Saipa Motronic Training M7.9.7 and M7.4 - …eng.saipayadak.org/CarDocument/RM/x100RM2C31 تعميرات بوش...Saipa Motronic Training M7.9.7 and M7.4.11NG. Fundamentals of trouble-shooting.

Saipa Motronic Training M7.9.7 and M7.4.11NGSaipa Motronic Training M7.9.7 and M7.4.11NGSaipa Motronic Training M7.9.7 and M7.4.11NGSaipa Motronic Training M7.9.7 and M7.4.11NG

Saipa Motronic Training M7.9.7 and M7.4.11NGSaipa Motronic Training M7.9.7 and M7.4.11NGSaipa Motronic Training M7.9.7 and M7.4.11NGSaipa Motronic Training M7.9.7 and M7.4.11NGInvented for life

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Automotive Aftermarket

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Usr820613

Typewritten Text

X100RM2C/3/1

Usr820613

Typewritten Text

Usr820613

Typewritten Text

Usr820613

Typewritten Text



1 987 726 1341 987 726 1341 987 726 1341 987 726 134



NameNameNameName : ............................................ : ............................................ : ............................................ : ............................................

Date : from ............... to ............. Date : from ............... to ............. Date : from ............... to ............. Date : from ............... to .............

Location : ............................................ Location : ............................................ Location : ............................................ Location : ............................................

This training documentation is intended to serve as information for study purposes. It is not to be used for vehicle repair work. Repairs are to be performed in line with the relevant workshop documentation.

All the values given here are application-specific and thus not generally valid.


Table of contents

• Fundamentals of troubleFundamentals of troubleFundamentals of troubleFundamentals of trouble----shootingshootingshootingshooting

• Sources of error Sources of error Sources of error Sources of error ---- airsystemairsystemairsystemairsystem

• Motronic System OverviewMotronic System OverviewMotronic System OverviewMotronic System Overview

• Fuel systemFuel systemFuel systemFuel system

• CNGCNGCNGCNG----Components and their functionComponents and their functionComponents and their functionComponents and their function

• Repair instructionsRepair instructionsRepair instructionsRepair instructions

• Fuel mixture Fuel mixture Fuel mixture Fuel mixture ---- Exhaust gas Exhaust gas Exhaust gas Exhaust gas ---- DiagnosisDiagnosisDiagnosisDiagnosis

•Ignition systemIgnition systemIgnition systemIgnition system



• SensorsSensorsSensorsSensors

• ActuatorsActuatorsActuatorsActuators

• Fuel systemFuel systemFuel systemFuel system • Fuel mixture Fuel mixture Fuel mixture Fuel mixture ---- Exhaust gas Exhaust gas Exhaust gas Exhaust gas ---- DiagnosisDiagnosisDiagnosisDiagnosis

• FSA450FSA450FSA450FSA450

• Practical workPractical workPractical workPractical work


Fundamentals of trouble-shooting

While carrying out troubleshooting or diagnosis, it is a misconception to follow only one track. In fact, it is far more important to close the entire loop. This includes naturally that the errors are read-out.

However, one fault code indicates always only one



However, one fault code indicates always only one test path. This means that with the help of a test instruction manual and the necessary test

equipment, the search is made firstly comprehensive and above all "leading to the desired result"."leading to the desired result"."leading to the desired result"."leading to the desired result".


Motronic System Overview




Induction system and components



1.1.1.1. What are the sources of errors?What are the sources of errors?What are the sources of errors?What are the sources of errors?

Intake air boot, connecting parts on the throttle valve part and the intake manifold, crankcase ventilationIntake air boot, connecting parts on the throttle valve part and the intake manifold, crankcase ventilationIntake air boot, connecting parts on the throttle valve part and the intake manifold, crankcase ventilationIntake air boot, connecting parts on the throttle valve part and the intake manifold, crankcase ventilation

2. What are the consequences of the errors?2. What are the consequences of the errors?2. What are the consequences of the errors?2. What are the consequences of the errors?

Unmeasured quantity of air leads to fuel leaning, fault memory entry, adaptations is activeUnmeasured quantity of air leads to fuel leaning, fault memory entry, adaptations is activeUnmeasured quantity of air leads to fuel leaning, fault memory entry, adaptations is activeUnmeasured quantity of air leads to fuel leaning, fault memory entry, adaptations is active

3. What are the diagnosis possibilities?3. What are the diagnosis possibilities?3. What are the diagnosis possibilities?3. What are the diagnosis possibilities?

Evaluate the actual value of the diagnosis tester, adaptations, fault entry. Flush the system with nonEvaluate the actual value of the diagnosis tester, adaptations, fault entry. Flush the system with nonEvaluate the actual value of the diagnosis tester, adaptations, fault entry. Flush the system with nonEvaluate the actual value of the diagnosis tester, adaptations, fault entry. Flush the system with non----inflammable medium (leak tightness test)inflammable medium (leak tightness test)inflammable medium (leak tightness test)inflammable medium (leak tightness test)


Intake system and components

4444

3333

bbbb

aaaa

2222

1111



1111

Label using :Label using :Label using :Label using :

Determine the measuring points for :Determine the measuring points for :Determine the measuring points for :Determine the measuring points for :

1 Intake side1 Intake side1 Intake side1 Intake side 2 Discharge side2 Discharge side2 Discharge side2 Discharge side 3 Return pipe3 Return pipe3 Return pipe3 Return pipe 4 Reference pressure4 Reference pressure4 Reference pressure4 Reference pressure

a Fuel pressurea Fuel pressurea Fuel pressurea Fuel pressure b Delivery quantityb Delivery quantityb Delivery quantityb Delivery quantity


In-tank unit/electric fuel pump (EKP)

The eeeelectric ffffuel ppppump (EKP) builds up the pressure in the low-pressure

circuit. Whereas in the early days of electronic gasoline injection the electric

fuel pump was always located outside the fuel tank in the fuel pipe, the electric

fuel pump is now usually installed in the tank (in-tank pump). It forms part of

an "in-tank unit" also known as . In addition to the fuel

pump, this also contains a pre-filter, a fuel filter, a pressure regulator, a tank

level sensor and a fuel reservoir for cornering. This reservoir is normally

"actively" filled by a suction jet pump or by a separate first stage of the electric

fuel pump. The suction jet pump and the fuel filter may also be part of the in-

tank unit.Electric fuel pump

delivery module



tank unit.

Integration of the pressure regulator into the tank module obviates the need

for the pressure regulator at the fuel metering unit and thus permits

implementation of a non-return fuel supply system. Consequently, the

pressure is no longer governed by the intake manifold pressure. The fuel fine

filter on the delivery end can also be installed in the in-tank unit. The pressure

is regulated directly at the tank, which makes the supply system as a whole

less complex whilst reducing the emission level, as the fuel no longer passes

through the hot engine compartment and thus does not heat up. With older

systems, the fuel filter is not integrated into the in-tank unit, but takes the form

of a separate component in the fuel pipe.In-tank unit

Electric fuel pump


Basics of engine speed sensor and reference mark sensor

Electrical voltage produced in an electrical conductor due to the change in the intensity of the magnetic Electrical voltage produced in an electrical conductor due to the change in the intensity of the magnetic Electrical voltage produced in an electrical conductor due to the change in the intensity of the magnetic Electrical voltage produced in an electrical conductor due to the change in the intensity of the magnetic field is called as electromagnetic induction.field is called as electromagnetic induction.field is called as electromagnetic induction.field is called as electromagnetic induction.

+ -

mVmVmVmV

U(V)



N

S

N

S

N

S

Amplitudet(s)

Oscillation

0


Engine-speed/reference-mark sensor

1. Permanent magnet

2. Engine-speed/reference-mark sensor

3. Crankcase

4. Soft iron core

5. Sensor coil

6. Sensor ring gear



The engine speed sensor detects the engine speed. As the crankshaft rotates, the teeth of the sensor ring gear/flywheel

induce an AC voltage in the engine-speed/reference-mark sensor. The control unit uses this AC voltage generated to

calculate the engine speed. In this process, the front edge of a tooth generates a positive voltage pulse and the rear edge a

negative voltage pulse.

The 60 - 2 teeth at the sensor ring gear yield a tooth width of 3° crank angle. The effect of the 2-tooth gap is that no voltage is

induced in the engine-speed/reference-mark sensor. This gap is used to identify the instantaneous crankshaft position and

appears twice per cycle. An additional is required for synchronization of injection. This only supplies one

signal per cycle and must coincide with the reference mark at the no. 1 cylinder crankshaft. The engine-speed/reference-mark

sensor can be checked by way of signal recording with an oscilloscope, resistance measurement and measurement of the

supply voltage.

camshaft sensor


Speed detection and reference-mark detection



1. Inductive sensor system with sensor wheel 601. Inductive sensor system with sensor wheel 601. Inductive sensor system with sensor wheel 601. Inductive sensor system with sensor wheel 60----2 teeth and the tests:2 teeth and the tests:2 teeth and the tests:2 teeth and the tests:

3. Inductive sensor system with segments on starter tooth crown and its assessment:3. Inductive sensor system with segments on starter tooth crown and its assessment:3. Inductive sensor system with segments on starter tooth crown and its assessment:3. Inductive sensor system with segments on starter tooth crown and its assessment:

2. Function of the gaps:2. Function of the gaps:2. Function of the gaps:2. Function of the gaps:

4. Function of the permanent magnets:4. Function of the permanent magnets:4. Function of the permanent magnets:4. Function of the permanent magnets:

Static resistance, air gap Dynamic voltage characteristic curve, level and polarityStatic resistance, air gap Dynamic voltage characteristic curve, level and polarityStatic resistance, air gap Dynamic voltage characteristic curve, level and polarityStatic resistance, air gap Dynamic voltage characteristic curve, level and polarity

Show the reference marksShow the reference marksShow the reference marksShow the reference marks

Dynamic voltage characteristic curve, level and polarityDynamic voltage characteristic curve, level and polarityDynamic voltage characteristic curve, level and polarityDynamic voltage characteristic curve, level and polarity

Show the reference marks, Injection loop detectionShow the reference marks, Injection loop detectionShow the reference marks, Injection loop detectionShow the reference marks, Injection loop detection


Hall-Effekt



Hall-Effekt

The principle of charge transfer.

If a current (I) flows through a semiconductorlayer in the longitudinal direction and simultaneously a magnetic field is applied perpendicular to the semiconductor layer, then the Hall voltage (UH) develops at right angles to the current flow (I).

