We hope you have had a fantastic summer and you are all set for a busy September. In this issue, we discuss potential upcoming changes to the MOT test and suppliers advise on how best to prepare for peak MOT season, from page 14.
Should you consider o ering upgraded parts and services for your braking system repairs? Rob Marshall asks the experts, from page 22 and looks at the upgrade opportunities with filtration and how technicians have their roles to play, from page 30.
On page 38, we travel to Grimsthorpe Castle in Lincolnshire to join the tenth anniversary of the ego-free Festival of the Unexceptional.
We hope you enjoy the issue!
Nicola St Clair Editor Nicola@autotechnician.co.uk
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* View and download previous digital issues at: www.autotechnician.co.uk
Increased car usage provides growth opportunities
The Independent Garage Association (IGA) has responded to the latest o cial statistics on daily domestic transport usage, released by the Department of Transport. The data compares current levels to pre-COVID-19 levels and reveals that car usage has not only returned to but has surpassed pre-pandemic levels, while public transport modes, including buses, National Rail, and the London Tube, continue to fall behind.
As of August 2024, motor tra c in Great Britain reached 103% of its pre-COVID-19 levels, indicating a strong and sustained reliance on private vehicles. In contrast, public transport usage remains below pre-pandemic levels.
Stuart James, Chief Executive of the IGA, commented: "The latest data from the Department of Transport highlights a critical shift in how the public is choosing to travel postpandemic. The sustained increase in car usage presents a significant opportunity for the independent garage sector. As more people rely on their personal vehicles, the demand for
maintenance, repairs, and overall vehicle care will continue to grow. Independent garages are uniquely positioned to meet this demand, providing essential services that ensure vehicle longevity and safety."
According to data from the European Automobile Manufacturers’ Association (ACEA) in its ‘Vehicles In Use’ report last year, the average car in the UK is now 10 years old. This average age will likely increase in the coming years due to a notable decline in new car sales. The IGA encourages all independent garages to embrace this opportunity, who can expect to see a steady or even increased volume of customers requiring a wide range of services, from routine check-ups and diagnostics to more complex repairs.
1,000 qualified young mechanics ready for work
Autotech Academy is helping to address the estimated current skills gap of between 3,000 to 9,000 technicians in the trade by providing a paid internship programme, giving newly qualified students the opportunity to gain vital experience whilst o ering employers a risk-free way to ‘grow their own’ talent.
There are currently 1,000 graduates signed up to the programme who are seeking their first role, equipped with a complete tool kit and uniform. Autotech Academy conducts thorough interviews and evaluations, saving employers significant time and resources in the hiring process. Interns receive hourly pay from Autotech Academy throughout their 6–12 month placement, alleviating any employment or PAYE issues for the employers.
Since its launch in 2021, Autotech Academy has placed almost 400 interns into the industry, with over 95% going on to secure permanent employment if they complete the programme. While many lack hands-on experience, each intern has at least a Level 3 qualification in Light
Vehicle Repair and Maintenance and will quickly become a valuable resource and additional pair of hands to an automotive business.
Employers are encouraged to take advantage ofthis opportunityto help bridge the skills gap and fosterthe next generation of automotive technicians. For
Schae er to introduce paperless delivery notes
Schae er’s delivery notes are going paperless, with all LuK, INA and FAG part shipments to customers set to include digital documentation by October 1st. The move to cut down unnecessary waste will save over 30 trees per year in the UK alone.
All customers have been emailed about the shift to digital.
“Moving to digital delivery notes is the right move for our customers, and for the environment,” said Matthew Selby,
Sales and Marketing Director at Schae er Automotive Aftermarket. “Apart from the amount of paper used for the delivery notes, which are looked at once and discarded, there is also the issue of the ink and toner used, and the energy expended powering printing machinery. By going digital, we are reducing energy usage, which is simply better for the environment.”
Professional body calls for balanced approach
The Institute of the Motor Industry (IMI) has responded to news that the Labour government is asking independent migration advisors to review the current systems for the approval of skilled worker visas.
Kevin Finn, Executive Chair of the IMI, said: “Fostering domestic talent across the UK economy is, of course, critical for long-term sustainability. However, the automotive sector is experiencing a significant skills gap right now, which a measured use of foreign workers skills could help to tackle.
“The latest IMI automotive vacancies data showed there are currently 20,000 job openings across 200 roles. We believe that a balanced approach will help address immediate workforce requirements with long-term skills development. As such, the IMI welcomes the proposal to establish stronger links between the Migration Advisory Committee (MAC) and the newly created Skills England body and we look forward to contributing our own insight and that of our membership whose experience is critical."
For peace of mind always use a Garage Equipment Association member. GEA accredited engineers work to an industry code of conduct. Your assurance their skills and knowledge have been independently assessed.
Test your skills and register for our 2025 training events
Test your technical knowledge online today!
There are 17 online multiple-choice assessments available, created to test technical knowledge and diagnostic procedures and are available FOC by logging on or quickly registering at www.autotechnician.co.uk/ registration/
Why not try Test 7 that consists of fifteen questions designed to test your knowledge of LIN Bus systems and your ability to analyse the data and waveforms provided to draw diagnostic conclusions?
Test 13 teases SCR system knowledge from users and presents the case of a VW Crafter, which has an illuminated AdBlue Malfunction Indicator, presenting code 'P202AReductant Tank Heating 2 circuit -open circuit'.
Test 16 is a logic check for the real-world fault assessments happening in workshops up and down the land. Questions centre around a real fault-to-fix scenario where a customer
presents an Audi A3 2005 8P model with several faults present.
Test 17 is a fuel pump case study involving a 2017 Land Rover Discovery Sport. The vehicle is fitted with the 204DT 2.0L Diesel common rail engine controlled by a BOSCH MEDC17.9 ECU and is presented with a start and cut-out fault. It has been recovered for diagnosis and the roadside recovery agent has included an explanation of the symptoms as follows, ‘The vehicle runs for approximately 20 seconds and then cuts out, after which, it does not start unless the Diagnostic Trouble Codes (DTCs) are cleared’. You will be required to direct the diagnosis through your analysis of test results and the technical information provided.
Get free, lifetime access to the full library simply by logging in or registering, by providing your email address at www.autotechnician.co.uk/registration/.
