Workshop Manual

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Workshop Manual

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This document is subject to changes which may become necessary in the course of further de-

velopment of the engines. Reprinting and reproductions of any kind, even in part, require our

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Summary of content (388 pages)

PAGE 1
Workshop Manual competence level 2 D Th is do i cu s al tr m lo ib en w u ed ti o ti sc w n ith in op yr ou eit ig t o he ht ur r p pr pr rin ot io te ec ra d te o d. gr r ee ele m ct en ro t. ni cf o rm is n ot D 2011 TD 2011 . 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.
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Regarding copyright questions and licensing agreements please contact : VE-FL, Mr. Lippke Tel.: + 49 (0) 221 822-2599 EMail: lippke.d@deutz.com Deutz AG Informations Systeme Vertrieb u. Service Ottostraße 1 D - 51149 Cologne Tel.: + 49 (0) 221-8 22-0 Fax: + 49 (0) 221-8 22-3525 http://www.deutz.com Printed in Germany All rights reserved 1st edition, 02/2011 Order No.
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DEUTZ engines 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 © 01/2009 Table of contents Sorted alphabetically Sorted numerically 6 Job cards 7 Commercial tools 8 Special tools 1/2 OBJ_DOKU-23449-001.
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DEUTZ engines Foreword ● 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. ● 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.
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DEUTZ engines 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.
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DEUTZ engines User notes 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.
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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. 3 z Only work on the fuel system in a clean environment (no dust, no grinding or welding). Avoid draughts (dust).
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DEUTZ engines User notes 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.
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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. 3 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.
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DEUTZ engines 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.
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D 2011 TD 2011 Job card overview Sorted alphabetically 5 © 01/2009 5 Job card overview 5.1 Sorted alphabetically 1/8 OBJ_DOKU-24383-001.
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D 2011 TD 2011 Job card overview Sorted alphabetically Activity Job card Maintenance group Calculating the thickness of shim W 07-06-03 Fuel system Check start of injection W 07-06-01 Fuel system Checking the compression pressure W 00-02-06 General Dismantling and assembling the cooling blower W 09-11-02 Cooling system Installing and removing charge air pressure-dependent full load stop W 07-08-02 Fuel system Mounting engine on assembly block and demounting W 00-05-01 General Remove a
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Job card overview Sorted alphabetically 5 D 2011 TD 2011 Activity Job card Maintenance group Removing and installing the lifting magnet (charge air pressure-dependent full load stop) W 07-08-01 Fuel system Removing and installing the lifting magnet (Engine shutdown) W 11-00-03 Monitoring system Removing and installing the lifting magnet (Start amount release) W 07-02-07 Fuel system Removing and installing the lubricating oil cooler W 08-08-02 Lube oil system Removing and installing the lub
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D 2011 TD 2011 Job card overview Sorted numerically 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 02-02-02 Renewing the crankshaft sealing ring (flywheel side) Drive system W 02-02-04 Renewing the crankshaft sealing ring (opposite side Drive s
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Job card overview Sorted numerically 5 D 2011 TD 2011 Job card Activity Maintenance group W 07-08-01 Removing and installing the lifting magnet (charge air pressure-dependent full load stop) Fuel system W 07-08-02 Installing and removing charge air pressure-dependent full load stop Fuel system W 07-10-06 Removing and installing fuel pipes Fuel system W 07-10-08 Removing and installing the fuel filter console Fuel system W 07-10-08 Removing and installing the fuel filter console Fuel syst
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D 2011 TD 2011 General W 00-02-06 Checking the compression pressure Standard tools: – Compression pressure tester 8005 Special tools: – Connector 100120 – W 01-01-01 – W 07-07-01 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.
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General W 00-02-06 D 2011 TD 2011 ● Mount clamping shoe (1). ● Tighten screw (2). 21 Nm 1 2 6 © 47002-0 ● Connect adapter (1) to connector. 1 © 47004-0 ● Mount the compression tester on the adapter. ● Turn over engine with starter. 25 - 30 bar (2500 - 3000 kPa) © 46308-0 © 01/2009 2/6 OBJ_DOKU-23456-001.
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D 2011 TD 2011 General W 00-02-06 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. No. Zyl.
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General W 00-02-06 D 2011 TD 2011 ● Unscrew screw (1). 1 6 © 47005-0 ● Remove connector (1). ● Remove sealing ring. ● Install fuel injectors. W 07-07-01 1 © 47001-0 © 01/2009 4/6 OBJ_DOKU-23456-001.
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D 2011 TD 2011 General W 00-02-06 Technical Data Testing and setting data ID no. Name P00 51 Compression pressure Additional information Value 25 - 30 bar (2500 - 3000 kPa) Tightening specifications ID no. Name A07 001 Fuel injector on cylinder head Screw type Notes / Remark Value 21 Nm For the tightening procedure according to torque using a torque wrench, a maximum variation of the tightening torque of +/- 10% is permissible. © 01/2009 5/6 OBJ_DOKU-23456-001.
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D 2011 TD 2011 General W 00-05-01 Mounting engine on assembly block and demounting Standard tools: – Lifting gear – Suspension ropes – Eyelet bolts Special tools: – Assembly block – Supporting bracket – Clamping bracket – W 13-03-02 Danger! When using hoists (workshop crane) the safety regulations for handling hoists must be observed. It is not permitted to stay under moving loads.
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General W 00-05-01 D 2011 TD 2011 ● Unscrew screws (1). ● Remove all mounting feet. – TD 2011 ● Unscrew screw (2). ● Remove holder (3). ● Remove oil return pipe (4). 4 3 1 6 2 © 47532-3 ● Mount clamping holder (1). ● Tighten screws (2). 90 Nm 1 2 © 47009-0 ● Align engine on engine block. ● Mount retainer plate (1). ● Tighten screws (2) and lock nuts. 90 Nm 1 2 © 47010-0 © 01/2009 2/6 OBJ_DOKU-23457-001.
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D 2011 TD 2011 General W 00-05-01 ● Unhook engine. ● Unscrew eyelet bolts (1). 1 6 © 47006-0 Demounting engine from assembly block ● Screw in eyelet bolts (1). 1 ● Hang engine on workshop crane. – D 2011 L02 approx. 169 - 175 kg – D 2011 L03 approx. 210 -217 kg – D 2011 L04 approx. 253 - 261 kg – TD 2011 L04 approx. 255 - 258 kg © 47006-0 ● Loosen lock nuts. ● Unscrew screws (2). ● Remove retainer plate (1). 1 2 © 47010-0 © 01/2009 3/6 OBJ_DOKU-23457-001.
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General W 00-05-01 D 2011 TD 2011 Danger! Lower engine with workshop crane. ● Unscrew screws (2). ● Remove clamping bracket (1). 1 2 6 © 47009-0 – TD 2011 ● Insert new O-ring (1). ● Lightly oil new O-ring (1). 1 © 39378-2 – TD 2011 ● Mount oil return pipe (1). Attention! Install tension-free. ● Mount holder (2). ● Tighten screw (3). 1 8.5 Nm – D 2011, TD 2011 ● Install all mounting feet. 2 ● Tighten screws (4). 4 200 Nm 3 © 47532-4 © 01/2009 4/6 OBJ_DOKU-23457-001.
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D 2011 TD 2011 General W 00-05-01 Danger! Put the engine down on a secure surface. 1 ● Unhook the engine from the workshop crane. ● Unscrew eyelet bolts (1). ● Install starter. W 13-03-02 6 © 47006-0 © 01/2009 5/6 OBJ_DOKU-23457-001.
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General W 00-05-01 D 2011 TD 2011 Technical Data Testing and setting data ID no. Name D 2011 L02 P00 04 Additional information Value approx. 169 175 kg Engine weight according to DIN 70020-A D 2011 L03 P00 04 approx. 210 217 kg Engine weight according to DIN 70020-A D 2011 L04 P00 04 6 approx. 253 261 kg Engine weight according to DIN 70020-A TD 2011 L04 P00 04 approx. 255 258 kg Engine weight according to DIN 70020-A Tightening specifications ID no.
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D 2011 TD 2011 Cylinder head W 01-01-01 Setting valve clearance Attention! Standard tools: – Feeler gauges In case of internal exhaust gas recirculation, the inlet valve is opened briefly by an additional cam on the camshaft. This is not to be confused with the valve overlap. Allow the engine to cool down for at least 30 minutes before setting the valve clearance. Engine oil temperature < 80 °C The following work procedure describes the setting of the valve clearance on an inlet valve.
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Cylinder head W 01-01-01 D 2011 TD 2011 Arrangement of the inlet and exhaust valves. IN = inlet valve EX = exhaust valve Valve overlap means: The inlet valve starts opening,exhaust valve closes. Attention! In case of internal exhaust gas recirculation, the inlet valve is opened briefly by an additional cam on the camshaft. This is not to be confused with the valve overlap. EX 6 IN EX IN © 39133-2 ● Select feeler gauge. ● Check the setting on the appropriate valve.
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D 2011 TD 2011 Cylinder head W 01-01-01 ● Check the valve clearance with feeler gauge (1). 1 6 © 39135-2 ● Hold adjusting screw (2). ● Tighten lock nut (1). 20 Nm Do not turn the setting screw when tightening the locking nut. 2 1 © 39136-1 ● Check the valve clearance again with feeler gauge. © 39135-1 © 01/2009 3/6 OBJ_DOKU-23458-001.
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Cylinder head W 01-01-01 D 2011 TD 2011 Valve clearance setting schematic – D 2011 According to the order given below, the setting of the valve clearance is possible in two turns of the crankshaft (each 360°). Crankshaft position 1 ● Turn over crankshaft until the valve overlap is achieved on cylinder 1. ● Set black marked valves. 6 Crankshaft position 2 © 25894-5 ● Turn the crankshaft one turn (360°). ● Set black marked valves.
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D 2011 TD 2011 Cylinder head W 01-01-01 ● Mount cylinder head cover. ● Oil the screws lightly. ● Tighten all screws (1) alternately. 1 8.5 Nm 6 © 39131-4 © 01/2009 5/6 OBJ_DOKU-23458-001.
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Cylinder head W 01-01-01 D 2011 TD 2011 Technical Data Testing and setting data ID no. Name D 2011 L02 P00 71 Ignition sequence D 2011 L03 P00 71 Ignition sequence D 2011 L04 P00 71 Ignition sequence D 2011, TD 2011 P01 61 Valve clearance (inlet) P01 62 Valve clearance (outlet) 6 Additional information Value 1-2 1-2-3 1-3-4-2 0.3 mm 0.5 mm Tightening specifications ID no. Name Screw type A01 003 Locking nut, valve adjuster A01 004 Cylinder head cover on cylinder head Notes / Remark Value 20 Nm 8.
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D 2011 TD 2011 Cylinder head W 01-02-02 Removing and installing the rocker arm and rocker arm bracket Standard tools: – Torx tool set – W 01-01-01 8189 6 Removing the rocker arm and rocker arm bracket ● Unscrew all screws (1). 1 ● Remove cylinder head cowling (2). ● Remove gasket. 2 © 39131-5 ● Unscrew screws (1). Loosen screws evenly to avoid tension on the rocker arm brackets. ● Remove rocker arm bracket (2). 1 Lay out components in the order in which they should be installed.
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Cylinder head W 01-02-02 D 2011 TD 2011 ● Remove push rods (1). Lay out components in the order in which they should be installed. ● Visually inspect the components. 1 1 6 © 39141-1 Installing the rocker arm and rocker arm bracket ● 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 1 © 39141-1 ● Loosen lock nut (1). ● Unscrew setting screws (2). ● Mount rocker arm bracket (3). 3 ● Position rocker arm.
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D 2011 TD 2011 Cylinder head W 01-02-02 ● Lightly oil screws (1). ● Tighten screws . 21 Nm Attention! Makes sure that the stop rods are not under stress due to valve overlap when fastening the screws. ● Set valve clearance. W 01-01-01 1 6 © 39143-1 ● Clean sealing surfaces. ● Mount new gasket. Note installation position: The bar (1) must face the front cover. 1 © 47500-0 ● Mount cylinder head cover. ● Oil the screws lightly. ● Tighten all screws (1) alternately. 1 8.
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Cylinder head W 01-02-02 D 2011 TD 2011 Technical Data Tightening specifications ID no. Name Screw type A01 002 Rocker arm bracket on cylinder head A01 004 Cylinder head cover on cylinder head Notes / Remark Value 21 Nm 8.5 Nm For the tightening procedure according to torque using a torque wrench, a maximum variation of the tightening torque of +/- 10% is permissible. 6 © 01/2009 4/4 OBJ_DOKU-23459-001.
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D 2011 TD 2011 Drive system W 02-02-02 Renewing the crankshaft sealing ring (flywheel side) Standard tools: – Pricker – Assembly lever 8198 9017 Special tools: – Assembly tool 142680 – W 12-06-01 – Self-tapping screw – Washer 6 Removing the crankshaft sealing ring ● Remove flywheel. W 12-06-01 ● Make a hole of approximately 3 mm in the crankshaft sealing ring with a pricker. Attention! Do not damage the rear cover and crankshaft! © 47083-0 ● Screw in a self-tapping screw (1) with washer.
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Drive system W 02-02-02 D 2011 TD 2011 ● Pull out the crankshaft sealing ring with assembly lever. ● Visually inspect the crankshaft sealing ring running surface. 6 © 47085-0 Installing the crankshaft sealing ring ● Mount guide sleeve (1). ● Tighten screws (2). 1 The bores in the guide sleeve must match the threaded holes in the crankshaft flange. 2 © 47088-1 ● Place the crankshaft sealing ring carefully on the peripheral surface. Do not oil waxed crankshaft sealing rings.
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D 2011 TD 2011 Drive system W 02-02-02 ● Mount assembly sleeve (1). ● Press on the crankshaft sealing ring to the stop. ● Plug in the bearing (2). ● Screw on nut (3). 2 3 1 6 © 47090-1 ● Tighten nut to the stop of the assembly sleeve (1). The installation depth is determined by the assembly tool. 1 ● Remove assembly tool. ● Install flywheel. W 12-06-01 © 47091-0 © 01/2009 3/4 OBJ_DOKU-23469-001.
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D 2011 TD 2011 Drive system W 02-02-04 Renewing the crankshaft sealing ring (opposite side to flywheel) Standard tools: – Pricker – Assembly lever 8198 9017 Special tools: – Assembly tool 142690 – W 04-04-15 – Self-tapping screw – Washer 6 Removing the crankshaft sealing ring ● Remove toothed belt wheel. W 04-04-15 ● Make a hole of approximately 3 mm in the crankshaft sealing ring with a pricker. Attention! Do not damage the front cover or crankshaft.
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Drive system W 02-02-04 D 2011 TD 2011 ● Pull out the crankshaft sealing ring with assembly lever. ● Visually inspect the crankshaft sealing ring running surface. 6 © 47100-0 ● Visually inspect all running surfaces. © 47101-0 Installing the crankshaft sealing ring ● Place new crankshaft sealing ring on assembly tool. Do not oil waxed crankshaft sealing rings. The sealing lip faces the crankcase. © 47102-0 © 01/2009 2/4 OBJ_DOKU-23470-001.
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D 2011 TD 2011 Drive system W 02-02-04 ● Mount assembly tool (1). ● Tighten screw until it reaches the assembly tool (1). The installation depth is determined by the assembly tool. 1 ● Unscrew screw. ● Remove assembly tool. ● Install toothed belt wheel. W 04-04-15 6 © 47103-0 © 01/2009 3/4 OBJ_DOKU-23470-001.
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D 2011 TD 2011 Crankcase W 03-01-11 Removing and installing the crankcase bleeding Standard tools Special tools: – Disassembly tool 110901 6 Removing the crankcase bleeding ● Unscrew screw (1). ● Remove crankcase bleeding (2). 1 2 © 47152-0 ● Remove the O-ring (1) with the disassembly tool. ● Visually inspect the components. 1 © 47153-0 © 01/2009 1/6 OBJ_DOKU-23477-001.
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Crankcase W 03-01-11 D 2011 TD 2011 – TD 2011 2 ● Unscrew screws (1). ● Remove gasket (2). 1 6 © 47703-0 ● Loosen hose clip (1) with clamping tongs. ● Pull off hose clip (1) in the direction of the arrow. 2 ● Pull out the pipe (2) in the direction of the arrow. 1 © 47657-2 ● Clean sealing surfaces. © 47702-0 © 01/2009 2/6 OBJ_DOKU-23477-001.
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D 2011 TD 2011 Crankcase W 03-01-11 Install crankcase bleeding 1 ● Push on the pipe (1) in the direction of the arrow. ● Position the hose clip (2) with clamping tongs. 2 6 © 47657-3 ● Fix new gasket (1) to the crankcase with a little grease. 1 © 47701-0 ● Position pipe (1). ● Tighten screws (2). 8.5 Nm 2 Attention! Install tension-free. 1 © 47703-1 © 01/2009 3/6 OBJ_DOKU-23477-001.
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Crankcase W 03-01-11 D 2011 TD 2011 – D 2011, TD 2011 ● Clean sealing surfaces. ● Insert new O-ring (1). 1 6 © 47160-0 ● Mount crankcase vent (2). Ensure that the installation location is free from faults. The crankcase bleeding must fit evenly. 1 ● Tighten screw (1). 8.5 Nm 2 © 47152-0 © 01/2009 4/6 OBJ_DOKU-23477-001.
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D 2011 TD 2011 Crankcase W 03-01-11 Technical Data Tightening specifications ID no. Name Crankcase bleeding on front cover / A03 060 on cylinder head cover / on cylinder head TD 2011 L04 Crankcase breather, pipe to cylinder A03 062 head Screw type Notes / Remark Value 8.5 Nm M6x30-8.8 8.5 Nm For the tightening procedure according to torque using a torque wrench, a maximum variation of the tightening torque of +/- 10% is permissible. © 01/2009 5/6 OBJ_DOKU-23477-001.
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D 2011 TD 2011 Crankcase W 03-09-01 Removing and installing rear cover Standard tools – W 02-02-02 – W 03-09-04 – W 08-04-07 – Packing compound DEUTZ DW 67 6 Removing rear cover ● Remove connection housing. W 03-09-04 ● Remove lubricating oil pan. W 08-04-07 ● Unscrew all screws (1). 1 ● Remove rear cover 2. 2 © 47211-0 ● Knock out crankshaft sealing ring (1). Attention! Do not damage the sealing surfaces. ● Visually inspect the components. 1 © 39512-1 © 01/2009 1/4 OBJ_DOKU-23481-001.
