Diagnostics and Spare Parts

from a single source Product Information Automotive

Gasoline systems

Only Bosch, the leading original equipment sup-

plier, 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 130 000 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
2 List of contents 3

At a glance:
PIA gasoline systems

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
Pages
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
4 - 5 Worldwide development and production 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-
6 - 7 Over a century of system expertise
customer service and Bosch’s 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-
cal fuel consumption, low emissions and maximum
12 - 17 Electric fuel pumps
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
uses its system know-how and the complex inter-
20 - 25 Lambda sensors
relationships 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-
turers, Bosch develops and produces everything
30 - 35 Ignition systems
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
Bosch can offer a product range that allies impres-
38 - 53 Gasoline injection components overview
sive quality and reliability with extensive market cov-
erage. Equally, the professional support available to
54 - 55 ESI[tronic] software and testing systems aftermarket and workshops is examplary.

56 - 57 Training, technical hotline, knowledge database

58 - 59 Sales promotion: Everything to help aftermarket businesses and workshops improve sales
4 Worldwide development and production 5

Bosch – Comprehensive expertise:

Vehicle manufacturers worldwide rely on ff Close co-operation with vehicle manufacturers

ff Complete range from components

Bosch for original equipment 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 10 000 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 sys-
tems. Meanwhile, you can benefit from Bosch’s 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 con-
stantly high quality at all times.

Locations worldwide
6 Over a century of system expertise 7

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
high-voltage source 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. 2008 500 million lambda sensors produced;
battery ignition sold as LH-Jetronic for the first time A development of the Mono-Jetronic 25 years of electrohydraulic transmission control;
1951 Launch of Bosch gasoline injection at the Mono-Monotric also featured 100 million control units produced
the Frankfurt Motor Show electronic map-controlled ignition and a
1967 First emission legislation in the USA, microprocessor
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 ules are pre-assembled units consisting of an
air-flow metering system intake manifold including injectors, throttle
1976 Bosch invents the lambda sensor, thus valve unit, pressure regulator etc.
paving the way for regulated catalytic converters
8 Gasoline injection systems 9

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 emis-
sion quality in combination with low fuel
Further technical information can be found consumption.
in the “K-Jetronic” booklet. 1 Electric fuel pump 6 Electric start valve
2 Fuel accumulator 7 Fuel distributor 1 Electric fuel pump
Order number 1 987 722 009. The booklets Further technical information can be found 6 Thermos-time switch
3 Fuel filter 8 Air-flow sensor 2 Fuel filter 7 Auxiliary-air device
are available from wholesalers. in the “L-Jetronic” booklet.
4 Warm-up regulator 9 Thermo-time switch 3 Fuel-pressure regulator 8 Throttle-valve switch
5 Injector 10 Auxiliary-air device Order number 1 987 722 010. The booklets
4 Injector 9 Lambda sensor
are available from wholesalers. 5 Air-flow sensor 10 Electronic control unit

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
measured result is thus independent of
Further technical information can be found temperature and pressure.
in the “KE-Jetronic” booklet.
Order number 1 987 722 021. The books Further technical information can be found
are available from wholesalers. 1 Electric fuel pump 8 Air-flow sensor in the “L-Jetronic” booklet.
2 Fuel accumulator 9 Thermo-time switch 1 Electric fuel pump
Order number 1 987 722 010. The booklets 6 Engine-temperature sensor
3 Fuel filter 10 Auxiliary-air device 2 Fuel filter 7 Idle rotary actuator
are available from wholesalers.
4 System pressure regulator 11 Engine-temperature sensor 3 Fuel-pressure regulator 8 Throttle-valve switch
5 Injector 12 Throttle-valve switch 4 Injector 9 Lambda sensor
6 Cold-start valve 13 Lambda sensor 5 Hot-wire air-mass meter 10 Electronic control unit
7 Fuel distributor 14 Electronic control unit
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 driver’s
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)
Further technical information can be found sets the amount of air needed to generate
in the “Mono-Jetronic” booklet. this torque. The corresponding fuel mass
Order number 1 987 722 033. The booklets is controlled in the gasoline injection sub- 1 Carbon canister 9 Air-mass meter 17 Primary catalytic
2 Canister-purge valve 10 Throttle device (ETC) converter
are available from wholesalers. system and the ignition sub-system sets
3 Intake-manifold pressure 11 EGR valve 18 Accelerator-pedal module
1 Electric fuel pump 6 Device connector with the appropriate ignition point as well as
sensor 12 Engine speed sensor 19 In-tank unit
2 Fuel filter intake air temperature sensor the necessary ignition energy. 4 Fuel rail/Injector 13 Knock sensor 20 Electronic control unit
3 Throttle-valve 7 Throttle-valve actuator
5 Camshaft adjuster 14 Temperature sensor 21 CAN
potentiometer 8 Engine-temperature sensor
6 Ignition coil/spark plug 15 Primary catalyst 22 Diagnosis lamp
4 Pressure regulator 9 Lambda sensor
7 Phase sensor 16 Lambda sensor 23 Diagnostic interface
5 Injector 10 Electronic control unit
8 Lambda sensor 24 Immobilizer