The magnitude of the voltage (UH) depends on the strength of the magnetic field.


Phase sensor



There is a reduction ratio of 1:2 between the camshaft and the crankshaft. The camshaft position indicates whether an engine

piston moved to top dead center is in the compression or exhaust stroke. The phase sensor at the camshaft passes this

information to the control unit. It employs the Hall effect. The phase sensor can be checked by way of signal recording with an

oscilloscope and measurement of the power supply.


Load request

Possible throttle valve setting as load requestPossible throttle valve setting as load requestPossible throttle valve setting as load requestPossible throttle valve setting as load request

1.1.1.1. Throttle valve switch with the following information:Throttle valve switch with the following information:Throttle valve switch with the following information:Throttle valve switch with the following information:

LL / VL switch opened or closed.LL / VL switch opened or closed.LL / VL switch opened or closed.LL / VL switch opened or closed.

2.2.2.2. Throttle valve potentiometer with the following Throttle valve potentiometer with the following Throttle valve potentiometer with the following Throttle valve potentiometer with the following information:information:information:information:

Voltage value, % Voltage value, % Voltage value, % Voltage value, % ---- specifications, steps.specifications, steps.specifications, steps.specifications, steps.



3.3.3.3. Load request via hall sensor:Load request via hall sensor:Load request via hall sensor:Load request via hall sensor:

The information The information The information The information

LL via TL to VL, contactless.LL via TL to VL, contactless.LL via TL to VL, contactless.LL via TL to VL, contactless.

4.4.4.4. Information content for :Information content for :Information content for :Information content for :

Control unit functions, possible value for Control unit functions, possible value for Control unit functions, possible value for Control unit functions, possible value for αααα/n/n/n/n

control or substitute value. control or substitute value. control or substitute value. control or substitute value.


Noise test - potentiometer 1



Conclusion: Potentiometer 2 is defective.

Pedal travel sensor must be replaced. Never perform repair work on PWG, always use new component.


Intake manifold pressure sensor

1. Housing with pressure sensor connection

2. Bond

3. Cover

4. Sensor chip

5. Ceramic substrate

6. Seal

7. NTC element

2 3

5

4

61



7. NTC element

7

1

The intake manifold pressure sensor is pneumatically connected to the intake manifold and thus records the intake manifold

absolute pressure. The intake manifold pressure is measured with respect to a reference vacuum and not to the ambient

pressure. The intake air mass can be calculated from the intake manifold pressure, the intake air temperature and the

measured engine speed.

A temperature sensor may be additionally integrated into the pressure sensor housing. The temperature sensor projects into the

flow of air and can thus react instantly to changes in temperature.


Idling speed control

What are the diagnostic and testing methods that What are the diagnostic and testing methods that What are the diagnostic and testing methods that What are the diagnostic and testing methods that could be used?could be used?could be used?could be used?

Electrical testsElectrical testsElectrical testsElectrical tests

The diagnostic tester Visual inspection The diagnostic tester Visual inspection The diagnostic tester Visual inspection The diagnostic tester Visual inspection

Mechanical assessment.Mechanical assessment.Mechanical assessment.Mechanical assessment.



A cold engine requires a larger air mass and more fuel to offset the increased friction torque. More air is also required for

example on switching in an A/C compressor so as to compensate for the torque loss. This information is supplied to the control

unit in the form of electrical signals. The additional air requirement is covered by a bypass air actuator routing an additional

bypass air flow past the throttle valve or by a throttle valve positioner altering the minimum stop of the throttle valve. The

additional air makes it possible at idle for example to regulate the engine speed to a constant value (idling speed control).


Purge control

1

2

3

4

5

67

8

1. Fuel tank

2. Vent pipe

3. Charcoal canister

4. Fresh air

5. Regeneration valve

6. Pipe to intake manifold

7. Throttle valve

8. Intake manifold

Purge control valve (regeneration valve)



4

The evaporative emission control system consists of a charcoal canister into which the fuel tank vent pipe is routed and a

regeneration valve connected to both the charcoal canister and the intake manifold. The activated charcoal absorbs the fuel

contained in the fuel vapor and only allows air to escape to the atmosphere. When the regeneration valve opens the pipe

between the charcoal canister and the intake manifold, fresh air is drawn through the activated charcoal on account of the

vacuum prevailing in the intake manifold. The fresh air entrains the fuel absorbed and passes it on for combustion

(regeneration of charcoal canister). The system control function reduces the amount of fuel injected by the quantity of fuel

supplied via the regeneration valve. Regeneration takes place on a controlled basis, with the fuel concentration in the

regeneration gas flow being constantly calculated by way of observation of the resultant changes in the excess air factor λ.

The volume of regeneration gas is controlled as a function of the operating point and can be finely metered with the

regeneration valve. Regeneration must be implemented at regular intervals to ensure that the charcoal canister is capable of

absorbing fuel vapor again.

Purge control valve (regeneration valve)


Temperature sensor

1.1.1.1. What does the designation NTC / PTC What does the designation NTC / PTC What does the designation NTC / PTC What does the designation NTC / PTC indicate?indicate?indicate?indicate?

• NTC Negative temperature coefficientNTC Negative temperature coefficientNTC Negative temperature coefficientNTC Negative temperature coefficient

The resistance decreases with rising The resistance decreases with rising The resistance decreases with rising The resistance decreases with rising temperaturetemperaturetemperaturetemperature

• PTC Positive temperature coefficientPTC Positive temperature coefficientPTC Positive temperature coefficientPTC Positive temperature coefficient

The resistance increases with rising The resistance increases with rising The resistance increases with rising The resistance increases with rising temperaturetemperaturetemperaturetemperature



2. 2. 2. 2. What are the possible diagnostic alternatives?What are the possible diagnostic alternatives?What are the possible diagnostic alternatives?What are the possible diagnostic alternatives?

Measuring the resistance, measuring the voltage drop, actual value diagnostic testerMeasuring the resistance, measuring the voltage drop, actual value diagnostic testerMeasuring the resistance, measuring the voltage drop, actual value diagnostic testerMeasuring the resistance, measuring the voltage drop, actual value diagnostic tester

3. 3. 3. 3. What is the maximum amount of resistance at?What is the maximum amount of resistance at?What is the maximum amount of resistance at?What is the maximum amount of resistance at?

a) 20a) 20a) 20a) 20°°°°CCCC b) 40b) 40b) 40b) 40°°°°CCCC c) 80c) 80c) 80c) 80°°°°CCCC


Knock sensor

Knocking is a phenomenon which occurs if the is too far advanced. Following

1 = Seismic mass2 = Piezoelectric ceramic perforated disk3 = Thrust sleeve4 = Sealing compound5 = Contakt disk6 = Resitant7 = Connector

1

2

3

4

5 6

7



Knocking is a phenomenon which occurs if the is too far advanced. Following

the start of normal combustion, the considerable increase in pressure in the combustion chamber

leads to spontaneous ignition of the unburnt residual mixture not yet reached by the flame front. The

subsequent abrupt combustion of the gas results in a sharp local increase in pressure. The pressure

wave thus generated is propagated, impacts against the cylinder walls and can be heard in the form

of knocking. Persistent knocking over lengthy periods can cause mechanical damage to the engine

on account of the pressure waves and the increased thermal load. Knock control is a standard,

integral feature of engine management systems to reliably prevent this in modern high-compression

engines, both of the intake manifold injection and gasoline direct injection type. As soon as knock

sensors detect the onset of knocking, this system effects retardation of the ignition point at the

relevant cylinder only.

ignition point

Knock sensor


Ignition coil and voltage distribution

The ignition coil stores the ignition energy required and generates the high voltage for

sparkover at the ignition point.

State of the art ignition coils consist of two magnetically coupled copper windings (primary and

secondary winding), an iron core made up of individual laminations and a plastic housing.

The operating principle of an ignition coil is based on . The energy stored in

the magnetic field of the primary winding is transferred to the secondary side by way of

magnetic induction. The engine control unit energizes the ignition driver stage during the

calculated dwell time � the primary current increases and builds up a magnetic field. At the

ignition point the ignition driver stage interrupts the flow of current. This gives rise to a self-

induced voltage which is limited to 200 - 400 V. Flashover occurs at the spark plug and ignites Single-spark coil

Faraday's law



induced voltage which is limited to 200 - 400 V. Flashover occurs at the spark plug and ignites

the fuel/air mixture.

Rotating highRotating highRotating highRotating high----voltage distribution (ROV)voltage distribution (ROV)voltage distribution (ROV)voltage distribution (ROV)

The high voltage generated by a single ignition coil is mechanically distributed to the individual

spark plugs by an ignition distributor.

Distributorless ignition system (RUV)Distributorless ignition system (RUV)Distributorless ignition system (RUV)Distributorless ignition system (RUV)

The ignition coils are connected directly to the spark plugs and voltage distribution takes place

on the primary side of the ignition coils. A distinction is made between:

---- SingleSingleSingleSingle----spark coilsspark coilsspark coilsspark coils – Each cylinder is assigned an ignition driver stage/ignition coil

---- DoubleDoubleDoubleDouble----spark coilsspark coilsspark coilsspark coils – One ignition driver stage and one ignition coil are each assigned to

two cylinders

Single-spark coil

Double-spark coil


Double spark coils - DFS



1.1.1.1. How many ignition sparks occur per working cycle of a cylinder?How many ignition sparks occur per working cycle of a cylinder?How many ignition sparks occur per working cycle of a cylinder?How many ignition sparks occur per working cycle of a cylinder?

Two sparks, i.e. every 360Two sparks, i.e. every 360Two sparks, i.e. every 360Two sparks, i.e. every 360°°°° of the crankshaft.of the crankshaft.of the crankshaft.of the crankshaft.

2.2.2.2. What is the polarity of the secondary voltages for DFS?What is the polarity of the secondary voltages for DFS?What is the polarity of the secondary voltages for DFS?What is the polarity of the secondary voltages for DFS?

One cylinder has a positive polarity, the corresponding cylinder connected to One cylinder has a positive polarity, the corresponding cylinder connected to One cylinder has a positive polarity, the corresponding cylinder connected to One cylinder has a positive polarity, the corresponding cylinder connected to the same ignition coil has negative polarity.the same ignition coil has negative polarity.the same ignition coil has negative polarity.the same ignition coil has negative polarity.


