Future Workshop

Spring 2009

www.bosch.com.au

Breathe Easy with Bosch Cabin Filters Spring is in the Air: So Too are Pollens Research has shown that unfil- But pollens are not the only ness, but also your customers as Today, more than 90% of all Japanese and European passen- tered pollutants entering the impurities to enter our cars; dust, it’s also a chance to educate them European vehicles are equipped ger vehicles. inside of a vehicle can be up to dirt, smoke and exhaust fumes on the harmful effects of a dirty with cabin filters. Australian ten times more concentrated all enter through a car’s HVAC or clogged cabin filter, which manufacturers are following Bosch is aware of the importance than in the air outside. These system and can be dangerous can not only these trends, with cabin of filters. Bosch cabin filters pollutants can trigger asthma for drivers. Driving filters fitted in most are made of special micro-fibre and allergies and, with more in suburban areas in new cars, paper which absorbs up to 99% than 2.2 million Australians heavy traffic, on free- of all pollen, dust par- diagnosed with asthma and ways and in tunnels, ticles and other more than double that number where air pollution is harmful sub- suffering from allergies, at its worst, can cause stances, result- breathing filtered air in the car drivers to experience ing in a remark- is essential. headaches, fatigue able improve- and a lack of concen- ment of the air Bosch cabin filters can prevent tration. Country driv- quality inside the these pollens and other harm- ing can also be hazard- vehicle. They also ful pollutants from entering the ous, especially in the assist in keeping vehicle interior through its heat- current climate, with your HVAC system, ing, ventilation and air condi- air quality adversely instrument panel and tioning system (HVAC). affected by frequent windscreen clean, by drought related dust significantly reducing storms and, in the dirt and dust deposits. Contents summer months, by bushfires. All Bosch filters meet or P2. • Bosch Spark Plugs exceed vehicle manufactur- - The History However, many motor- ers’ specifications. So benefit - Did You Know? ists are still not aware of cause breathing diffi- your customers while benefit- P3. • Tech Tips and Tricks the existence of cabin filters in culties, but also restrict airflow ting your business: fit Bosch - Working with Steering their vehicles. to the HVAC system. This will cabin filters. Angle Sensors This fact gives workshops the affect the efficiency of the sys- i n c l u d i n g • Meeting your Customers’ opportunity to increase business tem, leaving deposits and con- models such as For a copy of the new Bosch Service Expectations and profits by pulling customers taminants which not only leave the Ford Falcon FG, Filter catalogue contact back into their workshops for air conditioning systems dirty, BA and BF models, the Holden your local distributor or call P4. • The Future of Mobility annual cabin filter changes. This but can lead to corrosion of the VE Commodore, Toyota Corollas 1300 30 70 40. • Top Prize for Apprentice • New ABS Catalogue will not only benefit your busi- evaporator core. from 2000 onwards and all

P5. • Workshop Equipment - Complete Engine System Testing - Wheel Alignment Made Qik Tips - Replacing Cabin Filters Easy

P6. • AeroTwin Wiper Blades Regular cabin filter replacement ensures optimum air flow through • ESI[tronic] the blower and prevents the damage that overheating can cause. It is the only way to guarantee optimum filter performance. The cabin filter ➀ ➁ P7. • In-tank Fuel Pump Kits is usually easily accessible in the engine compartment, at the point • Testing Electric Fuel Pumps where it meets the passenger compartment. Basic instructions on the side of the packaging show step-by-step drawings, making it easy to P8. • Bosch - The Global Trainer remove and replace filters. • More Amps for Alternators

P9. • Meeting your Customers' Simple Replacement: Step-by-step we show you how Service Expectations  1. Locate cabin filter. Undo any catches and remove the (cont.) plastic cover • Timing Tensioner Kits ➂ ➃  2. Take out old filter and dispose as household waste P10. • Bosch Market Updates  3. Insert new filter into plastic cover (note air flow direction; - Mazda 3 see the instructions on the filter) • Bet on Bosch Nozzles  4. Insert cabin filter back into housing

P11. • In the Pits Important! - Calder Drive Day: Frosty Cabin filters cannot be “flushed out” with compressed air Revisits Bosch Starts or shaken out! These actions destroy the microfibre layer • Camera Competition and neutralise the filtering effect. • BAT415 Offer

To receive Future Workshop via email, email us at [email protected] 2 Spring | 2009 Future Workshop

Editorial Bosch Spark Plugs

Meet the Tech Guy Bob Tait, Service Engineer Supervisor, has just celebrated 25 years with Bosch and reminds us here about the importance of torque when replacing spark plugs.

“It’s important to remember that correct torque settings are crucial to spark plug installation. So Welcome to the Spring edi- many spark plug failures can be attributed to incorrect torque settings. A spark plug needs to be able tion of Future Workshop. to transfer heat to the cylinder head. This heat transfer will be slower than required if a spark plug Spring is the perfect time to is under-torqued, allowing plug temperatures to rise, resulting in pre-ignition. Insulators and earth focus on cabin filters. Many electrodes can also break and crack due to under-torqued spark plugs resulting in knocking. All workshops underestimate these issues can inevitably end up causing engine damage. So save yourself the headache of serious engine damage and make sure you tighten spark plugs to the correct torque.” the importance of cabin fil- For torque specifications refer to the Bosch Spark Plug catalogue. ters and the potential profit they can bring in to a busi- ness. Our handy tips on cabin The History of the Spark Plug filter replacement may help if Bosch produces more than 300 Benz described as the “prob- times higher than the spark ium, or yttrium. By varying the you are new to this area. million spark plugs per year in lem of all problems”, opening plugs of a hundred years ago. number, design and structure factories around the world. The the way for the surge in vehicle In recent years, Bosch has dem- of the electrodes, many adapta- plant in Bamberg, Germany, production during the following onstrated the ongoing potential tions are possible. All of these We have included more prac- founded in 1939, is the pri- decades. The result was afford- of its flagship product, adapting allow engines to comply with tical tech tips, hints and trou- mary factory for Australia's able vehicles for everyone. it to the ever-changing develop- ever stricter emissions targets, bleshooting suggestions, spark plug production and sets ments in engine technology such while at the same time increas- along with potential profit the manufacturing standards Developments Today as 4-valve engines, lean-burn ing performance and efficiency. opportunities. We explore the for all other Bosch spark plug Today, constant developments plants. in Bosch spark plugs as integral With a long history of expertise ease of servicing fuel pumps “Bosch invented the engine system components have in the field and intensive spark with the new universal fuel More than 105 years ago, Bosch enabled cleaner and more effi- spark plug in 1902” plug development projects in pump kits and the benefits an unveiled its first spark plug built cient fuel combustion, as well close collaboration with almost oscilloscope can bring to your with a high-voltage magneto, and as more reliable engines and engines, or ultra-efficient direct all vehicle manufacturers, Bosch workshop. patented the innovative system catalytic converters. Despite fuel injection. The versatility of is one of the world’s leading sup- in January 1902. Bosch spark the huge increases in perform- Bosch spark plugs is the result pliers for the original equipment plugs finally solved the problem ance, the service life for normal of well researched design modi- market and aftermarket, and is Peter Rowe returns again with of reliable ignition in early auto- spark plugs is today around fications and the use of special the market leader in Europe. a piece on the importance of motive engineering – what Carl 20-30,000kms, roughly 20-30 metals such as platinum and irid- good customer relationship management. He includes some valuable tips and ideas on dealing with customers, which we hope you’ll find helpful in your own day to day dealings.

