Workshop Manual competence level 3 D Th is do i cu s al tr m l o ib en w u ed tio ti sc w n ith in op yr o u e it ig t o he ht ur r p pr pr r i n ot io t e ec ra d te d. gr or ee ele m ct en ro t. n i cf o rm is no t TCD 2013 2V 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.
Regarding copyright questions and licensing agreements please contact : VE-FI, Mr. Sonntag Phone.: + 49 (0) 221 822-3053 E-Mail: sonntag.j@deutz.com DEUTZ AG Service Information Systems Ottostraße 1 D-51149 Köln (Cologne) Phone.: +49 (0) 221-822-0 Fax: +49 (0) 221-822-3525 Internet: www.deutz.com E-Mail: info@deutz.com The engine company. Printed in Germany All rights reserved 1st Edition © 02/2010 Order No.
Workshop Manual TCD 2013 2V 0312 2916 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 engines 1 Foreword 2 General 3 User notes 4 Technical data 5 © 02/2010 3.1 3.2 3.3 3.4 3.5 4.1 4.2 Table of contents General Specifications Operating manual and workshop manual Job cards Explanation of symbols Testing and setting data Tightening specifications Job card overview 5.1 5.2 Sorted alphabetically Sorted numerically 6 Job cards 7 Commercial tools 8 Special tools 1/2 OBJ_DOKU-21737-001.
Table of contents © 02/2010 DEUTZ engines 2/2 OBJ_DOKU-21737-001.
DEUTZ engines Foreword 1 1 © 05/2005 Foreword 1/4 OBJ_DOKU-21738-001.
Foreword DEUTZ engines 1 © 05/2005 2/4 OBJ_DOKU-21738-001.
DEUTZ engines Foreword ● Repair of the engine must correspond to its use for the intended purpose. Only parts released by the manufacturer for the respective purpose may be used for conversion work. Unauthorised modifications to the engine exclude manufacturer liability for resulting damages. Failure to observe this will void the warranty! ● Read and observe the information in this documentation.
Foreword DEUTZ engines 1 © 05/2005 4/4 OBJ_DOKU-21738-001.
DEUTZ engines General 2 2 © 11/2005 General 1/4 OBJ_DOKU-21739-001.
General DEUTZ engines 2 © 11/2005 2/4 OBJ_DOKU-21739-001.
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.
General DEUTZ engines 2 © 11/2005 4/4 OBJ_DOKU-21739-001.
DEUTZ engines User notes 3 3 © 02/2010 User notes 1/8 OBJ_DOKU-21740-001.
User notes DEUTZ engines 3 © 02/2010 2/8 OBJ_DOKU-21740-001.
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 legally prescribed rules for the prevention of accidents must be observed. These are available from professional associations or from dealers.
User notes DEUTZ engines ● 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. ● Only work on the fuel system in a clean environment (no dust, no grinding or welding). Avoid draughts (dust). Clean the workshop floor regularly. No brake or performance test benches may be kept or operated in the same room. – Damaged injection lines and high-pressure pipes must be renewed.
DEUTZ engines User notes ● When removing and installing components, no materials which can leave behind particles or fibres (cardboard, wood, cloths) may be used. newed parts / operating materials must be stored, transported and disposed of according to regulations. The owner himself is responsible for this. ● Removed parts may only be rubbed down with clean, lint-free cloths. No dirt particles may be rubbed into the components.
User notes DEUTZ engines 3.3 Operation manual and workshop manual 3 3.4 Job cards 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.
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 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 Note General notes on assembly, environmental protection etc. No potential danger for man or machine.
User notes DEUTZ engines 3 © 02/2010 8/8 OBJ_DOKU-21740-001.
Technical data Testing and setting data TCD 2013 2V 4 © 02/2010 4 Technical data 4.1 Testing and setting data 1/18 OBJ_DOKU-21741-001.
Technical data Testing and setting data TCD 2013 2V 4 © 02/2010 2/18 OBJ_DOKU-21741-001.
© 02/2010 ID no.
4 Name Information Series Value P01 63 Valve clearance setting Valve overlap according to setting schematic see: Table T01 63 TCD 2013 2V - P01 64 Clearance between control piston and rocker arm Oil temperature < 80 °C, after a cooling time of at least 0.
© 02/2010 ID no. Name Information Series P02 26 Radial run-out, crankshaft maximum permissible deviation TCD 2013 L4 2V L6 Unit 0,07 mm 0,10 mm mm Main bearing P02 34 Permissible axial clearance of crankshaft in installed state TCD 2013 2V 0,1 - 0,3 P02 35 Thrust ring, thickness Standard (upper and lower half) TCD 2013 2V 2,9 0 +0,05 mm TCD 2013 2V +0,05 3,1 0 mm P02 36 Thrust ring, oversize 1. Step = 0.
4 Name Information Series Value Unit P02 73 Piston, diameter, standard Measuring point 3 = height 97 mm TCD 2013 2V 107,660 mm P02 75 Piston protrusion 1 hole, cylinder head gasket, 1.42 mm TCD 2013 2V 0,28 - < 0,54 mm P02 76 Piston protrusion 2 hole, cylinder head gasket, 1.52 mm TCD 2013 2V 0,54 - < 0,64 mm P02 77 Piston protrusion 3 hole, cylinder head gasket, 1.
© 02/2010 ID no.
Technical data Testing and setting data TCD 2013 2V T01 63 Setting of valve and control piston clearance 4-cylinder ignition sequence: 1 - 3 - 4 - 2 Valves overlap Set to 4 1 4 Cylinder 3 4 2 2 1 3 Valve overlap: Outlet valve is not yet closed, inlet valve begins opening. The inlet valve opens briefly by 2 mm when the oulet valve is fully open.
Technical data Tightening specifications TCD 2013 2V 4 4.2 © 02/2010 Tightening specifications 9/18 OBJ_DOKU-21741-001.
Technical data Tightening specifications TCD 2013 2V 4 © 02/2010 10/18 OBJ_DOKU-21741-001.
© 02/2010 Name A00 001 Clamping holder on crankcase A00 002 Clamping bracket on adapter for assembly block A00 003 Feet/engine mounting on crankcase and gear case Screw type Notes / Remarks Screw Nut Screws M12x35-10.9 M12x40-10.9 M12x60-10.9 M12x75-10.9 M12x85-10.9 M12x90-10.9 M12x220-10.9 PostPre-tensioclamping ning value value Series TCD 2013 2V 90 Nm TCD 2013 2V 90 Nm TCD 2013 2V 95 Nm TCD 2013 2V 260 Nm TCD 2013 2V 90 Nm TCD 2013 2V ID no.
4 Cylinder head cowling on cylinder head Hood must be free from grease TCD 2013 and lubricant. 2V 13 Nm A01 011 Exhaust gas return module on cylinder head Observe tightening sequence.
© 02/2010 ID no. Name Screw type Notes / Remarks PostPre-tensioclamping ning value value Series M16x85-10.9 Connection housing on crankcase/gear case M12x85-10.9 99 Nm Observe tightening sequence. TCD 2013 2V M12x160-10.9 A03 085 99 Nm Observe assembly specification. Cover plate to connection housing 99 Nm TCD 2013 2V 9 Nm Gear case on crankcase M8x35-10.9 Gear case on crankcase M8x55-10.9 M8x80-10.9 Gear case on crankcase M16x60 A04 022 Locking cap on gear case M8x55-10.
4 14/18 Screw type Notes / Remarks Series A06 020 Turbocharger on exhaust pipe Nut M10 Insert with DEUTZ S1 mounting compound TCD 2013 2V 42 Nm A06 022 Pin bolt on exhaust pipe Insert with DEUTZ S1 mounting compound TCD 2013 2V 10 Nm A06 030 Charge air pipe on cylinder head TCD 2013 2V 11 Nm A06 042 Heating flange on charge air manifold M8x100-10.9 Stage 1: TCD 2013 2V 3 Nm A06 042 Heating flange on charge air manifold M8x100-10.
© 02/2010 Name A07 039 A07 040 A07 045 PostPre-tensioclamping ning value value Notes / Remarks Series Pressure limiting valve to rail Insert with mounting grease. TCD 2013 2V 100 Nm Rail pressure sensor to rail Insert with mounting grease.
4 Name A09 002 Outlet nozzle on coolant thermostat housing A09 010 Screw type Notes / Remarks PostPre-tensioclamping ning value value Series TCD 2013 2V 30 Nm Coolant pump on fan console Observe tightening sequence.
© 02/2010 Name Screw type A12 031 V-belt pulley on torsional vibration damper M10x70-10.9 A12 035 Belt tensioner on front cover A12 041 Clamping strap on coolant pump A12 091 Hollow screw pipe union A12 092 Pipe union, pipe diameter 8 mm, ring piece A12 093 A12 094 17/18 A12 095 Notes / Remarks PostPre-tensioclamping ning value value Series TCD 2013 2V 70 Nm TCD 2013 2V 80 Nm TCD 2013 2V 30 Nm TCD 2013 2V Hollow screw M12x1.
4 Name A13 065 Cable connection on heater flange A49 001 Connection piece on cylinder head, clamping shoe Screw type Notes / Remarks PostPre-tensioclamping ning value value Series Hexagonal, pole screw locked TCD 2013 2V 20 Nm TCD 2013 2V 25 Nm For the tightening procedure according to torque using a torque wrench, a maximum variation of the tightening torque of +/- 10% is permissible. Technical data Tightening specifications © 02/2010 ID no. 18/18 TCD 2013 2V OBJ_DOKU-21741-001.
Job card overview Sorted alphabetically TCD 2013 2V 5 © 02/2010 5 Job card overview 5.1 Sorted alphabetically 1/12 OBJ_DOKU-21742-001.
Job card overview Sorted alphabetically TCD 2013 2V 5 © 02/2010 2/12 OBJ_DOKU-21742-001.
Job card overview Sorted alphabetically TCD 2013 2V Activity Job card Maintenance group Assembling/disassembling shaft sleeve on the crankshaft (opposite side to flywheel) W 01-02-02 Front cover Check alignment of connection housing W 52-01-02 Connection housing Checking collar contact for cylinder liner W 01-13-01 Crankcase Checking piston overhang W 08-03-02 Cylinder head Checking the axial clearance of the crankshaft W 05-05-03 Crankshaft Checking the camshaft W 10-02-02 Camshaft C
Job card overview Sorted alphabetically 5 TCD 2013 2V Activity Job card Maintenance group Removing and installing the coolant pump (V-belt drive) W 37-03-01 Coolant pump Removing and installing the crankcase bleeding W 01-01-01 Crankcase Removing and installing the crankshaft W 05-05-01 Crankshaft Removing and installing the cylinder head cover W 08-01-01 Cylinder head Removing and installing the cylinder liner W 04-01-01 Cylinder liner Removing and installing the engine mounting (elast
Job card overview Sorted alphabetically TCD 2013 2V Activity Job card Maintenance group Removing and installing the piston cooling nozzles W 01-08-01 Crankcase Removing and installing the pressure holding valve W 01-07-03 Crankcase Removing and installing the pressure limiting valve W 21-02-03 Fuel pipes Removing and installing the pressure/temperature sensor (charge air) W 48-03-01 Electrical equipment Removing and installing the rail W 21-02-01 Fuel pipes Removing and installing the rail
Job card overview Sorted alphabetically TCD 2013 2V 5 © 02/2010 6/12 OBJ_DOKU-21742-001.
Job card overview Sorted numerically TCD 2013 2V 5 5.2 © 02/2010 Sorted numerically 7/12 OBJ_DOKU-21742-001.
Job card overview Sorted numerically TCD 2013 2V 5 © 02/2010 8/12 OBJ_DOKU-21742-001.
Job card overview Sorted numerically TCD 2013 2V Job card Activity Maintenance group W 01-01-01 Removing and installing the crankcase bleeding Crankcase W 01-02-01 Renewing the crankshaft sealing ring (opposite side Front cover to flywheel) W 01-02-02 Assembling/disassembling shaft sleeve on the crankshaft (opposite side to flywheel) Front cover W 01-03-01 Removing and installing the front cover (opposite side to flywheel) Front cover W 01-05-01 Checking the overhang of the cylinder liner
Job card overview Sorted numerically 5 TCD 2013 2V Job card Activity Maintenance group W 09-02-02 Removing and installing the gearcase cover Gearcase W 10-02-01 Removing and installing the camshaft Camshaft W 10-02-02 Checking the camshaft Camshaft W 11-01-01 Setting valve clearance (with exhaust return module Control parts installed) W 11-01-01 Setting valve clearance (with or without removal of exhaust return module) Control parts W 11-02-01 Removing and installing the rocker arm and
Job card overview Sorted numerically TCD 2013 2V Job card Activity Maintenance group W 41-01-01 Removing and installing the exhaust line Exhaust pipe W 43-01-01 Removing and installing the turbocharger Exhaust gas turbocharger W 44-02-01 Removing and installing the generator (V-belt drive) Generator W 44-03-01 Removing and installing the starter Starter W 46-00-01 Mounting engine on assembly block and demounting Engine mounting W 47-01-01 Removing and installing the engine mounting (elast
Job card overview Sorted numerically TCD 2013 2V 5 © 02/2010 12/12 OBJ_DOKU-21742-001.
DEUTZ engines 6 © 11/2005 Job cards Job cards 6 1/2 OBJ_DOKU-21743-001.
Job cards DEUTZ engines 6 © 11/2005 2/2 OBJ_DOKU-21743-001.
Crankcase W 01-01-01 TCD 2013 2V Removing and installing the crankcase bleeding Standard tools: – Hose clip pliers – Spring band pliers 8011 9090 6 Removing the crankcase bleeding ● Loosen spring band clip (1) with spring band pliers. ● Pull off bleeding hose (2). 1 2 © 44130-0 ● Unscrew screws (1). ● Remove crankcase bleeding (2). 1 1 2 © 44131-0 © 02/2010 1/4 OBJ_DOKU-21744-001.
Crankcase W 01-01-01 TCD 2013 2V ● Unscrew screw (1). ● Loosen pipe clip (2). ● Unscrew hollow screw (3). ● Remove sealing ring. 4 ● Loosen hose clip (4). 5 ● Pull off oil return line (5). ● Remove bleed line. 2 1 6 3 © 43944-0 ● Visually inspect the components. © 44132-0 Install crankcase bleeding ● Clean sealing surface on crankcase bleeding. ● Clean cylinder head cover. ● Insert new seal (1). 1 © 44106-0 © 02/2010 2/4 OBJ_DOKU-21744-001.
Crankcase W 01-01-01 TCD 2013 2V ● Mount crankcase bleeding (1). ● Tighten screws . 20 Nm 1 6 © 44107-0 ● Mount the bleed line. ● Plug in oil return line (5). ● Tighten hollow screw (3). 29 Nm 4 Use new sealing rings. 5 ● Position pipe clamp (2). ● Tighten screw (1). 2 – M8 1 30 Nm – M6 13 Nm 3 ● Fix the hose clip (4) with the hose clip pliers. © 43944-0 ● Plug on bleeding hose. ● Position the spring band clip (1) with the spring band pliers.
Crankcase W 01-01-01 TCD 2013 2V 6 © 02/2010 4/4 OBJ_DOKU-21744-001.
Front cover W 01-02-01 TCD 2013 2V Renewing the crankshaft sealing ring (opposite side to flywheel) Standard tools: – Pricker – Assembly lever 8198 9017 Special tools: – Assembly tool 142820 – W 05-01-01 – Self-tapping screw – Washer 6 Removing the crankshaft sealing ring ● Remove the V-belt, V-belt pulley. W 05-01-01 ● Make a hole of approximately 3 mm in the crankshaft sealing ring with a pricker. Attention! Do not damage the front cover or crankshaft.
Front cover W 01-02-01 TCD 2013 2V ● Pull out the crankshaft sealing ring with assembly lever. 6 © 44200-0 ● Visually inspect all running surfaces. © 44201-0 Installing the crankshaft sealing ring ● Remove clamping bushing (1). 1 © 44202-0 © 02/2010 2/6 OBJ_DOKU-21745-001.
Front cover W 01-02-01 TCD 2013 2V ● Mount guide sleeve (1). Make sure the clamping bushing (2) is in line with the bore (3). 1 2 3 6 © 44203-0 ● Tighten screws (1). 1 © 44204-0 ● Oil the sealing lip of the crankshaft sealing ring lightly. ● Push the crankshaft sealing ring carefully onto the guide sleeve. Use new crankshaft sealing ring. The sealing lip faces the crankcase. © 44205-0 © 02/2010 3/6 OBJ_DOKU-21745-001.
Front cover W 01-02-01 TCD 2013 2V ● Mount shims (1). ● Pay attention to installation depth of crankshaft sealing ring and select shim accordingly. – First assembly = 2 shims – 1. Repair installation depth = 1 shim – Maximum installation depth = without washers 6 1 © 44206-0 ● Mount assembly sleeve (1). ● Press on the crankshaft sealing ring to the stop. 1 © 44207-0 ● Plug in the bearing (1). ● Screw on nut (2). 2 1 © 44208-0 © 02/2010 4/6 OBJ_DOKU-21745-001.
Front cover W 01-02-01 TCD 2013 2V ● Tighten nut to the stop of the assembly sleeve (1). The crankshaft sealing ring is now at the pre-selected installation depth. ● Remove assembly tool. 1 6 © 44209-0 ● Insert clamping bushing (1). ● Mount V-belt, V-belt pulley. W 05-01-01 1 © 44210-0 © 02/2010 5/6 OBJ_DOKU-21745-001.
Front cover W 01-02-01 TCD 2013 2V 6 © 02/2010 6/6 OBJ_DOKU-21745-001.
Front cover W 01-02-02 TCD 2013 2V Assembling/disassembling shaft sleeve on the crankshaft (opposite side to flywheel) – W 01-02-01 – W 01-03-01 – W 16-01-01 Standard tools – Packing compound DEUTZ DW 74 The following work procedure is described for series 2012 as an example. The procedure for the other engines listed above is the same. 6 Installing the shaft sleeve ● Remove the crankshaft sealing ring. W 01-02-01 © 39876-0 ● Visually inspect the crankshaft journal.
Front cover W 01-02-02 TCD 2013 2V Attention! Do not damage the peripheral surfaces and the sealing surfaces. ● Join the impact sleeve (1) and the shaft sleeve (2). ● Place the shaft sleeve with impact sleeve centrally on the crankshaft with the collar (3) facing the crankshaft. 6 © 39872-0 ● Knock the shaft sleeve onto the crankshaft up to the stop by hitting the impact sleeve (1) lightly in the centre. ● Knock on the shaft sleeve evenly all round.
Front cover W 01-02-02 TCD 2013 2V Removing the shaft sleeve ● Remove the crankshaft sealing ring. W 01-02-01 ● Remove oil suction pipe W 16-01-01 6 © 39871-0 ● Unscrew screws (1). ● Remove front cover. 1 1 1 1 1 © 44542-0 ● Place two mounting levers on the gate of the front cover (arrows). Attention! Do not damage the sealing surfaces. © 39873-0 © 02/2010 3/4 OBJ_DOKU-21746-001.
Front cover W 01-02-02 TCD 2013 2V ● Pull off the shaft sleeve. ● Remove front cover. 6 © 39874-0 ● Install front cover. W 01-03-01 ● Install new shaft sleeve. Installing the shaft sleeve ● Install oil suction pipe. 1 W 16-01-01 ● Install a new crankshaft sealing ring. W 01-02-01 ● Insert clamping bushing (1). © 44875-0 © 02/2010 4/4 OBJ_DOKU-21746-001.
Front cover W 01-03-01 TCD 2013 2V Removing and installing the front cover (opposite side to flywheel) – W 01-02-01 – W 05-01-01 – W 16-01-01 Standard tools: – Feeler gauges – Locking agent DEUTZ DW 72 6 Remove the front cover ● Remove V-belt pulley. W 05-01-01 ● Unscrew screws (1). ● Remove clamping strap (2) and fuel supply pump. ● Unhook the fuel supply pump at the side. 1 2 © 44540-0 ● Unscrew screws (1). ● Remove holder with impulse transmitter (2).
Front cover W 01-03-01 TCD 2013 2V ● Unscrew screws (1). ● Remove front cover. 1 1 1 1 6 1 © 44542-0 ● Visually inspect the components. © 44543-0 Install front cover ● Knock out crankshaft sealing ring (1). Attention! Do not damage sealing surface when knocking out. ● Clean sealing surfaces. 1 © 44544-0 © 02/2010 2/6 OBJ_DOKU-21747-001.
Front cover W 01-03-01 TCD 2013 2V ● Fix the new gasket to the crankcase with a little grease. Note installation position. Make sure the clamping bushing (1) is in place. 1 6 © 44545-0 ● Oil oil pump with lubricating oil. © 44546-0 ● Position the inner rotor on the crankshaft. The countersinks on the crankshaft and the guides on the inner rotor must match (arrows). The inner rotor and crankshaft only match up in one position. © 44547-0 © 02/2010 3/6 OBJ_DOKU-21747-001.
Front cover W 01-03-01 TCD 2013 2V ● Mount front cover. ● Fasten screws. Do not tighten screws. ● Align front cover flush with the oil tray sealing surface. 6 © 44548-0 ● Tighten the screws according to the tightening sequence. – Stage 1: 3 4 1 3 Nm 2 – Stage 2: 5 21 Nm 7 10 6 13 9 12 8 11 14 © 44550-0 ● Cut off overhanging gasket (arrows) flush with the sealing surface of the oil tray. ● Install oil suction pipe. W 16-01-01 © 44551-0 © 02/2010 4/6 OBJ_DOKU-21747-001.
Front cover W 01-03-01 TCD 2013 2V ● Turn engine 180°. ● Lay cable between front cover and coolant pump (arrow). 6 © 44552-0 ● Mount clamping strap. ● Tighten screws (1). 30 Nm ● Install crankshaft sealing ring (opposite side to flywheel) 1 W 01-02-01 ● Install V-belt pulley. W 05-01-01 © 44553-0 ● Mount holder with impulse transmitter. ● Fasten screws. Clean the threads of the screws and holes.
Front cover W 01-03-01 TCD 2013 2V Set gap dimension for impulse transmitter (crankshaft) ● Push feeler gauge blade between tooth lock washer and impulse transmitter. ● Press the impulse transmitter lightly against the feeler gauge blade. 0,6 +0.1 - 0.1 mm 6 © 44092-0 ● Press the impulse transmitter lightly against the feeler gauge blade. ● Tighten screws (arrows). 20 Nm © 44093-0 ● Check gap dimension with feeler gauge blade. +0.1 0,6 - 0.
Crankcase W 01-05-01 TCD 2013 2V Checking the overhang of the cylinder liner Standard tools 8190 Special tools: – Dial gauge – Measuring device – W 08-03-01 100400 100750 6 Checking the overhang of the cylinder liner ● Remove cylinder head. W 08-03-01 The cylinder liner must be pressed in the crankcase to the stop. ● Place shims (1) and measuring beam (2) on the sealing surface of the crankcase. 2 ● Insert dial gauge into measuring beam. ● Fix dial gauge with knurled nut.
Crankcase W 01-05-01 TCD 2013 2V ● Move the measuring beam and spacing washers until the stylus (arrow) is touching the sealing surface of the cylinder liner. 0,03 - 0,08 mm Make measurements at at least 3 other points on the cylinder liner. When the wear limit is reached, the cylinder liner must be renewed. ● Install cylinder head. W 08-03-01 6 © 44073-0 © 02/2010 2/2 OBJ_DOKU-21748-001.
Crankcase W 01-07-03 TCD 2013 2V Removing and installing the pressure holding valve Standard tools Special tools: – Slide hammer – W 16-01-01 150800 Collect leaking operating substances in suitable vessels and dispose of according to regulations. – Locking agent DEUTZ DW 71 6 Removing the pressure holding valve ● Remove oil suction pipe W 16-01-01 ● Pull out oil dipstick. ● Drill out hole with a 6.7 mm Ø drill. Make sure no chips get into the crankcase.
