Service Bulletin. I:\H-Service\Mark H Hyundai\HANZ TSB's\HANZ Service Bulletins 2003\SB th Hyundai World Skills Olympics Competition Report.

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1 03035 Service Bulletin TO: Service Managers DATE: 26 th November 03 CC: Dealer Principals, Technicians FROM: Peter Tolley RE: 5 th Hyundai World Skills Olympics Competition Report Steve Niethe from Bayswater Hyundai reports on his successful trip to the 5 th Hyundai World Skills Olympics Competition held in Korea on the 14 th October Before traveling to the 5 th Hyundai Worlds Skills Olympics I spent two days at HANZ with Ian Fong freshening up on the use of Hi Scan Pro Tester. These two days proved to be invaluable to me and working one-on-one with Ian has given me a far greater understanding of just how valuable this tool is. Ian also took me through the process of down loading detailed information into a PC. Having a closer understanding of the Hi Scan Pro Tester will give me more confidence when working with it back at our Dealership. I also started to understand the use of CD Rom Shop Manual verses the use of the Shop Manual Book. It s a little strange at first but with more regular use it seems to be easier to use than the manual. At this stage I m pretty hyped about the trip ahead. This is my first trip out of the country. Once I knew I had won the 2 nd Hyundai New Zealand Skills Competition, the first thing I had do was arrange for a Passport, up until now I had no need for one. Saturday came around quickly and Ian and I met at Auckland s International Airport and went through all the normal stuff to clear Customs. Once on the aircraft we re on it for 9,600 Kms or around about 11½ Hrs of flying time. Well it s comfortable up here in Business Class unlike those poor people at the back all cramped up. The service is good and likewise the food. It didn t take long though before I went off to sleep. Finally we arrived at Incheon International Airport in Korea at 5.50am. This was an amassing sight, just the share size, its huge. Anyway, through Customs and onto the bus and taken to the Shilla Hotel in Seoul. When we arrived at the Shilla Hotel this left me stunned, an absolutely beautiful hotel and very flash. After freshening up and having all Sunday free, Ian and I negotiated our way into town and into the markets via an intricate subway system, which by the way would have been easier if I could have read and understood Korean. Monday morning we all met at 7.20am in the lobby of the hotel and took the bus to Hyundai Namyang R&D Centre. Here we were shown some of Hyundai futuristic aspirations. After watching the presentation back on the bus and off to the test track. A couple of times around the track hitting speeds up to 130Kmph, while traveling around the track we re passed by a Hyundai estimated to be traveling in access of 200Kmph, wow I didn t know they could travel so fast. From there we traveled to the Hyundai s Asan car assembly plant for a tour. This was a highlight for me. Watching panels being pressed, to seeing the car drive out of the building. Given that robots have built 80% of the vehicle, it seems unreal. I:\H-Service\Mark H Hyundai\HANZ TSB's\HANZ Service Bulletins 2003\SB th Hyundai World Skills Olympics Competition Report.doc

2 - 2 - From there it was 1½-hour drive to Chonan to Hyundai s Training Centre for the opening ceremony. Here Hyundai s Executive in brief speech welcomed all 52 competitors and wished them the best in the competition. Then we were taken back to Seoul, to the Seoul Tower, (a sky tower similar to Auckland s sky tower, which is on one of the many mountains looking over Seoul). The view was breath taking, and as it rotated we were able to see most of Seoul City. We had a banquet and I found the food most enjoyable. With a couple of more speeches the night was over and it was back to the hotel around 10.30pm Seoul time or 2.30am NZ. Tuesday is competition day. After breakfast we had a 2hr drive to Chonan, Hyundai s Technical Training Centre. The competition was to comprise of one written exam and six practical exams. The written exam I found wasn t too difficult, but the practical exams were a little more difficult than I had expected. The exams comprised of the following: High Tech Diagnostics: High tech diagnosing involved an Elantra with several Trouble Codes. Some where not relevant but when they were cleared continued to show up. The main tool used was Hi Scan Pro Tester; you were required to bring up on the screen of the Hi Scan Pro Tester several oscilloscope patterns simultaneously. The Crank and Cam Angle Sensors, when we checked them for comparison show that they were out of phase. The problem being that the Cam Timing was incorrect. Engine System: We had an Accent. It wouldn t start. The Hi Scan Pro Tester wouldn t communicate with ECM. Using the Hi Scan Pro and Multi Meter we had to identify the faulty component and replace it. This task I didn t manage to complete within the timeframe. Automatic Transaxle: I had an XG with shifting faults. Using Hi Scan Pro Tester it wouldn t communicate with the TMC. The TCM fuse was blown and when it was replaced kept blowing when the shift lever was moved into reverse. The fault was a short in the socket of the reverse light bulb (a piece of aluminium foil had been jammed into it). The Electrical System: This proved a little tricky; the windscreen wipers wouldn t work on intermittent. Using the Hi Scan Pro Tester and Multi Meter you had to find the fault. This proved a little difficult and before I had time to complete it the time had run out. Manual Transaxle: This exam was reasonably simply and consisted of disassembling of the transaxle and replacing the 1 st & 2 nd shift fork and rail. Then checking the preloads of the output shaft and final drive side bearings. Selecting the correct shim and adjusting the preloads to there correct values.

