03:04-02

Issue 3 en
Industrial & Marine Engines

Fuel system

9, 12 and 16 litre engines with

PDE unit injector

Work description

Art. nr.
1 588 862 ©
Scania CV AB, Sweden, 2002-09:3
 Contents
Important information ..................................................................................3

Components in the fuel system Removing unit injectors............................................4

Fitting unit injectors..................................................8
Adjusting unit injectors...........................................13
Order of adjustment for 9 litre engines ...................15
Order of adjustment for 12 litre engines .................17
Order of adjustment for 16 litre engines .................18
Adjustment of PDE unit injectors 31......................19
Adjustment of PDE unit injectors 32......................23
Feed pump...............................................................27
Fuel filter.................................................................29

Bleeding and pressure measuring

the fuel system 12 litre engine .........................................................34
9 and 16 litre engines ..............................................35
Measuring feed pump pressure ...............................36
Pressure relief valve................................................38

Renewing an unpressurised return

line ................................................................................40

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2 Scania CV AB 2002-09:3 03:04-02
 Important information
• The safety precautions and warnings in the
work description must be read thoroughly
before any work is carried out.

Mind the environment! Use a container

to avoid spillage when working on
the fuel system.

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03:04-02 Scania CV AB 2002-09:3 3
Components in the fuel system

Unit injector

Removal

Special tools

Number Description Illustration

99 309 Tool to rotate flywheel

87 596 Slide hammer

1. Open the bleed nipple and drain the fuel

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

! WARNING!

The fuel system must be empty or fuel

may run down into the cylinders, which
will result in a great risk of liquid ham-
mering.
If fuel runs into the combustion cham-
ber, it must be removed immediately
using a pump.

9 and 12 litre engines

16 litre engine

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4 Scania CV AB 2002-09:3 03:04-02
 2. Clean the rocker cover and the surrounding
area.
3. Remove the top part of the rocker cover.
4. Relieve the pressure on the valves by undo-
ing the bolts on the rocker arm shaft alter-
nately.

! WARNING!

Do not lean over the engine when remov-

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

Important If the spring comes loose from the

unit injector, the unit injector must be
renewed.
5. Remove the rocker arm shaft.

6. Remove the screw for the fork clamp hold-

ing the unit injector in place.

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

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03:04-02 Scania CV AB 2002-09:3 5
 7. Detach the cables on the unit injector. The
screws cannot be removed but unscrew
them as much as possible.

Important Do not lift the unit injector by the

spring. The spring can come loose. If the
spring comes loose from the unit injector,
the unit injector must be renewed.

8. It is easier to position the slide hammer if

one of the lower rocker cover bolts is
removed.

9. Turn the unit injector clockwise until it

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

Note If the slide hammer is placed

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

Place the slide hammer as indi-

cated by the arrow.

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6 Scania CV AB 2002-09:3 03:04-02
10. Withdraw the unit injector. If the unit injec-
tor is stuck, tap carefully with a rubber mal-
let on the solenoid valve housing.
Important The unit injector is not to be dis-
mantled. Renew the entire unit
11. Remove the sealing washer from the bot-
tom of the injector seat, if it was left behind
when the unit injector was removed.

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03:04-02 Scania CV AB 2002-09:3 7
Fitting

Specifications

Tightening torques

Lock nut on rocker arm 39 Nm

Bolt for fork on unit injector. 20 Nm + 75°

Bearing bracket and rocker arm shaft 105 Nm

Screws for cable connections on unit injector 2 +/- 0,2 Nm

Special tools

Number Description Illustration

588 179 Torque screwdriver

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8 Scania CV AB 2002-09:3 03:04-02
Important Check the unit injector spring
diameter before adjusting and ensure that
the correct tool is used when adjusting the
unit injector.

Note All work that involves opening the

fuel system must be completed in
the following way:

Start the engine and check for leaks. Allow the

engine to run until it is running smoothly.
Check and delete any fault codes that are regis-
tered in the control unit after the work has been
completed.

1. Make sure that the old seal is not at the bot-

tom of the injector seat. Clean the sealing
surfaces in the injector seat.
Important Always renew the O-rings and seal
on unit injectors that have been removed.
Make sure all sealing surfaces are clean.

2. Lubricate the unit injector O-rings with

O-ring grease, part No. 1 402 039.
3. Fit a new sealing washer on the unit injec-
tor. A rubber insert will keep the seal in
place on the unit injector.

