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Technical Customer Information 0 280 K00 849-702Page 1 of16Date 15.10.2007

Robert Bosch GmbH reserves all rights even in the event of industrial property. We reserve all rights of disposal such as copying and passing on to third parties.

Product: NGI Natural Gas Injector

Type: NGI2-DP (Durability Package)

Part Number: 0 280 158 813

Offer Drawing: 0 280 A01 321-702

Customer: Khodro

Valid from: Production

Index Page Revision Date GS-FI/ENI1-Mi

GS-FI/ENI

GS/SCI-P2

GS/SCI

1 - First edition 15.10.07

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Contents

General 3

1. Characteristics 4

2. Operating conditions 52.1 Operating life 52.2 Temperature range 52.3 Permitted media 52.4 Vibration/Shake load 52.5 Key data for full functionality 52.6 Limitations of key data for normal functionality 62.7 Robustness with regard to external media 62.8 Functional values 62.9 Maximum switch-on time 62.10 Flow direction 72.11 Interfaces 72.12 Mechanical strength 72.13 Usage in Bifuel vehicles 7

3. Test data/Test methods 83.1 Flow measurement 83.2 Linearity 83.3 Measurement of minimum opening voltage 93.4 Leakage test 93.5 Measurement of insulation resistance 103.6 Measurement of opening behavior at low temperatures 11

4. Endurance and environmental tests 124.1 Dynamic tests 124.2 Climate tests 134.3 Endurance 13

5. Carrying out testing (production audit tests) 15

6. Field return evaluation 156.1 Zero-mileage return 156.2 Field return 15

7. Type approval according to ECE R110 15

Legally binding signature 16

Further documentation

Bosch Norm: N28 No. 578002500

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General

The NGI2 natural gas injector is only to be used in intake manifold injectionsystems on Otto engines for civil automotive applications. Other applications for

the purpose of preparing or metering fluids or gases (e.g. liquid or gaseous LPG,paints, medicaments, etc.) are not permitted and may cause severe damage.

Safety Information

Bosch CNG components are only suitable for use in OEM (Original Equipment Manu-facturer, i.e. automakers) applications. Usage in other systems, e.g. in CNGaftermarket vehicle conversion kits, could create risks such as component wear ordamage, overpressure, gas release or explosions.

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1. Characteristics

Driver Stage 1 289 918 801 (SEFI)

Test medium Nitrogen (N2)

Operating pressure 700 kPa (absolute pressure)

Test temperature 23C 2C

Test Chapter Nominal Tolerance Assessment

Nominal flow 3.1

Qstat 3.1 10.40 kg/h 6 % cpk 1(2

qdyn (ti,E= 3.5 ms) 3.1 2.95 kg/h 7 % cpk 1(2

Deviation of linearity 3.2

ti1= 3 ms 3.2 0 % 5 %

ti2= 5 ms 3.2 0 % 5 %

cpk 1(2

Minimum operation voltage UBmin 3.3 -- < 7.2 V cpk 1(2

Leakage rate to the environ-ment

3.4 -- < 0,003 mbar*l/s(1 cpk 1(2

Leakage rate seat 3.4 -- < 0,003 mbar*l/s(1 cpk 1(2

Insulation resistance 3.5 -- 10 M cpk 1(2

Injector resistance REVat20 C

-- 8.5 5 % cpk 1(2

(1Leakage rates are specified in helium at operating pressure according to chapter3.4

(2 valuesof 100% measured injectors must be in tolerance

Proposed correlation factor for dynamic (qdyn) and static mass flow (Qstat)between nitrogen (N2) and natural gas (quality H): 0.72

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2. Operating conditions

The fuel injector acoustics in the overall system were assessed and released bythe customer. Especially the acoustics caused by the expansion of gas has to beavoided by the design of the manifold.

The use of the product is only permitted under the operating specified conditionsspecified in this document. Any change in the product's operating environmentmust be communicated to and released by Bosch. This applies especially forapplications subject to special reliability, robustness and safety requirements.