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Crankcase W 03-09-01 D 2011 TD 2011 Installing rear cover ● Clean sealing surfaces. ● Apply packing compound evenly to the sealing surface. Sealing cord strength approx. 0.5 0.6 mm. 6 © 47487-0 ● Mount rear cover. ● Oil the screws lightly. ● Fasten all screws (1). ● Align front cover flush with the oil tray sealing surface. 1 © 47212-0 ● Tighten the screws according to the tightening sequence. 1 21 Nm 5 4 6 3 7 2 8 © 47488-0 © 01/2009 2/4 OBJ_DOKU-23481-001.
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D 2011 TD 2011 Crankcase W 03-09-01 ● Renew crankshaft sealing ring (flywheel side). W 02-02-02 ● Install lubricating oil pan. W 08-04-07 ● Install connection housing. W 03-09-04 6 © 47213-0 © 01/2009 3/4 OBJ_DOKU-23481-001.
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Crankcase W 03-09-01 D 2011 TD 2011 Technical Data Tightening specifications ID no. Name Screw type A03 010 Rear cover on crankcase Notes / Remark Observe tightening sequence Value 21 Nm For the tightening procedure according to torque using a torque wrench, a maximum variation of the tightening torque of +/- 10% is permissible. 6 © 01/2009 4/4 OBJ_DOKU-23481-001.
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D 2011 TD 2011 Crankcase W 03-09-04 Removing and installing the connection housing Standard tools – W 12-06-01 6 Removing the connection housing ● Remove flywheel. W 12-06-01 ● Unscrew all screws (1). ● Remove connection housing. 1 © 47226-0 ● Visually inspect the components. © 39048-2 © 01/2009 1/4 OBJ_DOKU-23482-001.
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Crankcase W 03-09-04 D 2011 TD 2011 Installing the connection housing ● Clean contact surfaces. ● Make sure the clamping bushings (arrows) are in place. ● Drive in clamping sleeves in the crankcase as far as they will go. 6 © 47214-0 ● Mount connection housing. ● Centre connection housing over the clamping bushings. © 47215-0 ● Tighten all screws (1) alternately. Technical Data 1 © 47226-0 © 01/2009 2/4 OBJ_DOKU-23482-001.
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Crankcase W 03-09-04 D 2011 TD 2011 Technical Data Tightening specifications ID no.
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D 2011 TD 2011 Engine control W 04-03-01 Renew camshaft sealing ring (opposite side to flywheel) Standard tools: – Pricker – Assembly lever 8198 9017 Special tools: – Assembly tool – Counter support 142050 144130 – W 04-04-15 – Self-tapping screw – Washer 6 Remove camshaft sealing ring ● Remove toothed belt wheel (1). 1 W 04-04-15 © 47179-1 ● Position holder. ● Unscrew screw (1). 2 ● Remove toothed belt wheel (2). 1 © 47180-0 © 01/2009 1/4 OBJ_DOKU-23484-001.
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Engine control W 04-03-01 D 2011 TD 2011 Attention! Do not damage front cover and camshaft! ● Make a hole of approx. 3mm in the camshaft sealing ring with a pricker. 6 © 47259-0 ● Screw in a self-tapping screw (1) with washer. 1 © 47260-0 ● Pull out camshaft sealing ring with assembly lever. ● Visually inspect the components. © 47261-0 © 01/2009 2/4 OBJ_DOKU-23484-001.
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D 2011 TD 2011 Engine control W 04-03-01 ● Visually inspect all running surfaces. 6 © 47262-0 Install camshaft sealing ring ● Mount new camshaft sealing ring (1) on assembly tool (2). 1 Do not oil waxed crankshaft sealing rings. 2 The sealing lip faces the crankcase. © 39515-1 ● Carefully insert camshaft sealing ring. ● Fasten screw (1). 1 © 47263-0 © 01/2009 3/4 OBJ_DOKU-23484-001.
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Engine control W 04-03-01 D 2011 TD 2011 ● Tighten screw until it reaches the assembly tool (1). The installation depth is determined by the assembly tool. ● Unscrew screw. ● Remove assembly tool. 1 6 © 47264-0 All connecting surfaces must be clean and free of oil. 2 ● Mount toothed belt wheel (2). ● Position holder. ● Turn in new screw (1). 1 © 47180-0 ● Install toothed belt wheel (1). W 04-04-15 1 © 47179-1 © 01/2009 4/4 OBJ_DOKU-23484-001.
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D 2011 TD 2011 Engine control W 04-04-11 Check control times Standard tools Special tools: – Ajustable bolt 100700 – Chalk 6 Check control times ● Unscrew locking screw (1). ● Remove sealing ring. 1 © 47266-0 ● Insert adjustable bolt (1). 1 © 47267-0 © 02/2011 1/6 OBJ_DOKU-24551-001.
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Engine control W 04-04-11 D 2011 TD 2011 ● Press adjustable bolt in lightly in direction of arrow and hold. ● Turn crankshaft slowly in direction of engine until the adjustable bolt engages with the bore of the camshaft. 6 © 47268-0 ● Knock in the adjustable bolt (1) to the stop. 1 © 47269-0 ● Unscrew locking screw (1). ● Remove sealing ring. 1 © 47270-0 © 02/2011 2/6 OBJ_DOKU-24551-001.
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D 2011 TD 2011 Engine control W 04-04-11 ● Tension central screw in direction of arrow. 40 Nm ● Carefully relax torque wrench. Attention! Do not twist crankshaft. 6 © 47025-0 ● Insert adjustable bolt (1). 1 © 47296-0 ● Screw in adjustable bolt (1). Screw in adjustment bolts until they come into contact with the crankshaft Attention! Do not twist crankshaft. ● Apply help marking (arrow). 1 © 47277-0 © 02/2011 3/6 OBJ_DOKU-24551-001.
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Engine control W 04-04-11 D 2011 TD 2011 ● The engine control times are set correctly if the adjusting bolt can still be screwed into the crankcase 0.75 to 2.25 revolutions as far as the system. ● If the screwing depth “X“ diverges from the specification, the toothed belt and clamping roller must be replaced. X 6 © 47278-0 ● Unscrew adjustable bolt (1). 1 © 47271-0 ● Insert new sealing ring. ● Tighten screw plug (1). 18 Nm 1 © 47270-0 © 02/2011 4/6 OBJ_DOKU-24551-001.
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D 2011 TD 2011 Engine control W 04-04-11 ● Unscrew adjustable bolt (1). 1 6 © 47269-0 ● Insert new sealing ring. ● Tighten screw plug (1). 18 Nm 1 © 47266-0 © 02/2011 5/6 OBJ_DOKU-24551-001.
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Engine control W 04-04-11 D 2011 TD 2011 Technical Data Tightening specifications ID no. Name A03 003 Locking screw on crankcase Screw type M10x1 Notes / Remark Adapter for adjustable bolt on camshaft lock/ crankshaft lock. Replace sealing ring. Value 18 Nm For the tightening procedure according to torque using a torque wrench, a maximum variation of the tightening torque of +/- 10% is permissible. 6 © 02/2011 6/6 OBJ_DOKU-24551-001.
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D 2011 TD 2011 Engine control W 04-04-12 Renew toothed belt and tensioning pulley Standard tools: – Rotation angle disc – Special bit, 70 mm long 8190 9120 Special tools: – Ajustable bolt – Counter support 100700 144130 – W 12-01-04 – W 12-08-03 Attention! Re-tensioning of toothed belts which have already been running is not permissible! The setting of engine control times should only be carried out with new toothed belts! The crankshaft may only be turned in the direction of the engine.
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Engine control W 04-04-12 D 2011 TD 2011 ● Unscrew screw (1) with special bit. ● Unscrew screws (2). ● Remove holder. ● Remove protective hood. 2 6 1 © 47294-0 ● Unscrew screws (1). ● Remove protective hood. 1 1 © 47295-0 ● Unscrew locking screw (1). ● Remove sealing ring. 1 © 47266-0 © 01/2009 2/12 OBJ_DOKU-23486-001.
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D 2011 TD 2011 Engine control W 04-04-12 ● Insert adjustable bolt (1). 1 6 © 47267-0 ● Press adjustable bolt in lightly in direction of arrow and hold. ● Turn crankshaft slowly in direction of engine until the adjustable bolt engages with the bore of the camshaft. © 47268-0 ● Knock in the adjustable bolt (1) to the stop. 1 © 47269-0 © 01/2009 3/12 OBJ_DOKU-23486-001.
PAGE 88
Engine control W 04-04-12 D 2011 TD 2011 ● Unscrew locking screw (1). ● Remove sealing ring. 1 6 © 47270-0 ● Insert adjustable bolt (1). 1 © 47296-0 ● Knock in the adjustable bolt (1) to the stop. 1 © 47271-0 © 01/2009 4/12 OBJ_DOKU-23486-001.
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D 2011 TD 2011 Engine control W 04-04-12 ● Turn crankshaft in the direction of the engine until it reaches the stop of the adjustable bolt. 6 © 39130-1 ● Unscrew screw (1). ● Remove tensioning pulley (2). ● Remove the toothed belt (3). 3 1 2 © 47297-0 ● Position counter support (2). ● Loosen screw (1). Attention! Do not turn camshaft. 1 2 © 47312-0 © 01/2009 5/12 OBJ_DOKU-23486-001.
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Engine control W 04-04-12 D 2011 TD 2011 Install toothed belt and tensioning pulley ● Fasten screw (1). To guarantee the length adjustment of the toothed belt, the toothed belt wheel must still be able to be turned slightly. 1 6 © 47298-0 ● Turn crankshaft in the direction of the engine until it reaches the stop of the adjustable bolt. © 39130-1 ● Mount new toothed belt (1). 1 © 47299-0 © 01/2009 6/12 OBJ_DOKU-23486-001.
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D 2011 TD 2011 Engine control W 04-04-12 ● Mount new tensioning pulley (1). ● Position setting eccentric (arrow) at 6 o'clock. ● Fasten screw (2). 1 2 6 © 47300-0 ● Press tensioning pulley (1) against the toothed belt. ● Fasten screws. 1 © 47301-0 ● Align toothed belt. Align toothed belt centrally on the toothed belt wheels. © 34132-2 © 01/2009 7/12 OBJ_DOKU-23486-001.
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Engine control W 04-04-12 D 2011 TD 2011 ● Align toothed belt. ● Press tensioning pulley (1) against the stop. ● Turn the toothed belt wheel by hand in the direction of the arrow. The tension side (2) is tightened. 2 1 6 © 47302-2 ● Turn setting eccentric in the direction of arrow with hexagon socket. ● Bring markings (1) and bores into alignment. ● Tighten screw (2). 21 Nm 1 2 © 39605-1 ● Press tensioning pulley (1) against the stop. ● Hold toothed belt wheel (2) with counter support.
PAGE 93
D 2011 TD 2011 Engine control W 04-04-12 Check toothed wheel tension ● Unscrew adjustable bolt to the camshaft and crankshaft lock. ● Bring help markings (1) on toothed wheel and opposite screw into line. 1 ● Turn crankshaft two revolutions in the direction of the arrow (direction of engine) until the help markings are in line. 6 © 47303-0 Markings (1) and bores must be in alignment. If the markings are not aligned with each other, the toothed belt tension must be corrected.
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Engine control W 04-04-12 D 2011 TD 2011 ● Visually inspect the components. 6 © 34229-2 ● Mount protective hood. Ensure that the installation location is free from faults. 1 ● Tighten screws (1). 7 Nm 1 © 47295-0 ● Mount protective hood. ● Mount holder. ● Tighten screws (2). 7 Nm ● Tighten screw (1) with special bit. 7 Nm 2 1 © 01/2009 10/12 © 47294-0 OBJ_DOKU-23486-001.
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D 2011 TD 2011 Engine control W 04-04-12 ● Fix cable tie (1). 1 6 © 47292-0 ● Install toothed belt and tensioning pulley (hydraulic pump). W 12-08-03 ● Insert V-belt tensioning pulley. 1 ● Tighten screws (1). ● Install V-belt pulley. W 12-01-04 © 47293-1 © 01/2009 11/12 OBJ_DOKU-23486-001.
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Engine control W 04-04-12 D 2011 TD 2011 Technical Data Tightening specifications ID no. Name Screw type A04 001 Toothed belt wheel on camshaft A04 001 Toothed belt wheel on camshaft A04 052 Tensioning pulley on front cover Protective hood (toothed wheel) on A04 053 front cover Notes / Remark Stage 1: Use new screw. Stage 2: Value 30 Nm 210° 21 Nm 7 Nm For the tightening procedure according to torque using a torque wrench, a maximum variation of the tightening torque of +/- 10% is permissible.
PAGE 97
D 2011 TD 2011 Engine control W 04-04-15 Removing and installing the toothed belt wheel Standard tools: – Socket wrench insert, spanner size 32 – Force multiplier – Rotation angle disc – W 04-04-12 8036 8049 8190 Special tools: – Counter support – Counter support 143420 144130 – Packing compound DEUTZ DW 67 6 Remove toothed belt wheel ● Remove toothed belt and tensioning pulley. 2 W 04-04-12 ● Insert counter support 144130. 1 ● Unscrew screw (1). ● Remove toothed belt wheel (2).
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Engine control W 04-04-15 D 2011 TD 2011 ● Tighten screws (1). Attention! Do not twist crankshaft. 1 6 © 47182-0 ● Insert socket wrench insert and force multiplier (1). ● Snap in non-return device (2) in position CCW. 1 2 © 47183-1 ● Hold force multiplier. ● Loosen screw. ● Remove force multiplier and socket wrench insert. © 47184-0 © 01/2009 2/8 OBJ_DOKU-23487-001.
PAGE 99
D 2011 TD 2011 Engine control W 04-04-15 ● Unscrew screws (1). ● Remove counter holder. 1 6 © 47182-0 ● Unscrew screw (1). ● Remove flange (2). ● Remove toothed belt wheel (3). 3 2 1 © 47185-0 Install toothed belt wheel ● Mount toothed belt wheel (3). ● Mount flange (2). All connecting surfaces must be clean and free of oil. ● Turn in new screw (1). 3 2 1 © 47185-0 © 01/2009 3/8 OBJ_DOKU-23487-001.
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Engine control W 04-04-15 D 2011 TD 2011 ● Tighten screw. – Stage 1: 130 Nm 6 © 47190-1 ● Insert counter support 143420. ● Insert fixing bolts (1) in the bores (2). Attention! Do not twist crankshaft. 1 2 © 47181-0 ● Tighten screws (1). Attention! Do not twist crankshaft. 1 © 47182-0 © 01/2009 4/8 OBJ_DOKU-23487-001.
PAGE 101
D 2011 TD 2011 Engine control W 04-04-15 ● Insert socket wrench insert and force multiplier (1). ● Snap in non-return device (2) in position CW. 1 2 6 © 47191-1 ● Turn square bar (1) in direction of arrow to the stop. ● Set graduated collar (2) to zero. 2 1 © 39458-2 ● Hold force multiplier (1). ● Tighten screw. – Stage 2: 1 210° © 39459-2 © 01/2009 5/8 OBJ_DOKU-23487-001.
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Engine control W 04-04-15 D 2011 TD 2011 ● Hold force multiplier against counter pressure (arrow), ● release non-return device (1) and force multiplier. Danger! There is danger of injury if a force multiplier is removed without being discharged. ● Remove force multiplier and socket wrench insert. ● Remove counter holder. 1 6 © 47192-0 All connecting surfaces must be clean and free of oil. 2 ● Mount toothed belt wheel (2). ● Insert counter support 144130. ● Tighten new screw (1).
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D 2011 TD 2011 Engine control W 04-04-15 Technical Data Tightening specifications ID no. Name Screw type A02 015 Toothed belt wheel on crankshaft A02 015 Toothed belt wheel on crankshaft Notes / Remark Stage 1: Use new screw. Stage 2: Value 130 Nm 210° For the tightening procedure according to torque using a torque wrench, a maximum variation of the tightening torque of +/- 10% is permissible. 6 © 01/2009 7/8 OBJ_DOKU-23487-001.
PAGE 105
D 2011 TD 2011 Speed control W 05-07-01 Removing and installing the impulse transmitter Standard tools 6 Removing the impulse transmitter ● Unlock cable plug (1) and disconnect. 1 © 46966-0 ● Unscrew screw (1). ● Remove impulse transmitter (2). ● Remove spacing sleeve (3). 3 1 2 © 46967-0 © 01/2009 1/4 OBJ_DOKU-23492-001.
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Speed control W 05-07-01 D 2011 TD 2011 ● Visually inspect the components. ● Clean components. ● Clean sealing surfaces. 6 © 46968-0 Installing the impulse transmitter ● Position spacing sleeve (3). ● Insert impulse transmitter (2). ● Fasten screw (1). ● Tighten screw (1). 3 8.5 Nm 1 2 © 46967-0 ● Plug in the cable plug (1). Ensure that the cables are connected properly. 1 © 46966-0 © 01/2009 2/4 OBJ_DOKU-23492-001.
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D 2011 TD 2011 Speed control W 05-07-01 Technical Data Tightening specifications ID no. Name Screw type Speed transmitter on connection houA05 011 sing Notes / Remark Value 8.5 Nm For the tightening procedure according to torque using a torque wrench, a maximum variation of the tightening torque of +/- 10% is permissible. 6 © 01/2009 3/4 OBJ_DOKU-23492-001.
PAGE 109
Exhaust system/Charging W 06-01-05 D 2011 Removing and installing the exhaust damper Standard tools 6 Remove exhaust damper ● Unscrew nuts (1). 1 1 © 47318-0 ● Unscrew nuts (1). 1 1 © 47319-0 © 01/2009 1/6 OBJ_DOKU-23493-001.
PAGE 110
Exhaust system/Charging W 06-01-05 D 2011 ● Remove exhaust damper (1). 1 6 © 47320-0 ● Remove gaskets (1). ● Unscrew studs (2). 1 1 2 1 2 2 © 47321-1 Install exhaust damper ● Clean sealing surfaces. ● Turn on new pin bolts (2). 8.5 Nm 2 ● Mount new gaskets (1). 2 1 Note installation position. 2 © 47322-1 © 01/2009 2/6 OBJ_DOKU-23493-001.
