CDi Issue 6 - March / April 2020

Discover the Range!

Issue 6 March / April 2020

Engine Components Diagnostics Commercial Vehicles

Vehicle Focus with

Meyle

Spring into Action

Kilen New to Range Springs

Available soon

Oris Towbars Gates Water Pumps • Commercial Vehicle Range • Tech Tips from MechanExpert

3

March / April 2020

Issue 6

CONTENTS E

BL LA I A AV

ON

SO

7

10

13

Inside this issue ...

4 7 8 11 12 14 19 22 23 24 27

Industry News Oris Towbars Our Top Picks Gates : New to Range Kilen Coil Springs Meyle Bumper 2 Bumper Apec Brake Cables Commercial Vehicle Brands MAHLE: BrainBee Workshop Solutions Tech Tips: from MechanExpert Product Index

Your Sales Contacts Gareth Mercer

18

23

(NI)

07787 783449 GarethMercer@cd-group.com

Paul Ennis Component Distributors reserve the right to withdraw or amend any offers without prior notice. All offers are available while stocks last and subject to availability. All prices exclude VAT. Free deliver y is subject to terms and conditions.

Pictures shown are for illustration purposes only and may not be representative of actual products or vehicles. E&OE

086 466 9359 PaulEnnis@cd-group.com

Brian McGuinness 087 254 0739 BrianMcGuinness@cd-group.com

Mick Kenny 086 859 9361 MickKenny@cd-group.com

4

indus tr y news “Our lowest viscosity motor oil” LIQUI MOLY launches its new Special Tec AA 0W-16 on the market “This is the lowest viscosity oil that we have ever launched”, explains Tim Keller, Export Area Manager at LIQUI MOLY and responsible for the UK and Irish market, when talking about the new Special Tec AA 0W-16. It is suitable for selected models from Honda, Lexus, Suzuki and Toyota.

It is mainly Japanese car manufacturers that stipulate a viscosity of 0W-16. However up until now, it is very uncommon outside of Japan. However, this is changing slowly. 0W-16 oils are still very much a niche product but, technologically, they are very interesting, explains Tim Keller. This is why we are already producing it, even though the revenue earning potential is still low. Special Tec AA 0W-16 meets the requirements for API SN Plus + RC and ILSAC GF-5 and is suitable for selected models of Honda, Lexus, Suzuki and Toyota.

The lower the oil viscosity, the less power the engine has to use to pump the oil. This lowers fuel consumption and emission levels accordingly. A low viscosity oil is one of the many tricks car manufacturers use to reduce emissions. A thicker viscosity 10W-40 used to be the most widely spread viscosity, today it is 5W-30 and increasingly more 0W-20. And now 0W-16 has been launched.

The challenge for oil manufacturers is to develop an oil that has a low viscosity on the one hand but also ensures the lubrication of the engine under extreme loads. The actual oil used in the motor oil cannot manage this because its viscosity is too low. It is the highly-developed additive packages which are mixed with the actual oil in the motor oil which keeps the engine lubricated.

Safe eyes save lives: How Bosch engineers are innovating the 95-year-old sun visor.

Bosch is offering a solution with the revolutionary Virtual Visor, a transparent LCD and intuitive camera, which replaces the traditional vehicle sun visor completely. As the first reimagined visor in nearly a century, Bosch’s technology utilises intelligent algorithms to intuitively block the sun’s glare and not the view of the road ahead.

The ‘morphable’ seat, being trialled by Jaguar Land Rover’s Body Interiors Research division, uses a series of actuators in the seat foam to create constant micro-adjustments that make your brain think you’re walking, and could be individually tailored to each driver and passenger.

By simulating the rhythm of walking, a movement known as pelvic oscillation, the technology can help mitigate against the health risks of sitting down for too long on extended journeys with drivers covering an average of 146 miles every week.

NEWS BYTE

Jaguar Land Rover Develops Shape Shifting Seat

5

inside C D

We’re back on the road again!

28th - 30th April 2020

Newry, Dungannon & Limavady The CD technical and training initiative hits the road in April, once again bringing manufacturers and mechanics together to discuss the most relevant topics facing the independent aftermarket. www.mechanexpert.com

the way the aftermarket industry is working. Our roadshows will be coming to a location near you – and best of all, they’re absolutely free!

