Workshop Manual D 2008/2009 0312 3422 en Note for printers Color: white Paper: Ikonofix 250 g/m2 Workshop Manual D 2008/2009
Workshop Manual D 2008/2009 0312 3422 en 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.
DEUTZ AG Service Information Systems Ottostraße 1 51149 Köln Deutschland Tel.: +49 (0) 221-822-0 Fax: +49 (0) 221-822-5850 Web: http://www.deutz.com The engine company. Printed in Germany All rights reserved 1st Edition, 02/2006 Order No.
D 2008/2009 1 Foreword 2 General 3 User notes 3.1 3.2 3.2.1 3.2.2 3.3 3.4 3.5 4 Testing and setting data Tightening specifications Job card overview 5.1 © 01/2006 General Specifications Safety regulations and rules for the prevention of accidents Disposal regulations Operating manual and workshop manual Job cards Explanation of symbols Technical data 4.1 4.
D 2008/2009 Table of contents © 01/2006 2/2 5976-001
DEUTZ engines Foreword 1 1 © 11/2005 Foreword 1/4 5977-001
DEUTZ engines Foreword 1 © 11/2005 2/4 5977-001
DEUTZ engines Foreword z Read and observe the information in this documentation. You will avoid accidents, retain the manufacturer's warranty and possess a fully functional and ready to operate engine. z This engine is built exclusively for purpose according to the scope of delivery - defined by the equipment manufacturer (use for the intended purpose). Any use above and beyond this is considered improper use. The manufacturer will not be liable for damages resulting from this.
DEUTZ engines Foreword 1 © 11/2005 4/4 5977-001
DEUTZ engines General 2 2 © 11/2005 General 1/4 5982-001
DEUTZ engines General 2 © 11/2005 2/4 5982-001
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.
DEUTZ engines General 2 © 11/2005 4/4 5982-001
User notes 3 3 © 12/2005 User notes 1/6 5983-001
User notes 3 © 12/2005 2/6 5983-001
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.
User notes 3 – Injection lines and high pressure fuel lines must never be connected when the engine is running. 3.3 Operation manual and workshop manual – Do not place hands near to a leak in the high pressure fuel system. To structure the information to suit the user, the service documentation is divided into operation manual and workshop manual. – Also carefully check all high pressure components visually before performing tests on the running engine.
User notes 3.4 Job cards 3.4.2 Structure of a job card The job cards are divided in the workshop manual into "W" and "I" job cards. The "W" job card documents standard repairs on the engine and/or its components. The necessary tools and special tools are also specified in the "W" job card. The "I" job card additionally documents the appropriate work procedures for repairing the engine and/ or its components. The workshop must satisfy special conditions to perform these work procedures.
User notes 3.5 Explanation of symbols Danger! of death or to health. Must be observed! For example: The incorrect use or conversion of the turbocharger can lead to serious injury. Caution! Danger to the component/engine. Noncompliance can lead to destruction of the component/engine. Must be observed! Note General notes on assembly, environmental protection etc. No potential danger for man or machine. Tool Conventional and special tools required for the work.
D 2008/2009 Technical data 4 © 02/2006 4 Technical data 4.
Technical data Testing and setting data D 2008/2009 4 © 02/2006 2/14 5987-001
© 02/2006 Name 3/14 Compression ratio Direction of rotation Max. declared speed Min. idling speed Ignition sequence P00 40 P00 50 P00 60 P00 61 P00 71 Permissible axial backlash of crankshaft Piston, diameter, standard P02 34 P02 71 Power train Stroke Combustion system P00 20 P00 32 Working procedure P00 10 Bore Engine weight according to DIN 70020-A approx.
© 02/2006 Piston projection Piston pin bore Piston height Position of the piston ring joints P02 75 P02 78 P02 79 P02 95 Camshaft, axial backlash 4/14 Start of pumping (static) Start of pumping (static) Start of pumping (static) Nozzle opening pressure fuel injector P07 31 P07 31 P07 31 P07 52 Coolant thermostat, stroke distance P09 13 P12 11 Tension of the V-belt Other components Coolant thermostat start of opening P09 11 Cooling system Start of pumping (static) Start of pumping
Name Tension of the V-belt ID no.
© 02/2006 6/14 Width of engine Height of engine Engine weight according to DIN 70020-A approx. Working procedure Combustion system Total volume Bore Stroke Compression ratio Direction of rotation Ignition sequence P00 02 P00 03 P00 04 P00 10 P00 20 P00 30 P00 31 P00 32 P00 40 P00 50 P00 71 Max.
© 02/2006 Min.
© 02/2006 Start of pumping (static) Start of pumping (static) Start of pumping (static) Nozzle opening pressure fuel injector P07 31 P07 31 P07 31 P07 52 Coolant thermostat stroke distance P09 13 P12 21 P12 11 Tension of the V-belt Tension of the V-belt Other components Coolant thermostat start of opening P09 11 Cooling system Name TD 2009 TD 2009 Part number: 0411 4104, at 1,800 rpm (fixed speed) Part number: 0411 4074, at 3,000 rpm (variable speed) Check after 15 minutes running unde
Technical data Tightening specifications D 2008/2009 4 4.
Technical data Tightening specifications D 2008/2009 4 © 02/2006 10/14 5987-001
© 02/2006 Gear case cover on crankcase Lubricating oil pan on crankcase Drain plug on lubricating oil pan Connection housing to crankcase A03 020 A03 030 A03 031 A03 080 Main bearing housing on crankcase A02 010 Big end bearing cap on connecting rod Lifting log on cylinder head A01 092 A02 020 Cylinder head cover on cylinder head A01 004 Main bearing housing (assembly) Rocker arm bracket on cylinder head A01 002 A02 013 Cylinder head on crankcase A01 001 Main bearing housing on crankc
© 02/2006 Blocking screw on fuel injector pump Fule line on fuel supply pump Fuel supply pump on crankcase Fuel injector pump on crankcase Fuel lines on fuel filter console A07 013 A07 019 A07 024 A07 031 A07 084 Intake manifold on cylinder head A06 030 Pipe clamp for high pressure pipes Exhaust manifold on cylinder head A06 001 A07 006 Idler gear on crankcase A04 011 Union nuts for high pressure pipes Thrust washer camshaft on crankcase A04 005 A07 003 Fuel injector toothed gear on f
© 02/2006 13/14 D/TD 2008/ 2009 Bracket (generator) on gearcase cover and brakM8 x 1.25 ket M8 x 1.25 21 Nm 21 Nm A13 018 22 Nm D/TD 2008/ 2009 D/TD 2008/ 2009 41 Nm D/TD 2008/ 2009 M8 x 1.25 9 Nm D/TD 2008/ 2009 Generator on bracket 300 Nm D/TD 2008/ 2009 A13 013 96 Nm D/TD 2008/ 2009 Generator on gearcase cover M10 x 1.5 M6 x 1.0 M20 x 1.5 M12 x 1.
