02-25 Coolant Pump: Complete - Tightening Torques

Engine no.
: 6642331
02-25 Coolant pump

Complete - Tightening torques
Renewal - Coolant hoses
Renewal - Renewing the coolant pump on 9 and 13 litre engines

Note!
Tightening torques for the engine are
found in section 01-00, Engine assembly.
Renewal - Coolant hoses

Note!
Renew coolant hoses if there is clear
damage to the coolant hoses which were
removed.
Renewal
Renewing the coolant pump on 9 and 13 litre engines

Remove the coolant pump
1. Drain the cooling system according to the section for draining coolant.
80669703
2011-08-23 ?Scania CV 1 of 2
Engine no.: 6642331
2. Slacken off the belt transmission.

3. Remove upper idler roller.
4. Remove the bracket of the fan pulley.
5. Remove centre idler roller.
6. Undo and remove the pump with its housing.
7. Remove the pump housing from the pump
if the gasket must be renewed.
8066b677
Fit the coolant pump
1. Fit the pump gasket.

2. Screw the pump to the housing.
3. Fit the housing gasket.
4. Fit the housing and pump to the engine.
5. Secure the belt transmission.
6. Fill with coolant according to the work description for filling coolant.
2011-08-23 ?Scania CV 2 of 2
Engine no.: 6642331
02-30 T33, Coolant temperature sensor

Symbol
Location
Complete
Symbol
T33
806d74da
Location
T33
803c244e
Complete
The O-ring can be replaced separately. Check the O-ring, renew if necessary.
2011-08-23 ?Scania CV 1 of 1
Engine no.: 6642331
03-00 Accumulator
Location - Location, 9 and 13 litre engines with XPI
Location
Location, 9 and 13 litre engines with XPI
8076a11c

Note!
2011-08-23 ?Scania CV 1 of 1
Engine no.: 6642331
03-00 Calculating the fuel consumption factor

Explanation
Test stage:
Refuelling to reference level
Resetting route data
Driving and normal refuelling with monitoring of the number of litres added
Summary and calculation of the K factor
Recalibration
Explanation
If the fuel consumption displayed in the instrument cluster differs from the actual fuel
consumption, you can enter a calibration factor in SDP3 so that the display corresponds to the
actual fuel consumption.
The calibration factor is shown in the EMS, engine management system, under the
Adjustment tab.
The test that must be carried out to determine the difference between the displayed and actual
fuel consumption is described here. The procedure used to calculate the calibration factor, K,
which should be entered in SDP3, is also described.
Test stage:
1. Initial refuelling to a reference level.

2. Resetting of the route data in the instrument cluster.
3. Driving and normal refuelling with monitoring of the number of litres added.
4. Final refuelling to the reference level.
5. Summary and calculation of the K factor.
Refuelling to reference level
In order to assess the vehicle's actual fuel consumption as precisely as possible, it is

important for the fuel volume in the tank to be the same after refuelling for the first and the
last time.
It is therefore important to comply with the procedure below during the first and last
refuelling during the test.
z Select a reference level in the tank. Scania recommends reference level A, if possible
(see illustration). If it is difficult to see the level at point A, e.g. because of the
bodywork, reference level B can be used.
2011-08-23 ?Scania CV 1 of 4
Engine no.: 6642331
B
A
802c3324
Reference levels in the tank, select reference level A, if possible.

1. Filler pipe
Important!
Note the level that has been selected as a

reference level, so that the tank is filled to
the same level at the first and last
refuelling.
If the vehicle is equipped with double fuel tanks, the same procedure is carried out on
both tanks.
z Try to choose a filling station with a surface which is as level as possible. It is,
however, most important for the refuelling to be carried out in a consistent manner
when filling the tank for the first and last time during the test. This means that the
vehicle should be refuelled at the same filling station and positioned in the same
direction and on the same gradient.
2011-08-23 ?Scania CV 2 of 4
Engine no.: 6642331
Resetting route data
After refuelling for the first time, before the vehicle is driven, the vehicle route data should
be reset in the instrument cluster.
Note!
Use Route data 2. In order to ensure that
nobody can unintentionally reset the
information saved during the test, "Route
2" can be protected with a PIN code.
Resetting of the route data and activation of the PIN code is described in the Operator's
manual in Instruments and controls.
Driving and normal refuelling with monitoring of the number of litres

added
Drive the vehicle and refuel as usual. Write down the number of litres every time the vehicle
is refuelled, even including decimals.
Important!
Make sure that you write down the number

of litres every time you refuel. When the
test is completed, these values should be
added up to the total consumption.
Enter the volume including decimals.

