11 and 12 Litre Engines: en-GB

01:03-02
Issue 9 en-GB
11 and 12 litre engines
Work description
M
AS 0
H 91
IN 20
ES 14
O 62
FT 5
.C 9
O
M
106 351
©
1 585 592 Scania CV AB 2011, Sweden
www.motodiesel.ir
Contents
Contents
Engine assembly General information.................................................. 4
Removing the engine................................................ 6
Fitting the engine.................................................... 14
Mounting the engine in an engine stand................. 20
Measuring the compression pressure...................... 22
Cylinder head ................................................................................ 25

Removing the cylinder head................................... 26
Fitting the cylinder head......................................... 32
Checking and adjusting the valve clearance........... 36
Removing valves .................................................... 38
Fitting valves .......................................................... 38
Checking and machining valves............................. 39
Renewing the valve stem seal................................. 40
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Renewing the valve seats........................................ 41

Machining the cylinder head .................................. 43
AS 0
Renewing the valve guides..................................... 48

Renewing the injector sleeves ................................ 49
Renewing the unit injector sleeves ......................... 51
H 91
Cylinder block Reconditioning ....................................................... 54

IN 20
Removing the cylinder liners.................................. 55

Fitting the cylinder liners........................................ 56
Measuring and machining the cylinder liner
ES 14
height ...................................................................... 57
Renewing the rear crankshaft seal.......................... 63
Renewing camshaft bearings.................................. 65
O 62
Flywheel housing ................................................................................ 71

FT 5
Removing the flywheel housing............................. 72

Fitting the flywheel housing................................... 72
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Fan coupling Removing the fan coupling .................................... 76

Fitting the fan coupling .......................................... 76
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Renewing the bearing in the fan coupling.............. 77

Renewing the front crankshaft seal ........................ 80
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Closed crankcase ventilation Troubleshooting...................................................... 83

Renewing the diaphragm........................................ 85
Crank mechanism ................................................................................ 86

Removing a piston.................................................. 87
Fitting a piston........................................................ 89
Renewing a piston .................................................. 91
Checking the connecting rod .................................. 94
Bearing bush in connecting rod.............................. 96
Flywheel Removing the flywheel........................................... 98

Fitting the flywheel................................................. 99
Support bearing .................................................... 101
External ring gear ................................................. 102
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Contents
Crankshaft Removing the crankshaft...................................... 103

Fitting the crankshaft............................................ 104
Machining crankshafts.......................................... 105
Timing gear .............................................................................. 108

Removing the intermediate gear........................... 110
Fitting the intermediate gear................................. 112
Renewing the bearing in the intermediate gear
for the compressor ................................................ 113
Renewing the bearing in the intermediate gear
for the camshaft .................................................... 114
Removing the camshaft gear ................................ 115
Fitting the camshaft gear ...................................... 116
Removing the crankshaft gear .............................. 117
Fitting the crankshaft gear .................................... 118
Removing the camshaft ........................................ 119
Fitting the camshaft .............................................. 120
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Checking the camshaft setting.............................. 123

AS 0
Lubrication system General ................................................................. 124

Measuring the oil pressure.................................... 125
Oil filter ................................................................ 127
H 91
Oil cooler .............................................................. 128

Oil filter unit ......................................................... 130
IN 20
Oil pump............................................................... 135
Turbocharger .............................................................................. 136

ES 14
Measuring radial and axial clearance ................... 138

Checks after breakdown ....................................... 140
O 62
Belt transmission .............................................................................. 141

FT 5
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Engine assembly
Engine assembly
General information
1 2
B : 0.75
A : DSC 1201 Valve clearance cold engine
Inlet : 0.45 mm
Outlet : 0.70 mm
Pump timing : 15 o
before T.D.C.
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AS 0
H 91
IN 20
ES 14
3A Made by
Typ/Type DSC 12 01
Variant
Motor/Engine No
O 62
Made by
4
3B
FT 5
123 45XX
Type DSC 12 01
119 867
Variant
.C 9
1 Smoke values.
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2 Instruction plate.
3 A Engine type, Engine serial number (on engines built before November 2000).
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3 B Engine type (on engines built from November 2000 onwards).

4 Engine serial number, stamp.
DC11 DC12
Cylinder diameter 127.0 mm 127.0 mm
Piston stroke 140.0 mm 154.0 mm
Cubic capacity 10.64 dm3 11.7 dm3
No. of main bearings 7 7
Firing sequence 1-5-3-6-2-4 1-5-3-6-2-4
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Engine assembly
DC11 DC12
Compression ratio 18:1 18.5:1
Direction of rotation (engine viewed from the rear) Anticlockwise Anticlockwise
Engine speed, low idling 500 rpm 500 rpm
Engine speed, high idling 2,400 rpm 2,400 rpm
Oil capacity 28-35 litres 28-35 litres
Oil grade refer to booklet refer to booklet
00:03-09 00:03-09
Total weight without oil and water 1,010-1,030 kg 1,020-1,040 kg
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Lubrication
AS 0
Engine oil must be applied to all moving parts

before fitting unless otherwise stated.
H 91
IN 20
ES 14
O 62
FT 5
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Engine assembly
Removing the engine
Comments
1 Drain Oil and coolant.
2 Remove The battery cover and detach the
negative cable.
3 Remove The protective casing.
4 Remove Connectors 13 (C2) and 14 (C188). Connector 14 (C188) is only fitted
on vehicles without a coordinator.
5 Disconnect The positive and negative cables.
6 Remove The clamps to release electrical cables
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13 and 14.
7 Tilt the cab according to instructions, refer to Group 18.
AS 0
8 Remove The mudguards.

H 91
IN 20
ES 14
O 62
FT 5
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Engine assembly
120231
8
2
AS 0
H 91
IN 20
ES 14
3
O 62
FT 5
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Engine assembly
Right-hand side:
Comments
9 Pull through the detached cable harnesses and place them on the engine.
10 Remove The turbocharger induction pipe. The compressor air pipe and the
crankcase ventilation hose must be
detached from the induction pipe.
11 Cover the air filter.
12 Detach The radiator water hoses. The number of hoses varies
depending on the design. Only one
hose is illustrated.
13 Detach The flexible hose for the charge air pipe.
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14 Lift off The poly-V-belt. Only on vehicles with air

conditioning.
AS 0
15 Detach The air hose for the exhaust brake

cylinder.
H 91
16 Remove The exhaust pipe.

IN 20
ES 14
O 62
FT 5
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Engine assembly
14 12 13 9
11
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120234
IN 20
15 16 10
ES 14
O 62
FT 5
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Engine assembly
Left-hand side:
Comments
17 Detach The flexible hose for the charge air pipe.
18 Detach The AC compressor and move it aside. 4 bolts.
19 Detach The compressor feed pipe.
20 Detach The water heater hose. Only on vehicles equipped with a
water heater.
21 Detach The ground connection.
22 Detach The fuel pipes.
23 Detach The oil filler hose.
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24 Detach The oil dipstick.

AS 0
25 Detach The starter motor ground connection.

26 Detach The pressure regulator pipe. Detach at the compressor.
H 91
27 Detach The positive starter motor cable.

IN 20
28 Detach The hydraulic pump and move it aside. 5 bolts in the flange.
29 Remove The gearbox. Refer to Group 5.
ES 14
99 318
Note: When removing the gearbox, engine
O 62
support 99 318 must be used to support the

engine.
FT 5
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100329
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Engine assembly
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21
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19 18
25
AS 0
H 91
IN 20
17
ES 14
18
O 62
FT 5
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27 28
23 24 26
120235
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Engine assembly
IMPORTANT! The lifting eyes on the engine are

not designed to lift the whole vehicle and 98 094
therefore must not be used for this purpose. All
three lifting eyes must be used when lifting the
engine.
On vehicles built from May 2000 onwards, the

rear lifting eyes have been removed. They may be
ordered as a spare part, part number 1 360 442.
30 Fasten lifting chain 98 094 to the rear

lifting eyes.
01_1397
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AS 0
H 91
IN 20
587 308
ES 14
31 Fasten ratchet lever hoist 587 308 to the

front lifting eye.
O 62
FT 5
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01 1398
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Engine assembly
IMPORTANT! The lifting eyes are designed to

cope with a maximum inclination angle of 30°,
when lifting an engine with the gearbox removed.
For engines without the gearbox removed, the
maximum angle is 20°.
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32 Remove the bolts in the engine brackets

AS 0
and lift out the engine.

H 91
IN 20
01_1399
ES 14
O 62
FT 5
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Engine assembly
Fitting the engine
Tightening torques
Engine bracket bolts M14: 47 Nm

M16: 130 Nm+90°
V-clamp for the charge air cooler 8 Nm
1 Lift the engine so that the engine brackets are approx. 10 mm over the engine cushions.
2 Position the bolts and lower the engine so that it rests on the engine cushions and engine
supports 99 318. Tightening torques: M14 bolts, 47 Nm and M16 bolts, 130 Nm+90°.
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3 Fit the gearbox. Refer to Group 5.

AS 0
Left-hand side:
H 91
Comments
IN 20
4 Fit The hydraulic pump. Fit a new gasket.

5 Fit The positive starter motor cable.
ES 14
6 Fit The pressure regulator pipe. At the compressor.

7 Fit The starter motor ground connection.
O 62
8 Fit The oil dipstick.

FT 5
9 Fit The oil filler hose.

10 Fit The fuel pipes. RV= upper, RA= lower.
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11 Fit The ground connection. At the compressor.

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12 Fit The water heater hose.

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13 Fit The compressor feed pipe.

14 Fit The AC compressor.
15 Fit The flexible hose for the charge air pipe. Tightening torque, 8 Nm.
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Engine assembly
10
11
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13 12 7
AS 0
H 91
IN 20
15
ES 14
14
O 62
FT 5
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9 8 5 4
6
120545
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Engine assembly
Right-hand side:
Comments
16 Fit The exhaust pipe.
17 Fit The air hose for the exhaust brake
cylinder.
18 Fit The radiator water hoses. Only one hose is illustrated.
19 Fit The flexible hose for the charge air Tightening torque, 8 Nm.
cooler.
20 Fit The turbocharger induction pipe. Tightening torque, 10 Nm, must
be applied at max. 100 rpm.
21 Fit The compressor air pipe and the
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crankcase ventilation hose on the

induction pipe.
AS 0
22 Fit The poly-V-belt.

23 Route Cables 13 and 14 to the front of the cab.
H 91
IN 20
ES 14
O 62
FT 5
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Engine assembly
22 18 19 23
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120544
IN 20
17 16 20
ES 14
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FT 5
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Engine assembly
Comments
24 Fit The mudguards.
25 Tilt the cab back to the driving position.
26 Fit The positive and negative cables.
27 Fit Connectors 13(C2) and 14(C188) Connector 14 (C188) is only fitted
on vehicles without a coordinator.
28 Fit All cables with clamps.
29 Fit The plastic cover over the central
electric unit.
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30 Fit The negative cable on the battery and

the battery cover.
AS 0
H 91
IN 20
ES 14
O 62
FT 5
.C 9
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Engine assembly
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24 30
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IN 20
ES 14
29
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FT 5
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Engine assembly
Mounting the engine in an engine stand
Engines with injection pump

Remove: Pos.
Fuel filter A
Injection pump F
Bracket E
Starter motor D
Required brackets
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Engines with PDE unit injectors

AS 0
Remove: Pos.
Fuel filter A
H 91
Control unit B
IN 20
Compressor C
Starter motor D
ES 14
Required brackets
O 62
FT 5
Engines with HPI unit injectors

.C 9
Remove: Pos.
Fuel filter A
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Control unit B
Compressor C
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Starter motor D
Feed pump G
Securely bolt the engine to the engine stand as

illustrated. Use tool 99 331.
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Engine assembly
A B
D
M
AS 0
2 3
1
H 91
99 331
IN 20
F A
A
ES 14
E
O 62
FT 5
119 929
B
G
.C 9
D C D
1 Bolt M10x30 (8 off), Tightening torque 47 Nm.

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2 Nut M16 (4 off), Tightening torque 180 Nm.

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3 Bolt M16x50 (4 off).
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Engine assembly
Measuring the compression

pressure
The following description only applies to
engines with an injection pump.
Special tools
Number Denomination Illustration Tool board

98 249 Compression tester MV
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99 310 Socket D5
AS 0
100331
99 074 Impact setting tool D1

H 91
IN 20
ES 14
99 079 Puller for injector D1

O 62
99 308 Sleeve for injector D5

FT 5
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Measuring the compression pressure is used as a The results are only intended for comparison
step in troubleshooting. If an engine is running between the cylinders. Lower compression in
unevenly, this measurement may indicate one or more of the cylinders is a sign of
whether one or more cylinders is worn or abnormal wear or damage.
damaged. There may be damage to the cylinder
head valves, cylinder liners or piston rings. The
measurement indicates which cylinder(s) should
be subject to further testing.
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Engine assembly
The compression tester can be used on many

engine types by using various accessories.
Compression tester 98 249

1 Manometer
It is essential that the battery is fully charged
when carrying out the compression test. 2 Reset valve
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Otherwise, the compression pressure obtained 3 Flexible metal hose

will be insufficient. 4 Gauge rod
AS 0
1 Shut off the fuel supply by removing fuse 5 End sleeve, diameter 21 mm
No. 20 for fuel shut off in the central 6 Spacing sleeve with support lug
electrical unit.
H 91
7 Spacing sleeve with shoulder

2 Clean around the injectors. Remove the 8 Spacing sleeve, length 6 mm
IN 20
pressure pipes for the injectors using tool 9 Spacing sleeve, length 19 mm
99 310.
10 Spacing sleeve, length 25 mm
ES 14

12 Cap nut
O 62
13 Threaded socket nut

14 Large yoke
FT 5
15 Small yoke
.C 9
IMPORTANT! Place protective caps on the

delivery valve holders on the injection pump
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and on the injectors to protect them from dirt.

