01:03-02

Issue 6 en

Work Description - 12 Engine

Industrial & Marine Engines

Part no.
1 588 557 © Scania CV AB, Sweden, 2003-05:6
 Use a container to avoid spills when draining the
coolant and oil.
Dispose of used coolant and oil through an
authorised waste disposal contractor.

Contents
Complete engine . . . . . . . . . . . . . . . . . . . . . . . . . 3 Machining cylinder liner height. . . . . . . . . . . 48
Removing the engine . . . . . . . . . . . . . . . . . . . . 4 Fitting the cylinder liners . . . . . . . . . . . . . . . . 52
Fitting the engine . . . . . . . . . . . . . . . . . . . . . . . 5 Fitting the piston and connecting rod. . . . . . . 53
Mounting the engine in a universal stand . . . . 6 Flywheel and flywheel housing . . . . . . . . . . . . 55
Cylinder head . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Removing the flywheel . . . . . . . . . . . . . . . . . 56
Valve clearances (engines with injection pump)9 Removing the flywheel housing . . . . . . . . . . 58
Adjusting the valve clearance and unit injectors Fitting the flywheel housing . . . . . . . . . . . . . 59
(engines with PDE unit injector) . . . . . . . . . . 10 Fitting the flywheel . . . . . . . . . . . . . . . . . . . . 61
Compression . . . . . . . . . . . . . . . . . . . . . . . . . 14 Timing gear. . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
Removing the cylinder head (engines with Gearwheel timing gear . . . . . . . . . . . . . . . . . . . 64
injection pump) . . . . . . . . . . . . . . . . . . . . . . . 16 Intermediate gear . . . . . . . . . . . . . . . . . . . . . . 64
Removing the cylinder head (engines with Camshaft gear . . . . . . . . . . . . . . . . . . . . . . . . 67
PDE unit injector) . . . . . . . . . . . . . . . . . . . . . 17
Crankshaft gear . . . . . . . . . . . . . . . . . . . . . . . 68
Dismantling . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Camshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
Renewing the valve stem seal . . . . . . . . . . . . 21
Renewing the camshaft bearing . . . . . . . . . . . 70
Renewing the valve seats . . . . . . . . . . . . . . . . 22
Crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
Machining the valve seat insert . . . . . . . . . . . 23
Cylinder block . . . . . . . . . . . . . . . . . . . . . . . . 79
Renewing the valve guides . . . . . . . . . . . . . . 25
Belt transmission. . . . . . . . . . . . . . . . . . . . . . . . 82
Renewing injector sleeves (engines with
injection pump) . . . . . . . . . . . . . . . . . . . . . . . 26 Renewing the seal in the front cover . . . . . . . . 83
Renewing PDE unit injector sleeves . . . . . . . 28 Lubrication system . . . . . . . . . . . . . . . . . . . . . . 84
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29 Oil cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
Fitting (all engines) . . . . . . . . . . . . . . . . . . . . 29 Oil cleaner . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
Turbocharger. . . . . . . . . . . . . . . . . . . . . . . . . . . 32 Oil pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33 Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . 91
Measuring the radial and axial clearance. . . . 35 General information . . . . . . . . . . . . . . . . . . . . 91
If the turbocharger does not work . . . . . . . . . 36 Cylinder head . . . . . . . . . . . . . . . . . . . . . . . . . 92
Renewing the turbocharger . . . . . . . . . . . . . . 37 Valve clearances and unit injectors . . . . . . . . 93
Pistons and cylinder liners . . . . . . . . . . . . . . . . 38 Turbocharger . . . . . . . . . . . . . . . . . . . . . . . . . 94
Removing the scraper ring in the liner Pistons and cylinder liners . . . . . . . . . . . . . . . 94
(engines with injection pump) . . . . . . . . . . . . 40 Flywheel and flywheel housing . . . . . . . . . . . 95
Removing and dismantling connecting rods and Timing gear . . . . . . . . . . . . . . . . . . . . . . . . . . 96
pistons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40 Lubrication system. . . . . . . . . . . . . . . . . . . . . 97
Checking connecting rods . . . . . . . . . . . . . . . 42 Special tools . . . . . . . . . . . . . . . . . . . . . . . . . . . 98
Renewal of bearing bushing in connecting rod43
Assembling the piston and connecting rod . . 45
Removing the cylinder liners . . . . . . . . . . . . . 46
Measuring the cylinder liner height . . . . . . . . 47

2 © Scania CV AB, Sweden, 2003-05:6 01:03-02

Complete engine

General
DI, DC12 engine with injection pump DI, DC12 engine with EMS

1
1
2

3
1. Instruction plate: Valve clearance 3. Engine number, stamped
2. Type plate: Engine type, Engine number

Special tool
Number Designation Illustration Tool board
99 318 Engine support
98 094 Lifting chain

587 308 Lever block

01:03-02 © Scania CV AB, Sweden, 2003-05:6 3

Removing the engine
1. Drain the oil and coolant.
2. Remove the air filter and the inlet pipe
between the turbocharger and the air filter.
Cover the turbo inlet.
3. Undo the connections for coolant, charge air
pipes between engine and charge air cooler,
and ventilation line to the expansion tank.
4. Remove the cables with cable clamps.

Note The engine lifting eyes are sized for

lifting the engine only, not the
engine together with connected
equipment (high-current generator,
gearbox, reverse gear, etc.) or
frame. All three lifting eyes must be
used.

5. Fasten the lifting chain 98 094 to the rear lift-

ing eyes.
6. Fasten the lever block 587 308 to the front
lifting eye.

Note The lifting eyes are dimensioned for

a maximum inclination angle of 20°
when lifting the engine.

7. Undo all the engine brackets and lift

away/out the engine.

4 © Scania CV AB, Sweden, 2003-05:6 01:03-02

Fitting the engine

Note The engine lifting eyes are sized for

lifting the engine only, not the
engine together with connected
equipment (high-current generator,
gearbox, reverse gear, etc.) or
frame. All three lifting eyes must be
used.

Note The lifting eyes are dimensioned for

a maximum inclination angle of 20°
when lifting the engine.

1. Fasten the lifting chain 98 094 to the rear

lifting eyes.
2. Fasten the lever block 587 308 to the front
lifting eye.
3. Lift the engine in position and bolt it to the
front engine suspension.
4. Connect the wiring with clamps.
5. Fit the connections for coolant, charge air
pipes between engine and charge air cooler,
and ventilation line to the expansion tank.
6. Fit the air filter and the inlet pipe between the
turbocharger and the air filter.
7. Fill with oil and coolant as directed in book-
let 00:03-01.
8. Test run the engine to check that no leakage
occurs. Top up with coolant if necessary.

01:03-02 © Scania CV AB, Sweden, 2003-05-6 5

Mounting the engine in a universal stand

Special tools
Number Designation Illustration Tool board
99 331 Fixture

587 692 Universal stand

Engines with injection pump

Remove:
- Fuel filter
- Injection pump
- Starter motor
- Brackets as necessary

Engines with unit injectors PDE

Remove:
- Fuel filter
- Control unit
- Compressor
- Starter motor
- Brackets as necessary

Attach the engine to the universal stand in

accordance with the picture with tool 99 331.
1. Screw M10x30 (8 st), Torque 47 Nm.
2. Nut M16 (4 st), Torque 180 Nm.
3. Screw M16x50 (4 st).

6 © Scania CV AB, Sweden, 2003-05:6 01:03-02

 Cylinder head

1. Valve bridge 16. Shaft 29. Pin

2. Pin 17. Bearing bracket 30. Rivet plug
3. Bolt 18. Rocker arm for unit 31. Gasket
4. Collet injector 32. Exhaust valve
5. Valve spring collar 19. Adjusting screw 33. Valve seat insert
6. Valve spring 20. Hexagon nut 34. Intake valve
7. Valve spring 21. Rocker arm 35. Flange bolt
8. Valve stem seal 22. Spacing sleeve (injection 36. Flange bolt
9. Valve guide pump) 37. Rocker cover, upper section
10. Socket 23. Adjusting screw 38. Rocker cover gasket
11. Collet 24. Hexagon nut 39. Rocker cover, lower section
12. Valve spring collar 25. Rocker arm 40. Rocker cover gasket
13. Valve spring 26. Core plug
14. Rivet plug 27. Unit injector
15. Tight-fit screw 28. Cylinder head

01:03-02 © Scania CV AB, Sweden, 2003-05:6 7

 Special tools

87 596 Slide hammer 99 381 Drift

98 249 Compression tester 99 382 Drift
99 074 Impact drift 99 383 Drift
99 079 Extractor for injectors 99 384 Drift
99 308 Sleeve for injectors 99 385 Handle
99 309 Tool for turning flywheel 99 394 Guide
99 310 Socket 99 414 Setting tool
99 322 Press drift 99 442 Setting tool
99 323 Assembly drift 587 277 Valve seat cutter
588 221 Pilot tap

8 © Scania CV AB, Sweden, 2003-05:6 01:03-02

Valve clearances (engines with injection pump)

Checks and adjustments

Check the valve clearance. 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.
The following alternative methods of adjustment
are possible:
I. 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

J. Put cylinder 1 at exact TDC after the

compression stroke. The following valves can
now be adjusted: 1 2 3 4 5 6

01 1393
cyl. 1 intake and exhaust
cyl. 2 intake
O Intake valve
⊗ Exhaust valve
cyl. 3 exhaust
cyl. 4 intake
cyl. 5 exhaust

Turn the crankshaft precisely one revolution

so that TDC for No. 6 cylinder is set. The 1 2 3 4 5 6

remaining valves can now be adjusted:

01 1394

cyl. 2 exhaust
cyl. 3 intake O Intake valve
⊗ Exhaust valve
cyl. 4 exhaust
cyl. 5 intake
cyl. 6 exhaust and intake

01:03-02 © Scania CV AB, Sweden, 2003-05:6 9

Adjusting the valve clearance and unit injectors
(engines with PDE unit injector)

Note: Check and adjust the valve

clearance and unit injectors at the
same time and with the engine cold.

