Scania 9 Service Manual

program 96

Scania CV AB 1997-05:2

Issue 2

Part No.

1 588 468

Industrial & Marine Engines

01:01-02

Work Description - 9-series engine

Industrial and Marine engines

Scania CV AB 1997-05:2 01:01-02

Program 96

Contents

.................................... Page ....................................Page

Cylinderhead ...........................3

Valveclearance........................5

Compression ..........................6

Removing.............................8

Dismantling ...........................9

Checking,changingandmachining.........9

Assembly............................17

Fitting...............................17

Turbocharger...........................19

General..............................20

Measuring radial clearance and

axialclearance........................21

Iftheturbochargerisnotworking.........22

Changingtheturbocharger...............23

Pistonsandcylinderliners.................24

Removaloflooseringincylinderliner.....26

Removal and dismantling of piston and

connecting rod ........................26

Assembling piston and connecting rod .....29

Removingcylinderliner ................30

Fittingcylinderliner ...................35

Fitting piston and connecting rod .........36

Flywheel and flywheel housing............. 38

Removingflywheel....................40

Removing and fitting flywheel housing.....42

Fittingflywheel.......................43

Timinggear ............................44

Crankshaftseal........................46

Timinggearcover......................48

Intermediategear ......................50

Crankshaftgear........................51

Camshaftgear.........................52

Camshaft.............................53

Crankshaft............................55

Lubricationsystem.......................57

Oilcooler ............................57

Oilcleaner............................59

Oilpump.............................63

Liftingtheengine........................64

Specifications...........................65

Generalinformation....................65

Cylinderhead.........................65

Turbocharger..........................67

Pistonsandcylinderliners ...............67

Flywheel and flywheel housing ...........68

Timinggear...........................69

Lubricationsystem.....................71

Specialtools............................73

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Scania CV AB 1997-05:2 3

Program 96

Cylinder head

1. Cylinder head

2. Valve guide

3. Valve guide

4. Valve seat ring

5. Valve seat ring

6. Core plug

7. Core plug

8. Seal (not standard)

9. Intake valve

10. Exhaust valve

11. Valve spring collar

12. Valve spring

13. Valve spring

14. Valve spring collar

15. Collet

16. Valve stem cap

17. Bearing bracket

18. Rocker arm

19. Bushing

20. Adjusting screw

21. Hexagon nut

22. Retaining ring

23. Spiral pin

24. Bolt

25. Flange bolt

26. Cylinder head gasket

27. Pin

Scania CV AB 1997-05:2 01:01-02

Program 96

Special tools

87 125 Extractor 87 961 Drift 99 246 Drift 98 249 Compression tester 98500 Shank 98 503 Drift 98 622 Press drift 99 051 Fixture 99 074 Impact drift

99 079 Injector extractor 99 247 Assembly drift 99 195 Valve spring compressor, com-

plete 99 308 Sleeve for injector 99 310 Sleeve

587 272 Cylinder liner cutter with grooving

tool

587 277 Valve seat cutter 587 692 Engine stand

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Scania CV AB 1997-05:2 5

Program 96

Valve clearance

Checking and adjusting

Check valve clearance. The clearance for intake valves should be 0.45 mm and the clearance for exhaust valves should be 0.80 mm when the engine is cold.

Adjustment can be carried out in one of the following ways:

A. Adjust both valves in each cylinder starting with No. 1 cylinder at TDC after compression. Turn the crankshaft 1/3 turn at a time and adjust valves in injection sequence:

1-5-3-6-2-4

B. Set No. 1 cylinder a t precisely TDC after compression. The following valves can now be adjusted:

cylinder 1 intake and exhaust cylinder 2 intake cylinder 3 exhaust cylinder 4 intake cylinder 5 exhaust

Turn the crankshaft precisely one revolution so that TDC for No. 6 cylinder is set. The remaining valves can now be adjusted:

cylinder 2 exhaust cylinder 3 intake cylinder 4 exhaust cylinder 5 intake cylinder 6 exhaust and intake

Intake valve Exhaust valve

Scania CV AB 1997-05:2 01:01-02

Program 96

Compression

Measuring

The compression tester is used to quickly and simply check wear and damage to primarily the cylinder head valves, but also to cylinder liners and piston rings.