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3 Remove the rocker cover.

4 Remove the injectors and copper washers.
5 Turn the engine with the starter motor a
couple of times to remove any loose soot in
the cylinders.
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Engine assembly
6 Connect the compression tester to the

injector hole for one cylinder. Use copper
washer 16 between the compression tester
and the bottom of the injector hole.
4 Gauge rod
5 End sleeve, diameter 21 mm
7 Turn the engine with the starter motor and
read off the manometer. Note the reading. 7 Spacing sleeve with shoulder
8 Reset the manometer by pressing reset 12 Cap nut (Use socket 98 542 to tighten)
button 2.
16 Copper washer
9 Move the compression tester to the next
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cylinder and continue according to

steps 7-9.
AS 0
10 Compare the readings between the

cylinders. If one or more cylinders has a
lower compression pressure than the others,
H 91
the component parts such as valves, cylinder

liners and piston rings should be checked.
IN 20
ES 14
O 62
FT 5
Gauge rod 4 contains a check valve. In the event

of a leak clean the check valve as follows:
.C 9
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1 Unbolt valve seat 18.

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4 Gauge rod
2 Remove any soot from valve 17 and valve
seat 18. Do not scratch the sealing surfaces. 17 Check valve
Use compressed air to clean gauge rod 4 18 Valve seat
internally. 19 O-ring
3 Reassemble the parts. Ensure that O-ring 19
is not damaged. Screw valve seat 18 into
place properly so that it forms a seal with
gauge rod 4.
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Cylinder head
Cylinder head
Exploded view
25
17 26
23
27
24
20
15 22
5
5 33
18 16 37
11
22
13 21
14 19
10
8
35
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4
32
AS 0
2
31
36
1
H 91
2 34
29
IN 20
6 28
3
7
30
ES 14
12 9
O 62
FT 5
01 1401
1 Cylinder head 14 Valve spring, inner 27 Spacing sleeve

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2 Core plug 15 Valve spring collar 28 Rocker cover, lower

3 Rivet plug 16 Split collet 29 Thread insert
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4 Valve guide 17 Valve bridge 30 Rocker cover gasket, lower

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5 Pin 18 Bolt 31 Flange screw

6 Pin 19 Bearing bracket 32 Rocker cover, upper
7 Cylinder head gasket 20 Shaft 33 Rocker cover, upper, on
8 Valve stem seal 21 Rivet plug cylinder 1
9 Intake valve 22 Tight-fit screw 34 Rocker cover gasket, upper
10 Valve spring 23 Rocker arm 35 Flange screw
11 Valve spring collar 24 Rocker arm 36 Instruction plate
12 Exhaust valve 25 Adjusting screw 37 Emission plate
13 Valve spring, outer 26 Nut
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Cylinder head
Removing the cylinder head (engines with injection pump)
Special tools

99 079 Extractor for injector 99 079

D1
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113 009
AS 0
99 308 Sleeve for injector 99 308 -

H 91
IN 20
00 1540
99 310 Socket -
ES 14
100331
O 62
1 Remove the pressure pipes using socket

FT 5
99 310.
2 Detach the intake manifold and remove the
.C 9
fuel return pipe.

3 Remove the cooling system bleed pipe.
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4 Remove the heat shields on the exhaust

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manifold and remove the exhaust manifold.
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Cylinder head
Note: All the valve mechanism components

must be refitted in their original positions.
Therefore, mark the parts as they are removed.
5 Remove the top part of the rocker cover.
6 Remove the shaft, rocker arms, bearing

brackets and pushrods.
7 Remove the lower part of the rocker cover.
01_1344
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AS 0
8 Undo the injector nut using socket 99 308.

H 91
99 308
IN 20
ES 14
O 62
FT 5
01 1345
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9 Pull out the injectors with tools 99 079 and

99 074.
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10 Remove the cylinder head. Mark the

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99 074
cylinder heads if more than one is being
removed at the same time.
99 079
01 1346
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Cylinder head
Removing the cylinder head (engines with PDE unit injectors)
1 Open the bleed nipple and drain the fuel

system by undoing the banjo screw 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
slugging.
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If fuel runs into the combustion

chamber, it must be removed
108 036
AS 0
immediately using a pump.
2 Clean the rocker cover and the area around

H 91
it.
IN 20

ES 14
O 62
FT 5
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4 Relieve the pressure on the valves by

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undoing the bolts on the rocker arm shaft

alternately.
4
120513
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Cylinder head
! WARNING!
Do not lean over the engine when

removing the rocker arm shaft. The unit
injector spring is pre-tensioned and can 5
come loose, causing personal injury.
Note: If the spring comes loose from the unit

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

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120519
AS 0
6 Remove the bearing bracket.

H 91
7 Remove the pushrods. 7

IN 20
9
Note: The pushrod for the unit injector is
ES 14
secured with a retaining ring. Jiggle and pull

carefully on the pushrod to loosen it.
6
O 62
8 Remove the valve bridges.

8
9 Remove the lower rocker cover.
FT 5
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10 Remove the unit injector according to the

section Removing the unit injector, steps
6-10 in booklet 03:04-01.
11 Detach the intake manifold, fuel manifold,
cooling system bleed pipe and the exhaust
manifold.
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Cylinder head
Removing the cylinder head (engines with HPI unit injectors)
1 Clean the rocker cover and the area around

it.
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AS 0
3 Relieve the pressure on the valves by

undoing the bolts on the rocker arm shaft
alternately.
H 91
IN 20
3
ES 14
O 62
FT 5
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4 Remove the rocker arm shaft.

4
120520
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Cylinder head
5 Remove the bearing bracket.

6
6 Remove the pushrods.
8
7 Remove the valve bridges.
8 Remove the lower rocker cover.
5
120516
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AS 0
9 Remove the unit injector according to the

section Removing the unit injector in
booklet 03:04-04.
H 91
10 Detach the intake manifold, fuel manifold,

IN 20
cooling system bleed pipe and the exhaust

manifold.
ES 14

O 62
FT 5
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Cylinder head
Fitting the cylinder head
Specifications
Tightening torques (applies both to engines with injection pump and

unit injector)
Cylinder head bolts:
- First tightening 60 Nm
- Second tightening 150 Nm
- Third tightening 250 Nm
- Fourth tightening 90°
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Bolt for lower rocker cover 26 Nm

AS 0
Bolt for shaft with rocker arms 105 Nm

Bolt for support bracket 40 Nm + 60°
H 91
IN 20
Tightening torques (applies to engines with injection pump)

Nut for injector 70 Nm
ES 14
Bolt for upper rocker cover 26 Nm

Nut for adjusting screw on rocker arm 35 Nm
O 62
Bolt for exhaust manifold 59 Nm

FT 5
Bolt for pressure pipe 20 +/-5 Nm

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Lubricant
Lubricant for exhaust pipe bolts and joints 561 205
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Cylinder head
All engines: 1 2 3 4
1 Check liner height; refer to the section

Measuring the cylinder liner height.
2 Fit a new cylinder head gasket.
3 The cylinder head bolts may be reused a
maximum of 3 times. Mark the bolt with a
punch mark each time you reuse it; see
148 285
figure. Make sure the bolts have no more
than 2 punch marks on top of the head. If
any of the bolts has 3 marks, it must be
replaced with a new one.
4 Lubricate the threads and underneath the

heads of the cylinder head bolts. Tighten 1
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them in the following four stages in the

order given in the figure.
AS 0
1 Torque tighten all bolts to 60 Nm

5
2 Torque tighten all bolts to 150 Nm 3
H 91
3 Torque tighten all bolts to 250 Nm

IN 20
4 Finally, tighten all bolts by 90° 4

ES 14
5 Make a mark with a centre punch on the 6
139 851
head of the bolt.
2
5 Fit the lower part of the rocker cover and
O 62
tighten the bolts to 26 Nm.

FT 5
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Cylinder head
Engines with injection pump:

1 Fit the pushrods, bearing bracket and shaft
with rocker arms and tighten the bolts to
115 Nm.
2 Adjust the valve clearance.
3 Fit the injector with a new sealing washer
and new O-rings lubricated with assembly
compound 584 084.
100036
IMPORTANT! Always fit new O-rings and a
sealing washer to injectors that have been
removed.
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70 Nm
4 Tighten the injector to 70 Nm. Use socket
AS 0
99 308.
99 308
H 91
IN 20
ES 14
01_1351
O 62
FT 5
5 Fit the upper part of the rocker cover and

tighten the bolts to 26 Nm. 26 Nm
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6 Fit the exhaust manifold and tighten the

bolts to 59 Nm. Fit the heat shields.
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7 Fit the cooling system bleed pipe.

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8 Fit the intake manifold and fuel return pipe.

9 Fit the pressure pipes and tighten the bolts
01_1353
using tool 99 310 to 20 +/- 5 Nm. Secure the

pressure pipes with clamps.
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Cylinder head
Engines with PDE unit injectors:

1 Fit the unit injector according to the section
Fitting the unit injector, steps 1-5 in booklet
03:04-01.
2 Fit the pushrods. 3
3 Fit the bearing bracket and tighten the bolts

to 40 Nm + 60°. 4
2
4 Fit the valve bridges.
IMPORTANT! Lubricate the valve bridges with

engine oil.
5 Continue according to the section Fitting the

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unit injector, steps 6-14 in booklet 03:04-01.

AS 0
309 329
H 91
IN 20
ES 14
Engines with HPI unit injectors:

1 Fit the pushrods.
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2 Fit the bearing bracket and tighten the bolts

FT 5
3
to 40 Nm + 60°.
3 Fit the unit injector and rocker arm shaft 4
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2
according to the section Fitting the unit
injector, steps 1-8 in booklet 03:04-04.
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4 Fit the valve bridges.

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IMPORTANT! Lubricate the valve bridges with

engine oil.
5 Refit the upper rocker cover and torque

309 329
tighten the bolts to 18 Nm.
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Cylinder head
Checking and adjusting the valve clearance
Special tools

99 309 Flywheel rotation tool (from D5
below)
100330
99 109 Flywheel rotation tool (from -
above)
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AS 0
Check and adjust the valve clearance with the

engine cold. The intake valve clearance should be
H 91
0.45 mm and exhaust valve clearance 0.70 mm.

IN 20
Adjusting may be carried out in one of two ways:

Alternative 1: 1 2 3 4 5 6
ES 14
114 096
Set cylinder 1 exactly at TDC after the
compression stroke. Adjust the following valves:
O Intake valve
O 62
X Exhaust valve
FT 5
cyl 1 Intake and exhaust Turn the crankshaft exactly one revolution.
Adjust the following valves:
cyl 2 Intake
.C 9
cyl 3 Exhaust
cyl 4 Intake
O
cyl 5 Exhaust
M
1 2 3 4 5 6
114 097
cyl 2 Exhaust
cyl 3 Intake O Intake valve
X Exhaust valve
cyl 4 Exhaust
cyl 5 Intake
cyl 6 Intake and exhaust
36 ©
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Cylinder head
Alternative 2:
Adjust both valves for each cylinder when at
TDC after the compression stroke. Rotate the
crankshaft 1/3 turn at a time using a flywheel
rotation tool. Adjust the valves in the firing
order for the cylinders:
99 309
1-5-3-6-2-4
01_1388
Adjusting valve clearance and PDE unit injectors
M
Order of adjustment
AS 0
Mark on flywheel Valve Adjust valves on Adjust injector

(reading taken through transition on cylinder rocker arm on
lower window) cylinder cylinder
H 91
TDC Down (0°) 1 6 2

IN 20
120° 5 2 4
240° 3 4 1
ES 14
TDC Down (360°) 6 1 5

480° 2 5 3
600° 4 3 6
O 62
FT 5
Mark on flywheel Valve Adjust valves on Adjust injector

(reading taken through transition on cylinder rocker arm on
upper window) cylinder cylinder
.C 9
TDC Up (0°) 1 6 2
300° 5 2 4
O
60° 3 4 1
M
TDC Up 6 1 5
300° 2 5 3
60° 4 3 6
Engines fitted with flywheels marked TDC Up. Fit tool 99 109 in the holes of the upper window.
Push the pinion into the external ring gear and rotate the flywheel using a ratchet handle and a
14 mm socket. Read the marking on the flywheel in the upper window in the flywheel housing.
01:03-02 ©
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Cylinder head
Removing valves
Special tools

99 322 Drift 99 322
D5
100333
1 Remove split collets, valve spring collars,
springs and valves. Press down the spring
using tool 99 322 in a press so that the split
99 322
collets can be removed.
M
2 Place the valves in a stand so that they can

AS 0
be refitted in the same position in the

cylinder head.
H 91
IN 20
01_1347
Fitting valves
ES 14
Special tools
O 62
FT 5

99 322 Drift D5
.C 9
1 Lubricate all parts well with engine oil

O
before assembly.
M
2 Insert the valve into the guide.