Tuesday 28th April Southern Regional College Newry

Keep an eye on our MechanExpert social media channels and further issues of CDi for more details.

Wednesday 29th April South West College Dungannon Thursday 30th April Drummond Hotel Ballykelly, Limavady Designed to educate and inform rather than promote and sell, our MechanExpert roadshows are held in partnership with our biggest brands, giving you the chance to speak one on one with the people that designed and created the parts and tools that you use, to ask any questions you may have and to help understand

5 millionth brake pad sold CD Group have started off the year by selling their 5 millionth Apec brake pad.

This is a testament to our customer’s faith in the Apec brand and to the wide range of pads available for different makes and models.

Check out our extensive range of Apec braking components, featuring everything from pads to sensors to cables.

NEW to CD Group RETROFIT TOWBARS

FROM ORIS

ORIS is the leading manufacturer of towbars in Europe – we have the right technology to suit every vehicle and application. Our marketleading product is the innovative FIX4BIKE hitch system which couples with our range of easy-to-use FIXMATIC bicycle carriers.

Whether for leisure activities or for business, ORIS has the right towbar for you. We also manufacture electrical kits for your car, ensuring a secure, bespoke connection to your vehicle’s electronics.

Which towbar is right for me?

Fixed towbars are robust and the ideal solution for frequent users. The ball neck is fixed, so the coupling is always ready for use.

Detachable towbars give you the choice: the ball neck can be dismantled easily. The advantage is the coupling is no longer visible and therefore doesn’t disturb the vehicle design.

Did you know?

•

Oris ACPS acquired Bosal Towbars in November 2018.

•

You can still use Bosal part numbers on TecDoc listed under ‘Bosal-ORIS’.

Fixed Towbar Systems

Always ready to go If you often have something to transport, a towbar with a rigid ball neck is the best choice. It is functional, reliable and robust and always ready for use.

Detachable Towbar Systems

There when you need it

If you only want to use your towbar from time to time and don’t want to interfere with the appearance of your vehicle, then a removable system is the best choice.

ELECTRICAL SETS

ORIS has the right electrical set in its range for almost every application to ensure that the lighting and electronics of the bicycle rack or trailer connect with your car and work perfectly. ORIS electrical sets are of the highest quality and guarantee a long service life.

A secure connection ORIS offers a wide range of vehicle-specific electrical sets. These are compatible with automotive industry standard CAN bus technology and ensure an optimum connection of all electrical and electronic systems between the vehicle, bicycle rack or trailer.

Depending on the application, ORIS electrical sets have a 7-pole or 13-pin plug.

8

our t op pi cks Item No: MOK0056 100 1035 0114

Description

ATF Service Kit Application Audi S-Tronic DSG Audi A4, Audi A6, Audi A7, Audi Q5 ’07 > ‘18

Item No: 8EA012527-611

Description

Starter Motor Application Citroen Relay ‘06+ Ford Transit Mk7 ‘06>’14 Land Rover Defender ‘90>’16 Peugeot Boxer ‘05+

Item No: A2C9626040080

Description Injector Application VAG Group 1.6 TDI ’03 > ‘18

Item No: BOS0250403024

Description

Glow Plug Application Land Rover Defender ‘90>’16

9

our t op pi cks Item No: BOS0986594561 Description

Wheel Speed Sensor Application Audi Q3 11’+ Seat Alhambra ‘10+ Skoda Superb ’08+, Skoda Yeti ’09-‘17 VW Beetle ’11-’19, Jetta ‘08+, Sharan ‘10+

Item No: MSA0132 126 725 00124

Description

Shock Absorber, Rear Axle Application Seat Altea ‘04+, Seat Leon Mk2 ’05-‘13 Audi A3 ’03-‘13 Skoda Octavia ’04-’13, Skoda Yeti ’09-‘17 VW Golf ’03-’14, Touran ’10+, Passat ’05-‘15

Item No: LM8976

Item No: LM8977

Description Synthoil Longtime Engine Oil Description 0W-30 1 Litre & 5 Litre

Item No: COR80001663

Description

Repair Kit, Strut Top Mount L+R Front Fitting Application Audi A3 ’03-’15, Audi TT ’06-‘15 Seat Altea ‘04+, Leon Mk2 ’05-‘13 Skoda Octavia ’04-’13, Yeti ’09-‘17 VW Golf ’03-’14, Touran ’10-‘15, Passat ’05-‘15

11

wa ter pump kits

Gates automotive water pumps are recognised

in the industry for their exceptional durability, quality and efficiency in a range of vehicle systems, with coverage from late model and hybrid engine systems, to rare vintage cars and import vehicles.

