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
3
© 02/2010 OBJ_DOKU-21740-001.fm
7/8
DEUTZ engines User notes
3.4.2 Structure of a job card
1. DEUTZ AG,
publisher of service documentation
2. Engine type
3. Module
4. Numbering of the job cards
5. Title of job card
6. Reference to other modules with job cards
7. Chapter
8. Graphic or photo
9. DEUTZ internal creation number
10.Page number
11.Date of issue of job card
12.Note
13.Danger / Important
14.Work sequence
15.Auxiliary materials
16.Conventional tools, special tools
3.5 Explanation of symbols
6
16
12
4
6
1 2 3
8
10
11
5
7
5
9
13
14
15
8
Danger!
of death or to health. Must be observed!
For example: The incorrect use or conver
-
sion of the turbocharger can lead to serious
injury.
Caution!
Danger to the component/engine. Non-
compliance can lead to destruction of the
component/engine.
Must be observed!
Note
General notes on assembly, environmental
protection etc. No potential danger for man
or machine.
Tool
Conventional and special tools required for
the work.
Auxiliary materials
Working materials required in addition to
the tools for performing the work
(e.g. greases, oils, adhesives, sealants)
References
to important documents or job cards for the
work process.
For example: Job card W 04-05-05
Reference
to a document or a job card within the work
process.
Test and setting data
The necessary values are specified here.
If several values are necessary, a cross
reference is given to the Test and Setting
Values table.
For example:
ID no. P01 61 = valve clearance, inlet
Tightening specification
The necessary values are specified here.
If several values are necessary, a cross
reference is given to the Tightening
Specifications table.
For example:
ID no. A01 001 = cylinder head screws