Checking and adjusting the valve

clearance
1. Turn the flywheel (counterclockwise) with
tool 99 309 so that the marks on the flywheel
can be seen in the lower opening in the fly-
wheel casing. See table on next page for
order of adjustment.
2. Check the valve clearance using a feeler
gauge and, if necessary, use the adjusting
screw on the rocker arm to set the correct
clearance. 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. The intake valves are actuated
by the short rocker arms and the exhaust
valves by the long rocker arms. Make sure
the valve bridge is resting correctly against
the valves.
3. Adjust the unit injectors in accordance with
adjustment order in the table and Adjusting
unit injectors.
4. If reading cannot be performed from under-
neath but only in the upper opening: Start
with the TDC Up position and turn the fly-
wheel counterclockwise 120° (1/3 turn) at a
time, observe the valve change and adjust in
accordance with the table.
Important The flywheel marking is only correct
if the reading is taken through the lower
opening.

10 © Scania CV AB, Sweden, 2003-05:6 01:03-02

Order of adjustment:

Adjust
Mark on flywheel Valve Adjust injector
(reading from change on valves on rocker arm
underneath) cylinder cylinder on cylin-
der

TDC Down (0°) 1 6 2

120° 5 2 4

240° 3 4 1

TDC Down (0°) 6 1 5

480° 2 5 3

600° 4 3 6

Adjusting unit injectors, PDE31 and

PDE32

Important! The PDE31 unit injector is adjusted

using setting tool 99 414 or a digital sliding
caliper.
The PDE32 unit injector is adjusted using
setting tool 99 442 or a digital sliding
caliper.
This adjustment is important because an
incorrectly positioned unit injector may
result in poor performance and possible
breakdown.

Screw on the rocker arm adjusting screw 1 while

measuring the distance between plane a and the
top of the valve spring collar using a digital
sliding caliper.
The dimension should be 66.9 mm for PDE31 and Dimension A = PDE31: 66.9 +/- 0.1 mm
69.9 mm for PDE32.
PDE32: 69.9 +/- 0.1 mm
See dimension B in the figure for identifying the
injector. Dimension B = PDE31: 36.5 mm
PDE32: 38.8 mm

01:03-02 © Scania CV AB, Sweden, 2003-05:6 11

 ! WARNING!

Take care when carrying out the

adjustment if the dimension is well
outside the adjustment dimension. The
spring is pre-tensioned and can cause
personal injury if it is released.

PDE31
1. Position setting tool 99 414 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 99 414 is not available: Measure the
distance between plane a and the top of the
valve spring collar using a digital sliding cal-
iper. Adjust the rocker position by means of
the adjusting screw until the dimension is
66.9 +/- 0.1 mm.
4. Tighten the lock nut to 39 Nm.
5. See Order of adjustment on page 6 for check-
ing/adjusting the injector rockers.

Piston above or below the flat

surface. Adjustment necessary.

Piston level with the flat surface.

Adjustment is correct.

12 © Scania CV AB, Sweden, 2003-05:6 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 cal-
iper. 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 check-
ing/adjusting the injector rockers.

Piston above or below the flat

surface. Adjustment necessary.

Piston level with the flat surface.

Adjustment is correct.

01:03-02 © Scania CV AB, Sweden, 2003-05:6 13

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.

The results are only intended for comparison

between the cylinders. Lower compression in one
or more of the cylinders is a sign of abnormal
wear or damage.
Compression tester 98 249

1. Manometer
The compression tester may be used on many 2. Reset valve
engine types by using various accessories. 3. Flexible metal hose
4. Gauge rod
Important! The battery must have an adequate 5. End sleeve diameter 21 mm
voltage level in order to carry out a reliable 6. Spacing sleeve with support lug
compression test.
7. Spacing sleeve with shoulder
8. Spacing sleeve, length 6 mm
9. Spacing sleeve, length 19 mm
10. Spacing sleeve, length 25 mm
1. Cut off the supply of fuel by disconnecting 11. Spacing sleeve, length 38 mm
the power source. 12. Cap nut
13. Threaded socket nut
2. Clean around the injectors. Detach the deliv-
ery pipes to all injectors using tool 99 310. 14. Large yoke
15. Small yoke
Note: Fit protection caps on the delivery
valve holders in the injection pump
and on the injectors to protect them
from dirt.

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.

14 © Scania CV AB, Sweden, 2003-05:6 01:03-02

 6. Connect the compression tester in the injec-
tion aperture in one of the cylinders. Copper
washer 16 should be used between the com-
pression tester and the bottom of the injector
aperture.
7. Turn the engine with the starter motor and
read off the manometer. Note the reading.
8. Reset the manometer by pressing reset button
2. 4. Gauge rod
5. End sleeve diameter 21 mm
9. Move the compression tester to the next cyl-
inder and continue according to items 5-8. 7. Spacing sleeve with shoulder
10. Spacing sleeve, L = 25 mm
10. Evaluate the readings and assess what further 12. Cap nut (use socket
measures need to be taken on the engine. If
98 542 for tightening)
one or more cylinders have a lower compres-
sion pressure, the components such as valves, 16. Copper washer
cylinder liners and piston rings should be
checked.

Cleaning the gauge rod

Gauge rod 4 has a check valve which, in the case
of leakage, should be cleaned as follows:
1. Unscrew valve seat 18.
2. Remove any soot from valve 17 and valve
seat 18. Do not scratch the mating surfaces.
Use compressed air to clean gauge rod 4
internally.
3. Reassemble the parts. Ensure that O-ring 19
is not damaged. Bolt valve seat 18 securely 4. Gauge rod
so that it seals against gauge rod 4. 17. Valve
18. Valve seat
19. O-ring

01:03-02 © Scania CV AB, Sweden, 2003-05:6 15

Removing the cylinder head (engines with injection pump)

1. Drain coolant from engine and, if applicable,

from charge air circuit.
2. DI12: Detach the inlets and outlets for air and
water from the charge air cooler and unbolt
the charge air cooler. DC12: Remove the
intake pipe clamps from the intake manifold.
3. Remove the intake manifold and turbo-
charger.
4. Remove the heat shields and exhaust mani-
fold.
5. Detach the delivery pipes using tool 99 310
and remove them.
6. Insert protection plugs in the ends of the
delivery pipes and place protection caps on
the injectors and injection pump.
7. Remove the ventilation pipe for the cooling
system.

Note: All the valve mechanism

components must be refitted in
their original positions. Therefore,
mark the parts as they are removed.

8. Remove the top part of the rocker cover. Be

careful not to drop any parts into the engine.
9. Remove the shaft, rocker arms, bearing
bracket, valve bridges and pushrods.
10. Remove the lower part of the rocker cover. 99 074
11. Undo the injector nut using socket 99 308.
12. Extract the injectors using tools 99 074 and 99 079
99 079.
13. Remove the cylinder head bolts and lift off
the cylinder head. Mark the cylinder heads if
more than one are removed at the same time.
14. Cover the engine to keep out all extraneous
objects, etc.
01 1346

16 © Scania CV AB, Sweden, 2003-05:6 01:03-02

Removing the cylinder head (engines with PDE unit injector)

1. Open the bleeder nipple and drain the fuel

system by undoing the banjo screw on the
back of the fuel manifold.

! WARNING!

The fuel system must be empty or fuel

may run down into the cylinders, which
will result in a great risk of liquid
hammering. If fuel runs into the
combustion chamber, it must be removed 1. Bleeder nipple
immediately using a pump. 2. Banjo screw

2. Clean the rocker cover and the surrounding

area.
3. Remove the top part of the rocker cover.

4. Relieve the pressure on the valves by undo-

ing the bolts on the rocker arm shaft alter-
nately.

01:03-02 © Scania CV AB, Sweden, 2003-05:6 17

 ! WARNING!

Do not lean over the engine when

removing the rocker arm shaft. The unit
injector spring is pre-tensioned and can
come loose, causing personal injury.

Note: If the spring comes loose from the

unit injector, the unit injector must
be renewed.

5. Remove the rocker arm shaft.

6. Remove the bearing bracket.
7. Remove the pushrods.

Note: The pushrod for the unit injector is

secured with a retaining ring. Jiggle
and pull carefully on the pushrod to
loosen it.

8. Remove the valve bridges.

9. Remove the lower rocker cover.

18 © Scania CV AB, Sweden, 2003-05:6 01:03-02

10. Remove the fork clamp bolt holding the unit
injector in place.

1. Fork clamp
2. Fork clamp bolt
3. Unit injector

11. Detach the cables on the unit injector. The

screws cannot be removed but undo them as
far as possible.

Note: Do not lift the unit injector by the

spring. The spring can come loose.

12. Turn the unit injector anti-clockwise until it

stops. Place the slide hammer 87 596
between the solenoid valve and the edge of
the lower rocker cover as illustrated.

Note: If the slide hammer is placed

directly under the solenoid valve,
there is a risk of breaking the
solenoid valve.

Place the slide hammer as indicated by the

arrow.

01:03-02 © Scania CV AB, Sweden, 2003-05:6 19

13. It is easier to position the slide hammer if one
of the lower rocker cover bolts is removed.

14. Withdraw the unit injector. If the unit injector

is stuck, tap carefully with a rubber mallet on
the solenoid valve housing.

Important! The unit injector is not to be

dismantled. Renew the entire unit.

15. Remove the sealing washer from the bottom

of the injector seat, (if it was left behind
when the unit injector was removed).
16. Detach the intake manifold, fuel manifold,
ventilation pipe for the cooling system and
the exhaust manifold.
17. Remove the cylinder head. Mark the cylinder
heads if more than one is being removed at
the same time.

20 © Scania CV AB, Sweden, 2003-05:6 01:03-02

Dismantling
1. Remove collets, valve spring collars, springs
and valves. Press down the spring using tool
99 322 in a press so that the collets can be
removed.
2. Mark and 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 are
removed at the same time.

