03:04-04

Issue 5 en

Scania HPI injection system and

EDC S6

Work Description

126 715

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Scania CV AB 2006, Sweden
1 712 534
Contents

Contents
General .................................................................................. 3

Removing the unit injectors .................................................................................. 4

Fitting the unit injectors .................................................................................. 5

Adjusting valve clearances and

unit injector closing force .................................................................................. 7

Checking pressure and flow in fuel

system ................................................................................ 10

Integrity check ................................................................................ 15

Cylinder balancing ................................................................................ 16

Renewing the fuel filter ................................................................................ 18

Bleeding the fuel system ................................................................................ 21

Fuel manifold, valve housing and

solenoid valves Removing and fitting .............................................. 22
Fuel shut-off valve.................................................. 24

Fuel pipe Removal.................................................................. 25

Fitting ..................................................................... 28

Connections on the control unit Removal.................................................................. 29

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 General

General

! WARNING!

High tension voltage. Do not touch the

electrical connections on the solenoid
valves, the wiring or the pins of the
control unit when the engine is running
or when the solenoid valves are
activated by Scania diagnos. The control
unit sends 120 V pulses to the solenoid
valves.

The control unit sends 120 V pulses to the

solenoid valves. This, in turn, gives a current of
7.5 A which opens the solenoid valves at each
injection. The voltage then drops to 24 V, and
the current drops to 3.75 A.

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Removing the unit injectors

Removing the unit injectors

Conditions: The rocker cover, rocker arm

assembly, and valve bridges have been removed.
The parts should be marked so that they can be
refitted in their original positions.

Tools

Number Designation Picture Tool board

588 476 Crowbar D2

118 214
1 Unscrew the retainer.

B117893
2 Remove the unit injector using crowbar
588 476.
B117894

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 Fitting the unit injectors

Fitting the unit injectors

1 Fit new O-rings. Lubricate the O-rings with

engine oil.
2 Fit a new copper washer to the unit injector.

118 386
3 Fit the unit injector by pressing it into
position by hand as far as possible.
4 Fit the retainer and press down the unit
injector to its correct position by tightening
the bolt.
5 Unscrew the bolt.

118 406

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Fitting the unit injectors

6 Tighten the bolt on the retainer to 20 Nm

using a torque wrench, then change to a
ratchet handle and tighten the bolt 75°. See
the illustrations.

IMPORTANT! The marks on the rocker cover

are not intended for engines with HPI, therefore
they cannot be used for angle tightening.

IMPORTANT! Make sure the adjusting screws 20Nm + 75

o
105 Nm
on the rocker arms are in the unscrewed
position.

7 Refit the rocker arm assembly. Tightening

torque 105 Nm.

IMPORTANT! Make sure the pushrods and the

valve bridges are fitted in the correct positions.

118 425
8 Adjust the valve clearances and the unit
injector closing force.

75
118 479

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 Adjusting valve clearances and unit injector closing force

Adjusting valve clearances and unit injector closing force

Specifications

Valve clearance, intake valve (cold engine) 0.45 mm

Valve clearance, exhaust valve (cold engine) 0.70 mm

Tightening torque
Adjusting screw lock nut on rocker arm for valves 35 Nm
Adjusting screw on the unit injector rocker arm 6 Nm +60°
Adjusting screw lock nut on the unit injector rocker arm 39 Nm

Special tools

Number Designation Picture Tool board

99 309 Tool to rotate flywheel 99 309
D5
00 1548

Note: If the complete injection mechanism or

any of its components (valve tappets, pushrods,
rocker arms or unit injector) are renewed, the
unit injector closing force must be readjusted
after 20,000 km. The reason for this is that the
closing force is reduced as the components are
run in.

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Adjusting valve clearances and unit injector closing force

Order of adjustment
1 Rotate the flywheel in the direction of
engine rotation using tool 99 309 so that the
mark on the flywheel is visible in the lower
window of the flywheel housing.

IMPORTANT! Check and adjust the valve

clearances and adjust the unit injector closing
force with the engine cold.

2 Adjust the valve clearances and the unit

injector closing force as shown in the table
below.

Mark on flywheel Valve overlap on Adjust intake and Adjust the unit
(degrees) cylinder exhaust valves on injector on cylinder
cylinder
TDC Down 0° 6 1 4
120°/480° 2 5 1
240°/600° 4 3 5
TDC Down 360° 1 6 3
120°/480° 5 2 6
240°/600° 3 4 2

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 Adjusting valve clearances and unit injector closing force

Adjusting the valve clearance Adjusting the unit injectors

The intake valves are actuated by the short The unit injector must have a specific closing
rocker arms and the exhaust valves by the long force.
rocker arms.
To adjust the closing force, proceed as follows:
1 Make sure the valve bridge is resting
correctly against the valves. 1 Loosen the adjusting screw on the unit
injector rocker arm.
2 Check the valve clearance using a feeler
gauge and use the adjusting screw on the 2 Lubricate the adjusting screw.
rocker arm to set the correct clearance.
3 Tighten the adjusting screw to 6 Nm +60°.
- The clearance on the intake valves should
be 0.45 mm. 4 Tighten the lock nut on the unit injector
rocker arm to 39 Nm.
- The clearance on the exhaust valves should
be 0.70 mm.
3 Tighten the lock nut on the valve rocker arm
to 35 Nm.