100% WORRY-FREE, RELIABLE OPERATION •

Every Gates automotive water pump is constructed with premium alloy materials, backed by a 100% functional test of seals and bearings, and a 100% leakage test for both the casting and assembled water pump.

A true “all makes” premium-quality water pump programme

•

Covering more than 130 million vehicles in Europe

•

Constructed with premium alloy materials

•

Over 50% of all warranties are due to seal failure, but not with Gates: 100% quality tested mechanical seal for leak-free, long-life performance

New Water Pump Kits added to stock this month Item No: KP15673XS

Application Abarth 124, 595, Fiat 124/500, Jeep Compass

KP15686XS-1

Volvo S60, S80, S90, V40, V60, V70, V90, V90, XC40, XC60, XC70, XC90

KP25529XS

Honda Civic 1.4 ‘99 - ‘06

KP15680XS-1

Audi A3 1.4 TFSI ‘12>

KP15680XS-2

Audi A1, A3, A4, A5, Q2, Q3 , Seat Alhambra, Ateca, Ibiza, Leon, Toledo Skoda Fabia, Kodiaq, Octavia, Rapid, Superb, Yeti , VW Caddy, CC, Golf, Jetta, Passat, Polo, Scirocco, Sharan, Tiguan, Touran

KP25680XS-1

Seat Ibiza, Mii, Skoda Citigo, Fabia, VW Polo

KP25680XS-2

Audi A1, A3, Q2, Seat Arona, Ateca, Ibiza, Leon, Toledo, Skoda Fabia, Karoq, Octavia, Rapid, Yeti, VW Caddy, Golf, Jetta, Polo, T-Cross, Touran, T-Roc, Up

7 new

water pump kits covering

345 new

applications

13

springs Quality cars require a quality spring

Breakage is the main reason for spring replacement, and producers of quality springs therefore strive to maximise fatigue strength.

A springs’ fatigue strength is essentially the maximum stress it can withstand without breaking.

2

1

Modern highly stressed suspension spring designs, combined with potholes, speed bumps and salt on the roads, means that coil springs, especially those of lower quality, are increasingly prone to breakage!

1.

3

4

5

Freshly laid tarmac forms a solid impermeable barrier between the soft foundation under the road, and the elements above.

2.

Over time, with traffic volume acting as a catalyst, the tarmac becomes more porous and rain begins to penetrate the cracks.

3.

As temperatures plummet, the water freezes and expands, pushing the tarmac upwards.

4.

As the ice thaws, gaps appear below the surface. These gaps grow larger with each freeze-thaw cycle.

5.

Eventually the vibration and weight of the traffic above causes the tarmac to collapse into the void,

So what affects fatigue strength?

creating a pothole. The pothole becomes larger and deeper as the traffic continues to roll over it.

Poor quality spring wire, containing non-metallic inclusions influences fatigue strength, and will lead to premature breakage. The risk of breakage is therefore significantly greater for ‘budget’ springs using lower-quality steel.

Heat treatment is a critical part of spring manufacturing and, if not performed to OE standards can leave a spring too brittle. The more brittle the steel is, the more sensitive to defects such as corrosion, with resultant lower fatigue strength and increased risk of premature breakage.

Surface defects also lower fatigue strength and lead to early breakage. Use of OE quality spring wire combined with shot peening and pre-setting will improve fatigue strength.

Shot peening is a treatment where the complete surface of the spring is bombarded with millions of tiny steel shots. This closes any potential micro fissures, and introduces a positive residual stress in the material; whilst also preparing the steel suitably for surface treatment.

