Scania DC11 Work Description

©

Scania CV AB 2011, Sweden

1 585 592

01:03-02

Issue 9

en-GB

11 and 12 litre engines

Work description

106 351

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Contents

Engine assembly General information.................................................. 4

Removing the engine................................................ 6

Fitting the engine.................................................... 14

Mounting the engine in an engine stand................. 20

Measuring the compression pressure...................... 22

Cylinder head ................................................................................ 25

Removing the cylinder head................................... 26

Fitting the cylinder head......................................... 32

Checking and adjusting the valve clearance........... 36

Removing valves .................................................... 38

Fitting valves .......................................................... 38

Checking and machining valves............................. 39

Renewing the valve stem seal................................. 40

Renewing the valve seats........................................ 41

Machining the cylinder head .................................. 43

Renewing the valve guides..................................... 48

Renewing the injector sleeves ................................ 49

Renewing the unit injector sleeves......................... 51

Cylinder block Reconditioning ....................................................... 54

Removing the cylinder liners.................................. 55

Fitting the cylinder liners........................................ 56

Measuring and machining the cylinder liner

height ...................................................................... 57

Renewing the rear crankshaft seal.......................... 63

Renewing camshaft bearings.................................. 65

Flywheel housing ................................................................................ 71

Removing the flywheel housing............................. 72

Fitting the flywheel housing................................... 72

Fan coupling Removing the fan coupling .................................... 76

Fitting the fan coupling .......................................... 76

Renewing the bearing in the fan coupling.............. 77

Renewing the front crankshaft seal ........................ 80

Closed crankcase ventilation Troubleshooting...................................................... 83

Renewing the diaphragm........................................ 85

Crank mechanism ................................................................................ 86

Removing a piston.................................................. 87

Fitting a piston........................................................ 89

Renewing a piston .................................................. 91

Checking the connecting rod..................................94

Bearing bush in connecting rod.............................. 96

Flywheel Removing the flywheel........................................... 98

Fitting the flywheel................................................. 99

Support bearing .................................................... 101

External ring gear ................................................. 102

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Crankshaft Removing the crankshaft...................................... 103

Fitting the crankshaft............................................ 104

Machining crankshafts.......................................... 105

Timing gear .............................................................................. 108

Removing the intermediate gear........................... 110

Fitting the intermediate gear................................. 112

Renewing the bearing in the intermediate gear

for the compressor ................................................ 113

Renewing the bearing in the intermediate gear

for the camshaft .................................................... 114

Removing the camshaft gear ................................ 115

Fitting the camshaft gear ...................................... 116

Removing the crankshaft gear.............................. 117

Fitting the crankshaft gear.................................... 118

Removing the camshaft ........................................ 119

Fitting the camshaft .............................................. 120

Checking the camshaft setting.............................. 123

Lubrication system General ................................................................. 124

Measuring the oil pressure.................................... 125

Oil filter ................................................................ 127

Oil cooler.............................................................. 128

Oil filter unit......................................................... 130

Oil pump............................................................... 135

Turbocharger .............................................................................. 136

Measuring radial and axial clearance ................... 138

Checks after breakdown ....................................... 140

Belt transmission .............................................................................. 141

Contents

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Engine assembly

General information

1 Smoke values.

2 Instruction plate.

3 A Engine type, Engine serial number (on engines built before November 2000).

3 B Engine type (on engines built from November 2000 onwards).

4 Engine serial number, stamp.

DC11 DC12

Cylinder diameter 127.0 mm 127.0 mm

Piston stroke 140.0 mm 154.0 mm

Cubic capacity 10.64 dm

3

11.7 dm

3

No. of main bearings 7 7

Firing sequence 1-5-3-6-2-4 1-5-3-6-2-4

3B

A

Typ/Type DSC 12 01

Variant

Motor/Engine No

Made by

Valve clearance cold engine

Inlet

Outlet

Pump timing

:

mm

:

mm

0.45

0.70

15

:

o

A

B

: DSC 1201

: 0.75

123 45XX

before T.D.C.

1 2

3

4

Variant

Made by

Type DSC 12 01

119 867

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Lubrication

Engine oil must be applied to all moving parts

before fitting unless otherwise stated.

Compression ratio 18:1 18.5:1

Direction of rotation (engine viewed from the rear) Anticlockwise Anticlockwise

Engine speed, low idling 500 rpm 500 rpm

Engine speed, high idling 2,400 rpm 2,400 rpm

Oil capacity 28-35 litres 28-35 litres

Oil grade refer to booklet

00:03-09

refer to booklet

00:03-09

Total weight without oil and water 1,010-1,030 kg 1,020-1,040 kg

DC11 DC12

Engine assembly

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Removing the engine

Comments

1 Drain Oil and coolant.

2 Remove The battery cover and detach the

negative cable.

3 Remove The protective casing.

4 Remove Connectors 13 (C2) and 14 (C188). Connector 14 (C188) is only fitted

on vehicles without a coordinator.

5 Disconnect The positive and negative cables.

6 Remove The clamps to release electrical cables

13 and 14.

