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SEPTEMBER 2020 AFTERMARKET 43 www.aftermarketonline.net a degree of predictability which can help with diagnosis, as Helen Goldingay, Senior Head of Marketing at Communications at HELLA, observed: “While there are a variety of reasons why rotating electrics may develop faults, there are common symptoms and causes that technicians should be aware of and look for. As these parts are so important in the running of the vehicle, it’s crucial to recognise these potential problems quickly and resolve them.” Starter Motors On faults with starter motors, Helen observed: “There are common symptoms that may indicate a fault in the starter, such as no response when actuating the ignition switch: the starter ‘clicks’ but does not engage or it audibly turns but without the motor engaging with the flywheel. “A starter malfunction can have different causes including a faulty electrical connection, the solenoid switch (engaging relay) is stiff or faulty, the electric motor is damaged electrically or the single-pinion gear, starter pinion or freewheel has been damaged. Battery voltage may also be a factor to consider and/or loose (high resistant) connections. “Dependent on the problem, technicians should look at the starter and decide if it needs to be replaced. It must also be noted that some vehicles have inherent faults such as ignition switch failure, which again can cause premature failure of the starter motor.” Alternators Moving onto alternators, she said: “Symptoms for a faulty alternator can include the charging indicator warning light coming on, starting difficulties due to an insufficiently charged battery, the battery becomes too hot due to charge overload, the headlights get brighter or dimmer in relation to the engine RPM or bulbs burn out more quickly than normal. “Alternator malfunction is not always due to an internal fault, such as a faulty winding, rotor, rectifier or control unit. So, before replacing the alternator, additional components should be considered as a cause and checked. “The cause may be because of a prematurely aged or faulty battery, corrosion or loose electrical connections causing high resistance to the alternator, loose/faulty auxiliary belt or belt tensioner spring being to loose/tight or the tensioner bearing faulty.” Helen added: “While these are simple things to look out for, technicians should be aware of them but if the component needs replacing, it’s always best practice to replace it with one of premium or OE quality. It also best practice to make sure that the battery is fully charged before using the replacement alternator or starter motor.” For more information, visit HELLA Tech World: www.hella.com/techworld/uk/Car- parts/Auto-electrics/Starters-and-alter nators-47468/ Consolidation A move towards range consolidation, including around ignition parts, is making the repair process simpler, as Fatiha Laauich, Pan European Strategic Marketing Manager at DENSO explained: “Thanks to continual advancements by parts manufacturers, there is a trend for wholesalers to stock a smaller but just as widely applicable range of parts, enabling them to meet customers’ needs while reducing their overheads. “That’s where our concept of ‘smart consolidation’ comes in, merging products in a range just enough for wholesalers and workshops to benefit, but not so much that they experience problems.” “The DENSO Lambda Sensor range is optimised for smart consolidation: maximising benefits without incurring negative impacts. Not only do the sensors themselves match strict quality standards, the segmentation of the range confers the maximum possible benefits to workshops, calculated across the entire life cycle of a product from purchase to installation to use, while maximising vehicle reliability.” Some manufacturers have identified the lambda sensor as a target for range consolidation. “With their variety of wire lengths and fit types,” observed Fatiha, “it is easy to see why. “However, lambda sensors are a crucial component not only for optimising engine performance but also for reducing a car’s emissions – something the entire industry knows to be important in the context of global governments’ climate goals. Therefore, their performance cannot be compromised. “Consider a group of 10 different OE sensors, which all share an identical sensor core, connector type and pinout. The only differences are wire lengths. Here, DENSO puts smart consolidation into practice by selecting only three optimised wire lengths, thereby greatly improving the stock efficiency of servicing all related vehicles. “As a result, workshops can ensure maximum vehicle coverage without having to buy a prohibitive amount of stock. Having fewer parts in the workshop makes technicians’ lives easier and the right parts result in efficient and error-free fitting.” Extreme Would it be possible to take the concept further and reduce the range all the way down to one cable? “In theory, yes,” responded Fatiha, “and other manufacturers have indeed done this. However, reduce the range too much, and the constraints start to outweigh the benefits. With high temperatures, fast moving parts, and heavy vibrations, wire harness fixation is a safety and reliability issue that DENSO is not prepared to compromise on. In general, DENSO does not allow wire to be more than 35% over length. Others in the aftermarket do not apply such a limit, and may even permit wire that is more than 100% over length. “The most extreme version of consolidation is universal fit sensors. Such sensors will always require additional preparation time by cutting the wires to length and splicing them onto the original wire and connector. When done correctly, this provides a perfectly reliable result, but preparing the sensor will significantly extend the installation time. Additionally, there are many ways that a less experienced mechanic could make a mistake. “If this occurs, it goes without saying that the sensor will not work properly, which will be noticeable in the car’s driveability and fuel consumption. When making their buying decisions, workshops should consider the costs of rectifying these situations, not just the initial costs of the parts.” OEMs are developing technologies that will allow them to achieve the required improvements ”