101695-3340 ZEXEL 9 400 616 105 BOSCH INJECTION-PUMP ASSEMBLY 9400616105 1016953340 6206711335

At operating temperature, the engine cooling system is hot and under pressure. Steam can cause personal injury. Check the coolant level only after the engine has been stopped and the fill cap on the radiator is cool enough to touch with your bare hand. Remove the fill cap slowly to relieve pressure. Cooling system conditioner contains alkali. Avoid contact with skin and eyes to prevent personal injury.
1. Drain the coolant from the cooling system into a suitable container for disposal. 2. Disconnect the water supply hose from the water pump inlet.3. Remove connector pipe (1). Remove two bolts (2) and the washers. Remove oil fill pipe (3).4. Remove bolts and washers (4) and water pump (5) from the front housing. The following steps are for the installation of the water pump.5. Check the condition of the O-ring seal used between the water pump and the front housing. If the seal is worn or damaged, use a new part for replacement. Install the O-ring seal on the water pump.6. Lubricate the bore in the front housing with clean engine oil. Put the water pump in position in the front housing. Install bolts (4) and the washers that hold the water pump. Tighten the bolts evenly.7. Check the condition of the gaskets used with connector pipe (1) and oil fill pipe (3). If the gaskets are worn or damaged, use new parts for replacement.8. Position the gasket and connector pipe (1) on the engine. Install the bolts and washers that hold it.9. Put oil fill pipe (3) in position on the engine. Be sure the gasket is in position between the regulator and oil fill pipe. Install oil fill pipe. Install bolts (2) and the washers.10. Connect the water supply hose to the inlet of the water pump.11. After installation of the alternator, fill the cooling system with coolant to the correct level. See the Operation & Maintenance Manual for the correct filling procedure.End By:a. Install alternator.Disassemble Water Pump
Start By:Remove the water pump. Refer to Disassembly and Assembly, "Water Pump - Remove". The information is in this manual.
Keep all parts clean from contaminants. Contaminants may cause rapid wear and shortened component life
(3) Cover bolts(4) Hex washer(5) Bolt(6) Bearing(7) Gear(8) Retaining ring(9) Impeller(10) Shaft(11) Water seal(12) Oil seal(13) Water pump housing 1. Remove water pump elbow (1). Remove elbow (2). 2. Remove cover bolts (3). Carefully separate the housing from the cover. 3. Hold hex washer (4). Remove hex socket head bolt (5). 4. Remove bearing (6). 5. Use Tooling (A) to remove gear (7). 6. Use Tooling (B) to remove retaining ring (8). Remove inner bearing (6). 7. Use Tooling (C) to remove impeller (9). 8. Use a hydraulic press and remove shaft assembly (10). 9. Remove water seal (11). 10. Remove oil seal (12).Assemble Water Pump
Keep all parts clean from contaminants. Contaminants may cause rapid wear and shortened component life.
(3) Cover bolts(4) Hex washer(5) Bolt(6) Bearing(7) Gear(8) Retaining ring(9) Impeller(10) Shaft(11) Water seal(12) Oil seal(13) Water pump housing1. Use