D elphi’s Magazine for Automotive Technicians // Autumn 2010 THIS MONTH WE TALK: Delphi Service Centre P2 Fuel Pump Failure Analysis P4 OE Oxygen Sensors P6 New Delphi MAF Sensors P7 New OE EGR Valves P8 Training P8 Adding Profits With Delphi Diesel+ P9 New Diesel Filters P10 Industry Leading Chassis Range P11 PACE Awards P11 New Steering & Suspension Catalogue P11 Delphi’s New Fuel Analyser P12 VW Polo BlueMotion P14 Diagnosing Common Rail P16 Delphi Aftermarket SP Compressors P18 New Air Con Program P19 Peugeot Endurance Test P20 New Delphi Technology P22 Delphi Brake Pads & Discs P24 Endurance Test Delphi helps Peugeot to victory in ‘ultimate durability test’ Earlier this year, Delphi technology helped power S PEED AND ENDURANCE // two Peugeot RCZs to an impressive first and third COME AS STANDARD in-class standing in a gruelling 24-hour endurance race at the Nurburgring in Germany. The vehicles The two RCZs ran in the D1T category for diesel cars were equipped with Delphi diesel fuel injection between 1.7 litres and 2.0 litres. The key change to systems and powertrain cooling technology, the standard engine was an increase in turbo boost which unlike many of the 197 other vehicles, pressure, lifting the torque from 340Nm to 400Nm Don’T MISS: and the power from 120kW to 150kW. had not been highly modified for racing. // NEW OE EGR VALVES P8 Peugeot had recently launched the RCZ 2.0 litre HDi Even with this extra boost, Peugeot used production // NEW AIR CON ProgrAM P19 coupé to mark its 200th anniversary. For the 2010 Delphi charge air coolers, as supplied to road cars, race, the company took the decision to race models as they met the performance targets required for // NEW CHASSIS RANGE P11 that were largely unmodified from their road-going endurance racing. // Full article on page 20 TT // NEW DIESEL FILTERS P10 equivalents – a powerful way of demonstrating the reserves of performance and durability inherent in Above article image ©Julie Sueur – Endurance-info.com their standard production vehicles. P1 TURN TO PAGE 14 FOR DELPHI OE TECHNOLOGY FITTED TO THE 2010 WORLD CAR OF THE YEAR! Delphi Service Centre dashboard of a modern vehicle to see that an increasing number of automotive management systems are being controlled by electronics. In 2005, only 20% of systems in new cars were controlled by electronics… today this figure is more than 40% and rising. The result, engine management systems represent more than 60% of diagnostic fault codes. These advances represent a new challenge for garages. It is essential that any business invests in the right tools and parts to service these increasingly sophisticated vehicles. BRAK ING, STEERING & SUSPENSION // AiR Not so long ago, braking, steering and suspension CONDITIONING // D/ IESEL / were all separate un-integrated systems within a Air conditioning is no vehicle. The technology behind these systems has longer considered a The introduction of Common Rail has revolutionised since evolved to create a single, all encompassing luxury option. Fuelled the acceptability of diesel in passenger cars, system called ‘Unified Chassis Control’. The by drivers’ demand for offering comparable power and performance to introduction of reactive shock absorbers, steering greater comfort and many petrol alternatives, and fuelling extraordinary angle sensors and brake assist have all helped convenience, it now growth in diesel cars worldwide. Operating at to improve the safety, control and handling of comes as standard extreme pressures of up to 2000 bar, the Common in most new cars. Rail fuel injection system delivers precision control 15 years of successive of the combustion process. The injector is key growth in system Top issues facing Delphi Service to this. Each injector is allocated an individual fitment, and a rapidly characterisation code relating to its specific flow expanding parc, have Delphi rates, response times and performance at different today’s garage... Centre gives you all contributed to a Service Centre pressures. This must be programmed into the ECU strong air conditioning whenever a replacement injector is fitted to the market. And because is an innovative 1. Vehicle complexity the answers... vehicle. The ECU will then manage the delivery these systems need program designed of each injector to ensure that the engine runs at 2. Finding qualified people regular maintenance to help independent optimum efficiency. These advances mean that only 1. Advanced diagnostics to be effective, the garages around the 3. Ongoing education & training garages equipped with the right tools, skills and based on the ‘DS’ requirement for world partner with range of tools knowledge will be able to take advantage of the Delphi and benefit 4. Diagnostic tools rapidly growing diesel servicing opportunity. servicing and repair is from its comprehensive significant. Surprisingly 2. Access to OE the vehicle. This means that chassis component offering of parts, 5. OE quality products many garages still quality parts servicing can no