Diesel Systems

The diesel engine as a sign of the times

and on its way to new horizons
2  |  Diesel Systems   Diesel Systems  |  3

No diesels
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

without Bosch
around 225 diesel customers in
32 countries.

When, in 1927, Robert Bosch manufactured the world’s first diesel There is no challenge, however remotely You can rely on us throughout your diesel
1927
connected to diesels, that we have not engine’s entire life: alongside the workshops of
injection system capable of series production followed only four successfully taken up. vehicle manufacturers, 14,000 Bosch Service First series-mature
locations worldwide provide a comprehensive diesel injection
years later by the marketing of the first diesel system consisting of We are proud of the fact that, for more than  
network of specialized workshops. Our Bosch system
80 years, every decisive further development  
pump, injection nozzles, fuel lines, fuel filter, nozzle holders and of diesel technology, from fuel injection via eXchange program, whereby used diesel
1931
electronic control right up to exhaust-gas com­ponents are refurbished in Bosch factories,
glow plugs, even he probably had no idea of how successful the First complete
treat­ment, has been thought up, co-developed is an active contribution to husbanding
diesel system
onward march of the diesel engine would prove to be in the decades and brought to series maturity by our engineers. resources and protecting the environment.  
In addition, the more favorable prices benefit
that followed. Yet he had achieved something unique. For his devel­ The last two decades in particular have been both you and your customers. Our “Automotive 1960
opment provided the basis for diesel engines that were small and especially exciting, decisively advancing diesel Tradition” experts are always available to advise First distributor
progress. Thanks to our developments, the and assist all lovers of historic diesel vehicles. pump
powerful enough to drive an automobile. sturdy, thrifty but rather sluggish diesel engine
of yesteryear has blossomed into a high- The future needs the past
1986
per­for­mance power unit that has lost none of We know where our roots are and we know that
First electronic
The trailblazing inventions of the founder of our company insepara­ its sturdiness yet can now bear any comparison we will be accompanying diesels far into the
diesel control unit
with other propulsion units with regards to fuel future with developments that we are bringing
bly link the name Bosch to that of Diesel. An inseparable partnership
economy, environmental friendliness and sporty to series maturity today. And we look forward
that has been further extended and consolidated over the past de­ performance. to doing so with your help – so you can depend 1987
on us! First diesel direct
cades right up to the present day in an unbroken line and which will Unique anywhere in the world: our offerings injection
also continue into the future. for and our commitment to diesels
At 36 locations around the world, over 50,000 1994
diesel specialists are working on making diesel First unit injector
engines even more economical, cleaner, quieter system
and more powerful. No other company employs
so many diesel experts so close to you wherever
1997
in the world you are located. And no other
First common rail
company develops, manufactures and applies
system
so many diesel components and systems for
practically every diesel engine, no matter what
its planned usage may be. 2004
First common rail
system with piezo
injectors
4  |  Diesel Systems    Diesel Systems  |  5

Bosch and
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

enthusiasm
Bosch, was the first diesel vehicle to
win the Le Mans 24-hour race. And it
won again in 2007. And yet again in
2008!

for diesels

The enthusiasm and know-how with which we throw ourselves Achievements

into the challenge of making diesels ever better is best shown by since 1990 due to
innovations from
looking at the past twenty years or so. Because this is precisely the Bosch for diesel
time when our innovations – particularly the Common Rail System engines in cars:

in 1997 – made a decisive contribution to the unique diesel success 98 percent

story. And now, at this present point in time, old prejudices among lower particulate
emissions
end users are being swept away by ever more economical, even
thriftier, quieter yet at the same time considerably more sporty diesel 96 percent
reduction in
engines.
nitrous oxide –  
including hydro­
1990 – 2009: Diesels compared to diesels to opti­mized fuel distri­bution and combustion carbon emissions
So it is no wonder that nowadays virtually every second newly regis­ Since the early 1990s we have succeeded in and thus, on the other hand, to massive reduc-
drastically reducing the pollutant emissions of tions in untreated emissions while at the same 98 percent
tered passenger car in Europe is a diesel, and that in total almost a drop in carbon  
diesel engines: in passenger cars, for example, time increasing the dynamic performance of
quarter of all vehicles worldwide are driven by a modern compression- nitrous-oxide emissions have been reduced by diesel engines. mono­xide emis-
96 percent; particulate emissions have fallen by sions
ignition engine. Globally, we predict that the share of diesel vehicles as much as 98 percent. Parallel to this develop­ In addition, further fundamental improvements
will continue to rise over the years to come. Because the victorious ment, the fuel consumption, and thus the CO2 in combustion behavior such as higher turbo- And for diesel
output of diesel vehicles, has been considerably charger pressures together with higher exhaust- engines in com-
march of the most economical diesel engines of all time is meanwhile reduced. gas recirculation rates under part load condi- mercial vehicles:
conquering even markets where tough opposition had previously been tions have gradually made diesel engines even
The most important milestone here has un­doubt­ cleaner. 97 percent
encountered: for instance in the USA, or in Asia. edly been our Common Rail System, mean­while lower particulate
performing service in over 50 million diesel To supplement measures inside the engine, it emissions
engines and operating, depend­ing on the version was our ideas for efficient exhaust-gas treat-
involved, at pressures from 2,200 bar in passen­ ment systems which ensured that modern diesel
86 percent
ger cars up to 2,500 bar in commercial vehicles. engines have always been and still are one step
reduction in  
These high pressures and the possi­bility to – or rather several years – ahead of the ever-
nitrous oxide –  
indi­vidually adapt the injec­tion rate by sepa- more-demanding emissions legislation. How we
including hydro-
rating pressure production, pressure storage foresee the progress of the next twenty years is
carbon emissions
and fuel injection have led, on the one hand, set out on pages 14 and 15.
87 percent
drop in carbon  
monoxide emissions
6  |  Diesel Systems    Diesel Systems  |  7

Bosch for the most

A 40-tonne diesel traveling
1,000 kilometers consumes
about a table­spoon of fuel
for every kilogram of goods
transported.

economical diesel
of all times

In the old days, diesels were bought almost exclusively for their fuel Comparison
economy and sturdiness. Nobody would have thought of describing between a modern
diesel and a com-
a diesel as “clean”, never mind “sporty”. How times have changed! parable gasoline
How more and better technology and maximum fuel economy can passenger car:

be combined to harmonize with environmental compatibility and dy­ Over 30 percent

namic performance is proven today by every modern diesel engine, lower fuel  
consumption
no matter what its planned utilization may be.
About 40 percent
greater range
Private motorists and commercial-vehicle customers benefit to the
Economy meets ecology Keeping up with the times
same extent from this fuel economy. Economic parameters are enor­ Our developments contribute not only to Getting better all the time is, for us, both a
Some 25 percent
lower CO2  
mously important particularly for transport companies and other maxi­mum cost efficiency but are, at the same challenge and reality. So we never rest on our
production
time, the foundation for meeting the ever-more- laurels, but are working day by day on new
fleet operators for whom every cent per kilometer saved is a decisive demanding standards and threshold values of technical approaches such as solutions for
factor for competitiveness in their bottom-line financial calculations. global emission legislation. Thanks to innova- further significant downsizing of engines.   Around 50 percent
tions from Bosch it is already technically With our ideas we provide our colleagues at higher torque
Low fuel consumption combined with a high degree of dependability, possible today to meet the strict regulations of the vehicle manufacturers with new tools to
and thus shorter down times, add up to the ideal price-to-performance the EU6 standard that will probably come into enable ever smaller and ever more economical A diesel passenger
force in 2014. By comparison with a technically engines to be constructed without any loss of car is frequently
ratio of today’s diesels. equivalent gasoline vehicle, a diesel car of performance. an economical  
today consumes over 30 percent less fuel, thus pro­position even  
emitting about 25 percent less CO2 while being We are diligently working for you to globalize if the annual mile-
able to travel around 40 percent farther. In diesels and are at your disposal on the spot all age is less than
addition, it has roughly 50 percent higher over the world whenever engine and vehicle 10,000 kilometers
torque. And despite commonly-held opinions,   concepts have to be designed for a particular
a diesel passenger car is often an economical region, a particular market, a particular demand.
proposition even if the annual mileage is less And of course this service extends from the
than 10,000 kilometers. Check it out for prototype right up to large-series production
yourself at www.fuel-pilot.de. – and far beyond that.
8  |  Diesel Systems    Diesel Systems  |  9

Bosch and diesels

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

for town, country

to 19 liters; for large diesel engines
from 1.5 to 110 liters per cylinder.