The pre-setting operation is a manufacturing stage where the spring is compressed to implement a positive residual stress. All OE quality springs, where the design requires it, will be pre-set.

Coil springs are under continuous attack from the road below.

The sudden impact of a pothole is a well-documented cause of suspension damage. Road debris is a significant danger too; with stone chips and grit thrown up by the tyres striking the spring with sufficient force to damage the surface coating: This exposes the bare steel which, if untreated, will quickly rust.

In cold weather, as grit salt is spread on the roads it mixes with surface water to form an abrasive paste, grinding the protective paint off the spring and dramatically accelerating the corrosion process.

Cold temperatures affect the toughness of the steel; meaning that the steel becomes more brittle and is more liable to cracking.

Minute cracks can form on a rusty, damaged spring surface and, given repeated compression cycles will increase in size over time. One of these cracks will eventually propagate and it is not uncommon for coil-springs to fail catastrophically. The shock impact of hitting a speed bump or descending a kerb can be enough to cause a crack to propagate across the full diameter of the spring wire, often quite audibly.

A spring is a safety critical product, and to minimise the risk of breakage in use OE standards require one million cycles of fatigue testing, one thousand hours of salt spray testing, and zinc phosphate protection.

For the drivers safety, and that of your customers, it makes sense to stock and promote an OE quality spring.

9 NEW SPRINGS added to our range this month

KIL20168

Vauxhall Astra 1.4T ‘15- (Manual)

KIL20169

Vauxhall Astra 1.4T / 1.6T ‘15- (Automatic)

KIL25124

VW Touareg 3.0 ‘10-’18

KIL65130

VW Touareg ‘10-’18

KIL23242

Suzuki Grand Vitara 2.0 01-05

KIL63233

Suzuki Grand Vitara 01-05

KIL25128

VW Passat Alltrack 2.0 15-

KIL10622

Alfa Romeo Mito 0.9 08-

KIL62057

Renault Kangoo Express 12-

We look in detail at those brands with an answer for everything between the bumpers. In this edition we examine the many ways in which MEYLE can offer the right OE quality solution for every repair. MEYLE boasts a highly diversified product lineup. Whether it’s steering and suspension components, rubber-to-metal parts, drivetrain or anything else in the range, MEYLE is synonymous with top-grade quality-tested parts!

Bush, Control Arm Mounting (L&R)

Track Control Arm Rear (L)

Item No: MCB0089

Item No: MCA1208HD Bush, Control Arm Trailing Arm (L&R)

034 035 0035

116 050 0179/HD

Item No: MCM0150HD

114 711 0000/HD

Shock Absorber (R)

Item No: MSA0716

126 725 0017 Ball Joint (R)

Item No: MBJ0056

116 010 0017

Track Control Arm Rear (R)

Item No: MCA1209HD

116 050 0180/HD

Vehicle: Seat Leon

2012 - 2020

Track Control Arm Front (L)

Tie Rod End (L)

Item No: MTE0121

116 020 0025

Item No: MCA1013

116 050 0123/S

Ball Joint (L)

Item No: MBJ0057

116 010 0018

Bush, Control Arm Mounting (L&R)

Item No: MCB0077 100 407 0086

Stabiliser (R&L)

Item No: MSL0922HD

116 060 0063/HD

Tie Rod End (R)

Shock Absorber (F)

Item No: MTE0111

116 020 0003

Item No: MSA0722 Track Control Arm Front (R)

Item No: MCA1014

116 050 0124/S

126 623 0016

Tie Rod Axle Joint (R&L)

Item No: MAR0065 116 031 0000

16

hybrid wiper blades Designed with an integrated, fully covered blade and wiper arm they combine sophisticated design with a low, out-of-view profile. Inside the wiper housing, common-use vertebra deliver superior surface holding capability; whilst the rigid, graphite-coated rubber blade delivers a smooth, more efficient wiping performance.

The combined advantages of advanced engineering, superior materials and futuristic design make DENSO’s Hybrid Wiper Blades some of the most desirable in the world. It’s no wonder they are the original equipment choice of some of the world’s top vehicle marques. Featuring the same exacting technologies, our Aftermarket range is the first to be launched by an OEM brand - and gives you and your customers unprecedented access to the future of wiper technology.

