1 Scania Industrial and Marine Engines 16 Litre Engine Service Repair Manual - PDF

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Scania industrial
and marine
engines 16 litre
engine service
repair manual
Dec 16, 2020 •
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engine service repair
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Manual tecnico-motor-
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Scania industrial and marine engines 16 litre engine service repair manual
1. © Scania CV AB 2002-09:3 Issue 3 en Part No. 1 588 778 Industrial & Marine Engines 01:05-02 Work
description- 16-litre engine Industrial and marine engines

Page 15 of 21
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2. 2 © Scania CV AB 2002-09:3 01:05-02 Use a container to avoid spills when draining the coolant and oil.
Dispose of used coolant and oil through an authorised waste disposal contractor.
3. 01:05-02 © Scania CV AB 2002-09:3 3 General. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Specifications . . . . . .
. . . . . . . . . . . . . . . . . . . 4 General tightening torques . . . . . . . . . . . . . . . 5 Removing and li!ing the engine . . . . .
. . . . . . . 6 Special tools . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Li!ing and fitting the engine . . . . . . . . . . . . . . . 8
Mounting the engine in a universal stand . . . . . 9 Special tools . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Cylinder head
. . . . . . . . . . . . . . . . . . . . . . . . . . 10 Adjusting the valve clearance and unit injectors11 Adjusting the valve
clearance . . . . . . . . . . . . 12 Adjusting the unit injector. . . . . . . . . . . . . . . 12 Order of adjustment. . . . . . . . . . . . .
. . . . . . . 15 Renewing the upper rocker cover gasket . . . 16 Renewing the lower rocker cover gasket . . . 16
Cylinder head . . . . . . . . . . . . . . . . . . . . . . . . . . 20 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 Fitting . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . 24 Valves. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30 Removal . . . . . . . . . . . . . . . . . . . . . . . . . .
. . 30 Fitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30 Checking and machining. . . . . . . . . . . . . . . . 31 Valve stem
seal . . . . . . . . . . . . . . . . . . . . . . . . 32 Renewal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32 Valve seats . . . . . . . . . . . . . . . .
. . . . . . . . . . . . 33 Renewal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33 Machining the cylinder head . . . . . . . . . . . . . . 35
Specifications . . . . . . . . . . . . . . . . . . . . . . . . 35 Work description. . . . . . . . . . . . . . . . . . . . . . 37 Valve guides. . . . .
. . . . . . . . . . . . . . . . . . . . . . 39 Renewal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39 Sleeves for unit injectors . . . . . . . . . .
. . . . . . . 40 Renewal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40 Cylinder block . . . . . . . . . . . . . . . . . . . . . . . . . 42
Overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42 Cylinder liner . . . . . . . . . . . . . . . . . . . . . . . . . . 43 Removal . . . . . . . .
. . . . . . . . . . . . . . . . . . . . 43 Fitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44 Measuring the cylinder liner height . . .
. . . . 45 Machining cylinder liner height . . . . . . . . . . 47 Rear cranksha! seal . . . . . . . . . . . . . . . . . . . . . 52
Renewal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52 Flywheel housing . . . . . . . . . . . . . . . . . . . . . . . 53 Removal . . . . . . .
. . . . . . . . . . . . . . . . . . . . . 53 Fitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54 Closed crankcase ventilation . . . . . . . .
. . . . . . 56 Front timing gear casing. . . . . . . . . . . . . . . . . . 58 Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
Fitting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59 Front cranksha! seal . . . . . . . . . . . . . . . . . . . . 60 Renewal . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . 60 Crank mechanism. . . . . . . . . . . . . . . . . . . . . . . 62 Piston and connecting rod . . . . .
. . . . . . . . . . . 63 Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63 Fitting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
Renewing a piston . . . . . . . . . . . . . . . . . . . . . 66 Connecting rod . . . . . . . . . . . . . . . . . . . . . . . . . 69 Checking . . . . .
. . . . . . . . . . . . . . . . . . . . . . . 69 Renewal of bearing bushing in connecting rod. 71 Flywheel . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . 73 Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73 Fitting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
Support bearing . . . . . . . . . . . . . . . . . . . . . . . 75 Ring gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76 Cranksha! . . . . . .