Measurements are only intended for comparison between cylinders. Lower compression in one or several cylinders is a sign of abnormal wear or damage.

By using various accessories, the compression tester can be used for several engine types.

1. Lock the stop lever in the stop position.

2. Clean around injectors. Detach delivery pipes

and leak-off pipes from all injectors.

Note Fit protective caps on the delivery

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

3. Undo and remove the injectors and copper

washers.

4. Turn the engine over several times using the

starter motor to remove any loose soot in the cylinders.

1. Pressure gauge

2. Zeroing valve

3. Flexible metal hose

4. Measuring rod, complete

5. End sleeve, diameter 21 mm

6. Spacing sleeve with guide lug

7. Spacing sleeve with collar

8. Spacing sleeve, length 6 mm

9. Spacing sleeve, length 19 mm

10. Spacing sleeve, length 25 mm

11. Spacing sleeve, length 38 mm

12. Cap nut

13. Threaded socket nut

14. Large yoke

15. Small yoke Compression tester 98 249

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Scania CV AB 1997-05:2 7

Program 96

5. Connect the compression tester in the injec-

tion aperture in one of the cylinders. Copper washer 16 should be used between the compression tester and the bottom of the injector aperture.

6. Turn the engine over using the starter motor

and read the pressure gauge. Note the result.

7. Zero the pressure gauge by pressing zeroing

button 2.

8. Move the compression tester to the next cyl-

inder and proceed as in points 7-9.

9. Evaluate the readingsand assess what further

measures need to be taken on the engine.

Cleaning the measuring rod

Measuringrod4hasacheckvalvewhich,inthe case of leakage, should be cleaned as follows:

1. Unscrew valve seat 18.

2. Remove all soot from valve 17 and valveseat

18. Do not scratch the sealing surfaces. Use compressed air to clean the inside of measuring rod 4.

3. Assemble the parts. Makesure that O-ring 19

is not damaged. Fully screw on valve seat 18 so that it seals against measuring rod 4.

4 Measuring rod 5 End sleeve, diameter 21 mm 7 Spacing sleeve with collar 10 Spacing sleeve, L = 25 mm 12 Cap nut (use socket 99 308 for

tightening)

16 Copper washer

4Measuring rod 17 Valve 18 Valve seat 19 O-ring

Measuring rod, complete

Measuring rod

Scania CV AB 1997-05:2 01:01-02

Program 96

Removing

1. Remove the intake manifold, exhaust mani-

fold and turbocharger.

2. Remove the coolant manifold.

3. Remove the delivery pipes. Protect the con-

nections on the injection pump and injectors with plastic plugs.

4. Undo the injector nut using socket 99 308.

5. Extract the injectors using tools 99 079 and

99 074. Remove the copper washers using tool 87 125.

6. Insert protective plugs in the ends of the

delivery pipes and fit protective caps on the injectors and injection pump.

Note All parts in the valve mechanism

should be refitted in the same positions. For this reason, mark all parts that are removed.

7. Unscrew the rocker arm mechanism.

8. Lift out the pushrods.

9. Remove the cylinder head bolts. Lift off the

cylinder head. Place it on a bench on a soft surface to avoid damage to the mating surface.

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Scania CV AB 1997-05:2 9

Program 96

Dismantling

1. Remove the valve stem caps.

2. Extract collets, valve spring collars, springs

and valves. Use tools 99 195 and 99 196 to compress the valve springs so that the collets can be removed.

3. Place the valves in a stand so that they can be

refitted in the same cylinder head. Mark the cylinder heads if several are removed at the same time.

Checking, changing and machining

Valve stem seal (not standard)

Changing

1. Remove the valve stem seal.

2. Fit a new seal with tool 99 247.

Note Do not hammer on the seal so hard

that the valve guide is displaced.

