DON’T MISS:// Delphi ignition Coils: out-

performing the Competition p2

// Why Change shoCk absorbers in pairs?

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// Delphi’s teChnology tips

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// Chevrolet volt: 2012 Car of the year

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As legislation steers manufacturers to offer greener and safer automotive technologies, the aftermarket must prepare for its role in maintaining these automotive systems. To combat the environmental effects of carbon particles and NOx, vehicle manufacturers have been led to design catalyst reduction systems to reduce and trap soot particles, in particular, fine inhalable soot molecules which are invisible to the naked eye. Diesel particulate filters play a significant role in diesel emissions control, therefore it is imperative the complete system’s performance, from fuel injection through to the exhaust system, is managed carefully to guarantee successful replacements and repairs.// For more on Delphi’s DPFs, see page 14 tt

Check out our new range!simply scan the code (below) with your smartphone/device loaded with a Qr code reader available through your app store. Alternatively, go online at http://am.delphi.com/qr2

TurN TO page 4 TO fIND OuT hOw DelphI cONTINueS TO keep vehIcleS Safe, greeN aND cONNecTeD

Delphi’s New Diesel Particulate Filters.

Delphi launches a range of diesel particulate filters (Dpfs) to help reduce Co2 emissions, whilst maintaining optimal vehicle performance in the aftermarket.

ThIS MONTh we Talk:

Ignition Coils – Delphi vs Competitor

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Keeping Safe, Green and Connected

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Spotlight on Thermal p6

Diesel Injectors – find out how

p8

OE Braking Expertise p10

Shock Absorbers p11

Training opportunities around the globe

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New range of DPFs p14

Why check the O2 Sensor? p16

Fuel Analyser Case Study p17

Technology Tips p18

Global Product Portfolio p20

Chevrolet Volt – 2012 Car of the Year

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Delphi’s Magazine for Automotive Technicians // Issue 4

the symptoms associated with ignition coil failure include engine backfire, misfiring, carbon tracking and engine overheating. knowing how to quickly and correctly diagnose these issues is critical for today’s technicians. When an issue and/or failure is determined, it is equally important to ensure the coil is replaced with high quality parts in order to guarantee the same level of performance specified by the vehicle manufacturer.

As an Original Equipment manufacturer with over 100 years of automotive technology expertise, Delphi’s parts are designed to meet exacting OE standards. This is not always the case with other aftermarket parts suppliers, and the result is inferior parts that can affect the vehicle’s performance and are likely to fail earlier than their OE counterparts.

Technicians and parts distributors need to be aware not all ignition system parts are created

equally. But how do you tell the difference? Below are some examples of what

separates Delphi’s OE ignition coil technology from the rest –

High Standards. Below the Surface.

Delphi Ignition Coils:Outperforming the competition

Delphi’s ignition coils feature precise spark timing response for increased fuel economy and faster crank-to-run. providing accurate electrical energy to create voltage potential at the spark plug, Delphi’s ignition coils enhance engine performance, adjusting to driving and environmental conditions. and like all other Delphi ignition system components, they also enable the engine management system to maintain tighter control over emissions.

When comparing a sectioned Delphi ignition coil against a competitor product, the obvious

difference in the windings of the primary coil is the first sign of quality disparity. The competitor’s poor quality windings is tri-layered. The bubbles in the epoxy (the brittle thermosetting polymer mix which holds the coil together) show the coil is insufficiently impregnated. If the epoxy is exposed to high temperatures within the ignition system, bubbles in the epoxy are likely to lead to cracks. Should the epoxy crack, the strength of the coil is affected, becoming less durable and less effective.

1

parts distributors and technicians need to be aware not all ignition systems are created equally.

High quality windings, as viewed in the Delphi coil, allow direct currents (DC) to pass through the primary core, inducing a magnetic field coupled to the secondary core that produces the high voltage pulses required to produce the electric spark at the spark plugs secondary terminal igniting the fuel/air mixture. The competitor product’s poor quality windings affect the transfer of the electro-magnetic flux, affecting the timing of the voltage delivery from the primary to the secondary core.

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Delphi Ignition Coils:

In comparing the internal core designs further, it was found

that whilst Delphi’s ignition coils are using a suppressor to reduce electro-magnetic noise, the competitor’s lower quality design does not incorporate such a resistor.

The lack of electro-magnetic compatibility will lead to signal interference, susceptibility and immunity issues, which will affect the general operation of the coil and associated electrical components susceptible to interference.

When the parts are cut open, the differences are even more apparent.

2

3 As you can see in the product x-rays to the right, the competitor’s

wire connections (right) significantly differ from the Delphi part’s Printed Circuit Board. The competitor’s wires are connected via wires, making them susceptible to breakage and limiting the durability and strength of the connection. A break of one of the wires will lead to coil failure resulting in repair and replacement. A weakened or intermittent connection affects the coil’s reliability and can lead to engine misfiring, backfiring, difficulty starting the engine, increased emissions and/or poor fuel consumption. tt

In summary, the manufacturer of the competitor product has opted for an extra layer of wiring to make up for the disorganisation and lack of quality epoxy, this is thought to optimise the production of high voltage pulses in the primary core. Whilst the part will undoubtedly result in spark plug ignition to start the engine, without quality windings and epoxy there is no telling how long it will work before failing altogether.

Delphi continues to stress the importance of fitting high quality products, and vehicle electronics are no exception.

Low-quality parts can lead to costly failures, and the risks associated are not worth it. Proof you definitely get what you pay for. So help ensure you are getting quality and choose the company that makes the parts cars are born with, choose Delphi.

Delphi Competitor

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Keeping Vehicles and People…Safe, green and connected.

helping drivers – and passengers – stay safe on the roadGlobally, more than five million auto accidents result in injury every year. To help decrease this number and reduce the severity of crashes that cannot be prevented, Delphi is committed to offering vehicle manufacturers and consumers affordable safety products.