Fully covered, stylish, matt black body Common-use vertebra ensures superior surface-hold to the windscreen Very easy to attach wiper arm Integrated fitting system

Features & Benefits

Rigid, graphite-coated rubber blade for smooth, more efficient wiping performance Low profile, unobtrusive shape

DENSO Hybrid blades •

Superior wiping performance

•

Stylish, advanced low-profile design

•

Conveniently consolidated range

•

Highly durable for a long lifespan

•

Simple OEM click-on fitment, with additional clip supplied for large hook attachment.

17

steering & transmission Comprehensive range of stock available from CD Group on all these product lines.

CV Joints - 24 month/24,000 mile warranty The Shaftec range of CV joints consists of over 1,500 part numbers, which between them account for almost 99% of the European vehicle car parc. All CV joints are supplied with the boot, 2 steel clips, grease, hub nut and replacement circlip.

CV Boots & Steering Gaiters 500 conventional tailored fit CV boots. The universal CV boot range covers 98% of all European applications. 400 steering rack gaiters in range. Universal steering gaiter range covers 95% of all European applications.

Driveshafts - 24 month/24,000 mile warranty Entirely remanufactured in the UK, Shaftec offers the biggest range of driveshafts in the European aftermarket. The combined new and remanufactured programme of Shaftec branded driveshafts totals more than 5300 references offering 98% coverage of the European car parc.

Steering Racks - 12 month /12,000 mile warranty Shaftec’s premium programme of remanufactured steering racks consists of over 1,200 part numbers which offer 95% availability for the most popular vehicles on the road. Shaftec remanufactures the entire programme, in-house at their leading remanufacturing facility.

Steering Pumps The Shaftec remanufactured steering pump programme consists of over 1,600 part numbers which offer 95% availability for the most popular vehicles on the road. They remanufacture the entire programme, in-house at their leading remanufacturing facility.

19

N E W br ake c ab les

New to CD Group

Now stocking Apec’s Complete Range Of Brake Cables

Take the strain with our brake cables.

HANDBRAKE CABLES CAUSES OF FAILURE The handbrake, also known as the parking brake, has the task of securing a stationary or parked vehicle and of preventing it from rolling away when no driver is present in the vehicle. With the mechanical handbrake, the braking force is transferred to the wheel brakes of the rear axle via cables when the handbrake lever is operated using muscular pulling force.

A frequent cause of handbrake failure is operational impairment as a result of external damage or contamination.

A new high-quality range made for smooth operation and enduring reliability.

Easy does it, every time

Apec brake, clutch and gear control cables are designed and precision-manufactured for easy, precise control, every time.

Our cables are made with galvanised or nylon coated inner wires and strand design to exactly match OE specification, and are pre-lubricated.

The brake cables are 100% proof loading tested, up to 800 lbs.

Take the tough with the smooth.

249 new brake cables

A defect in the covering or dust protection sleeve can cause water or dirt to penetrate, which can lead to corrosion and jamming of the cables.

Apec cables use wear-resistant materials to perform dependably even in extreme environments.

In addition, moisture and frost can cause the cables to freeze up during cold seasons.

Our range of nearly 270 brake, clutch and gear control cables already covers several popular applications and will be growing rapidly.

All steel parts are surface protected with zinc trivalent plating, which is RoHS and EU compliant and more environmentally friendly than hexavalent coating.

Apec’s range of cables already covers several popular applications and will be growing rapidly. To get you started with Apec Braking cables, we’re offering handy stock packs covering 50 or 100 of the most requested part numbers.

20

refinish pro duc ts

Paint & Ancillaries

Bodyshop Consumables

Tools & Equipment

Ancillaries

For more information on the refinish solutions available from CD Group, reach out to your account manager.

21

engine comp onents This issue of CDi focuses on the top of the engine, primarily the cylinder head and it’s respective components. In an internal combustion engine, the head sits above the cylinders on top of the cylinder block. It closes in the top of the cylinder, forming the combustion chamber. This joint is sealed by a head gasket.

Top Engine › Camshafts › Cylinder Head › Head Bolts

In most engines, the head also provides space for the passag-

› Rocker Arms / Cam Followers

es that feed air and fuel to the cylinder, and that allow the

› Hydraulic Lifters

exhaust to escape. The head can also be a place to mount the valves, spark plugs, and fuel injectors.

