"user manual"
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1. and met the demands of completing the test without exhibiting excessive wear Like all products in Delphi s aftermarket thermal line the compressors are designed to last a minimum of 50 000 miles The SP compressors also meet the designated performance requirements and exceed the Delphi requirement that calls for a noise differential of less than 3 dB In addition Delphi s SP compressors underwent vehicle fit and leak testing to ensure Delphi caliber quality Because of our 100 year OE heritage this is the way Delphi has always engineered developed and tested parts which sets us apart from many of our competitors in the aftermarket said Shasteen Delphi s new compressors fit popular late model domestic and import applications with coverage for more than 13 million vehicles Since 1910 Delphi has brought heating and cooling innovations to the automotive market and remains a leader in developing OE quality solutions for vehicle manufacturers and the aftermarket This includes the first automotive radiator in 1911 the first car heater in 1929 and the first vehicle air conditioner in 1954 Innovation for the Real World Delphi is launching 105 new aftermarket part numbers for air conditioning systems including compact variable compressors condensers and blower motors ri aun CONDITION SPARE FANTES In addition to introducing the latest Delphi OE compressors we are also using Delphi s y engine2. 2 0L VOLKSWAGEN Bora Golf 1 6L 2 0L New Beetle Sharan 1 8L 2 0L Multivan Transporter 2 0L 2 0L Passat 2 5L AF10085 12B1 LAND ROVER Freelander 2 0L NISSAN Primera 2 0L AF10087 12B1 MERCEDES C Class Vito 2 2L Sprinter 2 2L 2 7L P6 Delphi s Magazine for Automotive Technicians TECH TALK P7 Innovation for the Real World your Business with Delphi Diesel Delphi Helps Vehicles Stay GREEN with Increased EGR Today s diesel user expects high performance coupled with low fuel consumption and low emissions Adding fuel treatments to a diesel fuel tank can not only help boost engine efficiency but can also provide an additional revenue stream for garages Valve Coverage Delphi engineers invented the linear EGR Valve for OEMs in the 90s Talk to us at Tech Talk delphi com Delphi has launched two new OE exhaust gas recirculation EGR valves fitted to the PSA DW10B engine Including popular Peugeot Citro n Ford Volvo and Fiat applications the new part numbers extend Delphi s coverage by more than 2 5 million vehicles The EGR valve re circulates finely metered amounts of exhaust gas Into the engine intake helping to reduce oxides of nitrogen NOX whilst maximising the performance of the engine DELPHI PART NUMBER KEY APPLICATIONS Available in port backpressure and linear contigurations the 100 OE program covers leading diesel and petrol engine applications All Delphi EGR v
3. EGR VALVES gt PS Peugeot had recently launched the RCZ 2 0 litre HDi Even with this extra boost Peugeot used production NEW AIR CON PROGRAM __ gt P19 coup to mark its 200th anniversary For the 2010 Delphi charge air coolers as supplied to road cars race the company took the decision to race models as they met the performance targets required for NEW CHASSIS RANGE gt P11 ve i ven endurance racing Full article on page 20 that were largely unmodified from their road going NEW DIESEL FILTERS gt P10 equivalents a powerful way of demonstrating the reserves of performance and durability inherent in Above article image Julie Sueur Endurance info com irene their standard production vehicles ENP HS i FL di We BORN WiTH TURN TO PAGE 14 FOR DELPHI OE TECHNOLOGY FITTED TO THE 2010 WORLD CAR OF THE YEAR tin is an innovative program designed to help independent garages around the world partner with Delphi and benefit from its comprehensive offering of parts tooling diagnostics training technical and marketing support Top issues facing todays garage Vehicle complexity Finding qualified people Ongoing education amp training Diagnostic tools OE quality products Technical support Marketing support SERVICE CENTRE DIESEL The introduction of Common Rail has revolutionised the acceptability of diesel in passenger cars offering comparable power and perfo
4. The Delphi brake pad and the disc show similar results to the OES parts after having passed the same tests Competitor 1 Discs Pads after tests Both the brake pad anoi weg Competitor 1 a gt Innovation for the Real World Delphi Product and Service Solutions Spartan Close Warwick CV34 6AG UK Tel 01926 470000
5. width of the equipped vehicle This innovative technology is featured on the new Ford C Max and Volvo S60 P22 Delphi s Magazine for Automotive Technicians Delphi is supplying the new Porsche Cayenne Renault Wind and Volkswagen Touareg with complete wiring assemblies ri Using the proprietary Velocity Tool Suite Delohi engineers around the globe develop complete electrical electronic architectures that streamline the development process offer cost competitive solutions and improve engineering efficiency and quality Delphi s electrical electronic architecture solutions help OEMs reduce mass minimise system complexity and overcome packaging challenges Delphi is supplying the new Porsche Cayenne Renault Wind and Volkswagen Touareg with complete wiring assemblies ES lee Delphi s TV Reception system with patented diversity technology featured on new BMW 5 series Mercedes Benz E Class Cabriolet and Porsche Cayenne sets vehicles apart with world class TV reception even when the vehicle is moving at high speed Viewers can enjoy colour TV with the quality they have come to expect at home TECH TALK P23 aaa Innovation for the Real World Trust Delphi for German and Asian Applications Delphi offers an extensive all makes braking range of over 8 500 references covering all major vehicle manufacturers German and Asian applications make up a significant part of this offering and it was these on which Brak
