Oct 2015 Edition

2014

Dear Partners,

This edition of the Service News will communicate our latest

technical information and answers to commonly asked
questions from the region. In addition, we will share important
technical material to assist you in handling customer issues. You
will also be updated with the development and expansion
progress concerning the Bosch Service Network.

We also count on you to provide us with feedback on the

newsletter and to share relevant information that can be
distributed to others, so please feel free to approach us on what
you would like to read in our Service News newsletter.

Enjoy reading!

Regards,

Technical Service and Workshop Concepts Teams

Robert Bosch Middle East FZE

Workshop Test Equipment

ESI[tronic] 2.0 - Change from DVD Updates to Online Updates

Keeping your diagnostic software up to date is highly critical to your daily business.
The latest information must be available quickly, easily and securely.

As such, you will benefit from a full online update service in 2016. This means that
you don`t need DVD`s anymore! The ESI[tronic] 2.0 online update has the following
benefits:
• access to most recent data
• automated download in the background
• comfortable handling: no more timely DVD installation

Please keep in mind that you will receive a last DVD delivery in 2016. The
following updates will be provided online.
 Multi-Touch zoom feature and Equipment Systems tab enhancement

The 2-finger zoom feature for the DCU 220 has been introduced in the 2015/2 DVD
update.
Similar to a smartphone operation, this further optimizes screen navigation. (for
example in the timing belt replacement instructions or the circuit diagrams, see
screenshots below)

Vehicle Coverage List in ESI[tronic] 2.0

One of the quickest ways to find what information is available in ESI[tronic] 2.0 for the
selected vehicle is to look for the Vehicle List from the Main Menu of ESI[tronic] 2.0.

Prior to going to the vehicle and connecting the KTS for troubleshooting or Diagnosis,
a simple way of checking the available Technical information in software reduces the
efforts and time of a mechanic.

Simply click on the main menu of ESI[tronic] 2.0 and click on the Vehicle List. Select
the information you want to look for, for example SIS for all technical information or
Control unit Diagnosis to check whether KTS can communicate with particular Control
Module of the selected vehicle or not.

In case you need any further clarification on this subject, please feel free to drop us an email on our Technical Hotline
email address: tech.support-dub@ae.bosch.com

Technical Service Support (TSS) Team

Jasdeep Singh

Based in Dubai and responsible for UAE, KSA, Oman, Kuwait, Qatar, Bahrain,
Lebanon, Ethiopia, Somalia, Eritrea and Djibouti.

Jasdeep.Singh@ae.bosch.com
Diesel Repair
Overflow Restriction VE-F Pumps

The distributor injection pump is cooled by fuel that flows back to the tank via an
overflow restriction screwed to the governor cover. The overflow restriction is
located at the fuel-injection pump’s highest point to bleed air automatically.

In applications where higher internal pump pressures are required for low-speed
operation, an overflow valve can be installed in place of the overflow restriction.
This spring-loaded ball valve functions as a pressure control valve.

The amount of fuel that the overflow restriction’s throttle port (5) allows to return
to the fuel tank varies as a function of pressure (6). The flow resistance furnished
by the port maintains the pump’s internal pressure.

This is due to the fact that a precisely defined fuel pressure is required for each
individual engine speed, the overflow restriction and the pressure control valve
must be matched.

CP1 Type Designation

Diesel Trainer
Magdy Shenoda

Based in Dubai and responsible for all Diesel Trainings for Middle East and
TSS function for Egypt, Libya, Sudan, Syria, Jordan, Iraq, Afghanistan,
Pakistan and Yemen.

Magdy.Shenoda@ae.bosch.com
Vehicle Repair
Emission Control System:

Graph Showing the Generation of CO/HC/NOx

This graph, shows the air-fuel ratio and the amounts of
CO/HC/NOx generated.

1. Richer
CO/HC: Increase
NOx: Decrease

2. Leaner
CO: Decrease
HC: Decrease
However it increases because of the misfire when the air-fuel
ratio is too lean.
NOx: The amount generated is greatest when the actual air-
fuel ratio is slightly leaner than the theoretical air-fuel ratio.
When the ratio becomes even leaner, the amount decreases
because the combustion temperature decreases. The
generated amounts of CO/HC/NOx increase under the
following conditions, except for the graph below.