Delphi offers a range of smart systems, including its RACam system, a single module that fuses radar and vision sensor inputs to help warn drivers, define mitigation strategies and automatically brake if a collision is imminent. “Our technical expertise and heritage of innovation help us create the right products, with the right quality, at the right price, at the right time for our customers and global markets.” Said Brown. Delphi’s commitment to safety extends beyond the road; to vehicle assembly processes, dealership service bays and even customers’ garages with shielded wiring connections and Electric Vehicle (EV) charging systems balancing convenience with safety.

research shows that worldwide today’s vehicle marketplace is driven by three “megatrends”: a demand for enhanced vehicle safety, concern for the environment, and consumers’ desire to increase the flow of information and entertainment media to – and from – the vehicle. vehicle manufacturers everywhere are using new advances to address these megatrends. at the same time, OeMs know vehicle technologies must be more than simply innovative. They must also be reliable, cost-effective and address real-world problems.

“our goal is to help vehicle manufacturers deliver cars and trucks that are safe, green and connected,” said Dr. andrew brown Jr., executive director and chief technologist, Delphi automotive. “Delphi understands how global automotive megatrends and drivers affect our customers and markets, and we’re working every day to deliver systems and components that will help our customers compete now and in the future.”

P4 Delphi’s Magazine for Automotive Technicians // Issue 4

Keeping Vehicles and People…

reducing the impact of vehicles on the environmentAnd speaking of EVs, consumers around the world are increasingly aware of climate change and its effects – as well as the impact vehicles have on our environment. Simultaneously, OEMs require green technologies that are both affordable and reliable. Delphi engineers are working to meet the needs of consumers and automakers alike with a broad portfolio of solutions – from advanced hybrid vehicle electronics to efficient gasoline and diesel powertrains with higher performance and lower emissions – to energy-efficient HVAC systems and compressors with compact designs and lower mass. Delphi also saves limited copper resources by creating efficient wiring with alternative materials such as aluminium. All designed to reduce the consumption of the earth’s valuable resources.

connecting the vehicle to the worldAll over the world, more people are living in a “24/7” world where connectivity at home, at work or on the go is not just a luxury – it’s a requirement. This increasing demand for information and entertainment anytime, anywhere, extends to the vehicle. But, when it comes to cars and trucks, connectivity must be partnered with safety and ease of use.

Delphi technologists have been at the forefront of in-vehicle information since installing the first in-dash radio in 1936. Today, they are applying that know-how to create value in the area of wireless communication. Delphi’s MyFiTM Connected Infotainment Systems provide safe, seamless information and entertainment access in vehicles. The systems bridge the great connectivity and distraction divide by integrating vehicle safety, connectivity and user interface systems to mitigate distraction and maximize safety.

working with automakers to find new opportunities through advanced vehicle systemsBrown emphasised Delphi’s research and development efforts extend beyond innovation. “It’s a combination of foresight and cooperation,” he said. “By working closely with auto manufacturers at every stage of development and production, we can help them anticipate consumer demand and seamlessly integrate advanced technologies into their vehicles.

Brown cited the importance of Delphi’s global engineering resources in these efforts. “We’re finding that our global footprint – which includes technical capabilities everywhere our customers conduct business – is helping us develop solutions for both passenger and commercial vehicles that take advantage of local standards. As a result, we’re able to help our customers meet the needs of the market wherever they want to grow.”

“At Delphi, we believe technology can do more than simply help our customers respond to the global megatrends of safe, green and connected,” said Brown. “By offering innovative, reliable and cost-effective advanced vehicle systems, we hope to help our customers see these megatrends as new opportunities to win in today’s competitive global marketplace.”

to learn more about how Delphi is using advanced technology to address global megatrends, visit Delphi at delphi.com/4innovation. tt

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why stock year roundThermal part failures do not only occur in summer, but along with front-end crash damage, all year round. Factors should be prepared for these types of repairs and… the untapped selling opportunity they could provide. Stock up for profitability with these simple tips from Delphi.

As you’re aware, the heater core is necessary in winter to heat and demist the cabin. But did you know it’s one of the primary thermal repair opportunities in the winter with main failure causes include leaking or clogs that may occur if the coolant is not checked and/or changed regularly? This is the same for AC compressors. Failure can occur anytime, and as the compressor is the heart of the air conditioning (A/C) system, the vehicle cannot run without it.

As for maintenance products, there is no particular period to service a car even when it comes to AC components. The receiver drier filters the refrigerant to capture small debris and moisture. Saturated with a small volume of water, it must be checked and changed regularly (every 2-3 years and each time the system is opened). The cabin filter purifies the air coming into the cabin, and efficiently retains small particles of pollution in the atmosphere. It’s necessary to change it every 12 months (10,000 miles) – every 6 months with urban use. Particle cabin air filters remove particles from the air too large to pass through the filter. Activated carbon air filters are more effective and retain smaller particles of pollutants, chemicals, gases, cigarette smoke and other toxins.

Besides general part failures and maintenance/service opportunities, in front end crashes, the main heat exchangers (which are located at the front end of the vehicle) are often directly impacted. These parts include radiators, condensers, charge air coolers, cabin air filter and heater cores. Delphi provides the aftermarket with almost 100 percent coverage on compressors, radiators,

Spotlight on Thermal:prepare to repair Year round

Stock up for Thermal Season... Year round!if you think thermal season is just one season, think again. your factor may be missing out on lost profits and growth opportunities.

charge air coolers and condensers and it’s total, first-to-market, all makes thermal product offering has over 90 percent application coverage with more than 2,000 part numbers.

Don’t forget the equipment and accessories Beyond parts, it’s important to be prepared when a garage comes in requesting advice and recommendations regarding new thermal equipment. This is your opportunity to demonstrate your thermal expertise on how a garage should tool up for service and repairs.

Key devices such as the refrigerant identifier, electronic leak detection tool and temperature gun all need to be tested and adjustments made, as required, to ensure they are performing to manufacturer specifications. A little preventative maintenance will go a long way.

The refrigerant recovery/recycle and recharging station is one of the most important tools for a technician conducting repairs. Not only does the RRR machine need annual, complete pre-season inspection, but Delphi also provides four different types of RRR machines to keep your customers happy.

Delphi introduced the four A/C recharging stations to its service portfolio in September 2011. These machines deliver quick, accurate recovery, and recharging of passenger and commercial vehicle thermal systems including hybrid and electric vehicles. Each system features a patented aluminium manifold which delivers efficient refrigerant recovery, enhanced leak protection, and easier assembly and access.

