Inspect cylinders with a light probe

AR01.00-W-0200H

Inspect cylinders with a light probe

23.07.2019

Engine

470.9, 471.9, 473.9 in model 963, 964

1

Endoscope

2

Light projector

 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

 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

 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 injury caused by body parts being pinched or crushed as cab is tilted

Ensure that no one is within the tilting range of the cab as it is being tilted. Always tilt the cab all the way to the end position and secure it with the safety strut.

AS60.80-Z-0001-01A

Topical note

Notes on avoiding damage through contamination and foreign objects

AH00.00-N-5000-01H

Topical note

Notes on tilting the cab

AH60.80-N-0003-01A



Remove

1

Start engine and bring to normal operating temperature then switch off engine

 Coolant temperature  80°C.

2

Tilt cab

3

Remove soundproofing

4

Attach turning device for engine

AR03.30-W-1600-03H

 Bolt, turning device to timing case

*BA01.60-N-1002-01N

 Turning device

*904589046300

5

Remove cylinder head cover

ENGINE 470.9

AR01.20-W-5014HB

Engine 471.9

AR01.20-W-5014HA

ENGINE 473.9

AR01.20-W-5014V

6.1

Remove intermediate frame under cylinder head cover

Engine 470.9, 471.9 up to engine no. 124618

AR01.20-W-5016H

6.2

Remove injection nozzle wiring harness

Engine 471.9 from engine no. 124619, 473.9

AR07.16-W-1008H

7

Remove high-pressure lines from rail to injection nozzle

AR07.16-W-1003H

 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

8

Open cover on expansion reservoir and relieve coolant pressure, then reseal expansion reservoir

9

Remove fuel injectors

AR07.03-W-0004H

Illuminate

10

Connect the endoscope (1) to the light projector (2) and switch on the light projector (2)

 Pay attention to manufacturer's operating instructions.
Use endoscope (1) with a diameter of  8.5 mm.

11

Lead endoscope (1) through the bore of the protective sleeve of the cylinder to be checked


The endoscope (1) must not touch on or hit against the piston crown.
The objective probe tip can get damaged otherwise.

 Coolant temperature approx. 80°C.

12

Position piston on 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

*904589046300

13

Check condition of cylinder barrel, piston crown, clearance volume and valves

Notes for evaluation of a cylinder barrel

AH01.40-N-0001-03A

Notes on the assessment of pistons and piston rings

AH03.10-N-0001-04A

In case of damage or when in doubt



Remove cylinder head.

ENGINE 470.9

AR01.30-W-5800HB

Engine 471.9

AR01.30-W-5800HA

ENGINE 473.9

AR01.30-W-5800HC

14

If applicable, check 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

15

Install fuel injectors

AR07.03-W-0004H

16

Install high-pressure line from rail to injection nozzle

AR07.16-W-1003H

17.1

Install intermediate frame under cylinder head cover.

Engine 470.9, 471.9 up to engine no. 124618.

AR01.20-W-5016H

17.2

Install fuel injector wiring harness

Engine 471.9 from engine no. 124619, 473.9

AR07.16-W-1008H

18

Install cylinder head cover

ENGINE 470.9

AR01.20-W-5014HB

Engine 471.9

AR01.20-W-5014HA

ENGINE 473.9

AR01.20-W-5014V

19

Remove turning device for engine

AR03.30-W-1600-03H

 Holder for front axle travel sensor to crossmember

*BA32.30-N-1005-04B

 Screw/bolt, cap of TDC inspection hole to timing case

*BA01.60-N-1001-01N

 Turning device

*904589046300

20

Fill fuel low-pressure circuit on engine

AR07.16-W-1007H

21

Install soundproofing

22

Tilt back cab

 Timing case

Number

Designation

Engine 470.9, 471.9

Engine 473.9

BA01.60-N-1001-01N

Screw/bolt, cap of TDC inspection hole to timing case

Nm

30

30

 Timing case

Number

Designation

Engine 470.9, 471.9

Engine 473.9

BA01.60-N-1002-01N

Bolt, turning device to timing case

Nm

30

30

 Level control

Number

Designation

Model 963, 964

BA32.30-N-1005-04B

Holder for front axle travel sensor to crossmember

M10

Nm

50