Workshop Manual
Table Of Contents
- Workshop Manual
- Table of contents
- 1 Foreword
- 2 General
- 3 User notes
- 4 Technical data
- 5 Job card overview
- 6 Job cards
- Removing and installing the crankcase bleeding
- Renewing the crankshaft sealing ring (opposite side to flywheel)
- Assembling/disassembling shaft sleeve on the crankshaft (opposite side to flywheel)
- Removing and installing the front cover (opposite side to flywheel)
- Checking the overhang of the cylinder liner
- Removing and installing the pressure holding valve
- Removing and installing the piston cooling nozzles
- Checking collar contact for cylinder liner
- Removing and installing the lubricating oil pan (metal sheet lubricating oil pan)
- Removing and installing the cylinder liner
- Testing the cylinder liner
- Removing and installing the V-belt, V-belt pulley
- Removing and installing torsional vibration damper (V-belt drive)
- Removing and installing the flywheel
- Removing and installing the crankshaft
- Checking the crankshaft
- Checking the axial clearance of the crankshaft
- Removing and installing the piston and con rod
- Checking the con rod
- Checking the piston
- Checking the piston rings and piston ring grooves
- Checking the compression pressure
- Removing and installing the cylinder head cover
- Removing and installing the exhaust return module
- Removing and installing the solenoid valve (exhaust gas return)
- Removing and installing cylinder head
- Checking piston overhang
- Removing and installing the valves
- Checking the valves
- Checking the valve guide
- Checking the valve lag
- Renewing the crankshaft sealing ring (flywheel side)
- Removing and installing the gearcase cover
- Removing and installing the camshaft
- Checking the camshaft
- Setting valve clearance (with or without removal of exhaust return module)
- Setting valve clearance (with exhaust return module installed)
- Removing and installing the rocker arm and rocker arm bracket
- Disassembling, assembling and checking the rocker arm and rocker arm bracket
- Removing and installing the lubricating oil cooler
- Removing and installing the lubricating oil cooler housing
- Removing and installing the oil suction pipe
- Removing and installing the control block
- Removing and installing the high-pressure pump (Installation position A)
- Removing and installing the high-pressure pump (Installation position B)
- Removing and installing the injector
- Removing and installing the fuel filter console
- Removing and installing the fuel supply pump (V-belt drive)
- Removing and installing the rail
- Removing and installing the pressure limiting valve
- Removing and installing the rail pressure sensor
- Removing and install the charge air line
- Removing and installing the coolant pump (V-belt drive)
- Removing and installing the thermostat
- Checking the thermostat (in the removed state)
- Removing and installing the thermostat housing
- Removing and installing the belt tensioner (V-rib belt)
- Removing and installing the fan drive
- Dismantling and assembling the fan drive
- Removing and installing the fan console (V-rib belt drive)
- Removing and installing the exhaust line
- Removing and installing the turbocharger
- Removing and installing the generator (V-belt drive)
- Removing and installing the starter
- Mounting engine on assembly block and demounting
- Removing and installing the engine mounting (elastic mounting)
- Removing and installing the cable harness
- Removing and installing the impulse transmitter (crankshaft)
- Removing and installing the impulse transmitter (camshaft)
- Removing and installing the pressure/temperature sensor (charge air)
- Removing and installing the oil pressure switch
- Removing and installing temperature transmitter (coolant)
- Removing and installing the fuel pressure sensor
- Installing and removing turning gear
- Installing and removing turning gear (Torsional vibration damper)
- Removing and installing the connection housing
- Check alignment of connection housing
- Removing and install the heating flange
- Removing and installing the glow plugs
- 7 Standard tools
- 8 Special tools
- Table of contents
2
© 11/2005 OBJ_DOKU-21739-001.fm
3/4
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.
Maintenance and care are the only way the engine
can satisfy the demands you make on it. Compli
-
ance with the prescribed maintenance times and the
careful execution of maintenance and care work are
therefore essential. Difficult operating conditions,
deviating from normal operation, must be particular
-
ly heeded.
Please consult one of our service representatives
responsible for operating faults and spare parts
questions. Our trained specialist personnel ensures
fast and professional repairs using original DEUTZ
spare parts in the event of damage.
Original spare parts from DEUTZ AG are always
manufactured according to the state of the art.