Gasoline Systems

Gasoline Systems
Bosch began setting new standards in gasoline injection systems over 30 years ago with its range of complete systems called ‘Jetronic Fuel Injection System’, which proved its worth in millions of vehicles. There are more than 18000 parts in the BOSCH Gasoline System with appropriate spare parts for the aftermarket and workshop trade. BOSCH Injection Systems offer advanced system technology which incorporates the very latest research and development innovations.
This is characterised by perfect harmonisation with the respective engine to minimise fuel consumption, optimise performance and reduce emissions. Since designing the first fuel injection system, Bosch has become the largest OE manufacturer of fuel engine management systems and components for vehicle manufacturers worldwide. With total commitment to remain at the cutting edge of systems design and innovation, Bosch is developing the next generation of systems for automobiles the world over. Bosch is the largest Original Equipment (OE) manufacturer of petrol injection systems and components for vehicle manufacturers worldwide. There are over 50 million Bosch systems currently in use in petrol engine cars. Bosch petrol injection components cover over 60 vehicle manufacturers all over the world.
Until now the fuel-air mixture was formed in the induction manifold. The search for new possibilities to improve fuel injection further has led to a new technique called the electronically controlled petrol direct injection - Motronic MED7. When idling, or in heavy urban traffic, the engine runs on miser mode with MED7. The layered cylinder charging allows the engine to run extremely lean and with low fuel consumption. As soon as full power is required, the MED7 injects petrol so that a uniform mixture is created. Even in this operating mode the direct injection engine is more economical than conventional engines. Advantages

• Advanced technology
• Higher power and performance
• Tried and tested technology
• 15% less fuel consumption
• Economical
• Longer engine life

Electric Fuel Pump & In-tank Module
The fuel pump continuously pumps fuel from the fuel reservoir to the engine for keeping up the necessary fuel pressure at all operating conditions. Fuel pumps can be installed in the fuel reservoir (in-tank) or in the fuel line (in-line). The in-tank module is a system that consists of an in-tank fuel pump, a fuel tank level sensor and a pressure regulator. In principle, the in-tank modules can be distinguished in systems with back-flow and without back-flow. In the future, in-tank modules will dominate due to cost and environment issues.
Features/ Benefits

• Highest performance
• Longer lifetime - greatest possible filter surface
• Increased driving comfort due to reduced noise
• Maximum reliability
• Simplified installation
• Recyclable and made of non-polluting material
• Exclusion of signal disturbances due to outstanding screening with condenser and suppression cap
• Adherence to the Law Regulation for Used cars 2003 - i.e. recyclable and use of non-polluting materials

BOSCH Ignition SystemsIn the area of ignition technology, the singular projection of Bosch in the experience of development for original equipment offers important advantages. BOSCH Ignition Systems combine the security of fully developed system engineering with the employment of the latest research results.
The ignition coil provides the ignition voltage. A spark flashes between the electrodes of the plug and the combustion of the fuel-air mixture in the cylinder of the engine. The induction principle is the basis for the ignition voltage between primary winding and secondary winding. For preventing eddy currents, the so called core package is made up of a bundle of iron sheet metals. The function of the core package is the amplification of the magnetic field in the secondary windings. 300 volts primary voltage (induced by the collapse of the magnetic field) will be transformed to 30,000 volts secondary voltage. Ignition-pulse generators or Motronic control units control the ignition coil directly and determine the ignition time. Defective ignition coils are recognised by the self-diagnosis of the vehicle or by a suitable engine tester.
Features

• Plastic ignition coils - low weight and low size
• High electrical tension solidity, high temperature solidity and high vibration solidity
• Suitable for direct engine installation (installation in the cylinder head)

Benefits

• Highest quality for maximum safe functions have already been realised with the asphalt ignition coil which distinguishes itself through high robustness in the application
• Advantages of the modern plastic ignition coils are minimisation of weight and size with production of higher electrical voltage, temperature and shock resistance
  • Ensures all advantages of the original equipment
  • Demand controlled ignition voltage
  • Long spark duration
  • Better engine performance
  • Reduced fuel consumption
  • Reduced obnoxious emissions in exhaust gas
• Highest expertise in production due to the laser based optimisation of coiling and redundant acquisition of measured data during the encapsulating process. 100% quality control and regular reliability tests assure the constant adherence to the OEM specifications

BOSCH Oxygen Sensors/ Lambda Sensors
Lambda sensors provide maximum engine power, clean exhaust gas and low fuel consumption. The Lambda sensor provides low emission values at great fuel economy and maximum engine power. This is why the inventor of the Lambda sensor, Bosch, suggests that, for economic as well as environmental reasons, the functioning of the sensor should be regularly checked and replaced if necessary. Bosch is the No. 1 supplier of Lambda sensors that are mainly used in the automotive equipment and the aftermarket. Bosch uses the original connector for all oxygen sensors which guarantees a secure connection and the easy change of the sensor. No additional adaptors are necessary. Bosch manufactures 33 million sensors every year.
Features/ Benefits

• Up to 15% savings on fuel savings compared to old or defective oxygen sensors
• Prevention of catalyst damage
• Adherence to the permissible emission figures, low contaminant output. Consequently no problems in the annual exhaust-emission check • Increased driving comfort due to better engine performance