Renewing the valve stem seal

1. Remove the valve.
2. Remove the valve stem seal with a pair of pli-
ers.

3. Fit the valve.

4. Tap in a new valve stem seal carefully using
tool 99 323 and a hammer.

01:03-02 © Scania CV AB, Sweden, 2003-05:6 21

Renewing the valve seats
1. Remove the valve seat inserts. Use a
discarded valve that has been ground so
that the diameter of the disc is slightly
smaller than the inside diameter of the seat.
2. Fit the valve and weld around it with an
electric welder. Cool with water. Turn over
the cylinder head and knock the valve stem
so that the valve and seat insert fall out.

! WARNING!

Wear protective goggles. Always turn

the cylinder head with the underside
face down while knocking out the valve
seat insert. Otherwise, there is a risk
that loose shivers of metal can cause
personal injury.

3. Press in new valve seat inserts. Use drift

99 384 and handle 99 385. Cool the drift
and valve seat to approximately -80°C in
dry ice or using liquid air. Pressing must be
carried out rapidly.

! WARNING!

Be careful with the above-mentioned

coolants and cooled components.
There is a risk of frost injuries.

Oversize valve seat inserts can be fitted if the

valve seat insert position has been damaged.
If this is the case, the seat must be machined
using valve seat cutter 587 277.

22 © Scania CV AB, Sweden, 2003-05:6 01:03-02

Machining the valve seat insert

Machining values

Intake valve Exhaust valve

A = 1.9 - 2.6 mm A = 1.8 - 2.6 mm
B = 0.75 - 1.8 mm B = 0.66 - 1.8 mm
C = diameter, 39.8 +/- 0.5 mm (setting value C = diameter, 37.9 +/- 0.5 mm (setting value
for machining tool) for machining tool)

Work description
The following description applies to valve seat
cutter 587 277.
Machining values and over-sized valve seat
inserts, see Specifications and above.
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 eas-
ily into the valve guide.Insert the guide
spindle and turn the feed screw to its upper-
most position.

01:03-02 © Scania CV AB, Sweden, 2003-05:6 23

 3. Select and fit the cutter.

4. Release the quick-action lock and move the

pivot plate to the upper position with the
adjusting screw.

5. Set up the dial on the cutter adjuster using a

valve.
6. Adjust the cutter. Diameter 37.9 mm or
39.8 mm, see Machining values.
7. Disconnect the magnetic base (position 2).
Insert the guide spindle into the valve bush-
ing. Adjust the pivot plate so that the distance
between the cutter and the valve seat is
approximately 1 mm.
Centre the tool precisely.
8. Connect the magnetic base (position 1).
9. Apply the quick-action lock. Make sure the
crank can be turned easily. If not, redo the
centering.

24 © Scania CV AB, Sweden, 2003-05:6 01:03-02

10. Machine the valve seat by cranking clock-
wise while turning the feed screw. Never
crank counterclockwise, as this could dam-
age the cutter. Lubricate with cutting oil dur-
ing the procedure.
11. When the machining of the valve seat is com-
pleted, reduce the cutting pressure by turning
the crank 2-3 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.

Renewing the 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, i.e. until it makes contact with
the spring seat in the cylinder head.

01:03-02 © Scania CV AB, Sweden, 2003-05:6 25

Renewing injector sleeves (engines with injection pump)

- The cylinder head must be removed when

renewing the injector sleeve.
- The valves do not need to be removed.
- The illustration shows the cylinder head with
valves removed to demonstrate clearly the
work described.

Important! Mark the position of the groove on

the cylinder head sleeve according to the
illustration. The new sleeve must sit in the
same position to ensure that the oil leakage /
return ducts are not blocked.

1. Thread the bottom part of the sleeve using

pilot tap 588 221 and guide 99 394.

2. Knock out the pilot tap and sleeve from

underneath. Use a 100 mm metal rod with a
9 mm diameter.

26 © Scania CV AB, Sweden, 2003-05:6 01:03-02

 3. Degrease and check the contact surfaces of
the sleeve and cylinder head. Smooth off any
burrs and irregularities that may score the
sleeve.
4. Degrease the new injector sleeve and apply a
thin film of sealing agent 561 200 on the
sleeve and cylinder head contact surfaces.
5. Drive in the sleeve using drift 99 381.

Important! Ensure that the groove in the sleeve

is located according to the marking.

01:03-02 © Scania CV AB, Sweden, 2003-05:6 27

Renewing PDE unit injector sleeves

- The cylinder head must be removed when

renewing the injector sleeve.
- The valves do not need to be removed.
- The illustration shows the cylinder head with
valves removed to demonstrate clearly the
work described.
1. Thread the bottom part of the sleeve with
pilot tap 588 221 and guide 99 394.

2. Knock out the pilot tap and sleeve from

underneath. Use a 100 mm metal rod with a
9 mm diameter.
3. Degrease and check the contact surfaces of
the sleeve and cylinder head. Smooth off any
burrs and irregularities that may score the
sleeve.
4. Degrease the new injector sleeve and apply a
thin film of sealing agent 561 200 on the
sleeve and cylinder head contact surfaces.

5. Press in the sleeve with drift 99 395 and

guide 99 394.

28 © Scania CV AB, Sweden, 2003-05:6 01:03-02

Assembly
1. Lubricate all parts well with engine oil
before assembly.
2. Fit the valves in the their guides and posi-
tion the cylinder head in a press.
3. Fit the valve springs and the valve spring
collars.
4. Compress the springs using tool 99 322 and
fit the collets, making sure that they go into
their correct positions.
5. Lubricate the threads on the cylinder head
bolts and the surface under the head.

Fitting (all engines)

1. Check liner height, refer to Measuring the
cylinder liner height.
2. Fit a new cylinder head gasket.
3. Fit the cylinder head and ensure that the
guide pins fit into the holes.
4. The cylinder head bolts can be reused up to
3 times. Therefore, make sure the bolts
have no more than 2 punch marks on top of
the bolt head. If any of the bolts has 3
marks, it must be replaced with a new one.

6. Tighten the bolts in the order given in the

figure and in four stages as follows:
• 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°
• Make a mark with a centre punch on the
head of the bolt.
01_1352

01:03-02 © Scania CV AB, Sweden, 2003-05:6 29

 7. Fit the lower part of the rocker cover and
tighten the bolts to 26 Nm.

Engines with injection pump:

8. Fit the injector with a new seal and new
O-rings lubricated with assembly compound
815 368.

Important! Always fit new O-rings to injectors

that have been removed.

100036
9. Use tool 99 308 and tighten it to 70 Nm.

10. Fit the valve bridges, pushrods, bearing 70 Nm

bracket and shaft with rocker arms and
tighten the bolts to 105 Nm.
99 308
11. Check the valve clearances when all cylinder
heads are in place. Refer to Valve clearance.

01_1351
12. Fit the upper part of the rocker cover and
tighten the bolts to 26 Nm.

30 © Scania CV AB, Sweden, 2003-05:6 01:03-02

Engines with PDE unit injector:
1. Fit the unit injector according to the section
Fitting the unit injector, steps 1-5 in booklet
03:04-02.
2. Fit the pushrods.
3. Fit the bearing bracket and torque tighten the
bolts to 105 Nm.
4. Fit the valve bridges.

Important! Lubricate the valve bridges with

engine oil.

5. Continue according to the section Fitting the

unit injector steps 6-11 in booklet 03:04-02.

All engines:
1. Fit the exhaust manifold and turbocharger
with oil lines. Tighten the nuts and bolts to
59 Nm. Fit the heat shields.
2. Fit the cooling system ventilation pipe.
3. DC12: Fit the intake manifold.
4. Fit the delivery pipes and tighten the nuts
using tool 99 310 to 20 Nm. Refit the deliv-
ery pipe clamps.
5. DI12: Fit the intake manifold and charge air
cooler and attach the intake and outlet pipes.
Tighten the bolts to 26 Nm. Refer to booklet
02:01-02 or 02:02-02 for a full description of
how to fit the charge air cooler.
6. Clamp the delivery pipes to the rear part of
the charge air cooler.

01:03-02 © Scania CV AB, Sweden, 2003-05:6 31

 Turbocharger
Special tools

98 075 Dial gauge

587 025 Filter wrench
587 107 Deflection gauge
587 250 Stand

DI12 DC12

1. Lubrication oil pipe 11. Turbocharger 1. Lubrication oil pipe 11. Hose
10. Bolt clamp
2. Union nut 12. Hose 2.
2. Ferrule
Ferrule 11. Bracket
12. Bolt
3. Ferrule 13. Hose clamp 3.
3. Union nut
Union nut 13. Bolt
12. Bracket
4. Straight union 14. Clamp 4.
4. Straight union
Straight union 13. Clamp
14. Bolt
5. Seal 15. Bushing 5.
5. Seal
Seal 14. Clamp
15. Clamp
6. Straight union 16. Bolt 6.
6. Straight union
Straight union 15. Bolt
16. Clamp
7. Gasket 17. Clamp 7.
7. Gasket
Gasket 16. Gasket
17. Bolt
8. Lubrication oil return 18. Clamp 8.
8. Lubrication oil
Lubrication oil return
return 18. Turbocharger
17. Gasket
pipe 19. Bolt pipe
pipe 18. Turbocharger
9. Gasket 20. Nut 9. Hose
9. Hose
10. Bolt 10. Hose clamp

32 © Scania CV AB, Sweden, 2003-05:6 01:03-02

General
Note: Observe strict cleanliness at all
times when working on the
turbocharger. The oil intake and
outlet connections must never be
left open. Foreign bodies in the
bearing housing will soon lead to
total breakdown.

Oil leaks
A blocked air cleaner will cause excessive
vacuum in the intake pipe. There is then a risk that
oil mist will be sucked out of the turbocharger
bearing housing.
If the sealing ring on the turbine side is worn, the
exhaust gases will be blue when idling.
If the oil drain tube from the turbo charger is
damaged, the lubrication oil pressure may cause
oil to leak out through the seals.

