Benz in System e

Diagnostics and Spare Parts
from a single source
Only Bosch, the leading original equipment supplier, can provide fully comprehensive system
expertise for workshops and the aftermarket.
Motor vehicle components
ff Supply, sales and logistics
ff Worldwide logistics network
ff More than 130000 different replacement parts
Diagnostics
ff Test Equipment
ff ESI[tronic] software
ff Workshop Equipment
ff Technical hotline and knowledge database
ff Service Training
ff Active assistance for all makes
For further information click onto:
www.werkstattportal.bosch.com
Product Information Automotive

Gasoline systems
2 List of contents
At a glance:
PIA gasoline systems
Pages
4 - 5
6 - 7
Worldwide development and production
Over a century of system expertise
The Product Information Automotive for passenger
A tradition of progress
car gasoline systems, PIA for short, is a supple-
In the early days of automotive engineering, ignition
ment to the existing information about Bosch gaso-
was one of the major technical issues. It was Robert
line systems and individual products. It summariz-
Bosch who came up with the solution in 1897 he
es the most important facts and provides a quick
succeeded in adapting a magneto for a motor vehi-
up to date overview of the key points. The PIA
cle engine. Since then, the name Bosch has been a
also provides information about technical features,
byword for progressive ideas and pioneering tech-
customer service and Boschs overall expertise in
nology, particularly in gasoline systems.
gasoline systems.
8 - 11
Overview of Bosch gasoline injection systems
Today, modern vehicles need to meet increasingly

tough requirements. They are judged on economi-
12 - 17
Electric fuel pumps
cal fuel consumption, low emissions and maximum

driving pleasure. To simultaneously meet all of these
demands, it is no longer sufficient to develop and
18 - 19
Injectors
enhance individual components. Progress can only

be achieved by adopting a holistic approach Bosch
20 - 25
Lambda sensors
uses its system know-how and the complex interrelationships between the various subsystems to
develop pioneering new solutions across systems.
26 - 29
Sensors and hot-film air-mass meters

In conjunction with leading motor vehicle manufac-
30 - 35
Ignition systems
turers, Bosch develops and produces everything

from individual components to complete gasoline
systems. This experience and the high quality
36 - 37
Idle actuators / eXchange program
demands from the original equipment market are

reflected in the aftermarket sector. This is why
38 - 53
Gasoline injection components overview
Bosch can offer a product range that allies impressive quality and reliability with extensive market coverage. Equally, the professional support available to
54 - 55
ESI[tronic] software and testing systems
56 - 57
Training, technical hotline, knowledge database
58 - 59
Sales promotion: Everything to help aftermarket businesses and workshops improve sales
aftermarket and workshops is examplary.
4 Worldwide development and production
Bosch Comprehensive expertise:
Vehicle manufacturers worldwide rely on

Bosch for original equipment
ff Close co-operation with vehicle manufacturers

ff Complete range from components
through to co-ordinated systems
ff Innovations for automotive progress
ff International development and production
network in 19 countries
Comprehensive system know-how
Complete range from a single source
Leading automotive manufacturers rely on the exper-
Bosch develops and produces gasoline systems for
tise and high quality stands of Bosch injection sys-
all types of engine. For the aftermarket and work-
tems for original equipment. As a pioneer in gasoline
shop sector, more than 10000 replacement and
injection systems, Bosch can offer a more complete
wear parts are available, as well as the correspond-
product range than anyone else from individual
ing testing and diagnostic systems.
components right through to complete injection systems. Meanwhile, you can benefit from Boschs dec-
Worldwide development and production
ades of experience as a technological leader in mani-
An international production network develops and
fold injection. Bosch has unique expertise in gaso-
produces the complete gasoline injection product
line direct injection.
range in 19 countries. As a result, components and

complete systems are always available close to the
market but all to the same uniform production and
quality standards. Bosch products guarantee a constantly high quality at all times.
Locations worldwide
6 Over a century of system expertise
Ignition and gasoline injection systems from

Bosch: Over a century of system expertise
L-Jetronic components
KE-Jetronic components
Motronic components
Mono-Jetronic components
Intake module
Gasoline direct injection
The Bosch success story in figures more than 100
1979 Motronic market launch.
1982 KE-Jetronic market launch.
2000 Market launch of Motronic gasoline direct
years of experience, more than 10,000 items in the full
The digital processing of numerous
The K-Jetronic expanded with an electronic
injection. The Motronic MED 7 system with
gasoline injection range. A comprehensive replace-
engine functions made this system unique.
control loop and lambda sensor was used
torque-based control enables
ment parts service supplying replacement and wear
It combines the L-Jetronic principle with
in a series production vehicle for the first time
minimum consumption to be combined with
parts to the aftermarket and workshop sector.
electronic map-controlled ignition. The first
as the KE-Jetronic
maximum dynamics
1902 Delivery of the first high-voltage magneto and
microprocessor in an automobile
1987 Mono-Jetronic market launch.
2003 Launch of throttle device for ETC
the first spark plug
1981 LH-Jetronic market launch.
The Mono-Jetronic is an exceptionally economical
2006 Launch of spray-form gasoline
1910 Separation of ignition distributor and
Instead of a flap-type air-flow sensor, the
single-point injection system that enabled even
direct injection (piezo technology); Extension
basic L-Jetronic system was fitted with a
smaller vehicles to be fitted with Jetronic
of product range with transmission control
1925 Robert Bosch GmbH introduces
hot-wire air-mass meter and
1989 Mono-Motronic market launch.
sold as LH-Jetronic for the first time
A development of the Mono-Jetronic
2008 500 million lambda sensors produced;

25 years of electrohydraulic transmission control;
1951 Launch of Bosch gasoline injection at
the Mono-Monotric also featured
electronic map-controlled ignition and a
1967 First emission legislation in the USA,
microprocessor
high-voltage source
battery ignition
the Frankfurt Motor Show
Introduction of the first electronic
1989 Electronic throttle controll (ETC). In systems
injection system - the intake-manifold pressure
with ETC, the driver input is detected by a
controlled D-Jetronic
sensor on the gas pedal. The Motronic control
1973 Energy crisis reduction in gasoline
unit evaluates the sensor signal and adjusts the
consumption becomes the number one devel
throttle valve, powered by an electric motor,
opment objective. Launch of the air-flow
taking account of other vehicle and engine data.
metering L-Jetronic and the mechanically/
1997 Increasing use of intake modules. Intake mod-
hydraulically controlled K-Jetronic also an
air-flow metering system
intake manifold including injectors, throttle
valve unit, pressure regulator etc.
1976 Bosch invents the lambda sensor, thus

paving the way for regulated catalytic converters
ules are pre-assembled units consisting of an
100 million control units produced
8 Gasoline injection systems
Overview of individual
systems
K-Jetronic
L-Jetronic
The K-Jetronic is a mechanical system in
The L-Jetronic is an electronically controlled
which the fuel is constantly metered on the
injection system with air-flow metering
basis of the volume of air drawn in by the
based on the air vane principle and elec-
engine. The K-Jetronic was used as origi-
tromagnetically controlled fuel injection
nal equipment in mass-produced vehicles
into the intake manifold. All engine-related
between 1973 and 1995. Since then, the
changes are recorded by a variety of sen-
K-Jetronic has only been of relevance in
sors and processed in the electronic con-
terms of service and maintenance work.
trol unit. This ensures constant good emission quality in combination with low fuel
consumption.
Further technical information can be found

in the K-Jetronic booklet.
Order number 1 987 722 009. The booklets
are available from wholesalers.
1 Electric fuel pump

2 Fuel accumulator
6 Electric start valve

7 Fuel distributor
3 Fuel filter
4 Warm-up regulator
8 Air-flow sensor
9 Thermo-time switch
5 Injector
10 Auxiliary-air device
in the L-Jetronic booklet.
2 Fuel filter
3 Fuel-pressure regulator

KE-Jetronic
LH-Jetronic
The KE-Jetronic is a mechanical/elec-
The LH-Jetronic is closely related to the
tronic injection system based on the
L-Jetronic. It differs in terms of how it
K-Jetronic. Additional electronics record
detects the volume of air drawn in by the
a variety of measurement variables in the
engine, which in this case is performed by
engine, thus permitting optimization of fuel
a hot-wire air-mass meter. This measures
requirements and emission quality.
the air mass drawn in by the engine. The
4 Injector
5 Air-flow sensor
6 Thermos-time switch
8 Throttle-valve switch
9 Lambda sensor
10 Electronic control unit
measured result is thus independent of

temperature and pressure.
in the KE-Jetronic booklet.

