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Essential Information for the Modern Workshop Issue 18 | Autumn 2013

Contents

At the heart of the Bosch Automotive Aftermarket strategy lies the Parts, Bytes and Services motto, but what does it really mean and how will it help garages and technicians?

To reflect the changing face of the automotive aftermarket and the increasing complexity of servicing and repairing modern vehicles, Bosch has developed a strategy to offer customers a more comprehensive range of products and services.

The right Parts As well as being the largest supplier of parts to vehicle manufacturers, Bosch also develops and manufactures parts specifically for the Aftermarket, using its experience

gained as an OEM supplier. This helps to ensure that Bosch maintains its position of having the world’s largest range of aftermarket parts available to support all makes of vehicles. Details of the opening of Bosch’s latest aftermarket manufacturing facility can be found on page 10.

With a huge increase in the number of diesel vehicles on roads in the UK and Ireland, garages are increasingly facing the challenge of how to repair faulty diesel systems. Bosch offers factory remanufactured diesel exchange parts, in addition to the repair solutions offered through the Bosch Diesel Centre network.

Parts, Bytes and Services – Bosch’s Bigger Picture Welcome

Page 2 Parts, Bytes and Services

Page 3 Data Engineering Centre

Page 4 Bosch team changes

Page 5 Battery business

Page 6 Bosch Car Service scheme

Page 7 Support for BCS network

Page 8 111 years Bosch spark plugs

Page 9 The role of air mass meters

0 Technical tip: DPF filters

Page 12 A century of electrical power

Page 13 Training Centre update

Page 14 Bosch safety system in Audi A3

Page 15 Bosch puts the spark in Citigo

Page 16 Modern electric drives by Bosch

In addition to finding out more about how Bosch’s Parts, Bytes and Services philosophy covers the automotive aftermarket, this latest edition of Auto Intelligence is packed with information - covering everything from the 111th birthday of Bosch spark plugs, through to the very latest developments in diesel engine technology.

You will also find out how the Bosch Service Training Centre (STC) has expanded to meet the rising demand within the industry and how Bosch is working with UK-based vehicle manufacturers to keep the Bosch KTS diagnostic tool right up to date. ■

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AutoIntelligence | Issue 18 | Autumn 20132


The Bosch eXchange programme provides replacement parts to customers quickly and cost effectively, so garages can benefit from the opportunities that the increasing diesel parc brings. In addition to off the shelf parts, Bosch also offers an electronic repair solution for high value components including ECUs, navigation systems and dashboards. It's an easy way for garages to source repairs at a fixed price or request a repair estimate.

The Byte solution The latest luxury cars contain up to 200 computers so workshop technicians need the right knowledge and tools to service them correctly. The Byte in "Parts, Bytes and Services" takes Bosch’s industry-leading know-how of vehicle systems and delivers it to technicians in a quick and effective way. The introduction of ESI [tronic] 2.0 last year gave technicians a quick and easy way to diagnose faults and repair and service the vehicle. This powerful software upgrade to the KTS range of diagnostic testers, means fewer mouse clicks to find and solve a fault, while features like PassThru allows the re-programming and updating of a vehicle's ECU for Euro 5 vehicles. The "Bytes" also includes the comprehensive range of Bosch’s state-of-the-art range of garage equipment:

KTS – ECU Diagnostic Equipment

FSA – Engine Analysers

BAT – Battery Service

ACS – Air Conditioning Service

BEA – Emission Analysers

EPS – Diesel Test Equipment

TCE – Tyre Changing Equipment

WBE – Wheel Balancing Equipment

FWA – Wheel Alignment

VLx – Lifts

BSA – Brake Testers

Bosch developers are working on enabling this equipment to be used in unison, with units ‘talking’ to each other and exchanging data, simplifying the task for the technician and speeding up servicing time.

The right Service Bosch offers a range of services to support independent garage businesses and technicians, including:

� Training

� Technical hotlines

� Dedicated resources in the field, visiting garage owners and technicians

� Garage concepts (Bosch Car Service, Bosch Diesel Centres and AutoCrew)

� Garage equipment servicing

Bosch aims to increase the level of expertise within independent garages, helping them to stay ahead in a competitive market.

A perfect example of this support is the Bosch Service Training Centre in Uxbridge, Middlesex, opened last year by HRH the Duke of York KG. This impressive site is dedicated to supporting the automotive aftermarket, with capacity to train 4500 technicians per year on everything from technical skills to customer service. The initial response proved overwhelming and as a result additional training dates have been announced to satisfy demand.

