Scania DC11 Work Description Download

Page: 1 / 143

1 585 592

01:03-02

Issue 9

en-GB

11 and 12 litre engines

106 351

Summary of Contents for DC11

Page 1: ...Scania CV AB 2011 Sweden 1 585 592 01 03 02 Issue 9 en GB 11 and 12 litre engines Work description 106 351 www motodiesel ir M A S H I N E S O F T C O M 0 9 1 2 0 1 4 6 2 5 9...

Page 2: ...54 Removing the cylinder liners 55 Fitting the cylinder liners 56 Measuring and machining the cylinder liner height 57 Renewing the rear crankshaft seal 63 Renewing camshaft bearings 65 Flywheel housi...

Page 3: ...e camshaft 114 Removing the camshaft gear 115 Fitting the camshaft gear 116 Removing the crankshaft gear 117 Fitting the crankshaft gear 118 Removing the camshaft 119 Fitting the camshaft 120 Checking...

Page 4: ...1 DC12 Cylinder diameter 127 0 mm 127 0 mm Piston stroke 140 0 mm 154 0 mm Cubic capacity 10 64 dm3 11 7 dm3 No of main bearings 7 7 Firing sequence 1 5 3 6 2 4 1 5 3 6 2 4 3B A Typ Type DSC 12 01 Var...

Page 5: ...viewed from the rear Anticlockwise Anticlockwise Engine speed low idling 500 rpm 500 rpm Engine speed high idling 2 400 rpm 2 400 rpm Oil capacity 28 35 litres 28 35 litres Oil grade refer to booklet...

Page 6: ...4 Remove Connectors 13 C2 and 14 C188 Connector 14 C188 is only fitted on vehicles without a coordinator 5 Disconnect The positive and negative cables 6 Remove The clamps to release electrical cables...

Page 7: ...01 03 02 Scania CV AB 2011 Sweden 7 120232 4 5 3 6 Engine assembly 120231 8 8 2 www motodiesel ir M A S H I N E S O F T C O M 0 9 1 2 0 1 4 6 2 5 9...

Page 8: ...ed from the induction pipe 11 Cover the air filter 12 Detach The radiator water hoses The number of hoses varies depending on the design Only one hose is illustrated 13 Detach The flexible hose for th...

Page 9: ...01 03 02 Scania CV AB 2011 Sweden 9 120234 12 9 13 10 16 15 11 14 Engine assembly www motodiesel ir M A S H I N E S O F T C O M 0 9 1 2 0 1 4 6 2 5 9...

Page 10: ...e Only on vehicles equipped with a water heater 21 Detach The ground connection 22 Detach The fuel pipes 23 Detach The oil filler hose 24 Detach The oil dipstick 25 Detach The starter motor ground con...

Page 11: ...01 03 02 Scania CV AB 2011 Sweden 11 120235 17 18 21 22 25 18 19 23 24 26 27 28 Engine assembly www motodiesel ir M A S H I N E S O F T C O M 0 9 1 2 0 1 4 6 2 5 9...

Page 12: ...used when lifting the engine On vehicles built from May 2000 onwards the rear lifting eyes have been removed They may be ordered as a spare part part number 1 360 442 30 Fasten lifting chain 98 094 to...

Page 13: ...um inclination angle of 30 when lifting an engine with the gearbox removed For engines without the gearbox removed the maximum angle is 20 Engine assembly 32 Remove the bolts in the engine brackets an...

Page 14: ...bolts 130 Nm 90 3 Fit the gearbox Refer to Group 5 Comments 4 Fit The hydraulic pump Fit a new gasket 5 Fit The positive starter motor cable 6 Fit The pressure regulator pipe At the compressor 7 Fit...

Page 15: ...01 03 02 Scania CV AB 2011 Sweden 15 120545 15 14 11 10 7 12 13 9 8 6 5 4 Engine assembly www motodiesel ir M A S H I N E S O F T C O M 0 9 1 2 0 1 4 6 2 5 9...

