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Scania industrial and marine engines 16 litre engine service repair manual
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© Scania CV AB
2002-09:3 Issue 3 en Part No. 1 588 778 Industrial & Marine Engines 01:05-02 Work description- 16-litre engine Industrial and marine engines
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2 © Scania CV
AB 2002-09:3 01:05-02 Use a container to avoid spills when draining the coolant and oil. Dispose of used coolant and oil through an authorised waste disposal contractor.
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01:05-02 © Scania CV
AB 2002-09:3 3 General. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Specifications . . . . . . . . . . . . . . . . . . . . . . . . . 4 General tightening torques . . . . . . . . . . . . . . . 5 Removing and lifting the engine . . . . . . . . . . . . 6 Special tools . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Lifting and fitting the engine . . . . . . . . . . . . . . . 8 Mounting the engine in a universal stand . . . . . 9 Special tools . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Cylinder head . . . . . . . . . . . . . . . . . . . . . . . . . . 10 Adjusting the valve clearance and unit injectors11 Adjusting the valve clearance . . . . . . . . . . . . 12 Adjusting the unit injector. . . . . . . . . . . . . . . 12 Order of adjustment. . . . . . . . . . . . . . . . . . . . 15 Renewing the upper rocker cover gasket . . . 16 Renewing the lower rocker cover gasket . . . 16 Cylinder head . . . . . . . . . . . . . . . . . . . . . . . . . . 20 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 Fitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 Valves. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30 Fitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30 Checking and machining. . . . . . . . . . . . . . . . 31 Valve stem seal . . . . . . . . . . . . . . . . . . . . . . . . 32 Renewal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32 Valve seats . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33 Renewal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33 Machining the cylinder head . . . . . . . . . . . . . . 35 Specifications . . . . . . . . . . . . . . . . . . . . . . . . 35 Work description. . . . . . . . . . . . . . . . . . . . . . 37 Valve guides. . . . . . . . . . . . . . . . . . . . . . . . . . . 39 Renewal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39 Sleeves for unit injectors . . . . . . . . . . . . . . . . . 40 Renewal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40 Cylinder block . . . . . . . . . . . . . . . . . . . . . . . . . 42 Overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42 Cylinder liner . . . . . . . . . . . . . . . . . . . . . . . . . . 43 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43 Fitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44 Measuring the cylinder liner height . . . . . . . 45 Machining cylinder liner height . . . . . . . . . . 47 Rear crankshaft seal . . . . . . . . . . . . . . . . . . . . . 52 Renewal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52 Flywheel housing . . . . . . . . . . . . . . . . . . . . . . . 53 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53 Fitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54 Closed crankcase ventilation . . . . . . . . . . . . . . 56 Front timing gear casing. . . . . . . . . . . . . . . . . . 58 Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58 Fitting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59 Front crankshaft seal . . . . . . . . . . . . . . . . . . . . 60 Renewal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60 Crank mechanism. . . . . . . . . . . . . . . . . . . . . . . 62 Piston and connecting rod . . . . . . . . . . . . . . . . 63 Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63 Fitting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64 Renewing a piston . . . . . . . . . . . . . . . . . . . . . 66 Connecting rod . . . . . . . . . . . . . . . . . . . . . . . . . 69 Checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69 Renewal of bearing bushing in connecting rod. 71 Flywheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73 Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73 Fitting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74 Support bearing . . . . . . . . . . . . . . . . . . . . . . . 