Service Maintenance and Repair ROI_October 2021

SERVICE, MAINTENANCE AND REPAIR

Get all the latest knowledge and product information to help shape your business

In this edition:

Around the Wheel ■ Optimal new product launch ■ MAD auxiliary springs ■ Maintain the OE look with Pagid

Around the Engine ■ Turbo chargers, a sales opportunity ■ Follow the 4T guidelines during belt system servicing

Exhaust and Emissions ■ Catalytic convertor failure awareness ■ Garage Services DPF and Carbon Clean

Serviceable Items

■ Lucas bulb stand ■ Bosch wipers display – all the blades you need for the workshop

November – December Edition

AROUND THE WHEEL

STEERING & SUSPENSION LINKAGE

NEW TO RANGE

A majority of the references also carry the highly sought after TÜV SÜD certification. TÜV SÜD is an internationally renowned independent organisation for undertaking safety, testing, certification, auditing and advisory services. control arms, stabiliser links, bushes and mountings is accredited to ISO/TS 16949. For 30 years the Optimal brand has gained a reputation for quality German engineering. The parts are manufactured in line with OE specifications using quality materials and equipment. The Optimal Steering and Suspension range, which covers ball joints, tie rods, track About Optimal

Integral to its ride, handling and safety, a vehicle's steering and suspension system is an intricate network of linked components. Since this system is also typically one of the first affected when it comes to the ever changing road surfaces, those same parts can be the first to wear out or even fail – accelerating wear and tear on other parts, and compromising the vehicle’s stability, control and ultimately safety.

A stabiliser link, otherwise known as a sway bar, anti- roll bar or even link stabiliser, connects the vehicles left and right wheels through short links, reducing body roll whilst cornering, and absorbing shocks from potholes and uneven road surfaces. Fitting a strong, durable part is therefore a must. STABILISER LINKS

Designed to reduce vibrations and structure-borne noise, rubber-to-metal plays an important role in the steering and suspension set-up of modern vehicles. BUSHES

LATERAL LINKS

Lateral links are located at the rear of the vehicle. They are hollow metal tubes with connection points on either end and they connect the hub to the midpoint of the body which keeps the wheel/hub assembly upright and centred while driving.

A safety-critical part, the ball joint acts as a Block 1 pivot between the wheels and suspension, allowing the vehicle to be steered, whilst also ensuring a comfortable ride. Since it constantly pivots through multiple planes and angles, it is subject to significant stress and wear. BALL JOINTS

The inner and outer tie rods connect to the steering arm in order to move the wheels of your vehicle. In the common rack-and-pinion steering system, the inner tie rods connect to the steering rack while the outer tie rods connect to the steering arms. INNER TIE ROD

CONTROL ARMS

Tie rod ends are a part of the steering system. Tie rods connect the spindle, on which your front wheel is mounted on one end, to the steering gear mechanism on the other end. TIE ROD ENDS

A control arm is the hinged suspension link that connects the chassis and the suspension that carries the wheel. Attached with a single pivot, normally a rubber bushing, the control arm can adjust the position of the outboard end while sustaining the radial distance from the inboard mount. A control arm is one of the most mechanically critical parts of the suspension system, which means it is important to replace them when they become worn or broken. Often the reason a replacement is required is due to the ball joint or bushing being worn out, but it can be very difficult and expensive to replace these components separately.

A crucial part of a vehicle’s steering system, is the centre drag link (also known as the centre link). This is connected to both the Pitman and idler arms at either end, the centre drag link is joined to the inner tie rods. The job of centre drag links is to manoeuvre inner tie rod ends such that a vehicle’s wheels turn properly when the steering wheel is moved. CENTRE DRAG LINK

Find out more about Optimal

AROUND THE WHEEL

CORTECO TOP STRUT MOUNT

SACHS SPRINGS CORROSION PREVENTION

Like any replacement part the suspension strut mount can wear. But what are the symptoms to look out for in case of wear? ■ Loose, stiff or noisy steering ■ Vibrations ■ Poor steering return ■ Roll, sway, slide or bounce while cornering or driving on winding roads ■ Increased stopping distance ■ ABS and Traction Control systems affected ■ Clunking noises while driving in normal conditions ■ Tyre alignment - the vehicle can no Ionger be aligned to OE specifications ■ Abnormal rear ‘squat’ while accelerating or front ‘dive’ while braking. CHECK THE SUSPENSION STRUT MOUNTS EVERY 12,000 MILES AND REPLACE THEM EVERY 56,000 MILES Always check the suspension strut mounts during inspection and make sure to renew them in pairs.

As country begin to take the necessary step of treating road surfaces with grit salt. Although very important, this is one of the leading causes of coil spring corrosion, leading to damage and eventual breakage. Essential checking of a vehicle when in your workshop, means problems can be identified early and rectified for your customer. By fitting Sachs, you and your customers can be assured you’re getting a superior product with production steps that ensure a long spring life whatever the conditions. As automotive coil springs are an integral part of a vehicle’s suspension system, constantly moving and working whilst battling the elements, eventual corrosion can’t be avoided. As the outer lacquered layer of the spring becomes chipped or damaged, without additional protection creep corrosion will set in quickly, spreading rapidly and significantly increasing the risk of breakage.

