ISSUE 20
oct – dec 2010
Timing is
Everything how modern engine management technology optimises the combustion process
Inside this issue:
Charge ahead The impact of fuelsaving technologies on the battery market
plus…
Lighten up The business benefits of upgrade bulbs
A clear winner Stocking the right wipers for winter
…and lots more!
feature title
VITAL NEWS
Note from the MD Dear Customer Welcome to the latest edition of Vital News.
CONTENTS
2 NOTE FROm THE MD
Neil Davis, Managing Director of FPS, welcomes you to this edition of Vital News
3 FPS NEWSDESK
What’s new in the aftermarket
4 move over petrol-heads!
Now you can have high performance with diesel economy! Vital News discovers how
6 Timing is everything
The latest additions to Cambiare’s Engine Management Programme
7 FOR YOUR INFORMATION More vital product news
8 charge ahead
Vital News looks at the new challenges facing the humble car battery
10 winter glow
The latest developments in glow plugs – from NGK and Blue Print
11 in particulate
Understanding the increasing role of the Diesel Particulate Filter
12 cold aS ICE
Essential winter products from CCA
13 a clear view
Champion describes innovations in the design of the often-overlooked wiper
14 lighten up
Lucas explains how to tap into the growing market for upgrade bulbs
15 BElt up!
Gates describes the vital role played by the accessory drive belt system
16 in control of cables
Vital News and First Line look at the many types of control cables
17 downsize me
The increasing pressure on gaskets
18 fps product index
An up-to-date listing of the extensive product lines supplied by FPS
20 competition time Win an amazing PalmerSport Track Day with Vital News and National Autoparts!
2 contents
The aftermarket seems relatively settled, suggesting that the hard winter and rise in March registrations has brought demand forward during the year. Having passed the lull in business caused by the World Cup campaign (if you can call it that!) and with the emergency budget measures swinging into action, the economy seems to be stumbling towards winter with low levels of consumer confidence. With the scrappage scheme out of the way, the car parc will continue to age once again. Interestingly, monthly sales of diesel vehicles overtook petrol sales for the first time ever in July of this year and in timely fashion this issue features a number of articles devoted to diesel issues. Our ongoing programme of vehicle parc analysis shows a sharp increase in sales of small Asian vehicles during 2009 – largely driven by the scrappage scheme. Clearly this gives a direction to product development and we are working hard to ensure we have the right products to meet this demand. The revised Block Exemption Regulations, which came into force in June, should make it easier (or at least stop the vehicle manufacturers making it harder) for independent garages to access the technical information they need and use matching quality spare parts. The new rules have elicited a variety of responses from vehicle manufacturers such as lifetime warranties (question – when is a lifetime warranty not a lifetime warranty?!) and approved-used-schemes. The independent aftermarket will have to continue to work hard to get the message across to consumers that they can still shop around without invalidating their vehicle warranties. As we head into the winter, colder weather and gloomier days make driving on UK roads a riskier business, bringing many opportunities to the aftermarket. Over 75% of glow plug sales are made over the 6 months stretching from October to March so this issue includes an overview of the glow plug market. Lighting components and wiper blades also become more important during the winter months as they experience more use and therefore more wear and tear. Suppliers Elta and Champion have also contributed to this issue and we hope their articles will help inform your stocking policies. In the last few months a number of suppliers, including Cambiare and Gates, have developed their programmes in line with the latest technological developments. In this issue of Vital News they have taken the opportunity to help us understand these new technologies and how they affect the replacement market. Also in this edition of Vital News, we introduce our new battery supplier, GS Batteries, who give us the lowdown on the current state of the automotive battery market. Anything we can help you with, do let us know. Meanwhile, happy reading! Neil Davis Managing Director FPS
Contributors this issue…
Proud to support
FPS newsdesk VITAL NEWS
FPS NEWSDESK What’s new from the market Autocat+ Autonet Development
Do you want to check stock availability and place orders directly with FPS from an Autocat+ lookup? FPS has worked with MAM to make catalogue lookups and ordering even simpler. • Search for the part you require within your Autocat+ screen • Click the new FPS button on Autocat+ • Your part will be added directly to the Autopart point of sale screen • Check stock and place orders seamlessly into your local branch, Sheffield NDC and WDS If you use Autocat+ and Autopart and have an FPS trading relationship set up, this is available to you now. Please contact MAM or the FPS eBusiness team to request the latest release of Autopart. If you require any further information please contact Laura Carr in the FPS eBusiness Team on 01789 413050 or email: ebusiness@fpsdistribution.co.uk
Remy Fault Diagnosis Poster competition Misdiagnosis of rotating electric faults is a common problem as some installers do not drill down to the actual cause of the failure.
winner
A Remy branded A1-size poster has been designed for wall placement in garages to provide a stepby-step process and diagnosis for the technician to follow when dealing with potential starter motor and alternator problems. This helps garages to decide if the product is actually faulty or not, thus saving excessive labour and cost.
EPB Calipers Remanufactured Electric Park Brake (EPB) calipers are now available from Remy. It is a growing product for Audi and VW as EPB calipers are being fitted on the VW Passat, Passat CC, Tiguan, Audi A5 and Q5. The EPB calipers come as standard on some models (VW Passat) or as an optional extra. All calipers are remanufactured to the highest quality standard and each caliper and electric motor is 100% function tested for quality and reliability.
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These posters are free of charge and available direct from Remy. Email cole.maureen@remyinc.co.uk
Leon Rzepa of EBC Motor Factors accepting his tickets for the MotoGP in San Marino from FPS Southampton Assistant Branch Manager Lisa Fildes
Congratulations to Leon Rzepa of EBC Motor Factors, winner of the MotoGP competition sponsored by NGK. Leon Rzepa, director of the business, is responsible for 3 branches in Brighton, Hove and Uckfield. Leon said ‘This is a great competition for me to win. The MotoGP is something I have always wanted to see and going to San Marino is just the icing on the cake.’
FPS newsdesk 3
diesel performance
VITAL NEWS
Diesel cars were again the dominant force at the 2010 Le Mans Endurance Race. Historically the fuel was slow and sluggish, so what has changed to mean it could be used in performance vehicles? Once considered the ugly duckling of the motoring world, for many years the defining characteristics of diesel were: soot, smoking exhausts and sluggishness. Consequently diesel-fuelled cars were always second choice to petrol. Technological development has helped diesel cars become faster, quieter and cleaner and in July 2010 dieselpowered cars outsold petrol cars for the first time ever. Inside The Diesel Engine Diesel Engine: Compression Ignition • Intakes air into the combustion chamber • Compresses the air • Injects fuel into the compressed air causing the air-fuel mix to spontaneously combust • Burned gases are then expelled via the exhaust valve
Charging Ahead Engine power is limited by how much fuel it can burn, and this is limited by the amount of oxygen in the cylinder. Increased air content is achieved with the addition of a turbocharger. A turbocharger is a simple air compressor with two turbines; a turbine wheel in the exhaust stream is powered by energy from the exhaust gas to drive a second turbine in the intake stream. The second turbine compresses the intake before it is fed into the combustion chamber. A turbo can provide up to 40% more power and greater torque without adding much weight - the average turbo weighs approximately 9 kilos (20lbs).
Turbocharger BMW applications often make use of a dualstage turbocharging system dubbed Variable Twin Turbo (VTT). This system comprises two turbochargers of different sizes. At lower engine speeds, the intake air passes through the inactive larger turbocharger into the active smaller turbocharger, which increases the air pressure. At medium engine speeds, the larger turbocharger becomes active, forcing air under pressure into the smaller unit, which increases the pressure still further. At higher engines speeds, the larger turbocharger alone forces air into the cylinders. The turbos can run individually or together, increasing the pressure of the intake air to the optimum level. The world’s first diesel-powered supercar, the Audi R8, employs similar technology. Two turbochargers help the 5.5-litre diesel engine produce 1,001Nm of torque to provide an 0-60mph sprint time of 4.2 seconds.
