The Garage 336

The
Supporting the Independent Garage and MOT sector
Issue 336
March 2022
Bridgestone’s simplified
sustainable and sporty
range heralded
Under the
Spotlight
Simon Kohler
Marketing & Development
Director at Hornby Hobbies Ltd
Nissens tackles EGR valve
problems on prominent
TDI applications
Please visit our website - www.garageandmot.com
1 Front.indd 1 21/02/2022 16:27

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Boston FP MoT Connected.indd 1 21/02/2022 15:21

The
Supporting the Independent Garage and MOT sector
Issue 336
March 2022
Hello
As I write this the country is in the
process of being battered by multiple
storms; it’s a perfect time to batten
down the hatches and turn to an indoor
activity. If modelling, Scalextric or Hornby
is your choice, you’ll find our ‘under the
Spotlight’ feature this month fascinating,
where we talk to Simon Kohler, Marketing &
Product Development Director at Hornby
Hobbies Ltd.
We’ve caught up with Joshua Rayner from
what3words for our ‘Industry Insight’ this
issue. The company are fast becoming a
household name and we find out their latest
developments in the automotive industry on
page 6.
We’ve got a busy Tyres, Brakes and Exhausts
feature starting on page 30 and in our packed
News pages, there’s an update on June’s UK
Garage & Bodyshop Event at the NEC.
Finally, we take to the skies with GS Yuasa
on page 12, as the battery manufacturer
sponsor air display team The Blades.
Enjoy the magazine.
Paul Gregory Editor
paul.gregory@ppmedia.co.uk
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Editor
Paul Gregory
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Publication Manager
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Mark Blacker
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Ben Coates
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The
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© Partnership Publishing 2020 / 2022 - All rights reserved. No part of the publication may be reproduced in any form without prior consent of the publisher.
3 Comment.indd 1 21/02/2022 17:01

CONTENTS
Inside
TICKETS
ON SALE
NOW!
Carden Park
Country Hotel,
Cheshire
Friday 4 th November, 2022
News
06. Industry Insight - what3words. The Garage Magazine talks
to Josh Rayner, Partnerships Manager at what3words.
08. News - PETRONAS Lubricants International launches
re-engineered PETRONAS Syntium oil range to deliver
maximum vehicle efficiency.
10. News - Gulf Lubricants UK and Titan Group announce a
new partnership to return the iconic Gulf brand back to
the UK Aftermarket sector.
12. News - GS Yuasa, take their sponsorship programme to
new heights by teaming up with world famous air display
team, The Blades.
22. News - How training can future proof and safeguard
an automotive business. We talk to Mandla Ndhlovu,
Training Deliver Director for Autotech Training.
Under the Spotlight
15. Simon Kohler.
Today the Garage speaks with Simon Kohler,
Marketing & Product Development Director at Hornby
Hobbies Ltd.
Tickets for the event are priced at
£110 + VAT per person
and there are various other ways for
companies to support the event.
For all ticket sales and sponsorship
opportunities please contact
Nick Phipps, Call: 01952 415334 or
email: nick.phipps@ppmedia.co.uk
TOW SHOW
2022
WEDNESDAY 28 AND
THURSDAY 29 SEPTEMBER
The largest trade show in the UK
dedicated to the vehicle recovery
and roadside assistance industry
Telford International Centre
www.recoverytowshow.co.uk
Features
32. Tyres
The Garage takes an indepth look at tyres, with Bridgestone,
Continental, Falken and Apollo.
42. Exhaust Systems
Nissens tackles EGR valve problems on prominent TDI
applications. Denso, discus air/fuel ratio sensors and oxygen
sensors – what’s the difference? Plus, NGK, a leading supplier
of Lambda sensors under its NTK brand.
People
48. People stories and movements from around your industry
Your data
The Garage is published by Partnership Publishing and is produced 12 times a year. Your data and privacy is
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4 THE GARAGE
4 Contents.indd 1 21/02/2022 14:40

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INDUSTRYNEWS
Industry insight
what3words
Recently the importance of what3words has
been highlighted in the news, as the brand
and technology becomes more integral to our
every day life, we talk to Josh Rayner from the
company as he looks at the reasons as to the app
now taking off as well as the future of the brand.
The what3words app took off by being installed in new A Class
Mercedes, the automotive industry really is embracing your
technology.
It certainly seems that what3words is taking off and becoming
a standard within the OEM sector as a whole. There really has
been an increasing focus on voice navigation and vehicles.
Lots of things are moving towards voice and software rather
than touchscreen and typing. So, I think that there’s definitely
steps to work out how, or what is the best way to allow people
to input those locations easily inside their vehicles. Mercedes
Benz was the first and they have a really good native system in
all new cars were what3words can be voice or typed input into
their system.
Another industry where your app is used is the recovery industry,
which is proving very successful.
Anyone can use what3words, any organisation or member
of the public. You can download our app or use our map
site for free. You can start training call handling staff to use
these and help improve customer service. what3words is a
global standard, and we want people and organisations to
go out there and use this system. We are also able to build
our technology, our core API, into any system that uses
coordinates, this means that you will be able to type in a three
word address and geocode that location within our system.
what3words are having an impact on the whole of the automotive
industry.
There’s been huge strides, and one of the key things to get
right in the automotive sector is the technology partnerships.
The sort of partners that provide the mapping behind the
software used by OEMs and car makers, for example Bosch,
Tom Tom and Amazon Alexa. We now have 10 automotive
partners on board including Mercedes Benz, Mitsubishi, Lotus,
Lamborghini, Triumph, Tata, Ford, VinFast, and Volta trucks
recently, which we announced at CES 2022. So there really has
been a lot of progress in this area. I think that one of the really
big advantages of what3words is a system that is completely
global and can be used in 50 languages. So, if you’re driving
your car in Germany, or in France, you can navigate that
country using your English voice input for navigation.
We’ve heard some great examples of how the technology can
pinpoint someone, especially in an emergency situation.
One of the projects I’ve been managing for the last year or
so has been the UK emergency services projects. This wasn’t
something that what3words set out to do. It was a originally an
organic use case by certain emergency services who wanted
to use what3words within their operations. It really has taken
off, and now over 85% of automotive services in the UK now
accept a what3words address over 999 which is amazing to
see. We see daily stories of it being used to help find people
or help find people in distressing situations, breakdowns, or
particularly cross organisational situations.
6 THE GARAGE
6, 7 Industry Insight.indd 1 21/02/2022 16:26

INDUSTRYNEWS
Are there any future developments you can announce?
The core product of what3words is there, working and ready to
be used. What we do as a business is B to B or B to C; we build
what3words with our partners into their systems, and then
they in turn offer it to their clients, partners or members of
the public to improve their service in whichever way they see
fit. Delivery logistics partners like Hermes will use our API to
get more accurate deliveries. Addison Lee will use it for better
pickup spots for taxis, Premier Inn will use it to help people
get to the right location of their booking confirmation. So the
actual core technology of what3words is kind of up and running
and has been for years now. It’s much more about working with
partners and helping them to use what3words to improve their
service.
The technology for what3words has been around for a while
now, why has it taken so long for it to be working and making
such a difference in day to day life?
I would say the ecosystem is probably the thing that’s taken
the time. People may have been aware of what3words but was
unsure to how it was relevant for them. I’m a dog walker, and
take my dog to the park, these are the spots where I meet up
with my friends. That person might actually work at a software
company that does logistics and has never even thought about
using what3words as a way of getting parcels to the right
houses, or to canal boats that don’t have permanent addresses
or to like all these other use cases that we see. It is really about
connecting the dots in people’s minds and the sort of network
effect of what3words where someone who’s been using it for
years has never thought about using an X or Y scenario. Now
people have got through that barrier, and there has really been
an explosion in use cases and downloads.
Have you got a final message for the automotive industry?
If you are interested in the automotive sector or vehicle
recovery, please download the app, have a play, see if you
can think of any useful cases with your breakdown partners
or providers. We also have a free API that can be downloaded
and implemented for free on our website. We bill on a usage
basis, so if you build it, don’t use it, you don’t pay for it. There’s
basically a very low barrier to entry to start using what3words
within your system. So, the best advice I can have for people
who are interested is just go on our website and have a look.
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6, 7 Industry Insight.indd 2 21/02/2022 16:27

NEWS
PETRONAS
Lubricants International
launches re-engineered PETRONAS
Syntium oil range to deliver maximum
vehicle efficiency
CoolTech+ technology lays the foundation for a next-gen
product range that exceeds industry sustainability standards
PETRONAS Lubricants International (PLI) recently launched
its new PETRONAS Syntium range, proudly crafted to boost
thermal efficiency, control engine heat dissipation, and reduce
the fuel emissions of passenger vehicles worldwide. With
new CoolTech+ technology supporting the Mercedes-AMG
PETRONAS Formula One Team to an eighth consecutive
Constructors’ Championship, PETRONAS Syntium will enable
motorists to unlock the same optimal engine performance and
achieve stronger sustainability on every journey, cementing PLI as
a world-leading developer of automotive lubricant efficiency.
Most modern engines only convert around one third of their
potential fuel energy into power. Not only is the rest of this
thermal energy left unconverted, but it dissipates as waste heat,
meaning more than half of the useful energy produced by cars
globally is lost to engine inefficiency. Excessive heat can also
cause damage to critical engine parts, such as turbochargers,
pistons, and bearings.
PETRONAS Syntium now offers almost 40% stronger protection
against the wear of critical parts than past generations, targeting
heat-critical zones within the engine to prevent deposit build-up,
extend parts life, and lower maintenance costs. Thanks to
exceptionally strong oil chains, the new PETRONAS Syntium range
also provides up to 68% higher oxidation resistance, controlling
sludge, delaying oil thickening, and maintaining a stable,
8 THE GARAGE
8,9 News Petronas.indd 1 21/02/2022 15:17

