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Diesel SystemsThe diesel engine as a sign of the timesand on its way to new horizons


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| Diesel Systems Diesel Systems | 3

There is no challenge, however remotely

connected to diesels, that we have not

successfully taken up.

We are proud of the fact that, for more than

80 years, every decisive further development

of diesel technology, from fuel injection via

electronic control right up to exhaust-gas

treatment, has been thought up, co-developed

and brought to series maturity by our engineers.

The last two decades in particular have been

especially exciting, decisively advancing diesel

progress. Thanks to our developments, the

sturdy, thrifty but rather sluggish diesel engine

of yesteryear has blossomed into a high-

performance power unit that has lost none of

its sturdiness yet can now bear any comparison

with other propulsion units with regards to fuel

economy, environmental friendliness and sporty

performance.

Unique anywhere in the world: our offerings

for and our commitment to diesels

At 36 locations around the world, over 50,000

diesel specialists are working on making dieselengines even more economical, cleaner, quieter

and more powerful. No other company employs

so many diesel experts so close to you wherever

in the world you are located. And no other

company develops, manufactures and applies

so many diesel components and systems for

practically every diesel engine, no matter what

its planned usage may be.

When, in 1927, Robert Bosch manufactured the worlds rst diesel

injection system capable of series production followed only four

years later by the marketing of the rst diesel system consisting of

pump, injection nozzles, fuel lines, fuel lter, nozzle holders and

glow plugs, even he probably had no idea of how successful the

onward march of the diesel engine would prove to be in the decades

that followed. Yet he had achieved something unique. For his devel-

opment provided the basis for diesel engines that were small and

powerful enough to drive an automobile.

The trailblazing inventions of the founder of our company insepara-

bly link the name Bosch to that of Diesel. An inseparable partnership

that has been further extended and consolidated over the past de-

cades right up to the present day in an unbroken line and which will

also continue into the future.

You can rely on us throughout your diesel

engines entire life: alongside the workshops of

vehicle manufacturers, 14,000 Bosch Service

locations worldwide provide a comprehensive

network of specialized workshops. Our Bosch

eXchange program, whereby used diesel

components are refurbished in Bosch factories,

is an active contribution to husbanding

resources and protecting the environment.

In addition, the more favorable prices benet

both you and your customers. Our Automotive

Tradition experts are always available to advise

and assist all lovers of historic diesel vehicles.

The future needs the past

We know where our roots are and we know that

we will be accompanying diesels far into the

future with developments that we are bringing

to series maturity today. And we look forward

to doing so with your help so you can depend

on us!

1927

First series

diesel injec

system

Since 1927, Bosch has registered

over 10,000 patents for diesel

components and sold over

180,000,000 injection systems

worldwide to date. Today we have

around 225 diesel customers in

32 countries.

2004

First comm

system wit

injectors

1997

First comm

system

1994

First unit insystem

1987

First diese

injection

1960

First distrib

pump

No dieselswithout Bosch

1931

First comp

diesel syst

1986

First electr

diesel cont


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1990 2009: Diesels compared to diesels

Since the early 1990s we have succeeded in

drastically reducing the pollutant emissions of

diesel engines: in passenger cars, for example,

nitrous-oxide emissions have been reduced by

96 percent; particulate emissions have fallen by

as much as 98 percent. Parallel to this develop-

ment, the fuel consumption, and thus the CO2

output of diesel vehicles, has been considerably

reduced.

The most important milestone here has undoubt-

edly been our Common Rail System, meanwhile

performing service in over 50 million diesel

engines and operating, depending on the version

involved, at pressures from 2,200 bar in passen-

ger cars up to 2,500 bar in commercial vehicles.

These high pressures and the possibility to

individually adapt the injection rate by sepa-

rating pressure production, pressure storage

and fuel injection have led, on the one hand,

to optimized fuel distribution and combustion

and thus, on the other hand, to massive reduc-

tions in untreated emissions while at the same

time increasing the dynamic performance of

diesel engines.

In addition, further fundamental improvements

in combustion behavior such as higher turbo-

charger pressures together with higher exhaust-

gas recirculation rates under part load condi-tions have gradually made diesel engines even

cleaner.

To supplement measures inside the engine, it

was our ideas for efcient exhaust-gas treat-

ment systems which ensured that modern diesel

engines have always been and still are one step

or rather several years ahead of the ever-

more-demanding emissions legislation. How we

foresee the progress of the next twenty years is

set out on pages 14 and 15.

The Audi R15 TDI dovetails into the

success story of its predecessor, the

Audi R10 TDI. In 2006 the Audi R10

TDI, with a Common Rail System

jointly developed by Audi Sport and

Bosch, was the rst diesel vehicle to

win the Le Mans 24-hour race. And it

won again in 2007. And yet again in

2008!

