Scania Work Description Engine - 12 Industrial And Marine Engine p1d9

01:03-02 Issue 2 Industrial & Marine Engines

Work Description - 12 Engine Industrial and Marine Engines

Part No. 1 588 557

© Scania CV AB, Sweden, 1999-09:02

en

Valve clearances, pump setting

Engine type, engine serial number Engine serial number

Contents Cylinder head . . . . . . . . . . . . . . . . . . . . . . . . . 3 Valve clearances . . . . . . . . . . . . . . . . . . . . . 5 Compression . . . . . . . . . . . . . . . . . . . . . . . . 6 Removing . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Dismantling . . . . . . . . . . . . . . . . . . . . . . . . . 9 Changing valve stem seal. . . . . . . . . . . . . . . 9 Replacement of valve seats . . . . . . . . . . . . 10 Machining of valve seats . . . . . . . . . . . . . . 11 Replacement of valve guides . . . . . . . . . . . 13 Replacement of injector sleeves. . . . . . . . . 14 Fitting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . 16 Turbocharger. . . . . . . . . . . . . . . . . . . . . . . . . 18 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 Measuring radial clearance and axial clearance . . . . . . . . . . . . . . . . . . . . . . . . . . 21 If the turbocharger does not work . . . . . . . 22 Changing the turbocharger. . . . . . . . . . . . . 23 Pistons and cylinder liners . . . . . . . . . . . . . . 24 Removal of the loose ring in the liner . . . . 26 Removing and dismantling connecting rods and pistons . . . . . . . . . . . . . . . . . . . . . . . . . 26 Assembling piston and connecting rod . . . 29 Removing cylinder liner . . . . . . . . . . . . . . 30 Fitting cylinder liner . . . . . . . . . . . . . . . . . 32 Fitting piston and connecting rod . . . . . . . 33

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Flywheel and flywheel housing . . . . . . . . . . .35 Removing flywheel . . . . . . . . . . . . . . . . . . .37 Removing flywheel housing . . . . . . . . . . . .39 Fitting flywheel housing . . . . . . . . . . . . . . .39 Fitting flywheel . . . . . . . . . . . . . . . . . . . . . .40 Timing gear . . . . . . . . . . . . . . . . . . . . . . . . . .41 Gearwheel timing gear . . . . . . . . . . . . . . . . . .43 Intermediate gear. . . . . . . . . . . . . . . . . . . . .43 Camshaft gear . . . . . . . . . . . . . . . . . . . . . . .46 Crankshaft gear . . . . . . . . . . . . . . . . . . . . . .47 Camshaft . . . . . . . . . . . . . . . . . . . . . . . . . . .48 Replacement of camshaft bearing . . . . . . . .49 Crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . .57 Belt timing gear . . . . . . . . . . . . . . . . . . . . . . .59 Lubrication system . . . . . . . . . . . . . . . . . . . . .61 Oil cooler. . . . . . . . . . . . . . . . . . . . . . . . . . .61 Oil cleaner . . . . . . . . . . . . . . . . . . . . . . . . . .63 Oil pump . . . . . . . . . . . . . . . . . . . . . . . . . . .67 Lifting the engine . . . . . . . . . . . . . . . . . . . . . .68 Specifications . . . . . . . . . . . . . . . . . . . . . . . . .69 General information . . . . . . . . . . . . . . . . . .69 Cylinder head . . . . . . . . . . . . . . . . . . . . . . .70 Turbocharger . . . . . . . . . . . . . . . . . . . . . . . .72 Pistons and cylinder liners. . . . . . . . . . . . . .72 Flywheel and flywheel housing. . . . . . . . . .73 Timing gear . . . . . . . . . . . . . . . . . . . . . . . . .74 Lubrication system . . . . . . . . . . . . . . . . . . .75 Special tools . . . . . . . . . . . . . . . . . . . . . . . . . .76


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Cylinder head

1. Cylinder head 2. Core plug 3. Rivet plug 4. Valve guide 5. Valve seat ring 6. Valve seat ring 7. Pin 8. Pin 9. Gasket 10. Seal 11. Intake valve 12. Valve spring 13. Valve spring collar 14. Exhaust valve

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15. Valve spring 16. Valve spring 17. Valve spring collar 18. Collet 19. Yoke 20. Bolt 21. bracket 22. Shaft 23. Rivet plug 24. Tight-fit screw 25. Rocker arm 26. Adjusting screw 27. Hexagon nut 28. Rocker arm


29. Adjusting screw 30. Hexagon nut 31. Spacer sleeve 32. Hexagon bolt 33. Rocker cover, lower section 34. Thread insert 35. Rocker cover gasket 36. Flange bolt 37. Rocker cover, upper section 38. Flange bolt 39. Rocker cover, upper section 40. Filler cap 41. Rocker cover gasket

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Special tools

98 249 99 074 99 079 99 308 99 309 99 310 99 322 99 323

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Compression tester Impact drift Extractor for injectors Sleeve for injectors Tool for turning flywheel Socket Press drift Assembly drift

99 381 99 382 99 383 99 384 99 385 99 394 587 277 588 221


Drift Drift Drift Drift Handle Styrning Valve seat cutter Tap

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Valve clearances Checking and adjusting Check valve clearances. The clearance for intake valves should be 0.45 mm and the clearance for exhaust valves should be 0.70 mm when the engine is cold.

Adjustment can be carried out in one of the following ways: A. Adjust all four valves for each cylinder when at TDC after compression. Start with cylinder No. 1 and turn the crankshaft 1/3 turn at a time using tool 99 309 in the following injection order: 1-5-3-6-2-4

B. Bring cylinder No. 1 exactly to TDC after compression. The following valves can now be adjusted: cyl. 1 cyl. 2 cyl. 3 cyl. 4 cyl. 5

intake and exhaust intake exhaust intake exhaust

O Intake valve ⊗ Exhaust valve

Turn the crankshaft precisely one revolution so that TDC for No. 6 cylinder is set. The remaining valves can now be adjusted: cyl. 2 exhaust cyl. 3 intake cyl. 4 exhaust cyl. 5 intake cyl. 6 exhaust and intake

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O Intake valve ⊗ Exhaust valve

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Compression Measuring The compression tester is used to quickly and simply check wear and damage to primarily the cylinder head valves, but also to cylinder liners and piston rings.

Measurements are only intended for comparison between cylinders. Lower compression in one or several cylinders is a sign of abnormal wear or damage.

By using various accessories, the compression tester can be used for several engine types.

1. Cut off the supply of fuel by disconnecting the power source. 2. Clean round the injectors. Detach the delivery pipes to all injectors using tool 99 310. Note Fit protection caps on the delivery valve holders in the injection pump and on the injectors to protect them from dirt.

1. Pressure gauge 2. Zeroing valve 3. Flexible metal hose 4. Test rod 5. End sleeve, diameter 21 mm 6. Spacing sleeve with guide lug 7. Spacing sleeve with collar 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 Compression tester 98 249

3. Remove the rocker covers. 4. Undo and remove the injectors and copper washers. 5. Turn the engine over several times using the starter motor to remove any loose soot in the cylinders.

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6. Connect the compression tester in the injection aperture in one of the cylinders. Copper washer 16 should be used between the compression tester and the bottom of the injector aperture. 7. Turn the engine over using the starter motor and read the pressure gauge. Note the result. 8. Zero the pressure gauge by pressing the zeroing button 2. 9. Move the compression tester to the next cylinder and proceed as in points 5-8. 10. Evaluate readings and assess what further measures need to be taken on the engine.

