_] 208877 & SERVICE SCANIA PRODUCTS 2 |Special Information ta (3-7 Wikis weer LEAKING DRAIN PLUGS IN CYLINDER BLOCK AND CYLINDER HEAD Drain Plug 207 191 l© This drain plugs fitted in our production, Sealing takes place by using a thin O-ring which is pessed together to the correct size when fitting, vans ‘On fitting this dain plug the O-ring shal fest of all be slightly oiled with engine oil and put in position in the cylin er block (eso. cylinder hoad) after which the plug is serewed in and tightened. Drain Plug 180 665 and 139 302 13 13a ‘These drain plugs have either boen fitted earlier on with a ‘thick O-ring or an aluminium washer for sealing purposes. \Wihon fitting a drain plug with O-ring ofthis type the O-ring shal be put on the crain plug “The drain plug must on no account be tightened up with ‘excessive torque since the O-ring can then be damaged. Measures against leakage “There is convex sealing washer (part No. 204541). On fit ting this item the sealing surface must first ofall be de- teased with trichiorethylene and afterwards smeared with ‘thread sealing compound (No. 561019) or, on severe carro: sion attack, plastic putty. The sealing washer is then put in its place and the washer peened inwards with @ hammer or large drift, 131 Its also possible to fit drain plugs with oversize. The hole ‘must then be tapped toa sutable oversize, after which, the 4rain plug can be fitted together witha thick O-ring. Do ot use too much torque when tightening as itis possible to ‘damage the O-ring, ‘Material Thread PartNo. Sealing Present Masx 1.5 207191 207192 (rub- drain plug 225596" bert Eorlior Ma@x 1.8 180665 182750 (alumi- drain plug 130302 sium) 130303 Convex sealing 204541 661019 (oct washer we Drain plug, 1st M46x 1.8 138279151225 (rub oversize bert Drain plug, 2nd MB2x 1.0 162695151229 (rub- oversize ber) * With connection for water hose,SERVICE SCANIA PRODUCTS jao330 MACHINING OF UPPER FACE OF CYLINDER BLOCK ON DSS ENGINES ‘On those DSE engines that did not have a liner with groove When carrying out machining in the field, our directions in the sealing ace towards the cylinder head gasket, gas must be strictly followed in order for a good result to be leakage was problematicl and frequently resulted in corso: obtained. After machining, the block must be marked with ‘sion damage to the upper face ofthe cylinder block, In LOA" at two places see Fig. 1 and 2. Every time pistons ‘otder to allow machining of the upper face, we have decided are changed on DSB engines iti necessary to check if the te supply as aspare part a special, low piston, which is block hes bean machined. (044 mm lower than the standard piston, Ths piston, which ‘may only be fited when the eyliner block has been ma chine, wil be fitted to @ large extent in our replacement engines, Fat The bloc is marked “LOA” immediatly above the engine number Fe? The block s marked “LOA” onthe upper fce ofthe block. SESF,SGSH 133" 97 [ie one Fad Low piton. The piston s marked withthe atl No lowed yt Replacement of pistons (applies to all DSB 1, Check if the marking "LOS" or "L" respectively is t0 te found on the block or pistons, See Fig. 1, 2and 3. 2, When new pistons have been fited, check the piston height on ane of the cylinders, To do this. press the ner down with the aid of tool 98318 see group Ta, [AR 3 page 2, Then measure dimensions & and B accord 179 10 fig, 4, Note that Both dimensions must be mea sured from the uppermost surface of the liner. Mea sutement B minus A must be between 0,070 and 0.500 al B Fae ‘Measurement of pson aight. The piston must bein es wpparmest position. Thelin is pressed down with ro! $8318, Mesure cin ons A and 8 wit adil indicator attached to 0 stright wd, Note {thatthe dimensions are measured from the upparmest site of the fir 353,110 - 353,190 wane Fos Haig of block ter machining Machining of upper block face 1. Measure the distance between the periphery of the main bearing seat |with the bearing sell removed) and the uP per face of the block with a measuring accuracy of # 0.015 rm, Make sue that there are no burrs on the bearing seat. A drawing ofa suitable measuring tool can be or ‘ered trom the Service Department, Scania division IVR 60194, VR 60195) 4, Machine the block (fine milling or grinding! to the pre cried height - 28 fig. 5, The profile depth must be max Fe25. 