6. DELPHI TECH Innovation for the Real World Delphi s Magazine for Automotive Technicians ar a THIS MONTH WE TALK Delphi Service Centre P2 Fuel Pump Failure Analysis P4 OE Oxygen Sensors P6 New Delphi MAF Sensors P7 New OE EGR Valves P8 Training P8 Adding Profits With Delphi Diesel P9 New Diesel Filters P10 Industry Leading Chassis Range P11 PACE Awards P11 New Steering amp Suspension Catalogue P11 Delphi s New Fuel Analyser P12 VW Polo BlueMotion P14 Diagnosing Common Rail P16 Delphi Aftermarket SP Compressors P18 New Air Con Program P19 Peugeot Endurance Test P20 New Delphi Technology P22 Delphi Brake Pads amp Discs P24 Delphi helps Peugeot to victory 3 E a i id in ultimate durability test E Earlier this year Delphi technology helped power SPEED AND ENDURANCE two Peugeot RCZs to an impressive first and third COME AS STANDARD in class standing in a gruelling 24 hour endurance race at the Nurburgring in Germany The vehicles The two RCZs ran in the D1T category for diesel cars SERVICE CENTRE x were equipped with Delphi diesel fuel injection between 1 7 litres and 2 0 litres The key change to systems and powertrain cooling technology the standard engine was an increase in turbo boost which unlike many of the 197 other vehicles pressure lifting the torque from 340Nm to 400Nm DON T MISS had not been highly modified for racing and the power trom 1Z0kW to 150kW TAN AN OE
7. NUMBER KEY APPLICATIONS AF10078 12B1 AUDI A3 1 9L A4 1 8L FORD Galaxy 1 9L SEAT Alhambra 1 9L Leon 1 8L SKODA Fabia Octavia 2 0L VOLKSWAGEN Bora Golf 1 9L New Beetle 1 8L Polo 1 4L AF10079 12B1 AUDI AS 1 8L VOLKSWAGEN Bora Golf 1 8L 2 0L New Beetle 2 0L Lupo 1 2L AF10080 12B1 VAUXHALL OPEL Astra Combo Corsa 1 7L Astra 2 0L AF10081 12B1 AUDI A3 A4 1 9L SEAT Leon Toledo 1 9L TOYOTA Liteace 2 0L VOLKSWAGEN Bora Golf Passat 1 9L Bora Caravelle Golf Passat 2 4L Transporter 2 5L AF10082 12B1 ALFA ROMEO 145 146 1 4L 1 6L 1 8L 147 1 6L 2 0L 156 1 6L 1 8L 1 9L 2 0L 2 4L 166 2 4L CITROEN Jumper Relay 2 8L FIAT Brava Bravo Multipla 1 9L Idea Panda Punto 1 2L Marea 1 9L 2 4L Ducato 2 8L FORD Mondeo 1 8L HONDA Accord 2 0L LADA 110 111 112 Diva Forma Sagano Samara 1 5L Niva 1 7L Samara 1 3L LANCIA Lybra 1 9L 2 4L Musa 1 2L MAZDA 6 2 0L MG ZS 2 0L NISSAN Primera 2 0L VAUXHALL OPEL Astra 1 2L 2 0L Corsa 1 0L 1 2L Frontera Omega Sintra 2 2L Vectra 2 0L 2 2L Zafira 2 0L PEUGEOT 406 2 0L ROVER 25 45 220 420 Streetwise 2 0L SAAB 900 2 0L SUZUKI Swift 1 3L 1 6L VOLVO S70 S80 V70 2 5L AF10083 12B1 AUDI A4 A6 1 9L SEAT Cordoba Ibiza 1 9L VOLKSWAGEN Caddy Caravelle Transporter 20L rassdt Folo gle AF10084 12B1 AUDI A4 A6 A8 2 5L CITROEN Jumpy 1 9L SEAT Alhambra Cordoba 2 0L Alhambra Toledo 1 8L SKODA Fabia Octavia
8. OEN Jumper 2 0L 2 2L 2 8L 3 0L Jumpy 2 0L FIAT 500 C 500 Multijet 1 3L Croma Multijet 1 9L Doblo Doblo Multijet 1 3L Pleated Filter Media Ducato Ducato Multijet 2 2L 2 8L 3 0L Idea 1 3L 1 9L Panda Panda Multijet 1 3L Panda Sedici Multijet 1 9L Strada Multijet 1 3L LANCIA Musa Multijet 1 3L Ypsilon 1 3L OPEL VAUX HALL Agila 1 3L Antara 2 0L Astra H 1 3L 1 9L Astravan 1 3L 1 9L Combo Body Combo Tour 1 3L Corsa C Corsavan Meriva Tigra 1 3L Signum Vectra Zafira 1 9L PEUGEOT Boxer 2 0L 22L 2al S0 SAAB 9 2 19L SUZUK lenis Splash Swi iB SX 4 LOL 20L HDF954 DACIA Logan Sandero 1 5L HDF597 RENAULT Kangoo 1 5L Laguna Grandtour 1 5L 2 0L 3 0L P10 Delphi s Magazine for Automotive Technicians An Industr Innovation for the Real World Leadinc Range Going From Strong to Stronger Delphi remains committed to developing its range to meet the needs of a diverse and ever growing vehicle parc Proven by the fact that in 2010 alone Delphi has added over 540 new parts to its industry leading range of chassis products Manufactured to exacting OE standards the new range includes 65 brake pads 103 brake discs 105 brake hoses 70 calipers and 200 steering parts But it doesn t stop there a further 300 plus parts are planned throughout the rest of the year Real Worl One area of significant focus for Delphi is brake pads and brake discs where our objective is to be first to market b
9. SV10166 or laptop based DS150E part number SV10546 technicians can identify the fault codes generated and then focus their attention on this area of the vehicle CHECK THE INJECTORS If the OBD system has generated a fuel injection system fault code the next item to be checked is the injector s functionality Tools such as Delphi s Sealed Rail Diagnostic Kit part number YDT278 can be connected to the injectors preventing the need for a complete system removal and refit As an all makes tool the Sealed Rail Kit is compatible with Common Rail systems from Delphi Bosch Denso and Continental reducing the need for investment in multiple tools The back leakage equipment on the Sealed Rail Kit collects and measures back leakage flow from the injectors and indicates which injector may be damaged or faulty and in need of replacement By replacing Individual injectors rather than a whole set garages can save both time and money P16 Delphi s Magazine for Automotive Technicians CHECK THE COMMON RAIL PUMP FUNCTION Once the injectors have been checked the functionality of the Common Rail pump should be investigated This time the Sealed Rail Kit is fitted directly onto the high pressure outlet pipe from the pump and the operator cranks the engine to record pressure in the system The Sealed Rail Kit displays the results digitally and if the figure differs from the specified pressure measurement for the vehicle application
