SCANIA Work Description Engine - 12 Industrial and Marine Engine

01:03-02
Issue 2
Industrial & Marine Engines
Work Description - 12 Engine

Industrial and Marine Engines
Part No.
1 588 557
Scania CV AB, Sweden, 1999-09:02
en
Valve clearances,
pump setting
Engine type,
engine serial number
Engine serial number
Contents
Cylinder head . . . . . . . . . . . . . . . . . . . . . . . . . 3
Valve clearances . . . . . . . . . . . . . . . . . . . . . 5
Compression . . . . . . . . . . . . . . . . . . . . . . . . 6
Removing . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Dismantling . . . . . . . . . . . . . . . . . . . . . . . . . 9
Changing valve stem seal. . . . . . . . . . . . . . . 9
Replacement of valve seats . . . . . . . . . . . . 10
Machining of valve seats . . . . . . . . . . . . . . 11
Replacement of valve guides . . . . . . . . . . . 13
Replacement of injector sleeves. . . . . . . . . 14
Fitting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Turbocharger. . . . . . . . . . . . . . . . . . . . . . . . . 18
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Measuring radial clearance and axial
clearance . . . . . . . . . . . . . . . . . . . . . . . . . . 21
If the turbocharger does not work . . . . . . . 22
Changing the turbocharger. . . . . . . . . . . . . 23
Pistons and cylinder liners . . . . . . . . . . . . . . 24
Removal of the loose ring in the liner . . . . 26
Removing and dismantling connecting rods
and pistons . . . . . . . . . . . . . . . . . . . . . . . . . 26
Assembling piston and connecting rod . . . 29
Removing cylinder liner . . . . . . . . . . . . . . 30
Fitting cylinder liner . . . . . . . . . . . . . . . . . 32
Fitting piston and connecting rod . . . . . . . 33
Flywheel and flywheel housing . . . . . . . . . . .35

Removing flywheel . . . . . . . . . . . . . . . . . . .37
Removing flywheel housing . . . . . . . . . . . .39
Fitting flywheel housing . . . . . . . . . . . . . . .39
Fitting flywheel . . . . . . . . . . . . . . . . . . . . . .40
Timing gear . . . . . . . . . . . . . . . . . . . . . . . . . .41
Gearwheel timing gear . . . . . . . . . . . . . . . . . .43
Intermediate gear. . . . . . . . . . . . . . . . . . . . .43
Camshaft gear . . . . . . . . . . . . . . . . . . . . . . .46
Crankshaft gear . . . . . . . . . . . . . . . . . . . . . .47
Camshaft . . . . . . . . . . . . . . . . . . . . . . . . . . .48
Replacement of camshaft bearing . . . . . . . .49
Crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . .57
Belt timing gear . . . . . . . . . . . . . . . . . . . . . . .59
Lubrication system . . . . . . . . . . . . . . . . . . . . .61
Oil cooler. . . . . . . . . . . . . . . . . . . . . . . . . . .61
Oil cleaner . . . . . . . . . . . . . . . . . . . . . . . . . .63
Oil pump . . . . . . . . . . . . . . . . . . . . . . . . . . .67
Lifting the engine . . . . . . . . . . . . . . . . . . . . . .68
Specifications . . . . . . . . . . . . . . . . . . . . . . . . .69
General information . . . . . . . . . . . . . . . . . .69
Cylinder head . . . . . . . . . . . . . . . . . . . . . . .70
Turbocharger . . . . . . . . . . . . . . . . . . . . . . . .72
Pistons and cylinder liners. . . . . . . . . . . . . .72
Flywheel and flywheel housing. . . . . . . . . .73
Timing gear . . . . . . . . . . . . . . . . . . . . . . . . .74
Lubrication system . . . . . . . . . . . . . . . . . . .75
Special tools . . . . . . . . . . . . . . . . . . . . . . . . . .76
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Cylinder head
1. Cylinder head
2. Core plug
3. Rivet plug
4. Valve guide
5. Valve seat ring
6. Valve seat ring
7. Pin
8. Pin
9. Gasket
10. Seal
11. Intake valve
12. Valve spring
13. Valve spring collar
14. Exhaust valve
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15. Valve spring

16. Valve spring
17. Valve spring collar
18. Collet
19. Yoke
20. Bolt
21. Support bracket
22. Shaft
23. Rivet plug
24. Tight-fit screw
25. Rocker arm
26. Adjusting screw
27. Hexagon nut
28. Rocker arm
29. Adjusting screw

30. Hexagon nut
31. Spacer sleeve
32. Hexagon bolt
33. Rocker cover, lower section
34. Thread insert
35. Rocker cover gasket
36. Flange bolt
37. Rocker cover, upper section
38. Flange bolt
39. Rocker cover, upper section
40. Filler cap
41. Rocker cover gasket
Special tools
98 249
99 074
99 079
99 308
99 309
99 310
99 322
99 323
Compression tester
Impact drift
Extractor for injectors
Sleeve for injectors
Tool for turning flywheel
Socket
Press drift
Assembly drift
99 381
99 382
99 383
99 384
99 385
99 394
587 277
588 221
Drift
Drift
Drift
Drift
Handle
Styrning
Valve seat cutter
Tap
01:03-02
Valve clearances
Checking and adjusting
Check valve clearances. The clearance for intake
valves should be 0.45 mm and the clearance for
exhaust valves should be 0.70 mm when the engine is cold.
Adjustment can be carried out in one of the following ways:

A. Adjust all four valves for each cylinder when
at TDC after compression. Start with cylinder
No. 1 and turn the crankshaft 1/3 turn at a
time using tool 99 309 in the following injection order:
1-5-3-6-2-4
B. Bring cylinder No. 1 exactly to TDC after

compression. The following valves can now
be adjusted:
cyl. 1
cyl. 2
cyl. 3
cyl. 4
cyl. 5
intake and exhaust

intake
exhaust
intake
exhaust
O Intake valve
Exhaust valve
Turn the crankshaft precisely one revolution

so that TDC for No. 6 cylinder is set. The
remaining valves can now be adjusted:
cyl. 2 exhaust
cyl. 3 intake
cyl. 4 exhaust
cyl. 5 intake
cyl. 6 exhaust and intake
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O Intake valve
Exhaust valve
Compression
Measuring
The compression tester is used to quickly and
simply check wear and damage to primarily the
cylinder head valves, but also to cylinder liners
and piston rings.
Measurements are only intended for comparison

between cylinders. Lower compression in one or
several cylinders is a sign of abnormal wear or
damage.
By using various accessories, the compression

tester can be used for several engine types.
1. Cut off the supply of fuel by disconnecting

the power source.
2. Clean round the injectors. Detach the delivery pipes to all injectors using tool 99 310.
Note Fit protection caps on the delivery
valve holders in the injection pump
and on the injectors to protect them
from dirt.
1. Pressure gauge
2. Zeroing valve
3. Flexible metal hose
4. Test rod
5. End sleeve, diameter 21 mm
6. Spacing sleeve with guide lug
7. Spacing sleeve with collar
8. Spacing sleeve, length 6 mm
12. Cap nut
13. Threaded socket nut
14. Large yoke
15. Small yoke
Compression tester 98 249
3. Remove the rocker covers.