Oil filter
The turbocharger rotates at high speed, sometimes
above 100,000 rpm.
The oil lubricates and cools the turbocharger. It is
vital that the lubrication functions properly. There
is no separate turbo filter; the oil is cleaned by the
engine oil filter. For this reason, change the oil
filter and clean the lubrication oil cleaner in
accordance with our instructions.
Use filter wrench 587 025 when removing the oil
filter.

Removing the oil filter

01:03-02 © Scania CV AB, Sweden, 2003-05:6 33

If the lubrication oil cleaner is not cleaned, the oil Air and exhaust leaks
filter will quickly block up and the flow resistance
in the filter increase. Even a minute leakage in the pipe between the air
cleaner and the turbo compressor will cause
If this happens, a valve in the filter retainer opens deposits of dirt on the compressor wheel.
and lets the oil pass the filter without being
filtered. Unfiltered oil is consequently supplied to The charging pressure will decrease, resulting in
the turbocharger with heavy bearing wear as a increased exhaust temperature and smoke. In
result. addition, it will lead to excessive wear of the
engine.
The valve is designed to fit original Scania filters,
and only these filters should be used. Exhaust leaks between the cylinder head and the
turbocompressor also cause a lower charge
pressure.

Foreign bodies Cleaning the compressor wheel

Foreign bodies in the turbine or compressor, e.g. a Low charging pressure could, for example, be
grain of sand or metal shavings, will ruin the caused by a dirty compressor wheel.
vanes. - Remove the compressor cover.
This will lead to imbalance and bearing wear. The
power output of the engine decreases, and if the - Clean the compressor wheel with white spirit
engine is still run the reduced air supply may and a brush.
cause the engine to overheat, resulting in engine - Fit the compressor cover and measure the
damage. charging pressure again.
This type of overheating does not show on the
coolant temperature gauge. Note: The compressor wheel must not be
removed from the shaft. Imbalance
Note: Never attempt to straighten a may occur when it is refitted.
damaged vane. It is then often
broken during operation causing
the turbo to break down completely,
which also can damage the engine.
Renew the entire turbocharger.

34 © Scania CV AB, Sweden, 2003-05:6 01:03-02

Measuring the radial and axial
clearance
In general, measuring the radial and axial
clearance gives no indication of the remaining
service life of the turbocharger.
When the turbocharger seems to be functioning
poorly or noisily, measuring the charging
pressure or radial and axial clearance can indicate
whether the turbocharger is at fault.
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 the turbine and compressor
wheels.
1. Place the tip of the dial gauge against the
turbine / compressor wheel.

2. Pull up both ends of the shaft. Take a read-

ing. Measuring turbine wheel radial clearance.

3. Press down both ends of the shaft. Take a

reading. The difference between the readings
is the radial clearance.

4. Repeat the test three times on each side.

5. If any of the wheels makes contact with the

housing despite the radial clearance being
within tolerances, the turbocharger must be
renewed.
Measuring compressor wheel
radial clearance

01:03-02 © Scania CV AB, Sweden, 2003-05:6 35

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 differ-
ence between the readings is the axial clear-
ance
3. Repeat the test three times.

Wear limits for Holset:

Measuring the axial clearance
Radial clearance................... 0.198-0.564 mm
Axial clearance
(after running in).................. 0.025-0.106 mm

If the turbocharger does not work

1. Check that there is no leakage or loose 7. Check that the air filter is not blocked and
objects in the line between the air cleaner and that there are no other reasons for the abnor-
turbocharger. mal increase of vacuum in the intake system.
2. Check that there are no loose particles in the 8. Check that engine output is correct. Exces-
exhaust or intake manifolds. sively high output reduces the service life of
the turbocharger.
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 turbo-
charger for any blockage, deformation and
leakage under pressure.
6. Check the condition and part number of the
oil filter.

36 © Scania CV AB, Sweden, 2003-05:6 01:03-02

Renewing the turbocharger

Note: When renewing the turbocharger,

all gaskets and the oil filter must be
changed and the centrifugal cleaner
must be cleaned.

Removal
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. Undo the bolts in the turbocharger base and
remove the turbocharger.

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 turbo-
charger. Lubricate the exhaust manifold bolts
with high-temperature resistant lubricant,
part No. 561 205.
Tighten the turbocharger to 50 Nm and the
exhaust manifold to 59 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 turbo-
charger.
6. Start the engine and check that there is no
leakage.

01:03-02 © Scania CV AB, Sweden, 2003-05:6 37

 Pistons and cylinder liners

1. O-ring 11. Aluminium piston

2. Scraper ring 12. Gudgeon pin
3. Cylinder liner for steel piston 13. Circlip
4. Cylinder liner for aluminium piston14. Bearing bushing
5. O-ring 15. Connecting rod
6. Compression ring 16. Crankshaft
7. Compression ring 17. Bearing shell
8. Oil scraper ring 18. Bearing cap
9. Circlip 19. Flange bolt
10. Steel piston

38 © Scania CV AB, Sweden, 2003-05:6 01:03-02

 Special tools

87 198 Rule for dial gauge 99 168 Dismantling tool

87 362 Drift 99 380 Assembly tool
98 075 Dial gauge 587 110 Test apparatus for connecting
98 212 Piston ring compressor rods
98 515 Pressing tool 587 309 Piston ring expander
99 003 Hydraulic cylinder
99 066 Puller for cylinder liner
99 074 Impact drift

01:03-02 © Scania CV AB, Sweden, 2003-05:6 39

Removing the scraper ring in the liner (engines with injection pump)

If the scraper 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 bot-
tom dead centre.
3. Fit tension lugs 98 515 on the edge of the cyl-
inder 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 scraper 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 pis-
ton ring pressed into the liner.
9. Drive out the scraper 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 in the cyl-
inder block.

Note: The piston cooling nozzle must not

be damaged. The oil jet must hit the
piston precisely. If it does not, the
piston will become too warm
resulting in engine breakdown.
Damaged nozzles must not be
straightened. They must be
renewed.

40 © Scania CV AB, Sweden, 2003-05:6 01:03-02

 3. Remove the bearing cap and bearing shells.
Protect the oil way in the crankcase using,
e.g. adhesive tape, applied with the sticky
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. Place the connecting rod in a vice with soft

jaws. Remove the retaining rings for the
gudgeon pin.

7. 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 after they have been in use
for a while. 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.

01:03-02 © Scania CV AB, Sweden, 2003-05:6 41

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 indicator studs horizontal.

- Check whether the connecting rod is bent with

the indicator studs vertical.

- The distance between the indicator studs on the

tool illustrated here is 75 mm.
- The distance between one of the indicator studs
and the measuring surface must be max.
0.1 mm when measured using this tool.
- Check with a feeler gauge.
Checking if connecting rod is bent

- Also check whether the connecting rod is bent

into an S-shape. This is done by measuring the
distance between the outside of the connecting
rod bushing and the level surface of the tool.
- Turn the connecting rod around and measure
the corresponding distance.

Important! The difference must not exceed

0.6 mm.

Checking whether the connecting rod is

bent into an S-shape

42 © Scania CV AB, Sweden, 2003-05:6 01:03-02

Renewal of bearing bushing in
connecting rod
Use tool 99 403 when renewing the bearing
bushing.
The tool comprises three parts:
1. Pressplate with guide pin
2. Press drift
3. Supports
There are different supports, depending on the
engine type.
The support marked with a D should be used for
the 12-engine.

Important! Before carrying out this

procedure, the connecting rod should be
checked for straightness in accordance
with Checking connecting rods

Work description
1. Fit the correct support on the pressplate and
place the connecting rod so that the wide
end of the connecting rod is resting against
the support. Turn the press drift with the
smaller diameter against the bearing
bushing and press it out.

2. Turn over the press drift and mount a new

bearing bushing onto it. Press in the bearing
bushing.

01:03-02 © Scania CV AB, Sweden, 2003-05:6 43

 3. After pressing in a new bearing bushing, it
must be finish-turned. This requires special
equipment.
Refer to illustration for the dimensions
required.

Diameter, d = 54.030 - 54.043 mm

Surface quality = 0.6 Ra

44 © Scania CV AB, Sweden, 2003-05:6 01:03-02

Assembling the piston and
connecting rod
1. Clean the piston and its rings thoroughly
without scratching the sides of the ring
grooves. The oil holes in the piston should be
cleaned using a suitable drill.
2. Make sure the piston ring gaps do not exceed
the permitted limit.
Place the piston rings in the cylinder liner
and measure the gap using a feeler gauge.
For permitted gap, see section entitled Speci-
fications, piston rings.

3. Fit the piston rings using tool 587 309. The

oil scraper ring has an expander. Pistons
rings marked with TOP must be turned with
TOP face up.
4. Oil all the bushings, the gudgeon pin hole
and the gudgeon pin before assembling.
5. Place one of the retaining rings in the piston.

6. Turn the piston and connecting rod as illus-

trated. The arrow mark should point forward
on the engine.

7. Insert the gudgeon pin using tool 87 362 and

fit the second retaining ring for the gudgeon
pin.

01:03-02 © Scania CV AB, Sweden, 2003-05:6 45

Removing the cylinder liners
1. Mark the liners with the numbers 1-6. The
mark is necessary so that the liners can be
refitted in the same place and position as
previously.

Note: The mark must be made only on the

surface indicated in the illustration.
Other surfaces are for sealing.

2. Withdraw the cylinder liner using puller

99 066 and hydraulic cylinder 99 003. Fit
spacers under the support lugs to avoid dam-
aging the surface of the block.

3. Remove the sealing ring in the cylinder

block.