10. alves use precision machined valves and seats to help maintain long term stability and high temperature materials for internal windings for high exhaust temperature performance They also offer rugged environmental protection for corrosion resistance And as an exact Tit there is no need for part or vehicle modification saving the garage both time and labour EG10395 12B1 FORD C Max Focus Galaxy Kuga Mondeo S Max 2 0L VOLVO C30 C70 S40 S80 V40 V50 2 0L EG10396 12B1 CITROEN C4 C8 2 0L FIAT Scudo Ulysse 2 0L LANCIA Phedra 2 0L PEUGEOT 207 307 308 407 607 807 2 0L Get a Competitive Edge with Delphi Training At Delphi we work closely with the world s leading vehicle manufacturers to help them meet the challenges of increasingly stringent vehicle emissions legislation as well as consumer demands for more powerful and more fuel efficient vehicles By helping design the systems at the outset we fully understand all of the complexities and can offer technicians access to the very best training and support at our state of the art training schools around the globe To help garages take advantage of the service opportunity on today s modern vehicles Delphi provides an extensive global training program covering all capabilities from basic level diagnostics right through to the in depth knowledge required to service the most advanced OE systems We even offer courses designed to help maximise business
11. ce Centre garages are trained in the very latest air conditioning technology equipped with specialist tools and have access to a wide range of OE quality parts TECH TALK P19 Endurance lest Delphi helps Peugeot to victory in ultimate durability test Earlier this year Delphi technology helped power two Peugeot RCZs to an impressive first and third in class standing in a gruelling 24 hour endurance race at the Nurburgring in Germany The vehicles were equipped with Delphi diesel fuel injection systems and powertrain cooling technology which unlike many of the 197 other vehicles had not been highly modified for racing Peugeot had recently launched the RCZ 2 0 litre HDi coup to mark its 200th anniversary For the 2010 race the company took the decision to race models that were largely unmodified from their road going equivalents a powerful way of demonstrating the reserves of performance and durability inherent in their standard production vehicles For a race car to use a production ECU is a particularly rare event but Delphi achieved this as well John Fuerst P20 Delphi s Magazine for Automotive Technicians Autumn 2010 Speed and endurance ome as standard The two RCZs ran in the D1T category for diesel cars between 1 7 litres and 2 0 litres The key change to the standard engine was an increase in turbo boost pressure lifting the torque from 340Nm to 400Nm and the power from 120kW to 150kW Even with t
12. dence of terminal overheating especially at the terminals supplying current flow to the fuel pump inside the module Badly charred and burnt terminals are easy to spot but seemingly undamaged connections should be checked more P4 Delphi s Magazine for Automotive Technicians Were they worn out or did they fail for another reason The answers to these questions are important and without them an accurate diagnosis is left to chance Vi No significant amount of rust or contamination was found in the fuel tank because the source of the rust was the metal return line on the vehicle The rust that was deposited went directly into the fuel module bucket as the return line on this vehicle puts fuel directly into the fuel module bucket not the fuel tank Once the rust was deposited it could not be removed The fuel filter was not able to catch the rust because it was developing in the vehicle return line This vehicle received two fuel modules in less than a week The complaint was noisy operation and erratic fuel pressure Both modules were analysed and found to have the fuel module bucket and internal strainer heavily contaminated with rust The external strainers showed some discolouration but had significantly less rust in them The cause was a rusted return fuel line downstream of the fuel filter Delphi aftermarket pumps and modular reservoir assemblies are exact fit OE replacements closely for evide
13. e bucket and internal pump strainer Contaminants entering the fuel module bucket are indefinitely trapped so the bucket will contain a contamination history of the fuel module A significant amount of contamination found in the bucket and internal strainer is a sure sign that the part failed due to contamination This indicates that there are other issues on the vehicle that need addressing prior to the installation of a new fuel module ANALYSIS OF ACTUAL FAILURES Above are actual scenarios showing failed modules Since these issues were not identified during the initial diagnosis the results were repeat failures Upon such closer inspection all the needed repairs could have been made More important a customer comeback would have been avoided TECH TALK P5 Innovation for the Real World How Refreshing Coverage with New Delphi MAF Sensors Delphi A Leader in Nine New MAF Sensors Provide Coverage Planar Technology for Over 600 Popular European Applications As one of the leading suppliers of oxygen Integral to the engine s performance and efficiency Delphi supplies the sensor and not the complete sensors Delphi planar technology is the the mass air flow MAF sensor measures the flow MAF assembly As a high percentage of failures result of our OE and aftermarket engineers and density of air into the combustion chamber relate to the sensor this ensures a cost effective partnering together to develop one of the The res