› Inlet Valve › Exhaust Valve

With our extensive range of top engine components, CD

› Inlet/Exhaust Manifold

Group stocks everything you need for a full head rebuild.

› Engine Valve Guide › Valve Seat Insert › Valve Spring › Valve Collet › Camshaft Bearings

Bottom Engine • Sump Pans • Sump Plug • Sump Washers • Crankshaft • Oil Pump • Pistons • Liners • Kit Sets (Piston+Liner+Rings) • Piston Ring Sets • Main Bearings • Thrust Washers • Small End Bushes • Conrod • Conrod Bolts

Gaskets Head Gaskets • Head Sets • Conversion Sets • Rocker Cover Gaskets • Manifold Gaskets • Sump Gaskets • Oil Seals • Valve Oil Seals • Sealing Compounds • Gasket Full Set Brands in stock

(ROI only)

(ROI only)

(ROI only)

22

commercial vehicles

CD Group stock

Commercial Vehicle Parts.

Filters

CD Group stocks everything you need to keep your commercial fleet (and your drivers) breathing easy. Direct replacement and OE quality means that time on the road will increase, and time in the workshop will decrease.

Batteries

Built to take the rigorous demands of long idles and harsh vibrations and able to tackle the strongest of electrical loads, our range of commercial batteries are fit to tackle the day to day strain in the worst of conditions.

Radiators & Cooling

Our stock of radiators are perfect for keeping most common applications from overheating.

OE fitment that simply bolt in, they’ll also reduce downtime in the garage, keeping your fleet on the road longer.

Rotating

Built to withstand the harshest conditions and designed to OE fit and performance, our range of Bosch, HC Cargo and Hella rotating parts are tested, proven and ready to last. Keep your commercial fleet running again and again.

Wiper Blades

Bulbs

We offer a full line of windshield wiper blades engineered for extreme all-weather performance to ensure visibility no matter the weather condition, with a factory fit design to ensure simple and quick changes.

Our range of commercial vehicle lighting provides numerous options for lighting the road ahead – with varying levels of brightness, alongside useful spares kits meaning your drivers can be prepared for every eventuality.

Engine Parts

For times when it’s easier to fix than swap, we have everything needed for a full rebuild, from top to bottom – including valves, bearings and pistons – for both lorries and buses.

Universal Lighting With everything from multi-function taillights to side lights and reflectors, CD Group stocks everything for lighting up trailers. With a wide variety of shapes and sizes, whatever the application, we have a light to suit.

Vehicle Specific Lighting OE quality and direct replacement, our vehicle specific lighting covers all headlight and taillight requirements. With all common models available in the range, we make it easier to help commercial vehicles stay on the road and shining bright.

Diagnostics

Offering products from both Hella Gutmann and Bosch, every base is covered – with the latest and greatest technologies, their diagnostics systems can help get to the root of the problem with ease.

23

vehi c le diagnos ti cs

THE INCREASING POPULARITY OF AUTOMATIC GEARBOXES DEMANDS NEW WAYS OF SERVICING. Our solution: the fully automatic ATF station.

Vehicle manufacturers recommend servicing automatic gearboxes: + To avoid high secondary costs in the event of problems + To extend the service life of automatic gearboxes + To maintain good vehicle performance + To prevent malfunctions due to wear and contaminated ATF + To ensure a more comfortable ride

Integrated database with illustrations: The database integrated in the station enables you to find the right adapter quickly and confidently. The database provides comprehensive instructions for the flushing process: + Vehicle model / gearbox type + ATF type with vehicle manufacturer’s specifications + ATF quantity + Tightening torques + Correct adapter

KEY FEATURES:

Advanced electronics: All servicing processes are monitored by advanced elec-

+ TIME SAVING: Tanks are replaced in seconds and there is

tronics, preventing any damage to components. + The automatic recirculation feature prevents damage due to excess pressure. + Automatic flow direction detection: The integrated

pressure sensors always detect the right direction of

unused oil can subsequently be reused. + PRECISION: Integrated draining unit for automatic & volume.

