ENGINE DIAGNOSTIC TEST PROCEDURES Section 6 FORM NO.  CGED-365 EXTERNAL LEAKAGE FUEL OIL AIR WATER RECORD LOCATION OF LEAKS IN "COMMENTS" METHOD 1ST CHECK 2ND CHECK VISUAL CHECK PRESSURE CHECK • External Leakage Inspect  fuel,  oil,  air  or  coolant  leaks.    If  no  leaks  are found,    enter    OK    in    1st    check    box.        Upon    visual inspection, check all hoses and look for water stains, oil stains   and   wetness   at   the   water   pump.      Record   the location of leaks in the comments section. Leakage  can  be  the  reason  for  complaints  of  poor  fuel economy,  or  high  oil  consumption.     A   leak   in   the   air intake  system  can  shorten  engine  life,  especially  under dusty conditions.  A coolant leak can result in a complaint of engine overheating. If coolant and air leaks are observed, but the source not readily  identified,  the  service  technician  may  utilize  the following  test  procedures  to  pin  point  the  coolant  or  air leak: I. ENGINE COOLANT LEAKAGE TEST General Too   often   attempts   to   correct   complaints   of   external and/or     internal     water     leakage     reflect     an     arbitrary replacement  of  oil  to  water  coolers  and/  or  a  complete engine  teardown  for  a  visual  inspection.    Components such as cylinder heads, coolers, etc., are either sent out for  inspection  and/or  replaced  as  the  result  of  a  guess. THIS IS NOT A RECOMMENDED APPROACH AND IN MOST CASES LEAVES MUCH DOUBT IF ALL LEAKAGE AREAS HAVE BEEN IDENTIFIED. THE  PROCEDURE  DESCRIBED  BELOW  IDENTIFIES THE   MOST   COMMON   POINTS   OF   LEAKAGE   and describes the step-by-step procedure to use to implement the test. Leakage Test Procedure 1. Drain  all  lube  oil  and  coolant  from  engine  and radiator. 2. Disconnect the radiator from the engine and cap off all the engine connections (with hose clamps and plugs). 3. Disconnect  the  unit’s  cab  heater  connections  at the engine and plug engine openings. 4. Disconnect  and  remove  air  discharge  pipe  from turbocharger to intercooler (if equipped). 5. Disconnect and leave open oil supply return line to crankcase from air compressor (if equipped). 6. Remove all valve covers, push rod or valve lifter side inspection covers, lube oil pan and oil drain plug from lube oil cooler. CAUTION Do    not    loosen    or    remove    any    injection nozzles   from   the   cylinder   head   while   the cooling system is under pressure. 7. Fill  the  engine  with  water  and  attach  an  air  line connection coupled with a regulator assembly to water drain in cylinder block. 8. Pressurize  the  crankcase  cooling  system  to  40 psi.  Pressure must be maintained until leakage location is evident. 9. It   is   essential   that   all   points   of   leakage    be identified   prior   to   teardown   and   repair.      NO EXTERNAL OR INTERNAL LEAKAGE IS ALLOWABLE. Possible Location of Leakage a. Cracked   or   porous   cylinder   head,   blown head gasket (engine). b. Cracked or loose injector nozzle sleeves. c. Cracked or porous crankcase. d. Damaged   or   eroded   cylinder   sleeve   "O" rings or crankcase area. e. Cracked or porous power cylinder sleeve. f. Cracked or loose tubes in oil cooler. g. Cracked   or   loose   tubes   in   intercooler   (if equipped). h. Cracked   or   porous   cylinder   head,   blown head gasket (air compressor). CGES-240-4 Printed in United States of America Page 4