Order number 1 987 722 021. The books

2 Fuel accumulator
8 Air-flow sensor
9 Thermo-time switch
3 Fuel filter
4 System pressure regulator 11 Engine-temperature sensor
5 Injector
6 Cold-start valve
7 Fuel distributor
13 Lambda sensor
in the L-Jetronic booklet.


2 Fuel filter
4 Injector
5 Hot-wire air-mass meter
6 Engine-temperature sensor
7 Idle rotary actuator
9 Lambda sensor
10 Gasoline injection systems
11
Overview of individual
systems
Mono-Jetronic
Motronic ME with ETC
Mono-Jetronic is an electronically control-
The principal function of the engine-man-
led single-point injection system, in which
agement system is to set the drivers
a solenoid injector injects the fuel for all
torque input whilst at the same time
cylinders at a central location above the
achieving optimum fuel consumption and
throttle valve. The operating data is record-
the lowest possible emission level. The
ed using sensors and converted into injec-
ME-Motronic engine-management system
tion pulses in an electronic control unit.
combines all the sub-systems required for

this: The electronic throttle control (ETC)
sets the amount of air needed to generate
in the Mono-Jetronic booklet.
this torque. The corresponding fuel mass
is controlled in the gasoline injection sub-
1 Carbon canister
9 Air-mass meter
system and the ignition sub-system sets
2 Canister-purge valve
3 Intake-manifold pressure
10 Throttle device (ETC)

2 Fuel filter
3 Throttle-valve
potentiometer
4 Pressure regulator
5 Injector
6 Device connector with
intake air temperature sensor
7 Throttle-valve actuator
8 Engine-temperature sensor
6 Ignition coil/spark plug

7 Phase sensor
12 Engine speed sensor

13 Knock sensor
14 Temperature sensor
15 Primary catalyst
19 In-tank unit
21 CAN
22 Diagnosis lamp
16 Lambda sensor
23 Diagnostic interface
10 EGR valve
11 Intake-manifold pressure
20 Diagnosis interface
2 Carbon canister
3 Canister-purge valve
21 Diagnosis lamp
12 High-pressure sensor
22 Immobilizer
4 High-pressure pump
5 Pressure-control valve
13 High-pressure injector
23 CAN
14 Knock sensor
24 Delivery module with
6 Fuel rail
7 Ignition coil
15 Engine-temperature
25 Engine speed sensor
8 Lambda sensor
24 Immobilizer
Engines with gasoline direct injection form
ment. Fuel metering and ignition are
the air/fuel mixture directly in the combus-
optimally co-ordinated with one another.
tion chamber. Only fresh air flows through
Other optimized electronic functions can
the open inlet valve on the induction stroke.
also be included. Digital data processing
Special injectors inject the fuel directly into
and the use of microprocessors make it
the combustion chamber at high pressure.
possible to convert a wide range of operat-
Exact metering, conditioning and distribu-
ing data into map-controlled injection and
tion of the air and fuel for each individual
ignition data.
sensor
4 Fuel rail/Injector
5 Camshaft adjuster
gasoline direct injection
and an ignition system for engine manage-
converter
18 Accelerator-pedal module
Motronic -
Motronic combines an injection system
in the Motronic booklet.
the necessary ignition energy.
9 Lambda sensor
Motronic manifold injection
the appropriate ignition point as well as
11 EGR valve
17 Primary catalytic
combustion stroke permit economical oper1 Electric fuel pump

2 Fuel filter
7 Idle rotary actuator

9 Engine speed and
4 Injector
5 Air-flow sensor
6 Engine-temperature
sensor
reference mark sensor
10 Lambda sensor
12 High-voltage distributor
ation and a low level of emissions. Thanks

to its torque-based electronic control, the
Motronic engine management system opens
up new dimensions in gasoline direct injection.
1 Air-mass meter with
temperature sensor
sensor
sensor
8 Accelerator-pedal module 16 Lambda sensor (LSU)

17 Lambda sensor (LSF)
9 Throttle device (ETC)
18 NOx-catalytic converter
primary pump
12 Electric fuel pumps
13
Innovative technology for optimum performance:
Electric fuel pumps: The complete range from

the system specialists
ff Original equipment quality across the range

ff Optimized for the specific engine type
ff Universal range of fuel pumps based on just 7
main types
ff New pump generation: XLM delivery modules
offering around 30% more efficiency
Customer satisfaction thanks to OEM quality
Electric fuel pumps from Bosch

reliable performance
Whether it is complete delivery module solutions, fuel

pumps or our special kits for repairs based on current
The electric fuel pump has to supply the engine with
value - With Bosch you can offer your customers reli-
sufficient fuel at the required pressure under all
able OEM quality. Bosch is constantly developing its
operating conditions. It is also increasingly assuming
technology to meet the aftermarket, workshop and
the function of a pre-supply pump for modern direct
OEM requirements of the future. That is why leading
injection systems in both gasoline and diesel engines.
vehicle manufacturers rely on state of the art Bosch
The principal requirements:
technology and on 40 years of experience.
ff Delivery between 60 and 200 l/h at rated voltage

ff Pressure in fuel system between 300 and
450 kPa (34.5 bar)
ff Reliable build up of system pressure even for
Impressive Bosch quality

Bosch electric fuel pumps are optimized for the speElectric fuel pump
Fuel delivery module
cific engine type and are produced to stringent quality standards. These are the key features of Bosch
electric fuel pumps:
ff Maximum operational reliability
ff Compliance with all original equipment demands
ff Long service life
ff Low noise
ff Optimum fuel delivery
ff Maximum reliability for hot gasoline delivery
ff High level of interference suppression
In 1967 Bosch supplied the first gasoline injection system

with electric fuel pump. And Bosch has been setting standards ever since with its high performance and durable systems. This is why a whole range of leading vehicle manufacturers put their trust in electric fuel pumps from Bosch.
Repair kit for
fuel delivery modules
Fuel-level sensor
cold starts or with adverse battery voltage
14 Electric fuel pumps
15
Compact and powerful:

The new generation of fuel delivery modules
The Bosch universal range:

7 instead of 72
One type for a variety of applications: The universal electric fuel pump range from Bosch The 72
Order number
Applications
Bosch is constantly working on improving and opti-
provide the precise fuel supply required for partial or
0 580 254 053
Audi, Porsche
mizing its motor vehicle components. This results
full load. This saves fuel and reduces CO2 emissions.
pumps used in the past can now be replaced by just
0 580 254 909
Audi, Bentley, BMW, Peugeot,
in innovative technology and products that play a
They also feature:
7 universal electric fuel pumps from Bosch. Parts set
Volvo, VW
pioneering role in the whole automotive sector. The
ff Improved cold start performance
new XML fuel delivery modules are just one example
ff Improved interference suppression
of this.
ff Improved compatibility with different fuel types
is the key - Each of the 7 electric fuel pumps is supplied with a parts set and easy to follow installation
instructions. These pumps form the Bosch universal
range.
0 580 254 910 Audi, Ferrari, Ford,

Mercedes-Benz, Suzuki, VW
0 580 254 911
Ford, Mercedes-Benz, Toyota
0 580 464 069 Alfa Romeo, Citron, Fiat, GAZ,

Porsche, Renault, Saab, Volvo
0 580 464 070 Alfa Romeo, AMC, Austin, BMW,

Chevrolet, Citron, Daewoo,
Fiat, Ford, Holden, Jaguar, Lancia,
Opel, Peugeot, Porsche, Renault,
Rover, Seat, Vauxhall, VW
0 580 464 085
Fiat, Holden, Opel, Renault,
Seat, VW
Beware of imitations!
It couldnt be simpler
Certain rival companies
The special parts set turns a
make use of inferior
universal electric fuel pump
imitation products in-
into a specialist for a particular
stead of Bosch pumps.
engine type. Needles to say, it
This can lead to a loss
meets all the requirements for
of power due to insuf-
original equipment.
ficient fuel.
Clear benefits:
Compared to conventional fuel pumps, the new generation offer an impressive 30 % higher efficiency and
In the original equipment market, numerous manufacturers

already use the new fuel pumps from Bosch,
including Audi, Fiat, Ford, GM, Mercedes-Benz, Renault, and VW.
16 Kit solutions
17
The new Bosch kit concept:
The Bosch kit concept:

The clever way to repair fuel delivery modules
ff The quick and easy way to repair

fuel delivery modules
ff Low-cost concept offering broad
market coverage
ff Complete package containing all wear parts
ff Easy to follow fitting instructions
Low-cost, easy to use
Impressing the aftermarket and workshop sector:

ff Repair concept for 750 additional vehicles
ff Maximum market coverage also including modern
Fitting tool
for fuel hose
diesel injection systems

ff Quick and easy to replace
ff Detailed fitting instructions provided with ever kit
Plastic hose
ff Less storage space required

ff Lower storage and handling costs
ff High Bosch original-equipment quality throughout
ff Long-term availability of all products
at competitive prices
Receptacle
Connector
Spacer ring
Rubber ring
Electric fuel pump
Rubber adapter
Plastic adapter
Fuel filter
A clever idea from Bosch
The kit provides the workshop with a complete pack-
The kit concept is an additional alternative for
age of all wear parts, allowing them to offer an eco-
repairing fuel delivery modules. Instead of complete-
nomical solution that will impress even the most
ly replacing them every time, the kit solution from
cost-conscious drivers. The replacement service,
Bosch enables many delivery modules to be
including removal and installation requires minimal
repaired.
time and work.
Calculation example: Catalog price excluding sales tax

VW fuel delivery module
Bosch kit solution
Purchase costs:
-36 %
Total costs:
-26 %
Kit solution
121 EUR
+ Installation costs* 19 EUR
Module price VW 188
EUR
Total
140 EUR
* Additional repair time 15 minutes
Uncomplicated, fast and reliable: Fuel delivery module repair

with the kit concept. Bosch provides you with all the necessary
parts and easy to follow fitting instructions. You can rely on us
and so can your customers.
18 Injectors
19
Geared to optimum performance:
Injectors: Excellent vehicle coverage,

optimum availability
ff Help in choosing the right injectors

ff A comprehensive range for the workshop and
aftermarket sector
ff All injectors come in original-equipment quality
ff Rapid availability
ff Simple, reliable installation
Despite correct signal patterns and

a positive function test, a mechanical malfunction such as a defective
spray pattern may exist.
Top technology from the top
Defective injectors
Properly functioning injectors
leader in injection technology
Engines benefit from timely
Top quality products keep cus-
Bosch offers the aftermarket
Bosch. Bosch partners can there-
replacement
tomers happy
and workshop sector
fore rely on the extensive system
Only properly functioning injec-
ff Optimum spray pattern for
ff The broadest range and the
know-how of the number one
tors can provide motorists with
perfect mixture generation and
name in original equipment. We
an assurance of:
efficient combustion, even for
have may years experience and
ff Minimized fuel consumption
have produced more than a bil-
ff Significantly improved starting
supplier
Every injector reflects the excellence of the inventors and world
lion injectors.
performance
ff Immediate acceleration
ff Longer service life for exhaust
components
dynamic driving
ff Low consumption and emissions, particularly in the
starting and warm-up phase
ff Outstanding warm start
ff Rapid availability thanks to

worldwide network for production, sales and logistics
ff Simple, reliable installation
ff Original-equipment quality with
the valves
Boschs ground-breaking developments have made it
Injectors supply the engine with the required quan-
thanks to use of high-alloy
one of the pioneers in gasoline injection systems.
tity of fuel for the relevant operating conditions. A
steels and almost complete
Example: The exceptionally fast operating high pres-
defective injector can lead to a higher injected fuel
plastic covering
sure injection valves with piezo technology, the devel-
quantity and thus to excessive fuel consumption.
ff Optimum corrosion resistance
opment of which won the German Future Prize.
The milestones for injectors
Since 1999: Intake manifold injector EV14
ity of application data
proved cross-sections inside

Geared to excellent engine performance
to high data quality and reliabil-
performance thanks to im-
Good ideas for better engine performance
greatest market coverage

ff Easy and secure ordering thanks
Since mid 2005: High pressure injector
Since late 2005: High pressure injector
HDEV5 for gasoline direct injection
(piezo injector) HDEV4 for gasoline

direct injection
excellent and leak-free fitting

and minimal function tolerances
20 Lambda sensors
21
Bosch lambda sensors:
Bosch the number one name worldwide

for lambda sensors
ff The worlds leading original equipment and

aftermarket products
ff An unsurpassed manufacturing record
ff Dependable thanks to high data quality with
reliable application data
ff Genuine connector and matching cable
length
Design and function of the lambda sensor

Design
Function
The lambda sensor
1 Sensor ceramic element
content in the exhaust gas

3 Protective tube
900 mV depending on the oxygen
content in the exhaust gas
ff Bosch supplies all lambda
All European vehicle manufacturers,
sensors for the aftermarket
and most leading producers world-
more than 500 million sensors
sector in original-equipment
wide, rely on lambda sensors from
produced.
quality.
Bosch. Bosch lambda sensors give
ff Bosch has the most production experience with 45 million

sensors produced each year.
ff Boschs innovations are continuously advancing development.
ff Bosch leads the way in the ori-
ff Bosch has a uniquely broad

product range.
ff Bosch provides the highest
detects the transition from a
rich mixture (lack of air < 1) to a
with integrated heater
lean mixture (excess air > 1)
2 Double-walled protective tube
and vice versa
Layout and functioning of the lambda sensor

Layout
Mode of operation
you a decisive advantage over the

competition and enable you to
Lambda control loop
offer your customers what they
1 Intake air
data quality with reliable and
want replacement parts that are
complete application data.
environmentally friendly, save fuel
ff Bosch guarantees rapid avai-
1 Planar sensor element
manufacturer, with a total of
oxygen content of the ambient air
Fig. 2: Planar sensor
ff Bosch is the worlds largest
compares the residual oxygen con-
tent in the exhaust gas with the
more than 30 years ago. Today
when warm (350 C) generates a
voltage of between approx. 25 and
Bosch invented lambda sensors
the residual oxygen
2 Heater
measures
Fig. 1: Finger-type sensor
and have a long service life.
2 Fuel supply
3 Injector
(upstream of
ket sectors.
international sales network.
catalytic converter)
the mixture composition and control the injection quantity accordingly. The fuel quantity has to be
5 Control sensor
lability anywhere, thanks to its
sensor voltage signal to regulate
ginal equipment and aftermar-
The control unit uses the lambda
reduced if the mixture is too rich

( < 1) and increased if it is too
lean ( > 1). An optional diagnostic
6 Catalytic converter
sensor after the catalytic converter
7 Exhaust gas
detects whether the control sen-
8 Diagnostic sensor
(downstream of
catalytic converter)

sor is still working properly.
22 Lambda sensors
23
The broad Bosch lambda sensor range:

Variety provides reliability
Unheated lambda sensors
Heated lambda sensors, 3-pole
Heated lambda sensors, 4-pole
Planar lambda sensors
Planar broadband sensors
Unheated lambda sensors paved the
To allow lambda sensors to be
The 4-pole sensors transmit their
Planar lambda sensors consist of
Planar broadband sensors have
tor, a small number of universal
way for future exhaust control. They
fitted away from the engine, the
signal via an additional fourth
several ceramic sheets with an
two measuring cells and a 6-pole
lambda sensors can be used to
require a minimum operating tem-
next stage in their development
connection rather than via the
integrated heater. They reach their
connector. They provide extremely
replace a wide range of original
perature of 350 C and therefore
was to incorporate a heater. This
housing. This enables to recog-
operating temperature twice as
accurate measurements in both the
sensors. This involves cutting the
need to be fitted close to the engine.
ensured that the sensor element
nize a cable break that would
quickly as previous lambda sen-
rich and the lean range. They can
cable for the fitted sensor at an
Replacement interval:
was continuously at its function-
make lambda control ineffective
sors, thus halving emissions in the
also be used to control gas and
appropriate point. The universal
Every 50 000 80 000 km
ing temperature of 350 C for the
to be detected.
critical cold starting phase.
diesel engines.
connector then connects the uni-
first time.
versal sensor to the end of the
Every 160 000 km
Every 160 000 km
Every 160 000 km
cable in the vehicle.
Universal lambda sensors