. . . . . . . . . . . . . . . . . . . . . . 77 Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77 Fitting. . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . 79 Checking and machining the cranksha! . . . . 82 Timing gear . . . . . . . . . . . . . . . . . . . . . . . . . . . 84 Gear
drive . . . . . . . . . . . . . . . . . . . . . . . . . . . 84 Intermediate gear . . . . . . . . . . . . . . . . . . . . . . . 86 Removal. . . . . . . . . . . .
. . . . . . . . . . . . . . . . . 86 Fitting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88 Bearing in intermediate gear . . . . . . . . . . .
. . 89 Camsha! gear. . . . . . . . . . . . . . . . . . . . . . . . . . 92 Cranksha! gear. . . . . . . . . . . . . . . . . . . . . . . . . 93
Camsha!. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95 Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95 Fitting. . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . 98 Checking camsha! setting. . . . . . . . . . . . . . 101 Removing the camsha! bearing . .
. . . . . . . 102 Fitting the camsha! bearing . . . . . . . . . . . . 106 Fan drive. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110
Lubrication system . . . . . . . . . . . . . . . . . . . . . 114 Oil filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114 Oil cooler. . . . . .
. . . . . . . . . . . . . . . . . . . . . 116 Oil cleaner . . . . . . . . . . . . . . . . . . . . . . . . . . 118 Oil pump . . . . . . . . . . . . . . . . . . . . . . .
. . . . 122 Exhaust manifold . . . . . . . . . . . . . . . . . . . . . . 124 Turbocharger . . . . . . . . . . . . . . . . . . . . . . . . . 125

Page 16 of 21
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Contents
4. 4 © Scania CV AB 2002-09:3 01:05-02 General Specifications Cylinder bore 127.0 mm Stroke 154.0 mm
Displacement 15.6 dm3 No. of main bearings 5 Firing sequence 1-5-4-2-6-3-7-8 Compression ratio 18:1
Direction of rotation (engine viewed from behind) Anticlockwise Engine speed, low idling (all-speed) 500
rpm Engine speed, high idling (all-speed) 2400 rpm Oil volume 35 litre Oil grade see booklet 00:03-01
Weight (without oil, coolant, radiator; with fan) 1,346 kg 1. Warning plates 2. Instruction plate: Valve
clearance 3. Type plate: Engine type, Engine serial number 4. Engine serial number, stamped DC16 engine
shown. Di 16: same location
5. 01:05-02 © Scania CV AB 2002-09:3 5 General tightening torques *) A tolerance of +/- 15% applies to
the specified tightening torques unless stated otherwise. The following tightening torques apply in
general unless otherwise specified:*) Flange bolt M6 8.6 Nm Flange bolt M8 26 Nm Flange bolt M10 50 Nm
Flange bolt M12 92 Nm Stud in casting M8 13 Nm Stud in casting M10 25 Nm
6. 6 © Scania CV AB 2002-09:3 01:05-02 Removing and li!ing the engine Special tools 1. Drain the oil and
coolant. Help protect our environment! Use a suitable container. Dispose of used coolant and oil through
an authorised waste disposal contractor. DC engine: - Remove the air filter and the inlet pipe between the
turbocharger and the air filter. - Undo the connections for coolant, charge air pipes between engine and
charge air cooler, and ventilation line to the expansion tank. - Remove the cables with cable clamp ring
on the rear right-hand side. DI engine: - Disassemble the engine and reverse gear. - Detach the pipe
between the seawater pump and heat exchanger. Remove the seawater pump. - Remove the
turbocharger oil pipes. 2. Disconnect the negative battery cable. 3. Remove the starter motor and
alternator wiring 4. Remove the wiring to the control unit. 5. Remove the fuel connection. Number
Description Illustration Tool board 99 398 Li!ing eyes 1 360 442 Li!ing eyes 1 512 730 Li!ing eye 98 094
Li!ing chain 587 308 Lever block
7. 01:05-02 © Scania CV AB 2002-09:3 7 DC engine: - Disconnect the filter housing for the crankcase
ventilation and place to one side so that it is free from the li!ing chain. - Undo the AC compressor and
move to one side. - Screw li!ing eyes 99 398 onto the engine using flange bolts M12x30 (4). DI engine: - Fit
the front li!ing eye 1512730 with two M12 x ? mm bolts through the expansion tank. Turn the li!ing eye
towards the centre of the engine. - Screw two li!ing eyes 1360442 into the flywheel housing over the
centre in the ten to two position. 6. Fasten the li!ing chain 98 094 to the rear li!- ing eyes. 7. Fasten the
lever block (587 308) to the front li!ing eye. Note: The engine li!ing eyes are sized for li!ing the engine
only, not the engine together with connected equipment (high-current generator, gearbox, reverse gear,
etc.) or frame. All three li!ing eyes must be used. 8. Undo the connecting pipe to the gearbox cooler or
reversing gear oil cooler. 9. Undo the connection to the gearbox or reverse gear. 10. Undo all the engine
brackets and li! away/out the engine. Note: The li!ing eyes are dimensioned for a maximum inclination
angle of 20° when li!ing the engine. DC16 engine DC16 engine
8. 8 © Scania CV AB 2002-09:3 01:05-02 Li!ing and fitting the engine DC engine: - Screw li!ing eyes 99 398
onto the engine using flange bolts M12x30 (4). - Disconnect the filter housing for the crankcase ventilation
and place to one side so that it is free from the li!ing chain. DI engine: - Screw two li!ing eyes 1360442
into the flywheel housing over the centre in the ten to two position. The seawater pump, the heater
exchanger pipe and the turbocharger oil pipes must be removed. - Remove the closed crankcase
ventilation filter. - Fit the front li!ing eye 1512730 with two M12 x ? mm bolts through the expansion tank.

