PDF, 16Mb - Dayco Aftermarket

ISSUE 2 - MAY 2012

David Martínez 

President EU/SAO/Asia 

Editorial 

Listening to the market, 

looking to the future. 

Times are difficult, there is no 

denying it. The world economic 

crisis that has tormented the 

markets for over three years 

shows no sign of ending, at least 

for the time being, and many companies 

continue to move with hesitation. It is 

however in this context, that Dayco has 

successfully achieved significant results in 

the renewal process that we started to 

outline in the pages of this magazine, one 

year ago. 

We are convinced that any type of difficulty 

can be overcome if it is tackled with the right 

“weapon”: trust. And specifically, trust in 

the future. Trust is the major strength that 

has constantly driven and motivated our 

actions. It is trust that has allowed us to 

plan, decide and invest resources in the 

great renewal challenge we have launched. 

And again, it is trust that has allowed us to 

update and align our own model to the new 

economic model, envisioning a new 

strategy and new form of market. Because 

for Dayco, trust in the future also means 

trust in the market - in its capacity to 

undergo radical change and give anyone 

willing to listen, the instructions to face each 

change in the best possible way. 

Trust therefore, has been both our driving 

force and our investment over the years. 

And above all, it is at the basis of the 

increasingly strong relations we have with 

our customers - at all levels. Customers that 

for us, have always been much more than 

“numbers” with whom we simply 

communicate or provide a service or 

product to, but who are true partners and 

active players in the success of our 

company. And this will continue to be ever 

more important in the future. 

The stakes are high but not unachievable; 

they involve a new development model that 

aims at a growth strategy shared by and 

profitable to everyone - the company, the 

end users and the market. Because there 

cannot be trust in the future if there is not 

mutual trust to start with. Without the 

relationship with our partners, we could not 

express our positive vision of the future. And 

without our investment, our partners could 

not trust us. “Sharing” therefore, is our 

watchword, the foundation of a new type of 

market and a new way of being present in 

the market, focusing not only on growth but 

on stability and the strengthening of growth 

itself. 

Our mission, our vision and our strategies 

are based on the sharing of values, 

objectives and the successes represented 

by our positive results over the last year, 

which have shown, in some areas, highly 

substantial growth. A situation which is 

even more significant when considered 

within the demanding context of the 

present Global economic difficulties. 

Aware of these challenging circumstances, 

we have decided to face possible 

developments with fair and balanced 

optimism - a positive, yet realistic attitude 

resulting from the knowledge that there is 

a future and in order to reach it, we need to 

follow a new path without hesitation. 

A path that is shaping, day by day, this large 

global company where we speak a single 

language and listen to a single message but 

which can however, be translated into 

countless languages and dimensions. A 

company constantly focused on the 

achievement of growing loyalty among 

partners and customers who, even in the 

most difficult moments, have stood by us.... 

and have continued to believe in us. For me, 

this observation is a great source of pride 

and hope for the future. 

Because people are truly the most 

important part of our business: A company 

lives from the market and the market 

consists of people. Believing in a market 

therefore, means believing in the people 

that make up that market, and knowing 

how to listen to them. 

If we have some merit in this success 

therefore, I believe it is in our ability to listen 

to the market, to understand it without 

conditioning it. Without this quality, we 

probably would not have made the same 

choices and the same investments. And we 

would not have found the right way to 

transmit our message of trust to our 

partners. 

Partners who have not only understood us, 

but who have in turn, rewarded us with their 

optimism, confidence and commitment to 

a brighter future. 

MAY 2012 

® 

1

4The 

customer is 

our partner 

6 

7 

2 POWER WORLD 

® 

Index 

Optimising 

the brand 

together 

All-out 

information 

ISSUE 2 

Periodical 

Registered at the Ordinary Court of Pescara 

N. 488/2011 V.G. 

N. 07/2011 Print Reg. 

N. 72/2011 Cron. 

Editor 

Daniela Panosetti 

10 

18 The eastern 

frontier 

Milestones 

of a leadership 

15 

Editorial coordination 

Franca Pierobon 

Graphics 

Pomilio Blumm srl 

Via Venezia, 4 - 65121 Pescara 

Printing 

Ivrea Grafica, Ivrea - To 

TB SET: 

solutions for 

every situation

16 

From Moscow 

to Warsaw 

28 

Response from the TAM 

30 

The Dayco 

mechanic 

D A Y C O M A G A Z I N E 

Editorial 

Marketing 

World 

May 

2012 

20 Sustainability 

and 

innovation: 

a team work 

Communication and Promotion 

Product 

Zoom 

Research & Development 

Garage 

Update 

MAY 2012 

3 

1 

4 

6 

10 

16 

20 

26 

36

Awhole new model at the 

production, logistic and 

marketing level. A truly 

innovative vision, based on two 

closely related principles: trust and quality. 

This is a strategic approach that enables 

Dayco to respond to change with change, 

reacting by relaunching rather than 

resisting, “betting” on the future without 

losing touch with the present. This is the 

objective that Dayco has been pursuing for 

some years with great conviction. 

A demanding choice, which has involved 

all company divisions, at all levels, but one 

that has quickly proved to be successful. 

EMERGING COUNTRIES, 

DEMANDING MARKETS 

Marketing 

The customer 

is our partner 

Bruno Vallillo 

Vice President 

General Manager Europe 

«In a period when most manufacturing 

sectors continue to feel the effects of the 

world economic crisis, Dayco holds a 

position of leader in many product families 

and on many markets» -, Bruno Vallillo, 

Vice President, General Manager Europe 

- declares with pride. «This year for 

instance, the kit range has positioned 

Dayco as a dominant player in the mature 

markets, but the demand for kits is also 

increasing strongly in the Eastern Europe 

and BRIC areas which are characterised 

by vehicle fleets that are often very 

different in terms of range and 

size». Today, it is these emerging 

markets that represent the 

A strategy with global objectives but local implementation. 

A logistic network increasingly adaptable to single markets. 

A “widened” sales process that only ends with the installation 

of the product. Bruno Vallillo, Vice President, General Manager Europe, 

explains the Dayco model. And the reasons for its success. 

most promising opportunity for our “bet on 

the future”. Alongside the already 

consolidated positions, the Dayco brand 

has experienced a remarkable growth of 

market share in many developing areas, 

notably Russia and Brazil. 

«Emerging, but most of all demanding 

countries – underlines Vallillo – with 

markets that are now modern and ready to 

receive new methods and new services». 

Among the most promising sectors is the 

Heavy Duty line, where Dayco is already 

the absolute leader as far as the OE offer 

is concerned. «A market that is 

becoming more demanding each 

month, especially for the 

medium vehicle range from 

3.5 to 7.0 tonnes. This is in 

line with the general trend of 

the present economic model 

which is to transport less 

goods, but with a 

higher frequency». 

Hence the 

decision to 

prepare a 

n e w 

catalogue and a specific product line for 

this vehicle category that can cover the 

whole of “mature” Europe as well as the 

emerging markets with a single range. 

HIGH QUALITY 

AND DIVERSIFIED SERVICES 

Dayco’s commitment therefore, is to 

further increase its already highly extended 

offer, by gradually integrating into its 

catalogue, the total range of applications 

present in the emerging 

markets. Many 

resources, for 

instance, have been 

allocated to those 

segments of the 

vehicle parc that, 

due to their age, 

are less and less covered by the official 

networks, but which need however, the 

same OE quality level. This is an extremely 

strategic sector in which significant 

investment has been made in the area of 

testing with the extension of the European 

R&D programme to the Asian and South 

American areas. 

On the other hand, explains Vallillo: «Not 

everything can be standardized. Each 

country has its own specifics not only in 

terms of age and range of vehicle parc, but 

also in terms of culture, language, infrastructure 

and even climate (for example 

seasonal differences)». Therefore, the first 

step to meet these diversified needs is to 

listen to the market, «being able to 

understand its needs in advance and being 

ready to respond promptly to the 

customers’ requests at all levels: from the 

distributor to the spare parts dealer to the 

mechanic installing the component». 

At an organisational level, this approach 

has led to the distribution of the different 

market needs into three major divisions: 

marketing, logistics and sales. «The 

sales division, in particular, has been 

completely restructured, abandoning the 

“classic” sales concept in favour of an 

approach aimed at adapting, as much as 

possible, the global strategy to the 

different markets». In Europe, for 

instance, the sales activities are 

now structured around three sales 

areas corresponding to 

South, Centre-North

A relationship 

based on trust 

“ 

The workshop represents the 

crucial point of our “value chain”. 

It is in the workshop that our 

product really comes to life, thanks to the 

mechanic’s experience and skills». 

Therefore, this stage must be as smooth 

as possible, and the workshops must 

know that they will not only get the best 

quality from Dayco, but also the best 

service and maximum availability of 

products». This is how Bruno Vallillo 

describes the great importance of the 

relationship between the company and the 

workshop in the Dayco model. 

From this viewpoint, we are further 

improving and developing the packaging 

and preparation of our products with the 

aim of providing, in a single package, not 

only the single component but also the 

specific accessories required for its correct 

installation. 

In the Dayco model therefore, the 

workshop is not merely the final stage of 

the sales process, but an active part of the 

company’s strategic decisions. «And if, as 

we have seen, these decisions have 

proved rewarding, it is because – says 

Vallillo – that the most important decision 

has been made by our customers, both 

and Eastern Europe, i.e. macro-areas 

characterised by countries with similar or 

comparable commercial and productive 

needs or which can be managed within 

some form of common framework. «In line 

with this approach, sales are currently 

being developed, particularly in some 

areas showing interesting growth levels 

including both “mature” markets such as 

the UK and above all, Eastern Europe 

where countries like Poland are becoming 

extremely promising areas». 

FROM THE WAREHOUSE 

TO THE WORKSHOP 

Dayco’s main objective is to guarantee a 

diversified offer, as suitable as possible for 

each country at a local level, whilst 

ensuring high and uniform quality 

standards for each area and aspect of the 

direct and indirect, who have responded 

to the company’s renewal effort by 

choosing our quality, our complete range 

of products, and our logistics, thus 

acknowledging the value of the investment 

we have made in this truly new operating 

model». And after all, the sharing of 

objectives and prospects with our 

customers is one of the most important 

aspects of the model which Dayco is 

defining year after year “We are trying to 

create an increasingly “closer” and more 

participative relationship, through direct 

involvement of our customers, as true 

partners, in the development of product 

and process innovation. I am referring, for 

instance to the creation of large 

purchasing groups – continues Vallillo – 

and the considerable investments made in 

communication, particularly in terms of 

service and information aimed specifically 

to the workshops». 

