Documente Academic
Documente Profesional
Documente Cultură
Issue 2
Industrial & Marine Engines
Part No.
1 588 557
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
01:03-02
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
01:03-02
Special tools
98 249
99 074
99 079
99 308
99 309
99 310
99 322
99 323
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
01:03-02
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.
O Intake valve
Exhaust valve
01:03-02
O Intake valve
Exhaust valve
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.
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
01:03-02
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
01:03-02
4.Measuring rod
17.Valve
18.Valve seat
19.O-ring
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.
01:03-02
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.
01:03-02
WARNING!
WARNING!
10
01:03-02
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 contact 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.
01:03-02
11
12
01:03-02
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.
01:03-02
13
2. Tap out the tap and sleeve from the underneath. Use a 100 mm metal rod with a
9 mm diameter.
14
01:03-02
01:03-02
15
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.
16
01:03-02
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.
01:03-02
17
Turbocharger
Special tools
98 075
587 025
587 107
587 250
DI12
1.
2.
3.
4.
5.
6.
7.
8.
18
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.
9. Gasket
10. Bolt
11. Bracket
12. Bolt
13. Clip
14. Clip
15. Bolt
16. Turbocharger
01:03-02
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 turbochargers 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 passes
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.
01:03-02
19
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 pass 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.
Foreign bodies
20
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.
01:03-02
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.
01:03-02
21
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.
8. Check that engine output is correct. Excessively high output reduces the life of the
turbo.
22
01:03-02
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 valves 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.
01:03-02
23
1.
2.
3.
4.
5.
6.
7.
8.
24
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
01:03-02
Special tools
87 198
87 362
98 075
98 212
98 515
99 066
01:03-02
99 074
99 168
99 380
587 110
587 309
Impact drift
Dismantling tool
Assembly tool
Test apparatus for connecting rods
Piston ring expander
25
26
01:03-02
01:03-02
27
01:03-02
01:03-02
29
30
01:03-02
- 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
01:03-02
31
32
01:03-02
01:03-02
33
34
01:03-02
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.
WARNING!
01:03-02
37
38
01:03-02
01:03-02
39
Fitting flywheel
1. Fit two guide pins 99 324 in the crankshaft
flange.
2. Fit the flywheel on the crankshaft.
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
41
Special tools
87 348
87 592
99 074
99 309
587 526
42
Drift
Drift
Impact drift
Flywheel turning tool
Support drift
01:03-02
01:03-02
43
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.
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.
48
01:03-02
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 contact
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 joint
should face the front of the engine.
01:03-02
49
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
01:03-02
51
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.
Distance (mm)
-12 to -14
150 to 152
314 to 316
478 to 480
642 to 644
806 to 808
970 to 972
01:03-02
53
54
01:03-02
01:03-02
55
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.
01:03-02
57
Fitting
1. Lubricate the main bearings and place them
in the block.
2. Lift in the crankshaft.
58
01:03-02
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
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.
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
64
01:03-02
01:03-02
65
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
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
561 045
561 200
561 205
561 019
816 064
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.
20,0-20,5
1,9 - 2,6 mm
46,054 - 46,065 mm
46,000 - 46,016 mm
11,25 - 11,35 mm
70
01:03-02
45,0-45,5
1,8 - 2,6 mm
44,081 - 44,092 mm
44,000 - 44,016 mm
11,25 - 11,35 mm
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. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
01:03-02
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
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
72
01:03-02
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
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
01:03-02
73
Timing gear
Camshaft 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
01:03-02
Lubrication system
Oil cleaner
Permitted thickness of deposits on wall of bowl . . . . . . . . . . . . . . . . . . max 20 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
01:03-02
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
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