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
A09 002 Outlet nozzle on coolant thermostat housing TCD 2013 2V 30 Nm
A09 010 Coolant pump on fan console Observe tightening sequence. TCD 2013 2V 30 Nm
A09 015
V-belt pulley on coolant pump TCD 2013 2V 30 Nm
V-belt pulley on V-belt pulley TCD 2013 2V 30 Nm
A09 031 Coolant temperature sensor on cylinder head TCD 2013 2V 22 Nm
A09 045 Fan console on crankcase TCD 2013 2V 30 Nm
A09 046 Fan drive on fan console TCD 2013 2V 60 Nm
A09 047 V-rib disc on fan drive Stage 1: TCD 2013 2V 30 Nm
A09 047 V-rib disc on fan drive Stage 2: TCD 2013 2V 90 °
A09 048 Adapter on V-belt pulley TCD 2013 2V 30 Nm
A12 001 Flywheel on crankshaft
M10x1x85
Observe tightening specifica-
tion.
Use new screws.
Renew screws every time they
are loosened.
TCD 2013 2V
30 Nm
+60°
+60°
M10x1x80
M10x1x75
M10x1x70
M10x1x55
M10x1x50
M10x1x45
30 Nm
M10x1x40
M10x1x35
M10x1x30
+60°
+30°
A12 030 Hub torsional vibration damper on crankshaft
Use new screws.
Observe assembly specifica-
tion.
TCD 2013 2V 30 Nm
+60°
+60°
ID no. Name Screw type Notes / Remarks Series
Pre-tensio-
ning value
Post-
clamping
value