Scania Engine

01:03-02 Issue 9

en-GB

11 and 12 litre engines

106 351

Work description

1 585 592

©

Scania CV AB 2011, Sweden

Contents

Contents

2

Engine assembly

General information.................................................. 4 Removing the engine................................................ 6 Fitting the engine.................................................... 14 Mounting the engine in an engine stand................. 20 Measuring the compression pressure...................... 22

Cylinder head

................................................................................ 25 Removing the cylinder head................................... 26 Fitting the cylinder head......................................... 32 Checking and adjusting the valve clearance........... 36 Removing valves .................................................... 38 Fitting valves .......................................................... 38 Checking and machining valves............................. 39 Renewing the valve stem seal................................. 40 Renewing the valve seats........................................ 41 Machining the cylinder head .................................. 43 Renewing the valve guides..................................... 48 Renewing the injector sleeves ................................ 49 Renewing the unit injector sleeves ......................... 51

Cylinder block

Reconditioning ....................................................... 54 Removing the cylinder liners.................................. 55 Fitting the cylinder liners........................................ 56 Measuring and machining the cylinder liner height ...................................................................... 57 Renewing the rear crankshaft seal.......................... 63 Renewing camshaft bearings.................................. 65

Flywheel housing

................................................................................ 71 Removing the flywheel housing............................. 72 Fitting the flywheel housing................................... 72

Fan coupling

Removing the fan coupling .................................... 76 Fitting the fan coupling .......................................... 76 Renewing the bearing in the fan coupling.............. 77 Renewing the front crankshaft seal ........................ 80

Closed crankcase ventilation

Troubleshooting...................................................... 83 Renewing the diaphragm........................................ 85

Crank mechanism

................................................................................ 86 Removing a piston.................................................. 87 Fitting a piston........................................................ 89 Renewing a piston .................................................. 91 Checking the connecting rod .................................. 94 Bearing bush in connecting rod.............................. 96

Flywheel

Removing the flywheel........................................... 98 Fitting the flywheel................................................. 99 Support bearing .................................................... 101 External ring gear ................................................. 102

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Contents

Crankshaft

Removing the crankshaft...................................... 103 Fitting the crankshaft............................................ 104 Machining crankshafts.......................................... 105

Timing gear

.............................................................................. 108 Removing the intermediate gear........................... 110 Fitting the intermediate gear................................. 112 Renewing the bearing in the intermediate gear for the compressor ................................................ 113 Renewing the bearing in the intermediate gear for the camshaft .................................................... 114 Removing the camshaft gear ................................ 115 Fitting the camshaft gear ...................................... 116 Removing the crankshaft gear .............................. 117 Fitting the crankshaft gear .................................... 118 Removing the camshaft ........................................ 119 Fitting the camshaft .............................................. 120 Checking the camshaft setting.............................. 123

Lubrication system

General ................................................................. 124 Measuring the oil pressure.................................... 125 Oil filter ................................................................ 127 Oil cooler .............................................................. 128 Oil filter unit ......................................................... 130 Oil pump............................................................... 135

Turbocharger

.............................................................................. 136 Measuring radial and axial clearance ................... 138 Checks after breakdown ....................................... 140

Belt transmission

.............................................................................. 141

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3

Engine assembly

Engine assembly General information 1

2 A : DSC 1201

B : 0.75

Valve clearance cold engine : 0.45 mm Inlet : 0.70 mm Outlet Pump timing : 15 o before T.D.C.

3A

Made by

Typ/Type DSC 12 01 Variant Motor/Engine No

4

Made by

3B

123 45XX 119 867

Type DSC 12 01

Variant

1 Smoke values. 2 Instruction plate. 3 A Engine type, Engine serial number (on engines built before November 2000). 3 B Engine type (on engines built from November 2000 onwards). 4 Engine serial number, stamp.

4

DC11

DC12

Cylinder diameter

127.0 mm

127.0 mm

Piston stroke

140.0 mm

154.0 mm

Cubic capacity

10.64 dm3

11.7 dm3

No. of main bearings

7

7

Firing sequence

1-5-3-6-2-4

1-5-3-6-2-4

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Engine assembly

Compression ratio

DC11

DC12

18:1

18.5:1

Direction of rotation (engine viewed from the rear) Anticlockwise

Anticlockwise

Engine speed, low idling

500 rpm

500 rpm

Engine speed, high idling

2,400 rpm

2,400 rpm

Oil capacity

28-35 litres

28-35 litres

Oil grade

refer to booklet 00:03-09

refer to booklet 00:03-09

Total weight without oil and water

1,010-1,030 kg

1,020-1,040 kg

Lubrication Engine oil must be applied to all moving parts before fitting unless otherwise stated.

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5

Engine assembly

Removing the engine Comments

6

1

Drain

Oil and coolant.

2

Remove

The battery cover and detach the negative cable.

3

Remove

The protective casing.

4

Remove

Connectors 13 (C2) and 14 (C188).

5

Disconnect

The positive and negative cables.

6

Remove

The clamps to release electrical cables 13 and 14.

7

Tilt the cab according to instructions, refer to Group 18.

8

Remove

Connector 14 (C188) is only fitted on vehicles without a coordinator.

The mudguards.

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Engine assembly

8

2

120231

8

3

5 6

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120232

4

7

Engine assembly

Right-hand side: Comments

8

9

Pull through the detached cable harnesses and place them on the engine.

10

Remove

11

Cover the air filter.

12

Detach

The radiator water hoses.

13

Detach

The flexible hose for the charge air pipe.

14

Lift off

The poly-V-belt.

15

Detach

The air hose for the exhaust brake cylinder.

16

Remove

The exhaust pipe.

The turbocharger induction pipe.

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The compressor air pipe and the crankcase ventilation hose must be detached from the induction pipe.

The number of hoses varies depending on the design. Only one hose is illustrated.

Only on vehicles with air conditioning.

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Engine assembly

14

13

12

9

15

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16

10

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120234

11

9

Engine assembly

Left-hand side: Comments 17

Detach

The flexible hose for the charge air pipe.

18

Detach

The AC compressor and move it aside.

19

Detach

The compressor feed pipe.

20

Detach

The water heater hose.

21

Detach

The ground connection.

22

Detach

The fuel pipes.

23

Detach

The oil filler hose.

24

Detach

The oil dipstick.

25

Detach

The starter motor ground connection.

26

Detach

The pressure regulator pipe.

27

Detach

The positive starter motor cable.

28

Detach

The hydraulic pump and move it aside. 5 bolts in the flange.

29

Remove

The gearbox.

Only on vehicles equipped with a water heater.

Detach at the compressor.

Refer to Group 5. 99 318

100329

Note: When removing the gearbox, engine support 99 318 must be used to support the engine.

4 bolts.

10

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Engine assembly

22

21

19 18

25

17

23

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26

24

©

27


28

120235

18

11

Engine assembly

IMPORTANT! The lifting eyes on the engine are not designed to lift the whole vehicle and therefore must not be used for this purpose. All three lifting eyes must be used when lifting the engine.

98 094

On vehicles built from May 2000 onwards, the rear lifting eyes have been removed. They may be ordered as a spare part, part number 1 360 442. Fasten lifting chain 98 094 to the rear lifting eyes. 01_1397

30

587 308 Fasten ratchet lever hoist 587 308 to the front lifting eye.

01 1398

31

12

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Engine assembly

IMPORTANT! The lifting eyes are designed to cope with a maximum inclination angle of 30°, when lifting an engine with the gearbox removed. For engines without the gearbox removed, the maximum angle is 20°.

Remove the bolts in the engine brackets and lift out the engine.

01_1399

32

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13

Engine assembly

Fitting the engine Tightening torques Engine bracket bolts

M14: 47 Nm M16: 130 Nm+90°

V-clamp for the charge air cooler

8 Nm

1

Lift the engine so that the engine brackets are approx. 10 mm over the engine cushions.

2

Position the bolts and lower the engine so that it rests on the engine cushions and engine supports 99 318. Tightening torques: M14 bolts, 47 Nm and M16 bolts, 130 Nm+90°.

3

Fit the gearbox. Refer to Group 5.

Left-hand side: Comments

14

4

Fit

The hydraulic pump.

5

Fit

The positive starter motor cable.

6

Fit

The pressure regulator pipe.

7

Fit

The starter motor ground connection.

8

Fit

The oil dipstick.

9

Fit

The oil filler hose.

10

Fit

The fuel pipes.

RV= upper, RA= lower.

11

Fit

The ground connection.

At the compressor.

12

Fit

The water heater hose.

13

Fit

The compressor feed pipe.

14

Fit

The AC compressor.

15

Fit

The flexible hose for the charge air pipe. Tightening torque, 8 Nm.

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Fit a new gasket.

At the compressor.

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Engine assembly

10

11

13 12

7

15

9

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8

6

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5


4

120545

14

15

Engine assembly

Right-hand side: Comments

16

16

Fit

The exhaust pipe.

17

Fit

The air hose for the exhaust brake cylinder.

18

Fit

The radiator water hoses.

Only one hose is illustrated.

19

Fit

The flexible hose for the charge air cooler.

Tightening torque, 8 Nm.

20

Fit

The turbocharger induction pipe.

Tightening torque, 10 Nm, must be applied at max. 100 rpm.

21

Fit

The compressor air pipe and the crankcase ventilation hose on the induction pipe.

22

Fit

The poly-V-belt.

23

Route

Cables 13 and 14 to the front of the cab.

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Engine assembly

17

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19

18

16

20

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23

120544

22

17

Engine assembly

Comments

18

24

Fit

The mudguards.

25

Tilt the cab back to the driving position.

26

Fit

The positive and negative cables.

27

Fit

Connectors 13(C2) and 14(C188)

28

Fit

All cables with clamps.

29

Fit

The plastic cover over the central electric unit.

30

Fit

The negative cable on the battery and the battery cover.

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Connector 14 (C188) is only fitted on vehicles without a coordinator.

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Engine assembly

24

30

120542

24

29

26 28

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120543

27

19

Engine assembly

Mounting the engine in an engine stand Engines with injection pump Remove: Fuel filter Injection pump Bracket Starter motor Required brackets

Pos. A F E D

Engines with PDE unit injectors Remove: Fuel filter Control unit Compressor Starter motor Required brackets

Pos. A B C D

Engines with HPI unit injectors Remove: Fuel filter Control unit Compressor Starter motor Feed pump

Pos. A B C D G

Securely bolt the engine to the engine stand as illustrated. Use tool 99 331.

20

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Engine assembly

A

B C

D

2

3

1

99 331 F

A

A

B

D

G

C

D

119 929

E

1 Bolt M10x30 (8 off), Tightening torque 47 Nm. 2 Nut M16 (4 off), Tightening torque 180 Nm. 3 Bolt M16x50 (4 off).

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21

Engine assembly

Measuring the compression pressure The following description only applies to engines with an injection pump. Special tools Denomination

Illustration

Tool board

98 249

Compression tester

MV

99 310

Socket

D5

99 074

Impact setting tool

D1

99 079

Puller for injector

D1

99 308

Sleeve for injector

D5

100331

Number

Measuring the compression pressure is used as a step in troubleshooting. If an engine is running unevenly, this measurement may indicate whether one or more cylinders is worn or damaged. There may be damage to the cylinder head valves, cylinder liners or piston rings. The measurement indicates which cylinder(s) should be subject to further testing.

22

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The results are only intended for comparison between the cylinders. Lower compression in one or more of the cylinders is a sign of abnormal wear or damage.