Page 16: ...The flexible hose for the charge air cooler Tightening torque 8 Nm 20 Fit The turbocharger induction pipe Tightening torque 10 Nm must be applied at max 100 rpm 21 Fit The compressor air pipe and the...

Page 17: ...01 03 02 Scania CV AB 2011 Sweden 17 120544 18 23 19 20 16 17 22 Engine assembly www motodiesel ir M A S H I N E S O F T C O M 0 9 1 2 0 1 4 6 2 5 9...

Page 18: ...cables 27 Fit Connectors 13 C2 and 14 C188 Connector 14 C188 is only fitted on vehicles without a coordinator 28 Fit All cables with clamps 29 Fit The plastic cover over the central electric unit 30...

Page 19: ...01 03 02 Scania CV AB 2011 Sweden 19 120542 30 24 24 120543 27 26 29 28 Engine assembly www motodiesel ir M A S H I N E S O F T C O M 0 9 1 2 0 1 4 6 2 5 9...

Page 20: ...ngines with PDE unit injectors Remove Pos Fuel filter A Control unit B Compressor C Starter motor D Required brackets Engines with HPI unit injectors Securely bolt the engine to the engine stand as il...

Page 21: ...1 Bolt M10x30 8 off Tightening torque 47 Nm 2 Nut M16 4 off Tightening torque 180 Nm 3 Bolt M16x50 4 off D C 99 331 3 2 1 A B C D E F A D A B G 119 929 Engine assembly www motodiesel ir M A S H I N E...

Page 22: ...ression pressure is used as a step in troubleshooting If an engine is running unevenly this measurement may indicate whether one or more cylinders is worn or damaged There may be damage to the cylinde...

Page 23: ...he battery is fully charged when carrying out the compression test Otherwise the compression pressure obtained will be insufficient 1 Shut off the fuel supply by removing fuse No 20 for fuel shut off...

Page 24: ...ccording to steps 7 9 10 Compare the readings between the cylinders If one or more cylinders has a lower compression pressure than the others the component parts such as valves cylinder liners and pis...

Page 25: ...valve 13 Valve spring outer 14 Valve spring inner 15 Valve spring collar 16 Split collet 17 Valve bridge 18 Bolt 19 Bearing bracket 20 Shaft 21 Rivet plug 22 Tight fit screw 23 Rocker arm 24 Rocker a...

Page 26: ...l return pipe 3 Remove the cooling system bleed pipe 4 Remove the heat shields on the exhaust manifold and remove the exhaust manifold Number Denomination Illustration Tool board 99 074 Impact setting...

Page 27: ...shaft rocker arms bearing brackets and pushrods 7 Remove the lower part of the rocker cover 01_1344 8 Undo the injector nut using socket 99 308 01 1345 99 308 9 Pull out the injectors with tools 99 0...

Page 28: ...may run down into the cylinders which will result in a great risk of liquid slugging If fuel runs into the combustion chamber it must be removed immediately using a pump 2 Clean the rocker cover and t...

Page 29: ...ushrod for the unit injector is secured with a retaining ring Jiggle and pull carefully on the pushrod to loosen it 8 Remove the valve bridges 9 Remove the lower rocker cover 120514 9 6 8 7 10 Remove...

Page 30: ...he rocker cover and the area around it 2 Remove the top part of the rocker cover 3 Relieve the pressure on the valves by undoing the bolts on the rocker arm shaft alternately 120515 3 4 Remove the roc...

Page 31: ...the unit injector according to the section Removing the unit injector in booklet 03 04 04 10 Detach the intake manifold fuel manifold cooling system bleed pipe and the exhaust manifold 11 Remove the...

Page 32: ...Bolt for lower rocker cover 26 Nm Bolt for shaft with rocker arms 105 Nm Bolt for support bracket 40 Nm 60 Tightening torques applies to engines with injection pump Nut for injector 70 Nm Bolt for upp...

Page 33: ...marks it must be replaced with a new one 4 Lubricate the threads and underneath the heads of the cylinder head bolts Tighten them in the following four stages in the order given in the figure 1 Torque...