Thanks to their universal connec-
Every 100 000 160 000 km
Reasons for Boschs variety

Bosch believes it is vital for every
This is why Bosch offers around
lambda sensor to exactly meet
1 000 different lambda sensors.
the vehicle manufacturers speci-
This variety of types results
fications. Because of the numer-
from the following features:
ous technical features of lambda

sensors, this necessarily results
ff Sensor type
in a very wide variety of types.
ff Heat output
Different lambda sensor types
ff Cable length
cannot therefore simply be com-
ff Number of wires
bined or interchanged. Liberal
ff Connector
combinations bring a deteriora-
ff Protective tube
tion in optimum functioning and

lead to fitting problems.
Protective
tube
Heat output
Cable length
Number of
wires
Connector
24 Lambda sensors
25
Lambda sensors:
Always right with Bosch
Used lambda sensor
New lambda sensor
You cant go wrong with Bosch

When it comes to replacing lambda sensors you can
rely on Bosch:
ff No risk thanks to guaranteed original-equipment
quality
ff Help in choosing the right sensor
Bosch: Always the best lambda sensor for the job
All Bosch lambda sensors are made to measure for
Lambda sensors are subject to extreme loads
each vehicle model. For guaranteed reliability and ease
A properly functioning lambda sensor forms the basis
of installation.
for reliable engine operation and thus fuel economy,
ff The right cable length
low pollutant emissions and good emission values.
ff Correct connectors
Bosch lambda sensors are unbeatable thanks to their
ff Pre-greased thread
long service life, excellent operation and optimum

engine compatibility.
Drivers save money

every mile
With used
lambda sensor
With new Bosch

lambda sensor
14000 km
14000 km
Regular checking and replacement are therefore

vital
There are any number of good reasons why
Average driving performance per year
motorists should make sure their Bosch lambda

sensors are always in top condition:
ff Up to 15% fuel savings compared to a used
Average fuel consumption
10,4 l
9,0 l
per 100 km
ff Avoiding expensive catalytic converter damage
Annual fuel consumption
1.456 l
1.260 l
Fuel price per liter
1,50
1,50
2 184,00 /year
1 890,00 /year
Annual costs of fuel
lambda sensor
fuel
% less
5
1
.
x
Appro 4 per year
9
Up to 2
ff Compliance with stringent emission standards

ff Improved performance
26 Sensors
27
For added comfort, safety and environmental

protection: Sensors are becoming increasingly important
Increasing original-equipment figures ensure a
Comprehensive range, impressive quality
Hot-film air-mass meters: Optimum performance and
Itemized benefits for you and your customers:
growing demand for replacements
Count on the OEM quality of the comprehensive
low levels of harmful emissions
ff Bosch hot-film air-mass meters are genuine re-
Modern vehicles are being equipped with more
sensor range from Bosch the worlds leading sen-
Hot-film air-mass meters measure the actual air flow in
and more electronic components. This increases
sor manufacturer. All Bosch sensors are fine-tuned to
the engine very quickly and precisely to allow the
the number of sensors, used to record a wide
the particular vehicle model and are easy to replace.
specified air/fuel ratio to be maintained. This ensures
range of parameters in the vehicle. Applications of
optimum engine combustion, which has the twin
sensors are almost limitless and are constantly
With over 2000 different products, Bosch supplies all
benefits of low levels of harmful emissions combined
being expanded. Todays drivers no longer want to
important types of sensor for applications ranging
with improved performance.
do without the benefits that these systems pro-
from engine management right through to passive
vide, which include improvements in cost-effi-
safety. Sensors supplied by Bosch include lambda
ciency, safety, convenience and performance. In
sensors, air-mass meters, pressure sensors, tempera-
fact, there are hardly any vehicles without sensors
ture sensors, knock sensors, engine speed sensors
on the road today.
and much more
placement parts, exactly tailored to the specific

engie type
ff All replacement parts offer original-equipment
quality
ff For repairs in line with current value, Bosch also
supplies hot-film air-mass meters as exchange
products
Genuine or imitation?
Only genuine parts are exactly tailored to the specific engine type
and guarantee optimum performance and compliance with the statutory emission values. The vehicle homologation will be invalidated if
non-genuine air-mass meters are used. In addition, this can result in a
considerable loss of engine power and thus higher fuel consumption.
28 Sensors
29
Comprehensive range, impressive quality:
Bosch sensors: The comprehensive range

from the sensor specialist
ff A rapidly expanding market with

excellent prospects
ff Comprehensive range in originalequipment quality
ff Over 2000 products in all the key
sensor groups
Knock sensors
Low-pressure sensors
High-pressure sensors
Crankshaft sensors
Knocking can permanently dam-
These are used to monitor oil,
These record the fuel pressure in
These sensors are fitted directly
For non-contact measurement
age an engine. Knock sensors fitted
fuel, intake manifold and ambient
the fuel rail of the Common Rail
opposite a pulse wheel, separated
of camshaft rotation angle. They
directly to the engine block record
pressure. This ensures excellent
System and in the high-pressure
by an air gap. They provide non-
are fitted directly to the cam-
structure-borne sound (knocking)
accuracy and fast response times.
rail of the direct gasoline injection
contact measurement of crank-
shaft.
in the engine and transfer this data
system. The sensors are vibration
shaft rotation angle and speed.
to the engine-management sys-
resistant and have an impressively
tem. These values can then be
compact and robust construction
used to counteract the problem
offering exceptional measuring
and ensure smoother combustion.
accuracy over their entire service
The ear of the engine ensures a
life.
Camshaft sensors (phase

sensors)
Temperature sensors
Temperature sensors monitor the
temperature of coolant, oil and air
and transfer the data to the
engine-management system.
Depending on the application, the
sensors may be installed in the
engine block, cooling circuit or
intake tract.
long service life and optimum
Renowned vehicle manufacturers rely on Bosch sensors:

Alfa Romeo
Lancia
Renault
Audi
Maybach
Saab
Bentley
Mazda
Seat
BMW
Mercedes-Benz
Skoda
Citron
Nissan
Toyota
Ferrari
Opel
Volvo
Fiat
Peugeot
VW
Ford
Porsche
Equipment proportion [%]
operation.
Vehicles with
sensors
Vehicles without
sensors
100%
80%
60%
Sensor systems: A rapidly expanding
40%
market with excellent prospects for

the aftermarket and workshop sectors
20%
0%
2001
2005
2009
30 Ignition systems
31
Expertise from a system supplier:
Bosch ignition systems

The first choice right from the start
ff The only supplier of all ignition

components
ff Comprehensive range in
original-equipment quality
ff Excellent market coverage
ff A leading innovator: Continuous
development
4
2
1 Spark plugs
4 Bosch ignition coils
In the early days, ignition in gasoline engines
No other manufacturer can call on this kind of
By constantly developing innovative spark plug
Proven successful models in original-equipment
was the problem of problems,
experience.
technologies, Bosch ensures high quality state
quality
as automotive pioneer Carl Benz once put it. A
of the art products for original equipment and
the aftermarket sector.
2 Silicone power and silicone copper
The tailored ignition cable range the right
connection every time.
5 Ignition modules

Compact range (7 part numbers) to spark off
success
number of leading brains set about solving this
Complete range? Only from Bosch
problem including Robert Bosch. Finally, Bosch
Bosch is the only supplier in the world that can offer
managed to develop a high voltage
its partners a complete range of all ignition com-
magneto, patented in 1902.
ponents. There is a good reason why Bosch stands

for quality and expertise, state of the art technol-
Benefit from over a century of experience

Bosch developed the spark plug over a century ago.
3 Ignition distributors

Since then, the company has worked on all the com-
Ignition distributors covered by exchange
ponents that play a role in ignition in combustion
programm
engines.
Excellent market coverage for ignition-dis-

tributor caps and rotors
ogy and pioneering developments.
32 Ignition systems
33
Bosch ignition coils:

