01:06-01

Issue 6 en-GB

16 litre engine

Work description

114 739

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1 712 265 Scania CV AB 2016, Sweden
Contents

Contents
Engine assembly General information.................................................. 4
Removing the truck engine....................................... 6
Fitting the truck engine........................................... 12
Removing and lifting industrial and marine
engines.................................................................... 13
Lifting and fitting industrial and marine engines ... 17
Mounting the engine on an engine stand................ 18

Cylinder head Exploded view ........................................................ 20

Removing the cylinder head................................... 21
Fitting the cylinder head......................................... 25
Adjusting the unit injectors .................................... 31
Order of adjustment for unit injectors and
valves...................................................................... 34
Removing valves .................................................... 35
Fitting valves .......................................................... 36
Checking and machining valves............................. 37
Renewing the valve stem seal................................. 38
Renewing the valve seats........................................ 39
Machining the cylinder head .................................. 41
Renewing the valve guides..................................... 47
Renewing PDE unit injector sleeves ...................... 48

Cylinder block Reconditioning ....................................................... 50

Removing the cylinder liners.................................. 51
Fitting the cylinder liners........................................ 52
Measuring the cylinder liner height........................ 53
Machining cylinder liner height ............................. 55
Renewing the rear crankshaft seal.......................... 60
Removing camshaft bearings ................................. 62
Fitting camshaft bearings ....................................... 66
Removing the flywheel housing............................. 70
Fitting the flywheel housing................................... 71
Removing the front timing gear casing .................. 73
Fitting the front timing gear casing ........................ 77
Renewing the front crankshaft seal ........................ 80
Removing the front cover....................................... 82
Fitting the front cover............................................. 85
Renewing the rivet plug in the cylinder block........ 88

Crank mechanism Exploded view ........................................................ 90

Removing a piston.................................................. 91
Fitting a piston........................................................ 92
Renewing a piston .................................................. 94
Checking the connecting rod .................................. 97
Renewing connecting rods ..................................... 99
Renewing the bearing bush in the connecting
rod......................................................................... 100

Flywheel Removing the flywheel......................................... 102

Fitting the flywheel............................................... 103
Renewing the support bearing in the flywheel ..... 104

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 Contents

Renewing the external ring gear on the flywheel . 105

Crankshaft Removing the crankshaft...................................... 106

Fitting the crankshaft............................................ 109

Timing gear Exploded view...................................................... 112

Removing the intermediate gear........................... 114
Fitting the intermediate gear................................. 116
Renewing the bearing in the intermediate gear .... 117
Removing camshaft gears .................................... 119
Fitting camshaft gears .......................................... 119
Removing the crankshaft gear .............................. 120
Fitting the crankshaft gear.................................... 121
Removing the camshaft ........................................ 122
Fitting the camshaft .............................................. 125
Checking the camshaft setting.............................. 128
Fan coupling ......................................................... 130

Lubrication system Oil pressure........................................................... 134

Renewing the oil filter135
Renewing oil cooler seals..................................... 137
Fitting the oil cooler ............................................. 138
Centrifugal oil cleaner .......................................... 139
Dismantling and cleaning the centrifugal oil
cleaner .................................................................. 140
Assembling the centrifugal oil cleaner ................. 142
Oil pump............................................................... 143

Exhaust manifold Renewing gaskets ................................................. 146

Turbocharger Exploded view...................................................... 147

Removing the turbocharger .................................. 150
Fitting the turbocharger ........................................ 151
Measuring radial and axial clearance ................... 153
Checks after breakdown ....................................... 155
Checking wastegate valve functionality............... 156
Renewing the wastegate valve bracket................. 157
Adjusting the wastegate valve .............................. 159

Engine suspension Renewing the vibration insulator ......................... 160

Renewing the engine bracket fitted on the
engine ................................................................... 162

Belt transmission Engines without AC ............................................. 164

Engines with AC .................................................. 165

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Engine assembly

Engine assembly

General information
Applies to truck engines

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

1
1,40
A : DC 1601
116 669

1 Smoke values. 3 Engine type.

2 Instruction plate. 4 Engine serial number, stamped.

Applies to industrial and marine engines

1. Warning plate 3. Type plate: Engine type, engine serial

2. Instruction plate: Valve clearance number
4. Engine serial number, stamped
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 Engine assembly

Specifications

Cylinder diameter 127.0 mm

Piston stroke 154.0 mm
Cubic capacity 15.6 dm3
No. of main bearings 5
Firing order 1-5-4-2-6-3-7-8
Compression ratio 18:1
Direction of rotation (engine viewed from the rear) Anti-clockwise
Engine speed, low idling 500 rpm
Engine speed, high idling 2,400 rpm
Oil volume 35 litres
Oil grade refer to booklet 00:03-09*
Total weight without oil and water Approximately 1,300 kg

* For industrial and marine engines, refer to

booklet 00:03-01.

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Engine assembly

Removing the truck engine

Special tools

Number Designation Illustration Tool board

99 398 Lifting eyes 99 398 D3

114 638
98 094 Lifting chain 98 094
D4

109 836

587 308 Ratchet lever hoist B

IMPORTANT!

Cover all the holes, e.g. for the turbocharger and

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

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 Engine assembly

Remove Comments Illustration

pos.
1 The cab. See 18:01:00-01. Only vehicles with
T cab. On vehicles with R cab, the cab
is tilted.
2 Oil and coolant.
3 The mudguards.
4 Catwalk. Only on vehicles with T cab.
5 Negative cable from the battery.
6 Control cable for thermostat to the Detach the housing and place it to one 6
electrical fan. side. Only on vehicles with electrically
operated fan.
7 Noise shields under the engine.
8 Coolant pipes. Upper and lower. 8
9 Charge air pipes. 9
10 Bleed pipe from the engine to the 10
expansion tank.
11 Inlet pipe between turbocharger and air To secure 587 308. 11
filter.
12 Front air cleaner pipe and air cleaner. 12
13 Bracket. 13
14 Cable harness. Mark to make fitting easier. 14
15 Cable duct to rotational speed sensor on 15
the flywheel.
16 Exhaust brake and exhaust bellows 16
downstream of the turbocharger.
17 Cable to rotational speed sensor. 17
18 The air hose for the exhaust brake. 18
19 Oil pipes from the gearbox oil cooler. Only on vehicles with fluid cooled 19
gearbox oil cooler.
20 Ground connections on the right and
left-hand sides.

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Engine assembly

19

11

16 15 9 10

18
b122312

17 14 13 12 8

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 Engine assembly

Remove Comments Illustration

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

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Engine assembly

Fit Comments Illustration

pos.
29 Lifting eye 99 398. One lifting eye at the rear of each 29
cylinder bank. Use flange screws
M12x30 and tighten them to 92 Nm. The
screw holes are plugged. Place the drain
pipe to one side to fit the right-hand
lifting eye and the fuel pressure test
connection to fit the left-hand lifting eye.
30 Lifting chain 99 094 to the rear lifting 30
eyes.
31 Ratchet lever hoist 587 308 to the front Using the ratchet lever hoist, it is 31
lifting eye. possible to adjust the angle of inclination
for the engine.

IMPORTANT!

The lifting eyes on the engine are not

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

IMPORTANT!

The lifting eyes are dimensioned for a maximum

lifting angle of 20° when lifting the engine.

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 Engine assembly

587 308 26
31 99 398

28

24

29
25

587 308 98 094

30

21 99 398
27

23 22
b121998

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Engine assembly

Remove Comments Illustration

pos.
32 The gearbox. See 05:00-01.
33 The 2 front engine brackets.
34 The engine.

Fitting the truck engine

Refit the engine in reverse order.

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 Engine assembly

Removing and lifting industrial and marine engines

Special tools

Number Designation Illustration Tool board

99 398 Lifting eyes

1 360 442 Lifting eyes

1 512 730 Lifting eye

98 094 Lifting chain

587 308 Ratchet lever hoist

1 Drain the oil and coolant.

Environment
Use a suitable container. Used coolant should be
handled in accordance with national and
international laws.

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Engine assembly

DC engine:
• Remove the air filter and inlet pipe between
the turbocharger and air filter.
• Undo the connections for coolant, charge air
pipes between engine and charge air cooler,
and bleed pipe for the expansion tank.
• Remove the electrical cables at the rear
right-hand side.
DI engine:
• Disassemble the engine and reverse gear.
• Detach the pipe between the sea water pump
and heat exchanger. Remove the sea water
pump.
• Unscrew the turbocharger oil pipes.
2 Detach the negative battery cable.
3 Remove the starter motor and alternator
cable harness.
4 Remove the cable harness for the control
unit.
5 Remove the fuel connection.

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 Engine assembly

DC engine:
• Disconnect the filter housing for the
crankcase ventilation and place to one side
so that it is free from the lifting chain.
• Undo the AC compressor and move to one
side.
• Screw lifting eyes 99 398 onto the engine
using flange screws M12 x 30 (4).

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Engine assembly

DI engine:
• Fit front lifting eye 1 512 730 with two M12
screws through the expansion tank. Turn the
lifting eye towards the centre of the engine.
• Screw two 1 360 442 lifting eyes into the
flywheel housing over the centre.
6 Fasten lifting chain 98 094 to the rear lifting
eyes.
7 Fasten lever block 587 308 to the front
lifting eye.

DC16 engine

Note: The engine lifting eyes are designed for

lifting the engine only, not the engine together
with connected equipment (high-current
generator, gearbox, reverse gear, etc.) or frame.
All 3 lifting eyes must be used.

8 Undo the connecting pipe to the gearbox

cooler or reverse gear oil cooler.
9 Undo the connection to the gearbox or
reverse gear.
10 Undo all the engine brackets and lift away/
out the engine.

Note: The lifting eyes are dimensioned for a

maximum lifting angle of 20° when lifting the
engine.

