Scania 9-Series Work Description
  1. Manuals
  2. Brands
  3. Scania Manuals
  4. Engine
  5. 9-Series
  6. Work description
Scania 9-Series Work Description

Scania 9-Series Work Description

Scania 9-series industrial and marine engines
Hide thumbs
Table of Contents

Advertisement

Quick Links

01:01-02
en
Issue 2
program 96
Industrial & Marine Engines
Work Description - 9-series engine
Industrial and Marine engines
Part No.
1 588 468
©
Scania CV AB 1997-05:2

Advertisement

Table of Contents
loading
Need help?

Need help?

Do you have a question about the 9-Series and is the answer not in the manual?

Questions and answers

Subscribe to Our Youtube Channel

Related Manuals for Scania 9-Series

Summary of Contents for Scania 9-Series

  • Page 1 01:01-02 Issue 2 program 96 Industrial & Marine Engines Work Description - 9-series engine Industrial and Marine engines Part No. 1 588 468 © Scania CV AB 1997-05:2...

  • Page 2: Table Of Contents

    Removing and fitting flywheel housing..42 Fitting flywheel ..... . . 43 © 01:01-02 Scania CV AB 1997-05:2...

  • Page 3: Cylinder Head

    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 © 01:01-02 Scania CV AB 1997-05:2...
  • Page 4 99 310 Sleeve 98 503 Drift 587 272 Cylinder liner cutter with grooving 98 622 Press drift tool 99 051 Fixture 587 277 Valve seat cutter 99 074 Impact drift 587 692 Engine stand © 01:01-02 Scania CV AB 1997-05:2...

  • Page 5: Valve Clearance

    TDC for No. 6 cylinder is set. The remaining valves can now be adjusted: cylinder 2 exhaust Intake valve cylinder 3 intake Exhaust valve cylinder 4 exhaust cylinder 5 intake cylinder 6 exhaust and intake © 01:01-02 Scania CV AB 1997-05:2...

  • Page 6: Compression

    Compression tester 98 249 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. © 01:01-02 Scania CV AB 1997-05:2...
  • Page 7 3. Assemble the parts. Make sure that O-ring 19 17 Valve is not damaged. Fully screw on valve seat 18 18 Valve seat so that it seals against measuring rod 4. 19 O-ring Measuring rod © Scania CV AB 1997-05:2 01:01-02...

  • Page 8: Removing

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

  • Page 9: Dismantling

    - 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 © 01:01-02 Scania CV AB 1997-05:2...
  • Page 10 New intake valve and new valve seat ring New intake valve and valve seat ring machined to maximum New exhaust valve and valve seat ring New exhaust valve and new valve seat ring machined to maximum. Surfaces at arrows aligned © 01:01-02 Scania CV AB 1997-05:2...
  • Page 11 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. © 01:01-02 Scania CV AB 1997-05:2...
  • Page 12 Fit the guide spindle and turn the feed screw to its upper position. 3. Select and fit cutter. 4. Undo the speed lock and move the pivot plate to the upper position using the adjusting screw. © 01:01-02 Scania CV AB 1997-05:2...
  • Page 13 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. © 01:01-02 Scania CV AB 1997-05:2...
  • Page 14 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. © 01:01-02 Scania CV AB 1997-05:2...
  • Page 15 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. © 01:01-02 Scania CV AB 1997-05:2...
  • Page 16 114.4 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 © 01:01-02 Scania CV AB 1997...

  • Page 17: Assembly

    • 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.) © 01:01-02 Scania CV AB 1997...
  • Page 18 99 310. Fit leak-off pipes, coolant manifold, intake manifold and exhaust mani- fold 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. © 01:01-02 Scania CV AB 1997...

  • Page 19: Turbocharger

    12. Hose clip 13. Elbow union 14. Clamp 15. Clamp 16. Flange bolt 17. Flange bolt 18. Turbocharger Special tools 98 075 Dial gauge 587 107 Out-of-true indicator 587 025 Filter wrench 587 250 Measuring stand © 01:01-02 Scania CV AB 1997...

  • Page 20: General

    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. © 01:01-02 Scania CV AB 1997...

  • Page 21: Measuring Radial Clearance And Axial Clearance

    4. Repeat measurements three times on each side. Measuring turbine wheel radial clearance. 5. If any wheel rubs against the housing, despite radial clearance being within tolerance, the turbocharger should be changed. Measuring compressor wheel radial clearance © 01:01-02 Scania CV AB 1997...

  • Page 22: If The Turbocharger Is Not Working

    4. Check the lubrication oil return pipe from the turbocharger for blockage or deformation. 9. Check that the exhaust brake, if fitted, works correctly. 5. Check the oil delivery pipe to the turbo- charger for any blockage, deformation and leakage under pressure. © 01:01-02 Scania CV AB 1997...

