Chassis serial number: 5237861

03-01 Unit injector [PDE]

Adjusting - Unit injector [PDE]
Tools

Number Designation Illustration Tool board

99 109 Turning tool

99 309 Turning tool D5

Measuring tool
99 414 Setting tool cabinet

Measuring tool
99 442 Setting tool cabinet

2 259 538 Torque screwdriver

7/5/2010 © Scania CV 1 of 13
 Chassis serial number: 5237861

WARNING!

For ethanol-powered engines:

Read the precautions for ethanol in 00:01-02
Safety and fire protection in service workshops,
before starting work.
Follow the instructions in Procedures for all
work in the workshop.
Follow the applicable local laws and regulations
for working with ethanol.

Note: Check and adjust the valve clearance

and unit injectors with the engine cold.

IMPORTANT!

Before checking and adjusting the valve

clearance, you must check what type of unit
injector is fitted on the vehicle. There are
different special tools for the two unit injector
types.

IMPORTANT!

Remember to remove the flywheel rotation tool

after adjustment.

Checking what type of unit injector is fitted on the engine

There are two different unit injector types, which one is fitted on the engine depends on
the engine type.
1. Measure diameter B on the unit injector spring
as illustrated. Different setting tools are used
according to the measurement obtained on the
spring.

7/5/2010 © Scania CV 2 of 13
 Chassis serial number: 5237861

Diameter B Setting tool which should be used Adjustment dimension A

36 mm 99 414 66.9 mm

38.8 mm 99 442 69.9 mm

1. Fit the setting tool with the metal plate around

the unit injector.

99 414

The setting tool acts as a gauge

and corresponds to the setting
dimension.

7/5/2010 © Scania CV 3 of 13
 Chassis serial number: 5237861

WARNING!

When the unit injector is being checked and the

measurement is outside the setting dimension
by +/-0.5 mm, it is necessary to be very careful
when handling this unit injector. The spring is
pre-tensioned and can come loose, causing
personal injury.

2. When adjusting, loosen the lock nut and adjust 1

the unit injector with adjusting screw 1. The

unit injector is correctly set when the small
piston 2 is level with the flat upper surface of
the tool. Use a finger to check. It is possible to 99 414

feel differences of less than a millimetre. The

setting dimension is 66.9 +/ -0.1 mm or 69.9 +/-
0.1 mm.
Refer to tables in Order of adjustment for unit 2

injectors.

The setting tool piston is above or

below the flat upper surface of the
tool. Adjust the unit injector. (The
illustration shows setting tool 99
414.)

7/5/2010 © Scania CV 4 of 13
 Chassis serial number: 5237861

The setting tool piston is above or

below the flat upper surface of the
tool. Adjust the unit injector. (The
illustration shows setting tool 99
442.)

The setting tool piston is level with

the flat upper surface of the tool.
The unit injector is correctly
adjusted. (The illustration shows
setting tool 99 414.)

7/5/2010 © Scania CV 5 of 13
 Chassis serial number: 5237861

The setting tool piston is level with

the flat upper surface of the tool.
The unit injector is correctly
adjusted. (The illustration shows
setting tool 99 442.)

3. Tighten the lock nut after adjusting.

4. Remove the setting tool.

99 414

7/5/2010 © Scania CV 6 of 13
 Chassis serial number: 5237861

Order of adjustment for 9 litre engines

Check and adjust the valve clearance with the engine cold. The intake valve clearance
should be 0.45 mm and the exhaust valve clearance 0.70 mm.
Rotate the flywheel in the normal direction of rotation using turning tool 99 309. Read the
mark on the flywheel visible in the lower window of the flywheel housing.
Engines equipped with flywheel with marking TDC Up: Fit turning tool 99 109 in the
holes of the upper hatch. Press the pinion into the external ring gear and turn the flywheel
with a ratchet handle and a 14 mm socket. Read the mark on the flywheel in the upper
window of the flywheel housing.

Note: Valve transition occurs when the

cylinder switches from exhaust stroke to intake
stroke. The exhaust valve is closing while the
intake valve is opening.

Note: For adjusting the injectors, see the

relevant work description in section 03-01.

Adjust valves according to the table below. Follow the respective column depending on
whether the reading is in the lower or the upper window. Start adjustment at the top of the
table. Check that there is no valve transition on cylinder 1.

Cylinder configuration, 5
cylinder engines

7/5/2010 © Scania CV 7 of 13
 Chassis serial number: 5237861

Adjust
Mark on Mark on
intake
flywheel. Valve Adjust flywheel.
and
Reading transition injector Reading
Revolution exhaust
in the on on in the
valves
lower cylinder cylinder upper
on
window window
cylinder

TDC Down 1 1 2 TDC Up

72/432 1 5 252/612

144/504 1 2 4 324/684

216/576 1 3 36/396

288/648 1 4 5 108/468

TDC Down 2 1 TDC Up

72/432 2 5 3 252/612

144/504 2 2 324/684

216/576 2 3 1 36/396

288/648 2 4 108/468

It is a good idea to mark the rocker arm with a pen after adjustment to keep track of what
has already been adjusted.
The flywheel also has markings at 240°/600° and 120°/480°, these markings apply to 6
cylinder engines.

