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Workshop Manual competence level 3

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do i cu s al tr m lo ib en w u ed ti o ti sc w n ith in op yr ou eit ig t o he ht ur r p pr pr rin ot io te ec ra d te o d. gr r ee ele m ct en ro t. ni cf o

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D 2011 w TD 2011 w, TCD 2011 w

.

This document is subject to changes which may become necessary in the course of further development of the engines. Reprinting and reproductions of any kind, even in part, require our written permission.

0312 3336 en

Regarding copyright questions and licensing agreements please contact : TE-FI, Mr. Sonntag Tel.: + 49 (0) 221 822-3053 EMail: [email protected] DEUTZ AG Sales & Service Information Systems Ottostraße 1 D-51149 Köln (Cologne) Phone.: +49 (0) 221-822-0 Fax: +49 (0) 221-822-3525 Internet: www.deutz.com E-Mail: [email protected]

The engine company.

Printed in Germany All rights reserved 1st Edition, 12/2008 Order No. 0312 3336 en

DEUTZ engines 1

Foreword

2

General

3

User notes 3.1 3.2 3.3 3.4 3.5

4

Testing and setting data Tightening specifications

Job card overview 5.1 5.2

© 06/2008

General Specifications Operating manual and workshop manual Job cards Explanation of symbols

Technical data 4.1 4.2

5

Table of contents

Sorted alphabetically Sorted numerically

6

Job cards

7

Commercial tools

8

Special tools

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Table of contents

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Foreword

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Foreword

z Read and observe the information in this documentation. You will avoid accidents, retain the manufacturer's warranty and possess a fully functional and ready to operate engine. z This engine is built exclusively for purpose according to the scope of delivery - defined by the equipment manufacturer (use for the intended purpose). Any use above and beyond this is considered improper use. The manufacturer will not be liable for damages resulting from this. The user bears the sole risk. z Use for the intended purpose also includes observance of the operating, maintenance and repair 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.

z 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 modifications to the engine exclude manufacturer liability for resulting damages. Failure to observe this will void the warranty! z The engines made by DEUTZ are developed for a wide range of applications. A wide range of variants ensures that the respective special requirements are met. z The engine is equipped according to the installation case, i.e. not all the parts and components described in this documentation are installed in your engine necessarily. z We have done our best to highlight the differences so that you can easily find the operating, maintenance and repair instructions relevant to your engine.

z Make sure that this documentation is available to everyone involved in the operation, maintenance and repair and that they have understood the contents. z Failure to observe this documentation may lead to malfunctions and engine damage as well as injury to persons for which the manufacturer will not accept any liability. z Prerequisite for proper maintenance and repair is the availability of all the necessary equipment, conventional and special tools and their perfect condition. z Engine parts such as springs, clamps, elastic retaining rings etc. pose an increased risk of injury when handled incorrectly. z The pertinent rules for the prevention of accidents and other generally recognised health and safety regulations must be observed.

We are at your service for any questions you may have in this matter.

z Maximum economy, reliability and long life is only guaranteed when using DEUTZ original parts.

Your DEUTZ AG

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Foreword

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General

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General

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General

DEUTZ engines are the product of years of research and development. The profound expertise gained through this, in combination with high demands on quality, attests to the fact that our engines possess all the qualities of long life, high reliability and low fuel consumption. It goes without saying that the high environmental protection requirements are also met.

2

Maintenance and care are the only way the engine can satisfy the demands you make on it. Compliance with the prescribed maintenance times and the careful execution of maintenance and care work are therefore essential. Difficult operating conditions, deviating from normal operation, must be particularly heeded. Please consult one of our service representatives responsible for operating faults and spare parts questions. Our trained specialist personnel ensures fast and professional repairs using original DEUTZ spare parts in the event of damage. Original spare parts from DEUTZ AG are always manufactured according to the state of the art.

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User notes

3.1 General

3.2 Specifications

The documentation of the workshop manual has been created based on the engine available at the time of going to press. There may be deviations in the descriptions, illustrations and parts due to further developments.

3.2.1 Accident prevention and safety regulations

The maintenance work described in the operation manual and in the workshop manual must be carried out on schedule and completely. The maintenance personnel must have the necessary technical knowledge to perform the work. Safety and protection devices which are removed during maintenance work must be replaced again afterwards.

The legally prescribed rules for the prevention of accidents must be observed. These are available from professional associations or from dealers. These are dependent on the application site, operating mode and the operating and auxiliary materials being used. Special protection measures are specified depending on the work being carried out, and are identified in the job description. Among other things it generally applies that:

Caution! The rules for the prevention of accidents and the safety regulations must be observed during maintenance work. Reference is made in the workshop manual job cards to the regulations in chapter 3.2. These must be read before working on the engine and must be strictly followed.

z for the personnel: – Only briefed personnel may operate or maintain the engine. Unauthorised persons are prohibited access to the machine room. – Wear close-fitting clothing and ear protectors in the machine room when the engine is in operation.

The maintenance intervals and the work to be performed are specified in the maintenance schedule of the operation manual. The job cards contain technical documentation on the execution of maintenance work.

– Only deploy trained personnel to do repairs and maintenance work. – Do not work on the fuel system when the engine is running. The fuel system is under high pressure - danger of death. – Go to the workshop immediately in case of leaks in the fuel system. z for the engine room: – Ensure adequate ventilation (do not cover air shafts). – Provide first aid kit and suitable fire extinguishers. Check the filling and readiness for operation regularly. – Only store inflammable materials in the machine room if they are essential for operation of the system. – Smoking and naked flames are prohibited in the machine room. z for operation, maintenance and repairs on the engine: – Wait 30 seconds after switching off the engine before working on the fuel sytem. – After all work on the fuel system, it must be bleeded - see the operation manual, chapter "6 Fuel system“. – Only start the engine when all the protective devices have been fitted. Make sure no-one is standing in the danger area. – Cleaning, maintenance and repair work may only be performed with the engine at a standstill and secured against starting. – Injection lines and high pressure pipes must not be deformed.

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– Damaged injection lines and high-pressure pipes must be renewed.

z Remove loose parts (for example paint chips from assembly work) with an industrial vacuum cleaner or other suction device. Only suction may be used in assembly work on the open fuel system.

– Injection lines and high pressure fuel lines must never be connected when the engine is running.

3

z Only work on the fuel system in a clean environment (no dust, no grinding or welding). Avoid draughts (dust). Clean the workshop floor regularly. No brake or performance test benches may be kept or operated in the same room.

– Do not place hands near to a leak in the high pressure fuel system. – Also carefully check all high pressure components visually before performing tests on the running engine. Wear suitable protective clothing (for example protective glasses). Leaks are a potential source of danger for workshop personnel.

z Air currents which kick up dust, such as those caused by brake repairs or the starting of engines, should be avoided.

– Even if no leaks are discernible on the high pressure fuel system, the workshop personnel should avoid the immediate danger zone or wear suitable protective clothing (such as protective glasses) when performing tests on the running engine and during the first trial run. – Always stay out of range of a fuel jet, as it could cause severe injury.

z For work such as removal and installation on defective hydraulic components on the Common Rail System it is recommended to partition off a separate workshop area in the factory. This must be separate from other areas in which general vehicle repairs such as brake repairs are carried out. z No general machine tools may be operated in this room.

– Smoking is strictly prohibited when working on the fuel system.

z Regular cleaning of the workshop area is mandatory. Draughts, ventilation systems and heating fans should be minimised.

– Do not work near to sparks and flames. – Never disconnect an injector when the engine is running.

z Areas of the engine room from which particles of dirt could be loosened (for example the bottom part of the tipped driver cab) must be covered with fresh clean film.

3.2.2 Cleanliness instructions and measures for handling the DEUTZ Common Rail System The DEUTZ Common Rail system used in the DEUTZ engines consists of high-precision components which are exposed to extreme stress. Great attention must be paid to cleanliness when working on the fuel system due to the high precision technology. Notes and measures to be observed before starting work on the fuel system

z Working materials and tools must be cleaned before work. Only use tools without damage to the chrome plating or tools which are not chromeplated. Notes and measures to be observed during work on the fuel system or with the fuel system open. z Only work in clean overalls. z Only lint-free cleaning cloths may be used for work on the fuel system.

z The fuel system must be closed. Make a visual inspection for leaks / damage to the fuel system.

z Remove loose parts (for example paint chips from assembly work) with an industrial vacuum cleaner or other suction device. Only suction may be used in assembly work on the open fuel system.

z Clean the whole engine and engine room with the system closed before starting work on the fuel system. z The engine must be dry when you start working on the fuel system. z Blowing (dry) with compressed air is only permissible with the fuel system closed.

z Working materials and tools must be cleaned before work. Only use tools without damage to the chrome plating or tools which are not chromeplated.

z When using a steam jet, first cover up the control unit, the cable plugs, all other electrical plug connections and the generator. Also, the steam jet may not be pointed directly at them.

z Do not use used cleaning fluid or test fluid for cleaning. z Compressed air must not be used for cleaning on the open fuel system.

z Electrical plug connections must be plugged when spraying.

z Work on removed components may only be performed at a suitably equipped workbench.

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z When removing and installing components, no materials which can leave behind particles or fibres (cardboard, wood, cloths) may be used.

operating materials among other things. The renewed parts / operating materials must be stored, transported and disposed of according to regulations. The owner himself is responsible for this.

z Removed parts may only be rubbed down with clean, lint-free cloths. No dirt particles may be rubbed into the components.

Disposal includes recycling and the scrapping of parts / operating materials, although recycling has priority.

z Openings on the components and on the engine must be closed immediately with suitable stoppers/caps.

Details of disposal and their monitoring are governed by regional, national and international laws and directives which the system operator must observe on his own responsibility.

z The stoppers/caps may only be removed immediately before installing. z Store stoppers/caps free from dust and dirt in the original packaging and dispose of after using once. z Only remove new parts from the original packaging just before installation. z Removed components must be kept in new, sealable bags or - if available - in the packaging of the new parts. z Always use the original packaging of the new part to send back the removed components. Notes and measures for the vehicle workshop area z For work such as removal and installation on defective hydraulic components on the Common Rail System it is recommended to partition off a separate workshop area in the factory. This must be separate from other areas in which general vehicle repairs such as brake repairs are carried out. z The workshop floor is sealed or tiled. z No welding gear, grinders, general machine tools, brakes or performance test benches may be operated in this room. z Regular cleaning of the workshop area is mandatory. Draughts, ventilation systems and heating fans should be minimised. Notes and measures for workbench and tools in the vehicle hall z A special workbench must be set up for work on removed components. z Clean the removal and installation tools regularly and keep them in a closed tool cabinet. z Remove loose parts (for example paint chips from assembly work) with an industrial vacuum cleaner or other suction device. z Working materials and tools must be cleaned before work. Only use tools without damage to the chrome plating or tools which are not chromeplated.

3.2.3 Disposal regulations The work described in the operation manual and workshop manual necessitates renewal of parts and © 06/2008

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3.3 Operation manual and workshop manual

3.4 Job cards

To structure the information to suit the user, the service documentation is divided into operation manual and workshop manual.

3

The operation manual contains a general description and instructions for all other maintenance work. It contains the following chapters: 1. Contents, General 2. Engine description 3. Operation 4. Operating media

The job cards are divided in the workshop manual into "W" and "I" job cards. The "W" job card documents standard repairs on the engine and/or its components. The necessary tools and special tools are also specified in the "W" job card. The "I" job card additionally documents the appropriate work procedures for repairing the engine and/ or its components. The workshop must satisfy special conditions to perform these work procedures. Special tools and machine tools must be available, for example.

3.4.1 Numbering of job cards

5. Maintenance

The job card numbers follow the pattern W 02-0401. The individual parts of this pattern are explained below:

6. Care and maintenance work 7. Faults, causes and remedies 8. Engine conservation

z W 02-04-01: Documentation type

9. Technical data

– WWorkshop manual

10.Service The workshop manual assumes knowledge of the contents of the operation manual. This applies especially for the safety regulations. The workshop manual describes repairs to the engine and components for which more effort and appropriately qualified technicians are required.

– I ...... Repair instructions z W 02-04-01: Maintenance group – 00 ... General / interdisciplinary activities – 01 ... Cylinder head – 02Drive system – 03 ... Crankcase – 04 ... Engine control system – 05 ... Speed governing – 06 ... Exhaust system / Charging – 07 ... Fuel system – 08 ... Lube oil system – 09 ... Cooling system – 10 ... Compressed air system – 11 ... Monitoring system – 12 ... Other components – 13 ... Electrical system z W 02-04-01: Component grouping z W 02-04-01: Consecutive number

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User notes 3.5 Explanation of symbols

3.4.2 Structure of a job card 1

2

Danger! of death or to health. Must be observed! For example: The incorrect use or conversion of the turbocharger can lead to serious injury.

3

Triebwerk W 02-04-01

4

Caution! Danger to the component/engine. Noncompliance can lead to destruction of the component/engine. Must be observed!

5 16

6

15

6

7

Note General notes on assembly, environmental protection etc. No potential danger for man or machine.

14 8 13

12

Tool Conventional and special tools required for the work.

8

Auxiliary materials Working materials required in addition to the tools for performing the work (e.g. greases, oils, adhesives, sealants) 11

10

9

References to important documents or job cards for the work process. For example: Job card W 04-05-05

1. DEUTZ AG, publisher of service documentation 2. Engine type (e.g. TCD 2013 4V)

Reference to a document or a job card within the work process.

3. Maintenance group 4. Job card number or topic 5. Title of job card

Test and setting data The necessary values are specified here. If several values are necessary, a cross reference is given to the Test and Setting Values table. For example: ID no. P01 61 = valve clearance, inlet

6. Reference to other job cards 7. Chapter 8. Graphic or photo 9. DEUTZ internal creation number 10.Page number

Tightening specification The necessary values are specified here. If several values are necessary, a cross reference is given to the Tightening Specifications table. For example: ID no. A01 001 = cylinder head screws

11.Date of issue of job card 12.Note 13.Danger / Important 14.Work sequence 15.Special tools; auxiliary materials 16.Conventional tools

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D 2011 w TD 2011 w, TCD 2011 w

ID no. Name Additional information D 2011 w / TD 2011 w / TCD 2011 w P00 04 Engine weight according to DIN 70020-A

4

Value

P00 51

Compression pressure

P00 71

Ignition sequence

approx. 268 kg 25 - 30 bar (2500 - 3000 kPa) 1-3-4-2

P01 31

Valve stem, diameter (inlet)

7.98 −0.015 mm

P01 32

Valve stem, diameter (outlet)

P01 33 P01 34

Valve stem clearance (inlet) Valve stem clearance (outlet)

7.96 −0.015 mm 0.045 - 0.075 mm 0.065 - 0.095 mm

P01 35

Valve edge thickness (inlet)

2.6 −0.1 mm

P01 36

Valve edge thickness (outlet)

2.8 −0.1 mm

P01 37

Valve plate, diameter (inlet)

41.5 −0.1 mm

P01 38

Valve plate, diameter (outlet)

P01 45 P01 46 P01 51 P01 61 P01 62

Valve lag dimension (inlet) Valve lag dimension (outlet) Valve spring, length (untensioned) Valve clearance (inlet) Valve clearance (outlet)

35.4 −0.1 mm 1.53 mm 1.53 mm 39.3 mm 0.3 mm 0.5 mm

P01 72

Rocker arm, bore, diameter (outlet)

+0.05 +0.05

+0.1 +0.1

Wear limit Wear limit Standard

18

+0.27

mm

Rocker arm, bore, diameter (inlet)

18

+0.27

mm

P01 74

Rocker arm pin, diameter

+0.01 17,97 −0.01

P02 03

Main journal, diameter

Standard

P02 04

Main journal, underdimension stage

two underdimension stages per

mm 0.25 mm

P02 07

Main journal, surface hardness

P02 08

Main journal, radial run-out

maximum

58 HRc 0.05 mm

P02 11

Fit bearing pin, width

Standard

35 +0

P02 12

Fit bearing pin, width, underdimension stage

one underdimension stage

0.4 mm

P02 13

Fit bearing pin, width

Oversize, wear limit

35.44 mm

P02 22

Lifting journal, diameter

Standard

P02 23 P02 34

Lifting journal, underdimension stage Crankshaft, permissible axial clearance

two underdimension stages per in the installed state

58 −0.03 mm 0.25 mm 0.100 - 0.273 mm

P02 35

Stop ring, wall thickness

Standard

2,4 +0

+0.05

mm

Oversize level

+0.05 2,6 +0

mm

P01 73

P02 36 P02 41 P02 42

Stop ring, wall thickness

mm

−0.01 70 −0.03 +0.4

maximum permissible deviation Parallelism of the con rod with respect to at a distance of 100 mm, the piston bolt vertical maximum permissible deviation Parallelism of the con rod with respect to at a distance of 100 mm, the piston bolt horizontal

mm

−0.01

0.03 mm 0.03 mm +0.035

P02 43

Small end bush, diameter, inside

P02 52

Con rod bearing shells, diameter, inside

30 +0.025 mm 57.944 - 58.036 mm

P02 55

Con rod, bearing bore, diameter, inside

61,6 +0.02 mm −0

P02 56

Theoretical clearance between the big end bearing and lifting journal

0.014 - 0.07 mm

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D 2011 w TD 2011 w, TCD 2011 w ID no.

Name

P02 61

Piston pin, diameter, outside

P02 62 P02 74 P02 75 P02 76 P02 77

Technical data Testing and setting data Additional information

Value 30 −0.005 mm −0

Theoretical clearance between piston pin bush and piston pin Piston, diameter, overmeasure one overmeasure stage Identification, cylinder head gasPiston overhang ket = 1 recess Identification, cylinder head gasPiston overhang ket = 2 recesses Identification, cylinder head gasPiston overhang ket = 3 recesses

0.025 - 0.040 mm 0.5 mm 0.325 - 0.604 mm 0.605 - 0.704 mm 0.705 - 0.804 mm +0.014

P02 78

Piston pin bore

30 +0.008 mm

P02 84

Piston ring 1, joint clearance Wear limit

0.30 +0 mm 0.8 mm

Wear limit

1.5 +0 mm 2.5 mm

+0.2

P02 84

Piston ring 1, joint clearance

P02 85

Piston ring 2, joint clearance

P02 85

Piston ring 2, joint clearance

P02 86

Piston ring 3, joint clearance

P02 86 P02 87 P02 88 P02 89 P03 13 P03 14

Piston ring 3, joint clearance Piston ring 1, axial clearance Piston ring 2, axial clearance Piston ring 3, axial clearance Camshaft, bearing liner, diameter, inside Camshaft, bearing liner, diameter, inside

Wear limit Trapezoidal groove wear gauge

P03 31

Cylinder, diameter, inside

Standard

P03 32 P04 31

Cylinder, diameter, inside Wear limit Camshaft, bearing pin, diameter Minimum speed, setting screw, basic setting Screw-in depth of the adjusting capsule, basic setting

P05 05 P05 06 P07 52 P08 41 P08 41 P08 42 P08 43 P08 44 P08 44 P08 45

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+0.5

+0.3

in the installed state Wear limit

Fuel injector (without leak oil), nozzle opening pressure Oil pressure regulating valve, opening pressure (with cabin heating connection) Oil pressure regulating valve, opening pressure (without cabin heating connection) Oil pressure regulating valve, opening pressure (with cabin heating connection) Oil pressure regulating valve, opening pressure (without cabin heating connection) Oil pressure regulating valve, compression spring, length Oil pressure regulating valve, compression spring, length Oil pressure regulating valve, compression spring, length

0.30 +0 mm 1,2 mm 0.080 - 0.115 mm 0.030 - 0.065 mm 54.000 - 54.054 mm 54.08 mm +0.020

96.000 mm 96.1 mm 53.945 - 53.960 mm 23

+1

mm

+0.5

6,4 −0.5 mm 170 (17

+10

+1

bar

MPa)

Coloured marking, yellow

1 bar

Coloured marking, green

3 bar

Coloured marking, red

1.7 bar

Coloured marking, blue

0.3 bar

with heating connection, yellow

80.5 mm

without heating connection, green 56.5 mm with heating connection, red

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Technical data Testing and setting data ID no.

P08 74 P09 11 P09 13

Name Oil pressure regulating valve, compression spring, length Thermostat, compression spring, length Thermostat, start of opening Thermostat, stroke distance

P12 11

V-belt tension, individual V-belts AVX 10 First assembly

P12 21

V-belt tension, individual V-belts AVX 10

P08 46

4

D 2011 w TD 2011 w, TCD 2011 w Additional information

Value

with heating connection, blue

61.8 mm 45.7 mm 86 - 90 °C at least 9 mm

Check after 15 minutes running under load

+50

450 −50 N +20

300 −20 N

D 2011 w Measuring point 1 = height 22 mm 95.900 +0.009 −0.009 mm P02 72 Piston, diameter, standard Measuring point 2 = height 47 mm 95.830 mm Measuring point 3 = height 62.2 +0.015 P02 73 Piston, diameter, standard 95.700 −0.015 mm mm Distance between crankcase sealing sur- Piston class A 188.380 P02 79 face and lifting journal Stroke 125 mm 188.548 mm Distance between crankcase sealing sur- Piston class B 188.549 P02 79 face and lifting journal Stroke 125 mm 188.718 mm TD 2011 w / TCD 2011 w P02 71

Piston, diameter, standard

P02 71

Piston, diameter, standard

P02 72

Piston, diameter, standard

Measuring point 1 = height 20 mm 95.850 +0.009 −0.009 mm Measuring point 2 = height 47 mm 95,778 mm

P02 73

Piston, diameter, standard

Measuring point 3 = height 63 mm 95.695 +0.015 −0.015 mm

TD 2011 w / TCD 2011 w High crankcase Distance between crankcase sealing sur- Piston class A P02 79 face and lifting journal Stroke 125 mm TD 2011 w / TCD 2011 w Recess cylinder head Distance between crankcase sealing sur- Piston class A P02 79 face and lifting journal Stroke 125 mm D 2011 w / TD 2011 w / TCD 2011 w Recess cylinder head Identification, cylinder head gasP02 75 Piston overhang ket = 1 recess Identification, cylinder head gasP02 76 Piston overhang ket = 2 recesses Identification, cylinder head gasP02 77 Piston overhang ket = 3 recesses

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197.880 198.175 mm 188.380 188.718 mm 9.820 - 10.140 mm 10.141 - 10.239 mm 10.240 - 10.310 mm

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Technical data Tightening specifications

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4.2

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Technical data Tightening specifications ID no. Name D 2011 w / TD 2011 w / TCD 2011 w A00 001 Clamping bracket on crankcase Clamping bracket on adapter for A00 002 assembly block Mounting foot/engine mounting on A00 003 crankcase

D 2011 w TD 2011 w, TCD 2011 w Screw type

90 Nm M14x55-12.9 M14x100-12.9

200 Nm Stage 1: Cylinder head screws can be used a maximum of 3x with written documentation. Otherwise use new cylinder head screws. Observe tightening sequence. Stage 2 Stage 3 Stage 4

A01 001 Cylinder head on crankcase

A01 001 A01 001 A01 001 A01 002 A01 003

Cylinder head on crankcase Cylinder head on crankcase Cylinder head on crankcase Rocker arm bracket on cylinder head Locking nut, valve adjuster Cylinder head cover on cylinder A01 004 head

30 Nm

80 Nm 160 Nm 90° 21 Nm 20 Nm 8.5 Nm

Stage 1: Screws can be used a maximum of 3x with written documentation. Otherwise use new cylinder head screws. Stage 2: Stage 3: Stage 1: Use new screw. Stage 2: Stage 1: Use new screws.

A02 010 Main bearing cover on crankcase

A02 010 Main bearing cover on crankcase A02 010 Main bearing cover on crankcase A02 015 Toothed belt wheel on crankshaft A02 015 Toothed belt wheel on crankshaft Big end bearing cover on connecting A02 020 rod Big end bearing cover on connecting A02 020 rod Big end bearing cover on connecting A02 020 rod M10x1

A03 004 Locking screw on crankcase A03 007 Locking screw on crankcase M18x1.5 Locking screw on crankcase (oil rise A03 008 M20x1.5 tube)

A03 020 Front cover on crankcase

50 Nm

60° 45° 130 Nm 210° 30 Nm

Stage 2:

60°

Stage 3:

60°

Adapter for adjustable bolt on camshaft lock/ 18 Nm crankshaft lock. Replace sealing ring. Adapter for adjustable bolt on control linkage 18 Nm lock. Replace sealing ring. Use new locking screw. 50 Nm Use new locking screw. 56 Nm Observe tightening sequence

A03 010 Rear cover on crankcase

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Value 90 Nm

4

A03 003 Locking screw on crankcase

Notes / Remark

21 Nm 21 Nm

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D 2011 w TD 2011 w, TCD 2011 w ID no. Name Screw type A03 024 Assembly tool on crankcase Lubricating oil pan (plate) on crankA03 030 M8x16 case A03 031 Locking screw on lubricating oil pan Crankcase bleeding on front cover / A03 060 on cylinder head cover / on cylinder head M12x20 M12x30 M12x35 Connection housing/connection ring A03 081 M12x55 to crankcase M12x70 M12x75 M12x95 Cylinder head A03 082 Connection housing to crankcase screws M10x40 M8x10 A03 082 Connection housing to crankcase M8x30 M8x50 M10x40 Connection housing/connection ring A03 082 M10x30 to crankcase M10x25 Connection housing/connection ring A03 082 M14x55 to crankcase A03 085 Cover plate to connection housing

A04 001 Toothed belt wheel on camshaft A04 002 Shim on camshaft A04 052 Tensioning pulley on front cover Protective hood (toothed wheel) on A04 053 front cover Locking nut on setting screw, shut-off A05 005 stop Speed transmitter on connection A05 011 housing A05 021 Regulator lever shaft on front cover A05 022 Idling capsule on front cover Adjusting capsule on front cover, A05 023 clamping nut A05 024 Eccentric shaft on front cover Cap (speed adjusting lever) on front A05 025 cover Lifting magnet (engine shutdown) on A05 041 front cover Lifting magnet (start amount release) A05 065 on front cover

Observe tightening sequence! Replace sealing ring

Value 21 Nm 21 Nm 55 Nm 8.5 Nm

4 106 Nm

60 Nm 22 Nm 45 Nm 180 Nm 9 Nm 30 Nm 210° 21 Nm 21 Nm 7 Nm 6 Nm 8.5 Nm 9.2 Nm 4.6 Nm 10 Nm Locking nut

7 Nm 4.5 Nm 8.5 Nm 10 Nm

Torx screw, coated

A07 001 Fuel injector on cylinder head Injection valve, clamping nut on A07 002 nozzle holder (without leak oil) © 12/2008

Notes / Remark

Stage 1: Use new screw. Stage 2:

A04 001 Toothed belt wheel on camshaft

A06 001 Exhaust pipe at cylinder head

Technical data Tightening specifications

Use new screws.

55 Nm 21 Nm 45 - 50 Nm

7/10

17765-001

Technical data Tightening specifications ID no. A07 003 A07 012 A07 015 A07 024 A07 061 A07 071

Name Injection line on fuel injector / injection pump Injection pump on crankcase Fuel supply line to injection pump Fuel supply pump on crankcase Fuel return line on injection pump Locking screw on injection pump

4 A08 003 Oil filter console on crankcase

D 2011 w TD 2011 w, TCD 2011 w Screw type

Notes / Remark

M12x1.5

25 Nm

Hollow screw

Replace sealing rings

Hollow screw

Replace sealing rings Replace sealing ring

Torx M8x50-8.8 Torx M8x90-8.8

21 Nm Packing compound DW73

A08 015 Oil suction pipe on crankcase

A08 051 A08 054 A08 062 A08 063 A08 064 A08 072 A08 091 A09 001 A09 002

Control line to oil filter console / crankcase Lubricating oil cooler on oil filter console Lubricating oil cooler connection on crankcase Locking screw on transfer fitting (heating connection) Locking screw on transfer fitting (heating connection) Transfer fitting on crankcase (heating connection) Thermostat on crankcase, locking screw, Oil pressure switch on crankcase Thermostat housing to crankcase Outlet nozzles on thermostat housing

A09 010 Coolant pump on thermostat housing A09 020 Pipe clip on holder Temperature transmitter on thermoA09 031 stat housing A09 042 Ventilator on flange hub A09 045 Air bearing on console A09 045 Air bearing on console A12 001 Flywheel on crankshaft A12 001 Flywheel on crankshaft A12 001 Flywheel on crankshaft V belt pulley/flange hub on output A12 031 flange V-belt tensioning pulley (holder) on A12 041 front cover Hydraulic pump on hydraulic pump A12 051 console

© 12/2008

21 Nm 29 Nm 21 Nm 29 Nm 45 Nm 21 Nm

A08 010 Lubricating oil pump on crankcase

A08 048

Value

21 Nm

Hollow screw M10x1

18 Nm

M6x16-10.9

13 Nm

M6x60

13 Nm

M18x1.5

Use new sealing ring

50 Nm

M24x1.5

Use new sealing ring

111 Nm

M24x1.5

Use new sealing ring

111 Nm 90 Nm

M10x1 M8x100-10.9

13 Nm 34 Nm

M8x30-10.9

22 Nm

M8x35-10.9 M8x100-10.9 M6x16

20 Nm 21 Nm 25 Nm

M8x40-10.9 Stage 1: Use new screw. M10x110-12.9 Stage 2: Stage 1: Use new screws Stage 2: Stage 3: M10x110-12.9

M10x30-8.8

30 Nm 30 Nm 120° 30 Nm 60° 30° 43 Nm 45 Nm 57 Nm

8/10

17765-001

D 2011 w TD 2011 w, TCD 2011 w ID no. A12 052 A12 056 A13 001 A13 009 A13 010 A13 012 A13 015 A13 016 A13 031 A13 032 A13 034 A13 081 A13 082 D 2011 w A06 030 A06 057 A06 062 A06 063 A06 071 A06 072

Name Screw type Tensioning pulley on hydraulic pump console Protective hood on hydraulic pump console Starter on crankcase Shield on crankcase M6x14-8.8 M8x75-10.9 Console on cylinder head M8x100-10.9 M8x70-10.9 Generator on console M8x75-10.9 Clamping bracket on generator M8x30-8.8 Clamping bracket on console M8x35-8.8 Glow plug in charge air line / intake pipe Heating plug on cylinder head Cable connection to glow plug Charging current cable to generator B+ Cable G1.D+ to generator M5 Air suction intake pipe on cylinder head Pipe to exhaust gas return valve/ cylinder head (cooling - intake) Exhaust return pipe to exhaust return valve Exhaust gas collection pipe to exhaust gas return valve Pipe to crankcase (exhaust gas return - cooling - return) Pipe to exhaust gas return valve (exhaust gas return - cooling return)

Torx screw, coated Hollow screw M12x1.5

Technical data Tightening specifications Notes / Remark

21 Nm 8.5 Nm 43.5 Nm 8.5 Nm 34 Nm

4

34 Nm 22 Nm 22 Nm 60 Nm 21 Nm 4 Nm 6.5 Nm 3.5 Nm Use new screws.

M8x65-10.9

21 Nm 29 Nm 20 Nm 20 Nm

Hollow screw M8x1

12 Nm

Hollow screw M12x1.5

29 Nm

Torx M10x25-10.9 Exhaust gas collection pipe (exhaust Torx A06 073 Use new screws. M10x30-10.9 gas return) on cylinder head Torx M10x45-10.9 Exhaust gas return pipe to cylinder A06 074 head (exhaust gas return) Locking screw Safety cover on sensor housing A06 075 Torx-Plus (exhaust gas return) 30IPR Sensor exhaust gas return on crankA06 076 case A07 087 Fuel filter console to crankcase TD 2011 w / TCD 2011 w A06 004 Pin bolts on exhaust pipe coated Use new pin bolts A06 020 Turbocharger on exhaust pipe M8 Torx screw, A06 030 Charge air pipe on cylinder head Use new screws. coated

© 12/2008

Value

9/10

55 Nm

8.5 Nm 8 Nm 21 Nm 21 Nm 12 Nm 21 Nm 21 Nm

17765-001

Technical data Tightening specifications

4

ID no. Name A06 094 Lifting magnet on fuel filter console Fuel filter console/full load stop to A07 087 crankcase Cap on charge air-dependent full A07 096 load stop Lubricating oil pipe on turbocharger / A08 042 crankcase Oil return line, hex spuds to turbochA08 044 arger A08 049 Holder oil return line on crankcase

D 2011 w TD 2011 w, TCD 2011 w Screw type

Notes / Remark Renew O-ring

Torx, M8x50-8.8

Value 10 Nm 22 Nm 8 Nm

Hollow screw

Replace sealing rings

29 Nm

M16x1.5

Use new sealing ring

40 Nm

Torx, M6x14-8.8

8.5 Nm

For the tightening procedure according to torque using a torque wrench, a maximum variation of the tightening torque of +/- 10% is permissible.