2, Set the block up in a milling or surtace grinding machine, Make sure that there are no burrs on the surtace of the sump and stand the block on this surface, Align the block ‘onthe basis of the measured distances, 4, Mark the block with 61mm high figures at two places according to fig, 1 and 2, 134(reoosee arom SERVICE 7403-30 Fitting of pistons after machining 1, Fit tow pistons - se fig. 3. 2, Check the piston height on the two outermost cylinders ‘00 fig, 4. To do this, press the liner down with tool 98318 as described in AR 12, No, 3, page 2. Measurement 8 minus A must be between 0.070 and 0,500 mm, Material Engine type Piston, complete Naked piston Ring sat Art. No. Punched Art. No. Art. No. ose 2agi77 2ag178L 550108 {milled down 0.4 mm) 135 SCANIA ae al” a7 |S Romarks Must not be fitted ‘ogether with other pistons SESESGSHarene? | Special Information SERVICE SCANIA |ia [378 T PRODUCTS a Panes I REPLACEMENT OF CYLINDER BLOCK ON D/DS10 AND D/DS11 "880840 a modified cylinder block was introduced for the 1D/DS11. The most noticeabie change in the cylinder black concerned the lubricating system, where among other things ‘the injection nozzles for el cooling ofthe pistons was intro- duced. The oil connections 10 the eylinder block were changed {rom inch threads (NPSF] to metccal threads with axial sealing cylinder block is marked "A" on the right-hand side atthe front, top corner. During the Autumn of 1974, stating from engine No, 888606 a further modified cylinder block marked 'B” was introduced, The B-marked cylinder block has in comparison to the A-marked cylinder block altered imensions for the cylinder head bolts, Brmarked cylinder head blocks are now delivered start ing trom the beginning of 1975 as spare cylinder blocks for all D/DS10 and 0/0811, \When ordering reference is made to Spare Pets Bulletin Group 2 No. 229. Depending on the type of engine, a number of parts must be ordered together with each cylinder block, Some parts ‘ate to be newly fitted and others replace earlier ones, Please see the spare parts bulletin. ‘A few points to observe when replacing the cylinder block ‘The holes in the longitudinal lubricating cilway for injection ‘nozzles ae to be sealed off with six plugs part No. 11017 anc gasket No. 35456, Tightening Torque 23 Nm (2.8 kp). 137 bs ‘Plug part Na. 11017 inthe holes for injection nazoes for oi! cooling of pctons, (On the modified engine the return oll sled from the turbo- charger tothe righthand side ofthe cylinder block. This hoe shall, on being replaced by older type cylinder block, be sealed off with plug part No, 18564 and gasket No. 35492 {By reason ofthe fact thatthe lubricating oil connections (on the cylinder block have been changed to Mtthreads new pipes are now added for the cil supply to the injection pumps and the oll outlet from the injection pump. Thus to be able to keep the old oil iter for turbocharger, the existing nipple for the supply of lubricating oil must be exchanged ‘or nipple part No, 251771, ‘The hole ust above the attachment plane for the lubricating «il cleaner isto be sealed with plug part No. 228799 and gasket part No, 739467. SE, SF, SG, SHeran] [or ida talsi | 38 [2 (On engines where the injection pump is not lubricated by the engines usual lubricating system (centrally lubricated) the holes for the supply and discharge ofthe lubricating ‘il shall be sealed off with plug No, 11017 and gasket No, ‘36456 and plug No, 10891 and gasket