NEWS
protective film for maximum engine performance. And with its
superior ability to control heat by reducing friction, CoolTech+
technology cuts vehicle emissions and fuel consumption by up
to 3%, minimising the environmental impact of driving and saving
motorists money.
It’s this attention to detail makes PETRONAS Syntium not
only the fastest hybrid oil in the world but also the number
one choice for the fastest racing team on the planet,
Mercedes-AMG PETRONAS. As their official technology partner,
PETRONAS Syntium with CoolTech+ technology enables the
team’s Formula One car to achieve more than 50% thermal
efficiency, making it the most efficient racing engine ever
created. And now, this expertise is embedded into the new, highperformance
range of engine oils for motorists around the world.
As part of its largest product launch of 2022, PLI has also
redesigned PETRONAS Syntium’s packaging, now using 15% less
plastic across the entire range. The company is also set to launch
a new 20L bag in box packaging that will reduce plastic usage
by up to 90%.while continuing its partnership with sustainability
platform Treedom to combat CO2 emissions. Now recognised
as world-leading technical innovators, PLI believes it’s time
to change and redeploy its skills for a new journey: achieving
net-zero emissions by 2050.
After all, energy is a precious resource. Conserving it and
sourcing it sustainably is now more important than ever. With
so many pressures to contend with, both inside and outside of
motoring, it’s all too easy for drivers to lose their cool and waste
energy. With PETRONAS Syntium with CoolTech+ technology,
motorists can control the heat, make the most of every drop, and
truly maximise efficiency.
Domenico Ciaglia, MD EMEA for PETRONAS Lubricants
International (PLI), said: “Modern vehicles must work harder and
more efficiently to generate more power from smaller engines,
all while consuming less fuel to reduce emissions. That’s why the
new PETRONAS Syntium range focuses on addressing thermal
efficiency and controlling the dissipation of engine heat,
transforming the performance of road car engines for cleaner,
more cost-effective mobility. With our new CoolTech+
technology, motorists can enjoy the confidence to take on the
open road, safe in the knowledge that our products reduce
impacts on their engine, their wallet, and the planet as a whole.”
Availability
The new PETRONAS Syntium range will become available in
March 2022.
VARTA Batteries to be a new exhibitor
at the 2022 Recovery Tow Show
Another positive announcement for the
return to live trade exhibitions this year
is the presence of VARTA Batteries at
the Recovery Tow Show.
This is also being seen in the calibre of
companies already exhibiting including many
from the Automotive Aftermarket, one of
which is VARTA Batteries.
A spokesperson for VARTA Batteries
said “We are delighted to be attending the
Recovery Tow Show this September. We
will show you how to maximise your battery
lifetime with important tips on fitting the
correct battery type and how best to
maintain it. PLUS ‘Enter our free prize draw
to win a battery tester’. We look forward to
seeing you on stand A130.”
Nick Phipps, Tow Show Director added: “It’s
tremendous news we are able to announce
VARTA as a new exhibitor at this year’s show
and we really look forward to welcoming them
and introducing team VARTA to the wider
roadside assistance and vehicle recovery
sector at their annual UK trade event.”
The Tow Show will be returning to the
Telford International Centre on Wednesday
28th and Thursday 29th September 2022. For
more details visit the Tow Show website at
www.recoverytowshow.co.uk
THE GARAGE 9
8,9 News Petronas.indd 2 21/02/2022 16:38

NEWS
Gulf Lubricants UK and Titan Group
are delighted to announce a new partnership
to return the iconic Gulf brand back to the
UK Aftermarket sector
In each area where it operates,
Titan Group will be the
exclusive partner of Gulf
Lubricants as its premium
lubricant offering to the
Independent Garage trade.
Formed by experienced motor factor
managers and trade professionals with
decades of combined experience,
Titan Group is the first employee-owned
motor factor in the UK, working with some of
the leading aftermarket suppliers to provide
premium products of the highest quality.
Dave Woodman, General Manager, Gulf
Lubricants UK, said: “From late 2021, we
have been entrusted to revitalise the Gulf
Lubricants brand in the UK and our aim is to
achieve this through the formation of strong,
long-term, partnerships within each sector
that we operate.
“Titan is setting the standard for a new
model of Motor Factor in the UK and we
are delighted to be part of their journey by
adding Gulf Lubricants as a Premium offering
alongside their existing portfolio of products.
We’re really excited about what we can
achieve together!”
Damon Peacock, Founding Partner, Titan
Group, said: “One of our primary focuses
at Titan is to listen to our customers’
requirements. Finding a premium oil supplier
that shared the same vision and values
wasn’t as easy as you would think!
“After carefully researching the possible
options, Gulf stood out as a partner with
real passion and desire. They have a totally
different approach and want to work with
partners that understand that the oil market
is changing and can embrace that change
and develop long term partnerships with
them.”
Rossmore Lubricants partners with CDG
to deliver Gulf Lubricants brand
Rossmore Lubricants has committed
to continue to support the Convenience
Distribution Group Ltd (CDG), ensuring
improved availability on Gulf Lubricant
products for all Gulf dealers nationwide.
In addition to improved Gulf product
availability, Rossmore Lubricants is also
providing added support to CDG through
simplification of the range required by
forecourts and better communication
materials at point of sale.
Dave Woodman, General Manager,
Rossmore Lubricants, said: “We have been
entrusted to revitalise the Gulf Lubricants
brand in the UK and our aim is to achieve
this through the formation of strong,
long-term, partnerships within each sector
that we operate. CDG is an ideal partner
to help us achieve this within the forecourt
sector given its scale, reach and access
to the Gulf forecourt estate – allowing for
faster delivery times and no minimum order
quantities.
“We understand the complexity for
forecourts in stocking and recommending
the correct lubricant and, for this reason,
we are providing a simplified set of support
materials to help provide better advice. A QR
code at point of sale, directed to our online
lubricant advisor, will also help to better
advise the consumer.
“The partnership with CDG is a natural
choice and we look forward to working
together to improve the lubricant buying
experience for both forecourts and
consumers alike!”
Graham Tissiman, Sales and Marketing
Manager of Convenience Distribution Group
added: “We at CDG are delighted with the
opportunity to distribute the high-quality
Gulf Lubricant range and are looking forward
to working with the Gulf dealer network. We
believe we will develop a strong partnership
that will benefit all parties.”
Gulf Oil Supply Company Ltd, part of Gulf
Oil International Ltd, recently announced
that it has appointed Rossmore Lubricants, a
new distributor, to represent Gulf Lubricants
throughout the UK & Ireland.
Rossmore Lubricants, established in 2021
with the sole focus of representing Gulf
Lubricants across the UK & Ireland, signed
an agreement to become the sole Gulf representative
and distributor of the Gulf range
of lubricants for these key markets and
commenced activities in December 2021.
10 THE GARAGE MAGAZINE
10,11 News Blog.indd 1 21/02/2022 15:23

NEWSBLOG
Banner winter
promotion proves
the ‘Perfect Fit’
DAYCO ADDS ELECTRIC
WATER PUMPS FOR ELECTRIC,
HYBRID AND ICE VEHICLES
As Banner brings the curtain down on its latest winter sales
promotion, the leading manufacturer of batteries and battery
accessories has hailed it another campaign success. Indeed
feedback from the aftermarket on the receiving end of the
promotional goodies was nothing but encouraging. It seems
that the Banner branded gloves on offer with every Banner
branded battery purchased between the promotion dates of
December 1st 2021 to January 31st 2022 proved the perfect
fit!
As Country Manager, Lee Quinney states: “This year’s glove
promotion has proved to be a big hit not just with garage
technicians, but also those who work in frontline parts and
distribution and delivery across the automotive aftermarket.
They are, after all, very much an essential item in today’s
working environment.”
And whilst the feedback from every single campaign that
we have run over the last six or seven years appears to have
stuck an accord with our aftermarket customers, the novelty
of this year’s campaign appears to have reached another
level. On that note, and not surprisingly, we are already
turning our attention to trying to top this once again later in
the year. So watch this space,” he added.
Subscribe to
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D
ayco has further expanding its thermal management
portfolio with the introduction of electric water pumps
(e-pumps), for not only hybrid and electric vehicles
(EV), but for selected traditional internal combustion engine
(ICE) powered applications.
When it comes EVs and selected hybrid applications,
e-pumps are the only solution assuring correct temperature
management of the inverters and battery packs, for example.
Nowadays, to maximise efficiencies for ICE thermal
management, maintaining different operating temperatures
around the engine is a necessity. To optimise the combustion
process for example, the cylinder head area needs to run
several degrees hotter than the block, where, to enhance
the performance characteristics of the oil, it needs to run
cooler. These differences would not be possible without split,
or dual, cooling systems and the use of additional, electrically
operated ‘on demand’ e-pumps to supplement, and in some
applications, replace, the system’s mechanical pump.
As a result, to support its aftermarket customers and to
provide installers with the service and repair solutions they
need, Dayco has introduced a wide range of main and auxiliary
e-pumps to its thermal management programme. The company’s
water pump offering, which is naturally manufactured to OE
equivalent standards, is under continuous development and
reflects the requirements of an ever-changing market.
To further underpin the e-pump offering, Dayco
also provides the technical advice and fitting tips, and
comprehensive cataloging support for which it is renowned, to
ensure these new to range additions are a superb aftermarket
solution for installers and wholesalers alike.
For more information regarding the OEM quality
power transmission products in the Dayco range,
please email: info.uk@dayco.com
or visit: www.daycoaftermarket.com
THE GARAGE 11
10,11 News Blog.indd 2 21/02/2022 15:23

Yuasa get set for takeoff
with world famous air
display team The Blades
Yuasa, a brand of global battery manufacturer GS Yuasa, are taking their sponsorship programme
to new heights by teaming up with world famous air display team The Blades. The partnership
will see Yuasa logos feature prominently on the team’s four aircraft as they perform exhilarating
close-formation aerobatic displays to well over four million people at events in 2022.
Flown by a team of former top
Red Arrows pilots, The Blades’
award-winning displays feature over
30 high G manoeuvres, some of which
involve flying as close as four feet apart.
They are firm favourites at major events
including the likes of The Bournemouth Air
Festival, Goodwood Festival of Speed and
The Royal International Air Tattoo.
As well as these spectacular
appearances, The Blades are the world’s
only aerobatic airline… which means
they fly passengers in formation and
through a host of aerobatic moves.
They also regularly feature on television
programmes and in media articles flying
journalists, presenters and a whole host
12 THE GARAGE
12,13 News GS Yuasa.indd 1 21/02/2022 15:08

NEWS
of A-list celebrities that have included
Ant and Dec, James Corden and Mark
Webber.
Since launching in 2006 the team
have been watched by over 60 million
spectators and flown over 3,500
passengers. They are also the reigning
World Formation Aerobatic Champions.
Yuasa are the UK’s leading brand of
vehicle and industrial batteries, which
are used by millions of people to power
everything from trips to the shops to
missions in outer space. Their new
partnership with The Blades will take the
company’s brand awareness to new levels
by engaging families and enthusiasts at air
shows, which are regularly hailed as the
largest spectator attended events in the
country behind only football.
James Douglas, European Group
Marketing Manager of GS Yuasa Battery
Europe Ltd, said: “We are delighted to
announce our sponsorship of The Blades.
We believe our solid partnership will be
a winning one. With former Red Arrows
at the controls, precision flying, and a
busy schedule of display and experience
flying, the team very much share, and
demonstrate, our own core values of
quality, reliability, performance, and
teamwork in everything they do.
“This fantastic new partnership really
does take our sponsorship programme
to an exciting new level, with the team’s
breath-taking close formation aerobatic
displays being watched by millions of
people every year. We will be working
closely with the team on many exciting
events and projects throughout 2022 so
the sky’s the limit!”
Ben Murphy, Head of The Blades
added: “We are excited to head into the
2022 season with GS Yuasa; two forward
thinking teams that share the same values
of quality, continuous improvement, and
teamwork.
We also share a great passion for
motorsport and seeing what can be
achieved when man and machine strive
for perfection and top-level performance;
we just do it in the air rather than on the
ground! There are so many crossovers
between us, and we look forward to
this partnership going from strength to
strength.”
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THE GARAGE 13
12,13 News GS Yuasa.indd 2 21/02/2022 15:08