© 12/2008

10/10

17765-001

D 2011 w TD 2011 w, TCD 2011 w

Job card overview

5

© 12/2008

5

Job card overview

5.1

Sorted alphabetically

1/12

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Job card overview Sorted alphabetically

D 2011 w TD 2011w, TCD 2011 w

5

© 12/2008

2/12

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D 2011 w TD 2011w, TCD 2011 w

Job card overview Sorted alphabetically

Activity

Job card

Maintenance group

Check start of injection

W 07-06-01

Fuel system

Checking fuel injectors

W 07-07-02

Fuel system

Checking piston overhang

W 01-04-09

Cylinder head

Checking the axial clearance of the crankshaft

W 02-01-04

Drive system

Checking the camshaft

W 04-05-06

Engine control

Checking the compression pressure

W 00-02-06

General

Checking the con rod

W 02-03-01

Drive system

Checking the crankshaft

W 02-01-07

Drive system

Checking the cylinder

W 03-03-01

Crankcase

Checking the piston

W 02-09-07

Drive system

Checking the piston rings and piston ring grooves

W 02-10-03

Drive system

Checking the thermostat (in the removed state)

W 09-08-01

Cooling system

Checking the valve guide

W 01-06-03

Cylinder head

Checking the valve lag

W 01-07-08

Cylinder head

Checking the valves

W 01-05-04

Cylinder head

Determining the thickness of the shim

W 07-06-03

Fuel system

Disassembling, assembling and checking the rocker arm and rocker arm W 01-02-06 bracket

Cylinder head

Dismantling and assembling the front cover

Crankcase

W 03-08-01

Installing and removing charge air pressure-depenW 07-10-08 dent full load stop

Fuel system

Mounting engine on assembly block and demounting

W 00-05-01

General

Removing and install the charge air line

W 06-02-03

Exhaust system/Charging

Removing and installing cylinder head

W 01-04-04

Cylinder head

Removing and installing fuel pipes

W 07-10-06

Fuel system

Removing and installing rear cover

W 03-09-01

Crankcase

Removing and installing small end bush

I 02-03-03

Drive system

Removing and installing temperature transmitter

W 09-12-01

Cooling system

Removing and installing the camshaft

W 04-05-05

Engine control

Removing and installing the connection housing

W 03-09-04

Crankcase

Removing and installing the control line

W 08-16-01

Lube oil system

Removing and installing the control linkage

W 05-04-15

Speed control

Removing and installing the coolant pump

W 09-07-08

Cooling system

Removing and installing the crankcase bleeding

W 03-01-11

Crankcase

Removing and installing the crankshaft

W 02-04-01

Drive system

© 12/2008

3/12

5

17766-001

Job card overview Sorted alphabetically

5

D 2011 w TD 2011w, TCD 2011 w

Activity

Job card

Maintenance group

Removing and installing the exhaust gas collection pipe (Exhaust gas recirculation)

W 06-09-08

Exhaust system/Charging

Removing and installing the exhaust gas return pipe W 06-09-07

Exhaust system/Charging

Removing and installing the exhaust gas return valW 06-09-06 ve

Exhaust system/Charging

Removing and installing the exhaust line

W 06-01-05

Exhaust system/Charging

Removing and installing the flywheel

W 12-06-01

Other components

Removing and installing the front cover

W 03-08-01

Crankcase

Removing and installing the fuel filter console

W 07-10-08

Fuel system

Removing and installing the fuel injector pump

W 07-04-01

Fuel system

Removing and installing the fuel injectors

W 07-07-01

Fuel system

Removing and installing the fuel supply pump

W 07-11-01

Fuel system

Removing and installing the generator

W 13-02-03

Electrical system

Removing and installing the glow plug

W 13-06-02

Electrical system

Removing and installing the guide bushes (Control linkage)

W 07-02-06

Speed control

Removing and installing the heating plugs

W 13-06-01

Electrical system

Removing and installing the hydraulic pump

W 12-08-02

Other components

Removing and installing the impulse transmitter

W 05-07-01

Speed control

Removing and installing the intake manifold

W 06-07-03

Exhaust system/Charging

Removing and installing the lifting magnet (charge air pressure-dependent full load stop)

W 07-10-08

Fuel system

Removing and installing the lifting magnet (Engine shutdown)

W 11-00-03

Monitoring system

Removing and installing the lifting magnet (Start amount release)

W 07-02-07

Fuel system

Removing and installing the lubricating oil cooler

W 08-08-02

Lube oil system

Removing and installing the lubricating oil pan (meW 08-04-07 tal sheet lubricating oil pan)

Lube oil system

Removing and installing the lubricating oil pump

W 08-04-05

Lube oil system

Removing and installing the magnet clip (Exhaust gas recirculation)

W 06-09-10

Exhaust system/Charging

Removing and installing the oil filter console

W 08-11-07

Lube oil system

Removing and installing the oil pressure regulating valve

W 08-11-02

Lube oil system

Removing and installing the oil pressure switch

W 08-11-08

Lube oil system

Removing and installing the oil suction pipe

W 08-04-06

Lube oil system

Removing and installing the piston and con rod

W 02-09-03

Drive system

Removing and installing the piston cooling nozzles

W 02-15-01

Drive system

© 12/2008

4/12

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D 2011 w TD 2011w, TCD 2011 w

Job card overview Sorted alphabetically

Activity

Job card

Maintenance group

Removing and installing the rocker arm and rocker arm bracket

W 01-02-02

Cylinder head

Removing and installing the sensor (Exhaust gas reW 06-09-09 circulation)

Exhaust system/Charging

Removing and installing the starter

W 13-03-02

Electrical system

Removing and installing the thermostat

W 09-08-02

Cooling system

Removing and installing the thermostat (Lubricating W 08-11-12 oil cooler)

Lube oil system

Removing and installing the thermostat housing

W 09-08-04

Cooling system

Removing and installing the toothed belt wheel

W 04-04-15

Engine control

Removing and installing the turbocharger

W 06-06-04

Exhaust system/Charging

Removing and installing the valves

W 01-05-01

Cylinder head

Removing and installing the V-belt pulley

W 12-01-04

Other components

Removing and installing, testing camshaft bearing

W 03-11-01

Crankcase

Renew camshaft sealing ring (opposite side to flywW 04-03-01 heel)

Engine control

Renew toothed belt and tensioning pulley

Engine control

W 04-04-12

Renew toothed belt and tensioning pulley (Hydraulic W 12-08-03 pump)

Other components

Renew V-belts, check V-belt tension

Other components

W 12-02-01

Renewing the crankshaft sealing ring (flywheel side) W 02-02-02

Drive system

Renewing the crankshaft sealing ring (opposite side W 02-02-04 to flywheel)

Drive system

Renewing the injection lines

W 07-03-01

Fuel system

Renewing toothed starter ring on the flywheel

W 12-06-03

Other components

Setting valve clearance

W 01-01-01

Cylinder head

© 12/2008

5/12

5

17766-001

Job card overview Sorted alphabetically

D 2011 w TD 2011w, TCD 2011 w

5

© 12/2008

6/12

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D 2011 w TD 2011 w, TCD 2011 w

Job card overview Sorted numerically

5 5.2

© 12/2008

Sorted numerically

7/12

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Job card overview Sorted numerically

D 2011 w TD 2011 w, TCD 2011 w

5

© 12/2008

8/12

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D 2011 w TD 2011 w, TCD 2011 w

Job card overview Sorted numerically

Job card

Activity

Maintenance group

I 02-03-03

Removing and installing small end bush

Drive system

W 00-02-06

Checking the compression pressure

General

W 00-05-01

Mounting engine on assembly block and demounting

General

W 01-01-01

Setting valve clearance

Cylinder head

W 01-02-02

Removing and installing the rocker arm and rocker arm bracket

Cylinder head

W 01-02-06

Disassembling, assembling and checking the rocker arm and rocker arm Cylinder head bracket

W 01-04-04

Removing and installing cylinder head

Cylinder head

W 01-04-09

Checking piston overhang

Cylinder head

W 01-05-01

Removing and installing the valves

Cylinder head

W 01-05-04

Checking the valves

Cylinder head

W 01-06-03

Checking the valve guide

Cylinder head

W 01-07-08

Checking the valve lag

Cylinder head

W 02-01-04

Checking the axial clearance of the crankshaft

Drive system

W 02-01-07

Checking the crankshaft

Drive system

W 02-02-02

Renewing the crankshaft sealing ring (flywheel side) Drive system

W 02-02-04

Renewing the crankshaft sealing ring (opposite side Drive system to flywheel)

W 02-03-01

Checking the con rod

Drive system

W 02-04-01

Removing and installing the crankshaft

Drive system

W 02-09-03

Removing and installing the piston and con rod

Drive system

W 02-09-07

Checking the piston

Drive system

W 02-10-03

Checking the piston rings and piston ring grooves

Drive system

W 02-15-01

Removing and installing the piston cooling nozzles

Drive system

W 03-01-11

Removing and installing the crankcase bleeding

Crankcase

W 03-03-01

Checking the cylinder

Crankcase

W 03-08-01

Removing and installing the front cover

Crankcase

W 03-08-01

Dismantling and assembling the front cover

Crankcase

W 03-09-01

Removing and installing rear cover

Crankcase

W 03-09-04

Removing and installing the connection housing

Crankcase

W 03-11-01

Removing and installing, testing camshaft bearing

Crankcase

W 04-03-01

Renew camshaft sealing ring (opposite side to flywEngine control heel)

W 04-04-12

Renew toothed belt and tensioning pulley

Engine control

W 04-04-15

Removing and installing the toothed belt wheel

Engine control

© 12/2008

9/12

5

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Job card overview Sorted numerically

5

D 2011 w TD 2011 w, TCD 2011 w

Job card

Activity

Maintenance group

W 04-05-05

Removing and installing the camshaft

Engine control

W 04-05-06

Checking the camshaft

Engine control

W 05-04-15

Removing and installing the control linkage

Speed control

W 05-07-01

Removing and installing the impulse transmitter

Speed control

W 06-01-05

Removing and installing the exhaust line

Exhaust system/Charging

W 06-02-03

Removing and install the charge air line

Exhaust system/Charging

W 06-06-04

Removing and installing the turbocharger

Exhaust system/Charging

W 06-07-03

Removing and installing the intake manifold

Exhaust system/Charging

W 06-09-06

Removing and installing the exhaust gas return valExhaust system/Charging ve

W 06-09-07

Removing and installing the exhaust gas return pipe Exhaust system/Charging

W 06-09-08

Removing and installing the exhaust gas collection pipe (Exhaust gas recirculation)

W 06-09-09

Removing and installing the sensor (Exhaust gas reExhaust system/Charging circulation)

W 06-09-10

Removing and installing the magnet clip (Exhaust gas recirculation)

Exhaust system/Charging

W 07-02-06

Removing and installing the guide bushes (Control linkage)

Speed control

W 07-02-07

Removing and installing the lifting magnet (Start amount release)

Fuel system

W 07-03-01

Renewing the injection lines

Fuel system

W 07-04-01

Removing and installing the fuel injector pump

Fuel system

W 07-06-01

Check start of injection

Fuel system

W 07-06-03

Determining the thickness of the shim

Fuel system

W 07-07-01

Removing and installing the fuel injectors

Fuel system

W 07-07-02

Checking fuel injectors

Fuel system

W 07-10-06

Removing and installing fuel pipes

Fuel system

W 07-10-08

Removing and installing the lifting magnet (charge air pressure-dependent full load stop)

Fuel system

W 07-10-08

Installing and removing charge air pressure-depenFuel system dent full load stop

W 07-10-08

Removing and installing the fuel filter console

Fuel system

W 07-11-01

Removing and installing the fuel supply pump

Fuel system

W 08-04-05

Removing and installing the lubricating oil pump

Lube oil system

W 08-04-06

Removing and installing the oil suction pipe

Lube oil system

W 08-04-07

Removing and installing the lubricating oil pan (meLube oil system tal sheet lubricating oil pan)

W 08-08-02

Removing and installing the lubricating oil cooler

© 12/2008

10/12

Exhaust system/Charging

Lube oil system

17766-001

D 2011 w TD 2011 w, TCD 2011 w

Job card overview Sorted numerically

Job card

Activity

Maintenance group

W 08-11-02

Removing and installing the oil pressure regulating valve

Lube oil system

W 08-11-07

Removing and installing the oil filter console

Lube oil system

W 08-11-08

Removing and installing the oil pressure switch

Lube oil system

W 08-11-12

Removing and installing the thermostat (Lubricating Lube oil system oil cooler)

W 08-16-01

Removing and installing the control line

Lube oil system

W 09-07-08

Removing and installing the coolant pump

Cooling system

W 09-08-01

Checking the thermostat (in the removed state)

Cooling system

W 09-08-02

Removing and installing the thermostat

Cooling system

W 09-08-04

Removing and installing the thermostat housing

Cooling system

W 09-12-01

Removing and installing temperature transmitter

Cooling system

W 11-00-03

Removing and installing the lifting magnet (Engine shutdown)

Monitoring system

W 12-01-04

Removing and installing the V-belt pulley

Other components

W 12-02-01

Renew V-belts, check V-belt tension

Other components

W 12-06-01

Removing and installing the flywheel

Other components

W 12-06-03

Renewing toothed starter ring on the flywheel

Other components

W 12-08-02

Removing and installing the hydraulic pump

Other components

W 12-08-03

Renew toothed belt and tensioning pulley (Hydraulic Other components pump)

W 13-02-03

Removing and installing the generator

Electrical system

W 13-03-02

Removing and installing the starter

Electrical system

W 13-06-01

Removing and installing the heating plugs

Electrical system

W 13-06-02

Removing and installing the glow plug

Electrical system

© 12/2008

11/12

5

17766-001

Job card overview Sorted numerically

D 2011 w TD 2011 w, TCD 2011 w

5

© 12/2008

12/12

17766-001

DEUTZ engines

6

© 11/2005

Job cards

Job cards

6

1/2

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Job cards

DEUTZ engines

6

© 11/2005

2/2

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D 2011 w TD 2011 w, TCD 2011 w

General W 00-02-06

Checking the compression pressure Commercial available tools: – Compression pressure tester. . . . . . . . . . . . . . . . . . . . . . . . 8005

– W 01-01-01 – W 07-07-01

Special tools: – Connector . . . . . . . . . . . . . . . . . . 100120

Attention! Pay attention to utmost cleanliness when working on the fuel system. Remove residue paint and particles of dirt before removing. Clean the respective affected parts carefully. Blow damp areas dry with compressed air. Observe the safety regulations and national specifications for handling fuels. Close all connections immediately after opening with new, clean plugs/caps. Do not remove plugs/caps until immediately before assembling. Collect leaking operating substances in suitable vessels and dispose of according to regulations. After all work on the fuel system, it must be bleeded - see the operation manual, chapter "6 Fuel system“.

Checking the compression pressure z Set valve clearance.  W 01-01-01 z Removing fuel injectors.  W 07-07-01 2

z Mount sealing ring (1). Use sealing ring (1) for fuel injector.

1

z Insert connector (2).

© 47534-0

© 12/2008

1/6

17768-001

6

General W 00-02-06

D 2011 w TD 2011 w, TCD 2011 w

z Mount clamping shoe (1). z Tighten screw (2).  21 Nm

1

2

6 © 47535-0

z Connect adapter (1) to connector. 1

© 47536-0

z Mount the compression tester on the adapter. z Turn over engine with starter.  25 - 30 bar (2500 - 3000 kPa)

© 46308-0

© 12/2008

2/6

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D 2011 w TD 2011 w, TCD 2011 w

No. Kompression in bar Compression value in bar Pression en bar Dat. _________ 10 15 20 25 30 35 40

Zyl.

The measured compression pressure depends on the starting speed during the measuring process and the altitude of the engine installation site. Therefore, limit values cannot be determined exactly. The compression pressure measurement is only recommended as a reference measurement of all cylinders of an engine to each other. If more than 15% deviation has been determined, the cause should be determined by disassembling the cylinder unit concerned.

General W 00-02-06

1 2 3 4 5 6 7 8 DBGM

Made in Germany

6

MOTOMETER © 45103-0

z Remove the compression pressure tester.

© 47537-0

z Remove the compression pressure tester and adapter (1).

1

© 47536-0

© 12/2008

3/6

17768-001

General W 00-02-06

D 2011 w TD 2011 w, TCD 2011 w

z Unscrew screw (1).

1

6 © 47535-1

z Remove connector (1). z Remove sealing ring. z Install fuel injectors.  W 07-07-01

1

© 47534-1

© 12/2008

4/6

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D 2011 w TD 2011 w, TCD 2011 w

General W 00-02-06

Technical Data Testing and setting data ID no.

Name

P00 51

Compression pressure

Additional information

Value 25 - 30 bar (2500 - 3000 kPa)

Tightening specifications ID no. Name A07 001 Fuel injector on cylinder head

Screw type

Notes / Remark

Value 21 Nm

For the tightening procedure according to torque using a torque wrench, a maximum variation of the tightening torque of +/- 10% is permissible.

6

© 12/2008

5/6

17768-001

General W 00-02-06

D 2011 w TD 2011 w, TCD 2011 w

6

© 12/2008

6/6

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D 2011 w TD 2011w, TCD 2011 w

General W 00-05-01

Mounting engine on assembly block and demounting Commercial available tools: – Lifting gear – Suspension ropes – Eyelet bolts

– W 13-03-02

Special tools: – Assembly block. . . . . . . . . . . . . . . . 6067 – Supporting bracket . . . . . . . . . .6067/114 – Clamping bracket . . . . . . . . . . .6067/115

When using hoists (workshop crane) the safety regulations for handling hoists must be observed. It is not permitted to stay under moving loads.

Danger!

Different customer scopes are not taken into account in the repair sequence shown here, accessories which deviate from the standard equipment are not shown.

Mounting engine on assembly block z Remove starter.  W 13-03-02

1

z Screw in eyelet bolts (1).

1

© 47538-0

z Hang engine on workshop crane.  approx. 268 kg

© 47539-0

© 12/2008

1/6

17769-001

6

General W 00-05-01

D 2011 w TD 2011w, TCD 2011 w

z Unscrew screws (1). z Remove all mounting feet. – TD 2011 w, TCD 2011 w z Unscrew screw (2). z Remove holder (3). z Remove oil return pipe (4).

4

3 1

6

2 © 47532-3

z Mount clamping holder (1). z Tighten screws (2).  90 Nm

1

2

© 47009-0

z Align engine on engine block. z Mount retainer plate (1). z Tighten screws (2) and lock nuts.  90 Nm 1

2

© 47577-0

© 12/2008

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D 2011 w TD 2011w, TCD 2011 w

General W 00-05-01

z Unhook the engine from the workshop crane. z Unscrew eyelet bolts (1). 1

1

6 © 47538-0

Demounting engine from assembly block z Screw in eyelet bolts (1). z Hang engine on workshop crane.

1

1

 approx. 268 kg

© 47538-0

z Loosen lock nuts. z Unscrew screws (2). z Remove retainer plate (1).

1

2

© 47577-0

© 12/2008

3/6

17769-001

General W 00-05-01

D 2011 w TD 2011w, TCD 2011 w

Danger! Lower engine with workshop crane. z Unscrew screws (2). z Remove clamping bracket (1).

1

2

6 © 47009-0

– TD 2011 w, TCD 2011 w z Insert new O-ring (1). z Lightly oil new O-ring (1).

1

© 39378-2

– TD 2011 w, TCD 2011 w z Mount oil return pipe (1).

Attention! Install tension-free. z Mount holder (2).

1

z Tighten screw (3).  8.5 Nm – D 2011 w, TD 2011 w, TCD 2011 w z Install all mounting feet.

2

z Tighten screws (4).

4

 200 Nm

3 © 47532-4

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General W 00-05-01

Danger! Put the engine down on a secure surface. z Unhook the engine from the workshop crane.

1

z Unscrew eyelet bolts (1).

1

z Install starter.  W 13-03-02

6 © 47538-0

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General W 00-05-01

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Technical Data Testing and setting data ID no. P00 04

Name Additional information Engine weight according to DIN 70020-A

Value approx. 268 kg

Tightening specifications

6

ID no. Name A00 001 Clamping bracket on crankcase Clamping bracket on adapter for A00 002 assembly block Mounting foot/engine mounting on A00 003 crankcase TD 2011 w, TCD 2011 w A08 049 Holder oil return line on crankcase

Screw type

Notes / Remark

Value 90 Nm 90 Nm

M14x55-12.9 M14x100-12.9

200 Nm

Torx, M6x14-8.8

8.5 Nm

For the tightening procedure according to torque using a torque wrench, a maximum variation of the tightening torque of +/- 10% is permissible.

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Cylinder head W 01-01-01

Setting valve clearance Commercial available tools: – Feeler gauges

Attention! In case of internal exhaust gas recirculation, the inlet valve is opened briefly by an additional cam on the camshaft. This is not to be confused with the valve overlap. Allow the engine to cool down for at least 30 minutes before setting the valve clearance. Engine oil temperature < 80 °C The following work procedure describes the setting of the valve clearance on an inlet valve. The procedure is the same for the setting on an outlet valve, taking into consideration the setting dimension.

z Unscrew all screws (1). z Remove cylinder head cowling (2). z Remove gasket. 1

2

© 47540-0

Setting engine to valve overlap z Turn crankshaft in the direction of the engine (arrow). z Turn over crankshaft until the valve overlap is achieved on cylinder 1.

© 47541-0

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Arrangement of the inlet and exhaust valves. IN = inlet valve EX = exhaust valve Valve overlap means: The inlet valve starts opening,exhaust valve closes.

Attention! In case of internal exhaust gas recirculation, the inlet valve is opened briefly by an additional cam on the camshaft. This is not to be confused with the valve overlap.

EX

EX

IN

6 © 47542-0

z Select feeler gauge. z Check the setting on the appropriate valve. The feeler gauge must pass between the rocker arm's sliding surface and the valve without too much resistance.

© 47543-0

Setting valve clearance z Loosen lock nut (1). z Hold adjusting screw (2). z Set valve clearance. If there is not enough valve clearance, unscrew setting screw (2). If there is too much valve clearance, turn in setting screw (2). – Inlet

2

1

 0.3 mm – Outlet  0.5 mm © 47544-0

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z Check the valve clearance with feeler gauge (1).

1

6 © 47543-1

z Hold adjusting screw (2). z Tighten lock nut (1).  20 Nm Do not turn the setting screw when tightening the locking nut.

2

1

© 47544-0

z Check the valve clearance again with feeler gauge.

© 47543-0

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Valve clearance setting schematic According to the order given below, the setting of the valve clearance is possible in two turns of the crankshaft (each 360°).

Crankshaft position 1 z Turn over crankshaft until the valve overlap is achieved on cylinder 1. z Set black marked valves.

6 Crankshaft position 2 © 25894-5

z Turn the crankshaft one turn (360°). z Set black marked valves.

z Clean sealing surfaces. z Mount new gasket. Note installation position: The bar (1) must face the front cover. 1

© 47567-0

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z Mount cylinder head cover. z Oil the screws lightly. z Tighten all screws (1) alternately.

1

 8.5 Nm

6 © 47540-1

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Technical Data Testing and setting data ID no. P00 71 P01 61 P01 62

Name Ignition sequence Valve clearance (inlet) Valve clearance (outlet)

Additional information

Value 1-3-4-2 0.3 mm 0.5 mm

Tightening specifications ID no. Name Screw type A01 003 Locking nut, valve adjuster A01 004 Cylinder head cover on cylinder head

6

Notes / Remark

Value 20 Nm 8.5 Nm

For the tightening procedure according to torque using a torque wrench, a maximum variation of the tightening torque of +/- 10% is permissible.

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Cylinder head W 01-02-02

Removing and installing the rocker arm and rocker arm bracket Commercial available tools: – Torx tool set . . . . . . . . . . . . . . . . . . 8189

– W 01-01-01

6

Removing the rocker arm and rocker arm bracket z Unscrew all screws (1). z Remove cylinder head cowling (2). z Remove gasket.

1

2

© 47540-0

z Unscrew screws (1). Loosen screws evenly to avoid tension on the rocker arm brackets. 1

z Remove rocker arm bracket (2). Lay out components in the order in which they should be installed. Note order of cylinders.

2

© 47544-1

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z Remove push rods (1). Lay out components in the order in which they should be installed. z Visually inspect the components.

1

6

1 © 47565-0

Installing the rocker arm and rocker arm bracket z Insert stop rods (1). Note the assignment of the stop rods. The stop rod must be seated with the ball head in the ladle of the tappet.

1

1 © 47565-0

z Loosen lock nut (1). z Unscrew setting screws (2). z Mount rocker arm bracket (3). z Position rocker arm.

3

The ball heads (4) must be seated in the ladles of the stop rods. The rocker arm (arrow) must sit on the valve stem. 1 2 4

© 47591-0

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z Lightly oil screws (1). z Tighten screws .  21 Nm

Attention! Makes sure that the stop rods are not under stress due to valve overlap when fastening the screws. z Set valve clearance.  W 01-01-01 1

6 © 47566-0

z Clean sealing surfaces. z Mount new gasket. Note installation position: The bar (1) must face the front cover. 1

© 47567-0

z Mount cylinder head cover. z Oil the screws lightly. z Tighten all screws (1) alternately.

1

 8.5 Nm

© 47540-1

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Technical Data Tightening specifications ID no. Name Screw type A01 002 Rocker arm bracket on cylinder head A01 004 Cylinder head cover on cylinder head

Notes / Remark

Value 21 Nm 8.5 Nm

For the tightening procedure according to torque using a torque wrench, a maximum variation of the tightening torque of +/- 10% is permissible.

6

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Cylinder head W 01-02-06

Disassembling, assembling and checking the rocker arm and rocker arm bracket Commercial available tools: – Internal measuring device – Micrometer gauge – Locking ring pliers

– W 01-02-02

Special tools: – Dial gauge. . . . . . . . . . . . . . . . . . 100400

6

Disassembling the rocker arm bracket 1

z Remove rocker arm and rocker arm bracket.  W 01-02-02 z Remove locking ring (1). 1

© 39144-1

z Remove rocker arm. Lay out components in the order in which they should be installed.

© 39145-1

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z Hold adjusting screw (2).

2

z Loosen lock nut (1). z Unscrew adjusting screw (2).

1

Lay out components in the order in which they should be installed.

6 © 47031-0

z Visually inspect the components. z Check oil channels (arrows) for free passage.

© 39147-1

z Screw in setting screw (1). z Screw in locking nut (2).

1 2

© 47031-1

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Checking the rocker arm z Prepare internal measuring device: – Mount probe bolt for the appropriate measuring range in the internal measuring device. – Mount dial gauge with approx. 1 mm pre-tension in the internal measuring device. – Set micrometer gauge to 18 mm. – Balance the internal measuring device between the test surfaces of the micrometer gauge and set the dial gauge at the reversal point of the pointer to "0".

6 © 34768-2

z Insert internal measuring device. z Measure rocker arm bore. – Outlet  18 +0.27 mm – Inlet  18 +0.27 mm When the wear limit is reached the rocker arm must be renewed.

© 39032-1

Checking the rocker arm pin z Measure diameter with micrometer gauge. +0.01

 17,97 −0.01 mm When the wear limit is reached the rocker arm bracket must be replaced.

© 39148-1

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Assembling the rocker arm bracket z Lightly oil the rocker arm pin. z Push rocker arm (1) onto rocker arm pin.

1

6 © 39149-2

z Insert new locking rings (1). Ensure that the installation location is free from faults.

1

z Install rocker arm and rocker arm bracket.  W 01-02-02

1 © 39150-1

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Technical Data Testing and setting data ID no.

Name

P01 72

Rocker arm, bore, diameter (outlet)

Additional information

Value 18

+0.27

mm

+0.27

mm

P01 73

Rocker arm, bore, diameter (inlet)

18

P01 74

Rocker arm pin, diameter

+0.01 17,97 −0.01

mm

6

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6

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Cylinder head W 01-04-04

Removing and installing cylinder head Commercial available tools: – Socket wrench insert Torx E18 . . . . . . . . . . . . . . . . . . . . . . . . . 8116 – Dog wrench. . . . . . . . . . . . . . . . . . . 8018 – Rotation angle disc . . . . . . . . . . . . . 8190 Special tools: – Plugs/caps . . . . . . . . . . . . . . . . . 170160

– W 01-02-02 – W 01-04-09 – W 06-02-03 . . . . . . . . . . . . TD 2011 w, TCD 2011 w – W 06-07-03 . . . . . . . . . . . . D 2011 w – W 06-09-08 . . . . . . . . . . . . TD 2011 w, TCD 2011 w – W 09-08-04

Attention! Pay attention to utmost cleanliness when working on the fuel system. Remove residue paint and particles of dirt before removing. Clean the respective affected parts carefully. Blow damp areas dry with compressed air. Observe the safety regulations and national specifications for handling fuels. Close all connections immediately after opening with new, clean plugs/caps. Do not remove plugs/caps until immediately before assembling. Collect leaking operating substances in suitable vessels and dispose of according to regulations. After all work on the fuel system, it must be bleeded - see the operation manual, chapter "6 Fuel system“.

Removing the cylinder head z Unscrew screws (1).

1

© 47551-1

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z Unscrew lock nuts (1) with dog wrench. z Remove thermostat housing.  W 09-08-04 – D 2011 w z Remove the air intake pipe.

1

 W 06-07-03 – TD 2011 w, TCD 2011 w z Remove the charge air pipe.  W 06-02-03

1

z Remove exhaust gas collection pipe.  W 06-09-08

6 © 47550-0

z Remove rocker arm and rocker arm bracket.  W 01-02-02 z Remove push rods (1). Lay out components in the order in which they should be installed. Note order of cylinders.

1

1

© 47547-0

z Unscrew all screws (1) with the socket wrench insert. z Remove cylinder head. z Remove gasket.

1

z Visually inspect the components.

© 47548-0

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Installing the cylinder head Measure the piston overhang on all pistons. Select cylinder head gasket according to the largest piston projection measured. z Check piston overhang.  W 01-04-09

6 © 47552-0

z Select cylinder head gasket according to the largest piston projection measured. – 1 recess  0.325 - 0.604 mm – 2 recesses  0.605 - 0.704 mm – 3 recesses  0.705 - 0.804 mm Example:Piston overhang = 0.7 mm, corresponds to cylinder head gasket with 2 recesses (arrow).

© 47552-1

– Recess cylinder head z Select cylinder head gasket according to the largest piston projection measured. – 1 recess  9.820 - 10.140 mm – 2 recesses  10.141 - 10.239 mm – 3 recesses  10.240 - 10.310 mm Example:Piston overhang = 10.150 mm, corresponds to cylinder head gasket with 2 recesses (arrow). z Remove the measuring device and holders. © 47552-1

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z Clean sealing surfaces. The sealing surfaces for the cylinder head gasket must be clean and free of oil.

1

Make sure the clamping bushings (1) are in place.

1

6 © 47549-0

z Fit a new cylinder head gasket. Label OBEN / TOP facing the cylinder head. 1

© 47549-1

z Fit cylinder head. z Oil the cylinder head screws slightly.

Attention!

1

Screws can be reused a maximum 3 times with written documentation. z Fasten all screws (1).

© 47548-0

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z Tighten cylinder head screws with socket wrench insert according to the tightening sequence. – Stage 1:  30 Nm – Stage 2:  80 Nm

8

6

4

5

9

10

3

1

2

7

– Stage 3:  160 Nm – Stage 4:  90°

6 © 39154-2

z Insert stop rods (1). z Install rocker arm and rocker arm bracket.  W 01-02-02 – D 2011 w z Install the air intake pipe.  W 06-07-03 – TD 2011 w, TCD 2011 w z Install the charge air pipe.  W 06-02-03 1

1

© 47547-0

z Install exhaust gas collection pipe.  W 06-09-08 z Install thermostat housing.  W 09-08-04 1

z Mount new injection lines (1).

1

z Tighten union nuts (2) with claw spanner.  25 Nm

2

© 47550-1

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z Position clamping claws (1).

Attention! Install tension-free.

2

z Tighten screws (2).  21 Nm

1

6 © 47551-0

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Technical Data Testing and setting data ID no.

Name

P02 75

Piston overhang

P02 76

Piston overhang

P02 77

Piston overhang

Additional information Identification, cylinder head gasket = 1 recess Identification, cylinder head gasket = 2 recesses Identification, cylinder head gasket = 3 recesses

Value 0.325 - 0.604 mm 0.605 - 0.704 mm 0.705 - 0.804 mm

Recess cylinder head P02 75

Piston overhang

P02 76

Piston overhang

P02 77

Piston overhang

Identification, cylinder head gasket 9.820 - 10.140 mm = 1 recess Identification, cylinder head gasket 10.141 - 10.239 mm = 2 recesses Identification, cylinder head gasket 10.240 - 10.310 mm = 3 recesses

Tightening specifications ID no.

Name

Screw type

A01 001 Cylinder head on crankcase

A01 001 Cylinder head on crankcase A01 001 Cylinder head on crankcase A01 001 Cylinder head on crankcase Injection line on fuel injector / injection A07 003 M12x1.5 pump A09 020 Pipe clip on holder M6x16

Notes / Remark Stage 1: Cylinder head screws can be used a maximum of 3x with written documentation. Otherwise use new cylinder head screws. Observe tightening sequence. Stage 2 Stage 3 Stage 4

Value

30 Nm

80 Nm 160 Nm 90° 25 Nm 21 Nm

For the tightening procedure according to torque using a torque wrench, a maximum variation of the tightening torque of +/- 10% is permissible.

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Cylinder head W 01-04-04

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6

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Checking piston overhang Commercial available tools

8190

– W 01-04-04

Special tools: – Dial gauge. . . . . . . . . . . . . . . . . . 100400 – Digital dial gauge . . . . . . . . . . . . 100410 – Measuring device . . . . . . . . . . . . 100750 – Holder . . . . . . . . . . . . . . . . . . . . . 150180

6

Checking piston overhang z Remove cylinder head.  W 01-04-04 z Turn the crankshaft until the respective piston is just in front of the top dead centre (arrow).

© 39156-2

z Insert dial gauge 100400 in measuring beam. z Place spacing washers (1) on the sealing surface of the crankcase. z Place measuring beam (2) on the spacing washers. z Apply stylus of the dial gauge to the crankcase sealing surface with pre-tension (arrow).

2

z Adjust dial gauge to "0".

1

1

© 39158-2

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– Recess cylinder head z Insert dial gauge 100410 in measuring beam. z Place holders (1) on the sealing surface of the crankcase. z Place measuring beam (2) on the holders. z Apply stylus of the dial gauge to the crankcase sealing surface with pre-tension (arrow). z Adjust dial gauge to "0".

2

6

1

1 © 46933-0

z Measure at the points (1) and (2) on the piston.

1

Schematic representation

2 © 34151-2

z Move the measuring beam. z Apply the stylus to the piston base (arrow) under pretension. z Continue turning the crankshaft evenly until the reversal point of the pointer on the dial gauge is reached. The stylus may not be positioned on the labelling of the piston. Note greatest measured value.

© 39159-1

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– Recess cylinder head z Move the measuring beam. z Apply the stylus to the piston base (arrow) under pretension. z Continue turning the crankshaft evenly until the reversal point of the pointer on the dial gauge is reached. The stylus may not be positioned on the labelling of the piston. Note greatest measured value.

6 © 46934-0

z Select cylinder head gasket according to the largest piston projection measured. – 1 recess  0.325 - 0.604 mm – 2 recesses  0.605 - 0.704 mm – 3 recesses  0.705 - 0.804 mm Example:Piston overhang = 0.7 mm, corresponds to cylinder head gasket with 2 recesses (arrow). z Remove the measuring device and spacer discs. z Install cylinder head.

© 47552-1

 W 01-04-04

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– Recess cylinder head z Select cylinder head gasket according to the largest piston projection measured. – 1 recess  9.820 - 10.140 mm – 2 recesses  10.141 - 10.239 mm – 3 recesses  10.240 - 10.310 mm

6

Example:Piston overhang = 10.150 mm, corresponds to cylinder head gasket with 2 recesses (arrow). z Remove the measuring device and holders. © 47552-1

z Install cylinder head.  W 01-04-04

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Technical Data Testing and setting data ID no.

Name

Additional information Identification, cylinder head gasket P02 75 Piston overhang = 1 recess Identification, cylinder head gasket P02 76 Piston overhang = 2 recesses Identification, cylinder head gasket P02 77 Piston overhang = 3 recesses D 2011 w / TD 2011 w / TCD 2011 w Recess cylinder head Identification, cylinder head gasket P02 75 Piston overhang = 1 recess Identification, cylinder head gasket P02 76 Piston overhang = 2 recesses Identification, cylinder head gasket P02 77 Piston overhang = 3 recesses

Value 0.325 - 0.604 mm 0.605 - 0.704 mm 0.705 - 0.804 mm

9.820 - 10.140 mm 10.141 - 10.239 mm 10.240 - 10.310 mm

For the tightening procedure according to torque using a torque wrench, a maximum variation of the tightening torque of +/- 10% is permissible.

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Cylinder head W 01-04-09

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6

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Cylinder head W 01-05-01

Removing and installing the valves Commercial available tools: – Slide gauge – Assembly pliers. . . . . . . . . . . . . . . . 8024 – Assembly lever . . . . . . . . . . . . . . . . 9017

– W 01-04-04

Special tools: – Support bracket . . . . . . . . . . . . . 120900 – Base plate. . . . . . . . . . . . . . . . . . 120910 – Assembly tool . . . . . . . . . . . . . . . 121410 – Assembly sleeves . . . . . . . . . . . . 121420

6

Removing the valves z Remove cylinder head.

1

 W 01-04-04 z Mount support bracket (1) on base plate (2). z Mount cylinder head on support bracket.

2 © 39164-1

z Install assembly lever (1). z Press down valve spring with assembly lever. z Remove both tapper collets (2).

1

z Remove valve spring plates, valve springs and valves. z Remove assembly lever. Lay out components in the order in which they should be installed.

2 © 39165-1

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z Remove valve shaft seal with assembly pliers.

6 © 39166-1

z Clean cylinder head. z Check cylinder head. z Visually inspect the components.

© 39167-1

Installing the valves z Measure valve spring length with slide gauge.  39.3 mm When the wear limit is reached, the valve spring must be renewed.

© 35856-2

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z Oil the valve stem lightly. z Insert and hold valve. z Push assembly sleeve (1) over the valve V-grooves.

1

6 © 33889-2

z Push new valve stem seal onto valve guide over the assembly sleeve with assembly tool (1). 1

© 47055-0

z Remove assembly sleeve (1).

1

© 33889-2

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z Insert valve spring (1). z Insert valve spring plate (2).

2

1

6 © 39169-1

z Mount assembly lever. z Press down the valve spring with the assembly lever and insert both tapper collets (1). Make sure the tapper collets fit correctly in the valve keyway.

1

© 39170-1

z Remove assembly lever. z Remove cylinder head from support bracket. z Install cylinder head.  W 01-04-04

© 39171-1

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Technical Data Testing and setting data ID no. P01 51

Name Valve spring, length (untensioned)

Additional information Standard

Value 39.3 mm

6

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6

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Cylinder head W 01-05-04

Checking the valves Commercial available tools: – Micrometer gauge – Slide gauge

– W 01-05-01

Clean valves before testing. When the wear limit is reached, the valve must be renewed.

6

Checking valve stem diameter z Remove valves.  W 01-05-01 z Measure valve stem diameter with micrometer gauge. – Inlet valve  7.98 −0.015 mm – Exhaust valve  7.96 −0.015 mm

© 42182-1

Checking valve edge thickness z Measure valve edge thickness with slide gauge. – Inlet valve +0.05

 2.6 −0.1 mm – Exhaust valve +0.05

 2.8 −0.1 mm

© 42183-1

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Checking valve head diameter z Measure valve head diameter with slide gauge. – Inlet valve  41.5 +0.1 −0.1 mm – Exhaust valve  35.4 +0.1 −0.1 mm z Install valves.  W 01-05-01

6 © 42184-1

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Technical Data Testing and setting data ID no.

