V-SMART June 2018

V. SMART ISSUE N O .1 June 2018

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This Month In Valeo Technical

Welcome Back! Following the introduction of the weekly technical magazine in 2017, we’ve received positive feedback from so many of you. For this reason the Valeo Service UK Technical team decided to put our thinking caps back on and redesign the magazine. The aim of the new 2018 editions is to bring you new articles that will help you understand Valeo products, help increase your knowledge and keep you informed about all of the exciting things going on in the Valeo Technical world. In this issue we talk about one of the most important factors that make Valeo a leading brand in clutch kits and why vehicle manufacturers ask major clutch manufacturers around the world to use Valeo technology. We also send one of our warranty master technicians out on the road to identify a big problem with a Mini. Our Technical Hotline is back providing answers to frequently asked question as well as a new feature designed to pass on their unique knowledge to answer common queries received over the phones. All the usual favourites are back too including our Technical Service Bulletins and this month we are happy to announce the launch of our new external clutch training programme!

Technical Manager

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CONTENTS

The Learning Zone Fact or Friction- 04 Valeo clutches are used by vehicle manufacturers all over the world. We discuss Valeo Friction Material, what makes it so good and who else other than Valeo use it on their clutch kits. 10 things you need to know about... 07 Valeo Conversion Kits! Learn why Valeo Clutch Conversion kits are becoming increasingly popular with vehicle manufacturers. Save money with Valeo SAT-08 Find out why using a Valeo self adjusting clutch kit is more cost effective than any other competitors. Garage Area The Valeo Auto Repair Centre- 22 The Valeo Technical Team guide you through a clutch installation on a Peugeot 207 1.4i engine. Identifying a Big Problem on a Mini- 24 We head out on the road to Identify a common clutch problem on a BMW Mini Products and Services Connected Hotline Video- 19 Learn more about the new Valeo Connected Hotline Train With The Best- 20 Need clutch training from one of the world’s leading suppliers? Take a look at our NEW clutch training programme

Technical Support Catalogue Focus- 12 Our catalogue expert Rhod Griffiths talks about the importance of cataloguing for you and Valeo. Technical Service Bulletins- 16 Check out our latest three Technical Service Bulletins produced by our Technical Team Hotline Topics of the Month- 23 Members of the Technical Hotline provide answers to three frequently asked questions. Q&A- 14 One of our technical team answers the follwing question from a member of the public. “ The heating in my vehicle only works on setting four and I have a bad smell in my car. What could the problem be?” Introducing the Connected Hotline- 15 The Valeo Technical Team is happy to introduce the launch of the Valeo Connected Hotline, a free serivce for all customers to use to help solve issues more effectively. General 60 Second Interview-10 Get to know members of the Valeo Technical Team. We start off with Technical Manager Steve Knight Competition Time!- 25 Have a go at our crossword to be in with a chance of winning a prize and get your own feature in V-SMART!

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The Learning Zone Fact or Friction? Why Valeo clutch friction material is the best in the market

For 95 years Valeo has been a byword for premium clutch products. As one of the worlds recognised experts in clutch and transmission systems, Valeo clutches are known for delivering high quality clutches. One of the main reasons for many vehicle manufacturers choosing Valeo clutches as the preferred choice is due to the performance of Valeo friction material. With vehicle manufacturers producing more and more vehicles with higher torque and higher horsepower outputs, it’s imperative that that the horsepower and torque ratings complement each other and provide a well-balanced driving experience. When each of these factors are increased it’s important that the engine and transmission have the capabilities to deal with the additional load. More powerful engines, longer ratios and new lifetime specifications have led to the development and introduction

of more complex friction designs as well as an increase in clutch designs such as the Valeo SAT (Self Adjusting Technology). The SAT is a Valeo revolutionary technology that uses a self adjusting facing wear compensation device on the pressure plate, thereby enhancing the clutch life and improving the pedal comfort. Valeo engineers have also introduced a new clutch kit design named HEC (High Efficiency Clutch) to replace our competitors’ old self-adjusting clutch and give full satisfaction in terms of quality, reliability and durability. Our High Efficiency Clutch (HEC) high resistance G5 generation facings are best in the market for their high durability & clean technology. With various production and R&D sites located around the world, Valeo employ over 1000 people to bring to the UK a range of clutches that cover over 90% of the total car range, with a major presence within all major car makers such as

French, German, Korean, Spanish, Japanese and Italian manufacturers. “vehicle manufacturers request that Valeo clutch competitors use Valeo friction material facings in conjunction with their own clutches” In total, Valeo produce approximately 75 million friction facings each year. Surprisingly, not all of these friction materials are found in Valeo clutch kits. Due to the friction material being best in class, vehicle manufacturers request that Valeo clutch competitors use Valeo friction material facings in conjunction with their own clutches. In total around 30% of friction facings produced are supplied to and used by Valeo’s major clutch competitors!

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All your customers are different, Valeo has a repair solution for every one of them

Conversion Kit Developed specifically for intensive usage ● Reliable ● Duarable ● Cost-efficient

Reliable technology converting your dual-mass flywheel transmission to single-mass flywheel transmission meaning you never change your flywheel again!