  • Page 23: Changing 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. © 01:01-02 Scania CV AB 1997...

  • Page 24: Pistons And Cylinder Liners

    4. Oil scraper ring 14. Pin 5. Retaining ring 15. Key 6. Gudgeon pin 16. Cylinder liner 7. Connecting rod 17. Seal 8. Flange bolt 18. O-ring 9. Bushing 19. Loose ring 10. Pin © 01:01-02 Scania CV AB 1997...
  • Page 25 99 168 Dismantling tool 98 323 Piston ring compressor 587 110 Connecting rod tester 98 515 Pressing tool 587 272 Cylinder liner cutter 99 066 Puller for cylinder liner 587 309 Piston ring expander © 01:01-02 Scania CV AB 1997...

  • Page 26: Removal Of Loose Ring In Cylinder Liner

    Note The piston cooling nozzle must not be damaged. If the jet of oil does not strike the piston in the right place, there could be a danger of engine breakdown. Damaged nozzles must be changed. © 01:01-02 Scania CV AB 1997...
  • Page 27 Bent connect- ing rods must not be straightened. 6. Push out the gudgeon pin using drift 87 362. © 01:01-02 Scania CV AB 1997...
  • Page 28 - Turn the connecting rod round and measure the corresponding dimension. - The difference should be no more than 0.6 mm. Checking whether the connecting rod is bent into an S shape © 01:01-02 Scania CV AB 1997...

  • Page 29: Assembling Piston And Connecting Rod

    Heat the piston to 100 C and place it on the connecting rod with the arrow pointing as shown in the figure. 7. Push in the gudgeon pin using drift 87 362. 8. Fit the second retaining ring. © 01:01-02 Scania CV AB 1997...

  • Page 30: Removing Cylinder Liner

    (A-B) as shown in the figure. - Measure each liner at two diametrically oppo- site points. A Measuring surface on cylinder liner B Measuring surface on cylinder block C Measuring tip D Cylinder liner height D = A-B © 01:01-02 Scania CV AB 1997...
  • Page 31 - Remove any burrs and measure the thickness of the shims using a micrometer. Only use one shim, i.e. a thick shim, instead of several thin ones. - Try to set liner height close to the upper limit of 0.33 mm. © 01:01-02 Scania CV AB 1997...
  • Page 32 0.12 mm 2. Clean contact surfaces between tool and block surface. Fit cutter in cutting head by lifting the speed feed ring. 3. Centre the tool with the centre roller. Connect the magnet (position 1). © 01:01-02 Scania CV AB 1997...
  • Page 33 6. Lift the speed feed ring and withdraw the bit until the point is just inside the liner seat sur- face. 7. Set the vertical feed screw to required depth. See point 1. © 01:01-02 Scania CV AB 1997...
  • Page 34 12. Measure the thickness of the shim with the tool’s micrometer. 13. Fit shim and cylinder liner. 14. Press down the cylinder liner with tension lugs and check cylinder liner height as per instructions. © 01:01-02 Scania CV AB 1997...

  • Page 35: Fitting Cylinder Liner

    Check that the O-rings are intact. 8. Check and adjust cylinder liner height as described in Measuring cylinder liner height and Adjusting cylinder liner height © 01:01-02 Scania CV AB 1997...

  • Page 36: Fitting Piston And Connecting Rod

    Check that connecting rod and cap have the same marking and that they are opposite each other. 10. Lubricate the bolts, fit them and tighten alter- nately in two stages. Stage 1: 50 Nm, stage 2: 110 Nm. © 01:01-02 Scania CV AB 1997...
  • Page 37 Damaged nozzles must be changed. 13. Fit the oil sump. 14. Fit the cylinder head. Tighten the cylinder head bolts as described in the Cylinder head section. © 01:01-02 Scania CV AB 1997...

  • Page 38: Flywheel And Flywheel Housing

    20. Hexagon bolt 31. Ball bearing (not stand- ard) 9. Tapping screw 21. Washer 32. Retaining ring (not 10. Stud 22. Guide sleeve (not stand- standard) ard) 11. Locknut 23. Oscillation damper 12. Washer © 01:01-02 Scania CV AB 1997...
  • Page 39 Program 96 Special tools 87 368 Puller bolts 98 321 Assembly tool 87 488 Guide pins 98 433 Drift © 01:01-02 Scania CV AB 1997...