Most A/C system oils and lubricants have a shelf life. Using anything that’s past the expiration date could damage the system you’ve just repaired. Another good supply check is O-rings. These, too,

P6 Delphi’s Magazine for Automotive Technicians // Issue 4

For more on Delphi’s thermal product offering, check out our new ‘Spotlight on Thermal’ on Delphi’s aftermarket website by visiting: http://am.delphi.com/news-spotlight/spotlight-on-thermal/

won’t last forever. Ask your customers if their oils, lubricants and O-rings are up to date. It could avoid an unnecessary return and an unhappy consumer.

Unfortunately, spanner wrenches won’t work on newer style compressor clutches. Ask your customers if they’ve invested yet in a compressor turning tool. You might also want to consider recommending they add a diagnostics tool such as Delphi’s new A/C Analyzer to their garage. This unique device measures eight key air-conditioning system areas to help take the guesswork out of servicing today’s A/C systems. The hand-held, wireless device links to any Bluetooth-equipped PDA and services R-134a systems.

Thermal technologies entering the aftermarketTechnology is constantly evolving. Today’s motor factors should be aware of the technologies found on new production vehicles. These will be the aftermarket vehicles of tomorrow. Take for example Delphi’s new technology Phase Change Material (PCM) storage system. One of the unique characteristics of a hybrid vehicle is the engine can shut-off at any time during a drive cycle, such as while waiting at a stop sign or stop light, which increases fuel efficiency and

Did you know?

The most common leaks are from defective valves. Before any intervention, you have to check and replace if necessary. Delphi can supply valve kits and valve remover tools. Ask your Delphi sales representative for more information.

reduces emissions. Conventional vehicles use an air conditioning compressor that is belt-driven by the engine. When the engine shuts off, so does the air conditioning system. To help keep passengers comfortable when this happens, Delphi has developed a PCM storage system.

This thermal storage system enables a hybrid or electric vehicle to store excess thermal energy while the engine is running efficiently, and then releases this energy during engine-off idle stops or when the vehicle is running inefficiently. This means the air conditioning system is turned off but the vehicle is still comfortable. The expected launch of this technology in new production vehicles is 2014.

Stocking up to profitability doesn’t involve just parts. It’s important to educate your team to the new technologies entering the market, as well as the services and training offered by suppliers to support the parts you stock. Is your factor ready? tt

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Delphi Diagnostics

The solution:

Step 1:the technician connected Delphi’s Ds150 diagnostic tool to the 16-pin eobD diagnostics socket to interrogate the vehicle’s fault code history.

Fault returned ‘P0263 Injector cylinder 1 – Drift’ indicating an injector related fault.

Step 2:the technician checked all of the injector’s backleakage using the Delphi sealed rail kit (yDt278) in order to identify which injectors are not performing to specification, and to confirm correct levels of rail pressure.

In this case, it was a fault with one of the injectors, but if low rail pressure was an issue, the technician would have used Delphi’s False Actuator Kit (YDT410) to determine whether or not the pressure was generated mechanically by the pump, or if there was a possible fault with the pump’s Inlet Metering Valve (IMV) or Pressure Control Valve.

Step 3:to ensure the damage was not due to contaminated fuel, the technician’s next step was to test the fuel within the system with Delphi’s fuel analyser (yDt553).

After testing the fuel from the vehicle’s tank, and/or the fuel filter assembly, it was found the fuel was not contaminated.

how To: code Diesel Injectors

The Symptoms:Poor Starting – Increased Fuel Consumption

If the fuel analyser had shown fuel contamination, the technician could use this diagnosis to explain the damage, as well as to refute any possible warranty claims. The fuel analyser can be connected to a PC so results can be downloaded and printed for the workshop or customers records.

Step 4:once the technician concluded the fault was a worn injector, he removed all of the injectors from the vehicle. as all of the injectors had done the same mileage, it was important to have the complete set diagnosed to rule out any other potential problems. the injectors were sent to a local Delphi Diesel Centre.

The Delphi Diesel Centre tested the injectors on a Delphi authorised test bench to confirm which injector was at fault. This included electrically testing the injectors for resistance and insulation failures.

P8 Delphi’s Magazine for Automotive Technicians // Issue 4

pleaSe NOTe!Diesel Common rail fuel systems proDuCe very high pressures, in eXCess of 1,400 bar. please folloW all safety guiDelines before CommenCing any Work to avoiD personal inJury. Delphi Can proviDe training Courses anD more information if reQuireD.

Ds Diagnostic toolProviding comprehensive all makes diagnostics across the key electronic systems, the DS solution is available on a variety of platforms, ensuring the right tool for any business.

sealed rail kitDelphi’s Sealed Rail Kit is able to accurately measure the rail pressure generated by all makes of Common Rail (CR) pump and the backleakage returning from each injector while the components are still fitted to the engine. If the vehicle does not run, the tests can be carried out at engine cranking speed. This avoids removing the CR pump and injectors to later find there is no fault with these components. In most cases, this work can be carried out in less than one hour.

false actuator kitIf it is proven the rail pressure at engine cranking speed is below the minimum required value, this may be caused by a faulty Rail Pressure Control Valve or Inlet Metering Valve attached to the CR pump. Suspect valve can be removed and replaced with a false (or dummy) actuator from this all-makes kit. The Sealed Rail test (described above) can then be repeated. If sufficient rail pressure is generated, work can be completed by fitting a replacement valve.

fuel analyserDelphi’s fuel analyser is a robust, hand-held unit which provides immediate and accurate results via a digital display screen. The tool specifies the level of biodiesel present in the fuel sample. If the fuel is contaminated with unrefined biodiesels or vegetable oils, a simple error code will be displayed identifying the potential cause of contamination. Using this data can immediately identify whether there is an unacceptable amount of biodiesel present or contamination which will have impacted on the fuel injection system.

Technician’s Tool Box

Step 5:after the injectors had been tested, any which did not pass the authorised test were dismantled, repaired and reassembled in a filtered clean environment. in this case the one repaired injector was, once again, put through a complete test procedure on an authorised test bench, and finally, recalibrated with a new C2i/C3i code, which was printed onto a label and attached to the injector body.