When a gas is compressed, its temperature rises; the air temperature in a diesel engine reaches 700–900°C. As the diesel engine does not introduce fuel until the compression stroke is nearly complete, it can achieve higher compression ratios than an equivalent petrol engine.
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A petrol engine compresses air at a ratio of 8:1 to 12:1, a diesel engine compresses at a ratio of 14:1 to as high as 25:1. More compression of air inside the engine results in increased efficiency and more power. The higher compression ratio of the diesel engine also means that more torque is available compared to their petrol equivalents.
Turbo lag is the delay between depressing the accelerator pedal and the arrival of increased power at the wheels. Lag is caused because the exhaust fumes which power the turbo do not immediately reach the high pressure level necessary to initiate the turbo. Manufacturers of modern diesel engines have come up with a number of clever strategies to counteract this.
Audi R8 the world’s first diesel-powered supercar
The problem with compressing air is that as it gets hot it becomes less dense and therefore contains less oxygen. This is solved with the help of an intercooler. The intercooler channels cold air between the turbo and the inlet side of the engine to cool the air inside. This increases the air density, giving up to 10% more power. Over the past decade, the use of intercoolers has risen from circa 25% of new applications to more than 50% in 2009. Injection Strategies Fuel has to be injected at very high pressure in a
Diesel Timeline 1893 Rudolph Diesel patents his eponymous engine 1905 Alfred Buchi patents his design for the turbocharger 1933 The first commercially available diesel-powered passenger car, Citroën’s Rosalie, is released in Europe
4 diesel performance
1978 The Mercedes Benz S-Class is the first diesel production car to be fitted with a turbocharged engine 1989 Turbocharged Direct Injection (TDI) is debuted at the Frankfurt Motorshow 1997 Common Rail fuel injection is introduced to the mass market
diesel performance VITAL NEWS
diesel engine in order to counteract the immense pressure inside the combustion chamber. The higher the fuel injection pressure, the higher the resulting power and the cleaner the resulting exhaust emissions.
pressure of the ambient air. A new generation of common rail injection which will achieve pressure in excess of 1800 bar is currently under development by Volvo and could hit the market as early as 2012.
Since 1997 common rail fuel injection has rapidly replaced the traditional mechanical fuel pump and first came to the mass market in the Alfa Romeo 156 1.9 JTD and known as UniJet.
In 2003, the Fiat Group replaced the UniJet with the MultiJet. MultiJet improves the efficiency of the engine by introducing five injections during the same combustion cycle – at 4000 rpm that means 33 injections a second. Staggering the fuel injection makes the combustion process more efficient and less noisy as the combustion chamber is not subject to such extreme changes in temperature and pressure.
Basic components of a common rail system: • High pressure pump with regulator and inlet valve • Rail containing a pressurised reserve of fuel • Injectors which can atomize the fuel • Control unit In the common rail system, highly pressurised fuel is distributed to the injectors by a long metal cylinder known as the fuel rail. The same rail serves every cylinder, hence the term common rail.
Further development of the MultiJet means a number of new applications, such as the 2010 Alfa Romeo MiTo, will benefit from the new generation of MultiJet technology which provides eight injections per stroke. Variable Valve Timing Within the combustion chamber, the intake and exhaust valves define when air enters the cylinders and when exhaust gas is expelled. The timing of these events is defined by the engine’s camshafts. The time that the valves open and shut is optimised for one engine speed, and away from this speed, fixed camshaft timing is very inefficient. With variable valve timing (VVT), it is possible to optimise the timing of air-fuel mixture charge in the cylinder in line with the actual operating conditions. Advantages of VVT in a diesel engine:
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Common Rail System
In today’s common rail engines, fuel is injected into the combustion chamber at approximately 1600bar – equivalent to 1600 times the
• Higher torque up to the medium speed range • More dynamic engine response at low revs • Greater fuel efficiency and lower CO2 output
Greener, Cleaner Diesel The efficiency of compression ignition means that diesel engines offer extremely economical motoring. This can be paired with a hybrid powertrain to provide even better performance, increased fuel efficiency and reduced emissions. Range Rover is currently developing a dieselhybrid engine, scheduled for release late 2011/early 2012. Range Rover’s diesel-hybrid features a diesel engine driving the front wheels while the rear wheels are driven by a supplementary electric motor, hence the term Electric Rear Axle Drive (ERAD). ERAD is particularly significant in Land Rover terms as it can provide additional torque and maximum electrical torque from standstill. This additional torque provides excellent low-speed control and enhanced pull-away on difficult surfaces or when towing – ideal for Range Rover drivers. A host of other carmakers including Citroën, Peugeot, Land Rover, Ford, Vauxhall, VW and Toyota are also developing diesel-powered hybrids, so we could be seeing a great deal of these vehicles in the future. With so much hype surrounding electric vehicles and hydrogen fuel cells, it is easy to lose track of developments in traditional engine systems such as the diesel. With continued investment in diesel technology by car manufacturers, it is certain that diesel technology is here to stay for the foreseeable future. Simple technology such as the turbocharger will continue to be refined and developed to give greater performance and efficiency, and there is certainly more that can be achieved with the advanced systems such as VVT and hybrids to boost performance even further.
2006 The Audi R10 becomes the first diesel-fuelled car to win the 24 Hours of Le Mans
July 2010 For the first time ever, sales of diesel cars in the UK overtake petrol
2006 Mitsubishi state their intent to release a diesel engine which incorporates variable valve timing (VVT)
2010 Mitsubishi plan to release a diesel engine with variable valve timing
2007 SEAT Leon Mk2 becomes the first diesel car to win a round of the World Touring Car Championship
2011/2012 The first diesel-hybrid powertrains are scheduled to hit the market
diesel performance 5
engine management
VITAL NEWS
Timing is Everything As Cambiare strengthen their engine management programme with the addition of Knock and MAP sensors, Vital News takes a look at the technology involved and its function
In its most severe form, knocking can cause serious engine damage. To detect and prevent this, engine manufacturers use a piezoelectric sensor mounted on the engine block to listen for engine knocking. the Knock Sensor The knock sensor acts like a microphone, transforming the vibrations caused by the sound waves from knocking into a voltage signal that can be read by the ECU. The ECU will analyse the sound from each cylinder and compare it to a reference noise based on the average noise level
6 engine management
Knock Sensor
for a set period. If the sensor detects any noise exceeding the reference level, the ECU will identify it as knocking and begin to retard the ignition timing until the noise level returns to normal. This process happens continually to achieve optimum timing.
If a sensor fails and needs replacing, it is important to check that the surface of the mounting point is clean and free of contamination so the new sensor can be properly mated to the block. If not, the sensor may not operate correctly and could result in damage to the engine.
The MAP sensor is connected to the inlet manifold by a vacuum hose. The vacuum and pressure act upon the sensor diaphragm which the electronic control module converts into an electrical signal. The manifold absolute pressure is calculated using the following formula: Atmospheric Pressure – Manifold Pressure = Manifold Absolute Pressure The map sensor also tests the functionality of the EGR valve, as part of OBD II standards, on vehicles fitted with a MAF (Manifold Air Flow) sensor. Following the introduction of Euro V and the upcoming Euro VI standards, emission control products are becoming increasingly important, leading to an increase in demand.
Garages should always use up to date diagnostic tools when dealing with any engine management issue. In the event of a knock sensor failure the following Generic P0 Series Fault Codes are likely to appear: P0325 Knock Sensor Circuit Malfunction P0326 Knock Sensor Circuit Range P0327 Knock Sensor Low Input P0328 Knock Sensor Input P0329 Knock Sensor Input Intermittent These should always be taken as a guide to the problem and followed with a thorough check of the engine management system which will help to identify underlying problems. the MAP Sensor The Manifold Absolute Pressure (MAP) sensor helps the ECU to determine the exact amount of fuel required to create the optimum air-fuel ratio
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Knocking Ignition timing can be disrupted by engine knocking, a common phenomenon where pockets of the air-fuel mixture ignite away from the normal flame front and outside of the standard ignition cycle. Knocking takes energy away from the combustion process because the increase of pressure in the cylinder works against the compression stroke.
