Check cylinders for leaks

AR01.00-S-1300PS

Check cylinders for leaks

17.07.2018

Engine

642 in model 470, 471

2

Center bolt

3

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

Topical note

Notes on avoiding damage through contamination and foreign objects

AH00.00-P-5000-01A

Preparation

 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

1

Bring engine to operating temperature (approx. 80 °C) and switch off.

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

2

Detach transmitter key and store outside of transmission range (at least 2 m).

 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

3

Turn cap on coolant expansion reservoir counterclockwise by a half revolution, release overpressure and unscrew cap from coolant expansion reservoir.

4

Unscrew oil filler cap.

5

Remove all glow plugs.

AR15.20-S-4111PS

6

Remove noise damper in front of charge air cooler.

AR09.40-S-6930PS



Check

7

Turn engine at center bolt (2) of the crankshaft in the direction of engine rotation and place piston of the cylinder to be checked at top dead center (TDC).

8

Connect pressure loss tester (3) to the cylinder to be checked.

AR01.00-S-1400-01PS

 Screw-in fitting

*642589026300

 Pressure loss tester

*450589172100

9

Apply compressed air to the cylinder to be checked and read pressure loss from pressure loss tester (3).

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 increased pressure loss is detected,



Determine cause and eliminate cause.

10

Perform testing procedure in the cylinder order on the remaining cylinders in the same way.

AR01.00-S-1400-01PS

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

 Screw-in fitting

*642589026300

 Pressure loss tester

*450589172100

If increased pressure loss is detected,



Determine cause and eliminate cause.



Install

11

Install noise damper in front of charge air cooler.

AR09.40-S-6930PS

12

Install all glow plugs.

AR15.20-S-4111PS

13

Screw on oil filler cap.

14

Screw cap onto coolant expansion reservoir.

Cylinder leakage

Number

Designation

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

BE01.00-P-1003-02Z

Cylinder leaktightness: Permissible losses at pistons and piston rings

%

 20