Work Shop Manual TCD2012 2V [PDF]

Zitiervorschau

Workshop Manual

Competence level 3

TD/TCD 2012 2V

Th is do D i cu s al t r m lo i b en w u ed t i o ti sc w n ith i n op yr ou e i t ig t o he ht ur r p pr pr r i n ot io t e ec ra d te d. gr o r ee e l m ec en t r o t. n ic fo

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Mechanical Injection

This document is subject to changes which may become necessary in the course of further development of the engines. Reprinting and reproductions of any kind, even in part, require our written permission.

0312 3822 en

Regarding copyright questions and licensing agreements please contact : VS-DL, Mr. Lippke Phone.: + 49 (0) 221 822-2599 E-Mail: [email protected] DEUTZ AG Informations Systeme Vertrieb u. Service Ottostraße 1 D-51149 Köln (Cologne) Phone.: +49 (0) 221-822-0 Fax: +49 (0) 221-822-3525 Internet: www.deutz.com E-Mail: [email protected]

The engine company.

Printed in Germany All rights reserved 1st Edition © 02/2011 Order No. 0312 3822 en

TD 2012 2V TCD 2012 2V 1

Foreword

2

General

3

User notes 3.1 3.2 3.3 3.4 3.5

5

General Specifications Operating manual and workshop manual Job cards Explanation of symbols

Job card overview 5.1 5.2 5.3

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Table of contents

Sorted alphabetically Sorted numerically Job card references

6

Job cards

7

Commercial tools

8

Special tools

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Foreword

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Foreword

z Read and observe the information in this documentation. You will avoid accidents, retain the manufacturer's warranty and possess a fully functional and ready to operate engine. z This engine is built exclusively for purpose according to the scope of delivery - defined by the equipment manufacturer (use for the intended purpose). Any use above and beyond this is considered improper use. The manufacturer will not be liable for damages resulting from this. The user bears the sole risk. z Use for the intended purpose also includes observance of the operating, maintenance and repair instructions specified by the manufacturer. The engine may only be used, maintained and repaired by persons who are familiar with this and are aware of the risks involved.

z Repair of the engine must correspond to its use for the intended purpose. Only parts released by the manufacturer for the respective purpose may be used for conversion work. Unauthorised modifications to the engine exclude manufacturer liability for resulting damages. Failure to observe this will void the warranty! z The engines made by DEUTZ are developed for a wide range of applications. A wide range of variants ensures that the respective special requirements are met. z The engine is equipped according to the installation case, i.e. not all the parts and components described in this documentation are installed in your engine necessarily. z We have done our best to highlight the differences so that you can easily find the operating, maintenance and repair instructions relevant to your engine.

z Make sure that this documentation is available to everyone involved in the operation, maintenance and repair and that they have understood the contents. z Failure to observe this documentation may lead to malfunctions and engine damage as well as injury to persons for which the manufacturer will not accept any liability. z Prerequisite for proper maintenance and repair is the availability of all the necessary equipment, conventional and special tools and their perfect condition. z Engine parts such as springs, clamps, elastic retaining rings etc. pose an increased risk of injury when handled incorrectly. z The pertinent rules for the prevention of accidents and other generally recognised health and safety regulations must be observed.

We are at your service for any questions you may have in this matter.

z Maximum economy, reliability and long life is only guaranteed when using DEUTZ original parts.

Your DEUTZ AG

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Foreword

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General

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General

DEUTZ engines are the product of years of research and development. The profound expertise gained through this, in combination with high demands on quality, attests to the fact that our engines possess all the qualities of long life, high reliability and low fuel consumption. It goes without saying that the high environmental protection requirements are also met.

2

Maintenance and care are the only way the engine can satisfy the demands you make on it. Compliance with the prescribed maintenance times and the careful execution of maintenance and care work are therefore essential. Difficult operating conditions, deviating from normal operation, must be particularly heeded. Please consult one of our service representatives responsible for operating faults and spare parts questions. Our trained specialist personnel ensures fast and professional repairs using original DEUTZ spare parts in the event of damage. Original spare parts from DEUTZ AG are always manufactured according to the state of the art.

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General

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3.1 General

3.2 Specifications

The documentation of the workshop manual has been created based on the engine available at the time of going to press. There may be deviations in the descriptions, illustrations and parts due to further developments.

3.2.1 Accident prevention and safety regulations

The maintenance work described in the operation manual and in the workshop manual must be carried out on schedule and completely. The maintenance personnel must have the necessary technical knowledge to perform the work. Safety and protection devices which are removed during maintenance work must be replaced again afterwards.

The legally prescribed rules for the prevention of accidents must be observed. These are available from professional associations or from dealers. These are dependent on the application site, operating mode and the operating and auxiliary materials being used. Special protection measures are specified depending on the work being carried out, and are identified in the job description. Among other things it generally applies that:

Caution! The rules for the prevention of accidents and the safety regulations must be observed during maintenance work. Reference is made in the workshop manual job cards to the regulations in chapter 3.2. These must be read before working on the engine and must be strictly followed.

z for the personnel: – Only briefed personnel may operate or maintain the engine. Unauthorised persons are prohibited access to the machine room. – Wear close-fitting clothing and ear protectors in the machine room when the engine is in operation.

The maintenance intervals and the work to be performed are specified in the maintenance schedule of the operation manual. The job cards contain technical documentation on the execution of maintenance work.

– Only deploy trained personnel to do repairs and maintenance work. – Do not work on the fuel system when the engine is running. The fuel system is under high pressure - danger of death. – Go to the workshop immediately in case of leaks in the fuel system. z for the engine room: – Ensure adequate ventilation (do not cover air shafts). – Provide first aid kit and suitable fire extinguishers. Check the filling and readiness for operation regularly. – Only store inflammable materials in the machine room if they are essential for operation of the system. – Smoking and naked flames are prohibited in the machine room. z for operation, maintenance and repairs on the engine: – Wait 30 seconds after switching off the engine before working on the fuel sytem. – After all work on the fuel system, it must be bleeded - see the operation manual, chapter "6.2 Fuel system“. – Only start the engine when all the protective devices have been fitted. Make sure no-one is standing in the danger area. – Cleaning, maintenance and repair work may only be performed with the engine at a standstill and secured against starting. – Injection lines and high pressure pipes must not be deformed.

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User notes

DEUTZ engines z Remove loose parts (for example paint chips from assembly work) with an industrial vacuum cleaner or other suction device. Only suction may be used in assembly work on the open fuel system.

– Damaged injection lines and high-pressure pipes must be renewed. – Injection lines and high pressure fuel lines must never be connected when the engine is running.

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z Only work on the fuel system in a clean environment (no dust, no grinding or welding). Avoid draughts (dust). Clean the workshop floor regularly. No brake or performance test benches may be kept or operated in the same room.

– Do not place hands near to a leak in the high pressure fuel system. – Also carefully check all high pressure components visually before performing tests on the running engine. Wear suitable protective clothing (for example protective glasses). Leaks are a potential source of danger for workshop personnel.

z Air currents which kick up dust, such as those caused by brake repairs or the starting of engines, should be avoided.

– Even if no leaks are discernible on the high pressure fuel system, the workshop personnel should avoid the immediate danger zone or wear suitable protective clothing (such as protective glasses) when performing tests on the running engine and during the first trial run. – Always stay out of range of a fuel jet, as it could cause severe injury.

z For work such as removal and installation on defective hydraulic components on the Common Rail System it is recommended to partition off a separate workshop area in the factory. This must be separate from other areas in which general vehicle repairs such as brake repairs are carried out. z No general machine tools may be operated in this room.

– Smoking is strictly prohibited when working on the fuel system.

z Regular cleaning of the workshop area is mandatory. Draughts, ventilation systems and heating fans should be minimised.

– Do not work near to sparks and flames. – Never disconnect an injector when the engine is running.

z Areas of the engine room from which particles of dirt could be loosened (for example the bottom part of the tipped driver cab) must be covered with fresh clean film.

3.2.2 Cleanliness instructions and measures for handling the DEUTZ Common Rail System The DEUTZ Common Rail system used in the DEUTZ engines consists of high-precision components which are exposed to extreme stress. Great attention must be paid to cleanliness when working on the fuel system due to the high precision technology. Notes and measures to be observed before starting work on the fuel system

z Working materials and tools must be cleaned before work. Only use tools without damage to the chrome plating or tools which are not chromeplated. Notes and measures to be observed during work on the fuel system or with the fuel system open. z Only work in clean overalls. z Only lint-free cleaning cloths may be used for work on the fuel system.

z The fuel system must be closed. Make a visual inspection for leaks / damage to the fuel system.

z Remove loose parts (for example paint chips from assembly work) with an industrial vacuum cleaner or other suction device. Only suction may be used in assembly work on the open fuel system.

z Clean the whole engine and engine room with the system closed before starting work on the fuel system. z The engine must be dry when you start working on the fuel system. z Blowing (dry) with compressed air is only permissible with the fuel system closed.

z Working materials and tools must be cleaned before work. Only use tools without damage to the chrome plating or tools which are not chromeplated.

z When using a steam jet, first cover up the control unit, the cable plugs, all other electrical plug connections and the generator. Also, the steam jet may not be pointed directly at them.

z Do not use used cleaning fluid or test fluid for cleaning.

z Electrical plug connections must be plugged when spraying.

z Work on removed components may only be performed at a suitably equipped workbench.

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z Compressed air must not be used for cleaning on the open fuel system.

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z When removing and installing components, no materials which can leave behind particles or fibres (cardboard, wood, cloths) may be used.

operating materials among other things. The renewed parts / operating materials must be stored, transported and disposed of according to regulations. The owner himself is responsible for this.

z Removed parts may only be rubbed down with clean, lint-free cloths. No dirt particles may be rubbed into the components.

Disposal includes recycling and the scrapping of parts / operating materials, although recycling has priority.

z Openings on the components and on the engine must be closed immediately with suitable stoppers/caps.

Details of disposal and their monitoring are governed by regional, national and international laws and directives which the system operator must observe on his own responsibility.

z The stoppers/caps may only be removed immediately before installing. z Store stoppers/caps free from dust and dirt in the original packaging and dispose of after using once. z Only remove new parts from the original packaging just before installation. z Removed components must be kept in new, sealable bags or - if available - in the packaging of the new parts. z Always use the original packaging of the new part to send back the removed components. Notes and measures for the vehicle workshop area z For work such as removal and installation on defective hydraulic components on the Common Rail System it is recommended to partition off a separate workshop area in the factory. This must be separate from other areas in which general vehicle repairs such as brake repairs are carried out. z The workshop floor is sealed or tiled. z No welding gear, grinders, general machine tools, brakes or performance test benches may be operated in this room. z Regular cleaning of the workshop area is mandatory. Draughts, ventilation systems and heating fans should be minimised. Notes and measures for workbench and tools in the vehicle hall z A special workbench must be set up for work on removed components. z Clean the removal and installation tools regularly and keep them in a closed tool cabinet. z Remove loose parts (for example paint chips from assembly work) with an industrial vacuum cleaner or other suction device. z Working materials and tools must be cleaned before work. Only use tools without damage to the chrome plating or tools which are not chromeplated.

3.2.3 Disposal regulations The work described in the operation manual and workshop manual necessitates renewal of parts and © 12/2005

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User notes

DEUTZ engines

3.3 Operation manual and workshop manual

3.4 Job cards

To structure the information to suit the user, the service documentation is divided into operation manual and workshop manual.

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The operation manual contains a general description and instructions for all other maintenance work. It contains the following chapters: 1. Contents, General 2. Engine description 3. Operation 4. Operating media

The job cards are divided in the workshop manual into "W" and "I" job cards. The "W" job card documents standard repairs on the engine and/or its components. The necessary tools and special tools are also specified in the "W" job card. The "I" job card additionally documents the appropriate work procedures for repairing the engine and/ or its components. The workshop must satisfy special conditions to perform these work procedures. Special tools and machine tools must be available, for example.

3.4.1 Numbering of job cards

5. Maintenance 7. Faults, causes and remedies

The job card numbers follow the pattern W 02-0401. The individual parts of this pattern are explained below:

8. Engine conservation

z W 02-04-01: Documentation type

6. Care and maintenance work

9. Technical data

– W.... Workshop manual

10.Service

– I ...... Repair instructions

The workshop manual assumes knowledge of the contents of the operation manual. This applies especially for the safety regulations. The workshop manual describes repairs to the engine and components for which more effort and appropriately qualified technicians are required.

z W 02-04-01: Maintenance group – 00 ... General / interdisciplinary activities – 01 ... Cylinder head – 02 ... Drive system – 03 ... Crankcase – 04 ... Engine control system – 05 ... Speed governing – 06 ... Exhaust system / Charging – 07 ... Fuel system – 08 ... Lube oil system – 09 ... Cooling system – 10 ... Compressed air system – 11 ... Monitoring system – 12 ... Other components – 13 ... Electrical system z W 02-04-01: Component grouping z W 02-04-01: Consecutive number

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User notes 3.5 Explanation of symbols

3.4.2 Structure of a job card 1

2

Danger! of death or to health. Must be observed! For example: The incorrect use or conversion of the turbocharger can lead to serious injury.

3

Triebwerk W 02-04-01

4

Caution! Danger to the component/engine. Noncompliance can lead to destruction of the component/engine. Must be observed!

5 16

6

15

6

7

13

Note General notes on assembly, environmental protection etc. No potential danger for man or machine.

12

Tool Conventional and special tools required for the work.

14 8

8

Auxiliary materials Working materials required in addition to the tools for performing the work (e.g. greases, oils, adhesives, sealants) 11

10

9

References to important documents or job cards for the work process. For example: Job card W 04-05-05

1. DEUTZ AG, publisher of service documentation 2. Engine type (e.g. TCD 2013 4V)

Reference to a document or a job card within the work process.

3. Maintenance group 4. Job card number or topic

Test and setting data The necessary values are specified here. If several values are necessary, a cross reference is given to the Test and Setting Values table. For example: ID no. P01 61 = valve clearance, inlet

5. Title of job card 6. Reference to other job cards 7. Chapter 8. Graphic or photo 9. DEUTZ internal creation number 10.Page number

Tightening specification The necessary values are specified here. If several values are necessary, a cross reference is given to the Tightening Specifications table. For example: ID no. A01 001 = cylinder head screws

11.Date of issue of job card 12.Note 13.Danger / Important 14.Work sequence 15.Special tools; auxiliary materials 16.Conventional tools

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Job card overview Sorted alphabetically

Activity

Job card

Maintenance group

Checking axial backlash of crankshaft (crankshaft removed)

W 02-01-04

Drive system

Checking fuel injectors

W 07-07-05

Fuel system

Checking piston overhang

W 01-04-09

Cylinder head

Checking the camshaft

W 04-05-06

Engine control

Checking the compression pressure

W 00-02-06

General

Checking the con rod

W 02-03-01

Drive system

Checking the crankshaft

W 02-01-07

Drive system

Checking the cylinders

W 03-03-01

Crankcase

Checking the piston

W 02-09-07

Drive system

Checking the piston rings and piston ring grooves

W 02-10-03

Drive system

Checking the thermostat (in the removed state)

W 09-08-01

Cooling system

Checking the valve guide

W 01-06-03

Cylinder head

Checking the valve lag

W 01-07-08

Cylinder head

Checking the valves

W 01-05-04

Cylinder head

Determining the installation dimension of the injection pump (engine with injection adjuster)

W 07-06-04

Fuel system

Determining the installation dimension of the injection pump (engine with injection adjuster)

W 07-06-04

Fuel system

Determining the thickness of the shim (engine with injection adjuster)

W 07-06-03

Fuel system

Determining the thickness of the shim (engine without injection adjuster)

W 07-06-03

Fuel system

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Disassembling, assembling and checking the rocker W 01-02-06 arm and rocker arm bracket

Cylinder head

Dismantling and assembling the air bearing

W 09-13-01

Cooling system

Installing and removing turning gear

W 04-06-03

Engine control

Mounting engine on assembly block and demounting

W 00-05-01

General

Removing and and installing the fuel filter console

W 07-10-08

Fuel system

Removing and installing coolant pump

W 09-07-08

Cooling system

Removing and installing temperature transmitter

W 09-12-01

Cooling system

Removing and installing the air bearing

W 09-13-04

Cooling system

Removing and installing the camshaft

W 04-05-05

Engine control

Removing and installing the charge air line

W 06-07-03

Exhaust system / Charging

Removing and installing the connection housing

W 03-09-04

Crankcase

Removing and installing the crankcase bleeding

W 03-01-11

Crankcase

Removing and installing the crankshaft

W 02-04-01

Drive system

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Activity

Job card

Maintenance group

Removing and installing the cylinder head

W 01-04-04

Cylinder head

Removing and installing the engine shutdown

W 11-00-03

Monitoring system

Removing and installing the exhaust line

W 06-01-05

Exhaust system / Charging

Removing and installing the flywheel

W 12-06-01

Other components

Removing and installing the front cover (opposite side to flywheel)

W 03-08-01

Crankcase

Removing and installing the fuel injector pump

W 07-04-01

Fuel system

Removing and installing the fuel injectors

W 07-07-01

Fuel system

Removing and installing the fuel supply pump

W 07-11-01

Fuel system

Removing and installing the gearcase cover

W 04-04-09

Engine control

Removing and installing the generator (V-belt drive) W 13-02-03

Electrical system

Removing and installing the heating flange

W 06-02-08

Exhaust system / Charging

Removing and installing the lubricating oil pan (die-cast lubricating oil pan)

W 08-04-07

Lube oil system

Removing and installing the lubricating oil pan (metal lubricating oil pan)

W 08-04-07

Lube oil system

Removing and installing the oil cooler

W 08-08-02

Lube oil system

Removing and installing the oil cooler housing

W 08-08-03

Lube oil system

Removing and installing the oil pressure switch

W 08-11-08

Lube oil system

Removing and installing the oil suction pipe

W 08-04-06

Lube oil system

Removing and installing the piston and con rod

W 02-09-03

Drive system

Removing and installing the piston cooling nozzles

W 02-15-01

Drive system

Removing and installing the rocker arm and rocker arm bracket

W 01-02-02

Cylinder head

Removing and installing the speed governor

W 05-05-01

Speed governing

Removing and installing the starter

W 13-03-02

Electrical system

Removing and installing the thermostat

W 09-08-02

Cooling system

Removing and installing the turbocharger

W 06-06-04

Exhaust system / Charging

Removing and installing the valves

W 01-05-01

Cylinder head

Removing and installing the V-belt pulley

W 12-01-04

Other components

Removing and installing, checking and setting the control linkage

W 05-04-14

Speed governing

Removing and installing, checking the mass compensation shafts

W 02-08-01

Drive system

Removing and installing, testing camshaft bearing

W 03-11-01

Crankcase

Renewing the crankshaft sealing ring (flywheel side) W 02-02-02

Drive system

Renewing the crankshaft sealing ring (opposite side W 02-02-04 to flywheel)

Drive system

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Activity

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Maintenance group

Renewing toothed starter flywheel ring

W 12-06-03

Other components

Setting valve clearance

W 01-01-01

Cylinder head

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Job card

Activity

Maintenance group

W 00-02-06

Checking the compression pressure

General

W 00-05-01

Mounting engine on assembly block and demounting

General

W 01-01-01

Setting valve clearance

Cylinder head

W 01-02-02

Removing and installing the rocker arm and rocker arm bracket

Cylinder head

W 01-02-06

Disassembling, assembling and checking the rocker Cylinder head arm and rocker arm bracket

W 01-04-04

Removing and installing the cylinder head

Cylinder head

W 01-04-09

Checking piston overhang

Cylinder head

W 01-05-01

Removing and installing the valves

Cylinder head

W 01-05-04

Checking the valves

Cylinder head

W 01-06-03

Checking the valve guide

Cylinder head

W 01-07-08

Checking the valve lag

Cylinder head

W 02-01-04

Checking axial backlash of crankshaft (crankshaft removed)

Drive system

W 02-01-07

Checking the crankshaft

Drive system

W 02-02-02

Renewing the crankshaft sealing ring (flywheel side) Drive system

W 02-02-04

Renewing the crankshaft sealing ring (opposite side Drive system to flywheel)

W 02-03-01

Checking the con rod

Drive system

W 02-04-01

Removing and installing the crankshaft

Drive system

W 02-08-01

Removing and installing, checking the mass compensation shafts

Drive system

W 02-09-03

Removing and installing the piston and con rod

Drive system

W 02-09-07

Checking the piston

Drive system

W 02-10-03

Checking the piston rings and piston ring grooves

Drive system

W 02-15-01

Removing and installing the piston cooling nozzles

Drive system

W 03-01-11

Removing and installing the crankcase bleeding

Crankcase

W 03-03-01

Checking the cylinders

Crankcase

W 03-08-01

Removing and installing the front cover (opposite side to flywheel)

Crankcase

W 03-09-04

Removing and installing the connection housing

Crankcase

W 03-11-01

Removing and installing, testing camshaft bearing

Crankcase

W 04-04-09

Removing and installing the gearcase cover

Engine control

W 04-05-05

Removing and installing the camshaft

Engine control

W 04-05-06

Checking the camshaft

Engine control

W 04-06-03

Installing and removing turning gear

Engine control

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Job card

Activity

Maintenance group

W 05-04-14

Removing and installing, checking and setting the control linkage

Speed governing

W 05-05-01

Removing and installing the speed governor

Speed governing

W 06-01-05

Removing and installing the exhaust line

Exhaust system / Charging

W 06-02-08

Removing and installing the heating flange

Exhaust system / Charging

W 06-06-04

Removing and installing the turbocharger

Exhaust system / Charging

W 06-07-03

Removing and installing the charge air line

Exhaust system / Charging

W 07-04-01

Removing and installing the fuel injector pump

Fuel system

W 07-06-03

Determining the thickness of the shim (engine without injection adjuster)

Fuel system

W 07-06-03

Determining the thickness of the shim (engine with injection adjuster)

Fuel system

W 07-06-04

Determining the installation dimension of the injection pump (engine with injection adjuster)

Fuel system

W 07-06-04

Determining the installation dimension of the injection pump (engine with injection adjuster)