75 Ring gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76 Crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77 Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77 Fitting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79 Checking and machining the crankshaft . . . . 82 Timing gear . . . . . . . . . . . . . . . . . . . . . . . . . . . 84 Gear drive . . . . . . . . . . . . . . . . . . . . . . . . . . . 84 Intermediate gear . . . . . . . . . . . . . . . . . . . . . . . 86 Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86 Fitting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88 Bearing in intermediate gear . . . . . . . . . . . . . 89 Camshaft gear. . . . . . . . . . . . . . . . . . . . . . . . . . 92 Crankshaft gear. . . . . . . . . . . . . . . . . . . . . . . . . 93 Camshaft. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95 Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95 Fitting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98 Checking camshaft setting. . . . . . . . . . . . . . 101 Removing the camshaft bearing . . . . . . . . . 102 Fitting the camshaft bearing . . . . . . . . . . . . 106 Fan drive. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110 Lubrication system . . . . . . . . . . . . . . . . . . . . . 114 Oil filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114 Oil cooler. . . . . . . . . . . . . . . . . . . . . . . . . . . 116 Oil cleaner . . . . . . . . . . . . . . . . . . . . . . . . . . 118 Oil pump . . . . . . . . . . . . . . . . . . . . . . . . . . . 122 Exhaust manifold . . . . . . . . . . . . . . . . . . . . . . 124 Turbocharger . . . . . . . . . . . . . . . . . . . . . . . . . 125 Contents
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AB 2002-09:3 01:05-02 General Specifications Cylinder bore 127.0 mm Stroke 154.0 mm Displacement 15.6 dm3 No. of main bearings 5 Firing sequence 1-5-4-2-6-3-7-8 Compression ratio 18:1 Direction of rotation (engine viewed from behind) Anticlockwise Engine speed, low idling (all-speed) 500 rpm Engine speed, high idling (all-speed) 2400 rpm Oil volume 35 litre Oil grade see booklet 00:03-01 Weight (without oil, coolant, radiator; with fan) 1,346 kg 1. Warning plates 2. Instruction plate: Valve clearance 3. Type plate: Engine type, Engine serial number 4. Engine serial number, stamped DC16 engine shown. Di 16: same location
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01:05-02 © Scania CV
AB 2002-09:3 5 General tightening torques *) A tolerance of +/- 15% applies to the specified tightening torques unless stated otherwise. The following tightening torques apply in general unless otherwise specified:*) Flange bolt M6 8.6 Nm Flange bolt M8 26 Nm Flange bolt M10 50 Nm Flange bolt M12 92 Nm Stud in casting M8 13 Nm Stud in casting M10 25 Nm
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AB 2002-09:3 01:05-02 Removing and lifting the engine Special tools 1. Drain the oil and coolant. Help protect our environment! Use a suitable container. Dispose of used coolant and oil through an authorised waste disposal contractor. DC engine: - Remove the air filter and the inlet pipe between the turbocharger and the air filter. - Undo the connections for coolant, charge air pipes between engine and charge air cooler, and ventilation line to the expansion tank. - Remove the cables with cable clamp ring on the rear right-hand side. DI engine: - Disassemble the engine and reverse gear. - Detach the pipe between the seawater pump and heat exchanger. Remove the seawater pump. - Remove the turbocharger oil pipes. 2. Disconnect the negative battery cable. 3. Remove the starter motor and alternator wir- ing 4. Remove the wiring to the control unit. 5. Remove the fuel connection. Number Description Illustration Tool board 99 398 Lifting eyes 1 360 442 Lifting eyes 1 512 730 Lifting eye 98 094 Lifting chain 587 308 Lever block