All your customers are different, Valeo has a repair solution for every one of them

D.M.F. ®

Valeo offers a wide range of D.M.F. * to the aftermarket for quality transmission repairs

Discover the new FullPACK DMF ® range: the perfect match of components to make your repair easier * Dual-mass flywheel

● Optimal filtration of vibrations

Noise reduction Driving comfort

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10 THINGS YOU NEED TO KNOW ABOUT VALEO CLUTCH CONVERSION KITS 1. Valeo conversion kits have been mass produced since 2002. This is longer than Apples iPhone! In Europe, the story began in Spain when the first kit was built for Volkswagen 1.9Tdi engines that were used on taxi models. The vehicles suffered from poor heat dissipation and rapid wear. The Valeo conversion kit solved the problem and worked more effectively than the OE D.M.F version. 2. Due to the increased level of performance seen with our conversion kits, the technology used in Valeo conversion kits is used at OE level by many vehicle manufacturers. You can find Valeo conversion kit technology in Ford Transits 2000-2006 2.4Tdi models, Peugeot Expert, Citroen Jumpy, Fiat Scudo 2.0Hdi 2011> models, Ford with new Ecoboost 1.3l engines, Renault Scenic 1.9dCi and Renault Megane Fluence 1.5Dci models just to name a few. 3. The friction plate within the conversion kit contains along travel damper clutch disc, which incorporates a high-tech pre-damper multi- cassette and “long-travel” dampers. The long travel dampers can travel more than twice as much as dampers within a standard friction plate in order to compensate for the dual mass flywheel. 4. As one of world leaders in clutch friction material design, the friction material used in our conversion kits have been specifically designed to allow for greater heat dissipation. The clutch facing within a conversion kit works at lower temperatures compared to a D.M.F. version (between 100ºC and 270ºC) thus ensuring that the overall lifetime of the clutch is improved. 5. No specific tools are required in order to fit Valeo conversion kits. Through years of research and development, Valeo engineers have designed and built viable time and cost saving alternatives compared to the OE technology that requires you to use specific tooling to fit the clutch and flywheel! Valeo also provides within the box some installation tips for garages and shares technical fitting instructions on electronic catalogues and Valeo TechAssist.

6. The solid flywheel does not require replacement unless there is abnormal damage on the friction surface or the starter ring. When the second clutch replacement is due, only the cover, the disc and the bearing need to be replaced. Valeo offers a complete range of Service Kits for vehicles equipped with conversion kits. 7. The rigid flywheel does not require replacement unless there is abnormal damage on the friction surface or the starter ring. When the second clutch replacement is due, only the cover, the disc and the bearing need to be replaced. Valeo offers a complete range of Service Kits for every conversion kit available. 8. Every conversion kit is supplied with specifically designed stretch bolts suitable for their intended purpose. No bolts need to be sourced and the existing bolts on the D.MF version can be discarded. 9. Valeo Service UK offer a two year warranty on standard conversion kit fitments. For peace of mind we also offer all customers a 1 million mile guarantee on every solid flywheel! Check out the Valeo Service website for terms and conditions. 10. Due to the demand of conversion kit technology by both vehicle manufacturers and the Aftermarket, Valeo Service UK currently have over 100 conversion kits covering over 7 million vehicles in the UK.

For more information about Valeo conversion kits find our Valeoscope at; www.valeoservice.co.uk

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The Learning Zone

SAVE MONEY WITH VALEO SELF ADJUSTING TECHNOLOGY

With many clutch manufacturers it is necessary to use specific tooling for pre-tensioning self adjusting clutches before removal or installation. If the special tool is not used, the pressure plate can be damaged which will cause the clutch to malfunction. These additional tools typically cost repairers hundreds of pounds to buy before they can fit the clutch. The good news is Valeo conversion kits are now built without self adjusting technology incorporated into the clutch cover that would require an additional tool to fit. All Valeo SAT clutches are either locked in place by a transport plate (right) or have SAT technology that requires no setting during fitment. Valeo have also designed and manufactured a new type of technology to replace SAT. A HEC (High Efficiency Clutch) looks similar to a standard type clutch where there is no self adjusting system incorporated into the clutch cover, but the friction material used is a high performance design with low wear rate properties. This will mean the clutch cover assembly will be working within the ideal operating window for longer and will offer the same lifetime performance as a SAT clutch. The advantage of the low wear material used in a HEC clutch will mean the clutch will offer a longer life and will not suffer from a progressively heavier pedal action. Again, no self adjusting tool is required when fitting the clutch.

A Valeo self adjusting clutch cover with a built in locking plate

A self adjusting tool not required for Valeo self adjusting technology

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The UK’s ONLY OE supplier to offer a FULL RANGE of CLUTCH TECHNOLOGIES

DUAL MASS FLYWHEELS FullPack DMF® Flexible Flywheels Conversion Kit VBLADE®

TRADITIONAL KITS Self-Adjusting Technology High Efficiency Clutches HYDRAULICS Clutch Release Cylinder Concentric Slave Cylinder Clutch Master Cylinder

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6 SECOND INTERVIEW

In the Valeo Technical department we don’t want to just put a face to a name, we want to let you know about the real people you speak to on a daily basis and who are dedicated in bringing you the best possible service. In our first 60 second interview we have a chat to Stephen Knight our Technical Manager … So how long have you worked at Valeo?

