09800-00180 PUMP ASSY, INJECTI Denso Cross

Introduction
The following Special Instruction is for the repair of Long Fiber Injection (LFI) components with Polymethyl Methacrylate (PMMA) surfaces on the machines listed above. The Surfaces consist of four parts: cover layer, color layer, carrier layer, and backing foam. Refer to "Repair Procedure" for the proper procedure to repair these surfaces.Do not perform any procedure in this Special Instruction until you have read the information and you understand the information.Safety Section
Do not operate or work on this product unless you have read and understood the instruction and warnings in the relevant Operation and Maintenance Manuals and relevant service literature. Failure to follow the instructions or heed the warnings could result in injury or death. Proper care is your responsibility.
When removing a major component or attachment, ensure that it is properly blocked or secured before removing mounting hardware. An assembly that is disconnected without proper blocking may shift or fall, resulting in serious injury or death of personnel or machine damage.
Personal injury can result from improper handling of chemicals.Make sure you use all the necessary protective equipment required to do the job.Make sure that you read and understand all directions and hazards described on the labels and material safety data sheet of any chemical that is used.Observe all safety precautions recommended by the chemical manufacturer for handling, storage, and disposal of chemicals.
Climbing equipment may be required to access this service point. Refer to the Operation and Maintenance Manual, "Mounting and Dismounting" topic for safety information.
Before servicing/performing maintenance on the machine, electrical power must be physically disconnected; battery plugs must be disconnected from the batteries, or the trailing cable must be unplugged, and warning tags and padlocks shall be applied by a certified electrician. Certified electricians shall perform or direct any electrical work, including any energized testing, repair work in controllers, motors, or other approved compartments, and shall insure that all compartments are properly closed and inspected prior to re-energization. All applicable lock out and tag out procedures must be followed.
Observe the safe working load limits of all lifting and blocking devices and keep a safe distance from suspended/blocked loads. Personnel may be seriously injured or killed by falling loads.
Required Parts
The LFI component PMMA surface characteristics are as follows
Cover Layer
Gloss
Scratch resistance
Weather resistance
Color Layer
Coloring
Ultraviolet resistance
Carrier Layer
Adhesion to backing foam
Heat deformation resistance
Backing Foam
Strength
Stability
Impact resistance
Heat deformation resistanceRepair Procedure
Illustration 1 g06509785
Simulated punch hole
Illustration 2 g06509787
Location to grind off backside
Grind material off from backside
Illustration 3 g06509788
Fiberglass mat and plastic filler
Place fiberglass mat and place plastic filler on backside
Illustration 4 g06509791
Location to grind off exterior side
Grind material off from exterior side
Illustration 5 g06509792
Location to add filler on exterior side
Fill hole on exterior side with plastic filler