Академический Документы
Профессиональный Документы
Культура Документы
Montr hjlper 1
SCANIA SERVICE
Nordhavn A/S
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
Service info DI 9
Service info DI 11
Service info DI 12
Service info DEC 2
Service info DI 14
Service info DI 16
Service info EMS blink koder
Service info olie cyklon/centrifuge
Service info Klevand/ Etylen glycol
Service info Dyser / indsprjtnings tidspunkt
DI 9
1.
2.
3.
4.
5.
6.
Annually
At least
4800 h
2400 h
400 h
Interval
200 h
400 h
At first start
Daily
First
time at
1200 h
MAINTENANCE SCHEDULE
l
l1
l1
l1
l5
l5
l6
l6
l1
l
l1
l
l3
l
l
l
l1
l
l
l2
l2
l2
l
l
l
l
l
l
2001-05:1
19
Program 96
Specifications
General information
Cylinder configuration. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Number of cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Cylinder bore . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Stroke . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Swept volume . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Number of main bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Firing order . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Injection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Cooling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Approx. weight, incl. alternator. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Direction of rotation (engine viewed from rear) . . . . . . . . . . . . . . . .
Compression ratio
Output
Engine speed
Torque
Oil capacity
Oil grade
In-line engine
6
115 mm
144 mm
8.97 dm3
7
1-5-3-6-2-4
Direct
4 stroke
Liquid
805 kg
anticlockwise
561 045
561 200
561 205
584 010
561 019
Cylinder head
Minimum cylinder head height after machining, page 17. . . . . . . . . 114.4 mm
Distance B between cylinder head surface and valve head, page 11
With new parts, min. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.78 mm
With machined parts, max. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.80 mm
Intake valve
Clearance (cold engine) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.45 mm
Head angle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19.4-19.6
Minimum dimension A for machined valve, page 10 . . . . . . . . . . . . 3.0 mm
01:01-02
Scania CV AB 1997
65
Program 96
Exhaust valve
Clearance (cold engine) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.80 mm
Head angle. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44.4-44.6
Minimum dimension A for machined valve, page 10. . . . . . . . . . . . . 1.7 mm
Valve guides
Length, intake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68.2 mm
exhaust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68.2 mm
Height above surface for valve guide:
intake. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16.7 mm
exhaust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16.7 mm
66
Scania CV AB 1997
01:01-02
Program 96
Tightening torques
Cylinder head bolts:
First tightening . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60 Nm
Second tightening . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 150 Nm
Third tightening . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 250 Nm + 90
Injector nut. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Nut for adjusting screw on rocker arm . . . . . . . . . . . . . . . . . . . . . . .
Rocker cover bolt. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Exhaust manifold bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Rocker arm mechanism bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
70 Nm
40 Nm
20 Nm
50 Nm
150 Nm
Turbocharger
Wear limits
Radial shaft clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.329-0.501 mm
Axial shaft clearance (after running in). . . . . . . . . . . . . . . . . . . . . . . 0.038-0.093 mm
Tightening torques
Bolts, turbocharger - exhaust pipe. . . . . . . . . . . . . . . . . . . . . . . . . . . 40 Nm
Hose clip, exhaust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Nm
01:01-02
Scania CV AB 1997
67
Program 96
Pistons
Fitted with arrow on piston crown facing forwards.
Piston rings
Number of compression rings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Gap:
1st ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.4 - 0.75 mm
2nd ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.3 - 0.6 mm
Clearance in groove max 2nd ring . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.25 mm
Rings marked TOP should be turned with the marking facing upwards.
Number of oil scraper rings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Gap
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.3 - 0.55 mm
Clearance in groove max. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.25 mm
Connecting rods
Connecting rods and caps marked 1 to 6.
Fitted with marking facing inwards.
Tightening torques
Bolts for tension lugs when pressing down cylinder liner . . . . . . . . . 50 Nm
Oil sump bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 Nm
Connecting rod bolts (oiled threads). . . . . . . . . . . . . . . . . . . . . . . . . . 20 Nm + 90
Ring gear
Heated to 100 - 150 C before fitting.
68
Scania CV AB 1997
01:01-02
Program 96
Flywheel housing
Seal in flywheel housing: Dimension B, page 43 . . . . . . . . . . . . . . . 7 mm
Tightening torques
Flywheel bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 180 Nm
Bolts for flywheel housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90 Nm
Timing gear
Camshaft gear
Heated to 100 C before fitting.
Backlash against intermediate gear . . . . . . . . . . . . . . . . . . . . . . . . . . 0.03 - 0.18 mm
Intermediate gear
Axial clearance max . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.23 mm
Camshaft
Axial clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.15 - 0.30 mm
01:01-02
Scania CV AB 1997
69
Program 96
Crankshaft
Main bearing races . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Diameter:
Standard
Undersize 1
Undersize 2
Undersize 3
Undersize 4
Undersize 5
Undersize 6
95.000 - 94.978 mm
94.750 - 94.728 mm
94.500 - 94.478 mm
94.250 - 94.228 mm
94.000 - 93.978 mm
93.750 - 93.728 mm
93.500 - 93.228 mm
Fillet radius
4.75 - 4.85 mm
Surface quality
0.25 Ra
Width, max
46.78 mm
80.000 - 79.981 mm
79.750 - 79.731 mm
79.500 - 79.481 mm
79.250 - 79.231 mm
79.000 - 79.981 mm
78.750 - 78.731 mm
78.500 - 78.481 mm
Fillet radius
4.8 - 5.2 mm
Surface quality
0.25 Ra
Width, max
53.10 mm
70
Scania CV AB 1997
Standard
Oversize 1
Oversize 2
Oversize 3
Oversize 4
Oversize 5
3.38 - 3.43 mm
3.46 - 3.51 mm
3.51 - 3.56 mm
3.64 - 3.69 mm
3.89 - 3.94 mm
4.27 - 4.32 mm
Axial clearance
0.14 - 0.37 mm
01:01-02
Program 96
Tightening torques
Tightening torques
Nut for camshaft gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Nut for compressor gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Bolts for intermediate gear shaft journal . . . . . . . . . . . . . . . . . . . . . .