Fuel system

W 07-07-01

Removing and installing the fuel injectors

Fuel system

W 07-07-05

Checking fuel injectors

Fuel system

W 07-10-08

Removing and and installing the fuel filter console

Fuel system

W 07-11-01

Removing and installing the fuel supply pump

Fuel system

W 08-04-06

Removing and installing the oil suction pipe

Lube oil system

W 08-04-07

Removing and installing the lubricating oil pan (die-cast lubricating oil pan)

Lube oil system

W 08-04-07

Removing and installing the lubricating oil pan (metal lubricating oil pan)

Lube oil system

W 08-08-02

Removing and installing the oil cooler

Lube oil system

W 08-08-03

Removing and installing the oil cooler housing

Lube oil system

W 08-11-08

Removing and installing the oil pressure switch

Lube oil system

W 09-07-08

Removing and installing coolant pump

Cooling system

W 09-08-01

Checking the thermostat (in the removed state)

Cooling system

W 09-08-02

Removing and installing the thermostat

Cooling system

W 09-12-01

Removing and installing temperature transmitter

Cooling system

W 09-13-01

Dismantling and assembling the air bearing

Cooling system

W 09-13-04

Removing and installing the air bearing

Cooling system

W 11-00-03

Removing and installing the engine shutdown

Monitoring system

W 12-01-04

Removing and installing the V-belt pulley

Other components

W 12-06-01

Removing and installing the flywheel

Other components

W 12-06-03

Renewing toothed starter flywheel ring

Other components

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Job card

Activity

Maintenance group

W 13-02-03

Removing and installing the generator (V-belt drive) Electrical system

W 13-03-02

Removing and installing the starter

Electrical system

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Job card overview Sorted numerically

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Job card overview Job card references

5 5.3

© 11/2005

Job card references

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Job card overview Job card references

00 General Job card W 00-02-06 W 00-05-01

Activity and additional job cards necessary for its execution Checking the compression pressure W 01-01-01

W 07-07-01

Mounting engine on assembly block and demounting

01 Cylinder head Job card W 01-01-01 W 01-02-02 W 01-02-06

5

Activity and additional job cards necessary for its execution Setting valve clearance W 01-04-04

W 04-06-03

Removing and installing the rocker arm and rocker arm bracket W 01-01-01

W 01-04-04

Disassembling, assembling and checking the rocker arm and rocker arm bracket W 01-02-02 Removing and installing the cylinder head

W 01-04-04

W 01-04-09 W 01-05-01 W 01-05-04 W 01-06-03 W 01-07-08

W 01-01-01

W 01-02-02

W 07-07-01

W 09-13-04

W 01-04-09

W 06-01-05

W 06-07-03

Checking piston overhang W 01-04-04

W 04-06-03

Removing and installing the valves W 01-04-04 Checking the valves W 01-05-01 Checking the valve guide W 01-05-01 Checking the valve lag W 01-04-04

02 Drive system Job card W 02-01-04 W 02-01-07

© 11/2005

Activity and additional job cards necessary for its execution Checking the axial clearance of the crankshaft W 02-04-01

W 03-08-01

W 04-04-09

Checking the crankshaft W 02-04-01

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02 Drive system (continued) Job card W 02-02-02 W 02-02-04 W 02-03-01

5

Activity and additional job cards necessary for its execution Renewing the crankshaft sealing ring (flywheel side) W 12-06-01 Renewing the crankshaft sealing ring (opposite side to flywheel) W 12-01-04 Checking the con rod W 02-09-03 -

W 02-04-01 W 02-08-01 W 02-09-03 W 02-09-07 W 02-10-03 W 02-15-01

Removing and installing the crankshaft W 02-01-07

W 02-09-03

W 03-08-01

W 04-04-09

Removing and installing, checking the mass compensation shafts W 04-04-09 Removing and installing the piston and con rod W 01-04-04

W 02-10-03

W 08-04-06

Checking the piston W 02-09-03 Checking the piston rings and piston ring grooves W 02-09-03 Removing and installing the piston cooling nozzles W 02-04-01

03 Crankcase Job card W 03-01-11 W 03-03-01 W 03-08-01 W 03-09-04 W 03-11-01

© 11/2005

Activity and additional job cards necessary for its execution Removing and installing the crankcase bleeding Checking the cylinders W 02-09-03 Removing and installing the front cover (opposite side to flywheel) W 02-02-04

W 08-04-06

W 12-01-04

Removing and installing the connection housing Removing and installing, testing camshaft bearing W 02-04-01

W 04-05-05

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04 Engine control Job card

Activity and additional job cards necessary for its execution Removing and installing the gearcase cover

W 04-04-09

W 02-02-02

W 03-09-04

W 05-05-01

W 08-04-07

W 12-06-01

W 13-03-02 W 04-05-05 W 04-05-06 W 04-06-03

Removing and installing the camshaft W 01-02-02

W 02-04-01

W 07-04-01

W 07-07-01

5

Checking the camshaft W 04-05-05 Installing and removing turning gear

05 Speed governing Job card W 05-04-14 W 05-05-01

Activity and additional job cards necessary for its execution Removing and installing, checking and setting the control linkage W 04-04-09

W 05-05-01

W 07-04-01

Removing and installing the speed governor

06 Exhaust system / Charging Job card W 06-01-05 W 06-02-08 W 06-06-04 W 06-07-03

Activity and additional job cards necessary for its execution Removing and installing the exhaust line W 06-06-04 Removing and installing the heating flange Removing and installing the turbocharger Removing and installing the charge air line W 01-04-04

07 Fuel system Job card W 07-04-01 W 07-06-03

© 11/2005

Activity and additional job cards necessary for its execution Removing and installing the fuel injector pump W 01-04-04

W 07-06-03

W 07-06-03

W 07-06-04

W 07-06-04

Determining the thickness of the shim (engine without injection adjuster) W 07-04-01 17/20

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07 Fuel system (continued) Job card W 07-06-03 W 07-06-04 W 07-06-04

5

W 07-07-01 W 07-07-05 W 07-10-08 W 07-11-01

Activity and additional job cards necessary for its execution Determining the thickness of the shim (engine with injection adjuster) W 07-04-01 Determining the installation dimension of the injection pump (engine with injection adjuster) W 07-04-01 Determining the installation dimension of the injection pump (engine with injection adjuster) W 07-04-01 Removing and installing fuel injectors W 01-04-04

W 07-07-05

Checking the fuel injector W 07-07-01 Removing and and installing the fuel filter console User notes Removing and installing the fuel supply pump (V-belt drive) User notes

W 13-02-03

08 Lube oil system Job card W 08-04-06 W 08-04-07 W 08-04-07 W 08-08-02 W 08-08-03 W 08-11-08

Activity and additional job cards necessary for its execution Removing and installing the oil suction pipe W 08-04-07 Removing and installing the lubricating oil pan (die-cast lubricating oil pan) Removing and installing the lubricating oil pan (metal sheet lubricating oil pan) Removing and installing the oil cooler W 08-08-03 Removing and installing the oil cooler housing User notes Removing and installing the oil pressure switch User notes

09 Cooling system Job card W 09-07-08

© 11/2005

Activity and additional job cards necessary for its execution Removing and installing the coolant pump (V-belt drive) W 07-11-01

W 09-13-04

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09 Cooling system (continued) Job card W 09-08-01 W 09-08-02 W 09-12-01 W 09-13-01 W 09-13-04

Activity and additional job cards necessary for its execution Checking the thermostat (in the removed state) W 09-08-02 Removing and installing the thermostat Removing and installing the temperature transmitter

5

Dismantling and assembling the air bearing W 09-13-04 Removing and installing the air bearing

11 Monitoring system Job card W 11-00-03

Activity and additional job cards necessary for its execution Removing and installing the engine shutdown

12 Other components Job card W 12-01-04 W 12-06-01 W 12-06-03

Activity and additional job cards necessary for its execution Removing and installing the V-belt pulley W 04-06-03

W 13-02-03

Removing and installing flywheel Renewing toothed starter flywheel ring W 12-06-01

13 Electrical system Job card W 13-02-03 W 13-03-02

© 11/2005

Activity and additional job cards necessary for its execution Removing and installing the generator Removing and installing the starter

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© 11/2005

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DEUTZ engines

6

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Job cards

Job cards

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Job cards

DEUTZ engines

6

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General W 00-02-06

Checking the compression pressure Commercial available tools: – Compression pressure tester. . . . . . . . . . . . . . . . . . . . . . . . 8005 – Torx tool set . . . . . . . . . . . . . . . . . . 8189

– W 01-01-01 – W 07-07-01

Special tools: – Connector . . . . . . . . . . . . . . . . . . 100190

6

Checking the compression pressure z Set valve clearance.  W 01-01-01 z Removing fuel injectors.  W 07-07-01

2

z Mount sealing ring (1). z Insert connector (2).

1

© 46377-1

z Mount clamping shoe (1). z Tighten screw (2).  16 Nm

2 1 © 46378-0

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z Connect adapter (1) to connector.

1

6 © 46379-0

z Connect compression pressure tester to connector. z Turn over engine with starter.  30 - 38 bar

© 46308-0

No. Kompression in bar Compression value in bar Pression en bar Dat. _________ 10 15 20 25 30 35 40

Zyl.

The measured compression pressure depends on the starting speed during the measuring process and the altitude of the engine installation site. Therefore, limit values cannot be determined exactly. The compression pressure measurement is only recommended as a reference measurement of all cylinders of an engine to each other. If more than 15% deviation has been determined, the cause should be determined by disassembling the cylinder unit concerned.

1 2 3 4 5 6 7 8 DBGM

Made in Germany

MOTOMETER © 33771-5

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General W 00-02-06

z Remove the compression pressure tester and adapter (1).

1

6 © 46308-1

z Unscrew screw (1). z Remove clamping shoe (2). z Remove connector. z Remove sealing ring. z Install fuel injectors.  W 07-07-01

1 2 © 46378-1

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General W 00-02-06

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General W 00-05-01

Mounting engine on assembly block and demounting Different customer scopes are not taken into account in the repair sequence shown here, accessories which deviate from the standard equipment are not shown.

Commercial available tools: – Lifting gear – Suspension ropes Special tools: – Assembly block incl. adapter plates . . . . . . . . . . . . . . . . . . . . . 6066 – Clamping bracket . . . . . . . . . . .6066/158 – Engine lifting device . . . . . . . . . . . . 6068

6

Mounting engine on assembly block z Hang the engine director onto the transport lashes (arrows) with support chain. – 4-cylinder  410 kg z Hang engine on workshop crane. Remove all mounting feet.

z Insert engine in engine block.

© 46446-0

z Mount clamping holder 6066/158-1 (1) on holder. z Tighten screws (2) and lock nuts.  70 Nm z Tighten screws (3) and lock nuts.

3

 90 Nm

1 3

2

© 46448-0

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General W 00-05-01

TD 2012 2V TCD 2012 2V

z Mount clamping bracket 6066/158-2 (1) on holder. z Tighten screws (2) and lock nuts.  70 Nm z Tighten screws (3) and lock nuts.

1

2

 90 Nm

3

3

6

© 46449-0

z Mount clamping bracket 6066/158-3 (1) on crankcase. z Tighten screw (2).  70 Nm

2

z Tighten screws (3) and lock nuts.  90 Nm 1

3

3

© 46447-0

z Mount clamping holder 6066/158-4 (1) on crankcase. z Tighten screws (2).  70 Nm z Tighten screws (3) and lock nuts.  90 Nm

2 3 1

3 © 46450-0

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General W 00-05-01

z Align engine on engine block. z Tighten all screws (1). z Unhook the engine from the workshop crane.

1

1

6 © 46459-0

Demounting engine from assembly block z Hang the engine director onto the transport lashes (arrows) with support chain. – 4-cylinder  410 kg z Hang engine on workshop crane.

© 46446-0

z Loosen lock nuts. z Remove screws(3) and lock nuts. z Unscrew screws (2). z Remove clamping holder (1). 2 3 1

3 © 46450-0

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z Loosen lock nuts. z Remove screws(3) and lock nuts. z Remove clamping holder (1). 1

3

3

3

6

© 46449-1

z Loosen lock nuts. z Remove screws(3) and lock nuts. z Remove clamping holder (1). 3

1 3

3

© 46448-1

z Loosen lock nuts. z Unscrew screw (2). z Remove screws(3) and lock nuts. z Remove clamping bracket (1).

2

Mount all mounting feet.

z Set down engine. 1

z Unhook the engine from the workshop crane.

3

3

© 46447-0

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Cylinder head W 01-01-01

Setting valve clearance Commercial available tools: – Rotation angle disc . . . . . . . . . . . . . 8190 – Open wrench size 13 . . . . . . . . . . . 8196 – Screwdriver insert for slotted screws. . . . . . . . . . . . . . . . . . . . 8191 – Screwdriver insert for hexagon socket head screws (5 mm) . . . . . . . . . . . . . . . . 8193

– W 01-04-04 – W 04-06-03 Let the engine cool down for at least 30 minutes before setting the valve clearance. Engine oil temperature < 80 °C

Special tools: – Turn-over gear . . . . . . . . . . . . . . 100320

6

Setting engine to valve overlap z Attach turning gear.  W 04-06-03 z Remove the cylinder head hood.  W 01-04-04 z Turn crankshaft using the turning gear until the valve overlap of cylinder 1 is reached.

© 46461-0

Arrangement of the inlet and exhaust valves. IN = inlet valve EX = exhaust valve

EX

IN

© 46381-0

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TD 2012 2V TCD 2012 2V

 4-cylinder Ignition sequence:

1-3-4-2 Valves

overlap set to

1 4

Cylinders 3 4 2 2 1 3

Valve overlap means: The inlet valve starts opening,exhaust valve closes.

6 © 46380-0

Setting the inlet valve clearance z Loosen lock nut (1). z Press in the adjusting screw (2) to the stop.

2

The rocker arm must touch the thrust washer of the spring cap (arrow).

Attention! Pay attention to versions of the adjusting screws (slotted, hexagonal, hexagonal socket).

1

© 46382-0

z Set the rotation angle disc with a screwdriver insert at the adjusting screw. z Fix magnet of rotation angle disc on cylinder head. z Set the rotation angle disc in the direction of the arrow to „0“. Do not rotate adjusting screw.

© 46462-0

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Cylinder head W 01-01-01

z Turn the adjusting screw in the direction of the arrow. – Inlet  75°

6 © 46463-0

z Hold adjusting screw. z Tighten lock nut (1) with open wrench.  20 Nm z Remove rotation angle disc.

1

© 46464-0

Setting the exhaust valve clearance z Loosen lock nut (1). z Press in the adjusting screw (2) to the stop. The rocker arm must touch the thrust washer of the spring cap (arrow). 2

1 © 46387-0

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z Set the rotation angle disc on the adjusting screw with a screwdriver insert for slotted screws. z Fix magnet of rotation angle disc on cylinder head. z Set the rotation angle disc in the direction of the arrow to „0“. Do not rotate adjusting screw.

6 © 46465-0

z Turn the adjusting screw in the direction of the arrow. – Outlet  120 °

© 46466-0

z Hold adjusting screw. z Tighten lock nut (1) with open wrench.  20 Nm z Remove rotation angle disc. z Mount cylinder head cover.  W 01-04-04 z Remove turning gear.  W 04-06-03

1

© 46467-0

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Cylinder head W 01-02-02

Removing and installing the rocker arm and rocker arm bracket Commercial available tools: – Pin wrench insert Torx E14 . . . . . . . 8113 – Rotation angle disc . . . . . . . . . . . . . 8190

– W 01-01-01 – W 01-04-04

6

Removing the rocker arm and rocker arm bracket z Remove the cylinder head hood.  W 01-04-04 z Unscrew the cylinder head screw (1) with the socket wrench insert.

2

z Unscrew screw (2). z Remove rocker arm bracket. Lay out components in the order in which they should be installed. 1

© 46451-2

z Remove push rods (1). Lay out components in the order in which they should be installed.

1

© 46452-0

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z Visually inspect the components.

6 © 46453-0

Installing the rocker arm and rocker arm bracket z Insert stop rods (1). Note the assignment of the stop rods. The stop rod must be seated with the ball head in the ladle of the tappet.

1

© 46452-0

z Mount rocker arm bracket (1). The ball heads (2) must be seated in the ladles of the stop rods . 1

2 © 46454-0

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Cylinder head W 01-02-02

z Fasten screw (1). Do not tighten the screw.

1

6 © 46455-0

Attention! Cylinder head screws can be used max. 3 times with written proof, otherwise renew every time they are loosened.

1

z Lightly oil cylinder head screw (1). z Turn in cylinder head screw (1).

© 46456-0

z Align rocker arm bracket symmetrically with the valve axles. z Tighten cylinder head screw with the socket wrench insert. – Pre-clamping value:  30 Nm

Attention! Make sure that the stop rods are not under stress due to valve overlap when fastening the screw.

© 46457-0

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z Tighten screw (1).  21 Nm

1

6 © 46451-1

z Tighten cylinder head screw with the socket wrench insert. – Post-clamping value:  + 80 Nm + 90° z Set valve clearance.  W 01-01-01

© 46457-0

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Cylinder head W 01-02-06

Disassembling, assembling and checking the rocker arm and rocker arm bracket Commercial available tools: – Internal measuring device – Micrometer gauge – Locking ring pliers

– W 01-02-02

Special tools: – Dial gauge. . . . . . . . . . . . . . . . . . 100400

6

Disassembling the rocker arm bracket z Remove rocker arm and rocker arm bracket.  W 01-02-02 z Remove locking ring with locking ring pliers.

© 46389-0

z Remove rocker arm. Lay out components in the order in which they should be installed.

© 46390-0

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Checking the rocker arm z Measure rocker arm bore. – Outlet  21,02

+0,033 −0

mm

+0,033 −0

mm

– Inlet  21,02

When the wear limit is reached the rocker arm must be renewed.

6 © 39032-1

z Loosen lock nut (1). z Unscrew adjusting screw (2).

Attention! Pay attention to versions of the adjusting screws (slotted, hexagonal, hexagonal socket). Lay out components in the order in which they should be installed. 2

1 © 46393-0

z Check components for visible signs of wear. z Check oil channels (arrows) for free passage.

© 46392-0

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Cylinder head W 01-02-06

z Screw in setting screw (1). z Loosen lock nuts (2).

2

1

6 © 46468-0

Checking the rocker arm pin z Measure the diameter of journals with the micrometer gauge.  21

+0 − 0,052

mm

When the wear limit is reached the rocker arm bracket must be replaced.

© 46469-0

Assembling the rocker arm bracket z Lightly oil the rocker arm pin.

2

z Push rocker arm (1) onto rocker arm pin. z Push rocker arm (2) onto rocker arm pin. 1

The rocker arm's sliding surface (3) must face the threaded bore (arrow). Mount the rocker arm (1) on the outlet side. Mount the rocker arm (2) on the inlet side.

3 © 46471-0

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z Insert new locking rings (1). z Install rocker arm and rocker arm bracket.  W 01-02-02

1

6 © 46453-1

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Cylinder head W 01-04-04

Removing and installing cylinder head Commercial available tools: – Pin wrench insert Torx E14 . . . . . . . 8113

– W 01-01-01 – W 01-02-02 – W 01-04-09 – W 06-01-05 – W 06-07-03 – W 07-07-01 – W 09-13-04

6

Removing cylinder head z Unscrew all screws (1).

2

z Remove cylinder head cowling (2).

1

© 46471-1

z Cut through the gasket at the gates (1). z Remove gasket. z Visually inspect the components.

© 46587-0

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z Remove the fan mounting.  W 09-13-04 z Remove the exhaust pipe.  W 06-01-05

6 © 46590-0

z Removing fuel injectors.  W 07-07-01 z Remove rocker arm brackets.  W 01-02-02 z Remove the charge air pipe.  W 06-07-03

2

z Unscrew screws (1). z Remove holder (2).

1

© 46331-0

z Unscrew all screws (1) with the socket wrench insert. z Remove cylinder head.

1

z Remove gasket. z Clean sealing surfaces.

1

© 46334-0

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Cylinder head W 01-04-04

Installing the cylinder head Measure the piston overhang on all pistons. Select cylinder head gasket according to the largest piston projection measured. z Check piston overhang.  W 01-04-09

6 © 42565-0

z Select cylinder head gasket according to the largest piston projection measured. 

Piston projection

Hole

0.33 - 0.55 mm

1

0.56 - 0.65 mm

2

0.66 - 0.76 mm

3

Example: Piston projection = 0.7 mm corresponds to cylinder head gasket with 3 holes (arrow). © 44154-0

Make sure the clamping bushings (1) are in place.

1

© 46335-0

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z Fit a new cylinder head gasket. The sealing surfaces for the cylinder head gasket must be clean and free of oil. Label OBEN / TOP facing the cylinder head.

6 © 46336-0

z Fit cylinder head.

© 46591-0

z Insert stop rods (1). Note the assignment of the stop rods. The stop rod must be seated with the ball head in the ladle of the tappet.

1

© 46452-0

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Cylinder head W 01-04-04

z Mount rocker arm bracket (1). The ball heads (2) must be seated in the ladles of the stop rods . 1

2

6 © 46454-0

z Fasten screw (1). Do not tighten the screw.

1

© 46455-0

Attention! Cylinder head screws can be used max. 3 times with written proof, otherwise renew every time they are loosened.

1

z Lightly oil cylinder head screw (1). z Turn in cylinder head screw (1).

© 46456-0

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z Align rocker arm bracket symmetrically with the valve axles. z Tighten cylinder head screw with the socket wrench insert.  30 Nm

Attention! Make sure that the stop rods are not under stress due to valve overlap when fastening the screw.

6 © 46457-0

z Tighten screw (1).  21 Nm

1

© 46451-1

z Tighten all cylinder head screws according to the tightening sequence. – Post-clamping value:  30 Nm + 80 Nm + 90° Use socket wrench insert.

14

6

12

4

18

10

2

8

16

17

9

1

7

15

13

5

3

11

© 45131-0

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Cylinder head W 01-04-04

z Mount holder (2). z Tighten screws (1). z Install the charge air pipe.  W 06-07-03 z Install rocker arm brackets.  W 01-02-02 2

z Set valve clearance.  W 01-01-01

1

z Install fuel injectors.  W 07-07-01

6 © 46331-0

z Install the exhaust pipe.  W 06-01-05 z Install fan mounting.  W 09-13-04

© 46590-0

Installing cylinder head cover. z Cut through the new gasket at the gates (1).