Once again, we encourage you all to give us any feedback you have on Future Workshop. We want to make this publication as informative and interesting as we can for you. Please feel free to email any feedback to [email protected]. com.

Spark Plug Production 1928 Advertising Poster 1955 Spark Plug Production Today Happy Reading!

Rolf Schillinger Did You Know? - Bosch Spark Plugs Marketing Manager Automotive Aftermarket • Bosch invented the spark plug in 1902

• Total number of Bosch spark plugs manufactured since 1902: More than 10 billion

• Annual Bosch spark plug production: Well over 300 million (1902: approx 300)

The next issue of Future • Material required for daily production (600,000 units) at Bamberg plant: 28t of steel, 1.2t of nickel, 0.6t copper, 15km nickel wire, Workshop will be published 2kg of platinum and 20t of aluminium oxide in Summer 2009. • Working conditions of Bosch spark plugs: Voltage up to 30,000V, temperatures up to 1000°C, pressures up to 100 bar; extremely For any enquiries or feedback aggressive mixture of petrol vapour, combustion products, fuel and oil residues email us at: [email protected] • Vehicle manufacturers using Bosch spark plugs in series product: Alfa Romeo, Audi, BMW, Citroen, Daewoo, Daimler-Chrysler, Fiat, Customer Service: 1300 30 70 40 Ford, GM, Lancia, Mitsubishi, Peugeot, Porsche, Renault, Saab, Seat, Skoda, Ssangyong, Suzuki, Toyota, Volvo and Volkswagen.

© Copyright 2009 • Applications of Bosch spark plugs: Cars, motorcycles and scooters, commercial vehicles, engines for boats and jet-skis, gardening Material cannot be used or reproduced without approval from the Bosch and forestry equipment, stationary gas engines, emergency generators, water pumps and small engines. Automotive Aftermarket Division. Future Workshop Spring | 2009 3 Tech Tips and Tricks Working with Steering Angle Sensors

With so many sensors now fit- the ESP® to detect a potential grammed by the microcontrol- ted to new vehicles (in some skid situation. In the event that ler. cases up to 150), it is easy to the vehicle is approaching a skid create problems for yourself by condition, the ESP® will interact The steering angle sensor is pro- impacting the performance of with the ABS, TCS and engine grammed to read the straight a sensor, without realising it, management system to help ahead position of the steering during some service activities. return the vehicle to its intend- column. If the steering column ed course. is rotated too far from ”straight ahead” when it is removed from The functional principle of steer- the vehicle, then the steering ing angle sensors relies on two angle sensor must be recalibrat- resistance bridges positioned at ed. 90 degrees to each other, the bridge parts consisting of GMR After performing any work on (Giant Magneto Resistance) ele- the steering system, including ments. wheel alignment, make sure the Calibrating the Steering Angle Sensor with a KTS 200 steering angle sensor is in the In simple terms, when the steer- “straight ahead” position when ing wheel is turned, a measure- the wheels are in a “straight ESP Components ment cog wheel rotates over a ahead” direction. Failure to do GMR element. An integrated this can cause ESP® errors or microcontroller uses the change incorrect ESP® operation. In this example we look at steer- in the bridge voltage to accu- ing angle sensors and what rately calculate a steering angle. Performing a steering angle sen- to watch out for. But first, lets Therefore it becomes possible sor calibration is possible with a understand the basics of how to cover a measurement range of diagnostic scan tool such as the steering angle sensors function. several steering wheel rotations Bosch KTS range. This process without the need to use a revolu- programs the steering wheel’s The steering angle sensor is used tion counter. straight ahead position to the with ESP® to measures the steer- ABS/ESP® modulator’s ECU ing angle relative to the vehicle’s The steering angle sensors is which ensures the vehicle’s ESP® direction of travel as determined fitted as standard with a CAN system is working to the original by the yaw sensor. This enables interface and individually pro- specifications. Steering Angle Sensor