Motronic manifold injection Motronic -

gasoline direct injection
Motronic combines an injection system
and an ignition system for engine manage- 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. combustion stroke permit economical oper-
1 Air-mass meter with 10 EGR valve 19 Electronic control unit
ation and a low level of emissions. Thanks
1 Electric fuel pump 7 Idle rotary actuator temperature sensor 11 Intake-manifold pressure 20 Diagnosis interface
Further technical information can be found to its torque-based electronic control, the
2 Fuel filter 8 Throttle-valve switch 2 Carbon canister sensor 21 Diagnosis lamp
in the “Motronic” booklet. Motronic engine management system opens 3 Canister-purge valve 12 High-pressure sensor 22 Immobilizer
3 Fuel-pressure regulator 9 Engine speed and
Order number 1 987 722 029. The booklets 4 Injector up new dimensions in gasoline direct injec- 4 High-pressure pump 13 High-pressure injector 23 CAN
reference mark sensor
are available from wholesalers. 5 Air-flow sensor 10 Lambda sensor tion. 5 Pressure-control valve 14 Knock sensor 24 Delivery module with

6 Engine-temperature 11 Electronic control unit 6 Fuel rail 15 Engine-temperature primary pump

sensor 12 High-voltage distributor 7 Ignition coil sensor 25 Engine speed sensor
8 Accelerator-pedal module 16 Lambda sensor (LSU)
9 Throttle device (ETC) 17 Lambda sensor (LSF)
18 NOx-catalytic converter
12 Electric fuel pumps 13

Innovative technology for optimum performance:

Electric fuel pumps: The complete range from ff Original equipment quality across the range
ff Optimized for the specific engine type

the system specialists 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 (3…4.5 bar)
ff Reliable build up of system pressure even for
Impressive Bosch quality cold starts or with adverse battery voltage

Bosch electric fuel pumps are optimized for the spe-

Electric fuel pump Fuel delivery module cific engine type and are produced to stringent qual-
ity 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 stand-
ards ever since with its high performance and durable sys-
tems. This is why a whole range of leading vehicle manufac-
turers put their trust in electric fuel pumps from Bosch.
Repair kit for Fuel-level sensor
fuel delivery modules
14 Electric fuel pumps 15

The Bosch universal range: Compact and powerful:

7 instead of 72 The new generation of fuel delivery modules

One type for a variety of applications: The univer- Order number Applications Bosch is constantly working on improving and opti- provide the precise fuel supply required for partial or
sal electric fuel pump range from Bosch The 72 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
0 580 254 910 Audi, Ferrari, Ford,
is the key - Each of the 7 electric fuel pumps is sup- new XML fuel delivery modules are just one example ff Improved interference suppression
Mercedes-Benz, Suzuki, VW
plied with a parts set and easy to follow installation 0 580 254 911 Ford, Mercedes-Benz, Toyota of this. ff Improved compatibility with different fuel types
instructions. These pumps form the Bosch universal 0 580 464 069 Alfa Romeo, Citroën, Fiat, GAZ,
range. Porsche, Renault, Saab, Volvo Clear benefits:
0 580 464 070 Alfa Romeo, AMC, Austin, BMW, Compared to conventional fuel pumps, the new gen-
Chevrolet, Citroën, Daewoo,
eration offer an impressive 30 % higher efficiency and
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 couldn’t be simpler