NEWS
UK Garage and Bodyshop Event
kickstarts new year with unrivalled
backing from aftermarket
The new UK Garage and Bodyshop Event, presented by Automechanika, has kickstarted 2022 on a high,
with a host of renowned automotive companies committing to exhibit at this year’s national launch event.
The latest additions to the already
impressive line-up include newly
announced Platinum Partners, LKQ
Euro Car Parts, Bilstein Group (Blue Print
& febi Bilstein) and Castrol with their
ambassador partner, The Race Group.
They join other event partners Autogem,
Automotive Alliance Group (Group Auto),
Bosch Automotive Aftermarket UK, Bosch
Car Service, Dayco Europe, Liqui Moly UK,
Snap-on Diagnostics, Thatcham Research,
The Tool Connection and ZF [pro]Tech,
along with a growing exhibitor list of 50+
leading suppliers to the UK garage and
bodyshop sectors.
ZF[pro]Tech, one of the first sponsors
for the event explains: ‘This event gives us
a great opportunity to engage directly with
our end customers at a time where such
support is much needed. With so much
change and development taking place in our
industry, it is imperative we take a proactive
approach in regards to delivering training,
advice and support to our networks,
ensuring our industry is equipped to face
the future.’
Backed by the leading industry
associations including GEA, HEVRA, IAAF,
IGA, IMI, NBRA, School of Thought, SMMT
& The Motor Ombudsman, with more to be
announced, the event has the full weight of
the industry behind it and is set to be the
event for the aftermarket in 2022.
“With industry skills at the top of the IMI’s
agenda, we are delighted to be supporting
a national event dedicated to the garage
and bodyshop sector,” explained Steve
Scofield, Head of Business Development
at the Institute of the Motor Industry. “We
are planning a strong presence, supporting
the expert-led training programmes
and addressing the widening skills gap.
In particular, we are excited to have the
opportunity to talk to those working in
garages and bodyshops about the immense
career opportunities that electric vehicles,
ADAS and other automotive innovations
offer for those with the right skills, with
IMI TechSafeTM providing the industry
standard. The event presents an important
opportunity for the aftermarket to come
together and take our industry forward and
we are proud to be supporting it.”
Taking place 8-9 June at the NEC
Birmingham, the event is designed for
visitors to engage directly with the latest
training, technology and tools for the
garage and bodyshop sector. In a highly
interactive format visitors will have free
access to three technical hubs delivering
60+ sessions on expert training and advice,
as well as interactive feature areas including
a Collision Repair Demonstration Zone,
Modern Workshop Showcase and a Garage
Equipment Showcase. A further three
networking areas will provide visitors access
to leading industry experts and business
advice to ensure the event is a one-stop
shop for every business need, from both
a technical and business management
perspective.
Project Director at Messe Frankfurt UK,
Kristan Johnstone, said: “The UK Garage and
Bodyshop Event brings a unique and tailored
offering to the aftermarket after extensive
consultation with the industry. The focus
on showcasing practical demonstrations
of new technologies, products and training
initiatives is what our captive audience
of garage and bodyshop customers has
asked for, especially as this will be the
first major opportunity to do so since the
return of face-to-face events. Since the
announcement, the event has proven
incredibly popular, and we’re delighted to
kickstart the year with the further support
of some of the industry’s key players.”
14 THE GARAGE
14, News UK Garage.indd 1 21/02/2022 15:28

UNDERTHESPOTLIGHT
Under the Spotlight
Every child’s
dream job
It’s a very good chance that as a young child, one of Hornby’s brand
names would have been one of your favourite toys.
Under the Spotlight this month chats with Simon Kohler,
Marketing & Product Development Director at Hornby Hobbies Ltd.
Aboom in the hobby market has
boosted the companies fortunes with
plastic kits and trains flying of the
shelf but the tracks haven’t always been
smooth with the Margate based company
experiencing a turbulent past. As Marketing
and Product Development Director, Simon
Kohler may just have every little boy or
girls dream job; endless supply of cars, a
warehouse full of kits and as many pots of
paint as he needs. How did he find himself
in the position of looking after some of
Britain’s best loved brand names?
After leaving school and working initially
for the Inland Revenue then a local concrete
mixing business, Simon was approached
by his friend who asked him to help in his
father’s model shop. “I was approached by
one of my friends, his father had passed
away and he asked me if he could help run
his model shop. So, in 1971, I entered into
the model business. You learn a lot in retail,
talking to the consumer, manufacturers,
local reps etc, so I really got to know
the industry. But after seven years, I was
thinking am I going to be doing this for the
rest of my life?”
“I answered an advert for a company
that had recently been taken over by
Hornby, Hammant & Morgan, they produced
transformers for model railways. After
an interview I was given the job. It was a
good company and product, and after
Hornby took over it was looking to expand.
Although I was enjoying working for them,
going to exhibitions showing off their
products, meeting new people etc there
THE GARAGE 15
15,16,17 Spotlight.indd 1 21/02/2022 15:43

Under the Spotlight
was a few changes in my life. My brother
had offered me a position with his forklift
business, and I was at the point of resigning
and working for him. The details had been
organised, company car, business cards
etc and I was going in with my resignation
letter. Coincidentally, Hornby were at the
same time holding a board meeting, which
resulted in them offering me the position of
brand manager. It was a great opportunity,
one which I couldn’t turn down. My brother
was really good about it, and I moved to
Margate and joined Hornby in 1981.”
“At that point, Hornby was owned by a
holding company. Shortly after I joined,
they branched out on their own and
started expending their product line. It
was an exciting time; we didn’t have a lot
of money so I had to make do and mend.
You had to get creative with marketing and
advertising; you will be surprised about how
much printing you can get for a couple of
Scalextric sets. It was an exciting time, the
whole of the Hornby team were learning as
we went along.”
By the mid 90’s, Hornby’s attention was
once more focused on Scalextric and
Hornby. The quality of manufacturing in
China was increasing. “We were losing
ground. I decided to pay for myself to
go over to China and have a look at their
techniques. I was only there for a week and
learned a huge amount. I came back and
said if we carry on the way we’re going,
we will close the doors. We then had a big
management change. A new chief executive
arrived with new ideas. The manufacturing
was moved to China, focusing on more
detailed products. The fortunes of Hornby
went up like a rocket. Our first locomotive
we’d manufactured in China sold over
17,000 pieces alone. Unfortunately, we then
had the financial crash. We had too many
eggs in one basket, with the manufacturer
in China not being able to produce our
products. There were delays and all sorts
of problems. We had another management
change with fresh ideas. One of them was to
totally destroy the marketing department,
people who were incredibly passionate
and knew the product. We were notified
in Christmas 2013 that the department
was now defunct. So, I took voluntary
redundancy. I always said if I don’t want to
go to work, that’s the time when you leave.
I could see the way things were going, it was
it was on a suicide trip.”
“After I left, I did consultancy work,
which was interesting. I worked for the
Science Museum and all sorts of different
companies. By then I’m reaching a particular
age milestone and I thought I may as well
stick with clients I like. One of them was
gentleman called Lyndon Davies, who
owned a business called Oxford Diecast. He
was actually approached in 2017 to become
the Chief Executive of Hornby. The fortunes
at Hornby were then hanging by a thread.
He accepted with the proviso being that he
could bring his own team in. He asked me
if I would like to come back, and it took me
about a nanosecond to say yes.”
On his return to Hornby, Simon found
things a little different.
“On the first day back, I walked into the
building, sat down, and the Hornby team
saw me, and they started to applaud, which
was actually quite nice. I had also brought
them a load of doughnuts so that may have
had something to do with it. Just walking
around meeting people, you felt that at
least something now was going to happen.
You had people there who knew what
they’re doing.
“The previous management had moved to
some really depressing building in Sandwich
and left Margate, which was the home of
Hornby. We started basically from scratch.
I walked into a company I didn’t recognise;
any of the systems and a lot of people. It
was just pure, bloody chaos. What you have
to do in this business is you have to plan
ahead, and you have to place orders ahead
or you don’t get. So, the first thing was to
try and get some order and having the right
people and the right team.
Then it really was let’s go back to basics.
The product line plans were sorted, with
the correct order quantities. Hornby at the
time had a really atrocious name, a bad
reputation. Lyndon knows about working
with Chinese manufacturing and went over
to China and persuaded them that we
were genuine, we were on the right track.
Believe it or not, we had to do that on more
than one occasion with companies here
like Land Rover, etc. The National Railway
Museum was another one where we had
to prove to them we were genuine, that
we’re not like the previous management.
We were re-establishing relationships.
Gradually the fortunes turned round. We
have just launched our 2022 range and the
reaction we’re getting is probably the most
successful for some time.
The COVID outbreak in 2020 was
obviously disastrous for some companies,
but with people spending more time at
home, many with time on their hands, the
hobby market took off. Hornby customers
new and old were turning back to their old
pastimes, with a demand for their products.
“I think with all the investment we had
done in tooling; it would have happened
anyway. But we were lucky that the
warehouse stayed open, and we were able
to push products out. It just so happened
16 THE GARAGE
15,16,17 Spotlight.indd 2 21/02/2022 15:43

UNDERTHESPOTLIGHT
Simon Kohler, Marketing & Development Director at Hornby Hobbies Ltd
that 2020 was Hornby’s 100th anniversary.
We had so many great plans, and special
events. Of course, with the country locking
down, the celebrations were put on hold
and we had to come at it from a different
angle.”
“We had two people handling social
media, but we spotted an opportunity,
people needed support entertaining their
children. Each of the brands put together
pages with competitions, word searches,
colouring competitions, etc. We expanded
that to the social media side. So now each
brand has its own social media team. So
really since 2020 the social media side has
become a major part of our marketing.”
“We also wanted to celebrate the NHS
and give them something back. A model
locomotive ‘Captain Tom Moore’ special
issue was produced with all the profits
going to the NHS, we hoped it would raise
around £17,000 but it ended up at £140,000
which was amazing.”
In 2021, Yesterday TV Channel began
broadcasting ‘Hornby: A Model World’ giving
viewers a behind the scenes look at Hornby
and making stars of some of the team. The
producers approached us with a ‘fly on
the wall’ idea. We were wary it would be
some sort of hatchet job, but they put our
minds at rest. They started filming in late
2020, with the restrictions there was just a
cameraman doing all the jobs himself. They
just fitted into the business and didn’t get
in the way. All the feedback we’ve had from
the programme has been very positive.
They have to make a programme that
appeals to the masses, it’s fired people’s
interest. It’s got people back into model
railways or getting the old Scalextric out.
Most people have found it fascinating.”
Overseeing the future and development
of some of the public’s best loved brand
names comes with a unique set of
responsibilities. Rather than being a key
figure at the top of a business, I suggest
Simon has got more in common with a
football chairman; having to balance the
profits of a business with the feelings and
fanbase of your customers. “What we’re
selling is fun. The key thing is, you have to
remember is that people don’t necessarily
need to buy our product. They don’t need
us, so we have to try that bit harder to
make people say ‘Yeah, I want Hornby’.
Modelling is entertainment. It may be a
model railway or model aircraft and if
you’ve had a bad day, you now focussed
on making a tree or painting a wheel and
by doing all that, all of that day’s trials and
tribulations start to disappear. We’re very
conscious of the benefits of modelling and
how it can help mental stress.”
Hornby are in a great position at the
moment, but what can we expect in
the future? “The future is pretty good.
Obviously, we’re all faced with increasing
prices, which we have to pass on. So,
this coming year will be one of positive
challenges. We’ve got new tooling coming,
the 2022 ranges have been well received.
What we have planned for 2023 and 2024 is
equally exciting, if not more exciting. So yes,
very positive.”
THE GARAGE 17
15,16,17 Spotlight.indd 3 21/02/2022 15:43

