Scania Helper

NORDHAVN A/S
Montr hjlper 1 SCANIA SERVICE
Nordhavn A/S
1. 2. 3. 4. 5. 6. 7. 8. 9. 10. Service info DI 9 Service info DI 11 Service info DI 12 Service info DEC 2 Service info DI 14 Service info DI 16 Service info EMS blink koder Service info olie cyklon/centrifuge Service info Klevand/ Etylen glycol Service info Dyser / indsprjtnings tidspunkt
MAINTENANCE SCHEDULE
DI 9
First time at At first start Interval At least Every 5th year
l l l3 l l l l1 l l l l l l l l l l l l l l l2 l2 l2 l l l l l l l l l l l l l l l
19
LUBRICATION OIL SYSTEM, page 20 1. Checking oil level 2. Oil change 3. Cleaning the lubrication oil cleaner 4. Changing the turbo filter COOLING SYSTEM, page 24 5. Checking coolant level 6. Checking corrosion protection rods 4) 7. Checking seawater pump impeller 4) 8. Checking coolant 9. Cleaning cooling system AIR CLEANER, page 32 10. Test reading low pressure indicator 11. Cleaning coarse cleaner 12. Cleaning or changing filter insert 13. Changing safety cartridge FUEL SYSTEM, page 35 14. Checking fuel level 15. Changing main filter 16. Checking injectors ELECTRICAL SYSTEM, page 37 17. Checking electrolyte level in batteries 18. Checking charge state of batteries 19. Cleaning batteries 20. Checking level monitor 21. Checking temperature monitor 22. Checking oil pressure monitor 23. Checking stop function MISCELLANEOUS, page 42 24. Checking transmission belt 25. Look for leaks. Remedy as necessary 26. Checking/adjusting valve clearance. 27. Changing (or cleaning) valve for closed crankcase ventilation
l l1 l1 l1 l l l
l l5 l5 l l6 l1 l l1 l l l6
1. 2. 3. 4. 5. 6.
More often if required. For engines with few operating hours, see page 18. Earlier if low pressure indicator shows red. Applies only to M engines with sea water pump. Reference value. Varies depending on the composition of the sea water. If inhibitor has not been topped up for five years, the coolant should be changed.
Scania Industrial & Marine Engines
2001-05:1
Annually
1200 h
2400 h
4800 h
400 h
200 h
400 h
Daily
Program 96
Specifications
General information
Cylinder configuration. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Number of cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Cylinder bore . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Stroke . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Swept volume . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Number of main bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Firing order . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Injection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Cooling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Approx. weight, incl. alternator. . . . . . . . . . . . . . . . . . . . . . . . . . . . . Direction of rotation (engine viewed from rear) . . . . . . . . . . . . . . . . Compression ratio Output Engine speed Torque Oil capacity Oil grade In-line engine 6 115 mm 144 mm 8.97 dm3 7 1-5-3-6-2-4 Direct 4 stroke Liquid 805 kg anticlockwise
See Operators Manual.
Locking compound, lubricants, sealing compounds T Activator for faster curing of locking compound 561 200. . . . . . . Locking compount. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Lubricant for exhaust pipe bolts and joints . . . . . . . . . . . . . . . . . . . . Sealant for cylinder liner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Thread-locking adhesive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 561 045 561 200 561 205 584 010 561 019
Cylinder head
Minimum cylinder head height after machining, page 17. . . . . . . . . 114.4 mm Distance B between cylinder head surface and valve head, page 11 With new parts, min. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.78 mm With machined parts, max. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.80 mm Intake valve Clearance (cold engine) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.45 mm Head angle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19.4-19.6 Minimum dimension A for machined valve, page 10 . . . . . . . . . . . . 3.0 mm
01:01-02
Scania CV AB 1997
65
Program 96 Exhaust valve Clearance (cold engine) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.80 mm Head angle. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44.4-44.6 Minimum dimension A for machined valve, page 10. . . . . . . . . . . . . 1.7 mm
Intake valve seat Seat angle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20.0 Contact surface width A, page 11 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.3 - 2.8 mm Valve seat ring OD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53.066 - 53.079 mm Position for valve seat ring, diameter . . . . . . . . . . . . . . . . . . . . . . . . . 53.000 - 53.019 mm Position for valve seat ring, depth. . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.25 - 11.35 mm
Exhaust valve seat Seat angle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45.0 Contact surface width A, page 11 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.9 - 2.6 mm Valve seat ring OD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49.081 - 49.092 mm Position for valve seat ring, diameter . . . . . . . . . . . . . . . . . . . . . . . . . 49.000 - 49.016 mm Position for valve seat ring, depth. . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.25 - 11.35 mm
Valve guides Length, intake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68.2 mm exhaust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68.2 mm Height above surface for valve guide: intake. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16.7 mm exhaust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16.7 mm
Rocker arm mechanism Rocker arm bushing, ID (pressed in and machined). . . . . . . . . . . . . . 30.007 - 30.028 mm Surface quality . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.8 Ra Oil hole diameter drilled to same diameter as in rocker arm.
66
Scania CV AB 1997
01:01-02
Program 96 Tightening torques Cylinder head bolts: First tightening . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60 Nm Second tightening . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 150 Nm Third tightening . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 250 Nm + 90 Injector nut. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Nut for adjusting screw on rocker arm . . . . . . . . . . . . . . . . . . . . . . . Rocker cover bolt. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Exhaust manifold bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Rocker arm mechanism bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70 Nm 40 Nm 20 Nm 50 Nm 150 Nm
Turbocharger
Wear limits Radial shaft clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.329-0.501 mm Axial shaft clearance (after running in). . . . . . . . . . . . . . . . . . . . . . . 0.038-0.093 mm
Tightening torques Bolts, turbocharger - exhaust pipe. . . . . . . . . . . . . . . . . . . . . . . . . . . 40 Nm Hose clip, exhaust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Nm
Pistons and cylinder liners

Cylinder liner Shims for cylinder liner, thickness . . . . . . . . . . . . . . . . . . . . . . . . . . 0.20, 0.25, 0.30, 0.40, 0.50, 0.75 mm Cylinder liner height above cylinder block . . . . . . . . . . . . . . . . . . . . 0.27 - 0.33 mm Maximum permitted height difference on individual liner between measurements read at two diametrically opposite points across the engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.035 mm
01:01-02
Scania CV AB 1997
67
Program 96 Pistons Fitted with arrow on piston crown facing forwards.
Piston rings Number of compression rings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Gap: 1st ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.4 - 0.75 mm 2nd ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.3 - 0.6 mm Clearance in groove max 2nd ring . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.25 mm Rings marked TOP should be turned with the marking facing upwards. Number of oil scraper rings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 Gap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.3 - 0.55 mm Clearance in groove max. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.25 mm
Connecting rods Connecting rods and caps marked 1 to 6. Fitted with marking facing inwards.
Tightening torques Bolts for tension lugs when pressing down cylinder liner . . . . . . . . . 50 Nm Oil sump bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 Nm Connecting rod bolts (oiled threads). . . . . . . . . . . . . . . . . . . . . . . . . . 20 Nm + 90
Flywheel and flywheel housing

Flywheel Maximum machining of contact surface for plate: See group 4, Clutch
Ring gear Heated to 100 - 150 C before fitting.
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Scania CV AB 1997
01:01-02
Program 96
Flywheel housing
Seal in flywheel housing: Dimension B, page 43 . . . . . . . . . . . . . . . 7 mm
Tightening torques Flywheel bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 180 Nm Bolts for flywheel housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90 Nm
Timing gear
Camshaft gear Heated to 100 C before fitting. Backlash against intermediate gear . . . . . . . . . . . . . . . . . . . . . . . . . . 0.03 - 0.18 mm
Injection pump gear Backlash against intermediate gear . . . . . . . . . . . . . . . . . . . . . . . . . . 0.03 - 0.16 mm
Intermediate gear Axial clearance max . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.23 mm
Power take-off gear Backlash against intermediate gear . . . . . . . . . . . . . . . . . . . . . . . . . . 0.03 - 0.18 mm
Camshaft Axial clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.15 - 0.30 mm
01:01-02
Scania CV AB 1997
69
Program 96 Crankshaft Main bearing races . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Diameter: Standard Undersize 1 Undersize 2 Undersize 3 Undersize 4 Undersize 5 Undersize 6 Fillet radius Surface quality Width, max 95.000 - 94.978 mm 94.750 - 94.728 mm 94.500 - 94.478 mm 94.250 - 94.228 mm 94.000 - 93.978 mm 93.750 - 93.728 mm 93.500 - 93.228 mm 4.75 - 4.85 mm 0.25 Ra 46.78 mm
Bearing clearance 0.054 - 0.116 mm
Big-end bearing journals. . . . . . . . . . . . . . . . . . . . . . . . . . . Diameter: Standard Undersize 1 Undersize 2 Undersize 3 Undersize 4 Undersize 5 Undersize 6 Fillet radius Surface quality Width, max 80.000 - 79.981 mm 79.750 - 79.731 mm 79.500 - 79.481 mm 79.250 - 79.231 mm 79.000 - 79.981 mm 78.750 - 78.731 mm 78.500 - 78.481 mm 4.8 - 5.2 mm 0.25 Ra 53.10 mm
Bearing clearance 0.050 - 0.112 mm
Thrust bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Thickness: Standard Oversize 1 Oversize 2 Oversize 3 Oversize 4 Oversize 5 Axial clearance 3.38 - 3.43 mm 3.46 - 3.51 mm 3.51 - 3.56 mm 3.64 - 3.69 mm 3.89 - 3.94 mm 4.27 - 4.32 mm 0.14 - 0.37 mm
70
Scania CV AB 1997
01:01-02
Program 96 Tightening torques Tightening torques Nut for camshaft gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Nut for compressor gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Bolts for intermediate gear shaft journal . . . . . . . . . . . . . . . . . . . . . . Main bearing bolts: Stage I . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Stage II . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Flywheel bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Crankshaft bolt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 600 Nm 200 Nm 49 Nm 70-90 Nm 290 Nm 180 Nm 300 Nm+60 30 Nm
Lubrication system
Oil pump Backlash: Crankshaft gear - intermediate gear on oil pump . . . . . . . . . . . . . . . 0.03 - 0.36 mm Intermediate gear - crankshaft gear . . . . . . . . . . . . . . . . . . . . . . . . . . 0.03 - 0.16 mm
Oil pressure valve (Note: not safety valve) Oil pressure: With hot engine at 2000 rpm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6 bar With hot engine at 800 rpm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . min. 1.5 bar Free spring length . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98 mm
Oil cleaner Permitted thickness of deposits on wall of bowl . . . . . . . . . . . . . . . . 20 mm
Oil filter Use only genuine Scania filters (screwed on by hand).
01:01-02
Scania CV AB 1997
71
Program 96 Tightening torques
Oil pump: Bolts for oil pump cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 Nm Bolts, oil pump - cylinder block . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42 Nm Lock bolt (left-hand thread) for intermediate gear . . . . . . . . . . . . . . . 40 Nm
Oil cleaner: Locknut for oil cleaner housing cover . . . . . . . . . . . . . . . . . . . . . . . . 10 Nm Nut for rotor bowl . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Tighten by hand Rotor shaft. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34 Nm
Oil nozzle for piston cooling: Banjo bolt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 Nm
72
Scania CV AB 1997
01:01-02
Program 96
Valve clearance
Checking and adjusting Check valve clearance. The clearance for intake valves should be 0.45 mm and the clearance for exhaust valves should be 0.80 mm when the engine is cold.
Adjustment can be carried out in one of the following ways: A. Adjust both valves in each cylinder starting with No. 1 cylinder at TDC after compression. Turn the crankshaft 1/3 turn at a time and adjust valves in injection sequence: 1-5-3-6-2-4
B. Set No. 1 cylinder at precisely TDC after compression. The following valves can now be adjusted: cylinder 1 intake and exhaust cylinder 2 cylinder 3 cylinder 4 cylinder 5 intake exhaust intake exhaust
Turn the crankshaft precisely one revolution so that TDC for No. 6 cylinder is set. The remaining valves can now be adjusted: cylinder 2 exhaust cylinder 3 intake cylinder 4 exhaust cylinder 5 intake cylinder 6 exhaust and intake
Intake valve Exhaust valve
01:01-02
Scania CV AB 1997-05:2
First time at At first start
DI 11
Interval At least Every 5th year
l l l l l l3 l l l l1 l l l l l l l l l l l l l l l2 l2 l2 l l l l l l l l l l l l l l l
13
LUBRICATION OIL SYSTEM, page 14 1. Checking oil level 2. Oil change 3. Cleaning the lubrication oil cleaner 4. Changing the turbo filter COOLING SYSTEM, page 18 5. Checking coolant level 6. Checking corrosion protection rods 4) 7. Checking seawater pump impeller 4) 8. Checking coolant 9. Cleaning cooling system AIR CLEANER, page 26 10. Test reading low pressure indicator 11. Cleaning coarse cleaner 12. Cleaning or changing filter insert 13. Changing safety cartridge FUEL SYSTEM, page 29 14. Checking fuel level 15. Changing main filter 16. Checking injectors ELECTRICAL SYSTEM, page 31 17. Checking electrolyte level in batteries 18. Checking charge state of batteries 19. Cleaning batteries 20. Checking level monitor 21. Checking temperature monitor 22. Checking oil pressure monitor 23. Checking stop function MISCELLANEOUS, page 36 24. Checking V-belts 25. Look for leaks. Remedy as necessary 26. Checking/adjusting valve clearance. 27. Changing (or cleaning) valve for closed crankcase ventilation
l l1 l1 l1
1. 2. 3. 4. 5. 6.
More often if required For engines with few operating hours, see page 12. Earlier if low pressure indicator shows red. Applies only to M engines with seawater pump. Guidline values. Vary according to composition of seawater. If inhibitor has not been topped up for five years, coolant should be changed.
1997-11:2
Every year
1200 h
2400 h
4800 h
400 h
200 h
400 h
Daily
Program 96
Specifications
General information
Cylinder configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . In-line engine Number of cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Cylinder bore . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127 mm Stroke . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 145 mm Displacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.02 dm3 Number of main bearings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Firing sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5-3-6-2-4 Injection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Direct Principle of operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 stroke Cooling. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fluid Weight including alternator approx. . . . . . . . . . . . . . . . . . . . . . . . . . . . 990 kg Direction of rotation (engine viewed from rear) . . . . . . . . . . . . . . . . . . Anti-clockwise Compression ratio Output Engine speed Torque Oil capacity Oil grade
See Operators Manual or Engine Card
Locking compound, lubricants, sealing compounds Activator T for faster curing of locking compound 561 200 . . . . . . . . . 561 045 Locking fluid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 561 200 Lubricant for exhaust pipe bolts and joints . . . . . . . . . . . . . . . . . . . . . . 561 205 Hydraulic sealant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 561 019
Cylinder head
Minimum cylinder head height after machining, page 17 . . . . . . . . . . . 124.4 mm Distance B between the surface of the cylinder head and valve disc, page 11 With new parts min. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.72 mm With machined parts max. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.80 mm Intake valve Clearance (cold engine) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.45 mm Head angle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19.4- 19.6 Minimum dimension A for ground valve, page 10 . . . . . . . . . . . . . . . . 3.0 mm
01:02-02
Scania CV AB 1998
65
Program 96
Exhaust valve Clearance (cold engine). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.80 mm Disc angle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44.4- 44.5 Minimum dimension A for machined valve, page 10 . . . . . . . . . . . . . . 1.7 mm
Intake valve seat Seat angle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Width A of contact surface, page 11 . . . . . . . . . . . . . . . . . . . . . . . . . . . Valve seat ring outer diameter. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Seat for valve seat ring, diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Seat for valve seat ring, depth . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20.0- 20.5 2.3 - 2.8 mm 56.0 mm 55.934 - 55.953 mm 11.25 - 11.35 mm
Valve seat ring in oversize: Outer diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56.2 mm Seat for valve seat ring, diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56.134 - 56.153 mm Cooling temperature when fitting valve seat ring . . . . . . . . . . . . . . . . . approx. -80 C
Exhaust valve seat Seat angle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Width A of contact surface, page 11 . . . . . . . . . . . . . . . . . . . . . . . . . . . Valve seat ring, outer diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Seat for valve seat ring, diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Seat for valve seat ring, depth . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45.0- 45.5 1.9 - 2.6 mm 52.0 mm 51.914 - 51.933 mm 11.25 - 11.35 mm
Valve seat ring in oversize: Outer diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52.2 mm Seat for valve seat ring, diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52.114 - 52.133 mm Cooling temperature when fitting valve seat ring . . . . . . . . . . . . . . . . . approx. -80 C
Valve guides Height above surface for valve spring washer: Without valve stem seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23.75 - 24.25 mm With valve stem seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.95 - 9.45 mm
Rocker arm mechanism Rocker arm bushing, inside diameter (pressed in and machined) . . . . . 25.00 - 25.02 mm Surface quality. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.25 Ra Diameter of oil holes (2 holes) drilled to same diameter as in rocker arm.
66
Scania CV AB 1998
01:02-02
Program 96
Tightening torques Cylinder head bolts: First time. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120 Nm Second time . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 180 Nm Third tightening . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 250 Nm + 90 Nut for injector. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70 Nm Nut for rocker arm adjusting screw . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40 Nm Bolt for rocker cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 Nm Bolts for exhaust manifold. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63 Nm
Turbocharger
Wear limits Shaft radial clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.198-0.564 mm Shaft axial clearance (after running in) . . . . . . . . . . . . . . . . . . . . . . . . . 0.025-0.106 mm
Tightening torques Bolts, turbocharger - exhaust pipe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40 Nm Bolts against turbine housing (exhaust line) . . . . . . . . . . . . . . . . . . . . . 24 Nm

