Tips & Technology For Bosch business partners

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1 Tips & Technlgy Fr Bsch business partners Current tpics fr successful wrkshps N. 35/2011 Gasline injectin Invented fr life Lambda sensr Knw-hw frm the market leader Bsch, innvative cmpany and wrld's largest manufacturer, prduces mre than 33 millin lambda sensrs every year. Almst all vehicle manufacturers use Bsch riginal lambda sensrs, even diesel vehicles have been equipped with lambda sensrs as standard since This knw-hw is fully transferred t Aftermarket, ffering wrkshps the highest f prductin quality, reliable applicatin data, the latest technlgy fr all sensr types, a wrkshp-riented replacement parts prgram with quick availability. Ideal fr the wrkshp Bsch lambda sensrs are reliable and bast a lng service life. Hwever, they include parts that are subject t wear and these need t be regularly checked and, if necessary, replaced. We recmmend an inspectin every 30,000 km. T ensure a prblem-free replacement, Bsch lambda sensrs have a pre-lubricated thread fr a quick and simple swap, tailred cnnectin cable fr every type f vehicle. Test and replace lambda sensrs easily 1. Step: Perfrm visual inspectin and read ut fault memry a) Check faulty lamp: A faulty lambda sensr will cause the OBD lamp t light up (n-bard diagnsis). When checking the lamp, make sure the engine has been warmed up. b) Read ut fault memry: Use a tester here (e.g. Bsch KTS 570).

2 Tips & Technlgy N. 35/2011 Page 2 c) Carry ut visual inspectin (when installed): Cnnectrs, wiring and lambda sensr are affected. d) Perfrm leak test n intake and exhaust system: In particular, check the area between engine and lambda sensr. The ingress f additinal air will bias the Lambda sensr signals. 2. Step: Check lambda sensr systematically Lambda sensrs may be faulty fr several reasns, e.g. electrical fault, mechanical damage, cntaminatin, thermal verlading. By carrying ut the fllwing test steps, it will be pssible t determine the fault. Imprtant is that the engine mechanical system and the ignitin system are in gd wrking rder. Detailed test steps and test values are cntained in ESI[trnic]. Check lambda sensr heater a) Check the pwer supply fr the lambda sensr heating. The pwer supply must remain between 10.5 V 13.5 V. Is the pwer supply OK? If nt: Pssible causes include: - Relay nt switching thrugh "cntinuus psitive" - N grund actuatin by cntrl unit - Wire break, shrt t grund r t psitive b) Check heating resistance at ambient temperature. The higher the temperature f the lambda sensr, the higher the heating resistance and vice versa. Are the test data OK? If nt: Lambda sensr faulty c) Allw engine t warm up and measure heating current. T ensure the lambda sensr is quickly ready fr peratin, it is initially energized strnger and gradually less by switching the grund supply n and ff. Des the heating current reduce with increasing temperature? If nt: Lambda sensr faulty d) Check vehicle wiring harness fr - damage - crrsin damage

3 Tips & Technlgy N. 35/2011 Page 3 - cntacting faults n the cnnectrs - pen circuit, shrt t grund, shrt t psitive and transfer resistances Is the wiring harness OK between lambda sensr and cntrl unit? If nt: Repair/replace wiring harness e) Check cntrl unit - Check multi-pint cnnectr fr damage, crrsin and cntact faults Is the cntrl unit OK? If nt: Cntrl unit defective, replace it. Lambda sensr heater is OK. - Erase fault memry - Run a test drive - Check fault memry Check lambda sensr signal a) Test requirements: - Fuel injectin system, ignitin and engine mechanical system OK - Intake system and exhaust tract leak-tight - Engine at perating temperature and idling b) Check signal prfile step change sensr: - Signal swings between apprx V - The greater the vltage excursin, the better the signal - Frequency between Hz - Vltage belw 0.4 V lean mixture - Vltage abve 0.5 V rich mixture Or: c) Check signal prfile - brad-band sensr: - At lambda = 1 => pump current 0 ma - Pump current belw 0 ma => rich mixture - Pump current abve 0 ma => lean mixture Is the signal prfile OK? If nt:

4 Tips & Technlgy N. 35/2011 Page 4 Lambda sensr faulty d) Check vehicle wiring harness fr: - damage - crrsin damage - cntacting faults n the cnnectrs - pen circuit, shrt t grund, shrt t psitive and transfer resistances Is the wiring harness OK between lambda sensr and cntrl unit? If nt: Repair/replace wiring harness e) Check cntrl unit - Is the reference 450 MV? - Check multi-pint cnnectr fr damage, crrsin and cntact faults Is the cntrl unit OK? If nt: Cntrl unit defective. Lambda sensr heater is OK. - Erase fault memry - Run a test drive - Check fault memry 3. Step: Remval and installatin Tasks: a) Select assembly tl: Use a 22 mm pen bx wrench r tl adapter. b) Set tightening trque: Mnitr Nm using trque wrench. c) Renewed installatin f sensr: Attentin: Make sure the assembly paste des nt cme int cntact with the guard tube. d) Fitting new sensr: Bsch Lambda sensrs are supplied with a ready-greased thread and a prtective cap. Only remve the prtective cap immediately prir t installatin. Fitting instructins: Take care nt t twist the wiring harness n fitting/screwing in the sensr. Avid pulling heavily n the cable r the cnnectr.

5 Tips & Technlgy N. 35/2011 Page 5 Sensrs are nt t be used if the cnnectr is dirty r damaged. Fr the Lambda sensr t functin prperly, it is imprtant t keep the inside f the cnnectr clean. Fr this purpse, prtect the cnnectr frm any kind f siling. Use cable ties t take up any excess length f cnnecting cable int a lp. Regular checks help prevent cstly subsequent damage Infrm yur custmers that sund lambda sensrs save up t 15% fuel adhere t the strictest exhaust-gas values prevent damage t the catalytic cnverter Yur custmers shuld be made aware f the fllwing in rder t avid as much cstly repairs as pssible: Only use unleaded fuel withut additives. Have the vehicle serviced at regular intervals. Only jump start the car with jump leads where necessary, as push starting can cause unburned fuel t enter the exhaust system. D nt fill the engine with il beynd the max. mark n the dipstick. Observe checking and replacement intervals: Regularly check and, if necessary, replace the lambda sensr every 30,000 km. This infrmatin des nt claim t be exhaustive. Always make use f the crrespnding service dcumentatin when perfrming testing and repair wrk. N liability. All rights, including patent applicatins, as well as sle pwer f dispsal and duplicatin and transfer rights, reserved by Rbert Bsch GmbH.

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