Certain rival companies The special parts set turns a In the original equipment market, numerous manufacturers
make use of inferior universal electric fuel pump already use the new fuel pumps from Bosch,
imitation products in- into a specialist for a particular including Audi, Fiat, Ford, GM, Mercedes-Benz, Renault, and VW.
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.
16 Kit solutions 17

The new Bosch kit concept:

The Bosch kit concept: ff The quick and easy way to repair
fuel delivery modules

The clever 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:

Fitting tool
ff Repair concept for 750 additional vehicles
for fuel hose
ff Maximum market coverage also including modern
diesel injection systems
ff Quick and easy to replace Plastic hose
ff Detailed fitting instructions provided with ever kit
ff Less storage space required
ff Lower storage and handling costs Receptacle
ff High Bosch original-equipment quality throughout
ff Long-term availability of all products – Connector
at competitive prices 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

Uncomplicated, fast and reliable: Fuel delivery module repair

Purchase costs: -36 %
with the kit concept. Bosch provides you with all the necessary
Total costs: -26 % parts and easy to follow fitting instructions. You can rely on us
– and so can your customers.
Kit solution 121 EUR
+ Installation costs* 19 EUR

Module price VW 188 EUR Total 140 EUR * Additional repair time 15 minutes
18 Injectors 19

Geared to optimum performance:

Injectors: Excellent vehicle coverage, ff Help in choosing the right injectors

ff A comprehensive range for the workshop and

optimum availability 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 mechani-
cal malfunction such as a defective
spray pattern may exist.

Top technology from the top

Defective injectors Properly functioning injectors
supplier
Every injector reflects the excel-
lence of the inventors and world
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 greatest market coverage
name in original equipment. We an assurance of: efficient combustion, even for ff Easy and secure ordering thanks
have may years’ experience and ff Minimized fuel consumption dynamic driving to high data quality and reliabil-
have produced more than a bil- ff Significantly improved starting ff Low consumption and emis- ity of application data
lion injectors. performance sions, particularly in the ff Rapid availability thanks to
ff Immediate acceleration starting and warm-up phase worldwide network for produc-
ff Longer service life for exhaust ff Outstanding warm start tion, sales and logistics
components performance thanks to im- ff Simple, reliable installation
proved cross-sections inside ff Original-equipment quality with
the valves excellent and leak-free fitting
Good ideas for better engine performance Geared to excellent engine performance ff Optimum corrosion resistance and minimal function tolerances
Bosch’s 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.
opment of which won the German Future Prize.

The milestones for injectors

Since 1967: Intake manifold injector EV1 Since 1992: Intake manifold injector EV6 Since 1999: Intake manifold injector EV14 Since mid 2005: High pressure injector Since late 2005: High pressure injector
HDEV5 for gasoline direct injection (piezo injector) HDEV4 for gasoline
direct injection
20 Lambda sensors 21

Bosch lambda sensors:

Bosch – the number one name worldwide ff The world’s leading original equipment and
aftermarket products

for lambda sensors

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

3 The lambda sensor

measures the residual oxygen
Fig. 1: Finger-type sensor 

1 Sensor ceramic element content in the exhaust gas

 when warm (350 °C) generates a
2 Heater
3 Protective tube voltage of between approx. 25 and
1 900 mV depending on the oxygen
2
content in the exhaust gas
 compares the residual oxygen con-
tent in the exhaust gas with the
2 oxygen content of the ambient air
Fig. 2: Planar sensor
 detects the transition from a
1 Planar sensor element
2 rich mixture (lack of air λ < 1) to a
with integrated heater
lean mixture (excess air λ > 1)
2 Double-walled protective tube
Bosch invented lambda sensors and vice versa
1
more than 30 years ago. Today…