Attention! Do not bend or deform metal beading gasket. Remove burr from cut surfaces.

© 46587-0

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TD 2012 2V TCD 2012 2V

z Clean sealing surfaces. z Mount new gasket. Ensure that the installation location is free from faults. z Mount cylinder head cover. z Tighten all screws (1) alternately.  11 Nm

1

6 © 46474-2

Pay attention to perfect installation position (arrow).

© 46473-2

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Cylinder head W 01-04-09

Checking piston overhang Commercial available tools

– W 01-04-04 – W 04-06-03

Special tools: – Turn-over gear . . . . . . . . . . . . . . 100330 – Dial gauge. . . . . . . . . . . . . . . . . . 100400 – Measuring device . . . . . . . . . . . . 100750

6

Checking piston overhang z Attach turning gear.  W 04-06-03 z Remove cylinder head.  W 01-04-04

© 46474-0

z Turn the crankshaft until the respective piston is just in front of the top dead centre (arrow).

© 46333-0

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Cylinder head W 01-04-09

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z Insert dial gauge into measuring beam. z Place shims (1) and measuring beam (2) on the sealing surface of the crankcase.

2

1

1

6 © 30240-4

z Move the measuring beam. z Apply stylus of the dial gauge to the crankcase sealing surface with pre-tension (arrow). z Adjust dial gauge to "0".

© 43614-1

z Measure at the points (1) and (2) on the piston. 1

Schematic representation

2 © 34151-2

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Cylinder head W 01-04-09

z Move the measuring beam. z Apply stylus to the specified measuring points under pre-tension. z Continue turning the crankshaft evenly until the reversal point of the pointer on the dial gauge is reached. The stylus may not be positioned on the labelling of the piston. Note greatest measured value.

6 © 43514-1

z Select cylinder head gasket according to the largest piston projection measured. 

Piston projection

Hole

0.33 - 0.55 mm

1

0.56 - 0.65 mm

2

0.66 - 0.76 mm

3

Example: Piston projection = 0.7 mm corresponds to cylinder head gasket with 3 holes (arrow). © 44154-0

z Install cylinder head.  W 01-04-04 z Remove turning gear.  W 04-06-03

© 46474-0

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Cylinder head W 01-05-01

Removing and installing the valves Commercial available tools: – Slide gauge – Assembly pliers. . . . . . . . . . . . . . . . 8024 – Assembly lever . . . . . . . . . . . . . . . . 9017

– W 01-04-04

Special tools: – Support bracket . . . . . . . . . . . . . 120900 – Base plate. . . . . . . . . . . . . . . . . . 120910 – Assembly tool . . . . . . . . . . . . . . . 121410 – Assembly sleeves . . . . . . . . . . . . 121420

6

Removing the valves z Remove cylinder head.  W 01-04-04

1

z Mount support bracket (1) on base plate (2). z Mount cylinder head on support bracket.

2 © 42583-0

z Remove snap ring (1).

Danger! Risk of injury! Snap ring springs off.

1

© 42584-0

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z Remove thrust washer (1).

1

6 © 42585-0

z Install assembly lever (1). z Press down valve spring with assembly lever. z Remove both tapper collets (2).

1

z Remove valve spring plates, valve springs and valves. z Remove assembly lever.

2

© 42586-0

z Remove valve shaft seal with assembly pliers.

© 42587-0

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z Clean cylinder head, check and visually inspect for damage.

6 © 42588-0

z Install valves. z Measure valve spring length with slide gauge.  59 mm When the wear limit is reached, the valve spring must be renewed.

© 35856-2

z Oil the valve stem lightly. z Insert and hold valve. z Push assembly sleeve (1) over the valve V-grooves.

1

2

© 42589-0

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z Push new valve shaft seal (1) over the assembly sleeve. z Remove assembly sleeve.

1

6 © 42590-1

z Press in valve shaft seal to stop with assembly tool (1).

1

© 42591-0

z Insert valve spring (1). z Insert valve spring plate (2). 2

1

© 42592-0

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Cylinder head W 01-05-01

z Mount assembly lever. z Place assembly lever on valve spring plate. z Press down the valve spring with the assembly lever and insert both tapper collets (1). Make sure the tapper collets fit correctly in the valve keyway.

1

6 © 42593-0

z Remove assembly lever. z Insert thrust washer (1).

1

© 42585-0

z Insert spring ring (1). Pay attention to the correct fit of the spring ring in the groove. 1

© 42594-0

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z Remove cylinder head from support bracket (1). z Remove support bracket from base plate (2). z Install cylinder head. 1

 W 01-04-04

2

6

© 42583-0

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Cylinder head W 01-05-04

Checking the valves Commercial available tools: – Micrometer gauge – Slide gauge

– W 01-05-01

Clean all valves. When the wear limit is reached, the valve must be renewed.

6

Checking valve stem diameter z Remove valves.  W 01-05-01 z Measure valve stem diameter with micrometer gauge. – Inlet valve  7,98

+0 −0,015

mm

– Exhaust valve  7,96

+0 −0,015

mm

© 42182-1

Checking valve edge thickness z Measure valve edge thickness with slide gauge. – Inlet valve  2,3 mm – Exhaust valve  1,61 mm

© 42183-1

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Checking valve head diameter z Measure valve head diameter with slide gauge. – Inlet valve  41,7

+0,1 −0,1

mm

– Exhaust valve  35,9

+0,1 −0,1

mm

z Install valves.  W 01-05-01

6 © 42184-1

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Cylinder head W 01-06-03

Checking the valve guide Commercial available tools: – Magnetic measuring stand

– W 01-05-01

Special tools: – Dial gauge. . . . . . . . . . . . . . . . . . 100400

New valves are used for testing. When the wear limit is reached, the valve guide must be renewed.

6

Checking the valve guide z Remove valves.  W 01-05-01 z Visually inspect valve guide for wear. z Mount magnetic measuring stand. z Insert dial gauge. z Insert new valve. z Place stylus on the valve stem under pretension (arrow). z Adjust dial gauge to "0".

© 42595-0

Measure valve stem clearance z Move valve back and forth in direction of arrow. – Inlet valve +0

 0,028 - 0,068 − 0,015 mm – Exhaust valve +0

 0,048 - 0,088 − 0,015 mm The whole rocker path must be taken into consideration.

© 42597-0

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z Remove magnetic measuring stand. z Remove dial gauge. z Install valves.  W 01-05-01

6 © 42596-0

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Cylinder head W 01-07-08

Checking the valve lag Commercial available tools: – Depth-measuring appliance

– W 01-04-04

Special tools: – Support bracket . . . . . . . . . . . . . 120900 – Base plate. . . . . . . . . . . . . . . . . . 120910

Attention! When the wear limit is reached, the valve seat insert and/or valve must be renewed.

6

Checking the valve lag 1

z Remove cylinder head.  W 01-04-04 z Mount support bracket (1) on base plate (2).

2

© 44178-0

z Screw cylinder head onto support bracket (1) and base plate (2). 1

2 © 46588-0

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TD 2012 2V TCD 2012 2V

z Measure the valve lag from the centre of the valve head to the cylinder head sealing surface. – Inlet valve  0,9

+0,15 −0,1

mm

– Exhaust valve  0,9

+0,15 −0,1

mm

6 © 42598-0

z Remove cylinder head from support bracket (1). z Remove support bracket from base plate (2). z Install cylinder head. 1

 W 01-04-04

2 © 46588-0

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Drive system W 02-01-04

Checking the axial clearance of the crankshaft Commercial available tools: – Magnetic measuring stand – Micrometer gauge – Internal measuring device – Socket wrench insert . . . . . . . . . . . 8035

8190

– W 02-04-01 – W 03-08-01 – W 04-04-09

Special tools: – Dial gauge. . . . . . . . . . . . . . . . . . 100400

6

z Remove front cover.  W 03-08-01 z Remove the gear case cover.  W 04-04-09 z Mount magnetic measuring stand. z Insert dial gauge. z Apply stylus to the crankshaft end with pre-tension. z Press crankshaft in direction of arrow. z Adjust dial gauge to "0".

© 44179-0

z Press crankshaft in direction of arrow. z Read off measured value.  0,1 - 0,3 mm In case of deviating axial clearance, the permissible axial clearance should be set by changing the thrust ring halves.

© 44180-0

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TD 2012 2V TCD 2012 2V

z Unscrew screws (1). Use socket wrench insert. 1

z Remove bearing cap (2). z Remove lower bearing shell. z Remove both thrust ring halves (arrows).

2

1

6 © 44181-0

z Remove both thrust ring halves (arrows).

© 44182-0

z Measure the strength of thrust ring halves. – Standard  2,00

+0,05 −0 mm

– 1. Overmeasure  2,20

+0,05 −0

mm

z Select thrust ring halves according to measured value.

© 43504-0

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Drive system W 02-01-04

z Remove crankshaft.  W 02-04-01 z Set micrometer gauge to 32 mm. z Push the internal measuring device between the test surfaces of the micrometer gauge and set to "0".

6 © 35825-2

z Measure locating bearing width z Note measured value, dimension (a).

© 42606-0

z Place thrust ring halves on bearing caps (arrows). z Measure width with micrometer gauge. z Note measured value, dimension (b).

© 35827-2

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TD 2012 2V TCD 2012 2V

z Determine axial backlash.  0,1 - 0,3 mm Calculation example Desired: Axial backlash Given: Measured: (a) = 32,8 mm (b) = 32.7 mm Dimension (a) - Dimension (b) Result: = 0.1 mm

z Install crankshaft.  W 02-04-01

6 © 00000-0

Make sure the clamping bushings (1) are in place.

1

© 44183-0

z Install upper thrust ring halves according to measured axial clearance. Oil grooves (1) of the thrust ring halves face the web face (2) of the crankshaft (arrows)

2

Insert thrust ring halves between crankcase and crankshaft web (arrows).

1

© 44184-0

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Drive system W 02-01-04

z Fix both thrust ring halves with a little grease to the bearing cap. Use lower thrust ring halves with guide lug (arrow). Install thrust ring halves according to measured axial clearance.

2

Bearing cap with identification “2“. The oil grooves (1) face the crankshaft web face.

1

6 © 42663-0

z Insert bearing cap (1). The gate (arrow) on the bearing cap faces the manifold side.

1 © 44185-0

z Tighten screws (1) with the socket wrench insert.  50 Nm + 90° + 90°

Attention! Screws can be reused a maximum 3 times with written documentation. Otherwise renew every time they are loosened.

1

© 44186-1

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TD 2012 2V TCD 2012 2V

z Check axial backlash of crankshaft.  0,1 - 0,3 mm z Remove magnetic measuring stand. z Remove dial gauge. z Install front cover.  W 03-08-01 z Remove the gear case cover.  W 04-04-09

6 © 44187-0

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Drive system W 02-01-07

Checking the crankshaft Commercial available tools: – Magnetic measuring stand – Micrometer gauge – Internal measuring device – Prisms – Hardness tester

– W 02-04-01

Special tools: – Dial gauge. . . . . . . . . . . . . . . . . . 100400

6

Checking the bearing pin hardness z Remove crankshaft.  W 02-04-01 z Place crankshaft on prism.

© 42602-0

z Put hardness tester on journal.

© 30560-1

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TD 2012 2V TCD 2012 2V

z Raise stylus (1) and press release (2). Stylus (1) falls down, briefly strikes the surface and jumps up to the measured value.

1

2

6 © 43499-0

z Read off displayed value (arrow) from hardness tester. – Nominal value, at least  55

+6

HRc

The measured value is to be converted according to the table of the measuring device.

© 43515-0

Diagram for measuring the journals at the points 1 and 2 in the levels a and b.

© 36424-2

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Drive system W 02-01-07

Checking the diameter of the main bearing pins z Measure main bearing pin with micrometer gauge. – Standard  84

+0 − 0,02

mm

– Undermeasure stage  0,25 mm See schematic diagram for measuring points.

6 © 42603-0

Checking the diameter of the lifting journals z Measure lifting journal with micrometer gauge.  62,994

+0 −0,02

mm

– Undermeasure stage  0,25 mm See schematic diagram for measuring points.

© 42604-0

Checking the rotation z Mount magnetic measuring stand. z Insert dial gauge. z Apply stylus to the main bearing pin with pre-tension (arrow) and adjust dial gauge to "0". z Turn crankshaft evenly and check rotation.  0,1 mm z Remove magnetic measuring stand. z Remove dial gauge.

© 42605-0

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Drive system W 02-01-07

TD 2012 2V TCD 2012 2V

Measuring the fit bearing width z Set micrometer gauge to 32 mm. z Push the internal measuring device between the test surfaces of the micrometer gauge and set to "0".

6 © 35825-2

z Measure bearing width with internal measuring device between thelay-on surfaces of the thrust rings.  32,2

+0,04 −0

mm

– 1. Undermeasure stage  0,4 mm

© 42606-0

Visual inspection z Check the running surfaces (1) of the crankshaft sealing rings visually. z Visually inspect gear wheel (2).

1

z Install crankshaft.

2

1

 W 02-04-01

© 42607-0

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Drive system W 02-02-02

Renewing the crankshaft sealing ring (flywheel side) Commercial available tools: – Pricker. . . . . . . . . . . . . . . . . . . . . . . 8198 – Assembly lever . . . . . . . . . . . . . . . . 9017

– W 12-06-01

Special tools: – Assembly tool . . . . . . . . . . . . . . . 142830 – Self-tapping screw – Washer

6

Removing the crankshaft sealing ring z Remove flywheel.  W 12-06-01 z Make a hole of approximately 3 mm in the crankshaft sealing ring with a pricker.

Attention! Do not damage the gearcase cover and crankshaft.

© 46472-0

z Screw in a self-tapping screw (1) with washer.

1

© 46561-0

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Drive system W 02-02-02

TD 2012 2V TCD 2012 2V

z Pull out the crankshaft sealing ring with assembly lever. z Visually inspect the crankshaft sealing ring running surface.

6 © 46562-0

Installing the crankshaft sealing ring z Mount guide sleeve (1). z Tighten screws (2). The bores in the guide sleeve must match the threaded holes in the crankshaft flange.

1

2

© 46563-0

z Oil the sealing lip of the crankshaft sealing ring lightly. z Place the crankshaft sealing ring carefully on the peripheral surface. The sealing lip faces the crankcase.

© 46564-0

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Drive system W 02-02-02

z Mount shims (1). If there is a run-in groove on the crankshaft flange it is possible to mount the crankshaft sealing ring in three installation depths: - first assembly = 2 discs - 1st repair - installation stage = 1 disc - 2nd repair - installation stage = 0 discs.

1

6 © 46565-0

z Mount assembly sleeve (1). z Press on the crankshaft sealing ring to the stop.

1

© 46566-0

z Plug in the bearing (1). z Screw on nut (2).

1

2 © 46567-0

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TD 2012 2V TCD 2012 2V

z Tighten nut to the stop of the assembly sleeve (1). The crankshaft sealing ring is now at the pre-selected installation depth. z Remove assembly tool. z Install flywheel.

1

 W 12-06-01

6 © 44197-0

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Drive system W 02-02-04

Renewing the crankshaft sealing ring (opposite side to flywheel) Commercial available tools: – Pricker. . . . . . . . . . . . . . . . . . . . . . . 8198 – Assembly lever . . . . . . . . . . . . . . . . 9017

– W 12-01-04

Special tools: – Assembly tool . . . . . . . . . . . . . . . 142670 – Self-tapping screw – Washer

6

Removing the crankshaft sealing ring z Remove V-belt pulley.  W 12-01-04 z Make a hole of approximately 3 mm in the crankshaft sealing ring with a pricker.

Attention! Do not damage the front cover or crankshaft.

© 43643-0

z Screw in a self-tapping screw (1) with washer.

1

© 44872-0

© 04/2007

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TD 2012 2V TCD 2012 2V

z Pull out the crankshaft sealing ring with assembly lever. z Visually inspect the crankshaft sealing ring running surface.

6 © 44873-0

Installing the crankshaft sealing ring z Remove clamping bushing (1).

1

© 44875-0

z Mount guide sleeve (1). Make sure the clamping bushing (2) is in line with the bore (3). 1

2

3

© 42623-0

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Drive system W 02-02-04

z Tighten screws (1).

1

6 © 44877-0

z Oil the sealing lip of the crankshaft sealing ring lightly. z Place the crankshaft sealing ring carefully on the peripheral surface. The sealing lip faces the crankcase.

© 44878-0

z Mount shims (1). z Pay attention to installation depth of crankshaft sealing ring and select shim accordingly. – First assembly = 2 shims – 1. Repair installation depth = 1 shim – Maximum installation depth = without washers

1

© 44879-0

© 04/2007

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Drive system W 02-02-04

TD 2012 2V TCD 2012 2V

z Mount assembly sleeve (1). z Press on the crankshaft sealing ring to the stop.

1

6 © 44880-0

z Plug in the bearing (1). z Turn on nut (2).

2 1

© 44881-0

z Tighten nut to the stop of the assembly sleeve (1). The crankshaft sealing ring is now at the pre-selected installation depth. 1

z Remove assembly tool.

© 44882-1

© 04/2007

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Drive system W 02-02-04

z Knock in the clamping sleeve (1) to the stop. z Install V-belt pulley.  W 12-01-04

1

6 © 42622-0

© 04/2007

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Drive system W 02-02-04

TD 2012 2V TCD 2012 2V

6

© 04/2007

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Drive system W 02-03-01

Checking the con rod Commercial available tools: – Micrometer gauge – Internal measuring device – Rotation angle disc . . . . . . . . . . . . . 8190 – Con rod test device

– W 02-09-03

Special tools: – Dial gauge. . . . . . . . . . . . . . . . . . 100400

6

z Remove piston and connecting rod.  W 02-09-03 z Remove piston from con rod.

© 40592-1

Checking small end bush z Prepare internal measuring device: – Mount probe bolt for the appropriate measuring range in the internal measuring device. – Mount dial gauge with approx. 1 mm pre-tension in the internal measuring device. – Set micrometer gauge to 38 mm. – Balance the internal measuring device between the test surfaces of the micrometer gauge and set the dial gauge at the reversal point of the pointer to "0".

© 34768-2

© 04/2007

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Drive system W 02-03-01

TD 2012 2V TCD 2012 2V

Diagram for measuring the small end bush at the points "a" and "b" in the levels "1" and "2".

6 © 37239-1

z Insert internal measuring device. z Balance the internal measuring device at the given measuring points and read off the measured value at the reversal point of the pointer.  38,025 +0,010 mm Measuring points see diagram.

z Note the measured value, dimension (A). The dimension A is required to determine the piston bolt clearance.

© 34770-2

Checking diameter of the piston bolt z Measure piston pin with micrometer gauge. +0

 38 −0,006 mm z Note the measured value, dimension B. The dimension B is required to determine the piston bolt clearance.

© 35908-2

© 04/2007

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Drive system W 02-03-01

Determining piston pin clearance The piston pin clearance is given by the difference between the internal diameter of the small end bush (a) and the piston pin diameter (b).  0,025 - 0,041 mm Calculation example Desired: Piston pin clearance Given: Measured: Internal diameter small end bush (a) (a) = 38.025 mm Diameter piston pin (b) (b) = 38.000 mm Dimension (a) - Dimension (b) 38.025 mm - 38.000 mm Result: = 0.025 mm

6

Checking the con rod bearing bore z Mount big end bearing cap. Note the assignment of the big end bearing cap. The identification numbers (1) on the con rod and the big end bearing cap must be identical and opposite to each other when assembled.

1

26519

Attention!

26519 © 44212-0

z Tighten screws alternately with rotation angle disc and socket wrench insert.  30 Nm + 60° + 30°

© 44213-0

© 04/2007

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Drive system W 02-03-01

TD 2012 2V TCD 2012 2V

z Prepare internal measuring device: – Mount probe bolt for the appropriate measuring range in the internal measuring device. – Mount dial gauge with approx. 1 mm pre-tension in the internal measuring device. – Set micrometer gauge to 66 mm. – Balance the internal measuring device between the test surfaces of the micrometer gauge and set the dial gauge at the reversal point of the pointer to "0".

6 © 36094-1

Diagram for measuring the con rod bearing bore at the points "a" and "b" in the levels "1" and "2".

© 37239-1

z Insert internal measuring device. z Balance the internal measuring device at the given measuring points and read off the measured value at the reversal point of the pointer.  66,6 +0,019 mm If the measured values deviate slightly, additional measurements must be made with new bearing shells.

© 44214-0

© 04/2007

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Drive system W 02-03-01

Checking internal diameter of the con rod bearing shells z Remove screws. z Remove the con rod bearing cover. Make sure the clamping bushings (1) are in place.

1

6 © 44440-0

z Insert bearing shell in the con rod.

Attention! Note the assignment of the bearing shells. The anti-rotation lock (1) must lock in groove (2).

2

1 © 44215-0

z Insert bearing shell in the respective big end bearing cap.

Attention! Note the assignment of the bearing shells. The anti-rotation lock (1) must lock in groove (2).

1

2

© 44216-0

© 04/2007

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TD 2012 2V TCD 2012 2V

z Mount big end bearing cap.

Attention! 9

1

2651

The identification numbers (1) on the connecting rod and the big end bearing cover must be identical and opposite to each other when assembled.

9

2651

6 © 44217-0

z Tighten screws alternately with rotation angle disc and socket wrench insert.  30 Nm + 60° + 30°

© 44218-0

z Prepare internal measuring device: – Mount probe bolt for the appropriate measuring range in the internal measuring device. – Mount dial gauge with approx. 1 mm pre-tension in the internal measuring device. – Set micrometer gauge to 63 mm. – Balance the internal measuring device between the test surfaces of the micrometer gauge and set the dial gauge at the reversal point of the pointer to "0".

© 36094-1

© 04/2007

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Drive system W 02-03-01

Diagram for measuring the inside diameter of the con rod bearing shells at the points "a" and "b" in the levels "1" and "2".

6 © 37239-1

z Insert internal measuring device. z Balance the internal measuring device at the given measuring points and read off the measured value at the reversal point of the pointer. See schematic diagram for measuring points.  63,026 - 63,065 mm z Note measured value, dimension (a). When the wear limit is reached the con rod must be replaced.

© 44219-0

Checking the diameter of the lifting journals Diagram for measuring the journals at the points 1 and 2 in the levels a and b.

