TechTalk - Delphi Technologies

What took 9 days, covered 3400 miles or 5500 kms in 99% automated operation, all whilst gathering 3TB of data?

The answer: Another Delphi first. The longest automated drive across the US.

Contents5 Layers of Quality. Delphi Brake Pads ...... 2Delphi OE Technologies at IAA .................. 4Troubleshooting MAF Sensors ................... 6Turbo Tech Tips ........................................... 8Vehicle Technical Information ................... 10Copper-Free Brake Pads ........................... 12Coast-to-Coast With Delphi ..................... 14Best Practice Steering Advice .................. 16Social For Your Business .......................... 18OE Ignition Winding Technology .............. 20Coming Clean About Diesel. .................... 22High Performance Brake Grease .............. 24Diagnosing Brake Faults ........................... 26Get Technical With Cam and Crank .......... 28Go? No Go? With Delphi’s YDT-35 .......... 3048-Volt. ...................................................... 32Does your Injector have Delphi DNA?...... 34

Equipped with a full suite of advanced

technologies, including collision mitigation,

integrated radar and camera systems

and lane departure warning, Delphi’s

“Roadrunner” travelled from San Francisco

to New York in the first coast-to-coast trip

ever taken by an automated vehicle. Our

OE technologies were also featured on

new vehicles, such as the BMW 7 Series,

Ferrari 488 Spider and Jaguar F-PACE at

the recent IAA Frankfurt Motor Show.

Read on to learn more about both, as well

as important information on our extensive

aftermarket portfolio. Including five

reasons why you should always choose

Delphi brake pads, steering repair advice,

the truth about diesel, how-to diagnose

turbo faults…and much, much more.

TechTalkDelphi’s Magazine for Automotive Technicians Issue 7 2015 delphiautoparts.com

Five Layers of Quality. Delphi Brake Pads. Page 2DDSX552(EN)

5 Layers of Quality. Delphi Brake Pads.

Brake pads are one of the most important components in the braking system. Responsible for stopping vehicles quicker and quieter than ever before, they are

subjected to incredible stress, day in, day out. In fact, the pressure created within the

system can build up to 2000 psi, and temperatures can reach as high as 700ºC. This

is why you mustn’t compromise when choosing which brake pads to fit...so don’t!

As a leading manufacturer of OE safety technology, Delphi brake pads are designed,

manufactured and tested to the meet the same standards of performance, consistency

and longevity as the OE. We call it Delphi’s “5 Layers of Quality”.

So when you think braking quality, remember the five reasons why. Remember Delphi.

1: Shims.

One of the secrets to quiet

brakes is noise-dampening

shims. However, many

aftermarket companies do

not fit these as standard.

Our OE-quality shims are

multi-layered with differing

grades of dampening

materials. These layers are

finely tuned to bring out

the very best qualities – the

material is carefully selected

and either mechanically

attached, clipped and/or

hot bonded for improved

noise dampening.

2: Back Plate.

The back plate provides a base

for all other components, so it

goes without saying that it must

be strong and resistant. All Delphi

back plates are manufactured

from high-strength pressed steel

to the same shape and design as

the OE. A special powder coating,

highly resistant to extreme

temperatures and chemicals/

oils, helps to ensure optimum

protection against corrosion.

It also helps to maintain precise

dimensions and tolerances, for

easier pad installation and uniform

transmission of pressure from the

brake system to the pads.

3: OE Underlayer

Technology.

Unlike other aftermarket

manufacturers, every Delphi pad

incorporates a special underlayer.

Sandwiched between the back

plate and friction material, the 3mm

layer of noise-absorbing friction

material acts as a thermal insulator,

lowering the caliper’s operating

temperature. This is critical during

prolonged or heavy braking, as it

helps to reduce heat transfer to the

brake fluid, preventing it from boiling

and helping to maintain effective

braking. The underlayer also helps to

increase the adhesion between the

back plate and friction material for a

much stronger pad.

4: Friction Material.

Brakes on high performance vehicles

work very differently to those on

small, “about town” cars, so it stands

to reason that the pad’s friction

material should be tailored to the

vehicle. We use over 130 different

friction ingredients to create 20 unique

formulations for the very best match.

Other aftermarket manufacturers

use only one or two, resulting in an

inevitable compromise in performance.

But we don’t rest on our laurels. We’re

constantly testing new formulations

– more than 300, every year. This

continual development helps us always

stay ahead of the curve when it comes

to both vehicle performance and

the environment.

5: Friction Surface.

Delphi pads feature OE

configured chamfers, where

required, to help shorten

bedding in, and reduce noise

during this period. Whatever

their angle, shape, or position,

they’re designed to perfectly

compliment the friction

material and pad shape, for

OE performance from day

one. Our brake pads also

include slots, again, where

required. Just like the OE,

they allow the pad to flex

without cracking the friction

material, and help to remove

water and dust from between

the pads and discs.

For five layers of quality, you and your

customers can trust, choose Delphi.

Watch our 5 layers of quality video at

delphiau.to/Delphi5Layers

2 TechTalk 3delphiautoparts.com

Delphi OE Technology on the Very Latest Vehicles.

At the recent IAA Frankfurt motor show, the world’s leading vehicle manufacturers unveiled a fleet of new vehicles featuring Delphi OE technology. From safety, body and security to engine management systems, connection systems to infotainment and driver interface and electrical/electronic distribution systems, all designed to reduce CO2 emissions, save lives and keep people connected.

Delphi OE Technology by Vehicle:

Alfa Romeo Giulia Quadrifoglio:

engine wiring harnesses, various

connectors including SRS (safety

restraint systems) connectors,

pressure sensor.

Audi A4 Sedan & Avant: ultrasonic

sensor, LED modules, siren (battery

backed sounder), electrical distribution

systems (terminals, housings),

SRS connectors.

BMW 7 Series: roof module with

gesture recognition, short-range

radar, DC/DC converter, vehicle sound

generator (hybrid version).

Citroën DS 3: various switches,

selespeed (paddle switches for

automatic gearbox), variable valve train,

ignition coils, GDi system.

Citroën DS 4: alarm sounder, alarm

ultrasonic module, integrated center

panel, various switches, underhood

body controller, rear body controller.

Ferrari 488 Spider: wiring harnesses.

Infiniti Q30: passive occupant

detection system, fuse and relay

box, various connectors including

SRS connectors.

Jaguar F-PACE: integrated center

panel, switches (including steering

wheel switches and paddles),

connectivity panel (including USB, SD

card connections), immobilizer, interior

motion sensor, siren (battery backed

sounder), passive occupant detection

system, electronically scanning radar.

Mercedes-Benz S-Class Cabriolet:

passive occupant detection system,

alarm system, satellite digital audio

radio service (SDARS) receiver.

Mini Clubman: wiring harnesses,

carbon canister.

Opel/Vauxhall Astra: integrated

center panel, radio, wiring harnesses,

electrical centers.

Porsche 911 Facelift: various

connectors including SRS connectors,

carbon canister.

Renault Mégane Five-Door: fuse and

relay box, various connectors.

Renault Talisman Sedan & Estate:

fuse and relay box, various connectors.

Škoda Superb Combi: ultrasonic

sensors, immobilizer, siren (battery

backed sounder), various connectors

including SRS connectors, electrical

centers, diesel Common Rail.

