Check cylinders for leaks

AR01.00-S-1300CD

Check cylinders for leaks

18.12.2018

Model

415 with engine 607, 608

Modification notes

18.12.2018

Work procedure revised, special tools updated

Operation steps 1 to 11

4

Pressure loss tester

 Danger

Risk of explosion caused by 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

 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.
Wear protective gloves, protective clothing and safety glasses.

AS20.00-Z-0001-01A

 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.

AS00.00-Z-0002-01A

 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.

AS00.00-Z-0005-01A

 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.
Do not fill engine oil into beverage containers.

AS18.00-Z-0001-01A

Topical note

Notes on avoiding damage through contamination and foreign objects

AH00.00-P-5000-01A

Determine loss of pressure at cylinder

AH01.00-N-1300-02A



Remove

1

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

 Only check cylinder leakage when the engine is at normal operating temperature.

2

Switch off ignition and remove transmitter key.

3

Remove glow plugs.

Model 415 with engine 607

AR15.20-S-4111CD

Model 415 with engine 608

AR15.20-S-4111CE



Check

4

Position piston of cylinder to be checked at top dead center (TDC).


Do not crank engine in opposite direction of engine rotation.
Damage and measurement errors can occur otherwise.

 To do this, turn the engine at the center bolt of the crankshaft until the marking 0° on the belt pulley matches the marking on the oil pan.

5

Install screw-in piece and adapter in the glow plug hole as shown.

 Screw-in fitting

*607589009100

 Intermediate piece

*611589026300

6

Connect pressure loss tester (4) as shown.

 Calibrate  pressure loss tester (4) before the start of the test. Observe manufacturers instructions.

 Pressure loss tester

*450589172100

7

Check cylinder leakage.

 To do this, apply compressed air to the cylinder and read off pressure loss.

Cylinder leakage: 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:



remove starter, insert retaining lock in the ring gear of the flywheel and fasten using a suitable nut.

Model 415 with engine 607

AR15.30-S-7100CD

Model 415 with engine 608

AR15.30-S-7100CE

 Retaining lock

*607589014000

8

Remove pressure loss tester (4).

 Pressure loss tester

*450589172100

9

Remove screw-in piece and adapter.

 Screw-in fitting

*607589009100

 Intermediate piece

*611589026300

10

Perform check of the additional cylinders in the same way as per the firing order of the engine.

Model 415 with engine 607

AR01.00-P-1300-03T

Firing order

Model 415 with engine 608

AH01.00-N-0100-02P



Install

11

Install glow plugs.

Model 415 with engine 607

AR15.20-S-4111CD

Model 415 with engine 608

AR15.20-S-4111CE

Cylinder leakage

Number

Designation

Engine 000, 104, 112, 161, 166, 200, 272, 274, 607, 608, 611, 622, 642, 646, 651, 661, 662, 668, 699

BE01.00-P-1001-02Z

Cylinder leakage: permissible loss total indication

%

 25

Cylinder leakage

Number

Designation

Engine 000, 104, 112, 161, 166, 200, 272, 274, 607, 608, 611, 622, 642, 646, 651, 661, 662, 668, 699

BE01.00-P-1002-02Z

Cylinder leaktightness: Permissible losses at valves and cylinder head gasket

%

 10

Cylinder leakage

Number

Designation

Engine 000, 104, 112, 161, 166, 200, 272, 274, 607, 608, 611, 622, 642, 646, 651, 661, 662, 668, 699

BE01.00-P-1003-02Z

Cylinder leaktightness: Permissible losses at pistons and piston rings

%

 20