AutoIntelligenceaa-boschww-uk.resource.bosch.com/media/__uk/workshop_world/ww/3270... · Issue 17 | Summer 2012 Contents With a standardised interface, a new search function and a

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Essential Information for the Modern Workshop Issue 17 | Summer 2012

Contents

With a standardised interface, a new search function and a range of sales promotions, the arrival of the new ESI[tronic] 2.0 workshop software means it’s easier and cheaper than ever before to diagnose faults on passenger and light commercial vehicles using the Bosch KTS diagnostic testers.

The comprehensive overhaul of the system means fewer mouse clicks are required to deliver faster results, while the streamlined user interface cuts the time spent navigating within the system.

New look – new functionalityThe significant changes to the world’s leading workshop software means it provides a clearer overview

of all control units fitted to a vehicle, as well as all the stored error codes. Saving time and money, the enhanced software has been designed to cut the time mechanics spend cross referencing the different types of information available. The new ESI software also enables the KTS tester to act as a PassThru device, allowing the reprogramming or updating of an ECU – vital when working on Euro 5 compliant vehicles.

Built-in shortcuts allow the user to quickly switch between the different types of information the Bosch workshop software package offers, for example between the control unit diagnosis, the troubleshooting instructions and even the parts

catalogue. The software includes diagnostics data and troubleshooting instructions, repair instructions, test values, wiring diagrams as well as optional service schedules and technical data. Each year, around 1400 new vehicle systems are added to the ESI[tronic] database, along with many updates to the details of existing systems. The new software is the first stage of an exciting year for Bosch diagnostic test equipment, with the introduction of an online version of the workshop software package later in the year. This powerful new offering will allow customers around the world to access updates on an ongoing basis via the Internet, ensuring they’re always working with the very latest data. All customers subscribed to ESI[tronic] will automatically receive the online version on trial until the end of 2013. u

The world's leading workshop software – Bosch ESI[tronic]. The best just got better.

ESI 2.0 Arrives on KTS

3 Component diagnosis

4 Electronic repair portal

5 Hybrid testing and training

6 – 7 Bosch Car Service

7 New appointments

8 – 9 Lambda sensors

10 – 11 Piezo common rail injectors

12 Brake pressure fault technical tip

13 Expansion at Karlsruhe site

14 – 15 Original equipment news

16 Motorsport

AutoIntelligence | Issue 17 | Summer 2012 AutoIntelligence | Issue 17 | Summer 2012 32


Less time spent testingESI[tronic] 2.0 makes it much easier to use a KTS diagnostic tester, especially for service tasks, but even diagnostic specialists will find the new functions a benefit. Comprehensive troubleshooting tools for repairs on electronic vehicle systems are clearly laid out, and the user can switch from the diagnosis screen with the read-out fault memory entries straight to the troubleshooting function, and then to the component testing screen. This means a technician can obtain all the relevant information regarding the fault or vehicle system as quickly as possible. With just a click of the mouse or stylus, the user can switch back and forth between the different information screens, and even

access the parts catalogue to find replacement parts quickly and easily. The addition of a PassThru functionon the KTS tester means that garages can tackle the relatively new issue of reprogramming and updating Euro 5 compliant vehicles. The introduction of the Euro 5 emissions regulation requires manufacturers to provide all relevant information on software updates, helping independent garages service and maintain the latest vehicles. Reprogramming is a prescribed part of some maintenance plans and is used when diagnosing faults, replacing control unit devices or encoding components.

Some great promotionsThere’s also a comprehensive range of promotions on Bosch’s KTS and DCU diagnostic units, available until the end of the 2012. A money-back guarantee on the KTS 540 and KTS 570 testers means garages can try the units for 12 months with no risk. Buy either unit, subscribe to ESI[tronic] 2.0 for 12 months, and you can receive a refund on the cost of the hardware if you’re not completely satisfied. Special bundle packages

are also available, lowering the cost of investment. With the DCU 130 and KTS 570 available for £5495, you save a total of £1185, and receive a year’s subscription to the new ESI[tronic] 2.0 software. ■

To find out more about ESI[tronic] 2.0, our latest diagnostic offers and Euro 5, visit:www.boschautoparts.co.uk

Welcome

Component diagnosis using FSA 500

Read-outs of various fault memories provide workshop technicians with important information for service and repairs. However, in order to isolate the fault and reliably identify a defective component, further electrical and electronic tests are usually required.