We will shortly be announcing our return to Cheltenham next year for our Workshop Takeover and we are also planning to hold additional events in the South and East of the country. Email Nicola@autotechnician.co.uk to hear the news first and gain access to limited, cost-price tickets.
REMANUFACTURING MAKES SENSE
At ACTRONICS, we specialize in remanufacturing a wide range of electronic car parts, including ABS modules, instrument clusters, TCU’s, and more. Contact us and we will help you further!
Voltage drop circuit testing –
Part Three
By Des Davies AAE MIMI, Top Gear Motor Services
This is the third article on voltage drop circuit testing, following on from the fundamentals of the circuit testing method, explained in Part One and Two
Just to recap, good access to the manufacturer’s schematic diagrams and technical information is essential.
Always test the source of electrical power first, which in this case is the battery. You need a minimum of 12V on your multimeter, ideally 12.6V indicating that the battery is fully charged. Before testing the circuit, if your source of electrical power is below 12V then the circuit will not function correctly and give you incorrect readings.
It is also essential that you have a good ground/earth on your multimeter black lead, maximum of 0.5V before starting to diagnose the circuit.
When testing vehicle circuit faults and components you need a good digital multimeter.
Make sure when you are testing any circuit with a multimeter that the circuit is loaded e.g. ignition switched on or the circuit operated correctly.
What does a voltmeter do? The voltmeter checks the reading at the negative point where you place the black meter lead in a circuit, and the positive point where you place the second (red meter) lead in the circuit, and the meter will display a voltage reading if there is a di erence in reading in that circuit between the red lead and the black leads.
"Always test the source of electrical power first, which in this case is the battery. You need a minimum of 12V on your multimeter, ideally 12.6V, indicating that the battery is fully charged"
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Don't forget the 4 rules explained in Part One and Part Two when using voltmeters to test circuits, these are essential to understand, as well as Ohm’s law.
I need to use Ohm’s law for these series circuits and here are the rules:
Current is the same in all parts of the circuit
The applied voltage equals the sum of the volt drops around the circuit
The total resistance of the circuit (Rt) equals the sum of the individual resistance values (R1 + R2 + R3 etc.)
Always check the vehicle battery first for system voltage, a fully charged battery will provide 12.6V
In a series circuit, all the resistors/bulbs/components will share the circuit voltage together, therefore, if one or more resistors/bulbs/components go open circuit, then none of the other resistors/bulbs/components will function correctly.
This is like a Christmas tree arrangement where one bulb goes open circuit, all the lights on the tree will not light up because they are all connected in series – they must obey the rules of a series circuit.
Let's now look at an electrical circuit with two resistors and test using a basic digital multimeter…
Voltage Drop
Below is a good functioning circuit and power source in a 2 resistor/bulb circuit.
Meter 1 (M1) = 12.6V across the power source and Meter 2 (M2) = 12.6v across the resistors in the circuit, these readings must be equal if the circuit is operating correctly.
The black lead connected to the battery negative post and the red lead connected to the input or feed wire of the first bulb/resistor checks the voltage at the input of the first bulb/ resistor, it’s 12.3V, good.
"In a series circuit, all the resistors/bulbs/ components will share the circuit voltage together"
Overleaf, in Figure 3, the black lead is connected to the battery negative post and the red lead now connected to the ouput wire between the first bulb/resistor output and the second, bulb/resistor input/feed wire in the circuit, reading 6.15V, good.
This is a series circuit, therefore both bulb/resistors will now share the voltage of the circuit and if both bulb/resistors have the same resistance value it will be equally shared between each other.
If the resistance values of the bulb/resistors are di erent then the volt drop across each bulb/resistor will have a di erent volt drop reading, the volt drop values of each resistor must
Fig 1.
Fig 2.
DIAGNOSTICS
equal the system voltage and in this case, it would be 12.6V.
Black lead connected to the battery negative post and the red lead now connected to the input or feed wire of the second bulb/resistor between the first bulb/resistor output and the second, bulb/resistor input/feed wire in the circuit reading 6.15V, which again is good.
Because they have the same resistance values, they are therefore sharing the system voltage equally (half) in this case 6.30V each, totaling 12.6V system voltage.
If I had a di erence in resistance readings between both the bulb/resistors, then the voltage drop would not be the same across them and they would be of di erent values, but they must both add up to system voltage of 12.6V in this case, and there will be a di erence in the light outputs as they will not have the same brightness.
The bulb with the higher resistance will be dimmer than the bulb with the lower resistance.
Fig 4.
Black lead connected to the battery negative post and the red lead now connected to the output or earth/ground wire of the second bulb/resistor, 0.30V indicating a good earth/ ground to that circuit. Note that because each bulb is sharing the circuit voltage, these lights will not shine brightly as they only have half each of the system voltage, 6.30V each addingup to system voltage of 12.6V.
Fig 5.
This diagram below illustrates the testing of both resistors in the circuit displaying half the voltage drop in the circuit. Remember that all the resistors must add up to battery or system voltage if the circuit is operating correctly. In this case, both resistors have the same value, therefore they will have an equal share of the voltage, which is 6.30V each adding up to battery/source voltage of 12.6V.
Fig 6.
If the resistance values of the two bulbs inFigure 7 have di erent resistance values, then the voltage drop across each bulb would also have di erent values but would still add up to battery or system voltage of 12.6V: 8.4V +4.2V = 12.6V.
The bulbs will emit di erent light outputs, the bulb with the largest voltage drop 8.4V will be dimmer than the bulb with the 4.2V drop.
Fig 3.
"Remember, if you are not sure of your test results readings then you must have access to the manufacturer’s data to proceed and work safely. Test don't guess!"
I hope that I have explained in detail how to diagnose and test these circuits and to help you make it easier to understand the basic functionality of electrical circuits, and better understand basic testing for voltage drops and faults in an electrical circuit, by using the correct equipment. Remember practice makes perfect!
This article will be continued by a fourth and final article to help you to further your knowledge of basic electrical circuits and systems.
Remember, if you are not sure of your test results readings then you must have access to the manufacturer’s data to proceed and work safely. Test don't guess!
Fig 7.