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Today’s modern combustion engines are still relatively inefficient, despite over 150 years of development. Most engines will only convert approximately 35% of energy created in the combustion process into forward motion. This is why ensuring an optimum combustion process is vital to achieving maximum performance and best economy. The engine needs to burn the air-fuel mixture in a controlled way and at a precise point in the piston’s stroke cycle. The modern ECU calculates the ignition timing in order for the combustion process to reach peak pressure and allow maximum energy recovery.
for combustion. Pressure is measured at the inlet manifold to determine the air density and calculate the air mass flow into the engine. This measurement is used in conjunction with an air temperature reading to determine the correct amount of fuel required.
Map Sensor
If the MAP sensor is suspected to be faulty, a simple test to measure the output voltage will establish if this is the case. A correctly working sensor will operate at approximately 1.5V at idle and increase to approximately 4V as the engine speed increases. Full details of the Cambiare engine management programme can be found at: www.cambiare-ve.com along with full catalogue details and product images. You can also contact Cambiare on the free technical helpline 0845 543 8280.
FOR YOUR INFORMATION VITAL NEWS
in-car technology
car maintenance
accessories & styling
travel & leisure
valeting
Car care & accessories new ranges The FPS Car Care & Accessories portfolio continues to grow. Here are some of the latest additions to the range: • Autotek Paints – Top Coats, Primers and Lacquers • Universal Products – Door Guard Protectors
Gates Technical Bulletin Catalogue Gates provides regular technical back-up with technical bulletins that tackle specific drive system problems. Technical bulletins 1-26 are now available in printed catalogue format, part number E2/70503. The catalogues are being distributed at trade fairs, technical training evenings and Gates’ customer work out sessions. To request your own personal copy please e-mail catrionahi@gates.com All technical bulletins can also be accessed at www.gates.com/europe/technicalbulletins
• Styling Essentials – Stickers, L Plates & Window Tints • Cosmos – Seat Covers • 2010/11 Winter range
New Klarius Exhaust Systems Catalogue Klarius has recently published a new Exhausts Systems & Catalytic Converters catalogue, which includes more than 11,200 exhausts, catalysts & mounting references, covering 97% of the UK car parc, part number UKC24A4. This new catalogue contains 1600 new references including applications for: BMW X3, Citroën C4 Picasso, Peugeot 207, 308 & 1007, Toyota Aygo, VW Fox and Volvo C70 and XC70. Klarius’ complete range of exhausts are designed and manufactured to EC Type Approval standards. Type approval is a stamp of quality which allows the motorist to rest assured that the product being fitted to their car has been tested to European legal standards.
Autotek Professional Paint – exclusive to fps Autotek Professional is a high quality paint supplied exclusively to FPS by the manufacturer of prestigious brands including Hycote. The majority of specialist paint applications are covered by the product range including primers, satin, matt and gloss top coats, very high temperature paint, wheel paint, lacquer and bumper/trim paints. ‘MAX’ paint is also part of the Autotek range. The ‘MAX’ range has been specially designed for bodyshops to give the best possible coverage; up to 65% more when compared to competitors’ aerosol products. The range is compliant with the ‘Volatile Organic Compounds’ (VOC) regulation (2004/42IIB9e), which sets limits on the maximum VOC content of coatings. For more information see the F:Drive www.fdrive.co.uk
FOR YOUR INFORMATION 7
batteries
VITAL NEWS
Charge Ahead The automotive battery market is entering a new era thanks to a raft of emerging fuel saving technologies. Battery expert GS helps Vital News to make sense of the increasingly complicated battery market The approaching winter season will turn the minds of readers to the humble automotive battery as the cold weather is one of the ancient enemies of this unassuming and unglamorous technology that gets millions of motorists started every day. But the lead-acid battery – invented in 1859 by Gaston Plante – has been improved significantly over recent years and, despite being one of the heaviest electrochemical systems, still maintains its position as the number one choice in the automotive industry for starting, lighting and ignition (SLI). Now, bigger challenges await the lead-acid battery. The Battery Market In The 21st Century One of the principal reasons that lead-acid batteries maintain popularity is that their cost and recyclability enjoys a significant 10 times cost advantage over new technologies such as lithium-ion. This factor will obviously change as mass production of newer technologies drives down production costs and end user prices. However, for the time being, lead-acid is still the first choice in SLI.
Cross section of six cell configuration battery
8 batteries
Existing Technology The production of electrical power is governed by two complex chemical reactions between cathode and anode. They deliver a combined voltage of just over 2V per cell or 12V for the six cell configuration used in automotive batteries. As the positive and negative electrodes are made of weak materials, they require support provided by a grid made from a lead alloy. As well as providing physical support for the active materials, the grid also conducts the electrical charge from the electrodes to the outside world. Over the years many different lead alloys have been developed for the grid, and this technology is often used in marketing batteries to make it appear as if there is a whole new battery technology – calcium-calcium, silver-calcium etc. In truth, however, these are simply process improvements in the development of Plante’s original design that have beneficial effects such as reducing water loss and making the automotive batteries of today maintenance-free and longer lasting than their ancestors. New Technology Concerns over climate change are heavily influencing all aspects of vehicle design including batteries. New technologies, such as Stop-Start, alternator management and regenerative braking are being introduced by all volume vehicle manufacturers to optimise the use of fuel and energy storage. However, these changes increase the requirements on the battery. Consequently, standard leadacid batteries will no longer do the job. Absorbent Glass Mat (AGM) automotive batteries are needed for these latest StopStart technology vehicles. Stop-Start is designed to save fuel in heavy urban traffic by switching off the engine when a vehicle is stationary. This obviously leads to greater demands on batteries.
Alternator Management monitors a battery’s state of charge during driving and switches off the alternator when the battery reaches its full operating state of charge. Since the alternator typically takes up to 10% of an engine’s power when operating, management of the alternator can give fuel savings depending on the exact conditions of the battery and how the vehicle is driven. The battery supports all the electrical loads on the vehicle during these times, leading again to greater life requirements on the battery. Regenerative Braking, as the name implies, uses the braking of the car to charge the battery, allowing additional fuel economy as the alternator can be switched off more frequently. This requires the battery to accept current in
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batteries VITAL NEWS
The design benefits of the glass mat over conventional lead-acid batteries enable individual cells within the battery to operate under higher pressures without the fear of squeezing out the acid between the plates which is required for the battery to work. This leads to a step change in durability offered by AGM over conventional lead-acid. The quality of the glass mat is a critical item in ensuring optimum life of the battery in such demanding applications. Laboratory evaluation is boasting four- to fivefold increase in cyclic durability compared with standard designs and typically 16% higher starting power. Increasing surface area and modification to plate designs within the battery improve the engine cranking speed for StopStart usage as well as the charge acceptance of the battery for use with regenerative braking. Benefits of AGM over conventional lead-acid
short bursts delivered during braking. In order to optimise recovery of this energy lead-acid battery design had to change to improve charge acceptance ability. These features, generally called “micro hybrid”, are gradually being adopted into volume manufactured vehicles with 5% of vehicles currently being produced incorporating some or all of these features. They differ from the typical association with the word hybrid seen on vehicles such as the Toyota Prius where the demands on the battery are even higher, meaning more durable (and expensive) battery technologies such as Nickel metal hydride (NiMH) and Lithium-ion (Li-ion) must be employed.
