Inspect cylinders for leaks

AR01.00-P-1300HV

Inspect cylinders for leaks

19.1.98



Remove, Install

Danger!

Risk of accident from vehicle starting off by itself when engine running. Risk of injury suffered in the form of bruises or burns to the hands when reaching in while the engine cranks or runs

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

AS00.00-Z-0005-01A

1

Bring engine to operating temperature (approx. 80 °C )

 Check the cylinder for leaks only when the engine is at normal operating temperature.

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

2

Open cap (2) of expansion reservoir

In Model 463 with Engine 112, 113, a cap (2) with a detent is built-in

Turn cap carefully up to the first pre-detent, relieve the pressure and then unscrew the cap (2).

 A 1-stage cap is fitted to Model 163 with Engine 112, 113.

Turn the 1-stage and 2-stage cap half a revolution counterclockwise, relieve the pressure, then unscrew the 1-stage or 2-stage cover.

3

Remove a spark plug (19) from each cylinder



Model 202, 208, 209, 210 with Engine 112, 113.

Model 203, 170 with Engine 112.

AP15.10-P-1580A



Model 163 with Engine 112, 113.

AP15.10-P-1580GH



Model 215, 220 with Engine 137.

AP15.10-P-1580L



Model 230.474/475, 211, 220 with Engine 112, 113

AP15.10-P-1580AB



Model 240 with Engine 285.

AP15.10-P-1580H



Model 463 with Engine 112,113

AP15.10-P-1580GA

4

Position piston of cylinder to be tested to ignition TDC

Crank the engine at the center bolt of the crankshaft in the direction of rotation of engine.

5

Connect cylinder leak tester (04)

Calibrate cylinder leakage tester (04) and screw the connection hose into the spark plug bore

Cylinder leak tester

*WH58.30-Z-1015-05A

6

Remove the oil filler cap (3)



Inspection

7

Apply compressed air to the cylinder, read off pressure loss on the cylinder leakage tester (04) and determine the cause if there is an increased pressure loss

Cylinder leaktightness permissible loss total indication

*BE01.00-P-1001-02Z

Cylinder leaktightness permissible losses at valves and cylinder head gasket

*BE01.00-P-1002-02Z

Cylinder leaktightness permissible losses at pistons and piston rings

*BE01.00-P-1003-02Z

If the crankshaft rotates:

Engine 112, 113, 137.

Install retaining lock for crankshaft

AR03.30-P-5000B

Engine 285.

Lock crankshaft with counterholder.

 Retainer

*112589004000

8

Conduct the test of the other cylinders in the firing order of the engine

AR01.00-P-1300-03HA

9

Install in the reverse order

Number

Designation

All Engines

BE01.00-P-1001-02Z

Cylinder leakage permissible loss total indication

%

25

BE01.00-P-1002-02Z

Cylinder leakage permissible losses at valves and cylinder head gasket

%

10

BE01.00-P-1003-02Z

Cylinder leakage permissible losses at pistons and piston rings

%

20

Number

Designation

WH58.30-Z-1015-05A

Cylinder leakage testing unit