Bosch Celebrates 125 Years

Future Workshop
Autumn 2011
www.bosch.com.au
NOW
Incorporates
Brake Talk
www.bosch.co.nz
Bosch Celebrates 125 Years
This year Bosch celebrates its
125th anniversary as well as
the 150th anniversary of the
birth of founder Robert Bosch.
On November 15, 1886, Bosch
established his Workshop
for Precision Mechanics and
Electrical Engineering in
Stuttgart, Germany.
Since then the company has
grown to include more than 300
subsidiaries and regional companies in over 60 countries with
more than 280,000 employees
in 150 countries. From the very
beginning, Bosch played a deci-
sive part in shaping the automobile’s evolution.
In 1913 Bosch launched its automotive lighting system, with its
own power supply from a generator and a battery. It was followed by innovations such as
spark plugs, electric windshield
wipers, power-assisted brakes,
starters and indicators.
With the establishment of Bosch
Service in 1921 and the development of its network of salesrooms and branch offices in
other countries, Bosch created
an extensive repair service for
customers. At the same time, it
laid the foundations for an internationally comprehensive automotive aftermarket business.
1920-1940s
In 1927 the diesel injection
pump was launched, initially for
use on trucks and later installed
in the first diesel-powered
passenger cars in 1936.
1950-1960s
In 1951 Bosch introduced gasoline injection for the two-stroke
engine of the compact Gutbrod
Superior car. This paved the way
for the development of passenger car gasoline engines that
combined higher performance
with lower fuel consumption
and emissions.
Three years later, gasoline injection for four-stroke engines
debuted in the legendary gullwing Mercedes-Benz 300 SL.
Continued page 2.
Brake Talk in
Future Workshop
Training Focus for 2011 – Diesel
and Gasoline Direct Injection
From this issue of Future
Workshop onwards Brake
Talk, the publication that was
specially designed to cater for
the needs of brake servicing
specialists, will be incorporated into Future Workshop.
Developments in automotive
technology are moving faster
than ever, Bosch is acutely
aware of this as the company
is an integral part of enabling
car makers all over the world
to surge forward with this technology.
tion will be left out and the full
spectrum of stories and data will
be included.
Brake products, news and
stories are on pages 8-11 in this
issue.
See page 9 for more details
Now that PBR’s integration
into the Bosch global family is
complete information on Bosch
braking products will come
quarterly as part of this publication.
Not only is technology moving faster but Australia’s vehicle population is changing and
diversifying. Just look at how
many diesel cars are now on the
road and how many are in the
showroom awaiting delivery.
Not so long ago it was just trucks
that used diesel now even the
most desired marques have
many diesel options – look at
BMW’s line-up.
However, the introduction of
so many diesel vehicles has not
slowed development of systems
for petrol powered cars with
direct injection gasoline systems
developing very quickly.
Workshops now need to be able
to service both diesel and petrol vehicles to ensure that they
survive into the future and make
good profit.
Continued page 16.
Bosch Brakes Sponsors Australian Rally Championship
As a special feature of this issue
we have committed four pages
to the braking business which
will mean that no key informa-
Bosch Brakes will be the naming rights sponsor of the Australian Rally Championship
(ARC) in 2011. The deal will see one of
the world’s leading brake brands part-
nering one of the world’s oldest rally
championships in what is sure to be a
big year of expansion for both parties.
Continued page 8.
Contents
P2.
News
P3.
osch Car Service
B
P4-5.Service Parts
P6.
Diagnostics
P7.
Wheel Servicing
P8-11.
Brakes
P12-13. Diesel
P14.
Electrical Systems
P15.Engine Management
Gasoline Systems
P16.
Training
Switch Up to Bosch at the AAAE
Bosch is set to roll out its biggest
ever display at the Australian
Automotive Aftermarket Expo
in May. The Expo is the industry’s bi-annual showcase of the
latest products and services
and provides workshop owners with a unique opportunity
to study the current and future
trends that will shape their
businesses.
A key feature of the stand will
be the range of diagnostic and
wheel servicing equipment
on display. As vehicle systems
become increasingly complex, and customers demand
more from their service centre,
Bosch diagnostic equipment
and Beissbarth wheel servicing equipment can increase
profits in every workshop.
Bosch will have the largest
presence of any company at the
expo, covering 54 square metres
across two stands.
Three vehicles will be linked
to various pieces of equipment
on the stand to allow workshop
owners to see how they oper-
ate within their businesses and
ultimately, how it can work for
their businesses. This is the
perfect place to explain Bosch
workshop training courses and
the Bosch Service Network.
Bosch training courses are
widely recognised as the most
comprehensive within the automotive aftermarket, and they
are an essential tool for futureproofing your business.
The Bosch Service network also
offers workshops a pathway to
Switch Up to Bosch for your Competitive Edge
business success through the
provision of technical and business support for independent
workshops.
The AAAE will be held at the
Melbourne Exhibition Centre
between 12-14 May 2011. Check
out www.aaaa.com.au for further details.
2
Autumn | 2011
Editorial
Here we are already one quarter of the way through 2011.
First thing I must say is that
everyone at Bosch is aware
that many in our industry have
faced hardships as a result of
the turbulent weather that
has struck the east coast of
Australia as well as the earthquake in New Zealand. We
have felt the impact ourselves
both personally and on a business level.
On a lighter note we are
pleased that we have arrived
at the point where we can
incorporate PBR Brake Talk
magazine into our Bosch
Future Workshop. It is a positive sign of how well the integration is progressing. You
will have noticed that this is
a bumper issue with 16 pages
of information.
We have made some revisions
to how we present Future
Workshop with specific pages
to highlight our areas of
expertise: diesel, diagnostics,
brake systems, service parts,
electrical, wheel servicing,
engine management/gasoline
systems, the Bosch Service
Network and training
Since it is the beginning of
the year it is a good time to
reflect on the history of Bosch
as the company celebrates
125 years. You will see our
125 year logo on the front of
this publication as well as on
advertisements and other
promotional items throughout 2011.
We would like to hear from
you if there are specific items
or information you would like
to see in the publication as
we want to ensure it is relevant and interesting for
you. You can contact us at
[email protected]
with any suggestions or comments.
Please enjoy the first issue of
Future Workshop for 2011.
Rolf Schillinger
Marketing Manager
Automotive Aftermarket
The next issue of Future
Workshop will be published
in Winter 2011.
For any enquiries or feedback
email us at:
[email protected]
Customer Service: 1300 30 70 40
© Copyright 2011
Material cannot be used or reproduced
without approval from the Bosch
Automotive Aftermarket Division.
Future Workshop News
Bosch Celebrates 125 Years
In the latter half of the 20th
century,
semiconductors
became the key components
of new electronic systems,
featuring in everything from
engine management systems to
driver assistance systems.
The first Bosch product to
feature electronic components
manufactured in-house was
the Bosch alternator regulator
introduced in 1958. It was
followed in 1967 by the Bosch
Jetronic fuel-injection system, the first-ever electronic
fuel-injection system to be
manufactured on an industrial
scale.
1970s to present
Without Bosch's innovative
semiconductor technology, the
(cont.)
lambda sensor (1976), which
allowed a catalytic converter to
be used to make exhaust cleaner, would not have been conceivable. Nor would the ABS antilock
braking system (1978) or the
ESP® electronic stability program (1995) have been possible.
Today the company's parallel
full hybrid technology, which
allows vehicles to run solely on
electricity, has already gone into
series production at VW and
Porsche.
Bosch does not forget the past
though and still offers a selection of more than 50,000 spare
parts for classic and vintage cars
– just one way in which the company helps to keep the history of
mobility alive.
Bosch and Hyundai Alliance Develops New
Vehicle Technology
The Hyundai Motor Group and
Robert Bosch GmbH signed a
memorandum of understanding (MOU) to develop vehicle
powertrain electronic-control
technology and infotainment
systems.
signed on January 19 2011 by Dr.
Hyun-Soon Lee, Vice Chairman
at Hyundai’s R&D Center and
Dr. Bernd Bohr, Chairman of
the Bosch automotive group
at Hyundai’s headquarters in
Seoul, Korea.
The
“The alliance between leading
initial
agreement
was
automotive brands Hyundai
Motor Group and Robert Bosch
GmbH means an exciting future
for our infotainment systems
and our powertrains – the heart
of the vehicle,” Dr. Lee said.
trains and produce new IT products based on Hyundai technology and Bosch platforms.
Bosch has been a partner with
Hyundai in engine development
for 20 years.
The alliance aims to accelerate
development of new power-
New Focus On Automotive Social Skills Advance for
Skills & Training
Bosch Online
Auto Skills Australia Ltd
(ASA) has been established as
a wholly owned subsidiary of
Manufacturing Skills Australia
and will assume responsibility
for the automotive industry’s
training advisory arrangements.
Workshops will be pleased as
the ASA will deal with issues
specific to training for work in
this industry which is specialised and requires promotion.
“This is an important step forward for the industry and will
provide a specialist, national
voice on education and training
matters in the automotive industry,” said Chair ASA Board of
Directors Danielle Andrews.
The ASA Board of Directors
consists of a range of stakeholders including engineering
associations, automotive vehicle
and truck manufacturers and
retailers as well as the truck and
trailer, construction, mining,
power equipment, marine and
bicycle industries.
“It is vital that the industry
has one, strong voice when
communicating to governments,
stakeholders and training
providers on matters relating to automotive education,”
Ms Andrews said.
“We are proud that all areas of
the industry have come together to establish this vital body
and we thank the Minister for
Tertiary Education, Senator
Chris Evans, for his support,”
she said.
“Automotive technology is
rapidly changing and the industry now has the confidence to
move forward and support the
development of high quality VET
advisory and product services to
the industry,” Ms Andrews said.
ASA is working closely with
MSA to ensure that it can take
over all responsibility for the
automotive training packages and their qualifications,
namely the Retail Service and
Repair (AUR05) and Automotive
Manufacturing (AUM08).
Bosch has entered the age of
social networking by launching its very own Facebook page,
which currently has more than
600 people as friends.
tional venue as the Bosch site is
written by a mix of German and
English speaking fans.