14. e Testing International a third party test house recently carried out a series of independent tests The results Well they speak for themselves Delphi s brake pads excelled in AK Master brake pad performance tests on the BMW 3 Series E46 Z3 Z4 and Nissan Primera The tests which conform to SAE J2522 standards measure friction performance under different braking conditions The Delphi pads outperformed key aftermarket competitors closely matching the performance of the OES pad and demonstrating consistency across all test cycles Friction Coefficient KEY BMW 3 Series E46 Z3 Z4 Characterisation 80 gt 30 km h Speed Series 120 gt 80 km h Speed Series 200 gt 170 km h Characterisation 80 gt 30 km h Cold 40 km h Motorway Stop Characterisation 80 gt 30 km h Fade 1 MINIMUM Characterisation 80 gt 30 km h High Temperature 100 500 degrees MINIMUM Characterisation 80 gt 30 km h Fade 2 MINIMUM Characterisation 80 gt 30 km h We want to hear from you Let us know what you think about Delphi s new magazine for automotive technicians Or if you have any questions on the articles featured in TechTalk then just drop us a line at TechTalk Delphi com Ge TECH TALK DDSX552 EN Discs Pads after tests The OES brake pad and the disc have successfully passed all the tests after vigorous testing They just show some wear but they are still roadworthy DELPHI Discs Pads after tests
15. een supplying innovative OE technology to vehicle manufacturers around the globe Today our diesel fuel filters are fitted as OE to millions of car and light duty vehicles as well as the best known truck buses and off highway applications DELPHI PART NUMBER HDF575 SEAT Ibiza 1 4L 1 6L 1 9L Cordoba SKODA Fabia Praktik Roomster 1 4L VOLKSWAGEN Fox 1 4L Polo 1 4L 1 6L HDF576 SEAT Cordoba Ibiza Ibiza Cupra SKODA Fabia 1 9L VOLKSWAGEN Polo 1 9L HDF577 RENAULT Megane Sc nic 1 5L 2 0L Grand Sc nic 2 0L KEY APPLICATIONS HDF579 HONDA Accord 2 2L Civic 1 7L HDRES LANDROVER Defender Discovey O OO OOOO O HYUNDAI Accent Getz Matrix 1 5L Sonata 2 0L H 1 2 5L KIA Cerato Rio 1 5L Magentis 2 0L HYUNDAI Accent Getz Matrix 1 5L Sonata 2 0L Grandeur Santa F 2 2L H 1 2 5L KIA Carens Rio Sorento 2 0L HDF598 00s VOLKSWAGEN LT 28 46 2 8L VOLVO S60 580 V70 XC70 2 4L HDF578 MITSUBISHI Grandis Lancer Outlander 2 0L HDF580 NISSAN Cabstar 3 5L 4 5L RVI Maxity 2 8L 3 2L 3 5L 4 5L DACIA Logan 1 5L SUZUKI Jimny 1 5L HDF582 NISSAN Qashqai 1 5L 2 0L X Trail 2 0L SMART Cabrio City Coup Fortwo 0 8L AUDI A4 A6 2 0L Hors fonoa Acco Cwe avza SS mores aomas OOO HYUNDAI Accent GLS 1 5L Getz GLS 1 5L Matrix 1 5L KIA Cerato 1 5L 1 6L Rio 1 5L HDF606 INECO Dally 2 35 Zo Dally 29 35 00760 2 01 HDF607 CHRYSLER Voyager 2 5L HDF608 CHEVROLET Captiva Epica Lacetti Nubira 2 0L CITR
16. ering capabilities and proven technology ve 2 to bring OE solutions to the aftermarket said o Marcelo Ganasevici Global Product Line Director a Independent Aftermarket Delphi Product amp Service Solutions We are fitting our OE compressor to a broader range of OE models to help deliver true value by allowing the aftermarket customer to gain access to our long Tier 1 OE supplier history technology and quality through an attractive Delphi s new alternative to current product offerings air conditioning marketing All of these new compressors can be found in the new European air conditioning catalogue which is support program the most comprehensive to date with some 1773 for garages and part numbers covering cars commercial vehicles distributors and heavy duty applications says Redouane Benhmida DPSS business line manager for includes a thermal system products The range covers 94 catalogue and of the European car parc including 97 for cabin air filters 94 for compressors 94 for four product condensers and 94 for receiver driers leaflets Included for the first time are blower motors with FE key applications such as Vauxhall Opel Astra Alfa Romeo 147 and Renault Laguna 01 The catalogue also includes new applications for Delphi OE condensers for PSA C5 407 Astra H Zatira and Ford Transit The catalogue Is supported by a compre hensive range of marketing Support material Delphi Servi
17. ever produced with the new 3 cylinder VW Polo BlueMotion developed one of the After more than a year of co development with Volkswagen Delphi is supplying its Multec Diesel Common Rail System for the new 1 2 litre 3 cylinder Volkswagen Polo BlueMotion Voted 2010 World Car of the Year the result is a cleaner greener car that achieves record low CO emissions and fuel consumption without compromising on performance DELPHI S MULTEC COMMON RAIL SYSTEM Delphi s Multec Diesel Common Rail System with a balanced valve fast servo solenoid injector was launched in 2000 and has since evolved to meet changing emissions standards while maintaining cost and performance competitiveness The Common Rail system on VW Polo BlueMotion includes the latest solenoid type diesel Common Rail injector technology with Delphi s next generation DFP6 fuel pump This combination allows for just 87 g km of CO emissions Delphi s new Common Rail system provides Significantly improved fuel delivery control extended multiple injection capability enhanced spray atomisation and air mixing said John Fuerst General Manager Delphi Diesel Systems The system in this vehicle can deliver up to six injection events per combustion cycle which translates into a very smooth combustion process and therefore lowers the NVH levels In addition to Delphi s Multec Diesel Common Rail system the VW Polo BlueMotion is fitted with a Delphi
