HARRIER SERVICE MANUAL PART -1

KRYOTEC ENGINE 23 CYLINDER LEAKAGE TEST The cylinder leakage test provides an accurate means for determining engine condition. Cylinder leakage testing will detect: • Exhaust and intake valve leaks (improper seating). • Leaks between adjacent cylinders or into water jacket. 1. Check the coolant level and fill as required. DO NOT install the radiator cap. 2. Start and operate the engine until it attains normal operating temperature. 3. Turn the engine OFF. 4. Remove the fuel injector. 5. Set the piston of the cylinder to be tested at TDC on the compression stroke. 6. Install the 5412 5890 0702 dummy injector complete with the fitting into fuel injector hole of cylinder to be tested. 7. Install the clamp and tighten the nut 25 Nm (18 ft. lbs.). 8. Calibrate the tester according to the manufacturer's instructions. The shop air source for testing should maintain a regulated air pressure at 552 kPa (80 psi). 9. Connect the leakage tester and perform the leakage test procedure on each cylinder according to the tester manufacturer's instructions. 10. As each cylinder is pressurized, listen for the air escaping through the EGR air flow control valve, tailpipe, and the oil filler cap opening. Check for bubbles in the pressurized coolant bottle. 11. All gauge pressure indications should be equal, with no more than 25% leakage. Refer to CYLINDER LEAKAGE DIAGNOSIS CHART below. CYLINDER LEAKAGE DIAGNOSIS CHART CONDITION POSSIBLE CAUSE CORRECTION AIR ESCAPES THROUGH THROTTLE BODY Intake valve bent, burnt, or not seated properly. Inspect valve and valve seat. Reface Or replace, as necessary. Inspect valve springs. Replace as necessary. AIR ESCAPES THROUGH TAILPIPE Exhaust valve bent, burnt, or not seated properly. Inspect valve and valve seat. Reface or replace, as necessary Inspect valve springs. Replace as necessary. AIR ESCAPES THROUGH RADIATOR Head gasket leaking or cracked cylinder head or block. Remove cylinder head and inspect. Replace the defective part. MORE THAN LEAKAGE FROM ADJACENT CYLINDERS Head gasket leaking or crack in cylinder head or block between adjacent cylinders. Remove cylinder head and inspect. Replace gasket, head, or block as necessary. MORE THAN 25% LEAKAGE AND AIR ESCAPES THROUGH OIL FILLER CAP OPENING ONLY Stuck or broken piston rings; cracked piston; worn rings and/or cylinder wall. Inspect for broken rings or piston. Measure ring gap and cylinder diameter, taper and out-of-round. Replace defective part as necessary.