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can provide fully comprehensive system expertise


for workshops and the aftermarket.
Motor vehicle components
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Diagnostics
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ff Service training
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AA-SP/MKT F 026 P02 564 / 200908 64.64.XX

Diagnostics and replacement


parts all from one supplier

Product Information - Automotive


Spark plugs

2 Contents

At a glance:
PIA Spark plugs

Pages

Product Information (Automotive) for spark plugs, or

A long history of progress

PIA for short, is designed to supplement the existing

More than 100 years ago Bosch presented the first

sources of information on the Bosch spark plug range,

spark plug in combination with a high-voltage magneto.

the individual products and their applications. It is

This reliable product for high-speed engines solved

4-5

Global presence: Production, service and sales

a concise guide to the principal facts, providing an

the ignition problem once and for all. In conjunction

up-to-date, quick reference to each item and thus

with industrial manufacturing processes, the Bosch

6-9

The history of the spark plug

presenting a consistent approach to sales arguments

spark plug paved the way for the immense growth of

for all spark plugs. The PIA also describes technical

motor vehicle production in the following decades.

features, customer services and the full range of

10 - 11

Quality from the spark plug inventors

12 - 15

First choice for original equipment and motor sports

16 - 17

The spark plug the nerve center of the engine

18 - 19

Design features

20 - 21

Spark plug faces and what they reveal

22 - 23

The complete Bosch spark plug range: A summary

24 - 25

Bosch Super

26 - 27

Bosch Super plus and Double platinum

28 - 29

Bosch Super 4

same experience and high original equipment quality

30 - 31

Bosch Super special and special applications

tor. The Bosch product range can thus offer outstan-

32 - 33

Spark plug type designation

level of market coverage. Another excellent feature

Bosch expertise in the spark plug sector.

Todays modern vehicles have to satisfy ever increasing


demands. They are judged by their fuel economy,
low emission levels and the greatest possible driving
pleasure. Efforts to reconcile all these aims can no
longer just be concentrated on improvements to particular components. Progress can only be achieved
with an all-round approach system expertise and an
understanding of the complex relationships between
the sub-systems enable Bosch to create new, pioneering
overall concepts.
In conjunction with leading motor vehicle manufacturers,
Bosch develops and produces both separate components such as spark plugs and complete systems. This
standard are also invested into the aftermarket secding quality and reliability while attaining a high
is the professional assistance offered to the trade

34 - 35

Spark plugs for gas engines

36 - 37

Bosch Diagnostics and practical spark plug advice from Bosch

38 - 39

Advanced training

40 - 41

Sales promotion

42 - 43

Glossary

44 - 47

Frequently asked questions

and workshops.

4 Global presence

Bosch all-round expertise:

Exciting ideas, close customer contact:


Production, development and sales

ff Close contact with vehicle manufacturers


ff Full range of original equipment from components right through to coordinated systems
ff Innovations for advanced automobile technology
ff International development and manufacturing
network in 5 countries

Spark plug expertise

Comprehensive range

Leading automobile manufacturers rely on Bosch

In addition to a full range of more than 10 000 spark

spark plugs for surfisticated technology and high

plugs for all types of engine, Bosch can also supply

quality standards. As pioneers in the area of ignition

the appropriate replacement and wear parts for the

systems, Bosch can offer an extensive product range:

aftermarket and workshops as well as the correspon-

ff Super

ding testing and diagnostic systems.

ff Super Plus
ff Super 4

Worldwide development and production

ff Platinum

An international manufacturing network develops and

ff Specials

produces the entire spark plug product range in 5

ff Gas applications

countries. This means that components and products

ff Other applications

can be created close to the market while maintaining

ff Komplettes Programm

consistent manufacturing and quality standards. In this


way, the constant high quality of Bosch products is
always guaranteed.

Worldwide presence

Bamberg
Germany

Saratow
Russia

Nanjing
China

Naganathapura
India
Aratu
Brazil

6 The history of the spark plug

More than a century of experience

Bosch present the very first spark plug:


A real boost to mobility

ff Bosch invented the spark plug


ff Bosch manufacture more than 350 million
spark plugs every year
ff Worldwide production to the same constant
high quality standard

Bosch spark plugs. A history of success.

Bosch spark plugs. Still the number 1

More than 100 years ago Bosch presented their spark

Bosch produces a million spark plugs at the Bamberg

plug with high-voltage magneto to the world and

works alone. Every day. There are now also Bosch

thus solved the problem of ignition in the early days

manufacturing plants in other countries and on other

of automotive engineering. Thanks to industrial pro-

continents, for example in India, Brazil, Russia and

duction processes, cars became affordable for the

China. Altogether that adds up to a world-wide pro-

general public. On 7th January 1902 Bosch was

duction total of more than 350 million spark plugs

awarded a patent on their spark plug and this marked

a year. If all the spark plugs manufactured to date

the start of the success story. Since then Bosch has

were to be placed end to end, they would form a

developed more than 20 000 types of spark plug.

chain 350 000 kilometers long reaching to the moon.

Nothing but the best.


Bosch products undergo continues development
process to maintain quality standards. In this way,
it has been possible to continuously enhance performance since the invention of the Bosch spark plug.
The outcome: Spark plugs have become more durable
and last for up to 30 000 km, with some special
models even managing 100 000 km.

1902 The first spark plug with highvoltage magneto is developed by


Bosch and revolutionizes motoring

8 The history of the spark plug

More than 100 years old.


But just as innovative as ever

100 years of spark plugs 1902 to 2002


04 1905 1906
1903 19

1902

1907

1908

1909

1913

1910
1911

1912

1914

1915

1918 1919

1916

1920

1921

1917

1975
Copper core in ground electrode:
To improve heat dissipation, the center
and ground electrodes are provided
with a copper core. This also reduces
the amount of wear.
1922

1923

1924

1925
1926

1928

1927

1930

1929

1931

1933

1932

1934

1935 1936

1937

1938

1939

1940

1941

1983
Platinum range:
The special platinum spark plugs from
Bosch have sintered-in center electrodes
made of pure platinum. They are thus
extremely resistant to wear and have a

1943
1942

1945
1944

1946

1947

1948

1949

1950

1951

1970

1971

1952

1954

1953

1956

1955

1957

1958

1959

1960

1961

far longer service life.

1992
Surface gap design:
The layout of the ground electrodes is
such that only surface air gap sparks are

1962

1963

1964

1965

1966

1967

1968

1969

1974
1972

formed. This produces a larger arc and

1975

1976

1977

1978

1980

1981

1979

1973

results in greatly enhanced ignition properties.

1998
Laser double platinum:
Laser-welded platinum tips (center
electrode) and platinum-tipped ground
electrodes ensure a high power yield
and an above average service life.

1982

1983

1984

1985

1986

1987

1988

1989

1990

1991

1992

1993

1994

1995

1996

1997

1998

1999

2000

2001

2002

10 Quality from the spark plug inventors

11

Research, development, inspection:


Quality is not a matter of chance

Deliberate deception.

Imitations no match for the genuine item.

Manufacturers of imitation products copy the design

The inferior quality of imitation products can have

of Bosch spark plugs to wrongly create the impression

disastrous consequences for the engine: Misfiring,

that they are offering the same high quality as Bosch.

starting problems and even costly engine damage.

