Scania Industrial Diesel 9 litre engine with 5 cylinders Service Repair Manual

01:07-02 Edition 1

Work description9 litre engine with 5 cylinders Industrial Engine

Part No. 1 715 049

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en

Use a container to avoid spills when draining the coolant and oil.

Dispose of used coolant and oil through an authorised waste disposal contractor.

Immobilise the starting device when working on the engine.

If the engine starts out of control, there is a SERIOUS RISK OF INJURY.

It is highly dangerous to consume corrosion inhibitor.

Avoid skin contact with glycol.

Avoid naked flames or sparks near the batteries.

When the batteries are charged, oxyhydrogen gas is formed which is inflammable and explosive.

Only start the engine in a well ventilated area.

If it is run in a enclosed space, there should be an effective device to draw off exhaust gases and crankcase gases.

Corrosion inhibitor is highly dangerous if ingested and can prove fatal.

Avoid contact with the skin.

Wear gloves and protective goggles when charging and handling batteries The batteries contain a highly corrosive acid.

Never start the engine without the air filter.

There is a risk of injury or serious engine damage.

Handling cleaning agents for the cooling system: Carefully read the warning label on the container.

Do not connect the terminals up incorrectly.

This can cause serious damage to the electrical system.

If the terminals are shorted, sparking will occur.

WARNING The oil may be hot.

Wear protective gloves and goggles

2

Hot engine with pressurised cooling system: Open the cap carefully.

Water and steam may spray out.

Risk of burn injuries.

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Contents General. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . 4 General tightening torques. . . . . . . . . . . . . . . . . 5 Engine assembly . . . . . . . . . . . . . . . . . . . . . . . . . 6 Special tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Removing the engine . . . . . . . . . . . . . . . . . . . . . 6 Fitting the engine . . . . . . . . . . . . . . . . . . . . . . . . 7 Mounting the engine in a universal stand . . . . . 8 Special tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Cylinder head. . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Checking and adjusting the valve clearance and unit injectors . . . . . . . . . . . . . . . . . . . . . . . . . . 10 Removing the cylinder head . . . . . . . . . . . . . . 15 Fitting the cylinder head . . . . . . . . . . . . . . . . . 17 Removal of valves . . . . . . . . . . . . . . . . . . . . . . 20 Fitting the valves . . . . . . . . . . . . . . . . . . . . . . . 20 Checking and machining of valves . . . . . . . . . 21 Renewal of valve stem seal . . . . . . . . . . . . . . . 22 Renewal of valve seats. . . . . . . . . . . . . . . . . . . 23 Machining the cylinder head . . . . . . . . . . . . . . 25 Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . 25 Renewal of valve guides . . . . . . . . . . . . . . . . . 29 Renewal of sleeves for unit injectors . . . . . . . . 30 Cylinder block . . . . . . . . . . . . . . . . . . . . . . . . . . 32 Reconditioning. . . . . . . . . . . . . . . . . . . . . . . . . 32 Removal of cylinder liner . . . . . . . . . . . . . . . . 33 Fitting of cylinder liner . . . . . . . . . . . . . . . . . . 34 Measuring the cylinder liner height . . . . . . . . . 35 Renewal of rear crankshaft seal . . . . . . . . . . . . 40 Removal of flywheel housing . . . . . . . . . . . . . 41 Fitting the flywheel housing . . . . . . . . . . . . . . 41 Renewal of the front crankshaft seal . . . . . . . . 44 Crank mechanism . . . . . . . . . . . . . . . . . . . . . . . 47 Removal of connecting rod with piston . . . . . . 48 Fitting of connecting rod with piston. . . . . . . . 49 Renewing a piston . . . . . . . . . . . . . . . . . . . . . . 51 Checking connecting rods . . . . . . . . . . . . . . . . 54 Renewal of bearing bushing in connecting rod 56 Removal of flywheel . . . . . . . . . . . . . . . . . . . . 58 Fitting the flywheel . . . . . . . . . . . . . . . . . . . . . 59 Support bearing . . . . . . . . . . . . . . . . . . . . . . . . 61 Renewal of ring gear . . . . . . . . . . . . . . . . . . . . 62