4. Undo and remove the injectors and copper
washers.
5. Turn the engine over several times using the
starter motor to remove any loose soot in the
cylinders.
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6. Connect the compression tester in the injection aperture in one of the cylinders. Copper
washer 16 should be used between the compression tester and the bottom of the injector
aperture.
7. Turn the engine over using the starter motor
and read the pressure gauge. Note the result.
8. Zero the pressure gauge by pressing the zeroing button 2.
9. Move the compression tester to the next cylinder and proceed as in points 5-8.
10. Evaluate readings and assess what further
measures need to be taken on the engine.
4.
5.
7.
10.
12.
Test rod
End sleeve, diameter 21 mm
Spacing sleeve with collar
Spacing sleeve, L = 25 mm
Cap nut (use socket
98 542 for tightening)
16. Copper washer
Cleaning of measuring rod

Measuring rod 4 has a check valve which, in the
case of leakage, should be cleaned as follows:
1. Unscrew valve seat 18.
2. Remove all soot from valve 17 and valve seat
18. Do not scratch the sealing surfaces. Use
compressed air to clean the inside of measuring rod 4.
3. Assemble the parts. Make sure that O-ring 19
is not damaged. Fully screw on valve seat 18
so that it seals against measuring rod 4.
01:03-02
4.Measuring rod
17.Valve
18.Valve seat
19.O-ring
Removing
1. DSI12: Detach the inlets and outlets for air
and water from the charge air cooler and
unbolt the charge air cooler. DSC12: Remove
the intake pipe clamps from the intake manifold.
2. Remove the intake manifold and turbocharger.
3. Remove the heat shields and exhaust manifold.
4. Detach the delivery pipes using tool 99 310
and remove same.
5. Insert protection plugs in the ends of the
delivery pipes and place protection caps
on the injectors and injection pump.
6. Remove the cooling system ventilation pipe.
Note All parts of the valve mechanism
must be refitted in the same positions. The removed parts must
therefore be marked.
7. Remove the upper part of the rocker cover,
being careful not to drop any parts into the
engine.
8. Remove the shaft, rocker arms, bearing
brackets, valve braces and pushrods.
9. Remove the lower part of the rocker cover.
10. Undo the injector nut using socket 99 308.
11. Extract the injectors using tools 99 079 and
99 074.
12. Remove the cylinder head bolts and lift off
the cylinder head. Mark the cylinder heads if
more than one is removed at the same time.
13. Cover the engine to keep out all extraneous
objects, etc.
01:03-02
Dismantling
1. Remove collets, valve spring collars, springs
and valves. Press the spring down using tool
99 322 in a press so that the collets can be
removed.
2. Place the valves in a rack so that they can be
refitted in the same position in the cylinder
head.
3. Mark the cylinder heads if more than one is
removed at the same time.
Changing valve stem seal

1. Remove the valve.
2. Remove the valve stem seal using pliers.
3. Fit the valve.

4. Carefully tap in the new valve stem seal
using tool 99 323 and a hammer.
01:03-02
Replacement of valve seats

1. Remove the valve seat rings. Use a discarded valve which is ground off so that the
valve head diameter is slightly less than the
inner diameter of the seat.
2. Fit the valve and electro-weld around it to
secure it in place. Cool with water. Turn the
cylinder head around and tap the valve stem
so that the valve and seat ring fall out.
WARNING!
Use protective goggles. Always turn the

cylinder head around with the underside
downwards when tapping out the valve
seat ring. Otherwise there is a risk of
loose splinters causing personal injury.
3. Press in new valve seat rings. Use drift

99 384 and handle 99 385. Cool the drift
and valve seat to approx -80C in dry ice or
using liquid air. The rings must be pressed
in very quickly.
WARNING!
Be careful with the above-mentioned

coolants and cooled components. There
is a risk of frost injuries.
Over-sized valve seat rings may be fitted if the
seat for the valve seat ring has been damaged. If
this is the case, the seat must be machined using
tool 587 277.
10
01:03-02
Machining of valve seats

Machining values
Inlet valve
A = 1,9 - 2,6 mm
B = 0,75 - 1,8 mm
C = diameter 39,8 +/- 0,5 mm (setting value
for machining tool)
Exhaust valve
A = 1,8 - 2,6 mm
B = 0,66 - 1,8 mm
C = diameter 37,9 +/- 0,5 mm (setting value
for machining tool)
Work description
The following description applies to valve seat
cutter 587 277.
Machining values and over-sized valve seat
rings, see Specifications.
1. Check that the contact surface and the magnetic base are smooth and clean. Clean the
valve bushings.
2. Select the largest spindle which slides easily into the valve guide. Fit the guide spindle and turn the feed screw to the position.
01:03-02
11
3. Select and fit the cutter.
4. Slacken off the quick-release lock and

move the pivot plate to the upper position
using the adjustment screw.
5. Set the indicator on the cutter adjuster using

a valve.
6. Set the cutter. Diameter value 37.9 mm and
39.8 mm, see Valve seat ring, machining
values.
7. Disconnect the magnetic base (position 2).

Insert the guide spindle in the valve bushing. Adjust the pivot plate so that the distance between the cutter and the valve seat
is approximately 1 mm. Centre the tool
carefully.
8. Connect the magnetic base (position 1).
9. Lock the quick-release lock. Check that the
crank is easy to turn. If not, centre the tool
again.
12
01:03-02
10. Cut the valve seat by simultaneously turning the crank clockwise and turning the
feed screw. Never turn the crank anti-clockwise. This may break the cutter. Lubricate
with cutting oil during the procedure.
11. When the machining of the valve seat is
completed, reduce the cutting pressure by
turning the crank 2 or 3 turns without feeding. Then continue to turn the crank while
turning the feed screw anti-clockwise. The
valve seat cutter is now ready for the next
valve seat.
The valve seats may also be machined using
tools from kit 587 061.
Replacement of valve guides

1. Press out the valve guides using drift
99 383.
2. Press in the new valve guides using drift

99 382. Press the guide down as far as the
drift allows, ie until it makes contact with
the spring seat in the cylinder head.
01:03-02
13
Replacement of injector sleeves

- When replacing an injector sleeve, the cylinder head must be removed.
- The valves do not need to be removed.
- The figs. show the cylinder head with the
valves removed so that it is easier to see the
procedure described.
Important Mark the position of the groove in

the sleeve on the cylinder head as illustrated. The new sleeve must sit in the same
position to ensure that the oil leakage /
return ducts are not blocked.
1. Thread the top part of the sleeve using tap

588 221 and guide 99 394.
2. Tap out the tap and sleeve from the underneath. Use a 100 mm metal rod with a
9 mm diameter.
14
01:03-02
3. Degrease and check the contact surfaces of

the sleeve and the cylinder head. Remove
any burrs or unevenness which could
scratch the sleeve.
4. Degrease the new injector sleeve and apply
a thin film of sealing agent 561 200 on the
sleeve and on the mating surfaces in the
cylinder head.
5. Push in the sleeve using drift 99 381.
Important Ensure that the groove in the sleeve
is in the correct position according to the
mark.
01:03-02
15
Assembly
1. Liberally lubricate all parts using engine oil
before assembly.
2. Fit the valves in their guides and position the
cylinder head in a press.
3. Fit the valve springs and valve spring collars.
4. Compress the springs using tool 99 322 and
fit the collets, making sure that they go into
their correct positions.
Fitting
1. Check liner heights,
see Pistons and cylinder liners.
2. Fit a new cylinder head gasket.
3. Fit the cylinder head and ensure that the
guide pins fit in the holes.
4. Cylinder head bolts can be reused a maximum of 3 times. Check therefore that the
bolts have no more than 2 punch marks on
the surface of the head. If any of the screws
has 3 marks, it should be changed for a new
one.
5. Lubricate the threads on the cylinder head

bolts and the surface under the head.
6. Tighten the bolts in the order given in the

figure and in three stages + 90 degrees as
follows:
16
Tighten all bolts to 60 Nm

Finally, tighten all bolts a further 90
Using a centre punch, make a mark on the
head of the bolt.
01:03-02
7. Fit the lower part of the rocker cover and

tighten the bolts to 22 Nm.
8. Fit the injector with a new seal and new Orings lubricated with assembly compound
815 368.
Important Always change the O-rings on the
injectors when they have been removed.
9. Use tool 99 308 and tighten it to 70 Nm.
10. Fit the valve braces, pushrods, bearing brackets and shaft with rocker arms and tighten the
bolts to 115 Nm.
11. Check the valve clearances when all cylinder
heads are in place. See page 5.
12. Fit the upper part of the rocker cover and

tighten the bolts to 22 Nm.
13. Fit the exhaust manifold and turbocharger
with oil lines. Tighten the nuts and bolts to
59 Nm. Fit the heat shields.
14. Fit the ventilation pipe for the cooling system.
15. DSC12: Fit the intake manifold.
16. Fit the delivery pipes and tighten the nuts to
20 Nm using tool 99 310. Refit the delivery
pipe clamps.
17. DSI12: Fit the intake manifold and charge air
cooler and attach the intake and outlet pipes.
Tighten the bolts to 26 Nm. Clamp the delivery pipes to the rear part of the charge air
cooler.
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17
Turbocharger
Special tools
98 075
587 025
587 107
587 250
DI12
1.
2.
3.
4.
5.
6.
7.
8.
18
Lubrication oil pipe

