AR01.00-D-1300NA | Check cylinders for leaks | 17.1.08 |
ENGINES 612.981 in MODEL WD1, WD2, WD3, WD6, WD7, XD1, XD2, XD3, XD4, XD5, XD6, XD7, YD1, YD2, YD3, YD4, YD5, YD6, YD7
ENGINES 647.981 in MODEL WD1, WD2, WD3, WD6, WD7, XD1, XD2, XD3, XD4, XD5, XD6, XD7, YD1, YD2, YD3, YD4, YD5, YD6, YD7
ENGINES 612.981 in MODEL 903.61 /66 /67, 904.61 /66 with CODE (ZU7) National version for Canada
ENGINES 612.981 in MODEL 903.61 /66 /67, 904.61 /66 with CODE (ZU8) National version for USA
ENGINES 612.981 in MODEL 903.61 /62 /66 /67, 904.61 /62 /66 with CODE (ZU9) National version for Mexico
ENGINES 647.981 in MODEL 903.61 /66 /67, 904.61 /66 with CODE (ZU7) National version for Canada
ENGINES 647.981 in MODEL 903.61 /66 /67, 904.61 /66 with CODE (ZU8) National version for USA
ENGINES 647.981 in MODEL 903.61 /62 /66 /67, 904.61 /62 /66 with CODE (ZU9) National version for Mexico
D01.00-1109-06
Shown on engine 612.981
1 Cooling system cap
2 Coolant expansion reservoir
3 Oil filler cap
4 Glow plug
5 Cylinder leakage tester
6 Intermediate piece
| Remove/install | ||
1 | Bring engine to operating temperature (approx. 80°C) | Check cylinder for leaks when the engine is at normal operating temperature. | |
Danger! | Risk of injury to skin and eyes caused by scalding from contact with hot coolant spray. Risk of poisoning caused by 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 containers. Wear protective gloves, protective clothing and safety glasses. | |
2 | Open cooling system cap (1) at coolant expansion reservoir (2) | Turn cooling system cap (1) carefully to first predetent, release pressure, then unscrew cooling system cap (1). | |
3 | Unscrew oil filler cap (3) | ||
4 | Remove glow plugs (4) | Engine 612.981 | |
Engine 647.981 | |||
5 | Position piston of cylinder to be tested using the TDC selector at ignition TDC | The TDC marking on the belt pulley (arrow) can also be used on the first cylinder. Crank engine at crankshaft in direction of rotation of the engine (clockwise). | |
6 | Install retaining lock for crankshaft/starter ring gear | ||
7 | Connect cylinder leakage tester (5) | Calibrate cylinder leakage tester (5). Remove check valve in screw-in fitting. | |
Intermediate piece from compression recorder set | |||
Socket | |||
Connection piece | |||
Intermediate piece | |||
| Checking | ||
8 | Pressurize cylinder with compressed air and read off pressure loss at cylinder leakage tester (5) | Cylinder leakage: permissible loss total indication | |
Cylinder leaktightness: permissible losses at valves and cylinder head gasket | |||
Cylinder leaktightness: permissible losses at pistons and piston rings | |||
If there is high pressure loss, determine the cause: | |||
| Determining pressure loss of cylinders | ||
9 | Conduct test for other cylinders in the firing order of the engine | See: | |
Firing order | |||
10 | Install in the reverse order |
Cylinder leakage
Number | Designation | All engines | ||
BE01.00-P-1001-02Z | Cylinder leakage: permissible loss total indication | % | 25 | |
BE01.00-P-1002-02Z | Cylinder leaktightness: permissible losses at valves and cylinder head gasket | % | 10 | |
BE01.00-P-1003-02Z | Cylinder leaktightness: permissible losses at pistons and piston rings | % | 20 | |
001 589 78 09 00
Intermediate piece
Wrench socket
Compression tester
Connector
001 589 76 21 00
611 589 02 63 00
611 589 04 63 00
Referenced documents
- ah0100n130002a Determine loss of pressure at cylinder
- ar0100d130001b Connect cylinder leak tester
- ar0100d130003na Firing order
- ar0330d5000na Remove/install retaining lock for crankshaft / ring gear
- ar1520d4111na Remove/install glow plugs
- ar1520d4111nb Remove/install glow plugs
- as2000z000101a Risk of injury to skin and eyes suffering scalding from contact with hot coolantspray. Risk of poisoning from swallowing coolant.