part No. 237976 respectvaly. “The previous studs and nuts forthe cylinder heads are ‘eplaced by hexagon screws, The A-marked cylinder ‘block i intendes for M16:bols, The B-marked cylinder block is intended for six MI8-bolts (under the injectors) ‘and for remaining MI6-bolts, Wien the B marked cylinder block is to be used for older ‘engines (up to engine No, 888805) six special studs are ‘sed with MIB.theead atthe bottom and M16-dimension at the top (see Spare Parts Bulletin) (On fitting the lubricating oil cleaner, the O-rings ae dis continued, Instead the O-rings have beon replaced by 3 now gasket part No, 239106. Pug onthe right hand side of he cylinder bloc. (Does not ‘on cenvaly lubricated injetin pumps) On a tandem-mounted compressor with lang pump coupling and where the injoction pump is centrally lubricated the lubricating i conveyed to the pump and compressor and ‘ut from the same hole in the cylinder block. The hole is sityated just beneath the compressor and in this hole @ T-ftting part No, 239913 is threaded, The usual oil supply hole to the injection pump is sealed off with plug part No. 11017 and gasket No. 35466, ‘There is no hole behind the impellers of the water pump on the new cylinder block. ‘The new guide washers part No, 170692 for the axial movement fof the crankshaft shal be fitted. The new guide washers have pins in the ends, which minimize the risk of them turning in te wrong direction, Hoxagon screns replace the studs and washers forthe ‘astening of the main bearing caps and side covers 138SERVICE SCANIA PRODUCTS Special Information 6201 REDUCTION VALVE IN OILWAY ON D/DS11 ENGINES strom engine No, 880840 2 moditied cylinder Block was Introduced for D/DS11 engines, m which the reduction salve forthe lubricating a1 lacates in the cylinder Block, Plug 136777 must be fitted in the vertical alway ust above the eauction valve ~ see Fig, If this plug isnot fitted no ‘ol pressure wil be obtained, hs ‘Par of hibcsting system on D/DS11 a8 fom engine No. 880840 1. Cylinder back (3 2 Aeaucronvave 133. Pup 136777 2 Labresung ait cleaner 138 Replacement of Cylinder Block, Newer Engines The cylinder block stocked a a spare part for D/DS11 engines as trom engine No, 860840 is fitted with plug 136777. Despite hs, iti essential to check when charg- ing cylinder blocks that this plug is actually ited. Ifthe ‘lug it missing, plug must be fitted and secured with iock Ing lui, article No, 561200. Replacement of Cylinder Block, Older Engines Te same cylinder block i also stocked asa spare part for D/DS10 and 0/081 with engine numbers up 10 880839, the only diHerence being that plug 196777 i not included con these cylinder blocks, For these engines, the eld fbi catingol cleaner and te old oi! sump with fitted reduction valve are used, If plug 136777 i fitted inthis case the reduc tion valve wil be disconnected, The oi! pressure will shen be injutiusly high Cylinder blocks stocked with or without plug 196777 have aiferent spare part numbers, but the above difference has been pointed out $0 a8 to completely eliminate the “sh of fiting the wrong block SE, SF, SG, SH3200-1305] SERVICE SCANIA PRODUKTER-PRODUCTS -PRODUKTE—PRODUCTOS VATTENLACKAGE FRAN CYLINDERHUVUD- PACKNINGEN Bakgrund Fall a vattenlackaye mellan cylinderfodres ove anda och cylinderblocket har forekommit. Detta har ovsakat kara ‘vonsskador pa cylinderblocket Aktuell information Clindermuvadpackningen bestar av en massi stp samt 150 gummirngar, Ytorna melian gummiringarna har ste nagor ta tande uppaift, Dartor kan Korrosionstkador tilitas 8 cylinder blockers ovecplan mellan tatmngstingarnasanliggningsytor Diupet pa korrosionsskadorne kan 13 uppga fill 1 om. Att iaktta ‘Vid reparation av motor a grund av vatteniackage melian cylindertoder och cylinderbiock ska ttwingsmassa 584 002 anvandas, vilken kan betallas fran var reeevaeavdelning \Vid reparation av motor med korrosionskador pa cylinder blockets overplan, Kontrollea at skadorna inte forekommer a nageatatningsytor id anvandning av tatningsmassa ska foljande purkterfoias: 1. Rengor eylinge:todret noggrant. 