What is a typical day at work like? I can honestly and happily say that I do not have what you would call a “typical day”. The Technical team is linked to a larger network that includes Quality, Warranty, TechCare and Technical. I spread myself across these four areas on a daily basis and each day bringssomething new.

What is the most challenging thing about your job?

I think I have just answered it. Valeo Service UK wants to be one of the best suppliers in the UK aftermarket. In order to aid in this I try and spread my skills across many areas in order to support customers as best as I can. With many areas come many challenges.

Wow! It’s been pretty much all of my working life. I finished college at 18 and a month later I joined Valeo so it has been 12 years now.

What is your favourite piece of Valeo Technology?

What did you want to do when you were at school?

That’s tough. Valeo have so much great technology atboth OE and Aftermarket level. As I work in the Aftermarket sector I guess I’ll go with some technology that started out as Aftermarket but is now used at OE level too. The Valeo clutch conversion kit. It’s been in production since 2002, is incredibly high quality and offers a fantastic alternative to a dual mass flywheel system. What things do you wish you’d known before starting your career? You don’t have to be near the top of the tree to make a difference. For several years I kept good ideas locked away because I assumed the people in the top positions with the best salaries are the only people that could make a difference to a business. I’d encourage anybody to be the first person to put your hand up and share any idea you have in any situation.

Ask any 10 year old what they want to be when they were older and the majority will tell you “a footballer”. I was no different. It was strange, I have always had an affinity with motor vehicles. My granddad was a mechanic and my dad worked for Land Rover and the pair were always taking a car apart in the garage. My friends at school spent their time either building computers and/or were talking about cars. It wasn’t until later in life that the wonderful world of the automotive industry sucked me in. To get my foot in the door at Valeo I started out as an apprentice in the Customer Service department. This gave me a fantastic opportunity to improve on personal development, improve my communication skills and work on my product knowledge, whilst remaining patient waiting for a job that would allow me to work more closely with the parts. That’s where I really wanted to be, handling and talking about the technology that Valeo have to offer. When the chance came I seized it with both hands and slowly worked my way up until I could implement my own ideas and tools for both Valeo and our customers. What made you want to pursue your current role?

What do you do in your down time outside of work?

I’m married and have two beautiful little daughters aged 7 and 2 so they like to keep me on my toes when I’m outside of work. When I’m not spending time with them I act as a midfield enforcer for my local Sunday football team. I would

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What car do you own now? I am currently the proud owner of a Peugeot 2008. I bought the Crossover so it has all the bells and whistles. Its missing the side mounted machine guns though.

like to say we win more cups than I get yellow cards but my competitive nature can sometimes take over.

What is your pet hate?

I’m not sure I have any. It annoys me when people send me text messages in “text-speak”. I look at it and think “I have no idea what this says”. I then have to get my 7 year old daughter to translate it for me. I guess I’m just not down with the kids anymore.

What would be your ideal superpower?

To understand text messages people send me in textspeak.

What would be your dream car?

What is your favorite movie car?

If I couldn’t have the DB5 then I would be more than happy with the Aston Martin One-77. I guess I will have to wait until I’ve won the lottery though as at a cool £1.2 million it doesn’t come cheap. However with a 750BHP engine, a top speed of 203MPH and 0-60 in 3.5 seconds, it means I would never be late for work. Look out for next month’s 60 Second Interview when we interview Steve Degville – Technical Support

Now that’s a good question, there have been so many. I think I’m going to have to go with James Bond’s Aston Martin DB5. It’s been used in six different films by 4 different James Bond’s. However one of those films isn’t a James Bond film. If you know which film I’m talking about and which actor drove it then you will be useful in a quiz team. In all seriousness, aside from the oil slick,smoke screen, ejector seat, radar tracking system, machine guns and revolving license plates (yes I watch a lot of Bond) it’s a fantastic piece of British ingenuity.

1897

Sutton & Company of Manchester, England purchased a Daimler parcel van, the first sale of a gaso- line-powered motor truck in Great Britain.

1929

The Hon Mrs Victor Bruce drove a Bentley 4½ Litre at Montlhéry for 24 hours, to capture the world record for single-handed driving, averaging over 89 mph (142 km/h).

1990

British rally driver Tony Pond became the first to average 100 mph around the Isle of Man TT Motor Bike race circuit in a standard production car - a Rover Vitesse. This record stood until 2011

2002 The 163-bhp Mini Cooper S with a 6-speed gearbox, capable of 0 to 60 mph in 7 seconds and a top speed of 135 mph, went on sale in the UK.