ISN Garage Assist says that testing new technologies within the MOT cost e ectively presents a huge challenge and it is likely that any future trial will be along the lines of checks we already have for emissions control systems or ABS
Keeping up with technology
Evolving the MOT to keep up with vehicle technology, while remaining cost e ective, is a significant challenge. Here, equipment and training suppliers consider upcoming changes and how best to prepare for peak MOT season
Comment from MOT specialist Chris Pleass and Mark Bristow, Technical Manager at ISN Garage Assist
For all of us – the future of the MOT is really important, and we take an active part in the development of the test for the future – we are represented on the Garage Equipment Association MOT working group through Chris Pleass, something which also allows us to be at the forefront of testing technologies available to our customers.
As vehicles develop, the challenge for the DVSA is to maintain an MOT Test that is e ective and relevant to today’s vehicles and fit for the future. For example, should modern technologies on vehicles such as Advanced DriverAssistance Systems (ADAS), become part of the MOT? How you test these technologies cost e ectively has become a huge challenge and it’s likely that any future trial will be along the lines of checks we already have for emissions control systems or ABS – where the vehicles own diagnostic information is checked, rather than checking the system itself.
As new tests are introduced into the MOT Test, we need to ensure there’s an environment where investment is encouraged. If fees do not increase (and they’ve remained unchanged for years) but investment is required to retain accreditation, the return on investment calculation for a test
station becomes less interesting – and with more vehicles on the road each year, demand is increasing.
Headlamp Beam Testing
Today’s advanced LED headlamps are not being adequately tested with the equipment currently in use. A new specification has been tested but under the previous government this was ‘pushed into the long grass’. With the election out of the way, the focus might change again but don’t hold your breath! The DVSA is looking to tighten up the calibration procedure's for HBTs, but some would argue there are more important things to address.
Particulate Number (PN) Testing
This is something that’s being rolled out in Germany. A UK trial in 2023, involving 1,800 vehicles and a variety of PN testing machines, revealed a failure rate of 5%. It’s much lower on current emissions test equipment as new diesel engines are too clean to register any significant readings on the current opacimeters. The DVSA is conducting a ‘cost-benefit analysis’ on the introduction of new equipment. Either way, ISN have the new technology ready and waiting as soon as the DVSA make their decision.
Electronic Park Brake testing
Testing EPBs on modern vehicles can cause challenges with the car being ejected from the brake rollers. So, often a decelerometer is used which tests the overall deceleration of the vehicle when the handbrake is applied at a set speed. However, many modern cars deploy the hydraulic braking system if the handbrake is applied above a certain speed, rendering the conventional decelerometer test unreliable in certain circumstances.
Thankfully, moves are afoot to change this at DVSA level; ISN Garage Assist has developed software for single wheel parking brake testing on current roller brake testers along with technology to allow the handbrake to be tested using the applied method. This allows the handbrake to be applied and then the brake rollers build up force against the handbrake to try and move the wheels.
Should ADAS checks and calibration be part of the MOT?
Lane-keeping assistance, automatic emergency braking, adaptive cruise control and pedestrian detection are just a few examples of the ADAS systems heading into independent workshops and Andy Brooke of Maverick Diagnostics suggests that given the prevalence of ADAS, not only is it important that the independent aftermarket is qualified to tackle this technology, but given the safety-critical nature of the system, should it be part of the annual MOT?
Andy states that these systems all rely on sensors and cameras working correctly to ensure accuracy and that a front-facing camera, for example, that is just 1.5° out of calibration – possible from an innocuous knock – can be approximately 60ft o over distance. “This emphasises the need for these systems to be maintained and calibrated and that maintenance is currently the responsibility of the driver. In the UK, motorists, like when it comes to any type of vehicle servicing, are accountable for the functionality of ADAS on their vehicle. This includes cleaning sensors, checking alignment and calibration.
“Unfortunately, according to the Institute of the Motor Industry’s December 2023 research*, ADAS technologies and calibrations are not well understood by the general public.
“The automotive industry continues to evolve at pace and it’s essential that the MOT, as a legal roadworthiness test, doesn’t fall behind. Change should be delivered with drivers’ and garages’ best interests at heart, as we continue to see increasingly sophisticated vehicles enter the car parc – be those hybrids and EVs, or any vehicle fitted with ADAS technology.”
Spokesperson at LKQ UK & Ireland
Of 1,036 respondents, 18% knew what ADAS was and could correctly identify it; given 86% of drivers surveyed have ADAS on their vehicles, that is a startling revelation.
“It gets worse: according to the same research, 39% of drivers thought ADAS calibration was conducted during an MOT, and 47% thought ADAS calibration, if required, was an urgent job. Absolutely, we, as an industry, need to do better in terms of educating the general public about the systems; however, given the safety-critical and complex nature of them, is it justifiable to place such responsibility on them? If ADAS checks and calibration were part of the MOT, wouldn’t this help alleviate the problem?”
Welcome to MARS!
Maverick Diagnostics has recently struck an agreement with American company, Dynamic Automotive Solutions, to sell the Mobile ADAS Recalibration System, M.A.R.S for short. It is ideal for mobile technicians and independent workshops with limited space. The system conducts ADAS calibrations; boasts a compact design and has a collapsible stand that reduces to a 36” frame.
It is fully compatible with OEM service information, which allows for exact calibrations of front radar and blind spot radar systems using both OEM and aftermarket scan tools. The kit also comes with multiple, space-saving targets, as they can be rolled up.
“Electric vehicles – like them or loathe them – they’re here and technicians have no choice but to get a grip on their needs, such as putting a Tesla into the correct mode for testing. Specialist EV training should become a standard part of an independent workshop’s education. Ultimately, vehicle systems are evolving and independent workshops must adapt – and adapt quickly.”
Andy Brooke, Maverick Diagnostics
12-volt battery opportunities
Although many workshops are reluctant to embrace the repair of electric vehicles, Ecobat Battery says the annual MOT presents a di erent proposition that opens the door for an addition profit opportunity – their 12-volt battery.