NEWS
IDTechEx discuss being
a motor manufacturer
in a materials crisis
Author: Dr James Edmondson, Senior Technology Analyst
The past two years have been
extremely turbulent for many
industries with production lines
shutting down, chip shortages, and a host
of general supply chain issues. Amongst the
dismay, electric vehicles (EVs) have been a
shining light. In 2021, sales of EVs globally
grew by around 80% over 2020 which in
turn was a growth of 44% over 2019. So,
in the midst of all of these shortages, the
demand for EV components has been
drastically increasing. Whilst much news
is focused towards the battery pack (and
rightly so), the electric motors are equally
critical to an EVs operation. EV motors
rely on a host of materials including rare
earths, copper, aluminum, and steel. These
materials have seen sharp rises in price
over the past two years and this impacts
the margin that a motor manufacturer can
obtain. How could motor design changes
help with this issue and what steps are
already being taken?
The electric motor market for EVs is
one that IDTechEx follows closely, with
research reports such as “Electric Motors
for Electric Vehicles 2022-2032” and
continued interviews and projects with
motor manufacturers in the industry
available through its “Future Mobility”
platform.
Price Increases for Motor
Materials
Motors widely used in EVs can largely be
categorized into permanent magnet (PM)
motors, induction motors, and wound
rotor motors. These motors generally
use copper wire in the stator (stationary
component), the difference is in the rotor
(rotating component). PM motors utilize
rare earth magnets on the rotor, induction
motors utilize copper or aluminum cages
or windings, and wound rotor motors utilize
copper windings on the rotor. Each design
has inherent pros and cons, but if we just
consider the materials, there are some
significant differences in cost between
designs, this is compounded when we look
at the volatility of materials prices over the
past two years. The price of neodymium
(the main rare earth for magnets) in
January of 2022 has increased by over
200% compared to its 2019 value, copper
by 59%, aluminum by 62%, and steel by
24%.
Materials prices have increased dramatically in 2021. Data source:
IDTechEx, Trading Economics
This sort of volatility can be a serious
issue for motor manufacturers and OEMs.
In fact, Japanese motor manufacturer
Nidec reported a drop in operating profit
in the final quarter of 2021, with one of the
stated causes being the increase in copper
prices. 5-10 kg of copper are typically used
in an EV motor and make up a significant
portion of the bill of materials, this varies
depending on design, with wound rotor
motors utilizing more than the other types.
More drastic price issues can be seen with
PM motors where that huge 200% price
increase is worsened by the fact that 1-2
kg of magnets are used and the price of
neodymium is, on average, 13 times higher
than copper. The choice of materials used
in an EV motor is critical to the bill of
materials and hence the profit margin that
can be obtained. Is it worth taking minor
performance detriments to change how
materials are utilized?
Motor Design Changes
In 2021, 83% of electric motors in EVs were
PM motors, a figure which has risen 6%
since 2020. Typically they provide the best
power density and efficiency and the prices
of rare earths have remained fairly stable
over the past 10 years (until 2020/2021).
A significant reason for the increasing PM
motor share has been Tesla’s adoption of
a PM motor replacing an induction motor
in the Model 3 and subsequent models.
However, due to the high cost and severe
price volatility of rare earths in 2011/2012,
several manufacturers have opted for
alternatives. Audi’s e-tron uses induction
motors with aluminum rotor segments
and Renault uses a wound rotor design.
More recently, BMW’s 5th generation drive
system also uses a wound rotor design with
copper windings on the rotor.
Whilst wound rotor and induction
motors eliminate the reliance on expensive
18 THE GARAGE
18,19 ID Tech.indd 1 21/02/2022 15:26

NEWS
Permanent magnet motors currently dominate the EV market. Source:
IDTechEx - “Electric Motors for Electric Vehicles 2022-2032”
rare-earths, they can increase the reliance
on copper, another material that has
experienced a significant price increase.
A question several have asked is whether
the copper in motors can be replaced by
aluminum to further reduce costs? Whilst
aluminum is lighter and cheaper than
copper, the trouble is that aluminum is less
electrically conductive, requiring a greater
volume of metal. So, whilst aluminum
windings can provide weight and cost
savings, they sacrifice volumetric power
density. Despite this, we have still seen
some players opt for this approach,
such as UK-based manufacturer
Advanced Electric Machines, which
uses a compressed aluminum winding
technology to not sacrifice the
volumetric performance and avoid the use
of any rare earths or copper windings.
Concluding Thoughts
In general, electric motors are a mature
technology and most of the cost is down
to the bill of materials. As the EV market
ramps up and if material prices continue
to be volatile, it would not be surprising to
see more OEMs and tier 1s adopt magnet
free designs in the near future. Thanks to
China’s current control of the rare earth
supply, they are likely to largely remain
with PM motors and hence a very large
portion of the global market remaining with
that technology. In other regions, it will
be interesting to see how the market and
designs of electric motors evolve.
IDTechEx’s report on “Electric Motors
for Electric Vehicles 2022-2032” details
OEM strategies, trends, and emerging
technologies within the motor market for
EVs. An extensive model database of over
250 EV models sold between 2015-2020
aids in a granular market analysis of motor
type, performance, thermal management,
and market shares. Technologies
and markets are considered for cars,
two-wheelers, light commercial vehicles
(vans), trucks, and buses along with several
use-cases and benchmarking. Emerging
technologies are also addressed with
market forecasts through to 2032 such as
axial flux and in-wheel motors.
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THE GARAGE 19
18,19 ID Tech.indd 2 21/02/2022 15:26

NEWS
Delphi Technologies
strengthens its ADAS
training offering with
three-part online course
Delphi Technologies is continuing
its drive to help those working in
the aftermarket to understand and
service the latest automotive technologies
with the introduction of a new online
training course covering how today’s car
lighting systems are tied into ADAS safety
functions.
Accessed via the Delphi Technologies
Academy e-learning platform, the new
three-part course begins with an insight
into the evolution of lighting technology
and culminates with a practical
demonstration of how ADAS connected
lighting systems work on the road. An end
test is then available to participants, with
those reaching the required level able to
download a certificate to show the course
pass and earning IMI CPD credits.
The new course strengthens the
ADAS-focused service offering from
Delphi Technologies, which spans training
to its easy-to-use ADAS recalibration
modular kit that is compatible with the
most popular vehicle brands. Together
with electric vehicles, ADAS training is the
most in-demand by Delphi Technologies’
customers, showing how garages are now
seeing the need to be able to service the
latest technologies.
“Lighting has changed massively in the
last 30 years, from simple Sealed Beam
units right through to Laser lights and
ultimately those that are now increasingly
integrated into ADAS functions,” said Phil
Mitchell, Technical Services Manager,
Delphi Technologies Aftermarket.
“With more and more cars rapidly
featuring some level of ADAS, such
advanced lighting is only going to get
more common, and we want to give
independents and individuals the chance
to be able to service it. Our latest course
provides a fantastic understanding of
what’s involved.”
By using the Delphi Technologies
Academy online training platform
participants can expand their knowledge
in a highly convenient and cost-effective
way, the facility overcoming many of the
time and cost issues that independent
garages and individuals face when
pursuing training that is essential in
keeping their skillsets up to date.
Further information on the Delphi
Technologies Academy can be found at:
https://academy.delphiautoparts.com/
20 THE GARAGE
20 News Delphi.indd 1 21/02/2022 15:27

We care about tyres
that care about drivers.
Every day, for the last 150 years we have reinvented the wheel,
striving to improve what appeared already perfect.
www.continental-tyres.co.uk
Continental FP.indd 1 21/02/2022 15:50

NEWS
How training
can future proof
and safeguard
an automotive
business
By Mandla Ndhlovu,
Training Deliver Director for Autotech Training
Automotive technology is changing rapidly, and cars are
getting increasingly complex. Vehicle technicians not
only need a huge amount of mechanical skill they also
need an excellent ability to engage with customers and be
able to explain what repairs are needed on their vehicles.
Without this, they risk jeopardising customer confidence and
losing repeat business to the competition.
Even the most experienced vehicle technician requires
ongoing training to ensure they remain current in this evolving
industry. However, training garage and workshop staff can
still be a low priority for many employers, particularly those
working within the independent sector. A survey* conducted
by LKQ Euro Car Parts, revealed that 29% of independent
garages sometimes turn away work because they don’t have
the skills to service modern vehicles.
This is largely down to the fact that employers are already
suffering from a shortage of skilled vehicle technicians and
releasing them for just a day’s training can have a financial
impact on the business. However, over the long term, not
building in a culture of ongoing training could cost a garage
thousands of £££’s in lost revenue.
Training will not only create a counteract this but
ensure that the garage retains the best talent.
There are many ways in which training can be delivered.
For instance, using online training platforms can be an
efficient way of updating a vehicle technician’s knowledge
and identifying which areas of automotive systems they
need further training on. Equally, to minimise travel costs
and time away from work, training providers, such as
Autotech Training, can deliver a course on the premises of
any garage or business looking to upskill their employees.
With complex vehicle technology increasingly filtering
through the aftermarket for repairs, such as advanced
driver assistance system (ADAS,) being able to match
demand with skills isn’t the only motive for training.
Insurance can be compromised if a technician is unable
to repair a vehicle safely and an employer may find
themselves liable if an untrained vehicle technician injures
themselves while carrying out even the most basic of
repairs on an electric/hybrid vehicle.
To create a training plan to suit your garage needs exactly
contact hello@autotechtraining.co.uk or visit
www.autotechrecruit.co.uk/training/
22 THE GARAGE
22 News Autotech.indd 1 21/02/2022 15:29

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Introducing . . .
Services Provided:
There’s no short answer to that. Back in 2015, our American
parent company, Integrated Supply Network, which, by
the way, is America’s largest independent automotive
tool & equipment specialist, entered the UK; acquiring
four businesses over a period of roughly two years. These
businesses gave us an immediate foothold in what are
currently our 3 core business areas; specialist tools for
technicians, garage equipment sales, and service, which
includes workshop design and build, equipment installation
and training, routine service and maintenance, MOT bay
management and emergency breakdown services.
Those businesses were J&S Products, which trades
as ToolTruck, Hofmann Megaplan, Tyre Bay Direct and
AMN Garage Services (now ISN Garage Assist) but, more
importantly, it gave us the people capable of driving the
business and matching the ambition of that on the other
side of the Atlantic.
Years in Business:
Well, obviously, ISN Europe has only been around since 2015
but Integrated Supply Network was established in the USA
in 1985. All four of the businesses that now make up ISN
Europe are, of course, well established in the UK.
Where you are based:
ISN Europe is based just outside the Village of Kimbolton,
near Huntingdon in Cambridgeshire, which is where most of
the admin team operate from but ToolTruck still operates
out of Norwich. Our team of over 60 installation and service
engineers are located all over the country though.
Companies Biggest Success:
Ha ha! That’s definitely still to come. Our biggest
achievements include staying fully operational all the way
through the last two Covid disrupted years, and successfully
integrating the four businesses and their people at the same
time.
What’s the Future for ISN Europe:
Sustained and steady growth. The foundations are in place,
we have the resources and we have a fantastic team to
bring everything together. As the vehicle parc shifts towards
electric propulsion, we’ll continue to develop the range
of products and services we offer to support the UK’s
automotive workshops for their current and future needs.
One question you would love to be asked:
Of all the brands you have in your armoury, is there one that
you see as being the most powerful?
Answer to the above:
It’s got to be Hofmann Megaplan. Alongside Hofmann, we
do own other great machinery brands, including Redback,
Atlas and Atlas Platinum, so we’re able to provide really
good quality garage equipment no matter what your budget;
but Hofmann has a reputation for ultimate quality and a
heritage going all the way back to 1931. Hofmann built its
reputation on wheel balancers and tyre changing machines
but the range now includes vehicle lifts, compressors,
wheel alignment, ADAS, MOT bays, truck and mobile fitting
equipment. We even have a range of equipment specifically
designed for Electric and Hybrid Vehicles. Hofmann
equipment will never be the cheapest and we will never
apologise for that, because we strongly believe it’s the
best – and, in our opinion, ‘cheap’ and ‘best’ have yet to be
combined.
ISN
T: 01480 884 885
W: isn-europe.co.uk
24 Introducing.indd 1 21/02/2022 15:31