3. While engine is cold

The generated amounts of CO/HC increase because the rich air-fuel mixture is supplied.

4. At heavy load
The emission gas is increased because both the fuel and the air are increased.
• The generated amounts of CO/HC increase because the rich air-fuel mixture is supplied.
• The generated amounts of NOx increase because the combustion temperature rises.

Some possible causes of LEAN fuel mixtures include:

1. Air or vacuum leaks in the intake manifold, near the throttle body or at vacuum hose connections.
2. Weak fuel pump that is not generating enough pressure or volume
3. Fuel line restrictions (like a pinches hose or plugged filter)
4. A weak fuel pressure regulator that is not maintaining adequate fuel pressure
5. Air leaks in the PCV plumbing
6. Dirty MAF (Mass Airflow) sensor that is under reading airflow into the engine
7. Dirty or dead fuel injectors
8. Ignition misfire (a fouled spark plug, weak ignition coil or bad plug wire that causes a misfire allows unburned
oxygen to pass into the exhaust and fool the O2 sensors)
9. Compression leaks (bad exhaust valve that allows unburned oxygen into exhaust and fools O2 sensors)
10. Exhaust manifold crack or gasket leak (allows unburned air into exhaust and fools O2 sensors)
11. Bad O2 sensor (signal shorted to ground so the sensor reads lean all the time)

Some possible causes of RICH fuel mixtures include:

1. Coolant Temperature Sensor

2. Leaky fuel injector
3. Excessive fuel pressure due to bad fuel pressure regulator or restricted fuel return line
4. Extremely dirty air filter or restrictions in air intake system
5. Exhaust restrictions (clogged converter, crushed exhaust pipe or plugged muffler)
6. Bad O2 sensor (output shorted to voltage so it reads RICH all the time

Jackson Joseph
Based in Dubai and responsible for all Petrol Vehicle Systems and Vehicle Maintenance
Trainings, Brake System Trainings for Middle East.

Jackson.Joseph@ae.bosch.com
Workshop Service Concepts

Tips & Technology for Bosch Partners

Please click here to download the latest Tips and Technology regarding Batteries. This will help you to find the right
battery for the specific use. The symbols provide practical information on the features such as short/long distance
driving, electrical load and start/stop operation.

Optimum Diesel Partner (ODP) Concept

Early this year we introduced a new Diesel Concept to our region. It is called Optimum Diesel Partner or ODP for short,
and the main aim was to create a diesel repair service network able to compete with the market needs with a
reasonable quality and fair prices. In addition, to use Bosch Know-how by sharing information, training and technical
know-how.

The requirements are very basic:

1. An existing Diesel Pump Repair workshop
2. At least one test bench ( must not be Bosch)
3. Willingness to be part of a network
4. Basic tools to carry out the essential repairs

If you are interested or you know someone who will be then please contact your local partner for further details.

Service Booklet for BCS workshops

A new Service Booklet for BCS workshops is under preparation by Bosch and should be released soon.

In addition to a clear and detailed view of service operations carried out, the booklet contains useful tips and hints for
car maintenance and promotes the use of Bosch parts.
Workshop Concepts

Elie Nasr

Based in Dubai and responsible for Bosch Service Network expansion in Middle East and
North East Africa.

Elie.Nasr@ae.bosch.com

Amine El Kabiri

Workshop concepts specialist.

amine.elkabiri@ae.bosch.com

We hope that you have enjoyed reading this edition of Service Newsletter. It is meant to keep you all up-to-date with
the latest activities and information from Bosch Automotive and Equipment fields.

We would also like to confirm to all Bosch Service partners and assure you that we are ready to support your inquiries.

Furthermore, we encourage you to send us all your best practices, activities, special campaigns, promotions to share
with the region by Jan 05th on this e-mail address: BoschService.News@ae.bosch.com

The next newsletter is planned for mid of Jan 2016.

Best Regards,

Bosch Service Team