Titled the Bosch Automotive
Tradition keen followers of
Bosch products will be able to
log on and interact.
The site's current fan base is
growing rapidly. Bosch's wall
is peppered with interesting
photos and advertisements from
long ago as well as You Tube
videos.
This site is visible proof that the
internet world, and specifically
Facebook, is truly an interna-
visit www.facebook.com search for Bosch Automotive
Tradition
Future Workshop Bosch Car Service
Autumn | 2011
3
Narellan Auto Electrical
2 Orielton Road, Narellan NSW 2567
Narellan Auto Electrical is one of NSW's finest Bosch
Car Service businesses and has been operating for
more than 25 years under proprietors, brothers Jack
and John Acuri.
The business started with a single bay workshop and was located in Narellan’s
industrial area. Twenty years ago they moved to this purpose-built workshop in the
Smeaton Grange Industrial Estate, still in Narellan.
vided us not only obvious access to a full range of parts and diagnostic equipment
but also to training,” said Jack. “It is vitally important to have up-to-date training as
the industry is moving so fast.”
Both Jack and John are qualified motor mechanics and auto electricians though
Jack now divides his time between working on vehicles and working in the office.
The company also employs a staff of eight qualified tradespeople including two
apprentices and an office assistant.
Narellan Auto Electrical specialises in auto electrical repairs, LPG, air conditioning
and EFI as well as general mechanical repairs such as engine, brakes, suspension
and transmission work. They are also an authorised RTA inspection station for registered and unregistered vehicles.
In November 2010, Narellan Auto Electrics conducted a major upgrade to their
facilities. On the outside the building was totally refurbished and now better
reflects the workshop’s capabilities.
For the future the company anticipates that there will be a move to more hybrid car
servicing but on the downside believes that many car dealerships will be working
much harder to keep car servicing under their roof after a car is sold. However,
Jack also knows that many car dealers still turn to his company for help when diagnosing difficult problems or with specific areas where his workshop has expertise
such as EFI issues or injector testing and servicing.
As part of the upgrade it was also decided to utilise the roof space with 54 solar
panels installed that feed electricity back into the grid. Not many workshops are
as forward thinking in their approach to environmental issues, and it is certainly a
positive point in an industry that is often seen as environmentally unfriendly.
Upgrading the premises was a result of wanting to display a much better image and
one that is more widely recognised. It was also a strong show of alliance with Bosch
Service, who had been a business partner of Narellan Auto Electrical for more than
20 years.
“We have taken advantage of our association with Bosch Car Service as it has pro-
Customers are a major focus for Jack and John's business and they have worked
hard to put in place value-added services that are both practical and facilitate customer retention. As an example the company offers loan cars, as well as a drop-off
and pick-up service.
This attention to detail has not gone unnoticed as the company was an MTA finalist
in 2006 for an award for auto electrical services and has either won or been a finalist in the Macquarie Small Business Awards in 2003, 2002 and 2001.
New Bosch Car Service Reps Vic & Qld
Two new Bosch Car Service
Representatives have started with Bosch to look after
Dealers in Victoria, Tasmania,
Queensland and the Northern
Territory.
Colin Miller and Ashley Walford
started working in these roles
in February 2011, and they
offer a vital support structure to
the growing Bosch Car Service
Dealer group to help these small
and medium sized businesses
grow and develop.
“In the long term we will
have
Bosch
Car
Service
Representatives servicing every
state in Australia,” said Mark
Jones, Regional Workshop
Concepts Manager, Oceania.
"This is all about establishing
specialised representatives who
can work with our dealers at the
right level.
”Through these positions we
will support and strengthen
the Bosch Car Service Network,
helping them to develop and
position themselves correctly in
their marketplace.”
This year is the 90th anniversary
of Bosch Service, so the service
network is nothing new but it
is a concept that continues to
evolve and needs the expertise
of skilled Bosch service representatives to do so.
The availability of dedicated
service representatives will provide vital support to these businesses and assist them to capitalise on the resources available
through a market leading company like Bosch.
Through the Bosch Car Service
network, workshop owners can
run an independent business
under a larger, international
banner and benefit from the
support, knowledge-base and
exposure that such a partnership offers.
The Bosch Car Service network
is the largest network of independent workshops in Australia
and New Zealand, and forms
part of the Bosch global service
network with more than 15,000
workshops.
Mark Gardiner in New Zealand
on +64 2194 2854.
Working at Bosch is not new
to Colin Miller who has been
with the company since 2008.
Colin has worked as an SIS technical officer and then in technical sales within the workshop test equipment area.
Ashley Walford
Colin trained as a mechanic with
BP and later worked for major
motor vehicle dealerships before
taking on a position in diagnostic equipment sales and training.
Colin will look after Victoria and
Tasmania.
Colin Miller
Workshops interested in joining the Bosch Car Service network should call Rob Johnson,
Bosch Service Network Manager
Australia on +61 3 9541 7317 or
Join the Bosch Car
Service Network
Like Colin, Ashley has a background as a mechanic having completed his apprenticeship with Stillwell Ford in
Melbourne.
Ashley has extensive experience in automotive aftermarket
in Queensland and is well known
in the industry.
The world’s largest network
of independent workshops.
Key Benefits Include:
4 Industry leading technical training
❏
4 Business and management training
❏
4 Advertising support
❏
4 Support from a leading automotive brand
❏
For further information contact Rob Johnson in
Australia on 03 9541 7317 or Mark Gardiner in
New Zealand on +61 021 942 854.
4
Autumn | 2011
Future Workshop Service Parts
What is Package-Based Servicing?
How to explain it to customers to gain their trust in your business
Contemporary vehicle design
is increasingly centred on
package-based
servicing,
making it easier and more
efficient for service outlets
to complete large blocks of
maintenance in the shortest
possible timeframes. In effect,
a traditionally singular repair
now covers the replacement of
a group of components which
have very similar wear rates.
More steps in the process
On the surface, this trend
presents some issues for workshops when it comes to explaining repair costs to customers.
In the eyes of manufacturers,
the days of the drive-in, driveout $100 service are over, but as
we know, the customer doesn’t
understand the complex reasons behind why this change has
occurred.
Many consider that technology should bring with it faster
and more efficient repair procedures, and this basic belief
certainly carries some weight.
However, the missing factor in
this equation is that progressive
automotive technology has
brought with it so many advances in safety, comfort and economy, that there are simply so
many more components requiring regular maintenance or
replacement.
It is not that the process has
become inefficient - quite the
opposite - it is that the process must now incorporate many
more steps.
Complexity
has
gained
momentum
This general trend of complexity
has really gained momentum in
recent years and there are many
contributing factors.
Emissions control and environmental concerns are central to
this; clean-running cars are now
sought by many customers who
wish to do their part by safeguarding the environment as
much as possible; and there is of
course comprehensive governmental drive behind this as well.
However, it’s important that this
customer group understands
that there are many individual
components in their vehicle that
require consistent replacement
so as to maximise this “green
effect”.
Clean air and fuel filters ensure
clean running engines, by ensuring no impurities enter the combustion chambers.
Nitrogen Oxide (NOx) sensors,
catalytic converters and oxygen
(O2) sensors are all a part in the
polluant-control process.
They all have a lifespan.
Adhering to the manufacturers’ recommended replacement
schedule for all such components maximises any vehicles’
clean-running potential.
Grappling with packaging
issues
It is a matter of understanding
manufacturers’ repair processes.
These tend to operate on a logical package basis, so that groups
of components in close proximity are all replaced at the same
time. The timing belt system is a
common example.
Given the presence of so much
technology within an engine
bay, and the compact vehicular
proportions required to minimise weight (allowing for smaller engines, and thus lower emissions outputs), manufacturers
are grappling with comprehensive packaging issues.
This has led to components
like the water pump being
mounted internally, where it is
then driven by the timing belt.
It is designs like this that have led
to Bosch’s recent range expansion of timing belt tensioner kits
that include the water pump,
and commonly, the o-ring seal.
Take the steps
There are countless examples where standard service
Relieve the Tension with Bosch
Bosch Timing Tensioner Kits with Water Pump
The use of timing belts has
been common practice in the
passenger car market for many
years now, and the service life
of these products has continuously improved throughout this
time. Nowadays, it is common
practice for manufacturers to
stipulate replacement intervals
in excess of 100,000km, which
demonstrates the modern timing belt’s durability. Despite
this being the case, the components connected to the timing
belt are often overlooked, only
being replaced when they show
obvious signs of wear.
of the engine, it should also be
remembered that a coolant leak
from the pump area will usually
cause damage to a timing belt’s
material. In this instance, that
timing belt job your customer
paid for only a few weeks prior
will need redoing.
Bosch’s
rapidly-expanding
Timing Tensioner Kit with Water
Pump range aims to provide the
complete solution to these problems, safeguarding your customers’ vehicles, ensuring their
return business and in-turn,
your workshop’s profit margins.
Thankfully, it is becoming
more common for mechanics to replace tensioners and
guide rollers when completing
a timing belt job, yet many still
overlook the water pump. High
engine speeds, high-frequency
vibrations, oil leaks and extreme
engine temperatures, can all
have a drastic affect on the
lifespan of the water pump.
These complete kits are available for most standard passenger cars; they simplify the
parts ordering process,
maximise profit margins and maintain
your workshop’s reputation as an installer
of quality products
and a source of superior workmanship.
Other timing components are
replaced in light of all these dangers and so too should the water
pump, say Bosch’s engineers.
Apart from the critical nature
of the water pump to the safety
Bosch’s comprehensive
2011 Timing Belts & Tensioner
Kits catalogue is due out in the
first quarter of this year, so keep
an eye out for your copy.
procedures have incurred
additional steps and processes.
When you check the air filter, do
you also check the cabin filter?
Do you religiously scan the
engine management systems at
every service?
Do you ensure you are using
Original Equipment quality components? Bear in mind, a comprehensive range of all these
components is available from
your Bosch distributor, often at
far lower prices than the genuine parts.
Talk to your customers
And last of all, are you spending time with your customers
to explain the presence of new
technology in their vehicles?
This is the best way for them
to understand why these parts
may need replacement. It is also
one of best ways to maximise the
profitability of your workshop,
while keeping your customer
base happy and well-informed.
