THE ESSENTIAL
Engine Management product guide 2010/11
OE & matching quality engine management parts
Why Quality Matters...
Copy
OE & Matching Quality
Fitting a copied part can be an expensive choice. Although it may seem the cheaper option, the part may turn out to cost much more than you think. When your customer returns the vehicle with the failed copy part, it will not only cost you time and money to replace with the OE quality part, but it will also damage your reputation. Pictured above are two air mass meters, both of which are for the same application. From the outside you can see a few differences, although this is not always the case. Some copies are near perfect replicas of the originals, so it can be difficult to tell. Many copies may look the same, but all of the important components are inside. As you can see from the pictured copy sensor they can be very crudely constructed, using none of the modern technology of the OE quality sensor. This is why at Allparts, we believe it is better to buy OE or Matching Quality first time.
Allparts supply OE or Matching Quality products Your essential information guide to Engine Management products supplied by Allparts
Dear Customer Did you know that Allparts specialises in Engine Management products at your local branch? With our comprehensive range of Original Equipment suppliers such as Bosch, Delphi, Hella, Siemens and Pierburg, to mention a few, we offer a real alternative to the VM main dealers for quality parts in the aftermarket. All of our internal sales advisors are trained in modern engine management components and we have our own expert engine management product managers supporting them with advanced product identification and fitment queries. Contact your local Allparts branch for more information. To complement this, our Allparts Technical Centre (ATC) team are able to offer diagnostic equipment to accurately identify engine management faults, together with training and diagnostic support. Call them for details on 01494 470018.
Sensors : Air : Fuel Supply : Diesel Injection : Petrol Injection : Electronic Control Units
Full index on Inside Back Cover
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Sensors
There is a huge range of sensors available from Allparts that you may think are only available from a main dealer. Everything from knock sensors, lambda sensors, ABS sensors, tyre pressure sensors, MAP sensors, yaw rate sensors and more.
Acceleration Sensors Acceleration sensors are used on systems such as air-bags to trigger their deployment in the event of an accident (abrupt deceleration).
Lambda Sensors
Also known as: Hego Sensors, Oxygen Sensors Lambda sensors are used to regulate the air fuel mixture of a vehicle and are located in the exhaust system anywhere from the manifold to just past the catalytic converter(s).
TOP TIP - Lambda Sensors Always change the lambda sensorS if you are changing the catalytic converter
Your essential information guide to Engine Management products supplied by Allparts
Knock Sensors
Also known as: Mixture Formation Sensors The function of a knock sensor is to detect vibration caused by uncontrolled ignition. They are bolted to the side of the head and when the sensor detects vibrations out of the set tolerances, a signal is sent to the ECU to determine if the timing needs to be adjusted.
TOP TIP - Knock Sensors never use a washer when fitting a Knock sensor as this can impair the sensors function and give false information to the ecu resulting in more engine management problems
ABS Sensors
Also known as: Wheel Speed Sensors The main function of an ABS sensor is to measure the wheel speed for systems such as ABS (anti lock braking system), TCS (traction control system), ESP (electronic stability Program) and SATNAV (Vehicle Navigation Systems).
TOP TIP - ABS Sensors always clean the sensor holder of any dirt or rust as the gap between the sensor and the mounting is vitally important
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Sensors MAP Sensors
(MAP - Manifold Absolute Pressure) Also known as: Boost Pressure Sensors
TOP TIP - MAP Sensors Change the Air filter if replacing the MAP sensor
A MAP (Manifold Absolute Pressure) Sensor is a micromechnical sensor that measures the absolute pressure in the intake manifold and compares it with a reference vacuum, not with the ambient pressure. This enables the air mass to be precisely defined.
Coolant Temperature Sensors Coolant temperature sensors are installed in the coolant circuit; the signals from the sensor are used by the ECU to calculate the engine temperature.
