16 litre engine

Remove & Install

PT UNITED TRACTORS Tbk - SITE ADARO 2006

Contents

Contents
Engine assembly General information.................................................. 4
Removing the engine ................................................ 6
Fitting the engine.................................................... 12
Mounting the engine in a universal stand ............... 13

Cylinder head Exploded view drawing .......................................... 15

Removing the cylinder head ................................... 16
Fitting the cylinder head ......................................... 20
Adjusting the unit injector with tool 99 414........... 26
Order of adjustment for unit injectors and
valves. ..................................................................... 29
Removing valves .................................................... 30
Fitting valves .......................................................... 31
Checking and machining valves ............................. 32
Renewing the valve stem seal................................. 33
Renewing the valve seats........................................ 34
Machining the cylinder head .................................. 36
Renewing the valve guides ..................................... 42
Renewing PDE unit injector sleeves....................... 43

Cylinder block Overhaul ................................................................. 45

Removing the cylinder liners.................................. 46
Fitting the cylinder liners........................................ 47
Measuring the cylinder liner height........................ 48
Machining cylinder liner height ............................. 50
Renewing the rear crankshaft seal .......................... 55
Removing the camshaft bearing ............................. 56
Fitting the camshaft bearing ................................... 60
Removing the flywheel housing ............................. 64
Fitting the flywheel housing................................... 65
Removing the front timing gear casing .................. 67
Fitting the front timing gear casing ........................ 71
Renewing the front crankshaft seal ........................ 74
Removing the crankshaft cover .............................. 76
Fitting the crankshaft cover .................................... 79
Renewing rivet plug in cylinder block.................... 82

Crank mechanism Exploded view drawing .......................................... 84

Removing a piston .................................................. 86
Fitting a piston........................................................ 87
Renewing a piston .................................................. 89
Checking the connecting rod .................................. 92
Flywheel ................................................................. 97
Crankshaft............................................................. 101

Timing gear Exploded view drawing ........................................ 107

Removing the intermediate gear........................... 109
Fitting the intermediate gear................................. 111
Renewing bearing in intermediate gear ................ 112
Removing the crankshaft gear .............................. 115
Fitting the crankshaft gear .................................... 116
Removing the camshaft ........................................ 117

 Scania CV AB 2005, Sweden

2 01:06-01
 Contents

Fitting the camshaft .............................................. 120

Checking camshaft setting.................................... 123
Fan drive ............................................................... 125

Lubrication system .............................................................................. 127

Renewing the oil filter .......................................... 128
Renewing oil cooler seals ..................................... 130
Oil cleaner ............................................................ 132
Oil pump............................................................... 136

Exhaust manifold Renewing gaskets ................................................. 139

Turbocharger .............................................................................. 140

Removing the turbocharger .................................. 143
Fitting the turbocharger ........................................ 144
Measuring radial and axial clearance ................... 146
Checks after breakdown ....................................... 148
Checking wastegate valve function ...................... 149
Renewing wastegate valve bracket ....................... 150
Adjusting the wastegate valve .............................. 152

Engine suspension Renewing the vibration insulator.......................... 153

Renewing the engine bracket fitted to the
engine ................................................................... 155

Belt transmission Engines without AC.............................................. 157

Engines with AC................................................... 158

 Scania CV AB 2005, Sweden

01:06-01 3
Specifications

Work description

Engine assembly

General information

3 Made by 2
Typ/Type DC 16 XX
Variant Valve clearance cold engine
Motor/Engine No
Inlet : 0.45 mm
Outlet : 0.70 mm
4
123 45XX

1
1,40
A : DC 1601
116 669

1 Smoke values.
2 Instruction plate.
3 Engine type.
4 Engine serial number, stamp.
Specifications

Cylinder diameter 127.0 mm

Stroke 140.0 mm
Cylinder capacity 15.6 dm3
No. of main bearings 5
Firing sequence 1-5-4-2-6-3-7-8
Compression ratio 18:1
Direction of rotation (engine viewed from behind) Anticlockwise

 Scania CV AB 2005, Sweden

4 01:06-01
 Specifications

Engine speed, low idling 500 rpm

Engine speed, high idling 2400 rpm
Oil capacity 35 litres
Oil grade refer to booklet
00:03-09
Total weight without oil and water 1,290 kg

General

General tightening torques

Type of bolt Tightening torques

Flange bolt M6 8.6 Nm
Flange bolt M8 26 Nm
Flange bolt M10 50 Nm
Flange bolt M12 92 Nm
Stud in casting M8 13 Nm
Stud in casting M10 25 Nm

 Scania CV AB 2005, Sweden

01:06-01 5
Changing engine

Removal

Special tools

Number Designation Illustration Tool board

99 398 Lifting eyes 99 398 D3

114 638
98 094 Lifting chain 98 094
D4

109 836
587 308 Lever block B
114 070

IMPORTANT! Cover all the holes for e.g. turbo

and oil filler while work is in progress so that
bolts or other objects do not enter the engine.
Contamination in the engine may lead to severe
engine damage.

 Scania CV AB 2005, Sweden

6 01:06-01
 Changing engine

Remove Remarks Illustration

pos.
1 The cab. See 18:01-01. Only vehicles with T cab.
On vehicles with R cab, the cab is tilted
2 Oil and coolant.
3 The mudguards.
4 Catwalk. Only on vehicles with T cab.
5 The negative cable from the battery.
6 Control cable for thermostat to electrical Detach the housing and place it to one 6
fan. side. Only on vehicles with electrical fan.
7 Noise shields under the engine.
8 Coolant lines. Upper and lower. 8
9 Charge air pipes. 9
10 Ventilation line from the engine to the 10
expansion tank.
11 Inlet pipe between turbo and air filter. To secure 587 308. 11
12 Front air cleaner pipe and air cleaner. 12
13 Bracket 13
14 Wiring Mark to make fitting easier. 14
15 Cable duct to rotation speed sensor on 15
the flywheel.
16 Exhaust brake and exhaust bellows 16
behind the turbocharger.
17 Cable to rotation speed sensor. 17
18 The air hose for the exhaust brake. 18
19 Oil pipes from the gearbox oil cooler. Only on vehicles with fluid cooled 19
gearbox oil cooler.
20 Earth braids on the right and left-hand
sides.

 Scania CV AB 2005, Sweden

01:06-01 7
Changing engine

 Scania CV AB 2005, Sweden

8 01:06-01
 Changing engine

Remove Remarks Illustration

pos.
21 Compressed air lines. 21
22 Signal cable from the compressor. 22
23 The fuel pipes. Mark the cables for making fitting easier. 23
24 The AC compressor. Place to one side without detaching the 24
hoses.
25 Power steering pump. Place to one side without detaching the 25
hoses.
26 Filter housing to crankcase ventilation. Place to one side so that the lifting chain 26
is free.
27 Oil filler and oil dipstick. Plug the hole so that the engine does not 27
get contaminated.
28 Draining pipe for crankcase ventilation. 28

 Scania CV AB 2005, Sweden

01:06-01 9
Changing engine

Fit Remarks Illustration

pos.
29 Lifting eye 99 398. One lifting eye at the rear of each cylinder 29
line. Use flange bolts M12x30 and tighten
them to 92 Nm. Bolt holes are plugged.
Place the draining pipe to one side to fit
the right-hand lifting eye and the fuel
pressure test connection to fit the left-
hand lifting eye.
30 Lifting chain 99 094 to the rear lifting 30
eyes.
31 Lever block 587 308 to the front lifting Using the lever block it is possible to 31
eye. adjust the angle of inclination for the
engine.

IMPORTANT! The lifting eyes on the engine

are not dimensioned to lift the whole vehicle and
therefore must not be used for this purpose. All
three lifting eyes on the engine must be used
when lifting the engine.

IMPORTANT! The lifting eyes are

dimensioned for a maximum lifting angle of 20°
when lifting the engine.

 Scania CV AB 2005, Sweden

10 01:06-01
 Changing engine

 Scania CV AB 2005, Sweden

01:06-01 11
Changing engine

Remove Remarks Illustration

pos.
32 The gearbox. See 05:00-01.
33 The two front engine brackets.
34 The engine.

Fitting
Refit the engine in reverse order.

 Scania CV AB 2005, Sweden

12 01:06-01
 Universal stand

Mounting the engine in a universal stand

Special tools

Number Designation Illustration Tool board

99 349 Spacer 99 349

111 690
98 163 Fixture 98 163
A

109 858
587 692 Universal stand
112 804

1 Remove the side cover and gasket on the

left and right-hand sides.
2 Undo the clamping for the wiring to the
starter motor on the left-hand side.
3 Bolt spacer 99 349 onto the right and left-
hand sides. Use the bolts for the side covers.

 Scania CV AB 2005, Sweden

01:06-01 13
Universal stand

4 Place the engine in the universal stand. Use

fixture 98 163, bolt on the fixture using
bolts M8x25 and washer M8.

99 349

114 738
98 163

 Scania CV AB 2005, Sweden

14 01:06-01
 Cylinder head

Cylinder head

Exploded view drawing

28 27

29
30
31

32 112 169

33 34

1 Cylinder head 13 Screw 24 Cylinder head gasket

2 Core plug 14 Bearing bracket 25 Exhaust valve
3 Valve guide 15 Rocker arm shaft 26 Intake valve
4 Pin 16 Rivet plug 27 Rocker cover
5 Valve stem seal 17 Tight-fit bolt 28 Flange bolt
6 Valve spring, intake 18 Rocker arm, intake 29 Rocker cover gasket
7 Valve spring collar 19 Rocker arm, exhaust 30 Flange bolt
8 Valve spring, exhaust 20 Adjusting bolt 31 Rocker cover
9 Valve spring, exhaust 21 Lock nut 32 Rocker cover gasket
10 Valve spring collar 22 Rocker arm, unit injector 33 Valve seat insert, exhaust
11 Valve collet 23 Guide pin 34 Valve seat insert, intake
12 Valve yoke

 Scania CV AB 2005, Sweden

01:06-01 15
Cylinder head

Removing the cylinder head

1 Open the bleeder nipple and drain the fuel

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

! 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
immediately using a pump.
3

2 Remove the inlet pipe between the air filter

and the turbocharger.
Removing cylinder head 1-2
3 Remove the control unit and fuel filter.
Removing cylinder head 3-4

115 787
4 Remove the crankcase ventilation unit.
2

Removing cylinder head 5-8

5 Detach the inlet pipe for the crankcase

4
ventilation filter.
6 Disconnect the connection pipe between the
intake manifolds on the left-hand side.
7 Remove the charge air pipe between the
turbocharger and the charge air cooler.
115 788

7 6 5

 Scania CV AB 2005, Sweden

16 01:06-01
 Cylinder head

Removing cylinder head 1-8, continued:

8 Detach the intake manifold and fuel
manifold from the cylinder head or cylinder
heads to be removed. If all the cylinder
heads on the left-hand side (5-8) are to be
removed, detach the AC compressor and
place it to one side and remove the intake
manifold and the fuel manifold.
If all the cylinder heads on the right-hand 9
side (1-4) are to be removed, detach the
intake manifold to the crankcase ventilation
and remove the intake manifold from the
fuel manifold.

9 Remove the ventilation pipes for the coolant

system.

114 727
10 Remove the exhaust manifolds.
11 Clean the rocker cover and the surrounding
area.
12 Remove the upper part of the rocker cover.

Note: All the valve mechanism components

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

111 689

 Scania CV AB 2005, Sweden

01:06-01 17
Cylinder head

13 Relieve the pressure on the valves by

undoing the bolts on the rocker arm shaft
alternately. Remove the rocker arm shaft.

13
! WARNING!

Do not lean over the engine when

removing the rocker arm shaft. The unit
injector spring is pre-tensioned and can

111 684
come loose, causing personal injury.

Note: If the spring comes loose from the unit

injector, the unit injector must be renewed.

14 Remove the bearing bracket.

18 15
15 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.
14
16 Remove the valve bridges.

17 Disconnect the cables on the unit injector

19
and pull them out through the opening in the
rocker cover.
114 728

18 Remove the lower rocker cover. 17 16

19 Remove the screw for the fork clamp
holding the unit injector in place.

 Scania CV AB 2005, Sweden

18 01:06-01
 Cylinder head

Note: Do not lift the unit injector by its spring,

the spring can come loose.

20 Turn the unit injectors clockwise until they

stop. Place slide hammer 87 596 on the
inside of the solenoid valve as illustrated.

21 If the unit injector is stuck, tap carefully

with a rubber mallet on the solenoid valve
housing.
22 Remove the cylinder head, mark the
cylinder heads if several are to be removed
at the same time.