By demonstrating that it’s more than just a supplier of parts, Bosch plans to offer the best equipment, expertise and services to help garages safeguard their businesses. There’s a wide range of projects coming that will support and enhance this initiative, but if you want to find out more on how Bosch Automotive Aftermarket can support you, please visit www.boschautoparts.co.uk ■


AutoIntelligence | Issue 18 | Autumn 2013 3


Bosch training course dates: Oct - Dec 2013

Staying ahead in the automotive industry is always a race against progress, but the Data Engineering Centre team in Denham have been working hard to keep the Bosch KTS diagnostic tool right up to date.

Vehicle manufacturers regularly introduce new models and upgrade existing ones in line with emerging technologies. Now we have cars that can park themselves, engines that stop automatically when the vehicle stops and then re-start, and there are growing numbers of hybrids.

Keeping pace in terms of the KTS software is a demanding process. The UK and Ireland Data Engineering Centre (DEC), in Denham is one of 14 around the world in which over 300 engineers work on diagnostic coverage for the KTS range.

The work at Denham is focused on UK built vehicles, such as the products of

Jaguar and Land Rover. Recently the team has been supporting colleagues in Germany with developing Ford systems and taking responsibility for Triumph motorbike systems, which have been created for the [ESI]tronic Bike software. (available to existing [ESI]tronic 2.0 subscribers in 2014).

A key part of the process is ‘reverse engineering’ which helps the team to really understand the vehicle, increasing the value to the KTS user by introducing functions that may not even be on the OE tool. Here the background of Bosch as an OE manufacturer also helps as the team may have a better knowledge of the systems on a vehicle than perhaps even the vehicle’s manufacturer.

This detailed work is carried out by a dedicated team, but the results enable technicians to perform more effectively and independent garages to achieve main dealer service levels. ■

Data Engineering Centre takes a significant step forward in the UK

DEC Team

Mark Banks

Bernd Hummes

Kedar Raxa

Steve Meloy

ATABDT - ATA Assessment - Diagnostic Technician 01/10/13 - 1 day

VSG35 - Lambda Oxygen Sensor Diagnosis Bosch Trouble-shooting Workshop 01/10/13 - 1 day

VSC6 - Braking & Chassis Systems, ABS & ESP Automotive Technology Training 08/10/13 - 2 days

WTE4 - Operation of the Bosch FSA 500 Oscilloscope Workshop Test Equipment Training 08/10/13 - 1 day

VSE1 - Essential Test Procedures Automotive Technology Training 15/10/13 - 2 days

VSE7 - Automotive Electronics: Vehicle Sensors & Components Automotive Technology Training 15/10/13 - 3 days

VSTD33 - Understanding Diagnostic Fault Codes & Live Data Bosch Trouble-shooting Workshop 22/10/13 - 1 day

AC1RHA - Automotive Air Conditioning Refrigerant Handling Certification (IMIAL Level 3 QCF) 07/11/13 - 1 day

ATABMT - ATA Assessment - Master Technician 19/11/13 - 1 day

VSB26 - Automotive Air Conditioning Systems Diagnosis Automotive Technology Training 19/11/13 - 2 days

VSE11 - Automotive Electronics Advanced: ECU Control & Microelectronics Automotive Technology Training 26/11/13 - 3 days

VSD14 - Distributor Pumps System Diagnosis Automotive Technology Training 03/12/13 - 1 day

VSG5 - Engine Management: Diagnosis of Universal Components Automotive Technology Training 03/12/13 - 2 days

VSD16 - Unit Injector System Diagnosis Automotive Technology Training 04/12/13 - 2 days

VSTD9 - Oscilloscope Operation & Signal Test Methods Automotive Technology Training 10/12/13 - 2 days

VSH25 - High Voltage Vehicle Systems Diagnosis & Repair (IMIAL Level 3 QCF) Automotive Technology Training 17/12/13 - 2 days




Team changes and new members

New YouTube channel leads to smarter workingA brand new Bosch YouTube channel helps vehicle technicians to be better informed, with a smarter working approach. The channel can be found at www.youtube.com/BoschAutoPartsUK

Featuring videos on the latest automotive technology and best practice in car servicing and repair, the channel is accessible to all workshops in the UK and Ireland and can be viewed on mobile and other devices.