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Braking Systems

Braking systems Brake pads
The braking system is only as strong as its weakest point. That.s why there must be no compromises on the overall braking system, especially in key components like brake pads. Asbestos-free BOSCH Brake Pads are specially formulated for absolute assurance of safe, sure stopping power, from the first stop . because when it comes to safety, there can be no compromises. Available for a wide range of cars and MUVs, these brake pads provide high comfort and performance, with little pedal effort. Brought to you by Bosch, the world leader in braking systems, these pads are manufactured to international standards. BOSCH Brake Pads offer great value for money.
Features/ Benefits
Advanced, environment-friendly, non-asbestos friction technology
Human safety for us is a top priority hence, we use 100% asbestos-free friction material to manufacture our brake pads.
Excellent stopping power
The brake pads are manufactured using material which has highly stable co-efficient of friction and hence excellent stopping power.
Good pedal feel
Closely controlled tolerances in the manufacturing process give the driver a comfortable feel at the brake pedal.
High temperature performance
Friction co-efficient of the material used in the brake pads is of highest quality and is tested for stability at high temperature conditions. Bosch Warranty (against manufacturing defects)
In the unlikely event of a failure of brake pad due to any manufacturing defect pertaining to friction material or back plate, the same is supported by an all India Bosch Warranty System.
Brake fluids
Brake fluid is one of the most important components in a braking system. It plays the role of transferring the braking force from the brake master cylinder to the wheel brakes, of lubricating the hydraulic components and protecting against corrosion. For this, the brake fluid must have a constant viscosity and a boiling point that is as high as possible under all temperature and operating conditions, in order to prevent the formation of bubbles.
The quality and safety of a brake fluid is defined by its boiling point. Bosch brake fluids exceed these standards. With higher wet and dry boiling points, you can recommend Bosch Brake fluids every time, and your customers will be secure knowing that they have made the safest choice.
Being a critical component of the vehicle's braking system, brake fluid should be checked regularly and replaced if required. Bosch recommends that brake fluid is completely replaced annually.
Depending on the brake system and manufacturer's specification, Bosch offers several brake fluid variants, Conforming to DOT standards, in accordance with IS: 8654-2001
DOT 3 is the most commonly used brake fluid in vehicles. It cannot be mixed with or replaced by other brake fluid variants. DOT 4 indicates brake fluid with higher boiling points. This fluid is used in new generation vehicles.
Features / benefits:
Consistent and steady brake pressure response throughout its service life
Optimal viscosity even under extreme temperature conditions
Maximum protection against vapour formation and corrosion
Enhanced lubrication of the hydraulic components

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Clutch plates and Cover assemblies

Clutch plates and Cover assemblies
For years, Clutch Plates and Cover Assemblies from Bosch Ltd. and Bosch have been a force in driving technology in India. Now they are even better as the new range is completely asbestos-free, in keeping with international standards. So you get the same high-quality and high performance, only now, the clutch plates and cover assemblies you have trusted for years are even more environmentally friendly. Asbestos-free clutch plates eliminate exposure to harmful cancer-causing materials – hence it is environmentally friendly. Features/ Benefits

• Non-carcinogenic and safe
• Longer life - At least 1.5 times the asbestos type
• High wear resistance
• Improved power transmission
• Maximum driving comfort with no jerky movements
• Easier shifting of gears
• Sturdy design for high-performance and reliability
• Reduced noise and vibration
• 3-stage design of damper is torsional vibration free, hence longer life
• Asbestos-free woven clutch facing for judger-free operation
• Higher coefficient of friction at high temperatures which results in better torque transmission
• Reduced clutch slippage, noise and vibration

Functions

• It allows the gear box to be disengaged from the engine when stopping and starting in traffic and when changing gears to allow for smooth, easy changes.
• It allows power from the engine to be progressively fed into the gear box and to the wheels for smooth starting.
• Engagement of the clutch allows for power transfer from the engine to the transmission and eventually to the drive wheels. Disengagement of the clutch provides the necessary halt-of-power transfer that allows the engine to continue running while no power is supplied to the drive wheels.

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Belts

Belts
Bosch Ltd. and BOSCH Automotive Belts are manufactured using superior quality rubber compounds and by state-of-the-art machines, which make these belts perform better and give it longer life. Maintaining our high standards of quality, these belts are available in three types: Wrapped Belts, Cogged Auto Belts, and Ribbed V-Belts for wide range of applications. Wrapped Belts (Ordinary Belts)

• Heat-stretched polyester cord ensures low expansion even in adverse conditions
• Compact belt-pulley relationship for optimum power transmission
• Greater resistance to wear and tear
• Special quality rubber makes it anti-static
• Excellent resistance to heat, oil and abrasion

Cogged Auto Belts

• Special anti-stretch rubber compound for higher resistance
• High corrosion and abrasion resistance
• Unique cog design for smooth flexing and longer belt life
• Optimum power transmission
• Minimum energy loss

Ribbed V-Belts (Poly V-Belts)

• Single belt for multiple drives
• Highly flexible
• High resistance to heat, wear and tear
• Low noise and vibration when in use
• Greater drive stability
• Larger shock-load tolerance
• Excellent tensile properties 
• CLICK HERE for more info and find pats number price list also.