In this issue we look at a number of solutions from Bosch to enable technicians to carry out these essential tests including our FSA 500 measurement module, product/technical advice, training courses and our new ESI[tronic] 2.0 workshop software. Bosch – Parts, Bytes and Services from a single source. ■

Despite the power of many workshop diagnostic systems, a technician may still have to rely on a higher level of technology and training when it comes to isolating and identifying a defective component. The Bosch FSA 500 system provides advanced testing facilities and a fast yet affordable route to accurate fault analysis.Minimising the need for additional equipment, the FSA 500 connects wirelessly to an existing PC or a

Diagnostic Control Unit (DCU 130) and these, in turn, can control the measurement module. When fitted to a Bosch KTS module the values from the control unit are displayed in the FSA software. This approach means you can configure the diagnostic system to suit your workshops requirements and integrate with any existing Bosch diagnostic equipment already onsite.

The FSA 500 measurement module is equipped with engine test functions, a universal oscilloscope with a 2-channel and 4-channel mode, an ignition scope and a 2-channel multimeter. As a result it meets all standard requirements for the electrical and electronic testing of vehicle systems, including CAN bus.

The unit also features a signal generator for simulating sensor signals as well as an extensive range of preset component tests. The FSA software provides step-by-step guidance through the test sequence, and allows access to Bosch’s ESI[tronic] technical data and Technical Service Bulletins, which highlight common vehicle faults.

Garages looking to exploit the FSA500’s power can tap into Bosch’stechnical expertise by taking the VSTD9 Oscilloscope Operation & Signal Test Methods training course (available dates can be found below). ■

VSE1 Essential Test Procedures: Bosch Diagnostic Technician 10/07/12 to 11/07/12

VSB10 Body Control Systems, CAN & Multiplexed Networks: Bosch Master Technician 12/07/12 to 13/07/12

VSH24.1 Hybrid & Electric Vehicle Systems (IMIAL Level 2 QCF): Bosch Diagnostic Technician 17/07/12 to 18/07/12

VSD15 Common Rail System Diagnosis: Bosch Diagnostic Technician 24/07/12 to 25/07/12

VSG5 Engine Management Diagnosis of Universal Components: Bosch Diagnostic Technician 30/07/12 to 31/07/12

VSB8 Airbag & Supplementary Restraint Systems: Bosch Diagnostic Technician 02/08/12 to 02/08/12

CS1 Customer Care for Technicians: Bosch Diagnostic Technician 03/08/12 to 03/08/12

VSG17 Gasoline Engine Emissions Analysis & OBD: Bosch Master Technician 07/08/12 to 08/08/12

VSC6 Braking & Chassis Systems, ABS & ESP: Bosch Diagnostic Technician 14/08/12 to 15/08/12

VSTD9 Oscilloscope Operation & Signal Test Methods: Bosch Diagnostic Technician 16/08/12 to 17/08/12

VSH24.1 Hybrid & Electric Vehicle Systems (IMIAL Level 2 QCF): Bosch Diagnostic Technician 21/08/12 to 22/08/12

VSG11 Gasoline Direct Injection System Diagnosis: Bosch Diagnostic Technician 30/08/12 to 31/08/12

VSG14 Gasoline Engine Management Advanced System Controls: Bosch Master Technician 05/09/12 to 07/09/12

VSB26 Automotive Air Conditioning Systems Diagnosis: Bosch Diagnostic Technician 11/09/12 to 12/09/12

AC1RHA Automotive Air Conditioning Refrigerant Handling Certification: Qualifications Credit Framework 13/09/12 to 13/09/12

VSC6 Braking & Chassis Systems, ABS & ESP: Bosch Diagnostic Technician 17/09/12 to 18/09/12

VSG2 Engine Management Spark Ignition & Diagnosis: Bosch Diagnostic Technician 19/09/12 to 20/09/12

VSD12 Electronic Diesel Control Systems: Bosch Diagnostic Technician 24/09/12 to 25/09/12

VSC13 Advanced Brake, Chassis & Steering Control Systems: Bosch Master Technician 26/09/12 to 28/09/12

For more information on these courses, please call: 01895 878032 or visit www.boschautoparts.co.uk

All courses held at Robert Bosch Ltd, Denham.

Bosch training course dates: Summer 2012

Euro 5 PassThru capability

75,000 workshops subscribe to ESI[tronic] worldwide

▶ New look, new functionality

▶ Enables KTS to act as a Euro5 PassThru device

▶ Streamlined user interface

▶ 1000+ systems added each year

▶ Great promotions in 2012



With the aftermarket receiving cars with increasingly complex electronic systems, locating a cost-effective repair provider and meeting customer expectations can prove tricky, but the Bosch Electronic Repair Service provides workshops with access to a one-stop-shop for electronic repairs. Covering engine

control units, dashboards, navigation devices, car radios and even vehicle diagnostic equipment, the Bosch Electronic Repair Service is founded on the company’s expertise as the world's leading developer and manufacturer of electronic vehicle systems for the automotive industry.