The videos cover a wide range of subjects, including vehicle technology, catalytic converter analysis, oscilloscope readings and the correct fitment of the Bosch Park Pilot reversing aid. Content is optimised to be easily identified and is visually appealing, with clear hints

and tips and practical ideas.

“With online access steadily rising among garages, conveying up-to-the-minute news and information via YouTube makes excellent practical sense and will support technicians in maintaining a high level of service to customers,” explains Mark Heard, Marketing Manager of Bosch Automotive Aftermarket UK.

“Every video we post on our YouTube channel is being developed to deliver maximum knowledge and expert advice on both technically challenging and standard maintenance work. We’ll also release details of our latest products and services, new vehicle technologies and vehicle maintenance advice for drivers.” ■

Bosch have launched a new bulb program with high quality bulbs of OE specification which are highly durable and offer an excellent service life. The range includes standard and upgrade bulbs and all the bulbs now have the recognised ‘Bosch’ logo stamped on them.

Bosch Bulbs

Dan Main National Sales Manager

Dan Main has been announced as the new National Sales Manager for Bosch and Beissbarth Workshop Test Equipment. Dan will be working closely with customers to better understand their needs and ensure they understand Bosch’s philosophy to support garages in increasing revenue and efficiency.

Dan’s background in the automotive industry makes him a perfect fit for the role: a Rover apprentice then Master Technician for three years, followed by Technical Trainer Instructor for the MG Rover Group and then the Ford Motor Group in Daventry.

In 2006, Dan became Service Operations Manager at Delphi, responsible for training and the technical helplines.

Dan and his team will be the face of the Workshop Test Equipment business for Bosch customers and have the objective of delivering sales growth and a larger market share.

Dan replaces Dave Buffey who has moved to a key account manager position within Bosch Automotive Aftermarket.

Other recent appointments and team changes at Bosch:

Roy Rogers, Sales Manager, Retail and Fleet

Mark Heard, Marketing Manager.

Iain Procter, Product Specialist, Diesel.

Helen Watkins, Marketing Communications Manager

Claire Cassidy, Bosch Diesel Centre Concept Manager/Consumer Communications Manager

Ricky Rai, Customer Database Coordinator

Alex Raynor, Workshop Business Developer

Steven Mould, Workshop Business Developer

Oliver Westlake, Workshop Business Developer




Fast, precise and user-friendly Bosch Battery TesterApproximately 17 out of every 100 cars visiting a workshop may require battery replacement, which can lead to a sale, and more importantly, saving the customer the inconvenience of a flat battery. To support workshops with effective testing of batteries and provide more opportunities to sell batteries, Bosch offers a range of battery testing and charging equipment. That's why Bosch recommends garages to test every single car that enters the workshop.

When designing the BAT 131, Bosch took account of the workshop conditions in which it will be used. The robust housing enables it to withstand the knocks and bumps it will inevitably endure. It is supplied with 3 metre long replaceable cables which provides added flexibility when carrying out battery and starter/alternator diagnosis.

The BAT 131 portable battery tester

is ideal for testing both 6 volt and 12 volt starter batteries, whether lead-acid, gel or fleece/AGM, and incorporates an advanced starter and alternator test capability.

The device supports a wide range of applications including car, commercial vehicle, motorcycle and marine along with testing norms in a CCA range up to 2000 amps.

Its intuitive operation and the load free test function provide fast, precise and reliable measurement results on a large LCD screen. The optional use of a current clamp also improves test results and the tester displays a “wrong polarity” message when not connected properly.

An integrated printer provides a simple to understand printout which can be given to customers to show the condition of the battery and advise if a new battery is required. The printout can carry

customised workshop information in the header and a date and time stamp is also available. Up to one hundred test reports can be stored on the device and these can be downloaded through the USB port. This function allows a history of service records to be maintained for future follow-ups with customers.

The BAT 131 can be used to test new, unused in-stock batteries prior to fitting. Also, extended tests can be carried out for both 12 volt and 24 volt starting and charging systems. ■

Are you missing out on battery business?




When businessman Steve Churchill opened his third garage, he knew that a sure-fire way of ensuring its success was signing it up to the Bosch Car Service scheme.

