At the 2014 Geneva Motor Show, the World's Leading Vehicle

TechTalkDelphi’s Magazine for Automotive Technicians Issue 6 2014 delphiautoparts.com

Contents Serious Protection for a Serious Kit 2 Can You Spot the Difference? 4 At the 2014 Geneva Motor Show, the OE Technology on the Latest Vehicles 6 Our Latest Cool OE Innovation 8 world’s leading vehicle manufacturers Troubleshooting Turbo Failures 10 Our Story – The Birth of a Brand 12 unveiled a fleet of new vehicles A Cool Service All Year Round 14 Cleaning Up with Delphi’s Cleaning Kit 16 featuring Delphi OE technology. Spotlight on Filters 18 Delphi Launches Oil Pressure Switches 20 Delphi Wins VW Group Award 22 Award Winning Delphi Connect 24 A Boiling Hot Service Opportunity 26 Ignition Coils Do’s and Don’ts 28 Why Replace the Ball Joint? 30

What’s in your tool box?

Delphi’s new aftermarket website has been designed to keep technicians informed. Featuring relevant product information, how-to videos, technical information and more, users will be able to customise their experience by creating their very own toolbox with content that’s of most interest to them. Designed for optimum functionality across web, mobile and tablet platforms, the new site features a vibrant look and feel, more engaging content and improved usability and navigation. © Mercedes-Benz

Active safety on the new Ford In the aftermarket, our technologies Focus, gasoline direct injection cover every aspect of today’s vehicles on Peugeot 308, diesel Common too. From brakes to steering, air Rail on Mercedes-Benz C Class conditioning to ignition, engine and Volkswagen Polo and high- management to fuel systems. Just as performance reception systems on importantly we also understand what the BMW 2-Series Active Tourer it takes to repair them. That’s why to name but a few. All designed we offer the right tools, support and to keep passengers safe, green expert training. Read on to learn more Visit delphiautoparts.com for essential and connected. about what Delphi can offer. tool box information 24 / 7 / 365.

DDSX552(EN) Our Story – The Birth of a Brand. Page 12 Serious Protection for a Serious Kit.

Being able to plug into a vehicle and run a Delphi software program that correctly identifies Diagnostics. the source of a problem is critical. The right diagnosis depends on the plug and play installation of the dongle accuracy of information in the software, drivers for faster set-up and ease of as well as the ability of the hardware use. And, it’s also paired with the Easy to Use. to take the correct readings from the individual VCI for optimum protection. vehicle and accurately decode it. And The new dongle replaces the current Hard to of course, the technicians system’s license key, simplifying both the knowledge and expertise. installation process and ongoing Crack. management of software releases. Having the right tool may not always be The licenses will still be initiated via the the case. As featured in the last edition internet with the only difference being of TechTalk, a number of sub-standard that the dongle is activated, rather counterfeit diagnostics tools and than the software. software are available in the market. Whilst these may look similar, on the It’s a tough nut to crack! inside it’s a completely different story. …And deservedly so! Delphi’s DS software offers OE level diagnostics They almost certainly do not offer across the key electronic systems the same level of OE expertise and including: petrol and diesel engine capability as the official solution. management, ABS, SRS, gearbox, They have not benefited from climate control, traction control, extensive research and development. instrument panel and immobilizer, They haven’t been tested on for both car and commercial a wide range of vehicles. vehicle applications. Nor have they been engineered to the same high standards. Delphi software also includes intelligent system identification, an These counterfeit products could intelligent all systems scan of all be putting you and your customers ECU/ECM’s for a complete vehicle at risk. To address this Delphi has diagnosis, VIN recognition for implemented a new, highly-secure accurate vehicle selection, full vehicle solution for its DS software. The information tree allowing vehicle patented concept integrates software specific check of OBD functionality and dongle, and offers multilayered without being connected to a vehicle protection. Based on a mini-USB and a customer reporting system. design, the solution has been developed by a security specialist, The comprehensive solution allows whose customer portfolio includes read and erase of fault codes, real many of the world’s leading banks. time data including graphing and It is delivered pre-configured with saving of data, ECU coding, parameter

2 TechTalk delphiautoparts.com BenefitsThink toDelphi the Technician. for Diesel

adjustments, component configuration, P lug-and-play installation of the E asier automatic checks for test routines and programming, with dongle drivers for faster set-up software patches, fixes and comprehensive help files to assist the and less hassle. intermediate vehicle and technician through each process. functionality updates between No license keys required - licenses major software releases. Using the DS software technicians can will be activated automatically on quickly determine fault codes and be set-up and checked every 30 days N o ‘missed’ days as software guided to the suspect area. To finalise for ease of use. start date is at point of activation. their diagnosis they can link to technical data, repair history, training support, D ongle can be moved freely E nhanced communications as well as their own experience or the between computers as long with individual notifications internet for additional information. as the right VCI is used – direct to the user. the software is not bound The DS software supports an extensive to a specific PC. M ini USB design to prevent damage. vehicle database with regular updates for more than 61 car manufacturers D ongle paired with VCI 1 0-metre range with latest on more than 82,000 systems during production. Bluetooth© wireless technology applications and 45 truck Heavy Duty for freedom of movement. manufacturers on more than 51,000 O nly one dongle per VCI systems applications. The car software is required regardless of includes car and LCV applications and license set-up. the heavy duty, truck, trailer, bus and LCV applications.

A B C D

Check out our latest range of hardware platforms:

A DS150E: B DS350E: C DS450E: D DS650E: Software only option, Rugged, 10 inch Latest technology, Dedicated and tested designed for customers convertible PC based touch screen Windows Windows 7 Professional who wish to use their on Windows 7. 8 Pro tablet with rugged PC with shock-absorbing own Windows based Can be used as touch case for enhanced shell. Also water, dust hardware for reduced screen tablet or as a protection against and splash resistant. investment costs. conventional keyboard. workshop environment.