  • Page 40: Removing Flywheel

    2. Clean contact surfaces on the flywheel using a wire brush. 3. Heat the new ring gear so that it is at an even temperature of about 100-150 °C. © 01:01-02 Scania CV AB 1997...
  • Page 41 Then screw in the set screw against the inner part and lock the wing nut. 3. Remove the tool and prise out the seal using tool 98 484 and a screwdriver. © 01:01-02 Scania CV AB 1997...

  • Page 42: Removing And Fitting Flywheel Housing

    Changing gasket behind flywheel housing 1. Remove the starter motor. 2. Remove the 16 bolts securing the flywheel housing. Remove flywheel housing. 3. Clean the sealing surface on the flywheel housing and engine. © 01:01-02 Scania CV AB 1997...

  • Page 43: Fitting Flywheel

    1. Fit two guide pins 87 488 in the end of the crankshaft. 2. Fit the flywheel on the crankshaft. Note Always use new bolts. 3. Fit the washer and tighten the bolts to 180 Nm. © 01:01-02 Scania CV AB 1997...

  • Page 44: Timing Gear

    10. Flange bolt 23. Crankshaft gear 36. Camshaft 11. Flange bolt 24. Injection pump gear 37. Tappet 12. Flange bolt 25. Bolt 38. Retaining ring 13. Flange bolt 26. Washer 39. Pushrod 40. Bushing © 01:01-02 Scania CV AB 1997...
  • Page 45 98 721 Assembly tool 87 596 Slide hammer 99 059 Slogging wrench 87 663 Support drift 99 088 Puller 87 665 Puller 99 093 Support drift 87 932 Drift 587 315 Puller 98 133 Washer © 01:01-02 Scania CV AB 1997...

  • Page 46: Crankshaft Seal

    Then unscrew the bolt a few turns and tap the hub in to loosen the cone. 6. Pull the hub off altogether. 7. Remove the seal using slide hammer 87 596. Protect the end of the crankshaft against scratches. © 01:01-02 Scania CV AB 1997...
  • Page 47 (60°) using slogging wrench 99 059. 6. Fit the oscillation damper and, if fitted, the belt pulley. Tighten the bolts to 110 Nm. 7. Refit the components that were removed ear- lier because they were in the way. © 01:01-02 Scania CV AB 1997...

  • Page 48: Timing Gear Cover

    9. Engine equipped with compressor: Remove the coolant manifold between the coolant pump and compressor. 10. Undo the three compressor retaining bolts in the timing gear housing. Extract the compres- sor and gear. © 01:01-02 Scania CV AB 1997...
  • Page 49 300 Nm and then a further sixth of a turn (60°) using slogging wrench 99 059. 7. Fit the oil sump with a new gasket. 8. Refit the components that were removed ear- lier because they were in the way. © 01:01-02 Scania CV AB 1997...

  • Page 50: Intermediate Gear

    2. Fit the washer and tighten the bolts to a torque of 39 Nm. 3. Fit the oil catcher on the end of the crankshaft. 4. Fit the timing gear cover. See Timing gear cover: Fitting. © 01:01-02 Scania CV AB 1997...

  • Page 51: Crankshaft Gear

    3. Fit the intermediate gear. See Intermediate gear: Fitting, points 1-2. 4. Fit the oil pump. 5. Fit oil catcher on end of crankshaft. 6. Fit the timing gear cover. See Timing gear cover: Fitting. © 01:01-02 Scania CV AB 1997...

  • Page 52: Camshaft Gear

    4. Check that the gear has cooled down. Secure the flywheel. Tighten the camshaft nut to a torque of 600 Nm. 5. Fit oil catcher on end of crankshaft. 6. Fit the timing gear cover. See Timing gear cover: Fitting. © 01:01-02 Scania CV AB 1997...

  • Page 53: Camshaft

    587 315 or can be left in place when the camshaft is extracted. 5. Remove the intermediate gear and the guide flange bolts. 6. Extract the camshaft from the front. Take care to avoid damaging cams and bearings. © 01:01-02 Scania CV AB 1997...
  • Page 54 TDC position is reached again. 6. Read the two dial gauges and compare the results with the values given below: Intake valve lifting height 0.55-1.65 mm Exhaust valve lifting height 0.50-1.50 mm © 01:01-02 Scania CV AB 1997...

  • Page 55: Crankshaft

    It is important that the fillet radius of the pivot pins is correct. After grinding the pivot pins, the oil hole ori- fices at the bearing surfaces should be rounded and polished. © 01:01-02 Scania CV AB 1997...
  • Page 56 6. Fit pistons, connecting rods and oil pump. 7. Fit the fan bearing and fan, oil sump, timing gear housing and intermediate gear. 8. Fit the flywheel and flywheel housing. 9. Fit the cylinder heads and pushrods. © 01:01-02 Scania CV AB 1997...