Since Steve’s first garage, Four Square Garage in Dorset, joined the Network in 2005, he has seen the business go from strength to strength. So, when he bought Bickerley Garage, in Ringwood, Hampshire, there was no question of how he would differentiate the business from other garages.

“I could have joined any garage scheme,” explained Steve. “However we didn’t want to become just another independent garage, we wanted to stand out and, given the success of my other two sites, Bosch Car Service seemed the only way forward.”

The team at Bickerley Garage realised that most customers’ major gripe was that fact that other garages don’t always identify the root of the problem from the outset. This is why Steve’s aim is to get it right,

first time every time and, in order to achieve that, he has invested heavily in training his employees at the new Bosch Service Training Centre in Uxbridge.

“Being part of the Bosch Car Service Network means that we are constantly having to push ourselves harder and further in order to keep up with Bosch’s high standards making us the best we can be, which is why we have recently made a significant investment in new equipment. The latest equipment we have purchased is Bosch DCU 130 and the Oscilloscope FSA 500”. Steve added.

The Bosch Car Service package offers its members marketing and PR support, signage and a customer care programme, all of which have provided valuable support to Steve’s three garages and he’s also been able to draw on Bosch’s training schemes and technical expertise. “Little details, like the easy-to-use postcode search facility on the new Bosch Car Service booking website, make all the difference in helping us reach more motorists,” says Steve.

For more information on how you could benefit by joining Bosch Car Service email [email protected] or visit boschcarservice.co.uk. ■

The dedicated WBD Team

Steven GloverTel. [email protected]

Alex RaynorTel. 07792144417Alex.raynor@ uk.bosch.com

Oliver WestlakeTel. [email protected]

Steve MouldTel. [email protected]

Iain MacleodTel. 07977548941Iain.macleod@ uk.bosch.com

Bosch Car Service Scheme Boosts Business

Bickerley Garage, Hampshire




BCS network gets a huge boost in supportWith an investment in both personnel and resources, Bosch UK has significantly increased the level of support it provides to members of the Bosch Car Service network, with a new team of Workshop Business Developers.

Encompassing the role of the old BCS Development Managers, the new team of Workshop Business

Developers (WBDs) will provide an increase in the level of expertise available to the BCS network, helping them to get the best from the scheme as well as the latest information on Bosch’s portfolio of Parts, Bytes and Services.

Headed by Steve Shorto, as Workshop Business Manager, the new structure retains the

expertise of the old five-strong team, and increases in size to 11 WBDs. This means that each WBD now covers a smaller geographical area, allowing a more focused approach to driving forward the network and maintaining its high standards.

“We have reconsidered how best to support the BCS garages, and concluded that the entire Bosch field based team should be reorganised into one, highly efficient unit,” explains Steve Shorto. “This will allow a closer working relationship with the garages, and deliver technical and commercial expertise when and where it’s needed.” ■

Steve RouseTel. 07818017317Steve.rouse@ uk.bosch.com

Dave LloydTel. 07854829763Dave.lloyd@ uk.bosch.com

Steve HenryTel. [email protected]

Shaun KillianTel. 07778257774Shaun.killian@ uk.bosch.com

Gary WalkerTel. 07790488293Gary.walker@ uk.bosch.com

Peter Flynn Tel. [email protected]

Steve ShortoWorkshop Business Manager

Iain Macleod & Brian Muir

David Lloyd

Gary Walker

Peter Flynn

Shaun Killian

Steven Glover

Steve Mould

Alex Raynor

Oliver Westlake

Steve Rouse

Steve Henry




Joti RandhawaProduct Specialist

111 Years ago, Robert Bosch was awarded a patent on his high voltage magneto and spark plug combination. It was an event that marked a significant turning point in the development of the internal combustion engine and the start of the Bosch success story.

The crucial function it performs within the engine cycle requires it to operate to a high level of precision. The average spark plug has to withstand more than 30,000 volts without causing the insulator to breakdown, while the electrical resistance of the insulator has to be good enough to function at temperatures of up

to 1,000ºC without overheating, if operated for long periods at maximum load.

In the 111 years since the patent, Bosch has continuously developed the spark plug, working closely with nearly every vehicle manufacturer to produce more than 20,000 types to date. These variations have played an essential role in the development of the engine, contributing to higher performance, greater fuel economy and reduced environmental impact.

The latest spark plugs from Bosch offer a tailor-made range for workshops in the aftermarket

sector with clear-cut assignment to specific engines.