2. Kontroliers, om nodvandigtjustere, fodernojden genom brotschning. Eventuela korrosionsskador méste brothas bort innan tatningsmassananbvingas. 3, Satt tatningsringarna i blocket och anol ringar och recr styrningsytan for eylindertocret med motorola 4, Avtetta med avtetiningsmedel, foderkragen och sparet ‘under samt foxerlaget, 5. For palaggning av tatningamassan anvands en sprutpistol vilken tuben med munstycke placeras. Lagg pa tatmingsmassa "en obruten strang (9 3 mm! i sparet under foderkragen. Se fig, Lag tatringsmasson pa ett eylindertode tage 6, Montera eylindertogret 9a vanligsatt inom 1S min efter det att tatningsmassan plats. OBS! laktta fesiktighet 3 art, strangen med tatningemassa inte skads. 7, Tryck ner eylinderfodret med hjaip av 1a spannklackar, 98515, Atdragningsmoment: 50 Nm (5,0 kpm). Avlagsra overtloaigtatringsmassa. Lat eylindertodret vara nad: pressat tills nasa cylinderfoder sks monterss 1 Gylindertoder 2 Cylinderbiack 3 Taningsmas pines tin ylinaer block Seatog compound Zphnseriuteichse 2. Zylinderback Dicheungsmasse 1. Comisa de ciniro Blogue de citindras 1, Pasta do cirre 1400 Special Information wvwnwee | Informacion especial la 78-03-15 ETS 5014312 [Gare] WATER LEAKAGE FROM CYLINDER HEAD GASKE Background (Cases have been recorded of water i ‘of eylinder liner and cylinder Blo corrosion damage to cylinder block. age between top end This has resulted in Current information The evlinder head gasket consists of a solid steel plate and separate rubber rings. The surtaces between the rubber rings 60 not pertorm any sealing function. For this reason cuir ‘sion damage to the upper surtace of the cylinder block peemitted between the contact surfaces of the Fubber rings. Depths of corrosion attack shuld not exceed 1 10m To be observed When working on engine for repairs to water leakage betwee cylinder liner and cylinder block, use sealing compound Fel-Pro RTV Clear (Part No, 360) or General Electric RTV108. When repairing corvosion damage to top surface of eylindes block, check for damage to sealing surfaces. The sealing compourd should be used as follows 1. Caretully clean eylinde liner seas. 2. Check cylinder liner height and, if necessary, adjust by reaming, Any corrosion damage must be reamed away betore sesiing compound is applies 43, Fit sealing rings ito block and use engine oll ta oil rs and lower guide sutace for eylinde line. 4, Ongrease with degreesing agent, liner collar, groove below collar an liner sat. If shims are used, these must alo be ear eased, 5. To apply sealing compound, use an injector gun, into wich the tube with the nozzle is ite. Apply a continu us bead (3.0 mm dial into groove below liner collar as shown in figure below. Apply sealing compound to one cylinder line a ati. 6, Fit the cylinder liner in the usual manner within 18 mi ‘tes after applying sealing compound, Nate: Take eare nat to damage bead of sealing compound. 7, Press.cylinder liner down by means of two elampiny Dsds ‘98516. Tightening torque: 60 Nm 16.0 kg/m), Remove surplus sealing compound. Keep liner pressed dowa until next liner i 0 be fitted Cyindertoer Cylinder iar Tatingsmassa Seating compound Zlindeciautoicse Camis de cilindro Dichwungsmasse Pasta de civre 9/12/78sopo]sa Tar fede tals) | 3— VASSERLECKAGE VON ZYLINDERKOPF- DICHTUNGEN Ania alle von Wasserieckage zwischen dem oberen Ende der !ylinderlautbiichse und dem Zylinderblock sind vorge: ‘ommen, welehes Korrosionsschaden am Zylinderblock werursacht hat, Aktuelle Information die Zvlinderkoptdichtung bestent aus einem massiven Stahiblech und loren Gummiringen, Die Flachen zwischen sen Gummiringen haben keine abdichtende Aufgabe. Des- 1alb konnen Kortosionsschiden an der oberen