© 36424-2

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Drive system W 02-03-01

TD 2012 2V TCD 2012 2V

z Measure lifting journal with micrometer gauge.  62,994

+0 −0,02

mm

– Undermeasure stage  0,25 mm Measuring points see diagram.

z Note measured value, dimension (b).

6 © 36424-2

Determine big end bearing clearance The big end bearing clearance is given by the difference between the internal diameter of the big end bearing shell (a) and the lifting journal diameter (b).  0,032 - 0,073 mm Calculation example Desired: Big end bearing clearance Given: Measured: Internal diameter big end bearing shell (a) (a) = 63.026 mm Diameter lifting journal (b) (b) = 62.992 mm Dimension (a) - Dimension (b) Result: = 0.034 mm

– Wear limit  0,12 mm z Remove screws. z Remove the con rod bearing cover.

© 44218-0

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Drive system W 02-03-01

Checking the con rod z Mount connecting rod on test instrument without bearing shells.

A

Attention! Aligning the con rod is not permissible.

B

z Move test fork in direction of arrow. z Check that the con rod is parallel. z Permissible deviation from (A) to (B).  0,04 mm Distance between “A“ and “B“ = 100 mm.

6 © 30579-1

z Move test fork in direction of arrow. z Check the angle of the con rod. z Permissible deviation from (C) to (D).  0,04 mm Distance between “C“ and “D“ = 100 mm

C D

z Assembly pistons and con rod. z Install piston and connecting rod.  W 02-09-03

© 30580-1

© 04/2007

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Drive system W 02-03-01

TD 2012 2V TCD 2012 2V

6

© 04/2007

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Drive system W 02-04-01

Removing and installing the crankshaft Commercial available tools

– W 02-01-07 – W 02-09-03 – W 03-08-01 – W 04-04-09

Special tools: – Socket wrench insert . . . . . . . . . . . 8035 – Turn-over gear . . . . . . . . . . . . . . 100330

6

Removing crankshaft z Remove front cover.  W 03-08-01 z Remove the gear case cover.  W 04-04-09

© 42647-2

z Screw in screws (1). z Remove all con rod bearing covers. z Remove con rod bearing shells.  W 02-09-03

1 1

© 42648-1

© 04/2007

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Drive system W 02-04-01

TD 2012 2V TCD 2012 2V

z Make a mark (1) on the camshaft gear wheel for assistance.

2

Your mark must be on a line between the marking (2) and the middle (3) of the camshaft. 1

3

6 © 42651-0

z Turn the crankshaft evenly until the marking (1) on the crankshaft flange is in line with your mark (2) on the camshaft gear wheel. The marking on the camshaft gear wheel is covered by the crankshaft flange when it is in line.

1

Attention! Do not jam the con rods when turning the crankshaft. 2

© 42652-0

Removing the main bearing cover z Unscrew all screws (1) with the socket wrench insert.

1

1

© 42653-1

© 04/2007

2/8

13989-001

TD 2012 2V TCD 2012 2V

Drive system W 02-04-01

z Remove bearing cap (1). z Remove bearing shell. z Remove both thrust ring halves (arrows). z Remove all main bearing covers (2). z Remove bearing shells.

1

Lay out components in the order in which they should be installed. Note order of cylinders.

2

6 © 44228-1

z Press the con rods carefully out of the lifting journal. z Lift out the crankshaft.

© 42655-1

z Remove both thrust ring halves (arrows). z Remove all main bearing shells (1). Lay out components in the order in which they should be installed. Note order of cylinders. z Visually inspect the components. z Check axial backlash of crankshaft (crankshaft removed).

1

 W 02-01-07

© 44231-2

© 04/2007

3/8

13989-001

Drive system W 02-04-01

TD 2012 2V TCD 2012 2V

Installing the crankshaft z Insert upper main bearing shells. Note the assignment of the bearing shells. The anti-rotation lock (1) must lock in groove (2). 1 2

6 © 42658-0

z Insert lower main bearing shells in the respective main bearing cover. Note the assignment of the bearing shells. The anti-rotation lock (1) must lock in groove (2).

1

2

© 44233-0

Make sure the clamping bushings (arrows) are in place.

© 44231-1

© 04/2007

4/8

13989-001

TD 2012 2V TCD 2012 2V

Drive system W 02-04-01

z Position camshaft. The bore (1) must be facing the cylinder head. z Lightly oil bearing surfaces.

1

6 © 42661-0

z Insert the crankshaft carefully in the crankcase.

Attention! Do not jam the con rods when inserting the crankshaft! z Set the crankshaft in line with the camshaft. Make sure that the markings match up.

© 44238-2

z Check control times. The marking (1) on the crankshaft flange must be in line with your mark (2).

1

2

© 42652-0

© 04/2007

5/8

13989-001

Drive system W 02-04-01

TD 2012 2V TCD 2012 2V

z Install upper thrust ring halves according to measured axial clearance. Thrust ring halves, without guide lugs, between the crankshaft and the crankcase (arrows). Oil grooves (1) of the thrust ring halves face the web face (2) of the crankshaft (arrows)

2

1

6 © 42662-0

z Fix both thrust ring halves with a little grease to the bearing cap. Bearing cap with identification “2“. Use thrust ring halves with guide lug (arrow).

2

Oil grooves (1) face the crankshaft web face.

1

© 42663-0

Mounting the main bearing cover z Insert bearing cap (1). z Insert main bearing cover (2) according to the numbering. Note assignment and installation position:

1

Insert main bearing cover with the number 1 on the flywheel side. Gate (arrow) on the bearing cover faces the manifold side.

7

6

5

4

3

1

2

2

© 44240-1

© 04/2007

6/8

13989-001

TD 2012 2V TCD 2012 2V

Drive system W 02-04-01

z Main bearing cover with socket wrench insert and rotary angle disc.  50 Nm + 90° + 90°

Attention! Screws can be reused a maximum 3 times with written documentation. Otherwise renew every time they are loosened. z Install the con rod bearing cover.  W 02-09-03

6 © 44241-1

z Unscrew screws (1).

1 1

© 42648-1

z Install the gear case cover.  W 04-04-09 z Install front cover.  W 03-08-01

© 42647-2

© 04/2007

7/8

13989-001

Drive system W 02-04-01

TD 2012 2V TCD 2012 2V

6

© 04/2007

8/8

13989-001

TD 2012 2V TCD 2012 2V

Drive system W 02-08-01

Removing and installing, checking the mass compensation shafts Commercial available tools: – Micrometer gauge – Torque wrench

– W 04-04-09

Special tools: – Centring bolts (2x) . . . . . . . . . . . 100810 – Chalk – Locking agent DEUTZ DW 72

6

Removing the mass compensation shafts z Remove the gear case cover.  W 04-04-09 z Set piston cylinder 1 at top dead centre. The marking (1) on the crankshaft flange must be in line with your mark (2).

2 1

© 36652-2

z Unscrew screw (1). z Remove washer (2). z Remove idler gear (3). z Remove the bearing pin.

1

3

2

© 46605-0

© 04/2007

1/8

13990-001

Drive system W 02-08-01

TD 2012 2V TCD 2012 2V

z Unscrew screw (1). z Remove lubricating oil pipe (2). z Remove idler gear (3). z Remove the bearing pin. 1

2 3

6 © 46606-0

z Unscrew screws (1). z Remove shims (2).

1

2

1

2

© 46607-0

z Pull out mass compensation shafts in direction of arrow.

Attention! Do not damage the mass compensation shafts.

© 36666-3

© 04/2007

2/8

13990-001

TD 2012 2V TCD 2012 2V

Drive system W 02-08-01

Checking the mass compensation shafts z Check components for visible signs of wear.

6 © 36664-1

z Measure the diameter of journals with the micrometer gauge.  54

− 0,02

mm

© 36665-1

Installing the mass compensation shafts z Oil the journal lightly. z Insert mass compensation shafts in direction of arrow. The weight position (1) faces the lubricating oil pan.

1 © 36666-4

© 04/2007

3/8

13990-001

Drive system W 02-08-01

TD 2012 2V TCD 2012 2V

z Unscrew locking screws (1).

1

1

6 © 36651-2

z Insert centring bolt (1). z Fix mass compensation shafts with centring bolts (1).

Attention!

1

Do not turn the mass compensation shafts any more!

1 © 36659-2

z Install shims (2). z Tighten screws (1). Do not tighten the screw.

1

2

1

2

© 46607-0

© 04/2007

4/8

13990-001

TD 2012 2V TCD 2012 2V

Drive system W 02-08-01

z Mount intermediate gear of the B-side. Position the intermediate gear (1) centred with the threaded bore (2).

2

If the tooth edges do not match, the crankshaft can easily be turned.

Attention! Do not turn the mass compensation shafts any more!

1

6 © 36669-1

z Lightly oil journal (1). z Insert bearing pin (1). z Mount washer (2). z Turn in screw (3). Insert screw with safety agent DEUTZ DW 72. Do not tighten the screw.

1

3

2 © 36670-2

z Make help marks (1) and (2). z Turn out centring bolts (A-side). z Turn mass compensation shaft two teeth in direction of the arrow.

1 2

© 36656-2

© 04/2007

5/8

13990-001

Drive system W 02-08-01

TD 2012 2V TCD 2012 2V

z Insert the intermediate wheel (1) into the toothing from above. Turn the mass compensation shaft in the direction of the arrow until the help marks are in line. Position the intermediate gear (1) centred with the threaded bore (2).

1

2

6 © 36657-2

z Lightly oil journal (1). z Insert bearing pin (1).

1

© 36667-2

z Insert new O-ring (1).

1

© 36668-2

© 04/2007

6/8

13990-001

TD 2012 2V TCD 2012 2V

Drive system W 02-08-01

z Mount lubrication oil line (1). z Fasten screw (2). Insert screw with safety agent DEUTZ DW 72. 1

Do not tighten the screw.

2

6 © 36658-2

z Unscrew all centring bolts (1).

1

1 © 36659-2

z Mount new sealing rings. z Tighten locking screws (1).  9 Nm 1

1

© 36651-2

© 04/2007

7/8

13990-001

Drive system W 02-08-01

TD 2012 2V TCD 2012 2V

z Tighten screws (1).  29 Nm z Tighten screws (2).  22 Nm z Install the gear case cover.  W 04-04-09 1 1 2

6

© 36660-2

© 04/2007

8/8

13990-001

TD 2012 2V TCD 2012 2V

Drive system W 02-09-03

Removing and installing the piston and con rod Commercial available tools: – Rotation angle disc . . . . . . . . . . . . . 8190

– W 01-04-04 – W 02-10-03 – W 08-04-06

Special tools: – Piston ring compressor . . . . . . . . 130670

Collect leaking operating substances in suitable vessels and dispose of according to regulations. Lubricating oil and coolant must be filled according to the instructions in the operating manual.

6

Removing the piston and con rod z Remove cylinder head.  W 01-04-04 z Remove oil suction pipe  W 08-04-06 z Pull out oil dipstick.

© 46477-0

Removing the big end bearing cap z Turn the crankshaft with the turning gear. z Set lifting journal at bottom dead centre (BDC). z Unscrew screws (1). z Remove big end bearing cap (2). Lay out components in the order in which they should be installed.

2

Note order of cylinders.

1

z Remove bearing shell.

© 46480-0

© 04/2007

1/8

13991-001

Drive system W 02-09-03

TD 2012 2V TCD 2012 2V

z Remove piston and connecting rod. Lay out components in the order in which they should be installed. Note order of cylinders.

6 © 46478-0

z Remove con rod bearing shells (1). z Visually inspect the components.

1 © 44250-0

z Remove locking ring. z Press out piston pin. z Visually inspect the components.

© 44251-0

© 04/2007

2/8

13991-001

TD 2012 2V TCD 2012 2V

Drive system W 02-09-03

Completing con rod and piston z Insert new locking ring. Ensure that the installation location is free from faults.

6 © 44252-0

The flywheel/crankshaft symbol (1) on the piston base must face to the right and the identification number (2) on the con rod must face upwards.

2

26519

z Insert con rod.

1

© 44253-0

z Oil the piston bolt lightly. z Press the piston bolt through. z Insert new locking ring. Ensure that the installation location is free from faults.

© 44254-0

© 04/2007

3/8

13991-001

Drive system W 02-09-03

TD 2012 2V TCD 2012 2V

Installing the piston and con rod Make sure the clamping bushings (1) are in place.

1

6

1 © 46296-0

z Insert bearing shell in the con rod. Note the assignment of the bearing shells. The anti-rotation lock (1) must lock in groove (2). 2

1 © 46295-0

z Insert bearing shell in the respective big end bearing cap.

Attention! Note the assignment of the bearing shells. The anti-rotation lock (1) must lock in groove (2).

1

2

© 44216-0

© 04/2007

4/8

13991-001

TD 2012 2V TCD 2012 2V

Drive system W 02-09-03

z Arrange the piston ring joints with an offset of about 120° to each other. z Check piston rings and piston ring grooves.  W 02-10-03

6 © 42380-1

z Lightly oil cylinder running surface, piston, piston rings and lifting bearing journal lightly. z Clamp piston rings with piston ring compressor (1). Do not turn the piston rings any further.

1

© 44255-0

z Set lifting journal at bottom dead centre (BDC). z Push piston and con rod completely into cylinder liner. Note the cylinder assignment of the piston. Note the label indicating the installation position on the piston base.

1

The symbol flywheel/crankshaft (1) must face the flywheel. The piston ring compressor must lie flat on the cylinder liner.

© 45004-1

© 04/2007

5/8

13991-001

Drive system W 02-09-03

TD 2012 2V TCD 2012 2V

z Press the con rod carefully against the lifting journal.

Attention! Do not jam the con rod with the crankshaft.

6 © 46481-0

Installing the big end bearing cap z Mount big end bearing cap.

© 46482-0

z Tighten new screws with rotation angle disc.  30 Nm + 60° + 30°

Attention! Renew screws every time they are loosened.

© 46483-0

© 04/2007

6/8

13991-001

TD 2012 2V TCD 2012 2V

Drive system W 02-09-03

z Insert oil dipstick. z Install oil suction pipe.  W 08-04-06 z Install cylinder head.  W 01-04-04

6 © 46479-0

© 04/2007

7/8

13991-001

Drive system W 02-09-03

TD 2012 2V TCD 2012 2V

6

© 04/2007

8/8

13991-001

TD 2012 2V TCD 2012 2V

Drive system W 02-09-07

Checking the piston Commercial available tools: – Micrometer gauge – Internal measuring device

– W 02-09-03

Special tools: – Dial gauge. . . . . . . . . . . . . . . . . . 100400

When the piston wear limit is reached, the piston must be renewed.

6

Checking the piston bolt bore z Remove piston from con rod.  W 02-09-03

© 44262-0

z Prepare internal measuring device: – Mount probe bolt for the appropriate measuring range in the internal measuring device. – Mount dial gauge with approx. 1 mm pre-tension in the internal measuring device. – Set micrometer gauge to 38 mm. – Balance the internal measuring device between the test surfaces of the micrometer gauge and set the dial gauge at the reversal point of the pointer to "0".

© 34768-2

© 04/2007

1/4

13992-001

Drive system W 02-09-07

TD 2012 2V TCD 2012 2V

Diagram for measuring the piston bolt bore at the points "a" and "b" in the levels "1" and "2".

6 © 37239-1

z Insert internal measuring device in the piston bolt bore. z Balance the internal measuring device at the given measuring points and read off the measured value at the reversal point of the pointer.  38

+ 0,009 + 0,004

mm

See schematic diagram for measuring points.

© 43483-0

Checking the piston diameter Diagram for measuring the piston diameter at the measuring points "1, 2 and 3", transverse to the piston bolt bore.

3 2 1

© 37244-1

© 04/2007

2/4

13992-001

TD 2012 2V TCD 2012 2V

Drive system W 02-09-07

z Measure piston diameter with micrometer gauge.  Diameter Measuring height 16 mm 50 mm 78.5 mm

Standard 100,820

+0,009 −0,009

100,588

+0,007 −0,007

100,270

+0,012 −0,012

Overmeasure mm 101,320

+0,009 −0,009

mm

mm 101,088

+ 0,007 − 0,007

mm

mm 100,770

+0,012 −0,012

mm

See schematic diagram for measuring points. z Assemble con rod and piston.

6

 W 02-09-03 © 43427-0

© 04/2007

3/4

13992-001

Drive system W 02-09-07

TD 2012 2V TCD 2012 2V

6

© 04/2007

4/4

13992-001

TD 2012 2V TCD 2012 2V

Drive system W 02-10-03

Checking the piston rings and piston ring grooves Commercial available tools: – Feeler gauges

– W 02-09-03

Special tools: – Universal piston ring pliers . . . . . 130300 – Trapezoidal groove wear gauge . . . . . . . . . . . . . . . . . . . . . 130440

6

Checking the piston rings and piston ring grooves z Remove piston from con rod.  W 02-09-03 z Set universal piston ring pliers to the piston diameter.  101 mm z Remove piston rings with universal piston ring pliers.

© 44263-1

z Clean piston. z Visually inspect piston. z Visually inspect piston ring grooves.

© 44264-1

© 04/2007

1/4

13993-001

Drive system W 02-10-03

TD 2012 2V TCD 2012 2V

z Measure piston ring groove for first piston ring with trapezoidal groove wear gauge.

6 © 33866-3

If there is a gap "S" between the trapezoidal groove wear gauge and piston, the piston can be used again.

S

© 33867-3

If the trapezoidal groove wear gauge is touching the piston (arrow), the piston must be changed.

© 33868-3

© 04/2007

2/4

13993-001

TD 2012 2V TCD 2012 2V

Drive system W 02-10-03

Checking the piston ring joint clearance z Insert the piston ring (1) in the cylinder. z Align the piston ring in the cylinder by pushing the piston.

1

6 © 45011-1

z Measure the piston ring joint clearance with a feeler gauge. – 1. piston ring = double keystone ring  0,20 - 0,35 mm – 2. piston ring = taper-faced ring  1,5 - 2,0 mm – 3. piston ring = bevelland-edge oil control ring  0,3 - 0,55 mm When the wear limit is reached, the piston ring must be renewed.

© 45012-1

z Install piston rings. Order and position of the piston rings as seen from the piston base. 1

- Double-sided keystone ring (1) - Taper-faced ring (2) - Bevelland-edge oil control ring with coiled spring expander (3)

2

“Top“ label faces the combustion chamber.

3

© 44267-0

© 04/2007

3/4

13993-001

Drive system W 02-10-03

TD 2012 2V TCD 2012 2V

z Install piston rings with universal piston ring pliers. Set spring joint of the bevelland-edge oil control ring 180° to the ring joint.

6 © 44268-0

Checking the piston ring axial clearance Check with new piston rings.

z Check axial backlash with feeler gauge between piston ring and piston ring groove. – 2. piston ring  0,06 - 0,08 mm – 3. piston ring  0,02 - 0,04 mm When the piston wear limit is reached, the piston must be renewed.

© 44269-0

z Assemble con rod and piston.  W 02-09-03

© 44270-0

© 04/2007

4/4

13993-001

TD 2012 2V TCD 2012 2V

Drive system W 02-15-01

Removing and installing the piston cooling nozzles Commercial available tools

– W 02-04-01

6

Removing the piston cooling nozzles z Remove crankshaft.  W 02-04-01 z Screw self-tapping screw (1) carefully into the piston cooling nozzle.

1

© 44271-0

z Pull out piston cooling nozzle (1) with pliers.

1

© 44272-0

© 04/2007

1/2

13994-001

Drive system W 02-15-01

TD 2012 2V TCD 2012 2V

Installing the piston cooling nozzles z Clean the bores for the piston cooling nozzles in the crankcase. z Knock in new piston cooling nozzle (1) with pin to the stop. z Install crankshaft.  W 02-04-01

1

6 © 44273-0

© 04/2007

2/2

13994-001

TD 2012 2V TCD 2012 2V

Crankcase W 03-01-11

Removing and installing the crankcase bleeding Commercial available tools: – Spring band pliers . . . . . . . . . . . . . . 9090

6

Removing the crankcase bleeding z Loosen the spring band clip with spring band pliers and pull down. z Pull off hose pipe (1).

3

z Unscrew screws (2).

2

z Remove crankcase bleeding (3).

1

© 46473-3

z Visually inspect the component. z Clean sealing surfaces. z Insert new seal (1). 1

© 46475-0

© 04/2007

1/2

13995-001

Crankcase W 03-01-11

TD 2012 2V TCD 2012 2V

z Mount crankcase bleeding (1). Pay attention to perfect installation position (arrow).

1

6 © 46476-0

z Tighten screws (1).  21 Nm z Position hose pipe (2). z Position spring band clip with spring band pliers.

1 2

© 46473-4

© 04/2007

2/2

13995-001

TD 2012 2V TCD 2012 2V

Crankcase W 03-03-01

Checking the cylinder Commercial available tools: – Micrometer gauge – Internal measuring device – Depth-measuring appliance

– W 02-09-03

The crankshaft bearing covers must be mounted properly for measuring the cylinders.

Special tools: – Dial gauge. . . . . . . . . . . . . . . . . . 100400

6

Checking the cylinders z Remove piston and connecting rod.  W 02-09-03 z Check cylinder for visible signs of wear.

© 46474-0

z Prepare internal measuring device: – Mount probe bolt for the appropriate measuring range in the internal measuring device. – Mount dial gauge with approx. 1 mm pre-tension in the internal measuring device. – Set micrometer gauge to 101 mm. – Balance the internal measuring device between the test surfaces of the micrometer gauge and set the dial gauge at the reversal point of the pointer to "0".

© 36094-1

© 04/2007

1/2

13996-001

Crankcase W 03-03-01

TD 2012 2V TCD 2012 2V

Diagram for measuring the cylinder running surface at the points "a" and "b" in the levels "1" - "3".