Crankcase W 01-07-03 TCD 2013 2V ● Turn slide hammer into thread. ● Pull out pressure holding valve. ● Remove any drill shavings carefully. 6 © 44572-0 Install pressure holding valve. ● Apply locking agent to the collar of the new pressure holding valve. © 44573-0 ● Insert new pressure holding valve in the crankcase. © 44574-0 © 02/2010 2/4 OBJ_DOKU-21749-001.
Crankcase W 01-07-03 TCD 2013 2V ● Knock in pressure holding valve to the stop with a suitable tool. ● Install oil suction pipe. W 16-01-01 ● Insert oil dipstick. 6 © 44575-0 © 02/2010 3/4 OBJ_DOKU-21749-001.
Crankcase W 01-07-03 TCD 2013 2V 6 © 02/2010 4/4 OBJ_DOKU-21749-001.
Crankcase W 01-08-01 TCD 2013 2V Removing and installing the piston cooling nozzles Standard tools – W 05-05-01 6 Removing the piston cooling nozzles ● Remove crankshaft. W 05-05-01 ● Screw self-tapping screw (1) carefully into the piston cooling nozzle. 1 © 44271-0 ● Pull out piston cooling nozzle (1) with pliers. 1 © 44272-0 © 02/2010 1/2 OBJ_DOKU-21750-001.
Crankcase W 01-08-01 TCD 2013 2V Installing the piston cooling nozzles ● Clean the bores for the piston cooling nozzles in the crankcase. ● Knock in new piston cooling nozzle (1) with pin to the stop. ● Install crankshaft. W 05-05-01 1 6 © 44273-0 © 02/2010 2/2 OBJ_DOKU-21750-001.
Crankcase W 01-13-01 TCD 2013 2V Checking collar contact for cylinder liner Standard tools: – Micrometer gauge – Depth-measuring appliance – W 04-01-01 6 Checking the collar rest for the cylinder liner ● Remove cylinder liner. W 04-01-01 ● Visually inspect collar rest (arrow). ● Visually inspect sealing surface. © 44076-0 ● Measure collar rest with depth measuring appliance. +0.03 8,92 - 0 mm Measure collar rest at several points. © 44077-0 © 02/2010 1/2 OBJ_DOKU-21751-001.
Crankcase W 01-13-01 TCD 2013 2V 6 © 02/2010 2/2 OBJ_DOKU-21751-001.
Lubricating oil sump W 02-01-01 TCD 2013 2V Removing and installing the lubricating oil pan (metal sheet lubricating oil pan) Attention! Standard tools: – Wire brush – 4 pin bolts M8x70 Special tools: – Separating tool Make sure that no gasket residue falls into the crankcase. Seal all openings. 151500 Collect leaking operating substances in suitable vessels and dispose of according to regulations.
Lubricating oil sump W 02-01-01 TCD 2013 2V ● Drive in separating tool (1) to the stop (2). Attention! The tool can only be driven in in the area of the crankcase. Separation in the area of aluminium parts is not allowed. Do not damage the sealing surfaces. 2 1 6 © 45969-0 ● 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.
Lubricating oil sump W 02-01-01 TCD 2013 2V ● Visually inspect the component. 6 © 43450-1 Installing the lubricating oil pan ● Scrape off sealing compound with separating tool. © 46907-0 Attention! Wear protective glasses. ● Clean the sealing surface on the crankcase with a wire brush. The sealing surfaces must be dry and free from grease and dirt. © 46908-0 © 02/2010 3/6 OBJ_DOKU-21752-001.
Lubricating oil sump W 02-01-01 TCD 2013 2V Attention! Wear protective glasses. ● Clean the sealing surface on the lubricating oil pan with a wire brush. The sealing surfaces must be dry and free from grease and dirt. 6 © 45972-0 ● Apply packing compound evenly to the sealing surface and in the beading of the lube oil tray. Apply the packing compound in an even bead (thickness approx. 3.5 mm). The position of the packing compound is only partly illlustrated.
Lubricating oil sump W 02-01-01 TCD 2013 2V ● Fasten all screws (1). Note different screw lengths. 1 6 © 45971-0 ● Tighten the screws according to the tightening sequence.
Lubricating oil sump W 02-01-01 TCD 2013 2V ● Insert new sealing ring. ● Tighten screw plug (2). 55 Nm (M18x1,5) ● Insert oil dipstick (1). ● Fill in lubricating oil according to operating manual. 6 1 2 © 44480-1 © 02/2010 6/6 OBJ_DOKU-21752-001.
Cylinder liner W 04-01-01 TCD 2013 2V Removing and installing the cylinder liner Standard tools 8190 Special tools: – Extraction tool, universal – Tension plate – Assembly lever – Washer – – – – 150170 150171 150190 150191 W 01-05-01 W 01-13-01 W 04-01-02 W 06-01-01 Collect leaking operating substances in suitable vessels and dispose of according to regulations. – Fitting compound DEUTZ AP1908 Lubricating oil and coolant must be filled according to the instructions in the operating manual.
Cylinder liner W 04-01-01 TCD 2013 2V ● Fold the plate (1) to the side and insert the disassembly device in the cylinder liner. Attention! Do not damage the running surfaces and the sealing surfaces. 1 6 © 44442-0 ● Mount the counter holder (1) on the crankcase. Do not mount the counter holders on the cylinder liner's sealing surface. 1 1 © 44443-0 ● Place the plate (1) with the lay-on surfaces against the cylinder liner (2) and hold them together.
Cylinder liner W 04-01-01 TCD 2013 2V ● Turn the nut (1) clockwise. ● Remove the disassembly device. 1 6 © 44064-0 ● Pull the cylinder liner up and out. © 44065-0 ● Remove O-rings. ● Visually inspect the components. ● Testing the cylinder liner. W 04-01-02 © 44066-0 © 02/2010 3/6 OBJ_DOKU-21753-001.
Cylinder liner W 04-01-01 TCD 2013 2V Install cylinder liner ● Check collar contact for cylinder liner. W 01-13-01 ● Clean cylinder liner. ● Insert new O-rings. 6 © 43568-0 ● Coat the crankcase and the cylinder liner in area (X) with lubricating oil. X © 44441-0 ● Insert the cylinder liner in the crankcase. Make sure that the liner surface and the crankcase are absolutely clean before installing the cylinder liner. © 44067-0 © 02/2010 4/6 OBJ_DOKU-21753-001.
Cylinder liner W 04-01-01 TCD 2013 2V ● Select the pressing disc (1) according to the diameter of the cylinder liner and screw to the assembly lever. 1 6 © 43610-0 ● Fasten screw (2). ● Hook assembly lever (1) to screw. ● Mount disc (3) on cylinder liner. Ensure that the installation location is free from faults. 3 1 2 © 44068-0 ● Press in the cylinder liner to the stop with the assembly lever. © 44069-0 © 02/2010 5/6 OBJ_DOKU-21753-001.
Cylinder liner W 04-01-01 TCD 2013 2V ● Remove assembly lever. ● Check the overhang of the cylinder liner. W 01-05-01 6 © 44070-0 ● Mount liner holder (2). ● Tighten screws (1). ● Install piston and connecting rod. W 06-01-01 2 1 1 © 44260-0 © 02/2010 6/6 OBJ_DOKU-21753-001.
Cylinder liner W 04-01-02 TCD 2013 2V Testing the cylinder liner Standard tools: – Micrometer gauge – Internal measuring device Special tools: – Dial gauge – W 04-01-01 – W 06-01-01 – W 08-03-01 The crankshaft bearing covers must be mounted properly for measuring the cylinders. 100400 6 Testing the cylinder liner ● Remove cylinder head. W 08-03-01 ● Check cylinder liner for visible signs of wear. ● Remove piston and connecting rod.
Cylinder liner W 04-01-02 TCD 2013 2V Diagram for measuring the cylinder running surface at the points "a" and "b" in the levels "1" - "3". a b a b a b 1 2 3 6 © 39100-1 ● Insert internal measuring device in cylinder. ● Balance the internal measuring device at the given measuring points and read off the measured value at the reversal point of the pointer. ● Compare actual value with setpoint value. +0.02 108 - 0 mm When the wear limit is reached, the cylinder liner must be renewed.
Cylinder liner W 04-01-02 TCD 2013 2V ● Measure collar height in area (X) with micrometer gauge. +0 9 - 0.02 mm Measure collar height at several points. X 6 © 48168-1 ● Install cylinder liner. W 04-01-01 ● Install piston and connecting rod. W 06-01-01 ● Install cylinder head. W 08-03-01 © 44080-0 © 02/2010 3/4 OBJ_DOKU-21754-001.
Cylinder liner W 04-01-02 TCD 2013 2V 6 © 02/2010 4/4 OBJ_DOKU-21754-001.
V-belt pulley add-on W 05-01-01 TCD 2013 2V Removing and installing the V-belt, V-belt pulley Standard tools: – Feeler gauges – V-belt tension measuring device 8115 – Operation manual – W 01-03-01 Attention! Only test / tighten / renew V-belts when the engine is not running. – Locking agent DEUTZ DW 72 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 ● Loosen screws (1). Do not unscrew screws.
V-belt pulley add-on W 05-01-01 TCD 2013 2V ● Loosen V-belt by unscrewing the clamping screw (1). 1 6 © 44039-0 ● Remove V-belt (1). 1 © 44040-0 ● Unscrew screws (1). ● Remove V-belt pulley (2). 1 2 © 44041-0 © 02/2010 2/12 OBJ_DOKU-21755-001.
V-belt pulley add-on W 05-01-01 TCD 2013 2V ● Loosen all screws (arrow). Do not unscrew screws. 6 © 44526-0 ● Loosen screws (1). ● Swing the fuel supply pump (2) to the side (arrow). 1 2 © 44042-0 ● Remove V-belt (1). 1 © 44043-0 © 02/2010 3/12 OBJ_DOKU-21755-001.
V-belt pulley add-on W 05-01-01 TCD 2013 2V ● Unscrew all screws (arrow). ● Remove the torsional vibration damper. 6 © 44527-0 ● Unscrew screws (arrows). ● Remove adapter (1). ● Remove V-belt pulley (2). Block flywheel with suitable tool. 1 2 © 44528-0 ● Unscrew screws (1). ● Remove tooth lock washer (2). 1 1 2 © 44529-0 © 02/2010 4/12 OBJ_DOKU-21755-001.
V-belt pulley add-on W 05-01-01 TCD 2013 2V ● Visually inspect the components. 6 © 44530-0 Installing the V-belt, V-belt pulley ● Make sure the clamping bushing (arrow) is in place. Clean the threads of the screws and holes. © 44531-0 ● Fix the tooth lock washer with the largest hole (1) to the V-belt pulley with clamping bushing (2). Note installation position of the tooth lock washer. 1 2 © 44532-0 © 02/2010 5/12 OBJ_DOKU-21755-001.
V-belt pulley add-on W 05-01-01 TCD 2013 2V ● Tighten screws (arrows). 60 Nm Insert screw with locking agent. 6 © 44533-0 ● Make sure the clamping bushings (arrows) are in place. © 44534-0 ● Mount V-belt pulley. The clamping bushing (1) must grip in the hole (2). 1 2 © 44535-0 © 02/2010 6/12 OBJ_DOKU-21755-001.
V-belt pulley add-on W 05-01-01 TCD 2013 2V ● Mount adapter. ● Fasten screws. The centring bolt (1) must face the V-belt pulley. 1 6 © 44536-0 ● Tighten new screws (1) with rotation angle disc. – Stage 1: 30 Nm – Stage 2: 60° 1 – Stage 3: 60° Attention! Renew screws every time they are loosened. 1 Block flywheel with suitable tool. © 44537-0 ● Mount the torsional vibration damper. ● Tighten the screws (arrow) alternately. 70 Nm Note installation position of the torsional vibration damper.
V-belt pulley add-on W 05-01-01 TCD 2013 2V ● Mount V-belt (1) for coolant pump. 1 6 © 44043-0 ● Press clamping strap (1) in direction of arrow with a suitable tool. ● Tighten screw (2). 30 Nm 1 2 © 44049-0 Check V-belt tension with V-belt tension measuring device ● Lower indicator arm (1) into V-belt tension measuring device. 1 © 44591-0 © 02/2010 8/12 OBJ_DOKU-21755-001.
V-belt pulley add-on W 05-01-01 TCD 2013 2V ● Mount V-belt tension measuring device on V-belt. The V-belt must be between the guides (arrow). 6 © 44050-0 ● 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. Operation manual Note different units on the scale. ● If the nominal value is not reached, the tensioning process must be repeated. 1 © 44051-0 ● Tighten screw (arrow).
V-belt pulley add-on W 05-01-01 TCD 2013 2V ● Mount V-belt pulley (2). ● Tighten screws (1). 1 2 6 © 44041-0 ● Mount V-belt (1) for generator. 1 © 44040-0 ● Tighten V-belt (1) by turning the clamping screw (2). 2 1 © 44053-0 © 02/2010 10/12 OBJ_DOKU-21755-001.
V-belt pulley add-on W 05-01-01 TCD 2013 2V ● Lower indicator arm (1) into V-belt tension measuring device. 1 6 © 44591-0 ● Mount V-belt tension measuring device on V-belt. The V-belt must be between the guides (arrow). © 44054-0 ● 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. Operation manual Note different units on the scale.
V-belt pulley add-on W 05-01-01 TCD 2013 2V ● Tighten screw (1). 30 Nm ● Tighten screw (2). 1 30 Nm ● Tighten screw (3). 30 Nm 6 3 2 © 44056-0 ● Tighten screws (arrows). 30 Nm © 44057-0 Set gap dimension for impulse transmitter (crankshaft). ● Check gap dimension with feeler gauge blade. +0.1 0,6 - 0.1 mm The feeler gauge blade must fit between the tooth lock washer and impulse transmitter (crankshaft) with low resistance. ● Set gap dimension for speed governor (crankshaft).
Torsional vibration damper W 05-02-01 TCD 2013 2V Removing and installing torsional vibration damper (V-belt drive) Standard tools 6 Removing the torsional vibration damper ● Unscrew all screws (1). ● Remove the torsional vibration damper. ● Visually inspect the components. 1 1 1 © 44436-0 Installing the torsional vibration damper ● Mount the torsional vibration damper. Note installation position. The holes in the torsional vibration damper must match the threaded holes in the Vbelt pulley.
Torsional vibration damper W 05-02-01 TCD 2013 2V 6 © 02/2010 2/2 OBJ_DOKU-21756-001.
Flywheel W 05-03-01 TCD 2013 2V Removing and installing the flywheel Standard tools: – Rotation angle disc – Guide pin (self-constructed) 8190 6 Removing the flywheel ● Unscrew all screws (arrow). Block flywheel with suitable tool. ● Remove flywheel. © 44569-0 ● Visually inspect the components. © 44276-0 © 02/2010 1/4 OBJ_DOKU-21757-001.
Flywheel W 05-03-01 TCD 2013 2V Installing the flywheel ● Insert clamping bushing (1). 1 6 © 44555-0 ● Insert self-made guide pin (arrow). For example a pin bolt. ● Mount flywheel. The bores in the flywheel must match the threaded bores in the crankshaft flange. © 34224-2 ● Fasten screws. Attention! Use new screws. ● Remove guide pin. © 44556-0 © 02/2010 2/4 OBJ_DOKU-21757-001.
Flywheel W 05-03-01 TCD 2013 2V M10x35 - M10x85 ● Tighten screws . – Stage 1: 30 Nm – Stage 2: 60° – Stage 3: 60° Block flywheel with suitable tool. 6 © 42826-0 M10x30 ● Tighten screws . – Stage 1: 30 Nm – Stage 2: 60° – Stage 3: 30° Block flywheel with suitable tool. © 42826-0 ● Drive plugs into the threaded bores (arrows) to the stop. © 31115-1 © 02/2010 3/4 OBJ_DOKU-21757-001.
Flywheel W 05-03-01 TCD 2013 2V 6 © 02/2010 4/4 OBJ_DOKU-21757-001.
Crankshaft W 05-05-01 TCD 2013 2V Removing and installing the crankshaft Standard tools: – Socket wrench insert 8035 Special tools: – Turn-over gear 100380 – W 01-03-01 – W 05-05-03 – W 09-02-02 6 Removing crankshaft ● Remove front cover (opposite side to flywheel). W 01-03-01 ● Remove the gear case cover (flywheel side). W 09-02-02 © 44220-0 ● Pull out oil dipstick (1). 1 © 44221-0 © 02/2010 1/12 OBJ_DOKU-21758-001.
Crankshaft W 05-05-01 TCD 2013 2V Removing the big end bearing cap ● Insert turn-over gear (1). ● Tighten screws (2). 1 2 6 © 44222-0 ● Place lifting journal of the respective cylinder at bottom dead centre (BDC). Attention! Do not jam the con rods when turning the crankshaft. © 44223-0 ● Unscrew screws (1). ● Remove big end bearing cap (2). ● Remove bearing shell. Lay out components in the order in which they should be installed. 2 Note order of cylinders.
Crankshaft W 05-05-01 TCD 2013 2V ● Make a mark (1) on the camshaft gear wheel for assistance. 2 1 Your mark must be on a line between the marking (2) and the middle (3) of the camshaft. 3 6 © 44225-0 ● Turn the crankshaft evenly until the marking (1) on the crankshaft flange is in line with your mark (2) on the camshaft gear wheel. The marking on the camshaft gear wheel is covered by the crankshaft flange when it is in line. 1 Attention! Do not jam the con rods when turning the crankshaft.
Crankshaft W 05-05-01 TCD 2013 2V ● Remove bearing cap (1). ● Remove bearing shell. ● Remove both thrust ring halves (arrows). ● Remove all main bearing covers (2). 1 ● Remove bearing shells. Lay out components in the order in which they should be installed. Note order of cylinders. 2 6 © 44228-0 ● Press the con rods carefully out of the lifting journal. ● Lift out the crankshaft. © 44230-0 ● Remove both thrust ring halves (arrows). ● Remove bearing shells (1) and (2).
Crankshaft W 05-05-01 TCD 2013 2V Installing the crankshaft ● Insert upper main bearing shells. Note the assignment of the bearing shells. The anti-rotation lock (1) must lock in groove (2). 2 1 6 © 44232-0 ● Insert lower main bearing shells in the respective main bearing cover. Note the assignment of the bearing shells. The anti-rotation lock (1) must lock in groove (2). 1 2 © 44233-0 Make sure the clamping bushings (1) are in place. 1 © 44234-0 © 02/2010 5/12 OBJ_DOKU-21758-001.
Crankshaft W 05-05-01 TCD 2013 2V ● Insert bearing shell in the con rod. Note the assignment of the bearing shells. The anti-rotation lock (1) must lock in groove (2). 1 2 6 © 44235-0 ● Insert bearing shell in the respective big end bearing cap. Note the assignment of the bearing shells. The anti-rotation lock (1) must lock in groove (2). 1 2 © 44216-0 Make sure the clamping bushings (arrows) are in place. © 44236-0 © 02/2010 6/12 OBJ_DOKU-21758-001.
Crankshaft W 05-05-01 TCD 2013 2V ● Position camshaft. The bore (1) must be facing the cylinder head. ● Lightly oil bearing surfaces. 1 6 © 44237-0 ● Insert the crankshaft carefully in the crankcase. Attention! Do not jam the con rods when inserting the crankshaft! ● Set the crankshaft in line with the camshaft. Make sure that the markings match up. © 44238-1 ● Check control times. The marking (1) on the crankshaft flange must be in line with your mark (2).
Crankshaft W 05-05-01 TCD 2013 2V ● Install upper thrust ring halves according to measured axial clearance. Thrust ring halves, without guide lugs, between the crankshaft and the crankcase (arrows). Oil grooves (1) of the thrust ring halves face the web face (2) of the crankshaft (arrows) 2 1 6 © 42662-0 ● Fix both thrust ring halves with a little grease to the bearing cap. Bearing cap with identification “2“. Use thrust ring halves with guide lug (arrow).
Crankshaft W 05-05-01 TCD 2013 2V Attention! Screws can be used a maximum 3 times with written documentation. Use socket wrench insert. ● Tighten all screws (1) of the main and fit bearing covers. – Stage 1: 1 50 Nm – Stage 2: 60° 6 – Stage 3: 60° © 44241-0 Installing the big end bearing cap ● Pull con rods carefully on to the lifting journal. © 44242-0 ● Place lifting journal of the respective cylinder at bottom dead centre (BDC).
Crankshaft W 05-05-01 TCD 2013 2V ● Mount big end bearing cap. Attention! Note the assignment of the big end bearing cap. The identification numbers (1) on the con rod and the big end bearing cap must be identical and opposite to each other when assembled. 1 9 2651 9 2651 6 © 44244-0 ● Tighten new screws with rotation angle disc. – Stage 1: 30 Nm – Stage 2: 60° – Stage 3: 60° © 44245-0 ● Unscrew screws (2). ● Remove turning gear (1). 1 2 © 44222-0 © 02/2010 10/12 OBJ_DOKU-21758-001.
Crankshaft W 05-05-01 TCD 2013 2V ● Insert oil dipstick (1). 1 6 © 44221-0 ● Check axial backlash of crankshaft (crankshaft installed). W 05-05-03 © 44187-0 ● Install the gear case cover (flywheel side). W 09-02-02 ● Install front cover (opposite side to flywheel). W 01-03-01 © 44220-0 © 02/2010 11/12 OBJ_DOKU-21758-001.
Crankshaft W 05-05-01 TCD 2013 2V 6 © 02/2010 12/12 OBJ_DOKU-21758-001.
Crankshaft W 05-05-02 TCD 2013 2V Checking the crankshaft Standard tools: – Magnetic measuring stand – Micrometer gauge – Internal measuring device – Prisms – Hardness tester Special tools: – Dial gauge – W 05-05-01 100400 6 Checking the bearing pin hardness ● Remove crankshaft. W 05-05-01 ● Place crankshaft on prism. © 42602-0 ● Put hardness tester on journal. © 30560-1 © 02/2010 1/4 OBJ_DOKU-21759-001.
Crankshaft W 05-05-02 TCD 2013 2V ● Raise stylus (1) and press release (2). Stylus (1) falls down, briefly strikes the surface and jumps up to the measured value. 1 2 6 © 44445-0 ● Read off displayed value (arrow) from hardness tester. 53 +3 - 3 HRC The measured value is to be converted according to the table of the measuring device. © 43515-1 Diagram for measuring the journals at the points 1 and 2 in the levels a and b. © 36424-2 © 02/2010 2/4 OBJ_DOKU-21759-001.
Crankshaft W 05-05-02 TCD 2013 2V Checking the diameter of the main bearing pins ● Measure main bearing pin with micrometer gauge. – Standard 0 85,00 - 0.02 mm Measuring points see diagram. 6 © 42603-0 Checking the diameter of the lifting journals ● Measure lifting journal with micrometer gauge. – Standard 0 68,00 - 0.02 mm Measuring points see diagram. © 42604-0 Checking the rotation ● Mount magnetic measuring stand. ● Insert dial gauge.
Crankshaft W 05-05-02 TCD 2013 2V Measuring the fit bearing width ● Set micrometer gauge to 38 mm. – Balance the internal measuring device between the test surfaces of the micrometer gauge and set the dial gauge at the reversal point of the pointer to "0". 6 © 35825-2 ● Measure bearing width with internal measuring device between thelay-on surfaces of the thrust rings. – Standard 38 +0.06 mm © 42606-0 Visual inspection ● Check the running surfaces (1) of the crankshaft sealing rings visually.
Crankshaft W 05-05-03 TCD 2013 2V Checking the axial clearance of the crankshaft Standard tools: – Magnetic measuring stand – Micrometer gauge – Internal measuring device – Socket wrench insert 8035 8190 Special tools: – Dial gauge – W 01-03-01 – W 05-05-01 – W 09-02-02 100400 6 ● Remove front cover. W 01-03-01 ● Remove the gear case cover. W 09-02-02 ● Mount magnetic measuring stand. ● Insert dial gauge. ● Apply stylus to the crankshaft end with pre-tension.