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AB 2002-09:3 7 DC engine: - Disconnect the filter housing for the crankcase ventilation and place to one side so that it is free from the lifting chain. - Undo the AC compressor and move to one side. - Screw lifting eyes 99 398 onto the engine using flange bolts M12x30 (4). DI engine: - Fit the front lifting eye 1512730 with two M12 x ? mm bolts through the expansion tank. Turn the lifting eye towards the centre of the engine. - Screw two lifting eyes 1360442 into the flywheel housing over the centre in the ten to two position. 6. Fasten the lifting chain 98 094 to the rear lift- ing eyes. 7. Fasten the lever block (587 308) to the front lifting eye. 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. 8. Undo the connecting pipe to the gearbox cooler or reversing gear oil cooler. 9. Undo the connection to the gearbox or reverse gear. 10. Undo all the engine brackets and lift away/out the engine. Note: The lifting eyes are dimensioned for a maximum inclination angle of 20° when lifting the engine. DC16 engine DC16 engine
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AB 2002-09:3 01:05-02 Lifting and fitting the engine DC engine: - Screw lifting eyes 99 398 onto the engine using flange bolts M12x30 (4). - Disconnect the filter housing for the crankcase ventilation and place to one side so that it is free from the lifting chain. DI engine: - Screw two lifting eyes 1360442 into the flywheel housing over the centre in the ten to two position. The seawater pump, the heater exchanger pipe and the turbocharger oil pipes must be removed. - Remove the closed crankcase ventilation filter. - Fit the front lifting eye 1512730 with two M12 x ? mm bolts through the expansion tank. Turn the lifting eye towards the centre of the engine. 1. Fasten the lifting chain 98 094 to the rear lifting eyes. 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. DI16: Remove the rear lifting eyes. 5. Bolt together the engine and gearbox or reverse gear. 6. Bolt the engine to the rear engine suspension. 7. Remove the lifting eyes. 8. DC16: Fit the filter housing for the crankcase ventilation. 9. Fit the connecting pipes to the gearbox cooler or reverse gear oil cooler. 10. Connect the wiring to the control unit and starter motor/alternator. 11. Fit the fuel pipe. DC engine: - Fit the coolant connections, charge air lines between the charge air cooler and the engine. - Fit the ventilation line and static line. Fit the inlet pipe to the turbocharger and refit the air filter. DI engine: - Fit the turbocharger oil pipes and the seawater pump and pipe from the pump to the heat exchanger. - Fit the closed crankcase ventilation filter. 12. Connect the negative battery cable. 13. Fill with oil and coolant as directed in book- let 00:03-01. 14. Test run the engine to check that no leakage occurs. Top up with coolant if necessary.
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AB 2002-09:3 9 Mounting the engine in a universal stand Special tools DI engine: - Remove the heat exchanger pipe connections and remove the entire heat exchanger. - Remove the exhaust manifolds. - Remove the control unit connectors. DC and DI engines: 1. Remove the side covers and the gaskets on the right and left-hand sides. 2. Undo the clamps on any obstructing wiring. 3. Bolt spacer 99 349 onto the right and left- hand sides. Use the bolts for the side covers. 4. Screw fixture 98 163 onto the spacers. Use M8 x 25 bolts and M8 washers. 5. Screw the fixture to the universal stand and place the fixture's support on the opposite side as illustrated. Number Description Illustration Tool board 99 349 Spacer 98 163 Fixture 587 692 Universal stand DC16
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AB 2002-09:3 01:05-02 Cylinder head 1. Cylinder head 2. Core plug 3. Valve guide 4. Pin 5. Valve stem seal 6. Valve spring, intake 7. Valve spring collar 8. Valve spring, exhaust 9. Valve spring, exhaust 10. Valve spring collar 11. Valve collet 12. Valve bridge 13. Bolt 14. Bearing bracket 15. Rocker arm shaft 16. Rivet plug 17. Tight-fit screw 18. Rocker arm, intake 19. Rocker arm, exhaust 20. Adjusting screw 21. Lock nut 22. Rocker arm, unit injector 23. Guide pin 24. Cylinder head gasket 25. Exhaust valve 26. Intake valve 27. Rocker cover 28. Flange bolt 29. Rocker cover gasket 30. Flange bolt 31. Rocker cover 32. Rocker cover gasket 33. Valve seat insert, exhaust 34. Valve seat insert, intake