Name Heating plug on cylinder head Connecting rail on heating plug Cable (cl. 30) on starter A13 032 © 02/2006 A13 033 A13 071 M4 x 0.7 M10 x 1.0 Screw type Notes / Remarks Pre-clamping value 15 Nm 2.5 Nm 9 Nm Series D/TD 2008/ 2009 D/TD 2008/ 2009 D/TD 2008/ 2009 4 ID no.
D 2008/2009 Job card overview 5 © 02/2006 5 Job card overview 5.
Job card overview Sorted numerically D 2008/2009 5 © 02/2006 2/4 5988-001
Job card overview Sorted numerically D 2008/2009 Job card Activity Maintenance group W 01-02-02 Removing and installing the rocker arm Cylinder head W 01-04-04 Removing and installing the cylinder head Cylinder head W 01-04-09 Measuring the piston projection Cylinder head W 01-05-01 Removing and installing the valves Cylinder head W 02-01-04 Checking the axial clearance of the crankshaft Drive system W 02.02.
D 2008/2009 Job card overview 5 © 02/2006 4/4 5988-001
DEUTZ engines 6 © 11/2005 Job cards Job cards 6 1/2 5989-001
DEUTZ engines Job cards 6 © 11/2005 2/2 5989-001
Cylinder head W 01-02-02 D 2008/2009 Removing and installing the rocker arm Commercial available tools 6 Removing the rocker arm z Loosen hose clip (1). z Unscrew screws (2). z Remove cylinder head cover (3). 2 z Remove gasket (4). 3 1 4 © 41001-1 z Unscrew screw (1). z Remove rocker arm bearing (2). 1 z Remove rocker arm (3). Lay out components in the order in which they should be installed. 2 z Visually inspect the components.
Cylinder head W 01-02-02 D 2008/2009 Installing the rocker arm z Grease the rocker arm (arrow) lightly. 1 z Mount rocker arm (3) and rocker arm bearing (2). Align rocker arm centred to the valve spring! 2 3 z Fasten screw (1). 6 © 41002-1 z Press down rocker arm (1) and pushrod. z Tighten screw (2). 27 Nm Oil rocker arm lightly! 2 1 © 41004-1 z Clean sealing surfaces. The sealing surfaces must be dry and free from grease and dirt. 2 z Mount new gasket (4). z Mount cylinder head cover (3).
Cylinder head W 01-04-04 D 2008/2009 Removing and installing cylinder head Commercial available tools – W 01-02-02 – W 01-04-09 – W 06-01-05 – W 06-07-03 6 Removing the cylinder head 3 1. Valve 2 2. Rocker arm 5 3. Cylinder head bolts 4. Pushrods 5. Thermostat housing 6. Fuel injector 7. Coolant duct 1 7 6 4 © 41014-0 z Remove rocker arm. W 01-02-02 z Remove exhaust manifold. W 06-01-05 z Remove intake manifold.
Cylinder head W 01-04-04 D 2008/2009 z Remove push rods (1). Lay out components in the order in which they should be installed. z Visually inspect the components. 1 6 © 41007-1 Representation: 3-cylinder engine Loosen the screws in the specified order. z Remove screws. 7 3 2 6 8 4 1 5 © 41178-0 Representation: 4-cylinder engine Loosen the screws in the specified order. z Remove screws.
Cylinder head W 01-04-04 D 2008/2009 z Lift the cylinder head carefully from the crankcase. z Remove gasket. z Clean sealing surfaces. Do not place cylinder head on sealing surface. 6 © 41009-1 Installing the cylinder head 1 z Measure piston projection. W 01-04-09 Note installation position of the hydro tappets. Make sure the clamping bushings (1) are in place. 1 © 41010-0 z Fit a new cylinder head gasket. The sealing surfaces for the cylinder head gasket must be clean and free of oil.
Cylinder head W 01-04-04 D 2008/2009 z Fit cylinder head. Pay attention to clamping bushings (1). ! 1 1 6 © 41012-1 Representation: 3-cylinder engine Attention! Use new screws. 7 3 2 6 8 4 1 5 z Oil the cylinder head screws slightly. z Tighten the screws according to the tightening sequence. – Step 1: 35 Nm – Step 2: 60° – Step 3: © 41178-0 60° Representation: 4-cylinder engine Attention! Use new screws. 7 3 2 6 10 8 4 1 5 9 z Oil the cylinder head screws slightly.
Cylinder head W 01-04-04 D 2008/2009 z Lightly oil pushrods. z Insert pushrods in hydro-tappets (1). Note installation position! 1 6 © 41013-1 z Mount intake manifold. W 06-07-03 z Install exhaust manifold. W 06-01-05 z Install rocker arm.
Cylinder head W 01-04-04 D 2008/2009 6 © 02/2006 6/6 5992-001
Cylinder head W 01-04-09 D 2008/2009 Measuring the piston projection Commercial available tools: – Micrometer gauge – W 01-04-04 Special tools: – Dial gauge. . . . . . . . . . . . . . . . . . 100400 – Measuring device . . . . . . . . . . . . 100750 6 z Remove cylinder head. W 01-04-04 z Clean sealing surfaces. © 41155-0 z Turn the crankshaft until the respective piston is just in front of the top dead centre (arrow).