Meeting Your Customers’ Service Expectations By Peter Rowe

indifference, incompetence or human beings, and finding everyone’s trying to book in, poor communications from the things about them to which etc) is failing to make time for people in your business then you can relate. It also means business! no matter how technically gift- showing you care with a wel- ed you are, the best CRM soft- coming reception area, a pro- 4. Interpret, recommend – ware in the world is unlikely to fessional standard of pres- when you encounter work that encourage them to repeat that entation, courtesy and good your customer did not expect experience. manners to all. remind yourself of your role before you pick up the phone. If, on the other hand they expe- 2. Make it easy for them to trust It is their car; it is their prob- rience respect, care, profes- you – by deciding to be scru- lem (stop feeling responsible sionalism and open and honest pulously honest in all of your for finding it!) You are their communications then not only dealings. You may do this honest, skilled technical advi- are they likely to keep dealing already in an unconscious sor and you like them and with you, but they are also like- way but if you adopt honesty empathize with them. Your ly to be out there singing your and integrity as conscious role is to interpret their prob- praises to others. And if that is values within your business, lem so that they can clearly your habitual way of dealing and walk and talk them with understand its implications with your existing customers, it your team every day, they will for reliability, economy and is going to shine through when permeate your business. This safety. Your role is to protect you are being “interviewed” by does make a difference. Try them from what they don’t These days, every car owner is invariably huge! And Customer each prospective, new customer it. understand and to make a rec- looking for “a friendly expert” Relationship Maintenance and will probably win you their ommendation if they appear whom they can trust and, with (CRM) has always been more work, too. 3. Make the time to understand unsure of what to do next. the service bar being continu- about personal relationship them – develop your listening ally raised by dealerships and skills than about computerized So, as a quick boost to your skills. Investing 5-10 minutes In the next section of this arti- good independent repairers relationship systems. already good Customer in exploring and fully under- cle we’ll look at some persua- like you, customers have higher Relationship Maintenance, here standing what your customer sive techniques that will make expectations and a wider choice Why is it that the people who is "The World’s Shortest CRM wants and expects also ena- decision making easier for your of providers than ever before. are exceptionally good with Course ". bles them to become aware of customers. machinery and can fix anything, your genuine interest in them, Developing and then maintain- are often exceptionally bad with 1. Make it easy for them to like and that usually leads to dis- ing good relationships with people and can upset just about you - by liking them first. cussion of a wider range of Continued on page 9. customers takes time, planning anyone? Let’s face it, if your cus- That means taking a moment work. Failing to make time for and focus but the rewards are tomers encounter rudeness, to appreciate them as fellow this (yes, I know, you’re busy, 4 Spring | 2009 Future Workshop

Bosch Technology for the Future of Mobility: Protecting the Environment

The issue of what type of engine will to considerably improve the perform- Both petrol and diesel engines will power the cars of the future is cur- ance of these vehicles. be subject to extreme downsizing, rently a hot topic. It was the main resulting in three cylinder, 1.1 or 1.2lt focus of the recent 2009 International Bosch is vastly stepping up its develop- engines that still offer the same 100kw Automotive Press Briefing, hosted ment activities to get the electric vehi- power and performance of the stand- by Bosch, in Boxberg, Germany, and cle ready for large-scale series produc- ard engine. They will also be equipped attended by more than 200 journal- tion, in three ways: with several additional technologies ists from 30 countries. 1. Gathering experience with the which will improve the overall efficien- hybrid drive, which Bosch sees as a cy of the drive train: The briefing was an opportunity for bridge to the electric vehicle. Bosch - a start-stop system that automatically Bosch to discuss the future of the car technology is set to go into series starts and stops the engine when the and present an outline of the research production at the start of 2010. In car is not in motion, e.g. at a red light or and development work it is undertak- itself, hybridization can reduce fuel in a traffic jam. ing, to provide more environmentally consumption in petrol engines by - a thermal management system that friendly automotive technology in the 39% and diesel engines by 40%. quickly gets the engine up to optimum future. 2. A dedicated business unit working operating temperature, and keeps it on power-train electrification. there. Making Electric Cars a Reality 3. In cooperation with Samsung SDI, - a highly efficient generator with a With the increasing need to find more developing the lithium-ion battery. control unit that uses additional brak- environmentally friendly transport Developers are currently working to ing energy to charge the battery. options, there is no doubt that the elec- reduce the weight and price of the tric car will come. The ability to travel lithium-ion battery that powers the two and a half times the distance of a electric vehicle. The aim is to launch car fitted with a combustion engine, this new battery technology in 2011. Further developing gasoline and diesel “Bosch will continue to whilst using the same amount of energy, engines is the fastest way to effective- makes an electric vehicle an extremely So, given the current state of this tech- ly reduce fuel consumption and CO² further improve internal energy efficient option. nology and the developments that are emissions. still needed, realistically for the next 20 combustion engines, By 2015 Bosch expects to see a global years, the internal combustion engine Changes in Engine Technology whilst working on sales volume of some 500,000 elec- will remain the drive of choice. Given Bosch’s efforts to advance internal tric vehicles. However, to achieve this, Bosch will continue to further combustion engines are resulting in electric technology.” these higher volumes in order to meet improve internal combustion engines, new engine concepts that will be ready demand, a lot of work needs to be done whilst working on electric technology. for market by 2015.

World First Bosch ABS Top Prize for Apprentice Catalogue Now Available! At the recent Box Hill Institute Centre for Automotive Transport and Engineering The 2009/2010 Bosch ABS catalogue is now available. This Automotive Awards night, catalogue is a world first for the aftermarket, containing listings Christian Gunawan was pre- for hydraulic units, electronic control units and wheel-speed sented the award for the top 3rd sensors. year automotive apprentice, in recognition of his achieve- Practical application and product technical information is a ments at TAFE in 2008. key feature of the new Bosch ABS catalogue. Product technical information, such as design types and functions, and fault Christian has been undertaking diagnosis and repair, including step-by-step ECU and wheel- his apprenticeship at Topshift speed sensor replacement guides, are all included to provide Automatic in Abbottsford, additional valuable information. Victoria, while completing auto- motive mechanic studies at Box Bosch ABS components are now Hill Institute of TAFE. available through aftermarket distributors. So, with the Bosch was a proud sponsor of right diagnostic tools, ABS the awards nights, held annu- repairs can now be part of ally by the Institute’s Centre any independent workshop's for Automotive, Transport and service offering. Engineering, which is highly regarded by industry and statu- The Bosch ABS program tory bodies as a training leader offers a comprehensive in the automotive field. range coverage and all components are Bosch would like to congratulate manufactured according Christian and wish him all the to Original Equipment very best in the future. specifications, ensuring quality and reliability.