Secondary adaptation

1. 1. 1. 1. How are the polarities of the terminals 4a and 4bHow are the polarities of the terminals 4a and 4bHow are the polarities of the terminals 4a and 4bHow are the polarities of the terminals 4a and 4bdetermined on the respective ignition coils?determined on the respective ignition coils?determined on the respective ignition coils?determined on the respective ignition coils?

By carefully approaching the ignition cable with By carefully approaching the ignition cable with By carefully approaching the ignition cable with By carefully approaching the ignition cable with

the red secondary sensor. the red secondary sensor. the red secondary sensor. the red secondary sensor.

(Caution, take note of UVV.)(Caution, take note of UVV.)(Caution, take note of UVV.)(Caution, take note of UVV.)

Observe the course of the signal on the Observe the course of the signal on the Observe the course of the signal on the Observe the course of the signal on the

oscilloscope, use red sensor in case of upward oscilloscope, use red sensor in case of upward oscilloscope, use red sensor in case of upward oscilloscope, use red sensor in case of upward

beambeambeambeam.

4a



Do not touch the cables!Do not touch the cables!Do not touch the cables!Do not touch the cables!

1 = Black terminal (-) 2 = Red terminal (+)3 = Yellow plug (T.15) 4 = Green plug (T.1/A)5 = Green plug (T.1/B) 6 = Trigger clamp of 1st cylinder7 = Secondary sensing device

red or black

4a

4b

4b


Double spark coils - DFSHow do the patterns here differ from one How do the patterns here differ from one How do the patterns here differ from one How do the patterns here differ from one another?another?another?another?Oscillogram RUV (static high voltage distribution) Oscillogram RUV (static high voltage distribution) Oscillogram RUV (static high voltage distribution) Oscillogram RUV (static high voltage distribution) with double spark coils, all positive signals are with double spark coils, all positive signals are with double spark coils, all positive signals are with double spark coils, all positive signals are displayed. Pickdisplayed. Pickdisplayed. Pickdisplayed. Pick----up through red capacitive terminals.up through red capacitive terminals.up through red capacitive terminals.up through red capacitive terminals.

Oscillogram of a RUVOscillogram of a RUVOscillogram of a RUVOscillogram of a RUV----ignition system with double ignition system with double ignition system with double ignition system with double spark coils. Display of all the negative signals. Pickspark coils. Display of all the negative signals. Pickspark coils. Display of all the negative signals. Pickspark coils. Display of all the negative signals. Pick----up through black capacitive terminals.up through black capacitive terminals.up through black capacitive terminals.up through black capacitive terminals.



Oscillogram of a RUVOscillogram of a RUVOscillogram of a RUVOscillogram of a RUV----ignition system with double ignition system with double ignition system with double ignition system with double spark coils. All signals are displayed (main ignition spark coils. All signals are displayed (main ignition spark coils. All signals are displayed (main ignition spark coils. All signals are displayed (main ignition signals and auxiliary ignition signals). signals and auxiliary ignition signals). signals and auxiliary ignition signals). signals and auxiliary ignition signals). PickPickPickPick----up: Red and black capacitive terminals.up: Red and black capacitive terminals.up: Red and black capacitive terminals.up: Red and black capacitive terminals.Sum representation.Sum representation.Sum representation.Sum representation.


Spark plug

3

1. Center electrode

2. Ground electrode

The spark plug ignites the air/fuel mixture in the combustion chamber by

means of a spark between the electrodes.

The spark plug is a ceramic-insulated, gas-tight high-voltage feedthrough

into the combustion chamber with a center electrode and one or more

ground electrode(s).

The position of the ground electrode(s) determines the type of spark. If the

ground electrode is opposite the center electrode, this is referred to as an

. Surface air gap spark plugs or just surface gap spark

plugs are obtained if the ground electrodes are positioned on the side.

After interrupting the primary current at the ignition point, the voltage in the

Center electrode wear air gap spark plug



1

2

2. Ground electrode

3. Ceramic bodysecondary winding of the ignition coil increases rapidly (approx. 30 µs) to

the ignition voltage level. On exceeding the necessary ignition voltage,

the spark gap of the spark plug between the center and ground electrodes starts to conduct. The capacitors

charged to ignition voltage level in the secondary circuit (spark plug, ignition cable and ignition coil) are

abruptly discharged in a spark head. The stored ignition coil energy is then converted into glow discharge

(spark tail) during a spark duration of typically 1 - 2 ms. The residual energy contained in the ignition coil is

dissipated in the post-oscillation phase.

During engine operation, the spark plug electrodes become worn as a result of erosion caused by the spark

current and corrosion from the hot gases in the combustion chamber. The becomes

larger. The ignition voltage requirement thus increases. This requirement must be reliably satisfied by the

secondary voltage supply of the ignition system in all operating situations until the end of the specified

replacement interval.

electrode gap


Electromagnetic injectors

1

2

2

3

3

1

1. Hydraulic connection

2. Electrical connection

3. Sealing ring

4. Housing

Electrically actuated injectors inject the fuel under system pressure into the intake manifold. Electromagnetic injectors

4



Electrically actuated injectors inject the fuel under system pressure into the intake manifold. Electromagnetic injectors

essentially consist of the housing with electrical and pneumatic connections, the coil of the solenoid, the needle with solenoid

armature and spherical seal, the seat with injection orifice plate and the spring. When the coil is deenergized, the spring and the

force resulting from the fuel pressure press the needle with the spherical seal into the tapered seat. Energization of the coil

produces a magnetic field which attracts the solenoid armature of the needle. The spherical seal is lifted off the seat and the

fuel is injected. On shutting off the excitation current, spring force causes the needle to close again. The fuel is atomized by

means of an injection orifice plate with one or more orifice(s). The spray pattern of the fuel emerging results from the

arrangement and number of injection orifices. The lower sealing ring seals off the injector from the intake manifold. The quantity

of fuel injected per unit time is essentially governed by the pressure in the fuel supply system, the back pressure in the intake

manifold and the geometry of the fuel outlet area.


Injection valve Jetronic / Motronic

1.1.1.1. How do you differentiate between the various How do you differentiate between the various How do you differentiate between the various How do you differentiate between the various injection injection injection injection valves?valves?valves?valves?

a): Mechanically acc. to the type of construction a): Mechanically acc. to the type of construction a): Mechanically acc. to the type of construction a): Mechanically acc. to the type of construction and acc. to the spray pattern.and acc. to the spray pattern.and acc. to the spray pattern.and acc. to the spray pattern.

b): Electrically acc. to the coil resistance.b): Electrically acc. to the coil resistance.b): Electrically acc. to the coil resistance.b): Electrically acc. to the coil resistance.

2.2.2.2. What corrective maintenance options are you What corrective maintenance options are you What corrective maintenance options are you What corrective maintenance options are you aware of aware of aware of aware of ????



????

OOOO----Ring, protection cover, mesh filter and cleaning.Ring, protection cover, mesh filter and cleaning.Ring, protection cover, mesh filter and cleaning.Ring, protection cover, mesh filter and cleaning.

3.3.3.3. How can the injection valves be judged?How can the injection valves be judged?How can the injection valves be judged?How can the injection valves be judged?

LeakLeakLeakLeak----tightness, mechanical seating, spray patterntightness, mechanical seating, spray patterntightness, mechanical seating, spray patterntightness, mechanical seating, spray patternand fuel quantity comparison.and fuel quantity comparison.and fuel quantity comparison.and fuel quantity comparison.


Ignition signal evaluation



1.1.1.1. How can the ti signal be represented?How can the ti signal be represented?How can the ti signal be represented?How can the ti signal be represented?With the help of oscilloscope in the KTS or FSA. With the help of oscilloscope in the KTS or FSA. With the help of oscilloscope in the KTS or FSA. With the help of oscilloscope in the KTS or FSA.

2. 2. 2. 2. Name the control unit functions that can be derived from the ti signalName the control unit functions that can be derived from the ti signalName the control unit functions that can be derived from the ti signalName the control unit functions that can be derived from the ti signalStart and acceleration enrichments, overrun shutStart and acceleration enrichments, overrun shutStart and acceleration enrichments, overrun shutStart and acceleration enrichments, overrun shut----off, corrections of off, corrections of off, corrections of off, corrections of Lambda control, voltage correction. Lambda control, voltage correction. Lambda control, voltage correction. Lambda control, voltage correction.

3. 3. 3. 3. How can the contact resistances be detected?How can the contact resistances be detected?How can the contact resistances be detected?How can the contact resistances be detected?Through the signal form and the distance to the base line.Through the signal form and the distance to the base line.Through the signal form and the distance to the base line.Through the signal form and the distance to the base line.


LSH Lambda sensor (finger sensor) The sensor signal in case of The sensor signal in case of The sensor signal in case of The sensor signal in case of

a: insufficient air has a value of approx. 800 a: insufficient air has a value of approx. 800 a: insufficient air has a value of approx. 800 a: insufficient air has a value of approx. 800 –––– 1000 mV1000 mV1000 mV1000 mV

b: excessive air has a value of approx. 100 b: excessive air has a value of approx. 100 b: excessive air has a value of approx. 100 b: excessive air has a value of approx. 100 mVmVmVmV

a b

mV

1000

800

Sensor voltage Us

1 4 2



600

400

200

0

Sensor voltage Us

Air ratio λ

0.8 1 1.2

3 5 6 7 8

sensor signal curvesensor signal curvesensor signal curvesensor signal curve

1. Housing (-) with screw-in thread and

2. electrical connection(+)

3. active sensor ceramic

4. ceramic support tube

5. protective tube

6. heating element

7. connection for heating element

8. sensor housing


Planar two-position Lambda sensor (LSF)

3

1

2

The planar two-position Lambda sensor LSF consists of a special ceramic body

and the sensor element which takes the form of an elongated plate with rectangular

cross-section. Not only the measurement cell but also the heater is integrated into

this planar ceramic body. External heating achieves rapid warm-up, with the result

that operating temperature is attained within 20 - 30 s after starting the engine and

Lambda control thus enabled. The outer side of the electrode projects into the flow

of exhaust gas, whereas the inner side is in contact with the ambient atmosphere.

The difference in oxygen between the outer and inner electrode can be measured

in the form of a difference in voltage.

The sensor voltage changes abruptly when the air/fuel mixture composition is in the



4

5

1. Connecting cable

2. Contact holder

3. Planar sensor element

4. Ceramic sealing element

5. Housing

The sensor voltage changes abruptly when the air/fuel mixture composition is in the

stoichiometric range. This step change is evaluated in the 450 - 500 mV range of

the system regulated to λ = 1.

