Engine Description; Standard Procedure Standard Procedure - Compression; Testing Engine; Standard Procedure - Cylinder Leak Down Test - Dodge Sprinter 2006 Manual

VA
DESCRIPTION
Engine

Engine Description

Air Intake
Fuel Injection System
Fuel
Firing Order
Rated Output
Torque
Maximum Speed
Compression Ratio
Bore/Stroke
Eff. Displacement
STAN DARD PROCEDU RE
STANDARD PROCEDURE - COMPRESSION

TESTING ENGINE

(1) Wa r m u p en gin e t o oper a t in g t em per a t u r e
(a ppr ox. 80 °C, 176°F ).
(2) Sh u t off en gin e.
(3) Rem ove en gin e cover (Refer t o 9 - E NGINE -
RE MOVAL).
(4) Rem ove glow plu gs (Refer t o 8 - E LE CTRICAL/
IGNITION CONTROL/GLOW P LUG - RE MOVAL).
(5) Cr a n k en gin e sever a l t im es wit h t h e st a r t er t o
elim in a t e com bu st ion r esidu es in t h e cylin der s.
(6) In ser t com pr ession t est er a da pt er #8927 (Refer
t o 9 - E NGINE - SP E CIAL TOOLS) wit h ch eck va lve
in st a lled in t o glow plu g h ole of cylin der t o be t est ed.
(7) Con n ect com pr ession t est er h ose a da pt er #9295
t o com pr ession ga u ge a n d t est com pr ession pr essu r e
by cr a n kin g en gin e wit h st a r t er for a t lea st 8 r evolu -
t ion s.
(8) Ca r r y ou t t est pr ocedu r e a t t h e r em a in in g cyl-
in der s in t h e sa m e wa y.
(9) Com pa r e pr essu r e r ea din gs obt a in ed wit h t h e
specified pr essu r es. If t h e pr essu r e r ea din g is below
t h e m in im u m com pr ession pr essu r e or if t h e per m is-
sible differ en ce bet ween t h e in dividu a l cylin der s is
exceeded. Refer t o cylin der lea k down t est .
(10) Rem ove com pr ession t est er a n d a da pt er fr om
cylin der h ea d.
(11) In st a ll glow plu gs (Refer t o 8 - E LE CTRICAL/
IGNITION CONTROL/GLOW P LUG - INSTALLA-
TION).
SPECIFICATION
2.7L CDI
5 Cylinder In-Line En-
gine With 4-Valve Tech-
nology
Turbo-Charged Engine
with Charge Air Cooling
2 nd. Generation Com-
mon Rail Direct Injection
(CDI)
Diesel
1-2-4-5-3
154 HP at 3800 RPM
243 ft. lbs. at 1600-2400
RPM
4800 RPM
18:1
3.46/3.48
2688 cm3
(12) In st a ll en gin e cover (Refer t o 9 - E NGINE -
INSTALLATION).
COM PRESSI ON SPECI FI CAT I ON S
Maximum Compression
Minimum Compression
Permissible Difference
Between Cylinders
STANDARD PROCEDURE - CYLINDER LEAK
DOWN TEST
(1) Wa r m en gin e t o oper a t in g t em per a t u r e.
WARNING: DO NOT OPEN COOLING SYSTEM
UNLESS COOLANT TEMPERATURE IS BELOW 90C
(194°F). RISK OF INJURY TO SKIN AND EYES AS A
RESULT OF SCALDING WITH HOT COOLANT
WHICH SPLASHES OUT. RISK OF POISONING
FROM SWALLOWING
SLOWLY AND RELEASE PRESSURE. STORE COOL-
ANT IN PROPER CONTAINERS ONLY. WEAR PRO-
TECTIVE GLOVES,
PROTECTION.
NOTE: Turn cap carefully as far as first detent,
release pressure, then unscrew cap.
(2) Open coolin g syst em ca p a t coola n t r ecover
pr essu r e con t a in er.
(3) Rem ove en gin e cover (Refer t o 9 - E NGINE -
RE MOVAL).
(4) Un scr ew oil filler ca p.
(5) Rem ove glow plu gs (Refer t o 8 - E LE CTRICAL/
IGNITION CONTROL/GLOW P LUG - RE MOVAL).
NOTE: Crank engine at crankshaft in direction of
rotation of the engine (clockwise).
(6) P osit ion cylin der t o be t est ed t o ign it ion Top
Dea d Cen t er (DTC).
NOTE: Calibrate cylinder leak down tester and
remove check valve in screw-in fitting.
(7) Con n ect cylin der lea k down t est er a n d follow
INSP E CTING In st r u ct ion .
INSPECTING
NOTE: If crankshaft rotates, install retaining lock for
crankshaft/ring gear.
(1) P r essu r ize cylin der wit h com pr essed a ir a n d
r ea d off pr essu r e loss a t cylin der lea k t est er. If exces-
sive pr essu r e loss exist s, det er m in e possible ca u se
(Refer t o 9 - E NGINE - STANDARD P ROCE DURE ).
ENGINE 9 - 3
29-35 bar (420-507 psi)
18bar (261 psi)
± 3bar (± 44 psi)
COOLANT. OPEN
CLOTHING AND
CAP
EYE