The new calibration code is critical for the operation of the repaired injector. When fitted to the engine, it allows the software within the ECU to accurately control the injector’s fuel delivery and switching times according to the specific parameters and performance for the vehicle.

Step 6:once the technician received the tested, repaired and recalibrated injectors, he was able to re-fit them to the engine, continuing to maintain a high standard of cleanliness at all times.

After the injectors were fitted to the engine, the technician utilised the DS diagnostic tool to calibrate the vehicle with the new C2i/C3i code for the repaired injector and to recheck the other three. This is a straightforward process as the tool provides help files for the technician to guide them through the process. Please note, recalibrating the vehicle with the new codes is essential – if the new codes are not entered, the vehicle will have poor running and idling issues, and fault codes are likely to be generated.

Step 7:the final step for the technician was to re-interrogate with the Ds diagnostic tool and clear all fault codes to confirm the fault was eliminated.

Job done!

Technician time: approximately two hours…Ensuring the repair is carried out correctly and efficiently the first time, on time!

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expertise to the aftermarket

Used accessory components may appear to be in good condition, however, they will undoubtedly have reduced tension and function, as these parts are exposed to strain, moisture and salt corrosion and, in most climates, extreme temperature conditions. Not replacing these components could lead to unequal braking; hence a reduction in stability and safety, as well as an increased wear on pads and discs, resulting in pad vibration and increased brake noise.

Whilst Delphi recommend to change pads and fitting accessories at the same time, the current sales results show that only one kit is sold per 25 sets of pads. With the price of an accessory kit at only 3-6% of the total cost of brake disc and pad repair, don’t skip this all important step when performing a braking service. tt

with the price of an accessory kit at only 3-6% of the total cost of brake disc and pad repair, don’t skip this all important step.

when performing a braking service, Delphi strongly recommends technicians fit new braking accessories with every fitment. By replacing accessory kits when changing brake pads, you ensure: a complete high quality brake repair, a reduction in potential warranty claims, a reduction in brake noise, increased customer safety, as well as a brake repair identical to Oe service.

Bringing OE Braking…

P10 Delphi’s Magazine for Automotive Technicians // Issue 4

Around the Wheel

many motorists tend to ignore the importance of shock absorbers to their vehicle’s drive comfort and performance. yet shock absorbers are essential elements of the suspension system, absorbing car vibrations and aiding in vehicle stability, even on the bumpiest terrains. in addition, a vehicle’s shock absorbers have a direct impact on braking and steering effectiveness and road handling. a majority of drivers will change their shock absorbers only when they are completely worn, but according to Delphi’s technical engineers, this is risky, as other components can be affected by faulty shocks.

Similar to tyres, Delphi recommends changing shock absorbers in pairs to avoid imbalance of the vehicle axle. Changing only one shock absorber in an axle can automatically affect the vehicle’s road handling, and hence, the vehicle’s security. With an unsteady axle, there is either, no contact between the tyre and the road, or the excess weight transfers from right to left or vice versa. Both affects will reduce the handling of the car, possibly leading to pitching when braking or cornering and ultimately increasing the risk of collision.

The vehicle’s braking distance can also be increased with an unsteady axle. With one defective or worn shock absorber, the tyres can lose contact

with the road, leading to uneven tyre wear. As a consequence, the vehicle may have difficulty stopping once braking is activated. Travelling at a speed of 80km/h with one new and one worn shock absorber in the same axle, braking distance is likely to be increased by almost 3 metres. For better vehicle road handling and increased vehicle safety, Delphi engineers recommend changing not only shock absorbers in pairs, but all suspension components including the top mount kit, protection and coil springs. Every single Delphi shock absorbers reference is available as a set of two. Not only is this is easier to manage for distributors, but also more convenient for the technician who is able to complete the full shock absorbers service, whilst improving customer’s vehicle stability and road handling, and most importantly, their safety. tt

why change shock absorbers in pairs?

Similar to tyres, Delphi recommends changing shock absorbers in pairs in order to avoid imbalance of the vehicle axle.

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Delphi Extends its Expertise to the Networkvia Training Opportunities around the globe

Delphi product & Service Solutions has recently updated its global training centre in warwick, united kingdom. The centre’s world-class training facilities provide a state-of-the-art learning environment for global customers, including franchise technical staff, as well as supporting the promotion of its hartridge test equipment and advanced diagnostic capabilities.

“This exceptional new facility will dramatically enhance the learning experience of students. Visitors and trainees will be impressed with the quality of the facilities and the work gone into ensuring this is one of the best technical training centres in the world,” said Graham Borley, global training manager, Delphi diesel aftermarket.

The centre’s new layout is more than 19,500 square feet and features several workshops, all equipped to carry out fault diagnosis, repair and testing on the full range of Delphi diesel fuel injection equipment. Diagnostic skills can also be improved using the latest Delphi diagnostic equipment in fully equipped garage areas.

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Delphi Extends its Expertise to the Network

Delphi’s training curriculum focuses on service and repair of thermal, vehicle electronics, braking, diesel and steering and suspension systems; as well as business management courses for garage growth and profitability.

Upon course completion, students receive a Delphi certificate which is also certified by the Society of Operations Engineers (SOE) and Institute of Road Transport Engineers (IRTE), where Delphi is recognised as an Academic Partner. Students also receive a printed student workbook and embroidered “Delphi Trained Technician” workshop coat. All technical seminars are listed online in Delphi’s Learning Management System (LMS), where webinar schedules, access to 150 eLearning courses and downloads to several training videos are available to Delphi’s trainees. tt

For more information on Delphi’s training programmes, please contact your Delphi sales representative or visit our website: www.delphi.com/am

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Delphi…Offering a complete DPF solutionBacked by a brand you can trust!

In compliance with european emissions standards, Delphi has launched a range of diesel particulate filters (Dpfs) to the aftermarket. The Delphi Dpf features a Silicon carbide filter which offers consumers a quality equivalent to the Original equipment in terms of performance.

Diesel particulate filters play a significant role in diesel emissions control.