99 322
3 Fit the valve springs and the valve spring
collar.
4 Press together the springs in a press with
tool 99 322 and fit the split collets. Ensure
that the split collets are positioned correctly.
01 1350
38 ©
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Cylinder head
Checking and machining valves
Specifications
Intake valve
Head angle 19.5°
Minimum dimension A for ground valve 2.6 mm
Exhaust valve
Head angle 44.5°
M
Minimum dimension A for ground valve 1.8 mm

AS 0
H 91
IN 20
ES 14
Grind the valves in a valve grinding machine.

O 62
FT 5
.C 9
Minimum dimension A for ground valve

O
Check dimension A on all valves.

M
01:03-02 ©
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Cylinder head
Renewing the valve stem seal
Special tools

99 323 Drift 99 323 D5
100334
1 Remove the valve.
2 Remove the valve stem seal with a pair of

M
pliers.
AS 0
H 91
IN 20
01_1348
ES 14
3 Fit the valve.

O 62
4 Tap in a new valve stem seal carefully using

FT 5
tool 99 323 and a hammer.
99 323
.C 9
O
M
01_1349
40 ©
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Cylinder head
Renewing the valve seats
Special tools

99 384 Drift 99 384
D1-A3
110 966
99 385 Shank 99 385 D1-B1
M
AS 0
110 967
587 270 Kit with standard puller

H 91
1 Remove the valve seat inserts with an

IN 20
expanding sleeve from the kit with standard

puller 587 270.
ES 14
1
Note: Insert, for example, an aluminium sheet
between the cylinder head and counterhold to 2
protect against damage.
O 62
FT 5
.C 9
307 223
O
M
01:03-02 ©
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Cylinder head
! WARNING! 99 385
Wear protective goggles. Always turn
the cylinder head with the underside 99 384
face down while knocking out the valve
seat insert. Otherwise, there is a risk
that loose shivers of metal can cause
personal injury.
146 597
2 Press in new valve seat inserts. Use drift
99 384 and shank 99 385. Cool the drift and
valve seat to about -80°C with dry ice or
liquid air. Pressing must be carried out
M
rapidly.
AS 0
! WARNING!
H 91
Be careful when handling the cold parts

and refrigerants mentioned above. Risk
IN 20
of frost injuries.
ES 14
Oversize valve seat inserts can be fitted if the

O 62
valve seat insert position has been damaged. The

position must then be machined using tool
FT 5
587 277.
.C 9
O
M
42 ©
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Cylinder head
Machining the cylinder head
Valve seat insert, machining measurement
C C
M
AS 0
112 267
112 266
H 91
Intake valve Exhaust valve

IN 20
A = 1.9 - 2.6 mm A = 1.8 - 2.6 mm

B = 0.75 - 1.8 mm B = 0.66 - 1.8 mm
ES 14
C= diameter, 39.8+/-0.5 mm (setting dimension C= diameter, 37.9+/-0.5 mm (setting dimension

for machining tool) for machining tool)
O 62
Specifications
FT 5
When machining the cylinder head, it must not be below 124.4 mm.
.C 9
Intake valve seat

O
Seat angle 20.0°-20.5°

M
Width of contact surface A 1.9 - 2.6 mm

Valve seat insert, outer diameter 46.054 - 46.065 mm
Valve seat insert position, diameter 46.000 - 46.016 mm
Valve seat insert position, depth 11.25 - 11.35 mm
Distance B between the cylinder head face and the valve disc 0.75 - 1.8 mm
Oversize valve seat insert:
External diameter 46.254 - 46.265 mm
Cooling temperature when fitting valve seat insert approx. -80°C
01:03-02 ©
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Cylinder head
Exhaust valve seat

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

AS 0
H 91
IN 20
ES 14
O 62
FT 5
.C 9
O
M
44 ©
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Cylinder head
Tools
Number Denomination Illustration

587 277 Valve seat cutter -
106 794
587 061 Valve seat cutter
Two equally good alternatives for cutters are

specified above.
M
The following description applies to valve seat

cutter 587 277.
AS 0
Refer to Specifications for machining

measurements and oversize valve seat inserts.
H 91
1 Make sure the contact surface and magnetic

stand are level and clean. Clean the valve
IN 20
bushes.
2 Select the largest spindle that moves easily
ES 14
in the valve guide. Insert the guide spindle

and turn the feed screw to its uppermost
position.
O 62
FT 5
.C 9
O
M
3 Select the cutter and fit it.
01:03-02 ©
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Cylinder head
4 Release the quick-release catch and move

the pivot plate to the upper position with the
adjusting screw.
5 Set up the dial on the cutter adjuster using a

M
valve.
6 Adjust the cutter. Diameter 37.9 mm or
AS 0
39.8 mm, refer to Valve seat insert,

machining measurement.
H 91
IN 20
ES 14
O 62
7 Turn off the magnet (position 2). Insert the

guide spindle into the valve bush. Adjust the
FT 5
pivot plate so that the distance between the

cutter and the valve seat is approx. 1 mm.
Centre the tool precisely.
.C 9
O
M
8 Turn on the magnet (position 1).

9 Lock the quick-release catch. Make sure the
crank can be turned easily. If not, redo the
centering.
01_1233
46 ©
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Cylinder head
10 Machine the valve seat by cranking

clockwise while turning the feed screw.
Never turn anticlockwise, as this could
damage the cutter. Lubricate with cutting oil
while machining.
11 When the surface of the valve seat has been

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

AS 0
The valve seats can also be machined using

tools from kit 587 061.
H 91
IN 20
ES 14
O 62
FT 5
.C 9
O
M
01:03-02 ©
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Cylinder head
Renewing the valve guides
Special tools

99 382 Drift 99 382
D1-C6
110 864
99 383 Drift 99 383 D1-B1
M
AS 0
110 865
H 91
1 Press out the valve guides using drift

IN 20
99 383.
ES 14
O 62
FT 5
.C 9
O
2 Press in the new valve guides using drift

M
99 382. Press the guide down as far as the

drift allows, i.e. until it makes contact with
the spring seat in the cylinder head.
48 ©
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Cylinder head
Renewing the injector sleeves

The following applies to engines with an
injection pump.
Special tools

99 394 Guide 99 394 D2-A1
113 219
M
99 381 Drift 99 381 D2-A1

AS 0
H 91
110 863
IN 20
588 221 Pilot tap

ES 14
O 62 113 297
FT 5
The cylinder head must be removed when

renewing the injector sleeve. The valves do not
need removing. The illustrations show the
.C 9
cylinder head with valves removed to

demonstrate clearly the work described.
O
IMPORTANT! Mark the position of the groove

M
on the cylinder head sleeve according to the

illustration. The new sleeve must be in the same
position to allow the return and leak-off pipe to
be free.
01:03-02 ©
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Cylinder head
1 Thread the upper part of the sleeve with

pilot tap 588 221 and guide 99 394.
588 221
99 394
113 263
2 Knock out the pilot tap and sleeve from
underneath. Use a 100 mm metal rod with a
9 mm diameter.
M
AS 0
H 91
IN 20
ES 14
113 284
O 62
3 Degrease and check the contact surfaces of

the sleeve and cylinder head. Smooth off
FT 5
any burrs and irregularities that could score

the sleeve.
.C 9
4 Degrease the new injector sleeve and apply

a thin film of sealant 561 200 on the sleeve
and cylinder head contact surfaces.
O
5 Drive in the sleeve using drift 99 381.

M
IMPORTANT! Ensure that the groove in the

sleeve is located according to the marking.
113 220
50 ©
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Cylinder head
Renewing the unit injector sleeves
The following description applies both to engines with PDE and HPI unit injectors.
Special tools
PDE unit injector

99 394 Guide 99 394
D2-B1
113 219
99 395 Drift 99 395
D2-A1
M
AS 0
113 221
99 397 Extension piece with threaded 99 397

D2-C5, C6
H 91
shank
113 262
IN 20
588 221 Pilot tap

ES 14
113 297
O 62
HPI unit injector

FT 5

.C 9
99 396 Guide + pilot tap M30x1.5 D2-B1

O
120 026
99 381 Drift 99 381

D2-A1
110 863
99 397 Extension piece with threaded 99 397

D2-C5, C6
shank
113 262
588 222 Pilot tap M30x1.5

113 297
01:03-02 ©
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Cylinder head
The cylinder head must be removed when

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

pilot tap and guide.
M
AS 0
Unit injector, PDE

H 91
IN 20
ES 14
120 024
O 62
Guide 99 394
Pilot tap 588 221
FT 5
Extension piece 99 397

.C 9
O
Unit injector, HPI

M
120 023
Guide 99 396
Pilot tap 588 222
Extension piece 99 397
52 ©
www.motodiesel.ir
Cylinder head
2 Knock out the pilot tap and sleeve from

underneath. Use a 100 mm metal rod with a
9 mm diameter.
3 Degrease and check the contact surfaces of

the sleeve and cylinder head. Smooth off
any burrs and irregularities that could score
the sleeve.
4 Degrease the new injector sleeve and apply
a thin film of sealant 561 200 on the sleeve
and cylinder head contact surfaces.
113 284
M
AS 0
H 91
IN 20
5 Press in the sleeve using the drift and guide.

ES 14
O 62
PDE unit injector. HPI unit injector.

FT 5
.C 9
99 395
O
99 394
M
113 231
01:03-02 ©
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Cylinder block
Cylinder block
Reconditioning
Heat arising from the main bearings seizing and
rotating in the cylinder block will change the
properties of the material in the cylinder block.
Such cylinder blocks must be discarded.
If the main bearing seizes but does not rotate in
the cylinder block, the cylinder block can be
reconditioned. The main bearing seats must
comply with the demands on roundness given in
the table. Machining out-of-round main bearing
seats is something we do not recommend.
M
Tightening torques
AS 0
Main bearing cap Torx bolt 110 Nm +

H 91
90°
IN 20
Main bearing cap hexagon bolt 50 Nm + 90°
1 Measure the diameter at four different

ES 14
positions as illustrated. The diameter must

be measured with the main bearing caps
tightened and without main bearings.
O 62
2 Compare the dimensions with those in the

FT 5
table.
.C 9
Minimum permitted Maximum permitted Greatest permitted difference between

diameter diameter the largest and smallest diameter on the
O
same main bearing seat.

M
112.200 mm 112.222 mm 0.016 mm
54 ©
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Cylinder block
Removing the cylinder liners
Special tools

99 066 Cylinder liner puller D2
1 Mark the liners with the numbers 1-6. The

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

previously.
AS 0
Note: The mark must be made only on the

surface indicated in the illustration. Other
H 91
surfaces are for sealing. If you use a marker, you

can mark anywhere.
IN 20
ES 14
O 62
100214
FT 5
.C 9
2 Remove the cylinder liner using puller

99 066.
99 003
O
M
3 Remove the sealing ring in the cylinder 99 066

block.
100040
Cylinder liner extractor with hydraulic hole

cylinder
01:03-02 ©
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Cylinder block
Fitting the cylinder liners

1 Check the cylinder liner height according to
the section "Measuring the cylinder liner
height".
2 Make sure the interior of the cylinder block
is clean. Clean the O-ring surfaces.
3 Carefully check the cylinder liners, both
new and old, for cracks that can arise during
transport or careless handling.
Tap the liner carefully with a metal object. It

should give a clear metallic ring if it is
intact. If it is cracked, it will sound
"cracked".
M
4 Lubricate the sealing ring to be located in

AS 0
the cylinder liner with glycerol, part number

584 084, and fit it.
5 Lubricate the lower guide surface on the
H 91
cylinder liner.
IN 20
6 Turn the liner with the stamped cylinder

number facing forward and carefully tap it
01_1354
ES 14
down with a rubber mallet.

O 62
FT 5
.C 9
O
M
56 ©
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Cylinder block
Measuring the cylinder liner height
Specifications
Cylinder liner height above cylinder block 0.20 - 0.30 mm

Maximum permitted height difference on one and the 0.02 mm
same liner between measurements made at two
diametrically opposite points
M
AS 0
H 91
IN 20
Special tools
ES 14

87 198 Frame gauge D2
O 62
FT 5
98 075 Dial gauge D2

.C 9
O
M
01:03-02 ©
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Cylinder block
1 Thoroughly clean the cylinder block liner

shelf, the face around the cylinder, the
cylinder liner shelf and the upper face of the
cylinder liner.
2 Fit the cylinder liner without O-rings and
push down using two tension lugs 98 515.
Tighten the bolts to 20 Nm.
D
IMPORTANT! The tension lug bolts must not C
C
be tightened more than 20 Nm. Otherwise the
cylinder liner may be damaged. B A
3 Place frame gauge 87 198 with dial gauge
100024
98 075 on the liner and zero the dial gauge
to the liner (A). Slide the tip of the dial
M
gauge over to the cylinder block (B) and A Measured surface on the cylinder liner
measure the height of the liner (A-B) as B Measured surface on the cylinder block
AS 0
illustrated. Measure each liner at two C Tip of dial gauge

diametrically opposite points.
D Height of the cylinder liner D = A-B
H 91
IN 20
ES 14
O 62
4 The cylinder liner must be slightly above

FT 5
the face of the cylinder block.