18. gineering Delphi Product amp Service Solutions All parts released for the aftermarket undergo the same rigorous product development processes including Production Part Verification PPV and Production Part Approval Process PPAP according to Shasteen The purpose of PPV is to confirm the part being produced performs exactly as the prototype was designed and the purpose of the PPAP is to ensure every part meets all of the requirements defined in the engineering samples What s more any plant manufacturing a Delphi part must adhere to all of Delphi s manufacturing standards to include performance noise and durability testing Unlike some competitors in the aftermarket Delphi has a validation and durability test schedule to ensure our products perform in the most extreme conditions vehicles would experience worldwide said Shasteen P18 Delphi s Magazine for Automotive Technicians ATtermarke More than a decade ago Delphi created its exclusive compressor life cycle test based on data from cars driving in real world conditions including personal vehicles taxi fleets and police fleets After recording the conditions the vehicle compressors were exposed to Delphi standardised its durability test schedule which is used for its OE and aftermarket compressors Delphi s SP compressors were tested to Delphi s durability requirements which in some cases are more stringent than those of the global OEMs it serves
19. his extra boost Peugeot used production Delphi charge air coolers as supplied to road cars as they met the performance targets required for endurance racing This event has been called the ultimate durability test said John Fuerst Delphi s General Manager Diesel Engine Management Systems Delphi successfully faced this test with production products on the RCZs that needed little or no modifications to perform in this gruelling race We are delighted to have been selected as a technical partner for Peugeot and to have helped them achieve such an impressive result in the company s 200th anniversary year Delphi s production 2000 bar Common Rail system with Multec balanced valve fast servo solenoid injectors met the modified engines demands with minimal revisions Extensive trials established that the only significant upgrade required was to change the nozzle definition optimising the spray pattern to suit the increased swirl created by the higher boost levels The new configuration also increased maximum fuel flow contributing to the increase in power and torque The standard fuel pump was retained without modification For a race car to use a production ECU is a particularly rare event but Delphi achieved this as well said Fuerst Our technical specialists moditied the software of the standard ECU to allow Peugeot to re calibrate the engine mapping to suit the demands of endurance racing with the re tu
20. ignificant Surprisingly many garages still outsource this work To tap into this lucrative servicing opportunity technicians need to be trained on the very latest technology keep up to date with regulation and have access to the right tools and parts As an original equipment manufacturer Delphi is in a unique position to provide valuable knowledge of the technology the market will see in vehicles today tomorrow and ten years down the road Join the Delphi Service Centre network to access all the tools skills and knowledge you need to stay ahead of the game To find out how Delphi Service Centre could benefit your business read more at www delphi com DSC P2 Delphi s Magazine for Automotive Technicians TECH TALK P3 Delphi Fuel Pump Failure Analysis A lot It tells a story Take the fuel pumps to the right These failed pumps were not a result of incorrect testing All tests performed were valid and provided useful data for making a diagnosis but more could have been learned Were they worn out or did they fail for another reason The answers to these questions are important and without them an accurate diagnosis is left to chance inviting future problems for you and your customer A failed part analysis should always be conducted on failed fuel modules through close visual examination and some simple disassembly FIRST CHECKPOINT Examine the electrical connectors closely and look for evi
21. ions drop us an e mail at TechTalk delphi com Delphi s DS100E and DS150E enable garages to quickly diagnose faults across a wide range of on board electronic vehicle systems including engine management ABS air conditioning gearbox instrument dashboard and immobiliser systems The tools support 47 vehicle manufacturers and over 30 000 applications Other platforms in the DS range include the DS350E based on a UMPC DS500E DS550E and DS800E Vi SERVICE CENTRE TECH TALK P17 NN SP Compressors Validated to Meet or Exceed OE Specifications Unlike some competitors in the aftermarket Delphi has a validation and durability test schedule to ensure our products perform in the most extreme conditions vehicles would experience worldwide ri When Delphi introduced its aftermarket SP compressors earlier this year the product line was developed based on Delphi s innovative SP technology used by major OEMs worldwide But Delphi did more than bring Original Equipment OE engineering and design expertise to the aftermarket It applied the same stringent validation testing and manufacturing processes it does to every component It produces Whether it s engineered and designed for OE production or an aftermarket application every Delphi part must adhere to the company s global technical requirements said Mark Shasteen Vice President Global Service and En
22. nce of melting or bubbling near the electrical terminals Any melting is an indication of excessive heating due to a poor electrical connection caused by a damaged vehicle body harness If this type of damage is found poor pump performance will occur due to this bad connection The vehicle s electrical connector must be replaced or repeat failures will occur SECOND CHECKPOINT Examine the external strainer on the fuel module Look for signs of dirt and or rust contamination Any form of dirt found in the strainer should immediately trigger an inspection of the fuel tank A tank cleaning or replacement should be conducted based on what is found It is Important to understand how contamination entered the fuel tank so preventative action can be taken to eliminate future occurrences Areas like the tank vent system should be checked to determine if contaminants entered through this area If determined contaminants were pumped into the tank or intentionally added It s Important to change fuel supplies or add a locking gas cap to the vehicle Innovation for the Real World THIRD CHECKPOINT Visually examine the fuel module bucket and internal strainer Depending on the module design you may be able to view the module bucket through an opening in the fuel module design If not the bucket may have to be removed from the fuel module through disassembly What is important to note is what has accumulated in the fuel modul