With regard to handling, storage and installation the following specificationsmust be observed:- Installation specification NGI2: No. see Offer Drawing- Storage and handling recommendation: No. see Offer Drawing

2.1 Operating life

The component is designed for an operating life of 15 years and 380 millionswitching cycles, corresponding to a distance of approximately 240,000 km.The information concerning the design of the product for a certain operating lifedoes not represent a warranty for the properties of the product.

2.2 Temperature range

Temperature range Engine compartment 30C to +125C

Maximum temperatureEngine compartment short-term

(max. 45 minutes)

+135C

Temperature range Gas at injector inlet 30C to +125C

Maximum temperatureGas short-term at injectorinlet (max. 5 minutes)

+135C

Minimum temperatureGas short-term at injectorinlet(max. 5 minutes aftercold start)

-40C

2.3 Permitted media

Natural gas conforming to DVGW Regulation G260; Status 01.2000- Water content: Dew point < -5C @ 10 bar absolute- Filtered to particles < 10 m

- No liquid phase (e.g. oil or other media) in the framework of the condi-tions of use

Deviations can lead to functional changes.

2.4 Vibration/Shake load

400 m/s on product (peak value)Customer-specific check by measuring is required

2.5 Key data for full functionality

Operating

condition

Battery

voltage

Temperature Rail primary

pressure(absolute)

Duration Frequency

of occur-rence

Normal 7.516 V See above 550 700 kPa Any Any

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2.6 Limitations of key data for normal functionality

Operatingcondition

Batteryvoltage

Temperature Rail primarypressure

(absolute)

Duration Frequencyof occur-

rence

Cold start,gas direct

> 7.5 V > 15C gastemp. atinjector inlet& environment

< 700 kPa (2000 x)

Cold start,switchoverfrom gasolineoperation

> 12 V > 5C gastemp. injectorinlet &environment

< 700 kPa (2000 x)

Hot start > 8.5 V 135 C gas &environment

< 700 kPa Temperature< 125C

after 5mins.Full loadafter coldstart

1216 V > -40C gastemp. atinjector inlet

< 700 kPa 5 mins. 300 x

Description of limitations:

Operating condition Limitation

Booster start Not possible with driver stage CJ945

Overvoltage operation 1618 V @ Tamb > 20C with driver stage CJ945

Cold start, gas direct qdyn = f(pulse)

Cold start, switchover fromgasoline operation

qdyn = f(pulse)

Hot start qdyn = f(pressure, temperature)

Full load after cold start qdyn = f(temperature)

2.7 Robustness with regard to external media

The component is resistant to inlet manifold gases and external media:Engine oil (e.g. 0W40); transmission oil (e.g. Titan Gear MP 80); brake fluid(e.g. DOT4); engine cleaner (e.g. P3 solveclean HK), FAM test fuels (e.g. FAM-B).

2.8 Functional values

For gas valves, the metered fuel quantities depend on the following parameters:

- Gas quality Calorific value- Gas temperature Density- Primary pressure (Rail) Density- Battery voltage Valve switch times- Environment temperature Switch times, coil resistance

Compensation for these factors in the course of application of the system isrequired.

2.9 Maximum switch-on time

0,5 h (at 13,4 V Batt, 110C TAmb, 40C TGas)

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2.10 Flow direction

Top-feed

2.11 Interfaces

- Valves fitted decoupled from vibrations through floating fit in o-rings

- Valve tip in inlet manifold positioned outside the stream of the gasolinevalve (for bifuel- or monofuel+ vehicles)

- Injector tip faces downwards when in vehicle to avoid collecting liquids suchas oil or fuel from manifold

- Injector must not dip into liquids that have collected in inlet manifoldAlso see AZ 0 280 A01 321-702

2.12

Mechanical strength

Axial stress: 600 N

Bending stress: 6 Nm

Torsional stress: 4 Nm

The load values are permitted only during the assembly and dismantling proce-dures. Application of force below the manifold side o-ring in the direction ofthe outlet is not permitted.

2.13 Usage in Bifuel vehicles

The gas injector must be operated every 1000 km or once every month for a minimumof 50 pulses.