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Auto Electricals

Auto Electricals For close to a hundred years, Robert Bosch GmbH has been a world leader in Auto Electricals. The first batch of high-voltage Magnetos were delivered from Bosch, way back in 1902. This led to the development of high-speed automotive engines. In the years that followed, Bosch pioneered many a breakthrough development that spurred the phenomenal growth of the automotive sector. The thrust on quality, reliability and innovation endeared the Bosch name to millions of customers worldwide.
Inspired by its principal's worldwide success, Bosch Ltd. started its auto electricals operation in 1989. Today, Bosch Ltd. manufactures a wide range of Starter Motors and Alternators at its state-of-the-art plant in Naganathapura, near Bangalore, catering to the ever-increasing demands of the Indian automotive industry.
A national field-service network has been set-up to provide comprehensive service support for all Bosch Ltd. products. A strong in-house Auto Electricals R&D set-up, supported by the rich experience and vast infrastructure of Robert Bosch GmbH helps Bosch Ltd. to offer the latest and the best technology to Indian customers.
Starter motor
Internal-combustine (IC) engines must be started by separate system because they cannot self-start like electric motor or steam engines. When starting these engines, considerable resistance resulting from compression, piston friction and bearing friction (static friction) must be overcome. Frictional resistance is highest at low temperatures.
The starter (also known as the “starting motor”) must rotate the flywheel at a minimum starting speed overcoming these resistances. It must also continue to support rotation during initial combustion to maintain momentum until the engine can sustain operation.
Alternator
Motor vehicles need their own efficient, reliable & constantly available source of energy for ignition, lighting, starting motor etc. When the engine is stopped, the battery represents the vehicle’s energy source, the alternator is the on-board “electricity generating plant” when the engine is in operation. The task of the alternator is to supply power to all current consuming loads. Alternator output, battery capacity & power demand of the loads must be matched to each other as ideally as possible so that the entire system is reliable & trouble-free in operation.
The requirements of an alternator are:

• Supplying all connected loads with direct current.
• Additional power reserves for the fast charging of the battery – even when continuous loads are switched on and when the engine is only idling.
• Keeping the alternator voltage constant over the entire engine speed range.
• As maintenance-free as possible in operation.
• Rugged construction to withstand all external loading caused by vibration, changes in temperature, dirt, damp, fuel & lubricants.
• Low weight & compact dimensions.
• Low noise. 
•  Long life.

Function :
The basis for the generation of electricity is formed by electromagnetic induction i.e. when an electric conductor cuts through the lines of force of a magnetic field, a voltage is induced in the conductor. It is immaterial whether the magnetic field remains stationary while the conductor moves, or vice versa. The generation of three phase current in alternator takes place in conjunction with a rotary motion. There are three identical, independent windings which are arranged at 120° from each other. According to the law of induction, as the rotor rotates, sinusoidal alternating voltages & alternating currents of identical magnitude & frequency are generated in the windings. The result is a constantly recurring rotation. The resulting three phase alternating current known as three phase current is rectified through semiconductor diodes since it cannot be supplied directly to the electrical loads or the battery.

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Batteries

BatteriesPassenger car batteries
BOSCH Silver Perfect Maintenance Free (PMF) Battery comes with breakthrough Silver alloy technology. This means it offers greater electrical conductivity and better corrosion resistance, substantial increase in service life, and a totally maintenance-free battery experience.  Features

• Factory charged and sealed; so, no charging or topping required
• Consistent power output
• Withstands heavy loads
• Greater acid volume above the plates (safety reserve)
• Charge-eye indicator
• Side wall ribbing
• Polyethylene envelope separators

 The sealed maintenance-free battery has optimised grid geometry and contains calcium silver alloy that offers excellent cold start performance, improved power consumption during charging, greater starting power and longer service life. The water consumption is much less than conventional batteries because the labyrinth for gas condensation and return to the battery minimises the loss of water.
Benefits

• Faster charging
• Better short-trip resistance
• Long-life
• Improved cyclic loading
• 30% higher starting power
• Minimises the danger of ignition from external sources

Truck and tractor batteries: Bosch Ustad and Kranti

• Longer life
• Higher cranking power
• Leak resistant
• Low on maintenance. Special hybrid alloy minimises water loss
• Extreme vibration resistance. Ribbed container withstands temperature extremes and shocks/ vibration damages
• Factory filled and wet shipped
• Better corrosion resistance with superior plate design and weld systems
• No electrical shorts, with glass matt lined enveloped PE separators

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Filters

Filters
Filters are a very important component in any vehicle and its importance is always underestimated. For cost reasons, many vehicle owners change their filters less frequently than recommended and thereby damage high-grade technical components of their vehicle and the jeopardising the occupants in the vehicle from harmful pollutants.
As a system supplier with expertise in the entire field of engine management, Bosch Ltd. and Bosch is aware of the importance of filters. Continuous activities in research and development consolidates the leading position and the competitive edge of Bosch Ltd. and Bosch and ensures further developments of innovative and environmentally compatible filters. The filter range is updated constantly to incorporate state-of-the-art technology. Features Stable filter paper - Special micro-fibre paper impregnated with phenolic resin ensures high mechanical, thermal and chemical stability of the filters resulting in high wet strength and stability.
Excellent contaminant separation - The porosity of the paper and an even pore distribution ensures that contaminants are well separated and gives low, flow resistance. Long life - The folded paper has a much larger filter area, which extends the service life of the filters compared to unfolded paper filters.
Excellent filter stability - Corrosion-resistant housings of aluminum, galvanised steel or high-grade plastic connections guarantee high mechanical, thermal and chemical stability. Ultra strong housings - The aluminum and plastic housings are welded through CO2 lasers or ultrasonic and steel housings are welded through double flaring. This adhesive free process protects the joints from aggressive fuels, oils and extreme temperature changes.
Petrol Filters
Bosch Ltd. and BOSCH Petrol Filters trap even the smallest particles – in the range of a few thousandths of a millimeter and ensures optimum function and long service life of the components.
Features
Filter Medium - The medium used for the filters are of high-grade to ensure that the contaminants are filtered completely
Installation - The filters are developed in such a way that they can be installed with minimum effort
Filter tightness - The tightness of the filter is secured by an adhesive-free double flaring – the housing with a rubberised cover outside and rubber sealing inside
Advantages

