101492-3791 ZEXEL INJECTION-PUMP ASSEMBLY Calibration Data 1014923791 6202731141

A maximum of $100 will be allowed for machining of cylinder head face to achieve required surface finish after failure.
Product smu/age whichever comes first Caterpillar Dealer Suggested Customer Suggested
Parts % Labor Hrs% Parts % Labor Hrs% Parts % Labor Hrs%
*******Group 2*******
0-3000 hrs,
0-48 mo 100.0% 100.0% 0.0% 0.0% 0.0% 0.0%
This is a 13.0-hour job for Group 2
A maximum of $100 will be allowed for machining of cylinder head face to achieve required surface finish after failure.
Product smu/age whichever comes first Caterpillar Dealer Suggested Customer Suggested
Parts % Labor Hrs% Parts % Labor Hrs% Parts % Labor Hrs%
*******Group 3*******
0-3000 hrs,
0-48 mo 100.0% 100.0% 0.0% 0.0% 0.0% 0.0%
This is a 13.0-hour job for Group 3
A maximum of $100 will be allowed for machining of cylinder head face to achieve required surface finish after failure.
PARTS DISPOSITION
****Parts Stock****
Handle the parts in accordance with your Warranty Bulletin on warranty parts handling.
****Affected Product****
Handle the parts in accordance with your Warranty Bulletin on warranty parts handling.
Rework Procedure
If the head gasket has failed follow the rework procedure for both head gasket replacement and for fuel injection pump replacement. Check that the fuel pump has not suffered a mechanical failure that has resulted in a head gasket failure, such as mechanical failure of the advance box due to air ingress. Head gasket failure due to mechanical failure of the fuel pump is not covered by this service letter.
Head gasket replacement:
Confirm the head gasket has failed through removal of the cylinder head and visual inspection of the gasket. Remove cylinder head ? refer to Disassembly and Assembly, "Cylinder Head - Remove". Confirm head gasket has failed through visual inspection, as per the images shown in Image 1.1.1.
Clean the cylinder head face and the cylinder block face to remove any deposits on the gasket sealing surface using an appropriate cleaner. Do not use abrasive materials to remove the deposits during the cleaning process to ensure that the correct surface flatness is maintained.
Inspect cylinder head for flatness and distortion. Refer to Image 1.1.2 for surface finish. Refer to System Operation Testing and Adjusting, "Cylinder Head ? Inspect" for more information. Resurface the cylinder head if required as per Testing and Adjusting, "Cylinder Head ? Inspect".
Inspect cylinder block for surface finish on the top deck of the cylinder block. Refer to Image 1.1.2 for surface finish. If the cylinder block is within specifications, install a new 258-4946 Cylinder Head Gasket. If the block is not within specification, refer to Reuse And Salvage Guidelines, SEBF8076, "Specifications to Salvage Contact Surfaces of Cylinder Blocks" for more information.
Note: A 369-3705 Cylinder Head Gasket may be required, depending on reuse and salvage guidelines.
Follow Disassembly and Assembly, "Cylinder Head ? Install" with a new gasket as per above information.
Fuel injection pump replacement:
Follow Disassembly and Assembly, "Fuel Injection Pump - Remove - Delphi DP210". Do not reuse the fuel pump. Record removed fuel pump serial number in claim story. The fuel pump serial number is in the format "12345ABC".
Install the new 483-2328 Fuel Pump as per Disassembly and Assembly, "Fuel Injection Pump -