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Engine assembly

The compression tester can be used on many engine types by using various accessories.

It is essential that the battery is fully charged when carrying out the compression test. Otherwise, the compression pressure obtained will be insufficient. 1 Shut off the fuel supply by removing fuse No. 20 for fuel shut off in the central electrical unit. 2 Clean around the injectors. Remove the pressure pipes for the injectors using tool 99 310.

Compression tester 98 249 1 Manometer 2 Reset valve 3 Flexible metal hose 4 Gauge rod 5 End sleeve, diameter 21 mm 6 Spacing sleeve with support lug 7 Spacing sleeve with shoulder 8 Spacing sleeve, length 6 mm 9 Spacing sleeve, length 19 mm 10 Spacing sleeve, length 25 mm 11 Spacing sleeve, length 38 mm 12 Cap nut 13 Threaded socket nut 14 Large yoke 15 Small yoke

IMPORTANT! Place protective caps on the delivery valve holders on the injection pump and on the injectors to protect them from dirt. 3 Remove the rocker cover. 4 Remove the injectors and copper washers. 5 Turn the engine with the starter motor a couple of times to remove any loose soot in the cylinders.

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23

Engine assembly

6 Connect the compression tester to the injector hole for one cylinder. Use copper washer 16 between the compression tester and the bottom of the injector hole.

7 Turn the engine with the starter motor and read off the manometer. Note the reading. 8 Reset the manometer by pressing reset button 2. 9 Move the compression tester to the next cylinder and continue according to steps 7-9.

4 Gauge rod 5 End sleeve, diameter 21 mm 7 Spacing sleeve with shoulder 10 Spacing sleeve, length 25 mm 12 Cap nut (Use socket 98 542 to tighten) 16 Copper washer

10 Compare the readings between the cylinders. If one or more cylinders has a lower compression pressure than the others, the component parts such as valves, cylinder liners and piston rings should be checked.

Gauge rod 4 contains a check valve. In the event of a leak clean the check valve as follows:

1 Unbolt valve seat 18. 2 Remove any soot from valve 17 and valve seat 18. Do not scratch the sealing surfaces. Use compressed air to clean gauge rod 4 internally.

4 Gauge rod 17 Check valve 18 Valve seat 19 O-ring

3 Reassemble the parts. Ensure that O-ring 19 is not damaged. Screw valve seat 18 into place properly so that it forms a seal with gauge rod 4.

24

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Cylinder head

Cylinder head Exploded view 17 15

5

22

20

24

27

23

26

25

33

5 18

37

16 11 22 13

21 19

14 10 8

35

4 32 2

31

36

1

2

34 29

6

3

7

28

30

9

01 1401

12

1 2 3 4 5 6 7 8 9 10 11 12 13

Cylinder head Core plug Rivet plug Valve guide Pin Pin Cylinder head gasket Valve stem seal Intake valve Valve spring Valve spring collar Exhaust valve Valve spring, outer

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14 15 16 17 18 19 20 21 22 23 24 25 26

©

Valve spring, inner Valve spring collar Split collet Valve bridge Bolt Bearing bracket Shaft Rivet plug Tight-fit screw Rocker arm Rocker arm Adjusting screw Nut


27 28 29 30 31 32 33 34 35 36 37

Spacing sleeve Rocker cover, lower Thread insert Rocker cover gasket, lower Flange screw Rocker cover, upper Rocker cover, upper, on cylinder 1 Rocker cover gasket, upper Flange screw Instruction plate Emission plate

25

Cylinder head

Removing the cylinder head (engines with injection pump)

Special tools Denomination

Illustration

99 074

Impact setting tool

99 079

Extractor for injector

99 308

Sleeve for injector

99 310

Socket

Tool board D1

D1

99 079

113 009

Number

-

00 1540

99 308

100331

-

1 Remove the pressure pipes using socket 99 310. 2 Detach the intake manifold and remove the fuel return pipe. 3 Remove the cooling system bleed pipe. 4 Remove the heat shields on the exhaust manifold and remove the exhaust manifold.

26

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Cylinder head

Note: All the valve mechanism components must be refitted in their original positions. Therefore, mark the parts as they are removed. 5 Remove the top part of the rocker cover. 6 Remove the shaft, rocker arms, bearing brackets and pushrods.

01_1344

7 Remove the lower part of the rocker cover.

99 308

01 1345

8 Undo the injector nut using socket 99 308.

9 Pull out the injectors with tools 99 079 and 99 074. 10 Remove the cylinder head. Mark the cylinder heads if more than one is being removed at the same time.

99 074

01 1346

99 079

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27

Cylinder head

Removing the cylinder head (engines with PDE unit injectors) 1 Open the bleed nipple and drain the fuel system by undoing the banjo screw on the back of the fuel manifold.

!

WARNING!

The fuel system must be empty or fuel may run down into the cylinders, which will result in a great risk of liquid slugging. 108 036

If fuel runs into the combustion chamber, it must be removed immediately using a pump. 2 Clean the rocker cover and the area around it. 3 Remove the top part of the rocker cover.

4 Relieve the pressure on the valves by undoing the bolts on the rocker arm shaft alternately.

120513

4

28

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01:03-02

Cylinder head

!

WARNING!

Do not lean over the engine when removing the rocker arm shaft. The unit injector spring is pre-tensioned and can come loose, causing personal injury.

5

Note: If the spring comes loose from the unit injector, the unit injector must be renewed.

120519

5 Remove the rocker arm shaft.

6 Remove the bearing bracket. 7 Remove the pushrods.

7

Note: The pushrod for the unit injector is secured with a retaining ring. Jiggle and pull carefully on the pushrod to loosen it. 8 Remove the valve bridges.

9 6 8

120514

9 Remove the lower rocker cover.

10 Remove the unit injector according to the section Removing the unit injector, steps 6-10 in booklet 03:04-01. 11 Detach the intake manifold, fuel manifold, cooling system bleed pipe and the exhaust manifold. 12 Remove the cylinder head. Mark the cylinder heads if more than one is being removed at the same time.

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29

Cylinder head

Removing the cylinder head (engines with HPI unit injectors)

1 Clean the rocker cover and the area around it. 2 Remove the top part of the rocker cover.

3 Relieve the pressure on the valves by undoing the bolts on the rocker arm shaft alternately.

120515

3

4 Remove the rocker arm shaft.

120520

4

30

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Cylinder head

5 Remove the bearing bracket.

6

6 Remove the pushrods.

8

7 Remove the valve bridges. 8 Remove the lower rocker cover.

5

120516

7

9 Remove the unit injector according to the section Removing the unit injector in booklet 03:04-04. 10 Detach the intake manifold, fuel manifold, cooling system bleed pipe and the exhaust manifold. 11 Remove the cylinder head. Mark the cylinder heads if more than one is being removed at the same time.

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31

Cylinder head

Fitting the cylinder head Specifications Tightening torques (applies both to engines with injection pump and unit injector) Cylinder head bolts: - First tightening

60 Nm

- Second tightening

150 Nm

- Third tightening

250 Nm

- Fourth tightening

90°

Bolt for lower rocker cover

26 Nm

Bolt for shaft with rocker arms

105 Nm

Bolt for support bracket

40 Nm + 60°

Tightening torques (applies to engines with injection pump) Nut for injector

70 Nm

Bolt for upper rocker cover

26 Nm

Nut for adjusting screw on rocker arm

35 Nm

Bolt for exhaust manifold

59 Nm

Bolt for pressure pipe

20 +/-5 Nm

Lubricant Lubricant for exhaust pipe bolts and joints

32

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561 205

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Cylinder head

All engines:

1

2

3

4

1 Check liner height; refer to the section Measuring the cylinder liner height. 2 Fit a new cylinder head gasket.

148 285

3 The cylinder head bolts may be reused a maximum of 3 times. Mark the bolt with a punch mark each time you reuse it; see figure. Make sure the bolts have no more than 2 punch marks on top of the head. If any of the bolts has 3 marks, it must be replaced with a new one. 4 Lubricate the threads and underneath the heads of the cylinder head bolts. Tighten them in the following four stages in the order given in the figure.

1

1 Torque tighten all bolts to 60 Nm 2 Torque tighten all bolts to 150 Nm

5 3

3 Torque tighten all bolts to 250 Nm 4 Finally, tighten all bolts by 90° 5 Make a mark with a centre punch on the head of the bolt.

6

5 Fit the lower part of the rocker cover and tighten the bolts to 26 Nm.

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2

139 851

4

33

Cylinder head

Engines with injection pump: 1 Fit the pushrods, bearing bracket and shaft with rocker arms and tighten the bolts to 115 Nm. 2 Adjust the valve clearance.

100036

3 Fit the injector with a new sealing washer and new O-rings lubricated with assembly compound 584 084. IMPORTANT! Always fit new O-rings and a sealing washer to injectors that have been removed.

70 Nm 99 308

01_1351

4 Tighten the injector to 70 Nm. Use socket 99 308.

5 Fit the upper part of the rocker cover and tighten the bolts to 26 Nm.

26 Nm

6 Fit the exhaust manifold and tighten the bolts to 59 Nm. Fit the heat shields. 7 Fit the cooling system bleed pipe. 9 Fit the pressure pipes and tighten the bolts using tool 99 310 to 20 +/- 5 Nm. Secure the pressure pipes with clamps.

34

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01_1353

8 Fit the intake manifold and fuel return pipe.

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Cylinder head

Engines with PDE unit injectors: 1 Fit the unit injector according to the section Fitting the unit injector, steps 1-5 in booklet 03:04-01. 2 Fit the pushrods.

3

3 Fit the bearing bracket and tighten the bolts to 40 Nm + 60°.

4

2

4 Fit the valve bridges. IMPORTANT! Lubricate the valve bridges with engine oil.

309 329

5 Continue according to the section Fitting the unit injector, steps 6-14 in booklet 03:04-01.

Engines with HPI unit injectors: 1 Fit the pushrods. 2 Fit the bearing bracket and tighten the bolts to 40 Nm + 60°. 3 Fit the unit injector and rocker arm shaft according to the section Fitting the unit injector, steps 1-8 in booklet 03:04-04.

3

2

4

4 Fit the valve bridges.

5 Refit the upper rocker cover and torque tighten the bolts to 18 Nm.

01:03-02

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309 329

IMPORTANT! Lubricate the valve bridges with engine oil.