Innovative technology in original-equipment quality
Asphalt ignition coil
Multi-spark ignition coil
Module
Multi-spark ignition coil
Single spark ignition coil
Ignition coil technology
System partner to the automo-
Reduced
fuel consumption
Progress made by Bosch
tive industry for plastic ignition
Reduced
harmful emissions
Modern plastic ignition coils
coils
minimize the weight and size of
Bosch plastic ignition coils are
Excellent market coverage
the component, while still offer-
used as original-equipment
thanks to continuous expansion
ing excellent electrical voltage,
worldwide. As a replacement
of range
temperature and vibration resist-
part, this innovative ignition coil
Technical innovations are incor-
ance. Bosch will continue to set
technology provides
porated into engine production
the tone for ignition systems in
in close cooperation with the
the future For example, with its
all the benefits of original

equipment quality:
innovative compact coils with
Demand-based
stant expansion and updating of
primary current control and
voltage
diagnostic function.
Long
automotive industry. This con-
ignition
the range results in ever-increas-
spark duration
Improved
ing market coverage for ignition
engine performance
Bosch ignition modules:

The compact range for modern ignition systems
coils.
Bosch ignition modules set

standards
Numerous vehicle manufacturers put their trust in Bosch.
With good reason. As well as
excellent reliability, they know
that Bosch ignition systems
are 100% tailored to the
engine.
Additional plus points
ff Constantly high ignition voltage
ff Absolute freedom from
leaks and maximum corrosion protection
Innovative plastic ignition coil in original-equipment quality
ff No exposed connecting cables

ff Excellent heat resistance
and functional reliability
ff High heat capacity and conductivity
ff Extreme break resistance
Applications
0 227 100 123
Alfa Romeo, Austin, Citron,
Fiat, Lancia, Opel, Peugeot,
Seat, Talbot, Zastava
0 227 100 124
Bentley, Citron, Daewoo, Ford,
Peugeot, Porsche, Saab, Volvo
0 227 100 137 Audi, BMW, Nissan, VW

0 227 100 140
Citron, Peugeot
0 227 100 200 BMW, Chevrolet, Porsche, Opel
The Bosch compact range:

7 instead of 49
with low storage costs
ff Supplied with installation
materials for easy fitting
0 227 100 203 Alfa Romeo, Fiat, Lancia,

Opel, Volvo
0 227 100 211
Audi, Seat, Skoda, VW
Components of a transistor ignition system
Primary winding
Connector
Spark plug connectors (silicon rubber)
Order number
Secondary winding
1 Battery
5 Sensor
2 Ignition
switch
6 Ignition distributor
7 Spark plug(s)
3 Ignition coil
4 Switching
device
Core
Bosch ignition modules are used by many leading

vehicle manufacturers:
Alfa Romeo, Audi, BMW, Citron, Fiat, Ford, Lancia,
Spark plug contact (spring)
Interference suppression resistor
Mercedes-Benz, Opel, Peugeot, Porsche, Renault,

Saab, Seat, Skoda, Volvo, VW
34 Ignition systems
35
Bosch ignition cables:

The high performance connection
Spark plugs from Bosch:

The right solution for everyone
Bosch Super special
Reliability in original-equipment quality
All well-known vehicle manufacturers fit Bosch
Vehicle manufacturers trust Bosch ignition cables
spark plugs as standard. The Bosch range cur-
as original equipment. There are many reasons for
rently includes 1250 variations with 31 different
this:
electrode configurations the right spark plug
ff Outstanding interference suppression and in-
for every engine and 98% market coverage.
sulation
ff Corrosion resistant and safe contact plug-in
Quality in original-equipment technology

Bosch spark plugs impress with their outstand-
connections
ff Extreme heat and cold resistance from
ing technology, excellent reliability and

exemplary quality.
60 C to over +200 C
ff Resistance to chemical and mechanical
influences
Bosch Super / Super plus
ff Protects engine and catalytic converter
ff For long-term performance under different

operating conditions
ff Factory-set electrode gap
Over 92 % market coverage
ff Bosch Super plus the 55 top products for
ff More than 220 resistance ignition-cable sets
Bosch Super / Super plus
almost any vehicle
ff Over 410 pre-assembled resistance individual

cables
Bosch Super 4
ff Around 130 pre-assembled copper-core
ff Improved engine power with up to 60% high-
individual cables
er efficiency
ff Over 110 copper-core ignition cable sets
ff Considerably improved acceleration

ff Greater ride comfort thanks to smoother ope-
Two product series guarantee success
ration and superior engine power
Silicon-Power: The high performance ignition

cable specially for vehicles with resistance igni-
Bosch Super special
tion cables as original equipment.
ff Special spark plugs for two-wheeled vehicles,
ff With carbon-impregnated fiberglass internal
snowmobiles, garden equipment, motor
conductors durable and break resistant.
boats etc.
ff Outstanding starting performance over the
Silicon-Copper: The high performance ignition
entire service life
cable for all vehicles with copper-core ignition
ff Effective protection against corrosion and
cables as original equipment.

ff Highly conductive copper inner conductor
refined with tin
thread seizing
Silicone-Power
Silicone-Copper
Bosch Super 4
36 Idle actuators
37
Bosch idle actuators:

Compact range with high market coverage
Order number
Application
0 280 140 516

Alfa, Chevrolet, Citron, Fiat,

Opel, Peugeot, Renault, Saab,
Vauxhall, Volvo
0 280 140 505

Alfa, Audi, Ferrari, Fiat, Hyunda,

Kia, Lancia, Nissan, Saab, Seat,
VW
0 280 140 501

Alfa, AMC, Citron, Lancia,

Peugeot, Porsche, Renault, Volvo
0 280 140 510
MB
0 280 140 545
BMW
Around 32 million vehicles
That means: An increased
have been fitted with Bosch
demand for repairs can be
idle actuators. Around 80% of
expected. Bosch idle actuators
0 280 140 509
BMW, Citron, Peugeot, Porsche
them are more than 7 years
thus represent an attractive and
old.
lucrative market.
0 280 140 574
BMW
0 280 140 512
Audi, VW
An attractive market
Reach your market with just 15
0 280 140 542
Volvo
Idle actuators have primarily
order numbers
been fitted in the KE-Jetronic/
With just 15 order numbers, the
0 280 140 537
Citron, Fiat, Lancia, Peugeot
Motronic, L-Jetronic and
Bosch compact range covers
0 280 140 529
BMW, Bertone
Motronic systems. Most vehicles
around 88% of all vehicles fitted
0 280 140 549
BMW
fitted with an idle actuator there-
with Bosch idle actuators. The
fore have already had several
complete range includes a total
0 280 140 551
VW
0 280 140 520
Volvo
years of service and have clocked
of 60 different types.
up high mileage.
0 280 140 532
BMW, MAN, Rover
eXchange Back in Box

Outstanding quality, comprehensive range,
top class service
1. Purchase of a genuine Bosch exchange product
2. Exchange for the corresponding used part
3. The used part comes in the packaging of

the exchange product
4. Return of used part to Bosch
The comprehensive, intelligent
Gasoline injection products
exchange range
Currently a total of 21 product groups
from the starter/alternator, diesel/
gasoline injection and brake caliper
sectors.
ff Excellent market coverage for all
major vehicle manufacturers
ff Constant updating of range
ff First-class service
ff Quick and easy processing of used
products
Benefits for aftermarket and workshops:

ff Low ordering and storage costs
ff Customer satisfaction thanks to
rapid availability
ff Quality standards comparable to

original equipment
ff 100 % replacement of all critical
components
ff Consistent use of genuine Bosch replacement parts
ff Same warranty as for new products
in exchange program
ff Hot-film air-mass meter
ff Hot-wire air-mass meter
ff Air-flow sensor
ff Fuel distributor
ff Electronic control units
ff Central injection unit (ZEE)
bottom section
ff Central injection unit (ZEE)
Top section
ff Ignition distributor
38 Components
39
Gasoline injection components:

A to Z guide
Accelerator-pedal module
Air-flow sensor
Air-flow sensor (mechanical)
Systems: Motronic with ETC
Systems: L-Jetronic, Motronic
Systems: K-, KE-Jetronic,
Function: In contrast to conven-
Function: The air flowing into the
KE-Motronic
tional engine-management
engine deflects a sensor plate in
Function: The air-flow sensor and
systems, with the Motronic with
opposition to the restoring force
the fuel distributor combine to the
ETC the drivers acceleration input
of a spring. A potentiometer con-
form the mixture control unit. The
is no longer relayed to the throttle
verts the deflection of the sensor
two components must be replaced
valve by cable. Instead, the input
plate into a voltage. The elec-
individually. The air flowing
is detected using a pedal- travel
tronic control unit uses this signal
through the air funnel moves the
sensor (also referred to as elec-
to calculate the quantity of fuel
sensor plate by a certain distance.
tronic throttle control) and trans-
required.
The deflection of the sensor plate
mitted to the electronic control
Order number:
is transmitted by way of a lever
unit. The accelerator-pedal module
0 280 200 ..., 0 280 201 ...,
system to the fuel distributor.
is a pre-assembled unit contain-
0 280 202 ..., 0 280 203 ...,
Order number:
ing a vehicle-specific foot plate
BX: 0 986 280 0..
0 438 120 ..., 0 438 121 ...,
alongside the pedal-travel sensor

