JCB Engines Deutz 2009 (03123-438) Workshop Manual - PDF DOWNLOAD

Workshop Manual competence level 3

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D 2009 TD 2009

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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 3488 en

Regarding copyright questions and licensing agreements please contact : TE-FI, Mr. Sonntag Tel.: + 49 (0) 221 822-3053 EMail: sonntag.j@deutz.com DEUTZ AG Service Information Systems Ottostraร e 1 D-51149 Kรถln (Cologne) Phone.: +49 (0) 221-822-0 Fax: +49 (0) 221-822-5850 Internet: www.deutz.com E-Mail: info@deutz.com

The engine company.

Printed in Germany All rights reserved 1st Edition, 01/2008 Order No. 0312 3488 en

D 2009 TD 2009 1

Foreword

2

General

3

User notes 3.1 3.2 3.3 3.4 3.5

4

5

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

Technical data 4.1 4.2

Testing and setting data Tightening specifications

Job card overview 5.1 5.2

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Table of contents

Sorted alphabetically Sorted numerically

6

Job cards

7

Commercial tools

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Special tools

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Table of contents

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Foreword

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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

DEUTZ engines

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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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General

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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: – After all work on the fuel system, it must be bleeded - see the operation manual, chapter "6.2 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.

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

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DEUTZ engines

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

3.3 Operation manual and workshop manual

– Do not place hands near to a leak in the high pressure fuel system.

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

– 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.

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

– 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.

3. Operation

– Always stay out of range of a fuel jet, as it could cause severe injury.

8. Engine conservation

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

10.Service

4. Operating media 5. Maintenance 6. Care and maintenance work 7. Faults, causes and remedies 9. Technical data 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.

– Do not work near to sparks and flames.

3.2.2 Disposal regulations The work described in the operation manual and workshop manual necessitates renewal of parts and 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.

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

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.

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User notes

3.4 Job cards

3.4.2 Structure of a job card

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.

1

2

3

Triebwerk W 02-04-01

4 5

16 6 15

6

7

14

3.4.1 Numbering of job cards

8 13

The job card numbers follow the pattern W 02-0401. The individual parts of this pattern are explained below: z W 02-04-01: Documentation type

12

8

– WWorkshop manual – I ...... Repair instructions z W 02-04-01: Maintenance group – 00 ... General / interdisciplinary activities

11

– 01 ... Cylinder head

10

– 03 ... Crankcase

1. DEUTZ AG, publisher of service documentation

– 04 ... Engine control system

2. Engine type (e.g. TCD 2013 4V)

– 05 ... Speed governing

3. Maintenance group

– 06 ... Exhaust system / Charging

4. Job card number or topic

– 07 ... Fuel system

5. Title of job card

– 08 ... Lube oil system

6. Reference to other job cards

– 09 ... Cooling system

7. Chapter

– 10 ... Compressed air system

8. Graphic or photo

– 11 ... Monitoring system

9. DEUTZ internal creation number

– 12 ... Other components

10.Page number

– 13 ... Electrical system

11.Date of issue of job card

– 02Drive system

z W 02-04-01: Component grouping

12.Note

z W 02-04-01: Consecutive number

13.Danger / Important

9

14.Work sequence 15.Special tools; auxiliary materials 16.Conventional tools

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3.5 Explanation of symbols 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

Caution!

Danger to the component/engine. Noncompliance can lead to destruction of the component/engine.

Must be observed!

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

Tool Conventional and special tools required for the work.

Auxiliary materials Working materials required in addition to the tools for performing the work (e.g. greases, oils, adhesives, sealants) References to important documents or job cards for the work process.

For example: Job card W 04-05-05 Reference to a document or a job card within the work process.

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 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

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Technical data Testing and setting data

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Technical data Testing and setting data

D 2009 TD 2009

ID no.

Name D / TD 2009 P00 31 Bore, diameter P00 32 Stroke P00 50 Direction of rotation

4

Additional information

Value

Nominal value

90 mm 90 mm left 25 - 30 bar (2500 - 3000 kPa) 7.155 - 7.170 mm 7.155 - 7.170 mm 0.1 - 0.4 mm 0.1 - 0.4 mm 36.90 - 37.10 mm 33.90 - 34.10 mm 55.005 - 55.020 mm 53 - 58 HRc 49.990 - 50.005 mm 0.13 - 0.56 mm

looking onto the flywheel

P00 51

Compression pressure

P01 31 P01 32 P01 35 P01 36 P01 37 P01 38 P02 03 P02 07 P02 22 P02 34

Valve stem, diameter, inlet Valve stem, diameter, outlet Valve edge thickness, inlet Valve edge thickness, outlet Valve plate, diameter, inlet Valve plate, diameter, outlet Main journal, diameter Bearing pin, surface hardness Lifting journal, diameter Crankshaft, permissible axial clearance

P02 75

Standard in the installed state 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 Piston bolt bush, diameter, inside 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 Piston protrusion

0.70 - 1.0 mm

P02 78

Piston pin bore

28 +0.008 +0.003 mm

P02 84

Piston ring 1, joint clearance

0,15 +0

mm

P02 85

Piston ring 2, joint clearance

+0.25 0,15 +0

mm

P02 86

Piston ring 3, joint clearance

+0.25 0,30 +0

P02 87 P02 88 P02 89

Piston ring 1, axial clearance Piston ring 2, axial clearance Piston ring 3, axial clearance Camshaft bearing, locating hole, diameter Camshaft bearing, diameter, inside Crankshaft, bearing bush, installation depth

P02 41

P02 42 P02 43 P02 52 P02 55 P02 56 P02 61 P02 62

P03 11 P03 13 P03 29 P03 31

Cylinder, diameter, inside

P04 31

Camshaft, bearing pin, diameter Camshaft, bearing pin, diameter (drive side) Camshaft, axial clearance Thermostat, start of opening Thermostat, stroke distance V-belt tension

P04 31 P04 35 P09 11 P09 13 P12 11 © 01/2008

0.03 mm

0.03 mm 28.010 - 28.025 mm 50.045 - 50.057 mm 53.525 - 53.545 mm 0.040 - 0.067 mm 28 −0.005 −0.01 mm 0.015 - 0.035 mm

+0.20

mm 0.11 - 0.15 mm 0.045 - 0.090 mm 0.045 - 0.090 mm 50.060 - 50.095 mm in the installed state

45.960 - 45.980 mm approx. 3 mm

Standard

+0.025

90 +0 mm 41.925 - 41.955 mm 45.950 - 45.970 mm

(not adjustable)

First assembly 2/8

0.07 - 0.29 mm 86 - 90 °C at least 9 mm 450 N 16342-001

D 2009 TD 2009 ID no.

Name

P12 21

V-belt tension

Technical data Testing and setting data Additional information Check after 15 minutes running under load.

D / TD 2009 L03 P00 04 Engine weight according to DIN 70020-A P00 71 Ignition sequence D / TD 2009 L04 P00 04 Engine weight according to DIN 70020-A P00 71 Ignition sequence D 2009

Value 300 +20 −20 N approx. 180 kg 1-2-3 approx. 220 kg 1-3-4-2 Indirect injection eddy chamber method 22 : 1

P00 20

Combustion process

P00 40

Compression ratio

P02 71

Piston, diameter, standard

Measuring point 1 = height 10 mm 89,400 +0.167 +0.153 mm

P02 72

Piston, diameter, standard

Measuring point 2 = height 44 mm 89,400 +0.008 −0.008 mm

P02 73

Piston, diameter, standard

Measuring point 3 = height 65 mm 89,400 −0.175 −0.145 mm

TD 2009 P00 20 Combustion process P00 40 Compression ratio P02 71 Piston, diameter, standard

Direct injection 17 : 1 Measuring point 1 = height 10 mm 89,825 +0.152 +0.138 mm

P02 72

Piston, diameter, standard

Measuring point 2 = height 36 mm 89,825 +0.009 −0.009 mm

P02 73

Piston, diameter, standard

Measuring point 3 = height 66 mm 89,825 −0.220 −0.190 mm

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Technical data Testing and setting data

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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 A00 001 Clamping bracket on crankcase Clamping bracket on adapter for A00 002 assembly block Mounting foot/engine mounting on A00 003 crankcase

4

D 2009 TD 2009 Screw type Notes / Remark M10x20-10.9

90 Nm M10x20-10.9

A01 001 Cylinder head on crankcase

M12x13010.9

A01 002 A01 004 A01 092 A02 010 A02 010 A02 012

M8x30-8.8 M8x50-10.9 M8x16 M8x20-8.8 M8x20-8.8 M10x80-8.8

Rocker arm on cylinder head Cylinder head cover on cylinder head Transport bracket on cylinder head Main bearing housing on crankcase Main bearing housing on crankcase Bearing housing in crankcase Big end bearing cover on connecting A02 020 rod

M8x52-10.9

41 Nm Use new screws.

Observe tightening order.

Stage 1: Stage 2: Use new screws.

A03 020 Gearcase cover on crankcase

M8x35-12.9 M8x50-10.9 M8x70-8.8

A03 030 Lubricating oil pan on crankcase

M8x20-8.8

A03 031 Locking screw on lubricating oil pan

M14x14

A03 060 A03 080 A04 001 A04 002

M8x40-8.8 M12x25-12.9 Locking screw M12x35-8.8 M8x16-8.8 Torx screw

Oil trap on crankcase Connection housing to crankcase Camshaft gear wheel on camshaft Camshaft, shim on crankshaft Injection pump gear wheel on injecA04 004 tion pump Injection pump gear wheel on injecA04 004 tion pump A04 011 Intermediate gear on crankcase A04 022 Cap on gearcase cover A06 001 Exhaust pipe at cylinder head A06 010 A06 020 A06 030 A06 030 A06 059 A06 062 A06 063 A06 064 A06 070 A06 083 A07 001 A07 001

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Value 41 Nm

M12x75-10.9 M8x70-8.8 M8x20-8.8 M8x55-10.9

27 Nm 27 Nm 21 Nm 15 Nm 27 Nm 41 Nm 20 Nm + 45° 27 Nm

Observe tightening sequence.

Use new Cu sealing ring.

32 Nm 39 Nm 27 Nm 81 Nm 81 Nm 21 Nm

Stage 1:

10 Nm

Stage 2:

81 Nm 81 Nm

Torx screw

Insert with Deutz S1 Exhaust manifold to turbocharger M8x25-10.9 mounting compound.

M10x20-10.9 Insert with Deutz S1 Turbocharger on exhaust pipe M8x16-8.8 mounting compound.

Observe tightening Charge air pipe on cylinder head M8x45-10.9 sequence.

Air suction intake pipe on cylinder Observe tightening M8x70 head sequence.

Exhaust return pipe to cooler M8x12-10.9 Exhaust return pipe to charge air pipe M8x70-8.8 Compensator pipe on exhaust pipe M8x20-10.9 Compensator pipe to cooler M8x12-8.8 Exhaust retgurn pipe to exhaust M8x20-8.8 return valve Charge air manifold to charge air pipe M8x20-8.8 Fuel injector on cylinder head M8x35-10.9 Torx screw Fuel injector on cylinder head M22

6/8

35 Nm + 60° + 60°

27 Nm 27 Nm 41 Nm 41 Nm 27 Nm 27 Nm 25 Nm 20 Nm 20 Nm 25 Nm 20 Nm 21 Nm 35 Nm 68 Nm

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D 2009 TD 2009 ID no.