116 271
87 596

111 685

 Scania CV AB 2005, Sweden

01:06-01 19
Cylinder head

Fitting the cylinder head

Tightening torques

Cylinder head bolts:

First stage 60 Nm
Second stage 150 Nm
Third stage 250 Nm
Fourth stage 90°
Screws for lower rocker cover 26 Nm
Bolt for fork on unit injector 20 Nm + 75°
Bearing bracket and rocker arm shaft 105 Nm
Screw for upper rocker cover 18 Nm
Adjusting screw lock nut on rocker arm for unit injector 39 Nm
Adjusting screw lock nut on rocker arm for valves 35 Nm
Cable connection, unit injector 2 +/-0.2 Nm
Bolt for exhaust manifold 63 Nm
Bolt for fuel manifold 26 Nm
Banjo screw for overflow line 11 Nm

Special tools

Number Designation Illustration Tool board

588 179 Torque screwdriver 588 179
112 104

 Scania CV AB 2005, Sweden

20 01:06-01
 Cylinder head

1 Check liner height, refer to section on

pistons and cylinder liners.
2 Fit a new cylinder head gasket.
3 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.
4 Lubricate the threads and underneath the
heads of the cylinder head bolts. Tighten
them in the following four stages in the 5
order given in the figure.
1 Torque tighten all bolts to 60 Nm.
2
2 Torque tighten all bolts to 150 Nm. 3

3 Torque tighten all bolts to 250 Nm.

4 Finally, tighten all bolts by 90° 4
1
5 Make a mark with a centre punch on the

01_1396
head of the bolt. 6

5 Fit the lower part of the rocker cover and

torque tighten the bolts to 26 Nm.

 Scania CV AB 2005, Sweden

01:06-01 21
Cylinder head

6 Make sure there is not an old sealing washer

at the bottom of the injector seat. Clean the
sealing surfaces in the injector aperture.

IMPORTANT! Always fit new O-rings and

sealing washer to unit injectors that have been
removed. Make sure all sealing surfaces are
clean.

107 512
7 Lubricate the unit injector O-rings with
engine oil.
8 Fit a new sealing washer on the unit injector.
A rubber insert will keep the sealing washer
in place on the unit injector.
9 Place the fork clamp with screw in position
on the unit injector and insert it into the

107 513
cylinder head. Press down the unit injector
by hand as far as possible.

 Scania CV AB 2005, Sweden

22 01:06-01
 Cylinder head

10 Torque tighten the bolt to 20 Nm and then a

further 75°. There are two marks on the
rocker cover with a 75° angle between them.

IMPORTANT! Make sure the pushrods are

placed in their correct positions. Make sure the
pushrod to the unit injector is firmly secured in
position by the retaining ring.

11 Fit the pushrods.

12 Fit the bearing bracket and torque tighten
the bolts to 105 Nm.

115 633
13 Refit the rocker arm shaft. Screw in the
bolts alternately so that they are tightened in
parallel or one of the bolts may bend.
Tighten the bolts to 105 Nm.
14 Check the valve clearance and unit injector
setting as described in Adjusting the valve
clearance and unit injector.

 Scania CV AB 2005, Sweden

01:06-01 23
Cylinder head

IMPORTANT! Use torque screwdriver 588 179

to avoid the risk of shearing off the screws. The
entire unit injector must be renewed if the
screws shear off.

15 Reconnect the cables on the unit injectors.

Their relative position is not important. Use
torque screwdriver 588 179 to tighten the
screws to 2 Nm.
588 179
16 Fit the upper part of the rocker cover and 2 Nm
torque tighten the screws to 18 Nm.
17 Fit the exhaust manifold and tighten the

111 688
bolts to 63 Nm.
18 Fit the cooling system ventilation pipe.
19 Fit the fuel manifold with overflow line. 26 Nm
Torque tighten the screws to 26 Nm and the
banjo screws on the overflow line to 11 Nm.

112 367

Note: Make sure all the washers with rubber

seals are intact.

20 Fit the intake manifold.

 Scania CV AB 2005, Sweden

24 01:06-01
 Cylinder head

If cylinder head 1-2 was removed:

21 Fit the control unit cooler with control unit
and fuel filter.

If cylinder head 3-4 was removed:

22 Fit the crankcase ventilation unit.

If cylinder head 5-8 was removed:

23 Fit the charge air pipe between the
turbocharger and the charge air cooler.
24 Fit the inlet pipe to the crankcase ventilation
filter.
25 Screw on the connecting pipe between the
intake manifolds.

On all cylinder heads:

26 Connect the air line to the compressor.
27 Connect the pipe from the crankcase
ventilation.
28 Fit the inlet pipe between the air filter and
the turbocharger.

 Scania CV AB 2005, Sweden

01:06-01 25
Adjusting the unit injectors

Adjusting the unit injector with tool 99 414

Special tools

Number Designation Illustration

99 414 Setting tool Measuring tool cabinet

588 179 Torque screwdriver

114 769
29 Fit adjusting tool 99 414 with the metal
plate around the unit injector.

! WARNING!

When the unit injector is checked and 66.9

the measurement is outside

66.9+/-0.1 mm, it is necessary to be very
careful when handling this unit injector.
The spring is pre-tensioned and can
come loose, causing personal injury.
124 856

Setting tool 99 414 acts as a gauge with the

measurement 66.9 mm.

 Scania CV AB 2005, Sweden

26 01:06-01
 Adjusting the unit injectors
30 When adjusting, loosen the lock nut and
adjust the unit injector with adjusting screw
1. The unit injector is correctly set when the
small piston 2 is level with the flat upper
surface of the tool. Check using a finger. It
is possible to feel differences of less than a
millimetre. The setting dimension is
66.9 +/-0.1 mm.

Refer to tables in Order of adjustment for

unit injectors.

The setting tool piston is above or below the flat The setting tool piston is level with the flat upper
upper surface of the tool. Adjust the unit surface of the tool. The unit injector is correctly
injector. adjusted.

31 Torque tighten the lock nut to 39 Nm after

adjusting.
32 Remove tool 99 414.

IMPORTANT! Do not leave tool 99 414 in the

engine. The tool will break and the engine may
be damaged.

 Scania CV AB 2005, Sweden

01:06-01 27
Adjusting the unit injectors

IMPORTANT! Fit the cables so that they face

in the correct direction when fitting them on the
unit injector.

118 482
33 Reconnect the cables on the unit injectors.
Their relative position is not important. Use
torque screwdriver 588 179 to tighten the 588 179
screws to 2 Nm.

IMPORTANT! Use torque screwdriver 588 179

to avoid the risk of shearing off the screws. The
entire unit injector must be renewed if the
screws shear off.

107 675
34 If the cables to the unit injector are too long,
they can be clamped round the solenoid
valve on the unit injector.
35 Refit the upper rocker cover and torque
tighten the bolts to 12 Nm or 18 Nm
depending on the type of bolt, refer to 18 +− 3Nm 12 +− 3Nm
illustration.

36 Close the bleeder nipple and tighten the

banjo screw.
37 Fill and bleed the fuel system, refer to
Bleeding the fuel system.
116 621

 Scania CV AB 2005, Sweden

28 01:06-01
 Order of adjustment for unit injectors and valves

Order of adjustment for unit injectors and valves

Check and adjust the valve clearance with the

engine cold. The intake valve clearance should
be 0.45 mm and exhaust valve clearance
0.70 mm.
Rotate the flywheel using tool 99 309 so that the
mark on the flywheel is visible in the bottom
window according to the table below.

Mark on flywheel Valve change on Adjust injector Adjust intake Adjust exhaust
(degrees) cylinder rocker arm on valve on cylinder valve on cylinder
cylinder
TDC Down (0°) 6 4 and 5 7 and 8 4 and 5
TDC Up (180°) 7 2 and 6 1 and 5 2 and 6
TDC Down (360°) 1 3 and 7 2 and 4 3 and 7
TDC Up (540°) 4 1 and 8 3 and 6 1 and 8

It is a good idea to mark the rocker arm with a

pen after adjustment to keep track of what has
already been adjusted.
Torque tighten the lock nut on the rocker arm for
the unit injector to 39 Nm and the lock nut for
the valves to 35 Nm after adjusting. 5 1
6 2
7 3
8 4
106 007

Cylinder numbering

 Scania CV AB 2005, Sweden

01:06-01 29
Removing valves

Removing valves

Special tools

Number Designation Illustration Tool board

99 322 Drift 99 322
D5

100333
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.
99 322
2 Place the valves in a stand so that they can
be refitted in the same position in the
cylinder head.

01_1347

 Scania CV AB 2005, Sweden

30 01:06-01
 Fitting valves

Fitting valves

Special tools

Number Designation Illustration Tool board

99 322 Drift D5

1 Lubricate all parts well with engine oil

before assembly.

2 Insert the valve in the guide.

99 322
3 Fit the valve springs and the valve spring
collar.
4 Press together the springs in a press with
tool 99 322 and fit the collets. Ensure that
the collets are fitted in their correct
positions.

01 1350

 Scania CV AB 2005, Sweden

01:06-01 31
Checking and machining valves

Checking and machining valves

Specifications

Intake valve
Head angle 19.5°
Minimum dimension A for ground valve 2.6 mm

Exhaust valve
Head angle 44.5°
Minimum dimension A for ground valve 1.8 mm

Minimum dimension A for ground valve

Check dimension A on all valves. If the
measurement does not achieve the minimum
permitted dimension, the valve should be
renewed. The valve should also be renewed if
there are visible defects on intake valve head
surfaces.

 Scania CV AB 2005, Sweden

32 01:06-01
 Renewing the valve stem seal

Renewing the valve stem seal

Special tools

Number Designation Illustration Tool board

99 323 Drift 99 323 D5

100334
1 Remove the valve.

2 Remove the valve stem seal with a pair of

pliers.
3 Fit the valve.

01_1348
4 Tap in a new valve stem seal carefully using
tool 99 323 and a hammer.

99 323
01_1349

 Scania CV AB 2005, Sweden

01:06-01 33
Renewing the valve seats

Renewing the valve seats

Special tools

Number Designation Illustration Tool board

99 384 Drift 99 384
D1-A3

110 966
99 385 Shank 99 385 D1-B1

110 967

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.

111 213

 Scania CV AB 2005, Sweden

34 01:06-01
 Renewing the valve seats

! 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 Turn over the cylinder head and knock the

valve stem so that the valve and seat insert
fall out.

4 Press in new valve seat inserts. Use drift

99 384 and shaft 99 385. Cool the drift and
valve seat to approx. -80°C in carbon acid
ice or using liquid air. Pressing must be
carried out rapidly.

! WARNING!

Be careful when handling the cold parts

and the cooling agents named above.
Risk for frost injuries.

Oversize valve seat inserts can be fitted if the

valve seat insert position has been damaged. The
position must then be machined using tool
587 277.

 Scania CV AB 2005, Sweden

01:06-01 35
Machining the cylinder head

Machining the cylinder head

Valve seat insert, machining measurement

112 266

Exhaust valve Intake valve

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

 Scania CV AB 2005, Sweden

36 01:06-01
 Machining the cylinder head

Specifications

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
Valve seat insert position, diameter 46.000 - 46.016 mm
Valve seat insert position, depth 11.25 - 11.35 mm
Distance B between the cylinder head face and the valve disc 0.75 - 1.8 mm
Oversize valve seat insert:
External diameter 46.254 - 46.265 mm
Valve seat insert position, diameter 46.200 - 46.216 mm
Cooling temperature when fitting valve seat insert. approx. -80°C

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
Valve seat insert position, diameter 44.000 - 44.016 mm
Valve seat insert position, depth 11.25 - 11.35 mm
Distance B between the cylinder head face and the valve disc 0.66 - 1.8 mm
Oversize valve seat insert:
External diameter 44.281 - 44.292 mm
Valve seat insert position, diameter 44.200 - 44.216 mm
Cooling temperature when cooling valve seat insert. approx. -80 °C

 Scania CV AB 2005, Sweden

01:06-01 37
Machining the cylinder head

Tools

Number Designation Illustration

587 277 Valve seat cutter

106 794
588 487 Cutter (for exhaust valves)
588 488 Cutter (for intake valves)
588 489 Guide spindle

121027

588 145 Valve seat cutter 1

5
6

3
2
7
4
114 772

588 146 Cutter attachment

1 2

3
114 773

587 061 Valve seat cutter The tool has been

discontinued.
Tool kit 588 146 fits 587 061
when available.

Two equally good alternatives for cutters are

specified above.

 Scania CV AB 2005, Sweden

38 01:06-01
 Machining the cylinder head

The following description applies to valve seat

cutter 587 277.
Machining measurement and oversize valve seat
inserts, refer to Specifications.
1 Make sure the contact surface and magnetic
stand are level and clean. Clean the valve
bushings.