Cylinder liner Shims for cylinder liner, thickness. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.20 , 0.25 , 0.30 , . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.40 , 0.50 , 0.75 mm Cylinder liner height above cylinder block . . . . . . . . . . . . . . . . . . . . . . 0.22 - 0.28 mm
Maximum permitted height difference on individual liner between measurements read at two diametrically opposed points across the engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.02 mm Max. permissible difference in height under same cylinder head . . . . . 0.03 mm
01:02-02
Scania CV AB 1998
67
Program 96
Pistons Fitted with arrow on piston crown towards the front of the engine
Piston rings Number of compression rings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Gap: 1st ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2nd ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Max. clearance in groove, 2nd ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . Rings marked TOP should be turned with the mark upwards Number of oil scraper rings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 Gap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.40 - 0.80 mm Clearance in groove max. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.25 mm Connecting rods Connecting rod and cap marked 1 to 6. Fitted with marking in. 2 0.60 - 0.80 mm 0.50 - 0.70 mm 0.25 mm
Tightening torques Bolts for tension lugs when pressing down cylinder liner . . . . . . . . . . 60 Nm Bolts, oil sump. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50 Nm Connecting rod bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 Nm + 90

Flywheel Maximum machining of contact surface for disc: 2.0 mm
68
Scania CV AB 1998
01:02-02
Program 96
Flywheel housing Seal in flywheel housing: Dimension B, page 46 . . . . . . . . . . . . . . . . . 7 mm
Tightening torques Flywheel bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 180 Nm Bolts for flywheel housing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90 Nm
Timing gear
Camshaft gear Heated to 100 C before fitting. Backlash against intermediate gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.03 - 0.15 mm
Injection pump gear Backlash against intermediate gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.03 - 0.15 mm
Intermediate gear Axial clearance max. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.238 mm
Bushing for power take-off gear Diameter. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45.009 - 45.034 mm
Camshaft Axial clearance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.10 - 0.25 mm
01:02-02
Scania CV AB 1998
69
Program 96
Crankshaft Main bearing journals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Diameter: Standard Undersize 1 Undersize 2 Undersize 3 Undersize 4 Undersize 5 Undersize 6 Fillet radius 101.598 - 101.620 mm 101.348 - 101.370 mm 101.098 - 101.120 mm 100.848 - 100.870 mm 100.598 - 100.620 mm 100.348 - 100.370 mm 100.098 - 100.120 mm 4.8 - 5.2 mm
Surface quality 0.25 Ra Width, max. Radial clearance Big-end bearing journals . . . . . . . . . . . . . . . . . . . . . . . . . . . Diameter: Standard Undersize 1 Undersize 2 Undersize 3 Undersize 4 Undersize 5 Undersize 6 Fillet radius Surface quality Width, max. 84.233 - 84.255 mm 83.983 - 84.005 mm 83.733 - 83.755 mm 83.483 - 83.505 mm 83.233 - 83.255 mm 82.983 - 83.005 mm 82.733 - 82.755 mm 4.8 - 5.2 mm 0.25 Ra 59.10 mm 51.28 mm 0.054 - 0.116 mm
Radial clearance 0.050 - 0.112 mm
Thrust bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Thickness: Standard Undersize 1 Undersize 2 Undersize 3 Undersize 4 Undersize 5 3.378 - 3.429 mm 3.454 - 3.505 mm 3.505 - 3.556 mm 3.632 - 3.683 mm 3.886 - 3.937 mm 4.267 - 4.318 mm
Axial clearance 0.14 - 0.37 mm
70
Scania CV AB 1998
01:02-02
Program 96
Tightening torques Nut for camshaft gear. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 600 Nm Nut for compressor gear. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 200 Nm Bolts for intermediate gear shaft journal . . . . . . . . . . . . . . . . . . . . . . . . 39 Nm Connecting rod bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 Nm + 90 Main bearing bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50 Nm + 90 Flywheel bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 180 Nm Crankshaft bolt. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 300 Nm+60 Bolts for crankshaft damper and pulley . . . . . . . . . . . . . . . . . . . . . . . . . 110 Nm Fan bolts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70 Nm
Lubrication system
Oil pump Radial clearance: pump gear - pump housing . . . . . . . . . . . . . . . . . . . . 0.130 - 0.179 mm Axial clearance: pump gear - pump housing cover (without gasket). . . 0.07 - 0.10 mm
Oil pressure valve (Note: not safety valve) Oil pressure: With warm engine at 2,000 rpm. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.5 - 6 bar With warm engine at 800 rpm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.5 bar Free spring length. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61.4 mm
Oil cleaner Permitted thickness of deposits on wall of bowl . . . . . . . . . . . . . . . . . . 20 mm
Oil filter Use only genuine Scania filters.
01:02-02
Scania CV AB 1998
71
Program 96
Tightening torques Oil pump: Bolts for oil pump cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 Nm Bolts oil pump - cylinder block . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59 Nm Valve sleeve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30 Nm
Oil cleaner: Lock nut for oil cleaner housing cover . . . . . . . . . . . . . . . . . . . . . . . . . 10 Nm Nut for rotor bowl . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Tighten by hand Rotor shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41 Nm
Oil nozzle for piston cooling: Banjo bolt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 Nm M8 Bolt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 Nm
72
Scania CV AB 1998
01:02-02
Program 96
Valve clearance
Checking and adjusting Check valve clearance. The clearance for intake valves should be 0.45 mm and the clearance for exhaust valves should be 0.80 mm when the engine is cold. Adjustment can be carried out in one of the following ways:
A. Adjust both valves in each cylinder starting with No.1 cylinder at TDC after compression. Turn the crankshaft 1/3 turn at a time and adjust valves in injection sequence: 1-5-3-6-2-4
B. Set No.1 cylinder at precisely TDC after compression. The following valves can now be adjusted: cyl. 1 cyl. 2 cyl. 3 cyl. 4 cyl. 5 intake and exhaust intake exhaust intake exhaust
Turn the crankshaft precisely one revolution so that TDC for No.6 cylinder is set. The remaining valves can now be adjusted: cyl 2 cyl 3 cyl 4 cyl 5 cyl 6 exhaust intake exhaust intake exhaust and intake
01:02-02
Scania CV AB 1998
Program 96
Compression
Measuring The compression tester is used to quickly and simply check wear and damage to primarily the cylinder head valves, but also to cylinder liners and piston rings.
Measurements are only intended for comparison between cylinders. Lower compression in one or several cylinders is a sign of abnormal wear or damage.
By using various accessories, the compression tester can be used for several engine types.
1. Switch off the fuel supply. 2. Clean around injectors. Detach delivery pipes and leak-off pipes from all injectors. Note Place protective caps on the pressure valve holders in the injection pump and on the injectors in order to protect them from dirt. 3. Undo and remove the injectors and copper washers. 4. Turn the engine several times using the starter motor to remove any loose soot in the cylinders.
1. Pressure gauge 2. Zeroing valve 3. Flexible metal hose 4. Test rod 5. End sleeve, diameter 21 mm 6. Spacing sleeve with guide lug 7. Spacing sleeve with collar 8. Spacing sleeve, length 6 mm 9. Spacing sleeve, length 19 mm 10. Spacing sleeve, length 25 mm 11. Spacing sleeve, length 38 mm 12. Cap nut 13. Threaded socket nut 14. Large yoke 15. Small yoke Compression tester 98 249
Scania CV AB 1998
01:02-02
Noter
First time at
DI 12
Interval At least Every 5th year 29
First start
LUBRICATING OIL SYSTEM, page 30 1. Checking the oil level 2. Oil change 3. Cleaning the oil cleaner 4. Renewing the oil filter COOLING SYSTEM, page 34 5. Checking the coolant level 6. Checking the corrosion bars 4) 7. Checking the marine water pump impeller 4) 8. Checking the coolant 9. Cleaning the cooling system AIR CLEANER, page 42 10. Checking the vacuum sensor 11. Cleaning the coarse cleaner 12. Cleaning or renewing filter element 13. Renewing the safety cartridge FUEL SYSTEM, page 45 14. Checking the fuel level 15. Renewing the main filter 16. Checking the injectors ELECTRICAL SYSTEM, page 47 17. Checking the electrolyte level in batteries 18. Checking the state of charge in batteries 19. Cleaning the batteries 20. Checking the level monitor 21. Checking the temperature monitor 22. Checking the oil pressure monitor MISCELLANEOUS, page 51 23. Checking the drive belt 24. Checking for leakage, rectify as necessary 25. Checking/adjusting valve clearance 26. Renewing (or cleaning) the valve for closed crankcase ventilation
1 1 1
5 5 6 1 6
1 3
2 2 2
1. 2. 3. 4. 5. 6.
More often if required. For engines with few operating hours, see page 28. Earlier if low pressure indicator shows red. Only applies to M engines with sea water pump. Reference value. Varies depending on the composition of the sea water. If inhibitor has not been topped up for five years, the coolant should be changed.
2005-03:1
Annually
1200 h
2400 h
4800 h
400 h
200 h
400 h
Daily
Specifications
General information
Cylinder configuration. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Number of cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Cylinder bore . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Stroke length . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Swept volume . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Number of main bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Firing order . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Injection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Principle of operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Cooling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Approx. weight, including alternator. . . . . . . . . . . . . . . . . . . . . . . . . . . Direction of rotation (engine viewed from rear) . . . . . . . . . . . . . . . . . . In-line engine 6 127 mm 154 mm 11.7 dm3 7 1-5-3-6-2-4 Direct 4-stroke Liquid 990 kg Anti-clockwise
Compression ratio Output Engine speed Torque Oil capacity Oil grade
See Operator's Manual or Service Card for the particular engine
Locking compound, lubricants, sealing compound Activator T for faster hardening of locking compound 561 200 . . . . . . Locking compound . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Lubricant for exhaust pipe bolts and joints . . . . . . . . . . . . . . . . . . . . . . Thread sealant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Sealing compound for flywheel housing . . . . . . . . . . . . . . . . . . . . . . . . 561 045 561 200 561 205 561 019 816 064
General tightening torques The following tightening torques apply in general unless otherwise specified: Thread M5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Thread M6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Thread M8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Thread M10 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Thread M12 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Thread M14 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.7 Nm 10.2 Nm 26 Nm 50 Nm 92 Nm 149 Nm
01:03-02
Scania CV AB, Sweden, 2003-05:6
91
Cylinder head
Intake valve Valve head angle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19.5 Minimum dimension A for ground valve . . . . . . . . . . . . . . . . . . . . . . . 2.6 mm Distance between the surface of the cylinder head and the valve head. 0.75-1.8 mm Exhaust valve Valve head angle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44.5 Minimum dimension A for ground valve . . . . . . . . . . . . . . . . . . . . . . . 1.8 mm Distance between the surface of the cylinder head and the valve head. 0.66-1.8 mm - Check dimension A for each valve. - Grind the valves in a valve grinding machine
Minimum dimension A for ground valve
Intake valve seat Seat angle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Width of contact surface A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Valve seat insert, outer diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Seat for valve seat insert, diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . Seat for valve seat insert, depth. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Oversized valve seat insert: Outer diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46.254 - 46.265 mm Seat for valve seat insert, diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46.200 - 46.216 mm Cooling temperature when fitting valve seat insert. . . . . . . . . . . . . . . . approx. -80C 20.0-20.5 1.9 - 2.6 mm 46.054 - 46.065 mm 46.000 - 46.016 mm 11.25 - 11.35 mm
92
01:03-02
Exhaust valve seat Seat angle. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Width of contact surface A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Valve seat insert, outer diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Seat for valve seat insert, diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . Seat for valve seat insert, depth . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Oversized valve seat insert: Outer diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44.281 - 44.292 mm Seat for valve seat insert, diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44.200 - 44.216 mm Cooling temperature when fitting valve seat insert . . . . . . . . . . . . . . . . approx. -80C 45.0-45.5 1.8 - 2.6 mm 44.081 - 44.092 mm 44.000 - 44.016 mm 11.25 - 11.35 mm
Tightening torques Cylinder head bolts: First tightening . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Second tightening . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Third tightening . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fourth tightening . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Nut for injector. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Bolts for shaft with rocker arms. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Nut for adjusting screw on rocker arm . . . . . . . . . . . . . . . . . . . . . . . . . Bolt for rocker cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Bolts for exhaust manifold. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Bolts for turbocharger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Bolts for support bracket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60 Nm 150 Nm 250 Nm 90 70 Nm 105 Nm 40 Nm 26 Nm 59 Nm 50 Nm 105 Nm
Valve clearances and unit injectors