ff …Bosch is the world’s largest ff … Bosch supplies all lambda All European vehicle manufacturers,
manufacturer, with a total of sensors for the aftermarket and most leading producers world- Layout and functioning of the lambda sensor
more than 500 million sensors sector in original-equipment wide, rely on lambda sensors from
produced. quality. Bosch. Bosch lambda sensors give Layout Mode of operation
ff … Bosch has the most produc- ff … Bosch has a uniquely broad you a decisive advantage over the
tion experience with 45 million product range. competition and enable you to Lambda control loop The control unit uses the lambda
1 Intake air 4 sensor voltage signal to regulate
sensors produced each year. ff … Bosch provides the highest offer your customers what they
2 Fuel supply the mixture composition and con-
ff …Bosch’s innovations are conti- data quality with reliable and want – replacement parts that are 2
3 Injector trol the injection quantity accord-
nuously advancing development. complete application data. environmentally friendly, save fuel 4 Electronic control unit ingly. The fuel quantity has to be
3
ff …Bosch leads the way in the ori- ff … Bosch guarantees rapid avai- and have a long service life. 5 Control sensor reduced if the mixture is too rich
ginal equipment and aftermar- lability anywhere, thanks to its (upstream of (λ < 1) and increased if it is too
1 5
ket sectors. international sales network. catalytic converter) lean (λ > 1). An optional diagnostic
6 Catalytic converter 8 sensor after the catalytic converter
7 Exhaust gas detects whether the control sen-
8 Diagnostic sensor 7 sor is still working properly.
(downstream of
catalytic converter)
6

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 Universal lambda sensors
Thanks to their universal connec-
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. Replacement interval: Replacement interval: Replacement interval: versal sensor to the end of the
Replacement interval: Every 160 000 km Every 160 000 km Every 160 000 km cable in the vehicle.
Every 100 000 – 160 000 km

Reasons for Bosch’s 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 manufacturer’s 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 Heat output Cable length Number of Connector
tube wires
24 Lambda sensors 25

Lambda sensors:
Always right with Bosch

Used lambda sensor New lambda sensor

You can’t 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 Regular checking and replacement are therefore

With used With new Bosch
every mile lambda sensor lambda sensor vital
There are any number of good reasons why
Average driving per- 14 000 km 14 000 km motorists should make sure their Bosch lambda
formance per year
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 lambda sensor
per 100 km ff Avoiding expensive catalytic converter damage
Annual fuel consumption 1.456 l 1.260 l ff Compliance with stringent emission standards
ff Improved performance

Fuel price per liter 1,50 € 1,50 €

Annual costs of fuel 2 184,00 € /year 1 890,00 € /year

fuel
x . 1 5  % less
Appro 4 € per year
9
Up to 2
26 Sensors 27

For added comfort, safety and environmental

protection: Sensors are becoming increas-
ingly 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 world’s leading sen- Hot-film air-mass meters measure the actual air flow in placement parts, exactly tailored to the specific
and more electronic components. This increases sor manufacturer. All Bosch sensors are fine-tuned to the engine very quickly and precisely to allow the engie type
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 ff All replacement parts offer original-equipment
range of parameters in the vehicle. Applications of optimum engine combustion, which has the twin quality
sensors are almost limitless and are constantly With over 2 000 different products, Bosch supplies all benefits of low levels of harmful emissions combined ff For repairs in line with current value, Bosch also
being expanded. Today’s drivers no longer want to important types of sensor – for applications ranging with improved performance. supplies hot-film air-mass meters as exchange
do without the benefits that these systems pro- from engine management right through to passive products
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…

Genuine or imitation?
Only genuine parts are exactly tailored to the specific engine type
and guarantee optimum performance and compliance with the statu-
tory 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 ff A rapidly expanding market with

excellent prospects

from the sensor specialist ff Comprehensive range in original-

equipment quality
ff Over 2 000 products in all the key
sensor groups

Knock sensors Low-pressure sensors High-pressure sensors Crankshaft sensors Camshaft sensors (phase Temperature sensors
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 Temperature sensors monitor the
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 temperature of coolant, oil and air
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- and transfer the data to the
structure-borne sound (knocking) accuracy and fast response times. rail of the direct gasoline injection contact measurement of crank- shaft. engine-management system.
in the engine and transfer this data system. The sensors are vibration shaft rotation angle and speed. Depending on the application, the
to the engine-management sys- resistant and have an impressively sensors may be installed in the
tem. These values can then be compact and robust construction – engine block, cooling circuit or
used to counteract the problem offering exceptional measuring intake tract.
and ensure smoother combustion. accuracy over their entire service
The “ear” of the engine ensures a life.
long service life and optimum
operation.