4. 5. 7. 10. 12.

Test rod End sleeve, diameter 21 mm Spacing sleeve with collar Spacing sleeve, L = 25 mm Cap nut (use socket 98 542 for tightening) 16. Copper washer

Cleaning of measuring rod Measuring rod 4 has a check valve which, in the case of leakage, should be cleaned as follows: 1. Unscrew valve seat 18. 2. Remove all soot from valve 17 and valve seat 18. Do not scratch the sealing surfaces. Use compressed air to clean the inside of measuring rod 4. 3. Assemble the parts. Make sure that O-ring 19 is not damaged. Fully screw on valve seat 18 so that it seals against measuring rod 4.

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4.Measuring rod 17.Valve 18.Valve seat 19.O-ring

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Removing 1. DSI12: Detach the inlets and outlets for air and water from the charge air cooler and unbolt the charge air cooler. DSC12: Remove the intake pipe clamps from the intake manifold. 2. Remove the intake manifold and turbocharger. 3. Remove the heat shields and exhaust manifold. 4. Detach the delivery pipes using tool 99 310 and remove same. 5. Insert protection plugs in the ends of the delivery pipes and place protection caps on the injectors and injection pump. 6. Remove the cooling system ventilation pipe. Note All parts of the valve mechanism must be refitted in the same positions. The removed parts must therefore be marked. 7. Remove the upper part of the rocker cover, being careful not to drop any parts into the engine. 8. Remove the shaft, rocker arms, bearing brackets, valve braces and pushrods. 9. Remove the lower part of the rocker cover. 10. Undo the injector nut using socket 99 308. 11. Extract the injectors using tools 99 079 and 99 074. 12. Remove the cylinder head bolts and lift off the cylinder head. Mark the cylinder heads if more than one is removed at the same time. 13. Cover the engine to keep out all extraneous objects, etc.

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Dismantling 1. Remove collets, valve spring collars, springs and valves. Press the spring down using tool 99 322 in a press so that the collets can be removed. 2. Place the valves in a rack so that they can be refitted in the same position in the cylinder head. 3. Mark the cylinder heads if more than one is removed at the same time.

Changing valve stem seal 1. Remove the valve. 2. Remove the valve stem seal using pliers.

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

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Replacement of valve seats 1. Remove the valve seat rings. Use a discarded valve which is ground off so that the valve head diameter is slightly less than the inner diameter of the seat. 2. Fit the valve and electro-weld around it to secure it in place. Cool with water. Turn the cylinder head around and tap the valve stem so that the valve and seat ring fall out.

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WARNING!

Use protective goggles. Always turn the cylinder head around with the underside downwards when tapping out the valve seat ring. Otherwise there is a risk of loose splinters causing personal injury.

3. Press in new valve seat rings. Use drift 99 384 and handle 99 385. Cool the drift and valve seat to approx -80°C in dry ice or using liquid air. The rings must be pressed in very quickly.

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WARNING!

Be careful with the above-mentioned coolants and cooled components. There is a risk of frost injuries. Over-sized valve seat rings may be fitted if the seat for the valve seat ring has been damaged. If this is the case, the seat must be machined using tool 587 277.

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Machining of valve seats Machining values

Inlet valve A = 1,9 - 2,6 mm B = 0,75 - 1,8 mm C = diameter 39,8 +/- 0,5 mm (setting value 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 value for machining tool)

Work description The following description applies to valve seat cutter 587 277. Machining values and over-sized valve seat rings, see Specifications. 1. Check that the surface and the magnetic base are smooth and clean. Clean the valve bushings. 2. Select the largest spindle which slides easily into the valve guide. Fit the guide spindle and turn the feed screw to the position.

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3. Select and fit the cutter.

4. Slacken off the quick-release lock and move the pivot plate to the upper position using the adjustment screw.

5. Set the indicator on the cutter adjuster using a valve. 6. Set the cutter. Diameter value 37.9 mm and 39.8 mm, see Valve seat ring, machining values.

7. Disconnect the magnetic base (position 2). Insert the guide spindle in the valve bushing. Adjust the pivot plate so that the distance between the cutter and the valve seat is approximately 1 mm. Centre the tool carefully. 8. Connect the magnetic base (position 1). 9. Lock the quick-release lock. Check that the crank is easy to turn. If not, centre the tool again.

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10. Cut the valve seat by simultaneously turning the crank clockwise and turning the feed screw. Never turn the crank anti-clockwise. This may break the cutter. Lubricate with cutting oil during the procedure. 11. When the machining of the valve seat is completed, reduce the cutting pressure by turning the crank 2 or 3 turns without feeding. Then continue to turn the crank while turning the feed screw anti-clockwise. The valve seat cutter is now ready for the next valve seat. The valve seats may also be machined using tools from kit 587 061.

Replacement of valve guides 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, ie until it makes with the spring seat in the cylinder head.

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Replacement of injector sleeves - When replacing an injector sleeve, the cylinder head must be removed. - The valves do not need to be removed. - The figs. show the cylinder head with the valves removed so that it is easier to see the procedure described.

Important Mark the position of the groove in the sleeve on the cylinder head as illustrated. The new sleeve must sit in the same position to ensure that the oil leakage / return ducts are not blocked.

1. Thread the top part of the sleeve using tap 588 221 and guide 99 394.

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

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3. Degrease and check the surfaces of the sleeve and the cylinder head. Remove any burrs or unevenness which could scratch the sleeve. 4. Degrease the new injector sleeve and apply a thin film of sealing agent 561 200 on the sleeve and on the mating surfaces in the cylinder head. 5. Push in the sleeve using drift 99 381. Important Ensure that the groove in the sleeve is in the correct position according to the mark.

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Assembly 1. Liberally lubricate all parts using engine oil before assembly. 2. Fit the valves in their guides and position the cylinder head in a press. 3. Fit the valve springs and valve spring collars. 4. Compress the springs using tool 99 322 and fit the collets, making sure that they go into their correct positions.

Fitting 1. Check liner heights, see Pistons and cylinder liners. 2. Fit a new cylinder head gasket. 3. Fit the cylinder head and ensure that the guide pins fit in the holes. 4. Cylinder head bolts can be reused a maximum of 3 times. Check therefore that the bolts have no more than 2 punch marks on the surface of the head. If any of the screws has 3 marks, it should be changed for a new one.

5. Lubricate the threads on the cylinder head bolts and the surface under the head.

6. Tighten the bolts in the order given in the figure and in three stages + 90 degrees as follows: • • • • •

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Tighten all bolts to 60 Nm Tighten all bolts to 150 Nm Tighten all bolts to 250 Nm Finally, tighten all bolts a further 90° Using a centre punch, make a mark on the head of the bolt.


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7. Fit the lower part of the rocker cover and tighten the bolts to 22 Nm. 8. Fit the injector with a new seal and new Orings lubricated with assembly compound 815 368. Important Always change the O-rings on the injectors when they have been removed. 9. Use tool 99 308 and tighten it to 70 Nm.

10. Fit the valve braces, pushrods, bearing brackets and shaft with rocker arms and tighten the bolts to 115 Nm. 11. Check the valve clearances when all cylinder heads are in place. See page 5.