In order to ensure that the value is as accurate as possible, the vehicle should be driven at
least 10,000 km during the test.
Note that the longer the distance driven, the more reliable the result. Therefore, drive more
than 10,000 km if it is possible for you to do so.
When the vehicle has been driven far enough, the tank should be filled to the same reference
level as when it was first refuelled. Unlike the first refuelling, the last refuelling should be
included in the test.
Summary and calculation of the K factor
z Add up the actual total fuel consumption.

z Read the number of litres consumed as displayed in the instrument cluster.
The fuel consumption factor is calculated as follows:

K= R/S
2011-08-23 ?Scania CV 3 of 4
Engine no.: 6642331
K= Calibration factor
R= Actual consumption, i.e. total number of litres added during the test.
S= Displayed consumption, i.e. total number of litres consumed as displayed in the
instrument cluster.
It is only possible to enter the calibration factor within the range 0.81 - 1.20.
Recalibration
If, after a period of driving, you think that the result from the calibration is unsatisfactory and
you would like to repeat the calibration, this can be carried out in two ways.
1. Reset the calibration factor to 1.0 using SDP3 before starting a new test.
2. Carry out the test and then multiply the new calibration factor by the current one set in
SDP3 to obtain a new calibration factor.
Example of option 2.
The first test resulted in the calibration factor = 0.94
The vehicle has been calibrated with the calibration factor, but after driving for some time it
appears that the consumption level read off still does not correspond to the actual
consumption level.
A second test is therefore carried out.
Test number two shows that there is still a difference of a factor of 0.96 between the read-off
and actual consumption levels.
The new calibration factor is calculated as follows:
0.94 x 0.96 = 0.9024
Since the calibration factor is shown to a precision of two decimal places, the new calibration
factor is 0.90.
2011-08-23 ?Scania CV 4 of 4
Engine no.: 6642331
03-00 Fuel system Scania XPI

Check - Measuring the fuel pressure on 9 and 13 litre engines with Scania XPI
Removal - Removing the fuel manifold on 9 and 13 litre engines with Scania XPI
Fitting - Fitting the fuel manifold on 9 and 13 litre engines with Scania XPI
Removal - Removing high pressure pipes and connections
Fitting - Fitting high pressure pipes and connections
Removal - Removing the high pressure pump on 9 and 13 litre engines
Fitting - Fitting the high pressure pump on 9 and 13 litre engines
Removal - Removing the gear on the high pressure pump
Removal - Removing torsion damper
Renewal - Renewing the cylinder head for the high pressure pump on engines with
the Scania XPI fuel system
Removal - Removing injectors
Fitting - Fitting injectors
Check - Checking Scania XPI injectors

Note!
Check
Measuring the fuel pressure on 9 and 13 litre engines with

Scania XPI
Important!
The fuel system is very sensitive to dirt. It

is therefore very important that everything
is as clean as possible when work is carried
out on the fuel system.
Do not use compressed air to blow
components in the fuel system clean.
When cleaning, rags or paper which shed
fibres must not be used. Use lint-free rags.
Clean tools before use.
2011-08-23 ?Scania CV 1 of 26
Engine no.: 6642331
Do not use worn chrome-plated tools as

flakes of chrome may come off.
Cover connections of removed components
with a lint-free rag and tape.
Tools
Tool
Number Designation Picture
board
99 362 Pressure gauge
804cf31d
The test connection for measuring fuel pressure is located on the high pressure pump (at the
arrow to the left in the illustration) and the fuel manifold (at the arrow to the right in the
illustration).
Measuring supply pressure
1. Connect pressure gauge 99 362 to the test connection on the high pressure pump and open
the test connection.
2. Crank with the starter motor for approximately 20 seconds. Read the pressure. The
pressure should be more than 3 bar.
3.
If the engine starts: Increase engine speed to 1,500 rpm. Read the pressure. The pressure
2011-08-23 ?Scania CV 2 of 26
Engine no.: 6642331
should be between 9 and 14 bar.