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 Engine assembly

Lifting and fitting industrial and marine engines

DC engine:

• Screw lifting eyes 99 398 onto the engine • Fit the bleed pipe and the static line pipe. Fit
using flange screws M12 x 30 (4). the inlet pipe to the turbocharger and refit
the air filter.
• Disconnect the filter housing for the
crankcase ventilation and place to one side DI engine:
so that it is free from the lifting chain.
• Fit the turbocharger oil pipes and the sea
DI engine: water pump and pipe from the pump to the
heat exchanger.
• Screw two 1 360 442 lifting eyes into the
flywheel housing over the centre. The sea • Fit the closed crankcase ventilation filter.
water pump, the heater exchanger pipe and
the turbocharger oil pipes must be removed. 12 Connect the negative battery cable.

• Remove the closed crankcase ventilation 13 Fill with oil and coolant as directed in
filter. booklet 00:03-01.

• Fit front lifting eye 1 512 730 with 2 M12 14 Test run the engine to check that no leakage
screws through the expansion tank. Turn the occurs. Top up with coolant if necessary.
lifting eye towards the centre of the engine.
1 Fasten lifting chain 98 094 to the rear lifting
eyes.
2 Fasten ratchet lever hoist 587 308 to the
front lifting eye.
3 Lift the engine into position and screw it to
the front engine suspension.
4 DI16: Remove the rear lifting eyes.
5 Assemble the engine and gearbox or reverse
gear.
6 Fit the engine to the rear engine suspension.
7 Remove the lifting eyes.
8 DC16: Fit the filter housing for the
crankcase ventilation.
9 Fit the connecting pipes to the gearbox
cooler or reverse gear oil cooler.
10 Connect the electrical cables to the control
unit, starter motor and alternator.
11 Fit the fuel pipe.
DC engine:
• Fit the coolant connections and charge air
cooler pipes between the charge air cooler
and the engine.

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Engine assembly

Mounting the engine on an engine

stand

Special tools

Number Designation Illustration Tool board

99 349 Spacer 99 349

111 690
98 163 Fixture 98 163
A

109 858
587 692 Engine stand
112 804

DI engine (industrial and marine engine):

• Remove the heat exchanger pipe
connections and remove the entire heat
exchanger.
• Remove the exhaust manifolds.
• Remove the control unit connectors.

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 Engine assembly

All engines:
1 Remove the side covers and gaskets on the
left and right-hand sides.
2 Undo the clamping for the cable harness to
the starter motor on the left-hand side, or to
other obstructing cable harnesses.
3 Fit spacer 99 349 onto the right and left-
hand side. Use the screws for the side
covers.

4 Place the engine in the engine stand. Use

fixture 98 163. Screw on the fixture using
M8x25 screws and M8 washers, and the
supporting leg on the opposite side as
illustrated.

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Cylinder head

Cylinder head

Exploded view

28 27

29
30
31

32 112 169

33 34

1 Cylinder head 13 Screw 24 Cylinder head gasket

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

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 Cylinder head

Removing the cylinder head

DC engine:
1 Open the bleed nipple on the fuel filter and
drain the fuel system by undoing the banjo
screws or nipples on the back of the fuel
manifolds.

WARNING!

The fuel system must be empty or fuel may run

down into the cylinders, which will result in a
great risk of liquid slugging.
If fuel runs into the combustion chamber, it
must be removed immediately using a pump.

Environment
Help protect our environment. Use a suitable
container. 3

2 Remove the inlet pipe between the air filter

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

115 787

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Cylinder head

Removing cylinder head 3–4

4 Remove the crankcase ventilation unit. 4
Removing cylinder head 5–8

5 Detach the inlet pipe for the crankcase

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

115 788
8 Detach the intake manifold and fuel
7 6 5
manifold from the cylinder head or cylinder
heads to be removed. If all the cylinder
heads on the left-hand side (5–8) are to be
removed, detach the A/C compressor and
place it to one side and remove the intake
manifold and the fuel manifold.
If all the cylinder heads on the right-hand
side (1–4) are to be removed, detach the
inlet pipe to the crankcase ventilation and
remove the intake manifold and the fuel
manifold.
On the DI engine (industrial and marine engine),
remove the charge air cooler with connecting
pipe, expansion tank and catwalk.

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 Cylinder head

All engines
9 Remove the bleed pipes for the cooling
system.
10 Remove the exhaust manifolds.
11 Clean the rocker cover and the area around
it.
12 Remove the upper part of the rocker cover.

Note: All the valve mechanism components

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

111 689
13 Relieve the pressure on the valves by
undoing the screws on the rocker arm shaft
alternately. Remove the rocker arm shaft.

WARNING!

Do not lean over the engine when removing the

rocker arm shaft. The unit injector spring is pre- 13
tensioned and can come loose, causing personal
injury.

111 684
Note: If the spring comes loose from the unit
injector, the unit injector must be renewed.

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Cylinder head

14 Remove the bearing bracket.

18 15
15 Remove the pushrods.

Note: The pushrod for the unit injector is

secured with a retaining ring. Jiggle and pull
carefully on the pushrod to loosen it.
14
16 Remove the valve bridges.

17 Disconnect the electrical cables on the unit

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

114 728
18 Remove the lower rocker cover. 17 16
19 Remove the fork clamp screw holding the
unit injector in place.

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

the spring could come loose.

20 Turn the unit injectors clockwise until they

stop. Place the slide hammer 87 596 on the
inside of the solenoid valve as illustrated.
21 Pull out the unit injector. If the unit injector
is stuck, tap carefully with a rubber mallet
on the solenoid valve housing.
22 Remove the cylinder head, mark the
116 271

cylinder heads if several are to be removed

at the same time.

87 596
111 685

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 Cylinder head

Fitting the cylinder head

Tightening torques

Cylinder head screws:

First stage 60 Nm
Second stage 150 Nm
Third stage 250 Nm
Fourth stage 90°
Screws for lower rocker cover 26 Nm
Screw for fork on unit injector 20 Nm + 75°
Rocker arm shaft 105 Nm
Bearing bracket 40 Nm + 60°
Screw for upper rocker cover 18 Nm
Adjusting screw lock nut on rocker arm for unit injector 39 Nm
Adjusting screw lock nut on the valve rocker arm 35 Nm
Cable connection, unit injector 2 +/- 0.2 Nm
Screw for exhaust manifold 63 Nm
Screw for fuel manifold 26 Nm
Banjo screw for overflow duct 11 Nm

Special tools

Number Designation Illustration Tool board

588 179 Torque screwdriver

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Cylinder head

1 Check liner height, refer to section on

pistons and cylinder liners.
2 Fit a new cylinder head gasket.
1 2 3 4

3 The cylinder head bolts can be reused up to

3 times. Therefore, make sure the cylinder
head bolts have no more than 2 punch marks
on top of the bolt head. If any of the cylinder
head screws has 3 marks, they must be
replaced with a new one.

4 Lubricate the threads and underneath the

148 285
heads of the cylinder head screws. Tighten
them in the following 4 stages in the order
given in the figure.
1 Torque tighten all cylinder head bolts to
60 Nm
2 Torque tighten all cylinder head bolts to
150 Nm
3 Torque tighten all cylinder head bolts to
250 Nm
4 Finally, tighten all cylinder head screws
by 90°
5 Make a mark with a centre punch on the
head of the screw.

5 Fit the lower part of the rocker cover and

torque tighten the screws to 26 Nm.

5
3

4
6
139 851

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 Cylinder head

6 Make sure that the old sealing washer is not

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

IMPORTANT!

Always fit new O-rings and a new sealing

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

107 512
7 Lubricate the unit injector O-rings with
engine oil.
8 Fit a new sealing washer on the unit
injector. A rubber insert will keep the
sealing washer in place on the unit injector.
9 Place the fork clamp with screw in position
on the unit injector and insert it in the
cylinder head. Press down the unit injector
by hand as far as possible.
107 513

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Cylinder head

10 Torque tighten the screw to 20 Nm and then

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

IMPORTANT!

Make sure the pushrods are placed in their

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

11 Fit the valve bridges.

WARNING!

Take great care when fitting the valve bridges.

Check that the valve bridge is not resting on the
valve disc and that the top of the valve stem is
not visible. Check by turning the valve bridge
around its own axis. It should not be possible to
turn the valve bridge more than 0.5 mm in either
direction (1.0 mm from end position to end
position). An incorrectly fitted valve bridge will
lead to engine breakdown within 40–60 hours of
use. This breakdowns are extremely serious and
will often lead to the entire engine having to be
renewed.

12 Fit the pushrods.

312 308

13 Fit the bearing bracket and tighten the

screws to 40 Nm + 60°.
14 Refit the rocker arm shaft. Screw in the
screws alternately so that they are tightened
in parallel or one of the screws may bend.
Torque tighten the screws to 105 Nm.
15 Check the valve clearance and unit injector
setting as described in Adjusting the valve
clearance and unit injector.
115 633

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 Cylinder head

IMPORTANT!

Use torque screwdriver 588 179 to avoid the risk

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

16 Reconnect the cables on the unit injectors. 588 179

Their relative position is not important. Use 2 Nm
torque screwdriver 588 179 to tighten the
screws to 2 Nm.

111 688
17 Fit the upper part of the rocker cover and
torque tighten the screws to 18 Nm.
18 Fit the exhaust manifold and tighten the
screws to 63 Nm.
19 Fit the cooling system bleed pipe.
20 Fit the fuel manifold with overflow duct.
Torque tighten the screws to 26 Nm and the
banjo screws on the overflow duct to
11 Nm.

Note: Make sure all the washers with rubber

seals are intact.

