Chassis serial number: 5237861

01-01 Cylinder head [PDE]

Check - Checking the cylinder heads for leaks
Applies to engines with cylinder block generation 1 or 2.

WARNING!

Always wear protective goggles when carrying

out this work. If the crankshaft were to rotate
during work, fuel which has run into a cylinder
or metal chips from a damaged engine may
cause injury to the eyes or face.

Tools

Number Designation Illustration Tool board

Cylinder leakage MC1

99 527
indicator

99 309 Turning tool D5

Leakage equipment calibration

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 Chassis serial number: 5237861

1. Fit the quick release coupling 1 of the

measuring hose to the union on the aluminium
block on the back of the test equipment 2.

2. Connect at least 6 bar of compressed air to the

test equipment union 3.

3. Pull out the wheel on the pressure regulator 4

and turn it until the manometer pointer 5
indicates 23%. Press in the wheel and lock the
regulator.

4. Disconnect the compressed air and remove the

quick release coupling 1 on the measuring hose
from the back of the test equipment 2.

Tolerance for leakage measurement

< 23% Engine is in good condition

23-30% Engine is in acceptable condition

30-40% Engine is worn and may have poorer performance than expected.

40-50% Engine is very worn. Consider reconditioning.

> 50% Engine is in poor condition and must be reconditioned.

If the leak cannot be located: remove the cover on the expansion tank and check whether
bubbles appear, or measure the pressure in the cooling system using adapter 588 872 and
cooling system tester 587 048.
If the pressure increases or bubbles appear, this may indicate a cracked cylinder head or
cylinder liner.

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 Chassis serial number: 5237861

Integrity check
1. Warm up the engine to operating temperature.

2. Remove all rocker arms and valve bridges.

3. Remove all injectors as instructed in the work

description for Removing the injectors.

4. Turn the engine with the turning tool 99 309 so

that cylinder number 1 is at TDC.

5. Block the engine so that the crankshaft does not

begin to rotate when the cylinder is pressurised,
e.g. by leaving the turning tool in position with
tommy bar, T-handle or ratchet handle.
If using a ratchet handle, set the ratchet handle
direction based on whether the engine is before
or after TDC so that the ratchet handle blocks
rotation.

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 Chassis serial number: 5237861

6. Assemble the nozzle adapter. Nozzle adapter

component parts, position 1-3.

1. Copper gasket
2. Nozzle adapter 99 487
3. Guide sleeve PDE 99 489
4. Clamp PDE

7. Fit the nozzle adapter to the injector hole of

cylinder 1. Use the ordinary injector screw and
clamp 4.

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 Chassis serial number: 5237861

8. Fit the nozzle adapter/spark plug adapter with

the test adapter 5 for the test equipment and 5
then with the quick release coupling 6 on the
measuring hose. 2

XX XX

XX XX

XX x

9. Connect at least 6 bar of compressed air to the

test equipment union 7. Allow the air to blow
for a short while until the pressure has
stabilised.

10. Listen for leaking air in the crankcase. Air

leakage indicates worn or damaged piston rings
or cylinder bore, or cracked pistons.

3/3/2015 © Scania CV 5 of 6
 Chassis serial number: 5237861

11. Listen for leaking air in the exhaust pipe. If

possible, remove the flexible exhaust hose.
Leaking air in the exhaust pipe indicates
exhaust valves that are not fully sealed.
If the value read is great, you can tap gently a
few times on the end of the valve stem using a
small hammer. If the value falls when the valve
has settled, this indicates worn valve guides.

12. Detach the hose from the charge air cooler and
listen for leaking air in the intake manifold.
Leaking air indicates intake valves that are not
fully sealed.
If the value read is great, you can tap gently a
few times on the end of the valve stem using a
small hammer. If the value falls when the valve
has settled, this indicates worn valve guides.

13. Check the other cylinders for leaks.

On 11, 12 and 16 litre engines, cylinder 6 can
also be measured when cylinder 1 is in the TDC
position. The crankshaft must be rotated to
check other cylinders.
9 litre engines:Rotate the crankshaft in the
direction of engine rotation in increments of
144°. The cylinders can then be measured in the
sequence 2-4-5-3.
11, 12 and 13-litre engines:Rotate the
crankshaft 120° in the direction of engine
rotation to measure cylinders 2 and 5, then
rotate a further 120° in the direction of engine
rotation to measure cylinders 3 and 4.
16-litre engines:Rotate the crankshaft 90° in
the direction of engine rotation to measure
cylinders 3 and 5, then rotate a further 90° to
measure cylinders 4 and 7, and finally 90° to
measure cylinders 2 and 8.

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