The battery distributor urges garages to test the condition of the 12-volt battery every time an EV comes in for its annual MOT test – whether an EV incorporates a combustion engine with a 48-volt or 350-volt battery in hybrid form or uses a 400-volt plus battery as a fully battery powered variant, a ‘traditional’ 12-volt battery is also fitted, and failure of this battery remains the most common cause of breakdowns. It remains integral to hybrids and EVs to enable them to perform vital functions; not only powering the lighting system, both internal and external, but the central locking, alarm, and other security features. It also powers the vehicle’s onboard computer and diagnostic systems and plays a role in starting the main high voltage (HV) battery pack. Furthermore, the cyclic nature of the electrical loads and usage patterns when fitted in an EV, can leave it in a discharged state, and increase the likelihood of premature failure.
If its state of charge is 12.7-volts or above, there’s no problem, good news for the owner. If, however, it’s 12.5-volts or lower, there could be a problem, but it’s one that the workshop can
resolve either by charging or, if needs be, by replacement. In this case, providing they use the correct protocols for working on a HV vehicle, installing a replacement not only solves a problem for the owner, but it also makes a profitable job for the business.
Use the Battery Finder on its refreshed website: www.ecobatbattery.com/applications/cars-vans/
Should the EV MOT Test be di erent?
"With the exception of emissions testing, the vast majority of the existing MOT is entirely applicable to EVs. It might make sense to add a test for some additional items, such as the function of ‘Acoustic Vehicle Alerting Systems’ but there’s a lot of work to do to identify the relevance of possible tests and to assess how feasible and a ordable they might be.”
Mark Bristow, Technical Manager, ISN Europe
Prepare for peak MOT demand
LKQ Euro Car Parts is calling on garages to ensure they are MOT ready as September promises to be one of the busiest periods in MOT testing history, with 3.4 million MOT certificates expected to expire this month.
LKQ o ers the following tips to maximise testing capacity and e ciency and make the most of the spike in demand:
Keep on top of training requirements
MOT refresher courses and advanced training are on o er for technicians looking to improve their e ciency and accuracy when carrying out tests – with MOT Tester Class 1, 2, 4 and 7 and MOT Centre Manager courses, available to book through the IMI-accredited LKQ Academy (https://lkqacademy. co.uk/)
Manage demand
It recommends implementing garage management software solutions such as CarSys to help workshops proactively manage demand, as testing numbers fluctuate. Set up online booking systems to manage appointments and send out reminders ahead of MOT expiry dates to make best use of chargeable time in the workshop at one of the busiest times of the year.
Common failures
Another key heads-up for garages is that this MOT season, increased demand is expected for common parts like brakes,
tyres and lights. Around 8.5 million motorists have reported neglecting car maintenance to save money and so an MOT will likely be their only visit to the garage in a year, meaning garages should prepare to pick up on more repairs, that will need to be made to ensure a vehicle is roadworthy. Its Euro Car Parts Service Kit Builder, available via online parts ordering platform Omnipart (https://omnipart.eurocarparts. com/), is designed to minimise the administrative burden on technicians by enabling them to easily select applicable parts by entering a vehicle’s registration.
Bob Wi en, Workshop Solutions Director, states: “The September peak in MOT demand, which arose during the coronavirus pandemic when hundreds of thousands of tests were deferred, will inevitably level out at some point – but not yet.
“With the right preparation, workshops can capitalise on the record number of vehicles expected to come through their doors for testing this month – using digital tools and e ective diary management to make sure they can accept every enquiry.
“Building capacity is crucial for garages to maximise revenue opportunities, and to provide a great experience that will encourage customers to come back for future repairs.”
While
Stay connected
New MOT equipment needs to be able to connect to the DVSA MOT testing service and MAHA UK's MOT garage equipment, including the MBT 2250 EUROSYSTEM software, allows seamless integration with other modules, and this connectivity improves e ciency and futureproofs the workshop for evolving industry demands.
Beissbarth alignment system gains VAG approval
Furthermore, independent workshops face increasing scrutiny in meeting DVSA specifications. The suppliers collaboration with the Garage Equipment Association (GEA) ensures that its equipment consistently meets the stringent criteria for being 'green coded' – a marker of equipment that is current and fully compatible for use in MOT sites.
The new Beissbarth Q.Lign system now carries full approval status for all VW / Audi / Seat / Skoda / Cupra / Porsche/ Lamborghini / Bentley vehicles and has the very latest wheel alignment data and software, as approved by the manufacturer, from June 2024.
The Q.Lign is available through Straightset, which states that it is the world’s first web-based wheel aligner and that being a compact webbased technology, creates more space by replacing the need for trolley with PC & printer. It can stream to directly display the software on any TV, PC, laptop or Android device.
Using the Q.Grip clamps provides accurate and full alignment data which can be viewed on the display instantly, together with an overview of the wheelbase, o -sets and wheel centre dimensions.
As today’s vehicles have some form of forward facing ADAS equipment installed, the Q.Lign is complimented both with the Q.DAS ADAS calibration rig and the VAS6430 rig, which seamlessly integrates with the aligner, to meet the high accuracy requirements of all OEMs.
To see the Q.Lign for yourself you can visit Straightset’s Wheel Alignment Training Studio, contact Straightset on info@straightset. co.uk for more information
THE FORMULA FOR SPEED
Custom t all-inclusive chassis repair solutions.
Custom- t solutions – everything in one box
Schae ler’s high-performance FAG steering and suspension parts are tailor-made to suit each speci c application. Depending on the product, our comprehensive and complete kits contain up to three times as many ancillary components as some competitors - all in uncompromising quality. This makes for simpler and quicker repairs, and reduces the risk of follow-on problems caused by mismatched or missing parts.
Our Schae ler repair solutions under the FAG brand are tailor-made for every type of vehicle. Depending on the repair kit, our comprehensive, complete solutions contain up to three times as many parts as is customary on the market – naturally in uncompromising quality. In this way, we ensure smooth workflows in the workshop and reduce the risk of problems caused by mismatched or missing steering and suspension parts.
Braking Bonanzas
When considering fitting upgrades to a customer's car, consider its usage. Track vehicle braking needs are very di erent to that of a road-going car. Therefore, ensure that a well-intentioned upgrade is not a serious safety downgrade.
Should you even consider o ering upgraded parts and services for your braking system repairs? Rob Marshall asks the experts to find out.