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Valeo Cataloguing: Developing Everyday To Improve Ease Of Use

At Valeo Service UK we understand the importance of cataloguing. Valeo Service UK recognise that the use of paper catalogues is becoming a thing of the past and in the Internet age, searching via electronic catalogues quickly and efficiently is essential to the end user. Accurate searching of part numbers for specific vehicles using paper or electronic catalogues can be a daunting and tedious task at times, therefore, Valeo Service UK strive to make correct part selection an easy and quick process for motor factors, garages and even members of the public. At Valeo Service UK Technical, making this a reality is our priority! “Valeo Service UK strive to make correct part selection an easy and quick process for motor factors, garages and even members of the public” The Valeo Service UK Technical Team recognises that automotive technology is constantly developing and has therefore significantly enhanced its digital customer support to ensure customer requirements are met and communication of both products and services are improved and cataloguing is no exception! Over the last several years significant resource has been put into ensuring that our catalogue data is improved on a daily basis. Additional tools have been invested in to ensure that electronic cataloguing software such as Tecdoc and AutoCat+ are improved and issues that are found or reported can be updated almost immediately. In the last three years Valeo Service UK have prioritised improving our cataloguing data in Autocat+ as we recognised certain areas of our data required improvements. Significant improvements have been made to our data in Autocat+ in recent years which has resulted in very positive feedback from customers across the UK. To maintain this level and continue to progress, we implement a five step programme to ensure that we are meeting all of your catalogue needs. These five steps consist of the following:

1. Accuracy - Checking of catalogue data in both existing part number applications and new part number applications is carried out to ensure that each part number is linked to the correct vehicle. 2. Efficiency - Additional technical information is added to the part and application fields to help determine correct part numbers quicker and easier. 3. Consistency - Cataloguing rules and standards are applied consistently to each part number in each product family to provide a consistent level of cataloguing quality. 4. Competence - There is nothing more important in cataloguing than professional knowledge; this includes theoretical background as well as technical skills for cataloguing. Knowledge of cataloguing tools is a must-have. 5. Commitment - As mentioned above, knowledge of cataloguing tools is a must-have. Through the our Technical magazine, we will regularly bring you news, user guidelines, ‘How to documents’ (detailing how to make cataloguing easier and more efficient) and much more!

If you have any issues or queries regarding cataloguing please contact Rhodri Griffiths at: Rhodri.Griffiths@ valeo.com

HOTLINE TOPICS OF THE MONTH

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Phil Edwards

Steve Degville

Adam Edney The sun has come out and everyone is winding down their windows for the first time in months! This means the Valeo UK hotline has been receiving plenty of calls on our window regulator range. A regular query this month has been ‘that the wiring loom on the Valeo regulator is not compatible with the original. If the design / shape of the wiring connector is different to that on the vehicle, Valeo will supply a small wiring loom (Comes in a plastic bag) with a fitting instruction included in the regulator box. This is often overlooked and not noticed by the installer. We do our best to also include this information in our application data against the part number in Tecdoc, Autocat+ and Techassist.

Struggling with a tricky application? Spending too much time on a customer request? For some vehicles you may be able save some time and use a vehicle manufacturer electronic product catalogue. Take for instance Citroen and Peugeot. Both have a dedicated website for independent operators whereby you can search for parts via the vehicles VIN. The service box is capable of determining the correct OE part number for almost all components on the vehicle saving you time! This provides vehicle owners, garages and motor factors a free, reliable and easy way of finding the correct OE number for any UK vehicle. The service box is provided on a subscription basis and the first tier of subscription is free which is inclusive of all application functions.

Valeo Service have received several calls this month regarding the fixation holes on some of our wiper motors claiming there is no thread.

In these instances the fixation holes are manufactured with no thread as they are self threading!

As you begin to bolt the unit down, the fixation bolts will produce their own thread and will secure firmly to the bracket. We do our best to also include this information in our application data against the part number in Tecdoc, Autocat+ and Techassist.

By the Technical Hotline Support Team

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with Steve Degville

“The heating in my vehicle only works on setting four and I have a bad smell in my car. What could the problem be?”

Sonny Injabulo- Taxi Driver- Barking,London

To understand this issue it's important to realise that the temperature of the air passed into the cabin is created from the engine cooling and air conditioning loop in the vehicles. The flow of air passing through the cabin determines the thermal exchanges in the system and, therefore, the performance of the air conditioning /heating. Obstructing or reducing the air flow will immediately impact the comfort of the occupants in the cabin and have a damaging effect on the reliability of the system components. In this particular instance, with the heating system only working on setting four, it sounds like the blower motor has failed. Couple this with the fact there is a bad smell entering the cabin, the cabin filter may be the root cause of the issue. What is the function of the cabin filter? The cabin air filter cleans the air that comes into the interior through the heating, ventilation and air- conditioning system. It catches dust, pollen and other airborne material that can make riding in a car unpleasant, particularly if you have allergies or other respiratory problems.

Valeo recommends the cabin filter is changed every 12 months.

(leaves,etc.) from the air inlet circuit and scuttle panel. 2) Replacing the cabin air filter. 3) Checking that the extractors are not blocked. Valeo recommend a cabin filter be replaced every 12 months to ensure maximum longevity of parts in the ventilation system and to ensure a cleanand safe environment inside the vehicles cabin.

Why must the cabin filter be changed?