3 Can You Spot the Difference?

Delphi recently completed a The results? They speak for themselves! series of in-depth tests to analyse the physical properties as well as Poor Performance: Excess Fuel: the performance and endurance of injectors repaired by A non-authorised repairer cannot The inaccurate opening of a non- non-authorised workshops. produce a new calibration code and genuine nozzle, combined with the must reuse the old one. The ECU will inability of a non-authorised repair to These tests highlighted a number of be reset to the parameters of this code generate a unique calibration code, significant issues - namely the use and essentially has to ‘guess’ how can cause an increase in fuel of non-genuine components and to perform. This repeated inaccuracy injection. This doesn’t just waste your unauthorised processes. causes the engine to run poorly due to customer’s money – the burning of offset corrections. Also, the pressure the excess fuel can cause a notable build up, can produce excess smoke increase in exhaust smoke. and erratic noise from the engine.

Injector repaired by authorised Delphi Diesel Centre network.

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

Newly generated calibration code for accurate communication with the ECU and injection control.

C2i / C3i code generated with 450 test points.

Repaired in clean environment, free from contamination to approved standards.

Diamond Like Carbon coated Delphi control valve to prevent seat valve seating deformation and erosion.

Precision engineered Delphi nozzle for optimal spray atomisation, less emissions and enhanced engine performance.

Repaired by highly-skilled, trained technicians. All with the backing of the OE manufacturer!

4 TechTalk delphiautoparts.com Your Customer Can.

Increased Wear and Damage: The smart technician chooses a Delphi-approved repair every time!

The use of non-genuine control Delphi Diesel Centres have invested in the very latest equipment, valves significantly increases the flow skills and training. They… and temperature of the injector’s back leak. In turn, the temperature band pressure builds in the injector, Diagnose and test using Fit genuine Delphi generating fault codes by the ECU. authorised test equipment components only. A non-genuine nozzle can open and tooling. Employ highly-qualified irregularly, unbalancing the cylinders Perform repairs to OE and trained technicians. and damaging the engine. In addition standards and processes. Offer competitive pricing the reusing of old calibration codes will Replace all wearable and exceptional after-sale lead to ECU faults and increase stress and performance-critical service and support. on the engine due to out-of-sync components. injection and overcompensation.

Injector repaired outside of the Delphi Diesel Centre network.

Repaired to unauthorised test plans on low quality test benches.

Reused calibration code, unable to accurately instruct the ECU when and how much to inject.

Non-audited workshop standards.

Non-genuine, low-compatibility control valve with no coating.

Non-genuine nozzle manufactured with inferior materials.

5 Delphi OE Technology on the Latest Vehicles.

At the 2014 SAFE: Protecting Vehicle GREEN: Low CO2 Geneva Motor Passengers with Active Emissions and Show, the world’s Safety Technologies. Fuel Consumption. leading vehicle Featured on several Ford models, Demand for gasoline direct injection manufacturers including the new Ford Focus, Delphi’s (GDi) technology is increasing and unveiled a fleet award-winning electronically scanning nearly half of all gasoline engines are radar (ESR) enables adaptive cruise expected to feature GDi technology of new vehicles control with forward alert. worldwide in 2020. Delphi’s GDi featuring Delphi system significantly reduces CO2 technology. All Delphi has also developed state-of- emissions while offering an industry designed to keep the-art safety restraint system (SRS) benchmark for low noise. Delphi’s connectors that enable airbags to system is featured on the new passengers safe perform when needed. Delphi’s SRS Peugeot 308 SW. and connected connectors are now featured on the while respecting Audi S1 and TT, Mercedes-Benz C The Delphi Multec® light duty diesel Class, Peugeot 308 SW, Qoros 3 Hatch Common Rail system is featured on the environment. and Volkswagen Polo. the new Mercedes-Benz C Class and Volkswagen Polo. With its smart balanced valve solenoid injector design, this system is extremely fast and has injection performances similar to competitive servo-piezo technologies.

6 TechTalk delphiautoparts.com CONNECTED: Additional vehicles at the Geneva Motor High-Performance Show with Delphi technologies include: Reception Systems.

Delphi’s integrated antennas offer Audi S1: Various connectors Mercedes-Benz C Class: Passive vehicle manufacturers the flexibility of including SRS, electrical centre, occupant detection system, alarm multiple high-performance reception radiator, ultrasonic alarm, system, DAB tuner, TV tuner, satellite transponder, immobilizer digital audio reception system tuner systems without compromising and antenna, various connectors on styling. Delphi’s latest antenna Audi TT: LED module, transponder including SRS, ignition, central technology is featured on the new antenna, immobilizer components, powertrain controller, diesel BMW 2-Series Active Tourer, Citroën ultrasonic and inclination sensors, Common Rail various connectors including SRS, C4 Cactus, Ford Focus, Mercedes- compressor, radiator, charge Mercedes-Benz S-Class Coupé: Benz C Class and S-Class Coupé. air cooler Passive occupant detection system, alarm system, DAB tuner, TV tuner, BMW 2-Series Active Tourer: satellite digital audio reception system Antenna, various connectors tuner and antenna including SRS, powertrain cooling module (radiator, condenser and Mini: Engine wiring, powertrain cooling charge air cooler), for hybrid module (radiator, condenser and charge versions: inverter and charger air cooler), variable valve train, ignition pencil coils BMW 4 Series Gran Coupé: Roof module, various connectors Peugeot 108: Heat exchanger, condenser Citroën C1: Heat exchanger, condenser Peugeot 308 SW: Valvetrain, ignition, gasoline direct injection system, fuel Citroën C4 Cactus: Various switches, delivery module, canister, wiring antenna, body controller for trailers, harnesses, body controllers, stop variable valve train, ignition pencil coils, & start DC/DC converter, various various connectors including SRS connectors including SRS, switches, ultrasonic alarm module Ferrari California T: Air conditioning system including dual-zone HVAC, Qoros 3 Hatch: Various connectors condenser with integrated receiver including SRS, engine harness, drier, compressor, control box, alarm system, ultrasonic interior software and comfort calibration, protection system complete power and signal distribution system including wiring Renault Twingo: Fuse and relay box harnesses and electrical centres Volkswagen Polo facelift: Various Ford Focus facelift: Various connectors including SRS, diesel connectors, antennas, adaptive cruise Common Rail, electrical centre, control (electronically scanning radar), radiators, ultrasonic alarm, transponder, interior motion sensor, alarm system immobilizer, alarm system

7 Check Out Our Latest Cool OE Innovation.

While stop-start systems dramatically improve vehicle efficiencies in urban or congested areas, they can create challenges for the supporting systems.