Valves

Checking and machining

- Check dimension A on all valves.

- Machine the valves in a valve grinder.

Intake 19.5°and exhaust 44.5°.

See specifications.

Minimum dimension A for

ground valve

Intake 3.0 mm

Exhaust 1.7 mm

Scania CV AB 1997-05:2 01:01-02

Program 96

New exhaust valve and new valve seat ring

New intake valve and new valve seat ring

New exhaust valve and valve seat ring

machined to maximum. Surfaces at arrows

aligned

New intake valve and valve seat ring

machined to maximum

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Scania CV AB 1997-05:2 11

Program 96

Valve seats

Changing

1. Remove valve seat rings. Use an old valve

which has been machined so that the diameter of the head is slightly smaller than the inside diameter of the seat.

2. Place the valve in position and weld it all

round using an arc welder. Cool with water. Turn the cylinder head over and tap the valve stem so that valve and seat ring fall out. Wear protective goggles!

WARNING!

Always turn the cylinder head with the underside down when the valve seat ring is being tapped out. Otherwise, there is a risk of loose swarf causing injury.

3. Press in new valve seat rings. Use drift

98 503 and shank 98 500. Cool the drift and valve seat to about -80 °C in dry ice or liquid air. The rings must be pressed in very quickly.

WARNING!

Take care when using the above coolants and cooled parts. Danger of frostbite.

Oversize valve seat rings can be fitted if the valve seat ring position has been damaged. The seat must then be machined using tool 587 277.

Scania CV AB 1997-05:2 01:01-02

Program 96

Machining Machining dimensions and oversize valve seat

rings, see Specifications.

1. Check that the contact surface and magnetic

foot are smooth and clean. Clean valve bushings.

2. Select the largest spindle which easily goes

into the valve guide. Fit the guide spindle and turn the feed screw to its upper position.

3. Select and fit cutter.

4. Undo the speed lock and movethe pivotplate

to the upper position using the adjusting screw.

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Scania CV AB 1997-05:2 13

Program 96

5. Set the pointer on the cutter using a valve.

6. Set the cutter.

7. Disconnect the magnet (position 2). Insert the

guide spindle in the valve bushing. Adjust the pivot plate so that the gap between the cutter and the valve seat is about 1 mm. Carefully centre the tool.

8. Connect the magnet (position 1).

9. Secure speed lock. Check that crank is easy

to turn. If not, repeat centring.

10. Cut valve seat bycranking clockwise and turn-

ing the feed screw at the same time. Never crank anticlockwise. The cutter may break. Lubricate with cutting oil while working.

11. When the valve seat surface is finished,

reduce cutting pressure by cranking 2-3 turns without feeding. Continue cranking and turn the feed screw anticlockwise. The valve seat cutter is now ready for the next valve seat.

Scania CV AB 1997-05:2 01:01-02

Program 96

Rocker arms

Changing bushing

1. Remove the retaining ring.

2. Remove rocker arm from support bracket.

3. Press bushing out of rocker arm using drift

98 622.

4. If wear is light, the surface of the rocker arm

which presses against the valve stem cap can be adjusted using a grinding machine.

5. Turn the slit in the bushing up. Press bushing

into rocker arm using drift 98 622.

6. Drill the oil hole in the bushing to the same

diameter as the oil hole in the rocker arm.

7. The bushing should then be finely worked.

See specifications.

8. Lubricate the bushing using engine oil before

the rocker arm is placed on the support bracket.

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Scania CV AB 1997-05:2 15

Program 96

Valve guides

Changing

1. Press out valve guides using drift 87 961.

2. Press in new valve guides using drive 99 246

(exit). Press down the guide as far as the drift will allow, i.e. until it is against the spring seat in the cylinder head.

Scania CV AB 1997 01:01-02

Program 96

Cylinder head

Checking and machining the sealing surface

against cylinder block.

Cylinder head is checked for cracks and other defects. The sealing surface against the cylinder block is checked against a surface plate. If the sealing surface must be machined, cylinder head height after machining must not be less than 114.4 mm.