I f the cabin filter is not replaced regularly and is clogged, the flow of air will be restricted and the blower motor will be working harder with less air passing across it to reduce its temperature. This will lead to premature failure of the motor. If the pollen filter has become damp due to a leaking heater matrix or blocked water drain holes, the moisture will be sucked in by the blower motor causing corrosion. An indication of this will be moisture in the vehicles cabin, a noisy motor in the advanced stage, or blower motor damage. A blower motor with damaged fan blades can be caused by a missing cabin filter allowing debris from outside entering the ventilation system or the incorrect cabin filter being fitted. This issue will have symptoms of a noisy blower motor, or in extreme cases, the motor will not work. In all cases, the ventilation cabin filter must be replaced before fitment of a new blower motor. When servicing the system, it is essential to check the complete air circuit from capture to extraction: 1) Extraction of any residue

Replacing a dirty or clogged cabin air filter, like the one seen above, helps protect passengers as well as the vehicle’s heating and air conditioning system

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Have A Question Or Problem You Would Like Us To See? Introducing “Valeo Connected Hotline”

The Valeo Technical Hotline answers calls all over the world and allows its customers and workshops to get product support on fitment issues, product application or cross reference enquiries. Our “We Care 4 You” strategy is the promise to improve our brand’s service to all of our customers individually: distributors, workshops, drivers, fleet owners and insurers. As an Aftermarket Specialist, Valeo’s role is to bring an adapted answer to all customer needs, with customised product offers and added value services. In accordance with this spirit, Valeo has boosted its Technical Hotline services with the launch of Connected Hotline. With Connected Assistance, the Technical Hotline team now offer a new interactive and visual support feature to its callers. In some cases, this allows the Valeo Technical Hotline team to solve technical problems faster and better by seeing what the user sees instead of only using the telephone. This interactive service, based on true augmented

reality, fills the gap and delivers even greater performances.

How does it work?

The Valeo Technical Hotline team now have the ability to remotely take over the control of the callers Smartphone tablet or diagnostic tool camera directly see the user’s problem and give advanced and customised support. This unique and interactive service, based on true augmented reality, fills the gap between a regular hotline and an onsite operation. The Valeo Connected Hotline delivers great performances thanks to the following features: • Real-Time HD Video (on front and rear camera of the Smartphone or tablet) • Hi-Band Audio • Picture Sharing (including Augmented Reality • Drawing and Annotation) • Co-Browse internet pages for a detailed solution • Video sharing • Take and save picture (for case archiving) • Desktop and document sharing

The Valeo Connected enables to: • Improve customer satisfaction by 15% • Increase 1st time fix rate by 35%

• Reduce Repair time by 19% • Reduce car downtime and related costs by 14%

To utilise this excellent service get in touch with us today on: 01527 838300 EXT2

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Technical BULLETINS

836004 flywheel spacer

Part Number: 836004

For Vehicle : Renault Megane, Renault Scenic, Nissan Micra, Nissan Note, Nissan NV200, Suzuki Jimni Valeo part number 836004 is a flexible flywheel. The flexible flywheel is Valeo technology, an evolution of a rigid flywheel. It incorporates a solid outer flywheel and a thinner flex plate. The aim of the flexible flywheel is to add an additional spring mass element to isolate the vibrations from the engine to the gearbox. In summary the flexible flywheel is a hybrid of the dual mass and solid flywheel technologies. There are a number of benefits of this technology including reduced engine noise at high rpm, a lower amount of vibration experienced through the clutch pedal and reduced stress on the crankshaft creating a greater life expectancy of the flywheel. The flexible flywheel 836004 may be visually different to the design of the flywheel you remove from the vehicle but the flywheel spacer (see image below) needs to be retained (OE number for flywheel spacer 82 00 432 132) and used in conjunction with the 836004. If this is not retained or replaced the bolts (OE number for bolts 12 31 568 46R) will be too long to bolt the flywheel into location.

Flywheel, flywheel spacer and bolts

Vibration dampening technology within the hydraulic clutch line The reduction of oscillations in the clutch actuation system is a top priority for automotive manufacturers with the end users driving experience at the forefront of this prioritisation. The clutch line frequency modulator and the ‘oscillation absorber’ are two components placed on many vehicles within a hydraulic clutch line that are specifically calibrated to different vehicles and engines to dampen vibrations felt through the clutch line. These oscillations/vibrations are experienced by the end user when the clutch pedal is actuated. These symptoms are sometimes incorrectly attributed to a faulty clutch or flywheel but these vibrations can be a result of a faulty/worn or missing frequency modulator or oscillation absorber.

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Welcome to our Technical Service Bulletin page! Here you can find a snapshot of our latest Technical Bulletins produced by the Valeo Technical Team. All Technical Service Bulletins can now be found on our new Technical Library page at: www.valeoservice.co.uk

Keeping you up to date with all out latest technical literature

the torsional vibrations inside the crankshaft.