21 Fit the intake manifold.

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Cylinder head

If cylinders 1–2 have been removed: DI engine (industrial and marine engine)
22 Fit the control unit cooler with control unit Fit the charge air cooler with connecting pipe.
and fuel filter. Use new gaskets.
If cylinders 3–4 have been removed: Fit the charge air temperature sensor.
23 Fit the crankcase ventilation unit. Refit the expansion tank and catwalk.
If cylinders 5–8 have been removed:
24 Fit the charge air pipe between the
turbocharger and the charge air cooler.
25 Fit the inlet pipe to the crankcase ventilation
filter.
26 Screw on the connecting pipe between the
intake manifolds.
On all cylinders:
27 Connect the compressed air line to the
compressor.
28 Connect the pipe from the crankcase
ventilation.
29 Fit the inlet pipe between the air filter and
the turbocharger.

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 Cylinder head

Adjusting the unit injectors

With tool 99 414 or 99 442

Special tools

Number Designation Illustration

99 414 or Setting tool Measuring tool cabinet
99 442

588 179 Torque screwdriver

114 769
1 Fit the setting tool with the metal plate
around the unit injector.

IMPORTANT!

Unit injector PDE31 (truck engines and some

industrial and marine engines) is adjusted with
tool 99 414: measurement A=66.9+/-0.1 mm,
measurement B=36.5 mm.
Unit injector PDE32 (some industrial and
marine engines) is adjusted with tool 99 442:
measurement A=69.9+/-0.1 mm, measurement
B=38.8 mm.

WARNING!

When the unit injector is being checked and the

measurement is outside the tolerance, it is
necessary to be very careful when handling this
unit injector. The spring is pre-tensioned and
can come loose, causing personal injury.

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Cylinder head

2 When adjusting, loosen the lock nut and

adjust the unit injector with adjusting screw
1. The unit injector is correctly set when the
small piston 2 is level with the flat upper
surface of the tool. Use a finger to check. It
is possible to feel differences of less than a
millimetre.

Refer to tables in Order of adjustment for

unit injectors.

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

3 Torque tighten the lock nut to 39 Nm after

adjusting.
4 Remove the tool.

IMPORTANT!

Do not leave the tool in the engine. The tool will

break and the engine may be damaged.

IMPORTANT!

Fit the electrical cables so that they face in the

correct direction when fitting them on the unit
injector.

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 Cylinder head

5 Reconnect the electrical cables on the unit

injectors. Their relative position is not
important. Use torque screwdriver 588 179
to tighten the screws to 2 Nm.

IMPORTANT!

Use torque screwdriver 588 179 to avoid the risk

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

118 482
588 179

107 675
6 If the cables to the unit injector are too long,
they can be clamped round the solenoid
valve on the unit injector.
7 Refit the upper rocker cover and torque
tighten the screws to 12 Nm or 18 Nm
depending on the type of screw, refer to
illustration.

8 Close the bleed nipple and tighten the banjo

screw.
9 Fill and bleed the fuel system; refer to
Bleeding the fuel system.
18 +− 3Nm 12 +− 3Nm
116 621

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Cylinder head

Order of adjustment for unit injectors and valves

Check and adjust the valve clearance with the

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

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

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

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

Cylinder numbering

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 Cylinder head

Removing valves

Special tools

Number Designation Illustration Tool board

99 322 Drift D5

1 Remove split collets, valve spring collars,

springs and valves. Press down the spring
using tool 99 322 in a press so that the split
collets can be removed.
99 322
2 Place the valves in a stand so that they can
be refitted in the same position in the
cylinder head.

01_1347

01:06-01 ©
Scania CV AB 2016, Sweden 35
Cylinder head

Fitting valves

Special tools

Number Designation Illustration Tool board

99 322 Drift D5

1 Lubricate all parts well with engine oil

before assembly.

2 Insert the valve into the guide.

99 322
3 Fit the valve springs and the valve spring
collar.
4 Press together the springs in a press with
tool 99 322 and fit the split collets. Ensure
that the split collets are positioned correctly.

01_1350

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Checking and machining valves

Specifications

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

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

Minimum dimension A for ground valve

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

01:06-01 ©
Scania CV AB 2016, Sweden 37
Cylinder head

Renewing the valve stem seal

Special tools

Number Designation Illustration Tool board

99 323 Drift D5

1 Remove the valve.

2 Remove the valve stem seal with a pair of

pliers.
3 Fit the valve.

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

99 323
01_1349

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 Cylinder head

Renewing the valve seats

Special tools

Number Designation Illustration Tool board

99 384 Drift 99 384
D1-A3

110 966
99 385 Shank 99 385 D1-B1

110 967

587 270 Kit with standard puller

1 Remove the valve seat inserts with an

expanding sleeve from the kit with standard
puller 587 270.

1
Note: Insert, for example, an aluminium sheet
between the cylinder head and counterhold to
protect against damage.
2

307 223

01:06-01 ©
Scania CV AB 2016, Sweden 39
Cylinder head

2 Press in new valve seat inserts. Use drift

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

99 385
WARNING!

Be careful when handling the cold parts and 99 384

refrigerant mentioned above. There is a risk of
frost injury.

Oversize valve seat inserts can be fitted if the

valve seat insert position has been damaged. The

146 597
position must then be machined using tool
587 277.

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 Cylinder head

Machining the cylinder head

Valve seat insert, machining measurement

112 266

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

01:06-01 ©
Scania CV AB 2016, Sweden 41
Cylinder head

Specifications

Intake valve seat

Seat angle 20.0°–20.5°
Width of contact surface A 1.9–2.6 mm
Valve seat insert, outer diameter 46.054–46.065 mm
Valve seat insert position, diameter 46.000–46.016 mm
Valve seat insert position, depth 11.25–11.35 mm
Distance B between the cylinder head face and the valve disc 0.75–1.8 mm
Oversize valve seat insert:
External diameter 46.254–46.265 mm
Valve seat insert position, diameter 46.200–46.216 mm
Cooling temperature when fitting valve seat insert approx. -80°C

Exhaust valve seat

Seat angle 45.0°–45.5°
Width of contact surface A 1.8–2.6 mm
Valve seat insert, outer diameter 44.081–44.092 mm
Valve seat insert position, diameter 44.000–44.016 mm
Valve seat insert position, depth 11.25–11.35 mm
Distance B between the cylinder head face and the valve disc 0.66–1.8 mm
Oversize valve seat insert:
External diameter 44.281–44.292 mm
Valve seat insert position, diameter 44.200–44.216 mm
Cooling temperature when cooling valve seat insert. approx. -80°C

42 ©
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 Cylinder head

Tools

Number Designation Illustration

587 277 Valve seat cutter

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

121 027

588 145 Valve seat cutter 1

5
6

3
2
7
4
114 772

588 146 Cutter attachment

1 2

3
114 773

587 061 Valve seat cutter The tool has been

discontinued.
Tool kit 588 146 fits with
587 061 if it is available.

Two equally good alternatives for cutters are

specified above.

01:06-01 ©
Scania CV AB 2016, Sweden 43
Cylinder head

The following description applies to valve seat

cutter 587 277.
Refer to Specifications for machining
measurements and oversize valve seat inserts.
1 Make sure the contact surface and magnetic
stand are level and clean. Clean the valve
bushes.

2 Select the largest spindle that moves easily

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

4 Release the quick-action lock and move the

pivot plate to the upper position with the
adjusting screw.

44 ©
Scania CV AB 2016, Sweden 01:06-01
 Cylinder head

5 Set up the dial on the cutter adjuster using a

valve.

6 Adjust the cutter. Diameter 37.9 mm and

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

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

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

01:06-01 ©
Scania CV AB 2016, Sweden 45
Cylinder head

8 Connect the magnet (position 1).

9 Lock the quick-release catch. Make sure the
crank can be turned easily. If not, redo the
centring.
10 Machine the valve seat by cranking
clockwise while turning the feed screw.
Never turn anticlockwise, as this could
damage the cutter. Lubricate with cutting oil
while machining.

11 When the surface of the valve seat has been

machined, reduce the cutting pressure by
turning 2–3 revolutions without any feed.
Continue turning while backing off the feed
screw. The valve seat cutter is now ready for
the next valve seat.

The valve seats may also be machined using

tools from kit 587 061. The tool has been
replaced but can be used if it is available in the
workshop. Tool kit 588 146 fits 587 061
Tool 588 145 with supplementary kit 588 146
are now available as an alternative to cutter
587 277.

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 Cylinder head

Renewing the valve guides

Special tools

Number Designation Illustration Tool board

99 382 Drift D1-C6

99 383 Drift D1-B1

1 Press out the valve guides using drift

99 383.

2 Press in the new valve guides with drift

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

01:06-01 ©
Scania CV AB 2016, Sweden 47
Cylinder head

Renewing PDE unit injector sleeves

Special tools

Number Designation Illustration Tool board

99 394 Guide 99 394
D2-B1

113 219
99 395 Drift D2-A1

99 397 Extension piece with threaded 99 397

D2-C5, C6
shank
113 262

588 221 Pilot tap

113 297

The cylinder head must be removed when

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

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 Cylinder head

2 Knock out the pilot tap and sleeve from

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

113 284
3 Degrease and check the contact surfaces of
the sleeve and cylinder head. Smooth off
any burrs and irregularities that could score
the sleeve.
99 395
4 Degrease the new injector sleeve and apply
a thin film of sealant 561 200 on the sleeve 99 394
and cylinder head contact surfaces.
5 Press in the sleeve using the drift and guide.

113 231

01:06-01 ©
Scania CV AB 2016, Sweden 49
Cylinder block

Cylinder block

Reconditioning
Heat arising from the main bearings seizing and
rotating in the cylinder block will change the
properties of the material in the cylinder block.
Such cylinder blocks must be discarded.
If the main bearing seizes but does not rotate in
the cylinder block, the cylinder block can be
reconditioned. The main bearing seats must
comply with the demands on roundness given in
the table. Machining out-of-round main bearing
seats is something Scania does not recommend.

Tightening torques

Main bearing cap screws 90 Nm + 90°

Side screws 50 Nm + 90°

1 Measure the diameter at 4 different

positions as illustrated. The diameter must

113 584
be measured with the main bearing caps
tightened and without main bearings.

