1980 Scania DS11 / DN11 Diesel Engine Factory Service Manual (P/N 1-80 06 30 SP)

This 1980 Scania factory service manual covers the DN11 naturally aspirated and DS11 turbocharged diesel engines. The manual is in Spanish and carries document code 1-80 06 30 SP.

• Cylinder head: Disassembly, valve and guide replacement, seat machining, rocker-shaft service, head-bolt tightening sequences, and compression testing.

• Turbocharger: Boost-pressure diagnosis, radial and axial clearance measurements, component inspection, disassembly, reassembly, and installation.

• Cylinder block and crankshaft: Wet-liner removal and height adjustment, piston and connecting-rod service, bearing checks, and crankshaft grinding specifications.

• Timing drive: Gear removal and alignment, camshaft replacement and timing checks, tappet and pushrod inspection, and injection-pump drive-shaft repair.

• Lubrication system: Oil-pump overhaul, pressure-relief valve adjustment, centrifugal-cleaner service, turbo oil-filter replacement, and oil-cooler leak testing.

This manual is suited to experienced diesel mechanics with access to precision measuring tools and the machining equipment required for internal engine work.

Cylinder Head, Liners and Rotating Assembly

The service procedures assume an engine already removed from the vehicle, with oil and coolant drained and the clutch removed.

The cylinder-head section covers sealing-face resurfacing, gasket-groove machining, valve guides, and rocker-shaft bushings. Valve-seat drawings and cylinder-head tightening diagrams accompany the procedures, with separate staged tightening schedules for the different head-bolt sizes.

Wet liners and pistons: Liner-height measurement, shim selection, and sealing-ring differences are documented. Scania measuring bridge 87198 and dial indicator 98075 are identified for liner measurement; piston assembly instructions address ring orientation and the locating arm for the piston-cooling nozzles.

Crankshaft and flywheel: Grinding tables distinguish six main-journal undersizes from seven crankpin undersizes, alongside bearing clearances and connecting-rod inspection limits. Flywheel ring-gear replacement and vibration-damper hub removal are covered, including keyed and polygonal crankshaft connections.

The manual warns that deforming the vibration damper can impair its operation and lead to crankshaft failure.

Timing Gears and Injection-Pump Drive

Timing-gear alignment drawings support camshaft, tappet, pushrod, and injection-pump drive-shaft work. The camshaft timing check distinguishes DS11 camshaft 238401 from DN11 camshaft 228830.

The injection-pump coverage concerns its mounting bracket, drive shaft, bearings, and seal; it is not an internal injection-pump overhaul manual.

Turbocharger Diagnosis and Overhaul

Cross-sectional views identify the KKK/Schwitzer 4LGZ compressor-side arrangement and Holset 4LGK turbocharger. The repair text addresses oil leaks, intake and exhaust leaks, compressor-wheel cleaning, and shaft inspection. Turbocharger rebuilding requires specialized measuring, cleaning, and balancing equipment.

Separate DS1101 and DS1102 boost-pressure charts include intake-air-temperature corrections. Combined with the discussion of air-filter restriction, leakage, and fuel-system faults, they help investigate low power before attributing it to the turbocharger.

Lubrication System Service

Oil-pump clearance illustrations and the lubrication-circuit drawing accompany the service procedures. The text explains crankcase ventilation, pump-bushing machining, centrifugal-cleaner operation, and oil-cooler seal replacement and pressure testing.

An unsuitable turbo oil filter can open its bypass too early, allowing unfiltered oil to accelerate bearing wear. The centrifugal-cleaner section also explains why a rotor without the expected sludge deposit needs investigation.

Follow workshop safety procedures when handling high-pressure diesel injection lines or heavy rotating assemblies.

A Preview of Valve-Lift and Lubrication Specifications

These examples are a small selection from the manual's valve-train and lubrication data.

At zero valve clearance, DN11 and DS11 intake-valve lift is 14.6 mm; exhaust-valve lift is 15.1 mm. The oil-pressure specifications give 4.5–6.0 bar with the engine hot at 2,200 rpm.

The oil-pump table specifies 0.07–0.10 mm axial clearance between the pump gear and housing cover.

PDF Readability and Included Pages

Search, navigation, and legibility: PDF text search and embedded bookmarks are unavailable. Small component labels benefit from enlargement. Dark marks make parts of the liner instructions and boost-pressure notes difficult to read.

Supplied as a single printable, 67-page PDF, including one cover page, one contents page, and one duplicate of printed page 4. All are included in the total. The printed pagination skips page 10.