Smart Fortwo Cabrio: vehicle

sound generator, passive occupant

detection system.

SsangYong Tivoli Diesel: diesel

Common Rail, connection systems.

Volkswagen Golf Cabrio Facelift:

anti-theft systems, passive

occupant detection system, LED

module, connection systems

(electronic distribution system,

SRS connectors).

Engine Management Systems

› Alfa Romeo Giulia Quadrifoglio

› DS 3 (GDi system)

› Mini Clubman

› Porsche 911 facelift

› Škoda Superb Combi

(diesel common rail)

› SsangYong Tivoli Diesel

(diesel common rail)

Electrical/Electronic Distribution Systems

› Alfa Romeo Giulia Quadrifoglio

› Audi A4 sedan & Avant

› Ferrari 488 Spider

› Mini Clubman

› Opel/Vauxhall Astra

Infotainment & Driver Interface

› BMW 7 Series

› DS 3

› DS 4

› Jaguar F-PACE

› Mercedes-Benz S-Class Cabriolet

› Opel/Vauxhall Astra

Electronic Controls (Safety, Body & Security)


› BMW 7 Series

› DS 4

› Jaguar F-PACE

› Infiniti Q30

› Mercedes-Benz S-Class Cabriolet


› smart fortwo cabrio

› Volkswagen Golf Cabrio facelift

Connection Systems › Alfa Romeo Giulia Quadrifoglio


› Infiniti Q30

› Jaguar F-PACE

› Porsche 911 facelift

› Renault Mégane five-door

› Renault Talisman


› SsangYong Tivoli Diesel

› Volkswagen Golf Cabrio facelift


Delphi MAF Sensors. Bringing OE Technology and Expertise to the Aftermarket.

The Delphi difference.

Proprietary temperature

compensation design for

outstanding performance

over a wide range of

ambient temperatures.

Fast response to changing

engine conditions - typically less

than 15 milliseconds to respond

to 90 percent of a flow change.

Tested on state-of-the-art

sonic nozzle-testing equipment

capturing over 6,000 data

points per flow, for optimal

calibration accuracy.

Flow tested to match

the OE including:

› Signal stability (noise).

› Temperature compensation

(ability of the MAF sensor to

measure air flow accurately

from -30°C to 70°C).

› Electromagnetic compatibility.

Innovative, dual-heated elements

on specific references for optimal

performance, fuel efficiency and

reduced emissions.

Built with all-new components, never

remanufactured – remanufactured

MAFs are simply cleaned and tested,

so any contamination on the sensor

may not be eliminated, resulting in

inaccurate readings to the ECU.

Two service options available: as a

complete unit including the flow tube

and probe, or as a probe-only design.

Advanced DS diagnostics with the

ability to read live data from the MAF,

and where applicable, recode it back

to the ECU. Optional Vehicle Technical

Information package includes wiring

diagrams, guided diagnostic test

procedures and component locations.

Access to training, technical support

and online information.

A global leader, we now hold

more than 30 patents in MAF

sensing technology and signal

processing, including a proprietary

Temperature Compensation circuit

design, the world’s best T-Comp

technology. Today, Delphi has

delivered more than 50 million OE

MAF sensors for more than 500

customer applications.

Better still, we now supply an

extensive range of complete

MAF sensors for the aftermarket.

By testing and calibrating to OE

specifications, our aftermarket

sensors provide the same accurate

readings and airflow output as

the OE. And with Delphi you get

access to the complete package:

The range, covering more than 25

million vehicles in Europe, OE-level

diagnostics, and expert training and

technical support.

So why wouldn’t you choose Delphi for your aftermarket needs?

Did you know that Delphi has been producing OE Mass Airflow (MAF)Sensors since the 1970’s?

A MAF sensor, also known as an “air meter,” measures the air

coming into the intake system and transmits this information to the

ECU. The ECU utilizes the MAF sensor output signal to precisely

schedule fuel injection, creating an optimal air-to-fuel ratio. This

results in reduced emissions and improved fuel economy, all whilst

maintaining drivability.

What is a MAF Sensor.

Why do MAF sensors fail?

Contamination is a key reason

why MAF sensors fail and require

replacement. As air, dirt and other

debris get into the sensor, the

parts become contaminated and

fail. Drivers often notice sluggish

performance, rough idling, poor

acceleration or even stalling. There

may also be a more frequent need

to refuel. Other common failure

problems include:

Contact fault at the

electrical connections.

Damaged measuring elements.

Mechanical damage (vibrations,

accident, etc).

Measuring element

drift (exceeding the

measuring framework).

Symptoms of failure.

“Check engine” or “service

engine soon” light is on.

Hesitation / stall on

rapid acceleration.

Poor engine running at

idle and/or surge.

Excessive vibrations

when stationary.

Noticeable changes to

RPM without driver input.

Troubleshooting a MAF sensor.

Conduct an electronic test of the mass air flow

sensor by the engine management control unit. If

a fault occurs, a fault code is stored in the control

unit and can be obtained using a diagnostics unit.

Check the connector for a correct fit

and good contact.

Check the mass air flow sensor for damage.

Check the measuring elements for damage.

Check the voltage supply with the ignition

switched on (circuit diagram for pin assignment is

necessary). Ref. value: 7.5-14 V.

Check the output voltage or frequency with the

engine running (circuit diagram for pin assignment

is necessary). Ref. value: 0-5V resp. 0 – 12.000 Hz.

Check the connection cables between the

removed control unit connector and sensor

connector for transmission (circuit diagram for pin

assignment necessary). Ref. value: approx. 0 ohm.


Troubleshooting Turbos.Common Failures.

Turbo Replacements.What to Do and Not to Do when Replacing a Faulty Turbo.

DO.

Check the entire air supply system, including the EGR valve and

intercooler, for evidence of debris or damage. Clean thoroughly

and replace where necessary.

Perform an engine oil and oil filter change, observing for evidence

of oil contamination.

Inspect, clean, and replace where necessary the turbo oil feed

and return lines.

Check, and replace where necessary, the vehicle’s air

filter element.

Ensure that the internal bearings are thoroughly pre- lubricated

with priming oil (supplied with all Delphi turbos), and that the

supply of fresh engine oil to the turbocharger is immediate and

uninterrupted before starting the vehicle.

Perform an engine oil pressure check to ensure that the

lubrication system is performing to OE specifications, where

feasible to do so.

Replace all seals and o-rings when re-fitting a

turbocharger with new items (supplied with all

Delphi turbos), paying particular attention to the

orientation and position of any gaskets used.

Maintain a systematic, clean and thorough

approach when dealing with a turbocharger

fault, keeping in mind the potential

consequences of a mechanical failure.

DON’T.

Remove the protective caps or covers from the replacement

turbocharger until each respective pipe/hose is to be fitted.

Use liquid sealant at any joint or mating face associated

with the air or oil system. Liquid sealant is liable to

displace and block oilways, and may harden and fragment

into the turbocharger’s rotating assembly, causing

irreversible damage.

Adjust the actuator or linkage mechanism. All Delphi

turbochargers are 100 percent set and calibrated

to OE specifications. Any such adjustment will

invalidate the warranty.