Ferrule
Union nut
Straight union
Seal
Straight union
Gasket
Lubrication oil return
pipe
Dial gauge
Filter wrench
Deflection gauge
Stand
DC12
9. Gasket
10. Bolt
11. Flange pipe
12. Hose
13. Hose clamp
14. Clamp
15. Turbocharger
1.
2.
3.
4.
5.
6.
7.
8.
Lubrication oil pipe

Ferrule
Union nut
Straight union
Seal
Straight union
Gasket
Lubrication oil
return pipe
9. Gasket
10. Bolt
11. Bracket
12. Bolt
13. Clip
14. Clip
15. Bolt
16. Turbocharger
01:03-02
General
Note Whenever working on the turbocharger, observe utmost cleanliness. The oil intake and outlet
connections must never be left
open. A foreign body in the bearing
housing can quickly cause total
breakdown.
Oil leakage
With a clogged air cleaner, the vacuum in the
intake pipe will be excessive. There is then a risk
that oil mist will be sucked out of the turbochargers bearing housing.
If the seal on the turbine side is worn, exhaust gas
is blue when idling.
If the oil outlet pipe from the turbocharger is
damaged, there is a risk of oil leaking out through
the seals due to lubrication oil pressure.
Oil filter
The turbocharger rotates at high speed, sometimes
above 100,000 rpm.
The oil lubricates and cools the turbocharger.
Efficient lubrication is extremely important.
There is no separate turbo filter and the oil passes
through the engine oil filter. For this reason,
change the oil filter and clean the oil filter assembly in accordance with our instructions.
Use filter wrench 587 025 when removing the oil
filter.
Removing oil filter
01:03-02
19
If the oil filter assembly is not cleaned, the oil filter will soon become clogged and its resistance to
the flow of oil will increase.
A valve in the filter holder then opens and allows
the oil to pass through the filter without being cleaned (filtered). Unfiltered oil is consequently
supplied to the turbocharger with heavy bearing
wear as a result.
The valve is designed for genuine Scania filters
and only these should be used.
Air and exhaust leakage
Foreign bodies
Cleaning the compressor wheel
Foreign bodies, such as grains of sand or metal

filings, in the turbine or compressor will damage
their blades.
This leads to imbalance and bearing wear. Engine
output falls off and continued operation could
give rise to overheating damage on account of a
decrease in the supply of air.
This type of overheating cannot be observed on
the coolant temperature gauge.
Low charge pressure can be caused by a dirty

compressor wheel, for example.
- Remove the compressor housing.
Note Never attempt to straighten a damaged impeller. It will usually break in

operation causing the turbocharger
to break down and may also cause
engine damage.
Change the entire turbocharger.
20
Even small leaks in the line between the air cleaner and turbocharger cause dirt deposits on the
compressor wheel.
Charge pressure decreases with increased exhaust
temperature, causing smoke. In addition, the engine is worn unnecessarily.
Exhaust leakage between cylinder head and turbocharger also results in lower charge pressure.
- Wash the compressor wheel using white spirit

and a brush.
- Fit the compressor housing and measure
charge pressure again.
Note The compressor wheel must not be
removed from the shaft. Imbalance
may occur when it is refitted.
01:03-02
Measuring radial clearance and

axial clearance
Measuring radial clearance and axial clearance
does not usually give any indication of the
remaining service life of the turbocharger.
When the turbocharger is not working correctly
or sounds abnormal, measuring charge pressure
or measuring radial clearance or axial clearance
can show that the turbocharger is defective.
To measure axial and radial clearances it is advisable to remove the turbocharger and bolt it to a
steel plate, which will also serve as a base for the
magnetic stand holding the dial gauge.
Radial clearance
Take readings on both turbine wheel and compressor wheel.
1. Place the tip of the dial gauge against the
turbine wheel and compressor wheel.
2. Pull both ends of the shaft up. Take a reading.
Measuring turbine wheel radial clearance
3. Press both ends of the shaft down. Take a

reading. The difference between readings
is radial clearance.
4. Repeat measurements three times on each

side.
5. If any wheel rubs against the housing,
despite radial clearance being within tolerance, the turbocharger should be changed.
Measuring compressor wheel
radial clearance
01:03-02
21
Axial clearance
1. Place the tip of the dial gauge against the end
of the shaft.
2. Press the shaft forwards and backwards and
read the dial at the end positions. The difference between readings is axial clearance.
3. Repeat measurements three times.
Wear limits for Holset:

Radial clearance...................0.198-0.564 mm
Axial clearance
(after running in).................. 0.025-0.106 mm
Checking axial clearance
If the turbocharger does not work

1. Check that there is no leakage or loose
objects in the line between the air cleaner
and turbocharger.
7. Check that the air filter is not blocked and

that there are no other reasons for the abnormal increase of vacuum in the intake system.
2. Check that there are no loose particles in the

exhaust manifold or intake manifold.
8. Check that engine output is correct. Excessively high output reduces the life of the
turbo.
3. Check that all valves are intact.

4. Check the lubrication oil return pipe from the
turbocharger for blockage or deformation.
5. Check the oil delivery pipe to the turbocharger for any blockage, deformation and
leakage under pressure.
6. Check the condition and part number of the
oil filter.
22
01:03-02
Changing the turbocharger

Note When changing the turbocharger,
all gaskets and the oil filter must
be changed and the centrifugal
cleaner must be cleaned.
Removing
1. Detach the delivery and return oil lines from
the turbocharger.
2. Detach the exhaust pipe, induction pipe and
charge air cooler pipe from the turbocharger.
3. Unscrew the bolts in the turbocharger mounting and remove it.
Fitting
1. Check the connecting flange on the exhaust
manifold to ensure that there are no remnants
of the old gasket.
2. Fit a new gasket and bolt on a new turbocharger. Lubricate the exhaust manifold bolts
with high-temperature resistant lubricant,
part No. 561 205.
Tighten to 42 Nm.
3. Connect the oil supply and return lines.
4. Connect the charge air pipe, induction pipe
and exhaust pipe.
5. Disconnect the fuel valves power supply
(fuel shut-off) and turn the engine over with
the starter motor for at least 30 seconds so
that the lubricating oil will reach the turbocharger.
6. Start the engine and check that there is no
leakage.
01:03-02
23
Pistons and cylinder liners
1.
2.
3.
4.
5.
6.
7.
8.
24
Piston
Compression ring
Compression ring
Oil scraper ring
Retaining ring
Gudgeon pin
Connecting rod
Bushing
9. Bearing shell
10. Bearing cap
11. Flange bolt
12. Crankshaft
13. O-ring
14. Cylinder liner
15. O-ring
16. Loose ring
01:03-02
Special tools
87 198
87 362
98 075
98 212
98 515
99 066
01:03-02
Rule for dial gauge

Drift
Dial gauge
Piston ring compressor
Pressing tool
Puller for cylinder liner
99 074
99 168
99 380
587 110
587 309
Impact drift
Dismantling tool
Assembly tool
Test apparatus for connecting rods
Piston ring expander
25
Removal of the loose ring in the liner

If the loose ring is so firmly seated that it cannot
be removed by hand, use the following method:
1. Remove the cylinder head and oil sump.
2. Turn the crankshaft until the piston is at bottom dead centre.
3. Fit tension lugs 98 515 on the edge of the cylinder liner in such a way that the liner will
not be pulled out of place.
4. Position plate 99 168 on the piston crown.
5. Press a piston ring into the liner until it is
below the loose ring.
6. Fit handle 99 168 on impact drift 99 074. If it
proves difficult to fit the bolt in the handle,
the head of the bolt can be ground down
slightly. Take care not to weaken the bolt if
this is done.
7. Screw the bolt into the plate.
8. Pull up the plate until it abuts against the piston ring pressed into the liner.
9. Drive out the loose ring with the impact drift.
Removing and dismantling

connecting rods and pistons
1. Remove the cylinder head and oil sump.
2. Remove the piston cooling nozzle from the
cylinder block.
Note The piston cooling nozzle must on

no account be damaged. The jet of
oil must hit the piston in the correct
place. If it does not, the piston gets
too hot and engine breakdown will
result.
Damaged nozzles must not be
straightened. They must be
changed.
26
01:03-02
3. Remove the bearing cap and bearing halves.