1 2 3

a

b

a

b

a

b

6 © 39100-1

z Insert internal measuring device in cylinder. z Balance the internal measuring device at the given measuring points and read off the measured value at the reversal point of the pointer. z Compare actual value with setpoint value.  101

+0,02 −0

mm

See schematic diagram for measuring points. z Install piston and connecting rod.  W 02-09-03

© 46470-0

© 04/2007

2/2

13996-001

TD 2012 2V TCD 2012 2V

Crankcase W 03-08-01

Removing and installing the front cover (opposite side to flywheel) Commercial available tools

– W 02-02-04 – W 08-04-06 – W 12-01-04

6

Remove the front cover z Removing torsional vibration damper.  W 12-01-04 z Remove oil suction pipe  W 08-04-06

© 46397-0

z Turn the engine on the assembly block. z Unscrew all screws (1). z Remove front cover. z Remove gasket.

1 © 44542-1

© 04/2007

1/6

13997-001

Crankcase W 03-08-01

TD 2012 2V TCD 2012 2V

z Visually inspect the components.

6 © 42996-0

Install front cover z Knock out crankshaft sealing ring (1).

Attention! Do not damage sealing surface when knocking out.

1

© 42997-0

Make sure the clamping bushings (1) are in place. z Mount new gasket.

1

© 44545-1

© 04/2007

2/6

13997-001

TD 2012 2V TCD 2012 2V

Crankcase W 03-08-01

z Position the inner rotor on the crankshaft. The countersinks on the crankshaft and the guides on the inner rotor must match (arrows). The inner rotor and crankshaft only match up in one position.

6 © 44547-1

z Mount front cover. z Fasten screws. Do not tighten screws.

z Align front cover flush with the oil tray sealing surface.

© 44548-1

z Cut off overhanging gasket (arrows) flush with the sealing surface of the oil tray.

© 44551-1

© 04/2007

3/6

13997-001

Crankcase W 03-08-01

TD 2012 2V TCD 2012 2V

z Tighten the screws according to the tightening sequence. – Pre-clamping value:  3 Nm – Post-clamping value:  21 Nm

6 © 36521-1

z Fill lubricating oil into the oil pump housing.

© 45369-0

z Install oil suction pipe.  W 08-04-06

© 44548-1

© 04/2007

4/6

13997-001

TD 2012 2V TCD 2012 2V

Crankcase W 03-08-01

z Turn the engine on the assembly block. z Install crankshaft sealing ring (opposite side to flywheel)  W 02-02-04

6 © 43492-2

z Install torsional vibration damper.  W 12-01-04

© 46397-0

© 04/2007

5/6

13997-001

Crankcase W 03-08-01

TD 2012 2V TCD 2012 2V

6

© 04/2007

6/6

13997-001

TD 2012 2V TCD 2012 2V

Crankcase W 03-09-04

Removing and installing the connection housing Commercial available tools: – Socket wrench insert . . . . . . . . . . . 8113 – Socket wrench insert . . . . . . . . . . . 8114

6

Removing the connection housing z Unscrew screws (1). z Remove the cover (2). 1

2

1

1 © 42698-1

z Unscrew screws (1). z Remove connection housing. Use socket wrench insert. 1

z Visually inspect the components.

1 1

1

1 1 © 42699-1

© 04/2007

1/4

13998-001

Crankcase W 03-09-04

TD 2012 2V TCD 2012 2V

Installing the connection housing 1

z Clean contact surfaces. Make sure the clamping bushings (1) are in place.

1

6 © 44083-1

z Mount connection housing. z Centre connection housing over the clamping bushings. z Fasten screws.

2

Note different screw lengths. M12 = (1)

2

M16 = (2)

1

1

2 2 © 42703-1

z Tighten the screws according to the tightening sequence. 4

See graphic for tightening sequence.

2

Use socket wrench insert. 1

z Fasten screw (1) hand tight.

6

z Pre-tighten screws (2), (3) (4) and (5) alternately. – Pre-clamping value:  99 Nm z Tighten screws (1) and (6).  99 Nm

3

z Tighten screws (2), (3), (4) and (5) alternately.

5

– Post-clamping value:  243 Nm

© 04/2007

© 44085-0

2/4

13998-001

TD 2012 2V TCD 2012 2V

Crankcase W 03-09-04

z Press on cover plate to the stop. 1

z Tighten screws (2).  9 Nm

2

The hollow gorge (1) faces the lube oil tray.

2

2

6 © 42704-1

© 04/2007

3/4

13998-001

Crankcase W 03-09-04

TD 2012 2V TCD 2012 2V

6

© 04/2007

4/4

13998-001

TD 2012 2V TCD 2012 2V

Crankcase W 03-11-01

Removing and installing, testing camshaft bearing Commercial available tools: – Micrometer gauge – Internal measuring device

– W 02-04-01 – W 04-05-05

Special tools: – Dial gauge. . . . . . . . . . . . . . . . . . 100400 – Assembly tool . . . . . . . . . . . . . . . 143840

6

Testing camshaft bearing z Remove crankshaft.  W 02-04-01 z Remove camshaft.  W 04-05-05

© 42710-1

z Prepare internal measuring device: – Mount probe bolt for the appropriate measuring range in the internal measuring device. – Mount dial gauge with approx. 1 mm pre-tension in the internal measuring device. – Set micrometer gauge to 70 mm. – Balance the internal measuring device between the test surfaces of the micrometer gauge and set the meter at the reversal point of the pointer to "0".

© 34768-2

© 04/2007

1/6

13999-001

Crankcase W 03-11-01

TD 2012 2V TCD 2012 2V

Diagram for measuring the camshaft bearing at the points "a and b" in the levels "1 and 2".

6 © 37239-1

z Insert internal measuring device. z Balance the internal measuring device at the given measuring points and read off the measured value at the reversal point of the pointer.  63

+ 0,054

mm

– Wear limit  63,080 mm Measuring points see diagram. When the wear limit is reached, the camshaft bearing must be replaced.

© 46337-0

Removing camshaft bearing z Insert spindle (1). z Insert guide piece (2). z Insert counter support (3).

3

2

1

© 45259-0

© 04/2007

2/6

13999-001

TD 2012 2V TCD 2012 2V

Crankcase W 03-11-01

z Insert pressure piece (1). z Screw on nut (2). 1

2

6 © 45266-1

z Hold spindle (1). z Tighten nut (2). Tighten the nut further until the bearing liner falls out. z Remove bearing bush. z Remove assembly tool.

2

1

© 46338-0

Installing camshaft bearing Mark position of the lubricating oil bore.

© 45268-0

© 04/2007

3/6

13999-001

Crankcase W 03-11-01

TD 2012 2V TCD 2012 2V

z Check that the lubricating oil bores (1) are in line.

1

1

6 © 45269-0

z Insert spindle (1). z Insert counter bearing (2). z Position new bearing liner on the pressure piece.

Attention! Make sure that the lubricating oil bores are in line.

2

1

3

z Insert pressure piece (3).

© 45267-1

z Press in the bearing liner flush with the assembly device. The bearing bush is pressed into the crankcase by the thrust pad.

© 46338-1

© 04/2007

4/6

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TD 2012 2V TCD 2012 2V

Crankcase W 03-11-01

z Check that the lubricating oil bores (1) are in line. If the lubricating oil bore is not in line, the camshaft bearing must be removed and reinstalled.

1

6 © 45502-1

z Install the camshaft.  W 04-05-05 z Install crankshaft.  W 02-04-01

© 42710-1

© 04/2007

5/6

13999-001

Crankcase W 03-11-01

TD 2012 2V TCD 2012 2V

6

© 04/2007

6/6

13999-001

TD 2012 2V TCD 2012 2V

Engine control W 04-04-09

Removing and installing the gearcase cover Commercial available tools

– W 02-02-02 – W 03-09-04 – W 05-05-01 – W 08-04-07 – W 12-06-01 – W 13-03-02

– Packing compound DEUTZ DW 67

6

Removing the gearcase z Remove starter.  W 13-03-02 z Remove connection housing.  W 03-09-04 z Remove flywheel.  W 12-06-01 z Remove speed governor.  W 05-05-01

© 46488-1

z Remove lubricating oil pan.  W 08-04-07 z Turn the engine on the assembly block.

1

z Unscrew screws (1). z Remove cover (2).

2 1 © 46419-2

© 04/2007

1/6

14000-001

Engine control W 04-04-09

TD 2012 2V TCD 2012 2V

z Unscrew screws (1).

1

1

1

6 © 46596-0

z Unscrew screws (1). z Remove gearcase cover.

1

1 1 © 46599-0

z Knock out crankshaft sealing ring (1).

Attention! Do not damage sealing surface when knocking out.

1

© 42750-0

© 04/2007

2/6

14000-001

TD 2012 2V TCD 2012 2V

Engine control W 04-04-09

Installing the gearcase cover z Clean sealing surfaces. The sealing surfaces must be dry and free from grease and dirt. z Apply packing compound (arrow).

Attention! The assembly must be completed within 1 hour at most. Use packing compound DEUTZ DW 67. Sealing bead thickness approx. 1.4 mm.

6 © 42525-0

z Align gearcase cover. z Mount gearcase cover. Do not move the gearcase cover after mounting.

1

z Tighten screws (1). Do not tighten screws.

1

1 © 46598-0

z Fasten screws. Note different screw lengths. Screws M8 x 45 mm (1) Screws M8 x 35 mm (2) Do not tighten screws.

1

2

2

© 46596-1

© 04/2007

3/6

14000-001

Engine control W 04-04-09

TD 2012 2V TCD 2012 2V

z Press up gearcase cover and align flush with the oil tray sealing surface (arrows). The oil tray sealing surface on the crankcase must face downwards.

6 © 46597-0

z Tighten the screws according to the tightening sequence.

5

 30 Nm

6

7

4

1

3

2

12

8

13

11 9

14

10

© 36520-3

z Clean sealing surfaces. The sealing surfaces must be dry and free from grease and dirt. z Mount new O-ring (1). z Lightly oil O-ring.

1

© 46460-0

© 04/2007

4/6

14000-001

TD 2012 2V TCD 2012 2V

Engine control W 04-04-09

z Press in cover (2) to the stop. z Tighten screws (1). Use screws M8 x 45 mm.

1

 21 Nm z Install new crankshaft sealing ring (flywheel side).  W 02-02-02

2

6

1 © 46419-2

z Install connection housing.  W 03-09-04 z Install flywheel.  W 12-06-01 z Install speed governor.  W 05-05-01 z Install starter.  W 13-03-02 z Turn the engine on the assembly block. z Install lubricating oil pan.  W 08-04-07 © 42759-0

© 04/2007

5/6

14000-001

Engine control W 04-04-09

TD 2012 2V TCD 2012 2V

6

© 04/2007

6/6

14000-001

TD 2012 2V TCD 2012 2V

Engine control W 04-05-05

Removing and installing the camshaft Commercial available tools: – Lifting gear

– W 01-02-02 – W 02-04-01 – W 07-04-01 – W 07-07-01

6

Removing the camshaft z Remove injection pumps.  W 07-04-01 z Removing fuel injectors.  W 07-07-01 z Remove rocker arm and rocker arm bracket.  W 01-02-02 z Remove crankshaft.  W 02-04-01

© 42705-0

z Screw in screws (1). z Hang crankcase on suitable workshop crane.

1 1

© 42707-0

© 04/2007

1/4

14001-001

Engine control W 04-05-05

TD 2012 2V TCD 2012 2V

z Remove clamping bracket (1) from the adapter plates (2).

1

1

2 2

6 © 42708-0

z Push away the assembly block on the flywheel side.

© 42709-0

z Press in all tappets. z Pull out the camshaft (1) carefully to the flywheel side.

1

© 42710-0

© 04/2007

2/4

14001-001

TD 2012 2V TCD 2012 2V

Engine control W 04-05-05

z Remove all tappets (arrow). Lay out components in the order in which they should be installed. Note order of cylinders. z Visually inspect the components.

6 © 42711-0

Installing the camshaft z Oil all tappets lightly. z Insert all tappets. Note the assignment of the tappets.

© 42711-0

z Oil camshaft bearing lightly. z Oil cam shaft pin lightly. z Insert camshaft carefully. The bore (1) must be facing the cylinder head.

1

© 42712-0

© 04/2007

3/4

14001-001

Engine control W 04-05-05

TD 2012 2V TCD 2012 2V

z Push on and align the flywheel side assembly block. z Mount the clamping bracket (1) on the adapter plate (2).  90 Nm 1

1

2 2

6 © 42708-0

z Unhook the crankcase from the workshop crane. z Unscrew screws (1).

1 1

© 42707-0

z Install crankshaft.  W 02-04-01 z Install rocker arm and rocker arm bracket.  W 01-02-02 z Install fuel injectors.  W 07-07-01 z Install injection pumps.  W 07-04-01

© 42705-0

© 04/2007

4/4

14001-001

TD 2012 2V TCD 2012 2V

Engine control W 04-05-06

Checking the camshaft Commercial available tools: – Micrometer gauge – Prisms

– W 04-05-05

6

Checking the camshaft z Remove camshaft.  W 04-05-05 z Visually inspect cams and bearing pins for wear.

© 42713-0

Diagram for measuring the journals at the points 1 and 2 in the levels a and b.

© 36424-2

© 04/2007

1/2

14002-001

Engine control W 04-05-06

TD 2012 2V TCD 2012 2V

z Measure the bearing pin.  63

− 0,05 − 0,07

mm

See schematic diagram for measuring points. When the limit value is reached the camshaft must be replaced.

6 © 42714-0

z Check camshaft gear wheel for visible signs of wear. z Install the camshaft.  W 04-05-05

© 42713-0

© 04/2007

2/2

14002-001

TD 2012 2V TCD 2012 2V

Engine control W 04-06-03

Installing and removing turning gear The turning gear 100330 may also be used depending on the installation ratio.

Commercial available tools Special tools: – Turn-over gear . . . . . . . . . . . . . . 100320

6

Disassembly z Unscrew screws (1). z Remove cover (2).

1

1

2 1 © 46419-0

Attaching turning gear z Insert turn-over gear (1). 2

The toothed gear of the turn-over gear must grip into the teeth of the camshaft wheel. z Tighten screws (2).

1

2 © 46420-0

© 04/2007

1/2

14003-001

Engine control W 04-06-03

TD 2012 2V TCD 2012 2V

Removing turning gear z Unscrew screws (2). 2

z Remove turning gear (1).

1

6

2 © 46420-0

z Clean the sealing surface on cover and gearcase. z Mount new O-ring (1). z Lightly oil O-ring.

1

© 46460-0

z Press in the cover (3) to the stop. z Tighten screw (2).  30 Nm

1

z Tighten screws (1).  21 Nm

2

3 1 © 46419-1

© 04/2007

2/2

14003-001

TD 2012 2V TCD 2012 2V

Speed control W 05-04-14

Removing and installing, checking and setting the control linkage Commercial available tools: – Slide gauge

– W 04-04-09 – W 05-05-01 – W 07-04-01

Special tools: – Setting device . . . . . . . . . . . . . . . 100800

6

Removing the control linkage z Remove speed governor.  W 05-05-01 z Remove the gear case cover.  W 04-04-09 z Remove injection pumps.  W 07-04-01 z Unscrew screw (1). 1

© 46355-0

z Pull out control linkage.

© 46356-0

© 04/2007

1/6

14004-001

Speed control W 05-04-14

TD 2012 2V TCD 2012 2V

z Visually inspect control linkage. z Measure width of the groove (1).  5

+0,03 −0,06

mm

1 1 1

6 © 46346-0

Installing the control linkage z Insert control linkage.

© 46356-0

z Tighten new screw (1).  10 Nm

Attention! Self-locking screw! z Install the gear case cover.  W 04-04-09

1

© 46355-0

© 04/2007

2/6

14004-001

TD 2012 2V TCD 2012 2V

Speed control W 05-04-14

z Press the control linkage slowly in the direction of the arrow. Stop position! No uneven resistance may occur. z Release control linkage. The control linkage must be pressed back into the initial position from any position by the spring force. Start position!

6 © 46344-1

Measure control linkage travel (injection pumps removed) z Install setting device (1).

1

© 46340-1

z Bring control linkage into stop position. z Measure distance between control linkage and setting device.

© 46341-0

© 04/2007

3/6

14004-001

Speed control W 05-04-14

TD 2012 2V TCD 2012 2V

z Release control linkage. Start position!

z Measure distance between control linkage and setting device. – Difference between stop and start position gives the control linkage travel.

6

Calculation example Desired: Control linkage travel Given: Measured: Stop position (a) (a) = 30.7 mm Start position (b) (b) = 13.4 mm Dimension (a) - Dimension (b) Result: = 17.3 mm Nominal di= 17.0 mm - 17.5 mm mension

© 46343-0

z Turn setting device. z Turn in knurled screw (1) until reaching the stop position. z Install injection pumps.  W 07-04-01 1

© 46342-1

Measure control linkage travel (injection pumps installed) z Install setting device (1).

1

© 46357-0

© 04/2007

4/6

14004-001

TD 2012 2V TCD 2012 2V

Speed control W 05-04-14

z Bring control linkage into stop position. z Measure distance between control linkage and setting device.

6 © 46358-0

z Release control linkage. Start position!

z Measure distance between control linkage and setting device. – Difference between stop and start position gives the control linkage travel. Calculation example Desired: Control linkage travel Given: Measured: Stop position (a) (a) = 30.5 mm Start position (b) (b) = 13.4 mm Dimension (a) - Dimension (b) Result: = 17.1 mm Nominal di= >16.8 mm mension

© 46359-0

z Check smooth action of the control linkage. z Press the control linkage slowly in the direction of the arrow. No uneven resistance may occur.

z Release control linkage. The control linkage must be pressed back into the initial position from any position by the spring force. Start position!

© 46344-1

© 04/2007

5/6

14004-001

Speed control W 05-04-14

TD 2012 2V TCD 2012 2V

Measure control linkage standback dimension for governor adaptation z Measured standback dimension from gear case cover to stop position.

Attention! The determined dimension must be specified when changing or repairing the governor. z Install speed governor.  W 05-05-01

6 © 46345-0

© 04/2007

6/6

14004-001

TD 2012 2V TCD 2012 2V

Speed control W 05-05-01

Removing and installing the speed governor Commercial available tools

– Packing compound DEUTZ DW 73

6

Removing the speed governor. z Disconnect cables. z Unscrew hollow screw (1). z Remove sealing rings.

1

© 46487-0

z Unscrew screws (1). z Remove speed governor.

1

1 1 © 46488-0

© 04/2007

1/4

14005-001

Speed control W 05-05-01

TD 2012 2V TCD 2012 2V

z Clean sealing surfaces. z Visually inspect the component.

6 © 46489-0

Installing the speed governor z Apply packing compound evenly to the sealing surface of the gear case. The sealing surfaces must be dry and free from grease and dirt.

© 46348-1

z Install speed governor. z Mount speed governor. Turn the governor toothed wheel (1) slightly if necessary to enable tracking.

1

© 46347-1

© 04/2007

2/4

14005-001

TD 2012 2V TCD 2012 2V

Speed control W 05-05-01

z Tighten the screws according to the tightening sequence.  17 Nm 3

The existing control linkage standback dimension must be set on the new governor when the governor is changed.

1

5

2

6

4 © 46349-0

z Tighten hollow screw (1).  18 Nm Use new sealing rings.

z Connect cable. Ensure that the connection is perfect.

1

© 46487-0

© 04/2007

3/4

14005-001

Speed control W 05-05-01

TD 2012 2V TCD 2012 2V

6

© 04/2007

4/4

14005-001

TD 2012 2V TCD 2012 2V

Exhaust system/Charging W 06-01-05

Removing and installing the exhaust line Commercial available tools

– W 06-06-04

– Fitting compound DEUTZ S1

6

Removing exhaust line z Remove turbocharger.  W 06-06-04 z Unscrew nuts (1). z Remove spacing sleeves.

1

1

1

1

z Remove exhaust line (2).

2

© 46354-0

z Remove seals. z Remove studs.

© 46484-0

© 04/2007

1/4

14006-001

Exhaust system/Charging W 06-01-05

TD 2012 2V TCD 2012 2V

z Visually inspect the component.

6 © 46485-0

Installing exhaust line z Clean sealing surfaces. z Coat new pin bolts with DEUTZ S1 mounting compound. z Mount new studs. z Mount new gaskets.

© 46484-0

z Mount exhaust line (2). z Mount spacer sleeves (1). 1

2

© 46486-0

© 04/2007

2/4

14006-001

TD 2012 2V TCD 2012 2V

Exhaust system/Charging W 06-01-05

z Turn on new nuts (2).

2

2

2

2

6 © 46354-3

z Tighten all nuts (1).  25 Nm Tightening sequence from inside to outside, start with nut (1). z Install the turbocharger.  W 06-06-04

1

© 46354-2

© 04/2007

3/4

14006-001

Exhaust system/Charging W 06-01-05

TD 2012 2V TCD 2012 2V

6

© 04/2007

4/4

14006-001

TD 2012 2V TCD 2012 2V

Exhaust system/Charging W 06-02-08

Removing and install the heating flange Commercial available tools

6

Removing the heating flange z Disconnect cables.

1

Attention! Hold on the hexagon of the plus pole screw. z Unscrew screws (1). 1

© 46360-0

z Remove hose nozzles (1). z Remove gasket (2). z Remove heating flange. z Remove gasket (3).

1 3

2

© 44360-1

© 04/2007

1/2

14007-001

Exhaust system/Charging W 06-02-08

TD 2012 2V TCD 2012 2V

z Visually inspect the component.

6 © 44831-0

Installing the heating flange z Mount gasket (3). z Mount heating flange. z Mount gasket (2). z Mount hose nozzles (1).

1 3

2

© 44360-1

z Tighten screws (1). z Tighten screws alternately.

1

 3 Nm + 30° z Connect cable.  20 Nm

Attention! 1

Hold on the hexagon of the plus pole screw.

© 46360-0

© 04/2007

2/2

14007-001

TD 2012 2V TCD 2012 2V

Exhaust system/Charging W 06-06-04

Removing and installing the turbocharger Collect leaking operating substances in suitable vessels and dispose of according to regulations.

Commercial available tools Special tools: – Disassembly tool. . . . . . . . . . . . . 110901

Emptying and filling the engine with operating media must be carried out according to the operating manual and the appropriate documentation of the vehicle/equipment manufacturer.

– Fitting compound DEUTZ S1

6

Removing turbocharger z Hold nut (2). z Unscrew screw (1).

2

1

© 46499-0

z Unscrew hollow screws (1). z Remove sealing rings.

1

z Remove lubricating oil pipe (2).