Name

Additional information

Value

P01 31

Valve stem, diameter (inlet)

7.98 −0.015 mm

P01 32

Valve stem, diameter (outlet)

7.96 −0.015 mm

P01 35

Valve edge thickness (inlet)

2.6 −0.1 mm

P01 36

Valve edge thickness (outlet)

2.8 −0.1 mm

P01 37

Valve plate, diameter (inlet)

41.5 −0.1 mm

P01 38

Valve plate, diameter (outlet)

35.4 −0.1 mm

+0.05 +0.05

+0.1 +0.1

6

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Cylinder head W 01-06-03

Checking the valve guide Commercial available tools: – Magnetic measuring stand

– W 01-05-01

Special tools: – Dial gauge. . . . . . . . . . . . . . . . . . 100400

New valves are used for testing. When the wear limit is reached, the valve guide must be renewed.

6

Checking the valve guide z Remove valves.  W 01-05-01

© 39167-1

Measure valve stem clearance z Mount magnetic measuring stand. z Insert dial gauge. z Insert new valve. z Place stylus under pre-tension on the valve head (arrow). z Adjust meter to "0".

© 47061-1

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z Move valve back and forth in direction of arrow. The valve stem ends must be flush with the valve guide. The whole tilt distance must be taken into account. – Inlet  0.045 - 0.075 mm – Outlet  0.065 - 0.095 mm

6 © 47062-1

z Remove magnetic measuring stand. z Remove dial gauge. z Install valves.  W 01-05-01

© 47556-0

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Cylinder head W 01-06-03

Technical Data Testing and setting data ID no. P01 33 P01 34

Name Valve stem clearance (inlet) Valve stem clearance (outlet)

Additional information

Value 0.045 - 0.075 mm 0.065 - 0.095 mm

6

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6

© 12/2008

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Cylinder head W 01-07-08

Checking the valve lag Commercial available tools: – Depth-measuring appliance

Attention! When the wear limit is reached, the valve seat insert and/or valve must be renewed.

6

Checking the valve lag z Measure the valve lag from the centre of the valve head to the cylinder head sealing surface. – Inlet  1.53 mm – Outlet  1.53 mm

© 39175-1

©12/2008

1/2

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Cylinder head W 01-07-08

D 2011 w TD 2011 w, TCD 2011 w

Technical Data Testing and setting data ID no. P01 45 P01 46

Name Valve lag dimension (inlet) Valve lag dimension (outlet)

Additional information Wear limit Wear limit

Value 1.53 mm 1.53 mm

6

©12/2008

2/2

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Drive system W 02-01-04

Checking the axial clearance of the crankshaft Commercial available tools: – Magnetic measuring stand – Micrometer gauge – Internal measuring device – Prisms

– W 02-04-01 – W 03-08-01 – W 03-09-01

Special tools: – Dial gauge. . . . . . . . . . . . . . . . . . 100400

6

Check axial clearance (crankshaft removed) z Remove crankshaft.  W 02-04-01 z Place crankshaft on prism.

© 47067-0

z Set micrometer gauge to 30 mm. z Push the internal measuring device between the test surfaces of the micrometer gauge and set to "0".

© 35825-2

© 12/2008

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Drive system W 02-01-04

D 2011 w TD 2011 w, TCD 2011 w

z Measure locating bearing width – Standard +0.04

 35 +0

mm

– 1. Overmeasure  35.44 mm z Note measured value, dimension (a).

6 © 41389-3

z Place thrust ring halves on bearing caps (arrows). z Measure width with micrometer gauge. z Note measured value, dimension (b). z Determine axial backlash. Calculation example Desired: Axial backlash Given: Measured: (a) = 35,00 mm (b) = 34,80 mm Calculation: Axial backlash = dimension (a) - dimension (b) 35,00 mm - 34,80 mm Result: = 0,2 mm

– Nominal value:  0.100 - 0.273 mm © 35827-2

With deviating axial backlash: Correct axial clearance by changing the thrust ring halves. z Measure the wall thickness of the thrust ring halves. – Standard +0.05

 2,4 +0

mm

– 1. Overmeasure +0.05

 2,6 +0

mm

© 43504-0

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Drive system W 02-01-04

z Install crankshaft.  W 02-04-01

6 © 47499-0

Check axial clearance (crankshaft installed) z Remove front cover.  W 03-08-01 z Remove rear cover.  W 03-09-01

© 47499-0

z Mount magnetic measuring stand. z Insert dial gauge. z Apply stylus to the crankshaft end with pre-tension. z Press crankshaft in direction of arrow. z Turn the dial until the pointer points to "0".

© 47070-0

© 12/2008

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Drive system W 02-01-04

D 2011 w TD 2011 w, TCD 2011 w

z Press crankshaft in direction of arrow. z Read off measured value.  0.100 - 0.273 mm With deviating axial backlash: Correct axial clearance by changing the thrust ring halves.

6 © 47071-0

z Measure the wall thickness of the thrust ring halves. – Standard  2,4 +0.05 mm +0 – 1. Overmeasure  2,6 +0.05 mm +0

© 43504-0

z Remove magnetic measuring stand. z Remove dial gauge. z Install front cover.  W 03-08-01 z Mount rear cover.  W 03-09-01

© 47070-1

© 12/2008

4/6

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Drive system W 02-01-04

Technical Data Testing and setting data ID no.

Name

Additional information

Value

P02 11

Fit bearing pin, width

Standard

35 +0

+0.04

mm

P02 34

Crankshaft, permissible axial clearance

Oversize, wear limit in the installed state

P02 35

Stop ring, wall thickness

Standard

2,4 +0

+0.05

mm

P02 36

Stop ring, wall thickness

Oversize level

+0.05 2,6 +0

mm

P02 13

Fit bearing pin, width

35.44 mm 0.100 - 0.273 mm

6

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6

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Drive system W 02-01-07

Checking the crankshaft Commercial available tools: – Magnetic measuring stand – Micrometer gauge – Internal measuring device – Prisms – Hardness tester

– W 02-04-01

Special tools: – Dial gauge. . . . . . . . . . . . . . . . . . 100400

6

Visual inspection z Remove crankshaft.  W 02-04-01 z Visually inspect the component.

© 41390-0

Checking the bearing pin hardness z Place crankshaft on prism.

1

z Put hardness tester on journal. z Raise stylus (1) and press release (2). Stylus (1) falls down, briefly strikes the surface and jumps up to the measured value.

2

© 43499-0

© 12/2008

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Drive system W 02-01-07

D 2011 w TD 2011 w, TCD 2011 w

z Read off displayed value (arrow) from hardness tester. – Nominal value, at least  58

+0.4

HRc

The measured value is to be converted according to the table of the measuring device.

6 © 43515-0

Checking the diameter of the main bearing pins Diagram for measuring the journals at the points 1 and 2 in the levels a and b.

© 36424-2

z Measure main bearing pin with micrometer gauge. – Standard −0.01

 70 −0.03 mm – Two underdimension steps (value per step)  0.25 mm See schematic diagram for measuring points.

© 41389-0

© 12/2008

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Drive system W 02-01-07

Measuring the fit bearing width z Set the micrometer gauge to 35 mm. z Balance the internal measuring device between the test surfaces of the micrometer gauge and set the dial gauge at the reversal point of the pointer to "0".

6 © 35825-2

z Measure bearing width with internal measuring device between thelay-on surfaces of the thrust rings.  35 +0.04 mm +0 – One underdimension stage  0.4 mm

© 41389-3

Checking the diameter of the lifting journals z Measure lifting journal with micrometer gauge. See schematic diagram for measuring points. −0.01

 58 −0.03 mm – Two underdimension steps (value per step)  0.25 mm

© 41389-1

© 12/2008

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Drive system W 02-01-07

D 2011 w TD 2011 w, TCD 2011 w

Checking the rotation z Mount magnetic measuring stand. z Insert dial gauge. z Apply stylus to the main bearing pin with pre-tension (arrow) and adjust dial gauge to "0". z Turn crankshaft evenly and check rotation.  0.05 mm z Remove magnetic measuring stand. z Remove dial gauge. z Install crankshaft.  W 02-04-01

6 © 41389-2

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Drive system W 02-01-07

Technical Data Testing and setting data ID no.

Name

Additional information

Value

P02 03

Main journal, diameter

Standard

P02 04

Main journal, underdimension stage

two underdimension stages per

70 −0.03 mm 0.25 mm

P02 07

Main journal, surface hardness

P02 08

Main journal, radial run-out

maximum

58 HRc 0.05 mm

P02 11

Fit bearing pin, width

Standard

35 +0

P02 12

Fit bearing pin, width, underdimension stage

one underdimension stage

0.4 mm

P02 22

Lifting journal, diameter

Standard

P02 23

Lifting journal, underdimension stage

two underdimension stages per

58 −0.03 mm 0.25 mm

−0.01

+0.4

+0.04

mm

−0.01

6

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6

© 12/2008

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Drive system W 02-02-02

Renewing the crankshaft sealing ring (flywheel side) Commercial available tools: – Pricker. . . . . . . . . . . . . . . . . . . . . . . 8198 – Assembly lever . . . . . . . . . . . . . . . . 9017

– W 12-06-01

Special tools: – Assembly tool . . . . . . . . . . . . . . . 142680 – Self-tapping screw – Washer

6

Removing the crankshaft sealing ring z Remove flywheel.  W 12-06-01 z Make a hole of approximately 3 mm in the crankshaft sealing ring with a pricker.

Attention! Do not damage the rear cover and crankshaft!

© 47083-0

z Screw in a self-tapping screw (1) with washer.

1

© 47084-0

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Drive system W 02-02-02

D 2011 w TD 2011 w, TCD 2011 w

z Pull out the crankshaft sealing ring with assembly lever. z Visually inspect the crankshaft sealing ring running surface.

6 © 47085-0

Installing the crankshaft sealing ring z Mount guide sleeve (1). z Tighten screws (2). The bores in the guide sleeve must match the threaded holes in the crankshaft flange.

1

2

© 47088-1

z Place the crankshaft sealing ring carefully on the peripheral surface. Do not oil waxed crankshaft sealing rings. The sealing lip faces the crankcase.

© 47089-0

© 12/2008

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Drive system W 02-02-02

z Mount assembly sleeve (1). z Press on the crankshaft sealing ring to the stop. z Plug in the bearing (2). z Screw on nut (3).

2

3

1

6 © 47090-1

z Tighten nut to the stop of the assembly sleeve (1). The installation depth is determined by the assembly tool. 1

z Remove assembly tool. z Install flywheel.  W 12-06-01

© 47091-0

© 12/2008

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Drive system W 02-02-02

D 2011 w TD 2011 w, TCD 2011 w

6

© 12/2008

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Drive system W 02-02-04

Renewing the crankshaft sealing ring (opposite side to flywheel) Commercial available tools: – Pricker. . . . . . . . . . . . . . . . . . . . . . . 8198 – Assembly lever . . . . . . . . . . . . . . . . 9017

– W 04-04-15

Special tools: – Assembly tool . . . . . . . . . . . . . . . 142690 – Self-tapping screw – Washer

6

Removing the crankshaft sealing ring z Remove toothed belt wheel.  W 04-04-15 z Make a hole of approximately 3 mm in the crankshaft sealing ring with a pricker.

Attention! Do not damage the front cover or crankshaft.

© 47098-0

z Screw in a self-tapping screw (1) with washer.

1

© 47099-0

© 12/2008

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Drive system W 02-02-04

D 2011 w TD 2011 w, TCD 2011 w

z Pull out the crankshaft sealing ring with assembly lever. z Visually inspect the crankshaft sealing ring running surface.

6 © 47100-0

z Visually inspect all running surfaces.

© 47101-0

Installing the crankshaft sealing ring z Place new crankshaft sealing ring on assembly tool. Do not oil waxed crankshaft sealing rings. The sealing lip faces the crankcase.

© 47102-0

© 12/2008

2/4

17782-001

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Drive system W 02-02-04

z Mount assembly tool (1). z Tighten screw until it reaches the assembly tool (1). The installation depth is determined by the assembly tool.

1

z Unscrew screw. z Remove assembly tool. z Install toothed belt wheel.  W 04-04-15

6 © 47103-0

© 12/2008

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Drive system W 02-02-04

D 2011 w TD 2011 w, TCD 2011 w

6

© 12/2008

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Drive system W 02-03-01

Checking the con rod Commercial available tools: – Micrometer gauge – Internal measuring device – Con rod test device – Rotation angle disc . . . . . . . . . . . . . 8190

– W 02-09-03

Danger! A mixed installation of the standard con rod with crack con rod is not permissible.

Special tools: – Dial gauge. . . . . . . . . . . . . . . . . . 100400

Attention! The assignment of con rod and big end bearing cover must stay as it is. If con rod and big end bearing cover are assembled the wrong way around, the con rod will be unusable! Do not damage the fracture surfaces of the con rod and big end bearing cover! Only one piston class is allowed for each engine.

z Remove piston and connecting rod.  W 02-09-03 z Remove piston from con rod.

© 41044-1

© 12/2008

1/10

17783-001

6

Drive system W 02-03-01

D 2011 w TD 2011 w, TCD 2011 w

Checking small end bush z Prepare internal measuring device: – Mount probe bolt for the appropriate measuring range in the internal measuring device. – Mount dial gauge with approx. 1 mm pre-tension in the internal measuring device. – Set micrometer gauge to 30 mm. – Balance the internal measuring device between the test surfaces of the micrometer gauge and set the dial gauge at the reversal point of the pointer to "0".

6 © 34768-2

Diagram for measuring the small end bush at the points "a" and "b" in the levels "1" and "2".

© 37239-1

z Insert internal measuring device. z Balance the internal measuring device at the given measuring points and read off the measured value at the reversal point of the pointer. +0.035

 30 +0.025 mm Measuring points see diagram. z Note the measured value, dimension (A). The dimension A is required to determine the piston bolt clearance.

© 41391-0

© 12/2008

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Drive system W 02-03-01

Checking diameter of the piston bolt z Measure piston pin with micrometer gauge.  30 −0.005 mm −0 z Note the measured value, dimension B. The dimension B is required to determine the piston bolt clearance.

6 © 35908-3

Determining piston pin clearance The piston pin clearance is given by the difference between the internal diameter of the small end bush (a) and the piston pin diameter (b).  0.025 - 0.040 mm Calculation example Desired: Piston pin clearance Given: Measured: Internal diameter small end bush (a) (a) = 30.025 mm Diameter piston pin (b) (b) = 29.998 mm Calculation: Dimension (a) - Dimension (b) 30.025 mm - 29.998 mm Result: = 0.027 mm

Checking the con rod bearing bore z Mount big end bearing cap.

Attention! 1

651 9

2

Note the assignment of the big end bearing cap. The identification numbers (1) on the con rod and the big end bearing cap must be identical and opposite to each other when assembled.

265 19

© 41395-1

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Drive system W 02-03-01

D 2011 w TD 2011 w, TCD 2011 w

z Tighten new screws with bihexagonal socket wrench insert and torque wrench. – Stage 1:  30 Nm z Tighten screws with bihexagonal socket wrench insert and rotation angle disc. – Stage 2:  60° – Stage 3:  60°

6 © 41396-1

z Prepare internal measuring device: – Mount probe bolt for the appropriate measuring range in the internal measuring device. – Mount dial gauge with approx. 1 mm pre-tension in the internal measuring device. – Set micrometer gauge to 62 mm. – Balance the internal measuring device between the test surfaces of the micrometer gauge and set the dial gauge at the reversal point of the pointer to "0".

© 36094-1

Diagram for measuring the con rod bearing bore at the points "a" and "b" in the levels "1" and "2".

© 37239-1

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Drive system W 02-03-01

z Insert internal measuring device. z Balance the internal measuring device at the given measuring points and read off the measured value at the reversal point of the pointer. +0.02

 61,6 −0

mm

When the wear limit is reached the con rod must be replaced.

6 © 41392-0

Checking internal diameter of the con rod bearing shells z Unscrew screws (1). z Remove the con rod bearing cover.

1

© 41393-0

z Insert bearing shell in the con rod.

Attention! Note the assignment of the bearing shells. The anti-rotation lock (1) must lock in groove (2).

2

1

2

© 41048-2

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Drive system W 02-03-01

D 2011 w TD 2011 w, TCD 2011 w

z Insert bearing shell in the respective big end bearing cap.

Attention! Note the assignment of the bearing shells. The anti-rotation lock (1) must lock in groove (2).

2

6

1 © 41394-0

z Mount big end bearing cap.

Attention!

19

265

The identification numbers (1) on the connecting rod and the big end bearing cover must be identical and opposite to each other when assembled. 1 19

265

© 41395-0

z Tighten new screws with bihexagonal socket wrench insert and torque wrench. – Stage 1:  30 Nm z Tighten screws with bihexagonal socket wrench insert and rotation angle disc. – Stage 2:  60° – Stage 3:  60°

© 41396-0

© 12/2008

6/10

17783-001

D 2011 w TD 2011 w, TCD 2011 w

Drive system W 02-03-01

z Prepare internal measuring device: – Mount probe bolt for the appropriate measuring range in the internal measuring device. – Mount dial gauge with approx. 1 mm pre-tension in the internal measuring device. – Set micrometer gauge to 58 mm. – Balance the internal measuring device between the test surfaces of the micrometer gauge and set the dial gauge at the reversal point of the pointer to "0".

6 © 36094-1

Diagram for measuring the inside diameter of the con rod bearing shells at the points "a" and "b" in the levels "1" and "2".

© 37239-1

z Insert internal measuring device. z Balance the internal measuring device at the given measuring points and read off the measured value at the reversal point of the pointer. See schematic diagram for measuring points.  57.944 - 58.036 mm z Note measured value, dimension (a). If the measured values deviate slightly, additional measurements must be made with new bearing shells.

© 41397-0

© 12/2008

7/10

17783-001

Drive system W 02-03-01

D 2011 w TD 2011 w, TCD 2011 w

Determine big end bearing clearance The big end bearing clearance is given by the difference between the internal diameter of the big end bearing shell (a) and the lifting journal diameter (b).  0.014 - 0.07 mm

6

Calculation example Desired: Big end bearing clearance Given: Measured: Internal diameter big end bearing shell (a) (a) = 58.020 mm Diameter lifting journal (b) (b) = 57.980 mm Calculation: Dimension (a) - Dimension (b) 58.020 mm - 57.980 mm Result: = 0.040 mm

z Remove screws. z Remove the con rod bearing cover.

© 41396-0

Checking the con rod z Mount connecting rod on test instrument without bearing shells.

A

Attention! Aligning the con rod is not permissible.

B

z Move test fork in direction of arrow. z Check that the con rod is parallel. z Permissible deviation from (A) to (B).  0.03 mm Distance between “A“ and “B“ = 100 mm.

© 30579-1

© 12/2008

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Drive system W 02-03-01

z Move test fork in direction of arrow. z Check the angle of the con rod. z Permissible deviation from (C) to (D).  0.03 mm Distance between “C“ and “D“ = 100 mm

C D

z Assembly pistons and con rod. z Install piston and connecting rod.  W 02-09-03

6 © 30580-1

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Drive system W 02-03-01

D 2011 w TD 2011 w, TCD 2011 w

Technical Data Testing and setting data ID no.

Additional information maximum permissible deviation Parallelism of the con rod with respect to at a distance of 100 mm, the piston bolt vertical maximum permissible deviation Parallelism of the con rod with respect to at a distance of 100 mm, the piston bolt horizontal

Value

P02 43

Small end bush, diameter, inside

P02 52 P02 55

Con rod bearing shells, diameter, inside Con rod, bearing bore, diameter, inside Theoretical clearance between the big end bearing and lifting journal Piston pin, diameter, outside Theoretical clearance between piston pin bush and piston pin

30 +0.025 mm 57.944 - 58.036 mm

P02 41 P02 42

6

P02 56 P02 61 P02 62

Name

Standard, when installed

0.03 mm 0.03 mm +0.035

61,6 +0.02 mm −0 0.014 - 0.07 mm 30 −0.005 mm −0 0.025 - 0.040 mm

Tightening specifications ID no.

Name Big end bearing cover on connecting A02 020 rod Big end bearing cover on connecting A02 020 rod Big end bearing cover on connecting A02 020 rod

Screw type

Notes / Remark Stage 1: Use new screws.

Value 30 Nm

Stage 2:

60°

Stage 3:

60°

For the tightening procedure according to torque using a torque wrench, a maximum variation of the tightening torque of +/- 10% is permissible.

© 12/2008

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Drive system I 02-03-03

Removing and installing small end bush Commercial available tools Special tools: – Disassembly/assembly tool . . . . . . . . . . . . . . . . . .

– W 02-09-03

Attention!

131350

Never hammer out the small end bush!

6

Removing the small end bush z Remove piston and connecting rod.  W 02-09-03 z Position the disassembly/assembly tool. – 131350

© 39411-1

z Insert pressure piece (1). z Mount pressure sleeve (2).

4

The open end faces the con rod.

5

z Insert screw (3).

3

z Mount washer (4). z Turn in nut (5).

2

1

© 39330-2

© 12/2008

1/6

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Drive system I 02-03-03

D 2011 w TD 2011 w, TCD 2011 w

z Hold screw (1). z Tighten nut (2). The small end bush is pushed out of the con rod by tightening the nut.

1

2

Make sure that the tool fits perfectly.

6 © 39331-2

z Remove disassembly/assembly tool. z Remove small end bush. z Visually inspect the components.

© 47161-0

Installing small end bush z Clean the bush bore. The bush bore must be free from grease and dirt.

© 47162-0

© 12/2008

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Drive system I 02-03-03

z Install small end bush. Make sure that the lubricating oil bores (1) are in line. 1

6 © 39332-1

z Insert pressure piece (1). z Mount pressure sleeve (2). The closed end lies flush with the con rod.

1 5

3

z Insert screw (3). z Mount washer (4). z Turn in nut (5). 2

4

© 39333-2

z Hold screw (1). z Tighten nut (2). The small end bush is pushed into the con rod by tightening the nut.

1

Make sure that the tool fits perfectly.

2

© 39334-2

© 12/2008

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Drive system I 02-03-03

D 2011 w TD 2011 w, TCD 2011 w

z Check installation position. The small end bush may not protrude over the surface on any side of the conrod. The lubricating oil bores of the small end bush and the con rod must be in line with each other.

6 © 47164-0

Mechanical machining of the small end bush is necessary after assembly work. z Spindle small end bush to dimension A . +0.035

 30 +0.025 mm

A

© 47490-0

z Install piston and connecting rod.  W 02-09-03

© 47122-0

© 12/2008

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Drive system I 02-03-03

Technical Data Testing and setting data ID no.

Name

Additional information

Value

P02 43

Small end bush, diameter, inside

Standard, when installed

30 +0.025 mm

+0.035

6

© 12/2008

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Drive system I 02-03-03

D 2011 w TD 2011 w, TCD 2011 w

6

© 12/2008

6/6

17784-001

D 2011 w TD 2011 w, TCD 2011 w

Drive system W 02-04-01

Removing and installing the crankshaft Commercial available tools: – Prisms – Bihexagonal socket wrench insert, spanner size 13 – Socket wrench insert, spanner size 22, reinforced . . . . . . . . . . . . . . . . . . . . . . . 8035 – Rotation angle disc . . . . . . . . . . . . . 8190

– W 02-01-04 – W 02-01-07 – W 03-08-01 – W 03-09-01 – W 08-04-06

Attention! When replacing the crankshaft and/or the crankcase, the piston class for each individual cylinder must be re-determined.

Special tools: – Ajustable bolt . . . . . . . . . . . . . . . 100700

6

Removing crankshaft z Remove rear cover.  W 03-09-01 z Remove front cover.  W 03-08-01

1

z Remove oil suction pipe  W 08-04-06 z Unscrew adjustable bolt (1).

© 47271-0

z Tighten screws (1) with the bihexagonal socket wrench insert. z Remove all big end bearing caps (2). 2

Attention! The assignment of con rod and big end bearing cover must stay as it is. If con rod and big end bearing cover are assembled the wrong way around, the con rod will be unusable!

1

Lay out components in the order in which they should be installed. Note order of cylinders.

© 47129-0

© 12/2008

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Drive system W 02-04-01

D 2011 w TD 2011 w, TCD 2011 w

z Remove bearing shell. Note order of cylinders. Lay out components in the order in which they should be installed.

6 © 47155-0

z Unscrew all screws (1) with the socket wrench insert 8035.

1

© 47131-0

z Remove bearing cap (1). z Remove bearing shell. z Remove both thrust ring halves (arrows). z Remove all main bearing covers (2). z Remove bearing shells.

2

Lay out components in the order in which they should be installed.

1

Note order of cylinders.

© 47132-0

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Drive system W 02-04-01

z Press the con rods carefully out of the lifting journal. z Lift out the crankshaft. z Place crankshaft on prism.

6 © 47133-0

z Remove all main bearing shells (1). z Remove all big end bearing shells (2). z Visually inspect the components. Lay out components in the order in which they should be installed. Note order of cylinders.

1

2

© 47134-0

z Check crankshaft.  W 02-01-07 z Check axial backlash of crankshaft (crankshaft removed).  W 02-01-04

© 47067-0

© 12/2008

3/10

17785-001

Drive system W 02-04-01

D 2011 w TD 2011 w, TCD 2011 w

Installing the crankshaft z Insert upper main bearing shells.

Attention! Note the assignment of the bearing shells. The anti-rotation lock (1) must lock in groove (2).

1

2

6 © 47135-0

z Insert lower main bearing shells in the respective main bearing cover.

1

Attention! Note the assignment of the bearing shells. The anti-rotation lock (1) must lock in groove (2).

2

© 37043-2

z Insert bearing shell in the con rod.

Attention! Note the assignment of the bearing shells. The anti-rotation lock (1) must lock in groove (2). 1

2

© 47136-0

© 12/2008

4/10

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Drive system W 02-04-01

z Insert big end bearing shells in the respective big end bearing cap.

Attention! Note the assignment of the bearing shells. The anti-rotation lock (1) must lock in groove (2).

2 1

6 © 47127-0

Make sure the clamping bushings (arrows) are in place.

© 47137-0

z Lightly oil bearing surfaces. z Insert the crankshaft carefully in the crankcase.

Attention! Do not jam the con rods when inserting the crankshaft!

© 47133-0

© 12/2008

5/10

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Drive system W 02-04-01

D 2011 w TD 2011 w, TCD 2011 w

Install thrust ring halves according to measured axial clearance. z Fix both thrust ring halves with a little grease to the bearing cap. Bearing cap with identification “2“. Oil grooves (1) face the crankshaft web face.

1

6

© 47075-0

z Insert bearing cap (1). z Insert main bearing covers (2). Note assignment and installation position: Assignment of the main bearing covers: With identification "1" = flywheel side. 2

Chamfered edge (arrow) faces front cover.

1

© 47138-0

z Oil the screws lightly. z Fasten all screws (1).

Attention! Screws can be used a maximum 3 times with written documentation. 1

© 47131-0

© 12/2008

6/10

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D 2011 w TD 2011 w, TCD 2011 w

Drive system W 02-04-01

z Move the crankshaft axially to and fro. The bearing is aligned in position as a result.

6 © 47154-0

z Unscrew all screws (1) with the socket wrench insert 8035 and tighten with torque wrench. – Stage 1:  50 Nm – Stage 2:  60° z Unscrew all screws (1) with the socket wrench insert 8035 and tighten with rotation angle disc. – Stage 3:  45°

1

Attention! Install tension-free. © 47140-0

z Pull con rods carefully on to the lifting journal.

© 47069-0

© 12/2008

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Drive system W 02-04-01

D 2011 w TD 2011 w, TCD 2011 w

z Mount big end bearing cap.

Attention!

265

Note assignment and installation position: The identification numbers (1) on the connecting rod and the big end bearing cover must be identical and opposite to each other when assembled. Pay attention to utmost cleanliness.

19

1 265 19

6 © 41395-0

z Tighten new screws with bihexagonal socket wrench insert and torque wrench. – Stage 1:  30 Nm z Tighten screws with bihexagonal socket wrench insert and rotation angle disc. – Stage 2:  60° – Stage 3:  60°

© 47142-0

z Check axial backlash of crankshaft (crankshaft installed).  W 02-01-04

© 47092-0

© 12/2008

8/10

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D 2011 w TD 2011 w, TCD 2011 w

Drive system W 02-04-01

z Knock in the adjustable bolt (1) to the stop.

1

6 © 47271-0

z Turn crankshaft in the direction of the engine until it reaches the stop of the adjustable bolt. z Install oil suction pipe.  W 08-04-06 z Mount rear cover.  W 03-09-01 z Install front cover.  W 03-08-01

© 39130-1

© 12/2008

9/10

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Drive system W 02-04-01

D 2011 w TD 2011 w, TCD 2011 w

Technical Data Tightening specifications ID no.

Name

Screw type

A02 010 Main bearing cover on crankcase

6

A02 010 Main bearing cover on crankcase A02 010 Main bearing cover on crankcase Big end bearing cover on connecting A02 020 rod Big end bearing cover on connecting A02 020 rod Big end bearing cover on connecting A02 020 rod

Notes / Remark Stage 1: Screws can be used a maximum of 3x with written documentation. Otherwise use new cylinder head screws. Stage 2: Stage 3: Stage 1: Use new screws.

Value

50 Nm

60° 45° 30 Nm

Stage 2:

60°

Stage 3:

60°

For the tightening procedure according to torque using a torque wrench, a maximum variation of the tightening torque of +/- 10% is permissible.

© 12/2008

10/10

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D 2011 w TD 2011 w, TCD 2011 w

Drive system W 02-09-03

Removing and installing the piston and con rod Commercial available tools: – Bihexagonal socket wrench insert, spanner size 13 – Depth-measuring appliance – Rotation angle disc . . . . . . . . . . . . . 8190

– W 01-04-04 – W 02-09-07 – W 02-10-03 – W 08-04-06

Danger! A mixed installation of the standard con rod with crack con rod is not permissible.

Special tools: – Piston ring clamping band, diameter 96 mm . . . . . . . . . . . . . 130850 – Disassembly tool. . . . . . . . . . . . . 131100

Attention! The assignment of con rod and big end bearing cover must stay as it is. If con rod and big end bearing cover are assembled the wrong way around, the con rod will be unusable! Do not damage the fracture surfaces of the con rod and big end bearing cover! Only one piston class is allowed for each engine. Collect leaking operating substances in suitable vessels and dispose of according to regulations. Lubricating oil and coolant must be filled according to the instructions in the operating manual.

Removing the piston and con rod z Remove cylinder head.  W 01-04-04 z Remove oil suction pipe  W 08-04-06

© 47143-0

© 12/2008

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6

Drive system W 02-09-03

D 2011 w TD 2011 w, TCD 2011 w

z Set lifting journal at bottom dead centre (BDC). z Tighten screws (1) with the bihexagonal socket wrench insert. z Remove all big end bearing caps (2).

Attention! The assignment of con rod and big end bearing cover must stay as it is. If con rod and big end bearing cover are assembled the wrong way around, the con rod will be unusable!

1

2

Lay out components in the order in which they should be installed. Note order of cylinders.

6 © 47144-0

z Remove bearing shell. Note order of cylinders. Lay out components in the order in which they should be installed.

© 47155-0

z Press out the piston and connection rod. Note order of cylinders. Lay out components in the order in which they should be installed.

© 47145-0

© 12/2008

2/10

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Drive system W 02-09-03

z Remove bearing shell. Note order of cylinders. Lay out components in the order in which they should be installed. z Visually inspect the components.

6 © 47146-0

z Insert a suitable tool in the cavity (1). z Remove locking ring (2). Remove locking ring on the opposite side in the same way.

1

2

© 47156-0

z Insert disassembly tool (1).

1

© 47157-0

© 12/2008

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Drive system W 02-09-03

D 2011 w TD 2011 w, TCD 2011 w

z Press out piston bolt (1). z Visually inspect the components. z Check piston.  W 02-09-07 1

6 © 47147-0

Determine piston class z Clean sealing surfaces. z Set lifting journal of each cylinder at top dead centre.

© 39250-1

z Measure the distance from the crankcase sealing surface to the highest point of the lifting journal with the depth gauge. – D 2011 w Piston class A  188.380 - 188.548 mm Piston class B  188.549 - 188.718 mm – TD 2011 w / TCD 2011 w Recess cylinder head Piston class A  188.380 - 188.718 mm – TD 2011 w / TCD 2011 w High crankcase Piston class A © 39251-1

 197.880 - 198.175 mm © 12/2008

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Drive system W 02-09-03

Completing con rod and piston z Select piston in accordance with the determined piston class (1).

Attention! Only one piston class is allowed for each engine. 1

6 © 39249-1

z Insert new locking ring.

X

Ensure that the installation location is free from faults. Ring joint must face piston base.

© 39257-1

z Insert con rod. The flywheel/crankshaft symbol (1) on the piston base must face to the left and the identification number (2) on the con rod must face upwards.

2

6010

z Check installation position of the connecting rods.

1

© 47158-0

© 12/2008

5/10

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Drive system W 02-09-03

D 2011 w TD 2011 w, TCD 2011 w

z Oil the piston bolt lightly. z Press in the piston bolt. z Insert new locking ring. Ensure that the installation location is free from faults. Ring joint must face piston base.

6 © 39260-1

Installing the piston and con rod z Insert bearing shell in the con rod.

Attention! Note the assignment of the bearing shells. The anti-rotation lock (1) must lock in groove (2).

2

1

© 47126-0

z Insert bearing shell in the respective big end bearing cap.

Attention! Note the assignment of the bearing shells. The anti-rotation lock (1) must lock in groove (2).

2 1

© 47127-0

© 12/2008

6/10

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D 2011 w TD 2011 w, TCD 2011 w

Drive system W 02-09-03

z Arrange the piston ring joints with an offset of about 120° to each other. z Check piston rings and piston ring grooves.  W 02-10-03

6 © 36216-1

z Lightly oil cylinder running surface, piston, piston rings and lifting bearing journal lightly. z Clamp piston rings with piston ring compressor (1). Do not turn the piston rings any further.

1 © 39284-1

z Set lifting journal at bottom dead centre (BDC). z Push piston and con rod completely into cylinder. Note the cylinder assignment of the piston. Note the label indicating the installation position on the piston base. The symbol flywheel/crankshaft (1) must face the flywheel. The piston ring clamping band must touch flat on the cylinder.

1

© 39285-1

© 12/2008

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Drive system W 02-09-03

D 2011 w TD 2011 w, TCD 2011 w

z Press the con rod carefully against the lifting journal.

Attention! Do not jam the con rod with the crankshaft.

6 © 47145-0

z Mount big end bearing cap.

Attention! Note assignment and installation position: The identification numbers (1) on the connecting rod and the big end bearing cover must be identical and opposite to each other when assembled. Pay attention to utmost cleanliness. 1

© 47141-0

z Tighten new screws with bihexagonal socket wrench insert and torque wrench. – Stage 1:  30 Nm z Tighten screws with bihexagonal socket wrench insert and rotation angle disc. – Stage 2:  60° – Stage 3:  60°

© 47159-0

© 12/2008

8/10

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D 2011 w TD 2011 w, TCD 2011 w

Drive system W 02-09-03

z Install oil suction pipe.  W 08-04-06 z Install cylinder head.  W 01-04-04

6 © 47143-0

© 12/2008

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Drive system W 02-09-03

D 2011 w TD 2011 w, TCD 2011 w

Technical Data Testing and setting data

6

ID no. Name D 2011 w Distance between crankcase sealing surP02 79 face and lifting journal Distance between crankcase sealing surP02 79 face and lifting journal TD 2011 w / TCD 2011 w Recess cylinder head Distance between crankcase sealing surP02 79 face and lifting journal TD 2011 w / TCD 2011 w High crankcase Distance between crankcase sealing surP02 79 face and lifting journal

Additional information

Value

Piston class A Stroke 125 mm Piston class B Stroke 125 mm

188.380 188.548 mm 188.549 188.718 mm

Piston class A Stroke 125 mm

188.380 188.718 mm

Piston class A Stroke 125 mm

197.880 198.175 mm

Tightening specifications ID no.

Name Big end bearing cover on connecting A02 020 rod Big end bearing cover on connecting A02 020 rod Big end bearing cover on connecting A02 020 rod

Screw type

Notes / Remark Stage 1: Use new screws.