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Exhaust system/Charging W 06-01-05 D 2011 ● Install exhaust damper (1). 1 6 © 47320-0 ● Screw on nuts (1). 1 1 © 47319-0 ● Screw on nuts (1). 1 1 © 47318-0 © 01/2009 3/6 OBJ_DOKU-23493-001.
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Exhaust system/Charging W 06-01-05 D 2011 ● Tighten nuts (1). 40 Nm 1 1 6 © 47319-0 ● Tighten nuts (1). 40 Nm 1 1 © 47318-0 © 01/2009 4/6 OBJ_DOKU-23493-001.
PAGE 113
Exhaust system/Charging W 06-01-05 D 2011 Technical Data Tightening specifications ID no. Name A06 001 Exhaust damper on cylinder head A06 005 Pin bolt on cylinder head Screw type Notes / Remark Use new pin bolts Value 40 Nm 8.5 Nm For the tightening procedure according to torque using a torque wrench, a maximum variation of the tightening torque of +/- 10% is permissible. 6 © 01/2009 5/6 OBJ_DOKU-23493-001.
PAGE 115
D 2011 TD 2011 Exhaust system/Charging W 06-01-05 Removing and installing the exhaust line Standard tools: – Torx tool set – W 06-06-04 8189 6 Removing exhaust line – TD 2011 ● Remove turbocharger. W 06-06-04 ● Unscrew all screws (1). ● Remove exhaust line (2). 1 1 1 2 1 © 47523-1 ● Remove gaskets (1). 1 © 47525-1 © 01/2009 1/4 OBJ_DOKU-23494-001.
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Exhaust system/Charging W 06-01-05 D 2011 TD 2011 ● Unscrew studs (1). ● Visually inspect the components. 1 1 6 © 47524-0 Installing exhaust line 2 ● Clean sealing surfaces. ● Turn on new pin bolts (1). ● Tighten pin bolts (1). 1 12 Nm 1 2 © 47524-1 ● Clean sealing surfaces. ● Mount exhaust line (1). ● Mount new gaskets. Note installation position. 2 ● Turn in new screws (2). 2 1 ● Tighten new screws (2). 55 Nm – TD 2011 ● Install the turbocharger.
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D 2011 TD 2011 Exhaust system/Charging W 06-01-05 Technical Data Tightening specifications ID no. Name A06 001 Exhaust pipe at cylinder head A06 004 Pin bolts on exhaust pipe Screw type Torx screw, coated coated Notes / Remark Value Use new screws. 55 Nm Use new pin bolts 12 Nm For the tightening procedure according to torque using a torque wrench, a maximum variation of the tightening torque of +/- 10% is permissible. 6 © 01/2009 3/4 OBJ_DOKU-23494-001.
PAGE 119
Exhaust system/Charging W 06-02-03 TD 2011 Removing and install the charge air line Standard tools: – Torx tool set – W 06-01-05 – W 06-06-04 8189 6 Remove charge air line ● Remove turbocharger. 2 W 06-06-04 1 1 ● Remove the exhaust pipe. 1 W 06-01-05 ● Unscrew all screws (1). ● Remove charge air pipe (2). ● Remove seals. 1 1 © 47655-0 ● Clean sealing surfaces. © 47656-0 © 01/2009 1/4 OBJ_DOKU-23495-001.
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Exhaust system/Charging W 06-02-03 TD 2011 Install charge air line ● Mount charge air line (1). 1 ● Mount new gaskets. ● Tighten screws (2) alternately working from the centre to the outside. 2 2 2 21 Nm ● Install the exhaust pipe. W 06-01-05 2 ● Install the turbocharger. 2 W 06-06-04 6 © 47655-1 © 01/2009 2/4 OBJ_DOKU-23495-001.
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Exhaust system/Charging W 06-02-03 TD 2011 Technical Data Tightening specifications ID no. Name A06 030 Charge air pipe on cylinder head Screw type Torx screw, coated Notes / Remark Value Use new screws. 21 Nm For the tightening procedure according to torque using a torque wrench, a maximum variation of the tightening torque of +/- 10% is permissible. 6 © 01/2009 3/4 OBJ_DOKU-23495-001.
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Exhaust system/Charging W 06-06-04 TD 2011 Removing and installing the turbocharger Standard tools: – Clamping tongs – Spring band pliers Attention! 9088 9090 Do not remove the stoppers/caps until immediately before assembly. Collect leaking operating substances in suitable vessels and dispose of according to regulations. – Lubricating oil – Fitting compound DEUTZ S1 6 Removing turbocharger ● Unscrew screw (1). ● Remove the holder (2). ● Remove oil return pipe (3). ● Unscrew hollow screw (4).
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Exhaust system/Charging W 06-06-04 TD 2011 ● Unscrew screw (1). 1 6 © 00000-0 ● Loosen spring band clip (1) with spring band pliers. ● Remove reducer (2). 2 1 © 47554-0 ● Unscrew hollow screw (1). ● Remove lubricating oil pipe (2). ● Remove sealing rings. ● Press in stoppers. 1 2 © 47526-0 © 01/2009 2/10 OBJ_DOKU-23496-001.
PAGE 125
Exhaust system/Charging W 06-06-04 TD 2011 ● Loosen spring band clip (1) with spring band pliers. ● Pull off spring band clip (1) in the direction of the arrow. 1 6 © 47527-0 ● Unscrew nuts (1). 1 1 © 47528-0 ● Remove turbocharger in the direction of the arrow. ● Remove gasket (1). 1 © 47555-0 © 01/2009 3/10 OBJ_DOKU-23496-001.
PAGE 126
Exhaust system/Charging W 06-06-04 TD 2011 ● Remove the O-ring (1) with the disassembly tool. ● Unscrew screw-in nipple (2). ● Remove sealing ring (3). 2 3 1 6 © 47529-0 ● Unscrew studs (1). ● Check components for visible signs of wear. 1 1 © 47523-0 Installing the turbocharger ● Mount sealing ring (1). ● Tighten screw-in nipple (2). 40 Nm ● Insert new O-ring (3). 2 1 3 © 47529-1 © 01/2009 4/10 OBJ_DOKU-23496-001.
PAGE 127
Exhaust system/Charging W 06-06-04 TD 2011 ● Clean sealing surfaces. ● Coat pin bolts with mounting compound. ● Screw in studs (1). ● Tighten all pin bolts (1). 12 Nm 1 1 6 © 47523-0 ● Mount gasket (1). ● Plug in the tubing connection (2). ● Insert turbocharger in the direction of the arrow. 1 2 © 47555-1 ● Mount turbocharger (1). ● Turn on new nuts (2). ● Tighten nuts (2). 2 21 Nm 2 1 © 47528-1 © 01/2009 5/10 OBJ_DOKU-23496-001.
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Exhaust system/Charging W 06-06-04 TD 2011 ● Position the spring band clip (1) with the spring band pliers. ● Pull out stoppers. ● Fill in clean lubricating oil (arrow). 1 6 © 47659-1 ● Mount lubrication oil line (1). ● Mount sealing rings (2). ● Screw on hollow screw (3). 3 2 1 © 47526-1 ● Insert new O-ring (1). ● Lightly oil new O-ring (1). 1 © 39378-2 © 01/2009 6/10 OBJ_DOKU-23496-001.
PAGE 129
Exhaust system/Charging W 06-06-04 TD 2011 ● Mount oil return pipe (1). ● Mount holder (2). ● Tighten screw (3). 8.5 Nm 4 Attention! 1 Install tension-free. ● Mount new sealing rings (4). 5 ● Tighten hollow screw (5). 2 6 3 © 47532-1 ● Fasten screw (1). ● Tighten screw (1). 8.5 Nm Attention! Install tension-free. 1 © 00000-0 Attention! Install tension-free. ● Tighten hollow screw (1). 29 Nm 1 © 47526-2 © 01/2009 7/10 OBJ_DOKU-23496-001.
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Exhaust system/Charging W 06-06-04 TD 2011 ● Mount the reducer (1). Attention! 1 Install tension-free. 2 ● Position spring band clip (2) with spring band pliers. 6 © 47554-3 ● Position hose clip (1) with clamping tongs. 1 © 47657-1 © 01/2009 8/10 OBJ_DOKU-23496-001.
PAGE 131
Exhaust system/Charging W 06-06-04 TD 2011 Technical Data Tightening specifications ID no. Name A06 004 Pin bolts on exhaust pipe A06 020 Turbocharger on exhaust pipe Lubricating oil pipe, holder on A08 041 crankcase Lubricating oil pipe on turbocharger / A08 042 crankcase Oil return line, hex spuds to turA08 044 bocharger A08 049 Holder oil return line on crankcase Screw type coated M8 Notes / Remark Use new pin bolts Value 12 Nm 21 Nm M6x14-8.8 8.
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D 2011 TD 2011 Exhaust system/Charging W 06-07-03 Removing and installing the intake manifold Standard tools: – Torx tool set – W 06-01-05 – W 06-01-05 8189 Exhaust pipe Exhaust damper 6 Removing the intake manifold ● Remove the exhaust pipe. W 06-01-05 – or ● Remove exhaust damper. W 06-01-05 © 47327-0 ● Unscrew all screws (1). ● Remove intake manifold (2). 2 1 © 47325-0 © 01/2009 1/4 OBJ_DOKU-23497-001.
PAGE 134
Exhaust system/Charging W 06-07-03 D 2011 TD 2011 ● Remove gaskets (1). ● Visually inspect the components. 1 1 6 © 47326-0 Installing the intake manifold ● Clean sealing surfaces. ● Mount new gaskets (1). 1 1 © 47326-0 ● Mount intake manifold (2). ● Turn in new screws (1). 2 ● Tighten all screws (1). 21 Nm 1 © 47325-0 © 01/2009 2/4 OBJ_DOKU-23497-001.
PAGE 135
D 2011 TD 2011 Exhaust system/Charging W 06-07-03 ● Install the exhaust pipe. W 06-01-05 – or ● Install exhaust damper. W 06-01-05 6 © 47327-0 © 01/2009 3/4 OBJ_DOKU-23497-001.
PAGE 136
Exhaust system/Charging W 06-07-03 D 2011 TD 2011 Technical Data Tightening specifications ID no. Name Air suction intake pipe on cylinder A06 030 head Screw type Torx screw, coated Notes / Remark Value Use new screws. 21 Nm For the tightening procedure according to torque using a torque wrench, a maximum variation of the tightening torque of +/- 10% is permissible. 6 © 01/2009 4/4 OBJ_DOKU-23497-001.
PAGE 137
Exhaust system/Charging W 06-09-06 D 2011 Removing and installing the exhaust gas return valve Standard tools: – Special bit, 70 mm long 9120 6 Removing the exhaust gas return valve ● Unscrew screw (1) with special bit. ● Remove safety cover (2). ● Unlock cable plug (3) and remove. 1 2 3 © 46964-0 ● Pull out pipe holder (1). 1 © 46937-0 © 01/2009 1/8 OBJ_DOKU-23498-001.
PAGE 138
Exhaust system/Charging W 06-09-06 D 2011 ● Unscrew hollow screws (1). ● Remove pipe (2). 3 ● Remove sealing rings (3). 1 3 2 1 6 © 46935-0 ● Unscrew hollow screw (1). ● Remove sealing rings (2). ● Unscrew hollow screw (3). ● Remove sealing rings (4). ● Remove pipe (5). 2 1 5 3 4 © 46938-0 ● Unscrew screws (1). 1 © 46939-0 © 01/2009 2/8 OBJ_DOKU-23498-001.
PAGE 139
Exhaust system/Charging W 06-09-06 D 2011 ● Remove gasket (1). 1 6 © 46940-0 ● Unscrew screws (1). ● Remove the exhaust gas return valve. 1 1 © 46941-0 ● Remove gasket (1). 1 © 46942-0 © 01/2009 3/8 OBJ_DOKU-23498-001.
PAGE 140
Exhaust system/Charging W 06-09-06 D 2011 ● Visually inspect the components. 6 © 46965-0 Installing the exhaust gas return valve ● Clean sealing surfaces. ● Mount gasket (1). ● Mount exhaust gas return valve (2). 1 2 © 46943-0 ● Tighten screws (1). 1 ● Tighten screws (1). 20 Nm 1 © 46941-0 © 01/2009 4/8 OBJ_DOKU-23498-001.
PAGE 141
Exhaust system/Charging W 06-09-06 D 2011 ● Clean sealing surfaces. ● Mount gasket (1). ● Mount exhaust gas collection pipe (2). ● Fasten screws (3). ● Tighten screws (3). 1 20 Nm 3 3 2 6 © 46939-1 ● Insert pipe (5). ● Mount new sealing rings (4). ● Screw on hollow screw (3). ● Mount sealing rings (2). ● Screw on hollow screw (1). 2 ● Tighten hollow screw (1). 1 29 Nm ● Tighten hollow screw (3). 12 Nm 5 3 4 © 46938-0 ● Insert pipe (1). ● Mount sealing rings (2).
PAGE 142
Exhaust system/Charging W 06-09-06 D 2011 ● Press in pipe holder (1). 1 6 © 46937-0 ● Plug in the cable plug (3). ● Mount the safety cover (2). ● Fasten screw (1). ● Tighten screw (1) with special bit. 8 Nm 1 3 2 © 46964-0 © 01/2009 6/8 OBJ_DOKU-23498-001.
PAGE 143
Exhaust system/Charging W 06-09-06 D 2011 Technical Data Tightening specifications ID no.
PAGE 145
Exhaust system/Charging W 06-09-07 D 2011 Removing and installing the exhaust gas return pipe Standard tools: – Special bit, 70 mm long 9120 6 Removing the exhaust gas return pipe ● Unscrew screw (1). ● Remove safety cover (2). ● Unlock cable plug (3) and remove. 1 2 3 © 46964-0 ● Pull out pipe holder (1). 1 © 46937-0 © 01/2009 1/8 OBJ_DOKU-23499-001.
PAGE 146
Exhaust system/Charging W 06-09-07 D 2011 ● Unscrew hollow screws (1). ● Remove pipe (2). 3 ● Remove sealing rings (3). 1 3 2 1 6 © 46935-0 ● Unscrew hollow screw (1). ● Remove sealing rings (2). ● Unscrew hollow screw (3). ● Remove sealing rings (4). ● Remove pipe (5). 2 1 5 3 4 © 46938-0 ● Unscrew screws (1). 1 © 46939-0 © 01/2009 2/8 OBJ_DOKU-23499-001.
PAGE 147
Exhaust system/Charging W 06-09-07 D 2011 ● Remove gasket (1). 1 6 © 46940-0 ● Unscrew screws (1). ● Remove the exhaust return pipe. 1 1 1 1 © 46961-0 ● Remove gasket (1). 1 © 46962-0 © 01/2009 3/8 OBJ_DOKU-23499-001.
PAGE 148
Exhaust system/Charging W 06-09-07 D 2011 ● Unscrew screws (3). ● Remove exhaust gas return valve (2). ● Remove gasket (1). 1 2 3 3 6 © 46960-0 ● Visually inspect the components. © 46963-0 Installing the exhaust gas return pipe ● Clean all sealing surfaces. ● Mount gasket (1). 1 ● Mount exhaust gas return valve (2). ● Fasten screws (3). 2 ● Tighten screws (3). 20 Nm 3 3 © 46960-0 © 01/2009 4/8 OBJ_DOKU-23499-001.
PAGE 149
Exhaust system/Charging W 06-09-07 D 2011 ● Clean all sealing surfaces. ● Mount gasket (1). 1 6 © 46962-0 ● Install the exhaust gas return pipe. ● Tighten screws (1). ● Tighten screws (1). 8.5 Nm 1 1 1 1 © 46961-0 ● Clean sealing surfaces. ● Mount gasket (1). ● Mount exhaust gas collection pipe (2). ● Fasten screws (3). ● Tighten screws (3). 1 20 Nm 3 3 2 © 46939-1 © 01/2009 5/8 OBJ_DOKU-23499-001.
PAGE 150
Exhaust system/Charging W 06-09-07 D 2011 ● Insert pipe (5). ● Mount new sealing rings (4). ● Screw on hollow screw (3). ● Mount sealing rings (2). ● Screw on hollow screw (1). 2 ● Tighten hollow screw (1). 1 29 Nm ● Tighten hollow screw (3). 12 Nm 5 3 4 6 © 46938-0 ● Insert pipe (1). ● Mount sealing rings (2). 2 ● Screw on hollow screw (3). ● Mount new sealing rings (4). 3 ● Turn in hollow screw (5). ● Tighten hollow screw (3). 29 Nm ● Tighten hollow screw (5).
PAGE 151
Exhaust system/Charging W 06-09-07 D 2011 ● Plug in the cable plug (3). ● Mount the safety cover (2). ● Fasten screw (1). ● Tighten screw (1). 8 Nm 1 3 2 6 © 46964-0 © 01/2009 7/8 OBJ_DOKU-23499-001.
PAGE 152
Exhaust system/Charging W 06-09-07 D 2011 Technical Data Tightening specifications ID no.
PAGE 153
Exhaust system/Charging W 06-09-08 D 2011 Removing and installing the exhaust gas collection pipe (Exhaust gas recirculation) Standard tools: – Cleaning brush – W 06-01-05 – W 06-09-07 8167 6 Remove exhaust gas collection pipe ● Remove the exhaust pipe. W 06-01-05 ● Remove the exhaust return pipe. W 06-09-07 1 ● Unscrew screws (1). © 46946-0 ● Unscrew screws (1). Note different screw lengths. 2 3 ● Remove throttle (2). ● Remove gaskets (3). 1 Note installation position.
PAGE 154
Exhaust system/Charging W 06-09-08 D 2011 ● Remove gaskets (1). 1 6 © 46948-0 ● Clean exhaust channels (1) with cleaning brush (2). ● Clean all sealing surfaces. 1 1 2 1 © 46949-0 Install exhaust gas collection pipe ● Check that mounting lugs (1) are sufficiently pre-tensioned. 1 1 © 46950-0 © 01/2009 2/6 OBJ_DOKU-23500-001.
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Exhaust system/Charging W 06-09-08 D 2011 ● Mount gasket (1). Make sure that the installation site of the mounting lugs (2) is in perfect condition. 2 2 6 1 © 46951-0 ● Mount new gaskets (3). ● Mount new throttle (2). Note installation position. 2 The marking (arrow) on the throttle is dependent on the engine version. ● Insert exhaust gas collection pipe. 3 1 ● Turn in new screws (1). © 46952-1 ● Turn in new screws (1). ● Tighten new screws (1).