35

Cylinder head

Checking and adjusting the valve clearance Special tools Denomination

Illustration

99 309

Flywheel rotation tool (from below)

99 109

Flywheel rotation tool (from above)

Tool board D5

100330

Number

-

Check and adjust the valve clearance with the engine cold. The intake valve clearance should be 0.45 mm and exhaust valve clearance 0.70 mm. Adjusting may be carried out in one of two ways: Alternative 1: Set cylinder 1 exactly at TDC after the compression stroke. Adjust the following valves: cyl 1

Intake and exhaust

cyl 2

Intake

cyl 3

Exhaust

cyl 4

Intake

cyl 5

Exhaust

2

3

4

5

6 114 096

1

O Intake valve X Exhaust valve Turn the crankshaft exactly one revolution. Adjust the following valves:

2

3

4

5

6 114 097

1

36

cyl 2

Exhaust

cyl 3

Intake

cyl 4

Exhaust

cyl 5

Intake

cyl 6

Intake and exhaust

O Intake valve X Exhaust valve

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01:03-02

Cylinder head

Alternative 2: Adjust both valves for each cylinder when at TDC after the compression stroke. Rotate the crankshaft 1/3 turn at a time using a flywheel rotation tool. Adjust the valves in the firing order for the cylinders:

99 309

01_1388

1-5-3-6-2-4

Adjusting valve clearance and PDE unit injectors Order of adjustment Mark on flywheel (reading taken through lower window) TDC Down (0°) 120° 240° TDC Down (360°) 480° 600°

Valve transition on cylinder 1 5 3 6 2 4

Adjust valves on cylinder

Mark on flywheel (reading taken through upper window) TDC Up (0°) 300° 60° TDC Up 300° 60°

Valve transition on cylinder 1 5 3 6 2 4

Adjust valves on cylinder

6 2 4 1 5 3

6 2 4 1 5 3

Adjust injector rocker arm on cylinder 2 4 1 5 3 6 Adjust injector rocker arm on cylinder 2 4 1 5 3 6

Engines fitted with flywheels marked TDC Up. Fit tool 99 109 in the holes of the upper window. Push the pinion into the external ring gear and rotate the flywheel using a ratchet handle and a 14 mm socket. Read the marking on the flywheel in the upper window in the flywheel housing.

01:03-02

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37

Cylinder head

Removing valves Special tools Denomination

99 322

Drift

Illustration

Tool board D5

99 322

100333

Number

1 Remove split collets, valve spring collars, springs and valves. Press down the spring using tool 99 322 in a press so that the split collets can be removed.

99 322

01_1347

2 Place the valves in a stand so that they can be refitted in the same position in the cylinder head.

Fitting valves Special tools Number

Denomination

99 322

Drift

Illustration

Tool board D5

1 Lubricate all parts well with engine oil before assembly. 2 Insert the valve into the guide. 3 Fit the valve springs and the valve spring collar.

99 322

01 1350

4 Press together the springs in a press with tool 99 322 and fit the split collets. Ensure that the split collets are positioned correctly.

38

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Cylinder head

Checking and machining valves

Specifications Intake valve Head angle

19.5°

Minimum dimension A for ground valve

2.6 mm

Exhaust valve Head angle

44.5°

Minimum dimension A for ground valve

1.8 mm

Grind the valves in a valve grinding machine.

Minimum dimension A for ground valve Check dimension A on all valves.

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39

Cylinder head

Renewing the valve stem seal Special tools Denomination

99 323

Drift

Illustration

Tool board D5

99 323

100334

Number

1 Remove the valve.

01_1348

2 Remove the valve stem seal with a pair of pliers.

3 Fit the valve. 4 Tap in a new valve stem seal carefully using tool 99 323 and a hammer.

01_1349

99 323

40

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Cylinder head

Renewing the valve seats Special tools Denomination

99 384

Drift

99 385

Shank

587 270

Kit with standard puller

Illustration

Tool board D1-A3

99 384

110 966

Number

D1-B1

110 967

99 385

1 Remove the valve seat inserts with an expanding sleeve from the kit with standard puller 587 270. 1

2

307 223

Note: Insert, for example, an aluminium sheet between the cylinder head and counterhold to protect against damage.

01:03-02

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41

Cylinder head

WARNING!

99 385

Wear protective goggles. Always turn the cylinder head with the underside face down while knocking out the valve seat insert. Otherwise, there is a risk that loose shivers of metal can cause personal injury.

2 Press in new valve seat inserts. Use drift 99 384 and shank 99 385. Cool the drift and valve seat to about -80°C with dry ice or liquid air. Pressing must be carried out rapidly.

!

99 384

146 597

!

WARNING!

Be careful when handling the cold parts and refrigerants mentioned above. Risk of frost injuries.

Oversize valve seat inserts can be fitted if the valve seat insert position has been damaged. The position must then be machined using tool 587 277.

42

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Cylinder head

Machining the cylinder head Valve seat insert, machining measurement

112 266

112 267

C

C

Intake valve A = 1.9 - 2.6 mm B = 0.75 - 1.8 mm C= diameter, 39.8+/-0.5 mm (setting dimension for machining tool)

Exhaust valve A = 1.8 - 2.6 mm B = 0.66 - 1.8 mm C= diameter, 37.9+/-0.5 mm (setting dimension for machining tool)

Specifications When machining the cylinder head, it must not be below 124.4 mm. Intake valve seat Seat angle

20.0°-20.5°

Width of contact surface A

1.9 - 2.6 mm

Valve seat insert, outer diameter

46.054 - 46.065 mm

Valve seat insert position, diameter

46.000 - 46.016 mm

Valve seat insert position, depth

11.25 - 11.35 mm

Distance B between the cylinder head face and the valve disc

0.75 - 1.8 mm

Oversize valve seat insert: External diameter

46.254 - 46.265 mm


46.200 - 46.216 mm

Cooling temperature when fitting valve seat insert

approx. -80°C

01:03-02

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43

Cylinder head

Exhaust valve seat Seat angle

45.0°-45.5°

Width of contact surface A

1.8 - 2.6 mm

Valve seat insert, outer diameter

44.081 - 44.092 mm


44.000 - 44.016 mm

Valve seat insert position, depth

11.25 - 11.35 mm

Distance B between the cylinder head face and the valve disc

0.66 - 1.8 mm

Oversize valve seat insert:

44

External diameter

44.281 - 44.292 mm


44.200 - 44.216 mm

Cooling temperature when cooling valve seat insert.

approx. -80°C

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01:03-02

Cylinder head

Tools Denomination

587 277

Valve seat cutter

587 061

Valve seat cutter

Illustration -

106 794

Number

Two equally good alternatives for cutters are specified above. The following description applies to valve seat cutter 587 277. Refer to Specifications for machining measurements and oversize valve seat inserts. 1 Make sure the contact surface and magnetic stand are level and clean. Clean the valve bushes. 2 Select the largest spindle that moves easily in the valve guide. Insert the guide spindle and turn the feed screw to its uppermost position.

3 Select the cutter and fit it.

01:03-02

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45

Cylinder head

4 Release the quick-release catch and move the pivot plate to the upper position with the adjusting screw.

5 Set up the dial on the cutter adjuster using a valve. 6 Adjust the cutter. Diameter 37.9 mm or 39.8 mm, refer to Valve seat insert, machining measurement.

7 Turn off the magnet (position 2). Insert the guide spindle into the valve bush. Adjust the pivot plate so that the distance between the cutter and the valve seat is approx. 1 mm. Centre the tool precisely.

8 Turn on the magnet (position 1).

01_1233

9 Lock the quick-release catch. Make sure the crank can be turned easily. If not, redo the centering.

46

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01:03-02

Cylinder head

10 Machine the valve seat by cranking clockwise while turning the feed screw. Never turn anticlockwise, as this could damage the cutter. Lubricate with cutting oil while machining.

11 When the surface of the valve seat has been machined, reduce the cutting pressure by turning 2-3 revolutions without any feed. Continue turning while backing off the feed screw. The valve seat cutter is now ready for the next valve seat. The valve seats can also be machined using tools from kit 587 061.

01:03-02

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47

Cylinder head

Renewing the valve guides Special tools Denomination

99 382

Drift

99 383

Drift

Illustration

Tool board D1-C6

99 382

110 864

Number

D1-B1

110 865

99 383

1 Press out the valve guides using drift 99 383.

2 Press in the new valve guides using drift 99 382. Press the guide down as far as the drift allows, i.e. until it makes contact with the spring seat in the cylinder head.

48

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01:03-02

Cylinder head

Renewing the injector sleeves The following applies to engines with an injection pump. Special tools Denomination

99 394

Guide

99 381

Drift

588 221

Pilot tap

Illustration

Tool board D2-A1

99 394

113 219

Number

D2-A1

113 297

110 863

99 381

The cylinder head must be removed when renewing the injector sleeve. The valves do not need removing. The illustrations show the cylinder head with valves removed to demonstrate clearly the work described. IMPORTANT! Mark the position of the groove on the cylinder head sleeve according to the illustration. The new sleeve must be in the same position to allow the return and leak-off pipe to be free.

01:03-02

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49

Cylinder head

1 Thread the upper part of the sleeve with pilot tap 588 221 and guide 99 394.

588 221

113 263

99 394

113 284

2 Knock out the pilot tap and sleeve from underneath. Use a 100 mm metal rod with a 9 mm diameter.

3 Degrease and check the contact surfaces of the sleeve and cylinder head. Smooth off any burrs and irregularities that could score the sleeve. 4 Degrease the new injector sleeve and apply a thin film of sealant 561 200 on the sleeve and cylinder head contact surfaces.

IMPORTANT! Ensure that the groove in the sleeve is located according to the marking.

50

©


113 220

5 Drive in the sleeve using drift 99 381.

01:03-02

Cylinder head

Renewing the unit injector sleeves The following description applies both to engines with PDE and HPI unit injectors. Special tools PDE unit injector Number

Denomination

Illustration

99 394

Guide

99 395

Drift

99 397

Extension piece with threaded shank

588 221

Pilot tap

Tool board D2-B1

113 219

99 394

D2-A1

113 221

99 395

D2-C5, C6

113 297

113 262

99 397

HPI unit injector Denomination

Illustration

99 396

Guide + pilot tap M30x1.5

99 381

Drift

99 397

Extension piece with threaded shank

588 222

Pilot tap M30x1.5

Tool board D2-B1

120 026

Number

D2-A1

110 863

99 381

D2-C5, C6

113 297

113 262

99 397

01:03-02

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51

Cylinder head

The cylinder head must be removed when renewing the sleeve for the unit injector. The valves do not need removing. The illustrations show the cylinder head with valves removed to demonstrate clearly the work described.

1 Thread the lower part of the sleeve using the pilot tap and guide.

120 024

Unit injector, PDE

Guide 99 394 Pilot tap 588 221 Extension piece 99 397

120 023

Unit injector, HPI

Guide 99 396 Pilot tap 588 222 Extension piece 99 397

52

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01:03-02

Cylinder head

2 Knock out the pilot tap and sleeve from underneath. Use a 100 mm metal rod with a 9 mm diameter. 3 Degrease and check the contact surfaces of the sleeve and cylinder head. Smooth off any burrs and irregularities that could score the sleeve.

113 284

4 Degrease the new injector sleeve and apply a thin film of sealant 561 200 on the sleeve and cylinder head contact surfaces.

5 Press in the sleeve using the drift and guide.

PDE unit injector.

HPI unit injector.

99 395

113 231

99 394

01:03-02

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53

Cylinder block

Cylinder block Reconditioning Heat arising from the main bearings seizing and rotating in the cylinder block will change the properties of the material in the cylinder block. Such cylinder blocks must be discarded. If the main bearing seizes but does not rotate in the cylinder block, the cylinder block can be reconditioned. The main bearing seats must comply with the demands on roundness given in the table. Machining out-of-round main bearing seats is something we do not recommend. Tightening torques Main bearing cap Torx bolt

110 Nm + 90°

Main bearing cap hexagon bolt

50 Nm + 90°

1 Measure the diameter at four different positions as illustrated. The diameter must be measured with the main bearing caps tightened and without main bearings. 2 Compare the dimensions with those in the table.

54

Minimum permitted diameter

Maximum permitted diameter

Greatest permitted difference between the largest and smallest diameter on the same main bearing seat.

112.200 mm

112.222 mm

0.016 mm

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01:03-02

Cylinder block

Removing the cylinder liners Special tools Number

Denomination

99 066

Cylinder liner puller

Illustration

Tool board D2

1 Mark the liners with the numbers 1-6. The mark is necessary so that the liners can be refitted in the same place and position as previously.