Value 30 Nm

Stage 2:

60°

Stage 3:

60°

For the tightening procedure according to torque using a torque wrench, a maximum variation of the tightening torque of +/- 10% is permissible.

© 12/2008

10/10

17786-001

D 2011 w TD 2011 w, TCD 2011 w

Drive system W 02-09-07

Checking the piston Commercial available tools: – Micrometer gauge – Internal measuring device

– W 02-09-03

Special tools: – Dial gauge. . . . . . . . . . . . . . . . . . 100400

When the piston wear limit is reached, the piston must be renewed.

6

Checking the piston bolt bore z Remove piston from con rod.  W 02-09-03

© 41044-1

z Prepare internal measuring device: – Mount probe bolt for the appropriate measuring range in the internal measuring device. – Mount dial gauge with approx. 1 mm pre-tension in the internal measuring device. – Set micrometer gauge to 30 mm. – Balance the internal measuring device between the test surfaces of the micrometer gauge and set the dial gauge at the reversal point of the pointer to "0".

© 34768-2

© 12/2008

1/4

17787-001

Drive system W 02-09-07

D 2011 w TD 2011 w, TCD 2011 w

Diagram for measuring the piston bolt bore at the points "a" and "b" in the levels "1" and "2".

6 © 37239-1

z Insert internal measuring device in the piston bolt bore. z Balance the internal measuring device at the given measuring points and read off the measured value at the reversal point of the pointer. See schematic diagram for measuring points. +0.014

 30 +0.008 mm

© 43483-0

Checking the piston diameter z Measure piston diameter with micrometer gauge.

© 43427-0

© 12/2008

2/4

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Drive system W 02-09-07

– D 2011 w – Measuring point 1 +0.009

 95.900 −0.009 mm – Measuring point 2 3

 95.830 mm – Measuring point 3

2

+0.015

 95.700 −0.015 mm Measuring point height - see Technical Data.

1

z Assemble con rod and piston.  W 02-09-03

6 © 41154-0

– T 2011 w / TCD 2011 w – Measuring point 1  95.850 +0.009 −0.009 mm – Measuring point 2 3

 95,778 mm – Measuring point 3

2

 95.695 +0.015 −0.015 mm Measuring point height - see Technical Data.

1

z Assemble con rod and piston.  W 02-09-03

© 41154-0

© 12/2008

3/4

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Drive system W 02-09-07

D 2011 w TD 2011 w, TCD 2011 w

Technical Data Testing and setting data ID no. Name D 2011 w

Additional information

Value

P02 71

Piston, diameter, standard

P02 72

Piston, diameter, standard

P02 73

Piston, diameter, standard

Measuring point 1 = height 22 mm 95.900 +0.009 −0.009 mm Measuring point 2 = height 47 mm 95.830 mm Measuring point 3 = height 62.2 +0.015 95.700 −0.015 mm mm

TD 2011 w / TCD 2011 w

6

P02 71

Piston, diameter, standard

P02 72

Piston, diameter, standard

Measuring point 1 = height 20 mm 95.850 +0.009 −0.009 mm Measuring point 2 = height 47 mm 95,778 mm

P02 73

Piston, diameter, standard

Measuring point 3 = height 63 mm 95.695 +0.015 −0.015 mm

D 2011 w / TD 2011 w / TCD 2011 w P02 74 Piston, diameter, overmeasure P02 78

© 12/2008

one overmeasure stage

Piston pin bore

0.5 mm 30 +0.014 +0.008 mm

4/4

17787-001

D 2011 w TD 2011 w, TCD 2011 w

Drive system W 02-10-03

Checking the piston rings and piston ring grooves Commercial available tools: – Feeler gauges

– W 02-09-03

Special tools: – Universal piston ring pliers . . . . . 130300 – Trapezoidal groove wear gauge . . . . . . . . . . . . . . . . . . . . . 130420

6

Checking the piston rings and piston ring grooves z Remove piston from con rod.  W 02-09-03

Attention! Do not overstretch the piston ring! z Only set the universal piston ring pliers to the maximum necessary diameter. z Remove piston rings with universal piston ring pliers.

© 44263-1

z Clean piston. z Visually inspect piston. z Visually inspect piston ring grooves.

© 44264-1

© 12/2008

1/6

17788-001

Drive system W 02-10-03

D 2011 w TD 2011 w, TCD 2011 w

Checking the piston ring joint clearance z Insert the piston ring (1) in the cylinder. z Align the piston ring in the cylinder by pushing the piston. 1

6 © 41388-0

z Measure the piston ring joint clearance with a feeler gauge. – 1. piston ring  0.30 +0.2 +0 mm – 2. piston ring = taper-faced ring  1.5 +0.5 +0 mm – 3. piston ring = bevelland-edge oil control ring  0.30 +0.3 +0 mm When the wear limit is reached, the piston ring must be renewed.

© 41386-1

z Mount the piston rings with the marking "TOP" facing the combustion chamber. Order and position of the piston rings as seen from the piston base:

1

z (1):

2

– 1. piston ring = double keystone ring z (2):

3

– 2. piston ring = taper-faced ring z (3): – 3. piston ring = bevelland-edge oil control ring

© 41154-1

© 12/2008

2/6

17788-001

D 2011 w TD 2011 w, TCD 2011 w

Drive system W 02-10-03

z Measure piston ring groove for first piston ring with trapezoidal groove wear gauge.

6 © 33866-3

If there is a gap "S" between the trapezoidal groove wear gauge and piston, the piston can be used again.

S

© 33867-3

If the trapezoidal groove wear gauge is touching the piston (arrow), the piston must be changed.

© 33868-3

© 12/2008

3/6

17788-001

Drive system W 02-10-03

D 2011 w TD 2011 w, TCD 2011 w

Checking the piston ring axial clearance Check with new piston rings. z Check axial backlash with feeler gauge between piston ring and piston ring groove. – 2. piston ring  0.080 - 0.115 mm – 3. piston ring  0.030 - 0.065 mm When the piston wear limit is reached, the piston must be renewed.

6 © 44269-0

z Assemble con rod and piston.  W 02-09-03

© 41047-0

© 12/2008

4/6

17788-001

D 2011 w TD 2011 w, TCD 2011 w

Drive system W 02-10-03

Technical Data Testing and setting data ID no.

Name

P02 84

Piston ring 1, joint clearance

P02 84

Piston ring 1, joint clearance

P02 85

Piston ring 2, joint clearance

P02 85

Piston ring 2, joint clearance

P02 86

Piston ring 3, joint clearance

P02 86 P02 87 P02 88 P02 89

Piston ring 3, joint clearance Piston ring 1, axial clearance Piston ring 2, axial clearance Piston ring 3, axial clearance

© 12/2008

Additional information

Value

Wear limit

0.30 +0 mm 0.8 mm

Wear limit

1.5 +0 mm 2.5 mm

+0.2

+0.5

+0.3

Wear limit Trapezoidal groove wear gauge

5/6

0.30 +0 mm 1,2 mm 0.080 - 0.115 mm 0.030 - 0.065 mm

17788-001

6

Drive system W 02-10-03

D 2011 w TD 2011 w, TCD 2011 w

6

© 12/2008

6/6

17788-001

D 2011 w TD 2011 w, TCD 2011 w

Drive system W 02-15-01

Removing and installing the piston cooling nozzles Commercial available tools

– W 02-04-01

6

Removing the piston cooling nozzle z Remove crankshaft.  W 02-04-01 z Press out the piston cooling nozzle (1) with a suitable tool (2) in the direction of the arrow.

1

2

© 39210-2

z Visually inspect the component.

© 47150-0

© 12/2008

1/2

17789-001

Drive system W 02-15-01

D 2011 w TD 2011 w, TCD 2011 w

Installing the piston cooling nozzle z Clean the bores for the piston cooling nozzles in the crankcase. z Knock in new piston cooling nozzle (1) with pin to the stop. z Install crankshaft.  W 02-04-01

1

6 © 39211-1

© 12/2008

2/2

17789-001

D 2011 w TD 2011 w, TCD 2011 w

Crankcase W 03-01-11

Removing and installing the crankcase bleeding Commercial available tools Special tools: – Disassembly tool. . . . . . . . . . . . . 110901

6

Removing the crankcase bleeding z Unscrew screw (1). z Remove crankcase bleeding (2). 1

2

© 47152-0

z Remove the O-ring (1) with the disassembly tool. z Visually inspect the components.

1

© 47153-0

© 12/2008

1/4

17790-001

Crankcase W 03-01-11

D 2011 w TD 2011 w, TCD 2011 w

Install crankcase bleeding z Clean sealing surfaces. z Insert new O-ring (1). 1

6 © 47160-0

z Mount crankcase vent (2). Ensure that the installation location is free from faults. The crankcase bleeding must fit evenly. 1

z Tighten screw (1).  8.5 Nm

2

© 47152-0

© 12/2008

2/4

17790-001

D 2011 w TD 2011 w, TCD 2011 w

Crankcase W 03-01-11

Technical Data Tightening specifications ID no.

Name Crankcase bleeding on front cover / A03 060 on cylinder head cover / on cylinder head

Screw type

Notes / Remark

Value 8.5 Nm

For the tightening procedure according to torque using a torque wrench, a maximum variation of the tightening torque of +/- 10% is permissible.

6

© 12/2008

3/4

17790-001

Crankcase W 03-01-11

D 2011 w TD 2011 w, TCD 2011 w

6

© 12/2008

4/4

17790-001

D 2011 w TD 2011 w, TCD 2011 w

Crankcase W 03-03-01

Checking the cylinder Commercial available tools: – Micrometer gauge – Internal measuring device

– W 02-09-03

Special tools: – Dial gauge. . . . . . . . . . . . . . . . . . 100400

The crankshaft bearing covers must be mounted properly for measuring the cylinders.

6

Checking the cylinders z Remove piston and connecting rod.  W 02-09-03 z Check cylinder for visible signs of wear.

© 39239-1

z Prepare internal measuring device: – Mount probe bolt for the appropriate measuring range in the internal measuring device. – Mount dial gauge with approx. 1 mm pre-tension in the internal measuring device. – Set micrometer gauge to 96 mm. – Balance the internal measuring device between the test surfaces of the micrometer gauge and set the dial gauge at the reversal point of the pointer to "0".

© 36094-1

© 12/2008

1/4

17791-001

Crankcase W 03-03-01

D 2011 w TD 2011 w, TCD 2011 w

Diagram for measuring the cylinder running surface at the points "a" and "b" in the levels "1" - "3".

1 2 3

a

b

a

b

a

b

6 © 39100-1

z Insert internal measuring device in cylinder. z Balance the internal measuring device at the given measuring points and read off the measured value at the reversal point of the pointer. z Compare actual value with setpoint value.  96.000

+0.020

mm

– Wear limit  96.1 mm

© 39241-2

z Install piston and connecting rod.  W 02-09-03

© 47122-0

© 12/2008

2/4

17791-001

D 2011 w TD 2011 w, TCD 2011 w

Crankcase W 03-03-01

Technical Data Testing and setting data ID no.

Name

Additional information

Value

P03 31

Cylinder, diameter, inside

Standard

P03 32

Cylinder, diameter, inside

Wear limit

96.000 96.1 mm

+0.020

mm

6

© 12/2008

3/4

17791-001

Crankcase W 03-03-01

D 2011 w TD 2011 w, TCD 2011 w

6

© 12/2008

4/4

17791-001

D 2011 w TD 2011 w, TCD 2011 w

Crankcase W 03-08-01

Removing and installing the front cover Commercial available tools

– W 02-02-04 – W 04-03-01 – W 04-04-15 – W 08-04-05 – W 08-04-07

– Packing compound DEUTZ DW 67

6

Remove the front cover z Pull out cable plug (1).

1

© 47177-0

z Unlock cable plug (1) and remove. z Remove toothed belt wheel.  W 04-04-15

1

© 47178-0

© 12/2008

1/6

17792-001

Crankcase W 03-08-01

D 2011 w TD 2011 w, TCD 2011 w

z Removing the lubricating oil pump.  W 08-04-05 z Remove lubricating oil pan.  W 08-04-07

6 © 47188-0

z Unscrew all screws (1). z Remove front cover.

1

© 47186-0

z Visually inspect the components.

© 47170-0

© 12/2008

2/6

17792-001

D 2011 w TD 2011 w, TCD 2011 w

Crankcase W 03-08-01

z Knock out crankshaft sealing ring (1). z Knock out camshaft sealing ring.

Attention! Do not damage sealing surface when knocking out. z Clean sealing surfaces.

1

6 © 39527-1

Install front cover z Apply packing compound evenly to the sealing surface. All connecting surfaces must be clean and free of oil.

© 34110-2

z Mount front cover. z Fasten all screws (1). z Align front cover flush with the oil tray sealing surface.

1

© 47187-0

© 12/2008

3/6

17792-001

Crankcase W 03-08-01

D 2011 w TD 2011 w, TCD 2011 w

z Tighten the screws according to the tightening sequence.  21 Nm z Install lubricating oil pan.  W 08-04-07 z Renew crankshaft sealing ring (opposite side to flywheel).  W 02-02-04 z Renew camshaft sealing ring.  W 04-03-01

6 © 34112-2

z Install the lubricating oil pump  W 08-04-05 z Install toothed belt wheel.  W 04-04-15

© 47188-0

z Plug in the cable plug (1). Ensure that the connection is perfect.

1

© 47178-0

© 12/2008

4/6

17792-001

D 2011 w TD 2011 w, TCD 2011 w

Crankcase W 03-08-01

z Plug in the cable plug (1). Ensure that the connection is perfect.

1

6 © 47177-0

© 12/2008

5/6

17792-001

Crankcase W 03-08-01

D 2011 w TD 2011 w, TCD 2011 w

Technical Data Tightening specifications ID no. Name A03 020 Front cover on crankcase

Screw type

Notes / Remark

Value 21 Nm

For the tightening procedure according to torque using a torque wrench, a maximum variation of the tightening torque of +/- 10% is permissible.

6

© 12/2008

6/6

17792-001

D 2011 w TD 2011 w, TCD 2011 w

Crankcase W 03-08-03

Dismantling and assembling the front cover Commercial available tools: – Depth-measuring appliance – Plier insert. . . . . . . . . . . . . . . . . . . . 8027

– W 03-08-01

Special tools: – Special wrench . . . . . . . . . . . . . . 101640 – Disassembly tool. . . . . . . . . . . . . 110901

All modifications on the speed control and the setting measures connected with this must be carried out on an engine test bench. According to the intended purpose of the engine, different types of regulator are used and/or different settings are necessary.

Attention!

– Locking agent DEUTZ DW 71

6

Dismantle front cover z Make help marks (1) and (2). z Remove front cover.  W 03-08-01

1

2

© 47193-0

z Unscrew screws (1). z Remove lifting magnet (2).

1

2

© 47194-0

© 12/2008

1/24

17793-001

Crankcase W 03-08-03

D 2011 w TD 2011 w, TCD 2011 w

z Remove the O-ring (1) with the disassembly tool.

1

6 © 47355-0

z Unscrew screw (1).

1

z Remove crankcase bleeding (2). z Remove gasket.

2

© 47195-0

z Unscrew all screws (1). z Remove cover (2). z Remove gasket.

1

2

© 47196-0

© 12/2008

2/24

17793-001

D 2011 w TD 2011 w, TCD 2011 w

Crankcase W 03-08-03

z Bring out spring (1).

1

6 © 47197-0

z Unscrew nuts (1). 2

z Remove regulator lever shaft (2). z Remove torque-control lever (3).

1

3

© 39632-1

z Remove shims (1). Note number of items and assignment.

1

1

© 39633-1

© 12/2008

3/24

17793-001

Crankcase W 03-08-03

D 2011 w TD 2011 w, TCD 2011 w

z Remove centrifugal force movement (1).

1

6 © 39634-1

z Unscrew nut (1). z Remove clamping shoe (2). z Unscrew idling capsule (3). 1

1

3

2

© 47198-0

z Unscrew nut (1). z Remove clamping shoe (2).

1 2

© 47200-0

© 12/2008

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z Unscrew adjusting capsule (1).

1

6 © 47201-0

z Remove locking ring (1). z Remove deflection lever (2).

1

2

© 47202-0

z Unscrew lifting magnet (1) with plier insert. Note direction of terminal.

1

© 47203-0

© 12/2008

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D 2011 w TD 2011 w, TCD 2011 w

z Remove the O-ring (1) with the disassembly tool.

1

6 © 47392-0

z Remove locking ring (1).

1

© 47204-0

z Insert special wrench (1).

1

© 47205-0

© 12/2008

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Crankcase W 03-08-03

z Unscrew nut (1) with special wrench (2). z Press out eccentric shaft in direction of arrow. z Remove guide bush. z Remove O-ring. 1 2

6 © 47206-0

z Remove locking ring (1). z Pull out control lever (2). z Remove washer. z Remove spring (3).

2

3

1

© 47207-0

z Bring out spring (1).

1

© 47208-0

© 12/2008

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Crankcase W 03-08-03

D 2011 w TD 2011 w, TCD 2011 w

z Knock out clamping pin (1). z Remove stop lever (2). z Remove washer.

1

2

6 © 39528-1

z Remove guide bush (1). z Remove O-ring (2). z Pull out shutdown spindle (3). 1

3

2

© 39056-1

z Pull out lock bolt (1) with suitable tool.

Attention! Do not damage the sealing surfaces. 1

© 47209-0

© 12/2008

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Crankcase W 03-08-03

z Knock out clamping pin (1). Do not twist clamping pin into front cover when pulling out.

1

6 © 39470-1

z Pull out speed adjusting lever (1). z Remove guide bush. z Remove O-ring.

1

z Remove adjustment lever (2).

2

© 39273-1

z Loosen lock nut (1). z Unscrew adjustable bolt (2).

2

1

© 39274-1

© 12/2008

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Crankcase W 03-08-03

D 2011 w TD 2011 w, TCD 2011 w

Assemble front cover z Screw in adjustable bolt (1). z Screw in locking nut (2).

1

2

6 © 39274-2

z Set adjustable bolt (1) to dimension "X".  23 +1 mm

2

X

Dimension "X" = basic setting of the minimum speed. z Tighten nut (2).  6 Nm

1

© 33950-2

z Push guide bush (1) onto speed adjusting shaft. z Insert new O-ring (2). z Oil the speed adjusting shaft lightly. z Insert speed adjusting lever (3).

1

2

3

© 39469-1

© 12/2008

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z Insert adjusting lever (1). Note installation position. The hanging hole for the governor spring (arrow) must face the outside the of the front cover. z Press in the speed adjusting shaft (2) to the stop.

1

2

6 © 39209-1

z Bring bore holes for clamping pin into line. z Knock in clamping pin (1) flush.

1

© 39470-1

z Position speed adjusting shaft until it is in line with the bolt and the bore. z Knock in the lock bolt (1) to the stop.

1

© 47210-0

© 12/2008

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z Oil the shutdown spindle lightly. z Insert shutdown spindle. z Pre-tighten spring (1). z Hook the spring in to the stop (arrow).

1

Note installation position.

6 © 39473-1

z Insert new O-ring (1). z Mount guide bush (2). 1

2

© 39474-1

z Mount washer (1). z Mount stop lever (2). z Insert clamping pin. Note installation position.

2 1

© 39475-1

© 12/2008

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Crankcase W 03-08-03

z Bring bore holes for clamping pin into line. z Knock in clamping pin (1) flush.

1

6 © 39466-1

z Insert control lever (1). z Insert spring (2). z Mount disc. Note installation position.

1

2

© 47343-0

z Insert new locking ring (1). Ensure that the installation location is free from faults.

1

© 47222-0

© 12/2008

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z Lightly oil the eccentric shaft. z Insert eccentric shaft. z Insert new O-ring (1). z Mount guide bush (2).

1 2

6 © 39472-1

z Make help marks (1) and (2). z Screw on nut (3).

3

1

2

© 47225-0

z Insert special wrench (1). Do not turn the eccentric shaft.

1

© 47205-0

© 12/2008

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Crankcase W 03-08-03

z Insert special wrench (1). Do not turn the eccentric shaft. z Tighten nut (2).

2

 7 Nm

1

6 © 47223-0

z Insert new locking ring (1).

1

© 47204-0

z Insert new O-ring (1).

1

© 47392-0

© 12/2008

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Crankcase W 03-08-03

D 2011 w TD 2011 w, TCD 2011 w

z Tighten lifting magnet (1) with plier insert. 1

 10 Nm Note direction of terminal.

6 © 47203-0

z Mount deflection lever (1). z Insert new locking ring (2). Note installation position.

2

1

© 47202-1

z Insert centrifugal force movement (1).

Attention! Do not damage shaft sealing ring!

1

© 39634-1

© 12/2008

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Crankcase W 03-08-03

z Mount shims (1). Note number of items and assignment. Minimum height of shims: minimum 0.3 mm, maximum 0.5 mm.

1

1

6 © 39633-1

z Insert regulator lever shaft (1). z Tighten nuts (2).

2

 9.2 Nm 1

Note installation position. Long milled edges "X" faces front cover.

2

X © 39277-2

z Push the roller lever under the contact surface (1). Ball bearings may not touch the bush (2) any longer. 1

2

© 47354-0

© 12/2008

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D 2011 w TD 2011 w, TCD 2011 w

z Insert dial gauge into measuring beam. z Apply stylus with pre-tension onto the ball bearing (1). z Adjust dial gauge to "0".

1

6 © 39279-1

z Move the measuring beam. z Apply stylus onto the ball bearing (1). z Read off measured value. z Maximum difference between both ball bearings:  0,05 mm The difference may be corrected by exchanging the shims. Minimum height of shims:

1

minimum 0.3 mm, maximum 0.5 mm.

© 39280-1

z Unscrew nuts (1). z Remove regulator lever shaft (2).

1 2

1

© 47065-0

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Crankcase W 03-08-03

z Change shims (1) according to difference. Minimum height of shims: minimum 0.3 mm, maximum 0.5 mm. Repeat measurement after setting.

1

1

6 © 39633-1

z Insert torque-control levelr (1) in regulator level shaft (2). Note installation position.

2

1

© 33967-2

z Insert regulator lever shaft (1). z Mount torque-control lever (2).

1

z Tighten nuts (3).  9.2 Nm Note installation position.

3

2 3 © 39632-2

© 12/2008

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z Hook in spring (1).

1

6 © 47197-0

z Insert new O-ring (1). z Lightly oil O-ring.

1

© 47227-0

z Insert adjusting capsule with locking agent. z Screw in adjusting capsule (1).

1

© 47201-0

© 12/2008

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Crankcase W 03-08-03

z Measure screw-in depth "X". z Nominal value: +0.5

 6,4 −0.5 mm Setting dimension "X" = basic setting.

X

6 © 47228-0

z Mount clamping shoe (1). z Tighten nut (2).  10 Nm

2

1

© 47200-1

z Insert new O-ring (1). z Lightly oil O-ring. 1

© 47224-0

© 12/2008

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Crankcase W 03-08-03

D 2011 w TD 2011 w, TCD 2011 w

z Insert spring (1). z Turn in idling capsule (2) flush to the inner edge of the front cover (arrow).

2 1

6 © 34002-2

z Mount clamping shoe (1). z Tighten nut (2).  4.6 Nm Note installation position.

1

2 © 39264-1

z Mount new gasket. z Mount cover (2). z Tighten all screws (1).  7 Nm

1

2

© 47196-0

© 12/2008

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Crankcase W 03-08-03

z Mount new gasket.

1

z Mount crankcase vent (2). z Tighten screw (1).  8.5 Nm

2

6 © 47195-0

z Insert new O-ring (1).

1

© 39036-1

z Insert lifting magnet (2). z Tighten screws (1).

1

 8.5 Nm

2

z Install front cover.  W 03-08-01

© 47194-0

© 12/2008

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Technical Data Testing and setting data ID no.

Name Additional information Minimum speed, setting screw, basic setting Screw-in depth of the adjusting capsule, basic setting

P05 05 P05 06

Value 23

+1

mm

+0.5

6,4 −0.5 mm

Tightening specifications ID no. A03 060

6

A05 005 A05 021 A05 022 A05 023 A05 024 A05 025 A05 041 A05 065

Name Screw type Crankcase bleeding on front cover / on cylinder head cover / on cylinder head Locking nut on setting screw, shut-off stop Regulator lever shaft on front cover Idling capsule on front cover Adjusting capsule on front cover, clamping nut Eccentric shaft on front cover Cap (speed adjusting lever) on front cover Lifting magnet (engine shutdown) on front cover Lifting magnet (start amount release) on front cover

Notes / Remark

Value 8.5 Nm 6 Nm 9.2 Nm 4.6 Nm 10 Nm

Locking nut

7 Nm 4.5 Nm 8.5 Nm 10 Nm

For the tightening procedure according to torque using a torque wrench, a maximum variation of the tightening torque of +/- 10% is permissible.

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Crankcase W 03-09-01

Removing and installing rear cover Commercial available tools

– W 02-02-02 – W 03-09-04 – W 08-04-07

– Packing compound DEUTZ DW 67

6

Removing rear cover z Remove connection housing.  W 03-09-04 z Remove lubricating oil pan.  W 08-04-07 z Unscrew all screws (1).

1

z Remove rear cover 2.

2 © 47211-0

z Knock out crankshaft sealing ring (1).

Attention! Do not damage the sealing surfaces. z Visually inspect the components.

1

© 39512-1

© 12/2008

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Installing rear cover z Clean sealing surfaces. z Apply packing compound evenly to the sealing surface. Sealing cord strength approx. 0.5 0.6 mm.

6 © 47487-0

z Mount rear cover. z Oil the screws lightly. z Fasten all screws (1). z Align front cover flush with the oil tray sealing surface. 1

© 47212-0

z Tighten the screws according to the tightening sequence.

1

 21 Nm

5 4 6 3 7 2 8

© 47488-0

© 12/2008

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Crankcase W 03-09-01

z Renew crankshaft sealing ring (flywheel side).  W 02-02-02 z Install lubricating oil pan.  W 08-04-07 z Install connection housing.  W 03-09-04

6 © 47213-0

© 12/2008

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Technical Data Tightening specifications ID no.

Name

Screw type

A03 010 Rear cover on crankcase

Notes / Remark Observe tightening sequence

Value 21 Nm

For the tightening procedure according to torque using a torque wrench, a maximum variation of the tightening torque of +/- 10% is permissible.

6

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Crankcase W 03-09-04

Removing and installing the connection housing Commercial available tools

– W 12-06-01

6

Removing the connection housing z Remove flywheel.  W 12-06-01 z Unscrew all screws (1). z Remove connection housing.

1

© 47226-0

z Visually inspect the components.

© 39048-2

© 12/2008

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D 2011 w TD 2011 w, TCD 2011 w

Installing the connection housing z Clean contact surfaces. z Make sure the clamping bushings (arrows) are in place. z Drive in clamping sleeves in the crankcase as far as they will go.

6 © 47214-0

z Mount connection housing. z Centre connection housing over the clamping bushings.

© 47215-0

z Tighten all screws (1) alternately.  Technical Data

1

© 47226-0

© 12/2008

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Crankcase W 03-09-04

z Install flywheel.  W 12-06-01

6 © 47082-0

© 12/2008

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D 2011 w TD 2011 w, TCD 2011 w

Technical Data Tightening specifications ID no.

Name

A03 081

Connection housing/connection ring to crankcase

A03 082 Connection housing to crankcase

6

A03 082

Connection housing/connection ring to crankcase

A03 082 Connection housing to crankcase A03 082

Connection housing/connection ring to crankcase

Screw type Notes / Remark M12x20 M12x30 M12x35 M12x55 M12x70 M12x75 M12x95 M8x10 M8x30 M8x50 M10x40 M10x30 M10x25 Cylinder head screws M10x40

Value

M14x55

180 Nm

106 Nm

22 Nm 45 Nm 60 Nm

For the tightening procedure according to torque using a torque wrench, a maximum variation of the tightening torque of +/- 10% is permissible.

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Crankcase W 03-11-01

Removing and installing, testing camshaft bearing Commercial available tools: – Micrometer gauge – Internal measuring device – Depth-measuring appliance

– W 00-05-01 – W 02-04-01 – W 04-05-05 – W 09-08-04

Special tools: – Dial gauge. . . . . . . . . . . . . . . . . . 100400 – Disassembly/assembly tool . . . . . . . . . . . . . . . . . . . . . . . 143720

Attention! Do not damage bearing liners while removing and changing over the assembly tool! The work process is described for a bearing liner. The procedure is the same to install and remove further bearing liners.

6

Testing camshaft bearing z Mount clamping bracket on assembly block.  W 00-05-01 z Remove thermostat housing.  W 09-08-04 z Remove crankshaft.  W 02-04-01 z Remove camshaft.  W 04-05-05 z Prepare internal measuring device: z Mount probe bolt for the appropriate measuring range in the internal measuring device. z Mount dial gauge with approx. 1 mm pre-tension in the internal measuring device.

© 34768-2

z Set micrometer gauge to 54 mm. z Balance the internal measuring device between the test surfaces of the micrometer gauge and set the dial gauge at the reversal point of the pointer to "0".

© 12/2008

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D 2011 w TD 2011 w, TCD 2011 w

Diagram for measuring the camshaft bearing at the points "a and b" in the levels "1 and 2".

6 © 37239-1

z Insert internal measuring device. z Balance the internal measuring device at the given measuring points and read off the measured value at the reversal point of the pointer.  54.000 - 54.054 mm – Wear limit  54.08 mm Measuring points see diagram. When the wear limit is reached, the camshaft bearing must be replaced.

© 39304-1

Removing camshaft bearing z Insert pressure piece (1).

1

© 39306-1

© 12/2008

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Crankcase W 03-11-01

z Insert spindle (1). z Insert pressure piece (2). z Insert counter support (3). z Mount washers (4). z Screw in nuts (5). 3

5

1

2

5

4

4

6 © 39307-2

z Hold spindle (1). z Tighten nut (2). Tighten the nut further until the bearing liner falls out. z Remove bearing bush. z Remove assembly tool. 2

1

© 47054-0

Installing camshaft bearing Schematic diagram: Butt joint faces direction of arrow.

© 39311-1

© 12/2008

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Crankcase W 03-11-01

D 2011 w TD 2011 w, TCD 2011 w

Note the different bearing liners. The wide bearing liners are each installed at the end of the crankcase. z Position new bearing liner.

Attention! Installation position of the butt joint (1) see schematic diagram. Make sure that the lubricating oil bores (arrow) are in line.

1

6 © 39312-1

z Insert spindle. z Insert pressure piece (1). z Mount washer (2). z Screw on nut (3).

1

2 3 © 39313-2

z Insert counter bearing (1). z Mount washer (2). z Screw on nut (3).

1 2

3 © 39309-3

© 12/2008

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Crankcase W 03-11-01

z Hold spindle (1). z Tighten nut (2). Holder fits evenly on the crankcase.

Attention! Do not change installation position of the bearing liner! 2

1

6 © 47054-0

z Tighten nut (1). Pressure piece (arrow) lies almost flush with the crankcase. z Loosen nuts.

1 © 39314-2

Diagram for the installation depth of the camshaft bearings. 1

1 2 3 4

2,5

+0,3 −0,3

118,9 0,5

+ 0,3 − 0,3

+0,3 −0,3

117,1

+ 0,3 − 0,3

2

4

3

mm mm mm mm

© 47491-0

© 12/2008

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Crankcase W 03-11-01

D 2011 w TD 2011 w, TCD 2011 w

z Measure screw-in depth with depth measuring appliance (1). Measure distance from the crankcase to the bearing liner. If necessary, correct screw-in depth of the bearing liner. z Remove assembly tool

1

6 © 39318-2

z Check that the lubricating oil bores (1) are in line. If the lubricating oil bore is not in line, the camshaft bearing must be removed and reinstalled. z Install the camshaft.  W 04-05-05 z Install crankshaft.  W 02-04-01 z Install thermostat housing.  W 09-08-04

1

z Remove engine from assembly block  W 00-05-01

© 45502-1

© 12/2008

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Crankcase W 03-11-01

Technical Data Testing and setting data ID no. P03 13 P03 14

Name Additional information Camshaft, bearing liner, diameter, inside in the installed state Camshaft, bearing liner, diameter, inside Wear limit

Value 54.000 - 54.054 mm 54.08 mm

For the tightening procedure according to torque using a torque wrench, a maximum variation of the tightening torque of +/- 10% is permissible.

6

© 12/2008

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D 2011 w TD 2011 w, TCD 2011 w

6

© 12/2008

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Engine control W 04-03-01

Renew camshaft sealing ring (opposite side to flywheel) Commercial available tools: – Pricker. . . . . . . . . . . . . . . . . . . . . . . 8198 – Assembly lever . . . . . . . . . . . . . . . . 9017

– W 04-04-15

Special tools: – Assembly tool . . . . . . . . . . . . . . . 142050 – Counter support . . . . . . . . . . . . . 144130 – Self-tapping screw – Washer

6

Remove camshaft sealing ring z Remove toothed belt wheel (1).

1

 W 04-04-15

© 47179-1

z Position holder. z Unscrew screw (1).

2

z Remove toothed belt wheel (2).

1

© 47180-0

© 12/2008

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Engine control W 04-03-01

D 2011 w TD 2011 w, TCD 2011 w

Attention! Do not damage front cover and camshaft! z Make a hole of approx. 3mm in the camshaft sealing ring with a pricker.

6 © 47259-0

z Screw in a self-tapping screw (1) with washer.

1

© 47260-0

z Pull out camshaft sealing ring with assembly lever. z Visually inspect the components.

© 47261-0

© 12/2008

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Engine control W 04-03-01

z Visually inspect all running surfaces.

6 © 47262-0

Install camshaft sealing ring z Mount new camshaft sealing ring (1) on assembly tool (2).

1

Do not oil waxed crankshaft sealing rings.

2

The sealing lip faces the crankcase.

© 39515-1

z Carefully insert camshaft sealing ring. z Fasten screw (1).

1

© 47263-0

© 12/2008

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Engine control W 04-03-01

D 2011 w TD 2011 w, TCD 2011 w

z Tighten screw until it reaches the assembly tool (1). The installation depth is determined by the assembly tool. z Unscrew screw. z Remove assembly tool. 1

6 © 47264-0

z Install toothed belt wheel (1).  W 04-04-15

1

© 47179-1

© 12/2008

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D 2011 w TD 2011 w, TCD 2011 w

Engine control W 04-04-12

Renew toothed belt and tensioning pulley Commercial available tools: – Rotation angle disc . . . . . . . . . . . . . 8190 – Special bit, 70 mm long. . . . . . . . . . 9120

– W 09-08-04 – W 12-01-04 – W 12-08-03

Special tools: – Ajustable bolt . . . . . . . . . . . . . . . 100700 – Counter support . . . . . . . . . . . . . 144130

Attention! Re-tensioning of toothed belts which have already been running is not permissible! The setting of engine control times should only be carried out with new toothed belts! The crankshaft may only be turned in the direction of the engine.

– Chalk

6

Remove toothed belt and tensioning pulley z Remove V-belt pulley.

2

 W 12-01-04 z Remove toothed belt and tensioning pulley (hydraulic pump).  W 12-08-03 z Unscrew screw (1) with special bit. z Unscrew screws (2). z Remove protective hood (3).

1

2

3

© 47640-1

z Remove thermostat housing. 2

 W 09-08-04

1

z Unscrew screws (1). z Remove protective hood (2).

1

1 © 47641-1

© 12/2008

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Engine control W 04-04-12

D 2011 w TD 2011 w, TCD 2011 w

z Unscrew locking screw (1). z Remove sealing ring.

1

6 © 47619-0

z Insert adjustable bolt (1).

1

© 47620-0

z Press adjustable bolt in lightly in direction of arrow and hold. z Turn crankshaft slowly in direction of engine until the adjustable bolt engages with the bore of the camshaft.

© 47621-0

© 12/2008

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Engine control W 04-04-12

z Knock in the adjustable bolt (1) to the stop.

1

6 © 47621-1

z Unscrew locking screw (1). z Remove sealing ring.

1

© 47270-0

z Insert adjustable bolt (1).

1

© 47296-0

© 12/2008

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Engine control W 04-04-12

D 2011 w TD 2011 w, TCD 2011 w

z Knock in the adjustable bolt (1) to the stop.

1

6 © 47271-0

z Turn crankshaft in the direction of the engine until it reaches the stop of the adjustable bolt.