Designed to be as easy and efficient as possible, the service is accessed via a website. Once registered, a workshop can search for a product and see a fixed price for the repair, where possible, or request a cost estimate. The garage then completes a repair order, a courier collects the device and it’s dispatched to the repair centre. Here, more than 200 highly-qualified electronics specialists repair thousands of devices using the latest diagnostic and repair procedures. Repaired components are usually dispatched

back to the workshop within 48 hours and all repairs come with a 12-month guarantee. To make things simple, Bosch organise collection once the repair order has been completed online and the courier fee is included in the cost of the repair. ■

To find our more, and to register and start using the Electronic Repair Service in just a few steps, visit www.bosch-repair-service.com

The ChallangeThe rise of hybrids and electric cars means that service and repair garages now have to handle a new range of technical challenges. Believe it or not, the Toyota Prius is currently the world’s bestselling car, but it’s been estimated that around 90% of the service and repair work on Toyota hybrid models is still carried out by franchised dealer workshops. There’s clearly an opportunity for independent garages, but how can you make sure you have the skills, understanding and equipment to do the job properly?

The SolutionBosch has pioneered many developments in hybrid vehicle systems, including powertrains and batteries, and it offers a comprehensive range of diagnostic equipment and training.

Hybrid vehicles with high-voltage battery systems can represent a challenge to independent workshops, if they don’t really understand how the vehicle works, or what precautions need to be taken. For a technician to safely and successfully work on a hybrid vehicle the high-voltage battery must be isolated.

After any servicing or repair has taken place, an insulation test is then required to check that there are no earth leaks or bridged contacts.

The EquipmentBosch’s FSA 050 Hybrid Tester is a quick and accurate high-voltage insulation tester. It is CAT III (1000 V) and CAT IV (600 V) safety rated, and is capable of testing vehicles with hybrid electric and electric drives. It allows workshops to perform hybrid diagnostic tasks quickly, efficiently and accurately, improving productivity and increasing service opportunities. Most hybrid testers feature the sort of functions that can be found on a general multi-meter, but the Bosch FSA 050 allows for a 1000 V insulation test to be

performed as well, so technicians can make every safety check possible.

The SoftwareTo complement the FSA 050, Bosch’s ESI[tronic] software now includes updates for the latest hybrid models, with more being added throughout 2012.

The TrainingTo help support independentgarages who want to understandmore about hybrid and electricvehicles, Bosch is currently runninga hybrid and electric vehicle systems training programme for technicians (VSH24.1). Dates for the next available courses can be found on pages 2 & 3. ■

Electronic repair portal Hybrid testing and training with FSA 050

The rising cost of fuel and ever stricter emissions laws means that start/stop systems are becoming increasingly popular on modern cars, and since 2007 Bosch has produced five million start/stop starters from its factory in Hildesheim, Germany.

First appearing on mainstream models like the BMW 3 Series and 5 Series in 2007, and more recently on popular models from Volkswagen and Audi, the system shuts the engine down when the vehicle is stationary at a junction or sat in traffic. When the driver is ready to

move off they simply depress the clutch and the engine starts automatically.

Currently, one in every three new cars registered in Europe features a start/stop system, and almost every European car maker is now integrating Bosch start/stop technology into its range, be it compact cars, premium saloons or sports cars.

“Start/stop is a cost-effective way to reduce fuel consumption considerably,” explains Dr. Ulrich Kirschner, president of the Bosch Starter Motors and Generators division. “We are expecting every second new car in Europe to be fitted with a start/stop system by 2013.” ■

Five million Bosch start/stop starters

Congratulations to Grant Sturkey from Green Lanes Garage in Barnstable for winning a Bosch FSA 050. The competition held in conjunction with Professional Motor Mechanic magazine drew entries from garages who all wanted to try this quick and accurate tester for hybrid and electric vehicles. ■

FSA 050 winner from PMM

You can access the new Electronic Repair Portal in a flash using this QR code, without having to search or enter any information. Simply scan the QR code with your mobile device and, via software or an app, you will be taken straight to the Portal so that you can enter your repair order.

The new FSA 050: high voltage multimeter for hybrid and electric vehicles



Bosch Car Service

Why not join our national network of independent garages?

Bosch Aftermarket appoints range of new specialists

With almost ten years’ experience under its belt, it’s a good time to look back at the success of the Bosch Car Service program and its support for the UK’s independent garages.

With 525 members, the Bosch Car Service network offers motorists an easy way to find a reliable and competitively priced garage. Providing the support and knowhow to remain profitable in the service and repair business, the scheme comes with the full support and branding of Bosch – one of the world leading automotive companies. It’s this consistency that allows the scheme to deliver outstanding levels of customer satisfaction. When questioned, an impressive 99.4% of customers said they intended to use a Bosch Car Service centre again in the future.

Originally launched in 2003, the Bosch Car Service network received the coveted Stage Two certification from the Office of Fair Trading in July 2007 - a rating reserved for

only the most rigorous of consumer protection codes. It was the first car service and repair code to receive this accolade.