■ Sachs combats this corrosion through the use of Zinc Phosphating, adding an additional layer of protection between the paint and the spring ■ In addition to this protection, Sachs produces all springs from parallel steel ‘spring wire’, with a consistent wire diameter throughout the length of the spring, as opposed to tapered wire which thins out towards the ends of the spring ■ A corrosion attack on the end coils of a tapered spring will lead more quickly to breakage, as the reduced diameter increases the level of stress, especially when compared with parallel wire ■ Sachs are firmly committed to providing the highest quality products, able to withstand the worst conditions effortlessly, without affecting performance ■ All Sachs springs come with a 2-year warranty/ 20,000 miles and are certified ‘Matching Quality,’ allowing fitment without warranty restrictions.

Reasons for these symptoms If the bearing portion of the mount wears, the density of the insulating material changes, which results in more noise and vibration being transmitted into the vehicle. A simple rule to follow is if the struts or springs are being replaced because of age or wear, then you should also replace the mounts. During a rebound stop, the strut mount Iimits the shock absorber's rebound path and must absorb substantial forces over a short distance. These parts wear until they fail completely because of the constantly changing factors which are more common with poor road conditions. Strut mounts should be checked every 12,000 miles and replaced every 56,000 miles. They should always be checked during an inspection, and then replaced if necessary but always in pairs – something that’s particularly important when replacing the shock absorbers.

ARNOTT AIR SUSPENSION

GARAGE SERVICES – WHEEL ALIGNMENT

Air Suspension Installation Tips Being the aftermarket air suspension specialist, Arnott is keen to make sure all installers feel confident and are well informed when carrying out an air suspension repair.

With more than 30 years of experience in engineering, designing and manufacturing high quality air suspension components for the aftermarket, Arnott is the technical expert when it comes to air suspension systems. Arnott’s products are produced with high-quality OE components offering exact form, fit and function. Each product is extensively tested in Arnott American and European facilities and custom-tuned to suit the specific vehicle make and model before being produced, and they come with a 2-year warranty.

Why do you need wheel alignment? Most sources recommend an alignment service every 10,000 miles; one to three years; with each new set of tyres; or when replacing steering and suspension components. It only takes ten minutes to perform a wheel alignment check and It is estimated that one in five cars coming into a workshop will have an alignment issue. On average every fourteenth check will highlight vehicle issues which will require additional parts and labour work to be carried out. ■ Regular wheel alignment checks are recommended ■ If you replace steering or suspension components ■ If you replace tyres ■ One in five vehicles will require alignment.

WHEEL ALIGNMENT

Find out more about installation tips and tricks

GARAGE SERVICES

Regularalignmentchecksareanessentialpartofavehicle’sservicemaintenance schedule.Everydaydrivingaffectswheelalignmentandover time,wheelscan becomemisaligned.Poor roadconditions,potholes,kerbingavehicleandworn suspensioncomponentswillalso impactonavehicleswheelalignment. WHEELALIGNMENT

Ifyou’recurrently turningawayorsendingwork toanothergaragebecauseyoudon’thave the rightequipment atyourgarage todo the job,youshouldconsideraddingwheelalignmentasaservice. BENEFITS ■ Additional revenuestreams foryourworkshop ■ Avoid losingacustomerorwork toanothergarage ■ Increasedcustomersatisfactionand retention ■ Minimal time required Mostsources recommendanalignmentserviceevery 10,000miles, 1 to3years,witheachnewsetof tyresorwhen replacingsteeringand suspensioncomponents. Itonly takes 10mins toperformawheelalignmentcheckand It’sestimated that 1 in5carscoming intoaworkshop willhaveanalignment issueandonaverageevery fourteenthcheckwillhighlightvehicle issues thatwill requireadditionalpartsand labour work tobecarriedout. WHYALIGNMENT ■ Regularwheelalignmentchecksare recommended ■ Ifyou replacesteeringorsuspensioncomponents ■ Ifyou replace tyres ■ One in5vehicleswill requirealignment

autoclimate TM

AROUND THE WHEEL

FOLLOW THIS BEST PRACTICE FOR SAFE AND SUCCESSFUL BRAKING SERVICE AND REPLACEMENT. GET THE JOB DONE RIGHT AND KEEP YOUR CUSTOMERS HAPPY. C. L. E. A. R. C CLEAN Remove rust and dirt using the Pagid over stud hub cleaner Or use the Pagid hub cleaning tool Remove all loose dirt and dust using Pagid brake cleaner

TRW EPB CALIPERS

TRW is the leading supplier of advanced parking brake systems worldwide and was first-to-market with its Electric Park Brake (EPB) on a mass production vehicle in 2001. The system functions as a conventional hydraulic brake for standard service brake applications and as an electric brake for parking. The EPB caliper is composed of one electro-mechanical actuator integrated into the disc brake caliper and an electronic control unit which is activated from inside the vehicle

Thanks to our innovative EPB, the vehicle can benefit from the following: ■ Emergency braking: ensures safe braking of the car to a standstill via closing and opening the parking brakes in rapid succession (similar to the ABS function) ■ Child safety lock: when ignition is off, the parking brake cannot be released ■ Automatic hold: the parking brake can be applied automatically as soon as the driver’s door is opened or ignition is switched off ■ Electronically controlled: EPB can work with a variety of vehicle systems and sensors to improve safety performance ■ No need for cable: the absence of a hand brake lever and cables allow greater freedom for interior styling and simplifies EPB installation on vehicles. ■ Maximum brake power in all operating conditions. The TRW EPB range includes standard EPB and integrated EPB (or EPBi). EPBi reduce the number of ECUs required due to its integration with the Electronic Stability Control system and make this technology more affordable for smaller vehicle segments. cabin by a simple rocker switch. Here are some of the benefits of an electrically operated parking brake: ■ Low operating forces and flexible interior design, due to the use of a switch instead of a lever ■ Parking brake cables are replaced by electric wires (no freezing or tearing of cables) ■ High safety level due to the use of a software similar to ABS, which avoids blocking of the parking brake when being operated while driving