100214

Note: The mark must be made only on the surface indicated in the illustration. Other surfaces are for sealing. If you use a marker, you can mark anywhere.

2 Remove the cylinder liner using puller 99 066.

99 003

3 Remove the sealing ring in the cylinder block.

100040

99 066

Cylinder liner extractor with hydraulic hole cylinder

01:03-02

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55

Cylinder block

Fitting the cylinder liners 1 Check the cylinder liner height according to the section "Measuring the cylinder liner height". 2 Make sure the interior of the cylinder block is clean. Clean the O-ring surfaces. 3 Carefully check the cylinder liners, both new and old, for cracks that can arise during transport or careless handling. Tap the liner carefully with a metal object. It should give a clear metallic ring if it is intact. If it is cracked, it will sound "cracked". 4 Lubricate the sealing ring to be located in the cylinder liner with glycerol, part number 584 084, and fit it. 5 Lubricate the lower guide surface on the cylinder liner.

56

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01_1354

6 Turn the liner with the stamped cylinder number facing forward and carefully tap it down with a rubber mallet.

01:03-02

Cylinder block

Measuring the cylinder liner height Specifications Cylinder liner height above cylinder block

0.20 - 0.30 mm

Maximum permitted height difference on one and the same liner between measurements made at two diametrically opposite points

0.02 mm

Special tools Number

Denomination

87 198

Frame gauge

D2

98 075

Dial gauge

D2

01:03-02

Illustration

©


Tool board

57

Cylinder block

1 Thoroughly clean the cylinder block liner shelf, the face around the cylinder, the cylinder liner shelf and the upper face of the cylinder liner. 2 Fit the cylinder liner without O-rings and push down using two tension lugs 98 515. Tighten the bolts to 20 Nm.

3 Place frame gauge 87 198 with dial gauge 98 075 on the liner and zero the dial gauge to the liner (A). Slide the tip of the dial gauge over to the cylinder block (B) and measure the height of the liner (A-B) as illustrated. Measure each liner at two diametrically opposite points.

D C B

C A

100024

IMPORTANT! The tension lug bolts must not be tightened more than 20 Nm. Otherwise the cylinder liner may be damaged.

A Measured surface on the cylinder liner B Measured surface on the cylinder block C Tip of dial gauge D Height of the cylinder liner D = A-B

4 The cylinder liner must be slightly above the face of the cylinder block. 5 Height of cylinder liner D (= A-B) over the cylinder block after machining must be: 0.20-0.30 mm. 6 The difference between two diametrically opposite points on the same cylinder liner may be max. 0.02 mm.

58

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01:03-02

Cylinder block

Machining cylinder liner height If, during control measuring, the cylinder liner does not reach the specified value the liner seat must be machined. Adjust the liner to the correct height using a shim. Shims are available in thicknesses of 0.20 mm, 0.30 mm and 0.40 mm. If the cylinder liner height should be increased less than e.g. 0.20 mm, machine the bearing seat until the liner height including shim is correct. IMPORTANT! If a shim is used to adjust the liner height, the cylinder liner seat must always be machined. Tolerances for liner height Lowest permissible cylinder liner height before machining Permissible cylinder liner height on engines with machined liner seats Desired measurement when machining

0.15 mm 0.20-0.30 mm 0.25 mm

Example of calculation of cutting depth Height required Current cylinder liner height Increase in cylinder height = 0.25-0.14 Shim thickness Material to be removed = 0.2-0.11

01:03-02

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0.25 mm 0.14 mm 0.11 mm 0.2 mm 0.09 mm


59

Cylinder block 1 Clean the contact surface between the setting ring (which is included in the extension kit) and the top plane of the cylinder block.

Note: It is important for the surface to be cleaned thoroughly, otherwise the cylinder liner seat may be cut to the wrong depth or may be slanted. 2 Fit extension 588 672 on the cutter 587 512.

3 Set the depth of the extension to 206 mm.

60

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01:03-02

Cylinder block 4 Position the setting ring over the relevant cylinder and then position the cutter. Energise the magnet on the cutter by setting the switch to position 1.

5 Check that the tool (cutter) does not touch the edge of the liner seat when the cutter is fitted in the setting ring. Otherwise the vertical feed screw must be wound up until the cutter is released from the liner seat.

6 Lift the rapid feed ring and move the cutter by hand until it is positioned above the liner seat surface without including the cylinder block walls.

01:03-02

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61

Cylinder block 7 Wind round and at the same time turn the vertical feed screw clockwise until the cutter just touches the liner seat. 8 Lift the rapid feed ring and move the cutter back so that it is within the liner seat surface.

9 Adjust the vertical feed screw in order to start machining. Maximum feed per cut = 0.05 mm. If 0.05 mm is not enough, several cuts may be required until the required position is reached. 10 Wind clockwise with an even movement. Hold in the horizontal feed screw with the other hand at the same time. The cutter will be fed horizontally at 0.13 mm per turn. Wind carefully when the cutter starts to approach the outer edge of the liner seat. Release the horizontal feed screw when the cutter has gone over the edge so that feeding stops. IMPORTANT! Never wind the cylinder liner cutter anticlockwise; otherwise the cutter will break.

62

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01:03-02

Cylinder block

Renewing the rear crankshaft seal Special tools Number

Denomination

Illustration

99 410

Assembly tool

99 058

Drift (used together with 99 410 when renewing 185 mm crankshaft seal)

Tool board D5

116 247

99 410

156 015

D7

1 Remove the flywheel according to the section Removing the flywheel.

01_1356

2 Remove the crankshaft seal using a screwdriver. Take care not to scratch the sealing surfaces on the crankshaft and the flywheel housing. Alternatively a selftapping screw can be screwed into the crankshaft seal so that the crankshaft seal can be pulled out with a slide hammer.

01:03-02

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63

Cylinder block

Note: When working with 175 mm crankshaft seal: The crankshaft seal must be fitted dry and on no account must it be lubricated. The sleeve in the seal must be left in place. Do not touch the sealing lip with your fingers. Note: When working with 185 mm crankshaft seal: The crankshaft seal must be fitted dry and on no account must it be lubricated. Remove the plastic ring protecting the sealing lip. Do not touch the sealing lip with your fingers.

315 234

3 When working with 175 mm crankshaft seal: Fit a new crankshaft seal using tool 99 410. Place the crankshaft seal on the tool and fasten the tool with the bolts. When working with 185 mm crankshaft seal: Fit a new crankshaft seal using tools 99 058 and 99 410. Place the crankshaft seal on 99 058 and secure 99 410 to the crankshaft. 4 Turn the tool clockwise until it stops in order to attain the correct crankshaft seal position.

116 612

Note: When working with 185 mm crankshaft seal: The edge of drift 99 058 will stop against the recess in the flywheel housing.

5 Fit the flywheel according to the section Fitting the flywheel.

64

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01:03-02

Cylinder block

Renewing camshaft bearings Special tools Number 99 373

Denomination Tool for renewing camshaft bearings

99 003

Hydraulic cylinder

99 004

Pneumatic hydraulic pump

Illustration

Tool board D5

H1 109 403

99 003

109 402

H1

1 Remove the camshaft according to section Removing the camshaft. 2 Remove the camshaft blanking piece at the front of the engine. Note: Wipe around the edges and the bearing seat surfaces around the old bearings to avoid damaging the contact surfaces when fitting the new bearings. 3 Wipe the bearing seat surfaces clean around the old bearings.

01:03-02

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65

Cylinder block

Note: The recess in the bearing joint must be turned towards the front of the engine.

109 690

4 Place the new bearings in the space between the bearing seats for the camshaft.

Tool 99 373

5 Place the flange nuts on the threaded stem, included in tool 99 373, as illustrated.

1

2

4

3

5

1 Threaded stem with eight flange nuts 2 Press drift 3 Flange

6

7 8

164 328 492

820 984

66

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109 297

656

01:03-02

Cylinder block

6 Take the threaded stem and insert the end with flange nut number 1 from the rear of the engine past the rearmost bearing seat. Insert it further through the bearing seats and the new bearings until flange nut 1 protrudes from the front of the engine.

7 Screw the flange part of tool 99 373 securely onto hydraulic cylinder 99 003 with two M6x12 bolts. Press together cylinder 99 003 if not already in neutral position.

8 Screw the flange securely to the hydraulic cylinder at the rear of the engine with two M10x25 bolts. 9 Screw flange nut 8, from tool 99 373, onto the threaded stem.

01:03-02

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67

Cylinder block

10 Hang a new bearing on the stem at the front of the engine. 11 Place the press drift on the threaded stem and place the bearing on the drift.

109 689

Note: The recess in the bearing joint must be turned towards the flange on the press drifts. Secure the bearing on the drift by placing the spring-loaded ball in an oil way. The bearing is correctly located on the drift when the ball and a marking hole are centred on the bearing oil hole.

The bearing is correctly located on the drift when the ball and a marking hole are centred on the bearing oil hole. 12 Clean around the bearing contact surface. Note: The marking on the drift must be uppermost and vertical so that the oil hole in the bearing will be central to the oil ways.

13 Hold the press drift with the new bearing against the old. Secure the threaded stem between the press drift and hydraulic cylinder 99 003 by tightening flange nut 8 on the stem.

Secure the threaded stem by tightening flange nut 8.

68

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01:03-02

Cylinder block

Note: The new bearing is in the correct position before the old bearing is completely released. The new bearing has the correct position when the distance from the front edge of the cylinder block to the front edge of the press drift has a permitted value according to the table. -12 mm means that the drift should protrude 12 mm out of the cylinder block. Table for correctly located camshaft bearings Camshaft bearing No. 1 2 3 4 5 6 7

Distance (mm) -12 to -14 150 to 152 314 to 316 478 to 480 642 to 644 806 to 808 970 to 972 Check measurement of bearing number 1.

14 Press in the new bearing at the same time as pressing out the old bearing with hydraulic cylinder 99 003 and hydraulic pump 99 004. Measure to check that the bearing is correctly positioned. 15 Carefully knock with a plastic hammer to release the old bearing.

01:03-02

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69

Cylinder block

16 Remove the press drift by detaching flange nut 8 and pushing in the threaded stem. Note: The races for camshaft bearing numbers 2, 4 and 6 have two oil ways. The others only have the lower one. 17 Check that the bearing oil hole is central to the cylinder block oil ways. 18 Repeat the procedure for the remaining bearings.

Pressing out/pressing in bearing number 2.

19 Clean the sealing surface, take a new gasket and fit the blanking piece for the camshaft at the front of the engine. 20 Refit the camshaft according to the section Fitting the Camshaft. Then check the camshaft setting.

70

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Check measurement of bearing number 2.

01:03-02

Flywheel housing

Flywheel housing Exploded view

26

17

20

23

7

21

19 21

22

18

17 5 9

8

24 10

25 24

4 3

12 2 1

15

13

16

14 15

16

11 6 28

27

33

32

33

30 29

1 2 3 4 5 6 7 8 9 10 11

Flywheel housing Sealing ring Bolt Washer Flange screw Flange screw Flange screw Cover Gasket Flange screw Cover

01:03-02

12 13 14 15 16 17 18 19 20 21 22

©

Lifting eye Stud Stud Spacer Lock nut Rotational speed sensor Flange screw Clamp Clamp Bolt Timing gear plate


23 24 25 26 27 28 29 30 31 32 33

100029

31

Stud Pin Flange screw Crankshaft Crankshaft gear Pin Flywheel External ring gear Bolt Ball bearing Circlip

71

Flywheel housing

Removing the flywheel housing 1 Remove the starter motor. 2 Detach and move the power steering hydraulic pump to one side.