Valve clearance, intake valve (cold engine) . . . . . . . . . . . . . . . . . . . . . Valve clearance, exhaust valve (cold engine) . . . . . . . . . . . . . . . . . . . . Dimension for PDE31 unit injector (cold engine) . . . . . . . . . . . . . . . . . Dimension for PDE32 unit injector (cold engine) . . . . . . . . . . . . . . . . . 0.45 mm 0.70 mm 66.9 +/- 0.1 mm 69.9 +/- 0.1 mm
Tightening torques Adjusting screw lock nut on rocker arm for unit injector . . . . . . . . . . . Adjusting screw lock nut on rocker arm for valves . . . . . . . . . . . . . . . . Bolt for upper rocker cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Bolt for lower rocker cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Support bracket and rocker arm shaft . . . . . . . . . . . . . . . . . . . . . . . . . . Cable connection, unit injector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39 Nm 35 Nm 26 Nm 26 Nm 105 Nm 2 +/- 0,2 Nm
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Turbocharger
Wear limits Shaft radial clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.198-0.564 mm Shaft axial clearance (after running in) . . . . . . . . . . . . . . . . . . . . . . . . . 0.025-0.106 mm
Tightening torques Bolts, turbocharger - exhaust manifold . . . . . . . . . . . . . . . . . . . . . . . . . 63 Nm Bolts in turbine housing (exhaust pipe). . . . . . . . . . . . . . . . . . . . . . . . . 24 Nm V-clamps, exhaust and intake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-10 Nm

Cylinder liner Shims for cylinder liner, thickness . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.20, 0.25, 0.30, . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.40, 0.50, 0.75 mm Height of cylinder liner above cylinder block. . . . . . . . . . . . . . . . . . . . 0.20 - 0.30 mm Maximum permitted height difference on one liner between dimensions measured at two diametrically opposite points . . . . . . . . . 0.02 mm
Pistons Fitted with arrow on piston crown facing forward.
Piston rings Number of compression rings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Gap: 1st ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2nd ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Maximum clearance in groove, 2nd ring. . . . . . . . . . . . . . . . . . . . . . . . Rings marked "TOP" should be turned with the marking up. Number of oil scraper rings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 Gap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.40 - 0.65 mm Max. clearance in groove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.25 mm 2 0.35 - 0.60 mm 0.45 - 0.65 mm 0.25 mm
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Connecting rods Connecting rod and bearing cap marked 1 to 6. Fitted with marking in. Tightening torques Oil sump bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30 Nm Connecting rod bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 Nm + 90

Flywheel Maximum machining allowance for disc pressure surface: 2.0 mm
Ring gear Heated to 100 - 150C before fitting.
Tightening torques Flywheel bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 130 Nm + 90 Bolts for flywheel housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . M10: 50 Nm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . M12 : 90 Nm
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Timing gear
Camshaft gear Backlash against intermediate gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.03 - 0.15 mm
Injection pump gear Backlash against intermediate gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.03 - 0.15 mm
Intermediate gear Max. axial clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.238 mm
Camshaft Axial clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.10 - 0.25 mm
Tightening torques Bolts for camshaft gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Bolts for intermediate gears . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Bolts for compressor gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Connecting rod bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Main bearing bolts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Bolts for driver . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Bolts for crankshaft damper and pulley. . . . . . . . . . . . . . . . . . . . . . . . . Flange bolts and banjo bolts for valve tappets . . . . . . . . . . . . . . . . . . . Bolts for timing gear plate. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63 Nm 50 Nm + 60 105 Nm 20 Nm + 90 50 Nm + 90 135 Nm 110 Nm 32 Nm 63 Nm
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Lubrication system
Oil cleaner Permitted thickness of deposits on wall of cover . . . . . . . . . . . . . . . . . max. 20 mm
Oil pressure valve (Note: not safety valve) Oil pressure: Idle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . With warm engine running at 1000 rpm . . . . . . . . . . . . . . . . . . . . . . . . With warm engine running at 2,000 rpm . . . . . . . . . . . . . . . . . . . . . . . . Free spring length . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.6 bar 2.5 bar 4.5 - 6.0 bar 61.4 mm
Oil filter Only use original Scania filters.
Tightening torques Oil pump: Bolts for oil pump cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 Nm Bolts, oil pump - cylinder block . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 Nm Oil cleaner: Lock nut for oil cleaner housing cover . . . . . . . . . . . . . . . . . . . . . . . . . 15 Nm Nut for rotor bowl . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Tightened by hand Rotor shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34 Nm Oil nozzle for piston cooling: Banjo bolt. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 Nm Oil cooler: Bolts for oil cooler insert . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 Nm
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Valve clearances (engines with injection pump)

Checks and adjustments Check the valve clearance. The clearance for intake valves should be 0.45 mm and the clearance for exhaust valves should be 0.70 mm when the engine is cold. The following alternative methods of adjustment are possible: I. Adjust all four valves for each cylinder when at TDC after compression. Start with cylinder No. 1 and turn the crankshaft 1/3 turn at a time using tool 99 309 in the following injection order: 1-5-3-6-2-4
J. Put cylinder 1 at exact TDC after the compression stroke. The following valves can now be adjusted: cyl. 1 cyl. 2 cyl. 3 cyl. 4 cyl. 5 intake and exhaust intake exhaust intake exhaust
O Intake valve Exhaust valve
Turn the crankshaft precisely one revolution so that TDC for No. 6 cylinder is set. The remaining valves can now be adjusted: cyl. 2 exhaust cyl. 3 intake cyl. 4 exhaust cyl. 5 intake cyl. 6 exhaust and intake
O Intake valve Exhaust valve
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Adjusting the valve clearance and unit injectors (engines with PDE unit injector)
Note: Check and adjust the valve clearance and unit injectors at the same time and with the engine cold. Checking and adjusting the valve clearance 1. Turn the flywheel (counterclockwise) with tool 99 309 so that the marks on the flywheel can be seen in the lower opening in the flywheel casing. See table on next page for order of adjustment. 2. Check the valve clearance using a feeler gauge and, if necessary, use the adjusting screw on the rocker arm to set the correct clearance. The clearance for intake valves should be 0.45 mm and the clearance for exhaust valves should be 0.70 mm when the engine is cold. The intake valves are actuated by the short rocker arms and the exhaust valves by the long rocker arms. Make sure the valve bridge is resting correctly against the valves. 3. Adjust the unit injectors in accordance with adjustment order in the table and Adjusting unit injectors. 4. If reading cannot be performed from underneath but only in the upper opening: Start with the TDC Up position and turn the flywheel counterclockwise 120 (1/3 turn) at a time, observe the valve change and adjust in accordance with the table. Important The flywheel marking is only correct if the reading is taken through the lower opening.
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Order of adjustment:
Mark on flywheel (reading from underneath) TDC Down (0) 120 240 TDC Down (0) 480 600
Valve change on cylinder 1 5 3 6 2 4
Adjust valves on cylinder 6 2 4 1 5 3
Adjust injector rocker arm on cylinder 2 4 1 5 3 6
Adjusting unit injectors, PDE31 and PDE32 Important! The PDE31 unit injector is adjusted using setting tool 99 414 or a digital sliding caliper. The PDE32 unit injector is adjusted using setting tool 99 442 or a digital sliding caliper. This adjustment is important because an incorrectly positioned unit injector may result in poor performance and possible breakdown. Screw on the rocker arm adjusting screw 1 while measuring the distance between plane a and the top of the valve spring collar using a digital sliding caliper. The dimension should be 66.9 mm for PDE31 and 69.9 mm for PDE32. See dimension B in the figure for identifying the injector.
Dimension A = PDE31: 66.9 +/- 0.1 mm PDE32: 69.9 +/- 0.1 mm Dimension B = PDE31: 36.5 mm PDE32: 38.8 mm
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WARNING!
Take care when carrying out the adjustment if the dimension is well outside the adjustment dimension. The spring is pre-tensioned and can cause personal injury if it is released. PDE31 1. Position setting tool 99 414 with the metal plate around the injector spring. 2. Finely adjust dimension A by simultaneously using a finger to sense that the small piston 2 is level with the flat upper surface of the tool. It is possible to sense differences of less than a tenth of a millimetre. 3. If tool 99 414 is not available: Measure the distance between plane a and the top of the valve spring collar using a digital sliding caliper. Adjust the rocker position by means of the adjusting screw until the dimension is 66.9 +/- 0.1 mm. 4. Tighten the lock nut to 39 Nm. 5. See Order of adjustment on page 6 for checking/adjusting the injector rockers.
Piston above or below the flat surface. Adjustment necessary.
Piston level with the flat surface. Adjustment is correct. 12
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PDE32 1. Position setting tool 99 442 with the metal plate around the injector spring. 2. Finely adjust dimension A by simultaneously using a finger to sense that the small piston 2 is level with the flat upper surface of the tool. It is possible to sense differences of less than a tenth of a millimetre. 3. If tool 99 442 is not available: Measure the distance between plane a and the top of the valve spring collar using a digital sliding caliper. Adjust the rocker position by means of the adjusting screw until the dimension is 69.9 +/- 0.1 mm. 4. Tighten the lock nut to 39 Nm. 5. See Order of adjustment on page 6 for checking/adjusting the injector rockers.
Piston above or below the flat surface. Adjustment necessary.
Piston level with the flat surface. Adjustment is correct.
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Location of sensors for DEC2 on DI12
1. Connection of lead to charge air 2. 3. 4. 5. 6.