+ Automatic ATF temperature measurement: The flushing process is started automatically. ideal flushing speed, adapted to the type of gearbox.

+ EFFICIENCY: No oil is lost when oil tanks are changed;

adjustment of the fill level and return quantity in weight

flow to ATF.

+ The electronically controlled two pumps ensure the

no need to clean or empty them.

+ INTEGRATED PRINTER

For more information contact: Peter

Vahey

mobile: +353 (0)86 145 1174 tel: +353 (0)1 820 8860 email: PeterVahey@MechanExpert.com

24

TECH TIPS

brought to you by

Audi A3 1.9 TDI Clutch and Dual Mass Flywheel Replacement An ‘08 Audi A3 1.9 TDI which has covered over 129,000 miles is booked in for a judder on drive, more noticeable when using the clutch - the suspicion before diagnosis is a fault with the flywheel.

Audi launched the A3 in 1996, and in 2003 the second generation was released which lasted until 2012. It shares the same platform as the Audi TT, VW Golf, Caddy and Touran, Seat Leon, Toledo and Skoda Octavia. The A3 has three model styles - 3 door, 5 door and Cabriolet, available in two wheel drive or four wheel drive (Quattro), so the chances of an independent garage seeing one of these is quite high. The model we are looking at is a three door, two wheel drive 1.9 TDI. The special workshop equipment we are using for this repair is a two post ramp, engine support beam, transmission jack, Dual Mass flywheel test kit and a SelfAdjusting Clutch installation kit.

With the vehicle placed on the ramp, locate the locking wheel bolt key and slacken the N/S/F wheel, also slacken the N/S/F hub bolt, raise the bonnet, disconnect and remove the battery, battery housing and battery tray. Then disconnect the air mass meter and remove the air filter assembly and hose to the inlet manifold. This then gives us good access to the top of the gearbox.

Remove the gear linkage assembly by releasing the two “C” clips and removing the three bolts, disconnect the multiplug for the reverse light switch, then remove the two bolts that retain the slave cylinder, the hydraulic pipe can be unclipped and swivelled up to give better access to the bolts, remove the slave cylinder from the bell housing and stow the gear linkage and slave cylinder against the bulkhead and secure if required. (fig1) At this point the top bell housing bolts can be removed with the engine earth connected, disconnect the starter motor wiring and top starter motor bolt. Now fit an engine beam to support the engine and gearbox, once fitted the top gearbox mounting can be removed. Raise the vehicle, remove the N/S/F wheel, remove the N/S driveshaft flange bolts and the hub bolt, the N/S driveshaft can now be removed at the gearbox end and then removed from the hub, remove the bolts from the O/S driveshaft inner joint flange and disconnect from the gearbox.

We can now remove the O/S drive flange from the gearbox by removing the allen bolt from the centre of the flange to aid gearbox removal.

25 TECH TIPS brought to you by Remove the lower gearbox mounting/stabiliser unit from the gearbox and front sub frame, then remove the bottom starter motor bolt and remove the starter motor. Lower the engine/gearbox on the engine beam to gain some clearance for gearbox removal, support the gearbox with a transmission jack, remove the remaining bell housing bolts and remove the gearbox with the transmission jack.

With the gearbox removed the cause of the judder was now visible, the Dual Mass Flywheel had not returned to its rest position indicating that it had reached the end of its service life (fig2), so the Dual Mass Flywheel tester kit was now not required.

We removed the clutch assembly which showed signs of normal wear expected at the vehicles mileage. We held the primary mass of the flywheel by the starter ring gear and rotated the secondary mass back to the neutral position with two pin wrench, which meant the bolts were now visible for removal. We removed the flywheel, carried out visual inspection of the rear main oil seal which showed no signs of leakage and then mounted the new flywheel.

Using Schaeffler’s REPXPERT Checkpoint app, the tightening torque settings could easily be obtained (fig3) and the flywheel torqued. Before fitting the clutch, confirm the clutch plate fits the splines of the gearbox input shaft. Mount the new Self-Adjusting Clutch using Schaeffler’s special tool (400 0237 10) combining the clutch alignment tool to eliminate any rotation of the adjuster ring and to ensure the clutch pressure plate is installed evenly removing the risk of any clutch judder (fig4).