In the 800 - 1000 mV range, the mixture is rich (λ < 1). If the sensor voltage is

around 100 mV, the mixture is lean (λ > 1).


Planar lambda sensor (LSF)

Protective layer

Outer electrode

Foil

Inner electrode

Reference air channel foil

Insulation

Planar

sensor element

Connecting cable

Contact holder



Heating

Insulation

Foil

Connection contact

1.1.1.1. Which significant advantage is offered by the planar sensor LSF?Which significant advantage is offered by the planar sensor LSF?Which significant advantage is offered by the planar sensor LSF?Which significant advantage is offered by the planar sensor LSF?

Faster control readiness and faster control frequency and accuracyFaster control readiness and faster control frequency and accuracyFaster control readiness and faster control frequency and accuracyFaster control readiness and faster control frequency and accuracy

Ceramic

packing

Housing


Electronics for improved exhaust gas compositionExhaust gases without catalytic Exhaust gases with catalytic Exhaust gases without catalytic Exhaust gases with catalytic Exhaust gases without catalytic Exhaust gases with catalytic Exhaust gases without catalytic Exhaust gases with catalytic converter converter converter converter

converterconverterconverterconverter and and and and λ controlcontrolcontrolcontrol

NOx

CO

a



λ = 1

HC

CO

λ = 0.97 – 1.03

HC

NOx

a = Lambda rangea = Lambda rangea = Lambda rangea = Lambda range


1 2 3

1.1.1.1. Describe the structure and the principle Describe the structure and the principle Describe the structure and the principle Describe the structure and the principle of the catalytic converter.of the catalytic converter.of the catalytic converter.of the catalytic converter.– Reduction and oxidation:Reduction and oxidation:Reduction and oxidation:Reduction and oxidation:– NOx is deoxidized to N2 and O2.NOx is deoxidized to N2 and O2.NOx is deoxidized to N2 and O2.NOx is deoxidized to N2 and O2.– CO is oxidized to CO2,CO is oxidized to CO2,CO is oxidized to CO2,CO is oxidized to CO2,– HC is oxidized to H2O and CO2.HC is oxidized to H2O and CO2.HC is oxidized to H2O and CO2.HC is oxidized to H2O and CO2.

2.2.2.2. What is the temperature range at which What is the temperature range at which What is the temperature range at which What is the temperature range at which the catalytic converter attains the ideal the catalytic converter attains the ideal the catalytic converter attains the ideal the catalytic converter attains the ideal conversion rate?conversion rate?conversion rate?conversion rate?

Three-way catalytic converter



4 5 6

1111 Honeycomb ceramic substrate

2222 Heat-resistant wire mesh

3333 Steel housing

4444 Ceramic substrate

5555 Intermediate layer (wash-coat)

6666 Active catalytic layer

conversion rate?conversion rate?conversion rate?conversion rate?400 400 400 400 ---- 800800800800°°°°CCCC


Three-way catalytic converterThreeThreeThreeThree----way catalytic converterway catalytic converterway catalytic converterway catalytic converter

The function of a three-way catalytic converter is to convert the three pollutant components HC (hydrocarbons), CO (carbon

monoxide) and NOx (nitrogen oxides) occurring during combustion of the air/fuel mixture into non-toxic substances. The end

products are H2O (water vapor), CO2 (carbon dioxide) and N2 (nitrogen).

The catalytic converter consists of a ceramic or metal carrier with several thousand ducts running through it. A so-called wash

coat on the surface increases the effective area by a factor of . The wash coat is covered by a catalytic layer made up

of noble metals which are responsible for conversion of the pollutants.

The pollutant conversion process (exhaust treatment) takes place in two phases: The carbon monoxide and the hydrocarbons

are converted by way of oxidation. The oxygen required for oxidation is either present in the exhaust gas in the form of residual

oxygen as a result of incomplete combustion or it is taken from the nitrogen oxides, thus reducing these at the same time.

For the three-way catalytic converter to achieve the highest possible conversion rate for all three pollutant components, the

7000



For the three-way catalytic converter to achieve the highest possible conversion rate for all three pollutant components, the

pollutants must be in chemical equilibrium. This requires a mixture composition with λ = 1.0.stoichiometric


Lambda control loop

lean lean lean lean

mixturemixturemixturemixtureExcess O2 Excess O2 Excess O2 Excess O2 in the in the in the in the

exhaust gasexhaust gasexhaust gasexhaust gas

UUUUλ

approx. 100mVapprox. 100mVapprox. 100mVapprox. 100mV

Control unit Control unit Control unit Control unit

enleansenleansenleansenleans

QE falls 1111

Lambda control allows very precise maintenance of air-fuel mixture. A closed control loop is developed which is based on measuring the residual oxygen content in the exhaust gas. With this, the injection quantity and time are influenced. Optimum fuel metering can be achieved for all operating modes.

λ = 1.03, slightly lean mixture – lambda-

control compensates by adding fuel.



Control unit Control unit Control unit Control unit

enrichesenrichesenrichesenriches

QE risesQE risesQE risesQE rises

Rich Rich Rich Rich

mixturemixturemixturemixture

Less O2Less O2Less O2Less O2

in in in in exhaust gas.exhaust gas.exhaust gas.exhaust gas.

UUUUλ

800 800 800 800 –––– 1000100010001000

mVmVmVmV

1 Lean mixture

2 Excess oxygen in the exhaust gas

3 λ-sensor voltage approx. 100mV

4 Control unit enriches

5 Iinjection quantity increases

6 Rich mixture

7 Less oxygen in the exhaust gas

8 λ-sensor voltage approx. 800 – 1000mV

9 Control unit enleans

10 Lean mixture


Integrator signal

Λ

100%100%100%100%

1. Leak air 1. Leak air 1. Leak air 1. Leak air enters, the enters, the enters, the enters, the integrator takes integrator takes integrator takes integrator takes up enrichment, up enrichment, up enrichment, up enrichment, ti increases.ti increases.ti increases.ti increases.

2. Adaptation 2. Adaptation 2. Adaptation 2. Adaptation takes up the takes up the takes up the takes up the enrichment.enrichment.enrichment.enrichment.

<

1111 2222 44443333



titititi

Ad.Ad.Ad.Ad.

enrichment.enrichment.enrichment.enrichment.

3. Additional leak air, 3. Additional leak air, 3. Additional leak air, 3. Additional leak air, fuel mixture too lean, fuel mixture too lean, fuel mixture too lean, fuel mixture too lean, adaptation limit adaptation limit adaptation limit adaptation limit reached. integrator at reached. integrator at reached. integrator at reached. integrator at the end stop, ti at the the end stop, ti at the the end stop, ti at the the end stop, ti at the end stop, MIL lamp is end stop, MIL lamp is end stop, MIL lamp is end stop, MIL lamp is burning.burning.burning.burning.

4. MIL lamp is 4. MIL lamp is 4. MIL lamp is 4. MIL lamp is burning.burning.burning.burning.>

tttt


Evaluation of the diagnosis data

In which range does the In which range does the In which range does the In which range does the integrator level itself up?integrator level itself up?integrator level itself up?integrator level itself up?

2222.

2.1 What does this value indicate?2.1 What does this value indicate?2.1 What does this value indicate?2.1 What does this value indicate?

0.1 0.1 0.1 0.1 –––– 0.9 V 0.9 V 0.9 V 0.9 V

100% +/100% +/100% +/100% +/---- 25% 25% 25% 25%

(value is vehicle(value is vehicle(value is vehicle(value is vehicle----specific)specific)specific)specific)

1.1.1.1. In which range does the In which range does the In which range does the In which range does the Lambda probe voltage level Lambda probe voltage level Lambda probe voltage level Lambda probe voltage level itself up?itself up?itself up?itself up?



2.1 What does this value indicate?2.1 What does this value indicate?2.1 What does this value indicate?2.1 What does this value indicate?

2.2 In which range can this 2.2 In which range can this 2.2 In which range can this 2.2 In which range can this value lie?value lie?value lie?value lie?

Each deviation of 100% shows Each deviation of 100% shows Each deviation of 100% shows Each deviation of 100% shows that an adaptation of the that an adaptation of the that an adaptation of the that an adaptation of the Lambda range has taken place. Lambda range has taken place. Lambda range has taken place. Lambda range has taken place.

SystemSystemSystemSystem----dependent, refer todependent, refer todependent, refer todependent, refer to

ESI[tronic].ESI[tronic].ESI[tronic].ESI[tronic].


Evaluation of the diagnosis data

1.1.1.1. What initiates a correction (adaptation)?What initiates a correction (adaptation)?What initiates a correction (adaptation)?What initiates a correction (adaptation)?

Fuel mixture adaptation ti +/Fuel mixture adaptation ti +/Fuel mixture adaptation ti +/Fuel mixture adaptation ti +/---- deviating deviating deviating deviating

from the “Basic injection time”.from the “Basic injection time”.from the “Basic injection time”.from the “Basic injection time”.

2.2.2.2. What can be the preconditions for this?What can be the preconditions for this?What can be the preconditions for this?What can be the preconditions for this?

Continuous followContinuous followContinuous followContinuous follow----up by the up by the up by the up by the λλλλ ---- control.control.control.control.

----25 +2525 +2525 +2525 +25

----1 +11 +11 +11 +1

----1 +11 +11 +11 +1



3.In which ranges are the adaptations?3.In which ranges are the adaptations?3.In which ranges are the adaptations?3.In which ranges are the adaptations?

----1 +11 +11 +11 +1


Exhaust gas mixture diagnostics

1.1.1.1. What do these values suggest?What do these values suggest?What do these values suggest?What do these values suggest?

An engine that runs at An engine that runs at An engine that runs at An engine that runs at λ=1. =1. =1. =1.

The catalytic converter functions and The catalytic converter functions and The catalytic converter functions and The catalytic converter functions and

the Lambda sensor voltage fluctuates the Lambda sensor voltage fluctuates the Lambda sensor voltage fluctuates the Lambda sensor voltage fluctuates

around 450 mV.around 450 mV.around 450 mV.around 450 mV.

2.2.2.2. What are the reactions that take place in What are the reactions that take place in What are the reactions that take place in What are the reactions that take place in the 3the 3the 3the 3----way catalytic converter?way catalytic converter?way catalytic converter?way catalytic converter?

0,50,50,50,5

tttt

UUUUλ

16161616

15.715.715.715.7

100100100100



the 3the 3the 3the 3----way catalytic converter?way catalytic converter?way catalytic converter?way catalytic converter?