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AB 2002-09:3 11 Adjusting the valve clearance and unit injectors Specifications Tightening torques (See page 3 for general tightening torques) Special tools Valve clearance, intake valve (cold engine) 0.45 mm Valve clearance, exhaust valve (cold engine) 0.70 mm Dimension for PDE 31 unit injector (cold engine) 66.9+/-0.1 mm Dimension for PDE 32 unit injector (cold engine) 69.9+/-0.1 mm Adjusting screw lock nut on rocker arm for unit injector 39 Nm Adjusting screw lock nut on the valve rocker arm 35 Nm Screw for upper rocker cover 18 Nm Bolt for lower rocker cover 26 Nm Bearing bracket and rocker arm shaft 105 Nm Cable connection, unit injector 2 +/-0.2 Nm Number Description Illustration Tool board 99 309 Tool to rotate flywheel D 5 99 414 Setting tool Measuring tool cabinet 99 442 Setting tool Measuring tool cabinet 588 179 Torque screwdriver
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AB 2002-09:3 01:05-02 Adjusting the valve clearance Note: Check and adjust the valve clearance and unit injectors with the engine cold. - Use tool 99 309 to rotate the engine. - Check the valve clearance using a feeler gauge and use the adjusting screw on the rocker arm to set the correct clearance. - The intake valves are actuated by the short rocker arms and the exhaust valves by the long rocker arms. - Make sure the valve bridge is resting correctly against the valves. - The intake valve clearance should be 0.45 mm and exhaust valve clearance 0.70 mm. - See page 15 for the adjusting order. Adjusting the unit injector Important! The PDE 31 unit injector is adjusted using setting tool 99 414 or a digital sliding caliper. The PDE32 unit injector is adjusted using setting tool 99 442 or a digital sliding caliper. This adjustment is essential as a fault in the position of the unit injector can result in poor performance and possible breakdown. 1. Screw on the rocker arm adjusting screw 1 while measuring the distance between plane a and the top of the valve spring collar using a digital sliding caliper. The distance should be 66.9 mm for PDE31 and 69.9 for PDE32. See measurement B in the figure for identifying the injector. A= PDE31: 66.9 +/-0.1 mm PDE32: 69.9 +/-0.1 mm B = PDE31: 36.5 mm PDE32: 38.8 mm
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AB 2002-09:3 13 WARNING!! Take care when carrying out the adjustment if the dimension is well outside the adjustment dimension. The spring is pre-tensioned and can cause personal injury if it is released. PDE31: 2. Position setting tool 99 414 with the metal plate around the injector spring. 3. Finely adjust dimension A by simultaneously using a finger to sense that the small piston 2 is level with the flat upper surface of the tool. It is possible to sense differences of less than a tenth of a millimetre. 4. If tool 99 414 is not available: Measure the distance between plane a and the top of the valve spring collar using a digital sliding cal- iper. Adjust the position of the rocker arm with the adjusting screw until the distance is 66.9+/-0.1 mm. 5. Torque tighten the lock nut to 39 Nm. 6. The order in which the injector rockers are to be checked/adjusted is shown in the table on page 15. Piston above or below the flat surface. Adjustment necessary Piston level with the flat surface. The adjustment is correct
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AB 2002-09:3 01:05-02 PDE32: 7. Position setting tool 99 442 with the metal plate around the injector spring. 8. Finely adjust dimension A by simultaneously using a finger to sense that the small piston 2 is level with the flat upper surface of the tool. It is possible to sense differences of less than a tenth of a millimetre. 9. If tool 99 442 is not available: Measure the distance between plane a and the top of the valve spring collar using a digital sliding cali- per. Adjust the position of the rocker arm with the adjusting screw until the distance is 69.9+/-0.1 mm. 10. Torque tighten the lock nut to 39 Nm. 11. The order in which the injector rockers are to be checked/adjusted is shown in the table on page 15. Piston above or below the flat surface. Adjustment necessary Piston level with the flat surface. The adjustment is correct