Crankshaft W 05-05-03 TCD 2013 2V ● Unscrew screws (1). Use socket wrench insert. 1 ● Remove bearing cap (2). ● Remove lower bearing shell. ● Remove both thrust ring halves (arrows). 2 1 6 © 44181-0 ● Remove both thrust ring halves (arrows). © 44182-0 ● Measure the wall thickness of the thrust ring halves. – Standard +0.05 2,9 0 mm ● Select thrust ring halves according to measured value. © 43504-0 © 02/2010 2/6 OBJ_DOKU-21760-001.
Crankshaft W 05-05-03 TCD 2013 2V ● Remove crankshaft. W 05-05-01 ● Set micrometer gauge to 38 mm. ● Push the internal measuring device between the test surfaces of the micrometer gauge and set to "0". 6 © 35825-2 ● Measure locating bearing width ● Note measured value, dimension (a). © 42606-0 ● Place thrust ring halves on bearing caps (arrows). ● Measure width with micrometer gauge. ● Note measured value, dimension (b). © 35827-2 © 02/2010 3/6 OBJ_DOKU-21760-001.
Crankshaft W 05-05-03 TCD 2013 2V ● Determine axial backlash. 0,1 - 0,3 mm Calculation example Desired: Axial backlash Given: Measured: (a) = 38.6 mm (b) = 38.4 mm Calculation: Dimension (a) - Dimension (b) Result: = 0.2 mm ● Install crankshaft. W 05-05-01 6 © 35827-2 Make sure the clamping bushings (1) are in place. 1 © 44183-0 ● Install upper thrust ring halves according to measured axial clearance. Oil grooves (1) of the thrust ring halves face the crankshaft web face (2).
Crankshaft W 05-05-03 TCD 2013 2V ● Fix both thrust ring halves with a little grease to the bearing cap. Use lower thrust ring halves with guide lug (arrow). Install thrust ring halves according to measured axial clearance. 2 Bearing cap with identification “2“. The oil grooves (1) face the crankshaft web face. 1 6 © 42663-0 ● Insert bearing cap (1). The gate (arrow) on the bearing cap faces the manifold side. 1 © 44185-0 ● Tighten screws (arrows).
Crankshaft W 05-05-03 TCD 2013 2V ● Check axial backlash of crankshaft. 0,1 - 0,3 mm ● Remove magnetic measuring stand. ● Remove dial gauge. ● Install front cover. W 01-03-01 ● Install the gear case cover. W 09-02-02 6 © 44187-0 © 02/2010 6/6 OBJ_DOKU-21760-001.
Connecting rod W 06-01-01 TCD 2013 2V Removing and installing the piston and con rod Standard tools: – Rotation angle disc 8190 Special tools: – Piston ring compressor – Liner holder 130640 150180 – W 07-02-02 – W 08-03-01 – W 16-01-01 Attention! The assignment of con rod and big end bearing cover must stay as it is.
Connecting rod W 06-01-01 TCD 2013 2V Removing the big end bearing cap ● Set lifting journal at bottom dead centre (BDC). ● Unscrew screws (1). ● Remove big end bearing cap (2). ● Remove bearing shell. Lay out components in the order in which they should be installed. 2 Note order of cylinders. 1 6 © 44248-0 ● Press out the piston and connection rod. Lay out components in the order in which they should be installed. Note order of cylinders. © 44249-0 ● Remove con rod bearing shells (1).
Connecting rod W 06-01-01 TCD 2013 2V Removing the piston ● Remove locking ring. ● Press out piston pin. ● Visually inspect the components. 6 © 44251-0 Completing con rod and piston ● Insert new locking ring. Ensure that the installation location is free from faults. © 44252-0 The flywheel/crankshaft symbol (1) on the piston base must face to the right and the identification number (2) on the con rod must face upwards. 2 26519 ● Insert con rod. 1 © 44253-0 © 02/2010 3/8 OBJ_DOKU-21761-001.
Connecting rod W 06-01-01 TCD 2013 2V ● Oil the piston bolt lightly. ● Press the piston bolt through. ● Insert new locking ring. Ensure that the installation location is free from faults. 6 © 44254-0 Installing the piston and con rod Make sure the clamping bushings (1) are in place. 1 © 44211-0 ● Insert bearing shell in the con rod. Note the assignment of the bearing shells. The anti-rotation lock (1) must lock in groove (2). 2 1 © 44215-0 © 02/2010 4/8 OBJ_DOKU-21761-001.
Connecting rod W 06-01-01 TCD 2013 2V ● Insert bearing shell in the respective big end bearing cap. Note the assignment of the bearing shells. The anti-rotation lock (1) must lock in groove (2). 1 2 6 © 44216-0 ● Arrange the piston ring joints with an offset of about 120° to each other. ● Check piston rings and piston ring grooves. W 07-02-02 © 42380-1 ● Lightly oil cylinder running surface, piston, piston rings and lifting bearing journal lightly.
Connecting rod W 06-01-01 TCD 2013 2V ● Set lifting journal at bottom dead centre (BDC). ● Push piston and con rod completely into cylinder liner. Note the cylinder assignment of the piston. Note the label indicating the installation position on the piston base. The symbol flywheel/crankshaft (1) must face the flywheel. The piston ring compressor must lie flat on the cylinder liner. 1 6 © 44256-0 ● Press the con rod carefully against the lifting journal.
Connecting rod W 06-01-01 TCD 2013 2V ● Tighten new screws with rotation angle disc. – Stage 1: 30 Nm – Stage 2: 60° – Stage 3: 60° 6 © 44259-0 ● Insert oil dipstick. ● Unscrew screws (1). ● Remove the liner holder (2). 2 1 1 © 44260-0 ● Install oil suction pipe. W 16-01-01 ● Install cylinder head. W 08-03-01 © 44261-0 © 02/2010 7/8 OBJ_DOKU-21761-001.
Connecting rod W 06-01-01 TCD 2013 2V 6 © 02/2010 8/8 OBJ_DOKU-21761-001.
Connecting rod W 06-01-02 TCD 2013 2V Checking the con rod Standard tools: – Micrometer gauge – Internal measuring device – Con rod test device – Rotation angle disc 8190 Special tools: – Dial gauge – W 05-05-02 100400 6 Checking small end bush ● Prepare internal measuring device: – Mount probe bolt for the appropriate measuring range in the internal measuring device. – Mount dial gauge with approx. 1 mm pre-tension in the internal measuring device. – Set micrometer gauge to 42 mm.
Connecting rod W 06-01-02 TCD 2013 2V ● Insert internal measuring device. ● Balance the internal measuring device at the given measuring points and read off the measured value at the reversal point of the pointer. +0.05 42 +0.04 mm Measuring points see diagram. ● Note the measured value, dimension (A). The dimension A is required to determine the piston bolt clearance. 6 © 34770-2 Checking diameter of the piston bolt ● Measure piston pin with micrometer gauge. 0 42 - 0.
Connecting rod W 06-01-02 TCD 2013 2V Checking the con rod bearing bore Make sure the clamping bushings (1) are in place. 6 1 © 44440-0 ● Mount big end bearing cap. Attention! 1 26519 Note the assignment of the big end bearing cap. The identification numbers (1) on the con rod and the big end bearing cap must be identical and opposite to each other when assembled. 26519 © 44212-0 ● Tighten screws alternately with rotation angle disc and socket wrench insert.
Connecting rod W 06-01-02 TCD 2013 2V ● Prepare internal measuring device: – Mount probe bolt for the appropriate measuring range in the internal measuring device. – Mount dial gauge with approx. 1 mm pre-tension in the internal measuring device. – Set micrometer gauge to 72 mm. – Balance the internal measuring device between the test surfaces of the micrometer gauge and set the dial gauge at the reversal point of the pointer to "0".
Connecting rod W 06-01-02 TCD 2013 2V Checking internal diameter of the con rod bearing shells ● Remove screws. ● Remove the con rod bearing cover. Make sure the clamping bushings (1) are in place. 6 1 © 44440-0 ● Insert bearing shell in the con rod. Attention! Note the assignment of the bearing shells. The anti-rotation lock (1) must lock in groove (2). 2 1 © 44215-0 ● Insert bearing shell in the respective big end bearing cap. Attention! Note the assignment of the bearing shells.
Connecting rod W 06-01-02 TCD 2013 2V ● Mount big end bearing cap. Attention! 2651 9 Note the assignment of the big end bearing cap. The identification numbers (1) on the con rod and the big end bearing cap must be identical and opposite to each other when assembled. 1 2651 9 6 © 44217-0 ● Tighten screws alternately with rotation angle disc and socket wrench insert.
Connecting rod W 06-01-02 TCD 2013 2V Diagram for measuring the inside diameter of the con rod bearing shells at the points "a" and "b" in the levels "1" and "2". 6 © 37239-1 ● Insert internal measuring device. ● Balance the internal measuring device at the given measuring points and read off the measured value at the reversal point of the pointer. +0.02 72,5 0 mm When the wear limit is reached the con rod must be replaced. ● Note the measured value, dimension (C).
Connecting rod W 06-01-02 TCD 2013 2V Checking the con rod ● Mount connecting rod on test instrument without bearing shells. A Attention! Aligning the con rod is not permissible. B ● Move test fork in direction of arrow. ● Check that the con rod is parallel. ● Permissible deviation from (A) to (B). 0,05 mm Distance between “A“ and “B“ = 100 mm. 6 © 30579-1 ● Move test fork in direction of arrow. ● Check the angle of the con rod. ● Permissible deviation from (C) to (D).
Piston W 07-01-02 TCD 2013 2V Checking the piston Standard tools: – Micrometer gauge – Internal measuring device Special tools: – Dial gauge – W 06-01-01 When the piston wear limit is reached, the piston must be renewed. 100400 6 Checking the piston bolt bore ● Remove piston from con rod. W 06-01-01 © 44262-0 ● Prepare internal measuring device: – Mount probe bolt for the appropriate measuring range in the internal measuring device. – Mount dial gauge with approx.
Piston W 07-01-02 TCD 2013 2V Diagram for measuring the piston bolt bore at the points "a" and "b" in the levels "1" and "2". 6 © 37239-1 ● Insert internal measuring device in the piston bolt bore. ● Balance the internal measuring device at the given measuring points and read off the measured value at the reversal point of the pointer. 42 +0.017 +0.010 mm See schematic diagram for measuring points.
Piston W 07-01-02 TCD 2013 2V ● Measure piston diameter with micrometer gauge. – Measuring point 1 107,700 mm – Measuring point 2 107,800 mm – Measuring point 3 107,660 mm See schematic diagram for measuring points. ● Assemble con rod and piston. W 06-01-01 6 © 43427-0 © 02/2010 3/4 OBJ_DOKU-21763-001.
Piston W 07-01-02 TCD 2013 2V 6 © 02/2010 4/4 OBJ_DOKU-21763-001.
Piston W 07-02-02 TCD 2013 2V Checking the piston rings and piston ring grooves Standard tools: – Feeler gauges – W 06-01-01 Special tools: – Universal piston ring pliers 130300 – Trapezoidal groove wear gauge 130420 6 Checking the piston rings and piston ring grooves ● Remove piston from con rod. W 06-01-01 ● Set universal piston ring pliers to the piston diameter. 108 mm ● Remove piston rings with universal piston ring pliers. © 44263-0 ● Clean piston. ● Visually inspect piston.
Piston W 07-02-02 TCD 2013 2V ● Measure piston ring groove for first piston ring with trapezoidal groove wear gauge. 6 © 33866-2 If there is a gap "S" between the trapezoidal groove wear gauge and piston, the piston can be used again. S © 33867-2 If the trapezoidal groove wear gauge is touching the piston (arrow), the piston must be changed. © 33868-2 © 02/2010 2/6 OBJ_DOKU-21764-001.
Piston W 07-02-02 TCD 2013 2V Checking the piston ring joint clearance ● Unscrew screws (1). ● Remove the liner holder (2). 2 1 1 6 © 44260-0 ● Insert the piston ring (1) in the cylinder. ● Align the piston ring in the cylinder by pushing the piston. 1 © 44265-0 ● Measure the piston ring joint clearance with a feeler gauge. 1. piston ring 0,3 - 0,55 mm 2. piston ring 1,5 - 2,0 mm 3. piston ring 0,3 - 0,6 mm When the wear limit is reached, the piston ring must be renewed.
Piston W 07-02-02 TCD 2013 2V ● Install piston rings. Order and position of the piston rings as seen from the piston base. - Double-sided keystone ring (1) - Taper-faced ring (2) 1 - Bevelland-edge oil control ring with coiled spring expander (3) 2 “Top“ label faces the combustion chamber. 3 6 © 44267-0 ● Install piston rings with universal piston ring pliers. Set spring joint of the bevelland-edge oil control ring 180° to the ring joint.
Piston W 07-02-02 TCD 2013 2V ● Assemble con rod and piston. W 06-01-01 6 © 44270-0 © 02/2010 5/6 OBJ_DOKU-21764-001.
Piston W 07-02-02 TCD 2013 2V 6 © 02/2010 6/6 OBJ_DOKU-21764-001.
Cylinder head W 08-00-01 TCD 2013 2V Checking the compression pressure Standard tools: – Compression pressure tester – Torx tool set 8005 8189 Special tools: – Connector 100190 – W 11-01-01 – W 19-01-01 6 Checking the compression pressure ● Setting the valve clearance (with exhaust return module installed). W 11-01-01 ● Remove injector. W 19-01-01 ● Insert connector (1). Use sealing ring for injector. 1 © 44100-0 ● Mount clamping shoe (1). ● Tighten screw (2).
Cylinder head W 08-00-01 TCD 2013 2V ● Connect adapter (1) to connector. 1 6 © 44102-0 ● Connect compression pressure tester to connector. ● Turn over engine with starter. © 44103-0 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.
Cylinder head W 08-00-01 TCD 2013 2V ● Remove the compression pressure tester. 6 © 44103-0 ● Unscrew screw (1). ● Remove clamping shoe (2). ● Remove connector. ● Remove sealing ring. ● Installing the injector. W 19-01-01 1 2 © 44101-0 © 02/2010 3/4 OBJ_DOKU-21765-001.
Cylinder head W 08-00-01 TCD 2013 2V Technical Data Tightening specifications ID no. Name Connection piece on cylinder head, A49 001 clamping shoe Screw type 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 © 02/2010 4/4 OBJ_DOKU-21765-001.
Cylinder head W 08-01-01 TCD 2013 2V Removing and installing the cylinder head cover Standard tools: – Spring band pliers 9090 6 Removing cylinder head ● Loosen spring band clip (1) with spring band pliers. ● Pull off bleeding hose (2). 1 2 © 44130-0 ● Unscrew screws (1). ● Remove the cover (2). 1 2 © 44126-0 © 02/2010 1/4 OBJ_DOKU-21766-001.
Cylinder head W 08-01-01 TCD 2013 2V ● Unscrew all screws. ● Remove cylinder head cover and gasket. 6 © 44127-0 Installing cylinder head cover. ● Clean sealing surfaces. ● Insert new gasket (arrow). © 44128-0 ● Mount cylinder head cover. ● Tighten screws alternately. 13 Nm Attention! Do not trap the cable (1). 1 © 44162-0 © 02/2010 2/4 OBJ_DOKU-21766-001.
Cylinder head W 08-01-01 TCD 2013 2V ● Mount cover (2). ● Tighten screws (1). 8.5 Nm 1 2 6 © 44126-0 ● Plug on bleeding hose. ● Position the spring band clip (1) with the spring band pliers. 1 © 44129-0 © 02/2010 3/4 OBJ_DOKU-21766-001.
Cylinder head W 08-01-01 TCD 2013 2V Technical Data Tightening specifications ID no. Name Cylinder head cowling on cylinder A01 004 head A13 041 Cover plate on cylinder head cover Screw type Notes / Remark M6 M6x16 Value 13 Nm self-tapping 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 © 02/2010 4/4 OBJ_DOKU-21766-001.
Cylinder head W 08-02-01 TCD 2013 2V Removing and installing the exhaust return module Standard tools – W 08-01-01 – W 11-01-01 6 Remove exhaust return module ● Remove the cylinder head hood. W 08-01-01 ● Unscrew screws (1). Loosen screws evenly to avoid jamming the exhaust return module. 2 ● Pull the exhaust return module (2) off the plug element in the direction of the arrow. ● Remove exhaust return module (2). 1 1 © 44097-0 ● Unscrew screws (1). ● Remove exhaust return module (2).
Cylinder head W 08-02-01 TCD 2013 2V ● Visually inspect the components. 6 © 44099-0 Installing the exhaust return module ● Setting the valve clearance (with or without removal of exhaust return module). W 11-01-01 ● Pull out plug element (1). 1 © 42927-0 ● Insert new O-rings (arrows). ● Oil O-rings lightly. ● Push plug element into exhaust return module. © 42928-0 © 02/2010 2/6 OBJ_DOKU-21767-001.
Cylinder head W 08-02-01 TCD 2013 2V ● Mount exhaust return module for cylinders 1 - 3. ● Fasten screws. 1 Note identification (1) for assignment of the exhaust gas return modules. Note different screw lengths: Screws M8 x 55 mm (2) Screws M8 x 120 mm (3) 2 6 © 44108-1 ● Retighten the screws (1), (2) and (3) in the tightening order. – Stage 1: 10 Nm 2 – Stage 2: 3 1 30 Nm © 44109-0 ● Push exhaust return module for cylinders 4 - 6 onto plug element. ● Fasten screws.
Cylinder head W 08-02-01 TCD 2013 2V ● Retighten the screws (1), (2) and (3) in the tightening order. – Stage 1: 10 Nm – Stage 2: 30 Nm 2 3 1 ● Set the control piston clearance. W 11-01-01 ● Mount cylinder head cover. W 08-01-01 6 © 44275-0 © 02/2010 4/6 OBJ_DOKU-21767-001.
Cylinder head W 08-02-01 TCD 2013 2V Technical Data Tightening specifications ID no. Name A01 011 Exhaust gas return module on rocker arm bracket A01 011 Exhaust gas return module on rocker arm bracket Screw type Notes / Remark Stage 1: Observe tightening sequence Stage 2: Observe tightening sequence Value 10 Nm 30 Nm For the tightening procedure according to torque using a torque wrench, a maximum variation of the tightening torque of +/- 10% is permissible. © 02/2010 5/6 OBJ_DOKU-21767-001.
Cylinder head W 08-02-01 TCD 2013 2V 6 © 02/2010 6/6 OBJ_DOKU-21767-001.
Cylinder head W 08-02-02 TCD 2013 2V Removing and installing the solenoid valve (exhaust gas return) Standard tools – W 01-01-01 Collect leaking operating substances in suitable vessels and dispose of according to regulations. 6 Removing the solenoid valve (exhaust return line) ● Removing the crankcase breather. W 01-01-01 ● Unlock cable plug. ● Pull out cable plug (1). 1 © 44417-0 ● Unscrew solenoid valve (1). 1 © 44418-0 © 02/2010 1/4 OBJ_DOKU-21768-001.
Cylinder head W 08-02-02 TCD 2013 2V ● Visually inspect the components. 6 © 44419-0 Installing the solenoid valve (exhaust return line) 3 ● Clean sealing surfaces. 2 ● Mount new O-ring (1). ● Insert new O-ring (2). Observe the order of installation of the Oring (2) and the support ring (3). 1 ● Oil O-rings lightly. © 42834-0 ● Tighten solenoid valve (1). 24 Nm 1 © 44420-0 © 02/2010 2/4 OBJ_DOKU-21768-001.
Cylinder head W 08-02-02 TCD 2013 2V ● Plug in the cable plug (1). Ensure that the connection is perfect. ● Install crankcase breather. W 01-01-01 1 6 © 44417-0 © 02/2010 3/4 OBJ_DOKU-21768-001.
Cylinder head W 08-02-02 TCD 2013 2V 6 © 02/2010 4/4 OBJ_DOKU-21768-001.
Cylinder head W 08-03-01 TCD 2013 2V Removing and installing cylinder head Standard tools: – Torx tool set – Rotation angle disc – – – – – – – – – – – 8189 8190 W 01-05-01 W 08-01-01 W 08-03-02 W 11-02-01 W 19-01-01 W 21-02-01 W 22-01-01 W 38-02-01 W 41-01-01 W 44-02-01 W 49-02-01 6 Removing the cylinder head ● Attach turning gear. W 49-02-01 1 ● Remove generator. W 44-02-01 ● Unscrew screw (1). ● Remove clamping strap (2). ● Remove thermostat housing. W 38-02-01 ● Remove the exhaust pipe.
Cylinder head W 08-03-01 TCD 2013 2V ● Unlock cable plug (1) and remove. ● Unlock cable plug (2) and remove. 1 6 2 © 44144-0 Hold connection piece (3). ● Unscrew hollow screw (1). ● Remove sealing rings. ● Remove fuel return line (2). 3 1 2 © 44145-0 ● Unscrew all screws (arrows). © 44146-0 © 02/2010 2/8 OBJ_DOKU-21769-001.
Cylinder head W 08-03-01 TCD 2013 2V ● Hang cylinder head on suitable cross beam (1) and workshop crane. Align chains parallel to the cross beam. 1 ● Lift the cylinder head carefully from the crankcase. 6 © 44147-0 ● Remove the cylinder head gasket. ● Clean sealing surfaces. © 44148-0 Installing the cylinder head ● Check the overhang of the cylinder liner. W 01-05-01 ● Check piston overhang. W 08-03-02 © 44149-0 © 02/2010 3/8 OBJ_DOKU-21769-001.
Cylinder head W 08-03-01 TCD 2013 2V ● Select cylinder head gasket according to the largest piston projection measured. 0,28 - <0,54 mm 1 hole, cylinder head gasket 1.42 mm 0,54 - <0,64 mm 2 hole, cylinder head gasket 1.52 mm 0,64 - <0,75 mm 3 hole, cylinder head gasket 1.62 mm Example: Piston projection = 0.7 mm corresponds to cylinder head gasket with 3 holes (arrow). 6 © 44154-0 ● Make sure the clamping bushings (arrows) are in place. © 44155-0 ● Fit a new cylinder head gasket.
Cylinder head W 08-03-01 TCD 2013 2V ● Fit cylinder head. ● Oil the cylinder head screws slightly. ● Fasten screws. Attention! Cylinder head screws can be used max. 3 times with written proof, otherwise renew every time they are loosened. 6 © 44157-0 ● Tighten all cylinder head screws according to the tightening sequence.
Cylinder head W 08-03-01 TCD 2013 2V ● Mount fuel return pipe (1). ● Tighten hollow screw (arrow) with new sealing rings. 29 Nm 1 6 © 44159-0 ● Plug cable plug (1) onto temperature transmitter. ● Plug cable plug (2) into the solenoid valve (exhaust gas return line). Ensure that the connection is perfect. 2 1 © 44160-0 ● Installing the injector. W 19-01-01 ● Mount cylinder head cover. 1 W 08-01-01 Do not tighten the screws of the clamping shoe until after assembling the rail. ● Install rail.
Cylinder head W 08-03-01 TCD 2013 2V ● Install the charge air pipe. W 22-01-01 ● Install the exhaust pipe. 1 W 41-01-01 ● Install thermostat housing. W 38-02-01 ● Mount clamping strap (2). ● Fasten screw (1). ● Install generator. W 44-02-01 ● Remove turning gear. 2 W 49-02-01 © 02/2010 6 © 44142-0 7/8 OBJ_DOKU-21769-001.
Cylinder head W 08-03-01 TCD 2013 2V 6 © 02/2010 8/8 OBJ_DOKU-21769-001.
