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 2V Tightening specifications
A12 031 V-belt pulley on torsional vibration damper M10x70-10.9 TCD 2013 2V 70 Nm
A12 035 Belt tensioner on front cover TCD 2013 2V 80 Nm
A12 041 Clamping strap on coolant pump M8x25-8.8 TCD 2013 2V 30 Nm
A12 091 Hollow screw pipe union
Hollow screw Ring piece pipe 6 mm
TCD 2013 2V
18 Nm
Union nut 20 Nm
A12 092 Pipe union, pipe diameter 8 mm, ring piece
Hollow screw
M12x1.5
TCD 2013 2V 29 Nm
A12 093 Pipe union, pipe diameter 10 mm, ring piece
Hollow screw
M14x1.5
TCD 2013 2V 39 Nm
A12 094 Pipe union, pipe diameter 12 mm, ring piece
Hollow screw
M16x1.5
TCD 2013 2V 49 Nm
A12 095
Pipe clip, fastening M6
TCD 2013 2V
13 Nm
Pipe clip for return pipe M8 20 Nm
A13 001 Starter on crankcase/gear case TCD 2013 2V 60 Nm
A13 012 Generator on holder M8x75 TCD 2013 2V 30 Nm
A13 015 Generator on clamping strap M8x75 TCD 2013 2V 30 Nm
A13 017 V-belt clamping strap on console M8x25 TCD 2013 2V 30 Nm
A13 018 Generator console on cylinder head TCD 2013 2V 70 Nm
A13 030 Cable shoe on connection bolt M6 TCD 2013 2V 3 Nm
A13 032 Heating plug / screw cap on cylinder head TCD 2013 2V 20 Nm
A13 041 Cable rail on cylinder head M6x16 self-tapping TCD 2013 2V 8.5 Nm
A13 046
Pressure/temperature transmitter on charge air
line
Screw M6 maximum
TCD 2013 2V
4.5 Nm
M5 lightly oiled, maximum 3.3 Nm
A13 051 Cab le connection on injector TCD 2013 2V 1.5 Nm
ID no. Name Screw type Notes / Remarks Series
Pre-tensio-
ning value
Post-
clamping
value