Disassemble the turbocharger in any way. As specified in

the core acceptance criteria defined by Delphi (DM0932),

disassembled turbochargers are not liable to be accepted for

a core surcharge refund.

Replace the turbo without first identifying and

rectifying the root cause of the initial failure.

Not doing so could lead to repeated

failures and extensive engine damage.

This is costly to your business, time

consuming to your customer and worse

still, damaging to your reputation!

Understanding Turbochargers.

The turbocharger is an integral part

of the engine’s air and oil supply

systems; any mechanical failure can

result in extensive damage, and time-

consuming repairs.

Simply replacing a problematic turbo

will not guarantee that the original

problem is solved.

It is therefore essential, when faced

with a turbocharger failure, that the

necessary investigations are conducted

to establish the root cause of failure,

along with any necessary repairs and

preparations to minimise the risk of a

repeated failure occurring.

Likely symptoms of a Turbo Fault.

The common symptoms of a

turbocharger-related problem may

include, but are not limited to,

the following:

Progressive or sudden loss of power.

Low boost pressure.

Black or blue smoke

from the exhaust.

Harsh metallic noises originating

from under bonnet.

Engine management fault light

(manifold pressure-related

fault codes).

If any combination of the above

symptoms is presented, the

turbocharger system and associated

parts should be thoroughly inspected

and replaced, if necessary.

Because 95 percent of turbo failures are caused by external problems, it’s important to understand and fix the root cause before you fit a new turbo.

The Delphi Turbo Difference:

High quality parts at a competitive

price, now with a 24-month guarantee.

Engineered and tested to OE standards.

Free fitting kit, including oil primer,

in every box.

Complete service package: Delphi

diagnostics, hands-on training and

technical support.

NEW industry leading catalogue,

part number DDCX127C, fully

integrated into TecDoc.

For Fewer Customer Comebacks:

Before fitting a new turbo, always determine what caused

the first unit to fail or you risk the replacement turbo failing

too! Watch our video to learn more about turbo mode failure:

delphiau.to/FOI


Vehicle Technical Information at Your Fingertips.

Today’s intelligent automotive technology requires an equally intelligent approach to diagnostics and servicing.

Access to high quality, in-depth technical information is a must. Where better to get this information than direct from the manufacturer?!

Integrated into our DS software, Delphi’s

all-makes Vehicle Technical Information

(VTI), combines essential maintenance and

repair data with detailed technical drawings,

manuals, procedures and more. This will

help you to work more efficiently, saving

you both time and money. And here are just

a few examples of the in-depth technical

information included within each pack:

Three Levels of Technical Information are Available:

Basic Pack:

Identification

Maintenance

Repair manuals

Adjustment data

Lubricants & fluids

Recalls

Technical Pack + Smart Pack + Basic Pack:

Fuses & relays

Technical drawings

SmartFIX (Technical Service Bulletins)

SmartCASE (verified fixes & tips)

Ultimate Pack + Technical Pack + Smart Pack + Basic Pack:

VESA (guided diagnostics of components)

› 90% of UK vehicle parc coverage

Repair times

Comfort wiring diagrams

Standard

with DS softw

are

Exclusive

to mem

bers of DSC network

Optional

Upgrade

Basic Pack.The smallest adjustments can make a big difference - with

adjustment data for multiple systems we’ve got you covered.

Technical Pack + Smart Pack + Basic Pack.

Interactive technical drawings make component location and fuse

identification quick and easy.

Smart case guides you through the symptoms, cause and

solution, including step by step on how to repair the fault.

SmartFIX’s Technical Service Bulletins (TSBs) keep you up-to-date with manufacturer’s recommended servicing and maintenance work.

The bulletins contain checklists of items requiring inspection or repair, and specify the required replacement parts and labour times.

Ultimate Pack + Technical Pack, Smart Pack + Basic Pack.Test, don’t guess! You’ve checked your fault codes and reviewed

the live data. With guided diagnostics you can now follow an easy

step by step procedure to confirm the failure.

Don’t get caught out by only having engine management wiring

diagrams. With electronics from bumper-to-bumper you need

diagrams for comfort systems too. This, and more, is included.

It’s all in the planning. Make your workshop more efficient by

planning repair times. You can calculate overlaps too!

To gain access to Delphi’s Vehicle Technical Information, or to upgrade

from an existing package, speak to your Delphi sales representative.

The route to many electrical problems is the circuit’s grounding point.

With interactive drawings you can be sure you are testing the right one.


One of these injectors has been repaired using OE-approved test plans, equipment and parts for optimum performance and fuel efficiency. The other hasn’t. The result? Increased fuel consumption, reduced engine performance and shorter life. Even worse - a very dissatisfi ed customer. For OE-approved repairs you can trust, choose the Delphi Diesel Centre network.

Your Engine Can.

Can You Spot The Di� erence?

delphiautoparts.com

©2015 Delphi Automotive PLC. All rights reserved.

delphiautoparts.com

5 Layers of Quality.Just Like Delphi Brake Pads.

Just like this sandwich, Delphi brake pads are packed with quality ingredients. Five layers of quality to be precise. And each one is designed to meet the OE’s appetite for braking performance, consistency and longevity. For five layers of quality you and your customers can trust, ‘tuck-in’ with Delphi.

A Little Extra Change?But a Big Change for the Environment.

Look out for......the ‘ leaf symbol’ on our packaging labels for low copper content pads.

Why the change?

Every time you press the brake pedal,

a small amount of copper and other

metal is deposited onto the road. When

it rains, this is washed into nearby

streams and rivers. With millions of

drivers using their brakes day in, day

out, it is estimated that brake pads

account for up to half of the copper

entering water systems in urban areas.

And with copper known to be very

toxic to aquatic life, this can cause

significant damage to the environment.

What have we changed?

When it comes to braking, copper

is intrinsically difficult to replace,

as it acts as both an abrasive and

lubricant in the friction mix. Yet as a

result of our continuous research and

development programme, our CF rear

wheel friction formulation, used in

popular pads such as LP565, is already

copper-free. And we’ve achieved all

this without compromising on vehicle

performance or safety. Better still,

our new formulation offers improved

fade performance, and unlike some

competitor brands, retains all its life

too. That’s a change for the better you

can put your money on.

Why this matters to you!

We all know price and safety are

important when it comes to retaining,

and even, gaining new braking

business. But there are other important

considerations too. The introduction

of premium, environmentally friendly

copper-free brake pads is yet another

reason, in an ever growing list, of

why you and your customers should

choose Delphi.

Starting January 2025, legislation will dictate that brake pads must contain no more than 0.5 percent copper, whilst still meeting the same rigorous safety standards. Just like vehicles fitted with Delphi brakes, we have stopped sooner.

> 5% Copper .5 - 5% Copper < 5% Copper

2015 2021 2025

12 TechTalk delphiautoparts.com

Coast-to-Coast with Delphi.

In March 2015 Delphi completed the longest automated drive in North America, traveling from San Francisco to New York in the first coast-to-coast trip ever taken by an automated vehicle. Nearly 3,400 miles were covered with 99 percent of the drive in fully automated mode.

The drive was used by Delphi

engineers to research and collect

information that will help further

advance active safety technology – the

most rapidly growing technology sector

of the auto industry. The team collected

nearly three terabytes of data—about

30 percent of all of the printed material

in the Library of US Congress.