The current range includes 1,250 different versions and 31 different electrode designs. It consists of the Bosch Super/Super Plus with a factory-set electrode gap for constantly high performance, even at combustion temperatures of up to 3,000 ºC. Bosch Platinum plugs have similar levels of wear resistance thanks to the platinum coating on both electrodes. Bosch Super 4, part of Bosch’s upgrade range, offers 60% greater efficiency versus the Super/Super Plus equivalent for higher engine output. ■

A bright spark...

Joti RandhawaProduct Specialist

111 Years ago, Robert Bosch was awarded a patent on his high

to 1,000ºC without overheating, if operated for long periods at

sector with clear-cut assignment to specific engines.

Often seen as a ‘fit and forget’ item, the humble spark plug is one of the most important components to have revolutionised transportation since the invention of the internal combustion engine. Here, we take a look at Bosch spark plugs and how they have developed to meet modern demands.




With vehicle emissions and engine efficiency becoming increasingly important, the role of the air mass meter has never been greater. However, behind a relatively simple concept lies a surprisingly complex component.

Air mass meters, or mass flow sensors, play a vital role in ensuring that fuel injected combustion engines operate at their optimum efficiency. No matter what the engine speed, the air mass meter provides a stream of data to the electronic control unit (ECU), in order to control the ratio between the air and fuel entering the combustion chambers. If an air mass meter is not performing there’s a strong chance that the exhaust gas emissions are not within legal limits.

The sharp rise in low quality copy air mass sensors in the aftermarket means that it’s relatively easy to fit a part that will have a negative impact on an engine. Tests carried out by Bosch have shown that fake or copy parts do not deliver the durability of a Bosch OE standard unit and can both reduce fuel efficiency and raise emissions. In extreme cases they can cause costly damage to the engine, causing warranty problems, and even safety issues.

With air mass meters so critical to engine performance, it’s not only important to ensure the part is perfectly matched to the vehicle, but also that it has been manufactured to Original Equipment standards. Roughly half of Europe’s cars are fitted with Bosch Air Mass Meters as standard, and the company’s work in developing and producing engine management systems means that it has unrivalled expertise.

As you would expect, genuine Bosch units are precision engineered, tested and produced under the highest production standards.

Premium quality, recyclable materials are used, and the hot film air mass meter (HFM) range uses the latest miniaturised hybrid circuit and film technology. The sensor elements and housings are calibrated to exact tolerances as a complete unit, and the HFM range, developed solely by Bosch, covers both older and newer vehicles.

How to spot a fake Spotting fake or poor quality air mass meters isn’t always easy, but there are a few clues that can help identify genuine Bosch parts. Always look for the Bosch branding and that it’s accompanied with the armature logo. The part number should also be marked correctly and completely on the part itself and check that the plant code (the location of manufacture) is also present. Bosch air mass sensors carry a date code (a five digit number showing year,

month and day of manufacture: additional numbers also indicate production line and work shift) so you know when it was produced. The general appearance of the part is also an important clue. Poor grade plastics with a pungent smell are a sure give away and the tamper-proof screws holding the sensor into the housing should be 5-sided Torx screws instead of the more common 6-sided versions.

After fitting a new air mass meter, Bosch recommends changing the air filter and making sure the air filter housing is absolutely clean because the air filter cleans the combustion air drawn in and guards all the engine components behind it against dirt deposits and hard particles.

For more information on Bosch air mass meters visit www.boschautoparts.co.uk

The Vital Role of Air Mass Meters




DPF's are prone to malfunctioning as a result of becoming blocked or full, particularly when the vehicle makes an excessive number of short journeys. So knowing how to resolve this and the signs to look out for is very important. Lee Duffy and Matt Kyme from Bosch are our experts to tell you how.

Achieving the tough vehicle emissions levels under Euro 5 legislation requires a Diesel Particulate Filter (DPF) to be fitted to collect carbon soot particles generated from the combustion process in a diesel engine.

These particles are microscopic balls of carbon around which are deposits of different hydrocarbon compounds, metal oxides and sulphur, some of which are potentially hazardous to health.

A blocked or malfunctioning DPF will result in a fault code appearing (see list of typical DPF fault codes), such as P1471 – DPF regeneration

not completed. When this happens the first response is to try running a regeneration of the filter to see if that solves the problem.