2 Compare the dimensions with those in the

table.

Minimum permitted Maximum permitted Greatest permitted difference between

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

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Removing the cylinder liners

Special tools

Number Designation Illustration Tool board

99 066 Cylinder liner puller D2

1 Mark the liners with the numbers 1–8. The

mark is necessary so that the liners can be
refitted in the same place and position as
previously.

115 739

Note: The mark must be made only on the

surface indicated in the illustration. Other
99 003
surfaces are for sealing. If you use a marker pen,
you can mark anywhere.

2 Remove the cylinder liner using puller

99 066.
3 Remove the sealing ring in the cylinder 99 066
block.
100040

Cylinder liner puller with hydraulic hole

cylinder

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Scania CV AB 2016, Sweden 51
Cylinder block

Fitting the cylinder liners

1 Check cylinder liner height as described in

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

Tap the liner carefully with a metal object. It

should give a clear metallic ring if it is
intact. If it is cracked, it will sound cracked.
4 Lubricate the O-ring to be fitted in the
cylinder liner with glycerol, part No
584 584 and fit it.
5 Lubricate the lower guide surface on the
cylinder liner.
6 Turn the liner with the stamped cylinder
number facing forward and carefully tap it
down with a rubber mallet.

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Measuring the cylinder liner height

Specifications

Cylinder liner height above cylinder block 0.15–0.30 mm

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

Special tools

Number Designation Illustration Tool board

87 198 Straight edge D2

98 075 Dial gauge D2

98 515 Tension lug

1 Thoroughly clean the cylinder block liner

shelf, the face around the cylinder, the
cylinder liner shelf and the upper face of the
cylinder liner.
2 Fit the cylinder liner without sealing rings
and push down using two tension lugs
98 515. Torque tighten the screws to
20 Nm. 98 075 87 198

IMPORTANT!

The tension lug screws must not be tightened

more than 20 Nm. Otherwise the cylinder liner
may be damaged.

98 515 (x2)

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Scania CV AB 2016, Sweden 53
Cylinder block

3 Place straight edge 87 198 with dial gauge

98 075 on the liner and zero the dial gauge
to the liner (A). Slide the tip of the dial
gauge towards the cylinder block (B) and D
C
measure the height of the liner (A-B) as C
illustrated. Measure each liner at two
A
diametrically opposite points. B

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

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 Cylinder block

Machining cylinder liner height

If, during control measuring, the cylinder liner

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

IMPORTANT!

If a shim is used to adjust the liner height, the

cylinder liner seat must always be machined.

Tolerances for liner height

Lowest permissible cylinder liner height 0.15 mm
before machining
Permissible cylinder liner height on engines 0.20–0.30 mm
with machined liner seats
Desired measurement when machining 0.25 mm

Example of calculation of cutting depth

Height required 0.25 mm
Current cylinder liner height 0.14 mm
Increasing cylinder height (0.25–0.14) 0.11 mm
Shim thickness 0.2 mm
Material to be removed. (0.2–0.11) 0.09 mm

01:06-01 ©
Scania CV AB 2016, Sweden 55
Cylinder block

Special tools

Number Designation Illustration Tool board

587 512 Milling cutter

114 068
588 672 Extension

1 Clean the contact surface between the

setting ring (which is included in the
extension kit) and the top plane of the
cylinder block.

Note: It is important for the surface to be cleaned

thoroughly; otherwise the cylinder liner seat may

135637
be cut to the wrong depth or may be slanted.

2 Fit extension 588 672 on cutter 587 512.

3 Set the depth of the extension to 206 mm.

206mm
135638

56 ©
Scania CV AB 2016, Sweden 01:06-01
 Cylinder block

4 Position the setting ring over the relevant

cylinder and then position the cutter.
Energise the magnet on the cutter by setting
the switch to position 1.

5 Check that the tool (cutter) does not touch

the edge of the liner seat when the cutter is
fitted in the setting ring. Otherwise the
vertical feed screw must be wound up until
the cutter is released from the liner seat.

135639
6 Lift the rapid feeder ring and move the
cutter by hand until it is positioned above
the liner seat surface without including the
cylinder block walls.
135641

01:06-01 ©
Scania CV AB 2016, Sweden 57
Cylinder block

7 Wind round and at the same time turn the

vertical feed screw clockwise until the
cutter just touches the liner seat.

8 Lift the rapid feed ring and move the cutter

back so that it is within the liner seat
surface.

135642
9 Adjust the vertical feed screw in order to
start machining. The maximum feed per cut
is 0.05 mm. If 0.05 mm is not enough,
several cuts may be required until the
required position is reached.
10 Wind clockwise with an even movement.
Hold in the horizontal feed screw with the
other hand at the same time. The cutter will
be fed horizontally at 0.13 mm per turn.
Wind carefully when the cutter starts to
approach the outer edge of the liner seat.
Release the horizontal feed screw when the
cutter has gone over the edge so that feeding
stops.

IMPORTANT! 135640

Never wind the cylinder liner cutter

anticlockwise; otherwise the cutter will break.

58 ©
Scania CV AB 2016, Sweden 01:06-01
 Cylinder block

11 Move the cutter back towards the centre of

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

12 Repeat steps 9–11 if insufficient cutting

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

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

01:06-01 ©
Scania CV AB 2016, Sweden 59
Cylinder block

Renewing the rear crankshaft seal

Special tools

Number Designation Illustration Tool board

99 410 Assembly tool 99 410 D5

116 247
99 058 Drift (used together with 99 410 D7
when renewing 185 mm
crankshaft seal)

1 Remove the flywheel according to the

section Removing the flywheel.
2 Remove the crankshaft seal using a
screwdriver. Take care not to scratch the
sealing surfaces on the crankshaft and the
flywheel housing. Alternatively a self-
tapping screw can be screwed into the
crankshaft seal so that the crankshaft seal
can be pulled out with a slide hammer.

111 901

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Scania CV AB 2016, Sweden 01:06-01
 Cylinder block

Note: When working with 175 mm crankshaft

seal: The crankshaft seal must be fitted dry and
must not be lubricated. The sleeve in the seal
must be left in place. Do not touch the sealing
lip with your fingers.

Note: When working with 185 mm crankshaft

seal: The crankshaft seal must be fitted dry and
on no account must it be lubricated. Remove the
plastic ring protecting the sealing lip. Do not
touch the sealing lip with your fingers.

3 Fit a new crankshaft seal using tool 99 410.

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

4 Turn the tool clockwise until it stops in

order to attain the correct crankshaft seal
position.

315 234
Note: When working with 185 mm crankshaft
seal: The edge of drift 99 058 will stop against
the recess in the flywheel housing.

5 Fit the flywheel according to the section

Fitting the flywheel.

116 612

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Cylinder block

Removing camshaft bearings

Special tools

Number Designation Illustration Tool board

99 003 Hydraulic cylinder H1

99 004 Pneumatic hydraulic pump H1

99 373 Tool for renewing camshaft D5

bearing (only holder 3 should 3
be used)
1

2 113 838

99 516 Drift for pressing camshaft D1

bearings in and out
45

99 517 Sleeve D1

99 518 Bar for pressing camshaft D1

bearings in and out
135 647

99 519 Spacer D1
135648

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 Cylinder block

1 Remove the camshafts as described in this

booklet.

Note: Wipe around the edges and the bearing

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

2 Clean the camshaft seats.

3 Screw together hydraulic cylinder 99 003

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

4 Insert the bar through the hydraulic cylinder

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

01:06-01 ©
Scania CV AB 2016, Sweden 63
Cylinder block

5 Secure drift 99 516 in the outer hole on the

bar using a 12.9 M8 screw.

6 Pull the bar until the drift is locked in the

bearing. Attach the sleeve next to the
hydraulic cylinder using an 8 mm impact
setting tool.

7 Connect the hydraulic cylinder to the

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

64 ©
Scania CV AB 2016, Sweden 01:06-01
 Cylinder block

8 Detach the drift from the bar. Remove the

bearing.

9 Release the remaining bearings in the same

way.

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Cylinder block

Fitting camshaft bearings

Special tools

Number Designation Illustration Tool board

99 003 Hydraulic cylinder H1

99 004 Pneumatic hydraulic pump H1

99 373 Tool for renewing camshaft D5

bearing (only holder 3 should 3
be used)
1

2 113 838

99 516 Drift for pressing camshaft D1

bearings in and out

99 517 Sleeve D1

99 518 Bar for pressing camshaft D1

bearings in and out
135 647

99 519 Spacer D1
135648

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 Cylinder block

1 Clean the bearing seats thoroughly and

check that there is no damage to any of
them.

2 Screw together hydraulic cylinder 99 003

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

3 Insert the bar 99 518 through the hydraulic

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

01:06-01 ©
Scania CV AB 2016, Sweden 67
Cylinder block

4 Put a new bearing on drift 99 516. Make

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

IMPORTANT!

Make sure the bearings are facing the right

direction so that the lubricating oil holes in the
bearing correspond to the lubricating oil holes in
the cylinder block.

5 Fasten drift 99 516 in the outer hole on the

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

68 ©
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 Cylinder block

6 Pull out the bar through the hydraulic

cylinder so that sleeve 99 517 can be locked
in it using an 8 mm impact drift. The impact
setting tool should point vertically so that
the lubricating oil ducts are correctly
located.

7 Connect hydraulic cylinder 99 003 to

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

8 Check that the lubrication hole is open. This

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

Camshaft bearing Distance (mm)

number
1 -13
2 196
3 400
4 603
5 811

The values in the table should be interpreted as

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

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Cylinder block

Removing the flywheel housing

1 Remove the turbocharger oil pipe.

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

8 Remove the exhaust manifold, inlet pipe

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

111 903
10 Remove the power take-off or the cover for
the power take-off.
11 Remove the oil sump.
12 Remove the flywheel housing.
Additional information for DI engine
(industrial and marine engine):
• Remove the closed crankcase ventilation
filter.
• Remove the turbocharger oil pipes.
• Remove the sea water pump with the
connection pipes and connection housing.