5 Height of cylinder liner D (= A-B) over the
.C 9
cylinder block after machining must be:

0.20-0.30 mm.
O
6 The difference between two diametrically

opposite points on the same cylinder liner
M
may be max. 0.02 mm.
58 ©
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Cylinder block
Machining cylinder liner height

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

liner height, the cylinder liner seat must always
be machined.
M
Tolerances for liner height

AS 0
Lowest permissible cylinder liner height 0.15 mm

before machining
H 91
Permissible cylinder liner height on 0.20-0.30 mm

engines with machined liner seats
IN 20
Desired measurement when machining 0.25 mm

ES 14
Example of calculation of cutting depth

Height required 0.25 mm
O 62
Current cylinder liner height 0.14 mm

Increase in cylinder height = 0.25-0.14 0.11 mm
FT 5
Shim thickness 0.2 mm

Material to be removed = 0.2-0.11 0.09 mm
.C 9
O
M
01:03-02 ©
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Cylinder block
1 Clean the contact surface between the

setting ring (which is included in the
extension kit) and the top plane of the
cylinder block.
Note: It is important for the surface to be

cleaned thoroughly, otherwise the cylinder liner
seat may be cut to the wrong depth or may be
slanted.
2 Fit extension 588 672 on the cutter 587 512.

M
AS 0
H 91
IN 20
ES 14
3 Set the depth of the extension to 206 mm.

O 62
FT 5
.C 9
O
M
60 ©
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Cylinder block
4 Position the setting ring over the relevant

cylinder and then position the cutter.
Energise the magnet on the cutter by setting
the switch to position 1.
5 Check that the tool (cutter) does not touch

the edge of the liner seat when the cutter is
fitted in the setting ring. Otherwise the
vertical feed screw must be wound up until
the cutter is released from the liner seat.
M
AS 0
H 91
IN 20
ES 14
O 62
FT 5
6 Lift the rapid feed ring and move the cutter

.C 9
by hand until it is positioned above the liner

seat surface without including the cylinder
O
block walls.
M
01:03-02 ©
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Cylinder block
7 Wind round and at the same time turn the

vertical feed screw clockwise until the
cutter just touches the liner seat.
8 Lift the rapid feed ring and move the cutter

back so that it is within the liner seat
surface.
M
9 Adjust the vertical feed screw in order to

start machining. Maximum feed per cut =
AS 0
0.05 mm. If 0.05 mm is not enough, several

cuts may be required until the required
position is reached.
H 91
10 Wind clockwise with an even movement.

IN 20
Hold in the horizontal feed screw with the

other hand at the same time. The cutter will
be fed horizontally at 0.13 mm per turn.
ES 14
Wind carefully when the cutter starts to

approach the outer edge of the liner seat.
Release the horizontal feed screw when the
O 62
cutter has gone over the edge so that feeding

stops.
FT 5
IMPORTANT! Never wind the cylinder liner

.C 9
cutter anticlockwise; otherwise the cutter will

break.
O
M
62 ©
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Cylinder block
Renewing the rear crankshaft seal
Special tools

99 410 Assembly tool 99 410 D5
116 247
99 058 Drift (used together with 99 410 D7
when renewing 185 mm
crankshaft seal)
M
156 015
AS 0
1 Remove the flywheel according to the

section Removing the flywheel.
H 91
2 Remove the crankshaft seal using a

screwdriver. Take care not to scratch the
IN 20
sealing surfaces on the crankshaft and the

flywheel housing. Alternatively a self-
ES 14
tapping screw can be screwed into the

crankshaft seal so that the crankshaft seal
can be pulled out with a slide hammer.
O 62
01_1356
FT 5
.C 9
O
M
01:03-02 ©
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Cylinder block
Note: When working with 175 mm crankshaft

seal: The crankshaft seal must be fitted dry and
on no account must it be lubricated. The sleeve
in the seal must be left in place. Do not touch the
sealing lip with your fingers.

seal: The crankshaft seal must be fitted dry and
on no account must it be lubricated. Remove the
plastic ring protecting the sealing lip. Do not
touch the sealing lip with your fingers.
3 When working with 175 mm crankshaft

seal: Fit a new crankshaft seal using tool
99 410. Place the crankshaft seal on the tool
315 234
M
and fasten the tool with the bolts.

When working with 185 mm crankshaft
AS 0
seal: Fit a new crankshaft seal using tools

99 058 and 99 410. Place the crankshaft seal
on 99 058 and secure 99 410 to the
H 91
crankshaft.
IN 20
4 Turn the tool clockwise until it stops in

order to attain the correct crankshaft seal
ES 14
position.

O 62
seal: The edge of drift 99 058 will stop against

the recess in the flywheel housing.
FT 5
.C 9
116 612
O
5 Fit the flywheel according to the section

M
Fitting the flywheel.
64 ©
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Cylinder block
Renewing camshaft bearings
Special tools

99 373 Tool for renewing camshaft D5
bearings
99 003 Hydraulic cylinder 99 003 H1

M
109 403
AS 0
99 004 Pneumatic hydraulic pump H1

H 91
109 402
1 Remove the camshaft according to section

IN 20
Removing the camshaft.

2 Remove the camshaft blanking piece at the
ES 14
front of the engine.

O 62
Note: Wipe around the edges and the bearing

seat surfaces around the old bearings to avoid
FT 5
damaging the contact surfaces when fitting the

new bearings.
.C 9
3 Wipe the bearing seat surfaces clean around

the old bearings.
O
M
01:03-02 ©
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Cylinder block
Note: The recess in the bearing joint must be

turned towards the front of the engine.
4 Place the new bearings in the space between

the bearing seats for the camshaft.
109 690
Tool 99 373
M
AS 0
H 91
IN 20
ES 14
O 62
5 Place the flange nuts on the threaded stem, 1 Threaded stem with eight flange nuts
FT 5
included in tool 99 373, as illustrated. 2 Press drift

3 Flange
.C 9
O
M
1 2 3 4 5 6 7
8
164
328
492
656
820
109 297
984
66 ©
www.motodiesel.ir
Cylinder block
6 Take the threaded stem and insert the end

with flange nut number 1 from the rear of
the engine past the rearmost bearing seat.
Insert it further through the bearing seats
and the new bearings until flange nut 1
protrudes from the front of the engine.
7 Screw the flange part of tool 99 373

M
securely onto hydraulic cylinder 99 003

AS 0
with two M6x12 bolts. Press together

cylinder 99 003 if not already in neutral
position.
H 91
IN 20
ES 14
O 62
8 Screw the flange securely to the hydraulic

FT 5
cylinder at the rear of the engine with two

M10x25 bolts.
9 Screw flange nut 8, from tool 99 373, onto
.C 9
the threaded stem.

O
M
01:03-02 ©
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Cylinder block
10 Hang a new bearing on the stem at the front

of the engine.
11 Place the press drift on the threaded stem
and place the bearing on the drift.
Note: The recess in the bearing joint must be

turned towards the flange on the press drifts.
Secure the bearing on the drift by placing the
spring-loaded ball in an oil way. The bearing is
correctly located on the drift when the ball and a
marking hole are centred on the bearing oil hole.
M
AS 0
109 689
H 91
The bearing is correctly located on the drift

when the ball and a marking hole are centred on
IN 20
the bearing oil hole.

ES 14
12 Clean around the bearing contact surface.
Note: The marking on the drift must be

O 62
uppermost and vertical so that the oil hole in the

bearing will be central to the oil ways.
FT 5
.C 9
O
M
13 Hold the press drift with the new bearing

against the old. Secure the threaded stem
between the press drift and hydraulic
cylinder 99 003 by tightening flange nut 8
on the stem.
Secure the threaded stem by tightening

flange nut 8.
68 ©
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Cylinder block
Note: The new bearing is in the correct position

before the old bearing is completely released.
The new bearing has the correct position when
the distance from the front edge of the cylinder
block to the front edge of the press drift has a
permitted value according to the table. -12 mm
means that the drift should protrude 12 mm out
of the cylinder block.
Table for correctly located camshaft

bearings
Camshaft bearing No. Distance (mm)
1 -12 to -14
2 150 to 152
M
3 314 to 316
4 478 to 480
AS 0
5 642 to 644
6 806 to 808
7 970 to 972
H 91
Check measurement of bearing number 1.

IN 20
ES 14
14 Press in the new bearing at the same time as

O 62
pressing out the old bearing with hydraulic

FT 5
cylinder 99 003 and hydraulic pump 99 004.

Measure to check that the bearing is
correctly positioned.
.C 9
15 Carefully knock with a plastic hammer to

release the old bearing.
O
M
01:03-02 ©
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Cylinder block
16 Remove the press drift by detaching flange

nut 8 and pushing in the threaded stem.
Note: The races for camshaft bearing numbers

2, 4 and 6 have two oil ways. The others only
have the lower one.
17 Check that the bearing oil hole is central to

the cylinder block oil ways.
18 Repeat the procedure for the remaining
bearings.
M
Pressing out/pressing in bearing number 2.

AS 0
H 91
IN 20
ES 14
O 62
19 Clean the sealing surface, take a new gasket

FT 5
and fit the blanking piece for the camshaft at

the front of the engine.
20 Refit the camshaft according to the section
.C 9
Fitting the Camshaft. Then check the

camshaft setting. Check measurement of bearing number 2.
O
M
70 ©
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Flywheel housing
Flywheel housing
Exploded view
26
17 20
23 19 18
7 21 21
M
22
17
5
9
8
24
AS 0
10
25
24 4
H 91
12
IN 20
1 15
13 16
ES 14
14
15
16
11
6
28
O 62
27 33
FT 5
32
33
31
.C 9
100029
30
29
O
1 Flywheel housing 12 Lifting eye 23 Stud

M
2 Sealing ring 13 Stud 24 Pin

3 Bolt 14 Stud 25 Flange screw
4 Washer 15 Spacer 26 Crankshaft
5 Flange screw 16 Lock nut 27 Crankshaft gear
6 Flange screw 17 Rotational speed sensor 28 Pin
7 Flange screw 18 Flange screw 29 Flywheel
8 Cover 19 Clamp 30 External ring gear
9 Gasket 20 Clamp 31 Bolt
10 Flange screw 21 Bolt 32 Ball bearing
11 Cover 22 Timing gear plate 33 Circlip
01:03-02 ©
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Flywheel housing
Removing the flywheel housing

1 Remove the starter motor.
2 Detach and move the power steering
hydraulic pump to one side.
3 Remove the flywheel housing.
100025
M
Fitting the flywheel housing

AS 0
Specifications
H 91
Tightening torques
IN 20
Bolts for flywheel housing M10: 50 Nm

M12: 90 Nm
ES 14
Sealant
O 62
Sealant for flywheel housing 816 064

FT 5
Tools
.C 9

O
588 189 Air-operated spray gun - -

M
584 117 Adapter for cartridge - -

584 118 Nozzle - -
72 ©
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Flywheel housing
1 Remove all old sealing compound on the

sealing surfaces of the flywheel housing and
timing gear plate. Clean off any oil and
grease using an alcohol based cleaning
agent.
IMPORTANT! Clean thoroughly, as the sealing

surfaces must be completely free of grease.
2 Apply sealant to the flywheel housing using

a nozzle. The width of the bead should be
between 0.8 and 1.2 mm. Follow the pattern
as illustrated.
M
AS 0
H 91
Apply sealant to the flywheel housing on the side

towards the timing gear plate.
IN 20
IMPORTANT! Ensure that you apply sealant Apply sealant around the bolt holes marked with
inside the bolt holes, but without allowing arrows.
ES 14
sealant into the crankcase. The sealant may

From engine serial number 5 747 863 onwards,
block channels and nozzles. This is particularly
bolt A has been added and bolt B has been
important to bear in mind around oil ways,
moved.
O 62
where the flow of oil to the air compressor or

injection pump can be blocked.
FT 5
IMPORTANT! Assembly must be completed

within 25 minutes of starting to apply the
.C 9
sealant.
O
3 Fit the flywheel housing against the timing

gear plate.
M
Note: The bolts are of various sizes and lengths.

Ensure that they are fitted in the correct places.
01:03-02 ©
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Flywheel housing
4 Tighten the M12 bolts to 90 Nm and the

M10 bolts to 50 Nm.
M10 x 30
M10 x 60
M10 x 30 M10 x 30
M10 x 30 M10 x 30
M
M10 x 60
M10 x 60
AS 0
120 594
100 053
M10 x 30
H 91
M10 x 30
Flywheel housing and timing gear plate from
IN 20
Flywheel housing and timing gear plate, up to engine serial number:

and including engine serial number:
Scania Södertälje 6 123 710
Scania Södertälje 6 123 709
ES 14
Scania Latin America 3 138 539

Scania Latin America 3 138 538
O 62
FT 5
.C 9
O
M
M10 x 60
M12
100050
M12
74 ©
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Flywheel housing
5 Refit the hydraulic pump for the power steering gear.