Two mutually opposite reactions. Two mutually opposite reactions. Two mutually opposite reactions. Two mutually opposite reactions.

Oxidation of hydrocarbon andOxidation of hydrocarbon andOxidation of hydrocarbon andOxidation of hydrocarbon and

Carbon monoxide into water vapor Carbon monoxide into water vapor Carbon monoxide into water vapor Carbon monoxide into water vapor

and Carbon dioxide. Deand Carbon dioxide. Deand Carbon dioxide. Deand Carbon dioxide. De----oxidation ofoxidation ofoxidation ofoxidation of

Nitrogen oxides into Nitrogen andNitrogen oxides into Nitrogen andNitrogen oxides into Nitrogen andNitrogen oxides into Nitrogen and

Oxygen. Oxygen. Oxygen. Oxygen. CO Vol%CO Vol%CO Vol%CO Vol% <0.1<0.1<0.1<0.1

O2 Vol%O2 Vol%O2 Vol%O2 Vol% <0.5<0.5<0.5<0.5

HC ppmHC ppmHC ppmHC ppm 10101010

CO2 CO2 CO2 CO2 Vol%Vol%Vol%Vol%

15.715.715.715.7

CO Vol%CO Vol%CO Vol%CO Vol% O2 Vol%O2 Vol%O2 Vol%O2 Vol% HC ppmHC ppmHC ppmHC ppm CO2 Vol%CO2 Vol%CO2 Vol%CO2 Vol%

10101010

0.50.50.50.5

<0.1<0.1<0.1<0.1


Exhaust gas mixture diagnostics

1.1.1.1. What do these values suggest?What do these values suggest?What do these values suggest?What do these values suggest?

An engine that runs at >An engine that runs at >An engine that runs at >An engine that runs at >λ=1. =1. =1. =1.

The mixture is too lean and can The mixture is too lean and can The mixture is too lean and can The mixture is too lean and can

result in ignition interferences. Theresult in ignition interferences. Theresult in ignition interferences. Theresult in ignition interferences. The

Lambda sensor voltage does not Lambda sensor voltage does not Lambda sensor voltage does not Lambda sensor voltage does not

fluctuate around 450 mV.fluctuate around 450 mV.fluctuate around 450 mV.fluctuate around 450 mV.

2.2.2.2. Which possible fault does this behavior Which possible fault does this behavior Which possible fault does this behavior Which possible fault does this behavior

0,50,50,50,5

UUUUλ

tttt16161616

14.814.814.814.8

>100>100>100>100



CO Vol%CO Vol%CO Vol%CO Vol% <0.1<0.1<0.1<0.1

O2 Vol%O2 Vol%O2 Vol%O2 Vol% <0.5 >1<0.5 >1<0.5 >1<0.5 >1

HC ppmHC ppmHC ppmHC ppm 10101010

CO2 CO2 CO2 CO2 Vol%Vol%Vol%Vol%

15.7 14.815.7 14.815.7 14.815.7 14.8

2.2.2.2. Which possible fault does this behavior Which possible fault does this behavior Which possible fault does this behavior Which possible fault does this behavior suggest?suggest?suggest?suggest?

It is possible that the engine is It is possible that the engine is It is possible that the engine is It is possible that the engine is

supplied with leak air. Even defective supplied with leak air. Even defective supplied with leak air. Even defective supplied with leak air. Even defective

sensors, such as HFM or the Lambda sensors, such as HFM or the Lambda sensors, such as HFM or the Lambda sensors, such as HFM or the Lambda

sensor can be responsible for this sensor can be responsible for this sensor can be responsible for this sensor can be responsible for this

behavior and should therefore be checked.behavior and should therefore be checked.behavior and should therefore be checked.behavior and should therefore be checked.

Reference values ACTUAL valuesReference values ACTUAL valuesReference values ACTUAL valuesReference values ACTUAL values

CO Vol%CO Vol%CO Vol%CO Vol% O2 Vol%O2 Vol%O2 Vol%O2 Vol% HC ppmHC ppmHC ppmHC ppm CO2 Vol%CO2 Vol%CO2 Vol%CO2 Vol%

>1>1>1>1

0.20.20.20.2


Summary of diagnosis as Central theme

Engine mechanicsEngine mechanicsEngine mechanicsEngine mechanicsCustomer informationCustomer informationCustomer informationCustomer information

regarding lack of driving comfort

whenwhenwhenwhen howhowhowhow

Diagnosis testDiagnosis testDiagnosis testDiagnosis testKTS KTS KTS KTS

Read FSPRead FSPRead FSPRead FSP

Actuator testActuator testActuator testActuator test

Query on actual valueQuery on actual valueQuery on actual valueQuery on actual value

Basic settingBasic settingBasic settingBasic settingExhaust systemExhaust systemExhaust systemExhaust system

Condition / seal tightness

Intake manifoldIntake manifoldIntake manifoldIntake manifold

Exhaust systemExhaust systemExhaust systemExhaust systemCondition / function

�Air flow

0.3/0.4bar

EGR EGR EGR EGR ---- SystemSystemSystemSystem

KAT (catalytic KAT (catalytic KAT (catalytic KAT (catalytic converter)converter)converter)converter)ExhaustExhaustExhaustExhaust

λλλλ SensorSensorSensorSensor

CoolantCoolantCoolantCoolant

Engine oilEngine oilEngine oilEngine oil

Oil pressureOil pressureOil pressureOil pressure

Compression/pressure lossCompression/pressure lossCompression/pressure lossCompression/pressure loss

Control timingsControl timingsControl timingsControl timings



Engine testEngine testEngine testEngine testMOT / FSA

ExhaustExhaustExhaustExhaust----gas analysergas analysergas analysergas analyser

Ignition patternsIgnition patternsIgnition patternsIgnition patterns

RUV/ROVRUV/ROVRUV/ROVRUV/ROV

SignalsSignalsSignalsSignals

ComparisonComparisonComparisonComparison

Exhaust valuesExhaust valuesExhaust valuesExhaust values

Analysis / Analysis / Analysis / Analysis / ∆∆∆∆HCHCHCHC

Intake manifoldIntake manifoldIntake manifoldIntake manifold

LinesLinesLinesLinesSwitchover intake Switchover intake Switchover intake Switchover intake systemsystemsystemsystemEvaluate the DK Evaluate the DK Evaluate the DK Evaluate the DK (Throttle valve) part(Throttle valve) part(Throttle valve) part(Throttle valve) part

EquipmentEquipmentEquipmentEquipmentESI / others

ComponentsComponentsComponentsComponents

SystemSystemSystemSystem

VehicleVehicleVehicleVehicle


1. Charcoal canister2. Air mass meter with

temperature sensor3. Purge control valve4. Knock sensor5. Temperature sensor 6. Fuel rail7. Injector8. Ignition coil9. Phase sensor10. Accelerator pedal module11. Throttle device (EGAS)12. EGR valve (optional)13. Intake manifold pressure

sensor14. Engine speed sensor15. Lambda sensor (LSU)16. Lambda sensor (LSF)

1

2**9

8

5

3

1115

25**

6

12**

16

17713

27

26

28

Natural Gas Bifuel-Motronic



GS/EVP2 21011d

16. Lambda sensor (LSF)17. Primary catalytic

converter18. Tank module19. Main catalytic converter20. Control unit21. CAN22. Diagnosis interface23. Diagnosis lamp (MIL)24. Immobilizer25. Camshaft timing control 26. CNG Rail27. CNG Injector28. Rail Pressure Tenp

Sensor29. CNG Tank Valve30. CNG Pressure Controll-

Module31. Gasoline-CNG-Switch

21

20

24

23

22

14

4

29

18

19

30*

10

31

-Bosch-standard-components

-natural-gas-fuel-components

* consisting of

pressure regulator, pressure sensor, pressure limiting valve,shut of valve, filter

** optional

natural gas

200 bar


CCCCompressed NNNNatural GGGGas

HHHH----Gas and LGas and LGas and LGas and L----GasGasGasGasThe general designation criterion "High Caloric" and "Low Caloric" for natural gas were introduced for better categorising of the methane content.

Concept:Concept:Concept:Concept: Natural gas is a combustible, gaseous mixture of all gaseous hydrocarbon compounds, which come from the earth. The composition of natural gas can vary. The main component of natural gas is MethaneMethaneMethaneMethane (CH4), therefore, chemically speaking, an organic compound comprising Carbon(C) and Hydrogen(H) elements. Natural gas is lighter than airis lighter than airis lighter than airis lighter than air and rises upwards.

Natural gas along with petroleum and coal belongs to the group of naturally combustible organic natural resources. The fossil fuels used as energy sources by us today are formed from organic substances about 600 million years ago.



better categorising of the methane content.The categorisation is based on the methane content in natural gas:

•H-gas methane content is from 87 to 98.9 of volume % , corresponds to about 1.5 Lt super-gasoline

•L-gas methane content is from 80.1 to 87 of volume % , corresponds to about 1.3 Lt super-gasoline

Although the methane content of L-gas is lower than that in H-gas, it does not automatically mean that it is of poorer quality. Indeed, the fuel consumption with L-gas is higher when compared to the H-gas, however, L-gas is generally more reasonably priced than H-gas.

Compared to gasoline, L-gas is more energy-rich and favourable: approximately 1.2 lt super-gasoline corresponds to the energy content of 1 kg natural gas of the group L.


1. Activated carbon canister2. Air mass meter with

intake air temperature3. Tank vent valve4. Knock sensor5. Temperature sensor6. Fuel rail7. Injection valve8. Rod ignition coil9. Phase sensor10. Accelerator pedal module11. EGAS12. EGR valve (optional)13. Intake manifold pressure

sensor14. Engine speed15. Lambda sensor (LSU)16. Lambda sensor (LSF)

1

2**9

8

5

3

1115

25**

6

12**

16

17713

27

26

28

Natural Gas Bifuel-Motronic



16. Lambda sensor (LSF)17. Pre-catalytic converter18. Tank module19. Main catalytic converter20. Control unit21. CAN22. Diagnostic interface23. Diagnostic light (MIL)24. Immobiliser25. Camshaft adjustment26. CNG rail27. CNG injector28. Pressure-temperature

sensor29. CNG tank valve30. CNG pressure control

module31. Gasoline-CNG-switch

21

20

24

23

22

14

4

29

18

19

30*

10

31

-Bosch-standard-components

-natural-gas-fuel-components

* consisting of

pressure regulator, pressure sensor, pressure limiting valve,shut-off valve, filter

** optional

natural gas

200 bar


Natural Gas Bifuel-Motronic M7.4.11NG



The ECU is based on the motronic for gasoline injection and actuates the natural gas-injection valves through separate power stages. The torque-guided control allows the simple integration of functions specific to the CNG-operation. The integration of the two fuel systems in a Bifuel-ECU brings in a series of advantages such as reduced cable expenditure, cost reduction through elimination of a second ECU as well as a high optimisation potential for the entire system.