AROUND THE WHEEL
Equipment and Tools Solutions for the Tyre Industry
megaline
The UK’s most comprehensive CCD
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Traditionally built and
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favoured by tyre technicians for
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ISN The Europe Garage Hofmann ad January FP.indd 2022.indd 1 1 21/02/2022 17/01/2022 15:32
11:41

NEWS
Making
workshop
life simpler,
despite the
complexity
Cars are continuing to evolve, becoming more powerful, more environmentally friendly, more
comfortable, and safer. At the same time, they are becoming more complex, and with each
new innovation, independent workshops have to familiarise themselves with yet more
technology. That is why it’s good to have a partner like Schaeffler Automotive Aftermarket
on their side, because the company’s objective is to make things easier for them and their
customers, despite all the complexity involved.
‘Convenience’ is one of the key focus
points of Schaeffler Automotive
Aftermarket’s strategy designed to
shape the future of the independent
aftermarket. However, is convenience
really possible at a time when both cars
and the replacement parts they need are
becoming steadily more complicated? As
digitalisation and electric mobility gains
ground and the number of repairs and
services requiring special expertise and
tools continues to grow, along with the
pressure on workshops to work profitably
and efficiently?
It is a challenge, but one that can
be overcome with system expertise
and market knowledge, explains Jens
Schüler, President GKAM, Global Sales
& Marketing, Schaeffler Automotive
Aftermarket: “Schaeffler is a renowned
specialist and innovator in the powertrain,
engine and chassis segments, and a
leading global development partner for
vehicle manufacturers. Our Automotive
Aftermarket division is a longstanding and
reliable partner that provides support
and inspiration to the independent
aftermarket and independent workshops.
There is no organisation better placed
than we are to provide the right answers
to important questions the future of car
servicing.
Electric mobility, Industry 4.0,
and digitalisation as opportunities
Tapping into new trends, along with
preparing for them in advance, is
essential for the long-term success of a
workshop. Schaeffler is therefore working
on solutions that allow workshops to
participate in new trends, by helping
shape the process of digitalisation for
example: “We consider digitalisation to be
an opportunity to support complex repair
procedures on-site and intensify the
dialogue with our customers worldwide,”
says Schüler. REPXPERT will play an
increasingly important role in this context,
as the Schaeffler service brand provides
workshop professionals with appropriate
special tools and repair support, not
just via traditional channels like personal
training and hotlines, but increasingly
through digital formats such as virtual
installation instructions and training
sessions.
At the same time, Schaeffler is helping
to ensure that independent workshops do
not lose out on the opportunities offered
by electric mobility. For example, the
company has its sights set firmly on the
independent aftermarket as it develops
e-axles and hybrid modules for electric
vehicle manufacturers all over the world.
When electric vehicles become
relevant for the independent aftermarket,
Schaeffler will be ready with an aligned
portfolio of repair solutions and services
to support workshops, solutions that will
make it easy for garages to benefit from
the increasing prevalence of electric
vehicles, allowing them to tap into this
new segment and thus secure a profitable
future for their business.
Information on Schaeffler products,
fitting instructions, labour times and much
more can be found on the REPXPERT
workshop portal – www.repxpert.co.uk
– the REPXPERT app, or by calling the
Schaeffler REPXPERT hotline on 0872 737
0037.
26 THE GARAGE
26,27 Schaeffler.indd 1 21/02/2022 15:48

THE QUEEN’S AWARDS
FOR ENTERPRISE:
INNOVATION
2020
NEWS
PatFluid®
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Take Compliance Control!
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• Cost effective & highly
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temperature of soot trapped in the filter
• Transfer Kit available to refill the on-board tank
• UK aftermarket product of choice for over ten years
TruFleet is a brand-new fleet and O’Licence system for
planning and managing all vehicle compliance requirements.
Contact us today on +44 (0) 1293 804 770
or email: info@cdti.com
Live maintenance planning
Visibility of vehicles and drivers
Interactive dashboards and alerts
DVSA Earned Recognition accredited
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Tax, insurance and tachograph
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Online document storage for
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– TruFleet is fully compatible with TruTac’s modular suite of TruControl software
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THE GARAGE 27
26,27 Schaeffler.indd 2 21/02/2022 15:49

NEWS
Gulf Formula
Elite becomes
McLaren
Automotive
first fill lubricant
Gulf is proud to announce that Gulf Formula
Elite is now the first fill lubricant in all McLaren
Automotive supercars and hypercars that leave
the McLaren Production Centre in Woking, Surrey,
England.
As part of a long-term partnership, McLaren
Automotive will also give its customers access to Gulf
Formula Elite, a high-performance lubricant, as its
preferred supplier.
The technology teams at Gulf and McLaren
Automotive have worked collaboratively to develop
and test a lubricant that offers the ultimate protection
for McLaren’s high performance V8 and V6 engines
even in the most extreme conditions, to deliver
sustained peak performance.
Gulf Formula Elite uses Thermoshield Technology to
meet McLaren’s exacting performance and efficiency
demands by forming a robust coating on all critical
engine parts for enhanced wear defence. Gulf Formula
Elite maintains optimum temperature by helping to
dissipate heat, actively prevents oil deterioration, and
helps to provide greater deposit control.
Mike Jones, Chief Executive Officer, Gulf Oil
International said: “Our technical partnership with
McLaren Automotive enables Gulf to offer its industryleading
expertise and world class R&D capabilities to
accelerate the development of high-performance
technologies like Gulf Formula Elite.
“We are committed to helping McLaren Automotive’s
relentless drive to be the best and are excited to be
able to share our latest world class product – Gulf
Formula Elite – with McLaren’s customers.”
Gareth Dunsmore, Chief Marketing Officer, McLaren
Automotive added: “McLaren and Gulf’s long-standing
partnership is all about technical excellence enabling
high performance so we are delighted that our
supercar and hypercar customers will experience and
benefit from Gulf Formula Elite.
“Together with Gulf, we carefully selected and
tested Gulf Formula Elite to ensure it not only protects
our high-performance engines but helps deliver
sustained performance, even in the most extreme
conditions.”
28 THE GARAGE
28 News Gulf Extra.indd 1 21/02/2022 15:41

Primalec FP.indd 1 21/02/2022 15:51

BRAKES
How to: Discs Brake
Replacement Guide
Car manufacturers are constantly striving for weight-reduced cars paired with highly efficient engines. As this technology
evolves, Scott Irwin MIMI, Head of Technical Training at TMD Friction’s aftermarket brake brand, Mintex, is stressing that it is
essential that the motor repair industry evolves with it. And while all vehicle technicians will know how to change a disc brake, it
is often the simple things, such as cleaning, that can be overlooked due to time – yet it is possibly one of the most effective steps
that can be taken to ensure customers don’t come back complaining of brake judder.
Repairing brakes and removing rust
Before starting the brake repair process,
it’s key to look for signs of uneven wear
on the brake discs, as well as checking
all components surrounding the axle and
examining the hydraulic system or any
broken parts.
Any defective parts should be replaced
in accordance to the vehicle, system and
brake manufacturers’ guidelines. Attention
must be made to remove the brake fluid
reservoir cap prior to carrying out brake
pad /disc replacement.
When dismantled, it’s imperative to
remove any rust or residue from the
contact surfaces and caliper bracket.
Build-up of dirt and rust, for example, can
cause brake judder, leading to a vibration
through the brake pedal or steering wheel.
If this is the case, the technician should
use a wire brush or emery paper or even
a hub cleaning tool to remove any rust
or excessive pollutants from the contact
surfaces and hub.
When the rust has been removed, they
should use a brake cleaner to clean the
surface and check the cleaned hub with
a measuring stand for any possible lateral
run-out deviations.
It is advised to take care not to damage
the guide shafts of the caliper bracket
when undertaking the cleaning process.
Greasing the pads
Grease the new pads with a non-conductive,
heat-resistant and solids-free
agent such as Mintex Ceratec Advanced
Lubricant. The technician is advised to not
use copper paste on the surface of the
brake, as it can affect the vehicle’s ABS
system.
Fitting the new brake disc and moving
the brake piston
The technician should fit the new brake
disc onto the wheel hub and secure the
newly fitted disc with the wheel studs
and conical washers, using a DTI gauge to
check for lateral run-out. A lateral run out
of 0.07mm below the maximum radius is
recommended.
The brake piston must be moved back
using the correct adjusting tools at the
start of any brake replacement job and
attention should be paid to any brake
fluid that may spill out of the brake fluid
reservoir while moving the piston back.
It is also important to be sure to pay
attention to the different versions of
the caliper, the brake systems, as well as
manufacturer-specific requirements and
special tools.
Aftercare
To optimise braking performance, Mintex
recommends that the new brakes require
approximately 200 KM to become fully
conditioned. Hard or aggressive braking
must be avoided during this period, as it
can affect the overall performance of the
new brake system.
30 THE GARAGE
30 Brakes TMD.indd 1 21/02/2022 15:46

THE ART OF
GENUINE PARTS
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Each one is supported by a full manufacturer warranty, too.
GENUINE & ALL-MAKES
PARTS FOR THE TRADE
Distrigo Parts Distribution means:
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31, Adverts.indd 1 21/02/2022 15:47