12. Fit the upper part of the rocker cover and tighten the bolts to 22 Nm. 13. Fit the exhaust manifold and turbocharger with oil lines. Tighten the nuts and bolts to 59 Nm. Fit the heat shields. 14. Fit the ventilation pipe for the cooling system. 15. DSC12: Fit the intake manifold. 16. Fit the delivery pipes and tighten the nuts to 20 Nm using tool 99 310. Refit the delivery pipe clamps. 17. DSI12: Fit the intake manifold and charge air cooler and attach the intake and outlet pipes. Tighten the bolts to 26 Nm. Clamp the delivery pipes to the rear part of the charge air cooler.

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Turbocharger Special tools

98 075 587 025 587 107 587 250

DI12

1. 2. 3. 4. 5. 6. 7. 8.

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Lubrication oil pipe Ferrule Union nut Straight union Seal Straight union Gasket Lubrication oil return pipe

Dial gauge Filter wrench Deflection gauge Stand

DC12

9. Gasket 10. Bolt 11. Flange pipe 12. Hose 13. Hose clamp 14. Clamp 15. Turbocharger

1. 2. 3. 4. 5. 6. 7. 8.

Lubrication oil pipe Ferrule Union nut Straight union Seal Straight union Gasket Lubrication oil return pipe


9. Gasket 10. Bolt 11. Bracket 12. Bolt 13. Clip 14. Clip 15. Bolt 16. Turbocharger

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General Note Whenever working on the turbocharger, observe utmost cleanliness. The oil intake and outlet connections must never be left open. A foreign body in the bearing housing can quickly cause total breakdown.

Oil leakage With a clogged air cleaner, the vacuum in the intake pipe will be excessive. There is then a risk that oil mist will be sucked out of the turbocharger’s bearing housing. If the seal on the turbine side is worn, exhaust gas is blue when idling. If the oil outlet pipe from the turbocharger is damaged, there is a risk of oil leaking out through the seals due to lubrication oil pressure.

Oil filter The turbocharger rotates at high speed, sometimes above 100,000 rpm. The oil lubricates and cools the turbocharger. Efficient lubrication is extremely important. There is no separate turbo filter and the oil es through the engine oil filter. For this reason, change the oil filter and clean the oil filter assembly in accordance with our instructions. Use filter wrench 587 025 when removing the oil filter.

Removing oil filter

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If the oil filter assembly is not cleaned, the oil filter will soon become clogged and its resistance to the flow of oil will increase. A valve in the filter holder then opens and allows the oil to through the filter without being cleaned (filtered). Unfiltered oil is consequently supplied to the turbocharger with heavy bearing wear as a result. The valve is designed for genuine Scania filters and only these should be used.

Air and exhaust leakage

Foreign bodies

Cleaning the compressor wheel

Foreign bodies, such as grains of sand or metal filings, in the turbine or compressor will damage their blades. This leads to imbalance and bearing wear. Engine output falls off and continued operation could give rise to overheating damage on of a decrease in the supply of air. This type of overheating cannot be observed on the coolant temperature gauge.

Low charge pressure can be caused by a dirty compressor wheel, for example. - Remove the compressor housing.

Note Never attempt to straighten a damaged impeller. It will usually break in operation causing the turbocharger to break down and may also cause engine damage. Change the entire turbocharger.

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Even small leaks in the line between the air cleaner and turbocharger cause dirt deposits on the compressor wheel. Charge pressure decreases with increased exhaust temperature, causing smoke. In addition, the engine is worn unnecessarily. Exhaust leakage between cylinder head and turbocharger also results in lower charge pressure.

- Wash the compressor wheel using white spirit and a brush. - Fit the compressor housing and measure charge pressure again. Note The compressor wheel must not be removed from the shaft. Imbalance may occur when it is refitted.


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Measuring radial clearance and axial clearance Measuring radial clearance and axial clearance does not usually give any indication of the remaining service life of the turbocharger. When the turbocharger is not working correctly or sounds abnormal, measuring charge pressure or measuring radial clearance or axial clearance can show that the turbocharger is defective. To measure axial and radial clearances it is advisable to remove the turbocharger and bolt it to a steel plate, which will also serve as a base for the magnetic stand holding the dial gauge.

Radial clearance Take readings on both turbine wheel and compressor wheel. 1. Place the tip of the dial gauge against the turbine wheel and compressor wheel.

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

Measuring turbine wheel radial clearance

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

4. Repeat measurements three times on each side. 5. If any wheel rubs against the housing, despite radial clearance being within tolerance, the turbocharger should be changed. Measuring compressor wheel radial clearance

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Axial clearance 1. Place the tip of the dial gauge against the end of the shaft. 2. Press the shaft forwards and backwards and read the dial at the end positions. The difference between readings is axial clearance. 3. Repeat measurements three times.

Wear limits for Holset: Radial clearance...................0.198-0.564 mm Axial clearance (after running in).................. 0.025-0.106 mm

Checking axial clearance

If the turbocharger does not work 1. Check that there is no leakage or loose objects in the line between the air cleaner and turbocharger.

7. Check that the air filter is not blocked and that there are no other reasons for the abnormal increase of vacuum in the intake system.

2. Check that there are no loose particles in the exhaust manifold or intake manifold.

8. Check that engine output is correct. Excessively high output reduces the life of the turbo.

3. Check that all valves are intact. 4. Check the lubrication oil return pipe from the turbocharger for blockage or deformation. 5. Check the oil delivery pipe to the turbocharger for any blockage, deformation and leakage under pressure. 6. Check the condition and part number of the oil filter.

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Changing the turbocharger Note When changing the turbocharger, all gaskets and the oil filter must be changed and the centrifugal cleaner must be cleaned.

Removing 1. Detach the delivery and return oil lines from the turbocharger. 2. Detach the exhaust pipe, induction pipe and charge air cooler pipe from the turbocharger. 3. Unscrew the bolts in the turbocharger mounting and remove it.

Fitting 1. Check the connecting flange on the exhaust manifold to ensure that there are no remnants of the old gasket. 2. Fit a new gasket and bolt on a new turbocharger. Lubricate the exhaust manifold bolts with high-temperature resistant lubricant, part No. 561 205. Tighten to 42 Nm. 3. Connect the oil supply and return lines. 4. Connect the charge air pipe, induction pipe and exhaust pipe. 5. Disconnect the fuel valve’s power supply (fuel shut-off) and turn the engine over with the starter motor for at least 30 seconds so that the lubricating oil will reach the turbocharger. 6. Start the engine and check that there is no leakage.

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Pistons and cylinder liners

1. 2. 3. 4. 5. 6. 7. 8.

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Piston Compression ring Compression ring Oil scraper ring Retaining ring Gudgeon pin Connecting rod Bushing

9. Bearing shell 10. Bearing cap 11. Flange bolt 12. Crankshaft 13. O-ring 14. Cylinder liner 15. O-ring 16. Loose ring


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Special tools

87 198 87 362 98 075 98 212 98 515 99 066

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Rule for dial gauge Drift Dial gauge Piston ring compressor Pressing tool Puller for cylinder liner

99 074 99 168 99 380 587 110 587 309


Impact drift Dismantling tool Assembly tool Test apparatus for connecting rods Piston ring expander

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Removal of the loose ring in the liner If the loose ring is so firmly seated that it cannot be removed by hand, use the following method: 1. Remove the cylinder head and oil sump. 2. Turn the crankshaft until the piston is at bottom dead centre. 3. 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. 4. Position plate 99 168 on the piston crown. 5. Press a piston ring into the liner until it is below the loose ring. 6. Fit handle 99 168 on impact drift 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. 7. Screw the bolt into the plate. 8. Pull up the plate until it abuts against the piston ring pressed into the liner. 9. Drive out the loose ring with the impact drift.