TOP TIP - Coolant Temp Sensors always refill the cooling system with the vehicle specific coolant
Your essential information guide to Engine Management products supplied by Allparts
Crank Sensors (left)
Also known as: Crank Shaft Position Sensors, Pulse Sensors
Cam Sensors (below)
Also known as: Camshaft Position Sensors, Ignition Pulse Sensors Crank and Cam Sensors are used to determine what position the engine is in for starting and at which stage of combustion for ignition timing and injection.
TOP TIP - Cam & Crank Sensors Always clean the area ON WHICH you are mounting the sensor
Tyre Pressure Sensors Tyre pressure sensors monitor the tyre pressure for systems that can warn of low pressures to ensure they are always at the optimal pressure producing the best handling and fuel economy.
OE Suppliers Allparts supply parts from the Original Equipment Manufacturers to ensure OE/Matching Quality parts
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Sensors Fuel Rail Sensors
Also known as: Fuel Pressure Sensors Fuel rail sensors are located on the fuel rail and are vitally important in controlling injection, emissions, engine power and noise. When fuel pressures deviate from set tolerances, the pressure is compensated by the use of a pressure regulator usually also located on the rail.
TOP TIP - Fuel Rail Sensors COMMON RAIL Diesel fuel systems run at extremely high pressure so take care when working on the fuel system
Throttle Pedal Modules
Also known as: Accelerator Pedal Modules, Accelerator Potentiometers Throttle Pedal Modules register the exact position of the accelerator pedal via an in-built potentiometer.
Throttle Position Sensors & Electronic Throttle Switches Also known as: Accelerator Position Sensors, Throttle Pots Throttle position sensors are used to measure the angle of the engine throttle valve. The information the sensor provides is used in different ways depending on which vehicle it is fitted to. For example, if a vehicle is in limp home mode, it is used to provide an emergency signal in the case of air mass failure.
TOP TIP - Throttle Position Sensors Some applications may need to be calibrated during fitting
Your essential information guide to Engine Management products supplied by Allparts
Pressure Differential Sensors Also known as: Exhaust Pressure Sensors
Pressure differential sensors are used on systems such as diesel particulate filters to determine if the filter is blocked and in need of regeneration.
OE MANUFACTURERS - Allparts supplies Original Equipment or Matching Quality Parts
Yaw Rate Sensors Yaw rate sensors are used on systems such as ESP to monitor the vehicles rotation on its own axis and provide information to the ECU to counteract the yawing motion.
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Air
Turbos
Modern turbos are used by manufacturers to enable them to create the same amount of horse power from a small economical engine that a large normally aspirated engine would produce.
TOP TIP - Turbos a turbo failure is usually a side effect of other problems so be sure to check the whole system thoroughly
Air Mass Meters
Also known as: Air Flow Sensors The function of an air mass meter is to measure the air mass flow entering the induction system. This information, along with other information from other sensors such as the throttle position sensor, are used to calculate the air/fuel mixture.
TOP TIP - Air Mass Meters Always replace the whole unit - never just the sensor finger as the majority of sensor fingers are calibrated to the bodies. Also, always change the air filter when replacing the air mass meter
Your essential information guide to Engine Management products supplied by Allparts
EGR Valves
(EGR-Exhaust Gas Recirculation) Exhaust gas recirculation valves are used to reduce NOX emissions and can be used on both petrol and diesel engines. EGR valves work by recirculating a small amount of the exhaust gas produced back into the cylinder reducing the combustion temperature. Because NOX gases form faster at higher temperatures, EGR valves help limit the amount of NOX gases produced. Due to the nature of what this part does it can get clogged with carbon from the exhaust gases.
OE Suppliers
Secondary Air Pump and Valves Also known as: Electric Secondary Air Pumps Secondary air systems are fitted to older vehicles to bring the catalytic converter up to operating temperature faster by pumping fresh air into the exhaust system re-igniting the gases.
TOP TIP - Secondary Air Pump Always replace the valve when replacing the pump otherwise the replacement part will fail again soon
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Air
Throttle Bodies Throttle bodies are used to precisely control the air flow into the cylinder to achieve the required air/fuel ratio. Some throttle bodies come complete with throttle position sensor, air mass meter and idle air control valve attached.
