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
12/18
Technical data
TCD 2013 2VTightening specifications
A01 004 Cylinder head cowling on cylinder head
Hood must be free from grease
and lubricant.
TCD 2013 2V 13 Nm
A01 011 Exhaust gas return module on cylinder head Observe tightening sequence. TCD 2013 2V 10 Nm 30 Nm
A01 012
Locking nut setting screw exhaust gas return mo-
dule
TCD 2013 2V 20 Nm
A01 013
Solenoid valve (exhaust gas return) on cylinder
head
TCD 2013 2V 24 Nm
A02 010 Main bearing on crankcase
Can be used 3 times if
documented in writing otherwi-
se use new screws every time
they are loosened.
TCD 2013 2V 50 Nm
+60°
+60°
A02 020 Big end bearing cap on con rod
Observe assembly specifica-
tion.
Use new screws every time
they are loosened.
Screws oiled
TCD 2013 2V 30 Nm
+60°
+60°
A03 020 Front cover on crankcase
Observe tightening sequence.
Observe assembly specifica-
tion.
Wet rotors with engine oil befo-
re assembly.
TCD 2013 2V 3 Nm 21 Nm
A03 030 Oil pan on crankcase
Observe tightening sequence.
Note different screw lengths.
TCD 2013 2V 30 Nm
A03 031 Screw cap on oil pan M18x1.5 Cu sealing ring TCD 2013 2V 55 Nm
A03 060 Crankcase breather on cylinder head TCD 2013 2V 20 Nm
ID no. Name Screw type Notes / Remarks Series
Pre-tensio-
ning value
Post-
clamping
value