Removing and dismantling connecting rods and pistons 1. Remove the cylinder head and oil sump. 2. Remove the piston cooling nozzle from the cylinder block.

Note The piston cooling nozzle must on no be damaged. The jet of oil must hit the piston in the correct place. If it does not, the piston gets too hot and engine breakdown will result. Damaged nozzles must not be straightened. They must be changed.

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3. Remove the bearing cap and bearing halves. Protect the oilway in the crankshaft with tape or the like, wound with the adhesive side out. 4. Mark the piston and connecting rod before removing them. They must be refitted in the same place and in the same way. 5. Lift out the piston and connecting rod.

6. Clamp the connecting rod in a vice with soft jaws. Remove the gudgeon pin retaining rings.

7. Heat the piston to 100 °C and push out the gudgeon pin using drift 87 362. 8. Remove the piston rings using tool 587 309, taking care to avoid scratching the surface of the piston skirt with the piston rings. 9. When cleaning graphited pistons in a machine, the graphiting may disappear. This does not matter when it has been used for some time. However, new pistons should be washed carefully using white spirit or the like. Note Always inspect the connecting rod in cylinders which have seized, been filled with water or where the valve has broken. Bent connecting rods must not be straightened.

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Checking connecting rods Check the connecting rods using tool 587 110. Proceed as follows: 1. When the gudgeon pin bushing has been checked, insert the bearing cap as marked and tighten the bolts to full torque.

2. Mount the connecting rod in the tool using the expander and place the gudgeon pin in its bushing. Then place indicator studs on the gudgeon pin.

Checking if connecting rod is twisted - Check whether the connecting rod is twisted with the studs on the indicator horizontal.

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

- The distance between the indicator studs on the tool illustrated is 75 mm. - The distance between an indicator stud and the surface being measured must be no more than 0.1 mm, measured using this tool. - Checking using a feeler gauge.

Checking if connecting rod is bent

- Also check whether the connecting rod is bent into an S shape. Do this by measuring the distance between the outer side of the connecting rod bushing and the flat surface on the tool. - Turn the connecting rod and measure the corresponding dimension. - The difference must not exceed 0.6 mm.

Checking whether the connecting rod is bent into an S shape 28


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Assembling piston and connecting rod 1. Clean the piston and its ring grooves carefully without scratching the sides of the ring grooves. The oil holes in the piston should be cleaned using a suitable drill. 2. Check that the piston ring gaps do not exceed the permitted value. Place the piston rings in the cylinder liner and measure the clearance using a feeler gauge. For permitted gap, see section entitled Specifications, piston rings.

3. Fit the piston rings using tool 587 309. The oil scraper ring has an expander. Piston rings which are marked TOP should be turned with TOP up. 4. Oil all bushings and gudgeon pins before assembly. 5. Place one of the retaining rings in the piston.

6. Turn the piston and connecting rod as illustrated.

7. Heat the piston to 100 °C and insert the gudgeon pin using tool 87 362. Fit the second gudgeon pin retaining ring.

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Removing cylinder liner 1. Mark the liners with the numbers 1-6. Marking is essential to make it possible to fit the liners in the same place and same position as previously. Note Mark the liners only on the surface shown in the illustration. Other surfaces are sealing surfaces.

2. Withdraw the cylinder liner using puller 99 066 and hydraulic cylinder 99 003. Fit spacers under the lugs to avoid damaging the surface of the block.

3. Remove the seal from the cylinder block.

Puller for cylinder liner with hydraulic hole cylinder

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Measuring cylinder liner height 1. Carefully clean the cylinder block liner shelf, the surface around the cylinder, the cylinder liner shelf and the upper surface of the cylinder liner. 2. Insert the liner without O-rings and twist it down into position by hand. 3. Lift out the liner and wipe the liner shelf in the cylinder block and the cylinder liner shelf. 4. Insert the cylinder liner without O-rings and twist it down into position again by hand. 5. Place straight edge 87 198 and dial gauge 98 075 on the liner and zero the dial gauge against the liner (A). Push the measuring tip against the block (B) and measure liner height (A-B) as illustrated. 6. Measure each liner on two diametrically opposite points transversely across the engine.

A = Measuring surface on cylinder liner B = Measuring surface on cylinder block C = Tip of dial gauge D = Cylinder liner height D = A-B

- The cylinder liner should be slightly above the surface of the cylinder block.

Measuring cylinder liner height

- The difference between the two measurements on the same liner may be up to a maximum of 0.02 mm. - Cylinder liner height D (A-B) above the block should be 0.20 - 0.30 mm

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Fitting cylinder liner 1. Check cylinder liner height as described in the section entitled Measuring cylinder liner height. 2. Check that the inside of the cylinder block is clean. Clean the O-ring surfaces. 3. Check that the holes for coolant going to the cylinder head and cylinder liner are not clogged. 4. Carefully inspect the cylinder liners, both new and old ones, for cracks which might have arisen during transport or careless handling. 5. Tap the liner gently with a metal object. If intact it should make a clear metallic ringing sound. If it sounds cracked, change it.

6. Smear vaseline on the seal to be fitted in the cylinder block and fit it in place. 7. Smear vaseline on the seal to be fitted on the cylinder liner and fit it in place.

8. Turn the liner so that the stamped cylinder number faces forwards and carefully tap it down using a rubber mallet. 9. Fit the loose ring in place after the piston has been fitted.

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Fitting piston and connecting rod 1. Lubricate piston, piston rings, cylinder liner and piston ring compressor with engine oil. 2. Remove the protection from the crank pin and lubricate the pin. 3. Turn the piston rings so that ring gaps are evenly distributed round the piston. 4. Place the upper half of the big-end bearing in the connecting rod and lubricate the bearing surface. 5. Fit assembly tool 99 380 instead of the loose ring in the liner. 6. Carefully insert the connecting rod and piston so that the arrow mark on the piston points forward.

7. Clamp piston ring compressor 98 212 round the piston and push the piston down into the cylinder past the assembly tool. 8. Remove the assembly tool and press in the loose ring. Be careful to press it in straight so that it does not tilt.

9. Fit the lower half of the big-end bearing in the bearing cap and oil the bearing surface. Fit the bearing cap. Check that the connecting rod and bearing cap have the same marking and that they are opposite each other. 10. Lubricate the bolts, fit them and tighten to 20 Nm + 90°.

01:03-02


33

11. Check that the piston nozzles are in perfect condition and fully open. If necessary, blow clean with compressed air. 12. Fit the piston cooling nozzle and tighten the banjo bolts to 23 Nm.

Note The piston cooling nozzle must on no be damaged. The jet of oil must hit the piston in the correct place. If it does not, the piston gets too hot and engine breakdown will result. Damaged nozzles must not be straightened. They must be changed. 13. Fit the oil sump and tighten the bolts to 30 Nm. 14. Fit the cylinder head. Tighten the cylinder head bolts as described in the chapter entitled Cylinder head.

34


01:03-02

Flywheel and flywheel housing

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

Flywheel housing Seal Bolt Washer Flange bolt Flange bolt Flange bolt Cover Gasket Flange bolt Cover Lifting eye

01:03-02

13. 14. 15. 16. 17. 18. 19. 20. 21. 22. 23. 24.

Hexagon nut Washer Stud Engine speed sensors Connector housing Flange bolt Clip Clip Bolt Timing gear plate Stud Pin


25. 26. 27. 28. 29. 30. 31. 32. 33. 34. 35. 36.