Cylinder head W 08-03-02 TCD 2013 2V Checking piston overhang Standard tools Special tools: – Dial gauge – Measuring device – W 08-03-01 – W 49-02-01 100400 100750 6 Checking piston overhang ● Attach turning gear. W 49-02-01 ● Remove cylinder head. W 08-03-01 ● Turn the crankshaft until the respective piston is just in front of the top dead centre (arrow). Keep the cylinder liner pressed down to the stop. © 44150-0 ● Insert dial gauge into measuring beam.
Cylinder head W 08-03-02 TCD 2013 2V ● Move the measuring beam. ● Apply the stylus to the sealing surface of the cylinder liner (arrow) under pre-tension. ● Adjust dial gauge to "0". 6 © 44152-0 Measuring points see diagram. Measuring points (1) and (2). 1 2 © 34151-2 ● Move the measuring beam. ● Apply stylus to the specified measuring points under pre-tension. Measuring points see diagram. Do not position the stylus on the piston marking. ● Note the largest measured value.
Cylinder head W 08-04-01 TCD 2013 2V Removing and installing the valves Standard tools: – Slide gauge – Assembly lever 9017 Special tools: – Support bracket – Base plate 120900 120910 – W 08-03-01 6 Removing the valves ● Remove cylinder head. W 08-03-01 ● Mount support bracket (1) on base plate (2). ● Mount cylinder head on support bracket. 1 2 © 44163-0 ● Remove snap ring (1). Danger! Risk of injury! Snap ring springs off. 1 © 44164-0 © 02/2010 1/6 OBJ_DOKU-21771-001.
Cylinder head W 08-04-01 TCD 2013 2V ● Remove thrust washer (1). 1 6 © 44165-0 ● Install assembly lever (1). ● Press down valve spring with assembly lever. 1 ● Remove both tapper collets (2). ● Remove valve spring plates, valve springs and valves. ● Remove assembly lever. 2 © 44166-0 ● Remove valve stem sealing ring (arrow). © 44167-0 © 02/2010 2/6 OBJ_DOKU-21771-001.
Cylinder head W 08-04-01 TCD 2013 2V ● Clean cylinder head. ● Check cylinder head. ● Visually inspect the components. 6 © 44168-0 Installing the valves ● Measure valve spring length with slide gauge. 64,7 mm When the wear limit is reached, the valve spring must be renewed. © 35856-2 ● Oil the new valve stem sealing ring lightly. ● Insert the valve stem sealing ring (1) in the groove (arrow) of the valve guide. 1 © 44169-0 © 02/2010 3/6 OBJ_DOKU-21771-001.
Cylinder head W 08-04-01 TCD 2013 2V ● Oil the valve stem lightly. ● Insert the valve in the valve guide by turning with a slight pressure. Do not damage or press out the valve stem seal when inserting the valve. 6 © 44170-0 ● Insert valve spring (1). ● Insert valve spring plate (2). The closely wound end of the valve plate faces the cylinder head. 2 1 © 44171-0 ● Mount assembly lever. ● Press down the valve spring with the assembly lever and insert both tapper collets (1).
Cylinder head W 08-04-01 TCD 2013 2V ● Remove assembly lever. ● Insert thrust washer (1). Ensure that the installation location is free from faults. 1 6 © 44165-0 ● Insert snap ring (arrow). Ensure that the installation location is free from faults. © 44173-0 ● Remove cylinder head from support bracket (1). ● Remove support bracket from base plate (2). ● Install cylinder head. W 08-03-01 1 2 © 44163-0 © 02/2010 5/6 OBJ_DOKU-21771-001.
Cylinder head W 08-04-01 TCD 2013 2V 6 © 02/2010 6/6 OBJ_DOKU-21771-001.
Cylinder head W 08-04-02 TCD 2013 2V Checking the valves Standard tools: – Micrometer gauge – Slide gauge – W 08-04-01 Clean all valves. When the wear limit is reached, the valve must be renewed. 6 Checking valve stem diameter ● Remove valves. W 08-04-01 ● Measure valve stem diameter with micrometer gauge. – Inlet valve 8,98 0-0.05 mm – Exhaust valve 0 8,96 - 0.05 mm © 42182-1 Checking valve edge thickness ● Measure valve edge thickness with slide gauge.
Cylinder head W 08-04-02 TCD 2013 2V Checking valve head diameter ● Measure valve head diameter with slide gauge. – Inlet valve +0.1 48 - 0.1 mm – Exhaust valve +0.1 42 - 0.1 mm ● Install valves. W 08-04-01 6 © 42184-1 © 02/2010 2/2 OBJ_DOKU-21772-001.
Cylinder head W 08-04-03 TCD 2013 2V Checking the valve guide Standard tools: – Magnetic measuring stand Special tools: – Dial gauge – W 08-04-01 New valves are used for testing. 100400 When the wear limit is reached, the valve guide must be renewed. 6 Checking the valve guide ● Remove valves and valve shaft seals. W 08-04-01 ● Visually inspect valve guide for wear. © 44168-0 ● Mount magnetic measuring stand. ● Insert dial gauge. ● Insert new valve.
Cylinder head W 08-04-03 TCD 2013 2V Measure valve stem clearance ● Move valve back and forth in direction of arrow. – Inlet valve 0,045 - 0,075 mm – Exhaust valve 0,065 - 0,095 mm The valve stem ends must be flush with the valve guide. The whole rocker path must be taken into consideration. 6 © 44175-0 ● Remove magnetic measuring stand. ● Remove dial gauge. ● Install valves. W 08-04-01 © 44176-0 © 02/2010 2/2 OBJ_DOKU-21773-001.
Cylinder head W 08-04-04 TCD 2013 2V Checking the valve lag Standard tools: – Depth-measuring appliance Special tools: – Support bracket – Base plate – W 08-03-01 Attention! 120900 120910 When the wear limit is reached, the valve seat insert and/or valve must be renewed. 6 Checking the valve lag ● Mount support bracket (1) on base plate (2). 1 ● Remove cylinder head. W 08-03-01 2 © 44178-0 ● Mount cylinder head on support bracket (1). 1 © 44177-0 © 02/2010 1/2 OBJ_DOKU-21774-001.
Cylinder head W 08-04-04 TCD 2013 2V ● Measure the valve lag from the centre of the valve head to the cylinder head sealing surface. – Inlet valve +0.1 0,99 - 0.1 mm – Exhaust valve +0.15 1 - 0.1 mm 6 © 42598-0 ● Remove cylinder head from support bracket (1). 1 © 44177-0 ● Remove support bracket (1) from base plate (2). ● Install cylinder head. 1 W 08-03-01 2 © 44178-0 © 02/2010 2/2 OBJ_DOKU-21774-001.
Gearcase W 09-01-01 TCD 2013 2V Renewing the crankshaft sealing ring (flywheel side) Standard tools: – Pricker – Assembly lever 8198 9017 Special tools: – Assembly tool 142810 – W 05-03-01 – Self-tapping screw – Washer 6 Removing the crankshaft sealing ring ● Remove flywheel. W 05-03-01 ● Make a hole of approximately 3 mm in the crankshaft sealing ring with a pricker. Attention! Do not damage the gearcase cover and crankshaft. © 44188-0 ● Turn in a self-tapping screw with washer.
Gearcase W 09-01-01 TCD 2013 2V ● Pull out the crankshaft sealing ring with assembly lever. 6 © 44190-0 ● Visually inspect all running surfaces. © 44191-0 Install crankshaft sealing ring ● Mount guide sleeve (1). ● Tighten screws . 1 The bores in the guide sleeve must match the threaded holes in the crankshaft flange. © 44192-0 © 02/2010 2/4 OBJ_DOKU-21775-001.
Gearcase W 09-01-01 TCD 2013 2V ● Oil the sealing lip of the crankshaft sealing ring lightly. ● Push the crankshaft sealing ring carefully onto the guide sleeve. Use new crankshaft sealing ring. The sealing lip faces the crankcase. 6 © 44193-0 ● Mount shims (1). ● Pay attention to installation depth of crankshaft sealing ring and select shim accordingly. – First assembly = 2 shims – 1.
Gearcase W 09-01-01 TCD 2013 2V ● Plug in the bearing (1). ● Screw on nut (2). 2 1 6 © 44196-0 ● Tighten nut to the stop of the assembly sleeve (1). The crankshaft sealing ring is now at the pre-selected installation depth. ● Remove assembly tool. ● Install flywheel. 1 W 05-03-01 © 44197-0 © 02/2010 4/4 OBJ_DOKU-21775-001.
Gearcase W 09-02-02 TCD 2013 2V Removing and installing the gearcase cover Standard tools – – – – – – – Packing compound DEUTZ DW 67 – Packing compound DEUTZ DW 48 W 02-01-01 W 05-03-01 W 09-01-01 W 44-03-01 W 48-02-03 W 52-01-01 6 Removing the gearcase ● Unlock cable plug (1) and remove. ● Unlock cable plug (2) and remove. 2 ● Remove cable tie (arrows). ● Expose cable harness. ● Remove impulse transmitter (camshaft). W 48-02-03 1 © 44448-0 ● Remove cable tie (arrows). ● Expose cable harness.
Gearcase W 09-02-02 TCD 2013 2V ● Unlock central plug (1) (arrow) and pull off from holder. ● Remove connection housing. W 52-01-01 ● Remove flywheel. 1 W 05-03-01 ● Remove lubricating oil pan. W 02-01-01 6 © 44450-0 ● Unscrew screws (1). ● Remove the holder (2). 2 1 © 44451-0 ● Unscrew screws (1). ● Remove cover (2). 2 1 © 44452-0 © 02/2010 2/10 OBJ_DOKU-21776-001.
Gearcase W 09-02-02 TCD 2013 2V ● Unscrew screws (1). ● Remove cover (2). 1 1 2 6 © 44453-0 ● Unscrew screws (1). 1 1 1 © 44454-0 ● Unscrew screws (1). ● Remove gearcase cover. 1 1 1 © 44455-0 © 02/2010 3/10 OBJ_DOKU-21776-001.
Gearcase W 09-02-02 TCD 2013 2V ● Visually inspect the component. 6 © 44456-0 Installing the gearcase cover ● Knock out crankshaft sealing ring (1). Attention! Do not damage sealing surface when knocking out. 1 © 44457-0 ● Clean sealing surfaces. The sealing surfaces must be dry and free from grease and dirt. © 44456-0 © 02/2010 4/10 OBJ_DOKU-21776-001.
Gearcase W 09-02-02 TCD 2013 2V ● Apply packing compound (arrow). Attention! The assembly must be completed within 1 hour at most. Use packing compound DEUTZ DW 67. Sealing bead thickness approx. 1.4 mm. 6 © 44458-0 ● Align gearcase cover. ● Mount gearcase cover. Do not move the gearcase cover after mounting. 1 ● Tighten screws (1). Do not tighten screws. 1 1 © 44459-0 ● Fasten screws. Note different screw lengths: Screw M8 x 55 mm (1) Screws M8 x 35 mm (2) Do not tighten screws.
Gearcase W 09-02-02 TCD 2013 2V ● Press up gearcase cover and align flush with the oil tray sealing surface (arrows). The oil tray sealing surface on the crankcase must face downwards. 6 © 44461-0 ● Tighten the screws according to the tightening sequence. 11 Note different tightening values. 1 10 2 12 13 ● Tighten scews (1) and (2). M16x60 70 Nm 14 ● Tighten scews (3) to (14). M8x35 30 Nm 6 5 7 3 9 8 4 © 44589-2 ● Tighten screws (15) to (17).
Gearcase W 09-02-02 TCD 2013 2V ● Clean sealing surfaces. The sealing surfaces must be dry and free from grease and dirt. ● Fill the ring groove (arrows) with packing compound. Use packing compound DEUTZ DW 48. Sealing bead thickness approx. 1.5 mm. 6 © 44462-0 ● Mount cap (1). ● Tighten screws (2). Note the installation position of the cap (1). Use M8 x 50 mm screws. Mount holder (arrow). Do not tighten screws. 2 2 1 © 44463-0 ● Clean sealing surfaces. ● Mount the new O-ring. ● Lightly oil O-ring.
Gearcase W 09-02-02 TCD 2013 2V ● Press in the cap(1) to the stop. ● Tighten screws (2). Use M8 x 60 mm screws. Do not tighten screws. 1 2 2 6 © 44464-0 ● Mount holder (1). ● Tighten screws (2). Use M8 x 55 mm screws. 1 Do not tighten screws. 2 © 44465-0 ● Tighten screws (1) alternately. 30 Nm 1 1 © 44592-0 © 02/2010 8/10 OBJ_DOKU-21776-001.
Gearcase W 09-02-02 TCD 2013 2V ● Tighten screws (1) alternately. 20 Nm 1 6 © 44593-0 ● Install new crankshaft sealing ring (flywheel side). W 09-01-01 ● Install connection housing. W 52-01-01 ● Install flywheel. W 05-03-01 ● Install starter. W 44-03-01 ● Install lubricating oil pan. W 02-01-01 © 44467-0 ● Push the central plug onto the holder until it snaps in. © 44468-0 © 02/2010 9/10 OBJ_DOKU-21776-001.
Gearcase W 09-02-02 TCD 2013 2V ● Lay cable harness and fix with cable ties (arrows). 6 © 44449-0 ● Plug in the cable plug (1). ● Plug in the cable plug (2). Ensure that the connection is perfect. 2 ● Lay cable harness and fix with cable ties (arrows). ● Install impulse transmitter (camshaft). W 48-02-03 1 © 44448-0 © 02/2010 10/10 OBJ_DOKU-21776-001.
Camshaft W 10-02-01 TCD 2013 2V Removing and installing the camshaft Standard tools: – Lifting gear – – – – W 05-05-01 W 11-02-01 W 17-01-04 W 17-01-05 6 Removing the camshaft ● Remove high pressure pump and roller tappet (installation position A). W 17-01-04 ● Remove high pressure pump and roller tappet (installation position B). W 17-01-05 ● Remove rocker arm and rocker arm brackets. W 11-02-01 ● Remove crankshaft. W 05-05-01 © 44470-0 ● Screw in screws (1).
Camshaft W 10-02-01 TCD 2013 2V ● Remove clamping bracket (1) from the adapter plates (2). 1 1 2 2 6 © 44472-0 ● Push away the assembly block on the flywheel side. © 44473-0 ● Press in all tappets. ● Pull out the camshaft (1) carefully in the direction of the arrow. 1 © 44474-0 © 02/2010 2/4 OBJ_DOKU-21777-001.
Camshaft W 10-02-01 TCD 2013 2V Removing tappets. ● Remove all tappets (arrow). Lay out components in the order in which they should be installed. Note order of cylinders. ● Visually inspect the components. 6 © 42711-0 Installing tappets ● Oil all tappets (arrow) lightly. ● Insert all tappets. Note assignment! © 42711-0 Installing the camshaft ● Oil cam shaft pin lightly. ● Oil camshaft bearing lightly. ● Insert camshaft carefully. The bore (1) must be facing the cylinder head.
Camshaft W 10-02-01 TCD 2013 2V ● Push on and align the flywheel side assembly block. ● Install clamping holder (1) on adapter boards (2). 90 Nm 1 1 2 2 6 © 44472-0 ● Unhook the crankcase from the workshop crane. ● Unscrew screws (1). 1 1 © 44471-0 ● Install crankshaft. W 05-05-01 ● Install rocker arms and rocker arm brackets. W 11-02-01 ● Install high pressure pump and roller tappet (installation position B).
Camshaft W 10-02-02 TCD 2013 2V Checking the camshaft Standard tools: – Micrometer gauge – W 10-02-01 6 Checking the camshaft ● Remove camshaft. W 10-02-01 ● Visually inspect cams and bearing pins for wear. © 42713-0 Diagram for measuring the journals at the points 1 and 2 in the levels a and b. © 36424-2 © 02/2010 1/2 OBJ_DOKU-21778-001.
Camshaft W 10-02-02 TCD 2013 2V Checking the diameter of the journal ● Measure the bearing pin. 64,2 +0.2 - 0.2 mm See schematic diagram for measuring points. When the limit value is reached the camshaft must be replaced. 6 © 42714-0 ● Check camshaft gear wheel for visible signs of wear. ● Install the camshaft. W 10-02-01 © 42713-0 © 02/2010 2/2 OBJ_DOKU-21778-001.
Control parts W 11-01-01 TCD 2013 2V Setting valve clearance (with or without removal of exhaust return module) – W 08-01-01 – W 49-02-01 Standard tools: – Rotation angle disc 8190 – Screwdriver insert for slotted screws 8191 – Screwdriver insert for hexagon socket head screws (4 mm) 8194 – Open wrench size 13 8196 Special tools: – Socket wrench insert spanner size 15 Allow the engine to cool down for at least 30 minutes before setting the valve clearance.
Control parts W 11-01-01 TCD 2013 2V Set valve clearance. – 6-cylinder Ignition sequence: overlap set to Valves 1-5-3-6-2-4 1 6 5 2 Cylinders 3 6 2 4 1 5 4 3 Valve overlap: Outlet valve is not yet closed, inlet valve begins to open. When the inlet valve is fully open, the outlet valve opens briefly approx. 2 mm. This is not the valve overlap! 6 © 00000-0 Valve overlap means: The inlet valve starts opening,exhaust valve closes. © 44111-0 Arrangement of the inlet and exhaust valves.
Control parts W 11-01-01 TCD 2013 2V Setting the inlet valve clearance ● Loosen lock nut (1). ● Press in the adjusting screw (2) to the stop. The rocker arm must touch the thrust washer of the spring cap (arrow). 2 1 6 © 44113-0 ● Set the rotation angle disc with a socket wrench insert at the adjusting screw. ● Fix magnet of rotation angle disc on cylinder head. ● Set the rotation angle disc in the direction of the arrow to „0“. Do not rotate adjusting screw.
Control parts W 11-01-01 TCD 2013 2V ● Hold adjusting screw. ● Tighten locking nut (arrow) with box spanner. 20 Nm ● Remove rotation angle disc. 6 © 44116-0 Setting the exhaust valve clearance ● Loosen lock nut (1). ● Press in the adjusting screw (2) to the stop. The rocker arm must touch the thrust washer of the spring cap (arrow). 2 1 © 44117-0 ● Set the rotation angle disc on the adjusting screw with a screwdriver insert for slotted screws. ● Fix magnet of rotation angle disc on cylinder head.
Control parts W 11-01-01 TCD 2013 2V ● Turn back setting screw 150° in direction of arrow. 150° 6 © 44119-0 ● Hold adjusting screw. ● Tighten locking nut (arrow) with box spanner. 20 Nm ● Remove rotation angle disc. ● Set all other valves. – see page: – 1, 4 cylinders – 2, 6-cylinder ● Mount cylinder head cover. W 08-01-01 ● Remove turning gear. W 49-02-01 © 44120-0 © 02/2010 5/6 OBJ_DOKU-21779-001.
Control parts W 11-01-01 TCD 2013 2V Technical Data Testing and setting data ID no. P01 61 P01 62 Name Valve clearance (inlet) Valve clearance (outlet) Additional information with rotary angle disc with rotary angle disc Value 90° 150° Tightening specifications ID no.
Control parts W 11-01-01 TCD 2013 2V Setting valve clearance (with exhaust return module installed) – W 08-01-01 – W 49-02-01 Standard tools: – Rotation angle disc 8190 – Screwdriver insert for slotted screws 8191 – Screwdriver insert for hexagon socket head screws (4 mm) 8194 – Open wrench size 13 8196 Allow the engine to cool down for at least 30 minutes before setting the valve clearance.
Control parts W 11-01-01 TCD 2013 2V Setting valve and control piston clearance – 6-cylinder Ignition sequence: overlap set to Valves 1-5-3-6-2-4 1 6 5 2 Cylinders 3 6 2 4 1 5 4 3 Valve overlap: Outlet valve is not yet closed, inlet valve begins to open. When the inlet valve is fully open, the outlet valve opens briefly approx. 2 mm. This is not the valve overlap! 6 Valve overlap means: The inlet valve starts opening,exhaust valve closes. © 43040-0 Arrangement of the inlet and exhaust valves.
Control parts W 11-01-01 TCD 2013 2V Setting the inlet valve clearance ● Loosen lock nut (1). ● Press in the adjusting screw (2) to the stop. The rocker arm must touch the thrust washer of the spring cap (arrow). 2 6 1 © 43042-0 ● Set the rotation angle disc on the adjusting screw with the crowfoot wrench. ● Fix magnet of rotation angle disc on cylinder head. ● Set the rotation angle disc in the direction of the arrow to „0“. Do not rotate adjusting screw.
Control parts W 11-01-01 TCD 2013 2V ● Hold adjusting screw. ● Tighten locking nut (arrow) with box spanner. 20 Nm ● Remove rotation angle disc. 6 © 48241-0 Setting the exhaust valve clearance ● Loosen lock nut (1). ● Press in the adjusting screw (2) to the stop. The rocker arm must touch the thrust washer of the spring cap (arrow). 2 1 © 43046-0 ● Set the rotation angle disc on the adjusting screw with a screwdriver insert for slotted screws. ● Fix magnet of rotation angle disc on cylinder head.
Control parts W 11-01-01 TCD 2013 2V ● Turn back setting screw 150° in direction of arrow. 150° 6 © 43048-0 ● Hold adjusting screw. ● Tighten locking nut (arrow) with box spanner. 20 Nm ● Remove rotation angle disc. ● Set all other valves. – see page: – 1, 4-cylinder – 2, 6-cylinder © 43049-0 Setting the control piston clearance The control piston clearance (X) must be set after setting the valve clearance. © 43832-3 © 02/2010 5/8 OBJ_DOKU-21780-001.
Control parts W 11-01-01 TCD 2013 2V ● Turn crankshaft using the turning gear until the valve overlap of cylinder 1 is reached. ● Set control piston according to order of setting. – see page: – 1, 4-cylinder – 2, 6-cylinder 6 © 44110-0 ● Loosen lock nut (1). ● Press in the adjusting screw (2) to the stop. The rocker arm must touch the thrust washer of the spring cap (arrow). 2 1 © 44122-0 ● Set the rotation angle disc on the adjusting screw with a screwdriver insert for hexagon socket head screw.
Control parts W 11-01-01 TCD 2013 2V ● Turn back setting screw 144° in direction of arrow. 144° 6 © 44124-0 ● Hold adjusting screw. ● Tighten locking nut (arrow) with box spanner. 20 Nm ● Remove rotation angle disc. ● Set all other control pistons. – see page: – 1, 4-cylinder – 2, 6-cylinder ● Mount cylinder head cover. W 08-01-01 ● Remove turning gear. W 49-02-01 © 44125-0 © 02/2010 7/8 OBJ_DOKU-21780-001.
Control parts W 11-01-01 TCD 2013 2V Technical Data Testing and setting data ID no. P01 61 P01 62 P01 64 Name Valve clearance (inlet) Valve clearance (outlet) Clearance between control piston and rocker arm Additional information with rotary angle disc with rotary angle disc Value 90° 150° with rotary angle disc 144° Tightening specifications ID no.
Control parts W 11-02-01 TCD 2013 2V Removing and installing the rocker arm and rocker arm bracket Standard tools – W 08-02-01 – W 11-01-01 – W 49-02-01 6 Removing the rocker arm and rocker arm bracket ● Attach turning gear. W 49-02-01 1 1 ● Remove exhaust gas return module. W 08-02-01 ● Unscrew screws (1). ● Remove rocker arm brackets (2). Lay out components in the order in which they should be installed. Note order of cylinders. 2 2 © 43948-0 ● Remove push rods (1).
Control parts W 11-02-01 TCD 2013 2V ● Visually inspect the components. 6 © 44133-0 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 © 43949-0 ● Mount rocker arm bracket (1). The ball heads must be seated in the ladles of the pushrods (arrows). 1 © 44134-0 © 02/2010 2/4 OBJ_DOKU-21781-001.
