Technical and Sales Information

Oxygen Sensors
 Bosch Oxygen Sensors Bosch Oxygen Sensors

Technical and Sales Information Technical and Sales Information

This booklet is intended for your use as a sales and technical training reference. It answers many questions most Question 1
commonly asked by: What do oxygen sensors do, and where are they located on my customer’s vehicle?

• Automotive parts sales professionals Answer

• Automotive service and repair professionals Based on the oxygen content of the exhaust gas, the oxygen sensor located upstream of the catalytic converter sends a
• DIY (do-it-yourself) customers signal to the engine control unit (ECM), which adjusts the air/fuel mixture to the optimal level. Almost all petrol powered
• DIFM (do-it-for-me) customers vehicles newer than 1986 have at least one oxygen sensor. Many newer vehicles have at least two sensors, including possibly
Please review the answers to these questions on the pages that follow. Becoming knowledgeable about the features and one which is downstream of the catalytic converter. This sensor’s signal is used by the ECM to determine if the catalytic
benefits of Bosch Oxygen Sensors will be your final assurance that each oxygen sensor leaving the shelf is going to give every converter is functioning properly.
customer what they want…best-in-class performance and maximum service life. Above all, look forward to higher customer
Oxygen sensors are found in the vehicle’s exhaust system, but the exact location will vary depending on the year and model
satisfaction when you sell Bosch Oxygen Sensors.
of the vehicle. Therefore, to accurately pinpoint oxygen sensor location, use your standard reference source or the owner’s
guide for that particular vehicle.
Commonly Asked Questions Answer
1. What do oxygen sensors do, and where are they located on my customer’s vehicle? . . . . . . . . . . . . . . . . page 3 Question 2
Why should worn-out oxygen sensors be replaced?
2. Why should worn-out oxygen sensors be replaced? . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Page 3
Answer
3. When should oxygen sensors be replaced? . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Page 3
Replacing a worn-out* oxygen sensor will improve fuel economy, improve your customer’s overall vehicle performance,
4. What features and benefits make Bosch Oxygen Sensors stand out from all the others? . . . . . . . . . . . . . Page 4 drastically reduce exhaust emissions, and help to prevent premature failure of the expensive catalytic converter. This is why
checking for, and replacing, worn-out oxygen sensors is an important part of regular vehicle maintenance.
5. Is a replacement Bosch Oxygen Sensor comparable to the high-quality,
original equipment sensor that it is replacing? . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Page 6 A worn-out oxygen sensor: Replacing a worn-out oxygen sensor:

6. Can a thimble-type sensor be replaced with a planar-type sensor, or vice versa? . . . . . . . . . . . . . . . . . . . Page 6 Wastes fuel Saves money in fuel costs
Can cause engine performance problems, such as surging and
7. Should I recommend Bosch Direct Fit Oxygen Sensors with OEM connectors Improves engine performance
hesitating
or Bosch Universal Oxygen Sensors? . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Page 6
Is a major cause of excessive harmful exhaust emissions Reduces air pollution
8. Are Bosch Universal Oxygen Sensors easy to install? . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Page 7
Prevents premature failure of the expensive catalytic
9. How is Bosch leading the way in oxygen sensor technology? . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Page 7 Accelerates catalytic converter damage
converter

Question 3
When should oxygen sensors be replaced?
ECM

Answer
Oxygen
Sensors “Recommended Check/Replace Intervals“ can be located in the Technical Data section in the Bosch Oxygen Sensor
catalogue. The check/replace interval is not the only factor in determining whether an oxygen sensor may need to be
replaced. If your customer’s vehicle shows signs of increased fuel consumption, poor engine performance, or excessive
emissions, the oxygen sensor should be tested. If the “Check Engine” light on the vehicle is illuminated, retrieving the code
stored will help you determine whether a new oxygen sensor is required. Remember that deterioration of the oxygen sensor
generally occurs over time, so your customer will not see instant failure. The ability of modern management systems to
“adapt” can easily cover a faulty oxygen sensor. A faulty oxygen sensor can result in a rich “shift” of the vehicles fuel map.
This results in the vehicle being rich accross the entire driving range.
Catalytic Converter
*Oxygen sensors with 1- or 2- wires typically wear out after 50,000-80,000 Kms, while 3- or 4- wire sensors typically wear out
after 100,000 Kms.
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 Bosch Oxygen Sensors Bosch Oxygen Sensors

Technical and Sales Information Technical and Sales Information

Question 4 Planar Style Heated Oxygen Sensor

What features and benefits make Bosch Oxygen Sensors stand out from all the others?
Coated Improved
Laser Weld and Viton® Threads Protection Tube
Sealing System
Answer
• All Bosch Oxygen Sensors feature the most advanced ceramic technology for unparalleled quality and performance
(see detail below).

• Each Bosch Oxygen Sensor is function tested in 1000˚C heat to ensure 100% accurate sensor performance.

• All Bosch Oxygen Sensors are laser welded and totally submersible to seal tight and protect against contamination
for long life.
Thimble Style Heated Oxygen Sensor
Ceramic Seal
Double-Laser Packing Ceramic Support Tube
Patented Ceramic Welded Stainless
Protection Tube Element Steel Body Planar Sensor Element
with Integrated Heater

Viton® is a registered trademark of DuPont Dow Elastomers LLC.