4. Switch off the engine, remove the pressure gauge and close the test connection.
Measuring fuel pressure at the fuel manifold when the engine can be
started
1. Connect pressure gauge 99 362 to the test connection on the fuel manifold and open the
test connection.
2. Start the engine. Read the pressure with the engine idling. The pressure should be below
0.8 bar.
3. If the pressure is above 0.8 bar, proceed as follows:
z Remove the overflow valve.
z Clean the overflow valve and check that it is not blocked.
z Fit the overflow valve.
z Bleed the fuel system by idling the engine for a while.
z Take a new reading.
If the pressure of the new reading exceeds 0.8 bar, there is internal leakage in an injector.
4. Switch off the engine, remove the pressure gauge and close the test connection.
Measuring fuel pressure at the fuel manifold when the engine cannot be
started
1. Connect pressure gauge 99 362 to the test connection on the fuel manifold and open the
test connection.
2. Crank with the starter motor for approximately 20 seconds. Read the pressure. The value
should be below 0.8 bar.
3. If no value can be read after 20 seconds: Allow the starter motor to cool down and repeat
step 2.
Note!
If there is air in the filter housing, pressure
cannot build up. Bleed the filter housing
and try again.
4. Remove the pressure gauge and close the test connection.
Removal
Removing the fuel manifold on 9 and 13 litre engines with

Scania XPI
2011-08-23 ?Scania CV 3 of 26
Engine no.: 6642331
Important!

8049a7f5
1. Undo the brackets 1 and move the electrical cables to one side.
2. Remove the return pipes 2 and 3.
3. Undo the fuel manifold bolts, marked with arrows in the illustration, and pull out the fuel
manifold towards the rear end of the engine.
Fitting
Fitting the fuel manifold on 9 and 13 litre engines with
2011-08-23 ?Scania CV 4 of 26
Engine no.: 6642331
Scania XPI
Important!

8049a7f5
1. Insert the bolt at the far left of the fuel manifold. Pull in the fuel manifold from the rear
end of the motor and screw in all fuel manifold bolts; see the arrows.
2. Check that the gaskets around the intake
have not come loose. The gaskets must
protrude above the fuel manifold.
2011-08-23 ?Scania CV 5 of 26
Engine no.: 6642331
8049a7f1
3. Fit the return pipes 2 and 3.

4. Fit the electrical cables by screwing in the brackets 1.
Removal - Removing high pressure pipes and connections

Instructions
Warning!
The fuel system has a very high fuel
pressure of up to 3000 bars. The fuel
system must be depressurised using SDP3
before any work is started.
Use SDP3 to minimise the high pressure in
the fuel system.
The system should always be treated as
pressurised, even when the engine is
switched off.
Wear protective gloves and goggles.
Important!

When the fuel system has been opened,
compressed air must not be used to blow
2011-08-23 ?Scania CV 6 of 26
Engine no.: 6642331
clean components.
In order to remove an injector from the cylinder head, its connection must first be removed.
1
2 3
80508441
1. High pressure pipe

2. Connection
3. Injector
1. Start by depressurising the fuel system. Use SDP3 to minimise the high pressure in the
fuel system.
2. Place a rag over the high pressure pipe cap 1
nut 1 (at the accumulator) of the cylinder
in question. Then carefully undo the nut.
8044bf42
3. Undo the cap nut in the other end of the high pressure pipe and remove the pipe.
4. Undo the cap nut at connection 2. Hold tight so that the connection is not turned when the
cap nut is undone. There is a pin on the connection which can be damaged.
2011-08-23 ?Scania CV 7 of 26
Engine no.: 6642331
Important!
Make sure that it is clean around the

connection before it is drawn out from the
engine. Dirt must not enter the fuel system.
Important!
A high pressure pipe that has been

loosened or removed, must never be
refitted but must be replaced by a new one.
5. Pull out the connection from the cylinder head. If it jams and is difficult to pull out, you
can replace the cap nut with a nut with part number 812 889 and break carefully with a
crow bar.
When removing unions and safety valve:
80508445
Several unions and the safety valve in the system are sealed with a sealing washer which
must be renewed if the parts have been disassembled. There is a plug at the accumulator end
(same connection as for cylinder 1 on 6 cylinder engines) on 5 cylinder engines. This is
sealed with the same type of washer. The old washer is often stuck and can be difficult to
remove without damaging the sealing surface.
2011-08-23 ?Scania CV 8 of 26
Engine no.: 6642331
12.7
80508449
Tip: Make a simple special tool using a standard 3-4 mm hexagon key. Grind down the
shorter end as illustrated (12.7 mm) and use the tool to ease the washer out of its spot.
Fitting - Fitting high pressure pipes and connections

1. Lubricate the new O-ring on the connection using engine oil. Also check that the pin is
secure.
2. Press the connection into the cylinder head with the pin facing upwards in the designated
hole. Tighten the cap nut.
Important!
Make sure that the high pressure pipe is

free of dirt before it is fitted to the engine.
3. Fit the high pressure pipe. Remove the plugs and fit both ends of the high pressure pipe
before torque tightening.
Removal
Removing the high pressure pump on 9 and 13 litre

engines
Instructions
Warning!