Main bearing bolts:
Stage I . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Stage II . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Flywheel bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Crankshaft bolt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
600 Nm
200 Nm
49 Nm
70-90 Nm
290 Nm
180 Nm
300 Nm+60
30 Nm
Lubrication system
Oil pump
Backlash:
Crankshaft gear - intermediate gear on oil pump . . . . . . . . . . . . . . . 0.03 - 0.36 mm
Intermediate gear - crankshaft gear . . . . . . . . . . . . . . . . . . . . . . . . . . 0.03 - 0.16 mm
Oil cleaner
Permitted thickness of deposits on wall of bowl . . . . . . . . . . . . . . . . 20 mm
Oil filter
Use only genuine Scania filters (screwed on by hand).
01:01-02
Scania CV AB 1997
71
Program 96
Tightening torques
Oil pump:
Bolts for oil pump cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 Nm
Bolts, oil pump - cylinder block . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42 Nm
Lock bolt (left-hand thread) for intermediate gear . . . . . . . . . . . . . . . 40 Nm
Oil cleaner:
Locknut for oil cleaner housing cover . . . . . . . . . . . . . . . . . . . . . . . . 10 Nm
Nut for rotor bowl . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Tighten by hand
Rotor shaft. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34 Nm
72
Scania CV AB 1997
01:01-02
Program 96
Valve clearance
Checking and adjusting
Check valve clearance. The clearance for intake
valves should be 0.45 mm and the clearance for
exhaust valves should be 0.80 mm when the
engine is cold.
B. Set No. 1 cylinder at precisely TDC after compression. The following valves can now be
adjusted:
cylinder 1 intake and exhaust
cylinder 2
intake
cylinder 3
exhaust
cylinder 4
intake
cylinder 5
exhaust
Intake valve
Exhaust valve
cylinder 4 exhaust
cylinder 5 intake
cylinder 6 exhaust and intake
01:01-02
Scania CV AB 1997-05:2
DI 11
1.
2.
3.
4.
5.
6.
Every year
At least
4800 h
2400 h
400 h
Interval
200 h
400 h
At first start
Daily
First
time at
1200 h
MAINTENANCE SCHEDULE
l
l1
l1
l1
l
l5
l5
l6
l6
l1
l
l1
l
l3
l
l
l
l1
l
l
l2
l2
l2
l
l
l
l
1997-11:2
13
Program 96
Specifications
General information
Cylinder configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . In-line engine
Number of cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Cylinder bore . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127 mm
Stroke . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 145 mm
Displacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.02 dm3
Number of main bearings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Firing sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5-3-6-2-4
Injection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Direct
Principle of operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 stroke
Cooling. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fluid
Weight including alternator approx. . . . . . . . . . . . . . . . . . . . . . . . . . . . 990 kg
Direction of rotation (engine viewed from rear) . . . . . . . . . . . . . . . . . . Anti-clockwise
Compression ratio
Output
Engine speed
Torque
Oil capacity
Oil grade
Cylinder head
Minimum cylinder head height after machining, page 17 . . . . . . . . . . . 124.4 mm
Distance B between the surface of the cylinder head and valve disc, page 11
With new parts min. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.72 mm
With machined parts max. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.80 mm
Intake valve
Clearance (cold engine) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.45 mm
Head angle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19.4- 19.6
Minimum dimension A for ground valve, page 10 . . . . . . . . . . . . . . . . 3.0 mm
01:02-02
Scania CV AB 1998
65
Program 96
Exhaust valve
Clearance (cold engine). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.80 mm
Disc angle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44.4- 44.5
Minimum dimension A for machined valve, page 10 . . . . . . . . . . . . . . 1.7 mm
20.0- 20.5
2.3 - 2.8 mm
56.0 mm
55.934 - 55.953 mm
11.25 - 11.35 mm
45.0- 45.5
1.9 - 2.6 mm
52.0 mm
51.914 - 51.933 mm
11.25 - 11.35 mm
Valve guides
Height above surface for valve spring washer:
Without valve stem seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23.75 - 24.25 mm
With valve stem seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.95 - 9.45 mm
66
Scania CV AB 1998
01:02-02
Program 96
Tightening torques
Cylinder head bolts:
First time. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120 Nm
Second time . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 180 Nm
Third tightening . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 250 Nm + 90
Nut for injector. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70 Nm
Nut for rocker arm adjusting screw . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40 Nm
Bolt for rocker cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 Nm
Bolts for exhaust manifold. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63 Nm
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 pipe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40 Nm
Bolts against turbine housing (exhaust line) . . . . . . . . . . . . . . . . . . . . . 24 Nm
01:02-02
Scania CV AB 1998
67
Program 96
Pistons
Fitted with arrow on piston crown towards the front of the engine
Piston rings
Number of compression rings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Gap: 1st ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2nd ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Max. clearance in groove, 2nd ring . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2
0.60 - 0.80 mm
0.50 - 0.70 mm
0.25 mm
Tightening torques
Bolts for tension lugs when pressing down cylinder liner . . . . . . . . . . 60 Nm
Bolts, oil sump. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50 Nm
Connecting rod bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 Nm + 90
Ring gear
Heated to 100 - 150 C before fitting.
68
Scania CV AB 1998
01:02-02
Program 96
Flywheel housing
Seal in flywheel housing: Dimension B, page 46 . . . . . . . . . . . . . . . . . 7 mm
Tightening torques
Flywheel bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 180 Nm
Bolts for flywheel housing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90 Nm
Timing gear
Camshaft gear
Heated to 100 C before fitting.