“Our vehicle performed remarkably

well during this drive, exceeding our

expectations,” said Jeff Owens, Delphi

chief technology officer.

“The knowledge obtained from this trip

will help optimize our existing active

safety products and accelerate our

future product development, which

will allow us to deliver unsurpassed

automotive grade technologies to

our customers.”

The nine-day trip crossed 15 states and

the District of Columbia. Along the

way, the vehicle encountered complex

driving situations such as traffic circles,

construction zones, bridges, tunnels,

aggressive drivers and a variety of

weather conditions.

Delphi’s automated driving vehicle,

aptly named Roadrunner, is equipped

with a full suite of advanced

technologies and features, many of

which are already on the market today

including collision mitigation, integrated

radar and camera systems, forward

collision and lane departure warning.

See more?

To learn more visit

www.Delphi.com/

DelphiDrive


Delphi bushes are manufactured to OE quality standards and should be fitted according to the manufacturer’s instructions to avoid premature failure!!

Steering You Down the Right Path.Best Practice Advice for Replacing Suspension Arms Fitted with Horizontal Bushes.

Are you fitting horizontal bushes correctly? We hope so. But just in case, here’s some simple, best practice advice. Following these

steps should ensure the safe and efficient installation of the part and avoid premature failure as a result of incorrect fitment.

What you need to know: Installation tips

1 Wherever possible carry out the

repair on a four post lift, using a

jacking beam to support the vehicle,

and appropriate wheel chocks to

ensure the vehicle does not move.

2 Always use the new mounting

nuts and bolts, where supplied,

and ensure that any mounting

locking devices, such as “nyloc”

nuts, are replaced.

3 Always consult the workshop

manual, and tighten all mountings to

the manufacturer’s recommended

torque settings.

4 When the control arm/wishbone

is fitted with horizontal bushes,

care must be taken to tighten the

bush bolts when the vehicle is at

its neutral ride height i.e. with the

vehicle sat on its wheels and the

suspension settled.

5 Never tighten the bush bolts with

the vehicle in the air. This will lead

to excessive ‘wind up’ of the bushes

once the vehicle is returned to its

neutral ride height and when the

suspension is under compression,

and ultimately premature bush failure.

6 If in any doubt, consult the

manufacturer’s workshop manual

prior to carrying out any work.

And why? What happens if

bushes are not fitted correctly?

The bush will become over-

stressed leading to tears

in the rubber.

The bush loses resistance

and secure location, leading

to MOT failure.

Poor handling and a knocking noise

may be apparent during operation.

The Construction of a Rubber to Metal (RTM) Bush.

Rubber is moulded between the centre and outer tubes.

RTM bush does not function like a plain bearing.

There is no friction between surfaces.

During operation on the vehicle, the outer tube rotates

relative to the inner tube and the moulded rubber flexes.

Delphi’s Latest Steering & Suspension Catalogue (S190/26).

...includes more than 500 new references, with a significantly extended range of rubber to metal parts.

These cover popular applications such as BMW 5 Series, Honda Civic, Mazda 6, Kia Optima, Nissan Juke, Volkswagen Amarok and many, many more.

WRONG FITMENT. ARM UNDER COMPRESSION.

WRONG FITMENT. ARM HANGING OR UNDER EXTENSION.

RIGHT FITMENT. NEUTRAL RIDE HEIGHT.

Failure of a Bush Due to Incorrect Installation.

Incorrect tightening of the mountings has resulted in the bush being over stressed leading to tears in the rubber and failure of the bush.

VEH

ICLE

CH

ASS

IS

OUTERTUBE

WISHBONE STRUCTURE

BONDED RUBBER

CENTRE TUBE

BOLT


Social Media. A Business Tool Too Powerful to Ignore.

Why Companies Need Social Media.

1 Brand Recognition: We’ve all heard

the saying ‘out of sight, out of mind.’

In business, if you aren’t consistently

reminding your customers who you

are, why you’re different from the

competition and what you have to

offer, they will forget about you and

go elsewhere.

Social Solution: Establish your

brand as an industry expert, the

go-to company for questions. Use

your company social presence to

share regular tips, advice, and links

to interesting or industry-related

articles. Reinforce your brand voice

as an industry authority. Post one tip

or link per day with images during

a time that you know your fans

/ followers are online. According

to a HubSpot study, not only do

photo posts get more engagement

than links, videos or text-based

updates, they actually account for

93 percent of the most engaging

posts on Facebook.

2 Customer Insights: Unsure what

your customers are thinking but

don’t have the time or money to find

out? Social networks are a great way

to learn about what is motivating

your customer and prospects.

Social Solution: People commonly

use social networks as a place

to say what they’re thinking and

feeling. If they like a product or

have a problem you’ll hear about it

in a social post. Listening to these

conversations taking place on social

media can help you identify the real

and immediate needs and concerns

of your customers.

Want a pulse check on what your

customers are thinking? Post a

multiple choice question or ask what

your audience is thinking about X,

Y or Z topics.

3 Promotions and Sales: Struggling

to reach your target audience to

generate sales?

Social Solution: Some social

networks offer tools that allow

you to geo-target. This can be an

effective way to send promotions

out to a specific audience based on

their location. To identify additional

groups to target, search to see

what conversations are taking

place around a topic related to

your product or service. Be ready

to comment on conversations in

these forums in a neutral, non-

marketing manner.

4 Website Traffic: You’ve launched

a website for your company but no

one knows it’s live.

Social Solution: Broadcast the

launch on your social networks

encouraging your social connects

to help you spread the word. Then,

continually promote the website

when posting content by adding

links back to your website where

users can get more information.

Provide updates when new content

is posted, new promotions are

launched or there is news to share.

5 Search Engine Optimization

(SEO): Your website’s SEO ranking

is low causing limited visibility in

search engine results.

Social Solution: SEO ranking can

sometimes be affected by your

social networks. As your social

following grows, so could your SEO

score and visibility in search engine

results. Your social networks can

also be used to increase inbound

links, one of the major factors used

by search engine algorithms to rank

your website. A quick way to create

these links is to post content that

links directly back to your website.

Remember, you want your audience

to click on the link so be sure the

content you post is engaging.

Social media is not a fad, it is a fundamental change in how we communicate – not only personally, but in business.

At Delphi Product & Service

Solutions we’ve implemented

a social strategy that includes

profiles on Facebook, Twitter,

YouTube, LinkedIn and Google+.

Working to fine-tune our strategy

has meant trying new things,

listening to our audience and

sharing best practices with

others. If your company is well

established or just getting started,

please contact us with any

questions. We’d be happy to help

and share what we’ve learned.

And be sure to check us out on

social if you haven’t already.

In today’s connected world the growing

use of smartphones has made the

internet and social networks accessible

from anywhere at any time, seamlessly

making both a part of everyday life.

Social networks have fuelled the

creation of online communities,

but how can this world of “liking,”

“tweeting” and “sharing” impact the

automotive aftermarket?

Bottomline… without ever leaving the

office, social media can create touchpoint

opportunities of engagement with

customers and prospects alike, all while

helping to building purchase preference

and loyalty for your brand.


