104115-1030 ZEXEL 9 410 617 949 BOSCH FUEL-INJECTION PUMP 9410617949 1041151030

The information supplied in this service letter may not be valid after the termination date of this program. Do not perform the work outlined in this Service Letter after the termination date without first contacting your Caterpillar product analyst.
This Program must be administered as soon as possible. When reporting the repair, use "PI3596" as the Part Number, "77511" as the Group Number, "56" as the Warranty Claim Description Code and "T"as the SIMS Description Code. Exception: If the repair is done after failure, use "PI3596" as the Part Number, "77511" as the Group Number, "96" as the Warranty Claim Description Code, and "Z" as the SIMS Description Code.
Completion Date
October 31, 1992Termination Date
July 31, 1993Problem
The fuel injector may not seal properly in the injector bore of the cylinder head(s) of certain 3508, 3512, and 3516 Engines. The injector bore needs to be machined on these engines.
Affected Product
Model & Identification Number
3508 (1ZF666-668, 23Z4193-4273,23Z4277, 23Z4279, 23Z4283-4290,23Z4292,23Z4293,23Z4295,23Z4300,23Z4303,23Z4304;95Y822-830;96Y1253-1270;97Y676;69Z592-594,69Z597;70Z807,70Z808)
3512 ( 24Z4352-4411,24Z4413-4420, 24Z4424-4442, 24Z4444-4446,24Z4448,24Z4451-4453, 24Z4456, 24Z4458, 24Z4459,24Z4462,24Z4463;50Y1020-1043;51Y670-672;65Z742-752 ; 66Z486-489;67Z928-959;3YF665-678;49Y664-666)
3516 (25Z2652-2663, 25Z2665-2712, 25Z2715-2722, 25Z2724-2730; 29Z1001-1005; 4XF419-424; 72Z438-440; 73Z545-548)
Parts Needed
Dealers will need to order parts for this Program.
1 - 6V1250 Seal2 - 8J8725 Seal Use as required. Quantities listed are per cylinder.
Action Required
Call Dave Bradshaw (ph. (317) 448-5590) to obtain a tool kit containing the tools necessary to rework the cylinder heads. After obtaining the tool kit, perform the rework according to the attached rework procedure.
Owner Notification
U.S. and Canadian owners will receive the attached Owner Notification.
Service Claim Allowances
Parts Disposition
Handle the parts in accordance with your Warranty Bulletin on warranty parts handling.
Make Every Effort To Complete This Program As Soon As Possible.
Attach.
(1-Owner Notification)(2-Rework Procedure)Copy Of Owner Notification For U.S. And Canadian Owners
Rework Procedure
Do not remove the cylinder heads from the engine to complete this rework.If the cylinder heads are stamped with "B" or "R".rework is not required. The "B" or "R" designates that the rework was already completed by the Lafayette Facility. The stamping is located on the cylinder head face.
A procedure and tool kit have been developed to rework the cylinder heads. Please contact Dave Bradshaw of 3500 Customer Service at telephone number (317) 448-5590 for information on how to obtain a tool kit. A list of the components in the tool kit follow.
Use the appropriate service manual disassembly and assembly module as a guide for removing and installing components in this procedure.
1. Identify all the components to be removed by cylinder number so they can be installed in the correct locations.2. Remove the valve cover.3. Remove the rocker arm assembly.4. Remove the fuel line between the fuel manifold and the cylinder head. Remove the unit injector.5. Check for carbon in the cylinder head injector bore, and on the injector's nozzle seat and bottom O-ring area. (See Illustration 1