F o r a copy of the new catalogue please contact your local Charles Sibberas (Vic/Tas State Sales Manager) Bosch distributor or call the Bosch Customer Service Centre on presents Christian Gunawan with a Bosch Shop 1300 30 70 40. Gift Voucher for his achievements. Future Workshop Spring | 2009 5 Complete Engine System Testing The Bosch FSA Range

The increasing share of elec- However, scan tools are often as a complete trolley Bosch FSA system The FSA system can also be tronics in motor vehicles is misused. Taking a “quick fix” based workshop test- testers also fea- extended to include emission making ECU diagnostics stand- approach by reading the error ing system. tures a signal gen- testing with the BEA gas analyser ard practice in today’s work- and replacing the part can often erator that allows and the RTM diesel opacimeter shop. Even simple maintenance lead to trouble. Sometimes the for the testing of (smoke) modules. A gas analys- work or resetting the service identified fault can be caused by sensors, including sig- er offers the simplest diagnostic interval display on modern a loose connection or bad earth. nal lines and connec- connection to a motor vehicle, cars requires a workshop to tors. This, in conjunction but it is often overlooked as a have access to diagnostic tools. The reality is a scan tool with the powerful meas- will point you in the right uring technology of a 50 “....any electronic Some vehicles have up to 150 direction, however the megahertz oscilloscope sensors linked to as many as 80 only way to correctly and a multimeter, can diagnosis must be ECU systems and often share verify a faulty sensor's reduce the time consum- confirmed with an information via the CAN (Control waveform is with an ing and often unneces- Area Network). This can make oscilloscope, such as sary exchange of incor- oscilloscope.” fault diagnosis extremely diffi- the Bosch FSA range rectly diagnosed, faulty cult. For example, a rain sen- of vehicle systems components. diagnostic tool. Depending on sor not only operates the wind- analysers. the combination of gas emission screen wipers in wet weather, An important feature of readings it can be very useful in but may also communicate with The Bosch FSA in its the FSA is the ability to assisting to diagnose common the ABS system to lightly apply standard oscilloscope save comparative oscil- ignition, injection or even oxy- the brakes to maintain maxi- configuration can be loscope patterns and to gen sensor faults. mum dry braking efficiency. The combined with a KTS superimpose them over replacement of a windscreen scanner module. The a live pattern when test- Bosch offers a complete range with its rain sensor may bring on information program ing components on a of specialised workshop equip- a fault light if it is not introduced from the KTS with its vehicle. Technicians can, ment, from a comprehensive to the ABS system with an ECU guided repair analy- for example, save well- series of diagnostic scanners, scanner. sis is combined with defined patterns for through to vehicle systems ana- the FSA measure- later use and build-up lysers, exhaust gas analysers Information is the workshop’s ment data into one their own data base. and battery service equipment. most important diagnostic tool. integrated package. Importantly these products are A scanner, such as the Bosch The FSA motor test supported by comprehensive KTS module, can offer extensive The modular struc- function includes training packages direct from ECU communication functions ture of the Bosch FSA leads and probes that the manufacturer. which are supported by Bosch makes it an extreme- analyse ignition faults ESI[tronic] software. This pro- ly flexible diagnos- on all types of modern For more information con- gram has an encyclopaedia of tic platform with ignition systems includ- tact the Bosch Diagnostics information which offers a guid- measuring mod- ing the “pencil” type coils Customer Service Line on ed repair analysis from error ules that may be pur- prevalent on late model 1300 783 031. code to replacement part. chased separately or Commodores and Falcons.

Wheel Alignment Made Easy!

The new Beissbarth Easy 3D is it is no longer necessary for in each sensor head ensures the easiest solution for wheel mechanics to push the vehicle reliable, reproducible, virtually alignment. back and forth by hand. It is also real-time measurement results not necessary to exit the vehicle without complicated or poten- Providing precise and instanta- during the runout compensation tially error-prone calibration. neous measurement, the Easy process. This technical solution com- 3D guarantees rapid perform- prising high-tech state of the art ance, with high repeatability So how does it work? cameras, (which are lightweight of measurement results, easy The Easy 3D offers 3D wheel and impact resistant), and an runout compensation and real alignment for each wheel by integrated reference system is time displayed values plus it’s using the principle of triangula- the first of its kind and patent- mobile and compact! tion. Two cameras are used to ed. sight a single measuring plate. The Beissbarth Easy 3D is simple The angle and spacing of the two The slimline Easy 3D is com- and fast to operate, even with- cameras are known, so triangu- pletely mobile and compact, fit- out special knowledge of wheel lation can be applied to deter- ting perfectly in even the small- alignment. The entire measure- mine the angle and therefore est workshops. And thanks to the ment process, including runout the distance to the points on the Beissbarth patented reference compensation takes just seven plate. One camera handles toe system the Easy 3D sensors are minutes from driving onto the measurement to the other sen- portable, making fixed attach- lift, to producing the results sor and two pendulums deter- ment and calibration a thing of cars, through to vans and light As part of the Bosch organisa- printout. mine the centre of gravity ena- the past, leaving the lifting plat- commercial vehicles. tion Beissbarth offers a range of bling the position of the sensors form freed up for other work as high quality solutions for wheel With the Beissbarth universal to be determined. The stereo required. Easy 3D is also ideal With the federal government’s servicing. wheel clamps, runout compen- cameras serve to determine the for operation on wheel align- 50% tax rebate now passed as sation can be carried out sim- wheels axis of rotation. ment pits and four post hoists. legislation it’s never been a bet- For further information phone ply by driving the car. As motor The Easy 3D wheel aligner is ter time to invest in 3D technol- 1300 783 031 or visit our web- vibration does not affect results, The integrated reference system suitable for aligning all types of ogy. site at www.beissbarth.com.au 6 Spring | 2009 Future Workshop The Shape of Things to Come Bosch AeroTwin Wiper Blades