For example, when the engine shuts Delphi’s new Cold Storage Evaporator in the evaporator, the PCM gradually off, the compressor that circulates the will keep the cabin of start-stop and liquefies or melts, drawing heat refrigerant through the evaporator to hybrid/electric vehicles cooler for up from the air in the cabin to cool cool the car also turns off causing the to 120 seconds while at a stop light – the passengers. cabin temperature to rise quickly. twice as long as competitors’ products.

It does this by integrating a reservoir of Phase Change Material (PCM) within the air-conditioning evaporator. When the vehicle and air conditioning is running, thermal energy is removed from the material which solidifies or freezes. When the system is stopped, using a unique patented thermosiphon process and the refrigerant already

Introducing Cataphoretic Plating.

Delphi steering parts are exposed to 720 hours of salt spray for New Latest Generation Tyre Pressure Monitoring optimum protection against System Activalve Tool. corrosion. But if that’s not enough, we also apply an additional surface Vehicles fitted with Tyre Pressure The new Activalve tool, part treatment - cataphoretic plating. Monitoring Systems (TPMS) have a number SV11378, enables the warning light on the dash board which user to force first generation tyre An electrochemical process, indicates that tyre pressure is low in pressure valves open and emit their it is now commonly used in the one of the tyres. This information is information frames (tyre pressure, automotive industry. As it is has sent to the ECU from a sensor in each valve code etc) on a stationary a very high resistance to corrosion wheel. If the wheel position is changed vehicle. Used in conjunction with a and oxidation, Delphi wishbones, on the vehicle, the ECU will need to Delphi diagnostic tool, it allows the tie rod ends and inner tie rods be reprogrammed, to tell it in which user to programme the position of are now being treated with position each sensor is. This can only the valve to the vehicle ECU and cataphoretic plating for even be done when the sensor/valve is confirm the new valve is fitted. greater protection and open, which is normally only when enhanced aesthetics. the vehicle is in motion.

8 TechTalk delphiautoparts.com Think Delphi for Diesel

Not Just Brakes. Delphi Brakes.

WeWe believe believe that that how how a vehiclea vehicle stops stops is isjust just as as important important as ashow how it moves.it moves. That’s That’s why why all allour our braking braking products products are are designed designed and and manufacturedmanufactured to tomeet meet the the same same standards standards of ofperformance, performance, reliability, reliability, andand longevity longevity as as the the OE. OE. For For quality quality you you can can trust, trust, fit ﬁ tDelphi. Delphi. delphiautoparts.comdelphiautoparts.com Troubleshooting Turbo Failures: Foreign Object Impact.

When a turbo fails, However it is common for garages What is FOI? the first course of to prioritize minimizing vehicle down- action is to identify time before conducting a thorough Turbos are required to efficiently investigation into the cause and effects flow very high volumes of air. To do the cause of failure. of the failure. The result? Repeated this, they must rotate at very high turbocharger failure through incorrect speeds. In a modern high-performance preventative maintenance or system turbo, the turbine and compressor repair, and a very unhappy customer! wheel assembly can rotate at up to Because 95 percent of turbo failures 240,000rpm – that’s 4,000 rotations are caused by external problems every second! such as foreign object impact (FOI), oil starvation and contamination, it’s At these speeds, even small critical that you understand the root components have a lot of inertia cause of the problem before you fit (stored energy ready to be released). a new turbo. Failure to do so can Consequently, the contact of any dense cause repeated failures and extensive particles, even non-metallic deposits engine damage, which is costly to such as carbon build up, with the your business, time consuming to your internal workings can cause immediate customer and worse still, damaging to and total failure to the turbo. This is your reputation! known as a FOI failure.

Let’s take a close-up look at one of these issues – FOI.

Did You Know? Delphi offers a range of remanufactured turbos. Our extensive range is remanufactured with OE equivalent components and processes for proven performance, reliability and longevity.

10 TechTalk delphiautoparts.com Potential Causes. Consequences of FOI. Corrective Action if you Discover FOI. Items pulled into the air intake because FOI often causes instantaneous failure of an under-performing, poor fitting or of the turbo, and propagation of debris Clean the entire air supply system missing air filter. throughout the air supply system. ensuring it is free from any particles or Unfiltered particles drawn in through In severe cases, irreversible damage objects that may cause further damage splits in pipework or housings. to the engine is caused when metallic - this includes the intercooler, EGR valve Gasket material entering the intake. debris is forced into the combustion assembly and air supply pipework on Nuts, bolts, washers, etc left in the chamber, and impacts the piston, both the high and low-pressure sides intake pipe during servicing or which valves and cylinder head. of the turbo - if in any doubt replace the become loose during use. entire air supply system. Damaged engine components. Preventing FOI Flush and change the engine oil. Residual debris from a previous Related Failures. Fit a replacement OE quality oil filter. turbo failure. Inspect the oil supply, return pipes Thoroughly inspect the entire air and fittings for evidence of foreign How-to Determine FOI. induction system. objects; look specifically for metallic Fit new air filters, as per the vehicle fragments, which may not necessarily Typically categorised by damage to the manufacturers (VMs) specifications. be magnetic! This may require removal compressor, turbine wheels, or their Always ensure the filter is clean and and cleaning of the sump and surrounding housings - the leading edge fitted correctly. oil pump. of each wheel should reveal a clean Only ever use OE quality gaskets, and consistent face, with a uniform seals and fitting kits when replacing a gap between the housing - any sign of turbo – never compromise with inferior damage here is a sure indication of FOI. products which are liable to break, On rare occasions, harsh metallic fragment or not function correctly. noises originating from the engine bay Check there are no fragments in the as the turbo spools up can indicate FOI, system from the previous failure. or other turbo-related issues. In this Never use liquid sealant/gasket when instance it is imperative that the engine fitting a turbocharger – it is liable to is stopped immediately, and a thorough harden and fragment into the rotating investigation is carried out to identify assembly when heat-cycled. the source of the problem, and any subsequent damage.