2011-08-23 ?Scania CV 9 of 26
Engine no.: 6642331

switched off.
Important!

clean components.
Plug or tape connections on components
which are removed.
Important!

1. Start by depressurising the fuel system.

Use SDP3 to minimise the high pressure in the fuel system.
Place a rag over the high pressure pipe nut at the accumulator. Then carefully undo the
nut.
2. Remove the fuel pipes. Mark the them to make fitting easier.
3. Separate the fuel metering valve cable harness.
4. Remove the fuel filter housing.
5. Remove the starter motor.
2011-08-23 ?Scania CV 10 of 26
Engine no.: 6642331
6. Unscrew the high pressure pump and lift it out carefully. Leave the bracket for the high
pressure pump behind. This will make fitting easier.
Fitting
Fitting the high pressure pump on 9 and 13 litre engines

1. Lift the high pressure pump into position and screw into place.
2. Undo the tapered joint which holds the high pressure pump bracket against the cylinder
block, and then tighten it again. This is carried out to remove any stresses.
Fit:
2 5 4 6
8044bf2a
1. fuel filter housing

2. fuel pipe between the feed pump and the control unit cooler
3. fuel intake manifold.
4. fuel pipe between the fuel filter and the high pressure pump.
5. fuel pipe between the feed pump and the fuel filter.
6. return pipe between the high pressure pump and the fuel filter.
7. return pipe between the fuel manifold and the high pressure pump.
Removal
Removing the gear on the high pressure pump

Applies to engines with cylinder block generation 2.
Tools
2011-08-23 ?Scania CV 11 of 26
Engine no.: 6642331
Tool
board
99 633 Assembly tool
1. Fit the tool.
806d0964
806d090a
2. Undo the nut.
2011-08-23 ?Scania CV 12 of 26
Engine no.: 6642331
806d090c
3. Remove the nut.
806d0957
4. Remove the tool.
806d0958
5. Fit the puller and tighten it.
2011-08-23 ?Scania CV 13 of 26
Engine no.: 6642331
806d0959
6. Tap lightly on the puller to loosen the

gear.
806d095a
7. Make a
note of
the type
of gear. A B
Scissors
gears
should
be
parallel.
806d0962
80713f19
2011-08-23 ?Scania CV 14 of 26
Engine no.: 6642331
8. Fit the nut.
806d0963
9. Fit the tool.
806d0964
10. Tighten the nut
806d099b
11. Remove the tool.
2011-08-23 ?Scania CV 15 of 26
Engine no.: 6642331
806d0958
Removal
Removing torsion damper

Tools
Tool
board
99 633 Assembly tool
1. Remove the high pressure pump. See subgroup 03-00, Fuel system Scania XPI
2. Remove the high pressure pump gear. See subgroup 03-00, Fuel system Scania XPI
3.
80720c68
2011-08-23 ?Scania CV 16 of 26
Engine no.: 6642331
80720c69
Fit assembly tool 99 633 against a flat horizontal surface and place the gear in the assembly
tool.
4.
80720c6b
Detach the torsion damper screws from the gear.
Renewal
Renewing the cylinder head for the high pressure pump on

engines with the Scania XPI fuel system
Regulations
Warning!

2011-08-23 ?Scania CV 17 of 26
Engine no.: 6642331

switched off.
Important!

Do not use compressed air to blow clean
components in the fuel system.
which are removed.
Important!
A high-pressure pipe that has been

loosened or removed must never be refitted
but must be replaced with a new one.
1. Tilt the cab in accordance with the instructions.

2. Remove the mudguard in accordance with the instructions.
3. Clean around the fuel system.
4. Depressurise the fuel system. Use SDP3 to
minimise the pressure. Place a rag over the
high-pressure pipe nut (1). Then carefully
undo the nut.
2011-08-23 ?Scania CV 18 of 26
Engine no.: 6642331
5 4
80465cbc
5. Undo the cable connection.

6. Remove the high-pressure pipe (2) and fit clean plugs in the fuel connections. Note: The
high-pressure pipe must not be reused.
7. Undo the banjo unions on the high-pressure pump.
8. Remove the fuel return pipe (3) and plug the fuel manifold. Detach the pipes (4 and 5)
from the cylinder head.
9. Undo the cylinder head screws alternately. Remove the cylinder head and gasket.
10. Remove the protective plugs on the new cylinder head. Fit new springs, a new gasket
and new screws.
11.
8046a8b6
Clean the pump surface that faces the cylinder head. Check that the guide pins under the
2011-08-23 ?Scania CV 19 of 26
Engine no.: 6642331
roller tappets are straight and that the roller tappets are correctly positioned so that they go
down completely in their seats; see illustration. Screw the cylinder head into place
alternately.
12. Fit the pipes (3, 4 and 5). Use new washers.
13. Fit a new high pressure pipe 2.
14. Fit the high-pressure pipe brackets.
15. Fit the cable connection.
16. Start the engine and clear the fault codes.