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Checking pressure and flow in fuel system

Checking pressure and flow in fuel system

Measuring fuel pressure

Special tools

Number Designation Picture Tool board

99 362 Pressure gauge
14

OIL

14 TURBO

115 102
12 TURBO
8 FUEL

The fuel pressure in the valve housing can be

read off using Scania Diagnos. The fuel pressure
in Scania Diagnos is an absolute pressure, i.e.
the pressure produced by the feed pump plus
atmospheric pressure.
By connecting a pressure gauge 99 362 to the
bleeder nipple on the fuel filter, the supply
pressure before the fuel filter is measured.
Pressure gauge 99 362 measures overpressure,

126 716
i.e. the pressure produced by the feed pump.
User instructions for pressure gauge 99 362 can
be found in booklet 01:00-03. Connection of pressure gauge 99 362

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 Checking pressure and flow in fuel system

If the engine can be started

1 Connect the pressure gauge to the bleeder
nipple on the fuel filter.
2 Start the engine and measure the fuel
pressure at idling speed, 500 rpm. The
minimum permitted pressure is:
• 13.1 bar for engine types DC1204 and
DT1210
• 14.6 bar for other engines
3 Also measure the fuel pressure at
1500 r/min. If the fuel pressure is more than
25 bar, the fuel filter is probably blocked
and should be renewed.

If the fuel pressure is too low, inspect

the following:
• Overflow valve in valve housing.
• Overflow valve in filter.
• Fuel pipes with connections.
• Fuel pick-up unit.
• Feed pump.

To check whether the fault is before or after the

fuel shut-off valve, proceed as follows:
1 Remove one of the cables on the fuel shut-
off valve, which will close when it is no
longer powered.

IMPORTANT! Do not crank with the starter

motor for longer than 30 seconds at a time.

2 Crank with the starter motor and measure

the fuel pressure.
3 If the pressure is higher than it was
previously, the fault is after the fuel shut-off
valve.

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Checking pressure and flow in fuel system

If the engine cannot be started

If the engine fails to start this may be due to the
fuel pressure being too low.

IMPORTANT! Do not crank with the starter

motor for longer than 30 seconds at a time.

• Crank with the starter motor for

approximately 20 seconds. At the same
time, check the fuel pressure using Scania
Diagnos. It is the fuel pressure in the valve
housing that is displayed in Scania Diagnos. The fuel pressure does not exceed
10 bar:
1 Check whether the overflow valves are
sealing.
2 If they are not sealing, they should be
cleaned as follows:

There is no fuel pressure in the valve 3 Mount the overflow valve in a vice.
housing:
1 Measure the fuel pressure at the fuel filter.
2 If the fuel pressure at the fuel filter is OK,
there is probably a fault in the fuel shut-off
valve.
Check the fuel shut-off valve using Scania
Diagnos. 127 209

4 Open the overflow valve by pressing the

piston down with a screwdriver and blow it
clean with compressed air.

5 Check the sealing again.

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 Checking pressure and flow in fuel system

Checking the fuel flow

• Open the bleeder nipple and crank with the
starter motor for approximately 20 seconds.
Check the fuel flow from the fully open
bleeder nipple.

No fuel comes out Fuel and air comes out

1 Check that the air compressor is working. 1 Check that the suction pipes at the fuel pick-
Remove the pipe at the outlet and listen. up unit are sealed and are fitted correctly.
If the compressor is not working, check the 2 Check that the return line between the
gear driving the compressor. overflow valve and feed pump is sealed and
fitted correctly.
2 If the compressor is working, check the feed
pump. 3 Check the drain at the bottom of the fuel
filter, the filter cartridge should close the
drainage passage.
If you do not find any faults, disconnect the two
suction pipes from the feed pump. Plug the
lower connection. Connect a temporary pipe to
the upper connection and pull the pipe down to a
receptacle containing fuel or directly into the
fuel tank.
4 Crank with the starter motor with the
bleeder nipple open for approximately
20 seconds and check the fuel flow from the
fully open bleeder nipple.
5 If fuel is sprayed out of the bleeder nipple,
close the bleeder nipple and start the engine.
6 If the engine starts, the fault is between the
feed pump and fuel tank.
7 Check the suction pipes and fuel pick-up
unit and finally the feed pump.

