Delphi’s Magazine for Automotive Technicians // Issue 3 THIS MONTH WE TALK: Preventing Compressor Failures P2 Common Rail Injectors – Cracking the Code P4 PicoScope & DS350E Case Study P6 Electronic Diagnosis of Braking Systems P8 EGR Valves Outperform the Competition P10 Coil Springs P12 Delphi’s Linked Diagnostics System P13 Day in the Life of a WRC Technician P14 The Importance of Fuel Quality P16 Delphi Technologies Featured on Ford P18 Glow Plugs & Compressors P20 New VE, Braking & Steering Parts P21 Steering and Suspension Check out the Development and Testing P22 action from the WRC! As the Official Automotive Technology Partner of the FIA World Rally Championship, Delphi has unrivalled access to one of the world’s most challenging motorsport competitions... You too can experience the thrills Check out the action and spills of the rally with this short Simply scan the code (below) action packed video, showing exclusive with your smartphone/device footage from our first European races loaded with a QR code reader in Portugal, Sardinia and Greece. available through your app store. Alternatively, check out the video Watch the turbocharged, super-torqued, online at http://am.delphi.com/qr2 300bhp, four-wheel drive monsters DON’T MISS: accelerate from a standing start to 100kph // DELPHI EGR VALVES: OUTPER- in around three seconds and reach top P10 FORMING THE COMPETITION speeds of up to 220kph… as well as the skill and nerve required to drive flat-out on // A DAY IN THE LIFE OF A P14 some of the most testing roads in the world. WRC TECHNICIAN Whether speeding through forests, along // HELPING FORD STAY SAFE, cliff edges, or dodging snow banks, ditches P18 GREEN AND CONNECTED or rocks, there is no room for error... and plenty of action! // For more on the WRC, // STEERING AND SUSPENSION P22 see page 14 TT DEVELOPMENT AND TESTING TURN TO PAGE 18 TO FIND OUT HOW DELPHI CONTINUES TO KEEP VEHICLES SAFE, GREEN AND CONNECTED Best Practices to help prevent Compressor Failures Best Practice # 3: It goes without saying… Knowing the latest repair trends Use lubricant recommended can help improve service Seems simple… use the lubricant type Continuing education is critical to turnaround, avoid comebacks and recommended in the instructions that increase overall customer satisfaction. come with the new compressor. success. Every year the technology Unfortunately compressors fail every The same can be said for seemingly simple day by having the wrong lubricant. gap between original equipment repairs – whether complex or simple, maintaining best practices can help eliminate Without the correct lubrication, the and the aftermarket shrinks. a potential misdiagnosis or part failure. compressor has little or no chance of Did You Know? long-term stability. There are a number of lubricant types on the market depending Delphi’s CVC on the A/C system. PAG oil is the most technology is fitted common. It is important that high as original equipment quality PAG oil be used and the Best Practice # 1: Compressor Best Practice # 2: on some of the most technician follows the directions included popular platforms preparation prior to operation Flushing the A/C system 3. This is the inside of a failed compressor, with the new compressor so the correct in Europe including showing lubrication that has become a type and amount of oil is utilised, and in the Would you expect a rebuilt engine to run properly When flushing the A/C system with chemicals, Volkswagen, Renault, thick, black sludge. Ester oils, which are not proper location. if it wasn’t pre-lubed or only had one quart of oil in ensure no residual flush is left behind. If there is, recommended for use in Delphi compressors, Nissan and Opel the crankcase on initial startup? Of course not. it could dilute and contaminate the compressor can experience thermal breakdown in high applications. lubricant leading to compressor noise and heat conditions, and form sludge like this. Ester oils are also available, but should The same can be said for a compressor. There’s premature failure. not be used as they can break down under no difference. In order for the compressor to high heat conditions resulting in lubrication operate correctly on startup, it must have the If you are flushing an A/C system, it is critical and compressor failures. TT accurate amount of oil inside and be turned over, you use the approved OEM equipment, flushes by hand, using the right compressor turning tool, and procedures to help minimise concerns with Crank case plug so all the components inside are “prelubed.” potential residual flush. 