Future Workshop Service Parts
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Spark Plugs for New Zealand 2011
One of Bosch’s most comprehensive
catalogues, covering passenger
and light commercial vehicles,
right through to small engine
and agricultural applications. It
also features detailed technical
information and cross reference
sections, both tailored to the New
Zealand market.
As an example the endurance
test is done under clearly defined
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To order your catalogue contact
customer service on 1300 307 040
(Aust.) and 0800 452 896 (NZ)
or email [email protected]
Precious Metal
Bosch Spark Plugs, Powering
Global Motorsport
Every time a car comes in for
servicing he checks the condition of the wiper blades and if
they need changing he does it as
a matter of course.
DTM, Le Mans 24Hr, NASCAR…
Malcolm has done this for
hundreds of cars and says that
no one has questioned the item
on their bill.
After relocating to Australia
from the UK around five years
ago he opened a workshop in
WA and decided he wanted to
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Timing Belts and Timing Tensioner Kits for Australia and
New Zealand 2011
2011 sees a complete redevelopment
of the Timing Belts and Timing
Tensioner Kits catalogue for Australia
and New Zealand. Bosch’s Timing
Tensioner Kit range, in particular,
has undertaken significant growth,
with many new applications
entering the catalogue.
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The second group of tests are
the overstress tests – focussing
on impact resistance, freezing
and drop tests, endurance and
snow-load tests.
As a Bosch Car Service dealer
from way back, Malcolm is very
well acquainted with Bosch
products and is particularly sold
on the wiper range.
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There are road tests or wind
tunnel tests – called high speed
quality testing as Bosch requires
wipers to operate up to a speed
of 160 km/h.
“It’s not a high cost item,” said
Malcolm. “People don’t question
the wipers on their bill as long as
they are a reasonable price.”
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For UV resistance visible parts
The last two groups of tests are
chemical resistance and rubber
tests. Wiper blades have to resist
chemical attacks as windshield
washer fluids consist of alcohol
and water these are tested in
24-h-checks. The rubber must
not change more than a clearly
defined percentage in volume
and in weight.
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Environmental tests
Environmental influences could
lower the quality of wiping,
therefore corrosion, temperature cycle, heat aging and UV
resistance tests are conducted.
of the wipers are exposed to
UV radiation and the wiper is
checked for cracks and discoloration. Bosch requires that there
are no visible cracks at 40-times
zoom.
Filters for Australia 2011
Bosch’s dedicated filtration catalogue
for Australia is one of the most
comprehensive on the market. 2011
sees an updated cross reference
section alongside a comprehensive
range expansion in oil, air, fuel and
cabin filter applications.
8ñ
Performance tests
Performance tests are a very
important to reach a high standard of quality. These cover wiping quality, noise level, high
speed quality, attack angle sensibility and play in the wiper
arm.
conditions and performed on
a test windshield in a specific
cycle. It lasts for 750,000 wiping periods, or about six weeks
of non-stop wiping. This simulates mechanical abrasion of the
wiper blade used over 150,000
km.
New Bosch Catalogues
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Ever wondered how Bosch wins so many
awards for Wiping Systems?
Wiping systems have to be efficient in different weather and
climate conditions across the
world. So Bosch testing procedures are strict and often
exceed legal requirements to
guarantee long, reliable wiping quality. These procedures
consist of 18 tests grouped in 5
categories.
5
Autumn | 2011
continue as a Bosch Car
Service dealer. “I’ve been
a Bosch Car Service dealer for the past 20 years. It’s
a good network.” he said.
“When I had my business in the
UK I was using Bosch parts and
I continued with that. If you’re
going to be a Bosch Car Service
dealer and you go to the trouble
of painting your business then
you use Bosch parts.”
Petro Technics is always booked
2-3 weeks in advance and has a
loyal following.
“We do 7 to 8 services a day,”
said Malcolm. “Our client base is
strong and we get lots of repeat
business.” He puts that down to
doing a reasonably priced job,
using good quality parts and
that translates to a building a
very good reputation.
“We don’t believe in cutting
corners and doing things on the
cheap,” he said.
Bosch supplies spark plugs to
some of the most renowned motorsport events around the globe.
Robert Bosch invented the spark
plug in 1902 and Bosch engineers have refined the process
for well over 100 years, with motorsport and Original Equipment
markets providing much of the
real-world testing environment.
The sheer expanse of Bosch’s
knowledge and experience
across so many vehicle applications ensures there is a reliable,
thoroughly-tested spark plug
fitment for nearly every vehicle
on the road.
In fact, Bosch has developed
well over 20,000 different spark
plugs since it began production
and this experience encompassed more than 1,400 design
variations to ensure exceptional
performance.
Simply mention the Bosch name
to one of your customers and
chances are they will be instantly familiar with the brand and
the strong penchant for quality
with which it is aligned. Just try
doing the same with some of our
competitors.
6
Autumn | 2011
Future Workshop Diagnostics
Bosch Driving Hybrid Developments
In the coming years even more
buyers will buy hybrid vehicles as they offer low fuel consumption, reduced emissions,
less CO2 and greater driving
dynamics.
Workshops will need to have the
tools, parts and training to deal
with this new type of automotive
drive system.
Bosch is taking a leading role
in the development and production of hybrid drive systems as
the company is actively developing and evolving technologies
for electric and hybrid vehicles.
A new portfolio of products has
already commenced with items
such as power electronics that
control the flow of energy, and
electric motors with greater
torque characteristics as well
as workshop equipment for the
testing and diagnosis of hybrid
vehicles.
in the world with parallel full
hybrid technology from Bosch
to reach series production. The
use of Bosch hybrid technology
in other models from leading
vehicle manufacturers is currently underway.
Automotive components are
being manufactured by Bosch
for hybrid vehicles in close collaboration with the automobile manufacturers. Innovative
hybrid systems are developed
specifically for a vehicle and
integrated in the powertrain
technology.
In 2010 Bosch received an
Automechanika Innovations
Award in the OE Products and
Services category for the Bosch
parallel full hybrid system for
the Touareg and Cayenne.
Last year hybrid versions of
the VW Touareg and Porsche
Cayenne were the first vehicles
Automechanika, which is held
in Frankfurt, Germany every
two years, is by far the premier
automotive aftermarket show
in the world with around 4500
exhibitors from 76 countries
presenting their latest trends
and developments for the auto-
Hybrids are Here to Stay
motive aftermarket and supply
industry.
NEW
With hybrids on the road and more being developed
– you can’t ignore the fact that they are here to
stay. Do you have the right equipment to make sure
your workshop doesn't turn away a hybrid service?
In recent months the VW Touareg became the first mass-produced model powered
by Bosch hybrid technology. In cooperation with motor manufacturers, work is in
progress on hybrid technology for other models.
So it will not be long before hybrid vehicles are taken to independent workshops for
servicing. This means that workshops will be faced with new technology for which they
need to prepare with training and with new equipment.
These emerging powertrain technologies and high voltage assemblies will pose new
challenges for any workshop.
To cope with these requirements Bosch has just launched two products for the workshop that relate specifically to hybrid vehicle diagnosis – the Hybrid Vehicle Tester FSA
050 and the MMD540H Hybrid Automotive Multimeter.
The FSA 050 is a hand-held device that can be linked wirelessly to a PC or to the FSA
500, 720, 740 or 760 to document the measurement results.
This newly released product is designed for quick use and offers a means of testing
insulation and high voltage on electric and hybrid electric drive systems as a standalone option.
FSA 050
 Cost effective entry level
 High voltage measurement for
checking if high voltage supply is in
switched off state
 Isolation test for checking vehicle
wiring
 High voltage up to 600V TRMS
 Isolation test up to 200 Giga Ohm
 Inbuilt multimeter functions
Hybrid Automotive Multimeter
 Display 4000 counts LCD display with
function indication.
 Polarity automatic (-) negative polarity
indication.
 Over range OL mark indication.
 Low battery indication
 Measurement rate 2 times per second,
nominal
 Auto power off
Future Workshop – Soft and Hard News
Future Workshop magazine is available to all workshops in both printed form and as a PDF document.
Bosch can offer you the option of obtaining Future Workshop in PDF form as well as in its
printed form. There is no need to choose between them – you can have both!
 A PDF can be shared with staff, work associates and friends via email
 You can keep a PDF on file in your computer more easily
 A PDF can be printed again later if you want to refer to an article
of
To obtain your copy
se email:
ea
pl
F
PD
a
Future Workshop as
u.bosch.com
futureworkshop@a
Future Workshop Wheel Servicing
Autumn | 2011
7
Making Money with Wheel Alignments
Wheel alignment servicing
allows workshops to offer customers a great value-added
service.
Being able to offer customers a
more complete service is a great
way to retain customers and
maximise your profitability.
In the past some workshops have
been reluctant to get involved
in wheel alignment as they felt
that it was too time consuming
or lacked space to have a bay or
ramp dedicated to one operation, but the latest equipment
from Beissbarth overcomes
these concerns.
Beissbarth’s Easy 3D wheel
aligner fits into even the
smallest workshop all that’s
needed is just 600 millimetres
on each side of the hoist.
Easy 3D employs real 3D
technology which features
highly accurate cameras and
an integrated reference system.
It’s designed to be fast, reliable and easy to use. Since it
takes around just seven min-
utes to carry out a precise
wheel alignment it’s a great
value-added service that your
customers will appreciate.
Currently many customers view
a wheel alignment as something that is done only when you
replace tyres and the perception
is that they must go to a tyre specialist to have the work done.
Set-up features
Drive up
The runout compensation can be carried out quickly
and precisely. Following set-up the car is driven into
the correct position.
Measure
This new generation of wheel alignment technology
offers workshops fast, precise, acquisition of measured data, including toe, camber, thrust line, axle
and wheel offset, and following a 20 or 10 degree
steering routine a caster and king pin angle.
Done
In just a few minutes with the help of a simple guided
program, the operator has all the wheel alignment
Explaining the benefits of a
regular wheel alignment, and
that it is not a lengthy operation
can persuade customers that
the process should be part of
normal checks while their
vehicle is in for a service.
related information, as well as printable measured
results available for workshop reference or to show
the customer.
