Check cylinders for leaks

AR01.00-S-1300E

Check cylinders for leaks

28.06.2019

Model

447 with engine 651

Model

447 with engine 654.9

Example illustration

1

Screw-in piece

2

Adapter

3

Compressed air connection

4

Pressure loss tester

 Warning

Risk of injury. Moving parts can pinch, crush or, in extreme cases even sever extremities.

No parts of the body or limbs should be within the operating area of mechanical components when moving components.

AS00.00-Z-0009-01A

 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

Topical note

Notes on avoiding damage through contamination and foreign objects

AH00.00-P-5000-01A



Remove

1

Start engine and warm up to normal 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 resonator box.

Model 447 with engine 654

AR09.20-S-0010EA

4

Remove all glow plugs.

Model 447 with engine 651

AR15.20-S-4111E

Model 447 with engine 654

AR15.20-S-4111EA

 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

5

Remove cap from coolant expansion reservoir.

6

Remove oil filler cap.



Check

7

Set piston of the 1st cylinder onto the top dead center (ignition TDC).

Model 447 with engine 651

AR01.10-S-1000-01E

Model 447 with engine 654.9

AR01.10-S-1000-01EA


Only rotate the crankshaft in the direction of rotation of the engine.
The timing chain can skip otherwise and cause engine damage.

 Model 447 with engine 651
Counterholder

*651589084000

 Model 447 with engine 651
Counterholder

*651589004000

 Model 447 with engine 654
Counterholder

*654589004000

8

Screw in the screw-in piece (1) into the glow plug hole.


Do not tighten the screw-in piece (1) excessively.
Otherwise, the thread of the glow plug hole may be damaged.

 Model 447 with engine 651with glow plug hole M8
Screw-in fitting

*642589006300

 Model 447 with engine 651
with glow plug hole M10Model 447 with engine 654
Screw-in fitting

*642589026300

9

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

 Intermediate piece

*611589026300

10

Attach the pressure loss tester (4) to the compressed air connection (3) of the adapter (2).

 Pressure loss tester

*450589172100

11

Calibrate the pressure loss tester (4).

 Observe manufacturers instructions.

 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

12

Apply compressed air to the cylinder and read off pressure loss at pressure loss tester (4).

Determine loss of pressure at cylinder

AH01.00-N-1300-02A

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 the crankshaft rotates:



Install retaining lock for crankshaft or starter ring gear.

Model 447 with engine 651

AR03.30-S-5000E

If the crankshaft rotates:



Counterhold the crankshaft against the belt pulley using the counterholder.

Model 447 with engine 654.9

 Aid of helper required.

 Counterholder

*654589004000

If increased pressure loss is displayed,



Identify the cause after checking all cylinders.

13

Perform check of additional cylinders in engine firing order.

 Firing order: 1-3-4-2.
 Cylinder 1 is located opposite the power output side.

14

Remove the pressure loss tester (4), the adapter (2) and the screw-in piece (1).



Install

15

Install oil filler cap.

16

Install cap on coolant expansion reservoir.

17

Install all glow plugs.

Model 447 with engine 651

AR15.20-S-4111E

Model 447 with engine 654.9

AR15.20-S-4111EA

18

Install resonator box.

Model 447 with engine 654

AR09.20-S-0010EA

Cylinder leakage

Number

Designation

Engine 000, 104, 112, 161, 166, 200, 272, 274, 607, 608, 611, 622, 642, 646, 651, 654, 661, 662, 668, 699

BE01.00-P-1001-02Z

Cylinder leakage: permissible loss total indication

%

 25

Cylinder leakage

Number

Designation

Engine 000, 104, 112, 161, 166, 200, 272, 274, 607, 608, 611, 622, 642, 646, 651, 654, 661, 662, 668, 699

BE01.00-P-1002-02Z

Cylinder leaktightness: Permissible losses at valves and cylinder head gasket

%

 10

Cylinder leakage

Number

Designation

Engine 000, 104, 112, 161, 166, 200, 272, 274, 607, 608, 611, 622, 642, 646, 651, 654, 661, 662, 668, 699

BE01.00-P-1003-02Z

Cylinder leaktightness: Permissible losses at pistons and piston rings

%

 20