101041-9600 ZEXEL 9 410 613 437 BOSCH FUEL-INJECTION PUMP 9410613437 1010419600

Parts Needed
6 - 6I2538 Clip Add injectors and related seals if clip is broken in more than three pieces. Add 336044 O-Ring Seal if thrust pad o-ring is damaged.
Action Required
Parts Stock
Remove all of the following injector groups from parts stock. Rework as described in the attached procedure and return to stock.
4P1410 Injector Group4P1420 Injector Group4P2810 Injector Group4P2820 Injector Group4P9510 Injector Group4P9520 Injector Group4P9610 Injector Group4P9620 Injector Group0R3177 Injector Group0R3178 Injector Group0R3400 Injector GroupAffected Product
Rework the injector groups as described in the attached procedure.
Service Claim Allowances
Parts Stock
Submit one claim for all injector groups removed from parts stock and reworked. List the labor to repair each injector on a separate labor line. A maximum of .2 hours labor per fuel injector will be allowed to remove and install the clip.
Affected Product
Parts Disposition
Handle the parts in accordance with your Warranty Bulletin on warranty parts handling.
Attach.
(1-Rework Procedure)Rework Procedure
Parts Stock or Off Engine
Illustration 1 - 9U5300 Unit Injector Spring Compressor Group
Illustration 2 - Compressor Group In Bench Vice
Illustration 3 - Use caution when handling injectors with missing clips. Loose springs and retainers will allow ball to come loose and fall into the engine.1. Remove injectors from packaging and inspect for a paint stripe across the top face of the spring retainer (either yellow or red). The paint stripe indicates the unit injector has been reworked previously. If a clip has failed and the spring/tappet/plunger are loose, use care during injector removal. The plunger retention ball (see Illustration 3) can drop out and fall into the cylinder/engine.
2. Install service tool in a bench vice as shown in Illustration 2 (position to allow for horizontal installation of injector).3. Use an o-ring pick to remove the o-ring from the injector spring retainer. Remove the rocker arm thrust pad.4. Install the injector in the 9U5300 Unit Injector Spring Compressor Group. Tighten the 5P0541 Nut to compress the spring enough to allow removal of the clip (the clip works like a valve keeper).5. Use a small magnet (pencil size works best) and a suitable clip removal tool to remove the oil clip from the injector. Do not release tension on the spring until a new clip is installed. Releasing tension before a new clip is installed will cause the injector will come apart.
6. Injectors removed from engines only. Inspect the clip that was removed. If the clip is broken in more than three (3) pieces (or if you suspect small pieces have fallen into the injector) the unit injector must be replaced.7. Install a new 6I2538 clip and remove injector from spring compressor group.8. Install thrust pad and thrust pad retaining o-ring. If the thrust pad retaining o-ring is damaged install a new 336044 O-Ring Seal.
9. Mark across the top face of the spring retainer with a yellow paint stripe.10. Repackage new parts and mark "3X" on the box.Affected Product
1. Check for 3X stamped on the block next to the serial number plate. If the block has been stamped do not proceed with the rework unless suspect injectors