The enthusiasm and know-how with which we throw ourselves

into the challenge of making diesels ever better is best shown by

looking at the past twenty years or so. Because this is precisely the

time when our innovations particularly the Common Rail System

in 1997 made a decisive contribution to the unique diesel success

story. And now, at this present point in time, old prejudices among

end users are being swept away by ever more economical, even

thriftier, quieter yet at the same time considerably more sporty diesel

engines.

So it is no wonder that nowadays virtually every second newly regis-

tered passenger car in Europe is a diesel, and that in total almost a

quarter of all vehicles worldwide are driven by a modern compression-

ignition engine. Globally, we predict that the share of diesel vehicles

will continue to rise over the years to come. Because the victorious

march of the most economical diesel engines of all time is meanwhile

conquering even markets where tough opposition had previously been

encountered: for instance in the USA, or in Asia.

Bosch andenthusiasmfor diesels

Achieveme

since 1990

innovation

Bosch for d

engines in

96 percent

reduction i

nitrous oxi

including h

carbon em

98 percent

lower parti

emissions

98 percent

drop in car

monoxide e

sions

86 percent

reduction i

nitrous oxi

including h

carbon em

97 percent

lower parti

emissions

87 percent

drop in car

monoxide e

And for die

engines in

mercial ve


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Economy meets ecology

Our developments contribute not only to

maximum cost efciency but are, at the same

time, the foundation for meeting the ever-more-

demanding standards and threshold values of

global emission legislation. Thanks to innova-

tions from Bosch it is already technically

possible today to meet the strict regulations of

the EU6 standard that will probably come into

force in 2014. By comparison with a technically

equivalent gasoline vehicle, a diesel car oftoday consumes over 30 percent less fuel, thus

emitting about 25 percent less CO2while being

able to travel around 40 percent farther. In

addition, it has roughly 50 percent higher

torque. And despite commonly-held opinions,

a diesel passenger car is often an economical

proposition even if the annual mileage is less

than 10,000 kilometers. Check it out for

yourself at www.fuel-pilot.de.

In the old days, diesels were bought almost exclusively for their fuel

economy and sturdiness. Nobody would have thought of describing

a diesel as clean, never mind sporty. How times have changed!

How more and better technology and maximum fuel economy can

be combined to harmonize with environmental compatibility and dy-

namic performance is proven today by every modern diesel engine,

no matter what its planned utilization may be.

Private motorists and commercial-vehicle customers benet to the

same extent from this fuel ec onomy. Economic parameters are enor-

mously important particularly for transport companies and other

eet operators for whom every cent per kilometer saved is a decisive

factor for competitiveness in their bottom-line nancial calculations.

Low fuel consumption combined with a high degree of dependability,

and thus shorter down times, add up to the ideal price-to-performance

ratio of todays diesels.

Keeping up with the times

Getting better all the time is, for us, both a

challenge and reality. So we never rest on our

laurels, but are working day by day on new

technical approaches such as solutions for

further signicant downsizing of engines.

With our ideas we provide our colleagues at

the vehicle manufacturers with new tools to

enable ever smaller and ever more economical

engines to be constructed without any loss of

performance.

We are diligently working for you to globalize

diesels and are at your disposal on the spot all

over the world whenever engine and vehicle

concepts have to be designed for a par ticular

region, a particular market, a particular demand.

And of course this service extends from the

prototype right up to large-series production

and far beyond that.

A 40-tonne diesel traveling

1,000 kilometers consumes

about a tablespoon of fuel

for every kilogram of goods

transported.

Bosch for the mosteconomical dieselof all times

Compariso

between a

diesel and a

parable gas

passenger

Over 30 pe

lower fuel

consumpti

About 40 p

greater ran

Some 25 p

lower CO2

production

Around 50

higher torq

A diesel pa

car is frequ

an economproposition

if the annu

age is less t

10,000 kilo


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What do fruit from South America, shoes from Italy, tea from India,

machines from Germany, computers from the USA and televisions

from Asia all have in common? The answer is as logical as it is simple:

no matter where we live in the world, all these goods and products

are brought to us by diesels. Whether from near or far a diesel is

always part of the equation.

And thus so is Bosch. Because from the smallest to the largest

engine application, from cars, light commercial vehicles and gigantic

trucks right up to container ships, from stationary single-cylinder

engines right up to big dumper trucks and many other off-highway

applications, we develop and manufacture individual components

and complete systems for diesel injection as series products. So

thanks to our worldwide presence we are able to offer you local and

global solutions from a single supplier.

Diesel eng

with comp

and system

Bosch are

only found

and comm

vehicles.