It is in this context that the challenge 

launched (and won) by Dayco on the 

“guarantee front”, must be considered. In 

fact, Dayco’s products are presently 

supported by a level of guarantee which 

exceeds that imposed by the law: «A 

“plus” that we are able to offer because we 

offer at a global level. Not only with the 

quality of the product in mind but also the 

quality of the organisation, information and 

general service. 

«Clearly, we are talking about a process 

that will need a certain amount of time to 

be completely established, but the work 

is already well under way and will continue 

to keep us increasingly busy in the near 

future», points outs Vallillo. 

For example, we are continuing with 

substantial investment and development 

of our logistics department. Over the last 

few years, our distribution network has 

been gradually adapted to a model of 

increased “proximity” to each reference 

market, aligning it to the diverse infrastructures 

present in the various countries. 

«Our investment in logistics started about 

three years ago with the decision to move 

away from the concept of “central” 

warehouses and focus on peripheral 

Dayco`s strategy is to build a strong 

relationship and trust to the garage and 

motor factor. 

This is gained by sharing our mutual goals. 

are convinced that we are proceeding, 

together with our partners, towards 

increasingly high quality levels in all areas 

of our activity». 

This confidence can also be seen in our 

marketing decisions, which have included 

decidedly ambitious objectives, which can 

certainly be reached if we continue on the 

path we have defined. «Unlike our 

competitors, we have set ourselves one 

simple rule – reveals Vallillo - to always be 

distribution branches, in order to get the 

products as near as possible to the areas 

they are effectively used and thus 

providing our workshop partners with a 

guarantee of maximum product 

availability». 

Today, the process is continuing in two 

directions: the opening of new local 

warehouses, and the expansion of those 

existing ones. Furthermore, in addition to 

the direct regional investments, we have 

also allocated funds for specific studies 

aimed at identifying and developing the 

most suitable systems to reduce lead 

times and guarantee maximum logistic 

efficiency. In fact, as Vallillo explains, «for 

Dayco, the sale does not end simply when 

a component is ordered, but when it has 

been effectively and correctly installed on 

the vehicle. 

In other words, our “work” can only be 

considered complete when we have met 

an active player, and not a follower. Which 

means firstly observing the market and its 

evolution and only at a second stage, the 

competition. Because we believe that in 

order to lead the market, we must allow 

the market to lead us; in other words 

knowing how to listen to it. 

A model – concludes Vallillo – which I am 

certain, will always be successful, in all 

business contexts». 

fully, all the requirements of our end 

customer, in terms of quality and service». 

Therefore, our intention is to supply an 

increasingly wide range of additional 

services and facilities especially designed 

to make the installation procedures 

simpler, faster and more efficient; 

including “tools” ranging from the 

availability of specific Technical Information 

for each product and the constant support 

of our Aftermarket Technicians, to the 

organisation of seminars and training 

workshops within the different regions at 

a local level. 

MAY 2012 

5

6 POWER WORLD 


Optimising 

the brand together 

An increase in technical communication, structured around the requirements 

and specific requests of the end user: the installer. From the intensification of 

events in the market to the success of the Garage sector, let’s have a look at 

the various means used by Dayco to “communicate” to its target. 

Franca Pierobon 

Communication Manager 

Direct dialogue with repair 

shops, participation in fairs 

and events in the market and 

provision of clear, complete 

and technically detailed information. 

These are the three “pillars” at the basis 

of Dayco’s targeted communication. A 

strategy in line with the model of 

participation and partnership between 

company and customer, which appears 

heavily focused on what could be defined 

as the product “end user” who, as such, 

is in a position to express better than 

anyone else the specific requirements of 

the market and thus provide the most 

detailed image of the “demand” that the 

communication attempts to meet. The 

objective is therefore to stimulate this 

demand as much as possible so that, at 

the time of the purchase, the installer has 

a very clear idea of the Dayco brand, the 

quality of its products and the full range 

of products offered. 

A DIRECT DIALOGUE 

Reaching this type of target, however, 

implies a complicated process. As Franca 

Pierobon, Dayco Communication 

Manager, explains, «we are talking about 

a reference pool that includes over 

300,000 referents in Europe only. This 

clearly shows how difficult it is to create 

direct contacts and, even more so, to 

establish a stable loyal relationship. With 

the correct tools and a clear motivation, 

we are convinced that this dialogue is 

possible. Actually, in some context, it has 

already started». In this respect, Italy 

represents a pioneering market, with a 

global database of 2000 contacts, mainly 

“collected” during events held in the 

market and already involved in a series of 

interesting loyalty-related operations. 

The major initiative in this sense is 

certainly the creation of the Garage 

Section: «A section of Dayco’s website 

specifically dedicated to car repair shops 

that, after registration, gives access to a 

kind of “virtual work space”, making 

available some very useful tools for the 

daily activity of the workshops, such as 

online diagnostics, or technical and 

service information: (TI and SI Bulletins). 

The database currently available includes 

some 4000 transmission layouts and 

over 200 TI and SI bulletins. 

The TI and SI bulletins present clear and 

detailed technical characteristics of the 

product and the assembly procedure. 

They can also be accessed through the 

newsletter which is sent regularly to all the 

people registered to the portal and 

contains all the latest news on Dayco’s 

world: from the introduction of a new 

product line to the report on the last trade 

fair where Dayco were present. As 

Pierobon anticipates «During 2012, this 

channel will be further updated in its form 

and contents: its commercial and 

promotional function will be developed, 

making it a suitable vehicle for launching 

initiatives and special offers, and its 

increased frequency will make contacts 

with our interlocutors as continuous and 

rich as possible ». Another important 

move from Dayco in the last few months 

is the launching, from this issue of the 

magazine, of the “Aftermarket Technical 

Column” in hard copy: «A space designed 

to answer accurately the questions 

frequently asked by the repairers to our 

technicians». 

MEETING OPPORTUNITIES 

It is clear that all these initiatives are 

aimed at extending as much as possible 

the customer loyalty process, already 

relatively developed in Italy, to the other 

European markets. 

To this end, the pool of direct contacts 

with the repair shops is implemented 

month after month, mainly through the 

increasing number of events in the 

market, ranging from the participation in 

fairs to the organisation of seminars and 

technical courses for car repairers, 

«meeting opportunities that are essential 

to establish an effective dialogue with our 

targets and, above all, to follow their 

suggestions and requirements». 

In particular, the importance and number


of training courses are going to be increased on all 

markets, through the implementation of a new course 

concept and the reorganisation of the whole aftermarket 

technicians’ area, both aimed at greater physical proximity 

to the working place. 

These technical and training opportunities will be 

supported by a dense schedule of local events, 

conventions and road-shows with a more commercial 

purpose, both on the mature markets – France, England, 

Germany – and on the emerging market, in particular 

Eastern Europe – Poland, Romania, Hungary and, 

naturally, Russia. 

«Among the events already scheduled – indicates 

Pierobon – the annual Frankfurt Fair is definitely the 

unmissable event for the automotive industry at the 

European level, where Dayco will present many new 

products ». 

All-out information 

This intense communication activity below 

the line is obviously supported by the 

consistent use of more traditional forms, 

including the distribution of leaflets, flyers, 

brochures, with particular attention to the 

organisation of the selling points, whether it be 

workshops or spare parts shops, considered as perfect 

“showcases” for the brand. 

Dayco also pays great attention to the opportunities of 

involvement and direct interaction related to the new 

media. «The use of new technologies in the workshops 

is actually growing, encouraged by the parallel 

development of the mechanic figure, increasingly 

“high-tech” and increasingly used to making the most 

of the simplified opportunities offered by network communications». 

In line with this trend, Dayco is planning to launch an 

online version of the magazine in the near future, and 

to develop the use of QR codes, inserted in the 

advertising pages or on the product labels, starting 

from the kits to gradually include the timing belts and 

rigid components. «In this way, as soon as the product 

is opened, the installer will have immediate access, 

through the smartphone technology, to the relevant TI 

or SI bulletin, directly from the site and in the language 

of the market. Alternatively, if he does not have a 

smartphone technology is unavailable, the same 

information can be accessed by entering a numeric 

version of the code through the website. 

COMMUNICATION CHANNEL 

The portal actually represents the real lynchpin of 

Dayco’s communication strategy. «The number of 

contacts and registrations, particularly to the garage 

section, is increasing, probably owing to the fact that the 

target perceives Dayco’s will “speak the same 

language”, strongly aiming at a communication focused 

on the technical aspect of the products and their use». 

Besides the website, however, a critical part is played at 

communication level by the distribution chain. In fact, 

whilst the installer is the “end” target of Dayco’s 

communication, the role played by the spare part dealers 

and distributors is just as important for the company, as 

they can transfer the technical and product information 

in the most complete and efficient way to all the levels 

of the chain. «For example, the courses are often 

organised to answer specific requests from the 

distributors who, in turn, collect the specific input from 

the spare part dealers, who have a more direct contact 

with the end users. This is why the spare part dealer is 

often the one who organises the meetings, informing his 

own territorial customers and inviting them to 

participate». The distributors’ cooperation also helped 

organise various co-marketing operations at local level, 

where Dayco was present mainly as a brand rather than 

a direct interlocutor, as well as some interesting 

merchandising and sponsoring initiatives, including an 

activity aimed at involving the historical Abarth brand, 

through one of its most renowned engineers: «This is 

just a glimpse – concludes Pierobon – of an event 

calendar that will be undoubtedly very intense and 

demanding throughout 2012». 

MAY 2012 

7

8 POWER WORLD 


Different strategic choices 

Being flexible and listening to 

the market are two of the 

main elements of Dayco’s 

model, starting from a 

common strategic base then adapting it 

to the various market needs. Therefore it 

is of no real surprise that this its 

localisation formula also worked in 

countries with such varying 

requirements. 

«When we talk about Eastern Europe we 

tend to think of a sort of uniform macroarea, 

but on the contrary they are unique 

and characterised by local differences. 