Cylinder head W 01-04-09 D 2008/2009 z Insert dial gauge into measuring beam. z Place shims (1) and measuring beam (2) on the sealing surface of the crankcase. 1 z Apply the stylus to the piston base (arrow) under pretension. z Continue turning the crankshaft evenly until the reversal point of the pointer on the dial gauge is reached. The piston is now at top dead centre (TDC). 2 6 © 41149-0 z Move the measuring beam.
Cylinder head W 01-04-09 D 2008/2009 z Align the measuring apparatus on the spacing washers in such a way that the stylus lies on the specified measuring points. Measuring points see diagram. Do not position the stylus on the piston marking. z Note the largest measured value. z Compare actual value with setpoint value.
Cylinder head W 01-04-09 D 2008/2009 6 © 02/2006 4/4 5993-001
Cylinder head W 01-05-01 D 2008/2009 Removing and installing the valves Commercial available tools: – Assembly pliers. . . . . . . . . . . . . . . . 8024 – Assembly lever . . . . . . . . . . . . . . . . 9017 – W 01-04-04 – W 07-07-01 – W 13-06-01 Special tools: – Assembly sleeves . . . . . . . . . . . . 121420 – Assembly tool . . . . . . . . . . . . . . . 121430 6 Removing the valves 1. Exhaust valve 4 2. Inlet valve 3. Valve spring 3 4. Rocker arm 5.
Cylinder head W 01-05-01 D 2008/2009 z Attach assembly lever with screw (1) to cylinder head. z Press down valve spring with assembly lever. z Remove both tapper collets (2). z Remove valve spring plates, valve springs and valves. 2 z Remove assembly lever. 1 6 © 41020_2 z Pull off valve stem seal (1) with assembly pliers (2). 2 1 © 41021-1 z Clean cylinder head, check and visually inspect for damage. z Visually inspect the components.
Cylinder head W 01-05-01 D 2008/2009 Installing the valves z Oil the valve stem lightly. z Insert and hold valve. z Mount assembly sleeve. z Push new valve stem seal onto valve guide over the assembly sleeve with assembly tool (1). 1 6 © 41023-1 z Mount assembly lever. z Insert valve spring. z Insert valve spring plate (2). z Press down the valve spring with the assembly lever and insert both tapper collets (1). 1 2 © 41179_0 z Remove assembly lever.
Cylinder head W 01-05-01 D 2008/2009 z Install cylinder head (1) W 01-04-04 2 z Install fuel injectors (3) 3 W 07-07-01 1 z Install heating plugs (2) W 13-06-01 6 © 41019-0 © 02/2006 4/4 5996-001
Drive system W 02-01-04 D 2008/2009 Checking the axial clearance of the crankshaft Commercial available tools: – Magnetic measuring stand – Micrometer gauge 8190 Special tools: – Dial gauge. . . . . . . . . . . . . . . . . . 100400 6 Checking the axial backlash z Mount magnetic measuring stand. z Insert dial gauge. z Apply stylus to the crankshaft end with pre-tension. z Press crankshaft in direction of arrow. z Adjust dial gauge to "0".
Drive system W 02-01-04 D 2008/2009 6 © 02/2006 2/2 5997-001
Drive system W 02-02-02 D 2008/2009 Renewing the crankshaft sealing ring (flywheel side) Commercial available tools: – Pricker. . . . . . . . . . . . . . . . . . . . . . . 8198 – Assembly lever . . . . . . . . . . . . . . . . 9017 – W 12-06-01 Special tools: – Assembly tool . . . . . . . . . . . . . . . 142780 – Self-tapping screw – Washer 6 Removing the crankshaft sealing ring z Remove flywheel. W 12-06-01 © 41025-0 z Make a hole of approximately 3 mm in the crankshaft sealing ring with a pricker.
Drive system W 02-02-02 D 2008/2009 z Turn in a self-tapping screw with washer. z Pull out the crankshaft sealing ring with assembly lever. z Visually inspect all running surfaces. 6 © 41027-0 Installing the crankshaft sealing ring Use new crankshaft sealing ring. The sealing lip faces the crankcase. z Oil the sealing lip of the crankshaft sealing ring lightly. z Place the crankshaft sealing ring on the assembly tool. z Mount the assembly tool on the crankcase pin.
Drive system W 02-02-04 D 2008/2009 Renewing the crankshaft sealing ring (opposite side to flywheel) Commercial available tools: – Pricker. . . . . . . . . . . . . . . . . . . . . . . 8198 – Assembly lever . . . . . . . . . . . . . . . . 9017 – W 12-02-02 Special tools: – Assembly tool . . . . . . . . . . . . . . . 142790 – Self-tapping screw – Washer 6 Removing the crankshaft sealing ring z Remove V-belt pulley.
Drive system W 02-02-04 D 2008/2009 Installing the crankshaft sealing ring Use new crankshaft sealing ring. The sealing lip faces the crankcase. z Oil the sealing lip of the crankshaft sealing ring lightly. z Place the crankshaft sealing ring on the assembly tool. z Mount the assembly tool on the crankcase pin. z Drive in crankshaft sealing ring to the stop with the assembly tool. The installation depth is determined by the assembly tool. 6 z Remove assembly tool. z Install V-belt pulley.
Drive system W 02-04-01 D 2008/2009 Removing and installing the crankshaft Commercial available tools: – Assembly lever – 3-arm puller – W 02-01-04 – W 02.02.02 – W 02-09-03 – W 04-04-09 – W 08-11-10 – W08-04-06 – W 12-06-01 Special tools: – Dial gauge. . . . . . . . . . . . . . . . . . 100400 – Assembly tool . . . . . . . . . . . . . . . 143860 – Assembly tool . . . . . . . . . . . . . . . 143870 – Threaded rod . . . . . . . . . . . . . . . 143880 6 Removing crankshaft 1. Crankshaft 2.