! WARNING!

Check that there is no fuel left in the

cylinder. If fuel runs into the combustion
chamber, it must be removed immedi-
ately using a pump.

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03:04-02 Scania CV AB 2002-09:3 9
 Note Make sure that the fork clamp and
bolt are dry and free of oil.

4. Place the fork clamp with screw in position

on the unit injector and insert it into the cyl-
inder head. Press down the unit injector by
hand as far as possible.

5. Torque tighten the bolt to 20 Nm and then a

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

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10 Scania CV AB 2002-09:3 03:04-02
Important Make sure the pushrods are placed
in their correct positions. Make sure the
pushrod to the unit injector is firmly
secured in its lower position by the retain-
ing ring.

Important If the rocker arms have been

removed on more than one cylinder, the
rocker arm lock bolts must be completely
unscrewed before adjustment commences.
6. Refit the rocker arm shaft. Screw in the
bolts alternately so that they are tightened
in parallel or one of the bolts may bend.
Tighten the bolts to 105 Nm.
7. Check and adjust the unit injector as
described in Adjusting the unit injectors.
Important Make sure that the cable terminals
are the right way round when fitting the
cables to the unit injector.
8. Reconnect the cables on the unit injectors.
Their relative position is not important. Use
torque screwdriver 588 179 to tighten the
screws to 2 Nm.
118 482

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03:04-02 Scania CV AB 2002-09:3 11
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.

9. Refit the upper rocker cover and torque

tighten the bolts to 18 Nm.
10. Close the bleed nipple and tighten the banjo
screw.
11. Fill and bleed the fuel system. Refer to
Bleeding the fuel system.

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12 Scania CV AB 2002-09:3 03:04-02
Adjusting unit injectors

Specifications
The unit injectors must be adjusted when they are
replaced and when valves are adjusted or
checked in accordance with the maintenance
chart.

Dimension B, diameter of the spring for unit injector PDE31 36,5 mm

Dimension B, diameter of the spring for unit injector PDE32 38,5 mm

Dimension A for unit injector PDE31 (cold engine). 66,9+/-0,1 mm

Dimension A for unit injector PDE32 (cold engine). 69,9 +/-0,1 mm

Tightening torque

Lock nut on rocker arm 39 Nm

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03:04-02 Scania CV AB 2002-09:3 13
Special tools

Number Description Illustration

99 309 Tool to rotate flywheel

Preparatory work

Important Check the unit injector spring

diameter, dimension B, before adjusting
and ensure that the correct tool is used
when adjusting the unit injector.
Important Adjust the spring roughly first with
a sliding caliper, then fine adjust. If both
adjustments are not carried out, the unit
injector may assume an incorrect position,
which will result in poor performance and
possible breakdown.

Dimension A= PDE31: 66,9 +/- 0,1 mm

Dimension A= PDE32: 69,9 +/- 0,1 mm
Dimension B = PDE 31: 36,5 mm
Dimension B = PDE 32: 38,5 mm

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14 Scania CV AB 2002-09:3 03:04-02
Order of adjustment for 9 litre engines

Rotate the flywheel using tool 99 309 so that the

mark on the flywheel is visible in the bottom win-
dow according to the table below.

Flywheel seen from the rear of the engine.

* Direction of rotation when adjusting.
The continuous line show which sequence
the angles should be measured on revolu-
tion 1 and the dashed line show the
sequence for revolution 2

Adjust injec-
Mark on fly- Valve
tor rocker
wheel Turn change on
arm on cylin-
(degrees) cylinder
der

1 2
TDC Down 0
2 1

144 1 4

504 2 2

288 1 5

648 2 4

72 1 5

432 2 3

216 1 3

576 2 1

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 to 35 Nm after adjus-
ting.

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03:04-02 Scania CV AB 2002-09:3 15
If reading cannot be taken from underneath:

Turn the flywheel with tool 99 309 to valve over-

lap on cylinder 1 (which corresponds to TDC
down (0°) in the lower opening). Then turn the
flywheel anti-clockwise 144° at a time and
observe the valve overlap.