The use of this stolen appearance is a deliberate

A Bosch study of the design, materials and workman-

attempt to deceive the aftermarket and consumers.

ship of various imitation products revealed serious


deficiencies in almost every case.

Cheap production, inferior raw materials.


Bosch spark plugs are the product of extensive re-

So dont take any risks: Only buy top quality Bosch


spark plugs from authorized dealers.

Warranty:

Research and development:

search, careful production and more than a century

Bosch spark plugs can be used in all engines in

At Bosch, spark plugs are constantly adapted to the

of experience. None of which can be offered by imi-

accordance with the applicable recommendations

latest developments in engine technology. Whether an

tation spark plugs, usually from countries with low

issued by Bosch. Bosch provides warranty coverage

engine is of the four valve, lean mix or low-consump-

labor costs such as China.

for assured properties and perfect working order in

tion gasoline direct injection type the wide range

line with the current state of the art. The warranty

of applications of Bosch spark plugs is the result of

Almost identical but not when it comes to per-

period for material and manufacturing defects is 24

design modifications and the use of particularly

formance.

months. Normal wear and tear is not covered by the

hard-wearing metals such as platinum, iridium or

Even experts often find it difficult to distinguish bet-

warranty.

yttrium. And Bosch will continue to promote the

ween genuine and imitation products on the basis of

development of new spark plugs in the future as well.

their outward appearance or packaging. The lower


price can sometimes be the sign of a cheap copy.
The quality inside is what counts.
The true worth of a spark plug only comes to the
fore when it is put to the test. A closer look at the
inner workings is needed to reveal the poor manufacturing quality and inferior materials resulting in
unsatisfactory performance.

Years of experience and intensive spark plug develop-

Cheap copy (two aspects): Outwardly hardly distinguishable from

ment efforts in close association with virtually all vehicle

the genuine article but a world of difference in quality.

manufacturers have made Bosch one of the worlds


leading suppliers for original equipment and the aftermarket and also the market leader in Europe.

It is an offence to knowingly buy or sell imitations of Bosch


spark plugs.

12 First choice for original equipment

13

Unrivalled:
Bosch is the motorists number 1

A matter of trust:
Vehicle manufacturers count on Bosch

Many leading vehicle manufacturers decided in favor


of Bosch spark plugs right from the start. And there
Certification for all Bosch factories guarantees

are good reasons for doing so after all, Bosch is

Quality right from the start

synonymous with outstanding quality, innovation,


in-depth expertise and an unrivalled range in the
fields of gasoline injection and ignition.

Motorists have no doubts. For the third time in suc-

By constantly developing new spark plug concepts,

cession, Bosch was voted the most popular make in

Bosch can provide a guarantee of high-grade, state-

the spark plug sector by more than 100000 readers

of-the-art products.

of the magazines auto motor und sport and msa.


A close working relationship for perfect results
This high level of quality and reliability is the product

All Bosch original equipment spark plugs are developed

of a close, successful working relationship between

in close association with vehicle manufacturers and

Bosch and leading international vehicle manufacturers

are thus tailor-made to suit every engine.

and their joint development projects.


Important for workshops and the aftermarket sector:
Numerous certificates furnish proof of compliance with

Bosch only supplies original equipment quality to the

the high quality demanded at international levels. Its

aftermarket.

reassuring to know that the same high Bosch quality


Bosch original equipment spark plugs for motor

standards apply in all factories.

vehicles:
Spark plugs from Bosch Europes no. 1
original equipment and the aftermarket supplier

Bosch spark plugs in comparison with competitors

Competitors

Way out in front for the third time running: German motorists

In Europe nearly every second vehicle is fitted with

vote for Bosch spark plugs as Best Brand

Bosch spark plugs when it leaves the factory

Alfa Romeo

Mercedes-Benz

Smart

Audi

Mitsubishi

Ssangyong

BMW

Opel

Toyota

Cadillac

Peugeot

Vauxhall

Citron

Porsche

Volvo

Deawoo

Renault

Volkswagen

Fiat

Saab

Ford

Seat

Lancia

Skoda

14 Top technology for outstanding results

15

The winners choice:


Bosch spark plugs head the field

Bosch spark plugs are


always amongst the front
runners in the DTM.

Bosch spark plugs fear no comparison

High-tech developed for motor sports goes into

Bosch makes it mark in motor sports

Spark plugs are not the only driving force behind

When it comes to satisfying the toughest standards,

series production

For the ninth consecutive year Bosch is involved in the

victories

Bosch spark plugs never let you down. No wonder

Bosch spark plugs are always one step ahead in the

DTM. The extremely popular international touring car

As well as acting as sponsor for the DTM, Bosch

they are so successful in international motor sports.

motor sports sector thanks to special technical

race series, which is broadcast live not only in Europe

provide the absolute top quality technology on which

properties and standards and the use of high-grade

and Africa but also in China and North America,

racing teams depend. That is why all DTM vehicles

Pole position for Bosch

materials such as yttrium. Specially designed to cope

attracts more spectators than most other motor

are equipped with Bosch spark plugs. Whats more,

What ever the situation - be it the Le Mans 24-hour

with the exacting demands of motor sport, these

sports events. And Boschs support is clear for all to

the entire engine management system, the cockpit

race, the Indy Racing League, the V8 Supercar Series,

innovations are also incorporated into original equip-

see: On the rear windows of vehicles, in the in-board

displays, the sensors, injectors, starters and alternators

the Swedish Touring Car Championship or the DTM

ment spark plugs. In fact they are often perfected

cameras, in the pits and - most recently -

all come from Bosch.

in Germany spark plugs from Bosch have got what

still further before going into series production for

on the windshield as well.

it takes to be a winner. One of the guarantees for

workshops and the aftermarket.

this is the innovative, extremely durable and wear


resistant yttrium alloy.

Deutsche Tourenwagen Masters

Deutsche Tourenwagen Masters

Swedish Touring Car Championship

Indy Racing League

Indy Racing League

16 The spark plug the nerve center of the engine

17

Always up-to-date

The latest expertise:


What spark plugs have to offer

ff Workshops and the aftermarket benefit


directly from the latest original equipment
technology
ff Maximum reliability and a long service life
ff Guaranteed protection for engine and
catalytic converter

The function of the spark plug

Applications

Its really quite simple: The spark plug has to ignite

Vehicles and machinery are driven by gasoline

the air-fuel mixture in the combustion chamber of a

engines wherever mobility and power are essential:

gasoline engine by means of an electric spark.

ff Cars

Whenever needed, always at the right time, over and

ff Commercial vehicles

over again. It

ff Motorcycles

Bosch spark plugs provide workshops and the after-

Simply the best:

ff must guarantee reliable cold starting

ff Boats/ships

market with the latest original equipment trends.