(potentiometer / hall sensor).
The Motronic control unit evaluates the sensor signal and adjusts
the electric motor-driven throttle
valve (throttle device), taking into
account other vehicle and engine
data.
Order number:
0 280 755 ...
F 026 TX2 ..., BX: 0 986 439 ...
40 Components
41

A to Z guide
Air-mass meter
Camshaft sensor
Canister-purge valve
Central injection unit (Mono-
Crankshaft sensor
Cold-start valve
Jetronic)
Systems: LH-Jetronic, Motronic
System: Motronic
System: Motronic
System: Mono-Jetronic, Mono-
System: Motronic
Systems: D-, L-, LH-, K-,
Function: The air-mass meter is
Function: The camshaft position
Function: Vapors are produced in
Motronic
Function: A ferromagnetic gear
KE-Jetronic, Motronic (some)
installed between the air filter
indicates whether an
the fuel tank by external heat radi-
Function: The main component
wheel with reference mark (tooth
Function: The cold-start valve
and throttle valve and meas-
engine piston moving towards top
ation or surplus fuel having been
of Mono systems is the central
gap) is attached to the crank-
injects additional fuel into the
ures the intake-air mass. Use is
dead center is in the compression
warmed in the engine compart-
injection unit. This contains the
shaft. The speed sensor
intake manifold during the starting
made in practice of hot-wire and
or exhaust stroke.
ment flowing back from the fuel
injector, the pressure regulator,
scans the tooth sequence. The
phase. In this process, the fuel is
hot-film air-mass meters. Both
The speed sensor at the camshaft
circuit. These vapors are purged
the throttle-valve, the throttle-valve
electronic control unit uses the
highly atomized by a swirl nozzle.
sensors operate on the same
(also referred to as phase sensor)
by way of an activated charcoal
actuator and sensors for intake-air
signal to calculate the crank-
The cold-start valve is attached
principle: An electrically heated
passes this information to the
filter. This filter retains the fuel
temperature and throttle-valve posi-
shaft position and speed. Some
to the intake manifold so as to
thin platinum wire or platinum
electronic control unit.
vapor and only allows the air to
tion. Bosch supplies the appropri-
systems are fitted with two sen-
provide a uniform supply for all
film resistor is positioned in the
Part number:
escape into the open. This also
ate workshop parts sets for repair
sors. The crankshaft position and
cylinders. The injection time of the
intake-air flow together with a
0 232 10. ...
ensures pressure equalization. For
work.
speed are then measured sepa-
cold-start valve is limited by the
temperature sensor as a tem-
regular regeneration of the acti-
Order number:
rately.
thermoswitch or the electronic
perature-sensitive resistor. The
vated charcoal, a further pipe con-
BX: 0 986 438 5.., 0 986 438 6..
Order number:
control unit.
electronic control unit is supplied
taining the canister-purge valve is
0 438 201...,
0 261 210 ...
Order number:
with a voltage signal proportional
routed from the activated charcoal
to the air-mass flow and uses this
canister to the intake manifold.
signal to calculate the quantity of
The method of actuation of the
fuel required.
canister-purge valve (regeneration
Order number:
valve) is such that the activated
0 280 21 ...,
charcoal canister is adequately
BX: 0 986 280 1.. (HLM),
purged with minimal lambda devia-
0 986 280 2.. (HFM)
tions.
Order number:
0 280 142 150 0 280 142 499
0 280 170 ...
42 Components
43

A to Z guide
Electric fuel pump / in-tank unit
Electronic control unit
Fuel accumulator
Fuel distributor
Fuel rail
High-pressure injector HDEV-1 +

HDEV-5
Systems: All systems
Systems: Jetronic and Motronic
Systems: K-, KE-Jetronic
Systems: K-, KE-Jetronic,
Systems: L-, LH-Jetronic, Motronic
System: Motronic gasoline direct
Function: The electric fuel pump
Function: The electronic control
Function: The fuel accumula-
KE-Motronic
Function: Along with the electric
injection
has to supply the engine with suf-
unit determines the quantity of fuel
tor keeps the fuel-supply system
Function: The fuel distributor and
fuel pump, fuel filter, injectors
Function: The high-pressure injec-
ficient fuel at the required pressure
required in each case and regulates
pressurized after shutting off the
the air-flow sensor combine to
and pressure regulator, the fuel-
tor (HDEV), one of the key com-
under all operating conditions. The
all the connected actuators and
engine. This considerably enhances
form the mixture control unit.
rail forms part of the fuel-supply
ponents in gasoline direction
electric fuel pump is also increas-
injectors. This is implemented on
starting performance, particularly
The two components must be
system which always supplies the
injection, is linked to the fuel rail
ingly assuming the function of a
the basis of the signals from the
with a hot engine. The accumulator
replaced individually. The control
engine with the necessary amount
by hydraulic connections and is
pre-supply pump for modern direct
temperature, pressure and load-
also has a sound-absorbing effect.
plunger on the fuel distributor is
of fuel under all operating condi-
actuated by a current regulated
injection systems in both gaso-
detection sensors. Electronic con-
Order number:
deflected by way of a lever sys-
tions. The pressure generated by
output stage. The solenoid swirl
line and diesel engines. Principal
trol units for Motronic systems also
0 438 170...
tem on the air-flow sensor. This
the fuel pump is applied to all
valve injects a precisely metered
requirements: Delivery rate
regulate the ignition point. In mod-
meters the quantity of fuel to be
injectors by way of the fuel rail.
quantity of fuel with a defined
between 60 and 200 l/h at rated
ern systems, the electronic control
injected to each cylinder.
The unused fuel flows back to the
spray pattern directly into the
voltage, pressure in fuel system
unit additionally assumes diagnosis
Note: The fuel distributor can only
fuel tank via a pressure
combustion chamber in finely
between 300 and 450 kPa (3...4.5
functions. Faults occurring are
be replaced as a complete unit. It
regulator. In most cases, the pres-
atomized form. The injected fuel
bar), build-up of system pressure
stored in the fault memory and can
cannot be assembled using work-
sure regulator (fuel rail con-
quantity is determined by pres-
from 50% to 60% of rated voltage;
be read out using self-diagnosis
shop equipment after removing
ventional design with pressure
sure, flow rate and the actuation
cold starting operation is definitive
testers.
individual components.
regulator) uses the intake-manifold
time of the injector. The injection
for this.
Note: Electronic control units in
Order number:
pressure as a reference. The use
spray geometry is tailored to the
Order number:
vehicles with immobilizer some-
0 438 100 ..., 0 438 101 ...,
of this typical pressure and the
requirements of the corresponding
0 580 254..., 0 580 303...,
times have to be matched. This
T 026 TX2 ..., BX: 0 986 438 ...
flow through the fuel rail (fuel
engine and the combustion proc-
0 580 305..., 0 580 309 ...,
work can only be performed in spe-
cooling) prevent the formation of
ess.
0 580 310 ..., 0 580 313...,
cially equipped workshops.
any unwanted vapor bubbles in
Order number:
0 580 314..., 0 580 453...,
Order number:
the fuel.
0 261 500 ...
0 580 464 ..., 0 582 980...,
0 261 20.... (Motronic),
Order number:
0 986 580 ...
0 280 00.... (L/LH-Jetronic),
0 280 151 ..., 0 280 152 ...
0 280 800 ... (KE-Jetronic/