Tough, Tested and Built with OE Innovation.You’ll Never Get Wound-Up by Delphi Ignition Coils.

Winding the wire: Why it matters.

Much like a kite string should be wound

evenly along its spool, ignition coil

windings should be evenly distributed

and neatly wrapped, so voltage is

consistent and the most magnetic

power can be drawn out.

More length of wire generates

differences in voltage, which in turn

creates pressure that causes the

breakdown of insulation and wire

coatings. So Delphi has developed a

process to tightly control the length

of the wire between adjacent primary

and secondary windings. Just as

important, we ensure that both the

primary and secondary windings are

wound to the steel core as closely and

smoothly as possible.

By controlling the winding length

and ensuring proximity to the core,

we’ve developed ignition coils that

help drivers experience better engine

performance and fuel efficiency. This

level of design and manufacturing

sophistication cannot be matched

by many manufacturers, but you can

count on Delphi to deliver the highest

quality OE standards.

We put 100 years of under-the-bonnet experience into every ignition coil we make. We’re proud to offer ignition coils for all makes that are built using world-class winding technology—which means they provide peak power, OE performance, and 100 percent satisfaction for you and your customers.

High quality components

and smart processes.

Delphi uses only high-quality

wires, and coating that resists the

cracks, pin holes and imperfections

that might cause other ignition

coils to fail.

Epoxy helps insulate the wires and

keeps them separated. Gaps in the

epoxy reduce the integrity of the

insulation, so Delphi uses a special

vacuum technique to remove air

bubbles and imperfections. This

prevents internal arcing and short

circuits, which will lead to misfires.

The Delphi difference.

A Delphi has a proprietary steel

core allowing the winding to be

made directly on the core for

maximum magnetic, material and

space efficiency.

B Delphi primary and secondary coils

are wound as smoothly and tightly

as possible around the steel core for

maximum magnetic power in every

turn of the wire.

C The secondary winding is very thin

and much longer than the primary

to get the output needed for the

voltage to jump the spark plug gap.

D Delphi secondary coils are wound

into more bays than those of

the competition, resulting in

more evenly distributed voltage,

better reliability and more

consistent performance.

E The competition’s design is less

effective in the same size package,

with magnetic inefficiency caused

by clumped-up wire wrapped

around a plastic spool surrounding

the steel core.

F Competitors often use larger, and

fewer, bays to wrap their wiring.

Voltage is harder to control and

regulate, and performance and

reliability suffers. This also increases

radio frequency interference from

the ignition system.

Delphi Part No. Model Year

GN10477-12B1 Opel/Vauxhall Corsa 2010 -

GN10585-12B1 Hyundai i10; Kia Picanto 2011 -

GN10632-12B1 Audi A3, A4, A5; Seat Leon; Skoda Octavia; VW Beetle, Eos, Golf, Jetta 2011 -

GN10583-12B1 Citroén C1, C3, C4 Cactus, C-Elysee, DS3; Peugeot 108, 208, 301, 308, 2008 2012 -

GN10584-12B1Citroén C3, C3 Picasso, C4, C4 Cactus, C4 Picasso, DS3, DS4; Peugeot 208, 308, 2008, 2008, 3008 All Turbos

2012 -

GN10590-12B1 Hyundai Accent, Elantra, i20, i30, ix20, Elantra; Kia Ceed, Process, Rio, Soul, Venga 2007 -

GN10248-12B1 Honda Civic, Fit, Jazz 2006 -

GN10241-12B1Infiniti EX37, FX37, FX50, G37; Nissan 370 Z, Cube, Juke, Micra, Note, Qashqai, X-Trail; Renault Koleos

2008 -

GN10499-12B1 Mazda 3, 6, CX-7, MX5 2003 -

CE01840-12B1A Chevrolet Cruze, Kalos, Lacetti, Nubira, Orlando 2005 -

Check out our Latest Additions to our Comprehensive Ignition Range:

Delphi CompetitorWinding Bays

(Secondary Coils)


After all, it allows you to drive further, with less fuel, whilst still enjoying a more powerful ride. All this makes the recent opposition to this

technology even more remarkable. Here we aim to dispel some of those common, often ill-informed, misconceptions with a few key home

truths about diesel.

1 Diesel has the lowest Carbon

Dioxide (CO2) emissions of

current fuel sources:

› Diesel fuel has higher energy content

per liter than other transport fuels.

› The way diesel burns is well suited

to compression-ignition engines,

which have a higher thermodynamic

efficiency than gasoline spark-

ignition engines. This means they

convert more of the energy content

of the fuel into useful work.

› Because of these two key

factors, diesel cars consume about

25% less fuel by volume than

equivalent gasoline cars.

› Diesel cars also generate about

15% less CO2 per kilometer than

equivalent gasoline cars.

2 Diesel is a key contributor to

meeting CO2 reduction goals:

› Road transport contributes

to about 20%[1] of total

man-made greenhouse gas

emissions, mainly CO2.

› Vehicle makers rely on continued

diesel share to reduce fleet

average CO2 emissions to

95g/km for passenger cars by

2021 and to 147g/km for light

commercial vehicles.

› Diesel will help to further reduce

CO2 emissions beyond 2021.

3 Diesel is a cost-effective and

popular solution for many users:

› Diesel’s high fuel economy ensures

lower fuel costs and longer range

between refueling stops.

› Diesel engines provide high torque,

enabling load-carrying, towing, and

safe overtaking.

› In 2013, approximately 50% of new

passenger car buyers in Europe

chose diesel versions[2].

› Diesel remains the predominant

fuel source for heavy and light

commercial vehicles.

4 Clean diesel technology

successfully controls

emissions including under

real-world conditions:

› From September 2015, all new

cars and from September 2016, all

light-commercial vehicles registered

in the European Union (EU) must

comply with the Euro 6 emissions

standard, measured over the official

test cycle (NEDC).

› Emissions of Particulate Matter

(PM), including soot, are reduced

by 97% (EU1 140 mg/km versus

EU6 4,5 mg/km).

› From 2017, the limit values for

particle numbers will be the same

for diesel and gasoline.

› Since measurement of Nitrogen

Oxides (NOx) emission levels in Euro

3 (2000), NOx are reduced by 84%.

5 ‘Real Driving Emissions’

(RDE) testing will further

reduce emissions:

› Emission tests on roads have

already been introduced for heavy

commercial vehicles (HCVs).

› As a consequence, new HCVs

emit low emissions level in real

driving conditions.

› Due in part to these measures,

total NOx emissions from road

transportation in the EU in 2015

are expected to be 40% lower than

2005 levels[3].

› RDE testing is expected to become

mandatory for passenger and light-

commercial vehicles from 2017.

› Introduction of RDE test will

lead to significant reduction of

NOx emissions from light

duty vehicles[4].

Coming Clean About Diesel.It’s No Surprise that Diesel Remains a Popular Engine Choice Across Europe.

[1] ACEA publication Nov 2014 + potential for further controls of emissions from mobile sources in Europe’, TSAP Report #4 V2.0 – Jens Borken-Kleefeld & Leonidas Ntziachristos, November 2012

[2] JATO 2013 – 53% for EU27

[3] ‘The potential for further controls of emissions from mobile sources in Europe’, TSAP Report #4 V2.0 – Jens Borken-Kleefeld & Leonidas Ntziachristos, November 2012

[4] Assuming new vehicles stay within 50% of Euro 6 limits in real driving conditions from 2017, the total NOx emissions from all light-duty diesel vehicles will be cut by 30% from 2015 to 2020, and by 57% from 2015 to 2025

What is Euro-6?