• Increased lifespan results from battery design – all active materials are retained within the cell enhancing battery longevity • Higher available power giving faster engine starts • Totally maintenance-free – zero water consumption • Spill / leak proof – no free acid within the battery – all held in the glass mat • Improved efficiency of battery active material, all the acid required by the battery between the plates AGM Charging AGM automotive batteries require no special tooling to fit to a vehicle and can be charged from existing constant voltage chargers as well as the latest intelligent multi-stage charging
systems. Modern automotive battery testers now have an AGM option to enable correct testing and diagnosis of battery condition. AGM Specifics As new micro hybrid vehicles are developed, manufacturers are setting down unique criteria for each vehicle and battery manufacturers are developing batteries for these vehicles on a case-by-case basis. This means that AGM batteries, like engine control units (ECUs) are rapidly becoming vehicle specific.
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How It Works AGM batteries are built using a micrometre fine fibre glass mat separator material which stores all battery electrolyte, leaving no free acid within the battery. The clever part of the design is that oxygen formed at the positive plate during overcharging does not leave the cell as in a standard automotive lead-acid battery, but is reduced and reacts with hydrogen produced at the negative plate to form water. These reactions take place within the pores of the separator and mean that the batteries are totally maintenance-free and do not need to carry around an electrolyte “fuel tank” as with conventional lead-acid designs, and do not require top up water for maintenance.
FPS can provide specialist batteries for Honda’s popular Jazz models
This has significant ramifications for the vehicle aftermarket as the pace of change is becoming so rapid that current low cost battery manufacturers will not have the time or resources to make the investment needed to produce low cost alternatives. Consequently, the trade will need to align itself with the major OEM battery manufacturers in order to ensure they continue to have the product and the know-how required to replace these increasingly complex parts. GS Range Overview GS provides a complete range of automotive batteries covering Titan AGM advanced car batteries (2 part numbers); Titan high performance, sealed, maintenance-free car batteries (38 part numbers); Hercules heavy duty commercial vehicle batteries (16 part numbers); Neptune leisure and marine batteries (4 leisure and 3 marine part numbers); Premium car batteries (11 part numbers) and specialist batteries for Honda Jazz I & II, Mazda MX-5 AGM and Toyota Prius AGM auxiliary applications (5 part numbers). GS Batteries are due to arrive with FPS in time for the winter season. For further information ask your local representative for details.
batteries 9
glow plugs
VITAL NEWS
Winter glow Drivers of modern diesel vehicles expect to be able to just jump in, turn the key and go. With the help of NGK and Blue Print, Vital News looks at how glow plug technology has evolved to meet these demands Heading into winter the aftermarket sees that glow plug sales start to increase. Traditionally, glow plugs sales increase fourfold during the winter months compared to sales during the summer period. With such a big sales opportunity on the horizon, stocking up on glow plugs is a must for motor factors. New car buyers are increasingly swapping allegiance from spark ignition to compression ignition vehicles and in July this year diesel sales overtook petrol sales for the first time ever. This is part of an ongoing trend: in 2006 diesels accounted for 39.2% of new car registrations, by 2009 46.6% of new car registrations were diesel - a swing of 7% in just five years.
that there is no discernible delay between putting the key in the ignition and actually starting the engine - even at extremely low ambient temperatures - has led to the development of the following technologies:
join the heating coils, which are then tested for maximum temperature and rate of temperature rise. This is to ensure that each glow plug reaches maximum temperature within a specified time.
Twin-Coil Technology – (also called Dual Coil) are plugs that heat quickly and then self-stabilise at the correct temperature. This prevents overheating of the main coil and allows long post-glow periods. The long post-glow period gives cleaner exhaust emissions.
In theory, high quality glow plugs could last up to 10 years. In the real world they need to be replaced, on average, every 2 years. The high replacement rate of glow plugs results from the failure of associated parts such as:
Although glow plug technology is continually moving forward, the glow plug is essentially doing the same job today as it has always done: raising the temperature inside the combustion chamber in order to achieve stable combustion. New High Temperature Ceramic (NHTC) – are the latest generation of glow plug. The ceramic material enables these glow plugs to reach an operating temperature of up to 1300°C. Rapid temperature rise and high temperature post-glow provide faster starting times and lower emissions. The gap between petrol and diesel cars is closing
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However, the demands placed on the glow plug have become increasingly severe and the performance that the market demands is higher than ever. The search for glow plugs that will raise the temperatures of the combustion chamber so
10 glow plugs
• A faulty injection system spraying an abnormal fuel stream onto the probe • Excessive temperature due to high oil consumption or pump timing • Excess fuel or oil getting past the valve stem or piston rings The glow plug is part and parcel of the Engine Management System (EMS), so for the installer, it has never been more important to ensure fitment of the correct specification item. As with most other components, a ‘cheap’ alternative cannot be used nowadays because the EMS can identify the fact that it is the wrong specification. The OBD system will find fault with the item if it is not to the correct specification and the performance of the vehicle will suffer. Both NGK and Blue Print advise installers to always fit a plug that is manufactured to OE specification and all glow plugs distributed by FPS are at least of matching OE quality.
Advanced Quick Glow System (AQGS) plugs – The AQGS is based on twin coil technology but offers improved performance compared to the twin coil. Each glow plug supplied by FPS is subject to rigorous testing before it is sold through the aftermarket. It takes precision laser welding to
FPS offer the aftermarket’s best service solution with a comprehensive range of glow plugs from NGK and Blue Print, backed up by same day delivery.
diesel particulate filters VITAL NEWS
In Particulate The replacement market for diesel particulate filters is growing rapidly as the first cars fitted with these filters are coming onto the aftermarket. Klarius helps Vital News to understand the workings of the DPF
Diesel particulate matter (DPM) is a by-product of incomplete combustion of the fuel-air mix. Often less than 2.5 microns in size, these particles are suspended in the exhaust gasses and have been linked to a range of respiratory problems and heart conditions. The DPF collects and stores this matter preventing soot from coming out of the exhaust exit.
The DPF has a honeycomblike structure with alternative channels blocked; the channels that DPF substrate are open on the inlet end of the filter are blocked at the outlet end and vice versa. The result is that gasses cannot flow through the filter without passing through the porous cell walls between the channels. In doing so the gasses deposit any suspended DPM onto the channel walls. Here it remains and builds up until a regeneration cycle takes place, at which point the DPM is oxidised at a temperature of around 600°C. ≥
The Diesel Particulate Filter (DPF) is becoming the standard route for manufacturers of diesel vehicles to meet the particulate limit of 0.005 g/km. As such, DPFs have been fitted to almost 90% of new diesel cars since September 2009. Some manufacturers, most notably the PSA Peugeot Citroën Group, were already fitting DPFs on some models as early as 2000.
Particulate matter is deposited when gas flows through cell walls
≥ 90%+ reduction in soot particulate matter
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How It Works Due to the hostile environment in which the DPF operates, a hard wearing material with high thermal stability, excellent conductivity and porosity is required: Silicon Carbide and Cordierite material meet these requirements.