In fact the vibrations/pulsing felt through the clutch pedal are a result of axial torque deviations in the crankshaft conveyed right through to the clutch pedal via the clutch hydraulic line. To suppress these vibrations some engines are fitted with a frequency modulator that is situated within the hydraulic clutch actuation system. The frequency modulator absorbs these disruptive vibrations that occur within the clutch line and prevents vibrations/pulsations more specifically when using the clutch pedal. The oscillation absorber works in the static range as opposed to the frequency modulator which works in the dynamic range. Different dampening levels appropriated to the oscillation absorber are defined by the vehicle and engine set up. These oscillation absorbers are made from plastic and are situated in many clutch hydraulic lines the part is subject to wear and faults over a vehicle lifetime. This should be tested when the vehicle is stationary to check for vibration that may be felt through the clutch line. Crankshaft pulley/torsional vibration damper Part Number: 836161, 836162, 826740, 826550, 835071, 828392 For Vehicle: Peugeot, Citroen 1.6 HDI Engines The Valeo Service Technical department have received several claims stating that after fitment of the components listed above, vibration and or judder can be felt through the transmission. After investigating the issue Valeo technicians have identified that the clutch/flywheel kits are not at fault and the defect can be due to a worn, damaged or faulty crankshaft pulley/Torsional Vibration Damper. The crankshaft pulley/TVD directly reduces

It is recommended that the crankshaft pulley on these vehicles are changed during every flywheel replacement as the components are susceptible to wear, deformation and cracks in the rubber damping element of the TVD. In other circumstances it is also possible that the bushes on these units have become damaged and/or total failure of the unit resulting in strong vibrations or an immediate breakdown of the vehicle. Crankshaft pulley technology can differ dependent on application so it is always best to check with the dealer to ensure replacement is performed correctly

Visit our technical library today for more useful technical literature for you and your customers

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Discover the

Connected Hotline

As part of the ‘WE CARE 4 YOU’ strategy, the Valeo Technical Hotline has introduced the Valeo Connected Hotline.

Valeo Service UK offer a new interactive and visual support feature of the Technical Hotline for its customers. The Valeo Technical Hotline can now solve technical problems faster and better. How does it work? The hotliner remotely takes over the control of the garage or motor factors smar. phone or tablet camera to directly see the user’s problem and gives advanced and custom- ised support.

• • • • •

Real-Time HD Video

Picture sharing

Co-Browse internet pages for a detailed solution

Video sharing

Desktop and document sharing

The Valeo Technical Hotline is part of the Tech’Care programme and answers calls all over the world allowing its customers and workshops to get product support on fitment issues, product application or cross reference enquiries.

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TRAIN WITH THE BEST !

New IMI Quality Assured Clutch Training Course Launched For Factors and Garages Knowledge is power! It’s an age old saying that has never been more relevant. As an OE manufacturer of clutch technologies, Valeo are well aware of the ever changing products and environments motor factors and fitters

have to work with. In the last several decades alone, transmission components have undergone huge technological advancements and developments. With vehicle manufacturers now having to increase their focus on production costs, reliability and environmental compatibility, the need for newer and more efficient technology has become a priority. Launched at the beginning of 2018 Valeo Service UK offer our

own clutch training programme designed for both motor factors and garage fitters who work with Valeo transmission components on a daily basis. There are a range of benefits to this approach for the supplier and fitter: the motor factor experiences the dual advantage of being able to provide their customers with technical advice associated with clutch components and systems which it has expertise in (thus increasing the chances of future sales), and warranty

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Modules Covered:

• Basic Clutch • Intermediate Clutch

• Advanced Clutch • Converstion Kit • Avoiding Costly Warranty Replacements • Clutch Failures- Cause and Effect Delivered by Valeo clutch experts, this two day course is designed to provide the candidate with an opportunity to gain or enhance their knowledge on clutch and transmission systems and explore the range of new technology produced by Valeo and currently on offer at both aftermarket and OE level. Key Course Benefits: • Ideal for candidates with any level of clutch knowledge • IMI approved course and certification • Practical exercises under the guidance of an experianced tutor • Understanding of new clutch systems and technologues Contact our hotline for fees and details

claims levels – as a result of misdiagnosis or fitment – are more than likely to drop. The garage is also empowered with the technical knowledge required to take on clutch changes and associated repair tasks more efficiently, with greater confidence and a higher level of competence. The Valeo clutch training programme consists of hands- on training, refresher courses, a detailed look at the latest

OE and Aftermarket Valeo technologies and how to avoid secondary warranty replacements.

Dave Treadwell (Valeo TechCare Manager) says: “as a supplier to many of the world’s leading OEMs, we’re in a great position to provide motor factors and garages with a level of support that will help them grow as a business and increase levels of customer satisfaction”.

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AUTO RE

The Valeo Service UK

This month our Valeo TechCare and Quality Engineer, Steve Degville, guides you through a replacement clutch on a Peugeot 207 Sport fitted with a 1.4 four cylinder petrol engine

The little sports hatchback is jam packed with fun and the original 207 model launched in 2006. The Peugeot 207 was the successor to the 206 and was very similar in principle to the platform used for the Citroen C3. The 207 Sport was an ‘Urban’ hatchback and whilst it had nothing special on the ‘in car entertainment front’ it was successful in achieving an impressive reliable engine. Before the TechCare engineer made it to the garage premises, the customer had reported that gear change had become difficult and vibration was being felt through the pedal. Upon arrival to the garage premises, the TechCare engineer took the vehicle out for a test drive so he could understand the issues being encountered by the customer. After a little diagnosis a clutch replacement was advised and authorised by the customer.