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3. Test data/Test methods

3.1 Flow measurement

Test conditions

- Test setup: Approved and released Bosch test bench

- Test medium: Nitrogen (N2), Bosch Norm: N28 No. 578002500

- Density: 1.24 kg/m (at 0C and 1.013 bar)

- Test temperature: 23 C 2 C

- Test pressure: Nominal value see section 1, Characteristics

- Driver stage: See section 1, Characteristics

This driver stage is designed only for setting and measuring of injectors. Itworks in similar fashion to the driver in the vehicle, but is not necessarilyidentical.

- Supply voltage for driver stage: 14 V 0.02 V

- Wire resistance: 400 m 20 m

- Cycle time: T = 10 ms

Measurement procedure

The massflow [kg/h] must be measured at a stationary point.

Measurements are to be carried out in the following order:1. Dynamic flow qdyn: Deviation of inlet pressure < 1% of nominal

value; deviation of massflow < 2 % of actual average value for a pe-riod of t >5 sec.

2. Static flow Qstat: Deviation of inlet pressure < 1% of nominalvalue; deviation of massflow < 1% of actual average value for a pe-riod of t >5 sec.

The massflow per lift [mg/lift] can only be a calculated value.

3.2 Linearity

3.2.1 Definition of linearity of an injector (SAE method)

The deviation of linearity of an injector is defined as the difference between

the real dynamic flow rate and the individual ideal flow rate characteristic.The individual ideal flow rate characteristic of an injector is established bycalculating an ideal straight line by linear regression through 5 measurementpoints at ti= 3/4/5/6/7 ms (according to SAE method).

[ ]

10

5 =

xxix qqtm

m

qt

x

s

=

2,05

3.2.2 Calculation method for linearity deviation

The deviation percentage for a given tifrom the individual ideal flow rate can becalculated as:

m = slope of the ideal straight line

ts= delay time (intercept of regression linewith t-axis)

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[ ]( )

1001)(

%)(

=

si

idyn

idynttm

tqtq

with:

qdyn(ti) [%] = linearity deviation at tiqdyn(ti) [kg/h] = dynamic flow at titi[ms] = injection timets[ms] = delay time (intercept of regression line with t-axis)

3.3 Measurement of minimum opening voltage

3.3.1 Definition

The minimum opening voltage (UBmin) is the voltage required from the driver stage,to open the injector under dynamic cold start conditions. It is determined bycontinuously increasing the supply voltage of the driver stage until the injectorjust opens.

3.3.2 Test conditions

In the practical test, UBminis measured with a standard control unit at roomtemperature. The test value is the result of the temperature difference and thecontrol conditions.

- Test temperature: 23 C 3 C

- Cycle time T: 20 ms- Pulse width ti: 10 ms

- Voltage gradient: 1V/s

- Start voltage: 4 VDefinition "injector just opens": Opening time (ton) maximum 9 ms.

Test circuit:

Ubmin

batt

ECU

(DriverStage)

Rcable = 400 m

Fuel Injector

T = 20 ms / ti= 10 ms

3.4 Leakage test

Leakage rate is separated in seat leakage and leakage to environment. Leakagerate to environment includes all possible leak paths generated through operatingpressure without seat leakage. Seat leakage emit exclusive to inlet manifold.

Definition Leakage rate:Leakage is defined as emitted quantity of gas per time. The quantity of gases isdescribed with product of volume and pressure (cm * bar or equivalent mbar * l)

Leakage rate is influenced by

- pressure conditions

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- conditions of gas (particularly viscosity)

- geometrical dimensions of leak pathThe leakage rate corresponds with the geometrical dimensions of leak path. Gasand pressure conditions have to defined:

Leakage rates mentioned in chapter one are referenced to the followingconditions::Gas: HeliumViscosity : 1,9755 *10-5Pa s 0,015 *10-5Pa sTemperature: 21C 2CPressure downstream pa: < 0,05 kPa absolut (vacuum)Pressure upstream pz: operating pressure

The injector must be clean and dry. No liquid phase is allowed.