2

1

© 46500-0

© 04/2007

1/6

14008-001

Exhaust system/Charging W 06-06-04

TD 2012 2V TCD 2012 2V

z Unscrew screw (1). z Remove holder.

1

6 © 46501-0

z Remove oil return pipe (1).

1

© 46502-0

z Unscrew nuts (1). z Remove turbocharger (2). z Remove gasket. z Unscrew the pin bolts. z Visually inspect the components.

1

1

2 © 46503-0

© 04/2007

2/6

14008-001

TD 2012 2V TCD 2012 2V

Exhaust system/Charging W 06-06-04

Installing the turbocharger z Clean sealing surfaces. z Insert new pin bolts with mounting compound. z Mount new studs. z Mount gasket (1).

1

6 © 46504-0

z Insert new O-ring (1). z Lightly oil O-ring.

1

© 46437-0

z Mount turbocharger (2). z Tighten nuts (1).  22 Nm 1

1

2 © 46503-0

© 04/2007

3/6

14008-001

Exhaust system/Charging W 06-06-04

TD 2012 2V TCD 2012 2V

z Mount lubricating oil pipe (2). z Insert hollow screws (1) with new sealing rings tension-free.

1

 18 Nm 2

z Insert hollow screws (3) with new sealing rings tension-free.  34 Nm

3

6 © 46500-1

z Insert new O-ring (1). z Lightly oil O-ring. 1

© 46438-0

z Connect oil return pipe (2) in direction of arrow.

2

© 46507-0

© 04/2007

4/6

14008-001

TD 2012 2V TCD 2012 2V

Exhaust system/Charging W 06-06-04

z Push oil return line (1) into crankcase (arrow). z Mount holder. z Tighten screw (2).  21 Nm

1

2 © 46501-1

z Hold nut (2). z Tighten screw (1).  13 Nm

2

1

© 46499-0

© 04/2007

5/6

14008-001

6

Exhaust system/Charging W 06-06-04

TD 2012 2V TCD 2012 2V

6

© 04/2007

6/6

14008-001

TD 2012 2V TCD 2012 2V

Exhaust system/Charging W 06-07-03

Removing and install the charge air line Commercial available tools

– W 01-04-04

– Locking agent DEUTZ DW 72

6

Remove charge air line z Unscrew hollow screws (1). z Remove sealing rings.

1

© 46490-0

z Disconnect cables. z Unscrew screws (1). z Remove charge air manifold (2).

1

z Remove gasket.

1

z Remove plug piece.

2 1 © 46491-0

© 04/2007

1/4

14009-001

Exhaust system/Charging W 06-07-03

TD 2012 2V TCD 2012 2V

z Remove the cylinder head hood.  W 01-04-04 z Unscrew all screws (1).

2

z Remove charge air pipe (2). z Remove seals. z Visually inspect the component.

1

6 © 46492-0

Install charge air line z Clean sealing surfaces. z Mount new gaskets (1). Ensure that the installation location is free from faults.

1

© 46493-0

z Mount charge air line.

© 46494-0

© 04/2007

2/4

14009-001

TD 2012 2V TCD 2012 2V

Exhaust system/Charging W 06-07-03

z Fasten screws. Do not move gaskets.

z Tighten screws .  11 Nm Tightening sequence: From the centre outwards.

6 © 46495-0

z Mount cylinder head cover.  W 01-04-04 z Clean sealing surfaces. z Mount new gasket (1). 1

© 46496-0

z Fit new sealing rings (1).

1

© 46433-0

© 04/2007

3/4

14009-001

Exhaust system/Charging W 06-07-03

TD 2012 2V TCD 2012 2V

z Coat plug piece (1) with mounting compound. z Insert plug element (1).

1

6 © 46498-0

z Mount charge air manifold. z Insert screws (1) with locking agent. z Insert screws (2) with locking agent.

3

z Fasten screws. Note different screw lengths: M8 x 30 mm (1) M8 x 95 mm (2)

2

M8 x 80 mm (3) z Tighten screws .  30 Nm 1

z Connect cable.

© 46491-1

z Tighten hollow screw (1).  18 Nm Use new sealing rings.

1

© 46490-0

© 04/2007

4/4

14009-001

TD 2012 2V TCD 2012 2V

Fuel system W 07-04-01

Removing and installing the fuel injector pump Commercial available tools: – Socket wrench insert, 10 mm, 12-edge – Multi-toothed socket wrench insert . . . . . . . . . . . . . . . . . 8117 – Rotation angle disc . . . . . . . . . . . . . 8190

– W 01-04-04 – W 07-06-03 . . . . . . . . . . . . (engine without injection adjuster) – W 07-06-03 . . . . . . . . . . . . (engine with injection adjuster) – W 07-06-04 . . . . . . . . . . . . (engine without injection adjuster) – W 07-06-04 . . . . . . . . . . . . (engine with injection adjuster)

Special tools: – Turn-over gear . . . . . . . . . . . . . . 100320 – Pressing device . . . . . . . . . . . . . 100830 – Special pliers. . . . . . . . . . . . . . . . 103220 – Puller. . . . . . . . . . . . . . . . . . . . . . 110030 – Special wrench . . . . . . . . . . . . . . 110500 – Slide hammer . . . . . . . . . . . . . . . 150800 – Plugs/caps . . . . . . . . . . . . . . . . . 170160

Attention! Pay attention to utmost cleanliness when working on the fuel system. Remove residue paint and particles of dirt before removing. Clean the respective affected parts carefully. Blow damp areas dry with compressed air. Observe the safety regulations and national specifications for handling fuels. Close all connections immediately after opening with new, clean plugs/caps. Do not remove plugs/caps until immediately before assembling. Collect leaking operating substances in suitable vessels and dispose of according to regulations.

– Fitting compound DEUTZ AP1908

When changing the fuel injector pump the thickness of the shim must be redetermined. The EP-code must be changed on the company plate. When changing the crankcase, camshaft or roller tappet, the corrected fuel injector pump installation dimension "EK " and the corresponding EP code must be determined and changed on the company plate.

© 04/2007

1/14

14010-001

6

Fuel system W 07-04-01

TD 2012 2V TCD 2012 2V

Removing the fuel injector pump z Pull out the cable plug from the engine shutdown. z Remove cylinder head cover (1).  W 01-04-04

1

6 © 46474-3

z Unscrew screws (1).

1 © 46371-0

z Pull out engine shutdown (1).

1

© 46364-0

© 04/2007

2/14

14010-001

TD 2012 2V TCD 2012 2V

Fuel system W 07-04-01

z Insert pressing device (1).

1

6 © 46365-0

z Tighten screws (1).

1

© 46372-0

z Turn knurled screw (1). Turn knurled screw to stop. (control linkage stop position)

1

© 46373-0

© 04/2007

3/14

14010-001

Fuel system W 07-04-01

TD 2012 2V TCD 2012 2V

z Unscrew screws (1). z Remove cover (2). 1

1

2

6

1 © 46419-0

z Insert turn-over gear (1). The toothed gear of the turn-over gear must grip into the teeth of the camshaft wheel.

2

z Tighten screws (2). 1

2 © 00000-0

z Turn crankshaft in engine direction of rotation until the cam for actuating the fuel injector pump of the corresponding cylinder is on the base circle. Example: Inlet valve cylinder 1 is open.

© 35356-1

© 04/2007

4/14

14010-001

TD 2012 2V TCD 2012 2V

Fuel system W 07-04-01

z Remove injection line with special wrench.

6 © 46424-1

z Unscrew screws (1).

1

© 46425-0

z Remove flange.

© 46426-0

© 04/2007

5/14

14010-001

Fuel system W 07-04-01

TD 2012 2V TCD 2012 2V

If fuel injector pump is stuck tight:

z Assembly sliding hammer (1) and puller (2). z Tighten lock nut (3).

1

2 3

6 © 40958-0

z Apply slide hammer to fuel injector pump. z Screw on lock nut (1). z Pull out stuck fuel injector pump.

1

© 46427-0

z Pull out fuel injector pump. z Visually inspect the component.

© 46418-0

© 04/2007

6/14

14010-001

TD 2012 2V TCD 2012 2V

Fuel system W 07-04-01

z Pull out roller tappet (1) with special pliers. z Remove shim. z Visually inspect the components.

1

6 © 46421-1

Installing the fuel injector pump When changing the fuel injector pump the thickness of the shim must be redetermined. The EP-code must be changed on the company plate. z Determining the thickness of the shim (engine without injection adjuster)  W 07-06-03 z Determining the thickness of the shim (engine with injection adjuster)

1

 W 07-06-03 z Insert roller tappet (1) with special pliers. When changing the crankcase, camshaft or roller tappet, the corrected fuel injector pump installation dimension "EK " and the corresponding EP code must be determined and changed on the company plate.

© 46421-1

z Determining the installation dimension of the fuel injector pump (engine without injection adjuster)  W 07-06-04 z Determining the installation dimension of the fuel injector pump (engine with injection adjuster)  W 07-06-04

© 04/2007

7/14

14010-001

Fuel system W 07-04-01

TD 2012 2V TCD 2012 2V

z Insert new O-rings (1).

1

6 © 39865-1

z Turn the fuel injector pump control lever to approx. centre position.

© 46369-0

z Coat the locating hole in the crankcase and the Orings of the fuel injector pump with mounting compound. z Set the roller tappet of the respective cylinder on the base circle. z Install the fuel injector. z Insert the fuel injector pump control lever (1) in the control linkage.

1

© 46418-1

© 04/2007

8/14

14010-001

TD 2012 2V TCD 2012 2V

Fuel system W 07-04-01

z Mount flange. Chamfer must face the fuel injector pump body.

6 © 46426-0

Start respectively with screw (2).

z Lightly oil screws (2). z Lightly oil screws (1). z Tighten screws evenly with the socket wrench insert.  5 Nm + 80°

Attention! The flange must contact evenly. 1

2

© 46430-0

z Turn screws (1) 190° in direction of arrow.

1

1

© 46366-0

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z Turn injection pump carefully with multi-toothed socket wrench insert in direction of arrow to the tangible stop.

6 © 46429-0

Start respectively with screw (2).

z Tighten screws (1) and (2).  5 Nm + 150° z Tighten new injection lines with special wrench.  25 Nm

1

2

© 46430-0

z Unscrew screws (1). z Remove pressing device (2). 2

1

© 46372-1

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z Unscrew screws (2). z Remove turning gear (1). 2

1

6

2 © 00000-0

z Clean the sealing surface on cover and gearcase. z Mount new O-ring (1). z Lightly oil O-ring.

1

© 46460-0

z Press in the cover (3) to the stop. z Tighten screw (2).  30 Nm

1

z Tighten screws (1).  21 Nm

2

3 1 © 46419-1

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Attention! Check control linkage for smooth action. z Actuate the shutdown lever between start and stop position. z Mount new O-ring (1). z Lightly oil O-ring.

1

6

© 46417-0

z Press the control linkage into the stop position with the shutdown lever and hold. z Insert engine shutdown (1). 1

© 46364-0

z Tighten screws (1).  21 Nm

1 © 46371-0

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z Mount cylinder head cover (1).  W 01-04-04 z Plug cable plug to engine shutdown.

1

6 © 46474-3

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Fuel system W 07-06-03

Determining the thickness of the shim (Engine without injection adjuster) Commercial available tools: – Torque wrench

– W 07-04-01

Let the engine cool down for at least one hour. Lubricating oil temperature < 40 °C All contact and measuring surfaces must be absolutely clean to rule out measuring errors!

6

The following procedure describes the work for one fuel injector pump example. The work procedure is the same for any other fuel injector pump. z Remove fuel injector.  W 07-04-01

© 46418-0

z Read EP-code according to the cylinder concerned from the company plate. Example: EP-code 295 for cylinder 1 (1) z Read and note the corrected fuel injector pump dimension EK based on the EP-code. Example: EK = 120.875 mm  Table 3 - see Technical Data

1

© 46416-0

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z Read code number of the (new) fuel injector pump for fuel injector pump length dimension A. Example: Dimension A = 42 z Note dimension A for the calculation of the theoretical shim thickness TS. z Read and note basic dimension L0 of the injection pump. Example: 117.5 mm  Table 1 - see Technical Data z Calculate the thickness of the shim.  Tables 1,2, 3 - see Technical Data

6

Calculation example Desired: Theoretical shim thickness TS Shim thickness SS Given: Code for fuel injector pump length A Basic dimension of the fuel injector pump L0 from table 1 e.g. 117.5 mm EP-code (company plate) , e. g. 295 Corrected fuel injector pump installation dimension EK from table 3 according to the EPcode, e.g. 120.875 mm Calculation: TS = EK - (L0 + A/100) TS = 120.875 mm - (117.5 mm + 42/100 mm) TS = 120.875 mm - 117.92 mm Result: TS= 2.955 mm Select SS according to table 2 SS = 3.0 mm

© 30095-3

z Place determined shim on roller tappet. z Install the fuel injector.  W 07-04-01

© 46418-0

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Fuel system W 07-06-03

Determining the thickness of the shim (Engine with injection adjuster) Commercial available tools

– W 07-04-01

Let the engine cool down for at least one hour. Lubricating oil temperature < 40 °C All contact and measuring surfaces must be absolutely clean to rule out measuring errors!

6

The following procedure describes the work for one fuel injector pump example. The work procedure is the same for any other fuel injector pump. z Remove fuel injector.  W 07-04-01

© 46418-0

z Read EP-code according to the cylinder concerned from the company plate. Example: EP-code 670 for cylinder 1 (1) z Read and note the corrected fuel injector pump dimension EK based on the EP-code. Example: EK = 117.65 mm  Table 3.1 - see Technical Data

1

© 46416-0

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z Read code number of the (new) fuel injector pump for fuel injector pump length dimension A. Example: Dimension A = 23 z Note dimension A for the calculation of the theoretical shim thickness TS. z Read and note basic dimension L0 of the injection pump. Example: 111.15 mm  Table 1.1 - see Technical Data

23

z Calculate the thickness of the shim.  Tables 1.1, 2.1, 3.1 - see Technical Data

6

Calculation example Desired: Theoretical shim thickness TS Shim thickness SS Given: Code for fuel injector pump length A Basic dimension of the fuel injector pump L0 from table 1.1 e.g. 111.15 mm EP-code (company plate) , e.g. 670 Corrected fuel injector pump installation dimension EK from table 3.1 according to the EP-code, e.g. 117.65 mm Calculation: TS = EK - (L0 + A/100) TS = 117.65 mm - (111.15 mm + 23/100 mm) TS = 117.65 mm - 111.38 mm Result: TS= 6.27 mm Select SS according to table 2.1 SS = 6.25 mm

© 39865-0

z Place determined shim on roller tappet. z Install the fuel injector.  W 07-04-01

© 46418-0

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Fuel system W 07-06-04

Determining the installation dimension of the injector pump (Engine without injection adjuster) Commercial available tools

– W 07-04-01

Special tools: – Digital dial gauge . . . . . . . . . . . . 100410 – Measuring device . . . . . . . . . . . . 103210

Let the engine cool down for at least one hour. Lubricating oil temperature < 40 °C All contact and measuring surfaces must be absolutely clean to rule out measuring errors!

6

The following procedure describes the work for one fuel injector pump example. The work procedure is the same for any other fuel injector pump. z Remove fuel injector.  W 07-04-01

© 46418-0

Lubricating oil residue on the surface of the roller tappet can falsify the measuring result. z Clean surface of the roller tappet. z Place spacer disc (5 mm) on the roller tappet. z Insert roller tappet in the fuel injector pump shaft with special pliers.

© 46421-0

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z Turn crankshaft with turning gear in engine direction of rotation until the cam for actuating the fuel injector pump for cylinder 1 is on the base circle. Inlet valve cylinder 1 is open.

6 © 35356-1

z Mount measuring foot, short (2) on dial gauge holder (1).

1

2

© 39858-0

z Insert dial gauge in dial gauge holder. z Tighten knurled screw of the dial gauge holder.

© 39859-0

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z Insert spacer in the setting master with special pliers.

6 © 39860-0

z Insert dial gauge holder in the setting master. z Set dial gauge to "0" with pre-tension. Note unit of dimension. Depth dimension of the setting master corresponds to: Le = 122.25 mm

© 39861-0

z Clean contact and measuring surfaces on the crankcase. z Insert the dial gauge holder carefully in the fuel injector pump shaft. z Align the dial gauge holder. z Screw in screws (1) with spacer sleeves (2). z Tighten screws (1).  15 Nm 1

1

2

2 © 46422-0

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The dial gauge now shows a value in the plus or minus range. z Calculate dimension "L". Calculation example Desired: Dimension L Given: Depth setting master Le = 122.25 mm Thickness of the shim (d) = 5 mm Measured: Display dial gauge X = + 2.20 mm Calculation: L = Le - X + d L = 122.25 mm - 2.20 mm + 5.0 mm Result: L = 125.05 mm

"L"

z Note dimension "L".

6 © 46423-2

z Remove dial gauge holder. z Calculate corrected fuel injector pump installation dimension ’’EK’’.  Table 1 - see Technical Data Calculation example Desired: Corrected fuel injector pump installation dimension ’’EK’’. Given: Dimension L Commencement of delivery (company plate) Camshaft type W (company plate) Pre-stroke Vh nominal value from table 1 Calculation: EK = L - Vh nominal value EK = 125.05 mm - 5.337 mm Result: EK = 119.713 mm

z Note corrected fuel injector pump installation dimension ’’EK’’. © 39870-0

z Read code number of the fuel injector pump for fuel injector pump length dimension A. z Note dimension A for the calculation of the theoretical shim thickness TS. – Example: Dimension A = 42

© 30095-3

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Fuel system W 07-06-04

z Calculate the thickness of the shim.  Tables 1,2, 3 - see Technical Data Calculation example Desired: Theoretical shim thickness TS Shim thickness SS Given: Corrected fuel injector pump installation dimension EK (redetermined, see above calculation) Code for fuel injector pump length A Basic dimension of the fuel injector pump L0 from table 1 e.g. 117.5 mm Calculation: TS = EK - (L0 + A/100) TS = 119.713 mm - (117.5 mm + 42/100 mm) TS = 119.713 mm - 117.92 mm Result: TS= 1.793 mm Select SS according to table 2 SS = 1.8 mm

6

z Place determined shim on roller tappet. z Install the fuel injector.  W 07-04-01 Repeat the measuring process for every fuel injector pump. When changing the crankcase, camshaft or roller tappet, the newly determined corrected fuel injector pump installation dimension "EK " and the corresponding EP code must be determined and changed on the company plate. z Determine EP-code.  Table 3 - see Technical Data Calculation example Desired: EP-code

© 46418-0

Calculation example (continued) Given: Corrected fuel injector pump installation dimension EK (redetermined, see above calculation) EK = 119.713 mm EK symmetrically rounded = 119.725 mm Calculation: Select EP-code according to table 3 Result: EP-code = 249

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Fuel system W 07-06-04

Determining the installation dimension of the injection pump (Engine with injection adjuster) Commercial available tools: – Torque wrench

– W 07-04-01

Special tools: – Turn-over gear . . . . . . . . . . . . . . 100320 – Digital dial gauge . . . . . . . . . . . . 100410 – Measuring device . . . . . . . . . . . . 103210

Let the engine cool down for at least one hour. Lubricating oil temperature < 40 °C All contact and measuring surfaces must be absolutely clean to rule out measuring errors!

6

The following procedure describes the work for one fuel injector pump example. The work procedure is the same for any other fuel injector pump. z Remove fuel injector.  W 07-04-01

© 46418-0

Lubricating oil residue on the surface of the injection adjuster can falsify the measuring result. z Clean surface of the injection adjuster. z Insert roller tappet in the fuel injector pump shaft with special pliers.

© 46421-0

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z Turn crankshaft with turning gear in engine direction of rotation until the cam for actuating the fuel injector pump for cylinder 1 is on the base circle. Inlet valve cylinder 1 is open.

6 © 35356-1

z Mount measuring foot, short (2) on dial gauge holder (1).

1

2

© 39858-0

z Insert dial gauge in dial gauge holder. z Tighten knurled screw of the dial gauge holder.

© 39859-0

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Fuel system W 07-06-04

z Insert spacer in the setting master with special pliers.

6 © 39860-0

z Insert dial gauge holder in the setting master. z Set dial gauge to "0" with pre-tension. Note unit of dimension. Depth dimension of the setting master corresponds to: Le = 122.25 mm

© 39861-0

z Clean contact and measuring surfaces on the crankcase. z Insert the dial gauge holder carefully in the fuel injector pump shaft. z Align the dial gauge holder. z Screw in screws (1) with spacer sleeves (2). z Tighten screws (1).  15 Nm 1

1

2

2 © 46422-0

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The dial gauge now shows a value in the plus or minus range. Add 1 mm working piston travel of the injection adjuster (see calculation example). z Calculate dimension "L".

6

Calculation example Desired: Dimension L Given: Depth setting master Le = 122.25 mm Working piston travel = + 1 mm Measured: Display dial gauge X = + 0.45 mm Calculation: L = (Le + 1 mm) - X L = (122.25 mm + 1 mm) - (+ 0.45 mm) L = 123.25 mm - 0.45 mm Result: L = 122.80 mm

z Note dimension "L". © 39866-0

z Remove dial gauge holder. z Calculate corrected fuel injector pump installation dimension ’’EK’’.  Table 1.1 - see Technical Data Calculation example Desired: Corrected fuel injector pump installation dimension ’’EK’’. Given: Dimension L Commencement of delivery (company plate) Camshaft type W Pre-stroke Vh nominal value from table 1.1 Calculation: EK = L - Vh nominal value EK = 122.80 mm - 5.337 mm Result: EK = 117.463 mm

z Note corrected fuel injector pump installation dimension ’’EK’’. © 39870-0

z Read code number of the fuel injector pump for fuel injector pump length dimension A. z Note dimension A for the calculation of the theoretical shim thickness TS. – Example: Dimension A = 23

23

© 39865-0

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Fuel system W 07-06-04

z Calculate the thickness of the shim.  Tables 1.1, 2.1, 3.1 - see Technical Data Calculation example Desired: Theoretical shim thickness TS Shim thickness SS Given: Corrected fuel injector pump installation dimension EK (redetermined, see above calculation) Code for fuel injector pump length A Basic dimension of the fuel injector pump L0 from table 1.1 e.g. 111.15 mm Calculation: TS = EK - (L0 + A/100) TS = 117.463 mm - (111.15 mm + 23/100 mm) TS = 117.463 mm - 111.38 mm Result: TS= 6.083 mm Select SS according to table 2.1 SS = 6.1 mm

6

z Place determined shim on roller tappet. z Install the fuel injector.  W 07-04-01 Repeat the measuring process for every fuel injector pump. When changing the crankcase, camshaft or roller tappet, the newly determined corrected fuel injector pump installation dimension "EK " and the corresponding EP code must be determined and changed on the company plate. z Determine EP-code.  Table 3.1 - see Technical Data Calculation example Desired: EP-code

© 46418-0

Calculation example (continued) Given: Corrected fuel injector pump installation dimension EK (redetermined, see above calculation) EK = 117.463 mm EK symmetrically rounded = 117.475 mm Calculation: Select EP-code according to table 3.1 Result: EP-code = 663

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Removing and installing the fuel injectors Commercial available tools

– W 01-04-04 – W 07-07-05

Special tools: – Puller. . . . . . . . . . . . . . . . . . . . . . 110030 – Extraction tool . . . . . . . . . . . . . . . 120660 – Special wrench . . . . . . . . . . . . . . 110500 – Slide hammer . . . . . . . . . . . . . . . 150800

Danger! Wait 30 seconds after switching off the engine before working on the fuel system.