23. ned engine Io meet the challenges of such a gruelling race with systems that were originally designed for road car applications is very satisfying for us and is a clear indication of the quality of Delphi technology and manufacturing Left article image Julie Sueur Endurance info com CES Innovation for the Real World Delphi successfully faced this test with production products on the RCZs that needed little or no modifications to perform in this gruelling race We are delighted to have been selected as a technical partner for Peugeot and to have helped them achieve such an impressive result in the company s 200th anniversary year ri GED TECH TALK P21 Innovation for the Real World The Company That Makes The Parts Cars Are Born With As a partner to the world s leading manufacturers Delphi is helping to improve driver safety comfort and connectivity and deliver better fuel efficiency and vehicle performance all whilst taking care of the world we live in These same technologies featured in a number of vehicles launched at this year s Geneva Motor Show Unlike competitive radars the ESR provides two measurement modes simultaneously ESR s long range coverage provides accurate range and speed data with effective object detection while wide mid range coverage not only allows vehicles cutting in from adjacent lanes to be detected but also identifies vehicles and pedestrians across the
24. nit the tool provides workshops garages and fleets with real time analysis of fuel content at an affordable price It specifies the level of bio diesel in the fuel sample and identifies whether any impurities are present Independent research has shown that up to 80 percent of diesel engine problems stem from conta minated or poor quality fuel giving immediate and accurate results via a digital display screen The volume of fuel required to undertake the analysis is only 46ml which can be retrieved from the fuel pump or filter This will allow technicians receiving only system components to check the fuel just as easily as those working directly on the vehicle With this data the user can quickly establish whether there is an unacceptable amount of bio diesel or any impurities present that may impact on the fuel injection system The complete fuel analyser kit from Delphi includes a USB cable a mains adapter three 50mI measuring tubes a quickstart guide and a CD with a user manual and reporting software It is available in 10 languages through our network of authorised Delphi distributors and workshops TECH TALK P13 Innovation for the Real World Volkswagen Chooses Delphi Technology to Develop the Polo BlueMotion Cleanest Car in its Class and Voted 2010 World Car of the Year P14 Delphi s Magazine for Automotive Technicians Delphi Corp and Volkswagen have greenest diesel systems
25. noise TECH TALK P15 Innovation for the Real World Common Rail Diesel System Faults By following a simple guide to diagnosing faults with Common Rail diesel systems garages can improve their efficiency and open up a new and profitable revenue stream The growth in the Common Rail diesel parc presents a great servicing opportunity for garages with the right equipment and knowledge However to service these sophisticated systems effectively efficiently and safely garages should follow a few simple steps By replacing individual injectors rather than a whole set garages can save both time and money Vi ASSESS THE FUEL QUALITY The first step for any garage should be to perform an initial diagnostics on the quality of the fuel Delphi s fuel analyser part number YDT553 gives garages the ability to measure the percentage of bio diesel in the fuel and identify the presence of impurities This will enable the technician to confirm whether fuel is the root cause of the problem Once the quality of the fuel has been established further diagnostics will be required to either assess the component damage if fuel is the issue or pinpoint the fault if otherwise IDENTIFY THE FAULT CODE The first stage in identifying a fault with a Common Rail diesel system is to interrogate the vehicle s On Board Diagnostic OBD system By using a good quality all makes diagnostic tool such as Delphi s PDA based DS100E part number
26. opportunities Examples include Injector servicing and diagnostics Advanced ABS and chassis control systems Steering and suspension and wheel alignment fault finding and diagnosis Air conditioning servicing and fault diagnosis Engine management and diagnostics Multiplex and CAN databus systems Introduction to hybrid vehicle systems Parts operations and selling Maximising the Delphi Service Centre opportunity As a leading manufacturer of OE diesel fuel injection systems Delphi knows just what it takes to keep a diesel engine in optimum condition Our Diesel fuel treatment part number HAD100 is designed to provide superior engine protection Developed in conjunction with Chevron and incorporating the very latest Texaco fuel technology it enhances the fuel s ability to clean protect and restore Unlike many other fuel additives which are added during each refuelling Delphi s Diesel is a single dose fuel based treatment which is effective in the vehicle s fuel system for up to 6 months safeguarding the system long after it is filled up The high strength formula is supplied in 350ml bottles for single doses treating 50 to 70 litres of fuel This makes it an ideal product for garages By incorporating this as part of a standard service regime garages can offer an added value service to their customers whilst increasing their revenue and profits A win win for both Diesel is available through Delphi