Cylinder liner extractor with hydraulic

cylinder

46 © Scania CV AB, Sweden, 2003-05:6 01:03-02

Measuring the cylinder liner height
1. Thoroughly clean the cylinder block liner
shelf, the face around the cylinder, the
cylinder liner shelf and the upper face of
the cylinder liner.
2. Fit the cylinder liner without sealing rings
and push down using two tension lugs
98 515. Tighten the bolts to 20 Nm.
Important The tension lug bolts must not be
tightened more than 20 Nm. Otherwise the
cylinder liner may be damaged.
3. Place straight edge 87 198 with dial gauge
98 075 on the liner and zero the dial gauge
to the liner (A). Slide the tip of the dial
gauge over to the cylinder block (B) and
measure the height of the liner (A-B) as
illustrated. Measure each liner at two dia-
metrically opposite points.
4. The cylinder liner must be slightly above
the face of the cylinder block.
5. The height of the cylinder liner D (=A-B)
above the block should be 0.15 – 0.30 mm.
6. The difference between two diametrically
opposite points on the same cylinder liner
may be max. 0.02 mm.

A = Measuring surface on cylinder liner

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

01:03-02 © Scania CV AB, Sweden, 2003-05:6 47

Machining cylinder liner height
If, during control measuring, the cylinder liner
does not reach the specified value the liner seat
must be machined.
Adjust the liner to the correct height using a shim.
Shims are available in thicknesses of 0.20 mm,
0.30 mm and 0.40 mm.
If the cylinder liner height should be increased
less than e.g. 0.20 mm, machine the bearing seat
until the liner height including shim is correct.
Important If a shim is used to adjust the liner
height, the cylinder liner height must always
be machined.

Tolerances for liner height

Lowest permissible cylinder liner height 0,15 mm

before machining

Permissible cylinder liner height on 0,20-0,30 mm

engines with machined liner seats

Desired measurement when machining 0,25 mm

Example of calculation of cutter depth

Height required 0,25 mm

Current cylinder liner height 0,14 mm

Increasing cylinder height (0.25-0.14) 0,11 mm

Shim thickness 0,2 mm

Material to be removed. (0,2-0,11) 0,09 mm

48 © Scania CV AB, Sweden, 2003-05:6 01:03-02

 1. Clean the contact surface between the center-
ing ring (which is included in the extension
kit) and the top plane of the cylinder block.

Note It is important for the surface to be

cleaned thoroughly otherwise the
cylinder liner seat may be cut to the
wrong depth or may be slanted.

2. Fit extension 588 672 on the cylinder liner

cutter 587 512.

3. Set the depth of the extension to 206 mm.

01:03-02 © Scania CV AB, Sweden, 2003-05-6 49

 4. Position the centering ring over the relevant
cylinder and then position the cylinder liner
cutter. Energize the magnet on the cylinder
liner cutter by setting the switch to position 1.

5. Check that the tool (cutter) does not touch the

edge of the liner seat when the cylinder liner
cutter is fitted in the centering ring. Other-
wise the vertical feed screw must be wound
up until the cutter is released from the liner
seat.

6. Lift the rapid feeder ring and move the cutter

by hand until it is positioned above the liner
seat surface without including the cylinder
block walls.

50 © Scania CV AB, Sweden, 2003-05:6 01:03-02

 7. Wind round and at the same time turn the
vertical feed screw clockwise until the cutter
just touches the liner seat.
8. Lift the rapid feed ring and move the cutter
back so that it is within the liner seat surface.

9. Adjust the vertical feed screw in order to start

machining. The maximum feed per cut is
0.05 mm. If 0.05 mm is not enough, several
cuts may be required until the required posi-
tion is reached.
10. Wind clockwise with an even movement.
Hold in the horizontal feed screw with the
other hand at the same time. The cutter will
be fed horizontally at 0.13 mm per turn.
Wind carefully when the cutter starts to
approach the outer edge of the liner seat.
Release the horizontal feed screw when the
cutter has gone over the edge so that feeding
stops.
Important Never wind the cylinder liner cutter
anti-clockwise, otherwise the cutter will
break.

01:03-02 © Scania CV AB, Sweden, 2003-05-6 51

Fitting the cylinder liners
1. Check cylinder liner height as described in
the section entitled Measuring the cylinder
liner height.
2. Make sure the interior 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 check the cylinder liners, both new

and old, for cracks which might have arisen
during transport or careless handling.
5. Tap the liner carefully with a metal object. It
should give a clear metallic ring if it is intact.
If it sounds cracked, renew it.

6. Lubricate the sealing ring to be fitted in the

cylinder block with engine oil and fit it in
place.
7. Lubricate the sealing ring to be fitted in the
cylinder liner with engine oil and fit it in
place.

8. Turn the liner with the stamped cylinder

number facing forward and carefully tap it
down with a rubber mallet.
9. Fit the scraper ring in place after the piston
has been fitted.

52 © Scania CV AB, Sweden, 2003-05:6 01:03-02

Fitting the piston and connecting rod

1. Lubricate the piston, piston rings, cylinder

liner and piston ring compressor with engine
oil.
2. Remove the protection on the connecting rod
journal and lubricate the journal.

3. Turn the piston rings so that the ring gaps are

evenly distributed round the piston.

4. Fit the upper connecting rod bearing shell to

the connecting rod and lubricate the bearing
surface.

5. For engines with a scraper ring in the liner:

Fit assembly tool 99 380 instead of the
scraper 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

scraper ring. Be careful to press it in straight
so that it does not tilt.

9. For engines without a scraper ring in the

liner: Insert the connecting rod and piston.
On aluminium pistons the arrow mark on the
piston should point forward.
10. Clamp piston ring compressor 98 212 round
the piston and push the piston down into the
cylinder.

01:03-02 © Scania CV AB, Sweden, 2003-05:6 53

11. Fit the lower connecting rod bearing shell
into the cap and lubricate the bearing surface.
Fit the cap. Check that the connecting rod
and cap have the same marking and that they
are opposite each other.

12. Lubricate the bolts, fit them and tighten to

20 Nm + 90°. Check that the pistons nozzles
are in perfect condition and fully open. If
necessary, blow clean with compressed air.
13. Fit the piston cooling nozzle and tighten the
banjo bolts to 23 Nm.

Note: The piston cooling nozzle must not

be damaged. The oil jet must hit the
piston precisely. If it does not, the
piston will become too warm
resulting in engine breakdown.
Damaged nozzles must not be
re-aligned, renew them instead.

14. Fit the oil sump and tighten the bolts to

30 Nm.

15. Fit the cylinder head. Tighten the cylinder

head bolts as described in the section Cylin-
der head.

54 © Scania CV AB, Sweden, 2003-05:6 01:03-02

 Flywheel and flywheel housing

1. Flywheel housing 15. Stud 28. O-ring

2. Seal 16. Rotation speed sensor 29. Crankshaft gear PF
3. Bolt 17. Contact housing 30. Pin
4. Washer 18. Flange bolt 31. Ring gear
5. Flange bolt 19. Clamp 32. Flywheel
6. Flange bolt 20. Clamp 33. Circlip
7. Flange bolt 21. Bolt 34. Ball bearing
8. Cover 22. Timing gear plate, engines with 35. Bolt
9. Gasket injection pump 36. Washer
10. Flange bolt 23. Timing gear plate, engines with 37. Guide sleeve
11. Cover PDE unit injectors 38. Crankshaft
12. Lifting eye 24. Stud
13. Hexagon nut 25. Pin
14. Washer 26. Flange bolt
27. Cover

01:03-02 © Scania CV AB, Sweden, 2003-05:6 55

 Special tools

87 368 Puller bolts 588 189 Air powered sprayer

99 250 Drift 584 117 Cartridge adapter
99 321 Assembly tool 584 118 Nozzle
99 324 Guide pins
99 410 Assembly tool
99 411 Assembly tool

Removing the flywheel

1. Remove the engine speed sensor(s) in the
flywheel housing.
2. Remove the bolts for the flywheel.
14" flywheel: Also remove the washer.
3. Pull off the flywheel from the crankshaft
using puller bolts 87 368.

56 © Scania CV AB, Sweden, 2003-05:6 01:03-02

Renewing support bearing
1. Remove the retaining rings on both sides of
the support bearing.
2. Knock out the support bearing from the fly-
wheel using drift 99 250.
3. Fit the inner retaining ring and fit the new
support bearing with drift 99 250.
4. Fit the outer retaining ring.

Renewing ring gear

Renew the flywheel ring gear if the gear teeth
have become so worn that the starter motor pinion
will not engage.
1. Grind a groove as deep as possible in the ring
gear and crack it open with a chisel. Remove
the ring gear from the flywheel.

! WARNING!

Use protective goggles due to the risk of

metal shivers.

2. Clean the contact surfaces on the flywheel

with a wire brush.
3. Heat the new ring gear evenly around its cir-
cumference to 100 -150°C.
4. Place the heated ring gear on the flywheel so
that the marking with the part number is fac-
ing the engine when fitting the flywheel.
Make sure the ring gear is securely against
the flywheel. If necessary, knock down the
ring gear with a plastic hammer.
5. The ring gear must not be cooled rapidly but
be left to cool in the open air.

01:03-02 © Scania CV AB, Sweden, 2003-05:6 57

Renewing the rear crankshaft seal
1. Remove the crankshaft seal using a
screwdriver. Take care not to scratch the
sealing surfaces on the crankshaft and the
flywheel housing.

Note: The crankshaft seal must be fitted

dry and must not 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 99 410.

Place the crankshaft seal on the tool and fas-
ten the tool with the bolts.
3. Turn the tool clockwise until is stops in order
to attain the correct crankshaft seal position.

Removing the flywheel housing

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

58 © Scania CV AB, Sweden, 2003-05:6 01:03-02

Fitting the flywheel housing
1. Remove all old sealing compound on the
sealing surfaces of the timing gear casing and
timing gear plate. Clean off any oil and
grease using an alcohol based cleaning agent.

Note: The sealing surfaces must be

absolutely clean and free from
grease. Do not touch the surfaces
after degreasing.
Engines with injection pump, earlier
version
2. Apply the sealing agent (816 064) on the tim-
ing gear housing with the air powered sprayer
(588 189), cartridge adapter (584 117) and
nozzle (584 118). The width of the bead
should be between 0.8 and 1.2 mm. Follow
the pattern as illustrated.