Attention!

– Fitting compound DEUTZ AP1908

Ensure utmost cleanliness when working on the fuel system. Carefully clean the area around the affected parts. Blow damp areas dry with compressed air. Observe the safety regulations and national specifications for handling fuels. Close all connections immediately after opening with new, clean plugs/caps. Do not remove plugs/caps until immediately before assembling. Collect leaking operating fluids in suitable vessels and dispose of according to regulations. The following work procedure describes the removal and installation of a fuel injector. Proceed the same to remove another fuel injector.

Removing fuel injector z Remove the cylinder head hood.  W 01-04-04 z Unscrew union nut (1) with special wrench.

1

© 46569-0

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z Unscrew union nut (1) with special wrench. z Remove injection line. z Remove sealing rubber from injection line.

1

6 © 46570-0

z Unscrew screw (1). z Remove clamping shoe (2). z Pull out fuel injector (3).

3 1

2

© 46571-0

Removing stuck fuel injectors z Assembly sliding hammer (1) and puller (2). z Tighten lock nut (3). 1

2 3

© 46571-0

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Fuel system W 07-07-01

z Mount sliding hammer on fuel injector. z Screw on lock nut (1).

1

z Pull out stuck fuel injector. z Pull out stuck sealing ring on cylinder head with extraction tool.

6 © 46568-0

z Visually inspect the components. z Check the fuel injector.  W 07-07-05

© 45414-0

Installing the fuel injector z Mount new O-ring (1). z Mount sealing ring (2).

1

2

© 46435-0

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Attention! Note installation position. The countersink (1) on the fuel injector must face away from the clamping shoe. 1

6 © 46436-0

z Insert fuel injector (3). z Mount clamping shoe (2). z Tighten screw (1).  16 Nm 3 1

2

© 46571-0

z Install new high pressure pipe (1). z Tighten union nuts (2) with special wrench.

2

 25 Nm z Mount the sealing rubber (3). z Mount cylinder head cover.

1

 W 01-04-04

3

2 © 46431-0

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Fuel system W 07-07-05

Checking fuel injectors Commercial available tools: – Socket wrench insert size 15 . . . . . . . . . . . . . . . . . . . . . . . . . . 8012 – Nozzle tester. . . . . . . . . . . . . . . . . . 8008

– W 07-07-01

Special tools: – Holder . . . . . . . . . . . . . . . . . . . . . 110110

Danger of injury when handling the nozzle tester.

Danger!

The fuel penetrates deep into the flesh through the nozzle jet! Caution, blood poisoning! After about three or four actuations of the hand lever, the spring space above the nozzle needle in the injection valve fills up with diesel fuel/test oil. Then it is no longer possible to actuate the hand lever. The nozzle cap nut must be loosened carefully before every test procedure to release pressure from the spring space. Only use pure test oil according to ISO 4113 or clean diesel fuel to test the fuel injectors.

z Removing fuel injectors.  W 07-07-01

© 45414-0

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Connecting the fuel injector to the nozzle tester z Insert fuel injector in holder. z Loosen nozzle cap nut approx. 180° with socket wrench insert (release pressure) and re-tighten.  35 Nm

6 © 36271-2

z Connect the fuel injector to the nozzle tester

© 35889-2

Checking opening pressure z Press down the lever of the nozzle tester slowly with the pressure gauge connected. z Read off measured value. The pressure at which the pointer stands still or suddenly drops is the opening pressure. Repeat test 3 times.

© 36293-2

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Fuel system W 07-07-05

z Compare measured values.  220 bar The measured values of three tests must match the test value. z In case of deviations from the test value, the fuel injector must be renewed.

6 © 36293-2

Checking tightness z Blow the injection nozzle and nozzle holder dry with air. z Press the hand lever of the tester down slowly until about 20 bar below the previously read opening pressure are reached.

© 36293-2

Injection nozzle is tight if it does not drip within 10 seconds.

© 36294-2

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z If the injection nozzle drips, the fuel injector must be renewed.

Attention! Repairs are not permitted!

6 © 36295-2

Checking the easy action of the nozzle needle z Switch off the tester’s pressure gauge. z Carry out chatter and jet test of the nozzle needle. The easy action of the nozzle needle in the nozzle body is checked by the acoustic chatter test. Increasing wear in the needle seat of the fuel injectors changes the chatter behavior of the injecton nozzle. A used fuel injector must buzz audibly and atomize the fuel finely when the lever is actuated quickly. The jet profile may deviate considerably from that of a new fuel injector. © 36296-2

z If the injection nozzle does not buzz audibly, the fuel injector must be renewed.

© 36296-2

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Fuel system W 07-07-05

Removing the fuel injector from the nozzle tester z Loosen nozzle cap nut approx. 180° with socket wrench insert (release pressure) and re-tighten.  35 Nm

Attention! The pressure in the spring space must be reduced before installing the fuel injectors. z Install fuel injectors.  W 07-07-01

6 © 36271-2

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Fuel system W 07-10-08

Removing and installing the fuel filter console Commercial available tools

– User notes – Operation manual

Special tools: – Special wrench . . . . . . . . . . . . . . 170050 – Plugs/caps . . . . . . . . . . . . . . . . . 170160

Danger! Wait 30 seconds after switching off the engine before working on the fuel system.

Attention! Ensure utmost cleanliness when working on the fuel system. Carefully clean the area around the affected parts. Blow damp areas dry with compressed air. Observe the safety regulations and national specifications for handling fuels. Close all connections immediately after opening with new, clean plugs/caps. Do not remove plugs/caps until immediately before assembling. Collect leaking operating fluids in suitable vessels and dispose of according to regulations.

Removing the fuel filter console z Unscrew hollow screws (1). z Remove sealing rings. 1

Collect draining fuel and dispose of according to regulations.

© 46583-0

© 04/2007

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z Unscrew screws (1). z Remove fuel filter console (2). 1

2

6 © 46584-0

z Visually inspect the component.

© 46585-0

Installing the fuel filter console z Mount the fuel filter console. z Mount nut (1).

1

z Fasten screw (2).

2

© 46586-0

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Fuel system W 07-10-08

z Mount nut (1). z Fasten screw (2).

1

z Tighten screws .  30 Nm

2

6 © 46523-1

z Tighten hollow screw (1) with new sealing rings.  39 Nm z Tighten hollow screw (2) with new sealing rings.

2

 39 Nm

1

Attention! Lay the hose pipe free from chafing and tension. Bleed the fuel system via the manual fuel pump on the fuel pre-filter according to the operation manual.

© 46583-1

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Fuel system W 07-11-01

Removing and installing the fuel supply pump Commercial available tools

– W 13-02-03 – User notes – Operation manual

Special tools: – Plugs/caps . . . . . . . . . . . . . . . . . 170160

Danger! Wait 30 seconds after switching off the engine before working on the fuel system.

Attention! Pay attention to utmost cleanliness when working on the fuel system. Clean the affected parts carefully. Blow damp areas dry with compressed air. Observe the safety regulations and specific national rules for handling fuels. Seal all connections immediately with new and clean plugs/caps after opening. Do not remove plugs/caps until immediately before assembling. Collect escaping fuel in suitable vessels and dispose of according to regulations. Only test / tighten / renew V-belts with the engine at a standstill.

Removing the fuel supply pump Danger! Wait 30 seconds after switching off the engine before working on the fuel system. 1

z Unscrew hollow screw (1). Collect draining fuel and dispose of according to regulations.

© 46572-0

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z Unscrew screws (1). z Remove fuel supply pump. 1

z Remove V-belt. z Visually inspect the components.

1

6 © 46573-0

Installing the fuel supply pump z Mount fuel supply pump. z Tighten screws (1).

1

1

© 46574-0

z Mount V-belt. z Press clamping strap (1) in direction of arrow with a suitable tool.

1

© 46375-1

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z Pre-tighten screws (1). z Check V-belt tension.  W 13-02-03

1

1

6 © 46375-0

z Tighten hollow screw (1).  39 Nm (M12x1,5) Use new sealing rings. Bleed the fuel system via the manual fuel pump on the fuel pre-filter according to the operation manual.

1

© 46572-0

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Lube oil system W 08-04-06

Removing and installing the oil suction pipe Commercial available tools

– W 08-04-07

6

Removing the oil suction pipe z Remove lubricating oil pan.  W 08-04-07 z Unscrew screws (1).

1

z Remove oil suction pipe (2).

2

z Remove gasket. z Visually inspect the components.

1

1

© 42766-1

Installing the oil suction pipe z Clean sealing surfaces. z Mount new gasket. z Mount oil suction pipe.

1

z Fasten screws. Note installation position. Note different screw lengths. M8 x 25 mm (1) M8 x 16 mm (2)

1

2

© 42767-1

© 04/2007

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TD 2012 2V TCD 2012 2V

z Tighten screws (1).  21 Nm z Install lubricating oil pan.  W 08-04-07

1

1 1

6 © 42768-1

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Lube oil system W 08-04-07

Removing and installing the lubricating oil pan (die-cast lubricating oil pan) Commercial available tools

Collect leaking operating substances in suitable vessels and dispose of according to regulations.

– Packing compound DEUTZ DW 74

Emptying and filling the engine with operating media must be carried out according to the operating manual and the appropriate documentation of the vehicle/equipment manufacturer.

6

Removing the lubricating oil pan z Unscrew locking screw (1). z Remove sealing ring. z Drain lubricating oil, collect and dispose of according to regulations. 1

© 46593-0

z Unscrew screws (1). z Remove washer. z Remove filler neck (2). z Remove gasket.

2

1 1 © 46592-0

© 04/2007

1/4

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Lube oil system W 08-04-07

TD 2012 2V TCD 2012 2V

z Unscrew all screws (1). 1

z Remove lubricating oil pan.

6 © 46594-3

z Visually inspect the components.

© 44948-0

Installing the lubricating oil pan z Clean sealing surfaces. The sealing surfaces must be dry and free from grease and dirt. z Apply packing compound evenly to the sealing surface. Apply the packing compound in an even bead (thickness approx. 3.5 mm). The position of the packing compound is only partly illlustrated.

© 43451-0

© 04/2007

2/4

14020-001

TD 2012 2V TCD 2012 2V

Lube oil system W 08-04-07

z Mount lubricating oil pan. 1

Do not move the packing compound when mounting the lube oil tray. z Fasten screws. Screw length:

2

M8 x 130 mm (1) M8 x 110 mm (2)

2

6

1 © 46594-2

z Fasten all screws (1). 1

Screw length: M8 x 35 mm

© 46594-3

z Align lubricating oil pan to crankcase.

© 44951-0

© 04/2007

3/4

14020-001

Lube oil system W 08-04-07

TD 2012 2V TCD 2012 2V

z Tighten the screws according to the tightening sequence.

18

20

12

22

See graphic for tightening sequence.

8

21

4 1

19

5

 30 Nm

9 13

11 15

7 17

3 14

2

16

6

6

10 © 45133-0

z Clean sealing surfaces. z Mount new gasket. z Mount filler neck (1). z Fasten screws (3). z Mount disc. z Fasten screw (2). z Tighten screws (3).

1

 30 Nm z Tighten screw (2).  30 Nm

2 3 © 46592-1

z Insert new sealing ring. z Tighten screw plug (1).  55 Nm (M18 x 1,5) z Fill in lubricating oil according to operating manual. 1

© 46593-0

© 04/2007

4/4

14020-001

TD 2012 2V TCD 2012 2V

Lube oil system W 08-04-07

Removing and installing the lubricating oil pan (metal sheet lubricating oil pan) Attention!

Commercial available tools: – Wire brush – 4 pin bolts M8x70

Make sure that no gasket residue falls into the crankcase. Seal all openings.

Special tools: – Separating tool . . . . . . . . . . . . . . 151500

Collect leaking operating substances in suitable vessels and dispose of according to regulations.

– Packing compound DEUTZ DW 74

Emptying and filling the engine with operating media must be carried out according to the operating manual and the appropriate documentation of the vehicle/equipment manufacturer.

Removing the lubricating oil pan z Unscrew locking screw (1). z Remove sealing ring. z Drain lubricating oil, collect and dispose of according to regulations.

1 © 44480-0

z Unscrew all screws (1).

1

© 45971-0

© 04/2007

1/6

14021-001

6

Lube oil system W 08-04-07

TD 2012 2V TCD 2012 2V

z Drive in separating tool (1) to the stop (2).

Attention! The tool can only be driven in in the area of the crankcase. Separation in the area of aluminium parts is not allowed. Do not damage the sealing surfaces.

2

1

6 © 45969-0

z Drive in second separating tool (1) to the stop (2).

Attention! The tool can only be driven in in the area of the crankcase. Separation in the area of aluminium parts is not allowed. Do not damage the sealing surfaces.

2 1

© 45970-0

z Lever out lubricating oil pan. z Remove lubricating oil pan.

© 45968-0

© 04/2007

2/6

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TD 2012 2V TCD 2012 2V

Lube oil system W 08-04-07

z Visually inspect the component.

6 © 43450-1

Installing the lubricating oil pan z Scrape off sealing compound with separating tool.

© 45973-0

Attention! Wear protective glasses. z Clean the sealing surface on the crankcase with a wire brush. The sealing surfaces must be dry and free from grease and dirt.

© 45967-1

© 04/2007

3/6

14021-001

Lube oil system W 08-04-07

TD 2012 2V TCD 2012 2V

Attention! Wear protective glasses. z Clean the sealing surface on the lubricating oil pan with a wire brush. The sealing surfaces must be dry and free from grease and dirt.

6 © 45972-0

z Apply packing compound evenly to the sealing surface and in the beading of the lube oil tray. Apply the packing compound in an even bead (thickness approx. 3.5 mm). The position of the packing compound is only partly illlustrated.

© 43451-0

z To align the lubricating oil pan, screw four pin bolts (1) diagonally opposed into the crankcase. z Align the lubricating oil pan in the appropriate installation position with the pin bolts.

1

z Mount lubricating oil pan.

Attention! Do not move the lubricating oil pan any more. Observe the drying time for the packing compound. z Unscrew the pin bolts.

© 45678-0

© 04/2007

4/6

14021-001

TD 2012 2V TCD 2012 2V

Lube oil system W 08-04-07

z Fasten all screws (1). Note different screw lengths.

1

6 © 45971-0

z Tighten the screws according to the tightening sequence.  30 Nm

24 20 16 12 8

4

1

5

9 13 17 21 25 29

Representation: Tightening sequence 6cylinder 28

32

31

34

27

33

23 19 15 11 7

3

2

6 10 14 18 22 26 30

© 43414-0

Representation: Tightening sequence 4cylinder 20

16

12

8

4

1

5

9

13

17

24

21

26

25

23

22

19

15

11

7

3

2

6

10

14

18

© 43413-0

© 04/2007

5/6

14021-001

Lube oil system W 08-04-07

TD 2012 2V TCD 2012 2V

z Insert new sealing ring. z Tighten screw plug (1).  55 Nm (M18x1,5) z Fill in lubricating oil according to operating manual.

1

6

© 44480-0

© 04/2007

6/6

14021-001

TD 2012 2V TCD 2012 2V

Lube oil system W 08-08-02

Removing and installing the oil cooler Commercial available tools

– W 08-08-03

– Fitting compound DEUTZ AP1908

Collect leaking operating substances in suitable vessels and dispose of according to regulations. Emptying and filling the engine with operating media must be carried out according to the operating manual and the appropriate documentation of the vehicle/equipment manufacturer.

6

Removing the oil cooler z Remove oil cooler housing.  W 08-08-03

© 46509-0

z Remove locking plate (1).

1

© 46510-0

© 04/2007

1/4

14022-001

Lube oil system W 08-08-02

TD 2012 2V TCD 2012 2V

z Unscrew screws (1). z Remove sealing rings.

1

1

6 © 46511-0

z Remove oil cooler (2). z Visually inspect the components.

2

© 46512-0

Installing the oil cooler z Clean sealing surfaces. z Coat the sealing rings with fitting compound.

1

z Insert new sealing rings (1).

1

© 46513-0

© 04/2007

2/4

14022-001

TD 2012 2V TCD 2012 2V

Lube oil system W 08-08-02

z Align oil cooler. Use new sealing rings.

z Insert screws.

6 © 46514-0

z Tighten screws (1) alternately. z Tighten screws (1).  22 Nm 1

1

© 46511-0

z Insert locking plate (1). z Install oil cooler housing.  W 08-08-03

1

© 46510-0

© 04/2007

3/4

14022-001

Lube oil system W 08-08-02

TD 2012 2V TCD 2012 2V

6

© 04/2007

4/4

14022-001

TD 2012 2V TCD 2012 2V

Lube oil system W 08-08-03

Removing and installing the oil cooler housing Commercial available tools: – Hose clip pliers . . . . . . . . . . . . . . . . 8011

– Operation manual – User notes

Special tools: – Plugs/caps . . . . . . . . . . . . . . . . . 170160

Collect leaking operating substances in suitable vessels and dispose of according to regulations.

– Fitting compound DEUTZ AP1908

Emptying and filling the engine with operating media must be carried out according to the operating manual and the appropriate documentation of the vehicle/equipment manufacturer.

6

Removing the oil cooler housing z Disconnect cables.

© 46509-0

z Unscrew locking screw (1). z Drain, collect and dispose of coolant according to regulations.

1

© 46515-0

© 04/2007

1/6

14023-001

Lube oil system W 08-08-03

TD 2012 2V TCD 2012 2V

z Loosen hose clips (1). z Remove hose pipe (2).

1

2

1

6 © 46543-0

z Unscrew hollow screw (1). z Remove sealing rings. z Drain fuel, collect and dispose of according to regulations. 1

© 46517-0

z Unscrew screws (1). z Remove fuel filter console (2).

1

2

© 46518-0

© 04/2007

2/6

14023-001

TD 2012 2V TCD 2012 2V

Lube oil system W 08-08-03

z Unscrew screws (1). z Remove oil cooler housing (2).

1

1

z Remove gasket.

1

2

1

6 © 46519-0

z Visually inspect the component.

© 46534-0

Installing the oil cooler housing z Clean sealing surfaces. z Mount new gasket.

© 46521-0

© 04/2007

3/6

14023-001

Lube oil system W 08-08-03

TD 2012 2V TCD 2012 2V

z Mount oil cooler housing. z Fasten screws.

3

Pay attention to different screw lengths.

2

1

M8 x 55 mm (1) M8 x 90 mm (2) M8 x 110 mm (3) z Tighten screws alternately.  30 Nm

1 1

3

6

2 © 46519-1

z Mount the fuel filter console. z Mount nut (1). z Fasten screw (2).

2

1

© 46522-0

z Mount nut (1). z Fasten screw (2).

1

z Tighten screws .  30 Nm

2

© 46523-0

© 04/2007

4/6

14023-001

TD 2012 2V TCD 2012 2V

Lube oil system W 08-08-03

z Tighten hollow screw (1) with new sealing rings.  39 Nm

Attention! Lay the hose pipe free from chafing and tension.

1

6 © 46517-0

z Position hose clips. z Mount the hose pipe (1). z Fasten hose clips with hose clip pliers.

1

© 46548-0

z Position hose clips. z Mount the hose pipe (1). z Fasten hose clips with hose clip pliers.

1

© 46549-0

© 04/2007

5/6

14023-001

Lube oil system W 08-08-03

TD 2012 2V TCD 2012 2V

z Mount new sealing ring. z Tighten screw plug (1). z Connect cables. Ensure that the connection is perfect. Bleed the fuel system via the manual fuel pump on the fuel pre-filter according to the operation manual.

1

6 © 46550-0

© 04/2007

6/6

14023-001

TD 2012 2V TCD 2012 2V

Lube oil system W 08-11-08

Removing and installing the oil pressure switch Commercial available tools: –

– User notes

Special tools: – Long socket wrench insert . . . . . 110700 – Plugs/caps . . . . . . . . . . . . . . . . . 170160

Pay attention to utmost cleanliness when working on the lube oil system. Carefully clean the area around the affected parts. Blow damp areas dry with compressed air. Observe the safety regulations and national specifications for handling lube oils. Close all connections immediately after opening with new, clean plugs/caps. Do not remove plugs/caps until immediately before assembling.

Removing the oil pressure switch z Unlock cable plug (1) and remove.

1

© 42865-1

z Unscrew oil pressure switch (1). Collect lubricating oil and dispose of according to regulations. z Visually inspect the components. 1

© 42866-0

© 04/2007

1/2

14024-001

6

Lube oil system W 08-11-08

TD 2012 2V TCD 2012 2V

Installing the oil pressure switch z Tighten oil pressure switch (1) with new sealing ring.  40 Nm 1

6 © 42866-0

z Plug in the cable plug (1). Ensure that the connection is perfect.

1

© 42865-1

© 04/2007

2/2

14024-001

TD 2012 2V TCD 2012 2V

Cooling system W 09-07-08

Removing and installing the coolant pump Commercial available tools

– W 07-11-01 – W 09-13-04 Collect leaking operating substances in suitable vessels and dispose of according to regulations. Emptying and filling the engine with operating media must be carried out according to the operating manual and the appropriate documentation of the vehicle/equipment manufacturer.