1. This is the rotating assembly of an A/C compressor, which was destroyed Why and when do by lack of lubrication at start up. Notice the gun metal blue colour of parts which over-heated and seized causing a catastrophic failure. you have to change Gun metal blue the compressor? • Lack or excess of refrigerant oils • Internal corrosion • Lack of servicing (regular changing of receiver drier) • Circuit blocked – receiver drier clogged Failure to complete this prelubrication process and/or expansion valve blocked prior to compressor operation can lead to noise • Incorrect or no flushing of system complaints and premature failure. There are two when fitting new compressor types of compressors – with oil and without oil. Compressors with oil (prelubed) need to have the • Electrical problem in the clutch new oil drained, and the correct oil amount and type reinstalled. Dry compressors, or compressors • Faulty compressor generates: without oil, need to have the correct amount and 2. This is a destroyed reciprocating assembly 4. When lubricating compressors with a crank o A/C system does not operate at all type of oil added prior to compressor operation. from a compressor that failed due to lack of case plug, be sure to remove and install all Regardless of compressor type, instructions lubrication. The lubricant removed from the lubrication through this opening so the oil o Potentially result in damage to other A/C components included demonstrate how to correctly lubricate compressor was thin (had poor viscosity) can get directly to the rotating assembly and rotate the compressor prior to operation. and had a chemical flush odour. inside the compressor. P2 Delphi’s Magazine for Automotive Technicians // Issue 3 Delphi.com/am P3 Common Rail Injectors Cracking the Code The introduction of Common Rail technology has brought with it new challenges for the aftermarket. Every technician that has had to replace a Common Rail injector is aware that they each have their own individual characterisation code. But what exactly is this code and how important is it? Delphi’s global network of highly equipped, highly skilled diesel specialists offers cost-effective diagnostics, testing and repair of today’s most advanced diesel fuel injection technologies. Tech Talk takes a detailed look at what the coding actually means and its relevance to the aftermarket. Delphi Diesel Centres are equipped with the latest test The amount of fuel that is delivered by the What is a Delphi C2i/C3i code? injector is proportional to the injection time How should the ECU be re-programmed? equipment and With Common (pulse) and rail pressure. Therefore, it is possible Rail injectors All Delphi Common Rail injectors feature either to compensate for manufacturing variances by To replace a Delphi Common Rail injector, the technician must use service expertise, all an Individual Injector Characterisation (C2i), or managing the pulse time applied to each injector. a diagnostic tool that is capable of writing the C2i or C3i code to operating at on the latest generation systems, an Improved the ECU. Delphi’s DS100E or DS150E with Diesel Max software backed by a leading extremely high Individual Injector Characterisation (C3i) code. This Delphi’s characterisation codes are generated by is the only OE recognised tool targeted at independent garages pressures, even takes the form of a 16 digit, hexadecimal code for measuring the flow rate of each injector at four and workshops that can provide this capability. In addition to OE manufacturer: minute physical C2i, or a 20 digit, alphanumerical code for C3i. The different pressures (200, 800, 1200 & 1600 bar). this unique diesel capability, the simple, compact tool, offers full code relates to the specific characteristics of each These measurements are then compared against diagnostics across other key vehicle electronic systems. With this, variations • State-of-the-art test equipment, tooling injector such as flow rates, response times and a target (average) injector performance to assess the technician will be able to read and erase fault codes, as well as and technical information to perform between injectors performance at different pressures, and is designed what pulse time adjustment is required in order to read real time data. The DS tool with Diesel Max software is also OE approved repairs; will cause to allow precision management of the fuel injected obtain the required fuel delivery. This adjustment is available as part of the Delphi Service Centre – Diesel module. • Industry-leading software to generate discrepancies. into each cylinder for optimum engine efficiency, translated into the 16 or 20 digit C2i or C3i code. and to enable the ECU to be calibrated with the How does coding affect the repair the latest injector calibration coding; injection system. These characteristics are recorded The impact for the of injectors? • Fully-trained technicians guarantee to a code during manufacture, and subsequently expert diagnostics, testing and repair attached to the injector. During vehicle assembly aftermarket technician on the latest diesel technologies; the code is programmed to the ECU. When an injector is repaired, its characteristics will be Every Delphi Common Rail injector, be it new or significantly changed. It is therefore essential that a new C2i or • OE parts for high-quality repairs Why are these codes required? repaired, should have a label with a characterisation C3i code is allocated to the injector to reflect the performance of and less comebacks; code applied to it.