Protect the oilway in the crankshaft with tape
or the like, wound with the adhesive side out.
4. Mark the piston and connecting rod before
removing them. They must be refitted in the
same place and in the same way.
5. Lift out the piston and connecting rod.
6. Clamp the connecting rod in a vice with soft

jaws. Remove the gudgeon pin retaining
rings.
7. Heat the piston to 100 C and push out the

gudgeon pin using drift 87 362.
8. Remove the piston rings using tool 587 309,
taking care to avoid scratching the surface of
the piston skirt with the piston rings.
9. When cleaning graphited pistons in a
machine, the graphiting may disappear. This
does not matter when it has been used for
some time. However, new pistons should be
washed carefully using white spirit or the
like.
Note Always inspect the connecting rod
in cylinders which have seized,
been filled with water or where the
valve has broken. Bent connecting
rods must not be straightened.
01:03-02
27
Checking connecting rods

Check the connecting rods using tool 587 110.
Proceed as follows:
1. When the gudgeon pin bushing has been
checked, insert the bearing cap as marked
and tighten the bolts to full torque.
2. Mount the connecting rod in the tool using

the expander and place the gudgeon pin in its
bushing. Then place indicator studs on the
gudgeon pin.
Checking if connecting rod is twisted

- Check whether the connecting rod is twisted
with the studs on the indicator horizontal.
- Check whether the connecting rod is bent, with

the studs on the indicator vertical.
- The distance between the indicator studs on the

tool illustrated is 75 mm.
- The distance between an indicator stud and the
surface being measured must be no more than
0.1 mm, measured using this tool.
- Checking using a feeler gauge.
Checking if connecting rod is bent
- Also check whether the connecting rod is bent

into an S shape. Do this by measuring the distance between the outer side of the connecting
rod bushing and the flat surface on the tool.
- Turn the connecting rod and measure the corresponding dimension.
- The difference must not exceed 0.6 mm.
Checking whether the connecting

rod is bent into an S shape
28
01:03-02
Assembling piston and

connecting rod
1. Clean the piston and its ring grooves carefully without scratching the sides of the ring
grooves. The oil holes in the piston should be
cleaned using a suitable drill.
2. Check that the piston ring gaps do not exceed
the permitted value.
Place the piston rings in the cylinder liner
and measure the clearance using a feeler
gauge. For permitted gap, see section entitled
Specifications, piston rings.
3. Fit the piston rings using tool 587 309. The

oil scraper ring has an expander. Piston rings
which are marked TOP should be turned with
TOP up.
4. Oil all bushings and gudgeon pins before
assembly.
5. Place one of the retaining rings in the piston.
6. Turn the piston and connecting rod as

illustrated.
7. Heat the piston to 100 C and insert the

gudgeon pin using tool 87 362. Fit the
second gudgeon pin retaining ring.
01:03-02
29
Removing cylinder liner

1. Mark the liners with the numbers 1-6. Marking is essential to make it possible to fit the
liners in the same place and same position as
previously.
Note Mark the liners only on the surface
shown in the illustration. Other surfaces are sealing surfaces.
2. Withdraw the cylinder liner using puller

99 066 and hydraulic cylinder 99 003. Fit
spacers under the support lugs to avoid damaging the surface of the block.
3. Remove the seal from the cylinder block.
Puller for cylinder liner with

hydraulic hole cylinder
30
01:03-02
Measuring cylinder liner height

1. Carefully clean the cylinder block liner
shelf, the surface around the cylinder, the
cylinder liner shelf and the upper surface
of the cylinder liner.
2. Insert the liner without O-rings and twist it
down into position by hand.
3. Lift out the liner and wipe the liner shelf in
the cylinder block and the cylinder liner
shelf.
4. Insert the cylinder liner without O-rings
and twist it down into position again by
hand.
5. Place straight edge 87 198 and dial gauge
98 075 on the liner and zero the dial gauge
against the liner (A). Push the measuring
tip against the block (B) and measure liner
height (A-B) as illustrated.
6. Measure each liner on two diametrically
opposite points transversely across the
engine.
A = Measuring surface on cylinder

liner
B = Measuring surface on cylinder
block
C = Tip of dial gauge
D = Cylinder liner height D = A-B
- The cylinder liner should be slightly above

the surface of the cylinder block.
Measuring cylinder liner height
- The difference between the two measurements on the same liner may be up to a
maximum of 0.02 mm.
- Cylinder liner height D (A-B) above the
block should be 0.20 - 0.30 mm
01:03-02
31
Fitting cylinder liner

1. Check cylinder liner height as described in
the section entitled Measuring cylinder liner
height.
2. Check that the inside of the cylinder block
is clean. Clean the O-ring surfaces.
3. Check that the holes for coolant going to the
cylinder head and cylinder liner are not
clogged.
4. Carefully inspect the cylinder liners, both
new and old ones, for cracks which might
have arisen during transport or careless handling.
5. Tap the liner gently with a metal object. If
intact it should make a clear metallic ringing
sound. If it sounds cracked, change it.
6. Smear vaseline on the seal to be fitted in

the cylinder block and fit it in place.
7. Smear vaseline on the seal to be fitted on
the cylinder liner and fit it in place.
8. Turn the liner so that the stamped cylinder

number faces forwards and carefully tap it
down using a rubber mallet.
9. Fit the loose ring in place after the piston has
been fitted.
32
01:03-02
Fitting piston and connecting rod

1. Lubricate piston, piston rings, cylinder liner
and piston ring compressor with engine oil.
2. Remove the protection from the crank pin
and lubricate the pin.
3. Turn the piston rings so that ring gaps are
evenly distributed round the piston.
4. Place the upper half of the big-end bearing in
the connecting rod and lubricate the bearing
surface.
5. Fit assembly tool 99 380 instead of the loose
ring in the liner.
6. Carefully insert the connecting rod and piston
so that the arrow mark on the piston points
forward.
7. Clamp piston ring compressor 98 212 round

the piston and push the piston down into the
cylinder past the assembly tool.
8. Remove the assembly tool and press in the
loose ring. Be careful to press it in straight
so that it does not tilt.
9. Fit the lower half of the big-end bearing in

the bearing cap and oil the bearing surface.
Fit the bearing cap. Check that the connecting rod and bearing cap have the same marking and that they are opposite each other.
10. Lubricate the bolts, fit them and tighten to
20 Nm + 90.
01:03-02
33
11. Check that the piston nozzles are in perfect

condition and fully open. If necessary, blow
clean with compressed air.
12. Fit the piston cooling nozzle and tighten the
banjo bolts to 23 Nm.
Note The piston cooling nozzle must on

no account be damaged. The jet of
oil must hit the piston in the correct
place. If it does not, the piston gets
too hot and engine breakdown will
result.
Damaged nozzles must not be
straightened. They must be
changed.
13. Fit the oil sump and tighten the bolts to
30 Nm.
14. Fit the cylinder head. Tighten the cylinder
head bolts as described in the chapter entitled
Cylinder head.
34
01:03-02
Flywheel and flywheel housing
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
Flywheel housing
Seal
Bolt
Washer
Flange bolt
Flange bolt
Flange bolt
Cover
Gasket
Flange bolt
Cover
Lifting eye
01:03-02
13.
14.
15.
16.
17.
18.
19.
20.
21.
22.
23.
24.
Hexagon nut
Washer
Stud
Engine speed sensors
Connector housing
Flange bolt
Clip
Clip
Bolt
Timing gear plate
Stud
Pin
25.
26.
27.
28.
29.
30.
31.
32.
33.
34.
35.
36.
Flange bolt
Crankshaft
Crankshaft gear PF
Pin
Flywheel
Ring gear
Bolt
Ball bearing
Retaining ring
Bolt
Washer
Guide sleeve
35
Special tools
87 368
99 250
99 317
99 324
36
Puller bolts
Drift
Assembly tool
Guide pins
01:03-02
Removing flywheel
1. Remove the two engine speed sensors in the
flywheel housing.
2. Remove the flywheel retaining bolts.