Equipment features
 Simple set-up of wheel targets and sensor heads
 Sensitive electronic sensor heads are replaced by
simple wheel targets
 Fast, rolling runout compensation on all four
wheels simultaneously without having to manually push or lift the vehicle
 The integrated reference system ensures reliable,
reproducible results without complicated error
prone calibration.
For more information
1300 783 031
please
telephone
Resetting Steering Angle Sensors Using Bosch Diagnostic Equipment
After performing any suspension component replacement or repair including
a wheel alignment it will be necessary to check the steering angle sensor for
proper positioning.
The steering angle sensor should be checked and reset after a wheel alignment,
accident repair, and suspension work or when any of the following components
have been removed or replaced:
 ABS/EDL/ASR/ESP control units
 Steering Angle Sensors
 Steering column
 Under body steering components
Accurate calibration of the steering angle sensor is vital if the vehicle’s ESP system
is to perform correctly in an emergency situation.
Here is an example of how to check and adjust steering angle sensors.
First connect a diagnostic tool like the Bosch KTS 540, to the diagnostic port of the
vehicle to start the process of realigning the steering angle sensor.
Bosch’s KTS 540 is Bluetooth enabled and can talk wirelessly to a laptop over a
reasonable distance providing convenient diagnosis and calibration of the vehicle
being tested.
One of the features of the KTS 540 is its ability to evaluate steering angle sensor
alignment; the KTS 540 can also reset the steering angle sensor if required.
The example here is the procedure that is performed when working with a Holden
VE Commodore.
The KTS 540 provides a step-by-step procedure to ensure the sensor is evaluated and calibrated correctly.
The technician follows the simple prompts that appear on each screen to complete the evaluation and calibration procedure.
Step 1
After vehicle selection the technician will be
required to choose the adjustments and settings function on the KTS 540.
Step 4
Next the diagnostic tool will conduct an
alignment analysis to start the process of
determining the correct steering wheel angle
sensor position.
Step 2
Following this it will be necessary to choose
the steering angle initialisation function to
start the initialisation process.
Step 5
Next the technician will need to move the
steering wheel to the centre position.
Step 3
The next screen will confirm that you wish
to continue the process and the following
screen will require the technician to go
to the car and turn the steering wheel 15
degrees to the left and then 15 degrees to
the right.
Step 6
Once the diagnostic tool has established
the necessary parameters it will calibrate
the steering wheel angle sensor. The new
values are then programmed into the ESP
electronic control unit by the KTS 540 and
the process is complete.
The screen will then advise the technician
of the steering wheel angle, the vehicle
tested indicated minus 246.2 degrees.
Other scan tools may have a different sequence of screens or instructions; the
operation detailed here applies only to the Bosch KTS 540 tool. By following
the screen prompts on the KTS 540, any technician can easily and quickly reset
steering angle sensors.
8
Autumn | 2011
Future Workshop Brakes
Bosch Brakes Naming Rights Sponsor
Of Australian Rally Championship (cont)
range, we now have the most
comprehensive brake package
available. As our customers are
passionate about all forms
of motorsport, sponsorship
of the ARC provides a perfect
opportunity to highlight our
growing range and to talk about
the benefits of the Bosch brake
program.”
The sponsorship not only
provides
great
television
exposure for Bosch Brakes, but
also provides opportunities for
sales promotions that directly benefit Bosch customers.
Through its sponsorship of the
ARC, Bosch aims to increase
awareness of its extensive
range of Bosch products to
workshops and their customers.
Phil Robinson, Bosch Director
Automotive
Aftermarket
Division
explained
the
rationale
behind
the
sponsorship: “As a leading
supplier to the Automotive
Aftermarket, Bosch offers the
most comprehensive range of
vehicle servicing components,
PBR Disc Rotors
and Drums
Catalogue Now
Available
Along with the expansion
of the Bosch and PBR brake
range comes the new 2011
edition of the PBR rotors and
drums catalogue.
vehicle diagnostic and wheel
servicing equipment to the
industry.
“We are rapidly growing our
brake business and see an
alignment with the ARC as the
perfect vehicle to communicate
the development of our brake
range to both our existing and
future customers.
“Bosch is a global leader in the
development of braking systems, including ABS, and in
conjunction with the PBR brake
Promotions will coincide with
each of the five championship
rounds to be held throughout the year, beginning in
Western Australia in April.
Rounds will also be held in
Queensland, South Australia,
New South Wales and Victoria.
According to Scott Pedder,
CEO ARC, the signing of Bosch
is an enormous boost to the
championship and is part of a
major renaissance of the series.
“Bosch is a global company
and it is fantastic that it has
embraced the Australian Rally
Championship, not only by providing a great financial boost,
but also significant corporate
stature adding to the credibility
and positioning of the ARC.
“This comes at a time when we
have boosted TV coverage of the
series on Ten/One HD; initiated
some significant rule changes,
including reducing restrictions;
and revitalised interest in the
Championship. Signing Bosch
will lift the championship to
another level,” said Pedder.
More than 2.5 million Australians
will see the Bosch Brakes ARC
on TV in 2011 and the series will
generate more than 36 hours
of national television coverage
across the Ten/One HD network.
This provides an opportunity for Bosch to speak to your
customers about the value of
the Bosch brake range and the
global experience that supports
that range.
The Bosch 2011 ARC
Round 1 - April 15-17
Quit Forest Rally in WA
Round 2 - May 13-15
International Rally of
Queensland - Sunshine Coast
Round 3 - July 29-31
Rally of South Australia,
Adelaide Hills
Round 4 - September 9-11
Rally Australia Coffs Harbour
(World Championship round)
Round 5 - November 11-12
Rally Victoria Gippsland
Brake Into Servicing Opportunities
Many vehicles that come to
workshops for brake service
work will be fitted with an ABS/
ESP system.
This issue has more than 200
pages of applications and for
the first time includes a listing
for performance slotted
rotors.
To obtain your copy of the
catalogue contact your
Bosch/PBR representative
on 1300 369 727 or email
[email protected]
This offers an opportunity to
check the system’s ECU for any
stored fault codes. This is a
service that can be charged for
and may reveal a problem the
customer is unaware of.
The same diagnostic equipment
can be employed when bleeding
or replacing the brake fluid.
It’s important to inform the
customer of the need to replace
the brake fluid at regular
intervals, even if they feel
there is nothing wrong with the
brakes. It is essential to renew
the brake fluid completely every
two years of 15,000 kms as it
will not provide the necessary
lubrication of the hydraulic
module.
Any contamination of the old
fluid could result in damage
to the ABS/ESP hydraulic unit
and require an expensive
replacement. To correctly bleed
some of systems you need to use
equipment such as the Bosch
KTS 200 to access the ECU.
Benefits:
 Offers important additional
service to customers
 Can reveal hidden problems
leading to additional work
 Utilises features of diagnostic
equipment
for
service
operations
Future Workshop Brakes
Autumn | 2011
9
Brake Talk Now Part of Future Workshop
This issue of Future Workshop
incorporates Brake Talk for the
first time.
supplying braking components
to both local and global markets.
Bosch’s history is well known.
The company is celebrating
its 125th anniversary and has
created an enormous legacy
in the automotive industry.
The development of an Antilock Braking System (ABS) for
series production in the 1970s
is just one of many examples of
product development. This same
Bosch ingenuity is evident today
through the complete range of
braking products offered.
Brake Talk has been a popular
trade magazine among brake
distributors, brake specialists
and general workshops for
a number of years and will
continue to exist within Future
Workshop. All of the same
features will remain, including
product news, the basics of
braking and technical tips.
The amalgamation of Future
Workshop and Brake Talk is
one of the final steps in the
integration of PBR into the Bosch
business.
The overall aim is clear: to
provide
distributors
and
workshops with greater value by
supplying a complete range of
quality brake parts from a single
source – in other words, to be
your first choice in brake.
Bosch and PBR – Your First
Choice in Brake
The range of PBR brake products
perfectly
complements
the
Bosch range. PBR is a leader in
brake hydraulics, rotors and
drums, and consumables.
Bosch first acquired a share of
the PBR business in 2006 and
the two have worked closely
together ever since to develop a
comprehensive brake range.
Both Bosch and PBR have
had a long history in brake
development. PBR started life
as Patton’s Brake Replacements
A Proud History and a Bright
Future
Bosch and PBR brands will
continue to co-exist. There will
be a particular emphasis on
brake pads as Bosch draws upon
its global resources to strengthen
its pad range in Australia and
New Zealand.
in the Melbourne suburb of
Carlton in 1927. In the more
than eight decades that have
followed, PBR has developed a
reputation as one of Australia’s
most innovative companies,
Bosch is a leader in ABS and ESP,
brake pads and shoes. Together,
the two brands offer a range of
braking products and depth
of knowledge that no other
company can offer.
Braking without Driver Input
Today’s motor vehicles are
so complex that something
seemingly simple like a braking
system is in fact acted upon
not only by a driver but by the
car’s inbuilt systems. In other
words a driver is no longer the
only person who uses the car’s
brakes to control the vehicle.
Common systems currently in use include:
ABS – Antilock Braking System
EBD – Electronic Brake Distribution
ABD – Active Brake Differential
TCS – Traction Control System (also known as ETC and ASR)
ESP –Electronic Stability Program (including CBC – Corner Braking Control)
VDC – Vehicle Dynamics Control
Brake checks are therefore
becoming more important not
less. TCS is one system that is
applying braking force without
the perceptible knowledge of a
driver. So braking components
may be receiving far more use
in today’s cars than they once
were.
This additional use is important
for workshops to take into
account. Not only is the braking
system more complex with
wheel speed sensors and other
electronic functions but even
simple parts such as brake pads,
calipers and discs are receiving
a heavier workout.
This together with the fact that
unknowingly drivers are relying
more on the vehicle to control
itself, means that the safety of
customers is even more reliant
on workshop brake checks.
Traction Control System
This is a perfect example of how
a braking system is initiated
directly by the vehicle and not
HDC– Hill Descent Control
BA – Brake Assist
EBA – Electronic Brake Assist
SBC – Electro-Hydraulic Brake (brake-by-wire)
by the driver.