Regeneration Over time, the DPF will become clogged and start to restrict the flow of exhaust gases through the filter. An overfilled filter causes exhaust back pressure which can damage the filter and the engine. Upon reaching a load of 80% DPM, the DPF initiates the regeneration process whereby the accumulated DPM is burned off and converted to carbon dioxide gas which can pass through the filter. This process is referred to as ‘regeneration.’ Passive regeneration occurs on long journeys during which the exhaust temperature is
high enough to burn the DPM (around 600ºC). Consequently, the filter is ideally located as close to the engine as possible as this is where temperatures are highest. If the filter is sited further back, a fuel-borne catalyst aids the regeneration process by lowering the temperature at which soot particles ignite and burn off (between 350ºC to 500ºC). Active regeneration occurs when the electronic control unit (ECU) makes adjustments to the fuel injection timing in order to increase the exhaust gas temperature. This increases temperatures in the DPF to the level where the accumulated soot is burned away. Active regeneration is needed on short journeys. Replacement and Maintenance Vehicles equipped with a fuel-borne regeneration catalyst, such as the Peugeot 307 HDi, require more maintenance than those without. The fuel additive aiding the regeneration process must be regularly topped up. Fitters must also be aware that the fuelborne catalyst leaves a small ash residue which cannot be burned off. Therefore, it is necessary to replace DPFs at the 75,000 mile service interval – the DPF of the Peugeot 307 HDi commonly fails at around this mileage for this reason. Where the additive is not required, there is no need to change the DPF for the lifetime of the car, provided that regeneration is carried out as required. Klarius is developing replacement DPFs in order to meet market demands for popular and new applications. Development not only improves the specification of the product, but importantly, the testing and type approval to ensure the important regeneration process is achieved as well as any emission control.
diesel particulate filters 11
car care and accessories
VITAL NEWS
Cold as Ice The winter season brings a number of sales opportunities to the Car Care and Accessories side of a factor’s business. Approaching the winter season Vital News highlights some of these opportunities The Health Protection Agency estimate that up to 20% of cases of Legionnaires’ disease* in the UK can be traced back to dirty washer reservoirs. The stagnant water in the reservoir is an ideal environment for the Legionella bacteria to thrive. A good quality screenwash has antibacterial properties which kills the bacteria.
De-icer A 2009 Autoglass survey revealed some shocking winter driving habits: as many as 83% of respondents admitted to driving without fully clearing their windscreens of ice, leaving them with dangerously limited sight and a potential fine of £1,000. De-icers quickly clear frost from the windscreen making a car safe to drive in seconds. The active ingredients, Ethanol and Mono Ethylene Glycol (MEG), lower the freezing point of water, thus melting the ice. MEG is very slow to evaporate, so any product residue prevents water from re-freezing. Screenwash A good quality screenwash helps to prevent water freezing in the washer reservoir and jets, and has anti smear properties to help maintain a clear windscreen whilst driving on gritted or salted road surfaces. To achieve the full freeze protection benefits, it is important to eject all existing fluid in the washer reservoir before adding new screenwash. FPS offers a wide range of concentrated and ready mixed screenwash.
12 car care and accessories
Antifreeze Like de-icer, antifreeze is based on Mono Ethylene Glycol. Cars and LCVs manufactured in the last decade are originally filled with one of three distinctly different types of antifreeze: • Silicate based – 3 year service life. • OAT (Organic Additive Technology) – 5 year service life. • AOAT (Advanced Organic Additive Technology) – currently VW Group specific – 5 year service life. Each has a unique formulation to provide yearround protection to the components in engine and coolant systems. Do’s and Don’ts • Never mix different types of antifreeze – it will cancel out the protective properties or reduce the service life. • Ensure a “flush and replace” is carried out at the recommended service life intervals. Comma’s range of coolants, available from FPS, carries the highest number of vehicle manufacturer approvals in the aftermarket and covers the most applications. Application guidance is available online at: www.commaoil.com
Booster Cables For many years booster cables were made from 100% copper. Nowadays ‘value’ leads are offered in a copperaluminium hybrid, or copper coated aluminium. Maypole’s ‘Basic’ range consists of leads between 2m and 3m in length, covering engines from 1,600cc to 3,000cc. The ‘Performance’ range of cables consists of leads between 2m and 3m, for 3,500cc to 5,000cc engines including an anti-surge option. Finally, the ‘Professional’ range includes 5 more options with up to 4.5m in length covering 4,000cc to 9,500cc engines - ideal for agricultural use and starting heavier machinery. Battery Chargers To determine the correct choice of battery charger, divide the A/h of the battery by 10 and select a charger which has an output just under that figure. For a 100 Amp battery, an 8 Amp charger is great. A 4 Amp will do the job but not as quickly. Maypole has experienced a 25% increase in battery charger sales year on year. Their comprehensive range consists of plastic cased chargers, metal cased chargers, automatic and smart chargers as well as a trickle charger. Easy Engine Start Bradex Easy Start is made up of a mixture of combustible solvents and lubricating oil. It has a lower flashpoint than fuel-air mixture so aids cold starting and ignition even in the most arctic conditions. Simply spray it into the air intake chamber, regardless of the engine type. In addition to the products described above, FPS provides factors with the following seasonal essentials: batteries, battery top up water, car covers, hydrometers, ice scrapers, radiator sealer, snow chains, torches and lanterns, traffic film remover and more. Please see www.fdrive.co.uk for further details. * Legionnaires’ disease is an uncommon but potentially fatal form of pneumonia.
wipers VITAL NEWS
Wipers are not the first subject that comes to mind when thinking about automotive innovation so Vital News talks to Federal-Mogul, parent company of Champion, about how the wiper market is developing
Larger windscreens need longer wiper blades. The curved flexors of flat blades provide more uniform contact with the windscreen because the curved flexors distribute even pressure along the length of the wiper. High speed wipe performance is improved due to improved aerodynamics and less weight.
so successful that the F-M Bayonet Connection System is now found on 44% of new vehicles. Fitting and Replacement With so many different wiper fitments, arms and connectors, it is difficult to manage the ever-increasing range – traditionally sold in specific vehicle sets. By employing its Master Connector™ system for flat blades, Champion has adopted the strategy of offering single packed wipers with multiple adaptors, giving distributors the means to service the market from a low inventory.
Technology As simple as wipers first appear, the engineering behind the product is extensive. The primary requirements are wiping performance and connectivity. Champion Easyvision™ blades utilise a natural rubber formula which is highly resistant to cracking and UV degradation, and will not leave wax deposits on the windscreen. This brings durability, and when paired with an asymmetrical flexor ensures a permanent fit to the screen. All flat blades employ Variable Geometry Spoiler Technology™ (VGS) which adjusts blade down-force in response to changing wind speed, helping to maintain consistent VGS Technology™ wiping performance.
Master Connector System™
The Master Connector™ system ensures fast, secure installation on each of the five primary direct fit (top mount, top mount BMW, side pin, bayonet/push button and flat bayonet) and two retrofit (J-hook 9x3 and 9x4) arm designs. The pre-fitted connector base eliminates almost all user assembly apart from adding one of the provided adaptors, which greatly simplifies the fitting process.
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Flat Blades The rise of flat blades has been driven by a combination of vehicle design, performance requirements and aesthetics. As new vehicles are developed, new patterns and trends in wiper design and application emerge. Wipe quality and noise reduction are of paramount importance and have to be satisfied within the scope of prevailing trends.
Noise can be an issue with cheap wipers. The rubber used in Champion wipers has been formulated to be both flexible and durable under a wide range of temperatures to produce a smooth, noise and judder-free wipe. Special coatings are applied to the rubber to achieve this. The development of flat blades to meet these needs provides a like-for-like replacement market, and also a retrofit market for consumers who prefer the more aesthetically pleasing appearance of flat blades over their conventional counterparts.
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Wipers are fast moving items and distributors need to get their stock profiles right ahead of the winter season. Flat blades are now a pre-requisite to meet market needs and are undoubtedly the future of the wiper category, both within the OE sector and aftermarket. Some 70% of all new European passenger vehicles are equipped with flat blades, and this number rises to 93% among the 25 top-selling models. In the aftermarket, approximately one quarter of all passenger vehicles are flat blade equipped; Federal-Mogul predicts this to rise to one third of the European car parc by 2012.
