Delphi Diesel Particulate Filters Catalogue - baixardoc

2012

DIESEL PARTICULATE FILTERS (DPF)

2

Using this catalogue

This catalogue is designed as an Introduction to Delphi Diesel Particulate Filters, providing

essential information on

• Buyer’s guide, with images and cross-reference against applications

• Range of DPF Training courses

• Marketing Support

• Technical Support

Cross referencing guide against the vehicle manufacturer (VM) part number and the original

equipment manufacturer (OEM) part number. Alternatively, contact our technical support who

will be able to advise.

Product Information

Delphi Diesel Particulate Filters are fi tted with a premium Silicon Carbide Filter. To complement

our range of DPF’s Delphi also offer a number of complimentary products

• Diesel Particulate Filters

• Diesel Particulate Filter fi xing kits

• Eolys Regeneration Additive

• DS DPF capability

All Data within this catalogue is also available on Direct Evolution.

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Contents

Using this catalogue 2

Product Information 2

Technical Overview 4

Warranty 5

Training 7

Marketing Support 8

Application Data 9

Buyers Guide 13

Delphi DPF & Fixing Kits 18

DS Capabilities 19

Cross Reference 72

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Diesel Particulate Filter Technical Overview

A diesel particulate filter (DPF) is a device designed to reduce the emissions from diesel fuelled

vehicles. The Silicon Carbide based filter, traps particulate matter (soot) to remove it from

the exhaust gasses emitted to atmosphere. The soot collected by the filter is reduced to ash

during regeneration. Regeneration is controlled by the correct driving cycle of the vehicle and

its engine management system. Faults that occur on an engine can cause the DPF to become

blocked, then regeneration is not possible.

Common DPF Failures:

• EGR valve stuck; failed

• Turbo failure

• Injectors; leaking and/or stuck open

• Poor engine maintenance

• Faulty pressure and/or O2 sensors

• Faulty temperature sensors

• Blocked pipes

• Incorrect oil temperature

• Damaged exhaust system

• Corrosion/filter cracks

• Continuous urban drive cycles

• Incorrect fuel

Warranty Overview

A particulate filter returned due to blockage will not be considered as a warranty claim.

DPF Filter Care

When the DPF warning light illuminates you should consult your nearest Delphi Service Centre

or Diesel Approved Network immediately. Continued driving could result in a blocked DPF and

additional damage to the engine. DPF’s that regenerate by using the additive are known as

‘active regeneration’ and should not be driven without this fluid. When fitting a new active DPF

or topping up the additive, the ECU must be reset to: New DPF/ Refilled additive. Please ensure

all connections are sealed and air tight to prevent exhaust gas leakage

Regeneration will not take place when:

• The fuel light is on or there is less than 20 litres of fuel in the tank

• The engine management light is on

• Your foot is resting on the clutch pedal

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Warranty Policy

1.0 Introduction

This note outlines the warranty policy for all Delphi DPF applications.

1.1 Construction

The Delphi DPF is a welded stainless steel canister constructed in bespoke jigs per each

vehicle application. Support brackets, sensor mounts and sensor pipework are all replicated to OE

specification. The Substrate or filter media is constructed of Silicon Carbide for durability. The DPF

may be supplied with a diesel oxidation catalyst integral to the construction, but application specific.

2.0 Warranty

The Delphi DPF is warrantied for mechanical concerns providing the vehicle manufacturers

guide lines have been followed and all service protocols for engine oil and regen additive have

been acknowledged. It is imperative that the appropriate fitting kit is utilised in the replacement

process to minimise vibration and leakage opportunities. The unit is guaranteed to be free from

leaks at welded seems, sensor pipe welds, and sensor bosses.

2.1 Conditions where warranty will be rejected.

Blocked substrate is not a warrantable condition; this is attributable to malfunctions of

components outside of the DPF Damage to the external surface of the pipework or canister

Stripped threads on pipe or sensor bosses. Broken mountings as a result of engine or exhaust

system mounting defects. Accident damage through impact or grounding.

Drive cycle related issues necessitating re-occurring forced regen activity.

Absence of diagnostic data relevant to the potential failure mode.