Important! Ensure that you apply sealing agent

inside the screwholes, but without allowing
sealing agent into the crankcase. The
sealing agent may block channels and
nozzles.This is particularly important to
bear in mind around oil ways, where the
flow of oil to the air compressor or injection
pump can be blocked.
Engines with injection pump, later
version

Important! Assembly must be completed within Apply sealing agent to the timing gear casing
25 minutes of starting to apply the sealing on the side against the timing gear plate.
agent. Apply sealing agent around the screwholes
marked with arrows.
A = bolt added, later version
B = bolt moved, later version

Note: The bolts are of various sizes and

lengths. Ensure that they are fitted
in the correct places. See also the
illustrations on the next page.

3. Torque tighten the M12 bolts to 90 Nm and

the M10 bolts to 50 Nm.
4. Fit the power steering pump.
5. Fit the starter motor

01:03-02 © Scania CV AB, Sweden, 2003-05:6 59

 Engines with injection pump, earlier Engines with injection pump, later
version version

M10 x 60

M10 x 80
100052

M10 x 60
Engines with injection pump, Engines with injection pump, later
earlier version version

Engines with PDE unit injector

60 © Scania CV AB, Sweden, 2003-05:6 01:03-02

Fitting the 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.

01_1358
99 324

3. Lock the flywheel using tool:

- 99 321 for engines with injection pump
- 99 411 for engines with unit injector.

Locking the flywheel on engines with a

unit injector.

4. Torque tighten the bolts alternately to

130 Nm and then a further 90°.
5. Fit the engine speed sensor(s).

01:03-02 © Scania CV AB, Sweden, 2003-05:6 61

 Timing gear

1. Camshaft 14. Ball bearing 27. Flange bolt

2. Pin 15. Snap ring 28. Banjo screw
3. Camshaft bearing 16. Spacing sleeve 29. Shaft
4. Guide flange 17. Bolt 30. Pushrod
5. Flange bolt 18. Shaft 31. Slide ring
6. Thrust washer 19. Crankshaft gear 32. Snap ring
7. Camshaft gear 20. Oil pump gear 33. Pushrod
8. Flange bolt 21. Intermediate gear 34. Spacing sleeve
9. Compressor gear 22. Snap ring 35. Injection pump gear
10. Hydraulic pump wheel 23. Shaft 36. Roller tappet
11. Flange bolt 24. Spacing sleeve
12. Shaft 25. Roller tappet
13. Intermediate gear 26. Circlip

A = Parts for engine with injection pump.

62 © Scania CV AB, Sweden, 2003-05:6 01:03-02

 Special tools

87 348 87 592 99 074

587 526 99 309

100038
87 348 Drift
87 592 Drift
99 074 Impact drift
99 309 Flywheel turning tool
587 526 Support drift

01:03-02 © Scania CV AB, Sweden, 2003-05:6 63

 Gearwheel timing gear

Intermediate gear

Removal
- 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 cylinder number 1
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 sec-
tion Removing the flywheel.
3. Remove the flywheel housing as described in
Removing the flywheel housing.
4. Manufacture a thread block according to the
sketch.
5. The shaft on which the gear is located has a
groove. Fit puller 587 526, slide hammer
99 074 and the thread block. Loosen the gear
and shaft.

Note: After removing the intermediate

gear, neither the camshaft nor the
crankshaft must be rotated. This
may cause pistons and valves to
collide and be damaged. 587 526
99 074
01 1359

64 © Scania CV AB, Sweden, 2003-05:6 01:03-02

Renewing bearing in intermediate gear for
compressor
1. Remove the snap ring.
2. Press the bearing packet out of the gear.
3. Press the shaft journal out of the bearing.
4. Press the shaft journal into a new bearing
using tool 87 348.

Note: Do not press on the outer race.

5. Press the ring on the shaft journal.

6. Press the bearing packet into the intermediate
gear. Use tool 87 592.
7. Fit the snap ring.

Renewing bearing in intermediate gear for

camshaft
1. Press the shaft out of the bearing.
2. Press the bearing inner race shell from the
shaft and remove the retaining ring.
3. Place the removed bearing inner race in the
bearing and press out the bearing using drift
87 348.
4. Press a new bearing onto the shaft journal
using drift 87 348.

Note: Do not press on the outer race.

5. Press the bearing and shaft journal into the

intermediate gear using drift 87 592.
6. Fit the snap ring.
7. Press the spacing ring onto the shaft journal.
Ensure that the shaft journal is on the press
table.

01:03-02 © Scania CV AB, Sweden, 2003-05:6 65

 Fitting
1. Check that cylinder number 1 is close to
TDC. The markings on the camshaft gear and
crankshaft gear must point towards the centre
of the intermediate gear.
2. Lubricate the bearing surfaces.
3. Fit the intermediate gear against the camshaft
gear and the crankshaft gear so that the mark-
ings point towards each other.

100055
4. Fit the second intermediate gear.
5. Tighten the bolts on the intermediate gears to
50 Nm + 60°.
6. Fit the flywheel housing as described in the
section Fitting the flywheel housing.
7. Fit the flywheel as described in the section
Fitting the flywheel.

66 © Scania CV AB, Sweden, 2003-05:6 01:03-02

Camshaft gear

Removal
1. Turn the crankshaft so that cylinder number 1
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 sec-
tion Removing the flywheel.
3. Remove the flywheel housing as described in
the section Removing the flywheel housing.
4. Remove the intermediate gear.

Note: After removing the intermediate

gear, neither the camshaft nor the
crankshaft must be rotated. This
may cause pistons and valves to
collide and be damaged.

5. Remove the camshaft gear.

Fitting

01 1363
1. Fit the camshaft gear and torque tighten the
bolts to 63 Nm.
2. Fit the intermediate gear as described in
Intermediate gear, fitting.
3. Fit the flywheel housing as described in the
section Fitting the flywheel housing.
4. Fit the flywheel as described in the section
Fitting the flywheel.
01 1364

01:03-02 © Scania CV AB, Sweden, 2003-05:6 67

 Crankshaft gear

Removal
1. Turn the crankshaft so that cylinder number 1
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 sec-
tion Removing the flywheel.
3. Remove the flywheel housing as described in
the section Removing the flywheel housing.
4. Remove the intermediate gear.

Note: After removing the intermediate

gear, neither the camshaft nor the
crankshaft must be rotated. This
may cause pistons and valves to
collide and be damaged.

5. Remove the crankshaft gear.

01 1365
Fitting
1. Fit the crankshaft gear and guide pin.
2. Fit the intermediate gear as described in
Intermediate gear, fitting.
3. Fit the flywheel housing as described in the
section Fitting the flywheel housing.
4. Fit the flywheel as described in the section
Fitting the flywheel.
01 1366

68 © Scania CV AB, Sweden, 2003-05:6 01:03-02

Camshaft

Removal
1. Remove the flywheel as described in
Removing the flywheel.
2. Remove the flywheel housing as described in
Removing the flywheel housing.
3. Remove rocker arms, pushrods and valve
bridges.
4. Remove the camshaft gear.

01_1370
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. Pull the camshaft backwards. Take care not

to damage the cams and bearings.

01:03-02 © Scania CV AB, Sweden, 2003-05:6 69

 Renewing the camshaft bearing

Special tools

99 373

99 003 99 004

99 003 Hydraulic cylinder

99 004 Compressed air powered hydraulic pump
99 373 Tool for renewing camshaftbearing

Work description
1. Remove the camshaft according to the
section Camshaft, removal.
2. Remove the camshaft cover at the front end
of the engine.

Note: Wipe around the edges and the

bearing seat surfaces around the
old bearings to avoid damaging
the contact surfaces when fitting
the new bearings.

3. Wipe the bearing seat surfaces clean around

the old bearings.
109 690

Note: The recess in the bearing joint

must be turned towards the front
of the engine.

70 © Scania CV AB, Sweden, 2003-05:6 01:03-02

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

Tool 99 373
1. Threaded stem with eight flange nuts
2. Press drift
3. Flange

5. Place the flange nuts on the threaded stem,

included in tool 99 373, as illustrated.

01:03-02 © Scania CV AB, Sweden, 2003-05:6 71

 6. Take the threaded stem and insert the end
with flange nut number 1 from the rear
edge of the engine past the rearmost bear-
ing seat. Insert it further through the bear-
ing seats and the new bearings until flange
nut 1 protrudes from the front of the engine.

7. Screw the flange part of tool 99 373

securely onto hydraulic cylinder 99 003
with two M6x12 bolts. Press together cylin-
der 99 003 if not already in neutral position.

8. Screw the flange securely to the hydraulic

cylinder at the rear of the engine with two
of M10x25.
9. Screw on flange nut 8, from tool 99 373,
onto the threaded stem.

72 © Scania CV AB, Sweden, 2003-05:6 01:03-02

10. Hang a new bearing on the stem at the front
of the engine.
11. Place the press drift on the threaded stem
and place the bearing on the drift.

Note: The recess in the bearing joint

must be turned towards the flange
on the press drifts. Secure the
bearing on the drift by placing the
spring-loaded ball in an oil way.
The bearing is correctly located on
the drift when the ball and a
marking hole are centred on the
bearing oil hole.

109 689
The bearing is correctly located on the drift
when the ball and a marking hole are opposite
the bearing oil hole
12. Clean around the bearing contact surface.

Note: The marking on the drift must be

uppermost and vertical so that the
oil hole in the bearing will be
central to the oil ways.

13. Hold the press drift with the new bearing

against the old. Secure the threaded stem
between the press drift and hydraulic cylin-
der 99 003 by tightening flange nut 8 on the
stem.

Secure the threaded stem by tightening flange

nut 8.

01:03-02 © Scania CV AB, Sweden, 2003-05:6 73

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

Table for correctly located camshaft

bearing

Camshaft bearing
Distance (mm)
no.
1 -12 to -14
2 150 to 152
3 314 to 316
4 478 to 480
5 642 to 644
6 806 to 808 Check measurement of bearing number 1.
7 970 to 972

14. Press in the new bearing at the same time as

pressing out the old bearing with hydraulic
cylinder 99 003 and hydraulic pump
99 004. Check that the bearing is correctly
positioned by measuring.
15. Carefully knock with a plastic hammer to
release the old bearing.