70 ©
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 Cylinder block

Fitting the flywheel housing

Tightening torques

Screws for flywheel housing Flange screw and stud, M12:

92 Nm
Flange screw, M10: 50 Nm
Nut for turbocharger manifold 92 Nm
Oil sump, unmachined surface, 10.9 screws 32 Nm
Oil sump, machined surface, 8.8 screws 26 Nm
Plug for oil sump 80 Nm

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

2 Fit the flywheel housing with a new gasket.

M10 M10
The two appendages, A and B, are to be M10
removed and used for screws A and B.
3 Fit the screws. Torque tighten the M12
screws and the studs to 92 Nm and the M10 M12
screws to 50 Nm.
M10
4 Fit the oil sump with a new gasket. Fit the A B
power take-off or the cover for the power M12
take-off.
M12
5 Fit the turbocharger and the turbocharger
manifold; torque tighten the nut to 92 Nm.

A B
112 295

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Cylinder block

6 Fit the exhaust manifold, intake manifold

and exhaust pipe to the turbocharger.
7 Fit the compressor.
8 Fit the starter motor and the cable harness to
the starter motor.
9 Fit the flywheel as described in Flywheel,
fitting.
10 Fit the rotational speed sensors. Fit a new
O-ring onto the camshaft position sensor.
11 Fit the turbocharger oil pipe.
Additional information for DI engine
(industrial and marine engine):
• Fit the sea water pump with the housing and
connection lines.
• Fit the oil pipes to the turbochargers.
• Fit the closed crankcase ventilation filter.

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 Cylinder block

Removing the front timing gear casing

1 Drain the coolant.

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

4 Remove the ribbed charge air pipes between

the engine and the charge air cooler.
5 Remove the radiator pipe on the right-hand
side.
6 Remove the poly-V-belts.
7 Detach the AC pipe attachments to the
charge air pipes.
8 Remove the AC compressor without
breaking the circuit and place it over the
radiator.
9 Remove the charge air pipe that runs from
the charge air cooler to the engine. The
charge air pipe running between the
turbocharger and charge air cooler may
need to be loosened and moved slightly in
order to release the charge air pipe between
the charge air cooler and engine.

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Cylinder block

10 Remove the fan and place it in the radiator

mask.

136085
11 Remove the fan bearing assembly.

136081

12 Detach the hydraulic pump and place it to

one side. Do not detach the hoses.

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 Cylinder block

13 Remove the coolant temperature sensor and

oil pressure sensor.

14 Disconnect the fuel connections from the

feed pump and clamp them out of the way.
Detach the fuel pump and let it hang in the
inlet line.

15 Remove the oil filter housing, it is fitted

with 4 screws.

16 Remove the idler roller.

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Cylinder block

17 Remove the timing gear casing. See the

illustration for the location of the screws.

136 200

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 Cylinder block

Fitting the front timing gear casing

1 Fit a new gasket in the timing gear casing

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

4 Fit the feed pump and connect the fuel

connections.

5 Fit the coolant temperature sensor and oil

pressure sensor.

01:06-01 ©
Scania CV AB 2016, Sweden 77
Cylinder block

6 Fit the hydraulic pump.

7 Refit the idler roller.

8 Refit the fan bearing. Torque tighten the

screws to 39 Nm.

9 Refit the poly-V-belts.

136081

10 Refit the fan. Torque tighten the screws to

30 Nm (M8).
136084

78 ©
Scania CV AB 2016, Sweden 01:06-01
 Cylinder block

11 Fit the charge air pipe 9 running from the

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

18 Fill with coolant according to the work

description Cooling system, filling coolant.
19 Test run the engine and check that no
leakage occurs.

01:06-01 ©
Scania CV AB 2016, Sweden 79
Cylinder block

Renewing the front crankshaft seal

Special tools

Number Designation Illustration Tool board

99 374 Crimping tool for crankshaft D5
seal

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

crankshaft.

Note: The crankshaft seal seals against the inner

pulley. Handle the pulley with care

108 969

Sealing surface for crankshaft seal

2 Remove the crankshaft seal using a

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

80 ©
Scania CV AB 2016, Sweden 01:06-01
 Cylinder block

3 Wipe clean the sealing ring seat in the

housing.

Note: The crankshaft seal must be fitted dry and

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

4 Place the new seal in tool 99 374 and press

it into place by tightening the bolts
alternately. The seal is correctly fitted when
the tool reaches the bottom.

5 Remove the tool. Fit the screws into the

threaded holes and use as a handle to make
removal easier.
6 Wipe clean the sealing surface on the pulley
and fit it immediately.
7 Fit the outer pulley.
8 Fit the poly-V-belts.

01:06-01 ©
Scania CV AB 2016, Sweden 81
Cylinder block

Removing the front cover

1 Drain the coolant.

2 Remove the pipe between the air cleaner
and the turbocharger.
3 Remove the compressed air pipe in front of
the belts.
4 Remove the ribbed charge air pipes between
the engine and the charge air cooler.
5 Remove the radiator pipe on the right-hand
side.
6 Remove the poly-V-belts.
7 Detach the AC pipe attachments to the
charge air pipes.
8 Remove the AC compressor without
breaking the circuit and place it over the
radiator.
9 Remove the charge air pipe that runs from
the charge air cooler to the engine. The
charge air pipe running between the
turbocharger and charge air cooler may
need to be loosened and moved slightly in
order to release the charge air pipe between
the charge air cooler and engine.

82 ©
Scania CV AB 2016, Sweden 01:06-01
 Cylinder block

10 Remove the radiator fan and place it in the

radiator mask.

136085
11 Remove the fan bearing and its bracket.

136081
12 Remove the pulleys on the crankshaft.

13 Remove the immersion heater on engines

with an engine heater.

01:06-01 ©
Scania CV AB 2016, Sweden 83
Cylinder block

14 Remove the coolant temperature sensor.

136080
15 Remove the belt tensioner in the alternator
circuit.

16 Remove the oil sump.

IMPORTANT!

Do not prise off the front cover by prising with

something against the gasket surface between
the front cover and cylinder block. There is a
risk of the front cover being damaged.

136082

17 Remove the front cover by unscrewing the

13 screws which are used to fasten it. Then
tap off the front cover.

18 Remove the gasket and scrape off any

gasket residue.
136079

84 ©
Scania CV AB 2016, Sweden 01:06-01
 Cylinder block

Fitting the front cover

1 Fit a new gasket on the back of the front

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

3 Fit a new oil sump gasket.

4 Fit the oil sump.

136079
5 Fit the belt tensioner in the alternator circuit.

136082

01:06-01 ©
Scania CV AB 2016, Sweden 85
Cylinder block

IMPORTANT!

Handle the temperature sensor with care.

6 Fit the coolant temperature sensor.

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

9 Fit the fan bearing with bracket.

136081

10 Fit the fan.

136084

86 ©
Scania CV AB 2016, Sweden 01:06-01
 Cylinder block

11 Fit the pipe between the charge air cooler

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

13 Screw on the AC pipe attachments to the

engine (7).
14 Fit the poly-V-belts.
15 Fit the radiator pipe on the right-hand side
(5).
16 Fit the ribbed charge air pipes (4).
17 Fit the compressed air line from the
compressor (3).
18 Fit the suction pipe between the air filter
and the turbocharger (2).

19 Fill up with oil and coolant.

01:06-01 ©
Scania CV AB 2016, Sweden 87
Cylinder block

Renewing the rivet plug in the cylinder block

Special tools

Number Designation Illustration Tool board

587 542 Blind rivet tool

114 038
587 470 Pin extractor

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

3 Insert a 6 mm internal hexagon key in the

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

IMPORTANT!

The internal hexagon key must be inserted under

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

88 ©
Scania CV AB 2016, Sweden 01:06-01
 Cylinder block

4 Attach the internal hexagon key so that it

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

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

7 Screw on the pin extractor 587 470 with the

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

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

12 Fit the turbocharger according to section

Fitting the turbocharger.

01:06-01 ©
Scania CV AB 2016, Sweden 89
Crank mechanism

Crank mechanism

Exploded view

Crank mechanism

2
3
4

1
13

6 5
5

14

7
8

15

12

10
115 265

11

1 Piston 9 Bearing shell

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

90 ©
Scania CV AB 2016, Sweden 01:06-01
 Crank mechanism

Removing a piston

1 Remove the cylinder head as described in

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

IMPORTANT!

The piston cooling nozzle must not be damaged.

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

4 Remove the bearing cap and bearing shells.

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

Note: Always check the connecting rod as

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

01:06-01 ©
Scania CV AB 2016, Sweden 91
Crank mechanism

Fitting a piston

Tightening torques

Oil sump, unmachined surface, 10.9 screws 32 Nm

Oil sump, machined surface, 8.8 screws 26 Nm
Connecting rod screws 50 Nm + 90°
Piston cooling nozzle 23 Nm

Special tools

Number Designation Illustration Tool board

98 212 Piston ring compressor D3

Description
1 Lubricate the piston, piston rings, cylinder
liner and piston ring compressor with
engine oil.
2 Remove the protection on the connecting
rod journal and lubricate it.
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.

92 ©
Scania CV AB 2016, Sweden 01:06-01
 Crank mechanism

5 Fit the connecting rod and piston. The arrow

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

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

7 Fit the piston cooling nozzle. Tightening

torque 23 Nm.

116 085
IMPORTANT!

The piston cooling nozzle must not be damaged.

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

8 Fit the oil sump.

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

01:06-01 ©
Scania CV AB 2016, Sweden 93
Crank mechanism

Renewing a piston

Specifications

Piston rings
Number of compression rings 2 off
Gap:
1st ring 0.35–0.60 mm
2nd ring 0.55–0.80 mm
Maximum clearance in groove, 2nd ring 0.25 mm
Number of oil scraper rings 1 off
Gap 0.40–0.60 mm
Maximum clearance in groove 0.25 mm

Turn the rings marked TOP with the mark face

up.

