Doosan-DL550-Manual de Taller Del Motor Scania DC13

Engine no.
: 6642331
01-00 Cleaning the engine

Complete - Tightening torques
Cleaning - Cleaning 9, 11, 12 and 13 litre engines

Note!
Tightening torques for the engine are
found in section 01-00, Engine assembly.
Cleaning
Cleaning 9, 11, 12 and 13 litre engines

The engine must be cleaned before starting work.
Clean with water and use a hot wash. Also use a degreasing agent, if necessary.
Avoid spraying water on the engine control unit, see illustration. Clean the components that
are inside the marked area.
8057596d
Warning!
Beware of hot water! Use suitable
protective equipment.
2011-08-23 ?Scania CV 1 of 2
Engine no.: 6642331
Environment
The washing water must be disposed of in
compliance with the relevant national or
local regulations.
2011-08-23 ?Scania CV 2 of 2
Engine no.: 6642331
01-00 General engine documents

Overview - Engine data on plate, on 9, 13 and 16 litre engines with XPI, PDE or GAS
Overview - Engine data on plate on 9 and 13 litre engines with XPI
Overview
Engine data on plate, on 9, 13 and 16 litre engines with XPI,

PDE or GAS
Applies to engines with cylinder block generation 2.
B
C
8071610a
1. A Smoke value
2. B Engine type
3. C Engine serial number
8071610b
2011-08-23 ?Scania CV 1 of 2
Engine no.: 6642331
8071610c
Overview
Engine data on plate on 9 and 13 litre engines with XPI

1 Made by 2
123 45XX
Typ/Type DC 13 06
Variant
Motor/Engine No
3
after T.D.C.
: DC 1306
8046b473
1. Engine type and engine serial number

2. Engine serial number, stamped
3. Smoke data
4. Valve clearance
2011-08-23 ?Scania CV 2 of 2
Engine no.: 6642331
01-00 Mounting the engine in a universal stand

Complete - Mounting 9 and 13 litre engines with XPI, PDE or GAS in universal stand

Note!
Complete
Mounting 9 and 13 litre engines with XPI, PDE or GAS in

universal stand
Tools
Tool
Number Designation Picture
board
99 331 Fixture A
99 612
587 692 Universal stand
Preparations before commencing work:

z Remove the engine from the vehicle.
2011-08-23 ?Scania CV 1 of 2
Engine no.: 6642331
2 3
1 4
806707f8
1 Remove the engine control unit.

2 Remove the fuel filter.
3 Remove the high pressure pump and feed pump.
4 Remove the starter motor.
1. Mount the engine in the universal stand.
2 3
1
99 331
801d8a7a
1. Bolt M10x30 (8 off).

2. Nut M16 (4 off).
3. Bolt M16x50 (4 off).
2011-08-23 ?Scania CV 2 of 2
Engine no.: 6642331
01-00 Removal and installation of motor

Complete
Removal - Removing 9 and 13 litre engines
Fitting - Fitting 9 and 13 litre engines
Complete
Note!
Renew coolant hoses if there is clear
damage to the coolant hoses which were
removed.
Note!
Removal
Removing 9 and 13 litre engines

Tools
Tool
board
98 094
98 094 Lifting chain
587 308 Lever block
2011-08-23 ?Scania CV 1 of 3
Engine no.: 6642331
C D
99 637 Lifting eye
1. Drain the oil and coolant.

2. Remove the air filter and inlet pipe between the turbocharger and air filter. Cover the
turbocharger inlet pipe.
3. Undo the connections for coolant, charge air pipes between engine and charge air cooler,
and bleed pipe for the expansion tank.
4. Undo the cable harness with clamping.
Note!
The engine lifting eyes 99 637 are
designed for lifting the engine only, not
the engine together with connected
equipment (high-voltage current generator,
gearbox, reverse gear, etc.) or frame. All
three lifting eyes must be used.
5. Fasten the lifting chain 98 094 to the rear
lifting eyes 99 637.
80667bf6
2011-08-23 ?Scania CV 2 of 3
Engine no.: 6642331
6. Fasten the lever block 587 308 to the front

lifting eye.
Note!
o
The lifting eyes 99 637 are designed to max 30
manage a maximum inclination angle of

30° when lifting an engine.
o
max 20
800e7df6
7. Undo the engine insulator bolts and lift away/out the engine.
Fitting
Fitting 9 and 13 litre engines

1. Fasten the lifting chain 98 094 to the rear
lifting eyes.
Note!
The engine lifting eyes 99 637 are o
max 30
designed for lifting the engine only, not
the engine together with connected
equipment (high-voltage current generator,
gearbox, reverse gear, etc.) or frame. All
three lifting eyes must be used.
o
Note! max 20
The lifting eyes 99 637 are designed to

manage a maximum inclination angle of 800e7df6
30° when lifting an engine.

2. Fasten the lever block 587 308 to the front lifting eye.
3. Lift the engine, position it on the engine insulators and screw it into place.
4. Attach the cable harness with clamping.
5. Fit the connections for coolant, charge air pipes between engine and charge air cooler, and
bleed pipe for the expansion tank.
6. Fit the air filter and inlet pipe between the turbocharger and air filter.
7. Fill with oil and coolant as directed in booklet 00:03-01.
8. Test run the engine to check that no leakage occurs. Top up with coolant if necessary.
2011-08-23 ?Scania CV 3 of 3
Engine no.: 6642331
01-00 Tightening torques

Specification - Normal tightening torque
Specification - Special tightening torque
Specification - Tightening torque for 9 and 13 litre engines with XPI, PDE or GAS
Specification - Normal tightening torque

The specifications in the tables below show the normal tightening torque for screws, nuts and
unions. The values are to be used unless other values are specified in the inspection
information. Always check whether there are special tightening torques given in the
descriptions for the respective areas in the inspection information before using the general
values for normal and special tightening torques respectively.
The following conditions apply:
z A tolerance of ±15 % applies to all values unless otherwise specified.

z All contact surfaces are to be clean and free of paint and the like.
z Bolts and nuts are normally not lubricated regardless of surface treatment. All
exceptions are specified in the inspection information.
Union assemblies
The specified values apply with a tolerance of ±5 %. The values apply to tightening with a
counterhold.
Thread inserts
The specified tightening torques also apply to bolted joints with a thread insert (Heli-Coil).
Thread inserts often provide greater strength compared to a directly screwed thread. This
generates a stronger bolted joint in aluminium or the like. For this reason, thread inserts are
used in certain joints in Scania's production.
Note!
When a damaged thread is repaired with a
thread insert, the normal screw and
prescribed tightening torque are to be
maintained. Fit the thread insert as
instructed in the inspection information.
80772056
Hexagonal screws, hexagon socket screws, six-point socket screws, hexagon nuts
2011-08-23 ?Scania CV 1 of 14
Engine no.: 6642331
Metric thread, course pitch
Thread Strength class 8.8/8

Tightening torque [Nm]
M4 2.4
M5 5
M6 8
M8 20
M10 39
M12 70
M14 112
M16 180
M18 240
M20 350
M22 490
M24 600
80772057
Flange screws with hexagonal head and hexagonal flange nuts

Thread Strength class 8.8/8

M5 5.4
M6 8.6
M8 22
M10 42
M12 77
M14 123
M16 184
2011-08-23 ?Scania CV 2 of 14
Engine no.: 6642331
8076fd3c
Thread forming six-point socket screws and hexagon screws with captive washer
Modified metric thread, course pitch
Thread Class 8 Class 10

M4 2.9 -
M6 9.4 11
M8 24 26
M10 47 49
M12 80 85
80772058
Thread forming six-point socket screws ST thread
Thread Tightening torque [Nm]

ST2.9 1.1
ST3.5 1.9
ST4.2 3.1
ST4.8 4.5
ST5.5 7.1
ST6.3 9.7
80772059
Stud tap end in threaded hole, strength class 8.8/8
2011-08-23 ?Scania CV 3 of 14
Engine no.: 6642331

Tightening the stud tap end in the threaded hole must be done so that the stud does not come
loose when undoing the nut. To tighten the stud in the threaded hole the torque must just
overcome the friction in the thread and generate a preload. The torque for locking is 50% of
the normal torque for hexagonal screws, hexagon socket screws, six-point socket screws,
hexagon nuts.
8077205a
Union nuts for ferrule
Thread Tightening torque [+/-15% Nm]

For pipe diameter Steel pipe with Plastic pipe Plastic pipe with
greased steel nut with steel brass ferrule and
ferrule and nut with rubber
brass or steel seal
nut
M10x1 5 15 10 -
M12x1.5 6 20 10 -
M14x1.5 8 30 20 -
M16x1.5 10 40 25 15
M18x1.5 12 50 30 20
M20x1.5 12 55 35 -
M24x1.5 16 60 50 40
M30x2 22 120 - -
8077205b
Nuts for lead-in union

M12x1.5 20
M14x1.5 25
2011-08-23 ?Scania CV 4 of 14
Engine no.: 6642331
M16x1.5 35
M18x1.5 50
M24x1.5 70
M30x2 80
8077205c
Unions with tapered thread for port connection
Thread Tightening torque [+/-15% Tightening torque [Nm]

Nm]
Straight unions Elbow unions
M10x1k 10 8
M12x1.5k 10 8
M14x1.5k 15 10
M16x1.5k 15 10
M18x1.5k 20 15
M20x1.5k 25 20
M22x1.5k 25 20
M26x1.5k 45 40
807720c8
Unions, plugs and banjo screws with cylindrical threads for seal with flat copper gasket

M8x1 10
M10x1 20
M12x1.5 20
2011-08-23 ?Scania CV 5 of 14
Engine no.: 6642331
M14x1.5 25
M16x1.5 30
M18x1.5 35
M20x1.5 45
M22x1.5 50
M24x1.5 60
M26x1.5 70
M28x1.5 80
M30x1.5 110
M30x2 115
M32x1.5 115
M36x1.5 160
M38x1.5 170
M45x1.5 270
807720c9
Plugs with tapered thread

M10x1k 15
M12x1.5k 20
M14x1.5k 20
M16x1.5k 25
M18x1.5k 40
M20x1.5k 40
M22x1.5k 40
M26x1.5k 60
2011-08-23 ?Scania CV 6 of 14
Engine no.: 6642331
807720ca
Insert connections for port connection

M10x1 18
M12x1.5k 24
M14x1.5k 28
M16x1.5k 35
M22x1.5k 40
807720cb
Insert connections for union connection
Thread For pipe diameter Tightening torque [+/-15% Nm]

M14x1.5 4-8 10
M18x1.5 12 15
M24x1.5 16 25
Specification - Special tightening torque

The specifications recommend values for special tightening torques for certain threaded
joints where there are strict requirements on the distribution of prestressing force. The
distribution of the tightening torque is ± 15% and the clamping force then spread about ±
30%.
Hexagonal screws, hexagon socket screws, six-point socket screws, hexagon nuts.
Applies also with captive washer and hexagon screws with thread cleaning thread.
Metric threads, course pitch
80772056
2011-08-23 ?Scania CV 7 of 14
Engine no.: 6642331
Thread Strength class

8.8/8 10.9/10
M4 2.9 3.6
M5 6 7.5
M6 9.5 12
M8 24 30
M10 47 59
M12 84 105
M14 135 170
M16 210 270
M18 290 360
M20 420 530
M22 580 730
M24 730 910
80772056
Hexagonal screws, hexagon socket screws, six-point socket screws, hexagon nuts
Applies also with captive washer and hexagon screws with thread cleaning thread
Metric threads, fine interval

8.8/8 10.9/10
M8x1 26 32
M10x1.25 50 62
M12x1.25 92 115
M14x1.5 150 180
M16x1.5 230 290
M18x1.5 330 410
M20x1.5 470 590
M22x1.5 640 800
2011-08-23 ?Scania CV 8 of 14
Engine no.: 6642331
M24x1.5 830 1040
Flange screws with hexagonal head and hexagonal flange nuts

Metric threads, course pitch

8.8/ 10.9/10
M5 6.7 8.1
M6 10.2 13
M8 26 32
M10 50 63
M12 92 115
M14 149 187
Specification
Tightening torque for 9 and 13 litre engines with XPI, PDE

or GAS
Important!
Tightening torques for threaded joints in

engines.
If the tightening torque is not in the table
use the tightening torque for special
tightening torques.
Apart from the following two groups which
use the tightening torque for normal
tightening torques.
Torx and hexagon screws with captive
washer, Torx with ST thread, Stud tap end
in a threaded hole, Union nut for ferrule,
Nuts for a lead-in union, Unions with a
taper thread for port connection, Plugs with
taper thread, Insert connection for port
connection, Insert connection for union
connection, Hose clamps.
2011-08-23 ?Scania CV 9 of 14
Engine no.: 6642331
Tightening torques
ENGINE ASSEMBLY
Cylinder block
Piston cooling nozzle 23 Nm
Main bearing cap, Torx screw M19 110 Nm + 90°
Main bearing cap, hexagon screw M19 110 Nm + 90°
Engine suspension
Engine suspension M16x60 130 Nm + 90°
Engine suspension M16x90 130 Nm + 135°
CYLINDER HEAD AND VALVE PACKAGE
Cylinder head
Tighten the cylinder head screw in four stages:
- First stage 60 Nm
- Second stage 150 Nm
- Third stage 250 Nm
- Fourth stage 90°
Rocker cover
Rocker cover, upper/lower 18 Nm
Valve mechanism
Nut for adjusting bolt on rocker arm 35 Nm
Screw for rocker arm shaft bearing retainer 90 Nm + 60°
Banjo screw for roller tappet shaft 40 Nm
CRANK MECHANISM
Flywheel
Flywheel screw, manual gearbox 300 Nm + 90°
Flywheel screw, GA765-766-767-866-867/R 180 Nm + 120°
Flywheel screw GRSOH901R 100 Nm + 90°
Torsion damper
Crankshaft damper hub 90 Nm + 30°
Torsion damper hub, 9 litre industrial and marine engines 90 Nm + 30°
Torsion damper hub, 13 litre industrial and marine engines 60 Nm + 60°
Connecting rod
Connecting rod bolt 50 Nm + 90°
2011-08-23 ?Scania CV 10 of 14
Engine no.: 6642331
TIMING GEAR
Intermediate gear 50 Nm + 60°
Camshaft gear 20 Nm + 40°
LUBRICATION SYSTEM
Oil sump and ladder frame, metal
Oil sump against cylinder block, 8.8 screw 26 Nm
Ladder frame against cylinder block, 8.8 screw 26 Nm
Oil sump against ladder frame, 8.8 screw 26 Nm
Oil sump against cylinder block, 10.9 screw 32 Nm
Ladder frame against cylinder block, 10.9 screw 32 Nm
Oil sump, plastic
Oil sump, spring screw 20 Nm
Oil plug etc.
Thread insert for oil plug 320 Nm
Magnetic oil plug, oiled seal 80 Nm
Magnetic oil plug, dry seal 115 Nm
Oil plug for filler connection in oil sump 60 Nm
Oil pump 32 Nm
Hose connection for cooling system 85 Nm
EXHAUST SYSTEM
Exhaust manifold
Exhaust manifold - cylinder head hexagon screw 40 Nm + 60°
Exhaust manifold – cylinder head Torx screw 60 Nm + 60°
Turbocharger – exhaust manifold 50 Nm
Exhaust pipe from turbocharger
Turbocharger (V-clamp) 20 Nm
Turbocharger oil pipe
Oil pipe turbocharger 45 Nm
Turbocharger coolant pipe
Water inlet, turbocharger 40 Nm
Water inlet variable turbocharger's electric motor 10 Nm
Silencer
2011-08-23 ?Scania CV 11 of 14
Engine no.: 6642331
Band clamps, first tighten the lower screws 35 Nm

Band clamps, then tighten the upper screws 35 Nm
Charge air cooler
Pipe connection (V-clamp) 8 Nm
XPI FUEL SYSTEM
Injectors
Nut for cable connection 2 Nm
Tighten the injector in four stages:
- First stage, injector holder 20 Nm
- Second stage, connection 20 Nm
- Third stage, injector holder 56 Nm
- Fourth stage, connection 56 Nm
Pressure pipe
M20 nut 38 Nm
Nut M16 38 Nm
Accumulator
End connection 27 Nm + 90°
Safety valve 27 Nm + 90°
Pressure sensor 47 Nm
High pressure pump
Pump gear 300 Nm
Fuel pipe banjo screws:
- M8 11 Nm
- M10 15 Nm
- M12 28 Nm
- M14 45 Nm
- M16 55 Nm
Fuel manifold
Straight joint M16 55 Nm
Joint with check valve 55 Nm
End joint, inner 30 Nm
End joint, outer 15 Nm
PDE FUEL SYSTEM
Injectors
2011-08-23 ?Scania CV 12 of 14
Engine no.: 6642331
Electrical connection screw 2 Nm

Injectors, fitting 20 Nm + 60°
Injector rocker arm
Adjusting screw nut 39 Nm
Fuel pipe banjo screws
M8x1 11 Nm
M14x1.5 45 Nm
M16x1.5 50 Nm
Overflow valve 55 Nm
AUXILIARY UNIT
Starter motor 105P70
- stud M10 24 Nm
- connection 30 20 Nm
Starter motor GVB
- connection 50 2.7 Nm
Alternator 100A
Pulley M17 nut 115 Nm
Connection B+ 12.5 Nm
Alternator 150A
Pulley M20 nut 147 Nm
Connection B+ 25 Nm
Hydraulic pump
Pump gear 110 Nm
Belt transmission
Belt tensioner 50 Nm
Fan coupling, double nut M14 165 Nm
Compressor
Compressor gear 90 Nm + 60°
Coolant pipe, industrial and marine engines 30 Nm
INLET SYSTEM
Induction pipe
Induction pipe against cylinder head 26 Nm
2011-08-23 ?Scania CV 13 of 14
Engine no.: 6642331
Venturi, industrial and marine engines 18 Nm

APPLIES TO 9 LITRE ENGINES
Balance axle
Bearing cap M10 screw 25 Nm + 45°
Frame M14 bolt 90 Nm + 60°
Gear 50 Nm + 60°
EGR system
Water pipe
Hose clamps 6.5 Nm
Retaining strap for EGR cooler, M6 screw 8 Nm
Coolant pipe to actuator, industrial and marine engines 30 Nm
ELECTRICAL SYSTEM
Ignition system
Spark plug, new 30 Nm
Spark plug, used By hand + 30°
2011-08-23 ?Scania CV 14 of 14
Engine no.: 6642331
01-01 Cylinder head

Removal - Removing the cylinder head on 9 and 13 litre engines with XPI
Fitting - Fitting the cylinder head on 9 and 13 litre engines with XPI
Complete - Removing and fitting valves
Renewal - Renewing a valve stem seal
Renewal - Renewing the valve seats
Adjust - Machining the cylinder head
Renewal - Renewing the valve guides
Renewal - Renewing the XPI injector sleeves
Renewal - Renewing the valve bridge guide pins on 9 and 13 and 16 litre engines
Complete - Machining the valve seat position when fitting oversize valve seat inserts
Check - Checking the cylinder heads for leaks

Note!
Removal
Removing the cylinder head on 9 and 13 litre engines with

XPI
1. If the engine has EGR:
z Remove the water-cooled EGR cooler as instructed in the work description for
Removing the water-cooled EGR cooler.
z Remove the brackets for the water-cooled EGR cooler.
2. Remove the bolts for the exhaust manifold on the relevant cylinder and slacken the bolts
on the adjacent cylinders so that the relevant part of the exhaust manifold comes loose.
3. Remove the cooling system bleeder hose, separate the quick release coupling at the front
lifting eye.
4. Remove the cable duct from the intake.
5. Remove the cable ties for the cable harness from the engine control unit.
Important!
The fuel system components are extremely
2011-08-23 ?Scania CV 1 of 25
Engine no.: 6642331
sensitive to dirt. Clean thoroughly before

dismantling and plug all connections with
lint-free rags and tape.
6. Depressurise the fuel system and detach 7 9 8

the fuel pipe running between the
accumulator and fuel manifold.
803fa5b1
7. Detach the fuel manifold and remove the bolts on the relevant cylinder.
8. Detach the intake manifold and remove the bolts on the relevant cylinder.
Important!
All parts in the fuel injection system and

valve mechanism should be marked.
Everything must be refitted in the same
position.
9. Remove the injectors as instructed in the work description for Removing the injectors.
Also remove the high pressure pipes and connection on the cylinder head at the back
viewed from the coolant pump.
Warning!
If work is carried out on the 6th cylinder of
an engine with an EGR system, the EGR
valve control cylinder must be detached at
the damper and removed.
10. Remove the upper rocker cover and then

the rocker arm housing, valve bridges
and pushrods.
2011-08-23 ?Scania CV 2 of 25
Engine no.: 6642331
803fa58f
11. Pull the cable harness out of the lower

rocker cover and remove it.
Note!
Take care when pulling the cable harness
out of the rocker cover; the cable terminals
can be damaged which can cause the nut
securing the cable harness to the injector
to come loose.
803fa18c
12. Work on the adjacent cylinders. Remove the upper rocker cover, release the cable
harness and the lower rocker cover so that it can be moved.
13. Remove the relevant cylinder head. Be careful with the adjacent rocker covers.
Note!
Mark the cylinder heads if more than one
is being removed at the same time.
Note!
If all cylinder heads are removed at the
same time, the turbocharger must be
removed or supported against the frame.
Fitting
Fitting the cylinder head on 9 and 13 litre engines with XPI

1. Check the liner height as described in the work description for Checking the liner height.
2. Clean the cylinder head and cylinder block. Lubricate the threads and below the heads of
the cylinder head bolts.
3. Fit a new cylinder head gasket.
2011-08-23 ?Scania CV 3 of 25
Engine no.: 6642331
4. Fit the cylinder head.

5. Tighten the cylinder head as shown in the 1
illustration and according to specification.

5
3
4
6
80334cf7
1 2 3 4
803fa620
Cylinder head bolts can only be reused three times. Make a mark with a centre punch on the
head of the bolt. If any of the bolts already has three marks, it must be replaced.
6. Tighten the intake manifold. Use a new
gasket. Tighten the bolts in the order 1-20 2 4 6 8 10 12 14 16 18 20
or 1-24 as illustrated. Tighten the bolts in

the same order again. 1 3 5 7 9 11 13 15 17 19
80592c72
Intake manifold on 5 cylinder engine
2
4 6 8 10 12 14 16 18 20 22 24
1 3 5 7 9 11 13 15 17 19 21 23
80592c6a
Intake manifold on 6 cylinder engine

7. Tighten the intake manifold and the exhaust manifold. Use new gaskets.
8. Fit the cable bracket bolt in the lower rocker cover and fit the following parts:
z Lower rocker cover.

z Pushrods.
z Valve bridge.
2011-08-23 ?Scania CV 4 of 25
Engine no.: 6642331
z Rocker arm housing.
Important!
Lubricate the valve bridge and rocker arm

housing with engine oil
9. Fit the injector, high-pressure pipe connection and high-pressure pipe as instructed in the
work description.
10. Reset adjacent cylinders.
11. Adjust the valve clearance.
12. Fit the upper rocker covers.
13. Fit the cooling system vent
14. If the engine has an EGR system:
z Fit the brackets for the water-cooled EGR cooler.
z Fit the water-cooled EGR cooler as described in the work description for Fitting
the water-cooled EGR cooler.