© 39130-1

z Unscrew screw (1). z Remove tensioning pulley (2). z Remove the toothed belt (3). 3

1

2 © 47642-1

© 12/2008

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Engine control W 04-04-12

z Insert counter support (1). z Loosen screw (2).

Attention! Do not turn camshaft.

2 1

6 © 47180-1

Install toothed belt and tensioning pulley z Fasten screw (1). To guarantee the length adjustment of the toothed belt, the toothed belt wheel must still be able to be turned slightly.

1

© 47180-2

z Turn crankshaft carefully against the adjustable bolt.

© 39130-1

© 12/2008

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Engine control W 04-04-12

D 2011 w TD 2011 w, TCD 2011 w

z Mount new toothed belt (1).

6

1 © 47299-2

z Mount new tensioning pulley (1). z Position setting eccentric (arrow) at 6 o'clock. z Fasten screw (2).

1

2 © 47300-1

z Press tensioning pulley (1) against the toothed belt. z Fasten screws.

1

© 47301-1

© 12/2008

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Engine control W 04-04-12

z Align toothed belt. Align toothed belt centrally on the toothed belt wheels.

6 © 34132-2

z Align toothed belt. z Press tensioning pulley (1) against the stop. z Turn the toothed belt wheel by hand in the direction of the arrow. The tension side (2) is tightened.

2

1

© 47302-2

z Turn setting eccentric in the direction of arrow with hexagon socket. z Bring markings (1) and bores into alignment. z Tighten screw (2).  21 Nm 1

2

© 39605-1

© 12/2008

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Engine control W 04-04-12

D 2011 w TD 2011 w, TCD 2011 w

z Press tensioning pulley (1) against the stop. z Hold toothed belt wheel (2) with counter support. z Tighten new screw (3).

3

– Stage 1:

2

 30 Nm z Tighten screw (3) with rotation angle disc. – Stage 2:  210°

1

6 © 39674-3

Check toothed wheel tension z Unscrew adjustable bolt to the camshaft and crankshaft lock. z Bring help markings (1) on toothed wheel and opposite screw into line.

1

z Turn crankshaft two revolutions in the direction of the arrow (direction of engine) until the help markings are in line.

© 47303-0

Markings (1) and bores must be in alignment. If the markings are not aligned with each other, the toothed belt tension must be corrected. 1

© 39608-1

© 12/2008

8/12

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Engine control W 04-04-12

Correct toothed belt tension z Loosen screw (2). z Turn setting eccentric in the direction of arrow with hexagon socket. z Bring markings (1) and bores into alignment. z Tighten screw (2).

1

 21 Nm 2

6 © 39605-1

z Visually inspect the components.

© 34229-2

z Mount protective hood (1). 1

Ensure that the installation location is free from faults.

2

z Tighten screws (2).  7 Nm z Install thermostat housing.

2

 W 09-08-04

2 © 47641-2

© 12/2008

9/12

17798-001

Engine control W 04-04-12

D 2011 w TD 2011 w, TCD 2011 w

z Mount protective hood (1). z Tighten screws (2).  7 Nm

2

z Tighten screw (3) with special bit.  7 Nm z Install toothed belt and tensioning pulley (hydraulic pump).  W 12-08-03 z Install V-belt pulley.  W 12-01-04

6

3

1

2 © 47640-2

© 12/2008

10/12

17798-001

D 2011 w TD 2011 w, TCD 2011 w

Engine control W 04-04-12

Technical Data Tightening specifications ID no.

Name

Screw type

A04 001 Toothed belt wheel on camshaft A04 001 Toothed belt wheel on camshaft A04 052 Tensioning pulley on front cover Protective hood (toothed wheel) on A04 053 front cover

Notes / Remark Stage 1: Use new screw. Stage 2:

Value 30 Nm 210° 21 Nm 7 Nm

For the tightening procedure according to torque using a torque wrench, a maximum variation of the tightening torque of +/- 10% is permissible.

© 12/2008

11/12

17798-001

6

Engine control W 04-04-12

D 2011 w TD 2011 w, TCD 2011 w

6

© 12/2008

12/12

17798-001

D 2011 w TD 2011 w, TCD 2011 w

Engine control W 04-04-15

Removing and installing the toothed belt wheel Commercial available tools: – Socket wrench insert, spanner size 32 . . . . . . . . . . . . . . . 8036 – Force multiplier . . . . . . . . . . . . . . . . 8049 – Rotation angle disc . . . . . . . . . . . . . 8190

– W 04-04-12

Special tools: – Counter support . . . . . . . . . . . . . 143420 – Counter support . . . . . . . . . . . . . 144130 – Packing compound DEUTZ DW 67

6

Remove toothed belt wheel z Remove toothed belt and tensioning pulley.

2

 W 04-04-12 z Insert counter support 144130.

1

z Unscrew screw (1). z Remove toothed belt wheel (2).

© 47180-0

z Insert counter support 143420. z Insert fixing bolts (1) in the bores (2).

Attention! Do not twist crankshaft.

1 2

© 47181-0

© 12/2008

1/8

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Engine control W 04-04-15

D 2011 w TD 2011 w, TCD 2011 w

z Tighten screws (1).

Attention! Do not twist crankshaft.

1

6 © 47182-0

z Insert socket wrench insert and force multiplier (1). z Snap in non-return device (2) in position CCW. 1

2

© 47183-1

z Hold force multiplier. z Loosen screw. z Remove force multiplier and socket wrench insert.

© 47184-0

© 12/2008

2/8

17799-001

D 2011 w TD 2011 w, TCD 2011 w

Engine control W 04-04-15

z Unscrew screws (1). z Remove counter holder.

1

6 © 47182-0

z Unscrew screw (1). z Remove flange (2). z Remove toothed belt wheel (3).

3

2

1

© 47185-0

Install toothed belt wheel z Mount toothed belt wheel (3). z Mount flange (2). All connecting surfaces must be clean and free of oil. z Turn in new screw (1). 3

2

1

© 47185-0

© 12/2008

3/8

17799-001

Engine control W 04-04-15

D 2011 w TD 2011 w, TCD 2011 w

z Tighten screw. – Stage 1:  130 Nm

6 © 47190-1

z Insert counter support 143420. z Insert fixing bolts (1) in the bores (2).

Attention! Do not twist crankshaft.

1 2

© 47181-0

z Tighten screws (1).

Attention! Do not twist crankshaft.

1

© 47182-0

© 12/2008

4/8

17799-001

D 2011 w TD 2011 w, TCD 2011 w

Engine control W 04-04-15

z Insert socket wrench insert and force multiplier (1). z Snap in non-return device (2) in position CW. 1

2

6 © 47191-1

z Turn square bar (1) in direction of arrow to the stop. z Set graduated collar (2) to zero.

2

1 © 39458-2

z Hold force multiplier (1). z Tighten screw. – Stage 2: 1

 210°

© 39459-2

© 12/2008

5/8

17799-001

Engine control W 04-04-15

D 2011 w TD 2011 w, TCD 2011 w

z Hold force multiplier against counter pressure (arrow), z release non-return device (1) and force multiplier.

Danger! There is danger of injury if a force multiplier is removed without being discharged. z Remove force multiplier and socket wrench insert. z Remove counter holder. 1

6 © 47192-0

All connecting surfaces must be clean and free of oil.

2

z Mount toothed belt wheel (2). z Insert counter support 144130. z Tighten new screw (1).

1

z Install toothed belt and tensioning pulley.  W 04-04-12

© 47180-0

© 12/2008

6/8

17799-001

D 2011 w TD 2011 w, TCD 2011 w

Engine control W 04-04-15

Technical Data Tightening specifications ID no.

Name

Screw type

A02 015 Toothed belt wheel on crankshaft A02 015 Toothed belt wheel on crankshaft

Notes / Remark Stage 1: Use new screw. Stage 2:

Value 130 Nm 210°

For the tightening procedure according to torque using a torque wrench, a maximum variation of the tightening torque of +/- 10% is permissible.

6

© 12/2008

7/8

17799-001

Engine control W 04-04-15

D 2011 w TD 2011 w, TCD 2011 w

6

© 12/2008

8/8

17799-001

D 2011 w TD 2011 w, TCD 2011 w

Engine control W 04-05-05

Removing and installing the camshaft Commercial available tools

– W 01-02-02 – W 03-09-01 – W 04-03-01 – W 04-05-06 – W 07-04-01 – W 07-11-01

Special tools: – Ajustable bolt . . . . . . . . . . . . . . . 100700 – Counter support . . . . . . . . . . . . . 144130

6

Removing the camshaft z Remove camshaft sealing ring.  W 04-03-01 z Remove rocker arm and rocker arm bracket.  W 01-02-02 z Remove injection pumps.  W 07-04-01 z Remove fuel supply pump.  W 07-11-01

© 47262-0

z Remove rear cover.  W 03-09-01

© 47212-1

© 12/2008

1/6

17800-001

Engine control W 04-05-05

D 2011 w TD 2011 w, TCD 2011 w

z Unscrew screw (1). z Remove thrust washer (2). z Unscrew adjustable bolt (3). 1

2 3

6 © 47305-0

z Press all valve tappets back. z Pull out the camshaft (1) carefully to the flywheel side. z Visually inspect the components. z Remove all valve tappets with magnetic bar. z Check camshaft.  W 04-05-06 1

© 47306-0

Installing the camshaft z Insert all valve tappets. z Oil camshaft bearing lightly. z Oil cam shaft pin lightly. All connecting surfaces must be clean and free of oil.

© 47307-0

© 12/2008

2/6

17800-001

D 2011 w TD 2011 w, TCD 2011 w

Engine control W 04-05-05

z Insert camshaft carefully. z Bring bore (1) and (2) into alignment.

1

2

6 © 47309-0

z Insert camshaft pivots into the centrifugal force movement (1).

1

© 47121-0

z Mount thrust washer (1). The groove (2) faces the crankcase. z Fasten screws. 1

2

© 47310-0

© 12/2008

3/6

17800-001

Engine control W 04-05-05

D 2011 w TD 2011 w, TCD 2011 w

z Knock in the adjustable bolt (1) to the stop. z Tighten screw (2).  21 Nm

2

1

6 © 47311-0

z Mount rear cover.  W 03-09-01

© 47212-1

z Install camshaft sealing ring.  W 04-03-01 z Install fuel pump.  W 07-11-01 z Install injection pumps.  W 07-04-01 z Install rocker arm and rocker arm bracket.  W 01-02-02

© 47262-0

© 12/2008

4/6

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Engine control W 04-05-05

Technical Data Tightening specifications ID no. Name A04 002 Shim on camshaft

Screw type

Notes / Remark

Value 21 Nm

For the tightening procedure according to torque using a torque wrench, a maximum variation of the tightening torque of +/- 10% is permissible.

6

© 12/2008

5/6

17800-001

Engine control W 04-05-05

D 2011 w TD 2011 w, TCD 2011 w

6

© 12/2008

6/6

17800-001

D 2011 w TD 2011 w, TCD 2011 w

Engine control W 04-05-06

Checking the camshaft Commercial available tools: – Micrometer gauge – Prisms

– W 04-05-05

Repairing the camshaft is not permissible. The camshaft must be renewed.

6

Checking the camshaft z Remove camshaft.  W 04-05-05 z Visually inspect cams and bearing pins for wear.

© 47307-0

Diagram for measuring the journals at the points 1 and 2 in the levels a and b.

© 36424-2

© 12/2008

1/4

17801-001

Engine control W 04-05-06

D 2011 w TD 2011 w, TCD 2011 w

z Measure the diameter of journals with the micrometer gauge. Measuring points see diagram. When the wear limit is reached, the camshaft must be renewed.  53.945 - 53.960 mm

6 © 47313-0

z Install the camshaft.  W 04-05-05

© 47304-0

© 12/2008

2/4

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D 2011 w TD 2011 w, TCD 2011 w

Engine control W 04-05-06

Technical Data Testing and setting data ID no. P04 31

Name Camshaft, bearing pin, diameter

Additional information

Value 53.945 - 53.960 mm

6

© 12/2008

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17801-001

Engine control W 04-05-06

D 2011 w TD 2011 w, TCD 2011 w

6

© 12/2008

4/4

17801-001

D 2011 w TD 2011 w, TCD 2011 w

Speed control W 05-04-15

Removing and installing the control linkage Commercial available tools

– W 03-08-01 – W 06-09-10 – W 07-04-01 – W 09-08-04 – W 13-02-03 Collect leaking operating substances in suitable vessels and dispose of according to regulations.

6

Removing the control linkage z Remove front cover.  W 03-08-01 z Remove injection pumps.  W 07-04-01 z Remove generator. 1

 W 13-02-03 z Remove thermostat housing.  W 09-08-04 z Remove magnet clip.  W 06-09-10 z Knock out cylinder pin (1).

© 39072-1

z Pull out control linkage (1).

1

© 39073-1

© 12/2008

1/4

17802-001

Speed control W 05-04-15

D 2011 w TD 2011 w, TCD 2011 w

Installing the control linkage The lug (1) must face the oil filler (2). z Insert control linkage with spring in the guide bush. z Check the easy action of the control linkage. 1

2

6 © 39236-1

z Press spring together. z Insert cylinder pin (1) into the bores (2). z Insert cylinder pin in the recess (arrow) of the control path limit. Spring must touch the cylinder pin (3) . 3 1 2

© 39237-1

z Drive in cylinder pin flush with the crankcase. z Install magnet clip.  W 06-09-10 z Install front cover.  W 03-08-01 z Install injection pumps.  W 07-04-01 z Install thermostat housing.  W 09-08-04 z Install generator.  W 13-02-03 © 39238-1

© 12/2008

2/4

17802-001

D 2011 w TD 2011 w, TCD 2011 w

Speed control W 05-04-15

Technical Data Tightening specifications ID no.

Name

A13 010 Console on cylinder head

Screw type Notes / Remark M8x75-10.9 M8x100-10.9

Value 34 Nm

For the tightening procedure according to torque using a torque wrench, a maximum variation of the tightening torque of +/- 10% is permissible.

6

© 12/2008

3/4

17802-001

Speed control W 05-04-15

D 2011 w TD 2011 w, TCD 2011 w

6

© 12/2008

4/4

17802-001

D 2011 w TD 2011 w, TCD 2011 w

Speed control W 05-04-16

Removing and installing the guide bushes (Control linkage) Commercial available tools

– W 03-09-04 – W 05-04-15 – W 08-11-12

Special tools: – Disassembly/assembly tool . . . . . . . . . . . . . . . . . . . . . . . 110140 – Handle . . . . . . . . . . . . . . . . . . . . 150151 – Extraction tool . . . . . . . . . . . . . . . 150210 – Assembly pin . . . . . . . . . . . . . . . 150220 – Slide hammer . . . . . . . . . . . . . . . 160400

Collect leaking operating substances in suitable vessels and dispose of according to regulations.

– Locking agent DEUTZ DW 72

6

Remove guide bushes z Remove control linkage.  W 05-04-15 z Remove connection housing.  W 03-09-04 z Knock out cylinder pin (1). 1

© 39072-1

z Pull out control linkage (1).

1

© 39073-1

© 12/2008

1/12

17803-001

Speed control W 05-04-16

D 2011 w TD 2011 w, TCD 2011 w

Remove guide bushes (opposite side to flywheel) z Insert assembly pin (1) in guide bush (2).

2

1

6 © 47350-0

z Knock out guide bush.

© 39075-1

Install guide bush (opposite side to flywheel) z Unscrew locking screw (1). 1

© 39076-1

© 12/2008

2/12

17803-001

D 2011 w TD 2011 w, TCD 2011 w

Speed control W 05-04-16

z Push spacing sleeve (1) onto assembly pin (2). z Insert assembly pin into the centring (3). The pilot pin (arrow) must lock in groove (4).

2 1

4

3

6 © 39077-1

z Push guide bush (1) onto assembly pin. During assembly, the chamfer (arrow) must face the crankcase.

1

© 39078-1

z Clean contact surfaces. z Insert assembly pin with guide bush. The fixing bolt (1) must engage with the hole (2).

2 1

© 39079-1

© 12/2008

3/12

17803-001

Speed control W 05-04-16

D 2011 w TD 2011 w, TCD 2011 w

z Tighten screw (1).  21 Nm 1

z Drive in guide sleeve until the assembly pin touches the spacing sleeve (arrow) z Remove assembly tool.

6 © 39082-1

The thread hold for the locking screw must be dry and free of oil, corrosion and dirt. z Tighten new locking screw.  50 Nm

© 39084-1

Remove guide bushes (flywheel side) z Unscrew locking screw (1). z Remove thermostat.  W 08-11-12

1

© 39087-2

© 12/2008

4/12

17803-001

D 2011 w TD 2011 w, TCD 2011 w

Speed control W 05-04-16

z Remove cap (1).

1

6 © 39088-2

z Screw the extraction tool (1) tightly with the slide hammer (2).

2 1

© 46977-0

z Insert extraction tool (1) and turn in the direction of the arrow.

Attention! Pay attention to utmost cleanliness.

1

© 46957-1

© 12/2008

5/12

17803-001

Speed control W 05-04-16

D 2011 w TD 2011 w, TCD 2011 w

z Expel the oil rise tube with the slide hammer. z Remove oil rise tube.

Attention! Vacuum off any shavings!

6 © 46958-1

z Insert assembly pin (1) in guide bush (2).

2 1

© 39099-2

z Knock out guide bush.

© 39204-2

© 12/2008

6/12

17803-001

D 2011 w TD 2011 w, TCD 2011 w

Speed control W 05-04-16

Install guide bush (flywheel side) z Insert assembly pin (1) in the centring (2). The pilot pin (arrow) must lock in groove (3). 2 1

6

3 © 39205-1

z Push guide bush (1) onto assembly pin. During assembly, the chamfer (arrow) must face the crankcase.

1

© 39226-1

z Clean contact surfaces. z Insert assembly pin with guide bush.

© 39227-2

© 12/2008

7/12

17803-001

Speed control W 05-04-16

D 2011 w TD 2011 w, TCD 2011 w

z Tighten screw (1). z Drive in guide sleeve until the assembly pin touches the spacing sleeve (arrow)

1

z Remove assembly tool.

6 © 39228-2

z Insert new oil rise tube (1). During assembly, the chamfer (arrow) must face the crankcase.

1

© 39231-2

z Drive in oil rise tube until the assembly pin (1) lies on the crankcase (arrow).

1

© 39232-2

© 12/2008

8/12

17803-001

D 2011 w TD 2011 w, TCD 2011 w

Speed control W 05-04-16

z Coat new cap with locking agent.

6 © 33816-3

z Drive in cap flush with the crankcase. z Install thermostat.  W 08-11-12

© 39233-2

The thread hold for the locking screw must be dry and free of oil, corrosion and dirt. z Tighten new locking screw.  56 Nm

© 39235-2

© 12/2008

9/12

17803-001

Speed control W 05-04-16

D 2011 w TD 2011 w, TCD 2011 w

The lug (1) must face the oil filler (2). z Insert control linkage with spring in the guide bush. z Check the easy action of the control linkage.

1

2

6 © 39236-1

z Press spring together. z Insert cylinder pin (1) into the bores (2). The cylinder pin must engage with the recess (arrow) for the control path limit. The spring must touch the cylinder pin (3). 3 1 2

© 39237-1

z Drive in cylinder pin flush with the crankcase. z Install connection housing.  W 03-09-04

© 39238-1

© 12/2008

10/12

17803-001

D 2011 w TD 2011 w, TCD 2011 w

Speed control W 05-04-16

Technical Data Tightening specifications ID no. Name A03 007 Locking screw on crankcase Locking screw on crankcase (oil rise A03 008 tube) A03 024 Assembly tool on crankcase Lubricating oil cooler connection on A08 054 crankcase

Screw type M18x1.5

Notes / Remark Value Use new locking screw. 50 Nm

M20x1.5

Use new locking screw. 56 Nm 21 Nm

M6x60

13 Nm

For the tightening procedure according to torque using a torque wrench, a maximum variation of the tightening torque of +/- 10% is permissible.

© 12/2008

11/12

17803-001

6

Speed control W 05-04-16

D 2011 w TD 2011 w, TCD 2011 w

6

© 12/2008

12/12

17803-001

D 2011 w TD 2011 w, TCD 2011 w

Speed control W 05-07-01

Removing and installing the impulse transmitter Commercial available tools

6

Removing the impulse transmitter z Unlock cable plug (1) and disconnect.

1

© 46966-0

z Unscrew screw (1). z Remove impulse transmitter (2). z Remove spacing sleeve (3).

3

1

2

© 46967-0

© 12/2008

1/4

17804-001

Speed control W 05-07-01

D 2011 w TD 2011 w, TCD 2011 w

z Visually inspect the components. z Clean components. z Clean sealing surfaces.

6 © 46968-0

Installing the impulse transmitter z Position spacing sleeve (3). z Insert impulse transmitter (2). z Fasten screw (1). z Tighten screw (1). 3

 8.5 Nm

1

2

© 46967-0

z Plug in the cable plug (1). Ensure that the cables are connected properly.

1

© 46966-0

© 12/2008

2/4

17804-001

D 2011 w TD 2011 w, TCD 2011 w

Speed control W 05-07-01

Technical Data Tightening specifications ID no.

Name Screw type Speed transmitter on connection houA05 011 sing

Notes / Remark

Value 8.5 Nm

For the tightening procedure according to torque using a torque wrench, a maximum variation of the tightening torque of +/- 10% is permissible.

6

© 12/2008

3/4

17804-001

Speed control W 05-07-01

D 2011 w TD 2011 w, TCD 2011 w

6

© 12/2008

4/4

17804-001

D 2011 w TD 2011 w, TCD 2011 w

Exhaust system/Charging W 06-01-05

Removing and installing the exhaust line Commercial available tools: – Torx tool set . . . . . . . . . . . . . . . . . . 8189

– W 06-06-04

6

Removing exhaust line – TD 2011 w, TCD 2011 w z Remove turbocharger.  W 06-06-04 z Unscrew all screws (1).

1

z Remove exhaust line (2).

1

1

2

1

© 47523-1

z Remove gaskets (1).

1

© 47525-1

© 12/2008

1/4

17805-001

Exhaust system/Charging W 06-01-05

D 2011 w TD 2011 w, TCD 2011 w

z Unscrew studs (1). z Visually inspect the components.

1

1

6 © 47524-0

Installing exhaust line 2

z Clean sealing surfaces. z Turn on new pin bolts (1). z Tighten pin bolts (1).

1

 12 Nm

1

2

© 47524-1

z Clean sealing surfaces. z Mount exhaust line (1). z Mount new gaskets. Note installation position. 2

z Turn in new screws (2).

2

1

z Tighten new screws (2).  55 Nm – TD 2011 w, TCD 2011 w z Install the turbocharger.

2

 W 06-06-04

2

© 47523-2

© 12/2008

2/4

17805-001

D 2011 w TD 2011 w, TCD 2011 w

Exhaust system/Charging W 06-01-05

Technical Data Tightening specifications ID no.

Name

A06 001 Exhaust pipe at cylinder head A06 004 Pin bolts on exhaust pipe

Screw type Torx screw, coated coated

Notes / Remark

Value

Use new screws.

55 Nm

Use new pin bolts

12 Nm

For the tightening procedure according to torque using a torque wrench, a maximum variation of the tightening torque of +/- 10% is permissible.

6

© 12/2008

3/4

17805-001

Exhaust system/Charging W 06-01-05

D 2011 w TD 2011 w, TCD 2011 w

6

© 12/2008

4/4

17805-001

Exhaust system/Charging W 06-02-03

TD 2011 w, TCD 2011 w Removing and install the charge air line Commercial available tools: – Torx tool set . . . . . . . . . . . . . . . . . . 8189

– W 06-06-04 – W 06-01-05

6

Remove charge air line z Remove turbocharger.  W 06-06-04

2

z Remove the exhaust pipe.

1

1

 W 06-01-05

1

z Unscrew all screws (1). z Remove charge air pipe (2). z Remove seals. 1

1

© 47525-2

z Clean sealing surfaces.

© 47533-0

© 12/2008

1/4

17806-001

Exhaust system/Charging W 06-02-03

TD 2011 w, TCD 2011 w

Install charge air line z Mount charge air line (1). z Mount new gaskets. z Tighten screws (2) alternately working from the centre to the outside.  21 Nm

1 2

2

2

z Install the exhaust pipe.  W 06-01-05 z Install the turbocharger.

2

 W 06-06-04

2

6 © 47525-3

© 12/2008

2/4

17806-001

TD 2011 w, TCD 2011 w

Exhaust system/Charging W 06-02-03

Technical Data Tightening specifications ID no.

Name

A06 030 Charge air pipe on cylinder head

Screw type Torx screw, coated

Notes / Remark

Value

Use new screws.

21 Nm

For the tightening procedure according to torque using a torque wrench, a maximum variation of the tightening torque of +/- 10% is permissible.

6

© 12/2008

3/4

17806-001

Exhaust system/Charging W 06-02-03

TD 2011 w, TCD 2011 w

6

© 12/2008

4/4

17806-001

Exhaust system/Charging W 06-06-04

TD 2011 w, TCD 2011 w Removing and installing the turbocharger Commercial available tools: – Clamping tongs. . . . . . . . . . . . . . . . 9088 – Spring band pliers . . . . . . . . . . . . . . 9090

Attention!

– Lubricating oil – Fitting compound DEUTZ S1

Collect leaking operating substances in suitable vessels and dispose of according to regulations.

Do not remove the stoppers/caps until immediately before assembly.

6

Removing turbocharger z Unscrew screw (1). z Remove the holder (2). z Remove oil return pipe (3). z Unscrew hollow screw (4). z Remove sealing rings.

3 4 2

1 © 47532-0

z Loosen hose clip (1) with clamping tongs. z Pull off hose clip (1) in the direction of the arrow.

1

© 47553-0

© 12/2008

1/8

17807-001

Exhaust system/Charging W 06-06-04

TD 2011 w, TCD 2011 w

z Loosen spring band clip (1) with spring band pliers. 2

z Remove reducer (2).

1

6 © 47554-0

z Unscrew hollow screw (1). z Remove lubricating oil pipe (2). z Remove sealing rings. z Press in stoppers.

1 2

© 47526-0

z Loosen spring band clip (1) with spring band pliers. z Pull off spring band clip (1) in the direction of the arrow.

1

© 47527-0

© 12/2008

2/8

17807-001

Exhaust system/Charging W 06-06-04

TD 2011 w, TCD 2011 w z Unscrew nuts (1).

1

1

6 © 47528-0

z Remove turbocharger in the direction of the arrow. z Remove gasket (1). 1

© 47555-0

z Remove the O-ring (1) with the disassembly tool. z Unscrew screw-in nipple (2). z Remove sealing ring (3).

2 3 1 © 47529-0

© 12/2008

3/8

17807-001

Exhaust system/Charging W 06-06-04

TD 2011 w, TCD 2011 w

z Unscrew studs (1). z Check components for visible signs of wear.

1

1

6 © 47523-0

Installing the turbocharger z Mount sealing ring (1). z Tighten screw-in nipple (2).  40 Nm z Insert new O-ring (3).

2 1 3 © 47529-1

z Clean sealing surfaces. z Coat pin bolts with mounting compound. z Screw in studs (1). z Tighten all pin bolts (1).  12 Nm

1

1

© 47523-0

© 12/2008

4/8

17807-001

Exhaust system/Charging W 06-06-04

TD 2011 w, TCD 2011 w z Mount gasket (1). z Plug in the tubing connection (2). z Insert turbocharger in the direction of the arrow.

1

2

6 © 47555-1

z Mount turbocharger (1). z Turn on new nuts (2). z Tighten nuts (2). 2

 21 Nm

2

1 © 47528-1

z Position the spring band clip (1) with the spring band pliers. z Pull out stoppers. z Fill in clean lubricating oil (arrow).

1

© 47527-0

© 12/2008

5/8

17807-001

Exhaust system/Charging W 06-06-04

TD 2011 w, TCD 2011 w

z Mount lubrication oil line (1). z Mount sealing rings (2). z Screw on hollow screw (3). 3 2 1

6 © 47526-1

z Insert new O-ring (1). z Lightly oil new O-ring (1).

1

© 39378-2

z Mount oil return pipe (1). z Mount holder (2). z Tighten screw (3).  8.5 Nm 4

Attention! Install tension-free.

1

z Mount new sealing rings (4).

5

z Tighten hollow screw (5).

2

3 © 47532-1

© 12/2008

6/8

17807-001

Exhaust system/Charging W 06-06-04

TD 2011 w, TCD 2011 w Attention! Install tension-free. z Tighten hollow screw (1).  29 Nm

1

6 © 47526-2

z Mount the reducer (1).

1

Attention! Install tension-free.

2

z Position spring band clip (2) with spring band pliers.

© 47554-1

z Position hose clip (1) with clamping tongs.

1

© 47553-1

© 12/2008

7/8

17807-001

Exhaust system/Charging W 06-06-04

TD 2011 w, TCD 2011 w

Technical Data Tightening specifications ID no. Name Screw type Notes / Remark A06 004 Pin bolts on exhaust pipe coated Use new pin bolts A06 020 Turbocharger on exhaust pipe M8 Lubricating oil pipe on turbocharger / A08 042 Hollow screw Replace sealing rings crankcase Oil return line, hex spuds to turbochA08 044 M16x1.5 Use new sealing ring arger Torx, A08 049 Holder oil return line on crankcase M6x14-8.8

6

Value 12 Nm 21 Nm 29 Nm 40 Nm 8.5 Nm

For the tightening procedure according to torque using a torque wrench, a maximum variation of the tightening torque of +/- 10% is permissible.

© 12/2008

8/8

17807-001

Exhaust system/Charging W 06-07-03

D 2011 w Removing and installing the intake manifold Commercial available tools: – Torx tool set . . . . . . . . . . . . . . . . . . 8189

– W 06-01-05

6

Removing the intake manifold z Remove the exhaust pipe.

2

 W 06-01-05 z Unscrew all screws (1). z Remove intake manifold (2). z Remove seals. 1

1

1

1

© 47645-0

z Clean sealing surfaces.

© 47533-0

© 12/2008

1/4

17808-001

Exhaust system/Charging W 06-07-03

D 2011 w

Installing the intake manifold z Mount new gaskets.

1

z Mount intake manifold (1). z Tighten new screws (2) alternately working from the centre to the outside.  21 Nm z Install the exhaust pipe.  W 06-01-05

2

2

2

2

6 © 47645-1

© 12/2008

2/4

17808-001

Exhaust system/Charging W 06-07-03

D 2011 w Technical Data Tightening specifications ID no.

Name Air suction intake pipe on cylinder A06 030 head

Screw type Torx screw, coated

Notes / Remark

Value

Use new screws.

21 Nm

For the tightening procedure according to torque using a torque wrench, a maximum variation of the tightening torque of +/- 10% is permissible.

6

© 12/2008

3/4

17808-001

Exhaust system/Charging W 06-07-03

D 2011 w

6

© 12/2008

4/4

17808-001

Exhaust system/Charging W 06-09-06

D 2011 w

Removing and installing the exhaust gas return valve Commercial available tools: – Special bit, 70 mm long. . . . . . . . . . 9120

6

Removing the exhaust gas return valve z Unscrew screw (1) with special bit. z Remove safety cover (2). z Unlock cable plug (3) and remove.

1 2

3

© 46964-0

z Pull out pipe holder (1).

1

© 46937-0

© 12/2008

1/8

17809-001

Exhaust system/Charging W 06-09-06

D 2011 w

z Unscrew hollow screws (1). z Remove pipe (2).

3

z Remove sealing rings (3). 1

3 2 1

6 © 46935-0

z Unscrew hollow screw (1). z Remove sealing rings (2). z Unscrew hollow screw (3). z Remove sealing rings (4). z Remove pipe (5).

2 1

5 3 4

© 46938-0

z Unscrew screws (1).

1

© 46939-0

© 12/2008

2/8

17809-001

Exhaust system/Charging W 06-09-06

D 2011 w z Remove gasket (1).

1

6 © 46940-0

z Unscrew screws (1). 1

z Remove the exhaust gas return valve.

1

© 46941-0

z Remove gasket (1).

1

© 46942-0

© 12/2008

3/8

17809-001

Exhaust system/Charging W 06-09-06

D 2011 w

z Visually inspect the components.

6 © 46965-0

Installing the exhaust gas return valve z Clean sealing surfaces. z Mount gasket (1). z Mount exhaust gas return valve (2). 1

2

© 46943-0

z Tighten screws (1). 1

z Tighten screws (1).  20 Nm

1

© 46941-0

© 12/2008

4/8

17809-001

Exhaust system/Charging W 06-09-06

D 2011 w z Clean sealing surfaces. z Mount gasket (1). z Mount exhaust gas collection pipe (2). z Fasten screws (3). z Tighten screws (3).

1

 20 Nm

3 3 2

6 © 46939-1

z Insert pipe (5). z Mount new sealing rings (4). z Screw on hollow screw (3). z Mount sealing rings (2). z Tighten hollow screw (1).

2

 29 Nm

1

z Tighten hollow screw (3).  12 Nm

5 3 4

© 46938-0

z Insert pipe (1). z Mount sealing rings (2).

2

z Screw on hollow screw (3). z Mount new sealing rings (4). 3

z Turn in hollow screw (5). z Tighten hollow screw (5).  29 Nm z Tighten hollow screw (3).

4

 29 Nm

1 5

© 46935-1

© 12/2008

5/8

17809-001

Exhaust system/Charging W 06-09-06

D 2011 w

z Press in pipe holder (1).

1

6 © 46937-0

z Plug in the cable plug (3). z Mount the safety cover (2). z Fasten screw (1). z Tighten screw (1) with special bit.  8 Nm

1 3

2

© 46964-0

© 12/2008

6/8

17809-001

Exhaust system/Charging W 06-09-06

D 2011 w Technical Data Tightening specifications ID no. A06 057 A06 062 A06 063 A06 071 A06 072 A06 074

Name Pipe to exhaust gas return valve/cylinder head (cooling - intake) Exhaust return pipe to exhaust return valve Exhaust gas collection pipe to exhaust gas return valve Pipe to crankcase (exhaust gas return - cooling - return) Pipe to exhaust gas return valve (exhaust gas return - cooling - return) Exhaust gas return pipe to cylinder head (exhaust gas return)

Safety cover on sensor housing A06 075 (exhaust gas return)

Screw type Notes / Remark Hollow screw M12x1.5

Value

M8x65-10.9

20 Nm

29 Nm

20 Nm Hollow screw M8x1 Hollow screw M12x1.5

12 Nm 29 Nm

6

8.5 Nm Locking screw Torx-Plus 30IPR

8 Nm

For the tightening procedure according to torque using a torque wrench, a maximum variation of the tightening torque of +/- 10% is permissible.

© 12/2008

7/8

17809-001

Exhaust system/Charging W 06-09-06

D 2011 w

6

© 12/2008

8/8

17809-001

Exhaust system/Charging W 06-09-07

D 2011 w

Removing and installing the exhaust gas return pipe Commercial available tools: – Special bit, 70 mm long. . . . . . . . . . 9120

6

Removing the exhaust gas return pipe z Unscrew screw (1). z Remove safety cover (2). z Unlock cable plug (3) and remove.

1 2

3

© 46964-0

z Pull out pipe holder (1).

1

© 46937-0

© 12/2008

1/8

17810-001

Exhaust system/Charging W 06-09-07

D 2011 w

z Unscrew hollow screws (1). z Remove pipe (2).

3

z Remove sealing rings (3). 1

3 2 1

6 © 46935-0

z Unscrew hollow screw (1). z Remove sealing rings (2). z Unscrew hollow screw (3). z Remove sealing rings (4). z Remove pipe (5).

2 1

5 3 4

© 46938-0

z Unscrew screws (1).

1

© 46939-0

© 12/2008

2/8

17810-001

Exhaust system/Charging W 06-09-07

D 2011 w z Remove gasket (1).

1

6 © 46940-0

z Unscrew screws (1). z Remove the exhaust return pipe.

1

1

1

1

© 46961-0

z Remove gasket (1).

1

© 46962-0

© 12/2008

3/8

17810-001

Exhaust system/Charging W 06-09-07

D 2011 w

z Unscrew screws (3). z Remove exhaust gas return valve (2). z Remove gasket (1). 1 2

3

3

6 © 46960-0

z Visually inspect the components.

© 46963-0

Installing the exhaust gas return pipe z Clean all sealing surfaces. z Mount gasket (1). 1

z Mount exhaust gas return valve (2). z Fasten screws (3).

