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 2VTightening specifications
A06 020 Turbocharger on exhaust pipe Nut M10
Insert with DEUTZ S1 moun-
ting compound
TCD 2013 2V 42 Nm
A06 022 Pin bolt on exhaust pipe
Insert with DEUTZ S1 moun-
ting compound
TCD 2013 2V 10 Nm
A06 030 Charge air pipe on cylinder head TCD 2013 2V 11 Nm
A06 042 Heating flange on charge air manifold M8x100-10.9 Stage 1: TCD 2013 2V 3 Nm
A06 042 Heating flange on charge air manifold M8x100-10.9 Stage 2: TCD 2013 2V 30°
A06 046 Charge air manifold on charge air pipe TCD 2013 2V 30 Nm
A07 001 Clamping claw injector on cylinder head
Observe order of assembly.
Install injector without tension.
TCD 2013 2V hand tight 27 Nm
A07 003
Injection lines on rail and pressure pipe nozzle
High pressure pipe at high pressure pump
Union nut
Stage 1:
Observe assembly specifica-
tion.
Use new pipe.
TCD 2013 2V 10 Nm
A07 003
Injection lines on rail and pressure pipe nozzle
High pressure pipe at high pressure pump
Union nut Stage 2: TCD 2013 2V 60°
A07 024 Fuel supply pump on holder TCD 2013 2V 20 Nm
A07 031 High pressure pump to crankcase M10x30-10.9 Screws oiled TCD 2013 2V 10 Nm 50 Nm
A07 032 Control block to crankcase
M8x75
M8x85
Observe tightening sequence TCD 2013 2V 20 Nm
A07 034 Fuel line to high pressure pump TCD 2013 2V 26 Nm
A07 035 Fuel line to control block TCD 2013 2V 34 Nm
A07 038 Rail to cylinder head
Stage 1:
Observe assembly specifica-
tion.
TCD 2013 2V hand tight
A07 038 Rail to cylinder head Stage 2: TCD 2013 2V 30 Nm
ID no. Name Screw type Notes / Remarks Series
Pre-tensio-
ning value
Post-
clamping
value
+15°