One would have thought that ECE regulation 90 (R90) would provide clarity about brake friction specifications. Yet, it is far from clear-cut. Some aftermarket brake friction manufacturers view these standards as a target; others use them as a springboard. The Alliance Automotive Group's parts brand, 'NAPA,' for instance, sets higher standards. Its adhesive bond testing between its pad backing plates and the friction material is tested at double the force levels required by legislation. The firm then adds a further 50 complementary and preventative tests over those required by R90. This gives some explanation as to why braking performance di ers so much between brake friction components.
"It is important not to fit brake friction parts that do not comply with R90... Doing so can render the vehicle unroadworthy and you could be held liable"
It is important not to fit brake friction parts that do not comply with R90, or the relevant EU regulations. Doing so can render the vehicle unroadworthy and you could be held liable, if the car is driven from your premises.
Keeping compliant
ZF Aftermarket says that, depending on the intended use, discs and pads might not need to comply with ECE regulations. This explains why o -road parts can be obtained easily. This presents a problem, should you be instructed to fit motorsport brakes to road cars. For instance, some o -road race/track specification pads exceed the ECE maximum performance limits, by providing too much friction. Surprisingly, this is undesirable, meaning that these pads cannot be R90 compliant and, therefore, as ZF Aftermarket reasons, should not be fitted to a road car. This explains why the firm's TRW brand does not o er a performance range, although its True Originals range boasts enhanced braking performance, when bedding in, and DETC pads that release less dust without compromising performance.
Another example of an OE supplier going the extra mile with its R90-compliant friction o erings is Delphi's latest Bi-Metallic brake discs. Over the stock specification parts, they o er reduced weight, superior fuel consumption, lower braking temperatures, increased wear resistance and
enhanced corrosion resistance. A typical example of this latter claim is Delphi's equivalent Bi-Metallic brake disc taking twice as long to exhibit corrosion, compared with a BMW OE coated part.
Napa also o ers garages and technicians choices that you can present to your customers as upsells. These vary from the more budget-orientated 'Proformer' and 'Apec Blue' products to the premium-range 'Apec Black'. Notably, all of them are R90 compatible. Drilled, grooved, and pinned discs are available, which boast the 'Apec Black Advanced Friction Technology', which Napa says makes them quieter, longer lasting, and less susceptible to fade than the OE parts. Yet, Napa emphasises that these upgrades are not intended for race vehicles. Instead, they provide a premium braking option, while satisfying R90.
Napa Auto Parts is also an o cial stockist of Brembo, a brand recognised by many technicians and performance
Drilled, grooved, and pinned discs are available in Napa's Apec Black range, all of which are designed to exceed the OE performance, while maintaining R90 approval.
enthusiasts as a developer and supplier to both highperformance OEMs and the aftermarket. Yet, Brembo confirms that all of its friction parts comply with the relevant ECE safety regulations, including R90, indicating that you will not render a vehicle unroadworthy by installing its products. Regardless of whether you fit the firm's 'Upgrade GT disc kit', which allows you to retain the original callipers and wheel rims, or the 'Upgrade GT Kit', which comprises bigger discs, pads and a range of calliper options, you will not invalidate the Whole Vehicle Type Approval and make the vehicle unroadworthy.
Bigger is not always better
There is a misnomer that all upgraded parts must be better than OE, especially if the 'bigger is better' attitude is adopted. GSF Car Parts makes it clear that carmakers calculate braking requirements immensely carefully, so o ering larger brakes can introduce disadvantages. These include considerations that are not that obvious, such as increasing unsprung weight and raising CO2 emissions.
ZF Aftermarket adds that garages should think carefully about fitting bigger than standard parts, especially those supplied by an enthusiastic owner, who has all the best intentions but little intrinsic knowledge about how the modification a ects
adjacent components. The extra space required by larger brakes might dictate bigger wheels with di ering o sets, for instance. Spacers may also be needed to clear the larger callipers. These changes might place extra loads on the hubs and wheel bearings. Wider wheels might also cause undesirable and potentially unsafe contact between the vehicle body and suspension components.
ZF Aftermarket also requests technicians to consider the ramifications of bigger callipers. Has the owner considered if the existing master cylinder can cope with the increased volume of fluid needed to activate a greater number of calliper pistons? Is the car equipped to transfer the greater braking forces to the road? Can the suspension resist excessive dive under harder braking, so the car does not become unstable, or should firmer springs and appropriate dampers be fitted?
Yet, a customer is more likely to request that you install racing pads. Should you choose to do so, it is important that you describe possible consequences beforehand. Napa provides clarification that brakes for road vehicles are engineered to work well across a wide temperature band. This is a requirement of R90 that racing pads do not meet. Motorsport friction brakes are designed to work at elevated temperatures
TMD Friction has launched its UK Brake Distributor Search feature for the Textar, Mintex, and Don aftermarket braking brands.
that are atypical of everyday driving. This comes at the expense of low-temperature performance, which could introduce safety problems. Should the driver need to execute an emergency stop at the start of a journey, the racing pads will not have attained their optimal operating temperature and the stopping distance might be considerably longer than that achieved with OE-specification pads. This, Napa reasons, makes fitting racing pads to road cars incredibly dangerous.
The bilstein group adds that racing pads tend to possess harder friction compounds, the result of which, as First Line comments, can change the brake pedal feel and increase disc wear. Delphi also highlights the comfort considerations. R90-compliant brake pads are designed to reduce vibration and harshness. Racing pads sacrifice these characteristics for supreme high-temperature performance, which a customer should realise.
"Racing pads tend to possess harder friction compounds, which can change the brake pedal feel and increase disc wear"
However, this does not mean that you should avoid parts that are described as 'racing pads' altogether. DRiV markets a limited range of premium pads. While these are marketed as Ferodo Racing, they possess R90 homologation, meaning that they are suitable for road use. So too does TMD Friction, with its Mintex Racing pad range, which is road-legal but suitable for light track day use.