Drive system W 02-04-01 D 2008/2009 z Unscrew screw (1). z Pull out journal (2). z Remove idler gear (3). 3 2 1 6 © 41030-0 z Unscrew screw (1). z Remove camshaft toothed wheel (2). 2 1 © 41031-0 z Pull off camshaft toothed wheel with 3-arm puller.
Drive system W 02-04-01 D 2008/2009 z Unscrew screws (1). z Lever out main bearing housing (2) with a suitable tool in the recess clearances. Make sure that the thrust washer halves do not fall into the crankcase. z Visually inspect the components. 2 6 1 © 41034-1 z Unscrew screw (1). z Remove oil suction pipe (2). 3 1 z Unscrew fixing screws (3). z Remove oil pressure regulating valve (4). 2 W 08-11-10 4 © 41059-0 z Remove crankshaft. z Visually inspect the components.
Drive system W 02-04-01 D 2008/2009 Removing the main bearing z Insert thrust pad (1) in bearing bush. z Insert threaded rod (2). z Insert counter support (3). z Mount washers and screw on nuts. 1 3 6 2 © 41060-1 z Turn the nut (1) clockwise. The bearing bush is pressed onto the crankcase by the thrust pad. 1 z Dismantle assembly tool. z Remove bearing bush. © 41061-1 z Clamp main bearing housing in the vice. Use cushioned jaws. 2 z Insert thrust pad (1) in bearing bush.
Drive system W 02-04-01 D 2008/2009 Installing the main bearing z Oil bearing bush with engine oil. z Press in bearing bush with assembly tool 143870. Make sure the bearing bush is not twisted. The installation depth is determined by the assembly tool. Mark the position of the lubricating oil bore on the main bearing housing. 6 © 41058-1 z Oil bearing bush with engine oil. z Mount bearing bush. 1 z Mount guide plate (1). 2 z Insert threaded rod (2). z Insert counter support.
Drive system W 02-04-01 D 2008/2009 z Dismantle assembly tool. z Remove assembly tool. z Check that the lubricating oil bore is in line. If the lubricating oil bore is not in line, the bearing bush must be removed and reinstalled. z Check installation depth of the bearing bush with depth measuring appliance. ca. 3 mm 6 © 41064-1 Installing the crankshaft 1 z Lightly oil bearing bush (1) with engine oil. z Push crankshaft into crankcase. Align screw thread (2) and through hole (3).
Drive system W 02-04-01 D 2008/2009 z Install main bearing housing (1). z Tighten screws (2). – Step 1: 15 Nm – Step 2: 27 Nm z Renewing the crankshaft sealing ring. W 02-02-02 2 1 6 © 41038-1 z Check axial backlash of crankshaft. W 02-01-04 z Heat up crankshaft toothed wheel to approx. 100 °C. 2 Danger! Danger of burning! z Mount crankshaft toothed wheel (1). Note installation position of Woodruff key (2) and groove. 1 z Install oil pressure regulating valve.
Drive system W 02-04-01 D 2008/2009 The marks (1) of the crankshaft toothed wheel and the camshaft toothed wheel must be in line! z Tighten screw (2). 81 Nm 2 1 6 © 41081-1 z Insert idler gear. The marks (1) of the crankshaft toothed wheel, intermediate gear and fuel injector toothed wheel must be in line! 1 © 41066-0 z Oil the journal lightly. z Insert the journal carefully into the needle bearing. z Tighten screw.
Drive system W 02-04-01 D 2008/2009 z Install piston and connection rods. W 02-09-03 z Mount gearcase cover. W 04-04-09 z Install flywheel.
Drive system W 02-04-01 D 2008/2009 6 © 02/2006 10/10 6001-001
Drive system W 02-09-03 D 2008/2009 Removing and installing the piston and con rod Commercial available tools – W 01-04-04 – W 02-09-07 – W 08-04-07 – W 08-04-06 Special tools: – Universal piston ring pliers . . . . . 130300 – Piston ring compressor . . . . . . . . 130510 6 Removing the piston and con rod 1 1. Piston rings 2. Piston 2 3. Piston pin 4. Connection rod 3 5. Big end bearing cap 6 6. Coolant duct in the crankcase 4 5 © 41042-0 z Remove cylinder head.
Drive system W 02-09-03 D 2008/2009 Removing the big end bearing cap z Position lifting bearing journal in LDC position. z Unscrew screws (1). z Remove big end bearing cap (2). z Remove bearing shell (3). Lay out components in the order in which they should be installed. Note order of cylinders. 3 2 1 6 © 41041-0 z Press out the piston and connection rod. Lay out components in the order in which they should be installed. Note order of cylinders. z Remove con rod bearing shells (1).
Drive system W 02-09-03 D 2008/2009 z Remove piston rings with universal piston ring pliers. z Check piston. W 02-09-07 6 © 41045-0 Completing con rod and piston z Insert new locking ring. Ensure that the installation location is free from faults. z Insert con rod. The labelling on the piston base and the numbered label of the connection rod face the camshaft side. z Oil the piston bolt lightly. z Press the piston bolt through. z Insert new locking ring.
Drive system W 02-09-03 D 2008/2009 z Install piston rings with universal piston ring pliers. z Arrange the piston ring joints with an offset of about 120° to each other. Do not turn the piston rings any further. 120° 120° 6 0° © 41046-0 z Lightly oil cylinder running surface, piston, piston rings and lifting bearing journal lightly. z Clamp piston rings with piston ring compressor. z Set lifting journal at bottom dead centre (BDC). z Push piston and con rod completely into cylinder.
Drive system W 02-09-03 D 2008/2009 z Insert oil dipstick. z Install oil suction pipe. W 08-04-06 z Install lubricating oil pan. W 08-04-07 z Install cylinder head.
Drive system W 02-09-03 D 2008/2009 6 © 02/2006 6/6 6002-001
Drive system W 02-09-07 D 2008/2009 Checking the piston Commercial available tools: – Micrometer gauge – Internal measuring device – W 02-09-03 Special tools: – Dial gauge. . . . . . . . . . . . . . . . . . 100400 When the piston wear limit is reached the piston must be replaced. 6 Checking the piston bolt bore z Remove piston. W 02-09-03 © 41044-1 z Prepare internal measuring device: – Mount probe bolt for the appropriate measuring range in the internal measuring device.
