Checking compression pressure procedure |
2 | Tappet cover |
5 | Gearshift linkage |
6 | Gearshift lever support arm LHS |
7 | Gearshift lever support arm RHS |
8 | Gearshift lever carrier |
9 | Engine trim panel |
10 | High pressure pipes |
Y01.10-0113-06
11 | Special tool impact extractor 355 589 01 63 00 |
12 | Fuel injector retainer clamp bolt |
13 | Threaded insert 904 589 00 63 00 |
14 | Washer |
15 | Special tool compression gauge adapter 090 589 01 91 00 |
Y01.10-0008-06
15 | Special tool compression gauge adapter 090 589 01 91 00 |
16 | Retainer plate |
17 | Connecting piece |
Y01.10-0009-06
18 | Compression gauge |
Y01.10-0010-01
After checking all the cylinders compression pressure |
10 | High pressure pipes |
12 | Fuel injector retainer clamp bolt |
17 | Connecting piece |
19 | Adapter retainer plate bolt |
20 | Fuel injector |
Y01.10-0011-06
2 | Tappet cover |
5 | Gearshift linkage |
6 | Gearshift lever support arm left hand side |
7 | Gearshift lever support arm right hand side |
8 | Gear shift lever carrier |
9 | Engine trim panel |
10 | High pressure pipes |
Y01.10-0012-06
| Remove | ||
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 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. | |
Danger | 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. | No fires, sparks, open flames or smoking. Pour fuels into suitable and appropriately marked containers only. | |
1 | Remove gearshift linkage (5) from the gearshift lever assembly end by removing bolt. | ||
2 | Remove gearshift lever support arm on the left hand side (6) and right hand side (7) from the engine. | ||
3 | Remove gearshift lever carrier (8) along with gearshift lever assembly. | ||
4 | Remove engine trim panel (9) from tappet cover. | ||
5 | Remove tappet cover (2) by removing the cover screws. | ||
6 | Remove high pressure pipes (10) from the pressure pipe adapters and from the unit injection pumps. | ||
7 | Remove pressure pipe screw plugs using special tool impact extractor (11) from cylinder head. | Impact extractor | |
8 | Remove fuel injector safety clip (12). | ||
9 | Use special tool impact extractor (11) and threaded insert (13) remove fuel injectors from whole 6 cylinders. | Fuel injector, high pressure pipes and pressure pipe must be stored in a box by numbering it, so that it does not get interchanged during assembly. | |
Threaded insert | |||
Impact extractor | |||
10 | Apply lubricating grease to washer (14) and fix it to the special tool test adapter. | ||
| |||
Test adapter | |||
| Check | ||
11 | Install special tool test adapter (15) to the 1st cylinder fuel injector groove in the cylinder head. | Test adapter | |
12 | Fix retainer plate (16) and connecting piece (17) to the compression pressure gauge adapter. | ||
13 | Attach connecting piece (17) to the compression gauge adapter. | ||
14 | Attach connecting piece (17) and adapter to the pressure gauge. | ||
15 | Crank engine and check the compression gauge (18). | Once the maximum measurement value has been recorded, release the pressure gauge by depressing the air release knob. | |
16 | Remove compression test device from the first cylinder. | ||
17 | Follow step 11 to 16 for checking the compression pressure in the next cylinders 2nd to 6th. | Cylinder compression pressure | |
| Install | ||
18 | Disconnect positive and negative terminals from the starter motor assembly. | ||
19 | Remove connection piece (17) from the gauge and adapter. | ||
20 | Remove the adapter by loosening the adapter retainer plate bolt (19). | ||
21 | Fit the corresponding fuel injectors (20) into cylinders. | ||
22 | Fix the retainer clamps and tighten the bolts (12). | Retainer clamps | |
23 | Install corresponding pressure pipes (10) to the cylinder head and tighten the screw plugs. | Corresponding pressure pipes to the cylinder head | |
24 | Connect high pressure pipes (10) and tighten nuts at both ends. | High pressure pipes | |
25 | Install tappet cover (2) with seal on the cylinder head. | ||
26 | Install engine trim panel (9) over the engine. | ||
27 | Install gearshift lever carrier (8) along with shift control unit. | Gear shift lever bracket along with shift lever | |
28 | Install gearshift lever support arm to gearshift lever carrier and tighten bolts on left hand side (6) and right hand side (7). | Gear shift lever support bracket to shift lever bracket | |
29 | Install gearshift linkage (5) to the shift control unit. | Shift linkage to the shift lever assembly | |
30 | Tilt down the cab. | Engine 400.951 in model 400.241/243 | |
Topical note | Notes on tilting the cab | ||
31 | Crank and start engine. |
Check values for engine major assembly installation position |
Number | Designation | Engine 400.950 in model 400.204/207/212/216/231 | ||
BE01.00-Y-1002-03A | Cylinder compression pressure | Minimum. Pressure | kg / sq.cm | 25 |
Maximum. Pressure | kg / sq.cm | 32 |
090 589 01 91 00
Test adapter
904 589 00 63 00
Threaded insert
355 589 01 63 00
Impact extractor
Referenced documents
- ah6080n000301a Notes on tilting the cab
- 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.
- 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.
- bb0040p026701a Wheel bearing grease (NLGI grade 2)