Backlash against intermediate gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.03 - 0.15 mm
Intermediate gear
Axial clearance max. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.238 mm
Camshaft
Axial clearance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.10 - 0.25 mm
01:02-02
Scania CV AB 1998
69
Program 96
Crankshaft
Main bearing journals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Diameter:
Standard
Undersize 1
Undersize 2
Undersize 3
Undersize 4
Undersize 5
Undersize 6
101.598 - 101.620 mm
101.348 - 101.370 mm
101.098 - 101.120 mm
100.848 - 100.870 mm
100.598 - 100.620 mm
100.348 - 100.370 mm
100.098 - 100.120 mm
Fillet radius
4.8 - 5.2 mm
51.28 mm
Radial clearance
0.054 - 0.116 mm
84.233 - 84.255 mm
83.983 - 84.005 mm
83.733 - 83.755 mm
83.483 - 83.505 mm
83.233 - 83.255 mm
82.983 - 83.005 mm
82.733 - 82.755 mm
Fillet radius
4.8 - 5.2 mm
Surface quality
0.25 Ra
Width, max.
59.10 mm
3.378 - 3.429 mm
3.454 - 3.505 mm
3.505 - 3.556 mm
3.632 - 3.683 mm
3.886 - 3.937 mm
4.267 - 4.318 mm
70
Scania CV AB 1998
01:02-02
Program 96
Tightening torques
Nut for camshaft gear. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 600 Nm
Nut for compressor gear. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 200 Nm
Bolts for intermediate gear shaft journal . . . . . . . . . . . . . . . . . . . . . . . . 39 Nm
Connecting rod bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 Nm + 90
Main bearing bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50 Nm + 90
Flywheel bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 180 Nm
Crankshaft bolt. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 300 Nm+60
Bolts for crankshaft damper and pulley . . . . . . . . . . . . . . . . . . . . . . . . . 110 Nm
Fan bolts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70 Nm
Lubrication system
Oil pump
Radial clearance: pump gear - pump housing . . . . . . . . . . . . . . . . . . . . 0.130 - 0.179 mm
Axial clearance: pump gear - pump housing cover (without gasket). . . 0.07 - 0.10 mm
Oil cleaner
Permitted thickness of deposits on wall of bowl . . . . . . . . . . . . . . . . . . 20 mm
Oil filter
Use only genuine Scania filters.
01:02-02
Scania CV AB 1998
71
Program 96
Tightening torques
Oil pump:
Bolts for oil pump cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 Nm
Bolts oil pump - cylinder block . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59 Nm
Valve sleeve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30 Nm
Oil cleaner:
Lock nut for oil cleaner housing cover . . . . . . . . . . . . . . . . . . . . . . . . . 10 Nm
Nut for rotor bowl . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Tighten by hand
Rotor shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41 Nm
72
Scania CV AB 1998
01:02-02
Program 96
Valve clearance
Checking and adjusting
Check valve clearance. The clearance for intake
valves should be 0.45 mm and the clearance for
exhaust valves should be 0.80 mm when the
engine is cold.
Adjustment can be carried out in one of the following ways:
B. Set No.1 cylinder at precisely TDC after compression. The following valves can now be
adjusted:
cyl. 1
cyl. 2
cyl. 3
cyl. 4
cyl. 5
01:02-02
exhaust
intake
exhaust
intake
exhaust and intake
Intake valve
Exhaust valve
Scania CV AB 1998
Program 96
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
Scania CV AB 1998
01:02-02
Noter
DI 12
1.
2.
3.
4.
5.
6.
z1
z1
z1
z5
Annually
At least
4800 h
2400 h
400 h
Interval
200 h
400 h
First start
Daily
First
time at
1200 h
MAINTENANCE SCHEDULE
z
z5
z6
z6
z1
z
z1
z
z3
z
z
z
z1
z
z
z2
z2
z2
z
z
z
z
2005-03:1
29
Specifications
General information
Cylinder configuration. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Number of cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Cylinder bore . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Stroke length . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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
91
Cylinder head
Intake valve
Valve head angle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19.5
Minimum dimension 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 dimension 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 dimension 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
92
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 tightening . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Second tightening . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Third tightening . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fourth tightening . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Nut for injector. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Bolts for shaft with rocker arms. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Nut for adjusting screw on rocker arm . . . . . . . . . . . . . . . . . . . . . . . . .
Bolt for rocker cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Bolts for exhaust manifold. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Bolts for turbocharger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Bolts for support bracket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
60 Nm
150 Nm
250 Nm
90
70 Nm
105 Nm
40 Nm
26 Nm
59 Nm
50 Nm
105 Nm
0.45 mm
0.70 mm
66.9 +/- 0.1 mm
69.9 +/- 0.1 mm
Tightening torques
Adjusting screw lock nut on rocker arm for unit injector . . . . . . . . . . .
Adjusting screw lock nut on rocker arm for valves . . . . . . . . . . . . . . . .
Bolt for upper rocker cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Bolt for lower rocker cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Support bracket and rocker arm shaft . . . . . . . . . . . . . . . . . . . . . . . . . .
Cable connection, unit injector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
01:03-02
39 Nm
35 Nm
26 Nm
26 Nm
105 Nm
2 +/- 0,2 Nm
93
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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Maximum clearance in groove, 2nd ring. . . . . . . . . . . . . . . . . . . . . . . .
2
0.35 - 0.60 mm
0.45 - 0.65 mm
0.25 mm
94
01:03-02
Connecting rods
Connecting rod and bearing cap marked 1 to 6.
Fitted with marking in.
Tightening torques
Oil sump bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30 Nm
Connecting rod bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 Nm + 90
Ring gear
Heated to 100 - 150C before fitting.
Tightening torques
Flywheel bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 130 Nm + 90
Bolts for flywheel housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . M10: 50 Nm
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . M12 : 90 Nm
01:03-02
95
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. . . . . . . . . . . . . . . . . . . . . . . . .
Flange bolts and banjo bolts for valve tappets . . . . . . . . . . . . . . . . . . .