TCS detects when a wheel shows
a tendency to spin and changes
the engine torque by intervening
in
the
engine-management
system though torque reduction,
as well as by applying the wheel
brakes in order to achieve an
improvement in traction.
Wheel speed sensors located
on each of the driven wheels
recognise when a driven wheel
or wheels slip due to an excess
of torque for the amount of
grip available. In this event the
TCS cuts in within a fraction of
In this instance the brakes are
not being used by the driver
to slow the vehicle, in fact the
driver has no indication that the
brakes are being applied.
Therefore,
critical
braking
situations are not restricted to
braking initiated by a driver and
can occur during acceleration
from a standing start, during
acceleration
while
already
moving or during cornering.
a second to apply corrective
measures.
An effective and convenient
means for implementing the
traction control system is via
the ABS system to assist with
brake intervention. With the
addition of a priming valve and
a switching valve, the ABS unit
can apply pressure to the caliper
at the wheel with the greatest
tendency to slip. The forces are
then transferred to the opposite
driven wheel allowing for greater
traction.
If both wheels are about to enter
a slip condition the rear brakes
are applied to both rear wheels
and a reduction of torque is
implemented by the engine.
The engine management system
does this by retarding the
ignition timing or cutting fuel
supply to nominated cylinders
or both.
While TCS is operating, the TCS
Active warning light will be lit on
the instrument panel.
10
Autumn | 2011
Future Workshop Brakes
Hundreds Added to Bosch Brake List
Below is a list of new brake pads that have been introduced so far in 2011 and part of an ever growing list which will be added to substantially throughout the year.
Don't forget to get a your copy of the 2011 edition of the PBR rotors and drums catalogue which is now available.
Front Brake Pads
Front Brake Pads
Front Brake Pads
Bosch Short Code
Application
Bosch Short Code
Application
Bosch Short Code
Application
DB1149GB
Toyota Landcruiser 90 – 02
DB1366GB
Ford Courier 99 – Now
DB1328GB
Toyota Hiace 96 – Now
Toyota Prado 90 – 02
Ford Ranger 06 – 09
Toyota Commuter 00 – 05
Toyota Surf 88 – 97
Mazda BT50 06 – Now
DB1419GB
Lexus LS400 93 – 00
Toyota Celsior 92 - 94
Toyota Hilux 88 – 05
Mazda B series 99 – now
Toyota 4-Runner 90 - 96
DB1312GB
Suzuki XL-7 01 – Now
DB1439GB
Nissan Xterra 00 – 02
DB1116GB
Holden Rodeo 87 – 02
Suzuki Vitara 95 – 99
Nissan Navara 01 – Now
Holden Jackaroo 87 – 92
Suzuki Grand Vitara 98 – 03
DB1441GB
Mitsubishi Lancer 04 – Now
Isuzu Rodeo 80 – 84
Mazda Proceed 96 – Now
Mitsubishi Grandis 01 – Now
Mitsubishi Eclipse 01 – Now
Isuzu Trooper 88 – 92
DB1335GB
Kia Sephia 98 – Now
Isuzu Pick up 90 – 95
Kia Shuma 00 – 01
Mitsubishi Chariot 00 – Now
Isuzu Mu 89 – 93
Kia Spectra 01 – 04
Jeep Patriot 07 – Now
Isuzu Big Horn 86 - 91
Kia Mentor 96 – 00
Chrysler Sebring 07 – Now
DB1342GB
Subaru Outback 97 – Now
Kia Clarus 00 – Now
Dodge Avenger 08
Dodge Caliber 07 - 09
Subaru Liberty 97 – 03
Mazda 121 96 – 02
Subaru Legacy 98 – 02
DB1262GB
Isuzu Gemini 93 – 00
DB1748GB
Proton Savvy 05 – Now
Subaru Impreza 96 – 00
Honda Domani 92 – Now
Proton Saga 08 – Now
Subaru Forester 97 – 02
Honda Integra 93 – Now
Proton S16 09 – Now
DB1323GB
Toyota Parado 96 – 03
Honda Logo 96 – 04
Chevrolet Aveo 05 - Now
Kia Spectra 99 – 04
Toyota Landcruiser 96 – 03
Honda Partner 99 – Now
DB1753GB
DB1113GB
Mitsubishi Pajero 87 – 91
Honda Jazz 02 – Now
Kia Credos 98 - 04
Mitsubishi Triton 87 – 96
Honda Civic 91 – 00
DB1787GB
Kia Rio 05 – Now
Mitsubishi Delica 89 – 94
Honda Concerto 92 – Now
Hyundai 03 - 08
Mitsubishi L300 87 – 03
Honda CRX 92 – Now
DB1819GB
Nissan Tiida 05 – Now
Nissan Micra 07 - Now
DB1350GB
Toyota Hilux 92 – 05
DB1172GB
Honda Ascot 89 – Now
Toyota 4 Runner 88 – 93
Honda Vigor 89 – 92
DB1820GB
Toyota Yaris 05 – Now
DB438GB
Nissan Navara 92 – Now
Honda Rafaga 93 – Now
DB1468GB
Holden Rodeo 03 – Now
Nissan Pathfinder 92 – 95
Honda Accord 90 – 98
Isuzu D-Max 02 - Now
Nissan Pickup 86 – 87
Isuzu Aska 94 – 97
Nissan SVX 92 – 97
DB1124GB
Hyundai Stella 87 – 92
Nissan Gloria 87 – 98
Hyundai Excel 88 – Now
DB1270GB
Isuzu Mu 93 – 05
Hyundai Accent 95 – Now
Bosch Short Code
Application
Isuzu Piazza 91 – 93
DB1304GB
Suzuki Baleno 95 – 01
DB1280GB
Isuzu Mu 93 – 05
Isuzu Trooper 92 – 95
DB1454GB
Nissan Pulsar 00 – 06
Isuzu Trooper 92 – 95
Isuzu Big Horn 98 – Now
Mazda Familiar 99 – Now
Isuzu Big Horn 91 – Now
Holden Rodeo 98 – 03
Mazda Familiar Van 99 – Now
Holden Frontera 95 – 04
Holden Frontera 95 – 99
DB402GB
Suzuki Swift 85 – 88
Holden Rodeo 98 – 03
DB1297GB
Mitsubishi Triton 96 – 04
Chevrolet Sprint 85 – 87
Holden Jackaroo 92 – 96
Mitsubishi Delica 94 – 99
Holden Barina 85 - 89
DB1429GB
Toyota Prius 01 – Now
Mitsubishi Starwagon 94 – Now
DB1503GB
Hyundai Matrix II 03 – 06
Toyota Sprinter 00 – Now
Mitsubishi L400 94 – Now
Hyundai Elantra Latvia 03 – 07
Toyota Celica 99 – 05
DB1426GB
Mazda Tribute 2001 – Now
Hyundai Latvia 02 - Now
Toyota Corolla 01 – Now
Ford Escape 1997 – 06
DB143GB
Mercedes Benz 200, 300, 400 72-80
DB1278GB
Proton Persona 96 – 04
DB409GB
Mazda B Series 85 – 96
Mercedes Benz Van series 72-80
Proton Putra 97 – Now
Mazda Proceed 90 – 96
DB1485GB
Nissan Maxima 02 - Now
Proton Satria 99 – 06
Ford Raider 91 – 97
DB1134GB
Suzuki X-90 96 – 98
Proton Wira 95 – 96
Ford Courier 85 – 96
Suzuki Vitara 88 – 91
Mitsubishi Lancer Evo 95 – 96
DB388GB
Ford Econovan 84 – 92
Suzuki Esqudo 87 - 88
Mitsubishi Lancer 93 – 04
Ford Spectron 84 – 89
DB1201GB
Mitsubishi Lancer 90 – 93
Mitsubishi FTO 94 – 98
Mazda E-Series 84 – Now
Proton Jumbak 01 - 02
DB372GB
Mazda Premacy 02 – 03
DB340GB
Nissan 300C 84 – 85
DB1202WGB
Nissan Bluebird 89 - 92
Mazda RX series 84 – 85
Nissan Navara 85 – 92
DB1210GB
Nissan Sentra 91 – 94
Mazda 626 91 – 02
Nissan Pathfinder 86 – 92
Nissan NX 91 – 93
DB1451GB
Hyundai Sonata 99 – Now
Nissan 720 Series 84 – 86
Mazda Familiar 94 - 96
Hyundai Terracan 01 – Now
DB1311GB
Kia Carnival 99
DB1263GB
Nissan Serena 92 – 96
Hyundai Tucso 04 – Now
Jeep Wrangler I 90 – Now
DB1266GB
Suzuki Vitara 92 – 99
Hyundai XG350 04 – Now
Jeep Wrangler II 02 – Now
Mazda Proceed 98 – Now
Hyundai Trajet 00 – 04
Jeep Cherokee 90 – 01
DB1268GB
Honda Prelude 94 – 02
Hyundai Santa Fe 00 – 06
Jeep Grand Cherokee 96 – 99
Honda Vigor 93 – 97
Hyundai Grandeur 99 – 04
Honda Accord 96 – 98
Hyundai Getz 02 – Now
DB1315GB
Mitsubishi Canter 94 – Now
Hyundai Elantra 06 - Now
Rear Brake Pads
Future Workshop Brakes
Autumn | 2011
11
Air in a Braking System
In the previous issue of Brake Talk we looked at some common causes of
spongy brake pedals in drum and disc brakes. Here we look at another
possible cause, air in the brake system.
These steps will take you through the major components and the issues faced when air is in the system.
Master Cylinder
To determine if there is air in this system, first check the fluid level in the master
cylinder. If it is low then top it up and conduct a visual inspection of the system
looking for leaks. If a leak is found it must be repaired and the system bled to
remove air.
If there is no sign of any leaks then the next step is to review the brake circuit in
the vehicle. Nowadays, most vehicles operate a dual-circuit brake system so it
is possible that air could be in either system. These are two methods for testing
the circuits.