Page 17 of 21
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Turn the li!ing eye towards the centre of the engine. 1. Fasten the li!ing chain 98 094 to the rear li!ing
eyes. 2. Fasten the lever block (587 308) to the front li!ing eye. 3. Li! the engine in position and bolt it to
the front engine suspension. 4. DI16: Remove the rear li!ing eyes. 5. Bolt together the engine and gearbox
or reverse gear. 6. Bolt the engine to the rear engine suspension. 7. Remove the li!ing eyes. 8. DC16: Fit
the filter housing for the crankcase ventilation. 9. Fit the connecting pipes to the gearbox cooler or
reverse gear oil cooler. 10. Connect the wiring to the control unit and starter motor/alternator. 11. Fit the
fuel pipe. DC engine: - Fit the coolant connections, charge air lines between the charge air cooler and the
engine. - Fit the ventilation line and static line. Fit the inlet pipe to the turbocharger and refit the air filter.
DI engine: - Fit the turbocharger oil pipes and the seawater pump and pipe from the pump to the heat
exchanger. - Fit the closed crankcase ventilation filter. 12. Connect the negative battery cable. 13. Fill with
oil and coolant as directed in booklet 00:03-01. 14. Test run the engine to check that no leakage occurs.
Top up with coolant if necessary.
9. 01:05-02 © Scania CV AB 2002-09:3 9 Mounting the engine in a universal stand Special tools DI engine:
- Remove the heat exchanger pipe connections and remove the entire heat exchanger. - Remove the
exhaust manifolds. - Remove the control unit connectors. DC and DI engines: 1. Remove the side covers
and the gaskets on the right and le!-hand sides. 2. Undo the clamps on any obstructing wiring. 3. Bolt
spacer 99 349 onto the right and le!- hand sides. Use the bolts for the side covers. 4. Screw fixture 98 163
onto the spacers. Use M8 x 25 bolts and M8 washers. 5. Screw the fixture to the universal stand and place
the fixture's support on the opposite side as illustrated. Number Description Illustration Tool board 99
349 Spacer 98 163 Fixture 587 692 Universal stand DC16
10. 10 © Scania CV AB 2002-09:3 01:05-02 Cylinder head 1. Cylinder head 2. Core plug 3. Valve guide 4. Pin
5. Valve stem seal 6. Valve spring, intake 7. Valve spring collar 8. Valve spring, exhaust 9. Valve spring,
exhaust 10. Valve spring collar 11. Valve collet 12. Valve bridge 13. Bolt 14. Bearing bracket 15. Rocker arm
sha! 16. Rivet plug 17. Tight-fit screw 18. Rocker arm, intake 19. Rocker arm, exhaust 20. Adjusting screw
21. Lock nut 22. Rocker arm, unit injector 23. Guide pin 24. Cylinder head gasket 25. Exhaust valve 26.
Intake valve 27. Rocker cover 28. Flange bolt 29. Rocker cover gasket 30. Flange bolt 31. Rocker cover 32.