Adjust unit injector

Valve overlap on Adjust the valves
rocker arm on
cylinder on cylinder
cylinder
TDC-
1 5 5
down (0°)
(144°) 2 3 3
(288°) 4 1 1
(432°) 5 2 2
(576°) 3 4 4

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16 Scania CV AB 2002-09:3 03:04-02
Order of adjustment for 12 litre engines

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.

Adjust injector
Valve change
Mark on flywheel (degrees) rocker arm on
on cylinder
cylinder

TDC Down (0°) 1 2

Valve 2, 5/ 120 480 (120°) 5 4

Valve 3, 4/ 240 600 (240°) 3 1

TDC Down (0°) 6 5

Valve 2, 5/ 120 480 (120°) 2 3

Valve 3, 4/ 240 600 (240°) 4 6

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 to 39 Nm after
adjusting.

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03:04-02 Scania CV AB 2002-09:3 17
 Order of adjustment for 16 litre engines

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.

Valve change Adjust injector rocker

Mark on flywheel (degrees)
on cylinder arm on cylinder

TDC Down (0°) 6 4 och 5

TDC Up (180°) 7 2 och 6

TDC Down (360°) 1 3 och 7

TDC Up (540°) 4 1 och 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 to 39 Nm after
adjusting.

Cylinder numbering.
The illustration shows a 16 litre marine
engine

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18 Scania CV AB 2002-09:3 03:04-02
Adjustment of PDE unit injectors 31

Special tools

Number Description Illustration

99 414 Setting tool for PDE 31. Measuring tool cabinet

Important Check the diameter, dimension B,

of the unit injector spring before adjust-
ing:
PDE 31: 36,5 mm
PDE 32: 38,8 mm
Important Adjust roughly first with a sliding
caliper and then fine adjust using the set-
ting tool 99 414. If both adjustments are
not carried out, the unit injector may
assume an incorrect position, which will
result in poor performance and possible
breakdown.
1. First, measure the distance A between plane
a and the top edge of the valve spring
washer on the PDE injector using a digital
sliding caliper.
2. Dimension A should be 66.9 mm for Dimension A= PDE 31: 66,9 +/- 0,1 mm
PDE 31. Dimension B should be 36.5 mm
for PDE 31. Dimension B = PDE 31: 36,5 mm

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03:04-02 Scania CV AB 2002-09:3 19
 ! WARNING!

Take care when carrying out the adjust-

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

3. The dimension is adjusted by undoing the

lock nut and screwing the rocker arm
adjusting screw to the correct measurement.
4. Position setting tool 99 414 with the metal
plate around the unit injector spring.

5. Finely adjust dimension A by simultane-

ously using a finger to feel that the small
piston 2 is level with the flat upper surface
of the tool. It is possible to feel differences
of less than a tenth of a millimetre.
6. If setting tool 99 414 is not available, a dig-
ital sliding caliper can also be used for fine
adjustment. Adjust the position of the
rocker arm to 66.9 mm with adjusting
screw 1.

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20 Scania CV AB 2002-09:3 03:04-02
 7. Tighten the adjusting screw lock nut to
39 Nm and remove the tool.
8. For the order of checking and adjustment,
see For the order of checking and adjust-
ment, see Order of adjustment for 9 litre
engine, or Order of adjustment for 12 litre
engine or Order of adjustment for 16 litre
engine.

Note No further checking or adjustment

of the unit injector, such as check-
ing the opening pressure, must be
done. Faulty unit injectors must
always be replaced complete.

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03:04-02 Scania CV AB 2002-09:3 21
Setting tool 99 414

Piston above or below the flat surface of the Piston level with the flat surface of setting
setting tool. Adjustment necessary. tool. Adjustment is correct.

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22 Scania CV AB 2002-09:3 03:04-02
 Enhetsinsprutare

Adjustment of PDE unit injectors PDE 32

Special tools

Number Description Illustration

99 442 Setting tool for PDE 32 Measuring tool cabinet

Important Check the diameter, dimension B,

of the unit injector spring before adjust-
ing:
PDE 31: 36,5 mm
PDE 32: 38,8 mm
Important Adjust roughly first with a sliding
caliper and then fine adjust using the set-
ting tool 99 414. If both adjustments are
not carried out, the unit injector may
assume an incorrect position, which will
result in poor performance and possible
breakdown..
1. First, measure the distance A between plane
a and the top edge of the valve spring
washer on the PDE injector using a digital
sliding caliper.
Dimension A= PDE 32: 69,9 +/- 0,1 mm
2. Dimension A should be 69,9 mm for
PDE 32. Dimension B should be 38,5 mm Dimension B = PDE 32: 38,5 mm
for PDE 32.