Flange bolt Crankshaft Crankshaft gear PF Pin Flywheel Ring gear Bolt Ball bearing Retaining ring Bolt Washer Guide sleeve

35

Special tools

87 368 99 250 99 317 99 324

36

Puller bolts Drift Assembly tool Guide pins


01:03-02

Removing flywheel 1. Remove the two engine speed sensors in the flywheel housing.

2. Remove the flywheel retaining bolts. 14” flywheel: Also remove the washer.

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

Changing bearing 1. Remove the retaining rings on both sides of the bearing. 2. Using drift 99 250, carefully tap the bearing out of the flywheel.

3. Fit the inner retaining ring and fit the new bearing using drift 99 250. 4. Fit the outer retaining ring.

Changing ring gear Change the flywheel ring gear if the teeth have become so worn that the starter motor drive does not engage. 1. Grind as deep a groove as possible in the ring gear and split it using a cold chisel. Remove the ring gear from the flywheel.

!

WARNING!

Wear protective goggles as there is a risk of flying metal splinters.

01:03-02


37

2. Clean the surfaces on the flywheel using a wire brush. 3. Heat the new ring gear so that it is at an even temperature of about 100-150°C.

4. Place the heated ring gear on the flywheel so that the tooth chamfering faces the starter motor. 5. Make sure that the ring gear abuts firmly against the flywheel. If necessary, tap the ring down using a plastic mallet.

6. The ring gear must not be quickly cooled but must cool in the open air.

Changing crankshaft seal 1. Remove the crankshaft seal using a screwdriver. Be careful not to scratch the sealing surfaces on the crankshaft and flywheel housing. Note The crankshaft seal should be fitted dry and must not on any be lubricated. The sleeve in the seal should be left in place until the seal is fitted. The crankshaft should be degreased before the new seal is fitted. 2. Fit the new crankshaft seal using tool 99 317.

38


01:03-02

Removing flywheel housing 1. Remove the starter motor. 2. Detach the power steering pump and move it to one side. 3. Remove the flywheel housing.

Fitting flywheel housing 1. Remove all old sealing agent on the sealing surfaces on the timing gear housing and the transmission plate. Clean off the oil and grease with a spirit based cleaning agent. Note The sealing surfaces must be absolutely clean and free from grease. Do not touch the surfaces after degreasing.

2. Apply the sealing agent (816 064) on the timing gear housing with the special nozzle. The width of the bead must be between 0.8 and 1.2 mm. Follow the pattern illustrated.

Important Ensure that the sealing agent is applied inside screw holes, but without the sealing agent running into the crank housing. The agent can block the ducts and nozzle. This is especially important around the oil ducts. The oil flow to the air compressor or injection pump may become blocked.

Apply the sealing agent on the timing gear housing side against the transmission plate. Apply the sealing agent around the screw holes marked with arrows.

Important Assembly must take place within 25 minutes of starting sealing agent application.

01:03-02


39

Note The bolts are of different sizes and lengths. Make sure that they are fitted in the right places. 3. Tighten M12 bolts to 90 Nm and M10 bolts to 50 Nm. 4. Fit the power steering pump. 5. Fit the starter motor.

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

Important Always use new bolts. 14” flywheel: Fit washers also. 3. Tighten diametrically opposite bolts alternately to 130 Nm and then a further 90°. 4. Fit the two engine speed sensors.

40


01:03-02

Timing gear

1. 2. 3. 4. 5. 6. 7. 8. 9. 10.

Camshaft Pin Shaft Roller tappet Bushing Retaining ring Spacer sleeve Flange bolt Banjo bolt Pushrod

01:03-02

11. 12. 13. 14. 15. 16. 17. 18. 19. 20.

Camshaft bearing Camshaft gear Flange bolt Guide flange Flange bolt Crankshaft gear Intermediate gear Intermediate gear Ball bearing Shaft


21. Retaining ring 22. Spacer sleeve 23. Flange bolt 24. Injection pump gear 25. Hydraulic pump gear 26. Oil pump gear 27. Compressor gear

41

Special tools

87 348 87 592 99 074 99 309 587 526

42

Drift Drift Impact drift Flywheel turning tool drift


01:03-02

Gearwheel timing gear Intermediate gear Removing - The timing gear has two intermediate gears. - One for the camshaft and pump drive and one for driving the compressor. - Both these gears should be removed in the same manner. 1. Turn the crankshaft so that No. 1 cylinder is close to TDC. Use tool 99 309 and ratchet handle on the flywheel starter ring gear. 2. Remove the flywheel as described in the section entitled Flywheel, removal. 3. Remove the flywheel housing as described in the section entitled Flywheel housing, removal. 4. Fabricate a threaded piece of pipe as in drawing. 5. There is a groove in the shaft on which the gearwheel is located. Fit puller 587 526, slide hammer 99 074 and the threaded piece. Pull off the gearwheel and shaft. Note When the intermediate gear has been removed, neither the camshaft nor the crankshaft must be rotated. Pistons and valves could in such case strike each other and be damaged.

01:03-02


43

Changing bearing in intermediate gear for compressor 1. Remove the retaining ring. 2. Press the bearing unit 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 race on the shaft journal. 6. Press the bearing unit into the intermediate gear. Use tool 87 592. 7. Refit the retaining ring.

Changing bearing in intermediate gear for camshaft 1. Press the shaft out of the bearing. 2. Press the half of the inner bearing race off the shaft and remove the retaining ring. 3. Place the removed inner bearing race in the bearing and press out the bearing using drift 87 348. 4. Press a new bearing on the shaft journal using drift 87 348. Note Do not press on the outer race . 5. Press the bearing with shaft journal into the intermediate gear using drift 87 592. 6. Refit the retaining ring. 7. Press the spacing ring on the shaft journal. Make sure that the shaft journal is on the press table.

44


01:03-02

Fitting 1. Turn the crankshaft until No. 1 cylinder is close to TDC. Lubricate the bearing surfaces. 2. Turn the camshaft gear and crankshaft gear until the marks point towards the centre of the intermediate gear. 3. Fit the intermediate gear against the camshaft gear and crankshaft gear so that the markings point towards each other. 4. Fit the second intermediate gear. 5. Tighten the bolts in the intermediate gears to 50 Nm + 60°. 6. Fit the flywheel housing as described in the section entitled Flywheel housing, fitting. 7. Fit the flywheel as described in the section entitled Flywheel, fitting.

01:03-02


45

Camshaft gear Removing 1. Turn the crankshaft so that No. 1 cylinder is close to TDC. Use tool 99 309 and ratchet handle on the flywheel starter ring gear. 2. Remove the flywheel as described in the section entitled Flywheel, removal. 3. Remove the flywheel housing as described in the section entitled Flywheel housing, removal. 4. Remove the intermediate gear. Note When the intermediate gear has been removed, neither the camshaft nor the crankshaft must be rotated. Pistons and valves could in such case strike each other and be damaged. 5. Remove the camshaft gear.

Fitting 1. Fit the camshaft gear and tighten the bolts to 42 Nm. 2. Fit the intermediate gear, see section entitled Intermediate gear, fitting points 1-2. 3. Fit the flywheel housing as described in the section entitled Flywheel housing, fitting. 4. Fit the flywheel as described in the section entitled Flywheel, fitting.

