Spark

Cylinder Leakage Test

Special Tools

For equivalent regional tools, refer to Special Tools .

1. Remove the fuel injector. Refer to Fuel Injector Replacement .



2. Clean the injector sealing surfaces in the cylinder head using the EN-47632 cleaning tool (1) in following procedure:

2.1.	first use the brush side to loosen the dirt.

2.2.	second use the sponge side to remove the dirt.




3. Remove the 4 positive crankcase ventilation cover bolts (3).
4. Remove the positive crankcase ventilation cover (1).
5. Remove the positive crankcase ventilation cover gasket (2).



6. Remove the cylinder head core hole plug exhaust side (2) from the camshaft housing (1).
7. Clean the threads from cylinder head core hole plug and the camshaft housing.



8. Install the EN-50515 fixing tool (1) on exhaust side.



9. Apply pressure to the EN-50515 fixing tool (arrow) and turn crankshaft at crankshaft sprocket bolt (2) carefully in engine direction of rotation (arrow), until EN-50515 fixing tool (1) becomes engaged in the exhaust camshaft.




Note: The cylinder 1 is on TDC if the EN-50515 fixing tool and EN-46785 fixing tool are installed.

10. Turn the crankshaft carefully until the EN-46785 fixing tool (1) engages in the flywheel.




Note: The marking is necessary to adjust the TDC of the individual cylinders.

11. Make a marking on the oil pump housing (1) and 3 check marks on the oil separator (2).
12. Remove the EN-46785 fixing tool and the EN-50515 fixing tool .

1. Calibrate the pressure loss meter.
2. Engage 4th gear and apply the park brake.




Note: EN-46791 adapter can only be installed in pairs along with the fuel injector at cylinder 1 and cylinder 2.

3. Install the EN-46791 adapter (1) along with the fuel injector (2) and the fuel injector bracket in cylinder 1 with a NEW fuel injector gasket.
4. Install the fuel injector washer.

Caution: Refer to Fastener Caution in the Preface section.

5. Install the fuel injector bracket nut and tighten to 25 N·m (18 lb ft).
6. Install the EN-46783 thread adapter (3) to the EN-46791 adapter (1).



7. Install the pressure loss tester (2) to the EN-46783 thread adapter (1).
8. Pressurise cylinder 1.
9. Check pressure loss in cylinder 1.

•	Max. pressure difference between the individual cylinders 10% approx.

•	The pressure loss per cylinder should not exceed 25%.

•	Check escaping air to localise the damage on:

-	Intake ducts

-	Exhaust system

-	Oil dipstick guide tube

-	Oil filler port

10. Remove the fuel injector bracket nut cylinder 1 and 2.
11. Remove the fuel injector washer.
12. Remove the fuel injector cylinder 2 and pressure loss tester along with the EN-46791 adapter from cylinder 1.

1. Set the transmission to neutral.
2. Turn the engine 240° by crankshaft.

Note: Note the alignment marking on camshaft sprocket bolt.

•	Turn the crankshaft in the direction of the engine rotation by the bolt on the torsional vibration damper flange.

•	Engage 4th gear and apply the park brake.




3. Install the EN-46791 adapter (1) and the fuel injector bracket in cylinder 3 with a NEW fuel injector gasket.
4. Install the fuel injector washer.
5. Install the fuel injector bracket nut and tighten to 25 N·m (18 lb ft).
6. Install the EN-46783 thread adapter (2) to the EN-46791 adapter (1).



7. Install the pressure loss tester (2) to the EN-46783 thread adapter (1).
8. Pressurise cylinder 3.
9. Check pressure loss in cylinder  3.

•	Max. pressure difference between the individual cylinders 10% approx.

•	The pressure loss per cylinder should not exceed 25%.

•	Check escaping air to localise the damage on:

-	Intake ducts

-	Exhaust system

-	Oil dipstick guide tube

-	Oil filler port

10. Remove the fuel injector bracket nut .
11. Remove the fuel injector washer.
12. Remove the pressure loss tester along with the EN-46791 adapter from the cylinder 3.

1. Set the transmission to neutral.
2. Turn the engine 240° by crankshaft.

Note: Note the alignment marking on camshaft sprocket bolt.

•	Turn the crankshaft in the direction of the engine rotation by the bolt on the torsional vibration damper flange.

•	Engage 4th gear and apply the park brake.





Note: EN-46791 adapter can only be installed in pairs along with the fuel injector at cylinder 1 and cylinder 2.

3. Install EN-46791 adapter (1) along with the fuel injector (2) and fuel injector bracket in cylinder 2 with a NEW fuel injector gasket.
4. Install the fuel injector washer.
5. Install the fuel injector bracket nut and tighten to 25 N·m (18 lb ft).
6. Install the EN-46783 thread adapter (3) to the EN-46791 adapter (1).



7. Install the pressure loss tester (2) to the EN-46783 thread adapter (1).
8. Pressurise cylinder 2.
9. Check pressure loss in cylinder 2.

•	Max. pressure difference between the individual cylinders 10% approx.

•	The pressure loss per cylinder should not exceed 25%.

•	Check escaping air to localise the damage on:

-	Intake ducts

-	Exhaust system

-	Oil dipstick guide tube

-	Oil filler port

10. Remove the fuel injector bracket nut cylinder 1 and 2.
11. Remove the fuel injector washer.
12. Remove the fuel injector cylinder 1 and pressure loss tester with the EN-46791 adapter from the cylinder 2.

1. Remove the EN-46785 fixing tool (1).



2. Remove the EN-50515 fixing tool (1) from exhaust side.



3. Install the camshaft housing core hole plug exhaust side (2) to the camshaft housing (1) and tighten to 15 N·m (11 lb ft).



4. Install the positive crankcase ventilation cover gasket (2).
5. Install the positive crankcase ventilation cover (1).
6. Install the 4 positive crankcase ventilation cover bolts (3) and tighten in a cross sequence to 10 N·m (89 lb in).
7. Install the fuel injector. Refer to Fuel Injector Installation .