• Prevents irregularities in the fuel-feed through well-proven technology and the optimum pore size of the filter medium
• Best suited for injection system since the complete petrol injection system is developed and manufactured by Mico and Bosch
• High-resistance against variations in temperatures and aggressive fuels

Diesel Filters
In addition to filtering out contaminants, diesel filters are used to separate water contained in the diesel fuel. Since water is heavier than diesel, it collects in the water accumulation chamber of the diesel filter. After filtration, the lighter diesel fuel flows to the interior of the filter towards the outlet.
Types of Diesel Filters
Cloth Type (Primary)

• Consists of several layers of cloth wound over a layer of link cloth on a perforated metal tube
• Flow direction - From outside to inside
• Filtered fuel collects in the centre tube and is delivered to the pump
• Removes non-dissolving impurities like dust, foreign particles etc.

Coil Type (Secondary)

• Consists of a corrugated filter paper around a central tube with alternative layers glued
• Flow direction - Radial and axial
• Dual particles are held in the v-shaped folds

Star Type (Secondary)

• Formed out of pleated filter paper
• Paper is pleated along the breadth to provide a framework for filter dust
• Flow direction - Radial from outside to inside
• Filtered fuel collects at the centre and is delivered to the pump
•  Dust particles are deposited on the filter paper or settle down as sediments at the bottom of the filter housing
• Removes impurities of less than 2 microns

Advantages

• Integration of water separation, fuel heating and fuel cooling in one module
• Pressure stability at very high injection pressures
• Special filter media achieves high storage capacity and separation of fine particles
• Effective water separation from fuel prevents corrosion damage

Common Rail Filters
Common Rail Filters from Bosch are optimised for high injection pressures and low tolerances of the Common Rail precision technology. The double-layer filter medium of polyester and cellulose enables an extremely high absorption of dirt and the highest separation grades. The filter construction with a radial vee-form filter element results in maximum water separation. As a result of the knowhow of Bosch, the diesel systems developer, it is guaranteed that the Common Rail filters are precisely tailored to the respective engine and meet the highest requirements of performance and service life.
Advantages/ Benefits

• Integration of water separation, fuel heating and fuel cooling in one module
• Pressure stability also with very high injection pressures
• Special filter media achieve high storage capacity and separation of finest particles
• Effective water separation from the fuel prevents corrosion damage

Lub Oil Filters
The engine oil plays a critical function of reducing friction that occurs during the movement of the engine resulting in power loss and wear. In addition, it prevents abrasive particles from coming in contact with friction surfaces.
Features
Optimum protection - The filters remove contaminants such as dust, metal particles, combustion deposits and carbon particles from the oil and ensures optimum protection of the engine components.
Rubber seals - The seals in the filters are made of special rubber compounds that offer special protection against aggressive engine oils ensuring longer life.
Anti-drain valve - The anti-drain valve prevents the filter from drying up when the engine is switched off guaranteeing rapid pressure build-up and instant lubrication when the engine is restarted.
Bypass valve - In order to ensure continuous supply of oil to the engine, the bypass valve opens at a certain pressure ratio and allows the oil to flow to the engine without being filtered thus causing less damage than non-flow of oil.
Advantages

• Specially impregnated, tear-resistant filter medium with large surface provides longer service intervals and longer life
•  The filter prevents premature ageing of oil

Air Filters
The intake air always contains minute dust particles that can be harmful for the engine components. These filters ensure only clean air reaches the combustion chamber.
FeaturesTightness – These air filters are made of special polyurethane plastic compound that ensures only clean air reaches the combustion chamber.
Pulsation resistance – As the result of precision fitting and the high quality of filter paper, these filters are resistant to air blasts during the intake process ensuring longer service life to the engine and its components.
Advantages

• Made to measure for specific engines to ensure the right filter for every engine
• The permeability and degree of separation are tailored to each other in such a way that the engine is optimally supplied with clean air

Cabin Filters
Standard Cabin Filters
The Standard Cabin Filters absorb up to 100% of all pollen, dust particles and harmful substances ensuring clean air in the cabin.
It is assembled from three layers of fibres with an electro-statically charged middle layer that ensures that even smallest particles are filtered out of the air.
 Advantages/ Benefits

• Prevention of the growth of microorganisms, since the filtration medium is resistant against air humidity
• Reliable operation even with frost and heat
• Higher air quality in the vehicle protects the health of the vehicle occupants

Active Carbon Cabin Filters
The basic construction of the active carbon filter is similar to that of the standard filter. An additional layer of active carbon absorbs harmful and foul-smelling gases such as ozone, nitrogen, oxides, sulphur dioxide and hydrocarbons. Standard cabin filters can be easily replaced by BOSCH Active Carbon Filters of the same construction without any modifications to the vehicle.
Advantages/ Benefits

• Active carbon cabin filters provide the driver with even more comfort and health protection through the filtration of foul-smelling harmful gases.

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Horns

Horns

Great construction and consistent performance - that’s what Bosch Ltd. and BOSCH Horns have to offer. Disc horns and Fanfares can be used for 2-wheelers, 3-wheelers, cars, MUVs, LCVs and tractors.