A07 003

Name Injection line on fuel injector/injection pump Injection lines, fastening, pipe clip Injection pump on crankcase Blocking screw on injection pump Fuel line on injection pump Fuel lines on fuel supply pump and fuel filter console Fuel supply pump on crankcase Fuel lines on crankcase, pipe clip Fuel line to fuel filter console Fuel filter console to crankcase Lubricating oil filter on lubricating oil cooler Adapter on gearcase cover Lubricating oil pump on crankcase Oil suction pipe, holder on crankcase Lubricating oil pipe on exhaust turbocharger Oil return line to turbocharger Lubricating oil cooler on adapter Oil pressure switch in crankcase

Technical data Tightening specifications Screw type

Notes / Remark

Value

M12x1.5

28 Nm

M6x10-8.8 M8x30-10.9 1/2’’

9 Nm 27 Nm 10 Nm 9 Nm

1/2’’

9 Nm

M8x55-10.9 M8x12-10.9 M10x1.5 Hollow screw M10x25-10.9 Oil gasket lightly.

M14x1.5 See operating manual 3/4“ M6x25-8.8 M10x80-8.8

27 Nm 27 Nm 21 Nm 41 Nm

41 Nm 4 Nm + 9 Nm 41 Nm

M14x1.5

15 Nm

M6x16-8.8 M22x1.5 M10x1 M12x1 M14x1.5

9 Nm 41 Nm 20 Nm

A08 098

3/8“

21 Nm

A09 010 Coolant pump on gearcase cover

M8x30-10.9 M8x70-8.8 M8x30-10.9 M8x16-8.8

A07 006 A07 012 A07 013 A07 015 A07 019 A07 024 A07 044 A07 084 A07 087 A08 001 A08 003 A08 010 A08 016 A08 040 A08 044 A08 051 A08 091

A08 091 Oil pressure switch in crankcase Oil pressure control valve on crankcase A09 002 Outlet nozzles on cylinder head

A09 021 Pipe, holder to holder Temperature transmitter on cylinder A09 031 head A12 001 Flywheel on crankshaft A12 031 V-belt pulley on crankshaft A12 046 V-belt pulley on coolant pump A13 001 Starter on connection housing A13 012 Generator on gearcase cover A13 015 Generator on clamping bracket A13 016 Clamping bracket on gearcase cover A13 032 Glow plug on cylinder head A13 033 Connecting rail to glow plug Charge air pressure switch in charge A13 046 air line A13 071 Cable (terminal 30) to starter

© 01/2008

Hand tighten

50 Nm

27 Nm Observe tightening sequence.

27 Nm 21 Nm

Insert gasket with packing compound.

M12x50-10.9 Use new screws.

M20x55-10.9 M6x10-8.8 M10x45-8.8 M8x120-8.8 M8x20-8.8 M8x16-8.8 M10 M4 Locking nut

96 Nm 300 Nm 9 Nm 41 Nm 21 Nm 21 Nm 21 Nm 15 Nm 2.5 Nm

M10

20 Nm

M8

9 Nm

7/8

4

4 Nm

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Technical data Tightening specifications

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Job card overview Sorted alphabetically

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Job card overview

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Job card overview Sorted alphabetically

Activity

Job card

Maintenance group

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

W 00-02-06

General

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 valves

W 01-05-04

Cylinder head

Mounting engine on assembly block and demounting

W 00-05-01

General

Removing and install the charge air line

W 06-07-03

Exhaust system / Charging

Removing and installing cylinder head

W 01-04-04

Cylinder head

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 coolant pump

W 09-07-08

Cooling system

W 06-09-04

Exhaust system / Charging

W 02-04-01

Drive system

Checking the compression pressure D 2009 Checking the compression pressure TD 2009

Removing and installing the cooler (Exhaust gas recirculation) Removing and installing the crankshaft

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 fuel filter console

W 07-10-08

Fuel system

Removing and installing the fuel injector pump

W 07-04-01

Fuel system

W 07-07-01

Fuel system

Removing and installing the fuel injectors TD 2009

W 07-07-01

Fuel system

Removing and installing the fuel supply pump

W 07-11-01

Fuel system

Removing and installing the gearcase cover

W 04-04-09

Engine control

Removing and installing the fuel injectors D 2009

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Job card overview Sorted alphabetically

5

D 2009 TD 2009

Activity

Job card

Maintenance group

Removing and installing the generator

W 13-02-03

Electrical system

Removing and installing the glow plugs

W 13-06-01

Electrical system

Removing and installing the intake manifold

W 06-07-03

Exhaust system / Charging

Removing and installing the lubricating oil cooler

W 08-08-02

Lube oil system

Removing and installing the lubricating oil pan

W 08-04-07

Lube oil system

Removing and installing the lubricating oil pump

W 08-04-05

Lube oil system

Removing and installing the oil pressure regulating valve

W 08-11-10

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 rocker arm

W 01-02-02

Cylinder head

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 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 12-02-02

Other components

Removing and installing, testing camshaft bearing

W 03-11-01

Crankcase

W 02-02-02

Drive system

W 02-02-04

Drive system

W 07-04-14

Fuel system

Renewing the crankshaft sealing ring (flywheel side) Renewing the crankshaft sealing ring (opposite side to flywheel) Setting the injection pump

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Job card overview Sorted numerically

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Job card overview

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Sorted numerically

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Job card overview Sorted numerically

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D 2009 TD 2009

Job card W 00-02-06 W 00-02-06

Job card overview Sorted numerically

Activity

Maintenance group

Checking the compression pressure D 2009 Checking the compression pressure TD 2009

General General

W 00-05-01

Mounting engine on assembly block and demounting

General

W 01-02-02

Removing and installing the rocker arm

Cylinder head

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 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 W 02-02-04

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

Drive system Drive system

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 03-03-01

Checking the cylinder

Crankcase

W 03-09-04

Removing and installing the connection housing

Crankcase

W 03-11-01

Removing and installing, testing camshaft bearing

Crankcase

W 04-04-09

Removing and installing the gearcase cover

Engine control

W 04-05-05

Removing and installing the camshaft

Engine control

W 04-05-06

Checking the camshaft

Engine control

W 06-01-05

Removing and installing the exhaust 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 06-07-03

Removing and install the charge air line

Exhaust system / Charging

W 06-09-04

Removing and installing the cooler (Exhaust gas recirculation)

Exhaust system / Charging

W 06-09-06

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

W 07-04-01

Removing and installing the fuel injector pump

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Fuel system

16343-001

Job card overview Sorted numerically Job card

Activity

Maintenance group

W 07-04-14

Setting the injection pump

Fuel system

W 07-07-01 W 07-07-01

5

D 2009 TD 2009

Removing and installing the fuel injectors D 2009 Removing and installing the fuel injectors TD 2009

Fuel system Fuel system

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

Lube oil system

W 08-08-02

Removing and installing the lubricating oil cooler

Lube oil system

W 08-11-08

Removing and installing the oil pressure switch

Lube oil system

W 08-11-10

Removing and installing the oil pressure regulating valve

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 09-12-01

Removing and installing temperature transmitter

Cooling system

W 12-02-02

Removing and installing the V-belt pulley

Other components

W 12-06-01

Removing and installing the flywheel

Other components

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 glow plugs

Electrical system

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DEUTZ engines

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© 01/2008

Job cards

Job cards

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Job cards

DEUTZ engines

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General W 00-02-06

D 2009 Checking the compression pressure Commercial available tools: – Compression pressure tester. . . . . . . . . . . . . . . . . . . . . . . . 8005

– W 13-06-01

Special tools: – Connector . . . . . . . . . . . . . . . . . . 100220

6

Checking the compression pressure z Disconnect the shutoff solenoid. z Remove the glow plugs.

W 13-06-01

2

z Insert connector (1). z Tighten the connection piece.

15 Nm z Connect adapter (2) to connector.

1

© 41413-0

z Mount the compression tester on the adapter. z Turn over engine with starter.

25 - 30 bar (2500 - 3000 kPa)

© 41415-0

© 01/2008

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General W 00-02-06

D 2009

6

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.

1 2 3 4 5 6 7 8

Best. Nr. 5 1341 250 00 DBGM

Made in Germany

MOTOMETER 7250 Leonberg © 43669-0

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

1

© 41415-1

z Remove connector (1). z Install the glow plugs.

W 13-06-01 z Connect the shutoff solenoid.

1

© 41414-0

© 01/2008

2/4

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General W 00-02-06

D 2009 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 A13 032 Glow plug on cylinder head

Screw type M10

Notes / Remark

Value 15 Nm

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General W 00-02-06

D 2009

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General W 00-02-06

TD 2009 Checking the compression pressure Commercial available tools: – Compression pressure tester. . . . . . . . . . . . . . . . . . . . . . . . 8005 – Torx tool set . . . . . . . . . . . . . . . . . . 8189

– W 07-07-01

Special tools: – Connector . . . . . . . . . . . . . . . . . . 100170 – Clamping claw . . . . . . . . . . . . . . 100210

6

Checking the compression pressure z Disconnect the shutoff solenoid. z Removing fuel injectors.

W 07-07-01 z Mount sealing ring (1). z Insert connector (2).

2 1

© 41350-0

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

35 Nm

1

2

© 41348-0

© 01/2008

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16346-001

General W 00-02-06

TD 2009

z Connect adapter (1) to connector.

1

6 © 41349-0

z Mount the compression tester on the adapter. z Turn over engine with starter.

25 - 30 bar (2500 - 3000 kPa)

© 46308-0

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.

1 2 3 4 5 6 7 8

Best. Nr. 5 1341 250 00 DBGM

Made in Germany

MOTOMETER 7250 Leonberg © 43669-0

© 01/2008

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General W 00-02-06

TD 2009 z Remove the compression pressure tester and adapter (1).

1

6 © 46308-1

z Unscrew screw (2). z Remove clamping shoe (1). z Remove connector. z Remove sealing ring. z Install fuel injectors.

W 07-07-01 z Connect the shutoff solenoid.

1

2

© 41348-0

© 01/2008

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General W 00-02-06

TD 2009

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 M8x35-10.9

Notes / Remark Torx screw

Value 35 Nm

6

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D 2009 TD 2009

General W 00-05-01

Mounting engine on assembly block and demounting Different customer scopes are not taken into account in the repair sequence shown here, accessories which deviate from the standard equipment are not shown.

Commercial available tools: – Lifting gear – Suspension ropes Special tools: – Assembly block. . . . . . . . . . . . . . . . 6067 – Clamping bracket . . . . . . . . . . .6067 200 – Engine lifting device . . . . . . . . . . . . 6068

6

Mounting engine on assembly block z Hang the engine director onto the transport lashes (arrows) with support chain.

– D / TD 2009 L03 approx. 180 kg – D / TD 2009 L04 approx. 220 kg z Hang engine on workshop crane. z Remove all mounting feet. z Insert engine in engine block.

© 41351-0

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

41 Nm

2

z Mount clamping holder (3).

4

z Tighten screws (4).

2

41 Nm

1

4

3

© 41251-1

© 01/2008

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General W 00-05-01

D 2009 TD 2009

z Align engine on engine block.

2

z Tighten screws (1) and nuts (2).

90 Nm z Unhook the engine from the workshop crane.

1

2

6

1

© 41387-0

Demounting engine from assembly block z Hang the engine director onto the transport lashes (arrows) with support chain.

– D / TD 2009 L03 approx. 180 kg – D / TD 2009 L04 approx. 220 kg z Hang engine on workshop crane.

