Scania Engine
Short Description
Scania 11 and 12 litre engine...
Description
01:03-02 Issue 9
en-GB
11 and 12 litre engines
106 351
Work description
1 585 592
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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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Scania CV AB 2011, Sweden
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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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Scania CV AB 2011, Sweden
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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
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2
120231
8
3
5 6
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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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Scania CV AB 2011, Sweden
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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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
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21
19 18
25
17
23
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24
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120235
18
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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
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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
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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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Scania CV AB 2011, Sweden
Fit a new gasket.
At the compressor.
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Engine assembly
10
11
13 12
7
15
9
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6
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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
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18
16
20
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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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Scania CV AB 2011, Sweden
Connector 14 (C188) is only fitted on vehicles without a coordinator.
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Engine assembly
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30
120542
24
29
26 28
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Scania CV AB 2011, Sweden
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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.
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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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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.
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Scania CV AB 2011, Sweden
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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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.
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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
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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
Scania CV AB 2011, Sweden
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
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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.
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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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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
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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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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
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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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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
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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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139 851
4
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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.
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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.
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309 329
IMPORTANT! Lubricate the valve bridges with engine oil.
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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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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.
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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.
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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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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
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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.
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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.
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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
Valve seat insert position, diameter
46.200 - 46.216 mm
Cooling temperature when fitting valve seat insert
approx. -80°C
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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
Valve seat insert position, diameter
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
Valve seat insert position, diameter
44.200 - 44.216 mm
Cooling temperature when cooling valve seat insert.
approx. -80°C
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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.
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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.
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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.
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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.
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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.
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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.
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Scania CV AB 2011, Sweden
113 220
5 Drive in the sleeve using drift 99 381.
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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
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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
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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
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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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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
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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.
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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.
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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
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Illustration
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Scania CV AB 2011, Sweden
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.
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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
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0.25 mm 0.14 mm 0.11 mm 0.2 mm 0.09 mm
Scania CV AB 2011, Sweden
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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.
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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.
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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.
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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.
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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.
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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.
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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
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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.
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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.
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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.
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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.
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Check measurement of bearing number 2.
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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
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12 13 14 15 16 17 18 19 20 21 22
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Lifting eye Stud Stud Spacer Lock nut Rotational speed sensor Flange screw Clamp Clamp Bolt Timing gear plate
Scania CV AB 2011, Sweden
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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Scania CV AB 2011, Sweden
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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.
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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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Scania CV AB 2011, Sweden
100050
M12
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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
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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.
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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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Scania CV AB 2011, Sweden
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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
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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.
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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
Scania CV AB 2011, Sweden
17 18 19 20 21 22 23 24
Hose Hose clamp O-ring Pipe Flange screw Gasket Torsion damper Flange screw
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Front crankshaft seal
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
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Front crankshaft seal
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.
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Closed crankcase ventilation
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.
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Closed crankcase ventilation
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.
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Closed crankcase ventilation
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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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
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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.
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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.
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Crank mechanism
Fitting a piston Tightening torques Bolts for oil sump with unmachined surface
32 Nm
Bolts for oil sump with machined surface
26 Nm
Connecting rod cap with 4 bolts
20 Nm + 90°
Connecting rod cap with 2 bolts
50 Nm + 90°
Piston cooling nozzle
23 Nm
Special tools Denomination
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.
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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.
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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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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.
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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.
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Crank mechanism
Checking the connecting rod Specifications Connecting rod cap with 4 bolts
20 Nm+90°
Connecting rod cap with 2 bolts
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.
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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
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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
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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.
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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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Flywheel
Fitting the flywheel Specifications Tightening torques Flywheel bolts
130 Nm + 90°
Special tools Number
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
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Scania CV AB 2011, Sweden
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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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.
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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.
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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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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.
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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.
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Crankshaft
Measurements Main bearing races Standard, diameter
107.978-108.000 mm
Undersize 1, diameter
107.728-107.750 mm
Undersize 2, diameter
107.428-107.500 mm
Undersize 3, diameter
107.228-107.250 mm
Undersize 4, diameter
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
Undersize 1, diameter
86.728-86.750 mm
Undersize 2, diameter
86.478-86.500 mm
Undersize 3, diameter
86.228-86.250 mm
Undersize 4, diameter
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
Oversize 2, thickness
3.500-3.560 mm
Oversize 3, thickness
3.630-3.690 mm
Oversize 4, thickness
3.880-3.940 mm
Axial clearance
0.138-0.380 mm
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Crankshaft
01:03-02
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Timing gear
Timing gear Exploded view
A = Parts for engines with an injection pump.
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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
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Timing gear
Removing the intermediate gear Special tools Denomination
Illustration
Tool board
99 074
Impact setting tool
D1
99 309
Flywheel rotation tool (from below)
D5
99 109
Flywheel rotation tool (from above)
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
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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
Scania CV AB 2011, Sweden
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
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o
60
115 764
6 Fit the flywheel according to the section Fitting the flywheel.
01:03-02
Timing gear
Renewing the bearing in the intermediate gear for the compressor
Special tools Denomination
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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Timing gear
Renewing the bearing in the intermediate gear for the camshaft
Special tools Denomination
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.
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Timing gear
Removing the camshaft gear Special tools Denomination
Illustration
99 309
Flywheel rotation tool (from below)
99 109
Flywheel rotation tool (from above)
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.
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_1388
4 Remove the intermediate gear.
01 1363
5 Remove the camshaft gear.
01:03-02
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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
4 Fit the flywheel according to the section Fitting the flywheel.
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Timing gear
Removing the crankshaft gear Special tools Denomination
Illustration
99 309
Flywheel rotation tool (from below)
99 109
Flywheel rotation tool (from above)
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
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_1388
4 Remove the intermediate gear.
01 1365
5 Remove the crankshaft gear.
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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.
4 Fit the flywheel according to the section Fitting the flywheel.
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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.
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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
-
-
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Scania CV AB 2011, Sweden
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.
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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.
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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
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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
Bolts for oil sump with machined surface
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.
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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
Special tools Denomination
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.
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M14x1.5
Scania CV AB 2011, Sweden
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.
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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.
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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
Scania CV AB 2011, Sweden
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.
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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
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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
Scania CV AB 2011, Sweden
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.
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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.
01:03-02
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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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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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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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
Special tools Number
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.
01:03-02
100705
3 Repeat the test three times.
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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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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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Scania CV AB 2011, Sweden
Pulley on torsion damper. Belt tensioner. Coolant pump. Fan pulley Alternator. Poly-V-belt. Carrying roller.
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