temperature sensor Charge air temperature sensor Oil pressure monitor Connector panel Coolant temperature sensor Engine speed sensorse
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LED functions during normal operation

Note: The lamp test/fault code switch should not be
depressed. All LEDs come on briefly when the control unit is powered up.
POWERThe LED remains out during normal operation as long as no fault is detected by the control unit. See next page for the procedure to be adopted in the event of a fault.
CONTROL STATUS
The LED flashes continuously when the control unit is supplied with current, regardless of whether the engine is running or not.
POWER+
If the control unit is programmed to allow the engine to be operated according to more than one power/torque curve (map), the following applies. The LED comes on when the engine is run at more than 100% power output (MAP 2). It goes out when the engine returns to the 100% power output curve (MAP 1) or when the power output required is less than 100%.
SHUTDOWN
The LED is out.
STARTING
The LED lights up as soon as the engine turns over on cranking and follows the programmed starting sequence until it has been completed and then goes out.
RUNNING
The LED comes on when the engine has started and the "Starting" LED goes out. It remains on until the engine is stopped.
TORQUE LIMIT
The LED comes on when the control unit detects that the engine has received the maximum permissible quantity of injected fuel according to its power curve. This means 100% power output at the current rpm. If the load increases, engine rpm will decrease.
BOOST LIMIT
The LED comes on when the control unit smoke limiter restricts the maximum fuel quantity. Operation of the smoke limiter is dependent on the charge air pressure.
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Action in case of a fault

LED indications in case of a fault Note The main indicator lamp in the main supply
box and at the instrument panel has indicated a fault. The lamp test/fault code switch should not be depressed.
CONTROL STATUS
The LED will continue to flash even in case of a fault as long as voltage is supplied to the control unit.
POWER If the LED comes on, the control unit has detected a defect that could cause damage to the engine if operation continues. The control unit automatically reduces engine power output to a predefined level if the corresponding function has been selected. Action: Reduce engine speed to idle if possible and conduct troubleshooting according to instructions on page 20 and the chart on page 21
SHUTDOWN
The LED comes on and the engine is switched off automatically in case of a severe fault that could cause damage to the engine if operation continues. Action: Conduct troubleshooting according to instructions on page 20 and the chart on page 21 If the engine has not stopped, reduce engine speed to idle and conduct troubleshooting.
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Changing functions using the DIP switches in the control unit

There are 8 DIP switches in the control unit under the round black rubber cover. These switches shall be in the ON position to obtain normal functions according to the operating program. However, for single-speed engines, the normal position of DIP switches 6, 7, and 8 may also be OFF Shutdown at threshold values for low oil pressure and high coolant temperature can be selected by setting DIP switch 4 to OFF With DIP switch 4 in position ON, Power- indication is obtained for these threshold values. Engine output reduction (LOP) can be selected to prevent damage to the engine. Changes to the program must only be performed by authorized personnel.
Readout of fault codes

Note If the engine has stopped or lost power but
the main indicator lamp is out and neither POWER- nor SHUTDOWN are on, the fault is outside the control unit detection range. Probable causes: fuel shortage, temporary overload, mechanical fault. - Activate the lamp test/fault code switch. In Scania electrical equipment the main indicator lamp is located in this switch on the main supply box. - All LEDs will then come on for 2 seconds to indicate that they are intact and in working order. This also applies to the main indicator lamp in the main supply box and the instrument panel. Make a note of any LED that is defective. - All LEDs will then be out for approximately 4 seconds. - Following this, a fault code will be indicated on one of the LEDs for 2 seconds. Note which LED it is. - The control unit then resumes the operating mode automatically. - After having made a note of the fault code, reset the lamp test/fault code switch and reset the control unit by turning off its power supply momentarily. - The most probable cause of the fault can then be found in the trouble shooting schedule on the next page. - When the fault or faults have been rectified the engine can be restarted. - If the control system continues to indicate a fault by way of the main indicator lamp, further faults may have been recorded. The fault code readout must then be repeated as per above since the system can only display one fault code at a time. - The fault(s) will be stored in a special memory in the control unit along with information about the operating time when it(they) occurred. Stored faults can be accessed and erased by authorised service personnel.
Note Do not operate the engine with a Powerindication except for in emergencies.
The DIP switches are showed in ON position
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CONTROL STATUS
TORQUE LIMIT
BOOST LIMIT
SHUTDOWN
STARTING
RUNNING
POWER +
POWER -
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READOUT OF FAULT CODES

LED INDICATION WHEN THE LAMP TEST/FAULT CODE SWITCH IS ACTIVATED
Probable cause
Action
DEC2 has detected an internal fault in the control unit. The engine temperature has reached the threshold level or the temperature sensor is inoperative. The engine has reached the overrevving limit or the engine speed sensor is inoperative. Control rack position sensor inoperative. The intake air temperature has reached the threshold level or the charge air temperature sensor is inoperative. DEC2 detects no charge air pressure. The charge air pressure sensor is inoperative. Engine speed potentiometer or the idling safety switch is inoperative. The oil pressure has dropped to the threshold level or the oil pressure monitor is inoperative.
Send in the control unit for repair as soon as possible. Check the cooling system. Check the temperature sensor and cable routing. Check the wiring and connector. Renew the engine speed sensor. Check connectors and cables to governor. Check the intake system. Check the temperature sensor and cable routing. Check the charge air pressure hose. Send in the control unit for repair if the connection is damaged. Check the cable routing, connectors and cables. Check oil level, connector and cable. Renew the oil pressure monitor.
=LED on
DI 14
First time at At first start Interval At least Every 5th year
l l l3 l l l l1 l l l l l l l l l l l l l l l2 l2 l2 l l l l l l l l l l l l l l l
LUBRICATION OIL SYSTEM, page 20 1. Checking oil level 2. Oil change 3. Cleaning the lubrication oil cleaner 4. Changing the turbo filter COOLING SYSTEM, page 24 5. Checking coolant level 6. Checking corrosion protection rods 4) 7. Checking seawater pump impeller 4) 8. Checking coolant 9. Cleaning cooling system AIR CLEANER, page 32 10. Test reading low pressure indicator 11. Cleaning coarse cleaner 12. Cleaning or changing filter insert 13. Changing safety cartridge FUEL SYSTEM, page 35 14. Checking fuel level 15. Changing main filter 16. Checking injectors ELECTRICAL SYSTEM, page 37 17. Checking electrolyte level in batteries 18. Checking charge state of batteries 19. Cleaning batteries 20. Checking level monitor 21. Checking temperature monitor 22. Checking oil pressure monitor 23. Checking stop function MISCELLANEOUS, page 42 24. Checking V-belts 25. Look for leaks. Remedy as necessary 26. Checking/adjusting valve clearance. 27. Changing (or cleaning) valve for closed crankcase ventilation
l l1 l1 l1 l l l
1. 2. 3. 4. 5. 6.
More often if required For engines with few operating hours, see page 18. Earlier if low pressure indicator shows red. Applies only to M engines with seawater pump. Guidline values. Vary according to composition of seawater. If inhibitor has not been topped up for five years, coolant should be changed.
Every year
1200 h
2400 h
4800 h
400 h
200 h
400 h
Daily
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Specifications
General information
Cylinder locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Number of cylinders. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Cylinder bor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Stroke . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Swept volume. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Number of main bearings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Firing sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Injection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Principle of operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Cooling. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Weight, incl. generator, about . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . V engine 8 127 mm 140 mm 14,2 dm3 5 1-5-4-2-6-3-7-8 Direct 4 stroke Fluid 1230 kg
Compression ratio output Engine speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . See operators manual or Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . service card for engine Fluid volume . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . concerned Oil grade. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Locking compound, lubricants, sealing compounds Activator T for faster curing of locking compound 561 200 Locking compound . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Lubricant for exhaust pipe bolts and joints . . . . . . . . . . . . . . . . . . . . . Sealing compound for cylinder liners . . . . . . . . . . . . . . . . . . . . . . . . . Thread seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 561 045 561 200 561 205 584 106 561 019
Cylinder head
Minimum height of cylinder head after machining, page 17 . . . . . . . . 114,8 mm Distance B between the surface of the cylinder head and valve disc, page 11 With new parts, minimum . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0,72 mm With machined parts, maximum . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1,80 mm Intake valve Clearance (cold engine) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0,45 mm Head angle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19,4 - 19,6 Minimum dimension A for reground valve, page 10. . . . . . . . . . . . . . 3,0 mm
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Exhaust valve Clearance (cold engine) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Head angle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Minimum dimension A for reground valve, page 10 . . . . . . . . . . . . . Inlet valve seat Seat angle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Contact surface width A, page 11. . . . . . . . . . . . . . . . . . . . . . . . . . . . Valve seat ring, outside diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . Seat for valve seat ring, diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . Position of valve seat ring, depth . . . . . . . . . . . . . . . . . . . . . . . . . . . . Valve seat ring in oversize: Outside diameter. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Seat for valve seat ring, diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . Cooling temperature on fitting valve seat ring . . . . . . . . . . . . . . . . . . Exhaust valve seat Seat angle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Contact surface width A, page 11. . . . . . . . . . . . . . . . . . . . . . . . . . . . Valve seat ring, outside diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . Seat for valve seat ring, diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . Position of valve seat ring, depth . . . . . . . . . . . . . . . . . . . . . . . . . . . . Valve seat ring in oversize: Outside diameter. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Seat for valve seat ring, diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . Cooling temperature on fitting valve seat ring . . . . . . . . . . . . . . . . . . Valve guides Height above surface for valve spring washer . . . . . . . . . . . . . . . . . . Rocker arm mechanism Rocker bushing, inside diameter (pressed in and machined) . . . . . . . 30,007 - 30,028 mm Surface quality . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0,8 Ra Diameter of oil holes (2 holes) drilled to same diameter as in rocker arm. 19,00 - 19,45 mm 44,0 - 46,0 1,9 - 2,6 mm 52,0 mm 51,914 - 51,933 mm 11,25 - 11,35 mm 52,2 mm 52,114 - 52,133 mm ca -80 C 20,0 - 20,5 2,3 - 2,8 mm 56,0 mm 55,934 - 55,953 mm 11,25 - 11,35 mm 56,2 mm 56,134 - 56,153 mm ca -80 C 0,80 mm 44,4 - 44,6 1,7 mm
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Tightening torques Cylinder head bolts: First tightening . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110 Nm Second tightening. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 165 Nm Third tightening . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 220 Nm Injector nut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Nut for adjusting screw on rocker arm . . . . . . . . . . . . . . . . . . . . . . . . Rocker cover bolt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Exhaust manifold bolts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Intake manifold nuts, DSI . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Charge cooler cover nuts, DSI . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70 Nm 40 Nm 16 Nm 59 Nm 39 Nm 39 Nm
Turbocharger
Wear limits Shaft radial clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0,198-0,564 mm Shaft axial clearance (after running-in) . . . . . . . . . . . . . . . . . . . . . . . . 0,025-0,106 mm Tightening torques Bolts, turbocharger - exhaust pipe . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40 Nm V clamps, exhaust and inlet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-10 Nm

Cylinder liner Cylinder liner shims, thickness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0,20 , 0,25 , 0,30 , 0,40 , 0,50 0,75 mm Cylinder liner height above cylinder block . . . . . . . . . . . . . . . . . . . . . 0,08 - 0,12 mm Max. permitted height difference on the same liner measured at two diagonally opposite points in the transverse direction of the engine . . 0,02 mm
72
01:04-02
Pistons Fitted with arrow on piston crown towards the outside of the engine Piston rings Number of compression rings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Gap: 1st ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2nd ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Maximum clearance in groove, 2nd ring . . . . . . . . . . . . . . . . . . . . . . Rings marked TOP should be turned with the mark upwards Number of oil scraper rings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Gap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Maximum clearance in groove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Connecting rods Connecting rod and cap marked 1 to 8. Fitted with marking in. Weight classes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Only weight class B is available as a spare part. Tightening torques Bolts for tension lugs when pressing down cylinder liners . . . . . . . . Oil sump bolts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Connecting rod bolts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60 Nm 47 Nm 20 Nm + 90 1 st 0,4 - 0,65 mm 0,25 mm 2 st 0,50 - 0,75 mm 0,45 - 0,65 mm 0,25 mm
A, B och C

