IM-GROUP.COM.AU

JULY 2019

newsNOW BIGGERAND BETTER

EGR COOLER REDESIGNED & REENGINEEREDTo Suit:• Nissan Navara D22 & D40 YD25DDTI Diesel• Nissan Pathfinder R51 YD25DDTI Diesel

Part Number EC102

Goss has seen an increasing number of OE Nissan YD25DDTI EGR cooler failures. This has prompted our engineers to investigate the cause of this issue and develop a solution to manufacture a high quality aftermarket EGR cooler and reduce the risk of failure.

In turbo diesel engines, exhaust temperatures reach over 650 degrees celsius. This is too high to be fed directly into the cylinders as this would further increase combustion temperatures and defeat its actual purpose.

An EGR cooler is used to reduce exhaust gas temperatures before they enter the intake and reduce combustion temperatures. This process is known as EGR (Exhaust Gas Recirculation) and is one of the principal methods used to reduce NOX (Nitrogen Oxide) emissions from diesel engines.

The EGR cooler can help reduce the temperature down to 200 degrees celsius by transferring the heat via the engine’s cooling system. This can also cause issues if the EGR cooler splits or corrodes as seen with this engine, the Nissan YD25.

The EGR coolers tend to split or corrode around the flanged areas, each side of the cooling core and can also leak internally. In most cases the coolant evaporates without any signs of leakage. Once pressure tested, mechanics have noticed a drop in the radiator coolant level and upon start-up also notice steam exiting via the exhaust system. This is due to the engine coolant being drawn through the engine.

Goss have re-engineered the EGR cooler and developed a new manufacturing process to produce a product less prone to cracking or leakage. Internal tubes are manufactured from stainless steel for longevity and are TIG welded to laser cut plates isolating the coolant from the exhaust. This new design cools the exhaust gases more efficiently than the original design. This also helps to prevent a build-up of carbon that would usually diminish the effectiveness of the system. Additional collars have also been added to the flanged areas on the Nissan YD25 EGR cooler to help reduce the risk of external leaks.

These units are also supplied with fitment gaskets and brackets. For further information or your nearest Goss stockist, please visit www.goss.com.au

OEMCommon external leak areas

Re-engineed & re-designed Goss EGR Cooler

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IM NEWS JULY 2019P2

Injectronics ABS Repair Service

Injectronics have seen many units with various issues including Electronic Module failure. As of recent times it had come to our attention that these units were also developing a hydraulic leakage issue. This was causing issues with customers complaining of a “spongy” brake pedal and Mechanics having difficulties bleeding the hydraulic brake system after servicing or replacing brake components.

ATE MK70 ABS Pump assemblies are fitted to many Australian delivered vehicles which only have a basic Non-ESP type ABS system.

These vehicles include the following:

ABSMK70HREP

• Mazda 2 DY / Mazda 3 BK• Ford Focus LS-LT / Fiesta WP-WQ• Holden Astra AH / Barina TK

• Suzuki Alto GF / Swift ZC21-31• VW Caddy 2k / Golf 1k• Daihatsu Sirion

PRODUCTRANGE

Dorman - Coolant Reservoirs

Many OE Coolant reservoirs are failing due to the contamination, exposure to the elements and collision damage. Dorman offer replacement engine coolant reservoirs which are manufactured from premium plastic to withstand the stresses of under bonnet heat and engine vibration. Many have been redesigned with a more durable construction to withstand extreme temperatures and a longer service life (where applicable). It is thoroughly tested to ensure optimum fit and performance on specific vehicle applications.

• Direct replacement - engine coolant reservoir fits and functions like original equipment for a trouble-free installation.

• Most Dorman reservoirs also include a new reservoir cap and drain tube (where applicable).• Excellent value - OE quality at a lower price.

Injectronics – HIM Modules

This is where Injectronics can help, offering a prompt test and repair service for these units.

These units are fitted to all of the following vehicles: • Ford Falcon BA – BF series 2002-2011 • Ford Falcon FG series 2008-2016 • Ford Territory 2004-2016

Injectronics have seen these units displaying numerous faults including: • Blower fan inoperative • Unable to adjust temperature • Blower fan staying on • Unable to adjust fan speed • Unable to regulate temperature between zones

The Heater Integrated Module (HIM), also known as the HVAC is an electronic control module attached to the left side of the HVAC main unit. The HIM consists of a number of small electric motors, electrical connectors, circuit board and a blower motor control heat sink.

HIM01REP

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Goss – Fuel Rail Pressure Sensors RANGE EXTENSION

The Fuel Rail Pressure Sensor (RPS) is used on Common Rail Diesel and Direct Injection Petrol applications to provide the pressure reading in the fuel rail to the vehicles Powertrain Control Module (PCM) and is mounted in the fuel rail close to the injectors.