Since 1992, the European Union has

imposed increasingly strict limits on

emissions from cars. As the name

suggests, Euro-6 is the sixth version of

these standards, and from 1 September

2015 all new cars must meet these

limits. A Euro-6 car produces a lot less

pollutants than those from a Euro-5 car,

and just a tiny fraction of those emitted

from a Euro-1 car.

Euro standards for cars.

Euro Standard

Introduction date Emission limits

New approvals All new registrations Petrol NOx Diesel NOx Diesel PM

Euro-1 1 July 1992 31 December 1992 0.97 g/km* 0.97 g/km* 0.14 g/km

Euro-2 1 January 1996 1 January 1997 0.5 g/km* 0.9 g/km* (direct injection) 0.1 g/km

Euro-3 1 January 2000 1 January 2001 0.15 g/km 0.5 g/km 0.05 g/km

Euro-4 1 January 2005 1 January 2006 0.08 g/km 0.25 g/km 0.025 g/km

Euro-5 1 September 2009 1 January 2011 0.06 g/km 0.18 g/km 0.005 g/km

Euro-6 1 September 2014 1 September 2015 0.06 g/km 0.08 g/km 0.0045 g/km

DIESEL FUEL CONSUMPTION.

DIESEL NOx REDUCTIONS.

PARTICULATE MATTER

REDUCTIONS.

*Includes NOx and HC


One of these injectors has been repaired using OE-approved test plans, equipment and parts for optimum performance and fuel efficiency. The other hasn’t. The result? Increased fuel consumption, reduced engine performance and shorter life. Even worse - a very dissatisfi ed customer. For OE-approved repairs you can trust, choose the Delphi Diesel Centre network.

Your Engine Can.

Can You Spot The Di� erence?

delphiautoparts.com


High Performance Brake Grease that’s Up to the Job.

24 TechTalk

There’s a widespread view that copper grease, otherwise known as copper slip, should be applied to the back of brake pads to help lubrication and noise prevention. Not so. The need for copper grease has diminished in recent years in line with advances in shim technology.

In fact, its use could have the opposite

effect, preventing the shim, the basis of

quiet braking, from doing its job. The

result increased noise and judder, as

well as possible interference with the

electrical systems such as the ABS,

ESP wear sensors etc.

So Why Take the Risk?

Formulated from a non-mineral

oil based solution, Delphi’s

high performance brake

grease replaces the need

for traditional copper-based

variants, whilst also reducing

noise and preventing squealing

and chatter for the life of

the brake job.

Why choose Delphi brake grease?

Free of copper and acids, avoiding

the risk of corrosion.

Non-conductive eliminating

interference with

electrical components.

High pressure stability

helping to ensure longer-term

lubricating properties.

Compatible with all metals

and most rubber materials for

universal application.

Resistant to high temperatures and

water for increased protection.

Long-lasting protection against

corrosion, with no visible

residue or staining.

Supplied in a handy 100ml tube,

with applicator for easy application.

For a professional brake installation,

Delphi brake grease should be applied

sparingly to the metal-to-metal contact

points between the brake pad and

caliper only. But remember, never

coat the pad’s friction material or the

surface of the disc, and always keep

clear of all rubber parts.

...Not Like This!Use Like This...


The components of a braking system

are subject to considerable stresses,

even under normal driving conditions.

Over time they will naturally wear,

which means they’ll become less

effective at slowing and stopping

the vehicle. Dirt, driving style and

conditions could all help to accelerate

this. So it’s important that you are

able to spot any signs of wear and

tear at the earliest opportunity.

Check out our handy guide opposite

for advice on what to look out for and

how to fix it.

Brakes you can trust.

Because your customer’s safety

depends on brakes that work, you

won’t want to skimp when it comes

to replacing their old, worn out

brakes. So don’t! Choose a quality

brand, designed, engineered and

manufactured to OE specifications.

Choose Delphi for:

Shorter stopping distances: Tests

have proved that Delphi brakes stop

quicker than other brands.

Quieter braking: With a unique

underlayer and OE noise fixes, Delphi

brakes are quieter than ever.

Longer lasting: Designed to deliver

optimum wear without compromising

on performance.

Engineered for the vehicle: With

20 unique friction formulations, made

from over 130 ingredients, Delphi

brakes are designed to match the

vehicle application.

Superior finishing: Aids “bedding”

of brake pads to disc for maximum

braking efficiency.

Put your foot down: Compression

tested pads for consistent and

confident pedal feel and greater

driver comfort.

Delphi always recommends the use of a new fitting kit when replacing pads, discs, or calipers. For more best practice advice on diagnosing braking faults, visit delphiautoparts.com

› CAUSE: Even wear to pads and discs.

› EFFECT: Excessive brake pedal travel / wear indicator light showing.

› REMEDY: Replace pads at 3mm friction material thickness. Discs - see manufacturer’s specifications.

Pads / Discs - Normal Wear Conditions.

› CAUSE: Lack of servicing or seized components, uneven or excessive wear to friction material.

› EFFECT: Excessive travel, noisy operation.

› REMEDY: Check for seized caliper components, clean and replace pad.

Pads Left Too Long - Dangerous.

› CAUSE: Caliper piston or sliding pin caliper seized, lack of servicing.

› EFFECT: Poor brake performance, very noisy operation.

› REMEDY: Free off or fit new caliper, fit new pads and discs.

Pads Down to Bare Metal.

› CAUSE: New pad fitted against worn disc.

› EFFECT: Inefficient brakes and / or pull.

› REMEDY: Fit new discs and pads.

Poor Braking Performance with New Friction.

› CAUSE: Badly-worn pads, dirt or debris between pad and disc, seized caliper.

› EFFECT: Poor brake performance, noisy operation, possible brake pull.


Badly Worn Disc.

Severely Worn Disc.

› CAUSE: Pads and / or discs left too long before renewal.

› EFFECT: Brake failure.


› CAUSE: Side loading of disc due to partially-seized caliper.

› EFFECT: Severe brake pull and noise.

› REMEDY: Free off or fit new caliper and pins. Fit new discs and pads.

Disc Fracture.

› CAUSE: Corrosion build-up on hub flange face resulting in excessive run out on new discs.

› EFFECT: Brake judder.

› REMEDY: Clean hub mating face. Fit new discs and pads.

Corroded Hub.

› CAUSE: Run out tolerance not measured or acheived on new disc install.

› EFFECT: Brake judder after 2-3000 miles.

› REMEDY: Ensure hub flange is clean and undamaged, fit new discs and pads, ensure recommended run out.

Disc Run Out.

› CAUSE: Corrosion from water / salts after a period of inactivity.

› EFFECT: Noise, inefficient braking, possible seized caliper components.

› REMEDY: Fit new discs and pads, clean and lubricate caliper.

Severely Corroded Disc / Caliper.

› CAUSE: Over-tightened or corroded nipple.

› EFFECT: Unable to bleed caliper or brake failure.