01:04-02
73
Flywheel housing Seal in flywheel housing: dimension B, page 46 . . . . . . . . . . . . . . . . . 7 mm Tightening torques Flywheel bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 230 Nm + 60 Flywheel housing bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90 Nm
Timing gear
Camshaft gear Heated to 100 C before fitting. Backlash to intermediate gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0,05 - 0,15 mm Injection pump gear Backlash to intermediate gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0,05 - 0,14 mm Intermediate gear Maximum axial clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0,24 mm Bushing for power take-off gear Diameter. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45,009 - 45,034 mm Cam shaft Axial clearance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0,15 - 0,30 mm
74
01:04-02
Crankshaft
Main bearing races . . . . . . . . . . Diameter: Standard 1st undersize 2nd undersize 3rd undersize 4th undersize 5th undersize 6th undersize Fillet radius Surface quality Max. width Radial clearance Connecting rod races . . . . . . . . Diameter: Standard 1st undersize 2nd undersize 3rd undersize 4th undersize 5th undersize 6th undersize Fillet radius Surface quality Max. width Radial clearance Thrust bearing . . . . . . . . . . . . . . Thickness: Standard 1st oversize 2nd oversize 3rd oversize 4th oversize 5th oversize Axial clearance 3,378 - 3,429 mm 3,454 - 3,505 mm 3,505 - 3,556 mm 3,632 - 3,683 mm 3,886 - 3,937 mm 4,267 - 4,318 mm 0,18 - 0,37 mm 89,978 - 90,000 mm 89,728 - 89,750 mm 89,478 - 89,500 mm 89,228 - 89,250 mm 88,978 - 89,000 mm 88,728 - 88,750 mm 88,478 - 88,500 mm 4,8 - 5,2 mm 0,25 Ra 94,35 mm 0,050 - 0,112 mm 101,598 - 101,620 mm 101,348 - 101,370 mm 101,098 - 101,120 mm 100,848 - 100,870 mm 100,598 - 100,620 mm 100,348 - 100,370 mm 100,098 - 100,120 mm 4,8 - 5,2 mm 0,25 Ra 51,28 mm 0,054 - 0,116 mm
01:04-02
75
Tightening torques
Camshaft gear nuts Compressor gear nuts intermediate gear shaft journal bolts 600 Nm 200 Nm 39 Nm
Main bearing bolts: Vertical. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 420 Nm Horizontal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 140 Nm + 60 Flywheel bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 230 Nm + 60 Crankshaft bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 300 Nm + 60 Crankshaft counterweight bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50 Nm + 90
Lubrication system
Oil pump Radial clearance: pump gear - pump housing . . . . . . . . . . . . . . . . . . . 0,115 - 0,239 mm Axial clearance: pump gear - pump housing cover (without gasket). . 0,058 - 0,094 mm Oil pressure valve (Note: not safety valve) Oil pressure: Warmed-up engine at 2000 rpm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4,5 - 6,0 bar Warmed-up engine at 800 rpm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1,5 bar Free spring length. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70,85 mm Oil cleaner Permissible thickness of dirt deposits on cover walls . . . . . . . . . . . . . 20 mm Oil filter Use only genuine Scania filters
76
01:04-02
Tightening torques
Oil pump Oil pump cover bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Bolts, oil pump - cylinder block . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Valve sleeve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Oil cleaner Locknut on oil cleaner housing cover. . . . . . . . . . . . . . . . . . . . . . . . . Nut for rotor bowl. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Locknut on oil cleaner housing cover. . . . . . . . . . . . . . . . . . . . . . . . . Oil nozzle for piston cooling Banjo bolt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Bolt, M8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 Nm 20 Nm 10 Nm Tighten by hand 34 Nm 20 Nm 59 Nm 30 Nm
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77
Valve clearances
Checking and adjusting Check valve clearances. The clearance for intake valves should be 0.45 mm and the clearance for exhaust valves should be 0.80 mm when the engine is cold.
Adjustment can be carried out in one of the following ways: A. Adjust both valves in each cylinder starting with No. 1 cylinder at TDC after compression. Turn the crankshaft 1/4 turn at a time and adjust valves in injection sequence: 1-5-4-2-6-3-7-8
5 6 7 8
1 2 3 4
Cylinder numbering
B. Turn the crankshaft in the direction of rotation until the piston in No. 1 cylinder is 20 after TDC on the combustion stroke. There is a mark at this point.
01:04-02
Adjust the following valves: RH side: cyl. 1: exhaust and inlet cyl. 2: exhaust cyl. 4: exhaust LH side: cyl. 5: inlet and exhaust cyl. 7: inlet cyl. 8: inlet
1 5 6 3 7 8 4 2

Turn the crankshaft exactly one revolution in the direction of rotation so that the piston in No. 1 cylinder is 20 after TDC on the induction stroke and adjust the following valves: RH side: cyl. 2: inlet cyl. 3: exhaust and inlet cyl. 4: inlet LH side: cyl. 6: inlet and exhaust cyl. 7: exhaust cyl. 8: exhaust
01:04-02
Noter
First time at
DI 16
Interval At least Every 5th year
6 1 29
First start
LUBRICATING OIL SYSTEM, page 26 1. Checking oil level 2. Oil change 3. Cleaning oil cleaner 4. Changing the oil filter and filter for closed crankcase ventilation COOLING SYSTEM, page 31 5. Checking coolant level 6. Checking corrosion protection bars 4) 7. Checking the marine water pump impeller 4) 8. Checking coolant 9. Cleaning cooling system AIR CLEANER, page 44 10. Test reading low pressure indicator 11. Cleaning or changing filter element FUEL SYSTEM, page 46 12. Checking fuel level 13. Changing the main filter and water separating filter ELECTRICAL SYSTEM, page 48 14. Checking electrolyte level in batteries 15. Checking state of charge in batteries 16. Cleaning batteries 17. Checking coolant level monitor MISCELLANEOUS, page 50 18. Checking drive belt 19. Look for leakage, rectify as necessary 20. Checking/adjusting valve clearances 21. Checking/adjusting PDE injector rocker arms
1 1 1
5 5 6
1 2 2 2
1. 2. 3. 4. 5. 6.
More often if required For engines with few operating hours, see page 28. Earlier if low pressure indicator shows red. Only applies to M engines with marine water pump and heat exchanger. Reference value. Varies depending on the composition of the sea water. If inhibitor has not been topped up for five years, the coolant should be changed.
2003-09:4
Annually
1200 h
2400 h
4800 h
400 h
200 h
400 h
Daily
General
1. Warning plates 2. Instruction plate: Valve clearance
3. Type plate: Engine type, Engine serial number 4. Engine serial number, stamped
DC16 engine shown. Di 16: same location
Specifications
Cylinder bore Stroke Displacement No. of main bearings Firing sequence Compression ratio Direction of rotation (engine viewed from behind) Engine speed, low idling (all-speed) Engine speed, high idling (all-speed) Oil volume Oil grade Weight (without oil, coolant, radiator; with fan) 127.0 mm 154.0 mm 15.6 dm3 5 1-5-4-2-6-3-7-8 18:1 Anticlockwise 500 rpm 2400 rpm 35 litre see booklet 00:03-01 1,346 kg
01:05-02
General tightening torques

The following tightening torques apply in general unless otherwise specified:*) Flange bolt M6 Flange bolt M8 Flange bolt M10 Flange bolt M12 Stud in casting M8 Stud in casting M10 8.6 Nm 26 Nm 50 Nm 92 Nm 13 Nm 25 Nm
*) A tolerance of +/- 15% applies to the specified tightening torques unless stated otherwise.
01:05-02
Fitting
Tightening torques Cylinder head bolts: First stage Second stage Third stage Fourth stage Screws for lower rocker cover Bolt for fork on unit injector. Bearing bracket and rocker arm shaft Screw for upper rocker cover Adjusting screw lock nut on rocker arm for unit injector Adjusting screw lock nut on the valve rocker arm Cable connection, unit injector Bolt for exhaust manifold Bolt for fuel manifold Banjo screw for overflow line Special tools Number 588 179 Description Torque screwdriver Illustration Tool board 60 Nm 150 Nm 250 Nm 90 26 Nm 20 Nm + 75 105 Nm 18 Nm 39 Nm 35 Nm 2 +/-0.2 Nm 63 Nm 26 Nm 11 Nm
24
01:05-02
1. Check liner height, refer to 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 order given in the figure. Torque tighten all bolts to 60 Nm. Torque tighten all bolts to 150 Nm. Torque tighten all bolts to 250 Nm. Finally, tighten all bolts an additional 90 Make a mark with a centre punch on the head of the bolt.
5. Fit the lower part of the rocker cover and torque tighten the screws to 26 Nm.
01:05-02
25
Fitting
Tightening torques Bolts for oil sump Connecting rod bolts Piston cooling nozzle 32 Nm 50 Nm +90 23 Nm
Special tools Number 98 212 Description Piston ring compressor Illustration Tool board D3
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.
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01:05-02
Fitting
Tightening torques Main bearing cap bolts Side bolts Connecting rod cap bolts Bolts to crankshaft damper Bolts to inner belt pulley on crankshaft 90 Nm+90 180 Nm 50 Nm+90 135 Nm 92 Nm
Important! 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. Note: The main bearing caps are marked and must be refitted according to the marks on the block. 5. Torque tighten the side bolts to 180 Nm.
01:05-02
79
Adjusting the valve clearance and unit injectors

Specifications Valve clearance, intake valve (cold engine) Valve clearance, exhaust valve (cold engine) Dimension for PDE 31 unit injector (cold engine) Dimension for PDE 32 unit injector (cold engine) Tightening torques (See page 3 for general tightening torques) Adjusting screw lock nut on rocker arm for unit injector Adjusting screw lock nut on the valve rocker arm Screw for upper rocker cover Bolt for lower rocker cover Bearing bracket and rocker arm shaft Cable connection, unit injector Special tools Number 99 309 Description Tool to rotate flywheel Illustration Tool board D5 39 Nm 35 Nm 18 Nm 26 Nm 105 Nm 2 +/-0.2 Nm 0.45 mm 0.70 mm 66.9+/-0.1 mm 69.9+/-0.1 mm
99 414
Setting tool
Measuring tool cabinet
99 442
Setting tool
Measuring tool cabinet
588 179
Torque screwdriver
01:05-02
11
Adjusting the valve clearance

Note: Check and adjust the valve clearance and unit injectors with the engine cold. - Use tool 99 309 to rotate the engine. - Check the valve clearance using a feeler gauge and use the adjusting screw on the rocker arm to set the correct clearance. - The intake valves are actuated by the short rocker arms and the exhaust valves by the long rocker arms. - Make sure the valve bridge is resting correctly against the valves. - The intake valve clearance should be 0.45 mm and exhaust valve clearance 0.70 mm. - See page 15 for the adjusting order.
Adjusting the unit injector

Important! The PDE 31 unit injector is adjusted using setting tool 99 414 or a digital sliding caliper. The PDE32 unit injector is adjusted using setting tool 99 442 or a digital sliding caliper. This adjustment is essential as a fault in the position of the unit injector can result in poor performance and possible breakdown. 1. Screw on the rocker arm adjusting screw 1 while measuring the distance between plane a and the top of the valve spring collar using a digital sliding caliper. The distance should be 66.9 mm for PDE31 and 69.9 for PDE32. See measurement B in the figure for identifying the injector.
A= PDE31: 66.9 +/-0.1 mm PDE32: 69.9 +/-0.1 mm B = PDE31: 36.5 mm PDE32: 38.8 mm
12
01:05-02
WARNING!
Take care when carrying out the adjustment if the dimension is well outside the adjustment dimension. The spring is pre-tensioned and can cause personal injury if it is released. PDE31: 2. Position setting tool 99 414 with the metal plate around the injector spring. 3. Finely adjust dimension A by simultaneously using a finger to sense that the small piston 2 is level with the flat upper surface of the tool. It is possible to sense differences of less than a tenth of a millimetre. 4. If tool 99 414 is not available: Measure the distance between plane a and the top of the valve spring collar using a digital sliding caliper. Adjust the position of the rocker arm with the adjusting screw until the distance is 66.9+/-0.1 mm. 5. Torque tighten the lock nut to 39 Nm. 6. The order in which the injector rockers are to be checked/adjusted is shown in the table on page 15.
Piston above or below the flat surface. Adjustment necessary
Piston level with the flat surface. The adjustment is correct
01:05-02
13
PDE32: 7. Position setting tool 99 442 with the metal plate around the injector spring. 8. Finely adjust dimension A by simultaneously using a finger to sense that the small piston 2 is level with the flat upper surface of the tool. It is possible to sense differences of less than a tenth of a millimetre. 9. If tool 99 442 is not available: Measure the distance between plane a and the top of the valve spring collar using a digital sliding caliper. Adjust the position of the rocker arm with the adjusting screw until the distance is 69.9+/-0.1 mm. 10. Torque tighten the lock nut to 39 Nm. 11. The order in which the injector rockers are to be checked/adjusted is shown in the table on page 15.
Piston above or below the flat surface. Adjustment necessary
Piston level with the flat surface. The adjustment is correct
14
01:05-02
Order of adjustment
Rotate the flywheel using tool 99 309 so that the mark on the flywheel is visible in the bottom window according to the table below.
Mark on flywheel (degrees) TDC Down (0) TDC Up (180) TDC Down (360) TDC Up (540)
Valve change on cylinder 6 7 1 4
Adjust injector rocker arm on cylinder 4 and 5 2 and 6 3 and 7 1 and 8
Adjust intake valve on cylinder 7 and 8 1 and 5 2 and 4 3 and 6
Adjust exhaust valve on cylinder 4 and 5 2 and 6 3 and 7 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.
01:05-02
15
Renewing the upper rocker cover gasket