Control parts W 11-02-01 TCD 2013 2V ● Align rocker arm bracket symmetrically with the valve axles. The bore (arrow) in the rocker arm bracket must be in line with the threaded bore in the cylinder head. ● Tighten screw (1). 30 Nm 1 Attention! Make sure that the stop rods are not under stress due to valve overlap when fastening the screw. 6 © 44135-0 ● Setting the valve clearance (with or without removal of exhaust return module). W 11-01-01 ● Install exhaust gas return module.
Control parts W 11-02-01 TCD 2013 2V Technical Data Tightening specifications ID no. Name A01 002 Rocker arm support on the cylinder head Screw type Notes / Remark Value Assembly note: Rocker arm symmetrical 30 Nm to the valve centre axes. For the tightening procedure according to torque using a torque wrench, a maximum variation of the tightening torque of +/- 10% is permissible. 6 © 02/2010 4/4 OBJ_DOKU-21781-001.
Control parts W 11-02-02 TCD 2013 2V Disassembling, assembling and checking the rocker arm and rocker arm bracket – W 11-02-01 Standard tools: – Internal measuring device – Micrometer gauge Special tools: – Dial gauge 100400 6 Disassembling the rocker arm bracket ● Remove rocker arm and rocker arm bracket. W 11-02-01 ● Remove lockwashers (1). 1 © 44137-0 ● Remove rocker arm. Lay out components in the order in which they should be installed. © 44138-0 © 02/2010 1/4 OBJ_DOKU-21782-001.
Control parts W 11-02-02 TCD 2013 2V Checking the rocker arm ● Measure rocker arm bore. – Inlet +0.033 mm +0.033 mm 21,02 0 – Outlet 21,02 0 When the wear limit is reached the rocker arm must be renewed. 6 © 39032-1 ● Loosen lock nut (1). ● Hold adjusting screw (2). ● Unscrew adjusting screw (2). 2 ● Loosen lock nut (3). 3 ● Hold adjusting screw (4). ● Unscrew adjusting screw (4). 4 Attention! 1 Pay attention to versions of the adjusting screws (slotted, hexagonal, hexagonal socket).
Control parts W 11-02-02 TCD 2013 2V ● Screw in setting screw (1). ● Loosen lock nuts (2). 2 1 6 © 43011-0 Checking the rocker arm pin ● Measure the diameter of journals with the micrometer gauge. 0 21 - 0.021 mm When the wear limit is reached the rocker arm bracket must be replaced. © 44139-0 Assembling the rocker arm bracket ● Lightly oil the rocker arm pin. ● Push rocker arm (1) onto rocker arm pin. 2 ● Push rocker arm (2) onto rocker arm pin.
Control parts W 11-02-02 TCD 2013 2V ● Press new lockwashers (1) into the rocker arm pin up to the stop. ● Install rocker arm and rocker arm bracket. W 11-02-01 1 6 © 44141-0 © 02/2010 4/4 OBJ_DOKU-21782-001.
Lubricating oil cooler W 15-02-01 TCD 2013 2V Removing and installing the lubricating oil cooler Standard tools – W 15-02-02 – Fitting compound DEUTZ AP1908 Collect leaking operating substances in suitable vessels and dispose of according to regulations. Observe the appropriate operating instructions for emptying and filling the engine. 6 Removing the lubricating oil cooler ● Remove oil cooler housing. 1 W 15-02-02 ● Unscrew screws (1). ● Remove sealing rings.
Lubricating oil cooler W 15-02-01 TCD 2013 2V ● Remove the sealing ring (arrows) of both collar screws. ● Remove collar screws. 6 © 44487-0 ● Remove sealing ring (1). 1 ● Clean collar screw (2). 2 © 44488-0 ● Visually inspect the components. © 44489-0 © 02/2010 2/4 OBJ_DOKU-21783-001.
Lubricating oil cooler W 15-02-01 TCD 2013 2V Installing the lubricating oil cooler 1 ● Clean sealing surfaces. ● Cover thread with adhesive film. ● Push on new sealing ring (1). 6 © 44490-0 ● Cover thread with adhesive film. 1 ● Push on new sealing ring (1). The sealing ring must fit in the groove (arrow). © 44491-0 ● Coat the sealing ring (1) lightly with fitting compound. ● Oil sealing ring (2). 1 2 © 44501-0 © 02/2010 3/4 OBJ_DOKU-21783-001.
Lubricating oil cooler W 15-02-01 TCD 2013 2V ● Insert both collar screws (1). 1 6 © 44492-0 ● Insert oil cooler (2). ● Tighten collar screws (1). – Stage 1: 80 Nm – Stage 2: 1 160 Nm 2 © 44486-0 ● Coat new sealing rings with fitting compound . ● Tighten screw plug (1). 1 80 Nm ● Install oil cooler housing. W 15-02-02 © 44485-0 © 02/2010 4/4 OBJ_DOKU-21783-001.
Lubricating oil cooler W 15-02-02 TCD 2013 2V Removing and installing the lubricating oil cooler housing Standard tools – Operation manual – W 20-01-01 Collect leaking operating substances in suitable vessels and dispose of according to regulations. 6 Removing the lubricating oil cooler housing ● Remove fuel filter console. W 20-01-01 ● Remove oil filter cartridge. 2 Operation manual ● Pull out oil dipstick (1). ● Pull out cable plug (2). 1 © 44494-0 ● Unscrew screws (arrows).
Lubricating oil cooler W 15-02-02 TCD 2013 2V ● Visually inspect the components. 6 © 44496-0 Installing the lubricating oil cooler housing ● Clean sealing surfaces. 2 2 ● Mount new gasket. ● Mount the lubricating oil cooler housing. ● Tighten screws alternately. Pay attention to different screw lengths. 1 M8 x 50 mm (1) M8 x 80 mm (2). 2 1 2 2 © 44497-0 ● Tighten the screws according to the tightening sequence.
Lubricating oil cooler W 15-02-02 TCD 2013 2V ● Insert oil dipstick (1). ● Plug in the cable plug (2). Ensure that the connection is perfect. 2 ● Install oil filter cartridge. Operation manual ● Install the fuel filter console. W 20-01-01 1 6 © 44494-0 © 02/2010 3/4 OBJ_DOKU-21784-001.
Lubricating oil cooler W 15-02-02 TCD 2013 2V 6 © 02/2010 4/4 OBJ_DOKU-21784-001.
Oil suction pipe W 16-01-01 TCD 2013 2V Removing and installing the oil suction pipe Standard tools – W 02-01-01 6 Removing the oil suction pipe ● Remove lubricating oil pan. 1 W 02-01-01 2 ● Unscrew screws (1). 1 ● Remove oil suction pipe (2). ● Remove gasket. 1 1 © 44476-0 ● Visually inspect the components. © 44477-0 © 02/2010 1/2 OBJ_DOKU-21785-001.
Oil suction pipe W 16-01-01 TCD 2013 2V Installing the oil suction pipe ● Clean sealing surfaces. ● Mount new gasket. 2 ● Mount oil suction pipe. 1 ● Fasten screws. Ensure that the installation location is free from faults. Pay attention to different screw lengths. M8 x 25 mm (1) M8 x 20 mm (2) 1 6 2 © 44478-0 ● Tighten screws (1). 22 Nm 1 ● Install lubricating oil pan. W 02-01-01 1 1 1 © 44479-0 © 02/2010 2/2 OBJ_DOKU-21785-001.
High-pressure pump W 17-01-01 TCD 2013 2V Removing and installing the control block Standard tools Special tools: – Plugs/caps – User notes – Operation manual 170160 Danger! Wait 30 seconds after switching off the engine before working on the fuel system. Attention! Ensure utmost cleanliness when working on the fuel system. Carefully clean the area around the affected parts. Blow damp areas dry with compressed air. Observe the safety regulations and national specifications for handling fuels.
High-pressure pump W 17-01-01 TCD 2013 2V ● Unscrew hollow screws (1). ● Remove sealing rings. 1 ● Unscrew screw (2). ● Loosen pipe clip. 2 ● Remove fuel pipe. Collect draining fuel and dispose of according to regulations. 1 6 © 43998-0 ● Unscrew hollow screw (1). ● Remove fuel pipe (2), pipe connection and sealing rings. Collect draining fuel and dispose of according to regulations. 2 1 © 44000-0 ● Unscrew hollow screws (1). ● Remove fuel pipe (2) and sealing rings.
High-pressure pump W 17-01-01 TCD 2013 2V ● Unscrew screws (1). ● Remove control block (2). 1 2 6 © 44001-0 ● Visually inspect the component. © 44002-0 Installing the control block ● Insert screw (1). 1 © 44002-0 © 02/2010 3/8 OBJ_DOKU-21786-001.
High-pressure pump W 17-01-01 TCD 2013 2V ● Insert control block. ● Pre-assemble screws loosely. Pay attention to different screw lengths. 2 M8 x 75 mm (2) 1 M8 x 85 mm (1) Do not tighten screws. 6 © 44003-0 ● Install fuel pipe. Insert hollow screws (1) and (2) with new sealing rings tension-free. Use new sealing rings. Pay attention to different screws: Hollow screw M14 (1) Hollow screws M12 (2) 2 2 1 © 44004-0 ● Mount fuel pipe. ● Insert hollow screws (1) with new sealing rings tension-free.
High-pressure pump W 17-01-01 TCD 2013 2V ● Tighten hollow screw (1). 39 Nm ● Tighten hollow screws (2). 29 Nm 2 2 6 1 © 44006-0 ● Tighten hollow screws (1). 39 Nm ● Tighten screw (2). 20 Nm 2 ● Check the fuel pipes for perfect installation position. 1 1 © 44007-0 Attention! Observe the following order of tightening. 1 ● Tighten screw (1). 20 Nm ● Tighten screw (2). 20 Nm Attention! Do not bend high pressure and fuel pipe. © 44008-0 © 02/2010 5/8 OBJ_DOKU-21786-001.
High-pressure pump W 17-01-01 TCD 2013 2V ● Mount fuel return pipe (1) and pipe connection. ● Tighten hollow screw (2) with new sealing rings. 49 Nm Use new sealing rings. 1 6 2 © 44009-0 ● Plug in the cable plug (1). Ensure that the connection is perfect. Bleed the fuel system via the manual fuel pump on the fuel pre-filter according to the operation manual. 1 © 43986-0 © 02/2010 6/8 OBJ_DOKU-21786-001.
High-pressure pump W 17-01-01 TCD 2013 2V Technical Data Tightening specifications ID no. Name Screw type Injection pipe on rail and injector, A07 003 High pressure pipe on high pressure pump and rail Union nut Injection pipe on rail and injector, A07 003 High pressure pipe on high pressure pump and rail Union nut A07 031 High pressure pump to crankcase M10x30-10.9 A07 031 A07 032 A12 092 A12 093 A12 094 A12 095 Notes / Remark Stage 1: Observe assembly specification. Use new pipe.
High-pressure pump W 17-01-01 TCD 2013 2V 6 © 02/2010 8/8 OBJ_DOKU-21786-001.
High-pressure pump W 17-01-04 TCD 2013 2V Removing and installing the high-pressure pump (Installation position A) – User notes – W 17-01-01 – W 49-02-01 Standard tools Special tools: – Assembly pliers – Special wrench – Assembly case with assembly sleeves, guides and disassembly tool – Plugs/caps 103220 110500 Danger! Wait 30 seconds after switching off the engine before working on the fuel system. 110900 170160 Attention! Ensure utmost cleanliness when working on the fuel system.
High-pressure pump W 17-01-04 TCD 2013 2V Danger! Wait 30 seconds after switching off the engine before working on the fuel system. ● Remove control block. W 17-01-01 6 © 43954-0 ● Unscrew hollow screws (1). ● Remove fuel pipe (2) and sealing rings. Collect draining fuel and dispose of according to regulations. 1 2 © 43955-0 Collect draining fuel and dispose of according to regulations. Support the pipe connection of the high pressure pump. ● Remove high pressure pipe (1) with special wrench.
High-pressure pump W 17-01-04 TCD 2013 2V ● Loosen screws (1) evenly Loosen screws evenly to avoid jamming the high-pressure pump. If necessary, turn the crankshaft with turnover gear in the direction of rotation of the engine until the high-pressure pump is felt to release. 1 ● Unscrew screws (1) evenly. ● Remove high-pressure pump (2). 1 2 6 © 43957-0 ● Carefully remove the O-ring (1) from the high-pressure pump with the disassembly tool. Attention! Do not damage the high-pressure pump.
High-pressure pump W 17-01-04 TCD 2013 2V Installing the high-pressure pump ● Turn the crankshaft with the turn-over gear until the cam for the high-pressure pump is on the cam base circle (arrow). Roller tappet stroke is less than 0.5 mm. 6 © 42816-0 ● Oil roller tappet lightly and insert carefully with special pliers. The guide pin (1) on the roller tappet must grip in the groove (2). 1 2 © 42817-0 ● Push assembly guide (1) onto high-pressure pump. ● Push the new O-ring (2) onto the assembly guide.
High-pressure pump W 17-01-04 TCD 2013 2V ● Push the O-ring (1) with assembly sleeve (2) up to the groove (3). ● Coat the O-ring, mounting bore and chamfers in the crankcase with fitting compound. 1 2 3 6 © 43330-0 ● Insert the high-pressure pump carefully in the crankcase. © 43959-0 ● Oil the screws (1) lightly and tighten alternately until the high-pressure pump is flush with the crankcase. Do not tighten the screws yet. 1 1 © 43958-0 © 02/2010 5/10 OBJ_DOKU-21787-001.
High-pressure pump W 17-01-04 TCD 2013 2V ● Install control block. W 17-01-01 ● Tighten screws (arrows). – Stage 1: 10 Nm – Stage 2: 50 Nm 6 © 43979-0 Attention! The high-pressure line must always be renewed after disassembly. Install high pressure line without tension. 1 ● Mount new high-pressure line on high-pressure pump and rail. ● Screw on union nuts (1). Do not tighten union nuts. ● Check the high-pressure line for perfect installation position.
High-pressure pump W 17-01-04 TCD 2013 2V (1) Vibration damper – Dimension I 7,6 +1.5 - 1.5 I mm 2 – Dimension II 5,4 +0.5 - 0.5 mm II (2) Connection rail (3) Connection high pressure pump 1 3 6 © 48217-0 Attention! Install high pressure line without tension. Pay attention to alignment of the high pressure pipes. Pipes which touch the bore (1) of the union nut must be renewed. 1 © 43980-1 ● Tighten union nuts (arrows) with special wrench.
High-pressure pump W 17-01-04 TCD 2013 2V ● Mount fuel return pipe (1). ● Tighten hollow screw (arrow) with new sealing rings. 39 Nm Bleed the fuel system via the manual fuel pump on the fuel pre-filter according to the operation manual. 1 6 © 43982-0 ● Remove turning gear. W 49-02-01 © 43953-1 © 02/2010 8/10 OBJ_DOKU-21787-001.
High-pressure pump W 17-01-04 TCD 2013 2V Technical Data Tightening specifications ID no. Name Screw type Injection pipe on rail and injector, A07 003 High pressure pipe on high pressure pump and rail Union nut Injection pipe on rail and injector, A07 003 High pressure pipe on high pressure pump and rail Union nut A07 031 High pressure pump to crankcase M10x30-10.9 Notes / Remark Stage 1: Observe assembly specification. Use new pipe.
High-pressure pump W 17-01-04 TCD 2013 2V 6 © 02/2010 10/10 OBJ_DOKU-21787-001.
High-pressure pump W 17-01-05 TCD 2013 2V Removing and installing the high-pressure pump (Installation position B) – User notes – W 49-02-01 Standard tools Special tools: – Assembly pliers – Special wrench – Assembly case with assembly sleeves, guides and disassembly tool – Plugs/caps 103220 110500 Danger! Wait 30 seconds after switching off the engine before working on the fuel system. 110900 170160 Attention! Ensure utmost cleanliness when working on the fuel system.
High-pressure pump W 17-01-05 TCD 2013 2V Danger! Wait 30 seconds after switching off the engine before working on the fuel system. 1 ● Unlock cable plug (1) and remove. 6 © 43986-0 ● Unscrew hollow screws (1). ● Remove fuel pipe (2) and sealing rings. Collect draining fuel and dispose of according to regulations. 2 1 1 © 43988-0 Collect draining fuel and dispose of according to regulations. Support the pipe connection of the high pressure pump.
High-pressure pump W 17-01-05 TCD 2013 2V ● Unscrew screws (1). ● Remove high-pressure pump (2). Loosen screws evenly to avoid jamming the high-pressure pump. If necessary, turn the crankshaft with turnover gear in the direction of rotation of the engine until the high-pressure pump is felt to release. 1 1 2 6 © 43990-0 ● Carefully remove the O-ring (1) from the high-pressure pump with the disassembly tool. Attention! Do not damage the high-pressure pump.
High-pressure pump W 17-01-05 TCD 2013 2V Installing the high-pressure pump ● Turn the crankshaft with the turn-over gear until the cam for the high-pressure pump is on the cam base circle (arrow). Roller tappet stroke is less than 0.5 mm. 6 © 42816-0 ● Oil roller tappet lightly and insert carefully with special pliers. The guide pin (1) on the roller tappet must grip in the groove (2). 1 2 © 42822-0 ● Push assembly guide (1) onto high-pressure pump. ● Push the new O-ring (2) onto the assembly guide.
High-pressure pump W 17-01-05 TCD 2013 2V ● Push the O-ring (1) with assembly sleeve (2) up to the groove (3). ● Coat the O-ring, mounting bore and chamfers in the crankcase with fitting compound. 1 2 3 6 © 43330-0 ● Insert the high-pressure pump carefully in the crankcase. © 43992-0 ● Oil the screws (1) lightly and tighten alternately until the high-pressure pump is flush with the crankcase. Do not tighten the screws yet. 1 1 2 © 43991-0 © 02/2010 5/10 OBJ_DOKU-21788-001.
High-pressure pump W 17-01-05 TCD 2013 2V ● Mount the fuel pipe between the high-pressure pumps and the control block. ● Fasten hollow screws with new O-rings without tension. Use new sealing rings. Pay attention to different screws: Hollow screw M14 (1) Hollow screws M12 (2) 2 2 1 6 © 43993-0 ● Tighten hollow screw (1). 39 Nm ● Tighten hollow screws (2). 29 Nm 2 2 1 © 43993-0 ● Tighten screws (arrows). – Stage 1: 10 Nm – Stage 2: 50 Nm © 43994-0 © 02/2010 6/10 OBJ_DOKU-21788-001.
High-pressure pump W 17-01-05 TCD 2013 2V Attention! The high-pressure line must always be renewed after disassembly. Install high pressure line without tension. ● Mount new high-pressure line on high-pressure pump and rail. 1 ● Screw on union nuts (1). Do not tighten union nuts. ● Check the high-pressure line for perfect installation position. 6 © 43995-0 – Installation position of vibration damper. Attention! X 1 Pay attention to installation position. Do not turn vibration damper (1).
High-pressure pump W 17-01-05 TCD 2013 2V Attention! Install high pressure line without tension. Pay attention to alignment of the high pressure pipes. Pipes which touch the bore (1) of the union nut must be renewed. 1 6 © 43995-1 ● Tighten union nuts (arrows) with special wrench. – Stage 1: 10 Nm – Stage 2: 60° +15° ● Check the high-pressure line for perfect installation position. © 43996-0 ● Plug in the cable plug (1). Ensure that the connection is perfect.
High-pressure pump W 17-01-05 TCD 2013 2V ● Remove turning gear. W 49-02-01 6 © 43953-1 © 02/2010 9/10 OBJ_DOKU-21788-001.
High-pressure pump W 17-01-05 TCD 2013 2V Technical Data Tightening specifications ID no. 6 Name Screw type Injection pipe on rail and injector, A07 003 High pressure pipe on high pressure pump and rail Union nut Injection pipe on rail and injector, A07 003 High pressure pipe on high pressure pump and rail Union nut A07 031 High pressure pump to crankcase M10x30-10.9 Notes / Remark Stage 1: Observe assembly specification. Use new pipe.
Injector W 19-01-01 TCD 2013 2V Removing and installing the injector Standard tools: – Assembly pliers – Torx tool set Special tools: – Special wrench – Lever tool – Assembly case with assembly sleeves, guides and disassembly tool – Extraction tool – Slide hammer – Plugs/caps – User notes 8024 8189 Danger! 110500 110620 Wait 30 seconds after switching off the engine before working on the fuel system. 110900 120680 150800 170160 Ensure utmost cleanliness when working on the fuel system.
Injector W 19-01-01 TCD 2013 2V ● Unscrew lock nuts (1) with special wrench. Support the pipe connection of the injector. ● Remove injection line. 1 Collect draining fuel and dispose of according to regulations. 6 © 44012-0 ● Unscrew screws (1). ● Remove the cover (2). 1 2 © 44022-0 ● Unscrew nuts (1). ● Remove cable from injector. 1 1 © 44023-0 © 02/2010 2/10 OBJ_DOKU-21789-001.
Injector W 19-01-01 TCD 2013 2V ● Unscrew screw (1). ● Remove clamping shoe (2). When removing the injectors on cylinders 1 to 5, the clamping shoe can only be removed together with the injector. 1 2 6 © 44024-0 Attention! Remove residue paint and particles of dirt from the injector before removing it. Carefully clean the area around the injector. ● Pull out injector (1) and sealing ring (2). 1 2 © 44025-0 Removing a tightly fixed injector ● Insert lever tool (1) in the clamping claw (2).
Injector W 19-01-01 TCD 2013 2V Attention! Do not brush off the nozzle tip of the injector. Do not damage the nozzle tip of the injector when removing the sealing ring (1). ● Grip a tight sealing ring (1) with the assembly pliers (2) and pull off, turning slightly. 1 2 6 © 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.
Injector W 19-01-01 TCD 2013 2V ● Mount adapter (1) and slide hammer (2) on extraction device. ● Remove tight sealing ring. 2 1 6 © 44030-0 ● Remove the round sealing ring (1) carefully from the injector with the disassembly tool. Attention! Do not damage the injector. 1 © 43028-0 Installing the injector ● Push assembly guide (1) onto injector. ● Push the new O-ring (2) onto the assembly guide. 2 1 © 43030-0 © 02/2010 5/10 OBJ_DOKU-21789-001.
Injector W 19-01-01 TCD 2013 2V ● Push the O-ring (1) with assembly sleeve (2) up to the groove (3). 1 2 3 6 © 43029-0 ● Lightly oil round sealing ring (1). ● Mount new sealing ring (2) on injector. 1 2 © 42987-1 Attention! Before installing the injector, combustion residue must be cleaned carefully from the bore on the cylinder head. Suck off dirt particles. Install injector without tension. ● Insert injector carefully in the cylinder head. © 42988-0 © 02/2010 6/10 OBJ_DOKU-21789-001.
Injector W 19-01-01 TCD 2013 2V When installing the injectors on cylinders 1 to 5, the clamping shoe must be inserted together with the injector. In version with heating plugs: Pay attention to perfect cable laying (arrow). 6 © 48207-0 ● Mount clamping shoe. ● Tighten screw. – Stage 1: hand tight Do not tighten the screw until after assembling the injection line. © 44031-0 Attention! The injection lines must always be renewed after disassembly. Install injection line without tension.
Injector W 19-01-01 TCD 2013 2V ● Tighten screw (arrow). – Stage 2: 27 Nm 6 © 42992-0 Attention! Install injection pipes without tension! Pay attention to alignment of the injection pipes. Pipes which touch the bore (1) of the union nut must be renewed. 1 © 44034-1 ● Tighten union nuts (1) with special wrench. – Stage 1: 10 Nm – Stage 2: 60° +15° 1 ● Check the injection pipes for perfect installation position. © 44034-0 © 02/2010 8/10 OBJ_DOKU-21789-001.