46


01:03-02

Crankshaft gear Removing 1. Turn the crankshaft so that No. 1 cylinder is close to TDC. Use tool 99 309 and ratchet handle on the flywheel starter ring gear. 2. Remove the flywheel as described in the section entitled Flywheel, removal. 3. Remove the flywheel housing as described in the section entitled Flywheel housing, removal. 4. Remove the intermediate gear. Note When the intermediate gear has been removed, neither the camshaft nor the crankshaft must be rotated. Pistons and valves could in such case strike each other and be damaged.

5. Remove the crankshaft gear.

Fitting 1. Fit the crankshaft gear. 2. Fit the intermediate gear, see section entitled Intermediate gear, fitting points 1-2. 3. Fit the flywheel housing as described in the section entitled Flywheel housing, fitting. 4. Fit the flywheel as described in the section entitled Flywheel, fitting.

01:03-02


47

Camshaft Removing 1. Remove the flywheel as described in Flywheel, removing. 2. Remove the flywheel housing as described in Flywheel housing, removal. 3. Remove rocker arms, pushrods and valve braces. 4. Remove the camshaft gear. 5. Remove the intermediate gear and the guide flange bolts. 6. Remove the timing gear plate. 7. Remove the camshaft covers. 8. Remove the valve tappets.

Note Mark the valve tappets because they must be refitted in the same places. 9. Withdraw the camshaft rearwards. Be careful not to damage cams and bearings.

48


01:03-02

Replacement of camshaft bearing Special tools

99 373

99 003

99 003 99 004 99 373

99 004

Hydraulic cylinder Compressed air powered hydraulic pump Tool for replacing camshaft bearing

Work description 1. Remove the camshaft according to section Camshaft, removal. 2. Remove the camshaft cover at the front end of the engine. Note To avoid damaging the surfaces when pressing in the new bearings, the edges and the surfaces of the bearing seats around the old bearings must be wiped clean. 3. Wipe the surfaces of the bearing seats around the old bearings. Note The recess in the bearing t should face the front of the engine.

01:03-02


49

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

Tool 99 373 1. Threaded rod with eight flange nuts 2. Press drift 3. Flange 5. Position the flange nuts on the threaded rod, included in tool 99 373, as illustrated.

50


01:03-02

6. Insert the end of threaded rod with flange nut number 1 from the rear edge of the engine past the rearmost bearing seat. Insert the rod past the bearing seats and the new bearings until the flange nut 1 protudes from the front of the engine.

7. Screw the flange included in tool 99 373 into place on the hydraulic cylinder 99 003 with two M6x12. Press the cylinder 99 003 together if it is not in the neutral position.

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

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51

10. Hang a new bearing on the rod at the front of the engine. 11. Place the press drift on the threaded rod and the bearing on the drift. Note The recess in the bearing t should face towards the flange on the press drift. Secure the bearing on the drift by placing the springloaded ball in an oilway. The bearing is correctly located on the drift when the ball and a marking hole are opposite the bearing’s oil hole.

The bearing is correctly located on the drift when the ball and a marking hole are opposite the bearing’s oil hole 12. Wipe the bearing’s surface clean. Note The marking on the drift should be towards the top and vertical to ensure that the oil holes in the bearing will be opposite the oilways.

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

Fix the threaded rod by tightening flange nut 8.

52


01:03-02

Note The new bearing is correctly positioned before the old bearing has been removed completely. The new bearing is in the correct position when the distance from the front edge of the cylinder block and the front edge of the press drift have a permitted value according to the table. By -12 mm it means that the drift should protrude 12 mm out of the block.

Table for correctly located camshaft bearing: Camshaft bearing No.

Distance (mm)

1

-12 to -14

2

150 to 152

3

314 to 316

4

478 to 480

5

642 to 644

6

806 to 808

7

970 to 972

Check measuring bearing number 1

14. Press in the new bearing at the same time as the old bearing is pressed out with hydraulic cylinder 99 003 and hydraulic pump 99 004. Check that the bearing is correctly positioned by measuring. 15. Carefully tap using a plastic mallet to remove the old bearing.

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53

16. Remove the drift by loosening flange nut 8 and sliding the threaded rod in. Note The seats for camshaft bearings 2, 4 and 6 have two oil ducts. The others only have the lower duct. 17. Check that the bearing’s oil hole is opposite the cylinder block oil ducts. 18. Repeat the procedure for the other bearings.

Pressing in and pressing out bearing number 2

19. Clean the sealing surface, use a new gasket and fit the camshaft cover at the front of the engine. 20. Refit the camshaft according to section Camshaft, fitting. Then check the camshaft setting.

Check measuring bearing number 2

54


01:03-02

Fitting the camshaft 1. Fit the camshaft. Be careful not to damage cams and bearings. 2. Lubricate with engine oil and fit the valve tappets in the same places as they were before removal. Tighten the banjo bolts to 32 Nm. 3. Fit the camshaft covers. 4. Fit the guide flange bolts.

5. Remove all old sealing agent from the cylinder block, the timing gear housing and the transmission plate. Remove all oil and grease from the sealing surfaces using a spirit-based cleaning agent. Obs! The sealing surfaces must be absolutely clean and free from grease. Do not touch the surfaces after degreasing.

6. Apply the sealing agent (816 064) to the cylinder block with the special nozzle. The width of the bead must be between 0.8 and 1.2 mm. Follow the pattern illustrated.

Important Ensure that the sealing agent is applied inside screw holes, but without the sealing agent running into the crank housing. The agent can block the ducts and nozzles. This is especially important around the oil ducts. The oil flow to the air compressor or injection pump may become blocked. Important Assembly must take place within 25 minutes of starting sealing agent application.

01:03-02

Application of sealing agent on the block


55

7. Fit the timing gear plate on the engine block. Tighten the bolts to 63 Nm

8. Fit the intermediate gear 9. Make sure that the marking on the camshaft gear points towards the centre of the intermediate gear. 10. Fit the camshaft gear and tighten the bolts to 42 Nm. 11. Fit the flywheel housing as described in Flywheel housing, fitting. 12. Fit the flywheel as described in Flywheel, fitting.

Checking the camshaft setting 1. Position the crankshaft at TDC after the compression stroke of the first cylinder. 2. Set up two dial test indicators against the valve spring thrust washers. 3. Adjust the rocker arms so that there is no gap and then adjust a further 0.1 mm (so that both valves are open 0.1 mm). 4. Zero both dial indicators. 5. Turn the crankshaft one revolution in its direction of rotation until TDC position is again achieved. 6. Read off both the dial indicators and compare the readings with the values given below: - Inlet valve lift height 0.37-1.47 - Exhaust valve lift height 0.16-1.16

56


01:03-02

Crankshaft Removing 1. Remove the crankshaft gear as described in Crankshaft gear, removal. 2. Remove the fan drive at the front end of the crankshaft as described in Belt drive, Changing the seal in the front cover. 3. Remove the oil sump, oil suction pipe with strainer and oil pump. 4. Remove the pistons and connecting rods as described in Removing connecting rods and pistons. 5. Remove the crankshaft bearing caps and main bearings. Note The main bearings and bearing caps are marked and must be refitted in the same place. 6. Lift out the crankshaft.

Checking and grinding - Measure the crankshaft journals. Using a micrometer, measure two diameters 90 degrees apart. If one of these diameters is below the minimum limit, regrinding of the crankshaft should be considered. - Consideration must also be given to oil pressure, which is in turn affected by such things as main bearing and crankshaft bearing wear. - When regrinding, stated undersizes must be complied with. There are bearings adapted to these dimensions. - It is important that the fillet radius of the journals is correct. - After grinding the journals, the oil hole nozzles at the bearing surfaces should be rounded and polished.

