories are out of the way there is enough room to replace the worn out chain.

 
Restricted Exhaust Impairs Turbo Boost
Question 5
Recently, engine power dropped in my turbocharged 2005 Audi A4.  My shop has looked at the car a couple of times but has not come up with a cure for the problem.  He has checked the turbocharger and associated parts and can’t find anything wrong.  He has checked for trouble codes, bad solenoids, a faulty waste gate, checked for leaks, road tested the car with test equipment hooked up but he can’t find the problem.  He is sure something has gone wrong with the turbo and continues to find a code for low boost.  He says that at this point he wants to replace the turbo but he is not sure it will fix the trouble. 

My car has a 1.8-liter engine, an automatic transmission and 122,000 miles.  It’s in like new condition and I have followed the factory service schedule since it was new.  Until recently it has run strong and now it lacks power.  I can tell the turbo is not kicking in when I hit the gas.  Other than this, the car is perfect.  Can you help?  P.D.S., email

 
Answer 5
Yes indeed.  It’s time for a new Audi.  All kidding aside sometimes, and this happens to all of us, we become so focused we get stuck in a loop and can’t move forward with a project.  That’s when it is time to step back, take a deep breath or even walk away and do something else to unwind and gather thoughts. 

If everything checks perfectly except for the low boost code, there is something inhibiting its operation.  Ask your technician if he has looked into the possibility that something in the exhaust system is restricted.  Back pressure in the exhaust can impair turbocharger operation.  A pipe may be bent.  It’s possible the catalytic converter or muffler is blocked.  Tests can determine if a problem in the exhaust system is affecting performance.  A new catalytic converter might resolve the issue.

 
Rebuilt Module Fails To Fix Trouble
Question 6
I have a 1997 Infinity QX4 with a 3.3 engine that is in like new condition with only 66,000 miles.  It’s a great vehicle.  It hasn’t given me any trouble all these years although I have had to replace the battery, tires and brakes. 

Last week the engine would not start.  When I turned the key the engine turned but it did not start.  I had it towed to my local repair shop that has been servicing it for many years.  A mechanic did some tests and can get the engine to start if he jumps a relay that activates the fuel injectors.  He said the engine computer module is not completing a circuit to activate the relay.  He sent the module to a place that rebuilds them.  It took a week for them to send it back.  He installed the rebuilt module and he had the same problem.   He says the module is still the cause of the problem and is sending it back to the rebuilder.

Does this sound right to you or do you think something else is wrong?  W.J., email

 
Answer 6
Your technician is on the right track.  The engine control module does complete the circuit to a relay that energizes the fuel injectors.  It does this by completing a ground circuit for the relay.  If the module is not doing its job he should send it back to the company that allegedly rebuilt it.

The problem is that this issue leaves you without a vehicle causing a lot of inconvenience.  I hope you have alternate transportation.  Once the repaired module is installed, your Q should be back on the road.

Thank you for all the great questions.  Dr. Gizmo can’t wait to answer more.

Phil Arendt is a columnist, consultant and A.S.E.-Certified Master Technician.  Readers may send questions to Dr. Gizmo at P.O. Box 548, Cary, IL. 60013 or e-mail address drgizmo@hotmail.com.  08/04/2014 ® DR. GIZMO © 1989 - Present

Recalls for September 22, 2014

Good day everyone.  Happy Monday!

The National Highway Traffic Safety Administration has issued a new wave of recalls.  Issues this week include air bag problems, natural gas leaks,  fuel pump failures, dragging parking brakes, faulty windshields, improper side door reinforcement, incorrect wiring and more.

All of these issues are safety concerns.  If your vehicle is affected by a recall, please have it repaired as quickly as possible.

Have a safe week! 


Please click on the following NHTSA Campaign ID links to view the recall information.