After machine flat, new sealing grooves for the gasket must be milled. Use tool 587 272.

Also machine the recesses for the sealing rings. Depth 0.9-1.1 mm.

Sealing groove in cylinder head

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Scania CV AB 1997 17

Program 96

Assembly

1. Thoroughly lubricate all parts before assembly.

2. Insert the valve stem in the guide. (Fit the

valve stem seal, if any.)

3. Fit the lower guide washer, the two valve

springs and the upper guide washer.

4. Compress springs using tools 99 195 and

99 196 and fit collets.

5. Fit valve stem caps.

Fitting

1. Clean the cylinder head bolt holes in the

block using an M16 tap. Check the liner height, see Pistons and cylin- der liners.

2. Fit a new gasket.

3. Fit the cylinder head and ensure that the

guide pins fit in the holes.

4. Change bolts having three centre-punch

marks on the head for new ones.

5. Lubricate the threads on the cylinder head

bolts and the surface under the head.

6. Tighten the bolts in the order given in the fig-

ure and in three stages + 90 degrees as follows:

• Tighten all bolts to 60 Nm

• Tighten all bolts to 150 Nm

• Tighten all bolts to 250 Nm

• Finally tighten all bolts 90 degrees

7. Mark all bolts with a fresh centre-punch

mark. (Except new bolts.)

Scania CV AB 1997 01:01-02

Program 96

8. Fit the pushrods and rocker arm mechanism.

Tighten the rocker arm mechanism bolts to 150 Nm.

9. Check valve clearance as described in Valve

clearance, checking and adjusting on page 5.

10. Check that no old seal remainsin the injector

hole. Fit the injectors complete with new seals.

11. Tighten the injectors to 70 Nm using tool

99 308.

12. Fit the rocker covers and tighten them to

20 Nm.

13. Fit delivery pipes and tighten to 20 Nm using

socket 99 310. Fit leak-off pipes, coolant manifold, intake manifold and exhaust manifold with new gaskets and seals.

14. If the exhaust pipe has been removed and dis-

mantled, joints should be lubricated using lubricant 561 205 when reassembling.

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Scania CV AB 1997 19

Program 96

Turbocharger

1. Lubrication oil pipe

2. Ferrule

3. Union nut

4. Straight union

5. Gasket

6. Gasket

7. Hexagon socket screw

8. Lubrication oil return pipe

9. Gasket

10. Flange bolt

11. Hose

12. Hose clip

13. Elbow union

14. Clamp

15. Clamp

16. Flange bolt

17. Flange bolt

18. Turbocharger

587 107 Out-of-true indicator 587 250 Measuring stand

98 075 Dial gauge

587 025 Filter wrench

Special tools

Scania CV AB 1997 01:01-02

Program 96

General

Note When working on the turbocharger,

cleanliness is extremely important. Oil inlet and outlet connections must never be left unprotected. A foreign body in the bearing housing can quickly lead to total breakdown.

Oil leakage

A clogged air cleaner causes vacuum in the intake line to become excessive. If this occurs there is a riskthatoilmistwillbedrawnoutfromthebearing housing into the compressor and then on into the engine.

If the seal on the turbine side is worn, exhaust gas will be blue when idling.

If the oil outlet pipe from the turbocharger is damaged, there is a danger of oil being forced out through the seals due to lubrication oil pressure.

Foreign bodies

Foreign bodies such as grains of sand or metal swarf in the turbine or compressor will destroy the impeller vanes. This leads to imbalance and bearing wear. Engine output drops and, if operation continues, there will be a risk of damage due to overheating as the air supply drops. This type of overheating cannot be observed on the coolant temperature gauge.

Note Never attempt to straighten a dam-

aged vane. It will usually break when in operation and cause turbocharger breakdown and engine damage.

Air and exhaust leakage

Even very tiny leaks in the line between air cleaner and turbocharger cause deposits of dirt on the compressor wheel. Charge pressure then drops, resulting in higher exhaust temperature and smoke. Wear on the engine also increases.