TYRES
All-new premium Falken AZENIS
FK520 UHP tyre for performance
cars and SUVs available from
spring 2022
● Novel construction and material technology derived from
FALKEN’s European race-winning development programme
unlocks efficiency and performance in all-new UHP tyre
● Next-generation stiffer and lighter AZENIS FK520 reduces
unsprung mass, improves stability whilst improving efficiency
● Diamond-cut tread technologies include new Silencing Dimples,
delivering refinement often missing from UHP tyres now found in
mainstream car applications.
● Underling the performance credentials, a 109 Y-rated speed
rating (300km/h) is available to cater for ultra-high performance
heavier cars and SUVs
Thanks to its extensive experience in motorsport and access
to the most advanced materials and the latest simulation
technology, Falken has announced a new range of safe and
sporty handling oriented UHP tyres for performance and SUV
applications.
Reinforced with Aramid, just like its race-winning motorsport
tyres, the Falken AZENIS FK520 is structurally stronger to provide
greater stability and more precise steering behaviour. By using
the latest construction techniques, Falken’s engineers have
managed to reduce the weight of the tyre by 10 per cent in
comparison with its predecessor. Thanks to its lower weight, the
unsprung mass and rolling resistance are reduced, improving fuel
efficiency.
The effectiveness of the design is also reflected in the
outstanding performance of the tyre in both wet and dry
conditions. As the flagship of the range, Falken’s engineers
made no compromises during the development of these tyres
to achieve optimal surface traction and driving performance.
In addition, they also developed a new “Diamond Cut” tread
for AZENIS FK520. FALKEN used advanced 4D nano-simulation
technology from Japan to help with the development of the
“Diamond Cut” tread block edges and the integrated noise
reduction elements. The arrangement of these small indentations
causes tiny turbulences which effectively reduce the rolling noise
synonymous with UHP tyres. An optimised road contact area
helps to ensure they wear evenly and improves road contact.
“The Falken AZENIS FK520 offers grip, reliability, performance
and efficiency in a UHP tyre,” explains Andreas Giese, Senior
Manager Corporate Planning and Product Planning at Falken Tyre
Europe GmbH. “Here at Falken, we combined all our experience
in material development and simulation technology to create
outstanding, high-performance premium tyres.”
The Falken AZENIS FK520 will be available from spring 2022
and will initially come in 81 sizes, ranging from 17 to 21 inches, for
cars and powerful SUVs. All tyres in the series are authorised for
speed category Y (300 km/h).
32 THE GARAGE
32 Tyres Falken.indd 1 21/02/2022 15:36

Parts for All Vehicles
Our Omnicraft branded products are now supported
by Parts and components from some of the world’s
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Meaning you can get all the Parts you need,
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OE Connection FP.indd 1 21/02/2022 15:37

TYRES
Bridgestone
announces
inauguration of new
state-of-the-art
Wet Handling Track
at its European
Proving Ground
● As part of its continued efforts and investment in R&D,
Bridgestone EMIA’s new Wet Handling Track enables
them to rigorously test their premium tyres, helping
ensure optimal wet performance.
● The track was built just outside Rome and was designed
taking into consideration both traditional vehicle
manufacturers and new EV players, bringing one of the
most innovative and advanced tyre testing facilities in
the EU to life.
● Using virtual development it was possible to evaluate
different scenarios and choose the best configuration
and layout of the track, while also reducing the use
of physical resources – aligning with the company’s
ambitions to deliver sustainable mobility.
Bridgestone, a global leader in tyres and rubber providing
solutions for safe and sustainable mobility, has launched
a new Wet Handling Track at its European Proving Ground
(EUPG) based near Rome, Italy, investing approximately €3M in the
project. The new track, designed in a virtual environment ahead of
construction, provides the ability to test premium tyres in varied
weather conditions to ensure optimal wet performance.
To further refine the requirements for maximum testing
capabilities at the Wet Handling Track, Bridgestone worked in
collaboration with partners, including both new EV players and
traditional vehicle manufacturers. Analysing feedback and data
collected from vehicle manufacturers and EUPG drivers, as well
as creating virtual simulations and taking a modular approach
with separate areas of design and development – such as the new
surface, enhanced layout and more efficient water management –
helped Bridgestone to create the state-of-the-art facility.
A successful project rooted in virtual development and
close collaboration
The surface of the track was designed in association with Pisa
University, incorporating carefully selected aggregates that are
more resilient to wear. This is particularly beneficial when it comes
to consistency over time, helping to deliver constant friction and
enhanced grip levels that make it easier to evaluate the overall
performance of tyres.
The track’s cutting-edge layout results in a number of benefits,
including:
● Dynamic transient conditions with combined inputs and more
on/off throttle operation
● The possibility to perform slalom tests using the fast chicane
and the ability to drive in either direction
● More combined accelerations than the original layout
● More evident longitudinal accelerations than the original layout
(acceleration & braking)
Combined, these results allow Bridgestone to develop and test
premium tyres that match the requirements and demands of
customers.
Through virtual development, which uses track simulations to test
and fine tune the design before construction began, the project
34 THE GARAGE MAGAZINE
34,35 Tyres Bridgestone.indd 1 21/02/2022 15:39

offered significant advantages by providing the possibility to
evaluate in advance different scenarios and then select the best
possible configuration. Virtual development also offered significant
sustainability benefits, since the process allows for a more efficient
use of resources. In addition, a new water system utilising 6km of
piping can move water back to a 4-million litre reservoir, helping
to recycle up to 90 per cent of water and further reducing the
environmental impact of the new facility.
Safety and new features fundamental to new track
Safety at the Wet Handling Track is high on the agenda, with Argex
– a clay material – placed in run-off areas helping to reduce
stopping distances where most necessary.
The realisation of the new Wet Handling Track gave also the
opportunity to improve the entire EUPG security management,
with the introduction of a new EUPG Safety Management System.
The new system allows for fully digital and automated control
of the tracks at the facility: test drivers can be informed in real
time with safety prevention warnings, which are also shown on a
screen through visual dashboards and enforced with automatic
voice messages to ensure they can focus fully on driving, while still
receiving crucial safety information. Other new features include
digital access to all tracks at the facility by registered permissions,
along with virtual gates to help manage specific areas.
The bigger picture for Bridgestone
Bridgestone’s European R&D Centre and Proving Ground forms the
focal point of product and solution development in the region. As
one of the most advanced proving grounds in the tyre world, it is
designed specifically for testing tyres and is engineered with stateof-the-art
equipment. Various specific materials and combinations
provide a wide range of surfaces, representative of most road
conditions in Europe, and Bridgestone’s proprietary Virtual Tyre
Development technology was also developed there.
Emilio Tiberio, COO & CTO of Bridgestone EMIA, commented:
“Bridgestone is one of the leading investors in Research &
Development in the industry and our state-of-the-art testing
facilities are a substantial part of the company’s ongoing
commitment to innovation. By providing our customers and
partners with different testing environments, including new road
surfaces and conditions, we’re able to better address the seasonal
effects on tyre grip level, which ultimately improves safety for
drivers. And while safety is of the utmost importance to us as
a business, sustainability is too – that’s why we are continually
evolving our processes to reduce resource consumption in order
to have a more positive effect on people and planet.”
THE GARAGE 35
Banner-Garage-MOT-Professional-91x273-Ad-AW.indd 1 15/07/2019 12:45
34,35 Tyres Bridgestone.indd 2 21/02/2022 15:40

TYRES
VREDESTEIN
A tyre you probably
should know about!
Over the past six months, Vredestein brand tyres have seen a host of important
group-test award wins for the most popular passenger car tyre ranges. Their
‘Ultrac’, ‘Quatrac’, ‘Quatrac Pro’, ‘Wintrac’ and ‘Wintrac Pro’ ranges covering
the summer, all-season and winter segments have performed exceptionally
well against competitors in independent tyre tests conducted by a variety of
automotive magazines across Europe.
At the end of last year, Auto Express,
one of the UK’s leading consumer
motoring magazines, awarded
the Ultrac a ‘Recommended’ accolade
in its annual test of summer tyres. The
magazine evaluated 10 tyres from leading
brands and placed the Ultrac first for wet
handling performance and third overall,
ahead of products from a host of major
manufacturers including Bridgestone,
Goodyear, Continental, Pirelli and Dunlop.
The testers at Auto Express said: “front
grip was impressive and was matched by a
stable rear that gave the car great balance
through turns.”
The sixth generation of Quatrac
all-season tyres was named as the ‘Best
All-Season Tyre’ for 2021 by German
magazine Auto Zeitung. The Quatrac was
also the publication’s ‘Price-Performance
Recommendation,’ proving that a lower
price point doesn’t have to mean a
compromise on quality.
In November, another leading German
outlet, Auto Bild, commended the Wintrac
Pro during a variety of tests in different
conditions. The dedicated winter tyre
outperformed other brands when fitted
to a range of vehicles in harsh conditions,
receiving a ‘good’ rating when used on
all-wheel drive vehicles, such as SUVs,
and an ‘exemplary’ rating when used on
sports cars over ice and snow, but also
wet surfaces.
36 THE GARAGE MAGAZINE
36,37 Tyres Apollo.indd 1 21/02/2022 15:19

In Auto Bild’s largest winter tyre review, the
Wintrac achieved third place and a ‘very good’
overall rating; praised for its “convincing all-round
talent with dynamic driving characteristics on wet
and dry roads, precise steering response, and low
rolling resistance.”
The Wintrac Pro also finished third overall in the
Auto Bild Sportscars test of winter tyres, receiving
an ‘exemplary award’ for its “convincing all-round
talent with very good winter and wet qualities,
stable wet and dry handling, and low-price level.”
As well as awards for specific tread patterns,
the Vredestein brand overall has also performed
particularly well. Auto Bild named Vredestein ‘Tyre
Manufacturer of the Year’ in 2021. In allocating
these awards, Auto Bild took account of all its
tyre group tests throughout 2021, where it judged
each product across a range of scenarios in the
wet, dry, ice and snow to identify the best tyres
on the market. Fifty candidates were involved,
but only a handful were awarded Auto Bild’s
‘exemplary’ status.
This all goes to show the quality and
performance of Vredestein tyres. The company
continues to invest in R&D to create tyres with
next-generation compounds that perform well
all-round, making sure that safety is at forefront
of how well every tyre performs. Vredestein state
their intention to continue this winning streak and
ambition to outperform the market leaders in the
UK and throughout Europe.
The sixth generation of Quatrac
all-season tyres was named as the
‘Best All-Season Tyre’ for 2021, by
German magazine Auto Zeitung.
THE GARAGE 37
36,37 Tyres Apollo.indd 2 21/02/2022 15:19

TYRES
Continental
UltraContact
the mileage tyre
With the new UltraContact, a summer tyre for fleets and end consumers, Continental is
adapting to the changing mobility trends in society. What these trends have in common is
the call for more sustainability, in which includes tyres. This approach is not only
resource-saving, but also very cost-effective – because a tyre that combines increased
mileage and robust design also saves on purchase costs.
The experts at Continental know that
younger drivers today, particularly those
18-25, want personal mobility just as
much as older people. However, the younger
generation’s focus is more on personal mobility
than on car ownership. This means there’s more
demand for car sharing and rental cars. These
vehicles will spend much more time on the
road which means their tyres must offer higher
mileage and be extremely robust. According
to consumer surveys, demand for the greatest
possible safety is still highlighted as the most
important criteria in questions asked about tyre
characteristics.
Another equally important trend is rapidly
increasing electric mobility. In 2019, the number
of electric vehicles sold worldwide topped
two million for the first time. Experts expect
approximately 14 million of these vehicles to be
sold annually by 2025. Vehicle manufacturers
are responding with a large number of new
models. By 2030, global new registrations of
cars with electric drives are expected to reach
25 million a year (Statista.com). Vehicles like
these are normally equipped with quiet tyres,
as rolling noise is much more noticeable than in
cars with combustion engines.
With the new UltraContact, outstanding
mileage, excellent longevity and low driving
noise have all been optimised. The tyre is
tailored to the needs of fleet operators and
end users, and also well suited to electric
vehicles. This is also shown by the classifications
on the EU tyre label. It offers
the best wet braking performance with
a grade of “A,” and a rolling resistance
grade of “B.” For noise emission, it is
classified “A” or “B.” depending on the
size of the tyre.
The new tyre will be available in the UK
from spring 2022. There are already 100
sizes in the product range this year, with
more to come next year. The UltraContact
is produced for rims between 14 and 20
inches, in widths between 155 and 245
millimetres, with cross sections between
80 and 40 percent. Depending on the
dimension, the approvals are between 118 and
186 mph. Selected tyres are available with an
increased load capacity.
38 THE GARAGE
32,33 Continental.indd 1 21/02/2022 14:48