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Removal of crankshaft . . . . . . . . . . . . . . . . . . 63 Fitting the crankshaft. . . . . . . . . . . . . . . . . . . . 64 Checking and grinding of crankshaft . . . . . . . 65 Engine transmission . . . . . . . . . . . . . . . . . . . . . 67 Removal of intermediate gear . . . . . . . . . . . . . 69 Fitting the intermediate gear . . . . . . . . . . . . . . 71 Renewal of bearing in the intermediate gear for the fuel pump (or compressor and hydraulic pump if any) . . . . . . . . . . . . . . . . . . . . . . . . . . 73 Renewal of bearing in the intermediate gear for the camshaft . . . . . . . . . . . . . . . . . . . . . . . . . . 74 Removal of camshaft gear. . . . . . . . . . . . . . . . 75 Fitting the camshaft gear. . . . . . . . . . . . . . . . . 76 Removal of crankshaft gear . . . . . . . . . . . . . . 77 Fitting the camshaft gear. . . . . . . . . . . . . . . . . 76 Removal of camshaft. . . . . . . . . . . . . . . . . . . . 79 Fitting the camshaft. . . . . . . . . . . . . . . . . . . . . 80 Renewing the camshaft bearings. . . . . . . . . . . 84 Balance shaft unit . . . . . . . . . . . . . . . . . . . . . . . 90 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91 Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92 Fitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94 Renewing the ring gear on the crankshaft. . . . 96 Checking the ring gear on the crankshaft . . . . 98 Lubrication system . . . . . . . . . . . . . . . . . . . . . . 99 Measuring oil pressure . . . . . . . . . . . . . . . . . 100 Oil filter. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101 Oil cooler. . . . . . . . . . . . . . . . . . . . . . . . . . . . 102 Oil cleaner . . . . . . . . . . . . . . . . . . . . . . . . . . . 104 Oil pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109 Turbocharger. . . . . . . . . . . . . . . . . . . . . . . . . . 110 Measuring radial and axial play . . . . . . . . . . 112 Open crankcase ventilation . . . . . . . . . . . . . . . 115 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115 Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . 117 Fitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117 Checking the open crankcase ventilation . . . 119 Form for measuring the crankcase pressure . 121 Closed crankcase ventilation. . . . . . . . . . . . . . 122

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General 1

2 3

4

1.

2.

3.

4.

Instruction plate: Valve play Warning label, fuel EPA label Engine type designation and engine serial number, stamped

Specifications

4

Cylinder diameter

127,0 mm

Stroke

140,0 mm

Cylinder capacity

8,87 dm3

No. of main bearings

6

Firing sequence

1-2-4-5-3

Compression ratio

18:1

Direction of rotation (engine viewed from behind)

Anticlockwise

Engine speed, low idling (all speed)

500-800 rpm

Engine speed, high idle (all speed)

2200 rpm

Oil volume

23 - 29 litre

Oil quality

see booklet 00:03-01

Weight (without oil, coolant, radiator; with fan)

887 kg

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General tightening torques The following tightening torques apply in general unless otherwise specified:*) Thread M5

6,7 Nm

Thread M6

10,2 Nm

Flange screw M6

8,6 Nm

Flange screw M8

26 Nm

Flange screw M10

50 Nm

Flange screw M12

92 Nm

Stud screw in casting M8

13 Nm

Stud screw in casting M10

25 Nm

Thread M14

149 Nm

*) A tolerance of +/- 15% applies to the specified tightening torques unless stated otherwise.

Lubrication Engine oil must be applied to all moving parts before fitting unless otherwise stated.

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Engine assembly Special tools Number 99 318 98 094

Designation Engine support Lifting chain

587 308

Lever block

1 360 442

Lifting eye

Illustration

Removing the engine

Tool board

5. Fit the rear lifting eyes (1360442) and fasten the lifting chain 98 094.

Mind the environment Use a container to avoid spills when draining the coolant and oil. Dispose of used coolant and oilthrough an authorised waste disposal contractor.

1. Drain the oil and coolant.

2. Remove the air filter and the inlet pipe between the turbocharger and the air filter.

Cover the turbo inlet.

6. Fasten the lever block 587 308 to the front lifting eye.

Note The lifting eyes are dimensioned for a maximum inclination angle of 20° when lifting the engine.

7. Undo all the engine brackets and lift away/out the engine.

3. Undo the connections for coolant, charge air pipes between engine and charge air cooler, and ventilation line to the expansion tank.

4. Remove the cables with cable clamps.

Note The engine lifting eyes are sized for lifting the engine only, not the engine together with connected equipment (high-current generator, gearbox, reverse gear, etc.) or frame. All three lifting eyes must be used.

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Fitting the engine Note The engine lifting eyes are sized for lifting the engine only, not the engine together with connected equipment (high-current generator, gearbox, reverse gear, etc.) or frame. All three lifting eyes must be used.

Note The lifting eyes are dimensioned for a maximum inclination angle of 20° when lifting the engine.

1. Fasten the lifting chain 98 094 to the rear lifting eyes (1360442).

2. Fasten the lever block 587 308 to the front lifting eye.

3. Lift the engine in position and bolt it to the front engine suspension.

4. Connect the wiring with clamps.

5. Fit the connections for coolant, charge air pipes between engine and charge air cooler, and ventilation line to the expansion tank.