100025

3 Remove the flywheel housing.

Fitting the flywheel housing Specifications Tightening torques Bolts for flywheel housing

M10: 50 Nm M12: 90 Nm

Sealant Sealant for flywheel housing

816 064

Tools

72

Number

Denomination

Illustration

Tool board

588 189

Air-operated spray gun

-

-

584 117

Adapter for cartridge

-

-

584 118

Nozzle

-

-

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01:03-02

Flywheel housing

1 Remove all old sealing compound on the sealing surfaces of the flywheel housing and timing gear plate. Clean off any oil and grease using an alcohol based cleaning agent. IMPORTANT! Clean thoroughly, as the sealing surfaces must be completely free of grease. 2 Apply sealant to the flywheel housing using a nozzle. The width of the bead should be between 0.8 and 1.2 mm. Follow the pattern as illustrated.

IMPORTANT! Ensure that you apply sealant inside the bolt holes, but without allowing sealant into the crankcase. The sealant may block channels and nozzles. This is particularly important to bear in mind around oil ways, where the flow of oil to the air compressor or injection pump can be blocked.

Apply sealant to the flywheel housing on the side towards the timing gear plate. Apply sealant around the bolt holes marked with arrows. From engine serial number 5 747 863 onwards, bolt A has been added and bolt B has been moved.

IMPORTANT! Assembly must be completed within 25 minutes of starting to apply the sealant. 3 Fit the flywheel housing against the timing gear plate. Note: The bolts are of various sizes and lengths. Ensure that they are fitted in the correct places.

01:03-02

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73

Flywheel housing

4 Tighten the M12 bolts to 90 Nm and the M10 bolts to 50 Nm.

M10 x 30 M10 x 60 M10 x 30

M10 x 30 M10 x 30

M10 x 30

M10 x 60

M10 x 30

Flywheel housing and timing gear plate, up to and including engine serial number: Scania Södertälje 6 123 709 Scania Latin America 3 138 538

M10 x 30

120 594

100 053

M10 x 60

Flywheel housing and timing gear plate from engine serial number: Scania Södertälje 6 123 710 Scania Latin America 3 138 539

M10 x 60

M12 74

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100050

M12

01:03-02

Flywheel housing

5 Refit the hydraulic pump for the power steering gear. 6 Fit the starter motor.

M10 x 60

M10 x 60

M10 x 30 M10 x 80 M10 x 60

M10 x 80

Engines with injection pump, later version

M10 x 45

120 595

120 596

M10 x 30

Engines with unit injectors

M10 x 80 M10 x 60

100052

M10 x 60

Engines with injection pump, earlier version

01:03-02

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75

Fan coupling

Fan coupling The following description applies to an old design of fan coupling. Applies up to and including engine serial number: Scania Södertälje: 5719193 Scania Zwolle: 5719106 Scania Angers: 5718890 The new design is described in the section Front crankshaft seal.

Removing the fan coupling 1 Remove the fan and belt. 2 Remove the oil sump. 3 Undo the screw for the pulley. 4 Remove the fan bearing housing with the pulley.

Fitting the fan coupling Tightening torques Screw for pulley

290 Nm

Bolts for oil sump with unmachined surface

32 Nm

Bolts for oil sump with machined surface

26 Nm

1 Fit the fan bearing housing onto the engine. 2 Screw in the screw for the pulley. Tighten the screw to 290 Nm.

290 Nm

3 Fit the oil sump. 01_1383

4 Fit the belt and fan.

76

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01:03-02

Fan coupling

Renewing the bearing in the fan coupling Special tools Number

Denomination

Illustration

Tool board

87 752

Drift

-

98 334

Counterholding tube

-

98 433

Drift

-

98 622

Press drift

D1

98 647

Support drift

G2

Other tools Denomination

587 318

Puller

587 321

Puller

Illustration

Tool board 113 172

Number

01:03-02

-

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77

Fan coupling

Removal 1 Remove the screw for the pulley and extract the pulley using puller 587 321 and support drift 98 647. 98 647

01_1373

587 321

2 Remove the retaining ring.

01_1374

3 Press the shaft out of the fan coupling housing using drift 98 622.

98 622

4 Extract the bearing inner race from the spindle using pullers 587 318 and 587 319 and drift 98 647.

587 319

01_1375

98 647

587 318

5 Place the extracted bearing inner race on the bearing in the fan housing. Press the bearing out of the fan housing. Use drift 87 752 and counterholding tube 98 334.

87 752

01_1376

98 334

78

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01:03-02

Fan coupling

Fitting 1 Press the new ball bearing into the fan coupling housing using drift 98 433 and counterholding tube 98 334.

98 433

01_1380

98 334

01_1381

2 Fit the retaining ring.

3 Press the spindle into the housing.

01 1382

4 Push the pulley onto the fan coupling spindle.

01:03-02

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79

Front crankshaft seal

Renewing the front crankshaft seal The description applies from the following engine serial numbers onwards: Scania Södertälje: 5719194 Scania Zwolle: 5719107 Scania Angers: 5718891 Crankcase ventilation and front crankshaft seal

22 21 24

23 20 19

14

15

16

17

18 13 12 11

4

10 9 8 7 3

5

6

108 968

2

1

1 2 3 4 5 6 7 8

80

9 10 11 12 13 14 15 16

Nut Fan Stud Flange screw Pulley Shaft seal Flange screw Housing

©

Pin Gasket Cover plate Rivet Shaft journal Flange screw Cover Diaphragm


17 18 19 20 21 22 23 24

Hose Hose clamp O-ring Pipe Flange screw Gasket Torsion damper Flange screw

01:03-02


Tightening torques Bolts for crankcase ventilation pipe against rocker cover

12 Nm

Bolts for torsion damper

80 Nm + 45°

Special tools Number 99 374

Denomination Press tool for crankshaft seal

Illustration

Tool board D5

1 Remove the radiator according to the description in Group 02, Cooling system. 2 Remove the fan ring and the fan. Keep the fan upright. Note: The crankshaft seal seals against the pulley. Handle the pulley with care.

108 969

3 Remove the poly-V-belt and pulley.

Sealing surface for crankshaft seal

01:03-02

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81


4 Prise off the sealing ring using a screwdriver. Take care not to damage the sealing surface in the housing. 5 Wipe clean the sealing ring seat in the housing. Note: The crankshaft seal must be fitted dry and must not be lubricated. The sleeve in the seal must not be removed until just before the crankshaft seal is to be fitted on the engine. 6 Place the new seal in tool 99 374 and press it into place by tightening the bolts alternately. The seal is correctly fitted when the tool reaches the bottom.

7 Remove the tool. Fit the bolts into the threaded holes and use as a handle to make removal easier.

The seal is correctly fitted when the tool reaches the bottom.

8 Wipe clean the sealing surface on the pulley and fit it immediately. 9 Fit the fan belt. 10 Fit the fan and fan ring. 11 Refit the radiator according to the description in Group 02, Cooling system.

82

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01:03-02


Closed crankcase ventilation Troubleshooting Increased blow-by in engine Blow-by is the flow of gases through the engine crankcase and out via the crankcase ventilation. The closed crankcase ventilation system is very sensitive to changes in blow-by in the engine. If the blow-by increases, the amount of gas passing through the crankcase ventilation will also increase. The crankcase gases can then take with them small drops of oil from the crankcase. When the amount of oil increases, the oil separator will not be able to fulfil its task of separating out all the oil. Oil will then accompany the air into the charge air system. Causes of an increase in blow-by are leaking piston rings, valve guides, turbocharger or compressor. Gas leakage from the charge air system down to the crankcase also gives rise to increased blow-by and therefore increased oil carryover from the crankcase ventilation.

Too much oil in the oil sump If the engine is filled with too much oil, the excess will splash around in the crankcase and be atomised. This means that the crankcase gases will contain a large amount of atomised oil and that the crankcase ventilation will not be able to separate the oil properly. This will result in a large oil carryover from the crankcase ventilation.

01:03-02

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83


Air leak in the crankcase In a well-functioning closed crankcase ventilation system, there should be a certain amount of vacuum in the crankcase. If air enters the crankcase from outside, the flow of gas from the crankcase through the crankcase ventilation will increase. This is the same as an increase in blow-by and will lead to an increase in oil carryover. An air leak in the crankcase can be caused by: •

The oil filler cap is not properly secured.

•

The rubber plug on the oil dipstick handle is not located correctly.

Seal the oil dipstick connection as follows:

2 Press the oil dipstick down into the engine until it stops against the plastic pipe.

111 675

1 Pull the rubber seal, at the point shown by the arrow, towards the dipstick handle.

3 Press forward the rubber seal so that it forms a seal with the plastic pipe.

Damaged turbocharger Oil can leak into the charge air system from a damaged turbocharger. Refer to Workshop Manual 01:03-02, Turbocharger, for checking the turbocharger.

84

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01:03-02


Renewing the diaphragm 1 Remove the belt.

01_1377

2 Remove the idler roller on the fan coupling housing.

01 1378

3 Remove the crankcase ventilation cover.

4 Remove the diaphragm and spring. The spring has been removed from January 1999 onwards. On vehicles fitted with the spring, the spring does not need to be refitted. 5 Fit the new diaphragm. 6 Fit the cover. 7 Fit the idler roller.

01:03-02

120 015

8 Fit the belt.

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85

Crank mechanism

Crank mechanism Exploded view

1 2 3 4 5 6 7 8 9 10

86

O-ring Scraper ring Cylinder liner for steel piston Cylinder liner for aluminium piston O-ring Compression ring Compression ring Oil scraper ring Circlip Steel piston

©

11 12 13 14 15 16 17 18 19


Aluminium piston Gudgeon pin Circlip Bearing bush Connecting rod Crankshaft Bearing shell Bearing cap Flange screw

01:03-02

Crank mechanism

Removing a piston 1 Remove the cylinder head according to the section Removing the cylinder head. Industrial and marine engines have a scraper ring in the liner. See the next page for removal of the scraper ring. 2 Remove the oil sump. 3 Remove the piston cooling nozzle in the cylinder block. IMPORTANT! The piston cooling nozzle must not be damaged. The oil jet must hit the piston precisely. If it does not, the piston will become too warm, resulting in engine breakdown. Damaged nozzles must not be re-aligned; renew them instead. 4 Remove the connecting rod cap and connecting rod bearing shells. Protect the oilway in the crankshaft e.g. by winding tape around it with the adhesive side out. 5 Mark the piston before removing; the connecting rod is marked. The parts must be refitted in the same place and position. Lift out the piston and connecting rod. Note: Always check the connecting rod as described in Checking the connecting rod, if the cylinder has seized, been filled with water or had a broken valve. Bent connecting rods must not be straightened.

01:03-02

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87

Crank mechanism

Industrial and marine engines. Removal of the scraper ring in the lining If the scraper ring is so firmly seated that it cannot be removed by hand, use the following method: 1 Turn the crankshaft so that the piston is moved as far down as to allow the plate 99 168 to be accommodated below the scraper ring. 2 Fit tension lugs 98 515 on the edge of the cylinder liner in such a way that the liner will not be pulled out of place. 3 Position plate 99 168 on the piston crown. 4 Press a piston ring into the liner until it is below the scraper ring. 5 Fit handle 99 168 on impact setting tool 99 074. If it proves difficult to fit the bolt in the handle, the head of the bolt can be ground down slightly. Take care not to weaken the bolt if this is done. 6 Screw the bolt into the plate. 7 Pull up the plate until it abuts against the piston ring pressed into the liner. 8 Drive out the scraper ring with the impact setting tool. 9 Fit the scraper ring in place after the piston has been fitted.