Page 34: ...ectors that have been removed 4 Tighten the injector to 70 Nm Use socket 99 308 100036 01_1351 70 Nm 99 308 5 Fit the upper part of the rocker cover and tighten the bolts to 26 Nm 6 Fit the exhaust ma...

Page 35: ...section Fitting the unit injector steps 6 14 in booklet 03 04 01 4 3 2 309 329 Engines with HPI unit injectors 1 Fit the pushrods 2 Fit the bearing bracket and tighten the bolts to 40 Nm 60 3 Fit the...

Page 36: ...following valves Number Denomination Illustration Tool board 99 309 Flywheel rotation tool from below D5 99 109 Flywheel rotation tool from above cyl 1 Intake and exhaust cyl 2 Intake cyl 3 Exhaust cy...

Page 37: ...ernal ring gear and rotate the flywheel using a ratchet handle and a 14 mm socket Read the marking on the flywheel in the upper window in the flywheel housing Mark on flywheel reading taken through lo...

Page 38: ...on Illustration Tool board 99 322 Drift D5 100333 99 322 01_1347 99 322 Fitting valves Special tools 1 Lubricate all parts well with engine oil before assembly 2 Insert the valve into the guide 3 Fit...

Page 39: ...inimum dimension A for ground valve 2 6 mm Exhaust valve Head angle 44 5 Minimum dimension A for ground valve 1 8 mm Minimum dimension A for ground valve Check dimension A on all valves Grind the valv...

Page 40: ...the valve stem seal with a pair of pliers Number Denomination Illustration Tool board 99 323 Drift D5 100334 99 323 01_1348 3 Fit the valve 4 Tap in a new valve stem seal carefully using tool 99 323 a...

Page 41: ...ller 587 270 Note Insert for example an aluminium sheet between the cylinder head and counterhold to protect against damage Number Denomination Illustration Tool board 99 384 Drift D1 A3 99 385 Shank...

Page 42: ...ft 99 384 and shank 99 385 Cool the drift and valve seat to about 80 C with dry ice or liquid air Pressing must be carried out rapidly WARNING Be careful when handling the cold parts and refrigerants...

Page 43: ...not be below 124 4 mm Intake valve seat Seat angle 20 0 20 5 Width of contact surface A 1 9 2 6 mm Valve seat insert outer diameter 46 054 46 065 mm Valve seat insert position diameter 46 000 46 016 m...

Page 44: ...r 44 000 44 016 mm Valve seat insert position depth 11 25 11 35 mm Distance B between the cylinder head face and the valve disc 0 66 1 8 mm Oversize valve seat insert External diameter 44 281 44 292 m...

Page 45: ...erts 1 Make sure the contact surface and magnetic stand are level and clean Clean the valve bushes 2 Select the largest spindle that moves easily in the valve guide Insert the guide spindle and turn t...

Page 46: ...ve seat insert machining measurement 7 Turn off the magnet position 2 Insert the guide spindle into the valve bush Adjust the pivot plate so that the distance between the cutter and the valve seat is...

Page 47: ...hile machining 11 When the surface of the valve seat has been machined reduce the cutting pressure by turning 2 3 revolutions without any feed Continue turning while backing off the feed screw The val...

Page 48: ...n Illustration Tool board 99 382 Drift D1 C6 99 383 Drift D1 B1 99 382 110 864 99 383 110 865 2 Press in the new valve guides using drift 99 382 Press the guide down as far as the drift allows i e unt...

Page 49: ...d with valves removed to demonstrate clearly the work described IMPORTANT Mark the position of the groove on the cylinder head sleeve according to the illustration The new sleeve must be in the same p...

Page 50: ...k the contact surfaces of the sleeve and cylinder head Smooth off any burrs and irregularities that could score the sleeve 4 Degrease the new injector sleeve and apply a thin film of sealant 561 200 o...