We all know market trends But you don’t have to buy a new springs are enclosed under an are changing towards blade car to get this latest technology. aerodynamic integrated wind Quick Clip Installation Guide replacement over refills, but Bosch has accelerated access by spoiler, protecting them from did you also know that blade providing this next generation corrosion and ultra-violet rays. technology is changing? wiper blade technology to your The spoiler creates down-force, aftermarket customers, with preventing blade lift-off at high- Open top bracket lock by pressing side Basic wiper blade design has Bosch AeroTwin blades. way speeds or in severe winds. of clip remained virtually unchanged for more than 80 years. The Bracket-less Design This innovative design distrib- familiar steel or plastic bracket AeroTwin bracket-less wiper utes more uniform pressure with multiple joints and pres- blades are designed without along the entire length of the Insert wiper arm through top bracket in sure points has been the auto- metal or plastic brackets, joints blade for the perfect wipe. direction shown motive industry standard. But or hinges, offering design and that’s all beginning to change. performance improvements Innovative FX Dual Rubber over conventional wiper blades. Technology OE wiper blade technology is The Bosch AeroTwin features Lock hook on wiper arm into Quick-Clip taking a new bracket-less shape, The brackets and joints of con- innovative FX dual rubber tech- connector by sliding back until it clicks with more and more vehi- ventional wiper blades are nology. A soft, flexible rubber into place cle manufacturers specifying replaced by dual precision-ten- element reduces chatter and bracket-less blades. This new sioned Evodium steel springs, squeak, whilst the precision-cut technology conforms more pre- which are curved at a precise wiping edge, specially coated cisely to the curvature of today’s radius along each millimetre of with Quiet-Glide™ micro-finish Close top bracket vehicle windscreens, for better length, creating infinite pressure for smooth and quiet operation, wiping quality than convention- points for a perfect fit to the cur- resists wear and removes even al blades. vature of the windscreen. These the smallest droplets of mois- ture for the cleanest wipe over a all Bosch wiper blades are tested longer performance life. to the limits of weather condi- tions and speeds to guarantee Installation is quick and easy, ultimate safety, the best possible with the patented Quick-Clip performance and durability. connector system. But the real opportunity lies with At Bosch, safety is our main con- workshops. Most drivers trust cern and considering around their local mechanic, so take the 90% of driving decisions depend time to invest in their safety and on good vision, the performance make sure you’re offering them of wiper blades is essential to the latest in wiper blade tech- ensure a clean windscreen and nology, with Bosch AeroTwin unimpeded vision. This is why wiper blades. Protect Your Workshop's Future The Complete Software Solution with Bosch ESI[tronic]

The car is increasingly becom- Being a modular system, the ing a “computer on wheels”. In extensive range of ESI[tronic] this regard, time-saving soft- application modules allow Software Module Overview ware with troubleshooting workshops to tailor the infor- Application Module Contents instructions suitable for practi- mation they need to their indi- cal application is just as impor- vidual business requirements. Catalogue and parts information A Vehicle equipment tant as high-performance test The ESI[tronic] software can be equipment, making it simple used as is on your PC, or alter- D Diesel spare parts for workshops to offer complete natively can be combined with and thorough diagnostic service Bosch KTS test equipment. Data Electrical spare parts to customers. is updated quarterly, so you can E service even the newest of vehi- Diesel spare parts from Zexel Bosch ESI[tronic] is a complete cles with no problems. ZD software solution which pro- vides workshops with compre- ESI[tronic] is a complete, unique Diagnosis and repair on the vehicle C Vehicle diagnosis hensive, easy to use technical solution in the workshop mar- information. ket, which you can adapt to meet TSB Technical service bulletins the individual requirements of ESI[tronic] is a system of DVD- your workshop. Vehicle mechanics based technical information M modules, which individually For more information on Convenience vehicle wiring diagrams provide a range of information ESI[tronic] please contact Bosch P on topics such as catalogue and Diagnostics Customer Service parts information, diagnosis, on 1300 783 031. Diagnosis and repair on the Diesel pump and injector repair instructions product K1 troubleshooting and repairs for both vehicles and products, for K2 Electrical repair instructions an extensive range of petrol and diesel passenger vehicles in the K3 Diesel and electrical repair instructions Australian market. Future Workshop Spring | 2009 7 Universal In-tank Fuel Pump Kits Introducing the NEW BFP038

tion coverage and the inclusion The BFP038 is essential for any Contact Bosch Customer of the electrical adaptor means business repairing Asian vehi- Service on 1300 30 70 40 to this unit can also be used to cles and generously covers over locate your nearest Bosch replace pumps that use a small 40 part numbers in the market distributor. “pin-type” or post style electri- including BFP473; BFP474 and cal connection. 0 580 453 477. Pre ordering a few in advance would definitely The new Bosch “BFP038” uni- save time on your next applica- versal in-tank fuel pump kit ble Asian vehicle repair job. comprises – • An OE quality, Bosch manufac- tured, 38mm “turbine” design electric fuel pump - Flow rate of 105 l/hour at 3.0 bar pressure :hl\a8A`gbmbhg8D^Z]l“ - Ethanol compatible (E10 only) - High quality internal materials Qhnk8\ahb\^8_hk8DH? for superior performance and reliability Since the early 1990’s, vari- To simplify servicing in many • Two common pump strain- ous Asian vehicles have used of these applications, Bosch ers, 70mm and 100mm, with a variety of 38mm diameter has released a new “universal” retaining clip, for broad appli- in-tank electric fuel pumps 38mm fuel pump kit, containing cation coverage for high pressure fuel supply. two different aftermarket grade • Pre-wired electrical adaptor Many of the variations in appli- strainers, an electrical adaptor with bullet style terminals to cation are due to differing fuel and associated hardware. The replace pumps that use a small pump flow rates and strainer choice of two common strainer “pin type” or post style electri- designs. designs provides broad applica- cal connection

Testing Electric Fuel Pumps in the Vehicle - Fault Symptoms and General Hints

Fault Symptoms

The following fault symptoms can indicate a faulty electric fuel pump:

 Drop in engine power

 Engine misfiring

 Starting problems

Increased fuel consumption

 Fault memories in the engine management ECU in connection with air/fuel mixture control or fuel-supply system

