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
© 01/2009 OBJ_DOKU-23506-001.fm
7/12
6
D 2011 Fuel system
TD 2011 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).
● Tighten screw plug (1).
45 Nm
1
© 39192-1
● Actuate the high-pressure hand pump constantly.
● Turn the crankshaft slowly and evenly in the direction
of the arrow (engine direction of rotation) until the fuel
flow turns to drops.
The fuel must flow evenly out of the over-
flow pipe.
As soon as the fuel flow becomes drops,
the start of injection has been reached.
© 47635-2
● Read start of injection on the degree scale.
Start of injection:
Note specifications on the company plate.
The start of injection must be set if it does
not match the specifications.
The start of injection of other injection
pumps should be checked using this
method.
Calculate the ignition UDC of each cylinder
with the degree scale.
Observe ignition interval.
Cylinders Ignition interval
2 180°
3 120°
4 180°
© 39195-1