VP44 Inspection Points

Defects Cataloge VP44
Automotive Aftermarket
1 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 Indication of third-party
Yes product
Product information complete Page 3
No Indication of incomplete
Yes Reject
product information
Vehicle information complete Page 4
No Indication of incomplete
Yes Reject
vehicle information
In warranty period
No Indication of expired
Yes Reject
warranty period
2 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
Robert Bosch GmbH.
Vehicle Information
Vehicle manufacturer First registration

Engine manufacturer Date of sale
Fault code
Vehicle model
Pump control unit
Chassis number Mileage

Engine number
Robert Bosch GmbH.
Product Information
Part number
Complete product
Date of manufacture
Purchase date
Failure date
Robert Bosch GmbH.
Visual Inspection
Visual inspection for
mechanical damage
Yes Indication of mechanical

Rejection
damage
No
Visual inspection for

outside intervention
Yes Indication of outside

Rejection
intervention
No
Robert Bosch GmbH.
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
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
Dismantling
Dismantle pump as
per ESI instructions
Clean
and
ensure
absolute
cleanliness
Findings on parts
Assessment as per
fault symptoms catalog
Warranty case no Reference to

Reject
fault symptoms catalog
yes
Accept warranty claim
Observe keeping period

for parts
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
Robert Bosch GmbH.

 Complaint
 Wear assessment
 Symptoms
 Possible cause
 Assembly fault
Robert Bosch GmbH.

 Complaint
 Wear assessment
 Symptoms
 Possible cause
 Assembly fault
Robert Bosch GmbH.
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)
No warranty claim.
No material or manufacturing fault
Robert Bosch GmbH.
Cam ring damage

 Complaint
 No impairment of driveability
 Symptoms
 Slight marking on cam ring
 Possible cause
 Assembly fault
No warranty claim.
Robert Bosch GmbH.
Cam ring damage

 Complaint
 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)
 Particle through-flow
No warranty claim.
Robert Bosch GmbH.
Roller shoe damage

 Complaint
 Poor engine performance
 Fault memory entry (chatter detection)
 Symptoms
 Increased wear on roller shoe
 Local overloading
 Possible cause
 Overloading of pump due to defective
nozzle/holder assembly (hole clogged).
 Overloading of pump due to tuning
No warranty claim.
Robert Bosch GmbH.
Spring disk damage

 Complaint
 Wear assessment
 Symptoms
 Damage to spring disk
 Possible cause
 Corrosion
Robert Bosch GmbH.
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
Robert Bosch GmbH.
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
 Water in fuel
 Particles in fuel (poor filtering)
Robert Bosch GmbH.
Injection timing control pistondamage

 Complaint
 Lack of power (with severe wear)
 Symptoms
 Wear on injection timing control piston
 Causes
 Cavitation
 High mileage
 Particles in fuel (poor filtering)
Robert Bosch GmbH.
Injection timing control piston damage

 Complaint
 Starting problem
 Lack of power
 Symptoms
 Increased wear on piston
 Increased wear on cam coupling
 Causes
 High mileage
Robert Bosch GmbH.
Drive platedamage
 Complaint
 Wear assessment
 Symptoms
 Slight running and wear marks
 Causes
 Normal wear
 Wrong fuel
 Particles / water in fuel
 Incorrect assembly
Fuel supply pump damage

 Complaint
 White smoke at high power
 Interior pressure too low
 Symptoms
 Scoring in housing floor
 Sealing edges of wing rounded
 Causes
 Poor lubrication
Robert Bosch GmbH.

 Complaint
 Symptoms
 Corrosion on support ring
 Causes
 Water in fuel
Robert Bosch GmbH.

 Complaint
 Symptoms
 Slight marking on pump ring
 Contact edges on wing
 Causes
 High mileage
 Damage during assembly
Robert Bosch GmbH.
Pressure regulating valve damage

 Complaint
 Interior pressure
 Smoke under power
 Symptoms
 Damaged sealing varnish / engine varnish
 Impacted adjuster bolt
 Valve piston sticking
 Causes
 External intervention
 Interior pressure too high
Robert Bosch GmbH.
Pump housing damage

 Complaint
 Symptoms
 External damage to pump housing
 Causes
 Damage when installing or removing pump
Robert Bosch GmbH.
Pump housing damage

 Complaint
 Starting problems
 Symptoms
 Markings on housing floor of injection
timing control piston
 Possible cause
 Poor, abrasive fuel (particles)
Robert Bosch GmbH.
Distributor body damage

 Complaint
 Symptoms
 Slight leak from distributor head to outside
 Causes
 Assembly fault
 Leaky O-ring
 Inadmissible fuel
Robert Bosch GmbH.

 Complaint
 External leak
 Symptoms
 Cavitation under pressure pipe connection
 Causes
 Cavitation
 High mileage
 Tightening torque too low
(assembly fault)
Robert Bosch GmbH.

 Complaint
 Starting problems
 Lack of power
 Symptoms
 Diaphragm break
 Causes
 Corrosion
 Air in pump housing
Robert Bosch GmbH.
Grooved ball bearing damage

 Complaint
 Noise when removed
 Symptoms
 Wear on balls
 Causes
 Fuel quality
 Mileage
 Assembly fault
Robert Bosch GmbH.

VP44 Inspection Points

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VP44 Inspection Points

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Defects Cataloge VP44

Product information complete Page 3

Vehicle information complete Page 4

Further test steps:

Test bench audit

Vehicle manufacturer First registration

Chassis number Mileage

Yes Indication of mechanical

Visual inspection for

Yes Indication of outside

Severely damaged pumps

Test rig test

Incoming test with

Warranty case no Reference to

Observe keeping period

Throttle valve damage

Throttle valve damage

Throttle valve damage

Cam ring damage

Cam ring damage

Cam ring damage

Roller shoe damage

Spring disk damage

Drive shaft damage

Drive shaft damage

Injection timing control pistondamage

Injection timing control piston damage

Fuel supply pump damage

Fuel supply pump damage

Fuel supply pump damage

Pressure regulating valve damage

Pump housing damage

Pump housing damage

Distributor body damage

Distributor body damage

Distributor body damage

Grooved ball bearing damage

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