Planar Style Oxygen Sensor Ceramic

Sensor Layer 
Fast-Acting Heater (on 1. Porous protective layer
Coated Threads 
3- and 4-wire sensors 2. Outer electrode
only) 
3. Sensor sheet
4. Inner electrode 

Air Duct Layer
5. Air duct sheet
Thimble Style Oxygen Sensor Ceramic 
Heater Layer
Base Ceramic 
6. Insulation layer
Probe
7. Heater

8. Insulation layer
9. Heater sheet

10. Terminals

Patented
Platinum
Power Grid
Fine Particle Coarse Particle
Filter Filter


Bosch Patented Double
Layer Protection System

1. Planar sensor element with integrated heater requires less power to activate, and reaches operating
1. Tough base ceramic probe combines zirconium and yttrium to resist cracking. temperature more quickly than a thimble element, reducing harmful emissions during the critical cold
start phase.
2. Patented Platinum Power Grid for maximum service life.
2. Improved protection tube design provides increased thermal resistance for long life.
3. Patented double layer protection system for optimized sensing performance.
3. Sintered, one-piece ceramic element is highly stable, resisting damage due to vibration, for precise
4. World’s only double laser-welded, submersible sensor to prevent failure from water splash performance over a long service life.
and other contaminants.
4. Submersible, with double laser weld and Viton® sealing system to prevent failure from water splash and
other contaminants.
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 Bosch Oxygen Sensors Bosch Oxygen Sensors

Technical and Sales Information Technical and Sales Information

Question 5 Question 8
Is a replacement Bosch Oxygen Sensor comparable to the high-quality, original equipment sensor that it is replacing? Are Bosch Universal Heated Oxygen Sensors easy to install?

Answer Answer
Yes! Every Bosch Oxygen Sensor sold in the aftermarket meets or exceeds original equipment specifications, and frequently Yes! Bosch Universal Heated Oxygen Sensors feature a revolutionary patented connection system featuring specially
the Bosch replacement sensor is an improvement over the original equipment sensor that came on the vehicle. As a matter engineered, high heat resistant Posi-Lock® Connectors which can be unscrewed and reconnected in case of a wiring
of fact, Bosch invented the automotive oxygen sensor and today is the world’s largest producer of oxygen sensors with over mistake. Each Bosch Universal Sensor is manufactured with a 600mm sensor wire to allow maximum replacement of worn
350 million units manufactured since 1976. In addition to the aftermarket, Bosch currently supplies oxygen sensors to 38 wire on the OEM sensor being replaced.
original equipment manufacturers worldwide, including Ford, Holden, Mitsubishi and Toyota.
Most importantly, no special tools are required to install Bosch Universal Sensors and all sensors include user-friendly
From our state-of-the art manufacturing facilities in the USA and Germany, through our rigorous research and development instructions.
and quality control programs, to our in-house emissions test labs, you and your customers can count on Bosch Oxygen
Sensors for superior performance and maximum service life. Diagram 3 — Bosch Patented Universal Sensor Connection System

Question 6
Can a thimble-type sensor be replaced with a planar-type sensor, or vice versa?

Answer
Extensive vehicle testing by Bosch has demonstrated that there are somes cases when a planar sensor can be substituted
for an OE thimble sensor. In other cases, such a substitution could cause problems. Always follow Bosch Oxygen
Sensor catalog recommendations to determine the correct replacement sensor(s) for your customer’s vehicle.

To date, there are no known cases where a thimble sensor can be substitued for an OE planar sensor. High-heat
Resistant

Question 7 Posi-Lock®
Connector
Should I recommend Bosch Direct Fit Oxygen Sensors with OEM connectors or Bosch Universal Oxygen Sensors?
Posi-Lock® is a registered trademark of Swenco Products.

Answer
Sensors with OEM connectors are the easiest to install, but sometimes cost more than universal sensors. On the other hand,
Question 9
since numerous unique oxygen sensors are required to cover all vehicles on the road, it may take more time to get the sensor
How is Bosch leading the way in oxygen sensor technology?
with connector that is needed. Your recommendation should depend on whether your customer would rather save time or
money. That’s why it’s a good idea to offer both choices and let your customer make the final decision.
Answer
As the inventor of automotive oxygen sensors, Bosch continues to develop new technologies for the next generation of
vehicles - including planar wide-band sensors.

The Bosch planar wideband sensor has additional ceramic and printed circuit layers. Rather than switching from a low to a
high voltage as the exhaust gas changes from a lean mixture to a rich mixture, the wideband sensor provides a signal to the
engine control unit (ECM) that’s virtually proportional to the amount of oxygen in the exhaust stream. This allows the ECM to
precisely control the air-fuel ratio to maintain the optimum performance level.

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Bosch Oxygen Sensors

The most advanced ceramic technology

for best-in-class performance and maximum service life
Even though oxygen sensors have been standard equipment on most
vehicles since 1986, most people don’t know much about their service
requirements. This booklet is designed to help you explain the benefits of
checking and replacing oxygen sensors to your customers.

With this information, you will be able to sell and install Bosch Oxygen
Sensors with pride, knowing you are providing your customers with the
highest quality sensors available.

Robert Bosch (Australia) Pty Ltd

Head Office
Corner Centre and McNaughton Roads
Clayton, Victoria 3168

www.bosch.com.au