and the sea

What do fruit from South America, shoes from Italy, tea from India, Diesel engines
machines from Germany, computers from the USA and televisions with components
and systems from
from Asia all have in common? The answer is as logical as it is simple: Bosch are not
no matter where we live in the world, all these goods and products only found in cars
and commercial
are brought to us by diesels. Whether from near or far – a diesel is vehicles.
always part of the equation.
Additional fields
of application
include, among
And thus so is Bosch. Because from the smallest to the largest others:
engine application, from cars, light commercial vehicles and gigantic
Stationary diesel
trucks right up to container ships, from stationary single-cylinder engines:
engines right up to big dumper trucks and many other off-highway for example emer-
gency generators
applications, we develop and manufacture individual components Tailor-made system competence All these components and systems – and many,
We develop our diesel components specifically many others – are developed, applied and manu­
and complete systems for diesel injection as series products. So Agricultural
for integration in a system and tailored to every factured by us for you.
thanks to our worldwide presence we are able to offer you local and model range, every vehicle type and every engine machines:
application. Additionally, we undertake intensive fundamen- such as tractors
global solutions from a single supplier. tal research into and development of materials or combine har-
From engine management via air management and production processes in order to always vesters
right up to exhaust-gas management we offer   have the best possible solution ready for you in
Construction
you an integrated system solution with co­ keeping with the differing requirements of
machines:
ordinated interfaces for every application. For global markets with regard to technology and
such as bulldozers
only the perfect interplay of all system compo- materials.
and dump trucks
nents, from starter systems, control units, in-
jectors, sensors, nozzles and injection pumps,
can guarantee maximum performance and, at Rail vehicles:
the same time, minimized fuel-consumption and   such as railcars
emission values. and diesel loco­
motives

Ships:
ranging from yachts
to ocean giants
10  |  Diesel Systems    Diesel Systems  |  11

Bosch – for a
Annual savings achieved by series
refurbishment: approx. 500 tonnes
of steel, 180 tonnes of aluminum,
2,750 tonnes of CO2 and an energy
saving of 7,000,000 kilowatt hours

diesel’s entire
(corresponds to the energy require-
ments of a small town for two
months).

working life

We stand by our products. And we stand by the products of our Full service from
customers! Right from the start and throughout all development Bosch for diesels:

stages we offer you our specialists and engineering services such

Engineering  
as items in the field of tailor-made functions and software for diesel services
engine control units. Here we can guarantee to be close to you or –
Bosch is there for you – any time able and to keep workshop times at all service
if you wish – even right inside your factory. centers worldwide as short as pos­si­ble. In addi-
Test centers
and any place
We are there for you and your customers tion, we ensure that repairs carried out reflect
throughout a diesel’s long working life. Even the age value of the item and are eco­­logically Bosch service net-
Our developments and applications match your very individual when developing our products we place great sensible – whether by the use of new parts, work in all regions
requirements and wishes for large-series production, projects in­ importance on rapid and precise diagnostic through the Bosch eXchange program of series-
capabilities. Our sophisticated logistics con- refurbished products or by means of expert
volving a small number of items right down to special versions. cept permits us to make spares quickly avail- repairs at our specialized Bosch Diesel Centers. Bosch eXchange
And all this throughout the entire long life of program
At our technical test centers worldwide we carry out standardized
the vehicle.
tests and measurements for you and, last but not least, we manufac­
Bosch automotive
Full service as we understand it
ture “your” product to the highest possible quality and in accordance tradition
We even support lovers of classic vehicles via
with strict ecological guidelines that even exceed the legal require­ out “Bosch Automotive Tradition” division by
stocking and sourcing rare spare parts or even
ments long before they become applicable. having them specially made. As the original
manufacturer we are, after all, the only ones
with the necessary know-how and complete
documentation.
12  |  Diesel Systems    Diesel Systems  |  13

Bosch puts its trust

“We do not constantly redefine our
strategy, but stick to it even in
constantly changing circumstances.”

(Franz Fehrenbach, Chairman of

in diesels – put your

the Board of Management of Robert
Bosch GmbH)