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AB 2002-09:3 15 Order of adjustment Rotate the flywheel using tool 99 309 so that the mark on the flywheel is visible in the bottom window according to the table below. It is a good idea to mark the rocker arm with a pen after adjustment to keep track of what has already been adjusted. Torque tighten the lock nut on the rocker arm for the unit injector to 39 Nm and the lock nut for the valves to 35 Nm after adjusting. Mark on flywheel (degrees) Valve change on cylinder Adjust injector rocker arm on cylinder Adjust intake valve on cylinder Adjust exhaust valve on cylinder TDC Down (0°) 6 4 and 5 7 and 8 4 and 5 TDC Up (180°) 7 2 and 6 1 and 5 2 and 6 TDC Down (360°) 1 3 and 7 2 and 4 3 and 7 TDC Up (540°) 4 1 and 8 3 and 6 1 and 8
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AB 2002-09:3 01:05-02 Renewing the upper rocker cover gasket Removal 1. Clean the rocker cover and the surrounding area. 2. Remove the top part of the rocker cover. 3. Renew the rocker cover gasket. Fitting 1. Fit the upper part of the rocker cover. Torque tighten the screws to 18 Nm. Renewing the lower rocker cover gasket Removal 1. Clean the rocker cover and the surrounding area. 2. Remove the top part of the rocker cover. Note: All the valve mechanism components must be refitted in their original positions. Therefore, mark the parts as they are removed. 3. Relieve the pressure on the valves by undoing the bolts on the rocker arm shaft alternately. WARNING!! Do not lean over the engine when removing the shaft with rocker arms. The unit injector spring is pre-tensioned and can come loose, causing personal injury. Note: If the spring comes loose from the unit injector, the unit injector must be renewed.
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AB 2002-09:3 17 4. Remove the rocker arm shaft assembly. 5. Remove the bearing bracket. 6. Detach the cables on the unit injector. The screws cannot be removed but unscrew them as much as possible. Detach the cable grom- met and remove the cable from the rocker cover. 7. Remove the lower rocker cover. 8. Renew the lower rocker cover gasket. Press in place the new gasket in the lower rocker cover.
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AB 2002-09:3 01:05-02 Fitting Tightening torques Tools 1. Renew the gasket and fit the lower rocker cover. Tighten the bolts to 26 Nm. Note: If the spring has come loose from the unit injector the unit injector must be renewed. Cable connection, unit injector 2 +/-0.2 Nm Bearing bracket and rocker arm shaft 105 Nm Upper rocker cover 18 Nm Lower rocker cover 26 Nm Number Description Illustration 588 179 Torque screwdriver
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AB 2002-09:3 19 2. Screw on the cable grommet in the lower rocker cover and run the cable to the unit injector. Fit the seal to the rocker cover. 3. Refit the cables on the unit injector. Their rel- ative position is not important. Use torque screwdriver 588 179 to tighten the screws to 2 Nm. Important! Use torque screwdriver 588 179 to avoid the risk of shearing off the screws. The entire unit injector must be renewed if the screws shear off. 4. Fit the bearing bracket and torque tighten the bolts to 105 Nm. Important! Make sure the pushrods are positioned correctly. Refer to the illustration. 5. Refit the rocker arm shaft. Screw in the bolts alternately so that they are tightened in paral- lel or one of the bolts may bend. Tighten the bolts to 105 Nm. 6. Check the valve clearance and unit injector setting as described in Adjusting the valve clearance and unit injector. 7. Refit the upper part of the rocker cover. Tighten the bolts to 18 Nm.
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AB 2002-09:3 01:05-02 DC engine: 1. Open the bleed nipple on the fuel filter and empty the fuel system by opening and connecting hoses to the unions on the rear edge of the fuel manifolds and opening the unions. 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. Help protect our environment! Use a suitable container. 2. Remove the inlet pipe between the air filter and the turbocharger. Removing cylinder heads 1 and 2: 3. Remove the control unit with holder, cables and cable retainer, and the fuel filter. Removing cylinder heads 3 and 4: 4. Remove the crankcase ventilation unit. Cylinder head Removal Special tools Number Description Illustration Tool board 87 596 Slide hammer D 2
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