Check cylinders for leaks

AR01.00-D-1300TSV

Check cylinders for leaks

07.03.2019

Engine

642 in model 907

1

Screw-in piece

2

Adapter

4

Pressure loss tester

 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 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 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



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.

AR15.20-D-4111TSV

4

Remove cap on coolant expansion reservoir.

 To do so, turn cap half a revolution counterclockwise, release overpressure, and then unscrew cap.

5

Remove oil filler cap.



Check

6

Position piston of cylinder to be checked at ignition TDC.

AR01.00-D-0100-01TSV


Do not rotate engine against direction of engine rotation.
Damage may occur otherwise.

 To do this, rotate engine at belt pulley of crankshaft in direction of rotation.

 Socket wrench bit

*001589650900

7

Attach adapter (2) to screw-in piece (1).

 Intermediate piece

*611589026300

 Screw-in fitting

*640589006300

8

Screw the screw-in piece (1) into the glow plug hole of the cylinder to be checked.

 Screw-in fitting

*640589006300

9

Connect the pressure loss tester (4).

 Pressure loss tester

*450589172100

10

Calibrate the pressure loss tester (4).

 Follow the operating instructions for the pressure loss tester (4).

11

Pressurize the cylinder with compressed air and read off the pressure loss on the pressure loss tester (4).

Determine loss of pressure at cylinder

AH01.00-N-1300-02A

 Note down measured value.

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 increased pressure loss exists



identify cause – subject to separate repair order.

12

Remove pressure loss tester (4).

 Pressure loss tester

*450589172100

13

Remove screw-in piece (1) with adapter (2).

 Intermediate piece

*611589026300

 Screw-in fitting

*640589006300

14

Perform check of additional cylinders in engine firing order.

Firing order

AH01.00-N-0100-02P

15

Remove adapter (2) from screw-in piece (1).

 Intermediate piece

*611589026300

 Screw-in fitting

*640589006300



Install

16

Install cap on coolant expansion reservoir.

17

Install oil filler cap.

18

Install glow plugs.

AR15.20-D-4111TSV

Cylinder leakage

Number

Designation

Engine 000, 102, 115, 271, 272, 274, 602, 611, 612, 615, 616, 617, 632, 642, 646, 647, 651

BE01.00-P-1001-02Z

Cylinder leakage: permissible loss total indication

%

 25

Cylinder leakage

Number

Designation

Engine 000, 102, 115, 271, 272, 274, 602, 611, 612, 615, 616, 617, 632, 642, 646, 647, 651

BE01.00-P-1002-02Z

Cylinder leaktightness: Permissible losses at valves and cylinder head gasket

%

 10

Cylinder leakage

Number

Designation

Engine 000, 102, 115, 271, 272, 274, 602, 611, 612, 615, 616, 617, 632, 642, 646, 647, 651

BE01.00-P-1003-02Z

Cylinder leaktightness: Permissible losses at pistons and piston rings

%

 20