Any DPF subjected to external cleaning aids which are not part of the VM control system.

2.2 Warranty Period

The Delphi DPF is warrantied for a period of 12months or 24,000 miles /40,000Km from date

into service

3.0 Warranty Process

In all cases the Delphi National Distributor must be contacted before a replacement is made

under the warranty process. The National distributor will advise the appropriate course of action

to be taken. In every case an authorisation number must be issued before the unit is replaced.

This unique reference number must be quoted on the warranty claim form.

It will be necessary for the service centre to provide diagnostic data before and after

regeneration for a warranty claim to be accepted.

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Delphi form DDFX 100B or the Web warranty system can be used for warranty submission.

All claims must contain the following data

1. Make, model and year of vehicle

2. Odometer reading from the first fit and date of first fit

3. Odometer reading at the failure point and date of failure

4. Nature of the failure

a. This must be supported with diagnostic data and any relevant photographic evidence as an

attachment to the warranty claim.

b. Any relevant fault codes recorded in the vehicle management system

5. The authorisation number issued by the Delphi National Distributor.

Note:- The responsibility for the decision to change a DPF under warranty will remain with the

Delphi National Distributor with Guidance from Delphi Service Operations HQ.

The Delphi National Distributor will advise if the old product is required to be returned.

Free of charge parts will not be provided by Delphi. All parts used in the warranty repair will

be ordered through normal supply channels and invoiced accordingly. Credit will be awarded

through the warranty process.

Delphi will reimburse the distributor cost of the parts only. This will be inclusive of any fitting kit

used in the repair.

Delphi will not reimburse any labour cost required for remove and refit of the component to

the vehicle. Delphi may request material to be returned for examination if a warranty resolution

cannot be found locally.

In these cases, if the product is no trouble found, the costs will remain the responsibility of the

workshop concerned.

4.0 Factors to be considered before making a warranty claim.

DPF Failure Can Be Due To:

• Poor engine maintenance

• Malfunctioning pressure or temperature sensors/ pipes (condensation in the pipes)

• Incorrect oil temperature

• Faulty EGR valve

• Damaged exhaust system

• Corrosion/fractures

• Incorrect fuel

• All of the above should be confirmed serviceable before submitting a warranty claim

Note:- Active DPFs that use additive to assist in regeneration must never be used without this

fluid, as this could result in a blocked DPF

• When fitting a new active DPF or topping up the additive the ECU must be reset to: New DPF/

Refilled

• Additive This applies to replacing DPF in the warranty period as well as the general service interval.

• Regeneration Will Not Take Place When:

• The fuel light is on or there is less than 20 litres of fuel in the tank

The engine management light is on. The Delphi National Distributor is available for technical

support and warranty advice.

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Training

Course title:

Fault diagnosis on common rail fuel injection systems fitted with Particulate filters (DD4)

Who is it for?

Fuel injection Technician who will be conducting fault diagnosis on vehicles fitted with common

rail fuel injection systems and particulate filters.

What is it about?

The course will teach how to diagnose and repair faults on vehicles fitted with common rail fuel

injection systems fitted with particulate filters. Students will carry out diagnostic procedures to

Delphi Distributor Standards using the specified diagnostic and special tooling and diagnostic data.

Subjects covered

The course is divided into the following subjects:

• Overview of the principles and operation of common rail diesel fuel injection systems

• A detailed understanding of particulate filter systems and associated electronic controls

• Test injector additive

• Testing the fifth injector with ASNU

• Preventive maintenance for FAP

• Diagnostic strategies

• The principles of on-vehicle testing using Delphi diagnostic tools

• An understanding of the need for the cleanliness standards

• A detailed understanding of Delphi common rail fuel injection systems fault diagnosis and

repair procedures

• A detailed understanding the Delphi Direct Evolution system.

What will I get out of it?

By the end of the course you will be able to:

• Safely manage on-vehicle diagnostic procedures

• Correctly select and use the appropriate diagnostic tooling for the task.

• Correctly diagnose diesel fuel system faults associated with the particulate filter on common

rail fuel injection systems.

Pre-requisites

None.