Covering everything from training to marketing, the scheme guides independent garage owners through the important issues facing the industry as well as some key future challenges, like the maintenance of hybrid vehicles. A dedicated support team from Bosch ensures help is only a phone call away, and in addition to online marketing support, signage and a customer care programme, garages have access to Bosch training schemes and technical expertise. The Bosch Car Service website makes finding and using a network garage straight forward, thanks to an easy-to-use postcode search facility and online booking function.

Throughout the year a number of meetings, regional workshops and road shows keep garages up to date. The recent conference in Ireland provided a day of workshops, training sessions and brought the Irish independents up to date with the schemes’ newer services.If you want to find out more about joining the Bosch Car Service network visit www.boschcarservice.co.uk or contact a member of the BCS support team. ■

The dedicated BCS field support teamThe team work closely with member garages to help them get the most from the scheme’s many benefits. With years of automotive trade experience between them, the team offer phone support as well as onsite visits, to advise on all areas

where Bosch can make a difference. ■

Howard PriceBosch Car Service Manager

Gareth Campbell BCS Development Manager – North/IrelandTel: 07721 881 388

Gary Walker BCS Development Manager – MidlandsTel: 07790 488 293

Shaun Killian BCS Development Manager – South WestTel: 07778 257 774

Steve Rouse BCS Development Manager – South EastTel: 07818 017 317

Steven Glover BCS Development Manager – ScotlandTel: 07964 133 889

Bosch has appointed a number of new specialists within its Automotive Aftermarket team.

Robin Shaw, Divisional Director of Bosch Automotive Aftermarket in the UK said: “We are delighted to welcome all of the new members of our team in the UK. Each of them brings with them significant industry experience and will play an important part in supporting our customers.

Luke Jefferies is the new Workshop Specialist for the South West, taking over the position previously held by Shaun Killian.

Luke, a keen F1 fan, previously worked at Trade Parts Specialists (TPS) as a Sales Development Manager.

A new position of Technical Sales Specialist has been created in Scotland and will be taken up by Brian Muir. The role combines the jobs of Workshop Specialist and

Technical Sales Executive, requiring in-depth knowledge of both products and garage equipment. Brian has previously held workshop positions and training roles at Arnold Clark. Brian says,“I am looking forward to the new challenge, particularly promoting and supporting the latest garage equipment.”

Tony Tiffany brings with him over 30 years of automotive experience to his role of Diesel Specialist for the South. Tony started as an electrics and diesel apprentice and was Lucas Services’ Regional Sales and Operations Manager for six years. Before a stint as Regional Sales Manager for Bosal in the South West. Tony, who is a keen golfer said: “I could not pass up the opportunity to work for Bosch given its position in both the OEM and aftermarket sectors.”

Ken Geer, also arrives with almost 30 years of motor industry experience, taking

up a position as Technical Trainer to help support the expansion of Bosch’s training offer, Spending 12 years as a British Army vehicle mechanic, he has passed through a number of Bosch training courses and takes up his new role at an exciting time. Ken, who is a self-confessed F1 addict, said “I am looking forward to applying my learning and teaching experiences to helping others develop their own skills.”

Finally, Jason Rogers joins as Account Manager for the Midlands area. Jason, who is a third degree blackbelt in Tae Kwon-Do, spent 13 years at Valeo in quality engineer roles. He then joined Central Auto Supplies as a Business Development Representative, and spent a year with filter specialist Sogefi Filtration Ltd as an area sales manager in the South West. Jason commented: "I look forward to meeting and supporting customers in the Midlands" ■

▶ Over 500 in the UK & still growing

▶ A dedicated field support team

▶ Comprehensive training plans

▶ OFT Stage Two certification

▶ Strong marketing and branding package

▶ An industry leading customer care programme

▶ Regional meetings for all members

Bosch Car Service Key points:



With a development history that stretches back over 37 years, Lambda sensors are a vital component in modern petrol and diesel engines, yet they remain an enigma to many motorists and even some technicians.

Originally invented in 1976 by Bosch, the lambda sensor proved crucial in the development of electronic fuel injection systems, and direct injection engine design, by allowing the accurate control of emissions. Today’s sensors may look similar to the original types, but they’re a world away in terms of design and operation. Each of the four distinct generations of sensor have progressed their function and complexity, and the introduction of wideband planar sensors, in 1998, allowed the incorporation of a Lambda sensor into diesel engines for the first time, in 2002.