Goss have extended their range of Fuel Rail Pressure Sensors to include Petrol Direct injection fuel rail pressure sensors, demonstrating our commitment to continually expanding our ranges with the latest in vehicle technology. All Goss ranges are subjected to a stringent validation process, are engineered and sourced from leading OES manufacturers. See our website for more part numbers.

PRODUCTRANGE

Goss – Variable Valve Timing SolenoidsVariable Valve Timing (VVT) is a technology that’s used on newer model engines to improve fuel economy, idle smoothness, emissions and performance. The technology allows valve timing to change with engine speed and load, so the engine can develop more power while also getting better fuel economy and producing less emissions.

These vehicles include the following:• Electrical problems with the supply voltage, ground connection or wiring to the VVT can prevent the variable valve

control system from functioning

• Low oil pressure, due to a worn oil pump or worn cam bearings can prevent the cam phaser from developing enough internal pressure to rotate the cam

• Debris, sludge or varnish will restrict or even block the oil flow to the VVT, preventing it from working properly

• Incorrect oil viscosity in the engine can also impact on correct VVT operation, causing various fault codes to set

• Physical wear or damage inside the cam phaser housing may prevent it from rotating, cause it to stick, or make the unit noisy. A broken return spring may prevent it from returning to base timing.

MAP - Keys & RemotesMAP Have a range of solutions for your keys & remotes whether your remote has seen better days, lost or been damaged. Our latest options includes our universal remote. This option covers most makes and models on Australian roads.

• Offering a large range of replacement shells and buttons to remedy wear and tear.

• Grab a spare complete remote or integrated key and remote in the same design as original

• Try our universal remote solutions*. Using a standard remote we can provide remote controls for most vehicles in a quality flip key.

• Have your key blank cut to precision using our electronic key cutting services.

• Remote control repairs are available if your remote has been damaged. Most damaged keys can be fixed by our technicians.

*Not all vehicles available. Cosmetic design of remote/key may look different to original.

PURCHASE A REPLACEMENT SHELL

PICK UP A UNIVERSAL REMOTE REPLACEMENT

GRAB A COMPLETE REMOTE

UTILISE OUR KEY CUTTING & PROGRAMMING SERVICE

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IM NEWS JULY 2019P4

Ford Everest, Mondeo, Mustang

KF169Replacement Shell

Mazda CX7, CX9, Mazda 2, Mazda 3

KF266Complete Key & Remote

Toyota Avalon, Camry

49448Wiper Linkage Bush (5 Pack)

Subaru Forester, Impreza, Liberty, Outback

KF390Replacement Shell

Mazda 3, Mazda 6

KF267Complete Key & Remote

Holden VY, VZ, VT, VX

917-033Knock Sensor Loom

Toyota Corolla, Hilux

KF428Replacement Shell

Nissan Micra, Murano, Pathfinder, Tiida, X-Trail

KF298Complete Remote 3 Button

Toyota Corolla, Echo, Yaris

696-131Air Intake Hose

Toyota Camry

KF429Replacement Shell

Toyota Rav 4, Yaris

KF410Replacement Key & Shell

Toyota Landcruiser Prado

696-108Air Cleaner Hose

EXPANDING RANGE

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Lexus ES300 / Toyota Avalon, Camry

696-725Air Cleaner Hose

Suzuki Swift

SC589Cam Sensor

Audi A3, TT / Skoda Octavia / VW Golf, Passat, Jetta, Tiguan

EC112EGR Cooler

Hyundai i45, ix35, Santa Fe, Sonata / Kia Cerato, Sorento

902-5128Thermostat Housing

Toyota Hilux, Landcruiser, Rav 4

RPS116Fuel Rail Pressure Sensor

VW Amarok, Crafter

EC113EGR Cooler

Mercedes Benz

902-5177Thermostat Housing

Ford Ranger, Transit / Mazda BT50

EC101EGR Cooler

Citroen C4, C5 / Ford Focus, Mondeo / Peugeot 307, 308 / Volvo

EC114EGR Cooler

Mercedes Benz

902-5187Thermostat Housing

Nissan Navara, Pathfinder

EC103EGR Cooler

Ford Transit / Holden Rodeo / Land Rover Defender / Mits Pajero, Triton / Nissan Navara

RPS100Fuel Rail Pressure Sensor

EXPANDING RANGE

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IM NEWS JULY 2019P6

TECHNICAL BULLETINS

Injectronics technical team are seeing an increasing amount of inquires relating to the Toyota Hilux KUN 16/25/26 2005-2015 instrument cluster. The instrument cluster relies on many inputs from sensors such as the temperature sensor, wheel speed sensors via the ABS unit and fuel sender unit to relay important information to the driver.

