Scania 9 Service Manual
program 96
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Scania CV AB 1997-05:2
Issue 2
en
Part No.
1 588 468
Industrial & Marine Engines
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Work Description - 9-series engine
Industrial and Marine engines
2
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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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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
4
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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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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
6
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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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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
8
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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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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
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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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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.
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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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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.
14
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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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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.
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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.)
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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
20
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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
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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.
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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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