6. Fit the air filter and the inlet pipe between the turbocharger and the 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.

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Mounting the engine in a universal stand Special tools Number Designation 99 331 Fixture

587 692

Illustration

Tool board

Universal stand

1. Remove the fuel filter, the control unit and the starter motor.

2. Fit tool 99 331 to the universal stand and attach the engine.

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Cylinder head

1.

2.

3.

4.

5.

6.

7.

8.

9.

10.

11.

12.

Cylinder head Socket Core plug Rivet plug Valve guide Valve seat insert Valve seat insert Pin Pin Cylinder head gasket Seal Intake valve

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13.

14.

15.

16.

17.

18.

19.

20.

21.

22.

23.

24.

Valve spring Valve spring collar Exhaust valve Valve spring Valve spring Valve spring collar Collet Valve bridge Screw Bearing bracket Shaft Rivet plug

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25.

26.

27.

28.

29.

30.

31.

32.

33.

34.

35.

Tight-fit screw Rocker arm Adjusting screw Hexagon nut Rocker arm Adjusting screw Hexagon nut Rocker arm Adjusting screw Hexagon nut Rivet plug

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Checking and adjusting the valve clearance and unit injectors Specifications Valve clearance, intake valve(cold engine)

0,45 mm

Valve clearance, exhaust valve (cold engine)

0,70 mm

Measure for unit injector (cold engine)

66,9+/-0,1 mm

Tightening torques (See page 3 for general tightening torques) Lock nut for adjusting screw on the rocker arm for the unit injector

39 Nm

Lock nut for adjusting screw on the rocker arm for the valves

35 Nm

Screw for upper rocker cover

18 Nm

Screw for lower rocker cover

26 Nm

Bearing bracket and rocker arm shaft

105 Nm

Cable connection, unit injector

2 +/- 0,2 Nm

Special tools Number 99 309

Designation Tool to rotate flywheel

99 414

Setting tool

588 179

Torque screwdriver

10

Illustration

Tool board D5 Measuring tool cabinet

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Order of adjustment In order for the adjusting to be carried out on the correct revolution, proceed as follows: 1. Rotate the flywheel so that the 72° mark on the flywheel can be seen in the lower window of the flywheel housing whilst valve overlap occurs on cylinder 5.

2. Then turn the flywheel clockwise so that it passes TDC Down (0°) by about 20° and then turn it anticlockwise until TDC Down (0°) is visible in the lower window on the flywheel housing. The reason for turning past TDC down (0°) and then back is to counteract any backlash.

You are now on the first revolution and can adjust the valves and unit injectors according to the following table.

3. Rotate the flywheel anti-clockwise using tool 99 309 so that the mark on the flywheel is visible in the lower window of the flywheel housing.

Revolution

Mark on flywheel (degrees)

1 1 1 1 1 2 2 2 2 2

TDC Down 0 72 144 216 288 TDC Down 0 72 (432) 144 (504) 216 (576) 288 (648)

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Flywheel seen from the rear of the engine. * Direction of rotation when adjusting.

The solid line shows the order to take the angles on the first round and the broken line the order for round 2.

Adjust unit injector Adjust intake and rocker arm exhaust valves on on cylinder cylinder 2 1

Valve change on cylinder 5

4

2 3

5

4 1

3

5 2

1

3 4

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If reading cannot be taken from underneath: Turn the flywheel with tool 99 309 to valve overlap on cylinder 1 (which corresponds to TDC down (0°) in the lower opening). Then turn the flywheel anti-clockwise 144° at a time and observe the valve overlap. Adjust the valves according to the table below.

Valve overlap on cyl- Adjust the valves inder on cylinder

Adjust unit injector rocker arm on cylinder

TDCdown (0°)

1

5

5

(144°)

2

3

3

(288°)

4

1

1

(432°)

5

2

2

(576°)

3

4

4

The flywheel is also marked at 240°/600° and 120°/480°; these marks apply to 6 cylinder engines.

1. Start by rotating the flywheel so that the mark on the flywheel is visible in the lower window as illustrated. Never read off the flywheel mark in the top window - this reading will be completely wrong..

2. Fit adjusting tool 99 414 with the metal plate around the unit injector.

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!

WARNING!

When the unit injector is checked and the measurement is outside 66.9+/-0.1 mm, it is necessary to be very careful when handling the unit injector.

The spring is pre-tensioned and can come loose, causing personal injury.

Setting tool 99 414 acts as a gauge with the measurement 66.9 mm.

3. When adjusting, loosen the lock nut and adjust the unit injector with adjusting screw 1. The unit injector is correctly set when the small piston 2 is level with the flat upper surface of the tool. Check using a finger. It is possible to feel differences of less than a hundreth of a millimetre. The setting dimension is 66.9 +/-0.1 mm.

