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
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Job card overview
TCD 2013 2VSorted numerically
W 09-02-02 Removing and installing the gearcase cover Gearcase
W 10-02-01 Removing and installing the camshaft Camshaft
W 10-02-02 Checking the camshaft Camshaft
W 11-01-01
Setting valve clearance (with exhaust return module
installed)
Control parts
W 11-01-01
Setting valve clearance (with or without removal of
exhaust return module)
Control parts
W 11-02-01
Removing and installing the rocker arm and rocker
arm bracket
Control parts
W 11-02-02
Disassembling, assembling and checking the rocker
arm and rocker arm
bracket
Control parts
W 15-02-01 Removing and installing the lubricating oil cooler Lubricating oil cooler
W 15-02-02
Removing and installing the lubricating oil cooler
housing
Lubricating oil cooler
W 16-01-01 Removing and installing the oil suction pipe Oil suction pipe
W 17-01-01 Removing and installing the control block High-pressure pump
W 17-01-04
Removing and installing the high-pressure pump
(Installation position A)
High-pressure pump
W 17-01-05
Removing and installing the high-pressure pump
(Installation position B)
High-pressure pump
W 19-01-01 Removing and installing the injector Injector
W 20-01-01 Removing and installing the fuel filter console Fuel filter
W 20-02-01
Removing and installing the fuel supply pump (V-
belt drive)
Fuel pump
W 21-02-01 Removing and installing the rail Fuel pipes
W 21-02-03 Removing and installing the pressure limiting valve Fuel pipes
W 21-02-05 Removing and installing the rail pressure sensor Fuel pipes
W 22-01-01 Removing and install the charge air line Charge air line
W 37-03-01
Removing and installing the coolant pump (V-belt
drive)
Coolant pump
W 38-01-01 Removing and installing the thermostat Thermostat housing
W 38-01-02 Checking the thermostat (in the removed state) Thermostat housing
W 38-02-01 Removing and installing the thermostat housing Thermostat housing
W 39-01-01
Removing and installing the belt tensioner (V-rib
belt)
Fan drive
W 39-02-01
Removing and installing the fan drive
Fan drive
W 3
9-02-03
Dismantling and assembling the fan drive Fan drive
W 39-04-03
Removing and installing the fan console (V-rib belt
drive)
Fan console
Job card Activity Maintenance group