Scania DI16 XPI. Marine engine en-GB 2 741 685. Operator’s manual - part 4
Cooling system
Removing the heat exchanger
When the heat exchanger core needs cleaning,
the heat exchanger must be removed.
WARNING!
Use protective gloves as coolant can cause irrita-
tion if it comes in contact with the skin. Hot cool-
ant can also cause scalding.
1. Make sure that the cooling system is empty
as described earlier.
2. Remove the sea water pipe between the
charge air cooler and heat exchanger.
3. If the engine has a water-cooled exhaust pipe
bend: Remove the sea water pipe between
the heat exchanger and the exhaust pipe
bend.
4. Remove the coolant pipe with the thermostat
housing cover.
48
Cooling system
5. Remove the coolant pipe from the heat ex-
changer.
6. Remove the screws on the heat exchanger
and the 2 upper screws on the exhaust mani-
fold bracket.
7. Remove the heat exchanger by holding it in
the bracket, moving the heat exchanger
slightly to the side and removing it.
49
Cooling system
Cleaning the heat exchanger
1. Remove the screws on the heat exchanger
covers (1) and remove the covers. Mark the
covers so that you can put them back on the
1
correct side.
5
2. Press in the cooler core (5) slightly on one
3
side and pull it out from the other side.
3. Clean the cooler core on the outside with par-
affin-based engine detergent. Remove any
4
3
internal deposits using a round rod. Renew
2
1
the cooler core if it is damaged.
IMPORTANT!
Do not use caustic soda as this could damage the
aluminium.
4. Renew damaged or hard O-rings (3).
5. Assemble the heat exchanger. Tighten the
M8 screws on the cover to 15 Nm (11 lb-ft).
50
Cooling system
Fitting the heat exchanger
1. Fit the heat exchanger by holding it in the ex-
haust manifold bracket, moving it slightly to
the side and fitting it.
2. Fit all screws by hand and then tighten them.
Tightening torque 50 Nm (37 lb-ft).
1
2
3. Lubricate and fit the coolant pipe from the
heat exchanger. Angle the pipe from the ther-
mostat housing inwards and push it onto the
connection.
51
Cooling system
4. Fit the coolant pipe with the thermostat hous-
ing cover.
5. Fit the sea water pipe between the charge air
cooler and heat exchanger.
6. If the engine has a water-cooled exhaust pipe
bend: Fit the sea water pipe between the heat
exchanger and the exhaust pipe bend.
52
Cooling system
Fitting the charge air cooler
1. Fit the charge air cooler. Tighten the 4
screws to 50 Nm (37 lb-ft).
2. Carefully fit the charge air pipe from the left-
hand turbocharger and tighten the V-clamp
to 20 Nm (15 lb-ft).
3. Fit the charge air pipe from the left-hand tur-
bocharger. Fit the V-clamp first and then the
screw on the bracket.
4. Fit the sea water pipe from the sea water
pump, first to the charge air cooler (the inner
pipe) and then from the charge air cooler to
the heat exchanger (the outer pipe).
53
Cooling system
5. Fit the charge air pipe and the hose clamps.
6. Fit the crankcase ventilation hose.
7. Fit the catwalk:
- Loosely fit the protective plate to the
charge air pipe. Tighten the screws later.
- Fit the protective casing. Tighten the
screws later.
- Fit the catwalk with screws.
- Tighten all screws. The protective plate
and protective casing must be tightened to
a tightening torque of 15 Nm (11 lb-ft).
54
Cooling system
Internal: Removing oil and grease
Environment
Use a suitable container. Used coolant must be
disposed of as specified in national and interna-
tional laws and regulations.
Always fit a new thermostat and a new cover to
the expansion tank after cleaning, as the oil in the
cooling system destroys the seals. If the engine is
equipped with a coolant filter, also renew this fil-
ter.
It may be necessary to wash it multiple times if
the cooling system is very dirty. One cause of
contamination can be that oil is lying on top of
the coolant and collecting high up in the cooling
system. If several rinses are needed, this is not
necessarily because work has been carried out
incorrectly. Oil residues often need to be rinsed
repeatedly from the expansion tank and the ex-
ternal heating system to be completely clean.
Repeated washing is more effective and prefera-
ble to using higher concentrations of detergent
(max. 10%) or cleaning for a longer period (max
30 minutes).