LUBRICATE

L E A R

Use only Ceratec on metal/metal contact

Use only Hydratec on rubber contacts

ESSENTIAL

X

Do not use copper grease / copper paste

ACCESSORIES

Always use new accessories and fitting kits – do not reuse worn components

REPLACE / RUN-OUT

Replace discs close to minimum thickness and any with heavy corrosion, badly pitted or edge-lipped

Check brake disc run-out using Pagid run-out tool

Actuator

Pagid brake calipers

Find out more

Pagid brake calipers are remanufactured to OE quality standards which means they will be returned to as near the same condition as possible to the original part. After the casting is cleaned, inspected, and plated, the caliper is rebuilt using new components, including new pistons and seals. Unlike cheaper ‘reconditioning’ options (which could just be cleaned and rebuilt using the old worn parts), every Pagid caliper undergoes quality control at each stage and must pass a final pressure test at the end of the line before it can be approved and released for sale. With a 24 month or 24,000 miles warranty, you can’t go wrong. With vehicle usage being down and the cold weather earlier in the year, this can cause problems for brake calipers. The flexibility and efficiency of the caliper seals (in particular the outer piston seal and the inner D Cut seal) can deteriorate due to the lack of movement and salt

from the road. This combination can cause inefficiencies with the caliper performance - in some cases the piston may not

Pressure Nut

Spindle

Caliper Housing

Piston

Exclusive to LKQ Euro Car Parts

Motor Toothed Belt Drive Gear

release, causing the brakes to bind or, in the common fist type caliper, cause the sliders to stop working due to perished seals. This prevents the caliper from sliding as they are designed to do. Pagid and LKQ Euro Car Parts recommend an inspection of the efficient function of the caliper over the coming weeks to ensure 100% customer satisfaction each time.

Planetary Gear

The single stage swash plate gear is the first generation of gear, actuating the electric park brake. With a climbing force of up to 19kN by a transmission ratio of ~150:1, it nevertheless fulfils the demands on a park brake system for a wide range of cars. Swash Plate Gear

Brake Caliper

Actuator

Piston, Spindle and Pressure Nut

The double stage planetary gear integrated in the actuator, transmits the rotary movement of the toothed belt with an overall ratio of ~120:1 in at least up to 25kN clamping force. This high forces are necessary to last also for the growing number of bigger cars using the EPB system. Technical Data: • Transmission ratio ~120:1 (in 3 stages) • stage 1 ~ 3:1 (belt drive) • stage 2/3 ~ 40:1 (planetary gear)

The brake caliper is of the single-piston “Colette” fist type design. The hydraulic function of the brake caliper is not at all different from the function of a conventional brake system.

The actuator is screw-fixed directly to the brake caliper housing, and actuated via a switch in the vehicle interior. That eliminates the need for hand brake lever and cables, providing multiple advantages such as greater room inside the vehicle, simpler installation of EPB on vehicles, prevention of issues related to mechanical wear or temperature problems. All this ultimately results in brake power improvement in all conditions.

The spindle has a thread with the pressure nut screwed on. Spindle and pressure nut are integrated in the brake piston. With a flattened area and a corresponding shape of the piston the nut is locked against turning. If the spindle is turned via the connection to the gear mechanism in the actuator, the pressure nut will move the piston towards the brake pads and thereby towards the brake disc – the brake is applied.

Speak to your branch for more information

AROUND THE WHEEL

GEAR CABLES To go alongside the extensive range of brake pads, calipers, disc and other braking parts, Pagid also offers matching Gear Change Cables. Constructed using Push-Pull technology, which prevents the cable from stretching and losing strength in the transmission manual gearbox.

POWER STEERING - REASONS FOR FLUSHING

The main reasons for flushing the system on all power steering systems is that the fluid becomes contaminated during regular use, and the contamination will cause premature failure of hydraulic seals under pressure. Originally steering racks and pumps were made from hardened steel and would usually wear from the outside in, the steel steering rack and pumps are very heavy due to the structure of manufacture. As car manufacturers started exploring new materials to ultimately make the vehicle lighter, they generally switched to aluminium housed steering racks and pumps – a shift in failure became apparent as the lighter and softer metal would now wear from the inside out. The usual colour of hydraulic fluid is red (ATF) or clear or light coloured for the mineral based fluids, however, generally the fluid in a used steering rack quickly becomes a dirty grey colour. The grey colouring is caused by tiny particles of aluminium that have worn from the inside of the steering housings (particularly in the pump body and the pinion housing of the rack) – these particles are always the main failure cause of any power steering system. When the car is sat between use, the aluminium particles all sit at the bottom of the pump reservoir, or the bottom of a pipe, or body of the pump etc. As soon as the vehicle is turned on, they become live and active in the fluid again. As the particles move around the body of the pump and rack at high speed, they are like little pins or needles as they hit the face of a rubber seal – which can cause the seal to break as they cut the rubber under pressure. The fluid would usually flow at 8 litres per minute through small channels and pipes (up to 6mm in diameter) and at anything between 80 and 120 bar pressure, so the particles aren’t lightly grazing past a seal, but are hitting it with force every time. Ideally, a power steering flush should always be part of a service, such is the need. Another cause is from the particles that sit dormant when the vehicle is switched off, and as soon as the vehicle is started, they can cause scoring marks or scratches to vital areas of the steering pumps such as the pressure plates or pressure relief valve. These can also congeal

together in the same areas and almost bond to the internal components of the steering pump as the pressure is so great and the turning speed is so fast and hot. If a pressure plate becomes scored or scratched, it results in a drop of pressure for the pump and it can no longer perform to its optimum capacity.