As legislation steers manufacturers to offer greener and safer automotive technologies, the aftermarket must prepare for its role in maintaining these automotive systems. To combat the environmental effects of carbon particles and NOx, vehicle manufacturers have been led to design catalyst reduction systems that can both reduce and trap soot particles, in particular, fine inhalable soot molecules which are invisible to the naked eye. Diesel particulate filters play a significant role in diesel emissions control, therefore it is imperative that the complete system’s performance, from fuel injection through to the exhaust system, is managed carefully to guarantee successful replacements and repairs.

In order to support the increasing car parc, Delphi’s DPF programme represents a growth opportunity for workshops, not only through DPF service and repair, but also vehicle electronics and emission technology, which all work together to support reduced emissions.

In response to the aftermarket’s need for a quality DPF program, Delphi offers the parts, training, technical and diagnostic support for the service, regeneration and replacement of DPF components.

The Delphi product lineManufactured with Silicon Carbide (SIC), Delphi’s DPFs allow for multiple regeneration cycles at temperatures in excess of 600˚C, critical to the longevity of green performing diesel engines.

Delphi engineering studies identified SIC, a material commonly used by the OEM, as a far more robust and emission efficient alternative to the popular Cordierite substrate which has become common place in the aftermarket. In longevity tests, the Delphi substrate delivered equal emission and longevity results as the Original Equipment, lasting seven times longer than its aftermarket substitute Cordierite.

The Delphi DPF filters feature a wash coat of precious metals which aids a lower regeneration temperature whilst also protecting the substrate from high regeneration temperatures. The PSA applications work in conjunction with a catalyst additive which again assists the regeneration process by regulating combustion temperatures between 350-450˚C.

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Delphi…Offering a complete DPF solutionDelphi’s DPFs are designed with closed channels at opposite ends. The cell walls are porous allowing permeation of the gasses whilst retaining the solid soot matter in the filter/trap. When the pressure differential sensors or emission sensors register a variance in pressure, the ECU activates a regeneration cycle burning all soot collected in the filter.

The initial product launch includes 10 of the fastest moving DPF’s in the aftermarket covering popular applications such as the Peugeot 307, 807 as well as the Mazda 5 and Ford Focus. Additional expansion initiatives are scheduled throughout the remainder of 2012.

DiagnosticsAlready today, Delphi’s range of DS diagnostic tools and DIAMAND software, can activate forced regenerations, diagnose and reset fault codes and reset engine management warning lights relating to the DPF.

The DS tool offers the technician a bespoke suite of DPF diagnostics, integral within the vehicle application software, as well as providing technicians with the opportunity to diagnose the fuel system, as any malfunctions with the fuel system will affect the DPF performance. Leaking injectors, incorrect fuel pressure and blocked sensors all contribute to premature DPF failure and may also contribute to the failure of related components, such as the ECU, EGR valves, turbocharger and oxygen sensors.

TrainingOffering webinars and classroom based courses, Delphi now offers comprehensive training on diesel particulate filters to the aftermarket.

Technical SupportDelphi’s technical support is available for the Diesel Specialist and Delphi Service Centre networks, including a dedicated help line and technical bulletin information that is updated on a regular basis. Delphi’s technical support will help save garages in diagnostic time, under bonnet troubleshooting and unnecessary parts replacement.

Delphi part # Dpf oe #

hDp101 VECTRA CAT + DPF 1.9cdi 551876195555963858501225850213

hDp102 PSA -PARTICULATE FILTER 1740011731L6

hDp103 PSA - PARTICULATE FILTER 9655165680 1731ET 1740 21

hDp104 PSA- FILTER - FIAT ULYSSE 9456211680 1740 09 1731Y3 174008

hDp105 FOCUS 1.6 TDCI CAT & DPF 1322558/1420895

hDp106 MAZDA 5 2.0TD CAT & DPF RFY12055XB

hDp107 fitted with hDp108

PSA- CAT + DPF 307 / 407 2.0 HDI

1731Y6

hDp108 PSA- DPF 307 2.0 HDI 174007 1731Y71731FVSP231731S7SP231731X0SP231731Z5SP23

hDp109 ZAFIRA 1.9 CAT + DPF 13243546

hDp110 ZAFIRA 1.9 CAT + DPF 553521615850140

For more information on Delphi’s DPF training course, or to find out how your business can benefit from joining our global Delphi Service Centre network, please visit http://am.delphi.com/dsc

The Delphi Service centre OpportunityA high level of diesel expertise is required for technicians working on diesel vehicles and it is essential all upstream fuel problems are resolved to ensure that the DPF is performing optimally. The Delphi Service Centre network can offer quality repairs and accurate fault diagnosis for diesel engines.

SERVICE CENTRE

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1. The primary sensor is on the manifold or the

exhaust pipe; late-model vehicles also have sensors farther downstream. Be sure you know which one needs to be replaced.

2. Unplug the wire connection then spray a penetrating

lubricant onto the threaded connection.

3. Use an appropriate oxygen sensor tool.

4. Most oxygen sensors come with a special electrically

conductive anti-seize compound applied to the threads, so it’s merely a matter of threading the new sensor into the void left by the old one.

5. Use anti-seize compound to coat on the sensor’s threads

(some oxygen sensors have the anti-seize compound applied at the factory).

6. Always check the appropriate reference

material for the required torque specification. When there’s no torque value given for tightening the new oxygen sensor, treat it much like you would a spark plug. In other words, less is probably better here. Once it’s snug, plug the connector into your car’s factory wiring to finish the task.

Oxygen Sensor repair and refit Best practices:

the oxygen (o2) sensor, or lambda sensor, operates in an extremely hostile environment. like a spark plug, it is threaded and screws into its mounting location. normally the o2 sensor is supplied with anti-seize compound on the threads so it can be more easily removed at the specified change interval. over time, the anti-seize compound loses its effectiveness and the sensor can become “welded” into its location, making it nearly impossible to remove using normal tools. using excessive force to remove the oxygen sensor may damage the sensor and surrounding components.

If the sensor becomes seized in its mounting location, a simple 15 minute replacement job can become a much more complex and difficult task. Replacing the O2 sensor within the specified change interval will minimise the possibility of this problem and additional component damage.