Assessment

A certificate will be awarded for successful completion of the course. This will include

evaluation of practical activities and an end of course test.

Course duration

1 day

Marketing support

Delphi Advertisment Delphi Technical Tips

Delphi Datasheet

Delphi Brochure

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bhp i

CITROËNBerlingo 1.6 HDi 9HZ (DV6TED4) 109 04/08 - HDP124

C2 1.6 HDi 9HZ (DV6TED4) 109 09/05 - HDP124

C3 1.6 16V HDi DV6TED4 109 09/05 - HDP124

C3 Picasso 1.6 HDi 9HZ (DV6TED4) 109 02/09 - HDP124

C4 1.6 HDi DV6TED4, 9HZ (DV6TED4), 9HY (DV6TED4) 109 11/04 - HDP124

C4 2.0 HDi DW10BTED4, RHR (DW10BTED4) 136 11/04 - HDP119

C4 Coupe 1.6 HDi DV6TED4, 9HZ (DV6TED4), 9HY (DV6TED4) 109 11/04 - HDP124

C4 Coupe 2.0 HDi DW10BTED4, RHR (DW10BTED4) 136 11/04 - HDP119

C4 Grand Picasso 1.6 HDi 9HZ (DV6TED4), 9HY (DV6TED4) 109 10/06 - HDP124

C4 Grand Picasso 2.0 HDi RHJ (DW10BTED4), RHR (DW10BTED4) 136 10/06 - HDP119

C4 Picasso 1.6 HDi 9HZ (DV6TED4), 9HY (DV6TED4) 109 02/07 - HDP124

C4 Picasso 2.0 HDi RHJ (DW10BTED4), RHR (DW10BTED4) 136 02/07 - HDP119

C5 1.6 HDi 9HY (DV6TED4) 109 09/04 - HDP124

C5 2.0 HDi DW10BTED4 136 09/04 - HDP114

C5 2.2 HDi 4HX (DW12TED4/FAP) 133 03/01 - 08/04 HDP102

C5 Estate 1.6 HDi 9HY (DV6TED4), 9HZ (DV6TED4) 109 09/04 - HDP124

C5 Estate 2.0 HDi RHR (DW10BTED4) 136 09/04 - HDP114

C5 Estate 2.2 HDi 4HX (DW12TED4/FAP) 133 06/01 - 08/04 HDP102

C8 2.0 HDi RHW (DW10ATED4), RHT (DW10ATED4), RHM (DW10ATED4) 107 07/02 - HDP103 1 bracket

C8 2.0 HDi RHW (DW10ATED4), RHT (DW10ATED4), RHM (DW10ATED4) 107 07/02 - HDP104 2 bracket

C8 2.0 HDi RHR (DW10BTED4) 136 03/06 - HDP103 1 bracket

C8 2.0 HDi RHR (DW10BTED4) 136 03/06 - HDP104 2 bracket

C8 2.2 HDi 4HW (DW12TED4) 128 07/02 - HDP103 1 bracket

C8 2.2 HDi 4HW (DW12TED4) 128 07/02 - HDP104 2 bracket

Xsara Picasso 1.6 HDi DV6TED4 109 05/04 - HDP124

FIATCroma 1.9 D Multijet 939 A2.000 150 06/05 - HDP101

Croma 2.4 D Multijet 939 A3.000 200 06/05 - HDP101

Doblo 1.3 D Multijet 223 A9.000 084 10/05 - HDP123

Doblo 1.9 D Multijet 186 A9.000 120 10/05 - HDP129

Ulysse 2.0 JTD RHM(DW10ATED4) 107 05/03 - HDP103 1 bracket

Ulysse 2.0 JTD RHM(DW10ATED4) 107 05/03 - HDP104 2 bracket

Ulysse 2.0 JTD RHW(DW10ATED4) 109 08/02 - HDP103 1 bracket

Ulysse 2.0 JTD RHW(DW10ATED4) 109 08/02 - HDP104 2 bracket

Ulysse 2.2 JTD 4HW(DW12ATED4) 128 08/02 - HDP103 1 bracket

