POWERTRAIN SYSTEM S

Delphi Ignition Coils

Delphi Ignition Coils supply the required electrical energy needed to
ignite air-fuel mixtures in an engine’s combustion chamber. They
are designed to meet a wide variety of continually evolving
requirements for combustion calibrations. Delphi Ignition Coils are
also designed to operate dependably and reliably under all
operating conditions and throughout the entire engine speed range
to help manufacturers meet the highest engine performance,
exhaust emissions, and fuel economy objectives.

Delphi offers the most comprehensive line of ignition coils and smart
ignition systems in the industry. Packaging options include the
following:

 Pencil coils
 Plug top coils
 Coil-near-plugs
 Waste spark systems
Delphi Pencil Coil Cassette
All design options are available in single coil, multi-coil packs, and cassette
configurations.

Benefits

 Improved dwell accuracy decreases module and coil temperatures for greater reliability
 Noise abatement material between laminations reduces audible coil noise
 Cassettes have improved primary connector for greater ease of assembly compared to designs with one connector for
each coil
 Lower primary inductance provides high-speed performance
 Early and precise electronic spark timing helps improve fuel economy and provides faster crank-to-run
 Higher energy delivered to combustible mixture provides cleaner combustion to help manufacturers meet on-board
diagnostics (OBD II) requirements
 Direct connection to spark plugs (via small boot) eliminates spark plug wires
 Composite iron coils provide programmable energy
 Coil per cylinder dwell overlap electronics deliver better high speed performance and better heat dissipation compared
to some conventional technologies
 Coil per cylinder ramp and fire electronics decrease power dissipation and increase efficiency
 Radio frequency interference (RFI) suppressor optional

Typical Applications

Delphi Ignition Coils can be designed for use with conventional multi-port fuel injection or gasoline direct injection
(GDi) engines. Delphi offers ignition coils for a wide range of gasoline engine products including the following:

 Automotive
 Motorcycles
 Marine engines
 Commercial products
 Power sports products

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 Delphi Ignition Coils

Delphi’s Ignition Coils Product Portfolio:

Delphi Pencil Coils are designed to take advantage of unused space typically found
above a conventional spark plug (spark well). Their compact size enables them to fit
directly into any typical spark plug hole (>23 mm of inside diameter) of four-valve
engines. Delphi pencil coils are available in a variety of configurations and they are
offered with outside diameters ranging from 22.0 mm to 29.1 mm, and energy rates
from 35 mJ to 80 mJ (depending on size). They can include magnetic biasing that
provides a combination of small size, high energy performance, and ease of packaging.
Additional options include:
Delphi Pencil Coils
 Igniter
 Twin spark capability
 Cassette design
 Conventional or boltless fastening
 Ion Sense capability
 Multi-Charge feature

Delphi Gasoline Direct Injection (GDi) Pencil Coils offer the highest energy
density coil in the industry ranging from 40 mJ to 86 mJ, and industry-leading
durability. They are designed to provide variable energy output to match engine
operating conditions and supply the required energy level needed to ignite a
diluted stratified charge. Typically, they are packaged within the GDi cylinder
head space constraints.

Delphi Gasoline Direct Injection

(GDi) Pencil Coil

Delphi Plug Top Coils are designed to be used when packaging constraints prevent
the use of pencil coils (spark well inside diameter <22 mm) and when a high output
energy coil is required (energy >80 mJ). Secondary output energy up to 125 mJ (190
mJ at boost mode) and up to 90 mJ (130 mJ at boost) for the magnet-less version.
Delphi plug top coils are available in coil per cylinder configurations, either individual or
cassette-type packages. They offer small package size while providing the required
output voltage to break the spark plug gap and the necessary high energy level to
ensure and enhance combustion stability. Options include:
Delphi Plug Top Coils
 Igniter
 Twin spark capability
 Cassette design
 Conventional or boltless fastening
 Ion Sense capability
 Multi-Charge feature

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 Delphi Ignition Coils

Delphi Coil-Near-Plugs are typically used in overhead valve (OHV) engine

applications in which the spark plugs are located close to the exhaust system and,
thus, will experience extreme temperatures. Coil-near-plugs are connected to the
spark plugs via short plug wires. They feature coil per cylinder configurations and
are available with or without integrated igniters. Delphi coil-near-plugs offer high
quality, robust durability and excellent reliability.

