Check cylinders for leaks

AR01.00-D-1300R

Check cylinders for leaks

30.4.15

Engine

646 in model 909

1

Cylinder leakage tester

 Danger !

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

 Danger !

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

 Danger !

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

 

Remove/install

1

Warm up engine to operating temperature of approximately 80°C

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

2

Turn cooling system cap on expansion reservoir counterclockwise by half a revolution, release overpressure, then unscrew cap on cooling system expansion reservoir

3

Remove glow plugs

AR15.20-D-4111R

4

Position piston of cylinder to be tested using the TDC selector at ignition TDC

 Crank engine at center bolt, the belt pulley in the direction of engine rotation.

 Socket wrench bit

*001589650900

5

Connect cylinder leakage tester (1)

AR01.00-D-1300-01R

 Intermediate piece

*611589026300

 Female connector

*611589016300

 Socket wrench

*001589780900

6

Remove oil filler cap

7

Install retaining lock for crankshaft

AR03.30-D-5000R



Check

8

Apply compressed air to the cylinder, read off pressure loss on cylinder leakage tester (1) and determine the cause if there is an increased pressure loss



Determine loss of pressure at cylinder

AH01.00-N-1300-02A

Cylinder leaktightness: permissible losses at pistons and piston rings

*BE01.00-P-1003-02Z

Cylinder leaktightness: permissible losses at valves and cylinder head gasket

*BE01.00-P-1002-02Z

Cylinder leakage: permissible loss total indication

*BE01.00-P-1001-02Z

9

Perform checking of other cylinders in the same way according to the firing order

AR01.00-D-1300-03R

10

Install in the reverse order

Cylinder leakage

Number

Designation

ENGINE ALL

BE01.00-P-1001-02Z

Cylinder leakage: permissible loss total indication

%

25

Cylinder leakage

Number

Designation

ENGINE ALL

BE01.00-P-1002-02Z

Cylinder leaktightness: permissible losses at valves and cylinder head gasket

%

10

Cylinder leakage

Number

Designation

ENGINE ALL

BE01.00-P-1003-02Z

Cylinder leaktightness: permissible losses at pistons and piston rings

%

20