14 flywheel: Also remove the washer.
3. Pull the flywheel off the crankshaft using

puller bolts 87 368.
Changing support bearing

1. Remove the retaining rings on both sides of
the support bearing.
2. Using drift 99 250, carefully tap the support
bearing out of the flywheel.
3. Fit the inner retaining ring and fit the new

support bearing using drift 99 250.
4. Fit the outer retaining ring.
Changing ring gear

Change the flywheel ring gear if the teeth have
become so worn that the starter motor drive does
not engage.
1. Grind as deep a groove as possible in the ring
gear and split it using a cold chisel. Remove
the ring gear from the flywheel.
WARNING!
Wear protective goggles as there is a risk

of flying metal splinters.
01:03-02
37
2. Clean the contact surfaces on the flywheel

using a wire brush.
3. Heat the new ring gear so that it is at an even
temperature of about 100-150C.
4. Place the heated ring gear on the flywheel

so that the tooth chamfering faces the starter
motor.
5. Make sure that the ring gear abuts firmly
against the flywheel. If necessary, tap the
ring down using a plastic mallet.
6. The ring gear must not be quickly cooled but

must cool in the open air.
Changing crankshaft seal

1. Remove the crankshaft seal using a screwdriver. Be careful not to scratch the sealing
surfaces on the crankshaft and flywheel housing.
Note The crankshaft seal should be fitted
dry and must not on any account be
lubricated. The sleeve in the seal
should be left in place until the seal
is fitted.
The crankshaft should be degreased
before the new seal is fitted.
2. Fit the new crankshaft seal using tool 99 317.
38
01:03-02
Removing flywheel housing

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

1. Remove all old sealing agent on the sealing
surfaces on the timing gear housing and the
transmission plate. Clean off the oil and
grease with a spirit based cleaning agent.
Note The sealing surfaces must be absolutely clean and free from grease.
Do not touch the surfaces after
degreasing.
2. Apply the sealing agent (816 064) on the

timing gear housing with the special nozzle.
The width of the bead must be between 0.8
and 1.2 mm. Follow the pattern illustrated.
Important Ensure that the sealing agent is

applied inside screw holes, but without the
sealing agent running into the crank housing. The agent can block the ducts and nozzle. This is especially important around the
oil ducts. The oil flow to the air compressor
or injection pump may become blocked.
Apply the sealing agent on the timing gear

housing side against the transmission plate.
Apply the sealing agent around the screw
holes marked with arrows.
Important Assembly must take place within 25

minutes of starting sealing agent application.
01:03-02
39
Note The bolts are of different sizes and

lengths. Make sure that they are fitted in the right places.
3. Tighten M12 bolts to 90 Nm and M10 bolts
to 50 Nm.
4. Fit the power steering pump.
5. Fit the starter motor.
Fitting flywheel
1. Fit two guide pins 99 324 in the crankshaft
flange.
2. Fit the flywheel on the crankshaft.
Important Always use new bolts.

14 flywheel: Fit washers also.
3. Tighten diametrically opposite bolts alternately to 130 Nm and then a further 90.
4. Fit the two engine speed sensors.
40
01:03-02
Timing gear
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
Camshaft
Pin
Shaft
Roller tappet
Bushing
Retaining ring
Spacer sleeve
Flange bolt
Banjo bolt
Pushrod
01:03-02
11.
12.
13.
14.
15.
16.
17.
18.
19.
20.
Camshaft bearing
Camshaft gear
Flange bolt
Guide flange
Flange bolt
Crankshaft gear
Intermediate gear
Intermediate gear
Ball bearing
Shaft
21. Retaining ring

22. Spacer sleeve
23. Flange bolt
24. Injection pump gear
25. Hydraulic pump gear
26. Oil pump gear
27. Compressor gear
41
Special tools
87 348
87 592
99 074
99 309
587 526
42
Drift
Drift
Impact drift
Flywheel turning tool
Support drift
01:03-02
Gearwheel timing gear

Intermediate gear
Removing
- The timing gear has two intermediate gears.
- One for the camshaft and pump drive and one
for driving the compressor.
- Both these gears should be removed in the
same manner.
1. Turn the crankshaft so that No. 1 cylinder is
close to TDC. Use tool 99 309 and ratchet
handle on the flywheel starter ring gear.
2. Remove the flywheel as described in the section entitled Flywheel, removal.
3. Remove the flywheel housing as described
in the section entitled Flywheel housing,
removal.
4. Fabricate a threaded piece of pipe as in
drawing.
5. There is a groove in the shaft on which the
gearwheel is located. Fit puller 587 526, slide
hammer 99 074 and the threaded piece. Pull
off the gearwheel and shaft.
Note When the intermediate gear has
been removed, neither the camshaft nor the crankshaft must be
rotated. Pistons and valves could in
such case strike each other and be
damaged.
01:03-02
43
Changing bearing in intermediate gear

for compressor
1. Remove the retaining ring.
2. Press the bearing unit out of the gear.
3. Press the shaft journal out of the bearing.
4. Press the shaft journal into a new bearing
using tool 87 348. Do not press on the outer
race.
5. Press the race on the shaft journal.
6. Press the bearing unit into the intermediate
gear. Use tool 87 592.
7. Refit the retaining ring.
Changing bearing in intermediate gear

for camshaft
1. Press the shaft out of the bearing.
2. Press the half of the inner bearing race off the
shaft and remove the retaining ring.
3. Place the removed inner bearing race in the
bearing and press out the bearing using drift
87 348.
4. Press a new bearing on the shaft journal using
drift 87 348.
Note Do not press on the outer race .
5. Press the bearing with shaft journal into the
intermediate gear using drift 87 592.
6. Refit the retaining ring.
7. Press the spacing ring on the shaft journal.
Make sure that the shaft journal is on the
press table.
44
01:03-02
Fitting
1. Turn the crankshaft until No. 1 cylinder is
close to TDC. Lubricate the bearing surfaces.
2. Turn the camshaft gear and crankshaft gear
until the marks point towards the centre of
the intermediate gear.
3. Fit the intermediate gear against the camshaft
gear and crankshaft gear so that the markings
point towards each other.
4. Fit the second intermediate gear.
5. Tighten the bolts in the intermediate gears to
50 Nm + 60.
6. Fit the flywheel housing as described in the
section entitled Flywheel housing, fitting.
7. Fit the flywheel as described in the section
entitled Flywheel, fitting.
01:03-02
45
Camshaft gear
Removing
3. Remove the flywheel housing as described in
the section entitled Flywheel housing,
removal.
4. Remove the intermediate gear.
damaged.
5. Remove the camshaft gear.
Fitting
1. Fit the camshaft gear and tighten the bolts to
42 Nm.
2. Fit the intermediate gear, see section entitled
Intermediate gear, fitting points 1-2.
46
01:03-02
Crankshaft gear
Removing
the section entitled Flywheel housing,
removal.
4. Remove the intermediate gear.
damaged.
5. Remove the crankshaft gear.
Fitting
1. Fit the crankshaft gear.
2. Fit the intermediate gear, see section entitled
Intermediate gear, fitting points 1-2.
01:03-02
47
Camshaft
Removing
1. Remove the flywheel as described in
Flywheel, removing.
Flywheel housing, removal.
3. Remove rocker arms, pushrods and valve
braces.
4. Remove the camshaft gear.
5. Remove the intermediate gear and the guide
flange bolts.
6. Remove the timing gear plate.
7. Remove the camshaft covers.
8. Remove the valve tappets.
Note Mark the valve tappets because they

must be refitted in the same places.
9. Withdraw the camshaft rearwards. Be careful
not to damage cams and bearings.
48
01:03-02
Replacement of camshaft bearing