Motronic)
44 Components
45

A to Z guide
High-pressure injector HDEV-4
High-pressure pump HDP-1
High-pressure sensor
Idle actuator
Systems: LH, KE-Jetronic,
injection
injection
injection
injection
injection
KE-Motronic, Motronic
Function: The HDEV-4 is a high-
Function: The 3-barrel radial pis-
Function: In contrast to the
Function: The HDP-5 is a quan-
Function: The sensor installed
Function: The idle actuator is
speed piezo injector for gasoline
ton high-pressure pump is driven
HDP-1, the HDP-2 high-pressure
tity-controlled single-barrel high-
in the high-pressure fuel rail is
installed in a bypass around the
with variable needle lift. The noz-
by the camshaft via a coupling. It
pump is a unit pump. It is also a
pressure pump for 4 to 8-cylinder
designed to detect the fuel-pres-
throttle valve and keeps the idling
zle opens outwards and ensures
compresses the fuel provided by
demand-regulated, intermittent
engines. In new engine projects
sure level in the rail. The pressure
speed steady under all conditions.
outstanding spray stability whilst
the electric fuel pump to up to 12
delivery 1-barrel piston pump with
it supersedes all the previous 1st
measured is used as the actual
Electrical actuation is effected
at the same time being extremely
MPa and conveys it into the high-
a maximum pressure range up to
generation Bosch high-pressure
quantity for rail-pressure regulation.
by way of the engine control unit
resistant to coking. The injector
pressure fuel rail (KVS-HD). The fuel
120 bar. It features an integral
pumps (HDP-1 and HDP-2).
Order number:
or the idle controller on vehicles
covers a wide metering range in
provides cooling and lubrication for
pressure damper and the integrat-
Order number:
0 261 545 ...
with idle-speed control. Extensive
which the quantity characteristic
the high-pressure pump.
ed fuel quantity control valve. In
0 261 520 ...
curve exhibits a high degree of
Order number:
addition, the pump is of modular
hose connection. Add-on idle
linearity. Its rapid and accurate
0 261 520...
(Piezo injector)
use is made of idle actuators with
design for flexible adaptation to
actuators are also employed in
multiple injections open up new
different customer requirements.
Motronic systems.
options for the design of the injec-
It is attached directly to the cylin-
Order number:
tion process.
der head or to an adapter housing.
0 280 140 5..
Order number:
Order number:
0 261 500 ...
0 261 520 ...
46 Components
47

A to Z guide
Idle controller (electronic control
Ignition cable
Ignition coil
Ignition distributor
Ignition module
unit)
Injector
(electromagnetic)
Systems: All systems with idle-
Function: The air/fuel mixture in
Function: The operating princi-
Function: The ignition distributor
Function: The ignition module
Systems: D-, L-, LH-Jetronic,
speed control
a gasoline engine is ignited by an
ple of an ignition coil is based
assigns the high voltage (ignition
controls the ignition point de-
Motronic
Function: The idle controller regu-
electrically generated spark. The
on Faradays law of Induction.
sparks) to the corresponding
pending on the current load and
Function: Each cylinder is
lates the idle rotary actuator and
required energy for this must be
Modern ignition coils consist of
power cylinder (firing order).
the engine speed.
assigned an injector. This is actu-
keeps the engine idling speed
transferred from the ignition coil
iron cores made up of individual
Type 1:
Order number:
ated electronically and injects the
absolutely steady. This avoids
via the ignition distributor to the
laminations and a plastic cas-
Ignition distributor with contact.
0 227 100 ...
fuel upstream of the engine inlet
speed fluctuations on activating
spark plug by the ignition cables
ing. To provide better insulation
Used for conventional coil ignition
valves. In this process, the nozzle
loads such as power steering, air
with no losses or interference.
of the windings, the casing is
and contact controlled transistor-
needle is lifted off its seat, allow-
conditioner or automatic transmis-
Order number:
cast in epoxy resin. The compact
ized ignition. The ignition point
ing the fuel to emerge through a
sion gearshift.
0 356 912 ..., 0 356 913 ...
coil shown is one of the plastic
is modified by way of speed-
precision annular orifice. Even the
Order number:
0 986 356 ..., 0 986 357 ...
ignition coils. It provides a high
dependent centrifugal or vacuum
slightest contamination of the fuel
spark energy (> 60 mJ) and a long
advance.
or deposits can impair operation.
spark duration ( 1.8 ms) and
Order number: 0 231 ... ...
The injectors are installed by way
thus ensures reliable, optimum
Type 2:
of special holders in rubber mold-
combustion of the air/fuel mixture
Ignition distributor with non-
ings. The thermal insulation thus
under all engine operating condi-
contacting sensor. This is used
achieved prevents the formation
tions.
for transistorized ignition with
of vapor bubbles and thus ensures
Order number:
inductive or Hall sensor. The igni-
good hot starting performance.
0 221 ... ..., F 000 ZS0 ...,
tion point is modified by way of
To avoid unmetered air and leak-
1 227 030 ..., 0 986 221 ...
speed-dependent centrifugal or
age, the O-rings are always to be
vacuum advance. Also double-act-
replaced prior to renewed instal-
ing. Also with add-on trigger box.
lation.
Order number: 0 237 ... ...
Order number:
Type 3: Ignition distributor for
0 280 150 ..., 0 280 155 ...,
electronic ignition. The ignition
0 280 156 ..., 0 280 157 ...,
distributor only has the high volt-
0 280 158 ...
0 280 220 ...
age section (cap, rotor).

Order number:
0 237 5.. ..., BX: 0 986 237 ...
48 Components
49

A to Z guide
Injector (electromagnetic, single
Injector (mechanical)
Knock sensor
Lambda sensor
Pressure-control valve
Pressure damper
Systems: Mono-Jetronic, Mono-
Systems: K-, KE-Jetronic
System: Motronic
Systems: All
Systems: D-, L-, LH-, K-,
Motronic
Function: K-Jetronic valves open
Function: The knock sensor con-
Function: With older systems,
injection
KE-Jetronic, Motronic
Function: The injector is installed
at a precisely defined fuel pressure
verts vibration into electric signals.
the lambda sensor is installed
Function: The pressure-control
Function: The pulsation of the
in the top section of the central
(usually between 3.5 and 4.1 bar).
This enables the electronic control
upstream of the catalytic con-
valve is positioned between the
injectors and the cyclic
injection unit. In this case one
In this process the valve needle
unit to detect knocking combus-
verter. The sensor measures the
rail and the low-pressure end of
delivery action of fuel pumps
injector supplies all the cylinders
oscillates at a high frequency and
tion and to retard the ignition
oxygen content of the exhaust gas
the high-pressure pump.
cause fluctuations in fuel pres-
with fuel. The fuel is injected into
the fuel is thoroughly atomized
point to prevent engine damage.
and supplies the electronic con-
The pressure in the rail is set by
sure. These may be transmitted to
the intake manifold upstream of
even in the case of very small
In some cases several sensors are
trol unit with a voltage of approx.
varying the flow cross-section. The
other components and the body
the throttle valve.
injected quantities. Each cylinder is
attached to the engine block for
800 mV for a rich mixture (< 1)
surplus fuel conveyed is returned
and result in noise. The pressure
As each ignition pulse also triggers
assigned an injector, which injects
knock control purposes.
and approx. 100 mV for a lean
to the tank.
damper smoothes the pressure
an injection pulse, the injector is
the fuel directly upstream of the
Order number:
mixture (> 1). Modern systems
Order number:
peaks and is primarily designed to
designed for very short switching
engine inlet valves. Atomization,
0 261 231 ...
require two lambda sensors - one
0 261 540 ...
reduce noise.
times. During injection, the valve
opening pressure and freedom from
upstream of the catalytic con-
Order number:
needle is lifted off its seat. Even
leaks have a major influence on
verter (= lambda control sensor)
0 280 161 ...
the slightest fuel contamination
emission characteristics, fuel con-
and one downstream (= lambda
can impair operation.
sumption and starting performance.
diagnosis sensor). Increasing use
Order number:
To avoid unmetered air and leak-
is being made of planar sensors.
0 280 150 051 0 280 150 099,
age, the O-rings are always to be
These attain the necessary oper-
0 280 150 651 0 280 150 699
replaced prior to installation.
ating temperature after just a few
Order number:
seconds. To permit lean opera-
0 437 502 ...
tion of the engine, the sensor
point injection)
upstream of the catalytic converter must be capable of detecting a

lean mixture composition. The latest broadband sensors are used
for this purpose.
Order number:
Unheated: 0 258 001 ...,
0 258 002 ...
Heated: 0 258 003 ..., 0 258 005
Planar: 0 258 006 ..., 0 258 007
0 258 010 ... und 0 258 017 ...
50 Components
51

