Delphi Product & Service Solutions –

Diesel
Agenda

• Delphi Diesel Systems

• Diesel Growth – Technological Revolution

• The Aftermarket Challenge

• Delphi Diesel Aftermarket

• Delphi Service Centre - Diesel

• Summary
Delphi Diesel Systems: Market Segment Coverage

Car / LCV’s Land-Rover EUI

Epic / DPC Common Rail tubular / spherical

Off Highway A3 EUI E1 EUI

DP 200 DP 210

Trucks A3 EUI E1 / E3 EUI EUP E1 / E3

Global Manufacturing Footprint

Sudbury, England Gillingham, England

Injectors, Nozzles & Filters Rotary IDI and DI pumps

Troy, Michigan Blois, France Changwon, Korea

Remanufacturing
Stonehouse, England CR injectors
Pumps & Injectors
Electronic Unit Injectors
La Rochelle, France
CR injectors

Isai, Romania
CR injectors
Saltillo, Mexico
Injectors & Filters
Izmir, Turkey
Unit pumps, Injectors

Chennai, India
Pumps, Injectors & Filters
Cotia, Brazil
Pumps, Injectors & Filters
Customers
European Mature CR Vehicles
Ford Renault Clio 1.5 KIA
Focus 1.8 TDCi 1461 cc Carnival KJ 2.9
115 CV 65 - 80 - 100 CV 145 CV

Ford Renault Kangoo 1.5 Hyundai

Focus 1.8 TDCi 1461 cc Terracan KJ 2.9
100 CV 65 - 80 CV 145 CV

Ford Renault Megane II Jaguar X-Type

Mondeo 2.0 1.5 TDCi 1461 cc 80 Ford 2.0 –2.2
TDCi - 100 CV 130CV 155CV
130 - 115 CV

Ford Nissan Almera Suzuki Jimmy

Mondeo 2.2 1.5 1461 cc 1461 cc
TDCi 82 CV 65 CV
150 CV

Ford Nissan Micra Suzuki Liana

Connect 1.8 1.5 dCi 1461 cc 1400 cc
TDCi 65 - 82 CV 90 CV
90 CV

Ford Ssangyong
Citroen C3
Transit 2.0 TDCi Rexton 2.7
1.4 16 valv.
125 CV 165 CV
90 CV
DELPHI DIESEL COMMON RAIL incl. DFP3.4
on Citroen C4 Picasso HDi 135 FAP EGS 6

C4 Picasso HDi 135 FAP

No. of Cylinders/arrangement 4/in-line
Total displacement (cc)
1997
Rated output (kW) 100
Rated torque (Nm) 270
Approx top speed (km/h) 195

DFP 3.4
DW10 B Euro 4
2 Plunger Pump
Capacity 0.7 cc/rev.
Pressure 2000
Max Engine Speed 4000 RPM
Rotation Clockwise
DELPHI DIESEL COMMON RAIL incl. DFP3.4
on Citroen C5 Estate HDi 135 FAP

DFP 3.4
DW10 B Euro 4
2 Plunger Pump
Capacity 0.7 cc/rev.
Pressure 2000
Max Engine Speed 4000 RPM
Rotation Clockwise

C5 Estate HDi 135 FAP

No. of Cylinders/arrangement 4/in-line
Total displacement (cc) 1997
Rated output (kW) 100
Rated torque (Nm) 270
Approx top speed (km/h) 195
DELPHI DIESEL COMMON RAIL incl. DFP3.4
on 307cc 2.0 HDI

DFP 3.4
DW10 B Euro 4
2 Plunger Pump
Capacity 0.7 cc/rev.
Rail Pressure 1650 Bar
Max Engine Speed 4000 RPM
Clockwise

307 cc 2.0 HDI

No. of Cylinders/arrangement 4/in-line
Total displacement (cc) 1997
Rated output (kW) 100
Rated torque (Nm) 320
Approx top speed (km/h) 208
Certified emission standard Euro 4
DELPHI DIESEL COMMON RAIL incl. DFP3.4
on Peugeot 308 2.0 HDI

DFP 3.4
DW10 B Euro 4
2 Plunger Pump
Capacity 0.7 cc/rev.
Pressure 1650
Max Engine Speed 4000 RPM
Rotation Clockwise