TOP TIP - Throttle Bodies Always replace the air filter when changing the Throttle Body
Your essential information guide to Engine Management products supplied by Allparts
Fuel System The fuel system is one of the most important systems on a vehicle so it is vitally important high quality replacement parts are used. If an inferior part is used it may lead to performance and safety issues as well as increased emissions and low fuel economy.
In-Line Pumps
In-Tank Pumps
Also known as: In-Tank Pump Modules In-tank pumps are used to lift the fuel from the tank and supply a constant pressure of around 3-6 bar to a second pump of higher pressure or other systems.
In-line pumps do a similar job as the in-tank pumps by providing a constant supply of fuel at around 3-6 bar for secondary high pressure pumps and other systems.
TOP TIP - Pumps Change the fuel filter at the same time as the pump to get the best results out of the fuel system
Fuel Rails
Also known as: Fuel Accumulators Fuel rails are used to accumulate the fuel and maintain the high pressure required for injection. The rails are relatively simple but do have sensors and regulators attached to them.
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Diesel Injection COMMON RAIL Diesel injection runs at a very high pressure. due to this and the tight tolerances required to deliver the fuel, the fitment of an inferior part could not only cause engine damage but could also lead to serious injury
Common Rail Injectors Also known as: Fuel Injectors
Common rail injectors run at very high pressures to enable them to create a very fine spray aiding the combustion. In most modern diesel engines the injectors can inject up to 6 or 7 times per stroke.
Diesel Injection Pumps As well as providing a constant high pressure fuel feed to the system, pumps also control injection timing, the duration and order in which the injectors fire.
TOP TIP - Remanufacturing Using remanufactured products can be more cost effective and environmentally friendly, than using a new part. It can also be a necessity for older vehicles where original new parts are no longer manufactured. This is not refurbished, where only the failed component is replaced, but remanufactured - stripped down and rebuilt, refreshing and replacing all the components within the unit, all to Original Equipment standards by reputable manufacturers.
Your essential information guide to Engine Management products supplied by Allparts
Unit Injectors
Also known as: PD Injectors The unit injector was designed to combine the high pressure diesel pump and injector into one unit which runs from a separate cam shaft.
Common Rail High Pressure Pumps Common rail high pressure pumps are used to pressurise and maintain pressures of up to 1,600 bar in the fuel rail to ensure there is always sufficient fuel for the vehicle to operate in all conditions.
TOP TIP - Unit Injectors Never touch the filter collar above the nozzle as it can become blocked by minute particles
Glow Plug Control Units Also known as: Preheating Relay, Glow Plug Relay
Glow plug control units are used to control how long glow plugs stay on after starting the vehicle to assist with emissions, noise and smoke production. Some advanced control units have diagnostic functions to detect failure in individual plugs.
TOP TIP - Diesel Injection Systems Diesel Injection systems run at extremely high pressure caution should be exercised at all times
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Petrol Injection Obtaining the correct air/fuel ratio is the only way to ensure the system is able to conform to emission regulations. If an inferior product is fitted, the vehicle may be unable to obtain the correct mixture which will not only cause the vehicle emissions to rise but may also cause damage to the catalytic converter and other components.
OE Suppliers Allparts supply parts from the Original Equipment Manufacturers to ensure OE/Matching Quality parts
Idle Air Control Valves Also known as: Idle Actuators, Idler Control Valves
The idle air control valve is installed in a circuit around the throttle valve. As the engine speed drops below a set level, the valve operates to bypass the throttle valve allowing air to pass through preventing the engine from stalling.
Non Direct Injection Injectors Also known as: Non GDI Injectors
Non direct injectors are located outside of the cylinder, usually in the intake manifold.
TOP TIP - Fuel System It is best to change the fuel filter whenever you change components of the fuel system
Your essential information guide to Engine Management products supplied by Allparts
GDI HP Pumps
(GDI-Gasoline Direct Injection) GDI high pressure pumps work in the same way as common rail high pressure pumps by supplying a constant feed to a fuel rail. Although they do not obtain the same pressures they can still produce up to 130 bar.