Spark plugs with interference suppression resistor

ff must operate without fail over its entire service life

ff Agricultural and construction machinery

Two examples: The profiled ground electrode and

In the original equipment sector, increasing use is being

ff must not overheat even if operated for long periods

ff Power saws

the interference suppression resistor.

made of spark plugs with interference suppression

at maximum load

ff Gardening implements

resistor, as a way of protecting electronic systems in


New technology for reliable ignition:

the vehicle against electromagnetic interference. For

The profiled ground electrode

this reason, Bosch also offers suppressed spark plugs

The profiling of the ground electrode ensures greater

for the replacement parts market:

ignition reliability thanks to more rapid sparkover and

ff Maximum interference suppression rate

mixture ignition.

ff Reliable operation of all electronic systems such

Added advantages:
ff Increased cold starting reliability

as ABS, TCS and ESP


ff No radio reception interference

ff Enhanced combustion protects engine and


catalytic converter
ff Reduced fuel consumption by avoidance of
misfiring

The key to mobility: Spark plugs govern the heart beat of gasoline engines

18 Design features

19

Spark plugs have a lot to contend with:


Top performance even in the toughest
conditions

Quality at every step:


The Bosch spark plug production process

Pre-assembly

All from one supplier


Spark plugs must offer the greatest possible reliability despite being subject to extreme wear and tear. Even the

Final assembly

Super plus

Center electrode

most minute fault can result in costly engine damage. Thats why Bosch the only manufacturer in Germany to
1

do so produce all their own spark plug components.

14

14

24

25

Connection rod
12

Requirements: Electrical properties

Requirements: Thermal properties

ff Voltages of more than 30000 V must not cause

ff Resistance to rapid, extreme changes in temperature

insulator breakdown
ff The electric resistance of the insulator must be
guaranteed even at temperatures of 1000 C

13

(hot combustion gases and cold air-fuel mixture)


ff Good heat dissipation to the cylinder head
ff Minimal heat generation at the connection end of

Insulator

the spark plug


Requirements: Chemical properties
ff Resistant to all chemical processes in the combustion chamber
ff Stable at combustion temperatures up to 3000 C

Requirements: Mechanical properties

22

ff Reliable gas-tightness at pressures up to 100 bar


ff Resistance to tightening forces on assembly

ff Resistant to corrosive deposits contained in the fuel

Spark plug shell

15

Design and operation:

16

17

Center electrode
1 Welding copper and nickel-yttrium
tablets to circular blank

Nickel-plated spark plug shell and threaded


section:

2 Impact extrusion in 4 steps step 1

To prevent corrosion and seizure of the

3 Impact extrusion in 4 steps step 4

thread in the aluminum cylinder head.

23

11

10

Effective leakage current barriers:


Prevent flashover and thus misfiring.

Connection rod
4 Cutting connection rod from wire
5 Impact extrusion in 3 steps step 3

18

19

20

Pre-assembly

22 Internal sealing washer


23 External sealing washer

14 Imprinting, glazing insulator,


mounting center electrode,
filling in contact and resistor
glass seal powder, mounting
connection rod, annealing

24 SAE terminal nut

Spark plug shell

6 Rolling thread and curling

15 Cutting from wire

7 Nickel plating

16 Impact extrusion
in 5 steps step

Reliable operation of all electronic systems


and no radio reception interference.

Copper core with high thermal conductivity


rapid attainment of operating temperature.
Provides protection against thermal overload,
corrosion and spark erosion.

8 Aluminium oxide
9 Casting insulator

Compound center electrode:


in wear-resistant chromium-nickel sheath for

Insulator

10 Grinding insulator
Ground electrode:
Positioning, number and geometry have

11 Sintering insulator

Final assembly

13 Resistor glass seal (powder)

Guarantees absolute gas-tightness and a


Interference suppression resistor:

21

12 Contact glass seal (powder)

Heat-shrink fitting:
precise heat range.

21

17 Impact extrusion
in 5 steps step
18 Latheing and
washing shell
19 Welding
ground electrode

an influence on the sparking process and

20 Rolling thread and


embossing shell

service life.

21 Nickel plating

25 Mounting internal sealing


washer and insulator into
shell, cold crimping, hot
crimping, screwing on SAE
terminal nut, cutting and
bending center electrode,
adjusting electrode gap,
mounting external sealing
washer

Super plus

20 Further developments and trends

21

Continuous development of a great idea


The spark plugs of tomorrow

Smaller, more efficient, longer lasting


Thanks to major expenditure on research and development, Bosch has worked closely with international car
manufacturers to bring new spark plug designes to production, which are optimized to meet the needs of
modern gasoline engines. Above all, this means less fuel consumption, lower emissions and reduced dimensions.

Minimal installation dimensions


Powerful, efficient engines require a lot of air to

Expensive platinum ensures that the electrodes retain

provide optimum combustion of the fuel.

their resistance in the long term, but optimized

However, more air also means larger ducts in the

materials could replace platinum in the future.

inlet and outlet valve. This leaves less space for

This would make spark plugs cheaper and, at the

installation of the spark plug. In other words, the

same time, more durable.

smaller the diameter of the spark plug, the more


options are available to engine designers.
Perfect spark plugs are the result of computer
simulation
Thanks to a new development method, Bosch is hot
on the heels of the perfect spark plug for direct
injection gasoline engines. The only simulation of its
kind in the world
ff Creates virtual spark plug designs
ff Visualizes processes in the engine
Based on maximum precision

Long ignition spark position

Modern internal combustion engines are highly com-

The layer charging method used in modern direct fuel

plex systems, in which every detail needs to be pre-

injection, demands exact placement of the ignition

cisely designed to work with the others. Spark plugs

spark in the area of the combustion chamber in

At critical operating points in the partial load and

are an important component, and are faced with

which the ignitable mixture is located. A long spark

idling speed range, optimized spark plugs result in:

totally new requirements, due to the latest generation

position provides the necessary reliability.

ff Increased ignition reliability

of direct injection systems.

ff Opens up new options for perfect derivation of


measuring results and optimization of spark plugs

ff Reduced fuel consumption and pollutant emissions

The basis for meeting all of these requirements is

Aligned ground electrode

almost tolerance-free production and new develop-

Precisely produced spark plugs with ground electrodes

ments in materials, geometry and manufacturing

already aligned during production guarantee reliable

Fighting nano-flashes - Less platinum in spark plugs

methods.

ignition in engines with fuel spray direct injection.

In conjunction with respected materials scientists

The installation angle and installation position relative

and supported by the German Ministry of Research,

New materials

to the injector are defined according to the specific

Bosch is conducting research into extremely reliable

Modern engines operate with extremely high combu-

engine type. Narrow production tolerances, modern

and durable electrode and contact materials for

stion chamber temperatures. This impacts the spark

measuring systems and, of course, close cooperation

electrical components. The focus is on electrical ero-

plugs. It increases the wear on the electrodes, which

with engine manufacturers, ensures optimum align-

sion due to so-called nano-flashes.

needs to be offset by the use of appropriate materi-

ment of the ground electrodes. An incorrect installation

With each ignition process, these tear nanometer-sized

als that are more resistant to arc erosion. Bosch

angle can result in malfunctions.

craters from the electrodes, causing permanent

uses high quality alloys, for example platinum, iridium


and rhodium.

ff Optimum catalytic converter protection

damage to them.

Min.

Max.

22 Spark Plug Faces

23

At a Glance:
Spark Plug Faces

1 2

12

Thick ash coating from oil and fuel additives

Effect: Can lead to auto-ignition with loss

or yellowish-grey and russet. Engine

on insulator nose, in scavenging area (an-

of power and engine damage.

OK. Correct heat range. A/F mixture

nular orifice) and on ground electrode.

Remedy: Repair engine. Use new spark

adjustment and timing OK, no ignition

Loose to cinder-like structure.

plugs and possibly different oil.

miss, cold-start enrichment functioning

Cause: Alloying constituents, particularly

correctly.

from oil, may deposit such ash in the

No residues from lead fuel additives or

combustion chamber and on the spark

engine-oil additives. No overheating.

plug face.