Special tools
99 373
99 003
99 003
99 004
99 373
99 004
Hydraulic cylinder
Compressed air powered
hydraulic pump
Tool for replacing camshaft
bearing
Work description
1. Remove the camshaft according to section
Camshaft, removal.
2. Remove the camshaft cover at the front end
of the engine.
Note To avoid damaging the contact
surfaces when pressing in the new
bearings, the edges and the surfaces of the bearing seats around
the old bearings must be wiped
clean.
3. Wipe the surfaces of the bearing seats
around the old bearings.
Note The recess in the bearing joint
should face the front of the engine.
01:03-02
49
4. Place the new bearings in the space

between the camshaft bearing seats.
Tool 99 373
1. Threaded rod with eight flange nuts
2. Press drift
3. Flange
5. Position the flange nuts on the threaded
rod, included in tool 99 373, as illustrated.
50
01:03-02
6. Insert the end of threaded rod with flange

nut number 1 from the rear edge of the
engine past the rearmost bearing seat. Insert
the rod past the bearing seats and the new
bearings until the flange nut 1 protudes
from the front of the engine.
7. Screw the flange included in tool 99 373

into place on the hydraulic cylinder 99 003
with two M6x12. Press the cylinder 99 003
together if it is not in the neutral position.
8. Screw the flange with hydraulic cylinder to

the rear of the engine, using two M10x25
bolts.
9. Screw flange nut 8 from tool 99 373, onto
the threaded rod.
01:03-02
51
10. Hang a new bearing on the rod at the front

of the engine.
11. Place the press drift on the threaded rod and
the bearing on the drift.
Note The recess in the bearing joint
should face towards the flange on
the press drift. Secure the bearing
on the drift by placing the springloaded ball in an oilway. The bearing is correctly located on the drift
when the ball and a marking hole
are opposite the bearings oil hole.
The bearing is correctly located on the drift

when the ball and a marking hole are opposite the bearings oil hole
12. Wipe the bearings contact surface clean.
Note The marking on the drift should be
towards the top and vertical to
ensure that the oil holes in the
bearing will be opposite the oilways.
13. Hold the press drift with the new bearing

against the old one. Secure the threaded rod
between the press drift and the hydraulic
cylinder 99 003 by tightening flange nut 8
on the rod.
Fix the threaded rod by tightening flange nut 8.
52
01:03-02
Note The new bearing is correctly positioned before the old bearing has
been removed completely. The
new bearing is in the correct position when the distance from the
front edge of the cylinder block
and the front edge of the press
drift have a permitted value
according to the table. By -12 mm
it means that the drift should protrude 12 mm out of the block.
Table for correctly located camshaft

bearing:
Camshaft bearing
No.
Distance (mm)
-12 to -14
150 to 152
314 to 316
478 to 480
642 to 644
806 to 808
970 to 972
Check measuring bearing number 1
14. Press in the new bearing at the same time as

the old bearing is pressed out with hydraulic cylinder 99 003 and hydraulic pump 99
004. Check that the bearing is correctly
positioned by measuring.
15. Carefully tap using a plastic mallet to
remove the old bearing.
01:03-02
53
16. Remove the drift by loosening flange nut 8

and sliding the threaded rod in.
Note The seats for camshaft bearings 2,
4 and 6 have two oil ducts. The
others only have the lower duct.
17. Check that the bearings oil hole is opposite
the cylinder block oil ducts.
18. Repeat the procedure for the other bearings.
Pressing in and pressing out bearing number 2
19. Clean the sealing surface, use a new gasket

and fit the camshaft cover at the front of the
engine.
20. Refit the camshaft according to section
Camshaft, fitting. Then check the camshaft
setting.
Check measuring bearing number 2
54
01:03-02
Fitting the camshaft

1. Fit the camshaft. Be careful not to damage
cams and bearings.
2. Lubricate with engine oil and fit the valve
tappets in the same places as they were
before removal. Tighten the banjo bolts
to 32 Nm.
3. Fit the camshaft covers.
4. Fit the guide flange bolts.
5. Remove all old sealing agent from the

cylinder block, the timing gear housing and
the transmission plate. Remove all oil and
grease from the sealing surfaces using a
spirit-based cleaning agent.
Obs! The sealing surfaces must be
absolutely clean and free from
grease. Do not touch the surfaces
after degreasing.
6. Apply the sealing agent (816 064) to the

cylinder block with the special nozzle. The
width of the bead must be between 0.8 and
1.2 mm. Follow the pattern illustrated.
Important Ensure that the sealing agent is

applied inside screw holes, but without the
sealing agent running into the crank
housing. The agent can block the ducts
and nozzles. This is especially important
around the oil ducts. The oil flow to the air
compressor or injection pump may
become blocked.
Important Assembly must take place within 25
minutes of starting sealing agent application.
01:03-02
Application of sealing agent on the block
55
7. Fit the timing gear plate on the engine block.

Tighten the bolts to 63 Nm
8. Fit the intermediate gear

9. Make sure that the marking on the camshaft
gear points towards the centre of the intermediate gear.
10. Fit the camshaft gear and tighten the bolts to
42 Nm.
11. Fit the flywheel housing as described in
Flywheel housing, fitting.
12. Fit the flywheel as described in Flywheel,
fitting.
Checking the camshaft setting

1. Position the crankshaft at TDC after the compression stroke of the first cylinder.
2. Set up two dial test indicators against the
valve spring thrust washers.
3. Adjust the rocker arms so that there is no gap
and then adjust a further 0.1 mm
(so that both valves are open 0.1 mm).
4. Zero both dial indicators.
5. Turn the crankshaft one revolution in its
direction of rotation until TDC position is
again achieved.
6. Read off both the dial indicators and compare the readings with the values given
below:
- Inlet valve lift height 0.37-1.47
- Exhaust valve lift height 0.16-1.16
56
01:03-02
Crankshaft
Removing
1. Remove the crankshaft gear as described in
Crankshaft gear, removal.
2. Remove the fan drive at the front end of the
crankshaft as described in Belt drive, Changing the seal in the front cover.
3. Remove the oil sump, oil suction pipe with
strainer and oil pump.
4. Remove the pistons and connecting rods as
described in Removing connecting rods and
pistons.
5. Remove the crankshaft bearing caps and
main bearings.
Note The main bearings and bearing caps
are marked and must be refitted in
the same place.
6. Lift out the crankshaft.
Checking and grinding

- Measure the crankshaft journals. Using a
micrometer, measure two diameters 90 degrees
apart. If one of these diameters is below the
minimum limit, regrinding of the crankshaft
should be considered.
- Consideration must also be given to oil pressure, which is in turn affected by such things
as main bearing and crankshaft bearing wear.
- When regrinding, stated undersizes must be
complied with. There are bearings adapted to
these dimensions.
- It is important that the fillet radius of the journals is correct.
- After grinding the journals, the oil hole nozzles
at the bearing surfaces should be rounded and
polished.
01:03-02
57
Fitting
1. Lubricate the main bearings and place them
in the block.
2. Lift in the crankshaft.
3. Insert the main bearings in the crankshaft

bearing caps and fit them.
Note Fit the main bearings and bearing
caps in the same places as they
were in before removal.
4. Tighten the bearing cap bolts to 50 Nm +

90.
5. Refit the pistons and connecting rods as

described in Fitting connecting rod and piston.
6. Fit the oil pump, oil suction pipe with
strainer and oil sump.
7. Change the seal in the front cover. Fit the
spacing sleeve on the crankshaft journal. Fit
the driver and crankshaft damper.
See Belt drive, Changing the seal in the front
cover.
8. Fit the crankshaft gear as described in Crankshaft gear, fitting.
58
01:03-02
Belt timing gear
1. Belt pulley on
crankshaft damper
2. Belt tensioner
3. Coolant pump
4. Belt pulley and fan
drive
5. Alternator
6. Multigroove V-belt
7. Idler roller
01:03-02
59
Changing the seal in the front

cover
1. Remove the fan ring and fan. Thermostatic
fan: Store it upright (vertical).
2. Remove the belt(s), crankshaft damper and
belt pulley.
3. Remove the driver bolts and withdraw the
driver. Mind the sealing surface.
4. Pull or prise off the seal in the cover. Take
care to avoid damaging the sealing surface
in the cover.
5. Wipe the sealing surface in the cover clean.
Note The crankshaft seal must be dry
when fitted and should on no
account be lubricated. The sleeve
in the seal should be left in place
until the seal is fitted.
6. Place the new seal on tool 99 379 and press
it in place by tightening diametrically opposite bolts alternately. The seal is correctly
fitted when the tool comes up against the
cover.
Tool 99 379 with crankshaft seal
7. Remove the tool by screwing the bolts into

the threaded holes.
8. Wipe the drivers sealing surface clean. Fit
a new seal on the end surface of the driver
and push the driver onto the spacer sleeve
on the end of the crankshaft.
9. Bolt the driver to the crankshaft flange and
tighten the flange bolts to 135 Nm.
10. Bolt the crankshaft damper and possibly the
belt pulley to the hub and tighten to 110
Nm.
11. Fit the belt(s), fan ring and fan.
60
01:03-02
Lubrication system
Oil cooler
1.
2.
3.
4.
5.
6.
7.
8.
01:03-02
Oil cooler
Gasket
Gasket
Flange bolt
Oil cooler cover
Core plug
Cover
Gasket
9.
10.
11.
12.
13.
14.
15.
Bolt
Piston
Spring
Plug
Gasket
Gasket
Flange bolt
61
Changing seals
1. Remove the side cover and oil cooler from
the block.
2. Remove the 4 bolts securing the oil cooler to

the side cover.
3. Remove the oil cooler.
4. Changing the four O-rings.