Page 51: ...ide D2 B1 99 395 Drift D2 A1 99 397 Extension piece with threaded shank D2 C5 C6 588 221 Pilot tap Number Denomination Illustration Tool board 99 396 Guide pilot tap M30x1 5 D2 B1 99 381 Drift D2 A1 9...

Page 52: ...nder head with valves removed to demonstrate clearly the work described 1 Thread the lower part of the sleeve using the pilot tap and guide Unit injector PDE Guide 99 394 Pilot tap 588 221 Extension p...

Page 53: ...nder head Smooth off any burrs and irregularities that could score the sleeve 4 Degrease the new injector sleeve and apply a thin film of sealant 561 200 on the sleeve and cylinder head contact surfac...

Page 54: ...chining out of round main bearing seats is something we do not recommend Tightening torques 1 Measure the diameter at four different positions as illustrated The diameter must be measured with the mai...

Page 55: ...n the surface indicated in the illustration Other surfaces are for sealing If you use a marker you can mark anywhere Number Denomination Illustration Tool board 99 066 Cylinder liner puller D2 100214...

Page 56: ...sport or careless handling Tap the liner carefully with a metal object It should give a clear metallic ring if it is intact If it is cracked it will sound cracked 4 Lubricate the sealing ring to be lo...

Page 57: ...0 20 0 30 mm Maximum permitted height difference on one and the same liner between measurements made at two diametrically opposite points 0 02 mm Special tools Number Denomination Illustration Tool b...

Page 58: ...the liner A Slide the tip of the dial gauge over to the cylinder block B and measure the height of the liner A B as illustrated Measure each liner at two diametrically opposite points A Measured surf...

Page 59: ...him is correct IMPORTANT If a shim is used to adjust the liner height the cylinder liner seat must always be machined Tolerances for liner height Lowest permissible cylinder liner height before machin...

Page 60: ...lane of the cylinder block Note It is important for the surface to be cleaned thoroughly otherwise the cylinder liner seat may be cut to the wrong depth or may be slanted 2 Fit extension 588 672 on th...

Page 61: ...does not touch the edge of the liner seat when the cutter is fitted in the setting ring Otherwise the vertical feed screw must be wound up until the cutter is released from the liner seat 6 Lift the r...

Page 62: ...s may be required until the required position is reached 10 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 horizonta...

Page 63: ...s 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 Number Denomin...

Page 64: ...h 175 mm crankshaft seal Fit a new crankshaft seal using tool 99 410 Place the crankshaft seal on the tool and fasten the tool with the bolts When working with 185 mm crankshaft seal Fit a new cranksh...

Page 65: ...e bearing seat surfaces around the old bearings to avoid damaging the contact surfaces when fitting the new bearings 3 Wipe the bearing seat surfaces clean around the old bearings Number Denomination...

Page 66: ...the space between the bearing seats for the camshaft 109 690 Tool 99 373 1 Threaded stem with eight flange nuts 2 Press drift 3 Flange 5 Place the flange nuts on the threaded stem included in tool 99...

Page 67: ...rotrudes from the front of the engine 7 Screw the flange part of tool 99 373 securely onto hydraulic cylinder 99 003 with two M6x12 bolts Press together cylinder 99 003 if not already in neutral posit...

Page 68: ...red on the bearing oil hole The bearing is correctly located on the drift when the ball and a marking hole are centred on the bearing oil hole 109 689 12 Clean around the bearing contact surface Note...

Page 69: ...f the cylinder block Table for correctly located camshaft bearings 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 Check measur...

Page 70: ...ntral to the cylinder block oil ways 18 Repeat the procedure for the remaining bearings Pressing out pressing in bearing number 2 Check measurement of bearing number 2 19 Clean the sealing surface tak...

Page 71: ...rew 6 Flange screw 7 Flange screw 8 Cover 9 Gasket 10 Flange screw 11 Cover 12 Lifting eye 13 Stud 14 Stud 15 Spacer 16 Lock nut 17 Rotational speed sensor 18 Flange screw 19 Clamp 20 Clamp 21 Bolt 22...