› REMEDY: Extract and replace bleed nipple or caliper if not possible.

Broken / Damaged Bleed Nipple.

› CAUSE: Infrequent servicing.

› EFFECT: Excessive pedal travel. Noisy operation.

› REMEDY: Fit new shoes, check drums etc. for damage.

Shoe Left Too Long - Dangerous.

› CAUSE: Front: Leaking caliper or split CV boot. Rear: leaking wheel cylinder and / or hub seal.

› EFFECT: Brake pull or brake seizure.

› REMEDY: Fit new CV boot, wheel cylinder, hub seal, pads and / or shoes.

Contaminated Friction Material.

› CAUSE: Water ingress or wheel cylinder leak.

› EFFECT: Unable to release brake, resulting in lining detachment.

› REMEDY: Replace seized components, clean surface and fit new shoes.

Detached Brake Shoe Lining.

› CAUSE: Water ingress due to worn outer coating.

› EFFECT: Overheated brakes and rapid shoe wear.

› REMEDY: Fit new hand brake cable and shoes. Free seized linkage.

Hand Brake Cable Seizure.

› CAUSE: Master cylinder cap not cleaned prior to removal.

› EFFECT: Dirt / moisture contamination of fluid, premature failure of seals.

› REMEDY: Thoroughly clean cap and top of reservoir prior to cap removal.

Contaminated Master Cylinder.

› CAUSE: LHM fluid used instead of correct brake fluid grade.

› EFFECT: Possible brake seizure or subsequent brake failure.

› REMEDY: Flush hydraulic system, fit new rubber components.

Incorrect Brake Fluid Used.

› CAUSE: Hose rubber perished or contaminated. Fatigue due to incorrect fitment.

› EFFECT: Possible hose and subsequent brake failure.

› REMEDY: Fit new hose and align correctly.

Cracked Brake Hose.

› CAUSE: Road salt etc. penetrating protective coating.

› EFFECT: Pipes and unions corrode causing possible brake failure.

› REMEDY: Fit new pipes and hoses if required.

Brake Pipe Corrosion.

› CAUSE: Hose incorrectly fitted and aligned.

› EFFECT: Possible premature hose failure.

› REMEDY: Fit new hose and align correctly.

Twisted Flex Hose with Rubbing Contact.


Diagnosing Brake Faults.

Get Technical!Crank up Your Knowledge of Delphi Sensors.

The Delphi Difference:

Adaptive Hall signal schemes provide

improved timing accuracy, optimized

sensor air gap and tilt sensitivity, and

zero speed sensing capability.

Accurate square wave output

eliminates square-up function in

the controller.

Enhanced sensing capability helps

reduce emissions and improve

reliability and drivability.

Transient protection helps protect

against stray electro-magnetic

fields interface.

Fewer wiring connections for

excellent reliability.

Self-generating electrical signal

requires no external power supply.

Subjected to extensive life

cycle testing to meet rigorous

OE specification.

Supplied with OE style mounting

brackets, o-rings, and spacers for

easier installation.

Single element option offers

simplified design, and valid power

on state (VPOS) for camshaft

applications to minimize engine

synchronization timing.

What Technologies are Available?

There are three types of technology available:

1 Variable Reluctance Technology: non-contact sensors that translate mechanical

motion into electrical signals utilizing a coil that holds a pole and a metallic magnet.

2 Hall Effect Technology: a transducer that varies the sensor output in response to a

magnetic field.

3 Magneto Resistive Technology: Changes the electrical resistance when exposed to

an external magnetic field.

Most of Delphi’s cam and crank sensors are based on integrated adaptive threshold

Hall effect technology. They employ adaptive threshold sensing schemes to improve

sensor performance and reduce the sensitivity of the sensor mounting location relative

to the target.

Why do sensors fail?

1 Engine vibration can cause the

sensor to loosen.

2 Water ingress or contamination of

the electrical signal plug connector.

3 Corrosion of the sensor’s

connecting terminals (if terminals

are not plated).

4 Short circuit, wire breakage in

the sensor loom.

5 EMI/EMF interference.

6 Magnetic contamination from

ferrous material particles from

wearing parts.

What to look for in a failing sensor!

1 The sensor output voltage/

current is not in line with

manufacturer’s parameters.

2 Sensor installation misalignment

leading to improper air gap.

3 Poor sensor grounding.

4 Loose, chafed or broken wires,

loose connector or loose

mounting screws.

5 Any indication of physical damage

to the sensor.

6 Engine misfire due to the

inconsistent profile of the

falling/rising edge angle of the

cam/crankshaft.

Next steps.

If you identify any of the above issues

it is likely the cam or crankshaft sensor

is at fault. In most cases you will need

to replace the complete sensor. Delphi

has as an extensive range of OE-

quality cam and crankshaft sensors,

such as part numbers SS10513-12B1

& SS10932, covering popular GM,

Renault and Nissan applications.

What are Cam and Crank Sensors?

A crankshaft sensor, otherwise

known as an engine speed or

position sensor, is an electronic

device used in an internal

combustion engine to monitor the

position or rotational speed of both

the camshaft and crankshaft. Simply

put, it converts mechanical motion

into an electrical signal. This signal is

used by the control unit to determine

the position and speed of the shaft

at any point in time.

The camshaft sensor on the other

hand, determines which cylinder

is firing in order to establish

injector synchronization and coil

firing sequence in DIS systems.

Crankshaft sensors set ignition

timing, supply the RPM signal,

and determine engine speed.

0

+V

-V

AMPLITUDE AND FREQUENCY VARY WITH SPEED

TIME

HIGH SPEED

VOLTAGE

LOW SPEED

HALL SENSOR

TIME

HIGH

HIGH SPEED

CURRENT

LOW

LOW SPEED

Only frequency varies with speed

TIME

HIGH

CURRENT

LOW


Go? No Go? Simple, Low Cost Diagnostic Capability for Common Rail Injectors.

Specifically designed by Hartridge for

garages and entry-level workshops,

Delphi’s YDT-35 gives technicians the

ability to troubleshoot faulty Common

Rail injectors. Complementing the

existing Delphi on-vehicle test solutions

for Common Rail injectors, the machine is

the first step in the diagnostics process.

It combines an electrical injector test with

visual spray pattern checks, to identify

individual injectors that have failed. All in

under five minutes. So from now on, only

faulty injectors need to be sent for repair,

delivering a wider and more controlled

stream of work to the authorised

network, as well as providing another

profitable service opportunity for garages

and workshops.

Let’s see just how easy…and quick… the YDT-35 is to use:

1 Set up is simple. First secure the

machine on a work bench. Then

fill with calibration fluid to ISO

4113 standard, Delphi Part number

HAD400, until the level is visible in

the sight glass. Also fill the injector

spray chamber until no air is present.

Finally connect to 5-10 bar air supply

and a standard mains supply.

2 Cleanliness is paramount. Before

fitting the injector ensure the nozzle

is free from contaminants. Use

either an ultrasonic rinse tank, or

soft wire brush, but remember to

avoid the very tip of the injector.

3 To mount the injector, lift the

protective door and place the

injector in the universal mount. Line

up the spray chamber and tighten

both the injector and chamber in

place. Once secure, fit the flexible

high pressure pipe and torque

correctly to 35nm. To complete

setup, connect the back-leak pipe

and electrical supply to the injector.