Drive system W 02-09-07 D 2008/2009 Diagram for measuring the piston bolt bore at the points "a" and "b" in the levels "1" and "2". 6 © 37239-1 z Insert internal measuring device in the piston bolt bore. z Balance the internal measuring device at the given measuring points and read off the measured value at the reversal point of the pointer. See schematic diagram for measuring points.
Drive system W 02-09-07 D 2008/2009 z Measure piston diameter with micrometer gauge. See schematic diagram for measuring points. P02 71 z Complete con rod and piston.
Drive system W 02-09-07 D 2008/2009 6 © 02/2006 4/4 6003-001
Crankcase W 03-09-04 D 2008/2009 Removing and installing the connection housing Commercial available tools – W 13-03-02 – W 12-06-01 6 Removing the connection housing z Remove starter (1). W 13-03-02 z Remove flywheel (2). W 12-06-01 2 1 © 41070-0 z Remove screws. z Remove connection housing. z Visually inspect the component.
Crankcase W 03-09-04 D 2008/2009 Installing the connection housing z Mount connection housing. z Tighten screws. 81 Nm 6 © 41072-0 z Install flywheel (1). W 12-06-01 z Install starter (2).
Engine control W 04-04-09 D 2008/2009 Removing and installing the gearcase cover Commercial available tools – W 12-02-02 – W 09-07-08 – W 13-02-03 – W 08-11-10 – W 08-10-07 Special tools: – Assembly tool . . . . . . . . . . . . . . . 142790 Collect leaking operating substances in suitable vessels and dispose of according to regulations. The engine oil and coolant should be added according to the operating manual. 6 Removing the gearcase z Remove V-belt pulley. W 12-02-02 z Remove fan impeller.
Engine control W 04-04-09 D 2008/2009 z Remove screws. z Remove gearcase cover. Attention! Do not damage the sealing surfaces. z Clean sealing surfaces. z Visually inspect sealing surfaces (arrows). 6 © 41053-0 Installing the gearcase cover z Knock out crankshaft sealing ring (1). Attention! Do not damage sealing surface when knocking out. 1 z Clean sealing surfaces. © 41054-1 z Fix the new gasket to the crankcase with a little grease.
Engine control W 04-04-09 D 2008/2009 z Mount gearcase cover. 10 17 1 9 Ensure that the installation location is free from faults. 16 2 8 15 z Tighten the screws according to the tightening sequence. 27 Nm 18 7 11 14 19 5 12 21 20 6 13 3 6 4 © 41069-1 z Mount oil filter console. z Tighten screws. 41 Nm © 41052-0 z Install oil filter. z Install coolant pump. W 09-07-08 z Install generator. W 13-02-03 z Install crankshaft sealing ring (flywheel side).
Engine control W 04-04-09 D 2008/2009 6 © 02/2006 4/4 6007-001
Engine control W 04-05-05 D 2008/2009 Removing and installing the camshaft Commercial available tools – W 01-04-04 – W 04-04-09 – W 07-11-01 Special tools: – Fixing pin . . . . . . . . . . . . . . . . . . 144180 – Dial gauge. . . . . . . . . . . . . . . . . . 100400 6 Removing the camshaft z Remove cylinder head (1). 1 W 01-04-04 z Remove gearcase cover (2). W 04-04-09 z Remove fuel supply pump (3). W 07-11-01 2 3 © 41074-0 z Set piston (1) at top dead centre.
Engine control W 04-05-05 D 2008/2009 z Pull out hydro-tappet (1). Use magnetic rod. 1 6 © 41076-1 z Unscrew screw (1). z Remove camshaft toothed wheel (2). 2 1 © 41031-1 z Remove screws. z Remove thrust washer.
Engine control W 04-05-05 D 2008/2009 z Fasten screw (1). z Pull out the camshaft carefully in the direction of the arrow. z Visually inspect the components. 1 6 © 41078-1 Installing the camshaft z Oil camshaft bearing lightly. z Insert camshaft carefully. © 41079-0 z Mount thrust washer. z Tighten screws.
Engine control W 04-05-05 D 2008/2009 Checking the axial backlash z Mount magnetic measuring stand. z Insert dial gauge. z Apply stylus to the camshaft end with pre-tension. z Press crankshaft in direction of arrow. 6 © 41160-1 z Adjust dial gauge to "0". z Press crankshaft in direction of arrow. z Read actual value from dial gauge. z Setpoint : 0,07 - 0,29 mm The axial backlash is not adjustable. If the axial backlash is greater than the setpoint, the camshaft must be renewed.
Engine control W 04-05-05 D 2008/2009 The marks (1) of the crankshaft toothed wheel and the camshaft toothed wheel must be in line! z Tighten screw (2). 81 Nm 2 1 6 © 41081-1 z Oil the hydro-tappet lightly. z Insert hydro-tappet. Note installation position of the hydro tappets. © 41084-0 z Install the fuel supply pump (1). W 07-11-01 3 z Mount gearcase cover (2). W 04-04-09 z Install cylinder head (3).
Engine control W 04-05-05 D 2008/2009 6 © 02/2006 6/6 6008-001
Exhaust system / Charging W 06-01-05 D 2008/2009 Removing and installing the exhaust manifold Commercial available tools – Fitting compound DEUTZ S1 6 Removing the exhaust manifold z Unscrew screws (1). z Remove exhaust manifold (2). z Remove gasket (3). 3 z Visually inspect the components. 2 1 © 41083-0 Installing the exhaust manifold z Clean sealing surfaces.
Exhaust system / Charging W 06-01-05 D 2008/2009 z Coat the screws with fitting compound . z Insert new seal (1). z Mount exhaust manifold (2). z Tighten screws (3). 1 27 Nm 2 Tightening sequence: From the centre outwards.
Exhaust system / Charging W 06-07-03 D 2008/2009 Removing and installing the intake manifold Attention! Commercial available tools Ensure utmost cleanliness when working on the fuel system. Carefully clean the area around the affected parts. Blow damp areas dry with compressed air. Observe the safety regulations and national specifications for handling fuels. Close all connections immediately after opening with new, clean plugs/caps. Do not remove plugs/caps until immediately before assembling.