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!

For more info on oil starvation and contamination, visit delphiautoparts.com

11 Our Story – The Birth of a Brand.

Everyday companies Recognising this growth opportunity, provided an even broader product invest significant Delphi Aftermarket, now known as portfolio with a strong braking and amounts of time, Delphi Product and Service Solutions, steering presence. was introduced to the industry in Brazil money and resources in March 1999, with the official In 2011, Delphi acquired a to create, develop and aftermarket brand strategy launched controlling interest in Hartridge, promote a brand. a few months later in October 1999, a leading diesel fuel injection test at Equip Auto, France. It was here equipment manufacturer. Some succeed. Some fail. With the the Red Oval was born. accurate combination of strategy, It’s certainly talent and a little luck they are able to In Europe, Delphi was already been a journey. But thrive and grow. This is one of those producing a wide variety of aftermarket where are we now? stories. This is the story of the Delphi products – including air conditioning aftermarket brand. systems and thermal parts, security systems, batteries, filtration and DPSS Europe Today. For more than a century, Delphi has lubricants – under several well- developed automotive technologies known brand names such as Diavia, Today our aftermarket technologies that help vehicles run better, longer Texalarm, Freedom and De Carbon. cover every aspect of a vehicle, from and more efficiently. Independent The new aftermarket division quickly brakes to steering, air conditioning to from General Motors in 1999, Delphi expanded worldwide. In 2000, Delphi ignition, engine management to fuel Automotive is a leading partner to 25 attended AAPEX in Las Vegas to systems — whether the vehicle is a of the largest vehicle manufacturers publicly announce its presence in North hybrid, or powered by gasoline worldwide. Whether automotive, America. Growth in South America and or diesel. commercial vehicle or other market Asia Pacific occurred at a similar pace. segments, Delphi delivers real-world Best of all, we understand that innovations that make products safer, Also in 2000, Delphi acquired Lucas aftermarket parts fit into a larger greener and more connected. And with Diesel Systems and AP Lockheed. The process for independent garages: more than 160,000 employees in 32 diesel acquisition enhanced Delphi’s Diagnosis. Parts ordering. Removal. countries, Delphi has the resources, fuel injection system and product Installation. Customer satisfaction. the reach and the OE expertise to capabilities, complementing its existing Because of this we the offer the bring these innovations to the global petrol engine management portfolio, tools, training and technical support aftermarket too. and gave it access to a global network for efficient, accurate and of authorised repairers. Lockheed affordable repair.

Did You Know? Delphi supplies OE automotive technologies to top 25 leading manufacturers worldwide.

12 TechTalk delphiautoparts.com 100 Years of Delphi.

See more? For over 100 years Delphi has been at the forefront of technological innovations. Check out our new brand video on Here are just a few of Delphi’s industry firsts… delphiautoparts.com

13 Offer a Cool Service All Year Round with Delphi

Did You Know? Even in Winter! Delphi has been managing air, liquids and temperature longer than Thanks to today’s air conditioning any other OE supplier in the world. technology, drivers and passengers We introduced the first now have complete control over the compressor in the 1950’s. temperature, quality and flow of the Delphi supplies OE air conditioning air – whether it’s humidity control in technology to the world’s leading the summer, or demisting in the winter. vehicle manufacturers - Audi, Any time. And all at the touch BMW, Chrysler, Ferrari, Fiat, Maserati, Mercedes, PSA Peugeot of a button! Citroën, Renault, Seat, Skoda and Volkswagen. Traditional air conditioning systems That means that servicing is account for up to 5 percent of a required all year round too. But vehicle’s average fuel usage in because of the complexity of these a hot climate and consequently systems, only garages with specialist a similar proportion of CO2 emissions. Delphi technologies knowledge, training and equipment can reduce system fuel usage by can take advantage of it, making this 50 percent while continuing to a market too good to miss out on! enhance occupant comfort.

14 TechTalk delphiautoparts.com Air Conditioning.

Cool Your Customers Down... And Heat Up Your Profits!

By choosing Delphi you can gain access to: We recommend the following checks every two years:

OE-level training with courses such as air conditioning Visually check all air conditioning components diagnostics and refrigerant handling Re-gas to correct quantity Advanced diagnostics including activation of air Check temperature and pressure conditioning components and system reset Check air conditioning system function Access to a technical hotline and support and performance Up to date information on industry developments Check for leaks and legislation Check the cabin filter for moisture And of course, OE parts and/or unpleasant odour Check belt tension All the support you need to repair today’s air conditioning Perform anti-bacterial cabin treatment systems quickly and efficiently and offer your customers a cool service all year round. Remember, some components should be replaced every time the system is opened for service. And as a minimum every 2 years during a routine service.

When you You should change also change

EXPANSION VALVE [or] ORIFICE TUBE, COMPRESSOR RECEIVER DRIER, OIL, UV DYE and O-RINGS

RECEIVER DRIER / ACCUMULATOR, CONDENSER OIL, UV DYE and O-RINGS

RECEIVER DRIER / ACCUMULATOR, EVAPORATOR OIL, UV DYE and O-RINGS

RECEIVER DRIER / OIL, UV DYE and O-RINGS ACCUMULATOR

CABIN AIR FILTER EVAPORATOR / CABIN [Treatment]

15 Cleaning Up with Delphi’s Solvent Cleaning Kit.

Coupled with the Electronic Injector Test Kit, part number YDT720, Delphi’s Injector Solvent Cleaning Kit, part number YDT714, enables technicians to quickly and cost effectively diagnose and resolve early stage lacquering on vehicle. The all makes solution provides a time saving solution and an additional revenue opportunity for garages.

