W01.00-1080-09
1 | Endoscope | 2 | Light projector |
Warning | Risk of accident from vehicle starting off by itself when engine running. Risk of injury (bruises and burns) resulting from working on the engine while it is being started or when it is running. | Secure vehicle to prevent it from starting off by itself. Wear closed and snug-fitting work clothes. Do not touch hot or rotating parts. | |
Warning | Risk of injury. Skin or eye injuries may result when handling hot or glowing objects. | Wear protective gloves, protective clothing and safety glasses, if necessary. | |
Warning | Risk of injury to skin and eyes suffering scalding from contact with hot coolantspray. 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 containers. | |
Caution | Risk of injury to skin and eyes due to handling of engine oil. Risk of poisoning caused by swallowing engine oil | Wear protective gloves, protective clothing and safety glasses. | |
Topical note | Notes on avoiding damage through contamination and foreign objects | ||
Notes for evaluation of a cylinder barrel | |||
Notes on the assessment of pistons and piston rings | |||
| Remove | ||
1 | Start engine and bring to operating temperature, then switch off engine. | Coolant temperature 80 °C. | |
2 | Attach turning device for engine. | ||
Bolt, turning device to timing case | |||
Turning device | |||
3 | Remove cylinder head cover. | ||
4.1 | Remove intermediate frame under cylinder head cover. | Engine 470.9 up to 222433, Engine 471.9 up to 124618 | |
4.2 | Remove fuel injector wiring harness. | Engine 470.9 as of 222434, 471.9 as of 124619 | |
5 | Remove high-pressure lines from rail to fuel injector. | ||
6 | Open cap on expansion reservoir and relieve pressure in cooling system; then close expansion reservoir again. | See information from body manufacturer. | |
7 | Remove fuel injectors. | ||
Illuminate | |||
8 | Connect endoscope (1) to light projector (2) and switch on light projector (2). | Pay attention to manufacturer's operating instructions. | |
9 | Lead endoscope (1) through bore of protective sleeve of cylinder to be checked. | | |
10 | Position piston on the cylinder to be checked at bottom dead center. | Check position of piston through the endoscope (1) and turn crankshaft using the turning device. | |
Turning device | |||
11 | Check condition of cylinder barrel, piston crown, clearance volume, and valves. | If damage is present or in case of doubt: | |
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Remove cylinder head. | |||
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12 | Test the remaining cylinders in the same way. | All cylinders can be checked using 3 crankshaft positions: cylinder 1 and 6, 2 and 5 or 3 and 4. | |
| Install | ||
13 | Install fuel injectors. | ||
14 | Install high-pressure line from rail to injection nozzle. | ||
15.1 | Install intermediate frame under cylinder head cover. | Engine 470.9 up to 222433, engine 471 up to 124618 | |
15.2 | Install fuel injector wiring harness. | Engine 470.9 as of 222434, engine 471 as of 124619 | |
16 | Install cylinder head cover. | ||
17 | Remove turning device for engine. | ||
Screw/bolt, cap of TDC inspection hole to timing case | |||
Turning device | |||
18 | Fill fuel low-pressure circuit on engine. |
904 589 04 63 00
Turning device
Referenced documents
- ah0000n500001h Notes on avoiding damage through contamination and foreign objects
- ah0140n000103a Notes for evaluation of a cylinder barrel
- ah0310n000104a Notes on the assessment of pistons and piston rings
- ar0120g5014nb Remove/install cylinder head cover
- ar0120g5016n Remove/install intermediate frame under cylinder head cover
- ar0130g5800n Remove/install cylinder head
- ar0130g5800nb Remove/install cylinder head
- ar0330g160003n Attach/detach cranking/blocking device for engine
- ar0703g0004n Remove/install fuel injectors
- ar0716g1003n Remove/install high-pressure line to fuel injector
- ar0716g1007n Fill fuel low-pressure circuit on engine
- ar0716g1008n Remove/install wiring harness for fuel injectors
- as0000z000201a Risk of injury. Skin or eye injuries may result when handling hot or glowing objects.
- as0000z000501a Risk of accident from vehicle starting off by itself when engine running. Risk of injury (bruises and burns) resulting from working on the engine while it is being started or when it is running.
- as1800z000101a Risk of injury to skin and eyes due to handling of engine oil. Risk of poisoning caused by swallowing engine oil
- as2000z000101a Risk of injury to skin and eyes suffering scalding from contact with hot coolantspray. Risk of poisoning from swallowing coolant.