5. Fit the oil cooler insert, bolt it to the side
cover and tighten to 26 Nm.
6. Bolt the side cover to the block.
62
01:03-02
Oil cleaner
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
17.
18.
19.
20.
21.
22.
23.
24.
25.
26.
27.
28.
29.
30.
31.
32.
01:03-02
Filter head
Overflow valve
Union
Straight union
Seal
Gasket
Flange bolt
Oil filter
Housing
Plug
Piston
Spring
Plug
Gasket
Shaft
Washer
Rotor
Nozzle
Strainer
Rotor bowl
Nut
O-ring
Cover
O-ring
Locknut
Lifting lug
O-ring
Retaining ring
Gasket
Flange bolt
Plug
Gasket
63
Dismantling and assembly

- During routine cleaning of the oil cleaner, there
should be a certain amount of dirt deposits in
the rotor bowl.
- If this is not the case, it indicates that the rotor
is not spinning. The cause of this must be
immediately investigated.
- If the dirt deposit exceeds 20 mm at the recommended intervals, the rotor bowl should be cleaned more often.
1. Unscrew the nut securing the outer cover and

remove the nut.
2. Lift out the rotor. Wipe the outside. Slacken

the rotor nut and unscrew it about three turns
to protect the bearing.
Note The rotor must not be clamped in

the vice. Never hit the rotor bowl.
This may cause damage leading to
imbalance.
3. If it is difficult to loosen the rotor nut, turn

the rotor upside down and clamp the rotor nut
in a vice.
4. Turn the rotor anti-clockwise three turns by
hand or, if this does not succeed, by placing
a screwdriver between the outlet holes.
64
01:03-02
5. Hold the rotor bowl and gently tap the rotor

nut with your hand or a plastic mallet until
the rotor bowl releases from the rotor.
Note Never hit the rotor directly as its
bearings may be damaged.
6. Remove the rotor nut and bowl from the

rotor.
7. Remove the strainer from the rotor. If the

strainer is jammed, carefully prise it loose
with a knife inserted at the lower edge
between the rotor and strainer.
8. Scrape the deposits from the inside of the

bowl using a knife.
9. Wash the parts.
10. Check the two nozzles on the rotor.
Make sure that they are not blocked or damaged. Change damaged nozzles.
11. Check that the bearings are not damaged.
12. Place the O-ring in position in the bowl.
Change the O-ring if it is in the slightest
way damaged.
01:03-02
65
13. Assemble the parts and tighten the rotor nut

hard by hand.
14. Check that the shaft is not loose. If it is, it can
be locked using locking compound 561 200.
First clean thoroughly using a suitable solvent.
15. Tighten the rotor shaft using socket wrench
98 421. Tightening torque 41 Nm.
16 Refit the rotor and turn it by hand to make

sure that it turns easily.
17. Check the O-ring on the cleaner housing
cover and fit it with a locknut.
Tighten the locknut to 10 Nm.
66
01:03-02
Oil pump
In the case of leakage or a fault in the oil pump, it should
not be reconditioned but should be changed as a unit.
1.
2.
3.
4.
5.
01:03-02
Oil pump
Flange bolt
Gasket
Flange bolt
Suction pipe
6.
7.
8.
9.
10.
Strainer
Ring
Flange bolt
Tube
Seal
67
Lifting the engine

Special tools
Note The engines lifting eyes are

designed for lifting the engine only,
not the engine together with its
ancillary equipment (alternator,
gearbox, etc.) or frame.
98 094 Lifting chain

587 308 Lever block
- Attach lifting chain 98 094 to the rear lifting

eyes.
- Attach lever block 587 308 to the front lifting
eye.
Note The lifting eyes are sized to cope

with a maximum angle of 30.
68
01:03-02
Specifications
General information
Cylinder configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Number of cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Cylinder bore . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Stroke . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Swept volume. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Number of main bearings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Firing order . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Injection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Principle of operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Cooling. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Approx. weight, including alternator . . . . . . . . . . . . . . . . . . . . . . . . . . .
Direction of rotation (engine viewed from rear) . . . . . . . . . . . . . . . . . .
Compression ratio
Output
Engine speed
Torque
Oil capacity
Oil grade
In-line engine
6
127 mm
154 mm
11.7 dm3
7
1-5-3-6-2-4
Direct
4 stroke
Liquid
990 kg
Anti-clockwise
See Operators Manual or Service Card for the particular engine.
Locking compound, lubricants, sealing compounds

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

The following tightening torques apply generally if nothing else is specified:
Thread M5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Thread M6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Thread M8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Thread M10 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Thread M12 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Thread M14 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
01:03-02
6,7 Nm
10,2 Nm
26 Nm
50 Nm
92 Nm
149 Nm
69
Cylinder head
Inlet valve
Valve head angle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19,5
Minimum value A for ground valve . . . . . . . . . . . . . . . . . . . . . . . . . . . 2,6 mm
Distance between the surface of the cylinder head and the valve head. 0,75-1,8 mm
Exhaust valve
Valve head angle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44,5
Minimum value A for ground valve . . . . . . . . . . . . . . . . . . . . . . . . . . . 1,8 mm
Distance between the surface of the cylinder head and the valve head. 0,66-1,8 mm
- Check value A for each valve.
- Grind the valves in a valve grinding machine.
Minimum value A for ground valve
Inlet valve seat

Seat angle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Contact surface width A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Valve seat ring outer diameter. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Position for the valve seat ring, diameter . . . . . . . . . . . . . . . . . . . . . . .
Seat for the valve seat ring, depth . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
20,0-20,5
1,9 - 2,6 mm
46,054 - 46,065 mm
46,000 - 46,016 mm
11,25 - 11,35 mm
Over-sized valve seat ring:

Outer diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46,254 - 46,265 mm
Position for the valve seat ring, diameter . . . . . . . . . . . . . . . . . . . . . . . 46,200 - 46,216 mm
Cooling temperature when fitting valve seat ring . . . . . . . . . . . . . . . . . approx. -80 C
70
01:03-02
Exhaust valve seat

Seat angle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Contact surface width A. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Valve seat ring outer diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Position for the valve seat ring, diameter. . . . . . . . . . . . . . . . . . . . . . . .
Seat for the valve seat ring, depth . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
45,0-45,5
1,8 - 2,6 mm
44,081 - 44,092 mm
44,000 - 44,016 mm
11,25 - 11,35 mm
Over-sized valve seat ring:

Outer diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44,281 - 44,292 mm
Position for the valve seat ring, diameter. . . . . . . . . . . . . . . . . . . . . . . . 44,200 - 44,216 mm
Cooling temperature when fitting valve seat ring . . . . . . . . . . . . . . . . . approx. -80 C
Tightening torques
Cylinder head bolts:
First time. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Second time . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Third tightening . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Nut for injector. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Nut for rocker arm adjusting screw . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Bolt for rocker cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Bolts for exhaust manifold. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
01:03-02
60 Nm
150 Nm
250 Nm + 90
70 Nm
40 Nm
22 Nm
59 Nm
71
Turbocharger
Wear limits
Shaft radial clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.198-0.564 mm
Shaft axial clearance (after running-in). . . . . . . . . . . . . . . . . . . . . . . . . 0.025-0.106 mm
Tightening torques
Bolts, turbocharger - exhaust manifold . . . . . . . . . . . . . . . . . . . . . . . . . 63 Nm
Bolts in turbine housing (exhaust pipe). . . . . . . . . . . . . . . . . . . . . . . . . 24 Nm
V clamps, exhaust and intake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-10 Nm
Pistons and cylinder liners