Tools
Tool
board
99 322 Drift D5
Warning!
There is a risk of personal injury, use
protective goggles!
Removing valves
1. Remove split collets, valve spring collars,

springs and valves. Press down the spring
using tool 99 322 in a press so that the
2011-08-23 ?Scania CV 5 of 25
Engine no.: 6642331
collets can be removed.
99 322
800ee593
2. Place the valves in a stand so that they can be refitted in the same position in the cylinder
head.
Fitting valves
Note!
There are different versions of the
combination valve – valve spring collar –
split collet. Parts from the different
versions must not be mixed on the same
valve.
1. Lubricate all parts well with engine oil before assembly.
2. Insert the valve in the guide.
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 collets. Ensure that
the collets are fitted in their correct
positions.
2011-08-23 ?Scania CV 6 of 25
Engine no.: 6642331
99 322
800ee5ad
Renewal - Renewing a valve stem seal

Tools
Tool
board
99 323 Drift D5
1. Remove the valve according to the work description for Removing valves.
2. Remove the valve stem seal with a pair of
pliers.
800eeacb
3. Fit the valve

4. Carefully tap a new valve stem seal into
place using tool 99 323 and a hammer.
2011-08-23 ?Scania CV 7 of 25
Engine no.: 6642331
99 323
800eeacc
Renewal
Renewing the valve seats

Tools
Tool
board
99 384
D1-
99 384 Drift
A3
D1-
99 385 Shank
B1
2011-08-23 ?Scania CV 8 of 25
Engine no.: 6642331
99 385
587 270 Kit with puller
1. Remove the valve seat inserts with an

expanding sleeve from the kit with puller
587 270.
Note! 1
Insert, for example, an aluminium sheet

between the cylinder head and counterhold 2
to protect against damage.
Warning!
Wear protective goggles. There is a risk
that loose slivers of metal can cause
personal injury when pulling out the valve
seats.
805cc212
2. Press in new valve seat inserts. Use drift

99 384 and shank 99 385. Cool the drift
and valve seat insert to about -80°C with
dry ice or liquid air. Pressing must be
carried out rapidly.
2011-08-23 ?Scania CV 9 of 25
Engine no.: 6642331
99 385
99 384
8040cb99
Warning!
Be careful when handling the cold parts
and refrigerant mentioned above. Risk of
frost injuries.
Oversize valve seat inserts can be fitted if the valve seat insert position has been damaged.
The position is then machined using tool 587 277 in accordance with the work description for
Machining a valve seat position.
Adjust
Machining the cylinder head

In 9 litre engines, 13 litre engines and 16 litre engines, XPI, the cylinder head may not
be ground flat.
Renewal - Renewing the valve guides

Tools
Tool
board
D1-
99 382 Drift
C6
D1-
99 383 Drift
B1
2011-08-23 ?Scania CV 10 of 25
Engine no.: 6642331
1. Press out the valve guides using drift 99

383. 99 383
802fbd1a
2. Press in the new valve guides using drift

99 382. Press the guide down as far as the
99 382
drift allows, i.e. until it makes contact with
the spring seat in the cylinder head.
802fbd1b
Renewal
Renewing the XPI injector sleeves

Tools
Tool
board
99 574 Tool kit (guide, drift and pilot tap) D7
D2-
2011-08-23 ?Scania CV 11 of 25
Engine no.: 6642331
C5,
C6
99 397 Extension piece with threaded shaft
The cylinder head must be removed when renewing the unit injector sleeve. The valves do
not need removing. The illustrations show the cylinder head with valves removed to
demonstrate clearly the work described.
802fc073
Guide and pilot tap on extension piece 99 397

1. Thread the lower part of the sleeve using the pilot tap and guide from tool kit 99 574.
2. Knock out the pilot tap and sleeve from
underneath. Use a 100 mm long metal rod
of diameter 9 mm.
802fbe1d
3. Degrease and check the contact surfaces of the sleeve and cylinder head. Smooth off any
burrs and irregularities that may 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.
5. Press in the sleeve using the drift and guide from tool kit 99 574.
Renewal
Renewing the valve bridge guide pins on 9 and 13 and 16

litre engines
2011-08-23 ?Scania CV 12 of 25
Engine no.: 6642331
Tools
Tool
board
587 470 Pin extractor
99 015 Press drift
The cylinder head must be removed when renewing the guide pins.
1. Remove: 1. Outlet valves 2. Intake valves
2
1
803391fd
2. Fit shrink sleeve number 10 from tool kit

587 470.
2011-08-23 ?Scania CV 13 of 25
Engine no.: 6642331
80339209
3. Use pin extractor 587 470 to remove the

guide pins.
587 470
803391cc
4.
2011-08-23 ?Scania CV 14 of 25
Engine no.: 6642331
8033920c
5. Press in the new guide pins using drift 99

015. Maximum press force 15 kN.
Note!
Check before pressing in that the tool is 99 015
not deformed.
Note!
Check after pressing in that the valve
bridge slides easily on the guide pin.
80446879
6. Refit all the parts in the cylinder head.
2011-08-23 ?Scania CV 15 of 25
Engine no.: 6642331
Complete - Machining the valve seat position when fitting

oversize valve seat inserts
Tools
Tool
board
587 277 Valve seat cutter
Cutter for machining the valve seat positions in the

587 923
cylinder head (part of 587 277)
Applies to 9, 11, 12 and 16 litre engines with cylinder block generation 1 and PDE or
HPI fuel system
Specifications
Intake valve
Oversize valve seat, outer diameter 46.254 - 46.265 mm
Valve seat position, outer diameter 46.200 - 46.216 mm
Valve seat position, deep 11.25 - 11.35 mm
Exhaust valve seat
Applies to 9 and 13 litre engines with cylinder block generation 2 and XPI or PDE
Specifications
2011-08-23 ?Scania CV 16 of 25
Engine no.: 6642331
Intake valve
Exhaust valve seat
Preparation
z Remove the cylinder head according to the work description for Removing the cylinder
head.
z Remove the inlet and exhaust valves according to the work description for Removing
the valves.
Machining the valve seat position
1. Check that the contact surface on the cylinder head is level and clean. Also check that the
magnetic stand on the valve seat cutter is clean. Clean the valve guides.
2. Zero the micrometer.
8040caa4
3. Assemble the micrometer with a suitable

spindle on the valve seat cutter and adjust
the cutter. It is very important that the tip
of the cutter is in the centre of the
micrometer spindle.
2011-08-23 ?Scania CV 17 of 25
Engine no.: 6642331
8040cabc
4. Select the largest control spindle that

moves easily in the valve guide. Fit the
valve seat cutter and turn the feed screw to
its upper position.
8040cac8
5. Turn off the magnet (position 2). Insert the guide spindle into the valve guide. Adjust the
pivot plate so that the distance between the cutter and the valve seat is approx. 1 mm.
Centre the valve seat cutter precisely.
6. Turn on the magnet (position 1).
7. Apply the quick-action lock. Make sure
the crank can be turned easily. If not, redo
the centring.
2011-08-23 ?Scania CV 18 of 25
Engine no.: 6642331
8040caf9
8. Machine the valve seat by cranking

clockwise while turning the screw
clockwise. Lubricate with cutting oil while
machining.
Important!
The cutter must never be cranked anti-

clockwise.
8040cb2e
9. When the surface of the valve seat has been machined, reduce the cutting pressure by
turning 2-3 revolutions without any feed. Continue turning clockwise while turning the
screw counter clockwise until the cutter is free. Disconnect the solenoid by briefly
pressing switch position 2.
10. The valve seat cutter is now ready for the next valve seat.
Check - Checking the cylinder heads for leaks
2011-08-23 ?Scania CV 19 of 25
Engine no.: 6642331
Warning!
Always wear protective goggles when
carrying out this work. If the crankshaft
were to rotate during work, fuel which has
run into a cylinder or metal chips from a
damaged engine may cause injury to the
eyes or face.
Tools
Tool
board
XX XX
XX XX
XX x
99 527 Cylinder leakage indicator MC1
99 309 Turning tool D5
Leakage equipment calibration
3 5
XX XX
XX XX
XX x
4
2
804a356a
1. Fit the quick-release coupling 1 of the measuring hose to the nipple on the aluminium
block on the back of the test equipment 2.
2. Connect at least 6 bar of compressed air to the connection nipple of the test equipment 3.
3. Pull out the wheel on the pressure regulator 4 and turn it until the manometer pointer 5
indicates 23%. Press in the wheel and lock the regulator.
2011-08-23 ?Scania CV 20 of 25
Engine no.: 6642331
4. Disconnect the compressed air and remove the quick-release coupling 1 on the measuring
hose from the back of the test equipment 2.
Tolerance for leakage measurement
< 23 % Engine is in good condition

23-30 % Engine is in acceptable condition
30-40 % Engine is worn and may have poorer performance than expected.
40-50 % Engine is very worn. Consider reconditioning.
> 50 % Engine is in poor condition and must be reconditioned.
If the leak cannot be located: remove the cover on the expansion tank and check whether
bubbles appear, or measure the pressure in the cooling system using adapter 99 312 and
cooling system tester 587 048.
If the pressure increases or bubbles appear, this may indicate a cracked cylinder head or
cylinder liner.
Integrity check
1. Warm up the engine to operating temperature.

2. Remove all rocker arms and valve bridges.
3. Remove all injectors as instructed in the work description for Removing the injectors.
4. Turn the engine with the turning tool 99 309 so that cylinder number 1 is at TDC.
5. Block the engine so that the crankshaft does not begin to rotate when the cylinder is
pressurised, e.g. by leaving the turning tool in position with tommy bar, T-handle or
ratchet handle.
If using a ratchet handle, set the ratchet handle direction based on whether the engine is
before or after TDC so that the ratchet handle blocks rotation.
6. Assemble the nozzle adapter. The Engines with PDE fuel system
component parts of the nozzle adapter are
dependent on the engine type as shown in
the illustrations, position 1-3.
2011-08-23 ?Scania CV 21 of 25
Engine no.: 6642331
1 2 3
804a359c
1. Copper gasket
2. Nozzle adapter 99 487
3. Guide sleeve PDE 99 489
4. Clamp PDE
Engines with HPI fuel system
1 2 3
2011-08-23 ?Scania CV 22 of 25
Engine no.: 6642331
804a35b5
1. Nylon tip HPI 99 488 and O-ring

9.3x2.4 and 17.3x2.4
3. Guide sleeve HPI 99 490
4. Clamp HPI
Engines with XPI fuel system
1 2 3
804a35bf
1. Copper gasket
3. Guide sleeve XPI 99 573
4. Clamp XPI
7. Fit the nozzle adapter in the injector hole on cylinder 1 as shown in the illustrations for
the respective engine type. Use the ordinary injector screw and clamp 4.
8. Fit the nozzle adapter with the test adapter
5 for the test equipment and then with the
quick-release coupling 6 on the measuring
hose.
2011-08-23 ?Scania CV 23 of 25
Engine no.: 6642331
8049f2b9
XX XX
XX XX
XX x
804a35d6
9. Connect at least 6 bar of compressed air to the connection nipple 7 of the test equipment.
Allow the air to blow for a short while until the pressure has stabilised.
10. Listen for leaking air in the crankcase. Air leakage indicates worn or damaged piston
rings or cylinder bore, or cracked pistons.
11. Listen for leaking air in the exhaust pipe. If possible, remove the flexible pipe. Leaking
air in the exhaust pipe indicates exhaust valves that are not fully sealed.
If the value read is great, you can tap gently a few times on the end of the valve stem
using a small hammer. If the value falls when the valve has settled, this indicates worn
valve guides.
12. Detach the hose from the charge air cooler and listen for leaking air in the intake
manifold. Leaking air indicates intake valves that are not fully sealed.
If the value read is great, you can tap gently a few times on the end of the valve stem
using a small hammer. If the value falls when the valve has settled, this indicates worn
valve guides.
13.
Check the other cylinders for leaks.
2011-08-23 ?Scania CV 24 of 25
Engine no.: 6642331
On 11, 12 and 16 litre engines, cylinder 6 can also be measured when cylinder 1 is in the
TDC position. The crankshaft must be rotated to check other cylinders.
9 litre engines:Rotate the crankshaft in the direction of engine rotation in increments of
144°. The cylinders can then be measured in the sequence 2-4-5-3.
11, 12 and 13 litre engines:Rotate the crankshaft 120° in the direction of engine rotation
to measure cylinders 2 and 5, then a further 120° in the direction of engine rotation to
measure cylinders 3 and 4.
16 litre engines:Rotate the crankshaft 90° in the direction of engine rotation to measure
cylinders 3 and 5, then a further 90° to measure cylinders 4 and 7, and finally 90° to
measure cylinders 2 and 8.
2011-08-23 ?Scania CV 25 of 25
Engine no.: 6642331
01-01 Valve mechanism

Check - Checking the valve
Adjust - Checking and adjusting the valve clearance on 13 litre XPI engines

Note!

Tools
Tool
board
99 322 Drift D5
Warning!
There is a risk of personal injury, use
protective goggles!
Removing valves
1. Remove split collets, valve spring collars,

springs and valves. Press down the spring
using tool 99 322 in a press so that the
collets can be removed.
2011-08-23 ?Scania CV 1 of 6
Engine no.: 6642331
99 322
800ee593
2. Place the valves in a stand so that they can be refitted in the same position in the cylinder
head.
Fitting valves
Note!
There are different versions of the
combination valve – valve spring collar –
split collet. Parts from the different
versions must not be mixed on the same
valve.
1. Lubricate all parts well with engine oil before assembly.
2. Insert the valve in the guide.
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 collets. Ensure that
the collets are fitted in their correct
positions.
2011-08-23 ?Scania CV 2 of 6
Engine no.: 6642331
99 322
800ee5ad
Check - Checking the valve
Intake valve
Head angle 19,5°
Minimum measurement A 2.6 mm
Outlet valve
Head angle 45,5°
Minimum measurement A 1.8 mm
Specifications
Check dimension A on all valves. If the measurement does not achieve the minimum
permitted dimension, the valve should be renewed. The valve should also be renewed if there
are visible defects on the intake valve surface.
800eeab0
Minimum measurement A.
Adjust
2011-08-23 ?Scania CV 3 of 6
Engine no.: 6642331
Checking and adjusting the valve clearance on 13 litre XPI

engines
Tools
Tool
board
99 309 Turning tool
99 109 Turning tool
588 179 Torque screwdriver
Check and adjust the valve play with the engine cold. Play for the intake valves should be
0.45 mm and for the exhaust valves 0.70 mm.
Adjusting may be carried out in one of two ways. Either by setting the TDC on the flywheel
and following the tables showing which valves can be adjusted, or by following the tables
showing which flywheel position to set to adjust all valves on a cylinder:
Important!
Remember to remove the turning tool from

the flywheel after adjustment.
Adjustment using TDC
1 2 3 4 5 6
2011-08-23 ?Scania CV 4 of 6
Engine no.: 6642331
8073b819
Cylinder configuration, 6 cylinder engines

Set cylinder 1 exactly at TDC after the compression stroke. Adjust the following valves:
cyl. 1 Intake valve and exhaust valve

cyl. 2 Intake valve
cyl. 3 Exhaust valve
cyl. 4 Intake valve
1 2 3 4 5 6
800ee551
O Intake valve
X Exhaust valve
Turn the crankshaft exactly one revolution. Adjust the following valves:

cyl. 3 Intake valve
cyl. 5 Intake valve
cyl. 6 Intake valve and exhaust valve
1 2 3 4 5 6
800ee559
O Intake valve
X Exhaust valve
Order of adjustment for 13 litre engines
Rotate the flywheel in the normal direction of rotation using turning tool 99 309. Read the
mark on the flywheel visible in the lower window of the flywheel housing.
Engines equipped with flywheel with marking TDC Up: Fit turning tool 99 109 in the holes
of the upper hatch. Press in the gear in the external ring gear and turn the flywheel with the
ratchet handle and a 14 mm socket. Read the mark on the flywheel in the upper window of
the flywheel housing.
2011-08-23 ?Scania CV 5 of 6
Engine no.: 6642331
8066ea84
Note!
Valve change occurs when the cylinder
goes from the outlet stroke to the inlet
stroke. The exhaust valve is about to close
at the same time that the intake valve is
opening
Adjust valves according to the table below. Follow the respective column depending on
whether the reading is in the lower or the upper window.
It is a good idea to mark the rocker arm with a pen after adjustment to keep track of what has
already been adjusted.
Mark on flywheel. Valve overlap on Adjust intake and Mark on flywheel.

Reading in the lower cylinder exhaust valves on Reading in the upper
window cylinder window
TDC Down 6 1 TDC Up
120/480 2 5 300/660
240/600 4 3 60/420
TDC Down 1 6 TDC Up
120/480 5 2 300/660
240/600 3 4 60/420
2011-08-23 ?Scania CV 6 of 6
Engine no.: 6642331
01-05 Cylinder block

Renewal - Renewing the camshaft bearing on 11, 12 and 13 litre engines with XPI,
PDE, HPI or GAS
Complete - Measuring the cylinder liner height, all engines.
Adjust - Machining the upper cylinder liner guide
Complete - Machining lower cylinder liner diameter
Adjust - Machining the cylinder liner seat, all engines

Note!
Renewal
Renewing the camshaft bearing on 11, 12 and 13 litre

engines with XPI, PDE, HPI or GAS
Tools
Tool
board
99 373 Tool for renewing the camshaft bearing D5
99 003 Hydraulic cylinder H1
99 004 Air-operated hydraulic pump H1
1. Remove the camshaft as described in the work description Removing the camshaft.
2. Remove the cover for the camshaft at the front of the engine.
2011-08-23 ?Scania CV 1 of 22
Engine no.: 6642331
3.
Important!
Wipe around the edges and the bearing seat

surfaces around the old bearings to avoid
damaging the contact surfaces when fitting
the new bearings.
Wipe the bearing seat surfaces clean around the old bearings.
4. Note!
The recess in the bearing joint must be
turned towards the front of the engine.
Place the new bearings in the space
between the bearing seats for the camshaft.
800eed04
1
2
800eed0a
1. Threaded stem with flange nuts

2. Press drift
3. Flange
2011-08-23 ?Scania CV 2 of 22
Engine no.: 6642331
5.
1 2 3 4 5 6 7
8
164
328
492
656
820
984
800eed16
Place the flange nuts on the threaded stem, part of tool 99 373, as illustrated.
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.
800eed1b
7. Screw the flange part of tool 99 373

securely onto hydraulic cylinder 99 003
with two M6x12 bolts. Press together 99 003
cylinder 99 003 if not already in neutral
position.
800eed20
8. Screw on the flange with the hydraulic cylinder at the rear of the engine with two M10x25
bolts.
9. Screw on flange nut 8, from tool 99 373, onto the threaded stem.
10. Hang a new bearing on the stem at the
front of the engine.
2011-08-23 ?Scania CV 3 of 22
Engine no.: 6642331
800eed2e
11. Note!
The recess in the bearing joint must be
turned towards the flange on the press
drift. 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.
Place the press drift on the threaded stem
and place the bearing on the drift.
800eed47
The bearing is correctly located on the drift

when the ball and a marking hole are centred
on the bearing oil hole.
12. Note!
The marking on the drift must be
uppermost and vertical so that the oil hole
in the bearing will be central to the oil
ways.
Clean around the bearing contact surface.
800eed56
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.
800eed5b
Secure the threaded stem by tightening flange

nut 8.
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
2011-08-23 ?Scania CV 4 of 22
Engine no.: 6642331
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 protrudes 12 mm from
the cylinder block.
Table for correctly located camshaft bearing
Camshaft bearing no. Distance (mm)

1 -12 to -14
2 150 to 152
3 314 to 316
4 478 to 480
5 642 to 644
6 806 to 808
7 970 to 972
800eed6d
Check measurement of bearing number 1.

14. Press in the new bearing at the same time as pressing out the old bearing with hydraulic
cylinder 99 003 and hydraulic pump 99 004. Measure to check that the bearing is
correctly positioned.
15. Remove the press drift by detaching flange nut 8 and pushing in the threaded stem.
16. Note!
The seats for camshaft bearing numbers 2,
4 and 6 have two oil ways. The others only
have the lower one.
Check that the bearing oil hole is central to
the cylinder block oil ways.
800eed7d
Pressing out/pressing in bearing number 2.

17. Repeat the procedure for the remaining
2011-08-23 ?Scania CV 5 of 22
Engine no.: 6642331
bearings.
800eed83
Check measurement of bearing number 2.

18. Carefully knock with a plastic hammer to
release the old bearings.
800eed75
19. Clean the sealing surface, take a new gasket and fit the cover for the camshaft at the
front of the engine.
20. Refit the camshaft according to the section Fitting the Camshaft. Then perform a check
on the camshaft setting.
Complete
Measuring the cylinder liner height, all engines.

Tools
Tool
board
87 198 Straight edge
98 075 Dial gauge
2011-08-23 ?Scania CV 6 of 22
Engine no.: 6642331
98 515 Tension lugs
Engines with unmachined liner seats

HPI engines manufactured before February 2006 0.20-0.37 mm
Other engines 0.15-0.30 mm
Engines with machined liner seats

All engines 0.20-0.30 mm
The maximum height difference between two sides of the same liner is 0.02 mm. If the height
difference is greater, the cylinder bearing seat must be re-machined.
1. Remove any soot from the top of the cylinder block and the edge of the cylinder liner.
2. Secure the cylinder liner with two diagonally positioned tension lugs 98 515. Tighten the
tension lug bolts.
3. Position the straight edge 87 198 with dial
gauge 98 075 on the cylinder liner and D
C
reset the dial gauge against the cylinder C
liner (A in illustration). B A
80194c0c
4. Slide the straight edge from the cylinder liner (A) to the cylinder block (B) and measure
the height difference. Measure the difference in the same way at four points, 90° offset
from each other. The maximum height difference between the four points is 0.02 mm
Adjust
Machining the upper cylinder liner guide

Tools
Tool
board
588 889 Tool for machining the cylinder liner guide
2011-08-23 ?Scania CV 7 of 22
Engine no.: 6642331
Specifications for checking and adjusting the cutter
Important!
Measure the upper cylinder liner diameter

to establish the current measurement before
starting machining.
805c466e
Setting dimension A for cutter.
Cylinder liner diameter, current Setting dimension for Machined

measurement cutter dimension
A
150,02 10,51 150,02 Standard
150,02 10,76 150,52 Oversize
1
150,52 11,01 151,02 Oversize
2
151,02 11,26 151,52 Oversize
3
151,52 11,51 152,02 Oversize
4
Setting dimension B for the bevelling blade is specified on the plate in the tool box.
2011-08-23 ?Scania CV 8 of 22
Engine no.: 6642331
805c4678
Cylinder liner diameter, current Setting dimension for Machined

measurement cutter dimension
B
150,02 Standard 150,02 Standard
150,02 + 0,25 150,52 Oversize
1
150,52 + 0,50 151,02 Oversize
2
151,02 + 0,75 151,52 Oversize
3
151,52 + 1,00 152,02 Oversize
4
Checking and adjusting the cutter and bevelling blade
z To check the cutter, turn the feed screw until the blade insert holder is in its upper
position.
z To check the bevelling blade, turn the feed screw until the blade insert holder is in its
lower position.
1. Position the tool with the feed screw in the

support block and fit the micrometer.
2011-08-23 ?Scania CV 9 of 22
Engine no.: 6642331
805c4687
2. Carefully turn the base clockwise until the blade is in the right position.
3. Screw the micrometer in towards the blade and check the setting dimension. The setting
dimension for the bevelling blade is indicated on the plate in the tool box.
4. If the setting dimension is incorrect, adjust
the blade by loosening the two internal
hexagon screws that hold it in place.
805c4691
Note!
The blade is spring-loaded in the blade
insert holder.
805c48b4
5. Set the micrometer with the right setting

dimension and tighten the internal
hexagon screws that hold the blade in
place. Turn back the micrometer and
tighten the internal hexagon screws until
the blade is locked firmly in place. Check
2011-08-23 ?Scania CV 10 of 22
Engine no.: 6642331
the setting dimension of the blade and the

micrometer.
805c490a
Fitting the swarf collector
805c4910
Fit the swarf collector in the cylinder approx. 63 mm from the upper face of the cylinder
block.
Machining the upper cylinder liner guide
1. Check that the upper face of the cylinder block is clean and free from damage.
2. Turn the feed screw of the tool until the blade insert holder is in its upper position.
3. Position the tool on the upper face of the
cylinder block. Make sure that the guide
pin ends up in the right position and that
the tool makes contact with the cylinder
block.
805c491d
2011-08-23 ?Scania CV 11 of 22
Engine no.: 6642331
4. Fit the three internal hexagon screws and

tighten them with the internal hexagon key
the comes in the kit.
805c4979
5. Fit the crank on the tool.
Important!
Do not crank the tool anticlockwise as this

will destroy the blade.
z A suitable feed rate is approx. 25 cutter turns per feed turn.

z Machine without stopping until the feed screw is in its lower position.
z Continue cranking clockwise will the feed screw backs to its upper position.
6. Machine the upper cylinder liner guide on

the cylinder block with the tool.
805c497e
7. Loosen the internal hexagon screws and remove the tool.
Cleaning and checking
1. Clean the swarf collector with a vacuum and then remove it.
2. Remove the burrs from the machined cylinder block edge with abrasive paper, size 400.
3. Clean the cylinder block.
4. Check that the cylinder liner can be inserted in the cylinder block.
2011-08-23 ?Scania CV 12 of 22
Engine no.: 6642331
5. Clean the tool and return it to the box.
805c4558
Complete
Machining lower cylinder liner diameter

Tools
Tool
board
588 866 Tool for machining the cylinder liner diameter
Checking and adjusting the cutter
Important!
Measure the lower cylinder liner diameter

to make sure the cylinder liner mounted in
the cylinder block is 139 mm or 140 mm.
2011-08-23 ?Scania CV 13 of 22
Engine no.: 6642331
80348735
1. Pin
2. Loose stop lug
1. Check the fixture. Insert the gauge and

check that the micrometer indicates 0.00
mm. The loose stop lug must be removed
in order to use the gauge. Refit the loose
stop lug after checking and adjusting if
required.
80354f71
1. Gauge
2. Key
3. Loose stop lug
2011-08-23 ?Scania CV 14 of 22
Engine no.: 6642331
2. Remove the hexagon socket screw in the

centre of the cutting head.
80348749
3. Place the cutting head in the fixture.

Centre the cutting head by turning it
clockwise until it rests against the pin and
the cutter stops against the loose stop lug.
8034875d
4. If this value is correct, refit the cutting head on the tool and tighten the hexagon socket
screw. If the value needs to be adjusted, proceed as follows:
z Cylinder liner diameter 139 mm Check that the cutter is set so that the
micrometer indicates 14.03 mm.
z Cylinder liner diameter 140 mm Check that the cutter is set so that the
micrometer indicates 14.53 mm.
5. Hold the cutter against the lug and undo
the hexagon socket screw securing the
cutter. The cutter is spring loaded.
2011-08-23 ?Scania CV 15 of 22
Engine no.: 6642331
80354f91
6. Hold the cutting head with your hand and

adjust the micrometer.
z 14.03 mm gives the cutting head a

diameter of 139.03 mm.
z 14.53 mm gives the cutting head a
diameter of 140.03 mm. 80348753
7. Lightly tighten the hexagon socket screw

securing the cutter.
80348758
8. Back off the micrometer.

9. Tighten the hexagon socket screw securing
the cutter.
80354fa6
10. Check the value again.

11. Refit the cutting head on the tool, tighten the hexagon socket screw in the centre.
2011-08-23 ?Scania CV 16 of 22
Engine no.: 6642331
Adjust the diameter of the cylinder liner seat
Diameter of lower liner seat

z 139.04 +/- 0.04 mm
z 140.04 +/- 0.04 mm
80348769
1. Crank handle
2. Feed screw
3. Lever
4. Guide plate
5. Cutting head
1. Check that the upper surface of the upper liner seat on the cylinder block is not damaged.
2. Turn the feed screw clockwise until the cutting head is at the top of the tool.
3. Lubricate the cutting head sliding surfaces with thin-bodied oil.
4. Lower the tool into the cylinder block
until the guide plate centres in the upper
liner seat.
2011-08-23 ?Scania CV 17 of 22
Engine no.: 6642331
80348777
5. Secure the guide plate with the lever.