•  Exclusive designs
• Compact size
• Superior quality
• Covered under warranty

The horns come with sturdy brackets, designed for specific vehicle models so it can be conveniently mounted internally or externally. What’s more, Bosch Ltd. and BOSCH Horns are tested under rigorous operating conditions, including vibration and corrosion resistance, continuous blast test, endurance, dust, water and dampness test, temperature stability test etc. With Bosch Ltd. and BOSCH Horns and Fanfare, get heard and get ahead on city roads and highways.
BOSCH Europa Horns: World-class super-tone horns

• Bosch design
• Teflon filter technology
• Corrosion resistant
• Premium quality
• For passenger cars and MUVs

BOSCH Europa Horns come in three variations
Standard Horn - 125 mm

• Standard horn for concealed mounting
• Housing, tone disc and diaphragm black, resi-coated

Decorative Ring Horn - 140 mm

• Decorative ring for visible mounting
• Housing and diaphragm black resi-coated
• Tone disc and ring shiny matt

Grilled Horn - 140 mm

• Grilled horn for visible mounting
• Housing and decorative cover resi-coated in black or chrome-plastic

BOSCH FC4 Horns

• Penetrating, strong sound even at long distances
• Galvanised steel for protection against corrosion, dust and humidity
• Pressure compensation through micro-porous Teflon filter

Impact Horns

• High quality construction
• Impactful sound output
• Attractive grills

100 Dia Horn

• Repairable
• Powerful tone
• High quality construction
• Consistent performance

Compact Horns

• Powder coated body
• Vibration resistant brackets
• Sealed, yet repairable
•  Compact design, ideal for concealed installations

Symphony Fanfare Horn

• Pleasant Tone
• Plastic trumpet - Fracture and corrosion resistant
• High quality construction - Consistent performance
• Sturdy yet flexible bracket
• Easy horizontal or vertical mounting
• Extremely resistant to vibrations

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Function of a Spark Plug

What is the function of a spark plug and why is it a vital engine component?

The function of the spark plug is to introduce the ignition energy into the combustion chamber and to initiate combustion of the compressed air-fuel mixture. It accomplishes this task by generating a spark between its electrodes, which then generates the required heat to ignite a smooth burn of the air/fuel mixture. The spark plug is an important factor in determining optimal performance and reliable functioning of an engine. It must permit reliable cold starting, it must guarantee that there is no misfiring during acceleration, and it must withstand the engine being operated for hours on end at maximum power. These requirements apply throughout the entire service life of the spark plug. For 100 years, Bosch Spark Plugs have been designed for optimal performance, reliable functioning, and to withstand extreme operating conditions. Today, the continuously developing spark plug is a key engine system component. It plays a major role in fuel economy, clean, efficient combustion, and the reliable operation of engines and catalytic converters.

What are the different types of spark plugs?

There is a large variety of different spark plug designs with more than 1,400 variations. Design variants and special materials such as platinum, silver, or yttrium allow Bosch spark plugs to be used in a wide variety of applications today. In all, Bosch has developed more than 20,000 different types of spark plugs over the last 100 years.

Why do we need to change spark plugs?

During operation, the spark plug is subjected to both wear and to fouling and should be replaced at regular intervals. In the course of its service life, the spark plug undergoes changes that increase the required ignition voltage. When the required voltage reaches a level that can no longer be compensated for by the voltage reserve, the result is misfiring. These changes can be caused by: Electrode wear Engine wear Abnormal operating conditions (pre-ignition, detonation, high oil consumption) Independent tests have shown that installing premium spark plugs such as Bosch’s Platinum+4 improves fuel mileage by as much as 4.8% over original equipment plugs. Platinum+4 uses race-tested technology including multiple electrode paths and more pure platinum to generate strong, consistent sparks.

How do I "read" a spark plug?

Reading the spark plugs provides valuable information on spark plug and engine operating conditions. See the Technical Info tab to review spark plug faces.

How should spark plugs be tightened for best performance?

Bosch recommends when installing spark plugs to use a torque wrench and the correct torque in ft.-lbs. As listed below:

	10mm With Gasket	12mm With Gasket	14mm With Gasket	14mm Tapered Seat	18mm With Gasket	18mm Tapered Seat
Torque Ft.-Lbs.	8-11	12-15	19-22	12-15	20-23	14-17

If a torque wrench is not available, hand tighten the plug until it is seated in the cylinder head. Spark plugs with gaskets should be tightened an additional 90°. Spark plugs with tapered seats should be tightened an additional 15°.

Are Bosch Spark Plugs pregapped at the factory?

Most Bosch Spark Plugs are factory pre-gapped for popular vehicle applications. The gap measurements are indicated either on the box, or by the part number located on the spark plug shell.

• X suffix = .044"
• Y suffix = .060"
• Z suffix = .080"

Gaps should never by adjusted on Platinum+4 or Platinum+2. Bosch Platinum+4 and Platinum+2 have factory pre-set gaps, and should never be gapped by the installer.
Bosch Platinum and Super Spark Plugs also have factory-set gaps. For most plugs, the setting is shown on the plug package. These gaps are correct for the most popular applications of these plugs. There are applications, however, for which the gap setting has to be adjusted according to the vehicle manufacturer’s specifications. To avoid damage to a spark plug in the process of adjusting the gap, it is important to follow these guidelines:

• To widen the electrode gap, use a tool that only pulls back the ground electrode, without applying pressure to the center electrode. The tool must not be wedged between the electrodes as that may cause damage to the insulator nose.
• To close the electrode gap, carefully tap the plug, electrode first, on a hard surface, as shown in the illustration.

What is detonation?

Detonation or "knocking" is uncontrolled combustion with a very steep rise in pressure. It is caused by spontaneous ignition of the fuel mixture, which has not yet been reached by the ignition spark. As the high-pressure waves hit the walls of the combustion chamber, their impact produces a metallic knocking sound. Failure to recognize and deal with knocking will inevitably lead to serious engine damage.

