Scania Engine Manual (EN)

Engine Tier-3 710655- Ch 1 page Chapter 1 Engine SHOP MANUAL MT26-31 - 06.2005

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Engine Tier-3 710655- Ch 1 page 2 Chapter 1 Engine Index Removal of engine assembly................................................................. 5 Lifting the engine.........................................................................................................................11 Engine identification............................................................................ 12 Fuel system...........................................................................................

13 Schematic diagram of the fuel system.........................................................................................13 Overflow valve..............................................................................................................................13 General........................................................................................................................................14 FUEL............................................................................................................................................14 Fuel filter......................................................................................................................................15 Water separating prefilter.............................................................................................................15 Feed pump...................................................................................................................................17 Diagnostic prosedure...........................................................................

18 Use of diagnostic kit, machine.....................................................................................................18 Measurement...............................................................................................................................21 Ecom standard settings code......................................................................................................24 Engine control unit, ECU......................................................................

27 Wiring and cable duct..................................................................................................................28 Throttle position sensor...............................................................................................................28 Positions of sensors for ECU.......................................................................................................29 Diagnostic lamp and switch.........................................................................................................31 Fault codes..................................................................................................................................32 How to read fault codes from the ECU control unit......................................................................33 Flash codes tables.......................................................................................................................35 Overview of flash codes for coordinator.......................................................................................37 Renewing the control unit............................................................................................................39 Removing the ECU wiring...........................................................................................................40 Cylinder head........................................................................................

44 Special tools................................................................................................................................44 Cylinder head, parts view.............................................................................................................45 Valve mechanism.........................................................................................................................46 Dismantling .................................................................................................................................51 Renewing the valve stem seal.....................................................................................................51 Replacement of valve seats.........................................................................................................52 Machining the valve seats insert..................................................................................................53 Renewing the valve guides.........................................................................................................55 Renewing PDE unit injector sleeves............................................................................................56 Assembly ....................................................................................................................................57 Fitting...........................................................................................................................................57 PDE Injectors.........................................................................................

58 Fitting the PDE injector................................................................................................................58 Adjusting unit injectors.................................................................................................................62 Adjusting the valve clearance and unit injectors..........................................................................64 Checking, adjusting the PDE32 injector rocker arms (I)..............................................................65 Turbocharger.........................................................................................

67 General .......................................................................................................................................68 Special tools................................................................................................................................69 Measuring radial clearance and axial clearance .........................................................................70 Renewing the turbocharger.........................................................................................................72 Continuation next page SHOP MANUAL MT26-31 - 06.2005

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Engine Tier-3 710655- Ch 1 page Pistons and cylinder liners..................................................................

73 Special tools................................................................................................................................74 Connecting rods...........................................................................................................................75 Removing and dismantling connecting rods and pistons.............................................................76 Renewal of bearing bushing in connecting rod............................................................................78 Pistons.........................................................................................................................................80 Assembling piston and connecting rod........................................................................................82 Cylinderblock........................................................................................

83 Cylinder liner................................................................................................................................83 Removing the cylinder liners........................................................................................................85 Measuring the cylinder liner height..............................................................................................86 Fitting the cylinder liners..............................................................................................................87 Fitting the piston and connecting rod...........................................................................................88 Flywheel and flywheel housing...........................................................

90 Special tools................................................................................................................................91 Removing the flywheel.................................................................................................................91 Renewing the rear crankshaft seal..............................................................................................93 Removing the flywheel housing...................................................................................................93 Fitting flywheel housing...............................................................................................................94 Fitting the flywheel.......................................................................................................................96 Timing gears.........................................................................................

97 Gear drive....................................................................................................................................97 Belt drive collant pump, generator and AC compressor...............................................................98 Renewing the seal in the front cover............................................................................................99 Crankshaft damper....................................................................................................................100 Timing gear, view exploded.......................................................................................................101 Special tools........................................................................................

102 Crankshaft seal..........................................................................................................................103 Timing gear cover......................................................................................................................105 Intermediate gear......................................................................................................................107 Crankshaft gear ........................................................................................................................108 Camshaft gear ..........................................................................................................................109 Camshaft ............................................................................................

110 Crankshaft........................................................................................... 112 Lubrication system.............................................................................

114 Oil pump....................................................................................................................................114 Lubrication oilways ..................................................................................................................115 Oil pressure...............................................................................................................................116 Oil cooler, engine ......................................................................................................................117 Oil cooler view...........................................................................................................................118 Renewing seals.........................................................................................................................119 Oil filter.......................................................................................................................................120 Centrifugal oil cleaner .......................................................................

121 Dismantling and assembly.........................................................................................................122 Cooling fan.......................................................................................... 126 Continuation next page SHOP MANUAL MT26-31 - 06.2005

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Engine Tier-3 710655- Ch 1 page Cooling system...................................................................................

127 View of the cooling system........................................................................................................127 Circulation..................................................................................................................................128 View of the radiator system.......................................................................................................128 Disassemble the cooling unit.....................................................................................................129 Thermostat and thermostat housing..........................................................................................131 Thermostat................................................................................................................................132 Coolant pump............................................................................................................................133 External cleaning.......................................................................................................................137 Internal cleaning........................................................................................................................137 Specifications.....................................................................................

138 General information...................................................................................................................138 Cylinder head.............................................................................................................................140 Turbocharger .............................................................................................................................142 Pistons and cylinder liners.........................................................................................................142 Connecting rods.........................................................................................................................143 Flywheel and flywheel housing..................................................................................................143 Timing gear................................................................................................................................144 Lubrication system ....................................................................................................................145 Troubleshooting tables......................................................................

146 White smoke..............................................................................................................................146 White smoke, water vapour.......................................................................................................146 Black smoke when running/under load......................................................................................147 Black smoke on starting.............................................................................................................148 Blue smoke................................................................................................................................148 Fuel in the oil.............................................................................................................................148 Oil in coolant .............................................................................................................................149 Coolant/water in oil ...................................................................................................................150 Low oil pressure.........................................................................................................................151 High oil pressure (Engine warmed up)......................................................................................153 Abnormal wear (liner, piston rings, etc.)....................................................................................153 Vibration, no driven components engaged................................................................................154 Delivery pipe fractures...............................................................................................................155 External corrosion on cylinder liner............................................................................................155 Engine difficult to start...............................................................................................................155 Fluid stroke................................................................................................................................156 Knocking noise..........................................................................................................................156 High oil consumption.................................................................................................................158 High fuel consumption...............................................................................................................159 Low compression.......................................................................................................................159 Low engine output.....................................................................................................................159 Hot engine.................................................................................................................................161 Cold engine................................................................................................................................162 Coolant loss...............................................................................................................................162 Polluted coolant.........................................................................................................................162 Engine heater............................................................................................................................163 High oil temperature..................................................................................................................163 High exhaust temperature..........................................................................................................164 Low charge air pressure............................................................................................................164 Low fuel pressure......................................................................................................................165 Low system voltage...................................................................................................................165 High system voltage..................................................................................................................165 External oil leakage...................................................................................................................166 External fuel leakage.................................................................................................................166 External coolant leakage...........................................................................................................167 Oil pressed out via crankcase ventilation...................................................................................167 Turbocharger breakdown...........................................................................................................167 SHOP MANUAL MT26-31 - 06.2005

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