Removal 1. Clean the rocker cover and the surrounding area. 2. Remove the top part of the rocker cover. 3. Renew the rocker cover gasket. Fitting 1. Fit the upper part of the rocker cover. Torque tighten the screws to 18 Nm.
Renewing the lower rocker cover gasket

Removal 1. Clean the rocker cover and the surrounding area. 2. Remove the top 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. 3. Relieve the pressure on the valves by undoing the bolts on the rocker arm shaft alternately.
WARNING!
Do not lean over the engine when removing the shaft with rocker arms. The unit injector spring is pre-tensioned and can come loose, causing personal injury. Note: If the spring comes loose from the unit injector, the unit injector must be renewed.
16
01:05-02
Troubleshooting using flashing codes for the EMS control unit

The diagnostics lamp on the instrument panel/s always comes on for two seconds when the system is powered up. As soon as a fault is detected by the control unit, it is stored in the EEPROM fault code memory and the diagnostics lamp on the instrument panel/s comes on. The diagnostics lamp will stay on for as long as a fault is active. Even if the lamp has gone off and the fault is no longer active, the code can generally be read off in accordance with the instruction below.
Reading off control unit fault codes

1. Turn on the ignition. 2. Activate the diagnostics switch to the left to view the flashing codes for
the control unit (EMS).
3. A fault code will then flash on the diagnostics lamp. This flashing code
consists of long flashes (approximately 1 second long) and short flashes (0.3 seconds long). Long flashes are equivalent to tens and short flashes to units. Example: long - short - short = fault code 12.
4. Repeat this procedure until the first flashing code is repeated. This
means that the entire fault code memory has been flashed up. If the fault code memory is empty, only one long flash approximately 4 seconds long will be given.
5. See the flashing code table on the next page for a description and
localisation of the fault.
6. In order to obtain further information on the fault code, the PC-based

diagnostics tool or Scania EMS Display must be used. Contact an authorised Scania workshop.
7. When a fault has been rectified the fault code can be erased as described
below.
Erasing fault codes (flashing codes)

1. Turn the ignition off. If the vessel has dual instrumentation the ignition
must be switched off on both panels.
2. Activate the diagnostics switch in the same direction as the flashing

codes indicate, i.e. to the right for the coordinator (COO) or to the left for EMS.
3. Switch on the ignition and keep at the same time the diagnostics switch
activated, to the right (COO) or to the left (EMS), for 3 seconds.
4. This will erase passive fault codes which can be read off via flashing
code for the relevant system. The rest of the fault code will remain in the EEPROM and can only be deleted using the PC tool.
18
2003-09:4
Overview of flashing codes for EMS control unit Code

0 11 12 13 14 15 16 17 18 20 23 24 25 27 28 31 32 33 37 43 47 48 49 51 52
2003-09:4
Description
No fault detected. Overspeed. One or both engine speed sensors are displaying speeds in excess of 3000 r/min. Engine speed sensor 1 faulty or faulty signal. Engine speed sensor 2 faulty or faulty signal. Coolant temperature sensor faulty or faulty signal. Charge air temperature sensor faulty or faulty signal. Charge air pressure sensor faulty or faulty signal. Oil temperature sensor faulty or faulty signal. Oil pressure sensor faulty or faulty signal. Coolant level sensor faulty. Fault code internally in the coordinator. Accelerator/brake. If the accelerator and brake have been operated simultaneously. Accelerator sensor/idle switch Accelerator sensor/kickdown switch Engine shutdown bypassed. Shut-off due to oil pressure. Torque limitation due to oil pressure Incorrect parameters for limp home function. Battery voltage incorrect or no signal. Emergency shut-off switch activated in accordance with CAN message from coordinator. CAN circuit faulty in the control unit. Immobiliser function. Ignition key code incorrect. CAN message from the coordinator incorrect or missing. Incorrect CAN version in control unit or coordinator. PDE in cylinder 1: The solenoid valve does not work correctly. PDE in cylinder 2: The solenoid valve does not work correctly.
Code
53 54 55 56 57 58 59 61 66 69 82 83 84 85 86 87 88 89 93 94 96 98 99
Description
PDE in cylinder 3: The solenoid valve does not work correctly. PDE in cylinder 4: The solenoid valve does not work correctly. PDE in cylinder 5: The solenoid valve does not work correctly. PDE in cylinder 6: The solenoid valve does not work correctly. PDE in cylinder 7: The solenoid valve does not work correctly. PDE in cylinder 8: The solenoid valve does not work correctly. Faulty signal in extra analog input. Incorrect control unit shutdown. Shut-off due to coolant level. Starter motor function interrupted or not activated. Engine speed above ref.speed at start Fault in memory circuit (EEPROM) in control unit. Data transfer to the control unit memory (EEPROM) has been interrupted. Incorrect temperature internally in the control unit. Internal fault in the control unit: Fault in hardware control. Fault in control unit RAM. Internal control unit fault: Memory fault Incorrect seal: Illegal editing of software. Engine speed sensors faulty or not connected. Shut-off due to coolant temperature. Torque limitation due to high coolant temperature. Faulty voltage supply to one of the sensors. Internal hardware fault in the processor (TPU).
19
Troubleshooting using flashing codes for the EMS coordinator

The diagnostics lamp on the instrument panel/s always comes on for two seconds when the system is powered up As soon as a fault is detected by the coordinator, it is stored in the EEPROM fault code memory and the diagnostics lamp on the instrument panel/s comes on. Even if the lamp has gone off and the fault is no longer active, the code can generally be read off in accordance with the instruction below.
Reading off coordinator fault codes

1. Turn on the ignition. 2. Activate the diagnostics switch to the right for 1 second to view the
flashing codes for the coordinator (COO).
3. A fault code will then flash on the diagnostics lamp. This flashing code
consists of long flashes (approximately 1 second long) and short flashes (0.3 seconds long). Long flashes are equivalent to tens and short flashes to units. Example: long - short - short = fault code 12.
4. Repeat this procedure until the first flashing code is repeated. This
means that the entire fault code memory has been flashed up. If the fault code memory is empty, only one long flash approximately 4 seconds long will be given.
5. See the flashing code table on the next page for a description and
localisation of the fault.
6. In order to obtain further information on the fault code, the PC-based

diagnostics tool or Scania EMS Display must be used. Contact an authorised Scania workshop.
7. When a fault has been rectified the fault code can be erased as described
below.
Erasing fault codes

1. Turn the ignition off. If the vessel has dual instrumentation the ignition
must be switched off on both panels.
2. Activate the diagnostics switch in the same direction as the flashing

codes indicate, i.e. to the right for the coordinator (COO) or to the left for EMS.
3. Switch on the ignition and keep at the same time the diagnostics switch
activated, to the right (COO) or to the left (EMS), for 3 seconds.
4. This will erase passive fault codes which can be read off via flashing
code for the relevant system. The rest of the fault code will remain in the EEPROM and can only be deleted using the PC tool.
20
2003-09:4
Overview of flashing codes for EMS co-ordinator

Flashing code 111) 112) 121) 122) 13 14 15 17 18 19 21 22 23 24 25 26 27 28 29 31 32 33 34 35 Description of fault Faulty signal from the nominal speed signal fine adjustment. Faulty signals from the accelerator pedal sensor. Incorrect signal from the resistor module for regulator setting. Incorrect signal from the resistor module for idle and fixed speed setting. No communication (EMS) with the engine. Short-circuit in the tachometer signal circuit. Faulty atmospheric pressure sensor. Short-circuit in the coolant temperature gauge signal cable. Short-circuit in the oil pressure gauge signal circuit. Short-circuit in the oil pressure lamp signal circuit. Different versions of the communications protocol between the coordinator and EMS. Faulty start switch or short circuit. The supply voltage is too high. The supply voltage is too low. Check value from End of line (EOL) is incorrect. Road speed sensor signal missing or faulty. The signals from the RCB (Remote Control Box) switches are implausible. Incorrect signals from the droop-setting switches. Faulty remote start switch or short circuit.. No communication from the slave-coordinator or the master-coordinator. Short circuit in the signal cable to the coolant temperature warning lamp. Short circuit in the signal cable to the charge indicator lamp. Incorrect signal from the Fixed speed switches. Fault in CAN communication.
1) Single speed engine 2) All-speed engine
2003-09:4
21
Assembly
Specifications Tightening torques Lock nut for oil cleaner housing lid Nut for rotor bowl Rotor shaft Locking compound 15 Nm Tighten by hand 34 Nm 561 200
1. Position the O-ring in the lid. Renew the Oring if it is at all damaged. 2. Assemble the parts and tighten the rotor nut by hand.
3. Make sure the shaft is not loose. If it is, it can be locked using locking compound 561 200. First clean thoroughly using a suitable solvent. Tighten the rotor shaft using socket 98 421. Tightening torque 34 Nm. 4. Refit the rotor and spin it by hand to make sure it rotates easily.
5. Inspect the O-ring on the cleaner housing lid and fit it. Torque tighten the lock nut to 15 Nm.
01:05-02
121
Concentration table for Scania anti-freeze (Ethylene glycol)

Example: 1. The total volume of the cooling system is 80 litres. 2. The measured freezing point is -6C (15% mixture by volume of ethylene glycol). According to the table there are 12 litres of ethylene glycol in the cooling system. 3. The required freezing point is -21C (35% mixture by volume of ethylene glycol). According to the table, 28 litres of ethylene glycol are required in the cooling system. Since there are already 12 litres in the cooling system, it must be topped up with16 litres of ethylene glycol.
% glycol by volume Ice slush starts to form at C
15 -6 5 6 8 9 11 12 14
20 -9 6 8 10 12 14 16 18 20 22 24 26 28 30 32 34 36 38 40
25
30
35
40
45
50
-12 -16 -21 -24 -30 -37 8 10 13 15 18 20 23 25 28 30 33 35 38 40 43 45 48 50 9 12 15 18 21 24 27 30 33 36 39 42 45 48 51 54 57 60 11 14 18 21 25 28 32 35 39 42 46 49 53 56 60 63 67 70 12 16 20 24 28 32 36 40 44 48 52 56 60 64 68 72 76 80 14 18 23 27 32 36 41 45 50 54 59 63 68 72 77 81 86 15 20 25 30 35 40 45 50 55 60 65 70 75 80 85 90 95
Cooling system capacity, dm3 30 40 50 60 70 80 90 100 110 120 130 140 150 160 170 180 190 200
Ethylene glycol dm3 (litres)
15 17 18 20 21 23 24 26 27 29 30
90 100
02:03-01
Fuel lines
The fuel lines should be routed so that the fuel cannot be heated by radiated heat from the engine. Engine output dependence on fuel temperature can be read in Fig. 4. Maximum permitted fuel temperature before injection is 60C. The minimum inside diameter of the fuel suction line is shown in the table in Fig. 5. The return line from the overflow valve should be routed to the fuel tank or to the day tank if used. Not that it must not be connected to the suction pipe. The return line should have the same diameter as the suction pipe. Both the suction and return lines are normally connected to the top side of the tank. The return line should always enter above the maximum fuel level. The suction pipe in the tank should be placed at least 50 mm from the bottom of the tank. This distance also applies to the suction strainer.
Fuel cooler
If there is a risk of the fuel being heated up due to the routing of fuel lines, a fuel cooler can be connected in the sea water circuit before the sea water pump.
In multi-engine installations, each engine should have separate fuel lines. The material for the fuel lines should not be copper as there is a risk of oxidation due to condensation. The sulphur content in the fuel can also have a negative effect on the copper.
Feed pump flow