Over time, the anti-seize compound loses its effectiveness …making it nearly impossible to remove using normal tools.

when replacing an oxygen sensor, keep these tips in mind:

P16 Delphi’s Magazine for Automotive Technicians // Issue 4

Why check the O2 Sensor?

“The fuel analyser has been particularly beneficial for warranty services. We have experienced customers returning with the same problem within 4-6 weeks following repair under warranty. Using the fuel analyser, we were able to quickly and easily identify the fuel in the system did not meet EN590 and consequently was the likely cause of defect. Not only did it save our company lost earnings in un-claimable labour hours, but reaffirmed the quality of our repair and reputation.”

Kavanagh went on to further explain “when using the fuel analyser, we always take a sample from the fuel pump and the tank – this ensures an accurate reading. Experience has shown fuel present in the tank is not always the same quality as the fuel in the pump.” These two readings will clearly identify if fuel is a likely cause of contamination, and necessary action to flush the system can be undertaken before carrying out any further repairs or replacing damaged units.

The print out facility from the fuel analyser has been especially advantageous to Kavanagh’s business. “It provides an added value to the end customer when the technician is able to provide a thorough printed report of the fuel analysis.”

Delphi is due to release an updated version of the software later this year, which includes an improved end user report. This latest reporting facility will give workshops and garages the ability to upload their company details and logo to produce a bespoke analysis report.

Also, following various customer requests, Delphi has added sample pots as an additional accessory to the fuel analyser. The part number is YDT705 and comes as a pack of 30. For further information, contact your Delphi sales representative. tt

case Study

Not only did it save our company lost earnings in un-claimable labour hours, but reaffirmed the quality of our repair and reputation.

Delphi Diesel Aftermarket introduced its fuel analyser in January 2011. Designed to provide workshops, garages and fleets with a first level diagnostic tool, the fuel analyser identifies if diesel fuel in the system meets European standards quickly, accurately and cost‑effectively. AD Ireland, a Delphi authorised distributor in the Republic of Ireland, ran a competition aimed at their DSCs to win a fuel analyser. Mick Kavanagh from Kavanagh’s Garage was the lucky winner. We contacted him for feedback on his winning prize.

P17Delphi.com/am

Fuel Analyser

Technology Tips

brakes: Just as electronics is revolutionizing the way cars operate, it also will revolutionize the way cars are serviced and repaired. A visual check and a good working knowledge of the system is no longer enough. Without an electronic diagnostic tool, the operation could take much longer, be less safe or even be impossible. For example, during repair there is a possibility even manually servicing the vehicle could confuse the control system resulting in fault codes. Electric handbrake systems, for example, which have been standard on an increasing number of cars must have their electronic control units engaged while winding back the calipers so the pad position is indexed. This is essential when replacing brake pads, as the control unit needs to know the thickness of the pads in order to engage correctly.

thermal: The refrigerant recovery/recycle and charging station should always be subjected to a complete pre-season inspection. Areas of concentration include changing the oil in the vacuum pump, calibrating the scales and gauges, inspecting all hoses for cracks and splits, checking the gauges for leaks, purging the storage tanks of air, replacing particulate and oil filters, and examining the O-rings at the service couplers for wear. To avoid inaccurate measurements by the recovery reservoir, you should also check it for “leftover” oil from the previous season. A deep vacuum test is also highly recommended. If your unit can’t achieve a deep vacuum, you won’t be able to secure a proper charge of the refrigerant and oil following a repair. An improper refrigerant charge can lead to premature component failures, particularly with compressors.

o2 sensors: Although oxygen sensors operate in an extremely hostile environment, technicians can minimize the possibility of seizure and additional component damage by choosing an O2 sensor with anti-seize compounds and replacing it within specified change intervals. Seizure in the mounting location can turn a simple, 15-minute replacement job into a much more complex and difficult task. Delphi either applies or provides a packet of anti-seize compounds to all its O2 sensors for easy removal with common tools. Removal at specified intervals is recommended because anti-seize compounds lose effectiveness over time, and sensors can become “welded” into their mount. Installation instructions are included with each Delphi O2 sensor and feature correct installation torque. It is important the correct torque is applied, as incorrect installation can lead to loosening or damage to the sensor. Avoiding excessive force and checking appropriate reference materials for required torque can minimize problems during future removal and replacement. If no torque value is given, treat the torque as a technician would a spark plug. In other words, less torque is better in this situation.

P18 Delphi’s Magazine for Automotive Technicians // Issue 4

Technology Tips

Did you know? We also provide, OE-based, leading diagnostic tools and training to keep customers coming back

abs: Anti-lock Braking System (ABS) speed sensors magnetically read the rotational speed of each wheel, which is fed back to the vehicle’s electronic control unit (ECU). When a wheel is starting to lock up and/or skid, the ABS system intervenes to gradually release and re-apply the brake many times per second to help ensure maximum braking efficiency and directional control can be maintained. If an ABS sensor fails, the car reverts to normal braking with no potential for ABS monitoring or modulation of pressure when a wheel, or wheels, lock up in a braking situation. Without ABS, a wheel will automatically lock up in slippery and/or gravel-like conditions, as well as potentially experience a loss of directional control and vehicle stability.

steering: Delphi is advising technicians to help ensure a quality steering and suspension repair by replacing the entire ball joint component where the rubber boot is split, cracked, damaged or missing. In these instances, there is a high probability that damage to the ball joint may have occurred, indicating the joint is likely to fail even after the boot cover has been replaced. Replacing the entire ball joint component can help avoid potential premature failure, which can be safety-critical and costly. By replacing the boot only and not the complete ball joint unit, the rubber boot could potentially seal in the damaging substances the joint has been exposed to, resulting in accelerated rust and corrosive damage to the joint. In addition, the ball joint is designed to operate with a grease lubricant. A defective boot could lead to a loss of this essential lubrication, as it may be washed away with water, dry out or become coated with dirt and other debris.

shock absorbers: Delphi is recommending in order to ensure a quality shock absorbers repair,

technicians should replace shocks in pairs versus replacing only the failed part. As part of its technician-focused “around

the wheel” communications campaign for a quality repair, Delphi’s six training courses for beginners to advanced technicians

demonstrate the importance of diagnosis and repair for complete steering and suspension systems, including shock absorbers and braking components.