3 4

13

Soot fouling

14

short distances, spark plug too cold, heat

Center electrode partially melted, blistered,

Center electrode melted away and

range too low.

spongy insulator nose tip.

ground electrode severely corroded.

matt-black coating of soot.

Effects: Ignition miss, poor cold starts.

Cause: Thermal overload due to auto-

Cause: Thermal overload due to auto-

Cause: Incorrect A/F mixture adjust-

Remedy: Adjust A/F mixture and cold-start

ignition, e.g. on account of excessively

ignition, e.g. on account of excessively

ment (carburetor, fuel injection): A/F

system, check air filter.

advanced ignition timing. Heat range

advanced ignition timing.

mixture too rich, extremely dirtly air

possibly too low.

Effect: Misfiring, loss of power, possibly

filter, automatic choke or choke cable

Effect: Misfiring, loss of power (engine

engine damage. Overheated center

defective, vehicle only used for extremely

damage).

electrode may cause insulator nose to

Remedy: Check engine, ignition and

crack.

mixture formation. New spark plugs with

Remedy: Check engine, ignition and

correct heat range.

mixture formation. New spark plugs.

15 Partially melted electrodes

16 Ferrocen

Cauliflower-like appearance of electrodes.

Firmly adhering reddish orange deposits

Possibly deposition of foreign matter.

coat the insulator nose, electrodes and

Cause: Thermal overload, e.g. on account

to some extent the spark plug shell.

of excessively advanced ignition timing,

Cause: Fuel additives containing iron.

combustion residue, defective valves or

Deposits occur in normal operation after

defective ignition distributors.

a few thousand kilometers.

Effect: Loss of power prior to total failure

Effect: The iron in the coating is electri-

(engine damage).

cally conductive and causes misfiring.

Remedy: Check engine, ignition and

Remedy: New spark plugs, cleaning has

mixture formation. New spark plugs.

no effect.

17 Ground electrode wear

18 Cracking of insulator nose

Cause: Corrosive fuel and oil additives.

Cause: Mechanical damage due to

Unfavourable flow conditions in com-

inexpert handling. In borderline cases -

bustion chamber, possibly on account of

particularly following excessive operating

deposits, engine knocking. No thermal

time - cracking of insulator nose may be

overload.

caused by deposits between center elect-

Effect: Misfiring, particularly on accelera-

rode and insulator nose and by corrosion

Oil fouling

Insulator nose, electrodes, and spark

Effects: Ignition loss. Starting difficulties.

plug shell covered with shiny oil layer of

Remedy: Overheaul engine, use correct

soot or carbon.

A/F mixture, replace spark plugs.

15

of piston rings, cylinder walls, or valve

16

seals/guides. Two-stroke engines: Too


much oil in fuel mixture.

Severly eroded center electrode

Lead deposits

Cause: Failure to observe spark plug

A brownish-yellow glaze, with a greenish

replacement intervals.

tint, has formed on the insulator nose.

Effects: Ignition miss, especially during

Cause: Fuel additives containing lead.

acceleration (ignition voltage not adequate

The glaze forms when the engine is

for bridging wider electrode gap).

operated at high loads after extended

Starting difficulties.

part-throttle operation.

Remedy: New spark plugs.

Effects: At high loads the glaze becomes


electr. conductive, leading to ignition miss.
Remedy: New spark plugs, cleaning them
is pointless.

9 10 Severe lead deposits


9

10

14 Center electrode melted away

plug shell covered with a felt-textured,

chamber. Oil level too high, severe wear

13 Center electrode partially melted

Insulator nose, electrodes, and spark

Cause: Excessive oil in combustion

11 12 Ash formation

Insulator nose with color between whitish

5 6
5

11

Normal

17

18

Thick, brownish-yellow glaze, thick in

Effects: At high loads the glaze becomes

tion (ignition voltage no longer sufficient

of center electrode.

some places, possibly with greenish tint,

electrically conductive, leading to ignition

for large electrode gap). Poor starting

Effect: Misfiring, sparkover at points not

has formed on the insulator nose.

miss.

performance.

reliably supplied with fresh mixture.

Cause: Fuel additives containing lead:

Remedy: New spark plugs, cleaning them

Remedy: New spark plugs.

Remedy: New spark plugs.

The glaze forms when the engine is

is pointless.

operated at high loads after extended


part-throttle operation.

24 The complete Bosch spark plug range

25

The full range

The right product for every application:


All the Bosch spark plugs at a glance

ff A total of 1250 spark plug versions


ff 31 different electrode designs
ff For 98% of all vehicles
ff Clear-cut assignment for rapid identification
of the right spark plug

Bosch Super/Super plus


ff For consistently high performance whatever the
operating conditions
ff Factory-set electrode gap
ff Satisfies manufacturers service life requirements
ff Bosch Super plus the 55 top products for virtually
all vehicles
Bosch Super 4

Bosch Super / Super plus

ff Up to 60% greater efficiency for higher engine


output
ff Greatly enhanced acceleration characteristics
ff Greater ride comfort thanks to smoother operation
and superior engine performance
ff Surface air gap principle always chooses the
best spark gap
All leading automobile manufacturers install Bosch

Clear-cut spark plug assignment to the engine

spark plugs as standard equipment. At present the

The clearly marked assignment of spark plugs to

Bosch Super special

Bosch range contains more than 1250 versions with

engines, in the catalog for example, makes the ordering

ff Special spark plugs for motorcycles, snowmobiles,

31 different electrode designs to guarantee the right

procedure more straight forward. Each engine is

spark plug for every engine and for around 98% of

assigned exactly the right spark plug. The simple ID

ff For a wide range of equipment

all vehicles.

number system permits rapid, reliable identification

ff Outstanding starting performance over the entire

of the appropriate spark plug.


Tailor-made range for workshops and the aftermarket

All the details of the Bosch spark plug type designa-

sector

tions can be found on Pages 34 and 35.

gardening implements, motor boats ...


Bosch Super 4

service life
ff Effective protection against corrosion and thread
seizure

The Bosch Super range offers just the right spark plug
for every vehicle. Technically, the spark plugs are
perfectly designed to satisfy the requirements of each
engine. The top range of spark plugs for the most
common vehicles Bosch Super plus provides market
coverage for more than 97% of vehicles with just
55 types.

Bosch Super special

26 Bosch Super

27

Millions of applications all round the world

Thousands of millions of spark plugs provide


ample proof: The Bosch Super is a real winner

ff The right spark plug for every engine


ff For around 98% of all vehicles
ff Convincing arguments for all motorists
ff Available individually or in packs of 10

A brief outline of the technology


Bosch employs three different spark plug technologies
depending on the engine characteristics.