74 © Scania CV AB, Sweden, 2003-05:6 01:03-02

16. Remove the press drift by detaching flange
nut 8 and pushing in the threaded stem.

Note: The seats for camshaft bearings 2,

4 and 6 have two oil ducts. The
others only have the lower one.

17. Check that the bearing oil hole is opposite

the cylinder block oil ducts.
18. Repeat the procedure for the remaining
bearings.

Extraction and pressing of bearing number 2.

19. Clean the sealing surface, take a new gasket

and fit the cover for the camshaft at the
front of the engine.
20. Refit the camshaft according to the section
Fitting the Camshaft. Then perform a check
on the camshaft setting.

Check measurement of bearing number 2.

01:03-02 © Scania CV AB, Sweden, 2003-05:6 75

 Fitting the camshaft
1. Fit the camshaft. Take care not to damage
the 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 compound on the

sealing surfaces of the timing gear casing
and timing gear plate. Clean off any oil and

01 1367
grease using an alcohol based cleaning
agent.

Note: 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

timing gear casing with the special nozzle.
The width of the bead should be between
0.8 and 1.2 mm. Follow the pattern as illus-
trated.

Important! Ensure that you apply sealing

agent inside the screwholes, but without
allowing sealing agent into the crankcase.
The sealing agent may block channels and
nozzles. This is particularly important to
bear in mind around oil ways, where the
flow of oil to the air compressor or
injection pump can be blocked.

Important! Assembly must be completed Application of sealing agent on the block

within 25 minutes of starting to apply the
sealing agent.

76 © Scania CV AB, Sweden, 2003-05:6 01:03-02

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

8. Fit the intermediate gear as described in

Intermediate gear, fitting.

01_1369
9. Ensure that the markings on the camshaft
gear point towards the centre of the interme-
diate gear.
10. Fit the camshaft gear and torque tighten the
bolts to 63 Nm.
11. Fit the flywheel housing as described in Fit-
ting the flywheel housing.
12. Fit the flywheel as described in Fitting the
flywheel.

Checking camshaft setting

1. Set the crankshaft to TDC after the
compression stroke on cylinder number one.
2. Put two dial gauges against the valve spring
thrust washers.
3. Adjust the rocker arms to remove the free
play and then adjust them further so that both
valves are open 0.1 mm.
4. Zero both the dial gauges.
5. Turn the crankshaft one revolution in its
direction of rotation until TDC position is
again achieved.
6. Read off both dial gauges and compare with
the values given below:
- Intake valve lifting height 0.37-1.47
- Exhaust valve lifting height 0.16-1.16

01:03-02 © Scania CV AB, Sweden, 2003-05:6 77

 Crankshaft

Removal
1. Remove the crankshaft gear as described in
Removing the crankshaft gear.
2. Remove the fan drive at the front end of the
crankshaft as described in Belt transmission,
Renewing the seal in the front cover.
3. Remove the oil sump, oil suction pipe with
strainer and the 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

Important Grinding of a crankshaft can and

should only be carried out by workshops
that have machine equipment for such jobs.
- Measure the crankshaft journals. Use a
micrometer to measure two diameters at right
angles to each other.
- If either of these diameters is lower than the
minimum indicated 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.

78 © Scania CV AB, Sweden, 2003-05:6 01:03-02

- When regrinding, stated undersizes must be
complied with. Suitable bearings are
available for these sizes.
- Refer to the next page for the diameters
required for different undersizes.
- It is important that the fillet radius of the
journals is correct.
- After grinding the journals, the oil hole
connections to the bearing surfaces should be
rounded off and polished.

Cylinder block

Reconditioning
Heat arising from the main bearings seizing and
rotating in the cylinder block will change the
properties of the material in the cylinder block.
These cylinder blocks must be discarded.
If the main bearing seizes but does not rotate in
the cylinder block, the cylinder block can be
overhauled. The main bearing seats must
comply with the demands on roundness given in
the table. Machining out-of-round main bearing
seats is something we do not recommend.
1. Measure the diameter at four different
positions as illustrated. The diameter must
be measured with the main bearing caps
tightened and without main bearings.
2. Check the dimensions with those in the
table.

Minimum Maximum Maximum

permitted permitted permitted
diameter diameter difference*
112.200 mm 112.222 mm 0.016 mm
*) Maximum permitted difference between the largest
and smallest diameter on the same main bearing
seat.

01:03-02 © Scania CV AB, Sweden, 2003-05:6 79

 Dimensions when regrinding

Main bearing journals

Standard, diameter 107.978-108.000 mm
Undersize 1, diameter 107.728-107.750 mm
Undersize 2, diameter 107.428-107.450 mm
Undersize 3, diameter 107.228-107.250 mm
Undersize 4, diameter 106.978-107.000 mm
Hole recess radius 4.75-4.85 mm
Surface quality 0.25 Ra

Connecting rod journals

Standard, diameter 86.978-87.000 mm
Undersize 1, diameter 86.728-86.750 mm
Undersize 2, diameter 86.478-86.500 mm
Undersize 3, diameter 86.228-86.250 mm
Undersize 4, diameter 85.978-86.000 mm
Hole recess radius 4.8-5.2 mm
Surface quality 0.25 Ra
Width, max. 56.05
Radial clearance 0.051-0.114 mm

Thrust washers
Standard, thickness 3,370-3,430 mm
Oversize 1, thickness 3,450-3,510 mm
Oversize 2, thickness 3,500-3,560 mm
Oversize 3, thickness 3,630-3,690 mm
Oversize 4, thickness 3,880-3,940 mm
Axial clearance 0,138-0,380 mm

80 © Scania CV AB, Sweden, 2003-05:6 01:03-02

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 caps in

the same place as before removal.

4. Tighten the bearing cap bolts to 50 Nm

+ 90°. 50 Nm + 90

5. Fit the pistons with connecting rods as

described in Fitting the connecting rod and
piston.
6. Fit the oil pump, oil suction pipe with strainer 90
o

and the oil sump.

100150

7. Renew the seal in the front cover. Fit the

spacing sleeve on the crankshaft journal. Fit
the driver and crankshaft damper.
See Belt transmission, Renewing the seal in
the front cover.
8. Fit the crankshaft gear as described in Crank-
shaft gear, fitting.

01:03-02 © Scania CV AB, Sweden, 2003-05:6 81

 Belt transmission

1. Belt pulley on
crankshaft damper
2. Belt tensioner
3. Coolant pump
4. Fan pulley
5. Alternator
6. Poly-V-belt
7. Idler roller

82 © Scania CV AB, Sweden, 2003-05:6 01:03-02

Renewing the seal in the front
cover
1. Remove the fan ring and the 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 fitted

dry and must not 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 Tool 99 379 with crankshaft seal
it in place by tightening the diametrically
opposite bolts alternately. The seal is cor-
rectly fitted when the tool comes up against
the cover.
7. Remove the tool by screwing the bolts into
the threaded holes.
8. Wipe the driver sealing surface clean. Fit a
new seal on the end surface of the driver
and push the driver onto the spacing 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.

01:03-02 © Scania CV AB, Sweden, 2003-05:6 83

 Lubrication system

Oil cooler

1. Gasket 9. Gasket
2. Flange bolt 10. Cover
3. O-ring 11. Bolt
4. O-ring 12. Piston
5. Oil cooler 13. Spring
6. Oil cooler cover 14. Gasket
7. Flange bolt 15. Plug
8. Core plug

84 © Scania CV AB, Sweden, 2003-05:6 01:03-02

Renewing 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. Renew the 4 O-rings.

5. Fit the oil cooler insert and bolt securely to
the side cover using 26 Nm torque.
6. Bolt the side cover to the block.

01:03-02 © Scania CV AB, Sweden, 2003-05:6 85

 Oil cleaner

1. Filter head
2. Gasket
3. Seal
4. Straight union
5. Gasket
6. Flange bolt
7. Gasket
8. Plug
9. Union
10. Overflow valve
11. Oil filter
12. O-ring
13. Strainer
14. Rotor
15. O-ring
16. Lock nut
17. Lifting eye
18. Cover
19. O-ring
20. Snap ring
21. Nut
22. Rotor bowl
23. Gasket
24. Shaft
25. Washer
26. Plug
27. Housing
28. Gasket
29. Plug
30. Piston
31. Spring
32. Flange bolt
33. Nozzle

86 © Scania CV AB, Sweden, 2003-05:6 01:03-02

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. Undo the nut holding the outer cover and

remove the nut.

2. Lift out the rotor. Wipe off the outside. Undo

the rotor nut and unscrew it about one and a
half turns to protect the bearing.

Note: The rotor must not be put in a vice.

Never strike the rotor bowl. This
may cause damage resulting in
imbalance.

3. If the rotor nut is jammed:

Turn the rotor upside down and fasten the
nut, absolutely not the rotor, in a vice, and
turn the rotor one and a half turn anti-clock-
wise by hand, or use an M20 nut as illus-
trated. The width across flats should be
30 mm.

01:03-02 © Scania CV AB, Sweden, 2003-05:6 87

 4. Grasp the rotor bowl and tap lightly with
your hand or a plastic mallet on the rotor nut
so that the rotor bowl comes loose from the
rotor.

Note: Never strike on the rotor directly as

this may damage its bearings.

5. Remove the rotor nut and bowl from the

rotor.

6. Remove the strainer located on the rotor. If

the strainer has fastened, prise carefully with
a knife at the bottom between the rotor and
the strainer.

7. Scrape away the deposits inside the bowl

with a knife.
8. Wash the parts.
9. Inspect the two nozzles on the rotor. Make
sure they are not blocked or damaged. Renew
any damaged nozzles.
10. Make sure the bearings are not damaged.
11. Position the O-ring in the lid. Renew the
O-ring if it is at all damaged.