Page 72: ...housing 100025 Fitting the flywheel housing Specifications Tools Tightening torques Bolts for flywheel housing M10 50 Nm M12 90 Nm Sealant Sealant for flywheel housing 816 064 Number Denomination Illu...

Page 73: ...bolt holes marked with arrows From engine serial number 5 747 863 onwards bolt A has been added and bolt B has been moved IMPORTANT Ensure that you apply sealant inside the bolt holes but without allo...

Page 74: ...ert lje 6 123 709 Scania Latin America 3 138 538 M10 x 30 M10 x 60 M10 x 30 M10 x 30 100 053 Flywheel housing and timing gear plate from engine serial number Scania S dert lje 6 123 710 Scania Latin A...

Page 75: ...gines with injection pump later version M10 x 60 M10 x 80 M10 x 30 120 596 M10 x 60 Engines with unit injectors M10 x 60 M10 x 80 M10 x 45 M10 x 30 120 595 Engines with injection pump earlier version...

Page 76: ...e the fan and belt 2 Remove the oil sump 3 Undo the screw for the pulley 4 Remove the fan bearing housing with the pulley Fitting the fan coupling Tightening torques 1 Fit the fan bearing housing onto...

Page 77: ...umber Denomination Illustration Tool board 87 752 Drift 98 334 Counterholding tube 98 433 Drift 98 622 Press drift D1 98 647 Support drift G2 Number Denomination Illustration Tool board 587 318 Puller...

Page 78: ...housing using drift 98 622 01_1374 98 622 4 Extract the bearing inner race from the spindle using pullers 587 318 and 587 319 and drift 98 647 01_1375 587 319 98 647 587 318 5 Place the extracted bear...

Page 79: ...ling housing using drift 98 433 and counterholding tube 98 334 01_1380 98 433 98 334 2 Fit the retaining ring 01_1381 3 Press the spindle into the housing 4 Push the pulley onto the fan coupling spind...

Page 80: ...nkshaft seal 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 108 968 24 1 Nut 2 Fan 3 Stud 4 Flange screw 5 Pulley 6 Shaft seal 7 Flange screw 8 Housing 9 Pin 10 Gasket 11 Cover plate 12 R...

Page 81: ...shaft seal seals against the pulley Handle the pulley with care Bolts for crankcase ventilation pipe against rocker cover 12 Nm Bolts for torsion damper 80 Nm 45 Number Denomination Illustration Tool...

Page 82: ...ew seal in tool 99 374 and press it into place by tightening the bolts alternately The seal is correctly fitted when the tool reaches the bottom The seal is correctly fitted when the tool reaches the...

Page 83: ...he oil Oil will then accompany the air into the charge air system Causes of an increase in blow by are leaking piston rings valve guides turbocharger or compressor Gas leakage from the charge air syst...

Page 84: ...ap is not properly secured The rubber plug on the oil dipstick handle is not located correctly Seal the oil dipstick connection as follows 1 Pull the rubber seal at the point shown by the arrow toward...

Page 85: ...ilation cover 01 1378 4 Remove the diaphragm and spring The spring has been removed from January 1999 onwards On vehicles fitted with the spring the spring does not need to be refitted 5 Fit the new d...

Page 86: ...r for aluminium piston 5 O ring 6 Compression ring 7 Compression ring 8 Oil scraper ring 9 Circlip 10 Steel piston 11 Aluminium piston 12 Gudgeon pin 13 Circlip 14 Bearing bush 15 Connecting rod 16 Cr...

Page 87: ...in engine breakdown Damaged nozzles must not be re aligned renew them instead 4 Remove the connecting rod cap and connecting rod bearing shells Protect the oilway in the crankshaft e g by winding tape...

Page 88: ...ut of place 3 Position plate 99 168 on the piston crown 4 Press a piston ring into the liner until it is below the scraper ring 5 Fit handle 99 168 on impact setting tool 99 074 If it proves difficult...

