VP44 Inspection Points

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AA/ASA1 | 09.03.2006 | Alle Rechte bei Robert Bosch GmbH, auch für den Fall von Schutzrechtsanmeldungen. Jede Verfügungsbefugnis, wie Kopier- und Weitergaberecht, bei uns.

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AA/ASA1 | 09.03.2006 | All rights, including patent applications. as well as sole power of disposal and duplication and transfer rights, reserved by Robert Bosch GmbH. Automotive Aftermarket

Test Procedure

Indication of incomplete vehicle information In warranty period VP44

Product information complete

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Vehicle information complete No Yes Reject No Yes Reject No Yes Reject Indication of incomplete product information Indication of expired warranty period Bosch product No

Yes Reject Indication of third-party

product Page 3

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Test Procedure

Visual inspection Dismantling Test bench audit Further test steps:

Visual inspection

Dismantling Test bench audit Further test steps:

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AA/ASA1 | 09.03.2006 | All rights, including patent applications. as well as sole power of disposal and duplication and transfer rights, reserved by Robert Bosch GmbH. Automotive Aftermarket Chassis number Engine number First registration Date of sale Fault code Pump control unit Vehicle manufacturer

Engine manufacturer

Vehicle model

Mileage

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Product Information

Part number Complete product Date of manufacture Purchase date Failure date

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Visual Inspection

Indication of mechanical damage

Visual inspection for mechanical damage

Visual inspection for outside intervention Rejection Yes No Yes No

Rejection Indication of outside

intervention

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Automotive Aftermarket

Visual Inspection

Severely damaged pumps and pumps with sticking

drive shaft must not be tested

yes no

Dismantle

Damaged bolt heads and/or pressure control

valve lock

yes no

Reject Reference to external

intervention Severely damaged pumps

and pumps with sticking drive shaft must

not be tested

yes no

Dismantle

Damaged bolt heads and/or pressure control

valve lock

yes no

Reject Reference to external

intervention

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Incoming test on pump test rig

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Automotive Aftermarket Evaluation of test report Dismantle

no

yes

Pump OK No warranty case Incoming test with Bosch test values on Bosch test rig EPS 815

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Findings on parts Assessment as per fault symptoms catalog

Accept warranty claim Observe keeping period

for parts Dismantle pump as per ESI instructions

Clean and ensure absolute cleanliness no yes Warranty case Reject Reference to fault symptoms catalog

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AA/ASA1 | 09.03.2006 | All rights, including patent applications. as well as sole power of disposal and duplication and transfer rights, reserved by Robert Bosch GmbH.

Throttle valve damage



Complaint

 Wear assessment



Symptoms

 Damage to throttle valve



Possible cause

 Mechanical damage  Assembly fault

 Tightening torques exceeded



Warranty decision:

 No warranty claim.

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Throttle valve damage



Complaint

 Wear assessment



Symptoms



Possible cause



Warranty decision:

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Throttle valve damage



Complaint

 Wear assessment



Symptoms



Possible cause



Warranty decision:

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Cam ring damage



Complaint

 Poor performance (vehicle)  Cold start problems

 White smoke in full-load range



Symptoms

 Wear on cam ring /

injection timing control piston mount



Possible cause

 Poor, abrasive fuel (particles)

 Severe chatter of injection timing control  Poor, inadequate filtration

 Air in system (low pressure)



Warranty decision:

No warranty claim.

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Cam ring damage



Complaint

 No impairment of driveability



Symptoms

 Slight marking on cam ring



Possible cause

 Assembly fault



Warranty decision:

No warranty claim.

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Cam ring damage

 Complaint

 Poor performance (vehicle)  White smoke in full-load range

 Symptoms

 Severe wear on cam ring

 Slight smoothing in area of cam  "Dents" of rollers in cam incline

 Possible cause

 Poor lubricating, abrasive fuel (particles)  Poor, inadequate filtration

 Particle through-flow

 Warranty decision:

No warranty claim.

