Check cylinders for leaks

AR01.00-P-1300PI

Check cylinders for leaks

28.10.09

8.10.09

Special tool 640 589 00 63 00 replaced by 642 589 00 63 00

Operation step 7

 

Remove/install

 Danger!

Risk of accident caused by vehicle starting off by itself when engine is running. Risk of injury caused by contusions and burns during starting procedure or when working near the engine as it is running

Secure vehicle to prevent it from moving by itself.
Wear closed and snug-fitting work clothes.
Do not touch hot or rotating parts.

AS00.00-Z-0005-01A

 Danger!

Risk of injury to skin and eyes caused by handling hot or glowing objects.

Wear safety gloves, protective clothing and safety glasses, if necessary.

AS00.00-Z-0002-01A

Danger!

Risk of injury to skin and eyes caused by scalding from contact with hot coolant spray. Risk of poisoning caused by 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

1

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

 Test compression pressure when engine is at normal operating temperature.

2

Turn key in electronic starter/ignition switch (EIS) control unit to position "0".

3

Open the cap (1) of the expansion reservoir (2)

 Rotate cap (1) counterclockwise half a revolution, release pressure relief and remove cap (1).

4

Unscrew oil filler cap (3)

5

Remove glow plugs (R9)

AR15.20-P-4111PI

6

Position piston for cylinder to be tested at ignition TDC

 Rotate engine at center Bolt for vibration damper of crankshaft. Do not turn engine against the direction of engine rotation.

7

Connect cylinder leakage tester (4)

 Calibrate cylinder leakage tester (4).

AR01.00-P-1300-01PI

 Screw-in fitting

*642589006300

 Intermediate piece

*611589026300

Cylinder leakage tester (pressure loss)

gotis://A_01_04.0



Checking

8

Check cylinders for leaks

 Pressurize cylinder with compressed air and read off pressure loss at cylinder leakage tester (4).

 If high pressure loss exists, determine cause, see:





Determining pressure loss of cylinders

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

9

Conduct test for other cylinders in the firing order of the engine

 Observe ignition sequence.

AR01.00-P-1300-03T

10

Install in the reverse order

Number

Designation

All engines

BE01.00-P-1001-02Z

Cylinder leakage: permissible loss total indication

%

25

BE01.00-P-1002-02Z

Cylinder leaktightness: permissible losses at valves and cylinder head gasket

%

10

BE01.00-P-1003-02Z

Cylinder leaktightness: permissible losses at pistons and piston rings

%

20