3 - 3 - Diagnostic Tools 1: We worked in groups for this exam. Our group had to use a Hi Scan Pro Tester to capture a Hall Effect signal and transfer this onto a PC using Webscan. We were also required to test two batteries using the Hyundai Battery Approved Battery Checker. Diagnostic Tools 2: This exam comprised of completing a circuit by testing and inserting two diodes into the circuit to make two lamps illuminate. Then using a terminal gauge tool to test the holding force of electrical terminals. Finally to solder wires onto terminals, and secure them using heat shrink covering. This completed the day of competition and I found it quiet exhausting. That evening we were taken to a Korean Restaurant to experience Korean cuisine. Several of us found using Chop Sticks a challenge. When some started to pick the food in our hands we all joined in. I even gave eating Kimci, Korea s National Dish (like our roast dinner) a go, although some seemed to enjoy it, I for one didn t. Wednesday, and we were taken for a tour through Mando, an HMC Supplier, here they manufacture braking components. Through the plant tour it was mainly fully automated with C.N.C Lathes fully enclosed, this made it difficult to see components being made and assembled. We then travelled to a Korean Palace; this was very old and large. It s amazing to believe that people used to live there. Thursday morning we travelled to the HMC Head Office, the foyer is an excellence display of Hyundai technology of Engines and Transmissions as well as a line-up of all models of vehicles. I was unaware that they manufactured 33 Litre Tank Engines, V8 diesel twin turbo, an impressive 1,200HP, weighting 1,200Kgs. We then entered a room for the Award Ceremony, what a proud moment this was for me. The overall winner was announced; Hyundai Technician Mr. Huang Wen Chu from Taiwan, first runnerups, Mr. Jan Pedersen from Denmark, Mr. Nick Cukrudz from Australia and second runner-ups, Mr. Mathew Godber, from Australia, Mr Arthur Anderson, from U.S.A, Mr G Gremmen from Netherlands. Several other competitors also received recognition and were awarded prizes. After, we had a group photo taken and were presented with a momentum of this occasion. That evening we attended a farewell banquet and had an exquisite dinner followed by the formal closure of the 5 th Hyundai World Olympic Competition. To complete the evening a social time was had by all with many discussing the success of the past few days. Friday provided enough time for Ian and I to have a final look around and shopping before we were off to the airport and flying home again business class. It s difficult to explain my overall emotions to the whole of the lead-up to the event. First starting off simply by completing the HANZ Self Training Modules (Three), which gave me the opportunity to enter the finals of the 2 nd Hyundai Technicians Skills Competition. Obliviously I understood from the beginning the very importance of training, hence the reason why I was happy to carry out a little study and complete the Self Training modules. Not only are they worthwhile but also they assist me in my day-to-day job functions.

4 - 4 - Winning the New Zealand 2nd Hyundai Technicians Skills Competition was a great triumph for me, and not for one moment did I expect to be able to achieve that result let alone be on my way to Korea, representing Hyundai New Zealand in the 5 th Hyundai World Olympics. Finally I suggest that if any Hyundai Technician considers training worthwhile and is prepared to be self-disciplined in working towards increasing their technical knowledge then get in behind the type of training HANZ prepares and presents. For me it will be part of my career that will look good on my CV and the memories will last a lifetime. To HANZ I wish to thank them for the tremendous support they have provided leading up to the competition and for the travel arrangement to Korea. To all our other Hyundai Technicians, give consideration to supporting the training HANZ provides, it could well be you in two years time competing in the next Hyundai World Olympics. Steve Neithe Please find included a Video Tape of the Hyundai Technicians Skills Competition held at HANZ. Photos taken at the competition: - Photo Gallery - Written Test Practice Test - 1 Practice Test - 2 Practice Test - 3

5 - 5 - Award Ceremony 1 Award Ceremony - 2 Farewell Dinner 1 Farewell Dinner - 2