Exhaust system / Charging W 06-07-03 D 2008/2009 z Clean sealing surfaces. 6 © 41089-0 Install intake manifold z Screw on fuel line (5). z Coat the screws (2) with fitting compound. z Mount gasket (4). 5 1 z Mount intake manifold (3). z Tighten screws (2). 27 Nm Tightening sequence: From the centre outwards. z Tighten pipe clip (1). 4 3 2 © 41090-1 z Mount high pressure pipes. z Screw on union nuts. Attention! Install injection pipes without tension. z Tighten union nuts.
Fuel system W 07-04-01 D 2008/2009 Removing and installing the fuel injector pump Commercial available tools – W 04-04-09 Special tools: – Measuring pin . . . . . . . . . . . . . . . 110180 6 Attention! Ensure utmost cleanliness when working on the fuel system. Carefully clean the area around the affected parts. Blow damp areas dry with compressed air. Observe the safety regulations and national specifications for handling fuels.
Fuel system W 07-04-01 D 2008/2009 z Turn crankshaft. The marks (1) of the crankshaft toothed wheel, intermediate gear and fuel injector toothed wheel must be in line! 1 6 © 41066-0 z Push the measuring pin (1) through the marking hole (arrow) into the crankcase. The bore in the fuel injector toothed wheel must be in line with the bore in the crankcase. 1 © 41094-1 z Loosen blocking screw (1). 2 z Push locking ring (2) towards larger opening. The blocking screw can now be screwed in further.
Fuel system W 07-04-01 D 2008/2009 z Unscrew nut (1). z Remove washer (2). z Remove measuring pin (3). 3 z Pull off fuel injector toothed wheel (4). Use suitable puller if necessary. 4 2 1 6 © 41144-0 z Disconnect cables. z Unscrew screws (1). z Remove fuel injector pump(2). 2 1 © 41145-0 Installing the fuel injector pump z Mount fuel injector pump (2). z Tighten screws (1). 21 Nm Attention! 2 The blocking screw may not be loosened.
Fuel system W 07-04-01 D 2008/2009 z Push fuel injector toothed wheel (4) onto fuel injector shaft. 3 4 Attention! The marks of the fuel injector toothed wheels and the idler gear must be in line. z Push the measuring pin (3) through the marking hole into the crankcase. z Mount washer (2). z Mount nut (1). 2 1 z Tighten nut (1). 10 Nm 6 © 41147-0 z Loosen blocking screw (1). z Push locking ring (2) towards smaller opening.
Fuel system W 07-07-01 D 2008/2009 Removing and installing the fuel injectors Attention! Commercial available tools Ensure utmost cleanliness when working on the fuel system. Carefully clean the area around the affected parts. Blow damp areas dry with compressed air. Observe the safety regulations and national specifications for handling fuels. Close all connections immediately after opening with new, clean plugs/caps. Do not remove plugs/caps until immediately before assembling.
Fuel system W 07-07-01 D 2008/2009 Installing the fuel injector z Mount new sealing ring (1) on fuel injector. 1 6 © 41098-1 z Insert fuel injector (3) in cylinder head. 1 The fuel leakage connection faces the exhaust manifold. 2 z Mount clamping shoe (2). 3 Note installation position of the clamping shoe. 4 z Tighten screw (1). 27 Nm © 41097-0 z Mount high presssure pipes (1). z Screw on union nuts. 2 Attention! Install injection pipes without tension. z Tighten union nuts.
Fuel system W 07-10-08 D 2008/2009 Removing and installing the fuel filter console Attention! Commercial available tools Ensure utmost cleanliness when working on the fuel system. Carefully clean the area around the affected parts. Blow damp areas dry with compressed air. Observe the safety regulations and national specifications for handling fuels. Close all connections immediately after opening with new, clean plugs/caps. Do not remove plugs/caps until immediately before assembling.
Fuel system W 07-10-08 D 2008/2009 z Unscrew screws (1). z Remove fuel filter console (2). z Visually inspect the components. 1 2 6 © 41101-0 Installing the fuel filter console z Install the fuel filter console (2). z Tighten screws (1). 1 41 Nm z Clean sealing surfaces. 2 © 41101-0 z Mount fuel pipes. z Tighten hollow screw (1) with new sealing rings. 1 21 Nm z Tighten fuel lines (2). 21 Nm z Mount fuel return line. Check fuel lines and renew if necessary.
Fuel system W 07-10-08 D 2008/2009 z Lightly oil gasket on new fuel filter. z Screw on fuel filter by hand. The seal must fit evenly. z Tighten the fuel filter by another half turn (tightening torque see fuel filter print).
Fuel system W 07-10-08 D 2008/2009 6 © 02/2006 4/4 6014-001
Fuel system W 07-11-01 D 2008/2009 Removing and installing the fuel supply pump Attention! Commercial available tools Ensure utmost cleanliness when working on the fuel system. Carefully clean the area around the affected parts. Blow damp areas dry with compressed air. Observe the safety regulations and national specifications for handling fuels. Close all connections immediately after opening with new, clean plugs/caps. Do not remove plugs/caps until immediately before assembling.
Fuel system W 07-11-01 D 2008/2009 z Clean sealing surfaces. 6 © 41105-0 Installing the fuel supply pump z Push in pump plunger (4). z Turn crankshaft. The pump plunger must touch the base circle of the camshaft. 4 2 z Mount new O-ring (3). 3 z Mount fuel supply pump (2). z Tighten screws (1). z Tighten screws (1). 27 Nm 1 © 41104-0 z Mount fuel pipe. z Tighten screw.
Lube oil system W 08-04-05 D 2008/2009 Removing and installing the lubricating oil pump Commercial available tools – W 02-04-01 – W 04-04-09 – W 08-04-06 Collect leaking operating substances in suitable vessels and dispose of according to regulations. 6 Removing the lubricating oil pump z Remove gearcase cover (1). W 04-04-09 z Remove idler gear (2). W 02-04-01 1 2 z Remove oil suction pipe (3). W 08-04-06 3 © 41106-1 z Unscrew screws (1). z Remove lubricating oil pump (2).
