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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.
Defects Cataloge VP44
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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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
Test Procedure 1
Further test steps:
Visual inspection
Test bench audit
Dismantling
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
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
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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
Product Information Part number
Complete product
Date of manufacture
Purchase date
Failure date
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
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
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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
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
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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.
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
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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.
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
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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.
Defects Cataloge VP44
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
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
Throttle valve damage
Complaint
Symptoms
Damage to throttle valve
Possible cause
Wear assessment
Mechanical damage Assembly fault
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
Throttle valve damage
Complaint
Symptoms
Damage to throttle valve
Possible cause
Wear assessment
Mechanical damage Assembly fault
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
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
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
Cam ring damage
Complaint
Symptoms
Slight marking on cam ring
Possible cause
No impairment of driveability
Assembly fault
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
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
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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
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
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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
Spring disk damage
Complaint
Symptoms
Damage to spring disk
Possible cause
Wear assessment
Mechanical damage Corrosion
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
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:
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
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)
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
Injection timing control pistondamage
Complaint
Symptoms
Wear on injection timing control piston
Causes
No impairment of driveability Lack of power (with severe wear)
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
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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
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
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
Drive platedamage
Complaint
Symptoms
Slight running and wear marks
Causes
No impairment of driveability Wear assessment
Normal wear Wrong fuel Particles / water in fuel Incorrect assembly
Warranty decision:
No warranty claim. No material or manufacturing fault
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.
Defects Cataloge VP44
Fuel supply pump damage
Complaint
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
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
Fuel supply pump damage
Complaint
Symptoms
Corrosion on support ring Sealing edges of wing rounded
Causes
Poor engine performance White smoke at high power Interior pressure too low
Particle through-flow Poor lubrication Water in fuel
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
Fuel supply pump damage
Complaint
Symptoms
Slight marking on pump ring Contact edges on wing Sealing edges of wing rounded
Causes
Poor engine performance White smoke at high power Interior pressure too low
Particle through-flow Poor lubrication High mileage Damage during assembly
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
Pressure regulating valve damage
Complaint
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
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
Pump housing damage
Complaint
Symptoms
External damage to pump housing
Causes
No impairment of driveability
Damage when installing or removing pump
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
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
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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
Distributor body damage
Complaint
Symptoms
Slight leak from distributor head to outside
Causes
No impairment of driveability
Assembly fault Leaky O-ring Inadmissible fuel
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
Distributor body damage
Complaint
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)
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
Distributor body damage
Complaint
Symptoms
Diaphragm break
Causes
Starting problems Lack of power
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
Symptoms
Wear on balls
Causes
Noise when removed
Particle through-flow Fuel quality Mileage Assembly fault
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.