Workshop Manual
Table Of Contents
- Workshop Manual
- 1 Foreword
- 2 General
- 3 User notes
- 5 Job card overview
- 5.1 Sorted alphabetically
- 5.2 Sorted numerically
- 6 Job cards
- Checking the compression pressure
- Mounting engine on assembly block and demounting
- Setting valve clearance
- Removing and installing the rocker arm and rocker arm bracket
- Renewing the crankshaft sealing ring (flywheel side)
- Renewing the crankshaft sealing ring (opposite side to flywheel)
- Removing and installing the crankcase bleeding
- Removing and installing rear cover
- Removing and installing the connection housing
- Renew camshaft sealing ring (opposite side to flywheel)
- Check control times
- Renew toothed belt and tensioning pulley
- Removing and installing the toothed belt wheel
- Removing and installing the impulse transmitter
- Removing and installing the exhaust damper
- Removing and installing the exhaust line
- Removing and install the charge air line
- Removing and installing the turbocharger
- Removing and installing the intake manifold
- Removing and installing the exhaust gas return valve
- Removing and installing the exhaust gas return pipe
- Removing and installing the exhaust gas collection pipe (Exhaust gas recirculation)
- Removing and installing the sensor (Exhaust gas recirculation)
- Removing and installing the magnet clip (Exhaust gas recirculation)
- Removing and installing the lifting magnet (Start amount release)
- Renewing the injection lines
- Removing and installing the fuel injector pump
- Check start of injection
- Calculating the thickness of shim
- Removing and installing the fuel injectors
- Removing and installing the lifting magnet (charge air pressure-dependent full load stop)
- Installing and removing charge air pressure-dependent full load stop
- Removing and installing fuel pipes
- Removing and installing the fuel filter console
- Removing and installing the fuel filter console
- Removing and installing the fuel supply pump
- Removing and installing the lubricating oil pump
- Removing and installing the oil suction pipe
- Removing and installing the lubricating oil pan (metal sheet lubricating oil pan)
- Removing and installing the lubricating oil cooler
- Removing and installing the oil pressure regulating valve
- Removing and installing the oil filter console
- Removing and installing the oil pressure switch
- Removing and installing temperature transmitter
- Removing and installing the thermostat (Lubricating oil cooler)
- Removing and installing the control line
- Remove and install the cooling blower
- Dismantling and assembling the cooling blower
- Removing and installing air duct
- Removing and installing the air bearing
- Removing and installing the lifting magnet (Engine shutdown)
- Removing and installing the V-belt pulley
- Renew V-belts, check V-belt tension
- Removing and installing the flywheel
- Removing and installing the hydraulic pump
- Renew toothed belt and tensioning pulley (Hydraulic pump)
- Removing and installing the generator
- Removing and installing the starter
- Removing and installing the starter
- Removing and installing the heating plugs
- Removing and installing the glow plug
- 7 Standard tools
- 8 Special tools
5
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D 2011 Job card overview
TD 2011 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 demoun-
ting
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
to flywheel)
Drive system
W 03-01-11 Removing and installing the crankcase bleeding Crankcase
W 03-09-01 Removing and installing rear cover Crankcase
W 03-09-04 Removing and installing the connection housing Crankcase
W 04-03-01
Renew camshaft sealing ring (opposite side to fly-
wheel)
Engine control
W 04-04-11 Steuerzeiten prüfen Engine control
W 04-04-12 Renew toothed belt and tensioning pulley Engine control
W 04-04-15 Removing and installing the toothed belt wheel Engine control
W 05-07-01 Removing and installing the impulse transmitter Speed control
W 06-01-05 Removing and installing the exhaust line Exhaust system/Charging
W 06-01-05 Removing and installing the exhaust damper Exhaust system/Charging
W 06-02-03 Removing and install the charge air line Exhaust system/Charging
W 06-06-04 Removing and installing the turbocharger Exhaust system/Charging
W 06-07-03 Removing and installing the intake manifold Exhaust system/Charging
W 06-09-06
Removing and installing the exhaust gas return val-
ve
Exhaust system/Charging
W 06-09-07 Removing and installing the exhaust gas return pipe Exhaust system/Charging
W 06-09-08
Removing and installing the exhaust gas collection
pipe (Exhaust gas recirculation)
Exhaust system/Charging
W 06-09-09
Removing and installing the sensor (Exhaust gas
recirculation)
Exhaust system/Charging
W 06-09-10
Removing and installing the magnet clip (Exhaust
gas recirculation)
Exhaust system/Charging
W 07-02-07
Removing and installing the lifting magnet (Start
a
mount
release)
Fuel system
W 07-03-01 Renewing the injection lines Fuel system
W 07-04-01 Removing and installing the fuel injector pump Fuel system
W 07-06-01 Check start of injection Fuel system
W 07-06-03 Calculating the thickness of shim Fuel system
W 07-07-01 Removing and installing the fuel injectors Fuel system