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
4
© 02/2010 OBJ_DOKU-21741-001.fm
4/18
Technical data
TCD 2013 2VTesting and setting data
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 0.5 h
TCD 2013 2V 144 °
Rocker arm/bracket
P01 72 Rocker arm, bore, diameter, outlet TCD 2013 2V 21,02 mm
P01 73 Rocker arm, bore, diameter, inlet TCD 2013 2V 21,02 mm
P01 74 Rocker arm journal Diameter, fit h7 TCD 2013 2V 21 mm
Main bearing pin
P02 03 Main bearing pin Standard, diameter TCD 2013 2V 85,00 mm
P02 04 Crankshaft main bearing pin Underdimension stage TCD 2013 2V 0,25 mm
P02 05 Limit for undermeasure step TCD 2013 2V 84,50 mm
P02 06 Pin unroundness Wear limit TCD 2013 2V 0,01 mm
P02 07
Crankshaft main bearing pin and lifting journal,
hardness
Standard HRC TCD 2013 2V 53 HRC
Fit bearing pin
P02 11 Fit bearing pin, width TCD 2013 2V 38
P02 12 Fit bearing pin, width one overmeasure stage TCD 2013 2V 0,4 mm
P02 13 Limit for overmeasure step TCD 2013 2V 38,46 mm
Lifting journal
P02 22 Lifting journal, diameter TCD 2013 2V 68,00 mm
P02 23 Lifting journal, diameter Undermeasure per stage TCD 2013 2V 0,25 mm
P02 24 Limit for undermeasure step TCD 20113 2V 67,50 mm
P02 25 Pin unroundness Wear limit TCD 2013 2V 0,01 mm
ID no. Name Information Series Value Unit
+0,033
0
+0,033
0
0
- 0,021
0
- 0,02
0
- 0,02
+3
- 3
+0,06
0
- 0,02
0
- 0,02