EV upgrades
Ferodo reminds technicians that the friction brakes, fitted to Battery Electric Vehicles are more likely to corrode and drag. This is not only down to regenerative braking resulting in less use but also because the brakes are exposed to average temperatures of under 100 degrees Celsius, considerably lower than combustion-engined cars. This reduces the chance of them drying out. Brembo says that friction wear might be less (unless the brakes have been dragging for a long time) but technicians should also remain vigilant for signs of oxidation. The bilstein group highlights that some BEVs require more brake maintenance and many manufacturers recommend that the brakes be stripped and lubricated annually to reduce the risk of corrosion-induced seizure and consequent brake binding. You may have to explain to your customer why this extra work is necessary, when they might have been led to believe (incorrectly) that BEVs require little to no workshop attention. TMD Friction suggests that garages could o er a Braking System Inspection Package as an upsell service.
You can also upgrade the brakes and aftermarket suppliers have worked hard on developing R90compliant options. For instance, Delphi's EV brake pads
Brakes for All Makes.
Complete All-Makes Range
boast a silver powder-coated backplate that resists corrosion. A multi-layered steel and rubber composite shim is also included to reduce noise and vibration, which is relevant for BEVs, because brake noise is not masked by that of a combustion engine. Delphi also reveals that excessive brake noise is a common reason for product returns. Therefore, not fitting brake pads that are designed with comfort in mind risks a customer returning with a complaint. Brembo, too, o ers coated discs and brake pads with high corrosion resistance and low noise levels, through its 'Beyond EV' aftermarket o ering. ZF's TRW brand provides garages with the same advantages for replacement pads, under its Electric Blue umbrella.
Blue Print offers a complete All-Makes range of more than 3,550 brake friction components with a coverage of over 98% of all passenger cars and LCVs on European roads - for brake discs and pads launched after the year 2000.
Precision Fit
Each stage of the production process undergoes a sample analysis to check accuracy, ensuring that regulation standards are met and that everything is being produced to the correct specification.
OE-matching Quality
All braking components are developed and manufactured to exactly match the OE, ensured with rigorous quality checks such as dynamometer testing for braking, noise and wear performance, and physical and chemical tests for hardness, strength and compressibility (meeting various ISO, SAE and JASO standards).
Confidence that brakes will fit ‘Right First Time®.’
Brake fluid upgrades
While brake fluid should be replaced every two years, due to its water-absorbing nature, Brembo highlights that this essential safety task tends to be neglected. The result is a lowering of boiling point and an increased risk of brake failure and internal corrosion. While DOT 4 fluid suits most cars, Brembo highlights that low-viscosity fluids can work better, especially at low temperatures, in cars equipped with stability/traction control systems – which is most modern vehicles! Should you work on a vehicle with neglected fluid changes, or you know that the brakes are used hard (especially if the owner lives in a hilly area), Ferodo comments that it may be worth using DOT 5.1 fluid, which has a higher boiling point than DOT 3, or 4, but this should not be used as an excuse to extend fluid flush intervals. Yet, it increases the safety margin. Helpfully, the bilstein group confirms that all DOT 4 and DOT 5.1 fluids (including low viscosity/'plus' types) are backwards compatible, despite it being not best practice to mix fluids.
To overcome the hygroscopic problem, and fluid flush requirements, you may o er the much more expensive DOT 5 fluid as an upgrade. ZF Aftermarket comments that, because it is silicone-based, DOT5 must not be mixed with glycol-derived DOT 3/4/5.1. Napa agrees and does not recommend you use it.
As TMD Friction highlights, because DOT5 is more compressible and can aerate easily, it is unsuitable for vehicles fitted with ABS/ESP. However, DOT 5 has found favour with many classic car owners, especially those that are used infrequently.
Going the extra mile: Brake hoses
Delphi reminds us that brake hoses have limited lifespans, because the rubber degrades. After 8-10 years, the material becomes brittle and is susceptible to cracking. Interestingly, Napa highlights that some vehicle manufacturers' service documents specify brake hose replacement every 5 years, or 50,000 miles. In reality, they tend to be replaced only when an MOT inspector spots a problem, which is usually excessive perishing on the outside. Yet, a hose is likely to have deteriorated internally long before this is noticed. Delphi advises that discoloration, or even rust on the metal parts, are early warning signs that the hose is degrading. As the picture shows, the old hose has lost its flexibility and has collapsed internally. ZF reasons that a reduction in this structural integrity can also cause abnormal expansion of the hose under braking, reducing the braking performance and attributing to poor pedal feel for the driver. In extreme cases, the hose could burst, leading to partial or full, brake failure. The bilstein group highlights that a consequence of neglected brake fluid changes is an increased rate of internal flexible hose degradation. Yet, the firm behind the febi brand thinks it unlikely that a typical owner of a 20-year-old car, which receives very basic maintenance, will be convinced easily to pay for a set of brake hoses, purely for preventative safety. Comline realises this too and advises that calliper replacement, or removal, is an ideal time to schedule a brake hose change.
You, or the car owner, might consider fitting stainlesssteel braided brake hoses. These products involve the internal hose being wrapped in a strong braid. The main advantage is a decreased risk of the hose ballooning under pressure, meaning that more of the braking force is transferred to the hydraulic pistons. Yet, it can be argued that this advantage is not relevant to normal road cars. While it is logical that good-quality braided brake hoses will last longer, they are harder to inspect than conventional flexis.
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While there are not too many options for filter upgrades, lateral thinking and research will aid customer choice and bolster your income stream - but be wary of any compromises.
KIDNEYS FOR CARS
Without means of filtering contaminations, motorcar life would be seriously compromised. Rob Marshall, therefore, looks at the upgrade opportunities and how technicians have their roles to play.
From a technician's standpoint, addressing a car's filtration requirements seems fairly straightforward. Renewing an air filter, for instance, tends to be one of the easiest tasks within the realms of vehicle maintenance. Ditto the cabin filter, despite some car designers presuming that service technicians are born contortionists. Oil and fuel filter renewal tend also to be relatively straightforward, if a comparatively messy a air. Yet, it is easy to be complacent and forget the importance of decent filtration.
Considering the parts
As you would expect, quality filtration manufacturers advise strongly that you insist on OE quality, a stance confirmed by Comline and First Line, for instance. As a seller of multiple brands, GSF Car Parts advocates selecting the highest quality brands and highlights 'MANN' and 'HENGST' as typical examples. Yet, the company realises that this is not always possible, which is why it o ers filters under its 'DR!VE+' brand, which it says is a strong option for the aftermarket.