Tools
Tool
board
99 475 Crow bar for removing injectors
Regulations
Warning!
switched off.
Important!

2011-08-23 ?Scania CV 20 of 26
Engine no.: 6642331

clean components.

2. Place a rag over the high pressure pipe nut at the accumulator for the cylinder where the
injector has to be removed. Then carefully undo the nut.
3. Remove the upper rocker cover.
4. Undo the nuts for the electric connections to the injector.
5. Remove the high pressure pipe. Undo the cap nut at the connection to the injector.
Important!

connection before the connection is
removed from the engine. Dirt must not
enter the fuel system.
Important!

removed, must never be refitted but must
be replaced by a new one. Note! When
working on injectors on cylinder 5, the pipe
for cylinder 6 must also be renewed.
6. Plug the connections so that dirt cannot penetrate.

7. Undo the cap nut for the connection and
pull the connection upwards. Note! To
gain access to the connection for cylinder
5, the high pressure pipe for cylinder 6
2011-08-23 ?Scania CV 21 of 26
Engine no.: 6642331
must first be removed. If it is difficult to

pull the connection upwards, you can
replace the cap nut with nut part number
812 889 and break carefully with a crow
bar.
8043213d
The connection must be removed before the

injector can be removed.
9. Undo the injector holder screw.
Important!
The injector must be re-fitted to the same

cylinder it was removed from.
Important!
Do not prise into the valve part.
10. Undo the injector using the special tool,

by prising in the groove on the injector
sleeve.
2011-08-23 ?Scania CV 22 of 26
Engine no.: 6642331
805906c5
Groove on injector where the crowbar is to be

used.
11. Plug the injection part of the injector, as well as where the connection is made, so that
dirt cannot enter.
12. If several injectors are removed, number and place the injectors in sequence so that they
are refitted on the same cylinders.
Important!
If one or more injectors are renewed, the

engine control unit must be programmed so
that the injector(s) injects(inject) the
correct amount.
Important!

Important!
Check carefully that all parts that are

refitted are clean. It is very important that
no dirt enters the fuel system.
Important!
The connectors on the injector are very

susceptible to knocks.
1. Remove the old washer by prising it off

using a screwdriver, for example. Take
care not to damage the injection nozzle tip.
Fit a new sealing washer on the unit
injector.
2011-08-23 ?Scania CV 23 of 26
Engine no.: 6642331
Cut a plastic pipe to approximately 50

mm, diameter 16 mm (part number 1 483
546). Press the washer into position as far
as it will go. Then place the plastic pipe
over the injection nozzle tip as illustrated.
Hold the injector in one hand and the
plastic pipe in the other hand. Carefully
tap the washer into place against a work
bench. Make sure that the connectors are
not subjected to any knocks.
805906d1
2. Note the code which appears on the

bottom line of text on the injector; see the xx xxx x
xx xxx x
xx xxx x xx
illustration. The code is needed later when xx xxx x x xx
calibrating the injector.
8049ba52
3. Renew the O-ring on the injector and lubricate the O-ring with engine oil.
Important!
The injector is carefully placed in position

and screwed into place using the holder.
4. Fit the holder to the injector and place the injector loosely in the groove.
5. Use the holder to make sure that the injector is in the correct position.
6. Screw on the holder.
secure.
8. Press the connection into the cylinder head, with the pin facing upwards, in the designated
9. Tighten the injector holder screw.
2011-08-23 ?Scania CV 24 of 26
Engine no.: 6642331
10. Tighten the connection cap nut.

11. Fit the electrical connectors and the nuts.
12. Position the high pressure pipe. Remove the plugs and fit both ends of the high pressure
pipe before torque tightening.
13. Fit the rocker cover.
14. Enter the code for the new injector into the control unit using the Calibration of injectors
function in SDP3.
15. Reset the adaptation of the fuel amount using Basic setting of adaptation of the injectors
in SDP3.

Tools
Tool
board
588 179 Torque screwdriver
1. Check whether there are any fault codes using SDP3.