Special tools

Number Designation Illustration Tool board

87 362 Drift D3

Other tools

Number Designation Illustration Tool board

587 309 Piston ring pliers D3
106 796

94 ©
Scania CV AB 2016, Sweden 01:06-01
 Crank mechanism

1 Place the connecting rod in a vice with soft

jaws. Remove the gudgeon pin retaining
rings.

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

87 362

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

4 It is possible that the graphite coating will

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

01:06-01 ©
Scania CV AB 2016, Sweden 95
Crank mechanism

5 Clean the piston and its rings thoroughly

without scratching the sides of the ring
grooves. Clean the oil holes in the piston.
6 Make sure the piston ring gaps do not
exceed the permitted limit. Place the piston
rings inside the cylinder liner and measure
the gap with a feeler gauge. Refer to
Specifications for permitted gap.
7 Fit the piston rings using tool 587 309. The
oil scraper ring has an expander. Pistons
rings marked with TOP must be turned with
TOP face up.
8 Oil all bushes, gudgeon pin holes and the
gudgeon pin before assembling.
9 Fit the piston skirt to the piston crown and
fit one of the gudgeon pin retaining rings.
10 Put the piston onto the connecting rod so
that the arrow marks on the piston are facing
forwards towards the engine. Applies only
to aluminium pistons; steel pistons are
symmetrical.

11 Insert the gudgeon pin using tool 87 362 and

fit the second gudgeon pin retaining ring.

116 033

116 085

96 ©
Scania CV AB 2016, Sweden 01:06-01
 Crank mechanism

Checking the connecting rod

Tools

Number Designation Illustration Tool board

587 110 Test apparatus -

Connecting rod and bearing cap marked 1 to 8.

Check the connecting rods using tool 587 110.
Check that the gudgeon pin bush is undamaged
and then proceed as follows:
1 Fit the bearing cap as marked and torque
tighten the screws to 50 Nm + 90°.
2 Fit the connecting rod in the tool using the
expander and put the corresponding
gudgeon pin in the gudgeon pin bush.
3 Then apply the indicator to the gudgeon pin.
Check whether the connecting rod is twisted
with the indicator studs horizontal. 01_1216

01:06-01 ©
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Crank mechanism

Check whether the connecting rod is bent with

the indicator studs vertical.

The distance between the indicator studs on the

tool illustrated here is 75 mm. The distance
between one of the indicator studs and the
measuring surface must be max. 0.05 mm when
measured using this tool. Check with a feeler
gauge.

01_1215
Also check whether the connecting rod is bent in
an S-shape. This is done by measuring the
distance between the outside of the connecting
rod bush and the level surface of the tool. Turn
the connecting rod around and measure the
corresponding distance. The difference between
the two measurements should be between
3.3–4.5 mm.
01_1227

98 ©
Scania CV AB 2016, Sweden 01:06-01
 Crank mechanism

Renewing connecting rods

If a connecting rod needs renewing it is

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

During production, the connecting rods are

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

Only connecting rods of weight class B are

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

01:06-01 ©
Scania CV AB 2016, Sweden 99
Crank mechanism

Renewing the bearing bush in the connecting rod

Special tools

Number Designation Illustration

99 403 Tool for renewing bearing bush 99 403

1
2

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

1. Pressplate with guide pin

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

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

1 Place the connecting rod on the press plate

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

100 ©
Scania CV AB 2016, Sweden 01:06-01
 Crank mechanism

2 Turn the press drift and mount a new

bearing bush onto it. Press in the bearing
bush.

After pressing in a new bearing bush, it must be

finish-turned. This requires special equipment.
Measurements as illustrated.

115 529

Diameter, d = 54.030–54.043 mm.

Surface quality = 0.6 Ra.

01:06-01 ©
Scania CV AB 2016, Sweden 101
Flywheel

Flywheel

Removing the flywheel

Special tools

Number Designation Illustration Tool board

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

00_1805
1 Remove the rotational speed sensor from
the flywheel.
2 Remove the flywheel screws.
3 Pull off the flywheel from the crankshaft
using puller screws 87 368.

4 The flywheel can be lifted using two

M10x100 screws that have been partially
threaded into the holes.

111 898

87 368
111 899

102 ©
Scania CV AB 2016, Sweden 01:06-01
 Flywheel

Fitting the flywheel

Specifications

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

Tightening torques
Flywheel screws 130 Nm+90°

Special tools

Number Designation Illustration Tool board

99 324 Guide pins 99 324 D5
100335

99 411 Flywheel locking tool 99 411

D5
116 489

1 Fit 2 guide pins 99 324 in the flywheel

housing.
2 Fit the flywheel on the crankshaft.

IMPORTANT!

Always use new screws.

o
130Nm + 90

3 Torque tighten the screws alternately to

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

01:06-01 ©
Scania CV AB 2016, Sweden 103
Flywheel

Renewing the support bearing in the flywheel

Special tools

Number Designation Illustration Tool board

99 250 Drift 99 250
D3, C4

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

01_1392

104 ©
Scania CV AB 2016, Sweden 01:06-01
 Flywheel

Renewing the external ring gear on the flywheel

Renew the flywheel external ring gear if the

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

WARNING!

Use eye protection due to the risk of metal

shivers.

2 Clean the contact surfaces of the flywheel

with a wire brush.
3 Heat the new external ring gear evenly
around its circumference to 100–150°C.

111 900
4 Lay the heated external ring gear on the
flywheel so that the bevelled side is facing
the starter motor. Ensure that the external
ring gear is properly in contact with the
flywheel. If necessary, tap down the
external ring gear using a plastic hammer.
5 The external ring gear must not be cooled
down rapidly but be left to cool in the open
air.

01:06-01 ©
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Crankshaft

Crankshaft

Removing the crankshaft

The crankshaft must be removed while the

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

106 ©
Scania CV AB 2016, Sweden 01:06-01
 Crankshaft

11 Remove the piston cooling nozzles.

IMPORTANT!

The piston cooling nozzle must not be damaged.

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

12 Turn the engine so that it is vertical.

13 Lift out the pistons and connecting rods.
Turn the crankshaft so that the piston to be 2
removed is at top dead centre, TDC. To be

113 059
able to rotate the crankshaft, the crankshaft 1
gear must be secured with two flywheel
screws and two 50 mm spacers. 1 50 mm long spacers
2 Flywheel screws

14 Turn the engine upside down.

15 Remove the crankshaft gear.
112 362

Engine, after removing steps 1–13

01:06-01 ©
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Crankshaft

16 Remove the main bearing caps. Protect the

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

Note: The main bearing caps are marked and

must be refitted in the same place.

17 Remove the lower and upper thrust washers.

18 Lift out the crankshaft.

112 363

108 ©
Scania CV AB 2016, Sweden 01:06-01
 Crankshaft

Fitting the crankshaft

Tightening torques

Main bearing cap screws 90 Nm + 90°

Side screws 180 Nm
Connecting rod cap screws 50 Nm + 90°
Crankshaft damper screws 80 Nm + 45°
Screws for inner pulley on crankshaft 92 Nm

All parts must be cleaned before fitting.

1 Place the bearing shells in the main bearing
seats in the cylinder 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
screws to 90 Nm + 90°. 5

90 Nm + 90
5

Note: The main bearing caps are marked and

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

5 Torque tighten the side screws to 180 Nm.

112 364

01:06-01 ©
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Crankshaft

6 Fit the crankshaft gear so that the marks on

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

113 059
1

1 50 mm long spacers
2 Flywheel screws

7 Turn the engine so that it is vertical.

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

10 Clean the cylinder heads and fit them as

described in Cylinder head, fitting.

112 365

110 ©
Scania CV AB 2016, Sweden 01:06-01
 Crankshaft

11 Fit the crankshaft damper and spacing

sleeve. Torque tighten the screws to 92 Nm
80 Nm + 45°.
12 Clean and fit the gaskets for the front
housing and engine heater outlet. Fit the
front cover.
13 Fit the pulleys on the crankshaft. Torque
tighten the screws on the inner pulley to
92 Nm.

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

01:06-01 ©
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Timing gear

Timing gear

Exploded view

42

45
46 44 38
45
7 9

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

2 15
1

14

10

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

18
116 686

17

35

1 Camshaft
2 Camshaft
3 Pin

112 ©
Scania CV AB 2016, Sweden 01:06-01
 Timing gear

4 Guide flange 20 Ball bearing 36 Hydraulic pump gear

5 Flange screw M10x30 21 Retaining ring 37 Feed pump gear
6 Thrust washer 22 Shaft journal 38 Shaft
7 Camshaft gear 23 Screw 39 Roller tappet
8 Camshaft gear 24 Spacing sleeve 40 Roller tappet
9 Flange screw M10x40 25 Intermediate gear 41 Roller tappet
10 Intermediate gear 26 Ball bearing 42 E-circlip
11 Ball bearing 27 Ball bearing 43 Guide sleeve
12 Retaining ring 28 Retaining ring 44 Flange screw
13 Spacing sleeve 29 Shaft journal 45 Pushrod
14 Shaft 30 Screw 46 Pushrod
15 Screw 31 Camshaft gear
16 Oil pump gear 32 Flange screw
17 Spacing sleeve 33 Power take-off drive gear
18 Intermediate gear 34 Compressor gear
19 Ball bearing 35 Crankshaft gear

01:06-01 ©
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Timing gear

Removing the intermediate gear

Special tools

Number Designation Illustration Tool board

99 309 Turning tool D5

100330
87 596 Slide hammer D2

1 Position the engine so that cylinder 6

changes direction, the crankshaft is turned
to 0° and the text "down TDC" is visible in
the lower window on the flywheel. Use tool
99 309 to rotate the engine.