Typical cabin filter replacement intervals are between 6 - 12,500 miles, annually, or as specified by the vehicle manufacturer, whichever interval comes first.
Options for filter upgrades are, therefore, very limited. Yet, should you work on classic/vintage/specialist/kit cars, you may encounter aftermarket spin-on oil filter adapters. In the case of kit cars, they may be necessary due to restricted engine bay space. They may even be a solution for older cars, where the original cartridge filter has long become obsolete. Should you be asked to install a spin-on filter conversion, resources are available to help you and an inquisitive owner select a suitable filter. For instance, Mann's online catalogue provides not just dimensional details, including thread sizes, but also bypass valve pressures, too. Where a car su ers from oil drain issues, causing harmful cold-start rattle/knocking, you might wish to suggest that the owner tries a filter from another brand. For instance, some OE quality filters may contain a single non-return valve, whereas another OE quality alternative one might possess two, which could reduce, or even eliminate the problem. Yet, UFI warns not to deviate from catalogue recommendations, because using incorrect part numbers could cause the filter to collapse.
Look also for specialist filters, including those for transmissions and couplings, such as the Haldex type. Linked to this are certain BEV applications, should you be looking to widen your o erings. Naturally, quality aftermarket suppliers are keen to assist. As part of its
Inspecting pleats of removed filters, before they are discarded, can give hints of pending mechanical problems. Pictured is a diesel fuel filter.
growing eSolutions portfolio 'MEYLE', for instance, has introduced complete Tesla S,X,3,Y driveline model oil and filter change kits for aftermarket garages.
So favoured by the performance community are aftermarket free-flow air filters. Many of these types require periodic cleaning and lubricating, instead of replacement. Should you be confronted with a vehicle thus-equipped, you may have to discuss the issue with the car owner. First Line advises that such filters have the potential to increase power, torque and e ciency but, because of the increased airflow, there is a chance that the engine has to deal with debris and contaminants. GSF Car Parts adds that, if upgraded filters are fitted to a modern engine, further engine upgrades are recommended. It emphasises that the range of filters it provides are made to carmaker specifications and the majority of its brands are designers, R&D and suppliers for the vehicle manufacturers. LKQ Euro Car Parts informs us that the oil used in reusable air filters can contaminate and damage mass air flow sensors if the cleaning process is not followed correctly, so technicians should be cautious.
Cabin filters o er the greatest potential for upgrades, the
benefits of which are easier to explain to a non-technical customer. Should an impecunious owner try to shave several pennies from the service bill, by instructing you not to replace this filter, the increased presence of dust, pollen and damp can increase the risk of allergies within the interior and prevent the heating, air conditioning and ventilation systems from working properly. Window demisting ability, for instance, would be compromised severely, which explains why cabin/ pollen filters should be replaced at least once annually.
First Line advises that many cabin filter makers o er carbonactivated filters as a premium option. These extract not just particulate matter, but also harmful gases and odours. The amount of carbon used is chosen carefully, to permit the filter to protect the interior from harmful Volatile Organic Compounds for a long period. Therefore, in First Line's view, carbon-activated filters are a good upgrade option, although it highlights that there is nothing wrong with the standard filter. Comline agrees, citing that upgrading a standard pollen filter to a carbon-activated one is a good idea, due to the enhanced air purification characteristics. 'DENSO' adds that its charcoal-activated combination filters remove 25% more
Never install new filters in dirty housings.
major pollutants than standard cabin filters, in addition to eliminating unpleasant, or harmful, gases and smells. 'NAPA' says that its carbon-activated filters eliminate almost 90% of odours and trap harmful gases, such as ozone, nitrogen oxides and sulphur dioxide. These qualities are beneficial for occupants, especially those who su er from asthma and respiratory conditions.
Yet, there are other options, too. Aside from o ering standard and carbon-activated cabin filters, GSF Car Parts highlights bio-functional filters, which o er almost complete protection against nitrogen oxides, dust, allergens and mould.
The technician input
While parts quality is essential, even the finest filter cannot overcome improper fitting. When changing the cartridgestyle oil filter element, Comline recommends that you check the pleats and housing for any excess metal filings, which is likely to be a sign of high wear levels, or damage. Additionally, checking for leaks is always a wise idea, as First Line highlights.
With air filters, GSF Car Parts advises that you should clear the air box of any debris and ensure that the trunking is secure and in good order. Naturally, placing a new filter within a dirty housing will also compromise the filter's lifespan. UFI also says that technicians should ensure a decent seal at the housing edges, so all incoming air passes through the filter.
Denso says that the same advice applies to cabin filters. Should debris be found, the housing must be cleaned, before the new filter is installed. LKQ Euro Car Parts reminds technicians to upsell air conditioning cleaner spray/bombs. These products not only sanitise the air ducts and evaporator (key areas for mould spores to breed) but also enhance the filter's e ectiveness.
Finally, do not forget post-fitting checks. Comline says that, after fitting a new cabin filter, technicians should inspect the heating, ventilation, and air conditioning components for wear and damage, before checking for correct airflow and potential odours, so you can be sure that the new cabin filter is working properly.
PARTS, TOOLS & TIPS
New products, fitting tips & technical advice to ease fault-finding and installation
OESAA Academy Live heads to Gloucester, Exeter and Fareham
OESAA is providing apprentices and college sta hands-on experience and industry insights through OESAA Academy Live, taking place at Gloucestershire College on Wednesday 16th October, Exeter College on Thursday 17th October and Fareham College on Thursday 14th November. The event will feature presentations and demos, explain best practice techniques and career pathways within the trade.
Gloucestershire College Lecturer in Motor Vehicle, Robert Papps, is looking forward to his students receiving information first-hand from OEMs for the first time – “For many of our students, this will be the first time they hear key information directly from a manufacturer, giving them the opportunity to ask questions and hear first-hand from those already in the trade.”
OESAA Chairman, Nigel Morgan, said: “These events are crucial; giving back to the grassroots of the industry is essential and demonstrates to everyone involved that the sector is dynamic, inclusive, and profitable.”
£200 Virgin voucher giveaway with free access to VM repair data
Workshops who sign up to a free trial of Alldata Repair before September 9th will enter a prize draw to win a £200 Virgin Experience Day voucher.