© 41351-0

z Unscrew the nuts (2).

2

z Remove screws (1).

1

2

1

© 41387-0

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D 2009 TD 2009

General W 00-05-01

z Unscrew screws (2). z Remove clamping bracket (1). z Unscrew screws (4).

2

z Remove clamping bracket (3).

4

z Install all mounting feet.

2

41 Nm

4

z Set down engine. z Unhook the engine from the workshop crane.

1

3

6 © 41251-1

© 01/2008

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General W 00-05-01

D 2009 TD 2009

Technical Data Testing and setting data ID no.

Name Additional information D / TD 2009 L03 P00 04 Engine weight according to DIN 70020-A D / TD 2009 L04 P00 04 Engine weight according to DIN 70020-A

Value approx. 180 kg approx. 220 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

Š 01/2008

Screw type Notes / Remark M10x20-10.9

Value 41 Nm 90 Nm

M10x20-10.9

4/4

41 Nm

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D 2009 TD 2009

Cylinder head W 01-02-02

Removing and installing the rocker arm Commercial available tools: – Open-ended spanner (24 mm spanner size) – Hose clip pliers . . . . . . . . . . . . . . . . 8011 Special tools: – Disassembly tool. . . . . . . . . . . . . 110901

6

Removing the rocker arm 2

– TD 2009 z Unscrew screws (1). z Place charge air pipe (2) to one side.

1

© 41252-1

– TD 2009 z Remove the O-ring (1) with the disassembly tool.

1

© 41254-0

© 01/2008

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Cylinder head W 01-02-02

D 2009 TD 2009

z Loosen hose clip (1). z Place pipe (2) to one side.

1 2

6 © 41253-1

z Unscrew all screws (1). z Remove cylinder head cowling (2). z Remove gasket (3).

1

2 3

© 41001-3

z Unscrew screw (1). z Remove rocker arm bearing (2).

1

z Remove rocker arm (3).

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

2

z Visually inspect the components.

3

© 41183-0

© 01/2008

2/6

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D 2009 TD 2009

Cylinder head W 01-02-02

Installing the rocker arm z Grease the rocker arm (arrow) lightly.

1

z Mount rocker arm (3) and rocker arm bearing (2).

Align rocker arm centred to the valve spring!

2

z Fasten screw (1).

3

6 © 41002-1

z Press down rocker arm (1) and pushrod. z Hold rocker arm with open-ended wrench (2). z Tighten screw (3).

27 Nm

1

3

2

© 41255-1

z Clean sealing surfaces.

The sealing surfaces must be dry and free from grease and dirt.

1

z Mount new gasket (3). z Mount cylinder head cover (2). z Tighten screws (1).

2

27 Nm Tightening sequence: From the centre outwards.

3

© 41001-3

© 01/2008

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Cylinder head W 01-02-02

D 2009 TD 2009

z Push in pipe (1). z Fix the hose clip (2) with the hose clip pliers.

1 2

6 © 41253-1

– TD 2009 z Clean sealing surfaces. z Insert new sealing ring (1).

1

© 41254-1

– TD 2009 z Clean sealing surfaces.

1

z Mount charge air pipe (1). z Tighten screws (2).

21 Nm

2

© 41252-2

© 01/2008

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D 2009 TD 2009

Cylinder head W 01-02-02

Technical Data Tightening specifications ID no.

A01 002 A01 004 A06 083

Name Rocker arm on cylinder head Cylinder head cover on cylinder head Charge air manifold to charge air pipe

Screw type M8x30-8.8 M8x50-10.9 M8x20-8.8

Notes / Remark

Value 27 Nm 27 Nm 21 Nm

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D 2009 TD 2009

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D 2009 TD 2009

Cylinder head W 01-04-04

Removing and installing cylinder head Commercial available tools: – Rotation angle disc . . . . . . . . . . . . . 8190

– W 01-02-02 – W 01-04-09 – W 06-06-04 – W 06-07-03 . . . . . . . . . . . . . . . . . D 2009 – W 06-07-03 . . . . . . . . . . . . . . . . TD 2009

6

Removing the cylinder head 3

1. Valve

2

2. Rocker arm

5

3. Cylinder head bolts 4. Pushrods 5. Thermostat housing 6. Fuel injector

1

7

4

6

© 41014-0

z Remove turbocharger.

W 06-06-04 3

z Loosen hose clips (1). z Unscrew screws (2).

2

z Remove the oil trap (3).

1

1 2

© 41256-1

© 01/2008

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Cylinder head W 01-04-04

D 2009 TD 2009

z Remove the rocker lever.

W 01-02-02 z Remove the charge air pipe.

– D 2009 W 06-07-03 – TD 2009 W 06-07-03

6 © 41006-1

z Remove push rods (1). z Put aside components in the order in which they were removed. z Visually inspect the components.

1

© 41007-1

– D / TD 2009 L03 z Loosen screws in specified order. z Remove screws.

7

3

2

6

8

4

1

5

© 41178-0

© 01/2008

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D 2009 TD 2009

Cylinder head W 01-04-04

– D / TD 2009 L04 z Loosen screws in specified order. z Remove screws.

7

3

2

6

10

8

4

1

5

9

6 © 41177-0

z Lift the cylinder head carefully from the crankcase. z Remove gasket.

Do not place cylinder head on sealing surface. z Visually inspect the components.

© 41009-1

Installing the cylinder head

1

z Clean sealing surfaces. z Check piston overhang.

W 01-04-09 Note installation position of the hydro tappets. z Pay attention to clamping bushing (1).

1

© 41010-0

© 01/2008

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Cylinder head W 01-04-04

D 2009 TD 2009

z Fit a new cylinder head gasket.

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

Label OBEN / TOP facing the cylinder head.

6 © 41011-1

z Fit cylinder head. z Pay attention to clamping bushing (1).

!

1

1

© 41012-1

– D / TD 2009 L03

Attention!

Use new screws.

7

3

2

6

8

4

1

5

z Oil the cylinder head screws slightly. z Tighten new screws with rotation angle disc according to the tightening order.

35 Nm + 60° + 60°

© 41178-0

© 01/2008

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D 2009 TD 2009

Cylinder head W 01-04-04

– D / TD 2009 L04

Attention!

Use new screws. z Oil the cylinder head screws slightly.

7

3

2

6

10

8

4

1

5

9

z Tighten new screws with rotation angle disc according to the tightening order.

35 Nm + 60° + 60°

6 © 41177-0

z Grease the ball heads of the pushrods lightly. z Insert pushrods in hydro-tappets (1).

Note installation position.

1

© 41013-1

z Install the charge air pipe.

– D 2009 W 06-07-03 – TD 2009 W 06-07-03 z Install the rocker arm.

W 01-02-02

© 41006-1

© 01/2008

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Cylinder head W 01-04-04

D 2009 TD 2009

z Mount oil trap (1). z Tighten screws (2).

1

27 Nm z Fasten hose clips (3) with hose clip pliers.

2

z Install the turbocharger.

W 06-06-04

3

3 2

6 © 41256-2

© 01/2008

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D 2009 TD 2009

Cylinder head W 01-04-04

Technical Data Tightening specifications ID no.

Name

Screw type

A01 001 Cylinder head on crankcase

M12x13010.9

A03 060 Oil trap on crankcase

M8x40-8.8

Notes / Remark Use new screws.

Observe tightening order.

Value 35 Nm + 60° + 60° 27 Nm

6

© 01/2008

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Cylinder head W 01-04-04

D 2009 TD 2009

6

© 01/2008

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D 2009 TD 2009

Cylinder head W 01-04-09

Checking piston overhang Commercial available tools: – Micrometer gauge

– W 01-04-04

Special tools: – Dial gauge. . . . . . . . . . . . . . . . . . 100400 – Measuring device . . . . . . . . . . . . 100750

6

z Remove cylinder head.

W 01-04-04 z Clean sealing surfaces.

© 41155-0

z Turn the crankshaft until the respective piston is just in front of the top dead centre (arrow).

© 41156-0

© 01/2008

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16350-001

Cylinder head W 01-04-09

D 2009 TD 2009

z Insert dial gauge into measuring beam. z Place shims (1) and measuring beam (2) on the sealing surface of the crankcase. z Apply the stylus to the piston base (arrow) under pretension.

2

z Continue turning the crankshaft evenly until the reversal point of the pointer on the dial gauge is reached.

The piston is now at top dead centre (TDC).

1

1

6 © 41149-2

z Move the measuring beam. z Apply stylus of the dial gauge to the crankcase sealing surface with pre-tension (arrow). z Adjust dial gauge to "0".

© 41157-1

Measuring points see diagram.

Measuring points (1) and (2).

1

2

© 41148-0

© 01/2008

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D 2009 TD 2009

Cylinder head W 01-04-09

z Align the measuring apparatus on the spacing washers in such a way that the stylus lies on the specified measuring points.

Measuring points see diagram.

Do not position the stylus on the piston marking. z Note the largest measured value. z Compare actual value with setpoint value.

0.70 - 1.0 mm z Install cylinder head.

W 01-04-04

6 Š 41149-1

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Cylinder head W 01-04-09

D 2009 TD 2009

Technical Data Testing and setting data ID no.

P02 75

Name Piston protrusion

Additional information

Value 0.70 - 1.0 mm

6

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D 2009 TD 2009

Cylinder head W 01-05-01

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

–W 01-04-04 –W 07-07-01 . . . . . . . . . . . . . . . . D 2009 –W 07-07-01 . . . . . . . . . . . . . . . TD 2009 –W 13-06-01

Special tools: – Assembly sleeves . . . . . . . . . . . . 121420 – Assembly tool . . . . . . . . . . . . . . . 121430

6

Removing the valves 1. Exhaust valve

4

2. Inlet valve 3. Valve spring

3

4. Rocker arm 5. Pushrod

2

1

5 © 41018-1

z Remove cylinder head.

W 01-04-04 z Remove the glow plugs.

W 13-06-01 z Removing fuel injectors.

– D 2009 W 07-07-01 – TD 2009 W 07-07-01

© 41019-1

© 01/2008

1/4

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Cylinder head W 01-05-01

D 2009 TD 2009

z Attach assembly lever with screw (1) to cylinder head. z Press down valve spring with assembly lever. z Remove both tapper collets (2). z Remove valve spring plates, valve springs and valves.

2

z Remove assembly lever.

1

6

© 41020_2

z Pull off valve stem seal (1) with assembly pliers (2).

2

1

© 41021-1

z Clean cylinder head, check and visually inspect for damage. z Visually inspect the components.

© 41022-1

© 01/2008

2/4

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D 2009 TD 2009

Cylinder head W 01-05-01

Installing the valves z Oil the valve stem lightly. z Insert and hold valve. z Mount assembly sleeve. z Push new valve stem seal onto valve guide over the assembly sleeve with assembly tool (1).

1

6 © 41023-1

z Mount assembly lever. z Insert valve spring. z Insert valve spring plate (2). z Press down the valve spring with the assembly lever and insert both tapper collets (1).

1 2

© 41179_0

z Remove assembly lever.

Make sure the tapper collets fit correctly in the valve keyway.

© 41024-1

© 01/2008

3/4

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Cylinder head W 01-05-01

D 2009 TD 2009

z Install fuel injectors.

– D 2009 W 07-07-01 – TD 2009 W 07-07-01 z Install the glow plugs.

W 13-06-01 z Install cylinder head.