6 Fit the starter motor.
M10 x 60 M10 x 60
M
AS 0
H 91
M10 x 30 M10 x 30
IN 20
120 596
120 595
M10 x 80 M10 x 60 M10 x 80 M10 x 45
ES 14
Engines with injection pump, later version Engines with unit injectors
O 62
FT 5
.C 9
O
M10 x 60
M
M10 x 80
100052
M10 x 60
Engines with injection pump, earlier version
01:03-02 ©
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Fan coupling
Fan coupling
The following description applies to an old design of fan coupling.
Applies up to and including engine serial number:
Scania Södertälje: 5719193
Scania Zwolle: 5719106
Scania Angers: 5718890
The new design is described in the section Front crankshaft seal.
Removing the fan coupling

M
1 Remove the fan and belt.

AS 0
2 Remove the oil sump.

3 Undo the screw for the pulley.
H 91
4 Remove the fan bearing housing with the

IN 20
pulley.
ES 14
Fitting the fan coupling

O 62
Tightening torques
FT 5
Screw for pulley 290 Nm

.C 9
Bolts for oil sump with unmachined surface 32 Nm

Bolts for oil sump with machined surface 26 Nm
O
1 Fit the fan bearing housing onto the engine.

M
2 Screw in the screw for the pulley. Tighten

290 Nm
the screw to 290 Nm.
3 Fit the oil sump.

4 Fit the belt and fan.
01_1383
76 ©
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Fan coupling
Renewing the bearing in the fan

coupling
Special tools

87 752 Drift -
98 334 Counterholding tube -

M
98 433 Drift -
AS 0
H 91
98 622 Press drift D1

IN 20
ES 14
98 647 Support drift G2

O 62
FT 5
Other tools
.C 9

O
587 318 Puller -

M
113 172
587 321 Puller -
01:03-02 ©
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Fan coupling
Removal
1 Remove the screw for the pulley and extract
the pulley using puller 587 321 and support
drift 98 647.
98 647
587 321
01_1373
2 Remove the retaining ring.
98 622
M
3 Press the shaft out of the fan coupling

housing using drift 98 622.
AS 0
H 91
IN 20
01_1374
ES 14
4 Extract the bearing inner race from the

spindle using pullers 587 318 and 587 319
O 62
and drift 98 647.

587 319
FT 5
98 647
.C 9
01_1375
O
587 318
M
5 Place the extracted bearing inner race on the

bearing in the fan housing. Press the bearing 87 752
out of the fan housing. Use drift 87 752 and
counterholding tube 98 334.
98 334
01_1376
78 ©
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Fan coupling
Fitting
1 Press the new ball bearing into the fan
coupling housing using drift 98 433 and
counterholding tube 98 334.
98 433
98 334
01_1380
M
2 Fit the retaining ring.

AS 0
H 91
IN 20
ES 14
01_1381
O 62
FT 5
3 Press the spindle into the housing.

4 Push the pulley onto the fan coupling
.C 9
spindle.
O
M
01 1382
01:03-02 ©
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Front crankshaft seal
Renewing the front crankshaft seal

The description applies from the following engine serial numbers onwards:
Scania Södertälje: 5719194
Scania Zwolle: 5719107
Scania Angers: 5718891
Crankcase ventilation and front crankshaft seal
22
21
M
24
23
AS 0
20
19
18
H 91
16 17
15
14
13
IN 20
12
11
4
ES 14
10
9
8
O 62
7
6
FT 5
5
3
2
108 968
.C 9
1
O
M
1 Nut 9 Pin 17 Hose

2 Fan 10 Gasket 18 Hose clamp
3 Stud 11 Cover plate 19 O-ring
4 Flange screw 12 Rivet 20 Pipe
5 Pulley 13 Shaft journal 21 Flange screw
6 Shaft seal 14 Flange screw 22 Gasket
7 Flange screw 15 Cover 23 Torsion damper
8 Housing 16 Diaphragm 24 Flange screw
80 ©
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Tightening torques
Bolts for crankcase ventilation pipe against rocker cover 12 Nm

Bolts for torsion damper 80 Nm + 45°
Special tools

99 374 Press tool for crankshaft seal D5
1 Remove the radiator according to the

M
description in Group 02, Cooling system.

AS 0
2 Remove the fan ring and the fan. Keep the

fan upright.
H 91
Note: The crankshaft seal seals against the

IN 20
pulley. Handle the pulley with care.

ES 14
O 62
FT 5
.C 9
O
M
3 Remove the poly-V-belt and pulley.

108 969
Sealing surface for crankshaft seal
01:03-02 ©
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4 Prise off the sealing ring using a

screwdriver. Take care not to damage the
sealing surface in the housing.
5 Wipe clean the sealing ring seat in the
housing.
Note: The crankshaft seal must be fitted dry and

must not be lubricated. The sleeve in the seal
must not be removed until just before the
crankshaft seal is to be fitted on the engine.
6 Place the new seal in tool 99 374 and press

it into place by tightening the bolts
alternately. The seal is correctly fitted when
the tool reaches the bottom.
M
AS 0
H 91
IN 20
ES 14
O 62
7 Remove the tool. Fit the bolts into the The seal is correctly fitted when the tool reaches
FT 5
threaded holes and use as a handle to make the bottom.

removal easier.
8 Wipe clean the sealing surface on the pulley
.C 9
and fit it immediately.

O
9 Fit the fan belt.

M
10 Fit the fan and fan ring.

11 Refit the radiator according to the
description in Group 02, Cooling system.
82 ©
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Closed crankcase ventilation
Closed crankcase
ventilation
Troubleshooting
Increased blow-by in engine
Blow-by is the flow of gases through the engine
crankcase and out via the crankcase ventilation.
The closed crankcase ventilation system is very
sensitive to changes in blow-by in the engine. If
the blow-by increases, the amount of gas
passing through the crankcase ventilation will
also increase. The crankcase gases can then take
M
with them small drops of oil from the crankcase.

When the amount of oil increases, the oil
AS 0
separator will not be able to fulfil its task of

separating out all the oil. Oil will then
accompany the air into the charge air system.
H 91
Causes of an increase in blow-by are leaking

IN 20
piston rings, valve guides, turbocharger or

compressor. Gas leakage from the charge air
system down to the crankcase also gives rise to
ES 14
increased blow-by and therefore increased oil

carryover from the crankcase ventilation.
O 62
FT 5
.C 9
O
M
Too much oil in the oil sump

If the engine is filled with too much oil, the
excess will splash around in the crankcase and
be atomised. This means that the crankcase
gases will contain a large amount of atomised
oil and that the crankcase ventilation will not be
able to separate the oil properly. This will result
in a large oil carryover from the crankcase
ventilation.
01:03-02 ©
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Air leak in the crankcase

In a well-functioning closed crankcase
ventilation system, there should be a certain
amount of vacuum in the crankcase. If air enters
the crankcase from outside, the flow of gas from
the crankcase through the crankcase ventilation
will increase. This is the same as an increase in
blow-by and will lead to an increase in oil
carryover.
An air leak in the crankcase can be caused by:
• The oil filler cap is not properly secured.
• The rubber plug on the oil dipstick handle is
not located correctly.
M
AS 0
H 91
Seal the oil dipstick connection as follows:

IN 20
1 Pull the rubber seal, at the point shown by

ES 14
the arrow, towards the dipstick handle.
2 Press the oil dipstick down into the engine

O 62
until it stops against the plastic pipe.
111 675
3 Press forward the rubber seal so that it
FT 5
forms a seal with the plastic pipe.

.C 9
O
M
Damaged turbocharger
Oil can leak into the charge air system from a
damaged turbocharger.
Refer to Workshop Manual 01:03-02,
Turbocharger, for checking the turbocharger.
84 ©
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Renewing the diaphragm

1 Remove the belt.
2 Remove the idler roller on the fan coupling
housing.
01_1377
3 Remove the crankcase ventilation cover.
M
AS 0
H 91
IN 20
ES 14
01 1378
O 62
4 Remove the diaphragm and spring.

FT 5
The spring has been removed from January

1999 onwards. On vehicles fitted with the
spring, the spring does not need to be
.C 9
refitted.
O
5 Fit the new diaphragm.

M
6 Fit the cover.

7 Fit the idler roller.
8 Fit the belt.
120 015
01:03-02 ©
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Crank mechanism
Crank mechanism
Exploded viewM
AS 0
H 91
IN 20
ES 14
O 62
FT 5
.C 9
O
M
1 O-ring 11 Aluminium piston

2 Scraper ring 12 Gudgeon pin
3 Cylinder liner for steel piston 13 Circlip
4 Cylinder liner for aluminium piston 14 Bearing bush
5 O-ring 15 Connecting rod
6 Compression ring 16 Crankshaft
7 Compression ring 17 Bearing shell
8 Oil scraper ring 18 Bearing cap
9 Circlip 19 Flange screw
10 Steel piston
86 ©
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Crank mechanism
Removing a piston
1 Remove the cylinder head according to the
section Removing the cylinder head.
Industrial and marine engines have a scraper
ring in the liner. See the next page for
removal of the scraper ring.
2 Remove the oil sump.
3 Remove the piston cooling nozzle in the
cylinder block.
IMPORTANT! The piston cooling nozzle must

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

them instead.
AS 0
4 Remove the connecting rod cap and

H 91
connecting rod bearing shells. Protect the

oilway in the crankshaft e.g. by winding
IN 20
tape around it with the adhesive side out.

5 Mark the piston before removing; the
ES 14
connecting rod is marked. The parts must be

refitted in the same place and position. Lift
out the piston and connecting rod.
O 62
FT 5
Note: Always check the connecting rod as

described in Checking the connecting rod, if the
cylinder has seized, been filled with water or
.C 9
had a broken valve. Bent connecting rods must

not be straightened.
O
M
01:03-02 ©
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Crank mechanism
Industrial and marine engines.

Removal of the scraper ring in the
lining
If the scraper ring is so firmly seated that it
cannot be removed by hand, use the following
method:
1 Turn the crankshaft so that the piston is
moved as far down as to allow the plate
99 168 to be accommodated below the
scraper ring.
2 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.
3 Position plate 99 168 on the piston crown.
M
4 Press a piston ring into the liner until it is

AS 0
below the scraper ring.

5 Fit handle 99 168 on impact setting tool
H 91
99 074. If it proves difficult to fit the bolt in

the handle, the head of the bolt can be
IN 20
ground down slightly. Take care not to

weaken the bolt if this is done.
ES 14
6 Screw the bolt into the plate.

7 Pull up the plate until it abuts against the
O 62
piston ring pressed into the liner.

8 Drive out the scraper ring with the impact
FT 5
setting tool.
9 Fit the scraper ring in place after the piston
.C 9
has been fitted.

O
M
88 ©
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Crank mechanism
Fitting a piston
Tightening torques

Connecting rod cap with 4 bolts 20 Nm + 90°
Connecting rod cap with 2 bolts 50 Nm + 90°
Piston cooling nozzle 23 Nm
Special tools
M
AS 0

98 212 Piston ring compressor 98 212
D3
H 91
IN 20
110 060
ES 14
99 380 Assembly tool

O 62
FT 5
1 Lubricate the piston, piston rings, cylinder

liner and piston ring compressor with
.C 9
engine oil.
2 Remove the protection on the connecting
O
rod race and lubricate it.

M
3 Turn the piston rings so that the gaps are

distributed around the piston.
4 Fit the upper connecting rod bearing shell to
the connecting rod and lubricate the bearing
surface.
5 For engines with a scraper ring in the lining:
Fit the assembly tool 99 380 in the lining in
place of the scraper ring.
01:03-02 ©
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Crank mechanism
6 Insert the connecting rod bearing shell in the

connecting rod cap, lubricate the bearing
surface and fit the connecting rod cap.
7 Fit the connecting rod and piston. The arrow
on the piston must be facing the front of the
engine. Applies only to aluminium pistons;
steel pistons are symmetrical. Clamp the
piston ring compressor 98 212 and push the
piston into the cylinder.
120 029
M
The arrow must be facing forwards in the

direction of the engine.
AS 0
H 91
8 For connecting rod cap with four bolts: 1 2 3 4

IN 20
Lubricate the bolts, fit them and torque

tighten to 20 Nm + 90°. The bolts may only
be reused a maximum of 3 times. Mark the
ES 14
bolt with a punch mark each time you reuse

it; see figure. If a bolt already has three
marks, it must be renewed.
O 62
148 285
For connecting rod cap with two bolts:
FT 5
The bolts must not be reused. Always

replace the bolts with new ones. Lubricate
the bolts, fit them and torque tighten to
.C 9
50 Nm + 90°.
9 Fit the piston cooling nozzle. Tightening
O
torque 23 Nm.
M
IMPORTANT! The piston cooling nozzle must

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

11 Fit the cylinder head. Tighten the cylinder
head bolts according to the section Fitting
the cylinder head.
90 ©
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Crank mechanism
Renewing a piston
Specifications
Piston rings
Number of compression rings 2 off
Gap:
1st ring (upper), engines with aluminium pistons 0.35 - 0.60 mm
1st ring (upper), engines with steel pistons 0.35 - 0.60 mm
2nd ring 0.55 - 0.80 mm
M
Maximum clearance in groove, 2nd ring 0.25 mm

Number of oil scraper rings 1 off
AS 0
Gap 0.40 - 0.60 mm

Maximum clearance in groove 0.25 mm
H 91
IN 20
Turn the rings marked "TOP" with the mark

face up.
ES 14
Special tools
O 62

FT 5
87 362 Drift 87 362 D3

.C 9
O
110 315
Other tools

587 309 Piston ring expander D3
106 796
01:03-02 ©
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Crank mechanism
1 Place the connecting rod in a vice with soft

jaws. Remove the gudgeon pin retaining
rings.
100 209
2 Push out the gudgeon pin using drift 87 362.
M
87 362
AS 0
H 91
100 210
IN 20
3 Remove the piston rings using tool 587 309.