Lube oil system W 08-04-05 D 2008/2009 Installing the lubricating oil pump z Insert lubricating oil pump (2). z Tighten screws (1). – Step 1: 4 Nm – Step 2: 9 Nm 1 2 6 © 41107-0 z Install oil suction pipe (3). W 08-04-06 z Install idler gear (2). W 02-04-01 z Mount gearcase cover (1).
Lube oil system W 08-04-06 D 2008/2009 Removing and installing the oil suction pipe Commercial available tools – W 08-04-07 6 Removing the oil suction pipe z Remove lubricating oil pan. W 08-04-07 © 41108-0 z Unscrew screw (1). z Remove oil suction pipe (2). z Remove O-ring (3).
Lube oil system W 08-04-06 D 2008/2009 Installing the oil suction pipe. z Insert new O-ring (3). z Lightly oil O-ring (3). z Mount oil suction pipe (2). z Tighten screw (1). 41 Nm 3 1 6 2 © 41109-0 z Install lubricating oil pan.
Lube oil system W 08-04-07 D 2008/2009 Removing and installing the lubricating oil pan Collect leaking operating substances in suitable vessels and dispose of according to regulations. Commercial available tools Observe the appropriate operating instructions for emptying and filling the engine. 6 Removing the lubricating oil pan z Unscrew drain plugs (1). Collect the engine oil and dispose of according to regulations. z Insert new sealing ring. z Tighten drain plugs (1).
Lube oil system W 08-04-07 D 2008/2009 Installing the lubricating oil pan z Grease lubricating oil pan (arrows). z Mount new gasket. 1 z Mount lubricating oil pan. Do not move the gasket when mounting the lubricating oil pan. z Tighten screws (arrows). z Mount strips (1). z Fasten all screws. z Tighten screws. 32 Nm 6 © 41112-1 z Fill engine oil according to operating instructions. max. min.
Lube oil system W 08-11-10 D 2008/2009 Removing and installing the oil pressure regulating valve Commercial available tools – W 04-04-09 – W 12-02-02 Collect leaking operating substances in suitable vessels and dispose of according to regulations. 6 Removing the oil pressure regulating valve z Remove V-belt pulley. W 12-02-02 z Remove gearcase cover. W 04-04-09 © 41115-0 z Unscrew oil pressure regulating valve. z Visually inspect the component.
Lube oil system W 08-11-10 D 2008/2009 Installing the oil pressure regulating valve z Insert oil pressure regulating valve. z Tighten oil pressure regulating valve. 27 Nm 6 © 41116-0 z Mount gearcase cover. W 04-04-09 z Install V-belt pulley.
Cooling system W 09-07-08 D 2008/2009 Removing and installing the coolant pump Commercial available tools – W 12-02-02 Collect leaking operating substances in suitable vessels and dispose of according to regulations. The appropriate documentation of the vehicle/equipment manufacturer should be observed for emptying and filling the cooling system. 6 Removing the coolant pump z Remove fan impeller. z Remove V-belt pulley. W 12-02-02 © 41117-0 z Unscrew screws (1). z Remove coolant pump (2).
Cooling system W 09-07-08 D 2008/2009 Installing the coolant pump z Mount new gasket (3). z Mount coolant pump (2). z Tighten screws (1). 2 27 Nm 3 1 6 © 41119-0 z Install V-belt pulley. W 12-02-02 z Install V-belt. z Install fan impeller.
Cooling system W 09-08-01 D 2008/2009 Checking the coolant thermostat when uninstalled Commercial available tools – W 09-08-02 6 Checking the coolant thermostat z Remove the coolant thermostat. W 09-08-02 © 41120-0 z Measure dimension "a" on the coolant thermostat.
Cooling system W 09-08-01 D 2008/2009 z Heat up the coolant thermostat in the water bath. In order to determine the exact beginning of opening, the temperature should be measured as close as possible to the thermostat without touching it. The water should be continuously stirred for an even temperature distribution. The temperature rise should not take place faster than 1°C/min. Otherwise the beginning of opening will be delayed accordingly. 6 © 41123-0 z Measure dimension "b" on the coolant thermostat.
Cooling system W 09-08-02 D 2008/2009 Removing and installing the coolant thermostat Commercial available tools – W 09-08-01 Collect leaking operating substances in suitable vessels and dispose of according to regulations. The appropriate documentation of the vehicle/equipment manufacturer should be observed for emptying and filling the cooling system. 6 Removing the coolant thermostat 1 z Unscrew screws (1). z Remove outlet nozzle (2). z Remove coolant thermostat (3). 2 z Remove O-ring.
Cooling system W 09-08-02 D 2008/2009 6 © 02/2006 2/2 6022-001
Other components W 12-02-02 D 2008/2009 Removing and installing the V-belt, V-belt pulley Commercial available tools: – V-belt tension measuring device . . . . . . . . . . . . . . . . . . . . . . . 8115 Attention! Only test / tighten / renew V-belts when the engine is not running. The V-belt tension of new V-belts must be checked after they have been running for 15 minutes. 6 Removing the V-belt, V-belt pulley z Loosen screw (1). z Loosen screw (2). z Press generator in direction of arrow.
Other components W 12-02-02 D 2008/2009 Installing the V-belt, V-belt pulley z Mount V-belt pulley (1). z Tighten screw (2). 300 Nm 1 2 6 © 41132-1 z Fit V-belt. z Fasten screw (1). z Press generator in direction of arrow. z Tighten screw (1). 21 Nm z Tighten screw (2). 22 Nm 1 z Check V-belt tension. 2 © 41128-1 Check V-belt tension with V-belt tension measuring device z Lower indicator arm (1) into V-belt tension measuring device. z Mount V-belt tension measuring device on V-belt.