There are two cables: The Shift Cable is used for fore and aft movement and the Select Cable is used for side-to-side movement of the gear lever. Automatic Gearbox, there is one Shift cable sending the guidelines High-quality push and pull wire and specially engineered plastic material highly resistant to corrosion and friction. If you have a need to replace gear cables, LKQ Euro Car parts has over 400+ Pagid active references in stock included LCV application.

In effect, it causes an internal bleed and pressure will drop from 80 bar to 50 bar and lower, which becomes a steady decline to full failure. If the pressure relief valve gets scored or scratched or an accumulation of aluminium particles build up in this area, it affects mainly the performance of a steering pump under low revs. I.e. in a car park when turning out of a difficult spot, or when the vehicle is first turned on. What happens is the pressure relief valve sticks in its housing when the revs are below 2000 rpm – as you rev more, the pressure valve is able to force its way past the debris in the fluid, but every time it moves, it causes more damage to the internal housing of the pump, thus creating more particles in the system and permanent failure. When bleeding the system, it cannot just be a draining and re-filling of the fluid, because the sediment caused by the particles, will sit at the bottom of every component, or in the nooks and crannies of the steering pump and rack. As soon as you re-fill the system, they will become live again. Bleeding the system needs to be flushing the system fully – running fluid through under pressure with the return pipe to the reservoir into a bucket to collect the waste. When the fluid runs through completely clean again, then couple up the return hose again and fill up the system.

Exclusive to LKQ Euro Car Parts

Clean brakes made easy with pagid Why use brake cleaner? Pagid brake cleaner can be directly applied without parts removal and helps prevent dust escaping into working environment. Pagid brake cleaner can help overall braking performance and efficiency and importantly, helps restore friction on brake components but can also be used on clutch components. Benefits include: ■ Quickly and effectively remove oil, dirt, brake fluid and dust ■ Quick drying solvent with smear-free effect

■ Reduces brake squeal and sticking ■ Protection against instant rusting ■ Powerful jet spray cleans with ease

■ Pagid – a quality trusted brand ■ Made to an approved formulation ■ Use on all brake parts – drum and discs, linings, pads, springs, cylinders and calipers ■ Use as part of routine maintenance whenever replacing brake components.

SHOP NOW

Find out more on Omnihub

AROUND THE ENGINE

VALEO DDC

DMF TESTING The LuK testing tool 400 0080 10 (ECP Ref 400776250) allows you to perform the following tests on the DMF: ■ Measuring the freeplay angle ■ Measuring the rock These tests, alongside a visual inspection to check grease egress, thermal load, clutch condition, etc. allow for a reliable assessment of the DMF’s operational condition. What are the freeplay angle and rock?

The new Valeo smart OE transmission systems technology for outstanding responsiveness and comfort. The Valeo Dual Dry Clutch stands for outstanding performances embedded in OE technology. A smoothly continuous acceleration, with a minimum loss of torque means powerful driving sensations and electromechanically controlled gears change boosts driving efficiency.

The Valeo Dual Dry Clutch’s 7 gears actuators offers 15% faster gears change compared to previous generation of DDC from Hyundai-Kia, with a 6 gears transmission. Combined, these features make the Valeo Dual Dry Clutch one of the best available on the aftermarket, offering the comfort of an automatic transmission and the responsiveness of a manual transmission. CO2 emissions reduction is important to Valeo and has been at the centre of the development of the Dual Dry Clutch. As a result, Valeo DDC was designed to offer a continuous transmission of engine power, with minimum torque loss during gears change. Its gears disengagement operates without electrical power being controlled by the electromechanical actuator. Working together, these innovations enhance smoothness, lower vibrations and resistance, ultimately reducing fuel consumption and CO2 emissions. Valeo offer offers a simple manual calibration procedure for better efficiency in the workshop too. In addition, the offer comes with a complete technical support programme, including fitting instructions, live training, webinars, interactive presentations and videos from the Valeo Tech @ssist free online technical web platform.

The freeplay angle is the angle at which primary and secondary mass can be rotated against each other until load is exerted on the arc springs. The measuring points are both end stops in the left-hand and right-hand direction of rotation. The measured freeplay serves as a wear indicator. Caution: Some DMFs have a friction control disc that can be felt as a hard stop in one direction. In this case apply greater force to rotate the secondary mass a few more millimetres until spring resistance can be felt, and then allow it to return. This also rotates the friction control disc in the DMF. The term ‘rock’ describes the clearance between the two DMF masses which allows them to be tilted towards and away from each other. Your assessment of the DMF’s operational reliability should be based on the following criteria: ■ Grease leakage ■ Condition of the friction surface (e.g. signs of thermal load/thermal cracks) ■ Noise behaviour ■ Condition of the clutch ■ Loading condition of the vehicle (towing a trailer, driving school, taxi, etc.)

If in doubt, always replace the DMF along with the clutch.

Call your local branch more information.

VAICO – YOUR EXPERT FOR AUTOMATIC TRANSMISSION COMPONENTS

WINTER IS COMING Frozen coolant in your engine can cause a multitude of problems: split pipes, burst radiator, cracked cylinder head, seized water pump, etc, so it’s important to make sure vehicles have the correct coolant level. If you require a new water pump, you should consider opting for optimum protection and peace of mind this season and using a High-Quality PROFLOW© water pump. Designed, engineered, produced and tested in the UK, PROFLOW© water pumps have over 40 years of engineering experience and OE level workmanship behind them. These water pumps are available from LKQ Euro Car Parts with all the expected guarantees to ensure a problem free experience both mechanical and thermal.