trust in us

The “Workshop for Precision Mechanics” founded by Robert Bosch in Investment in

1886 has developed in the course of over 120 years into the world’s research and
development in
largest automobile components supplier and the technological 2008:
leader – especially for diesels. Its is the hard work of each individual,
Bosch Group:
their willingness to take a long-term approach, accept mistakes and 3.9 billion euros
– around 9 percent
overcome setbacks which has permitted Bosch to build up a company
more than in the
culture rich in tradition and experience yet always oriented toward the previous year and
some 9 percent of
future. For us the past is not a comfortable chair to simply rest upon, “It is better to lose money than people’s Invented for life – 3,850 times our total turnover
trust.” With firm decision we continuously invest more
it is always a springboard to the future – true to the philosophy of
At Bosch, “corporate culture” is not just a money in research and development than any
Worldwide, the
the founder of our company, Robert Bosch, who once said: “Those phrase. It is, rather, the result of the trust other player in the market. In Automotive Tech-
Bosch Group em-
which we have built up for ourselves over de- nology, the most research-intensive sector of
who have ceased to be better have ceased to be good!” cades of contact with you. Long-term coopera- our company, investments of some 3.25 billion
ploys a staff of over
32,500 in research
tion among partners is the foundation of the euros in 2008 amounted to around 12 percent of
and development,
relationship between our customers and our- turnover and thus some 12 percent more than in
Even today we owe our independence to his foresightedness. This selves. The above quote from Robert Bosch is 2007. With more than 3,850 inventions, about
18,300 of them in
Germany
is why we at Bosch still think and act with a view to the long term our guiding star, the maxim which we will con- 15 patents per working day, the Bosch Group
tinue to follow without compromise and which was the biggest patent applicant in Germany in
without looking for short-term gain and financing our growth from is mirrored both in the way we treat each other 2008. Around 45 percent of these patents help
A total of over  
3,850 patents.
and in our claim to supply you exclusively with to conserve the environment and our natural
our own profits. To allow this to succeed, our internal obligation is Around 45 percent
nothing but top quality. resources.
of these help to
to constantly use our new ideas and innovations to set market-ori­
conserve the envi-
But money alone cannot generate innovations –  
ented trends in the motor-vehicle sector in general and on the diesel these only mature in creative brains. At the
ronment and our
natural resources
market in particular, trends that we drive forward until we achieve start of 2009 our research and development
depart­ments had a staff of at least 32,500, over
success. With this aim in mind we also participate strongly on the 10,000 of them outside Europe, over 7,000 in Automotive Tech-
nology Division:
international level on numerous technical boards and committees. Asia alone. For a long time now, our innovations
have been the results of international networking. 3.25 billion euros
– approximately
12 percent more
than in the previ-
ous year and some
12 percent of our
total turnover
14  |  Diesel Systems   Diesel Systems  |  15

Bosch and the

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
CO2 could be saved. This corre-

diesels of the
sponds to the CO2 output of 65,000
vehicles with an annual mileage of
20,000 kilometers.

future

The future of automobile traffic is electric. Most experts and research Diesels on the
institutes are in agreement here. At first it is assumed that only very way to the future:

small numbers will be involved. The probable forecast for 2015 is Even better diesels will be here tomorrow
around 500,000 new vehicle registrations worldwide. A good start, In a few years, a mid-range compression-igni-
tion car will only need 3 liters of fuel for 100
but still far too few to sustainably help the automobile industry to kilometers – with a CO2 output of less than
meet the stricter CO2 regulations applicable to the fleet of new cars 100 grams per kilometer. And we predict that
this can also be achieved for lower vehicle seg-
required for Europe. Therefore, it is all the more important to continue ments even for future exhaust-gas standards
without additional costs.
to consistently reduce the fuel consumption of internal combustion
engines. The technical potential for this already exists.
Further increases in injection pressures and
turbocharging, improvements which we are
We at Bosch assume that internal combustion engines will continue working on in our joint project with Mahle, will
permit an even more pronounced downsizing
to play a dominant role for the next 20 to 30 years. Consequently we of engines. This development will lead to a re-
And the diesel hybrid will be here the day
after tomorrow Higher injection
Nothing can disguise the fact that our oil re- pressures
serves will one day dry up.
So a company with a long-term orientation like
Bosch adjusts at an early stage to fundamen-
Improved tur-
bocharging
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 Downsizing
drives and brakes as well as engine and trans-
mission control.
At our “Hybrid Project House”, hundreds of Downspeeding

are continuing to develop our diesel systems as a top priority – so duction in the number of cylinders. It is certain
that more 3-cylinder engines will be developed
successfully indeed that we can forecast further reductions in fuel and built in the very near future.
consumption for diesel engines of up to 30 percent over the next few
An important role will also be given to down­
years. speeding. Specially designed transmissions
will reduce engine revolutions, resulting in
lower frictional losses in the engine and thus
Parallel to this, we are pushing ahead with the electrification of the greater efficiency.
specialists are working outside the confines of
our individual Divisions to develop systems and
components for hybrid and electric vehicles.
Thermal  
management
So we are developing both – the car of tomorrow
and that of the day after tomorrow.
Start/Stop

powertrain. With our partner Samsung, for instance, we have com­ Further measures such as improvements in Diesel hybrid
menced a joint venture to develop to market maturity the lithium-ion thermal management which will permit the
cooling system to adapt to the requirements of
batteries of the future. 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.
Robert Bosch GmbH
Diesel Systems

Postfach 30 02 20
70442 Stuttgart
Germany
Fax: +49 711 811-45090
diesel@bosch.com

www.bosch-diesel.de

Printed in Germany
292000P075-C/SMC2-200906-En