With the vehicle still on the floor, disconnect the gear selector cables/linkage from the gearbox and slacken off the gearbox mounting. Raise the vehicle to around waist height and remove the gearbox bolts around the bell housing and the starter motor. Leave one of the lower large bolts in to prevent the gearbox from coming away from the engine. Remove the wheels, the driveshaft hub nuts on both sides and remove the plastic wheel arch liner. In order to gain more access to the gearbox, remove the bottom sub frame strut and the bottom cross bar. Next drain off the gearbox oil, disconnect both bottom wishbone ball joints and remove the drive shafts. Disconnect the clutch slave cylinder from its mounting and remove the crank sensor from its mounting otherwise it will get broken during the refitting of the Gearbox.

Fig. 1

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AIR CENTRE

Fig. 2

the durability of the solid flywheel. In this instance, during the removal of the clutch, the TechCare engineer identified excessive ‘preload wear’ to the fingers (Fig 4) on the pressure plate; a direct consequence of the defective release arm. At this stage the TechCare engineer and the garage technician contacted the customer via the Valeo Connected Hotline tool which enabled them to contact the customer and share video footage of the release arm and gain authorisation from the customer to replace the release arm. It is also recommended to replace the guide tube due to the amount of wear and tear that can occur on the cylindrical tube.

Using a clutch alignment tool (Fig 5) or one that is supplied with the clutch, mount the drive plate to the clutch pressure plate and bolt the clutch assembly to the flywheel. Torque the bolts (according to vehicle manufacturer specifications) up in an even and sequential order to ensure correct installation.

Next, remove the bottom exhaust mounting and support the engine with a transmission jack on the underside as there is no contact area or support within the engine bay to allow an engine cradle to be used. Finally, remove the gearbox mounting bolts on the near side mount bracket. Remove the final bell housing bolt and ease the gearbox out and transport to a safe working area. Remove the release arm (Fig 3) from its mounting. Ensure the release arm is gently removed from the metal ball joint/pivot. In this instance the release arm was worn and the plastic ball socket/mounting (which fits over the metal ball joint) was damaged.

Fig. 5

Refit the Gearbox and rebuild in reverse order. Refill the gearbox oil according to the manufacturer’s specification. Please refer to the gear oil recommended for the transmission otherwise difficult gear selection issues can occur. Once the vehicle is on the ground, re-torque the hub nuts and wheel nuts to the manufacturer’s specification. Once the repair is complete carry out a road test to ensure the clutch and gear change operations are correct. 1) To reduce the risk of spline damage please ensure the correct clutch alignment tool is used during the course of replacing the clutch assembly and the gearbox is fitted in line with the engine during clutch replacement. 2) It is critical to ensure the correct gear oil that is specified by the manufacturer is used. 3) Check the integrity of the release arm; specifically the plastic molded ball socket. Replace any wearing parts, guide tube, bushes etc. Top tips from the TechCare engineer:

Fig. 4

Fig. 3

Before continuing with the fitment of the clutch, clean the gearbox of dust and debris and clean the input shaft with a soft wire brush. Next, spray brake cleaner onto a clean cloth and wipe the input shaft so it is clean. Open the sachet of grease provided with the clutch and empty it out on to some clean paper or card (please note there is no need to use all the grease provided). Do not use copper slip. Using a fine brush, lubricate the input shaft with grease. Do not apply grease on to the input shaft using your fingers as this will cause excessive grease to radiate outwards when the clutch is in use. Do not apply grease directly to the clutch friction plate.

Remove the clutch assembly from the flywheel. Check the flywheel for surface/heat damage or signs of wear and thoroughly examine the flywheel and check its integrity (hotspots/cracks etc). If in doubt replace the flywheel if necessary. On this vehicle the flywheel is a solid flywheel used on the vehicle since manufacturer launch and was in good condition, a testament to

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DISCOVER THE MINI ISSUE CAUSING A BIG PROBLEM

the preferred choice by BMW Technicians. BMW had wanted the engine to have a Getrag gearbox, but the original UK engineers put the Midland gearbox instead due to it being cheaper and more compact. The Midland gearbox is no longer produced and a BMW dealer will only supply a reconditioned gearbox or replace it with the later. After July 2004 the Getrag gearbox was put in on the facelift model. With this in mind I was expecting to help the respective garage remove the gearbox and clutch and find either a fault with the gearbox itself or fault with the clutch release mechanism. What I found however was

