Scania 420 Diesel Engine

Model DC1201HP

Eng Number 6184253

This Report is prepared for;

Shell UK

On behalf of;

Global Fuel Solutions UK Ltd

In conjunction with Cool Solutions (UK) Ltd

Author Colin Gawthorpe

(AMIRTE AMOSE)

Location Scania (GB) Ltd

Date14th April 2004

This report is not for publication

1
 Contents

Page

3. ………………. Assignment
4. ………………. Glossary
5. ………………. Methodology
6. ………………. Procedure
(A)…………… Valve Rocker Cover
(B)…………… Valve/P T Injector Rocker Arm
7. (C)…………… Valve Shim Post
(D)…………… Cylinder Head
8. (E)…………… Valve Seats
9. (F)…………… Exhaust Valves
10. (G)…………… Inlet Valves
11. (H)…………… Piston
12. (I)……………. Cylinder Liner
13. (J)……………. Cylinder Measurement
14. (K)…………… Crankshaft
15. (L)……………. Injector Nozzle
16. (M)…………… Inlet Manifold
(N)…………… Number 6 Cylinder Inlet Port
17. (O)…………… Inlet Manifold Air Intake
(P)…………… Air Delivery Flex
18. (Q)…………… Exhaust Manifold
19. ………………. Conclusion

2
 Assignment

Dismantle engine, investigate and report on engine wear.

This report will cover the unscheduled dismantling of a 13 month old Scania
DC 120 HPI diesel engine that has been running on duel fuel and has covered 152000
kilometers.

All the main reciprocating components were measured with the assistance of the local
automotive Engineering Company and all the results and comparison were recorded.

All unusual findings were address and corrective actions taken on the assembly of the
engine, after the cleaning process.

The engine was dismantled in reverse order of assembly using the necessary specialist
tools and equipment together with the technician’s own hand tools, as laid down in the
Scania workshop manual section 1 work description.

All the components were necessary cleaned and laid out for inspection, measurements
were taken with the necessary micrometer vernier caliper and a D T I comparison
clock. These measurements were recorded, see appendix 1.

At the time of dismantling, the engine oil centrifugal filter was stripped and cleaned;
no adverse build up of carbon was found. Also, an engine oil sample was taken for
analysis. The oil had covered 1000 kilometers since its last oil change interval.

After the cleaning process had taken place with the aid of the hot wash and solvent
cleaning machine, all the disposable old gasket and seals were removed and
discarded. All the matting surfaces boltholes and threads were cleaned to make ready
for reassemble.

The reassemble of the engine, this followed the instruction of the workshop Manual in
the section 1, works description. For the assembly, other specialist tools were
necessary to ensure accurate location of key reciprocating components, the setting of
critical tolerances on the fuel injection system and the overhead valve gear.

All the con rods, main bearing cylinder heads and valve rocker gear bolts, in
accordance with the workshop manual section 1, work description, were lightly
lubricated to ensure equal torque and tightening sequences was applied. In the case of
the main bearing and cylinder head bolts were stage and angle torques.

3
 Glossary

Scania Swedish based Company,

which manufactures commercial
vehicles and diesel engines with a
world wide customer base.

DC 120 HPI engine A 12 litre, 6 cylinder in line, high

pressure injection system, diesel
engine.

Micrometer, Vernier Calliper

DT1 Clock Are all instruments for measuring
wear on engine components.

Oil Central Fugal The century fugal cleaner, has a

rotor that rotates, as a reaction to
the lubrication oil been sprayed
from two nozzles, in the base of
the rotor. Dense particles are
flung against the wall and
collected.

Engine Oil Castrol tection 15/40.

4
 Methodology

This procedure of dismantling and reassembly of the Scania engine, at this early stage
of its life, was performed in accordance and with the aid of specialist tools as
described in the l workshop manual section (1) work description and service data 4
series book.

The engine was reassembled to its original state.

Mr P Kerswill was chosen to perform this task and provide a preliminary

investigation report on his findings.

Mr Kerswill is a Scania Master Technician (MT10) with 13 years experience on the

Scania product.

5
 Procedure

Commencement of the initial dismantling, the engine tappet/rocker covers were removed
exposing the over head valve components and P T injector rocker gear.

Please note, all these mechanisms are lubricated with pressurised engine oil and were found
to have negligible carbon deposits or sludge of any description on exposed surfaces.

(A) Valve (Rocker) Cover.

The inside of the valve cover reveals minor carbon deposits.
A thick layer of carbon usually darkens this surface.

(B) Valve/P T Injector Rocker Arm

This photo shows insignificant wear on these components.

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(C) Valve Shim Posts
This photo shows negligible wear and low carbon deposits.

(D) Cylinder Head

Low carbon deposits on valve surfaces.
This area would normally contain heavy deposits of un-burnt fuel.

Cross markings are from where cylinder head was placed after removal from
the engine.

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(E) Valve Seats.

Valve seats including the inlet/exhaust ports in this photo are in good
condition with minor coking and wear.

8
(F) Exhaust Valves.

DIMENSIONS FROM SCANIA MANUAL

Cylinder Heads/Exhaust Valves
Cylinder Bore No 1 2 3 4 5 6
Exhaust Valve 9.6mm 9.6mm 9.6mm 9.6mm 9.6mm 9.6mm

This photo depicts low carbon deposits and condition of valve seats.

RESULTS FROM ALEX CARR ENGINEERS

Cylinder Heads/Exhaust Valves
Cylinder Bore No 1 2 3 4 5 6
Exhaust Valve 9.6mm 9.6mm 9.6mm 9.6mm 9.6mm 9.6mm

9
(G) Inlet Valves.