Coil on Plugs
Also known as: Pencil Coils, Single Spark Ignition Coils Coil on plugs sit directly on the spark plug optimising the space and also eliminating the need for extra high voltage cabling.
TOP TIP - Coils Change the spark plugs too It is Recommended YOU REPLACE COILS IN SETS!
GDI Injectors
(GDI-Gasoline Direct Injection) Working on the same principle as the diesel common rail, GDI injectors run at high pressures to obtain a very fine spray pattern allowing the modern GDI engine to run ultra lean air/fuel mixtures resulting in lower emissions and higher miles per gallon.
TOP TIP - GDI Injectors Gdi injectors run at 110V! be careful when you’re dealing with them
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Electronic Control Units ECUs
(ECU - Electronic Control Unit) ECU’s are vital to the whole running of a vehicle. They monitor the information from every sensor on a vehicle and control everything from fuel mixture, tyre pressure, ESP, chassis control and just about anything else you can think of!
OBD
On Board Diagnotics OBD systems allow repair technicians access to vehicle health information for its various sub-systems. Modern OBD implementations use a standardised fast digital communications port to provide real-time data in addition to a series of diagnostic trouble codes, which allow technicians to rapidly identify and rectify faults. All petrol vehicles models since 2001 and diesel vehicle models since 2003 in Europe, use an updated version called EOBD (Europe On-Board Diagnostics). Allparts offer a wide range of quality diagnostic equipment.
Autumn 2010
Workshop Solutions 01494 - 470018 www.allpartsatc.co.uk
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Focus on Delphi
Our Guide to Confusing Technical Jargon
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Your essential information guide to Engine Management products supplied by Allparts
Glossary of Terms 4MOTION: Four Wheel Drive (VW) ABS: Anti-lock Braking System AC: Air Conditioning ACC: Adaptive Cruise Control AD BLUE: An additive injected into the exhaust system to reduce NOX gases ASR: Acceleration Skid Control BLUE MOTION: VW low emission package that may be fitted with an Ad Blue System BLUE-EFFICIENCY: Mercedes low emission package that may be fitted with an Ad Blue System CAM: Camshaft CAT: Catalytic Converter CAN: Controller Area Network CC: Cubic Capacity (i.e. 1298cc) DMF: Dual Mass Flywheel DI: Direct Injection DPF: Diesel Particulate Filter EBA: Emergency Brake Assist EGR: Exhaust Gas Recirculation
EOLYS FLUID: An additive injected into the exhaust system to reduce NOX gases (Peugeot/Citroen) EURO 1 to 5: Existing European Emission Standards ECU: Electronic Control Unit EDC: Electronic Diesel Control EMS: Engine Management System EOBD: European On-Board Diagnostics ESP: Electronic Stability Program FAP: French “Filtre a Particules” Vehicle is fitted with a Particulate Filter (Peugeot/ Citroen) FSI: Fuel Stratified Injection (VW) GDI: Gasoline Direct Injection HDI: High-Pressure Direct Injection (Peugeot) ISO: International Organization for Standardization LSD: Limited Slip Differential MANIVERTER: A combination of exhaust manifold and catalytic converter
MIL: MPV: MPI: MPG: OAP: OBD: QUATTRO: SCI: SPI: SRS: TCS: TD: TDDI: TDCI: TDC: TDI: TSI: VVTI:
Malfunction Indicator Lamp Multi-Purpose Vehicle Multi Point Injection Miles Per Gallon Overrunning Alternator Pulley On-board Diagnostics Four Wheel Drive (Audi) Smart Charge Injection (Ford) Single Point Injection Safety Restrain Systems Traction Control System Turbo Diesel Turbo Diesel Direct Injection (Ford) Turbo Diesel Common-Rail Injection (Ford) Top Dead Centre Turbo Direct Injection (VW) Turbo Stratified Injection. Also vehicle is fitted with both a turbo and a supercharger (VW) Variable Valve Timing with Intelligence (Toyota)
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Illustrations representative only. Produced as an informative guide only, not intended as an educational manual. All efforts have been made to ensure product descriptions are accurate and up-to-date.