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Spare parts and accessories
Engine management | Gasoline injection
Expertise and quality – for the future of your workshop
Editorial closing: 31. 07. 2007
Subject to change without
notice. Please direct questions
and comments to our
Authorized Representative in
your country. This edition
supersedes all previous
editions.
2008 | 2009
Engine
management
Gasoline injection
2008 | 2009
4 047023 038968
Just right!
Lambda sensors from Bosch
Explanation of symbols
Part number
Date / Production period
The right sensor!
The right cable!
The right connector!
Electric fuel pump (in-line/in-tank)
Universal electric fuel pump
EKP non-return valve
Search number
Passenger cars
Original equipment number / Return number
Passenger cars / Small vans
Core deposit values
Quantity per pack
O-rings - Quantity per injector
pcs
Fuel inje ctor
O-ring on top
O-ring below
Parts kit
Export market
Special case
Convincing reasons for choosing Bosch lambda sensors
Bosch invented the lambda sensor.
Bosch has the most know-how in terms of development and
production. Since then Bosch has made more than 400 million
lambda sensors.
Bosch lambda sensors are all available in OEM quality.
Bosch has patented this convincing technology.
Most automobile manufacturers around the world use
Bosch lambda sensors as original equipment.
As market leader in the OEM and aftermarket sector, Bosch has
the ideal replacement sensor for more than 80 % of all vehicles.
Bosch has a comprehensive range of multipurpose lambda
sensors.
The multipurpose lambda sensors won awards at the Auto-
mechanika 2004 and the “Equip Auto 03” exhibition in Paris.
All your advantages at a glance:
Bosch lambda sensors…
… always right
through exact application data.
… save up to 15 % fuel
… avoid expensive consequential damage
as, e.g. a faulty catalytic converter.
… minimize emissions
The most stringent emission levels can be complied with.
… optimize engine performance
… are resistant
to splash water and contamination through the use of a stainless,
laser-welded steel casing.
… have a long service life
through continuous innovations such as, e.g. optimized protective
electrode layers and suitable protective tube devices.
… undergo 100 % functional testing in the manufacturing plant
… come with a pre-greased thread
Technology, program
Content
A 2 Counterfeit and imitation products
A 3 More than 100 years of Bosch ignition systems
A 4 Ignition and gasoline-injection systems from Bosch
A 6 Gasoline injection systems
A 14 Electric fuel pumps
A 20 Sensors
A 21 Gasoline injectors
A 22 Ignition coils
A 24 eXchange – Back in Box
Applications
Cross-reference
A 26 eXchange – conditions for component return
A 30 Gasoline injection components
A 46 Central injection unit (ZEE)
A 50 Parts-assortment case
A 54 List of applications for O-rings
A 72 Low-way plug-in connections
B 1 Vehicle-specific equipment
B 2 Overview contents
B 9 Passenger cars, vans
C 2 Non-Bosch Bosch
C 92 Bosch-original parts (new) Bosch Exchange (BX)
C 99 Bosch (OE) Bosch Aftermarket (IAM)
2008 | 2009 Bosch Automotive Aftermarket
A2 |
A2 | Counterfeit and imitation products
Counterfeit and imitation products
Important information
Warning about Lambda sensors
Be wary of using universal sensors which do not meet the standards
of vehicle manufacturers. There is a risk of premature damage and
thus failure of the Lambda sensor. In the interests of your customers please therefore make exclusive use of genuine Lambda sensors or universal Lambda sensors from Bosch.
Warning about electric fuel pumps
Certain rival companies make use of inferior imitation products instead of high-performance Bosch pumps. This can lead to problems
when driving and to a loss of engine power due to an inadequate
fuel supply. In the interests of your customers please therefore
make exclusive use of genuine fuel pumps from Bosch.
Warning about the use of non-Bosch air-mass meters
Only genuine air-mass meters from Bosch can ensure compliance
with the legally prescribed emission values. The vehicle homologation will be invalidated if use is made of air-mass meters from other
manufacturers. In addition, this can result in a considerable loss of
engine power and thus higher fuel consumption.
Warning about ignition coils
Bosch ignition coils always provide the engine with sufficient energy
for the ignition spark. This prevents cold-starting difficulties and
exhaust-emission test problems. The high-grade plastic or asphalt
insulation materials used by Bosch ensure a high breakdown voltage
and guard against the risk of fire, in contrast to the oil-based products of certain low-cost suppliers. High-precision, corrosion-proof
connections form the basis for a long product service life.
More than 100 years of Bosch ignition systems | A3
More than 100 years of Bosch ignition systems
1
2
7
Bosch started supplying high-voltage magnetos and spark plugs
as far back as 1902.
After 1910 the ignition distributors were separated from the
high-voltage source.