6. Fit the crank handle and crank the cutter clockwise.
Important!
The cutter must never be cranked anti-

clockwise.
7. Feed the cutting head right down until the

feed screw reaches the guide plate by
turning the feed screw anti-clockwise. A
suitable feed rate is 15-20 cutter turns per
feed turn.
8034ef53
8. Continue to crank the cutting head clockwise and feed it back up by turning the feed
screw clockwise all the way up.
9. Undo the lever on the guide plate and lift up the tool.
10. Clean the cylinder block and check that the new cylinder liner fits.
11. Clean the tool.
Adjust - Machining the cylinder liner seat, all engines

Tools
2011-08-23 ?Scania CV 18 of 22
Engine no.: 6642331
Tool
board
587 512 Milling cutter
588 672 Extension
1. Shims should be used to adjust the liner to the correct height. Shims are available in
thicknesses of 0.2 mm, 0.3 mm and 0.4 mm. If the cylinder liner needs to be raised by less
than 0.2 mm, the bearing seat should be machined until its height including the shim is
correct.
Example of cutting depth calculation
Height required 0.25 mm

Current cylinder liner height 0.16 mm
Raising the cylinder liner (0.25 0.09 mm
mm - 0.16 mm)
Shim thickness 0.2 mm
Layer which must be machined 0.11 mm
off (0.2 mm - 0.09 mm)
2. 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.
Clean the contact surface between the
setting ring (which is included in the
8019c7f4
extension kit) and the upper face of the
cylinder block.
3. Fit extension 588 672 on the milling cutter
587 512.
2011-08-23 ?Scania CV 19 of 22
Engine no.: 6642331
8019c66c
4. Set the depth of the extension to 206 mm.
206mm
8019c668
5. Position the setting ring over the relevant

cylinder and then position the milling
cutter. Energise the magnet on the cutter
by setting the switch to position 1.
8019c7f7
6. Check that the tool (cutter) does not touch the edge of the liner seat when the milling
cutter is fitted in the setting ring. Otherwise the vertical feed screw must be wound up
until the cutter is free from the liner seat.
7. Lift the rapid feeder ring and move the
2011-08-23 ?Scania CV 20 of 22
Engine no.: 6642331
cutter by hand until it is positioned above

the liner seat surface without being in
contact with the cylinder block wall.
8019c66a
8. Wind round and at the same time turn the

vertical feed screw clockwise until the
cutter just touches the liner seat.
8019c66b
9. Life the rapid feed ring and move the cutter back so that it is within the liner seat surface.
10. Adjust the vertical feed screw in order to start machining. The maximum feed per cut is
0.05 mm. If 0.05 mm is not enough, several cuts may be required until the required
position is reached.
11.
Important!
Never wind the milling cutter

anticlockwise; otherwise the cutter will
break.
Wind clockwise with an even movement

Hold in the horizontal feed screw with the
other hand at the same time. The cutter will
be fed horizontally at 0.13 mm per turn.
Wind carefully when the cutter starts to
8019c669
approach the outer edge of the liner seat.
Release the horizontal feed screw when the
cutter has gone over the edge so that
feeding stops.
12. Move the cutter back towards the centre
of the cylinder bore by holding down the
rapid feed ring at the same time as the
cutter is moved back by hand.
2011-08-23 ?Scania CV 21 of 22
Engine no.: 6642331
8019c66a
13. Repeat steps 10-12 if insufficient cutting depth has been attained.
14. When the required depth has been attained, hold down the rapid feed ring and move the
cutter to the middle of the cylinder bore. Change the switch on the milling cutter to
position 2 and lift out the entire tool. Then remove the setting ring.
15. Clean any swarf from the liner seat.
16. Position the shim on the liner seat. The shim should be dry.
17. Position the cylinder liner.
18. Measure to ensure that the height corresponds to the height specified in the work
description for measuring cylinder liner height.
2011-08-23 ?Scania CV 22 of 22
Engine no.: 6642331
01-05 Cylinder liner

Check - Cylinder liner type
Check - Measuring cylinder liner
Removal - Removing the cylinder liners
Fitting - Fitting the cylinder liner on 9 and 13 litre engines with XPI, PDE or GAS
Removal - Removing the scraper ring in the cylinder liner

Note!
Check
Cylinder liner type

1. Clean the cylinder wear ridge
A B
807147b9
It may be difficult to identify cylinder liner type when extremely worn. Clean the cylinder
wear ridge and check if there are marks after honing.
2. Identifying cylinder liner
2011-08-23 ?Scania CV 1 of 8
Engine no.: 6642331
1 A 1 B
2 2
807147ba
Identifying cylinder liner without removing from the cylinder block.

Check if there are any marks after honing 1
Cylinder liner type A No honing on the cylinder wear ridge.
Cylinder liner type B Honing on the cylinder wear ridge.
Identifying cylinder liner removed from the cylinder block.
Check if there are signs of machining on the lower edge 2.
Cylinder liner type A No signs of machining on the lower edge.
Cylinder liner type B Signs of machining on the lower edge.
Check
Measuring cylinder liner

1.
2011-08-23 ?Scania CV 2 of 8
Engine no.: 6642331
A B
C C
D D
807147bc
Check wear by measuring the cylinder wear ridge and cylinder bore.
C Measure the diameter of the cylinder wear ridge 2-8 mm down the cylinder bore.
D Measure the diameter of the cylinder bore 10-12 mm down the cylinder bore.
2. Cylinder liner type A
The difference between the diameter of cylinder wear ridge C and the diameter of
cylinder bore D must not exceed 0.06 mm
Cylinder liner type B
The difference between the diameter of cylinder wear ridge C and the diameter of
cylinder bore D must not exceed 0.06 mm
Removal - Removing the cylinder liners
2011-08-23 ?Scania CV 3 of 8
Engine no.: 6642331
Tools
Tool
board
99 066 Cylinder liner puller D2
1. Mark the cylinder liners. The mark is necessary so that the liners can be refitted in the
same place and position as previously.
Important!
The mark must be made only on the

surface indicated in the illustration. Other
surfaces are for sealing. If you use a
marker, you can mark anywhere.
800d7683
2. Remove the cylinder liner using puller 99 066.
2011-08-23 ?Scania CV 4 of 8
Engine no.: 6642331
99 003
99 066
800d7684
3. Remove the sealing ring in the cylinder block.
Fitting
Fitting the cylinder liner on 9 and 13 litre engines with XPI,

PDE or GAS
Important!
Use only glycerol to lubricate the cylinder

block, cylinder liner and O-rings. Other
lubricants may swell the O-rings.
Important!
The O-rings for the cylinder block and

cylinder liner have different thicknesses
and diameters. The thinnest O-ring with the
smallest diameter fits on the cylinder liner.
Tools
2011-08-23 ?Scania CV 5 of 8
Engine no.: 6642331
Tool
board
99 616 Compression ring
1. Check the cylinder liner height according to the work description for measuring cylinder
liner height.
2. Make sure the interior of the cylinder block is clean. Clean the O-ring surfaces.
3. Clean away any grease and dirt from compression ring 99 616.
4. Position the compression ring on the
cylinder block. Check that it does not
make contact with the cylinder head guide
pins. If it does, tap down the guide pins
further.
805cbcdf
5. Set the compression ring to one side.

6. Lubricate the O-ring to be fitted in the cylinder block with glycerol and fit it.
7. Carefully check the cylinder liner, both new and old, for cracks which might have arisen
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, there will be no clear ringing sound.
8. Clean the O-ring groove of the cylinder liner.
9. Check the O-ring to be fitted in the cylinder liner and fit it.
10. Lubricate the lower guide surface on the cylinder liner with glycerol.
11. Thoroughly lubricate the compression
ring 99 616 with glycerol and refit it in
the cylinder block, centred over the
cylinder liner bore.
2011-08-23 ?Scania CV 6 of 8
Engine no.: 6642331
805cbce0
12. Turn the liner with the stamped cylinder

number facing forward. If an old liner is
being refitted, ensure that it is refitted in
the same place and position as before.
Position the cylinder liner in the cylinder
block and press it down past the first
resistance. The cylinder liner should
protrude approx. 1 cm in the compression
ring. While the cylinder liner slides
down, the compression ring is centred
automatically. 805cbce1
13. Grasp the cylinder liner with both hands

and press it down into place with a
single, even movement. If the cylinder
liner does not go into place immediately,
there is a great risk that the upper O-ring
is damaged.
805cbce2
14. Check that the liner goes down

completely.
2011-08-23 ?Scania CV 7 of 8
Engine no.: 6642331
805cbce3
Removal
Removing the scraper ring in the cylinder liner

If the scraper ring is so firmly seated that it cannot be removed by hand, use the following
method:
1. Remove the cylinder head and oil sump.
2. Turn the crankshaft so that the piston goes down far enough so that there is enough room
for plate 99 168 under the scraper ring.
3. Fit tension lugs 98 515 on the edge of the cylinder liner in such a way that the liner will
not be pulled out of place.
4. Position plate 99 168 on the piston crown.
5. Press a piston ring into the liner until it is below the scraper ring.
6. Fit handle 99 168 on impact drift 99 074.
If it proves difficult to fit the screw in the
handle, the head of the screw can be
ground down slightly. Take care not to
weaken the screw if this is done. 99 074
99 168
8065e9bb
7. Screw the screw into the plate.

8. Pull up the plate until it abuts against the piston ring pressed into the liner.
9. Drive out the scraper ring with the impact drift.
2011-08-23 ?Scania CV 8 of 8
Engine no.: 6642331
01-05 Flywheel housing

Removal - Removing the flywheel housing on 9 and 13 litre engines
Fitting - Fitting the flywheel housing on 9 and 13 litre engines
Renewal - Renewing the rear crankshaft seal on 9, 13, and 16 litre engines with XPI,
PDE or GAS

Note!
Removal
Removing the flywheel housing on 9 and 13 litre engines

1. Remove the oil sump, oil suction pipe and ladder frame, if fitted.
2. Remove the starter motor. Refer to work description for removing the starter motor.
3. Remove the flywheel. Refer to work description for removing the flywheel.
4. If the engine has a hydraulic pump.
Detach the hydraulic pump and move it aside.
5. Where appropriate, remove the power take-off and units connected to it.
6. Remove the flywheel housing.
Note!
The ladder frame is attached to the
flywheel housing. The ladder frame gasket
must not be refitted.
802ff187
Fitting
Fitting the flywheel housing on 9 and 13 litre engines
2011-08-23 ?Scania CV 1 of 6
Engine no.: 6642331
Sealant
Sealant for flywheel housing 816 064
Tools
588 189 Air-operated spray gun
584 117 Adapter for cartridge
584 118 Nozzle
Tools
Tool
board
588 189 Air-operated spray gun
1. Remove all old sealant 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!
The sealing surfaces must be absolutely

clean and free from grease.
2. Using nozzle 584 118, apply sealant to the

flywheel housing on the side towards the
timing gear plate. The bead (X) should be
approx. 1.5 mm wide. Follow the pattern
illustrated. Also apply sealant around the
screw holes marked with arrows.
Important!
The sealant should be applied inside the

bolt holes, but without allowing sealant
into the crankcase. The sealant may block
channels and nozzles. This is particularly
important to bear in mind around oilways,
where the flow of oil to the air compressor
and injection pump can be blocked.
2011-08-23 ?Scania CV 2 of 6
Engine no.: 6642331
Important!
Assembly must be completed within 25

minutes of starting to apply the sealant.
To facilitate assembly and avoid sealant
getting into the wrong places, make 2 guide
pins which are fitted into the upper bolt
holes on the flywheel housing.
=X
806efb26
3. Fit the flywheel housing against the timing gear plate.

4. Tighten the bolts.
M10x30
Note!
The bolts are of various sizes and lengths.
Ensure that they are fitted in the correct
places.
M10x30
80449a70
M10x60 M12x100 M10x60
M10x80 M12x100 M10x60
2011-08-23 ?Scania CV 3 of 6
Engine no.: 6642331
80449a69
M10x30 M10x45
80449a74
5. Where appropriate, fit the power take-off and units connected to it.
6. If the engine has a hydraulic pump.
Fit the hydraulic pump.
7. Fit the flywheel. Refer to the work description for fitting the flywheel.
8. Fit the starter motor. Refer the work description for fitting the starter motor.
9. Fit the oil sump, oil suction pipe and ladder frame, if fitted.
Renewal
Renewing the rear crankshaft seal on 9, 13, and 16 litre

engines with XPI, PDE or GAS
Tools
Tool
board
99 148 Press drift
1. Remove the flywheel according to instructions.
2011-08-23 ?Scania CV 4 of 6
Engine no.: 6642331
2. Remove the crankshaft seal using a

screwdriver. Take care not to scratch the
sealing surfaces on the crankshaft and the
flywheel housing. Alternatively a self-
tapping screw can be screwed into the
crankshaft seal so that the crankshaft seal
can be pulled out with a slide hammer.
803b6369
Note!
The crankshaft seal must be fitted dry and
must not be lubricated. The sleeve in the
seal must be left in place. Do not touch the
sealing lip with your fingers.
3. Fit a new crankshaft seal using tool 99
148. Place the crankshaft seal on the tool
and fasten the tool with the bolts.
806b9d21
99 148
8043097a
2011-08-23 ?Scania CV 5 of 6
Engine no.: 6642331
4. Tighten the bolts alternately until the tool stops against the cover. Then remove the tool
and the protection ring of the crankshaft seal.
5. Clean the flywheel sealing surface using degreasing agent and wipe it dry before
assembly.
6. Fit the flywheel according to instructions.
2011-08-23 ?Scania CV 6 of 6
Engine no.: 6642331
01-05 Front cover

Removal - Removing the front cover on 9 and 13 litre engines with XPI, PDE or GAS
Fitting - Fitting the front cover on 9 and 13 litre engines with XPI, PDE or GAS
Renewal - Renewing the front crankshaft seal on 9 and 13 litre engines with XPI,
PDE or GAS

Note!
Removal
Removing the front cover on 9 and 13 litre engines with

XPI, PDE or GAS
1. Switch off the main power supply.
2. Remove the radiator if necessary. See the work description for removing the radiator,
section 02-01 Radiator.
3. Remove the fan ring, marking its position.
4. Remove the fan electrical cable.
5. Remove the fan. Maintain the fan upright.
6. Drain the oil from the oil sump.
7. Remove the poly-V-belt(s). Refer to 01-15 Belt circuit, Renewing drive belts.
8. Remove the pulley and the hub.
9. Remove the oil sump and ladder frame.
10. Remove the 8 front cover bolts and
remove the front cover.
2011-08-23 ?Scania CV 1 of 5
Engine no.: 6642331
805a5617
805a5618
11. Remove the front cover and ladder frame gaskets. If the surfaces have been sealed with
silicone, it must be washed away.
Fitting
Fitting the front cover on 9 and 13 litre engines with XPI,

PDE or GAS
1. Fit the front cover.
2011-08-23 ?Scania CV 2 of 5
Engine no.: 6642331
805a5617
805a5618
2. Fit the ladder frame and oil sump.

3. Fit the poly-V-belt(s). Refer to 01-15 Belt circuit, Renewing drive belts.
4. Fit the fan.
5. Fit the fan electrical cable.
6. Fit the fan ring.
7. If the radiator was removed: Fit the radiator. See section 02-01 Radiator, Fitting the
radiator.
8. Fill with engine oil.
9. Switch on the main power supply.
Renewal
Renewing the front crankshaft seal on 9 and 13 litre

2011-08-23 ?Scania CV 3 of 5
Engine no.: 6642331
Tools
Tool
board
99 149 Press drift D7
1. Remove the cooling package and fan then release the belt drive and loosen the pulley
(pulley on engines with geared-up fan) as described in the relevant work description under
Cooling system.
2. Remove the crankshaft seal with a screwdriver, take care not to damage any sealing
surfaces. Alternatively a self-tapping screw can be screwed into the crankshaft seal so that
the crankshaft seal can be pulled out with a slide hammer.
3. Wipe around all surfaces.
4. Note!
The crankshaft seal must be fitted dry and
on no account must it be lubricated. Do
not touch the sealing lip with your fingers.
Fit the new crankshaft seal onto tool 99 149.
8071610d
2011-08-23 ?Scania CV 4 of 5
Engine no.: 6642331
99 149
807214f3
Note!
Note the fitting direction of the seal!
5. Press the new seal into position with tool 99 149. The seal is correctly fitted when the tool
is pressed home against the front cover.
6. Fit the pulley (pulley on engines with geared-up fan), fan and cooling package as
described in the relevant work description under Cooling system.
2011-08-23 ?Scania CV 5 of 5
Engine no.: 6642331
01-05 Front timing gear housing

Note!
2011-08-23 ?Scania CV 1 of 1
Engine no.: 6642331
01-05 Oil mist separator

Removal - Removing the oil mist separator on 9 and 13 litre engines with XPI, PDE or
GAS
Fitting - Fitting the oil mist separator on 9 and 13 litre engines with XPI, PDE or GAS
Dismantling - Dismantling the oil mist separator on 9 and 13 litre engines with XPI,
PDE or GAS
Assembly - Assembling the oil mist separator on 9 and 13 litre engines with XPI, PDE
or GAS
Check - Measuring the speed on the oil mist separator
Specification

Note!
Removal
Removing the oil mist separator on 9 and 13 litre engines

with XPI, PDE or GAS
1. If the engine has an exhaust brake:
Remove the exhaust pipe between the exhaust brake and silencer.
Undo the V-clamp between the turbocharger and exhaust brake. Lift up the exhaust brake
and undo the compressed air hose. Remove the exhaust brake.
2. Remove the outlet pipe and inlet pipe from the compressor.
3. Note!
Cover all inlets and outlets.
4. Undo the hose clamps for the oil return
pipe and remove the hose.
2011-08-23 ?Scania CV 1 of 9
Engine no.: 6642331
8 4 7 5
80430c66
5. Remove the delivery pipe for the oil mist separator.

6. Undo the inlet pipe for the oil mist separator.
7. Remove the oil mist separator outlet pipe.
8. Remove the oil mist separator.
Fitting
Fitting the oil mist separator on 9 and 13 litre engines with

XPI, PDE or GAS
1. Fit the oil mist separator and the inlet pipe at the same time.
2. Fit the pressure pipe and the oil mist separator outlet pipe.
3. Fit the compressor outlet pipe and inlet pipe. Renew damaged O-rings
4. Fit the oil return pipe.
5. If the engine has an exhaust brake:
Fit the exhaust brake and the exhaust pipe between the exhaust brake and silencer.
Dismantling
Dismantling the oil mist separator on 9 and 13 litre engines

2011-08-23 ?Scania CV 2 of 9
Engine no.: 6642331
Warning!
Read the regulations for ethanol in 00:01-
02 before starting the work.
Follow the instructions in section
Procedures for all work in the workshop.
In addition, adhere to any local rules and
regulations for working with ethanol
applicable to the workshop.
Remove the oil mist separator from the engine before it is dismantled.
2011-08-23 ?Scania CV 3 of 9
Engine no.: 6642331
4
13
3
14
2 15
16
1
5
6
8
17
11
9 18
10
16
18
19
20
12
25 21
26
27 22
23
24
28 29
804a419b
1. Remove the gasket (26) between the turbine housing (27) and oil mist separator housing
(1).
2. Lift the rotor assembly out of the oil mist separator housing. If the rotor assembly is
difficult to remove, use a rubber mallet to carefully tap alternately on the three screw
joints.
2011-08-23 ?Scania CV 4 of 9
Engine no.: 6642331
804a4124
3. Remove the turbine (23) from the rotor unit shaft. Press the turbine downwards and
release the snap ring (24).
4. Detach the rotor discs by removing the snap ring (19). The magnets fitted in the
uppermost rotor disc can easily be detached when the rotor discs are dismantled.
5. Remove the diaphragm cover (8).
6. Remove the diaphragm spring (7) and diaphragm (6).
Assembly
Assembling the oil mist separator on 9 and 13 litre engines

Important!
New O-rings and gaskets should be used

when the oil mist separator is reassembled.
2011-08-23 ?Scania CV 5 of 9
Engine no.: 6642331
4
13
3
14
2 15
16
1
5
6
8
17
11
9 18
10
16
18
19
20
12
25 21
26
27 22
23
24
28 29
804a419b
1. Fit the rotor discs (17) on the rotor shaft and fit the snap ring (19).
2. Fit the rotor in the insert (21).
3. Fit the turbine (23) on the rotor shaft and press on the snap ring (24).
4. Fit a new O-ring (20).
5. Press the rotor assembly down into the oil mist separator housing (1).
2011-08-23 ?Scania CV 6 of 9
Engine no.: 6642331
6. Fit the diaphragm (6) and diaphragm spring (7).

7. Fit the diaphragm cover (8).
Check - Measuring the speed on the oil mist separator

An angled ABS sensor should be used to measure the speed on the oil mist separator. Cut the
electrical cables and fit two connectors suitable for a multimeter which can measure Hz, see
illustration.
80235645
1. Start the engine and rev it up to 1000 rpm.

2. Hold the sensor against the oil mist separator and read the multimeter. The value should
be at least 150 Hz at an engine speed of 1000 rpm.
9, 11 and 12 litre engines with PDE or HPI
8023564d
9 and 13 litre engines
2011-08-23 ?Scania CV 7 of 9
Engine no.: 6642331
80714144
16 litre engine with XPI
80714145
Specification
Measurements
2011-08-23 ?Scania CV 8 of 9
Engine no.: 6642331
Cold engine at idling speed, oil temperature of 20- 120 +/-50 Hz

50°C
Warm engine at engine speed of 1000 rpm 150 - 220 Hz
2011-08-23 ?Scania CV 9 of 9
Engine no.: 6642331
01-05 T74, Engine speed sensor 1

Location
9 and 13 litre engines with XPI, PDE or GAS
T74
803c2420
2011-08-23 ?Scania CV 1 of 1
Engine no.: 6642331
01-05 T75, Engine speed sensor 2

Location
9 and 13 litre engines with XPI, PDE or GAS
T75
803c2421
2011-08-23 ?Scania CV 1 of 1
Engine no.: 6642331
01-10 Camshaft
Removal - Removing the camshaft on 9, 11, 12 and 13 litre engines with PDE, HPI,
XPI or GAS
Removal - Removing the camshaft from the front on 9, 11, 12 and 13 litre engines
with PDE, HPI, XPI or GAS
Fitting - Fitting the camshaft on 9, 11, 12 and 13 litre engines with PDE, HPI, XPI or
GAS
Fitting - Fitting the camshaft from the front on 9, 11, 12 and 13 litre engines with
PDE, HPI, XPI or GAS

Note!
Removal
Removing the camshaft on 9, 11, 12 and 13 litre engines

with PDE, HPI, XPI or GAS
1. Remove the flywheel according to the work description Removing the flywheel.
2. Remove the flywheel housing according to the work description Removing the flywheel
housing.
3. Note!
Check the condition of the rocker arms,
valve bridges and pushrods. Renew
damaged parts. Mark the parts that are
undamaged because they must be refitted
in their original positions.
Remove rocker arms, pushrods and valve bridges.
4. Remove the camshaft gear.
5. Remove the intermediate gear according to the work description Removing the
intermediate gear and bolts for the guide flange.
6. Remove the timing gear plate.
7. Remove the camshaft covers.
2011-08-23 ?Scania CV 1 of 10
Engine no.: 6642331
800f1c2d
8. Note!
Mark the roller tappets, as they must be
refitted in the same place.
Remove the roller tappets.
800f1c2e
9. Pull the camshaft backwards. Take care not to damage the cams and bearings.
Removal
Removing the camshaft from the front on 9, 11, 12 and 13

litre engines with PDE, HPI, XPI or GAS
If there is room, it is easiest to remove the camshaft from the rear. On many vehicles with
bodywork this is not, however, possible so that it becomes necessary to remove it from the
front. It is not necessary to lift out the engine, but the cooling package needs to be removed.
1. If the engine has a gearbox:
Remove the gearbox as instructed in the work description Removing the gearbox.
2. Remove the flywheel as instructed in the work description Removing the flywheel.
3. Remove the flywheel housing as instructed in the work description Removing the
flywheel housing.
5. Remove the intermediate gear as instructed in the work description Removing the
intermediate gear.
6. Remove the timing gear plate.
7. Drain the cooling system as instructed in the work description Draining the cooling
system.
8. Remove the cooling package as instructed in the work description Removing the radiator.
2011-08-23 ?Scania CV 2 of 10
Engine no.: 6642331
9. Working from the front with the cab tilted: Remove the fan and drive belt as instructed in
the work description Renewing the drive belt. Remove both belts if the vehicle is
equipped with a geared-up fan.
10. Remove the alternator 1, AC compressor 2 4 3
(if fitted), belt tensioner for the outer belt 3
and idler roller 4. Leave the belt tensioner
lock in position while the belt tensioner is
2
removed. Keep the belt tensioner so that
there is no risk of the lock coming loose.
Important!
1
The belt tensioner can break if the lock
comes loose. Make sure the bolt or drill is
pushed in properly!
8050844f
11. Unscrew the front camshaft cover. The

camshaft is then exposed so that it can be
removed from the front.
80508494
80508498
Camshaft exposed.
12. Lift off the rocker covers and remove the rocker arms, pushrods and valve bridges.
Note!
Check the condition of the rocker arms,
2011-08-23 ?Scania CV 3 of 10
Engine no.: 6642331
valve bridges and pushrods. Renew

damaged parts. Mark the parts that are
undamaged because they must be refitted
in their original positions.
13. Release the camshaft covers so that they can be unscrewed. The high pressure pump,
fuel filter housing with holder, engine control unit and AC compressor cooling coil (if
applicable) must be removed to access the covers.
Important!
Depressurise the fuel system before

starting to work on the high pressure pump.
Use SDP3 to minimise the high pressure in
the fuel system.
14. Remove the camshaft covers.
800f1c2d
15. Remove the roller tappets.

Note!
Mark the roller tappets, as they must be
refitted in the same place.
800f1c2e
16. Remove the guide flange with thrust washer in the rear end of the camshaft.
17. Pull the camshaft out forwards. Take care not to damage the cams and bearings.
Fitting
Fitting the camshaft on 9, 11, 12 and 13 litre engines with

PDE, HPI, XPI or GAS
1. Note!
2011-08-23 ?Scania CV 4 of 10
Engine no.: 6642331
Lubricate the entire camshaft and the

bearing seats with engine oil before fitting
the camshaft in the cylinder block.
Fit the camshaft. Take care not to damage the cams and bearings.
2. Lubricate the valve tappets with engine oil
and fit them in the same places as before
they were removed. Remember to
lubricate the shells before fitting the
pushrods. Tighten the screws.
800f1c2e
3. Fit the camshaft apertures. Tighten the screws.

4. Fit the guide flange bolts.
Now the camshaft axial clearance can be checked:
z Fit the camshaft gear temporarily.

z Measure the camshaft axial clearance using a dial gauge. The axial clearance should be
between 0.05 - 0.35 mm.
z If the clearance is outside the permitted range, renew the thrust washer.
z Remove the camshaft 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 timing gear plate

using nozzle 584 118. The sealant should
be placed outside the milled grooves as
illustrated. The diameter of the bead
should be approximately 4 mm.
2011-08-23 ?Scania CV 5 of 10
Engine no.: 6642331
=4
8044da2d
Important!
Ensure that you apply sealant inside the

screwholes, but without allowing sealant
important to bear in mind around oil ways,
or injection pump can be blocked.
Important!

7. Fit the timing gear plate onto the cylinder

block. Tighten the screws.
800f1c8b
8. Fit the intermediate gear as described in the work description Fitting the intermediate
gear.
9.
Ensure that the markings on the camshaft gear point towards the centre of the intermediate
2011-08-23 ?Scania CV 6 of 10
Engine no.: 6642331
gear.
10. Fit the camshaft gear and tighten the screws.
11. Fit the flywheel housing as described in the work description Fitting the flywheel
housing.
12. Fit the flywheel as described in the work description Fitting the flywheel.
Fitting
Fitting the camshaft from the front on 9, 11, 12 and 13 litre

engines with PDE, HPI, XPI or GAS
1. Note!
Lubricate the entire camshaft and the
bearing seats with engine oil before fitting
the camshaft in the cylinder block.
Fit the camshaft. Take care not to damage the cams and bearings.
2. Lubricate the valve tappets with engine oil
and fit them in the same places as before
they were removed. Remember to
lubricate the shells before fitting the
pushrods. Tighten the screws. Refit the
rocker covers.
800f1c2e
3. Fit the camshaft covers. Tighten the screws.