Take care not to scratch the piston skirt 587 309
ES 14
surface with the piston rings.

O 62
FT 5
.C 9
O
4 It is possible that the graphite coating will

M
disappear after washing graphite coated

pistons in a washer. This does not matter
after they have been in use for a while. New
pistons, however, should be washed with
care in e.g. white spirit.
5 Clean the piston and its rings thoroughly
without scratching the sides of the ring
grooves. Clean the oil holes in the piston
using a suitable drill bit.
92 ©
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Crank mechanism
6 Make sure the piston ring gaps do not

exceed the permitted limit. Place the piston
rings inside the cylinder liner and measure
the gap with a feeler gauge. Refer to
Specifications for permitted gap.
7 Fit the piston rings using tool 587 309. The
oil scraper ring has an expander. Pistons
rings marked with TOP must be turned with
TOP face up.
8 Oil all bushes, the gudgeon pin hole and the
gudgeon pin before assembling.
9 Fit the piston skirt to the piston crown and
fit one of the gudgeon pin retaining rings.
10 Put the piston onto the connecting rod so
M
that the arrow marks on the piston are facing

forwards towards the engine. Applies only
AS 0
to aluminium pistons; steel pistons are

symmetrical.
H 91
120 029
IN 20
The arrow must be facing forwards in the

ES 14
direction of the engine. Short end of the

connecting rod on left hand side.
O 62
FT 5
.C 9
O
11 Insert the gudgeon pin using tool 87 362 and

M
fit the second retaining ring for the gudgeon

pin.
01:03-02 ©
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Crank mechanism
Checking the connecting rod
Specifications
Connecting rod cap with 4 bolts 20 Nm+90°

Connecting rod cap with 2 bolts 50 Nm+90°
Connecting rod and bearing cap marked 1 to 6.
Tools

M
587 110 Test apparatus -

AS 0
H 91
IN 20
ES 14
Check the connecting rods using tool 587 110.

Check that the gudgeon pin bush is undamaged
and then proceed as follows:
O 62
1 Fit the connecting rod cap as marked and

FT 5
tighten the bolts.

2 Mount the connecting rod in the tool using
.C 9
the expander and fit the corresponding

gudgeon pin in the gudgeon pin bush.
O
3 Then apply the indicator to the gudgeon pin.

M
94 ©
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Crank mechanism
Check whether the connecting rod is twisted

with the indicator studs horizontal.
01 1216
M
Checking whether the connecting rod is twisted.

AS 0
Check whether the connecting rod is bent with

the indicator studs vertical.
H 91
IN 20
ES 14
O 62
FT 5
The distance between the indicator studs on the

tool illustrated here is 75 mm. The distance
.C 9
01_1215
between one of the indicator studs and the

measuring surface must be max. 0.1 mm when
O
measured using this tool. Check with a feeler Checking whether the connecting rod is bent.
gauge.
M
Also check whether the connecting rod is bent in

an S-shape. This is done by measuring the
distance between the outside of the connecting
rod bush and the level surface of the tool. Turn
the connecting rod around and measure the
corresponding distance. The deviation must not
be greater than 0.6 mm.
01_1227
Checking whether the connecting rod is bent in

an S-shape
01:03-02 ©
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Crank mechanism
Bearing bush in connecting rod
Renewal
Special tools

99 403 Tool for renewing bearing bush 99 403
1
2
115 527
M
AS 0
H 91
IN 20
Use tool 99 403 when renewing the bearing 99 403

bush.
ES 14
3
The tool comprises three parts:
1. Pressplate with guide pin
O 62
2. Press drift
FT 5
3. Supports
.C 9
There are different supports, depending on the 1

2
115 527
engine type. The support marked D is for the

DC11 and DSC/DC12.
O
M
96 ©
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Crank mechanism
1 Place the connecting rod on the pressplate

so that the wide end of the connecting rod
rests on support D. Turn the press drift with
the smaller diameter against the bearing
bush and press it out.
115 528
2 Turn the press drift and mount a new
bearing bush onto it. Press in the bearing
bush.
M
AS 0
H 91
115 529
IN 20
ES 14
After pressing in a new bearing bush, it must be d

finish-turned. This requires special equipment.
Measurements as illustrated.
O 62
0.007
FT 5
0.008
0.008 A
.C 9
O
M
115 537
Diameter, d = 54.030-54.043 mm.

Surface quality = 0.6 Ra.
01:03-02 ©
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Flywheel
Flywheel
Removing the flywheel
Special tools

87 368 Puller bolts 87 368 AM1, D3, B1, AD1D3
00 1805
M
1 Remove the rotational speed sensor(s) in the

AS 0
flywheel housing.
2 Remove the flywheel bolts. 14" flywheel:
Also remove the washers.
H 91
3 Pull off the flywheel from the crankshaft

IN 20
87 368
using puller bolts 87 368.
ES 14
O 62
FT 5
.C 9
01_1355
O
M
98 ©
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Flywheel
Fitting the flywheel
Specifications
Tightening torques
Flywheel bolts 130 Nm + 90°
Special tools

99 324 Guide pins 99 324 D5
M
AS 0
100335
H 91
99 321 Tool for locking the flywheel on 99 321 D5

engines with injection pump.
IN 20
ES 14
00 1549
99 411 Tool for locking the flywheel on 99 411 D5

engines with unit injectors.
O 62
FT 5 116 489
.C 9
O
M
01:03-02 ©
www.motodiesel.ir
Flywheel
1 Fit two guide pins 99 324 in the flywheel

housing.
2 Fit the flywheel on the crankshaft.
IMPORTANT! Always use new bolts. 14"

flywheel: Washers should also be fitted.
01_1358
99 324
3 Lock the flywheel using tool:

99 411
M
99 321 for engines with an injection pump

99 411 for engines with unit injectors.
AS 0
H 91
IN 20
ES 14
O 62
FT 5
120 167
.C 9
O
Locking the flywheel on engines with unit

injectors.
M
4 Torque tighten the bolts alternately to

130 Nm and then a further 90°.
5 Refit the rotational speed sensor(s).
100 ©
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Flywheel
Support bearing
Renewal
Special tools

99 250 Drift 99 250
D3,C4
112 640
M
1 Remove the retaining rings on both sides of 99 250

the support bearing.
AS 0
2 Knock out the support bearing from the

flywheel using drift 99 250.
H 91
3 Fit the inner retaining ring and fit the new

IN 20
support bearing with drift 99 250.

4 Fit the outer retaining ring.
ES 14
01_1392
O 62
FT 5
.C 9
O
M
01:03-02 ©
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Flywheel
External ring gear
Renewal
Specifications
Heat the external ring gear to 100 - 150°C
before fitting.
Renew the flywheel external ring gear if the
gear teeth have become so worn that the starter
pinion will not engage.
1 Grind a groove as deep as possible in the
external ring gear and crack it open with a
M
chisel. Remove the external ring gear from

the flywheel.
AS 0
! WARNING!
H 91
Wear protective goggles due to the risk

IN 20
of metal shivers.
ES 14
2 Clean the contact surfaces of the flywheel

O 62
with a wire brush.

3 Heat the new external ring gear evenly
FT 5
around its circumference to 100 - 150°C.

4 Place the heated external ring gear on the
.C 9
flywheel so that the marking with the part

number is facing the engine when fitting the
O
flywheel. Ensure that the external ring gear

is properly in contact with the flywheel. If
M
necessary, tap down the external ring gear

using a plastic hammer.
5 The external ring gear must not be cooled
down rapidly but be left to cool in the open
air.
102 ©
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Crankshaft
Crankshaft
Removing the crankshaft

1 Remove the crankshaft gear according to
the section Removing the crankshaft gear.
2 Remove the fan coupling as described in the
section Removing the fan coupling.
3 Remove the oil sump, oil suction pipe with
strainer and the oil pump.
4 Remove the pistons and connecting rods
according to the section Removing the
connecting rod and piston.
M
5 Remove the main bearing caps and main

AS 0
bearings.
Note: The main bearings and main bearing caps

H 91
are marked and must be refitted in the same

place.
IN 20
6 Lift out the crankshaft.

ES 14
100147
O 62
FT 5
.C 9
O
M
01:03-02 ©
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Crankshaft
Fitting the crankshaft
Tightening torques
Main bearing cap Torx bolt 110 Nm + 90°

Main bearing cap hexagon bolt 50 Nm + 90°
All parts must be cleaned before fitting.

1 Place the bearing shells in the main bearing
seats in the cylinder block and then lubricate
the bearing surface with engine oil.
M
Note: The outside of the bearing shells must not

be lubricated.
AS 0
100148
H 91
2 Lift in the crankshaft.

IN 20
3 Place the main bearings in the main bearing

caps and fit them.
ES 14
Note: Fit the main bearings and caps in the

same place as before removal.
O 62
FT 5
Note: You may only reuse a main bearing bolt

or connecting rod bolt 3 times. Mark the bolt
with a punch mark each time you reuse it.
.C 9
4 Lubricate the bolt thread and the surface of

O
the main bearing cap where the bolt is

tightened. Scania engine oil can be used.
M
Tighten the bearing cap bolts.
5 Fit the pistons with connecting rods

according to the section Fitting the
connecting rod and piston.
50 Nm + 90 110 Nm + 90
6 Fit the oil pump, oil suction pipe with
strainer and the oil sump.
7 Fit the fan coupling as described in the
section Fitting the fan coupling.
8 Fit the crankshaft gear according to the
section Fitting the crankshaft gear.
149304
104 ©
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Crankshaft
Machining crankshafts
1 Measure the diameter on the crankshaft
bearing journals using a micrometer as
illustrated. Measure at several points around
the bearing journal. If any of these
diameters is lower than the minimum
indicated limit, regrinding of the crankshaft
should be considered. Oil pressure should
also be checked, as it is affected by such
factors as wear in the main bearings and
connecting rod bearings.
120 164
M
AS 0
2 When regrinding, keep to the specified

minimum dimensions. Suitable bearings are
H 91
available for these sizes. It is important that

the fillet radius of the bearing journals is
IN 20
correct. Check the fillet radius using a

template as illustrated.
ES 14
O 62
FT 5
.C 9
O
M
3 After grinding the bearing journals, round

off and polish the oil hole openings on the
bearing surfaces.
01:03-02 ©
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Crankshaft
Measurements
Main bearing races

Standard, diameter 107.978-108.000 mm
Undersize 1, diameter 107.728-107.750 mm
Fillet radius 4.75-4.85 mm
Surface quality 0.25 Ra
M
Connecting rod races

AS 0
Standard, diameter 86.978-87.000 mm

H 91

IN 20

ES 14
Fillet radius 4.8-5.2 mm

Surface quality 0.25 Ra
O 62
Width, max. 56.05

FT 5
Radial clearance 0.051-0.114 mm

.C 9
Thrust washers
Standard, thickness 3.370-3.430 mm
O
Oversize 1, thickness 3.450-3.510 mm

M

Axial clearance 0.138-0.380 mm
106 ©
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Crankshaft
M
AS 0
H 91
IN 20
ES 14
O 62
FT 5
.C 9
O
M
01:03-02 ©
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Timing gear
Timing gear
Exploded view
M
AS 0
H 91
IN 20
ES 14
O 62
FT 5
.C 9
O
M
A = Parts for engines with an injection pump.
108 ©
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Timing gear
1 Camshaft 19 Crankshaft gear

2 Pin 20 Oil pump gear
3 Camshaft bearing 21 Intermediate gear
4 Guide flange 22 Retaining ring
5 Flange screw M10x30 23 Shaft
6 Thrust washer 24 Spacing sleeve
7 Camshaft gear 25 Roller tappet
8 Flange screw M10x40 26 Circlip
9 27
M
Compressor gear Flange screw

10 Hydraulic pump gear 28 Banjo screw
AS 0
11 Bolt M18x120 29 Shaft

12 Shaft 30 Pushrod
13 Intermediate gear 31 Slide ring
H 91
14 Ball bearing 32 Retaining ring

IN 20
15 Retaining ring 33 Pushrod

16 Spacing sleeve 34 Spacing sleeve
ES 14
17 Bolt 35 Injection pump gear

18 Shaft 36 Roller tappet
O 62
FT 5
.C 9
O
M
01:03-02 ©
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Timing gear
Removing the intermediate gear
Special tools


below)
M
100330
AS 0

above)
H 91
IN 20
ES 14
Other tools
O 62
FT 5

587 526 Puller -
.C 9
O
M
The timing gears consist of one or two

intermediate gears depending on the design. The
gears are removed in the same way.
1 Turn the crankshaft so that cylinder number
1 is close to TDC. Use tool 99 309 or 99 109
and a ratchet handle at the flywheel starter
gear.
99 309
01_1388
110 ©
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Timing gear

3 Remove the flywheel housing according to
the section Removing the flywheel housing.
4 Manufacture a thread block according to the
min 20
sketch.
M10 15−20
100054
M
5 The shaft on which the gear is located has a

groove. Fit puller 587 526, impact setting
AS 0
tool 99 074 and the thread block. Pull off

the gear and shaft. 587 526
99 074
H 91
IMPORTANT! After removing the

intermediate gear, neither the camshaft nor the
IN 20
crankshaft must be rotated. This may cause

pistons and valves to collide and be damaged.
ES 14
01 1359
O 62
FT 5
.C 9
O
M
01:03-02 ©
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Timing gear
Fitting the intermediate gear
Tightening torques
Bolts for intermediate gears 50 Nm + 60°
1 Check that cylinder number 1 is close to

TDC. The markings on the camshaft gear
and crankshaft gear must point towards the
centre of the intermediate gear.
M
100055
AS 0
2 Fit the intermediate gear against the

H 91
camshaft gear and the crankshaft gear so

that the markings point towards each other.
IN 20
3 Fit the second intermediate gear.