2

z Tighten screws (3).  20 Nm

3

3

© 46960-0

© 12/2008

4/8

17810-001

Exhaust system/Charging W 06-09-07

D 2011 w z Clean all sealing surfaces. z Mount gasket (1).

1

6 © 46962-0

z Install the exhaust gas return pipe. z Tighten screws (1). z Tighten screws (1).  8.5 Nm 1

1

1

1

© 46961-0

z Clean sealing surfaces. z Mount gasket (1). z Mount exhaust gas collection pipe (2). z Fasten screws (3). z Tighten screws (3).

1

 20 Nm

3 3 2 © 46939-1

© 12/2008

5/8

17810-001

Exhaust system/Charging W 06-09-07

D 2011 w

z Insert pipe (5). z Mount new sealing rings (4). z Screw on hollow screw (3). z Mount sealing rings (2). z Tighten hollow screw (1).

2

 29 Nm

1

z Tighten hollow screw (3).  12 Nm

5 3 4

6 © 46938-0

z Insert pipe (1). z Mount sealing rings (2).

2

z Screw on hollow screw (3). z Mount new sealing rings (4). 3

z Turn in hollow screw (5). z Tighten hollow screw (5).  29 Nm z Tighten hollow screw (3).

4

 29 Nm

1 5

© 46935-1

z Press in pipe holder (1).

1

© 46937-0

© 12/2008

6/8

17810-001

Exhaust system/Charging W 06-09-07

D 2011 w z Plug in the cable plug (3). z Mount the safety cover (2). z Fasten screw (1). z Tighten screw (1).  8 Nm

1 3

2

6 © 46964-0

© 12/2008

7/8

17810-001

Exhaust system/Charging W 06-09-07

D 2011 w

Technical Data Tightening specifications ID no. A06 057 A06 062 A06 063 A06 071 A06 072

6

A06 074

Name Pipe to exhaust gas return valve/cylinder head (cooling - intake) Exhaust return pipe to exhaust return valve Exhaust gas collection pipe to exhaust gas return valve Pipe to crankcase (exhaust gas return - cooling - return) Pipe to exhaust gas return valve (exhaust gas return - cooling - return) Exhaust gas return pipe to cylinder head (exhaust gas return)

Safety cover on sensor housing A06 075 (exhaust gas return)

Screw type Notes / Remark Hollow screw M12x1.5

Value

M8x65-10.9

20 Nm

29 Nm

20 Nm Hollow screw M8x1 Hollow screw M12x1.5

12 Nm 29 Nm 8.5 Nm

Locking screw Torx-Plus 30IPR

8 Nm

For the tightening procedure according to torque using a torque wrench, a maximum variation of the tightening torque of +/- 10% is permissible.

© 12/2008

8/8

17810-001

Exhaust system/Charging W 06-09-08

D 2011 w

Removing and installing the exhaust gas collection pipe (Exhaust gas recirculation) Commercial available tools: – Cleaning brush . . . . . . . . . . . . . . . . 8167

– W 06-01-05 – W 06-09-07

6

Remove exhaust gas collection pipe z Remove the exhaust pipe.  W 06-01-05 z Remove the exhaust return pipe.  W 06-09-07

1

z Unscrew screws (1).

© 46946-0

z Unscrew screws (1). Note different screw lengths. 2

3

z Remove throttle (2). z Remove gaskets (3). 1

Note installation position.

© 46947-1

© 12/2008

1/6

17811-001

Exhaust system/Charging W 06-09-08

D 2011 w

z Remove gaskets (1).

1

6 © 46948-0

z Clean exhaust channels (1) with cleaning brush (2). z Clean all sealing surfaces. 1

1

2

1

© 46949-0

Install exhaust gas collection pipe z Check that mounting lugs (1) are sufficiently pre-tensioned.

1

1

© 46950-0

© 12/2008

2/6

17811-001

Exhaust system/Charging W 06-09-08

D 2011 w z Mount gasket (1). Make sure that the installation site of the mounting lugs (2) is in perfect condition.

2

2

1

6 © 46951-0

z Mount new gaskets (3). z Mount new throttle (2). Note installation position.

2

The marking (arrow) on the throttle is dependent on the engine version. z Insert exhaust gas collection pipe.

3

1

z Turn in new screws (1).

© 46952-1

z Turn in new screws (1). z Tighten new screws (1).  55 Nm

1

© 46946-0

© 12/2008

3/6

17811-001

Exhaust system/Charging W 06-09-08

D 2011 w

z Tighten new screws (1).  55 Nm z Install the exhaust gas return pipe.  W 06-09-07 z Install the exhaust pipe.  W 06-01-05

1

6 © 46947-0

© 12/2008

4/6

17811-001

Exhaust system/Charging W 06-09-08

D 2011 w Technical Data Tightening specifications ID no.

Name

A06 073

Exhaust gas collection pipe (exhaust gas return) on cylinder head

Screw type Notes / Remark Torx M10x25-10.9 Torx Use new screws. M10x30-10.9 Torx M10x45-10.9

Value

55 Nm

For the tightening procedure according to torque using a torque wrench, a maximum variation of the tightening torque of +/- 10% is permissible.

6

© 12/2008

5/6

17811-001

Exhaust system/Charging W 06-09-08

D 2011 w

6

© 12/2008

6/6

17811-001

Exhaust system/Charging W 06-09-09

D 2011 w Removing and installing the sensor (Exhaust gas recirculation) Commercial available tools

Attention!

Special tools: – Special bit, 70 mm long. . . . . . . . . . 9120

If the sensor (exhaust gas return) is exchanged/adjusted, the engine must be set on the engine test bench.

6

Remove sensor z Disconnect the battery. z Unscrew screw (1) with special bit. z Remove safety cover (2). z Unlock cable plug (3) and remove.

1

2

3 © 46964-1

z Unscrew screws (1). z Swing fuel filter console (2) to the side.

2

1

© 46973-0

© 12/2008

1/4

17812-001

Exhaust system/Charging W 06-09-09

D 2011 w

z Unscrew screw (1). z Remove sensor (2). z Clean sealing surfaces.

1

2

6 © 46974-0

z Remove sealing ring (1). z Visually inspect the components.

1

© 46975-0

Install sensor z Insert new sealing ring (1). Ensure that the installation location of the sealing ring is free from faults.

1

© 46975-1

© 12/2008

2/4

17812-001

Exhaust system/Charging W 06-09-09

D 2011 w z Mount sensor (2). Ensure that the installation location is free from faults. z Fasten screw (1).

1

2

6 © 46974-0

z Mount fuel filter console (1). z Tighten screws (2). z Tighten screws (2).  21 Nm

3

z Tighten screw (3). 1

 21 Nm

2

© 46973-1

z Plug in the cable plug (3). z Mount the safety cover (2). z Fasten screw (1). z Tighten screw (1) with special bit.  8 Nm z Connect the battery.

1

2

3 © 46964-1

© 12/2008

3/4

17812-001

Exhaust system/Charging W 06-09-09

D 2011 w

Technical Data Tightening specifications ID no.

Name

A06 075

Safety cover on sensor housing (exhaust gas return)

Screw type Locking screw Torx-Plus 30IPR

Sensor exhaust gas return on crankcase A07 087 Fuel filter console to crankcase A06 076

Notes / Remark

Value 8 Nm 21 Nm 21 Nm

For the tightening procedure according to torque using a torque wrench, a maximum variation of the tightening torque of +/- 10% is permissible.

6

© 12/2008

4/4

17812-001

Exhaust system/Charging W 06-09-10

D 2011 w Removing and installing the magnet clip (Exhaust gas recirculation) Commercial available tools

– W 06-09-09 – W 07-04-01

6

Remove magnet clip z Disconnect the battery. z Remove sensor of exhaust gas return.  W 06-09-09 z Remove fuel injector 3rd cylinder.  W 07-04-01

© 47230-1

z Insert clean rags (1) under the control linkage. z Move the control linkage in the direction of the arrow.

2

z Hold on to the control linkage.

2

z Bend the retaining tab (2).

1 © 46972-1

© 12/2008

1/4

17813-001

Exhaust system/Charging W 06-09-10

D 2011 w

z Hold on to the control linkage. z Pull off magnet clip (1) in the direction of the arrow.

Attention! Make sure no parts fall into the crankcase! Pay attention to utmost cleanliness.

1

6

© 46971-0

Install magnet clip z Insert clean rags (1) under the control linkage. z Position control linkage. z Hold on to the control linkage. z Push new magnet clip (2) onto the control linkage.

1

2

© 46971-1

Attention! The magnet clip must sit tightly in the recess of the control linkage. Retaining tab (1) must snap in. Ensure that the installation location is free from faults. 1

1

© 46976-0

© 12/2008

2/4

17813-001

Exhaust system/Charging W 06-09-10

D 2011 w z Install fuel injector 3rd cylinder.  W 07-04-01 z Install sensor of exhaust gas return.  W 06-09-09 z Connect the battery.

6 © 47230-0

© 12/2008

3/4

17813-001

Exhaust system/Charging W 06-09-10

D 2011 w

6

© 12/2008

4/4

17813-001

D 2011 w TD 2011 w, TCD 2011 w

Fuel system W 07-02-07

Removing and installing the lifting magnet (Start amount release) Commercial available tools: – Plier insert. . . . . . . . . . . . . . . . . . . . 8027

Collect leaking operating substances in suitable vessels and dispose of according to regulations.

Special tools: – Disassembly tool. . . . . . . . . . . . . 110901

6

Remove lifting magnet z Pull out cable plug (1).

1

© 47128-0

z Unscrew lifting magnet (1) with plier insert. Note direction of terminal.

1

© 39663-1

© 12/2008

1/4

17814-001

Fuel system W 07-02-07

D 2011 w TD 2011 w, TCD 2011 w

z Remove the O-ring (1) with the disassembly tool. z Visually inspect the components.

1

6 © 47392-0

Install lifting magnet z Insert new O-ring (1).

1

© 47392-0

z Clean all sealing surfaces. z Insert lifting magnet (1).

1

© 47393-0

© 12/2008

2/4

17814-001

D 2011 w TD 2011 w, TCD 2011 w

Fuel system W 07-02-07

z Tighten lifting magnet (1) with plier insert.  10 Nm 1

Note direction of terminal.

6 © 39664-1

z Plug in the cable plug (1).

1

© 47128-0

© 12/2008

3/4

17814-001

Fuel system W 07-02-07

D 2011 w TD 2011 w, TCD 2011 w

Technical Data Tightening specifications ID no.

Name Screw type Lifting magnet (start amount release) A05 065 on front cover

Notes / Remark

Value 10 Nm

For the tightening procedure according to torque using a torque wrench, a maximum variation of the tightening torque of +/- 10% is permissible.

6

© 12/2008

4/4

17814-001

D 2011 w TD 2011 w, TCD 2011 w

Fuel system W 07-03-01

Renewing the injection lines Commercial available tools: – Dog wrench. . . . . . . . . . . . . . . . . . . 8018

Danger! Wait 30 seconds after switching off the engine before working on the fuel system.

Special tools: – Plugs/caps . . . . . . . . . . . . . . . . . 170160

Attention! Pay attention to utmost cleanliness when working on the fuel system. Remove residue paint and particles of dirt before removing. Clean the respective affected parts carefully. Blow damp areas dry with compressed air. Observe the safety regulations and national specifications for handling fuels. Close all connections immediately after opening with new, clean plugs/caps. Do not remove plugs/caps until immediately before assembling. Collect leaking operating substances in suitable vessels and dispose of according to regulations. Injection pipes may not be bent. After all work on the fuel system, it must be bleeded - see the operation manual, chapter "6 Fuel system“.

Removing injection pipes z Unscrew lock nuts (1) with dog wrench.

1

© 47653-0

© 12/2008

1/6

17819-001

6

Fuel system W 07-03-01

D 2011 w TD 2011 w, TCD 2011 w

z Remove injection pipes (1). Lay out components in the order in which they should be installed.

1

Note assignment!

1

6 © 47652-0

z Mount the caps (1).

1

1 © 47654-0

z Visually inspect the components.

© 47340-0

© 12/2008

2/6

17819-001

D 2011 w TD 2011 w, TCD 2011 w

Fuel system W 07-03-01

Installing injection pipes z Pull off the caps (1). z Mount new injection pipe. 1

6

1 © 47654-0

z Screw on union nuts (1).

Attention! Install injection line without tension. Note installation position.

1 1

1

1 © 00000-0

z Tighten union nuts (1) with claw spanner.  25 Nm

1

© 47653-0

© 12/2008

3/6

17819-001

Fuel system W 07-03-01

D 2011 w TD 2011 w, TCD 2011 w

Technical Data Tightening specifications ID no.

Name Screw type Injection line on fuel injector / injection A07 003 M12x1.5 pump

Notes / Remark

Value 25 Nm

For the tightening procedure according to torque using a torque wrench, a maximum variation of the tightening torque of +/- 10% is permissible.

6

© 12/2008

4/6

17819-001

D 2011 w TD 2011 w, TCD 2011 w

Fuel system W 07-04-01

Removing and installing the fuel injector pump Commercial available tools

– W 07-03-01 – W 07-06-03 – W 07-06-01 – W 07-10-06 – W 11-00-03

Special tools: – Ajustable bolt . . . . . . . . . . . . . . . 100710 – Rig pin. . . . . . . . . . . . . . . . . . . . . 101100 – Test template . . . . . . . . . . . . . . . 103040 – Special pliers. . . . . . . . . . . . . . . . 103220 – Disassembly tool. . . . . . . . . . . . . 110901 – Plugs/caps . . . . . . . . . . . . . . . . . 170160

Danger! Wait 30 seconds after switching off the engine before working on the fuel system.

– Fitting compound DEUTZ AP1908

Attention! Pay attention to utmost cleanliness when working on the fuel system. Remove residue paint and particles of dirt before removing. Clean the respective affected parts carefully. Blow damp areas dry with compressed air. Observe the safety regulations and national specifications for handling fuels. Close all connections immediately after opening with new, clean plugs/caps. Do not remove plugs/caps until immediately before assembling. Collect leaking operating substances in suitable vessels and dispose of according to regulations. After all work on the fuel system, it must be bleeded - see the operation manual, chapter "6 Fuel system“. The following work procress is described for a cylinder as an example.

Removing the fuel injector pump z Unscrew all screws (1). z Remove cylinder head cowling (2). 1

2

© 47540-0

© 12/2008

1/14

17815-001

6

Fuel system W 07-04-01

D 2011 w TD 2011 w, TCD 2011 w

z Remove gasket. z Remove injection lines.  W 07-03-01 z Remove fuel pipes.  W 07-10-06 z Remove lifting magnet (engine shutdown).  W 11-00-03

6 © 47634-0

z Turn crankshaft in the direction of the engine (arrow). z Turn over crankshaft until the valve overlap is achieved on cylinder 1.

© 47541-0

Arrangement of the inlet and exhaust valves. IN = inlet valve EX = exhaust valve Valve overlap means: The inlet valve starts opening,exhaust valve closes.

Attention! In case of internal exhaust gas recirculation, the inlet valve is opened briefly by an additional cam on the camshaft. This is not to be confused with the valve overlap.

EX

IN

EX

© 47612-0

© 12/2008

2/14

17815-001

D 2011 w TD 2011 w, TCD 2011 w

Fuel system W 07-04-01

z Turn crankshaft approx. 180° in the direction of the engine.

6 © 47541-0

The cam (1) for the actuation of the injection pump of the corresonding cylinder must be located on the base circle.

1

© 47356-0

z Loosen nuts (1) alternately. Loosen nuts evenly to avoid tension on the injection pump. z Unscrew nuts (1). z Remove washers.

2

z Remove fuel injector pump(2). Lay out components in the order in which they should be installed. Note assignment!

1

© 47627-0

© 12/2008

3/14

17815-001

Fuel system W 07-04-01

D 2011 w TD 2011 w, TCD 2011 w

z Remove shim (1). Lay out components in the order in which they should be installed. Note assignment! 1

6 © 47558-0

z Pull out roller tappet (1) with special pliers.

Attention! Do not damage the roller tappet! Lay out components in the order in which they should be installed. Note assignment!

1

© 47628-0

z Remove the O-ring (1) with the disassembly tool. z Visually inspect the components. 1

© 47233-0

© 12/2008

4/14

17815-001

D 2011 w TD 2011 w, TCD 2011 w

Fuel system W 07-04-01

z Unscrew locking screw (1). z Remove sealing ring.

1

6 © 47629-0

z Move the control linkage in the direction of the arrow. z Knock in the adjustable bolt (1) to the stop. The control linkage is stopped by the adjustable bolts. Ensure that the installation location is free from faults.

1 © 47630-1

Installing the fuel injector pump Note assignment of injection pump/roller tappet/shim to the cam.

© 47235-0

© 12/2008

5/14

17815-001

Fuel system W 07-04-01

D 2011 w TD 2011 w, TCD 2011 w

z Turn camshaft until the cam for the injection pump is on the base circle (arrow).

6 © 46048-0

z Oil the roller tappet lightly. z Insert roller tappet with special pliers. Note assignment! The pilot pin (1) must lock in groove (2). 1

2 © 47639-0

z Oil the locating hole lightly. z Determining the thickness of the shim.  W 07-06-03

© 47631-0

© 12/2008

6/14

17815-001

D 2011 w TD 2011 w, TCD 2011 w

Fuel system W 07-04-01

z Select shim using table.  P07 21 z Check thickness of the shim with test template. The reference line must lie centrally to the round recess (dimension a). a

6 © 47357-1

z Position shim. Note assignment! The bolt (1) must face in the direction of the cylinder head.

1

© 47631-1

z Insert new O-ring (1). z Coat the O-ring with fitting compound. 1

© 47233-0

© 12/2008

7/14

17815-001

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z Pull out locking pin (1). Pay attention to sealing.

1

6 © 47239-0

z Insert rig pin (1). Do not press in rig pin.

1

© 47240-0

z Press in rig pin (1) slightly. z Turn adjusting sleeve (2) back and forth. Turn the adjusting sleeve until the rig pin you can feel and hear it lock into the punch mark (3).

1

2 3 © 47241-0

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z Insert injection pump (1). Note assignment! z Tighten nuts (2) alternately.  21 Nm

1

2

6 © 47632-0

z Loosen clamping bar (arrow). z Pull out rig pin (1).

1

© 47632-1

z Press in the locking pin (1) to the stop.

1

© 47633-0

© 12/2008

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D 2011 w TD 2011 w, TCD 2011 w

z Unscrew adjustable bolt (1).

1

6 © 47632-2

z Mount new sealing ring. z Tighten screw plug (1).  18 Nm z Check start of injection.  W 07-06-01

1 © 47627-1

z Install lifting magnet (engine shutdown).  W 11-00-03 z Install fuel pipes.  W 07-10-06 z Install injection lines.  W 07-03-01

© 47634-0

© 12/2008

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Fuel system W 07-04-01

z Mount new gasket. z Mount cylinder head cover (2). z Tighten all screws (1).  8.5 Nm 1

2

6 © 47540-0

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Technical Data Testing and setting data ID no.

6 P07 21

Thickness of shim Dimension a of the (difference Ss calThickness of shim Part number identification culated) up to 0.375 0,3751 - 0,425 0,4251 - 0,475 0,4751 - 0,525 0,5251 - 0,575 0,5751 - 0,625 0,6251 - 0,675 0,6751 - 0,725 0,7251 - 0,775 0,7751 - 0,825 0,8251 - 0,875 0,8751 - 0,925 0,9251 - 0,975 0,9751 - 1,025 1,0251 - 1,075 1,0751 - 1,125 1,1251 - 1,175 1,1751 - 1,250 1,2501 - 1,36

17 mm 15 mm 20 mm 18 mm 23 mm 21 mm 26 mm 24 mm 8 mm 27 mm 11 mm 30 mm 29 mm 33 mm 7 mm 10 mm 13 mm 16 mm 19 mm

0.35 mm 0.40 mm 0.45 mm 0.50 mm 0.55 mm 0.60 mm 0.65 mm 0.70 mm 0.75 mm 0.80 mm 0.85 mm 0.90 mm 0.95 mm 1.00 mm 1.05 mm 1.10 mm 1.15 mm 1.20 mm 1.30 mm

04287618 04287619 04287620 04287621 04287622 04287623 04287624 04287625 04287626 04287627 04287628 04287629 04287630 04287631 04287632 04287633 04287634 04287635 04287636

Tightening specifications ID no. Name Screw type A01 004 Cylinder head cover on cylinder head

Notes / Remark Adapter for adjustable bolt on control linkage lock. Replace sealing ring.

A03 004 Locking screw on crankcase A07 012 Injection pump on crankcase

Value 8.5 Nm 18 Nm 21 Nm

For the tightening procedure according to torque using a torque wrench, a maximum variation of the tightening torque of +/- 10% is permissible.

© 12/2008

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Fuel system W 07-06-01

Check start of injection Commercial available tools

– W 07-03-01 – W 07-10-06 – W 11-00-03

Special tools: – Ajustable bolt . . . . . . . . . . . . . . . 100700 – Degree scale. . . . . . . . . . . . . . . . 101020 – Adapter . . . . . . . . . . . . . . . . . . . . 101030 – Pointer . . . . . . . . . . . . . . . . . . . . 101300 – High-pressure hand pump . . . . . 101500 – Supply tank . . . . . . . . . . . . . . . . . 101510 – Plugs/caps . . . . . . . . . . . . . . . . . 170160

Danger! Wait 30 seconds after switching off the engine before working on the fuel system.

Attention! Pay attention to utmost cleanliness when working on the fuel system. Remove residue paint and particles of dirt before removing. Clean the respective affected parts carefully. Blow damp areas dry with compressed air. Observe the safety regulations and national specifications for handling fuels. Close all connections immediately after opening with new, clean plugs/caps. Do not remove plugs/caps until immediately before assembling. Collect leaking operating substances in suitable vessels and dispose of according to regulations. After all work on the fuel system, it must be bleeded - see the operation manual, chapter "6 Fuel system“. This descriptions refers to the cylinder on the front cover. When checking other cylinders, the corresponding ignition UDC should be calculated from the degree scale.

Check start of injection z Remove injection lines.  W 07-03-01 z Remove fuel pipes.  W 07-10-06 z Remove lifting magnet.  W 11-00-03 z Unscrew locking screw (1).

1

z Remove sealing ring.

© 47619-0

© 12/2008

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6

Fuel system W 07-06-01

D 2011 w TD 2011 w, TCD 2011 w

z Insert adjustable bolt (1).

1

6 © 47620-0

z Press adjustable bolt in lightly in direction of arrow and hold. z Turn crankshaft slowly in direction of engine until the adjustable bolt engages with the bore of the camshaft.

© 47621-0

z Knock in the adjustable bolt (1) to the stop.

1

© 47621-1

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Fuel system W 07-06-01

z Unscrew locking screw (1). z Remove sealing ring.

1

6 © 47270-0

z Insert adjustable bolt (1).

1

© 47296-0

z Knock in the adjustable bolt (1) to the stop. z Turn crankshaft carefully against the adjustable bolt. The cylinder on the front cover is now located in the ignition UDC.

1

© 47271-0

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z Loosen screw (1). z Mount pointer with holding device (2). z Tighten screw (1).  21 Nm 1

2

6

© 47622-0

z Mount adapter (1). z Tighten screws (2). z Screw on degree scale (3).

1

2

3 © 47623-0

z Bring degree scale into line with pointer. z Set the pointer (1) in line with the “0°“ marking. z Fasten degree scale. z Fasten pointer. 1

© 47635-3

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Fuel system W 07-06-01

z Unscrew locking screw (1). z Remove sealing ring.

1

6 © 47624-0

z Bring control linkage into the middle position. z Knock in the adjustable bolt (1) to the stop.

1

© 47244-0

z Mount overflow pipe (1). z Connect hose (2) to overflow pipe.

1

z Connect hose (2) to supply tank. z Connect pressure pipe (3) to fuel injector.

3 2

z Connect intake pipe (4) to supply tank. z Fill supply tank with clean fuel. 4

© 47625-0

© 12/2008

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z Mount locking screw (1). Do not tighten locking screw.

1

6 © 47626-0

z Unscrew adjustable bolt to the camshaft and crankshaft lock. z Turn crankshaft carefully approx. 90° in the direction of the arrow (against the direction of the engine).

© 47635-1

z Bleed the suction chamber of the injection pump. z Activate high-pressure hand pump until fuel emerges at the locking screw (1). z Tighten screw plug (1).  45 Nm 1

© 47626-0

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Fuel system W 07-06-01

z Actuate the high-pressure hand pump constantly. The fuel must flow evenly out of the overflow pipe. z Turn the crankshaft slowly and evenly in the direction of the arrow (engine direction of rotation) until the fuel flow turns to drops. As soon as the fuel flow becomes drops, the start of injection has been reached.

6 © 47635-2

z Read start of injection on the degree scale. Start of injection: Note specifications on the company plate. The start of injection must be set if it does not match the specifications. The start of injection of other injection pumps should be checked using this method. Calculate the ignition UDC of each cylinder with the degree scale. Observe ignition interval. Cylinders 4

Ignition interval 180°

© 47635-0

z Unscrew adjustable bolt (1).

1

© 47244-0

© 12/2008

7/12

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D 2011 w TD 2011 w, TCD 2011 w

z Mount new sealing ring. z Tighten screw plug (1).  18 Nm

1

6 © 47624-0

z Loosen screw (1). z Remove pointer with holding device (2). z Tighten screw (1).  21 Nm 1

2 © 47622-0

z Remove intake pipe (4). z Remove pressure pipe (3).

1

z Remove hose (2). z Remove overflow pipe (1).

3 2

z Remove the high-pressure hand pump.

4

© 47625-0

© 12/2008

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Fuel system W 07-06-01

z Unscrew locking screw (1). z Remove sealing ring.

1

6 © 47626-0

z Unscrew degree scale (1). z Unscrew screws (2). z Remove adapter (3).

3

2

1 © 47623-1

z Loosen screw (1). z Remove pointer with holding device (2). z Tighten screw (1).  21 Nm 1

2 © 47622-0

© 12/2008

9/12

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Fuel system W 07-06-01

D 2011 w TD 2011 w, TCD 2011 w

z Insert new sealing ring. z Tighten screw plug (1).  18 Nm

1

6 © 47619-0

z Insert new sealing ring. z Tighten screw plug (1).  18 Nm z Install injection lines.  W 07-03-01

1

z Install fuel pipes.  W 07-10-06 z Install lifting magnet.  W 11-00-03

© 47270-0

© 12/2008

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Technical Data Tightening specifications ID no.

Name

A03 003 Locking screw on crankcase

Screw type M10x1

A03 004 Locking screw on crankcase A03 020 Front cover on crankcase A07 071 Locking screw on injection pump

Notes / Remark Adapter for adjustable bolt on camshaft lock/ crankshaft lock. Replace sealing ring. Adapter for adjustable bolt on control linkage lock. Replace sealing ring. Replace sealing ring

Value 18 Nm

18 Nm 21 Nm 45 Nm

6 For the tightening procedure according to torque using a torque wrench, a maximum variation of the tightening torque of +/- 10% is permissible.

© 12/2008

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6

© 12/2008

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Fuel system W 07-06-03

Determining the thickness of the shim Commercial available tools: – Depth measuring screw . . . . . . . . . 8170

– W 07-04-01

All contact and measuring surfaces must be absolutely clean to rule out measuring errors! The following work process should be carried out on each injection pump if necessary.

6

z Removal and installation of roller tappet, visual inspection.  W 07-04-01

© 47561-1

z Mount probe for measuring range 50 to 75 mm on depth measuring screw. Measuring range default approx. 52 mm.

© 39183-1

© 12/2008

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z Place the depth measuring screw on the contact surface of the crankcase and keep it pressed against the stop. z Turn the depth measuring screw until the probe is touching the roller tappet.

6 © 39184-2

z To determine the total depth dimension, in the case of hydro-roller tappets, the working piston (1) in the roller tappet must be pressed down until touching (arrow) (approx. 1 mm) by turning the depth measuring screw further.

© 39128-1

z Measure, read and note the depth dimension "A" from the crankcase rest to the plate spring rest of the roller tappet. – Example:  60,25 mm

© 39184-1

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z Read and note installation dimension "X" from the rating plate of the respective injection pump.

X

The installation dimension "X" serves to calculate the shim/gasket. Do not measure on the removed injection pump. The exact installation dimension "X" is specified on the injection pump's rating plate. Example: 6160 Installation dimension "X" = 61,60 mm

6 © 47494-0

z Read and note value of the pre-stroke correction from the company rating plate. The pre-stroke correction value is specified with a minus (-) or plus (+) sign. Example: –16 z Calculate thickness of the shim "Ss". Calculation example Desired: - Thickness of shim Ss - Thickness of shim without prestroke correction So Given: - Installation dimension of the injection pump X - Prestroke correction Vk Measured: - Depth gauge A Calculation: S o= X – A So= 61,60 mm – 60,25 mm So= 1,35 mm Calculation: Ss= So + Vk Ss= 1,35 mm + (– 0,16 mm) Result: Ss= 1,19 mm

© 39877-1

z Select shim using table.  P07 21 z Install injection pumps.  W 07-04-01

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Technical Data Testing and setting data ID no.

6 P07 21

© 12/2008

Thickness of shim Dimension a of the (difference Ss calThickness of shim Part number identification culated) bis 0,375 0,3751 - 0,425 0,4251 - 0,475 0,4751 - 0,525 0,5251 - 0,575 0,5751 - 0,625 0,6251 - 0,675 0,6751 - 0,725 0,7251 - 0,775 0,7751 - 0,825 0,8251 - 0,875 0,8751 - 0,925 0,9251 - 0,975 0,9751 - 1,025 1,0251 - 1,075 1,0751 - 1,125 1,1251 - 1,175 1,1751 - 1,250 1,2501 - 1,36

17 mm 15 mm 20 mm 18 mm 23 mm 21 mm 26 mm 24 mm 8 mm 27 mm 11 mm 30 mm 29 mm 33 mm 7 mm 10 mm 13 mm 16 mm 19 mm

0,35 mm 0,40 mm 0,45 mm 0,50 mm 0,55 mm 0,60 mm 0,65 mm 0,70 mm 0,75 mm 0,80 mm 0,85 mm 0,90 mm 0,95 mm 1,00 mm 1,05 mm 1,10 mm 1,15 mm 1,20 mm 1,30 mm

4/4

04287618 04287619 04287620 04287621 04287622 04287623 04287624 04287625 04287626 04287627 04287628 04287629 04287630 04287631 04287632 04287633 04287634 04287635 04287636

17817-001

D 2011 w TD 2011 w, TCD 2011 w

Fuel system W 07-07-01

Removing and installing the fuel injectors Commercial available tools: – Assembly pliers. . . . . . . . . . . . . . . . 8024

– W 07-03-01 – W 07-07-02

Special tools: – Puller. . . . . . . . . . . . . . . . . . . . . . 110090 – Slide hammer . . . . . . . . . . . . . . . 150800 – Plugs/caps . . . . . . . . . . . . . . . . . 170160

Danger! Wait 30 seconds after switching off the engine before working on the fuel system.

Attention! Pay attention to utmost cleanliness when working on the fuel system. Remove residue paint and particles of dirt before removing. Clean the respective affected parts carefully. Blow damp areas dry with compressed air. Observe the safety regulations and national specifications for handling fuels. Close all connections immediately after opening with new, clean plugs/caps. Do not remove plugs/caps until immediately before assembling. Collect leaking operating substances in suitable vessels and dispose of according to regulations. After all work on the fuel system, it must be bleeded - see the operation manual, chapter "6 Fuel system“.

Removing fuel injector z Remove injection lines.  W 07-03-01

© 47557-0

© 12/2008

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Fuel system W 07-07-01

D 2011 w TD 2011 w, TCD 2011 w

z Unscrew screw (1). z Remove clamping shoe (2).

1

2

6 © 47562-0

z Pull out fuel injector (1) and sealing ring (arrow). Lay out components in the order in which they should be installed. Note cylinder assignment. 1

© 47636-0

Removing stuck fuel injectors z Assembly sliding hammer (1) and puller (2). z Tighten lock nut (3). 1

2 3

© 40958-0

© 12/2008

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Fuel system W 07-07-01

z Mount sliding hammer on fuel injector. z Screw on lock nut (1). z Pull out stuck fuel injector.

1

6 © 47564-0

z Grip a tight sealing ring (1) with the assembly pliers (2) and pull off, turning slightly.

Attention! Do not damage the nozzle tip!

1 2 © 43303-0

z Visually inspect the components. z Check the fuel injector.  W 07-07-02

© 47349-0

© 12/2008

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Installing the fuel injector z Mount new sealing ring (1) on fuel injector.

6 © 47351-0

z Insert fuel injector. z Mount clamping shoe. Note installation position of the clamping shoe. z Fasten screws.

© 39488-1

z Tighten screw (1).  21 Nm

1

© 47562-1

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Fuel system W 07-07-01

z Install injection lines.  W 07-03-01

6 © 47557-0

© 12/2008

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Technical Data Tightening specifications ID no. Name A07 001 Fuel injector on cylinder head

Screw type

Notes / Remark

Value 21 Nm

For the tightening procedure according to torque using a torque wrench, a maximum variation of the tightening torque of +/- 10% is permissible.

6

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Fuel system W 07-07-02

Checking fuel injectors Commercial available tools: – Nozzle tester. . . . . . . . . . . . . . . . . . 8008 – Socket wrench insert spanner size 15 . . . . . . . . . . . . . . . 8012

– W 07-07-01

Special tools: – Holder . . . . . . . . . . . . . . . . . . . . . 110110

Danger of injury when handling the nozzle tester.

Danger!

The fuel penetrates deep into the flesh through the nozzle jet! Caution, blood poisoning! After about three or four actuations of the hand lever, the spring space above the nozzle needle in the injection valve fills up with diesel fuel/test oil. Then it is no longer possible to actuate the hand lever. The nozzle cap nut must be loosened carefully before every test procedure to release pressure from the spring space. Only use pure test oil according to ISO 4113 or clean diesel fuel to test the fuel injectors.

Connecting the fuel injector to the nozzle tester z Removing fuel injectors.  W 07-07-01 z Insert fuel injector in holder. z Loosen nozzle cap nut approx. 180° with socket wrench insert (release pressure) and re-tighten.  45 - 50 Nm

© 36271-2

© 12/2008

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6

Fuel system W 07-07-02

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z Connect the fuel injector to the nozzle tester

6 © 35889-2

Checking opening pressure z Press down the lever of the nozzle tester slowly with the pressure gauge connected. z Read off measured value.  170

+10

bar (17

+1

MPa)

The pressure at which the pointer stands still or suddenly drops is the opening pressure. Repeat test 3 times.

© 36293-2

z Compare measured values. The measured values of three tests must match the test value. z In case of deviations from the test value, the fuel injector must be renewed.

© 36293-2

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Fuel system W 07-07-02

Checking tightness z Blow the injection nozzle and nozzle holder dry with air. z Press the hand lever of the tester down slowly until about 20 bar below the previously read opening pressure are reached.

6 © 36293-2

Injection nozzle is tight if it does not drip within 10 seconds.

© 36294-2

z If the injection nozzle drips, the fuel injector must be renewed.

Attention! Repairs are not permitted!

© 36295-2

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Checking the easy action of the nozzle needle z Switch off the tester’s pressure gauge. z Carry out chatter and jet test of the nozzle needle. The easy action of the nozzle needle in the nozzle body is checked by the acoustic chatter test. Increasing wear in the needle seat of the fuel injectors changes the chatter behavior of the injecton nozzle. A used fuel injector must buzz audibly and atomize the fuel finely when the lever is actuated quickly. The jet profile may deviate considerably from that of a new fuel injector.

6

© 36296-2

z If the injection nozzle does not buzz audibly, the fuel injector must be renewed.

© 36296-2

Removing the fuel injector from the nozzle tester z Loosen nozzle cap nut approx. 180° with socket wrench insert (release pressure) and re-tighten.  45 - 50 Nm

Attention! The pressure in the spring space must be reduced before installing the fuel injectors. z Install fuel injectors.  W 07-07-01

© 36271-2

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Fuel system W 07-07-02

Technical Data Testing and setting data ID no.

Name

P07 52

Fuel injector (without leak oil), nozzle opening pressure

Additional information

Value 170 (17

+10

+1

bar

MPa)

Tightening specifications ID no.