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Exhaust system/Charging W 06-09-08 D 2011 ● Tighten new screws (1). 55 Nm ● Install the exhaust gas return pipe. W 06-09-07 ● Install the exhaust pipe. W 06-01-05 1 6 © 46947-0 © 01/2009 4/6 OBJ_DOKU-23500-001.
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Exhaust system/Charging W 06-09-08 D 2011 Technical Data Tightening specifications ID no. Name A06 073 Exhaust gas collection pipe (exhaust gas return) on cylinder head Screw type Notes / Remark Torx M10x25-10.9 Torx Use new screws. M10x30-10.9 Torx M10x45-10.9 Value 55 Nm For the tightening procedure according to torque using a torque wrench, a maximum variation of the tightening torque of +/- 10% is permissible. 6 © 01/2009 5/6 OBJ_DOKU-23500-001.
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Exhaust system/Charging W 06-09-09 D 2011 Removing and installing the sensor (Exhaust gas recirculation) Attention! Standard tools Special tools: – Special bit, 70 mm long If the sensor (exhaust gas return) is exchanged/adjusted, the engine must be set on the engine test bench. 9120 6 Remove sensor ● Disconnect the battery. ● Unscrew screw (1) with special bit. ● Remove safety cover (2). ● Unlock cable plug (3) and remove. 1 2 3 © 46964-1 ● Unscrew screws (1).
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Exhaust system/Charging W 06-09-09 D 2011 ● Unscrew screw (1). ● Remove sensor (2). ● Clean sealing surfaces. 1 2 6 © 46974-0 ● Remove sealing ring (1). ● Visually inspect the components. 1 © 46975-0 Install sensor ● Insert new sealing ring (1). Ensure that the installation location of the sealing ring is free from faults. 1 © 46975-1 © 01/2009 2/4 OBJ_DOKU-23501-001.
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Exhaust system/Charging W 06-09-09 D 2011 ● Mount sensor (2). Ensure that the installation location is free from faults. ● Fasten screw (1). 1 2 6 © 46974-0 ● Mount fuel filter console (1). ● Tighten screws (2). ● Tighten screws (2). 21 Nm 3 ● Tighten screw (3). 1 21 Nm 2 © 46973-1 ● Plug in the cable plug (3). ● Mount the safety cover (2). ● Fasten screw (1). ● Tighten screw (1) with special bit. 8 Nm ● Connect the battery. 1 2 3 © 46964-1 © 01/2009 3/4 OBJ_DOKU-23501-001.
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Exhaust system/Charging W 06-09-09 D 2011 Technical Data Tightening specifications ID no. Name A06 075 Safety cover on sensor housing (exhaust gas return) Screw type Locking screw Torx-Plus 30IPR Sensor exhaust gas return on crankcase A07 087 Fuel filter console to crankcase A06 076 Notes / Remark Value 8 Nm 21 Nm 21 Nm For the tightening procedure according to torque using a torque wrench, a maximum variation of the tightening torque of +/- 10% is permissible.
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Exhaust system/Charging W 06-09-10 D 2011 Removing and installing the magnet clip (Exhaust gas recirculation) Standard tools – W 06-09-09 – W 07-04-01 6 Remove magnet clip ● Disconnect the battery. ● Remove sensor of exhaust gas return. W 06-09-09 ● Remove fuel injector 3rd cylinder. W 07-04-01 © 47230-1 ● Insert clean rags (1) under the control linkage. ● Move the control linkage in the direction of the arrow. 2 ● Hold on to the control linkage. 2 ● Bend the retaining tab (2).
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Exhaust system/Charging W 06-09-10 D 2011 ● Hold on to the control linkage. ● Pull off magnet clip (1) in the direction of the arrow. Attention! Make sure no parts fall into the crankcase! Pay attention to utmost cleanliness. 1 6 © 46971-0 Install magnet clip ● Insert clean rags (1) under the control linkage. ● Position control linkage. ● Hold on to the control linkage. ● Push new magnet clip (2) onto the control linkage.
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Exhaust system/Charging W 06-09-10 D 2011 ● Install fuel injector 3rd cylinder. W 07-04-01 ● Install sensor of exhaust gas return. W 06-09-09 ● Connect the battery. 6 © 47230-0 © 01/2009 3/4 OBJ_DOKU-23502-001.
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D 2011 TD 2011 Fuel system W 07-02-07 Removing and installing the lifting magnet (Start amount release) Standard tools: – Plier insert 8027 Special tools: – Disassembly tool 110901 Collect leaking operating substances in suitable vessels and dispose of according to regulations. 6 Remove lifting magnet ● Pull out cable plug (1). 1 © 47128-0 ● Unscrew lifting magnet (1) with plier insert. Note direction of terminal. 1 © 39663-1 © 01/2009 1/4 OBJ_DOKU-23503-001.
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Fuel system W 07-02-07 D 2011 TD 2011 ● Remove the O-ring (1) with the disassembly tool. ● Visually inspect the components. 1 6 © 47392-0 Install lifting magnet ● Insert new O-ring (1). 1 © 47392-0 ● Clean all sealing surfaces. ● Insert lifting magnet (1). 1 © 47393-0 © 01/2009 2/4 OBJ_DOKU-23503-001.
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D 2011 TD 2011 Fuel system W 07-02-07 ● Tighten lifting magnet (1) with plier insert. 10 Nm 1 Note direction of terminal. 6 © 39664-1 ● Plug in the cable plug (1). 1 © 47128-0 © 01/2009 3/4 OBJ_DOKU-23503-001.
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Fuel system W 07-02-07 D 2011 TD 2011 Technical Data Tightening specifications ID no. Name Screw type Lifting magnet (start amount release) A05 065 on front cover Notes / Remark Value 10 Nm For the tightening procedure according to torque using a torque wrench, a maximum variation of the tightening torque of +/- 10% is permissible. 6 © 01/2009 4/4 OBJ_DOKU-23503-001.
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D 2011 TD 2011 Fuel system W 07-03-01 Renewing the injection lines Standard tools: – Dog wrench 8018 Special tools: – Plugs/caps 170160 – W 08-08-02 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. Remove residue paint and particles of dirt before removing. Clean the respective affected parts carefully. Blow damp areas dry with compressed air.
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Fuel system W 07-03-01 D 2011 TD 2011 ● Unscrew lock nuts (1) with dog wrench. ● Remove injection line. Lay out components in the order in which they should be installed. Note assignment! 1 1 6 © 39482-1 ● Visually inspect the components. © 47340-0 Installing injection pipes ● Mount new injection pipe. ● Screw on union nuts (1). Attention! Install injection line without tension. Note installation position. 1 © 47339-0 © 01/2009 2/4 OBJ_DOKU-23504-001.
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D 2011 TD 2011 Fuel system W 07-03-01 ● Tighten union nuts (1) with claw spanner. 25 Nm 1 1 6 © 39482-1 – D 2011 i ● Install the lubricating oil cooler. W 08-08-02 © 47338-0 © 01/2009 3/4 OBJ_DOKU-23504-001.
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Fuel system W 07-03-01 D 2011 TD 2011 Technical Data Tightening specifications ID no. Name Screw type Injection line on fuel injector / injection A07 003 M12x1.5 pump Notes / Remark Value 25 Nm For the tightening procedure according to torque using a torque wrench, a maximum variation of the tightening torque of +/- 10% is permissible. 6 © 01/2009 4/4 OBJ_DOKU-23504-001.
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D 2011 TD 2011 Fuel system W 07-04-01 Removing and installing the fuel injector pump Standard tools Special tools: – Ajustable bolt – Rig pin – Test template – Special pliers – Disassembly tool – Plugs/caps – – – – – – 100710 101100 103040 103220 110901 170160 W 07-03-01 W 07-06-03 W 07-06-01 W 07-10-06 W 11-00-03 W 12-01-04 Danger! Wait 30 seconds after switching off the engine before working on the fuel system.
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Fuel system W 07-04-01 D 2011 TD 2011 ● Remove injection lines. W 07-03-01 ● Remove fuel pipes. W 07-10-06 ● Remove lifting magnet (engine shutdown). W 11-00-03 6 © 47229-0 ● Turn crankshaft until the valves of the respective cylinder overlap. Arrangement of the inlet and exhaust valves. IN = inlet valve EX = exhaust valve Valve overlap means: The inlet valve starts opening,exhaust valve closes.
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D 2011 TD 2011 Fuel system W 07-04-01 The cam (1) for the actuation of the injection pump of the corresonding cylinder must be located on the base circle. 1 6 © 47356-0 ● Loosen nuts (1) alternately. Loosen nuts evenly to avoid tension on the injection pump. ● Unscrew nuts (1). ● Remove washers. 2 ● Remove fuel injector pump(2). Lay out components in the order in which they should be installed. Note assignment! 1 © 47230-0 ● Remove shim (1).
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Fuel system W 07-04-01 D 2011 TD 2011 ● Pull out roller tappet (1) with special pliers. Attention! Do not damage the roller tappet! Lay out components in the order in which they should be installed. Note assignment! 1 6 © 47232-0 ● Remove the O-ring (1) with the disassembly tool. ● Visually inspect the components. 1 © 47233-0 ● Unscrew locking screw (1). ● Remove sealing ring. 1 © 47234-0 © 01/2009 4/12 OBJ_DOKU-23505-001.
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D 2011 TD 2011 Fuel system W 07-04-01 ● Bring control linkage into the middle position. ● Knock in the adjustable bolt (1) to the stop. Ignition off. Stop magnet free. 1 6 © 39115-1 Installing the fuel injector pump Note assignment of injection pump/roller tappet/shim to the cam. © 47235-0 ● Turn camshaft until the cam for the injection pump is on the base circle (arrow). © 46048-0 © 01/2009 5/12 OBJ_DOKU-23505-001.
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Fuel system W 07-04-01 D 2011 TD 2011 ● Oil the roller tappet lightly. ● Insert roller tappet with special pliers. Note assignment! The pilot pin (1) must lock in groove (2). 2 1 6 © 47236-0 ● Oil the locating hole lightly. ● Determining the thickness of the shim. W 07-06-03 © 47237-0 ● Select shim using table. P07 21 ● Check thickness of the shim with test template. The reference line must lie centrally to the round recess (dimension a). a © 47357-1 © 01/2009 6/12 OBJ_DOKU-23505-001.
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D 2011 TD 2011 Fuel system W 07-04-01 ● Position shim. Note assignment! The bolt (1) must face in the direction of the cylinder head. 1 6 © 47238-0 ● Insert new O-ring (1). 1 © 47233-0 ● Pull out locking pin (1). Pay attention to sealing. 1 © 47239-0 © 01/2009 7/12 OBJ_DOKU-23505-001.
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Fuel system W 07-04-01 D 2011 TD 2011 ● Insert rig pin (1). Do not press in rig pin. 1 6 © 47240-0 ● Press in rig pin (1) slightly. ● Turn adjusting sleeve (2) back and forth. Turn the adjusting sleeve until the rig pin you can feel and hear it lock into the punch mark (3). 1 2 3 © 47241-0 ● Coat the O-ring with fitting compound. 1 © 47233-0 © 01/2009 8/12 OBJ_DOKU-23505-001.
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D 2011 TD 2011 Fuel system W 07-04-01 ● Insert injection pump (1). Note assignment! ● Tighten nuts (2) alternately. 1 21 Nm 2 6 © 47252-0 ● Loosen clamping bar (arrow). ● Pull out rig pin (1). 1 © 47242-0 ● Press in the locking pin (1) to the stop. 1 © 47243-0 © 01/2009 9/12 OBJ_DOKU-23505-001.
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Fuel system W 07-04-01 D 2011 TD 2011 ● Unscrew adjustable bolt (1). 1 6 © 47244-0 ● Mount new sealing ring. ● Tighten screw plug (1). 18 Nm ● Check start of injection. W 07-06-01 1 © 47245-0 ● Install lifting magnet (engine shutdown). W 11-00-03 ● Install fuel pipes. W 07-10-06 – D 2011, D 2011 i ● Install injection lines. W 07-03-01 – D 2011 i ● Install V-belt pulley. W 12-01-04 © 47229-0 © 01/2009 10/12 OBJ_DOKU-23505-001.
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D 2011 TD 2011 Fuel system W 07-04-01 ● Mount new gasket. ● Mount cylinder head cover (2). ● Tighten all screws (1). 8.5 Nm 1 2 6 © 47011-0 © 01/2009 11/12 OBJ_DOKU-23505-001.
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Fuel system W 07-04-01 D 2011 TD 2011 Technical Data Testing and setting data ID no.
PAGE 187
D 2011 TD 2011 Fuel system W 07-06-01 Check start of injection Standard tools Special tools: – Ajustable bolt – Degree scale – Adapter – Pointer – High-pressure hand pump – Supply tank – Plugs/caps – – – – 100700 101020 101030 101300 101500 101510 170160 W 07-03-01 W 07-10-06 W 11-00-03 W 12-01-04 D 2011i 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.
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Fuel system W 07-06-01 D 2011 TD 2011 – D 2011i ● Remove V-belt pulley. W 12-01-04 L03i ● Unscrew locking screw (1). ● Remove sealing ring. 1 6 © 47266-0 ● Insert adjustable bolt (1). 1 © 47267-0 ● Press adjustable bolt in lightly in direction of arrow and hold. ● Turn crankshaft slowly in direction of engine until the adjustable bolt engages with the bore of the camshaft. © 47268-0 © 01/2009 2/12 OBJ_DOKU-23506-001.
PAGE 189
D 2011 TD 2011 Fuel system W 07-06-01 ● Knock in the adjustable bolt (1) to the stop. 1 6 © 47269-0 ● Unscrew locking screw (1). ● Remove sealing ring. 1 © 47270-0 ● Insert adjustable bolt (1). 1 © 47296-0 © 01/2009 3/12 OBJ_DOKU-23506-001.
PAGE 190
Fuel system W 07-06-01 D 2011 TD 2011 ● Knock in the adjustable bolt (1) to the stop. ● Turn crankshaft carefully against the adjustable bolt. The cylinder on the front cover is now located in the ignition UDC. 1 6 © 47271-0 ● Loosen screw (1). ● Mount pointer with holding device (2). ● Tighten screw (1). 21 Nm 1 2 © 47622-0 ● Mount adapter (1). ● Tighten screws (2). ● Screw on degree scale (3). 1 2 3 © 01/2009 4/12 © 47623-0 OBJ_DOKU-23506-001.
PAGE 191
D 2011 TD 2011 Fuel system W 07-06-01 ● Bring degree scale into line with pointer. ● Set the pointer (1) in line with the “0°“ marking. ● Fasten degree scale. ● Fasten pointer. 1 6 © 47635-3 ● Unscrew locking screw (1). ● Remove sealing ring. 1 © 00000-0 ● Bring control linkage into the middle position. ● Knock in the adjustable bolt (1) to the stop. Ignition off. Stop magnet free. 1 © 00000-0 © 01/2009 5/12 OBJ_DOKU-23506-001.
PAGE 192
Fuel system W 07-06-01 D 2011 TD 2011 ● Mount overflow pipe (1). ● Connect hose (2) to overflow pipe. ● Connect hose (2) to supply tank. ● Connect pressure pipe (3) to fuel injector. ● Connect intake pipe (4) to supply tank. ● Fill supply tank with clean fuel. 1 2 3 6 4 © 39191-2 ● Mount locking screw (1). Do not tighten locking screw. 1 © 39192-1 ● Unscrew adjustable bolt to the camshaft and crankshaft lock. ● Turn crankshaft carefully approx.
PAGE 193
D 2011 TD 2011 Fuel system W 07-06-01 ● Bleed the suction chamber of the injection pump. ● Activate high-pressure hand pump until fuel emerges at the locking screw (1). 1 ● Tighten screw plug (1). 45 Nm 6 © 39192-1 ● Actuate the high-pressure hand pump constantly. The fuel must flow evenly out of the overflow pipe. ● Turn the crankshaft slowly and evenly in the direction of the arrow (engine direction of rotation) until the fuel flow turns to drops.
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Fuel system W 07-06-01 D 2011 TD 2011 ● Unscrew adjustable bolt (1). 1 6 © 00000-0 ● Mount new sealing ring. ● Tighten screw plug (1). 18 Nm 1 © 00000-0 ● Loosen screw (1). ● Remove pointer with holding device (2). ● Tighten screw (1). 21 Nm 1 2 © 47622-0 © 01/2009 8/12 OBJ_DOKU-23506-001.
PAGE 195
D 2011 TD 2011 Fuel system W 07-06-01 ● Remove intake pipe (4). ● Remove pressure pipe (3). ● Remove hose (2). ● Remove overflow pipe (1). ● Remove the high-pressure hand pump. 1 2 3 4 6 © 39191-2 ● Unscrew locking screw (1). ● Remove sealing ring. 1 © 39192-1 ● Unscrew degree scale (1). ● Unscrew screws (2). ● Remove adapter (3). 3 2 1 © 01/2009 9/12 © 47623-1 OBJ_DOKU-23506-001.
PAGE 196
Fuel system W 07-06-01 D 2011 TD 2011 ● Insert new sealing ring. ● Tighten screw plug (1). 18 Nm 1 6 © 47266-0 ● Insert new sealing ring. ● Tighten screw plug (1). 18 Nm – D 2011 i ● Install V-belt pulley. 1 W 12-01-04 © 47270-0 ● Install injection lines. W 07-03-01 ● Install fuel pipes. W 07-10-06 ● Install lifting magnet (shut-off magnet). W 11-00-03 © 47032-0 © 01/2009 10/12 OBJ_DOKU-23506-001.
PAGE 197
D 2011 TD 2011 Fuel system W 07-06-01 Technical Data Tightening specifications ID no. Name A03 003 Locking screw on crankcase Screw type M10x1 A03 004 Locking screw on crankcase A03 020 Front cover on crankcase A07 071 Locking screw on injection pump Notes / Remark Adapter for adjustable bolt on camshaft lock/ crankshaft lock. Replace sealing ring. Adapter for adjustable bolt on control linkage lock. Replace sealing ring.