What is heat range?

The spark plugs’ heat range is an index of its capacity to dissipate thermal energy. The different characteristics of automotive engines regarding operating load, compression, engine speed, cooling, and fuel make it impossible to run all engines with a standard spark plug. The same spark plug may get very hot in one engine type, but may reach only a relatively low temperature in another. In the first case, the air-fuel mixture would ignite on the glowing parts of the spark plug projecting into the combustion chamber (pre-ignition) and, in the second case, the insulator tip would soon become so badly fouled by combustion deposits that misfiring would occur. To ensure that the plug runs between the desired temperatures, plugs with different heat capacities were developed. The so called “heat range”, which is assigned to each spark plug, is used to characterize these heat dissipation capacities. A plug with a low heat range number (e.g., 2-4) indicates a cold plug that quickly dissipates heat to the engine block and cooling system, while a high code (e.g., 7-10) indicates a hot plug that retains heat. By properly selecting the heat range of the plug, it ensures that the plug will operate between the plug’s designed operating range of 500-900 degrees Celsius. In this range, the spark plug will be self-cleaning, yet will not be hot enough to pre-ignite the air/fuel mixture.

How does Bosch test engines to determine the heat range and what heat range should I use?

To ensure optimal performance in your car, Bosch has tested each vehicle model and the various engines available for that model listed in the Spark Plug catalog or our web-page. Using a special spark plug with a thermocouple built in, Bosch engineers find the hottest cylinder in an engine and then test various spark plugs in that cylinder until the ideal plug is found. This ensures that you will always get the best performance possible.

I want to use Bosch Spark Plugs, but have modified my engine by adding a performance system. Can I still use the plug listed in the catalog for my vehicle?

If you have modified your engine with a performance system such as a turbocharger, supercharger, or nitrous, the recommended spark plug may not be correct. You may need to use a plug with a colder heat range to compensate for the additional heat generated by the engine. Bosch recommends that in these situations, you consult a qualified engine builder for assistance in determining the appropriate heat range

How often do I need to change my plugs?

As a rule, Bosch recommends that you follow the replacement interval listed in your vehicle owners manual, however we highly recommend that you inspect (read) your spark plugs annually and replace as required, to insure optimum engine performance

Do Bosch Spark Plugs meet original equipment requirements?

Yes! Bosch Spark Plugs meet or exceed warranty requirements of all vehicle and engine manufacturers, and when properly installed in accordance with the recommended application, will not adversely affect the emission control system of any vehicle.

What about vehicle manufacturer warranties?

Consumers are sometimes told by an automobile dealer’s service writer or mechanic that a brand of replacement spark plug cannot be used in the consumer’s vehicle during the warranty period. The claim is made that use of the brand will “void the warranty”, with the statement or implication that only the original equipment brand of spark plugs may be used. This, of course, tends to cast doubt on the quality of the replacement spark plug. That claim is not true. Under the Magnuson-Moss Warranty Act and general principles of the Federal Trade Commission Act, a manufacturer may not require the use of any brand of spark plug (or any other article) unless the manufacturer provides the item free of charge under the terms of the warranty.
So, if the consumer is told that only the original equipment spark plug will not void the warranty, they should request that the OE spark plug be provided free of charge. If they are charged for the spark plug, the manufacturer or dealer is in violation of the Magnuson-Moss Warranty Act.

Does the Bosch part number have meaning to help determine the specifications of the plug?

Yes! See the Technical Info tab for the list of designation codes.

How does platinum improve a spark plug?

Perhaps the greatest innovation in spark plug design over the years is “pure platinum” technology, combined with multiple electrodes. As early as the 1960’s engineers recognized the value that platinum added to automotive plugs: it provides improved corrosion and erosion resistance and imparts a longer performance life than the standard copper core center electrode plug design. The use of platinum not only broadens the heat range beyond that achieved with a copper core center electrode design, but also provides extremely consistent performance, a reliable spark and a longer performance life.

What are the advantages of surface air gap plugs such as Platinum+4 and Platinum+2?

To validate the improved performance of surface air gap plugs with a pure platinum core and multiple ground electrodes, extensive testing was conducted in the laboratory and in the field:

• The first test measured the energy transfer efficiency of the four-electrode platinum plug compared to conventional and other premium plugs with a single ground electrode. This certified laboratory test measured the additional pressure generated by the spark discharge in a pressure chamber. Higher pressure equals a higher energy transfer by the spark. The test showed that the four-electrode platinum plugs transferred more energy to the air/fuel mixture resulting in improved driveablility and lower emissions.
• As a spark plug wears via erosion and corrosion, the gap between the center electrode and ground electrode gets larger. The larger the gap, the more voltage is required to produce a spark, until the capability of the ignition system is exceeded and the plug misfires. It was found that the multiple ground electrode, pure platinum center electrode plug reduces gap erosion and increasing voltage requirements over time.
• Roush Industries, an independent test lab, measured the fuel consumption for the four-electrode platinum plug, as well as, that for original equipment and other premium single ground electrode plugs. Fuel savings up to 4.8% were found in the four electrodes, platinum core plugs. Tests were conducted in accordance with Federal Test Procedure 75FTP and HFE.
• Tests for carbon fouling were simulated in a cold cell by repeatedly cooling, starting and operating the engine without letting the spark plugs reach their self-cleaning temperature. This cycle does not let the spark plug reach its self-cleaning temperature and allows the formation of carbon deposits. The tests found that the four ground electrode spark plugs had up to 33% better cold restart reliability than conventional plugs.