Name Injection valve, clamping nut on A07 002 nozzle holder (without leak oil)

Screw type

Notes / Remark

Value 45 - 50 Nm

For the tightening procedure according to torque using a torque wrench, a maximum variation of the tightening torque of +/- 10% is permissible.

© 12/2008

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6

Fuel system W 07-07-02

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6

© 12/2008

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Fuel system W 07-08-01

TD 2011 w, TCD 2011 w Removing and installing the lifting magnet (charge air pressure-dependent full load stop) Commercial available tools: – Plier insert. . . . . . . . . . . . . . . . . . . . 8027 Special tools: – Disassembly tool. . . . . . . . . . . . . 110901

6

Remove lifting magnet z Pull out cable plug. z Unscrew lifting magnet (1) with plier insert.

1

© 47646-0

z Remove the O-ring with the disassembly tool. z Visually inspect the components.

© 47647-0

© 12/2008

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Fuel system W 07-08-01

TD 2011 w, TCD 2011 w

Install lifting magnet z Mount new O-ring. z Insert lifting magnet (1).

1

6 © 47648-0

z Tighten lifting magnet (1) with plier insert.  10 Nm 1

© 47646-0

© 12/2008

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Fuel system W 07-08-01

TD 2011 w, TCD 2011 w Technical Data Tightening specifications ID no. Name A06 094 Lifting magnet on fuel filter console

Screw type

Notes / Remark Renew O-ring

Value 10 Nm

For the tightening procedure according to torque using a torque wrench, a maximum variation of the tightening torque of +/- 10% is permissible.

6

© 12/2008

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TD 2011 w, TCD 2011 w

6

© 12/2008

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Fuel system W 07-08-02

TD 2011 w, TCD 2011 w

Installing and removing charge air pressure-dependent full load stop Commercial available tools: – Plier insert. . . . . . . . . . . . . . . . . . . . 8027

– W 07-10-08

Special tools: – Disassembly tool. . . . . . . . . . . . . 110901

6

Removing the charge air-pressure dependent full load stop z Remove fuel filter console.  W 07-10-08 z Unscrew screws (1). 1

© 39385-2

z Remove cover (1). z Remove diaphragms (2). z Remove spring (3). 3

1 2

© 39386-2

© 12/2008

1/4

17822-001

Fuel system W 07-08-02

TD 2011 w, TCD 2011 w

z Unscrew lifting magnet (1) with plier insert. 1

6 © 39387-1

z Remove the O-ring with the disassembly tool. z Visually inspect the components.

© 47647-0

Installing the charge air-pressure dependent full load stop z Clean sealing surfaces.

1

z Mount new O-ring. z Tighten lifting magnet (1) with plier insert.  10 Nm

© 39388-1

© 12/2008

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17822-001

Fuel system W 07-08-02

TD 2011 w, TCD 2011 w z Insert spring (1). z Insert diaphragm (2) and cap (3).

Attention! Note installation position.

3

2

1

6 © 39389-1

z Tighten screws (1).  8 Nm z Install the fuel filter console.  W 07-10-08 1

© 39385-2

© 12/2008

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17822-001

Fuel system W 07-08-02

TD 2011 w, TCD 2011 w

Technical Data Tightening specifications ID no. Name Screw type A06 094 Lifting magnet on fuel filter console Cap on charge air-dependent full load A07 096 stop

Notes / Remark Renew O-ring

Value 10 Nm 8 Nm

For the tightening procedure according to torque using a torque wrench, a maximum variation of the tightening torque of +/- 10% is permissible.

6

© 12/2008

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Fuel system W 07-10-06

Removing and installing fuel pipes Commercial available tools: – Hose clip pliers . . . . . . . . . . . . . . . . 8011 – Torx tool set . . . . . . . . . . . . . . . . . . 8189 – Spring band pliers . . . . . . . . . . . . . . 9090

Danger!

Special tools: – Plugs/caps . . . . . . . . . . . . . . . . . 170160

Attention!

Wait 30 seconds after switching off the engine before working on the fuel system. Pay attention to utmost cleanliness when working on the fuel system. Remove residue paint and particles of dirt before removing. Clean the respective affected parts carefully. Blow damp areas dry with compressed air. Observe the safety regulations and national specifications for handling fuels. Close all connections immediately after opening with new, clean plugs/caps. Do not remove plugs/caps until immediately before assembling. Collect leaking operating substances in suitable vessels and dispose of according to regulations. After all work on the fuel system, it must be bleeded - see the operation manual, chapter "6 Fuel system“.

– Fitting compound DEUTZ AP1908

Removing fuel pipes z Unscrew screws (1).

1

© 47551-1

© 12/2008

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17823-001

6

Fuel system W 07-10-06

D 2011 w TD 2011 w, TCD 2011 w

z Loosen spring band clips (1) with spring band pliers.

1 1

6 © 47572-0

z Pull off hose pieces (1) in the direction of the arrow.

1

© 47573-0

z Loosen hose clip (1). z Pull off fuel pipe (2). z Pull off protective hose (3). Collect draining fuel and dispose of according to regulations.

1 2 3 © 47615-0

© 12/2008

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Fuel system W 07-10-06

z Loosen hose clip (1). z Pull off fuel pipe (2). Collect draining fuel and dispose of according to regulations.

2

1

6 © 47614-0

z Unscrew hollow screws (1). z Remove fuel pipe (2). z Remove sealing rings.

1 1

2

© 47616-0

z Unscrew hollow screws (1). z Remove fuel return line (2). Remove fuel return line in the direction of the flywheel.

2

z Remove sealing rings.

1

1

1

© 47617-0

© 12/2008

3/8

17823-001

Fuel system W 07-10-06

D 2011 w TD 2011 w, TCD 2011 w

z Visually inspect the components.

6 © 47618-0

Installing fuel pipes z Mount fuel return pipe (1). z Mount sealing rings (2).

1

z Tighten hollow screw (3).  29 Nm

2

2 3

3

2 3

© 47617-1

z Mount fuel pipe (1). z Mount sealing rings (2). z Tighten hollow screw (3).

3

 29 Nm

3 2 2

1

© 47616-1

© 12/2008

4/8

17823-001

D 2011 w TD 2011 w, TCD 2011 w

Fuel system W 07-10-06

z Mount fuel hose (2). Lay hose without contact. Ensure that the installation location is free from faults. z Mount new hose clip (1). z Fix the hose clip (1) with the hose clip pliers. Ensure that the installation location is free from faults.

2

1

6 © 47614-0

z Slip protective hose (3) over with mounting compound. Lay hose without contact. Ensure that the installation location is free from faults. z Mount fuel hose (2). z Mount new hose clip (1).

1 2 3 © 47615-0

z Position protective hose, dimension X.  20 mm

X © 47615-1

© 12/2008

5/8

17823-001

Fuel system W 07-10-06

D 2011 w TD 2011 w, TCD 2011 w

z Push on hose pieces (1) in the direction of the arrow.

1

6 © 47573-1

z Position spring band clips (1) with spring band pliers.

1 1

© 47572-0

z Position clamping claws (1).

Attention! Install tension-free.

2

z Tighten screws (2).  21 Nm

1

© 47551-0

© 12/2008

6/8

17823-001

D 2011 w TD 2011 w, TCD 2011 w

Fuel system W 07-10-06

Technical Data Tightening specifications ID no. A07 015 A07 061 A09 020

Name Fuel supply line to injection pump Fuel return line on injection pump Pipe clip on holder

Screw type Notes / Remark Hollow screw Replace sealing rings Hollow screw Replace sealing rings M6x16

Value 29 Nm 29 Nm 21 Nm

For the tightening procedure according to torque using a torque wrench, a maximum variation of the tightening torque of +/- 10% is permissible.

6

© 12/2008

7/8

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D 2011 w TD 2011 w, TCD 2011 w

6

© 12/2008

8/8

17823-001

Fuel system W 07-10-08

TD 2011 w, TCD 2011 w Removing and installing the fuel filter console Commercial available tools: – Hose clip pliers . . . . . . . . . . . . . . . . 8011 – Torx tool set . . . . . . . . . . . . . . . . . . 8189

Danger! Wait 30 seconds after switching off the engine before working on the fuel system.

Special tools: – Disassembly tool. . . . . . . . . . . . . 110901 – Special wrench . . . . . . . . . . . . . . 170050 – Plugs/caps . . . . . . . . . . . . . . . . . 170160

Attention! Pay attention to utmost cleanliness when working on the fuel system. Remove residue paint and particles of dirt before removing. Clean the respective affected parts carefully. Blow damp areas dry with compressed air. Observe the safety regulations and national specifications for handling fuels. Close all connections immediately after opening with new, clean plugs/caps. Do not remove plugs/caps until immediately before assembling. Collect leaking operating substances in suitable vessels and dispose of according to regulations. After all work on the fuel system, it must be bleeded - see the operation manual, chapter "6 Fuel system“.

– Fitting compound DEUTZ AP1908

Removing the fuel filter console z Loosen hose clips (1) with hose clip pliers.

1

Collect draining fuel and dispose of according to regulations. z Pull off fuel hoses.

1

© 47592-0

© 12/2008

1/6

17824-001

6

Fuel system W 07-10-08

TD 2011 w, TCD 2011 w

z Pull off hose pipe (1).

1

6 © 47593-0

z Unscrew screws (1). z Remove fuel filter console (2). 1

2

1 © 47594-0

z Remove the O-ring (1) with the disassembly tool.

1

© 47595-0

© 12/2008

2/6

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Fuel system W 07-10-08

TD 2011 w, TCD 2011 w z Visually inspect the components.

6 © 47596-0

Installing the fuel filter console z Clean sealing surfaces.

© 47597-0

z Insert new sealing ring (1).

1

© 47598-0

© 12/2008

3/6

17824-001

Fuel system W 07-10-08

TD 2011 w, TCD 2011 w

z Install the fuel filter console (2). z Tighten screws (1).  22 Nm 1

2

1

6

© 47594-0

z Mount the hose pipe (1).

1

© 47593-0

Note assignment! Lay hoses without contact.

1

z Install fuel hoses. z Mount new hose clips (1). z Fasten hose clips (1) with hose clip pliers. Ensure that the installation location is free from faults. 1

© 47592-0

© 12/2008

4/6

17824-001

Fuel system W 07-10-08

TD 2011 w, TCD 2011 w z Position protective hoses, dimension X.  20 mm

X

X 6 © 47599-0

© 12/2008

5/6

17824-001

Fuel system W 07-10-08

TD 2011 w, TCD 2011 w

Technical Data Tightening specifications ID no.

Name Fuel filter console/full load stop to A07 087 crankcase

Screw type Torx, M8x50-8.8

Notes / Remark

Value 22 Nm

For the tightening procedure according to torque using a torque wrench, a maximum variation of the tightening torque of +/- 10% is permissible.

6

© 12/2008

6/6

17824-001

D 2011 w TD 2011 w, TCD 2011 w

Fuel system W 07-11-01

Removing and installing the fuel supply pump Commercial available tools: – Hose clip pliers . . . . . . . . . . . . . . . . 8011

Danger! Wait 30 seconds after switching off the engine before working on the fuel system.

Special tools: – Disassembly tool. . . . . . . . . . . . . 110901 – Plugs/caps . . . . . . . . . . . . . . . . . 170160

Attention! Pay attention to utmost cleanliness when working on the fuel system. Remove residue paint and particles of dirt before removing. Clean the respective affected parts carefully. Blow damp areas dry with compressed air. Observe the safety regulations and national specifications for handling fuels. Close all connections immediately after opening with new, clean plugs/caps. Do not remove plugs/caps until immediately before assembling. Collect leaking operating substances in suitable vessels and dispose of according to regulations. After all work on the fuel system, it must be bleeded - see the operation manual, chapter "6 Fuel system“.

– Fitting compound DEUTZ AP1908 – Lubricating oil

Removing the fuel supply pump z Pull out oil dipstick (1).

1

© 47608-0

© 12/2008

1/6

17825-001

6

Fuel system W 07-11-01

D 2011 w TD 2011 w, TCD 2011 w

z Loosen hose clip (1). z Pull off fuel pipe (2). z Pull off protective hose (3). Collect draining fuel and dispose of according to regulations.

1

6

3

2 © 47610-0

z Unscrew screws (1). z Remove fuel supply pump (2).

1 2 1 © 47609-0

z Remove the O-ring (1) with the disassembly tool. z Visually inspect the components.

1

© 47611-0

© 12/2008

2/6

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D 2011 w TD 2011 w, TCD 2011 w

Fuel system W 07-11-01

Installing the fuel supply pump z Turn the crankshaft until the eccentric of the camshafts is in the top dead centre (arrow).

6 © 47398-0

z Insert new O-ring (1). z Oil tappet (2) lightly with lubricating oil.

1

2

© 47176-0

z Clean all sealing surfaces. z Mount fuel supply pump. z Press fuel supply pump centrally on the crankcase. z Tighten screws (1).  21 Nm

1

1 © 47609-1

© 12/2008

3/6

17825-001

Fuel system W 07-11-01

D 2011 w TD 2011 w, TCD 2011 w

z Slip protective hose (3) over with mounting compound. Lay hose without contact. z Mount fuel hose (2). z Mount new hose clip (1).

1

6

3

2 © 47610-0

z Position protective hose, dimension X.  20 mm

X © 47610-1

z Fix the hose clip (1) with the hose clip pliers. Ensure that the installation location is free from faults.

1

© 47402-0

© 12/2008

4/6

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D 2011 w TD 2011 w, TCD 2011 w

Fuel system W 07-11-01

z Insert oil dipstick (1).

1

6 © 47608-0

© 12/2008

5/6

17825-001

Fuel system W 07-11-01

D 2011 w TD 2011 w, TCD 2011 w

Technical Data Tightening specifications ID no. Name A07 024 Fuel supply pump on crankcase

Screw type

Notes / Remark

Value 21 Nm

For the tightening procedure according to torque using a torque wrench, a maximum variation of the tightening torque of +/- 10% is permissible.

6

© 12/2008

6/6

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D 2011 w TD 2011 w, TCD 2011 w

Lube oil system W 08-04-05

Removing and installing the lubricating oil pump Commercial available tools: – Torx tool set . . . . . . . . . . . . . . . . . . 8189

– W 04-04-12

Collect leaking operating substances in suitable vessels and dispose of according to regulations.

6

Removing the lubricating oil pump z Remove toothed belt and tensioning pulley.  W 04-04-12 z Pull out oil dipstick (1). 1

© 47403-0

z Unscrew all screws (1). z Remove lubricating oil pump (2).

1

2

© 47404-0

© 12/2008

1/4

17826-001

Lube oil system W 08-04-05

D 2011 w TD 2011 w, TCD 2011 w

z Remove gasket (1). z Visually inspect the components.

1

6

© 39496-1

Install the lubricating oil pump z Clean all sealing surfaces. z Mount new gasket (1).

1 © 39496-1

z Make sure the clamping bushings (arrows) are in place.

© 47405-0

© 12/2008

2/4

17826-001

D 2011 w TD 2011 w, TCD 2011 w

Lube oil system W 08-04-05

z Centre the lubricating oil pump (1) with clamping pins (2). z Mount lubricating oil pump.

2

1 © 47406-0

z Tighten all screws (1).  21 Nm

1

© 47407-0

z Insert oil dipstick (1). z Install toothed belt and tensioning pulley.  W 04-04-12

1

© 47403-0

© 12/2008

3/4

17826-001

6

Lube oil system W 08-04-05

D 2011 w TD 2011 w, TCD 2011 w

Technical Data Tightening specifications ID no. Name A08 010 Lubricating oil pump on crankcase

Screw type

Notes / Remark

Value 21 Nm

For the tightening procedure according to torque using a torque wrench, a maximum variation of the tightening torque of +/- 10% is permissible.

6

© 12/2008

4/4

17826-001

D 2011 w TD 2011 w, TCD 2011 w

Lube oil system W 08-04-06

Removing and installing the oil suction pipe Commercial available tools

– W 08-04-07

– Packing compound DEUTZ DW 73

Collect leaking operating substances in suitable vessels and dispose of according to regulations.

6

Removing the oil suction pipe z Remove lubricating oil pan.  W 08-04-07 z Unscrew screws (1).

2

z Remove oil suction pipe (2).

1

© 47408-0

z Visually inspect the components. z Clean sealing surfaces.

© 47409-0

© 12/2008

1/4

17827-001

Lube oil system W 08-04-06

D 2011 w TD 2011 w, TCD 2011 w

Installing the oil suction pipe z Clean sealing surfaces. The sealing surfaces must be dry and free from grease and dirt. z Apply packing compound (arrow). Sealing cord strength approx. 1.0 mm

Attention! No packing compound must get into the oil channel (1)! 1

6 © 47342-0

z Mount oil suction pipe (2). Note installation position. Do not displace the packing compound. z Tighten screws (1).

2

 21 Nm z Install lubricating oil pan.  W 08-04-07

1

© 47408-0

© 12/2008

2/4

17827-001

D 2011 w TD 2011 w, TCD 2011 w

Lube oil system W 08-04-06

Technical Data Tightening specifications ID no.

Name

Screw type

A08 015 Oil suction pipe on crankcase

Notes / Remark Packing compound DW73

Value 21 Nm

For the tightening procedure according to torque using a torque wrench, a maximum variation of the tightening torque of +/- 10% is permissible.

6

© 12/2008

3/4

17827-001

Lube oil system W 08-04-06

D 2011 w TD 2011 w, TCD 2011 w

6

© 12/2008

4/4

17827-001

D 2011 w TD 2011 w, TCD 2011 w

Lube oil system W 08-04-07

Removing and installing the lubricating oil pan (metal sheet lubricating oil pan) Commercial available tools: – Torx tool set . . . . . . . . . . . . . . . . . . 8189

Collect leaking operating substances in suitable vessels and dispose of according to regulations.

Special tools: – Separating tool . . . . . . . . . . . . . . 151500

Emptying and filling the engine with operating media must be carried out according to the operating manual and the appropriate documentation of the vehicle/equipment manufacturer.

– Packing compound DEUTZ DW 73 – Lubricating oil

6

Removing the lubricating oil pan z Unscrew locking screw (1). z Drain lubricating oil, collect and dispose of according to regulations. z Oil the screw plug lightly. z Mount new sealing ring. z Tighten screw plug (1).  55 Nm

1

© 47410-0

z Pull out oil dipstick (1). z Turn engine 180°.

1

© 47411-0

© 12/2008

1/8

17828-001

Lube oil system W 08-04-07

D 2011 w TD 2011 w, TCD 2011 w

z Unscrew screws (1). z Remove washers. z Remove the cover (2). 2

1

6 © 47412-0

z Unscrew all screws (1).

1

© 47413-0

z Drive in separating tool (1) to the stop (2).

Attention! The tool can only be driven in in the area of the crankcase. Separation in the area of aluminium parts is not allowed. Do not damage the sealing surfaces.

1

2

© 47414-0

© 12/2008

2/8

17828-001

D 2011 w TD 2011 w, TCD 2011 w

Lube oil system W 08-04-07

z Drive in second separating tool (1) to the stop (2).

Attention! The tool can only be driven in in the area of the crankcase. Separation in the area of aluminium parts is not allowed. Do not damage the sealing surfaces. 1

2

6 © 47415-0

Attention! Do not drive in separating tool in the area of the lubricating oil pump (1).

X

1

© 47416-1

z Lever out lubricating oil pan. z Remove lubricating oil pan. z Visually inspect the components.

© 47417-0

© 12/2008

3/8

17828-001

Lube oil system W 08-04-07

D 2011 w TD 2011 w, TCD 2011 w

z Clean sealing surfaces. z Scrape off sealing compound with separating tool. The sealing surfaces must be dry and free from grease and dirt.

6 © 47418-0

Installing the lubricating oil pan z Apply packing compound (arrow). Sealing cord strength approx. 3 mm

© 47363-0

z Mount lubricating oil pan. z Align lubricating oil pan to crankcase. Do not move the packing compound when mounting the lube oil tray.

© 47419-0

© 12/2008

4/8

17828-001

D 2011 w TD 2011 w, TCD 2011 w

Lube oil system W 08-04-07

z Oil the screws lightly. z Fasten all screws (1).

1

6 © 47413-0

z Tighten screws (arrows).

© 34255-2

z Tighten the screws according to the tightening sequence.

13 19

 21 Nm

12

11

2

1

8

9

10 20

18

21

22

17 16

15

14

3

4

5

6

7 © 47485-0

© 12/2008

5/8

17828-001

Lube oil system W 08-04-07

D 2011 w TD 2011 w, TCD 2011 w

z Mount cover (2). z Mount washers. z Tighten screws (1).  9 Nm 2

1

6 © 47412-0

z Turn engine 180°. z Insert oil dipstick (1). z Fill in lubricating oil according to operating manual.

1

© 47411-0

© 12/2008

6/8

17828-001

D 2011 w TD 2011 w, TCD 2011 w

Lube oil system W 08-04-07

Technical Data Tightening specifications ID no.

Name Lubricating oil pan (plate) on crankA03 030 case A03 031 Locking screw on lubricating oil pan A03 085 Cover plate to connection housing

Screw type M8x16

Notes / Remark Observe tightening sequence! Replace sealing ring

Value 21 Nm 55 Nm 9 Nm

For the tightening procedure according to torque using a torque wrench, a maximum variation of the tightening torque of +/- 10% is permissible.

6

© 12/2008

7/8

17828-001

Lube oil system W 08-04-07

D 2011 w TD 2011 w, TCD 2011 w

6

© 12/2008

8/8

17828-001

D 2011 w TD 2011 w, TCD 2011 w

Lube oil system W 08-08-02

Removing and installing the lubricating oil cooler Commercial available tools

– W 08-11-07

Collect leaking operating substances in suitable vessels and dispose of according to regulations. Emptying and filling the engine with operating media must be carried out according to the operating manual and the appropriate documentation of the vehicle/equipment manufacturer.

6

Removing the lubricating oil cooler 1

z Remove oil filter console.

2

1

 W 08-11-07 z Unscrew screws (1). z Remove lubricating oil cooler (2).

1

1

© 47517-0

z Remove sealing ring (1). 1

© 47518-0

© 12/2008

1/4

17829-001

Lube oil system W 08-08-02

D 2011 w TD 2011 w, TCD 2011 w

Installing the lubricating oil cooler z Visually inspect the components.

6 © 47519-0

z Clean sealing surfaces. z Insert new sealing ring (1).

1

© 47518-0

z Mount lubricating oil cooler (1). 2

Ensure that the installation location of the sealing ring is free from faults.

1

2

z Tighten screws (2). z Tighten screws (2).  13 Nm z Mount oil filter console.  W 08-11-07

2

2

© 47517-1

© 12/2008

2/4

17829-001

D 2011 w TD 2011 w, TCD 2011 w

Lube oil system W 08-08-02

Technical Data Tightening specifications ID no.

Name Screw type Lubricating oil cooler on oil filter conA08 051 M6x16-10.9 sole

Notes / Remark

Value 13 Nm

For the tightening procedure according to torque using a torque wrench, a maximum variation of the tightening torque of +/- 10% is permissible.

6

© 12/2008

3/4

17829-001

Lube oil system W 08-08-02

D 2011 w TD 2011 w, TCD 2011 w

6

© 12/2008

4/4

17829-001

D 2011 w TD 2011 w, TCD 2011 w

Lube oil system W 08-11-02

Removing and installing the oil pressure regulating valve Collect leaking operating substances in suitable vessels and dispose of according to regulations.

Commercial available tools: – Slide gauge

6

Removing the oil pressure regulating valve

1

– (1) Oil pressure regulating valve – (2) Oil channel output with transfer fitting (Option cabine heating connection)

2

– (3) Oil pressure regulating valve (TD 2011) – (4) Oil channel input with transfer fitting (Option cabine heating connection) 3 4

© 39520-2

Attention! Parts are under tensions and can spring out during disassembly! 1

z Unscrew locking screw (1). z Remove sealing ring. z Remove compression spring. z Remove oil pressure regulating valve.

© 46955-0

© 12/2008

1/4

17830-001

Lube oil system W 08-11-02

D 2011 w TD 2011 w, TCD 2011 w

z Visually inspect the components.

6 © 39061-1

z Measure length of the compressor spring with calliper gauge. – Coloured marking, green  56.5 mm – Coloured marking, yellow  80.5 mm – Coloured marking, red  78.4 mm – Coloured marking, blue  61.8 mm When the wear limit is reached, the compressor spring must be renewed. © 39062-1

Installing the oil pressure regulating valve z Lightly oil oil pressure regulating valve (1). Note installation position. z Insert oil pressure regulating valve.

1

z Insert compression spring (2)

2

© 46954-0

© 12/2008

2/4

17830-001

D 2011 w TD 2011 w, TCD 2011 w

Lube oil system W 08-11-02

z Mount new sealing ring. z Mount locking screw (1). z Tighten screw plug (1).

1

 111 Nm

6 © 46955-0

Cabin heating connection, input Attention! Parts are under tensions and can spring out during disassembly! z Unscrew locking screw (1). z Remove sealing ring. z Remove compression spring. z Remove oil pressure regulating valve. 1

© 46955-1

Attention! Observe order of installation! z Insert compression spring (1) z Lightly oil oil pressure regulating valve (2). z Insert oil pressure regulating valve. z Mount new sealing ring.

1

z Tighten transfer fitting.  111 Nm

2

© 46956-0

© 12/2008

3/4

17830-001

Lube oil system W 08-11-02

D 2011 w TD 2011 w, TCD 2011 w

Technical Data Testing and setting data ID no. P08 41 P08 41 P08 42

6

P08 43 P08 44 P08 44 P08 45 P08 46

Name Oil pressure regulating valve, opening pressure (without cabin heating connection) Oil pressure regulating valve, opening pressure (with cabin heating connection) Oil pressure regulating valve, opening pressure (with cabin heating connection) Oil pressure regulating valve, opening pressure (without cabin heating connection) Oil pressure regulating valve, compression spring, length Oil pressure regulating valve, compression spring, length Oil pressure regulating valve, compression spring, length Oil pressure regulating valve, compression spring, length

Additional information

Value

Coloured marking, green

3 bar

Coloured marking, yellow

1 bar

Coloured marking, red

1.7 bar

Coloured marking, blue

0.3 bar

without heating connection, green

56.5 mm

with heating connection, yellow

80.5 mm

with heating connection, red

78.4 mm

with heating connection, blue

61.8 mm

Tightening specifications ID no.

Name Locking screw on transfer fitting (heaA08 062 ting connection) Locking screw on transfer fitting (heaA08 063 ting connection) Transfer fitting on crankcase (heating A08 064 connection)

Screw type

Notes / Remark

Value

M18x1.5

Use new sealing ring

50 Nm

M24x1.5

Use new sealing ring

111 Nm

M24x1.5

Use new sealing ring

111 Nm

For the tightening procedure according to torque using a torque wrench, a maximum variation of the tightening torque of +/- 10% is permissible.

© 12/2008

4/4

17830-001

D 2011 w TD 2011 w, TCD 2011 w

Lube oil system W 08-11-07

Removing and installing the oil filter console Commercial available tools: – Torx tool set . . . . . . . . . . . . . . . . . . 8189

– Operation manual – W 08-08-02

Special tools: – Disassembly tool. . . . . . . . . . . . . 110901 – Special wrench . . . . . . . . . . . . . . 170050

Collect leaking operating substances in suitable vessels and dispose of according to regulations.

– Fitting compound DEUTZ AP1908

Emptying and filling the engine with operating media must be carried out according to the operating manual and the appropriate documentation of the vehicle/equipment manufacturer.

6

Removing the oil filter console z Loosen spring band clip (1) with spring band pliers.

1 1

© 47572-0

z Pull off hose pieces (1) in the direction of the arrow.

1

© 47573-0

© 12/2008

1/6

17831-001

Lube oil system W 08-11-07

D 2011 w TD 2011 w, TCD 2011 w

z Unscrew hollow screw (1). z Remove sealing rings (2).

1 2

6 © 47514-0

z Unscrew lubricating oil filter (1) with special wrench. Collect draining lubricating oil and dispose of properly.

1

© 47515-0

z Unscrew screws (1). z Unscrew screw (2). z Remove oil filter console (3). 2

1

1

3 © 47516-0

© 12/2008

2/6

17831-001

D 2011 w TD 2011 w, TCD 2011 w

Lube oil system W 08-11-07

z Remove gasket (1). z Clean sealing surfaces.

1

6 © 47520-0

Installing oil filter console z Visually inspect the components.

© 47521-0

z Fix new gasket (1) to the crankcase with a little grease.

1

© 47520-0

© 12/2008

3/6

17831-001

Lube oil system W 08-11-07

D 2011 w TD 2011 w, TCD 2011 w

z Mount oil filter console (1). Do not move gasket. 3

z Tighten screws (2). z Turn in screw (3). z Tighten screws (2).  21 Nm

2

2

z Tighten screw (3).  21 Nm

1

6

© 47516-1

z Clean sealing surfaces. z Lightly oil sealing ring on new lubricating oil filter. z Tighten the lubricating oil filter (1) according to the operating instructions.  Operation manual 1

© 47515-0

z Insert control line (1). z Mount sealing rings (2). z Tighten hollow screw (3).  18 Nm 1

3 2

© 47514-2

© 12/2008

4/6

17831-001

D 2011 w TD 2011 w, TCD 2011 w

Lube oil system W 08-11-07

z Push on hose pieces (1) in the direction of the arrow.

1

6 © 47573-1

z Position the spring band clip (1) with the spring band pliers.

1 1

© 47572-0

© 12/2008

5/6

17831-001

Lube oil system W 08-11-07

D 2011 w TD 2011 w, TCD 2011 w

Technical Data Tightening specifications ID no.

Name

Screw type Notes / Remark Torx M8x50-8.8 A08 003 Oil filter console on crankcase Torx M8x90-8.8 Control line to oil filter console / crank- Hollow screw A08 048 case M10x1

Value 21 Nm 18 Nm

For the tightening procedure according to torque using a torque wrench, a maximum variation of the tightening torque of +/- 10% is permissible.

6

© 12/2008

6/6

17831-001

D 2011 w TD 2011 w, TCD 2011 w

Lube oil system W 08-11-08

Removing and installing the oil pressure switch Collect leaking operating substances in suitable vessels and dispose of according to regulations.

Commercial available tools

6

Removing the oil pressure switch z Pull out cable plug (1).

1

© 47344-0

z Unscrew oil pressure switch (1).

1

© 47432-0

© 12/2008

1/4

17832-001

Lube oil system W 08-11-08

D 2011 w TD 2011 w, TCD 2011 w

z Visually inspect the components.

6 © 47433-0

Installing the oil pressure switch z Screw on oil pressure switch (1).

1

© 47434-0

z Tighten oil pressure switch (1).  13 Nm

1

© 47432-0

© 12/2008

2/4

17832-001

D 2011 w TD 2011 w, TCD 2011 w

Lube oil system W 08-11-08

z Plug in the cable plug (1). Ensure that the connection is perfect.

1

6 © 47344-0

© 12/2008

3/4

17832-001

Lube oil system W 08-11-08

D 2011 w TD 2011 w, TCD 2011 w

Technical Data Tightening specifications ID no. Name A08 091 Oil pressure switch on crankcase

Screw type M10x1

Notes / Remark

Value 13 Nm

For the tightening procedure according to torque using a torque wrench, a maximum variation of the tightening torque of +/- 10% is permissible.

6

© 12/2008

4/4

17832-001

D 2011 w TD 2011 w, TCD 2011 w

Lube oil system W 08-11-12

Removing and installing the thermostat (Lubricating oil cooler) Commercial available tools: – Slide gauge – Torx tool set . . . . . . . . . . . . . . . . . . 8189

Collect leaking operating substances in suitable vessels and dispose of according to regulations.

Special tools: – Disassembly tool. . . . . . . . . . . . . 110901

6

Removing the thermostat Attention! Parts are under tensions and can spring out during disassembly! z Unscrew locking screw (1).

1

© 47569-0

z Remove thermostat (1). z Remove compression spring.

1

© 47575-0

© 12/2008

1/4

17833-001

Lube oil system W 08-11-12

D 2011 w TD 2011 w, TCD 2011 w

z Remove the O-ring (1) with the disassembly tool.

1

6 © 47439-0

z Visually inspect the components.

© 47568-0

Installing the thermostat z Measure length of the compressor spring with calliper gauge.  45.7 mm When the wear limit is reached, the compressor spring must be renewed.

© 47576-0

© 12/2008

2/4

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D 2011 w TD 2011 w, TCD 2011 w

Lube oil system W 08-11-12

z Clean sealing surfaces. z Oil the thermostat lightly. z Insert compression spring. z Insert thermostat (1). Note installation position.

1

6 © 47575-0

z Lightly oil new O-ring (1). z Insert new O-ring (1).

1

© 47439-0

z Tighten screw plug (1).  90 Nm

1

© 47569-0

© 12/2008

3/4

17833-001

Lube oil system W 08-11-12

D 2011 w TD 2011 w, TCD 2011 w

Technical Data Testing and setting data ID no. P08 74

Name Thermostat, compression spring, length

Additional information

Value 45.7 mm

Tightening specifications ID no.

Name Thermostat on crankcase, locking A08 072 screw,

Screw type

Notes / Remark

Value 90 Nm

For the tightening procedure according to torque using a torque wrench, a maximum variation of the tightening torque of +/- 10% is permissible.

6

© 12/2008

4/4

17833-001

D 2011 w TD 2011 w, TCD 2011 w

Lube oil system W 08-16-01

Removing and installing the control line Commercial available tools

– W 07-10-08 – W 08-11-07 Collect leaking operating substances in suitable vessels and dispose of according to regulations. Emptying and filling the engine with operating media must be carried out according to the operating manual and the appropriate documentation of the vehicle/equipment manufacturer.

6

Removing control line z Unscrew hollow screw (1). z Remove sealing rings (2). z Remove fuel filter console.  W 07-10-08 z Remove oil filter console.  W 08-11-07

1 2

© 47514-0

z Unscrew hollow screws (1). z Remove sealing rings (2). z Remove control line (3).

3

Collect draining lubricating oil and dispose of properly.

2 2

2

1 1

1

© 47650-0

© 12/2008

1/4

17834-001

Lube oil system W 08-16-01

D 2011 w TD 2011 w, TCD 2011 w

z Visually inspect sealing surfaces (arrows).

6 © 47651-0

z Visually inspect the components.

© 47649-0

Installing control line z Insert control line (1).

1

z Mount sealing rings (2). z Screw in all hollow screws.

2

z Tighten hollow screws (3). 2

 18 Nm

2

Attention! Install tension-free.

3 3

3

© 47650-1

© 12/2008

2/4

17834-001

D 2011 w TD 2011 w, TCD 2011 w

Lube oil system W 08-16-01

z Install the fuel filter console.  W 07-10-08 z Mount oil filter console.  W 08-11-07 z Insert control line (1).

1

z Mount sealing rings (2). z Tighten hollow screw (3).

3

 18 Nm

2

6 © 47514-2

© 12/2008

3/4

17834-001

Lube oil system W 08-16-01

D 2011 w TD 2011 w, TCD 2011 w

Technical Data Tightening specifications ID no.

Name Screw type Notes / Remark Control line to oil filter console / crank- Hollow screw A08 048 case M10x1

Value 18 Nm

For the tightening procedure according to torque using a torque wrench, a maximum variation of the tightening torque of +/- 10% is permissible.

6

© 12/2008

4/4

17834-001

D 2011 w TD 2011 w, TCD 2011 w

Cooling system W 09-07-08

Removing and installing the coolant pump Commercial available tools

8190

– Operation manual – W 13-02-03

Special tools: – Disassembly tool. . . . . . . . . . . . . 110901

Collect leaking operating substances in suitable vessels and dispose of according to regulations. The appropriate documentation of the vehicle/equipment manufacturer should be observed for emptying and filling the cooling system.

6

Removing coolant pump z Remove V-belt.  W 13-02-03

3

Pay attention to different screw lengths.

1

1

z Unscrew screws (1). z Unscrew screw (2). z Remove coolant pump (3). Collect and dispose of coolant according to regulations. 2

1 © 47510-0

z Remove the O-ring (1) with the disassembly tool. z Clean sealing surfaces. z Check components for visible signs of wear. 1

© 47512-0

© 12/2008

1/4

17835-001

Cooling system W 09-07-08

D 2011 w TD 2011 w, TCD 2011 w

z Clean sealing surfaces.

6 © 47511-0

Installing coolant pump z Clean sealing surfaces. z Insert new O-ring (1).