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D 2011 TD 2011 Fuel system W 07-06-03 Calculating the thickness of shim Standard tools: – Depth measuring screw – W 07-04-01 8170 All contact and measuring surfaces must be absolutely clean to rule out measuring errors! The following work process should be carried out on each injection pump if necessary. 6 ● Remove injection pump and shim. ● Removal and installation of roller tappet, visual inspection. W 07-04-01 © 47561-1 ● Mount probe for measuring range 50 to 75 mm on depth measuring screw.
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Fuel system W 07-06-03 D 2011 TD 2011 ● Place the depth measuring screw on the contact surface of the crankcase and keep it pressed against the stop. ● Turn the depth measuring screw until the probe is touching the roller tappet. 6 © 39184-2 ● To determine the total depth dimension, in the case of hydro-roller tappets, the working piston (1) in the roller tappet must be pressed down until touching (arrow) (approx. 1 mm) by turning the depth measuring screw further.
PAGE 201
D 2011 TD 2011 Fuel system W 07-06-03 ● Read and note installation dimension "X" from the rating plate of the respective injection pump. The installation dimension "X" serves to calculate the shim/gasket. X Do not measure on the removed injection pump. The exact installation dimension "X" is specified on the injection pump's rating plate. Example: 6088 Installation dimension "X" = 60.88 mm 6 © 47494-0 ● Calculate thickness of the shim "Ss".
PAGE 202
Fuel system W 07-06-03 D 2011 TD 2011 Technical Data Testing and setting data ID no.
PAGE 203
D 2011 TD 2011 Fuel system W 07-07-01 Removing and installing the fuel injectors Standard tools: – Assembly pliers 8024 Special tools: – Puller – Extraction tool – Slide hammer – Plugs/caps 110090 120660 150800 170160 – W 07-03-01 – W 07-07-02 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. Remove residue paint and particles of dirt before removing.
PAGE 204
Fuel system W 07-07-01 D 2011 TD 2011 ● Unscrew screw (1). ● Remove clamping shoe (2). 1 2 6 © 47369-0 ● Pull out fuel injector (1) and sealing ring (arrow). Lay out components in the order in which they should be installed. Note cylinder assignment. 1 © 47345-0 Removing stuck fuel injectors ● Assembly sliding hammer (1) and puller (2). ● Tighten lock nut (3). 1 2 3 © 40958-0 © 01/2009 2/6 OBJ_DOKU-23508-001.
PAGE 205
D 2011 TD 2011 Fuel system W 07-07-01 ● Mount sliding hammer on fuel injector. ● Screw on lock nut (1). ● Pull out stuck fuel injector. 1 6 © 47346-0 ● Grip a tight sealing ring (1) with the assembly pliers (2) and pull off, turning slightly. Attention! Do not damage the nozzle tip! 1 2 © 43303-0 Removing a tightly fixed sealing ring from the cylinder head ● Insert extraction device (1). The holders (arrow) must sit in the bore of the sealing ring. 1 © 47347-0 © 01/2009 3/6 OBJ_DOKU-23508-001.
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Fuel system W 07-07-01 D 2011 TD 2011 ● Turn in the spindle. The sealing ring must be fixed on the puller. Hold puller on hexagon. ● Mount adapter (1) and slide hammer (2) on extraction device. 2 ● Remove tight sealing ring. 1 6 © 47348-0 ● Visually inspect the components. ● Check the fuel injector. W 07-07-02 © 47349-0 Installing the fuel injector ● Mount new sealing ring (1) on fuel injector. © 47351-0 © 01/2009 4/6 OBJ_DOKU-23508-001.
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D 2011 TD 2011 Fuel system W 07-07-01 ● Insert fuel injector. ● Mount clamping shoe. Note installation position of the clamping shoe. ● Fasten screws. 6 © 39488-1 ● Tighten screw (1). 21 Nm 1 © 47370-0 ● Install injection lines. W 07-03-01 © 47229-0 © 01/2009 5/6 OBJ_DOKU-23508-001.
PAGE 208
Fuel system W 07-07-01 D 2011 TD 2011 Technical Data Tightening specifications ID no. Name A07 001 Fuel injector on cylinder head Screw type Notes / Remark Value 21 Nm For the tightening procedure according to torque using a torque wrench, a maximum variation of the tightening torque of +/- 10% is permissible. 6 © 01/2009 6/6 OBJ_DOKU-23508-001.
PAGE 209
Fuel system W 07-08-01 TD 2011 Removing and installing the lifting magnet (charge air pressure-dependent full load stop) Standard tools: – Plier insert 8027 Special tools: – Disassembly tool 110901 6 Remove lifting magnet – TD 2011 i 2 ● Unscrew screws (1). ● Remove air guidance cowling (2). 1 © 47358-0 ● Pull out cable plug. 1 ● Unscrew lifting magnet (1) with plier insert. © 47660-0 © 01/2009 1/4 OBJ_DOKU-23510-001.
PAGE 210
Fuel system W 07-08-01 TD 2011 ● Remove the O-ring with the disassembly tool. ● Visually inspect the components. 6 © 47647-0 Install lifting magnet ● Mount new O-ring. ● Insert lifting magnet (1). 1 © 47661-0 ● Tighten lifting magnet (1) with plier insert. 1 10 Nm © 47660-0 © 01/2009 2/4 OBJ_DOKU-23510-001.
PAGE 211
Fuel system W 07-08-01 TD 2011 – TD 2011 i ● Mount air guidance cowling (1). Air guidance cowling must sit under the stand plate and rubber profile (arrow). 1 6 © 47358-0 ● Tighten screws (1). 21 Nm 1 1 © 47358-1 © 01/2009 3/4 OBJ_DOKU-23510-001.
PAGE 212
Fuel system W 07-08-01 TD 2011 Technical Data Tightening specifications ID no. Name A06 094 Lifting magnet on fuel filter console Air guidance cowling on blower A09 087 jacket / stand plate Screw type Notes / Remark Renew O-ring Value 10 Nm 21 Nm For the tightening procedure according to torque using a torque wrench, a maximum variation of the tightening torque of +/- 10% is permissible. 6 © 01/2009 4/4 OBJ_DOKU-23510-001.
PAGE 213
Fuel system W 07-08-02 TD 2011 Installing and removing charge air pressure-dependent full load stop Standard tools: – Plier insert 8027 Special tools: – Disassembly tool 110901 – W 07-10-08 6 Removing the charge air-pressure dependent full load stop ● Remove fuel filter console. W 07-10-08 ● Unscrew screws (1). 1 © 39385-2 ● Remove cover (1). ● Remove diaphragms (2). ● Remove spring (3). 3 1 2 © 39386-2 © 01/2009 1/4 OBJ_DOKU-23511-001.
PAGE 214
Fuel system W 07-08-02 TD 2011 ● Unscrew lifting magnet (1) with plier insert. 1 6 © 39387-1 ● Remove the O-ring with the disassembly tool. ● Visually inspect the components. © 47647-0 Installing the charge air-pressure dependent full load stop ● Clean sealing surfaces. 1 ● Mount new O-ring. ● Tighten lifting magnet (1) with plier insert. 10 Nm © 39388-1 © 01/2009 2/4 OBJ_DOKU-23511-001.
PAGE 215
Fuel system W 07-08-02 TD 2011 ● Insert spring (1). ● Insert diaphragm (2) and cap (3). Attention! Note installation position. 3 2 1 6 © 39389-1 ● Tighten screws (1). 8 Nm ● Install the fuel filter console. W 07-10-08 1 © 39385-2 © 01/2009 3/4 OBJ_DOKU-23511-001.
PAGE 216
Fuel system W 07-08-02 TD 2011 Technical Data Tightening specifications ID no. Name Screw type A06 094 Lifting magnet on fuel filter console Cap on charge air-dependent full load A07 096 stop Notes / Remark Renew O-ring Value 10 Nm 8 Nm For the tightening procedure according to torque using a torque wrench, a maximum variation of the tightening torque of +/- 10% is permissible. 6 © 01/2009 4/4 OBJ_DOKU-23511-001.
PAGE 217
D 2011 TD 2011 Fuel system W 07-10-06 Removing and installing fuel pipes Standard tools: – Hose clip pliers – Torx tool set 8011 8189 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. Remove residue paint and particles of dirt before removing. Clean the respective affected parts carefully. Blow damp areas dry with compressed air.
PAGE 218
Fuel system W 07-10-06 D 2011 TD 2011 ● Unscrew screws (1). ● Remove stand plate (2). 2 1 1 6 © 47359-0 – D 2011, TD 2011 ● Loosen hose clip (1). ● Pull off fuel pipe (2). ● Pull off protective hose (3). Collect draining fuel and dispose of according to regulations. 1 2 3 © 47360-1 ● Loosen hose clip (1). ● Pull off fuel pipe (2). Collect draining fuel and dispose of according to regulations. 1 2 © 47361-0 © 01/2009 2/8 OBJ_DOKU-23512-001.
PAGE 219
D 2011 TD 2011 Fuel system W 07-10-06 ● Unscrew hollow screws (1). ● Remove fuel pipe (2). ● Remove sealing rings. 2 1 1 6 © 47362-0 ● Unscrew hollow screws (1). ● Remove fuel return line (2). Remove fuel return line in the direction of the flywheel. 1 ● Remove sealing rings. 1 2 © 47364-0 ● Visually inspect the components. © 47365-0 © 01/2009 3/8 OBJ_DOKU-23512-001.
PAGE 220
Fuel system W 07-10-06 D 2011 TD 2011 Installing fuel pipes ● Mount new sealing rings. ● Mount fuel return pipe (1). 2 ● Tighten hollow screws (2). 29 Nm 2 1 6 © 47364-1 ● Mount new sealing rings. ● Mount fuel pipe (2). Position hose connection (arrow) in rubber profile. 2 ● Tighten hollow screws (1). 29 Nm 1 1 © 47371-0 ● Mount fuel hose (2). Lay hose without contact. Ensure that the installation location is free from faults. 1 ● Mount new hose clip (1).
PAGE 221
D 2011 TD 2011 Fuel system W 07-10-06 ● Slip protective hose (3) over with mounting compound. Lay hose without contact. Ensure that the installation location is free from faults. 1 ● Mount fuel hose (2). ● Mount new hose clip (1). 2 3 6 © 47360-1 ● Position protective hose, dimension X. 20 mm X © 47367-0 ● Fix the hose clip (1) with the hose clip pliers. Ensure that the installation location is free from faults. 1 © 47368-0 © 01/2009 5/8 OBJ_DOKU-23512-001.
PAGE 222
Fuel system W 07-10-06 D 2011 TD 2011 – D 2011 i, TD 2011 i 2 ● Install stand plate (2). ● Tighten screws (1). 1 1 6 © 47359-0 ● Position stand plate (1). Lug (2) must lie in the hole. 1 2 © 47373-0 ● Tighten screws (1). 21 Nm ● Tighten screws (2). 21 Nm 2 1 © 47375-0 © 01/2009 6/8 OBJ_DOKU-23512-001.
PAGE 223
D 2011 TD 2011 Fuel system W 07-10-06 ● Feed hose pipe (1) through the hole (2). 1 2 6 © 47374-0 ● Mount air guidance cowling (1). Note installation position. Air guidance cowling must sit under the stand plate and rubber profile (arrow). 1 © 39490-2 ● Tighten screws (1). 21 Nm 1 © 47372-0 © 01/2009 7/8 OBJ_DOKU-23512-001.
PAGE 224
Fuel system W 07-10-06 D 2011 TD 2011 Technical Data Tightening specifications ID no.
PAGE 225
Fuel system W 07-10-08 D 2011 Removing and installing the fuel filter console Standard tools: – Hose clip pliers – Torx tool set 8011 8189 Special tools: – Special wrench – Plugs/caps 170050 170160 – Operation manual Danger! Wait 30 seconds after switching off the engine before working on the fuel system. – Fitting compound DEUTZ AP1908 Attention! Pay attention to utmost cleanliness when working on the fuel system. Remove residue paint and particles of dirt before removing.
PAGE 226
Fuel system W 07-10-08 D 2011 ● Loosen hose clips (1). Collect draining fuel and dispose of according to regulations. ● Pull off fuel hoses. ● Pull off protective hoses (2). 1 2 6 © 47386-0 ● Unscrew screws (1). ● Remove fuel filter console (2). 1 2 © 47387-0 ● Visually inspect the components. © 47388-0 © 01/2009 2/6 OBJ_DOKU-23513-001.
PAGE 227
Fuel system W 07-10-08 D 2011 Installing the fuel filter console ● Install the fuel filter console (2). 1 ● Tighten screws (1). 21 Nm 2 6 © 47387-0 ● Slip protective hoses (2) over with mounting compound. Note assignment! Lay hoses without contact. ● Install fuel hoses. 1 ● Mount new hose clips (1). 2 © 47386-0 ● Position protective hoses, dimension X. 20 mm X X © 47389-0 © 01/2009 3/6 OBJ_DOKU-23513-001.
PAGE 228
Fuel system W 07-10-08 D 2011 ● Fasten hose clips (1) with hose clip pliers. Ensure that the installation location is free from faults. 1 6 © 47390-0 ● Clean sealing surfaces. ● Lightly oil gasket on new fuel filter. ● Screw on fuel filter by hand. The seal must fit evenly. ● Lightly oil gasket on new fuel filter. ● Tighten the fuel filter according to the instruction manual. Operation manual © 47391-0 © 01/2009 4/6 OBJ_DOKU-23513-001.
PAGE 229
Fuel system W 07-10-08 D 2011 Technical Data Tightening specifications ID no. Name A07 087 Fuel filter console to crankcase Screw type Notes / Remark Value 21 Nm For the tightening procedure according to torque using a torque wrench, a maximum variation of the tightening torque of +/- 10% is permissible. 6 © 01/2009 5/6 OBJ_DOKU-23513-001.
PAGE 231
Fuel system W 07-10-08 TD 2011 Removing and installing the fuel filter console Standard tools: – Hose clip pliers – Torx tool set 8011 8189 Special tools: – Disassembly tool – Special wrench – Plugs/caps 110901 170050 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. Remove residue paint and particles of dirt before removing. Clean the respective affected parts carefully.
PAGE 232
Fuel system W 07-10-08 TD 2011 – TD 2011 ● Loosen hose clips (1) with hose clip pliers. 2 Collect draining fuel and dispose of according to regulations. 1 ● Pull off fuel hoses. ● Pull off hose pipe (2). 6 1 © 47662-0 ● Unscrew screws (1). ● Remove fuel filter console (2). 1 2 1 © 47663-0 ● Remove the O-ring (1) with the disassembly tool. 1 © 47595-0 © 01/2009 2/6 OBJ_DOKU-23514-001.
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Fuel system W 07-10-08 TD 2011 ● Visually inspect the components. 6 © 47596-0 Installing the fuel filter console ● Clean sealing surfaces. © 47664-0 ● Insert new sealing ring (1). 1 © 47598-0 © 01/2009 3/6 OBJ_DOKU-23514-001.
PAGE 234
Fuel system W 07-10-08 TD 2011 ● Install the fuel filter console (2). ● Tighten screws (1). 1 22 Nm 2 1 6 © 47663-0 Note assignment! Lay hoses without contact. 2 ● Install fuel hoses. 1 ● Mount new hose clips (1). ● Fasten hose clips (1) with hose clip pliers. Ensure that the installation location is free from faults. ● Mount the hose pipe (2). 1 © 47662-0 ● Position protective hoses, dimension X. 20 mm X X © 47599-1 © 01/2009 4/6 OBJ_DOKU-23514-001.
PAGE 235
Fuel system W 07-10-08 TD 2011 – TD 2011 i ● Mount air guidance cowling (1). Air guidance cowling must sit under the stand plate and rubber profile (arrow). 1 6 © 47358-0 ● Tighten screws (1). 21 Nm 1 1 © 47358-1 © 01/2009 5/6 OBJ_DOKU-23514-001.
PAGE 236
Fuel system W 07-10-08 TD 2011 Technical Data Tightening specifications ID no. Name Fuel filter console/full load stop to A07 087 crankcase Air guidance cowling on blower A09 087 jacket / stand plate Screw type Torx, M8x50-8.8 Notes / Remark Value 22 Nm 21 Nm For the tightening procedure according to torque using a torque wrench, a maximum variation of the tightening torque of +/- 10% is permissible. 6 © 01/2009 6/6 OBJ_DOKU-23514-001.
PAGE 237
D 2011 TD 2011 Fuel system W 07-11-01 Removing and installing the fuel supply pump Standard tools: – Hose clip pliers 8011 Special tools: – Disassembly tool – Plugs/caps 110901 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. Remove residue paint and particles of dirt before removing. Clean the respective affected parts carefully. Blow damp areas dry with compressed air.
PAGE 238
Fuel system W 07-11-01 D 2011 TD 2011 ● Loosen hose clip (1). ● Pull off fuel pipe (2). ● Pull off protective hose (3). Collect draining fuel and dispose of according to regulations. 1 3 2 6 © 47395-1 ● Unscrew screws (1). ● Remove fuel supply pump (2). 2 1 © 47397-0 ● Remove the O-ring (1) with the disassembly tool. ● Visually inspect the components. 1 © 47397-0 © 01/2009 2/6 OBJ_DOKU-23515-001.
PAGE 239
D 2011 TD 2011 Fuel system W 07-11-01 Installing the fuel supply pump ● Turn the crankshaft until the eccentric of the camshafts is in the top dead centre (arrow). 6 © 47398-0 ● Insert new O-ring (1). ● Oil tappet (2) lightly with lubricating oil. 1 2 © 47176-0 ● Clean all sealing surfaces. ● Mount fuel supply pump. ● Press fuel supply pump centrally on the crankcase. ● Tighten screws (1). 21 Nm 1 © 47399-0 © 01/2009 3/6 OBJ_DOKU-23515-001.
PAGE 240
Fuel system W 07-11-01 D 2011 TD 2011 ● Slip protective hose (3) over with mounting compound. Lay hose without contact. ● Mount fuel hose (2). ● Mount new hose clip (1). 1 3 2 6 © 47400-1 ● Position protective hose, dimension X. 20 mm X © 47401-0 ● Fix the hose clip (1) with the hose clip pliers. Ensure that the installation location is free from faults. 1 © 47402-0 © 01/2009 4/6 OBJ_DOKU-23515-001.
PAGE 241
D 2011 TD 2011 Fuel system W 07-11-01 ● Insert oil dipstick (1). 1 6 © 47394-0 © 01/2009 5/6 OBJ_DOKU-23515-001.