W 01-04-04

6 © 41019-1

© 01/2008

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D 2009 TD 2009

Cylinder head W 01-05-04

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

– W 01-05-01

Clean all valves.

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 7.155 - 7.170 mm – Exhaust valve 7.155 - 7.170 mm

© 42182-1

Checking valve edge thickness z Measure valve edge thickness with slide gauge.

– Inlet valve 0.1 - 0.4 mm – Exhaust valve 0.1 - 0.4 mm

© 42183-1

© 01/2008

1/4

16352-001

Cylinder head W 01-05-04

D 2009 TD 2009

Checking valve head diameter z Measure valve head diameter with slide gauge.

– Inlet valve 36.90 - 37.10 mm – Exhaust valve 33.90 - 34.10 mm z Install valves.

W 01-05-01

6 © 42184-1

© 01/2008

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D 2009 TD 2009

Cylinder head W 01-05-04

Technical Data Testing and setting data ID no.

P01 31 P01 32 P01 35 P01 36 P01 37 P01 38

Name Valve stem, diameter, inlet Valve stem, diameter, outlet Valve edge thickness, inlet Valve edge thickness, outlet Valve plate, diameter, inlet Valve plate, diameter, outlet

Additional information

Value 7.155 - 7.170 mm 7.155 - 7.170 mm 0.1 - 0.4 mm 0.1 - 0.4 mm 36.90 - 37.10 mm 33.90 - 34.10 mm

6

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Cylinder head W 01-05-04

D 2009 TD 2009

6

© 01/2008

4/4

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D 2009 TD 2009

Drive system W 02-01-04

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

– W 04-04-09

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

6

Checking the axial backlash z Remove the gear case cover.

W 04-04-09 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 Adjust dial gauge to "0".

© 41158-1

z Press crankshaft in direction of arrow. z Read off measured value.

0.13 - 0.56 mm z Compare actual value with setpoint value. z Remove magnetic measuring stand. z Remove dial gauge. z Install the gear case cover.

W 04-04-09

1 © 41159-1

© 01/2008

1/2

16353-001

Drive system W 02-01-04

D 2009 TD 2009

Technical Data Testing and setting data ID no.

P02 34

Name Crankshaft, permissible axial clearance

Additional information in the installed state

Value 0.13 - 0.56 mm

6

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2/2

16353-001

D 2009 TD 2009

Drive system W 02-01-07

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

– W 02-04-01

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

6

Checking the bearing pin hardness z Remove crankshaft.

W 02-04-01 z Place crankshaft on prism.

© 41390-0

z Put hardness tester on journal. z Raise stylus (1) and press release (2).

1

Stylus (1) falls down, briefly strikes the surface and jumps up to the measured value.

2

© 43499-0

© 01/2008

1/4

16354-001

Drive system W 02-01-07

D 2009 TD 2009

z Read off displayed value (arrow) from hardness tester.

– Nominal value, at least 53 - 58 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 55.005 - 55.020 mm See schematic diagram for measuring points.

© 41389-0

© 01/2008

2/4

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D 2009 TD 2009

Drive system W 02-01-07

Checking the diameter of the lifting journals z Measure lifting journal with micrometer gauge.

49.990 - 50.005 mm See schematic diagram for measuring points.

6 © 41389-1

Visual inspection z Visually inspect the component. z Check the running surfaces (1) of the crankshaft sealing rings visually. z Visually inspect gear wheel (2). z Install crankshaft.

W 02-04-01

© 41390-0

© 01/2008

3/4

16354-001

Drive system W 02-01-07

D 2009 TD 2009

Technical Data Testing and setting data ID no.

P02 03 P02 07 P02 22

Name Main journal, diameter Bearing pin, surface hardness Lifting journal, diameter

Additional information

Standard

Value 55.005 - 55.020 mm 53 - 58 HRc 49.990 - 50.005 mm

6

Š 01/2008

4/4

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D 2009 TD 2009

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 . . . . . . . . . . . . . . . 142780 – Self-tapping screw – Washer

6

Removing the crankshaft sealing ring z Remove flywheel.

W 12-06-01

© 41025-0

z Make a hole of approximately 3 mm in the crankshaft sealing ring with a pricker.

Attention!

Do not damage the main bearing housing and crankshaft.

© 41026-0

© 01/2008

1/2

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Drive system W 02-02-02

D 2009 TD 2009

z Turn in a self-tapping screw with washer. z Pull out the crankshaft sealing ring with assembly lever. z Visually inspect all running surfaces.

6 © 41027-0

Installing the crankshaft sealing ring Use new crankshaft sealing ring.

The sealing lip faces the crankcase. z Oil the sealing lip of the crankshaft sealing ring lightly. z Place the crankshaft sealing ring on the assembly tool. z Mount the assembly tool on the crankcase pin. z Drive in crankshaft sealing ring to the stop with the assembly tool.

1 mm installation depth between connection housing and crankshaft sealing ring.

© 41028-1

z Remove assembly tool. z Install flywheel.

W 12-06-01

© 41025-0

© 01/2008

2/2

16355-001

D 2009 TD 2009

Drive system W 02-02-04

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

– W 12-02-02

Special tools: – Assembly tool . . . . . . . . . . . . . . . 142790 – Self-tapping screw – Washer

6

Removing the crankshaft sealing ring z Remove V-belt pulley.

W 12-02-02 z Make a hole of approximately 3 mm in the crankshaft sealing ring with a pricker.

Attention!

Do not damage the gearcase cover and crankshaft.

© 41174-0

z Turn in a self-tapping screw with washer. z Pull out the crankshaft sealing ring with assembly lever. z Visually inspect all running surfaces.

© 41173-0

© 01/2008

1/2

16356-001

Drive system W 02-02-04

D 2009 TD 2009

Installing the crankshaft sealing ring Use new crankshaft sealing ring.

The sealing lip faces the crankcase. z Oil the sealing lip of the crankshaft sealing ring lightly. z Place the crankshaft sealing ring on the assembly tool. z Mount the assembly tool on the crankcase pin. z Drive in crankshaft sealing ring to the stop with the assembly tool.

The installation depth is determined by the assembly tool.

6

z Remove assembly tool. z Install V-belt pulley.

Š 41055-0

W 12-02-02

Š 01/2008

2/2

16356-001

D 2009 TD 2009

Drive system W 02-03-01

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

– W 02-09-03

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

6

z Remove piston and connecting rod.

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

© 41044-1

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 28 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

© 01/2008

1/10

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Drive system W 02-03-01

D 2009 TD 2009

Diagram for measuring the small end bush 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.

28.010 - 28.025 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

Checking diameter of the piston bolt z Measure piston pin with micrometer gauge. −0.005

28 −0.01 mm z Note the measured value, dimension B. The dimension B is required to determine the piston bolt clearance.

© 35908-3

© 01/2008

2/10

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D 2009 TD 2009

Drive system W 02-03-01

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).

0.015 - 0.035 mm Calculation example Desired: Piston pin clearance Given: Measured: Internal diameter small end bush (a) (a) = 28.015 mm Diameter piston pin (b) (b) = 27.990 mm Calculation: Dimension (a) - Dimension (b) 28.015 mm - 27.990 mm Result: = 0.025 mm

6

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

Attention!

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.

1

19

265

© 41395-1

z Tighten screws alternately with rotation angle disc and socket wrench insert.

20 Nm + 45°

© 41396-1

© 01/2008

3/10

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Drive system W 02-03-01

D 2009 TD 2009

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 53 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 con rod bearing bore 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.

53.525 - 53.545 mm When the wear limit is reached the con rod must be replaced.

© 41392-0

© 01/2008

4/10

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D 2009 TD 2009

Drive system W 02-03-01

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

1

6 © 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 2

1

© 41048-2

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 © 41394-0

© 01/2008

5/10

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Drive system W 02-03-01

D 2009 TD 2009

z Mount big end bearing cap.

Attention!

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.

19

1 265 19

6 © 41395-0

z Tighten screws alternately with rotation angle disc and socket wrench insert.

20 Nm + 45°

© 41396-0

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 50 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

© 01/2008

6/10

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D 2009 TD 2009

Drive system W 02-03-01

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

6 Š 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.

50.045 - 50.057 mm z Note measured value, dimension (a).

If the measured values deviate slightly, additional measurements must be made with new bearing shells.

Š 41397-0

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).

0.040 - 0.067 mm Calculation example Desired: Big end bearing clearance Given: Measured: Internal diameter big end bearing shell (a) (a) = 50.040 mm Diameter lifting journal (b) (b) = 50.000 mm Calculation: Dimension (a) - Dimension (b) 50.040 mm - 50.000 mm Result: = 0.040 mm

Š 01/2008

7/10

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Drive system W 02-03-01

D 2009 TD 2009

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

6 © 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

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

© 30580-1

© 01/2008

8/10

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D 2009 TD 2009

Drive system W 02-03-01

Technical Data Testing and setting data ID no.

P02 41

P02 42 P02 43 P02 52 P02 55 P02 56 P02 61 P02 62

Name

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 Piston bolt bush, diameter, inside 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

Value 0.03 mm

0.03 mm 28.010 - 28.025 mm 50.045 - 50.057 mm 53.525 - 53.545 mm 0.040 - 0.067 mm 28 −0.005 −0.01

mm

0.015 - 0.035 mm

Tightening specifications ID no.

Name Big end bearing cover on connecting A02 020 rod

© 01/2008

Screw type

Notes / Remark

Value

M8x52-10.9

Use new screws.

20 Nm + 45°

9/10

16357-001

6

Drive system W 02-03-01

D 2009 TD 2009

6

© 01/2008

10/10

16357-001

D 2009 TD 2009

Drive system W 02-04-01

Removing and installing the crankshaft Commercial available tools: – Depth-measuring appliance – 3-arm puller

– W 02-01-04 – W 02-02-02 – W 02-09-03 – W 04-04-09 – W 08-04-06 – W 12-06-01

Special tools: – Disassembly/assembly tool . . . . . . . . . . . . . . . . . . . . . . . 143860 – Disassembly/assembly tool . . . . . . . . . . . . . . . . . . . . . . . 143870 – Blocking tool . . . . . . . . . . . . . . . . 144200 – Fitting compound DEUTZ AP1908

6

Removing crankshaft 1. Crankshaft 2. Connecting rod 3

3. Piston 4. Bearing housing

2

5. Main bearing housing

1

4

5 © 41033-2

z Remove the gear case cover.

W 04-04-09

© 41029-2

© 01/2008

1/12

16358-001

Drive system W 02-04-01

D 2009 TD 2009

z Mount blocking tool (1). z Loosen screw (2). z Loosen screw (3). z Remove blocking tool (1).

3 1 2

6 © 41258-2

z Unscrew screw (1). z Pull out journal (2). z Remove idler gear (3).

3

2

1

© 41030-0

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

2

1

© 41031-0

© 01/2008

2/12

16358-001

D 2009 TD 2009

Drive system W 02-04-01

z Remove cylindrical pin (1).

1

6 © 41261-0

z Turn in screw (1) a few turns. z Pull off camshaft toothed wheel with 3-arm puller.

1

© 41260-0

z Remove flywheel.

W 12-06-01 z Remove piston and connecting rod.

W 02-09-03

© 41029-2

© 01/2008

3/12

16358-001

Drive system W 02-04-01

D 2009 TD 2009

z Unscrew screws (1). z Lever out main bearing housing (2) with a suitable tool in the recess clearances.