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03:04-02 Scania CV AB 2002-09:3 23
 ! WARNING!

Take care when carrying out the adjust-

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

3. The dimension is adjusted by undoing the

lock nut and screwing the rocker arm
adjusting screw to the correct measurement.
4. Position setting tool 99 442 with the metal
plate around the unit injector spring.

5. Finely adjust dimension A by simultane-

ously using a finger to feel that the small
piston 2 is level with the flat upper surface
of the tool. It is possible to feel differences
of less than a tenth of a millimetre.
6. If setting tool 99 442 is not available, a dig-
ital sliding caliper can also be used for fine
adjustment. Adjust the position of the
rocker arm to 69,9 mm with adjusting
screw 1.

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24 Scania CV AB 2002-09:3 03:04-02
 7. Tighten the adjusting screw lock nut to
39 Nm and remove the tool.
8. For the order of checking and adjustment,
see Order of adjustment for 9 litre engine, or
Order of adjustment for 12 litre engine or
Order of adjustment for 16 litre engine.

Obs! No further checking or adjustment

of the unit injector, such as check-
ing the opening pressure, must be
done. Faulty unit injectors must
always be replaced complete.

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03:04-02 Scania CV AB 2002-09:3 25
Setting tool 99 442

Piston above or below the flat surface of the Piston level with the flat surface of setting
setting tool. Adjustment necessary. tool. Adjustment is correct.

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26 Scania CV AB 2002-09:3 03:04-02
Feed pump

Renewal

1. Clean the outside of the feed pump. 12 litre engine

Remove the suction and pressure lines from
the feed pump. Fit protective plugs.
2. Unscrew the bolts and remove the feed
pump.
3. Place a new O-ring onto the feed pump and
lubricate with O-ring grease.
4. Fit the feed pump.
5. Connect the suction and pressure pipes.
6. Bleed the fuel system; refer to Bleeding the
fuel system.
7. Start the engine and check for leaks.

The illustration shows the 12 litre industrial

engine, The location is the same on the 12
litre marine engine and the 9 litre industrial
engine

16 litre engine

If the feed pump has been changed or if the

pipes on the suction and pressure sides of the
pump have been removed, the pump may not
succeed in pumping the fuel. This is because
there is still fuel in the fuel filter. Refer to next
page.

The illustration shows the 16 litre industrial

engine. The location is the same on the 16
litre marine engine.

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03:04-02 Scania CV AB 2002-09:3 27
 1. Detach the inlet pipe to the filter and bend it 12 litre industrial and marine engines and
downwards. 16 litre marine engine
2 1

2. Pump with the hand pump until resistance

is felt and the fuel begins to run out of the
pipe.

107 676
3. If this does not help, disconnect the outgo-
ing pipe from the feed pump. Pump until 1. Inlet pipe
fuel begins to run out of the pipe.
2. Outlet pipe
4. Bleed the fuel system; refer to Bleeding the
fuel system. 12 litre marine engine

2
1

9 and 16 litre industrial engines

1. Inlet pipe

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28 Scania CV AB 2002-09:3 03:04-02
Fuel filter

Fuel filter on 12 litre engine and 16 litre marine engine

Removal

Special tools

Number Description Illustration

587 025 Filter tongs

1. Wash the filter and the filter retainer.

03_0808

2. Unscrew the filter. Use filter tongs,

e.g. 587 025.
03_0809

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03:04-02 Scania CV AB 2002-09:3 29
 Fitting

Note All work that involves opening the

fuel system must be completed in
the following way:

Start the engine and check for leaks. Allow the

engine to run until it is running smoothly.
Check and delete any fault codes that are regis-
tered in the control unit after the work has been
completed.

1. Oil the filter O-ring.

2. Screw on the new fuel filter by hand until
the O-ring is against the filter retainer.
3. Then tighten it another half turn without
using any tools.
4. Check for correct sealing. Fill the fuel sys-
tem and bleed as described in Bleeding the
fuel system.

03_0810

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30 Scania CV AB 2002-09:3 03:04-02
Water separating prefilter

Note Close the shut-off cock when

renewing the filter.