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Checking pressure and flow in fuel system

Note: All work that involves opening the fuel

system must be completed in the following way:
Start the engine and check for leaks. Allow the
engine to run until it is running smoothly.
Check and delete any fault codes registered in
the control unit using Scania Diagnos after the
work has been completed.

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 Integrity check

Integrity check

The following check can be carried out to check

the sealing of the fuel system suction and
pressure sides up to the fuel shut-off valve.

Checking the remaining pressure

in the fuel system
1 Connect pressure gauge 99 362 to the
bleeder nipple on the fuel filter. Refer to the
section Measuring fuel pressure.
2 Start the engine and then turn it off. Then
read the fuel pressure.
3 The fuel pressure should rise first to
approximately 26 bar (overflow valve
opening pressure) and then fall to
approximately 4 bar.
4 The fuel pressure should then fall slowly to
zero bar, provided that the fuel system has
been bled properly.
5 If the fuel system falls to zero bar in less
than 5 minutes, there are abnormal leaks.
6 Check the fuel pipes, check valve in fuel
pick-up unit, overflow valves and fuel shut-
off valve.

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Cylinder balancing

Cylinder balancing
The following examples show how it is possible
to carry out troubleshooting on the fuel system
by looking at cylinder balancing in Scania
Diagnos.
The fault is generally found on a cylinder or
cylinders receiving more fuel than normal, so
start by looking for a fault on these cylinders.

Fault on injection timing solenoid

valve
If one of the injection timing solenoid valves is 1 2 3 4 5 6
20
defective, the control unit will direct more fuel
to the cylinders on that bank.
In the example in the illustration it is the
solenoid valve on the rear bank, cylinders 4-5-6,
which is defective and must be renewed.
0
A vehicle with a defective injection timing
solenoid valve will emit white smoke when
idling at 1,500 rpm.

127 207
-20
-12 -10 -13 4 11 20

Example from the cylinder balancing window in

Scania Diagnos.

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 Cylinder balancing

Fault on intake or exhaust valve 1 2 3 4 5 6

20
If there is a fault on one of the intake or exhaust
valves, the control unit will direct more fuel to
the cylinder on which there is a fault.
In the example in the illustration, one of the
valves on cylinder 6 is not working correctly
0

127 208
-20
-2 -1 -8 -5 -5 20

Example from the cylinder balancing window in

Scania Diagnos.

Fault on a unit injector 1 2 3 4 5 6

20
If a unit injector does not open when it should
fill with fuel, the control unit will direct more
fuel to the cylinder (No. 5 in the example).
In the example in the illustration, the unit
injector on cylinder 5 is defective.
0
To check whether the cylinder is receiving any
fuel, the exhaust temperature can be checked.

127 285

-20
4 -2 -2 0 18 -19

Example from the cylinder balancing window in

Scania Diagnos.

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Renewing the fuel filter

Renewing the fuel filter

Removal

Special tools

Number Designation Picture Tool board

588 475 Sleeve Maintenance trolley

118 268
1 Open the bleeder nipple on the filter to
release any remaining pressure. It may be
difficult to unscrew the filter cover if the
system pressure has not fallen enough.

Note: Fuel will come out of the bleeder nipple

and this should be collected in a suitable
manner.

2 Unscrew the filter cover with a closed tool

with hexagon driver, e.g. socket 588 475.

Note: Do not use an adjustable spanner or other

open tool as there is a risk of damaging the filter
lid.

3 Lift out the filter cover with filter element

from the fuel filter housing. The filter
housing will drain automatically (slowly)
once the filter element has been removed.

Note: If the drain is not working, the remaining

fuel should be removed.

4 Unscrew the overflow valve and blow the

strainer in the filter housing clean.
5 Also wipe the bottom of the filter housing.
6 Undo the old filter element from the cover
by carefully bending it to one side.

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 Renewing the fuel filter

Fitting

Tightening torque

Fuel filter cover 25 Nm

Special tools

Number Designation Picture Tool board

588 475 Sleeve Maintenance trolley

118 268
1 Fit a new O-ring on the lid. Lubricate the
O-ring with O-ring grease 1 402 039.
25 Nm
2 Press a new filter element into the snap
fastener in the cover.

IMPORTANT! Fit the filter element into the

cover before placing it in the housing or the
filter element might be damaged.

3 Press down the filter element into the

housing with the cover. Tighten the cover
with a closed tool with hexagon driver, e.g.
socket 588 475. Tightening torque 25 Nm.

IMPORTANT! Screw on the cover to the

specified torque or the filter element may break.
Do not use an adjustable spanner or other open
tool as there is a risk of damaging the filter lid.
B 119 290

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Renewing the fuel filter

4 Bleed the fuel system as described in the

section Bleeding the fuel system.