A further advantage of the single ECU concept is the possibility of a co-ordinated switching between gasoline and CNG operation at every operating point, without a torque jump.


CNG tank valveTV-NG1

Shut-off valve:

Natural gas

tank

200 bar



- Single connection or cascading of the natural gas tanks

- Solenoid shut-off valve

- Thermal pressure relief valve (pressure relief valve high pressure optional)

- Optional temperature sensor

Manual valve


CNG tank valve

The inner tank valve with an electro-magnetic shut-off valve offers the possibility of connecting individual natural gas tanks or tank cascades. Through the inner structure, the space available in the vehicle is optimally used for the tank cylinder, this way the coverage is increased with simultaneous increase in crash safety due to the locationof the components, which lie protected in the tank. In addition, a thermal fuse, the optional overpressure safety control device and a flow limiter offer the protection necessary for natural gas applications.




Shut-off valve

U-slot connector

Pot

Armature

Coil

Spring

Moulding



Coil

Magnet core

Secondary sealing point

Primary sealing point

Flat sealing ring

Piston rod

Union nut


SOV

pressure sensor

Low pressure outlet

Pressure Regulator METATRON ND1



Coolant connection

high pressure inlet

Regulator cylinder

Filter screw


Working PrincipleWorking PrincipleWorking PrincipleWorking Principle

Methane flows from the tank pressure trough the inlet (1) and the filter (2) and reaches the shut-off valve which is normally closed as the gas pressure and the spring force the plunger (4) against the alluminium body seat. When the solneoid is energized the plunger (4) is magnetically attracted by the plug (5) the shut-off valve opens and the gas flows to the reduction stage where the pressure is reduched to the set value.

As the set value is higher than the atmospheric value (positive flow) the use of downstream injectors is needed.

Pressure Regulator METATRON ND1



(positive flow) the use of downstream injectors is needed. When the injectors are closed the flow trough the regulator is inhibited, the reduction stage closes as soon as the pressure is a bit higher than the set value. By opening the Injectors the gas flows out from the regulator at a constant pressure which is nearly independent of the flow rate.

Due to the gas pressure reduction a temperature drop occurs; to compensate this effect the engine cooling fluid is partially driven throgh the regulator in order to provide some heat. The pressure relief valve (6) is fitted to the pressure regulator stage and all the downstream fitte components: in case of abnormal pressure rise up to 19+1 barg the valve opens in order to discharge the excess of gas and closes again when the pressure falls down.


CNG fuel rail



The stainless steel rail was developed for gas applications. In an extraordinarily compact and robust design, it is suitable for all qualities of gases and for high pressures. After mounting the NGI2 gas injectors, the natural gas rail is tested for tightness and functioning.


Pressure Sensor DS M1-TF_CNG

FeaturesFeaturesFeaturesFeatures



Customer BenefitsCustomer BenefitsCustomer BenefitsCustomer Benefits


Natural gas injector NGI2

The first Bosch natural gas injection valve is available since many years. The new injection valve NGI2 was developed specially for the requirements of natural gas injection. With a series of technical innovations it sets the standards for gas metering. The gas flow-through components are adapted to the large gas volumes and to the high flow-through speed. A special flow guide reduces the pressure loss in front of the throttle point and also reduces the operating noise.

The solenoid coil can be operated with a standard power stage. The surface of the magnet armature is coated in such a manner that it does not get worn out even with oil-free gas.



not get worn out even with oil-free gas.

With its special design, the NGI2 surpasses all gas injection valves till date and can be integrated into existing intake manifold geometry without any problem.


Representation of tiININININJECTOR ININININJECTOR ININININJECTOR ININININJECTOR ININININJECTOR ININININJECTOR ININININJECTOR ININININJECTOR

CYL. 2 CYL. 4 CYL. 3 CYL. 1 CYL. 2 CYL: 4 CYL. 3 CYL. 1

CNG CNG CNG CNGCNG CNG CNG CNGCNG CNG CNG CNGCNG CNG CNG CNG



1. Indicate the signal curve:1. Indicate the signal curve:1. Indicate the signal curve:1. Indicate the signal curve:

a ) Ignition "on"a ) Ignition "on"a ) Ignition "on"a ) Ignition "on"

b ) Output stage is switched throughb ) Output stage is switched throughb ) Output stage is switched throughb ) Output stage is switched through

d ) Output stage is inhibitedd ) Output stage is inhibitedd ) Output stage is inhibitedd ) Output stage is inhibited

c ) Duration of the actuation time of c ) Duration of the actuation time of c ) Duration of the actuation time of c ) Duration of the actuation time of the EV (injection valve) (ti)the EV (injection valve) (ti)the EV (injection valve) (ti)the EV (injection valve) (ti)

Oscilloscope

ECU


Ports and function keysMeasuring channel Input Measuring channel Input Measuring channel Input Measuring channel Input CH1 CH1 CH1 CH1 –––– CH4CH4CH4CH4

Ground Ground Ground Ground connectionconnectionconnectionconnection

Menu keyMenu keyMenu keyMenu key

Help keyHelp keyHelp keyHelp key

DVOM DVOM DVOM DVOM Digital Volt Ohm MeterDigital Volt Ohm MeterDigital Volt Ohm MeterDigital Volt Ohm Meter

Enter key (Input key)Enter key (Input key)Enter key (Input key)Enter key (Input key)

Exit (End)Exit (End)Exit (End)Exit (End)



On / Off switchOn / Off switchOn / Off switchOn / Off switch

Cursor keysCursor keysCursor keysCursor keys

COM 1 Port Stylus for Touchscreen COM 1 Port Stylus for Touchscreen COM 1 Port Stylus for Touchscreen COM 1 Port Stylus for Touchscreen

COM 2 Port LAN portCOM 2 Port LAN portCOM 2 Port LAN portCOM 2 Port LAN port

Exit (End)Exit (End)Exit (End)Exit (End)

Brightness settingBrightness settingBrightness settingBrightness settingfor the TFT Monitorfor the TFT Monitorfor the TFT Monitorfor the TFT Monitor

PCMCI Card SlotPCMCI Card SlotPCMCI Card SlotPCMCI Card Slot


Ports and function keys

Port for trigger clampPort for trigger clampPort for trigger clampPort for trigger clamp

Primary ignition (PRI IGN)Primary ignition (PRI IGN)Primary ignition (PRI IGN)Primary ignition (PRI IGN)

Auxiliary port forAuxiliary port forAuxiliary port forAuxiliary port forVacuum and pressure sensorsVacuum and pressure sensorsVacuum and pressure sensorsVacuum and pressure sensors

8“ TFT colour display 8“ TFT colour display 8“ TFT colour display 8“ TFT colour display with Touchscreenwith Touchscreenwith Touchscreenwith Touchscreen



Secondary ignition (SEC IGN)Secondary ignition (SEC IGN)Secondary ignition (SEC IGN)Secondary ignition (SEC IGN)

12V DC Input 12V DC Input 12V DC Input 12V DC Input

Adjustable device positionAdjustable device positionAdjustable device positionAdjustable device position

Supporting loopsSupporting loopsSupporting loopsSupporting loops


FTU (File Transfer Utility)

> Configuring the COM Port in the programme> Configuring the COM Port in the programme> Configuring the COM Port in the programme> Configuring the COM Port in the programme

> Connecting the FSA 450 COM2 with the PC > Connecting the FSA 450 COM2 with the PC > Connecting the FSA 450 COM2 with the PC > Connecting the FSA 450 COM2 with the PC



1.1.1.1. From where can I procure the Software FTU?From where can I procure the Software FTU?From where can I procure the Software FTU?From where can I procure the Software FTU?

The FTU software is free of charge for the SystemSoft of FSA 450.The FTU software is free of charge for the SystemSoft of FSA 450.The FTU software is free of charge for the SystemSoft of FSA 450.The FTU software is free of charge for the SystemSoft of FSA 450.

2.2.2.2. What are the possibilities offered by Software FTU? What are the possibilities offered by Software FTU? What are the possibilities offered by Software FTU? What are the possibilities offered by Software FTU?

FTU facilitates the transfer of the memory of FSA 450 to FTU facilitates the transfer of the memory of FSA 450 to FTU facilitates the transfer of the memory of FSA 450 to FTU facilitates the transfer of the memory of FSA 450 to

the PC and the printthe PC and the printthe PC and the printthe PC and the print----out of measurement records.out of measurement records.out of measurement records.out of measurement records.

3.3.3.3. What are the prerequisites for transferring the files?What are the prerequisites for transferring the files?What are the prerequisites for transferring the files?What are the prerequisites for transferring the files?

The file transfer is only possible if the mask of the FSA 450 displays Menu Extras.The file transfer is only possible if the mask of the FSA 450 displays Menu Extras.The file transfer is only possible if the mask of the FSA 450 displays Menu Extras.The file transfer is only possible if the mask of the FSA 450 displays Menu Extras.


FTU (File Transfer Utility)

SCP_20062001_122834.bmp

1 2 3 4 5 6 7 8

1 – Memory Index2 – Year3 – Month



4 – Day5 – Hour6 – Minute7 – Second8 – File type

SCPIGN VAC GMM CKK

= 4 Channel Oscilloscope= Ignition mode= Vacuum mode= Graphic Multimeter= KV Quick test


Utility programme - Menu - Settings / File Manager

– necessary only for networkingnecessary only for networkingnecessary only for networkingnecessary only for networking– Measurement units (temperature Measurement units (temperature Measurement units (temperature Measurement units (temperature

pressure) Startpressure) Startpressure) Startpressure) Start----up test kV settingup test kV settingup test kV settingup test kV setting

1.1.1.1. What are the functions of the file What are the functions of the file What are the functions of the file What are the functions of the file manager? manager? manager? manager?