2. Check the function of the injectors using the check Activation of injector solenoid valves
in SDP3.
3. Remove the rocker cover for the defective cylinder and disconnect the electrical cables
from the screws on the solenoid valve.
4. Measure the resistance on the contact
surfaces of the solenoid valve for about 20
seconds until a stable value is obtained. The
resistance should be 0.2-0.6 Ohms at room
temperature when the engine is cold.
Important!
To obtain a correct reading, resistance must

be measured directly between the
connections and not on the screws.
Note!
Check the condition of the measuring
instrument before taking a reading.
2011-08-23 ?Scania CV 25 of 26
Engine no.: 6642331
587 423
805f8a29
5. Place one measurement probe against the contact surface on the solenoid valve. Place the
other measurement probe against the metal sheath on the solenoid valve to check that
there is no short circuit. Check the other connection in the same way.
6. Refit the electrical cables to the injector by tightening the screws using torque screwdriver
588 179.
Note!
If the injectors cannot be checked using
SDP3, one injector may be short circuited
to earth via the chassis. The EDC control
unit is thus not working or generating
diagnostic trouble codes. If this is the case,
each injector must be checked.
2011-08-23 ?Scania CV 26 of 26
Engine no.: 6642331
03-00 Overflow valve

Location - Overflow valve, 9 and 13 litre engines with XPI
Location
Overflow valve, 9 and 13 litre engines with XPI
8076c0c9

Note!
2011-08-23 ?Scania CV 1 of 1
Engine no.: 6642331
03-01 Feed pump

Location
Complete - Removing and fitting the feed pump on 9 and 13 litre XPI engines
Location
80300ea1
The position also applies to 11 and 12 litre engines.

The feed pump is located at the back of the compressor.

Note!
Complete
Removing and fitting the feed pump on 9 and 13 litre XPI

engines
Regulations
Warning!
2011-08-23 ?Scania CV 1 of 3
Engine no.: 6642331

Use SDP3 to minimise the high pressure in
the fuel system.
switched off.
Important!

Compressed air must not be used to blow
components clean if the fuel system is
open.
with a lint free cloth and tape.
2 A
80449a65
1. The fuel pipes (1 and 2) must be removed before the feed pump (A) can be removed.
Mark the feed pump and fuel pipes to make fitting easier.
2. Undo the feed pump (three bolts) and draw it out.
2011-08-23 ?Scania CV 2 of 3
Engine no.: 6642331
3. Renew the O-ring.

4. Refit the pump. Turn and carefully push in the pump until the pump coupling engages.
5. Make sure that the feed pump is pressed all the way in against the high-pressure pump
before tightening the bolts.
2011-08-23 ?Scania CV 3 of 3
Engine no.: 6642331
03-01 Injector Scania XPI

Cleaning - Cleaning 9, 11, 12 and 13 litre engines

Note!
Cleaning
Cleaning 9, 11, 12 and 13 litre engines

The engine must be cleaned before starting work.
Clean with water and use a hot wash. Also use a degreasing agent, if necessary.
Avoid spraying water on the engine control unit, see illustration. Clean the components that
are inside the marked area.
8057596d
2011-08-23 ?Scania CV 1 of 8
Engine no.: 6642331
Warning!
Beware of hot water! Use suitable
protective equipment.
Environment
The washing water must be disposed of in
compliance with the relevant national or
local regulations.

Tools
Tool
board
99 475 Crow bar for removing injectors
Regulations
Warning!
switched off.
Important!

2011-08-23 ?Scania CV 2 of 8
Engine no.: 6642331

clean components.

2. Place a rag over the high pressure pipe nut at the accumulator for the cylinder where the
injector has to be removed. Then carefully undo the nut.
3. Remove the upper rocker cover.
4. Undo the nuts for the electric connections to the injector.
5. Remove the high pressure pipe. Undo the cap nut at the connection to the injector.
Important!

connection before the connection is
removed from the engine. Dirt must not
enter the fuel system.
Important!

removed, must never be refitted but must
be replaced by a new one. Note! When
working on injectors on cylinder 5, the pipe
for cylinder 6 must also be renewed.

7. Undo the cap nut for the connection and
pull the connection upwards. Note! To
2011-08-23 ?Scania CV 3 of 8
Engine no.: 6642331
gain access to the connection for cylinder

5, the high pressure pipe for cylinder 6
must first be removed. If it is difficult to
pull the connection upwards, you can
replace the cap nut with nut part number
812 889 and break carefully with a crow
bar.
8043213d
The connection must be removed before the

injector can be removed.
9. Undo the injector holder screw.
Important!
The injector must be re-fitted to the same

cylinder it was removed from.
Important!
Do not prise into the valve part.
10. Undo the injector using the special tool,

by prising in the groove on the injector
sleeve.
2011-08-23 ?Scania CV 4 of 8
Engine no.: 6642331
805906c5
Groove on injector where the crowbar is to be

used.
11. Plug the injection part of the injector, as well as where the connection is made, so that
dirt cannot enter.
12. If several injectors are removed, number and place the injectors in sequence so that they
are refitted on the same cylinders.
Important!
If one or more injectors are renewed, the

engine control unit must be programmed so
that the injector(s) injects(inject) the
correct amount.
Important!

