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
5/18
Technical data
TCD 2013 2V Testing and setting data
P02 26 Radial run-out, crankshaft maximum permissible deviation TCD 2013
L4 2V 0,07 mm
L6 0,10 mm
Main bearing
P02 34 Permissible axial clearance of crankshaft in installed state TCD 2013 2V 0,1 - 0,3 mm
P02 35 Thrust ring, thickness Standard (upper and lower half) TCD 2013 2V 2,9 mm
P02 36 Thrust ring, oversize 1. Step = 0.2 mm TCD 2013 2V 3,1 mm
Con-rod
P02 41
Parallelism of the con rod with respect to the pis-
ton bolt
permissible deviation
at a distance of 100 mm
TCD 2013 2V 0,05 mm
P02 42
Parallelism of the con rod with respect to the pis-
ton bolt
permissible deviation
at a distance of 100 mm
TCD 2013 2V 0,05 mm
P02 43 Piston bolt liner, inside diameter installed, unmachined TCD 2013 2V 42 mm
P02 45
Small end bush clearance between piston pin
and small end bush
TCD 2013 2V 0,034 - 0,056 mm
Big end bearing
P02 52 Big end bearing shells, inside diameter installed TCD 2013 2V72,5 mm
P02 55 Big end bearing, bore in con rod H6 TCD 2013 2V 72,5 mm
P02 56
Theoretical clearance between the big end
bearing / lifting journal
TCD 2013 2V 0,036 - 0,095 mm
Piston bolt
P02 61 Piston pin, diameter TCD 2013 2V 42 mm
Piston
P02 70 Piston Identification of the installation position on the piston base
P02 71 Piston, diameter, standard Measuring point 1 = height 12 mm TCD 2013 2V 107,700 mm
P02 72 Piston, diameter, standard Measuring point 2 = height 64 mm TCD 2013 2V 107,800 mm
ID no. Name Information Series Value Unit
+0,05
0
+0,05
0
+0,05
+0,04
+0,02
0
- 0,006