88

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01:03-02

Crank mechanism

Fitting a piston Tightening torques Bolts for oil sump with unmachined surface

32 Nm


26 Nm

Connecting rod cap with 4 bolts

20 Nm + 90°


50 Nm + 90°

Piston cooling nozzle

23 Nm


98 212

Piston ring compressor

99 380

Assembly tool

Illustration

Tool board D3

98 212

110 060

Number

1 Lubricate the piston, piston rings, cylinder liner and piston ring compressor with engine oil. 2 Remove the protection on the connecting rod race and lubricate it. 3 Turn the piston rings so that the gaps are distributed around the piston. 4 Fit the upper connecting rod bearing shell to the connecting rod and lubricate the bearing surface. 5 For engines with a scraper ring in the lining: Fit the assembly tool 99 380 in the lining in place of the scraper ring.

01:03-02

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89

Crank mechanism

6 Insert the connecting rod bearing shell in the connecting rod cap, lubricate the bearing surface and fit the connecting rod cap.

120 029

7 Fit the connecting rod and piston. The arrow on the piston must be facing the front of the engine. Applies only to aluminium pistons; steel pistons are symmetrical. Clamp the piston ring compressor 98 212 and push the piston into the cylinder.

The arrow must be facing forwards in the direction of the engine.

For connecting rod cap with two bolts: The bolts must not be reused. Always replace the bolts with new ones. Lubricate the bolts, fit them and torque tighten to 50 Nm + 90°.

1

2

3

4

148 285

8 For connecting rod cap with four bolts: Lubricate the bolts, fit them and torque tighten to 20 Nm + 90°. The bolts may only be reused a maximum of 3 times. Mark the bolt with a punch mark each time you reuse it; see figure. If a bolt already has three marks, it must be renewed.

9 Fit the piston cooling nozzle. Tightening torque 23 Nm. IMPORTANT! The piston cooling nozzle must not be damaged. The oil jet must hit the piston precisely. If it does not, the piston will become too warm, resulting in engine breakdown. Damaged nozzles must not be re-aligned; renew them instead. 10 Fit the oil sump. 11 Fit the cylinder head. Tighten the cylinder head bolts according to the section Fitting the cylinder head.

90

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01:03-02

Crank mechanism

Renewing a piston Specifications Piston rings Number of compression rings

2 off

Gap: 1st ring (upper), engines with aluminium pistons

0.35 - 0.60 mm

1st ring (upper), engines with steel pistons

0.35 - 0.60 mm

2nd ring

0.55 - 0.80 mm

Maximum clearance in groove, 2nd ring

0.25 mm

Number of oil scraper rings

1 off

Gap

0.40 - 0.60 mm

Maximum clearance in groove

0.25 mm

Turn the rings marked "TOP" with the mark face up. Special tools Denomination

87 362

Drift

Illustration

Tool board D3

87 362

110 315

Number

Other tools Denomination

587 309

Piston ring expander

Illustration

Tool board D3

106 796

Number

01:03-02

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91

Crank mechanism

100 209

1 Place the connecting rod in a vice with soft jaws. Remove the gudgeon pin retaining rings.

2 Push out the gudgeon pin using drift 87 362.

100 210

87 362

3 Remove the piston rings using tool 587 309. Take care not to scratch the piston skirt surface with the piston rings.

587 309

4 It is possible that the graphite coating will disappear after washing graphite coated pistons in a washer. This does not matter after they have been in use for a while. New pistons, however, should be washed with care in e.g. white spirit. 5 Clean the piston and its rings thoroughly without scratching the sides of the ring grooves. Clean the oil holes in the piston using a suitable drill bit.

92

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01:03-02

Crank mechanism

6 Make sure the piston ring gaps do not exceed the permitted limit. Place the piston rings inside the cylinder liner and measure the gap with a feeler gauge. Refer to Specifications for permitted gap. 7 Fit the piston rings using tool 587 309. The oil scraper ring has an expander. Pistons rings marked with TOP must be turned with TOP face up. 8 Oil all bushes, the gudgeon pin hole and the gudgeon pin before assembling. 9 Fit the piston skirt to the piston crown and fit one of the gudgeon pin retaining rings.

120 029

10 Put the piston onto the connecting rod so that the arrow marks on the piston are facing forwards towards the engine. Applies only to aluminium pistons; steel pistons are symmetrical.

The arrow must be facing forwards in the direction of the engine. Short end of the connecting rod on left hand side.

11 Insert the gudgeon pin using tool 87 362 and fit the second retaining ring for the gudgeon pin.

01:03-02

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93

Crank mechanism

Checking the connecting rod Specifications Connecting rod cap with 4 bolts

20 Nm+90°


50 Nm+90°

Connecting rod and bearing cap marked 1 to 6. Tools Number

Denomination

587 110

Test apparatus

Illustration

Tool board -

Check the connecting rods using tool 587 110. Check that the gudgeon pin bush is undamaged and then proceed as follows: 1 Fit the connecting rod cap as marked and tighten the bolts. 2 Mount the connecting rod in the tool using the expander and fit the corresponding gudgeon pin in the gudgeon pin bush. 3 Then apply the indicator to the gudgeon pin.

94

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01:03-02

Crank mechanism

01 1216

Check whether the connecting rod is twisted with the indicator studs horizontal.

Checking whether the connecting rod is twisted.

The distance between the indicator studs on the tool illustrated here is 75 mm. The distance between one of the indicator studs and the measuring surface must be max. 0.1 mm when measured using this tool. Check with a feeler gauge.

01_1215

Check whether the connecting rod is bent with the indicator studs vertical.

Checking whether the connecting rod is bent.

01_1227

Also check whether the connecting rod is bent in an S-shape. This is done by measuring the distance between the outside of the connecting rod bush and the level surface of the tool. Turn the connecting rod around and measure the corresponding distance. The deviation must not be greater than 0.6 mm.

Checking whether the connecting rod is bent in an S-shape

01:03-02

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95

Crank mechanism

Bearing bush in connecting rod Renewal Special tools Number

Denomination

Illustration

99 403

Tool for renewing bearing bush

99 403

3

2

115 527

1

Use tool 99 403 when renewing the bearing bush.

99 403

3

The tool comprises three parts: 1. Pressplate with guide pin 2. Press drift 3. Supports

96

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1 2

115 527

There are different supports, depending on the engine type. The support marked D is for the DC11 and DSC/DC12.

01:03-02

Crank mechanism

115 528

1 Place the connecting rod on the pressplate so that the wide end of the connecting rod rests on support D. Turn the press drift with the smaller diameter against the bearing bush and press it out.

115 529

2 Turn the press drift and mount a new bearing bush onto it. Press in the bearing bush.

After pressing in a new bearing bush, it must be finish-turned. This requires special equipment. Measurements as illustrated.

d

0.008 A

A

115 537

0.007 0.008

Diameter, d = 54.030-54.043 mm. Surface quality = 0.6 Ra.

01:03-02

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97

Flywheel

Flywheel Removing the flywheel Special tools Denomination

87 368

Puller bolts

Illustration

Tool board AM1, D3, B1, AD1D3

87 368

00 1805

Number

1 Remove the rotational speed sensor(s) in the flywheel housing. 2 Remove the flywheel bolts. 14" flywheel: Also remove the washers. 87 368

01_1355

3 Pull off the flywheel from the crankshaft using puller bolts 87 368.

98

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01:03-02

Flywheel

Fitting the flywheel Specifications Tightening torques Flywheel bolts

130 Nm + 90°


Denomination

Illustration

99 324

Guide pins

99 321

Tool for locking the flywheel on engines with injection pump.

99 411

Tool for locking the flywheel on engines with unit injectors.

Tool board D5

100335

99 324

D5

00 1549

99 321

D5

116 489

99 411

01:03-02

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99

Flywheel

1 Fit two guide pins 99 324 in the flywheel housing. 2 Fit the flywheel on the crankshaft.

99 324

01_1358

IMPORTANT! Always use new bolts. 14" flywheel: Washers should also be fitted.

3 Lock the flywheel using tool: 99 321 for engines with an injection pump

99 411

120 167

99 411 for engines with unit injectors.

Locking the flywheel on engines with unit injectors.

4 Torque tighten the bolts alternately to 130 Nm and then a further 90°. 5 Refit the rotational speed sensor(s).

100

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01:03-02

Flywheel

Support bearing Renewal Special tools Denomination

99 250

Drift

Illustration

Tool board D3,C4

99 250

112 640

Number

1 Remove the retaining rings on both sides of the support bearing.

99 250

2 Knock out the support bearing from the flywheel using drift 99 250. 3 Fit the inner retaining ring and fit the new support bearing with drift 99 250.

01_1392

4 Fit the outer retaining ring.

01:03-02

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101

Flywheel

External ring gear Renewal Specifications Heat the external ring gear to 100 - 150°C before fitting. Renew the flywheel external ring gear if the gear teeth have become so worn that the starter pinion will not engage. 1 Grind a groove as deep as possible in the external ring gear and crack it open with a chisel. Remove the external ring gear from the flywheel.

!

WARNING!

Wear protective goggles due to the risk of metal shivers.

2 Clean the contact surfaces of the flywheel with a wire brush. 3 Heat the new external ring gear evenly around its circumference to 100 - 150°C. 4 Place the heated external ring gear on the flywheel so that the marking with the part number is facing the engine when fitting the flywheel. Ensure that the external ring gear is properly in contact with the flywheel. If necessary, tap down the external ring gear using a plastic hammer. 5 The external ring gear must not be cooled down rapidly but be left to cool in the open air.

102

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01:03-02

Crankshaft

Crankshaft Removing the crankshaft 1 Remove the crankshaft gear according to the section Removing the crankshaft gear. 2 Remove the fan coupling as described in the section Removing the fan coupling. 3 Remove the oil sump, oil suction pipe with strainer and the oil pump. 4 Remove the pistons and connecting rods according to the section Removing the connecting rod and piston. 5 Remove the main bearing caps and main bearings. Note: The main bearings and main bearing caps are marked and must be refitted in the same place.

01:03-02

100147

6 Lift out the crankshaft.

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103

Crankshaft

Fitting the crankshaft Tightening torques Main bearing cap Torx bolt

110 Nm + 90°

Main bearing cap hexagon bolt

50 Nm + 90°

All parts must be cleaned before fitting. 1 Place the bearing shells in the main bearing seats in the cylinder block and then lubricate the bearing surface with engine oil.

100148

Note: The outside of the bearing shells must not be lubricated.

2 Lift in the crankshaft. 3 Place the main bearings in the main bearing caps and fit them. Note: Fit the main bearings and caps in the same place as before removal. Note: You may only reuse a main bearing bolt or connecting rod bolt 3 times. Mark the bolt with a punch mark each time you reuse it. 4 Lubricate the bolt thread and the surface of the main bearing cap where the bolt is tightened. Scania engine oil can be used. Tighten the bearing cap bolts. 5 Fit the pistons with connecting rods according to the section Fitting the connecting rod and piston.

50 Nm + 90

110 Nm + 90

6 Fit the oil pump, oil suction pipe with strainer and the oil sump. 7 Fit the fan coupling as described in the section Fitting the fan coupling.