2 Select the largest spindle that moves easily

in the valve guide. Insert the guide spindle
and turn the feed screw to its uppermost
position.
3 Select the cutter and fit it.

4 Release the quick-action lock and move the

pivot plate to the upper position with the
adjusting screw.

 Scania CV AB 2005, Sweden

01:06-01 39
Machining the cylinder head

5 Set the dial on the cutter adjuster using a

valve.

6 Adjust the cutter. Diameter 37.9 mm and

39.8 mm respectively, refer to Valve seat
insert, machining measurement.

7 Turn off the magnet (position 2). Insert the

guide spindle into the valve bushing. Adjust
the pivot plate so that the distance between
the cutter and the valve seat is approx.
1 mm. Centre the tool precisely.
01_1233

 Scania CV AB 2005, Sweden

40 01:06-01
 Machining the cylinder head

8 Turn on the magnet (position 1).

9 Apply the quick-action lock. Make sure the
crank can be turned easily. If not, redo the
centering.
10 Machine the valve seat by cranking
clockwise while turning the feed screw.
Never crank counterclockwise as this will
damage the cutter. Lubricate with cutting oil
while machining.

11 When the surface of the valve seat has been

machined, reduce the cutting pressure by
turning 2-3 revolutions without any feed.
Continue turning while backing the feed
screw. 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. The tool has been
replaced but can be used if it is available in the
workshop. Tool kit 588 146 fits 587 061
Tool 588 145 with supplementary kit 588 146
are now available as an alternative to cutter
587 277.

 Scania CV AB 2005, Sweden

01:06-01 41
Renewing the valve guides

Renewing the valve guides

Special tools

Number Designation Illustration Tool board

99 382 Drift 99 382
D1-C6

110 864
99 383 Drift 99 383 D1-B1

110 865

1 Press out the valve guides using drift

99 383.

2 Press in the new valve guides with drift

99 382. Press down the guide as far as
possible using the drift, i.e. until it bottoms
against the spring seat in the cylinder head.

 Scania CV AB 2005, Sweden

42 01:06-01
 Renewing PDE unit injector sleeves

Renewing PDE unit injector sleeves

Special tools

Number Designation Illustration Tool board

99 394 Guide 99 394
D2-B1

113 219
99 395 Drift 99 395
D2-A1

113 221

99 397 Extension piece with threader 99 397

D2-C5, C6
shank 113 262

588 221 Pilot tap

113 297

The cylinder head must be removed when

renewing the sleeve for the unit injector. The
valves do not need removing. The illustration
shows the cylinder head with valves removed to
demonstrate clearly the work described.
1 Thread the lower part of the sleeve using the
pilot tap and guide.

 Scania CV AB 2005, Sweden

01:06-01 43
Renewing PDE unit injector sleeves

2 Knock out the pilot tap and sleeve from

underneath. Use a 100 mm long metal rod
of diameter 9 mm.

113 284
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 99 395
a thin film of sealing agent 561 200 on the
sleeve and cylinder head contact surfaces. 99 394

5 Press in the sleeve using the drift and guide.

113 231

 Scania CV AB 2005, Sweden

44 01:06-01
 Cylinder block

Cylinder block

Overhaul
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.

Tightening torques

Main bearing cap bolts 90 Nm + 90°

Side bolts 50 Nm + 90°

1 Measure the diameter at four different

113 584
positions as illustrated. The diameter must
be measured with the main bearing caps
tightened and without main bearings.

2 Compare the dimensions with those in the

table.

Minimum permitted Maximum permitted Greatest permitted difference between

diameter diameter the largest and smallest diameter on the
same main bearing seat.
112.200 mm 112.222 mm 0.016 mm

 Scania CV AB 2005, Sweden

01:06-01 45
Removing the cylinder liners

Removing the cylinder liners

Special tools

Number Designation Illustration Tool board

99 066 Cylinder liner puller D2

1 Mark the liners with the numbers 1-8. 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
115 739

surfaces are for sealing. If you use a marker, you

can mark anywhere.

2 Remove the cylinder liner using puller

99 066. 99 003

3 Remove the sealing ring in the cylinder

block.
99 066
100040

Cylinder liner puller with hydraulic hole

cylinder

 Scania CV AB 2005, Sweden

46 01:06-01
 Fitting the cylinder liners

Fitting the cylinder liners

1 Check liner height; refer to the section

Measuring the cylinder liner height.
2 Make sure the interior of the cylinder block
and cylinder liner is clean. Clean the O-ring
surfaces.
3 Carefully check the cylinder liners, both
new and old, for cracks that can arise during
transport or careless handling.

Tap the liner carefully with a metal object. It

should give a clear metallic ring if it is
intact. If it is cracked, it will sound
"cracked".
4 Lubricate the O ring to be located in the
cylinder liner with glycerine or unscented
soap and fit them.
5 Lubricate the lower guide surface on the
cylinder liner.
6 Turn the liner with the stamped cylinder
number facing forward and carefully tap it
down with a rubber mallet.

 Scania CV AB 2005, Sweden

01:06-01 47
Measuring the cylinder liner height

Measuring the cylinder liner height

Specifications

Cylinder liner height above cylinder block 0.15 - 0.30 mm

Cylinder liner height above cylinder block (with 0.20 - 0.30 mm
machined liner seat)
Maximum permitted height difference on one and the 0.02 mm
same liner between measurements made at two
diametrically opposite points

Special tools

Number Designation Illustration Tool board

87 198 Straight edge D2

98 075 Dial gauge D2

98 515 Tension lug

1 Thoroughly clean the cylinder block liner

shelf, the face around the cylinder, the
cylinder liner shelf and the upper face of the
98 075 87 198
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.

98 515 (x2)

 Scania CV AB 2005, Sweden

48 01:06-01
 Measuring the cylinder liner height

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 towards the cylinder block (B) and D
C
measure the height of the liner (A-B) as C
illustrated. Measure each liner at two
B A
diametrically opposite points.

100024
A Measured surface on cylinder liner
B Measured surface on cylinder block
C Tip of dial gauge
D Height of cylinder liner D = A-B
4 The cylinder liner must be slightly above
the face of the cylinder block.
5 The difference between the two
measurements on the same liner must not
exceed 0.02 mm. Height of cylinder liner D
(= A-B) over the cylinder block must be:
The height should be 0.15-0.30 mm after
renewing the cylinder liner or cylinder liner
seals.

 Scania CV AB 2005, Sweden

01:06-01 49
Machining cylinder liner height

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 engines 0.20 - 0.30 mm
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

 Scania CV AB 2005, Sweden

50 01:06-01
 Machining cylinder liner height

Special tools

Number Designation Illustration Tool board

587 512 Cylinder liner cutter

114 068
588 672 Extension

1 Clean the contact surface between the

centering 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

135637
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.

206mm
135638

 Scania CV AB 2005, Sweden

01:06-01 51
Machining cylinder liner height

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.
Otherwise the vertical feed screw must be
wound up until the cutter is released from
the liner seat.

135639
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.
135641

 Scania CV AB 2005, Sweden

52 01:06-01
 Machining cylinder liner height

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.

135642
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 position 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

135640
cutter anti-clockwise, otherwise the cutter will
break.

 Scania CV AB 2005, Sweden

01:06-01 53
Machining cylinder liner height

11 Move the cutter back towards the centre of

the liner hole by holding down the rapid
feed ring at the same time as the cutter is
moved back by hand.

12 Repeat steps 9-11 if insufficient cutting

depth has been attained.
13 When the required depth has been obtained,
hold down the rapid feed ring and move the
cutter to the middle of the cylinder hole.
Change the switch on the cylinder liner

135641
cutter to position 2 and lift out the entire
tool. Then remove the centering ring.
14 Clean the liner seat and the engine from
grindings.
15 Put the shim in place in the liner seat. The
shim should be dry.
16 Position the cylinder liner.
17 Check the measurement to ensure that the
height corresponds to the height according
to the measurement of the cylinder liner
height.

 Scania CV AB 2005, Sweden

54 01:06-01
 Renewing the rear crankshaft seal

Renewing the rear crankshaft seal

Special tools

Number Designation Illustration Tool board

99 410 Assembly tool 99 410 D5

116 247
1 Remove the flywheel according to the
section Removing the flywheel.
2 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
must not be removed until just before the

11 901
crankshaft seal is to be fitted on the engine.

3 Fit a new crankshaft seal using tool 99 410.

Place the crankshaft seal on the tool and
fasten the tool with the bolts.

4 Turn the tool clockwise until it stops in

order to attain the correct crankshaft seal
position.
5 Fit the flywheel according to the section
Fitting the flywheel.
116 612

 Scania CV AB 2005, Sweden

01:06-01 55
Removing the camshaft bearing

Removing the camshaft bearing

Special tools

Number Designation Illustration Tool board

99 003 Hydraulic cylinder H1

99 004 Air-operated hydraulic pump H1

99 373 Tool for renewing camshaft D5

bearing (only the holder (3) 3
should be used)
1

2 113 838

99 516 Drift for pressing camshaft D1

bearings in and out
135 645

99 517 Socket D1

99 518 Bar for pressing camshaft D1

bearings in and out
135 647

99 519 Spacer D1
135 648

 Scania CV AB 2005, Sweden

56 01:06-01
 Removing the camshaft bearing

1 Remove the camshafts as described in this

booklet.

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.

2 Clean the camshaft seats.

3 Screw together hydraulic cylinder 99 003

and flange 99 373. Align spacer 99 519 and
screw the flange onto the cylinder block.

4 Insert the bar through the hydraulic cylinder

so that the outer hole on the bar is behind
the bearing to be renewed.

 Scania CV AB 2005, Sweden

01:06-01 57
Removing the camshaft bearing

5 Secure drift 99 516 in the outer hole on the

bar using a 12.9 M8 screw.

6 Pull the bar until the drift is locked in the

bearing. Attach the socket next to the
hydraulic cylinder using an 8 mm impact
drift.

7 Connect the hydraulic cylinder to the

hydraulic pump. Start the hydraulic pump
and run it until the bearing has become
completely detached from the bearing seat.

 Scania CV AB 2005, Sweden

58 01:06-01
 Removing the camshaft bearing

8 Detach the drift from the bar. Remove the

bearing.

9 Release the remaining bearings in the same

way.

 Scania CV AB 2005, Sweden

01:06-01 59
Fitting the camshaft bearing

Fitting the camshaft bearing

Special tools

Number Designation Illustration Tool board

99 003 Hydraulic cylinder H1

99 004 Air-operated hydraulic pump H1

99 373 Tool for renewing camshaft D5

bearing (only the holder (3) 3
should be used)
1

2 113 838

99 516 Drift for pressing camshaft D1

bearings in and out
135 645

99 517 Socket D1

99 518 Bar for pressing camshaft D1

bearings in and out
135 647

99 519 Spacer D1
135 648

 Scania CV AB 2005, Sweden

60 01:06-01
 Fitting the camshaft bearing

1 Clean the bearing seats thoroughly and

check that there is no damage to any of
them.

2 Screw together hydraulic cylinder 99 003

and flange 99 373. Align spacer 99 519 and
screw the flange into the cylinder block.

3 Insert the bar 99 518 through the hydraulic

cylinder 99 003 so that the outer hole on the
bar 99 518 is behind the bearing seat the
bearing should be fitted to.

 Scania CV AB 2005, Sweden

01:06-01 61
Fitting the camshaft bearing

4 Put a new bearing on drift 99 516. Make

sure that the ball on drift 99 516 fits the
round bearing lubrication hole correctly.
The bearing must be fitted in the right
direction. On the right camshaft, the recess
on the bearing must be turned forwards in
the direction of the water pump. On the left
camshaft, the bearings should be turned so
that the recesses are turned towards the
flywheel. Lubricate the bearings externally
so that they slide in more easily.

IMPORTANT! Make sure the bearings are

facing the right direction so that the lubrication
holes in the bearing correspond to the
lubrication holes in the cylinder block.

5 Fasten drift 99 516 in the outer hole on the

bar with the lubrication hole facing
upwards. Fasten with a 12.9 M8 bolt.

 Scania CV AB 2005, Sweden

62 01:06-01
 Fitting the camshaft bearing

6 Pull out the bar through the hydraulic

cylinder so that socket 99 517 can be locked
in it using an 8 mm impact drift. The impact
drift should point vertically so that the
lubrication ducts are correctly located.

7 Connect the hydraulic cylinder 99 003 to the

hydraulic pump 99 004. Run it until the
bearing is correctly located according to the
measurements on the next page. Check that
the drift is still vertical when the bearing is
in position.

