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Ford Ka 1.3 between 1996 and 2009 is commonly affected by a wiring fault causing the alternator/battery warning light to remain on or flicker although the alternator is charging. This is usually caused due to poor condition of the wiring and/or terminals or broken wiring. The wiring harness has three wires which are connected between the ECM (engine control module), the alternator and the vehicle dash board. The three wires usually are grey, blue (to the ECM) and the black/blue wire (to the vehicle dash for the warning lamp). The wiring must be checked for continuity and if any faults are found the loom either needs to be replaced or repaired.

A few notes about the Ford Ka (1996-2009):

Engine Oil

For this particular car, Ford list only one or two specifications for engine oil which should be covered by Comma Xtech 5W30. However, always make sure you get the right product for the vehicle you are servicing.

With service intervals of up to 12,500 miles, supplying the customer with a top up pack and reminding them that they should be checking the engine oil regularly might also be prudent here. A quick check before you change might be a good way of reinforcing the importance of top up to the customer. Combined with longer service intervals, a smaller sump size makes checking your oil more critical than ever before.

The Ka has only had 3 recalls via VOSA, though all were for braking issues. Ka’s built between March 1998 and June 1998 often suffered with reduced braking efficiency from the brake master cylinder.

Ka’s in 2002 were recalled to check the security of the front flexible brake hoses. Unsecured hoses can rub against the tyre and wear through, causing a loss of brake fluid.

Ignition coils and lead sets are often requested from Cambiare due to hard-starting and misfires. In fact, 33 percent of the top-selling Cambiare parts for this model are ignition coils, whilst nearly 20 percent are lead sets. Technicians should take care when replacing lead sets on this model as the end that fits the spark plug has a transit plug fitted to protect the spring. Remove the transit plug before fitment of new leads. Failure to do so will result in misfire as the lead will jump off the plug after a few miles.

The aftermarket is crackling with chat around the publication of a new report in the US which describes ECP-owning LKQ as a cashless clunker driving ‘rabid’ and ‘desperate’ branch expansion in the UK with little regard for long term value.

Sven Nielsen, Technical Director from MEYLE, says the following difficulties may arise with the BMW 1 Series:

Defective wheel bearings

The BMW E81/87 1-Series (2004-2011) replaced the BMW 3-Series in 2004 as the smallest and cheapest vehicle (depending on the engine model) in the BMW range. BMW introduced a smaller capacity 1.6-litre petrol engine for the 1-Series, alongside the 2.0-litre and 3.0-litre petrol and 2.0-litre diesel engines.

Challenge: simplify installation of a complex multi-link suspension

The multi-link suspension system on the newer BMW series is complex, and includes many track control arms and link stabilisers. Ensuring a complete quality repair of the suspension system is critical, but can be difficult and time-consuming.

The new kits are specifically compiled for both the front and rear axle and allow all the vital components to be replaced with new ones in one go. This easy and efficient solution improves driver safety. Moreover, it ensures enhanced vehicle steering and suspension performance on both the front and rear axle.

BMW 1

116d with 2.0d engine, erratic running smoking and engine management warning light illuminated-EGR control sticking, may clean out but there is a modified part available. The timing chain is prone to rattle-failure of the secondary timing chain tensioner.

116d with N43 engine, running lumpy and fault codes P00A and P00B- VVT adjuster failure.

All models with parking sensors, failure of dash warning lights- parking sensor module contaminated with rain water on o/s/r boot floor well.

120d with 2.0d 4D4 engine code (04-07), lack of power and poor idle with fault code P1117- mass air/intake temp sensor corrosion damage.

Ignition coil failure

BMW 1 Series 116i

Reference number(s): 0012230300

Fault symptoms: Ignition misfire Non-concentric engine running Engine warning light is on

Causes: Production defect.

Remedy: Replace ignition coils.

Timing chain issues

BMW 1 Series 116i

Reference number(s): 0011550200

Fault symptoms: Timing chain elongation cannot be compensated by built-in chain tensioner.

Causes: Design error

Remedy: Replace chain tensioner.

Injection nozzle/injector