General Hints

 Strict cleanliness must be observed: Before installing a new fuel pump, it is imperative that the :hl\a8Kni^k8Kihkml8A`gbmbhg8D^Z]l“8La^8lni^kbhk8\ahb\^8 fuel system is cleaned and flushed – particles of dirt could damage the new fuel pump _hk8DH?’8DH?8_n^ee^]8o^ab\e^l8ieZ\^8Z8lb`gby\Zgm8]^fZg]8 hg8 b`gbmbhg8 lrlm^f8 i^k_hkfZg\^’8 :hl\a8 Kni^k8 Kihkml8  Avoid having the fuel tank open too long: If the tank remains open for a long time it can b`gbmbhg8 e^Z]l—8 pbma8 ›Ag]n\mbo^8 ;hk^š8 m^\agheh`r—8 f^^m8 ma^l^8]^fZg]l8mh8ikhob]^8fZqbfnf8^g^k`r8mkZgl_^k8_hk8 deform [^mm^k8b`gbmbhg8hi^kZmbhg’  Replace all seals and gaskets when carrying out repairs: When not subjected to pressure, seals >hk8 _nkma^k8 bg_hkfZmbhg8 hg8 ma^8 :hl\a8 A`gbmbhg8 D^Z]8 kZg`^8 and gaskets can expand and swell ie^Zl^8 \hgmZ\m8 rhnk8 :hl\a8 J^ik^l^gmZmbo^8 hk8 \Zee8 :hl\a8 ;nlmhf^k8K^kob\^8hg8ˆˆ8ˆ8 ˆ8‚ˆ’88ppp’[hl\a’\hf’Zn  After having replaced the pump, it may in some cases be necessary to perform a learning function: Depending upon the vehicle manufacturer, the diagnostics unit must be used to carry out a learning function for the electric fuel pump/fuel-level sensor

Demand-controlled electric fuel pumps These fuel pumps only deliver the amount of fuel actually required by the engine

They are controlled by means of a pulse-width modulated signal (PWM) from the engine ECU

 A return line is unnecessary, although there can be a leakage line installed from the pressure- limiting valve for instance 8 Spring | 2009 Future Workshop Bosch – The Global Trainer

The automotive servicing trade money, Bosch ensures that only 30 years of automotive training courses are developed by the instruction combined with trou- has seen, and will continue to the very highest level of training experience. Our trainers have expert; the systems designer. Our ble-shooting and practical exer- see, more changes and inno- is provided, using the very latest numerous years of industry and courses cover body electronics, cises in order to provide ‘real- vations than almost any other in test equipment technology, on training experience, as well as gasoline engine management, world’ scenarios for our partici- industry. Having the knowl- current vehicle systems. important backing and support diesel systems, braking systems pants. Our class sizes are always edge and ability to diagnose limited to encourage student and service modern vehicle interaction and involvement. systems is crucial in order to safeguard the future of your All course participants are business. Investing in your own issued with a globally recognised training and that of your staff Bosch Training Certificate. is therefore an imperative ele- ment to running a successful A well trained technician is an workshop. asset to your business. A tech- nician that has the ability to Bosch Automotive Service diagnose problems quickly and Training is conducted world- accurately increases the effi- wide, with 43 service training ciency of your workshop, lead- centres in 35 countries. Last ing to greater customer satisfac- year global participants num- tion and improved profits. bered nearly 64,000. As a lead- ing provider of complete auto- The remaining training sessions motive system technology for for 2009 are limited to members more than 100 years, Bosch has of the Bosch Car Service net- the extensive expertise of being work however a new program for able to provide training in all independent workshop training areas of automotive technology. is currently being planned for 2010. All Bosch training courses are designed in close collaboration For any further informa- with the Bosch research and tion on training courses call development units to guarantee Bosch Australia is a recognised from our Bosch research, devel- and vehicle diagnostics. 03 9541 5553. the latest automotive technol- training provider. Our involve- opment and engineering depart- ogy is translated into practical ment with training is well estab- ments, worldwide. All Bosch training courses are training courses. With continu- lished and our training meth- run with the philosophy of ous investment in both time and ods are based and built on over Bosch technical service training hands-on learning: theoretical

Are you a workshop looking for a strong business partner?

To receive your copy of the Bosch Car Service "Road to Success" brochure email [email protected] or phone 03 9541 7317

More Amps for Alternators New Oxygen Sensor Catalogue Bosch continues to stay ahead of the The BXH1238A alternator can now be used in competition in terms of quality and a greater number of universal applications, Have you got your copy of the new performance with an upgrade to including light stationary engines Bosch Oxygen Sensor catalogue? its popular BXH1236A alterna- and agricultural machinery. tor. The new Bosch BXH1238A It is also ideal for upgrading • New easy to read format is a 70 amp alternator that early Commodore, Calais, • Comprehensive range coverage can be used in place of the Kingswood and Torana 6 and • Expanded diesel range older 55 amp model, in vehi- 8 cylinder models, without • Practical application cles that require a higher doing any modifications to information current output. the vehicle. • Technical data included

The new BXH1238A 70 amp Both BXH1236A and alternator allows drivers to BXH1238A will be available run higher electrical load in their through Bosch distributors. For a copy of any of this catalogue contact your local Bosch vehicle, enabling them to fit after- distributor or call Bosch Customer Service on 1300 30 70 40. market electrical accessories, such as amplifiers and driving lamps. Future Workshop Spring | 2009 9 Meeting Your Customers’ Service Expectations From page 3

but go easy on the bill, can work, tell them how things will that you thought to check than you please?” proceed. Use clear and com- the actual contact. If you were Give them space to work through mitted language and ask for to write your service recall the sequence; don’t take any- confirmation of understand- letters to build your relation- thing that is said in this phase ing. That may go, “Susan, we’ll ships as well as to generate as personal; consider yourself do the 10,000km service and on-going work, do you think in a similar situation. Remain replace the alternator that they would read better and respectful – that will provide is causing your flat battery. accomplish more? Could you the bridge along which they will Depending on the alterna- enclose a service or economy return to ask you to do the work. tor pricing, you can expect a or value tip of some sort to All of it. total between $500 and $600 further demonstrate that you including our labour. Will actually do care about them? 6. Take responsibility for pro- your budget stand up to $600? tecting them. We said it’s not . . . and I’m going to call your As we said at the beginning of your role to decide what to mobile if I find anything that this two-part article: If you’re do - unless it’s a matter of safe- needs immediate attention, presently too busy to look after ty, in which case you have a alright? Otherwise I’ll just note your customers at a level that professional responsibility to routine items to discuss with they will appreciate, then some- guide them to the right deci- you this evening. Is that OK one else will be doing that for 5. Make it easy for them to kidding! You’re ripping me sion - or to decline the work. with you? Any questions?” As them shortly - and you’ll have decide about work they did off! Whose fault?” Avoid being judgmental in this a very good technician once plenty of time to think about not anticipate. Provide facts. c. Bargaining – “Maybe it’s situation. Remain courteous, told me, “If you have to nego- doing this! Provide options where they not as bad as you thought. empathetic and professional tiate the bill at the end of the exist (these give your custom- Can you just patch it up for but hold the line on what you job, you have a problem!” Peter Rowe is Managing Director er power despite the situation now?” know to be right. You may lose of ProfiTune Business whose sole not being of their choosing). d. Depression – “What am I the job, but if you do all of 8. Take the relationship ini- purpose is to improve clients’ Provide time to process any going to tell my husband/ the above, you won’t lose their tiative afterwards. If your overall business performance shock factor. Be aware that wife? Bloody heap of gar- respect - or your own! dentist’s office can call you such that it can be measured at most of us do this in a well- bage! Why does this always the day after a $200 filling to the bottom line. For informa- defined sequence of: happen to me? There goes 7. Take responsibility for clear check that you’re OK, can you tion: [email protected] a. Denial – “No, that can’t be my holiday.” agreements. Script your rou- do the same for your customer or 1300 2 PROFIT right. You’ve made a mis- e. Acceptance – “I should have tine communications to pro- who spent $200 on a service? take. Check it again!” guessed from the noise it tect misunderstandings. Once You could even text if time b. Anger – “You’ve got to be made last week. OK, fix it, you’ve agreed on the scope of was tight; it’s more the fact