88 © Scania CV AB, Sweden, 2003-05:6 01:03-02

12. Assemble the parts and tighten the rotor nut
by hand.
13. Make sure the shaft is not loose. If it is, it can
be locked using locking compound 561 200.
First clean thoroughly using a suitable sol-
vent.
14. Tighten the rotor shaft using socket 98 421.
Tightening torque 34 Nm.
15. In order to tighten the rotor shaft, it is neces-
sary to modify socket wrench 98 421:
- Drill out the threads from a M20 nut so that
it fits on the square drive of the socket
wrench.
- Weld on the nut.

Note The socket wrench still fits the old

centrifugal oil cleaner after
modification.

16 Refit the rotor and spin it by hand to make

sure it rotates easily.
17. Inspect the O-ring on the cleaner housing
cover and fit it with a lock nut.
Tighten the lock nut to 15 Nm.

01:03-02 © Scania CV AB, Sweden, 2003-05:6 89

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

1. Oil pump 7. Ring

2. Flange bolt 8. Flange bolt
3. Gasket 9. Pipe
4. Flange bolt 10. Seal
5. Suction pipe
6. Strainer

90 © Scania CV AB, Sweden, 2003-05:6 01:03-02

Specifications

General information
Cylinder configuration. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . In-line engine
Number of cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Cylinder bore . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127 mm
Stroke length . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 154 mm
Swept volume . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.7 dm3
Number of main bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Firing order . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5-3-6-2-4
Injection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Direct
Principle of operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-stroke
Cooling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Liquid
Approx. weight, including alternator. . . . . . . . . . . . . . . . . . . . . . . . . . . 990 kg
Direction of rotation (engine viewed from rear) . . . . . . . . . . . . . . . . . . Anti-clockwise

Compression ratio
Output
Engine speed See Operator's Manual or Service Card for the particular engine
Torque
Oil capacity
Oil grade

Locking compound, lubricants, sealing compound

Activator T for faster hardening of locking compound 561 200 . . . . . . 561 045
Locking compound . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 561 200
Lubricant for exhaust pipe bolts and joints . . . . . . . . . . . . . . . . . . . . . . 561 205
Thread sealant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 561 019
Sealing compound for flywheel housing . . . . . . . . . . . . . . . . . . . . . . . . 816 064

General tightening torques

The following tightening torques apply in general unless otherwise specified:
Thread M5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.7 Nm
Thread M6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.2 Nm
Thread M8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 Nm
Thread M10 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50 Nm
Thread M12 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92 Nm
Thread M14 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 149 Nm

01:03-02 © Scania CV AB, Sweden, 2003-05:6 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

Minimum dimension A for ground

valve

Intake valve seat

Seat angle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20.0°-20.5°
Width of contact surface A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.9 - 2.6 mm
Valve seat insert, outer diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46.054 - 46.065 mm
Seat for valve seat insert, diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46.000 - 46.016 mm
Seat for valve seat insert, depth. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.25 - 11.35 mm

Oversized valve seat insert:

Outer diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46.254 - 46.265 mm
Seat for valve seat insert, diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46.200 - 46.216 mm
Cooling temperature when fitting valve seat insert. . . . . . . . . . . . . . . . approx. -80°C

92 © Scania CV AB, Sweden, 2003-05:6 01:03-02

Exhaust valve seat
Seat angle. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45.0°-45.5°
Width of contact surface A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.8 - 2.6 mm
Valve seat insert, outer diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44.081 - 44.092 mm
Seat for valve seat insert, diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44.000 - 44.016 mm
Seat for valve seat insert, depth . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.25 - 11.35 mm

Oversized valve seat insert:

Outer diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44.281 - 44.292 mm
Seat for valve seat insert, diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44.200 - 44.216 mm
Cooling temperature when fitting valve seat insert . . . . . . . . . . . . . . . . approx. -80°C

Tightening torques
Cylinder head bolts:
First tightening . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60 Nm
Second tightening . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 150 Nm
Third tightening . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 250 Nm
Fourth tightening . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90°
Nut for injector. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70 Nm
Bolts for shaft with rocker arms. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105 Nm
Nut for adjusting screw on rocker arm . . . . . . . . . . . . . . . . . . . . . . . . . 40 Nm
Bolt for rocker cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 Nm
Bolts for exhaust manifold. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59 Nm
Bolts for turbocharger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50 Nm
Bolts for support bracket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105 Nm

Valve clearances and unit injectors

Valve clearance, intake valve (cold engine) . . . . . . . . . . . . . . . . . . . . . 0.45 mm
Valve clearance, exhaust valve (cold engine) . . . . . . . . . . . . . . . . . . . . 0.70 mm
Dimension for PDE31 unit injector (cold engine) . . . . . . . . . . . . . . . . . 66.9 +/- 0.1 mm
Dimension for PDE32 unit injector (cold engine) . . . . . . . . . . . . . . . . . 69.9 +/- 0.1 mm

Tightening torques
Adjusting screw lock nut on rocker arm for unit injector . . . . . . . . . . . 39 Nm
Adjusting screw lock nut on rocker arm for valves . . . . . . . . . . . . . . . . 35 Nm
Bolt for upper rocker cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 Nm
Bolt for lower rocker cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 Nm
Support bracket and rocker arm shaft . . . . . . . . . . . . . . . . . . . . . . . . . . 105 Nm
Cable connection, unit injector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 +/- 0,2 Nm

01:03-02 © Scania CV AB, Sweden, 2003-05:6 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 and cylinder liners

Cylinder liner
Shims for cylinder liner, thickness . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.20, 0.25, 0.30,
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.40, 0.50, 0.75 mm
Height of cylinder liner 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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Gap: 1st ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.35 - 0.60 mm
2nd ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.45 - 0.65 mm
Maximum clearance in groove, 2nd ring. . . . . . . . . . . . . . . . . . . . . . . . 0.25 mm

Rings marked "TOP" should be turned with the marking up.

Number of oil scraper rings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

Gap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.40 - 0.65 mm
Max. clearance in groove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.25 mm

94 © Scania CV AB, Sweden, 2003-05:6 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°

Flywheel and flywheel housing

Flywheel
Maximum machining allowance for disc pressure surface: 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

01:03-02 © Scania CV AB, Sweden, 2003-05:6 95

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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63 Nm
Bolts for intermediate gears . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50 Nm + 60°
Bolts for compressor gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105 Nm
Connecting rod bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 Nm + 90°
Main bearing bolts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50 Nm + 90°
Bolts for driver . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 135 Nm
Bolts for crankshaft damper and pulley. . . . . . . . . . . . . . . . . . . . . . . . . 110 Nm
Flange bolts and banjo bolts for valve tappets . . . . . . . . . . . . . . . . . . . 32 Nm
Bolts for timing gear plate. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63 Nm

96 © Scania CV AB, Sweden, 2003-05:6 01:03-02

Lubrication system

Oil cleaner
Permitted thickness of deposits on wall of cover . . . . . . . . . . . . . . . . . max. 20 mm

Oil pressure valve (Note: not safety valve)

Oil pressure:
Idle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.6 bar
With warm engine running at 1000 rpm . . . . . . . . . . . . . . . . . . . . . . . . 2.5 bar
With warm engine running at 2,000 rpm . . . . . . . . . . . . . . . . . . . . . . . . 4.5 - 6.0 bar
Free spring length . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 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 © Scania CV AB, Sweden, 2003-05:6 97

 Special tools
Number Designation Shown on page
87 198 Rule for dial gauge 47
87 348 Puller 63, 65
87 362 Drift 39, 41, 45
87 368 Puller bolt 56
87 592 Drift 63, 65
87 596 Slide hammer 8, 20
98 075 Dial gauge 32, 39, 47
98 094 Lifting chain 3, 4
98 212 Piston ring compressor 39, 53
98 249 Compression tester 8, 14
98 421 Socket wrench 89
98 515 Tension lugs 39, 40
98 599 Oil pressure gauge -
99 003 Hydraulic hole cylinder 39, 46, 70, 72, 73, 74
99 004 Compressed air powered hydraulic pump 62, 66, 70, 74
99 007 Support plate -
99 066 Puller for cylinder liner 39, 46
99 074 Impact drift 8, 16, 39, 63, 64
99 079 Extractor for injectors 8, 16
99 168 Dismantling tool for scraper ring 39, 40
99 250 Drift 56, 57
99 308 Sleeve for injectors 8, 16, 30
99 309 Tool for turning flywheel 8, 9, 10, 63, 64, 67, 68
99 310 Socket 8, 14, 16, 31
99 321 Assembly tool 56
99 322 Press drift for valve spring 8, 21, 29
99 323 Assembly drift 8, 21
99 324 Guide pins, flywheel 56, 61
99 373 Tool for renewing camshaft bearing 70, 71, 72
99 379 Drift for seal in front cover 83
99 380 Assembly tool, scraper ring 39, 53
99 381 Drift for injector sleeve 8, 27
99 382 Drift for valve guides 8, 25
99 383 Drift for valve guides 8, 25
99 384 Drift for valve seats 8, 22
99 385 Drift for valve seats 8, 22
99 394 Guide, thread cutting of injector sleeve 8, 26, 28
99 395 Drift 28
99 397 Extension piece 28
99 403 Tool for renewing bearing bushing 43
99 410 Assembly tool 56, 58
99 411 Assembly tool 56, 61
99 414 Setting tool 8, 12
99 442 Setting tool 8, 13
587 025 Filter wrench 32, 33
587 107 Deflection gauge 32
587 110 Test apparatus for connecting rods 39, 42

98 © Scania CV AB, Sweden, 2003-05:6 01:03-02

 Special tools
Number Designation Shown on page

587 250 Indicator stand 32

587 277 Valve seat cutter 8, 22, 23
587 308 Lever block 3
587 309 Piston ring expander 39, 41, 45
587 512 Liner cutter 49
587 526 Support drift 63, 64
587 692 Engine stand 6
588 221 Pilot tap for injector sleeve 8, 26, 28
588 672 Extension 49

01:03-02 © Scania CV AB, Sweden, 2003-05:6 99