In the field of automatic transmission components, VAICO offers an extensive range of over 700 products for more than 10,000 vehicle models. With EXPERT KITS+, VAICO offers repair solutions designed by experts that make it easier for workshops to identify and procure parts, while conserving warehouse resources. All in one solution for your transmission - Expert Kits+ Offeting complete solutions in the transmission filter kit category, VAICO supplies comprehensive Basic Expert Kits (BEK) like article V10-5390-BEK, which include all necessary components like seals, gaskets, filters and mounting kit. The filter media of the VAICO transmission filters and its accessories and assembly materials are supplied in OE quality. Matching seals and gaskets are made of high-quality, heat-resistant ACM, NBR or Viton elastomers. Get back on track Tips for a successful filter and oil change of an automatic transmission, along with installation instructions, are available in our videos, available on YouTube (youtube.de/brandvaico). Vehicle parts from VIEROL VIEROL AG is a successful international specialist for electronic components and engine management in the automotive sector. Delivering more than 43,000 high-quality vehicle parts in 125 countries on all continents, its product portfolio includes quality brands like VEMO, VAICO and ACKOJA, and covers transmission components through to sensors. As an owner-managed, family company with its headquarter in Oldenburg, Germany, and subsidiaries in Shanghai and Singapore, VIEROL guarantees mobility worldwide with automotive replacement parts.

Ensure there is no leakage at the vent hole

Ensure there is no damage or loose parts

AROUND THE ENGINE

Follow the 4T guidelines during belt system servicing 4T was created to introduce a simple best practice process during the service or installation of belt system kits and components, helping to prevent the chance of fitting errors that can lead to premature belt failure. The four ‘T’s are: ■ Temperature Do not attempt to start work until the engine has completely cooled down - this can take up to 4 hours ■ Tools The correct tools must be used in accordance with vehicle manufacturer (VM) instructions - locking tools are recommended for a reason, Tippex doesn’t lock! ■ Torque Use a torque wrench to tighten all bolts to the correct VM specifications - that includes degrees of rotation where stated, as each step is critical for obtaining the correct clamp load for the fixing ■ Tension Belt tension must be accurate, correct and to VM recommendations - following the recommended number of engine revolutions as part of the setup is critical to a setting the tension correctly.

Belt and tensioner diagnosis A broken timing belt and/or tensioner can cause engine failure, which can be catastrophic, time consuming and very expensive. That’s why it’s imperative that technicians always check the system for wear during a routine service, and always replace it at the vehicle manufacturer’s recommended change point. Diagnosing what causes a timing belt to break is not straight forward, but common reasons for failure can usually be classified:

Straight break Caused by belt ‘crimping’, usually because of fitting or handling error

Jagged break Caused by incorrect/excessive tension (fitting error) or a foreign body entering the drive system

Sheared teeth Caused by incorrect tension and misalignment (fitting error), or because the recommended change point has been exceeded

INA belt system specialist, Tim Adams, said: “We are not trying to teach mechanics how to suck eggs, but it is amazing how many problems can be created by not following these simple rules in the workshop. “Being familiar with a particular engine timing setup doesn’t mean you no longer need to look at the instructions, as that’s when problems can occur. It is not uncommon for VM setup instructions to change, or for different designs of OE tensioner to be introduced during the engine’s lifetime. Each new tensioner design can have its own unique setup instructions, which must be followed to the letter to guarantee an accurate and professional results. “4T is easy to remember, and adhering to its principles will help to prevent fitting errors, saving time, effort and money for both the garage and its customers.” Investigate and repair If a driver notices any unexplained noises or vibrations coming from the engine, the cause should be investigated by a technician immediately. If a timing belt replacement is required, our partners, along with the vehicle manufacturers, recommend that all the belt system components need to be changed at the same time to reduce the risk of major engine damage caused by premature failure. By using the wide range of Timing Belt KITs, technicians will save time by having everything they need to carry out a professional repair in just one box, with the Timing Belt Kits with Water Pump range also including the belt driven water pump and even the thermostat where required.

Cracked back Caused by heat exposure and/or the change point exceeded

Side wear/polishing Caused by misalignment (fitting error)

Worn teeth flanks Caused by incorrect/excessive tension and misalignment (fitting error), and/or exceeding the change point

Marked belt back Caused by incorrect tension and alignment (fitting error) or a foreign body entering the drive system

Gap (land) wear Caused by incorrect/excessive tension (fitting error)

Contaminated belt (grease/oil) Caused by other defective or damaged components or an incorrectly installed timing belt cover.

Signs of a broken tensioner include the following: ■ Worn end stop/broken stop pin ■ Caused by an incorrect tension (fitting error) ■ Contact damage on pulley rims ■ Caused by misalignment (fitting error) or defective components, such as a worn water pump bearing. Note:

The condition of the timing belt system cover is very important, as there must be no cracks, holes, or any other damage to the covers through which the timing system can be contaminated. Check for oil leaks, as the environment under the timing cover must be clean and dry, as automatic belt tensioners are not designed to be lubricated and can prematurely fail if they become contaminated by oil.

AROUND THE ENGINE

TURBO FAILURE - THE IMPORTANCE OF ASKING “WHY?”

