vp44 inspection points

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1 Defects Cataloge VP44 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. Automotive Aftermarket

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Page 1: VP44 Inspection Points

1

Defects Cataloge VP44

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.

Automotive Aftermarket

Page 2: VP44 Inspection Points

2

Defects Cataloge VP44

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 incompletevehicle information

In warranty period

VP44

Product information complete

1

Vehicle information complete

NoYes Reject

NoYes Reject

NoYes Reject

Indication of incomplete product information

Indication of expired warranty period

Bosch product

NoYes Reject Indication of third-party

product

Page 3

Page 4

Page 3: VP44 Inspection Points

3

Defects Cataloge VP44

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

Visual inspection

Dismantling

Test bench audit

Further test steps:

Visual inspection

Dismantling

Test bench audit

Further test steps:

1

Page 4: VP44 Inspection Points

4

Defects Cataloge VP44

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 numberEngine number

First registrationDate of sale

Fault codePump control unit

Vehicle manufacturerEngine manufacturer

Vehicle model

Mileage

Vehicle Information

Page 5: VP44 Inspection Points

5

Defects Cataloge VP44

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

Product Information

Part number

Complete product

Date of manufacture

Purchase date

Failure date

Page 6: VP44 Inspection Points

6

Defects Cataloge VP44

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

Visual Inspection

Indication of mechanical damage

Visual inspection for mechanical damage

Visual inspection for outside intervention

RejectionYes

No

Yes

No

RejectionIndication of outside

intervention

2

Page 7: VP44 Inspection Points

7

Defects Cataloge VP44

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.

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

2

Incoming test on

pump test rig

Page 8: VP44 Inspection Points

8

Defects Cataloge VP44

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.

Automotive Aftermarket

Evaluation of test report

Dismantleno

yes

Pump OK No warranty case

Incoming test with Bosch test values on

Bosch test rig EPS 815

Test rig test

Page 9: VP44 Inspection Points

9

Defects Cataloge VP44

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.

Automotive Aftermarket

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 caseReject

Reference to fault symptoms catalog

Dismantling

Page 10: VP44 Inspection Points

10

Defects Cataloge VP44

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

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

Page 11: VP44 Inspection Points

11

Defects Cataloge VP44

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

Throttle valve damage Complaint

Wear assessment

Symptoms Damage to throttle valve

Possible cause Mechanical damage Assembly fault

Warranty decision: No warranty claim. No material or manufacturing fault

Page 12: VP44 Inspection Points

12

Defects Cataloge VP44

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

Throttle valve damage Complaint

Wear assessment

Symptoms Damage to throttle valve

Possible cause Mechanical damage Assembly fault

Warranty decision: No warranty claim. No material or manufacturing fault

Page 13: VP44 Inspection Points

13

Defects Cataloge VP44

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

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. No material or manufacturing fault

Page 14: VP44 Inspection Points

14

Defects Cataloge VP44

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

Cam ring damage Complaint

No impairment of driveability

Symptoms Slight marking on cam ring

Possible cause Assembly fault

Warranty decision: No warranty claim. No material or manufacturing fault

Page 15: VP44 Inspection Points

15

Defects Cataloge VP44

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

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

Page 16: VP44 Inspection Points

16

Defects Cataloge VP44

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

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

Page 17: VP44 Inspection Points

17

Defects Cataloge VP44

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

Spring disk damage Complaint

Wear assessment

Symptoms Damage to spring disk

Possible cause Mechanical damage Corrosion

Warranty decision: No warranty claim. No material or manufacturing fault

Page 18: VP44 Inspection Points

18

Defects Cataloge VP44

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

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: No warranty claim. No material or manufacturing fault

Page 19: VP44 Inspection Points

19

Defects Cataloge VP44

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

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: No warranty claim. No material or manufacturing fault

Page 20: VP44 Inspection Points

20

Defects Cataloge VP44

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

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: No warranty claim. No material or manufacturing fault

Page 21: VP44 Inspection Points

21

Defects Cataloge VP44

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

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: No warranty claim. No material or manufacturing fault

Page 22: VP44 Inspection Points

22

Defects Cataloge VP44

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.

Automotive Aftermarket

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: No warranty claim. No material or manufacturing fault

Page 23: VP44 Inspection Points

23

Defects Cataloge VP44

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

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: No warranty claim. No material or manufacturing fault

Page 24: VP44 Inspection Points

24

Defects Cataloge VP44

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

Fuel supply pump damage

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: No warranty claim. No material or manufacturing fault

Page 25: VP44 Inspection Points

25

Defects Cataloge VP44

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

Fuel supply pump damage Complaint

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

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:

No warranty claim. No material or manufacturing fault

Page 26: VP44 Inspection Points

26

Defects Cataloge VP44

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

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: No warranty claim. No material or manufacturing fault

Page 27: VP44 Inspection Points

27

Defects Cataloge VP44

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

Pump housing damage Complaint

No impairment of driveability

Symptoms External damage to pump housing

Causes Damage when installing or removing

pump

Warranty decision: No warranty claim. No material or manufacturing fault

Page 28: VP44 Inspection Points

28

Defects Cataloge VP44

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

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

Page 29: VP44 Inspection Points

29

Defects Cataloge VP44

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

Distributor body damage Complaint

No impairment of driveability

Symptoms Slight leak from distributor head to

outside

Causes Assembly fault Leaky O-ring Inadmissible fuel

Warranty decision: No warranty claim. No material or manufacturing fault

Page 30: VP44 Inspection Points

30

Defects Cataloge VP44

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

Distributor body damage 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: No warranty claim. No material or manufacturing fault

Page 31: VP44 Inspection Points

31

Defects Cataloge VP44

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

Distributor body damage Complaint

Starting problems Lack of power

Symptoms Diaphragm break

Causes Corrosion Air in pump housing

Warranty decision: No warranty claim. No material or manufacturing fault

Page 32: VP44 Inspection Points

32

Defects Cataloge VP44

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

Grooved ball bearing damage Complaint

Noise when removed

Symptoms Wear on balls

Causes Particle through-flow Fuel quality Mileage Assembly fault

Warranty decision: No warranty claim. No material or manufacturing fault