Important!
Check carefully that all parts that are

refitted are clean. It is very important that
no dirt enters the fuel system.
Important!
The connectors on the injector are very

susceptible to knocks.
1. Remove the old washer by prising it off

using a screwdriver, for example. Take
care not to damage the injection nozzle tip.
Fit a new sealing washer on the unit
injector.
2011-08-23 ?Scania CV 5 of 8
Engine no.: 6642331
Cut a plastic pipe to approximately 50

mm, diameter 16 mm (part number 1 483
546). Press the washer into position as far
as it will go. Then place the plastic pipe
over the injection nozzle tip as illustrated.
Hold the injector in one hand and the
plastic pipe in the other hand. Carefully
tap the washer into place against a work
bench. Make sure that the connectors are
not subjected to any knocks.
805906d1
2. Note the code which appears on the

bottom line of text on the injector; see the xx xxx x
xx xxx x
xx xxx x xx
illustration. The code is needed later when xx xxx x x xx
calibrating the injector.
8049ba52
3. Renew the O-ring on the injector and lubricate the O-ring with engine oil.
Important!
The injector is carefully placed in position

and screwed into place using the holder.
4. Fit the holder to the injector and place the injector loosely in the groove.
5. Use the holder to make sure that the injector is in the correct position.
6. Screw on the holder.
secure.
8. Press the connection into the cylinder head, with the pin facing upwards, in the designated
9. Tighten the injector holder screw.
2011-08-23 ?Scania CV 6 of 8
Engine no.: 6642331
10. Tighten the connection cap nut.

11. Fit the electrical connectors and the nuts.
12. Position the high pressure pipe. Remove the plugs and fit both ends of the high pressure
pipe before torque tightening.
13. Fit the rocker cover.
14. Enter the code for the new injector into the control unit using the Calibration of injectors
function in SDP3.
15. Reset the adaptation of the fuel amount using Basic setting of adaptation of the injectors
in SDP3.

Tools
Tool
board
588 179 Torque screwdriver
1. Check whether there are any fault codes using SDP3.

2. Check the function of the injectors using the check Activation of injector solenoid valves
in SDP3.
3. Remove the rocker cover for the defective cylinder and disconnect the electrical cables
from the screws on the solenoid valve.
4. Measure the resistance on the contact
surfaces of the solenoid valve for about 20
seconds until a stable value is obtained. The
resistance should be 0.2-0.6 Ohms at room
temperature when the engine is cold.
Important!
To obtain a correct reading, resistance must

be measured directly between the
connections and not on the screws.
Note!
Check the condition of the measuring
instrument before taking a reading.
2011-08-23 ?Scania CV 7 of 8
Engine no.: 6642331
587 423
805f8a29
5. Place one measurement probe against the contact surface on the solenoid valve. Place the
other measurement probe against the metal sheath on the solenoid valve to check that
there is no short circuit. Check the other connection in the same way.
6. Refit the electrical cables to the injector by tightening the screws using torque screwdriver
588 179.
Note!
If the injectors cannot be checked using
SDP3, one injector may be short circuited
to earth via the chassis. The EDC control
unit is thus not working or generating
diagnostic trouble codes. If this is the case,
each injector must be checked.
2011-08-23 ?Scania CV 8 of 8
Engine no.: 6642331
03-05 Fuel filter

Location - 9 and 13 litre engines with XPI
Removal - Removing the fuel filter on Scania XPI
Fitting - Fitting a fuel filter on Scania XPI
Complete - Bleeding the fuel system on 9 and 13 litre engines with XPI
Removal - Removing the fuel filter housing on 9 and 13 litre engines with XPI
Location
9 and 13 litre engines with XPI
1 2
8044befa
1. Water separating suction filter