Does technology used in racing plugs find its way into Bosch Premium plugs?

YES! Racing, as it has for 100 years, provides a great developmental impetus and test bed for spark plug durability and performance, and what is learned at Indy or Darlington, or Le Mans helps improve the spark plugs installed in today’s cars or trucks. From the first Indy 500 won by Ray Harroun’s Marmon Wasp to the last 17 Indy 500 winners, and many in between, each have used Bosch spark plugs. Many premium passenger car spark plugs use multiple ground electrodes and precious metals, such as platinum, which are a direct result of their development and testing in long distance racing.
See the Technical Info tab for more details on how racing improves the breed of passenger car spark plugs.

What if I do not feel a difference after I have Bosch Premium Spark Plugs installed?

Bosch guarantees that you will feel improved performance in your vehicle when using a spark plug of the Bosch Platinum Series (Platinum+4, Platinum2, and Platinum). However, if you do not experience quicker starts, smoother acceleration, and improved fuel efficiency, you can return the plugs with a dated sales receipt and Bosch will refund the purchase price of the spark plugs.
Glossary:
Multi Ground- Plugs with multiple ground electrodes are called multi ground. These plugs also use surface gap spark patterns and the multiple ground electrodes increase service life.
Surface Gap- Surface gap technology is when the ground electrode is to the side of the center electrode. There can be no ground electrode (racing applications), multiple ground electrodes (PT+4 and PT2), or a single ground electrode. These spark plugs have improved efficiency and a higher probability of igniting a lean air/fuel mixture.
Resistor- Many spark plugs have a special conductive glass seal between the center electrode and the terminal stud. This seal acts as a resistor in the plug which reduces the transmission of pulses of energy to the ignition cables. These pulses can cause Radio Frequency Interference (RFI) with electrical components in the car. For some newer cars, resistor plugs are required for effective communication between the plugs and the electronic ignition.
Radio Frequency Interference (RFI)- When the spark plug creates a spark, a high frequency burst of energy is created. If this energy was to travel through the ignition wires, it could cause interference with other sensitive electronic devices, such as the radio or electronic control units. The resistor in the spark plug reduces this energy before it causes interference with other electrical components.
Fouling- Fouling occurs when a plug becomes contaminated with fuel, oil, or other contaminates that prevent the plug from generating a spark. Most plugs today are designed to reduce fouling and become self-cleaning when they reach 500 degrees Celsius. However, short trips, low speed driving, improper spark plug heat range (too cold), improper timing, or an oil leak in the combustion chamber can cause a spark plug to become fouled.
Bridging- Over time, contaminants can build on the surface of the spark plug if it does not reach self-cleaning temperature often. These buildups can grow between the electrodes until they are actually connected by a bridge of contaminants. This will often cause misfire.
Flashover- Occurs when the spark does not jump between the electrodes within the combustion chamber, but instead jumps between the metal shell and the terminal on top of the plug. This will always cause a misfire since the air/fuel mixture will not be ignited. Bosch spark plugs have a ribbed insulator to prevent flashover.
Quenching- The purpose of a spark plug is to introduce enough heat into the combustion chamber to initiate a smooth burn of the air/fuel mixture. Quenching occurs when that heat generated by the spark is reabsorbed back into the ground electrode, the center electrode, and the ceramic insulation. To reduce quenching and ensure an efficient transfer of heat, Bosch Platinum+4 and Platinum2 spark plugs use surface gap technologies.

Spark Plugs
More than a century ago, in combination with a high-voltage magneto, Bosch presented the first spark plug. Bosch was awarded the patent for this ground-breaking system on 7 January, 1902. Manufactured using world-class Bosch technology, Bosch Ltd. Spark Plugs meets world-class standards of reliability and performance. A testimony to this is the fact that Bosch Ltd. is the preferred OE supplier for companies like Bajaj Auto, Hero Honda, Yamaha, T.V.S., Kinetic, Maruti, Hindustan Motors, PAL and M&M, to name a few.

Features - Highly effective anti-tracking barriers
Prevents arcing which would otherwise result in misfiring
- Suppression resistor
Reliable functioning of all electronic systems and interference-free radio reception
- Ground electrode
The number of electrodes, their configuration and their geometry have a decisive effect on ignition-spark techniques and service life
- Nickel-plated spark-plug shell and screw-in thread
Guards against corrosion and prevents seizure in the aluminum cylinder heads
- Heat-shrink assembly
Guarantees 100% gas tightness and precise heat rating
- Compound centre electrode
The copper core with high thermal-conductivity characteristics inside a non-wearing, chrome-nickel sheath ensures that the operating temperature is reached quickly. Protects against thermal overloading, conventional corrosion and spark erosion Range
Bosch Ltd. and BOSCH Super

• Centre electrode with non-corroding chrome-nickel sheath and copper core
  • Rapid burn-off and protection against thermal overload
  • Insensitive to shunts
  • Highly resistant to wear
• With interface suppression resistor - follows the Original Equipment trend
  • Reliable functioning of all electronic systems
  • Interference-free radio reception

BOSCH Super Plus

• The technology plus: Yttrium - the innovative alloy
  • Outstanding protection against corrosion
  •  Absolutely reliable ignition
• The Original Equipment plus: Tried and proven million times over
  • State-of-the-art technology from Original Equipment and motor racing
  • Installed by leading vehicle manufacturers at the factory
• Specially shaped ground electrode
  • Ever higher ignition reliability and better protection for the catalytic converter

BOSCH Super 4

• The technology combination which is unique throughout the world
  • Air-surface principle
  • Four, thin, ground electrodes
  • Pointed, silver-plated centre electrodes
• Optimum engine performance throughout the plug’s operating time, even under extreme operating conditions

BOSCH Super: pointed ground electrode for 2 / 3 wheelersThe ground electrode has a structured profile and is less vulnerable to wear than centre electrode. As a result, the advantages of this structured profile can be utilised throughout the entire service life of the spark plug.