– observes Taverna. – Therefore it is 

also necessary to modify the 

communication activity according to the 

requirements of the markets, focusing in 

some cases on an institutional brand 

communication, in other cases on a more 

focused promotional strategy, through 

activities such as, shows, exhibitions and 

events on the premises of our partners. 

In Poland for instance, the very unique 

distribution situation which is very 

structured, even more than in some 

mature markets of Western Europe, 

requires the ability to support the market 

locally in a more targeted manor. 

The situation is different in Russia where, 

due to the geographical extension, Dayco 

decided to maintain it’s core business in 

Moscow and, from there, to move to 

other big cities like Saint Petersburg. 

The case of the Lada, the Russian car par 

excellence is emblematic in this sense; 

«For Dayco, entering the Lada market 

provided automatically a strong 

advertising arm, that allowed the brand 

awareness to grow from the bottom 

much more quickly than what would 

have been the case using the classic 

advertising channels, without waiting for 

the brand value to move from the top of 

the chain to the bottom». The strategy 

consisted of identifying the distributors 

specialising in the Lada Aftermarket who, 

even though small in number, handle 

important volumes, particularly outside 

the Moscow area, where the vehicle parc 

is more similar to that of Western Europe. 

A choice that clearly worked, as Dayco 

quickly became the leader in the Russian 

market, and thus proving the strength of 

a model that does not merely intends to 

“talk” to the customers, but wants to 

involve them in a real dialogue, to learn 

their language and to adapt it to its own. 

From this point of view, the presence at 

the Moscow MIMS Fair is of fundamental 

importance in this country. 

«Over the years, this fair has developed 

from a national event mainly attracting 

the former Soviet countries of the 

Russian Federation, to an international 

event in all respects, in terms of visitors 

and exhibitors, who are now coming from 

all European countries». Most of all, given 

the huge extent of the Russian territory, 

MIMS represents a unique opportunity to 

know and meet customers from every 

corner of the country, from cities that are 

as remote as Vladivostok. 

«We can say – adds Taverna – that while 

the approach to the Lada market enabled 

us to make ourselves known from the 

bottom, through the repair shops and 

spare parts dealers, the Moscow Fair 

helped us to push our brand at an 

institutional level, introducing it in the 

local competition framework. In addition 

it has also allowed us to reach new 

customers, to consolidate those already 

acquired»


Quality as 

security 

Amechanic is working in his 

workshop. Suddenly, a dark and 

threatening figure walks by: it is 

a roaming shadow, death looming over, 

waiting for the mechanic to make a 

mistake and fit a second-rate or faulty 

part on a car. But the mechanic keeps his 

composure and, unperturbed and 

smiling, shows the unusual guest how a 

job well done leaves nothing to fear, until 

an ironic conclusion that leaves the 

audience amused, but also more aware. 

This is the video that was shown in Spain 

and Portugal in recent months, as part of 

an awareness campaign “recambioletal”, 

promoted by a group of component 

producers operating in the area, among 

which Dayco. Launched with the catch 

line “elegir calidad es elegir seguridad” 

(choosing quality means choosing 

safety”), the campaign intends to 

emphasize with strength the importance 

for the end customer to choose OEM 

quality brands for their spare parts. 

As Bruno Padierna, Sales manager for 

Spain and Portugal explains, the project 

was developed as the result of a fact 

observed on the market. «Over the past 

few years, there has been an increasing 

number of customers requesting 

products that cost less, but offer a quality 

that repair shops consider insufficient to 

guarantee not only a job well done but, 

above all, a safe result». 

For this reason we decided to join forces 

to send a strong message to the market, 

explaining that choosing quality is not an 

accessory choice but a necessary one. 

«Initially, the group was rather small but 

the number of members grew quickly». 

The objective is to explain, not only to the 

end customer but also to distributors and 

repair shops, a simple yet extremely 

important principle, i.e. «the price cannot 

and should not be the first and sole 

parameter in the choice of a component, 

because before the cost, the quality of 

the repair is and remains the most 

important factor». Fitting a part that is not 

certified implies fitting a part that has 

probably not received correct approval 

and may therefore create serious 

problems in the long term. 

The channel chosen to communicate this 

message is deliberately “strong”, 

although clearly sarcastic. A choice that, 

even though it drew inevitable criticism, 

turned out to be rewarding, as the video 

was viewed nearly 15 million times on the 

related website. 

«The second stage of the campaign 

should be launched soon – concludes 

Padierna –; it is aimed at opening a direct 

dialogue with the main local interlocutors 

of the industry: purchasing groups, 

distributors, major producers, in order to 

create a single front, united by the 

conscious choice of quality». 

MAY 2012 

9

Product 

Milestones 

of a leadership 

Corrado Bisegna 

Senior Product Manager 

Collaboration with all major vehicle manufacturers improving 

product technology and range. One result of this is the extension 

of the automatic tensioners with a range of over 1000 parts, 

covering 93% of the European vehicle car parc. 

Together with the belt, 

automatic tensioners are 

actually the leading product of 

Dayco’s offer. They represent 

the most technologically advanced line, 

both for the primary timing system and 

for the accessory system. The tensioner 

function is to absorb constantly, for the 

whole life of the belt, the tension and 

vibration peaks generated by the 

movement of the belt itself, ensuring a 

constant tension. This objective can be 

reached with various methods and 

devices having different structural characteristics 

and different advantages. 

In detail, the Dayco catalogue offers two 

types of tensioners; i.e. automatic and 

fixed. “Active spring” or hydraulic 

FROM THE UNITED 

STATES TO EUROPE 

For many years, Dayco has been a 

leader on the European market of 

automatic tensioners. This objective 

was reached after a long route that 

started some thirty years ago. «It was 

at the end of the 80’s that the 

American multinational “landed” on 

the old continent, introducing the 

automatic tensioner production 

technology» explains Corrado 

Bisegna, Senior Product Manager. 

«Here, the know-how already 

developed in the United States was 

improved and adapted to suit the 

different operating and 

manufacturing procedures of local 

engines, and resulted in the timing 

belt product, which was and remains 

a typically European production». 

The intense cooperation between 

Dayco and the major car 

manufacturers and heavy duty (HD) 

producers started at that time, and led 

to an increasingly complete and 

specialised range of products, both 

for the primary and secondary timing 

systems. In particular, the offer of 

solutions for automatic tensioners 

was strongly developed, as these 

components have become absolutely 

necessary for some types of engines. 

«This cooperation has also allowed 

the accurate fulfilment of the quality 

standards required by the various 

producers – adds Bisegna – and 

from the 90’s on, Dayco has become 

the market leader for this line of 

product: a record that is still holding». 

automatic tensioners are – explains 

Bisegna – «intelligent“ tensioners: when 

installed correctly, they are actually 

capable of optimising the tension 

according to the engine load. 

On the other hand, fixed tensioners are 

components that help the operator 

adjust the belt tension at the same time 

as the fastening operation. 

Consequently, once it is set, this type of 

tensioner cannot be adapted to possible 

variations of external tension. Therefore, 

Dayco invites the installer to use the 

Dayco tensiometer in order to check the 

correct tensioning of the belt. Tensioners 

are components of a more complex 

system, which requires a number of 

accessory components that are essential 

to optimise the performance of the whole 

belt route system. These components, 

which must have the same operative life 

as the tensioner, include for example the 

dampers (see special box), but also the 

idlers, which follow the route of the belt 

to facilitate its movement inside the 

transmission, interrupting the so-called 

“free span”. «If there is no idler or pulley 

to govern it, the longer the belt section is 

and the more likely it is to resonate», 

explains Bisegna. 

PRODUCERS AND INSTALLERS: 

FULL RIGHT PARTNERS 

Tensioners and dampers perform a 

highly important function for the correct

Focus on DAMPERS 

In a transmission system, the main circuit is supported by the so-called 

auxiliary circuit, which governs elements such as the alternator, the air 

conditioning compressor and, in some cases, the water pump. 

Among the internal accessories of this transmission, one of the most important 

is the damper. It is usually a pulley fitted with rubber components, 

capable of absorbing and damping the 

crankshaft vibrations, preventing them 

from reaching other parts of the system. 

Besides the traditional dampers, Dayco 

also produces much more complex variants 

called DDS (double damping system), 

designed to be fitted on more 

powerful and efficient engines. 

An example is the series 

of Fiat Multijet 

1.9/2.0 engines: 

these new-generation 

diesel engines 

are extremely 

efficient and 

therefore require a 

double damping system. All this implies the capacity to 

face a number of significant technological difficulties, from 

the need to join and “merge” rubber and metal components, to the formulation 

of specific compounds capable of reacting immediately to the intense 

vibrations transmitted to the system by these types of engines. Finally, it 

should be noted that each engine requires a specific damper with the wide 

range of applications, currently including some 110 models. 

and efficient operation of the transmission 

system. This function is reflected in the 

structural complexity of the product: each 

tensioner actually consists of a rather 

articulated system of components, the 

design and implementation of which 

require significant commitment in terms 

of technical knowledge and research 

investments. 

For this reason, says Gianluca Fantozzi, 

Technical department, Dayco pays 

particular attention to the constant and 

progressive technological development: 

«This requirement is directly related to the 

direct relation we have with the car 

manufacturers, who express 

their precise and advanced 

requirements, for products 

that are increasingly efficient 

and effective in terms of 

weight, performance and 

reliability. In line with this approach – 

adds Fantozzi – we have 

established with some 

OEM producers strong 

relations of design 

synergies, for 

example with Fiat, 

Psa, Ford, 

Volkswagen for the 

a u t o m o t i v e 

segment and 

with Scania, 

Volvo, Iveco, Mercedes for 

the heavy duty segment». 

The relation with the 

producers and with the new 

technologies introduced on the 

market is the first and most specific 

parameter followed by Dayco 

when drafting its OEM 

development 

plans. Another element that 

is just as important, if not more, for the 

Aftermarket Division is the direct and 

ongoing contact with the end user, i.e. the 

installer who is considered a full right 

partner of the company, as he is capable 

of indicating in the most precise and 

specific manner the various requirements 

and problems of the engines. 