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57

Fitting 1. Lubricate the main bearings and place them in the block. 2. Lift in the crankshaft.

3. Insert the main bearings in the crankshaft bearing caps and fit them. Note Fit the main bearings and bearing caps in the same places as they were in before removal.

4. Tighten the bearing cap bolts to 50 Nm + 90°.

5. Refit the pistons and connecting rods as described in Fitting connecting rod and piston. 6. Fit the oil pump, oil suction pipe with strainer and oil sump. 7. Change the seal in the front cover. Fit the spacing sleeve on the crankshaft journal. Fit the driver and crankshaft damper. See Belt drive, Changing the seal in the front cover. 8. Fit the crankshaft gear as described in Crankshaft gear, fitting.

58


01:03-02

Belt timing gear

1. Belt pulley on crankshaft damper 2. Belt tensioner 3. Coolant pump 4. Belt pulley and fan drive 5. Alternator 6. Multigroove V-belt 7. Idler roller

01:03-02


59

Changing the seal in the front cover 1. Remove the fan ring and fan. Thermostatic fan: Store it upright (vertical). 2. Remove the belt(s), crankshaft damper and belt pulley. 3. Remove the driver bolts and withdraw the driver. Mind the sealing surface. 4. Pull or prise off the seal in the cover. Take care to avoid damaging the sealing surface in the cover. 5. Wipe the sealing surface in the cover clean. Note The crankshaft seal must be dry when fitted and should on no be lubricated. The sleeve in the seal should be left in place until the seal is fitted. 6. Place the new seal on tool 99 379 and press it in place by tightening diametrically opposite bolts alternately. The seal is correctly fitted when the tool comes up against the cover.

Tool 99 379 with crankshaft seal

7. Remove the tool by screwing the bolts into the threaded holes. 8. Wipe the driver’s sealing surface clean. Fit a new seal on the end surface of the driver and push the driver onto the spacer sleeve on the end of the crankshaft. 9. Bolt the driver to the crankshaft flange and tighten the flange bolts to 135 Nm. 10. Bolt the crankshaft damper and possibly the belt pulley to the hub and tighten to 110 Nm. 11. Fit the belt(s), fan ring and fan.

60


01:03-02

Lubrication system Oil cooler

1. 2. 3. 4. 5. 6. 7. 8.

01:03-02

Oil cooler Gasket Gasket Flange bolt Oil cooler cover Core plug Cover Gasket

9. 10. 11. 12. 13. 14. 15.

Bolt Piston Spring Plug Gasket Gasket Flange bolt


61

Changing seals 1. Remove the side cover and oil cooler from the block.

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

4. Changing the four O-rings. 5. Fit the oil cooler insert, bolt it to the side cover and tighten to 26 Nm. 6. Bolt the side cover to the block.

62


01:03-02

Oil cleaner

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.

01:03-02


Filter head Overflow valve Union Straight union Seal Gasket Flange bolt Oil filter Housing Plug Piston Spring Plug Gasket Shaft Washer Rotor Nozzle Strainer Rotor bowl Nut O-ring Cover O-ring Locknut Lifting lug O-ring Retaining ring Gasket Flange bolt Plug Gasket

63

Dismantling and assembly - During routine cleaning of the oil cleaner, there should be a certain amount of dirt deposits in the rotor bowl. - If this is not the case, it indicates that the rotor is not spinning. The cause of this must be immediately investigated. - If the dirt deposit exceeds 20 mm at the recommended intervals, the rotor bowl should be cleaned more often.

1. Unscrew the nut securing the outer cover and remove the nut.

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

Note The rotor must not be clamped in the vice. Never hit the rotor bowl. This may cause damage leading to imbalance.

3. If it is difficult to loosen the rotor nut, turn the rotor upside down and clamp the rotor nut in a vice. 4. Turn the rotor anti-clockwise three turns by hand or, if this does not succeed, by placing a screwdriver between the outlet holes.

64


01:03-02

5. Hold the rotor bowl and gently tap the rotor nut with your hand or a plastic mallet until the rotor bowl releases from the rotor. Note Never hit the rotor directly as its bearings may be damaged.

6. Remove the rotor nut and bowl from the rotor.

7. Remove the strainer from the rotor. If the strainer is jammed, carefully prise it loose with a knife inserted at the lower edge between the rotor and strainer.

8. Scrape the deposits from the inside of the bowl using a knife. 9. Wash the parts. 10. Check the two nozzles on the rotor. Make sure that they are not blocked or damaged. Change damaged nozzles. 11. Check that the bearings are not damaged. 12. Place the O-ring in position in the bowl. Change the O-ring if it is in the slightest way damaged.

01:03-02


65

13. Assemble the parts and tighten the rotor nut hard by hand. 14. Check that the shaft is not loose. If it is, it can be locked using locking compound 561 200. First clean thoroughly using a suitable solvent. 15. Tighten the rotor shaft using socket wrench 98 421. Tightening torque 41 Nm.

16 Refit the rotor and turn it by hand to make sure that it turns easily. 17. Check the O-ring on the cleaner housing cover and fit it with a locknut. Tighten the locknut to 10 Nm.

66


01:03-02

Oil pump In the case of leakage or a fault in the oil pump, it should not be reconditioned but should be changed as a unit.

1. 2. 3. 4. 5.

01:03-02

Oil pump Flange bolt Gasket Flange bolt Suction pipe

6. 7. 8. 9. 10.

Strainer Ring Flange bolt Tube Seal


67

Lifting the engine Special tools

Note The engine’s lifting eyes are designed for lifting the engine only, not the engine together with its ancillary equipment (alternator, gearbox, etc.) or frame.

98 094 Lifting chain 587 308 Lever block

- Attach lifting chain 98 094 to the rear lifting eyes. - Attach lever block 587 308 to the front lifting eye.

Note The lifting eyes are sized to cope with a maximum angle of 30°.

68


01:03-02

Specifications General information Cylinder configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Number of cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Cylinder bore . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Stroke . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Swept volume. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Number of main bearings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Firing order . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Injection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Principle of operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Cooling. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Approx. weight, including alternator . . . . . . . . . . . . . . . . . . . . . . . . . . . Direction of rotation (engine viewed from rear) . . . . . . . . . . . . . . . . . .

Compression ratio Output Engine speed Torque Oil capacity Oil grade

In-line engine 6 127 mm 154 mm 11.7 dm3 7 1-5-3-6-2-4 Direct 4 stroke Liquid 990 kg Anti-clockwise

See Operator’s Manual or Service Card for the particular engine.

Locking compound, lubricants, sealing compounds Activator T for faster curing of locking compound 561 200 . . . . . . . . . Locking fluid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Lubricant for exhaust pipe bolts and ts . . . . . . . . . . . . . . . . . . . . . . Thread sealant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Sealing compound for flywheel housing . . . . . . . . . . . . . . . . . . . . . . . .

561 045 561 200 561 205 561 019 816 064

General tightening torques The following tightening torques apply generally if nothing else is specified: Thread M5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Thread M6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Thread M8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Thread M10 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Thread M12 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Thread M14 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

01:03-02


6,7 Nm 10,2 Nm 26 Nm 50 Nm 92 Nm 149 Nm

69

Cylinder head Inlet valve Valve head angle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19,5 Minimum value A for ground valve . . . . . . . . . . . . . . . . . . . . . . . . . . . 2,6 mm Distance between the surface of the cylinder head and the valve head. 0,75-1,8 mm Exhaust valve Valve head angle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44,5 Minimum value A for ground valve . . . . . . . . . . . . . . . . . . . . . . . . . . . 1,8 mm Distance between the surface of the cylinder head and the valve head. 0,66-1,8 mm - Check value A for each valve. - Grind the valves in a valve grinding machine.