Make sure that the thrust washer halves do not fall into the crankcase. z Visually inspect the components.

6

2

1 © 41034-1

z Unscrew fixing screws (1). z Remove oil suction pipe (2).

1

1

z Unscrew oil pressure control valve (3).

2

3

© 41059-1

z Remove crankshaft. z Visually inspect the components.

© 41035-0

© 01/2008

4/12

16358-001

D 2009 TD 2009

Drive system W 02-04-01

Removing the main bearing z Insert thrust pad (1) in bearing bush. z Insert threaded rod (2). z Insert counter support (3). z Mount washers and screw on nuts.

1

3

2

6 © 41060-1

z Turn the nut (1) clockwise.

The bearing bush is pressed onto the crankcase by the thrust pad.

1

z Dismantle disassembly/assembly tool. z Remove bearing bush.

© 41061-1

z Clamp main bearing housing in the vice.

Use cushioned jaws.

2

z Insert thrust pad (1) in bearing bush. z Insert threaded rod (2). z Insert assembly bell (3). z Mount washers and screw on nuts.

1

z Turn nut (4) clockwise.

The bearing bush is pressed onto the main bearing housing by the thrust pad.

3

4

© 41384-0

© 01/2008

5/12

16358-001

Drive system W 02-04-01

D 2009 TD 2009

Installing the main bearing z Oil bearing liner with lubricating oil. z Press in bearing liner with disassembly/assembly tool 143870.

Make sure the bearing bush is not twisted.

The installation depth is determined by the assembly tool.

Mark the position of the lubricating oil bore on the main bearing housing.

6 © 41058-2

z Oil bearing liner with lubricating oil. z Mount bearing bush.

1

z Mount guide plate (1).

2

z Insert threaded rod (2). z Insert counter support. z Mount washers and screw on nuts.

Mark position of the lubricating oil bore.

Position bearing bush.

© 41062-1

z Turn the nut (1) clockwise.

The bearing bush is pressed into the crankcase by the thrust pad.

The installation depth is determined by the assembly tool.

Make sure the bearing bush is not twisted.

1

© 41063-1

© 01/2008

6/12

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D 2009 TD 2009

Drive system W 02-04-01

z Dismantle disassembly/assembly tool. z Remove disassembly/assembly tool. z Check that the lubricating oil bore is in line.

If the lubricating oil bore is not in line, the bearing bush must be removed and reinstalled. z Check installation depth (1) with depth measuring appliance. approx. 3 mm

6 © 41064-1

Installing the crankshaft z Oil bearing liner (1) lightly with lubricating oil.

1

z Push crankshaft into crankcase.

Align screw thread (2) and through hole (3).

4

z Insert thrust washers (4) at the rear with grease.

Lubricating oil grooves face the crankshaft.

3 2

© 41036-1

z Push in the crankshaft in the direction of the arrow to the stop. z Tighten locating screws (1).

41 Nm z Install oil suction pipe.

1

W 08-04-06

© 41037-1

© 01/2008

7/12

16358-001

Drive system W 02-04-01

D 2009 TD 2009

z Insert new O-ring (1). z Coat O-ring with DEUTZ AP1908 mounting compound.

1

6 © 41398-0

z Coat the back of the shims with a little grease.

Note installation position.

2

The lubricating oil grooves (2) face upwards.

1

z Install shims (1).

2

© 41399-0

z Install main bearing housing (1). z Tighten screws (2).

– Stage 1: 15 Nm – Stage 2: 27 Nm z Renew crankshaft sealing ring (flywheel side).

W 02-02-02

2 1 © 41038-1

© 01/2008

8/12

16358-001

D 2009 TD 2009

Drive system W 02-04-01

z Install flywheel.

W 12-06-01 z Install the gear case cover.

W 04-04-09

6 © 41029-2

z Check axial backlash of crankshaft.

W 02-01-04 z Heat up crankshaft toothed wheel to approx. 100 °C.

2

Danger!

Danger of burning! z Mount crankshaft toothed wheel (1).

Note installation position of Woodruff key (2) and groove.

3

1

z Tighten oil pressure control valve (3).

21 Nm

© 41039-1

z Insert cylindrical pin (1). z Insert camshaft toothed gear with cylindrical pin (1) in bore (2).

2

1

© 41262-1

© 01/2008

9/12

16358-001

Drive system W 02-04-01

D 2009 TD 2009

The marks (1) of the crankshaft toothed wheel and the camshaft toothed wheel must be in line! z Fasten screw (2).

2 1

6 © 41081-1

z Insert idler gear.

The marks (1) of the crankshaft toothed wheel, intermediate gear and fuel injector toothed wheel must be in line!

1

© 41066-0

z Oil the journal lightly. z Insert the journal carefully into the needle bearing. z Fasten screws.

© 41067-0

© 01/2008

10/12

16358-001

D 2009 TD 2009

Drive system W 02-04-01

z Mount blocking tool (1). z Tighten screw (3).

81 Nm 3

z Tighten screw (2).

81 Nm 1

z Remove blocking tool (1).

2

6 © 41258-2

z Install piston and connecting rod.

W 02-09-03

© 41029-2

© 01/2008

11/12

16358-001

Drive system W 02-04-01

D 2009 TD 2009

Technical Data Testing and setting data ID no.

P03 29

Name Crankshaft, bearing bush, installation depth

Additional information

Value approx. 3 mm

Tightening specifications

6

ID no.

A02 010 A02 010 A02 012 A04 001 A04 011

Name Main bearing housing on crankcase Main bearing housing on crankcase Bearing housing in crankcase Camshaft gear wheel on camshaft Intermediate gear on crankcase Oil pressure control valve on crankA08 098 case

Š 01/2008

Screw type Notes / Remark M8x20-8.8 Stage 1: M8x20-8.8 Stage 2: M10x80-8.8 M12x35-8.8 M12x75-10.9

Value 15 Nm 27 Nm 41 Nm 81 Nm 81 Nm

3/8“

21 Nm

12/12

16358-001

D 2009 TD 2009

Drive system W 02-09-03

Removing and installing the piston and con rod Commercial available tools: – Rotation angle disc . . . . . . . . . . . . . 8190

– W 01-04-04 – W 08-04-06

Special tools: – Universal piston ring pliers . . . . . 130300 – Piston ring compressor . . . . . . . . 130510

6

Removing the piston and con rod 1

1. Piston rings 2. Piston

2

3. Piston pin 4. Connection rod

3

5. Big end bearing cap

4 5

© 41042-1

z Remove cylinder head.

W 01-04-04 z Remove oil suction pipe W 08-04-06 z Pull out oil dipstick.

© 41040-0

© 01/2008

1/6

16359-001

Drive system W 02-09-03

D 2009 TD 2009

Removing the big end bearing cap z Position lifting bearing journal in LDC position. z Unscrew screws (1). z Remove big end bearing cap (2). z Remove bearing shell (3).

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

Note order of cylinders.

3

2

1

6 © 41041-0

z Press out the piston and connection rod.

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

Note order of cylinders. z Remove con rod bearing shells (1).

1

z Visually inspect the components.

© 41043-1

Removing the piston z Remove locking ring with locking ring pliers. z Press out piston pin. z Remove connection rod. z Visually inspect the components.

© 41044-1

© 01/2008

2/6

16359-001

D 2009 TD 2009

Drive system W 02-09-03

z Remove piston rings with universal piston ring pliers.

6 © 41045-0

Completing con rod and piston z Insert new locking ring.

Ensure that the installation location is free from faults. z Insert con rod.

The labelling on the piston base and the numbered label of the connection rod face the camshaft side. z Oil the piston bolt lightly. z Press the piston bolt through. z Insert new locking ring.

Ensure that the installation location is free from faults. © 41047-1

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

Note the assignment of the bearing shells.

The anti-rotation lock (1) must lock in groove (2). z Insert bearing shell in the respective big end bearing cap.

2

Note the assignment of the bearing shells.

The anti-rotation lock must lock in groove.

?

1

© 41048-1

© 01/2008

3/6

16359-001

Drive system W 02-09-03

D 2009 TD 2009

z Install piston rings with universal piston ring pliers. z Arrange the piston ring joints with an offset of about 120° to each other.

Do not turn the piston rings any further.

120° 120°

z Lightly oil cylinder running surface, piston, piston rings and lifting bearing journal lightly. z Clamp piston rings with piston ring compressor.

6

0° © 41046-0

z Set lifting journal at bottom dead centre (BDC). z Push piston and con rod completely into cylinder.

Attention!

Note installation position.

Numeric identification faces the camshaft side. z Place piston ring clamping band flat on the crankcase. z Push piston and con rod completely into cylinder.

Attention!

Do not jam the con rod with the crankshaft.

UT © 41049-0

z Mount big end bearing cap.

Renew screws every time they are loosened.

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.

1

z Tighten new screws with rotation angle disc.

xxx

xxx

Attention!

UT

20 Nm + 45°

© 41068-1

© 01/2008

4/6

16359-001

D 2009 TD 2009

Drive system W 02-09-03

z Insert oil dipstick. z Install oil suction pipe.

W 08-04-06 z Install cylinder head.

W 01-04-04

6 © 41040-0

© 01/2008

5/6

16359-001

Drive system W 02-09-03

D 2009 TD 2009

Technical Data Tightening specifications ID no.

Name Big end bearing cover on connecting A02 020 rod

Screw type

Notes / Remark

Value

M8x52-10.9

Use new screws.

20 Nm + 45°

6

© 01/2008

6/6

16359-001

D 2009 TD 2009

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 28 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

© 01/2008

1/4

16360-001

Drive system W 02-09-07

D 2009 TD 2009

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. +0.008

28 +0.003 mm

© 43483-0

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

© 43427-0

© 01/2008

2/4

16360-001

D 2009 TD 2009

Drive system W 02-09-07

– D 2009 – Measuring point 1 +0.167

89,400 +0.153 mm – Measuring point 2 +0.008

3

89,400 −0.008 mm – Measuring point 3

2

−0.175

89,400 −0.145 mm Measuring point height - see Technical Data.

1

6 © 41154-0

– TD 2009 – Measuring point 1 89,825 +0.152 +0.138 mm – Measuring point 2 89,825 +0.009 −0.009 mm

3

– Measuring point 3

2

89,825 −0.220 −0.190 mm Measuring point height - see Technical Data.

1

z Assemble con rod and piston.

W 02-09-03

© 41154-0

© 01/2008

3/4

16360-001

Drive system W 02-09-07

D 2009 TD 2009

Technical Data Testing and setting data

6

ID no.

D 2009

Name

Additional information

Value

P02 71

Piston, diameter, standard

Measuring point 1 = height 10 mm 89,400 +0.167 +0.153 mm

P02 72

Piston, diameter, standard

Measuring point 2 = height 44 mm 89,400 +0.008 −0.008 mm

P02 73

Piston, diameter, standard

Measuring point 3 = height 65 mm 89,400 −0.175 −0.145 mm

TD 2009 P02 71 Piston, diameter, standard

Measuring point 1 = height 10 mm 89,825 +0.152 +0.138 mm

P02 72

Piston, diameter, standard

Measuring point 2 = height 36 mm 89,825 +0.009 −0.009 mm

P02 73

Piston, diameter, standard

Measuring point 3 = height 66 mm 89,825 −0.220 −0.190 mm

D / TD 2009 P02 78

© 01/2008

+0.008

Piston pin bore

28 +0.003 mm

4/4

16360-001

D 2009 TD 2009

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

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

© 01/2008

1/4

16361-001

Drive system W 02-10-03

D 2009 TD 2009

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 0,15 +0.20 mm +0 – 2. piston ring = taper-faced ring 0,15 +0.25 mm +0 – 3. piston ring = bevelland-edge oil control ring 0,30 +0.25 mm +0 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 z (2):

3

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

© 41154-1

© 01/2008

2/4

16361-001

D 2009 TD 2009

Drive system W 02-10-03

z Install piston rings with universal piston ring pliers.