Air gap design: The ignition spark

Arguments guaranteed to convince all motorists

travels along a direct path to the

ff Exactly the right spark plug for every

ground electrode and thus ignites


the air-fuel mixture.

passenger car gasoline engine


ff Cuts fuel consumption and reduces harmful
emissions
ff Protects engine and catalytic converter
Arguments guaranteed to convince workshops

Surface gap design: The layout of the

and the aftermarket

ground electrodes is such that only

ff A long service life and reliability keep

surface air gap sparks, which are

customers satisfied

particularly long and powerful, can

ff Clear-cut identification, ease of replacement

be formed.

ff Combination of several spark plug types


less storage space required

Original equipment technology

The Bosch Super range also includes Bosch double

Your customers can rest assured knowing that. The

platinum with a particularly high level of wear resi-

Bosch Super range offers genuine original equipment

stance thanks to the platinum coating on both elec-

combines both spark paths. Both

technology. In other words Bosch quality designed

trodes.

air gap sparks and surface air gap

Surface air gap design: This design

sparks ignite the air-fuel mixture.

to suit the exact requirements of the engine.


For virtually all gasoline engines
The Bosch Super range contains a total of 350 types.
The top most frequently used spark plugs have a plus
identifiing them is the fastest movers.

Packaging unit tailored to workshops:


Endurance hardness testing has shown: Electrodes

All Bosch Super spark plugs are available individually and

with yttrium alloy are far less susceptible to wear

in packs of 10. Ideal for one-off orders or for keeping a

than electrodes with no yttrium additive.

With yttrium

Without yttrium

stock of common types.

28 Bosch Super plus

Double platinum 29

Tested in the world of racing, successful in


everyday use. Bosch Super plus

Top performance in every phase:


Bosch Double Platinum

An unconventional material is the source of the out-

The advantages of Bosch Super plus:

This spark plug deserves a medal.

Bosch Double Platinum:

standing reliability of Bosch Super Plus spark plugs:

ff Excellent protection against corrosion

The platinum on both electrodes gives the Bosch

Convincing from start to finish

nickel-yttrium. This rare earth metal alloy guarantees

ff Outstanding ignition reliability

Double Platinum its name and helps to ensure out-

ff Extremely smooth operation and superior engine

top performance in motor sports.

ff Compact range with 54 spark plug models

standing ignition reliability and wear resistance.

In everyday use it enhances ignition reliability and

ff Optimum warehousing

Whats more, the center electrode with its thickness

ff Engine and catalytic converter protection

reduces wear.

ff Simple ID number system

of just 0.6 mm permits a lower ignition voltage in

ff Maximum service life and wear resistance

combination with higher-energy ignition sparks.

ff No misfiring throughout the entire service life

elasticity

ff Optimum suppression ensures no interference


with electronic systems
ff Lower ignition voltage, ideal for turbo engines

Geared to all requirements:

Just right for the workshop:

The Bosch Super Plus is available

Packs of 1 and 10 to suit every need

individually and in packs of 4 or 10

30 Bosch Super 4

31

Bosch Super 4:

High capacity: The Bosch Super 4 for


demanding applications

ff The first spark plug with four thin ground


electrodes
ff Reliable ignition based on the surface air
gap principle
ff Superior engine elasticity and high ignition
reliability
ff Factory-set electrode gap

Surface air gap design

Crucial advantages of the Bosch Super 4

The surface air gap design selects the optimum path

ff Superior engine elasticity for better response

for ignition between the center electrode and the

ff High ignition reliability and thus sound protection

ground electrode. This occurs by way of either an air


gap or a surface air gap. The air gap spark follows a
direct path and thus ignites the air-fuel mixture. The

for engine and catalytic converter


ff High power yield thanks to a 60% increase in
spark plug efficiency

surface air gap spark travels over charge carriers on

ff Risk of misfiring reduced to a minimum

the tip of the insulator nose.

ff Enhanced acceleration performance and optimum


engine efficiency
ff Far smoother operation
ff Also ideal for retrofitting on older vehicles

Bosch Super 4 the first spark plug with four

Innovative technology for even more efficient engines

ground electrodes

ff Surface air gap principle with four ground electro-

This heavy-duty retrofit spark plug is a real power


house for every engine. The Bosch Super 4 is the
first spark plug to feature four thin ground electrodes
with a pointed center electrode made of a chromiumnickel alloy. It has a sheat a sheathed copper core and
operates on the surface air gap principle. A unique
combination: The ignition spark always selects the
optimum path for reliable ignition to suit the engine

des the optimum spark gap is always selected.


ff Ground electrode wear is evenly distributed over
all four electrodes.
ff The silver-plated center electrode ensures good
heat dissipation and thus avoids the risk of autoignition due to overheating.
ff Spark plug efficiency is enhanced by the up to 40%
increase in ignition energy.

load.

Always complete: The practical packs of 4


in a box or the blister packs of 4 for large
display areas.

32 Bosch Super special

33

Water, snow, garden: The Bosch Super special


is always ready for action

Special spark plugs for special requirements:


The full range from Bosch

Not just for cars

Spark plugs with special electrodes

As the inventor and worlds largest manufacturers,

The comprehensive Bosch range is rounded off by

Bosch have produced more spark plugs than any

special spark plugs for special applications. These

other company. And not just for cars either. Bosch

are of differing design to suit the corresponding

For gardening enthusiasts and professional users:

Just a few types for all sorts of equipment:

can supply the appropriate spark plugs for virtually

usage conditions and installation situations on the

Mobile, motorized implements are becoming ever

The compact Bosch self-service range.

any gasoline engine. They are, after all, an important

engine.

more popular and consequently the demand for spark

In the Super special self-service range you will always

system component for economical, clean and efficient

plugs for low-power engines is also increasing. The

find the right spark plug. The customer only need a

fuel combustion.

compact self-service range for gardening implements

small sales area, as the compact assortment covers

and forestry equipment from Bosch: Bosch Super

virtually every application:

Unrestricted mobility

special.

ff Leaf blowers

ff Power supply units

Bosch Super, Super plus and platinum spark plugs

ff Garden tractors

ff Lawnmowers

are also used on

ff Hedge trimmers

ff Lawn trimmers

ff Motorcycles and scooters

ff Chain saws

ff Snow cutters

ff Jetskis and snow mobiles

ff Leaf vacuums

ff Snow throwers

ff Boats

ff Power scythes

ff Water pumps

Powerful spark plugs for demanding applications


ff Spark plugs for motor sports: Designed for constant
full load operation and high thermal loads
ff Fully shielded spark plugs: The insulator is
surrounded by a metal shielding sleeve. Added
advantage: Water-tight shielding
ff Spark plugs with resistor: A resistor in the lead stops
disturbance pulses being relayed to the ignition
cables and thus prevents interference radiation
ff Spark plugs for stationary engines and emergency
generating sets: For exacting demands associated
with sustained loading or large engine size

Bosch Super special all the advantages at a glance:


ff Outstanding starting performance and reliable ignition over
the entire service life thanks to a chromium-nickel ground
electrode.
ff Nickel-plated shell and threaded section for effective protection
against corrosion and thread seizure.
ff Sealed connection of center electrode and terminal stud
ensures a permanent, tight connection and good electrical
conductivity.

34 Spark plug type designation

35

Quick and easy identification instead of a

How to find the right type:


The Bosch spark plug type designation

tedious search:
The key below provides an instant explanation
of the spark plug code.