2. Pressure filter

Note!
Removal
Removing the fuel filter on Scania XPI
Important!
2011-08-23 ?Scania CV 1 of 5
Engine no.: 6642331

which are removed.
Tools
Number Designation Picture Tool board
Maintenance
588 475 Sleeve
cabinet
1. Open the bleed nipple on the fuel filter housing to release any remaining pressure. It may
be difficult to unscrew the filter cover if the fuel pressure has not fallen sufficiently.
Note!
Fuel will come out of the bleed nipple. It
should be collected as specified in
environmental regulations.
Important!
Do not use an adjustable spanner or other

open tool to undo the filter cover, as this
risks damaging the filter cover.
2. Unscrew the filter cover with a closed tool with hexagon driver, e.g. socket 588 475.
3. Lift the filter cover with filter element out of the fuel filter housing. The fuel filter housing
will drain automatically (slowly) once the filter element has been removed. Always suck
out the fuel left in the filter housing.
4. Undo the old filter element from the cover by carefully bending it to one side.
2011-08-23 ?Scania CV 2 of 5
Engine no.: 6642331
Fitting
Fitting a fuel filter on Scania XPI

Tools
Number Designation Picture Tool board
Maintenance
588 475 Sleeve
cabinet
1. Fit a new O ring to the cover. Lubricate the O-ring with O-ring grease 1 402 039.
2. Press a filter element into the snap fastener on the cover.
Important!
Fit the filter element to the filter cover

before positioning it in the fuel filter
housing. The filter element can otherwise
be damaged.
Important!
In order to prevent back pressure in the

filter housings when the filter elements are
screwed on, the bleed nipple should be
open.
3. Press down the filter element with filter cover into the filter housing. Screw the filter
cover into place with a closed tool with hexagon driver, e.g. socket 588 475. Check that
there is no gap between the filter cover and the filter housing. If there is a gap, repeat the
procedure and make sure that the bleed nipple is open.
Complete
Bleeding the fuel system on 9 and 13 litre engines with XPI
Important!

2011-08-23 ?Scania CV 3 of 5
Engine no.: 6642331

which are removed.
1. Attach a clear plastic hose to the bleed nipple on the fuel filter housing. Let the plastic
hose drop into a container that holds at least 5 litres.
2. Unscrew the hand pump handle.
3. Open the bleed nipple and pump until fuel runs out, which will take around 100 pump
strokes. Close the bleed nipple.
4. Start the engine and open the bleed nipple carefully. Approximately 3 litres will run out
into the container before the fuel coming out will be free of air.
Removal
Removing the fuel filter housing on 9 and 13 litre engines

with XPI
Important!

2011-08-23 ?Scania CV 4 of 5

02-25 Coolant Pump: Complete - Tightening Torques

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02-25 Coolant Pump: Complete - Tightening Torques

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Engine no.

02-25 Coolant pump

Complete - Tightening torques

Renewal - Coolant hoses

Renewing the coolant pump on 9 and 13 litre engines

2. Slacken off the belt transmission.

Fit the coolant pump

1. Fit the pump gasket.

02-30 T33, Coolant temperature sensor

Location, 9 and 13 litre engines with XPI

Complete - Tightening torques

03-00 Calculating the fuel consumption factor

1. Initial refuelling to a reference level.

Refuelling to reference level

In order to assess the vehicle's actual fuel consumption as precisely as possible, it is

Reference levels in the tank, select reference level A, if possible.

Note the level that has been selected as a

Resetting route data

Driving and normal refuelling with monitoring of the number of litres

Make sure that you write down the number

Enter the volume including decimals.

Summary and calculation of the K factor

z Add up the actual total fuel consumption.

The fuel consumption factor is calculated as follows:

03-00 Fuel system Scania XPI

Complete - Tightening torques

Measuring the fuel pressure on 9 and 13 litre engines with

The fuel system is very sensitive to dirt. It

Do not use worn chrome-plated tools as

99 362 Pressure gauge

Measuring supply pressure

should be between 9 and 14 bar.

Removing the fuel manifold on 9 and 13 litre engines with

The fuel system is very sensitive to dirt. It

Fitting the fuel manifold on 9 and 13 litre engines with

The fuel system is very sensitive to dirt. It

3. Fit the return pipes 2 and 3.

Removal - Removing high pressure pipes and connections

The fuel system is very sensitive to dirt. It

1. High pressure pipe

Make sure that it is clean around the

A high pressure pipe that has been

Fitting - Fitting high pressure pipes and connections

Make sure that the high pressure pipe is

Removing the high pressure pump on 9 and 13 litre

The fuel system has a very high fuel

system must be depressurised using SDP3

The fuel system is very sensitive to dirt. It

A high pressure pipe that has been

1. Start by depressurising the fuel system.

Fitting the high pressure pump on 9 and 13 litre engines

1. fuel filter housing

Removing the gear on the high pressure pump

99 633 Assembly tool

1. Fit the tool.

2. Undo the nut.

3. Remove the nut.

4. Remove the tool.

5. Fit the puller and tighten it.

6. Tap lightly on the puller to loosen the

8. Fit the nut.

9. Fit the tool.

10. Tighten the nut