7 Tilt the cab according to instructions, refer to Group 18.

8 Remove The mudguards.

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120232

4

5

3

6

Engine assembly

120231

8

2

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Right-hand side:

Comments

9 Pull through the detached cable harnesses and place them on the engine.

10 Remove The turbocharger induction pipe. The compressor air pipe and the

crankcase ventilation hose must be

detached from the induction pipe.

11 Cover the air filter.

12 Detach The radiator water hoses. The number of hoses varies

depending on the design. Only one

hose is illustrated.

13 Detach The flexible hose for the charge air pipe.

14 Lift off The poly-V-belt. Only on vehicles with air

conditioning.

15 Detach The air hose for the exhaust brake

cylinder.

16 Remove The exhaust pipe.

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120234

12

9

13

10

16

15

11

14

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Left-hand side:

Note: When removing the gearbox, engine

support 99 318 must be used to support the

engine.

Comments

17 Detach The flexible hose for the charge air pipe.

18 Detach The AC compressor and move it aside. 4 bolts.

19 Detach The compressor feed pipe.

20 Detach The water heater hose. Only on vehicles equipped with a

water heater.

21 Detach The ground connection.

22 Detach The fuel pipes.

23 Detach The oil filler hose.

24 Detach The oil dipstick.

25 Detach The starter motor ground connection.

26 Detach The pressure regulator pipe. Detach at the compressor.

27 Detach The positive starter motor cable.

28 Detach The hydraulic pump and move it aside. 5 bolts in the flange.

29 Remove The gearbox. Refer to Group 5.

100329

99 318

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120235

17

18

21

22

25

18

19

23

24

26

27

28

Engine assembly

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IMPORTANT! The lifting eyes on the engine are

not designed to lift the whole vehicle and

therefore must not be used for this purpose. All

three lifting eyes must be used when lifting the

engine.

On vehicles built from May 2000 onwards, the

rear lifting eyes have been removed. They may be

ordered as a spare part, part number 1 360 442.

30 Fasten lifting chain 98 094 to the rear

lifting eyes.

01_1397

98 094

31 Fasten ratchet lever hoist 587 308 to the

front lifting eye.

01 1398

587 308

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IMPORTANT! The lifting eyes are designed to

cope with a maximum inclination angle of 30°,

when lifting an engine with the gearbox removed.

For engines without the gearbox removed, the

maximum angle is 20°.

Engine assembly

32 Remove the bolts in the engine brackets

and lift out the engine.

01_1399

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Fitting the engine

Tightening torques

Left-hand side:

Engine bracket bolts M14: 47 Nm

M16: 130 Nm+90°

V-clamp for the charge air cooler 8 Nm

1 Lift the engine so that the engine brackets are approx. 10 mm over the engine cushions.

2 Position the bolts and lower the engine so that it rests on the engine cushions and engine

supports 99

318. Tightening torques: M14 bolts, 47 Nm and M16 bolts, 130 Nm+90°.

3 Fit the gearbox. Refer to Group 5.

Comments

4 Fit The hydraulic pump. Fit a new gasket.

5 Fit The positive starter motor cable.

6 Fit The pressure regulator pipe. At the compressor.

7 Fit The starter motor ground connection.

8 Fit The oil dipstick.

9 Fit The oil filler hose.

10 Fit The fuel pipes. RV= upper, RA= lower.

11 Fit The ground connection. At the compressor.

12 Fit The water heater hose.

13 Fit The compressor feed pipe.

14 Fit The AC compressor.

15 Fit The flexible hose for the charge air pipe. Tightening torque, 8 Nm.

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15

120545

15

14

11

10

7

12

13

9

8

6

5

4

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Right-hand side:

Comments

16 Fit The exhaust pipe.

17 Fit The air hose for the exhaust brake

cylinder.

18 Fit The radiator water hoses. Only one hose is illustrated.

19 Fit The flexible hose for the charge air

cooler.

Tightening torque, 8 Nm.

20 Fit The turbocharger induction pipe. Tightening torque, 10 Nm, must

be applied at max. 100 rpm.

21 Fit The compressor air pipe and the

crankcase ventilation hose on the

induction pipe.

22 Fit The poly-V-belt.

23 Route Cables 13 and 14 to the front of the cab.

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17

120544

18

23

19

20

16

17

22

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Comments

24 Fit The mudguards.

25 Tilt the cab back to the driving position.

26 Fit The positive and negative cables.

27 Fit Connectors 13(C2) and 14(C188) Connector 14 (C188) is only fitted

on vehicles without a coordinator.

28 Fit All cables with clamps.

29 Fit The plastic cover over the central

electric unit.

30 Fit The negative cable on the battery and

the battery cover.

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120542

30

24

120543

27

26

29

28

Engine assembly

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Mounting the engine in an engine stand

Engines with injection pump

Remove: Pos.

Fuel filter A

Injection pump F

Bracket E

Starter motor D

Required brackets

Engines with PDE unit injectors

Remove: Pos.

Fuel filter A

Control unit B

Compressor C

Starter motor D

Required brackets

Engines with HPI unit injectors

Securely bolt the engine to the engine stand as

illustrated. Use tool 99 331.

Remove: Pos.

Fuel filter A

Control unit B

Compressor C

Starter motor D

Feed pump G

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