In line with this approach, 

with particular 

reference to the 

automatic tensioner range, 

for which Dayco is already 

the European leader, 

the company has 

decided to produce 

real “monographs” 

dedicated to some 

selected engines which, due 

to their complex architecture, 

generate some management and 

maintenance criticalities. The increased 

diffusion of automatic tensioners, which 

are already fitted to modern engines at 

design level, actually carries, together 

with many benefits, a collateral risk, that 

is a tendency for the installer to think that, 

in many engines, the tensioner “does 

everything by itself” so to speak. In reality, 

although these engines are equipped with 

automatic tensioners with 

an extremely simple 

layout, their 

i n s t a l l a t i o n 

requires specific 

attention and 

skills that must be 

implemented to avoid a 

series of rather frequent 

issues, from the skipping 

of a tooth to more serious 

problems, such as the 

failure of the tensioner. It is 

therefore essential that the 

installers are given all the necessary 

information to carry out the assembly 

correctly. 

«Among the engines that Dayco is treating 

MAY 2012 

11

with particular attention – explains 

Fantozzi – the 1.7 TD model by General 

Motors is one of the most widespread at 

the European level in the Opel and 

Vauxhall range». 

AN OFFER 

IN CONTINUOUS EXPANSION 

The ongoing search for new technological 

solutions, constant dialogue with the 

OEM producers, as 

well as direct and organised contacts 

with the end customers: these are the 

three pillars of Dayco`s product strategy, 

which have allowed, over the years, to 

achieve an extensive range coverage for 

all products, in 

12 POWER WORLD 

Product 

particular rigid components. As explained 

in detailed by Corrado Bisegna, «Dayco’s 

range of automatic tensioners currently 

includes over 500 items for each of the 

two product families, i.e. primary timing 

and accessory timing, reaching in both 

cases a coverage exceeding 93% of the 

European circulating fleet of vehicles, 

and therefore all the major manufacturers». 

As a whole, we are talking about 

over 1000 “single” codes that are subsequently 

combined within the kits according 

to the different engine layouts. 

On the other hand, the expansion of 

the range is an ongoing and 

constant process: 

the catalogue is 

updated and 

completed on 

a daily basis, 

in an attempt 

to follow as 

closely as 

possible the 

continuous evolution of 

the product on the OE market. In this 

respect, the horizontal integration 

model adopted by Dayco proves to 

be highly efficient. «The OE and 

Aftermarket Divisions – explains 

Bisegna – actually operate 

on a continuous 

basis: the addition 

of new applications 

is 

always implemented 

in 

agreement with 

the producer in 

the first place to 

achieve the best 

quality, before 

being transferred 

to the Aftermarket 

segment, with virtually 

no continuity solution. 

In this way, we can 

guarantee a coverage that 

is not only vast, but also effective 

and highly functional, 

or guarantee products equivalent to 

the original at every stage of the vehicle 

life and in various combinations of offers, 

thus achieving, as we claim, “infinite 

possibilities”: infinite solutions for the infinite 

situations and requirements 

that may arise».

Prodotti 

MAY 2012 

13


Prodotti

Product 

TB SET: solutions 

for every situation 

Researched by Dayco, one successful product line to 

the range are timing belt sets in one box. When a 

complete substitution of the transmission is not 

required this is the perfect solution to the garage. 

Dayco`s mission is to provide quality products to offer the garage every solution in the substitution 

of the components within the transmission, whether it be a partial or complete substitution. 

This is precisely the idea behind the recent introduction in the Dayco catalogue of a new product 

line: the TB SET. The purpose is to provide, in a single solution, the combination of two belts that 

are usually found in more complex timing kits, but that could be replaced, in specific situations, 

without involving the rest of the system. 

«For example on some diesel engines, the injection pump is controlled by the belt, therefore 

when the pump is faulty, it is sufficient to replace the flexible part of the timing system without 

touching the rest – explains Gianluca Fantozzi –. 

In other cases, a complete replacement has just been made and an additional service is required 

on a single part, for example the water pump». In this way, Dayco can provide the installer with 

specific solutions for all types of services on the engine: from the replacement (always 

recommended) of the whole system, including the water pump, to the fitting of the basic kit 

and the fitting of the belt-belt set or single “loose” component. «The mechanic can therefore 

choose independently, on the basis of his experience and the various situations that may 

occur, the most suitable tool for each application», concludes Fantozzi. 

In this sense, the launching of the TB SET is 

in perfect keeping with the mutual trust and 

cooperation relation between producer and 

spare part dealer, which Dayco focused on 

from the start. In no way does the TB-SET 

association imply a weakening of the kit 

solution, which remains the most 

recommended solution and is widely 

expanding on the whole European market 

but, on the contrary, its extension: a ‘plus’, 

a further facility designed for the customer 

who carries out partial replacements. 

MAY 2012 

15

Zoom 

From Moscow to Warsaw: 

a fast growing horizon 

Very different, promising and unique markets. 

Central-Eastern Europe proves to be one 

of the most strategic scenarios of the Dayco’s 

globalisation process 

From Russia to Poland, from the Czech 

Republic to the former Soviet Republics 

of Central Asia: these country’s express 

the extent and vastness of the market area 

that is generally known as Central-Eastern 

Europe. 

A region with very different requirements, 

cultures and vehicle parcs that Dayco started 

exploring about six years ago as a new 

territory. Initially with a limited presence 

that gradually expanded and eventually 

led to Dayco creating an important distribution 

network and to develop the awareness 

of a brand that was at the time almost 

totally unknown in the area. A goal 

achieved above all else through to the implementation 

in the different countries of 

Dayco’s core principle of cooperation and 

partnership between the company and 

it’s customer. 

MARKETS TO BE EXPLORED 

«The gradual penetration in Central-Eastern 

Europe was probably the most difficult 

challenge we had to face – explains 

Andrea Taverna, Regional Sales Manager 

Central Eastern Europe – Today we can 

state that even though the brand awareness 

has grown considerably, we need to 

continue to support it with targeted marketing 

and promotional activities in all the 

different areas. 

Within this area, Russia certainly represents 

the main market due to it’s size and 

vehicle parc. Russia is also the country 

where the turnover grew most significantly. 

«Hence – continues Taverna – the 

need to be present in loco. In fact, three 

years ago we opened an office in Moscow, 

in order to serve our customers more closely. 

The customer service, now available 

in Russian, was established with this purpose 

in mind. Furthermore, Dayco has 

now been present at the Moscow MIMS 

Fair for five years with its own stand; our 

presences at the show growing in proportion 

to Dayco’s presence within the 

market. Again with the aim of consolidating 

and strengthening the customer-partner 

relationship, a requirement that is 

even more important in a territory as large 

as Russia. 

Poland is certainly another important market 

and is seen to have the greatest potenial 

of all the countries in the. Central-Eastern 

Europe area. In fact it is very similar 

to the Italian and German markets, both 

for its vehicle parc size and age. In this 

case, the strategy being implemented is 

therefore slightly different to the other 

countries of the area. «Dayco’s activity in 

Poland is predominantly based on marketing 

and advertising activities aimed at 

supporting sales. Here too, we can also 

rely on a local team to provide customer 

service and maintain good daily contact 

and support for the customers.

GREAT POTENTIAL 

Zoom 

Continuing south of Poland, the Dayco 

brand was introduced to the Czech 

Republic, to Hungary and Rumania. 

Rumania in particular has provided many 

opportunities and has enabled Dayco to 

establish a strong presence in the market 

which has resulted in new customers, 

brand awareness growth and sales. 

There are also the various former Soviet 

Republics, characterised by rather 

different economic contexts: some of 

which are already significant, as in 

Byelorussia and Ukraine, who are 

As well as the participation in fairs 

one of most efficient methods to 

increase and consolidate the company’s 

presence in a new market is to organize 

training activities in loco, managed 

by the Aftermarket staff but often organized 

by the customer’s themselves. Customer’s 

who, even if they are new, are receptive to 

the updating process and, in general, to the 

use of highly advanced technologies, in 

terms of logistics and supporting data processing 

systems. 

In this context, the training service offered 

by Dayco, in many cases part of an “academy” 

formula, also works as an instrument 

to gain the customer’s loyalty. Therefore, 

the aim for the future is to intensify this type 

of activity, transferring more and more knowhow 

from the company to the customer, 

thus stimulating as much as possible a sort 

of “requirement from the bottom”. 

In Poland, as already pointed out, the distribution 

situation is rather different each distributor 

works on the national scale, with 

their own regional warehouse network and 

owned or franchised workshops with which 

they maintain a direct relation. Consequently, 

there are no intermediaries between the distributor 

and the customer. As a result knowledge 

and information provided to the distributor 

is automatically cascaded down to 

the workshops explains Taverna. The situation 

is different in the Balkan region, Slovenia, 

Macedonia, Croatia, Bosnia, Serbia and 

Montenegro. «In this case – continues Taverna 

– there are organized distribution net- 

supported by the Moscow office, others 

are still developing, like Kazakhstan, 

Uzbekistan, Kyrgyzstan, Tajikistan, 

Turkmenistan Republics. «However, these 

countries have great potentials that has 

not yet been fully exploited. 

And it is this potential we are aiming at – 

intervenes Taverna. –We are present in 

each of these markets with at least one 

distributor, and in some cases these 

distributors have pre-existing customers 

structures that are growing rapidly. In both 

cases, creating a relationship of 

cooperation with the distribution operators 

becomes crucial, with the common 

Objective: 

customer loyalty 

works similar to the Italian or the Polish ones, 

but smaller in terms of numbers. In fact, 

these markets can be considered as immature 

where new structures still coexist with 

those of the past, like the old-style mechanic 

who might try to import the component directly 

from abroad and who only contacts 

the distributor when he finds himself in trouble. 

To conclude, as far as Eastern Europe 

is concerned, Dayco’s strategy of listening 

to the market seems to be even more important. 

Each market presents its own unique 

challenges and requirements and must 

be understood and translated into strategic 

objective of reaching, satisfying and 

retaining the end customer». 

These emerging countries have huge 

potentials that provides great 

opportunities for for the automotive sector 

but is characterised by a rather structured 

and deep-rooted competitive framework. 