308 2.0 HDI

No. of Cylinders/arrangement 4/in-line
Total displacement (cc) 1997
Rated output (kW) 100
Rated torque (Nm) 320
Approx top speed (km/h) 206
DELPHI DIESEL COMMON RAIL incl. DFP3.4
on Ford 2.0 TDi

DFP 3.4
DW10 B Euro 4
2 Plunger Pump
Capacity 0.7 cc/rev.
Pressure 1650
Max Engine Speed 4000 RPM
Rotation Clockwise

Ford 2.0 TDI

No. of Cylinders/arrangement 4/in-line
Total displacement (cc) 1997
Rated output (kW) 100
Rated torque (Nm) 320
Approx top speed (km/h) 203
DELPHI DIESEL COMMON RAIL incl. DFP3.1
on Mercedes Benz C200CDI

DFP 3.1
OM646 Evo
3 Plunger Pump
Capacity 0.85 cc/rev.
Rail Pressure 1600 Bar
Max Engine Speed 4600 RPM
Rotation Anti-Clockwise

C 200 CDI
No. of Cylinders/arrangement 4/in-line
Total displacement (cc) 2148
Rated output (kW at rpm) 100/3800
Rated torque (Nm at rpm) 270/1600-3000
Approx top speed (km/h) 215
DELPHI DIESEL COMMON RAIL incl. DFP3.1
on Mercedes Benz E220CDI

DFP 3.1
OM646 Evo
3 Plunger Pump
Capacity 0.85 cc/rev.
Rail Pressure 1600 Bar
Max Engine Speed 4600 RPM
Rotation Anti-Clockwise

E 220 CDI
No. of Cylinders/arrangement 4/in-line
Total displacement (cc) 2148
Rated output (kW at rpm) 125/3800
Rated torque (Nm at rpm) 400/2000
Approx top speed (km/h) 227
 DIESEL GROWTH
Technology Revolution
 Global Emissions Legislation

TERRITORY
2004 2005 2006 2007 2008 2009 2010 2011 2012 2013 2014 2015
W.EUROPE P.Cars EURO 4 EURO 5 EURO 6
LCV's EURO 4 EURO 5
ROMANIA EURO 3 EURO 4
POLAND Transition EURO3/EURO4 EURO 4 EURO 5
TURKEY Imported cars and trucks must comply with EU legislation EURO 4
US TIER
US2 EPA
BIN 8 TIER 2 BIN 5 TIER 3
(CARB) CALIFORNIA LEV2 LEV 2 BIN 8 LEV 2 BIN 5

JAPAN JP2002 JP2005 JP2009 JP2013

SOUTH KOREA PC(<= 2,5 t GVW) EURO 3+ EURO 4 EURO 5

PC & LCV ( > 2,5 t. GVW) EURO 4
INDIA (11 big cities) EURO 3 EURO 4 EURO 5
(countrywide) EURO 2 EURO3 EURO 4
CHINA PC (Beijing and Shanghai) EURO 3 EURO 4 (Jan08) EURO 5
LCVs EURO 4 without OBD OBD obligatory
PC (countrywide) EURO 2 (July 04) EURO3 +OBD EURO 4 (Jan10) EURO 5
CV EURO 2 (Jly05) EURO3 (July10) w/OBD EURO 4
ASEAN COUNTRIES EURO 3 EURO 4 EURO 5
ARGENTINA EURO3 EURO 4

Below EURO3 std + NMHC

BRAZIL Prior to 2007, Diesel cars not allowed
test similar to US Tier2 ProconVe 5

AUSTRALIA EURO 4 equivalent EURO 5

RUSSIA EURO 2 (July06) EURO 3 EURO 4 EURO 5
Diesel Technology Revolution!

25

• Emissions legislation 20

15 New
• Fuel Economy Technology
10

Old
• Performance 5 Technology

• Noise reduction 0

95

96

97

98

99

00

01

02

03

04

05

06

07

08

09

10

11

12

13
19

19

19

19

19

20

20

20

20

20

20

20

20

20

20

20

20

20

20
Mechanical Control Electronic Control

DPA DPCn / EPIC DP200

Common Rail
Electronic Unit Injector
Technology Review – Common Rail

Cylinder
Capacity
(Litre/Cylinder
2 Heavy Truck

1,5

On highway MD
Off highway MD
1

Light Truck

0,5 Pass Car

LD Commercial Engine
Capacity
(Litre)