Method 1
1. Pump the brake pedal around 10-12 times and then hold it down
2. Remove the master cylinder reservoir cap and place rags around the area to
soak up any spill
3. Release the brake pedal suddenly
4. Check the reservoir to note the amount of disturbance in the reservoir once
the fluid returns from the circuits
5. A small disturbance is normal but a large eruption indicates air in the system
which has been compressed and released
Hoses
Hoses can be damaged externally via abrasion, exposure to other oils and
chemicals or by being kinked, bent or extended – this can occur during
servicing. Internally hoses can be damaged through fracturing, deterioration
due to exposure to contaminated fluid or exposure to heat over a prolonged
period. There are three common inspection methods for hoses.
1. Have someone apply the brake pedal at high pressure with another person
visually inspecting the hoses for weeping or leaks.
2. Feel the hose to detect expansion not visible to the naked eye. It is usually
best to feel a new hose before conducting this test so that you can feel the
difference.
3. Conduct a visual inspection, look for bubbles, blisters, cracks or chafe marks
on the hose surface. Look for any wet areas especially around crimps and
hydraulic joints. Look for hoses that are either very stiff or too soft. Again,
feel a new hose to see the difference.
Method 2
This allows you to identify which circuit has air
1. Isolate each wheel or pair of wheels with brake hose clamps – do not use this
method on braided hoses
2. Have someone release the clamps one at a time while the brake pedal is
depressed
3. Alternatively, if the brake pedal travel is still excessive with all clamps on
then the fault is likely to be in the master cylinder
Brake Fluid
Brake fluid in poor condition is a very common cause of air in the brake system.
Brake fluid can be contaminated by water entering the system as water lowers
the boiling point of brake fluid. Water can enter through breather holes in
master cylinder reservoir caps or the fittings around the flexible rubber hoses.
Regardless of how the water enters the system, the high levels of heat generated
in the braking system can cause the fluid to boil which creates vapour which is a
mix of water and oxygen adding air to the system.
Wheel Cylinder Cups
Heat and age cause wheel cylinder cups to deteriorate resulting in a lack of
tension between the cup surface and the cylinder. When the brake pedal is
released it will create a partial vacuum, sucking air over the cup lips.
Look at the cups for signs of age and deterioration of the rubber. Check for a
snug fit between the cups and the wheel cylinder.
If in any doubt replace the cups and seals together.
To test the boiling point of the fluid, you need a boiling point tester. It is
important that it measure the boiling point and not just the moisture content.
If the boiling point is below the recommended level then the fluid must be
replaced.
12
Autumn | 2011
Future Workshop Diesel
Oxygen Sensors Critical for Diesel Engines
Oxygen sensors are crucial
to ensuring compliance with
statutory emission limits.
They ensure environmentally
– friendly vehicle operation
and optimize fuel consumption throughout the vehicle's
service life.
Oxygen sensors are now installed
in virtually every passenger car
with a gasoline engine and in
diesel models from emission
standard EU4 or higher.
As a leading supplier, the Bosch
product range includes the right
oxygen sensor for virtually every
vehicle.
The range of spare parts for
workshops has been expanded
to include sensors for diesel
engines. Currently there are 15
diesel specific oxygen sensors
held in stock in Australia.
To make the enormous variety of parts more manage-
able for workshops, Bosch
is grouping whole ranges of
oxygen sensors together. For
example, 300 different oxygen
sensors for vehicles of a major car
manufacturer have been reduced
to just 22.
Furthermore, a range of
different fastening elements are
provided with the sensors.
The importance of oxygen
sensors in vehicle construction
and for workshop business will
continue to increase.
Two oxygen sensors per exhaust
train are often installed in
vehicles with gasoline engines.
The second sensor downstream
of the catalytic converter continuously monitors the function of
the exhaust gas after-treatment.
The oxygen sensor is becoming a standard component for
diesel vehicles. Its equipment
rate is increasing as a result of
new exhaust gas after-treatment
concepts.
As with gasoline engines,
it is used in diesel engines to
comply with strict emissions
targets. Thanks to its control
function, the spread of emissions is reduced and emissions
of diesel soot on acceleration
are eliminated.
Modern
Bosch
oxygen
sensors are designed to last a
long time, but contaminated fuel
or oil residues during combustion can reduce their service life.
A faulty oxygen sensor impairs
the behaviour of the exhaust
system and gradually pushes up
fuel consumption.
In modern vehicles, oxygen sensors are checked as part of the
on-board diagnosis (OBD). This
allows the workshop to identify
and replace faulty sensors.
Bosch Diesel Filters — An Internal Bodyguard
It only takes a short drive
through any Australian city
to realise the growing presence of common-rail diesel
passenger vehicles on our
roads. Consumers are becoming increasingly responsive to
the benefits surrounding diesel
motoring, such as the increased
fuel economy, higher torque
outputs and lower emissions.
While navigating the complexities of the common-rail diesel
system, we need to ensure simple service-based items like the
diesel filter are not overlooked.
As diesel sales continue to
increase, so too does the service demand for these vehicles.
Workshops that once saw just a
handful of diesel cars are now
beginning to book them in on a
consistent basis throughout the
week. This has meant changes in
workshop floor stock and often
in staff training levels.
Secondly, though, the incredibly
finite tolerances used by the diesel injection components mean
exceptionally clean fuel is the
only way to ensure absolute reliability.
pulses around two microns in
movement.
unfiltered lead to abrasive erosion, particularly in the ball seat
area.
Given the significantly high price
of complex common rail diesel system components, avoiding the risk of damage in this
area should always remain a key
workshop priority.
Bosch Diesel Filters offer a
significant profit opportunity,
with competitive trade pricing
resulting in healthy mark-up
potential.
Bosch
Consider that a human hair measures approximately 60 microns
in diameter; a diesel injector
Nozzle Checks
Nozzles
are
wearing
components and must be
checked. Nozzles should be
checked as part of routine
inspections at your workshop
during vehicle servicing.
They
must
be
checked
whenever a loss of power or an
increase in fuel consumption is
experienced, especially under
the following conditions:
 In the event of increased
smoke production
 If loud combustion noise is
evident when the engine is
cold
Any small, hard
particles
that
reach the injector
Diesel Filters
offer a filtration
capacity down
to just two
microns and
represent
Original
Equipment
quality as a
minimum manufacturing standard.
The relatively cheap price of
filter replacement means there
is really no excuse for avoiding
this critical step in the servicing
procedure.
Diesel filter replacement represents a win-win scenario: it is a
growing profit centre for your
workshop and a critical safeguard for your diesel-driving
customer base.
Bosch offers dedicated commonrail diesel training. If you are yet
to attend this course and wish to
participate in the 2011 training
program contact our Technical
Training
Department
on
+61 (0) 3 9543 4293.
AADS to the Diesel Flavour of Bosch
 If the engine is running roughly even when warmed-up
Bosch nozzles deliver full diesel
performance along with low fuel
consumption. Your customer
will no doubt be pleased with
that.
The AADS Annual National
Conference and Exhibition is on
from March 25-27 in Adelaide
with Bosch as one of two major
sponsors.
This is the 36th annual
conference and has a full
program of business speakers
and technical speakers such
as Bosch diesel specialist Brett
Hayward.
The industry exhibition is back
on the program with exhibitors showing current and
new diesel specific products.
Bosch is a major part of that
exhibition and will have a stand
featuring a number of existing
and new diagnostic products.
The exhibition will be held in Hall
G of the Adelaide Convention &
Exhibition Centre and open on
Friday and Saturday.
Bosch’s new diesel manager
for Australia David Ryan, will
be present throughout the
event as it is a great introduction to the Australian industry.
David has amassed quite a
number of years working in
diesel for Bosch in the UK and so
is no stranger to the industry.
Keynote Speakers for the
conference include:
 Brett Hayward - Bosch
 Michael Keen - Business
Continuity Institute
 Brian Sander – Australian
Institute of Business Brokers
 Mike Rayne – Delphi Diesel
 Keith Payne – Hartridge
 Mike Cenica - Stanadyne
Special Guest Speaker:
 Paul Carter
Future Workshop Diesel
Autumn | 2011
Bosch Diesel Wins the Dakar
Green COTY for TDI Audi
Efficiency and sportiness are
not at odds with diesel as was
demonstrated by the A3 TDI,
winner of the Green Car of the
Year Award at the Los Angeles
Motor Show.
The
Audi
A3
2.0
TDI
develops 140 hp and emerged
victorious
against
all
competitors including hybrid
drive vehicles.
The Dakar Rally started in
Buenos Aires on January 1,
2011 and finished in Buenos
Aires 16 days and 9500 kms
later. Of those 9500 kms, a staggering 5000 were race kilometres which were spread over 13
stages.
overall categories.
The Dakar Rally has been
one of the world's toughest
long-distance races for more
than 30 years. The 2011 course
wound its way through Argentina
and Chile. Winners are awarded in car, truck, quad, bike and
The Volkswagen Race Touareg,
which won first, second, and
third place in the rally, was
equipped with Bosch injection
technology. Bosch Motorsport
provided the Race Touareg 3
with a specially designed MS16.1
Volkswagen diesel vehicles won
the overall title in both of the
past two years. And Bosch highpressure diesel injection technology was on board again this
year.
engine control unit, as well as a
high-pressure pump and injection nozzles that have both been
adapted to the engine.
Bosch engineers optimized the
system so that the engine would
run reliably under the race's
extreme climate conditions – be
it in the sizzling Atacama Desert
or high in the Andes, at altitudes
of over 4000 metres.
High dust content in the fuel is a
particular challenge for the race
vehicles.
Bosch Diesel does it for Audi and Hyundai
13
The Green Car Journal has been
making the award annually
since 2005. The idea behind it
is to highlight achievements in
environmental
protection
across all technologies and drive
systems. The key factors are fuel
efficiency and reduction of CO2
and other emissions.
Its
highway
consumption
according
to
US
EPA
(Environmental
Protection
Agency) figures is just 42 US
mpg. Bosch supplies piezo injectors for the CRS 3.2 fuel injection
system, the high-pressure pump
(CP 4.1) and engine control unit
(EDC 17).
To limit the resulting increase
in friction, Bosch specially
coated the components that
come into contact with the fuel.