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Roller shoe damage

 Complaint

 Poor engine performance

 Fault memory entry (chatter detection)

 Symptoms

 Increased wear on roller shoe  Local overloading

 Possible cause

 Severe chatter of injection timing control  Overloading of pump due to defective

nozzle/holder assembly (hole clogged).  Overloading of pump due to tuning

No warranty claim.

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Spring disk damage



Complaint

 Wear assessment



Symptoms

 Damage to spring disk



Possible cause

 Mechanical damage  Corrosion 

Warranty decision:

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Drive shaft damage



Complaint

 May result in failure of pump  Wear assessment



Symptoms

 Severe rust

 also seen on other pump components



Causes

 Water in fuel



Warranty decision:

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Drive shaft damage



Complaint

 Chatter

 Wear assessment  Lack of power  Cold start problems



Symptoms

 Increased wear on splines of vane-cell pump

 Wear on bearing bush



Causes

 High mileage

 Air in system (low pressure)  Water in fuel

 Particles in fuel (poor filtering)



Warranty decision:

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Injection timing control pistondamage



Complaint

 No impairment of driveability  Lack of power (with severe wear)



Symptoms

 Wear on injection timing control piston



Causes

 Cavitation

 Air in system (low pressure)  High mileage

 Particles in fuel (poor filtering)



Warranty decision:

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Injection timing control piston damage



Complaint

 Starting problem  Lack of power



Symptoms

 Increased wear on piston

 Increased wear on cam coupling



Causes

 Air in system (low pressure)  High mileage



Warranty decision:

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Drive platedamage



Complaint

 No impairment of driveability  Wear assessment 

Symptoms

 Slight running and wear marks



Causes

 Normal wear  Wrong fuel

 Particles / water in fuel  Incorrect assembly



Warranty decision:

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Fuel supply pump damage



Complaint

 Poor engine performance  White smoke at high power  Interior pressure too low



Symptoms

 Scoring in housing floor

 Sealing edges of wing rounded



Causes

 Particle through-flow  Poor lubrication 

Warranty decision:

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Fuel supply pump damage



Complaint



Symptoms

 Corrosion on support ring  Sealing edges of wing rounded



Causes

 Particle through-flow  Poor lubrication  Water in fuel 

Warranty decision:

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Fuel supply pump damage



Complaint



Symptoms

 Slight marking on pump ring  Contact edges on wing

 Sealing edges of wing rounded



Causes

 Particle through-flow  Poor lubrication  High mileage

 Damage during assembly



Warranty decision:

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Pressure regulating valve damage



Complaint

 Poor engine performance  Interior pressure

 Smoke under power



Symptoms

 Damaged sealing varnish / engine varnish  Impacted adjuster bolt

 Valve piston sticking



Causes

 External intervention  Interior pressure too high  Particle through-flow



Warranty decision:

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Pump housing damage



Complaint



Symptoms

 External damage to pump housing



Causes

 Damage when installing or removing pump



Warranty decision:

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Pump housing damage

 Complaint

 Poor performance (vehicle)  Starting problems

 Symptoms

 Markings on housing floor of injection timing control piston

 Possible cause

 Poor, abrasive fuel (particles)

 Severe chatter of injection timing control  Poor, inadequate filtration

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Distributor body damage



Complaint



Symptoms

 Slight leak from distributor head to outside



Causes

 Assembly fault  Leaky O-ring  Inadmissible fuel 

Warranty decision:

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Distributor body damage



Complaint

 External leak

 White smoke in full-load range



Symptoms

 Cavitation under pressure pipe connection



Causes

 Cavitation  High mileage

 Tightening torque too low (assembly fault)



Warranty decision:

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Distributor body damage



Complaint

 Starting problems  Lack of power 

Symptoms

 Diaphragm break 

Causes

 Corrosion

 Air in pump housing



Warranty decision:

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Grooved ball bearing damage



Complaint

 Noise when removed



Symptoms

 Wear on balls 

Causes

 Particle through-flow  Fuel quality  Mileage  Assembly fault 