Minimum value A for ground valve

Inlet valve seat Seat angle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . surface width A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Valve seat ring outer diameter. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Position for the valve seat ring, diameter . . . . . . . . . . . . . . . . . . . . . . . Seat for the valve seat ring, depth . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

20,0°-20,5° 1,9 - 2,6 mm 46,054 - 46,065 mm 46,000 - 46,016 mm 11,25 - 11,35 mm

Over-sized valve seat ring: Outer diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46,254 - 46,265 mm Position for the valve seat ring, diameter . . . . . . . . . . . . . . . . . . . . . . . 46,200 - 46,216 mm Cooling temperature when fitting valve seat ring . . . . . . . . . . . . . . . . . approx. -80 °C

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Exhaust valve seat Seat angle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . surface width A. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Valve seat ring outer diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Position for the valve seat ring, diameter. . . . . . . . . . . . . . . . . . . . . . . . Seat for the valve seat ring, depth . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

45,0°-45,5° 1,8 - 2,6 mm 44,081 - 44,092 mm 44,000 - 44,016 mm 11,25 - 11,35 mm

Over-sized valve seat ring: Outer diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44,281 - 44,292 mm Position for the valve seat ring, diameter. . . . . . . . . . . . . . . . . . . . . . . . 44,200 - 44,216 mm Cooling temperature when fitting valve seat ring . . . . . . . . . . . . . . . . . approx. -80 °C

Tightening torques Cylinder head bolts: First time. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Second time . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Third tightening . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Nut for injector. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Nut for rocker arm adjusting screw . . . . . . . . . . . . . . . . . . . . . . . . . . . . Bolt for rocker cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Bolts for exhaust manifold. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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60 Nm 150 Nm 250 Nm + 90° 70 Nm 40 Nm 22 Nm 59 Nm

71

Turbocharger Wear limits Shaft radial clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.198-0.564 mm Shaft axial clearance (after running-in). . . . . . . . . . . . . . . . . . . . . . . . . 0.025-0.106 mm

Tightening torques Bolts, turbocharger - exhaust manifold . . . . . . . . . . . . . . . . . . . . . . . . . 63 Nm Bolts in turbine housing (exhaust pipe). . . . . . . . . . . . . . . . . . . . . . . . . 24 Nm V clamps, exhaust and intake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-10 Nm

Pistons and cylinder liners Cylinder liner Shims for cylinder liner, thickness . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.20, 0.25, 0.30, . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.40, 0.50, 0.75 mm Cylinder liner height above cylinder block . . . . . . . . . . . . . . . . . . . . . . 0.20 - 0.30 mm Maximum permitted height difference on one liner between dimensions measured at two diametrically opposite points . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.02 mm

Pistons Fitted with arrow on piston crown facing forward

Piston rings Number of compression rings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Gap: 1st ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2nd ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Max. clearance in groove, 2nd ring . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2 0.35 - 0.60 mm 0.45 - 0.65 mm 0.25 mm

Rings marked ”TOP” should be turned with the mark upwards Number of oil scraper rings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 Gap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.40 - 0.65 mm Max. clearance in groove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.25 mm

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Connecting rods Connecting rod and bearing cap marked 1 to 6. Fitted with marking inwards. Tightening torques Bolts, oil sump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30 Nm Connecting rod bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 Nm + 90°

Flywheel and flywheel housing Flywheel Maximum machining of surface for disc: 2.0 mm

Ring gear Heated to 100 - 150 °C before fitting.

Tightening torques Flywheel bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 130 Nm + 90° Bolts for flywheel housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . M10 :50 Nm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . M12 : 90 Nm

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73

Timing gear Camshaft gear Backlash against intermediate gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.03 - 0.15 mm

Injection pump gear Backlash against intermediate gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.03 - 0.15 mm

Intermediate gear Max. axial clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.238 mm

Camshaft Axial clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.10 - 0.25 mm

Tightening torques Bolts for camshaft gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Bolts for intermediate gears . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Bolts for compressor gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Connecting rod bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Main bearing bolts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Bolts for driver . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Bolts for crankshaft damper and pulley. . . . . . . . . . . . . . . . . . . . . . . . . Banjo bolts for valve tappets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Bolts for timing gear plate. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

74


42 Nm 50 Nm + 60° 105 Nm 20 Nm + 90° 50 Nm + 90° 135 Nm 110 Nm 32 Nm 63 Nm

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Lubrication system Oil cleaner Permitted thickness of deposits on wall of bowl . . . . . . . . . . . . . . . . . . max 20 mm

Oil pressure valve (Note: not safety valve) Oil pressure: Idle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.6 bar With warm engine at 1000 rpm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.5 bar With warm engine at 2,000 rpm. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.5 - 6 bar Free spring length. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61.4 mm

Oil filter Use only genuine Scania filters.

Tightening torques Oil pump: Bolts for oil pump cover. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 Nm Bolts, oil pump - cylinder block. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 Nm Oil cleaner: Locknut for oil cleaner housing cover . . . . . . . . . . . . . . . . . . . . . . . . . . 15 Nm Nut for rotor bowl . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Tighten by hand Rotor shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34 Nm Oil nozzle for piston cooling: Banjo bolt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 Nm Oil cooler: Bolts for oil cooler insert . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 Nm

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75

Special tools Number 87 198 87 348 87 362 87 368 87 592 98 075 98 094 98 212 98 249 98 599 99 003 99 004 99 007 99 066 99 074 99 079 99 168 99 250 99 308 99 309 99 310 99 317 99 322 99 323 99 324 99 373 99 379 99 380 99 381 99 382 99 383 99 384 99 385 99 394 587 025 587 107 587 110 587 250 587 277 587 308 587 309 587 526 587 692 588 221

76

Designation

Shown on page

Rule for dial gauge Puller Drift Puller bolt Drift Dial gauge Lifting chain Piston ring compressor Compression tester Oil pressure gauge Hydraulic hole cylinder Compressed air powered hydraulic pump plate Puller for cylinder liner Impact drift Extractor for injectors Dismantling tool for loose ring Drift Sleeve for injectors Tool for turning flywheel Socket Assembly tool Press drift for valve spring Assembly drift Guide pins, flywheel Tool for replacing camshaft bearing Press drift for crankshaft seal Assembly tool, loose ring Drift for injector sleeve Drift for valve guides Drift for valve guides Drift for valve seats Drift for valve seats Guide, thread cutting of injector sleeve Filter wrench Deflection gauge Test apparatus for crankshafts Measuring stand Valve seat cutter Lever block Piston ring expander drift Engine stand Thread tap for injector sleeve


25 42 25 36, 37 42, 44 18, 25 68 25, 33 4, 6 24 49 25, 30 4, 8, 25, 26, 42, 43 4, 8 25, 26 36, 37 4, 8, 17 4, 5, 42, 46, 47 4 36, 38 4, 9, 16 4, 9 36, 40 49, 50 60 25, 33 4, 15 4, 13 4, 13 4, 10 4, 10 4, 14 18, 19 18, 21 25, 28 18, 21 4, 11, 12, 13 68 25, 27 42, 43 4, 14

01:03-02

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