In March, our very own Rob Hancox took to the road to take a look at an issue experienced with a BMW Mini Cooper… As a Valeo warranty engineer, whose responsibility it is to analyse claims sent back to Valeo, I was extremely intrigued to find out why a BMW Mini Cooper would be experiencing clutch selection problems after having a brand new clutch fitted. As a car enthusiast I am well aware that the Mini 5 speed gearbox (GS5 65BH) found in the Cooper models (non-S) built between 2001 and July 2004 is referred to as the R65 or the Midland gearbox and was not

something slightly different. As a fully trained VW Master Technician, it has become second nature to drain and replace the gearbox oil during each and every clutch change. This, however, is not standard practice with every garage or clutch fitter. Transmission fluid, just like engine oil, is a lubricant. Its purpose is to ensure that the various working parts of the transmission are not subject to damage. The fluid will keep the transmission both lubricated and cool. When transmission fluid goes bad, problems will begin to surface. When the fluid stops becoming affective it loses its viscosity and

does not sufficiently lubricate the gears in the gearbox. This results in metal gears grinding on each other. When this occurs small pieces of metal, often described as filings, will be produced from the metal on metal contact. In this particular vehicle, this is exactly what I saw. When removing the gearbox drain plug I found the drain plug saturated in metal filings. As the drain plug is magnetic (which is becoming increasingly more common) the filings are collected at the bottom of the tank so they

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Valeo Clutch PN: 826234 Vehicle: Mini Cooper 1.6i R50/R53 models 2001>2004 G55-65BH (5 Speed transmission)

Right: The drain plug from the gearbox is saturated in metallic filings

transmission fluid is kept at the proper level, otherwise it will result in the transmission wearing significantly. If the transmission oil is low, the wear on the synchro rings and sliders will accelerate significantly as they require a slick surface in order to match speeds when shifting, thus saturating the oil with more debris. A Mini clutch change takes 5.5 hours. In my experience changing the transmission is a 10 minute job that may stop you having Big problems with a Mini.

do not get stuck between the gear synchros. However, when the magnetic drain plug is completely saturated in metal filings and can no longer magnetically attract anymore, the metal filings are free to float around inside the gearbox oil. An accumulation of these filings in a gear synchro can seriously affect its performance. If a gear synchro is not free to turn as required, then gear changes will be affected.

The manual transmission fluid/ gearbox oil should be changed at regular intervals. Even though Mini call it “lifetime” fluid there is no filtration system in the manual transmission, only the magnetic drain plugs to capture debris. I recommend that the transmission oil be changed every time the clutch is changed and the magnetic draining plugs cleaned of all debris before it circulates causing potential damage to the gearbox bearings and syncrhos. It is also equally important to ensure that

Best Practice for Best Results

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CROSSWORD

WIN! A VALEO GOODY BAG The Valeo Service UK Technical team are dedicated in bringing you reliable and up-to-date automotive technical information from one of the market leaders in OE technology. However the need for useful technical information is an ever growing need for all levels of the automotive industry whether you are motor factor, garage, or simply somebody performing regular maintenance on your vehicle. For this reason the Valeo Service UK Technical team would like to offer each and every one of you a chance to share your very own technical publication in the V-SMART magazine! This can be anything from a detailed fitting guide, a technical service bulletin on a particular problem you may have solved, or general tips on vehicle maintenance you have performed. Get involved today and share your knowledge with the rest of the automotive community! The best piece of technical literature submitted will be published in V-SMART and the winner will receive a goody bag full of prizes from Valeo Service UK. How to enter: Complete the Crossword using the above clues. When you have completed the puzzle and filled in all the answers, either fax or email the puzzle to 0800 035 8324(fax), vsa.uk.technical. mailbox@valeo.com. (email). If you are unable to print the entire puzzle, simply send the answers using the same methods Winners will be selected at random. Answers must be submitted by July 31st 2018.

Across Down Using the clues provided find the vehicle models and fill in the answers!

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2017 American superhero film featuring Hugh Jackman (Dacia) (5) Large insect, commonly black in colour (VW) (6) City in Arizona, USA (Hyundai) (6) Balearic Island renowned for its association with electronic music (Seat) (5) A single sound at a particular level (Nissan (4) Score designed to assess human intelligence (Toyota) (2) One of lifes biggest bug bears for motorists (Renault) (6) Large hairy creature, resembling a human or bear, that lives in snowy conditions (Skoda) (4) Indigenous people generally deriving from the Southwestern states in the USA ( Jeep) (8) A person who is very knowledgeable/skillful in a particular area (Peugeot) (6) An American breed of horse (Ford) (7) Fourth letter in the Greek alphabet (Lancia) (5) Team sport played on horseback (VW) (4) A system of stars held together by gravitational attraction (Ford) (6)

A Spanish religious festival (Ford) (6) To concentrate on something and pay particular attention to it (Ford) (5) Taylor ______, American singer-song- writer (Suzuki) (5) Tom Cruise’s nickname in Top Gun (Ford) (8) Athletes who run short distances in lim- ited periods of time (Mercedes-Benz) (8) Type of breakfast offered at hotels (Bentley) (11) An optical illusion, typically a sheet of water in a desert or on a hot road (Mit- subishi) (6) Black and white bear native to south China (Fiat) (5) Genre of music that combines gospel, R&B and Jazz (Kia) (4) 2009 Pixar animated movie featuring an elderly widower, Carl, and a young boy, Russell (VW) (2)

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