Early stage lacquering affects all makes of injectors. This issue which is typically seen at around 20/30,000 kilometres, can be caused by poor fuel quality, additives and driving style such as periods of high idling. It manifests itself in stalling and erratic / low idling, poor or non-start when the engine is cold. If these symptoms are present, and no faults are identified during the standard Common Rail diagnostics procedure (Fuel Analyser, DS Diagnostics, Sealed Rail, False Actuator and now the Electronic Injector Test 1 Set up the solvent application gun 3 Disconnect the injector back leak Kit) then this is a good indication that with a syringe of solvent cleaner, connectors, and connect the back valve lacquering is present and will part number 9001-908 (supplied as leak bottles, ready to collect the need addressing. box of 10 individually packed syring- used solvent and lacquer deposits es), and the correct injector adaptor following the cleaning operation, So let’s get cleaning! to the syringe. Ensure the syringe is with the correct backleak connector. locked securely in place. Remember to plug the vehicle tank return circuit with an appropriate 2 Remove the HP pipes from the protection plug for cleanliness. injectors; plug all opening to avoid contamination. Note cleanliness is critical with Common Rail systems. 4 Set up and connect the Electronic Remove the injector electrical Injector Test Kit, YDT720, as shown connectors and move them out in TechTalk 5. of the way.

16 TechTalk delphiautoparts.com 5 Initialise the unit and set to 6 Let the solvent act for one 7 Connect the injector harnesses back ‘cleaning’ mode. The Electronic hour: The timing is important to the correct injectors. Start the Injector Test Kit will automatically as prolonged soaking can cause engine and collect the fuel in the detect the Common Rail injector Common Rail injector seizure due to back leak containers. Reconnect the coil type, and go through the normal the two surfaces becoming bonded vehicle backleaks and remove all diagnostics process. The cleaning together (valve/valve seat). test equipment. cycle can then be activated.

Connect the syringe and Introduce fresh solvent into all 8 It is important to re-enter the Electronic Injector test Kit to the injectors and flush out C2i / C3i codes back into the vehicle each injector in turn dissolved deposits ECU with a DS Diagnostics tool Activate the cleaning cycle, while Replace HP pipes; operate (or similar) and then road test squeezing the trigger to introduce the starter to fill the circuit the vehicle. the solvent with diesel and to thoroughly Repeat until clear solvent is seen purge the injectors of solvent to flow into the back leak tube Check fuel flow through the Job Done! Total time: Repeat the solvent cleaner backleak circuit into the containers 1.5 - 2.5 hours introduction if necessary (with 1 hour soaking time - during which Repeat for all injectors time you can be doing something else).

17 Spotlight on Filters.

Delphi is fitted as With today’s advanced diesel engines Contamination from such particles can OE on the following now injecting fuel at pressures up lead to significant wear on the pump applications: to 2200 bar, and injector tolerances and injector, resulting in reduced power being measured in microns, even the and engine performance, inefficient smallest amount of dirt or water can running, starting problems and poor Citroën: C3 1.4L / Berlingo / C3 / C4 / start a problem. For example, five fuel economy. Xsara / Jumpy / C5 1.6 HDi microns or more can cause surface Dacia: Logan / Logan MCV / Duster / damage to pump and injectors. As little Even worse, because of the high Sandero 1.5L as three to five microns can block an pressures and flows involved, this can Fiat: Scudo 1.6L / Palio / Palio Weekend / Punto I / Siena / Strada 1.9L injector valve completely. That’s tiny! then spread to the rest of the engine, Ford: Focus Mk I / Mk II / Transit Connect Especially when you consider a human resulting in yet more damage. / Tourneo Connect / C-Max 1.8L TDCi / hair measures 50 to 70 microns. Mondeo Mk III 2.0L / 2.2L TDCi / Focus C-Max 1.8 / 2.0L / Galaxy / Mondeo IV 1.8L / S-Max 1.8L / C-Max / Fiesta V / Fusion 1.6L / Transit 2.4 / 2.5L Fitting a high performance filter is essential Hyundai: Terracan 2.5L TD in combating these problems, helping to Jaguar: X type 2.0 / 2.2L / S Type 2.7L safeguard both the fuel injection system and Kia: Bongo 2.9L / Carnival Mk III / Grand Carnival Mk II / Pregio / engine and avoid any unnecessary costs for Sedona II 2.9L CRDi the vehicle owner. Land Rover: Discovery III / Range Rover Sport 2.7L / Range Rover L405 Mazda: 3 1.6L Mini: Clubman 1.6L / Cooper 1.6L Nissan: Interstar / Primastar 1.9L / 2.2L / Kubistar / Micra / Tiida 1.5L Opel/Vauxhall: Movano 2.2L / 2.5L / Vivaro 1.9L Peugeot: 206 / 206 SW / 207 / 207 SW / 307 / 308 / 407 / Expert / Partner 1.6L HDi Renault: Traffic 2.5L / Clio II / Kangoo II / Symbol / Thalia 1.5L dCi / Master I & II 1.9L / Megane II / Scenic II / Modus / Clio III 1.5L dCi Ssangyong: Actyon / Kyron / Rodius / Stavic 2.0L / 2.7L / C200 / Korando / Actyon II 2.0L Suzuki: Liana / Aerio / SX4 1.4L DDIS / Jimny 1.5L DDIS Volvo: C 30 / S 40 II / V50 1.6L

And more! Did You Know? Fuel from a Common Rail injector travels faster than a speeding bullet. That’s up to 720 miles per hour!

18 TechTalk delphiautoparts.com DIRTY SIDE CLEAN SIDE LAYER 1 LAYER 2 LAYER 3 With this in mind Delphi filters feature a patented high efficiency three-layer media:

Layer 1: Coarse glass fiber layer with hydrophobic coating for tight filtration and water separation DIESEL FLOW

Layer 2: Tight, thick glass fiber layer for even greater particle removal and enhanced filtration capacity and efficiency

Layer 3: 100% coarse cellulose as a base for the media and protection against glass fibres

A bee’s wing pulses 200 times per second – The tolerances in a Common Rail system allow a Delphi Common Rail injector pulses twice as fast. for 1 micron clearance. That’s smaller than a neuron cell.