PAGE 242
Fuel system W 07-11-01 D 2011 TD 2011 Technical Data Tightening specifications ID no. Name A07 024 Fuel supply pump on crankcase Screw type Notes / Remark Value 21 Nm For the tightening procedure according to torque using a torque wrench, a maximum variation of the tightening torque of +/- 10% is permissible. 6 © 01/2009 6/6 OBJ_DOKU-23515-001.
PAGE 243
D 2011 TD 2011 Lube oil system W 08-04-05 Removing and installing the lubricating oil pump Standard tools: – Torx tool set – W 04-04-12 8189 Collect leaking operating substances in suitable vessels and dispose of according to regulations. 6 Removing the lubricating oil pump ● Remove toothed belt and tensioning pulley. W 04-04-12 ● Pull out oil dipstick (1). 1 © 47403-0 ● Unscrew all screws (1). ● Remove lubricating oil pump (2). 1 2 © 47404-0 © 01/2009 1/4 OBJ_DOKU-23516-001.
PAGE 244
Lube oil system W 08-04-05 D 2011 TD 2011 ● Remove gasket (1). ● Visually inspect the components. 1 6 © 39496-1 Install the lubricating oil pump ● Clean all sealing surfaces. ● Mount new gasket (1). 1 © 39496-1 ● Make sure the clamping bushings (arrows) are in place. © 47405-0 © 01/2009 2/4 OBJ_DOKU-23516-001.
PAGE 245
D 2011 TD 2011 Lube oil system W 08-04-05 ● Centre the lubricating oil pump (1) with clamping pins (2). ● Mount lubricating oil pump. 2 1 © 47406-0 ● Tighten all screws (1). 21 Nm 1 © 47407-0 ● Insert oil dipstick (1). ● Install toothed belt and tensioning pulley. W 04-04-12 1 © 47403-0 © 01/2009 3/4 OBJ_DOKU-23516-001.
PAGE 246
Lube oil system W 08-04-05 D 2011 TD 2011 Technical Data Tightening specifications ID no. Name A08 010 Lubricating oil pump on crankcase Screw type Notes / Remark Value 21 Nm For the tightening procedure according to torque using a torque wrench, a maximum variation of the tightening torque of +/- 10% is permissible. 6 © 01/2009 4/4 OBJ_DOKU-23516-001.
PAGE 247
D 2011 TD 2011 Lube oil system W 08-04-06 Removing and installing the oil suction pipe Standard tools – W 08-04-07 – Packing compound DEUTZ DW 73 Collect leaking operating substances in suitable vessels and dispose of according to regulations. 6 Removing the oil suction pipe ● Remove lubricating oil pan. W 08-04-07 ● Unscrew screws (1). 2 ● Remove oil suction pipe (2). 1 © 47408-0 ● Visually inspect the components. ● Clean sealing surfaces. © 47409-0 © 01/2009 1/4 OBJ_DOKU-23517-001.
PAGE 248
Lube oil system W 08-04-06 D 2011 TD 2011 Installing the oil suction pipe ● Clean sealing surfaces. The sealing surfaces must be dry and free from grease and dirt. ● Apply packing compound (arrow). Sealing cord strength approx. 1.0 mm Attention! No packing compound must get into the oil channel (1)! 1 6 © 47342-0 ● Mount oil suction pipe (2). Note installation position. Do not displace the packing compound. ● Tighten screws (1). 2 21 Nm ● Install lubricating oil pan.
PAGE 249
D 2011 TD 2011 Lube oil system W 08-04-06 Technical Data Tightening specifications ID no. Name Screw type A08 015 Oil suction pipe on crankcase Notes / Remark Packing compound DW73 Value 21 Nm For the tightening procedure according to torque using a torque wrench, a maximum variation of the tightening torque of +/- 10% is permissible. 6 © 01/2009 3/4 OBJ_DOKU-23517-001.
PAGE 251
D 2011 TD 2011 Lube oil system W 08-04-07 Removing and installing the lubricating oil pan (metal sheet lubricating oil pan) Standard tools: – Torx tool set 8189 Special tools: – Separating tool 151500 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.
PAGE 252
Lube oil system W 08-04-07 D 2011 TD 2011 ● Unscrew screws (1). ● Remove washers. ● Remove the cover (2). 2 1 6 © 47412-0 ● Unscrew all screws (1). 1 © 47413-0 ● 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. 1 2 © 47414-0 © 01/2009 2/8 OBJ_DOKU-23518-001.
PAGE 253
D 2011 TD 2011 Lube oil system W 08-04-07 ● 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. 1 2 6 © 47415-0 Attention! Do not drive in separating tool in the area of the lubricating oil pump (1). X 1 © 47416-1 ● Lever out lubricating oil pan. ● Remove lubricating oil pan. ● Visually inspect the components.
PAGE 254
Lube oil system W 08-04-07 D 2011 TD 2011 ● Clean sealing surfaces. ● Scrape off sealing compound with separating tool. The sealing surfaces must be dry and free from grease and dirt. 6 © 47418-0 Installing the lubricating oil pan ● Apply packing compound (arrow). Sealing cord strength approx. 3 mm © 47363-0 ● Mount lubricating oil pan. ● Align lubricating oil pan to crankcase. Do not move the packing compound when mounting the lube oil tray. © 47419-0 © 01/2009 4/8 OBJ_DOKU-23518-001.
PAGE 255
D 2011 TD 2011 Lube oil system W 08-04-07 ● Oil the screws lightly. ● Fasten all screws (1). 1 6 © 47413-0 ● Tighten screws (arrows). © 34255-2 ● Tighten the screws according to the tightening sequence. 13 19 21 Nm 12 11 2 1 8 9 10 20 18 21 22 17 16 15 14 3 4 5 6 7 © 47485-0 © 01/2009 5/8 OBJ_DOKU-23518-001.
PAGE 256
Lube oil system W 08-04-07 D 2011 TD 2011 ● Mount cover (2). ● Mount washers. ● Tighten screws (1). 9 Nm 2 1 6 © 47412-0 ● Turn engine 180°. ● Insert oil dipstick (1). ● Fill in lubricating oil according to operating manual. 1 © 47411-0 © 01/2009 6/8 OBJ_DOKU-23518-001.
PAGE 257
D 2011 TD 2011 Lube oil system W 08-04-07 Technical Data Tightening specifications ID no. Name Lubricating oil pan (plate) on A03 030 crankcase A03 031 Locking screw on lubricating oil pan A03 085 Cover plate to connection housing Screw type M8x16 Notes / Remark Observe tightening sequence! Replace sealing ring Value 21 Nm 55 Nm 9 Nm For the tightening procedure according to torque using a torque wrench, a maximum variation of the tightening torque of +/- 10% is permissible.
PAGE 259
D 2011 i TD 2011 i Lube oil system W 08-08-02 Removing and installing the lubricating oil cooler Standard tools: – Torx tool set Collect leaking operating substances in suitable vessels and dispose of according to regulations. 8189 6 Removing the lubricating oil cooler ● Unscrew screws (1). 2 ● Remove air guidance cowling (2). 1 © 47358-0 ● Unscrew screws (1). 1 © 47424-0 © 01/2009 1/6 OBJ_DOKU-23519-001.
PAGE 260
Lube oil system W 08-08-02 D 2011 i TD 2011 i ● Unscrew screws (1). ● Lift oil cooler. ● Visually inspect the components. 1 6 © 47484-0 ● Pull out plug elements (1). 1 © 47421-0 ● Visually inspect the components. © 39557-1 © 01/2009 2/6 OBJ_DOKU-23519-001.
PAGE 261
D 2011 i TD 2011 i Lube oil system W 08-08-02 Installing the lubricating oil cooler ● Clean sealing surfaces. ● Insert plug elements (1). ● Press in plug elements as far as they will go. X 1 Note installation position. The "X" end faces upwards. 6 © 47422-0 ● Mount oil cooler (1). ● Align lubricating oil cooler. ● Insert plug elements (2) in holes (arrow) ● Press in oil cooler as far as it will go. 1 2 2 © 47423-0 ● Tighten screws (1).
PAGE 262
Lube oil system W 08-08-02 D 2011 i TD 2011 i ● Tighten screws (1). Screw length: M8 x 20 mm 1 6 © 47424-0 ● Position oil cooler (1). 1 Lug (2) must lie in the hole. 2 © 47425-0 ● Tighten screws (1). 21 Nm ● Tighten screws (2). 21 Nm 1 2 © 47420-0 © 01/2009 4/6 OBJ_DOKU-23519-001.
PAGE 263
D 2011 i TD 2011 i Lube oil system W 08-08-02 ● Mount air guidance cowling (1). Note installation position. Air guidance cowling must sit under the stand plate and rubber profile (arrow). 1 6 © 39490-2 ● Tighten screws (1). 21 Nm 1 © 47372-0 © 01/2009 5/6 OBJ_DOKU-23519-001.
PAGE 264
Lube oil system W 08-08-02 D 2011 i TD 2011 i Technical Data Tightening specifications ID no. Name Screw type Torx A08 051 Lubricating oil cooler to air duct M8x25 Stand plate on crankcase / lubricating Torx A09 070 oil cooler M8x20 Air guidance cowling on blower A09 087 jacket / stand plate Notes / Remark Value 21 Nm 21 Nm 21 Nm For the tightening procedure according to torque using a torque wrench, a maximum variation of the tightening torque of +/- 10% is permissible.
PAGE 265
D 2011 TD 2011 Lube oil system W 08-11-02 Removing and installing the oil pressure regulating valve Collect leaking operating substances in suitable vessels and dispose of according to regulations.
PAGE 266
Lube oil system W 08-11-02 D 2011 TD 2011 ● Visually inspect the components. 6 © 39061-1 ● Measure length of the compressor spring with calliper gauge. – Coloured marking, green 56.5 mm – Coloured marking, yellow 80.5 mm – Coloured marking, red 78.4 mm – Coloured marking, blue 61.8 mm When the wear limit is reached, the compressor spring must be renewed. © 39062-1 Installing the oil pressure regulating valve ● Lightly oil oil pressure regulating valve (1). Note installation position.
PAGE 267
D 2011 TD 2011 Lube oil system W 08-11-02 ● Mount new sealing ring. ● Mount locking screw (1). ● Tighten screw plug (1). 1 111 Nm 6 © 46955-0 Cabin heating connection, input Attention! Parts are under tensions and can spring out during disassembly! ● Unscrew locking screw (1). ● Remove sealing ring. ● Remove compression spring. ● Remove oil pressure regulating valve.
PAGE 268
Lube oil system W 08-11-02 D 2011 TD 2011 Technical Data Testing and setting data ID no.
PAGE 269
D 2011 TD 2011 Lube oil system W 08-11-07 Removing and installing the oil filter console Standard tools: – Torx tool set 8189 Special tools: – Disassembly tool – Special wrench 110901 170050 – Operation manual 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.
PAGE 270
Lube oil system W 08-11-07 D 2011 TD 2011 ● Remove the O-ring (1) with the disassembly tool. ● Visually inspect the components. 6 1 © 47431-0 Installing oil filter console ● Clean sealing surfaces. ● Insert new O-ring (1). 1 © 47431-0 ● Mount oil filter console (2). ● Tighten screws (1). 21 Nm 1 2 © 47430-0 © 01/2009 2/4 OBJ_DOKU-23521-001.
PAGE 271
D 2011 TD 2011 Lube oil system W 08-11-07 ● Clean sealing surfaces. ● Lightly oil sealing ring on new lubricating oil filter. ● Tighten the lubricating oil filter (1) according to the operating instructions. Operation manual The seal must fit evenly. 1 6 © 47429-0 © 01/2009 3/4 OBJ_DOKU-23521-001.
PAGE 272
Lube oil system W 08-11-07 D 2011 TD 2011 Technical Data Tightening specifications ID no. Name A08 003 Oil filter console on crankcase Screw type Notes / Remark Value 21 Nm For the tightening procedure according to torque using a torque wrench, a maximum variation of the tightening torque of +/- 10% is permissible. 6 © 01/2009 4/4 OBJ_DOKU-23521-001.
PAGE 273
D 2011 TD 2011 Lube oil system W 08-11-08 Removing and installing the oil pressure switch Collect leaking operating substances in suitable vessels and dispose of according to regulations. Standard tools 6 Removing the oil pressure switch ● Pull out cable plug (1). 1 © 47344-0 ● Unscrew oil pressure switch (1). 1 © 47432-0 © 01/2009 1/4 OBJ_DOKU-23522-001.
PAGE 274
Lube oil system W 08-11-08 D 2011 TD 2011 ● Visually inspect the components. 6 © 47433-0 Installing the oil pressure switch ● Screw on oil pressure switch (1). 1 © 47434-0 ● Tighten oil pressure switch (1). 13 Nm 1 © 47432-0 © 01/2009 2/4 OBJ_DOKU-23522-001.
PAGE 275
D 2011 TD 2011 Lube oil system W 08-11-08 ● Plug in the cable plug (1). Ensure that the connection is perfect. 1 6 © 47344-0 © 01/2009 3/4 OBJ_DOKU-23522-001.
PAGE 276
Lube oil system W 08-11-08 D 2011 TD 2011 Technical Data Tightening specifications ID no. Name A08 091 Oil pressure switch on crankcase Screw type M10x1 Notes / Remark Value 13 Nm For the tightening procedure according to torque using a torque wrench, a maximum variation of the tightening torque of +/- 10% is permissible. 6 © 01/2009 4/4 OBJ_DOKU-23522-001.
PAGE 277
D 2011 TD 2011 Lube oil system W 08-11-11 Removing and installing temperature transmitter Collect leaking operating substances in suitable vessels and dispose of according to regulations. Standard tools 6 Removing temperaure transmitter – D 2011 i, TD 2011 i 2 ● Unscrew screws (1). ● Remove air guidance cowling (2). 1 © 47358-0 – D 2011, TD 2011 ● Pull out cable plug (1). Note the assignment of the terminal designations. 1 © 47435-1 © 01/2009 1/4 OBJ_DOKU-23523-001.
PAGE 278
Lube oil system W 08-11-11 D 2011 TD 2011 ● Unscrew temperature transmitter (1). 1 6 © 39265-1 ● Remove sealing ring. ● Visually inspect the components. © 39096-1 Installing temperature transmitter ● Mount new sealing ring. ● Tighten temperature transmitter (1). 25 Nm 1 © 39265-1 © 01/2009 2/4 OBJ_DOKU-23523-001.
PAGE 279
D 2011 TD 2011 Lube oil system W 08-11-11 ● Plug in the cable plug (1). Note the assignment of the terminal designations. Ensure that the connection is perfect. 1 6 © 47435-1 – D 2011 i, TD 2011 i ● Mount air guidance cowling (1). Note installation position. Air guidance cowling must sit under the stand plate and rubber profile (arrow). 1 © 39490-2 ● Tighten screws (1). 21 Nm 1 © 47372-0 © 01/2009 3/4 OBJ_DOKU-23523-001.
PAGE 280
Lube oil system W 08-11-11 D 2011 TD 2011 Technical Data Tightening specifications ID no. Name Temperature transmitter on A08 095 crankcase Air guidance cowling on blower A09 087 jacket / stand plate Screw type Notes / Remark Value 25 Nm 21 Nm For the tightening procedure according to torque using a torque wrench, a maximum variation of the tightening torque of +/- 10% is permissible. 6 © 01/2009 4/4 OBJ_DOKU-23523-001.
PAGE 281
D 2011 i TD 2011 i Lube oil system W 08-11-12 Removing and installing the thermostat (Lubricating oil cooler) Standard tools: – Slide gauge – Torx tool set 8189 Special tools: – Disassembly tool 110901 Collect leaking operating substances in suitable vessels and dispose of according to regulations. 6 Removing the thermostat ● Unscrew screws (1). 2 ● Remove air guidance cowling (2). 1 © 47358-0 ● Unscrew screws (1). ● Remove stand plate (2).
PAGE 282
Lube oil system W 08-11-12 D 2011 i TD 2011 i Attention! Parts are under tensions and can spring out during disassembly! ● Unscrew locking screw (1). 1 6 © 47438-0 ● Remove thermostat (1). ● Remove compression spring. 1 © 39086-1 ● Remove the O-ring (1) with the disassembly tool. 1 © 47439-0 © 01/2009 2/8 OBJ_DOKU-23524-001.
PAGE 283
D 2011 i TD 2011 i Lube oil system W 08-11-12 ● Visually inspect the components. 6 © 39437-1 Installing the thermostat ● Measure length of the compressor spring with calliper gauge. 116.7 mm When the wear limit is reached, the compressor spring must be renewed. © 39085-1 ● Clean sealing surfaces. ● Oil the thermostat lightly. ● Insert compression spring. ● Insert thermostat (1). Note installation position. 1 © 39086-1 © 01/2009 3/8 OBJ_DOKU-23524-001.
PAGE 284
Lube oil system W 08-11-12 D 2011 i TD 2011 i ● Lightly oil new O-ring (1). ● Insert new O-ring (1). 1 6 © 47439-0 ● Tighten screw plug (1). 50 Nm 1 © 47438-0 ● Install stand plate (2). ● Tighten screws (1). 2 1 1 © 47359-0 © 01/2009 4/8 OBJ_DOKU-23524-001.
PAGE 285
D 2011 i TD 2011 i Lube oil system W 08-11-12 ● Position stand plate (1). Lug (2) must lie in the hole. 1 2 6 © 47373-0 ● Tighten screws (1). 21 Nm ● Tighten screws (2). 21 Nm 2 1 © 47375-0 ● Feed hose pipe (1) through the hole (2). 1 2 © 47374-0 © 01/2009 5/8 OBJ_DOKU-23524-001.
PAGE 286
Lube oil system W 08-11-12 D 2011 i TD 2011 i ● Mount air guidance cowling (1). Note installation position. Air guidance cowling must sit under the stand plate and rubber profile (arrow). 1 6 © 39490-2 ● Tighten screws (1). 21 Nm 1 © 47372-0 © 01/2009 6/8 OBJ_DOKU-23524-001.
PAGE 287
D 2011 i TD 2011 i Lube oil system W 08-11-12 Technical Data Testing and setting data ID no. P08 74 Name Thermostat, compression spring, length Additional information Value 116.7 mm Tightening specifications ID no.