Range Update Belts Trouble Shooting Problem Cause Remedy Timing Belt Tensioner Kits Belts breaking after fitting 1. Belt forced over pulley Reduce drive centre distance damaging tension member to fit belt and cover fabric

2. Shock load Recheck design. Check belt tension

3. Incorrect number of belts Recheck design and fit fitted correct number of belts

4. Foreign matter obstructions Install effective guard

Problem Cause Remedy

Excessive elongation 1. Worn or badly machined Replace pulley pulley grooves

2. Belts of different Use matching set from one manufacturers on one drive manufacturer

The inclusion of oil seals in tim- That’s why Bosch is ensuring ed. These kits cover some of the In addition to oil seals, Bosch comebacks. This way work- ing tension kits can help avoid a that all of its timing tensioner more popular European based timing tensioner kits include shops can ensure the safety of few headaches in the workshop kits include whichever oil seals vehicles including the Holden tensioners, idler pulleys and their customer's engine whilst when replacing timing belts. are required to guarantee the Astra, Ford Fiesta, Volkswagen guide pulleys, along with all kit benefitting from the increased best possible service, including Golf, Audi A3 and the Holden components, all of which are profit opportunity that fitting If the camshaft or crankshaft oil pump and balance shaft seals Barina. manufactured to original equip- the entire kit provides. seal is removed during service where necessary. ment specifications. there is a risk that sealing per- Over 90% of the Bosch timing formance will be compromised As part of upgrading their tensioner kit range now has oil Bosch recommends that all tim- if the old seal is refitted, not to European applications Bosch seals as part of the kit; includ- ing belt components rather than mention the loss of time and the has recently released another ing all of the Asian and local just the belt are replaced at the frustration of finding out later eight timing tensioner kits with Australian manufactured vehi- time of servicing. This results in that it is required. the appropriate oil seals includ- cles in the range. a much better service and fewer 10 Spring | 2009 Future Workshop

Bosch Market Updates Bet on Quality, Bet on Mazda 3 Bosch Nozzles

Knowing that you are fitting genuine Bosch diesel Service Tips injection nozzles can save a lot of heartache and extra expense. We’ve really struggled this time to come up with service tips for the Mazda 3: everyone keeps tell- ing us what a great, reliable car it is! Bosch Nozzle Fake Nozzle But we know that nothing is perfect, so we’ve kept digging and managed to find a few issues from the field that we might be able to help with.

1. A number of workshops have reported customers complaining of a harsh or rough idle. This can often be caused by the failure of the right hand engine mount of the vehicle. This can be easily confirmed by checking under the vehicle for a visible fluid leak from the mount. The only way to correct this problem is to replace the mount. Characteristic: Excessively pointed nozzle pin of a fake nozzle. Risk: Tip of nozzle pin may break, 2. Another problem that can occur is the vehicle’s engine check light comes on due to misfire engine damage codes logged into the vehicle PCM (powertrain control module). A common cause of this has been found to be fuel contaminated with water. This problem is common in many vehicles, however in the Mazda 3 you need to be aware that water gets easily trapped in the large fuel Bosch Nozzle Fake Nozzle injection rail. Removal and thorough cleaning of the rail is required in addition to standard tank and fuel line cleaning if you encounter this problem.

3. A final issue we’ve come across has been in the manual models. Occasionally an audible click- ing sound can be heard coming from the centre of the dash/transmission tunnel area, when the driver is changing gear. If this is occurring, try adding a 6mm nut to the gear shift cable mount (located on the firewall). This will secure the mount and stop it from moving slightly during Characteristic: Wrong nozzle-seat diameter of a fake gear changes. nozzle. Risk: Incorrect opening pressure, wrong injection timing, weakened engine performance, increased fuel consumption and emissions

Bosch Nozzle Fake Nozzle

Bosch Aftermarket Part Numbers for Mazda 3 (BK) 07/03 ➞ 2.0 LF

Characteristic: Rough surface of a fake nozzle. Risk: Uncontrolled combustion due to sealing Product Description Bosch Part Number problems