Forced regeneration is a simple procedure that can be carried out by a technician and is usually needed because an active regeneration has not been successful during everyday driving by the driver. Depending on the type of diagnostic programme available this can either be a Static Regeneration or a Regeneration Run.

To carry out a Static Regeneration the vehicle is normally positioned outdoors on a suitable surface and the regeneration is initiated and controlled by the KTS. Strict safety procedures must be observed prior to and during this process.

For a Regeneration Run the technician must select the programme on the KTS and take the vehicle for a drive at a moderate cruising speed for a suitable period of time, usually about 20 minutes. The KTS initiates the Regeneration Run and monitors the process throughout so a second person is required to operate the KTS while this is being performed.

Bosch runs a half day training course (VSD 36) for technicians who wish to effectively diagnose faults with Diesel Particulate Filters.

The course covers the design and function of a DPF, what the driver

Technical Tip – Solving DPF Fault Codes

Bosch Automotive Aftermarket Opens New Plant in ChinaA state-of-the-art plant for the production of spark plugs, brake pads and workshop test equipment in Nanjing, China, is the result of a 120 million Euro investment by Bosch.

The new plant is the biggest investment Bosch Automotive Aftermarket have ever made in expanding production capacity. When it reaches planned capacity in 2015, the new plant will

be able to produce 125 million spark plugs, 80 million brake pads and 25,000 testing units a year. Only state-of-the-art manufacturing techniques will be utilised ensuring Bosch’s exceptional quality standards are met.

Over 2,000 people are already employed at the Nanjing plant and this is set to total some 3,500 by 2015. In addition, a new research and

development centre on the site will employ a team of over 100 engineers working to develop safe, efficient and practical solutions for Bosch’s workshop customers across in Asia Pacific. ■

Diesel Particulate Filter PM = Particulate Material




Technical Tip – Solving DPF Fault Codes

Typical DPF fault codes:

P1471 Diesel particulate filter (bank 1) regeneration not completed

P2002 Diesel particulate filter (bank 1) efficiency below threshold

P2003 Diesel particulate filter (bank 1) particulate mass too high

P242F Diesel particulate filter (bank 1) regeneration not active

P244A Particulate filter differential pressure too low

P224B Particulate filter differential pressure too high

P2452 Particulate filter differential pressure sensor malfunction

P2453 Diesel particulate filter differential pressure sensor malfunction

P2454 Diesel particulate filter differential pressure sensor voltage too low

P2455 Diesel particulate filter differential pressure sensor malfunction

P2458 Particulate filter regeneration maximum regeneration time exceeded

P2459 Particulate filter regeneration, regeneration frequency implausible

may experience with a blocked DPF, and what conditions might cause the DPF to block prematurely, giving a technician background information on DPFs before covering the different types of regeneration strategies.

To find out more information about the VSD 36 course or to book a place, please visit: http://www.boschautoparts.co.uk/training or call: 01895 816160. ■

Matt KymeTechnical Support Advisor

Matt KymeMatt KymeMatt KymeMatt Kyme

Lee DuffyTechnical Support Manager




As the popularity of motor vehicles grew in the early part of the 1900s, Bosch looked at how lighting could be incorporated into the first vehicles.

Development work on a system began in 1910 and by 1913 it was in full scale production. Consisting of an alternator, regulator, battery and headlights, it formed the basis of today’s vehicle electrical systems - with the alternator at its heart.

All Bosch alternators and replacement parts are manufactured to Original Equipment quality and use advanced technology enabling them to support drive systems that save fuel and CO², such as

start/stop systems.

In 1933, Bosch was the first company in the world to introduce a combined alternator and starter motor. In 1958, it introduced the Variode, a semi-conductor device which allowed just the right amount of electricity to flow into the battery. These were replaced after 1967 by smaller temperature-resistant silicon rectifiers called diodes.

Lower noise levels and a 25% increase in power came in 1989, when the Kompaktgeneratoren LI-C was introduced. In 2005, the Highline alternators brought greater efficiency and in 2008, Bosch introduced the new Baseline alternators aimed

at small vehicles with lower electrical demands.

The new generation Efficiency Line alternators, launched in 2011, boast an improved electrical design and achieve a remarkable 77% efficiency level. This contributes to reductions in fuel consumption as well as CO2 output of up to 2% - good for motorists and good for the environment.