The UK market for Lambda sensors is huge and, for garages, represents a significant business opportunity. There are roughly 22.5 million petrol vehicles on UK roads, and all petrol vehicles produced since the mid 1990s have at least one sensor

fitted. Since the introduction of the European On-Board Diagnostics (EOBD) regulations, which cover all petrol cars sold within Europe since 1 Jan 2001, vehicles will have at least two sensors and, in some cases, as many as eight.Mounted directly into the exhaust system, the sensor precisely measures the oxygen content of the

exhaust gases, allowing the engine management ECU to adjust the air/fuel mixture entering the engine for combustion. By maintaining the optimal air to fuel ratio, the car runs as efficiently as possible and the continual feedback from the sensor allows the ECU to constantly adjust the mixture and prevent damage to the car’s catalytic converter. As the largest supplier into the

original equipment manufacturers, Bosch has an unrivalled product range of replacement parts for the aftermarket. It has produced over 500 million sensors to date, with over 45 million manufactured each year. Bosch’s research and development work, and close relationship with vehicle manufacturers, means that virtually all vehicle manufacturers use Bosch lambda sensors. As a result 80 percent of the European vehicle parc is covered by Bosch’s product range. This is the largest coverage available from any single supplier in the aftermarket.

Direct fitAs all lambda sensors share a common outward looking design, it’s easy to assume that if two look similar, and the threads match, the sensors are interchangeable. However, this is not the case, and each sensor has to provide exactly the right data to the car’s ECU. With over 1,000 separate part numbers, and a range of direct fit sensors that is constantly growing, Bosch’s close links with manufacturers means that each sensor is perfectly matched to the desired vehicle. This ‘like-for-like’ replacement provides peace of mind for workshops, and eliminates the risk of future issues as a result of fitting the wrong part.

Universal fitMany universal fit lambda sensors have a gained a bad reputation but, in reality, they can provide a quick and cost effective solution for garages. Unlike some universal sensors, Bosch parts are true OE quality sensors and come complete with a patented connector system, for easy integration into the vehicle’s existing lambda sensor wiring and connector, while full instructions ensure quick and correct installation.

Inspect and replaceIt is recommended lambda sensors should be checked every 20,000

miles and, depending on the generation of sensor fitted, have an official replacement interval of between 30,000 and 100,000 miles. This is because, due to thermal aging and their design and construction characteristics, their efficiency will deteriorate over time.

However, the majority of sensor failures are due to consequential damage; a failure somewhere else in the engine, physical impact or poor handling prior to installation. Contamination as a consequence of mis-fuelling, internal oil leaks or head gasket failure, can all compromise performance.

The consequence of fitting the wrong type of sensor, or an inferior product, isn’t always immediately obvious, but the long-term effects can be serious. High emissions levels, resulting in an MoT failure, as well as engine and catalytic converter damage are a real possibility. A drop of performance and fuel economy is also common, yet often go unnoticed by the driver as it occurs over an extended period of time. It’s not until the sensor is replaced that the extent of the problem is revealed and the driver appreciates how poorly the car had been performing. ■

Workshop PostersBosch offers four Lambda sensor posters providing easy to understand technicaladvice for workshops.

To obtain your copies, please email [email protected]

Lamda sensors:Opportunity and best practiceAlthough common rail diesel

technology first appeared in cars 14 years ago, Bosch has just produced their 75 millionth common-rail fuel system and diesel cars now account for 50% of all newly registered cars in Western Europe.

Traditionally seen as economical and robust, but not very desirable, diesel engine design was transformed by this new technology, which provided efficiency, refinement and performance. The first Bosch common-rail systems appeared on the Alfa Romeo 156 JTD and Mercedes-Benz C220 CDI in 1997, but unit sales have continually grown every year since. By 2001, three million Bosch common-rail

systems were in use, by 2002 it was up to ten million, and by the start of 2009 it was 50 million. This year’s milestone of 75 million Bosch systems also coincides with the 75th anniversary of Bosch involvement with diesel in passengers cars.

The name ‘common rail’ refers to the pressure accumulator from which fuel is injected at

high pressure into the cylinders via multiple injectors. The use of multiple injections not only produces quieter engines, but reduces fuel consumption and cuts the emissions of CO2 and other pollutants.

The necessary components required for a Bosch common-rail system are produced by an international manufacturing network, comprising of 17 locations and in 2011 alone Bosch produced some nine million common-rail systems. However, these aren’t just fitted in passenger cars, as commercial vehicles, the off-highway segment, and even the large diesel engines found in ships also use common-rail technology.Even though the technology

has developed quickly, Bosch continues to push advancements in this area to continually improve engine performance. The first generation of common-rail systems operates at a pressure of 1,350-bar, but today’s systems achieve up to 2,200-bar, and make it possible to meet the strictest emissions targets, including the Euro 6 regulations that will be mandatory in Europe from 2014. ■

Bosch produces its 75 millionth common-rail diesel system

Paul Alder Product Specialist

▶ Invented by Bosch in 1976▶ Over 500 million now

manufactured ▶ Largest range coverage from any

single supplier▶ Quality is vital for correct engine

performance

Key facts:



Technical Tip – Piezo common rail injectorsDangers of disconnecting while the engine is running

It’s possibly the most important safety system in a car after the seatbelt, yet it was only introduced to mainstream vehicles in 1995. Electronic Stability Programme, or ESP®, has saved countless lives since its introduction.