19 Delphi Launches Oil Pressure Switches.

As its name suggests, the oil pressure switch Easy Access to Customer monitors the engines oil pressure. The switch Vehicles with the Latest incorporates a diaphragm that threads into the Tablet Computing. oil passage. Delphi has strengthened its diagnostic When the oil pressure gets below As a loss in oil pressure can cause portfolio with two new platforms. a specified point, because of poor damage to the engine, it is important Powered by Windows 8 and on oil pump performance for example, that the oil pressure switch functions the very latest ThinkPad tablet, the the diaphragm collapses and closes correctly. A faulty switch could hide DS450E combines ultra-mobility and the switch. The oil warning light is the condition after the damage complete connectivity with rugged illuminated, alerting the driver that the has occurred. reliability. Designed with the technician oil pressure is low. in mind, it offers a wide-view 10.1” In support of this, and leveraging IPS display, five-finger multitouch Delphi’s OE sensor expertise, Delphi technology and a rugged case with has launched 21 new part numbers to six foot drop/shock, dirt and its rapidly expanding sensor portfolio. vibration protection. The new programme covers popular brands such as BMW, Citroën, The DS650E is a Motion tablet Vauxhall, Fiat, Ford, Peugeot, and comes with rubberized casing, Saab & Volkswagen. integrated handle and Gorilla® Glass in order to prevent and protect from any bumps or falls. The ergonomic design features a 10.4” XGA standard display with projective capacitive dual-touch and digitizer pen input for greater ease of use.

Igniting Your Business.

Delphi has recently introduced three new OE pencil ignition coils, covering more than one and a half million vehicles in Europe, and an OE cassette coil, covering a further million. The coils cover popular vehicle applications such as BMW, Chevrolet, Citroën, Mini, Opel, Peugeot and Vauxhall and take our total OE range to 20 part numbers covering over 10 million vehicles.

DPSS P/N OE PN OE PN 2 OE PN 3 OE PN 4

GN10572-12B1 12137575010 5970.91 5970.64 12137550012

GN10571-12B1 12137594596 12138616153

GN10476-12B1 12137559842 12137571644 12137582627 12137594935

GN10401-12B1 55579072 55577898 1208093 1208092

We Protect It Too.

Delphi filters are designed with patented OE technology and high efficiency media to help ensure optimum filtration performance. Which is no more than you’d expect from a supplier to the world’s leading vehicle manufacturers. Backed by over 100 years of OE heritage, expertise and knowledge, you get more than a ﬁ lter. You get a Delphi ﬁ lter. delphiautoparts.com Delphi Wins Volkswagen Group Award.

As a major OE The award recognized Delphi’s “This award from one of our largest supplier, Delphi outstanding performance and customers is representative of continued development of solenoid Delphi’s significant role as a partner won the highly- technology for diesel Common with Volkswagen and illustrates the regarded Volkswagen Rail systems. Whilst specific to Volkswagen’s 1.2-liter, three-cylinder exceptional work of our diesel team,” Group Award 2013 Euro 5 programme, where Delphi said Rodney O’Neal, chief executive for its advanced helped to significantly reduce officer and president of Delphi. emissions and fuel consumption, diesel Common the group said it looks forward Michael Gassen, president Delphi to partnering with Delphi on Rail technology. Europe, Middle-East and Africa added: future projects.

“We are very proud that the Volkswagen Group recognized the excellent performance of our diesel technology which is gaining strong interest in the industry”

22 TechTalk delphiautoparts.com Other recently launched Volkswagen Group vehicles featuring Delphi OE technologies include:

Audi A3 Sportback: anti-theft Škoda Rapid: anti-theft systems, systems, charge air cooler, low interior wiring, condenser temperature radiator Škoda Rapid Spaceback: wiring Audi S1: connectors, electrical centre, harnesses, connectors, radio, radiators, ultrasonic alarm, transponder, condenser, compressor immobilizer Volkswagen Polo facelift: Audi TT: LED module, transponder connectors, electrical centre, radiators, antenna, immobilizer components, ultrasonic alarm, transponder, ultrasonic and inclination sensors, immobilizer, alarm system connectors, compressor, radiator, charge air cooler Volkswagen Golf: anti-theft systems, passive occupant detection system, SEAT Leon (5-door): anti-theft charge air cooler, low temperature systems, LED module radiator, LED module

Seat Leon SC (3-door): charge air Volkswagen Golf R: anti-theft cooler, low temperature radiator, SRS systems, passive occupant detection (safety restraint systems) connectors, system, charge air cooler, LED module, connection systems connectors Delphi Common Rail technology is fitted as OE to the following SEAT León ST: anti-theft systems, Volkswagen Golf Variant: Volkswagen Group models: LED module, SRS connectors, low anti-theft systems, passive occupant Audi A1 - 1.4L 3 Cyl Euro 6 temperature radiator, charge air cooler detection system, charge air cooler, low temperature radiator, LED Seat Ibiza - 1.2L SEAT Toledo: anti-theft systems, module, connectors Seat Ibiza, Leon - 1.4L interior wiring, condenser 3 Cyl Euro 6

Skoda Fabia, Roomster and Praktik - Škoda Octavia: charge air cooler, low 1.2L and 1.4L 3 Cyl Euro temperature radiator, SRS connectors, connection systems Volkswagen Polo - 1.2L

Volkswagen Polo Up, Polo Bluemotion and Golf - 1.4L 3 Cyl Euro 6

Volkswagen Golf - 1.6L 4 Cyl Euro 6

23 Introducing Award Winning Delphi Connect.

Telematics is a Total Solution.

...from helping garages get an alert finding the right parts to complete the for a repair needed by a customer, to repair. Delphi Connect provides the obtaining data from that vehicle, to aftermarket with a cost effective, data accurately diagnosing the problem, and rich, and commercially viable option.

An Aftermarket Friendly Solution.

Delphi has developed a “plug-and-play” by VMs, but with all makes coverage telematics device along with a turnkey too. An “aftermarket friendly” solution, connected car care solution for the it includes an easy-to-use web and aftermarket. It offers many of the same smartphone interface tailored to meet connected car care features provided the needs of a garage.

A Little Device that Does a Big Job.

The heart of the system is a device The device was designed and designed by Delphi that fits in the validated to meet rigorous automotive palm of your hand. It can be easily standards for temperature, vibration connected to a vehicle’s OBDII socket and durability and offers superior with an extension cable that allows the antenna performance for both mobile device to be installed securely behind communication and SatNav. the dashboard. The device provides wireless communications to and from A real time operating system and the vehicle via a mobile connection. dual CPUs provide precise timing of events, and a computing platform The device integrates seamlessly into for system control and interface the vehicle’s architecture to create to automotive electronics and a totally connected solution. It’s a communication systems. computer, scan tool, SatNav and mobile phone all in one, with superior processing power, OE-component robustness, vehicle protocols, Coming Soon and requires no driver interface to Europe. or interaction. Delphi Connect is currently available in North America only, but will be coming to Europe soon. Speak to your Delphi sales representative to find out more.

