VP44 Inspection Points

Defects Cataloge VP44

Automotive Aftermarket

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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.


Test Procedure VP44

Bosch product

No Reject

Yes

Product information complete

Page 3

No Reject

Yes

Vehicle information complete

No Yes

Indication of third-party product

Indication of incomplete product information

Page 4

Reject

Indication of incomplete vehicle information

In warranty period

No Reject

Yes

Indication of expired warranty period

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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.


Test Procedure 1

Further test steps:

Visual inspection

Test bench audit

Dismantling


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Vehicle Information Vehicle manufacturer Engine manufacturer

First registration Date of sale

Vehicle model

Fault code Pump control unit

Chassis number Engine number

Mileage


4



Product Information Part number

Complete product

Date of manufacture

Purchase date

Failure date


5



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


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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


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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


8



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


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Throttle valve damage 

Complaint 



Symptoms 



Damage to throttle valve

Possible cause   



Wear assessment

Mechanical damage Assembly fault Tightening torques exceeded

Warranty decision:  

No warranty claim. No material or manufacturing fault


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Complaint 



Symptoms 




Possible cause 





Wear assessment

Mechanical damage Assembly fault




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Complaint 



Symptoms 




Possible cause  



Wear assessment

Mechanical damage Assembly fault




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Cam ring damage 

Complaint   



Symptoms 



Wear on cam ring / injection timing control piston mount

Possible cause    



Poor performance (vehicle) Cold start problems White smoke in full-load range

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


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Cam ring damage 

Complaint 



Symptoms 



Slight marking on cam ring

Possible cause 



No impairment of driveability

Assembly fault



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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





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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  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





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Spring disk damage 

Complaint 



Symptoms 



Damage to spring disk

Possible cause 





Wear assessment

Mechanical damage Corrosion




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Drive shaft damage 

Complaint  



Symptoms  



Severe rust also seen on other pump components

Causes 



May result in failure of pump Wear assessment

Water in fuel

Warranty decision: 





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Drive shaft damage 

Complaint    



Symptoms 





Increased wear on splines of vane-cell pump Wear on bearing bush

Causes    



Chatter Wear assessment Lack of power Cold start problems

High mileage Air in system (low pressure) Water in fuel Particles in fuel (poor filtering)




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Injection timing control pistondamage 

Complaint  



Symptoms 



Wear on injection timing control piston




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

Cavitation Air in system (low pressure) High mileage Particles in fuel (poor filtering)




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Injection timing control piston damage 

Complaint 





Symptoms  



Increased wear on piston Increased wear on cam coupling

Causes  



Starting problem Lack of power

Air in system (low pressure) High mileage




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Drive platedamage 

Complaint  



Symptoms 



Slight running and wear marks




No impairment of driveability Wear assessment

Normal wear Wrong fuel Particles / water in fuel Incorrect assembly






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Fuel supply pump damage 




Symptoms 





Scoring in housing floor Sealing edges of wing rounded

Causes  



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

Particle through-flow Poor lubrication




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Complaint 

 



Symptoms  



Corrosion on support ring Sealing edges of wing rounded

Causes   




Particle through-flow Poor lubrication Water in fuel




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

Symptoms   



Slight marking on pump ring Contact edges on wing Sealing edges of wing rounded





Particle through-flow Poor lubrication High mileage Damage during assembly




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Pressure regulating valve damage 




Symptoms   



Damaged sealing varnish / engine varnish Impacted adjuster bolt Valve piston sticking

Causes   



Poor engine performance Interior pressure Smoke under power

External intervention Interior pressure too high Particle through-flow




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Pump housing damage 

Complaint 



Symptoms 



External damage to pump housing

Causes 




Damage when installing or removing pump




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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  Air in system (low pressure)



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


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Distributor body damage 

Complaint 



Symptoms 



Slight leak from distributor head to outside

Causes   




Assembly fault Leaky O-ring Inadmissible fuel




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

Symptoms 



Cavitation under pressure pipe connection

Causes   



No impairment of driveability External leak White smoke in full-load range

Cavitation High mileage Tightening torque too low (assembly fault)




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Complaint 





Symptoms 



Diaphragm break

Causes  



Starting problems Lack of power

Corrosion Air in pump housing






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Grooved ball bearing damage 

Complaint 



Symptoms 



Wear on balls




Noise when removed

Particle through-flow Fuel quality Mileage Assembly fault




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VP44 Inspection Points

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