Rocker cover gasket 33. Valve seat insert, exhaust 34. Valve seat insert, intake
11. 01:05-02 © Scania CV AB 2002-09:3 11 Adjusting the valve clearance and unit injectors Specifications
Tightening torques (See page 3 for general tightening torques) Special tools Valve clearance, intake valve
(cold engine) 0.45 mm Valve clearance, exhaust valve (cold engine) 0.70 mm Dimension for PDE 31 unit
injector (cold engine) 66.9+/-0.1 mm Dimension for PDE 32 unit injector (cold engine) 69.9+/-0.1 mm
Adjusting screw lock nut on rocker arm for unit injector 39 Nm Adjusting screw lock nut on the valve
rocker arm 35 Nm Screw for upper rocker cover 18 Nm Bolt for lower rocker cover 26 Nm Bearing bracket
and rocker arm sha! 105 Nm Cable connection, unit injector 2 +/-0.2 Nm Number Description Illustration
Tool board 99 309 Tool to rotate flywheel D 5 99 414 Setting tool Measuring tool cabinet 99 442 Setting
tool Measuring tool cabinet 588 179 Torque screwdriver
12. 12 © Scania CV AB 2002-09:3 01:05-02 Adjusting the valve clearance Note: Check and adjust the valve
clearance and unit injectors with the engine cold. - Use tool 99 309 to rotate the engine. - Check the valve
clearance using a feeler gauge and use the adjusting screw on the rocker arm to set the correct clearance.
- The intake valves are actuated by the short rocker arms and the exhaust valves by the long rocker arms.
- Make sure the valve bridge is resting correctly against the valves. - The intake valve clearance should be

Page 18 of 21
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0.45 mm and exhaust valve clearance 0.70 mm. - See page 15 for the adjusting order. Adjusting the unit
injector Important! The PDE 31 unit injector is adjusted using setting tool 99 414 or a digital sliding
caliper. The PDE32 unit injector is adjusted using setting tool 99 442 or a digital sliding caliper. This
adjustment is essential as a fault in the position of the unit injector can result in poor performance and
possible breakdown. 1. Screw on the rocker arm adjusting screw 1 while measuring the distance between
plane a and the top of the valve spring collar using a digital sliding caliper. The distance should be 66.9
mm for PDE31 and 69.9 for PDE32. See measurement B in the figure for identifying the injector. A= PDE31:
66.9 +/-0.1 mm PDE32: 69.9 +/-0.1 mm B = PDE31: 36.5 mm PDE32: 38.8 mm
13. 01:05-02 © Scania CV AB 2002-09:3 13 WARNING!! Take care when carrying out the adjustment if the
dimension is well outside the adjustment dimension. The spring is pre-tensioned and can cause personal
injury if it is released. PDE31: 2. Position setting tool 99 414 with the metal plate around the injector
spring. 3. Finely adjust dimension A by simultaneously using a finger to sense that the small piston 2 is
level with the flat upper surface of the tool. It is possible to sense di"erences of less than a tenth of a
millimetre. 4. If tool 99 414 is not available: Measure the distance between plane a and the top of the
valve spring collar using a digital sliding caliper. Adjust the position of the rocker arm with the adjusting
screw until the distance is 66.9+/-0.1 mm. 5. Torque tighten the lock nut to 39 Nm. 6. The order in which
the injector rockers are to be checked/adjusted is shown in the table on page 15. Piston above or below
the flat surface. Adjustment necessary Piston level with the flat surface. The adjustment is correct
14. 14 © Scania CV AB 2002-09:3 01:05-02 PDE32: 7. Position setting tool 99 442 with the metal plate
around the injector spring. 8. Finely adjust dimension A by simultaneously using a finger to sense that the
small piston 2 is level with the flat upper surface of the tool. It is possible to sense di"erences of less than
a tenth of a millimetre. 9. If tool 99 442 is not available: Measure the distance between plane a and the top
of the valve spring collar using a digital sliding caliper. Adjust the position of the rocker arm with the
adjusting screw until the distance is 69.9+/-0.1 mm. 10. Torque tighten the lock nut to 39 Nm. 11. The
order in which the injector rockers are to be checked/adjusted is shown in the table on page 15. Piston
above or below the flat surface. Adjustment necessary Piston level with the flat surface. The adjustment
is correct
15. 01:05-02 © Scania CV AB 2002-09:3 15 Order of adjustment Rotate the flywheel using tool 99 309 so
that the mark on the flywheel is visible in the bottom window according to the table below. It is a good
idea to mark the rocker arm with a pen a!er adjustment to keep track of what has already been adjusted.