For all Bosch injection pumps, the feed pump flows given in Fig. 6 apply at normal working pressure (9 and 12 engines: 0.6 - 1.0 bar, 12 and 16-series engines with S6/PDE: 4 - 6 bar).
Engine speed Length of fuel pipes: Engine type Under 6 m Inside diameter mm 9 12 16 10 10 10 Over 6 m Inside diameter mm 12 12 12 500 1200 1500 1800 2000 2100 2200
9 and 12series engines l/hour 63 106 135 149 150 146 149
12-series engine PDE l/hour 91 220 271 325 362 380
16-series engine l/hour 93 223 276 330 369 387
Fig. 5. Inside diameters of fuel lines
Fig. 6. Table of feed pump flows 7
19:02-13
Scania CV AB, Sweden 2003-09:2
Motortyp Engine type Motortyp DN9 42A..S D9 61A MIL..S D9 90A..S D9 92A..S D9 93M..S D9 95M..S DC9 46A..S DC9 47A..S DC9 49A..S DC9 50A..S DI9 44M..S DI9 46M..S DI9 47M..Q DI9 48A..E DI9 48A..S DI9 49A..S DI9 50M..S DI9 51A..S DI9 53A..E DI9 53A..S DI9 55M..E DI9 59M..E
Insprutningspump / Injection pump / Einspritzpumpe Komplett Pumptyp Regulatortyp Assembly Pump type Governor type Komplett Pumpentyp Reglertyp 1403477 PES 6P 120A 1320/5 RS 3380 RSV350-1100 P8A 664 1393866 1393866 1393867 1393864 1393867 1393866 1393864 1393867 1393869 1393866 1393870 1393871 1412887 1393866 1393866 1393867 1403477 1412887 1393866 1412293 1412293 PES 6P 120A 1320/5 RS 3380 PES 6P 120A 1320/5 RS 3380 PES 6P 120A 1320/5 RS 3381 PES 6P 120A 1320/5 RS 3380 PES 6P 120A 1320/5 RS 3381 PES 6P 120A 1320/5 RS 3380 PES 6P 120A 1320/5 RS 3380 PES 6P 120A 1320/5 RS 3381 PES 6P 120A 1320/5 RS 3381 PES 6P 120A 1320/5 RS 3380 PES 6P 120A 1320/5 RS 3385 PES 6P 120A 320 RS 8048 PES 6P 120B 320 RS 3398 PES 6P 120A 1320/5 RS 3380 PES 6P 120A 1320/5 RS 3380 PES 6P 120A 1320/5 RS 3381 PES 6P 120A 1320/5 RS 3380 PES 6P 120B 320 RS 3398 PES 6P 120A 1320/5 RS 3380 PES 6P 120A 320 RS 8053 PES 6P 120A 320 RS 8053 RSV350-1100 P8A 664 RSV350-1100 P8A 664 RSV350-1100 P1A 666 RSV350-1100 P8A 664 RSV350-1100 P1A 666 RSV350-1100 P8A 664 RSV350-1100 P8A 664 RSV350-1100 P1A 666 RSV350-1100 P1A 666 RSV350-1100 P8A 664 RSV350-1100 P8A 665 RQV350-1150 PA 1320K RE 30. Hi-Ex and high oil level RSV350-1100 P8A 664 RSV350-1100 P8A 664 RSV350-1100 P1A 666 RSV350-1100 P8A 664 RE 30. Hi-Ex and high oil level RSV350-1100 P8A 664 RE 30. Hi-Ex and high oil level RE 30. Hi-Ex and high oil level
Hllare / Holder / Halter 20 19 17 20 19 15 17 13 13 16 20 20 15 15 16 12 15 15 20 20 Manufacturer KDEL 97 P31 XHDM 781589 XHDM 781589 XHDM 781589 XHDM 781589 XHDM 781589 XHDM 781589 XHDM 781589 XHDM 781589 XHDM 781589 XHDM 781589 XHDM 781589 KDEL 97 P10 XHDM 781589 XHDM 781589 XHDM 781589 XHDM 781589 KDEL 97 P31 XHDM 781589 XHDM 781589 KDEL 97 P10 KDEL 97 P10 Scania 1340655 1382917 1382917 1318812 1318812 1318812 1382917 1318812 1318812 1395954 1382917 1395954 1372541 1382917 1382917 1382917 1318812 1340655 1382917 1382917 1372541 1372541
Insprutare / Injector / Einspritzer Hl- mm Spridare / Nozzle / Dsen Hole mm Manufacturer Scania Loch- mm DLLA 142 P406 1340656 6x0,272 XNBM 870733 XNBM 870733 XNBM 770894 XNBM 770894 XNBM 770894 XNBM 870733 XNBM 770894 XNBM 770894 XNBM 870739 XNBM 870733 XNBM 870739 DLLA 142 P544 XNBM 870733 XNBM 870733 XNBM 870733 XNBM 770894 DLLA 142 P406 XNBM 870733 XNBM 870733 DLLA 142 P544 DLLA 142 P544 1382918 1382918 1318814 1318814 1318814 1382918 1318814 1318814 1382261 1382918 1382261 1372542 1382918 1382918 1382918 1318814 1340656 1382918 1382918 1372542 1372542 5x0,350 5x0,350 5x0,315 5x0,315 5x0,315 5x0,350 5x0,315 5x0,315 5x0,360 5x0,350 5x0,360 5x0,348 5x0,350 5x0,350 5x0,350 5x0,315 6x0,272 5x0,350 5x0,350 5x0,348 5x0,348
ppningstryck, bar Opening pressure, bar ffnungsdruck, bar 300 300 300 300 300 300 300 300 300 300 300 300 300 300 300 300 300 300 300 300 300 300
KDEL: Bosch XNBM: Stanadyne
DLLA: Bosch XHDM: Stanadyne
03:00-01
Motortyp Engine type Motortyp D11 94A..S D11 95A..S D11 96A..S D11 97A..S D11 98M..S D11 99M..S DC11 56A..S DC11 57A..S DC11 58A..T DC11 58A..T DI11 71A..S DI11 71A..S DI11 72A..S DI11 73M..S DI11 74M..S DI11 75M..Q DI11 76M..T DI11 76M..T DI11 76M..T DI11 76M..T DI11 77M..T DI11 77M..T DI11 77M..T DI11 77M..T DI11 78M..S DI11 79M..S DI11 80M..S DI11 81M..S
Komplett Assembly Komplett 1388635 1388635 1388638 1388638 1388636 1388640 1359930 1382923 1397783 1397781 1359594 1359930 1382923 1388637 1388631 1388633 1390279 1390280 1397779 1397780 1390279 1390280 1397779 1397780 1388637 1388636 1397107 1397107
Insprutningspump / Injection pump / Einspritzpumpe Pumptyp Regulatortyp Pump type Governor type Pumpentyp Reglertyp PES 6P 120A 1320/5 RS 3373 RSV350-1050 P8A 643 PES 6P 120A 1320/5 RS 3373 RSV350-1050 P8A 643 PES 6P 120A 1320/5 RS 3372 RSV350-1050 P1A 641 PES 6P 120A 1320/5 RS 3372 RSV350-1050 P1A 641 PES 6P 120A 1320/5 RS 3373 RSV350-900 P8A 643 PES 6P 120A 1320/5 RS 3372 RSV350-1050 P1A 641 PES 6P 120A 1320/5 RS 3373 PES 6P 120A 1320/5 RS 3372y PES 6P 120A 720 RS 8049 PES 6P 120A 720 RS 8049 PES 6P 120A 1320/5 RS 3373 PES 6P 120A 1320/5 RS 3373 PES 6P 120A 1320/5 RS 3372y PES 6P 120A 1320/5 RS 3373 PES 6P 120A 720 RS 8045 PES 6P 120A 720 RS 8045 PES 6P 120A 720 RV (RP46) PES 6P 120A 720 RV (RP46) PES 6P 120A 720 RS 8049 PES 6P 120A 720 RS 8049 PES 6P 120A 720 RV (RP46) PES 6P 120A 720 RV (RP46) PES 6P 120A 720 RS 8049 PES 6P 120A 720 RS 8049 PES 6P 120A 1320/5 RS 3373 PES 6P 120A 1320/5 RS 3373 PES 6P 120A 1320/5 RS 3372 PES 6P 120A 1320/5 RS 3372 RSV350-1050 P8A 643 RSV350-1050 P1A 641 RQ900 ( PA 1299-1) RQ750 PA ...(PA 1227-1) RSV350-1050 P8A 643 RSV350-1050 P8A 643 RSV350-1050 P1A 641 RSV350-1050 P8A 643 RQV350-1100 PA 1305K RQV350-1100 PA 1305-1K RQ750 P... RQ900 P .... RQ750 PA 1299 RQ900 PA 1299 RQ750 P... RQ900 P .... RQ750 PA 1299 RQ900 PA 1299 RSV350-1050 P8A 643 RSV350-900 P8A 643 RSV350-1050 P1A 641 RSV350-1050 P1A 641
Hllare / Holder / Halter 21 21 21 21 23 22 20 19 16 16 17 17 21 23 23 23 20 20 20 20 20 20 20 20 23 23 22 22 Manufacturer KDEL 97 P13 KDEL 97 P13 KDEL 97 P13 KDEL 97 P13 KDEL 97 P10 KDEL 97 P10 KDEL 97 P13 KDEL 97 P13 KDEL 97 P13 KDEL 97 P13 KDEL 97 P13 KDEL 97 P13 KDEL 97 P13 KDEL 97 P61 KDEL 97 P61 KDEL 97 P61 KDEL 97 P61 KDEL 97 P61 KDEL 97 P61 KDEL 97 P61 KDEL 97 P61 KDEL 97 P61 KDEL 97 P61 KDEL 97 P61 KDEL 97 P61 KDEL 97 P10 KDEL 97 P61 KDEL 97 P61 Scania 1340592 1340592 1340592 1340592 389676 389676 1386852 1386852 1340592 1340592 1386852 1386852 1386852 1394528 1394528 1394528 1394528 1394528 1394528 1394528 1394528 1394528 1394528 1394528 1394528 389676 1394528 1394528
Insprutare / Injector / Einspritzer Hl- mm Spridare / Nozzle / Dsen Hole mm Manufacturer Scania Loch- mm DLLA 155 P387 1340593 8x0,264 DLLA 155 P387 1340593 8x0,264 DLLA 155 P387 1340593 8x0,264 DLLA 155 P387 1340593 8x0,264 DLLA 146 P190 389677 5x0,352 DLLA 146 P190 389677 5x0,352 DLLA 155 P686 DLLA 155 P686 DLLA 155 P387 DLLA 155 P387 DLLA 155 P686 DLLA 155 P686 DLLA 155 P686 DLLA 146 P693 DLLA 146 P693 DLLA 146 P693 DLLA 146 P693 DLLA 146 P693 DLLA 146 P693 DLLA 146 P693 DLLA 146 P693 DLLA 146 P693 DLLA 146 P693 DLLA 146 P693 DLLA 146 P693 DLLA 146 P190 DLLA 146 P693 DLLA 146 P693 1386853 1386853 1340593 1340593 1386853 1386853 1386853 1394530 1394530 1394530 1394530 1394530 1394530 1394530 1394530 1394530 1394530 1394530 1394530 389677 1394530 1394530 8x0,280 8x0,280 8x0,264 8x0,264 8x0,280 8x0,280 8x0,280 5x0,374 5x0,374 5x0,374 5x0,374 5x0,374 5x0,374 5x0,374 5x0,374 5x0,374 5x0,374 5x0,374 5x0,374 5x0,352 5x0,374 5x0,374
ppningstryck, bar Opening pressure, bar ffnungsdruck, bar 300 300 300 300 250 250 300 300 300 300 300 300 300 300 300 300 300 300 300 300 300 300 300 300 300 250 300 300
KDEL: Bosch
DLLA: Bosch
Motortyp Engine type Motortyp D14 52A..S DC14 57A..T DC14 57A..T DC14 61A..T DC14 61A..T DC14 62A..T DC14 62A..T DC14 63A..S DI14 68M..S DI14 68M..S DI14 68M..S DI14 69M..E DI14 69M..E DI14 69M..S DI14 70A..S DI14 71A..Q DI14 72A..T DI14 72A..T DI14 72A..T DI14 72A..T DI14 73M..S DI14 74M..S DI14 74M..S DI14 75M..S DI14 75M..S DI14 75M..S DI14 77A..T DI14 77A..T DI14 78M..T DI14 78M..T DI14 78M..T DI14 78M..T DI14 79A..S DI14 82M..E DI14 82M..E DI14 83A..S
2
Insprutningspump / Injection pump / Einspritzpumpe Komplett Pumptyp Regulatortyp Assembly Pump type Governor type Komplett Pumpentyp Reglertyp 1391878 PE 8P 120A 720 LS7189-10 RSV350-1050 P8A 652 1391886 1371441 1391888 1371442 1391886 1371441 1391878 1391880 1359815 1411028 1391889 1359932 1359815 1391883 1391875 1391886 1371441 1391888 1371442 1391882 1391881 1391880 1359815 1391880 1411028 1391886 1371441 1391886 1371441 1391888 1371442 1391878 1391889 1359932 1391882 PE 8P 120 A 720 LS 7427t PE 8P 120 A 720 LS7266-2 PE 8P 120 A 720 LS 7427z PE 8P 120 A 720 LS7266-2 PE 8P 120 A 720 LS 7427t PE 8P 120 A 720 LS7266-2 PE 8P 120A 720 LS7189-10 PE 8P 120A 720 LS7358 PES 8P A 720 LS 7476 PES 8P 120A 720 LS7446 PE 8P 120 A 720 LS 7436 PE 8P 120 A 720 LS7481 PES 8P A 720 LS 7476 PE 8P 120A 720 LS7189-10 PE 8P 120A 720 LS7189-10 PE 8P 120 A 720 LS 7427t PE 8P 120 A 720 LS7266-2 PE 8P 120 A 720 LS 7427z PE 8P 120 A 720 LS7266-2 PE 8P 120A 720 LS7189-10 PE 8P 120A 720 LS7189-10 PE 8P 120A 720 LS7358 PES 8P A 720 LS 7476 PE 8P 120A 720 LS7358 PES 8P 120A 720 LS7446 PE 8P 120 A 720 LS 7427t PE 8P 120 A 720 LS7266-2 PE 8P 120 A 720 LS 7427t PE 8P 120 A 720 LS7266-2 PE 8P 120 A 720 LS 7427z PE 8P 120 A 720 LS7266-2 PE 8P 120A 720 LS7189-10 PE 8P 120 A 720 LS 7436 PE 8P 120 A 720 LS7481 PE 8P 120A 720 LS7189-10 RQ750 PA 1227-1 RQ 750 PA 758-15 RQ900 PA 1227-1 RQ 900 PA 758-20 RQ750 PA 1227-1 RQ 750 PA 758-15 RSV350-1050 P8A 652 RSV350-1100 P8A 652-1 RSV350-1100 P8A 652-1 RSV350-1050 P8A 652-1 RE 30. Hi-Ex and high oil level RE 30. Hi-Ex and high oil level. RSV350-1100 P8A 652-1 RSV350-1050 P8A 652 RQV350-1100 PA 1357 RQ750 PA 1227-1 RQ 750 PA 758-15 RQ900 PA 1227-1 RQ 900 PA 758-20 RSV350-900 P8A 652 RSV350-900 P8A 652 RSV350-1100 P8A 652-1 RSV350-1100 P8A 652-1 RSV350-1100 P8A 652-1 RSV350-1050 P8A 652-1 RQ750 PA 1227-1 RQ 750 PA 758-15 RQ750 PA 1227-1 RQ 750 PA 758-15 RQ900 PA 1227-1 RQ 900 PA 758-20 RSV350-1050 P8A 652 RE 30. Hi-Ex and high oil level RE 30. Hi-Ex and high oil level. RSV350-900 P8A 652
Hllare / Holder / Halter 20 14 14 16 16 12 12 17 19 19 19 Manufacturer KDEL 99 P15 KDEL 99 P15 KDEL 99 P15 KDEL 99 P15 KDEL 99 P15 KDEL 99 P15 KDEL 99 P15 KDEL 99 P15 KDEL 99 P15 KDEL 99 P15 KDEL 99 P15 KDEL 99 P15 KDEL 99 P15 KDEL 99 P15 KDEL 99 P15 KDEL 99 P15 KDEL 99 P15 KDEL 99 P15 KDEL 99 P15 KDEL 99 P15 KDEL 99 P15 KDEL 99 P15 KDEL 99 P15 KDEL 99 P15 KDEL 99 P15 KDEL 99 P15 KDEL 99 P15 KDEL 99 P15 Scania 1341480 1327374 1327374 1327374 1341480 1351806 1351806 1351806 1351806 1351806 1351806 1342165 1342165 1327374 1327374 1327374 380807 1351806 1351806 1351806 1351806 1327374 1327374 1327374 1341480 1351806 1351806 1327374
Insprutare / Injector / Einspritzer Hl- mm Spridare / Nozzle / Dsen Hole mm Manufacturer Scania Loch- mm DLLA 155 P386 1341481 8x0,270 DLLA 155 P307 DLLA 155 P307 DLLA 155 P307 DLLA 155 P386 DLLA 144 P467 DLLA 144 P467 DLLA 144 P467 DLLA 144 P467 DLLA 144 P467 DLLA 144 P467 DLLA 155 P383 DLLA 155 P383 DLLA 155 P307 DLLA 155 P307 DLLA 155 P307 DLLA 144 P144 DLLA 144 P467 DLLA 144 P467 DLLA 144 P467 DLLA 144 P467 DLLA 155 P307 DLLA 155 P307 DLLA 155 P307 DLLA 155 P386 DLLA 144 P467 DLLA 144 P467 DLLA 155 P307 1327375 1327375 1327375 1341481 1351807 1351807 1351807 1351807 1351807 1351807 1342166 1342166 1327375 1327375 1327375 380808 1351807 1351807 1351807 1351807 1327375 1327375 1327375 1341481 1351807 1351807 1327375 8x 0,246 8x 0,246 8x 0,246 8x0,270 5x0,390 5x0,390 5x0,390 5x0,390 5x0,390 5x0,390 8x0,288 8x0,288 8x 0,246 8x 0,246 8x 0,246 5x0,366 5x0,390 5x0,390 5x0,390 5x0,390 8x 0,246 8x 0,246 8x 0,246 8x0,270 5x0,390 5x0,390 8x 0,246
ppningstryck, bar Opening pressure, bar ffnungsdruck, bar 300 260 260 260 300 300 300 300 300 300 300 300 300 260 260 260 300 300 300 300 300 260 260 260 300 300 300 260
15 15 16 16 16 16 16 18 18 19 19 19 12 12 18 18 18 18 18
KDEL: Bosch Scania CV AB 2000-07:3
11
DLLA: Bosch
03:00-03
Motortyp Engine type Motortyp DC12 40A..T DC12 40A..T DC12 41A..E DC12 42A..T DC12 42A..T DC12 43A..Q DI12 40A..E DI12 41M..E DI12 42M..E DI12 43M..E DI12 44M..E DI12 45M..E DI12 46A..E DI12 47A..Q
Komplett Assembly Komplett 1409259 1409835 1364497 1409259 1409835 1445225 1364497 1364497 1364497 1364497 1364497 1364497 1364497 1445225
Insprutningspump / Injection pump / Einspritzpumpe Pumptyp Regulatortyp Pump type Governor type Pumpentyp Reglertyp PES 6P 120A 1320/5 LS 3399 RQ750 PA 1387 PES 6P 120A 1320/5 LS 3399 RQ900 PA 1387 PES 6P 120 A 720 LS8032 RE 30. Hi-Ex and high oil level. PES 6P 120A 1320/5 LS 3399 RQ750 PA 1387 PES 6P 120A 1320/5 LS 3399 RQ900 PA 1387 PES 6P 120A1320/5 LS3399 RQV 300-900 PA (PA1443) PES 6P 120 A 720 LS8032 PES 6P 120 A 720 LS8032 PES 6P 120 A 720 LS8032 PES 6P 120 A 720 LS8032 PES 6P 120 A 720 LS8032 PES 6P 120 A 720 LS8032 PES 6P 120 A 720 LS8032 PES 6P 120A1320/5 LS3399 RE 30. Hi-Ex and high oil level. RE 30. Hi-Ex and high oil level. RE 30. Hi-Ex and high oil level. RE 30. Hi-Ex and high oil level. RE 30. Hi-Ex and high oil level. RE 30. Hi-Ex and high oil level. RE 30. Hi-Ex and high oil level. RQV 300-900 PA (PA1443)
Hllare / Holder / Halter 20 20 20 20 20 Manufacturer KDEL 109 P62 KDEL 109 P62 KDEL 109 P62 KDEL 109 P62 KDEL 109 P62 KDEL 109 P62 KDEL 109 P62 KDEL 109 P62 KDEL 109 P62 KDEL 109 P62 KDEL 109 P62 KDEL 109 P62 KDEL 109 P62 KDEL 109 P62 Scania 1422540 1422540 1404009 1404009 1404009 1404009 1412614 1387056 1404009 1433445 1404009 1404009 1412614 1404009
Insprutare / Injector / Einspritzer Hl- mm Spridare / Nozzle / Dsen Hole mm Manufacturer Scania Loch- mm DLLA 155 P859 1422542 8x0,260 DLLA 155 P859 1422542 8x0,260 DLLA 147 P799 1404010 8x0,260 DLLA 147 P799 1404010 8x0,260 DLLA 147 P799 1404010 8x0,260 DLLA 147 P799 1404010 8x0,260 DLLA 155 P796 DLLA 147 P538 DLLA 147 P799 DLLA 142 P985 DLLA 147 P799 DLLA 147 P799 DLLA 155 P796 DLLA 147 P799 1412615 1364500 1404010 1433446 1404010 1404010 1412615 1404010 8x0,240 8x0,22 8x0,260 8X0,30 8x0,260 8x0,260 8x0,240 8x0,260
ppningstryck, bar Opening pressure, bar ffnungsdruck, bar 300 300 270 270 270 270 300 270 270 270 270 270 300 270
18 21 21 25 25 21
KDEL: Bosch
DLLA: Bosch
03:00-04
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Scania Helper