Bolts for timing gear plate. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
96
63 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 cover . . . . . . . . . . . . . . . . . max. 20 mm
1.6 bar
2.5 bar
4.5 - 6.0 bar
61.4 mm
Oil filter
Only use original Scania filters.
Tightening torques
Oil pump:
Bolts for oil pump cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 Nm
Bolts, oil pump - cylinder block . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 Nm
Oil cleaner:
Lock nut for oil cleaner housing cover . . . . . . . . . . . . . . . . . . . . . . . . . 15 Nm
Nut for rotor bowl . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Tightened 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
97
O Intake valve
Exhaust valve
01:03-02
O Intake valve
Exhaust valve
10
01:03-02
Order of adjustment:
Mark on flywheel
(reading from
underneath)
Valve
change on
cylinder
Adjust
valves on
cylinder
Adjust
injector
rocker arm
on cylinder
120
240
480
600
01:03-02
11
WARNING!
01:03-02
PDE32
1. Position setting tool 99 442 with the metal
plate around the injector spring.
2. Finely adjust dimension A by simultaneously
using a finger to sense that the small piston 2
is level with the flat upper surface of the tool.
It is possible to sense differences of less than
a tenth of a millimetre.
3. If tool 99 442 is not available: Measure the
distance between plane a and the top of the
valve spring collar using a digital sliding caliper. Adjust the rocker position by means of
the adjusting screw until the dimension is
69.9 +/- 0.1 mm.
4. Tighten the lock nut to 39 Nm.
5. See Order of adjustment on page 6 for checking/adjusting the injector rockers.
01:03-02
13
2005-03:1
temperature sensor
Charge air temperature sensor
Oil pressure monitor
Connector panel
Coolant temperature sensor
Engine speed sensorse
17
CONTROL STATUS
<
SHUTDOWN
P The LED is out.
STARTING
<
POWER+
<
RUNNING
<
TORQUE LIMIT
<
BOOST LIMIT
<
18
2005-03:1
CONTROL STATUS
<
POWER -
<
SHUTDOWN
<
2005-03:1
19
20
2005-03:1
POWER +
POWER -
BOOST LIMIT
TORQUE LIMIT
RUNNING
STARTING
SHUTDOWN
2005-03:1
<
<
<
<
<
<
<
<
<=LED on
Probable cause
Action
21
DI 14
1.
2.
3.
4.
5.
6.
Every year
At least
4800 h
2400 h
400 h
Interval
200 h
400 h
At first start
Daily
First
time at
1200 h
MAINTENANCE SCHEDULE
l
l1
l1
l1
l5
l5
l6
l6
l1
l
l1
l
l3
l
l
l
l1
l
l
l2
l2
l2
l
l
l
l
2001-05:1
19
Specifications
General information
Cylinder locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Number of cylinders. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Cylinder bor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Stroke . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Swept volume. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Number of main bearings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Firing sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Injection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Principle of operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Cooling. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Weight, incl. generator, about . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
V engine
8
127 mm
140 mm
14,2 dm3
5
1-5-4-2-6-3-7-8
Direct
4 stroke
Fluid
1230 kg
561 045
561 200
561 205
584 106
561 019
Cylinder head
Minimum height of cylinder head after machining, page 17 . . . . . . . . 114,8 mm
Distance B between the surface of the cylinder head and valve disc, page 11
With new parts, minimum . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0,72 mm
With machined parts, maximum . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1,80 mm
Intake valve
Clearance (cold engine) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0,45 mm
Head angle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19,4 - 19,6
Minimum dimension A for reground valve, page 10. . . . . . . . . . . . . . 3,0 mm
70
01:04-02
Exhaust valve
Clearance (cold engine) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Head angle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Minimum dimension A for reground valve, page 10 . . . . . . . . . . . . .
0,80 mm
44,4 - 44,6
1,7 mm
20,0 - 20,5
2,3 - 2,8 mm
56,0 mm
55,934 - 55,953 mm
11,25 - 11,35 mm
56,2 mm
56,134 - 56,153 mm
ca -80 C
44,0 - 46,0
1,9 - 2,6 mm
52,0 mm
51,914 - 51,933 mm
11,25 - 11,35 mm
52,2 mm
52,114 - 52,133 mm
ca -80 C
Valve guides
Height above surface for valve spring washer . . . . . . . . . . . . . . . . . .
19,00 - 19,45 mm
01:04-02
71
Tightening torques
Cylinder head bolts:
First tightening . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110 Nm
Second tightening. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 165 Nm
Third tightening . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 220 Nm
Injector nut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Nut for adjusting screw on rocker arm . . . . . . . . . . . . . . . . . . . . . . . .
Rocker cover bolt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Exhaust manifold bolts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Intake manifold nuts, DSI . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Charge cooler cover nuts, DSI . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
70 Nm
40 Nm
16 Nm
59 Nm
39 Nm
39 Nm
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 pipe . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40 Nm
V clamps, exhaust and inlet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-10 Nm
72
01:04-02
Pistons
Fitted with arrow on piston crown towards the outside of the engine
Piston rings
Number of compression rings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Gap:
1st ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2nd ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Maximum clearance in groove, 2nd ring . . . . . . . . . . . . . . . . . . . . . .
2 st
0,50 - 0,75 mm
0,45 - 0,65 mm
0,25 mm
1 st
0,4 - 0,65 mm
0,25 mm
Connecting rods
Connecting rod and cap marked 1 to 8.
Fitted with marking in.
Weight classes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Only weight class B is available as a spare part.
A, B och C
Tightening torques
Bolts for tension lugs when pressing down cylinder liners . . . . . . . .
Oil sump bolts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Connecting rod bolts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
60 Nm
47 Nm
20 Nm + 90
01:04-02
73
Flywheel housing
Seal in flywheel housing: dimension B, page 46 . . . . . . . . . . . . . . . . . 7 mm
Tightening torques
Flywheel bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 230 Nm + 60
Flywheel housing bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90 Nm
Timing gear
Camshaft gear
Heated to 100 C before fitting.