Vehicles with Vehicles without

sensors sensors
Equipment proportion [%] 100%

Renowned vehicle manufacturers rely on Bosch sensors: 80%

Alfa Romeo Lancia Renault 60%

Audi Maybach Saab
Sensor systems: A rapidly expanding
Bentley Mazda Seat 40%
market with excellent prospects for
BMW Mercedes-Benz Skoda
the aftermarket and workshop sectors
Citroën Nissan Toyota 20%
Ferrari Opel Volvo
0%
Fiat Peugeot VW
2001 2005 2009
Ford Porsche
30 Ignition systems 31

Expertise from a system supplier:

Bosch ignition systems ff The only supplier of all ignition

components

The first choice right from the start ff Comprehensive range in

original-equipment quality
ff Excellent market coverage
ff A leading innovator: Continuous
development

1 3

5
3

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 number of leading brains set about solving this Complete range? Only from Bosch
5 Ignition modules
the aftermarket sector. problem – including Robert Bosch. Finally, Bosch Bosch is the only supplier in the world that can offer
Compact range (7 part numbers) to spark off
managed to develop a high voltage its partners a complete range of all ignition com-
success
2 Silicone power and silicone copper magneto, patented in 1902. ponents. There is a good reason why Bosch stands
The tailored ignition cable range – the right for quality and expertise, state of the art technol-
connection every time. Benefit from over a century of experience ogy and pioneering developments.
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
32 Ignition systems 33

Bosch ignition coils: Bosch ignition modules:

Innovative technology in original-equipment quality The compact range for modern ignition systems

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 Bosch ignition modules set ff No exposed connecting ca- Order number Applications
temperature and vibration resist- part, this innovative ignition coil Technical innovations are incor- standards bles 0 227 100 123 Alfa Romeo, Austin, Citroën,
ance. Bosch will continue to set technology provides porated into engine production Numerous vehicle manufactur- ff Excellent heat resistance Fiat, Lancia, Opel, Peugeot,
ers put their trust in Bosch. Seat, Talbot, Zastava
the tone for ignition systems in all the benefits of original in close cooperation with the and functional reliability
0 227 100 124 Bentley, Citroën, Daewoo, Ford,
the future For example, with its equipment quality: automotive industry. This con- With good reason. As well as ff High heat capacity and con-
Peugeot, Porsche, Saab, Volvo
innovative compact coils with  Demand-based ignition stant expansion and updating of excellent reliability, they know ductivity 0 227 100 137 Audi, BMW, Nissan, VW
primary current control and voltage the range results in ever-increas- that Bosch ignition systems ff Extreme break resistance 0 227 100 140 Citroën, Peugeot
diagnostic function.  Long
are 100% tailored to the 0 227 100 200 BMW, Chevrolet, Porsche, Opel
spark duration ing market coverage for ignition
 Improved
engine. The Bosch compact range: 0 227 100 203 Alfa Romeo, Fiat, Lancia,
engine performance coils.
7 instead of 49 Opel, Volvo
Additional plus points 0 227 100 211 Audi, Seat, Skoda, VW
ff Excellent market coverage
ff Constantly high ignition vol- with low storage costs
tage ff Supplied with installation
ff Absolute freedom from materials for easy fitting
Innovative plastic ignition coil in original-equipment quality leaks and maximum corrosi-
on protection

Primary winding Components of a transistor ignition system

Connector 1 Battery 5 Sensor
Spark plug connectors (silicon rubber) Secondary winding 2 Ignition 6 Ignition distributor
switch
7 Spark plug(s)
3 Ignition coil
4 Switching
device

Core
6
Bosch ignition modules are used by many leading
vehicle manufacturers:
Alfa Romeo, Audi, BMW, Citroën, Fiat, Ford, Lancia,
Mercedes-Benz, Opel, Peugeot, Porsche, Renault,
Spark plug contact (spring) Interference suppression resistor 1 2 3 4 5 7
Saab, Seat, Skoda, Volvo, VW
34 Ignition systems 35

Bosch ignition cables: Spark plugs from Bosch:

The high performance connection 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
connections Bosch spark plugs impress with their outstand-
ff Extreme heat and cold resistance from ing technology, excellent reliability and
–60 °C to over +200 °C exemplary quality.
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 Bosch Super / Super plus
ff More than 220 resistance ignition-cable sets 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 Bosch Super 4
cable for all vehicles with copper-core ignition ff Effective protection against corrosion and
cables as original equipment. thread seizing
ff Highly conductive copper inner conductor
refined with tin
Silicone-Power Silicone-Copper
36 Idle actuators 37