7/5/2010 © Scania CV 8 of 13
 Chassis serial number: 5237861

Order of adjustment, 11, 12 and 13 litre engines

Check and adjust the valve clearance with the engine cold. The intake valve clearance
should be 0.45 mm and the exhaust valve clearance 0.70 mm.
Rotate the flywheel in the normal direction of rotation using turning tool 99 309. Read the
mark on the flywheel visible in the lower window of the flywheel housing.
Engines equipped with flywheel with marking TDC Up: Fit turning tool 99 109 in the
holes of the upper hatch. Press the pinion into the external ring gear and turn the flywheel
with a ratchet handle and a 14 mm socket. Read the mark on the flywheel in the upper
window of the flywheel housing.

Note: Valve transition occurs when the

cylinder switches from exhaust stroke to intake
stroke. The exhaust valve is closing while the
intake valve is opening.

Note: For adjusting the injectors, see the

relevant work description in section 03-01.

Cylinder configuration, 6
cylinder engines

Adjust based on the table below according to whether the reading is taken from the lower
or the upper window.
It is a good idea to mark the rocker arm with a pen after adjustment to keep track of what
has already been adjusted.

7/5/2010 © Scania CV 9 of 13
 Chassis serial number: 5237861

Reading in the lower window of the flywheel housing:

Mark on flywheel. Valve Adjust Adjust PDE Adjust HPI

transition on valves on injectors injectors
cylinder cylinder

TDC Down 1 6 2 3

120° 5 2 4 6

240° 3 4 1 2

TDC Down 6 1 5 4

120° 2 5 3 1

240° 4 3 6 5

Reading from the upper window of the flywheel housing:

Mark on flywheel. Valve Adjust Adjust PDE Adjust HPI

transition on valves on injectors injectors
cylinder cylinder

TDC Up 1 6 2 3

300° 5 2 4 6

60° 3 4 1 2

TDC Up 6 1 5 4

300° 2 5 3 1

60° 4 3 6 5

7/5/2010 © Scania CV 10 of 13
 Chassis serial number: 5237861

Order of adjustment for 16 litre engines with PDE or XPI

Check and adjust the valve clearance with the engine cold. The intake valve clearance
should be 0.45 mm and the exhaust valve clearance 0.70 mm.
Rotate the flywheel in the normal direction of rotation using turning tool 99 309. Read the
mark on the flywheel visible in the lower window of the flywheel housing.
Note: Valve transition occurs when the
cylinder switches from exhaust stroke to intake
stroke. The exhaust valve is closing while the
intake valve is opening.

Note: For adjusting the injectors, see the

relevant work description in section 03-01.

Cylinder configuration, 8
cylinder engines

Adjust valves and injectors on 16 litre engines with PDE following the table below.

7/5/2010 © Scania CV 11 of 13
 Chassis serial number: 5237861

Mark on
Adjust Adjust
flywheel. Valve Adjust
intake exhaust
Reading in transition injector on
valve on valve on
the lower on cylinder cylinder
cylinder cylinder
window

TDC Down 6 4 and 5 7 and 8 4 and 5

(0°)

TDC Up (180°) 7 2 and 6 1 and 5 2 and 6

TDC Down 1 3 and 7 2 and 4 3 and 7

(360°)

TDC Up (540°) 4 1 and 8 3 and 6 1 and 8

It is a good idea to mark the rocker arm with a pen after adjustment to keep track of what
has already been adjusted.
Adjust valves on 16 litre engines with XPI following the table below.

Adjust
Mark on
Valve intake Adjust
flywheel.
transition valve exhaust valve
Reading in the
on cylinder on on cylinder
lower window
cylinder

TDC Down (0°) 6 7 and 8 4 and 5

TDC Up (180°) 7 1 and 5 2 and 6

TDC Down (360°) 1 2 and 4 3 and 7

TDC Up (540°) 4 3 and 6 1 and 8

7/5/2010 © Scania CV 12 of 13
 Chassis serial number: 5237861

It is a good idea to mark the rocker arm with a pen after adjustment to keep track of what
has already been adjusted.
Alternate adjustment table

5 1 5 1
A B
6 2 6 2

7 3 7 3

8 4 8 4

5 1 5 1
C D
6 2 6 2

7 3 7 3

8 4 8 4

7/5/2010 © Scania CV 13 of 13