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THE GARAGE 39
32,33 Continental.indd 2 21/02/2022 14:48

TYRES
Bridgestone’s
simplified, sustainable
and sporty range
heralded
Bridgestone has looked to the past,
present and the future in developing
its most comprehensive consumer
tyre range to date, which is more
simplified, sustainable and sportier than
ever before.
The tyre giant – now recognised as a
global leader in sustainable mobility and
advanced solutions – has received a
number of positive test results in recent
times for its product range, which has
been simplified and revitalised in the past
two years.
Notably, the new Potenza Sport, the
Turanza T005, the Weather Control A005
EVO and the Duravis All Season van tyre
are recent additions to the line-up and all
(bar the Potenza Sport and Duravis) benefit
from Bridgestone’s unique DriveGuard
run-flat technology, which allows
motorists to keep on moving for 50 miles –
at speeds up to 50mph – after a puncture.
POTENZA SPORT
In a nod to the past, Bridgestone has
leant on its many years of motorsport
experience to produce the Potenza Sport,
which is arriving at dealers shortly having
been revealed in December 2020.
This next generation tyre represents a
new standard in premium, high-end sports
performance, providing best-in-class
performance in the dry supported by a
premium wet package.
Tested by TÜV SÜD, one of Europe’s
most respected independent automotive
testing institutes, Potenza Sport achieves
the best performance in both dry
braking (shortest braking distance on a
dry surface) and cornering and straight
line stability (maintaining vehicle stability
when travelling both in a straight line and
through a curve) versus competitors in
the premium segment [1] And, with an
EU label A-grade in wet grip across its
full line-up and deemed best performer
in wet cornering and handling in further
tests performed by TÜV SÜD, Bridgestone
Potenza Sport also offers outstanding wet
performance.
In a huge early coup for the
product, it has been selected as the
exclusive original equipment tyre for the
Lamborghini Huracán STO supercar, as
well as long-time partner Maserati’s MC20
supercar.
WEATHER CONTROL A005 EVO
The Weather Control A005 EVO tyre
is Bridgestone’s second generation
all-season touring tyre. Like its
predecessor, it has been designed to
deliver year-round control, safety, and
convenience – but has been reengineered
to offer additional performance benefits.
It has been built using Bridgestone’s
advanced, high silica NanoPro-tech
compound technology. Bridgestone has
combined the compound with a new
mixing technology that improves its silica
dispersion to give the A005 EVO excellent
fuel efficiency and enhance its overall
snow potential.
Alongside an optimised carcass
construction and optimised contact
pressure distribution, this enables the
new tyre to be capable of handling
everyday driving challenges across all four
seasons without compromising on wear
performance.
DURAVIS ALL-SEASON
For the present, Bridgestone’s latest
Duravis All Season van tyre is also being
seen as a crucial piece in the overall
product jigsaw, which boasts an ‘A’ rating
in wet handling.
Like the Weather Control A005 EVO
consumer tyre, the Duravis All Season
has been designed to deliver year-round
control, safety, and convenience, using
Bridgestone’s advanced, high silica
NanoPro-tech compound technology.
Bridgestone has combined the compound
with a new mixing technology that
improves its silica dispersion to give the
A005 EVO excellent fuel efficiency and
enhance its overall snow potential.
And when looking to the future,
Bridgestone’s commitment to providing
sustainable mobility and advanced
solutions can be seen in the fact that
around 30 per cent of all new OE fitments
developed by Bridgestone EMIA in 2020
were created specifically for EVs. From its
ologic Technology - created specifically for
BMW’s all-electric i3 – to the pioneering
ENLITEN Technology, Bridgestone has
always supported the development
of EVs through ground-breaking tyre
technologies.
SUSTAINABILITY
As well as shaping a sustainable future of
mobility in its product output, Bridgestone
is showing equal commitment to investing
in greener practices in the development of
those products.
Virtual Tyre Modelling represents the
future of tyre development at Bridgestone,
and its already in use today. The
technology enables Bridgestone to create
a digital twin of the tyre at its development
stage, reducing the volume of physical
prototype tyres – and subsequently raw
materials – needed, and cutting the
product development time by up to 50 per
cent. Thanks to Bridgestone’s continued
40 THE GARAGE
40,41 Bridgestone 2.indd 1 21/02/2022 16:53

TYRES
advancement and application of the
technology in 2020, 20 per cent fewer
experimental tyres were used in the
development phase of OE tyres in EMIA
from 2019. Furthermore, thanks again
to the use of Virtual Tyre Modelling and
the rise of indoor testing, Bridgestone
EMIA reduced the distance of its fleet
tests for OE by 25% from 2019 to 2020.
Commenting on Bridgestone’s
comprehensive product range,
Consumer Sales Director Brett Emerson
said: “We’re pushing the boundaries
of what is possible in engineering to
deliver new cutting-edge products that
are developed in more advanced and
sustainable ways to offer a superior
performance.
“In our Turanza T005, Weather
Control A005 EVO, Duravis All Season
and Potenza Sport we do believe
we have one of the most impressive
consumer product portfolio’s in the
marketplace today.
“It’s also great that we’ve been able
to work in partnership with the world’s
leading car manufacturers to meet our
collective environmental goals and
shape a more sustainable future of
mobility, via our ENLITEN technology.”
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THE GARAGE 41
40,41 Bridgestone 2.indd 2 21/02/2022 14:45

EXHAUSTSYSTEMS
Air/fuel ratio sensors and oxygen
sensors – what’s the difference?
Despite the rise in popularity of pure electric powertrains, vehicle
manufacturers (VMs) are still under intense pressure to improve
the ecological performance of their combustion engines to comply
with evermore strict emissions targets. As a result, monitoring the
engine’s exhaust emissions takes central stage and the air/fuel ratio
sensor is a special type of oxygen sensor that can support more
sophisticated emission control processes.
To comply with current and future emissions
targets, engine management technology
never rests, as leading original equipment
(OE) component manufacturers such
as DENSO, continue to develop more
sophisticated sensors to satisfy the needs
of the VMs. As a result, the trusted oxygen,
more commonly referred to as Lambda,
sensor has had to be supported with the
addition of many other sensors, including
air/fuel ratio sensors.
Although both these sensors serve a
similar purpose – to monitor the exhaust
gases and communicate this data to the
vehicle’s engine management system (EMS),
to optimise the fuel and air mixture coming
into the engine’s combustion chambers, as
well as the engine’s ignition timing etc. – the
air/fuel ratio sensor provides a higher level
of sensitivity than the traditional oxygen
sensor. This allows the EMS to respond
to the needs of the engine with higher
accuracy, which enables the fuel to burn
more efficiently, therefore producing lower
emissions and increasing the vehicle’s fuel
economy.
This difference in sensitivity can be
demonstrated by the fact that the oxygen
sensor produces a voltage signal that
suddenly changes on either side of the
‘Lambda ratio’ – defined as 14.7 parts air to
one part fuel, which is the most efficient air/
fuel mixture for a combustion engine – 0.8
volts if the mixture is too rich or 0.2 volts if
it’s too lean.
In contrast, the signal output of an air/fuel
ratio sensor is not a voltage, but a current.
This current, measured in mA, changes in
proportion to the amount of oxygen left in
the exhaust gases. In other words, the ECU
(engine control unit) can understand, not
Figure 1: typical O2 signal
Figure 2: typical A/F signal
only if the mixture is rich or lean, but can
also precisely understand by how much.
This quantitative measurement allows
the EMS to respond to the immediate air/
fuel mixture requirements of the engine
more quickly and accurately. This provides
a greater degree of control over the
combustion process, and as a result, the
efficiency of the catalytic converter can be
improved significantly. Also, in case of a cold
start, the engine can reach a closed loop
control much quicker, which reduces the
emission of unburned hydrocarbons.
It goes without saying that the signals that
these two types of sensors produce are
Figure 3: more efficient utilisation of the catalytic converter
Figure 4: quick
“light-off” means great reduction of cold start emissions
very different from each other, therefore,
they cannot be exchanged. In fact, there
are many different varieties of air/fuel ratio
sensors. Some differences are visible from
the outside, whereas others vary electronically,
but most differences are hidden inside
the composition of the ceramic recipe or
the protection coatings on the sensor’s
elements. Therefore, it is very important to
always choose the exact same original design
specifications, when replacing an air/fuel
ratio sensor.
DENSO has recently witnessed a few
examples of imitation sensors appearing on
the market and its laboratory and vehicle
tests of these products have revealed
very poor performance levels and lifetime,
as well as over-consolidation of vehicle
applications, which would certainly lead to
premature failure and re-occurring engine
warning lights on the dashboard should they
be fitted to a customer’s vehicle.
Further details of the DENSO Aftermarket
programme are available online at: www.
denso-am.co.uk
42 THE GARAGE
42 Exhausts Denso.indd 1 21/02/2022 14:52

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The Race Group 1 .indd 1 21/02/2022 15:52

EXHAUSTSYSTEMS
NGK is a leading supplier
of Lambda sensors
under its NTK brand
The company is the world’s largest
manufacturer of Lambda sensors
and supplies a market-leading range
to the UK aftermarket under the NTK
brand name.
There are good reasons why NTK
Lambda sensors are the No.1 choice of
vehicle manufacturers (VMs) around the
world, they are ‘Similar but different’.
NGK says the experience it has in
supplying the VMs worldwide allows it to
offer exactly the right sensor for every
vehicle application.
The company advises distributors to
encourage garages to always go with a
bespoke OE-quality Lambda sensor and
steer well clear of ‘universal sensors’. A
‘universal’ Lambda sensor is designed to
cover as many applications as possible by
splicing in the connector from the unit
being replaced. In theory, this sounds like
a good idea. In practice the potential for
a mismatch with the vehicle’s system or
subsequent premature failure is very high.
NGK says distributors should help
educate garages by ensuring they fit a
new NTK Lambda sensor whenever they
replace a vehicle’s catalytic convertor.
A worn or failed sensor can result in
drastically reduced control of the fuelling
system which could result in increased
fuel consumption, uneven running,
generally poor performance or failure of
an MoT emission test, so replacement is
good news for the customer, garage and
distributor.
NGK recommends that the function
of the sensor is checked every 20,000
miles or annually. The emissions check as
part of the current MoT test samples the
exhaust gases to monitor the efficiency
of the engine, exhaust system and engine
control systems. The Lambda sensor is a
vital part of this system and its function
is therefore influenced by many other
components.
A malfunction of an associated part
may directly affect the performance of a
sensor. An oscilloscope and gas analyser
is a much more accurate way of assessing
sensor performance than relying on fault
codes alone. Garages need to look for
slow response times, output range and
heater function.
Contaminants from poor quality oils and
fuel which remain in the exhaust gases
can become deposited on the sensor
element affecting its operation. Even
coolant from a leaking head gasket can
reach the element.
Links to NGK’s improved PartFinder
website can be accessed with just two
clicks from its BoxClever App’s homepage.
The App also enables members of its
independent garage loyalty scheme to
check their points balance, browse the
gift range, redeem points and win prizes
instantly, all from their mobile phones.
For more information on NGK Spark Plugs
(UK) Ltd and its products and services,
please visit the website at
www.ngkntk.com/uk
44 THE GARAGE
44 Exhausts NGK.indd 1 21/02/2022 14:50