Page 89: ...e connecting rod and lubricate the bearing surface 5 For engines with a scraper ring in the lining Fit the assembly tool 99 380 in the lining in place of the scraper ring Bolts for oil sump with unmac...

Page 90: ...mum of 3 times Mark the bolt with a punch mark each time you reuse it see figure If a bolt already has three marks it must be renewed For connecting rod cap with two bolts The bolts must not be reused...

Page 91: ...1st ring upper engines with steel pistons 0 35 0 60 mm 2nd ring 0 55 0 80 mm Maximum clearance in groove 2nd ring 0 25 mm Number of oil scraper rings 1 off Gap 0 40 0 60 mm Maximum clearance in groov...

Page 92: ...he piston rings 587 309 4 It is possible that the graphite coating will disappear after washing graphite coated pistons in a washer This does not matter after they have been in use for a while New pis...

Page 93: ...nd 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...

Page 94: ...the connecting rod cap as marked and tighten the bolts 2 Mount the connecting rod in the tool using the expander and fit the corresponding gudgeon pin in the gudgeon pin bush 3 Then apply the indicat...

Page 95: ...ance 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 Also check whether the connecting rod is bent in an S shape...

Page 96: ...403 115 527 1 2 3 Use tool 99 403 when renewing the bearing bush The tool comprises three parts 1 Pressplate with guide pin 2 Press drift 3 Supports There are different supports depending on the engi...

Page 97: ...ush and press it out 115 528 2 Turn the press drift and mount a new bearing bush onto it Press in the bearing bush 115 529 After pressing in a new bearing bush it must be finish turned This requires s...

Page 98: ...eel housing 2 Remove the flywheel bolts 14 flywheel Also remove the washers Number Denomination Illustration Tool board 87 368 Puller bolts AM1 D3 B1 AD1D3 00 1805 87 368 3 Pull off the flywheel from...

Page 99: ...0 Number Denomination Illustration Tool board 99 324 Guide pins D5 99 321 Tool for locking the flywheel on engines with injection pump D5 99 411 Tool for locking the flywheel on engines with unit inje...

Page 100: ...be fitted 01_1358 99 324 3 Lock the flywheel using tool 99 321 for engines with an injection pump 99 411 for engines with unit injectors Locking the flywheel on engines with unit injectors 99 411 120...

Page 101: ...ock out the support bearing from the flywheel using drift 99 250 3 Fit the inner retaining ring and fit the new support bearing with drift 99 250 4 Fit the outer retaining ring Number Denomination Ill...

Page 102: ...e to the risk of metal shivers 2 Clean the contact surfaces of the flywheel with a wire brush 3 Heat the new external ring gear evenly around its circumference to 100 150 C 4 Place the heated external...

Page 103: ...ng 3 Remove the oil sump oil suction pipe with strainer and the oil pump 4 Remove the pistons and connecting rods according to the section Removing the connecting rod and piston 5 Remove the main bear...

Page 104: ...ce as before removal Note You may only reuse a main bearing bolt or connecting rod bolt 3 times Mark the bolt with a punch mark each time you reuse it 4 Lubricate the bolt thread and the surface of th...

Page 105: ...uld also be checked as it is affected by such factors as wear in the main bearings and connecting rod bearings 120 164 2 When regrinding keep to the specified minimum dimensions Suitable bearings are...

Page 106: ...87 000 mm Undersize 1 diameter 86 728 86 750 mm Undersize 2 diameter 86 478 86 500 mm Undersize 3 diameter 86 228 86 250 mm Undersize 4 diameter 85 978 86 000 mm Fillet radius 4 8 5 2 mm Surface qual...

Page 107: ...01 03 02 Scania CV AB 2011 Sweden 107 Crankshaft www motodiesel ir M A S H I N E S O F T C O M 0 9 1 2 0 1 4 6 2 5 9...

Page 108: ...108 Scania CV AB 2011 Sweden 01 03 02 Timing gear Exploded view A Parts for engines with an injection pump Timing gear www motodiesel ir M A S H I N E S O F T C O M 0 9 1 2 0 1 4 6 2 5 9...