8 Check that the lubrication hole is open. This

can be done by looking down the hole and
for example by sticking a scribing needle
into it.

Camshaft bearing number Distance (mm)

1 -13
2 196
3 400
4 603
5 811

The values in the table should be interpreted as

follows. The bearing is in the correct position
when the distance between the cylinder block
and the front edge of drift 99 516 corresponds to
the value in the table. 13 mm therefore means
that the drift protrudes 13 mm from the front
edge of the cylinder block.

 Scania CV AB 2005, Sweden

01:06-01 63
Removing the flywheel housing

Removing the flywheel housing

1 Remove the oil pipe to the turbocharger.

2 Remove the engine speed sensors.
3 Remove the flywheel as described in
Flywheel, removing.
4 Disconnect the negative battery cable.
5 Detach the cables to the starter motor.
6 Remove the starter motor.
7 Remove the compressor.

8 Remove the exhaust manifold, intake

manifold and exhaust pipe from the
turbocharger.
9 Remove the turbocharger and the

111 903
turbocharger manifold.
10 Remove the power take-off or the cover for
the power take-off.
11 Remove the oil sump.
12 Remove the flywheel housing.

 Scania CV AB 2005, Sweden

64 01:06-01
 Fitting the flywheel housing

Fitting the flywheel housing

Tightening torques

Bolts for flywheel housing Flange bolt and stud, M12:

92 Nm
Flange bolt, M10: 50 Nm
Nut for turbocharger manifold 92 Nm
Bolts for oil sump 32 Nm
Plug for oil sump 80 Nm

Description
1 Clean the sealing surfaces. Carefully
remove any remains of the old gasket. M12

2 Fit the flywheel housing with a new gasket. M10 M10

M10
The two appendages, A and B, are to be
removed and used for bolts A and B.
3 Fit the bolts. Torque tighten the M12 bolts M12
and studs to 92 Nm and the M10 bolts to
50 Nm. M10
A B
4 Fit the oil sump with a new gasket. Tighten
the bolts to 32 Nm. Fit the power take-off or M12
the cover for the power take-off. M12

5 Fit the turbocharger and the turbocharger

manifold, torque tighten the nut to 92 Nm.

A B
112 295

 Scania CV AB 2005, Sweden

01:06-01 65
Fitting the flywheel housing

6 Fit the exhaust manifold, intake manifold

and exhaust pipe from the turbocharger.
7 Fit the compressor.
8 Fit the starter motor and the cables to the
starter motor.
9 Fit the flywheel as described in Flywheel,
fitting.
10 Fit the engine speed sensors. Fit a new
O-ring onto the camshaft sensor.
11 Fit the oil pipe to the turbocharger.

 Scania CV AB 2005, Sweden

66 01:06-01
 Removing the front timing gear casing

Removing the front timing gear casing

1 Drain the coolant.

2 Remove the pipe between the air cleaner
and the turbocharger.
4 9 5 4
3 Remove the compressed air pipe in front of
the belts.

4 Remove the ribbed charge air pipes between 7

the engine and the charge air cooler.
5 Remove the right-hand side radiator pipe.
6 Remove the poly-V-belts.
7 Detach the AC pipe attachments to the
charge air pipes.
8 Remove the AC compressor without 3
breaking the circuit and place it over the
radiator. 2

9 Remove the charge air cooler to engine

charge air pipe. The charge air pipe running
between the turbocharger and charge air
cooler may need to be loosened and moved
slightly in order to release the charge air
pipe between the charge air cooler and
engine.

136 136

 Scania CV AB 2005, Sweden

01:06-01 67
Removing the front timing gear casing

10 Remove the fan and place it in the radiator

mask.

136085
11 Remove the fan bearing assembly.

136081

12 Disconnect the power steering pump and

place to one side. Do not detach the hoses.
136 188

 Scania CV AB 2005, Sweden

68 01:06-01
 Removing the front timing gear casing

13 Remove the coolant temperature sensor and

oil pressure sensor.

136 139
14 Disconnect the fuel connections from the
feed pump and clamp them out of the way.
Detach the fuel pump and let it hang in the
supply pipe.

136 138
15 Remove the oil filter housing, it is fitted
with four bolts.

16 Remove the idler roller.

136 140

 Scania CV AB 2005, Sweden

01:06-01 69
Removing the front timing gear casing

17 Remove the timing gear casing. See the

illustration for the location of the screws.

136 200

 Scania CV AB 2005, Sweden

70 01:06-01
 Fitting the front timing gear casing

Fitting the front timing gear casing

1 Fit a new gasket in the timing gear casing

groove.
2 Bolt the front timing gear casing to the
cylinder block.
3 Fit the oil filter housing with a new filter
element and a new gasket.

136 140
4 Fit the feed pump and connect the fuel
connections.

136 196

5 Fit the coolant temperature sensor and oil

pressure sensor.
136 139

 Scania CV AB 2005, Sweden

01:06-01 71
Fitting the front timing gear casing

6 Fit the power steering pump.

7 Refit the idler roller.

136 195
8 Refit the fan bearing. Tighten the bolts to
39 Nm.

9 Refit the poly-V-belts.

136081

10 Refit the fan. Tighten the bolts to 30 Nm

(M8).
136084

 Scania CV AB 2005, Sweden

72 01:06-01
 Fitting the front timing gear casing

11 Fit the charge air cooler to engine charge air

pipe (9).
4 9 5 4
12 Refit the AC compressor.
13 Refit the AC compressor attachments (7) to
the charge air pipes.
7
14 Fit the radiator pipes (5) on the right-hand
side.
15 Fit the ribbed charge air pipes (4).
16 Fit the compressed air pipe (3).
17 Fit the pipe between the air cleaner and
turbocharger (2).
3

136 136
18 Fill with coolant according to the work
description Cooling system, Filling coolant.
19 Test run the engine and check that no
leakage occurs.

 Scania CV AB 2005, Sweden

01:06-01 73
Renewing the front crankshaft seal

Renewing the front crankshaft seal

Special tools

Number Designation Illustration Tool board

99 374 Press tool for crankshaft seal D5

1 Remove the poly-V-belts and belt pulleys on

the crankshaft.

Note: The crankshaft seal seals against the inner

belt pulley. Handle the belt pulley with care

108 969

Sealing surface for crankshaft seal

2 Remove the crankshaft seal using a

screwdriver. Take care not to damage the
sealing surface in the housing.
114 486

 Scania CV AB 2005, Sweden

74 01:06-01
 Renewing the front crankshaft seal

3 Wipe clean the sealing ring seat in the

housing.

Note: The crankshaft seal must be fitted dry and

must not be lubricated. The sleeve in the seal
must not be removed until just before the
crankshaft seal is to be fitted on the engine.

4 Place the new seal in tool 99 374 and press

it in place by tightening the bolts alternately. 99 374
The seal is correctly fitted when the tool
bottoms.

114 487
5 Remove the tool. Fit the bolts into the
threaded holes and use as a handle to make
removal easier.
6 Wipe clean the sealing surface on the belt
pulley and fit it immediately.
7 Fit the outer belt pulley.
8 Fit the poly-V-belts.

 Scania CV AB 2005, Sweden

01:06-01 75
Removing the crankshaft cover

Removing the crankshaft cover

1 Drain the coolant.

2 Remove the pipe between the air cleaner
and the turbocharger.
4 9 5 4
3 Remove the compressed air pipe in front of
the belts.
4 Remove the ribbed charge air pipes between
7
the engine and the charge air cooler.
5 Remove the right-hand side radiator pipe.
6 Remove the poly-V-belts.
7 Detach the AC pipe attachments to the
charge air pipes.
8 Remove the AC compressor without 3
breaking the circuit and place it over the
radiator. 2

9 Remove the charge air cooler to engine

charge air pipe. The charge air pipe running
between the turbocharger and charge air
cooler may need to be loosened and moved
slightly in order to release the charge air
pipe between the charge air cooler and
engine.

136 136

 Scania CV AB 2005, Sweden

76 01:06-01
 Removing the crankshaft cover

10 Remove the radiator fan and place it in the

radiator mask.

136085
11 Remove the fan bearing and its bracket.

136081
12 Remove the belt pulleys on the crankshaft.

13 Remove the immersion heater on vehicles

with an engine heater.
136 126

 Scania CV AB 2005, Sweden

01:06-01 77
Removing the crankshaft cover

14 Remove the coolant temperature sensor.

136080
15 Remove the belt tensioner in the alternator
circuit.

16 Remove the oil sump.

IMPORTANT! Do not prise off the crankshaft

cover by prising with something against the
gasket surface between the crankshaft cover and
cylinder block. There is a risk of the crankshaft
cover being damaged.

136082

17 Remove the crankshaft cover by unscrewing

the 13 bolts which are used to fasten it. Then
tap off the crankshaft cover.

18 Remove the gasket and scrape off any

gasket debris.
136079

 Scania CV AB 2005, Sweden

78 01:06-01
 Fitting the crankshaft cover

Fitting the crankshaft cover

1 Fit a new gasket on the back of the

crankshaft cover. Make sure it is secured in
the groove.
2 Fit the crankshaft cover. Make sure the
gasket is correctly located once the cover is
fitted. Tighten the crankshaft cover. See the
illustration for the location of the screws.

3 Fit a new oil sump gasket.

4 Fit the oil sump.

136079
5 Fit the belt tensioner in the alternator circuit.

136082

 Scania CV AB 2005, Sweden

01:06-01 79
Fitting the crankshaft cover

IMPORTANT! Handle the temperature sensor

with care.

6 Fit the coolant temperature sensor.

7 Fit the immersion heater on vehicles with an
engine heater.
8 Fit the belt pulleys on the crankshaft.

136 126
9 Fit the fan bearing with bracket.

136081

10 Fit the fan.

136084

 Scania CV AB 2005, Sweden

80 01:06-01
 Fitting the crankshaft cover

11 Fit the pipe between the charge air cooler

and the engine (9). If the pipe cannot be
fitted, move the charge air cooler pipe
between the turbocharger and charge air
cooler slightly.
12 Fit the AC compressor.

13 Screw on the AC pipe attachments to the

engine (7). 9 5 4
4

14 Fit the poly-V-belts.

15 Fit the radiator pipe on the right-hand side
(5). 7

16 Fit the ribbed charge air pipes (4).

17 Fit the compressed air line from the
compressor (3).
18 Fit the inlet pipe between the air filter and
the turbocharger (2).

19 Fill up with oil and coolant. 3

136 136

 Scania CV AB 2005, Sweden

01:06-01 81
Renewing rivet plug in cylinder block

Renewing rivet plug in cylinder block

Special tools

Number Designation Illustration Tool board

587 542 Blind rivet tool

587 470 Pin extractor

136 155
In case of leakage around the rivet plug, the
rivet plug should be renewed as follows:
1 Remove the turbocharger according to
section Removing the turbocharger.
2 Remove the straight union which is
connected to the turbocharger lubrication oil
pipe.

137 470

3 Insert a 6 mm internal hexagon key in the

lubrication duct where the straight union
was fitted. Check that the internal hexagon
key is inserted the whole way under the
rivet plug to prevent the plug from falling
into the cylinder block.

IMPORTANT! The internal hexagon key must

be inserted under the rivet plug. There is a great
risk of serious engine damage if the rivet plug
falls into the cylinder block.
137 471

 Scania CV AB 2005, Sweden

82 01:06-01
 Renewing rivet plug in cylinder block

4 Attach the internal hexagon key so that it

does not move out of place when the rivet
plug is tapped.
5 Tap out the middle part of the rivet plug
using a 4 mm impact drift.

137 472
6 Attach a 6 mm plate screw (815 191 or
similar) in a suitable socket to pin extractor
587 470. Make sure that the screw is
properly attached.

7 Screw on pin extractor 587 470 with the

screw in the outer part of the rivet plug. Pull
it off hard.
8 Lift out the middle part of the rivet plug
using a magnet.

137 473
9 Remove the internal hexagon key.
10 Fit a new rivet plug using tool 587 542.
11 Fit the straight sleeve.

12 Fit the turbocharger according to section

Fitting the turbocharger.
137 470

 Scania CV AB 2005, Sweden

01:06-01 83
Crank mechanism

Crank mechanism
Exploded view drawing

Crank mechanism

2
3
4

1
13

6 5
5

14

7
8

15

12

10
115 265

11

1 Piston 9 Bearing shell

2 Compression ring 10 Bearing cap
3 Compression ring 11 Flange bolt
4 Oil scraper ring 12 Crankshaft
5 Retaining ring 13 O-ring
6 Gudgeon pin 14 Cylinder liner
7 Connecting rod 15 O-ring
8 Bearing bushing

 Scania CV AB 2005, Sweden

84 01:06-01
 Crank mechanism

General tightening torques

Specifications

The following tightening torques apply in general

unless otherwise specified:
Flange bolt M6 8.6 Nm
Flange bolt M8 26 Nm
Flange bolt M10 50 Nm
Flange bolt M12 92 Nm
Stud in casting M8 13 Nm
Stud in casting M10 25 Nm

A tolerance of +/-15% applies to the specified

tightening torques unless stated otherwise.