149304

8 Fit the crankshaft gear according to the section Fitting the crankshaft gear.

104

©


01:03-02

Crankshaft

Machining crankshafts

120 164

1 Measure the diameter on the crankshaft bearing journals using a micrometer as illustrated. Measure at several points around the bearing journal. If any of these diameters is lower than the minimum indicated limit, regrinding of the crankshaft should be considered. Oil pressure should also be checked, as it is affected by such factors as wear in the main bearings and connecting rod bearings.

2 When regrinding, keep to the specified minimum dimensions. Suitable bearings are available for these sizes. It is important that the fillet radius of the bearing journals is correct. Check the fillet radius using a template as illustrated.

3 After grinding the bearing journals, round off and polish the oil hole openings on the bearing surfaces.

01:03-02

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105

Crankshaft

Measurements Main bearing races Standard, diameter

107.978-108.000 mm

Undersize 1, diameter

107.728-107.750 mm


107.428-107.500 mm


107.228-107.250 mm


106.978-107.000 mm

Fillet radius

4.75-4.85 mm

Surface quality

0.25 Ra

Connecting rod races Standard, diameter

86.978-87.000 mm


86.728-86.750 mm


86.478-86.500 mm


86.228-86.250 mm


85.978-86.000 mm

Fillet radius

4.8-5.2 mm

Surface quality

0.25 Ra

Width, max.

56.05

Radial clearance

0.051-0.114 mm

Thrust washers

106

Standard, thickness

3.370-3.430 mm

Oversize 1, thickness

3.450-3.510 mm


3.500-3.560 mm


3.630-3.690 mm


3.880-3.940 mm

Axial clearance

0.138-0.380 mm

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01:03-02

Crankshaft

01:03-02

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107

Timing gear

Timing gear Exploded view

A = Parts for engines with an injection pump.

108

©


01:03-02

Timing gear

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18

19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36

Camshaft Pin Camshaft bearing Guide flange Flange screw M10x30 Thrust washer Camshaft gear Flange screw M10x40 Compressor gear Hydraulic pump gear Bolt M18x120 Shaft Intermediate gear Ball bearing Retaining ring Spacing sleeve Bolt Shaft

01:03-02

©

Crankshaft gear Oil pump gear Intermediate gear Retaining ring Shaft Spacing sleeve Roller tappet Circlip Flange screw Banjo screw Shaft Pushrod Slide ring Retaining ring Pushrod Spacing sleeve Injection pump gear Roller tappet


109

Timing gear

Removing the intermediate gear Special tools Denomination

Illustration

Tool board

99 074

Impact setting tool

D1

99 309


D5

99 109


100330

Number

-

Other tools Number

Denomination

587 526

Puller

Illustration

Tool board -

The timing gears consist of one or two intermediate gears depending on the design. The gears are removed in the same way. 1 Turn the crankshaft so that cylinder number 1 is close to TDC. Use tool 99 309 or 99 109 and a ratchet handle at the flywheel starter gear.

01_1388

99 309

110

©


01:03-02

Timing gear

2 Remove the flywheel according to the section Removing the flywheel. 3 Remove the flywheel housing according to the section Removing the flywheel housing. 4 Manufacture a thread block according to the sketch.

min 20

15−20 100054

M10

IMPORTANT! After removing the intermediate gear, neither the camshaft nor the crankshaft must be rotated. This may cause pistons and valves to collide and be damaged.

01:03-02

©

587 526 99 074


01 1359

5 The shaft on which the gear is located has a groove. Fit puller 587 526, impact setting tool 99 074 and the thread block. Pull off the gear and shaft.

111

Timing gear

Fitting the intermediate gear Tightening torques Bolts for intermediate gears

50 Nm + 60°

100055

1 Check that cylinder number 1 is close to TDC. The markings on the camshaft gear and crankshaft gear must point towards the centre of the intermediate gear.

2 Fit the intermediate gear against the camshaft gear and the crankshaft gear so that the markings point towards each other. 3 Fit the second intermediate gear.

4 Tighten the bolts on the intermediate gears to 50 Nm + 60°.

50 Nm + 60

5 Fit the flywheel housing according to the section Fitting the flywheel housing.

112

©


o

60

115 764


01:03-02

Timing gear

Renewing the bearing in the intermediate gear for the compressor


87 348

Drift

87 592

Drift

Illustration

Tool board AM1

87 348

104 862

Number

-

110 331

87 592

1 Remove the retaining ring. 2 Press the bearing packet out of the gear. 3 Press the shaft journal out of the bearing. 4 Press the shaft journal into a new bearing using tool 87 348. Do not press on the outer race. 5 Press the ring on the shaft journal. 01 1360

6 Press the bearing packet into the intermediate gear. Use tool 87 592. 7 Fit the retaining ring.

01:03-02

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113

Timing gear

Renewing the bearing in the intermediate gear for the camshaft


87 348

Drift

87 592

Drift

Illustration

Tool board AM1

87 348

104 862

Number

-

110 331

87 592

1 Press the shaft out of the bearing. 2 Press the bearing inner race shell from the shaft and remove the retaining ring. 3 Place the removed bearing inner race in the bearing and press out the bearing using drift 87 348. 4 Press a new bearing onto the shaft journal using drift 87 348.

87 592

5 Press the bearing and shaft journal into the intermediate gear using drift 87 592. 6 Fit the retaining ring.

01_1361

Note: Do not press on the outer race.

7 Press the spacing ring onto the shaft journal. Ensure that the shaft journal is on the press table.

114

©


01:03-02

Timing gear

Removing the camshaft gear Special tools Denomination

Illustration

99 309


99 109


Tool board D5

100330

Number

-

1 Turn the crankshaft so that cylinder number 1 is close to TDC. Use tool 99 309 or 99 109 and a ratchet handle at the flywheel starter gear. 2 Remove the flywheel according to the section Removing the flywheel.

99 309

3 Remove the flywheel housing according to the section Removing the flywheel housing.


01_1388

4 Remove the intermediate gear.

01 1363

5 Remove the camshaft gear.

01:03-02

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115

Timing gear

Fitting the camshaft gear Tightening torques Bolts for camshaft gears

63 Nm

1 Fit the intermediate gear as described in the section Fitting the intermediate gear, steps 1-2. 2 Fit the camshaft gear and tighten the bolts to 63 Nm. 3 Fit the flywheel housing according to the section Fitting the flywheel housing.

01 1364


116

©


01:03-02

Timing gear

Removing the crankshaft gear Special tools Denomination

Illustration

99 309


99 109


Tool board D5

100330

Number

-

1 Turn the crankshaft so that cylinder number 1 is close to TDC. Use tool 99 309 or 99 109 and a ratchet handle at the flywheel starter gear. 2 Remove the flywheel according to the section Removing the flywheel. 3 Remove the flywheel housing according to the section Removing the flywheel housing.

99 309


01_1388

4 Remove the intermediate gear.

01 1365

5 Remove the crankshaft gear.

01:03-02

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117

Timing gear

Fitting the crankshaft gear 1 Fit the crankshaft gear. 2 Fit the intermediate gear, refer to Fitting the intermediate gear, steps 1-2.


118

©


01 1366

3 Fit the flywheel housing according to the section Fitting the flywheel housing.

01:03-02

Timing gear

Removing the camshaft 1 Remove the flywheel according to the section Removing the flywheel. 2 Remove the flywheel housing according to the section Removing the flywheel housing. 3 Remove rocker arms, pushrods and valve bridges. 4 Remove the camshaft gear. 5 Remove the intermediate gear according to the section Removing the intermediate gear and bolts for the guide flange. 6 Remove the timing gear plate.

01_1370

7 Remove the camshaft covers.

8 Remove the roller tappets. Note: Mark the roller tappets because they must be refitted in the same positions.

01_1371

9 Pull out the camshaft backwards. Take care not to damage the cams and bearings.

01:03-02

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119

Timing gear

Fitting the camshaft Specifications Tightening torques Flange screws and banjo screws for the roller tappets

32 Nm

Bolts for camshaft gears

63 Nm

Bolts for the timing gear plate

63 Nm

Camshaft covers

32 Nm

Sealant Sealant for flywheel housing

816 064

Axial clearance Permitted axial play

0.05-0.35 mm

Tools

120

Number

Denomination

Illustration

Tool board

588 189

Air-operated gun

-

-

584 117

Adapter for cartridge

-

-

584 118

Nozzle

-

-

©


01:03-02

Timing gear

1 Fit the camshaft. Take care not to damage the cams and bearings.

3 Fit the camshaft covers. Torque tighten the bolts to 32 Nm. 4 Fit the guide flange bolts.

01_1371

2 Lubricate with engine oil and fit the valve tappets in the same positions as they were before they were removed. Torque tighten the bolts to 32 Nm.

Now check the axial clearance of the camshaft: •

Fit the camshaft gear temporarily.

•

Measure the axial clearance of the camshaft using a dial gauge. The axial clearance should be between 0.05-0.35 mm.

•

If the play is outside the permitted range, renew the thrust washer.

•

Remove the camshaft gear.

01:03-02

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121

Timing gear

5 Remove all old sealing compound on the cylinder block and the sealing surface on the timing gear plate. Clean off any oil and grease from the sealing surfaces using an alcohol based cleaning agent. IMPORTANT! Clean thoroughly, as the sealing surfaces must be completely free of grease.

111 347

6 Apply sealant to the cylinder block using the nozzle. The width of the bead should be between 0.8 and 1.2 mm. Follow the pattern as illustrated.

IMPORTANT! Ensure that you apply sealant inside the bolt holes, but without allowing sealant into the crankcase. The sealant may block channels and nozzles. This is particularly important to bear in mind around oil ways, where the flow of oil to the air compressor or injection pump can be blocked.

Applying sealant to the cylinder block.

IMPORTANT! Assembly must be completed within 25 minutes of starting to apply the sealant.

01_1369

7 Fit the timing gear plate onto the cylinder block. Tighten the bolts to 63 Nm.

122

©


01:03-02

Timing gear

8 Fit the intermediate gear according to the section Fitting the intermediate gear. 9 Ensure that the markings on the camshaft gear point towards the centre of the intermediate gear. 10 Fit the camshaft gear and tighten the bolts to 63 Nm. 11 Fit the flywheel housing according to the section Fitting the flywheel housing. 12 Fit the flywheel as described in Flywheel, fitting.

Checking the camshaft setting 1 Set the crankshaft to TDC after the compression stroke on cylinder number one. 2 Put two dial gauges against the valve spring thrust washers. 3 Adjust the rocker arms to remove the play and then adjust them a further 0.1 mm (thus both valves are open 0.1 mm). 4 Zero both the dial gauges. 5 Turn the crankshaft one revolution in its direction of rotation until it is at TDC again. 6 Read off both dial gauges and compare with the values given below: Intake valve lifting height 0.37-1.47 Exhaust valve lifting height 0.16-1.16

01:03-02

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123

Lubrication system

Lubrication system General Specifications Lubrication oil volume Lubrication oil volume

28 - 35 litres

Tightening torques Magnetic plug in oil sump

80 Nm

Bolts for oil sump with unmachined surface

32 Nm


26 Nm

Oil nozzle for piston cooling, banjo screw

23 Nm

Plug for relief valve in oil filter unit

40 Nm

The magnetic plug in the oil sump must be lubricated with oil before fitting.