-Set Date / TimeSet Date / TimeSet Date / TimeSet Date / Time

- Select languageSelect languageSelect languageSelect language

- Configure IPConfigure IPConfigure IPConfigure IP----AddressAddressAddressAddress

- Measurements and settingsMeasurements and settingsMeasurements and settingsMeasurements and settings



manager? manager? manager? manager? – To call up the measurement and To call up the measurement and To call up the measurement and To call up the measurement and

snapshotssnapshotssnapshotssnapshots– To process noticesTo process noticesTo process noticesTo process notices– To delete measurements To delete measurements To delete measurements To delete measurements – To format flash memoryTo format flash memoryTo format flash memoryTo format flash memory– Search functionSearch functionSearch functionSearch function– To display the memory capacityTo display the memory capacityTo display the memory capacityTo display the memory capacity– To load TechView To load TechView To load TechView To load TechView


Utility programme - Menu - Extras

- Display SoftwareDisplay SoftwareDisplay SoftwareDisplay Software----version numberversion numberversion numberversion number

- SelfSelfSelfSelf----testtesttesttestCOM1 ; COM2 ; LCDCOM1 ; COM2 ; LCDCOM1 ; COM2 ; LCDCOM1 ; COM2 ; LCD----Test ; and TouchTest ; and TouchTest ; and TouchTest ; and Touch----Screen Screen Screen Screen –––– TestTestTestTest

- CalibrationCalibrationCalibrationCalibrationPressure converter ; Vacuum sensor ; Primary injection Pressure converter ; Vacuum sensor ; Primary injection Pressure converter ; Vacuum sensor ; Primary injection Pressure converter ; Vacuum sensor ; Primary injection Touchscreen calibration ; Port AUXILIARY Touchscreen calibration ; Port AUXILIARY Touchscreen calibration ; Port AUXILIARY Touchscreen calibration ; Port AUXILIARY

- To charge batteryTo charge batteryTo charge batteryTo charge battery



- To charge batteryTo charge batteryTo charge batteryTo charge batteryBattery will not be charged automatically by the power packBattery will not be charged automatically by the power packBattery will not be charged automatically by the power packBattery will not be charged automatically by the power packThe charge programme must be activated earlier. The maximum possible The charge programme must be activated earlier. The maximum possible The charge programme must be activated earlier. The maximum possible The charge programme must be activated earlier. The maximum possible charging capacity will be reached finally after many number of charge andcharging capacity will be reached finally after many number of charge andcharging capacity will be reached finally after many number of charge andcharging capacity will be reached finally after many number of charge anddischarge cycles. discharge cycles. discharge cycles. discharge cycles.

- To format the internal flash memoryTo format the internal flash memoryTo format the internal flash memoryTo format the internal flash memorydeletes the complete data memorydeletes the complete data memorydeletes the complete data memorydeletes the complete data memory

- Activate the ignition demonstrationActivate the ignition demonstrationActivate the ignition demonstrationActivate the ignition demonstrationDemoDemoDemoDemo----programmeprogrammeprogrammeprogramme


Display mode Primary / SecondaryTime/div

Volt/div

1.1.1.1. What are the advantages offered What are the advantages offered What are the advantages offered What are the advantages offered by the snapshotby the snapshotby the snapshotby the snapshotThe snapshot permits the The snapshot permits the The snapshot permits the The snapshot permits the recording of currently runningrecording of currently runningrecording of currently runningrecording of currently runningmeasurements similar to a film.measurements similar to a film.measurements similar to a film.measurements similar to a film.Thus the possibility exists toThus the possibility exists toThus the possibility exists toThus the possibility exists toevaluate a measurement over aevaluate a measurement over aevaluate a measurement over aevaluate a measurement over along period of time after thelong period of time after thelong period of time after thelong period of time after theevent, e.g. Warm running period.event, e.g. Warm running period.event, e.g. Warm running period.event, e.g. Warm running period.



event, e.g. Warm running period.event, e.g. Warm running period.event, e.g. Warm running period.event, e.g. Warm running period.The measurement need not beThe measurement need not beThe measurement need not beThe measurement need not beevaluated. At the same instanceevaluated. At the same instanceevaluated. At the same instanceevaluated. At the same instanceany more.any more.any more.any more.


Signal display Primary / Secondary



1.1.1.1. What should be taken into consideration during the signal evaluation What should be taken into consideration during the signal evaluation What should be taken into consideration during the signal evaluation What should be taken into consideration during the signal evaluation using FSA 450? using FSA 450? using FSA 450? using FSA 450? The start of signal of the primary and secondary injection is notThe start of signal of the primary and secondary injection is notThe start of signal of the primary and secondary injection is notThe start of signal of the primary and secondary injection is notwith the ignition voltage needle, as is normal for the well knownwith the ignition voltage needle, as is normal for the well knownwith the ignition voltage needle, as is normal for the well knownwith the ignition voltage needle, as is normal for the well knownBOSCHBOSCHBOSCHBOSCH----Testers, instead it is the start of the closing angle.Testers, instead it is the start of the closing angle.Testers, instead it is the start of the closing angle.Testers, instead it is the start of the closing angle.


Signal display Primary / Secondary




Secondary quick-test

1.1.1.1. Which connection leads can be used?Which connection leads can be used?Which connection leads can be used?Which connection leads can be used?

The secondary terminal of the FSAThe secondary terminal of the FSAThe secondary terminal of the FSAThe secondary terminal of the FSA

450 or the secondary test probe with450 or the secondary test probe with450 or the secondary test probe with450 or the secondary test probe with

cable adaptation.cable adaptation.cable adaptation.cable adaptation.

1.1.1.1. In which other system can the quickIn which other system can the quickIn which other system can the quickIn which other system can the quick----test test test test



1.1.1.1. In which other system can the quickIn which other system can the quickIn which other system can the quickIn which other system can the quick----test test test test be used?be used?be used?be used?

Also in case of Litronic Also in case of Litronic Also in case of Litronic Also in case of Litronic –––– Systems,Systems,Systems,Systems,

the ignition voltage of the Gasthe ignition voltage of the Gasthe ignition voltage of the Gasthe ignition voltage of the Gas

discharge lamp can be checkeddischarge lamp can be checkeddischarge lamp can be checkeddischarge lamp can be checked


Graphic Multimeter

Example SignalExample SignalExample SignalExample Signal

Lambda sensorLambda sensorLambda sensorLambda sensor



1.1.1.1. Where can the graphic multimeter be used?Where can the graphic multimeter be used?Where can the graphic multimeter be used?Where can the graphic multimeter be used?

For evaluation of the measuring values over a long period of time, e.g. For evaluation of the measuring values over a long period of time, e.g. For evaluation of the measuring values over a long period of time, e.g. For evaluation of the measuring values over a long period of time, e.g.

Consumer measurement in the vehicle electrical system.Consumer measurement in the vehicle electrical system.Consumer measurement in the vehicle electrical system.Consumer measurement in the vehicle electrical system.

2.2.2.2. How long is the maximum period of time in case of measurement with snapshot? How long is the maximum period of time in case of measurement with snapshot? How long is the maximum period of time in case of measurement with snapshot? How long is the maximum period of time in case of measurement with snapshot?

The maximum recording time is determined by the type of measurement and the freeThe maximum recording time is determined by the type of measurement and the freeThe maximum recording time is determined by the type of measurement and the freeThe maximum recording time is determined by the type of measurement and the free

space in memory.space in memory.space in memory.space in memory.

Lambda sensorLambda sensorLambda sensorLambda sensor


DVOM



1.1.1.1. What does the abbreviation DVOM stand for? What does the abbreviation DVOM stand for? What does the abbreviation DVOM stand for? What does the abbreviation DVOM stand for?

Digital Digital Digital Digital ---- Volt Volt Volt Volt ---- Ohm Ohm Ohm Ohm ---- Meter Meter Meter Meter


4-channel Oscilloscope Operation

Selection of the individual measuring channels Selection of the individual measuring channels Selection of the individual measuring channels Selection of the individual measuring channels >>>>

various prevarious prevarious prevarious pre----adjustments > adjustments > adjustments > adjustments >

Trigger selection >Trigger selection >Trigger selection >Trigger selection > < freezing the measurements< freezing the measurements< freezing the measurements< freezing the measurements



Connection help >Connection help >Connection help >Connection help >

Standard setting resetting >Standard setting resetting >Standard setting resetting >Standard setting resetting >

Measurement cycle filming >Measurement cycle filming >Measurement cycle filming >Measurement cycle filming >

Display Time axis >Display Time axis >Display Time axis >Display Time axis >

Setting Time axis >Setting Time axis >Setting Time axis >Setting Time axis >

< increasing the resolution< increasing the resolution< increasing the resolution< increasing the resolution

< automatic signal search< automatic signal search< automatic signal search< automatic signal search

< measuring the Signal< measuring the Signal< measuring the Signal< measuring the Signal


4-channel Oscilloscope Measurements



1.1.1.1. How can the metering bars be adjusted ?How can the metering bars be adjusted ?How can the metering bars be adjusted ?How can the metering bars be adjusted ?

The adjustment is carried out through the function keys.The adjustment is carried out through the function keys.The adjustment is carried out through the function keys.The adjustment is carried out through the function keys.


Component selection



1.1.1.1. What possibilities are offered by the component selection?What possibilities are offered by the component selection?What possibilities are offered by the component selection?What possibilities are offered by the component selection?A preA preA preA pre----adjusted measurement is involved. The parameter must not be adjusted measurement is involved. The parameter must not be adjusted measurement is involved. The parameter must not be adjusted measurement is involved. The parameter must not be adjusted.adjusted.adjusted.adjusted.


4-channel Oscilloscope Signal evaluation



3 Channel recording of the reference marks, NW3 Channel recording of the reference marks, NW3 Channel recording of the reference marks, NW3 Channel recording of the reference marks, NW---- sensor and speed sensor sensor and speed sensor sensor and speed sensor sensor and speed sensor

1.1.1.1. Are there exemplary patterns available from the various sensors for comparison?Are there exemplary patterns available from the various sensors for comparison?Are there exemplary patterns available from the various sensors for comparison?Are there exemplary patterns available from the various sensors for comparison?Some signal patterns are stored in the ESI[tronic], however, not in all the manuals. Some signal patterns are stored in the ESI[tronic], however, not in all the manuals. Some signal patterns are stored in the ESI[tronic], however, not in all the manuals. Some signal patterns are stored in the ESI[tronic], however, not in all the manuals. Here, it is advisable to store the failure patterns and to create a data base.Here, it is advisable to store the failure patterns and to create a data base.Here, it is advisable to store the failure patterns and to create a data base.Here, it is advisable to store the failure patterns and to create a data base.