 Scania CV AB 2005, Sweden

01:06-01 85
Removing a piston

Removing a piston

1 Remove the cylinder head as described in

Cylinder head, removing.
2 Remove the oil sump.
3 Remove the piston cooling nozzle in the
cylinder block.

IMPORTANT! 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 and result in engine breakdown.
Damaged nozzles must not be re-aligned, renew
them instead.

4 Remove the bearing cap and bearing shells.

Protect the oilway in the crankshaft e.g. by
winding tape around it with the adhesive
side out.
5 Mark the piston before removing it. The
parts must be refitted in the same place and
position. Lift out the piston and connecting
rod.

Note: Always check the connecting rod as

described in Connecting rod, checking, if the
cylinder has seized, been filled with water or
had a broken valve. Bent connecting rods must
not be straightened.

 Scania CV AB 2005, Sweden

86 01:06-01
 Fitting a piston

Fitting a piston

Tightening torques

Bolts for oil sump 32 Nm

Connecting rod bolts 50 Nm +90°
Piston cooling nozzle 23 Nm

Special tools

Number Designation Illustration Tool board

98 212 Piston ring compressor D3

Description
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 gaps are
distributed around the piston.
4 Fit the upper connecting rod bearing shell
and lubricate the bearing surface.

 Scania CV AB 2005, Sweden

01:06-01 87
Fitting a piston

5 Fit the connecting rod and piston. The arrow

on the piston must be facing the front of the
engine. Applies to aluminium pistons only,
steel pistons are symmetrical. Clamp the
piston ring compressor 98 212 and push the
piston into the cylinder.

116 033
6 Fit the connecting rod bearing shell into the
cap and lubricate the bearing surface. Fit the
cap. Lubricate the bolts, fit them and torque
tighten to 50 Nm +90°.

7 Fit the piston cooling nozzle. Tightening

torque 23 Nm.

IMPORTANT! The piston cooling nozzle must

116 085
not be damaged. The oil jet must hit the piston
precisely. If it does not, the piston will become
too warm and result in engine breakdown.
Damaged nozzles must not be re-aligned, renew
them instead.

8 Fit the oil sump. Torque tighten the bolts to

32 Nm.
9 Fit the cylinder head. Tighten the cylinder
head bolts as described in Cylinder head,
fitting.

 Scania CV AB 2005, Sweden

88 01:06-01
 Renewing a piston

Renewing a piston

Specifications

Piston rings
Number of compression rings 2 off
Gap:
1st ring 0.35 - 0.60 mm
2nd ring 0.45 - 0.65 mm
Maximum clearance in groove, 2nd ring 0.25 mm
Number of oil scraper rings 1 off
Gap 0.40 - 0.65 mm
Maximum clearance in groove 0.25 mm

Turn the rings marked "TOP" with the mark face

up.

Special tools

Number Designation Illustration Tool board

87 362 Drift 87 362 D3
110 315

Other tools

Number Designation Illustration Tool board

587 309 Piston ring expander D3
106 796

 Scania CV AB 2005, Sweden

01:06-01 89
Renewing a piston

1 Place the connecting rod in a vice with soft

jaws. Remove the retaining rings for the
gudgeon pin.

100 209
2 Push out the gudgeon pin using drift 87 362.

87 362

100 210
3 Remove the piston rings using tool 587 309.
587 309
Take care not to scratch the surface of the
piston skirt with the piston rings.

4 It is possible that the graphite coating will

disappear after washing graphite coated
pistons in a washer. This does not matter
after they have been in use for a while. New
pistons, however, should be washed with
care in e.g. white spirit.

 Scania CV AB 2005, Sweden

90 01:06-01
 Renewing a piston

5 Clean the piston and its rings thoroughly

without scratching the sides of the ring
grooves. Clean the oil holes in the piston.
6 Make sure the piston ring gaps do not
exceed the permitted limit. Place the piston
rings inside the cylinder liner and measure
the gap with a feeler gauge. Refer to
Specifications for permitted gap.
7 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.
8 Oil all the bushings, the gudgeon pin hole
and the gudgeon pin before assembling.
9 Fit the piston skirt to the piston crown and
fit one of the gudgeon pin retaining rings.
10 Put the piston onto the connecting rod so
that the arrow marks on the piston are facing
forwards towards the engine. Applies to
aluminium pistons only, steel pistons are
symmetrical.

11 Insert the gudgeon pin using tool 87 362 and

fit the second gudgeon pin retaining ring.

116 033

116 085

 Scania CV AB 2005, Sweden

01:06-01 91
Checking the connecting rod

Checking the connecting rod

Tools

Number Designation Illustration Tool board

587 110 Control device -

Connecting rods and bearing caps marked 1 up

to and including 8.
Check the connecting rods using tool 587 110.
Make sure the gudgeon pin bushing is not
damaged and then proceed as below:
1 Fit the bearing cap as marked and torque
tighten the bolts to 50 Nm +90°.
2 Fit the connecting rod in the tool using the
expander and put the corresponding
gudgeon pin in the gudgeon pin bushing.
3 Then apply the indicator to the gudgeon pin.
Check whether the connecting rod is twisted 01 1216

with the indicator studs horizontal.

 Scania CV AB 2005, Sweden

92 01:06-01
 Checking the connecting rod

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. 0.05 mm when
measured using this tool. Check with a feeler
gauge.

01_1215
Check also whether the connecting rod is bent in
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. The difference between
the two measurements should be between
3.3 - 4.5 mm.
01_1227

 Scania CV AB 2005, Sweden

01:06-01 93
Checking the connecting rod

Renewing connecting rods

If a connecting rod needs renewing it is

important to remember that the weight
classification of connecting rods affect the
engine performance.
In V-engines the connecting rods must be of a
compatible weight classification to avoid
imbalance. Imbalance leads to additional
vibrations which in the long term may damage
the engine.
There are five weight classifications for
connecting rods: AA, A, B, C and CC. The
weight classification is marked on the
connecting rod big end.

During production, the connecting rods are

paired as follows:
AA+CC
A+C
B+B
136 169

Only connecting rods with weight classification

B are available as spare parts. B+B is therefore
the only permitted combination when renewing
connecting rods. This means that if the
corresponding connecting rod is of a different
weight classification to B, it also must be
renewed.

 Scania CV AB 2005, Sweden

94 01:06-01
 Checking the connecting rod

Renewing bearing bushing in connecting rod

Special tools

Number Designation Illustration

99 403 Tool for renewing bearing 99 403

bushing 3

1
2

115 527
Use tool 99 403 when renewing the bearing 99 403
bushing.
3
The tool comprises three parts:

1. Pressplate with guide pin

2. Press drift
3. Supports
1
There are different supports, depending on the 2

115 527
engine type. A support marked E is for DC16.

1 Place the connecting rod on the pressplate

so that the wide end of the connecting rod is
resting against support E. Turn the press
drift with the smaller diameter against the
bearing bushing and press it out.
115 528

 Scania CV AB 2005, Sweden

01:06-01 95
Checking the connecting rod

2 Turn the press drift and mount a new

bearing bushing onto it. Press in the bearing
bushing.

115 529
After pressing in a new bearing bushing, it must
be finish-turned. This requires special
equipment. Measurements as illustrated.

Diameter, d = 54.030-54.043 mm.

Surface quality = 0.6 Ra.

 Scania CV AB 2005, Sweden

96 01:06-01
 Removing the flywheel

Flywheel

Removing the flywheel

Special tools

Number Designation Illustration Tool board

87 368 Puller bolt 87 368 AM1, D3, B1, AD1

00 1805
1 Remove the rotation speed sensor from the
flywheel.
2 Remove the bolts for the flywheel.
3 Pull off the flywheel from the crankshaft
using puller bolts 87 368.

4 The flywheel can be lifted using two

M10x100 bolts that have been partially
threaded into the holes.
111 898

87 368
111 899

 Scania CV AB 2005, Sweden

01:06-01 97
Fitting the flywheel

Fitting the flywheel

Specifications

Flywheel
Max. machining allowance for disc pressure surface Refer to group 4, clutch

Tightening torques
Flywheel bolts 130 Nm +90°

Special tools

Number Designation Illustration Tool board

99 324 Guide pins 99 324 D5
100335

99 411 Tool for locking flywheel 99 411

D5
116 489

1 Fit two guide pins 99 324 in the flywheel

housing.
2 Fit the flywheel on the crankshaft.

o
IMPORTANT! Always use new bolts. 130Nm + 90

3 Torque tighten the bolts alternately to

130 Nm and then a further 90°. Use tool
99 411 to lock the flywheel.
4 Fit the rotation speed sensor. o
90
115 798

 Scania CV AB 2005, Sweden

98 01:06-01
 Renewing support bearing in flywheel

Renewing support bearing in flywheel

Special tools

Number Designation Illustration Tool board

99 250 Drift 99 250
D3, C4

112 640
1 Remove the retaining rings on both sides of 99 250
the support bearing.
2 Knock out the support bearing from the
flywheel using drift 99 250.
3 Fit the inner retaining ring and a new
support bearing using drift 99 250.

01_1392
4 Fit the outer retaining ring.

 Scania CV AB 2005, Sweden

01:06-01 99
Renewing the ring gear on the crankshaft

Renewing the ring gear on the crankshaft

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
circumference to 100 - 150°C.

111 900
4 Lay the heated ring gear on the flywheel so
that the bevelled side is facing the starter
motor. 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.

 Scania CV AB 2005, Sweden

100 01:06-01
 Removing the crankshaft

Crankshaft

Removing the crankshaft

The crankshaft must be removed while the

engine is suspended in the universal stand. Refer
to Mounting the engine in a universal stand.
1 Remove the oil sump.
2 Remove the flywheel as described in
Flywheel, removing.
3 Remove the flywheel housing as described
in Flywheel housing, removing.
4 Remove the oil strainer and the suction pipe.
5 Remove the poly-V-belts.
6 Remove the fan ring and the fan.
7 Remove the cylinder heads as described in
Cylinder head, removing.
8 Remove the belt pulleys on the front of the
crankshaft.
9 Remove the front housing.
10 Remove the crankshaft damper with spacer
sleeve.

 Scania CV AB 2005, Sweden

01:06-01 101
Removing the crankshaft

11 Remove the piston cooling nozzles.

IMPORTANT! 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 and result in engine breakdown.
Damaged nozzles must not be re-aligned, renew
them instead.

12 Turn the engine so that it is vertical.

13 Lift out the pistons and connecting rods.
Turn the crankshaft so that the piston to be
removed is at TDC. To be able to rotate the
crankshaft, the crankshaft gear must be
secured with two flywheel bolts and two
50 mm spacers. 2

113 059
1

1 50 mm long spacers
2 Flywheel bolts

14 Turn the engine upside down.

15 Remove the crankshaft gear.
112 362

Engine, after removing steps 1-13

 Scania CV AB 2005, Sweden

102 01:06-01
 Removing the crankshaft

16 Remove the main bearing caps. Protect the

oilway in the crankshaft e.g. by winding
tape around it with the adhesive side out.

Note: The main bearing caps are marked and

must be refitted in the same place.

17 Remove the lower and upper thrust washers.

18 Lift out the crankshaft.

112 363

 Scania CV AB 2005, Sweden

01:06-01 103
Fitting the crankshaft

Fitting the crankshaft

Tightening torques

Main bearing cap bolts 90 Nm +90°

Side bolts 180 Nm
Connecting rod cap bolts 50 Nm +90°
Bolts to crankshaft damper 135 Nm
Bolts to inner belt pulley on crankshaft 92 Nm

All parts must be cleaned before fitting.

1 Place the bearing shells in the main bearing
seats in the engine block and then lubricate
the bearing surface with engine oil.

Note: The outside of the bearing shells must not

be lubricated.

2 Lift in the crankshaft.

3 Fit the thrust bearing washers.
4 Place the main bearings in the main bearing
caps and fit them. Torque tighten the cap
bolts to 90 Nm +90°. 5

90 Nm + 90
5

Note: The main bearing caps are marked and

must be refitted according to the marks on the
block. 180 Nm

5 Torque tighten the side bolts to 180 Nm.

112 364

 Scania CV AB 2005, Sweden

104 01:06-01
 Fitting the crankshaft

6 Fit the crankshaft gear so that the marks on

the crankshaft gear and the intermediate
gear are pointing at each other. Secure the
gear with two flywheel bolts and two
50 mm long spacers.