ES 14
O 62
FT 5
.C 9
O
M
4 Tighten the bolts on the intermediate gears

to 50 Nm + 60°. 50 Nm + 60
5 Fit the flywheel housing according to the

section Fitting the flywheel housing.
6 Fit the flywheel according to the section o
60
115 764
112 ©
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Timing gear
Renewing the bearing in the intermediate gear for the compressor
Special tools

87 348 Drift 87 348 AM1
104 862
87 592 Drift 87 592
-
M
AS 0
110 331
1 Remove the retaining ring.

H 91
IN 20
2 Press the bearing packet out of the gear.

3 Press the shaft journal out of the bearing.
ES 14
4 Press the shaft journal into a new bearing

using tool 87 348. Do not press on the outer
O 62
race.
5 Press the ring on the shaft journal.
FT 5
6 Press the bearing packet into the 01 1360
intermediate gear. Use tool 87 592.

.C 9

O
M
01:03-02 ©
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Timing gear
Renewing the bearing in the intermediate gear for the camshaft
Special tools

87 348 Drift 87 348
AM1
104 862
87 592 Drift 87 592
-
M
AS 0
110 331
1 Press the shaft out of the bearing.

H 91
2 Press the bearing inner race shell from the

IN 20
shaft and remove the retaining ring.

3 Place the removed bearing inner race in the
ES 14
bearing and press out the bearing using drift

87 348.
87 592
4 Press a new bearing onto the shaft journal
O 62
using drift 87 348.

FT 5
Note: Do not press on the outer race.

.C 9
5 Press the bearing and shaft journal into the

intermediate gear using drift 87 592.
01_1361
O

M
7 Press the spacing ring onto the shaft journal.

Ensure that the shaft journal is on the press
table.
114 ©
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Timing gear
Removing the camshaft gear
Special tools

below)
100330
above)
M
AS 0
H 91

IN 20

ES 14
gear.

O 62

99 309
FT 5

4 Remove the intermediate gear.
.C 9
01_1388
IMPORTANT! After removing the intermediate

O
gear, neither the camshaft nor the crankshaft

M
must be rotated. This may cause pistons and

valves to collide and be damaged.
5 Remove the camshaft gear.

01 1363
01:03-02 ©
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Timing gear
Fitting the camshaft gear
Tightening torques
Bolts for camshaft gears 63 Nm
1 Fit the intermediate gear as described in the

section Fitting the intermediate gear, steps
1-2.
2 Fit the camshaft gear and tighten the bolts to
63 Nm.

M

AS 0

H 91
01 1364
IN 20
ES 14
O 62
FT 5
.C 9
O
M
116 ©
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Timing gear
Removing the crankshaft gear
Special tools

below)
100330
above)
M
AS 0
H 91
IN 20

ES 14

gear.

O 62

FT 5
3 Remove the flywheel housing according to 99 309

.C 9
4 Remove the intermediate gear.

O
01_1388
IMPORTANT! After removing the intermediate

M
gear, neither the camshaft nor the crankshaft

must be rotated. This may cause pistons and
valves to collide and be damaged.
5 Remove the crankshaft gear.

01 1365
01:03-02 ©
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Timing gear
Fitting the crankshaft gear
1 Fit the crankshaft gear.
2 Fit the intermediate gear, refer to Fitting the

intermediate gear, steps 1-2.
01 1366
M
AS 0
H 91
IN 20
ES 14
O 62
FT 5
.C 9
O
M
118 ©
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Timing gear
Removing the camshaft

3 Remove rocker arms, pushrods and valve
bridges.
4 Remove the camshaft gear.
5 Remove the intermediate gear according to
the section Removing the intermediate gear
and bolts for the guide flange.
6 Remove the timing gear plate.
M
AS 0
H 91
IN 20
7 Remove the camshaft covers.

ES 14
O 62
FT 5
01_1370
.C 9
O
8 Remove the roller tappets.

M
Note: Mark the roller tappets because they must

be refitted in the same positions.
9 Pull out the camshaft backwards. Take care

not to damage the cams and bearings.
01_1371
01:03-02 ©
www.motodiesel.ir
Timing gear
Fitting the camshaft
Specifications
Tightening torques
Flange screws and banjo screws for the roller tappets 32 Nm
Bolts for camshaft gears 63 Nm
Bolts for the timing gear plate 63 Nm
Camshaft covers 32 Nm
Sealant
M
Sealant for flywheel housing 816 064

AS 0
Axial clearance
H 91
Permitted axial play 0.05-0.35 mm

IN 20
Tools
ES 14

O 62
588 189 Air-operated gun - -

FT 5
584 117 Adapter for cartridge - -

584 118 Nozzle - -
.C 9
O
M
120 ©
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Timing gear
1 Fit the camshaft. Take care not to damage

the cams and bearings.
2 Lubricate with engine oil and fit the valve
tappets in the same positions as they were
before they were removed. Torque tighten
the bolts to 32 Nm.
3 Fit the camshaft covers. Torque tighten the
01_1371
bolts to 32 Nm.
4 Fit the guide flange bolts.
M
Now check the axial clearance of the

camshaft:
AS 0
• Fit the camshaft gear temporarily.

H 91
• Measure the axial clearance of the

camshaft using a dial gauge. The axial
IN 20
clearance should be between

0.05-0.35 mm.
ES 14
• If the play is outside the permitted range,

renew the thrust washer.
O 62
• Remove the camshaft gear.

FT 5
.C 9
O
M
01:03-02 ©
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Timing gear
5 Remove all old sealing compound on the

cylinder block and the sealing surface on the
timing gear plate. Clean off any oil and
grease from the sealing surfaces using an
alcohol based cleaning agent.
IMPORTANT! Clean thoroughly, as the sealing

surfaces must be completely free of grease.
6 Apply sealant to the cylinder block using

the nozzle. The width of the bead should be
between 0.8 and 1.2 mm. Follow the pattern
as illustrated.
M
AS 0
H 91
IN 20
111 347
ES 14
IMPORTANT! Ensure that you apply sealant

inside the bolt holes, but without allowing Applying sealant to the cylinder block.
sealant into the crankcase. The sealant may
O 62
block channels and nozzles. This is particularly

important to bear in mind around oil ways,
FT 5
where the flow of oil to the air compressor or

injection pump can be blocked.
.C 9
IMPORTANT! Assembly must be completed

within 25 minutes of starting to apply the
O
sealant.
M
7 Fit the timing gear plate onto the cylinder

block. Tighten the bolts to 63 Nm.
01_1369
122 ©
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Timing gear
8 Fit the intermediate gear according to the

section Fitting the intermediate gear.
9 Ensure that the markings on the camshaft
gear point towards the centre of the
intermediate gear.
10 Fit the camshaft gear and tighten the bolts to
63 Nm.
12 Fit the flywheel as described in Flywheel,
fitting.
M
AS 0
H 91
IN 20
Checking the camshaft setting

1 Set the crankshaft to TDC after the
ES 14
compression stroke on cylinder number one.

2 Put two dial gauges against the valve spring
O 62
thrust washers.
FT 5
3 Adjust the rocker arms to remove the play

and then adjust them a further 0.1 mm (thus
both valves are open 0.1 mm).
.C 9
4 Zero both the dial gauges.

O
5 Turn the crankshaft one revolution in its

direction of rotation until it is at TDC again.
M
6 Read off both dial gauges and compare with

the values given below:
Intake valve lifting height 0.37-1.47
Exhaust valve lifting height 0.16-1.16
01:03-02 ©
www.motodiesel.ir
Lubrication system
Lubrication system
General
Specifications
Lubrication oil volume

Lubrication oil volume 28 - 35 litres
Tightening torques
Magnetic plug in oil sump 80 Nm
M

AS 0

Oil nozzle for piston cooling, banjo screw 23 Nm
H 91
Plug for relief valve in oil filter unit 40 Nm

IN 20
The magnetic plug in the oil sump must be

lubricated with oil before fitting.
ES 14
O 62
FT 5
.C 9
O
M
124 ©
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Lubrication system
Measuring the oil pressure
Oil pressure
Idling 1.6 bar

With warm engine running at 1,000 rpm 2.5 bar
With warm engine running at 2,000 rpm 4.5 - 6.0 bar
Special tools

M
99 362 Measuring set

AS 0
H 91
120 908
IN 20
The use of measuring set 99 362 is described in

booklet 01:00-03.
ES 14
There are two different designs of oil filter.

O 62
FT 5
.C 9
Version 1, early model OIL

14
1 Disconnect the connector from the oil
O
pressure sensor.
M
2 Remove the oil pressure sensor and fit the M14x1.5

115 929
115 954
OIL
measuring equipment. Use the union and
adapter according to the illustrations.
01:03-02 ©
www.motodiesel.ir
Lubrication system
Version 2, later model

OIL 14
1 Remove the oil pressure sensor from the oil M14x1.5
filter.
99 412
2 Fit the measuring equipment with the union
115 954
OIL
and adapters as illustrated.
120928
3 Fit the oil pressure sensor.
M
AS 0
H 91
IN 20
120913
ES 14
O 62
FT 5
.C 9
O
M
126 ©
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Lubrication system
Oil filter
Only use original Scania filters.
Tools

587 025 Filter tongs M1
Only use original Scania filters and renew the

oil filter according to our inspection
instructions.
M
587 025
Use filter tongs 587 025 when removing the oil
AS 0
filter.
H 91
IN 20
01_1389
ES 14
IMPORTANT! When renewing the oil filter,

the oil filter unit should also be cleaned
Removing the oil filter
O 62
according to our instructions.

FT 5
If the oil filter unit is not cleaned, the oil filter

will clog quickly increasing the flow resistance.
If this happens, an overflow valve in the filter
.C 9
retainer opens and lets the oil pass without being

filtered.
O
The oil lubricates and cools components such as

M
the turbocharger. The turbocharger rotates at

high speed, sometimes above 100,000 rpm. It is
vital that the lubrication functions properly.
There is no separate turbocharger filter; the oil
is cleaned by the engine oil filter. If the
turbocharger receives contaminated oil, the
bearings become severely worn.
01:03-02 ©
www.motodiesel.ir
Lubrication system
Oil cooler
Tightening torques
Bolts for oil cooler insert 26 Nm
Exploded view
M
AS 0
H 91
IN 20
ES 14
O 62
FT 5
.C 9
O
M
1 Oil cooler 6 Core plug 11 Spring

2 O-ring 7 Cover 12 Plug
3 O-ring 8 Gasket 13 Gasket
4 Flange screw 9 Bolt 14 Gasket
5 Oil cooler cover 10 Piston 15 Flange screw
128 ©
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Lubrication system
Renewing the O-rings

1 Remove the side cover and oil cooler from
the cylinder block.
01_1384
2 Remove the 4 bolts securing the oil cooler
M
to the side cover.

AS 0
3 Remove the oil cooler.

H 91
IN 20
ES 14
O 62
4 Renew the O-rings, 4 off.