The engine does not start.The engine does not start.The engine does not start.The engine does not start.System is okSystem is okSystem is okSystem is ok The engine does not startThe engine does not startThe engine does not startThe engine does not start


FSA 450 Accessories




Service Training CenterWe offer seminars on the following topics:We offer seminars on the following topics:We offer seminars on the following topics:We offer seminars on the following topics:---- AutomobileAutomobileAutomobileAutomobile----Electricals/Electronics Electricals/Electronics Electricals/Electronics Electricals/Electronics ---- Gasoline injectionGasoline injectionGasoline injectionGasoline injection---- Diesel injectionDiesel injectionDiesel injectionDiesel injection---- Brake systemsBrake systemsBrake systemsBrake systems---- Mechanical systemsMechanical systemsMechanical systemsMechanical systems

Multimedia training:Multimedia training:Multimedia training:Multimedia training:---- Web Based TrainingWeb Based TrainingWeb Based TrainingWeb Based Training

• Diesel technologyDiesel technologyDiesel technologyDiesel technology• Electrical/electronic systemsElectrical/electronic systemsElectrical/electronic systemsElectrical/electronic systems• Gasoline direct injectionGasoline direct injectionGasoline direct injectionGasoline direct injection• Active brake safety systemsActive brake safety systemsActive brake safety systemsActive brake safety systems



• Active brake safety systemsActive brake safety systemsActive brake safety systemsActive brake safety systems---- eLearning eLearning eLearning eLearning �� Multimedia lectures on motor vehicle technologyMultimedia lectures on motor vehicle technologyMultimedia lectures on motor vehicle technologyMultimedia lectures on motor vehicle technology

Training series:

Bosch diesel technician

Bosch diesel aggregate technician

Bosch vehicle technician for gasoline direct injection

Bosch vehicle technician for brake systems

Bosch vehicle technician for electrical systems

Bosch vehicle technician for electronic systems

Further information can be found in the internet under:

http://rb-aa.bosch.com/diagnostics/de/start/index_flash.htm


Additional informationReference books Reference books Reference books Reference books ISBNISBNISBNISBN Order numberOrder numberOrder numberOrder numberKraftfahrtechnisches Taschenbuch (Automotive handbook) (25th edition) 978-38348-01388 1 987 723 001 Autoelektrik, Autoelektronik (4. Auflage) (Automobile electrical, Automobile electronics (4th edition)) 978-35282-38728 1 987 723 501 Ottomotoren-Management (Otto engine management) 978-38348-00376 1 987 723 504 Sicherheits- und Komfortsysteme (3. Auflage) (Safety systems and comfort and convenience system (3rd edition)) 978-35282-38735 1 987 723 503Dieselmotormanagement (Diesel engine management) 978-35281-38752 1 987 723 502Ottomotor-Management (Gasoline engine management ) Gasoline engine management ) Gasoline engine management ) Gasoline engine management ) Abgastechnik für Ottomotoren (Emission technique for Otto engines) 978-3-86522-000-4 1 987 722 020 Benzineinspritzsystem K-Jetronic (Gasoline injection system K-Jetronic) 978-3-86522-001-1 1 987 722 009

Benzineinspritzsystem KE-Jetronic (Gasoline injection system KE-Jetronic) 978-3-86522-002-8 1 987 722 021 Benzineinspritzsystem L-Jetronic ( Gasoline injection system L-Jetronic) 978-3-86522-003-5 1 987 722 010 Benzineinspritzsystem Mono-Jetronic (Gasoline injection system Mono-Jetronic) 978-3-86522-028-8 1 987 722 033 Zündung im Ottomotor (Ignition in Otto engine) 978-3-86522-006-6 1 987 722 030 Ottomotor-Management - Grundlagen und Komponenten (Otto engine management –basic principles and components) 978-3-86522-004-2 1 987 722 036 Ottomotor-Management - Motronic-Systeme (Otto engine management –Motronic Systems) 978-3-86522-005-9 1 987 722 029 Diesel engine management (Diesel engine management (Diesel engine management (Diesel engine management (Dieselmotor-Management)Diesel-Reiheneinspritzpumpen (Diesel in-line fuel-injection pumps) 978-3-86522-013-4 1 987 722 057 Dieselmotor-Management im Überblick (Diesel engine management at a glance) 978-3-86522-007-3 1 987 722 058 Kantengesteuerte Diesel-Verteilereinspritzpumpen (Helix-controlled diesel distributor-type injection pumps) 978-3-86522-012-7 1 987 722 014 Magnetgesteuerte Diesel-Verteilereinspritzpumpen (Magnet-controlled diesel



Additional information on the topics handled in this training program as well as other topics of interest can be found in the following publications of Robert Bosch GmbH. They can be purchased from the bookstore.

Magnetgesteuerte Diesel-Verteilereinspritzpumpen (Magnet-controlled diesel distributor-type injection pumps) 978-3-86522-008-0 1 987 722 059 Diesel-Einspritzsyst.(Diesel injection system) Unit injector / Unit pump system 978-3-86522-009-7 1 987 722 056 Elektronische Dieselregelung EDC (Electronic diesel control EDC) 978-3-86522-011-0 1 987 722 035 Diesel-Speichereinspritzsystem Common Rail CR (Common Rail CR direct fuel injection system for diesel engines) 978-3-86522-010-3 1 987 722 062Abgastechnik für Dieselmotoren (Exhaust-gas technology for diesel engines) 978-3-86522-082-0 1 987 722 061SicherheitsSicherheitsSicherheitsSicherheits---- und Komfortsysteme (Safety systems and comfort and convenience systems)und Komfortsysteme (Safety systems and comfort and convenience systems)und Komfortsysteme (Safety systems and comfort and convenience systems)und Komfortsysteme (Safety systems and comfort and convenience systems)Konventionelle und elektronische Bremssysteme (Conventional and electronic brake systems) 978-3-86522-014-1 1 987 722 023 Fahrstabilisierungssysteme (Driving stability systems) 978-3-86522-015-8 1 987 722 026 Sicherheits- und Komfortsysteme (Safety sytems and comfort and convenience systems) 978-3-86522-019-6 1 987 722 037 Audio, Navigation und Telematik (Audio, Navigation and Telematics) 978-3-86522-020-2 1 987 722 032 Adaptive Fahrgeschwindigkeitsregelung ACC (Adaptative cruise control ACC) 978-3-86522-018-9 1 987 722 034 Elektronische Getriebesteuerung EGS (Electronic transmission Control EGS) 978-3-86522-026-4 1 987 722 027Nfz-Druckluftanlagen (1): (Commercial vehicle compressed air systems(1):) Grundl., Systeme und Pläne (Fundamentals, systems and drawings) 978-3-86522-016-5 1 987 722 015 Nfz-Druckluftanlagen (2): (Commercial vehicle compressed air systems(2):) Geräte (Devices) 978-3-86522-017-2 1 987 722 016 Autoelektrik / Autoelektronik (Automobile electricals / automobile electronics)Autoelektrik / Autoelektronik (Automobile electricals / automobile electronics)Autoelektrik / Autoelektronik (Automobile electricals / automobile electronics)Autoelektrik / Autoelektronik (Automobile electricals / automobile electronics)Batterien und Bordnetze (Batteries and vehicle electrical systems) 978-3-86522-024-0 1 987 722 003 Generatoren und Startanlagen (Generators and starting systems) 978-3-86522-025-7 1 987 722 028 Lichttechnik und Scheibenreinigung (Lighting technology and windshield and rear-window cleaning) 978-3-86522-023-3 1 987 722 039 Mikroelektronik im Kraftfahrzeug (Micro-electronics in the automobile) 978-3-86522-022-6 1 987 722 022 Sensoren im Kraftfahrzeug (Sensors in the automobile) 978-3-86522-021-9 1 987 722 031 Vernetzung im Kraftfahrzeug (Networking in the automobile) 978-3-86522-276-3 1 987 722 067Hybridantriebe, Brennstoffzellen und alternative Kraftstoffe (Hybrid drives, fuel cells and alternative fuels) 978-3-86522-277-0 1 987 722 065


One stop solutionOne stop solutionOne stop solutionOne stop solutionBosh Diagnostics for the workshop



Test EquipmentTest EquipmentTest EquipmentTest Equipment Technical Technical Technical Technical HotlineHotlineHotlineHotline

KnowledgeKnowledgeKnowledgeKnowledgeDatabaseDatabaseDatabaseDatabase

Spare partsSpare partsSpare partsSpare parts


Work sheet - Station Motronic

Checking component:Checking component:Checking component:Checking component:________________Measurement value:Measurement value:Measurement value:Measurement value:

Nominal value / Actual valueNominal value / Actual valueNominal value / Actual valueNominal value / Actual value




Work sheet – Signal of Component:









Checking component:Checking component:Checking component:Checking component:________________Measurement value:Measurement value:Measurement value:Measurement value:

Nominal value / Actual valueNominal value / Actual valueNominal value / Actual valueNominal value / Actual value













Measure and test:Measure and test:Measure and test:Measure and test:

ComponentsComponentsComponentsComponents DesignDesignDesignDesign

Motronic withMotronic withMotronic withMotronic with

Load info.Load info.Load info.Load info.




Load requirementLoad requirementLoad requirementLoad requirement

Idling speed control (LLR) asIdling speed control (LLR) asIdling speed control (LLR) asIdling speed control (LLR) as

Ignition systemIgnition systemIgnition systemIgnition system

Lambda controlLambda controlLambda controlLambda control

AddAddAddAdd----on moduleson moduleson moduleson modules

DiagnosticsDiagnosticsDiagnosticsDiagnostics



Measure and test:Measure and test:Measure and test:Measure and test:

ComponentsComponentsComponentsComponents Signal / Voltage / FunctionSignal / Voltage / FunctionSignal / Voltage / FunctionSignal / Voltage / Function






Idling speed control (LLR) asIdling speed control (LLR) asIdling speed control (LLR) asIdling speed control (LLR) as

Ignition systemIgnition systemIgnition systemIgnition system

Lambda controlLambda controlLambda controlLambda control

AddAddAddAdd----on moduleson moduleson moduleson modules

DiagnosticsDiagnosticsDiagnosticsDiagnostics

Saipa Motronic Training M7.9.7 and M7.4 - …eng.saipayadak.org/CarDocument/RM/x100RM2C31 تعميرات بوش...Saipa Motronic Training M7.9.7 and M7.4.11NG. Fundamentals of trouble-shooting.

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