VP44 Inspection Points

Defects Cataloge VP44
Automotive Aftermarket
AA/ASA1 | 09.03.2006 | Alle Rechte bei Robert Bosch GmbH, auch fr den Fall von Schutzrechtsanmeldungen. Jede Verfgungsbefugnis, wie Kopier- und Weitergaberecht, bei uns.
Test Procedure
VP44 Bosch product
No Yes Reject
Indication of third-party product
Product information complete
Page 3
No Yes Reject
Indication of incomplete product information
Vehicle information complete
Page 4
No Yes
Reject
Indication of incomplete vehicle information
In warranty period
No Yes Reject
Indication of expired warranty period
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.
Test Procedure
1
Further test steps:
Visual inspection
Test bench audit
Dismantling
Vehicle Information
Vehicle manufacturer Engine manufacturer First registration Date of sale
Vehicle model
Fault code Pump control unit
Chassis number Engine number
Mileage
Product Information
Part number
Complete product
Date of manufacture
Purchase date
Failure date
Visual Inspection
Visual inspection for mechanical damage
Yes
Rejection
Indication of mechanical damage
No
Visual inspection for outside intervention
Yes
Rejection
Indication of outside intervention
No 2
Visual Inspection
2
Severely damaged pumps and pumps with sticking drive shaft must not be tested
yes
Dismantle
no
Damaged bolt heads and/or pressure control valve lock
yes
Reject
Reference to external intervention
no
Incoming test on pump test rig
Test rig test

Incoming test with Bosch test values on Bosch test rig EPS 815
Evaluation of test report
no
Dismantle
yes
Pump OK No warranty case
Dismantling
Dismantle pump as per ESI instructions
Clean and ensure absolute cleanliness
Findings on parts Assessment as per fault symptoms catalog Warranty case
no
Reject
Reference to fault symptoms catalog
yes
Accept warranty claim Observe keeping period for parts
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. No material or manufacturing fault
10
Complaint
Wear assessment
Symptoms
Possible cause
Mechanical damage Assembly fault
Warranty decision:

11
Complaint
Wear assessment
Symptoms
Possible cause
Mechanical damage Assembly fault
Warranty decision:

12
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:
13
Cam ring damage
Complaint
No impairment of driveability
Symptoms
Slight marking on cam ring
Possible cause
Assembly fault
Warranty decision:
14
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. No material or manufacturing fault
15
Roller shoe damage
Complaint Poor engine performance Fault memory entry (chatter detection) Symptoms Increased wear on roller shoe Local overloading Possible cause Air in system (low pressure) Severe chatter of injection timing control Overloading of pump due to defective nozzle/holder assembly (hole clogged). Overloading of pump due to tuning Warranty decision: No warranty claim. No material or manufacturing fault
16
Spring disk damage
Complaint
Wear assessment
Symptoms
Damage to spring disk
Possible cause
Mechanical damage Corrosion
Warranty decision:

17
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:
18
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:

19
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:

20
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:

21
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:
22
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:

23
Complaint
Poor engine performance White smoke at high power Interior pressure too low
Symptoms

Corrosion on support ring Sealing edges of wing rounded
Causes

Particle through-flow Poor lubrication Water in fuel
Warranty decision:

24
Complaint

Poor engine performance White smoke at high power Interior pressure too low Slight marking on pump ring Contact edges on wing Sealing edges of wing rounded Particle through-flow Poor lubrication High mileage Damage during assembly
Symptoms

Causes

Warranty decision:

25
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:
26
Pump housing damage
Complaint
Symptoms
External damage to pump housing
Causes
Damage when installing or removing pump
Warranty decision:

27
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 Air in system (low pressure)
Warranty decision: No warranty claim. No material or manufacturing fault
28
Distributor body damage
Complaint
Symptoms
Slight leak from distributor head to outside
Causes

Assembly fault Leaky O-ring Inadmissible fuel
Warranty decision:

29
Complaint

No impairment of driveability 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:
30
Complaint
Starting problems Lack of power
Symptoms
Diaphragm break
Causes

Corrosion Air in pump housing
Warranty decision:
31
Grooved ball bearing damage
Complaint
Noise when removed
Symptoms
Wear on balls
Causes

Particle through-flow Fuel quality Mileage Assembly fault
Warranty decision:

32

VP44 Inspection Points

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VP44 Inspection Points

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Defects Cataloge VP44

Defects Cataloge VP44

Indication of third-party product

Product information complete

Indication of incomplete product information

Vehicle information complete

Indication of incomplete vehicle information

Indication of expired warranty period

Defects Cataloge VP44

Further test steps:

Test bench audit

Defects Cataloge VP44

Fault code Pump control unit

Chassis number Engine number

Defects Cataloge VP44

Defects Cataloge VP44

Indication of mechanical damage

Indication of outside intervention

Defects Cataloge VP44

Reference to external intervention

Defects Cataloge VP44

Test rig test

Evaluation of test report

Defects Cataloge VP44

Clean and ensure absolute cleanliness

Findings on parts Assessment as per fault symptoms catalog Warranty case

Reference to fault symptoms catalog

Defects Cataloge VP44

Throttle valve damage

Damage to throttle valve

Mechanical damage Assembly fault Tightening torques exceeded

No warranty claim. No material or manufacturing fault

Defects Cataloge VP44

Throttle valve damage

Damage to throttle valve

Mechanical damage Assembly fault

No warranty claim. No material or manufacturing fault

Defects Cataloge VP44

Throttle valve damage

Damage to throttle valve

Mechanical damage Assembly fault

No warranty claim. No material or manufacturing fault

Defects Cataloge VP44

Cam ring damage

Wear on cam ring / injection timing control piston mount

Defects Cataloge VP44

Cam ring damage

Slight marking on cam ring

Defects Cataloge VP44

Cam ring damage

Defects Cataloge VP44

Roller shoe damage

Defects Cataloge VP44

Spring disk damage

Damage to spring disk

Mechanical damage Corrosion

No warranty claim. No material or manufacturing fault

Defects Cataloge VP44

Drive shaft damage

May result in failure of pump Wear assessment

Severe rust also seen on other pump components

No warranty claim. No material or manufacturing fault

Defects Cataloge VP44