24 TechTalk delphiautoparts.com The Device. Delphi Connect. A computer, scan tool, GPS and mobile phone all in one…a value-added Transmits SatNav and vehicle information solution connecting you and your customers to a secure data server via a mobile network.

Vehicle Data. Air Plans.

Like your mobile phone, a variety of air plans Could include speed and location or vehicle are available to maintain wireless connectivity diagnostics data (based on selected features) between the device and secure data server. that is transmitted wirelessly to a data server.

Secure Data Server. Telematics Platform.

Collects, stores and analyses data transmitted Transforms raw vehicle data into useful information from the on-board device. formatted to help you manage your customer’s vehicles and your garage resources.

Vehicle Owner Access. Garage Access.

Vehicle owners receive service, maintenance, The garage receives real-time Diagnostic Trouble inspection and family safety alerts. They can Code (DTC) alerts, Delphi’s exclusive advanced also set geographic boundaries, speed limits battery prognostics, inspection and scheduled and curfews for teens and receive alerts via text maintenance reminders to help proactively manage message and/or email. Promote greener driving customer’s vehicles, improve business and with maintenance and service alerts. Get access to differentiate themselves from competitors. Delphi’s exclusive advanced battery prognostics.

How the device works.

The telematics device uses industry standard OBDII messaging In turn, customized user interfaces communicate with the protocols to communicate with the vehicle. Generic messages, garage and the vehicle owner in a model tailored to the individual such as speed and RPM, are used for mileage calculation. While preferences of the garage. Combining the data from the vehicle enhanced messaging is used to obtain VM specific diagnostic data. with the VIN decoded make/model/year, the system helps diagnose the potential causes of a DTC and/or maintenance alert. Data is sent from the device according to pre-programmed time What’s more your customers get smart reminders and customized intervals, or pushed when real-time action is required to Delphi alerts from your business, as well as educational tips about firewall protected servers, all within a Virtual Private Network. preventative maintenance — increasing loyalty and making it as The servers then process the information electronically and easy as possible for them to schedule appointments with you. execute predetermined commands such as alert notifications to client servers. All in a secure and privacy protected environment.

25 A Boiling Hot Service Opportunity.

Brake fluid is one of the most important but also most often ignored fluids in a vehicle. In fact it’s the only safety critical item not checked as part of an MOT test. And it represents a great service opportunity.

Anytime a brake line has been opened, Air in the lines can also upset brake After several years of service, brake or hydraulic components such as balance and the normal application of fluid becomes contaminated with calipers, wheel cylinders, master the brakes. If one caliper contains air, atmospheric dirt and abrasive metal cylinders or ABS hydraulic modulators it won’t apply with as much force as wear particles from moving parts in or pumps are replaced, air gets inside. the caliper on the opposite wheel. the master cylinder and calipers. This can cause a brake pull towards It also absorbs moisture from the air Air is compressible, so when the the stronger side. which causes the loss of pedal under brakes are applied any air bubbles in hard use. the system must first be compressed It’s important to remove this air before the hydraulic fluid will transmit by bleeding the brakes. As well as For this reason bleeding brakes should pressure to apply the brakes. This can ensuring effective braking, it also be part of every brake job. By doing cause a soft pedal and/or too much replaces the old moisture-contaminated this you are not pushing dirty fluid pedal travel. If there’s a lot of air in the brake fluid with fresh, clean fluid, through the entire system and causing system the pedal may go all the way to preventing contamination and restoring damage to components. As a minimum the floor when applying the brakes. the corrosion-inhibitors and lubricants it should be changed every two to three that help protect the metal and rubber years as part of a routine service. parts inside the system.

Brake fluid explained…

DOT 3, DOT 4 and DOT 5.1 (non- This can result in excessive brake pedal vapour is compressed, the brake pedal silicone based) brake fluids, through travel and possible brake failure. travels to the floor and the brakes fail. their chemical formulation, are As the brake fluid cools the vapour hygroscopic, which means they For brakes to operate correctly and the returns to moisture and the brake pedal absorb moisture. This moisture can brake pedal to remain solid, the brake becomes solid again. be absorbed through the brake fluid fluid must remain incompressible. But reservoir vent, and also through the as the moisture content increases, the walls of flexible brake hoses. As the boiling point falls. If the boiling point Delphi brake fluid has one of the highest moisture content of the fluid increases, of the fluid falls to 150 C (during heavy boiling points in the industry today. the boiling point falls. And as the boiling braking the fluid temperature reaches point falls, the risk of the fluid boiling 160 C) any moisture (water) in the fluid So there’s no debate – it’s designed and causing vapour lock increases. boils and turns to vapour (steam). This to keep cool under pressure.

26 TechTalk delphiautoparts.com How to Bleed an ABS System.

We’re now going to show you how to bleed an ABS system using DS diagnostics.

For older vehicles the brake bleeding procedure is normally a manual process, however many newer vehicles have a requirement to connect a diagnostic tool and run the brake bleeding procedure electronically.

Before starting it’s important to clean the reservoir of the master cylinder. Small particles of dirt will cause damage to master cylinders and ABS actuators-modulators. Failure to keep hydraulic systems completely clean will always shorten their service life.

Connect the pressure bleeder to the master cylinder reservoir, after checking that it is filled with the correct brake fluid as per the vehicle manufacturers recommendations.

Turn the ignition on. And connect the DS diagnostic tool. Select the automatic bleed procedure. Refer to the help file to understand the procedure and follow it carefully as this can differ from vehicle to vehicle. The tool will then energize and cycle the ABS solenoids in the BPMV.

After this, the scan tool will instruct you to bleed each corner and specify the correct order for doing this.

During this step, the pump runs and the respective release valve cycles. This is repeated for each corner. The bleed nipples will have to be opened and closed in turn. Remember to collect the discharged fluid in a suitable container.