2 Remove the flywheel as described in 99 309

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

01_1388

114 ©
Scania CV AB 2016, Sweden 01:06-01
 Timing gear

4 Secure the crankshaft gear to prevent it from

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

111 906
1

1 50 mm long spacers
2 Flywheel screws

5 Loosen the centre screw on the intermediate

gear.

IMPORTANT!

The camshaft and crankshaft must not be rotated

once the intermediate gear has been removed.
Pistons and valves can collide and be damaged.

6 Remove the intermediate gear with slide

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

01:06-01 ©
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Timing gear

Fitting the intermediate gear

Tightening torques

Screws for intermediate gears 50 Nm + 60°

1 Secure the crankshaft gear to prevent it from

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

IMPORTANT!

It is the same crankshaft gear on D9, D11, D12

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

3 Fit the flywheel housing as described in

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

50 Nm + 60

o
60
115 764

116 ©
Scania CV AB 2016, Sweden 01:06-01
 Timing gear

Renewing the bearing in the intermediate gear

Special tools

Number Designation Illustration Tool board

87 505 Drift AM1

87 504 Drift AD/AS3, G3

99 009 Puller AD/AS3

98 743 Assembly tool, tube section 98 743 C1

only used.
110 871

99 250 Drift D3, C4

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

2 Remove the retaining ring.

111 909

01:06-01 ©
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Timing gear

3 Press out the rest of the bearing from the

gear. Use tool 87 504. 87 504

305 903
4 Press the bearing off the shaft. Use tool
87 505.

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

99 009
111 911

2 Press the bearing and shaft into the gear.

Press on the outer race using the tube
section of tool 98 743.
98 743
3 Fit the retaining ring.
4 Press on the spacing ring using tool 99 250.
111 912

118 ©
Scania CV AB 2016, Sweden 01:06-01
 Timing gear

Removing camshaft gears

1 Remove the intermediate gear as described

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

Fitting camshaft gears

Tightening torques

Screws for camshaft gears 63 Nm

1 Fit the camshaft flanges and thrust bearings.

Note: The thrust bearings must be turned with

the level side forward.

Note: The camshaft gears are not identical.

Correct location is essential for the rotational
speed signal. See illustration.

2 Fit the gears and torque tighten the screws

111 914

to 63 Nm.
111 913

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Timing gear

Removing the crankshaft gear

Special tools

Number Designation Illustration Tool board

99 309 Tool to rotate flywheel D5

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

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

IMPORTANT!

The camshaft and crankshaft must not be rotated

once the intermediate gear has been removed.
Pistons and valves can collide and be damaged.

5 Remove the crankshaft gear.

111 915

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 Timing gear

Fitting the crankshaft gear

1 Fit the crankshaft gear.

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

IMPORTANT!

It is the same crankshaft gear on D9, D11, D12

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

3 Fit the flywheel housing as described in

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

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Timing gear

Removing the camshaft

Number Designation Illustration Tool board

99 522 Holder -

If there is room, it is easiest to remove the

camshaft from the rear. On many vehicles with
bodywork this is not possible. It is then
necessary to remove it from the front. It is not
necessary to lift out the engine, but the cooling
package needs to be removed.
1 Lift out the engine. See section Removing
the engine. Remove the poly-V-belts if they
have not been removed.
2 Mount the engine on an engine stand. See
section Mounting on an engine stand.

3 Remove the EDC control unit and fuel filter.

4 Remove the crankcase ventilation unit.

5 Disconnect the connecting pipe between the

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

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 Timing gear

9 Remove the front timing gear casing. See

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

14 Disconnect the banjo connections on the

front and rear edges of the fuel manifolds.

Note: The fuel manifolds are different. Mark the

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

15 Remove the fuel manifolds.

16 Remove the upper rocker covers

IMPORTANT!

Mark the rocker arms, pushrods, tappet shafts

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

17 Remove the rocker arm shafts and pushrods.

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Timing gear

18 Remove the camshaft covers.

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

23 Fit holder 99 522 on the rear of the

camshaft.

24 Attach the cab tilt pipe over the pin on the

holder.

25 Press out the camshaft forwards by pushing

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

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 Timing gear

Fitting the camshaft

Number Designation Illustration Tool board

99 522 Holder

Note: Check that the camshafts are located in

the correct camshaft channel and fitted the right
way round.

1 Fit holder 99 522 on the camshaft to be

fitted.

99 522

134 856
2 Oil the races and pull in the camshaft from
the front using the cab tilt pipe. The
camshaft is pressed in from the front by
hand while guiding it correctly onto the
bearings from the rear using the bar. Be
careful not to damage cams and bearings
when pushing in the camshaft. Remove
holder 99 522 from the camshaft.

3 Fit the front camshaft gear. Hold tight with a

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

4 Fit the guide flanges at the rear.

63 Nm
112 271

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Timing gear

5 Fit the camshaft gears at the back as

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

IMPORTANT!

Make sure none of the retaining rings for the

injector pushrods come loose or fall into the
engine.

10 Fit all the pushrods and rocker arm

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

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 Timing gear

12 Fit the rocker covers. Torque tighten the

screws to 18 Nm.

13 Fit the camshaft covers. Make sure the

sealing surfaces are clean and free from
damage.
14 Fit the fuel manifolds and torque tighten the
screws to 26 Nm. Lubricate the O-rings,
making sure they stay in their positions.

Note: The fuel manifolds are different. Make

sure they are positioned correctly.

15 Fit the banjo screws on the front and rear

edges of the fuel manifolds.

16 Fit the alternator (8).

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

18 Screw on the connecting pipe between the

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

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Timing gear

Checking the camshaft setting

Specifications

Injector lifting height 4.5-5.1 mm

Special tools

Number Designation Illustration Tool board

587 250 Indicator stand

102350

98 075 Dial gauge

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

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 Timing gear

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

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Timing gear

Fan coupling

Special tools

Number Designation Illustration Tool board

99 250 Drift 99 250
D3-C4

112 640
99 335 Drift 99 335 AD4-A2

00_1883
587 517 Puller plate XA1
587 518 Puller XA2

Renewing pulley bearing

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

6 Press out the bearing and fan bracket using

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

587 517
114 508

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 Timing gear

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

Note: Do not use the pulley as support when

pressing. Screw nuts onto the studs and use
them for support.

2 Fit the retaining ring.

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

4 Screw on the standard screw and washer.

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

114 510

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Timing gear

DC16 single speed (industrial and marine

engine). Renewing hub bearing.
1 Remove the fan drive poly-V-belt.

2 Disconnect the fan and place it in the fan

cover.
3 Remove the fan bracket with pulley.
4 Remove the pulley from the hub.
5 Remove the retaining ring in front of the
bearing.
6 Clamp the bracket in a vice and remove the
centre screw in the axle journal and washer.
7 Press out the axle journal from the hub
using a universal puller that grips around the
centre of the hub.
8 Place the hub in a press between parallel
pieces and press out the bearing. Use a
suitable drift with diameter 70–72 mm.
9 Check the that the bearing surface in the hub
is undamaged.

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 Timing gear

10 Place the hub in a press and press in place

the new bearing. Use a drift with diameter
78–80 mm and press on the outer race until
it stops.

11 Fit the retaining ring.

12 Mount the bracket in a press with support
under the opposite end of the axle journal.
13 Press the hub with bearing onto the axle
journal until it stops. Use a drift with
diameter 50–55 mm and a spacer washer
between the drift and the inner race.

14 Fit the pulley onto the hub.

15 Fit the fan bearing on the engine.
16 Fit the washer and centre screw. Torque
tighten the screw to 135 Nm.
17 Fit the poly-V-belt for the fan drive.
18 Fit the fan.

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Lubrication system

Lubrication system

Oil pressure
Idling min 1.4 bar
With warm engine running at 1,000 rpm min 3.0 bar
With warm engine running at 2,000 rpm 4.5 ± 1 bar

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 Lubrication system

Renewing the oil filter

Tightening torques

Filter housing cover 25 Nm

Special tools

Number Designation Illustration Location

587 637 Socket Maintenance cabinet

Note: The centrifugal oil cleaner must be

cleaned when renewing the filter.

1 Unscrew the filter cover with a closed tool

with hexagon driver, e.g. socket 587 637.

Note: Do not use an adjustable spanner or other

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

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

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Lubrication system

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

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

Note: The engine must not be run without a

filter element in the oil filter. There is a risk of
engine damage caused by particles and by the
oil pressure being too low.

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 Lubrication system

Renewing oil cooler seals

1 Drain the cooling system according to the

instructions. 3
2 Remove the inlet pipe between the air filter
and the turbocharger.
3 Disconnect the control unit cooler with
control unit and fuel filter and place to one
side.

4 Remove the crankcase ventilation with the

115 787
associated pipes.
2
5 Undo the connecting pipe between the inlet
pipes.
6 Remove the charge air pipe between the
turbocharger and the charge air cooler.
On the DI engine (industrial and marine
engine): Remove the catwalk and the pipe
between the charge air coolers. Remove the
pipe to the closed crankcase ventilation.

7 Remove the water pipe to the compressor. 9 8 4

8 Remove the centrifugal oil cleaner.

Note: Lift the oil cooler vertically so that no oil

leaks into the cooling system.
115 909

6 5

9 Remove the oil cooler cover with the oil

cooler.
112 312

The small cover need not be detached

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Lubrication system

10 Remove the 4 screws securing the oil cooler

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

Fitting the oil cooler

1 Screw on the oil cooler to the oil cooler

cover.
2 Fit the oil cooler cover with the oil cooler.