When Robert Bosch AG presented the battery-ignition system
in 1925, magneto ignition was predominant in the automotive
industry. This was considered to be the most reliable form of
ignition system.
At the same time, vehicle manufacturers were demanding a less
costly system and in the light of constant progress battery ignition
quickly became established in the automobile and motorcycle
industry throughout Europe.
8
6
5
3
4
In 2001, Bosch celebrated 50 years of gasoline injection.
The first experiments with injection systems for gasoline engines
took place in 1921. Following extensive trials between 1923 and
1928, gasoline injection was initially restricted to aircraft engines.
Whereas reliability and increased performance were the crucial
aspects with regard to aircraft engines, the economy aspect was
the main motivation in the development of automobile gasoline injection systems.
The Bosch gasoline-injection system presented at the Frankfurt
Motor Show in 1951 for the Gutbrod Superior two-stroke engine
achieved fuel savings of around 20 percent and raised the vehicle
power from 23 to 28 hp.
Nowadays, more advanced versions of this type of ignition are
standard equipment in virtually every gasoline-engine motor vehicle.
Spark plugs
H.T. cables
Distributor cap
Distributor rotor
Ignition distributors
Ignition coil
From battery
To contact breaker
The power-enhancement aspect was however the major factor in
the first mass-produced four-stroke vehicle with gasoline injection
(Mercedes 300 SL). The advantages offered by fuel injection ousted
the carburetor.
In 1967, in the light of stringent US emission legislation,
VW launched the 1600 TL with Bosch-Jetronic, thus marking the
introduction of electronic injection control. By 1972 the Jetronic
system was the choice of 18 manufacturers and well on its way
to success.
A4 | Ignition and gasoline-injection systems from Bosch
Ignition and gasoline-injection systems from Bosch
More than a century of system expertise
Renowned vehicle manufacturers rely on Bosch as original equipment supplier and thus form the basis for a fruitful replacement
parts business.
In addition to the full range of more than 10,000 items for gasolineinjection systems, Bosch also supplies the aftermarket and workshop sector with the appropriate replacement and wear parts.
1902 Delivery of the first high-voltage magneto and the first spark
plug
1910 Separation of ignition distributor and high-voltage source
1925 Presentation of battery-ignition system by Robert Bosch
GmbH
L-Jetronic components
KE-Jetronic components
1951 Presentation of Bosch gasoline-injection system at the
Frankfurt Motor Show
1967 First emission legislation in the USA
Introduction of the first electronic injection system:
The D-Jetronic controlled by intake-manifold pressure.
1973 Energy crisis – fuel consumption becomes the focus of
development efforts
Market launch of the L-Jetronic with air-flow sensor and the
K-Jetronic with mechanical-hydraulic control – this was also
an air-flow sensing system.
1976 Bosch invents the Lambda sensor, thus paving the way for the
closed-loop-controlled catalytic converter.
1979 Motronic market launch
The unique feature of this system was the digital processing
of a wide range of engine functions. It combines the
L-Jetronic principle with electronic map-controlled ignition.
The first microprocessor to be fitted in a motor vehicle.
1981 LH-Jetronic market launch
Instead of a flap-type air-flow sensor, the basic L-Jetronic
system was equipped with a hot-wire air-mass meter and
marketed for the first time as LH-Jetronic.
Motronic components
Bosch Automotive Aftermarket 2008 | 2009
1982 KE-Jetronic market launch
The K-Jetronic was extended to include an electronic
control loop and the Lambda sensor and was employed
for the first time in a mass-produced vehicle in the
form of the KE-Jetronic.
1987 Mono-Jetronic market launch
The Mono-Jetronic is a particularly inexpensive single-point
injection system, making it feasible to equip even smaller
vehicles with Jetronic.
1989 Mono-Motronic market launch
The Mono-Motronic is a more advanced form of the MonoJetronic and has been extended to incorporate an electronic
map-controlled ignition and a microprocessor.
Ignition and gasoline-injection systems from Bosch | A5
1989 Electronic throttle control (ETC)
With ETC systems, the driver input is detected by a sensor
at the accelerator pedal. The Motronic control unit evaluates
the sensor signal and adjusts the electric motor-driven
throttle valve, taking into account other vehicle and engine
data.
1997 Increasing use of intake modules
Intake modules are pre-assembled units comprising the
intake manifold with injectors, throttle-valve unit, pressure
regulator etc.
2000 Market launch of Motronic gasoline direct injection
The Motronic MED 7 system with torque-based control makes
it possible to combine extremely economical fuel consumption and highly dynamic performance.
Mono-Jetronic components
Intake module
Gasoline direct injection
2008 | 2009 Bosch Automotive Aftermarket
A6 | Gasoline injection systems
Gasoline injection systems
K-Jetronic
7
6
5
9
Further technical information can be found
in the “K-Jetronic” booklet.