Cylinder liner
Shims for cylinder liner, thickness . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.20, 0.25, 0.30,
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.40, 0.50, 0.75 mm
Cylinder liner height above cylinder block . . . . . . . . . . . . . . . . . . . . . . 0.20 - 0.30 mm
Maximum permitted height difference on one liner
between dimensions measured at two diametrically opposite
points . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.02 mm
Pistons
Fitted with arrow on piston crown facing forward
Piston rings
Number of compression rings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Gap: 1st ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2nd ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Max. clearance in groove, 2nd ring . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2
0.35 - 0.60 mm
0.45 - 0.65 mm
0.25 mm
Rings marked TOP should be turned with the mark upwards

Number of oil scraper rings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Gap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.40 - 0.65 mm
Max. clearance in groove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.25 mm
72
01:03-02
Connecting rods
Connecting rod and bearing cap marked 1 to 6.
Fitted with marking inwards.
Tightening torques
Bolts, oil sump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30 Nm
Connecting rod bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 Nm + 90
Flywheel and flywheel housing

Flywheel
Maximum machining of contact surface for disc: 2.0 mm
Ring gear
Heated to 100 - 150 C before fitting.
Tightening torques
Flywheel bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 130 Nm + 90
Bolts for flywheel housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . M10 :50 Nm
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . M12 : 90 Nm
01:03-02
73
Timing gear
Camshaft gear
Backlash against intermediate gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.03 - 0.15 mm
Injection pump gear

Backlash against intermediate gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.03 - 0.15 mm
Intermediate gear
Max. axial clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.238 mm
Camshaft
Axial clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.10 - 0.25 mm
Tightening torques
Bolts for camshaft gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Bolts for intermediate gears . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Bolts for compressor gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Connecting rod bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Main bearing bolts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Bolts for driver . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Bolts for crankshaft damper and pulley. . . . . . . . . . . . . . . . . . . . . . . . .
Banjo bolts for valve tappets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Bolts for timing gear plate. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
74
42 Nm
50 Nm + 60
105 Nm
20 Nm + 90
50 Nm + 90
135 Nm
110 Nm
32 Nm
63 Nm
01:03-02
Lubrication system
Oil cleaner
Permitted thickness of deposits on wall of bowl . . . . . . . . . . . . . . . . . . max 20 mm
Oil pressure valve (Note: not safety valve)

Oil pressure:
Idle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.6 bar
With warm engine at 1000 rpm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.5 bar
With warm engine at 2,000 rpm. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.5 - 6 bar
Free spring length. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61.4 mm
Oil filter
Use only genuine Scania filters.
Tightening torques
Oil pump:
Bolts for oil pump cover. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 Nm
Bolts, oil pump - cylinder block. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 Nm
Oil cleaner:
Locknut for oil cleaner housing cover . . . . . . . . . . . . . . . . . . . . . . . . . . 15 Nm
Nut for rotor bowl . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Tighten by hand
Rotor shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34 Nm
Oil nozzle for piston cooling:
Banjo bolt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 Nm
Oil cooler:
Bolts for oil cooler insert . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 Nm
01:03-02
75
Special tools
Number
87 198
87 348
87 362
87 368
87 592
98 075
98 094
98 212
98 249
98 599
99 003
99 004
99 007
99 066
99 074
99 079
99 168
99 250
99 308
99 309
99 310
99 317
99 322
99 323
99 324
99 373
99 379
99 380
99 381
99 382
99 383
99 384
99 385
99 394
587 025
587 107
587 110
587 250
587 277
587 308
587 309
587 526
587 692
588 221
76
Designation
Shown on page
Rule for dial gauge

Puller
Drift
Puller bolt
Drift
Dial gauge
Lifting chain
Piston ring compressor
Compression tester
Oil pressure gauge
Hydraulic hole cylinder
Compressed air powered hydraulic pump
Support plate
Puller for cylinder liner
Impact drift
Extractor for injectors
Dismantling tool for loose ring
Drift
Sleeve for injectors
Tool for turning flywheel
Socket
Assembly tool
Press drift for valve spring
Assembly drift
Guide pins, flywheel
Tool for replacing camshaft bearing
Press drift for crankshaft seal
Assembly tool, loose ring
Drift for injector sleeve
Drift for valve guides
Drift for valve guides
Drift for valve seats
Drift for valve seats
Guide, thread cutting of injector sleeve
Filter wrench
Deflection gauge
Test apparatus for crankshafts
Measuring stand
Valve seat cutter
Lever block
Piston ring expander
Support drift
Engine stand
Thread tap for injector sleeve
25
42
25
36, 37
42, 44
18, 25
68
25, 33
4, 6
24
49
25, 30
4, 8, 25, 26, 42, 43
4, 8
25, 26
36, 37
4, 8, 17
4, 5, 42, 46, 47
4
36, 38
4, 9, 16
4, 9
36, 40
49, 50
60
25, 33
4, 15
4, 13
4, 13
4, 10
4, 10
4, 14
18, 19
18, 21
25, 28
18, 21
4, 11, 12, 13
68
25, 27
42, 43
4, 14
01:03-02

SCANIA Work Description Engine - 12 Industrial and Marine Engine

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01:03-02

Work Description - 12 Engine

Scania CV AB, Sweden, 1999-09:02

Flywheel and flywheel housing . . . . . . . . . . .35

Scania CV AB, Sweden, 1999-09:02

15. Valve spring

Scania CV AB, Sweden, 1999-09:02

29. Adjusting screw

Scania CV AB, Sweden, 1999-09:02

Adjustment can be carried out in one of the following ways:

B. Bring cylinder No. 1 exactly to TDC after

intake and exhaust

Turn the crankshaft precisely one revolution

Scania CV AB, Sweden, 1999-09:02

Measurements are only intended for comparison

By using various accessories, the compression

1. Cut off the supply of fuel by disconnecting

3. Remove the rocker covers.

Scania CV AB, Sweden, 1999-09:02

Cleaning of measuring rod

Scania CV AB, Sweden, 1999-09:02

Scania CV AB, Sweden, 1999-09:02

Changing valve stem seal

3. Fit the valve.

Scania CV AB, Sweden, 1999-09:02

Replacement of valve seats

Use protective goggles. Always turn the

3. Press in new valve seat rings. Use drift

Be careful with the above-mentioned

Scania CV AB, Sweden, 1999-09:02

Machining of valve seats

Scania CV AB, Sweden, 1999-09:02

3. Select and fit the cutter.

4. Slacken off the quick-release lock and

5. Set the indicator on the cutter adjuster using

7. Disconnect the magnetic base (position 2).

Scania CV AB, Sweden, 1999-09:02

Replacement of valve guides

2. Press in the new valve guides using drift

Scania CV AB, Sweden, 1999-09:02

Replacement of injector sleeves

Important Mark the position of the groove in

1. Thread the top part of the sleeve using tap

Scania CV AB, Sweden, 1999-09:02

3. Degrease and check the contact surfaces of

Scania CV AB, Sweden, 1999-09:02

5. Lubricate the threads on the cylinder head

6. Tighten the bolts in the order given in the

Tighten all bolts to 60 Nm

Scania CV AB, Sweden, 1999-09:02

7. Fit the lower part of the rocker cover and

12. Fit the upper part of the rocker cover and

Scania CV AB, Sweden, 1999-09:02

Lubrication oil pipe

Lubrication oil pipe

Scania CV AB, Sweden, 1999-09:02

Removing oil filter

Scania CV AB, Sweden, 1999-09:02

Air and exhaust leakage

Cleaning the compressor wheel

Foreign bodies, such as grains of sand or metal

Low charge pressure can be caused by a dirty

Note Never attempt to straighten a damaged impeller. It will usually break in