TURBOCHARGERS - SALES OPPORTUNITY

Replacing a failed turbo is not just about how to remove and refit a replacement or what's wrong with it, it's arguably most important to ask why the turbo failed. Failure to ask this question can lead to a very expensive learning curve - disgruntled customers, unproductive workshop space and inevitably the question of who pays if the replacement turbo fails prematurely. The reason that asking “why?” is so important, especially where turbochargers are concerned, is the fact they rely on the engine being in good working order for its longevity. It is not just a bolt on standalone component such as an alternator or starter motor, it depends on the engine for lubrication, the integrity of the exhaust gasses to drive the impellor and the cleanliness of the intake air feeding the compressor.

The replacement Turbocharger market has grown significantly over the last few years, which is mainly due to the Global initiative to reduce emissions and increase fuel economy with nearly all Diesel and an increasing amount of Petrol vehicles being now fitted with a turbo as standard. With the increase of cars being fitted with turbos, so too comes an increase in failures. And with it, an opportunity for all garages to get into the replacement market. Most turbo failures are caused by the 3 ‘Turbo Killers’ of oil starvation, oil contamination and foreign object damage. More than 90% of turbocharger failures are caused oil related either by oil starvation or oil contamination. ■ Blocked or leaking pipes usually causes oil starvation. If a vehicle has been standing for long period of time, as many have during the pandemic, oil to drains away from the turbo and when the vehicle is started, there is little or no oil lubricating the turbo for a few seconds, which can cause damage to the bearings and ultimately turbo failure ■ Over a period, engine oil becomes contaminated with fine particles that build up from the combustion process and engine wear & tear and ultimately find their way to the turbo causing the bearings and shaft to wear prematurely and fail ■ Foreign object damage is when a piece of debris enters via the air intake system and impacts into the turbo impellor causing it to fail. LKQ Euro Car Parts can offer an extensive range of both new and remanufactured units for car and LCV applications, which come with a 2-year warranty. New Turbos ■ OE Units from leading turbo manufacturers – Garrett, Borg Warner, Mitsubishi, IHI and Continental. ■ Remanufactured turbos ■ These units represent a cost-effective solution for replacement units for cost conscious customer with an older vehicle ■ These units are remanufactured to the original specification using new parts and tested to meet original unit specification in terms of operational performance.

It is doubtful that a head gasket or cracked cylinder head would be replaced without consideration of reason: ■ Why is the cooling system faulty? ■ Are the surfaces warped? ■ Has a cylinder liner dropped? Clearly it is not possible or practical to ascertain the reason beyond doubt in every case, but in many cases obvious causes are often overlooked causing grief for all concerned. One such example: Peugeot 206/307/407 and Citroen Picasso with engine model DV6TED4 1.6HDI which has a habit

of blocking or restricting not only the turbo oil feed pipe, oil drainpipe and fittings with carbon but also the oil pump pick up strainer, which leads to premature failure due to oil starvation. Simply by noting the carbon build up in the oil feed pipe, fittings and the turbo inlet port would indicate that further investigation was needed before a replacement unit is fitted. Carbon deposits can be caused by short-distance driving, poor oil/ fuel grade, high mileage, service intervals too long and worn engine.

Turbojetzt is an LKQ Euro Car Parts brand. ■ Turbo Ancillaries ■ Oil feed pipes – it is recommended that these be replaced where possible when fitting a replacement turbo ■ Turbo Fitting Kits – these normally come with a replacement unit but are available separately for when a turbo is removed for another reason. Turbo and Intercooler Pipes Always check they are firmly fixed in place. Check for splits or tears and replace where necessary as the will affect the vehicles performance.

AROUND THE ENGINE

ELRINGKLINGER - LEADING FOR MORE THAN A CENTURY Elring aftermarket division offers a comprehensive, market-oriented range of gasket sets, gaskets, service parts and a wide range of sealing compounds under the brand name Elring - Das Original, all available from LKQ Euro Car Parts. ElringKlinger's high quality standards are guaranteed by the strictest controls and tests during the manufacturing process. This means you can be sure the gasket purchased meets all the necessary technical and design requirements for 100% perfect sealing of the engine. Dos & don’ts of cylinder-head gasket installation Training topics can be found on the Elring website. For the professional installation of a cylinder-head gasket, you will find instructions summarised in seven steps here:

Step 01 First, carefully clean and degrease the sealing surfaces of the cylinder head and block and carefully remove any coating and sealing residues.

EXCLUSIVELY AVAILABLE FROM

Step 02 Now clean the threaded holes for the cylinder head bolts from dirt and oil and check the threads for damage and ease of movement. The material deposits must be removed with an oil stone. In addition, the evenness of the components must be determined over the entire component using a straightedge. The following guide dimensions apply here: lengthwise = 0.05 mm, transverse = 0.03 mm.

Step 03 Any cavities must be eliminated, the maximum roughness depth of the components must be respected, for this purpose a plan treatment of the counter sealing surfaces may be necessary.

Brake Calipers

Brake Discs

Step 04 In the fourth step, you must centre the cylinder head gasket on the engine block (without additional sealant). It is important to be careful not to damage the coating.