If only a small amount of dirt has collected in the
expansion tank after cleaning, one extra rinse
and clean of the expansion tank only is usually
sufficient. There is no need to clean the whole
cooling system again.
1. Run the engine until it has reached operating
temperature and then drain the cooling sys-
tem following the previous description.
2. Remove the thermostats.
3. Fill the cooling system with clean hot water
mixed with detergent 2 479 017. Detergent
2 479 017 must make up 5-10% (depending
on the degree of dirt) of the total coolant vol-
ume.
If detergent 2 479 017 is not available, use a
dishwasher detergent for household dish-
washers that does not foam. Concentration
1%.
4. Run the engine until it has reached operating
temperature for approximately 20-30 min-
utes. Remember to switch on the cab heating
system, if one is installed.
5. Drain the cooling system.
6. Fill the cooling system with clean, hot water
and run the engine for about 20-30 minutes.
55
Cooling system
7. Repeat steps 3-6 if the cooling system is not
clean.
56
Cooling system
8. Drain the water from the cooling system.
9. If necessary, clean the expansion tank by de-
taching all hoses and rinsing and cleaning
with a degreasing agent and a dishwashing
brush.
Alternatively, dismantle the expansion tank
and clean it with water with 10% of detergent
2 479 017. Fill the expansion tank with the
mixture, shake it and drain it. Renew the cov-
er of the expansion tank.
10. Refit the thermostats.
11. Fill the cooling system with new coolant as
described in the next section.
12. Check again whether further dirt or oil has
collected in the expansion tank. Decide
whether it it is necessary to carry out another
full cleaning or whether only rinsing or
cleaning of the expansion tank will suffice.
Internal: Removing deposits
Environment
Use a suitable container. Used coolant must be
disposed of as specified in national and interna-
tional laws and regulations.
1. Run the engine until it has reached operating
temperature and then drain the cooling sys-
tem following the previous description.
2. Remove the thermostats.
3. Fill the cooling system with clean, hot water
mixed with radiator detergent which is based
on sulphamic acid and contains dispersing
agents. Follow the manufacturer's instruc-
tions for the concentration and cleaning peri-
od.
4. Run the engine for the specified time. Re-
member to switch on the cab heating system,
if one is installed.
5. Drain the cooling system.
6. Fill the cooling system with clean, hot water
and run the engine for about 20-30 minutes.
7. Drain the water from the cooling system.
8. Refit the thermostats.
9. Fill the cooling system with new coolant as
described in the next section.
57
Cooling system
Filling coolant
This procedure applies when the cooling system
has been drained and needs to be filled with a
large amount of coolant.
Special tool
Number, designation
2 443 679, coolant
pump
WARNING!
Use protective gloves as coolant can cause irrita-
tion if it comes in contact with the skin. Hot cool-
ant can also cause scalding.
IMPORTANT!
Mix the coolant as specified in the section head-
ed Coolant.
Never fill a large amount of cold coolant in a hot
engine. There is great risk of cracks forming in
the cylinder block and cylinder heads.
Do not start the engine until the correct coolant
level has been obtained. If the engine is started
with an insufficient coolant level, it can damage
the coolant pump shaft seal, which leads to cool-
ant leakage.
58
Cooling system
1. Open the expansion tank cap.
2. Connect the coolant pump to the filler nipple
in the cylinder block.
3. Connect the pump's 2 cable terminals to the
battery's negative and positive terminal.
Make sure that the filling starts. If the filling
does not start: Change the position of the ca-
ble terminals.
4. Start the engine and run it at idling for
15 minutes.
IMPORTANT!
It is very important that the engine is idling. En-
gine overspeed could damage the coolant pump
shaft seal, which leads to coolant leakage.
5. Switch off the engine and fill with coolant to
the maximum level through the expansion
tank.
Air pockets may still be left in the cooling sys-
tem. These will disappear after the engine has
been operated for a period of time. Therefore, the
coolant may need topping up at a later stage.
Finishing operations
1. Open the bottom valve on the sea water inlet.
2. Start the engine and check that no leakage
occurs.
3. Check the coolant level and top up the cool-
ant via the expansion tank if necessary.
59
Fuel system
Fuel system
Cleanliness requirements
IMPORTANT!