Additional

of applicat

include, am

others:

Stationary

engines:

for example

gency gene

Agricultur

machines:

such as tra

or combine

vesters

Construct

machines:

such as bu

and dump

Rail vehicl

such as rai

and diesel

motives

Ships:

ranging fro

to ocean gi

We supply individual components

and complete systems for passenger

cars and light commercial vehicles

with engine capacities from 0.4 to

6.7 liters; for heavy trucks from 3.3

to 19 liters; for large diesel engines

from 1.5 to 110 liters per cylinder.

Bosch and dieselsfor town, countryand the sea

Tailor-made system competence

We develop our diesel components specically

for integration in a system and tailored to every

model range, every vehicle type and every engine

application.

From engine management via air management

right up to exhaust-gas management we offer

you an integrated system solution with co-

ordinated interfaces for every application. For

only the perfect interplay of all system compo-

nents, from starter systems, control units, in-

jectors, sensors, nozzles and injection pumps,

can guarantee maximum performance and, at

the same time, minimized fuel-consumption and

emission values.

All these c omponents and systems and many,

many others are developed, applied and manu-

factured by us for you.

Additionally, we undertake intensive fundamen-

tal research into and development of materials

and production processes in order to always

have the best possible solution ready for you in

keeping with the differing requirements of

global markets with regard to technology and

materials.


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0 | Diesel Systems Diesel Systems | 11

Bosch is there for you any time

and any place

We are there for you a nd your customers

throughout a diesels long working life. Even

when developing our products we place great

importance on rapid and precise diagnostic

capabilities. Our sophisticated logistics con-

cept permits us to make spares quickly avail-

able and to keep workshop times at all service

centers worldwide as short as possible. In addi-

tion, we ensure that repairs carried out reect

the age value of the item and are eco logically

sensible whether by the use of new parts,

through the Bosch eXchange program of series-

refurbished products or by means of expert

repairs at our specialized Bosch Diesel Centers.

And all this throughout the entire long life of

the vehicle.

Full service as we understand it

We even support lovers of classic vehicles via

out Bosch Automotive Tradition division by

stocking and sourcing rare spare parts or even

having them specially made. As the original

manufacturer we are, after all, the only ones

with the necessary know-how and complete

documentation.

Annual savings achieved by series

refurbishment: approx. 500 tonnes

of steel, 180 tonnes of aluminum,

2,750 tonnes of CO2and an energy

saving of 7,000,000 kilowatt hours

(corresponds to the energy require-

ments of a small town for two

months).

Full servic

Bosch for d

Engineerin

services

Test center

Bosch serv

work in all

Bosch eXch

program

Bosch auto

tradition

We stand by our products. And we stand by the products of our

customers! Right from the start and throughout all development

stages we offer you our specialists and engineering services such

as items in the eld of tailor-made functions and software for diesel

engine control units. Here we can guarantee to be close to you or

if you wish even right inside your factory.

Our developments and applications match your very individual

requirements and wishes for large-series production, projects in-

volving a small number of items right down to special versions.

At our technical test centers worldwide we carry out standardized

tests and measurements for you and, last but not least, we manufac-

ture your product to the highest possible quality and in accordance

with strict ecological guidelines that even exceed the legal require-

ments long before they become applicable.

Bosch for adiesels entireworking life


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It is better to lose money than peoples

trust.

At Bosch, corporate culture is not just a

phrase. It is, rather, the result of the trust

which we have built up for ourselves over de-

cades of contact with you. Long-term coopera-

tion among partners is the foundation of the

relationship between our customers and our-

selves. The above quote from Robert Bosch is

our guiding star, the maxim which we will con-

tinue to follow without compromise and which

is mirrored both in the way we treat each other

and in our claim to supply you exclusively with

nothing but top quality.

The Workshop for Precision Mechanics founded by Robert Bosch in

1886 has developed in the course of over 120 years into the worlds

largest automobile components supplier and the technological

leader especially for diesels. Its is the hard work of each individual,

their willingness to take a long-term approach, accept mistakes and

overcome setbacks which has permitted Bosch to build up a company

culture rich in tradition and experience yet always oriented toward the

future. For us the past is not a comfortable chair to simply rest upon,

it is always a springboard to the future true to the philosophy of

the founder of our company, Robert Bosch, who once said: Those

who have ceased to be better have ceased to be good!

Even today we owe our independence to his foresightedness. This

is why we at Bosch still think and act with a view to the long term

without looking for short-term gain and nancing our growth from

our own prots. To allow this to succeed, our internal obligation is

to constantly use our new ideas and innovations to set market-ori-

ented trends in the motor-vehicle sector in general and on the diesel

market in particular, trends that we drive forward until we achieve

success. With this aim in mind we also participate strongly on the

international level on numerous technical boards and committees.