The same intervals between changes apply as

for those for an ordinary fuel filter.

109 700
1. Shut-off cock
2. Drain valve

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03:04-02 Scania CV AB 2002-09:3 31
 Fuel filter on 9 and 16 litre industrial engines

Removal

Special tools

Number Description Illustration Tool board

588 475 Sleeve Maintenance cabinet

118 268
1. Unscrew the filter cover with a closed tool
with hexagon driver, e.g. socket 588 475.

Note Do not use an adjustable spanner

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

2. Lift out the filter cover with filter element

from the fuel filter housing. The filter hous-
ing will drain automatically once the filter
element has been removed.

Note Contaminated fuel will enter the

injectors if the drainage does not
work.

3. Undo the old filter element from the cover

by carefully bending it to one side.

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32 Scania CV AB 2002-09:3 03:04-02
Fitting

Tightening torque

Fuel filter cover 25 Nm+/- 5 Nm

Note All work that involves opening the

fuel system must be completed in
the following way:

Start the engine and check for leaks. Allow the

engine to run until it is running smoothly.
Check and delete any fault codes that are regis-
tered in the control unit after the work has been
completed.

1. Fit a new O-ring on the lid. Lubricate the

O-ring with O-ring grease.
2. Make sure the fuel filter drain has emptied
the fuel from the filter housing.

Note Contaminated fuel will enter the

injectors if the drainage does not
work.

3. Press a new filter element into the snap fas-

tener in the lid.
Important Fit the filter element into the cover
before placing it in the housing or the fil-
ter element might be damaged.
4. Press down the filter element into the hous-
ing with the cover. Torque tighten the cover
to 25 Nm +/-5 Nm.
Important Screw on the cover to the specified
torque or the filter element may break.
5. Fill the fuel system and bleed as described
in Bleeding the fuel system.

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03:04-02 Scania CV AB 2002-09:3 33
 Bleeding and pressure measuring the fuel
system

Bleeding the fuel system

12 litre engine
1. Attach a clear plastic hose to the bleeder
nipple at the front of the fuel manifold.
2. Open the bleed nipple and pump with the
hand pump until fuel free from bubbles
comes out of the hose.
• If the system is completely empty, it will
take approximately 250 strokes.
• After renewing the fuel filter, it will take
approximately 170 strokes.
• Approximately 150 strokes are required to
bleed the fuel manifold.
3. Pump an additional 20 strokes to remove
the air.
4. Close the bleeder nipple and remove the
hose. Pump with the hand pump until the
pressure relief valve opens, approximately

116 545
20 strokes.
5. Start the engine and check for leaks.

Note If the engine is difficult to start,

repeat steps 2-4 a few times.

Important Do not crank with the starter motor

for longer than 30 seconds at a time.

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34 Scania CV AB 2002-09:3 03:04-02
Bleeding the fuel system

9 and 16 litre industrial engines:

1. Attach a clear plastic hose to the bleed nip-
ple on the fuel filter housing. Run the hose
to a container to collect the fuel.
2. Open the bleed nipple and pump with the
hand pump until fuel free from bubbles
comes out of the hose.
3. Close the bleed nipple and remove the hose

16 litre marine engine:

1. Connect transparent plastic hoses to the
fuel rail bleed nipples. Run the hose to a
container to collect the fuel.
2. Open the bleed nipples and pump the hand
pump until fuel without air bubbles flows
out. This may require 130-150 strokes of
the pump.
3. Close the bleed nipples and remove the
hoses.

116 545
Industrial and marine engines:
4. Continue pumping by hand until a resist-
ance is felt, which will be after approxi-
mately:
• 20 pump strokes after renewing the fuel fil-
ter.
• 50 pump strokes after renewing a unit
injector.
5. Start the engine and check for leaks.

Note If the engine is difficult to start,

repeat steps 2-4 a few times.

Important Do not crank with the starter motor

for longer than 30 seconds at a time.

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03:04-02 Scania CV AB 2002-09:3 35
Measuring feed pump pressure

Specifications

Lowest permitted fuel pressure at 1900 rpm 5,5 bar

Lowest permitted fuel pressure at 500 rpm 4,5 bar

Special tools

Number Description Illustration Tool board

98 113 Pressure gauge 98 113 D6

00 1572

99 362 Pressure gauge

Note All work that involves opening the

fuel system must be completed in
the following way:

Start the engine and check for leaks. Allow the

engine to run until it is running smoothly.
Check and delete any fault codes that are regis-
tered in the control unit after the work has been
completed.
Two different pressure gauges can be used for
measuring the pressure. Pressure gauge 98 113
or pressure gauge 99 362.
Renew the fuel filter and bleed the fuel system
before measuring.