The whole fuel system is very sensitive to dirt
and even very small particles. Foreign particles
in the system can cause serious malfunctions. It
is therefore very important that everything is as
clean as possible when work is carried out on the
fuel system. Before repair work, the engine must
be washed. If possible, a hot water wash should
be used.
It is strictly forbidden to carry out any machining
work or work with compressed air near an open
fuel system.
Be extra careful and always use clean, lint-free
and dust-free clothes and gloves when working
on the fuel system. Scania recommends using
Tegera 848 gloves.
Clean tools before they are used and do not use
any worn or chrome-plated tools. Material and
flakes of chrome may come off.
Clean connections and the surrounding area be-
fore removal. When cleaning, cloths or paper
which shed fibres must not be used. Use clean
and lint free cloths, part number 588 879.
Plug or cover the connections during removal.
Also clean the connections before the compo-
nents are fitted. Place removed components on a
thoroughly cleaned, dust-free surface. Scania
recommends using a stainless steel bench top,
part number 2 403 296. Cover the components
with a lint free cloth.
Checking the fuel level
Check the fuel level and top up with fuel as nec-
essary.
Note:
If the fuel tank has been run dry or if the engine
has not been used for a long time, bleed the fuel
system. See the section Bleeding the fuel system.
60
Fuel system
Draining and renewing the
water separating prefilter
4
IMPORTANT!
The sensor cable is sensitive. Handle it carefully.
Environment
3
3
Use a suitable container. The fuel collected must
be disposed of as specified in national and inter-
national laws and regulations.
1. Close the shut-off cock in the fuel pipe and
position a container under the filter.
1
2
1
2
2. Detach the sensor cables from the contact
housings (1) on the filters.
3. Open the filter drain plugs (2) and allow the
fluid to run down into the container.
4. Unscrew the filters (3) from the filter head
(4).
5. Discard the old filters and use new ones.
6. Lubricate the O-rings on the filters with en-
gine oil.
7. Fill the width of the filters with clean fuel.
8. Screw the filters into position until the O-
rings rest against the filter head. Tighten the
filters another quarter to three quarter turn by
hand.
9. Open the shut-off cock in the fuel pipe and
check that the fuel system is sealed.
10. Connect the sensor cable to the contact hous-
ings on the filters.
11. Bleed the fuel system according to the in-
structions in the Bleeding the fuel system
section.
61
Fuel system
Draining and renewing the
single water separating prefil-
ter
IMPORTANT!
The sensor cable is sensitive. Handle it carefully.
Environment
4
Use a suitable container. The fuel collected must
be disposed of as specified in national and inter-
national laws and regulations.
Before starting work: Close the shut-off cock in
3
the fuel pipe and position a container under the
filter.
1
1. Undo the sensor cable from the connector on
the filter bracket.
2
2. Open the drain tap in the filter cover and let
the fluid run down into the container.
3. Unscrew the filter cover.
4. Unscrew the filter from the filter head.
5. Discard the old filter and use a new filter.
6. Lubricate the O-ring in the filter cover with
engine oil.
7. Screw the filter cover onto the new filter by
hand. Make sure that the drain tap is fully
closed.
8. Lubricate the O-ring on the filter with engine
oil.
9. Fill the width of the filter with clean fuel.
10. Screw the filter into position until the O-ring
rests against the filter head. Tighten the filter
another 1/2 to 3/4 turn by hand.
11. Open the shut-off cock in the fuel pipe and
check that the fuel system is sealed.
12. Screw the sensor cable in the contact housing
onto the filter bracket.
13. Bleed the fuel system according to the in-
structions in the Bleeding the fuel system
section.
62
Fuel system
Draining the commutative wa-
ter separating prefilter
During operation, the rotary control should point
90° towards the filter being used.
Environment
Use a suitable container. The fuel collected must
be disposed of as specified in national and inter-
national laws and regulations.
1
2
3
4
1. Switch off the filter that needs renewing. The
arrow on the rotary control should point to-
wards the filter that should remain active
during renewal.
WARNING!
Be careful that the valve does not pass the closed
position when the engine is in operation. A
closed position can result in the engine stopping.
In marine applications, the engine stopping rep-
resents a safety hazard.
2. Remove the cover from the filter housing.
63