PAGE 289
Lube oil system W 08-16-01 TD 2011 Removing and installing the control line Standard tools – W 07-10-08 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 control line ● Remove fuel filter console. W 07-10-08 ● Unscrew hollow screw (1).
PAGE 290
Lube oil system W 08-16-01 TD 2011 ● Visually inspect sealing surfaces (arrows). 6 © 47651-0 ● Visually inspect the components. © 47649-0 Installing control line ● Insert control line (1). ● Mount sealing rings (2). ● Screw in all hollow screws. 1 ● Tighten hollow screws (3). 2 18 Nm Attention! Install tension-free. 2 2 3 3 3 © 47665-1 © 01/2009 2/4 OBJ_DOKU-23525-001.
PAGE 291
Lube oil system W 08-16-01 TD 2011 ● Insert control line (1). ● Mount sealing rings (2). ● Tighten hollow screw (3). 18 Nm 2 ● Install the fuel filter console. W 07-10-08 1 3 6 © 47666-1 © 01/2009 3/4 OBJ_DOKU-23525-001.
PAGE 292
Lube oil system W 08-16-01 TD 2011 Technical Data Tightening specifications ID no. Name Control line to oil filter console / A08 048 crankcase Screw type Notes / Remark Hollow screw M10x1 Value 18 Nm For the tightening procedure according to torque using a torque wrench, a maximum variation of the tightening torque of +/- 10% is permissible. 6 © 01/2009 4/4 OBJ_DOKU-23525-001.
PAGE 293
D 2011 i TD 2011 i Cooling system W 09-11-01 Remove and install the cooling blower Standard tools: – Torx tool set 8190 – W 12-02-01 8189 6 Removing the cooling blower ● Remove V-belt. 2 W 12-02-01 ● Unscrew screws (1). ● Remove air guidance cowling (2). 1 © 47358-0 ● Disconnect the battery's negative terminal. ● Remove cable from generator. 1 Note assignment! - (1) = terminal W - (2) = terminal D+ - (3) = terminal B+ 3 2 © 47265-0 © 01/2009 1/8 OBJ_DOKU-23526-001.
PAGE 294
Cooling system W 09-11-01 D 2011 i TD 2011 i ● Unlock cable plug (1) and remove. 1 6 © 39561-1 ● Remove cable tie (1). 1 © 47292-0 ● Unscrew screws (1). 1 1 © 47441-0 © 01/2009 2/8 OBJ_DOKU-23526-001.
PAGE 295
D 2011 i TD 2011 i Cooling system W 09-11-01 ● Unscrew screws (1). ● Remove cooling blower. 1 6 © 47443-0 ● Visually inspect the components. © 47443-0 Install cooling blower ● Install cooling blower. ● Fasten all screws. © 39564-1 © 01/2009 3/8 OBJ_DOKU-23526-001.
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Cooling system W 09-11-01 D 2011 i TD 2011 i ● Tighten screws (1). 21 Nm 1 6 © 47442-0 ● Tighten screws (1). 21 Nm 1 1 © 47441-0 ● Fix cable tie (1). 1 © 47292-0 © 01/2009 4/8 OBJ_DOKU-23526-001.
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D 2011 i TD 2011 i Cooling system W 09-11-01 ● Plug in the cable plug (1). Ensure that the connection is perfect. 1 6 © 39561-1 ● Remove cable from generator. Note assignment! 1 - (1) = terminal W - (2) = terminal D+ - (3) = terminal B+ ● Tighten nut (2). 3.5 Nm 3 ● Connect the battery's negative terminal. 2 © 47265-0 ● Mount air guidance cowling (1). ● Position air guidance cowling under the stand plate and rubber profile (arrow). Note installation position.
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Cooling system W 09-11-01 D 2011 i TD 2011 i ● Tighten screws (1). 21 Nm ● Install V-belt. W 12-02-01 1 6 © 47372-0 © 01/2009 6/8 OBJ_DOKU-23526-001.
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D 2011 i TD 2011 i Cooling system W 09-11-01 Technical Data Tightening specifications ID no. Name Screw type Notes / Remark A09 066 Blower jacket on crankcase / air duct Torx screws Air guidance cowling on blower A09 087 jacket / stand plate A13 082 Cable G1.D+ to generator M5 Value 21 Nm 21 Nm 3.5 Nm For the tightening procedure according to torque using a torque wrench, a maximum variation of the tightening torque of +/- 10% is permissible. 6 © 01/2009 7/8 OBJ_DOKU-23526-001.
PAGE 301
D 2011 i TD 2011 i Cooling system W 09-11-02 Dismantling and assembling the cooling blower Standard tools: – Torx tool set 8190 – W 09-11-01 8189 6 Dismantling the cooling blower 1 ● Remove cooling blower. W 09-11-01 ● Unscrew screws (arrows). ● Remove blower jacket (1). Note installation position. © 47469-0 ● Hold rotor shaft with hexagonal socket. ● Unscrew nut (1). 1 © 39566-1 © 01/2009 1/8 OBJ_DOKU-23527-001.
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Cooling system W 09-11-02 D 2011 i TD 2011 i ● Remove washer (1). ● Remove V-belt pulley (2). 1 ● Remove running wheel (3). 2 3 6 © 39567-1 ● Remove spacing disc (1). 1 © 39568-1 ● Remove guide washer (1). 1 © 39569-1 © 01/2009 2/8 OBJ_DOKU-23527-001.
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D 2011 i TD 2011 i Cooling system W 09-11-02 ● Unscrew nuts (1). ● Remove washers. 1 1 6 © 39571-1 ● Remove generator. ● Visually inspect the components. © 39572-1 Assembling the cooling blower ● Mount generator. Ensure that the installation location is free from faults. © 39572-1 © 01/2009 3/8 OBJ_DOKU-23527-001.
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Cooling system W 09-11-02 D 2011 i TD 2011 i ● Mount washers. ● Tighten nuts (1) alternately. 4 Nm ● Check installation position. 1 1 6 © 39571-1 ● Mount guide plate (1). 1 Recess (arrow) faces generator. © 39573-1 ● Mount shim (1). 1 © 39574-1 © 01/2009 4/8 OBJ_DOKU-23527-001.
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D 2011 i TD 2011 i Cooling system W 09-11-02 ● Install running wheel (1). 2 Ensure that the installation location is free from faults. 1 ● Mount V-belt pulley (2). ● Install the washer (3). 3 6 © 47221-0 ● Screw on nut. ● Hold rotor shaft with hexagonal socket. ● Tighten nut. 75 Nm © 39575-1 ● Mount blower jacket (1). Note installation position. Gasket (2) faces the lubricating oil pan. 1 2 © 46959-0 © 01/2009 5/8 OBJ_DOKU-23527-001.
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Cooling system W 09-11-02 D 2011 i TD 2011 i ● Tighten screws (arrows). 1 ● Tighten screws (arrows). 22 Nm ● Install cooling blower. W 09-11-01 6 © 47469-0 © 01/2009 6/8 OBJ_DOKU-23527-001.
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D 2011 i TD 2011 i Cooling system W 09-11-02 Technical Data Testing and setting data ID no. P09 91 Name Permissible gap between running wheel and blower jacket Additional information Value 0.2 - 0.8 mm Tightening specifications ID no. Name Screw type A09 065 Blower jacket casing on generator A09 067 Blower jacket on blower jacket casing Running wheel / belt pulley on geneA13 021 rator Charging current cable to generator A13 081 B+ Notes / Remark Value 4 Nm 22 Nm 75 Nm 6.
PAGE 309
D 2011 i TD 2011 i Cooling system W 09-11-03 Removing and installing air duct Standard tools: – Torx tool set 8190 – W 08-08-02 8189 6 Removing air duct ● Remove the lubricating oil cooler. W 08-08-02 ● Unscrew screw (1). 1 © 47444-0 ● Unscrew screws (1). ● Remove air duct (2). ● Visually inspect the components. 2 1 © 47384-0 © 01/2009 1/4 OBJ_DOKU-23528-001.
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Cooling system W 09-11-03 D 2011 i TD 2011 i Installing air duct ● Mount air duct (2). ● Tighten screws (1). 2 1 6 © 47384-0 ● Pre-tighten screw (1). 3 Nm 1 © 47444-0 ● Tighten screws (1). 21 Nm 1 © 47445-0 © 01/2009 2/4 OBJ_DOKU-23528-001.
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D 2011 i TD 2011 i Cooling system W 09-11-03 ● Tighten screw (1). 21 Nm ● Install the lubricating oil cooler. W 08-08-02 1 6 © 47444-0 © 01/2009 3/4 OBJ_DOKU-23528-001.
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Cooling system W 09-11-03 D 2011 i TD 2011 i Technical Data Tightening specifications ID no. Name Screw type Notes / Remark A09 066 Blower jacket on crankcase / air duct Torx screws Observe assembly A09 098 Air duct to cylinder head specification. Pre-tensioning value: Observe assembly A09 098 Air duct to cylinder head specification.
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D 2011 TD 2011 Cooling system W 09-13-02 Removing and installing the air bearing Standard tools: – Rotation angle disc – W 12-02-01 8190 6 Removing the fan mounting ● Remove V-belt. W 12-02-01 © 47039-0 ● Unscrew screw (1). ● Remove washer. ● Remove air bearing. 1 © 47040-0 © 01/2009 1/4 OBJ_DOKU-23530-001.
PAGE 314
Cooling system W 09-13-02 D 2011 TD 2011 ● Unscrew screws (1). ● Remove suction fan (2). ● Visually inspect the components. 1 2 1 6 © 47449-0 Installing the fan mounting Attention! Note installation position: "Engine side" label faces engine! 1 ● Mount suction fan. ● Tighten screws (1). – M8x22-8.8 22 Nm or – M8x20-10.9 1 30 Nm © 47449-1 Attention! Note installation position: "Engine side" label faces engine! ● Mount air bearing. 1 ● Mount disc. ● Tighten new screw (1).
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D 2011 TD 2011 Cooling system W 09-13-02 ● Install V-belt. W 12-02-01 6 © 47039-0 © 01/2009 3/4 OBJ_DOKU-23530-001.
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Cooling system W 09-13-02 D 2011 TD 2011 Technical Data Tightening specifications ID no. Name A09 042 Suction fan on fan drive A09 042 Suction fan on fan drive Screw type M8x22-8.8 M8x20-10.9 A09 045 Air bearing on console M10x110-12.9 A09 045 Air bearing on console Notes / Remark Stage 1: Use new screw. M10x110-12.9 Stage 2: Value 22 Nm 30 Nm 30 Nm 120° For the tightening procedure according to torque using a torque wrench, a maximum variation of the tightening torque of +/- 10% is permissible.
PAGE 317
D 2011 TD 2011 Monitoring system W 11-00-03 Removing and installing the lifting magnet (Engine shutdown) Standard tools Special tools: – Disassembly tool – W 12-02-01 110901 6 Remove lifting magnet – Version with V-belt tensioning pulley ● Remove V-belt. W 12-02-01 1 ● Remove V-belt tensioning pulley. ● Unlock cable plug (1) and remove. © 47166-0 ● Unscrew screws (1). ● Remove lifting magnet (2). 1 2 © 47450-0 © 01/2009 1/4 OBJ_DOKU-23531-001.
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Monitoring system W 11-00-03 D 2011 TD 2011 ● Remove the O-ring (1) with the disassembly tool. ● Visually inspect the components. 1 6 © 47355-0 Install lifting magnet ● Insert new O-ring (1). 1 © 39036-1 ● Insert lifting magnet (2). ● Tighten screws (1). 8.5 Nm 1 2 © 47450-0 © 01/2009 2/4 OBJ_DOKU-23531-001.
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D 2011 TD 2011 Monitoring system W 11-00-03 ● Plug in the cable plug (1). Ensure that the connection is perfect. – Version with V-belt tensioning pulley 1 ● Install V-belt tensioning pulley. ● Mount and tighten V-belt. W 12-02-01 6 © 47166-0 © 01/2009 3/4 OBJ_DOKU-23531-001.
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Monitoring system W 11-00-03 D 2011 TD 2011 Technical Data Tightening specifications ID no. Name Lifting magnet (engine shutdown) on A05 041 front cover Screw type Notes / Remark Value 8.5 Nm For the tightening procedure according to torque using a torque wrench, a maximum variation of the tightening torque of +/- 10% is permissible. 6 © 01/2009 4/4 OBJ_DOKU-23531-001.
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D 2011 TD 2011 Other components W 12-01-04 Removing and installing the V-belt pulley Standard tools – W 12-02-01 6 Removing the V-belt pulley ● Remove V-belt. W 12-02-01 ● Unscrew screws (1). ● Remove fan (2). 1 2 1 © 47012-0 ● Unscrew screws (1). ● Remove flange hub (2). 1 2 1 © 47013-0 © 01/2009 1/4 OBJ_DOKU-23532-001.
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Other components W 12-01-04 D 2011 TD 2011 ● Remove V-belt pulley (1). 1 6 © 47014-0 ● Remove centrifugal disc (1). Note installation position. 1 ● Visually inspect the components. © 47015-0 Installing the V-belt pulley ● Mount centrifugal disc (1). Note installation position. 1 © 39598-1 © 01/2009 2/4 OBJ_DOKU-23532-001.
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D 2011 TD 2011 Other components W 12-01-04 ● Mount V-belt pulley (1). 1 6 © 47014-0 ● Mount flange hub (2). ● Tighten screws (1). 43 Nm 1 2 1 © 47013-0 Attention! Note installation position: "Engine side" label faces engine! ● Mount fan (2). ● Tighten screws (1). 30 Nm ● Install V-belt. 1 W 12-02-01 2 1 © 47012-0 © 01/2009 3/4 OBJ_DOKU-23532-001.
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Other components W 12-01-04 D 2011 TD 2011 Technical Data Tightening specifications ID no. Name A09 042 Ventilator on flange hub V belt pulley/flange hub on output A12 031 flange Screw type M8x40-10.9 M10x30-8.8 Notes / Remark Value 30 Nm 43 Nm For the tightening procedure according to torque using a torque wrench, a maximum variation of the tightening torque of +/- 10% is permissible. 6 © 01/2009 4/4 OBJ_DOKU-23532-001.
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D 2011 TD 2011 Other components W 12-02-01 Renew V-belts, check V-belt tension Attention! Standard tools: – V-belt tension measuring device 8115 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 V-belt ● Loosen screws (1). 1 © 47454-0 ● Swing generator (1) in the direction of the arrow. ● Remove V-belt. 1 © 47455-0 © 01/2009 1/6 OBJ_DOKU-23533-001.
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Other components W 12-02-01 D 2011 TD 2011 – Version with V-belt tensioning pulley ● Loosen screws (1). ● Swing V-belt tensioning pulley (2) in the direction of the arrow. 1 ● Remove V-belt. 2 6 © 47451-0 Installing the V-belt. ● Mount V-belt. ● Swing generator (1) in the direction of the arrow. © 47456-1 ● Pre-tighten screw (1). ● Pre-tighten screw (2). 1 2 © 47457-0 © 01/2009 2/6 OBJ_DOKU-23533-001.
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D 2011 TD 2011 Other components W 12-02-01 – Version with V-belt tensioning pulley ● Mount V-belt. ● Press clamping strap (1) in direction of arrow with a suitable tool. 1 6 © 47452-0 ● Pre-tighten screws (1). 1 © 47453-0 Check V-belt tension with V-belt tension measuring device ● Lower indicator arm (1) into V-belt tension measuring device. 1 © 44591-0 © 01/2009 3/6 OBJ_DOKU-23533-001.
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Other components W 12-02-01 D 2011 TD 2011 ● Mount V-belt tension measuring device on V-belt. The V-belt must be between the guides (arrow). 6 © 47480-0 ● Press the V-belt measuring device against the V-belt with the button (1) until you hear it click. ● Read measured value at the intersection (arrow) of the indicator arm and scale. + 50 450 − 50 N Note different units on the scale. ● If the nominal value is not reached, the tensioning process must be repeated. 1 © 47458-0 ● Tighten screw (1).
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D 2011 TD 2011 Other components W 12-02-01 – Version with V-belt tensioning pulley ● Mount V-belt tension measuring device on V-belt. The V-belt must be between the guides (arrow). 6 © 47453-0 ● Press the V-belt measuring device against the V-belt with the button (1) until you hear it click. ● Read measured value at the intersection (arrow) of the indicator arm and scale. + 50 450 − 50 N Note different units on the scale. ● If the nominal value is not reached, the tensioning process must be repeated.
PAGE 330
Other components W 12-02-01 D 2011 TD 2011 Technical Data Testing and setting data ID no. P12 11 P12 21 Name Additional information V-belt tension, individual V-belts AVX 10 First assembly Check after 15 minutes running V-belt tension, individual V-belts AVX 10 under load Value + 50 450 - 50 N + 20 300 - 20 N Tightening specifications ID no.
PAGE 331
D 2011 TD 2011 Other components W 12-06-01 Removing and installing the flywheel Standard tools: – Self-made mandrin guide – Rotation angle disc 8190 6 Removing the flywheel ● Block flywheel with suitable tool. ● Unscrew all screws (1). ● Screw two long screws into the threaded bores. To improve the removal and installation of the flywheel. 1 ● Remove flywheel. © 47216-0 ● Visually inspect the components. © 44276-0 © 01/2009 1/4 OBJ_DOKU-23534-001.
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Other components W 12-06-01 D 2011 TD 2011 Installing the flywheel ● Screw two long screws into the threaded bores. To improve the removal and installation of the flywheel. 1 ● Insert self-made mandrin guide (1). For example a pin bolt. ● Mount flywheel. The bores in the flywheel must match the threaded bores in the crankshaft flange. 6 © 47460-0 ● Turn in new screws (1). Attention! Renew screws every time they are loosened. ● Remove self-made mandrin guide.
PAGE 333
D 2011 TD 2011 Other components W 12-06-01 Technical Data Tightening specifications ID no. Name Screw type A12 001 Flywheel on crankshaft A12 001 Flywheel on crankshaft A12 001 Flywheel on crankshaft Notes / Remark Stage 1: Use new screws Stage 2: Stage 3: Value 30 Nm 60° 30° For the tightening procedure according to torque using a torque wrench, a maximum variation of the tightening torque of +/- 10% is permissible. 6 © 01/2009 3/4 OBJ_DOKU-23534-001.
