Inspecting cylinders with a light probe · ar0100p0200hb · Mercedes-Benz WIS

AR01.00-P-0200HB

Inspecting cylinders with a light probe

17.1.08

ENGINES 611.960 /961 /962, 612.961 /962 /963 /965 /966 /967 /990, 613.960 /961, 628.960 /962 /963

P01.00-0475-09

Shown on engine 611.960

 	Remove/install
1	Withdraw ignition key	 To prevent starter being operated inadvertently.
2.1	Remove cylinder head cover trim	Engine 611.960/961/962	AR01.20-P-5014-02A
		Engine 612.961/962/963/965/967/990	AR01.20-P-5014-02B
		Engine 612.966 in model 461.331	AR01.20-P-5014-02GLC
		Engine 613.960/961	AR01.20-P-5014-02C
			*BA01.20-P-1002-01A
			*BA01.20-P-1003-01A
2.2	Remove air filter	Engine 628.960	AR09.10-P-1050M
		Engine 628.962	AR09.10-P-1050GD
2.3	Detach intake air distribution pipe	Engine 628.963	AR09.10-P-1250CD
3	Remove glow plugs (R9)	 Except engine 612.990	AR15.20-P-4111HB
		Engine 612.990	AR15.20-P-4111PF
Danger!	Risk of explosion caused by fuel igniting, risk of poisoning caused by inhaling and swallowing fuel and risk of injury to eyes and skin caused by contact with fuel	No fire, sparks, open flames or smoking. Pour fuels only into suitable and appropriately marked containers. Wear protective clothing when handling fuel.	AS47.00-Z-0001-01A
4	Remove fuel injectors (Y76)	Engine 611, 612, 613	AR07.16-P-1000HB
		Engine 628	AR07.16-P-1000M
	Notes on injectors	Engine 611.960/961/962/980/981/987, 612.961/962/963/965/966/967/981, 613.960/961, 628.960/961/962/963, 640.941, 646.951/961/962/963, 647.961/981, 648.960/961, 668.914/940/941/942, 612.990	AH07.16-P-1000-01A
5	Remove intercooler	Only with engine 628.960 in model 220	AR09.41-P-6817MA
		Only with engine 628.962 in model 463	AR09.41-P-6817GA
6	Remove viscous fan clutch	Only for engine 612.965/966	AR20.40-P-5660GP
7	Position piston of cylinder to be inspected to BDC	 To do this rotate engine at crankshaft in the running direction.
8	Inspecting cylinders with a light probe	 Connect cylinder inspection light (05) for this step and insert flexible test probe (06) of cylinder inspection light (05) into the injector well.
		Flexible endoscope, package contents 1 (complete unit),
		Flexible endoscope, package contents 2 (for workshops which already have an approved endoscope from the Wolf or Storz company),
		Cylinder inspection equipment
	Checking
9	Inspect cylinder walls	 In case of 'scoring' (cylinder wear), the cylinder wall has roughened and the honing marks are no longer visible. In cases of doubt:
		Remove cylinder head
		Engine 611.960/961	AR01.30-P-5800HB
		Engine 611.962, 612.962/990 in model 203 Engine 612.967 in model 209	AR01.30-P-5800PP
		Engine 612.961/963	AR01.30-P-5800HC
		Engine 612.965/966	AR01.30-P-5800GS
		Engine 613.960/961	AR01.30-P-5800HD
		Engine 628.960/962	AR01.30-P-5800MD
		Engine 628.963	AR01.30-P-5800MA
	General information on inspecting cylinder walls	Engine 112, 113, 134, 135, 137, 166, 275, 285, 611, 612, 613, 628, 639, 646, 647, 648	AH01.00-P-0300-01A
10	Install in the reverse order
 Danger!	Risk of accident caused by vehicle starting off by itself when engine is running. Risk of injury caused by contusions and burns during starting procedure or when working near the engine as it is running	Secure vehicle to prevent it from moving by itself. Wear closed and snug-fitting work clothes. Do not touch hot or rotating parts.	AS00.00-Z-0005-01A
 Danger!	Risk of explosion from fuel igniting. Risk of injury to skin and eyes caused by fuel spraying out at high pressure.	Keep all ignition sources out of hazard area. Do not carry out any work on system when it is pressurized.	AS07.16-Z-0001-01A
11	Check fuel system for leaks with engine running

 Crankcase ventilation, cylinder head cover

Number	Designation		Engine 611.960/ 961/962	Engine 612.961/ 962/967	Engine 612.963	Engine 613.960/ 961


BA01.20-P-1002-01A	Bolt, trim panel of cylinder head cover to cylinder head cover	Nm	10	10	10	10
BA01.20-P-1003-01A	Bolt, charge air distribution pipe cover to charge air manifold	Nm	10	10	10	10

 Crankcase ventilation, cylinder head cover

Number	Designation		Engine 612.965	Engine 612.966	Engine 612.990


BA01.20-P-1002-01A	Bolt, trim panel of cylinder head cover to cylinder head cover	Nm	10	10	8
BA01.20-P-1003-01A	Bolt, charge air distribution pipe cover to charge air manifold	Nm	10	10	-

Referenced documents

ah0100p030001a General information on inspecting cylinder walls
ah0716p100001a Notes on injectors
ar0120p501402a Remove/install cylinder head cover trim
ar0120p501402b Remove/install cylinder head cover trim
ar0120p501402c Remove/install cylinder head cover trim
ar0120p501402glc Remove/install cylinder head cover trim
ar0130p5800gs Remove/install cylinder head
ar0130p5800hb Remove/install cylinder head
ar0130p5800hc Remove/install cylinder head
ar0130p5800hd Remove/install cylinder head
ar0130p5800ma Remove/install cylinder head
ar0130p5800md Remove/install cylinder head
ar0130p5800pp Remove/install cylinder head
ar0716p1000hb Remove/install injectors
ar0716p1000m Remove/install injectors
ar0910p1050gd Remove air cleaner, install
ar0910p1050m Removing and installing air cleaner
ar0910p1250cd Detach and attach the intake air distribution pipe
ar0941p6817ga Removing and installing charge air cooler
ar0941p6817ma Removing/installing the charge air cooler
ar1520p4111hb Remove/install glow plugs
ar1520p4111pf Remove/install glow plugs
ar2040p5660gp Remove/install viscous fan clutch
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.
as0716z000101a Risk of explosion caused by fuel igniting. Risk of injury to skin and eyes caused by fuel spraying out at high pressure
as4700z000101a Risk of explosion caused by fuel igniting, risk of poisoning caused by inhaling and swallowing fuel as well as risk of injury to eyes and skin caused by contactwith fuel.