4. Fit the guide flange with thrust washer in the rear end of the camshaft.
Now the camshaft axial clearance can be checked:
z Fit the camshaft gear temporarily.

z Measure the camshaft axial clearance using a dial gauge. The axial play should be
between 0.05 and 0.35 mm.
z If the clearance is outside the permitted range, renew the thrust washer.
z Remove the camshaft gear again.
timing gear plate. Clean off any oil and grease from the sealing surfaces using an alcohol
based detergent.
Important!
2011-08-23 ?Scania CV 7 of 10
Engine no.: 6642331

6. Apply sealant to the timing gear plate

using nozzle 584 118. The sealant should
be placed outside the milled grooves as
illustrated. The diameter of the bead
should be approximately 4 mm.
=4
8044da2d
Important!
Ensure that you apply sealant inside the

screwholes, but without allowing sealant
important to bear in mind around oilways,
or injection pump can be blocked.
Important!

7. Fit the timing gear plate onto the cylinder

block. Tighten the screws.
800f1c8b
2011-08-23 ?Scania CV 8 of 10
Engine no.: 6642331
8. Fit the intermediate gear as instructed in the work description 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 screws.
11. Fit the flywheel housing as described in the work description Fitting the flywheel
housing.
13. Refit all components that were removed from the engine side: High pressure pump, fuel
filter housing with holder, engine control unit and cooling coil for AC compressor (if
fitted).
front camshaft cover. Clean off any oil and grease from the sealing surfaces using an
alcohol based detergent.
Important!

15. Apply sealant to the groove on the cover.

The diameter of the bead should be
approximately 4 mm.
Important!
Make sure that you apply the sealant

evenly along the groove on the cover. Be
particularly careful by the oilway which is
visible under the camshaft. Excess sealant
can block the channel.
Important!

8050849d
2011-08-23 ?Scania CV 9 of 10
Engine no.: 6642331
805091a2
Oilway under the camshaft.

16. Fit the camshaft cover. Tighten the screws.
17. Fit the idler roller, belt tensioner with the lock still in position, alternator and AC
compressor (if fitted).
18. Refit the drive belt and fan as described in the instructions Renewing the drive belt.
19. Fit the cooling package as instructed in the work description Fitting the radiator. Fill the
cooling system as instructed in the work description Filling coolant.
20. If the engine has a gearbox:
Fit the gearbox as instructed in the work description Fitting the gearbox.
2011-08-23 ?Scania CV 10 of 10
Engine no.: 6642331
01-10 Connecting rod

Check

Note!
Check
Checking the connecting rod
Tools
Tool
board
587 110 Control device
Check the connecting rods using tool 587 110.

Make sure the gudgeon pin bush is not damaged and then proceed as below:
1. Fit the connecting rod cap according to the markings and tighten the screws to the correct
torque according to the table above.
2. Fit the connecting rod in the tool using the expander and put the corresponding gudgeon
pin in the gudgeon pin bush.
3. Then apply the indicator to the gudgeon pin.
Check whether the connecting rod is twisted with the indicator studs horizontal.
2011-08-23 ?Scania CV 1 of 3
Engine no.: 6642331
800ef27b
Checking for twisted connecting rod.

Check whether the connecting rod is bent with the indicator studs vertical.
800ef290
Checking for bent connecting rod

The distance between the indicator studs on the tool illustrated here is 75 mm. The distance
2011-08-23 ?Scania CV 2 of 3
Engine no.: 6642331
between one of the indicator studs and the measuring surface must be max. 0.1 mm when
measured using this tool. Check with a feeler gauge.
Check also 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.
800ef297
Checking whether the connecting rod is bent in an S-shape
2011-08-23 ?Scania CV 3 of 3
Engine no.: 6642331
01-10 Crankshaft
Removal - Removing the crankshaft on 9 and 13 litre engines with XPI, PDE or GAS
Fitting - Fitting the crankshaft on 9 and 13 litre engines with XPI, PDE or GAS
Adjust - Machining the crankshaft
Specification - Dimensions for machining the crankshaft on 9 and 13 litre engines

Note!
Removal
Removing the crankshaft on 9 and 13 litre engines with

XPI, PDE or GAS
1. Remove the crankshaft gear as described in Removing the crankshaft gear.
2. Remove the crankshaft pulley as described in the work description Removing the pulley.
3. Remove the oil sump, oil pump suction pipe, ladder frame and oil pump as described in
the relevant work descriptions.
4. Remove the pistons and connecting rods according to the work description Removing
pistons.
5. Remove the main bearing caps and main bearings.
Note!
The main bearings and main bearing caps
are marked and must be refitted in the
same place.
6. Lift out the crankshaft.
2011-08-23 ?Scania CV 1 of 6
Engine no.: 6642331
800ef4f2
Fitting
Fitting the crankshaft on 9 and 13 litre engines with XPI,

PDE or GAS
All parts must be cleaned before fitting.
1. Place the bearing shells in the main bearing
seats in the cylinder block and in the main
bearing caps. Then lubricate the bearing
surfaces with engine oil.
Note!
The outside of the bearing shells must not
be lubricated.
800ef501
2. Lift in the crankshaft.

3. Lubricate the bolt thread and the surface of
the main bearing cap where the bolt is
tightened, see illustration. Scania engine
oil can be used.
2011-08-23 ?Scania CV 2 of 6
Engine no.: 6642331
802ac246
4. Fit the main bearing caps.

Note!
Fit the main bearings and caps in the same
place as before removal.
800ef50d
5.
Important!
The bolts can only be reused three times.

Check the number of punch marks on the
head, if a screw has three punch marks it
must be replaced.
Tighten the bolts for the main bearing caps, see tightening torques in the list in subgroup
01-00.
6. Mark the bolt heads with a punch mark
whenever they are tightened.
2011-08-23 ?Scania CV 3 of 6
Engine no.: 6642331
1 2 3 4
806a1afa
7. Fit the pistons with connecting rods according to the work description for Fitting pistons.
8. Fit the oil pump, ladder frame (if applicable), oil pump suction pipe and finally the oil
sump as specified in the relevant work descriptions.
Adjust
Machining the crankshaft

1. Measure the diameter of the crankshaft
bearing journal using a micrometer.
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. Refer to
the dimensions under the tab
"Specification".
Oil pressure should also be checked, as it
is affected by such factors as wear in the 805c8888
main bearings and connecting rod Measuring the crankshaft
bearings.
2. When regrinding, keep to the undersizes
indicated in the "Specification" tab.
Suitable bearings are available for these
sizes.
It is important that the fillet radius of the
bearing journals is correct. Use a template
to check fillet radius.
2011-08-23 ?Scania CV 4 of 6
Engine no.: 6642331
805c888c
Measure the fillet radius using a template

3. After grinding the bearing journals, round off and polish the oil hole openings on the
bearing surfaces.
Specification
Dimensions for machining the crankshaft on 9 and 13 litre

Main bearing races 9 litre engine 13 litre engine
Standard, diameter (mm) 107.978 - 108.000 107.978 - 108.000
Undersize 1, diameter (mm) 107.728 - 107.750 107.728 - 107.750
Fillet radius (mm) 4.8 - 5.2 4.8 - 5.2
Surface quality (Ra) 0.25 0.25
Connecting rod races 9 litre engine 13 litre engine

Standard, diameter (mm) 86.978 - 87.000 92.978 - 93.000
2011-08-23 ?Scania CV 5 of 6
Engine no.: 6642331

Fillet radius (mm) 4.8 - 5.2 4.8 - 5.2
Surface quality (Ra) 0.25 0.25
Width, max. (mm) 56.05 54.05
Radial clearance (mm) 0.051 - 0.114 0.051 - 0.114
Thrust bearing washers

Standard, thickness (mm) 3.370 - 3.430
Oversize 1, thickness (mm) 3.450 - 3.510
Axial clearance (mm) 0.138 - 0.380
2011-08-23 ?Scania CV 6 of 6
Engine no.: 6642331
01-10 Flywheel
Removal - Removing the flywheel on all engines
Fitting - Fitting the flywheel on 9 and 13 litre engines with XPI, PDE or GAS
Renewal - Renewing the external ring gear on the flywheel
Renewal - Renewing support bearing
Check - Checking the flywheel

Note!
Removal
Removing the flywheel on all engines

Tools
Tool
board
AM1,
D3,
87 368 Puller bolts B1,
AD1,
D3
1. Remove engine speed sensor(s) in flywheel housing.
2. Remove the flywheel bolts.
3. Pull off the flywheel from the crankshaft
using puller bolts 87 368. 87 368
2011-08-23 ?Scania CV 1 of 4
Engine no.: 6642331
80172540
The illustration shows the 9, 11, 12 and 13

litre engine but also applies to 16 litre
engines.
Fitting
Fitting the flywheel on 9 and 13 litre engines with XPI, PDE

or GAS
Tools
Tool
board
99 478 Guide pins
Tool for locking the flywheel on engines with unit

99 411 D5
injectors.
1. Fit two guide pins 99 478 in the

crankshaft.
99 478
80431099
2. Fit the flywheel on the crankshaft.
Important!
Use new hexagon screws and lubricate
2011-08-23 ?Scania CV 2 of 4
Engine no.: 6642331
them with engine oil before fitting.
3. Lock the flywheel with tool 99 411 on engines with unit injectors.
4. Refit the engine speed sensor(s).
Renewal - Renewing the external ring gear on the flywheel

Renew the flywheel external ring gear if the gear teeth have become so worn that the starter
pinion will not engage.
1. Grind a groove as deep as possible in the ring gear and crack it open with a chisel.
Remove the ring gear from the flywheel.
2. Clean the contact surfaces of the flywheel with a wire brush.
3. Heat the new ring gear evenly around its circumference to 100 - 150°C.
4. Lay the heated external ring gear on the flywheel so that the bevelled side is facing the
starter motor. Make sure the ring gear is securely against the flywheel. If necessary, knock
down the ring gear with a plastic hammer.
5. The ring gear must not be cooled rapidly but be left to cool in the open air.
Renewal - Renewing support bearing

Tools
Tool
board
D3,
99 250 Drift
C4
1. Remove the retaining rings on both sides of the support bearing.

2. Tap the support bearing out of the 99 250
flywheel using drift 99 250.
806690f3
3. Fit the inner retaining ring and a new support bearing using drift 99 250.
2011-08-23 ?Scania CV 3 of 4
Engine no.: 6642331
4. Fit the outer retaining ring.
Check - Checking the flywheel

Check the friction surface of the flywheel for heat damage.
If the friction surface of the flywheel has deep thermal cracks or blueing that may sometimes
be obvious as a movement of the material, the flywheel should not be re-used.
Heat, caused by incorrect use of the clutch, will often lead to the friction surface of the
flywheel distorting and becoming concave.
The concavity is not detrimental if the same flywheel and disc are refitted. However, when
renewing discs it is advisable to check how deep this concavity is.
If, by measuring as shown in the illustration, it is found that dimension B is greater than 0.6
mm, there is an increased risk of rapid disc wear in the future.
If the distortion or wear, dimension A, is greater than approx. 1 mm, the flywheel should be
renewed.
C D
A=C-D
8048209b
2011-08-23 ?Scania CV 4 of 4
Engine no.: 6642331
01-10 Piston
Removal - Removing the piston from 9, 13 and 16 litre engines with PDE or XPI
Fitting - Fitting the piston on 9, 13 and 16 litre engines with PDE or XPI
Renewal - Renewing piston on connecting rod, renewing piston rings

Note!
Removal
Removing the piston from 9, 13 and 16 litre engines with

PDE or XPI
1. Remove the cylinder head according to section Removing the cylinder head.
2. On engines with scraper ring:
Remove the scraper ring. See section 01-05 Cylinder block, Cylinder liner.
3. Drain the engine oil.
4. Remove the clamp in the ladder frame for the oil level sensor cable harness. Remove the
oil sump with oil level sensor.
5. Remove the oil pump suction pipe. Keep the two O-rings fitted on the pipe.
6. Remove the ladder frame if fitted.
7. Remove the piston cooling nozzle in the cylinder block on the relevant cylinder.
Important!
Damaged piston cooling nozzles must not

be re-aligned, renew them instead. The oil
jet must hit the piston precisely. If it does
not, the piston will become overheated
resulting in engine breakdown.
8. Remove the connecting rod cap and connecting rod bearing shells. Protect the oilway in
the crankcase e.g. by winding tape around it with the sticky side out.
Mark the piston before removing; the connecting rod is marked. The parts must be refitted
2011-08-23 ?Scania CV 1 of 7
Engine no.: 6642331
9. in the same place and position. Lift out the piston and connecting rod.
Note!
Always check the connecting rod as
described in Checking the connecting rod,
if the cylinder has seized, been filled with
water or had a broken valve. Bent
connecting rods must not be straightened.
Fitting
Fitting the piston on 9, 13 and 16 litre engines with PDE or

XPI
Tools
Tool
board
99 572 Piston ring compressor
99 631 Adapter for cylinder liner with scraper ring
1. Lubricate the piston, piston rings, cylinder liner and piston ring compressor with engine
oil.
2. Remove the protection on the connecting rod race and lubricate it.
3. Turn the piston rings so that the gaps are distributed around the piston.
4. Fit the upper connecting rod bearing shell to the connecting rod and lubricate the bearing
surface.
5. Put the piston onto the connecting rod so
that the arrow marks on the piston will
face the front of the engine. Applies only 1
to aluminium pistons, steel pistons are
symmetrical.
2
Place piston ring compressor 99 572 in
position and push the piston and 8066f9e3
connecting rod into the cylinder liner.

If the cylinder liner has a scraper ring, 1. Piston ring compressor
2. Adapter for cylinder liner with scraper
2011-08-23 ?Scania CV 2 of 7
Engine no.: 6642331
adapter 99 631 must be positioned ring.

between the cylinder liner and piston ring
compressor before the piston is slid down
into the cylinder liner. See illustration.
On an aluminium piston, the arrow on the
piston must point forward in the direction
of the engine. The short end of the
connecting rod should face the engine
intake manifold.
800ef142
The arrow must be facing the front of the

engine.
803004ce

engine.
6. Insert the connecting rod bearing shell in the connecting rod cap, lubricate the bearing
surface and fit the connecting rod cap the right way round. The number markings on the
connecting rod and on the connecting rod cap should be on the same side.
7. Lubricate and screw on new connecting rod bolts.
8.
Important!
Damaged piston cooling nozzles must not

be re-aligned, renew them instead. The oil
jet must hit the piston precisely. If it does
not, the piston will become overheated
resulting in engine breakdown.
Fit the piston cooling nozzle.

9. Fit the ladder frame if applicable.
10. Fit the oil pump pipe and suction pipe. Renew O-rings on the pipe and check that no O-
rings are left in the oil pump or suction pipe.
2011-08-23 ?Scania CV 3 of 7
Engine no.: 6642331
11. Fit the oil sump.

12. Fit the clamp for the oil level sensor electrical cables in the ladder frame.
13. Engines with scraper ring: Fit the scraper ring in the cylinder liner.
14. Fit the cylinder head. Tighten the cylinder head bolts according to work description
Fitting the cylinder head.
Renewal - Renewing piston on connecting rod, renewing

piston rings
Tools
Tool
board
87 362 Drift D3
587 309 Piston ring expander D3
1. Place the connecting rod in a vice with

soft jaws. Remove the retaining rings for
the gudgeon pin.
800ef15a
2. Push out the gudgeon pin using drift 87

362.
87 362
2011-08-23 ?Scania CV 4 of 7
Engine no.: 6642331
800ef15b
3. Remove the piston rings using tool 587

587 309
309. Take care not to scratch the piston
skirt surface with the piston rings.
800ef15c
4. It is possible that the graphite coating will disappear after washing graphite coated pistons
in an industrial washing machine. This does not matter after they have been in use for a
while. However, new pistons should be washed with some care, e.g. with 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.
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. Permitted gap according
to the table below.
Compression ring 1 (upper) 0.75 mm

Compression ring 2 (lower) 0.8 mm
Oil scraper ring 0.6 mm
Maximum piston ring gap for 9, 11,

Maximum piston ring gap for 9 and
13 litre engines with XPI, cylinder
block generation 2

Maximum piston ring gap for 9 and
13 litre engines with PDE, cylinder
block generation 2
7. Fit the piston rings using tool 587 309.
2011-08-23 ?Scania CV 5 of 7
Engine no.: 6642331
The oil scraper ring has an expander.

Pistons rings marked with TOP must be
turned with TOP face up.
800edc7f
Compression rings on 9, 11, 12 and 16 litre

engines
80721f6e
Compression rings on 9 and 13 litre engines

with cylinder block generation 2
2011-08-23 ?Scania CV 6 of 7
Engine no.: 6642331
800edc82
Oil ring
8. Oil all bushes, gudgeon pin holes and the gudgeon pin before assembling.
9. Fit the piston skirt to the piston crown and fit one of the gudgeon pin retaining rings.
10. Put the piston onto the connecting rod so
that the arrow marks on the piston will
face the front of the engine. Applies to
aluminium pistons only, steel pistons are
symmetrical.
800ef142

engine. The short end of the connecting rod
should be on the left-hand side.
803004ce
11. Insert the gudgeon pin using tool 87 362 and fit the second retaining ring for the
gudgeon pin.
2011-08-23 ?Scania CV 7 of 7
Engine no.: 6642331
01-15 Belt circuit

Renewal - Renewing the drive belt on 9 and 13 litre engines
Check - Checking the poly-V-belt
Renewal - Renewing the pulley bearing on 9 and 13 litre engines with XPI, PDE or
GAS
Renewal - Renewing the driver on 9 and 13 litre engines with XPI or PDE

Note!
Renewal
Renewing the drive belt on 9 and 13 litre engines
Warning!
Remember that the engine is hot just after
being turned off.
Warning!
Pinch risk when working with belt
transmissions!
The automatic belt tensioner must never be readjusted, opened, repaired or modified in any
way. If the belt tensioner does not provide sufficient tensioning of the poly-V-belt, it must be
renewed.
Removing the drive belt
1.
Important!
The belt tensioner should only be moved in

the direction which releases belt
transmission tension. The belt tensioner
2011-08-23 ?Scania CV 1 of 11
Engine no.: 6642331
can be damaged if the belt tensioner is

tightened in the incorrect direction.
Fit a ratchet handle to the outer belt

transmission belt tensioner.
80669703
2. Release tension on the outer belt transmission poly-V belt. Make sure the belt tensioner
does not stick or jerk by letting it return to its original position. Pull and release a couple
of times.
Renew the belt tensioner if it sticks or jerks.
3.
Important!
The screw used to lock the belt tensioner in

the relieved position must be pressed in far
enough that it reaches the bottom of the
belt tensioner.
Release the tension sufficiently so that the

belt tensioner can be locked by inserting an
8 mm screw in the designated hole.
80535f8c
4. Make sure that the belt tensioner is locked and that the poly-V belt has been released from
tension.
5. Remove the outer poly-V-belt.
6. Fit a ratchet handle and relieve the tension on the poly-V-belt of the inner belt
transmission.
Hold the ratchet handle in place and lift off the poly-V-belt.
7. Carefully release the belt tensioner back into position and remove the ratchet handle.
Fitting the drive belt
2011-08-23 ?Scania CV 2 of 11
Engine no.: 6642331
80669703
80669704
Inner belt transmission on engines with alternator or AC compressor.
806699da
Inner belt transmission with double alternators or one alternator and one AC compressor.
1.
Check that the rollers in the belt transmission rotate freely, without jamming or making
2011-08-23 ?Scania CV 3 of 11
Engine no.: 6642331
noise.
2. Slip the poly-V belts over the fan.
3. Inner belt transmission
Note!
The inner belt is always longer than the
outer one.
Fit the inner belt transmission poly-V-belt onto its pulleys; see picture above.
Important!
Make sure the drive belt is located

correctly in all the belt pulley grooves
before making it taut.
4. Tighten the inner belt transmission carefully.

5. Outer belt transmission
Note!
Check that the poly-V-belt is correctly
routed on all pulleys and idler rollers.
Fit the poly-V belt to the outer belt transmission pulleys and idler rollers, see picture.
6. Use the ratchet handle to relieve the tension from the screw used to secure the belt
tensioner. Keep hold of the ratchet handle and pull out the screw.
7.
Important!
Make sure the drive belt is located

correctly in all the belt pulley grooves
before making it taut.
Important!
The belt tensioner should only be moved in

the direction which releases belt
transmission tension. The belt tensioner
can be damaged if the belt tensioner is
tightened in the incorrect direction.
Tighten the outer belt transmission carefully.

8. Check that the poly-V-belt is correctly routed on all pulleys and idler rollers.
2011-08-23 ?Scania CV 4 of 11
Engine no.: 6642331
Check - Checking the poly-V-belt

Check poly-V-belt for cracks and wear as follows:
80448a70
The poly-V-belt has cracks and must be renewed.
80448a74
Poly-V-belt beginning to show signs of wear. The Poly-V-belt may be refitted.
80448a89
The poly-V-belt is worn down to the cord. Renew the poly-V-belt.
Renewal
Renewing the pulley bearing on 9 and 13 litre engines with
2011-08-23 ?Scania CV 5 of 11
Engine no.: 6642331
XPI, PDE or GAS

Tools
Tool
board
98 290 Intermediate piece G3
99 132 Drift R2
99 133 Drift R2
99 135 Drift R2
Remove the bearing in the belt pulley
1. Fit the tommy bar to the outer belt transmission belt tensioner.
2. Relieve the tension sufficiently so that the belt tensioner can be locked by inserting an 8
mm screw in the designated hole.
tension.
4. Fit a ratchet handle to the inner belt transmission belt tensioner.
5. Relieve the tension sufficiently so that the belt tensioner can be locked by inserting an 8
mm screw in the designated hole.
tension.
7. Lift the poly-V belts off the pulley.
2011-08-23 ?Scania CV 6 of 11
Engine no.: 6642331
8045f981
8. Undo the centre screw and remove the washer.

9. Detach the pulley from the engine.
99 135
8031d3ee
10. Remove the shaft journal. Use special tool 99 135.
8031d404
11. Remove the retaining ring. Use a snap ring pliers.
Important!
The bearing must be pressed out with the

screws facing downwards and the flange
2011-08-23 ?Scania CV 7 of 11
Engine no.: 6642331
upwards. Otherwise, the pulley will be

damaged.
99 132
8031d40b
12. Press out the bearing. Use special tool 99 132.
Fit the bearing in the belt pulley
98 290
8031d415
1. Fit the new bearing. Use special tool 98 290.

2. Fit the retaining ring. Use a snap ring
pliers.
8031d404
Important!
You must rotate the pulley as you press the

shaft journal on, or the bearing will be
damaged. Rotate the pulley approximately
2011-08-23 ?Scania CV 8 of 11
Engine no.: 6642331
20 turns.
3. Fit the shaft journal. Use special tool 99

133. Rotate the pulley 20 times during
99 133
fitting. x 20
8031d41c
4. Fit the belt pulley on the engine. Tighten the screws.

5. Fit the screw and washer. Rotate the pulley when the screw is tightened.
Renewal
Renewing the driver on 9 and 13 litre engines with XPI or

PDE
Tools
Tool
board
587 318 Puller plate XA1
587 319 Bearing puller XA1
98 575 Support drift G2
AM3
99 452 Drift
D4
2011-08-23 ?Scania CV 9 of 11
Engine no.: 6642331
1. Relieve the load on the outer belt transmission with the belt tensioner.
2. Remove the fan, belt pulley, spacer and screw from the driver.
3. Fit pullers 587 318 and 587 319 as
illustrated.
8066b265
4. Fit support drift 98 575 in the centre as illustrated.

5. Pull off the driver.
8066b297
6. Press a new driver with bearing onto the

shaft.
8066b299
7. Screw on a 110 mm long M14 screw with washers through drift 99 452.
8. Tighten the screw so that the driver is pressed onto the shaft.
9. Switch to a 75 mm long M14 screw and
tighten the driver until it reaches the
bottom of the shaft.
2011-08-23 ?Scania CV 10 of 11
Engine no.: 6642331
8066b29a
10. Tighten the driver.
8066b29e
11. Fit the pulley and spacer on the driver.

12. Fit the outer belt transmission poly-V-belt.
13. Fit the fan on the spacer.
2011-08-23 ?Scania CV 11 of 11
Engine no.: 6642331
01-15 Gear wheel transmission

Removal - Removing the intermediate gear on 9, 11, 12 and 13 litre engines with
XPI, PDE, HPI or GAS
Fitting - Fitting intermediate gears on 9 and 13 litre engines with XPI, PDE or GAS
Renewal - Renewing the bearing in the intermediate gear for the compressor on 9,
11, 12 and 13 litre engines with XPI, PDE, HPI or GAS
Renewal - Renewing the bearing in the intermediate gear for the camshaft on 9, 11,
12 and 13 litre engines with XPI, PDE, HPI or GAS
Removal - Removing the camshaft gear on 9, 11, 12 and 13 litre engines with XPI,
PDE, HPI or GAS
Fitting - Fitting the camshaft gear on 9, 11, 12 and 13 litre engines with XPI, PDE,
HPI or GAS
Removal - Removing the crankshaft gear on 9, 11, 12 and 13 litre engines with XPI,
PDE, HPI or GAS
Fitting - Fitting the crankshaft gear on 9, 11, 12 and 13 litre engines with XPI, PDE,
HPI or GAS

Note!
Removal
Removing the intermediate gear on 9, 11, 12 and 13 litre

Tools
Tool
board
99 074
99 074 Impact drift D1
2011-08-23 ?Scania CV 1 of 9
Engine no.: 6642331
99 309 Turning tool D5
587 526 Puller
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
and a locking bar on the flywheel starter
gear.
99 309
800efd10
housing.
4. Manufacture a thread block according to min 20
the sketch.
M10 15 - 20
800efd16
5.
Important!
After removing the intermediate gear,

587 526
neither the camshaft nor the crankshaft 99 074
must be rotated. This may cause pistons
and valves to collide and be damaged.
The shaft on which the gear is located has a
2011-08-23 ?Scania CV 2 of 9
Engine no.: 6642331
groove. Fit puller 587 526, thread block and 804319ea
impact drift 99 074. Pull off the gear and

shaft.
Fitting
Fitting intermediate gears on 9 and 13 litre engines with

XPI, PDE or GAS
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.
8044cf4d
2. Fit the intermediate gear against the camshaft gear and the crankshaft gear so that the
markings point towards each other.
3. Fit the second intermediate gear.
DC13
8044cf76
4. Tighten the screws on the intermediate gears.