Injector W 19-01-01 TCD 2013 2V ● Mount cable on injector. ● Tighten nuts (1). 1.5 Nm 1 1 6 © 44035-0 ● Mount cover (1). ● Tighten screws (arrows). 8.5 Nm 1 With oil dipstick guide pulled up on the side of the rail: – Insert oil dipstick. Bleed the fuel system via the manual fuel pump on the fuel pre-filter according to the operation manual. © 44036-0 © 02/2010 9/10 OBJ_DOKU-21789-001.
Injector W 19-01-01 TCD 2013 2V Technical Data Tightening specifications 6 ID no.
Fuel filter W 20-01-01 TCD 2013 2V Removing and installing the fuel filter console Standard tools Special tools: – Special wrench – Plugs/caps – User notes – Operation manual 170050 170160 Danger! Wait 30 seconds after switching off the engine before working on the fuel system. Attention! Ensure utmost cleanliness when working on the fuel system. Carefully clean the area around the affected parts. Blow damp areas dry with compressed air.
Fuel filter W 20-01-01 TCD 2013 2V ● Unscrew screw (1). ● Loosen pipe clip. 1 ● Unscrew hollow screw (2). ● Remove sealing rings. Collect draining fuel and dispose of according to regulations. 2 6 © 43961-0 ● Loosen the locking ring (1). ● Pull out cable plug. 1 © 43962-1 ● Unscrew hollow screw (1). ● Remove sealing rings. 1 Collect draining fuel and dispose of according to regulations. © 43963-0 © 02/2010 2/6 OBJ_DOKU-21790-001.
Fuel filter W 20-01-01 TCD 2013 2V ● Unscrew screws (1). ● Remove fuel filter console (2). 1 2 6 © 43963-0 ● Visually inspect the components. © 43965-0 Installing the fuel filter console ● Install the fuel filter console. Pay attention to different screw lengths. M8 x 40 mm (1) M8 x 55 mm (2) ● Tighten screws (1) and (2). 30 Nm 1 2 © 43966-0 © 02/2010 3/6 OBJ_DOKU-21790-001.
Fuel filter W 20-01-01 TCD 2013 2V ● Mount the fuel pipe with new sealing rings. ● Tighten hollow screw (arrow). 39 Nm 6 © 43968-0 ● Mount fuel pipe. ● Tighten hollow screw (arrow) with new sealing rings. Check hose pipes and renew if necessary. 1 ● Position pipe clip. ● Tighten screw (1). – M8 30 Nm ● Tighten hollow screw (arrow). 39 Nm © 43969-0 ● Press the cable plug onto the fuel pressure sensor. ● Turn in the locking ring (1) until it snaps in. Make sure that the contacts match up.
Fuel filter W 20-01-01 TCD 2013 2V ● Clean sealing surfaces. ● Lightly oil sealing ring on new fuel filter cartridge. ● Screw on fuel filter cartridge by hand. The seal must fit evenly. Operation manual 6 © 44577-0 © 02/2010 5/6 OBJ_DOKU-21790-001.
Fuel filter W 20-01-01 TCD 2013 2V 6 © 02/2010 6/6 OBJ_DOKU-21790-001.
Fuel pump W 20-02-01 TCD 2013 2V Removing and installing the fuel supply pump (V-belt drive) Standard tools: – Hose clip pliers 8011 – V-belt tension measuring device 8115 – User notes – Operation manual Special tools: – Plugs/caps Wait 30 seconds after switching off the engine before working on the fuel system. Danger! 170160 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.
Fuel pump W 20-02-01 TCD 2013 2V ● Loosen screws (1). 1 1 1 6 © 44038-0 ● Loosen V-belt by unscrewing the clamping screw (1). 1 © 44039-0 ● Remove V-belt (1). 1 © 44040-0 © 02/2010 2/6 OBJ_DOKU-21791-001.
Fuel pump W 20-02-01 TCD 2013 2V ● Unscrew screws (1). ● Remove V-belt pulley (2). 1 2 6 © 44041-0 ● Loosen screws (1). ● Swing the fuel supply pump (2) to the side (arrow). 1 2 © 44042-0 ● Remove V-belt (1). 1 © 44043-0 © 02/2010 3/6 OBJ_DOKU-21791-001.
Fuel pump W 20-02-01 TCD 2013 2V ● Loosen hose clip (1). ● Pull off fuel pipe (2). Check hose pipes and renew if necessary. 2 1 6 © 44044-0 ● Unscrew screws (1). ● Remove clamping strap (2) and fuel supply pump. 1 2 © 44045-0 ● Unscrew screws (1). ● Remove fuel supply pump (2). 1 2 © 44046-0 © 02/2010 4/6 OBJ_DOKU-21791-001.
Fuel pump W 20-02-01 TCD 2013 2V ● Visually inspect the components. 6 © 44047-0 Installing the fuel supply pump ● Mount fuel supply pump (2). 1 ● Tighten screws (1). 20 Nm Note installation position of the clamping strap. 2 © 44046-0 ● Mount clamping strap (2) with fuel supply pump. ● Tighten screws (1). 1 2 © 44045-0 © 02/2010 5/6 OBJ_DOKU-21791-001.
Fuel pump W 20-02-01 TCD 2013 2V ● Attach fuel pipe. ● Fix the hose clip (1) with the hose clip pliers. 1 6 © 44048-0 ● Mount V-belt (1) for coolant pump. 1 © 44043-0 ● Press clamping strap (1) in direction of arrow with a suitable tool. ● Tighten screw (2). 30 Nm 1 ● Check V-belt tension. Operation manual 2 © 44049-0 © 02/2010 6/6 OBJ_DOKU-21791-001.
Fuel pipes W 21-02-01 TCD 2013 2V Removing and installing the rail Standard tools: – Rotation angle disc 8190 Special tools: – Special wrench – Plugs/caps – User notes – W 21-02-03 – W 21-02-05 110500 170160 Danger! Wait 30 seconds after switching off the engine before working on the fuel system. Attention! Ensure utmost cleanliness when working on the fuel system. Carefully clean the area around the affected parts. Blow damp areas dry with compressed air.
Fuel pipes W 21-02-01 TCD 2013 2V ● Unscrew hollow screw (1). ● Remove fuel return pipe (2) and sealing rings from rail. 1 Collect draining fuel and dispose of according to regulations. 2 6 © 44010-0 Collect draining fuel and dispose of according to regulations. Support the pipe connection of the high pressure pump. ● Remove high pressure pipes (1) with special wrench. 1 1 © 44011-0 ● Unscrew the union nuts (1) of the injection lines from the injectors and rail.
Fuel pipes W 21-02-01 TCD 2013 2V ● Unlock cable plug (1) and remove. 1 6 © 44013-0 ● Unscrew screws (1). ● Remove the rail (2). 2 1 © 44014-0 ● Visually inspect the component. ● Remove pressure limiting valve. W 21-02-03 ● Remove rail pressure sensor. W 21-02-05 © 44015-0 © 11/2010 3/8 OBJ_DOKU-21792-001.
Fuel pipes W 21-02-01 TCD 2013 2V Mounting rail ● Install rail pressure sensor. 2 W 21-02-05 ● Install pressure limiting valve. W 21-02-03 ● Pre-assemble the rail (2) loosely with screws (1). hand tight Do not tighten screws. 1 6 © 44014-0 Attention! The injection lines must always be renewed after disassembly. Install injection pipes without tension! ● Pre-assemble new injection pipes (arrow) on rail and injectors. Note assignment and installation position of the injection lines.
Fuel pipes W 21-02-01 TCD 2013 2V ● Tighten screws (1). 30 Nm 1 6 © 44018-0 Attention! Install injection pipes without tension! Pay attention to alignment of the injection pipes. Pipes which touch the bore (1) of the union nut must be renewed. 1 © 48222-0 ● Tighten all union nuts (1) on the rail and on the injectors with a special wrench. – Stage 1: 10 Nm Use rotaqtion angle disc. 1 – Stage 2: 60° + 15° ● Check the injection pipes for perfect installation position.
Fuel pipes W 21-02-01 TCD 2013 2V Attention! Install high pressure line without tension. Pay attention to alignment of the high pressure pipes. Pipes which touch the bore (1) of the union nut must be renewed. 1 6 © 48223-0 ● Tighten union nuts (1) with special wrench. – Stage 1: 10 Nm Use rotaqtion angle disc. – Stage 2: 60° 1 + 15° ● Check high pressure pipes for perfect installation position. 1 © 44020-0 ● Mount fuel return pipe (1). ● Tighten hollow screw (arrow) with new sealing rings.
Fuel pipes W 21-02-01 TCD 2013 2V ● Plug in the cable plug (1). Ensure that the connection is perfect. 1 6 © 44021-0 © 11/2010 7/8 OBJ_DOKU-21792-001.
Fuel pipes W 21-02-01 TCD 2013 2V Technical Data Tightening specifications ID no. Name Screw type Injection pipe on rail and injector, A07 003 High pressure pipe on high pressure pump and rail Union nut Injection pipe on rail and injector, A07 003 High pressure pipe on high pressure pump and rail Union nut A07 038 Rail to cylinder head 6 A07 038 Rail to cylinder head Pipe union, pipe diameter 10 mm, ring Hollow screw A12 093 piece M14x1.5 Notes / Remark Stage 1: Observe assembly specification.
Fuel pipes W 21-02-03 TCD 2013 2V Removing and installing the pressure limiting valve Standard tools – User notes Special tools: – Disassembly tool – Plugs/caps 110901 170160 – Assembly grease 01016496 Danger! Wait 30 seconds after switching off the engine before working on the fuel system. Attention! Ensure utmost cleanliness when working on the fuel system. Carefully clean the area around the affected parts. Blow damp areas dry with compressed air. No foreign bodies may get into the rail.
Fuel pipes W 21-02-03 TCD 2013 2V ● Visually check the thread and the sealing edge of the pressure limiting valve. 6 © 43253-1 ● Remove the O-ring with the disassembly tool. © 43335-0 Installing the pressure limiting valve Attention! No foreign bodies may get into the rail. Ensure utmost cleanliness. Especially on the thread and the sealing surface of the rail. ● Mount new O-ring (1). ● Lightly coat the thread and sealing edge of the pressure limiting valve with assembly grease.
Fuel pipes W 21-02-03 TCD 2013 2V ● Screw in pressure limiting valve (1). ● Tighten pressure limiting valve. 100 Nm Bleed the fuel system via the manual fuel pump on the fuel pre-filter according to the operation manual. 1 6 © 43976-0 © 02/2010 3/4 OBJ_DOKU-21793-001.
Fuel pipes W 21-02-03 TCD 2013 2V 6 © 02/2010 4/4 OBJ_DOKU-21793-001.
Fuel pipes W 21-02-05 TCD 2013 2V Removing and installing the rail pressure sensor Standard tools – User notes Special tools: – Long socket wrench insert 110700 – Plugs/caps 170160 Danger! – Assembly grease Wait 30 seconds after switching off the engine before working on the fuel system. 01016496 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. No foreign bodies may get into the rail.
Fuel pipes W 21-02-05 TCD 2013 2V Attention! Do not touch the pin contacts of the rail pressure sensor with your hands to avoid electrostatic discharging. Ensure absolute cleanliness of the connector. ● Visually check the thread and the sealing edge (arrows)of the rail pressure sensor. 6 © 43017-0 Installing the rail pressure sensor Attention! No foreign bodies may get into the rail. Ensure utmost cleanliness. Especially on the thread and the sealing surface of the rail.
Charge air line W 22-01-01 TCD 2013 2V Removing and install the charge air line Standard tools – W 08-01-01 – W 48-03-01 6 Remove charge air line ● Remove pressure/temperature sensor. W 48-03-01 ● Remove the cylinder head hood. W 08-01-01 © 44126-1 ● Unscrew screws (1). ● Remove charge air manifold (2). ● Remove gasket. 1 2 1 © 44289-0 © 02/2010 1/4 OBJ_DOKU-21795-001.
Charge air line W 22-01-01 TCD 2013 2V ● Unscrew all screws (arrow). ● Remove charge air line (1). ● Remove gasket. 1 6 © 44290-0 ● Visually inspect the components. © 44291-0 Install charge air line ● Clean sealing surfaces. ● Mount new gaskets (1). Ensure that the installation location is free from faults. 1 © 44292-0 © 02/2010 2/4 OBJ_DOKU-21795-001.
Charge air line W 22-01-01 TCD 2013 2V ● Mount charge air line. ● Fasten screws. Do not move gaskets. ● Tighten screws alternately working from the centre to the outside. 11 Nm 6 © 44293-0 ● Clean sealing surfaces. ● Mount new gasket. ● Mount charge air manifold. ● Fasten screws. Note different screw lengths: Screws M8 x 30 mm (1) Screws M8 x 90 mm (2) ● Tighten screws . 30 Nm 1 2 © 44294-0 ● Install pressure/temperature sensor. W 48-03-01 ● Mount cylinder head cover.
Charge air line W 22-01-01 TCD 2013 2V 6 © 02/2010 4/4 OBJ_DOKU-21795-001.
Coolant pump W 37-03-01 TCD 2013 2V Removing and installing the coolant pump (V-belt drive) – Operation manual – W 38-02-01 Standard tools: – V-belt tension measuring device 8115 Attention! – Packing compound DEUTZ DW 76 Only test / tighten / renew V-belts with the engine at a standstill. Collect leaking operating substances in suitable vessels and dispose of according to regulations.
Coolant pump W 37-03-01 TCD 2013 2V ● Loosen screws (1). 1 1 1 6 © 44038-0 ● Loosen V-belt by unscrewing the clamping screw (1). 1 © 44039-0 ● Remove V-belt (1). 1 © 44040-0 © 02/2010 2/8 OBJ_DOKU-21796-001.
Coolant pump W 37-03-01 TCD 2013 2V ● Unscrew screws (1). ● Remove V-belt pulley (2). 1 2 6 © 44041-0 ● Loosen screws (1). ● Swing the fuel supply pump (2) to the side (arrow). 1 2 © 44042-0 ● Mount V-belt (1) for coolant pump. 1 © 44043-0 © 02/2010 3/8 OBJ_DOKU-21796-001.
Coolant pump W 37-03-01 TCD 2013 2V ● Unscrew screws (1). ● Remove V-belt pulley (2). 1 2 6 © 44514-0 ● Unscrew screws (1). ● Remove clamping strap (2) and fuel supply pump. ● Unhook the fuel supply pump at the side. ● Remove thermostat housing. 1 W 38-02-01 2 © 44515-0 ● Unscrew screws (arrows). ● Remove coolant pump (1). 1 ● Remove gasket. © 44516-0 © 02/2010 4/8 OBJ_DOKU-21796-001.
Coolant pump W 37-03-01 TCD 2013 2V ● Visually inspect the components. 6 © 44517-0 Installing coolant pump ● Clean sealing surfaces. ● Mount new gasket. 1 ● Insert screw (1) with packing compound. ● Fasten screw (1). © 44586-0 ● Tighten screws (arrows). © 44246-0 © 02/2010 5/8 OBJ_DOKU-21796-001.
Coolant pump W 37-03-01 TCD 2013 2V ● Tighten the screws according to the tightening sequence. 30 Nm 2 Tightening order: screw (1), then screw (2), then the other screws in any order. ● Install thermostat housing. W 38-02-01 1 6 © 44518-0 ● Mount clamping strap (2) with fuel supply pump. ● Tighten screws (1). Do not tighten screws. 1 2 © 44515-0 ● Mount V-belt pulley (2). ● Fasten screws. 1 2 © 44514-0 © 02/2010 6/8 OBJ_DOKU-21796-001.
Coolant pump W 37-03-01 TCD 2013 2V ● Mount V-belt (1) for coolant pump. 1 6 © 44043-0 ● Press clamping strap (1) in direction of arrow with a suitable tool. ● Tighten screw (2). 30 Nm 1 ● Check V-belt tension. Operation manual 2 © 44049-0 © 02/2010 7/8 OBJ_DOKU-21796-001.
Coolant pump W 37-03-01 TCD 2013 2V 6 © 02/2010 8/8 OBJ_DOKU-21796-001.
Thermostat housing W 38-01-01 TCD 2013 2V Removing and installing the thermostat 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. Standard tools – Fitting compound DEUTZ AP1908 6 Removing the thermostat ● Unscrew screws (1). ● Remove outlet nozzle (2). 1 © 44508-0 ● Remove thermostat (1).
Thermostat housing W 38-01-01 TCD 2013 2V Installing the thermostat ● Clean sealing surfaces. 1 ● Insert new sealing ring (1). ● Coat the sealing ring with fitting compound. 6 © 44439-0 ● Insert thermostat. Arrow (1) points up. 1 © 44424-1 ● Mount outlet nozzle. ● Tighten screws (arrows). 30 Nm © 44425-0 © 02/2010 2/2 OBJ_DOKU-21797-001.
Thermostat housing W 38-01-02 TCD 2013 2V Checking the thermostat (in the removed state) Standard tools: – Thermometer – W 38-01-01 Danger! Risk of injury! Hot water and hot thermostat. 6 Checking thermostat ● Remove thermostat. W 38-01-01 ● Measure beginning of stroke, dimension (a). ● Note measured value, dimension (a). © 44585-0 ● Heat up the thermostat in the water bath. ● Determine beginning of opening.
Thermostat housing W 38-01-02 TCD 2013 2V ● Measure end of stroke, dimension (b). ● Note measured value, dimension (b). 6 © 34679-2 ● Determine stroke. Calculation example Desired: Stroke Given: Measured: Beginning of stroke, dimension (a) End of stroke, dimension (b) Calculation: Dimension (b) - dimension (a) Result: = stroke ● Compare result with setpoint value. 8 mm ● Install thermostat. W 38-01-01 © 34679-1 © 02/2010 2/2 OBJ_DOKU-21798-001.
Thermostat housing W 38-02-01 TCD 2013 2V Removing and installing the thermostat housing 8190 Standard tools Collect leaking operating substances in suitable vessels and dispose of according to regulations. – Fitting compound DEUTZ AP1908 Emptying and filling the engine with operating media must be carried out according to the operating manual and the appropriate documentation of the vehicle/equipment manufacturer. 6 Removing the thermostat housing ● Unscrew screws (1).
Thermostat housing W 38-02-01 TCD 2013 2V ● Visually inspect the components. 6 © 44522-0 Installing the thermostat housing ● Insert new O-rings (arrows). ● Coat the O-rings with fitting compound. © 44523-0 ● Insert plug element (1). 1 © 44521-0 © 02/2010 2/4 OBJ_DOKU-21799-001.
Thermostat housing W 38-02-01 TCD 2013 2V ● Clean sealing surfaces. ● Insert new sealing ring (arrow). ● Coat the sealing ring with fitting compound. 6 © 44524-0 ● Push the coolant thermostat housing onto the adapter first. ● Mount the coolant thermostat housing. ● Tighten screws (arrows). 30 Nm © 44525-0 © 02/2010 3/4 OBJ_DOKU-21799-001.
Thermostat housing W 38-02-01 TCD 2013 2V 6 © 02/2010 4/4 OBJ_DOKU-21799-001.
Fan drive W 39-01-01 TCD 2013 2V Removing and installing the belt tensioner (V-rib belt) Standard tools: – Retaining pin, diameter 6 mm 6 Removing the belt tensioner ● Tighten the belt tensioner (1) in the direction of the arrow until the bores (2) are in line. 1 2 © 42852-0 ● Insert holding pin (1). 1 © 42837-0 © 02/2010 1/4 OBJ_DOKU-21800-001.
Fan drive W 39-01-01 TCD 2013 2V ● Remove V-rib belt. The running direction must be marked when the V-rib belt is to be re-used. First remove the V-rib belt from the V-rib belt pulley (1) 1 6 © 42853-0 ● Unscrew screw (1). ● Remove belt tightener (2). ● Visually inspect the components. 1 2 © 42836-0 Installing the belt tensioner ● Mount the belt tightener. The fixing bolts (1) must fit into the bores (2). 1 2 © 42838-0 © 02/2010 2/4 OBJ_DOKU-21800-001.
Fan drive W 39-01-01 TCD 2013 2V ● Tighten screw (1). 80 Nm 1 6 © 42839-0 ● Fit the V-rib belt according to the running direction. Place the V-rib belt over the V-rib belt pulley (1) last. Ensure that the installation location is free from faults. 1 © 42853-0 ● Hold the belt tensioner. ● Remove the retaining pin. ● Relieve the belt tightener. The belt tightener clamps the V-rib belt automatically. © 42840-0 © 02/2010 3/4 OBJ_DOKU-21800-001.
Fan drive W 39-01-01 TCD 2013 2V Check the wear limit of the V-rib belt The fuel pipe is removed for better illustration. ● Measure distance (a). If the distance (a) is less than 3 mm, the Vrib belt must be changed. 6 © 43851-1 © 02/2010 4/4 OBJ_DOKU-21800-001.
Fan drive W 39-02-01 TCD 2013 2V Removing and installing the fan drive Standard tools: – Retaining pin, diameter 6 mm 6 Removing the fan drive ● Unscrew screws (1). 1 ● Remove adapter (2). 2 1 © 42854-0 ● Tighten the belt tensioner (1) in the direction of the arrow until the bores (2) are in line. 1 2 © 42852-0 © 02/2010 1/4 OBJ_DOKU-21801-001.
Fan drive W 39-02-01 TCD 2013 2V ● Insert holding pin (1). The running direction must be marked when the V-rib belt is to be re-used. 1 6 © 42837-0 ● Mark the running direction of the V-rib belt. ● Remove V-rib belt. The running direction must be marked when the V-rib belt is to be re-used. First remove the V-rib belt from the V-rib belt pulley (1) 1 © 42853-0 ● Unscrew screws (1). ● Remove fan drive with V-rib belt pulley. 1 Note installation position of the fan drive.
Fan drive W 39-02-01 TCD 2013 2V Installing the fan drive ● Install fan drive with V-rib belt pulley. 1 ● Tighten screws (1). 60 Nm Note installation position of the fan drive. 6 1 © 42856-0 ● Fit the V-rib belt according to the running direction. Place the V-rib belt over the V-rib belt pulley (1) last. Ensure that the installation location is free from faults. 1 © 42853-0 ● Hold the belt tensioner. ● Remove the retaining pin. ● Relieve the belt tightener.
Fan drive W 39-02-01 TCD 2013 2V Check the wear limit of the V-rib belt The fuel pipe is removed for better illustration. ● Measure distance (a). If the distance (a) is less than 3 mm, the Vrib belt must be changed. 6 © 43851-1 ● Mount adapter (1). ● Tighten screws (2). 30 Nm 2 1 2 © 42857-0 © 02/2010 4/4 OBJ_DOKU-21801-001.
Fan drive W 39-02-03 TCD 2013 2V Dismantling and assembling the fan drive Standard tools – W 39-02-01 6 Dismantling the fan drive ● Remove the fan drive. 1 W 39-02-01 ● Mount adapter (1). ● Tighten screws (arrows). 30 Nm © 42874-0 ● Clamp the fan drive in the vice. ● Unscrew screw (1). Attention! 1 Screw has left-hand thread. © 42875-0 © 02/2010 1/6 OBJ_DOKU-21802-001.
Fan drive W 39-02-03 TCD 2013 2V ● Unclamp the fan drive. ● Unscrew screws (arrows). 1 ● Remove adapter (1). 6 © 42874-0 ● Press off tight V-rib belt pulley from the fan drive with twon forcing screws (1). 1 © 42877-0 ● Press out shaft and inside ball bearing. © 42878-0 © 02/2010 2/6 OBJ_DOKU-21802-001.
Fan drive W 39-02-03 TCD 2013 2V ● Press out outside ball bearing. 6 © 42879-0 ● Remove locking ring (1). 1 © 42880-0 ● Press pulley out of the inside ball bearing. © 42881-0 © 02/2010 3/6 OBJ_DOKU-21802-001.
Fan drive W 39-02-03 TCD 2013 2V ● Press shaft out of the inside ball bearing. ● Visually inspect the components. 6 © 42882-0 Assembling the fan drive ● Press shaft into the inside ball bearing to the stop. © 42883-0 ● Press pulley into the inside ball bearing to the stop. © 42884-0 © 02/2010 4/6 OBJ_DOKU-21802-001.