Torque tighten the lock nut on the rocker arm for the unit injector to 39 Nm and the lock nut for the
valves to 35 Nm a!er adjusting. Mark on flywheel (degrees) Valve change on cylinder Adjust injector
rocker arm on cylinder Adjust intake valve on cylinder Adjust exhaust valve on cylinder TDC Down (0°) 6 4
and 5 7 and 8 4 and 5 TDC Up (180°) 7 2 and 6 1 and 5 2 and 6 TDC Down (360°) 1 3 and 7 2 and 4 3 and 7
TDC Up (540°) 4 1 and 8 3 and 6 1 and 8
16. 16 © Scania CV AB 2002-09:3 01:05-02 Renewing the upper rocker cover gasket Removal 1. Clean the
rocker cover and the surrounding area. 2. Remove the top part of the rocker cover. 3. Renew the rocker
cover gasket. Fitting 1. Fit the upper part of the rocker cover. Torque tighten the screws to 18 Nm.
Renewing the lower rocker cover gasket Removal 1. Clean the rocker cover and the surrounding area. 2.
Remove the top part of the rocker cover. Note: All the valve mechanism components must be refitted in
their original positions. Therefore, mark the parts as they are removed. 3. Relieve the pressure on the

Page 19 of 21
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valves by undoing the bolts on the rocker arm sha! alternately. WARNING!! Do not lean over the engine
when removing the sha! with rocker arms. The unit injector spring is pre-tensioned and can come loose,
causing personal injury. Note: If the spring comes loose from the unit injector, the unit injector must be
renewed.
17. 01:05-02 © Scania CV AB 2002-09:3 17 4. Remove the rocker arm sha! assembly. 5. Remove the
bearing bracket. 6. Detach the cables on the unit injector. The screws cannot be removed but unscrew
them as much as possible. Detach the cable grommet and remove the cable from the rocker cover. 7.
Remove the lower rocker cover. 8. Renew the lower rocker cover gasket. Press in place the new gasket in
the lower rocker cover.
18. 18 © Scania CV AB 2002-09:3 01:05-02 Fitting Tightening torques Tools 1. Renew the gasket and fit the
lower rocker cover. Tighten the bolts to 26 Nm. Note: If the spring has come loose from the unit injector
the unit injector must be renewed. Cable connection, unit injector 2 +/-0.2 Nm Bearing bracket and rocker
arm sha! 105 Nm Upper rocker cover 18 Nm Lower rocker cover 26 Nm Number Description Illustration
588 179 Torque screwdriver
19. Thank you very much for your reading. Please Click Here. Then Get COMPLETE MANUAL. NO WAITING
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20. 01:05-02 © Scania CV AB 2002-09:3 19 2. Screw on the cable grommet in the lower rocker cover and
run the cable to the unit injector. Fit the seal to the rocker cover. 3. Refit the cables on the unit injector.
Their rel- ative position is not important. Use torque screwdriver 588 179 to tighten the screws to 2 Nm.
Important! Use torque screwdriver 588 179 to avoid the risk of shearing o" the screws. The entire unit
injector must be renewed if the screws shear o". 4. Fit the bearing bracket and torque tighten the bolts to
105 Nm. Important! Make sure the pushrods are positioned correctly. Refer to the illustration. 5. Refit the
rocker arm sha!. Screw in the bolts alternately so that they are tightened in paral- lel or one of the bolts
may bend. Tighten the bolts to 105 Nm. 6. Check the valve clearance and unit injector setting as
described in Adjusting the valve clearance and unit injector. 7. Refit the upper part of the rocker cover.
Tighten the bolts to 18 Nm.
21. 20 © Scania CV AB 2002-09:3 01:05-02 DC engine: 1. Open the bleed nipple on the fuel filter and
empty the fuel system by opening and connecting hoses to the unions on the rear edge of the fuel
manifolds and opening the unions. WARNING!! The fuel system must be empty or fuel may run down into
the cylinders, which will result in a great risk of liquid hammering. If fuel runs into the combustion
chamber, it must be removed immediately using a pump. Help protect our environment! Use a suitable
container. 2. Remove the inlet pipe between the air filter and the turbocharger. Removing cylinder heads
1 and 2: 3. Remove the control unit with holder, cables and cable retainer, and the fuel filter. Removing
cylinder heads 3 and 4: 4. Remove the crankcase ventilation unit. Cylinder head Removal Special tools
Number Description Illustration Tool board 87 596 Slide hammer D 2

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