NHTSA Campaign ID Number :
Manufacturer :
Chrysler Group LLC
Make / Model Years :
FIAT / 2014-2015
Subject :
Knee Air Bag may Deploy Improperly/FMVSS 208
NHTSA Campaign ID Number :
Manufacturer :
Ford Motor Company
Make / Model Years :
FORD / 2015
Subject :
Rear Caliper Brake Hoses may Leak
NHTSA Campaign ID Number :
Manufacturer :
Ford Motor Company
Make / Model Years :
FORD / 2015
Subject :
Epoxy Reinforcement Missing from Sliding Doors
NHTSA Campaign ID Number :
Manufacturer :
Ford Motor Company
Make / Model Years :
LINCOLN / 2015
Subject :
Air Bubbles in Windshield/FMVSS 205
NHTSA Campaign ID Number :
Manufacturer :
Newmar Corporation
Make / Model Years :
NEWMAR / 2014
Subject :
Headlight Wiring Harness may be Incorrect
NHTSA Campaign ID Number :
Manufacturer :
PACCAR Incorporated
Make / Model Years :
KENWORTH / 2015
PETERBILT / 2015
Subject :
Fuel Filter Shell may Separate and Cause Stall
NHTSA Campaign ID Number :
Manufacturer :
Ferrari North America, Inc.
Make / Model Years :
FERRARI / 2010-2014
Subject :
Front Trunk Release/FMVSS 401
NHTSA Campaign ID Number :
Manufacturer :
All Wheel Drive Equipment Mfg., Inc.
Make / Model Years :
SUPER DUTY / 2011-2012
Subject :
PTO Pressure Switch Oil Leak may Result in Fire
NHTSA Campaign ID Number :
Manufacturer :
Vanair Manufacturing, Inc.
Make / Model Years :
FORD / 2009-2013
Subject :
PTO Pressure Switch Oil Leak may Result in Fire
NHTSA Campaign ID Number :
Manufacturer :
Versalift East, LLC
Make / Model Years :
FORD / 2009-2013
Subject :
PTO Pressure Switch Oil Leak may Result in Fire
NHTSA Campaign ID Number :
Manufacturer :
General Motors LLC
Make / Model Years :
CHEVROLET / 2011-2014
GMC / 2011-2014
Subject :
CNG Regulator Leaking Natural Gas
NHTSA Campaign ID Number :
Manufacturer :
Adrian Steel Company
Make / Model Years :
FORD / 2012
Subject :
Corrosion of Propane Tank Fuel Line Fitting
NHTSA Campaign ID Number :
Manufacturer :
Chrysler Group LLC
Make / Model Years :
DODGE / 2011
JEEP / 2011
Subject :
Fuel Pump Relay may Fail Resulting in Stall
NHTSA Campaign ID Number :
Manufacturer :
New Flyer Industries Ltd.
Make / Model Years :
NEW FLYER / 2013-2014
Subject :
Brake Pedal Piston may Bind or Drag
NHTSA Campaign ID Number :
Manufacturer :
General Motors LLC
Make / Model Years :
CADILLAC / 2013-2015
CHEVROLET / 2014-2015
Subject :
Electronic Parking Brake may Drag
NHTSA Campaign ID Number :
Manufacturer :
Yamaha Motor Corporation, USA
Make / Model Years :
YAMAHA / 2014
Subject :
Headlight Harness may be too Short
NHTSA Campaign ID Number :
Manufacturer :
Honda (American Honda Motor Co.)
Make / Model Years :
HONDA / 2015
Subject :
Incorrect A-Pillar Cover Installed

Monday, September 8, 2014

Car Made With 3D-Printer



SABIC’s carbon fiber-reinforced material used to produce the world’s first 3D-printed vehicle at IMTS 2014

SABIC delivered the innovative materials and processing expertise needed to create a first-of-its-kind concept vehicle using advanced 3D printing (also known as additive manufacturing) during the International Manufacturing Technology Show (IMTS) in Chicago this week. This fully functional vehicle being printed from scratch and assembled by automotive design firm Local Motors, is expected to be driven off the tradeshow floor on Saturday.

This ground breaking event showcases a long-awaited solution to a major manufacturing challenge: how to avoid the significant investments in tooling and time necessary to produce large free form designs. Local Motors collaborated with Cincinnati Incorporated, a large-scale manufacturing system builder; Oak Ridge National Laboratory (ORNL), a pioneer in advanced materials research; and SABIC to develop and validate the technology and materials needed to deliver large format 3D printing technology.
“When the team was choosing our partners to produce the world’s first 3D-printed car, SABIC was an obvious choice because they would quickly and reliably deliver the proper materials needed to bring the Strati to life,” said John B. Rogers, Jr., Local Motors CEO.  
SABIC’s LNP™ STAT-KON™ carbon fiber-reinforced compound was chosen for its excellent strength-to-weight ratio and high stiffness, which minimizes warping during the 3D printing process, enabling enhanced aesthetics and performance.  Additionally, SABIC’s expertise in this emerging technology, including material selection and validation, equipment specification and processing, were instrumental throughout the development process.   
“Involving SABIC at the inception, with their experience in advanced processing technology and material validation, was critical to the project’s success,” said Andrew Jamison, CEO for CINCINNATI.  “Visitors will get a first-hand look at the future of additive manufacturing and its possibilities to transform the industry with our Big Area Additive Manufacturing (BAAM) machine running SABIC material and printing polymer components 200-500 times faster and 10 times larger than today’s additive manufacturing machines.“  
Tony Cerruti, Marketing Director, Americas, for SABIC’s Innovative Plastics business commented, “SABIC’s materials and processing knowledge together with this advanced additive manufacturing technology will help to address the manufacturing challenges our customers are facing – the high cost to innovate.  We believe that this technology has far-reaching potential for applications across the multiple industries that SABIC serves, bringing designs to market faster and enabling mass customization.”
The concept vehicle event stemmed from a Local Motor’s Design Challenge which resulted in the submission of over 200 entries from 30+ countries.  The winning concept, Strati, inspired the full sized 3D-printed prototype.