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Delphi Supplying Multec Diesel Common Rail System for 3-Cylinder, 1.2L VW Polo BlueMotion

DFP6 single plunger common rail fuel pump with injector. Click to enlarge.

After more than a year of co-development with Volkswagen, Delphi is supplying its Multec Diesel Common Rail System for the new 1.2-liter, 3-cylinder Volkswagen Polo BlueMotion. (Earlier post.)

The common rail system on VW Polo BlueMotion includes the latest evolution of solenoid type diesel common rail injector technology with Delphi’s next generation DFP6 fuel pump. This combination allows for just 87 g/km of CO2 emissions.

Our customers are downsizing their engines to meet stringent CO2 requirements. The new Volkswagen 3-cylinder Common Rail diesel engine allows Delphi to demonstrate the great potential of our solenoid-based fuel injection system technology.

This is Delphi’s first diesel Common Rail program with Volkswagen and it is on a vehicle that is now the most economical five-seater with the lowest emissions and the 2010 World Car of the Year. This is an excellent match for our technology.

—Michael Gassen, general director, Delphi Powertrain Systems and Delphi Europe, Sales & Marketing

Delphi’s Multec Diesel Common Rail System, with a balanced valve fast servo-solenoid injector, was launched in 2000 and has evolved and improved to meet changing emissions standards and drive new powertrain strategies, while maintaining cost and performance competitiveness.

The new common rail system provides improved fuel delivery control, extended multiple injection capability, enhanced spray atomization and air mixing, according to John Fuerst, general manager, Delphi Diesel Systems. The system in the Polo BlueMotion can deliver up to six injection events per combustion cycle.

As well as optimized combustion, the injection efficiency of the system is improved through reduced parasitic losses, reduced component mass, improved energy consumption and hydraulic performance. Delphi says that the common rail system will suit future generations of downsized engines in a range of vehicle classes.

DFP6. Delphi unveiled the new DFP6 single plunger common rail fuel pump during the 31st International Motor Symposium, 29-30 April, in Vienna. The pump is designed to simplify packaging and reduce weight while providing 2,000 bar maximum rail pressure. Its design combines a relatively small specific capacity of up to 0.42 cc/rev with the capability to run at engine speed to provide flexibility for efficient utilization on a range of engine sizes up to 2.2 liters.

This is achieved by an approach that includes a new compact hydraulic head design which helps to improve the volumetric and mechanical efficiency enabling a potential reduction of engine CO2. The new concept is much stiffer than the previous generation head, with Delphi’s integrated inlet valve assembled directly into the head and a forged high-pressure outlet, which incorporates the outlet valve and helps to achieve reduced stress and offers further room for extension to rail pressures higher than 2,000 bar.

An additional attribute of Delphi’s design involves the specific roller and shoe mechanism. The twin lobe cam offers two pumping events per revolution reducing the number of pump strokes needed. On later 4-cylinder engine applications, one further advantage will be the opportunity of running the pump at engine speed in combination with a twin cam lobe to generate pumping synchronized with injection. It is an effective means to achieve the lowest possible emissions at the highest performance level.

The roller cam shoe mechanism has been optimized for reduced torque, dynamic mass, and noise via the Delphi patented static shoe guide. The component is pressed straight into the housing so that the shoe guide, different from previous solutions, does not oscillate during pump operation keeping the dynamic mass low, permitting a small plunger return spring size and optimum packaging geometry. The design safely prevents the shoe on the DFP6 pump from lateral rotation which eliminates the risk of fatal pump damage and allows for a mass of just 2.4 kg.

In addition to Delphi’s Multec Diesel Common Rail system, the new 1.2-liter three-cylinder Volkswagen Polo BlueMotion is fitted with Delphi anti-theft and immobilizer systems, radiator and compressor.



Both USA's CAFE standards and EU's CO2 emission standards may have to be tighten up soon to remain meaningful.


In this article it became evident that the injection system on this engine is capable of a little more than I had anticipated, i.e. 2000 bar instead of 1600/1800 bar. Nevertheless, the Delphi system use solenoid actuators instead of the more advanced direct-action piezo-electric actuator used by Delphi on the newest Mercedes engines. Thus, the specific power could most likely be stepped up somewhat in comparison to that I indicated in my previous comments on the Skoda car.


Isn't it nice tot see Europe begin to actually chase its tail on emissions? After forty years of essentially skating by on forced American cleanup technologies, adopted for use fifteen to twenty years after the technology arrives, they are now actually doing something to meet CO2 emissions, of all things.

They are seeking to minimize the providing of esential plant fertilizer, for no understandable reason except polemics, that have painted them in a useless corner.

The continent of Europe, unlike the North American continent, actually does generate a net CO2 emission to the atmosphere, so their their money wasters in government, actually have a basis for their irrelevant nonsensical actions.

One of the few positive things that will come of the useless effort, is forced improvement in diesel technologies. EU bureaucrats have financially forced diesel adoption, on EU consumers by preferential taxing policies. The fact that this has badly polluted the EU is of no real consequences to Socialist Greens, who merely want to politically posture, and never really care about cleaning anything up, just like their bretheren in the former East Bloc environmental cesspools.

Henry Gibson

Low CO2 is the credo, is the faith and another large decrease in CO2 can be had if Bosch produces the Artemis series hybrid technology that they now own for road vehicles.

Diesel is cheaper to produce and therefore lower CO2 release in production as well as being more efficient in engines designed for it. The large ship engines can get 50 percent in single cycle mode on waste "tar" from the refineries. Capstone turbines can burn diesel with no exhaust treatment and meet standards. You could breathe the exhaust from the turbines for many minutes without damage.

Catalysts and filters can clean much other exhaust problems.

Rather than producing hydrogen from their spare electricity as they now do, EDF, the French power company, should save the power in vanadium redox batteries. Electric cars in France?; What is their CO2 per mile? In spite of their much touted windmills, Denmark gets most of its electricity from fossil fuels. ..HG..


Dual fuel diesel and natural gas fuel injectors are also being manufactured


Henry G,

Please try to obtain some perspective.

Don't you know that CARB has now admitted that the ICE engine is now CLEAN. These ultimate die-hard Greenies, did so, when they proposed their new job-preserving LEV III toxic emissions regulations. These proposed regulations did not tighten the categories for ICE cars. Fully 25% of the existing auto fleet in California already meets SULEV II, (sub-T2B2), and increases every year as older cars are scrapped and replaced with new absolutely CLEAN ICE gasoline powered ones.

Diesels are no where near as clean. As far as I know, not a single diesel, even in any lab, has reportedly achieved that same degree of cleanliness yet, in the pages of the SAE.

You can breathe the tailpipe exhaust of dirtier cars than SULEV II vehicles. It would be an improvement on the much cleaner LA ambient air.

In fact CARB has essentially told Californians that they must purchase "air cleaners" that suck in polluted air, and exhaust clean air. And Californians are and have been, purchasing them in the millions. They call these "air demogger/cleaners", cars.

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