Backlash to intermediate gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0,05 - 0,15 mm
Injection pump gear
Backlash to intermediate gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0,05 - 0,14 mm
Intermediate gear
Maximum axial clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0,24 mm
Bushing for power take-off gear
Diameter. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45,009 - 45,034 mm
Cam shaft
Axial clearance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0,15 - 0,30 mm
74
01:04-02
Crankshaft
Main bearing races . . . . . . . . . .
Thrust bearing . . . . . . . . . . . . . .
01:04-02
Diameter:
Standard
1st undersize
2nd undersize
3rd undersize
4th undersize
5th undersize
6th undersize
101,598 - 101,620 mm
101,348 - 101,370 mm
101,098 - 101,120 mm
100,848 - 100,870 mm
100,598 - 100,620 mm
100,348 - 100,370 mm
100,098 - 100,120 mm
Fillet radius
4,8 - 5,2 mm
Surface quality
0,25 Ra
Max. width
51,28 mm
Radial clearance
0,054 - 0,116 mm
Diameter:
Standard
1st undersize
2nd undersize
3rd undersize
4th undersize
5th undersize
6th undersize
89,978 - 90,000 mm
89,728 - 89,750 mm
89,478 - 89,500 mm
89,228 - 89,250 mm
88,978 - 89,000 mm
88,728 - 88,750 mm
88,478 - 88,500 mm
Fillet radius
4,8 - 5,2 mm
Surface quality
0,25 Ra
Max. width
94,35 mm
Radial clearance
0,050 - 0,112 mm
Thickness:
Standard
1st oversize
2nd oversize
3rd oversize
4th oversize
5th oversize
3,378 - 3,429 mm
3,454 - 3,505 mm
3,505 - 3,556 mm
3,632 - 3,683 mm
3,886 - 3,937 mm
4,267 - 4,318 mm
Axial clearance
0,18 - 0,37 mm
75
Tightening torques
Camshaft gear nuts
Compressor gear nuts
intermediate gear shaft journal bolts
600 Nm
200 Nm
39 Nm
Lubrication system
Oil pump
Radial clearance: pump gear - pump housing . . . . . . . . . . . . . . . . . . . 0,115 - 0,239 mm
Axial clearance: pump gear - pump housing cover (without gasket). . 0,058 - 0,094 mm
Oil pressure valve (Note: not safety valve)
Oil pressure:
Warmed-up engine at 2000 rpm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4,5 - 6,0 bar
Warmed-up engine at 800 rpm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1,5 bar
Free spring length. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70,85 mm
Oil cleaner
Permissible thickness of dirt deposits on cover walls . . . . . . . . . . . . . 20 mm
Oil filter
Use only genuine Scania filters
76
01:04-02
Tightening torques
Oil pump
Oil pump cover bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Bolts, oil pump - cylinder block . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Valve sleeve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
20 Nm
59 Nm
30 Nm
Oil cleaner
Locknut on oil cleaner housing cover. . . . . . . . . . . . . . . . . . . . . . . . .
Nut for rotor bowl. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Locknut on oil cleaner housing cover. . . . . . . . . . . . . . . . . . . . . . . . .
10 Nm
Tighten by hand
34 Nm
01:04-02
23 Nm
20 Nm
77
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 0.80 mm when the
engine is cold.
Cylinder numbering
B. Turn the crankshaft in the direction of rotation
until the piston in No. 1 cylinder is 20 after TDC
on the combustion stroke. There is a mark at
this point.
01:04-02
1
5
6
3
7
Intake valve
Exhaust valve
Turn the crankshaft exactly one revolution in the
direction of rotation so that the piston in No. 1
cylinder is 20 after TDC on the induction stroke
and adjust the following valves:
RH side:
cyl. 2: inlet
cyl. 3: exhaust and inlet
cyl. 4: inlet
LH side:
cyl. 6: inlet and exhaust
cyl. 7: exhaust
cyl. 8: exhaust
01:04-02
Noter
DI 16
1.
2.
3.
4.
5.
6.
Annually
4800 h
400 h
At least
2400 h
Interval
200 h
400 h
First start
Daily
First
time at
1200 h
MAINTENANCE SCHEDULE
1
1
1
5
5
6
6
1
1
2
2
2
2003-09:4
29
General
1. Warning plates
2. Instruction plate: Valve clearance
Specifications
Cylinder bore
127.0 mm
Stroke
154.0 mm
Displacement
15.6 dm3
Firing sequence
1-5-4-2-6-3-7-8
Compression ratio
18:1
Anticlockwise
500 rpm
2400 rpm
Oil volume
35 litre
Oil grade
1,346 kg
Scania CV AB 2002-09:3
01:05-02
8.6 Nm
Flange bolt M8
26 Nm
50 Nm
92 Nm
Stud in casting M8
13 Nm
25 Nm
*) A tolerance of +/- 15% applies to the specified tightening torques unless stated otherwise.
01:05-02
Scania CV AB 2002-09:3
Fitting
Tightening torques
Cylinder head bolts:
First stage
60 Nm
Second stage
150 Nm
Third stage
250 Nm
Fourth stage
90
26 Nm
20 Nm + 75
105 Nm
18 Nm
39 Nm
35 Nm
2 +/-0.2 Nm
63 Nm
26 Nm
11 Nm
Special tools
Number
588 179
24
Description
Illustration
Tool board
Torque screwdriver
Scania CV AB 2002-09:3
01:05-02
01:05-02
Scania CV AB 2002-09:3
25
Fitting
Tightening torques
Bolts for oil sump
32 Nm
50 Nm +90
23 Nm
Special tools
Number
Description
98 212
Illustration
Tool board
D3
64
Scania CV AB 2002-09:3
01:05-02
Fitting
Tightening torques
Main bearing cap bolts
90 Nm+90
Side bolts
180 Nm
50 Nm+90
135 Nm
92 Nm
01:05-02
Scania CV AB 2002-09:3
79
0.45 mm
0.70 mm
66.9+/-0.1 mm
69.9+/-0.1 mm
Tightening torques
(See page 3 for general tightening torques)
Adjusting screw lock nut on rocker arm for unit injector
39 Nm
35 Nm
18 Nm
26 Nm
105 Nm
2 +/-0.2 Nm
Special tools
Number
99 309
Description
Tool to rotate flywheel
99 414
Setting tool
99 442
Setting tool
588 179
Torque screwdriver
01:05-02
Illustration
Scania CV AB 2002-09:3
Tool board
D5
11
12
Scania CV AB 2002-09:3
01:05-02
WARNING!