5. Fit the flywheel housing as described in the work description Fitting the flywheel housing.
2011-08-23 ?Scania CV 3 of 9
Engine no.: 6642331
Renewal
Renewing the bearing in the intermediate gear for the

compressor on 9, 11, 12 and 13 litre engines with XPI, PDE,
HPI or GAS
Tools
Tool
board
87 348 Drift AM1
87 592 Drift
1. Remove the snap ring.
800f0187
2. Press the bearing packet out of the gear.

3. Press the shaft journal out of the bearing.
4. Press the shaft journal into a new bearing using tool 87 348. Do not press on the outer
race.
5. Press the ring on the shaft journal.
6. Press the bearing packet into the intermediate gear. Use tool 87 592.
7. Fit the snap ring.
Renewal
Renewing the bearing in the intermediate gear for the
2011-08-23 ?Scania CV 4 of 9
Engine no.: 6642331
camshaft on 9, 11, 12 and 13 litre engines with XPI, PDE,

HPI or GAS
Tools
Tool
board
87 348 Drift AM1
87 592 Drift
1. Press the shaft out of the bearing.

2. Press the bearing inner race shell from the shaft and remove the retaining ring.
3. Place the removed bearing inner race in the bearing and press out the bearing using drift
87 348.
4. Press a new bearing onto the shaft journal using drift 87 348.
Note!
Do not press on the outer race.
5. Press the bearing and shaft journal into the intermediate gear using drift 87 592.
87 592
800f01b9
6. Fit the snap ring.

7. Press the spacing ring onto the shaft journal. Ensure that the shaft journal is on the press
table.
2011-08-23 ?Scania CV 5 of 9
Engine no.: 6642331
Removal
Removing the camshaft gear on 9, 11, 12 and 13 litre

Tools
Tool
board
99 309 Turning tool

gear.
99 309
800efd10
housing.
4.
Important!

neither the camshaft nor the crankshaft
Remove the intermediate gear.

2011-08-23 ?Scania CV 6 of 9
Engine no.: 6642331
800f01c0
Fitting
Fitting the camshaft gear on 9, 11, 12 and 13 litre engines

with XPI, PDE, HPI or GAS
1. Fit the intermediate gear as described in the work description Fitting the intermediate
gear, steps 1-2.
2. Fit the camshaft gear and tighten the
screws.
800f02df
3. Fit the flywheel housing according to the section Fitting the flywheel housing.
4. Fit the flywheel according to the section Fitting the flywheel.
Removal
Removing the crankshaft gear on 9, 11, 12 and 13 litre

2011-08-23 ?Scania CV 7 of 9
Engine no.: 6642331
Tools
Tool
board
99 309 Turning tool

gear.
99 309
800efd10
housing.
4.
Important!

neither the camshaft nor the crankshaft
Remove the intermediate gear.

5. Remove the crankshaft gear.
2011-08-23 ?Scania CV 8 of 9
Engine no.: 6642331
800f0332
Fitting
Fitting the crankshaft gear on 9, 11, 12 and 13 litre engines

with XPI, PDE, HPI or GAS
1. Fit the crankshaft gear.
800f1bc6
2. Fit the intermediate gear, refer to the work description for Fitting the intermediate gear,
steps 1-2.
3. Fit the flywheel housing as described in the work description Fitting the flywheel housing.
4. Fit the flywheel as described in the work description for Fitting the flywheel.
2011-08-23 ?Scania CV 9 of 9
Engine no.: 6642331
01-20 Centrifugal oil cleaner

Cleaning - Removing the centrifugal oil cleaner on 9, 11, 12 and 13 litre engines with
XPI, PDE, HPI or GAS
Specification - 9, 11, 12 and 13 litre engines with XPI, PDE, HPI or GAS

Note!
Cleaning
Removing the centrifugal oil cleaner on 9, 11, 12 and 13

litre engines with XPI, PDE, HPI or GAS
Special tools
Number Designation Illustration
99 520 Socket
wrench
80408ee3
561 200 Thread-

locking
fluid
Specifications
Permitted thickness of dirt deposits
Permitted thickness of deposits on walls of bowl 28 mm
Tightening torque
Nut for rotor bowl Tighten by hand
There should be a certain amount of deposited dirt in the rotor bowl during cleaning of the
centrifugal oil cleaner. If this is not the case, this indicates that the rotor may not be rotating.
2011-08-23 ?Scania CV 1 of 5
Engine no.: 6642331
The cause must be established immediately.

If the dirt deposit exceeds the permitted thickness of deposits at the recommended intervals,
the rotor bowl should be cleaned more often.
Important!
On 9 litre engines with PDE or HPI fuel

systems, the oil filter must be removed so
the centrifugal oil cleaner can be
disassembled.
1. Undo the nut securing the outer cover.

2. Let the oil run out from the rotor.
3. Lift out the rotor. Wipe off the outside. Undo the rotor nut and screw it about one and a
half turns to protect the bearing.
x 1.5
8003cd7d
4. If the rotor nut is difficult to get loose, turn the rotor upside down. Fasten the rotor nut in
a vice. Turn the rotor one and a half turns counterclockwise by hand or use an M20 bolt as
illustrated.
Important!
The rotor must not be put in a vice. Never

strike the rotor bowl. This may cause
additional damage resulting in imbalance.
2011-08-23 ?Scania CV 2 of 5
Engine no.: 6642331
M20
x 1.5
8003cd7e
5. Remove the rotor cover by holding the rotor in both hands and tapping the rotor nut
against the table. Never strike the rotor directly as this may damage its bearings.
6. Remove the strainer from the rotor bowl. If the strainer is jammed in place, pry carefully
loose between the rotor bowl and the strainer using a screwdriver.
8003cd80
7. Scrape away the deposits inside the rotor cover with a knife.
8. Wash the parts.
9. Inspect the two nozzles on the rotor. Make sure they are not blocked or damaged. Renew
any damaged nozzles.
10. Check the bearings to ensure that they are not damaged.
11. Fit a new O-ring by sliding it over the strainer.
2011-08-23 ?Scania CV 3 of 5
Engine no.: 6642331
8003cd81
12. Refit the rotor bowl. Make sure that the O-ring sits correctly on the inside.
13. Tighten the rotor nut by hand.
14. Make sure the shaft is not loose. If it is, it should be locked using thread-locking fluid
561 200. Clean carefully with a suitable solvent. Tighten the rotor shaft using tool 99
520.
15. Refit the rotor and rotate it by hand to make sure it rotates easily.
8005ac87
16. Renew the O-ring in the cover. Tighten the lock nut.
2011-08-23 ?Scania CV 4 of 5
Engine no.: 6642331
15 Nm
8003cd83
Specification
9, 11, 12 and 13 litre engines with XPI, PDE, HPI or GAS

Permitted thickness of deposits on walls of bowl
Permitted thickness of deposits on walls of bowl 28 mm
2011-08-23 ?Scania CV 5 of 5
Engine no.: 6642331
01-20 Lubrication system

Check - Measuring the oil pressure on 9 and 13 litre engines
Check - Troubleshooting the lubrication system
Check - Lubrication oil consumption
Specification - Type of oil sump
Specification - Oil quantity, 9, 13 and 16 litre engines

Note!
Check
Measuring the oil pressure on 9 and 13 litre engines

Tools
Tool
board
99 362 Measuring set
The use of the measuring set 99 362 is described in booklet 01:00-03.

Oil pressure
When idling At least 1.5 bar
At 1000 rpm and engine warm At least 2.5 bar
At 1900 rpm and engine warm 5 +-0.5 bar
1. Remove the oil pressure sensor.

2. Fit the measuring equipment with union and adapters according to the illustrations.
3. Fit the oil pressure sensor.
2011-08-23 ?Scania CV 1 of 9
Engine no.: 6642331
OIL
M14x1.5
99 412
8033bc65
14
OIL
8033bd3f
804496c1
Check - Troubleshooting the lubrication system

Tools
Tool
board
99 362 Measuring set
2011-08-23 ?Scania CV 2 of 9
Engine no.: 6642331
USED OIL K GOOD
588 493 Viscosity gauge FLOSTICK

NEW OIL
Symptom Troubleshooting Action

Sudden low oil Does the vehicle oil pressure Check the oil pressure using tool 99 362.
pressure. gauge indicate the correct
value?
Is the oil of the correct grade Check the oil level and its viscosity using
and viscosity? tool 588 493.
Is the relief valve working? Check that the spring has not snapped and
that the piston is not seizing.
Is the centrifugal oil cleaner Check the centrifugal oil cleaner.
correctly assembled?
Are there any leaks from the Check the O-rings and that the line is
oil pump? properly fitted.
Are there any leaks from the Check the O-rings.
pressure side of the oil
pump?
Is the oil pump driving gear Check the oil pump driving gear.
loose?
Are all oil pump components Check the cover, housing and cold start
in place? valve with spring. Also check to ensure that
the pump wheel of the oil pump is not
damaged.
Gradually Does the vehicle oil pressure Check the oil pressure using tool 99 362.
dropping oil gauge indicate the correct
pressure. value?
Is the oil filter clogged? Renew the oil filter.
Is the relief valve working? Check that the spring is not worn out and
that the piston is not seizing.
Is the suction strainer Clean the suction strainer.
clogged?
Is the oil pump worn out? Renew the oil pump.
Is the engine worn out? Check bearing wear.
High oil Does the vehicle oil pressure Check the oil pressure using tool 99 362.
pressure gauge indicate the correct
2011-08-23 ?Scania CV 3 of 9
Engine no.: 6642331
value?
Is the relief valve working? Check that the piston is not stuck in the
closed position.
Does the piston cooling valve Check that the piston is not stuck in the
work? closed position.
Is the cold start valve in the Renew the oil pump.
oil pump stuck?
Check
Lubrication oil consumption

Introduction
Lubrication oil consumption refers to the lubrication oil that is consumed through combustion
in the engine.
Take into account the fuel consumption when assessing the lubrication oil consumption. Both
are affected by driving style and operating conditions.
Lubrication oil consumption is usually higher while running in. Lubricating oil consumption
cannot be considered constant until the engine has been run for around 40,000 km or 600
operating hours.
Oil consumption should not exceed 0.3% of fuel consumption.
Prolonged driving at high engine speeds (above the green zone on the tachometer) with low
power output or driving with heavy loads, however, will increase lubrication oil consumption
slightly in relation to fuel consumption. In such conditions, the lubrication oil consumption
can be considered as acceptable even if it exceeds 0.4% of fuel consumption.
Checking lubricating oil consumption
In order to prevent taking measures prematurely, the engine should be run with the crankcase
ventilation open for at least 10,000 km or 150 hours while carefully following the fuel and oil
consumption. The engine oil must be at operating temperature when measuring the oil level.
If the follow-up shows that the lubrication oil consumption is really abnormally high, the
engine must be inspected and repaired.
Instructions and follow-up documentation
Fuel consumption and lubrication oil consumption calculations must be based on information
that is as accurate as possible. Start with the fuel tank full and the lubrication oil topped up to
the max limit on the dipstick.
2011-08-23 ?Scania CV 4 of 9
Engine no.: 6642331
Check the level on the dipstick with the vehicle or engine standing level once all the
lubricating oil has collected in the oil sump.
MAX
MIN
800e7da7
The level can be checked on the dipstick three minutes after stop when the engine is at
operating temperature. Wait at least five minutes after stopping before checking the level if
the engine has been started but not attained operating temperature.
Use the form "Driver's log-book for measuring oil consumption" to note when fuel and
lubrication oil has been filled and the mileage or operating time during the follow-up period.
Example of completed driver's log-book for measuring oil consumption
Chassis number Chassis type Engine serial number Dealer Owner

No: 1 234 567 No:
Date Mileage (km) or Filled Lubrication oil Main type of driving,

operating time fuel consumption*, litres e.g. laden, unladen
(hours)
090703 37,905 km 250 1
090705 38,477 km 250 2
090711 39,125 km 300 etc.
090714 39,845 km 275
090720 40,256 km etc.
090722 etc.
090723
total: total: 12
3800
*Enter the amount of lubricating oil used to top up.
2011-08-23 ?Scania CV 5 of 9
Engine no.: 6642331
When changing oil, estimate how much oil has been consumed before the oil is drained or
measure how much oil is drained from the engine.
Fuel consumed = 3800 litres
Oil consumed = 12 litres
Oil consumption in percent of fuel consumption: 12/ 3800 * 100 % = 0,31
The consumption is slightly higher than recommended but is acceptable if most of the driving
has been on fast main roads with low vehicle load.
Driver's log-book for measuring oil consumption
Chassis Chassis type Engine serial number Dealer Owner

number
No: No:
Date Mileage (km) or Lubrication oil Filled Main type of
operating time consumption*, litres fuel driving, e.g. laden,
(hours) unladen
Litres
Litres
Litres
Litres
Litres
Litres
Litres
Litres
Litres
Litres
Litres
Litres
Litres
Litres
Litres
Litres
Litres
Litres
Litres
Litres
2011-08-23 ?Scania CV 6 of 9
Engine no.: 6642331
Litres
Litres
*Enter the amount of oil used to top up.
Tips for troubleshooting
The are several possible causes if the engine oil consumption is too high. Here are some tips
on possible faults that can cause high oil consumption.
Note!
First check that there are no external oil
leaks.
Note!
In order to prevent taking measures
prematurely, the engine should be run with
the crankcase ventilation open for at least
10,000 km or 150 hours while carefully
following the fuel and oil consumption.
Oil leak in the turbocharger
If the turbocharger is damaged:

If the sealing ring on the turbine side is worn, the exhaust gases will be blue when idling.
Check the return oil pipe from the turbocharger for blockage and deformation. In these cases
there is a risk that the lubrication oil pressure will force oil through the seals.
800e7dd4
Worn piston rings
2011-08-23 ?Scania CV 7 of 9
Engine no.: 6642331
Conduct a compression test on the engine as described in the Workshop Manual for the
respective engine type to check for piston ring and cylinder liner wear.
98 249
800e7ddc
Specification
Type of oil sump

Normal oil sump
806aaeca
Low oil sump
2011-08-23 ?Scania CV 8 of 9
Engine no.: 6642331
806aaecb
Specification
Oil quantity, 9, 13 and 16 litre engines

Engine, cylinder volume/oil sump* Max level** Min level

9 litres, low oil sump 35 litres 28 litres
9 litres, normal oil sump 38 litres 32 litres
13 litres, oil sump without ladder frame 38 litres 32 litres
* See separate specification for illustrations of different types of oil sump.

** The oil volume to be added at an oil change without changing the oil filter. When an oil
filter is renewed, the 2 litre oil filter volume must also be added.
Note!
These values are approximate as the
difference between different engines is
great. Always check the level on the
dipstick.
Note!
In an engine which has not been filled
with oil previously, such as following
reconditioning, a further 3 litres should be
added.
2011-08-23 ?Scania CV 9 of 9
Engine no.: 6642331
01-20 Oil cooler

Check - Leak testing the oil cooler on 9 and 13 litre engines with XPI, PDE or GAS
Removal - Removing the oil cooler on 9 and 13 litre engines with XPI, PDE or GAS
Fitting - Fitting the oil cooler on 9 and 13 litre engines with XPI, PDE or GAS

Note!
Check
Leak testing the oil cooler on 9 and 13 litre engines with

XPI, PDE or GAS
Tools
Tool
board
99 405 Clutch bleeder
99 484 Cover
1. Remove the oil cooler complete with cover from the engine.
2. Remove the oil filter housing from the oil cooler cover.
3. Clean the oil cooler and the cover. Fit special tool 99 484 with existing O-ring.
4. Connect special tool 99 405.
2011-08-23 ?Scania CV 1 of 5
Engine no.: 6642331
804cfde3
5. Lower the oil cooler complete with the

housing into a water bath. Raise the
pressure to 2 bar using the handle.
Maintain the pressure for at least one
minute.
804cfde7
6. Where there is leakage, renew the parts which leak and carry out the test one more time.
7. Refit the oil cooler.
8. Refit the oil filter housing.
Removal
Removing the oil cooler on 9 and 13 litre engines with XPI,

PDE or GAS
1. Drain the coolant. See section 02-00, Cooling system assembly, Cooling system.
2. Remove the turbocharger and exhaust brake. See subgroup 01-30 Turbocharger.
2011-08-23 ?Scania CV 2 of 5
Engine no.: 6642331
6 3 5 6
804016be
3. If the engine has EGR: Remove the hose and coolant pipe from the water-cooled EGR
cooler.
4. Drain the oil filter housing by lifting out the filter.
5. Undo the clamp of the turbocharger cable harness.
6. Remove the oil pressure sensor and coolant temperature sensor.
9 8 7
804016c2
7. Remove the oil filter housing. The turbocharger delivery pipe will come with it.
8. Remove the compressor hose and the lower coolant hose.
9. Remove the engine oil cooler cover.
2011-08-23 ?Scania CV 3 of 5
Engine no.: 6642331
Fitting
Fitting the oil cooler on 9 and 13 litre engines with XPI,

PDE or GAS
2 3 4
80403ded
1. Clean the gasket faces on the cylinder block and oil cooler cover.
2. Fit the oil cooler cover with a new gasket.
3. Fit the compressor hose and the lower coolant hose.
4. Fit the oil filter housing with a new gasket and new oil filter.
6 7 5 6
2011-08-23 ?Scania CV 4 of 5
Engine no.: 6642331
80403df3
5. Fit the clamp of the turbocharger cable harness.

6. Fit the oil pressure sensor and the coolant temperature sensor.
7. If the engine has EGR: Fit the hose and coolant pipe on the water-cooled EGR cooler.
8. Fit the turbocharger. See subgroup 01-30 Turbocharger.
9. Fill and bleed the cooling system. See section 02-00, Cooling system assembly, Cooling
system.
2011-08-23 ?Scania CV 5 of 5
Engine no.: 6642331
01-20 Oil filter

Renewal - Renewing the oil filter on 9 and 13 litre engines with XPI, PDE or GAS

Note!
Renewal
Renewing the oil filter on 9 and 13 litre engines with XPI,

PDE or GAS
Tools
Number Designation Picture Tool board
Maintenance
587 637 Sleeve
cabinet
Important!
Only use original Scania filters and renew

the oil filter according to Scania's
inspection instructions.
Important!
When renewing the oil filter, the

centrifugal oil cleaner should be cleaned
according to Scania's instructions.
If the centrifugal oil cleaner is not cleaned,
the oil filter will quickly block up,
increasing flow resistance in the filter. If
2011-08-23 ?Scania CV 1 of 3
Engine no.: 6642331
this happens, an overflow valve in the filter

retainer will open to let the oil bypass the
filter without being cleaned.
1. Unscrew the filter cover with a closed tool with hexagon driver, e.g. socket 587 637.
Important!
Do not use an adjustable spanner or other

open tool as there is a risk of damaging the
filter cover.
2. Lift out the filter housing cover with filter element. The filter housing will drain
automatically once the filter has been removed.
3. Detach the old filter from the cover by
holding the cover and carefully tapping the
entire filter element against something
hard. Remember that there will be oil
splashes.
80432780
2011-08-23 ?Scania CV 2 of 3
Engine no.: 6642331
80432784
4. Assemble the new filter and tighten the filter cover.
2011-08-23 ?Scania CV 3 of 3
Engine no.: 6642331
01-20 Oil pump

Complete
Complete - Oil pump on 13 litre engines with XPI or PDE
Complete
Note!
Complete
Oil pump on 13 litre engines with XPI or PDE
Important!
In the event of leakage or a fault with the

oil pump, it must not be overhauled but
renewed completely.
804cce96
Exploded view drawing
1. Oil pump
2011-08-23 ?Scania CV 1 of 2
Engine no.: 6642331
2. Flange bolt
3. Guide sleeve
4. Flange bolt
5. Suction pipe
6. Flange bolt
7. Pipe
8. O-ring
9. O-ring
2011-08-23 ?Scania CV 2 of 2
Engine no.: 6642331
01-20 Oil sump

Assembly - Tightening sequence, oil sump

Note!
Assembly
Tightening sequence, oil sump

Oil sump, 9 litre engine
11 7 3 1 5 9
15 13
19 17
21
23
24
22
18
20
14
10 6 2 4 8 12 16
806d15ea
Oil sump, 13 and 16 litre engines
2011-08-23 ?Scania CV 1 of 4
Engine no.: 6642331
9 5 1 3
7
13
11
17 15
16
18
14
12
8
4 2 6 10
806b8187
Location of spacer on 16 litre engines with XPI or PDE
80709e34
Ladder frame, 13 litre engine
2011-08-23 ?Scania CV 2 of 4
Engine no.: 6642331
29 25 21 17 13 9 5 1 3 7 11 15 19 23 27
33 31
37 35
41 39
40 42
36 38
32 34
28 24 20 16 12 8 4 2 6 10 14 18 22 26 30
806b8188
Ladder frame, 16 litre engine
13 9 5 1 3 7 11
17 15
21
19
25 23
24 26
20 22
18
16 12 8 4 2 6 10 14
806d15eb
Fitting the gasket between the ladder frame and cylinder block
3mm
3-5mm
8072e600
2011-08-23 ?Scania CV 3 of 4
Engine no.: 6642331
Apply silicone paste 816 064 in the groove on the gasket as illustrated.
2011-08-23 ?Scania CV 4 of 4
Engine no.: 6642331
01-20 T5, Oil pressure sensor

Symbol
Location
Symbol
8007214f
Location
T5
803c2451
2011-08-23 ?Scania CV 1 of 1
Engine no.: 6642331
01-30 Turbocharger
Location - 9 and 13 litre engines with PDE or XPI
Removal - Removing the turbocharger on 9 and 13 litre engines
Fitting - Fitting the turbocharger on 9 and 13 litre engines
Check - Checking the radial and axial play of the turbocharger
Check - Checks and corrective action in the event of failure
Check - Checking wastegate valve functionality
Location
9 and 13 litre engines with PDE or XPI

Applies to cylinder block generation 2.
806707a3
2011-08-23 ?Scania CV 1 of 7
Engine no.: 6642331
806aaf28

Note!
Removal
Removing the turbocharger on 9 and 13 litre engines

1. Remove the exhaust pipe by the
turbocharger.
2011-08-23 ?Scania CV 2 of 7
Engine no.: 6642331
8004cd89
2. Loosen and remove the oil pipes.
Important!
Plug the connections to prevent dirt ingress

into the engine and the turbocharger.
8004cd8b
3. Loosen and remove the oil connections.

Push the intake manifold between the
turbocharger and the air cleaner to one
side.
8004cd8e
4. Remove the nuts and then unscrew the

turbocharger.
2011-08-23 ?Scania CV 3 of 7
Engine no.: 6642331
Important!
Protect all connections from dirt.
8004cd90
Fitting
Fitting the turbocharger on 9 and 13 litre engines

Note!
The joint between the turbocharger and
turbo manifold should be tightened using
new parts: screw, spacer, nut and gasket.
Note!
If the turbocharger caused oil carryover
when it broke down, the catalytic
converter may have been damaged. If the
vehicle is equipped with SCR, run a
devalidation test with SDP3 to check
whether the catalytic converter is working.
1. Check that the turbocharger does not have any visible damage on the compressor, turbine
or housing.
2. Check the sealing surfaces on the turbocharger and turbo manifold and on the oil return
pipe.
3. Place the gasket between the turbocharger
and turbo manifold in position.
Important!
The gasket bevelling should sit with the

rounded side upwards.
8004d3ec
4.
2011-08-23 ?Scania CV 4 of 7
Engine no.: 6642331
8004cdcb
5. If studs are used in the joint, lubricate the stud threads with heat resistant lubricant.
6. Screw the turbocharger onto the turbo
manifold.
8004cd90
7. Connect the oil return pipe. Fill the

turbocharger with engine oil and connect
the lubrication pipe.
Important!
Before the turbocharger is used, make sure

that oil supply is working properly. If there
is insufficient lubrication there is a risk that
the turbocharger will seize, or that its
service life will be significantly reduced. 8004cd8b
Check - Checking the radial and axial play of the

turbocharger
If turbocharger functionality is impaired or there is noise, the first action is to check the radial
and axial play of the turbocharger.
1. Detach the exhaust pipe and inlet pipe from the turbocharger.
2011-08-23 ?Scania CV 5 of 7
Engine no.: 6642331
2. Check that the turbine wheel and compressor impeller rotate freely and are free from
damage.
3. Check the radial and axial play of the turbine shaft; see illustration. If there is so much
play that the turbine wheel or compressor impeller chafe against the turbocharger
housing at any position, the turbocharger must be renewed.
80716e06
Note!
In general, measuring the radial and axial
clearance gives no indication of the
remaining service life of the turbocharger.
Check - Checks and corrective action in the event of failure
Important!
The highest levels of cleanliness must be

observed when working on the
turbocharger. Never leave the oil inlet and
outlet connections unprotected. Foreign
bodies in the bearing housing will soon
lead to total breakdown.
Carry out the following:

1. Ensure that no leaks or loose particles are present in the line between the air filter and the
turbocharger.
2. Check that there are no loose particles in the exhaust or intake manifolds.
3. Renew the charge air cooler.
4. Make sure all valves are intact.
5. Check that the lubrication oil return pipe from the turbocharger is not clogged or
distorted.
6.
Check that the oil pressure pipe to the turbocharger is not clogged or deformed and that it
2011-08-23 ?Scania CV 6 of 7
Engine no.: 6642331
does not leak when pressurised.

7. Renew the oil filter and clean the lubrication system.
Check
Checking wastegate valve functionality

Tools
Tool
board
1. Detach the hose 1 from the union on the turbocharger and connect tool 99 405 as
illustrated. Fit a hose clamp 3.
2.
Important! 3 1 99 405 2
Do not pressurise the wastegate valve

actuator to more than 3 bar. A higher
pressure will damage it.
Pressurise the wastegate valve actuator.

Relieve the pressure by pressing on the
8019b8b7
screw 2.
3. Repeat the process a few times and check that the wastegate valve actuator is not leaking,
that its bracket is not broken and that the link arm and valve arm can move.
2011-08-23 ?Scania CV 7 of 7
Engine no.: 6642331
01-30 V109, Solenoid valve for wastegate valve

Symbol
Location
Symbol
2 1
8001314e
Location
V109
806a6c78
2011-08-23 ?Scania CV 1 of 1
Engine no.: 6642331
01-30 Wastegate valve

Check - Checking wastegate valve functionality

Note!
Check
Checking wastegate valve functionality

Tools
Tool
board
1. Detach the hose 1 from the union on the turbocharger and connect tool 99 405 as
illustrated. Fit a hose clamp 3.
2.
Important! 3 1 99 405 2
Do not pressurise the wastegate valve

actuator to more than 3 bar. A higher
pressure will damage it.
Pressurise the wastegate valve actuator.