Page 109: ...diate gear 14 Ball bearing 15 Retaining ring 16 Spacing sleeve 17 Bolt 18 Shaft 19 Crankshaft gear 20 Oil pump gear 21 Intermediate gear 22 Retaining ring 23 Shaft 24 Spacing sleeve 25 Roller tappet 2...

Page 110: ...so that cylinder number 1 is close to TDC Use tool 99 309 or 99 109 and a ratchet handle at the flywheel starter gear Number Denomination Illustration Tool board 99 074 Impact setting tool D1 99 309 F...

Page 111: ...ch M10 min 20 15 20 100054 5 The shaft on which the gear is located has a groove Fit puller 587 526 impact setting tool 99 074 and the thread block Pull off the gear and shaft IMPORTANT After removing...

Page 112: ...m 60 100055 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 4 Tighten the bolts on the in...

Page 113: ...earing 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 too...

Page 114: ...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 6 F...

Page 115: ...g according to the section Removing the flywheel housing 4 Remove the intermediate gear IMPORTANT After removing the intermediate gear neither the camshaft nor the crankshaft must be rotated This may...

Page 116: ...e intermediate gear steps 1 2 2 Fit the camshaft gear and tighten the bolts to 63 Nm 3 Fit the flywheel housing according to the section Fitting the flywheel housing 4 Fit the flywheel according to th...

Page 117: ...g according to the section Removing the flywheel housing 4 Remove the intermediate gear IMPORTANT After removing the intermediate gear neither the camshaft nor the crankshaft must be rotated This may...

Page 118: ...intermediate gear refer to Fitting the intermediate gear steps 1 2 3 Fit the flywheel housing according to the section Fitting the flywheel housing 4 Fit the flywheel according to the section Fitting...

Page 119: ...amshaft gear 5 Remove the intermediate gear according to the section Removing the intermediate gear and bolts for the guide flange 6 Remove the timing gear plate 7 Remove the camshaft covers 01_1370 8...

Page 120: ...camshaft gears 63 Nm Bolts for the timing gear plate 63 Nm Camshaft covers 32 Nm Sealant Sealant for flywheel housing 816 064 Axial clearance Permitted axial play 0 05 0 35 mm Number Denomination Illu...

Page 121: ...the camshaft covers Torque tighten the bolts to 32 Nm 4 Fit the guide flange bolts 01_1371 Now check the axial clearance of the camshaft Fit the camshaft gear temporarily Measure the axial clearance o...

Page 122: ...Follow the pattern as illustrated Applying sealant to the cylinder block 111 347 IMPORTANT Ensure that you apply sealant inside the bolt holes but without allowing sealant into the crankcase The seal...

Page 123: ...he camshaft setting 1 Set the crankshaft to TDC after the compression stroke on cylinder number one 2 Put two dial gauges against the valve spring thrust washers 3 Adjust the rocker arms to remove the...

Page 124: ...volume Lubrication oil volume 28 35 litres Tightening torques Magnetic plug in oil sump 80 Nm Bolts for oil sump with unmachined surface 32 Nm Bolts for oil sump with machined surface 26 Nm Oil nozzl...

Page 125: ...00 rpm 2 5 bar With warm engine running at 2 000 rpm 4 5 6 0 bar Number Denomination Illustration 99 362 Measuring set 120 908 Version 1 early model 1 Disconnect the connector from the oil pressure se...

Page 126: ...l pressure sensor from the oil filter 2 Fit the measuring equipment with the union and adapters as illustrated 3 Fit the oil pressure sensor 99 412 OIL M14x1 5 120928 14 OIL 115 954 120913 Lubrication...

Page 127: ...uctions If the oil filter unit is not cleaned the oil filter will clog quickly increasing the flow resistance If this happens an overflow valve in the filter retainer opens and lets the oil pass witho...