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36 Scania CV AB 2002-09:3 03:04-02
12 litre engines and 16 litre marine
engine
1. Connect the pressure gauge to the fuel filter
outlet connection.

Connecting pressure gauge 99 362 to a 12

litre engine and a 16 litre marine engine

9 and16 litre industrial engines

1. Connect the pressure gauge to the union on
the fuel filter.

All
116 251
2. Start the engine and increase the speed to
500 rpm. Take a pressure reading; the low- Connecting pressure gauge 99 362 to a 9
est permitted fuel pressure at 500 rpm is and a16 litre industrial engine
4.5 bar.
3. Increase the engine speed to 1900 rpm.
Take a pressure reading; the lowest permit-
ted fuel pressure at 1900 rpm is 5.5 bar.
Inspect fuel lines with connections, pressure
relief valve, fuel filter and feed pump if the fuel
pressure is too low.

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03:04-02 Scania CV AB 2002-09:3 37
 Pressure relief valve

Checking

Specifications

Lowest permitted fuel pressure 4,5 bar

Highest permitted fuel pressure 7,5 bar

Special tools

Number Description Illustration Tool board

98 113 Pressure gauge 98 113 D6

00 1572

99 362 Pressure gauge

Note All work that involves opening the

fuel system must be completed in
the following way:

Start the engine and check for leaks. Allow the

engine to run until it is running smoothly.
Delete any fault codes that are registered in the
control unit when the work is completed.
Two different pressure gauges can be used for
measuring the pressure. Pressure gauge 98 113
or pressure gauge 99 362.

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38 Scania CV AB 2002-09:3 03:04-02
12 litre engines and 16 litre marine
engine
1. Connect the pressure gauge to the fuel filter
outlet connection.

Connecting pressure gauge 99 362 to 12

litre engines and a 16 litre marine engine

16 litre industrial engines

1. Connect the pressure gauge to the back of
the left-hand fuel manifold.

9 litre industrial engine

1. Connect the pressure gauge to the back of
the fuel manifold.

All
2. Turn the starter key to the drive position.
3. Pump by hand using the hand pump. The
pressure must be at least 4.5 bar before the
pressure relief valve opens; if the pressure
relief valve opens at a lower pressure, its
opening pressure is too low and the valve
must be renewed.
4. Start the engine and increase the speed to
1500 rpm.
5. Take a pressure reading; if the pressure is
7.5 bar or above, the pressure relief valve is
blocked and must be renewed..

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03:04-02 Scania CV AB 2002-09:3 39
 Replacing an unpressurised return line

Special tools

Number Description Illustration

587 258 Pipe cutter

587 956 Pliers

12 litre engine

Fitting plastic pipe in union

1. Connect pipe with insert sleeve, ferrule and
union nut.

1. Plastic tube
2. Union nut
3. Ferrule
4. Insert sleeve
5. Union

2. Fit union and tighten union nut to the cor-

rect tightening torque.

Diameter Tightening torque

6 mm 10 Nm
12 mm 20 Nm

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40 Scania CV AB 2002-09:3 03:04-02
Fitting plastic pipe on banjo union

1. Cut the plastic pipe with pipe cutter 587 258.

See illustration for correct lengths.

A: Length = 106 mm
B: Length = 151 mm

2. Hold plastic pipe tightly with pliers

587 956 and fit union.

3. Tap in union with a plastic mallet.

Important Do not use a hammer

Important Avoid sharp bends on plastic pipes.

A kink may develop on the plastic pipe and
restrict the fuel flow. Diameter
Minimum internal
diameter of bend
6 mm 35 mm
12 mm 95 mm

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03:04-02 Scania CV AB 2002-09:3 41
16 litre engine
The pre-shaped return line is available as a spare
part. Fit as illustrated.
Important The pre-shaped return line must
not be replaced by plastic pipes sold by the
metre because of the risk of wear occur-
ring against other parts.

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42 Scania CV AB 2002-09:3 03:04-02