3 6 9 12
Technology Road Map – Common Rail

Common Rail Technology Road Map

EURO3 EURO4 EURO5
US ‘06 US ‘09

Piezotec 2000 bar

TM
Multec DCR 1800 bar

TM
Multec DCR 1600 bar

TM
Multec DCR 1400 bar
Technology Road Map – Common Rail
Engine Performance evaluation
Diesel Growth

New car Sales by fuel type

90%
80%
70%
60%
50%
40%
30%
Petrol
20%
10% Diesel
0%
91

93

94

95

96

97

98

99

00

01

02

03

04
19

19

19

19

19

19

19

19

20

20

20

20

20

10000 60.0
9000
50.0
Diesel Sales Volume 000

8000 Volume 000

Diesel Penetration %
7000 Diesel Share 40.0
6000
5000 30.0
4000
20.0
3000
2000
10.0
1000
0 0.0
1996 1997 1998 1999 2000 2001 2002 2003 2004 2005 2006 2007 2008
Common Rail Growth - Delphi

Delphi Diesel
20,000 Common Rail parc
18,000

16,000

14,000

12,000

10,000 + 4m
8,000

6,000

4,000

2,000

0
2000 2001 2002 2003 2004 2005 2006 2007 2008 2009 2010 2011 2012 2013 2014
The Aftermarket Challenge
IAM Service Challenge – Common Rail Technology

Main problems facing the garage network today?

Technological
53
evolution of cars
Finding qualified
43
people
Increased
28
competition

Waste products 17

Equipment (in
15
workshop)

Training 14

Implementing
7
marketing strategy
Source: GIPA Service Provider survey
The IAM Service Challenge

Vehicle Manufacturer dealerships aggressive in the aftermarket

80.0%
73.9% In
70.0% Warranty Out of warranty
57.9% 58.8%
60.0% 57.3% 57.3%
54.6%
51.5%
48.3% 49.6%
45.4% 47.1%
50.0%
38.1%
36.7%
40.0%
31.8%
27.9% 28.2%
30.0% 23.6%
17.9%
20.0% 12.2% 16.0% 13.1% 12.3%
10.4% 9.8%
6.6% 6.8%
10.0%

0.0%
1 2 3 4 5 6 7 8 9 10 11 12-13 14-15
Age of car
Mechanical Garage VM Dealer

Source: GIPA motorist survey

The IAM Service Challenge

Out of warranty parc

20,000

18,000 10m
16,000

14,000
6m
12,000

10,000
2m
8,000

6,000

4,000

2,000

0
2000 2001 2002 2003 2004 2005 2006 2007 2008 2009 2010 2011 2012 2013 2014
The IAM Service Challenge

6m
Diesel Service &
Diagnostics
500 in Europe

Independent
Garage
100,000 in Europe

VM Dealership
60,000 VM Dealers in Europe
7,000 (est) Renault
The IAM Service Challenge

Garage
Needs….
1. Diesel Education
2. Diesel Training
3. Diesel Diagnostic
Tools
4. Diesel Products
5. Technical Support
6. Marketing Support
7. Association to high
profile supplier
Delphi Diesel Aftermarket
Delphi Diesel Aftermarket

Business Unit
UK
France
• 400 staff globally Spain
Italy
• UK head quarters
Turkey

• 9 regional offices globally USA

Mexico
Brazil
China

Light Duty Common Rail System State-of-the-Art Injection Technology

Mission - Cradle to grave sales and service

Delphi Diesel Aftermarket Objectives by Market

1. Support OE product
• Warranty
• Out-of-warranty

2. Ensure market coverage

• Geographical
• Distribution channels
3. Maximise market share
4. Maximise brand development

Prepare for future growth

Delphi Diesel Aftermarket Strategy

Diagnostics
Training
Technical
Support
Products
Marketing
Signage

2 Levels of Service Network

Delphi Diesel Service Network – The
Diesel Specialist

Investment
Advanced € Diagnostics
Technology
Product
Products Training

Test
Tools Equip.
Skills

1. Advanced
Diagnostics
t
2. Testing il s
c ia
3. Repair Specialist e
Sp
4. Remanufacture
5. Warranty
Delphi Diesel Service Network – The Diesel
Specialist

3,000
VM Dealerships Independent Garage Fleets
Vehicle Owner Non-Authorised Workshops

Global coverage by the Diesel Specialist

Delphi Service Centre - Diesel

Diesel solution for garages

diesel
diagnostics

diesel diesel
tools training

marketing diesel
support products
technical
support
Delphi Service Centre – Diesel: Garage Pack

