Bosch is celebrating a significant milestone – the production of 50 million injection valves and 10 million high-pressure pumps that feed the injectors. A key in developing more economical engines, GDI produces up to 15 percent lower fuel consumption and CO2 emissions, while maintaining power and performance.
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Gasoline direct injection systems are enjoying rapid market growth, and only last year the 25 millionth injection valve and the 5 millionth high-pressure pump rolled off the line in the Bosch global manufacturing network. Within a year the total number of injection valves and pumps manufactured has doubled.
When gasoline direct injection is used in combination with turbocharging and electronic engine management, it results in a reduction in fuel consumption and CO2 emissions, and achieves this while producing good engine torque and performance. The combination of turbocharging and gasoline direct injection also permits downsizing. Lighter, smaller displacement engines produce comparable power and performance while consuming less fuel and emitting less CO2.
Keep fuel system pressure, voltage in mind when servicing GDI
“When servicing direct injection systems it is important to keep in mind the fuel pressures and high voltage the systems generate,” says Clayton Lindgren, Technical Specialist, Engine Systems for Bosch.
Among the key elements in GDI are the pressure of the fuel system and the design of the injection valve. Up to seven individually positioned injection holes in the Bosch injection valve enable the spray pattern to be flexibly adapted to different engines. The high-pressure injection valve and high-pressure pump are designed for system pressures of up to 200 bar (about 2900 psi), and make a major contribution to optimum, more fuel efficient, combustion.
“A direct injection system typically will operate from 725 psi up to 2050 psi. Bleeding down the fuel system properly is an important facet of service. Technicians should understand and follow the manufacturers’ procedures to relieve the fuel system pressure before performing any repairs to a GDI system, and carefully diagnose the fuel injector voltage signals. High-pressure GDI injectors often actuate at approximately 70 volts and 10 amps, with the capability to rise to over 120 volts,” Lindgren emphasized.
Bosch Launched GDI
Bosch launched gasoline injection technology for passenger vehicles in 1951, initially for the two-stroke engine of the compact Gutbrod Superior car. Three years later, gasoline direct injection for four-stroke engines debuted in the legendary gull-wing Mercedes-Benz 300 SL. This paved the way for the development of passenger car gasoline engines that combine higher performance with lower fuel consumption and emissions. The Bosch HDP pump went into series production in 2006 and was initially featured in the General Motors Ecotec engines. The Bosch HDEV5 injection valve had its premiere that same year in the PSA/BMW Prince engine.
The compact, lightweight HDP5 high-pressure pump and stainless steel components of the GDI system are highly contamination-resistant, and in addition to gasoline can handle fuels such as ethanol, making them suitable for worldwide use. Bosch currently produces high-pressure pumps and injection valves at its lead plants in Bamberg and Nuremberg (Germany), as well as in Charleston (U.S.), Bursa (Turkey), Wuxi (China), and Korea.
As more and more auto manufacturers opt for downsizing, the international market for gasoline direct injection systems is steadily growing, and estimates are that by 2015, the share of gasoline direct injection will triple to 18 percent of all vehicles manufactured worldwide.
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