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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.

Defects Cataloge VP44

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

Automotive Aftermarket

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.

Defects Cataloge VP44

Test Procedure
1

Further test steps:

Visual inspection

Test bench audit

Dismantling

Automotive Aftermarket

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.

Defects Cataloge VP44

Vehicle Information
Vehicle manufacturer Engine manufacturer First registration Date of sale

Vehicle model

Fault code Pump control unit

Chassis number Engine number

Mileage

Automotive Aftermarket

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.

Defects Cataloge VP44

Product Information
Part number

Complete product

Date of manufacture

Purchase date

Failure date

Automotive Aftermarket

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.

Defects Cataloge VP44

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

Automotive Aftermarket

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.

Defects Cataloge VP44

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

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.

Defects Cataloge VP44

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

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.

Defects Cataloge VP44

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

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.

Defects Cataloge VP44

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

Automotive Aftermarket

10

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.

Defects Cataloge VP44

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

Automotive Aftermarket

11

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.

Defects Cataloge VP44

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

Automotive Aftermarket

12

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.

Defects Cataloge VP44

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

Automotive Aftermarket

13

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.

Defects Cataloge VP44

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

Automotive Aftermarket

14

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.

Defects Cataloge VP44

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

Automotive Aftermarket

15

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.

Defects Cataloge VP44

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

Automotive Aftermarket

16

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.

Defects Cataloge VP44

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

Automotive Aftermarket

17

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.

Defects Cataloge VP44

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

Automotive Aftermarket

18

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.

Defects Cataloge VP44

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

Automotive Aftermarket

19

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.

Defects Cataloge VP44

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

Automotive Aftermarket

20

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.

Defects Cataloge VP44

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

Automotive Aftermarket

21

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.

Defects Cataloge VP44

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

Automotive Aftermarket

22

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.

Defects Cataloge VP44

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

Automotive Aftermarket

23

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.

Defects Cataloge VP44

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

Automotive Aftermarket

24

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.

Defects Cataloge VP44

Fuel supply pump damage

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:

No warranty claim. No material or manufacturing fault

Automotive Aftermarket

25

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.

Defects Cataloge VP44

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

Automotive Aftermarket

26

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.

Defects Cataloge VP44

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

Automotive Aftermarket

27

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.

Defects Cataloge VP44

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

Automotive Aftermarket

28

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.

Defects Cataloge VP44

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

Automotive Aftermarket

29

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.

Defects Cataloge VP44

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

Automotive Aftermarket

30

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.

Defects Cataloge VP44

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

Automotive Aftermarket

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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.

Defects Cataloge VP44

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

Automotive Aftermarket

32

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.