Ulysse 2.2 JTD 4HW(DW12ATED4) 128 08/02 - HDP104 2 bracket

FORDFocus C-Max 1.6 TDCi HHDA, HHDB 90 02/05 - 03/07 HDP105

Focus C-Max 2.0 TDCi G6DA, G6DB, G6DD, G6DG 136 10/03 - 03/07 HDP117

Focus II 1.6 TDCi HHDA, HHDB, GPDA, GPDC 90 11/04 - HDP105

Galaxy 2.0 TDCi QXWA, QXWB, QXWC, UFWA 140 05/06 - HDP121

Mondeo IV 2.0 TDCi QXBB, UFBA 140 03/07 - HDP121

S-Max 2.0 TDCi QXWA, QXWB, QXWC, UFWA 140 05/06 - HDP121

JAGUARS-Type 2.7 D 207 06/04 - HDP136

KIACarens III 2.0 CRDi D4EA 140 09/06 - HDP130

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bhp i

MAZDA5 2.0 CD 110 03/05 - HDP106

5 2.0 CD RF7J 143 06/05 - HDP106

6 2.0 DI RF7J 143 06/05 - HDP131

MERCEDES-BENZC200 2.0 CDI OM 611.962 116 09/00 - HDP120

C220 2.2 CDI OM 611.962 143 05/00 - HDP120

C220 2.2 CDI OM 611.962 143 03/01 - 06/11 HDP120

C200 T 2.0 CDI OM 611.962 116 03/01 - 08/07 HDP120

C220 T 2.2 CDI OM 611.962 143 03/01 - 08/07 HDP120

Sprinter 210 2.1 CDI OM 651.955 95 03/09 - HDP137







Sprinter 313 4X4 2.1 CDI OM 651.955, OM 651.956 129 06/06 - HDP137


Sprinter 316 4X4 2.1 CDI OM 651.957 163 03/09 - HDP137




NISSANPathfinder 2.5 dCi 4WD YD25DDTi 171 10/06 - HDP133

Pathfinder 2.5 dCi 4WD YD25DDTi 174 03/05 - HDP133

OPELAstra H 1.9 CDTI 16V Z 19 DTJ 120 04/04 - HDP127

Astra H Estate 1.9 CDTI Z 19 DTH 150 09/04 - HDP127

Astra H GTC 1.9 CDTi Z 19 DTH 150 03/05 - HDP127

Astra H GTC 1.9 CDTi 16V Z 19 DTJ 120 03/05 - HDP127

Astra H Twintop 1.9 CDTi Z 19 DTH 150 09/05 - HDP127

Corsa D 1.3 CDTI Z 13 DTJ, A 13 DTC 75 07/06 - HDP122

Corsa D 1.3 CDTI Z 13 DTH 90 07/06 - HDP122

Meriva 1.3 CDTI Z 13 DT, Y 13 DT 69 04/05 - 05/10 HDP122

Signum 1.9 CDTI Z 19 DT 100 08/05 - HDP101

Signum 1.9 CDTI Z 19 DT 120 04/04 - HDP101

Signum 1.9 CDTI Z 19 DTH 150 04/04 - HDP101

Vectra C 1.9 CDTI Z 19 DT 100 10/05 - HDP101

Vectra C 1.9 CDTI Z 19 DT 120 04/04 - HDP101

Vectra C 1.9 CDTI Z 19 DTH 150 04/04 - HDP101

Vectra C Estate 1.9 CDTI Z 19 DTL 100 10/05 - HDP101

Vectra C Estate 1.9 CDTI Z 19 DT 120 04/04 - HDP101

Vectra C Estate 1.9 CDTI Z 19 DTH 150 04/04 - HDP101

Vectra C GTS 1.9 CDTI Z 19 DT 100 10/05 - HDP101

Vectra C GTS 1.9 CDTI Z 19 DT 120 04/04 - HDP101

Vectra C GTS 1.9 CDTI Z 19 DTH 150 04/04 - HDP101

Zafira 1.9 CDTI Z 19 DTL 100 07/05 - HDP110

Zafira 1.9 CDTI Z 19 DT 120 07/05 - HDP110

Documents

Delphi Diesel Particulate Filters Catalogue - baixardoc