Invented for life 3,850 times

With rm decision we continuously invest more

money in research and development than any

other player in the market. In Automotive Tech-

nology, the most research-intensive sector of

our company, investments of some 3.25 billion

euros in 2008 amounted to around 12 percent of

turnover and thus some 12 percent more than in

2007. With more than 3,850 inventions, about

15 patents per working day, the Bosch Group

was the biggest patent applicant in Germany in

2008. Around 45 percent of these patents help

to conserve the environment and our natural

resources.

But money alone cannot generate innovations

these only mature in creative brains. At the

start of 2009 our research and development

departments had a staff of at l east 32,500, over

10,000 of them outside Europe, over 7,000 in

Asia alone. For a long time now, our innovations

have been the results of international networking.

We do not constantly redene our

strategy, but stick to it even in

constantly changing circumstances.

(Franz Fehrenbach, Chairman of

the Board of Management of Robert

Bosch GmbH)

Bosch puts its trustin diesels put yourtrust in us

Investmen

research a

developme

2008:

Bosch Gro

3.9 billion e

around 9

more than

previous ye

some 9 per

our total tu

Automotiv

nology Div

3.25 billion

approxim

12 percent

than in the

ous year an

12 percent

total turno

Worldwide,

Bosch Grou

ploys a staf

32,500 in r

and develo

18,300 of t

Germany

A total of o

3,850 pate

Around 45 of these he

conserve th

ronment an

natural res


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Even better diesels will be here tomorrow

In a few years, a mid-range compression-igni-

tion car will only need 3 liters of fuel for 100

kilometers with a CO2output of less than

100 grams per kilometer. And we predict that

this can also be achieved for lower vehicle seg-

ments even for future exhaust-gas standards

without additional costs.

The technical potential for this already exists.

Further increases in injection pressures and

turbocharging, improvements which we are

working on in our joint project with Mahle, will

permit an even more pronounced downsizing

of engines. This development will lead to a re-

duction in the number of cylinders. It is certain

that more 3-cylinder engines will be developed

and built in the very near future.

An important role will also be given to down-

speeding. Specially designed transmissionswill reduce engine revolutions, resulting in

lower frictional losses in the engine and thus

greater efciency.

Further measures such as improvements in

thermal management which will permit the

cooling system to adapt to the requirements of

operating conditions, or the Start/Stop System

which automatically switches off the engine

when the vehicle is stationary and re-starts it

when needed, offer a great deal of potential for

savings.

The future of automobile trafc is electric. Most experts and research

institutes are in agreement here. At rst it is assumed that only very

small numbers will be involved. The probable forecast for 2015 is

around 500,000 new vehicle registrations worldwide. A good start,

but still far too few to sustainably help the automobile industry to

meet the stricter CO2regulations applicable to the eet of new cars

required for Europe. Therefore, it is all the more important to continue

to consistently reduce the fuel consumption of internal combustion

engines.

We at Bosch assume that internal combustion engines will continue

to play a dominant role for the next 20 to 30 years. Consequently we

are continuing to develop our diesel systems as a top priority so

successfully indeed that we can forecast further reductions in fuel

consumption for diesel engines of up to 30 percent over the next few

years.

Parallel to this, we are pushing ahead with the electrication of the

powertrain. With our partner Samsung, for instance, we have com-

menced a joint venture to develop to mar ket maturity the lithium-ion

batteries of the future.

And the diesel hybrid will be here the day

after tomorrow

Nothing can disguise the fact that our oil re-

serves will one day dry up.

So a company with a long-term orientation like

Bosch adjusts at an early stage to fundamen-

tal developments. This is why we have been

involved in the subject of hybrids for over 30

years and now possess comprehensive know-

how on the management of batteries, electric

drives and brakes as well as engine and trans-

mission control.

At our Hybrid Project House, hundreds of

specialists are working outside the connes of

our individual Divisions to develop systems and

components for hybrid and electric vehicles.

So we are developing both the car of tomorrow

and that of the day af ter tomorrow.

If the share of diesel vehicles on

the German car market rose by only

1 percent, around 90 million liters

of fuel or about 210,000 tonnes of

CO2could be saved. This corre-

sponds to the CO2output of 65,000

vehicles with an annual mileage of

20,000 kilometers.

Bosch and thediesels of thefuture

Diesels on

way to the

Higher inje

pressures

Improved t

bocharging

Downsizing

Downspee

Thermal

manageme

Start/Stop

Diesel hyb


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Robert Bosch GmbH

Diesel Systems

Postfach 30 02 20

70442 Stuttgart

Germany

Fax: +49 711 811-45090

[email protected]

www.bosch-diesel.de

Printed in Germany292000P075-C/SMC2-200906-En

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