Test methods:All methods, that have a measurement capablitiy for the in chapter one mentionedvalue, are allowed. In dependance of the used test method a conversion isnecessary. Normaly test method differ from the above mentioned conditions by gas,pressure or temperature.

Examples for conversion by different test conditions:Different Pressure (proven correlation necessary):

=

h

barcm

pp

ppvaluemeteredleakage

az

az **3

2

1

2

1

22

Index 1 terms changed parameters

Different gas:By usage of a different gas the viscosity is changed. The leakage depends recip-rocally proportional to the viscosity:

=

h

barcmvaluemeteredleakage

**

3

1


Viscosities of other gases:Methane: 1,112 *10-5Pa sAir: 1,815 *10-5Pa sNitrogen: 1,772 *10-5Pa s

Different gas and pressure (proven correlation necessary):

=

h

barcm

pp

ppvaluemeterdleakage

az

az ***3

1

2

1

2

1

22


3.5 Measurement of insulation resistance

The insulation resistance is measured between the (+/-) connector pins andhousing. The resistance must not be below the determined value in section 1.

- Test voltage: 750 V D.C.- Test time: 2 secs.

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Measurement of opening behavior at low temperatures

3.5.1 Cold start, gas direct

Parameters:- Duration T [ms]: 690 5

- Drive pulses n [no.]: 9

- Test pressure p1 [kPa]: Operating pressure from 1.- Drive time ti [ms]: 8 0.5

- U batt [V]: 7.5V [ 0.1]

- Temperature [C]: +15

The opening time (ton) is to be measured for each injector and each pulse of alot.ton,av= average(ton, pulse 59) of all injectors of a lotOpening time deviation (ton, pulse 19) may only lie within the following range:Ton,max< ton,av.+ 0,6 ms

Ton,min> ton,av.- 0,7 msFor test of new injector lot size is 8 pcs.For field return tests the lot consists of all injectors out of one engine.

3.5.2 Cold start, changeover from gasoline to cng mode

Parameters:

- Duration T [ms]: 690 5Drive pulses n [no.]: 9

- Test pressure p1 [kPa]: Operating pressure from 1.

- Drive time ti [ms]: 6 0.5U batt [V]: 12V [ 0.1]

- Temperature [C]: +5

The opening time (ton) is to be measured for each injector and each pulse of alot.ton,av= average(ton, pulse 59) of all injectors of a lotOpening time deviation (ton, pulse 19) may only lie within the following range:Ton,max< ton,av.+ 0,35 msTon,min> ton,av.- 0,35 msFor test of new injector lot size is 8 pcs.For field return tests the lot consists of all injectors out of one engine.

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4. Endurance and environmental tests

The product functionality in the overall system must be confirmed by the customerthrough a corresponding vehicle test under realistic operating conditions.The following design verification tests are meant to give information about thefunctional stability, the wear and corrosion resistance of the injector.The tolerances indicated for the particular tests are related to the individual

original value, measured according to section 3.

4.1 Dynamic tests

4.1.1 Shock test

The injector is mounted in a fixture.

- Acceleration: a = 500 m/s2

- Shock duration: 5 ... 8 ms- Test procedure:

- 6 shocks in the direction of the injector axis and

- 6 shocks perpendicular to the injector axis

Test criteria and permissible deviation after the test:

- Qstat= 5 %

- qdyn = 7 % at ti= 3.5 ms

- Total leakage rates: See Section 1, characteristics

4.1.2 Sinusoidal acceleration Test

The injectors are mounted in a fixture. The test has sinusoidal and additionalrandom frequencies:

sinusoidal:

frequency

[Hz]

accelaration

[m/s]

50 10

200 160

250 160

random:

frequency

[Hz]

powerspectral

density

[(m/s)/Hz]

10 1,00

50 1,00

200 0,10

300 20,00

2000 20,00

duration: 24 h in every direction (injectors longitudinal axis and lateral axis)frequency alteration: 1 octave/min

- Medium: N2 5,0- Pressure: see section 1- T =25 ms, ti = 3,5 ms

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Ambient temperature cycle: -30...+120...-30 C