Other components W 12-02-02 D 2008/2009 z Press the V-belt measuring device against the V-belt with the button (1) until you hear it click. z Read the measured value at the point of intersection of the indicator arm and the scale (arrows). P12 11 P12 21 Note different units on the scale. z If the nominal value is not reached, the tensioning process must be repeated.
Other components W 12-02-02 D 2008/2009 6 © 02/2006 4/4 6023-001
Other components W 12-06-01 D 2008/2009 Removing and installing the flywheel Commercial available tools Special tools: – Fixing pin . . . . . . . . . . . . . . . . . . 144180 6 Removing the flywheel z Fix flywheel with fixing pin (1). z Unscrew all screws (arrow). z Remove fixing pin (1). z Remove flywheel. z Visually inspect the components. 1 © 41133-1 Installing the flywheel z Mount flywheel. z Fix flywheel with fixing pin (1).
Other components W 12-06-01 D 2008/2009 See graphic for tightening sequence. 1 3 1 6 z Tighten all screws. 96 Nm z Remove fixing pin (1).
Electrical system W 13-02-03 D 2008/2009 Removing and installing the generator Commercial available tools: – V-belt tension measuring device . . . . . . . . . . . . . . . . . . . . . . . 8115 Attention! Only test / tighten / renew V-belts when the engine is not running. The V-belt tension of new V-belts must be checked after they have been running for 15 minutes. 6 Removing the generator z Disconnect the battery's negative terminal. z Remove cable from generator. © 41135-1 z Loosen screws (1).
Electrical system W 13-02-03 D 2008/2009 z Unscrew screw (1). z Remove generator (2). z Visually inspect the components. 2 1 6 © 41136-0 Installing the generator z Mount generator. z Mount V-belt. z Tighten screws (1). 1 z Press generator in direction of arrow. V-belt is clamped. 1 1 © 41176-0 z Tighten screws (1). 21 Nm z Tighten screw (2). 1 21 Nm z Tighten screw (3). 22 Nm 2 z Check V-belt tension.
Electrical system W 13-02-03 D 2008/2009 Check V-belt tension with V-belt tension measuring device z Lower indicator arm (1) into V-belt tension measuring device. z Mount V-belt tension measuring device on V-belt. 1 6 © 41129-0 z Press the V-belt measuring device against the V-belt with the button (1) until you hear it click. z Read the measured value at the point of intersection of the indicator arm and the scale (arrows). P12 11 P12 21 Note different units on the scale.
Electrical system W 13-02-03 D 2008/2009 6 © 02/2006 4/4 6025-001
Electrical system W 13-03-02 D 2008/2009 Removing and installing the starter Commercial available tools 6 Removing the starter z Disconnect the battery's negative terminal. z Disconnect cables. z Unscrew screws (1). z Remove starter. 1 z Visually inspect the component. © 41138-1 Installing the starter z Insert starter. z Tighten screws (1). 41 Nm z Connect cables. A13 071 1 Note the assignment of the terminal designations. z Connect the battery's negative terminal.
Electrical system W 13-03-02 D 2008/2009 6 © 02/2006 2/2 6026-001
Electrical system W 13-06-01 D 2009 Removing and installing the heating plugs Commercial available tools 6 Removing the heating plugs 2 z Disconnect cables from heating plugs. 1 z Unscrew nut (1). z Remove connecting rail (2). z Unscrew heating plugs (3). 3 z Visually inspect the components. © 41140-0 Installing the heating plugs 1 z Screw in heating plugs (3). 15 Nm z Install connecting rail (2). 2 2,5 Nm Ensure that the installation location is free from faults.
Electrical system W 13-06-01 D 2009 6 © 02/2006 2/2 6027-001
D 2008/2009 7 Standard tools Standard tools 7 © 02/2006 1/6 6028-001
D 2008/2009 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.
D 2008/2009 Standard tools 8024 Assembly pliers Removing valve stem gaskets © 37509-2 7 8115 V-belt tension measuring device 150 to 600 N for checking the V-belt tension © 35416-3 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 © 02/2006 3/6 6028-001
D 2008/2009 Standard tools 8190 Rotation angle disc with magnet Setting valve clearance © 43202-0 7 8200 Counter support reinforced, size 22 removing and installing main bearing © 41162-0 9017 Assembly lever Example: Removing and installing the valves © 37511-2 © 02/2006 4/6 6028-001
D 2008/2009 Standard tools 9123 Torx plus Bit Safety screw on fuel injector pump gear cap 25 mm long © 39435-1 7 © 02/2006 5/6 6028-001
D 2008/2009 Standard tools 7 © 02/2006 6/6 6028-001
D 2008/2009 8 Special tools Special tools 8 © 02/2006 1/8 6029-001
D 2008/2009 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.
D 2008/2009 Special tools 100400 Dial gauge with fixing wheel Measuring range 0 - 10 mm / 0.
D 2008/2009 Special tools 121420 Assembly sleeves Set of assembly sleeves for valve stem gasket © 43210-0 8 121430 Assembly tool Assembling valve stem gasket © 37614-2 130300 Universal piston ring pliers Removing and installing the piston rings © 43021-0 © 02/2006 4/8 6029-001
D 2008/2009 Special tools 130510 Piston ring compressor Piston diameter 90 mm © 39408-1 142780 Assembly tool Installing crankshaft sealing ring (flywheel side) 8 © 41168-0 142790 Assembly tool Installing crankshaft sealing ring (opposite side to flywheel) © 41169-0 © 02/2006 5/8 6029-001
D 2008/2009 Special tools 143860 Assembly tool (in connection with threaded rod 143880) Removing and installing main bearing in crankcase © 41164-0 8 143870 Assembly tool (in connection with threaded rod 143880 and counter support 8200) Removing and installing main bearing in main bearing housing © 41165-0 143880 Threaded rod Removing and installing main bearing © 41167-0 © 02/2006 6/8 6029-001
D 2008/2009 Special tools 144180 Fixing pin Fixing the flywheel © 41163-0 170050 Special wrench Unscrewing the filter cartridges 8 © 37629-2 © 02/2006 7/8 6029-001
D 2008/2009 Special tools 8 © 02/2006 8/8 6029-001