Customers have experienced a number of faults with these instrument clusters. The most common being a faulty or inaccurate fuel level reading. The customers report running out of fuel even though the gauge indicates the tank is still a quarter full. This can cause damage to the fuel system components, including fuel injectors and fuel pumps, often leaving a costly repair bill, but can also leave the driver stranded on the side of the road. Other faults include but are not limited to:

Visit Injectronics.com.au and search DASKUNREP for more info.

• Inaccurate or faulty fuel level reading• Speedometer inoperative• Instrument back lighting not working or flickering• All gauges inoperative

Common Faults:

Injectronics can test and repair these instrument clusters for the above - mentioned faults avoiding the need to source a second hand replacement unit that may in turn have the same fault. The Injectronics repair service is also a more cost effective solution verse the cost of a new OEM unit.

Prior to sending in the instrument cluster for repair it is advised to check the function of the fuel sender unit for correct operation, the speedometer transducer and any related wiring. The fuel level sender can be easily checked by removing the sender unit and with a multi meter check the ohms reading by raising and lowering the float from full to empty, making sure the signal does not drop out and decreases and increases with the movement of the float.

Injectronics can offer the following solutions:

TOYOTA HILUX KUN 16/25/26 2005-2015INSTRUMENT CLUSTER FAULTY OR INACCURATE FUEL GAUGE & SPEEDOMETER

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TECHNICAL BULLETINS

CHRYSLER ENGINE OIL FILTER BYPASS VALVE FAILURE

DORMAN OE FIX

The featured Dorman OE Fix product is part number 917-992.

• Direct replacement for a proper fit every time• Ideal replacement part for protecting your vehicle from costly engine damage

• Easy to install - no special tools required during installation

OE FIX products are engineered solutions designed to correct OE part failures. Some OE FIX parts replace only the failed component, not the entire assembly, saving you money. Other OE FIX parts are designed to save you installation time. Look for Dorman OE FIX parts to help you do the job right, one time.

The Chrysler 3.7 litre V6 Pentastar engines are fitted to many vehicles in Australia and New Zealand, and a common fault is a broken Bypass valve in the oil filter housing.

In many cases, the bypass valve is damaged when the oil filter cap is removed due to the cage binding and breaking. It is important to check during the service, as it is possible previous workshops may not have noticed the valve was broken.

Previously the only option was to purchase a costly complete replacement Oil Filter housing. The housing is mounted in the valley below the intake plenum chamber, making it a time-consuming repair.

What is Dorman OE FIX?

Suitable for the following vehicles:

The Bypass valve is now available separately, enabling you to replace only the failed original valve, instead of the entire assembly which involves removing the Intake manifold, draining the cooling system and oil system and then refilling these fluids.

Constructed of quality materials, the Dorman Engine Oil Filter Bypass Valve is designed to provide a longer service life and includes a plastic valve and spring to assist with installation.

• Chrysler 300 V6 (2012-2017)• Dodge Journey JC V6 (2012-on)• Jeep Grand Cherokee WK V6 (2011-2017• Jeep Wrangler JK V6 (2012-on)

917-992

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IM NEWS JULY 2019

TECHNICAL BULLETINS

MAZDA 3 AUTOMATICTRANSMISSION CONTROL MODULE BK-BL SERIES

The Mazda 3 BK/BL 2.0L - 2.3L - 2.5L are an extremely common vehicle on Australian roads, produced from 2004-2009 (BK) & 2009-2013 (BL).

Common Faults Include:

Common Faults Include:

Part Numbers Include:

The transmission control modules have been presented to IM Group with various conditions ranging from poor & erratic shifts, shift solenoid operation malfunction fault codes, and transmission in limp mode.

The IM Group technicians have done extensive investigation into the reason’s & causes for these faults, and have now devised a reliable remanufacturing process to enable repair of the units, avoiding expensive new replacement units having to be purchased. Each unit can be tested on the IM Groups Virtual Automobile Tester stations, with all terminals being fully function tested under vibration and heat simulation. Each test generates a function report of the unit.

Visit www.injectronics.com.au for more information or to book in a repair and to locate your nearest reseller.

Repair Process:The manufacturer of the transmission control module uses a silicone type resin after assembly to protect /seal the tcm from water/oil contamination. This material is extremely time consuming to remove by hand when units require repairs to the electronic circuit board that is submerged within it. In order to reduce job turnaround time on repairs of these units, along with reducing the physical demands on technicians repairing them, the IM Group R&D team have designed a purpose built computer controlled robot which removes the resin covering the pcb, allowing technicians to get quicker access to the pcb and carry out the required repairs. Once the IM Group technicians have undertaken the required repairs to the pcb, the unit is again retested by the technician and after passing all testing requirements, units are then resealed again with a far more pliable protective resin and are then returned to the customer.

• LFAE189E• L34N189E

• L552189E• LFJS189E

TCMMAZ3REP