Relieve pressure at the bleed tool and remove it from the master cylinder. Then check the brake pedal to make sure all the air has been removed, there is no excess travel and the pedal is firm.

The brake bleeding tool should keep the fluid level topped up. The brake fluid level must then be checked to see if any additional top-up is necessary.

Watch our how-to bleed an ABS system video on delphiautoparts.com

27 Ignition Coils Do’s and Don’ts.

The basic function of an ignition coil is to provide adequate energy to ignite the compressed air/fuel mixture during the compression stroke of a gasoline engine.

An accurate and robust flame initiation When selecting an ignition coil for will lead to successful combustion repair it’s important to make sure under all engine conditions. An you go with a product you can trust electronics circuit (driver) is used to to help deliver no comebacks. It’s control the timing of the firing event. important to you, it’s important to your The driver circuit could be integrated customer… and it’s important to us. with the coil as one package, it could So, why Delphi ignition coils? Simple. be a standalone unit as in the case OE quality equals reduced comebacks of an ignition module, or could be and satisfied customers. located inside the engine controller (PCM/ECM/ECU). It’s just as important to remember a few simple best practices when performing ignition coil repair and replacements. Did You Know? Delphi manufactures more than 23 million OE coils per year.

28 TechTalk delphiautoparts.com Recommendation. Reason.

Coils should not have any visible damage and the boot should A damaged part could result in premature failure and a poorly be fully seated. If you notice any damage such as a cracked coil seated boot could lead to engine misfire. housing, broken anti-rotational tabs or broken connector while assembling coils to the engine, disregard it.

Never remove or disassemble the boot from the coil. Disassembling the boot from the coil could lead to losing the spring and / or suppressor. The result - engine misfires and RFI noise.

Do not scratch the HV towers or the coil housing. Scratches to the coil body could lead to a cracked case and / cracked HV tower which would lead to arc thru and coil failure.

Don’t strike any part of the ignition system with a tool This could lead to physical damage (micro-cracking that can’t be or other object. seen). The consequences are a system malfunction or failure.

Never use hammers or other striking devices to install plug wire to The striking process could induce micro-cracking at the coil HV the coil HV tower. This should be done by hand. tower and could deform / damage the plug wire terminal that may lead to premature failure.

Don’t apply any non-approved material to the surface of the high This can jeopardize the seal integrity of the mating surfaces, voltage tower which mates with the high voltage secondary leads. which in turn can create a secondary high voltage leak path and carbon tracking.

Do not permit paint or other sprayed materials to be sprayed onto Insulating-type spray can create a high resistance or open the electrical connectors. connection. Conductive-type spray can create an electrical short condition.

Always apply the specified torque to the specified mounting Loose thru-bolts could lead to failure under vibration. thru-bolt. Over-tightened thru-bolts could lead to cracked coil mounting ear and / or premature thru-bolt failure.

Do not support the ignition system by the wiring harness These leads are not designed to support the weight of the ignition or plug wire. system. It can create a poor electrical connection or become disconnected allowing the system to fall and subjected to potential physical damage.

Never force feed the engine wire harness mating connector into This maintains a proper connection and prevents intermittent the coil connector. Always ensure the mating connectors are electrical connections leading to an improper ignition entirely seated and locking mechanism is engaged. A snap system operation. should be heard / felt upon a good connection.

Take a look at our how-to replace an ignition coil video on delphiautoparts.com

29 Why Replace the Ball Joint?

To ensure a quality steering and suspension repair, it’s advisable to replace the entire ball joint where the rubber boot is split, cracked, damaged or missing.

In these instances, there is a high By replacing the boot only, and not the fitment ties, intended for repair and/ probability that damage to the ball joint complete ball joint unit, the rubber boot or modification of the part. The term may have occurred, indicating the joint could potentially seal in the damaging universal can be misleading as there are is likely to fail even after the boot cover substances the joint has been exposed many variations of boots used in any has been replaced. Replacing the entire to, resulting in accelerated rust and given range. And each rubber boot is ball joint component can help avoid corrosive damage to the joint. In specifically designed and manufactured potential premature failure, which can addition, the ball joint is designed for use with its specific ball joint. be both safety-critical and costly. to operate with a grease lubricant. A defective boot could lead to a loss To prevent splitting of the rubber boot of this essential lubrication, as it may in the first place, Delphi’s new dust be washed away with water, dry out cover design features an improved or become coated with dirt and Chloroprene Rubber formula that other debris. maintains its durability even in extreme temperatures, helping protect the You should also be aware of ‘universal’ internal components and continued free rubber boots and associated cable movement of the ball joint.

Delphi Auto Parts WebCat Gets a Makeover. Launches on LinkedIn and Google+. Delphi’s web catalogue, delphicat.com, Why Delphi? has recently been upgraded. New user Delphi Product & Service Solutions is friendly features include: Delphi ball joints adhere to expanding its social network presence global OE technical requirements with the addition of a Delphi Auto Direct access to WebCat with a desktop shortcut function and undergo testing focused Parts profile on LinkedIn and Google+. on strength and durability Similar to its existing Facebook, Twitter Addition of brake disc images for improved part information performance. The ball joint push out and YouTube pages, DPSS will provide Ability to enlarge thumbnail images test measures the force required to relevant and timely information (product push out/remove the ball pin from launches, range expansions, best Enhanced dimension search allowing a direct link to the the housing. Whereas the ball joint practices and tech tips, etc.), but also buyer’s guide pull out test measures the force encourage enquiries, questions and required to pull the ball-pin out. It is share information. So make sure you Improved look and feel an important safety check to ensure go to LinkedIn and follow Delphi Auto the part can withstand forces Parts. The same with Google +. applied to the vehicle suspension We hope to see you there! system in real world conditions.

30 TechTalk delphiautoparts.com Turn to Delphi for steering parts tested to the extreme. We test our products to temperatures as low as -40°C, ensuring they perform even under the harshest conditions. It’s just one of the many ways we commit to delivering products that are designed, engineered and manufactured to OE standards. delphiautoparts.com For essential toolbox information 24 hours a day.

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