In this context, the main challenge for 

Dayco is to make its brand known. When 

this goal is achieved, we can start working 

on the commercial growth. 

commitments. But they must also be adaptable 

to specific elements common to the 

whole area, i.e. the seasonal trends of the 

demand, which undergoes a considerable 

drop during the winter period, because of 

the extremely low temperatures and then 

followed by an explosion during the spring 

period . «Seasonal trend is definitely a rare 

characteristic in the automotive sector as it 

is usually not affected by the climate factor 

– concludes Taverna – but it is also a further 

confirmation of how important it is for a company 

like Dayco, to look at the market without 

prejudices or preconception, but to use all 

means available to understand it and to respond 

in the best possible manner». 

MAY 2012 

17

Anew Aftermarket production 

plant in the Suzhou industrial 

area is the most important in 

the Shanghai region and 

represents a further step forward in 

Dayco’s expansion in the Far East. This 

plant will support and complement a 

presence already established at a 

distribution and commercial level . 

It will also offer significant opportunities 

to the local community with promises of 

future developments and job 


Zoom 

The eastern frontier 

China being one of the most important regions in the Asian market is where 

Dayco are focusing expansion in development and coverage. 

Already implemented are the sales, communication and logistics and most 

recently production is well under way in Suzhou. 

opportunities. According to Riccardo 

Bosco, VP General Manager Dayco 

Aftermarket Asia, these are the main 

reasons that have led to Dayco’s decision 

to establish a production facilities a long 

side its existing distribution facilities – in 

the Chinese area. 

«Asia is an essential element of the 

globalisation and localisation strategy 

that Dayco is developing. And China is 

probably the most important market in 

this part of the world». 

PRODUCTION EXPANSION 

Launched in May 2011, the Suzhou plant 

houses two production lines, which are 

the most important, i.e. timing belts and 

accessory belts. However, due to the 

promising market conditions, Dayco is 

planning to extend this range in the near 

future. Currently, Dayco’s local 

production supports about 80% of the 

Aftermarket demand of the Chinese 

market, the remaining 20% is imported 

from Europe and Argentina: «This is a 

significant figure, which shows the 

company’s growing level of autonomy in 

this region» comments Bosco. « In 

addition to the aftermarket sector, the 

plant will also supply all the major world 

car manufacturers present in China, for 

example Volkswagen, Ford and General 

Motors, As well as local OE 

manufacturers who will also be supplied 

with product, particularly in the 

passenger car and heavy duty sectors,

Zoom 

with the aim of achieving a strong 

strategic position within the this Asian 

sector ». The last objective was made 

easier by recent acquisition from a local 

company in the South-East of China 

which specialised in the production of 

transmission belts for the heavy duty 

sector. These plants are currently 

undergoing, a technical-production 

restructuring to bring their procedures 

and processes in line with the standard 

Dayco model. While the aftermarket 

sector is moving with greater agility and 

speed, expansion in the OE sector 

requires more time. This is why the 

creation of a local production site 

represents a significant strategic asset, 

capable of bringing positive effects in the 

medium and long term. 

Furthermore, the opening of a local plant 

in loco, means significant improvements 

in terms of logistics due to the fact that 

transport costs are reduced and greater 

quantities can be handled over greater 

distances. The rapidly expanding 

Chinese market is thus provided with an 

improved service, at competitive prices 

and products that are in full compliance 

with the Dayco quality assurance. Bosco 

explains: «The production processes are 

the same in all our plants, from the 

material inspection to the quality control 

on the production line». 

A GROWING TEAM 

The growing production effort in the 

Chinese territory is obviously supported 

by the strengthening of the managerial 

and commercial activities. «The 

aftermarket organisation has been 

developed and consolidated – explains 

Bosco – and currently consists of a team 

of seven people: a sales manager, three 

area managers with various geographic 

responsibilities (North, Centre and South 

of the country), a person in charge of 

logistic planning and a product manager 

and a marketing manager for the 

customer service ». The OE organisation 

is also developing at the same rate, with 

the objective of bringing new supply 

opportunities for the local market, that 

will be made possible by the newly 

opened plant. «To this aim, an extremely 

interesting project is being undertaken in 

the current months, – declares Bosco – 

that will help Dayco develop its approach 

to the other aftermarket sectors of the 

Asian region, where two production 

plants already exist and where an 

increase in demand, would further 

increase their output. The distribution 

network that is growing in parallel is 

becoming increasingly diverse and 

widespread. Over a year, it increased 

from 4-5 independent distributors to the 

current 15, most of which are of 

significant size, with the aim of reaching 

20-25 distributors in a near future. «The 

covering of such a large territory requires 

a wide presence, capable of supporting 

all the major areas of demand: we are 

planning to start with business 

agreements in the areas with the highest 

demand potential, and expand gradually 

to all Chinese provinces», explains Bosco. 

As far as the spare parts dealers are 

concerned, the Dayco network currently 

includes approximately 30,000 people; 

a more accurate figure will be available 

when the results of specific market investigations 

which are still in progress are 

known. 

A PECULIAR MARKET 

«The Chinese market is a market that is 

growing at a extremely high rates – 

underlines Bosco – therefore it is very 

difficult to obtain accurate data: to obtain 

reliable information, we need to cross 

check various sources and various 

parameters, which complicates any 

analysis. Suffice it to think that, out of 14 

million registrations, statistics show that 

approximately 5-6 million vehicles 

produced in China evade registration». 

This situation is obviously worsened by 

the complexity of the cultural context, 

which requires highly specific marketing 

and communication strategies, mainly 

aimed, at this stage, at introducing the 

brand and making it familiar, increasing 

Daycos’s brand awareness among the 

Chinese public, as a worldwide OE and 

aftermarket leader. Considering the 

specific features of the Chinese market, 

this strategic process intends to prioritise 

channels such as advertising billposting 

in large specialised automotive centres, 

the so-called autocenters and autoparks, 

and the participation in dedicated fairs 

and shows. «Furthering this approach, 

we have also planned a strong 

advertising presence in some of the most 

widespread magazines dedicated to the 

automotive sector, focusing first of all on 

the offer of a complete range of products 

for the production of belts, and then 

progressing to the promotion of other 

families of products», concludes Bosco. 

This is yet another stage of Dayco’s 

expansion process, that is as complex as 

it is stimulating and rich in diversity. 

MAY 2012 

19

R&D - Research & Development 

Sustainability and innovation: 

a team work 


Reduction in emissions and increase in 

consumption is the potential to improve the overall 

performance of the engine. Not just from a 

supplier level on product innovation but also from 

vehicle manufacturers to end users. Carlo 

Trappolini explains from Dayco`s point of view our 

innovation and advanced technology of products 

we have collaborated with vehicle manufacturers. 

The continuous contact with car manufacturers 

for the production of original equipment 

has been a strategic pillar of Dayco’s 

philosophy, from the very beginning of its 

European experience. This type of cooperation 

has allowed Dayco to become the 

supplier of all the major world manufacturers 

in the European area: from PSA and 

Renault to Ford (England), from Volvo Car 

to Volkswagen, Daimler, Opel and BMW 

in Germany, as well as Fiat for Italy and, 

through a common platform, also Chrysler. 

A significant commitment that has allowed 

Dayco to reach a world leading position in 

the OEM sector. 

OEM 

Dayco’s cooperation with the producers 

covers, on the one hand, a specific sector 

of activity dedicated to the application and 

management of customer-centred projects 

and, on the other hand, a kind of special 

task force dealing more specifically with 

the HD sector. Discussed with Carlo Trappolini, 

[Project Manager], who is currently 

in charge of the management of specific 

development projects for the Aftermarket, 

after working at Dayco at first in the testing 

division (dynamic simulation of transmissions), 

then as Product Engineer, Technical 

Account Manager for the German market 

and finally as Project Manager. «All the 

above groups – explains Trappolini – are 

currently adopting massive production localisation 

strategies in the BRIC countries 

(Brazil, Russia, India and China), and we 

are compelled to adapt to this trend by 

opening new plants or developing the production 

plants already existing in these 

areas. Not only for economical reasons, 

but also for sustainability reasons related 

to the so-called “Global Footprint”». 

Dayco is already present in Asia and South 

America. «We have a plant for the production 

of flexible components in Argentina 

and a plant for rigid components in Brazil 

– adds Trappolini –. In China, the plant 

producing flexible components is already 

operational, whilst the rigid components 

are produced in India». 

However, the benefits of this cooperation 

model are best perceived in Europe, where 

it has reached full maturity. In fact, as a 

general rule, the local centres must strictly 

follow the instructions of the European parent 

company. 

Trappolini explains: “As a result of our will 

to discuss and exchange with the producers 

on an ongoing basis, especially as far 

as the most widespread engines are concerned, 

our OE technology, in line with the 

“Dayco model” i.e. the constant adjustment 

to the needs of the market, does not stem 

from “simple” observations, but from an 

effective cooperation, and thus from the 

direct experience with the producers and 

a thorough knowledge of the respective 

market requirements».


REDUCED CONSUMPTION, 

REDUCED EMISSIONS 

Among the most pressing requests from 

the market in recent years, those related 

to the reduction of fuel consumption clearly 

stand out (new European standards limiting 

the emission of CO2), for efficiency reasons. 

These restrictions complement those 

already in force for Euro 5 and subsequently 

for Euro 6, which impose the gradual 

reduction of the polluting elements deriving 

from combustion (CO HCNOx- particulates). 

«These standards, together with the 

constant search for methods to reduce fuel 

consumption, are making the engine management 

increasingly difficult – explains 

Trappolini –A great part of this management 

currently relies on electronic solutions, 

but mechanical research remains 

essential for the optimisation of the achieved 

results». To this end, the Dayco R&D 

service is already at work with the major 

manufacturers to produce engines com- 

pliant with the above standards, in order 

to anticipate the evolution of the circulating 

fleet and provide a prompt response to the 

requests from the market and from the regulatory 

framework governing their evolution 

in the European context. 

In these cases, it is particularly important 

to work from a systemic point of view. As a 

matter of fact, these objectives can be reached 

only through the cooperation of all 

the components of the system. The efficiency 

achieved by a single component 

has a relative impact, but considered on a 

large scale and interacting with the optimisation 

of the system, it can have considerable 

effects. «Working on several fronts 

allows to multiply the benefits. If each component 

manufacturer succeeds in reducing 

the CO2 emissions by just a few grams, 

improving the overall efficiency of the vehicle 

within the scope of their function, the 

overall result on millions of vehicles becomes 

important in terms of cost and pollution 

reduction”. 

Car manufacturers are urging each sup- 

plier to study optimised solutions and to 

give their contribution with their own products. 