Set spring joint of the bevelland-edge oil control ring 180° to the ring joint.

6 © 44268-0

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.

– 1. piston ring 0.11 - 0.15 mm – 2. piston ring 0.045 - 0.090 mm – 3. piston ring 0.045 - 0.090 mm When the piston wear limit is reached, the piston must be renewed.

© 44269-0

z Assemble con rod and piston.

W 02-09-03

© 41047-0

© 01/2008

3/4

16361-001

Drive system W 02-10-03

D 2009 TD 2009

Technical Data Testing and setting data ID no.

Name

Additional information

Value

P02 84

Piston ring 1, joint clearance

0,15 +0

mm

P02 85

Piston ring 2, joint clearance

+0.25 0,15 +0

mm

P02 86

Piston ring 3, joint clearance

+0.25 0,30 +0

P02 87 P02 88 P02 89

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

+0.20

mm 0.11 - 0.15 mm 0.045 - 0.090 mm 0.045 - 0.090 mm

6

Š 01/2008

4/4

16361-001

D 2009 TD 2009

Crankcase W 03-03-01

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

– W 02-09-03

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

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

6

Checking the cylinders z Remove piston and connecting rod.

W 02-09-03 z Check cylinder for visible signs of wear.

© 41029-3

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 90 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

© 01/2008

1/4

16362-001

Crankcase W 03-03-01

D 2009 TD 2009

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

b

a

b

a

b

1 2 3

6 Š 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. +0.025

90 +0

mm

See schematic diagram for measuring points. z Install piston and connecting rod.

W 02-09-03

Š 41416-0

Š 01/2008

2/4

16362-001

D 2009 TD 2009

Crankcase W 03-03-01

Technical Data Testing and setting data ID no.

Name

Additional information

Value

P03 31

Cylinder, diameter, inside

Standard

90 +0

+0.025

mm

6

Š 01/2008

3/4

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Crankcase W 03-03-01

D 2009 TD 2009

6

© 01/2008

4/4

16362-001

D 2009 TD 2009

Crankcase W 03-09-04

Removing and installing the connection housing Commercial available tools

– W 12-06-01 – W 13-03-02

6

Removing the connection housing z Remove starter.

W 13-03-02 z Remove flywheel.

W 12-06-01

2

1

© 41070-0

z Unscrew screws (1). z Remove connection housing. z Visually inspect the components.

© 41071-0

© 01/2008

1/4

16363-001

Crankcase W 03-09-04

D 2009 TD 2009

Installing the connection housing z Mount connection housing. z Tighten screws (1).

81 Nm

6 © 41072-0

z Install flywheel.

W 12-06-01 z Install starter.

W 13-03-02

1

2

© 41073-0

© 01/2008

2/4

16363-001

D 2009 TD 2009

Crankcase W 03-09-04

Technical Data Tightening specifications ID no.

Name A03 080 Connection housing to crankcase

Screw type Notes / Remark M12x25-12.9 Locking screw

Value 81 Nm

6

© 01/2008

3/4

16363-001

Crankcase W 03-09-04

D 2009 TD 2009

6

© 01/2008

4/4

16363-001

D 2009 TD 2009

Crankcase W 03-11-01

Removing and installing, testing camshaft bearing Commercial available tools: – Micrometer gauge – Internal measuring device – Counter support . . . . . . . . . . . . . . . 8200

– W 04-05-05

Special tools: – Dial gauge. . . . . . . . . . . . . . . . . . 100400 – Internal extractor. . . . . . . . . . . . . 143500 – Assembly tool . . . . . . . . . . . . . . . 143890 – Cable tie

6

Testing camshaft bearing z Remove camshaft.

W 04-05-05 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 45 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

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

© 37239-1

© 01/2008

1/8

16364-001

Crankcase W 03-11-01

D 2009 TD 2009

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.

45.960 - 45.980 mm Measuring points see diagram.

When the wear limit is reached, the camshaft bearing must be replaced.

6 © 41373-0

Removing camshaft bearing z Insert internal extractor (1). z Splay and centre the internal extractor. z Splay the internal extractor to the stop. z Screw spindle (2) to internal extractor.

2

z Mount counter holder (3). z Position holder.

1

3 © 41382-0

z Hold spindle (1). z Tighten nut (2). z Remove bearing halves (3).

3

2

1 © 41383-0

© 01/2008

2/8

16364-001

D 2009 TD 2009

Crankcase W 03-11-01

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 50 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 camshaft bearing 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.

50.060 - 50.095 mm Measuring points see diagram.

When the wear limit is reached, the crankcase must be exchanged.

© 41374-0

© 01/2008

3/8

16364-001

Crankcase W 03-11-01

D 2009 TD 2009

Installing camshaft bearing z Tighten pin bolts (1).

1

6

1 © 41376-0

z Place bearing halves (1) on pressure piece (2). z Fix bearing halves (1) with cable tie (3).

1

2

3

© 41377-0

z Mount pressure piece (1). z Position bearing halves (2).

2

1

© 41378-0

© 01/2008

4/8

16364-001

D 2009 TD 2009

Crankcase W 03-11-01

z Tighten knurled nuts (1).

1

1

6 © 41379-0

z Tighten screw (1).

1

© 41380-0

Attention!

Do not damage the bearing shells. z Remove cable tie (1).

1

© 41381-0

© 01/2008

5/8

16364-001

Crankcase W 03-11-01

D 2009 TD 2009

z Unscrew studs (1). z Install the camshaft.

W 04-05-05

1

6

1 © 41376-0

© 01/2008

6/8

16364-001

D 2009 TD 2009

Crankcase W 03-11-01

Technical Data Testing and setting data ID no.

P03 11 P03 13

Name Camshaft bearing, locating hole, diameter Camshaft bearing, diameter, inside

Additional information

Value 50.060 - 50.095 mm

in the installed state

45.960 - 45.980 mm

6

Š 01/2008

7/8

16364-001

Crankcase W 03-11-01

D 2009 TD 2009

6

© 01/2008

8/8

16364-001

D 2009 TD 2009

Engine control W 04-04-09

Removing and installing the gearcase cover Commercial available tools

– W 02-02-04 – W 08-08-02 – W 09-07-08 – W 12-02-02 – W 13-02-03

Special tools: – Assembly tool . . . . . . . . . . . . . . . 142790 – Special wrench . . . . . . . . . . . . . . 170050

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

The engine oil and coolant should be added according to the operating manual.

6

Removing the gearcase z Remove coolant pump.

W 09-07-08 z Remove V-belt pulley.

W 12-02-02 z Remove the oil cooler.

W 08-08-02 z Remove generator.

W 13-02-03

© 41051-1

z Unscrew all screws (1).

1

© 41265-0

© 01/2008

1/4

16365-001

Engine control W 04-04-09

D 2009 TD 2009

z Unscrew screw (1). z Unscrew screw (2). z Remove spacer (3). z Remove gearcase cover.

3

2

Attention!

Do not damage the sealing surfaces.

1

z Clean sealing surfaces.

6 © 41266-0

Installing the gearcase cover z Knock out crankshaft sealing ring (1).

Attention!

Do not damage sealing surface when knocking out.

1

z Clean sealing surfaces.

© 41054-1

z Fix the new gasket to the crankcase with a little grease.

Note installation position.

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

1

1

© 41056-0

© 01/2008

2/4

16365-001

D 2009 TD 2009

Engine control W 04-04-09

z Mount gearcase cover.

Ensure that the installation location is free from faults. z Mount spacer (1).

1

z Fasten all screws.

6 © 41266-1

z Tighten the screws according to the tightening sequence.

10 17 1 9

16

2

8

15

27 Nm Note different screw lengths.

18 7 11 14 19 5 12 21 20 13 3

6

4

© 41069-1

z Install crankshaft sealing ring (opposite side to flywheel) W 02-02-04 z Install generator.

W 13-02-03 z Install oil cooler.

W 08-08-02 z Install V-belt pulley.

W 12-02-02 z Install coolant pump.

W 09-07-08 © 41051-1

© 01/2008

3/4

16365-001

Engine control W 04-04-09

D 2009 TD 2009

Technical Data Tightening specifications ID no.

Name

A03 020 Gearcase cover on crankcase

Screw type M8x35-12.9 M8x50-10.9 M8x70-8.8

Notes / Remark

Value 27 Nm

6

Š 01/2008

4/4

16365-001

D 2009 TD 2009

Engine control W 04-05-05

Removing and installing the camshaft Commercial available tools

– W 01-04-04 – W 04-04-09 – W 07-10-08 – W 07-11-01

Special tools: – Dial gauge. . . . . . . . . . . . . . . . . . 100400 – Special pliers. . . . . . . . . . . . . . . . 103220 – Fixing pin . . . . . . . . . . . . . . . . . . 144180

6

Removing the camshaft z Remove cylinder head.

W 01-04-04 z Remove the gear case cover.

W 04-04-09 z Remove fuel supply pump.

W 07-11-01 z Remove fuel filter console.

W 07-10-08

© 41082-1

z Set piston (1) at top dead centre.

1

z Fix flywheel with fixing pin (2).

2

© 41075-0

© 01/2008

1/8

16366-001

Engine control W 04-05-05

D 2009 TD 2009

z Pull out hydraulic tappet (1) with special pliers. z Visually inspect the components.

1

6 © 41076-1

z Mount blocking tool (1). z Loosen screw (2). z Remove blocking tool (1).

2 1

© 41258-3

z Unscrew screw (1). z Remove camshaft toothed wheel (2). z Visually inspect the components.

2

1

© 41031-1

© 01/2008

2/8

16366-001

D 2009 TD 2009

Engine control W 04-05-05

z Remove cylindrical pin (1).

1

6 © 41261-0

z Unscrew screws (1). z Remove thrust washer (2).

1

z Visually inspect the components.

1

2

© 41264-0

z Fasten screw (1). z Pull out the camshaft carefully in the direction of the arrow. z Visually inspect the components.

1

© 41078-1

© 01/2008

3/8

16366-001

Engine control W 04-05-05

D 2009 TD 2009

Installing the camshaft z Oil camshaft bearing lightly. z Oil cam shaft pin lightly. z Insert the camshaft (1) carefully in the direction of the arrow.

6 © 41079-0

z Bore (1) faces the lubricating oil pan. z Mount thrust washer (2). z Tighten screws (3).

3

21 Nm

2

3

1

© 41264-2

Checking the axial backlash z Mount magnetic measuring stand. z Insert dial gauge. z Apply stylus to the camshaft end with pre-tension. z Press crankshaft in direction of arrow.

© 41160-1

© 01/2008

4/8

16366-001

D 2009 TD 2009

Engine control W 04-05-05

z Adjust dial gauge to "0". z Press crankshaft in direction of arrow. z Read actual value from dial gauge.

– Nominal value: 0.07 - 0.29 mm The axial backlash is not adjustable.

If the axial backlash is greater than the setpoint, the camshaft must be renewed. z Remove magnetic measuring stand. z Remove dial gauge.

