Inspect cylinder liner and piston for cracks

AR01.40-W-0001A

Inspect cylinder liner and piston for cracks

29.6.99

 

Remove/Install

 Danger!

Risk of injury to skin and eyes suffering scalding from contact with hot coolant spray. Risk of poisoning from
swallowing coolant.

Do not open cooling system unless coolant temperature is below 90 °C. Open cap slowly and release the pressure. Do not pour coolant into beverage bottles.

Wear protective gloves, protective clothing and eye protection.

AS20.00-Z-0001-01A

1

Open cap of expansion reservoir



Notes on coolant

All engines

AH20.00-N-2080-01A

2

Remove one coolant thermostat (3) and remove the bypass valve (3.1)

 Installation: Remove coolant thermostat again without bypass valve and install new coolant thermostat with
bypass valve.

AR20.10-W-2460B

3

Install coolant thermostat (3) without bypass valve (3.1) and pour in coolant



AP20.00-W-2080A

4

Screw on cap tight at expansion reservoir

 Danger!

Risk of accident. Accidents may result if the vehicle starts off unintentionally with the engine running. Risk of injury from bruises and burns if you insert your hand into the engine when it is being started or when
it is running.

Secure vehicle to prevent it from moving.
Wear closed and snug-fitting work clothes.
Do not grasp hot or rotating parts.

AS00.00-Z-0005-01A

5

Run engine at moderate revs to warm up to a coolant temperature of approx. 80 °C and hold at this coolant temperature for about 5 minutes

 The radiator can be covered
over if necessary.

6

Switch off engine and allow coolant temperature to cool down to approx. 50 °C

7

Remove nozzle holder combination

AR07.03-W-6831B

8

Take off end cover of TDC inspection hole and attach cranking device to timing case



*407589006300



*BA01.60-N-1001-01B

Inspect

9

Open cap of expansion reservoir

10

Attach adapter and tester to
expansion reservoir



*001589832100



*655589006300

11

Pressurize cooling system at tester with comrpessed air

 Test pressure approx. 1.2 bar.

12

Connect light projector (2) and insert inspection probe (1) through the protective sleeve hole into the cylinder

 Use flexible inspection
probe  8.5 mm.  The length tip of the flexible inspection probe must be handled particularly gently and carefully. Ambient
temperature  80 °C .

 Flexible endoscope (complete unit)

*WH58.30-Z-1006-05A

 Flexible endoscope (supply kit for workshops which already have an approved endoscope)

*WH58.30-Z-1007-05A

13

Rotate crankshaft with the cranking device (7) until the piston of the cylinder to be inspected is positioned at the bottom
dead center

 The flexible inspection probe must not be touching the piston crown otherwise the tip of the probe may be damaged.

14

Inspect cylinder wall, cylinder head and piston crown

 If coolant mist (arrows (A) present in cylinder, flows in through opened inlet or exhaust valves 

cracks in cylinder head

 If coolant channel (arrow B) is present on cylinder wall 

cracks in cylinder liner

The cylinder walls must not reveal any scorch streaks and rubbing streaks. Individual slight drawing scores
are not critical.

If the piston crown is damaged:

Replace piston and rectify the cause.

AR03.10-W-7021B

15

Install in the reverse order

16

Inspect the remaining cylinders in
the same way

17

Inspect coolant level



AP20.00-W-2010A

Number

Designation

Engines
541.9, 542.9

BA01.60-N-1001-01B

Bolt, TDC inspection hole cap to timing case

Nm

25

Number

Designation

WH58.30-Z-1006-05A

Flexible endoscope, package contents 1 (complete unit),

Firma Richard Wolf GmbH D-75438 Knittlingen

Firma Karl Storz GmbH D-78532 Tuttlingen

WH58.30-Z-1007-05A

Flexible endoscope package contents 2 (for workshops which already have an approved endoscope from the Wolf or Storz company),

Firma Richard Wolf GmbH D-75438 Knittlingen

Firma Karl Storz GmbH D-78532 Tuttlingen