Zylinder- slockttache zwischen den Anliegeflachen der Dichtringe 2uléssg sein. Die Korrosionsschaden Konnen bis 2u 1 mm. tie zein. Zu beachten Bei der Reparatur des Motors aufgrund von Wasserleckage wischen Zylinderlautbuchse und Zylinderblock mus die Dichtungsmasse 584 002 benutzt werden, die von unserer Ersatztellabteilung bestellt werden kann. Bei Reparatur des Motors mit Korrosionsschaden an der Zylingerblockobertiache ist 2 kontrollieren, da’ Schden nicht bei anderen Dichttlichen vorkommen. Bei Benutzung der Dichtungsmasse sind folgence Punkte 2u beachten: 1. Zylinderlautbuchse sorgtattig reinigen. 2. Zylinderlaufbichsenhohe Kontrollieren und wenn not- wendig durch Ausreiben justieren. Eventuelle Korrosions- schaden mussen ausgerieben werden, bevor die Dichtungs: masse angebracht wird 3. Dichtringe in den Block setzen und die Ringe und untere Fuhrungstlache fir die Zylinderlautbichse mit Motor6t leicht olen. 4. Den Zylinderlautbichsentiansch, die Nut darunter und den Zylinderlaufbichsensitz mit Entfextungsmitel ent ferten. 5. Fur das Autlegen der Dichtungsmasse eine Spritzpistole benutzen, in welcher die Tube mit der Duse placiert wird. Die Dichtungsmasse in einem zusammenhangenden Strang (Durchmesser 3 mm) in die Nut unter dem Bichsenflansch legen, Siehe Fig. Jede Zylinderlautbichse einzeln mit Dichtungsmasse belegen. 6. Die Zylinderlaufbichse wie Ublich montieren. ACHTUNG! Vorsichtig sein, damit der Strang der Dichtungs- ‘masse nicht beschidigt wird. 7. Die Zylinderlaufbiichse mit Hilfe von zwei Spannsticken, 98515, herunterdricken, Anzugsdrehmoment 60 Nm (6,0 kpm). Uberflassige Dichtungsmasse entfernen Die Zylinderlautbichse heruntergepreBt lassen, die nachste Zylinderlaufbichte montiert wird. FUGA DE AGUA DE LA JUNTA DE CULATA, Antecedentes ‘Se han dado casos de fuga de agua entre el extremo superior ela carisa del cilindro y el Bloque de cilindros. Esto ha ‘ocasionado dafios de corrosién en el Bloque de cilindros. Informacion actual La junta de culata consta de una chapa de acero macizs y anillos de goma sueltos. Las superficies entre los anillos de ‘gora no tienen ninguna funcion de cierre. Por esta razon se pueden permitir dafos de corrosion en el plano superior del bbloque de cilindros entre las superficies de contacto de los anillos de cierre. La profundidad permitida de los dafios de corrosion puede llegar hasta 1 rm. Se observard ‘Al reparar un motor debido 2 fuga de agua entre fa camisa del cilindro y el Bloque de cilindros se emplearé pasta de cierre 584 002, que puede obtenerse de nuestro Departamento de Repuestos, ‘Al reparar un motor con dafios de corrosién en el plano superior del Bloque de cilindros, controlar que no haya dafios em las superficies de cere ‘Al emplear pasta dé cierre se seqursn los siguientes puntos: 1. Limpiar minuciosamente la camisa del cilindro. 2. Controlar fa altura de la camisa, y si tuera necesario, ajustar la escariando. Antes de aplicar la pasta de clerre habré que uitar escariando eventuales dafios de corrosion. 3. Colocar los anillos de cierre en el bloque. Aceitar los anillos Y la superficie de guia inferior para la camisa con aceite pare motor. 4. Desengrasar el euello de la camisa, la ranura debajo y el alojamiento de la camisa con un producto desengrasador, Si se emplean arandelas de ajuste habra también que desengrasarlas 5. Para la aplicacion de la pasta de cierre emplear una pistola de inyeccién en la cual se coloce el tubo con boquill Aplicar la pasta en cordén continuo (de 3 mm de digmetro) en la ranura debsjo del cuello de la camise. Ver Ia figura ‘Aplicer la pasta en las camisas, una a una. 6. Montar la camisa como de costumbre. 7. Meter la camisa presionando hacia abajo con dos talones ‘tensores 98515. Par de apriete 60 Nm (5,0 mkg). Quitar Ia pasta de cierre supertiua. Mantener la camisa apretada hasta montar la siguiente. (Note: Pages 141 thru 146 have been obsoleted)