Note: Lower the oil cooler as vertically as

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

3 Fit the centrifugal oil cleaner, clean it as

described in Centrifugal oil cleaner,
dismantling and cleaning.
4 Screw on the control unit cooler with
control unit and fuel filter.
5 Fit the charge air pipe between the
turbocharger and the charge air cooler.
6 Screw on the connecting pipe between the
intake manifolds.
7 Fit the water pipe to the air compressor.
8 Fit the crankcase ventilation with its
associated pipes.
On the DI engine (industrial and marine
engine). Fit the pipe between the charge air
coolers. Fit the catwalk and connect the pipe
to the closed crankcase ventilation.
9 Fill the engine with coolant.

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 Lubrication system

Centrifugal oil cleaner

9
15

8 14
13
7
12
6
11

10

5
4

3
1

2
115 240

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

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Lubrication system

Dismantling and cleaning the centrifugal oil cleaner

Specifications

Permitted thickness of deposits on the walls of the cover 26 mm

There should be a certain amount of deposited

dirt in the rotor cover during routine cleaning of
the centrifugal oil cleaner. If not, this indicates
that the rotor is not spinning. The cause must be
established immediately.
If the dirt deposit exceeds 26 mm at the
recommended intervals, the rotor cover should
x3
be cleaned more often.
1 Unscrew the nut securing the outer cover.
2 Lift out the rotor. Wipe off the outside.
Undo the rotor nut and screw it about
3 turns to protect the bearing.

01_1286
3 If the rotor nut is difficult to get loose, turn
the rotor upside down and secure the rotor
nut in a vice. Turn the rotor
counterclockwise 3 turns by hand or if this
does not help, place a screwdriver between
the outlet holes. x3

IMPORTANT!

The rotor must not be put in a vice. Never strike

the rotor cover. This may cause damage
01_1287

resulting in imbalance.

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 Lubrication system

4 Grasp the rotor cover and tap the rotor nut

lightly with your hand or a plastic mallet so
that the rotor cover comes loose from the
rotor. Never strike the rotor directly as this
may damage its bearings.
5 Remove the rotor nut and cover from the
rotor.
6 Remove the strainer located on the rotor. If
the strainer has seized, prise carefully with a
knife at the lower edge between the rotor
and the strainer.

01_1289
7 Scrape away the deposits inside the cover
with a knife.
8 Wash the parts.
9 Check the 2 nozzles on the rotor. Ensure
that they are not blocked or damaged.
Renew damaged nozzles.
10 Check that the bearings are undamaged.

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Lubrication system

Assembling the centrifugal oil cleaner

Specifications

Tightening torques
Lock nut for oil cleaner housing cover 15 Nm
Nut for rotor cover Tightened by
hand
Rotor shaft 34 Nm

Thread-locking fluid 561 200

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

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

01_1293

3 Check that the shaft is not loose. Secure

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

4 Refit the rotor and rotate it by hand to make

sure it rotates easily.
112 313

5 Check the O-ring on the cover of the oil

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

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 Lubrication system

Oil pump

A leaking or defective oil pump must be

renewed completely and not reconditioned.

Tightening torques

Plug for oil sump 80 Nm

Screws for exhaust manifold 63 Nm
Oil sump, unmachined surface, 10.9 screws 32 Nm
Oil sump, machined surface, 8.8 screws 26 Nm

Special tools

Designation Number Illustration Tool board

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

2
112 315

1
1 Strainer
2 Suction pipe
3 Oil pump

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Lubrication system

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

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 Lubrication system

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

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Exhaust manifold

Exhaust manifold

Renewing gaskets

Tightening torques

Screws for exhaust manifold 63 Nm

1 Undo the screws and remove the front

exhaust manifold.
2 Undo the screws and remove the rear
exhaust manifold.
3 Scrape away the gaskets from the exhaust
manifolds and cylinder head.
4 Lubricate the joints with heat-resistant
grease and fit new gaskets. On the DI
engine, fit new O-rings in the water seals.
5 Fit the rear exhaust manifold and junction
pipe.
6 Fit the front exhaust manifold.
7 Torque tighten the screws to 63 Nm.

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 Turbocharger

Turbocharger

Exploded view

Turbocharger

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

8
116 685

10
11

1 Straight union

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Turbocharger

Important information

IMPORTANT!

Observe strict cleanliness at all times when

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

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

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

IMPORTANT!

Never attempt to straighten a damaged vane. It

is then often broken during operation causing
the turbocharger to break down completely,
which also can damage the engine.

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 Turbocharger

Air and exhaust leaks

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

Measuring the charge air pressure

Measure charge air pressure using Scania
Diagnos.

SCANIA Diagnos

00_1521
Tools for Scania Diagnos

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

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Turbocharger

Removing the turbocharger

1 Detach the oil pipes from the turbocharger.

IMPORTANT!

Plug the oil connections to prevent dirt ingress

into the engine and the turbocharger.

135 132
2 Detach the exhaust pipe and the inlet pipe.

135 133
3 Remove the screws in the turbocharger base
and remove the turbocharger. Pull the
turbocharger out of the charge air cooler
pipe in a straight line.
135 135

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 Turbocharger

Fitting the turbocharger

1 Check that the turbocharger does not have

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

3 Fit a new gasket on the turbocharger base

and grease the screws with heat resistant
grease 561 205.

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

135 135

5 Fit the exhaust pipe and suction pipe.

135 133

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Turbocharger

6 Fit the oil inlet and return lines.

7 Remove fuse F 20 for the fuel valve (fuel

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

IMPORTANT!

135 132
Before starting to use the turbocharger, it is
essential to make sure that the oil supply is
functioning correctly. If the lubrication is
inadequate there is a risk that the turbocharger
will seize, or that its service life will be
significantly reduced.

IMPORTANT!

Do not crank with the starter motor for longer

than 30 seconds at a time. Then leave the starter
motor off for at least 120 seconds.

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

Check for leakage.

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 Turbocharger

Measuring radial and axial clearance

Specifications

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

Special tools

Number Designation Illustration Tool board

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

80 20
20
80

15 5
30 10
70
70 30

40 60
60 50 40
50
00_1637

587 107 Rocker indicator

00_1569

587 250 Indicator stand M1

102350

Measuring radial and axial clearance often does

not give a good indication of the remaining
service life of the turbocharger.
When the turbocharger seems to be functioning
poorly or noisily, measuring the charge air
pressure or radial and axial clearance can
indicate whether the turbocharger is at fault.

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Turbocharger

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

2 Place the tip of the dial gauge against the

turbine or compressor impeller.

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

4 Press down both ends of the shaft. Take a

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

100704
5 Repeat the test 3 times on each side.
6 If any of the wheels makes contact with the
housing despite the radial clearance being
within tolerances, the turbocharger must be
renewed.

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

2 Press the shaft longitudinally to and fro and

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

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 Turbocharger

Checks after breakdown

Tightening torques

Screws, turbocharger – exhaust pipe 63 Nm

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

Description

IMPORTANT!

Observe strict cleanliness at all times when

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

1 Make sure leaks or loose particles do not

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

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Turbocharger

Checking wastegate valve functionality

Special tools

Number Designation Illustration Tool board

99 405 Tool kit 99 405

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

Note: The wastegate valve can withstand a

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

1 Detach the hose 1 from the union on the

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

2 Pressurise the wastegate valve with

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

116 226

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 Turbocharger

Renewing the wastegate valve bracket

1 Remove the turbocharger

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

3 Detach link arm 2 from short link arm 3 of

the wastegate valve. Forcing enough air into
the wastegate valve case (as described in
Checking wastegate valve function) to
cause the link arm to begin to move makes it
easier to detach it.
4 Evacuate air from the case. 3

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

4
132 904

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Turbocharger

6 Remove screws 5 that secure the bracket in

the turbine housing and remove the bracket. 5
7 Fit the new bracket with the supplied screws
and spacers. Tighten the screws to 25 Nm.
8 Fit the wastegate valve case in the new
bracket. Tighten the lock nuts to 8.5 Nm.
9 Fit the link arm on the wastegate valve short
link arm. Forcing enough air into the
wastegate valve case (as described in

132 905
Checking wastegate valve function) to
cause the link arm to begin to move makes it
easier to detach it. Tighten the link arm to
8.5 Nm.
10 Fit the retaining ring.

11 Use the magnetic stand 587 250 and dial

gauge 98 587 to check that the setting of the
wastegate valve case is correct. By
increasing the pressure in the case using
special tool 99 405 to the specified pressure,
the dial gauge should indicate a reading of
1.0 mm. If this is not correct, the setting
must be adjusted as described in Adjusting
the wastegate valve.
12 Fit the turbocharger.

132 906

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 Turbocharger

Adjusting the wastegate valve

Opening pressure for the wastegate valve on

DC16 01 is 1.85 bar

IMPORTANT!

If the setting of the wastegate valve is adjusted

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

By rotating the link arm and thereby decreasing

the effective length of the rod by 1.0 mm the
setting pressure will increase.
By rotating the link arm and thereby increasing
the effective length of the rod by 1.0 mm the
setting pressure will decrease.

01:06-01 ©
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Engine suspension

Engine suspension

Renewing the vibration insulator

Special tools

Number Designation Illustration

99 398 Lifting eyes 99 398

114 638
98 094 Lifting chain

587 308 Ratchet lever hoist

1 Remove the cable duct to the rotational

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

4 Disconnect the crankcase ventilation filter

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

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 Engine suspension

6 Fasten ratchet lever hoist 587 308 to the

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

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Engine suspension

Renewing the engine bracket fitted on the engine

Tightening torques

Screws for engine bracket 130 Nm + 90°

Special tools

Number Designation Illustration

99 398 Lifting eyes 99 398

114 638
98 094 Lifting chain

587 308 Ratchet lever hoist

1 Remove the cable duct to the rotational

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

4 Disconnect the crankcase ventilation filter

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

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 Engine suspension

6 Fasten ratchet lever hoist 587 308 to the

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

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Belt transmission

Belt transmission
Applies to truck engines.
Engines without AC

3
114 960

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

164 ©
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 Belt transmission

Engines with AC

7
6 8

5 6

3
114 961

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

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