  • Page 57: Lubrication System

    3. Remove pipes and hoses connected to the coolant pump and oil cooler. 4. Detach the oil cooler and coolant pump from the engine. 5. Unscrew the coolant pump retaining bolts and remove pump and pump housing. © 01:01-02 Scania CV AB 1997...
  • Page 58 14. Connect the pipes and hoses that were previ- ously detached. 15. Fit the drive belt. 16. Fill the cooling system with coolant. See Oils, lubricants, liquids, section 0for the composition of the coolant. Fitting new O-rings and the loose flange © 01:01-02 Scania CV AB 1997...

  • Page 59: Oil Cleaner

    15. Retaining ring 25. O-ring 6. Rotor bowl 16. Cyclone housing 26. Gasket 7. Nut 17. Plug 27. Flange bolt 8. O-ring 18. Gasket 28. Oil filter 9. Nozzle 19. Plug 10. Cover 20. Gasket © 01:01-02 Scania CV AB 1997...
  • Page 60 4. Turn the rotor anticlockwise three turns by hand or, if this does not succeed, by placing a screwdriver between the outlet holes. © 01:01-02 Scania CV AB 1997...
  • Page 61 Make sure that they are not blocked or dam- aged. Change damaged nozzles. 11. Check that the bearings are not damaged. 12. Place the O-ring in position in the bowl. Change the O-ring if it is even slightly dam- aged. © 01:01-02 Scania CV AB 1997...
  • Page 62 16. Refit the rotor and spin it by hand to make sure that it turns easily. 17. Check the O-ring on the cleaner housing cover and fit the cover, securing it with the locknut. Tighten the locknut to 10 Nm. © 01:01-02 Scania CV AB 1997...

  • Page 63: Oil Pump

    26. Flange bolt 7. Pump wheel 17. Oil pump gearwheel 27. Suction pipe 8. Pump wheel 18. Piston 28. Bracket 9. Guide sleeve 19. Spring 29. Flange bolt 10. Flange bolt 20. Plug 30. Seal © 01:01-02 Scania CV AB 1997...

  • Page 64: Lifting The Engine

    - Fasten lifting chain 98 094 in the rear lifting eyes. - Fasten lever block 587 308 in the front lifting eyes. Important The lifting eyes are sized for a maxi- mum lifting angle of 30°. © 01:01-02 Scania CV AB 1997...

  • Page 65: Specifications

    Head angle ..........19.4°-19.6° Minimum dimension A for machined valve, page 10 ... . 3.0 mm © 01:01-02 Scania CV AB 1997...
  • Page 66 Surface quality ......... . 0.8 Ra Oil hole diameter drilled to same diameter as in rocker arm. © 01:01-02 Scania CV AB 1997...

  • Page 67: Turbocharger

    ........0.035 mm © 01:01-02 Scania CV AB 1997...

  • Page 68: Flywheel And Flywheel Housing

    Connecting rod bolts (oiled threads)......20 Nm + 90° Flywheel and flywheel housing Flywheel Maximum machining of contact surface for plate: See group 4, Clutch Ring gear Heated to 100 - 150 °C before fitting. © 01:01-02 Scania CV AB 1997...

  • Page 69: Timing Gear

    Axial clearance ......... 0.15 - 0.30 mm © 01:01-02 Scania CV AB 1997...
  • Page 70 3.46 - 3.51 mm Oversize 2 3.51 - 3.56 mm Oversize 3 3.64 - 3.69 mm Oversize 4 3.89 - 3.94 mm Oversize 5 4.27 - 4.32 mm Axial clearance 0.14 - 0.37 mm © 01:01-02 Scania CV AB 1997...

  • Page 71: Lubrication System

    Oil cleaner Permitted thickness of deposits on wall of bowl ....20 mm Oil filter Use only genuine Scania filters (screwed on by hand). © 01:01-02...
  • Page 72 Banjo bolt ..........23 Nm © 01:01-02 Scania CV AB 1997...

  • Page 73: Special Tools

    98 421 Socket wrench 98 433 Drift 39, 40 98 500 Shank 4, 11 98 503 Drift 98 515 Pressing tool 28, 33 98 622 Press drift 4, 14 98 721 Assembly tool 45, 47 © 01:01-02 Scania CV AB 1997...
  • Page 74 25, 31, 32, 33, 34 grooving tool 587 277 Valve seat cutter 4, 11, 1 587 308 Lever block 587 309 Piston ring pliers 25,27 587 315 Puller 45, 52, 53 587 692 Engine stand © 01:01-02 Scania CV AB 1997...

Table of Contents

Save PDF