6 © 41161-1

z Insert cylindrical pin (1). z Insert camshaft toothed gear with cylindrical pin (1) in bore (2).

1

© 41262-0

The marks (1) of the crankshaft toothed wheel and the camshaft toothed wheel must be in line! z Fasten screw (2).

2 1

© 41081-1

© 01/2008

5/8

16366-001

Engine control W 04-05-05

D 2009 TD 2009

z Mount blocking tool (1). z Tighten screw (2).

81 Nm 2

z Remove blocking tool (1).

1

6 © 41258-3

z Oil the hydro-tappet lightly. z Insert hydraulic tappet (1) with special pliers.

Note installation position of the hydro tappets.

© 41084-0

z Install the fuel filter console.

W 07-10-08 z Install fuel pump.

W 07-11-01 z Install the gear case cover.

W 04-04-09 z Install cylinder head.

W 01-04-04

© 41082-1

© 01/2008

6/8

16366-001

D 2009 TD 2009

Engine control W 04-05-05

Technical Data Testing and setting data ID no.

P04 35

Name Camshaft, axial clearance

Additional information (not adjustable)

Value 0.07 - 0.29 mm

Tightening specifications ID no.

Name A04 001 Camshaft gear wheel on camshaft A04 002 Camshaft, shim on crankshaft

Screw type M12x35-8.8 M8x16-8.8

Notes / Remark Torx screw

Value 81 Nm 21 Nm

6

© 01/2008

7/8

16366-001

Engine control W 04-05-05

D 2009 TD 2009

6

Š 01/2008

8/8

16366-001

D 2009 TD 2009

Engine control W 04-05-06

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

– W 04-05-05

6

Checking the camshaft z Remove camshaft.

W 04-05-05 z Visually inspect cams and bearing pins for wear.

© 41358-0

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

© 36424-2

© 01/2008

1/4

16367-001

Engine control W 04-05-06

D 2009 TD 2009

z Measure bearing pin (1).

45.950 - 45.970 mm See schematic diagram for measuring points.

When the limit value is reached the camshaft must be replaced.

1

6 © 41358-1

z Measure bearing pin (1).

41.925 - 41.955 mm See schematic diagram for measuring points.

When the limit value is reached the camshaft must be replaced.

1

1

© 41358-2

z Install the camshaft.

W 04-05-05

© 41358-0

© 01/2008

2/4

16367-001

D 2009 TD 2009

Engine control W 04-05-06

Technical Data Testing and setting data ID no.

P04 31 P04 31

Name Camshaft, bearing pin, diameter Camshaft, bearing pin, diameter (drive side)

Additional information

Value 41.925 - 41.955 mm 45.950 - 45.970 mm

6

Š 01/2008

3/4

16367-001

Engine control W 04-05-06

D 2009 TD 2009

6

Š 01/2008

4/4

16367-001

Exhaust system/Charging W 06-01-05

TD 2009 Removing and installing the exhaust line Commercial available tools

– W 06-06-04

Special tools: – Disassembly tool. . . . . . . . . . . . . 110901 – Fitting compound DEUTZ S1

6

Removing exhaust line z Unscrew screws (1). z Remove gasket.

1

© 41299-0

z Loosen hose clip (1). z Remove charge air pipe (2).

2

1

© 41300-0

© 01/2008

1/8

16368-001

Exhaust system/Charging W 06-01-05

TD 2009

z Unscrew lock nut (1).

1

6 © 41301-0

z Unscrew screws (1). z Remove gasket.

1

© 41302-0

z Unscrew screw (1).

1

© 41303-1

© 01/2008

2/8

16368-001

Exhaust system/Charging W 06-01-05

TD 2009 z Unscrew screws (1). z Remove the compensator pipe (2). z Remove seals.

1 1

2

6 © 41307-0

z Unscrew screws (1). z Remove exhaust line (2). z Remove gasket.

1

z Remove turbocharger.

W 06-06-04

1

2

1

1

© 41305-0

z Visually inspect the components.

© 41308-0

© 01/2008

3/8

16368-001

Exhaust system/Charging W 06-01-05

TD 2009

Installing exhaust line z Install the turbocharger.

W 06-06-04

6 © 41306-0

z Clean sealing surfaces. z Mount new gasket. z Mount exhaust line (2).

1

z Tighten screws (1).

2

Coat screws with DEUTZ S1 mounting compound.

1

z Tighten screws (1).

27 Nm Tightening sequence: From the centre outwards.

1

1

© 41305-0

z Mount new gaskets. z Mount compensator pipe (2).

Note installation position.

1

z Tighten screws (1).

1

2

© 41307-0

© 01/2008

4/8

16368-001

Exhaust system/Charging W 06-01-05

TD 2009 z Fasten screw (1).

1

6 © 41303-1

z Tighten screws (1).

20 Nm z Tighten screws (2).

25 Nm

1 2

© 41303-3

z Tighten screw (1).

21 Nm

1

© 41303-1

© 01/2008

5/8

16368-001

Exhaust system/Charging W 06-01-05

TD 2009

z Mount new gasket. z Tighten screws (1).

9 Nm

1

6 © 41302-0

z Tighten lock nut (1).

15 Nm

Attention!

Lay the hose pipe free from chafing and tension.

1

© 41301-0

z Insert new sealing ring (1).

1

© 41254-0

© 01/2008

6/8

16368-001

Exhaust system/Charging W 06-01-05

TD 2009 z Mount charge air pipe (1). z Position hose clip (2). z Fix the hose clip (2) with the hose clip pliers.

1

2

6 © 41300-1

z Tighten screws (1).

21 Nm

1

© 41299-0

© 01/2008

7/8

16368-001

Exhaust system/Charging W 06-01-05

TD 2009

Technical Data Tightening specifications ID no.

A06 001 A06 063 A06 064 A06 083

Name Exhaust pipe at cylinder head Compensator pipe on exhaust pipe Compensator pipe to cooler Charge air manifold to charge air pipe Lubricating oil pipe on exhaust turboA08 040 charger A08 044 Oil return line to turbocharger A09 021 Pipe, holder to holder

Screw type M8x55-10.9 M8x20-10.9 M8x12-8.8 M8x20-8.8

Notes / Remark

Value 27 Nm 20 Nm 25 Nm 21 Nm

M14x1.5

15 Nm

M6x16-8.8 M8x16-8.8

9 Nm 21 Nm

6

Š 01/2008

8/8

16368-001

Exhaust system/Charging W 06-06-04

TD 2009 Removing and installing the turbocharger Commercial available tools

– W 06-01-05

– Fitting compound DEUTZ S1

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 exhaust manifold z Remove the exhaust pipe.

W 06-01-05

1

z Unscrew screws (1). z Remove exhaust manifold (2). z Remove gasket (3).

2

3

1

© 41309-0

Removing turbocharger z Unscrew all screws (1). z Remove turbocharger (2). z Remove gasket.

1

2 © 41310-0

© 01/2008

1/4

16369-001

Exhaust system/Charging W 06-06-04

TD 2009

z Loosen hose clips (1).

2

z Pull off hose pieces (2).

1

2

1

6

© 41311-0

z Visually inspect the components.

© 41312-0

Installing the turbocharger 2

z Push on hose pieces (2).

1

Ensure that the installation location is free from faults.

2

z Position hose clips (1). z Fasten hose clips with hose clip pliers.

1 © 41311-0

© 01/2008

2/4

16369-001

Exhaust system/Charging W 06-06-04

TD 2009 z Clean sealing surfaces. z Mount gasket (1).

Note installation position.

1

6 © 41314-0

z Mount turbocharger (2). z Tighten all screws (1).

41 Nm Coat screws with DEUTZ S1 mounting compound.

1

2 © 41310-0

Installing exhaust manifold z Clean sealing surfaces. z Mount gasket (3).

1

z Mount exhaust manifold (2). z Tighten screws (1).

41 Nm Coat screws with DEUTZ S1 mounting compound. z Install the exhaust pipe.

2

W 06-01-05

1

3

© 41309-0

© 01/2008

3/4

16369-001

Exhaust system/Charging W 06-06-04

TD 2009

Technical Data Tightening specifications ID no.

Name

A06 010 Exhaust manifold to turbocharger A06 020 Turbocharger on exhaust pipe

Screw type

Notes / Remark Insert with Deutz S1 M8x25-10.9 mounting compound.

M10x20-10.9 Insert with Deutz S1 M8x16-8.8 mounting compound.

Value 41 Nm 41 Nm

6

Š 01/2008

4/4

16369-001

Exhaust system/Charging W 06-07-03

D 2009 Removing and installing the intake manifold Commercial available tools

Danger!

Special tools: – Special wrench . . . . . . . . . . . . . . 110520 – Plugs/caps . . . . . . . . . . . . . . . . . 170160

Wait 30 seconds after switching off the engine before working on the fuel system.

– Fitting compound DEUTZ S1

Ensure utmost cleanliness when working on the fuel system.

Carefully clean the area around the affected parts. 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 fluids in suitable vessels and dispose of according to regulations.

Attention!

Removing the intake manifold 1

z Unscrew lock nuts (1) with special wrench.

1

1

1

1

© 41404-0

© 01/2008

1/6

16370-001

6

Exhaust system/Charging W 06-07-03

D 2009

z Unscrew screw (1). z Remove pipe clamp (2). z Remove all injection pipes. z Visually inspect the components.

1

2

6 © 41405-0

z Loosen hose clip (1). z Unscrew screws (2). z Remove intake manifold (3). z Remove gasket (4).

5

1

z Unscrew fuel line (5).

4 3

2 © 41088-0

z Clean sealing surfaces.

© 41089-0

© 01/2008

2/6

16370-001

Exhaust system/Charging W 06-07-03

D 2009 Install intake manifold z Screw on fuel pipe (5). z Coat the screws (2) with fitting compound. z Mount gasket (4).

5

1

z Mount intake manifold (3). z Tighten screws (2).

27 Nm Tightening sequence: From the centre outwards. z Tighten pipe clip (1).

4

6

3

2 © 41090-1

z Mount high pressure pipes. z Screw on union nuts.

Attention!

Install injection pipes without tension! z Mount pipe clamp (2).

1

2

z Fasten screw (1).

© 41405-0

z Tighten union nuts (1) with special wrench.

28 Nm

1

1

1

1

1

© 41404-0

© 01/2008

3/6

16370-001

Exhaust system/Charging W 06-07-03

D 2009

z Tighten screw (1).

9 Nm Ensure that the installation location is free from faults.

1

6 Š 41405-1

Š 01/2008

4/6

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D 2009 Technical Data Tightening specifications ID no.

Name Air suction intake pipe on cylinder A06 030 head Injection line on fuel injector/injection A07 003 pump A07 006 Injection lines, fastening, pipe clip

Screw type M8x70

Notes / Remark Observe tightening sequence.

Value 27 Nm

M12x1.5

28 Nm

M6x10-8.8

9 Nm

6

Š 01/2008

5/6

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D 2009

6

© 01/2008

6/6

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TD 2009 Removing and install the charge air line Commercial available tools

– W 06-09-06 – W 07-04-01

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

Attention!

Ensure utmost cleanliness when working on the fuel system.

Carefully clean the area around the affected parts. 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 fluids in suitable vessels and dispose of according to regulations.

– Fitting compound DEUTZ S1

Remove charge air line z Remove fuel injector.

W 07-04-01 z Remove the exhaust gas return valve.

