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
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
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
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
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
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
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
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
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
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
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
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
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
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
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
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
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
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
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
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
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
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
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
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
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
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
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
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
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
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
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
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
Top Related