Relieve the pressure by pressing on the
8019b8b7
screw 2.
3. Repeat the process a few times and check that the wastegate valve actuator is not leaking,
that its bracket is not broken and that the link arm and valve arm can move.
2011-08-23 ?Scania CV 1 of 1
Engine no.: 6642331
02-00 Cooling system

Complete
Adjust - Draining the coolant on 9 and 13 litre engines
Check - Checking the anti-freeze level
Complete
Note!
Note!
removed.
Adjust
Draining the coolant on 9 and 13 litre engines
Warning!
If the engine is at operating temperature,
the coolant is very hot and can cause burns.
Important!
The engine must not be started unless the

reservoir has the right amount of coolant.
Starting the engine with too little coolant
damages the coolant pump shaft seal,
which leads to coolant leakage.
Note!
Collect the old coolant and dispose of it
according to applicable regulations.
Tools
Number Designation Picture Tool
2011-08-23 ?Scania CV 1 of 2
Engine no.: 6642331
board
99 301 Adapter D5
587 129
or 588 Coolant tank
135
1. Connect adapter 99 301 to the drain nipple

on the right-hand side of the engine as 99 301
viewed from the rear (see illustration). Use
coolant tank 587 129 or 588 135 to drain
and collect the coolant.
8040824c
Check - Checking the anti-freeze level

References
For instructions on how to check frost protection as well as dosage tables: See Inspections,
00:16-10/2 Inspection instructions P, G, R and T series, Group 1-3.
For information on coolant and volumes: See Inspections 00:16-15 Fuel, lubricants and
fluids.
2011-08-23 ?Scania CV 2 of 2
Engine no.: 6642331
02-15 Thermostat
Location
Renewal - Coolant hoses
Removal - Removing the thermostat housing on 9 and 13 litre engines with PDE or
XPI
Fitting - Fitting the thermostat housing on 9 and 13 litre engines with PDE or XPI
Check - Inspection of thermostat operation
Location
806707a0

Note!

Note!
2011-08-23 ?Scania CV 1 of 3
Engine no.: 6642331

removed.
Removal
Removing the thermostat housing on 9 and 13 litre engines

with PDE or XPI
1. Drain the cooling system.
2.
80670866
Remove the turbocharger air hose, unscrew the outer part of the thermostat housing and
remove the thermostat.
Fitting
Fitting the thermostat housing on 9 and 13 litre engines

with PDE or XPI
1. Clean the thermostat housing and check that nothing obstructs the function of the
thermostat.
2.
2011-08-23 ?Scania CV 2 of 3
Engine no.: 6642331
80670866
Fit a new gasket, position the thermostat against the cylinder block and refit the thermostat
housing. Tighten the screws. Refit the turbocharger air hose.
3. Fill with coolant.
4. Start the engine and check that no leakage occurs. Check the coolant level and top up if
necessary.
Check
Inspection of thermostat operation

1. Unscrew the thermostat housing bolts and remove the thermostat.
2. Submerge the thermostat in a vessel of boiling water. It should hang freely without
touching the sides and bottom of the vessel.
3. Check that the thermostat opens fully without jamming within three minutes.
4. Check that the thermostat closes fully when it has cooled down.
5. If it does not work as described in points 3 and 4 or if it jams, renew the thermostat.
2011-08-23 ?Scania CV 3 of 3
Engine no.: 6642331
02-25 Coolant pump

Renewal - Renewing the coolant pump on 9 and 13 litre engines

Note!

Note!
removed.
Renewal
Renewing the coolant pump on 9 and 13 litre engines

Remove the coolant pump
1. Drain the cooling system according to the section for draining coolant.
80669703
2011-08-23 ?Scania CV 1 of 2
Engine no.: 6642331
2. Slacken off the belt transmission.

3. Remove upper idler roller.
4. Remove the bracket of the fan pulley.
5. Remove centre idler roller.
6. Undo and remove the pump with its housing.
7. Remove the pump housing from the pump
if the gasket must be renewed.
8066b677
Fit the coolant pump
1. Fit the pump gasket.

2. Screw the pump to the housing.
3. Fit the housing gasket.
4. Fit the housing and pump to the engine.
5. Secure the belt transmission.
6. Fill with coolant according to the work description for filling coolant.
2011-08-23 ?Scania CV 2 of 2
Engine no.: 6642331
02-30 T33, Coolant temperature sensor

Symbol
Location
Complete
Symbol
T33
806d74da
Location
T33
803c244e
Complete
The O-ring can be replaced separately. Check the O-ring, renew if necessary.
2011-08-23 ?Scania CV 1 of 1
Engine no.: 6642331
03-00 Accumulator
Location - Location, 9 and 13 litre engines with XPI
Location
Location, 9 and 13 litre engines with XPI
8076a11c

Note!
2011-08-23 ?Scania CV 1 of 1
Engine no.: 6642331
03-00 Calculating the fuel consumption factor

Explanation
Test stage:
Refuelling to reference level
Resetting route data
Driving and normal refuelling with monitoring of the number of litres added
Summary and calculation of the K factor
Recalibration
Explanation
If the fuel consumption displayed in the instrument cluster differs from the actual fuel
consumption, you can enter a calibration factor in SDP3 so that the display corresponds to the
actual fuel consumption.
The calibration factor is shown in the EMS, engine management system, under the
Adjustment tab.
The test that must be carried out to determine the difference between the displayed and actual
fuel consumption is described here. The procedure used to calculate the calibration factor, K,
which should be entered in SDP3, is also described.
Test stage:
1. Initial refuelling to a reference level.

2. Resetting of the route data in the instrument cluster.
3. Driving and normal refuelling with monitoring of the number of litres added.
4. Final refuelling to the reference level.
5. Summary and calculation of the K factor.
Refuelling to reference level
In order to assess the vehicle's actual fuel consumption as precisely as possible, it is

important for the fuel volume in the tank to be the same after refuelling for the first and the
last time.
It is therefore important to comply with the procedure below during the first and last
refuelling during the test.
z Select a reference level in the tank. Scania recommends reference level A, if possible
(see illustration). If it is difficult to see the level at point A, e.g. because of the
bodywork, reference level B can be used.
2011-08-23 ?Scania CV 1 of 4
Engine no.: 6642331
B
A
802c3324
Reference levels in the tank, select reference level A, if possible.

1. Filler pipe
Important!
Note the level that has been selected as a

reference level, so that the tank is filled to
the same level at the first and last
refuelling.
If the vehicle is equipped with double fuel tanks, the same procedure is carried out on
both tanks.
z Try to choose a filling station with a surface which is as level as possible. It is,
however, most important for the refuelling to be carried out in a consistent manner
when filling the tank for the first and last time during the test. This means that the
vehicle should be refuelled at the same filling station and positioned in the same
direction and on the same gradient.
2011-08-23 ?Scania CV 2 of 4
Engine no.: 6642331
Resetting route data
After refuelling for the first time, before the vehicle is driven, the vehicle route data should
be reset in the instrument cluster.
Note!
Use Route data 2. In order to ensure that
nobody can unintentionally reset the
information saved during the test, "Route
2" can be protected with a PIN code.
Resetting of the route data and activation of the PIN code is described in the Operator's
manual in Instruments and controls.
Driving and normal refuelling with monitoring of the number of litres

added
Drive the vehicle and refuel as usual. Write down the number of litres every time the vehicle
is refuelled, even including decimals.
Important!
Make sure that you write down the number

of litres every time you refuel. When the
test is completed, these values should be
added up to the total consumption.
Enter the volume including decimals.

In order to ensure that the value is as accurate as possible, the vehicle should be driven at
least 10,000 km during the test.
Note that the longer the distance driven, the more reliable the result. Therefore, drive more
than 10,000 km if it is possible for you to do so.
When the vehicle has been driven far enough, the tank should be filled to the same reference
level as when it was first refuelled. Unlike the first refuelling, the last refuelling should be
included in the test.
Summary and calculation of the K factor
z Add up the actual total fuel consumption.

z Read the number of litres consumed as displayed in the instrument cluster.
The fuel consumption factor is calculated as follows:

K= R/S
2011-08-23 ?Scania CV 3 of 4
Engine no.: 6642331
K= Calibration factor
R= Actual consumption, i.e. total number of litres added during the test.
S= Displayed consumption, i.e. total number of litres consumed as displayed in the
instrument cluster.
It is only possible to enter the calibration factor within the range 0.81 - 1.20.
Recalibration
If, after a period of driving, you think that the result from the calibration is unsatisfactory and
you would like to repeat the calibration, this can be carried out in two ways.
1. Reset the calibration factor to 1.0 using SDP3 before starting a new test.
2. Carry out the test and then multiply the new calibration factor by the current one set in
SDP3 to obtain a new calibration factor.
Example of option 2.
The first test resulted in the calibration factor = 0.94
The vehicle has been calibrated with the calibration factor, but after driving for some time it
appears that the consumption level read off still does not correspond to the actual
consumption level.
A second test is therefore carried out.
Test number two shows that there is still a difference of a factor of 0.96 between the read-off
and actual consumption levels.
The new calibration factor is calculated as follows:
0.94 x 0.96 = 0.9024
Since the calibration factor is shown to a precision of two decimal places, the new calibration
factor is 0.90.
2011-08-23 ?Scania CV 4 of 4
Engine no.: 6642331
03-00 Fuel system Scania XPI

Check - Measuring the fuel pressure on 9 and 13 litre engines with Scania XPI
Removal - Removing the fuel manifold on 9 and 13 litre engines with Scania XPI
Fitting - Fitting the fuel manifold on 9 and 13 litre engines with Scania XPI
Removal - Removing high pressure pipes and connections
Fitting - Fitting high pressure pipes and connections
Removal - Removing the high pressure pump on 9 and 13 litre engines
Fitting - Fitting the high pressure pump on 9 and 13 litre engines
Removal - Removing the gear on the high pressure pump
Removal - Removing torsion damper
Renewal - Renewing the cylinder head for the high pressure pump on engines with
the Scania XPI fuel system
Removal - Removing injectors
Fitting - Fitting injectors
Check - Checking Scania XPI injectors

Note!
Check
Measuring the fuel pressure on 9 and 13 litre engines with

Scania XPI
Important!
The fuel system is very sensitive to dirt. It

is therefore very important that everything
is as clean as possible when work is carried
out on the fuel system.
Do not use compressed air to blow
components in the fuel system clean.
When cleaning, rags or paper which shed
fibres must not be used. Use lint-free rags.
Clean tools before use.
2011-08-23 ?Scania CV 1 of 26
Engine no.: 6642331
Do not use worn chrome-plated tools as

flakes of chrome may come off.
Cover connections of removed components
with a lint-free rag and tape.
Tools
Tool
board
99 362 Pressure gauge
804cf31d
The test connection for measuring fuel pressure is located on the high pressure pump (at the
arrow to the left in the illustration) and the fuel manifold (at the arrow to the right in the
illustration).
Measuring supply pressure
1. Connect pressure gauge 99 362 to the test connection on the high pressure pump and open
the test connection.
2. Crank with the starter motor for approximately 20 seconds. Read the pressure. The
pressure should be more than 3 bar.
3.
If the engine starts: Increase engine speed to 1,500 rpm. Read the pressure. The pressure
2011-08-23 ?Scania CV 2 of 26
Engine no.: 6642331
should be between 9 and 14 bar.

4. Switch off the engine, remove the pressure gauge and close the test connection.
Measuring fuel pressure at the fuel manifold when the engine can be
started
1. Connect pressure gauge 99 362 to the test connection on the fuel manifold and open the
test connection.
2. Start the engine. Read the pressure with the engine idling. The pressure should be below
0.8 bar.
3. If the pressure is above 0.8 bar, proceed as follows:
z Remove the overflow valve.
z Clean the overflow valve and check that it is not blocked.
z Fit the overflow valve.
z Bleed the fuel system by idling the engine for a while.
z Take a new reading.
If the pressure of the new reading exceeds 0.8 bar, there is internal leakage in an injector.
4. Switch off the engine, remove the pressure gauge and close the test connection.
Measuring fuel pressure at the fuel manifold when the engine cannot be
started
1. Connect pressure gauge 99 362 to the test connection on the fuel manifold and open the
test connection.
2. Crank with the starter motor for approximately 20 seconds. Read the pressure. The value
should be below 0.8 bar.
3. If no value can be read after 20 seconds: Allow the starter motor to cool down and repeat
step 2.
Note!
If there is air in the filter housing, pressure
cannot build up. Bleed the filter housing
and try again.
4. Remove the pressure gauge and close the test connection.
Removal
Removing the fuel manifold on 9 and 13 litre engines with

Scania XPI
2011-08-23 ?Scania CV 3 of 26
Engine no.: 6642331
Important!

8049a7f5
1. Undo the brackets 1 and move the electrical cables to one side.
2. Remove the return pipes 2 and 3.
3. Undo the fuel manifold bolts, marked with arrows in the illustration, and pull out the fuel
manifold towards the rear end of the engine.
Fitting
Fitting the fuel manifold on 9 and 13 litre engines with
2011-08-23 ?Scania CV 4 of 26
Engine no.: 6642331
Scania XPI
Important!

8049a7f5
1. Insert the bolt at the far left of the fuel manifold. Pull in the fuel manifold from the rear
end of the motor and screw in all fuel manifold bolts; see the arrows.
2. Check that the gaskets around the intake
have not come loose. The gaskets must
protrude above the fuel manifold.
2011-08-23 ?Scania CV 5 of 26
Engine no.: 6642331
8049a7f1
3. Fit the return pipes 2 and 3.

4. Fit the electrical cables by screwing in the brackets 1.
Removal - Removing high pressure pipes and connections

Instructions
Warning!
The fuel system has a very high fuel
pressure of up to 3000 bars. The fuel
system must be depressurised using SDP3
before any work is started.
the fuel system.
The system should always be treated as
pressurised, even when the engine is
switched off.
Wear protective gloves and goggles.
Important!

When the fuel system has been opened,
compressed air must not be used to blow
2011-08-23 ?Scania CV 6 of 26
Engine no.: 6642331
clean components.
In order to remove an injector from the cylinder head, its connection must first be removed.
1
2 3
80508441
1. High pressure pipe

2. Connection
3. Injector
1. Start by depressurising the fuel system. Use SDP3 to minimise the high pressure in the
fuel system.
2. Place a rag over the high pressure pipe cap 1
nut 1 (at the accumulator) of the cylinder
in question. Then carefully undo the nut.
8044bf42
3. Undo the cap nut in the other end of the high pressure pipe and remove the pipe.
4. Undo the cap nut at connection 2. Hold tight so that the connection is not turned when the
cap nut is undone. There is a pin on the connection which can be damaged.
2011-08-23 ?Scania CV 7 of 26
Engine no.: 6642331
Important!
Make sure that it is clean around the

connection before it is drawn out from the
engine. Dirt must not enter the fuel system.
Important!
A high pressure pipe that has been

loosened or removed, must never be
refitted but must be replaced by a new one.
5. Pull out the connection from the cylinder head. If it jams and is difficult to pull out, you
can replace the cap nut with a nut with part number 812 889 and break carefully with a
crow bar.
When removing unions and safety valve:
80508445
Several unions and the safety valve in the system are sealed with a sealing washer which
must be renewed if the parts have been disassembled. There is a plug at the accumulator end
(same connection as for cylinder 1 on 6 cylinder engines) on 5 cylinder engines. This is
sealed with the same type of washer. The old washer is often stuck and can be difficult to
remove without damaging the sealing surface.
2011-08-23 ?Scania CV 8 of 26
Engine no.: 6642331
12.7
80508449
Tip: Make a simple special tool using a standard 3-4 mm hexagon key. Grind down the
shorter end as illustrated (12.7 mm) and use the tool to ease the washer out of its spot.
Fitting - Fitting high pressure pipes and connections

1. Lubricate the new O-ring on the connection using engine oil. Also check that the pin is
secure.
2. Press the connection into the cylinder head with the pin facing upwards in the designated
hole. Tighten the cap nut.
Important!
Make sure that the high pressure pipe is

free of dirt before it is fitted to the engine.
3. Fit the high pressure pipe. Remove the plugs and fit both ends of the high pressure pipe
before torque tightening.
Removal
Removing the high pressure pump on 9 and 13 litre

engines
Instructions
Warning!

2011-08-23 ?Scania CV 9 of 26
Engine no.: 6642331

switched off.
Important!

clean components.
Plug or tape connections on components
which are removed.
Important!

1. Start by depressurising the fuel system.

Use SDP3 to minimise the high pressure in the fuel system.
Place a rag over the high pressure pipe nut at the accumulator. Then carefully undo the
nut.
2. Remove the fuel pipes. Mark the them to make fitting easier.
3. Separate the fuel metering valve cable harness.
4. Remove the fuel filter housing.
5. Remove the starter motor.
2011-08-23 ?Scania CV 10 of 26
Engine no.: 6642331
6. Unscrew the high pressure pump and lift it out carefully. Leave the bracket for the high
pressure pump behind. This will make fitting easier.
Fitting
Fitting the high pressure pump on 9 and 13 litre engines

1. Lift the high pressure pump into position and screw into place.
2. Undo the tapered joint which holds the high pressure pump bracket against the cylinder
block, and then tighten it again. This is carried out to remove any stresses.
Fit:
2 5 4 6
8044bf2a
1. fuel filter housing

2. fuel pipe between the feed pump and the control unit cooler
3. fuel intake manifold.
4. fuel pipe between the fuel filter and the high pressure pump.
5. fuel pipe between the feed pump and the fuel filter.
6. return pipe between the high pressure pump and the fuel filter.
7. return pipe between the fuel manifold and the high pressure pump.
Removal
Removing the gear on the high pressure pump

Tools
2011-08-23 ?Scania CV 11 of 26
Engine no.: 6642331
Tool
board
99 633 Assembly tool
1. Fit the tool.
806d0964
806d090a
2. Undo the nut.
2011-08-23 ?Scania CV 12 of 26
Engine no.: 6642331
806d090c
3. Remove the nut.
806d0957
4. Remove the tool.
806d0958
5. Fit the puller and tighten it.
2011-08-23 ?Scania CV 13 of 26
Engine no.: 6642331
806d0959
6. Tap lightly on the puller to loosen the

gear.
806d095a
7. Make a
note of
the type
of gear. A B
Scissors
gears
should
be
parallel.
806d0962
80713f19
2011-08-23 ?Scania CV 14 of 26
Engine no.: 6642331
8. Fit the nut.
806d0963
9. Fit the tool.
806d0964
10. Tighten the nut
806d099b
11. Remove the tool.
2011-08-23 ?Scania CV 15 of 26
Engine no.: 6642331
806d0958
Removal
Removing torsion damper

Tools
Tool
board
99 633 Assembly tool
1. Remove the high pressure pump. See subgroup 03-00, Fuel system Scania XPI
2. Remove the high pressure pump gear. See subgroup 03-00, Fuel system Scania XPI
3.
80720c68
2011-08-23 ?Scania CV 16 of 26
Engine no.: 6642331
80720c69
Fit assembly tool 99 633 against a flat horizontal surface and place the gear in the assembly
tool.
4.
80720c6b
Detach the torsion damper screws from the gear.
Renewal
Renewing the cylinder head for the high pressure pump on

engines with the Scania XPI fuel system
Regulations
Warning!

2011-08-23 ?Scania CV 17 of 26
Engine no.: 6642331

switched off.
Important!

Do not use compressed air to blow clean
components in the fuel system.
which are removed.
Important!
A high-pressure pipe that has been

loosened or removed must never be refitted
but must be replaced with a new one.
1. Tilt the cab in accordance with the instructions.

2. Remove the mudguard in accordance with the instructions.
3. Clean around the fuel system.
4. Depressurise the fuel system. Use SDP3 to
minimise the pressure. Place a rag over the
high-pressure pipe nut (1). Then carefully
undo the nut.
2011-08-23 ?Scania CV 18 of 26
Engine no.: 6642331
5 4
80465cbc
5. Undo the cable connection.

6. Remove the high-pressure pipe (2) and fit clean plugs in the fuel connections. Note: The
high-pressure pipe must not be reused.
7. Undo the banjo unions on the high-pressure pump.
8. Remove the fuel return pipe (3) and plug the fuel manifold. Detach the pipes (4 and 5)
from the cylinder head.
9. Undo the cylinder head screws alternately. Remove the cylinder head and gasket.
10. Remove the protective plugs on the new cylinder head. Fit new springs, a new gasket
and new screws.
11.
8046a8b6
Clean the pump surface that faces the cylinder head. Check that the guide pins under the
2011-08-23 ?Scania CV 19 of 26
Engine no.: 6642331
roller tappets are straight and that the roller tappets are correctly positioned so that they go
down completely in their seats; see illustration. Screw the cylinder head into place
alternately.
12. Fit the pipes (3, 4 and 5). Use new washers.
13. Fit a new high pressure pipe 2.
14. Fit the high-pressure pipe brackets.
15. Fit the cable connection.
16. Start the engine and clear the fault codes.

Tools
Tool
board
99 475 Crow bar for removing injectors
Regulations
Warning!
switched off.
Important!

2011-08-23 ?Scania CV 20 of 26
Engine no.: 6642331

clean components.

2. Place a rag over the high pressure pipe nut at the accumulator for the cylinder where the
injector has to be removed. Then carefully undo the nut.
3. Remove the upper rocker cover.
4. Undo the nuts for the electric connections to the injector.
5. Remove the high pressure pipe. Undo the cap nut at the connection to the injector.
Important!

connection before the connection is
removed from the engine. Dirt must not
enter the fuel system.
Important!

removed, must never be refitted but must
be replaced by a new one. Note! When
working on injectors on cylinder 5, the pipe
for cylinder 6 must also be renewed.
6. Plug the connections so that dirt cannot penetrate.

7. Undo the cap nut for the connection and
pull the connection upwards. Note! To
gain access to the connection for cylinder
5, the high pressure pipe for cylinder 6
2011-08-23 ?Scania CV 21 of 26
Engine no.: 6642331
must first be removed. If it is difficult to

pull the connection upwards, you can
replace the cap nut with nut part number
812 889 and break carefully with a crow
bar.
8043213d
The connection must be removed before the

injector can be removed.
9. Undo the injector holder screw.
Important!
The injector must be re-fitted to the same

cylinder it was removed from.
Important!
Do not prise into the valve part.
10. Undo the injector using the special tool,

by prising in the groove on the injector
sleeve.
2011-08-23 ?Scania CV 22 of 26
Engine no.: 6642331
805906c5
Groove on injector where the crowbar is to be

used.
11. Plug the injection part of the injector, as well as where the connection is made, so that
dirt cannot enter.
12. If several injectors are removed, number and place the injectors in sequence so that they
are refitted on the same cylinders.
Important!
If one or more injectors are renewed, the

engine control unit must be programmed so
that the injector(s) injects(inject) the
correct amount.
Important!

Important!
Check carefully that all parts that are

refitted are clean. It is very important that
no dirt enters the fuel system.
Important!
The connectors on the injector are very

susceptible to knocks.
1. Remove the old washer by prising it off

using a screwdriver, for example. Take
care not to damage the injection nozzle tip.
Fit a new sealing washer on the unit
injector.
2011-08-23 ?Scania CV 23 of 26
Engine no.: 6642331
Cut a plastic pipe to approximately 50

mm, diameter 16 mm (part number 1 483
546). Press the washer into position as far
as it will go. Then place the plastic pipe
over the injection nozzle tip as illustrated.
Hold the injector in one hand and the
plastic pipe in the other hand. Carefully
tap the washer into place against a work
bench. Make sure that the connectors are
not subjected to any knocks.
805906d1
2. Note the code which appears on the

bottom line of text on the injector; see the xx xxx x
xx xxx x
xx xxx x xx
illustration. The code is needed later when xx xxx x x xx
calibrating the injector.
8049ba52
3. Renew the O-ring on the injector and lubricate the O-ring with engine oil.
Important!
The injector is carefully placed in position

and screwed into place using the holder.
4. Fit the holder to the injector and place the injector loosely in the groove.
5. Use the holder to make sure that the injector is in the correct position.
6. Screw on the holder.
secure.
8. Press the connection into the cylinder head, with the pin facing upwards, in the designated
9. Tighten the injector holder screw.
2011-08-23 ?Scania CV 24 of 26
Engine no.: 6642331
10. Tighten the connection cap nut.

11. Fit the electrical connectors and the nuts.
12. Position the high pressure pipe. Remove the plugs and fit both ends of the high pressure
pipe before torque tightening.
13. Fit the rocker cover.
14. Enter the code for the new injector into the control unit using the Calibration of injectors
function in SDP3.
15. Reset the adaptation of the fuel amount using Basic setting of adaptation of the injectors
in SDP3.

Tools
Tool
board
1. Check whether there are any fault codes using SDP3.

2. Check the function of the injectors using the check Activation of injector solenoid valves
in SDP3.
3. Remove the rocker cover for the defective cylinder and disconnect the electrical cables
from the screws on the solenoid valve.
4. Measure the resistance on the contact
surfaces of the solenoid valve for about 20
seconds until a stable value is obtained. The
resistance should be 0.2-0.6 Ohms at room
temperature when the engine is cold.
Important!
To obtain a correct reading, resistance must

be measured directly between the
connections and not on the screws.
Note!
Check the condition of the measuring
instrument before taking a reading.
2011-08-23 ?Scania CV 25 of 26
Engine no.: 6642331
587 423
805f8a29
5. Place one measurement probe against the contact surface on the solenoid valve. Place the
other measurement probe against the metal sheath on the solenoid valve to check that
there is no short circuit. Check the other connection in the same way.
6. Refit the electrical cables to the injector by tightening the screws using torque screwdriver
588 179.
Note!
If the injectors cannot be checked using
SDP3, one injector may be short circuited
to earth via the chassis. The EDC control
unit is thus not working or generating
diagnostic trouble codes. If this is the case,
each injector must be checked.
2011-08-23 ?Scania CV 26 of 26
Engine no.: 6642331
03-00 Overflow valve

Location - Overflow valve, 9 and 13 litre engines with XPI
Location
Overflow valve, 9 and 13 litre engines with XPI
8076c0c9

Note!
2011-08-23 ?Scania CV 1 of 1
Engine no.: 6642331
03-01 Feed pump

Location
Complete - Removing and fitting the feed pump on 9 and 13 litre XPI engines
Location
80300ea1
The position also applies to 11 and 12 litre engines.

The feed pump is located at the back of the compressor.

Note!
Complete
Removing and fitting the feed pump on 9 and 13 litre XPI

engines
Regulations
Warning!
2011-08-23 ?Scania CV 1 of 3
Engine no.: 6642331

the fuel system.
switched off.
Important!