Code Description Net Price (€'S)

DS150E Tester SV10546

1,144.89
OR

DS100E Tester SV10168 1,243.88

MAX software SV10192 403.38

SV10505 Diesel Max Upgrade pack
YDT278 Sealed Rail Kit
YDT410 False Actuator Kit
Tool Pack
YDT488
YDT201 Renault/Nissan Kit 900
YDT202 Ford Focus Kit
YDT209 Mondeo/Transit Kit
YDT250 Citroen Kit
DSX543 (Delphi Service Center) 126.90
DSX544(DE) Menu Tick Sign 77.63
DSX545(DE) Descriptor Sign - Diesel 63.45
Signage -

Direct Evolution DDRX208L Direct Evolution Lite Free for first year
Delphi Service Centre – Diesel: Diagnostics

1. Identify the 6. Install new pump or

fault code
2. Check Common Rail
Injector function
injector with C2i/C3i
code using specialised
tools & unique DSC:
Diesel Max Software 5. Remove faulty pump
or injector using specialised
tools

4. Confirm if a
3. Check Common Rail Pump function Mechanical or
Electrical pump fault
Effects of C2i/C3i

Every Delphi CR Injector has either C2i or C3i calibration

– The C2i/C3i configuration must be loaded into the ECU

– C2i 16 Hexadecimal Code: DFP Renault, Ford, Jaguar, Kia, Hyundai, PSA, etc

New CR Evolution moving to C3i

– C3i 20 digit alpha numerical code: DFP3 Mercedes C&E Class, PSA, Ford, Volvo, Kia, etc.
Before correction 10,00
After correction
10,00

9,00 9,00

8,00 8,00

7,00 7,00

6,00 6,00

DEBIT [MM3]
DEBIT [MM3]

5,00 5,00

4,00 4,00

3,00 3,00

2,00 2,00

1,00 1,00

0,00 0,00
200 210 220 230 240 250 260 270 280 290 300 200 210 220 230 240 250 260 270 280 290 300
IMPULSION [µs]
IMPULSION [µs]
Delphi Service Centre – Diesel: Technical
Support

Training

• Garage focused
• Diesel engine overview
• Diesel fuel injection systems detail
• Allmakes diesel diagnostics
technical
• Delphi accredited support
Delphi Service Centre – Diesel: Products

• High Pressure Pump

• Injector
• Fuel Filtration
• Glow plugs
• High Pressure Pipes
• Sensors
• Solenoids
Delphi Service Centre – Diesel: Filtration

OE Filtration Contracts:
– Citroen: C3, C4, C5, Xsara Picasso
– Ford: Focus, Mondeo, Transit Connect, C-Max
– Hyundai: Terracan
– Jaguar: X type, S Type
– JCB: 444 Tier III
– KIA: Carnival, Sedona
– Land Rover: Discovery 3, Range Rover Sport
– Mazda: 3
– Nissan: Almera, Micra, Note, Interstar, Primastar
– Peugeot: 206, 307, 407
– Renault: Clio, Kangoo, Trafic, Thalia, Master, Megane, Modus, Scenic
– Ssangyong: Rexton, Kyron
– Suzuki: Jimny
– Tata: Safari PLUS!
– Vauxhall: Monovan, Vitaro – ALLMAKES PASSENGER CAR
– Volvo: S40 FILTERS
– HD Filters
Delphi Service Centre – Diesel: Starting Aid
Range

Glow Plugs
Heat air in combustion chamber to assist engine start-up.

Glow Plug Controllers

Link battery and glow plugs, providing current to glow plugs for
heating process

Thermostarts
Fitted to heavy duty and commercial vehicle applications to directly
heat air in the engine inlet manifold and assist in engine start-up.

98% European parc coverage

OE specification product
Covers over 5,000 vehicle applications
Delphi Service Centre – Diesel: Extended
Range
Delphi Service Centre – Diesel: Supply Chain

Technical Partner:
- Training
- Product
- Technical Support

Technical Partner
Delphi Service Centre – Diesel: Summary

1. Diesel parc is growing

2. Advanced diesel technology => service challenge
3. Delphi Service Centre - Diesel:
 All makes diagnostics
 Training & technical support
 Diesel products
 Signage / Marketing Support

4. Designed to work with existing garage concepts