124

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01:03-02

Lubrication system

Measuring the oil pressure Oil pressure Idling

1.6 bar

With warm engine running at 1,000 rpm

2.5 bar

With warm engine running at 2,000 rpm

4.5 - 6.0 bar


99 362

Measuring set

Illustration

120 908

Number

The use of measuring set 99 362 is described in booklet 01:00-03. There are two different designs of oil filter.

OIL

14

2 Remove the oil pressure sensor and fit the measuring equipment. Use the union and adapter according to the illustrations.

01:03-02

©

M14x1.5


115 929

1 Disconnect the connector from the oil pressure sensor.

OIL

115 954

Version 1, early model

125

Lubrication system

Version 2, later model

14

OIL

99 412

OIL

120913

3 Fit the oil pressure sensor.

126

©


01:03-02

115 954

2 Fit the measuring equipment with the union and adapters as illustrated.

M14x1.5

120928

1 Remove the oil pressure sensor from the oil filter.

Lubrication system

Oil filter Only use original Scania filters. Tools Number

Denomination

587 025

Filter tongs

Illustration

Tool board M1

Only use original Scania filters and renew the oil filter according to our inspection instructions.

587 025

IMPORTANT! When renewing the oil filter, the oil filter unit should also be cleaned according to our instructions.

01_1389

Use filter tongs 587 025 when removing the oil filter.

Removing the oil filter

If the oil filter unit is not cleaned, the oil filter will clog quickly increasing the flow resistance. If this happens, an overflow valve in the filter retainer opens and lets the oil pass without being filtered. The oil lubricates and cools components such as the turbocharger. The turbocharger rotates at high speed, sometimes above 100,000 rpm. It is vital that the lubrication functions properly. There is no separate turbocharger filter; the oil is cleaned by the engine oil filter. If the turbocharger receives contaminated oil, the bearings become severely worn.

01:03-02

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127

Lubrication system

Oil cooler Tightening torques Bolts for oil cooler insert

26 Nm

Exploded view

1 2 3 4 5

128

6 7 8 9 10

Oil cooler O-ring O-ring Flange screw Oil cooler cover

©

Core plug Cover Gasket Bolt Piston


11 12 13 14 15

Spring Plug Gasket Gasket Flange screw

01:03-02

Lubrication system

Renewing the O-rings

01_1384

1 Remove the side cover and oil cooler from the cylinder block.

2 Remove the 4 bolts securing the oil cooler to the side cover. 3 Remove the oil cooler.

4 Renew the O-rings, 4 off. 5 Fit the oil cooler insert and bolt it into place in the cover to 26 Nm.

01 1386

6 Bolt the side cover into place in the cylinder block.

01:03-02

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129

Lubrication system

Oil filter unit Specifications Permitted thickness of deposits on walls of cover

26 mm

Tightening torques Lock nut for oil cleaner housing cover

15 Nm

Nut for rotor cover

Tightened by hand

Rotor shaft

27 Nm

Locking compound Locking compound

130

561 200

©


01:03-02

Lubrication system Exploded view

1 2 3 4 5 6 7 8 9 10 11

Filter head Overflow valve Union Straight union Sealing ring Gasket Flange screw Oil filter Housing Plug Piston

01:03-02

12 13 14 15 16 17 18 19 20 21 22

©

Spring Plug Gasket Shaft Washer Rotor Nozzle Strainer Rotor cover Nut O-ring


23 24 25 26 27 28 29 30 31 32

Cover O-ring Lock nut Lifting eye O-ring Retaining ring Gasket Flange screw Oil pressure sensor Gasket

131

Lubrication system

Cleaning There should be a certain amount of deposited dirt in the rotor cover during routine cleaning of the oil filter unit. If this is not the case, this indicates that the rotor may not be rotating. The cause must be established immediately. If the dirt deposit exceeds 20 mm at the recommended intervals, the rotor cover should be cleaned more often.

x3

1 Undo the nut holding the outer cover and remove the nut.

01 1286

2 Lift out the rotor. Wipe off the outside. Undo the rotor nut and unscrew it about three turns to protect the bearing.

IMPORTANT! The rotor must not be put in a vice. Never strike the rotor cover. This may cause damage resulting in imbalance.

132

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x3

01 1287

3 If the rotor nut is difficult to get loose, turn the rotor upside down and secure the rotor nut in a vice. Turn the rotor counterclockwise three turns by hand or if this does not help, place a screwdriver between the outlet holes.

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Lubrication system

4 Grasp the rotor cover and tap the rotor nut lightly with your hand or a plastic mallet so that the rotor cover comes loose from the rotor. Never strike the rotor directly as this may damage its bearings. 5 Remove the rotor nut and cover from the rotor.

01 1289

6 Remove the strainer located on the rotor. If the strainer has seized, prise carefully with a screwdriver at the lower edge between the rotor and the strainer.

7 Scrape away the deposits inside the cover with a knife. 8 Wash the parts. 9 Inspect the two nozzles on the rotor. Ensure that they are not blocked or damaged. Renew any damaged nozzles. 10 Check that the bearings are undamaged. 11 Position the O-ring in the cover. Renew the O-ring if it is at all damaged.

01 1293

12 Assemble the parts and tighten the rotor nut by hand.

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133

Lubrication system

13 Check that the shaft is not loose. Secure with locking compound 561 200 if it is loose. First clean thoroughly using a suitable solvent. Tighten the rotor shaft using socket wrench 98 421. Tightening torque 27 Nm. 14 Refit the rotor and rotate it by hand to make sure it rotates easily.

01 1419

15 Check the O-ring on the cover of the oil cleaner housing and fit it. Torque tighten the lock nut to 15 Nm.

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Lubrication system

Oil pump Tightening torques Bolts for oil pump cover

26 Nm

Bolts for oil pump against cylinder block

26 Nm

Exploded view

9

10

3

10 2

1

5 4

8

6

25943

7

1 2 3 4 5

6 7 8 9 10

Oil pump Flange screw Gasket Flange screw Suction pipe

Strainer Ring Flange screw Pipe Sealing ring

In the event of leakage or fault with the oil pump, it must not be overhauled but renewed completely.

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135

Turbocharger

Turbocharger Exploded view 1 Lubrication pipe 2 Ferrule 3 Union nut

4 Straight union 5 Sealing ring 6 Straight union

7 8 9 10

Gasket Lubrication oil return pipe Gasket Flange screw

13

12

11

25946

13

Important information

Oil leaks

Observe strict cleanliness at all times when working on the turbocharger. Never leave the oil inlet and outlet connections unprotected. Foreign bodies in the bearing housing will soon lead to total breakdown.

A blocked air filter will cause excessive vacuum in the intake pipe. There is then a risk of oil mist being drawn from the bearing housing. If the sealing ring on the turbine side is worn, the exhaust gases will be blue when idling. If the lubrication oil return pipe from the turbocharger is damaged, the pressure of the lubricating oil may cause oil to leak out through the seals.

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Turbocharger

Foreign bodies

Air and exhaust leaks

Foreign particles, e.g. grains of sand or metal particles, in the turbine or the compressor will ruin the vanes of the wheel. This will lead to imbalance and bearing wear. The power output of the engine decreases, and if the engine is still running the reduced air supply may cause overheating and engine damage. This type of overheating is not visible on the coolant temperature gauge.

Even small leaks in the line between the air cleaner and the turbocharger will cause dirt to be deposited on the compressor impeller. The charge pressure will be reduced, resulting in increased exhaust temperature and smoke, which will reduce the service life of the engine. Leaks in the exhaust pipe between the cylinder head and the turbocharger will also result in loss of charging pressure.

IMPORTANT! Never attempt to straighten a damaged vane. It is then often broken during operation causing the turbocharger to break down completely, which also can damage the engine.

Measuring the charging pressure Measure the charging pressure using Scania Diagnos 2.

00_1521

SCANIA Diagnos

Tools for Scania Diagnos

Cleaning Low charging pressure could be caused by a dirty compressor impeller. Remove the compressor cover. Clean the compressor impeller with white spirit and a brush. Fit the compressor cover and measure the charging pressure again.

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137

Turbocharger

Measuring radial and axial clearance Turbine shaft wear limits Holset make Radial clearance

max. 0.635 mm

Axial clearance

max. 0.093 mm

Allied Signal make Radial clearance

max. 0.157 mm

Axial clearance

max. 0.119 mm


Denomination

98 075

Dial gauge

Illustration

Tool board D2

98 075

0 90

10

10

90

80

20

20

80

15 30

5 10

70

70

30 40

60

60 50

40

00_1637

50

Rocker indicator

587 250

Indicator stand

00_1569

587 107

102350

M1

Measuring radial and axial clearance often does not give a good indication of the remaining service life of the turbocharger. When the turbocharger seems to be functioning poorly or noisily, measuring the charging pressure or radial and axial clearance can indicate whether the turbocharger is defective.

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Turbocharger

Radial clearance 1 Measure the clearance at the turbine wheel as well as at the compressor impeller.

100703

2 Place the tip of the dial gauge against the turbine or compressor impeller.

3 Pull up both ends of the shaft. Take a reading.

100704

4 Press down both ends of the shaft. Take a reading. The difference between the two readings is the radial clearance.

5 Repeat the test three times on each side. 6 If any of the wheels makes contact with the housing despite the radial clearance being within tolerances, the turbocharger must be renewed.

Axial clearance 1 Place the tip of the dial gauge against the end of the shaft. 2 Press the shaft longitudinally to and fro and take a reading at the end positions. The difference between the readings is the axial clearance.

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100705

3 Repeat the test three times.

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139

Turbocharger

Checks after breakdown Tightening torques Bolt, turbocharger - exhaust manifold

63 Nm

Nut, turbocharger - exhaust pipe

63 Nm

Stud, exhaust manifold

20 Nm

V-clamp between turbocharger and exhaust brake

20 Nm

IMPORTANT! Observe strict cleanliness at all times when working on the turbocharger. Never leave the oil inlet and outlet connections unprotected. Foreign bodies in the bearing housing will soon lead to total breakdown. 1 Ensure that there are no leaks or loose particles in the line between the air cleaner and the turbocharger. 2 Check that there are no loose particles in the exhaust or intake manifolds. Renew the charge air cooler. 3 Make sure all valves are intact. 4 Check that the lubrication oil return pipe from the turbocharger is not blocked or deformed. 5 Check that the oil pressure pipe to the turbocharger is not blocked, deformed or leaking under pressure. 6 Renew the oil filter and clean the lubrication system.

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Belt transmission

Belt transmission Engine with air conditioning and an idler roller

2

1 2 3 4 5 6

3 4 5

1

105 188

6

Automatic belt tensioner Coolant pump AC compressor Idler roller Alternator Crankshaft

Engine with air conditioning and two idler rollers

1 2 3 4 5 6

3

2

4 1 3

Automatic belt tensioner Coolant pump Idler roller AC compressor Alternator Crankshaft

5

105 190

6

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141

Belt transmission

Engine without air conditioning or idler roller

1 2 3 4

2 3

Automatic belt tensioner Coolant pump Alternator Crankshaft

1

105 189

4

Engine without air conditioning with an idler roller

2 3 1

4

105 191

5

1 2 3 4 5

142

Automatic belt tensioner Coolant pump Idler roller Alternator Crankshaft

©


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Belt transmission

Belt transmission, industrial and marine engines

1 2 3 4 5 6 7

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Pulley on torsion damper. Belt tensioner. Coolant pump. Fan pulley Alternator. Poly-V-belt. Carrying roller.

143

Scania Engine

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