Page 128: ...lts for oil cooler insert 26 Nm 1 Oil cooler 2 O ring 3 O ring 4 Flange screw 5 Oil cooler cover 6 Core plug 7 Cover 8 Gasket 9 Bolt 10 Piston 11 Spring 12 Plug 13 Gasket 14 Gasket 15 Flange screw Lub...

Page 129: ...emove the 4 bolts securing the oil cooler to the side cover 3 Remove the oil cooler 4 Renew the O rings 4 off 5 Fit the oil cooler insert and bolt it into place in the cover to 26 Nm 6 Bolt the side c...

Page 130: ...s of deposits on walls of cover 26 mm Tightening torques Lock nut for oil cleaner housing cover 15 Nm Nut for rotor cover Tightened by hand Rotor shaft 27 Nm Locking compound Locking compound 561 200...

Page 131: ...9 Housing 10 Plug 11 Piston 12 Spring 13 Plug 14 Gasket 15 Shaft 16 Washer 17 Rotor 18 Nozzle 19 Strainer 20 Rotor cover 21 Nut 22 O ring 23 Cover 24 O ring 25 Lock nut 26 Lifting eye 27 O ring 28 Re...

Page 132: ...the outer cover and remove the nut 2 Lift out the rotor Wipe off the outside Undo the rotor nut and unscrew it about three turns to protect the bearing 01 1286 x3 3 If the rotor nut is difficult to g...

Page 133: ...eized prise carefully with a screwdriver at the lower edge between the rotor and the strainer 01 1289 7 Scrape away the deposits inside the cover with a knife 8 Wash the parts 9 Inspect the two nozzle...

Page 134: ...able solvent Tighten the rotor shaft using socket wrench 98 421 Tightening torque 27 Nm 14 Refit the rotor and rotate it by hand to make sure it rotates easily 15 Check the O ring on the cover of the...

Page 135: ...lock 26 Nm 9 10 2 1 4 5 8 6 7 3 10 25943 1 Oil pump 2 Flange screw 3 Gasket 4 Flange screw 5 Suction pipe 6 Strainer 7 Ring 8 Flange screw 9 Pipe 10 Sealing ring In the event of leakage or fault with...

Page 136: ...et connections unprotected Foreign bodies in the bearing housing will soon lead to total breakdown Oil leaks A blocked air filter will cause excessive vacuum in the intake pipe There is then a risk of...

Page 137: ...en small leaks in the line between the air cleaner and the turbocharger will cause dirt to be deposited on the compressor impeller The charge pressure will be reduced resulting in increased exhaust te...

Page 138: ...587 107 Rocker indicator 587 250 Indicator stand M1 10 20 30 40 50 60 70 80 90 0 10 20 30 40 50 60 70 80 90 15 10 5 00_1637 98 075 00_1569 102350 Measuring radial and axial clearance often does not gi...

Page 139: ...ngs is the radial clearance 100704 5 Repeat the test three times on each side 6 If any of the wheels makes contact with the housing despite the radial clearance being within tolerances the turbocharge...

Page 140: ...here are no loose particles in the exhaust or intake manifolds Renew the charge air cooler 3 Make sure all valves are intact 4 Check that the lubrication oil return pipe from the turbocharger is not b...

Page 141: ...tensioner 2 Coolant pump 3 AC compressor 4 Idler roller 5 Alternator 6 Crankshaft Engine with air conditioning and two idler rollers 105 190 1 2 3 4 6 5 3 1 Automatic belt tensioner 2 Coolant pump 3...

Page 142: ...utomatic belt tensioner 2 Coolant pump 3 Alternator 4 Crankshaft Engine without air conditioning with an idler roller 1 Automatic belt tensioner 2 Coolant pump 3 Idler roller 4 Alternator 5 Crankshaft...

Page 143: ...ransmission industrial and marine engines 1 Pulley on torsion damper 2 Belt tensioner 3 Coolant pump 4 Fan pulley 5 Alternator 6 Poly V belt 7 Carrying roller Belt transmission www motodiesel ir M A S...

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