Part number 1 987 722 159.
The booklets are available from franchized
Bosch wholesalers.
10
2
The K-Jetronic is a mechanical system in
which the fuel is constantly metered on the
basis of the volume of air drawn in by the
engine.
The K-Jetronic was used as original equipment in mass-produced vehicles between
1973 and 1995. Since then, the K-Jetronic
has only been of relevance in terms of
service and maintenance work.
Further technical information can be found
in the “KE-Jetronic” booklet.
Part number 1 987 722 101.
The booklets are available from franchized
Bosch wholesalers.
13
9
11
The KE-Jetronic is a mechanical/electronic
injection system based on the K-Jetronic.
Additional electronics record a variety of
measurement quantities at the engine, thus
permitting optimization of fuel requirements
and emission quality.
Further technical information can be found
in the “L-Jetronic” booklet.
Part number 1 987 722 160.
The booklets are available from franchized
Bosch wholesalers.
9
6
The L-Jetronic is an electronically controlled injection system featuring air-flow
measurement based on the sensor-plate
principle and electromagnetically controlled
fuel injection into the intake manifold. All
engine-related changes are recorded by
a variety of sensors and processed in the
electronic control unit. This ensures constant good emission quality in combination
with low fuel consumption.
Further technical information can be found
in the “L-Jetronic” booklet.
Part number 1 987 722 160.
The booklets are available from franchized
Bosch wholesalers.
9
6
The LH-Jetronic is closely related to the
L-Jetronic. It differs in terms of the recording of the volume of air drawn in by the
engine, which in this case is performed by
a hot-wire air-mass meter. This measures
the air mass drawn in by the engine.
The measurement result is thus independent of temperature and pressure.
7
2
10
1
Electric fuel pump
Fuel filter
Fuel-pressure regulator
Injector
Hot-wire air-mass meter
Engine-temperature sensor
Rotary idle actuator
Throttle-valve switch
Lambda Sensor
N Electronic control unit
2008 | 2009 Bosch Automotive Aftermarket
A10 | Gasoline injection systems
Mono-Jetronic
6
5
4
7
3
2
8
9
Further technical information can be found
in the “Mono-Jetronic” booklet.
Part number 1 987 722 105.
The booklets are available from franchized
Bosch wholesalers.
The Mono-Jetronic is an electronically
controlled single-point injection system in
which a solenoid injector injects the fuel
for all cylinders at a central location above
the throttle valve. The operating data are
recorded by way of sensors and converted
into injection pulses in an electronic control
unit.
10
1
Electric fuel pump
Fuel filter
Throttle-valve potentiometer
Pressure regulator
Injector
Connector with intake-air temperature
sensor
Throttle-valve actuator
Engine-temperature sensor
Lambda Sensor
N Electronic control unit
Bosch Automotive Aftermarket 2008 | 2009
Motronic manifold injection
Gasoline injection systems | A11
Further technical information can be found
in the “Motronic” booklet.
Part number 1 987 722 161.
The booklets are available from franchized
Bosch wholesalers.
12
10
6
9
3
4
11
The Motronic combines the injection and
ignition systems to form an engine-management system. Fuel metering and ignition are
optimally matched. Other electronic functions can also be incorporated. Digital data
processing and the use of microprocessors
make it possible to convert a wide range of
operating data into map-controlled injection
and ignition data.
The principal function of the engine-management system is to set the driver’s torque
input whilst at the same time achieving
optimum fuel consumption and the lowest
possible emission level. The ME-Motronic
engine-management system combines
all the sub-systems required for this: The
electronic throttle control (EGAS) sets
the amount of air needed to generate this
torque. The corresponding fuel mass is controlled in the gasoline injection sub-system
and the ignition sub-system sets the appropriate ignition point as well as the necessary ignition energy.
In combination with other electronic systems in the vehicle, the ME-Motronic also
enhances ride comfort and user safety. If,
for example, an ABS or ESP system requires
a specific engine torque to provide vehicle
traction, the ME-Motronic sets the necessary torque.
The sub-systems have become more closely
integrated in order to deal with this wide
range of engine-management tasks.
Engines with gasoline direct injection form
the air/fuel mixture directly in the combustion chamber. Only fresh air flows through
the open intake valve on the induction
stroke. Special injectors inject the fuel
directly into the combustion chamber at
high pressure. Exact metering, conditioning and distribution of the air and fuel for
each individual combustion stroke permit
economical fuel consumption and a low
level of emissions. With its torque-based
electronic control function, the DI-Motronic
from Bosch sets new standards in the field
of gasoline direct injection. The intelligent
system adapts all the relevant quantities to
the corresponding driving situation with a
high degree of accuracy. In part-load mode
it generates a lean stratified air/fuel mixture
and at full load a homogeneous mixture.