113 059
1

1 50 mm long spacers
2 Flywheel bolts

7 Turn the engine so that it is vertical.

8 Fit the piston and connecting rod as
described in Fitting the piston and
connecting rod. o
50 Nm + 90
9 Fit the connecting rod bearing into the
connecting rod cap and lubricate the bearing
surface. Fit the cap. Lubricate the bolts and
torque tighten them to 50 Nm +90°.

10 Clean the cylinder heads and fit them as

described in Cylinder head, fitting.
11 Fit the crankshaft damper and spacer sleeve.

112 365
Torque tighten the bolts to 135 Nm.

 Scania CV AB 2005, Sweden

01:06-01 105
Fitting the crankshaft

12 Clean and fit the gaskets for the front

housing and engine heater outlet. Fit the 92 Nm
front housing.
13 Fit the belt pulleys on the crankshaft.
Torque tighten the bolts on the inner belt
pulley to 92 Nm.

14 Fit the oil strainer and suction pipe.

15 Fit the flywheel housing as described in

112 366
Flywheel housing, fitting.
16 Fit the flywheel as described in Flywheel,
fitting.
17 Fit the fan, the fan ring and the poly-V-belts.
18 Fit the oil sump.

 Scania CV AB 2005, Sweden

106 01:06-01
 Timing gear

Timing gear

Exploded view drawing

42

45
46 44 38
45
7 9

4
43 8 34
3 9
5 6
39
4
40
41 3
5

2 15
1

14

10

31
11
12 16
13
36
30
32
29
23
37 33 28
22
27
26 21
20
25
24 19

18
116 686

17

35

 Scania CV AB 2005, Sweden

01:06-01 107
Timing gear

1 Camshaft 17 Spacer sleeve 33 Power take-off drive gear

2 Camshaft 18 Intermediate gear 34 Compressor gear
3 Pin 19 Ball bearing 35 Crankshaft gear
4 Guide flange 20 Ball bearing 36 Hydraulic pump gear
5 Flange bolt M10x30 21 Retaining ring 37 Feed pump gear
6 Thrust washer 22 Shaft journal 38 Shaft
7 Camshaft gear 23 Screw 39 Roller tappet
8 Camshaft gear 24 Spacer sleeve 40 Roller tappet
9 Flange bolt M10x40 25 Intermediate gear 41 Roller tappet
10 Intermediate gear 26 Ball bearing 42 Retaining ring
11 Ball bearing 27 Ball bearing 43 Guide sleeve
12 Retaining ring 28 Retaining ring 44 Flange bolt
13 Spacer sleeve 29 Shaft journal 45 Pushrod
14 Shaft 30 Screw 46 Pushrod
15 Screw 31 Camshaft gear
16 Oil pump gear 32 Flange bolt

 Scania CV AB 2005, Sweden

108 01:06-01
 Removing the intermediate gear

Removing the intermediate gear

Special tools

Number Designation Illustration Tool board

99 309 Turning tool D5

100330
87 596 Slide hammer 87 596
D2

00_1610
1 Position the engine so that cylinder 6
changes direction, the crankshaft is turned
to 0°, the text "down TDC" is visible in the
lower window on the flywheel. Use tool
99 309 to rotate the engine.

2 Remove the flywheel as described in 99 309

Flywheel, removing.
3 Remove the flywheel housing as described
in Flywheel housing, removing.

01_1388

 Scania CV AB 2005, Sweden

01:06-01 109
Removing the intermediate gear

4 Secure the crankshaft gear to prevent it from

being moved out of position on the
crankshaft. Use two flywheel bolts and two
50 mm long spacers.

111 906
1

1 50 mm long spacers
2 Flywheel bolts

5 Loosen the centre bolt on the intermediate

gear.

IMPORTANT! The camshaft and crankshaft

must not be rotated once the intermediate gear
has been removed. Pistons and valves can
collide and be damaged.

6 Remove the intermediate gear with slide

hammer 87 596. Fit the slide hammer 87 596
alternately in the two timing holes.
111 907

 Scania CV AB 2005, Sweden

110 01:06-01
 Fitting the intermediate gear

Fitting the intermediate gear

Tightening torques

Screws to intermediate gear 50 Nm +60 °

1 Secure the crankshaft gear to prevent it from

being moved out of position on the
crankshaft. Use two flywheel bolts and two
50 mm long spacers.
2 Fit the intermediate gear. Make sure the
marks on the intermediate gear correspond
with the relevant marks on the crankshaft
and camshaft gears. Torque tighten the bolts
to 50 Nm +60°.

IMPORTANT! It is the same crankshaft gear on

D9, D11, D12 and DC16. Check the marking on
the crankshaft gear during fitting to make sure
that it corresponds to the current engine type.

3 Fit the flywheel housing as described in

Flywheel housing, fitting.
4 Fit the flywheel as described in Flywheel,
fitting.

50 Nm + 60

o
60
115 764

 Scania CV AB 2005, Sweden

01:06-01 111
Renewing bearing in intermediate gear

Renewing bearing in intermediate gear

Special tools

Number Designation Illustration Tool board

87 505 Drift 87 505 AM1

110 325
87 294 Drift 87 294
AD/AS3, G3

110 313

99 009 Puller 99 009 AD/AS3

110 994

98 743 Assembly tool, tube section 98 743 C1

only used.
110 871

99 250 Drift D3, C4

Removing
1 Press the shaft out of the gear. The bearing
is destroyed.
111 908

2 Remove the retaining ring.

111 909

 Scania CV AB 2005, Sweden

112 01:06-01
 Renewing bearing in intermediate gear

3 Press out the rest of the bearing from the

gear. Use tool 87 294.
87 294

111 910
4 Press the bearing off the shaft. Use tool
87 505.

Fitting
1 Press a new bearing onto the shaft. Use tool
99 009.

99 009
111 911

2 Press the bearing and shaft into the gear.

Press on the outer bearing race using the
tube section of tool 98 743.
98 743
3 Fit the snap ring.

4 Press on the spacer ring using tool 99 250.

111 912

 Scania CV AB 2005, Sweden

01:06-01 113
Camshaft gear

Removing the camshaft gears

1 Remove the intermediate gear as described

in Intermediate gear, removing.
2 Undo the bolts and remove the camshaft
gears by hand. Note that the camshaft gears
are different.

Fitting the camshaft gear

Tightening torques

Bolts for camshaft gears 63 Nm

1 Fit the camshaft flanges and thrust bearings.

Note: The thrust bearings must be turned with

the level side forward.

Note: The camshaft gears are not identical.

Correct location is essential for the engine speed
signal. Refer to the illustration.
111 914

2 Fit the gears and torque tighten the bolts to

63 Nm.
111 913

 Scania CV AB 2005, Sweden

114 01:06-01
 Removing the crankshaft gear

Removing the crankshaft gear

Special tools

Number Designation Illustration Tool board

99 309 Tool to rotate flywheel D5

100330
1 Position the engine so that cylinder 6
changes direction, the crankshaft is turned
to 0°, the text "down TDC" is visible on the
flywheel. Use tool 99 309 to rotate the
engine.
99 309
2 Remove the flywheel as described in
Flywheel, removing.
3 Remove the flywheel housing as described

01_1388
in Flywheel housing, removing.
4 Remove the intermediate gear as described
in Intermediate gear, removing.

IMPORTANT! The camshaft and crankshaft

must not be rotated once the intermediate gear
has been removed. Pistons and valves can
collide and be damaged.

5 Remove the crankshaft gear.

111 915

 Scania CV AB 2005, Sweden

01:06-01 115
Fitting the camshaft gear

Fitting the crankshaft gear

1 Fit the crankshaft gear.

2 Fit the intermediate gear as described in
Intermediate gear, fitting.

IMPORTANT! It is the same crankshaft gear on

D9, D11, D12 and DC16. Check the marking on
the crankshaft gear during fitting to make sure
that it corresponds to the current engine type.

3 Fit the flywheel housing as described in

Flywheel housing, fitting.
4 Fit the flywheel as described in Flywheel,
fitting.

 Scania CV AB 2005, Sweden

116 01:06-01
 Removing the camshaft

Removing the camshaft

Number Designation Illustration Tool board

99 522 Holder -

135 649
1 Lift out the engine. See section Removing
the engine. Remove the poly-V-belts if they
have not been removed.
2 Mount the engine in a universal stand. See
section Mounting in a universal stand.

3 Remove the EDC control unit and fuel filter.

4 Remove the crankcase ventilation unit.

5 Disconnect the connection pipe between the

intake manifolds on the left-hand side of the
engine.
6 Remove the charge air pipe between the
turbocharger and the charge air cooler.
7 Remove the centrifugal oil cleaner.
8 Remove the alternator.

 Scania CV AB 2005, Sweden

01:06-01 117
Removing the camshaft

9 Remove the front timing gear casing. See

Removing front timing gear casing under
Cylinder block.
10 Remove the coolant pump
11 Remove the front camshaft gear. A front
camshaft gear is fitted only on the left
camshaft.
12 Remove the flywheel. See Removing the
flywheel under Crank mechanism.
13 Remove the flywheel housing. See
Removing the flywheel housing under
Cylinder block.

14 Disconnect the banjo connections on the

front and rear edges of the fuel manifolds.

Note: The fuel manifolds are different. Mark the

fuel manifolds so that they can be refitted in the
same positions.

15 Remove the fuel manifolds.

16 Remove the upper rocker covers

IMPORTANT! Mark the rocker arms, pushrods,

tappet shafts and valve bridges because they
must be refitted in the same positions.

17 Remove the rocker arm shafts and pushrods.

 Scania CV AB 2005, Sweden

118 01:06-01
 Removing the camshaft

18 Remove the camshaft covers.

19 Remove the roller tappet shaft assemblies.
20 Remove the guide flanges.
21 Remove the intermediate gears. See
Removing the intermediate gear under
Timing gear.
22 Remove the camshaft gears. See Removing
the camshaft gears under Timing gear.

23 Mount holder 99 522 on the rear of the

camshaft.

24 Attach the cab tilt pipe over the pin on the

holder.

25 Push the camshaft out forwards by pushing

it with the pipe. When the part of the
camshaft has come out, it is easier to pull it
out by hand.

 Scania CV AB 2005, Sweden

01:06-01 119
Fitting the camshaft

Fitting the camshaft

Number Designation Illustration Tool board

99 522 Holder

135 649
Note: Check that the camshafts are located in
the correct camshaft channel and fitted the right
way round.

1 Fit holder 99 522 on the camshaft to be

fitted.

134 856
99 522

2 Oil the bearing races and pull in the

camshaft from the front using the cab tilt
pipe. The camshaft is pressed in from the
front by hand at the same time as guiding it
correctly onto the bearings from the rear
using the bar. Be careful not to damage
cams and bearings when pushing in the
camshaft. Remove holder 99 522 from the
camshaft.

3 Fit the front camshaft gear. Hold tight with a

screwdriver as illustrated and torque tighten
the bolts to 63 Nm.

4 Fit the guide flanges at the rear.

63 Nm
112 271

 Scania CV AB 2005, Sweden

120 01:06-01
 Fitting the camshaft

5 Fit the camshaft gears at the back as

described in Camshaft gear, fitting under
Timing gear.
6 Fit the intermediate gear according to
Intermediate gear, fitting under Timing gear.
7 Fit the coolant pump.
8 Fit the front timing gear casing. See Fitting
front timing gear casing under Cylinder
block.
9 Fit the valve tappets.

IMPORTANT! Make sure none of the snap

rings for the injector pushrods come loose or fall
into the engine.

10 Fit all the pushrods and rocker arm

housings.
11 Adjust the valve clearance and unit injectors
as described in Checking camshaft setting
under Timing gear.

 Scania CV AB 2005, Sweden

01:06-01 121
Fitting the camshaft

12 Fit the rocker covers. Tighten the bolts to

18 Nm.
13 Fit the camshaft covers. Make sure the
sealing surfaces are clean and free from
damage.
14 Fit the fuel manifolds and torque tighten the
bolts to 26 Nm. Grease the O-rings, making
sure they stay in their positions.

Note: The fuel manifolds are different. Make

sure they are positioned correctly.

15 Fit the banjo screws on the front and rear

edges of the fuel manifolds.

16 Fit the alternator (8).

17 Fit the centrifugal oil cleaner (7), EDC
control unit and fuel filter (3). Fit the banjo
screws on the fuel filter and oil filter. Fit the
connector on the control unit.