DIMENSIONS FROM SCANIA MANUAL

Cylinder Heads/Inlet Valves
Cylinder Bore No 1 2 3 4 5 6
Inlet Valves 9.6mm 9.6mm 9.6mm 9.6mm 9.6mm 9.6mm

This photo depicts low carbon deposits and condition of valve seats.

RESULTS FROM ALEX CARR ENGINEERS

Cylinder Heads/Inlet Valves
Cylinder Bore No 1 2 3 4 5 6
Inlet Valves 9.6mm 9.6mm 9.6mm 9.6mm 9.6mm 9.6mm

10
(H) Piston (Combustion Chamber)

DIMENSIONS FROM SCANIA MANUAL

Piston Ring Gap 1 2 3 4 5 6
Top Ring 0.35 0.35 0.35 0.35 0.35 0.35
Middle Ring 0.45 0.45 0.45 0.45 0.45 0.45
Oil Scraper Ring 0.25 0.25 0.25 0.25 0.25 0.25

Gudgin Pin 54mm 54mm 54mm 54mm 54mm 54mm

Small End Bearing 54.1mm 54.1mm 54.1mm 54.1mm 54.1mm 54.1mm

This photo indicates good combustion with low carbon deposits.

Injector spray paten is evenly distributed in combustion chamber.

RESULTS FROM ALEX CARR ENGINEERS

Piston Ring Gap 1 2 3 4 5 6
Top Ring 0.35 0.35 0.35 0.35 0.35 0.35
Middle Ring 0.45 0.45 0.45 0.45 0.45 0.45
Oil Scraper Ring 0.25 0.25 0.25 0.25 0.25 0.25

Gudin Pin 54mm 54mm 54mm 54mm 54mm 54mm

Small End Bearing 54.1mm 54.1mm 54.1mm 54.1mm 54.1mm 54.1mm

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(I) Cylinder Liner.

DIMENSIONS FROM SCANIA MANUAL

Cylinder Bore 1 2 3 4 5 6

Axle Measurement 127mm 127mm 127mm 127mm 127mm 127mm

Middle 127mm 127mm 127mm 127mm 127mm 127mm
Bottom 127mm 127mm 127mm 127mm 127mm 127mm

Thrust Measurement 127mm 127mm 127mm 127mm 127mm 127mm

Middle 127mm 127mm 127mm 127mm 127mm 127mm
Bottom 127mm 127mm 127mm 127mm 127mm 127mm

Piston cylinder shows minimal glazing with good crosshatch still

visable.

RESULTS FROM ALEX CARR ENGINEERS

Cylinder Bore No 1 2 3 4 5 6

Axle Measurement 127mm 127mm 127mm 127mm 127mm 127mm

Middle 127mm 127mm 127mm 127mm 127mm 127mm
Bottom 127mm 127mm 127mm 127mm 127mm 127mm

Thrust Measurement 127mm 127mm 127mm 127mm 127mm 127mm

Middle 127mm 127mm 127mm 127mm 127mm 127mm
Bottom 127mm 127mm 127mm 127mm 127mm 127mm

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(J) Cylinder Measurement.
These photos display the cylinder being measured for engine wear,
note that the internal micrometer shows no wear.

13
(K) Crank Shaft Upper & Lower Big End Bearings.

DIMENSIONS FROM SCANIA MANUAL

Crank Shaft
Cylinder Bore No 1 2 3 4 5 6
Main Bearing 108mm 108mm 108mm 108mm 108mm 108mm
Big End Bearing 86.98mm 86.98mm 86.98mm 86.98mm 86.98mm 86.98mm

White metal is still present indicating negligible wear on these components.

RESULTS FROM ALEX CARR ENGINEERING

Crank Shaft
Cylinder Bore No 1 2 3 4 5 6
Main Bearing 108mm 108mm 108mm 108mm 108mm 108mm
Big End Bearing 86.98mm 86.98mm 86.98mm 86.98mm 86.98mm 86.98mm

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(L) Injector Nozzle.
Injector is in excellent condition with negligible carbon deposits evident.

15
(M) Inlet Manifold.
This photo shows very low carbon deposits in the inlet ports.

In a diesel only engine these inlet ports would have a considerable amount of
carbon build up due to the engine breathing internally and not to atmosphere.

(N) Number 6 Cylinder Inlet Port.

Note low carbon deposits.

16
(O) Inlet Manifold Air Intake.
Air intake is very clean indicating low or negligible compression blow by.

(P) Air Delivery Flex Intercooler to Inlet Manifold.

17
(Q) Exhaust Port in Exhaust Manifold.

Once again this area is normally coated in carbon deposits.

Photo shows low carbon build up.

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 Conclusion

The engine had no adverse build up of any kind of carbon deposits or sludge in or
around the upper cylinder heads or overhead valve components.

This was mirrored though out the rest of the engine upon the dismantling procedure.

That included the removal of the cylinder heads, engine oil sump, piston connecting
rods, main bearing caps and turbo charger.

The main bearings and big end bearings were also measured and inspected for
contamination and wear.

It was also noted that the turbo charger and air intake pipes between the turbo output
and the inlet manifold intake had no oil residue or build up of any kind. The
intercooler was not dismantle or flushed out but due to the low oil build up in the
other components associated with the air intake apparatus it was assumed that the
intercooler would have a negligible amount of residue.

We can confirm that all the main reciprocating components were measured by Alex
Carr Engineering and compared with the manufacturer’s references; no degree of
wear was obvious.

It is confirmed that this engine has not suffered any visible or measured adverse
effects to any of its mechanisms as a result from the use of LPG.

This engine appears to be in excellent condition for the amount of miles travelled.

In my opinion the engine appears to be in better condition and cleaner through out,
with considerable less carbon deposits than a comparative engine of the same vintage
and mileage operating on diesel fuel only.

End Document.

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