101606-0041 ZEXEL 9 400 615 403 BOSCH INJECTION-PUMP ASSEMBLY 9400615403 1016060041 8943927081

Overhaul Instructions
If you elect to perform an in-frame overhaul yourself, without having a Caterpillar dealer perform the overhaul for you or without using an overhaul kit, then you should be aware of the following: Rebuild or Exchange Cylinder Head Assembly, Cylinder Packs, Oil Pump and Fuel Transfer PumpYour cylinder head assembly, cylinder packs, oil pump and fuel transfer pump should be inspected according to the instructions found in various Caterpillar reusability publications. Refer to the Index Of Publications On Reusability Or Salvage Of Used Parts section of the Guideline For Reusable Parts and Salvage Operations, form SEBF8029 to determine the reusability publications needed for inspecting your parts.The Guideline For Reusable Parts and Salvage Operations is part of an established Caterpillar parts reusability program. These guidelines were developed to assist Caterpillar dealers and customers reduce costs by avoiding unnecessary expenditures for new parts when existing parts can be used as is, repaired or salvaged. Parts complying with the specifications outlined in the reusable parts guideline will give an additional service life.If your parts comply with the established visual, dimensional, functional, etc., inspection specifications expressed in the reusable parts guideline, then they should be reused.If your parts are not within specification, then they should be salvaged, repaired or replaced. Failure to salvage, repair or replace out-of-spec parts will result in unscheduled downtime and could result in costly repairs caused by potential damage to other engine parts.Furthermore, the use of out-of-spec parts can reduce your engine's efficiency and increase fuel consumption. Reduced engine efficiency and increased fuel consumption translates into higher operating costs. Therefore, Caterpillar recommends that you salvage, repair or replace your out-of-spec parts. Replace Main and Connecting Rod BearingsIn most probability, your main and connecting rod bearings will not last until your second overhaul. Therefore, Caterpillar recommends the installation of new main and connecting rod bearings at each overhaul period. Inspect Crankshaft, Camshaft, Camshaft Followers, Damper, Spacer Plate, Fuel Pump Camshaft and Fuel RackThe ideal time for inspecting your crankshaft, camshaft, camshaft followers, damper, spacer plate, fuel pump camshaft and fuel rack is while your engine is disassembled for overhaul. Inspect each component for potential damage as follows: * Crankshaft - Inspect for bend, journal damage and bearing material seized to the journal. At the same time, check the taper and profile of the crankshaft journals by interpreting your main and connecting rod bearing wear patterns. In case of an out-of-frame overhaul, use the magnetic particle inspection process to check the crankshaft for cracks.* Camshaft - Inspect the camshaft for journal damage. In case of an out-of-frame overhaul, use the magnetic particle inspection process to check the camshaft for cracks.* Camshaft Followers - For out-of-frame overhaul, inspect the cam bearing for fatigue and wear.* Damper - Inspect the damper for rubber deterioration and movement of the outer ring relative to the inner hub. (Refer to the Vibration Damper topic in the PM Level 2 section of this publication for additional information.)* Spacer Plate - Inspect the spacer plate for