Inspect cylinders with light probe

AR01.00-P-0200T

Inspect cylinders with light probe

2.11.11

 

Remove/install

 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

1

Withdraw ignition key

 To prevent starter being operated inadvertently.

2

Remove cylinder head cover trim

Engine 646.8/9, 647.9

AR01.20-P-5014-02A

Engine 648.961

AR01.20-P-5014-02C

 Except engine 646.8

*BA01.20-P-1002-01G

 Except engine 646.8

*BA01.20-P-1003-01G

3

Remove glow plugs

Model 211 with engine 646.9, 647.9, 648.9

AR15.20-P-4111T

Model 211 with engine 646.8

AR15.20-P-4111TX

Model 203, 209 with engine 646

AR15.20-P-4111PM

4

Remove injectors

Model 203.007/207/707 with engine 646.963

Model 211 with engine 646.9, 647.9, 648.9,

Model 203.007/207/707 with engine 646.962,

Model 203.008/208/708, model 209.308 with engine 646.966

AR07.16-P-1000T

Model 204, 211 with engine 646.8

AR07.16-P-1000TX



Notes on injectors

AH07.16-P-1000-01A



Notes about Common-Rail components

Engine 646.8

AH07.16-P-0002-01TX

5

Position piston of cylinder to be inspected to BDC

 Rotate engine at crankshaft in direction of rotation.

6

Connect up cylinder inspection light (1) and insert flexible endoscope (2) through bore for injectors into cylinder

Endoscope (cold light)
gotis://A_01_02.1



Checking

7

Inspect cylinder barrel

 If there is 'scoring' (wear to the cylinder), the cylinder barrel has become rough and honing marks are no longer visible. In case of doubt, remove cylinder head.

See: 

Engine 646.951 in model 211.004,

Engine 646.961 in model 211.006/206/606,

Engine 646.8 in model 204, 211

Remove/install cylinder head

AR01.30-P-5800T

Engine 646 in model 203, 209

Remove/install cylinder head

AR01.30-P-5800PM

Engine 647.961 in model 211.016/216/616

Remove/install cylinder head

AR01.30-P-5800TB

Engine 648.961 in model 211.026/226/023/223

Remove/install cylinder head

AR01.30-P-5800TA



General information on checking cylinder barrel

AH01.00-P-0300-01A

8

Inspect the remaining cylinders following the same procedure

9

Install in the reverse order

10

Check fuel system for leaks with engine running

Number

Designation

Engine
646.951/961,
647.961

Engine
646.962/963/966

Engine
648

BA01.20-P-1002-01G

Bolt, cylinder head cover trim to cylinder head

Nm

9

9

9

BA01.20-P-1003-01G

Bolt, cover to charge air manifold.

Nm

9

9

9