■ Full range of REMANUFACTURED calipers – returned to “as NEW condition”

■ ALL Pagid discs are GEOMET® coated, reducing corrosion and providing a smarter appearance for longer and with no cleaning required saving time fitting straight from the box ■ Designed to work in harmony with Pagid brake pads ■ High carbon content, for improved heat transfer ■ Manufactured to OE quality standards, to a 10 microns tolerance ■ To ensure perfect balance, vented discs are edge ground for optimum performance ■ Covered by our 25/25 warranty, guaranteeing them for 25 months, or 25,000 miles

■ 100% pressure tested ■ 100% New components

■ Zinc coated for protection against Corrosion ■ Environmentally friendly – Recycled CORES

Step 05 In the next step, the cylinder head can be put on, whereby damage to the sealing surface through scratches must be avoided. In addition, attention should be paid to any residues such as metal chips that may get onto the gasket from the cylinder head

Brake Pads

■ Chamfers designed to avoid vibration and smooth the bedding in process ■ Specifically engineered shims for each application to reduce vibration and noise ■ Over 200 different raw materials evaluated, before deciding on final friction formula ■ Over 300,000 km of on-road and track driving is conducted for each and every brake pad ■ Covered by our 25/25 warranty, guaranteeing them for 25 months, or 25,000 miles

Brake Shoes and Assembled Kits

Step 06 Remember: Cylinder head bolts and metal washers must always be replaced. The thread and the bolt contact surface must be lightly oiled.

■ ECE R90 approved ■ Powder Coated Hand Brake shoes for longer life ■ Perfectly complements the Pagid range of Drums ■ Range of Pre-assembled kits – SAVE 50% LABOUR TIME

Step 07 Finally, make sure the tightening sequence is followed according to the manufacturer's instructions and if necessary, also retighten the bolts after a certain run-in time.

7

AROUND THE ENGINE

NEW AND REMANUFACTURED: THE COMPLETE SOLUTION FOR COMMON RAIL INJECTORS AND PUMPS FROM BOSCH

ADAS

What are Advanced Driver Assistance Systems (ADAS)? Vehicles are now commonly fitted with a wide variety of Advanced Driver Assistance Systems (ADAS). To function, ADAS features rely on sensors that continuously and accurately monitor the environment around the vehicle, making these sensors an important part of any repair process.

Complex, high performance injection systems lie at the heart of every diesel engine. When faults occur, the first step in resolving the issue is to correctly diagnose the cause of the problem and then to identify the faulty components. To be able to diagnose these problems, a significant investment has already been made by a workshop in technician training, purchase of diesel diagnostic equipment and most importantly the time taken to diagnosis the fault that is a premium commodity for modern workshops.

It is therefore important that when choosing a replacement component, workshops have the confidence it will be of a high quality and reliability. Today, this process of choosing the correct component is increasingly difficult for workshops as there are now an increasing number of options available, all with varying levels of quality. It is not always possible to differentiate between the components just from their visual appearance. The component may appear the same on the outside and would likely even be utilising the same Bosch part number. However, on the inside, the spare parts used, and the repair methods followed can differ vastly.

The range of ADAS systems include: ■ Autonomous emergency braking

■ Traffic sign recognition ■ Adaptive cruise control ■ Blind spot detection ■ Lane keep assistance ■ Cross traffic detection ■ Remote active park assist ■ Adaptive headlamps.

Responsibilities of service and repairers: * Identify the presence, or not, of ADAS on the vehicle and ensure this is recorded: Where ADAS are present, ensure repair procedures clearly identify if inspection, realignment and calibration are required and why. ■ Complete all relevant inspection, realignment and calibration activities as detailed within the repair procedures ■ Inspection, calibration, realignment, and road tests shall be carried out by a currently trained person ■ Ensure the calibration results confirm the sensors are functioning within the vehicle manufacturer’s technical specification ■ Produce fully verifiable and auditable records and provide a copy to the Asset Owner / Work Provider. * Information courtesy of Thatcham Research We’ve got you support you require to get you proficient with diagnosis, repair and recalibration. Training covered We can provide all the LKQ Academy can support you with all your ADAS proficiency training. Our specialist training providers can help you to Understand ADAS and ADAS Sensors: ■ Relationship To Vehicle Alignment and ADAS ■ Effects of Incorrect Calibration ■ Effects on Other Related Systems

Inspection, realignment and calibration requirements must be considered in all repair situations where ANY of the following is included within the repair, service or maintenance procedure: ■ ADAS sensors ■ Parts likely to affect the operation and functionality of ADAS sensors ■ Vehicle geometry. When specified, inspection, realignment and calibration operations must be completed post repair to confirm the sensors are functioning within the vehicle manufacturer’s technical specification. Why are they needed? As calibration requirements vary from vehicle-to-vehicle, it is essential the vehicle manufacturers’ technical specifications are met to reinstate the correct function of these ADAS features, so the safety and functionality of the vehicle is not compromised.

■ Tested, validated and inspected on the same production line as new parts which ensures that there is consistency ■ Look for the eXchange logo on the product to ensure quality. Choosing the correct replacement part is vital to ensure a satisfactory repair and ensures the vehicle stays on the road. ■ After all the hard work done in correctly diagnosing the diesel component fault, workshops should not jeopardise their diagnosis by fitting inferior products which could lead to the loss of credibility, profit and customers ■ Choosing the right product is critical to a successful repair ■ An increasing number of options are now available to workshops and it is not always possible to see the difference visually ■ Whilst the various options available may all be using the Bosch part number, the product may not be the same and, unfortunately, the Bosch part number does not always mean it is one of the authorised solutions from Bosch. If workshops want a guarantee that the components purchased are to Bosch authorised standards, then they will be in a Bosch branded box.