longer be performed with just a tooling, diagnostics, PTRO E L ENGINE MANAGEMENT // outsource this work. 6. Technical support diagnostic tool. Steering racks that are electrically training, technical To tap into this lucrative 3. In-depth training on The introduction of advanced technologies such as driven will need to be re-calibrated after being fitted, and marketing support. servicing opportunity, 7. Marketing support the very latest vehicle gasoline direct injection (GDI), enabling a stratified electric parking brakes need to be wound back, and technologies technicians need to fuel charge combustion for improved efficiency, vehicles with air suspension will need the ‘service be trained on the very has resulted in significantly more complex petrol mode’ selecting before maintenance. latest technology, 4. Technical knowledge powered vehicles. Coupled with this, you only keep up to date with need to look at the multi function displays on the 5. Specialist removal regulation and have and refit tooling access to the right tools and parts. TT 6. Comprehensive marketing support to promote the network As an original equipment manufacturer, Delphi is in a unique position to provide valuable knowledge of the technology the market will see in vehicles today, tomorrow... and ten years down the road. Join the Delphi Service Centre network to access all the tools, skills and knowledge you need to stay ahead of the game. To find out how Delphi Service Centre could benefit your business, read more at www.delphi.com/DSC P2 D elphi’s Magazine for Automotive Technicians // Autumn 2010 P3 Reduce Comebacks C ontamination caused P art No. 1 Part No. 2 by rusted fuel lines W ere they worn This vehicle received two fuel modules in less than out or did they a week. The complaint was noisy operation and erratic fuel pressure. Both modules were analysed, fail for another and found to have the fuel module bucket and External strainers of both parts show reason? internal strainer heavily contaminated with rust. The external strainers showed some discolouration, discolouration, but very little rust contamination. but had significantly less rust in them. The cause The answers to was a rusted return fuel line. these questions are important No significant amount of rust or contamination was found in the fuel tank because the source of the and without rust was the metal return line on the vehicle. The them, an accurate rust that was deposited went directly into the fuel diagnosis is left module bucket, as the return line on this vehicle puts to chance. fuel directly into the fuel module bucket, not the fuel tank. Once the rust was deposited, it could not be removed. The fuel filter was not able to catch the rust because it was developing in the vehicle return line, On both parts, rust was found inside downstream of the fuel filter. of bucket and on pump strainer. Did You Know? Delphi Fuel Pump Delphi aftermarket closely for evidence of melting or bubbling T HIRD CHECKPOINT // pumps and modular near the electrical terminals. reservoir assemblies Visually examine the fuel module bucket and internal strainer. Depending on the module design, Failure Analysis are exact-fit OE Any melting is an indication of excessive heating you may be able to view the module bucket through replacements. due to a poor electrical connection caused by a an opening in the fuel module design. If not, the What can a failed part tell you? damaged vehicle body harness. If this type of bucket may have to be removed from the fuel A lot... It tells a story. Take the fuel pumps to the damage is found, poor pump performance will module through disassembly. What is important to right. These failed pumps were not a result of occur due to this bad connection. The vehicle’s I ntermittent starts due to bad vehicle wiring note is what has accumulated in the fuel module incorrect testing. All tests performed were valid electrical connector must be replaced or repeat bucket and internal pump strainer. Contaminants and provided useful data for making a diagnosis, failures will occur. but more could have been learned. Were they worn The vehicle shown below received three fuel modules over a five week entering the fuel module bucket are indefinitely out or did they fail for another reason? The answers time period. In each instance the vehicle would not start. Sometimes SECOND CHECKPOINT // trapped, so the bucket will contain a contamination to these questions are important and without them, striking the bottom of the fuel tank would cause it to run. history of the fuel module. Examine the external strainer on the fuel module. an accurate diagnosis is left to chance, inviting Look for signs of dirt and/or rust contamination. future problems for you and your customer. All modules were analysed and failed due to a bad vehicle electrical A significant amount of contamination found in the Any form of dirt found in the strainer should A failed-part analysis should always be conducted connector, which had not been replaced in all instances.