M 14x1,25

Water-tight,
for shielded
ignition cable
dia. 7 mm

Water-tight, for
shielded ignition
cable dia. 5 mm

M 14x1,25

Surface gap
spark plug
without ground
electrode

M 18x1,5
Surface gap
spark plug
with ground
electrode(s)

13

12 11 10 9 8 7 6 5 4 3 2 09 08 07 06

Thread length
Spark position

*11,2

*11,2

19

19

Version

Copper

Nickelyttrium

19

M 10x1

Surface air gap


spark plug

19

17,5
17,5

M 14x1,25

Burn-off resistor

T
0,7

X
0,9

U
0,8

Platinumiridium

Y
1,1

V
1,0

Z
1,5

10
15
22
222
23
232
30
302
33
332

1,3

SUPER
plus

2,0

Quickheat

9,5

7,8

19

M 14x1,25
With interference
suppression
resistor

26,5

25

technology

*The thread length for spark plugs with seat shape D and spark position A or B is 10.9 mm.

17,5

M 12x1,25

1)

16

M 12x1,25

For low-power
engines

26,5

12,7
4

25

7,8

26,5

25

26,5

25

14

M 12x1,25

Differences from basic design


P0 design with Ni ground electrode
Binary ground electrode
Special length thread
Extended insulator nose
PSA design

) Double hexagon

9,5

0
1
2
3
4
9

Silver

For motor
sports

17,5

M 12x1,25

W
S

20,8

Platinum

14

Ce

Electrode
material

M 10x1

16

17,5

17,5

Type of
electrode

Half thread

17,5

19
19

16

M 12x1,25

Heat range
code number

12,7

14

26

Type

12,7

M 14x1,25

1)

14*

Gr
ou
Bi nd
na ele
yt ry n ctr
tri ic od
las um w kel- e
e i
pl r-all th
at oy
inu ed
m
inl
ay

M 18x1,5

16

Gr
ou
Mo nd
n el
wi o ni ectr
th ck od
pl lase el-y e
at r- tt
inu al riu
m loy m
inl ed
ay

16

nt
wi er e
th le
pl wel ctro
at d d
Di inum ed-o e
am w n
1. ete afe
1 r0 r
m .
m 8
po or
ss
Ce
ib
nt
le
wi er e
th le
c
w
pl el tro
at de d
e
i
Di num d-o
am w n
0. ete afe
8 r0 r
m .
m 6
po or
ss
Gr
ib
ou
le
Mo nd
no ele
yt ni ctr
tri ck od
um el e
-

20,8

Gr
o
Bi und
na el
yt ry n ectr
tri ic od
um ke e
l-

1)

Seat shape
and thread

36 Spark plugs for gas engines

37

Fully equipped to deal with the special

Reliable gas engine ignition:


Bosch can offer the right solution

features of gas engines


ff The right spark plug for every gas
application
ff Ideally suited to the particular
requirements of gas engines
ff Platinum spark plugs help to counteract
the high degree of wear

Different fuel, different spark plug

The differences between gasoline and gas engines

Adaptation of spark plugs to gas engines

Before they decide on a gas engine, motorists weigh

There are a few points to note when converting an

Spark plugs from Bosch can be perfectly matched to

all sorts of aspects: Consumption, safety and avai-

engine from gasoline to gas operation:

the requirements of gas engines:

lability of the fuel etc. In the trade, however, it is

ff Gas requires a higher ignition voltage than gasoline.

ff Automatic compensation for the higher ignition

essential to be familiar with the particular technical

Whereas the level required for an engine running

voltage needed is provided by a gas control unit in

features of gas engines. For instance, that new spark

on gasoline is 14 kV for example, 16 kV are needed

combination with an integrated ignition timing

plugs with modified properties are required when

for reliable ignition under the same conditions

advance feature. If this is not available, use a

converting an engine to gas operation.

when using gas.

spark plug with a 0.7 mm electrode gap or the

ff Gas operation results in a higher operating


temperature in the combustion chamber.

Regular replacement maintains performance and

ff Spark plugs with a lower heat range should be

ff Electrode wear is accelerated by the higher ignition

protects the engine

gap is to be adjusted accordingly.

Spark plugs in gas engines are subject to greater

voltage and the higher operating temperature in

wear than in gasoline engines. They should therefore

the combustion chamber

selected to offset the higher operating temperatures


in the combustion chamber.

be replaced at intervals of 15000 km at the latest.

Bosch spark plugs: Ideal for gas engines as well

As they have no way of knowing beforehand which

Bosch spark plugs excel thanks to their high quality.

engine the kit is going to be fitted in, manufacturers

Whats more, the right spark plug is available for

of conversion kits are not generally in a position to

almost every vehicle. Thanks to the material used,

provide any definite information about the spark plugs.

Bosch platinum spark plugs in particular are subject

Your competence and technical expertise are called

to less wear, have a longer service life and are thus

for to be able to decide on the correct spark plug and

ideally suited to use in gas engines.

the appropriate replacement interval.


Greater competence guarantees more customers
Its worth investing the effort to find out more about
the special requirements for spark plugs for gas-driven
vehicles. This is a good way of keeping customers,

Switching from gasoline to gas means changing the spark plugs

gaining new ones and earning the loyalty of motorists


who switch to gas.
Gas engines reduce fuel costs, protect the environment and they
need the right spark plugs to suit their special requirements.

38 Bosch diagnostics

39

All the professional needs to know:


Bosch ESI software and testing systems

Everything about ignition systems from a single source

Useful hints:
Practical spark plug advice from Bosch

All from one supplier

Complex interlinked motor vehicle systems demand


ever more qualified diagnosis from workshops in
addition to in-depth repair expertise. Thanks to Bosch

Bosch diagnostics

Diagnostics, workshops can acquire detailed system

Bosch parts

Flat seat

Fitting spark plugs with a torque wrench

Conical seat

Tightening torque (N m): 10N m 1 kpm for dry,

non-greased/non-oiled threads and new seals.

M 10 x1

10...15 10...15

M 14 x1,25

20...40

10...20

Reduce tightening torques by 1/3 for lubricated

M 12 x1,25

15...25 15...20

M 18 x1,5

30...45

15...23

threads or on re-installation.

M 14 x1,25 l<12,7 mm 20...25 15...20

information and the full range of testing systems all

ESI[tronic] software

from the same supplier. Modern, high-performance

Aftermarket products

M 14 x1,25 l>12,7 mm 20...40 20...30


M 18 x1,5

diagnostic equipment, technical training courses and

Testing systems

Replacement parts

necessary repair assistance.

Service training

New products

ESI[tronic] software for diagnosis and service

Technical hotline

Exchange

30...45 20...35

1 In cast iron 2 In light alloy

1 In cast iron 2 In light alloy

a hotline service provide workshops with all the


Fitting spark plugs without a torque wrench
Screw in the spark plug by hand until it is seated in
the cylinder head. Spark plugs with a flat seat and
new seal are then to be given a further approx. 90
ESI stands for Electronic Service Information and

turn with a spark plug wrench. The further turning

The efficient motor

is the name of the software used in the course of

angle for spark plugs with a conical seat and spark

vehicle workshop of the future

Service work. This includes:

plugs with a used flat seal is approx. 15.

ff System trouble-shooting
ff Maintenance

Tailor-made for the workshop

ff Repair instructions

The ESI[tronic] software was developed with workshop

Spark plug terminal nuts

requirements in mind. Straight forward operation,

Engines may be fitted with spark plugs of a different

rapid access and a standard system approach for all

length to Bosch spark plugs.

types of vehicle help to make ESI[tronic] software a

1. Screw out the old spark plugs.

user-friendly information tool. Broad market coverage

2. Compare to new Bosch spark plugs.

Bosch can offer a wide range of test equipment for

and constant updating are a matter of course. The

3. If applicable, replace the screwed-on terminal

trouble-shooting and diagnosis. The modular design

software packages are of modular design, so that

nut A with the longer terminal nut B provided.

of all components makes this a sound investment.

ignition system specialists are able to subscribe to

Testing systems: Professional diagnosis for all makes

exactly whichever Info types they choose.