In addition to the injection
system, Bosch also supplied a
number of sensors for the powertrain in the Race Touareg 3,
delivering the crankshaft sensor, the boost pressure sensor,
and the sensors that measure
the temperatures of the charge
air, exhaust, and fuel.
Nasser Al-Attiyah finished
first overall ahead of Giniel De
Villiers with Carlos Sainz third
– all were driving Volkswagen
Race Touaregs.
Introducing Bosch Diesel Managers
Bosch Diesel Key Account
Manager
Bosch Diesel Product
Manager
Shenoa Raft
David Ryan
The piezo injectors jet the fuel directly into the combustion chambers at a pressure of 2000
bar. The unit delivers respectable combined-cycle consumption figures of 7.6 litres per 100
kilometres.
Shenoa Raft has joined the
company as the new Bosch Key
Account Manager in the automotive aftermarket division for
diesel products and rotating
machines after spending more
than seven years with Pacific
Brands in sales.
David Ryan joined Bosch in the
UK more than 10 years ago and
has come to Australia on a sixmonth assignment to work as
product manager for diesel. He
has six years of experience as
the diesel product manager for
Bosch UK.
Hyundai Santa Fe: Refreshed
The second generation of the Hyundai Santa Fe has
been launched, with sporty exterior styling and a fresh
interior design.
Altogether Shenoa has more
than 14 years of sales experience and is looking forward to
her new role with Bosch.
But the major changes to the SUV are under the bonnet
with a completely new 2.2 litre four-cylinder turbo
diesel engine delivering 197 hp of power.
“I was looking for a change of
industry which involved more
technical aspects of the products I will be selling,” said Ms
Raft. “Automotive is a completely new field for me and I am
looking forward to a very steep
learning curve and the challenges ahead.”
In his Australian role David will
be in charge of ensuring that the
product range in this area effectively covers our vehicle range
in Australia as well as sourcing
new product for the future.
Audi A8: Luxurious and powerful
A8 fans had been waiting seven years for the new
edition of the Audi flagship. When it arrived it was
packed with plenty of high-tech features, including
Adaptive Cruise Control (ACC) and an infrared thermal
imaging camera for night vision, once again underscoring Audi's technical standing among luxury-class
carmakers.
The engine range for the new model was equally
impressive. The V8 TDI (Biturbo) with 4.2 litre capacity
and developing 350 hp of power output transmits a
maximum 800 Nm of torque to the crankshaft. The state-of-the-art common rail fuel injection
system from Bosch is what makes it possible.
The high-pressure pump, the control unit and the sensors are all optimized to match the engine.
The unit is combined with a Bosch common rail fuel
injection system featuring the high-pressure CP4.1
pump. The injectors inject at a pressure of 1800 bar.
The new systems in the Santa Fe have cut its consumption and emissions, meaning the 2.2 CRDi
conforms to the Euro 5 standard.
“I took on this position to get
more experience in the area of
diesel marketing and this was
ideal,” said Mr Ryan.
During his time in Australia,
David will also be in charge of
training a new permanent diesel
product manager.
14
Autumn | 2011
Future Workshop Electrical Systems
Bosch Alternators – Better for Business
The reputation of your business
depends largely on the quality of parts you fit. If a product
fails to perform as expected,
you could face costly warranty
procedures and the loss of customers. To protect your reputation, you need to trust that the
products you fit will perform as
expected.
Bosch stakes its own reputation upon its ability to provide
components that you can rely
on. As a leader in automotive
electrical technology, Bosch
places particular emphasis on
the quality of its starter motors
and alternators; utilising only
the highest quality raw materials and components, applying
cutting-edge manufacturing
techniques and ensuring all
units pass a rigorous test regime
before they reach the market.
Utilising the highest quality
components
Many alternators may look the
same on the outside, but it is the
parts that you don’t see that dic-
tate performance.
Inferior
parts
may
reduce costs,
but performance
and reliability suffer accordingly. In
selecting components,
Bosch always considers reliability and suitability for the particular application above all else.
Bosch stator windings are made
from high quality copper and
varnish. Higher quality copper
has fewer impurities, allowing
the current to conduct
with greater ease. As
a result charging
rates are higher
and the chances of overheating are
reduced.
Heat tole r a n t
materials in
Bosch alternators also mitigate the potential
affects of high
temperatures. Of
particular importance is the use of
heat tolerant slot sticks in the
stator housing. The use of inferior materials, such as wood, can
result in the stator sticks becoming dislodged and ultimately, the
failure of the alternator.
Bosch bearings are also rated
for automotive use, rather than
industrial use, to ensure they are
able to withstand the rigours of
automotive applications.
Bosch Batteries: Power and Precision
for Prestige Vehicles
Bosch is the largest Original Equipment supplier to the automotive industry across the globe
and this OE brand power carries into the battery market where Bosch supplies a comprehensive
program of OE quality batteries. The Bosch battery range for European vehicles is extensive and
has a commanding grasp on this market sector.
Consumers are very familiar with the Bosch brand and owners of European vehicles, in particular,
seek the quality and reliability that the Bosch name carries with it. The correlation between
Bosch and quality is one of the driving forces behind the Bosch company and the quality of Bosch
Batteries only further reinforces this relationship.
As our battery range expands and we further reinforce our coverage of the European sector,
we encourage you to grow with us, maximising your use of the Bosch branding and the
comprehensive pull it generates within the market.
For information on becoming a reseller, please contact your nearest Bosch Batteries distributor:
VIC/TAS: Independant
Battery Distributors
Ph: (03) 9315 3580
NSW: Lion Batteries
Ph: (02) 9674 6322
QLD: Australian Battery
Distributors
1300 305 377
SA: Independent Battery
Distributors
(08) 8260 6111
WA: Goodchild Enterprises
(08) 9417 7033
NT: Independent Battery
Distributors
(02) 8931 0811
O.E. standard components
Bosch regulators are tested to
suit the specific application, as
per O.E. standards. Rectifiers
also meet O.E. standards, using
heat tolerant materials, highquality diodes and spot welding where the diode meets the
circuit. Inferior rectifiers using
materials with lower tolerances can crack or deform under
normal operating conditions,
resulting in the failure of the
alternator.
Tested
to
protect
your
reputation
During the development phase,
Bosch starter motors and alternators are subjected to the following tests to ensure that they
meet strict performance criteria:
 Load and Heat testing over a
minimum of 300 continuous
hours at elevated temperatures to ensure long-life and
reliability
 Vibration testing to ensure the
strength of mounting points
and components.
 Salt water testing to ensure
resistance to corrosion
 Electrical, mechanical and
noise testing to ensure high
performance and minimal
noise
This test regime ensures that
Bosch units meet all performance claims made by Bosch,
and it is only after passing these
tests that they are released onto
the market. You can therefore
be assured that when you fit a
Bosch alternator, it will perform
to expectations.
Switch up to Bosch Alternators
A Bosch unit may not always be
the cheapest available, but it will
deliver long-term value for your
business. There is an obvious
temptation to use a cheaper unit
in order to minimise the costs of
a service for your customer, but
warranty returns cost money
and customers. If you want the
best for your business and your
customers, insist on Bosch.
Bosch Batteries Backs
Fenech’s Fight
Reigning Victorian Formula
Ford Series champion Jesse
Fenech has received a boost to
his 2011 Australian Formula
Ford Championship campaign,
with Bosch Batteries confirming a deal to secure naming rights sponsorship of his
Spectrum 012 racer.
From 2000 to 2005, Bosch
Batteries was synonymous with
success in Formula Ford and
Australian motorsport; a fact not
lost on Fenech.
“I remember watching Mark
Winterbottom, Tim Macrow,
Shane Price and Steve Owen
racing the Bosch Batteries cars,”
Fenech said. “Between them,
they have gone on to win the
CAMS Gold Star, secure two V8
Supercars Development Series
titles and establish careers in the
V8 Supercars Championship.
“They set a pretty high standard,
but I will be aiming to emulate
their achievements,” he said.
Bosch’s marketing team is
enthusiastic about the 2011
season.
“It’s terrific to once again see the
Bosch Batteries Spectrum racing
in the Australian Formula Ford
Championship.
“Bosch enjoyed fantastic results
from both a sporting and a commercial perspective when we
were involved previously.
“Jesse is an outstanding
young man who will be a great
ambassador for Bosch, our
products and our partners,”
said Rolf Schillinger, Bosch
Marketing Manager Automotive
Aftermarket.
Fenech’s
Bosch
Batteries
Spectrum finished second at
its first outing for 2011 at the
Clipsal 500 which was held in
Adelaide in March.
Future Workshop Engine Management Gasoline Systems
Autumn | 2011
15
The Big Bang Theory Continues for Bosch
Internal combustion systems,
including gasoline systems
will continue to offer excellent potential for the future
according to Steffen Berns,
who is a member of the
Bosch executive committee
responsible for engineering.
Mr Berns said that fuel consumption and CO2 emissions have
already been reduced considerably in recent years. Now one
of the important considerations
is downsizing, which involves
reducing engine displacement
through turbocharging and
direct injection.
creating a demonstration engine
of 1.2 litres with an output of
120kW which is very economical but still allows for a sporty
driving style.
While this is not a new concept
it does offer further potential
and Bosch is looking at what is
known as ‘extreme downsizing’.
Together with Mahle and the
Bosch-Marhle Turbosystems
joint venture, the company is
However, there are still technical challenges to overcome. For
example, with the downsizing
of cylinder capacity the injection spray may give rise to fuel
condensation on the manifold
wall and so generate emissions.
25 years of the Oxygen
Sensors in Australia
2011 is a year of anniversaries
at Bosch. Not only is it the 125th
anniversary of the founding
of the company, it is also the
25th anniversary of the Oxygen
Sensor in Australia. It provides
an opportunity to look back at
the Australian-built vehicles
released in 1986, and the role
Bosch played as an Original
Equipment supplier.
Technological change
In February 1986, Australian
Design Rule (ADR) 37 was introduced. It included several emission level revisions, the most
important of which dictated
that all vehicles sold in Australia
had to operate on unleaded fuel
(ULP).
ADR37 had a massive impact
on local manufacturers
as they had to adopt
major engineering
revisions to comply.