”It is not enough to operate on a 

single part of the engine as in the past: for 

instance, on the intelligent regulation of 

Ford Fox-Bio main transmission 

(belt tensioner) and oil pump belt 

the air – fuel quantity and the reduction of 

the polluting exhaust emissions. Today, to 

achieve the requested results, all the component 

manufacturers must work together 

under the supervision of the car manufacturer». 

The engine downsizing trend, i.e. the search 

for optimal performance on systems 

of increasingly reduced dimensions, is also 

part of this framework. “This result – explains 

Trappolini – can be obtained by increasing 

the performance of low displacement 

engines, which used to be limited 

to the compact car segment but have now 

extended, through the addition of the turbocharger 

and phase variator, to other car 

segments. Over the next 2/3 years, a 15% 

reduction of the average displacement of 

the circulating fleet is expected. This also 

explains the growing adoption of 2 and 3 

cylinder motorisations”. 

The general reduction of the moving masses, 

i.e. the “weight” carried by the vehicle, 

is a parallel and complementary aspect of 

this trend. “Consumption being related to 

the vehicle mass – continues Trappolini 

– one of the strategies regarding transmission 

systems consists in keeping 

down the belt operating tensions in order 

to reduce the losses due to friction and, 

consequently, the loss of energy». 

FORD AND VOLKSWAGEN: 

PILOT COOPERATION 

For Dayco, achieving these objectives has 

implied significant research work, essentially 

centred on the control of the static 

and operating levels of tension. 

«The solution we proposed, that has given 

excellent results up to now, concerns the 

use of belts in oil bath that can be fitted on 

engines initially designed with a chain system, 

with no need for the manufacturers 

to make important changes, but simply 

changing the pulleys. With this solution, 

the system becomes interchangeable with 

the chain system ». 

This has been done, for instance, with the 

Ford Lynx 1800 diesel engine, as part of a 

pilot project resulting from an agreement 

with the manufacturer and aimed at providing 

an alternative to the chain solution: 

«Originally, this engine was fitted with a 

transmission system characterised by a 

primary chain in oil bath, followed by a traditional 

tooth belt in cascade. Dayco supplied 

a kit of pulleys, slides and belts in ‘oil 

MAY 2012 

21

ath’ ” (The Dayco system was rewarded 

by Ford for its innovative contents in 2008). 

Another example of successful cooperation 

is the TDI Common Rail. 1.6 L engine of 

Volkswagen, introduced at the 30th International 

Vienna Engine Symposium in 

2009. «In this case, the chain system replaced 

by the belt concerned the oil pump 

control. The innovation introduced by 

Dayco, with a belt capable of operating without 

tensioner, directly in an oil bath, has 

allowed to obtain an average energy saving 

of about 50W”. 

The main benefits of the change from the 

chain system to the oil bath belt include: 

reduced stresses, reduced energy loss 



and, consequently, reduced consumption, 

reduced noise level, reduced overall weight 

and finally reduced total cost of the transmission. 

The evaluation of the saving must be calculated 

on the engine as a whole: «On a 

total of 150 gram emissions – points out 

Trappolini –the contribution on the transmission 

is approximately 0,5-1 gram, that 

is 0,4 to 0,6 % of the total: but at the same 

time the effect must be considered from a 

systemic point of view, therefore the contribution 

of each component, even if minimal, 

becomes critical». 

STOP AND START, 

A SUCCESSFUL 

CHALLENGE 

Still in line with the priority given to the gradual 

reduction of fuel consumption and 

polluting emissions, the “Stop and Start” 

project was launched on another very interesting 

research front. In this case too, 

the starting point is the EC directive on the 

reduction of polluting emissions. The systems 

that allow to switch off the engine 

every time the vehicle is stationary are part 

of this project. This has resulted in a highly 

challenging and complex project, preceded 

by a long process aimed at defining the 

manufacturers’ requirements and specific 

objectives. «To fulfil this function, a solution 

is to adopt alternators capable of fulfilling 

the dual function of loading the battery, 

absorbing energy in a “passive” way, and 

restarting the engine, through the accessory 

belt, in an “active” way. Based on the 

design criteria for the existing components, 

it was observed that, due to the strong 

stresses generated during the starting 

stage through the alternator, it would have 

been necessary to use a belt twice as wide 

as a normal belt. Which was unthinkable. 

PSA - belt starter generator 

Considering the reduction of the engine 

size under the bonnet, which has been pushed 

to a maximum, it would have been 

necessary to redesign the whole vehicle». 

Consequently, some manufacturers, 

among which Fiat, BMW, Ford, Volkswagen, 

have given up the idea and opted for 

the use of electric starting motors, asking 

the producers of these components to increase 

their power in order to provide greater 

reliability (a tenfold number of starts). 

«On the other hand – explains Trappolini 

– other manufacturers have preferred, for 

various reasons, to remain faithful to the 

belt system, which provides a faster and 

more silent start». PSA, for example, with 

Dayco’s contribution and following a long 

common process of research and cooperation, 

has started the production of a dual


function alternator starting system (“active” 

“passive”) plus belt. Trappolini continues: 

«We have adopted a belt with a traditional 

length, suitably optimised and coupled to 

a tensioning system capable of handling 

the correct operation of the starting stage 

which, as we mentioned previously, generates 

significant stress on all components». 

The Dayco system, duly patented, allows 

to obtain a number of benefits both in the 

traditional operating stage (defined as 

“passive”), where the engine gives the impulse 

to the alternator, and in the reverse 

starting stage, where the engine absorbs 

power from the alternator. This is the result 

of an operation that is no longer based on 

inversion, but on the maintenance of a balance 

between the incoming and outgoing 

branches of the belt in relation to the alternator: 

instead of having one or two tensioners 

on the branches, the tensioning 

device connects both branches of the transmission 

upstream and downstream the 

accessory absorbing power. 

«In practice - explains Trappolini – the system 

finds its balance by itself. 

In the traditional system, the increase of 

the forces on the downstream branch corresponds 

to a reduced tension on the upstream 

branch: in the reversal which takes 

place during the starting stage, the use of 

a traditional tensioning system would cause 

excessive stress that could lead to the com- 

ponent failure. The Dayco system, on the 

contrary, is designed geometrically in order 

to create a balance of forces between the 

two branches at all times». The cornerstone 

of this self-balancing device is the rigid 

connection of the pulleys. 

The project is an example of how the R&D 

activity often follows unexpected routes, 

and this is why the implementation of an 

innovative solution, that may be investiga- 

ted for external requirements, triggers a 

virtuous mechanism of further innovation 

which takes the research process to more 

advanced and unexpected results than 

those expected. 

Even in the “Stop and Start” system, explains 

Trappolini, «what started as a mere 

optimisation project gradually became a 

research process in itself, towards increasingly 

“smart” and intelligent systems». 

In conclusion, we can assert that, over the 

years, Dayco has acquired a thorough knowledge 

of the power transmission systems, 

becoming a leader of the OEM markets as 

the supplier of a full range of transmission 

components. This leading position allows 

us to choose, for each single project, the 

technical specifications of the different 

components, in order to optimise the overall 

behaviour of the transmission. 

MAY 2012 

23


Editoriale

Editoriale 

MAY 2012 

25

Garage 

From the motor factor 

to the garage. 

More complex engines with higher performance. The technical service provided by Dayco is 

becoming stronger and stronger with each market having a dedicated technical aftermarket 

manager on the field and also through the garage area on www.dayco.com. 

The accuracy of technical support is the 

one main asset that Dayco has focused on 

from the start. This support includes a 

series of tools that Dayco have made 

available to the customer to make their 

day to day job easier, more intuitive and, 

at the same time, extremely accurate, 

when dealing with engines that are 

becoming increasingly complex and 

innovative. From the role of the 

aftermarket technician, true interface 

between the company and the customer, 

to the implementation of a complete set 

of assembly information bulletins, to the 

online diagnostic tool. All these tools are 

accessible through a “special” section of 

the Dayco website: the virtual workshop. 

THE AFTERMARKET TECHNICIANS, 

‘HEARING TERMINALS’ 

ON THE MARKET 

The mandatory proximity and dedication 

to the customer at the basis of the “Dayco 

model” finds one of its most significant 

expressions in the Aftermarket Technician 

figure. A service that Dayco has made 

available to the customers directly in their 

region where specialised technicians 

provide sales support activities and 

technical assistance to customers. 

«As they reside permanently in the 

reference country, the aftermarket 

technicians have a thorough knowledge 

of the reference market, the language and 

the requirements of the customers - 

explains Gianluca Fantozzi, Technical 

Dept. –. This figure is currently present in 

Italy, Spain, France, Germany, England 

and will soon appear in Poland, Turkey 


and other areas offering growing 

economic interest». 

In detail, the role of the Aftermarket 

technician is to provide assistance both to 

the retailers, taking part in training 

activities or work sessions for the 

mechanics, often organised directly by the 

local distributors or retailers, and to the 

sales department, helping to illustrate 

new products to the customer, and 

explaining how they are organised and 

developed or how to identify them in the 

catalogue. 

«In short – explains Fantozzi, the 

Aftermarket Technician is a “technician 

who talks to technicians”, who speaks the 

same language as the mechanic and the 

retailer: a kind of “facilitator”, virtually a 

“scientific populariser” of the product, 

whose main function is to facilitate not 

only the use of the products but also the 

understanding of the technical 

advantages that a given component can 

give». In this sense, the Aftermarket 

Technician represents a “listening 

terminal” to the market, a very important 

asset for a company which, like Dayco, 

has based its own model on the 

understanding of the variable 

requirements and characteristics of the 

market. 

TECHNICAL INFORMATION 

Among the most efficient tools made 

available to the Aftermarket Technician to 

provide an accurate and specific support 

to the end customer are the technical 

information and service information: (TI 

and SI) bulletins for each product, 

containing detailed assembly instructions 

that the customer can download when 

needed and organise in a sort of 

customised and “technical database” «TI 

and SI bulletins are extremely useful tools 

– stresses Fantozzi – especially when 

working on more complex or uncommon 

engines, which may be seen very seldom 

in the workshop and therefore require a 

highly specific and more delicate 

treatment». 

As they are directly linked to the different 

products and engines, the TI and SI 

bulletins require a continuous implementation, 

which follows the market 

technological innovations. 