Quality Federal-Mogul has a strong OE pedigree, supplying wipers to many vehicle manufacturers. A driver of this success has been innovation. For example, the Federal-Mogul Bayonet Connection System for flat blade wipers won the 2010 Automotive News PACE Award for product innovation. This connection system has been
The innovative Master Connector™ system gives the Easyvision™ flat blade programme an exceptionally low part number requirement. Comprising just 14 part numbers the programme encompasses all primary wiper arm designs and covers 85% of the European car parc for all direct and retrofit applications. Thirteen standard blades are also available within the Easyvision™ range.
wipers 13
upgrade bulbs
VITAL NEWS
Lighten Up! The emergence of interchangeable automotive upgrade bulbs has opened rich seams for the motor factor. Lighting specialist Lucas explains the science behind the profit margin The aim of an upgrade bulb is to enhance the driver’s view of the road ahead. This can be done by: • Extending the light further down the road • Increasing the intensity of the light at a given point on the road • Changing the colour of the light Although designed to improve driver safety, to a growing percentage of younger drivers, high performance bulbs offer the opportunity to look different and enhance the styling on their vehicles. Upgrading Performance In the UK, only bulbs with E-mark certification can legally be fitted to road vehicles. Automotive bulbs are put through a series of tests to gain E-mark certification. One such tests measures light output in lumens to establish the brightness of the bulb. E-mark certification for a standard 12 Volt H7 bulb allows for 1500 lumens +/- 10%.
14 upgrade bulbs
When manufacturers of performance bulbs increase the light intensity they must keep within the E-mark criteria. Increasing brightness by 50% at a given point, in this instance 75 metres, requires modification of the bulb’s components. The design and length of the filament is modified, however this can result in it burning hotter and reducing life cycle. This is counteracted by changing the volume and type of gas inside the bulb. Colour Change Refining the light emitted from the bulb enables the manufacturer to alter the colour of the light. The perceived colour of daylight has a Kelvin temperature of approximately 5500K and a standard halogen bulb has a Kelvin temperature of 3400K. To reach the perceived colour of daylight a filter in the form of a coating is applied to the glass. This filter allows only the white light through and therefore the light is perceived to be whiter. The initial light output after the filter is applied is lower and therefore the type and volume of gas used is changed to increase brightness. The pressure of the gas required to make the bulb brighter can be as much as 10 bar and therefore the quality of materials and manufacturing process becomes increasingly important to ensure a longer life cycle. The net effect of any high performance bulb is a reduced life cycle over a standard bulb.
Off-roading For off-road users who wish the bulb to emit as much luminance as possible, the E-mark certification guidelines for lumens will be exceeded, therefore off-road bulbs are not E-marked and illegal for use on public roads. The effect of a combination of gas types, volume, filament wattage and glass coating enables the required lumens output. Buyer beware: for this type of bulb it is recommended that an in-line fuse and relay is fitted to prevent any wiring loom failures as the wiring loom is designed to work only within the limits of original equipment parts. It is always a wise move to have a qualified automotive engineer to check the wiring loom prior to fitting off-road bulbs. Installation It is highly recommended not to touch the glass of halogen bulbs, and this is especially true with high performance bulbs. Any grease or dirt residue left on the glass can create hotspots which can lead to hairline fractures and failure of the bulb. If a bulb is touched, lightly wipe with a cotton cloth dipped in a suitable cleaning fluid. 2010 Catalogue The Lucas brand has been part of the drive to bring performance upgrades to the market and continues to be a leader in this field. The range offered by Lucas includes Xenon plus 50% and Xenon plus 90%, Blue Lightning and Blue Lightning 50 and Rally Blue. All of these cover the popular H1, H4 and H7 bulbs with Xenon plus 50% and Blue Lightning including HB3 and HB4. These can be found in the latest Lucas Bulb Catalogue reference number XCB604.
accessory belt drive system VITAL NEWS
In today’s high-performance engines, the Accessory Belt Drive System (ABDS) plays a key role. Belt specialist Gates explains why DriveAlign® laser tool helps to detect mis-alignment
Fibre-reinforced EPDM Belt A multi-ribbed belt should combine robustness, flexibility and resistance to extremes of temperature. It has to show strong resistance to wear, oil, ozone, flex fatigue and pilling. Belts manufactured from Ethylene Propylene Diene Monomer (EPDM), a type of rubber, meet these demands completely. EPDM is 6 times more resistant to high temperatures, 8 times more resistant to low temperatures and 400 times more resistant to ozone than chloroprene – a material commonly used by some belt suppliers. Correct Installation Choosing the most durable belt in the market is not enough. Multi-ribbed belts need to be installed correctly in order to guarantee a long service life. When replacing a multi-ribbed belt, be sure to: • I nspect for wear and clear any dirt or grease •C orrect any misalignment •S et the correct tension
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Reliability of Belts Belts must be resistant to temperatures and shocks, and able to cope with complex drive layouts and different speeds. They have to be extremely reliable and capable of delivering high power transmission under difficult circumstances.
Worn pulleys and misalignment can cause the belt material to shear off and build up in the ribs, resulting in a condition known as pilling. Pilling causes accelerated wearing of the belt. Where the tension is set incorrectly, the belt is likely to slip. This generates heat, noise and vibration and will ultimately lead to premature belt failure. Specialised tools, such as laser alignment devices and sonic belt tension testers, are available to help detect misalignment and tension issues.
Fibre-reinforced EPDM Belt
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The Accessory Belt Drive System (ABDS) transfers power from the crank pulley to all accessories within the ABDS. The air-conditioning, power steering, cooling and electrical systems all employ components that are power-hungry. They also compete for space under the bonnet, causing temperatures to rise. As the engine environment becomes increasingly hostile, the components of the drive system are adversely affected. When servicing the ABDS, several factors must be taken into account.
DriveAlign® Overrunning Alternator Pulleys
Overrunning Alternator Decouplers (OADs) are included in the Gates OAP range. The OAD brings together the free-wheeling functionality of the OAP with a patented internal torsion spring that isolates torsional vibration. While the OAP rotates in one direction, OADs rotate freely in one direction and allow a limited, spring-like movement in the other. Consequently OAD and OAP parts are not interchangeable. As more technologies to reduce vehicle emissions are introduced, vibrations within the ABDS will increase. As a result OADs will become increasingly popular.
Technological Innovation The latest additions to the ABDS are the Torsional Vibration Damper and the Overrunning Alternator Pulley.
Recommendations Due to the growing complexity of components in the ABDS, Gates recommends the installation of components with original equipment quality. Components that are designed to operate together under the same harsh conditions will result in a better engine performance.
The Torsional Vibration Damper (TVD) absorbs vibrations from the crankshaft and extends the lifetime of other components in the drive system. The TVD is often overlooked during maintenance of the ABDS; a damaged or worn TVD will not only damage the accessory belt, but will damage the driven accessories. Overrunning Alternator Pulleys (OAPs) mark a significant development in ABDS technology. More than 100 million cars in Europe, from the Fiat 500 to the BMW 5 series utilise this technology. The basic function of the OAP (also referred to as a one-way clutch) is to allow the alternator to free-wheel or overrun when the belt suddenly slows down. This prevents the belt from slipping and reduces vibration, wear and chirp noises.
To ensure optimum performance and durability, it is advisable to change all components in the ABDS at the same time. This can mean the difference between a satisfied customer and an expensive repair job. Gates currently have the largest range of ABDS parts in the aftermarket, supplying all of the necessary elements to perform a complete ABDS overhaul: expert tools, multi-ribbed belts, tensioners, idlers, TVDs and OAPs, all of which fit and perform like the original.
accessory belt drive system 15
control cables
VITAL NEWS
In Control of Cables There is more to automotive cables than meets the eye as Vital News found out when speaking to supplier First Line
Control cables are used in a wide range of automotive applications from safety critical parts to accessories. The function of all automotive cables is simple: linking two points to actuate an operation at one end of the cable by performing a function at the other end.
First Line recommends that the following points are observed during cable replacement:
Safety First All brake, clutch and accelerator cables are safety critical parts. Replacement cables undergo the same rigorous quality assurance measures and testing phases as the OE product. Co-operation between OE and aftermarket manufacturers ensures that the highest standards are maintained across the automotive industry.