Bosch idle actuators: eXchange – Back in Box

Compact range with high market coverage Outstanding quality, comprehensive range,
top class service

Order number Application

1. Purchase of a genuine Bosch exchange product 2. Exchange for the corresponding used part
0 280 140 516 Alfa, Chevrolet, Citroën, 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, Citroën, Lancia,

Peugeot, Porsche, Renault, Volvo

0 280 140 510 MB

Around 32 million vehicles That means: An increased
0 280 140 545 BMW
have been fitted with Bosch demand for repairs can be
idle actuators. Around 80 % of expected. Bosch idle actuators 0 280 140 509 BMW, Citroën, Peugeot, Porsche

them are more than 7 years thus represent an attractive and 0 280 140 574 BMW 3. The used part comes in the packaging of 4. Return of used part to Bosch
old. lucrative market. the exchange product
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 The comprehensive, intelligent Gasoline injection products
0 280 140 537 Citroën, Fiat, Lancia, Peugeot
been fitted in the KE-Jetronic/ With just 15 order numbers, the exchange range in exchange program
Motronic, L-Jetronic and Bosch compact range covers 0 280 140 529 BMW, Bertone Currently a total of 21 product groups ff Hot-film air-mass meter
Motronic systems. Most vehicles around 88  % of all vehicles fitted 0 280 140 549 BMW
from the starter/alternator, diesel/ ff Hot-wire air-mass meter
fitted with an idle actuator there- with Bosch idle actuators. The gasoline injection and brake caliper ff Air-flow sensor
0 280 140 551 VW
fore have already had several complete range includes a total sectors. ff Fuel distributor
years of service and have clocked of 60 different types. 0 280 140 520 Volvo ff Excellent market coverage for all ff Electronic control units
up high mileage. major vehicle manufacturers ff Central injection unit (ZEE)
0 280 140 532 BMW, MAN, Rover
ff Constant updating of range bottom section
ff First-class service ff Central injection unit (ZEE)
ff Quick and easy processing of used Top section
products ff Ignition distributor
Benefits for aftermarket and workshops: ff Quality standards comparable to
ff Low ordering and storage costs original equipment
ff Excellent market coverage ff 100 % replacement of all critical
ff Customer satisfaction thanks to components
rapid availability ff Consistent use of genuine Bosch re-
placement parts
ff Same warranty as for new products
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 driver’s 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 F 026 TX2    ..., BX: 0 986 439    ...
(potentiometer / hall sensor).
The Motronic control unit evalu-
ates 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    ...
40 Components 41

Gasoline injection components:

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 0 280 170    ...
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
42 Components 43

Gasoline injection components:

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

Gasoline injection components:

A to Z guide

High-pressure injector HDEV-4 High-pressure pump HDP-1 High-pressure pump HDP-2 High-pressure pump HDP-5 High-pressure sensor Idle actuator
(Piezo injector)

System: Motronic gasoline direct System: Motronic gasoline direct System: Motronic gasoline direct System: Motronic gasoline direct System: Motronic gasoline direct 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 ... use is made of idle actuators with
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   ... 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

Gasoline injection components:

A to Z guide

Idle controller (electronic control Ignition cable Ignition coil Ignition distributor Ignition module Injector
unit) (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 Faraday’s 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
0 280 220    ... 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 ...
age section (cap, rotor).
Order number:
0 237 5.. ..., BX: 0 986 237 ...
48 Components 49

Gasoline injection components:

A to Z guide

Injector (electromagnetic, single Injector (mechanical) Knock sensor Lambda sensor Pressure-control valve Pressure damper
point injection)

Systems: Mono-Jetronic, Mono- Systems: K-, KE-Jetronic System: Motronic Systems: All System: Motronic gasoline direct 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 (λ< 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 (λ> 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
upstream of the catalytic convert-
er must be capable of detecting a
lean mixture composition. The lat-
est 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

Gasoline injection components:

A to Z guide

Pressure regulator Pressure sensor (Motronic) Pulse valve Secondary-air pump (electric) Shutoff valve Temperature sensor

Systems: D-, L-, LH-Jetronic, Systems: Motronic System: K-Jetronic (with lambda System: Motronic System: Motronic Systems: D-, L-, LH-Jetronic,
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 λ = 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. 0 438 140    ...
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 ...