Refer to tables in Order of adjustment for unit injectors

The setting tool piston is above or below the flat upper surface of the tool. Adjust the unit injector.

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The setting tool piston is level with the flat upper surface of the tool. The unit injector is correctly adjusted.

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4. Torque tighten the lock nut to 39 Nm after adjusting.

5. Remove tool 99 414.

6. Fit the upper rocker cover and tighten the screws to 18 Nm. 7. Close the bleeder nipple and tighten the banjo screw.

8. Fill and bleed the fuel system, refer to Bleeding the fuel system in booklet 03:04-02.

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Removing the cylinder head 1. Open the bleeder nipple and drain the fuel system by undoing the banjo screw on the back of the fuel manifold.

!

WARNING!

The fuel system must be empty or fuel may run down into the cylinders, which will result in a great risk of liquid hammering. If fuel runs into the combustion chamber, it must be removed immediately using a pump.

2. Clean the rocker cover and the surrounding area and remove the top part of the rocker cover.

3. Detach the cable to the unit injector and remove it from the lower part of the rocker cover.

4. Relieve the pressure on the valves by undoing the bolts on the rocker arm shaft alternately.

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!

WARNING!

Do not lean over the engine when removing the rocker arm shaft. The unit injector spring is pre-tensioned and can come loose, causing personal injury.

Important If the spring comes loose from the unit injector, the unit injector must be renewed.

5. Remove the rocker arm shaft.

6. Remove the bearing bracket.

7. Remove the pushrods.

Note The pushrod 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.

10. Remove the unit injector according to section Unit injector- Removal, items 6-11 in booklet 03:04-02.

11. Detach the intake manifold, fuel manifold, ventilation pipe for the cooling system and the exhaust manifold as necessary to remove one or more cylinder heads.

12. Remove the cylinder head. Mark the cylinder heads if more than one is being removed at the same time.

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Fitting the cylinder head Specifications

Tightening torques Cylinder head bolts: - First stage

60 Nm

- Second stage

150 Nm

- Third stage

250 Nm

- Fourth stage

90°

Screw for lower rocker cover

26 Nm

Screw for shaft with rocker arms

105 Nm

Screw for bearing bracket

105 Nm

Exhaust manifold

63 Nm

Inlet manifold

26 Nm

Lubricant Lubricant for the exhaust manifold screws and connections

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1. Check liner height, refer to Measuring the cylinder liner height.

2. Fit a new cylinder head gasket.

3. Fit the cylinder head.

4. The cylinder head bolts can be reused up to 3 times. Therefore, make sure the bolts have no more than 2 punch marks on top of the bolt head. If any of the bolts has 3 marks, it must be replaced with a new one.

5. Lubricate the cylinder head bolts on the thread and under the head. Tighten the bolts in the order given in the figure and in four stages as follows: 1. Tighten all bolts to 60 Nm 2. Tighten all bolts to 150 Nm 3. Tighten all bolts to 250 Nm 4. Finallt, tighten all bolts to 90° 5. Make a mark with a centre punch on the head of the bolt.

6. Fit the lower part of the rocker cover and tighten the bolts to 26 Nm.

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7. Fit the unit injector according to the section Unit injector - Fitting, steps 1-5 in booklet 03:04-02.

8. Fit the pushrods 2.

9. Fit the bearing bracket and torque tighten the bolts to 105 Nm. 10. Fit the valve bridges 4.

Important Lubricate the valve bridges with engine oil.

11. Continue according to the section Unit injector - Fitting, steps 6-8 in booklet 03:04-02.

12. Fasten the fuel manifold and the fuel lines.

Tighten the screws to 26 Nm and the banjo screws to 11 Nm. 13. Tighten the exhaust manifold using a torque of 63 Nm. 14. Attach the venting line for the cooling system.

15. Attach the intake manifold with the wiring bundles.

16. Finish according to the section Unit injector Fitting, steps 9-11 in booklet 03:04-02

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Removal of valves Special tools Number 99 322

Designation Drift

Illustration

Tool board D5

1. Press down the spring using tool 99 322 in a press so that the collets can be removed.

Remove the collets, valve spring collars, springs and valves.

2. Place the valves in a stand or mark them so that they can be refitted in the same position in the cylinder head.

Fitting the valves Special tools Number 99 322

Designation Drift

Illustration

Tool board D5

1. Lubricate all parts well with engine oil before assembly.

2. Fit the valve in the guide.

3. Fit a new valve stem seal as shown in page 22.

4. Fit the valve springs and the valve spring collar.

5. Compress the springs in a press using tool 99 322 and fit the collets. Take care to fit the collets in the correct position.

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