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
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Technical data
TCD 2013 2VTesting and setting data
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, 1.62 mm TCD 2013 2V 0,64 - 0,75 mm
P02 78 Piston bolt, bore TCD 2013 2V 42 mm
Piston rings
P02 84 Joint clearance, piston ring 1
Identification (TOP) in direction of
combustion chamber
TCD 2013 2V 0,3 - 0,55 mm
P02 85 Joint clearance, piston ring 2
Identification (TOP) in direction of
combustion chamber
TCD 2013 2V 1,5 - 2,0 mm
P02 86 Joint clearance, piston ring 3
Identification (TOP) in direction of
combustion chamber
TCD 2013 2V 0,3 - 0,6 mm
P02 87
Axial clearance, 1st ring (double-sided keystone
ring)
Wear limit TCD 2013 2V
Measure with trapezo-
idal groove wear
gauge
-
P02 88 Axial clearance, 2nd ring (taper-faced ring) TCD 2013 2V 0,09 - 0,13 mm
P02 89
Axial clearance, 3rd ring , (bevelland-edge oil
control ring)
TCD 2013 2V 0,03 - 0,075 mm
Crankcase
Cylinder liners
P03 31 Cylinder bore, inside diameter Standard TCD 2013 2V 108 mm
P03 35
Fit depth of collar rest and sealing surface for cy-
linder liner
TCD 2013 2V 8,92 mm
P03 36 Cylinder liners, collar height TCD 2013 2V 9 mm
P03 39 Cylinder liner, overhang TCD 2013 2V
max. 0.080 mm
at least 0.030 mm
ID no. Name Information Series Value Unit
+0,017
+0,01
+0,02
+0,03
- 0,02