The extrusion of inner tubes – the component that ensures smooth performance and durability – also utilises high-tech machinery. The production line is often controlled by a threedimensional ultrasound system to guarantee consistent production quality, thickness and dimensions. Cables are generally located in hostile environments such as the vehicle underside, so they must be able to withstand extreme temperatures and chemical exposure. Several environmental and performance related tests are carried out in line with the current OE
16 control cables
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The production of all types of metal outer-casing, and the extrusion process to which it is subject, require specialised machinery to guarantee a consistently high quality of finished product. Computer aided design (CAD) systems and failure modes and effects analysis (FMEA) techniques are used to monitor the product throughout development.
Cable load testing
requirements, such as proof load testing during cable assembly and on finished cables. Inner cable load testing can be up to 250 kilograms, whereas the average pedal effort needed to clear the clutch is 17 kilograms. Other tests include: • Salt Spray Resistance • Temperature • Performance • Cyclic Fatigue Replacement Issues If a brake cable is not functioning correctly it may mean that the brakes will not hold the vehicle in a parked position. If a clutch cable is beginning to fail then the driver may not be able to engage gears smoothly, if at all. Should an accelerator cable lose functionality, the pedal progression may not be smooth. If a speedometer cable becomes worn, then the instrument on the dashboard may cease to record vehicle speed accurately.
1 Identify cause of initial failure – have any associated parts seized? 2 Check route of existing cable to ensure correct routing on replacement. 3 Check for obstacles or intrusions that impede operation of the cable. 4 Use appropriate tools – use of pliers or vice grips on the inner cable will compromise performance and accelerate deterioration. 5 Check that the cable does not interfere with operation of the suspension, steering, exhaust system or other ancillary components. 6 Replace brake cables in matching pairs to ensure braking is evenly balanced. Premature failure of a clutch cable should always be thoroughly investigated as proof testing far outweighs the average pedal effort applied to the clutch pedal. The cause could be a faulty clutch release mechanism or the clutch itself may need replacing. Alternatively, premature failure can be due to “work hardening” of the inner clutch cable which can, in turn, be caused by incorrect installation/ misalignment or kinking in the inner cable, for example by using pliers to install. Common failures are normally due to general wear and tear, but it is always worthwhile conveying the importance of correct fitment to the installer at every opportunity. This can be best met by fitting the correct part in the first place. First Line cables, available from FPS same day, not only provide the range, but can also ensure that the installer has all the catalogue and technical information necessary to do the job right first time.
gaskets VITAL NEWS
Downsiz
e
me
Engine downsizing is having a big impact on sealing solutions as gaskets must be able to cope with increasingly higher temperatures, compression and pressure. Gasket manufacturer BGA tells Vital News more
The available technologies which allow for the reduction of capacity are: • Increasing the number of valves per cylinder • Introducing variable valve timing on intake and/or exhaust strokes • Increasing of compression ratio • Introducing turbochargers and/or superchargers Adding these technologies serves to increase temperature, compression and pressure within the engine. Consequently, new and improved sealing solutions have to be found, and gasket manufacturers are therefore developing new gasket designs and introducing new materials and manufacturing processes. Cylinder Head Gaskets Cylinder head gaskets have been improved in design, materials and coatings to cope with the increasingly hostile environment of the induction system. Steel laminated, fibre cylinder head gaskets have evolved to multi-layer spring steel cylinder head gaskets (MLS). The MLS is composed of two or more sheet-metal layers. The first (or upper) layer incorporates an annular sealing element – commonly referred to as the fire ring – which surrounds the opening to the combustion chamber.
New Materials New materials and material grades have been introduced, such as High Temperature Steel Alloy and high temperature coatings to ensure material stability under extreme operating temperatures. They provide sealing performance up to 1000ºC with a highly durable product. This has facilitated the industry shift from MLS gaskets to single layer steel (SLS) gaskets, which brings the benefit of ease of production and improved quality. Manufacturing The joining of the gasket layers by rivets, eyelets or electric spot welding has been replaced by the more efficient laser welding method to improve the manufacturing process and reliability of the gasket itself whilst reducing the cost of production. The fire ring is attached to the outer layer of the MLS/SLS by a process of laser welding. During this process a laser beam is aimed directly onto the visible side of the sealing ring so that the surface of the sealing ring adjacent to the cylinder head or the engine block is joined to the upper or lower plate of the gasket assembly respectively. The layers within the MLS can also be joined by the laser welding method as well as the fire rings. This avoids missed weld positions and reduces heat distortion. The laser targets localised areas without affecting the entire work piece, whereas the use of electric spot welding can pass a large current
between two points across the gasket, thus causing a distortion at the local source. This guarantees 100% gas tightness of fire ring attached to the gasket layer. A simple optical examination of the ring is sufficient after carrying out the laser welding in order to check whether the welding seam has been welded through all over its length.
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One of the strongest trends in engine design is downsizing. This is the process of reducing an engine’s size without compromising on performance. Downsizing enables vehicle manufacturers to meet the latest stringent emissions standards and deliver better fuel economy.
Laser welding improves quality of gaskets
The majority of laser welding machines are computer numerically controlled and can run to a tolerance of 0.001mm. The new process enables the machines to run at a much higher speed and accuracy. This in turn enables the reduction of inspection times and decreases rejection rates. All these improvements mean less manufacturing lead times and an increase of general productivity and quality within the factory. The aftermarket division of the British Gaskets Group – BGA (BG Automotive Ltd) – provides sealing solutions for the new generation of downsized engines and its laser welded gaskets are available to the aftermarket through FPS.
gaskets 17
Product index
VITAL NEWS
Product Index
Workshop Abrasives Anti-Rust Primer Axle Stands Battery Chargers Booster Cables Brake Cleaner Car Ramps Grinding Paste Paper Rolls Protective Seat Covers Sealants & Adhesives Trolley Jacks Welding Accessories White Spirit
Cooling & Heating
On these pages we’ve set out an alphabetical listing to help you find the item you need quickly and efficiently from the 250,000 products we list, covering 101,000 stock lines. If you can’t see what you need – ask your local branch!