01:05-02
Scania CV AB 2002-09:3
13
PDE32:
7. Position setting tool 99 442 with the metal
plate around the injector spring.
8. Finely adjust dimension A by simultaneously
using a finger to sense that the small piston 2
is level with the flat upper surface of the tool.
It is possible to sense differences of less than
a tenth of a millimetre.
9. If tool 99 442 is not available: Measure the
distance between plane a and the top of the
valve spring collar using a digital sliding caliper. Adjust the position of the rocker arm
with the adjusting screw until the distance is
69.9+/-0.1 mm.
10. Torque tighten the lock nut to 39 Nm.
11. The order in which the injector rockers are to
be checked/adjusted is shown in the table on
page 15.
14
Scania CV AB 2002-09:3
01:05-02
Order of adjustment
Rotate the flywheel using tool 99 309 so that the
mark on the flywheel is visible in the bottom
window according to the table below.
Mark on flywheel
(degrees)
Valve
change on
cylinder
Adjust injector
rocker arm on
cylinder
Adjust intake
valve on
cylinder
Adjust exhaust
valve on
cylinder
4 and 5
7 and 8
4 and 5
TDC Up (180)
2 and 6
1 and 5
2 and 6
3 and 7
2 and 4
3 and 7
TDC Up (540)
1 and 8
3 and 6
1 and 8
01:05-02
Scania CV AB 2002-09:3
15
Removal
1. Clean the rocker cover and the surrounding
area.
WARNING!
16
Scania CV AB 2002-09:3
01:05-02
The diagnostics lamp will stay on for as long as a fault is active. Even
if the lamp has gone off and the fault is no longer active, the code can
generally be read off in accordance with the instruction below.
3. A fault code will then flash on the diagnostics lamp. This flashing code
consists of long flashes (approximately 1 second long) and short flashes
(0.3 seconds long). Long flashes are equivalent to tens and short flashes
to units.
Example: long - short - short = fault code 12.
4. Repeat this procedure until the first flashing code is repeated. This
means that the entire fault code memory has been flashed up. If the fault
code memory is empty, only one long flash approximately 4 seconds
long will be given.
5. See the flashing code table on the next page for a description and
localisation of the fault.
7. When a fault has been rectified the fault code can be erased as described
below.
3. Switch on the ignition and keep at the same time the diagnostics switch
activated, to the right (COO) or to the left (EMS), for 3 seconds.
4. This will erase passive fault codes which can be read off via flashing
code for the relevant system. The rest of the fault code will remain in the
EEPROM and can only be deleted using the PC tool.
18
2003-09:4
Description
Code
Description
No fault detected.
53
11
54
12
55
13
56
14
57
15
58
16
59
17
61
18
66
20
69
23
82
24
83
25
84
27
85
28
86
31
87
32
88
33
89
37
93
43
94
47
96
48
98
49
99
51
52
2003-09:4
19
Even if the lamp has gone off and the fault is no longer active, the code
can generally be read off in accordance with the instruction below.
3. A fault code will then flash on the diagnostics lamp. This flashing code
consists of long flashes (approximately 1 second long) and short flashes
(0.3 seconds long). Long flashes are equivalent to tens and short flashes
to units.
Example: long - short - short = fault code 12.
4. Repeat this procedure until the first flashing code is repeated. This
means that the entire fault code memory has been flashed up. If the fault
code memory is empty, only one long flash approximately 4 seconds
long will be given.
5. See the flashing code table on the next page for a description and
localisation of the fault.
7. When a fault has been rectified the fault code can be erased as described
below.
3. Switch on the ignition and keep at the same time the diagnostics switch
activated, to the right (COO) or to the left (EMS), for 3 seconds.
4. This will erase passive fault codes which can be read off via flashing
code for the relevant system. The rest of the fault code will remain in the
EEPROM and can only be deleted using the PC tool.
20
2003-09:4
Description of fault
111)
112)
121)
122)
Incorrect signal from the resistor module for idle and fixed speed setting.
13
14
15
17
18
19
21
22
23
24
25
26
27
The signals from the RCB (Remote Control Box) switches are implausible.
28
29
31
32
Short circuit in the signal cable to the coolant temperature warning lamp.
33
34
35
2003-09:4
21
Assembly
Specifications
Tightening torques
Lock nut for oil cleaner housing lid
15 Nm
Tighten by hand
Rotor shaft
34 Nm
Locking compound
561 200
01:05-02
Scania CV AB 2002-09:3
121
Example:
1. The total volume of the cooling system is
80 litres.
2. The measured freezing point is -6C (15%
mixture by volume of ethylene glycol).
According to the table there are 12 litres of
ethylene glycol in the cooling system.