Intake manifold pressure sensor 0 261 230 180 Bosch Nozzle Fake Nozzle Spark plug, Platinum Ir Fusion F11-4 Spark plug, Double Platinum HR6DPP33V Spark plug, Double Platinum LPG HR5KI3325 NEW Ribbed V-belt - AC Compressor 5PK698 Ribbed V-belt - Alternator 6PK1300 Universal lambda control sensor 0 258 986 507 Characteristic: Sharp (cone-shaft) junction of a fake nozzle. Risk: Nozzle may break, engine damage Universal lambda diagnostic sensor 0 258 986 602 Injector, gasoline 0 280 156 155 Bosch Nozzle Fake Nozzle Oil filter 0 986 452 068 Air filter element, engine 0 986 AF2 156 Starter battery, S4 F005X04050 NEW Wiper blade element + rail (metal), refill, left BMN610 Wiper blade element + rail (metal), refill, right BMN610 Characteristic: Over-sized sack hole of a fake nozzle. Wiper blade Aerotwin, left BPA475 Risk: Incomplete combustion, increased emissions, failure to comply with emissions regulations Wiper blade Aerotwin, right BPA530 Wiper blade Micro Edge, left BB480 Bosch Nozzle Fake Nozzle Wiper blade Micro Edge, right BB530 Wiper blade ECO, left BBE480 Wiper blade ECO, right BBE530 Wiper blade element + rail (metal), refill, rear BMN610 Cabin filter 1 987 432 163 Brake pad set QikStop; front 0 986 AB4 183 Characteristic: Needle guide diameter of a fake nozzle is too small. Risk: Incorrect opening pressure, wrong Brake pad set QikStop; rear 0 986 AB4 180 injection timing, incomplete combustion, increasing emissions, weakened engine performance Future Workshop Spring | 2009 11 In The Pits! Calder Drive Day: Frosty Revisits Bosch Start

FPR V8 Supercar drivers Mark Winterbottom and Steve Richards were recently reunited with the category and the manufacturer that kicked off their respective car racing careers, when they got behind the wheel of some Spectrum Formula Fords at Calder Park Raceway.

For Frosty, the reunion was particularly special as he was reac- quainted with his 2002 Bosch Batteries Spectrum 09, the car in which he won Rookie of the Year and was runner up in his first attempt at the Ford Racing Australian Formula Ford Championship. The car has just completed a pain staking ground up restoration at the Braeside factory of Borland Racing Developments.

“It was great to get back into the Bosch Batteries car. How good are the brakes in these things? That was probably the thing that surprised me the most; I’d love it if we could stop our V8 Supercars that well!”

Both drivers remain appreciative of the role that Formula Ford and Michael Borland have played in their motor racing careers.

“I had some support through winning the Ford KartStars program,” Winterbottom said. “But we were still struggling for budget and it was Mike that put the Bosch Batteries deal together and if it wasn’t for that, then I’m sure we wouldn’t have been able to achieve what we did. The further I have progressed in my career, the luckier I realise I was to be associated with Mike and his team when I started racing cars,” he added.

Thanks to Borland Racing for supplying information and images.

2009 V8 Supercar Championship Calendar Round 9 Sept 11 – 13 Phillip Island 500, VIC Bosch Shots Competition Round 10 Oct 8 – 11 Bathurst 1000, NSW Round 11 Oct 22 – 25 Surfers Paradise, QLD Round 12 Nov 5 – 7 BIC, Bahrain Round 13 Nov 20 – 22 Barbagallo, WA WIN a Samsung Round 14 Dec 4 – 6 Homebush, NSW Digital Camera

Send us your most creative photo of Bosch in your workshop (eg. signage, product etc) ✂ for a chance to win 1 of 5 Samsung Digital Cameras which will be awarded to the 5 best photos.

Name:______

Company Name:______

Address:______

Please complete this form and return by 30th September with your photos to: Robert Bosch Australia Dept: AA/SAO-MKT3 Email your photos along with all contact details to: Special Reply Paid 73196 OR [email protected] Clayton South, Vic 3169 Price

Do you want your photos returned?  Yes  N o

 Please tick if you don’t want to receive another copy of Future Workshop,and we will take you off our database. BAT415 Battery  I would prefer to receive Future Workshop via email. Please send to: Email Address:______Charger $495 inc GST Don’t let your battery go flat while you’re scanning your Winners vehicle. Congratulations to the following winners of the SBR Watch Promotion in our last issue. Low voltages can cause faults in your scanning Colin Grech CG Automotive Repairs, Avondale Heights Vic communications. Bosch battery chargers let you perform Blaz Persich Oztech Automotive, Kealba VIC in-car battery charging, ensuring constant communication Mark Nelson Baker Motors, Wodonga VIC during ECU diagnostics, while also preserving the data Cheryl Coe Coe’s Auto Electrical, Port Pirie SA memory of car radios, ECUs and onboard computers. Andrew Ennis Ennis Automotive, Wodonga VIC Richard Johnson Gordon Institute of TAFE, Geelong VIC To purchase the BAT415 at the special price of $495 contact Cameron Horder Eclipse Automotive, Airport West VIC bosch Diagnostics on 1300 783 031. Danny Maul & Dean Maul-Dunn D & D Mechanical & 4WD, Goolwa SA Paul & Kel Gibbos Auto Spares, Ballina NSW Offer ends 31st October 2009 Stockist Details The Bosch filter family Below

An extensive range of Bosch Filters is now available to the Australian market. With more than 300 different filter types – oil, air, fuel and cabin filters, Bosch offers a competitive range for Australian, Asian and European vehicles.

For more than 75 years, vehicle manufacturers around the world have put their trust in Bosch Filters. As an OE system supplier, Bosch know how important filtration is in protecting your engine. With state-of-the-art production and testing facilities and the use of only the best manufacturing materials, when you buy Bosch you are guaranteed quality.

For further information on any filters in the Bosch range please contact your Bosch Representative or call Bosch Customer Service on 1300 30 70 40. www.bosch.com.au

Stockist Details: Automotive Service Solutions, TAS (03) 6231 3499 Automotive Service Solutions, WA (08) 9204 9888 Fyshwick Auto Parts, ACT (02) 6211 3755 Imparts, VIC 1300 467 278 Interpart Pty Ltd, NSW(02) 4627 2977 Kensington Spare Parts, NSW(02) 9663 0455 Blacktown Auto Spares, NSW (02) 9622 2322 Mikes Spare Parts, NSW (02) 6571 1337 Scotts Spare Parts Pty Ltd, NSW (02) 4728 5555 IBS, NSW (02) 9618 1774 Lager, NSW (02) 9439 3910 Sydney Wide European, NSW (02) 9708 4848 Cheapa Auto Spares, QLD (07) 4725 3088 Brisco Butler, QLD (07) 3857 3011 Hot Parts, QLD (07) 3208 1288 K & M Auto Parts, QLD (07) 3246 5111 Mackay Auto Parts, QLD (07) 4957 6111 Autobarn Cairns, QLD (07) 4054 1633 All Carbitz Pty Ltd, QLD (07) 3277 8066

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