Detailed information on all these systems is available in ESI [tronic], Tecdoc, and Bosch catalogues and complete documentation exists, stretching back over 75 years. ■

A century of electrical powerA century of electrical power




Training Centre goes from strength to strengthJust one year after its grand opening by HRH the Duke of York, the Bosch Service Training Centre (STC) is proving a hit with the Automotive service and repair industry.

The 2000 square metre multi-million pound facility in Uxbridge has the capacity to train over 4500 delegates a year. Additional training course dates have been added in 2013 to keep up with demand. Covering topics such as understanding diagnostic fault codes, common rail solenoid injector faults, lambda sensor diagnostics and steering geometry with four wheel alignment, the training is designed to help workshops stay up to date with the latest automotive technology.

Bosch has been working with the Institute of the Motor Industry (IMI) for many years and the STC is key to supporting the Institute’s Automotive Technician Accreditation (ATA) training. The technician training programmes at Diagnostic and Master Technician level incorporate exactly the right level of practical skills and theory. At the completion of each module, technicians take the ATA assessment and successful

candidates receive an ATA qualification. The Bosch Training Team has also been developing new courses, including ATA Vehicle Inspection and ATA Service Maintenance Technician .

For more information on all of the STC courses please contact 01895 81 6160 ■

Recently Bosch celebrated a significant milestone as the 10-millionth common-rail system for commercial vehicles (CRSN) rolled off the production line.

Since it was first launched in 1999, CRSN technology has developed rapidly with injection pressure increasing from 1,400 to 2,500 bar over four generations of the system. Today, Bosch systems are delivering enhanced efficiency and lower emissions across a wide range of commercial vehicles, off-highway and maritime applications. ■

Ten million Common-Rail Systems




The new Audi A3 features Adaptive Cruise Control (ACC) with “Stop & Go” function, which keeps the car at a distance specified by the driver from the vehicle in front, even at the maximum legal motorway speeds. The system is able to bring the car to a complete standstill behind a vehicle that has stopped and then automatically pull away again at the driver’s discretion.

In addition, Audi has recently confirmed its commitment to safety, thanks to innovative solutions from Bosch. At 30 km/hr or below, the system initiates exactly the right deceleration rate in order to avoid a possible collision with a stationary or moving vehicle. For this purpose Bosch provides the new-generation long-range radar sensor - LRR

This emergency braking function is supported by a new multi-purpose camera, by relaying objects detected in front of the vehicle to the LRR. For the “Audi active lane assist” lane departure warning system, the system even identifies lane markings and measures the position and alignment of the vehicle in relation to the lane.

The smart main beam control from the camera identifies road signs and the system is able to detect the current speed limits at road works and on variable signs in addition to detecting permanent signs.

Other Bosch systems in the Audi A3 include the injection systems for both petrol and diesel engines, the alternator, starter, glow plugs, lambda sensor and both the front and rear wiper systems.

Bosch also supplies new long-life double platinum spark plugs for the Audi A3 77 kW engines, which are designed to deliver the higher ignition voltage and flashover resistance required by modern, downsized engines.

The plugs’ advanced design ensures that the position of the ground electrode is perfectly aligned relative to the combustion chamber and the position of the fuel injection valve. This ensures that the air/fuel mixture has perfect access to the ignition spark. ■

For car drivers around the world, Audi represents quality, top-class design and the highest standards of technical expertise.

Advanced Bosch safety system for new Audi A3

Winner of the ‘Car of the Future’ category at the coveted awards, held in Germany, was the BMW 520d EfficientDynamics Edition BluePerformance model, equipped with a Bosch CRS2-18 common-rail injection system.

The Volkswagen Eco Up! was named “Best Innovation” in the “Innovation and Environment” category. Bosch worked with Volkswagen to deliver the injection technology found in the three-cylinder 1.0 litre engine and supplies the engine management system: injectors for both natural gas and gasoline, the gasoline rail and the lambda sensor system, as well as a mean pressure temperature sensor.

The engine can run on gasoline or on compressed natural gas (CNG) and delivers 50 kW (68 horsepower) at 6,200 rpm, reaching a maximum torque of 90 Nm at 3,000 rpm. In the NEDC the Eco Up! consumes just 2.9 kilograms of natural gas over 100 kilometres, corresponding to CO2 emissions of just 79 grams per kilometre. Burning natural gas produces up to 25 percent less CO2 than gasoline, making CNG a particularly eco-friendly form of fuel. The vehicle’s carbon footprint is even smaller when running on

biogas. ■

Bosch technology helps vehicles win prestigious Yellow Angel awards




Bosch in the ŠKODA Citigo

� Airbag� Alternator� Pressure/

temperature sensor

� Knock sensor� Fuel rail� Starter� Engine control unit� Wiper drive� Spark plug

Bosch puts the spark in Citigo

Launched last year to great acclaim, the new ŠKODA Citigo car boasts impressive range technology from Bosch.