But how can these TI and SI bulletins be 

accessed? With the purpose of providing 

the largest opportunities of use, Dayco 

proposes different channels: «First of all, 

through the database that can be found in 

the website garage section, made 

available free of charge to all members. 

Another channel is the periodical dispatch 

of the newsletter, with the TI and SI 

bulletin attached as they are completed. 

A brand new procedure is the QR code 

printed directly on the product box, which 

refers to a link to the corresponding TI and 

SI filed on the site». 

Apart from the access procedure, 

however, the usefulness of this tool mainly 

rests on the possibility for the mechanic 

to create his own “virtual library” that can 

be consulted at any time, “tailored” to the 

variable requirements of the local market 

on which he operates. 

«It is one of the many additional services 

offered to the members of the virtual 

garage - continues Fantozzi –. This 

section functions like a real virtual work 

platform, where the mechanics can 

prepare and plan beforehand all the 

details of their work on the engine, 

determining in advance which parts must 

be ordered, which operations must be 

carried out and, if required, they can 

obtain a one-year extension of the 

standard warranty for the kits containing 

a HT belt, with the Long Life +1 

operation». 

IMMEDIATE SOLUTIONS 

The creation of an online customised 

database of TI and SI bulletins is not the 

only advantage for the visitors to the 

Garage section. Another very efficient 

service, accessible from this specific 

section of the site, is the online diagnostic. 

Fantozzi explains: «We recently launched 

a new version of this interactive tool, 

complementing it with useful details and 

information, for a quicker and more 

efficient answer to the various product 

case records». 

If this tool is not sufficient, it is always 

possible to contact the aftermarket 

technician at the email address indicated 

in the aftermarket technician index, to 

obtain answers in real time, because we 

know that anybody working on an engine 

must respect very tight schedules to meet 

the requirements of their customers who 

are, ultimately, our end-customers, 

concludes Fantozzi».

Garage 

MAY 2012 

27

Gianluca Fantozzi 

Co-ordinator to the 

technical aftermarket group 

Andy Walters 


Response 

from the TAM 

The most frequent questions asked by the market can be posted online 

to info.it@dayco.com and answered by the technical aftermarket 

managers within a few hours. From now on all the frequent questions 

will also be in the Dayco magazine. 

What tool should be used for replacing 

rigid components on a transmission? 

The torque wrench is the essential tool for installing fixed or automatic tensioners, as it is capable of 

providing the correct torque to the bolt, as indicated in the drawings, layout and belt routing available in 

Dayco’s online catalogue. 

What is the price of the technical 

information on assembly procedures? 

They are totally free of charge and are available directly on the website 

www.dayco.com, in the Virtual Garage section. 

How to interpret the marking 

on the back of the Poly-V belt? 

A string of numbers and letters on the Poly-V belt indicates the general 

features of the item; this code is useful when the belt is assembled 

on the pulleys and the engine. 

For example, let’s take code 6PK 1836S: ‘6’ indicates the number of 

ribs, whilst ‘PK’ is the belt profile, that is Poly-V K profile as per the 

ISO 9981 standard; ‘1836’ indicates the effective length of the belt 

after it is fitted on the pulley; ‘S’ indicates the compound structure, 

enriched with fibres to ensure increased performance of the belt on 

the transmission.

Daniel Cosano 

Why is it not possible to refit 

a Timing Belt that has already 

been fitted, even if it is new? 

Because after the timing belt has been fitted and correctly tensioned, it has reached its maximum 

performance in terms of elongation. Therefore, if it is fitted a second time, the timing belt will no longer 

operate at the correct tension, with the risk of generating a series of consequences, including the skipping 

of a tooth, the belt failure or the engine failure. 

And what happens if 

it is not fitted correctly? 

In this case, it can be fitted again, however it should be noted that refitting a belt that is already tensioned 

is never recommended because its performance is exponentially reduced. 

Juergen Ohneberg Are Dayco products 

covered by a warranty? 

All Dayco products are covered by a two-year warranty. In addition, 

the kits containing the HT belt have an extended warranty of one year: 

this extension, called Long Life + 1, can be activated directly from 

Dayco’s website through five easy steps that allow the customer to 

obtain a personalised certificate. 

Franco D’Emilio 

MAY 2012 

29


Garage 

The Dayco mechanic

Garage 

What are the most frequent questions asked by the garage network? 

What type of problems are presented to the garage during the vehicle repair? 

What type of tools are available to assist the garage with their work? 

Why choose to work with Dayco products? 

Interview to Fabrizio Roma 

Fabrizio Roma, owner of the workshop “Autoriparazioni Roma 

Fabrizio” in Biella, tells us about his experience with Dayco 

products. 

When did you open your workshop? 

In 1985. Before that, I was working in another workshop, still 

in Biella, in the town-centre. 

For how long have you known and used Dayco products? 

For many years, I can’t remember exactly when. I got to know 

Dayco products through my suppliers. 

So you were recommended the product by spare part 

dealers? 

Certainly as far as belts are concerned. In our sector, Dayco is 

the preferred brand. 

Which Dayco products do you use most frequently? 

Timing kits and service belts. 

Are you using or have you used other brands after you 

got to know the Dayco products? 

70% to 80% or our spare part dealers supply Dayco products. 

Of course, they also offer other brands, but Dayco is widely used 

in our sector. 

So, you do not keep spare parts in your workshop, you 

purchase them as and when you need them? 

No, we also purchase stocks that the spare part dealer may 

propose. 

Over a one-year period, what is the average number of 

customers who request spare parts, whether Dayco or 

other brands? 

I would say more or less between 500 and 600. 

As a general rule, when a customer needs to replace a 

component, does he request specifically that only the 

tensioner be changed or do you encourage him to 

change everything? 

When working with belts, I prefer to change everything, to 

ensure greater safety, both for me and the customer. 

Has it ever happened that a customer requests a specific 

brand? 

Usually, customers just request an original spare part or a part 

equivalent to the original, as they are not much informed about 

the various brands. 

Why is it more convenient for a car owner to come to an 

independent workshop like yours rather than an 

authorised workshop? 

Because we can establish a relation based on trust, and 

eventually friendship. 

Dayco also offers a support service. Have you ever 

contacted this service directly to obtain clarifications? 

No. 

In this issue of the magazine, we dedicate a special 

section to the dampers. Have you ever replaced one? 

Yes, certainly. Actually, we have been replacing an increasing 

number of dampers recently. 

According to you, what is the reason for this? 

I have noticed that, when fitted as OEM products, the pulleys 

last between 120,000 and 150,000 km, then they have to be 

replaced. For this reason, when I work on timing system, I check 

the condition of the pulley and, if necessary, I replace it together 

with the service belt. 

In your opinion, is it necessary to have a direct relation 

with the company which manufactures the products you 

fit on the vehicles? 

Yes, it is essential because problems may arise at any time or 

we may need some clarification. Of course we often contact 

the spare part dealer, but having a direct contact with the 

producer is clearly an advantage. 

Do you use a computer for work? 

Yes, the manuals we usually refer to are all on PC. 

Dayco has launched on its website a section called 

Virtual Garage to have a direct contact with the 

mechanics. When you access this section, free of 

charge, you can download a series of very useful 

information. What do you think of this Dayco initiative? 

It is very positive: being able to have direct access to information 

is certainly quicker and allows to establish a direct relation of 

trust with Dayco. 

Do you read magazines? Do you find them useful for your 

work? 

Yes, I do. Especially ‘l’Autoriparatore’. 

MAY 2012 

31

32 POWER WORLD

Garage 

The Dayco mechanic 

Interview to Riccardo Asta 

Riccardo Asta has been working for four 

years as a mechanic in the Nicola dell’Orto 

workshop in Abbadia Alpina near Pinerolo. 

A true professional, he started this activity 

as a hobby when he was only 14 years old, 

and it gradually became a full time job. In 

the light of his long experience, we have 

asked him his opinion on Dayco products. 

For how long have you known and 

used Dayco products? 

Practically since I started this job, twentysix 

years ago, when I was working in a 

multi-brand workshop. After that I worked 

in a dealership where I used original 

products with Dayco belts. 

Do you purchase the products directly 

from the retailers? 

Yes. 

Have you ever had problems finding 

Dayco products from the retailer? 

Never. We always find them. 

What is the Dayco product that you 

use most frequently? 

The timing kits for the Fiat Fire engines, 

which are fitted on Punto, Grande Punto 

and Musa. 

Is it because they are older cars? 

No, because they are utility cars. 80% of 

the Fiat engines belong to the Fire family, 

so the transmission is always the same. 

The multijet Jtd is another engine on which 

I work frequently, as far as diesel is 

concerned. 

As a general rule, do you replace the 

components only or the whole 

system? 

The whole system, I never do things half 

way. We change both the internal and the 

external unit, it costs more but it is more 

convenient. It also means increased 

reliability and a job well-done. 

How many timing systems do you 

work on in a month? 

An average of 4 or 5 a week. 

Has it ever happened that a customer 

spontaneously requests a specific 

brand? 

No, the car owner does not know much 

about the brand, he trusts the mechanics. 

Do you believe that the level is merely 

economic? 

Basically yes, then it is the mechanic’s duty 

to explain to the customer that he does not 

need to give up quality by installing an 

unknown brand which may make him save 

5 euros but does not give the same 

guarantees. 

Do they request the original spare 

part? 

No, they seldom do. 

Dayco also offers an assistance 

service. Have you ever contacted this 

service to solve a problem? 

Yes, once we had a problem with a Jtd that 

we could solve by discussing and working 

together on the car, so I have a very good 

opinion of this service. 

What type of problem was it? 

A problem with a bearing bolt. 

What do you think of Dayco’s idea to 

establish a direct relation with the 

mechanic, offering a free service? 

It is an excellent idea. 

Do you use a computer for your 

business? 

Yes. 

Do you know that Dayco’s website 

now has a section dedicated to 

mechanics, the Virtual Garage, where 

you can find the technical information, 

the assembly instructions, free of 

charge? 

Yes. 

Do you know about the Long Life + 1 

operation, that allows to extend the 

warranty for one year. 

Yes, the technician G. Fantozzi, explained 

this operation during our meeting. 

In your opinion, there is more 

competition or cooperation between 

the workshops? 