Building on the features of ABS antilock braking systems, and TCS traction control systems, it represents the future of Bosch active safety systems.

Simplistically, ABS stops the wheels from

locking when the brakes are applied, while TCS helps to prevent the wheels from losing traction as the car drives. ESP® goes further and detects imminent skidding, using sensors to compare the direction in which the driver intends the vehicle to travel and the direction in which the vehicle is actually moving. If the two do not match, the system intervenes by reducing engine power and selectively applying the brakes to individual wheels helping prevent skidding and keeping the vehicle safely on track.

In 1983, Bosch began to consider using an optimised ABS system to improve vehicle stability during full braking. This approach was refined over the next few years, with Bosch registering the basic patent application for ABS in 1987. Development didn’t stop there and the system’s functions were expanded in order to make it effective in all driving situations. Development continued throughout the early 90s until ESP® was ready for series production, and manufacturing began in 1995. ■

Essential safety system hits 75 million milestone

During a recent training course, an older member of the group asked me, “what’s all the fuss about? Not disconnecting Piezo common rail injectors whilst the engine is running? I pull the wires off petrol port injectors and crack off the

injector pipes on old style rotary diesel pumps to find out which cylinder is misfiring. Why can’t I do this with Piezo injectors?”The difference is disconnecting Piezo injectors while the engine is running could possibly kill you and

the engine. Piezo injectors work by passing a current through a Piezo stack in one direction to expand the Piezo crystals then discharge them to ground to make them contract to their original size, this expansion and contraction operates a servo valve, this servo valve controls fuel pressure above the injector needle. The Piezo injectors are operated by up to 200 volts, 15 amps. This has the potential to kill you, and if you manage to disconnect the injector whilst the Piezo crystals are expanded they will not beable to discharge to ground. This will cause the crystals to remain in their expanded state keeping the injector open. The fuel pressure within the rail can be as high as 2000 Bar at higher engine speeds/loads, even at idle it will be several hundred Bar. At this high pressure the engine would not be able to burn the excessive amount of fuel being continuously injected and it would only take a few engine revolutions to spray enough fuel into the combustion chamber to cause a hydraulic lock and serious engine damage.The full operation of Piezo and solenoid operated common rail injectors are explained in the Bosch training course VSD 15. ■

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Control chamber

Piezo element

Hydraulic return

Hydraulic inlet

Actuator module

Coupler module

Servo valve

Nozzle needle 1

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Ken Geer Technical Trainer

Insist on a quality Piezo injector when replacing these items

Piezo common rail injector voltage and amp output

▶ ESP will be mandatory on all passenger cars from Nov 2014

▶ ESP was pioneered by Bosch in the 80's and 90's

▶ 72% of newly registered cars and LCV's have it fitted

▶ The more advanced ESP systems require diagnostic equipment to even change brake pads

▶ In the last 17 years Bosch has manufactured 75 million systems



A customer recently reported to the Bosch technical helpline they had a 2004 Audi A3 with the ABS/ESP light on. After connecting their Bosch KTS diagnostic equipment they retrieved the following fault code:

059B – Brake pressure sensor

This fault code indicates a faulty brake pressure sensor. However the sensor should be tested to confirm if it is working correctly or not. The Teves Mk 60 ABS/ESP control unit uses the signal from the pressure sensor to calculate the current brake pressure in the master cylinder; the

pressure sensor is supplied with 5 volts and outputs a signal voltage of less than 1 volt with the brakes off, the signal voltage will increase with increased brake pressure. As the brake pressure sensor is integrated into the hydraulic modulator control unit, the only real means of testing the sensor is to use a diagnostic tester such as the KTS and using actual values. It is worth testing the brake light switch at the same time. Testing actual values has been made even easier with with Bosch’s new ESI[tronic] 2.0 workshop software. After selecting

the correct vehicle, set the KTS to look at brake pressure and brake switch actual values, progressively press the brake pedal. The brake switch should immediately switch from “component not actuated” to “component actuated” as soon as the pedal moves. As increasing pressure is applied to the brake pedal, the brake pressure should increase proportionally.

The operation of Teves and other ABS/ESP systems are explained in the Bosch training course VSC6. ■

Technical Tip – Brake pressure switch fault

Expansion to the Karlsruhe siteBosch is spending a total of 100 million euros over the next six years expanding the distribution centre at the Karlsruhe site, as part of a project to extend its capacity in the automotive aftermarket. By 2018, the project will have completed the modernisation of the German distribution centre’s warehouse technology and material flow.