Different adaptors are supplied to

suit various applications.

4 You are now ready to test the

injector. To begin, press the start

button and select the correct

injector. Note the test will not

begin if the wrong injector type

is selected. Press start and the

machine will perform an electrical

test on the injector. The results

and limits are displayed on screen,

clearly showing pass or fail.

5 If the injector has failed the

electrical test it cannot be repaired

and must be replaced. If it has

passed, press stop and progress

to the spray pattern check. At

this point, the injector test will be

activated. Set the pressure to 600-

700 bar and allow the injector to

run for one minute to ensure the air

is purged from the back-leak unit.

Then perform a visual check on

the spray pattern inside the

spray chamber – Look for

consistent delivery

from each nozzle hole. Allow this

test to run for 30-60 seconds and

record the back-leak measurement

displayed on the return flow unit.

Repeat this step across all 4 test

plans for all injectors.

6 Once you have all the results,

you can compare the data

and quickly and easily

identify which injector needs

to be repaired or replaced.

So There You Have it – Job Done!

Key Functions: Tests all diesel Common Rail

injectors supplied by major manufacturers.

› Delphi, Denso and

Bosch solenoid.

› Denso, Bosch, and

Continental Piezo.

› Bosch CRIN and Denso Heavy

Duty adapters (optional).

Electrical injector tests resistance, inductance, capacitance.

Nozzle spray-pattern visual observation.

Optional back leak measurement.

See more? Watch our how-to video at

delphiau.to/YDT35HowTo


48-Volt.A Missing Piece of the Puzzle to Less CO2?

For an industry that has tried everything from 300-600 volts with pure electric vehicles, plug-in hybrids and big lithium-ion batteries, a widespread 48-Volt strategy may offer the biggest bang for the buck.

Europe is calling for CO2 emissions

reductions of more than 25 percent by

2021 and regulations in China and the

U.S. will require tighter CO2 mandates

over the next decade.

“Compared to higher voltage mild

hybrids, vehicles with 48-Volt systems

have demonstrated 70 percent of the

benefit at 30 percent of the cost,”

said Jeff Owens, chief technology

officer. “Delphi’s goal is to exceed the

benefit by maximizing the use of the

48-Volt architecture to deliver enhanced

overall performance.”

48-Volt mild hybrids, for gasoline

or diesel engines, could reduce the

percentage of CO2 emissions by

double digits, capture energy typically

lost while braking and provide torque

in the low rpm range for anemic

start-stop hybrids.

The beauty of a 48-Volt solution

is that drivers will not lose engine

performance to gain fuel efficiency

from downsized engines. Consumers

would drive these 48-Volt cars the

same way they would drive cars

powered by conventional powertrains,

and they would enjoy the 20 percent

extra horsepower the 48-Volt

system provides.

Great Benefit at a Low Cost.

48-Volt Mild Hybrid

Though a mild hybrid can be configured

in many ways, here is one example of

a cost effective, lower CO2 emitting.

48-volt mild hybrid using Stop/Start and

regenerative braking.

Stopping Energy is

Starting Energy.


How does Coding Affect the Repair of Injectors?

When an injector is repaired, its

characteristics will be significantly

changed. It is therefore critical that a

new code is allocated to reflect the

performance of the repaired injector.

The ECU must then be re-programmed

with this code when the injector is

fitted to the vehicle. This will ensure

that the adjustment to the pulse times

is made and that the correct fuel

delivery is maintained. Failure to do this

will mean that the ECU will continue

to work with the previous injector’s

characteristics, leading to issues such

as reduced power, excessive smoke

and increased engine noise.

The generation of this code is a

complex procedure. Only members of

the authorised Delphi Common Rail

repair network possess the specialist

equipment and software required to

accurately generate them.

Where to find a Correction Code?

The injector’s individual correction

code takes the form of a 16 digit,

hexadecimal code for C2i, or a 20 digit,

alphanumerical code for C3i and can

be found on either a label stuck

to the body, or engraved on a

plate on the injector.

Does your Injector have Delphi DNA?

What is an Injector Correction Code?

All Delphi Common Rail injectors feature

either an Individual Injector Correction

(C2i), or an Improved Individual Injector

Correction (C3i) code. This unique code

relates to the specific characteristics

of each injector such as flow rates,

response times and performance at

different pressures, and is designed to

allow precision management of the fuel

injected into each cylinder for optimum

engine efficiency, and to enable the

ECU to be calibrated with the injection

system. It is recorded to the injector

during manufacturing, and subsequently

programmed to the ECU during

vehicle assembly.

Why are Correction Codes so important?

It is impossible to produce injectors

that are absolutely identical. Operating

at extremely high pressures, even

minute physical variations between

injectors will cause discrepancies in the

amount of fuel delivered by each. This

in turn will result in inefficient engine

performance, which could lead to

reduced power, increased engine noise

and excessive smoke. The amount of

fuel that is delivered by the injector

is proportional to the injection time

(pulse) and rail pressure. Therefore,

it is possible to compensate for

manufacturing variances by managing

the pulse time applied to each injector.

Delphi’s correction codes are generated

by measuring the flow rate of each

injector at five different pressures

for C2i (230, 400, 800, 1200 bar

and maximum pressure) and three

different pressures for C3i (400, 800

bar and maximum pressure). These

measurements are then compared

against a target (average) injector

performance to assess what pulse

time adjustment is required in order to

obtain the required fuel delivery. This

adjustment is translated into the code.

Simple your reputation is at stake!

Installing an injector that has been

repaired with sub-standard components

or processes could have a significant

impact on engine performance.

The result? Increased fuel use,

emissions and wear and damage.

Not forgetting an unhappy customer.

The Delphi Diesel Centre Advantage.

So is it worth compromising customer satisfaction for the sake of a few extra pounds?

The simple answer is no! That’s why you should always ensure a Delphi-authorised

repair. The benefits are clear:

Repaired to OE-approved test plans using specialist test equipment and software.

Newly generated calibration code for accurate injection control.

Repaired in clean environment to OE-level standards.

Replacement of all wearable and performance critical components with OE parts.

Repair work performed by highly-skilled and trained technicians.

Delphi DNA guaranteed!

Why does it Matter?

Spotlight on the Injector Correction Code.

Want to know if your repaired Common Rail injector has Delphi DNA inside. Well now you can. Simply visit delphiautoparts.com/DNA, tap in your repaired injector correction code and click on ‘check my part’. In seconds, the intuitive site will tell you if your injector has been repaired to OE approved standards by an authorised Delphi Diesel Centre. Or not.

For OE-approved repairs you can trust, choose the Delphi Diesel Centre network!

Find your nearest at delphiautoparts.com


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FUELSYSTEMS

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IGNITION

TRAINING & TECHNICAL

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Delphi’s 360° Cycle of Innovation Comes Full Circle.

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From OE to Aftermarket.

From innovative OE technologies to the leading vehicle manufacturers globally. To a world of diagnostics, training and technical support. Our aftermarket engineers work hand-in-hand with OE, to give you access to the very latest vehicle technologies. We have the aftermarket covered. Discover the full 360˚ value of Delphi quality at delphiautoparts.com.

TechTalk - Delphi Technologies

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