Webasto aux heater trouble

This van was in our workshop to have a look at the rear aux heater. The heater is a Webasto that uses fuel to a heater underneath the vehicle.

This is the control on the dashboard. The green light flashes a code to help diagnose the issue.

The flash code on this vehicle told us that the system had shut down. So we had to perform a reset before we could proceed further. Once reset a code for fuel supply flashed up.

With accurate wiring diagrams we could trace the wiring to the fuel solenoid and found that there was a cut off switch circuit fault. We managed to repair the fault and confirm a fix with our thermal camera


Mercedes SL500

Into our workshop was this Merc that had problems with the aux battery under the bonnet not charging. This battery is used when cranking to help give extra amps. Also it is isolated from the main battery when ignition is off, so if main battery goes flat the vehicle can use this battery to in essence jump start the car.

The battery symbol was lit on the lcd panel on dash and the aux battery had gone flat.

There is a split charge relay that controls this along with a battery stabilisation module. We gained access to these components (not easy being a cabriolet, having to remove part of the roof mechanism) and checked wiring associated with this system all checked ok. On gaining access to components a burning smell was noticed but no burnt wiring was seen. With the battery disconnected the relay and module were removed and checked

The battery stabilisation module was burnt. We replaced this with a new O. E part and replaced charge relay to be safe reset fault codes and checked. Job correct first time and no unnecessary parts fitted.

2011Mini Cooper

Into our workshop was this Mini which had been recovered from another garage (BMW specialist) which had failed to fix the car after having it over 2 months!!

The problem with the car was ABS, traction light on and the steering lock inoperative. The previous garage as can be seen have tried fitting a new cas unit and then apparently 3 more(there were a total of 5cas units in vehicle)!!

The fault codes show faults in CAS and ABS modules. We coded in both modules correctly, this still left speed signal faults.

In live data the CAS unit thought car was moving even when stationary. That is why steering lock was not operating.

The CAS unit we know can think this if there is a wiring issue between itself and the ABS module. So examining wiring diagrams we can trace the loom and a broken wirer was found. A simple repair and the customer had car back the next day.


Hyundai i20 no heated rear screen

This vehicle came to us with a problem with the heated rear screen inoperative.

A look at the wiring diagram shows its more complicated than people would think.

When you push the switch it sends signal to chassis ecu, which then sends signal to fuse box and relay, which in turn sends signal to screen and engine ecu (which can raise revs slightly to help with the extra load the screen has).

The circuit tested it was found that the signal was being seen by the chassis ecu but it was not sending signal on. The rest of the circuit was checked in case of further faults, none were found.

A new module was sourced and fitted with confidence.

A first time fix with no parts cannon fired at it.


Mercedes horsebox

This old Mercedes horsebox came to us after it had a fire. An attempt to repair the loom had been tried elsewhere.

We decided a repair wasn’t feasible so we managed to source a complete vehicle harness.

After removing the old damaged loom and most of the interior the replacement loom was fitted, a time consuming job but worth the effort.

Radio Coding

Coding this set requires you to program the chassis number into the set

We have the equipment to be able to do this in house.

Rover 75 immobiliser fault

This car was towed into our workshop, the customer saying that they just came out one day and it failed to start.

Plugging in our diagnostic equipment brought up codes for immobiliser.

This car is based on a BMW e39 and knowing BMW quite well we were aware of communication issues between the dde (engine ecu) and the ews (immobiliser module).

We gained access to the module and were able to perform a coding of the module with specialist equipment.

The car started instantly and ran fine.

Peugeot non runner

Peugeot 206 came in from another garage. The original fault was wipers and left indicator on all the time. They fitted 2nd hand bsi which cured the faults but the car wouldn’t start because the bsi is part of the immobiliser system. So we were asked if we could help.

With the correct information and equipment we are able to swop the microprocessor containing the information from the original bsi to the 2nd hand unit

Not a simple task as you mustn’t damage the circuit board when unsoldering and reattaching chips and not shorting out the connections.

Another successful job perhaps saving a car from the breakers yard.

Hybrid Lexus

This hybrid Lexus was in our workshop to have a front camera fitted.

A neat professional and safe  job done. Another happy customer.


Hyundai wiring fault

 into our workshop was this Hyundai for a wiring fault. The fault was traced to behind the dashboard. As you can see here there is quite a bit of dismantling to gain access to the loom.