6

Removing coolant pump 1

z Remove the fan mounting.

1

 W 09-13-04 z Remove fuel supply pump.  W 07-11-01 z Unscrew screws (1).

1

Collect and dispose of coolant according to regulations.

1 © 46575-0

z Visually inspect the components.

© 46576-0

© 04/2007

1/4

14025-001

Cooling system W 09-07-08

TD 2012 2V TCD 2012 2V

Installing coolant pump The sealing surfaces must be dry and free from grease and dirt. z Clean sealing surfaces.

6 © 46577-0

z Mount new gasket. z Mount coolant pump (1).

Attention!

1

Use new coated screws. z Fasten screws.

© 46575-1

z Tighten the screws according to the tightening sequence.  30 Nm

2

Tightening order: screw (1), then screw (2), then the other screws in any order.

1 © 46578-0

© 04/2007

2/4

14025-001

TD 2012 2V TCD 2012 2V

Cooling system W 09-07-08

z Install fuel pump.  W 07-11-01 z Install fan mounting.  W 09-13-04

6 © 46580-0

© 04/2007

3/4

14025-001

Cooling system W 09-07-08

TD 2012 2V TCD 2012 2V

6

© 04/2007

4/4

14025-001

TD 2012 2V TCD 2012 2V

Cooling system W 09-08-01

Checking the thermostat (in the removed state) Commercial available tools: – Thermometer

– W 09-08-02

Danger! Risk of injury! Hot water and hot thermostat.

6

Checking thermostat z Remove thermostat.  W 09-08-02 z Measure beginning of stroke, dimension (a). z Note measured value, dimension (a).

© 34679-3

z Heat up the thermostat in the water bath. In order to determine the exact beginning of opening, the temperature should be measured as close as possible to the thermostat. The water should be continuously stirred for an even temperature distribution. The temperature rise should not take place faster than 1°C/min. Otherwise the beginning of opening will be delayed accordingly. z Determine beginning of opening.  83 °C

© 34680-2

© 04/2007

1/2

14026-001

Cooling system W 09-08-01

TD 2012 2V TCD 2012 2V

z Measure end of stroke, dimension (b). z Note measured value, dimension (b).

6 © 34679-2

z Determine stroke. Calculation example Desired: Stroke Given: Measured: Beginning of stroke, dimension (a) End of stroke, dimension (b) Dimension (b) - dimension (a) Result: = stroke

z Compare result with setpoint value. – Nominal value stroke travel:  at least 8 mm z Install thermostat.  W 09-08-02

© 34679-1

© 04/2007

2/2

14026-001

TD 2012 2V TCD 2012 2V

Cooling system W 09-08-02

Removing and installing the thermostat Commercial available tools

Collect leaking operating substances in suitable vessels and dispose of according to regulations.

– Fitting compound DEUTZ AP1908

Emptying and filling the engine with operating media must be carried out according to the operating manual and the appropriate documentation of the vehicle/equipment manufacturer.

6

Removing the thermostat z Unscrew screws (1). z Remove outlet nozzle (2).

1

1

2

© 46294-0

z Remove coolant thermostat (1). z Visually inspect the components. 1

© 46524-0

© 04/2007

1/2

14027-001

Cooling system W 09-08-02

TD 2012 2V TCD 2012 2V

Installing the thermostat 1

z Clean sealing surfaces. z Insert new sealing ring (1). z Coat the sealing ring with fitting compound.

6 © 44439-0

z Insert coolant thermostat.

© 46524-1

z Mount outlet nozzle (2). z Tighten screws (1).  30 Nm

1

1

2

© 46294-0

© 04/2007

2/2

14027-001

TD 2012 2V TCD 2012 2V

Cooling system W 09-12-01

Removing and installing temperature transmitter Collect leaking operating substances in suitable vessels and dispose of according to regulations.

Commercial available tools

Emptying and filling the engine with operating media must be carried out according to the operating manual and the appropriate documentation of the vehicle/equipment manufacturer.

6

Removing temperaure transmitter z Unlock cable plug (1) and remove.

1

© 46353-1

z Unscrew temperature transmitter (1).

1

© 46374-0

© 04/2007

1/2

14028-001

Cooling system W 09-12-01

TD 2012 2V TCD 2012 2V

z Visually inspect the component.

6 © 44084-0

Installing temperature transmitter z Tighten temperature transmitter (1).  24 Nm Make sure the sealing ring is in place.

1

© 46374-0

z Plug in the cable plug (1). Ensure that the connection is perfect.

1

© 46353-1

© 04/2007

2/2

14028-001

TD 2012 2V TCD 2012 2V

Cooling system W 09-13-01

Dismantling and assembling the air bearing Commercial available tools: – 2-arm puller – Internal extractor – Extension for extraction tool – Locking ring pliers – Press

– W 09-13-04

– Screw . . . . . . . . . . . . . . . . M10 x 40 mm – Washer

6

Dismantling the air bearing z Remove the fan mounting.

1

 W 09-13-04 z Unscrew screw (1). z Hold nut (2).

2

© 46525-0

z Turn in screw (1) a few turns. 1

© 46526-0

© 04/2007

1/8

14029-001

Cooling system W 09-13-01

TD 2012 2V TCD 2012 2V

Attention! Do not damage the component. z Pull off V-belt pulley with 2-arm puller.

6 © 46527-0

z Insert internal extractor (1). z Splay the internal extractor to the stop.

1

© 46528-0

z Mount counter holder.

© 46529-0

© 04/2007

2/8

14029-001

TD 2012 2V TCD 2012 2V

Cooling system W 09-13-01

z Pull out ball bearing and hollow shaft.

6 © 46530-0

z Remove locking ring (2).

2

© 46531-0

z Insert screw (1) and washer (2). Screw length: M10 x 40 mm (1)

1

2

© 46532-0

© 04/2007

3/8

14029-001

Cooling system W 09-13-01

TD 2012 2V TCD 2012 2V

z Turn extension (1) onto screw (2).

1

2

6 © 46547-0

z Mount counter holder. z Pull out ball bearing and nut.

© 46533-0

z Press out nut.

© 46535-0

© 04/2007

4/8

14029-001

TD 2012 2V TCD 2012 2V

Cooling system W 09-13-01

z Press out the hollow shaft. z Visually inspect the components.

6 © 46536-0

Assembling the fan drive z Press in hollow shaft.

© 46537-0

z Press in nut.

© 46538-0

© 04/2007

5/8

14029-001

Cooling system W 09-13-01

TD 2012 2V TCD 2012 2V

Nut (1) faces downwards.

z Mount ball bearing.

1

6 © 46539-0

z Press out ball bearing over the outer ring.

© 46540-0

z Insert locking ring (2).

Attention! Ensure that the installation location is free from faults. 2

© 46531-0

© 04/2007

6/8

14029-001

TD 2012 2V TCD 2012 2V

Cooling system W 09-13-01

z Press out ball bearing over the outer ring.

6 © 46542-0

z Mount V-belt pulley (1). z Fasten screw (2).

2

1

© 46526-1

z Hold nut (2). z Tighten screw (1).

1

– Stage 1:  3 Nm – Stage 2:  124 Nm z Install fan drive.  W 09-13-04

2

© 46525-0

© 04/2007

7/8

14029-001

Cooling system W 09-13-01

TD 2012 2V TCD 2012 2V

6

© 04/2007

8/8

14029-001

TD 2012 2V TCD 2012 2V

Cooling system W 09-13-04

Removing and installing the air bearing Emptying and filling the engine with operating media must be carried out according to the operating manual and the appropriate documentation of the vehicle/equipment manufacturer.

Commercial available tools

– Fitting compound DEUTZ AP1908

6

Removing the fan mounting z Unscrew screws (1). z Remove the fan mounting. 1 1

1

© 46551-0

z Remove gasket (1). z Pull out plug element (2).

1

z Visually inspect the components.

2

© 46552-1

© 04/2007

1/4

14030-001

Cooling system W 09-13-04

TD 2012 2V TCD 2012 2V

Installing the fan mounting z Insert new sealing ring (1). z Coat the sealing ring with fitting compound.

1

6 © 46553-0

z Fit new sealing rings (1). z Coat the sealing rings with fitting compound.

1

© 46554-1

z Insert plug element (1). 1

© 46555-0

© 04/2007

2/4

14030-001

TD 2012 2V TCD 2012 2V

Cooling system W 09-13-04

z Mount air bearing.

Attention! Ensure that the installation location is free from faults.

1

Note different screw lengths.

1

z Tighten screws (1). 1

z Tighten screws (1).  60 Nm

6 © 46551-0

© 04/2007

3/4

14030-001

Cooling system W 09-13-04

TD 2012 2V TCD 2012 2V

6

© 04/2007

4/4

14030-001

TD 2012 2V TCD 2012 2V

Monitoring system W 11-00-03

Removing and installing the engine shutdown Commercial available tools

6

Removing the engine shutdown z Pull out the cable plug from the engine shutdown. z Unscrew screws (1).

1

© 46432-0

z Pull out engine shutdown (1). z Visually inspect the components. 1

© 46434-0

© 04/2007

1/2

14031-001

Monitoring system W 11-00-03

TD 2012 2V TCD 2012 2V

Installing the engine shutdown Attention! Check control linkage for smooth action. z Actuate the shutdown lever between start and stop position. z Mount new O-ring (1). z Lightly oil O-ring.

1

6

© 46417-0

z Press the control linkage into the stop position with the shutdown lever and hold. z Insert engine shutdown (1).

1

© 46434-0

z Tighten screws (1).  21 Nm z Plug cable plug to engine shutdown.

1

© 46432-0

© 04/2007

2/2

14031-001

TD 2012 2V TCD 2012 2V

Other components W 12-01-04

Removing and installing the V-belt pulley Commercial available tools: – Torque wrench – Rotation angle disc . . . . . . . . . . . . . 8190 – Socket wrench insert Torx E20 . . . . . . . . . . . . . . . . . . . . . . . . . 8114

– W 04-06-03 – W 13-02-03

6

Removing the V-belt pulley z Loosen screws (1). z Remove V-belt.

1

1

© 46375-0

z Attach turning gear.  W 04-06-03 z Block flywheel with turning gear. z Unscrew screws (1) with the socket wrench insert. z Remove V-belt pulley.

1

1 © 46600-0

© 04/2007

1/4

14032-001

Other components W 12-01-04

TD 2012 2V TCD 2012 2V

z Visually inspect the component.

6 © 46601-0

Installing the V-belt pulley Make sure the clamping bushing (1) is in place.

1

© 46602-0

z Mount V-belt pulley. The bore (1) must match the bore (2).

1 2

© 46603-0

© 04/2007

2/4

14032-001

TD 2012 2V TCD 2012 2V

Other components W 12-01-04

Attention! Renew screws every time they are loosened. Screws: M16 x 1.5 z Tighten new screws with the socket wrench insert and rotation angle disc.  40 Nm + 60° + 60° z Remove turning gear.  W 04-06-03 z Install V-belt.

6

 W 13-02-03 © 46604-0

© 04/2007

3/4

14032-001

Other components W 12-01-04

TD 2012 2V TCD 2012 2V

6

© 04/2007

4/4

14032-001

TD 2012 2V TCD 2012 2V

Other components W 12-06-01

Removing and installing the flywheel Commercial available tools: – Rotation angle disc . . . . . . . . . . . . . 8190 – Self-made mandrin guide

6

Removing the flywheel z Remove stopper (1). 1

1 1

© 31115-2

z Block flywheel with suitable tool. z Unscrew screws (1). z Remove flywheel. z Visually inspect the components. 1

© 42825-1

© 04/2007

1/2

14033-001

Other components W 12-06-01

TD 2012 2V TCD 2012 2V

Installing the flywheel z Insert self-made guide pin (arrow). The bores in the flywheel must match the threaded bores in the crankshaft flange.

6 © 34224-2

Attention! Renew screws every time they are loosened. z Tighten screws alternately. – M10 x 30:  30 Nm + 60° + 30° – M10 x 35 - M10 x 85:  30 Nm + 60° + 60°

© 42826-0

z Drive plugs into the threaded bores (arrows) to the stop.

© 31115-1

© 04/2007

2/2

14033-001

TD 2012 2V TCD 2012 2V

Other components W 12-06-03

Renewing toothed starter ring on the flywheel Commercial available tools

8190

– W 12-06-01

Danger! Danger of injury, do not touch hot parts!

6

Removing toothed starter ring z Remove flywheel.  W 12-06-01 z Drill toothed wheel. Block flywheel with suitable tool.

© 45698-0

z Remove toothed starter ring with suitable tool.

© 45699-0

© 04/2007

1/2

14034-001

Other components W 12-06-03

TD 2012 2V TCD 2012 2V

z Clean flywheel. z Visually inspect flywheel.

6 © 45700-0

Install toothed starter ring z Heat up toothed starter ring to 220 °C. z Place toothed starter ring on flywheel. The toothed starter ring must lie evenly on the joint of the flywheel.

© 45701-0

z Install flywheel.  W 12-06-01

© 45702-0

© 04/2007

2/2

14034-001

TD 2012 2V TCD 2012 2V

Electrical system W 13-02-03

Removing and installing the generator (V-belt drive) Commercial available tools: – V-belt tension measuring device . . . . . . . . . . . . . . . . . . . . . . . 8115

Attention! Only test / tighten / renew V-belts when the engine is not running. The V-belt tension of new V-belts must be checked after they have been running for 15 minutes.

6

Removing the generator z Disconnect the battery's negative terminal. z Remove cable from generator.

1

Note assignment! - (1) = terminal W

2

- (2) = terminal D+ - (3) = terminal B+

3

© 46557-0

z Loosen screws (1). 1

1

© 46375-0

© 04/2007

1/4

14035-001

Electrical system W 13-02-03

TD 2012 2V TCD 2012 2V

z Remove V-belt. z Loosen screw (1).

2

z Unscrew screws (3). z Remove generator (2).

1

3

z Visually inspect the components.

3

6 © 46558-0

Installing the generator z Mount generator (3). z Tighten screws (2). 1

– M8-10.9

2

3

 30 Nm z Tighten screw (1). – M8-10.9  30 Nm z Tighten screw (4). – M8-10.9  30 Nm 4 © 46558-1

Installing the V-belt. z Mount V-belt. z Press clamping strap (1) in direction of arrow with a suitable tool.

1

© 46375-1

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z Pre-tighten screws (1). 1

1

6 © 46375-0

Check V-belt tension with V-belt tension measuring device z Lower indicator arm (1) into V-belt tension measuring device.

1

© 44591-0

z Mount V-belt tension measuring device on V-belt. The V-belt must be between the guides (arrow).

© 46559-0

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z Press the V-belt measuring device against the V-belt with the button (1) until you hear it click. z Read measured value at the intersection (arrow) of the indicator arm and scale. – First assembly:  650 Nm – Check after running for 15 minutes under load:

1

 400 Nm Note different units on the scale.

6

z If the nominal value is not reached, the tensioning process must be repeated. © 46560-0

z Tighten screws (1). – M8-10.9  30 Nm

1

1

© 46375-0

z Remove cable from generator. Note assignment! - (1) = terminal W 1

- (2) = terminal D+ - (3) = terminal B+ z Connect the battery's negative terminal.

2

3

© 46557-0

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Removing and installing the starter Commercial available tools

6

Removing the starter z Disconnect the battery's negative terminal.

1

z Disconnect cables. z Unscrew screws (1). z Remove starter. z Visually inspect the components.

1

© 46556-0

Installing the starter z Insert starter.

1

z Tighten screws (1). – M10x38-10.9  60 Nm – Nut M8  40 Nm – Pin bolt  10 Nm z Connect cables.

1

z Connect the battery's negative terminal.

© 46556-0

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Standard tools

Standard tools 7

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Standard tools Orders Conventional tools / special tools: These must be ordered like normal DEUTZ spare parts with specification of the order number.

7

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Standard tools

8002 Pressure pump Checking cooling system for leak-tightness

© 35409-2

7 8005 Compression pressure tester for diesel engines 10 - 40 bar Checking compression pressure

© 35410-3

8008 Nozzle tester with spray mist collecting vessel Check injection nozzles

© 35411-2

© 04/2007

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Standard tools 8011 Hose clip pliers Loosen and fasten hose clips e. g. fuel return pipe

© 39426-1

7 8012 Socket wrench insert Wrench size 15, long

© 35412-3

8024 Assembly pliers Removing valve shaft seals

© 37509-2

© 04/2007

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Standard tools

8035 Socket wrench insert reinforced, size 22 removing and installing main bearing

© 37504-2

7 8113 Socket wrench insert Torx - E 14

© 43022-0

8114 Socket wrench insert Torx - E 20

© 35415-1

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Standard tools 8115 V-belt tension measuring device 150 to 600 N Check V-belt tension

© 35416-3

7 8117 Multi-toothed socket wrench insert For turning the fuel injector pump

© 46422-0

8189 Torx tool set Contents of case: - Double-ended ring spanner E6/E8 - Double-ended ring spanner E10/E12 Socket wrench insert E8 and E10 (1/4 inch) - Socket wrench insert E10 and E12 (3/8 inch) - Socket wrench insert E18 (1/2 inch)

© 39432-1

© 04/2007

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Standard tools

8190 Rotation angle disc with magnet Setting valve clearance

© 42528-1

7 8191 Screwdriver insert for slotted screw Valve clearance setting

© 43060-0

8192 Bowl wrench Fuel pre-filter (type: Racor)

© 43193-1

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Standard tools 8193 Screwdriver insert with pressed in hexagonal pin (5 mm), 1/2 inch, long version (in conjunction with rotation angle disc 8190)

© 43183-0

7 8194 Screwdriver insert with pressed in hexagon pin (4 mm), 3/8 inch, long version (in connection with rotation angle disc 8190 and reducer 1/2 to 3/8 inch)

© 43183-0

8196 Open end wrench adapter Size 13, for torque wrench Tighten lock nut of the valve clearance setting screw.

© 43019-0

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Standard tools

8198 Pricker Removing rotary shaft lip seal

© 43206-0

7 8199 Crowfoot wrench Size 15 3/4 inch (in connection with rotation angle disc 8190)

© 44309-0

9017 Assembly lever e. g. removing and installing valves

© 37511-2

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Standard tools 9090 Spring band pliers 320 mm Tighten spring clamp

© 35420-3

7

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8

Special tools

Special tools

8

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Special tools Orders Conventional tools / special tools: These must be ordered like normal DEUTZ spare parts with specification of the order number.

8

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Special tools

100190 Connector (in conjunction with compression pressure tester 8005)

© 42524-0

100320 Turning gear flywheel side

8

© 35422-1

100330 Turning gear V-belt pulley Turning crankshaft on torsional vibration damper

© 48242-0

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Special tools 100400 Dial gauge with fixing wheel Measuring range 0 - 10 mm / 0.01 mm

© 35424-1

8

100410 Digital gauge Measuring range 0 - 30 mm / 0.01 mm

© 43205-0

100750 Measuring device Measuring bar with two shims (in conjunction with 100400 and 100410) Checking valve lag dimension Checking piston projection

© 39402-2

© 04/2007

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Special tools

100800 Setting device For measuring the control linkage travel and blocking the control linkage

© 46441-0

100810 Centring bolts for mass compensation shafts

8

© 46439-0

100830 Pressing device For control linkage

© 46443-0

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Special tools 103210 Measuring device For base circle measurement (in engines with injection adjuster)

© 46444-0

8

103220 Special pliers (part of measuring device 103210) for removing the roller tappet

© 43175-0

110030 Puller (in connection with sliding hammer 150800) Removing fuel injector

© 35433-2

© 04/2007

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Special tools

110110 Holder Wrench size 11, clamp the injection valve in the vice

© 35434-2

110500 Special wrench Wrench size 17 Removing and installing high-pressure lines

8

© 35436-1

110700 Socket wrench insert long Installing and removing pressure sensors (rail pressure, oil pressure, fuel pressure)

© 43198-2

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Special tools 110901 Disassembly tool (part of assembly case 110900) Removing and installing the O-rings

© 45950-1

8

120440 Assembly tool Removing and installing the glow plugs

© 40333-1

120660 Puller (in connection with sliding hammer 150800) Removing fuel injector

© 45111-0

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Special tools

120900 Support bracket pivoting Clamping cylinder head

© 35438-3

120910 Base plate (in conjunction with support bracket 120900 if support bracket is not screwed tightly)

8

© 35439-3

121410 Assembly tool Mounting valve shaft seal

© 37614-2

© 04/2007

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Special tools 121420 Assembly sleeves Set of assembly sleeves for valve shaft seal

© 43210-0

8

130300 Universal piston ring pliers Removing and installing the piston rings

© 43021-0

130440 Trapezoidal groove wear gauge Piston diameter 101 mmChecking piston ring groove

© 36461-2

© 04/2007

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Special tools

130670 Piston ring compressor Piston diameter 101 mm Installing piston

© 39408-1

142670 Assembly tool Installing crankshaft sealing ring (opposite side to flywheel)

8

© 35445-1

142830 Assembly tool Installing crankshaft sealing ring (flywheel side)

© 35446-1

© 04/2007

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Special tools 143840 Assembly tool Removing and installing camshaft bearing

© 46440-0

8

144800 Counter support for torsional vibration dampers

© 35453-1

150800 Slide hammer Removing fuel injector

© 35449-2

© 04/2007

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Special tools

151500 Separating tool Removing metal sheet lubricating oil pan from crankcase

© 45974-0

170050 Special wrench Unscrewing the filter cartridges

8

© 37629-2

170160 Stoppers/caps 1 set of differently-sized stoppers and caps Sealing openings on the fuel system

© 43663-0

© 04/2007

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Special tools 6066 Assembly block Engine clamping, double-sided

© 35451-2

8

6066/158 Clamping bracket consisting of: 1 holder 6066/158-1 rear right, 1 holder 6066/158-2 rear left, 1 holder 6066/158-3 front right, 1 holder 6066/158-4 front left (in connection with assembly block 6066) Clamping of the engine, double-sided

© 35452-1

6068 Engine lifting device Load (2000 kg), 3-point suspension, spindle clamp, cross member, chains and hooks

© 43184-0

© 04/2007

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