Compressed air must not be used to blow
components clean if the fuel system is
open.
with a lint free cloth and tape.
2 A
80449a65
1. The fuel pipes (1 and 2) must be removed before the feed pump (A) can be removed.
Mark the feed pump and fuel pipes to make fitting easier.
2. Undo the feed pump (three bolts) and draw it out.
2011-08-23 ?Scania CV 2 of 3
Engine no.: 6642331
3. Renew the O-ring.

4. Refit the pump. Turn and carefully push in the pump until the pump coupling engages.
5. Make sure that the feed pump is pressed all the way in against the high-pressure pump
before tightening the bolts.
2011-08-23 ?Scania CV 3 of 3
Engine no.: 6642331
03-01 Injector Scania XPI

Cleaning - Cleaning 9, 11, 12 and 13 litre engines

Note!
Cleaning
Cleaning 9, 11, 12 and 13 litre engines

The engine must be cleaned before starting work.
Clean with water and use a hot wash. Also use a degreasing agent, if necessary.
Avoid spraying water on the engine control unit, see illustration. Clean the components that
are inside the marked area.
8057596d
2011-08-23 ?Scania CV 1 of 8
Engine no.: 6642331
Warning!
Beware of hot water! Use suitable
protective equipment.
Environment
The washing water must be disposed of in
compliance with the relevant national or
local regulations.

Tools
Tool
board
99 475 Crow bar for removing injectors
Regulations
Warning!
switched off.
Important!

2011-08-23 ?Scania CV 2 of 8
Engine no.: 6642331

clean components.

2. Place a rag over the high pressure pipe nut at the accumulator for the cylinder where the
injector has to be removed. Then carefully undo the nut.
3. Remove the upper rocker cover.
4. Undo the nuts for the electric connections to the injector.
5. Remove the high pressure pipe. Undo the cap nut at the connection to the injector.
Important!

connection before the connection is
removed from the engine. Dirt must not
enter the fuel system.
Important!

removed, must never be refitted but must
be replaced by a new one. Note! When
working on injectors on cylinder 5, the pipe
for cylinder 6 must also be renewed.

7. Undo the cap nut for the connection and
pull the connection upwards. Note! To
2011-08-23 ?Scania CV 3 of 8
Engine no.: 6642331
gain access to the connection for cylinder

5, the high pressure pipe for cylinder 6
must first be removed. If it is difficult to
pull the connection upwards, you can
replace the cap nut with nut part number
812 889 and break carefully with a crow
bar.
8043213d
The connection must be removed before the

injector can be removed.
9. Undo the injector holder screw.
Important!
The injector must be re-fitted to the same

cylinder it was removed from.
Important!
Do not prise into the valve part.
10. Undo the injector using the special tool,

by prising in the groove on the injector
sleeve.
2011-08-23 ?Scania CV 4 of 8
Engine no.: 6642331
805906c5
Groove on injector where the crowbar is to be

used.
11. Plug the injection part of the injector, as well as where the connection is made, so that
dirt cannot enter.
12. If several injectors are removed, number and place the injectors in sequence so that they
are refitted on the same cylinders.
Important!
If one or more injectors are renewed, the

engine control unit must be programmed so
that the injector(s) injects(inject) the
correct amount.
Important!

Important!
Check carefully that all parts that are

refitted are clean. It is very important that
no dirt enters the fuel system.
Important!
The connectors on the injector are very

susceptible to knocks.
1. Remove the old washer by prising it off

using a screwdriver, for example. Take
care not to damage the injection nozzle tip.
Fit a new sealing washer on the unit
injector.
2011-08-23 ?Scania CV 5 of 8
Engine no.: 6642331
Cut a plastic pipe to approximately 50

mm, diameter 16 mm (part number 1 483
546). Press the washer into position as far
as it will go. Then place the plastic pipe
over the injection nozzle tip as illustrated.
Hold the injector in one hand and the
plastic pipe in the other hand. Carefully
tap the washer into place against a work
bench. Make sure that the connectors are
not subjected to any knocks.
805906d1
2. Note the code which appears on the

bottom line of text on the injector; see the xx xxx x
xx xxx x
xx xxx x xx
illustration. The code is needed later when xx xxx x x xx
calibrating the injector.
8049ba52
3. Renew the O-ring on the injector and lubricate the O-ring with engine oil.
Important!
The injector is carefully placed in position

and screwed into place using the holder.
4. Fit the holder to the injector and place the injector loosely in the groove.
5. Use the holder to make sure that the injector is in the correct position.
6. Screw on the holder.
secure.
8. Press the connection into the cylinder head, with the pin facing upwards, in the designated
9. Tighten the injector holder screw.
2011-08-23 ?Scania CV 6 of 8
Engine no.: 6642331
10. Tighten the connection cap nut.

11. Fit the electrical connectors and the nuts.
12. Position the high pressure pipe. Remove the plugs and fit both ends of the high pressure
pipe before torque tightening.
13. Fit the rocker cover.
14. Enter the code for the new injector into the control unit using the Calibration of injectors
function in SDP3.
15. Reset the adaptation of the fuel amount using Basic setting of adaptation of the injectors
in SDP3.

Tools
Tool
board
1. Check whether there are any fault codes using SDP3.

2. Check the function of the injectors using the check Activation of injector solenoid valves
in SDP3.
3. Remove the rocker cover for the defective cylinder and disconnect the electrical cables
from the screws on the solenoid valve.
4. Measure the resistance on the contact
surfaces of the solenoid valve for about 20
seconds until a stable value is obtained. The
resistance should be 0.2-0.6 Ohms at room
temperature when the engine is cold.
Important!
To obtain a correct reading, resistance must

be measured directly between the
connections and not on the screws.
Note!
Check the condition of the measuring
instrument before taking a reading.
2011-08-23 ?Scania CV 7 of 8
Engine no.: 6642331
587 423
805f8a29
5. Place one measurement probe against the contact surface on the solenoid valve. Place the
other measurement probe against the metal sheath on the solenoid valve to check that
there is no short circuit. Check the other connection in the same way.
6. Refit the electrical cables to the injector by tightening the screws using torque screwdriver
588 179.
Note!
If the injectors cannot be checked using
SDP3, one injector may be short circuited
to earth via the chassis. The EDC control
unit is thus not working or generating
diagnostic trouble codes. If this is the case,
each injector must be checked.
2011-08-23 ?Scania CV 8 of 8
Engine no.: 6642331
03-05 Fuel filter

Location - 9 and 13 litre engines with XPI
Removal - Removing the fuel filter on Scania XPI
Fitting - Fitting a fuel filter on Scania XPI
Complete - Bleeding the fuel system on 9 and 13 litre engines with XPI
Removal - Removing the fuel filter housing on 9 and 13 litre engines with XPI
Location
9 and 13 litre engines with XPI
1 2
8044befa
1. Water separating suction filter

2. Pressure filter

Note!
Removal
Removing the fuel filter on Scania XPI
Important!
2011-08-23 ?Scania CV 1 of 5
Engine no.: 6642331

which are removed.
Tools
Maintenance
588 475 Sleeve
cabinet
1. Open the bleed nipple on the fuel filter housing to release any remaining pressure. It may
be difficult to unscrew the filter cover if the fuel pressure has not fallen sufficiently.
Note!
Fuel will come out of the bleed nipple. It
should be collected as specified in
environmental regulations.
Important!
Do not use an adjustable spanner or other

open tool to undo the filter cover, as this
risks damaging the filter cover.
2. Unscrew the filter cover with a closed tool with hexagon driver, e.g. socket 588 475.
3. Lift the filter cover with filter element out of the fuel filter housing. The fuel filter housing
will drain automatically (slowly) once the filter element has been removed. Always suck
out the fuel left in the filter housing.
4. Undo the old filter element from the cover by carefully bending it to one side.
2011-08-23 ?Scania CV 2 of 5
Engine no.: 6642331
Fitting
Fitting a fuel filter on Scania XPI

Tools
Maintenance
588 475 Sleeve
cabinet
1. Fit a new O ring to the cover. Lubricate the O-ring with O-ring grease 1 402 039.
2. Press a filter element into the snap fastener on the cover.
Important!
Fit the filter element to the filter cover

before positioning it in the fuel filter
housing. The filter element can otherwise
be damaged.
Important!
In order to prevent back pressure in the

filter housings when the filter elements are
screwed on, the bleed nipple should be
open.
3. Press down the filter element with filter cover into the filter housing. Screw the filter
cover into place with a closed tool with hexagon driver, e.g. socket 588 475. Check that
there is no gap between the filter cover and the filter housing. If there is a gap, repeat the
procedure and make sure that the bleed nipple is open.
Complete
Bleeding the fuel system on 9 and 13 litre engines with XPI
Important!

2011-08-23 ?Scania CV 3 of 5
Engine no.: 6642331

which are removed.
1. Attach a clear plastic hose to the bleed nipple on the fuel filter housing. Let the plastic
hose drop into a container that holds at least 5 litres.
2. Unscrew the hand pump handle.
3. Open the bleed nipple and pump until fuel runs out, which will take around 100 pump
strokes. Close the bleed nipple.
4. Start the engine and open the bleed nipple carefully. Approximately 3 litres will run out
into the container before the fuel coming out will be free of air.
Removal
Removing the fuel filter housing on 9 and 13 litre engines

with XPI
Important!

2011-08-23 ?Scania CV 4 of 5
Engine no.: 6642331

which are removed.
1. Drain the fuel filter housing by unscrewing the filters according to the section Removing
fuel filter.
2. Loosen the connections to the fuel filter housing.
3.
8044bf16
Undo the fuel filter housing.
2011-08-23 ?Scania CV 5 of 5
Engine no.: 6642331
03-05 H15, Fuel heater

Location
9 and 13 litre engines with Scania XPI fuel system

H 15
8071788a
2011-08-23 ?Scania CV 1 of 1
Engine no.: 6642331
03-25 T113, Exhaust temperature sensor before

catalytic converter
Symbol
1
1
802c07c0
2011-08-23 ?Scania CV 1 of 1
Engine no.: 6642331
03-35 E44, Control unit EMS S8

Connection - 9 and 13 litre engines with XPI and SCR
Location - 9 and 13 litre engines
Removal - Removing connectors on the control unit
Removal - Removing EMS on 9 and 13 litre engines with XPI
Renewal - Renewing the control unit cooler
Complete - Clamping and routing the electrical cables
Connection
9 and 13 litre engines with XPI and SCR
B1 A1
B2 A2
B3 A3
B4 A4
B5 A5
B6 A6
B7 A7
8044df24
2011-08-23 ?Scania CV 1 of 14
Engine no.: 6642331
Control Task Signal type Source/destination

unit pin
A1/1 Control of injector, cylinder 4 +24V XPI injector, (V144)
A1/4 Not used
A1/5 Not used
A1/6 Grounding of injector, Ground XPI injector, (V144)
cylinder 4
A1/7 Control of injector, cylinder 5 Ground XPI injector, (V145)
A1/8 Grounding of injector, Ground XPI injector, (V146)
cylinder 6
A1/9 Not used
A1/10 Not used
A2/1 Not used
A2/2 Ground, exhaust back pressure Ground Exhaust back pressure sensor
sensor (T125)
A2/3 Voltage supply, exhaust back +5V Exhaust back pressure sensor
pressure sensor (T125)
A2/4 Ground, fuel pressure sensor Ground Fuel pressure sensor, (T111)
A2/5 Voltage supply, fuel pressure +5V Fuel pressure sensor, (T111)
sensor
A2/6 Not used
A2/7 Control of the exhaust back Analogue Exhaust back pressure sensor
pressure sensor input signal (T125)
A2/8 Not used
A2/9 Not used
A2/10 Control of the fuel pressure Analogue Fuel pressure sensor, (T111)
sensor input signal
A3/1 Not used
A3/2 Signal, camshaft position Frequency, Camshaft position sensor,
sensor input signal (T135)
A3/3 Signal, camshaft position Frequency, Camshaft position sensor,
A3/4 Signal from engine speed Frequency, Engine speed sensor 2, (T75) 1
sensor 2 input signal
A3/5 Signal from engine speed Frequency, Engine speed sensor 2, (T75) 2
2011-08-23 ?Scania CV 2 of 14
Engine no.: 6642331

A3/6 Not used
A3/7 Grounding of damper, EGR Ground Valve block, (V107)
A3/8 Control of damper, EGR PWM output Valve block, (V107)
signal
A3/9 Grounding of damper for Ground Valve block, (V107) 2
exhaust brake
A3/10 Control of damper for exhaust PWM output Valve block, (V107) 7
brake signal
A4/1 Not used
A4/2 Ground, position sensor for Ground Position sensor for throttle,
throttle (T162)
A4/3 Control of the throttle PWM output position sensor for throttle,
signal (T162)
A4/4 Grounding of position sensor Ground Position sensor for the EGR
for EGR valve valve, (T124) 3
A4/5 Voltage supply, position +5V Position sensor for the EGR
sensor for the EGR valve valve, (T124) 1
A4/6 CAN communication, electric CAN HIGH Electric motor for adjustable
motor for adjustable turbocharger, (M30)
turbocharger
A4/7 CAN communication, electric CAN LOW Electric motor for adjustable
motor for adjustable turbocharger, (M30)
turbocharger
A4/8 Not used
A4/9 Not used
A4/10 Signal from position sensor Analogue Position sensor for the EGR
for the EGR valve input signal valve, (T124) 2
A5/1 Not used
A5/2 Not used
A5/3 Not used
A5/4 Signal from engine speed Frequency, Engine speed sensor (T74) 1
Only gas engine
A5/5 Signal from engine speed Frequency, Engine speed sensor (T74) 2
Only gas engine
2011-08-23 ?Scania CV 3 of 14
Engine no.: 6642331
A5/6 Not used

A5/7 Not used
A5/8 Not used
A5/9 Not used
A5/10 Not used
A6/1 Not used
A6/2 Not used
A6/3 Heating of intake air +24V Intake air temperature and flow
temperature and flow sensor sensor (T126)
A6/4 Grounding, position sensor for Ground Position sensor for throttle,
throttle (T162)
A6/5 Voltage supply, position +5V Position sensor for throttle,
sensor for throttle (T162)
A6/6 Not used
A6/7 Not used
A6/8 Grounding of intake air Ground Intake air temperature and flow
A6/9 Signal from intake air Analogue Intake air temperature and flow
temperature and flow sensor input signal sensor (T126)
A6/10 Signal, position sensor for Analogue Position sensor for throttle,
throttle input signal (T162)
A7/1 Not used
A7/2 Grounding, oil pressure sensor Ground Oil pressure sensor, (T5)
A7/3 Voltage supply, oil pressure +5V Oil pressure sensor, (T5)
sensor
A7/4 Not used
A7/5 Not used
A7/6 Grounding of intake air Ground Intake air temperature and flow
Only for gas engine
A7/7 Voltage supply, intake air +5V Intake air temperature and flow
Only for gas engine
A7/8 Signal, oil pressure sensor Analogue Oil pressure sensor, (T5)
input signal
A7/9 Voltage supply, coolant +5V Coolant temperature sensor,
temperature sensor (T33)
2011-08-23 ?Scania CV 4 of 14
Engine no.: 6642331
A7/10 Grounding of coolant Ground Coolant temperature sensor,

B1/1 Control of injector, cylinder 1 +24V XPI injector (V141)
B1/2 Control of injector, cylinder 2 +24V XPI injector, (V142)
B1/3 Control of injector, cylinder 3 +24V XPI injector, (V143)
B1/4 Not used
B1/5 Not used
B1/6 Grounding of injector, Ground XPI injector, (V141)
cylinder 1
cylinder 2
cylinder 3
B1/9 Not used
B1/10 Not used
B2/1 Not used
B2/2 Not used
B2/3 Not used Fuel temperature sensor (T91)
B2/4 Grounding of charge air Ground Charge air pressure sensor
B2/5 Voltage supply, charge air Charge air pressure sensor
B2/6 Not used
B2/7 Not used
B2/8 Grounding, charge air Ground Charge air temperature sensor
B2/9 Voltage supply, charge air +5V Charge air temperature sensor
B2/10 Signal, charge air pressure Analogue Charge air pressure sensor
B3/1 Voltage supply 2, control unit +24V Battery
B3/2 Grounding 2, control unit Ground Battery
B3/3 Signal via starter lock Digital input Starter lock
signal
B3/4 Grounding, electric motor for Ground Battery
variable turbocharger
B3/5 Not used
2011-08-23 ?Scania CV 5 of 14
Engine no.: 6642331
B3/6 Voltage supply 1, control unit +24V Battery

B3/7 Grounding 1, control unit Ground Battery
B3/8 Voltage supply, electric motor +24V Battery
for variable turbocharger
B3/9 CAN red bus CAN HIGH Red CAN
B3/10 CAN red bus CAN LOW Red CAN
B4/1 Shutting down the alternator PWM output Only ADR
signal
Only ADR
B4/2 Not used
B4/3 Not used
B4/4 Not used
B4/5 Not used
B4/6 Not used
B4/7 CAN exhaust gas CAN HIGH EEC3
aftertreatment
B4/8 CAN exhaust gas CAN LOW EEC3
aftertreatment
B4/9 Not used
B4/10 Not used
B5/1 Control of starter motor Digital output Starter motor (relay) M1 A1
signal
B5/2 Not used
B5/3 Signal from alternator Digital input Alternator, (P3) A2
signal
B5/4 Signal from alternator Digital input Alternator, (P500) A3
signal
Only bus
B5/5 Signal, fan rotational speed PWM input Rotational speed sensor and
sensor and solenoid valve signal solenoid valve for the fan,
(T123)
B5/6 Not used
B5/7 Grounding, fuel inlet metering Ground Fuel inlet metering valve,
valve (V120)
B5/8 Control of the fuel inlet PWM output Fuel inlet metering valve,
metering valve signal (V120)
B5/9 Control of alternator 1 PWM output Alternator, (P3) A3
signal
2011-08-23 ?Scania CV 6 of 14
Engine no.: 6642331
B5/10 Control of alternator 2 PWM output Alternator, (P500) A3

signal
Only bus
B6/1 Control of fan rotational speed PWM output Rotational speed sensor and
sensor and solenoid valve signal solenoid valve for the fan,
(T123)
Hydraulic pump (V119) bus
B6/2 Not used
B6/3 Control of coupling coil for Digital output Coupling coil for AC
AC compressor signal compressor (V2)
B6/4 Grounding of coupling coil for Ground Coupling coil for AC
AC compressor compressor (V2)
B6/5 Voltage supply of fan +12V Rotational speed sensor and
rotational speed sensor and solenoid valve for the fan,
solenoid valve (T123)
B6/6 Grounding of fan rotational Ground Rotational speed sensor and
speed sensor and solenoid solenoid valve for the fan,
valve (T123)
Hydraulic pump (V119) bus
B6/7 Not used
B6/8 Not used
B6/9 Grounding of fan rotational Ground Rotational speed sensor and
speed sensor and solenoid solenoid valve for the fan,
valve (T123)
B6/10 Not used
B7/1 Signal, turbo speed sensor Frequency, Turbo speed sensor, (T120) 1
input signal
B7/2 Voltage supply, electric motor +24V Electric motor for variable
for variable turbocharger turbocharger, (M30)
B7/3 Not used
B7/4 Not used
B7/5 Not used
B7/6 Signal, turbo speed sensor Frequency, Turbo speed sensor, (T120) 2
input signal
B7/7 Grounding, electric motor for Ground Electric motor for variable
variable turbocharger turbocharger, (M30)
B7/8 Not used
B7/9 Not used
2011-08-23 ?Scania CV 7 of 14
Engine no.: 6642331
B7/10 Not used
Location
E44
80408bec
Removal - Removing connectors on the control unit

You can make an aid from steel wire, see illustration, to make it easier to remove the
connectors from the control unit.
42
2.5
60
15
803d7d99
2011-08-23 ?Scania CV 8 of 14
Engine no.: 6642331
803d7d9a
Removal
Removing EMS on 9 and 13 litre engines with XPI
Important!

Compressed air must not be used to blow
components clean if the fuel system is
open.
When cleaning, cloths or paper which shed
fibres must not be used. Use lint-free
cloths.
with a lint-free cloth and tape.
Important!
2011-08-23 ?Scania CV 9 of 14
Engine no.: 6642331
pressure of up to 3,000 bars. The fuel

system must be depressurised before any
work is started.
switched off.
80758347
1. Remove the control unit cover.
80758345
2. Remove the control unit connectors.
80758346
2011-08-23 ?Scania CV 10 of 14
Engine no.: 6642331
3.
8075834a
Detach the fuel pipes to the control unit cooling coil from the control unit.
4. Remove the fuel pipes to the control unit
cooling coil from the feed pump and the
fuel filter.
8076a224
5. Remove the control unit.
8075834b
6. Remove the control unit bracket.
2011-08-23 ?Scania CV 11 of 14
Engine no.: 6642331
8075834c
Renewal
Renewing the control unit cooler

When the control unit cooler is removed, there is residual thermal conducting putty on both
the control unit and the control unit cooler. The thermal conducting putty contains zinc oxide,
which is classified as harmful to the environment. Protective gloves should be worn during
handling.
In case of skin contact, wash thoroughly with soap and water.
Environment
Zinc oxide is extremely toxic to water
organisms and can cause detrimental long-
term effects to the water environment.
Cloths used to clean thermal conducting
putty from the control unit and cooler
surfaces must be collected in a container
for recycling or disposal in compliance
with local regulations. It should not be
drained into waterways or into the general
treatment system.
1. Remove the control unit assembly with the control unit cooler. See subgroup 01-35,
Removing EMS.
2. Detach the control unit cooler from the
control unit.
2011-08-23 ?Scania CV 12 of 14
Engine no.: 6642331
804e9682
Fitting
1. Clean away old thermal conducting putty from the parts. Use a lint-free rag and white
spirit.
2. Apply new thermal conducting putty
1885877 between the two grooves on the
control unit cooler. The bead should be
approx. 3 mm wide. Use the entire content
of the tube.
804e968c
3. Fit the control unit cooler on the control

unit
804e9682
Complete
2011-08-23 ?Scania CV 13 of 14
Engine no.: 6642331
Clamping and routing the electrical cables

Applies to 9 and 13 litre engines with XPI
Important!
Electrical cables must be correctly routed

and clamped in order to prevent chafing
and cable faults.
V141
V142 V143 V144 V145
V146
T121
T4000 T122
T123 T8
C4001
T33 G4000
T111 C4014
V109 C4013
C4000
T5 C4002
T74
P500
T75
V120
C4007
F4000
P3
M1
C4009
C4008
T110
G4001
8066e223
2011-08-23 ?Scania CV 14 of 14
Engine no.: 6642331
03-35 EMS, Engine Management System S8

Note!
2011-08-23 ?Scania CV 1 of 1
Engine no.: 6642331
03-35 T111, Fuel pressure sensor

Symbol
Location
Symbol
8007214f
Location
T111
803c21ae
2011-08-23 ?Scania CV 1 of 1
Engine no.: 6642331
03-35 T135, Camshaft position sensor

Symbol
T135
806d74cd
2011-08-23 ?Scania CV 1 of 1
Engine no.: 6642331
03-35 V120, Fuel inlet metering valve

Symbol
Location
Specification
Symbol
2 1
8001314e
Location
V120
806a15bb
Specification
Resistance values
Temperature °C Resistance ± 0.5 ohms

-20 1.8
0 2.0
20 2.2
40 2.3
60 2.5
80 2.7
2011-08-23 ?Scania CV 1 of 2
Engine no.: 6642331
2011-08-23 ?Scania CV 2 of 2
Engine no.: 6642331
03-35 V141, Solenoid valve for XPI injector

Symbol
Location
Symbol
800757cf
Location
V141
803c21aa
2011-08-23 ?Scania CV 1 of 1
Engine no.: 6642331

Symbol
Location
Symbol
800757cf
Location
V142
803c21ac
2011-08-23 ?Scania CV 1 of 1
Engine no.: 6642331

Symbol
Location
Symbol
800757cf
Location
V143
803c21ad
2011-08-23 ?Scania CV 1 of 1
Engine no.: 6642331

Symbol
Location
Symbol
800757cf
Location
V144
803c21af
2011-08-23 ?Scania CV 1 of 1
Engine no.: 6642331

Symbol
Location
Symbol
800757cf
Location
V145
803c21b0
2011-08-23 ?Scania CV 1 of 1
Engine no.: 6642331

Symbol
Location
Symbol
800757cf
Location
V146
803c21b1
2011-08-23 ?Scania CV 1 of 1
Engine no.: 6642331
16-05 P3, Alternator

Check
Specification
Check
Important!
Make sure that you never run an alternator

without the batteries connected! This may
cause the rectifiers and/or charge regulator
to be overloaded and damaged.
Note!
To obtain a correct result, the alternator
should be kept at a temperature of 20-25°
C. A higher temperature may give a lower
current.
When the engine control unit has generated fault codes for the alternator, the following tests
can be carried out.
z Output test
z Voltage test
z Phase measurement
z Length of brushes
z Slip rings, rotor resistance and overcharging
Test report
A more detailed explanation of the tests in the test report is provided under the test
concerned.
Test Test values Measured Acceptable Incorrect value

values value
1. Output test Bosch 80A: Carry out Carry out phase
>35A and 28V voltage test measurement
Bosch 100A:
>40A and 28V
Melco 100A:
2011-08-23 ?Scania CV 1 of 6
Engine no.: 6642331
>45A and 28V

Melco 150A:
>80A and 28V
Voltage test 28 +/- 1.0V at Alternator OK Check the brush
20°C length
Phase measurement <250 mV Check the brush Renew alternator
length.
Brush length¹ Bosch 80A: Check slip rings Renew alternator
>1.0 mm
Bosch 100A:
>1.0 mm
Melco 100A:
>5.0 mm
Slip rings¹ The surface Check the rotor Renew alternator
should be resistance
smooth and
bright
Rotor resistance between Bosch 80A: 8.0 Carry out Renew alternator
the slip rings (at 20°C)¹ +/-0.5 ohms overcharging
Bosch 100A: test
8.5 +/-0.5 ohms
Melco 100A:
9.0 +/-1.0 ohms
Measuring overcharging > 10 MOhm Renew regulator Renew alternator
between slip rings and
framework¹
¹Does not apply to Melco 150A.
Output test
1. Connect an ammeter and a voltmeter to the batteries as illustrated.
2011-08-23 ?Scania CV 2 of 6
Engine no.: 6642331
P2
D+
W
B-
B+
V A
802a942f
Connection to batteries
2. Start the engine and run it at idling speed for a few minutes. Then note how much current
is supplied from the alternator to the batteries. Check at the same time that the voltmeter
does not fall below 27 V. Run the engine at approximately 500 rpm.
3. Connect the same equipment as before to the central electric unit as illustrated.
P2
D+
W
B-
B+
V A
G31
802a9430
Connection to central electric unit

4. Hold the engine speed at 500 rpm and apply loads to the system by using the vehicle's
current consumers in accordance with the test report, column Check value. See below for
examples of current consumers.
2011-08-23 ?Scania CV 3 of 6
Engine no.: 6642331
Add the current you read at the batteries to the sum of the loads you are applying.
Example using 80 A Bosch alternator: If you obtained a value of 10 A at the batteries, you
only need to apply a load of 25 A to the alternator instead of 35 A. 10 A+25 A=35 A
5. Run the engine for a time while you are applying the load. Read the voltmeter again. It
should still not show less than 27 V.
Examples of current consumers:
Cab fan at maximum approx. 10 A
Main beam approx. 6 A
Two auxiliary lamps approx. 6 A
Seat heater approx. 2.5 A/seat
Electrically heated mirrors approx. 2.5 A/mirror
Coolant-operated cab heater approx. 6 A
Radio approx. 1.5 A
Voltage test
Carry out this test especially if you suspect there is overcharging.