Operation: With gasoline direct injection,
the high-pressure pump supplies the
high-pressure circuit with fuel at the high
pressure required for the fuel rail. The highpressure injector attached to the fuel rail
very quickly meters and atomizes the fuel
at high pressure, thus ensuring the bestpossible formation of the air/fuel mixture
directly in the combustion chamber.
J Electronic control unit
N Diagnosis interface
O Diagnosis lamp
Q Immobilizer
M CAN
K Delivery module with presupply pump
, Speed sensor
2008 | 2009 Bosch Automotive Aftermarket
A14 |Electric fuel pumps
Electric fuel pumps
Replacement parts range and “in-tank” units
Cutting-edge technology sets new standards
The winning features of Bosch fuel pumps and delivery units:
Maximum pulsation-free performance (pressure/delivery)
for constant injection pressure
Longer service life thanks to extensive filter area
Improved ride comfort due to lower noise level
Extremely compact dimensions and low weight simplify
installation
Outstanding reliability even for “in-tank” applications
Capacitor and interference suppression cap provide excellent
protection against signal interference
Comprehensive market coverage with fuel pumps and in-tank
units from Bosch
Broadest possible market coverage with series-production
pumps and modules
New “present value” repair options for fuel-supply modules for
10 million vehicles in Europe
Top quality level – all products supplied by Bosch are of original-
equipment standard
Universal range with only 7 types for 72 original-equipment
pumps
Aftermarket range also includes fuel pumps for modern diesel-
injection systems such as common rail and unit injector
Long-term availability of all products – at competitive prices
Bosch Automotive Aftermarket 2008 | 2009
The universal range “7 instead of 72”
Electric fuel pumps | A15
One type for a variety of applications: The universal electricfuel-pump range from Bosch
The 72 pumps used in the past can now be replaced by just
7 universal electric fuel pumps from Bosch. The key to this is
a parts set. Each of the 7 electric fuel pumps is supplied with
a parts set and easy-to-follow installation instructions. These
pumps form the Bosch universal range.
Bosch quality
Crucial criteria for electric fuel pumps:
Maximum operational reliability
Compliance with all original-equipment demands
Long service life
Low noise level
Optimum fuel delivery
Maximum possible safety for hot-fuel delivery
Excellent interference-suppression level
Warning about imitation pumps
Certain rival companies make use of inferior imitation products
instead of high-performance Bosch pumps. This can lead to
fuel-delivery problems and to a loss of engine power due to an
inadequate fuel supply. In the interests of your customers please
therefore make exclusive use of genuine fuel pumps from Bosch.
On certain electric fuel pumps the nonreturn valve integrated into the threaded
socket on the delivery end can be replaced.
Each of the parts sets listed comprises the
genuine threaded socket with non-return
valve and a corresponding sealing ring.
Even compact vehicle models are currently fitted with more than
50 individual sensors. With the exception of the Lambda sensor the
majority are not subject to wear, but accidents or other influences
may cause damage.
As the leading supplier of original-equipment automobile sensors,
Bosch can also offer the most comprehensive aftermarket range in
this sector. Suitable replacement parts can be found for nearly all
repair applications. In addition, Bosch provides workshops with the
essential electronic diagnosis techniques for the identification of
defective sensors.
The Bosch sensor range comprises several hundred different types.
The types of sensor based on ultra-modern micro electromechanical systems (MEMS) span a field of applications including pressure,
acceleration and yaw-rate detection. The wide range of conventional
measuring elements available extends from speed sensors and
hot-film air-mass meters or Lambda sensors right through to sensors
for automatic air-conditioning systems.
Bosch Automotive Aftermarket 2008 | 2009
Gasoline injectors
Bosch is the worldwide market leader
Gasoline injectors | A21
A Bosch milestone: 40 years of manufacturing expertise
Bosch manufactures 80 million gasoline injectors every year at
seven production plants distributed around the world. With particularly high market shares in Western Europe, the NAFTA area,
and China, Bosch is way out in front as the world-market leader.
Bosch has the innovative answers for optimized gasoline-injection
systems and natural-gas injectors:
2001: EV14 for manifold injection – an optimized injection
orifice plate and finer atomization permit a reduction of up to
15 percent in hydrocarbon emissions.
2005: Injectors for environmentally compatible, inexpensive
natural gas – as compared to conventional gasoline, carbon dioxide emissions can be reduced by up to 30 %.
Refinement of the DI-Motronic gasoline direct-injection system
to obtain a jet-directed combustion process: Consumption can be
reduced by up to 15 % in comparison with manifold injection.
Parallel development of solenoid-controlled high-pressure
injectors with multihole nozzle suitable for all gasoline direct injection combustion processes.
2008 | 2009 Bosch Automotive Aftermarket
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