101482-4440 ZEXEL 9 400 611 501 BOSCH INJECTION-PUMP ASSEMBLY 9400611501 1014824440 8970299940

Image1.1.1
5. Attach a hose to the other end of the fuel rail and hold the free end of the hose in a cup/bucket of water. Hose shown is a JIC 37o ?6 hose. Refer to Illustration 1.2.1
Image1.2.1
6. Pressurize the cooling system with compressed air and regulate pressure between 5-15 psi.
Do Not Exceed 15 psi or Cooling System Damage Can Result.
7. Submerse the hose in a cup/bucket of water.
8. Monitor for 10 minutes and check for a steady rate of air bubbles coming out of the hose that is submersed in the cup/bucket of water.
9. If steady stream of air is present, replace the cylinder head, coolant regulators, and both 030-7937 port connectors. Depending on the application, you will need to replace some cooling system seals. (List of seals by application to be included)
10. Once the cylinder heads have been replaced pressure test the head again using the same procedure. Once this has been completed the cooling system should be flushed using instructions listed below.
Cleaning the Cooling System
1. Drain all of the coolant form cooling system.
2. Fill the cooling system with clean water.
3. Start engine and run it until the thermostat opens.
4. Add two cups of non-foaming liquid automatic dish washer soap.
Note: Do not use plain dish soap. Aeration of the cooling system and resultant damage could occur.
5. After the soap has bee added run engine for approximately twenty minutes. Check to see if the fuel is breaking up.
6. If the fuel is still not breaking up than add two more cups of soap and run for 10 minutes. Drain mixture from cooling system.
7. Fill cooling system with clean water and check surface for fuel. If fuel is present, repeat steps 3 through 7. When water is clear, drain and rinse the cooling system one more time. Then add coolant and conditioner.