1

© 47512-0

z Mount coolant pump (1). Pay attention to different screw lengths. Screws M8 x 35 mm (2) Screw M8 x 100 mm (3)

1

z Tighten screws (2).

2

2

 20 Nm z Tighten screw (3).  20 Nm

3

2 © 47510-1

© 12/2008

2/4

17835-001

D 2011 w TD 2011 w, TCD 2011 w

Cooling system W 09-07-08

z Install V-belt.  W 13-02-03 z Fill cooling system according to the operating manual.

6 © 46986-2

© 12/2008

3/4

17835-001

Cooling system W 09-07-08

D 2011 w TD 2011 w, TCD 2011 w

Technical Data Tightening specifications ID no.

Name

Screw type Notes / Remark M8x35-10.9 A09 010 Coolant pump on thermostat housing M8x100-10.9

Value 20 Nm

For the tightening procedure according to torque using a torque wrench, a maximum variation of the tightening torque of +/- 10% is permissible.

6

© 12/2008

4/4

17835-001

D 2011 w TD 2011 w, TCD 2011 w

Cooling system W 09-08-01

Checking the thermostat (in the removed state) Commercial available tools: – Thermometer

– W 09-08-02

Danger! Risk of injury! Hot water and hot thermostat.

6

Checking thermostat z Remove thermostat.  W 09-08-02 z Measure beginning of stroke, dimension (a). z Note measured value, dimension (a).

© 34679-3

z Heat up the thermostat in the water bath. In order to determine the exact beginning of opening, the temperature should be measured as close as possible to the thermostat. The water should be continuously stirred for an even temperature distribution. The temperature rise should not take place faster than 1°C/min. Otherwise the beginning of opening will be delayed accordingly. z Determine beginning of opening.  86 - 90 °C

© 34680-2

© 12/2008

1/4

17836-001

Cooling system W 09-08-01

D 2011 w TD 2011 w, TCD 2011 w

z Measure end of stroke, dimension (b). z Note measured value, dimension (b).

6 © 34679-2

z Determine stroke. Calculation example Desired: Stroke Given: Measured: Beginning of stroke, dimension (a) End of stroke, dimension (b) Calculation: Dimension (b) - dimension (a) Result: = stroke

z Compare result with setpoint value. – Nominal value stroke travel:  at least 9 mm z Install thermostat.  W 09-08-01

© 34679-1

© 12/2008

2/4

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D 2011 w TD 2011 w, TCD 2011 w

Cooling system W 09-08-01

Technical Data Testing and setting data ID no. P09 11 P09 13

Name Thermostat, start of opening Thermostat, stroke distance

Additional information

Value 86 - 90 °C at least 9 mm

6

© 12/2008

3/4

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Cooling system W 09-08-01

D 2011 w TD 2011 w, TCD 2011 w

6

© 12/2008

4/4

17836-001

D 2011 w TD 2011 w, TCD 2011 w

Cooling system W 09-08-02

Removing and installing the thermostat Commercial available tools

– W 09-08-01

Collect leaking operating substances in suitable vessels and dispose of according to regulations. Emptying and filling the engine with operating media must be carried out according to the operating manual and the appropriate documentation of the vehicle/equipment manufacturer.

6

Removing the thermostat z Unscrew screws (1). z Remove outlet nozzle (2).

2

1

1

© 46982-0

z Remove O-ring. z Remove thermostat (1).

1

© 46983-0

© 12/2008

1/4

17837-001

Cooling system W 09-08-02

D 2011 w TD 2011 w, TCD 2011 w

z Check thermostat.  W 09-08-01 z Visually inspect the components.

6 © 46984-0

Installing the thermostat z Clean sealing surfaces. z Insert thermostat (1).

1

© 46983-0

z Clean sealing surfaces. z Insert new O-ring (1).

1

© 46985-0

© 12/2008

2/4

17837-001

D 2011 w TD 2011 w, TCD 2011 w

Cooling system W 09-08-02

z Mount outlet nozzle (2). z Tighten screws (1).  22 Nm

2

1

1

6 © 46982-0

© 12/2008

3/4

17837-001

Cooling system W 09-08-02

D 2011 w TD 2011 w, TCD 2011 w

Technical Data Tightening specifications ID no. Name Screw type A09 002 Outlet nozzles on thermostat housing M8x30-10.9

Notes / Remark

Value 22 Nm

For the tightening procedure according to torque using a torque wrench, a maximum variation of the tightening torque of +/- 10% is permissible.

6

© 12/2008

4/4

17837-001

D 2011 w TD 2011 w, TCD 2011 w

Cooling system W 09-08-04

Removing and installing the thermostat housing Commercial available tools: – Spring band pliers . . . . . . . . . . . . . . 9090

8190

– Operation manual – W 12-02-01

Special tools: – Disassembly tool. . . . . . . . . . . . . 110901

Collect leaking operating substances in suitable vessels and dispose of according to regulations. The appropriate documentation of the vehicle/equipment manufacturer should be observed for emptying and filling the cooling system.

– Fitting compound DEUTZ AP1908

6

Removing thermostat housing z Remove V-belt. 1

 W 12-02-01 z Loosen spring band clip (1) with spring band pliers.

1

© 47570-0

z Pull off hose pieces (1) in the direction of the arrow.

1

© 47522-0

© 12/2008

1/6

17838-001

Cooling system W 09-08-04

D 2011 w TD 2011 w, TCD 2011 w

z Unscrew screw (1). z Unscrew screws (2). z Remove the thermostat housing (3). 3

2 2 1

6

2 © 46990-0

z Pull out plug element (1). z Pull out plug element (2). 1

2

© 46991-0

z Remove the O-ring (1) with the disassembly tool.

1

© 47571-0

© 12/2008

2/6

17838-001

D 2011 w TD 2011 w, TCD 2011 w

Cooling system W 09-08-04

Installing thermostat housing z Clean all sealing surfaces. z Visually inspect the components.

6 © 46993-0

z Insert new O-ring (1).

1

© 46992-0

z Insert plug element (1). z Insert plug element (2). 1

2

© 46991-0

© 12/2008

3/6

17838-001

Cooling system W 09-08-04

D 2011 w TD 2011 w, TCD 2011 w

z Mount thermostat housing (1). Ensure that the installation location is free from faults. z Tighten screws (2).

1

 34 Nm z Turn in screw (3).

2 2

3

6

2 © 46990-1

z Coat hose pieces with mounting compound. z Push on hose pieces (1) in the direction of the arrow.

1

© 47522-1

z Position the spring band clip (1) with the spring band pliers. z Install V-belt.

1

z Check V-belt tension.  W 12-02-01

1

© 47570-0

© 12/2008

4/6

17838-001

D 2011 w TD 2011 w, TCD 2011 w

Cooling system W 09-08-04

Technical Data Tightening specifications ID no. Name A09 001 Thermostat housing to crankcase

Screw type Notes / Remark M8x100-10.9

Value 34 Nm

For the tightening procedure according to torque using a torque wrench, a maximum variation of the tightening torque of +/- 10% is permissible.

6

© 12/2008

5/6

17838-001

Cooling system W 09-08-04

D 2011 w TD 2011 w, TCD 2011 w

6

© 12/2008

6/6

17838-001

D 2011 w TD 2011 w, TCD 2011 w

Cooling system W 09-12-01

Removing and installing temperature transmitter Collect leaking operating substances in suitable vessels and dispose of according to regulations.

Commercial available tools

Emptying and filling the engine with operating media must be carried out according to the operating manual and the appropriate documentation of the vehicle/equipment manufacturer.

6

Removing temperaure transmitter z Disconnect cable connections. z Unscrew temperature transmitter (1).

1

© 46994-0

z Visually inspect the component.

© 46995-0

© 12/2008

1/4

17839-001

Cooling system W 09-12-01

D 2011 w TD 2011 w, TCD 2011 w

Installing temperature transmitter z Tighten temperature transmitter (1).  25 Nm Make sure the sealing ring is in place. z Connect cable. Ensure that the connection is perfect.

1

6 © 46994-0

© 12/2008

2/4

17839-001

D 2011 w TD 2011 w, TCD 2011 w

Cooling system W 09-12-01

Technical Data Tightening specifications ID no.

Name Temperature transmitter on thermoA09 031 stat housing

Screw type

Notes / Remark

Value 25 Nm

For the tightening procedure according to torque using a torque wrench, a maximum variation of the tightening torque of +/- 10% is permissible.

6

© 12/2008

3/4

17839-001

Cooling system W 09-12-01

D 2011 w TD 2011 w, TCD 2011 w

6

© 12/2008

4/4

17839-001

D 2011 w TD 2011 w, TCD 2011 w

Monitoring system W 11-00-03

Removing and installing the lifting magnet (Engine shutdown) Commercial available tools

– W 12-02-01

Special tools: – Disassembly tool. . . . . . . . . . . . . 110901

6

Remove lifting magnet 3

– Version with V-belt tensioning pulley z Remove V-belt.  W 12-02-01

1

z Loosen screws (1). z Swing V-belt tensioning pulley (2) in the direction of the arrow. z Remove V-belt (3). 4

2 © 46986-0

z Unscrew screw (1). z Unscrew screw (2). z Remove V-belt tensioning pulley (3). 1

2

3

© 47605-0

© 12/2008

1/4

17840-001

Monitoring system W 11-00-03

D 2011 w TD 2011 w, TCD 2011 w

z Remove cable tie (1). z Unscrew screws (2). 2

z Remove lifting magnet (3).

1

3 2

6 © 47606-0

z Remove the O-ring (1) with the disassembly tool. z Visually inspect the components. 1

© 47355-0

Install lifting magnet z Insert new O-ring (1).

1

© 39036-1

© 12/2008

2/4

17840-001

D 2011 w TD 2011 w, TCD 2011 w

Monitoring system W 11-00-03

z Insert lifting magnet (1). z Tighten screws (2). 2

 8.5 Nm z Fasten cable plug with cable tie (3). 3

1 2

6 © 47606-1

z Mount V-belt tensioning pulley (1). z Fasten screw (2). z Turn in screw (3). z Mount and tighten V-belt. 2

 W 12-02-01

3

1

© 47605-1

© 12/2008

3/4

17840-001

Monitoring system W 11-00-03

D 2011 w TD 2011 w, TCD 2011 w

Technical Data Tightening specifications ID no.

Name Lifting magnet (engine shutdown) on A05 041 front cover

Screw type

Notes / Remark

Value 8.5 Nm

For the tightening procedure according to torque using a torque wrench, a maximum variation of the tightening torque of +/- 10% is permissible.

6

© 12/2008

4/4

17840-001

D 2011 w TD 2011 w, TCD 2011 w

Other components W 12-01-04

Removing and installing the V-belt pulley Commercial available tools

– W 12-02-01

6

Removing the V-belt pulley z Remove V-belt.  W 12-02-01 z Unscrew screws (1). z Remove fan (2).

1

1

2

© 47574-0

z Unscrew screws (1). z Remove flange hub (2).

1 2

1

© 47013-0

© 12/2008

1/4

17841-001

Other components W 12-01-04

D 2011 w TD 2011 w, TCD 2011 w

z Remove V-belt pulley (1).

1

6 © 47014-0

z Remove centrifugal disc (1). Note installation position. 1

z Visually inspect the components.

© 47015-0

Installing the V-belt pulley z Mount centrifugal disc (1). Note installation position.

1 © 39598-1

© 12/2008

2/4

17841-001

D 2011 w TD 2011 w, TCD 2011 w

Other components W 12-01-04

z Mount V-belt pulley (1).

1

6 © 47014-0

z Mount flange hub (2). z Tighten screws (1).  43 Nm 1 2

1

© 47013-0

Attention! Note installation position: "Engine side" label faces engine! z Mount fan (2). z Tighten screws (1).  30 Nm

1

z Install V-belt.  W 12-02-01

1

2

© 47574-0

© 12/2008

3/4

17841-001

Other components W 12-01-04

D 2011 w TD 2011 w, TCD 2011 w

Technical Data Tightening specifications ID no. Name A09 042 Ventilator on flange hub V belt pulley/flange hub on output A12 031 flange

Screw type M8x40-10.9 M10x30-8.8

Notes / Remark

Value 30 Nm 43 Nm

For the tightening procedure according to torque using a torque wrench, a maximum variation of the tightening torque of +/- 10% is permissible.

6

© 12/2008

4/4

17841-001

D 2011 w TD 2011 w, TCD 2011 w

Other components W 12-02-01

Renew V-belts, check V-belt tension Commercial available tools: – V-belt tension measuring device . . . . . . . . . . . . . . . . . . . . . . . 8115 – Rotation angle disc . . . . . . . . . . . . . 8190

Attention! Only test / tighten / renew V-belts when the engine is not running. The V-belt tension of new V-belts must be checked after they have been running for 15 minutes.

6

Removing the V-belt 3

– Version with V-belt tensioning pulley z Loosen screws (1). z Swing V-belt tensioning pulley (2) in the direction of the arrow.

1

z Remove V-belt (3).

4

2 © 46986-0

z Loosen screw (1).

1

© 46988-2

© 12/2008

1/8

17842-001

Other components W 12-02-01

D 2011 w TD 2011 w, TCD 2011 w

z Loosen screws (1). z Loosen screw (2).

3

1

z Swing generator (3) in the direction of the arrow.

2

6

© 46987-0

z Unscrew screw (1). z Remove air bearing (2). 2

z Remove V-belt pulley (3). z Remove V-belt (4). 1

4

3 © 46988-0

Installing the V-belt. z Mount V-belt (1). 3

Note V-belt length. z Mount V-belt pulley (2).

4

z Insert air bearing (3). z Turn in screw (4).

1

2 © 46988-1

© 12/2008

2/8

17842-001

D 2011 w TD 2011 w, TCD 2011 w

Other components W 12-02-01

z Swing generator (1) in the direction of the arrow.

1

z Tighten screws (2).

2

z Fasten screws (3).

6

3 © 46987-1

z Tighten new screw (1). – Stage 1:  30 Nm z Tighten screw (1) with socket wrench insert and rotation angle disc. – Stage 2:

1

 120°

© 46988-2

Check V-belt tension with V-belt tension measuring device z Lower indicator arm (1) into V-belt tension measuring device.

1

© 44591-0

© 12/2008

3/8

17842-001

Other components W 12-02-01

D 2011 w TD 2011 w, TCD 2011 w

z Mount V-belt tension measuring device on V-belt. The V-belt must be between the guides (arrow).

6 © 46997-1

z Press the V-belt measuring device against the V-belt with the button (1) until you hear it click. z Read measured value at the intersection (arrow) of the indicator arm and scale. +50

 450 −50 N Note different units on the scale. 1

z If the nominal value is not reached, the tensioning process must be repeated.

© 46997-0

z Tighten screws (1).  34 Nm

1

z Tighten screw (2).  22 Nm The V-belt tension of new V-belts must be checked after they have been running for 15 minutes.  300 +20 −20 N

2 © 46987-2

© 12/2008

4/8

17842-001

D 2011 w TD 2011 w, TCD 2011 w

Other components W 12-02-01

– Version with V-belt tensioning pulley 1

z Mount V-belt (1). z Swing V-belt tensioning pulley (2) in the direction of the arrow.

3

z Fasten screws (3).

6

2 © 46986-1

z Press clamping strap (1) in direction of arrow with a suitable tool. 1

© 46996-0

z Mount V-belt tension measuring device on V-belt. The V-belt must be between the guides (arrow).

© 46998-1

© 12/2008

5/8

17842-001

Other components W 12-02-01

D 2011 w TD 2011 w, TCD 2011 w

z Press the V-belt measuring device against the V-belt with the button (1) until you hear it click. z Read measured value at the intersection (arrow) of the indicator arm and scale. +50

 450 −50 N

1

Note different units on the scale. z If the nominal value is not reached, the tensioning process must be repeated.

6 © 46998-0

z Tighten screws (1).  45 Nm The V-belt tension of new V-belts must be checked after they have been running for 15 minutes.

1

+20

 300 −20 N

© 46999-0

© 12/2008

6/8

17842-001

D 2011 w TD 2011 w, TCD 2011 w

Other components W 12-02-01

Technical Data Testing and setting data ID no.

Name

Additional information

P12 11

V-belt tension, individual V-belts AVX 10 First assembly

P12 21

V-belt tension, individual V-belts AVX 10

Check after 15 minutes running under load

Value +50

450 −50 N +20

300 −20 N

Tightening specifications ID no.

Name

A09 045 Air bearing on console A09 045 Air bearing on console V-belt tensioning pulley (holder) on A12 041 front cover A13 012 Generator on console A13 015 Clamping bracket on generator A13 016 Clamping bracket on console

Screw type

Notes / Remark Stage 1: M10x110-12.9 Use new screw. M10x110-12.9 Stage 2:

Value 30 Nm 120° 45 Nm

M8x70-10.9 M8x75-10.9 M8x30-8.8 M8x35-8.8

6

34 Nm 22 Nm 22 Nm

For the tightening procedure according to torque using a torque wrench, a maximum variation of the tightening torque of +/- 10% is permissible.

© 12/2008

7/8

17842-001

Other components W 12-02-01

D 2011 w TD 2011 w, TCD 2011 w

6

© 12/2008

8/8

17842-001

D 2011 w TD 2011 w, TCD 2011 w

Other components W 12-06-01

Removing and installing the flywheel Commercial available tools: – Self-made mandrin guide – Rotation angle disc . . . . . . . . . . . . . 8190

6

Removing the flywheel z Block flywheel with suitable tool. z Unscrew all screws (1). z Screw two long screws into the threaded bores. To improve the removal and installation of the flywheel.

1

z Remove flywheel.

© 47216-0

z Visually inspect the components.

© 44276-0

© 12/2008

1/4

17843-001

Other components W 12-06-01

D 2011 w TD 2011 w, TCD 2011 w

Installing the flywheel z Screw two long screws into the threaded bores. To improve the removal and installation of the flywheel. 1

z Insert self-made mandrin guide (1). For example a pin bolt. z Mount flywheel. The bores in the flywheel must match the threaded bores in the crankshaft flange.

6 © 47460-0

z Turn in new screws (1).

Attention! Renew screws every time they are loosened. z Remove self-made mandrin guide. 1

© 47216-0

z Tighten screws alternately. – Stage 1:  30 Nm – Stage 2:  60° – Stage 3:  30° Block flywheel with suitable tool.

© 47461-0

© 12/2008

2/4

17843-001

D 2011 w TD 2011 w, TCD 2011 w

Other components W 12-06-01

Technical Data Tightening specifications ID no.

Name

Screw type

A12 001 Flywheel on crankshaft A12 001 Flywheel on crankshaft A12 001 Flywheel on crankshaft

Notes / Remark Stage 1: Use new screws Stage 2: Stage 3:

Value 30 Nm 60° 30°

For the tightening procedure according to torque using a torque wrench, a maximum variation of the tightening torque of +/- 10% is permissible.

6

© 12/2008

3/4

17843-001

Other components W 12-06-01

D 2011 w TD 2011 w, TCD 2011 w

6

© 12/2008

4/4

17843-001

D 2011 w TD 2011 w, TCD 2011 w

Other components W 12-06-03

Renewing toothed starter ring on the flywheel Commercial available tools

– W 12-06-01

Danger! Danger of injury, do not touch hot parts!

6

Removing toothed starter ring z Remove flywheel.  W 12-06-01 z Drill toothed starter ring.

Attention! Do not damage the flywheel.

© 33837-2

z Remove toothed starter ring with suitable tool.

© 33838-2

© 12/2008

1/2

17844-001

Other components W 12-06-03

D 2011 w TD 2011 w, TCD 2011 w

z Visually inspect joint (arrow) and contact surface. z Clean flywheel. The joint and contact surface must be free from grease and dirt.

6 © 33839-2

Install toothed starter ring z Heat up toothed starter ring to 220 °C. z Place toothed starter ring on flywheel. The toothed starter ring must lie evenly on the joint of the flywheel. z Install flywheel.  W 12-06-01

© 33840-1

© 12/2008

2/2

17844-001

D 2011 w TD 2011 w, TCD 2011 w

Other components W 12-08-02

Removing and installing the hydraulic pump Commercial available tools

– Graphite grease G 500

6

Removing the hydraulic pump z Remove the hydraulic pipes. z Press in stoppers. z Unscrew screws (1). z Remove hydraulic pump (2).

1

z Remove coupling sleeve.

2

© 39090-2

z Pull off the collars (1). z Clean coupling sleeve (2). z Check components for visible signs of wear.

2

1

© 39091-2

© 12/2008

1/4

17845-001

Other components W 12-08-02

D 2011 w TD 2011 w, TCD 2011 w

Installing hydraulic pump z Pull collar (1) onto coupling sleeve (3). 3

z Align cutting on the toothing of the coupling sleeve. z Pull collar (2) onto coupling sleeve (3). z Align cutting on the toothing of the coupling sleeve. z Grease inner toothing of the coupling sleeve.

2

1

6 © 39092-2

z Grease gear shaft (1). z Push on coupling sleeve (2). Note installation position.

2

Toothing of the coupling sleeve must engage with the gear shaft. 1

© 34243-3

z Insert screws (1). z Measure protrusion dimension X. Maximum protrusion dimension X =18 mm. Use new screws or correct with washers under the head of the screw.

X

1

© 34244-3

© 12/2008

2/4

17845-001

D 2011 w TD 2011 w, TCD 2011 w

Other components W 12-08-02

z Insert hydraulic pump (1) and coupling sleeve. Toothing of the coupling sleeve must engage with the gear shaft. z Tighten screws (2).  57 Nm

2

z Pull out stoppers. z Insert hydraulic pipes. 1

6 © 39090-3

© 12/2008

3/4

17845-001

Other components W 12-08-02

D 2011 w TD 2011 w, TCD 2011 w

Technical Data Tightening specifications ID no.

Name Hydraulic pump on hydraulic pump A12 051 console

Screw type

Notes / Remark

Value 57 Nm

For the tightening procedure according to torque using a torque wrench, a maximum variation of the tightening torque of +/- 10% is permissible.

6

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Other components W 12-08-03

Renew toothed belt and tensioning pulley (Hydraulic pump) Commercial available tools

– W 12-01-04

6

Remove toothed belt and tensioning pulley

1

z Remove V-belt pulley.  W 12-01-04 z Unscrew all screws (1). z Remove protective hood (2).

2 © 47462-0

z Remove adapter (1).

1

© 47463-0

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Other components W 12-08-03

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z Unscrew screw (1). z Remove tensioning pulley (2). z Remove the toothed belt (3). z Visually inspect the components.

2

1

3

6

© 47464-0

Install toothed belt and tensioning pulley z Mount new tensioning pulley (1). z Position setting eccentric (arrow) at 11 o'clock. z Fasten screw (2). z Mount new toothed belt (3). 1

2

3 © 47465-0

z Position toothed belt centrally on the toothed belt wheels.

1

Attention! Note installation position. The toothed belt may not rub on the console or the guide band (1)!

© 39594-2

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Other components W 12-08-03

z Turn setting eccentric in the direction of arrow with hexagon socket. Markings (1) must be in alignment with bulge. z Tighten screw (2).

2

1

 21 Nm

6 © 47466-0

Check toothed wheel tension z Turn crankshaft 2 revolutions in the direction of the arrow (direction of engine rotation). Markings (1) must be in alignment with bulge.

1

If the markings are not aligned with each other, the toothed belt tension must be corrected.

© 47467-0

Correct toothed belt tension z Loosen screw (2). z Pre-tighten screw (2). z Turn setting eccentric in the direction of arrow with hexagon socket. Markings (1) must be in alignment with bulge.

1

2

z Tighten screw (2).  21 Nm

© 47466-0

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z Mount connecting piece (1). The flattened side (arrow) must face the toothed belt.

1

6 © 47468-0

z Mount protective hood (2). z Tighten all screws (1).

1

 8.5 Nm z Install V-belt pulley.  W 12-01-04

2 © 47462-0

© 12/2008

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Other components W 12-08-03

Technical Data Tightening specifications ID no.

Name Tensioning pulley on hydraulic pump A12 052 console Protective hood on hydraulic pump A12 056 console

Screw type

Notes / Remark

Value 21 Nm 8.5 Nm

For the tightening procedure according to torque using a torque wrench, a maximum variation of the tightening torque of +/- 10% is permissible.

6

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Other components W 12-08-03

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6

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Electrical system W 13-02-03

Removing and installing the generator Commercial available tools

– W 12-02-01

6

Removing the generator z Disconnect the battery's negative terminal. z Remove cable from generator.

1

Note assignment! - (1) = terminal W - (2) = terminal D+ - (3) = terminal B+ z Remove V-belt.  W 12-02-01

2

3 © 47600-0

z Loosen screw (1). z Unscrew nut (2). z Hold screw (3).

2

z Remove protective plate (4). 1

z Remove protective plate (5). z Remove screw (3).

4

z Lower generator in direction of arrow. 5

3

© 47601-0

© 12/2008

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z Unscrew screw (1). z Remove generator.

1

6 © 47602-0

Installing the generator z Mount generator. z Fasten screw (1).

1

© 47602-0

z Mount generator. z Insert screw (1). z Mount protective plate (2).

4

z Mount protective plate (3). z Screw on nut (4).

3 2

1

© 47601-1

© 12/2008

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Electrical system W 13-02-03

z Remove cable from generator. Note assignment! - (1) = terminal W

1

- (2) = terminal D+ - (3) = terminal B+ – (Position 2)  3.5 Nm – (Position 3)  6.5 Nm z Install V-belt.

2

 W 12-02-01 z Connect the battery's negative terminal.

6

3 © 47600-0

© 12/2008

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Technical Data Tightening specifications ID no.

Name Charging current cable to generator A13 081 B+ A13 082 Cable G1.D+ to generator

Screw type

Notes / Remark

Value 6.5 Nm

M5

3.5 Nm

For the tightening procedure according to torque using a torque wrench, a maximum variation of the tightening torque of +/- 10% is permissible.

6

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Electrical system W 13-03-02

Removing and installing the starter Commercial available tools

6

Removing the starter – TD 2011 w, TCD 2011 w

1

z Disconnect the battery's negative terminal. z Disconnect cables. z Unscrew screws (1). z Remove shielding plate (2).

2

© 47578-0

z Unscrew screws (1). z Remove starter.

1

1 © 47579-0

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z Visually inspect the components.

6 © 47476-0

Installing the starter z Insert starter. z Tighten screws (1).  43.5 Nm

1

1 © 47579-0

z Mount shielding plate (1). z Tighten screws (2).

2

Make sure that the installation site of the rubber pad (3) is in perfect condition. z Tighten screws (2).  8.5 Nm z Connect cables. – see Technical Circular 0199-44-1163 z Connect the battery's negative terminal.

1

3 © 47578-1

© 12/2008

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Electrical system W 13-03-02

Technical Data Tightening specifications ID no. Name A13 001 Starter on crankcase A13 009 Shield on crankcase

Screw type M6x14-8.8

Notes / Remark

Value 43.5 Nm 8.5 Nm

For the tightening procedure according to torque using a torque wrench, a maximum variation of the tightening torque of +/- 10% is permissible.

6

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6

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Electrical system W 13-06-01

Removing and installing the heating plugs Commercial available tools Special tools: – Assembly tool . . . . . . . . . . . . . . . 120440

6

Removing the glow plugs z Disconnect the battery. z Disconnect cables from heating plugs. z Unscrew heating plugs (1) with assembly tool.

1

© 46969-0

z Visually inspect the component.

© 46970-0

© 12/2008

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Electrical system W 13-06-01

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Installing the glow plugs z Screw in heating plug (1). z Tighten heating plug (1) with assembly tool.  21 Nm z Connect cables to heating plugs. z Connect the battery. 1

6 © 46969-0

© 12/2008

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Electrical system W 13-06-01

Technical Data Tightening specifications ID no. Name A13 032 Heating plug on cylinder head

Screw type

Notes / Remark

Value 21 Nm

For the tightening procedure according to torque using a torque wrench, a maximum variation of the tightening torque of +/- 10% is permissible.

6

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6

© 12/2008

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Electrical system W 13-06-02

Removing and installing the glow plug Commercial available tools

6

Removing the glow plug z Disconnect cable connections. z Unscrew glow plug (1). z Remove sealing ring. 1

© 47477-0

z Visually inspect the components.

© 47478-0

© 12/2008

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Electrical system W 13-06-02

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Installing the glow plug z Insert new sealing ring. z Insert glow plug (1).

1

6 © 47479-0

z Tighten glow plug (1).  60 Nm z Connect cable.  4 Nm

1

© 47477-0

© 12/2008

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Electrical system W 13-06-02

Technical Data Tightening specifications ID no.

Name Glow plug in charge air line / intake A13 031 pipe A13 034 Cable connection to glow plug

Screw type

Notes / Remark

Value 60 Nm 4 Nm

For the tightening procedure according to torque using a torque wrench, a maximum variation of the tightening torque of +/- 10% is permissible.

6

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Electrical system W 13-06-02

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6

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7

Standard tools

Standard tools 7

© 12/2008

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Standard tools Orders The tools can be ordered directly, stating the order number, from: WILBAER Wilhelm Bäcker GmbH & Co.KG Postfach 14 05 80 42826 Remscheid Germany Tel.: +49 (0) 2191 9339-0 Fax: +49 (0) 2191 9339-200 E-mail: [email protected] Web: http://www.deutz-tools.com

7

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Standard tools

8005 Compression pressure tester for diesel engines 10 - 40 bar Checking compression pressure

© 35410-3

7 8008 Nozzle tester with spray mist collecting vessel Check injection nozzles

© 35411-2

8011 Hose clip pliers Loosen and fasten hose clips e. g. fuel return pipe

© 39426-1

© 12/2008

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Standard tools 8012 Socket wrench insert Wrench size 15, long

© 35412-3

7 8018 Claw wrench Wrench size 17, Removing and installing injection pipes

© 37506-2

8024 Assembly pliers Removing valve shaft seals

© 37509-2

© 12/2008

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Standard tools

8027 Plier insert Removing and installing the lifting magnet

© 39531-1

7 8035 Socket wrench insert Wrench size 22, strengthened version

© 37504-1

8036 Socket wrench insert Wrench size 32, (in conjunction with force multiplier 8049)

© 39429-1

© 12/2008

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Standard tools 8049 Force multiplier Removing and installing the centre screw Tool kit, including socket wrench insert 8036 (in conjunction with holder 143420)

© 39430-1

7 8115 V-belt tension measuring device 150 to 600 N Check V-belt tension

© 35416-3

8116 Socket wrench insert Torx - E18

© 35415-1

© 12/2008

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Standard tools

8167 Cleaning brush Cleaning exhaust channels

© 46283-0

7 8170 Micrometre depth gauge Measure the depth of the roller tappet

© 39532-1

8189 Torx tool set Contents of case: - Double-ended ring spanner E6/E8 - Double-ended ring spanner E10/E12 Socket wrench insert E8 and E10 (1/4 inch) - Socket wrench insert E10 and E12 (3/8 inch) - Socket wrench insert E18 (1/2 inch)

© 39432-1

© 12/2008

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Standard tools 8190 Rotation angle disc with magnet (e. g. setting valve clearance)

© 42528-1

7 8198 Pricker Removing rotary shaft lip seal

© 43206-1

9017 Assembly lever e. g. removing and installing valves

© 37511-2

© 12/2008

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Standard tools

9088 Clamping tongs Loosening and tightening hose clips

© 39433-1

7 9090 Spring band pliers 320 mm Tighten spring clamp

© 35420-3

9120 Special bit 70 mm long

© 39434-1

© 12/2008

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Standard tools

7

© 12/2008

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8

Special tools

Special tools

8

© 12/2008

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Special tools Orders The tools can be ordered directly, stating the order number, from: WILBAER Wilhelm Bäcker GmbH & Co.KG Postfach 14 05 80 42826 Remscheid Germany Tel.: +49 (0) 2191 9339-0 Fax: +49 (0) 2191 9339-200 E-mail: [email protected] Web: http://www.deutz-tools.com

8

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Special tools

100120 Connector (in conjunction with compression pressure tester 8005)

© 39400-1

100400 Dial gauge with fixing wheel Measuring range 0 - 10 mm / 0.01 mm

8

© 35424-1

100410 Digital gauge Measuring range 0 - 30 mm / 0.01 mm

© 43205-0

© 12/2008

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Special tools 100700 Ajustable bolt Crankshaft and camshaft lock

© 39101-1

8

100710 Ajustable bolt Control linkage lock

© 39401-1

100750 Measuring device Measuring bar with two shims (in conjunction with 100400 and 100410) Checking valve lag dimension Checking piston projection

© 39402-2

© 12/2008

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Special tools

101020 Degree scale for testing and setting the static beginning of injection

© 47638-0

101030 Adapter (in conjunction with degree scale 101020)

8

© 47637-0

101100 Rig pin Lock the steering link of the injection pump

© 39404-1

© 12/2008

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Special tools 101300 Point for degree scale for testing and setting the static beginning of injection

© 39406-1

8

101500 High-pressure hand pump for testing and setting the static beginning of injection

© 36443-2

101510 Supply tank (in conjunction with high-pressure hand pump 101500)

© 36444-2

© 12/2008

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Special tools

101640 Special wrench Set minus adjustment

© 46981-0

103040 Test template Check shim thickness

8

© 47495-0

103220 Special pliers (part of measuring device 103210) for removing the roller tappet

© 43175-0

© 12/2008

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Special tools 110090 Puller (in connection with sliding hammer 150800) Removing fuel injector

© 35433-2

8

110110 Holder Wrench size 11, clamp the injection valve in the vice

© 35434-2

110140 Disassembly/assembly tool. Removing and installing the guide bushes (control linkage)

© 39407-1

© 12/2008

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Special tools

110901 Disassembly tool (part of assembly case 110900) Removing and installing the O-rings

© 45950-1

120440 Assembly tool Removing and installing the glow plugs

8

© 40333-1

120900 Support bracket pivoting Clamping cylinder head

© 35438-3

© 12/2008

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Special tools 120910 Base plate (in conjunction with support bracket 120900 if support bracket is not screwed tightly)

© 35439-3

8

121410 Assembly tool Mounting valve shaft seal

© 37614-2

121420 Assembly sleeves Set of assembly sleeves for valve shaft seal

© 43210-0

© 12/2008

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Special tools

130300 Universal piston ring pliers Removing and installing the piston rings

© 43021-0

130420 Trapezoidal groove wear gauge Testing piston ring groove

8

© 36461-2

130850 Piston ring compressor Piston diameter 96 mm

© 39408-1

© 12/2008

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Special tools 131100 Disassembly tool Remove piston bolt

© 39409-1

8

131350 Disassembly/assembly tool. Removing and installing the small end bush (Diameter 30mm)

© 39410-1

142050 Assembly tool Install camshaft sealing ring

© 39412-1

© 12/2008

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Special tools

142680 Assembly tool Installing crankshaft sealing ring (flywheel side)

© 47496-0

142690 Assembly tool Installing crankshaft sealing ring (opposite side to flywheel)

8

© 47497-0

143420 Counter support (in conjunction with force multiplier 8049 and socket wrench insert 8036)

© 39417-1

© 12/2008

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Special tools 143430 Washer (in conjunction with holder 143420)

© 39418-1

8

143720 Disassembly/assembly tool. Removing and installing camshaft bearing

© 39419-1

144130 Counter support Hold toothed belt wheel of the camshaft

© 39420-1

© 12/2008

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Special tools

150151 Handle (in conjunction with assembly pin 150220)

© 46978-0

150180 Holder (in conjunction with measuring device 100750) Measure piston overhand on recess cylinder head

8

© 43181-0

150210 Puller Remove oil rise tube

© 46979-0

© 12/2008

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Special tools 150220 Assembly pin Drive in oil rise tube

© 46980-0

8

150800 Slide hammer Removing fuel injector

© 35449-2

151500 Separating tool Removing metal sheet lubricating oil pan from crankcase

© 45974-0

© 12/2008

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Special tools

160400 Slide hammer Remove oil rise tube

© 43188-0

170050 Special wrench Unscrewing the filter cartridges

8

© 37629-2

170160 Stoppers/caps 1 set of differently-sized stoppers and caps Sealing openings on the fuel system

© 43663-0

© 12/2008

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Special tools 6067 Assembly block Engine clamping, one-sided

© 39424-1

8

6067/114 Supporting bracket (in conjunction with assembly block 6067) Engine clamping, one-sided

© 39369-1

6067/115 Clamping bracket (in conjunction with assembly block 6067) Engine clamping, one-sided

© 39425-1

© 12/2008

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