P19Delphi.com/am

Delphi Extends its global product portfolio

In an effort to continuously improve and expand our thermal aftermarket portfolio, and to offer our customers business opportunities throughout the year, Delphi announced its latest OE heat exchanger part numbers, including seven new radiators, one condenser and two charge air coolers. These parts include first-to-market applications such as new Opel Meriva, new Astra, Citroën DS4, Peugeot 308 and Peugeot 508. This range extension utilises Delphi’s engineering capabilities and proven innovative technology to bring OE solutions to the aftermarket. By fitting our OE heat exchangers to a broader range of OE models, we help deliver true value by allowing our aftermarket customers to gain access to our long Tier 1 OE supplier history, technology and quality through an attractive alternative to current product offerings.

To accompany the product expansion, Delphi has released an updated Air Conditioning catalogue (S211/13), which is available now.

Delphi extends its thermal product portfolio with the addition of 10 new Oe heat exchanger components and 11 new cabin filters, as well as introducing a new thermal parts catalogue.

Delphi expands its shock absorbers range with the addition of 22 new part numbersDelphi has also launched 22 new shock absorber part numbers to its aftermarket range – including seven OE and four first-to-market parts.

This latest extension covers applications including BMW MINI Countryman (first-to-market), X5(E70), X6 (E71); LAND ROVER Range Rover III (OE); RENAULT Megane III, Laguna III, and more. Please note, the complete EMEA product range is also accessible on Tecdoc, where Delphi is a certified “A class” supplier of product data.

Delphi strengthens its lubricants range with the addition of 20 new part numbersToday’s exhaust aftertreatment systems are not compatible with traditional lubricant components. Delphi’s current range of Low SAPS oils (Prestige Super Plus 0W40 C3, 5W30 C2, C3 and 5W40 C3) have been adapted to actual petrol, diesel and direct injection diesel engines equipped with exhaust aftertreatment systems. By adding an additional 20 part numbers to its already comprehensive lubricants range, Delphi has now closed the gap in this specific segment of high standard lubricants.

To accompany the product expansion, Delphi has created a range of marketing materials to support the full product portfolio including a brochure, leaflet, lubricant service labels and a metal display stand.

P20 Delphi’s Magazine for Automotive Technicians // Issue 4

2012/13S211/13

AIR CONDITIONING SPARE PARTS

PIÈCES DE RECHANGE POUR SYSTÈMES DE CLIMATISATION

ERSATZTEILE FÜR KLIMAANLAGEN

RICAMBI PER CLIMATIZZATORI

REPUESTOS PARA SISTEMAS DE AIRE ACONDICIONADO

PEÇAS SOBRESSALENTES PARA AR CONDICIONADO

CZĘŚCI ZAMIENNE DO UKŁADÓW KLIMATYZACJI

ЗАПАСНЫЕ ЧАСТИ ДЛЯ КОНДИЦИОНЕРОВ

VERVANGINGSONDERDELEN VOOR KLIMATISERINGEN

2012/13S211/13

AIR CONDITIONING SPARE PARTS

PIÈCES DE RECHANGE POUR SYSTÈMES DE CLIMATISATION

ERSATZTEILE FÜR KLIMAANLAGEN

RICAMBI PER CLIMATIZZATORI

REPUESTOS PARA SISTEMAS DE AIRE ACONDICIONADO

PEÇAS SOBRESSALENTES PARA AR CONDICIONADO

CZĘŚCI ZAMIENNE DO UKŁADÓW KLIMATYZACJI

ЗАПАСНЫЕ ЧАСТИ ДЛЯ КОНДИЦИОНЕРОВ

VERVANGINGSONDERDELEN VOOR KLIMATISERINGEN

Delphi Extends

Delphi’s new-to-range braking and friction partsDelphi has already launched an additional 45 braking and friction part numbers in 2012. The range extension includes nine brake pads, 12 drums, 10 brake shoes and 18 new hydraulic cylinders, covering popular European applications. All designed and manufactured to exacting engineering standards in line with vehicle manufacturer’s requirements.

The range will be complemented with a further 250+ new braking parts and accessories to be released before the end of the year.

Delphi extends its steering range with 60 new partsWith more than 300 parts introduced in 2011 and an additional 400 items planned for 2012, Delphi announces the addition of 60 part numbers to its industry-leading range of steering and suspension products.

Delphi’s latest range extension includes 21 inner tie rods, eight tie rod ends, 14 link stabilisers, one steering rack gaiter, 16 wishbones and control arms covering popular European and Asian vehicles. tt

Delphi continues to increase its offering of vehicle electronics parts and components to the aftermarket, with the introduction of several new Oe specification vehicle electronics parts, including 10 ignition coils and six key fast-moving fuel pumps:

Delphi ignition Coils: Included within the latest ignition coils extensions are five key OE part numbers, fitted to Peugeot, Citroën, Mercedes-Benz and Opel/Vauxhall applications, and incorporate the latest coil-near-plug and coil-at-plug ignition technologies. Five further ignition coils recently added to Delphi’s already comprehensive range cover Chrysler, Dodge, Jeep, Mitsubishi, Plymouth, Honda and Toyota applications, and increase Delphi parc coverage by 1.8 million vehicles. See below the five new OE numbers and key applications:

Delphi part # key appliCations

gn10231-12b1 MERCEDES-BENZ C-Class, CLC, CLK, CLS, E-Class

gn10234-12b1 OPEL/VAUXHALL Astra J, Astra Mk, Insignia, Insignia Saloon, Insignia Sports Tourer

gn10235-12b1 MERCEDES-BENZ C-Class, CLC-Class, CLK-Class, CLS-Class, E-Class, G-Class, GL-Class, GLK-Class, M-Class, R-Class, S-Class, SL-Class, SLK-Class, Sprinter, Viano, Vito

gn10239-12b1 CITROËN C2, C3, C4; PEUGEOT 1007, 206, 207, 307

gn10240-12b1 CITROËN C5, C6; PEUGEOT 407, 607

Delphi fuel pumps: Delphi’s latest range extension focuses on six popular fuel pumps, some which include connectors for multiple application fitments. Delphi range is designed to offer rationalised pump coverage for popular applications, with the latest additions providing access to in excess of 5 million parc, including BMW, Citroën, Jaguar, Mercedes-Benz, Opel/Vauxhall and Peugeot applications. See below the six new part numbers and key applications:

Delphi part # key appliCations

fe0446-12b1 CITROËN

fe0448-12b1 ALFA ROMEO; CITROËN; JAGUAR; LANCIA; OPEL/ VAUXHALL; PEUGEOT; RENAULT; SEAT; and VOLKSWAGEN

fe0449-12b1 HYUNDAI

fe0450-12b1 ALFA ROMEO; CITROËN; FORD; MERCEDES-BENZ; PORSCHE; RENAULT; SAAB and VOLVO

fe0451-12b1 NISSAN; FIAT and OPEL/ VAUXHALL

fe0452-12b1 RENAULT

The vehicle electronics reality

Delphi Ignition Coils

P21Delphi.com/am

The company that Makes the parts cars are Born with

Delphi has a long history of developing innovative real-world products that help keep vehicle manufacturers up-to-date with the latest automotive technologies.

Delphi is supplying innovative technologies to a significant number of vehicles recently introduced. from diesel systems to active safety technology and thermal innovations to connection systems, Delphi is working to help drivers stay safe and remain connected whilst lessening the environmental impact of the vehicles they drive.

ground breaking collision mitigation system featured on new volvo v40advanced radar on new ford kuga offers affordable active safetyenergy-efficient air conditioning system equips new ferrari f12 Berlinettaflexible connected navigation radio offers audi flexibility and vehicle differentiation

Chevrolet volt – 2012 Car of the year!

Delphi Technologies:

P22 Delphi’s Magazine for Automotive Technicians // Issue 4

recently launched vehicles featuring Delphi technology include:

audi a3 – charge air cooler, low temperature radiator, ultrasonic alarm, immobilizer

audi a6 allroad – connected navigation radio (radio media center), interior harness, ultrasonic alarm, leD modules

BMw 6 Series gran coupé – roof module, switches, antenna system, Tv tuner

Dacia lodgy – diesel common rail

fiat 500l– connection systems, fuse and relay box, 5-cvc compact variable compressor, steering column module

ferrari f12 Berlinetta – complete air conditioning system and automatic dual-zone comfort control including a highly-efficient electronically controlled compact variable compressor (cvc), electrical/electronic distribution system

ford B-Max – alarm sounder, ultrasonic alarm, connection systems

ford kuga – antenna system, alarm sounder, ultrasonic alarm, electronically scanning radar, adaptive cruise control, connection systems, diesel common rail

Jaguar Xf Sport Brake – electronically scanning radar, passive occupant detection system, alarm sounder, immobilizer and motion sensor, steering column module, gear shift paddles, antenna system

kia cee’d – diesel common rail

Mercedes-Benz a-class – DaB Tuner, satellite digital audio reception system, passive occupant detection system, head lamp levelling control, ultrasonic alarm, ecall antenna, signal relay box, diesel common rail system, ignition, engine wiring.

Opel Mokka – airbag controller (sensing diagnostic module), diesel engine control unit

peugeot 208 – switches, front directional lighting, transponder antenna, trailer body computer module (controlling all lightning and braking connections from the car to the trailer), alarm sounder, ultrasonic alarm, diesel electronic throttle controls and rail.

porsche Boxster – passive occupant detection system, antenna system, Tv tuner, carbon canister

renault Megane (facelift) – switches, diesel common rail, variable cam phaser and oil control valve

volvo v40 – collision mitigation system (enables multiple safety features: adaptive cruise control, forward collision warning with full autonomous braking for pedestrians and vehicles, pre-crash sensing, lane keeping aid, automatic head beam control, traffic sign recognition), rear and side detection system (enables blind spot detection, lane change aid, cross traffic alert), passive occupant detection system, ultrasonic sensor, immobilizer and alarm sounder, antenna system, switches, diesel throttle body.

green

Safe

connected

of particular note, Delphi is pleased to announce that our parts are fitted as original equipment to the opel ampera/Chevrolet volt, announced as the 2012 Car of the year at the geneva motor show. the 2012 opel ampera/Chevrolet volt feature Delphi’s integrated centre panel, radio receiver, seat belt reminder, connection systems, ignition coils, heating, ventilation and air conditioning (hvaC) module and powertrain cooling module.

P23Delphi.com/am

High standards. Below the surface.

Delphi Service Centre.

©2012 Delphi Automotive Systems, LLC. All rights reserved.

CHASSIS DIAGNOSTICS DIESEL THERMAL VEHICLE ELECTRONICS

Find out how your garage can benefit from Delphi’s Service Centre program by visiting: delphi.com/dsc

IT ’S WHAT’S UNDERNEATH THAT SETS DELPHI APART

Delphi Service centres // z Industry leading training to keep you up-to-date with the latest automotive technology including air conditioning, braking, steering and suspension and diesel and petrol engine management; z Technical support and information to provide expert back-up when you need it – from a hotline staffed by experts to detailed diagnostic manuals and infield support from our service operations team; z OE-approved diagnostic tools giving you extensive vehicle and system coverage and the ability to program key components such as Common Rail injectors, quickly and effectively; z Access to OE parts and tooling for high-quality repairs and fewer comebacks; z Professional marketing support to help drive business to your garage.

The Delphi Service Centre program is designed to ensure that independent garages benefit from Delphi’s knowledge and experience as a leading supplier to the top 25 global vehicle manufacturers. By joining the program, you can access OE-based training, technical support and equipment. What does that mean? The right tools to help you make the right repair for your customers. You can trust Delphi, the company who makes the parts cars are born with.

we want to hear from you! let us know what you think about Delphi’s magazine for automotive technicians. If you have any questions or comments, please contact us at: Delphi product & Service Solutions, Spartan close, warwick, cv34 6ag, uk / Tel: 01926 470000 / www.delphi.com/am.

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