Do you know what is inside the box? Components can indeed look like quality products but, in reality, inferior products could not only cause excessive fuel consumption and lower performance but can also lead to irreparable damage to the engine over time. All of these problems can lead to additional costs for the workshop and their customer that can be easily avoided by choosing an authorised solution from Bosch. Options available from Bosch include a new unit (same as the OE product), or Bosch eXchange factory remanufactured part (remanufactured in Bosch OE facilities). Bosch new units ■ Bosch produces over 65% of all diesel injectors globally for all major car manufacturers ■ This product is fitted into the vehicle at time of manufacture and is available in the aftermarket as the only identical product to the OE. Bosch eXchange factory remanufactured units Bosch eXchange parts are the only genuine Bosch factory remanufactured products available in the independent aftermarket. ■ The eXchange range covers 95% of Bosch Common Rail Systems ■ 100% replacement of wearing parts ■ Assembled to the latest OE specifications with product enhancements incorporated into the remanufacturing process

■ When a Calibration Should Take Place ■ How To Perform a Dynamic Calibrations ■ How To Perform a Static Calibration ■ Post Calibration. You will be able to: ■ Understand features of Dynamic and Static calibration ■ Accurately calibrate camera-based driver assist systems. SURROUND VIEWCAMERAS ■ Rearcamera ■ 360°cameras ■ Parkassist CORNERSENSORS ■ Lanechangeassist

ADVANCEDDRIVERASSISTANCESYSTEMS ADAS ECU (ELECTRONICCONTROLUNITS) ■ Safetycontrol (i.e.ESP,ACC) ■ Centralcomputingunit forsensordata fusion ■ Engineand transmissioncontrol ■ Brakeand lightingcontrol

■ Drivermonitoring ■ In-cabinsensing ■ Gesture recognition

FRONTCAMERA UNIT ■ Laneassist

■ Speed limitdisplay ■ Adaptive lighting ■ Rain/sunsensor ■ Pedestriandetection ■ Forwardcollisionwarning

LIDARSENSORS ■ Laneassist ■ Stop&Go function ■ Adaptivecruisecontrol

INFRARED CAMERA ■ Nightvision

FRONTRADAR SENSORS

■ Adaptivecruisecontrol ■ Emergencybrakeassist ■ Stop&Go function

STEERING ANGLE SENSOR

■ Cross trafficwarning ■ 360°Surroundview ■ Blindspotdetection ■ Electronicmirror replacement

LEADINGTHEWAYWITHNEWTECHNOLOGIES

Callyour localbranchnow!

Call 01827 838 632 or email training@eurocarparts.com

AROUND THE ENGINE

FAULT DIAGNOSIS OF GLOW PLUGS AT A GLANCE

KNOW YOUR SENSORS

Glow plug faces

Finding the right fault is essential when it comes to DPFs and CATs. A faulty sensor might be the fix as opposed to a blocked or new unit. Often misdiagnosed, it could save you time and your customer money. Our partners Bosch have a wide range of sensors backed up with their historic knowledge and expertise.

Replacing glow plugs in 3 steps, find out more

Lambda Sensors - 813 part numbers

Cause: Premature start of injection. Effect: Tip of heating element too hot, becomes brittle and breaks. Remedy: Check injection system, set injection point exactly. Tip of heating element damaged

Cause: Operation with excessively high voltage, e.g. starting assistance. Excessively long energization (power supply/preheating relay). Impermissible post-glow with engine running. Glow plug with no post-glow capability fitted. Increased alternator voltage. Effect: Break in heating wire. Remedy: Starting assistance with 12 V vehicle electrical system only. Check glow-plug system. Replace preheating-time relay. Cause: Annular orifice between plug shell and heating element constricted or blocked by coke depo-sits. Too much heat dissipated by heating ele-ment, control filament remains cold and allows too much current to reach heating wire. Effect: Break in heating wire, premature failure. Remedy: Check injection system. Set injection point ex-actly. Comply with specified tightening torque. No glow-plug continuity Cause: Excessive terminal-nut tightening torque. Use of incorrect tool. Effect: Terminal stud shears off, damage to hexagon, short circuit. Remedy: Use appropriate torque wrench. Comply exactly with specified tightening torque. Terminal stud damaged Cause: Installation of wrong glow plug (e. g. 12 V glow plug instead of 24 V glow plug). Defective con-trol unit generating too much voltage or not shutting off current flow soon enough. Effect: Ceramic heating element melts due to overvoltage. Remedy: Check alternator. Check correct operation of control unit. Use vehicle-specific glow plugs. Ceramic heating element melted Heating element creased and dented

NOX Sensor - 17 part numbers

Exhaust Temperature Sensor - 75 part numbers

Differential Pressure Sensor - 28 part numbers

Particulate Matter Sensor - 31 part numbers

Heating element melted/broken off

Cause: Premature start of injection. Nozzles with coke deposits or nozzle wear. Engine damage (after valve damage, piston seizure, etc.). Dribbling nozzles. Seized piston rings. Effect: Heating element too hot and melts or breaks. Remedy: Check injection system (e.g. nozzle-and- holder assembly), set injection point exactly.

Warranty extension for starters and alternators ■ Warranty extension from 2 to 3 years ■ Valid fro the entire Bosch starter and alternator program ■ No change to warranty process.

Warranty now 3 years

Heating element ruptured

Cause: Cheap glow plugs/imitations

(tube may swell, burst or even explode due to incorrect filling or poor drying of insulating powder before filling). Effect: Short circuit due to overheating. Tube may burst or explode. Remedy: Use Bosch glow plugs.

Cause: Incorrect injection point. Incorrect spray pattern. Overvoltage (refer to heating element melted). Incorrect fitting due to plug being tilted during installation. Effect: Ceramic heating element becomes too hot and breaks. Remedy: Check engine for loss of oil due to leakage. Check correct operation of control unit. Correct fitting of plug. Ceramic heating element broken