FT 5
5 Fit the oil cooler insert and bolt it into place

in the cover to 26 Nm.
.C 9
6 Bolt the side cover into place in the

cylinder block.
O
M
01 1386
01:03-02 ©
www.motodiesel.ir
Lubrication system
Oil filter unit
Specifications
Permitted thickness of deposits on walls of cover 26 mm
Tightening torques
Lock nut for oil cleaner housing cover 15 Nm
Nut for rotor cover Tightened by
hand
Rotor shaft 27 Nm
M
Locking compound
AS 0
Locking compound 561 200

H 91
IN 20
ES 14
O 62
FT 5
.C 9
O
M
130 ©
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Lubrication system
Exploded view
M
AS 0
H 91
IN 20
ES 14
O 62
FT 5
.C 9
1 Filter head 12 Spring 23 Cover

O
2 Overflow valve 13 Plug 24 O-ring

M
3 Union 14 Gasket 25 Lock nut

4 Straight union 15 Shaft 26 Lifting eye
5 Sealing ring 16 Washer 27 O-ring
6 Gasket 17 Rotor 28 Retaining ring
7 Flange screw 18 Nozzle 29 Gasket
8 Oil filter 19 Strainer 30 Flange screw
9 Housing 20 Rotor cover 31 Oil pressure sensor
10 Plug 21 Nut 32 Gasket
11 Piston 22 O-ring
01:03-02 ©
www.motodiesel.ir
Lubrication system
Cleaning
There should be a certain amount of deposited
dirt in the rotor cover during routine cleaning
of the oil filter unit. If this is not the case, this
indicates that the rotor may not be rotating. The
cause must be established immediately.
If the dirt deposit exceeds 20 mm at the
recommended intervals, the rotor cover should
be cleaned more often.
x3
1 Undo the nut holding the outer cover and
remove the nut.
2 Lift out the rotor. Wipe off the outside.
Undo the rotor nut and unscrew it about
three turns to protect the bearing.
M
01 1286
AS 0
H 91
IN 20
ES 14
O 62
FT 5
3 If the rotor nut is difficult to get loose, turn

the rotor upside down and secure the rotor
.C 9
nut in a vice. Turn the rotor x3

counterclockwise three turns by hand or if
O
this does not help, place a screwdriver

between the outlet holes.
M
IMPORTANT! The rotor must not be put in a

vice. Never strike the rotor cover. This may
01 1287
cause damage resulting in imbalance.
132 ©
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Lubrication system
4 Grasp the rotor cover and tap the rotor nut

lightly with your hand or a plastic mallet so
that the rotor cover comes loose from the
rotor. Never strike the rotor directly as this
may damage its bearings.
5 Remove the rotor nut and cover from the
rotor.
6 Remove the strainer located on the rotor. If
the strainer has seized, prise carefully with
a screwdriver at the lower edge between
01 1289
the rotor and the strainer.
M
AS 0
H 91
IN 20
7 Scrape away the deposits inside the cover

with a knife.
ES 14
8 Wash the parts.

9 Inspect the two nozzles on the rotor.
O 62
Ensure that they are not blocked or

damaged. Renew any damaged nozzles.
FT 5
10 Check that the bearings are undamaged.

.C 9
11 Position the O-ring in the cover. Renew the

O-ring if it is at all damaged.
O
12 Assemble the parts and tighten the rotor

nut by hand.
M
01 1293
01:03-02 ©
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Lubrication system
13 Check that the shaft is not loose. Secure

with locking compound 561 200 if it is
loose. First clean thoroughly using a
suitable solvent. Tighten the rotor shaft
using socket wrench 98 421. Tightening
torque 27 Nm.
14 Refit the rotor and rotate it by hand to
make sure it rotates easily.
15 Check the O-ring on the cover of the oil

cleaner housing and fit it. Torque tighten
the lock nut to 15 Nm.
01 1419
M
AS 0
H 91
IN 20
ES 14
O 62
FT 5
.C 9
O
M
134 ©
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Lubrication system
Oil pump
Tightening torques
Bolts for oil pump cover 26 Nm

Bolts for oil pump against cylinder block 26 Nm
Exploded view
M
9
10
3
AS 0
10
2
H 91
1
IN 20
4
ES 14
6
O 62
7
FT 5
25943
.C 9
O
1 Oil pump 6 Strainer

M
2 Flange screw 7 Ring

3 Gasket 8 Flange screw
4 Flange screw 9 Pipe
5 Suction pipe 10 Sealing ring
In the event of leakage or fault with the oil pump, it must not be overhauled but renewed completely.
01:03-02 ©
www.motodiesel.ir
Turbocharger
Turbocharger
Exploded view
1 Lubrication pipe
2 Ferrule
3 Union nut
4 Straight union
5 Sealing ring
M
6 Straight union
AS 0
7 Gasket
H 91
8 Lubrication oil return pipe

13
IN 20
9 Gasket 12
10 Flange screw
ES 14
13
25946
11
O 62
FT 5
Important information Oil leaks

.C 9
Observe strict cleanliness at all times when A blocked air filter will cause excessive
working on the turbocharger. Never leave the vacuum in the intake pipe. There is then a risk
O
oil inlet and outlet connections unprotected. of oil mist being drawn from the bearing
Foreign bodies in the bearing housing will soon housing.
M
lead to total breakdown.

If the sealing ring on the turbine side is worn,
the exhaust gases will be blue when idling.
If the lubrication oil return pipe from the
turbocharger is damaged, the pressure of the
lubricating oil may cause oil to leak out
through the seals.
136 ©
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Turbocharger
Foreign bodies Air and exhaust leaks

Foreign particles, e.g. grains of sand or metal Even small leaks in the line between the air
particles, in the turbine or the compressor will cleaner and the turbocharger will cause dirt to
ruin the vanes of the wheel. This will lead to be deposited on the compressor impeller. The
imbalance and bearing wear. The power output charge pressure will be reduced, resulting in
of the engine decreases, and if the engine is increased exhaust temperature and smoke,
still running the reduced air supply may cause which will reduce the service life of the engine.
overheating and engine damage. This type of
overheating is not visible on the coolant Leaks in the exhaust pipe between the cylinder
temperature gauge. head and the turbocharger will also result in
loss of charging pressure.
IMPORTANT! Never attempt to straighten a

damaged vane. It is then often broken during
operation causing the turbocharger to break
down completely, which also can damage the
M
engine.
AS 0
H 91
IN 20
Measuring the charging pressure

ES 14
Measure the charging pressure using Scania

Diagnos 2.
O 62
SCANIA Diagnos
FT 5
.C 9
O
00_1521
M
Tools for Scania Diagnos
Cleaning
Low charging pressure could be caused by a
dirty compressor impeller. Remove the
compressor cover. Clean the compressor
impeller with white spirit and a brush. Fit the
compressor cover and measure the charging
pressure again.
01:03-02 ©
www.motodiesel.ir
Turbocharger
Measuring radial and axial clearance
Turbine shaft wear limits
Holset make
Radial clearance max. 0.635 mm
Axial clearance max. 0.093 mm
Allied Signal make

Radial clearance max. 0.157 mm
Axial clearance max. 0.119 mm
M
Special tools
AS 0
H 91

98 075 Dial gauge D2
IN 20
98 075
0
90 10
10 90
80 20
20
80
15 5
ES 14
30 10
70
70 30
40 60
60 50 40
50
00_1637
O 62
587 107 Rocker indicator

FT 5 00_1569
.C 9
587 250 Indicator stand M1

O
M
102350
Measuring radial and axial clearance often does

not give a good indication of the remaining
service life of the turbocharger.
When the turbocharger seems to be functioning
poorly or noisily, measuring the charging
pressure or radial and axial clearance can
indicate whether the turbocharger is defective.
138 ©
www.motodiesel.ir
Turbocharger
Radial clearance
1 Measure the clearance at the turbine wheel
as well as at the compressor impeller.
2 Place the tip of the dial gauge against the

turbine or compressor impeller.
100703
3 Pull up both ends of the shaft. Take a
reading.
4 Press down both ends of the shaft. Take a
M
reading. The difference between the two

readings is the radial clearance.
AS 0
H 91
IN 20
100704
5 Repeat the test three times on each side.
ES 14
6 If any of the wheels makes contact with the

housing despite the radial clearance being
within tolerances, the turbocharger must be
O 62
renewed.
FT 5
.C 9
O
Axial clearance
M
1 Place the tip of the dial gauge against the

end of the shaft.
2 Press the shaft longitudinally to and fro

and take a reading at the end positions. The
difference between the readings is the axial
clearance.
3 Repeat the test three times.
100705
01:03-02 ©
www.motodiesel.ir
Turbocharger
Checks after breakdown
Tightening torques
Bolt, turbocharger - exhaust manifold 63 Nm

Nut, turbocharger - exhaust pipe 63 Nm
Stud, exhaust manifold 20 Nm
V-clamp between turbocharger and exhaust brake 20 Nm
IMPORTANT! Observe strict cleanliness at all

times when working on the turbocharger.
Never leave the oil inlet and outlet connections
M
unprotected. Foreign bodies in the bearing

housing will soon lead to total breakdown.
AS 0
1 Ensure that there are no leaks or loose

H 91
particles in the line between the air cleaner

and the turbocharger.
IN 20
2 Check that there are no loose particles in

the exhaust or intake manifolds. Renew the
ES 14
charge air cooler.

3 Make sure all valves are intact.
O 62
4 Check that the lubrication oil return pipe

from the turbocharger is not blocked or
FT 5
deformed.
5 Check that the oil pressure pipe to the
.C 9
turbocharger is not blocked, deformed or

leaking under pressure.
O
6 Renew the oil filter and clean the

M
lubrication system.
140 ©
www.motodiesel.ir
Belt transmission
Belt transmission
Engine with air conditioning and an idler roller
1 Automatic belt tensioner

2
3 2 Coolant pump
4 3 AC compressor
5 4 Idler roller
1
6 5 Alternator
6 Crankshaft
M
AS 0
105 188
H 91
IN 20
ES 14
Engine with air conditioning and two idler rollers

O 62
FT 5
2 3 1 Automatic belt tensioner

2 Coolant pump
.C 9
4
3 Idler roller
4 AC compressor
O
1 5 Alternator
6
M
Crankshaft
3 5
6
105 190
01:03-02 ©
www.motodiesel.ir
Belt transmission
Engine without air conditioning or idler roller

2 2 Coolant pump
3 Alternator
3 4 Crankshaft
1
4
M
105 189
AS 0
H 91
IN 20
ES 14
Engine without air conditioning with an idler roller

O 62
FT 5
2
.C 9
3
O
1 4
M
5
105 191

2 Coolant pump
3 Idler roller
4 Alternator
5 Crankshaft
142 ©
www.motodiesel.ir
Belt transmission
Belt transmission, industrial and marine engines
M
AS 0
1 Pulley on torsion damper.

H 91
2 Belt tensioner.
3 Coolant pump.
IN 20
4 Fan pulley
5
ES 14
Alternator.
6 Poly-V-belt.
7 Carrying roller.
O 62
FT 5
.C 9
O
M
01:03-02 ©
www.motodiesel.ir

11 and 12 Litre Engines: en-GB

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11 and 12 Litre Engines: en-GB

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01:03-02

11 and 12 litre engines

Cylinder head ................................................................................ 25

Renewing the valve seats........................................ 41

Renewing the valve guides..................................... 48

Cylinder block Reconditioning ....................................................... 54

Removing the cylinder liners.................................. 55

Flywheel housing ................................................................................ 71

Removing the flywheel housing............................. 72

Fan coupling Removing the fan coupling .................................... 76

Renewing the bearing in the fan coupling.............. 77

Closed crankcase ventilation Troubleshooting...................................................... 83

Crank mechanism ................................................................................ 86

Flywheel Removing the flywheel........................................... 98

Crankshaft Removing the crankshaft...................................... 103

Timing gear .............................................................................. 108

Checking the camshaft setting.............................. 123

Lubrication system General ................................................................. 124

Oil cooler .............................................................. 128

Oil pump............................................................... 135

Turbocharger .............................................................................. 136

Measuring radial and axial clearance ................... 138

Belt transmission .............................................................................. 141

3 B Engine type (on engines built from November 2000 onwards).

Engine oil must be applied to all moving parts

Removing the engine

8 Remove The mudguards.

14 Lift off The poly-V-belt. Only on vehicles with air

15 Detach The air hose for the exhaust brake

16 Remove The exhaust pipe.

24 Detach The oil dipstick.

25 Detach The starter motor ground connection.

27 Detach The positive starter motor cable.

support 99 318 must be used to support the

IMPORTANT! The lifting eyes on the engine are

On vehicles built from May 2000 onwards, the

30 Fasten lifting chain 98 094 to the rear

31 Fasten ratchet lever hoist 587 308 to the

IMPORTANT! The lifting eyes are designed to

32 Remove the bolts in the engine brackets

and lift out the engine.

Fitting the engine

Engine bracket bolts M14: 47 Nm

3 Fit the gearbox. Refer to Group 5.

4 Fit The hydraulic pump. Fit a new gasket.

6 Fit The pressure regulator pipe. At the compressor.

8 Fit The oil dipstick.

9 Fit The oil filler hose.

11 Fit The ground connection. At the compressor.

12 Fit The water heater hose.

13 Fit The compressor feed pipe.

crankcase ventilation hose on the

22 Fit The poly-V-belt.

30 Fit The negative cable on the battery and

Mounting the engine in an engine stand

Engines with injection pump

Engines with PDE unit injectors

Engines with HPI unit injectors

Securely bolt the engine to the engine stand as

1 Bolt M10x30 (8 off), Tightening torque 47 Nm.

2 Nut M16 (4 off), Tightening torque 180 Nm.

3 Bolt M16x50 (4 off).

Measuring the compression