Note!
The batteries should be fully charged to
give good results, i.e. maximum
consumption at 10A.
1. Connect the ammeter and voltmeter to the central electric unit as illustrated. Run the
engine at approximately 500 rpm.
2011-08-23 ?Scania CV 4 of 6
Engine no.: 6642331
P2
D+
W
B-
B+
V A
802a942f
Connection to batteries
2. Load the system with approximately 10-20A by using various current consumers.
3. Allow the engine to run for a while. The voltage on the voltmeter should be 28V +/- 0.5V
at 20°C.
Phase measurement
Keep the voltmeter connected as it was for the voltage test, but reset it to the AC voltage
position.
The voltmeter should be stable around 100 mV and at most 250 mV. If this performance is
not achieved, the alternator is defective and must be renewed.
Length of brushes
Check that the brush length does not fall below the permitted length, see specification.
Slip rings/Rotor resistance/Overcharging
The charge regulator must be removed in order to check the slip rings.
1. Check that the surfaces of the slip rings are smooth and bright. If the surfaces are not
bright, this indicates bad contact with the brushes.
2. Measure the rotor resistance, see measurement specification. Refer to the illustration.
2011-08-23 ?Scania CV 5 of 6
Engine no.: 6642331
800637b0
3. Measure the insulation resistance between the slip rings and alternator core (chassis
earth). The ohmmeter must show infinite resistance (at least 10 MOhm).
If one of the checks is not satisfactory, the alternator must be renewed.
Specification
Bosch 80 A Bosch 100 A

Designation NCB1 28V 35/80A NCB2 28V 40/100A
Output power at 6000 rpm 2200 W 2800 W
Resistance in rotor 8 ohm +/- 5% 8.5 ohm +/- 5%
Belt pulley tightening torque 75 Nm 75 Nm
Brush length >1 mm >1 mm
Melco 100 A Melco 150 A

Designation L3B 28V 52/100A BLA 28V 86/150A
Output power at 6000 rpm 2800 W 4200 W
Resistance in rotor 9 ohm +/-11 % -
Belt pulley tightening torque 139 Nm +/-6 Nm 150 Nm
Brush length >5 mm -
Engine speed (rpm) Bosch 80 A Bosch 100 A Melco 100 A Melco 150 A
500 35 40 52 85
600 46 60 65 103
800 62 80 80 125
1500 80 100 100 148
Max alternator current at an alternator temperature of 20-25 °C
2011-08-23 ?Scania CV 6 of 6
Engine no.: 6642331
16-10 M1, Starter motor

Location
Removal
Fitting
Location
M1
803c2423
Removal
Note!
On engines with a fuel heater located next
to the starter motor it may be necessary to
first remove the fuel heater. See section
03-05 Fuel filter unit.
1. Cut the power to the vehicle using the battery master switch or by disconnecting the
battery terminals.
2. Remove any noise shields.
3. Detach the positive cable 30 (B+) and the control cable 50.
4. Bend back the cables.
5. Undo the screws holding the starter motor in the flywheel housing.
6. Carefully pull out the starter motor.
Important!
Check whether the starter pinion is

damaged. If the starter pinion is damaged,
the entire starter ring gear must be checked
2011-08-23 ?Scania CV 1 of 3
Engine no.: 6642331
for damage.
Removing pre-relay on starter motor Bosch EVB, GVB and HXF
1. Unscrew the plastic protection.

2. Detach the cables from the starter relay.
3. Detach the pre-relay from the starter motor.
Fitting
Important!
Check whether the starter pinion is

damaged. If the starter pinion is damaged,
the entire starter ring gear must be checked
for damage.
1. Refit the starter motor.

2. Screw the starter motor onto the flywheel housing.
Connections
Connections to the starter motor
50
30
80725a8e
B+ (30) and control cable (50)

Note!
Use an angled connection to the starter
motor B+ (30) on buses and on D16
engines equipped with starter motor Melco
2011-08-23 ?Scania CV 2 of 3
Engine no.: 6642331
105P70.
80725a90
Connection between solenoid and pre-relay on Bosch EVB, GVB and HXF
6
5
4
1
2
3
8005aae6
1. B+ from battery (30)

2. Control cable from EMS (50)
3. Control cable from pre-relay, connection 6
4. B+ supply to pre-relay from connection 1
5. Control cable from connection 2
6. Controlled plus from solenoid, connection 3
2011-08-23 ?Scania CV 3 of 3
Engine no.: 6642331
16-75 EMS, Engine Management System S8

Overview - 9 and 13 litre engines with XPI
Sheet 1: Applies to 9 and 13 litre engines with XPI
Sheet 2: Applies to 13 litre engines with XPI
Sheet 4: Applies to 9 and 13 litre engines with XPI and twin alternators
Overview
9 and 13 litre engines with XPI

Sheet 1: Applies to 9 and 13 litre engines with XPI
2011-08-23 ?Scania CV 1 of 8
Engine no.: 6642331
8066d7dd
2011-08-23 ?Scania CV 2 of 8
Engine no.: 6642331
8076d66c
2011-08-23 ?Scania CV 3 of 8
Engine no.: 6642331
2011-08-23 ?Scania CV 4 of 8
Engine no.: 6642331
8066d97b
2011-08-23 ?Scania CV 5 of 8
Engine no.: 6642331
8066d97c
2011-08-23 ?Scania CV 6 of 8
Engine no.: 6642331
Sheet 4: Applies to 9 and 13 litre engines with XPI and twin alternators
2011-08-23 ?Scania CV 7 of 8
Engine no.: 6642331
8069ecb3
2011-08-23 ?Scania CV 8 of 8
03:14-01
Issue 3 en-GB
XPI fuel system
Troubleshooting
1 2 3 4 5
6
7
8
12
11
13
10
S7
151 459
9
©
Scania CV AB 2011, Sweden
Contents
Contents
XPI fuel system Troubleshooting........................................................ 3
M - Metal shavings in the engine ............................. 4
O - Oil pump............................................................. 5
S - Troubleshooting tree, Start-up check.................. 6
L - Troubleshooting tree, Low pressure check......... 8
L - Descriptions, Low pressure check .................... 11
H - Troubleshooting tree, High pressure check...... 13
H - Descriptions, High pressure check ................... 17
2 ©
Scania CV AB 2011, Sweden 03:14-01
Troubleshooting
XPI fuel system
Troubleshooting
A number of troubleshooting trees with their
associated descriptions are provided below.
IMPORTANT! Always wash the engine before

starting work on the fuel system.
Read the troubleshooting diagrams from left to

right as illustrated.
03:14-01 ©
Scania CV AB 2011, Sweden 3
4
M - Metal shavings in the engine
Can occur if the fuel system high pressure pump is defective and there are metal shavings in the oil sump and on the magnetic plug.
M - Check of metal shavings in the engine

D - Continue to O - Oil pump
M - Troubleshooting tree
B - Yes, there are metal shavings

A - Are there metal shavings on the magnetic plug and
in the oil sump?
C - No, there are no metal shavings
©
E - Continue to S - Start-up check

03:14-01
O - Oil pump
O - Oil pump check
03:14-01
E - Have the engine overhauled at an
authorised workshop.
Troubleshooting is complete.
Yes
D- Remove the rocker covers and
the rocker arm housing. Is there any
evidence of metal shavings at the
rocker arm housing?
Yes No
B - Remove the oil filter housing F - Troubleshooting is complete.
©
assembly. Remove the oil filter. Is there
any evidence of metal shavings in the oil
filter?
Yes No
A - Is the suction strainer G - Fit a new oil filter, clean the centrifugal oil
intact? cleaner and top up with oil. Troubleshooting is
complete.

No
C - Check the oil pump. Clean
if necessary. Continue
troubleshooting from B.
O - Troubleshooting tree
5
6
S - Start-up check
S - Start-up check
Carry out troubleshooting
as described in SDP3.
There are fault codes
S - Troubleshooting tree
S-a Check for any fault codes using Warm up the vehicle. Start again from S-a.
SDP3.
There are no fault codes Yes
Can the vehicle be started? Rectify the fault. Start
©
again from S-a.
No There is no fuel or the fuel contains
precipitated paraffin wax or
microorganisms.
Check that there is some fuel in the
tank and that it does not contain
precipitated paraffin wax. Check

whether there are any
microorganisms?
There is fuel or the fuel is OK
Continue from
troubleshooting tree S-b.
03:14-01
S - Start-up check
Repair the leak. Start again from
S-a.
03:14-01
Yes, there are leaks
S-b Pump with the hand pump until resistance builds
up. Check for external fuel leaks at the feed pump, filter
housing and fuel pipes.
No, there are no leaks or it is not
possible to build up pressure with the
hand pump
Check the low pressure section.
Continue from troubleshooting tree
L-a.
©
S - Troubleshooting tree
7
8
L - Low pressure check

S-a.
Air-free fuel comes out
L - Troubleshooting tree
Renew the fuel filter and bleed the

fuel system, see description L2.
During one check no fuel comes out No fuel comes out
Check the suction strainer
©
in the tank.
L-a Check the feed pump; see Continue from
description L1. troubleshooting tree S-a.
...of one pump
During both or one of the checks Continue from
fuel comes out troubleshooting tree L-b.
...of both the pumps

Continue from
troubleshooting tree L-c.
03:14-01
Renew the hand pump. Continue
from L-a.
03:14-01
...of the feed pump
Renew the feed pump.
L-b Fuel only comes out of one The pump drive is working
pump... correctly
Check the feed pump drive, continue
from description L4.
...of the hand pump No fuel comes out The pump drive is
defective
Check the feed pump, continue from Rectify in accordance with
©
description L3. description L5, then
continue to S-a.
A little fuel comes out
Renew the feed pump and
bleed the fuel system, then
continue to S-a.

9
10

H-a.
The pressure is normal
The pressure is high or normal

The pressure is too high
L-c Fuel comes out of both the Renew filter and feed pump,
pumps. Measure the supply pressure continue to description L-c.
in accordance with description L6.
©
The pressure is too low The pressure is correct
Renew filter. Bleed the fuel system Continue to
and start again from L-c. troubleshooting tree S-a.
The pressure is still too low
Renew the feed pump and

bleed the fuel system, then
continue to
troubleshooting tree S-a.
03:14-01
L - Descriptions
L - Descriptions, Low pressure L3 - Checking the feed pump

check 1 Detach the outlet fuel pipe from the feed
pump. Place a container under the free end of
the pipe.
L1 - Low pressure check
1 Open the test connection on the high 2 Turn the engine over using the starter motor
pressure pump. for about 20 seconds.
2 Pump using the hand pump. Check that The feed pump provides about 1.2 l/min.
fuel comes out of the test connection. The correct quantity for 20 seconds is
0.3-0.4 litres.
3 Turn the engine over using the starter
motor. Check that fuel comes out of the
test connection. L4 - Checking the feed pump drive
4 Close the test connection. 1 Remove the feed pump from the high
pressure pump bracket.
L2 - Checking the suction filter 2 Turn the feed pump by hand. Listen and
touch.
Note: When renewing the suction filter, check 3 Check that the drive pins in the high pressure
the following with the suction filter removed. pump are not damaged.
4 Turn the engine over using the starter motor.
1 Pump with the hand pump and check that Check that the feed pump drive in the high
fuel free from air flows out of the hole on pressure pump rotates.
the inside of the filter housing.
2 If no fuel comes out, check the suction
strainer and all joints on the suction pipe
up to the fuel tank armature. Renew the
seals and check-tighten the connections.
3 If fuel comes out, fit a new filter and bleed
the fuel system.
03:14-01 ©
L - Descriptions
L5 - Checking the high pressure pump

drive
1 Remove the high pressure pump.
motor. Check that the high pressure pump
drive rotates in the timing gear.
3 Renew the pump drive gear if it does not
rotate or is damaged. Check for resulting
damage to the high pressure pump gear.
Damaged gears should be renewed.
4 If the pump drive gear in the timing gear
rotates and is not damaged, check that the
high pressure pump gear is properly seated
on the shaft. If the gear is loose, the shaft
may be damaged. Do not tighten the gear.
Renew the high pressure pump instead. If
the gear is jammed, the high pressure pump
is defective. If this is the case, renew the
high pressure pump.
L6 - Checking the supply pressure at the

test connection on the high pressure
pump
1 Connect pressure gauge 99 362 to the test
connection on the high pressure pump and
open the test connection.
motor. Read the pressure after
approximately 20 seconds. The pressure
should be more than 3 bar.
3 If the engine starts. Increase the engine
speed to 1,500 rpm. Read the pressure. The
pressure should be between 9 and 14 bar.
4 Close the test connection and remove the
pressure gauge.
12 ©
H - High pressure check
03:14-01
Renew cylinder head on high pressure pump, see
description H9. Continue from S-a.
The pressure is normal
H-a The engine starts. Carry out Repair the leak, continue Renew the valve. Continue
description H1, Checking for from S-a. from S-a.
internal leaks. If the engine does not
start, continue from H-d.
External leaks The safety valve is
defective.
The pressure is falling Carry out a check on the safety
©
valve, see description H3.
No external leaks The pressure is The safety valve is not
normal faulty.
Carry out a check on the Renew cylinder head on
return fuel pressure, in high pressure pump, see
accordance with description H9. Continue
description H2. from troubleshooting tree

S-a.
High or fluctuating return
fuel pressure
Continue from
troubleshooting tree H-b.
H - Troubleshooting tree
13
14
Renew the safety valve, continue from S-a.
Check failed
Carry out a check on the safety valve, in accordance
with description H3.
Fluctuating pressure Check passed

H-b High or fluctuating return fuel Continue from High pressure below.
pressure.
©
High pressure Cylinder identified; see
troubleshooting tree H-c.
Check the injectors using SDP3; see Fault verified; Renew
description H4. injector and continue from
S-a.
Carry out "Checking for internal
leaks "; see description H6.
Cylinder not identified The injector cannot be verified.

Detach and visually inspect all high
pressure connections and torque
tighten them. Continue from S-a.
03:14-01
Renew the identified injector,
continue from S-a.
03:14-01
Fault verified
Carry out "Checking for internal
leaks "; see description H6.
The fault cannot be The injector cannot be identified
verified. Detach and visually inspect all high pressure
connections and torque tighten them. Continue
from S-a.
Verify with plug, in accordance with
description H5.
©
Cylinder identified Fault verified
H-c Check the injectors using SDP3. Renew injector and continue from S-a.

15
16
Continue from S-a.
The engine starts
Renew the fuel inlet metering valve.
The safety valve is working The engine will not start
Carry out check H8. Renew the cylinder head on the high
pressure pump. Start again from S-a.
Normal or low return fuel pressure The safety valve is not
working
©
H-d The engine will not start. Carry Renew the safety valve, continue
out check H7. from S-a.
Return fuel pressure too high

Continue from Cylinder not
identified in H-b.

03:14-01
H - Descriptions
H - Descriptions, High pressure

check
H1 - Checking for internal leaks

1 Start the engine.
2 Start the test "Checking for internal leaks "
in SDP3.
3 Switch off the engine. Read the pressure
remaining in the accumulator using SDP3.
There should be some pressure remaining.
There are internal leaks if the pressure
approaches 0 bar within 1 min.
H2 - Checking the return fuel pressure

connection on the return fuel manifold and
2 Start the engine. Read the pressure with the
engine idling. The value should be below
0.8 bar. If the pressure exceeds 0.8 bar the
overflow valve on the return fuel manifold
should be cleaned and visually inspected.
Start again from step 1.
Note: When the overflow valve is removed air

will be introduced, opposite the flow direction.
It will take some time for the system to bleed
itself. During this time the measurement is not
reliable. Leave the engine idling for a while
before repeating the test. If the pressure still
exceeds 0.8 bar, there is internal leakage in an
injector.
3 Switch off the engine, remove the pressure

gauge and close the test connection.
03:14-01 ©
H - Descriptions
H3 - Checking the safety valve for leaks
! WARNING!
The accumulator may be under high

pressure. Reduce the pressure using
SDP3 before starting work.
Wear protective goggles.
There is a risk of burn injuries when the
safety valve is open.
1 Remove the return pipe 2 from the safety

valve 1 to the return fuel manifold 5.
2 Plug the connection in the return fuel
manifold with cap nut 812 890 or 814 555
and sealing plug 813 878.
3 Refit the return pipe at a slight angle to the
engine. Connect a transparent hose 4 to a If the check failed:
union 3 - 366 082 on the pipe. Pull the hose
down into a can or similar. Check that the following starting conditions
have been met and try again.
4 Start the engine.
• The engine must be running.
5 Start "Checking the safety valve for leaks"
in SDP3. Follow the instructions in the • Parking brake activated.
check.
• Gearbox in neutral.
6 Refit the engine pipes. Torque tighten.
• Clutch pedal released.
18 ©
H - Descriptions
H4 - Checking injectors using SDP3 H6 - Checking for internal leaks

1 Check cylinder balancing at idling speed
using SDP3. Note if any cylinder deviates.
2 Perform a cylinder output test using SDP3. ! WARNING!
Note which cylinder deviates from the Wear protective goggles. There is a risk
others by having a higher output. of fuel splashing from the high
3 By comparing the two results with each pressure connections when
other, a cylinder with deviations in both pressurised.
tests can be identified. Continue The accumulator may be under high
troubleshooting on the injector for that pressure. Reduce the pressure using
cylinder. SDP3 before starting work.
H5 - Verification of a faulty injector

A tool must be made to determine whether the
1 Remove the high pressure pipe to the fuel system is leaking. A pressure regulator, a
injector which has been identified in H4. shut-off valve, two hose couplings, hose
clamps, hose and Tema quick release coupling
2 Plug the outlet of the identified injector at 1100N for connection to the test connection are
the outlet port on the fuel accumulator needed. Assemble the parts as illustrated on the
using tool 99 019. If the outlet port of next page. It is vital that all couplings and
cylinder 1 has to be plugged, see the connections are tight.
instructions in TI 03-08 01 28.
1 Detach and remove all high pressure pipes
3 Start the engine and run it at idling speed between the accumulator and the high
for at least 15 seconds. pressure connections.
4 Switch off the engine. Read the pressure 2 Connect the tool to the test connection on
remaining in the accumulator using SDP3. the return fuel manifold and open the test
If the pressure is more than 0 bar after 1 connection.
minute, the faulty injector has been found
and must be renewed. If the faulty injector
cannot be verified, continue IMPORTANT! Open the fuel filler cap so that
troubleshooting in accordance with H6. the pressure does not deform the tank.
03:14-01 ©
H - Descriptions
3 Pressurise the return fuel manifold. Slowly IMPORTANT! After renewing an injector
increase the pressure. Listen for a bubbling with internal leakage, the engine oil must be
noise in the tank. The bubbling noise changed and the oil filter renewed. If there is
indicates at what pressure the overflow internal leakage, soot quickly builds up in the
valve opens. The pressure should be higher engine oil.
than 0.5 bar. Then pressurise the manifold
to max. 3 bar.
4 Listen for return leakage in the injectors by
blocking one high pressure connection at a
time and quickly removing the obstacle. If
there is internal leakage in the injector, a
hissing sound will be heard.
5 Renew the injector or injectors with
internal leakage as described above.
6 When renewing an injector, the tuning
code of the new injector must be
programmed to the correct cylinder using
SDP3 and basic setting of injector
adaptation must be performed.
A B
153 069
Tools for test pressurising the fuel system

A - Shut-off valve
B - Pressure regulator
C - Hose for connection to the fuel system
20 ©
H - Descriptions
H7 - Checking the return fuel

pressure
connection on the return fuel manifold and
motor. Read the pressure after
approximately 20 seconds. The value
should be below 0.8 bar.
3 If there is no detectable value after
20 seconds, let the starter motor cool and
repeat step 2.
Note: If there is air in the filter housing,

pressure cannot build up. Vent the filter
housing and try again.
4 Remove the pressure gauge and close the

test connection.
03:14-01 ©
H - Descriptions
H8 - Checking the safety valve
! WARNING!
The accumulator may be under high

pressure. Reduce the pressure using
SDP3 before starting work.
Wear protective goggles.
1 Remove the return pipe 2 from the safety

valve 1 to the return fuel manifold 5.
2 Plug the connection in the return fuel
manifold with cap nut 812 890 or 814 555
and sealing plug 813 878.
3 Refit the return pipe at a slight angle to the
engine. Connect a transparent hose 4 to a
union 3 - 366 082 on the pipe. Pull the hose
down into a can or similar.
motor. If fuel leaks out of the safety valve,
it is faulty and must be replaced.
5 Refit the engine pipes. Torque tighten.
22 ©
H - Descriptions
H9 - Renewing the cylinder head

on the high pressure pump
! WARNING! IMPORTANT! The fuel system is very

sensitive to dirt. It is therefore very important
The fuel system has a very high fuel that everything is as clean as possible when
pressure of up to 3,000 bar. The fuel work is carried out on the fuel system.
system must be depressurised before
any work is started. Use SDP3 to
minimise the high pressure in the fuel Do not use compressed air to blow components
system. in the fuel system clean.
A jet of fuel at high pressure can cut When cleaning, cloths or paper which shed
through the skin. fibres must not be used. Use lint-free cloths.
The system should always be treated Clean tools before use.

as pressurised, even when the engine
Do not use worn chrome-plated tools as flakes
is switched off. of chrome may come off.
Plug or tape connections on components which
are removed.
IMPORTANT! A high pressure pipe that has

been detached or removed must never be
refitted but must be replaced with a new one.
03:14-01 ©
H - Descriptions
Tightening torques
Cylinder head bolts 68 Nm
High pressure pump, banjo unions 55 Nm
High pressure pipe 38 Nm
Bracket for high pressure pipe 22 Nm
1 Tilt the cab.

2 Remove the mudguard.
3 Clean around the fuel system.
4 Depressurise the fuel system. Use SDP3 to
minimise the pressure. Place a rag over the
high-pressure pipe nut (1). Then undo the
nut carefully.
5 Undo the cable connection.
6 Remove the high-pressure pipe (2) and fit
clean plugs in the fuel connections.
Note: The high pressure pipe must not be

reused.
7 Undo the banjo unions on the high pressure

pump.
8 Remove the fuel return pipe (3) and plug
the fuel manifold. Detach the pipes (4 and
5) from the cylinder head.
9 Undo the cylinder head bolts alternately.
Remove the cylinder head and gasket.
10 Remove the protection plugs on the new
cylinder head. Fit new springs, a new
gasket and new bolts.
24 ©
H - Descriptions
11 Clean the pump surface that faces against

the cylinder head. Check that the guide
pins under the roller tappets are straight
and that the roller tappets are correctly
positioned so that they go down completely
in their seats; see illustration. Screw the
cylinder head bolts in alternately.
Tightening torque 68 Nm.
12 Fit the pipes (3, 4 and 5). Use new washers.

Tightening torque for the banjo unions -
55 Nm.
13 Fit a new high pressure pipe (2).
Tightening torque - 38 Nm.
14 Fit the high pressure pipe brackets.
Tightening torque 22 Nm.
15 Fit the cable connection.
16 Test start and delete the fault codes.
03:14-01 ©
26 ©

Doosan-DL550-Manual de Taller Del Motor Scania DC13

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Engine no.

01-00 Cleaning the engine

Complete - Tightening torques

Cleaning 9, 11, 12 and 13 litre engines

01-00 General engine documents

Engine data on plate, on 9, 13 and 16 litre engines with XPI,

Engine data on plate on 9 and 13 litre engines with XPI

1. Engine type and engine serial number

01-00 Mounting the engine in a universal stand

Complete - Tightening torques

Mounting 9 and 13 litre engines with XPI, PDE or GAS in

587 692 Universal stand

Preparations before commencing work:

1 Remove the engine control unit.

1. Mount the engine in the universal stand.

1. Bolt M10x30 (8 off).

01-00 Removal and installation of motor

Removing 9 and 13 litre engines

98 094 Lifting chain

587 308 Lever block

99 637 Lifting eye

1. Drain the oil and coolant.

6. Fasten the lever block 587 308 to the front

manage a maximum inclination angle of

Fitting 9 and 13 litre engines

The lifting eyes 99 637 are designed to

30° when lifting an engine.

01-00 Tightening torques

Specification - Normal tightening torque

z A tolerance of ±15 % applies to all values unless otherwise specified.

Metric thread, course pitch

Thread Strength class 8.8/8

Flange screws with hexagonal head and hexagonal flange nuts

Thread Strength class 8.8/8

Thread Class 8 Class 10

Thread forming six-point socket screws ST thread

Thread Tightening torque [Nm]

Stud tap end in threaded hole, strength class 8.8/8

Metric thread, course pitch

Union nuts for ferrule

Thread Tightening torque [+/-15% Nm]

Nuts for lead-in union

Thread Tightening torque [+/-15% Nm]

Unions with tapered thread for port connection

Thread Tightening torque [+/-15% Tightening torque [Nm]

Thread Tightening torque [+/-15% Nm]

Plugs with tapered thread

Thread Tightening torque [+/-15% Nm]

Insert connections for port connection

Thread Tightening torque [+/-15% Nm]

Insert connections for union connection

Thread For pipe diameter Tightening torque [+/-15% Nm]

Specification - Special tightening torque

Thread Strength class

Thread Strength class

M24x1.5 830 1040

Flange screws with hexagonal head and hexagonal flange nuts

Thread Strength class

Tightening torque for 9 and 13 litre engines with XPI, PDE

Tightening torques for threaded joints in

Band clamps, first tighten the lower screws 35 Nm

Electrical connection screw 2 Nm

Venturi, industrial and marine engines 18 Nm