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
15/18
Technical data
TCD 2013 2V Tightening specifications
A07 039 Pressure limiting valve to rail Insert with mounting grease. TCD 2013 2V 100 Nm
A07 040 Rail pressure sensor to rail Insert with mounting grease. TCD 2013 2V 70 Nm
A07 045
Fuel line (feed) to control block Hollow screw
TCD 2013 2V
49 Nm
Fuel line (return) to rail 39 Nm
A07 046 Fuel line (return) to control block Hollow screw TCD 2013 2V49 Nm
A07 047 Fuel line (return) to cylinder head Hollow screw TCD 2013 2V29 Nm
A07 087 Fuel filter console on oil cooler housing TCD 2013 2V 30 Nm
A07 090 Fuel pressure sensor to fuel filter console TCD 2013 2V 30 Nm
A07 099 Fuel filter to fuel filter console
Wet gasket with clean diesel
fuel.
hand tight
approx.10
Nm
A08 001 Oil fillter/interchangeable filter Oil gasket lightly. TCD 2013 2V hand tight
approx.10
Nm
A08 015 Oil suction intake pipe/holder on oil pump TCD 2013 2V 22 Nm
A08 040
Lubricating oil pipe on exhaust turbocharger/
crankcase
Hollow screw TCD 2013 2V 39 Nm
A08 044 Pipe nozzle (oil return) to turbocharger TCD 2013 2V 20 Nm
A08 046
Holding bracket (oil return) on crankcase
TCD 2013 2V
20 Nm
Connection holder of the oil return line 20 Nm
A08 051 Oil cooler housing on crankcase
M8x50
M8x80
Observe tightening sequence. TCD 2013 2V 3 Nm 30 Nm
A08 052 Oil cooler on oil cooler housing Collar screw Oil sealing ring lightly. TCD 2013 2V 80 Nm 160 Nm
A08 058 Locking screw on oil cooler housing with sealing ring TCD 2013 2V 80 Nm
A08 091 Oil pressure switch on oil cooler housing TCD 2013 2V 30 Nm
A09 001 Coolant thermostat housing on cylinder head TCD 2013 2V 30 Nm
ID no. Name Screw type Notes / Remarks Series
Pre-tensio-
ning value
Post-
clamping
value