The present distribution centre, which covers a total floor space of 70,000 square meters, was opened in 1978. From here, approximately 450,000 spare parts for vehicles - from antilock braking systems to spark plugs - are sent to 140 countries around the world. Every day, more than 20,000 delivery items are processed here and around 120 containers leave the centre.

“This investment will allow us to continue to grow and strengthen our leading position in the global spare parts industry,” said Robert Hanser, president of the Automotive Aftermarket division. Bosch employs roughly 1,300 associates at the Karlsruhe site, which is also the location of the headquarters of the Automotive Aftermarket division.Between 2013 and 2015, several extensions providing an additional

storage area of approximately 20,000 square meters are set to be built in Karlsruhe. The total capacity of the high-rack warehouse is set to increase by 50 percent to approximately 160,000 pallet positions. It’s planned that the new storage areas will go into operation in 2014, while work to modernise the existing distribution centre will begin in parallel to this, and is set to be completed by 2018. ■

Established in 1997, Fortune’s ‘World’s Most Admired Companies’ is among the most renowned company reputation rankings available, and Bosch has been named as the world’s most admired supplier of automotive products.

Taking votes from 3855 directors, executives and analysts from 698 companies spread over 58 industries and 32 countries, the influential business magazine’s report highlighted Bosch’s innovation, people management, and quality of products. Overall, the company ranked the fifth most admired company in Germany, the 14th in Europe and the 11th in India. ■

Bosch rated as world’s most admired automotive supplier

Testing actual values with KTS and ESI[tronic] 2.0

Hydraulic modulator and control unitBrake pressure and switch readings in ESI[tronic]

Bosch's Karlsruhe warehouse and distribution centre set to Increase to 90,000 m2 by 2018

Ken Geer Technical Trainer

Test the sensor and brake light switch simultaneously using a diagnostic tester and actual values.



How does an innovative vehicle manufacturer go about producing a hybrid vehicle which will stand out from the crowd? By looking for an innovative supplier – and getting together to develop a new combined diesel engine and electric drive concept. Result: The axle-split concept from PSA Peugeot Citroën and Bosch. A four cylinder 2.0 HDi turbodiesel is the basic front-wheel drive unit. The electrically driven rear axle provides extra thrust. This advanced technology is already in use in the Peugeot 3008 Hybrid4 and will now feature in the new Citroën DS5 Hybrid4.

Innovative and ThriftyThe Citroën DS5 Hybrid4 combines a 163 hp diesel engine with a 37 hp electric motor. The benefit of this hybrid concept is temporary four-wheel drive. The driver can choose between four modes with a thumbwheel. In “Auto” mode the DS5 Hybrid4 regulates the

interaction between diesel engine and electric motor automatically. The main objective is then economical fuel consumption. Over 100 kilometres the hybrid has a combined fuel consumption of 3.8 litres of diesel with a CO2 output of 99 g/km. In the “ZEV” setting, the DS5 Hybrid4 drives in purely electric mode for as long as possible. In practice it can manage up to four kilometres at a maximum speed of 60 km/h – ideal for urban Stop/Start traffic. In “4WD” allwheel mode, the rear wheels are constantly driven to give the vehicle added traction on difficult terrain. “Sports mode” is designed for maximum acceleration. In this case the electric motor provides the extra power for a more dynamic driving style. There is no loss of power in the DS5 Hybrid4 even when the storage battery is flat. By way of a generator the internal combustion engine constantly supplies up to eight kilowatts to the rear axle. ■

Following on from the Peugeot 3008 Hybrid4, the Citroën DS5 Hybrid4 is now making its mark. The principal components of both diesel full hybrid models come from Bosch, for example the electronics for the axle-split drive system and the special technical design of the ESP®.

Technology-packed diesel hybrid: The new Citroën DS5 Hybrid4

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The latest generation of Bosch’s Driver Assistance Technology, including drowsiness detection, has made its debut on the new Volkswagen Passat Alltrack.

Fatigue and micro-sleeping at the wheel are a cause of serious accidents but, by spotting the initial signs of driver tiredness, potentially critical situations can be avoided. A number of studies have highlighted the impact of fatigue on traffic accidents. In 2010, the American Automobile Association (AAA) published an analysis that showed that overtired drivers were at the wheel in 17 percent of all fatal accidents in the US.

First introduced as a standard feature in the 2010, Volkswagen Passat, the all new Passat Alltrack is the latest model to receive drowsiness detection. The process of measuring a driver’s behaviour can be defined by a couple of key metrics. Fading concentration and fatigue compromise the driver’s steering behavior and response time, with the driver making small steering corrections more often.

Based on the frequency of the steering inputs and other parameters, (such as the length of a trip, use of turn signals, and the time of day) the system calculates the driver's level of fatigue. Once that level exceeds a certain value, the driver is alerted to the fact that they should stop and rest.