% glycol by
volume
15
20
25
-6
-9
11
12
14
15
30
10
12
14
16
18
20
40
10
13
15
18
20
23
25
50
12
15
18
21
24
27
30
60
11
14
18
21
25
28
32
35
70
12
16
20
24
28
32
36
40
80
14
18
23
27
32
36
41
45
90
15
20
25
30
35
40
45
50
100
17
22
28
33
39
44
50
55
110
18
24
30
36
42
48
54
60
120
20
26
33
39
46
52
59
65
130
21
28
35
42
49
56
63
70
140
23
30
38
45
53
60
68
75
150
24
32
40
48
56
64
72
80
160
26
34
43
51
60
68
77
85
170
27
36
45
54
63
72
81
90
180
29
38
48
57
67
76
86
95
190
30
40
50
60
70
80
90 100
200
Ethylene glycol
dm3 (litres)
30
35
40
45
50
Cooling system
capacity, dm3
02:03-01
Fuel lines
Fuel cooler
Engine
speed
9 and 12series
engines
l/hour
12-series
engine
PDE
l/hour
16-series
engine
l/hour
500
63
91
93
Under 6 m
Over 6 m
1200
106
220
223
Inside
diameter mm
Inside
diameter mm
1500
135
271
276
1800
149
325
330
10
12
2000
150
362
369
12
10
12
2100
146
380
387
16
10
12
2200
149
19:02-13
DN9 42A..S
D9 61A MIL..S
D9 90A..S
D9 92A..S
D9 93M..S
D9 95M..S
1393866
1393866
1393867
1393864
1393867
DC9 46A..S
DC9 47A..S
DC9 49A..S
DC9 50A..S
1393866
1393864
1393867
1393869
DI9 44M..S
DI9 46M..S
DI9 47M..Q
DI9 48A..E
DI9 48A..S
DI9 49A..S
DI9 50M..S
DI9 51A..S
DI9 53A..E
DI9 53A..S
DI9 55M..E
DI9 59M..E
1393866
1393870
1393871
1412887
1393866
1393866
1393867
1403477
1412887
1393866
1412293
1412293
Motortyp
Engine type
Motortyp
ppningstryck, bar
Opening pressure, bar
ffnungsdruck, bar
300
20
Manufacturer
KDEL 97 P31
Scania
1340655
19
17
20
19
XHDM 781589
XHDM 781589
XHDM 781589
XHDM 781589
XHDM 781589
1382917
1382917
1318812
1318812
1318812
XNBM 870733
XNBM 870733
XNBM 770894
XNBM 770894
XNBM 770894
1382918
1382918
1318814
1318814
1318814
5x0,350
5x0,350
5x0,315
5x0,315
5x0,315
300
300
300
300
300
15
17
13
13
XHDM 781589
XHDM 781589
XHDM 781589
XHDM 781589
1382917
1318812
1318812
1395954
XNBM 870733
XNBM 770894
XNBM 770894
XNBM 870739
1382918
1318814
1318814
1382261
5x0,350
5x0,315
5x0,315
5x0,360
300
300
300
300
16
20
20
15
15
16
12
15
15
20
20
XHDM 781589
XHDM 781589
KDEL 97 P10
XHDM 781589
XHDM 781589
XHDM 781589
XHDM 781589
KDEL 97 P31
XHDM 781589
XHDM 781589
KDEL 97 P10
KDEL 97 P10
1382917
1395954
1372541
1382917
1382917
1382917
1318812
1340655
1382917
1382917
1372541
1372541
XNBM 870733
XNBM 870739
DLLA 142 P544
XNBM 870733
XNBM 870733
XNBM 870733
XNBM 770894
DLLA 142 P406
XNBM 870733
XNBM 870733
DLLA 142 P544
DLLA 142 P544
1382918
1382261
1372542
1382918
1382918
1382918
1318814
1340656
1382918
1382918
1372542
1372542
5x0,350
5x0,360
5x0,348
5x0,350
5x0,350
5x0,350
5x0,315
6x0,272
5x0,350
5x0,350
5x0,348
5x0,348
300
300
300
300
300
300
300
300
300
300
300
300
KDEL: Bosch
XNBM: Stanadyne
Scania CV AB 2000-07:2
DLLA: Bosch
XHDM: Stanadyne
03:00-01
D11 94A..S
D11 95A..S
D11 96A..S
D11 97A..S
D11 98M..S
D11 99M..S
Komplett
Assembly
Komplett
1388635
1388635
1388638
1388638
1388636
1388640
21
21
21
21
23
22
Manufacturer
KDEL 97 P13
KDEL 97 P13
KDEL 97 P13
KDEL 97 P13
KDEL 97 P10
KDEL 97 P10
Scania
1340592
1340592
1340592
1340592
389676
389676
DC11 56A..S
DC11 57A..S
DC11 58A..T
DC11 58A..T
1359930
1382923
1397783
1397781
20
19
16
16
KDEL 97 P13
KDEL 97 P13
KDEL 97 P13
KDEL 97 P13
1386852
1386852
1340592
1340592
1386853
1386853
1340593
1340593
8x0,280
8x0,280
8x0,264
8x0,264
300
300
300
300
DI11 71A..S
DI11 71A..S
DI11 72A..S
DI11 73M..S
DI11 74M..S
DI11 75M..Q
DI11 76M..T
DI11 76M..T
DI11 76M..T
DI11 76M..T
DI11 77M..T
DI11 77M..T
DI11 77M..T
DI11 77M..T
DI11 78M..S
DI11 79M..S
DI11 80M..S
DI11 81M..S
1359594
1359930
1382923
1388637
1388631
1388633
1390279
1390280
1397779
1397780
1390279
1390280
1397779
1397780
1388637
1388636
1397107
1397107
17
17
21
23
23
23
20
20
20
20
20
20
20
20
23
23
22
22
KDEL 97 P13
KDEL 97 P13
KDEL 97 P13
KDEL 97 P61
KDEL 97 P61
KDEL 97 P61
KDEL 97 P61
KDEL 97 P61
KDEL 97 P61
KDEL 97 P61
KDEL 97 P61
KDEL 97 P61