Fan drive W 39-02-03 TCD 2013 2V ● Press the outside ball bearing into the housing to the stop. The press-in tool (1) must touch the outer ring of the ball bearing (arrow). 1 6 © 42885-0 ● Insert locking ring (1). Make sure the locking ring fits correctly in the groove. 1 © 42886-0 ● Press in shaft and inside ball bearing to the stop. Support inside ring of the outside ball bearing with a suitable tool (arrow). © 42887-0 © 02/2010 5/6 OBJ_DOKU-21802-001.
Fan drive W 39-02-03 TCD 2013 2V ● Mount adapter (1). ● Tighten screws (arrows). 1 30 Nm 6 © 42874-0 ● Clamp the fan drive in the vice. ● Install fan drive. ● Tighten screw (1). 1 – Stage 1: 30 Nm – Stage 2: 90 ° Attention! Screw has left-hand thread. © 42875-0 ● Unclamp the fan drive. ● Unscrew screws (arrows). 1 ● Remove adapter (1). ● Install fan drive. W 39-02-01 © 42874-0 © 02/2010 6/6 OBJ_DOKU-21802-001.
Fan console W 39-04-03 TCD 2013 2V Removing and installing the fan console (V-rib belt drive) – – – – Standard tools – Fitting compound DEUTZ AP1908 – Packing compound DEUTZ DW 74 W 20-02-01 W 39-01-01 W 39-02-01 W 44-02-01 Collect leaking operating substances in suitable vessels and dispose of according to regulations. 6 Removing the fan console ● Remove the fan drive. W 39-02-01 ● Remove the belt tensioner. W 39-01-01 ● Remove fuel supply pump. W 20-02-01 ● Remove generator.
Fan console W 39-04-03 TCD 2013 2V ● Unscrew screws (arrows). ● Remove fan console (1). 1 6 © 42902-0 Installing the fan console ● Pull cable (1) forward slightly. 1 © 42913-0 ● Clean sealing surfaces. ● Coat new sealing rings with fitting compound . ● Insert new sealing rings (arrows). © 42972-0 © 02/2010 2/6 OBJ_DOKU-21803-001.
Fan console W 39-04-03 TCD 2013 2V ● Apply packing compound (arrow). 6 © 42914-0 ● Install fan console. ● Tighten screws (arrows). 30 Nm Attention! Do not trap the cable (1). Do not displace the packing compound. ● Lay cable between front cover and fan console. 1 © 42915-0 ● Installa generator console (1) with transport flange (2). ● Fasten screws (3). Do not tighten screws. 2 1 3 3 © 42916-0 © 02/2010 3/6 OBJ_DOKU-21803-001.
Fan console W 39-04-03 TCD 2013 2V ● Mount generator. ● Tighten screws (1). Do not tighten screws. 1 1 6 © 42917-0 The holes in the transport flange (arrows) must match up with the threaded holes in the generator console. © 42973-0 ● Tighten screws (1). 70 Nm 2 ● Tighten screws (2). 60 Nm 1 2 © 02/2010 4/6 1 © 42918-0 OBJ_DOKU-21803-001.
Fan console W 39-04-03 TCD 2013 2V ● Install fuel pump. W 20-02-01 ● Install the belt tensioner. W 39-01-01 ● Install fan drive. W 39-02-01 ● Install generator. W 44-02-01 6 © 42919-0 © 02/2010 5/6 OBJ_DOKU-21803-001.
Fan console W 39-04-03 TCD 2013 2V 6 © 02/2010 6/6 OBJ_DOKU-21803-001.
Exhaust pipe W 41-01-01 TCD 2013 2V Removing and installing the exhaust line Standard tools – W 43-01-01 – Fitting compound DEUTZ S1 6 Removing exhaust line ● Remove turbocharger. W 43-01-01 © 44295-0 ● Unscrew all nuts (arrow). ● Remove exhaust manifold (1). ● Remove seals. ● Remove studs. 1 © 44579-0 © 02/2010 1/4 OBJ_DOKU-21804-001.
Exhaust pipe W 41-01-01 TCD 2013 2V ● Remove studs. ● Visually inspect the component. 6 © 44297-0 Installing exhaust line ● Coat new pin bolts with DEUTZ S1 mounting compound. ● Mount new pin bolts with locking nuts. 1 1 ● Tighten pin bolts (1). 10 Nm © 44297-1 ● Coat new pin bolts with DEUTZ S1 mounting compound. ● Mount new pin bolts with locking nuts. ● Tighten pin bolts (1). 1 10 Nm ● Clean sealing surfaces. ● Mount new seals. © 44580-1 © 02/2010 2/4 OBJ_DOKU-21804-001.
Exhaust pipe W 41-01-01 TCD 2013 2V ● Mount exhaust manifold. 6 © 44578-0 ● Mount washers (1). ● Mount spacer sleeves (2). ● Screw on new nuts. 1 2 © 44299-0 ● Tighten nuts alternately. 25 Nm Tightening sequence: From the centre outwards. © 44298-0 © 02/2010 3/4 OBJ_DOKU-21804-001.
Exhaust pipe W 41-01-01 TCD 2013 2V ● Install the turbocharger. W 43-01-01 6 © 44295-0 © 02/2010 4/4 OBJ_DOKU-21804-001.
Exhaust gas turbocharger W 43-01-01 TCD 2013 2V Removing and installing the turbocharger Collect leaking operating substances in suitable vessels and dispose of according to regulations. Standard tools – Fitting compound DEUTZ S1 – Fitting compound DEUTZ AP1908 6 Removing turbocharger ● Unscrew screw (1). ● Remove retainer. 1 © 44277-0 ● Unscrew screws (1). 1 © 44278-0 © 02/2010 1/6 OBJ_DOKU-21805-001.
Exhaust gas turbocharger W 43-01-01 TCD 2013 2V ● Pull out oil return pipe (1). ● Remove pipe socket (2). 2 1 6 © 44279-0 ● Unscrew hollow screws (1). ● Remove lubricating oil pipe (2). ● Remove sealing rings. 1 1 2 © 44280-0 ● Unscrew nuts (arrows). ● Remove turbocharger (1). ● Remove sealing ring. 1 © 44281-0 © 02/2010 2/6 OBJ_DOKU-21805-001.
Exhaust gas turbocharger W 43-01-01 TCD 2013 2V ● Visually inspect the components. 6 © 44282-0 Installing the turbocharger ● Clean sealing surfaces. ● Coat new pin bolts with DEUTZ S1 mounting compound. 2 ● Mount new pin bolts with locking nuts. ● Tighten pin bolts (1). 10 Nm ● Mount new gasket. ● Mount turbocharger (2). ● Tighten all nuts. 42 Nm 1 © 44283-1 ● Mount lubrication oil line (1). Use new sealing rings. 2 ● Tighten hollow screws (2).
Exhaust gas turbocharger W 43-01-01 TCD 2013 2V ● Unscrew screw (1). ● Pull pipe socket (2) out of oil return line (3). 2 1 3 6 © 44285-0 ● Insert new O-rings (arrows). ● Coat the O-rings with fitting compound. Use fitting compound AP 1908. © 44286-0 ● Plug pipe socket (2) into oil return line (3). ● Fasten screw (1). 2 1 3 © 44285-0 © 02/2010 4/6 OBJ_DOKU-21805-001.
Exhaust gas turbocharger W 43-01-01 TCD 2013 2V ● Clean sealing surfaces. ● Push oil return line (1) into crankcase (arrow). 1 6 © 44287-0 ● Mount new gasket. ● Mount pipe nozzle. ● Tighten screws (1). 20 Nm Attention! Install tension-free! 1 © 44278-0 ● Mount retainer. ● Tighten screw (1). 20 Nm 1 © 44277-0 © 02/2010 5/6 OBJ_DOKU-21805-001.
Exhaust gas turbocharger W 43-01-01 TCD 2013 2V ● Tighten screw (1). 20 Nm 1 6 © 44288-0 © 02/2010 6/6 OBJ_DOKU-21805-001.
Generator W 44-02-01 TCD 2013 2V Removing and installing the generator (V-belt drive) – Operation manual Standard 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 ● Disconnect the battery's negative terminal. ● Remove cable from generator.
Generator W 44-02-01 TCD 2013 2V ● Loosen V-belt by unscrewing the clamping screw (1). 1 6 © 44039-0 ● Remove V-belt (1). 1 © 44040-0 ● Unscrew screws (1). ● Remove generator (2). ● Visually inspect the components. 2 1 © 44431-0 © 02/2010 2/4 OBJ_DOKU-21806-001.
Generator W 44-02-01 TCD 2013 2V Installing the generator ● Mount generator (2). 2 ● Tighten screws (1). Do not tighten screws. 1 6 © 44431-0 ● Mount V-belt (1) for generator. 1 © 44040-0 ● Remove cable from generator. Note assignment! - (1) = terminal W - (2) = terminal D+ - (3) = terminal B+ 1 ● Connect the battery's negative terminal. 3 2 © 44429-0 © 02/2010 3/4 OBJ_DOKU-21806-001.
Generator W 44-02-01 TCD 2013 2V ● Tighten V-belt (1) by turning the clamping screw (2). ● Check V-belt tension. Operation manual 2 6 1 © 44053-0 © 02/2010 4/4 OBJ_DOKU-21806-001.
Starter W 44-03-01 TCD 2013 2V Removing and installing the starter Standard tools 6 Removing the starter ● Disconnect the battery's negative terminal. ● Disconnect cables. © 44432-0 ● Unscrew screws (arrows). ● Remove starter. ● Visually inspect the components. © 44554-0 © 02/2010 1/2 OBJ_DOKU-21807-001.
Starter W 44-03-01 TCD 2013 2V Installing the starter ● Insert starter. ● Tighten screws (arrows). 60 Nm 6 © 42898-0 ● Connect cables. ● Connect the battery's negative terminal. © 44432-0 © 02/2010 2/2 OBJ_DOKU-21807-001.
Engine mounting W 46-00-01 TCD 2013 2V Mounting engine on assembly block and demounting Standard tools: – Lifting gear – Suspension ropes – W 01-01-01 – W 47-01-01 Special tools: – Assembly block incl. adapter plates 6066 – Clamping bracket 6066/158 Danger! When using hoists (workshop crane) the safety regulations for handling hoists must be observed. It is not permitted to stay under moving loads. 6 Mounting engine on assembly block ● Removing the crankcase breather.
Engine mounting W 46-00-01 TCD 2013 2V ● Mount clamping bracket 6066/158-2 (1) on holder. ● Tighten screws (2) and lock nuts. 90 Nm ● Mount clamping bracket 6066/158-4 (3) on crankcase. ● Tighten screws (4). 90 Nm 4 2 6 3 1 © 43946-0 ● Insert engine in engine block. ● Align all clamping brackets (1) on the adapter plates (2) of the assembly block. 2 1 ● Insert screws. ● Tighten nuts (arrows). 90 Nm © 42645-0 ● Align engine on engine block. ● Tighten all screws (arrows). ● Unhook engine.
Engine mounting W 46-00-01 TCD 2013 2V Demounting engine from assembly block ● Hang engine on workshop crane. 6 © 44105-0 ● Remove all clamping brackets (1) from the adapter plates (2). ● Lift engine. 1 2 © 42740-0 ● Unscrew the nuts (2). ● Remove screws (2) and lock nuts. ● Remove clamping bracket (1). ● Unscrew screws (4). ● Remove clamping bracket (3). 4 2 1 3 © 43946-0 © 02/2010 3/6 OBJ_DOKU-21808-001.
Engine mounting W 46-00-01 TCD 2013 2V ● Unscrew nuts (4). ● Remove screws (4) and lock nuts. ● Remove clamping bracket (3). ● Unscrew screw (2). ● Remove clamping bracket (1). ● Install mounting feet. W 47-01-01 ● Install crankcase breather. W 01-01-01 4 2 6 1 3 © 43945-0 © 02/2010 4/6 OBJ_DOKU-21808-001.
Engine mounting W 46-00-01 TCD 2013 2V Technical Data Tightening specifications ID no. Name A00 001 Clamping holder on crankcase Clamping bracket on adapter for A00 002 assembly block Screw type Screw Nut Notes / Remark Value 90 Nm 90 Nm For the tightening procedure according to torque using a torque wrench, a maximum variation of the tightening torque of +/- 10% is permissible. 6 © 02/2010 5/6 OBJ_DOKU-21808-001.
Engine mounting W 46-00-01 TCD 2013 2V 6 © 02/2010 6/6 OBJ_DOKU-21808-001.
Engine mounting W 47-01-01 TCD 2013 2V Removing and installing the engine mounting (elastic mounting) – W 01-01-01 – W 46-00-01 Standard tools 6 Remove mounting feet ● Removing the crankcase breather. W 01-01-01 ● Hang engine on suitable workshop crane. W 46-00-01 ● Unscrew nuts (1). ● Remove mounting foot (2). Remove all mounting feet. 1 2 © 42640-0 ● Unscrew screws (1). ● Remove mounting foot (2). 2 1 © 42641-0 © 02/2010 1/6 OBJ_DOKU-21809-001.
Engine mounting W 47-01-01 TCD 2013 2V Mount mounting feet ● Hang engine on workshop crane. W 46-00-01 ● Mount mounting foot (1). 1 ● Tighten screw (2). – (2) = M12 95 Nm 2 Mount all mounting feet. 6 © 42641-1 ● Mount mounting foot (1). ● Tighten screw (2). – (2) = M12 95 Nm ● Set down engine. ● Unhook engine. ● Install crankcase breather. W 01-01-01 2 1 © 42640-1 Different installation variants are shown below as examples. Variant ● Fit rigid mounting foot (1). ● Tighten screw (2).
Engine mounting W 47-01-01 TCD 2013 2V Variant ● Mount holder (1). ● Fit washers (2). 1 ● Tighten screws (3). – (3) = M16 260 Nm 2 3 6 1 © 48226-0 Variant ● Fit sleeves (1). ● Fit holder (2). ● Fit washers (3). ● Tighten screws (4). 1 2 – (4) = M16 260 Nm 3 4 © 48230-0 ● Fit elastic mounting foot (1). ● Fit washers (2). ● Fasten screws (3). 4 ● Hold nut (4). ● Tighten screws (3). – (3) = M12 95 Nm 4 2 1 3 © 48231-0 © 02/2010 3/6 OBJ_DOKU-21809-001.
Engine mounting W 47-01-01 TCD 2013 2V Variant ● Mount holder (1). ● Fit mounting bracket (2). ● Fit washers (3). 5 1 ● Tighten screws (4). ● Fit washers (5). 2 ● Fasten screws (6). 6 ● Tighten screws (4). – (4) = M16 260 Nm ● Tighten screws (6). 6 1 – (6) = M12 90 Nm © 02/2010 3 4 © 48232-0 4/6 OBJ_DOKU-21809-001.
Engine mounting W 47-01-01 TCD 2013 2V Technical Data Tightening specifications ID no. Name Feet/engine mounting on holder/ A00 003 crankcase/connection housing/gear case Holder, engine mounting on A00 005 crankcase A00 006 Mounting bracket on holder/ crankcase Screw type Notes / Remark M12x35-10.9 M12x40-10.9 M12x60-10.9 M12x75-10.9 M12x85-10.9 M12x90-10.9 M12x220-10.9 M16x40-10.9 M16x45-10.9 M16x75-10.9 M16x85-10.9 M16x110-10.9 M16x140-10.9 M16x155-10.9 M16x220-10.9 M12x40-10.
Engine mounting W 47-01-01 TCD 2013 2V 6 © 02/2010 6/6 OBJ_DOKU-21809-001.
Cable harness W 48-01-01 TCD 2013 2V Removing and installing the cable harness Standard tools 6 Removing the cable harness ● Remove cable tie (1). ● Unlock cable plug (2) and disconnect. impulse transmitter (camshaft) 1 2 © 44059-0 ● Unlock cable plug (1) and remove. Temperature sensor 2 ● Unlock cable plug (2) and remove. Solenoid valve (exhaust return line) ● Remove cable tie (arrows). ● Expose cable harness. 1 © 44448-0 © 02/2010 1/12 OBJ_DOKU-21810-001.
Cable harness W 48-01-01 TCD 2013 2V ● Remove cable tie (arrows). ● Expose cable harness. 6 © 44449-0 ● Unscrew screw (1). ● Remove the cover (2). 2 1 © 44433-0 ● Unlock cable plug (1) and remove. Pressure/temperature sensor 1 © 44435-0 © 02/2010 2/12 OBJ_DOKU-21810-001.
Cable harness W 48-01-01 TCD 2013 2V ● Unlock central plug (1) (arrow) and pull off from holder. 1 6 © 44450-0 ● Unlock cable plug (1) and remove. Control block 1 © 44557-0 ● Loosen the locking ring (1). ● Pull off cable plug (2). 2 Fuel pressure sensor 1 ● Unlock cable plug (3) and remove. 3 Oil pressure switch © 44588-0 © 02/2010 3/12 OBJ_DOKU-21810-001.
Cable harness W 48-01-01 TCD 2013 2V ● Unlock cable plug (1) and disconnect. Impulse transmitter (crankshaft) 1 6 © 44559-0 ● Remove cable tie (arrows). ● Expose cable harness. © 44560-0 ● Unlock cable plug (1) and remove. Rail pressure sensor 1 © 44561-0 © 02/2010 4/12 OBJ_DOKU-21810-001.
Cable harness W 48-01-01 TCD 2013 2V ● Unscrew screws (1). ● Remove the cover (2). 1 2 6 © 44562-0 ● Unscrew nuts (1). ● Remove cable from injector. Remove cables from all injectors. ● Remove cable harness. 1 © 44563-0 ● Remove cable tie (arrows). ● Remove the cover (1). ● Visually inspect the components. 1 © 44564-0 © 02/2010 5/12 OBJ_DOKU-21810-001.
Cable harness W 48-01-01 TCD 2013 2V Installing the cable harness ● Position cable harness on the cover plate and fix with cable ties (arrows). 6 © 44565-0 ● Position the cable harness on the engine accordingly. ● Lay the cable plugs to the individual components. © 44566-0 ● Mount cable on injector. Mount cables on all injectors. ● Tighten nuts (1). 1,5 Nm 1 Tighten nuts of all injectors. © 44563-0 © 02/2010 6/12 OBJ_DOKU-21810-001.
Cable harness W 48-01-01 TCD 2013 2V ● Mount cover (2). ● Tighten screws (1). 8,5 Nm 1 2 6 © 44562-0 ● Plug in the cable plug (1). Rail pressure sensor Ensure that the connection is perfect. 1 © 44561-0 ● Plug cable plugs (1) together. Impulse transmitter (crankshaft) Ensure that the connection is perfect. 1 © 44567-0 © 02/2010 7/12 OBJ_DOKU-21810-001.
Cable harness W 48-01-01 TCD 2013 2V ● Press the cable plug onto the fuel pressure sensor. ● Turn in the locking ring (1) until it snaps in. Make sure that the contacts match up. 1 6 © 43970-1 ● Plug in the cable plug (1). Oil pressure switch Ensure that the connection is perfect. 1 © 44588-1 ● Lay cable harness and fix with cable ties (arrows). © 44568-0 © 02/2010 8/12 OBJ_DOKU-21810-001.
Cable harness W 48-01-01 TCD 2013 2V ● Plug in the cable plug (1). Control block Ensure that the connection is perfect. 1 6 © 44557-0 ● Push the central plug onto the holder until it snaps in. © 44468-0 ● Plug in the cable plug (1). Pressure/temperature sensor Ensure that the connection is perfect. 1 © 44435-0 © 02/2010 9/12 OBJ_DOKU-21810-001.
Cable harness W 48-01-01 TCD 2013 2V ● Mount cover (2). ● Tighten screw (1). 4,5 Nm 2 1 6 © 44433-0 ● Lay cable harness and fix with cable ties (arrows). © 44449-0 ● Plug in the cable plug (1). Temperature sensor Ensure that the connection is perfect. 2 ● Plug in the cable plug (2). Solenoid valve (exhaust return line) Ensure that the connection is perfect. ● Lay cable harness and fix with cable ties (arrows). 1 © 44448-0 © 02/2010 10/12 OBJ_DOKU-21810-001.
Cable harness W 48-01-01 TCD 2013 2V ● Plug in the cable plug (1). impulse transmitter (camshaft) Ensure that the connection is perfect. ● Lay cable harness and fix with cable tie (1). 1 2 6 © 44059-0 © 02/2010 11/12 OBJ_DOKU-21810-001.
Cable harness W 48-01-01 TCD 2013 2V 6 © 02/2010 12/12 OBJ_DOKU-21810-001.
Electrical equipment W 48-02-01 TCD 2013 2V Removing and installing the impulse transmitter (crankshaft) Standard tools: – Feeler gauges – Locking agent DEUTZ DW 72 6 Removing the impulse transmitter ● Unlock cable plug (1) and disconnect. 1 ● Remove cable tie (2). ● Lay cable bare. 2 © 44087-0 ● Unscrew screws (1). ● Remove holder with impulse transmitter (2). 2 1 © 44088-0 © 02/2010 1/6 OBJ_DOKU-21811-001.
Electrical equipment W 48-02-01 TCD 2013 2V ● Unscrew screw (1). ● Remove impulse transmitter from holder. 1 6 © 44089-0 ● Visually inspect the components. © 44090-0 Installing the impulse transmitter ● Press impulse transmitter into holder. Attention! Do not knock in impulse transmitter! Clean thread of the screw and bore. Insert screw (1) with safety agent DEUTZ DW 72. 1 © 44089-0 © 02/2010 2/6 OBJ_DOKU-21811-001.
Electrical equipment W 48-02-01 TCD 2013 2V ● Tighten screw (1). 9 Nm 1 6 © 44089-0 ● Mount holder with impulse transmitter. Clean the threads of the screws and holes. Pay attention to different screw lengths. Screw M8 x 45 mm (1) Screw M8 x 40 mm (2) Insert screws with safety agent DEUTZ DW 72. 1 Do not tighten screws. 2 © 44091-0 Set gap dimension for impulse transmitter (crankshaft) ● Select feeler gauge. +0.1 0,6 - 0.
Electrical equipment W 48-02-01 TCD 2013 2V ● Press the impulse transmitter lightly against the feeler gauge blade. ● Tighten screws (arrows). 20 Nm 6 © 44093-0 ● Check gap dimension with feeler gauge blade. 0,6 +0.1 - 0.1 mm The feeler gauge blade must fit between the tooth lock washer and impulse transmitter (crankshaft) with low resistance. © 44094-0 ● Lay cable between front cover and coolant pump (arrow). © 44095-0 © 02/2010 4/6 OBJ_DOKU-21811-001.
Electrical equipment W 48-02-01 TCD 2013 2V ● Plug cable plugs (1) together. Ensure that the connection is perfect. 1 ● Lay cable. ● Fix cable with cable tie (2). 2 6 © 44087-0 © 02/2010 5/6 OBJ_DOKU-21811-001.
Electrical equipment W 48-02-01 TCD 2013 2V 6 © 02/2010 6/6 OBJ_DOKU-21811-001.
Electrical equipment W 48-02-03 TCD 2013 2V Removing and installing the impulse transmitter (camshaft) Standard tools – Locking agent DEUTZ DW 72 6 Removing the impulse transmitter ● Unlock cable plug (1) and disconnect. ● Pull out cable plug (2). 1 2 © 44059-0 ● Unscrew screw (1). ● Remove impulse transmitter (2). 2 1 © 44060-0 © 02/2010 1/4 OBJ_DOKU-21812-001.
Electrical equipment W 48-02-03 TCD 2013 2V ● Visually inspect the components. 6 © 44058-0 Installing the impulse transmitter ● Clean sealing surfaces on impulse transmitter and gearcase cover. ● Insert new O-ring (arrow). ● Lightly oil O-ring. © 42739-0 Clean thread of the screw and bore. ● Insert impulse transmitter (2). ● Insert screw (1) with locking agent. ● Tighten screw (1). 9 Nm 2 1 © 44060-0 © 02/2010 2/4 OBJ_DOKU-21812-001.