With the clutch installed, ensure the three yellow adjuster ring springs are still compressed confirming the adjuster ring has not de-adjusted (fig5).

Clean the bell housing of the gearbox, replace the release bearing and ensure that there is no wear to the clutch release fork and gearbox snout. Lubricate the pivot points that are metal to metal with a smear of high melting point grease. Ensure the dowels are located properly on the engine and that the sandwich plate positioned correctly. Refit the gearbox and secure with the bell housing bolts - at this point we can check there is a small amount of free play on the clutch fork by pressing it with your finger to confirm correct installation. Refit all components in reverse order and torque bolts to the manufacturer’s specifications. Remember to reset electrical items as the battery has been disconnected.

When starting the car, the ABS, ESP and electric steering warning lights may be illuminated, turn the steering from lock to lock to reset the steering system, finally, a short test drive will reset the ABS and ESP systems so no warning lights are illuminated.

26

TECH TIPS

Premature Outer

brought to you by

Brake Pad Wear

The braking problem had endured over the course of a few months. It had started with the owner of the vehicle purchasing the vehicle and requesting that the brakes are replaced.

A couple of months after the brakes were replaced, the owner reported squealing noises at low speeds, as well as a burning smell. Upon removing the front discs and pads, the garage discovered that the NSF outer (or finger side pad) had worn down considerably more than the inner pad.

Suspecting that this was a caliper issue, they replaced the caliper together with a new set of discs and pads. However, after this replacement, the owner still complained of a squealing noise and an abnormal braking sensation. The garage, suspecting that the issue was with hydraulics further up the brake system, chose to replace the hose in case of a blockage. Following best practice, the garage ensured that the sliders were cleaned and relubricated to ensure free movement of the braking components. Unfortunately, this still did not resolve the issue and, suspecting a faulty caliper, the garage decided to replace the caliper twice more without success. Apec’s Techmate team were contacted to provide some assistance to resolve the issue.

After a test drive to confirm that the symptoms were present, the vehicle was stripped so that the parts could be inspected and measured. Contrary to the garage’s diagnosis that the caliper piston was seized and that the outer pad (finger side) was wearing prematurely, Techmate suspected that the actual issue was due to the outer pad not returning after the brake pedal had been depressed. As a result of this, the outer pad would have been left in contact with the brake disc, causing the brake pad to wear prematurely.

However, to ensure that there was no issue with residual hydraulic pressure causing the caliper to bind, a hydraulic pressure gauge was attached to the caliper to confirm this. With the gauge attached and without any pressure on the brake pedal, no pressure was recorded on the gauge. To ensure that the caliper pistons were moving freely, hydraulic pressure was blocked to the caliper by clamping the brake hose, which was then followed by pushing the pistons back into the caliper with the bleed nipple undone.

The brake fluid expelled could then be examined to ensure its condition and eliminate it from being contaminated, which would cause the piston to seize. The caliper pistons retracted easily, which indicated that they could move freely without any obstruction.

The brake fluid expelled wasn’t contaminated, and this proved that the brake fluid wasn’t causing the pistons to seize. With the caliper removed, the brake pads were moving freely in the carrier

and there was enough lubrication to assist with movement of the pads. The sliders were moving and had abundant lubrication to assist with movement.

As all components had been proven to move freely when disconnected from each other, Techmate suspected that a component may have been misaligned. Due to this misalignment, it would prevent the outer pad from returning. To confirm that the brake disc was in alignment, a runout measurement was taken to eliminate the brake disc as a source of misalignment. The maximum amount of tolerance for brake disc runout is 0.08mm. The runout reading was 0.04mm, which eliminated the brake disc.

The other source of misalignment is the brake carrier. If this had been misaligned, the angle would prevent the outer brake pad from returning. To confirm this, a feeler gauge was used to measure the gap between the disc and the carrier, and compare the differences between the nearside and offside.

This confirmed that there was a definite difference in measurement between the two. With the caliper bolted on to further confirm the misalignment, the nearside caliper kicked out slightly, rather than moving laterally when the brakes were applied, indicating a misalignment. The carrier was replaced which rectified the issue.

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