27. r of OE quality steering parts These latest additions take our vehicle parc coverage to in excess of 90 The range can also be found on TECDOC TECH TALK P11 Innovation for the Real World A robust hand held unit the tool is designed to provide workshops garages and fleets with real time analysis of fuel content at an affordable price Ad Tas a ate gt Pe e 4 gt E e r PA P12 Delphi s Magazine for Automotive Technicians A First for the Market with Delphis New Fuel Analyser Running vehicles on poor quality or contaminated fuel can lead to performance issues such as filter plugging injector coking piston ring sticking and breaking Such problems need to be identified at the earliest possible opportunity in order to minimise the risk of longer term damage to the engine Immediate and accurate analysis of the fuel is therefore critical Using the new Delphi Fuel Analyser part number YDT553 technicians will be able to perform a first level diagnostic to check if the fuel meets the latest EN590 standard and identify potential contamination problems Similarly commercial vehicle fleets can use the tool to analyse the quality of fuel before refuelling reducing the risk of fuel related engine problems Until now the only option has been to send samples to a specialist laboratory for analysis costing both time and money A robust hand held u
28. radiator compressor and antitheft and immobiliser systems A CLOSER LOOK AT THE DFP6 PUMP TAE VYY POO BlueMotion was chosen as 2010 World Car of the Year from a list of 30 entries nominated by 59 World Car jurors from 25 countries Unveiled at the International Motor Symposium in Vienna earlier this year Delphi s DFP6 single plunger rail fuel pump is designed to simplify packaging and reduce weight while providing 2 000 bar maximum rail pressure The pump combines a relatively small specific capacity of up to 0 42 cc rev with the capability to run at engine speed allowing it to be used on a range of engine sizes up to 2 2 litres It features a new compact hydraulic head design which helps to improve the volumetric and mechanical efficiency enabling a potential reduction of engine CO The new concept is much stiffer than the previous generation head with Delphi s integrated inlet valve assembled directly into the head and a forged high pressure outlet which incorporates the outlet valve and helps to achieve reduced stress The cars were judged on merit value safety environment significance and emotional appeal The DFP6 pump also features an innovative roller and shoe mechanism The twin lobe cam offers two pumping events per revolution reducing the number of pump strokes needed The roller cam shoe mechanism has a patented static shoe guide that has been designed to reduce torque dynamic mass and
29. rmance to many petrol alternatives and fuelling extraordinary growth in diesel cars worldwide Operating at extreme pressures of up to 2000 bar the Common Rail fuel injection system delivers precision control of the combustion process The injector is key to this Each injector is allocated an individual characterisation code relating to its specific flow rates response times and performance at different pressures This must be programmed into the ECU whenever a replacement injector is fitted to the vehicle The ECU will then manage the delivery of each injector to ensure that the engine runs at optimum efficiency These advances mean that only garages equipped with the right tools skills and knowledge will be able to take advantage of the rapidly growing diesel servicing opportunity PETROL ENGINE MANAGEMENT The introduction of advanced technologies such as gasoline direct injection GDI enabling a stratified fuel charge combustion for improved efficiency has resulted in significantly more complex petrol powered vehicles Coupled with this you only need to look at the multi function displays on the dashboard of a modern vehicle to see that an increasing number of automotive management systems are being controlled by electronics In 2005 only 20 of systems in new cars were controlled by electronics today this figure is more than 40 and rising The result engine management systems represent more than 60 of diagnostic fa
30. s authorised network of distributors is a single dose fuel based treatment which is effective in the vehicle s fuel system for up to 6 months FE part number IS designed to clean protect and restore Vi workshops and Delphi Service Centre garages For further information visit our website at www delphi com am P8 Delphi s Magazine for Automotive Technicians TECH TALK P9 Even the smallest amount of dirt air or water can cause damage to modern fuel injection systems In fact the most damaging particles are the smallest ones just 2 to 5 microns In size We bring this very same OE expertise to the after market Whether designed for an OE or aftermarket application we apply the same stringent validation manufacturing and testing procedures Every filter adheres to Delphi s exacting quality standards Delphi is launching 29 new original equipment quality filters fitted to popular diesel car and light duty applications including Fiat Punto Vauxhall Opel Corsa Renault Scenic VW Polo Seat Ibiza Audi A4 and Honda Civic providing coverage of an additional 10 million vehicles But what does this mean to the garage You know that when you install a Delphi filter you are getting a product that has been designed engineered and manufactured to provide the same levels of filtration performance and durability as demanded by the vehicle manufacturer For over 100 years Delphi has b
