Tips & Technology

For Bosch business partners

Current topics for successful workshops

Subject / Concern : Service procedure to diagnose heavy black smoke and poor AA/SAI-TT : 07
mileage. 23.08.2011
Affected Model : Ford Ikon Version : Gasoline
Engine Cubic Capacity : 1.3 L Variant : All

Summary : Vehicle starts emitting heavy black smoke after driving for approx 10-15 kms, fuel
consumption increases by 40%. At times the catalytic converter becomes red hot and engine tends to
back fire. In many occasions such complaints do not register DTC

Details of Trouble Diagnosis :

If there is a concern of black smoke and poor mileage in the above mentioned vehicle model,
diagnose the complaint as per the procedure mentioned below

1. Take out the spark plugs and inspect for electrode erosion and spark jump gap. In case spark
plug electrodes are eroded, replace the spark plug set.

2. Check the functionality of the ignition coil pack by holding each spark plug and touching the
ground electrode to the engine head. Crank the engine and check the brightness of the spark
jumping across the gap. If the spark is bright and is clearly
visible in day light then the Ignition coil is doing the job. If
not, replace the Ignition coil pack along with HT cable

Take the vehicle road test after ensuring the Ignition coil
pack, HT cable and spark plugs are in good condition. If
the complaint still persists proceed with next step.

3. Connect the lambda sensor output signal to any one of the

channels of the KTS oscilloscope and view sensor signal
output waveform.

Note: When performing lambda sensor checks, it is important to take measurements @ idle & 2000 rpm. Ensure
that you start taking measurements only after 2-3 minutes of engine start.

In case of discrepancy or inquiry please write to:

Mailbox.service2@in.bosch.com
The above figures depict good as well as faulty lambda sensor wave form. The first oscilloscope
screen shows output signal of faulty lambda sensor where in the response time of the lambda sensor
is 9 sec. A good lambda sensor response time should be 2 sec / cycle.

Further the ideal output voltage of the good lambda sensor should be in the range of 0.4~0.6 V. If the
output voltage stays continuously within 0.4V or less, it is clear that the fault lies with lambda sensor
and this needs replacement.

Concern Correction / Fix : The above mentioned complaint is generally caused by erratic lambda
sensor signal. Replacement of lambda sensor should resolve the mentioned complaint.

Bosch Parts / Part No. to fix above concern :

1. Universal Lambda Sensor / 0 258 986 507
2. Ignition Coil Pack / 0 221 503 490
3. Spark Plugs / 0 242 229 796 or 0 242 229 785

* Abbreviation :
HT Cord < High Tension Cord >
DTC < Diagnostic Trouble Code >

In case of discrepancy or inquiry please write to:

Mailbox.service2@in.bosch.com