KDEL 97 P61
KDEL 97 P61
KDEL 97 P61
KDEL 97 P10
KDEL 97 P61
KDEL 97 P61
1386852
1386852
1386852
1394528
1394528
1394528
1394528
1394528
1394528
1394528
1394528
1394528
1394528
1394528
1394528
389676
1394528
1394528
1386853
1386853
1386853
1394530
1394530
1394530
1394530
1394530
1394530
1394530
1394530
1394530
1394530
1394530
1394530
389677
1394530
1394530
8x0,280
8x0,280
8x0,280
5x0,374
5x0,374
5x0,374
5x0,374
5x0,374
5x0,374
5x0,374
5x0,374
5x0,374
5x0,374
5x0,374
5x0,374
5x0,352
5x0,374
5x0,374
300
300
300
300
300
300
300
300
300
300
300
300
300
300
300
250
300
300
Motortyp
Engine type
Motortyp
KDEL: Bosch
Scania CV AB 2000-07:2
DLLA: Bosch
ppningstryck, bar
Opening pressure, bar
ffnungsdruck, bar
300
300
300
300
250
250
D14 52A..S
20
Manufacturer
KDEL 99 P15
Scania
1341480
DC14 57A..T
DC14 57A..T
DC14 61A..T
DC14 61A..T
DC14 62A..T
DC14 62A..T
DC14 63A..S
1391886
1371441
1391888
1371442
1391886
1371441
1391878
RQ750 PA 1227-1
RQ 750 PA 758-15
RQ900 PA 1227-1
RQ 900 PA 758-20
RQ750 PA 1227-1
RQ 750 PA 758-15
RSV350-1050 P8A 652
14
14
16
16
12
12
17
KDEL 99 P15
1327374
1327375
8x 0,246
260
KDEL 99 P15
1327374
1327375
8x 0,246
260
KDEL 99 P15
1327374
1327375
8x 0,246
260
KDEL 99 P15
1341480
1341481
8x0,270
300
DI14 68M..S
DI14 68M..S
DI14 68M..S
DI14 69M..E
DI14 69M..E
DI14 69M..S
DI14 70A..S
DI14 71A..Q
DI14 72A..T
DI14 72A..T
DI14 72A..T
DI14 72A..T
DI14 73M..S
DI14 74M..S
DI14 74M..S
DI14 75M..S
DI14 75M..S
DI14 75M..S
DI14 77A..T
DI14 77A..T
DI14 78M..T
DI14 78M..T
DI14 78M..T
DI14 78M..T
DI14 79A..S
DI14 82M..E
DI14 82M..E
DI14 83A..S
1391880
1359815
1411028
1391889
1359932
1359815
1391883
1391875
1391886
1371441
1391888
1371442
1391882
1391881
1391880
1359815
1391880
1411028
1391886
1371441
1391886
1371441
1391888
1371442
1391878
1391889
1359932
1391882
19
19
19
KDEL 99 P15
KDEL 99 P15
KDEL 99 P15
KDEL 99 P15
KDEL 99 P15
KDEL 99 P15
KDEL 99 P15
KDEL 99 P15
KDEL 99 P15
1351806
1351806
1351806
1351806
1351806
1351806
1342165
1342165
1327374
1351807
1351807
1351807
1351807
1351807
1351807
1342166
1342166
1327375
5x0,390
5x0,390
5x0,390
5x0,390
5x0,390
5x0,390
8x0,288
8x0,288
8x 0,246
300
300
300
300
300
300
300
300
260
KDEL 99 P15
1327374
1327375
8x 0,246
260
KDEL 99 P15
KDEL 99 P15
KDEL 99 P15
KDEL 99 P15
KDEL 99 P15
KDEL 99 P15
KDEL 99 P15
1327374
380807
1351806
1351806
1351806
1351806
1327374
1327375
380808
1351807
1351807
1351807
1351807
1327375
8x 0,246
5x0,366
5x0,390
5x0,390
5x0,390
5x0,390
8x 0,246
260
300
300
300
300
300
260
KDEL 99 P15
1327374
1327375
8x 0,246
260
KDEL 99 P15
1327374
1327375
8x 0,246
260
KDEL 99 P15
KDEL 99 P15
KDEL 99 P15
KDEL 99 P15
1341480
1351806
1351806
1327374
1341481
1351807
1351807
1327375
8x0,270
5x0,390
5x0,390
8x 0,246
300
300
300
260
Motortyp
Engine type
Motortyp
15
15
16
16
16
16
16
18
18
19
19
19
12
12
18
18
18
18
18
11
KDEL: Bosch
Scania CV AB 2000-07:3
DLLA: Bosch
ppningstryck, bar
Opening pressure, bar
ffnungsdruck, bar
300
03:00-03
DC12 40A..T
DC12 40A..T
DC12 41A..E
DC12 42A..T
DC12 42A..T
DC12 43A..Q
Komplett
Assembly
Komplett
1409259
1409835
1364497
1409259
1409835
1445225
DI12 40A..E
DI12 41M..E
DI12 42M..E
DI12 43M..E
DI12 44M..E
DI12 45M..E
DI12 46A..E
DI12 47A..Q
1364497
1364497
1364497
1364497
1364497
1364497
1364497
1445225
Motortyp
Engine type
Motortyp
20
20
20
20
20
Manufacturer
KDEL 109 P62
KDEL 109 P62
KDEL 109 P62
KDEL 109 P62
KDEL 109 P62
KDEL 109 P62
Scania
1422540
1422540
1404009
1404009
1404009
1404009
18
21
21
25
25
21
1412614
1387056
1404009
1433445
1404009
1404009
1412614
1404009
KDEL: Bosch
Scania CV AB 2000-07:1
1412615
1364500
1404010
1433446
1404010
1404010
1412615
1404010
8x0,240
8x0,22
8x0,260
8X0,30
8x0,260
8x0,260
8x0,240
8x0,260
ppningstryck, bar
Opening pressure, bar
ffnungsdruck, bar
300
300
270
270
270
270
300
270
270
270
270
270
300
270
DLLA: Bosch
03:00-04
Noter