The airbag, alternator, sensors, fuel rail, wiper drive, starter and engine control unit are all supplied by Bosch, while the nickel-yttrium spark plugs have been specially developed to meet the challenges of higher final compression in the combustion chambers of smaller modern engines.

This nimble urban runabout seats four comfortably and offers best-in-class storage space, from 251 litres up to 951 litres with the rear seats folded down. Citigo’s urban credentials are further enhanced by its extremely thrifty three-cylinder engine, available at two power ratings: 44 kW (60 hp) and 55 kW (75 hp).

Citigo is available with the latest Green tec environmentally friendly technology. This includes energy recovery when braking, tyres with reduced rolling resistance and automatic start/stop technology, which was specially developed by Bosch for ŠKODA’s Green tec engines.

When the vehicle comes to a halt the engine automatically switches off when in neutral gear and to set off again the driver simply depresses the clutch. As a result the 44 kW (60 hp) Citigo with Green tec has a combined consumption of only 4.1 liters per 100 km and produces CO2 emissions of 95 g/km. ■




Bosch is a one-stop supplier for electric drives

Deutsche Tourenwagen MastersAll three vehicle manufacturers in the popular DTM international touring car series have once again opted to used Bosch engine management systems in their cars.

All DTM cars – the Audi RS5, BMW M3 and Mercedes-Benz AMG C-Coupé – are equipped

with Bosch Motorsport’s MS 5.1 engine management system.

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 wiring harness, wiper motors, and the power box.

“For every race series, whatever the application, Bosch offers the right technology,” says Klaus Böttcher, Vice President of Bosch Motorsport. ■

F3 racing carsBosch is adding to the excitement of this year’s FIA Formula 3 European Championship with its specially engineered motor sport technology featuring in the cars of all 22 teams.

Every car uses Bosch engine management systems and fuel injection technology and each is equipped with Bosch technology

for their intake manifold and gasoline direct injection engines.

Dr. Klaus Böttcher, Vice President of Bosch Motorsport, says: “The new direct injection engines are equipped with hydraulics components based on state-of-the-art series engineering that has been optimised to meet the requirements of motor racing. These include the HDEV 5.2 high-pressure injection valve and

the HDP 5 high-pressure pump, which is especially compact and lightweight.”

Data loggers, wire harnesses, starters and generators, as well as a broad range of sensors are amongst other equipment supplied. Bosch Motorsport has even developed a new steering wheel with an integrated display and shift paddles for use in Formula 3 cars. ■

Did you know, Bosch supplies systems for electrical powertrains? The Bosch portfolio includes all the components needed for modern electric drives - including electric motors, power electronics, batteries and regenerative braking - and can also combine them to form complete systems.

The best demonstration of this is the Fiat 500e. For this Italian-designed electric car, Bosch provides the complete powertrain. The technology in the Fiat 500e shows that Bosch not only manufactures components, but also has the expertise to combine these into a complete electrical powertrain.

And this electric drive certainly has power: thanks to the SMG 180/120 electric motor developed by Bosch, the Fiat 500e delivers 80 kilowatts of power. The permanent magnet synchronous motor is the drivetrain's powerhouse. Right from the start, it delivers 196 Newton metres of torque.

How it works: the central interface between electric motor and battery is the Bosch INVCON 2.3 inverter. This power electronic device is the command centre of the electrical powertrain. The pulse inverter transforms the direct current stored in the battery into alternating current for the electric motor. The reverse happens during braking: it

converts the alternating current generated by recuperation into direct current. This is the only way energy released while braking can be stored in the battery.

The DC-DC converter transforms high voltage into power for the 12-volt vehicle electrical system and also supplies power from the lithium-ion battery to comfort and safety systems such as electric steering and ESP, as well as to all the control units in the vehicle electrical system.

Finally, the Bosch battery pack allows the Fiat 500e to have a range of around 140 km, making Bosch a one-stop supplier of electric drives.


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