Specially for ignition systems:

Note:

ff ESI[tronic]-C for diagnosis including trouble-

Insofar as they were not made by the motor vehicle or engine manufacturer, the spark plug recommendations were drawn up by Bosch.

shooting
ff ESI[tronic]-M with a wealth of information on
gasoline systems

They apply to standard operating conditions for series models, however not to racing, special and high-performance versions (unless
specifically mentioned). Particular operating conditions may make it necessary to use different heat ranges. If spark plugs with the
specified electrode gap are not available, the electrode gap must be adjusted using the Bosch spark plug gauge.

40 Advanced training

41

Theoretical and practical instruction:

Always one step ahead with: Service training,


technical hotline and information database

ff Modern Training Centers throughout


the world
ff Up-to-date, in-depth training courses
ff 24-hour online database
ff Technical hotline offering expert assistance
ff Detailed informative publications

Service training: Worldwide and never far away

Online Help: Problem solutions are just a mouse


click away
Workshops have round-the-clock access to the extranet-

The training program includes courses on all ignition

based Bosch Online Help information database.

systems from Bosch and other manufacturers.

Containing lists of all the problems encountered in

Learning by doing means: All the instructors have a

recent years, it is a source of efficient self-help for

wealth of workshop experience and concentrate on

dealing with Service or repair difficulties. Enquiries

practical aspects. The training courses are held on

regarding topics not listed can be submitted by way

modern workshop premises using the latest vehicle

of a Trouble Ticket. Bosch specialists will then

models. Bosch Training Centers can be found all over

tackle the problem and give an immediate response.

the world. Courses of instruction, e.g. for wholesalers,


can also be held as required at individual locations.

Professional knowledge on call

Training specifically on gasoline injection is also


available in e-learning form.
If all else fails, just pick up the telephone: Our technical
The home of knowledge:

hotline will be only too pleased to assist workshops

The Plochingen Service Training Center

and the aftermarket. Whatever the question relating

The new Service Training Center in Plochingen was

to Service and repair, experienced specialists can

opened in 2005. Around 7500 employees from official

provide further assistance for all makes. This not only

bodies, associations and workshops as well as Bosch

saves time, it also ensures customers of competent,

instructors from abroad receive training here every

inexpensive help.

year.

In the future, workshop activities will concentrate more on the diagnosis of


interlinked systems and the specific replacement of high-grade components
rather than just the traditional replacement parts business. The professional
Service training courses offered by Bosch provide the ideal basis for workshops to meet this challenge. This theoretical and practical instruction from
Bosch imparts detailed information guaranteed to ensure the necessary
workshop expertise.

42 Sales promotion

43

A wealth of promotional and informative

Advice, information, persuasion:


Top class sales promotion

material:
ff Media presence for a well-known name
and brand acceptance
ff A full range of promotional material from
advertisements right through to catalogs
and brochures

Information for your sales area: Displays

Plain for all to see: Workshop posters

Clear, concise information:

ff Spark plug catalog

Comprehensive information helps to promote sales.

Clear, detailed and perfectly designed to be displayed

Catalogs, fold-out list

ff Super plus catalog

Customers are always glad of information about

just where the information is needed workshop

All the products, all the services. Clearly presented

ff Spark plug special range catalog

their vehicles. And the ideal place to obtain this is in

posters from Bosch.

for rapid identification of the right item.

ff Bosch Duraterm and Super plus catalog

a workshop or aftermarket sales room.

ff Spark plug faces: Cause and effect

ff Small Display: Convenient display with 24 hooks

ff Spark plug design: Technology down to the last

and capacity for 120 Super plus set packs.

ff Fold-out list for rapid assignment of the right


spark plug to the right vehicle model

detail

Dimensions: 130 x 46 x 21 cm (without placement). Order number: 1 987 710 563 Display

All you need to know: Info folders

(stand with 24 hooks incl. back board)

In-depth information, clearly presented, on specific

ff Rack: Convenient rack with 2 shelves and capacity


for 36 Super / Super plus standard packs.
Dimensions: 57 x 62 x 15,5 cm (without placement). Order number: 1 987 710 238 Rack
(2 shelves + head board)
ff Large Display: Visually appealing display with 24
hooks and capacity for 120 Super plus set packs
Dimensions: 210 x 58 x 27 cm (without placement). Order number: 1 987 710 232 Display
(stand with 24 hooks incl. back board)

topics relating to Bosch spark plugs.


ff Spark plug folder provides detailed insight into
the full range of spark plugs from Bosch
ff Low-power engines everything you need to know
about spark plugs in low-power engines
ff Gas applications points to watch when working
with gas-driven vehicles

Experience Bosch competence live: On factory visits, customers have


the opportunity to see test tracks or development centers in action and
to gain a personal impression of the expertise of one of the worlds
largest system manufacturers.

44 Glossary

45

At a glance:
Spark plug facts and figures

Air-fuel mixture / Lambda

Flashover protection

Homogeneous mixture

Insulating paste

Self-cleaning temperature

Surface gap

For complete ignition of the air-fuel mixture

Designed to prevent the high voltage

For engines with manifold injection.

Provides a seal between the ceramic and

High temperature at which carbon residue

Path covered by the spark as it travels

in the combustion chamber, the elements

current surge travelling along the outside

Same Lambda throughout the combustion

the spark plug connector. The use of

is burnt off.

first over the surface of the insulator tip

of this mixture must be in a stoichiometric

of the spark plug. For this reason the top

chamber. Even engines with a lean mixture

insulating paste prevents head sparkover.

This cleans the spark plug.

before jumping to the ground electrode.

ratio. This is the case with 14.7 parts air

part of the insulator is provided with

(large volume of air in the combustion

to 1 part fuel. This ratio is known as

circumferential grooves.

chamber) are operated with a homogene-

Insulator

Shunt

ous charge.

The insulator is made of an aluminum oxide

Branch of a parallel circuit of electric loads.

Lambda. Given a stoichiometric ratio,


Lambda is equal to 1.

Along this path it burns off unwanted

ceramic and insulates the center electrode

Gasoline direct ignition

to ground up to a voltage of 40000 V.

deposits and combustion residue.


Surface air gap/surface gap

In this modern process gasoline is injected

Ignition

Air gap

directly into the combustion chamber of

The ignition process is controlled by the

Path taken by the spark between the

the cylinders under pressure by a common

engine. The ignition system generates a

Insulator nose

electrodes to ignite the fuel-air mixture

rail system. This permits a stratified mix-

regular high voltage. In the form of a spark,

This projects into the combustion chamber

in the combustion chamber.

ture with less fuel than with conventional

this voltage produces current discharge

and has a considerable influence on the

Sintered-in center electrode

gaps. This in turn considerably extends

injection.

between the electrodes of a spark plug.

heat range of a spark plug.

In the stoving process the center electrode

the service life of the spark plugs.

Auto-ignition temperature
Head sparkover

auto-ignition can become a problem.

