0445020606 Original Bosch Pump

 

Torque Specifications:

Mounting bolts: 22 Nm ±10%

High-pressure lines: 30 Nm with copper washers

Priming Procedure:

Fill pump cavity with clean diesel

Bleed air via 8mm test port

Crank engine for ≤15 seconds

Maintenance Schedule

 

 

 

 

 

 

 

Common Issues:

 

Code P0087: Pressure drop from worn plungers

Metal Contamination: Failed pump typically shows >15ppm iron in fuel filter

Cold Start Problems: Stiction in pressure control valve below -20°C

 

Diagnostic Tips:

 

Use Bosch FSA-740 for waveform analysis

Check cam lobe wear pattern (uneven wear indicates misalignment)

 

Core Component Inspection Standards

Plunger Assembly Inspection

Wear Limits:

Plunger diameter: Ø7.980mm (<7.965mm = scrap)

Radial clearance: 0.002-0.004mm (>0.008mm = replace)

Pressure Control Valve Test

Using Bosch EPS-200 tester:

Opening pressure: 1800±50bar

Response time: <2ms

Drive Shaft Inspection

Radial runout: <0.03mm

Keyway wear: Depth <0.1mm

 

 

 

 

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