In my opinion, there is more competition 

because, unfortunately, the customer 

tends to save money. He does not always 

consider that a higher price also means a 

more complete product, for instance the 

fact that the accessories are replaced 

together with the belt. 

In your opinion, does a car owner 

know the difference between an 

original and an independent spare 

part? 

No. But he usually knows that the original 

spare part costs more. 

MAY 2012 

33

The main features of this engine are: inline 

4-cylinder configuration, cast iron engineblock, 

aluminium head, dual overhead 

camshaft (DOHC) and 4 valves per 

cylinder. Over the years, it was initially 

produced with direct injection then 

equipped with the common rail system 

and fitted on various Opel and Vauxhall 

vehicles: Corsa, Astra, Meriva, Combo C, 

Zafira. In the common rail version, it was 

the first engine with this system used by 

Opel. 

In its catalogue, Dayco offers a range of 

rigid and flexible components for various 

generations/versions of this engine, both 

for the timing system and the auxiliary 

system: timing kits, timing belts and 

accessories, idlers, tensioners, pulleys 

and dampers. In particular for the timing 

system control – consisting of a timing 

belt, a tensioner and an idler, in 

compliance with the OE requirements – 

the offer includes various alternatives 

according to the engine year/version 

combination. 

The main feature of this system is 

provided by the tensioner; its initial 

function is to tension the belt when it is 

assembled then, after the engine settling 

revolutions and the final tightening of the 

bolts, it becomes a fixed tensioner and 

loses its capacity to modulate the belt 

tension. The idler between the oil pump 

pulley and the injection pump pulley has 

been modified with the evolution of the 

engine, and its “cup” structure has 

become a “full” structure. Both versions 

have been designed and produced in 

order to withstand, with the utmost 


Garage 

GM 1.7 Diesel Engine: 

Assembling the Primary Drive 

The correct setting of a component is a very important operation, even 

on engines that are relatively simple, for example the GM 1.7 diesel model, 

based on the Isuzu 4EE1 engine and produced since the late 90’s by a 

joint venture between Opel and Isuzu. 

Maurizio Rissetto explains 

reliability, the stresses generated by the 

engines on which they are to be fitted. 

However, irrespective of the 

manufacturer, some idlers were found 

faulty in the “cup” version; it appears that 

these faults were caused by the excessive 

tensioning of the timing belt, determined 

by an incorrect assembly of the tensioner. 

For this reason, since the timing belt 

circuit is the same for the various versions, 

attention should be drawn on the 

importance of a correct adjustment, in the 

present case for the Z17DTH engine: 

– the engine must be cold and must have 

been stopped for at least 4 hours; 

– make sure Cylinder nr. 1 is at the TDC, 

then insert the fastening bolts in the 

appropriate holes in the camshaft 

pulley and the injection pump, making 

sure the notch on the crankshaft pinion 

is aligned with the belt reference line 

and with the notch on the oil pump 

guard; 

– position the tensioner and preload it by 

rotating it anticlockwise with an Allen 

key, until the hexagon hole is in a 5 

o’clock position, then secure the 

tensioner with the bolt; 

– install the timing belt, respecting the 

direction of rotation and positioning it in 

the following sequence:: crankshaft 

pulley, oil pump pulley, injection pump 

pulley, camshaft pulley; 

– loosen the tensioner bolt until the 

tensioner rests on the belt, in order to 

apply the correct tension to the belt; 

– remove the pulley fasteners and rotate 

the engine by 60° in the reverse 

direction of normal rotation; 

– secure permanently the tensioner to a 

torque of 38 Nm; 

– let the engine complete 6 settling 

revolutions and make sure that the 

fastening bolts can be inserted freely 

into the pulley holes and the reference 

mark on the crankshaft pulley coincides 

with the line on the belt and with the 

reference mark on the oil pump guard; 

– if not, repeat the above operations from 

the start. 

Should the tensioner be rotated or shifted, 

even very slightly, during the bolt 

tightening stage, the variation of the 

optimal position would cause an 

exponential increase of the belt operating 

tension, thus subjecting the whole system 

to high stresses and affecting its 

functionality and reliability. 

This example clearly shows how 

important it is to have a detailed 

knowledge of the assembly instructions 

for each component and to be able to 

consult them at any time. Dayco considers 

this customer requirement as a priority 

and does its best to fulfil it by all means: 

from the ability to download the relevant 

technical information to the opportunity to 

contact the Aftermarket technician to 

obtain clarifications in case of doubt and 

to avoid the occurrence of problems, 

tackling them at the root, before critical 

situations arise.

Garage 

MAY 2012 

35

Citro CX 25D 2.5 D KTB118 TBSET118 94374+94254 

Citro C25 D 2.5 D 

Peug J5 2.5 D 

FORD Courrier 1.8 D KTB142B TBSET142B 94696+94688 

FORD Escort 1.8 D 

FORD Escort 1.8 D 

FORD Fiesta 1.8 D 

FORD Mondeo 1.8 D 

FORD Mondeo Clipper 1.8 D 

MITS L200 2.5 D KTB268 TBSET268 94012+94019 

MITS L300 2.5 D 

MITS Pajero 2.3 TD 

MITS Shogun 2.3 TD 

ALFA Alfasud III 1.2 KTB275 TBSET275 94140+94140 

ALFA Alfasud 1.35 

ALF Arna 1.2 

ALFA 33 1.3 AS 

ALFA 33 Sport Wagon 1.3 AS 

ALFA 33 Super 1.3 DC 

AUDI A2 1.4 i KTB347 TBSET347 941014+941013 

SEAT Altea 1.4 i 

SEAT Altea XL 1.4 i 


Update Application details for TB SET 

SEAT Cordoba 1.4 i 

SEAT Ibiza 1.4 i 

SEAT Ibiza SC 1.4 i 

SEAT Ibiza ST 1.4 i 

SEAT Leon 1.4 i 

VOLK Bora 1.4 i 

VOLK Bora Variant 1.4 i 

VOLK Caddy 1.4 i 

VOLK Caddy Life 1.4 i 

VOLK Golf 1.4 i 

VOLK Golf Variant 1.4 i 

VOLK Golf SW 1.4 i 

VOLK Golf Plus 1.4 i 

VOLK Golf SW 1.4 i 

VOLK Lupo 1.4 i 

VOLK New Beetle 1.4 i 

VOLK Polo 1.4 i 

VOLK Polo Cross 1.4 i 

VOLK Polo Variant 1.4 i 

VOLK Polo Fun 1.4 

VOLK Polo Cross 1.4 i 

MITS Challenger 2.5 TD KTB400 TBSET400 94522+94658


MITS L300 2.5 D 

MITS L200 2.5 D 

MITS L400 2.5 TD 

MITS Montero 2.5 TD 

MITS Montero Sport 2.5 TD 

MITS Pajero Sport 2.5 TD 

MITS Pajero 2.5 D 

MITS Shogun 2.5 D 

MITS Space Gear 2.5 TD 

HOND Accord Aerodeck 2.0 i KTB437 TBSET437 94212+94213 

HOND Accord 2.0 i 

HOND Prelude 2.0 i 

HOND Shuttle 2.2 i 

ROVE 618 1.8 i 

ROVE 620 2.0 i 

ROVE 623 2.3 i 

HOND Accord 2.3 i KTB444 TBSET444 94212+94433 

HOND Prelude 2.3 i 

HOND Accord 2.0 TDi KTB456 TBSET456 94697+94698 

HOND Civic 2.0 TDi 

HOND Civic Aerodeck 2.0 iTD 

ROVE 220 2.0 TD 

ROVE 420 2.0 TD 

ROVE 620 2.0 Di 

AUDI A4 2.5 TDi KTB472 TBSET472 94839+94755 

AUDI A4 Avant 2.5 TDi 

AUDI A6 2.5 TDi 


VOLK Passat 2.5 TDi 

VOLK Passat Variant 2.5 TDi 

VOLK Transporter 2.4 D KTB473 TBSET473 94523+94774 

VOLK Transporter Allstar 2.4 D 

VOLK Transporter Camper 2.4 D 

VOLK Transporter Caravelle 2.4 D 

VOLK Transporter Classic 2.4 D 

VOLK Transporter Multivan 2.4 D 

VOLK Transporter Syncro 2.4 D 

VOLK LT 28 2.5 SDi KTB489 TBSET489 94775+94774 

VOLK LT 35 2.5 SDi 

VOLK LT 46 2.5 TDI 

VOLK Transporter 2.5 TDi 

VOLK Transporter Allstar 2.5 TDi 

VOLK Transporter Ambul. 2.5 TDi 

VOLK Transporter Camper 2.5 TDi 

MAY 2012 

37

VOLK Transporter Caravelle 2.5 TDi 

VOLK Transporter Classic 2.5 TDi 

VOLK Transporter Multivan 2.5 TDi 

VOLK Transporter Syncro 2.5 DTi 

VOLV S70 2.4 TDi 

VOLV S80 2.4 TDi 

VOLV V70 2.4 TDi 

VOLV 850 2.5 TDi 

Gallo Santamo 2.0 i KTB540 TBSET540 94195+94736 

HYUN Elantra 1.8 

HYUN Lantra 1.8 

MITS Colt 1800 

MITS Eclipse 2.0 i 

MITS Galant 2.0 

MITS Lancer Evolution IV 2.0 i 

MITS Lancer Evolution V 2.0 i 

MITS Lancer Evolution VI 2.0 i 

MITS Lancer Evolution VII 2.0 i 

MITS Lancer Evolution VIII 2.0 i 

MITS Lancer F 1800 

AUDI A4 Cabriolet 2.5 TDI KTB609 TBSET609 94839+94897 





AUDI A6 Allroad 2.5 TDi 




SKOD Superb 2.5 TDi 

FORD Courrier 1.8 D KTB613 TBSET613 94696+94379 

FORD Mondeo 1.8 TD 

FORD Mondeo Clipper 1.8 TD 

HOND Accord 2.0 i KTB661 TBSET661 94212+94460 



HYUN Elantra 1.6 KTB676 TBSET676 94195+94735 

HYUN Lantra 1.6 

MITS Galant 2.0 KTB704 TBSET704 94195+94468 

MITS Space Wagon 2.0 

VOLK Polo 1.3 D KTB720 TBSET720 94386+94237 

VOLK Polo 1.4 D

018248

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