Scania Engine Manual MT41 (EN)

Engine Ch 1 page Chapter 1 Engine SHOP MANUAL MT41 - 12.2004

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Engine Ch 1 page 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 810001 - 810052.......................................................................18 Use of diagnostic kit, machine 810053 - ....................................................................................20 Measurement...............................................................................................................................23 Ecom standard settings code......................................................................................................26 Engine control unit, ECU......................................................................

29 Wiring and cable duct..................................................................................................................30 Throttle position sensor...............................................................................................................30 Positions of sensors for ECU.......................................................................................................31 Diagnostic lamp and switch (810001 - 810035)...........................................................................32 Diagnostic lamp and switch (810036 - ).......................................................................................33 Fault codes..................................................................................................................................34 How to read fault codes from the ECU control unit......................................................................35 Flash codes tables.......................................................................................................................37 Overview of flash codes for coordinator.......................................................................................39 Renewing the control unit............................................................................................................41 Removing the ECU wiring...........................................................................................................42 Cylinder head........................................................................................

46 Special tools................................................................................................................................46 Cylinder head, parts view.............................................................................................................47 Valve mechanism.........................................................................................................................48 Dismantling .................................................................................................................................53 Renewing the valve stem seal.....................................................................................................53 Replacement of valve seats.........................................................................................................54 Machining the valve seats insert..................................................................................................55 Renewing the valve guides.........................................................................................................57 Renewing PDE unit injector sleeves............................................................................................58 Assembly ....................................................................................................................................59 Fitting...........................................................................................................................................59 PDE Injectors.........................................................................................

60 Fitting the PDE injector................................................................................................................60 Adjusting unit injectors.................................................................................................................64 Adjusting the valve clearance and unit injectors..........................................................................66 Checking, adjusting the PDE injector rocker arms.......................................................................67 Turbocharger.........................................................................................

69 General .......................................................................................................................................70 Special tools................................................................................................................................71 Measuring radial clearance and axial clearance .........................................................................72 Renewing the turbocharger.........................................................................................................74 Continuation next page SHOP MANUAL MT41 - 12.2004

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Engine Ch 1 page 3 Pistons and cylinder liners..................................................................

75 Special tools................................................................................................................................76 Connecting rods...........................................................................................................................77 Removing and dismantling connecting rods and pistons.............................................................78 Renewal of bearing bushing in connecting rod............................................................................80 Pistons.........................................................................................................................................82 Assembling piston and connecting rod........................................................................................84 Cylinderblock........................................................................................

85 Cylinder liner................................................................................................................................85 Removing the cylinder liners........................................................................................................87 Measuring the cylinder liner height..............................................................................................88 Fitting the cylinder liners..............................................................................................................89 Fitting the piston and connecting rod...........................................................................................90 Flywheel and flywheel housing...........................................................

92 Special tools................................................................................................................................93 Removing the flywheel.................................................................................................................93 Renewing the rear crankshaft seal..............................................................................................95 Removing the flywheel housing...................................................................................................95 Fitting flywheel housing...............................................................................................................96 Fitting the flywheel.......................................................................................................................98 Timing gears.........................................................................................

99 Gear drive....................................................................................................................................99 Belt drive collant pump, generator and AC compressor.............................................................100 Renewing the seal in the front cover..........................................................................................101 Crankshaft damper....................................................................................................................102 Timing gear, view exploded.......................................................................................................103 Special tools........................................................................................

104 Intermediate gear .....................................................................................................................105 Camshaft gear ..........................................................................................................................108 Crankshaft gear ........................................................................................................................109 Camshaft ............................................................................................

110 Replacement of camshaft bearing.............................................................................................111 Crankshaft .......................................................................................... 118 Removal.....................................................................................................................................119 Fitting.........................................................................................................................................122 Lubrication system.............................................................................

123 Oil pump....................................................................................................................................123 Lubrication oilways ..................................................................................................................124 Oil pressure...............................................................................................................................125 Oil cooler, engine ......................................................................................................................126 Oil cooler view...........................................................................................................................127 Renewing seals.........................................................................................................................128 Oil filter.......................................................................................................................................129 Centrifugal oil cleaner .......................................................................

130 Dismantling and assembly.........................................................................................................131 Cooling fan.......................................................................................... 135 Continuation next page SHOP MANUAL MT41 - 12.2004

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Engine Ch 1 page Cooling system...................................................................................

136 View of the cooling system........................................................................................................136 Circulation..................................................................................................................................137 View of the radiator system.......................................................................................................137 Disassemble the cooling unit.....................................................................................................138 Thermostat and thermostat housing..........................................................................................140 Thermostat................................................................................................................................141 Coolant pump............................................................................................................................142 External cleaning.......................................................................................................................146 Internal cleaning........................................................................................................................146 Specifications.....................................................................................

148 General information...................................................................................................................148 Electrical system........................................................................................................................148 Cylinder head.............................................................................................................................149 Turbocharger .............................................................................................................................151 Pistons and cylinder liners.........................................................................................................151 Connecting rods.........................................................................................................................152 Flywheel and flywheel housing..................................................................................................152 Timing gear................................................................................................................................153 Lubrication system ....................................................................................................................154 Troubleshooting tables......................................................................

155 White smoke..............................................................................................................................155 White smoke, water vapour.......................................................................................................155 Black smoke when running/under load......................................................................................156 Black smoke on starting.............................................................................................................157 Blue smoke................................................................................................................................157 Fuel in the oil.............................................................................................................................157 Oil in coolant .............................................................................................................................158 Coolant/water in oil ...................................................................................................................159 Low oil pressure.........................................................................................................................160 High oil pressure (Engine warmed up)......................................................................................162 Abnormal wear (liner, piston rings, etc.)....................................................................................162 Vibration, no driven components engaged................................................................................163 Delivery pipe fractures...............................................................................................................164 External corrosion on cylinder liner............................................................................................164 Engine difficult to start...............................................................................................................164 Fluid stroke................................................................................................................................165 Knocking noise..........................................................................................................................165 High oil consumption.................................................................................................................167 High fuel consumption...............................................................................................................168 Low compression.......................................................................................................................168 Low engine output.....................................................................................................................168 Hot engine.................................................................................................................................170 Cold engine................................................................................................................................171 Coolant loss...............................................................................................................................171 Polluted coolant.........................................................................................................................171 Engine heater............................................................................................................................172 High oil temperature..................................................................................................................172 High exhaust temperature..........................................................................................................173 SHOP MANUAL MT41 - 12.2004

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