• Higher ignition reliability due to faster flash-over of the spark and ignition of the mixture
• Additional cold-start reliability even when battery voltage is low
• Improved combustion protects the engine
• Since misfiring is avoided, fuel consumption drops even more

BOSCH Super: twin electrode for 2 wheelers

• Increased ignition reliability throughout the spark plug’s entire service life
• Improved cold-start characteristics
• Low ignition-voltage requirement
• Self-cleaning effects in case of sooting
• Two ground electrodes increase the plug’s service life

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Common Rail System

Common Rail System:-

Delivery concept UIS:-
Photo: Delivery concept UIS With the UIS, a separate Unit Injector (UI) for each cylinder is installed directly in the cylinder head. The engine camshaft provides the mechanical build-up of pressure. Via tappets or rocker arms it activates a small piston inside the UI unit. The cam is shaped in such a way that the desired high fuel pressure is built up as quickly as possible in the so-called plunger chamber below the plunger. A fast-switching solenoid valve determines start and end of injection while the duration of triggering determines the injected fuel quantity. Fitting in the cylinder head obviates the need for high-pressure lines which are required for traditional distributor injection pumps.

With the UIS, a separate Unit Injector (UI) for each cylinder is installed directly in the cylinder head. The engine camshaft provides the mechanical build-up of pressure. Via tappets or rocker arms it activates a smal

l piston inside the UI unit. The cam is shaped in such a way that the desired high fuel pressure is built up as quickly as possible in the so-called plunger chamber below the plunger. A fast-switching solenoid valve determines start and end of injection while the duration of triggering determines the injected fuel quantity. Fitting in the cylinder head obviates the need for high-pressure lines which are required for traditional distributor injection pumps.

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UIS Types:-

The first generation of UIS engines in commercial vehicles were capable of an injection pressure of 1,600 bar. The most recent stage of development of the second system generation achieves 1,800 bar. Since 2004, the third generati

on has been on the market. This can realize injection pressures of up to 2,200 bar.

Thanks to these high injection pressures, diesel models with UIS were the first commercial vehicles to achieve exhaust-gas values better than those prescribed by the EU4 regulations. Because of their high injection pressures, UI diesel engines also display an extremely good degree of efficiency and provide an extremely high torque with low fuel consumption even at low engine speeds. The third system generation permits precise injection with variable duration of injection throughout the entire engine map. The resulting rate-of-discharge curve and the high pressure produce improved combustion. This means more performance, lower fuel consumption and reduced exhaust and noise emissions.
Typ UIN2:

Applications: Commercial vehicles

Power output: 80 kW/cylinder

No. of cylinders: 8 (more with 2 ECUs)

Control: Electronic, solenoid valve

Injection pressure:1800 bar

Injected fuel quantity: 400 mm3 per stroke

Typ UIN3:

Application range: for commercial vehicles

Output: 80 kW/cylinder

No. of cylinders: 8 (or higher with two ECUs)

Control concept: electronic, solenoid valve

Injection pressure: 2200 bar

Injected fuel quantity: 400 mm3 per stroke

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Unit Pump System (UPS):-

 
The Unit Pump System (UPS) is a system for diesel direct injection. It is closely related to the Unit Injector System (UIS) and is exclusively available for commercial vehicles. Bosch was the world’s first manufacture

r to market this technology, also known as the “Unit Pump System”, in 1995. The feature
of the UPS is that each engine cylinder has a unit pump
of its own. This consists of the high-pressure pump with integrated solenoid valve, a short injection fuel-injection
line, a pressure-delivery connection and a conventional nozzle-and-holder assembly.

The advantage of this system: it permits injection pressures of up to 2,200 bar. In addition, conversion from injection systems with traditional in-line or distributor fuel-injection pumps does not require complete redesign of the cylinder head. Engine manufacturers save development costs. A further advantage: damaged pump/valve units are simple to exchange.

Bosch uses Unit Pump Systems particularly in commercial-
vehicle engines with performances of up to 92 kW per cylinder and with four to 18 cylinders. A second control unit is required if the number of cylinders exceeds eight.

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UPS Types:-

 
Typ UP 12, 20

Applications: Commercial vehicles

Power output: 80 kW/cylinder

No. of cylinders: 8 (more with 2 ECUs)

Control: Electronic, solenoid valve

Injection pressure: 1600 bar / 1800 bar

Injected fuel quantity: 150 mm3 / 400 mm3 per stroke

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Delivery concept UPS

Injection systems from Bosch make commercial vehicles even cleaner and more economical. Thanks to their high injection pressures and the precisely-metered amount of fuel injected, they permit extremely efficient, low-pollutant and low-consumption combustion.
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Injection systems:-

As with the UIS, pressure is built up by the engine camshaft.
As this generally lies beneath a truck engine, the cam pitch
is transferred to the small piston in the UP unit via a roller
tappet. The cam is shaped in such

a way that the desired
high pressure of the fuel is generated as quickly as possible
in the so-called plunger chamber below the piston. An electronically-controlled, fast-switching solenoid valve
determines both start and finish of injection. The triggering duration determines the amount of fuel injected.

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