18 Screw on the connecting pipe between the

intake manifolds (5).
19 Fit the charge air pipe between the
turbocharger and the charge air cooler (6).
20 Fit the crankcase ventilation unit (4).
21 Fit the flywheel housing according to
Flywheel housing, fitting under Cylinder
block.
22 Fit the flywheel as described in Flywheel,
fitting under Crank mechanism.

 Scania CV AB 2005, Sweden

122 01:06-01
 Checking camshaft setting

Checking camshaft setting

Specifications

Injector lifting height 4.5 - 5.1 mm

Special tools

Number Designation Illustration Tool board

587 250 Indicator stand

102350

98 075 Dial gauge

Right-hand camshaft:
1 Adjust the unit injector on cylinder 1 as
described in Adjusting the unit injector. The
engine position is such that TDC Up (540°)
is visible in the lower window of the
flywheel.
2 Zero the dial gauge against the valve spring
collar on the unit injector.
3 Turn the flywheel 180° in the direction of
rotation using tool 99 309 so that TDC
Down (0°) is visible in the lower window on
the flywheel.
4 Read the measurement on the dial gauge.
The measurement should be between
4.5 - 5.1 mm.

 Scania CV AB 2005, Sweden

01:06-01 123
Checking camshaft setting

Left-hand camshaft:
1 Adjust the unit injector on cylinder 6 as
described in Adjusting the unit injector. The
engine position is such that TDC Up (180°)
is visible in the lower window of the
flywheel.
2 Zero the dial gauge against the valve spring
collar on the unit injector.
3 Turn the flywheel 180° in the direction of
rotation using tool 99 309 so that TDC
Down (360°) is visible in the lower window
on the flywheel.
4 Read the measurement on the dial gauge.
The measurement should be between
4.5 - 5.1 mm.

 Scania CV AB 2005, Sweden

124 01:06-01
 Fan drive

Fan drive

Special tools

Number Designation Illustration Tool board

99 250 Drift 99 250
D3,C4

112 640
99 335 Drift 99 335 AD4-A2

00 1883
587 517 Puller plate XA1
587 518 Puller XA2

Renewal of belt pulley bearing

1 Remove the poly-V-belt.
99 250
2 Disconnect the fan and place it in the fan
cowling.
3 Remove the fan bracket with belt pulley.
4 Remove the centre nut and washer in the
belt pulley.
5 Remove the retaining ring on the back.
114 507

6 Press out the bearing and fan bracket using

tool 99 250.
7 Pull the bearing from the fan bracket using
tool 87 517 and 87 518.
587 518

587 517
114 508

 Scania CV AB 2005, Sweden

01:06-01 125
Fan drive

Fitting
1 Press a new bearing into the belt pulley
using tool 99 335.
99 335

Note: Do not use the belt pulley as support

when pressing. Screw nuts onto the studs and
use these for support.

2 Fit the snap ring.

114 509
3 Assemble the fan bracket and belt pulley.
Use an M14 bolt, at least 65 mm long, and
the standard washer as a counterhold when
tightening the fan bracket shaft in place in
the belt pulley.

4 Screw in the standard bolt and washer.

5 Fit the fan bracket with belt pulley.
6 Fit the fan.
7 Fit the poly-V-belt.

114 510

 Scania CV AB 2005, Sweden

126 01:06-01
 Lubrication system

Lubrication system

General tightening torques

Specifications

The following tightening torques apply in general

unless otherwise specified:
Flange bolt M6 8.6 Nm
Flange bolt M8 26 Nm
Flange bolt M10 50 Nm
Flange bolt M12 92 Nm
Stud in casting M8 13 Nm
Stud in casting M10 25 Nm

A tolerance of +/- 15% applies to the specified

tightening torques unless stated otherwise.

Oil pressure
Idle speed min 1.4 bar
With warm engine running at 1,000 rpm min 3.0 bar
With warm engine running at 2,000 rpm 4.5 +/-1 bar

 Scania CV AB 2005, Sweden

01:06-01 127
Renewing the oil filter

Renewing the oil filter

Tightening torques

Filter housing lid 25 Nm

Special tools

Number Designation Illustration Location

587 637 Socket Maintenance cabinet

Note: The oil cleaner must be cleaned when

renewing the filter.

1 Unscrew the filter lid with a closed tool with

hexagon driver, e.g. socket 587 637.

Note: Do not use an adjustable spanner or other

open tool as there is a risk of damaging the filter
lid.

115 765
2 Lift out the filter housing lid with filter
element. The filter housing will drain
automatically once the filter has been
removed.
3 Undo the old filter from the lid by carefully
bending it to one side.

 Scania CV AB 2005, Sweden

128 01:06-01
 Renewing the oil filter

4 Fit a new O-ring on the cover. Lubricate the

O-ring with engine oil.
5 Press a new filter element into the snap
fastener in the cover.
6 Make sure the oil filter drain has emptied
the oil from the filter housing. Screw on the
filter lid with a closed tool with hexagon
driver, e.g. socket 587 637. Tightening
torque 25 Nm.
7 Start the engine and inspect the filter
housing for leaks.

Note: The engine must not be run without a

filter element in the oil filter. This would risk
damaging the engine due to particles and low oil
pressure.

 Scania CV AB 2005, Sweden

01:06-01 129
Renewing oil cooler seal

Renewing oil cooler seals

1 Drain the cooling system. Refer to booklet

02:01-01, Cooling system, work 3
description.
2 Remove the inlet pipe between the air filter
and the turbocharger.
3 Disconnect the control unit cooler with
control unit and fuel filter and place to one
side.

115 787
4 Remove the crankcase ventilation with pipe.
5 Disconnect the connecting pipe between the
2
intake manifolds.
6 Remove the charge air pipe between the 9 8 4
turbocharger and the charge air cooler.

7 Remove the water manifold to the

compressor.
8 Remove the oil cleaner.

Note: Lift the oil cooler vertically so that no oil

leaks into the cooling system.

115 909
6 5

9 Remove the oil cooler lid with the oil cooler.

112 312

The small cover need not be detached

 Scania CV AB 2005, Sweden

130 01:06-01
 Renewing oil cooler seal

10 Remove the four bolts securing the oil

cooler to the oil cooler cover.
11 Remove the oil cooler.
12 Renew the four O-rings.

Fitting the oil cooler

1 Screw on the oil cooler to the oil cooler lid.

2 Fit the oil cooler lid with the oil cooler.

Note: Lower the oil cooler as vertically as

possible so that oil does not leak into the cooling
system.

3 Fit the oil cleaner, clean it as described in

Oil cleaner, dismantling and cleaning.
4 Screw into place the control unit cooler with
the control unit and fuel filter.
5 Fit the charge air pipe between the
turbocharger and the charge air cooler.
6 Screw on the connecting pipe between the
intake manifolds.
7 Fit the water pipe to the air compressor.
8 Fit the crankcase ventilation with pipe.
9 Fill the engine with coolant.

 Scania CV AB 2005, Sweden

01:06-01 131
Oil cleaner

Oil cleaner

9
15

8 14
13
7
12
6
11

10

5
4

3
1

2
115 240

1 Housing
2 Gasket
3 Washer
4 Shaft
5 Rotor
6 Strainer
7 O-ring
8 Rotor bowl
9 Nut
10 Retaining ring
11 O-ring
12 Cover
13 Lifting eye
14 O-ring
15 Lock nut

 Scania CV AB 2005, Sweden

132 01:06-01
 Dismantling and cleaning the oil cleaner

Dismantling and cleaning the oil cleaner

Specifications

Permitted thickness of deposits on walls of bowl 26 mm

There should be a certain amount of deposited

dirt apparent in the rotor bowl during routine
cleaning of the oil cleaner. If this is not the case,
it indicates that the rotor is not spinning. The
cause must be established immediately.
If the dirt deposit exceeds 26 mm after the
recommended interval, the rotor bowl must be
x3
cleaned more often.
1 Undo the nut securing the outer lid.
2 Lift out the rotor. Wipe off the outside.
Undo the rotor nut and screw it about three
turns to protect the bearing.

01 1286
3 If the rotor nut is difficult to get loose, turn
the rotor upside down and fasten the rotor
nut in a vice. Turn the rotor
counterclockwise three turns by hand or if x3
this does not help, place a screwdriver
between the outlet holes.

IMPORTANT! The rotor must not be put in a

vice. Never strike the rotor bowl. This may
01 1287

cause damage resulting in imbalance.

 Scania CV AB 2005, Sweden

01:06-01 133
Renewing oil cooler seal

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. 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.

01 1289
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 damaged nozzles.
10 Make sure the bearings are not damaged.

 Scania CV AB 2005, Sweden

134 01:06-01
 Assembling the oil cleaner

Assembling the oil cleaner

Specifications

Tightening torques
Lock nut for oil cleaner housing lid 15 Nm
Nut for rotor bowl Tighten by hand
Rotor shaft 34 Nm

Locking compound 561 200

1 Position the O-ring in the lid. Renew the

O-ring if it is at all damaged.
2 Assemble the parts and tighten the rotor nut
by hand.

01 1293

3 Make sure the shaft is not loose. Secure with

locking compound 561 200 if it is loose.
Clean thoroughly first with a suitable
solvent. Tighten the rotor shaft using socket
wrench 98 421. Tightening torque 34 Nm.

4 Refit the rotor and spin it by hand to make

sure it rotates easily.
112 313

5 Inspect the O-ring on the cleaner housing lid

and fit it. Torque tighten the lock nut to 15 Nm
15 Nm.
112 314

 Scania CV AB 2005, Sweden

01:06-01 135
Oil pump

Oil pump

A leaking or defective oil pump must be

renewed completely and not overhauled.

Renewing the oil pump

Tightening torques

Plug for oil sump 80 Nm

Bolts for exhaust manifold 63 Nm
Bolts for oil sump 32 Nm

Special tools

Designation Number Illustration Tool board

Engine 99 318
support
Lifting eyes 99 398 99 398
114 638

2
112 315

1
1 Strainer
2 Suction pipe
3 Oil pump

 Scania CV AB 2005, Sweden

136 01:06-01
 Oil pump

Removal
1 Drain the engine oil from the oil sump.
Clean the magnetic plug and torque tighten
to 80 Nm.
2 Remove the oil sump.
3 Remove the gearbox (refer to group 5).
Support the engine using tool 99 318.
Remove the clutch.
4 Remove the flywheel as described in
Flywheel, removing.
5 Remove the rear exhaust manifold.
6 Remove the flywheel housing as described
in Flywheel housing, removing.
7 Remove the strainer and the suction pipe.
8 Remove the oil pump.

 Scania CV AB 2005, Sweden

01:06-01 137
Oil pump

Fitting
1 Renew the O-ring and fit a new oil pump.
2 Renew the O-rings and refit the strainer and
suction pipe.
3 Fit the flywheel housing as described in
Flywheel housing, fitting.
4 Refit the air compressor and exhaust
manifold. Torque tighten the exhaust
manifold to 63 Nm.
5 Fit the flywheel as described in Flywheel,
fitting.
6 Refit the clutch and gearbox.
7 Fit the oil sump and torque tighten the bolts
to 32 Nm.
8 Fill with oil and check the oil level in the
engine using the dipstick.

 Scania CV AB 2005, Sweden

138 01:06-01
 Exhaust manifold

Exhaust manifold

Renewing gaskets

Tightening torques

Bolts for exhaust manifold 63 Nm

1 Undo the bolts and remove the front exhaust

manifold.
2 Undo the bolts and remove the rear exhaust
manifold.
3 Scrape away the gaskets from the exhaust
manifolds and cylinder head.
4 Lubricate the joints with heat-resistant
grease and fit new gaskets.
5 Fit the rear exhaust manifold and junction
pipe.
6 Fit the front exhaust manifold.
7 Tighten the bolts to 63 Nm.

 Scania CV AB 2005, Sweden

01:06-01 139
Turbocharger

Turbocharger
Exploded view drawing

Turbocharger

4
5 1 Straight union
2 Gasket
1 3
3 Lubrication oil pipe
2
4 Ferrule
5 Nut
6 Straight union
6
7
7 Gasket
8 Lubrication oil return pipe
9 Gasket
10 Flange bolt
11 Gasket
9
12 Flange bolt
12

8
116 685

10
11

General tightening torques

Specifications

The following tightening torques apply in general unless otherwise specified:

Flange bolt M6 8.6 Nm
Flange bolt M8 26 Nm
Flange bolt M10 50 Nm
Flange bolt M12 92 Nm
Stud in casting M8 13 Nm
Stud in casting M10 25 Nm

A tolerance of +/- 15% applies to the specified

tightening torques unless stated otherwise.

 Scania CV AB 2005, Sweden

140 01:06-01
 Turbocharger

Important information
Observe strict cleanliness at all times when
working on the turbocharger. Never leave
connections for oil inlets or outlets unprotected.
Foreign bodies in the bearing housing will soon
lead to total breakdown.

