101603-8781 ZEXEL 9 400 610 674 BOSCH INJECTION-PUMP ASSEMBLY 9400610674 1016038781 1156030261

Above Normal Heating Recommended Procedure1. Low Coolant Level If the coolant level is too low, not enough coolant will go through the engine and radiator. This lack of coolant will not take enough heat from the engine and there will not be enough flow of coolant through the radiator to release the heat into the cooling air. Low coolant level is caused by leaks or wrong filling of the radiator. With the engine cool be sure that coolant can be seen at the low end of the fill neck or at the sight glass on the radiator top tank.2. Bad Temperature Gauge A temperature gauge which does not work correctly will not show the correct temperature. If the temperature gauge shows that the coolant temperature is too hot but other conditions are normal, either install a gauge you know is good or check the cooling system with the 9S9102 Thermistor Thermometer Group.3. Dirty Radiator Check the radiator for debris in the radiator core which prevents free air flow through the radiator core. Check the radiator for debris, dirt, or deposits on the inside of the radiator core which prevents free flow of coolant through the radiator.4. Loose Belts Loose fan or water pump belts will cause a reduction in air or water flow. Tighten belts until a 25 lb. (11,3 kg.) force at the half way point between the pulleys, moves the belts .875 .125 in. (22,0 3,0 mm).5. Bad Hoses Bad hoses with leaks can normally be seen. Hoses that have no visual leaks can "collapse" (pull together) during operation and cause a restriction in the flow of coolant. Hoses become soft and/or get cracks after a period of time. Hoses must be changed after 50,000 miles or a year of use. The inside can become loose and the loose particles of the hose can cause a restriction in the flow of coolant.6. Shunt Line Restriction A restriction of the shunt line from the radiator top tank to the engine front cover, or a shunt line not installed correctly, will cause a reduction in water pump efficiency. The result will be low coolant flow and over-heating.7. Shutters Not Opening Correctly Check the opening temperature of the shutters. The shutters must be open at 200° F (93° C).8. Bad Thermostats A thermostat that does not open or only opens part of the way can cause above normal heating. To test the thermostats, see the Testing and Adjusting section of the Service Manual.9. Bad Water Pump A water pump with a loose pulley or impeller does not pump enough coolant for correct engine cooling. A loose pulley or impeller can be found by removing the drive belt for the water pump and by pushing the pulley back and pulling it forward. If the pulley or impeller is not loose, remove the water pump and check for damage to the impeller. If the impeller has no damage, check the impeller clearance. The clearance between the impeller and