High voltage leakage due to dirt or

The air-fuel mixture may be ignited by

moisture. Irregular sparkover of spark

overheated components and cause

discharge.

mixture in the combustion chamber.

Spark paths which can pass through the

Spark plugs operating on the air gap

air and over the insulator. The electrode

principle with just one ground electrode.

gap can be reduced by combining mutually


independent surface air and surface

is permanently joined to the ceramic.

This spark ignites the compressed air-fuel

This is roughly 850 C. Above this limit

Single ground electrode

Lean mixture

Terminal nut

The air-fuel mixture contains more air

Spark duration

Contact between spark plug connector

Ignition energy

than is needed for ignition. This results in

The ignition spark duration between the

and spark plug center electrode. Passes

The forward current and the design para-

misfiring. Fuel consumption increases

electrodes (approx. 2 ms). This must be

the ignition voltage to the electrode.

meters of the ignition coil determine the

while the power output decreases. As of

maintained long enough for the air-fuel

Heat range

amount of energy stored in the ignition

a certain volume of air the mixture is no

mixture to be ignited.

The heat range is an index of the thermal

coil and used as ignition energy (ignition

longer ignited.

Battery-based ignition

design of a spark plug.

spark). The correct ignition energy is

Use of an ignition coil to generate a high

It indicates the capacity of the spark plug

important for ignition of the air-fuel

Multiple ground electrode

The air-fuel mixture is prepared such that

Type designation

voltage and produce the spark.

to withstand thermal loads based on the

mixture, as a high power output and low

Spark plugs operating on the surface gap

at the moment of ignition there is only an

The spark plug specifications are

balance between heat absorption and

emission levels can only be guaranteed

or surface air gap principle with two, three

ignitable mixture (Lambda ~ 1) in the area

contained in the type designation. This

dissipation.

by efficient ignition.

or four ground electrodes.

of the spark plug. The mixture in the rest

shows all the principal features of the

of the combustion chamber is very lean

spark plug with the exception of the


electrode gap.

uncontrolled ignition which could


damage or even destroy the engine.

Electrode gap

Torque
Unit of force for fitting spark plugs.

Stratified charge

The electrode gap is the shortest path


between the center and the ground

Heat shrinking process

Inner seal

Rich mixture

and barely ignitable (Lambda ~ 10). This

electrode. The voltage is crucial to the

This produces a gas-tight joint between

This forms the gas-tight connection

The air-fuel mixture contains more fuel than

improves the efficiency of the engine with

electrode gap. If the voltage is too low,

the nickel-plated spark plug body and the

between the insulator and the metal

can be burnt. On cold starting, greater

regard to emissions and fuel consumption.

sparkover cannot take place.

insulator.

body and provides heat dissipation.

quantities of fuel have to be injected to


compensate for the losses caused by fuel
condensation.

46 FAQ

47

Frequently asked questions:


Answers from the experts for experts

What is the task of the spark plug and why are

self-igniting parts of the mixture that are ignited

Does anybody check on the appropriate heat range

To which types of load are spark plugs exposed?

spark plugs crucial for the life of the engine?

without a spark. Combustion occurs significantly

for a particular engine and what are optimized

Spark plugs may have to withstand electrical,

The spark plug has to ignite the air-fuel mixture in

faster than normal combustion.

spark plugs?

mechanical, chemical and thermal loads.

the combustion chamber of a gasoline engine by

Pressure fluctuations with high pressure peaks and

Bosch has developed a new method specifically to

means of an electric spark. During operation, spark

high frequencies occur, which interfere with the nor-

reflect the demanding requirements of direct injec-

Electrical requirements

plugs become contaminated and are subject to

mal pressure progression. If the combustion pressu-

tion gasoline engines.

Spark plugs must remain functional under extreme

wear. The resulting increase in the electrode gap

re reaches the walls of the combustion chamber,

This simulation is the only one of its kind in the

conditions. The ignition process involves voltages of

leads to a higher ignition voltage requirement. If the

this produces the metallic knocking noise.

world and is used to design virtual spark plugs and

up to 40 000 V and combustion chamber tempera-

required ignition voltage exceeds the ignition voltage

Serious engine damage may result if the problem is

visualize the processes in the engine. It also opens

tures in excess of 1 000C. Optimum insulation is

provided by the ignition coil, this results in misfiring.

not rectified in good time.

up new options for perfect derivation of measuring

essential.

Is the electrode gap set during production?

What is the heat range of a spark plug?

At critical operating points in the partial load and

Mechanical requirements

The electrode gaps are set during production. The

When cold, the engine is operated with a rich air/

idling speed range, optimized spark plugs result in:

Spark plugs must be capable of withstanding alter-

electrode gap does not normally need to be reset

fuel mixture. As a result, incomplete combustion can

Increased ignition reliability

nating pressures of around 100 bar in the combusti-

when changing the spark plug.

cause soot, which accumulates in the combustion

Reduced fuel consumption and pollutant emissions

on chamber.

The appropriate electrode gap for each vehicle appli-

chamber and on the spark plug.

Optimum catalytic converter protection

They must exhibit constant, high mechanical

cation can be found in the Bosch spark plug catalog.

This residue contaminates the insulator nose and

The electrode gap of the spark plug is specified on

produces a conductive connection between the cen-

Can the same spark plugs still be used after alte-

the packaging.

ter electrode and the spark plug shell. This shunt

ring the power output of an engine?

Chemical requirements

circuit discharges part of the ignition energy and

If the power output of an engine has been modified,

Resistance to chemicals in the combustion chamber

What is pre-ignition?

reduces the energy required for combustion.

e.g. on account of a turbocharger, a blower or other

and aggressive (corrosive) residue from the combu-

Pre-ignition (auto-ignition) is an uncontrolled ignition

The deposits of combustion residue on the insulator

systems, the recommended spark plug cannot be

stion process.

process in which the temperatures in the combusti-

nose depends greatly on the temperature and prima-

used. It may be necessary to employ a spark plug

on chamber rise so sharply that severe damage to

rily occurs below around 500 C.

with a lower heat range to compensate for the extra

Thermal requirements

the engine and the spark plug occurs. At full load

At higher temperatures, the carbon-containing resi-

heat generated by the engine. In such cases, Bosch

Thermal shock resistance (hot exhaust gases and

operation, auto-ignition can occur at the following

due on the insulator nose burns and the spark plug

recommends seeking the advice of an engine

cold intake air-fuel mixture). Good thermal conduc-

points:

cleans itself. It is important to choose the correct

construction expert to help determine the correct

tion of the insulator and the electrodes is essential

At the tip of the spark plug insulator nose

spark plug heat range and to ensure that the tempe-

heat range.

for reliable operation.

On the outlet valve

rature range of the spark plug remains between 500

On the cylinder head gaskets in front

and 900 C. In this range, the spark plug cleans itself

What are the recommended replacement intervals

On deposits that become detached

but without getting hot enough to cause severe wear

for spark plugs?

to the electrodes due to oxidation and hot gas corro-

The spark plug replacement interval is generally indi-

sion or to result in pre-ignition.

cated in the owners manual. Bosch advises having

results and optimization of spark plugs

What is meant by engine knocking?

strength under all operating conditions.

Engine knocking is uncontrolled combustion with a

the spark plugs inspected once a year and replaced

very rapid pressure increase.

if necessary to ensure optimum engine performance.

This kind of uncontrolled combustion is caused by

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