Check cylinders for leaks

AR01.00-P-1300LFD

Check cylinders for leaks

12.06.2017

Engine

642 (except 642.970) in model 463

Engine

642 in model 222

Shown on model 222

1

Belt pulley

2

Pressure loss tester

 Caution

Risk of injury caused by scraping or cutting body parts on sharp vehicle parts

Always wear protective gloves when working on or near sharp and non-deburred vehicle parts.
Deburr repair panels.

AS00.00-Z-0017-01A

 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

 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

Topical note

Notes on avoiding damage through contamination and foreign objects

AH00.00-P-5000-01A



Remove

1

Warm up engine to normal operating temperature

 Check for cylinder leakage when engine is at normal operating temperature.

2

Switch off ignition and store transmitter key outside of transmission range (min. 2 m)

3

Unscrew cap of coolant expansion reservoir

 Rotate cap half a revolution counterclockwise, release overpressure and then unscrew cap.

4

Unscrew oil filler cap

5

Remove glow plugs

Engine 642 (except 642.970) in model 463

AR15.20-P-4111GY

Engine 642 in model 222

AR15.20-P-4111LFD

6

Remove fan unit

Engine 642 (except 642.970) in model 463
Engine 642 in model 222

Engine 642.887 in model 463

AR20.40-P-5050MNF

Engine 642 in model 222

AR20.40-P-5050LF

7

Insert protective plate for radiator



WF58.50-P-0110-01A

8

Remove charge air cooler with attached coolant lines and place to one side

Engine 642 (except 642.970) in model 463
Engine 642 in model 222

Engine 642 in model 222
Engine 642.887 in model 463

AR09.41-P-6819LFD

9

Remove poly-V belt

Engine 642 (except 642.970) in model 463

AR13.22-P-1202GY

Engine 642 in model 222

AR13.20-P-0001LFD

10

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

 Turn engine at the center bolt of the belt pulley (1) of the crankshaft. Turn engine in direction of engine rotation.

 Socket wrench bit

*001589650900

11

Connect pressure loss tester (2)

Engine 642 (except 642.970) in model 463
Engine 642 in model 222

Engine 642 in model 222
Engine 642.887 in model 463

AR01.00-P-1300-01LFD

 Calibrate the pressure loss tester (2).

 Use a screw-in piece without check valve.

 Pressure loss tester

*450589172100

 Screw-in fitting

*642589026300



Check

12

Check for cylinder leakage

Determine loss of pressure at cylinder

AH01.00-N-1300-02A

 Apply compressed air to the cylinder and read off pressure loss at pressure loss tester (2).

 If high pressure loss exists, determine cause.

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

 Pressure loss tester

*450589172100

13

Check further cylinders according to engine firing order

Engine 642 (except 642.970) in model 463
Engine 642 in model 222

Engine 642.887 in model 463

AR01.00-P-1300-03HB

Engine 642 in model 222

AR01.00-P-1300-03T



Install

14

Disconnect pressure loss tester (2)

Engine 642 (except 642.970) in model 463
Engine 642 in model 222

Engine 642 in model 222
Engine 642.887 in model 463

AR01.00-P-1300-01LFD

 Pressure loss tester

*450589172100

 Screw-in fitting

*642589026300

15

Install poly-V belt

Engine 642 (except 642.970) in model 463

AR13.22-P-1202GY

Engine 642 in model 222

AR13.20-P-0001LFD

16

Install charge air cooler

Engine 642 (except 642.970) in model 463
Engine 642 in model 222

Engine 642 in model 222
Engine 642.887 in model 463

AR09.41-P-6819LFD

17

Remove protective plate on radiator



WF58.50-P-0110-01A

18

Install fan unit

Engine 642 (except 642.970) in model 463
Engine 642 in model 222

Engine 642.887 in model 463

AR20.40-P-5050MNF

Engine 642 in model 222

AR20.40-P-5050LF

19

Install glow plugs

Engine 642 (except 642.970) in model 463

AR15.20-P-4111GY

Engine 642 in model 222

AR15.20-P-4111LFD

20

Screw down the oil filler cap and cap for the coolant expansion reservoir

Cylinder leakage

Number

Designation

Engine all (4xWD, CAR, smart)

BE01.00-P-1001-02Z

Cylinder leakage: permissible loss total indication

%

 25

Cylinder leakage

Number

Designation

Engine all (4xWD, CAR, smart)

BE01.00-P-1002-02Z

Cylinder leaktightness: Permissible losses at valves and cylinder head gasket

%

 10

Cylinder leakage

Number

Designation

Engine all (4xWD, CAR, smart)

BE01.00-P-1003-02Z

Cylinder leaktightness: Permissible losses at pistons and piston rings

%

 20