Duration of the temperature cycle:- storage 1h at 30C

- increasing within 1h from 30C to 120C- storage 1h at 120C- decreasing within 1h from 120C to 30CTemperature tolerances: 5C


- Qstat = -10% / +10%

- qdyn = -15% / +15% at ti = 3.5 ms

- Total leakage rates: See Section 1, Characteristics

4.2 Climate tests

4.2.1 Salt spray test according to DIN 50 021

A 5% sodium chloride solution is sprayed continuously onto the injector.From the o-ring onwards, the fuel inlet and outlet and the electrical connectorplug are tightly covered.

- Duration: 144 hrs- Rating: No harmful rust must be observed.

4.2.2 Condensed moisture - climate change test according to DIN 50 017

1. Storage 8 hrs at 40 C in humid climate2. Storage 16 hrs at room temperature

The fuel inlet and outlet are tightly covered from the o-ring on.The plug is mounted onto the connector.

- Duration: 6 cycles (1 cycle = 24 hrs)

- Rating: No rust harmful to function must be found.

4.3 Endurance

4.3.1 Standard endurance test

- Gas and ambient temperature: 23 2C

- T = 5 ms, ti = 2.5 ms

- 380 million cycles (528 hrs), this approximately equals 240,000 km

- Medium: Natural gas quality H (DVGW Regulation see Section 2, Operatingconditions)

- Pressure: See Section 1, Characteristics


- Qstat = -4% / +7%

- qdyn = -5% / +12% at ti = 3.5 ms

- Total leakage rates: See Section 1, Characteristics

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4.3.2 Short endurance test (QZ test)

A short endurance test is carried out within specified periods (see section 5) to

monitor the manufacturing quality.

- Gas and ambient temperature: 23 2C

- T = 5 ms, ti = 2.5 ms- 144 million cycles (200 hrs)

- Medium: Natural gas quality H (DVGW Regulation See Section 2, Operatingconditions)

- Pressure: See Section 1, Characteristics


- See Section 4.3.1

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5. Carrying out testing (production audit tests)

At least once a year audit tests are performed per type family. For these testsparts of any injector type are taken out of production at random. For currentproduction, the quality assurance and development department select the testsneeded from Section 4.For design changes, the development department selects the tests needed and co-ordinates the special design verification testing.

6. Field return evaluation

Functional values are determined according to the test conditions listed in

section 3 with the test equipment of the manufacturing plant.In case of com-plaints, the product is declared free of fault if the following characteristicdata are attained:

6.1 Zero-mileage return

In the case of zero-mileage return, the tolerances of the new parts (see Section1) must be used. For the static and dynamic flow measurement, the tolerance forrepeatability of 2 % must be added.

6.2 Field return

The technical development/application engineering of the product is orientedtowards a service life of 240,000 km, but in any case for a maximum of 15 years.This statement regarding design of the product for a certain lifetime does not

represent a warranty for the characteristics of the product. The commercialwarranty and liability is regulated in the Conditions of Sale, irrespective ofthe above figures.In the case of an alleged defect of the injectors, the injectors are to beconsidered free of defects if the injector functional parameters are within the

following stated tolerances for Qstat, qdynand leakage.

- Qstat= 10 %

- qdyn= 15 % at ti= 3.5 ms

- Total leakage rate: See Section 1

The operation of the injector in accordance with the operating conditions speci-fied in Section 2, especially the use of the specified natural gas only, is thepremise for acceptance of field returns.

7. Type approval according to ECE R110

Release of the NGI2 injector for use in natural gas vehicles according to ECE R110 is carried out by a vehicle licensing authority. The release is documented bythe ECE mark on the injector. NGI2 injectors without an ECE mark are not li-censed for use on public roads.

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Legally binding signature

Robert Bosch GmbH

............................................ , ...............(City) (Date)

............................................ , ...............(City) (Date)

__________________________________________________________________________

Customer

............................................ , ...............(City) (Date)

............................................ , ...............(City) (Date)

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