Oil leaks
A blocked air filter creates excess vacuum in the
inlet line. There is then a risk of oil mist being
drawn from the bearing housing.
If the sealing ring on the turbine side is worn,
the exhaust gases will be blue when idling.
If the oil outlet pipe from the turbocharger is
damaged, there is risk of oil leaking out.

Foreign bodies
Foreign bodies in the turbine or compressor, e.g.
a grain of sand or metal shavings, will ruin the
vanes. This will lead to imbalance and bearing
wear. Engine output will drop.

IMPORTANT! Never attempt to straighten a

damaged vane. It will break off when running
and the turbocharger will break down
completely, causing damage to the engine.

 Scania CV AB 2005, Sweden

01:06-01 141
Turbocharger

Air and exhaust leaks

Even small leaks in the line between the air filter
and the turbocharger will cause dirt to be
deposited on the compressor wheel. The charge
pressure will be reduced, resulting in increased
exhaust temperature and smoke, which will
reduce the service life of the engine.
Leaks in the exhaust line between the cylinder
head and the turbocharger will also result in loss
of charging pressure.

Measuring the charging pressure

Charging pressure can be measured using
Scania Diagnos.

SCANIA Diagnos

00_1521
Tools for Scania Diagnos

Cleaning
Low charging pressure can sometimes be due to
dirt in the compressor housing. Disassemble the
compressor housing and clean with white spirit
and a brush. Renew the O-ring if it is damaged.
Assemble the compressor housing and measure
the charging pressure again.

 Scania CV AB 2005, Sweden

142 01:06-01
 Removing the turbocharger

Removing the turbocharger

1 Detach the turbocharger oil pipes.

IMPORTANT! Plug the oil connections to

prevent dirt ingress in the engine and the turbo.

135 132
2 Detach the exhaust pipe and the intake
manifold.

135 133
3 Remove the bolts in the turbocharger base
and remove the turbocharger. Pull the turbo
charger unit straight out through the charge
air cooler pipe.
135 135

 Scania CV AB 2005, Sweden

01:06-01 143
Fitting the turbocharger

Fitting the turbocharger

1 Check that the turbocharger does not have

any visible damage on the compressor,
turbine or housing.
2 Check that there are no remains of old
gaskets on the exhaust pipe flange.

3 Fit a new gasket on the turbocharger base

and grease the screws with heat resistant
grease 561 205.

135 136
4 Position the turbocharger base against the
manifold flange and align the charge air
pipe. Attach the charge air pipe and torque
tighten the turbocharger base screws to
63 Nm.

135 135

5 Fit the exhaust pipe and the intake pipe.

135 133

 Scania CV AB 2005, Sweden

144 01:06-01
 Fitting the turbocharger

6 Fit the inlet and return lines.

7 Remove fuse F 20 for the fuel valve (fuel

shut-off) and turn the engine over with the
starter motor for at least 30 seconds so that
the oil is pumped to the turbocharger.

IMPORTANT! Before starting to use the

turbocharger, it is essential to make sure that the

135 132
oil supply is functioning correctly. If lubrication
is insufficient there is a risk that the turbo will
seize or that its life is significantly reduced.

IMPORTANT! Do not crank with the starter

motor for longer than 30 seconds at a time. After
that the starter motor must be switched off for at
least 120 seconds.

8 Refit the fuse (F 20) and start the engine.

Check for leakage.

 Scania CV AB 2005, Sweden

01:06-01 145
Measuring radial and axial clearance

Measuring radial and axial clearance

Specifications

Wear limits
Turbine shaft clearance max. 0.611 mm
Turbine shaft axial clearance max. 0.102 mm

Special tools

Number Designation Illustration Tool board

98 075 Dial gauge 98 075 D2
0
90 10
10 90

80 20
20
80

15 5
30 10
70
70 30

40 60
60 50 40
50
00_1637

587 107 Rocker indicator

00_1569

587 250 Indicator stand M1

102350

Measuring radial and axial clearance often does

not give a good 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.

 Scania CV AB 2005, Sweden

146 01:06-01
 Measuring radial and axial clearance

Radial clearance
1 Measure the clearance at the turbine wheel
as well as at the compressor wheel.

2 Place the tip of the dial gauge against the

turbine or compressor wheel.

100703
3 Pull up both ends of the shaft. Take a
reading.

4 Press down both ends of the shaft. Take a

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

100704
5 Repeat the test three times on each side.
6 If any of the wheels makes contact with the
housing despite the radial clearance being
within tolerances, the turbocharger must be
renewed.

Axial clearance
1 Place the tip of the dial gauge against the
end of the shaft.

2 Press the shaft longitudinally to and fro and

take a reading at the end positions. The
difference between the readings is the axial
clearance.
3 Repeat the test three times.
100705

 Scania CV AB 2005, Sweden

01:06-01 147
Checking wastegate valve function

Checks after breakdown

Tightening torques

Bolts, turbocharger - exhaust pipe 63 Nm

V-clamps, M6 8 Nm
V-clamps, M8 20 Nm

Description

IMPORTANT! Observe strict cleanliness at all

times when working on the turbocharger. Never
leave connections for the oil inlet or outlet
unprotected. Foreign bodies in the bearing
housing will soon lead to total breakdown.

1 Make sure leaks or loose particles do not

occur in the line between the air filter and
the turbocharger.
2 Check that there are no loose particles in the
exhaust or intake manifolds. Renew the
charge air cooler.
3 Make sure all valves are intact.
4 Check that the oil return pipe from the
turbocharger is not blocked or deformed.
5 Check that the oil delivery pipe to the
turbocharger is not blocked, deformed or
leaking under pressure.
6 Renew the oil filter and clean the lubrication
system.

 Scania CV AB 2005, Sweden

148 01:06-01
 Checks after breakdown

Checking wastegate valve function

Special tools

Number Designation Illustration Tool board

99 405 Tool kit 99 405

115 550
The function of the wastegate valve is to reduce
the pressure so that the max. speed of the
turbocharger is not exceeded.

Note: The wastegate valve can withstand a

maximum pressure of 3 bar. Tool 99 405
delivers a maximum pressure of 2 bar.

1 Detach the hose 1 from the union on the

turbocharger and connect tool 99 405 as
illustrated. Fit a hose clamp 3. 3 1 99 405 2

2 Pressurise the wastegate valve with

compressed air by pressing the handle on
the tool. Relieve the pressure by pressing on
the screw 2.
3 Repeat the process a few times and check
that the shaft moves and listen for leaks
from the wastegate valve.

116 226

 Scania CV AB 2005, Sweden

01:06-01 149
Renewing the wastegate valve bracket

Renewing wastegate valve bracket

1 Remove the turbocharger

1 2
2 Remove the retaining ring 1 from the link
arm using a small flat screwdriver.

3 Detach the link arm 2 from the short link

arm 3 of the wastegate valve. If enough air
is forced into the wastegate valve case as
described in Checking wastegate valve
function, so that the link arm begins to
move, it is easier to detach it.
4 Evacuate air from the case. 3

132 903
5 Remove lock nuts 4 at the wastegate valve
case and remove the case together with the
link arm.

4
132 904

 Scania CV AB 2005, Sweden

150 01:06-01
 Renewing the wastegate valve bracket

6 Remove bolts 5 that secure the bracket in

the turbine housing and remove the bracket. 5

7 Fit the new bracket with the supplied bolts

and spacers. Tighten the bolts to 25 Nm.
8 Fit the wastegate valve case in the new
bracket. Tighten the lock nuts to 8.5 Nm.
9 Fit the link arm on the wastegate valve short
link arm. If enough air is forced into the

132 905
wastegate valve case as described in
Checking wastegate valve function, so that
the link arm begins to move, it is easier to fit
it. Tighten the link arm to 8.5 Nm.
10 Fit the retaining ring.

11 Us the magnetic stand 587 250 and dial

gauge 98 075 to check that the setting of the
wastegate valve case is correct. By
increasing the pressure in the case using
special tool 99 405 to the specified pressure,
the dial gauge should indicate a reading of
1.0 mm. If this is not correct the setting
must be adjusted as described in Adjusting
the wastegate valve.
12 Fit the turbocharger.

132 906

 Scania CV AB 2005, Sweden

01:06-01 151
Adjusting the wastegate valve

Adjusting the wastegate valve

Opening pressure for the wastegate valve on

DC16 01 is 1.85 bar

IMPORTANT! If the setting of the wastegate

valve is adjusted incorrectly it may lead to
damage to the engine and the turbocharger. The
function of the wastegate valve is to decrease
the turbocharger speed and charge pressure to
approved levels. If the speed is too high,
turbocharger components will be damaged
which can lead to engine damage.

By rotating the link arm and thereby

decreasing the effective length of the rod
by 1.0 mm the setting pressure will increase.

By rotating the link arm and thereby

increasing the effective length of the rod by
1.0 mm the setting pressure will decrease.

 Scania CV AB 2005, Sweden

152 01:06-01
 Renewing the vibration insulator

Engine suspension

Renewing the vibration insulator

Special tools

Number Designation Illustration

99 398 Lifting eyes 99 398

114 638
98 094 Lifting chain 98 094

109 836

587 308 Lever block

114 070

1 Remove the cable duct to the engine speed

sensor on the flywheel.
2 Remove the exhaust brake and exhaust
bellows after the turbocharger.
99 398
3 Screw on lifting eyes 99 398 to the engine
using flange bolt M12x30.

4 Disconnect the filter housing for the

crankcase ventilation and place to one side
so that it is free from the lifting chain.
5 Fasten the lifting chain 99 094 to the rear
lifting eyes.
114 718

 Scania CV AB 2005, Sweden

01:06-01 153
Renewing the vibration insulator

6 Fasten the lever block 587 308 to the front

lifting eye.
7 Undo the bolts holding together the
vibration insulator and the bracket.
8 Lift up the engine.
9 Remove the vibration insulator.
10 Fit a new vibration insulator.
11 Lower the engine and tighten the bolts.
12 Remove the lifting chain and lever block.
13 Fit the filter housing for the crankcase
ventilation.
14 Remove the lifting eyes.
15 Fit the exhaust brake and exhaust bellows
after the turbocharger.
16 Fit the cable duct to the rotation speed
sensor on the flywheel.

 Scania CV AB 2005, Sweden

154 01:06-01
 Renewing the engine bracket fitted to the engine

Renewing the engine bracket fitted to the engine

Tightening torques

Bolts for engine bracket 130 Nm +90 °

Special tools

Number Designation Illustration

99 398 Lifting eyes 99 398

114 638
98 094 Lifting chain 98 094

109 836

587 308 Lever block

114 070

1 Remove the cable duct to the rotation speed

sensor on the flywheel.
2 Remove the exhaust brake and exhaust
99 398
bellows after the turbocharger.
3 Screw on lifting eyes 99 398 to the engine
using flange bolt M12x30.

4 Disconnect the filter housing for the

crankcase ventilation and place to one side
so that it is free from the lifting chain.
5 Fasten the lifting chain 99 094 to the rear
lifting eyes.
114 718

 Scania CV AB 2005, Sweden

01:06-01 155
Renewing the engine bracket fitted to the engine

6 Fasten the lever block 587 308 to the front

lifting eye.
7 Undo the bolts holding together the
vibration insulator and the bracket.
8 Lift up the engine.
9 Undo the bolts and remove the engine
bracket from the engine.
10 Fit a new bracket and torque tighten the
bolts to the engine to 130 Nm + 90°.
11 Lower the engine and fit it. Tighten the bolts
to the vibration insulator.
12 Remove the lifting chain and lever block.
13 Fit the filter housing for the crankcase
ventilation.
14 Remove the lifting eyes.
15 Fit the exhaust brake and exhaust bellows
after the turbocharger.
16 Fit the cable duct to the rotation speed
sensor on the flywheel.

 Scania CV AB 2005, Sweden

156 01:06-01
 Belt transmission

Belt transmission

Engines without AC

3
114 960

1 Fan drive
2 Crankshaft, inner pulley
3 Crankshaft, outer pulley
4 Automatic belt tensioner
5 Coolant pump
6 Idler roller
7 Alternator
For more information on the belt drive, see
booklet 01:00-04

 Scania CV AB 2005, Sweden

01:06-01 157
Belt transmission

Engines with AC

7
6 8

5 6

3
114 961

1 Fan drive
2 Crankshaft, inner pulley
3 Crankshaft, outer pulley
4 Automatic belt tensioner
5 Coolant pump
6 Idler roller
7 Alternator
8 AC compressor
For more information on the belt drive, see
booklet 01:00-04

 Scania CV AB 2005, Sweden

158 01:06-01