Delphi Coil-Near-Plugs

Delphi Waste Spark Pencil Coil Packs (PCP) provide one coil per two pairs of
cylinders. (Two coils for 4-cylider engines; three coils for 6-cylinder engines.) Delphi
waste spark PCP feature pencil coil technology in a lower cost waste spark
configuration. The pack design offers the highest energy density to enable mass
reduction of up to 40 percent compared to conventional ignition coils. Delphi Waste
Spark PCP include:

 Cassette/miniature package or semi-direct mount

 Laminated core
 Enhanced performance option Delphi Waste Spark Pencil
Coil Packs

Delphi Ignition Coils for Small Engines are typically used on one- and two-cylinder
gasoline engines and range from small inductive ignition coils to stand-alone smart ignition
modules that can adjust spark timing to help provide economical fuel consumption and
optimal engine performance. They offer a fully laminated core and a coil igniter circuit that
provide reliable, robust design to meet harsh off-road conditions and demanding engine
requirements. RFI (radio frequency interference) and EMC (electromagnetic compatibility)
compliant versions also available.

Delphi Ignition Coil

for Small Engines

Delphi Multi-Charge features a coil-per-cylinder control that enables longer spark

duration, increased spark energy and re-ignition in the event of combustion blow-out
when liquid is present. It offers multiple opportunities for the initiation of robust
combustion, improved geometric strength, and compensation of fuel spray variation.
Delphi Multi-Charge is designed for spray guided GDi applications and other
engines that use highly diluted fuel mixtures. Coil smart electronics are fully
integrated and encapsulated.

Delphi Plug Top Ignition

Coil w ith Multi-Charge

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 Delphi Ignition Coils

Delphi Compact Modular Ignition Coils is an all-new family of innovative ignition

technology developed for modern engines. The coils do not require rare earth
magnets, thus enhancing application flexibility and mitigating the potential for costly
material price fluctuations. They offer manufacturers wide design flexibility, compact
size to help overcome packaging constraints, lower cost versus conventional ignition
coils, and impressive performance and durability to meet the most stringent program
requirements.

Delphi’s new family of Compact M odular Ignition Coils

includes plug top coils, coil packs and coil near plug
designs

 Pencil Coils Accelerated Life Testing:

Delphi Ignition Coils are designed for long-term durability and they consistently outlast products from major
competitive suppliers as demonstrated by this graph showing accelerated life test results.

Performance Advantages

Delphi Ignition Coils and Ignition Systems are built of highly sturdy materials and designed for long-term durability
and reliability. They feature cost-effective designs and are produced by smart manufacturing processes that enable
successful implementation across a wide range of engine applications. Delphi offers manufacturers a complete

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 Delphi Ignition Coils

systems integration approach to ignition systems development. Every step of the ignition process is analyzed,
including the creation, transmission, timing and delivery of the ignition spark energy. This strategy provides
optimized ignition systems tailored to customer requirements.

The Delphi Advantage

Delphi has a deep understanding of ignition systems and the combustion process. We offer the benefits of more
than 100 years’ experience in ignition systems and today we build millions annually. We offer a low cost, global
manufacturing footprint and the most comprehensive line of ignition systems in the industry. Our ignition products
excel in performance, quality and durability. We provide advanced and innovative technologies designed to help our
customers meet the market challenges of the future.

As a global leader in engine management systems technology, Delphi can help manufacturers meet emissions
requirements, improve fuel economy and enhance performance. Delphi is a source for high value solutions and our
systems expertise is built into every product. Delphi’s flexible engineering approach encourages collaboration. And,
Delphi has as thorough understanding of automotive markets around the world and a global network of resources.

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