Note: All work that involves opening the fuel

system must be completed in the following way:
Start the engine and check for leaks. Allow the
engine to run until it is running smoothly.
Check and delete any fault codes registered in
the control unit using Scania Diagnos after the
work has been completed.

Removing the fuel pipe between

the fuel filter and the fuel manifold
When removing the fuel pipe between the fuel
filter and the fuel manifold it can be difficult to
access the connection on the fuel manifold. To
facilitate removal, first detach the connection at
the fuel filter and then use tool 98 681 to detach
the connection on the fuel manifold.
126 717

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 Bleeding the fuel system

Bleeding the fuel system

1 Attach a clear plastic hose to the bleeder

nipple on the fuel filter housing.

IMPORTANT! Do not crank with the starter

motor for longer than 30 seconds at a time.

2 Open the bleeder nipple fully and crank

with the starter motor until the fuel system
is purged free of air.
Run until all the air has been removed and
there is a good flow of fuel.

3 Close the bleeder nipple and remove the

hose.

4 Start the engine and check for leaks.

B 119 292

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Fuel manifold, valve housing and solenoid valves

Fuel manifold, valve housing and solenoid valves

Removing and fitting

Remarks on the illustration

Pos. Designation Remarks

4 Seals Make sure the seals are positioned correctly.
13 Banjo screw Tightening torque 23 Nm.
18 Fuel shut-off valve The fuel shut-off valve consists of loosely fitted
component parts. When detaching it, it falls
apart. Assembly is described in the following
section.
28 Bolt Tightening torque 26 Nm.

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 Fuel manifold, valve housing and solenoid valves

4 (6x)

7 (6x)

6 (5x) 13 (6x)
23 Nm

14

3 (2x) 17 18

5 (2x)

2 (2x) 8 (4x)
29

30
15 16 12 (4x)

25 (2x) 31 (2x)

32

28 (4x)
19

20
26 (2x)
21
36
35 27 (4x) 26 Nm
22

23 33 (12x)

11 (12x)
34 (4x)
24 (2x)

126 718
9 (2x) 10 (2x)

1 Fuel manifold 12 Bolt 25 Sealing ring

2 Bracket* 13 Banjo screw 26 Pressure dampers
3 Coupling for fuel line 14 Valve housing 27 Bolt
4 Seals 15 Plug 28 Bolt
5 O-ring* 16 Sealing ring 29 Sealing ring
6 O-ring 17 O-ring 30 Union
7 Sealing ring 18 Fuel shut-off valve 31 Bolt
8 Bolt* 19 Nozzle 32 Sensors
9 Solenoid valves for fuel 20 O-ring 33 O-ring
volume 21 Valve housing 34 O-ring
10 Solenoid valves for 22 Pressure relief valve 35 Snap ring
injection timing
23 Coupling for fuel line 36 Filter
11 Bolt
24 Bolt

*Only fitted on vehicles with fuel pressure sensors.

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Fuel manifold, valve housing and solenoid valves

Fuel shut-off valve

Assembly
Assemble the component parts of the fuel shut-
off valve as illustrated.
The sealing rings A are identical.

IMPORTANT! Make sure the washer B is

turned the right way round. See illustration. If
the washer is turned the wrong way, it might be
difficult to start the engine.

118 351

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 Fuel pipe

Fuel pipe

Removal

Special tools

Number Designation Picture Tool board

99 425 Removal tool D5-B1

! WARNING!

There may be residual pressure in the

pipes. Use protective goggles during
removal.

1 Spray rust dissolver onto the fuel pipe

attachment on the pick-up unit.

126 030
2 Blow it clean with compressed air.

Note: It is important for the pick-up unit to be

clean so that there will be space for the tool to
push away the lugs in the lock sleeve.

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03:04-04 Scania CV AB 2006, Sweden 25
Fuel pipe

3 Grip the fuel pipe and pull it to and fro a few

times so that the O-rings are released from
the fuel pick-up unit. It should be possible to
pull the pipe 1-2 mm.

126 031
4 Place the tool around the fuel pipe.

126 032

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 Fuel pipe

5 Gently press the pipe into the fuel pick-up

unit and then press in the tool.

Note: Do not pull the hose when the tool is

pressed in. The lock operates differently from
traditional hose locks.

126 033
6 Pull out the pipe and tool from the pick-up
unit.

Note: The tool should be attached to it.

126 034

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03:04-04 Scania CV AB 2006, Sweden 27
Fuel pipe

Fitting
1 Check that the fuel pipe O-rings are intact
and lubricated. The O-rings can be
lubricated with diesel or red O-ring grease.
Check also that the snap ring in the fuel
pick-up unit is intact.

126 035
2 Press the fuel pipe into the pick-up unit until
a click can be heard.

126 036

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 Connections on the control unit

Connections on the control

unit

Removal
You can make an aid from steel wire, see
illustration, to make it easier to remove the 42
connections. 2.5

60

127 210
15

127 211

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