Exhaust leaks between cylinder head and turbo also result in low charge pressure.

Charge pressure

Note that low charge pressure does not necessarily mean that the turbocharger is faulty. Low pressure may be caused by such things as a clogged air filter, leakage in the intake or exhaust lines, an incorrectly adjusted throttle control, faulty injectors, defective injection pump or faulty smoke limiter.

Cleaning compressor wheel

Low charge pressure can be caused by a dirty compressor wheel. Remove the compressor cover. Wash the compressor wheel using white spirit and a brush. Fit the compressor cover and read the charge pressure.

Note The compressor wheel must not be

removed from the shaft. This could cause imbalance when refitted.

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Scania CV AB 1997 21

Program 96

Measuring radial clearance and axial clearance

Measuring radial clearance and axial clearance does not usually give any indication of the remaining service life of the turbocharger.

If the turbocharger appears to be functioning poorly or is making a noise, measuring charge pressure or measuring radial and axial clearance may indicate that the turbocharger is defective.

For measuring axial and radial clearance, the turbocharger can be removed and bolted to a steel plate to which the magnetic dial gauge stand can also be attached.

Radial clearance

Take readings on both turbine wheel and compressor wheel.

1. Place the point of the dial gauge against the

turbine wheel and compressor wheel.

2. Pull both ends of the shaftup. Take a reading.

3. Press both ends of the shaft down. Take a

reading. The difference between readings is radial clearance.

4. Repeat measurements three times on each

side.

5. If any wheel rubs against the housing, despite

radial clearance being within tolerance, the turbocharger should be changed.

Measuring turbine wheel radial clearance.

Measuring compressor wheel radial

clearance

Scania CV AB 1997 01:01-02

Program 96

Axial clearance

1. Place the point of the dial gauge against the

end of the shaft.

2. Press the shaft forwards and backwards and

read the dial at the end positions. The difference between readings is axial clearance.

3. Repeat measurements three times.

Wear limits for Holset:

Radial clearance 0.329-0.501 mm Axial clearance

(after running-in) 0.038-0.093 mm

If the turbocharger is not working

1. Check that there is no leakage nor any loose

objects in the linebetween theair cleaner and turbocharger.

2. Check that there are no loose objects in the

exhaust manifold or intake manifold. Change the charge air cooler.

3. Check that all valves are intact.

4. Check the lubrication oil return pipe from the

turbocharger for blockage or deformation.

5. Check the oil delivery pipe to the turbo-

charger for any blockage, deformation and leakage under pressure.

6. Check the condition and part number of the

oil filter.

7. Check that the air filter is not blocked and

that there are no other reasons for the abnormal increase of vacuum in the intake system.

8. Check that engine output is correct. Exces-

sively high output reduces the life of the turbo.

9. Check that the exhaust brake, if fitted, works

correctly.

01:01-02

Scania CV AB 1997 23

Program 96

Changing the turbocharger

Note When changing the turbocharger,

all gaskets and the oil filter must be changed and the centrifugal cleaner cleaned.

Removing

1. Detach exhaust pipe, induction pipe and

charge air cooler pipe from the turbocharger.

2. Detach then oil supply and return lines.

3. Unscrew the bolts in the turbocharger mount-

ing and remove the turbocharger.

Fitting

1. Check the connecting flange on the exhaust

manifold to ensure that no remnants of the old gasket are still present.

2. Fit a new gasket and bolt on a new turbo-

charger. Lubricate theexhaust manifoldbolts with temperature resistant lubricant, Part No. 561 205. Tighten to 40 Nm.

3. Connect oil supply and return lines.

4. Connect charge air pipe, induction pipe and

exhaust pipe.

5 Lock the stop lever in the stop position and

turn the engine over by means of the starter motor for at least 30 seconds so that the lubricating oil reaches the turbocharger. On engines with a fuel shut-off valve, this valve should be disconnected while the engine is being turned over.

6. Start the engine and check that there is no

leakage.

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