A to Z guide
Pressure regulator
Pressure sensor (Motronic)
Pulse valve
Secondary-air pump (electric)
Shutoff valve
Temperature sensor
Systems: Motronic
System: K-Jetronic (with lambda
System: Motronic
System: Motronic
Mono-Jetronic, Motronic,
Function: Pressure sensors can be
control)
Function: The electric secondary-
Function: The shutoff valve is used
K-Jetronic (with lambda sensor),
Mono-Motronic
used for a variety of applications.
Function: The pulse valve is
air pump is used to ensure compli-
in turbo engines to protect the
KE-Jetronic, KE-Motronic, Motronic
Function: The pressure regula-
Intake-manifold pressure sensors
installed in the connecting line
ance with the stringent emission
turbocharger. The turbocharger
Function: The temperature sen-
tor is designed to maintain the
measure the absolute pressure in
between the sub-chambers of the
legislation in the post-start phase.
remains in operation on switch-
sor measures the temperature in
system-specific difference in
the intake manifold. These sen-
fuel distributor and the fuel return.
Fresh air injected directly down-
ing from turbo to overrun mode.
the coolant circuit and provides
pressure between the fuel supply
sors are either integrated into the
It is actuated by the lambda con-
stream of the combustion cham-
Without a shutoff valve, the air
the electronic control unit with an
pipe and the intake manifold at
electronic control unit or fitted in
troller and opened and closed in
ber causes afterburning of the hot
would impact against the closed
electric signal. The sensor consists
a constant level. The regulator is
the vicinity of the intake manifold
a defined cycle. This enables the
exhaust gases and ensures more
throttle valve and flow back into the
of an NTC thermistor embedded
located at the end of the fuel rail
in the form of externally mounted
pressure in the sub-chambers to
rapid warm-up of the catalytic con-
turbocharger. This return flow of
in a threaded sleeve or a plastic
(in the top section of the central
sensors. Modern systems featuring
be varied and the air/fuel mixture
verter.
air could damage the turbocharger.
casing. The coolant temperature
injection unit on Mono systems).
on-board diagnosis are additionally
to be regulated to = 1.
Order number:
To guard against this, the seat
signal is particularly important for
If the set pressure is exceeded,
fitted with tank-pressure sensors.
Order number:
0 580 000 ...
of the shutoff valve is opened by
the starting and warm-up phase.
a diaphragm-actuated valve
Modern DUO sensors combine
0 280 150 300 0 280 150 349
the vacuum applied in the intake
Order number:
opens up the return pipe and the
pressure and temperature meas-
manifold in overrun mode with the
0 280 130 ...
depressurized surplus fuel flows
urement.
throttle valve closed. This enables
back to the tank.
Order number:
the air conveyed by the continued
Note: The pressure regulator at
0 261 230 ...
operation of the turbocharger to be
the central injection unit cannot
routed via a bypass around the tur-
be replaced separately. Bosch
bocharger and back into the intake
supplies top sections with pre-
manifold.
mounted pressure regulators.
Order number:
Order number:
0 280 142 100 0 280 142 117
0 280 160 0 .., 0 280 160 2 ..,

0 280 160 5 .., 0 280 160 7 ..,
0 438 161 ... System pressure
regulator for KE-Jetronic/Motronic
52 Components
53
Gasoline injection components

A to Z guide
Throttle-valve assembly
Throttle-valve potentiometer,
Throttle-valve switch
Vacuum limiter
Warm-up regulator
throttle-valve sensor
Systems: Motronic with ETC
Systems: Mono-Jetronic, Motronic,
Systems: D-, L-, LH-, KE-Jetronic,
Systems: L-, LH-, K-, KE-Jetronic,
System: K-Jetronic
Function: In engine-management
Mono-Motronic
Motronic
Motronic
Function: Warm-up regulators
systems with ETC, the throttle-valve
Function: Throttle-valve sensors
Function: The throttle-valve switch
Function: The vacuum
consist of a spring-controlled
is no longer adjusted directly using
are attached to the throttle-valve
is attached to the throttle-valve
limiter restricts the difference in
diaphragm valve and an electri-
a cable. The acceleration input is
assembly or the central injection
assembly. The switch is actuated
pressures upstream and down-
cally heated bimetallic spring. As
detected by pedal-travel sensor
unit. These sensors detect the
by the throttle-valve shaft. One
stream of the throttle valve.
a function of engine temperature
(also referred to as electronic
position of the throttle valve and
contact is made in each case in
Additional air flows into the
and time, the control pressure
throttle control) and the sensor
the angular velocity on opening
the idle and full load positions.
intake manifold if the set pressure
in the fuel distributor is reduced
signal is relayed to the electronic
and closing. The angular velocity
These signals enable the elec-
difference is exceeded.
and more fuel is injected into the
control unit. The signal received by
is an important signal for the elec-
tronic control unit to activate the
Order number:
engine.
the electronic control unit is con-
tronic control unit to provide com-
idle increase function with a cold
0 280 160 1.., 0 280 160 3..
Order number:
verted into a control signal incor-
pensation for load change jolts
engine and enrichment at full load.
porating other vehicle and engine
and to prevent part load bucking.
Order number:
data. This control signal opens or
Note: Throttle-valve sensors on
0 280 120 000 0 280 120 499
closes the throttle-valve (driven by
central injection units cannot be
an electric motor) in line with the
replaced. The entire bottom sec-
driver input and driving situation.
tion of the injection unit has to be
Order number:
renewed.
0 280 750 ...
Order number:
0 280 122 ...
0 438 140 ...

Benz in System e

Enviado por

Dados do documento

Direitos autorais

Formatos disponíveis

Compartilhar este documento

Compartilhar ou incorporar documento

Opções de compartilhamento

Você considera este documento útil?

Este conteúdo é inapropriado?

Direitos autorais:

Formatos disponíveis

Benz in System e

Enviado por

Direitos autorais:

Formatos disponíveis

Diagnostics and Spare Parts

from a single source

Product Information Automotive

Worldwide development and production

Over a century of system expertise

The Product Information Automotive for passenger

car gasoline systems, PIA for short, is a supple-

In the early days of automotive engineering, ignition

ment to the existing information about Bosch gaso-

was one of the major technical issues. It was Robert

line systems and individual products. It summariz-

Bosch who came up with the solution in 1897 he

es the most important facts and provides a quick

succeeded in adapting a magneto for a motor vehi-

up to date overview of the key points. The PIA

cle engine. Since then, the name Bosch has been a

also provides information about technical features,

byword for progressive ideas and pioneering tech-

customer service and Boschs overall expertise in

nology, particularly in gasoline systems.

Overview of Bosch gasoline injection systems

Today, modern vehicles need to meet increasingly

Electric fuel pumps

cal fuel consumption, low emissions and maximum

enhance individual components. Progress can only

Sensors and hot-film air-mass meters

turers, Bosch develops and produces everything

Idle actuators / eXchange program

demands from the original equipment market are

Gasoline injection components overview

ESI[tronic] software and testing systems

Training, technical hotline, knowledge database

aftermarket and workshops is examplary.

4 Worldwide development and production

Bosch Comprehensive expertise:

Vehicle manufacturers worldwide rely on

ff Close co-operation with vehicle manufacturers

Comprehensive system know-how

Complete range from a single source

Leading automotive manufacturers rely on the exper-

Bosch develops and produces gasoline systems for

tise and high quality stands of Bosch injection sys-

all types of engine. For the aftermarket and work-

tems for original equipment. As a pioneer in gasoline

shop sector, more than 10000 replacement and

injection systems, Bosch can offer a more complete

wear parts are available, as well as the correspond-

product range than anyone else from individual

ing testing and diagnostic systems.

Worldwide development and production

ades of experience as a technological leader in mani-

An international production network develops and

fold injection. Bosch has unique expertise in gaso-

produces the complete gasoline injection product

line direct injection.

range in 19 countries. As a result, components and

6 Over a century of system expertise

Ignition and gasoline injection systems from

Gasoline direct injection

The Bosch success story in figures more than 100

1979 Motronic market launch.

1982 KE-Jetronic market launch.

2000 Market launch of Motronic gasoline direct

years of experience, more than 10,000 items in the full