Electrical equipment W 48-02-03 TCD 2013 2V ● Plug cable plugs (1) together. Ensure that the connection is perfect. 1 ● Lay cable. ● Fix cable with cable tie (2). 2 6 © 44061-0 © 02/2010 3/4 OBJ_DOKU-21812-001.
Electrical equipment W 48-02-03 TCD 2013 2V 6 © 02/2010 4/4 OBJ_DOKU-21812-001.
Electrical equipment W 48-03-01 TCD 2013 2V Removing and installing the pressure/temperature sensor (charge air) Standard tools – Fitting compound DEUTZ AP1908 6 Remove pressure/temperature sensor ● Unscrew screw (1). ● Remove the cover (2). 2 1 © 44433-0 ● Unlock cable plug (1) and remove. ● Remove pressure/temperature sensor 1 © 44435-0 © 02/2010 1/2 OBJ_DOKU-21813-001.
Electrical equipment W 48-03-01 TCD 2013 2V Installing the pressure/temperature sensor ● Mount new O-ring (1). ● Lightly coat O-ring with fitting compound. 1 6 © 43271-0 ● Insert pressure/temperature sensor. ● Plug in the cable plug (1) and snap in lock. Ensure that the connection is perfect. 1 © 44435-0 ● Mount cover (2). ● Tighten screw (1). 4,5 Nm 2 1 © 44433-0 © 02/2010 2/2 OBJ_DOKU-21813-001.
Electrical equipment W 48-04-01 TCD 2013 2V Removing and installing the oil pressure switch Standard tools – User notes Special tools: – Long socket wrench insert 110700 – Plugs/caps 170160 Pay attention to utmost cleanliness when working on the lube oil system. Carefully clean the area around the affected parts. Blow damp areas dry with compressed air. Observe the safety regulations and national specifications for handling lube oils.
Electrical equipment W 48-04-01 TCD 2013 2V ● Unscrew oil pressure switch (1). Collect lubricating oil and dispose of according to regulations. 1 6 © 44511-0 ● Visually inspect the components. © 44512-0 Installing the oil pressure switch ● Mount new sealing ring. ● Tighten the oil pressure switch (1) with the socket wrench insert. 30 Nm 1 © 44511-0 © 02/2010 2/4 OBJ_DOKU-21814-001.
Electrical equipment W 48-04-01 TCD 2013 2V ● Plug in the cable plug (1). Ensure that the connection is perfect. 1 6 © 44510-0 © 02/2010 3/4 OBJ_DOKU-21814-001.
Electrical equipment W 48-04-01 TCD 2013 2V 6 © 02/2010 4/4 OBJ_DOKU-21814-001.
Electrical equipment W 48-05-01 TCD 2013 2V Removing and installing temperature transmitter (coolant) Collect leaking operating substances in suitable vessels and dispose of according to regulations. Standard tools Emptying and filling the engine with operating media must be carried out according to the operating manual and the appropriate documentation of the vehicle/equipment manufacturer. 6 Removing temperaure transmitter ● Unlock cable plug (1) and remove.
Electrical equipment W 48-05-01 TCD 2013 2V ● Visually inspect the component. 6 © 44084-0 Installing temperature transmitter ● Tighten temperature transmitter (1). 22 Nm Make sure the sealing ring is in place. © 44428-0 ● Plug in the cable plug (1). Ensure that the connection is perfect. 1 © 44426-1 © 02/2010 2/2 OBJ_DOKU-21815-001.
Electrical equipment W 48-06-01 TCD 2013 2V Removing and installing the fuel pressure sensor Standard tools – User notes Special tools: – Long socket wrench insert 110700 – Plugs/caps 170160 Danger! Wait 30 seconds after switching off the engine before working on the fuel system. Attention! Ensure utmost cleanliness when working on the fuel system. Carefully clean the area around the affected parts. Blow damp areas dry with compressed air.
Electrical equipment W 48-06-01 TCD 2013 2V ● Unscrew fuel pressure sensor (1) with the socket wrench. Collect draining fuel and dispose of according to regulations. 1 6 © 43973-0 ● Visually inspect the component. © 43974-0 Installing the fuel pressure sensor ● Mount new sealing ring. ● Install fuel pressure sensor (1) with the socket wrench. 30 Nm 1 © 43973-0 © 02/2010 2/4 OBJ_DOKU-21816-001.
Electrical equipment W 48-06-01 TCD 2013 2V ● Press the cable plug onto the fuel pressure sensor. ● Turn in the locking ring (1) until it snaps in. Make sure that the contacts match up. 1 Bleed the fuel system via the manual fuel pump on the fuel pre-filter according to the operation manual. 6 © 43970-0 © 02/2010 3/4 OBJ_DOKU-21816-001.
Electrical equipment W 48-06-01 TCD 2013 2V 6 © 02/2010 4/4 OBJ_DOKU-21816-001.
Tools W 49-02-01 TCD 2013 2V Installing and removing turning gear Standard tools Special tools: – Turn-over gear 100320 6 Disassembly ● Unscrew screws (1). ● Remove holder (2). ● Remove sleeve (3). ● Remove spacing sleeve (4). 2 3 4 3 1 4 © 43950-1 ● Unscrew screws (1). ● Remove cover (2). 1 2 1 © 43951-0 © 02/2010 1/4 OBJ_DOKU-21817-001.
Tools W 49-02-01 TCD 2013 2V Attaching turning gear ● Insert turn-over gear (1). The toothed gear of the turn-over gear must grip into the teeth of the camshaft wheel. 2 Attention! Do not trap the cable (2). 6 1 © 43952-0 ● Tighten screws (1). 1 1 © 43953-0 Removing turning gear ● Unscrew screws (1). 1 ● Remove turn-over gear. 1 © 43953-0 © 02/2010 2/4 OBJ_DOKU-21817-001.
Tools W 49-02-01 TCD 2013 2V ● Clean the sealing surface on cover and gearcase. ● Insert new O-ring (arrow). ● Lightly oil O-ring. 6 © 43983-0 ● Press in the cap to the stop. Note different screw lengths. See spare parts documentation. ● Tighten screws (arrows). 21 Nm © 43984-0 ● Fit holder (1). ● Fit sleeve (2). ● Position spacing sleeve (3). ● Tighten screws (4). 30 Nm 1 3 2 3 4 2 © 43950-2 © 02/2010 3/4 OBJ_DOKU-21817-001.
Tools W 49-02-01 TCD 2013 2V Technical Data Tightening specifications ID no. Name A03 092 Gear case on crankcase A04 022 Locking cap on gear case A04 025 Holder on gear case/crankcase Screw type M8x35-10.9 M8x55-10.9 M8x80-10.9 M8x55-10.9 M8x60-10.9 M8x80-10.9 Notes / Remark Value Observe tightening sequence 30 Nm 21 Nm 30 Nm For the tightening procedure according to torque using a torque wrench, a maximum variation of the tightening torque of +/- 10% is permissible.
Tools W 49-02-02 TCD 2013 2V Installing and removing turning gear (Torsional vibration damper) Attention! Standard tools Special tools: – Turn-over gear Observe engine rotation direction - see operating manual 100380 6 Attaching turning gear ● Insert turn-over gear (1). 1 © 48243-0 ● Position turning gear (1). 1 © 48244-0 © 02/2010 1/2 OBJ_DOKU-21818-001.
Tools W 49-02-02 TCD 2013 2V ● Depending on the installation situation mount the appropriate tool on the turning gear (1) for extension. Attention! Observe engine rotation direction - see operating manual ● Turn crank shaft in engine rotation direction with turning gear. 1 6 © 48245-1 Removing turning gear ● Remove turning gear (1). 1 © 48243-0 © 02/2010 2/2 OBJ_DOKU-21818-001.
Connection housing W 52-01-01 TCD 2013 2V Removing and installing the connection housing Standard tools: – Socket wrench insert – Socket wrench insert 8113 8114 6 Removing the connection housing ● Unscrew screws (arrows). ● Remove the cover (1). 1 © 42698-0 ● Unscrew screws (arrows). ● Remove connection housing. Use socket wrench insert. ● Visually inspect the components. © 44081-0 © 02/2010 1/4 OBJ_DOKU-21819-001.
Connection housing W 52-01-01 TCD 2013 2V Installing the connection housing ● Clean contact surfaces. 6 © 44082-0 ● Make sure the clamping bushing (arrow) is in place. © 44083-0 ● Mount connection housing. ● Centre connection housing over the clamping bushings. 2 1 ● Fasten screws. Note different screw lengths: M12x85-10.9 2 M12x160-10.9 (1) M16x85-10.9 M16x150-10.9 (2) 1 See spare parts documentation. 2 2 © 44421-1 © 02/2010 2/4 OBJ_DOKU-21819-001.
Connection housing W 52-01-01 TCD 2013 2V ● Tighten the screws according to the tightening sequence. See graphic for tightening sequence. 4 2 Use socket wrench insert. 1 ● Fasten screw (1) hand tight. 6 ● Pre-tighten screws (2), (3) (4) and (5) alternately. 5 3 6 © 44085-0 ● Tighten screws (1) and (6). 99 Nm 4 2 ● Tighten screws (2), (3), (4) and (5) alternately. – Stage 1: 1 99 Nm 6 5 3 © 44085-0 ● Tighten screws (2), (3), (4) and (5) alternately.
Connection housing W 52-01-01 TCD 2013 2V ● Press on cover plate to the stop. 1 ● Tighten screws (arrows). 9 Nm The hollow gorge (1) faces the lube oil tray. 6 © 42704-0 © 02/2010 4/4 OBJ_DOKU-21819-001.
Connection housing W 52-01-02 TCD 2013 2V Check alignment of connection housing 8190 Attention! Standard tools: – Magnetic measuring stand – Self-made mandrin guide Special tools: – Digital dial gauge Prerequisites: Radial bearing clearance and axial clearance of the crankshaft in the permissible tolerance range. 100410 Test surfaces must be dry and free from dirt and burr! 6 Checking the rotation ● Mount the engine on the assembly block.
Connection housing W 52-01-02 TCD 2013 2V Position (I) ● Set the dial gauge with probe pin to position (I) at a right angle to the connection housing. ● Apply the probe pin to the connection housing with pre-tension. 6 I © 47688-0 ● Adjust dial gauge to "0". © 47689-0 Position (II) ● Turn the crankshaft slowly to position (II). ● Read off measured value. ● Note measured value, dimension (a). II Note the sign! ● Note the measured value (a) with the appropriate sign on the measurement sheet.
Connection housing W 52-01-02 TCD 2013 2V Position (III) III ● Turn the crankshaft slowly to position (III). ● Read off measured value. ● Note measured value, dimension (b). Note the sign! ● Note the measured value (b) with the appropriate sign on the measurement sheet. 6 © 47691-0 Position (IV) ● Turn the crankshaft slowly to position (IV). ● Read off measured value. ● Note the measured value, dimension (c).
Connection housing W 52-01-02 TCD 2013 2V ● Press the connection housing in the appropriate direction and align. Attention! Never hit the connection housing with a hammer. ● Tighten the screws according to the tightening sequence. W 52-01-01 6 I © 47688-0 © 02/2010 4/6 OBJ_DOKU-21820-001.
Connection housing W 52-01-02 TCD 2013 2V Technical Data Table 1 (example) Connection housing SAE3 1 Display on dial gauge 100410 1a Arithmetic value (reversal of the sign) Correction radial bearing clearance (d) 2 (d) = 0.06 mm Half of the bearing clearance correction 3 (d/2) Corrected vertical total dial gauge 4 display (L ) v 5 6 Corrected horizontal dial gauge display (E1, E2) Horizontal total dial gauge display (LH) Position (I) 0 (II) a = 0.16 a1 = -0.16 (III) b = -0.08 b1 = +0.08 (IV) c = 0.
Connection housing W 52-01-02 TCD 2013 2V SAE 4 SAE 5 361,95 314,32 0,25 0,25 Measurement sheet - connection housing / radial run-out limit value Issued by: Date: Engine number: Connection housing: 6 1 Display on dial gauge 100410 1a Arithmetic value (reversal of the sign) Correction radial bearing clearance (d) 2 (d) = 0.
Start aid W 63-01-01 TCD 2013 2V Removing and install the heating flange Attention! Standard tools See the spare parts documentation. 6 Removing the heating flange ● Disconnect cables. 1 Attention! Hold on the hexagon of the plus pole screw. ● Unscrew screws (1). 1 © 46360-0 ● Remove hose nozzles (1). ● Remove gasket (2). ● Remove heating flange. ● Remove gasket (3). 1 3 2 © 44360-1 © 02/2010 1/4 OBJ_DOKU-21821-001.
Start aid W 63-01-01 TCD 2013 2V ● Visually inspect the component. 6 © 44831-0 Installing the heating flange ● Mount gasket (3). ● Mount heating flange. ● Mount gasket (2). ● Mount hose nozzles (1). 1 3 2 © 44360-1 ● Tighten screws (1). ● Tighten screws (1) alternately. 1 – Stage 1: 3 Nm – Stage 2: 30° ● Connect cable. 1 20 Nm Attention! Hold on the hexagon of the plus pole screw. © 46360-0 © 02/2010 2/4 OBJ_DOKU-21821-001.
Start aid W 63-01-01 TCD 2013 2V Technical Data Tightening specifications ID no. Name Screw type Notes / Remark A06 042 Heating flange on charge air manifold M8x100-10.9 Stage 1: A06 042 Heating flange on charge air manifold M8x100-10.9 Stage 2: Hexagonal, pole screw A13 065 Cable connection on heater flange locked Value 3 Nm 30° 20 Nm For the tightening procedure according to torque using a torque wrench, a maximum variation of the tightening torque of +/- 10% is permissible.
Start aid W 63-01-01 TCD 2013 2V 6 © 02/2010 4/4 OBJ_DOKU-21821-001.
Start aid W 63-02-01 TCD 2013 2V Removing and installing the glow plugs Standard tools Special tools: – Assembly tool – User notes – W 19-01-01 120440 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.
Start aid W 63-02-01 TCD 2013 2V ● Feed cable (1) through assembly tool (2). 1 2 6 © 48219-0 ● Unscrew heating plug (1) with assembly tool. ● Visually inspect the component. 1 © 48220-0 Installing the glow plugs ● Screw in heating plug (1). ● Tighten heating plug (1) with assembly tool. 20 Nm ● Install the injectors. W 19-01-01 1 © 48220-0 © 02/2010 2/4 OBJ_DOKU-21822-001.
Start aid W 63-02-01 TCD 2013 2V ● Install cable (arrows). ● Tighten nuts (1). 3 Nm 1 1 6 © 42728-0 © 02/2010 3/4 OBJ_DOKU-21822-001.
Start aid W 63-02-01 TCD 2013 2V Technical Data Tightening specifications ID no. Name A13 030 Cable shoe on connection bolt Heating plug / screw cap on cylinder A13 032 head Screw type M6 Notes / Remark Value 3 Nm 20 Nm For the tightening procedure according to torque using a torque wrench, a maximum variation of the tightening torque of +/- 10% is permissible. 6 © 02/2010 4/4 OBJ_DOKU-21822-001.
Standard tools W 49-00-01 TCD 2013 2V 7 Standard tools 7 © 02/2010 1/8 OBJ_DOKU-21823-001.
Standard tools W 49-00-01 TCD 2013 2V 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 Conventional tools / special tools: 7 These must be ordered directly from WILBAER with specification of the order number. Common Rail test instruments: These must be ordered like normal DEUTZ spare parts.
Standard tools W 49-00-01 TCD 2013 2V 8002 Pressure pump Checking cooling system for leak-tightness © 35409-2 7 8005 Compression pressure tester for diesel engines 10 - 40 bar Checking compression pressure © 35410-3 8011 Hose clip pliers Loosen and fasten hose clips e. g. fuel return pipe © 39426-1 © 02/2010 3/8 OBJ_DOKU-21823-001.
Standard tools W 49-00-01 TCD 2013 2V 8024 Assembly pliers Removing valve shaft seals © 37509-2 7 8035 Socket wrench insert reinforced, size 22 removing and installing main bearing © 37504-2 8113 Socket wrench insert Torx - E 14 © 43022-0 © 02/2010 4/8 OBJ_DOKU-21823-001.
Standard tools W 49-00-01 TCD 2013 2V 8114 Socket wrench insert Torx - E 20 © 35415-1 7 8115 V-belt tension measuring device 150 to 600 N Check 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 © 02/2010 5/8 OBJ_DOKU-21823-001.
Standard tools W 49-00-01 TCD 2013 2V 8190 Rotation angle disc with magnet Setting valve clearance © 42528-1 7 8191 Screwdriver insert for slotted screw Valve clearance setting © 43060-0 8192 Bowl wrench Fuel pre-filter (type: Racor) © 43193-1 © 02/2010 6/8 OBJ_DOKU-21823-001.
Standard tools W 49-00-01 TCD 2013 2V 8193 Screwdriver insert with pressed in hexagonal pin (5 mm), 1/2 inch, long version (in conjunction with rotation angle disc 8190) © 43183-0 7 8194 Screwdriver insert with pressed in hexagon pin (4 mm), 3/8 inch, long version (in connection with rotation angle disc 8190 and reducer 1/2 to 3/8 inch) © 43183-0 8196 Open end wrench adapter Size 13, for torque wrench Tighten lock nut of the valve clearance setting screw. © 43197-0 © 02/2010 7/8 OBJ_DOKU-21823-001.
Standard tools W 49-00-01 TCD 2013 2V 8198 Pricker Removing rotary shaft lip seal © 43206-1 7 9017 Assembly lever e. g. removing and installing valves © 37511-2 9090 Spring band pliers 320 mm Tighten spring clamp © 35420-3 © 02/2010 8/8 OBJ_DOKU-21823-001.
Special tools W 49-01-01 TCD 2013 2V 8 Special tools 8 © 02/2010 1/16 OBJ_DOKU-21824-001.
Special tools W 49-01-01 TCD 2013 2V 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 Conventional tools / special tools: These must be ordered directly from WILBAER with specification of the order number. 8 Common Rail test instruments: These must be ordered like normal DEUTZ spare parts.
Special tools W 49-01-01 TCD 2013 2V 100190 Connector (in conjunction with compression pressure tester 8005) © 42524-0 100320 Turning gear flywheel side 8 © 35422-1 100380 Turning gear on hub torsional vibration damper/V-belt pulley © 48242-0 © 02/2010 3/16 OBJ_DOKU-21824-001.
Special tools W 49-01-01 TCD 2013 2V 100400 Dial gauge with fixing wheel Measuring range 0 - 10 mm / 0.01 mm © 35424-1 8 100410 Digital gauge Measuring range 0 - 30 mm / 0.01 mm © 43205-2 100750 Measuring device Measuring bar with two shims (in conjunction with 100400 and 100410) Checking valve lag dimension Checking piston projection © 39402-1 © 02/2010 4/16 OBJ_DOKU-21824-001.
Special tools W 49-01-01 TCD 2013 2V 103050 Socket wrench insert Size 15 for valve clearance setting with removed exhaust return module (in connection with 8190) © 43023-0 103140 Crowfoot wrench with installed EGR module 8 © 48237-0 103220 Special pliers for removing the roller tappet © 43010-0 © 02/2010 5/16 OBJ_DOKU-21824-001.
Special tools W 49-01-01 TCD 2013 2V 110500 Special wrench Wrench size 17 Removing and installing high-pressure lines © 35436-1 8 110620 Lever tool Removing the injector © 45673-0 110640 Lever tool Removing the injector with removed rail © 43941-0 © 02/2010 6/16 OBJ_DOKU-21824-001.
Special tools W 49-01-01 TCD 2013 2V 110700 Socket wrench insert long Installing and removing pressure sensors (rail pressure, oil pressure, fuel pressure) © 43198-2 110900 Assembly case Case for O-rings, complete with: Disassembly tool 110901 and three assembly sleeves with guide: - High pressure pump (Ø 36), 110902 - Injector, 2V motor (Ø 16), 110903 - Injector, 4V motor (Ø 23), 110904 Removing and installing O-rings 8 © 43208-0 110901 Disassembly tool Removing and installing the O-rings © 45950-1
Special tools W 49-01-01 TCD 2013 2V 120440 Assembly tool Removing and installing the glow plugs © 48238-0 8 120680 Puller (in conjunction with slide hammer 150800) Removing jammed injector sealing ring © 35437-1 120900 Support bracket pivoting Clamping cylinder head © 35438-3 © 02/2010 8/16 OBJ_DOKU-21824-001.
Special tools W 49-01-01 TCD 2013 2V 120910 Base plate (in conjunction with support bracket 120900 if support bracket is not screwed tightly) © 35439-3 130300 Universal piston ring pliers Removing and installing the piston rings 8 © 43021-0 130420 Trapezoidal groove wear gauge Piston diameter 108 mm © 36461-2 © 02/2010 9/16 OBJ_DOKU-21824-001.
Special tools W 49-01-01 TCD 2013 2V 130640 Piston ring compressor Piston diameter 108 mm © 39408-1 8 142810 Assembly tool Installing crankshaft sealing ring (flywheel side) © 35446-1 142820 Assembly tool Installing crankshaft sealing ring (opposite side to flywheel) © 35445-1 © 02/2010 10/16 OBJ_DOKU-21824-001.
Special tools W 49-01-01 TCD 2013 2V 150170 Puller, universal comprising traverse, support and threaded rod (in conjunction with disc 150171) Removing cylinder liner © 43207-0 150171 Tension plate (in conjunction with disassembly device 150170) for liner diameter: 108 mm Removing cylinder liner 8 © 43204-0 150180 Liner holder (Set comprises 7 holders) Turning crankshaft with cylinder head removed © 43181-0 © 02/2010 11/16 OBJ_DOKU-21824-001.
Special tools W 49-01-01 TCD 2013 2V 150190 Assembly lever Lever with bolts (in conjunction with disc 150191) Installing cylinder liner © 43209-2 8 150191 Washer (in conjunction with assembly lever 150190) for liner diameter: 108 mm Installing cylinder liner © 43203-2 150800 Slide hammer (in conjunction with disassembly device 120680) Disassembling injector sealing ring © 35449-2 © 02/2010 12/16 OBJ_DOKU-21824-001.
Special tools W 49-01-01 TCD 2013 2V 151500 Separating tool Removing metal sheet lubricating oil pan from crankcase © 45974-0 170050 Special wrench Unscrewing the filter cartridges 8 © 37629-2 170160 Stoppers/caps 1 set of differently-sized stoppers and caps Sealing openings on the fuel system © 43663-0 © 02/2010 13/16 OBJ_DOKU-21824-001.
Special tools W 49-01-01 TCD 2013 2V 6066 Assembly block Engine clamping, double-sided © 35451-2 8 6066/158 Clamping bracket consisting of: 1 holder 6066/158-1 rear right, 1 holder 6066/158-2 rear left, 1 holder 6066/158-3 front right, 1 holder 6066/158-4 front left (in connection with assembly block 6066) Clamping of the engine, double-sided © 35452-1 6068 Engine lifting device Load (2000 kg), 3-point suspension, spindle clamp, cross member, chains and hooks © 43184-0 © 02/2010 14/16 OBJ_DOKU-21
Special tools W 49-01-01 TCD 2013 2V 02937495 Control signal transmitter Testing Common Rail Injectors © 48252-0 02937496 Hydraulic pressure generation 8 © 48249-0 02937497 Pressure loss tester Top dead centre gauge © 48251-0 © 02/2010 15/16 OBJ_DOKU-21824-001.
Special tools W 49-01-01 TCD 2013 2V 02937498 High pressure tester 2500 bar © 48250-0 8 © 02/2010 16/16 OBJ_DOKU-21824-001.