ACCESSORIES & STYLING Exterior Fuel Caps Horns L Plates Motorcycle Accessories Stickers Wheel Locking Bolts Wheel Trims Interior 12V Adaptors Air Fresheners Mats Seat Covers Seatbelts Security Locks Sport Harnesses Storage & Organisers Tax Disc Holders Window Film
BRAKING Dry Braking Brake Cables Brake Discs Brake Drums Brake Fitting Kits Brake Pads Brake Shoes Wear Lead Indicators
18 Product index
Wet Braking Adjusters Back Plates Brake Hoses Brake Master Cylinders Brake Pipes Calipers Caliper Housings Carriers Repair Kits Servos Wheel Cylinders
CAR MAINTENANCE Air ConDITIONING Air Conditioning Condensers Air Conditioning Gas Cleaners Books Non-Automotive Titles Performance Titles Service & Repair Manuals Technical Guide Books EXTERIOR Car Covers Heated Lenses Mirror Glass Mirror Complete Units Wiper Blades Wiper Jets & Piping
INTERIOR Bonnet struts Rear View Mirrors Hygiene Barrier Cream Disposable Gloves Hand Cleaner Heavy Duty Cleansers Hygiene Dispensers Specialist Cleansers Lubes & Fluids AdBlue © Antifreeze Brake Cleaner Brake & Clutch Fluid Damp Start De-Icer De-Ionised Water Easy Start Fuel Additives Greases Hydraulic Fluid Lubricants Oil Additives Oils Radiator Additives Screen Wash Transmission Fluid Surface TreatmentS Bodyfillers Paints & Finishing Primers
Cooling Gaskets Hoses Hose Clips Hose Coils Intercoolers Radiator Caps Radiators Thermostats Water Pumps Water Pump Kits
Electrical Engine Management EGR Valves Engine Position Sensors Fuel Injectors Fuel Pumps Fuel Pump Relays Idle Speed Control Valves Knock Sensors Map Sensors Modules Temperature Sensors Throttle Position Sensors Ignition Condensers Distributor Caps Glow Plugs Ignition Coils Ignition Leads Points Rotors Spark Plugs Lighting Beacons Bulb Holders Bulbs Flasher Units
product index VITAL NEWS
Head Lamps Indicators Lenses Rear Lamps
Fuel Line Accelerator Cables Fuel Pumps Fuel Tank Sender Units Turbos
Storage & Transfer Alternators Batteries Distributors Generators Inverters Starter Motors Window Regulators Wiper Motors
Top End Cam Followers Cam Gears Cam Kits Cam Shafts Cylinder Heads Gaskets Head Bolts Head Set & Bolt Kits Lifters Oil Pipes Pre Combustion Chambers Rocker Shafts Seat Inserts Tappets & Trust Pads Valve Guides Valve Springs Valves
Switches & Sensors ABS Sensors Air Flow Meters Air Mass Meters Column Switches Lambda Sensors Oil Pressure Switches Parking Sensors Pressure Regulators Radiator Fan Switches Reversing Sensors Solenoids Temperature Switches
Engine & Fuel Bottom End Bearings Con Rods Core Plugs Gaskets Oil Pumps Oil Seals Piston Rings Pistons & Liners Engine Timing Flexible Couplings Idlers & Pulleys Oil Seals Overrunning Alternator Pulleys Tensioners Tensioner Kits Timing Belts Timing Belt Kits Timing Chains Timing Chain Kits Torsion Vibration Dampers Engine Drive Belts Drive Belts Fan Belts Industrial Belts Micro-V Belt Kits Micro-V Belts Stretch Fit Belts
Exhaust Exhaust Parts Catalytic Converters Catalytic Converter Fitting Kits Diesel Particulate Filters Exhaust Fittings Exhaust Pipes Exhaust Universal Parts Front Pipes Inter-Pipe Silencers Rear Silencers
Filtration Filtration Air Filters Cabin Air Filters Fuel Filters Oil Filters Transmission Filters
IN-CAR TECHNOLOGY FITTING SOLUTIONS Acoustic Cloth & Carpet Aerials & Adaptors Phone & MP3 Connectivity Sound Proofing Sub-boxes & Accessories Wiring & Cables
Steering & Suspension Steering Manual Steering Racks Power Steering Pumps
Power Steering Racks Steering Boxes Steering Couplings Steering Rack Gaiters Tie Rod Assemblies Track Rod Ends Suspension Ball Joints Bushes Coil Springs Control Arms Engine Mountings Leaf Springs Lever Arms & Suspension Struts Link Arms Radius Arms Shock Absorbers Shock Absorber Adaptor & Protection Kits Sports Kits Stabilisers Suspension Kits Suspension Spheres Tailgate and Bonnet Struts Top Mounts Wishbones
Tools Tools Belt Length Finders Brake Tools Clutch Tools DMF Testing Tools Engine Tools Glow Plug Removal Tools Hand Tools Oil Filter Wrenches Stretch Fit Belt Tools Timing Belt Tools & Engine Tools
Drivetrain Bearing Hub Units Constant Velocity Boots Constant Velocity Joints Drive ShaftsFlexible Couplings Prop Shaft Centre Bearings Universal Joints Wheel Bearing Kits
TRAVEL & LEISURE ACCESSORIES Bicycle Carriers Cycle Accessories Domestic Batteries Fire Extinguishers First Aid Kits Funnels & Measuring Jugs Petrol & Diesel Cans Roof Boxes Roof Racks Tow Bar Fitting Kits Tow Bars Trailer & Towing Accessories
VALETING ACCESSORIES Cleaning Products Polish Pressure Washers Valeting Product
Transmission Clutch HydraulicS Clutch Hoses Clutch Master Cylinders Clutch Slave Cylinders
Clutch PartS Clutch Bearings Clutch Cables Clutch Kits Concentric Slave Cylinders (CARM) Dual Mass Flywheels Flywheels Pilot Bearings Speedometer Cables
product index 19
VITAL NEWS
competition time
WIN AN Amazing palmersport track day with national autoparts & fps! National Autoparts is enjoying great success with their clutch range – now 100% new and are no longer offering a range of remanufactured clutches. Times have changed, demands have changed, and so has National Autoparts.
National Autoparts has 25 years experience in designing, manufacturing and testing clutch kits. The new clutch programme is competitively priced and covers 97% of the UK vehicle parc. The range consists of approximately 900 references made up of clutch kits, single mass flywheel kits, concentric slave cylinders (CSC) and CSC kits, with many new references for key applications added each month. FPS carries a full stock range, so with their unique service and regular deliveries, customers can be sure a quality clutch product is only a call away. To celebrate National Autoparts’ 100% all new clutch range, along with Vital News, NAP is offering 2 readers (plus 1 guest each) the chance to experience a once-in-a-lifetime track day at PalmerSport’s race track at the Bedford Autodrome. You will drive several of the world’s top sports cars coached by the experts. The prize also includes 1 night’s local accommodation. Please see www.palmersport.com for further information. To be in with a chance of winning this fantastic prize all you have to do is rearrange the following words to create 3 sentences. 1. clutch the NAP references up 900 make Approximately range Answer:
2. Peugeot 3 and Mercedes NAP’s Expert, new fit Sprinter Ford SMF kits
the Mondeo Answer:
Name Company
3. range Autoparts is National new 100% clutch
Tel No
Answer:
Account No Entries must be received no later than 30/11/10. The winning entry will be drawn on the 01/12/10. Copy and fax your entry back to FPS on 01789 413038, or post to us at:National Autoparts Competition, FPS, Bridge House, Timothy’s Bridge Road, Stratford upon Avon, CV37 9NQ. Good Luck! FPS BARKING FPS BIRMINGHAM FPS BRISTOL FPS CARDIFF FPS CHARLTON FPS COLCHESTER FPS GLASGOW
Tel: 0845 456 2177 Tel: 0845 456 3144 Tel: 0845 456 3244 Tel: 0845 456 3255 Tel: 0845 456 3266 Tel: 0845 456 3277 Tel: 0845 456 3288
FPS LEEDS FPS LEICESTER FPS LIVERPOOL FPS LUTON FPS MAIDSTONE FPS MANCHESTER FPS NEWCASTLE
Terms & Conditions – 1. Open to all FPS account customers that are resident in the U.K. 2. Only one competition entry per person. 3. All competition entries must be received by 30/11/10. Proof of posting should not be taken as proof of delivery. 4. The first two all-correct entries to be drawn after the closing date will each win a PalmerSport Track Day experience for themselves and a guest. 5. FPS reserves the right to withdraw the competition at any time without prior notice. 6. There are no cash alternatives to the prize offered. 7. The judge’s decision is final and no correspondence will be entered into. 8. The winning entry will be drawn on 01/12/10. 9. FPS reserves the right to substitute the prize with an item of equivalent value.
Tel: 0845 456 3611 Tel: 0845 456 3622 Tel: 0845 456 3688 Tel: 0845 456 3811 Tel: 0845 456 3833 Tel: 0845 456 3844 Tel: 0845 456 3988
FPS NOTTINGHAM Tel: 0845 618 0087 FPS PRESTON Tel: 0845 456 4055 FPS READING Tel: 0845 456 4122 FPS SHEFFIELD Tel: 0845 456 4133 FPS SOUTHAMPTON Tel: 0845 456 4155 FPS STAPLES CORNER Tel: 0845 456 4144
The policy of FPS is one of continual improvement. Consequently we reserve the right to amend or withdraw any offers without prior notice. All prices exclude VAT.
CALL YOUR LOCAL FPS BRANCH
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