JOB NO.

BRANCH
UNIT MODEL R580 PUB. NO
ENG MODEL DC1603 PUB. DATE
Short Block & Ass'y Sheet
QA 4 ENG S/N
MACH S/N
REVISION NO
PAGE
Engine
SECTION Assembly
SCANIA DC16
CUST NAME
.
CHECK
NO PARTS NAME CONDITION TO BE CHECKED PICTURE, NOTES, DIAGRAM
(v)
~ Fit a new cylinder head gasket
~ Lubricate the threads and underneath the heads of the cylinder
head bolts
~ Tighten them in the following four stages in the order given in
the figure
Standard Actual
60 Nm
1 CYLINDER HEAD
150 Nm

250 Nm

+ 90°
~ Make a mark with a centre punch on the head of the bolt

~ Fit gasket
Fit the lower part of the rocker cover
ROCKER ARM HOUSING ~ Torque bolt :
2
(Lower Rocker Cover) Standard Actual
26 Nm
~ Fit valve bridges
~ Fit push rod
~ Fit bearing bracket & torque
Standard Actual
40 Nm + 60°
~ Fit the rocker arm
3 VALVE MECHANISM
!!! Screw in the bolts alternately so that they are tightened
in parallel or one of the bolts may bend
~ Torque bolt :
Standard Actual
105 Nm

!!! Make sure there is not an old sealing washer at the bottom
of the injector seat.
~ Clean the sealing surfaces in the injector aperture
~ Lubricate the unit injector O-rings with engine oil
~ Fit a new sealing washer on the unit injector. A rubber insert
will keep the sealing washer in place on the unit injector
~ Place the fork clamp with bolt in position on the unit injector
and insert it into the cylinder head.
4 INJECTOR
~ Press down the unit injector by hand as far as possible
~ Torque bolt :
Standard Actual
20 Nm

+ 75 º

~ Adjusting the unit injector with tool 99 414

~ Fit adjusting tool 99 414 with the metal plate around the unit
injector.
~ When adjusting, loosen the lock nut and adjust the unit
injector with adjusting screw .
~ The unit injector is correctly set when the small piston is level
with the flat upper surface of the tool.
Use a finger to check.
~ Refer to tables in Order of adjustment for unit injectors

Mark On Fly Wheel Valve Overlap Adjust Intake

(degrees) On Cyl Valve on Cyl
5 ADJUSTMENT INJECTOR
TDC Down (0º) 6 4 and 5
TDC Up (180º) 7 2 and 6
TDC Down (360º) 1 3 and 7
TDC Up (540º) 4 1 and 8
~ Torque tighten the lock nut to 39 Nm after adjusting

Cyl 1 Cyl 2 Cyl 3 Cyl 4 Cyl 5 Cyl 6 Cyl 7

~ 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.

QA4 DC 16 Assembly (Finish) 1

 CHECK
NO PARTS NAME CONDITION TO BE CHECKED PICTURE, NOTES, DIAGRAM
(v)
~ Adjust the valve clearance with the engine cold
~ Rotate the flywheel using tool 99 309 so that the mark on
the flywheel is visible in the bottom window according to
the table below.

Mark On Fly Wheel Valve Overlap Adjust Intake Adjust Exhaust

(degrees) On Cyl Valve on Cyl Valve on Cyl
TDC Down (0º) 6 7 and 8 4 and 5
TDC Up (180º) 7 1 and 5 2 and 6
TDC Down (360º) 1 2 and 4 3 and 7
ADJUSTMENT VALVE TDC Up (540º) 4 3 and 6 1 and 8
6
CLEARANCE
~ The intake valve clearance should be 0.45 mm and
exhaust valve clearance 0.70 mm.
~ Torque lock nut 40 Nm

Cyl 1 Cyl 2 Cyl 3 Cyl 4 Cyl 5 Cyl 6 Cyl 7 Cyl 8 Pos

Int

Exh

~ Fit the upper part of the rocker cover and torque tighten
the bolts.

Standard Actual
7 ROCKER ARM COVER
15 Nm

~ Fit the fuel manifold with overflow line.

~ Torque tighten the screws

Standard Actual
26 Nm
8 FUEL MANIFOLD
Torque tighten banjo screws on the overflow line

Standard Actual
11 Nm

~ Fit gasket and intake manifold

~ Torque bolt
Standard Actual
9 INTAKE MANIFOLD
26 Nm

~ Lubricate the joints with heat-resistant grease and fit new

gaskets
~ Fit turbo manifold & torque bolt
Standard Actual
92 Nm
TURBO MANIFOLD
10
EXHAUST MANIFOLD ~ Fit the rear exhaust manifold and junction pipe.
~ Fit the front exhaust manifold.
~ Torque bolt
Standard Actual
63 Nm

~ Fit gasket
~ Fit turbocharger & torque bolt
Standard Actual
63 Nm

~ Fit gasket & return tube

~ Torque bolt
Standard Actual
11 TURBOCHARGER
63 Nm

~ Apply oil to the inlet tube

~ Fit inlet lubricating tube

QA4 DC 16 Assembly (Finish) 2

 CHECK
NO PARTS NAME CONDITION TO BE CHECKED PICTURE, NOTES, DIAGRAM
(v)
~ Fit gasket then fit oil cooler
~ Torque bolt
Standard Actual
26 Nm

~ Assembling oil cooler as follow

OIL COOLER AND OIL i. Position the O-ring in the lid
12
CLEANER ii. Assemble the parts and tighten the rotor nut by hand
iii. Secure rotor shaft with locking compound
iv. Refit the rotor and spin it by hand to make sure it rotates
easily then tighten the lock nut
Standard Actual
15 Nm

~ Fit oil filter assembly

!!! Always used the new element

Standard Actual
13 OIL FILTER 25 Nm

~ Instal tube and connection line

~ Fit EDC Group

Torque bolt EDC CCV
Standard Actual
25 Nm

~ Fit CCV group (if any)

14 EDC & CCV GROUP
Torque bolt
Standard Actual
25 Nm

~ Instal tube and connection line

~ Fit gasket then fit coolant pump assy

Torque bolt
Standard Actual
15 COOLANT PUMP
25 Nm

~ Fit tentioner and torque bolt

Standard Actual Komponen

TENTIONER AND IDLER
16
ROLLER
50 Nm Tentioner

50 Nm Idler roller

~ Fit the fan bearing with bracket.

Standard Actual
50 Nm
17 FAN PULLEY
~ Install poly V-Belt

~ Install fuel filter and line

Torque bolt
Standard Actual
18 FUEL FILTER
25 Nm

~ Fit o-ring
~ Fit air compressor assy
~ Torque bolt
Standard Actual
50 Nm
19 AIR COMPRESSOR
~ Install lubricating & cooling line air compressor

QA4 DC 16 Assembly (Finish) 3

 CHECK
NO PARTS NAME CONDITION TO BE CHECKED PICTURE, NOTES, DIAGRAM
(v)
~ Fit priming pump
~ Torque bolt
Standard Actual
20 PRIMING PUMP 26 Nm

~ Install all sensor

~ Fit wiring harness and install clamp

WIRING HARNESS AND

21
SENSOR

REMARKS:

EXECUTED BY MECHANIC APPROVED BY SUPERVISOR VALIDATION BY QUALITY OFFICER

Name : Name : Name :

Start : Finish : Insp. Date : Insp. Date :

Signature Signature Signature

QA4 DC 16 Assembly (Finish) 4