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
1
© 05/2005 OBJ_DOKU-21738-001.fm
3/4
DEUTZ engines Foreword
● Read and observe the information in this docu
-
mentation. You will avoid accidents, retain the
manufacturer's warranty and possess a fully
functional and ready to operate engine.
● This engine is built exclusively for purpose ac
-
cording to the scope of delivery - defined by the
equipment manufacturer (use for the intended
purpose). Any use above and beyond this is con
-
sidered improper use. The manufacturer will not
be liable for damages resulting from this. The
user bears the sole risk.
● Use for the intended purpose also includes ob
-
servance of the operating, maintenance and re
-
pair instructions specified by the manufacturer.
The engine may only be used, maintained and
repaired by persons who are familiar with this
and are aware of the risks involved.
● Make sure that this documentation is available to
everyone involved in the operation, maintenance
and repair and that they have understood the
contents.
● Failure to observe this documentation may lead
to malfunctions and engine damage as well as in
-
jury to persons for which the manufacturer will
not accept any liability.
● Prerequisite for proper maintenance and repair is
the availability of all the necessary equipment,
conventional and special tools and their perfect
condition.
● Engine parts such as springs, clamps, elastic re
-
taining rings etc. pose an increased risk of injury
when handled incorrectly.
● The pertinent rules for the prevention of acci
-
dents and other generally recognised health and
safety regulations must be observed.
● Maximum economy, reliability and long life is only
guaranteed when using DEUTZ original parts.
● Repair of the engine must correspond to its use
for the intended purpose. Only parts released by
the manufacturer for the respective purpose may
be used for conversion work. Unauthorised mod
-
ifications to the engine exclude manufacturer lia
-
bility for resulting damages. Failure to observe
this will void the warranty!
● The engines made by DEUTZ are developed for
a wide range of applications. A wide range of var
-
iants ensures that the respective special require
-
ments are met.
● The engine is equipped according to the installa
-
tion case, i.e. not all the parts and components
described in this documentation are installed in
your engine necessarily.
● We have done our best to highlight the differenc
-
es so that you can easily find the operating, main
-
tenance and repair instructions relevant to your
engine.
We are at your service for any questions you may
have in this matter.
Your DEUTZ AG