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Scania Helper

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NORDHAVN A/S

Montr hjlper 1 SCANIA SERVICE

See Operators Manual.

Tightening torques Bolts, turbocharger - exhaust pipe. . . . . . . . . . . . . . . . . . . . . . . . . . . 40 Nm Hose clip, exhaust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Nm

Pistons and cylinder liners

Program 96 Pistons Fitted with arrow on piston crown facing forwards.

Flywheel and flywheel housing

Ring gear Heated to 100 - 150 C before fitting.

Tightening torques Flywheel bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 180 Nm Bolts for flywheel housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90 Nm

Injection pump gear Backlash against intermediate gear . . . . . . . . . . . . . . . . . . . . . . . . . . 0.03 - 0.16 mm

Intermediate gear Axial clearance max . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.23 mm

Power take-off gear Backlash against intermediate gear . . . . . . . . . . . . . . . . . . . . . . . . . . 0.03 - 0.18 mm

Camshaft Axial clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.15 - 0.30 mm

Bearing clearance 0.054 - 0.116 mm

Bearing clearance 0.050 - 0.112 mm

Oil cleaner Permitted thickness of deposits on wall of bowl . . . . . . . . . . . . . . . . 20 mm

Oil filter Use only genuine Scania filters (screwed on by hand).

Program 96 Tightening torques

Oil nozzle for piston cooling: Banjo bolt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 Nm

Intake valve Exhaust valve

See Operators Manual or Engine Card

Pistons and cylinder liners

Flywheel and flywheel housing

Ring gear Heated to 100 - 150 C before fitting.

Flywheel housing Seal in flywheel housing: Dimension B, page 46 . . . . . . . . . . . . . . . . . 7 mm

Tightening torques Flywheel bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 180 Nm Bolts for flywheel housing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90 Nm

Injection pump gear Backlash against intermediate gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.03 - 0.15 mm

Intermediate gear Axial clearance max. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.238 mm

Bushing for power take-off gear Diameter. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45.009 - 45.034 mm

Camshaft Axial clearance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.10 - 0.25 mm

Radial clearance 0.050 - 0.112 mm

Axial clearance 0.14 - 0.37 mm

Oil cleaner Permitted thickness of deposits on wall of bowl . . . . . . . . . . . . . . . . . . 20 mm

Oil filter Use only genuine Scania filters.

Oil nozzle for piston cooling: Banjo bolt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 Nm M8 Bolt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 Nm

Intake valve Exhaust valve

Scania Industrial & Marine Engines

See Operator's Manual or Service Card for the particular engine

Scania CV AB, Sweden, 2003-05:6

Minimum dimension A for ground valve

Scania CV AB, Sweden, 2003-05:6

Valve clearances and unit injectors

Scania CV AB, Sweden, 2003-05:6

Pistons and cylinder liners

Pistons Fitted with arrow on piston crown facing forward.

Scania CV AB, Sweden, 2003-05:6

Flywheel and flywheel housing

Ring gear Heated to 100 - 150C before fitting.

Scania CV AB, Sweden, 2003-05:6

Injection pump gear Backlash against intermediate gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.03 - 0.15 mm

Intermediate gear Max. axial clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.238 mm

Camshaft Axial clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.10 - 0.25 mm

Scania CV AB, Sweden, 2003-05:6

Oil filter Only use original Scania filters.

Scania CV AB, Sweden, 2003-05:6

Valve clearances (engines with injection pump)

O Intake valve Exhaust valve

O Intake valve Exhaust valve

Scania CV AB, Sweden, 2003-05:6

Scania CV AB, Sweden, 2003-05:6

Valve change on cylinder 1 5 3 6 2 4

Adjust valves on cylinder 6 2 4 1 5 3

Adjust injector rocker arm on cylinder 2 4 1 5 3 6