More complex engine
management systems
and catalytic converters were often required
to meet the new rules, and oxygen sensors, which could not be
used with leaded fuel, became
common place.
The entire automotive industry
went through an unprecedented
technology change that required
updated testing equipment and
a massive re-training of technicians. The changeover process
was still ongoing well into the
1990s with Bosch at the frontline, providing training to both
manufacturers and independent workshops.
New releases in 1986
In 1986, there were
five manufacturers
producing 11 different
models in Australia.
Bosch had deep relationships with all of them, sup-
plying a range of engine management components, including
oxygen sensors.
Holden
Holden released the VL
Commodore in 1986 with
a Nissan-sourced 3.0 litre
6 cylinder EFI engine. Holden
had worked hard to adapt the VK
series 3.3 litre 6 cylinder engine
to meet the ADR37 requirements, but failed to do so in
time. The VL therefore became
the first - and only - Commodore
to utilise a Japanese-sourced
engine.
Holden also introduced a turbo
charged version of this engine
that produced 155kw and was
the first locally-produced, turbo
charged
Holden
sold in
Australia.
Whilst the engine in the VK
employed Bosch LE-2 Jetronic
fuel injection, the VL engine
utilised a Nissan/JECS engine
management
system. It
d i d ,
however, use various Bosch
components including an air
mass sensor, fuel pump and
engine control unit.
Ford
The Ford Falcon XF series
required a more simple change
than the rival Commodore. It
received a styling facelift and
a Bosch designed, and locally
manufactured, Electronic Spark
Timing (EST) system. The XF
series still used a carburettor
and did not employ any oxygen
sensors, but did use a two way
catalytic converter. Ford did
not introduce an entirely new
Falcon until the EA26 model in
1988, which featured a Bosch
heated oxygen sensor.
Nissan
Nissan was already producing the N12 Pulsar and simply
upgraded it from a 1.5lt
engine to a 1.6lt version with a two
way catalytic
c o n v e r t e r.
The new N13
series released
in early 1987
used a Japanesesourced
engine
management system that
incorporated a single oxygen
sensor.
Nissan introduced a locally made
R31 series Skyline to
replace the imported R30 series,
and new model,
the R31 Pintara,
to replace the
locally
made
Bluebird.
The Skyline used
the same 3.0lt 6 cylinder engine as the Holden
Commodore with some minor
component changes. The new
Pintara model was powered by
In this situation injection valves
and controls must compensate.
A turbocharger that reacts
quickly is also a must and the
company is investigating methods to reduce the lag, especially
at lower engine speeds.
Another innovative step is
advanced port fuel injection (PFI) which is a package
comprising two injectors per
cylinder and using a higher
injection pressure. This significantly reduces emissions, particularly in the start-up phase.
So according to Mr Berne the
combustion engine still offers a
lot of potential and will remain
the dominant force for the next
20 years. It will remain a better
option for travelling long distances, something Australians
know quite a lot about.
New Suzuki Swift with Bosch
Motronic
The third generation Suzuki
Swift has been launched and
it is equipped with the Bosch
Value Motronic system.
Suzuki recognised Bosch’s
ability to react quickly and
flexibly to meet its future
requirements after having used
Bosch to supply the Suzuki SX4.
The company found Bosch supplied high quality products, with
a 2.0lt 4 cylinder engine that
used an Nissan/JECS engine
management system that used
various Bosch components,
including air flow sensor, fuel
pump, fuel injectors, engine
control unit and a single wire,
non-heated Bosch oxygen sensor in conjunction with a three
way catalytic converter.
Mitsubishi
Mitsubishi
updated
the
locally made Magna to include
an “ECI multi” electronic fuel
injected engine.
This engine used numerous
Bosch
components
including fuel injectors, fuel
pressure regulator, distributor
assembly, electronic control unit
and various sensors including a
single wire oxygen sensor.
Toyota
Production of the local Corolla
and Corona models continued
with little change. Imported EFI
a competitive price and had a
good supplier network.
Bosch was able to supply Suzuki
a complete turnkey application
for the new Swift range from
integration right through the
development process to final
delivery.
Around 235,000 Suzuki Swifts
are expected to roll off the
production lines every year.
versions of the Corona were
introduced that used a single
wire oxygen sensor.
Parts and training for the
past and the future
Bosch still supplies aftermarket engine management parts,
including oxygen sensors, for all
of the vehicles mentioned above.
Bosch also provides training on
the latest vehicle systems which
are evolving at a rate not seen
since the introduction of ULP.
That rate is set to increase
even further as advanced diesel, hybrid and electric systems
become more commonplace
in workshops and Bosch will
continue to play a vital role in
the development of those systems and the training required
to service them.
16
Autumn | 2011
Future Workshop Training
Trained To Train
Bosch is the right company. Our
range of training, backed by
our extensive experience in the
industry is a guarantee of that.
What about our training staff?
When you’re investing in training you want to be sure that
you’re getting the right training, from the right company
and by the right person.
Darren Todd is one of Bosch’s
most experienced trainers. He
has been with the company as
a senior technical trainer for
14 years and has worked in the
industry since completing his
apprenticeship.
Darren started work in the engine
and transmission rebuilding
industry before entering an auto
electrical apprenticeship with
a Bosch service dealership in
Canberra.
He was exceptionally skilled
and won awards including the
‘Most outstanding apprentice’ in
each of his three years of training at the Canberra Institute of
Technology (now CIT). This was
followed by the MTAA ‘Trades
person of the year’ and ‘Young
achiever of the year’ awards.
Not surprisingly Darren was
awarded his apprenticeship one
year early due to his skills and
abilities.
He is a trade qualified auto electrician, mechanic, welder and
holds diplomas in electronics as
well as being licensed to service
air conditioning systems.
Independent Workshop Training Information for Australia and New Zealand
Course Code
CRS-D*
Common Rail
System
Diagnosis
Days/
Hours
2
Days
Full Day(s)
Objective
The trainee will be able
to understand the
mechanisms behind the
combustion process,
exhaust emissions and
learn how to diagnose
electrical and fuel
system faults relating
to the Common Rail
System.
Content
This course will cover the
construction, operation and
diagnosis of a Common Rail
System as fitted to a modern
day diesel engine. Subjects
covered will include; Diesel
engine fundamentals, High
pressure fuel components,
engine-management &
emission control systems.
Dates
30 - 31 Mar
14 - 15 Apr
23 - 24 Jun
30 Jun - 1 Jul
15 - 16 Sep
Adelaide, SA
Christchurch, NZ
Sydney, NSW
Brisbane, Qld
Perth, WA
Price
$480 AUD
incl. GST
Common Rail
Diesel Systems
Overview
3
Hours
This course will provide
a valuable insight into
the technology,
operation and
diagnostics behind the
rapidly growing diesel
vehicle sector.
(Evening)
During this Technical Presentation we will look at the
Common Rail Diesel systems
that are found on modern
vehicles. This session is
designed to give participants a
general overview of a modern
common rail diesel system.
Topics covered will include;
basic system operating
principles, e.g. High pressure
pumps and injectors, identifying variations in fuel system
configuration and modern
emission reduction technology
e.g. DPF - Diesel Particulate
Filters will be overviewed.
10 Mar
29 Mar
4 Apr
13 Apr
22 Jun
27 Jun
12 Sep
13 Oct
Sydney, NSW
Adelaide, SA
Auckland, NZ
Christchurch, NZ
Sydney, NSW
Brisbane, Qld
Perth, WA
Brisbane, Qld
$120 AUD
incl. GST
Gasoline Direct
Injection
Overview
(Evening)
3
Hours
This course will provide
valuable information
and knowledge required
to work with
confidence on a
Gasoline Direct
Injection system.
We begin with an overview of
a typical GDI system and move
onto the operation of our
current state-of-the-art MED
7/9 GDI fuel and engine
management systems.
During 2010 Bosch trained in
excess of 60,000 people worldwide with Bosch Australia and
New Zealand conducting a range
of technical training courses
designed especially to suit our
vehicles and conditions.
This year the focus for training
is on diesel common rail systems
and gasoline direct injection
systems, starting with instruction on the system and principles, through to fault finding and
diagnosis.
Attendees are provided with
training, course books, manuals
and a participation certificate.
31 Mar
12 Apr
29 Jun
14 Sep
Adelaide, SA
Wellington, NZ
Brisbane, Qld
Perth, WA
$120 AUD
incl. GST
We will take a look at:
• Basic design and operation
of the key components,
control unit functions and
their interaction in the
complete system
• Fuel, mixture preparation
and emissions control
systems
• Diagnostic, setup and
servicing possibilities
• Requirement of special
servicing tools
*CRS-D is an updated version of the previous Diesel Systems Diagnostics course (EPBZ-7)
Training staff can be contacted week days between 9.00am and 2.00pm on 03 9541 5553, or email [email protected]
ADV0178H
Training Focus
for 2011 –
Diesel and
Gasoline Direct
Injection (cont.)
Using the latest in testing and
diagnosis equipment on current
vehicle systems is the way Bosch
will be training Australian and
New Zealand workshops for the
future.
Participants will also obtain an
awareness of the various
specialised tools and testing
procedures required to
diagnose these modern
common rail diesel systems.
TP-GDI
Bosch has a modern training centre for this in Germany covering
4600 square metres where all
the latest equipment and vehicle
drive systems are on hand.
Bosch is an OE supplier of diesel, gasoline and hybrid systems
and so is at the forefront of the
technology, this means that as
a trainer Bosch has exceptional
knowledge of all these systems.
This course will include both
practical and theory sessions.
The workshop practical
sessions will include, fault
diagnosis using KTS Scan tool,
High & Low fuel pressure
measuring Kits, Injector
back-flow measuring tools, and
Oscilloscope electrical testing.
TP-CR
Like every Bosch trainer, Darren
receives regular up-to-date
training in the use of diagnostic
equipment, upcoming technologies and training methods.
Technical courses run over
2-days. Technical information
sessions run for three hours and
are available in the evenings.
Training
enrolment
staff
can be contacted weekdays
between 9:00am to 2:00pm
on (03) 9541 5553 or email
[email protected]