PAGE 335
D 2011 TD 2011 Other components W 12-08-02 Removing and installing the hydraulic pump Standard tools – Graphite grease G 500 6 Removing the hydraulic pump ● Remove the hydraulic pipes. ● Press in stoppers. ● Unscrew screws (1). ● Remove hydraulic pump (2). ● Remove coupling sleeve. 1 2 © 39090-2 ● Pull off the collars (1). ● Clean coupling sleeve (2). ● Check components for visible signs of wear. 2 1 © 39091-2 © 01/2009 1/4 OBJ_DOKU-23536-001.
PAGE 336
Other components W 12-08-02 D 2011 TD 2011 Installing hydraulic pump ● Pull collar (1) onto coupling sleeve (3). 3 ● Align cutting on the toothing of the coupling sleeve. ● Pull collar (2) onto coupling sleeve (3). ● Align cutting on the toothing of the coupling sleeve. ● Grease inner toothing of the coupling sleeve. 2 1 6 © 39092-2 ● Grease gear shaft (1). ● Push on coupling sleeve (2). Note installation position. 2 Toothing of the coupling sleeve must engage with the gear shaft.
PAGE 337
D 2011 TD 2011 Other components W 12-08-02 ● Insert hydraulic pump (1) and coupling sleeve. Toothing of the coupling sleeve must engage with the gear shaft. ● Tighten screws (2). 57 Nm 2 ● Pull out stoppers. ● Insert hydraulic pipes. 1 6 © 39090-3 © 01/2009 3/4 OBJ_DOKU-23536-001.
PAGE 338
Other components W 12-08-02 D 2011 TD 2011 Technical Data Tightening specifications ID no. Name Hydraulic pump on hydraulic pump A12 051 console Screw type Notes / Remark Value 57 Nm For the tightening procedure according to torque using a torque wrench, a maximum variation of the tightening torque of +/- 10% is permissible. 6 © 01/2009 4/4 OBJ_DOKU-23536-001.
PAGE 339
D 2011 TD 2011 Other components W 12-08-03 Renew toothed belt and tensioning pulley (Hydraulic pump) Standard tools – W 12-01-04 6 Remove toothed belt and tensioning pulley ● Remove V-belt pulley. 1 W 12-01-04 ● Unscrew all screws (1). ● Remove protective hood (2). 2 © 47462-0 ● Remove adapter (1). 1 © 47463-0 © 01/2009 1/6 OBJ_DOKU-23537-001.
PAGE 340
Other components W 12-08-03 D 2011 TD 2011 ● Unscrew screw (1). ● Remove tensioning pulley (2). ● Remove the toothed belt (3). ● Visually inspect the components. 2 1 6 3 © 47464-0 Install toothed belt and tensioning pulley ● Mount new tensioning pulley (1). ● Position setting eccentric (arrow) at 11 o'clock. ● Fasten screw (2). ● Mount new toothed belt (3). 1 2 3 ● Position toothed belt centrally on the toothed belt wheels. © 47465-0 1 Attention! Note installation position.
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D 2011 TD 2011 Other components W 12-08-03 ● Turn setting eccentric in the direction of arrow with hexagon socket. Markings (1) must be in alignment with bulge. ● Tighten screw (2). 2 1 21 Nm 6 © 47466-0 Check toothed wheel tension ● Turn crankshaft 2 revolutions in the direction of the arrow (direction of engine rotation). Markings (1) must be in alignment with bulge. 1 If the markings are not aligned with each other, the toothed belt tension must be corrected.
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Other components W 12-08-03 D 2011 TD 2011 ● Mount adapter (1). The flattened side (arrow) must face the toothed belt. 1 6 © 47468-0 ● Mount protective hood (2). ● Tighten all screws (1). 1 8.5 Nm ● Install V-belt pulley. W 12-01-04 2 © 47462-0 © 01/2009 4/6 OBJ_DOKU-23537-001.
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D 2011 TD 2011 Other components W 12-08-03 Technical Data Tightening specifications ID no. Name Tensioning pulley on hydraulic pump A12 052 console Protective hood on hydraulic pump A12 056 console Screw type Notes / Remark Value 21 Nm 8.5 Nm For the tightening procedure according to torque using a torque wrench, a maximum variation of the tightening torque of +/- 10% is permissible. 6 © 01/2009 5/6 OBJ_DOKU-23537-001.
PAGE 345
D 2011 TD 2011 Electrical system W 13-02-03 Removing and installing the generator Standard tools – W 09-11-01 – W 09-11-02 – W 12-02-01 D 2011 i D 2011 i 6 Removing the generator – D 2011 i, TD 2011 i ● Remove cooling blower. W 09-11-01 ● Dismantling the cooling blower. W 09-11-02 © 47443-0 – D 2011, TD 2011 ● Disconnect the battery's negative terminal. ● Remove cable from generator. 3 Note assignment! - (1) = terminal W - (2) = terminal D+ - (3) = terminal B+ ● Remove V-belt.
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Electrical system W 13-02-03 D 2011 TD 2011 ● Unscrew screw (1). 1 ● Unscrew screw (2). ● Remove washer. ● Remove generator. 2 6 © 47471-0 ● Unscrew nut (1). ● Hold screw (2). ● Remove washer. ● Visually inspect the components. 1 2 1 2 © 47472-0 Installing the generator ● Insert screw (2). ● Mount disc. ● Screw on nut (1). © 01/2009 2/6 © 47472-0 OBJ_DOKU-23538-001.
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D 2011 TD 2011 Electrical system W 13-02-03 ● Mount generator. 1 ● Fasten screw (1). ● Mount disc. ● Fasten screw (2). ● Install V-belt. W 12-02-01 2 6 © 47471-0 ● Tighten screw (1). – M8 1 34 Nm – M10 46 Nm ● Hold locking nut (arrow). ● Tighten screw (2). 22 Nm 2 © 47473-0 ● Remove cable from generator. Note assignment! - (1) = terminal W - (2) = terminal D+ 3 - (3) = terminal B+ – (Position 2) 3.5 Nm – (Position 3) 1 6.5 Nm 2 ● Connect the battery's negative terminal.
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Electrical system W 13-02-03 D 2011 TD 2011 – D 2011 i, TD 2011 i ● Assembling the cooling blower. W 09-11-02 ● Install cooling blower. W 09-11-01 6 © 47443-0 © 01/2009 4/6 OBJ_DOKU-23538-001.
PAGE 349
D 2011 TD 2011 Electrical system W 13-02-03 Technical Data Tightening specifications ID no. A13 012 A13 012 A13 015 A13 015 A13 016 A13 017 Name Generator on console Generator on console Clamping bracket on generator Clamping bracket on generator Clamping bracket on console Clamping bracket on front cover Charging current cable to generator A13 081 B+ A13 082 Cable G1.D+ to generator Screw type Notes / Remark M8x80-10.9 M10x80-10.9 M8x30-8.8 M10x80-10.9 M8x35-8.
PAGE 351
Electrical system W 13-03-02 D 2011 Removing and installing the starter Standard tools 6 Removing the starter ● Disconnect the battery's negative terminal. ● Disconnect cables. © 47474-0 ● Unscrew screws (1). ● Remove starter. 1 © 47475-0 © 01/2009 1/4 OBJ_DOKU-23539-001.
PAGE 352
Electrical system W 13-03-02 D 2011 ● Visually inspect the components. 6 © 47476-0 Installing the starter ● Insert starter. 1 ● Tighten screws (1). 43.5 Nm © 47475-0 ● Connect cables. – see Technical Circular 0199-44-1163 ● Connect the battery's negative terminal. © 47474-0 © 01/2009 2/4 OBJ_DOKU-23539-001.
PAGE 353
Electrical system W 13-03-02 D 2011 Technical Data Tightening specifications ID no. Name A13 001 Starter on crankcase Screw type Notes / Remark Value 43.5 Nm For the tightening procedure according to torque using a torque wrench, a maximum variation of the tightening torque of +/- 10% is permissible. 6 © 01/2009 3/4 OBJ_DOKU-23539-001.
PAGE 355
Electrical system W 13-03-02 TD 2011 Removing and installing the starter Standard tools 6 Removing the starter ● Disconnect the battery's negative terminal. 1 ● Disconnect cables. ● Unscrew screws (1). ● Remove shielding plate (2). 2 © 47578-0 ● Unscrew screws (1). ● Remove starter. 1 1 © 47579-0 © 01/2009 1/4 OBJ_DOKU-23540-001.
PAGE 356
Electrical system W 13-03-02 TD 2011 ● Visually inspect the components. 6 © 47476-0 Installing the starter ● Insert starter. ● Tighten screws (1). 43.5 Nm 1 1 © 47579-0 ● Mount shielding plate (1). ● Tighten screws (2). 2 Make sure that the installation site of the rubber pad (3) is in perfect condition. ● Tighten screws (2). 8.5 Nm ● Connect cables. – see Technical Circular 0199-44-1163 ● Connect the battery's negative terminal. 1 3 © 47578-1 © 01/2009 2/4 OBJ_DOKU-23540-001.
PAGE 357
Electrical system W 13-03-02 TD 2011 Technical Data Tightening specifications ID no. Name A13 001 Starter on crankcase A13 009 Shield on crankcase Screw type M6x14-8.8 Notes / Remark Value 43.5 Nm 8.5 Nm For the tightening procedure according to torque using a torque wrench, a maximum variation of the tightening torque of +/- 10% is permissible. 6 © 01/2009 3/4 OBJ_DOKU-23540-001.
PAGE 359
D 2011 TD 2011 Electrical system W 13-06-01 Removing and installing the heating plugs Standard tools Special tools: – Assembly tool 120440 6 Removing the glow plugs ● Disconnect the battery. ● Disconnect cables from heating plugs. ● Unscrew heating plugs (1) with assembly tool. 1 © 46969-0 ● Visually inspect the component. © 46970-0 © 01/2009 1/4 OBJ_DOKU-23541-001.
PAGE 360
Electrical system W 13-06-01 D 2011 TD 2011 Installing the glow plugs ● Screw in heating plug (1). ● Tighten heating plug (1) with assembly tool. 21 Nm ● Connect cables to heating plugs. 1 ● Connect the battery. 6 © 46969-0 © 01/2009 2/4 OBJ_DOKU-23541-001.
PAGE 361
D 2011 TD 2011 Electrical system W 13-06-01 Technical Data Tightening specifications ID no. Name A13 032 Heating plug on cylinder head Screw type Notes / Remark Value 21 Nm For the tightening procedure according to torque using a torque wrench, a maximum variation of the tightening torque of +/- 10% is permissible. 6 © 01/2009 3/4 OBJ_DOKU-23541-001.
PAGE 363
D 2011 TD 2011 Electrical system W 13-06-02 Removing and installing the glow plug Standard tools 6 Removing the glow plug ● Disconnect cable connections. ● Unscrew glow plug (1). ● Remove sealing ring. 1 © 47477-0 ● Visually inspect the components. © 47478-0 © 01/2009 1/4 OBJ_DOKU-23542-001.
PAGE 364
Electrical system W 13-06-02 D 2011 TD 2011 Installing the glow plug ● Insert new sealing ring. ● Insert glow plug (1). 1 6 © 47479-0 ● Tighten glow plug (1). 60 Nm ● Connect cable. 4 Nm 1 © 47477-0 © 01/2009 2/4 OBJ_DOKU-23542-001.
PAGE 365
D 2011 TD 2011 Electrical system W 13-06-02 Technical Data Tightening specifications ID no. Name Glow plug in charge air line / intake A13 031 pipe A13 034 Cable connection to glow plug Screw type Notes / Remark Value 60 Nm 4 Nm For the tightening procedure according to torque using a torque wrench, a maximum variation of the tightening torque of +/- 10% is permissible. 6 © 01/2009 3/4 OBJ_DOKU-23542-001.
PAGE 368
D 2011 TD 2011 Standard tools Orders The tools can be ordered directly, stating the order number, from: WILBAER Wilhelm Bäcker GmbH & Co.KG Postfach 14 05 80 42826 Remscheid Germany Tel.: +49 (0) 2191 9339-0 Fax: +49 (0) 2191 9339-200 E-mail: info@wilbaer.de Web: http://www.deutz-tools.com 7 © 01/2009 2/8 OBJ_DOKU-24381-001.
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D 2011 TD 2011 Standard tools 8005 Compression pressure tester for diesel engines 10 - 40 bar Checking compression pressure © 35410-3 7 8011 Hose clip pliers Loosen and fasten hose clips e. g. fuel return pipe © 39426-1 8012 Socket wrench insert Wrench size 15, long © 35412-3 © 01/2009 3/8 OBJ_DOKU-24381-001.
PAGE 370
D 2011 TD 2011 Standard tools 8018 Claw wrench Wrench size 17, Removing and installing injection pipes © 37506-2 7 8027 Plier insert Removing and installing the lifting magnet © 39531-1 8035 Socket wrench insert Wrench size 22, strengthened version © 37504-1 © 01/2009 4/8 OBJ_DOKU-24381-001.
PAGE 371
D 2011 TD 2011 Standard tools 8036 Socket wrench insert Wrench size 32, (in conjunction with force multiplier 8049) © 39429-1 7 8049 Force multiplier Removing and installing the centre screw Tool kit, including socket wrench insert 8036 (in conjunction with holder 143420) © 39430-1 8115 V-belt tension measuring device 150 to 600 N Check V-belt tension © 35416-3 © 01/2009 5/8 OBJ_DOKU-24381-001.
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D 2011 TD 2011 Standard tools 8116 Socket wrench insert Torx - E18 © 35415-1 7 8167 Cleaning brush Cleaning exhaust channels © 46283-0 8170 Micrometre depth gauge Measure the depth of the roller tappet © 39532-1 © 01/2009 6/8 OBJ_DOKU-24381-001.
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D 2011 TD 2011 Standard tools 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 7 8190 Rotation angle disc with magnet (e. g. setting valve clearance) © 42528-1 8198 Pricker Removing rotary shaft lip seal © 43206-1 © 01/2009 7/8 OBJ_DOKU-24381-001.
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D 2011 TD 2011 Standard tools 9017 Assembly lever e. g. removing and installing valves © 37511-2 7 9088 Clamping tongs Loosening and tightening hose clips © 39433-1 9090 Spring band pliers 320 mm Tighten spring clamp © 35420-3 © 01/2009 8/8 OBJ_DOKU-24381-001.
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D 2011 TD 2011 Special tools Orders The tools can be ordered directly, stating the order number, from: WILBAER Wilhelm Bäcker GmbH & Co.KG Postfach 14 05 80 42826 Remscheid Germany Tel.: +49 (0) 2191 9339-0 Fax: +49 (0) 2191 9339-200 E-mail: info@wilbaer.de Web: http://www.deutz-tools.com 8 © 01/2009 2/14 OBJ_DOKU-24382-001.
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D 2011 TD 2011 Special tools 100120 Connector (in conjunction with compression pressure tester 8005) © 39400-1 100400 Dial gauge with fixing wheel Measuring range 0 - 10 mm / 0.01 mm 8 © 35424-1 100410 Digital gauge Measuring range 0 - 30 mm / 0.01 mm © 43205-0 © 01/2009 3/14 OBJ_DOKU-24382-001.
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D 2011 TD 2011 Special tools 100700 Ajustable bolt Crankshaft and camshaft lock © 39101-1 8 100710 Ajustable bolt Control linkage lock © 39401-1 100750 Measuring device Measuring bar with two shims (in conjunction with 100400 and 100410) Checking valve lag dimension Checking piston projection © 39402-2 © 01/2009 4/14 OBJ_DOKU-24382-001.
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D 2011 TD 2011 Special tools 101020 Degree scale for testing and setting the static beginning of injection © 47638-0 101030 Adapter (in conjunction with degree scale 101020) 8 © 47637-0 101100 Rig pin Lock the steering link of the injection pump © 39404-1 © 01/2009 5/14 OBJ_DOKU-24382-001.
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D 2011 TD 2011 Special tools 101300 Point for degree scale for testing and setting the static beginning of injection © 39406-1 8 101500 High-pressure hand pump for testing and setting the static beginning of injection © 36443-2 101510 Supply tank (in conjunction with high-pressure hand pump 101500) © 36444-2 © 01/2009 6/14 OBJ_DOKU-24382-001.
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D 2011 TD 2011 Special tools 103040 Test template Check shim thickness © 47495-0 110090 Puller (in connection with sliding hammer 150800) Removing fuel injector 8 © 35433-2 110110 Holder Wrench size 11, clamp the injection valve in the vice © 35434-2 © 01/2009 7/14 OBJ_DOKU-24382-001.
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D 2011 TD 2011 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 jammed fuel injector sealing ring © 45111-0 © 01/2009 8/14 OBJ_DOKU-24382-001.
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D 2011 TD 2011 Special tools 142050 Assembly tool Install camshaft sealing ring © 39412-1 142680 Assembly tool Installing crankshaft sealing ring (flywheel side) 8 © 47496-0 142690 Assembly tool Installing crankshaft sealing ring (opposite side to flywheel) © 47497-0 © 01/2009 9/14 OBJ_DOKU-24382-001.
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D 2011 TD 2011 Special tools 143420 Counter support (in conjunction with force multiplier 8049 and socket wrench insert 8036) © 39417-1 8 143430 Washer (in conjunction with holder 143420) © 39418-1 144130 Counter support Hold toothed belt wheel of the camshaft © 39420-1 © 01/2009 10/14 OBJ_DOKU-24382-001.
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D 2011 TD 2011 Special tools 150800 Slide hammer Removing fuel injector © 35449-2 151500 Separating tool Removing metal sheet lubricating oil pan from crankcase 8 © 45974-0 170050 Special wrench Unscrewing the filter cartridges © 37629-2 © 01/2009 11/14 OBJ_DOKU-24382-001.
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D 2011 TD 2011 Special tools 170160 Stoppers/caps 1 set of differently-sized stoppers and caps Sealing openings on the fuel system © 43663-0 8 6067 Assembly block Engine clamping, one-sided © 39424-1 6067/114 Supporting bracket (in conjunction with assembly block 6067) Engine clamping, one-sided © 39369-1 © 01/2009 12/14 OBJ_DOKU-24382-001.
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D 2011 TD 2011 Special tools 6067/115 Clamping bracket (in conjunction with assembly block 6067) Engine clamping, one-sided © 39425-1 8 © 01/2009 13/14 OBJ_DOKU-24382-001.