31. the pump could be faulty CONFIRM IF A MECHANICAL OR ELECTRICAL PUMP FAULT If the Common Rail pump is suspected of being faulty Delphi s False Actuator Kit part number YDT410 should be used in conjunction with the Sealed Rail Kit for further interrogation The False Actuator Kit temporarily replaces the vehicle s actuator to enable the pump to generate full system pressure If the pump generates the correct pressure with the False Actuator in place then the vehicle actuator is likely to be at fault and should be replaced However if the pressure is still below the required level when tested with the False Actuator then the Common Rail pump is likely to have a mechanical fault and should be repaired or replaced VEHICLE ENTERS WORKSHOP Fuel Analyser Assess fuel quality chanical test DS100E n ber YDT278 Electronic fault diagnosis False Actuator Kit Determine whether fault is actuator related or an internal mechanical failure part number YDT410 By joining an established network such as Delphi Service Centre independent garages are paired with technical partners who can provide extensive technical support and training to help overcome any challenging issues Garages are also provided with a full range of diagnostic tools ensuring they have all of the resources required to make their first step into diesel To learn what Delphi Service Centre can do for your business visit www delphi com DSC or if you have any quest
32. ult codes These advances represent a new challenge for garages It is essential that any business invests in the right tools and parts to service these increasingly sophisticated vehicles BRAKING STEERING amp SUSPENSION Not so long ago braking steering and suspension were all separate un integrated systems within a vehicle The technology behind these systems has since evolved to create a single all encompassing system called Unified Chassis Control The introduction of reactive shock absorbers steering angle sensors and brake assist have all helped to improve the safety control and handling of the vehicle This means that chassis component servicing can no longer be performed with just a diagnostic tool Steering racks that are electrically driven will need to be re calibrated after being fitted electric parking brakes need to be wound back and vehicles with air suspension will need the service mode selecting before maintenance Innovation for the Real World AIR CONDITIONING Air conditioning is no longer considered a luxury option Fuelled by drivers demand for greater comfort and convenience it now comes as standard in most new cars 15 years of successive growth in system fitment and a rapidly expanding parc have all contributed to a strong air conditioning market And because these systems need regular maintenance to be effective the requirement for servicing and repair is s
33. ulting voltage tells the vehicle computer to simple solution for the vehicle owner most innovative oxygen sensor programs adjust the injector pulse to change the amount of for the aftermarket fuel delivered The rationalised range of nine MAF sensors covers over 600 popular European applications including Capitalising on our OE technology we Delohi MAF sensors are designed engineered and Fiat Punto VW Golf Vauxhall Opel Corsa and developed a smarter solution with wider manufactured to exacting OE standards delivering Mazda 6 In consolidating the line we are helping aftermarket coverage for older and late accurate air flow measurements and enhanced distributors and garages to reduce their inventory As one of only four oo model applications The oxygen sensors engine performance And unlike other brands by stocking fewer part numbers OE manufacturers of oxygen sensors Delphi has manufactured more than 250 million O2 are configured and designed to replace previous conical sensor designs In doing so Delphi has increased coverage but decreased SKUs We call it intelligent SKU management a simpler way to repair sensors since 1974 Delphi MAF sensors are designed engineered and Delonas delivers manufactured to exacting OE more than 55 million standards delivering accurate MAF sensors for more air flow measurements and Hen aoe Cirer customer applications enhanced engine performance since 1993 Vi DELPHI PART
34. y launching replacement parts within 6 months to 1 year of vehicle launch This is happening now with parts available for the latest vehicle releases including BMW Z4 2009 gt Vauxhall Opel Astra 2009 gt Chevrolet Cruze 2009 gt Nissan 370Z 2009 gt Toyota Avensis 2009 gt Toyota Prius 2009 gt Honda Accord 2009 gt and Citro n DS3 2010 gt Earlier this year Delphi was honoured with two Automotive News Premier Automotive Suppliers Contribution to Excellence PACE awards for Innovation its multimode electronically scanning radar and Common Rail injector technology Recognised around the world as an Industry symbol of innovation PACE awards acknowledge innovation technology advancement and business performance Since 1995 when the award was first presented Delphi has been recognised with 12 PACE awards more than any other company Delphi helping to make vehicles safe green and connected New Steering amp Suspension Catalogue Delphi is pleased to announce the launch of its new European steering and suspension catalogue for 2010 11 The catalogue contains the full range of Delphi steering and suspension parts including ball joints wishbones bushes link stabilizers track control arms tie rod king pins and steering rack gaiters With over 380 new part numbers added since the last catalogue in September 2009 Delphi continues to demonstrate its strength as an industry leading provide
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