The 14-day trial provides full access to Alldata Repair and the add-on Labour Times, giving users comprehensive repair procedures, detailed wiring diagrams and maintenance schedules.
Sign up for a free trial and enter the voucher competition here.
Braking news
Apec has extended its Blue and Red ranges by 28 new braking components, including brake pad sets, master cylinders, cables and hoses.
Top applications in the Apec Red extension include the rear brake pad set for the Tesla Model S 2017, and the brake master cylinder for the MINI Cooper 2008-2015. Notable Apec Blue additions include the rear brake pad set for the Ford Escort 1986 -1994 and the front brake pad set for the Vauxhall Astra Mk III 1991 – 2001.
https://apecautomotive.co.uk
Programme takes new direction
KYB has introduced a new range of steering parts, comprising wishbones, ball joints, stabiliser links, tie rod ends and rack ends, and are available in the online TecDoc catalogue.
Growth in sensors
The KYB control arms all include the ball joints, and all ancillary parts are also supplied with the range.
www.kyb-europe.com/steering-parts
SMP Europe, home to the Lucas, Lemark and Intermotor brands, has boosted its ignition and engine management products with 17 new part numbers.
Additions include two new crank sensors to fit Fiat 500, 1.4 engine, 2007- and a new exhaust temperature sensor to fit popular passenger car applications, including various Citroen, Vauxhall and Peugeot models. www.smpeurope.com
The Blend reveals September lineup
An impressive lineup of speakers awaits independent garages at The Blend on Saturday 28th September in Birmingham.
James Dillon of Technical Topics will explore the potential of Artificial Intelligence, demonstrating how it can enhance diagnostics, boost e ciency, and elevate customer service. John Batten of Auto IQ will outline strategies for longterm success. Michael Shaikly of Shaikly Motor Company will provide tips on how to identify and retain ‘ideal’ customers to maximise profits, commenting: “There are thousands and thousands of cars out there that need fixing,” said Michael. “You’re never going to fix them all. Just make sure you’re serving the customers you want.”
Paul Gri ths from Elite Land Rover considers the pros and cons of scaling a business and as the diesel repair market shrinks, Andy Crook of Atomic Success will emphasise the
need for garages to diversify services and adapt to industry changes to replace lost revenue.
The full lineup is available at www.theblend.events
INTELLIGENT BATTERY CHARGING
Brake judder – cause and prevention
In many cases, no symptoms of brake judder will be apparent following the fitment of new discs, with vibration being felt after a few thousand miles. Like most things in life, preventing this comes down to preparation.
febi runs through the do’s and don’ts to prevent disc thickness variation and judder here
A 1982 Toyota Hilux won the Concours de L'Ordinaire, followed closely by a one-family owner from new 1998 Renault Clio. The Retro Repmobile Award went to the 21-year-old owner of a German-registered 1991 Nissan Primera and the Chairman's Award was bestowed upon an early Austin Metro.
HAGERTY FESTIVAL OF THE UNEXCEPTIONAL
27th July, 2024
Approving of the very British trait of not taking life too seriously, Rob Marshall travelled to Grimsthorpe Castle in Lincolnshire to join the tenth anniversary of the ego-free FOTU
Like white dog poo, certain cars used to litter every street corner. Then, they disappeared. While the world has become a safer place since, nostalgia has fostered a new breed of car fan that celebrates the 'chod' and preserves the memories of the mundane. This demands a special kind of car event; something di erent to the norm. Something diverse, something special, something fun.
A decade ago, insurance specialist, Hagerty, realised the advantages of tapping into this potentially lucrative market, involving thousands of low-value but low-risk vehicles. The idea was to attract the driver, who wants to be di erent, but with more sense than money. The Festival of the Unexceptional was born. Starting from humble beginnings in a field, hosting a smattering of Morris Marinas and Fiat 124s, the event has ballooned into one of the UK's must-attend events.
This was not an excuse to litter Grimsthorpe Castle's impressive grounds with scrapyard fodder. The most telling sign was the love and devotion that has been lavished
The Autotechnician award for the rattiest valve gear goes to...
on vehicles by enthusiastic owners, irrespective of their monetary value. Naturally, the best vehicles had been entered into the wonderfully apt Concours de L'Ordinaire, held in the castle courtyard, ready to be judged by such automotive royalty including Steve Cropley (Editor-in-Chief, Autocar) Danny Hopkins (Editor, Practical Classics magazine), Jon Bentley (Former Top Gear Producer, current Gadget Show presenter) and Richard Bremner (Freelance Editor and columnist).
Other celebrities were present too. Richard Porter (TV scriptwriter/sni petrol.com author) and Jonny Smith (of YouTube's The Late Brake Show) entertained the crowds with retro-themed games, such as Chod Swap Shop, where attendees could exchange car-related tat, before recording the latest episode of the popular podcast Sni and Sni . Their most popular show was the Wheel of Misfortune, seeing Smith spinning a carnival wheel in the style of an early
ever
to
1980s Ford Sierra Ghia wheel trim, while o ering gallons of Brut aftershave as prizes. Popular categories included the Flying Plughole (BL), 'Fwords' (Ford) and Luton Intolerance (Vauxhall).
Yet, the real heroes were the 4,000 visitors, many of whom were aged under forty, who brought along over 2,000 mundane but much-loved cars. Porsche Panameras were out; Perodua Nippas were in. The variety of cars was stunning. What other show would you be able to view the last Montego ever made (provided by the British Motor Museum) against a W140 Mercedes-Benz S-Class (base model, of course)?
FOTU also celebrates 'Rare but Nobody Cares' cars. Fiat Argenta, anybody?
If you
waited
see the dashboard from an Alfa Romeo Arna/Nissan Cherry Europe, FOTU is the show for you. It will return next year.
The two minds from the Smith and Sni podcast playing 'Wheel Trim of Misfortune' with the audience, with a passing Daihatsu Move.
WEDNESDAY 11TH DECEMBER • OLD BILLINGSGATE MARKET
GATSBY GLAMOUR AWAITS
Join your automotive family for a standout event lled with vintage elegance, festive cheer and unforgettable moments.