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EXHAUSTSYSTEMS
Nissens tackles
EGR valve
problems on
prominent
TDI
applications
The exhaust gas recirculation (EGR) valve is an integral part of a vehicle’s exhaust emission control system, influencing the operation
of the engine and its combustion process. Failure, malfunction or removal of the EGR valve will cause the engine not to operate
properly. Furthermore, valve failure can provoke faults in the exhaust emission control and cause severe failures of related devices
such as the diesel particulate filter, catalytic converter or turbocharger. In addition, impaired performance of the vehicle’s exhaust
emission system will seriously affect the environment and may breach regulated emissions levels.
COMMON SIGNS OF EGR VALVE
MALFUNCTION
• Engine check control lighting on the
dashboard
• ECU setting the engine into limp mode
• Reduced engine power
• Significant changes in fuel consumption
• Engine emitting pinging and knocking
sounds
• Rough, uneven idling
• Stalling and hesitation during acceleration
• Exhaust gases escaping within the engine
compartment
SAFETY
By their very nature, EGR valves are generally
located in the engine compartment and
close to heat-generating components, so
they can get very hot. Technicians should
therefore be mindful of the danger before
starting diagnostic and replacement
procedures and make sure the vehicle has
cooled down to a safe temperature before
undertaking the work.
THE PROBLEM
The EGR valve used in multiple VAG diesel
applications utilising the 1.4, 1.6 and 2.0-litre
TDI units can be particularly problematic,
as it is especially susceptible to heat and
vibration, as well as excessive engine load.
Naturally, the faulty valve has to be replaced
because its failure will impair the function
of the entire exhaust emissions system, so
affecting the engine’s proper operation.
However, as the issues are largely due to the
design of the original part, workshops must
be aware that these malfunctions can occur
both in the original, and a replacement part.
Fortunately, the Nissens Efficiency &
Emissions division has stepped in to provide
a solution to the problem by addressing
the issues that contribute to the value’s
premature failure and ensuring its proper
function and long lifespan, despite exposure
to the harsh working conditions it has to
deal with.
By applying several design improvements
over the original and proving them over a
series of comprehensive tests, the Nissens
team has developed a durable replacement
part that performs to the standards defined
by the vehicle manufacturer and therefore
provides the aftermarket with a competitive,
genuine Nissens quality, solution.
THE NISSENS SOLUTION
Optimised gearbox design – Recognising
the problems associated with heat and
lubrication, the Nissens team significantly
reduced tolerance and therefore friction,
by applying specific PTFE, high-temperature
resistant grease. Furthermore, the plastic
material of the gear wheels in the two-stage
gearbox has been upgraded.
Improved design of the valve stem – To
avoid the known, severe malfunction of
the valve caused by the engine load and
vibrations, Nissens improved the valve’s stem
and lever arm fixings by applying a unique
design of spiral pin.
DC-motor design upgrade – The motor’s
bearing system has also been improved
to ensure its flawless operation and long
service life, despite the vibrations and
frequent temperature changes it has to deal
with.
THE TESTING PROCESS
The value of these improvements is proven
by the redesigned valve undergoing a
comprehensive validation procedure to
secure its full functionality over its lifespan.
Naturally, these tests include complete EGR
valve operation and sensor feedback signal,
under temperatures simulating conditions
in the operational engine compartment, but
also cooler performance for NOx emissions
reduction, according to the EU5 norm,
as well as the cooler bypass function for
cold start. Finally, the valve undergoes a
comprehensive corrosion test.
To assist technicians fit EGR valves with
confidence, the Nissens technical team has
produced a useful installation guide which
can be found at: https://support.nissens.
com/material/egr-valve-installation-guide
For more information about the Nissens
Efficiency & Emissions programme or any
other product in the Nissens Automotive
range, please call: 02476 470340.
For product technical data, catalogue
information or installation advice, visit:
www.nissens.com
46 THE GARAGE
46 Nissens.indd 1 21/02/2022 14:53

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PEOPLE
People stories and movements from around your industry
First Line Ltd, kickstarts 2022
by bolstering its sales team
First Line Ltd has kickstarted the new
year by further strengthening its sales
team announcing a new appointment
and promotion, as it gears up for another
successful and productive 12 months.
Chris Peat has joined the company as Key
Account Manager, and is responsible for
accounts from Hull in the North East down
to Dover in the South East, from Tyne &
Wear, down to the Isle of Wight.
Previously working for the Parts Alliance
for the last 15 years, recently as a Regional
Support Manager, Peat brings a wealth of
experience and a clear understanding of the
needs of aftermarket distributors and their
customers.
Excited about his new role and the
opportunities it brings, Peat commented:
“I’m really excited to work for First Line Ltd,
who is a market leader and a highly regarded
supplier in the aftermarket.”
First Line Ltd has also announced the
creation of a new position within the
company by promoting Key Account
Manager, Keith Frost, to the role of
International Trading Groups (ITG) Manager.
Frost has been at the company for 10
years and is a well-known and reputable
team member among the UK customer base.
Recognising the importance of the
international buying group community, First
Line Ltd created the position to enhance
communication, support and activity
globally.
Andy Smithson has been appointed to
the new role of head of internal control,
compliance and legal relay at Startline
Motor Finance.
He will be responsible for ensuring a
robust and effective control environment
with strong ongoing legal, regulatory
and operational compliance, as well as
managing the interlock with the company’s
legal panel and leading the environmental,
social and governance agenda.
He joins from Lloyds Bank Commercial
Finance where he was a director, having
also spent 12 years at Lloyds Banking Group,
eventually becoming head of business risk
within commercial banking.
Andy has also spent a considerable
portion of his career in the United States,
working in motor finance before becoming
Chris Peat
Frost said: “Over the past decade, I’ve
enjoyed listening and communicating
with customers to continue to strengthen
relationships and develop our service
offering to their specific needs. Now, I look
forward to putting this into practice on an
international level and continuing to spread
the First Line Ltd message far and wide.”
First Line Ltd was recently recognised
at the 2021 Independent Automotive
Aftermarket’s (IAAF), ‘Pride of the
Aftermarket’ award ceremony, receiving
the prestigious runner up award in the Car
Supplier of the Year category.
The established aftermarket supplier
Andy Smithson appointed Head of Internal
Control, Compliance and Legal at Startline
vice president of risk management at HBOS
in the US and holding the same position at
Drive Financial Services.
He said: “It’s exciting to be working in
motor finance once more and great to
become part of the team here at Startline.
I have been genuinely impressed by how
invested everyone is in the success of the
business and how the company supports
both customers and colleagues.
“I’m looking forward to developing
the risk framework and oversight model
to support our ambitious future plans,
ensuring that effective controls and
regulatory compliance not only protects
the business but delivers positive customer
outcomes.”
Paul Burgess, CEO, added: “This is a
crucial new role for Startline as we embark
Keith Frost
remains committed to the development of
its products and services, which is reflected
in the company introducing a total of 568
new-to-range parts in the 2021 alone to
complement its market-leading portfolio,
including Steering and Suspension, Clutch,
Braking and Filter products.
The company has also recently expanded
its digital reach by increasing activity on its
social media channels through, Facebook,
LinkedIn, Instagram and Twitter, as it grows
its content library to further support motor
factors and garages with greater access to
updates than ever before.
The full product portfolio from First Line
Ltd consists of more than 40,000 part
numbers, across 60+ product lines. All of
which can be looked-up via application or
cross reference in the company’s marketleading
online catalogue, WebCat: webcat.
firstline.co.uk/Home
on our latest growth phase and we are very
pleased to welcome Andy to the business.
He has an impeccable track record and is
already making a positive impact here.”
48 THE GARAGE
48,49 people.indd 1 21/02/2022 16:32

PEOPLE
TruTac announces new Managing
Director and leadership team
TruTac, part of the Microlise Group, has promoted
Jemma James to Managing Director as Terry Ramsey
retires at the end of January. Jemma has been with
TruTac for over 14 years and became a Director in
Oct 2010, with her most recent role being Director
of Commercial Operations & Marketing.
Jemma James
Lee Oliver
Jemma has been a key figure in the leadership of TruTac and was
responsible for securing commercial relationships with both the
RHA and Confederation of Passenger Transport as well as developing
other key partnerships and being involved in the Microlise
acquisition.
Jemma possesses an excellent track record in business development
with extensive senior commercial management experience
in a variety of industries, including international banking and
corporate investigation and places great emphasis on customer
service.
Terry Ramsey states, “While retiring after 15 years is a big
change for me, I can relax knowing TruTac is in great hands with
Jemma as Managing Director. Through the hard work of everyone
at TruTac, we have transformed the business and made it the
success it is today. I have the utmost confidence the team will
continue to work together to drive further innovation and business
growth.”
Additional changes in the TruTac leadership team see Lee
Oliver promoted to Sales Director, having previously been Head
of Sales and Louise Connor joining as General Manager. Lee has
been with TruTac for 10 years and has been instrumental in securing
numerous large customers. Lee will focus on commercial
growth through new market opportunities and will continue to
build TruTac’s successful sales team.
Louise joined the business last October having previously
worked in manufacturing operations. Louise will continue to
ensure that the highest level of customer service and quality is
delivered to all customers. The leadership team also includes
Chris Williams, Technical & Product Director and James Pyne,
Finance Director, who all work alongside the Microlise Board to
achieve Group aims.
Chris Williams
Louise Connor
TMD Friction appoints
Jake Prout as new Area
Sales Manager
TMD Friction has grown its UK sales team
with the appointment of Jake Prout as
area sales manager for the South West IAM.
Prout brings over 15 years’ experience
in aftermarket sales to the brake
friction specialists, including most
recently two and a half years with BMW UK.
Prout said: “I’m delighted to join
TMD Friction and build on the excellent
foundations of service established by the
UK sales team.”
In his new role, Prout will support TMD
Friction’s customers in both passenger
car and commercial vehicle aftermarket
sectors.
“I’ll be looking to support customers
across the entire southwest region and be
their trusted advisor for braking solutions.
The changing landscape of the industry
represents numerous opportunities in my
new role, as TMD builds on its position as a
leader in braking technology, both now and
in the future.
“I have a solid background in automotive
aftermarket having worked with one of
the UK’s largest motor factors, and more
recently with a tech supplier to BMW,” he
added.
Nick Hayes, UK sales manager at TMD
Friction, said: “TMD Friction continues
to expand its expertise, and with Jake’s
appointment, we’re perfectly placed to
meet customer demand and support our
commercial vehicle customers across the
country.“
THE GARAGE 49
48,49 people.indd 2 21/02/2022 16:32

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Classified Example.indd 1 27/01/2021 13:53:17
50 Product and Services.indd 1 21/02/2022 14:58

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BEST IN TEST
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Quatrac
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Issue 19 / 2021
We are on a roll
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TYRE TEST
Apollo FP.indd 1 21/02/2022 15:02