The required information is provided either by the car’s electric power steering system, or by the steering angle sensor, which is part of a car's ESP® anti-skid system. This means that the technology can be cost-effectively and easily installed in passenger cars and light commercial vehicles, making a significant contribution to road safety. ■

Bosch Driver Drowsiness Detection Bosch Technology on the up!

▶ Airbag

▶ Pressure sensor

▶ Alternator

▶ Knock sensor

▶ Fuel rail

▶ Starter

▶ Start/stop system

▶ Control unit

▶ Tank delivery unit

▶ Wiper drive system

▶ Spark plugs

Bosch on board the up!

Volkswagen made their mark on automotive history with compact cars such as the Beetle, Golf and Polo. Now a new chapter has been opened up! The four-seater city specialist guaranteed to change the face of urban motoring. Not least thanks to plenty of sophisticated technology from Bosch!

With an extremely efficient drive system the up! has been launched as a three-cylinder model – with two gasoline versions (44 kW/60 hp or 55 kW/75 hp) and a 68 hp natural gas version (50 kW). Both gasoline versions feature special spark plugs from Bosch designed to withstand the higher final compression in the combustion chamber of the three cylinder engine. For this purpose Bosch developed the new cup terminal design with shorter contact and a nine millimetre longer insulator.

Thrifty start/stop systemThe up! will also be available as a “Blue Motion Technology” version with a Bosch start/stop system. When the vehicle comes to a halt the engine is simply switched off – the driver just has to press the clutch to set off again.

With BlueMotion Technology and the start/stop system, fuel consumption of the 60 hp up! is a mere 4.2 litres over 100 km – with CO2 emissions below the 100 g/km limit. ■

AutoIntelligence | Issue 17 | Summer 201216


As the cars lined up on the Hockenheimring starting grid for the opening race of the 2012 German Touring Car Masters (DTM) they all had one thing in common. Regardless of whether they were an Audi A5 DTM, a BMW M3 DTM or a DTM Mercedes AMG C-Coupé, each had Bosch technology on board.

Bosch has been a partner to the race series since the start of the new DTM in 2000, and supplies each team with a wide range of products including starters, generators, vehicle cable harnesses, wiper motors, and the power box. In addition to these standard components, the teams make use of Bosch Motorsport sensors, ignition components, and fuel injectors. These components are based on series-production

technology, but are adapted to meet the higher demands of motor racing. “We work together closely on this with the prototype production departments at Bosch plants,” explains Klaus Böttcher, Vice President of Bosch Motorsport. “As a result, teams benefit from the know-how of a leading automotive supplier in every component.”

This year’s DTM driver line upincludes ex-F1 stars David Coulthardand Ralf Schumacher. The UK iswell represented, with Gary Paffett,Andy Priaulx, Susie Wolff and JamieGreen also competing in this premier racing series. Although the bulk of the 11 races take place in Germany, there are also events in Britain, Spain, Netherlands and Austria.

Bosch Motorsport specializes in high-performance engineering services, and has over 111 years of experience in motor racing - first helping racing drivers to victory in 1901. Today it supplies a wide range of components and technology to different international race series, including the Le Mans 24 hours, Formula 3 and the U.S. Grand Am. ■

German Touring Car Masters

Reigning European Track Racing Champion, Jochen Hahn, got the 2012 season off to a flying start by winning all four races in the competition’s opening event in Istanbul. With the support of Bosch, Team Hahn Racing will be competing in all 11 rounds of this year’s ETRC championship, which will see its final races held at the famous Le Mans circuit in France.Despite fighting off rivals to take

maximum points at the event, there was no rest for the team, as the trucks had to leave the track within a few hours and begin the journey to Misano, Italy for the second heat of the championship.

Enduring changeable track conditions at the Italian circuit, Jochen had a hard fight to defend his leading position in the championship, but was able to pick up two additional podiums and remain seven points clear of his closest rival. ■

Bosch has thrown its technical expertise behind Honda’s 2012 British Touring Car Championship challenger, by providing a range of high quality motorsport components for its race-prepared Honda Civic.

Truck racingSponsorship

BTCC Sponsor

Covering everything from the engine’s motorsport fuel injectors, to specially modified fuel pressure regulators, Bosch have had significant input on the car’s design in three key areas: engine, throttle and fuel system.

Peter Fouquet, president of Bosch UK said: “We are delighted to be a technical sponsor for the Honda BTCC team in 2012. We have an established relationship with Honda, not only to provide components, but also in supplying Bosch's technical motorsport expertise to the team.” ■

Peter Fouquet with Matt Neal

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AutoIntelligenceaa-boschww-uk.resource.bosch.com/media/__uk/workshop_world/ww/3270... · Issue 17 | Summer 2012 Contents With a standardised interface, a new search function and a