W 06-09-06 z Unscrew screws (1). z Remove gasket.

1

© 41315-0

© 01/2008

1/6

16371-001

6

Exhaust system/Charging W 06-07-03

TD 2009

z Loosen hose clip (1). z Remove charge air pipe (2).

2

1

6 © 41300-0

z Unscrew screw (1).

1

© 41316-0

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

1

1

2

1

1

1

© 41317-0

© 01/2008

2/6

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Exhaust system/Charging W 06-07-03

TD 2009 z Remove gasket (1). z Visually inspect the components.

1

6 © 41318-0

Install charge air line z Clean sealing surfaces. z Mount gasket (1).

Note installation position.

1

© 41318-0

z Mount charge air line (1). z Tighten screws (2).

27 Nm Tightening sequence: From the centre outwards.

2

1

2

2

2

2

© 41317-1

© 01/2008

3/6

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TD 2009

z Tighten screw (1).

27 Nm

Attention!

Install fuel pipe tension free.

1

6 © 41316-0

z Insert new sealing ring (1).

1

© 41254-0

z Mount charge air pipe (1). z Position hose clip (2). z Fix the hose clip (2) with the hose clip pliers.

1

2

© 41300-1

© 01/2008

4/6

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TD 2009 z Tighten screws (1).

21 Nm z Install the exhaust gas return valve W 06-09-06 z Install the fuel injector.

W 07-04-01

1

6 © 41315-0

© 01/2008

5/6

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TD 2009

Technical Data Tightening specifications ID no.

Name

A06 030 Charge air pipe on cylinder head

Screw type M8x45-10.9

A06 083 Charge air manifold to charge air pipe M8x20-8.8 A07 044 Fuel lines on crankcase, pipe clip M8x12-10.9

Notes / Remark Observe tightening sequence.

Value 27 Nm 21 Nm 27 Nm

6

Š 01/2008

6/6

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Exhaust system/Charging W 06-09-04

TD 2009 Removing and installing the cooler (Exhaust gas recirculation) 8190

Commercial available tools

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 cooler z Loosen hose clips (1). z Pull off hose pipes (2).

2

1

2

1

© 41417-0

z Unscrew screws (1). z Unscrew screw (2).

1

z Remove cooler (3).

1

2 3

© 41418-0

© 01/2008

1/6

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Exhaust system/Charging W 06-09-04

TD 2009

z Unscrew screws (1). z Remove gaskets (2).

1

1 2

2

6 © 41419-0

z Visually inspect the components. z Clean sealing surfaces.

© 41420-0

Installing the cooler z Mount gasket (1). z Mount the exhaust gas return pipe (2). z Fasten screws (3).

2

3 1

© 41421-0

© 01/2008

2/6

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Exhaust system/Charging W 06-09-04

TD 2009 z Mount gasket (1). z Mount compensator pipe (2). z Fasten screws (3).

2

3 1

6 © 41422-0

z Mount new gaskets (1).

1

1

© 41423-0

z Mount the exhaust gas return pipe (1). z Mount compensator pipe (2).

3

Mount pipe without tension and touching flat.

3

z Fasten screws (3). z Tighten screws (4).

1 2

4

4 © 41424-1

© 01/2008

3/6

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Exhaust system/Charging W 06-09-04

TD 2009

z Tighten screws (1).

20 Nm

1

z Tighten screws (2).

2

20 Nm z Tighten screws (3).

25 Nm z Tighten screws (4).

25 Nm 4

3

6 © 41425-0

z Tighten screw (1).

21 Nm

1

z Tighten screw (2).

2

27 Nm

2 1 4

3

© 41425-1

z Push on hose pipes (1). z Position hose clips (2). z Tighten hose clips (2).

1

2

1

2

© 41417-1

© 01/2008

4/6

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Exhaust system/Charging W 06-09-04

TD 2009 Technical Data Tightening specifications ID no.

A01 092 A06 059 A06 062 A06 063 A06 064

Name Transport bracket on cylinder head Exhaust return pipe to cooler Exhaust return pipe to charge air pipe Compensator pipe on exhaust pipe Compensator pipe to cooler Exhaust retgurn pipe to exhaust A06 070 return valve A09 002 Outlet nozzles on cylinder head

Screw type M8x16 M8x12-10.9 M8x70-8.8 M8x20-10.9 M8x12-8.8

Notes / Remark

Value 21 Nm 25 Nm 20 Nm 20 Nm 25 Nm

M8x20-8.8

20 Nm

M8x30-10.9

27 Nm

6

Š 01/2008

5/6

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Exhaust system/Charging W 06-09-04

TD 2009

6

© 01/2008

6/6

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Exhaust system/Charging W 06-09-06

TD 2009

Removing and installing the exhaust gas return valve Commercial available tools

6

Removing the exhaust gas return valve z Disconnect cable connections. z Loosen screw (1). z Unscrew screws (2). z Remove gasket.

1

2

© 41267-0

z Unscrew screws (1). z Remove exhaust gas return pipe (2). z Remove gasket.

2 1

© 41268-0

© 01/2008

1/6

16373-001

Exhaust system/Charging W 06-09-06

TD 2009

z Unscrew screws (1). z Remove exhaust gas return valve (2). z Remove gasket.

1

2 1

6

© 41269-0

Installing the exhaust gas return valve z Clean sealing surfaces. z Mount gasket (1). z Mount exhaust gas return valve (2).

3

1

z Fasten screws (3).

2

3 © 41269-2

z Mount gasket (1). z Mount the exhaust gas return pipe (2). z Fasten screws (3).

1 2 3

© 41268-3

© 01/2008

2/6

16373-001

Exhaust system/Charging W 06-09-06

TD 2009 z Mount new gasket. z Tighten screws (1).

1

6 © 41267-1

z Tighten screws (1).

20 Nm

1

© 41268-1

z Tighten screws (1).

25 Nm

1

© 41267-1

© 01/2008

3/6

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Exhaust system/Charging W 06-09-06

TD 2009

z Tighten screws (1).

20 Nm 1

1

6 © 41268-2

z Tighten screw (1).

27 Nm z Connect cable.

1

© 41267-2

© 01/2008

4/6

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Exhaust system/Charging W 06-09-06

TD 2009 Technical Data Tightening specifications ID no.

Name A06 059 Exhaust return pipe to cooler A06 062 Exhaust return pipe to charge air pipe Exhaust retgurn pipe to exhaust A06 070 return valve A09 002 Outlet nozzles on cylinder head

Screw type M8x12-10.9 M8x70-8.8

Notes / Remark

Value 25 Nm 20 Nm

M8x20-8.8

20 Nm

M8x30-10.9

27 Nm

6

Š 01/2008

5/6

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Exhaust system/Charging W 06-09-06

TD 2009

6

© 01/2008

6/6

16373-001

D 2009 TD 2009

Fuel system W 07-04-01

Removing and installing the fuel injector pump Attention!

Commercial available tools: – Extraction tool . . . . . . . . . . . . . . . . . 8310 – Special bit . . . . . . . . . . . . . . . . . . . . 9123

Ensure utmost cleanliness when working on the fuel system.

Carefully clean the area around the affected parts. 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 fluids in suitable vessels and dispose of according to regulations.

Special tools: – Special pliers. . . . . . . . . . . . . . . . 110120 – Measuring pin . . . . . . . . . . . . . . . 110180 – Special wrench . . . . . . . . . . . . . . 110520 – Disassembly tool. . . . . . . . . . . . . 110901 – Fixing pin . . . . . . . . . . . . . . . . . . 144180 – Counter support . . . . . . . . . . . . . 144190 – Plugs/caps . . . . . . . . . . . . . . . . . 170160

Removing the fuel injector pump z Unscrew lock nuts (1) with special wrench.

1

1

1 1 © 41271-0

z Unscrew screws (1). z Remove pipe clamp (2).

Note assignment and installation position of the injection lines.

2

z Remove all injection pipes. z Visually inspect the components.

1

1

© 41272-0

© 01/2008

1/12

16374-001

6

Fuel system W 07-04-01

D 2009 TD 2009

z Disconnect cables. z Unscrew union nuts (1).

1

1

6 © 41273-0

z Pull off hose pipe (1). z Pull off hose pipe (2).

1

2

© 41274-0

z Unscrew screw (1) with special bit. z Unscrew all screws (2).

2

2

2 2 1 © 41275-0

© 01/2008

2/12

16374-001

D 2009 TD 2009

Fuel system W 07-04-01

z Remove cap (1). z Remove O-ring. z Visually inspect the components.

1

6 © 41276-0

z Turn crankshaft.

Attention!

The marks (1) of the fuel injector toothed wheels and the idler gear must be in line.

The marks of the crankshaft toothed wheel, intermediate gear and fuel injector toothed wheel must be in line!

1

© 41277-0

The bore in the fuel injector toothed wheel must be in line with the bore in the crankcase. z Push the measuring pin (1) through the marking hole into the crankcase.

1

© 41279-0

© 01/2008

3/12

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Fuel system W 07-04-01

D 2009 TD 2009

z Loosen blocking screw (1).

2

z Push locking ring (2) towards larger opening.

The blocking screw can now be screwed in further.

1

z Tighten blocking screw (1).

The fuel injector shaft is blocked.

Attention!

Pay attention to perfect fit of the blocking screw and the locking ring. z Remove measuring pin.

6 © 41095-0

z Mount holder (1) on V-belt pulley.

Attention!

1

Do not turn crankshaft.

© 41278-0

z Unscrew nut (1). z Remove washer (2).

2

1

© 41280-0

© 01/2008

4/12

16374-001

D 2009 TD 2009

Fuel system W 07-04-01

z Mount the extraction tool (1). z Pull off the fuel injector pump toothed gear with the extraction tool (1). z Visually inspect the component.

1

6 © 41281-0

z Unscrew screws (1). z Remove fuel injector pump(2).

2

1

© 41145-0

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

1

© 41284-0

© 01/2008

5/12

16374-001

Fuel system W 07-04-01

D 2009 TD 2009

Installing the fuel injector pump z Insert new O-ring (1).

1

6 © 41364-0

z Mount fuel injector pump (2). z Tighten screws (1).

27 Nm

Attention!

The blocking screw may not be loosened.

2

1

© 41146-0

z Push fuel injector toothed wheel (4) onto fuel injector shaft.

3

4

Attention!

The marks of the fuel injector toothed wheels and the idler gear must be in line. z Push the measuring pin (3) through the marking hole into the crankcase. z Mount washer (2). z Tighten nut (1).

2

1

10 Nm

© 41147-0

© 01/2008

6/12

16374-001

D 2009 TD 2009

Fuel system W 07-04-01

z Loosen blocking screw (1). z Push locking ring (2) towards smaller opening.

Attention!

1

Loosening the blocking screw releases the blocking of the fuel injector shaft.

Never start the engine with the fuel injector shaft blocked!

2

z Tighten blocking screw (1).

10 Nm

6 © 41143-0

z Remove measuring pin. z Tighten nut (1).

81 Nm

1

© 41280-1

z Remove holder (1).

1

© 41278-0

© 01/2008

7/12

16374-001

Fuel system W 07-04-01

D 2009 TD 2009

z Pull new round sealing ring onto cap. z Mount cover (2).

1

z Tighten all screws (1).

1

27 Nm

2 1 1

6 © 41275-1

z Tighten screw (1).

27 Nm

1 © 41275-2

z Mount the hose pipe (2). z Mount the hose pipe (1).

1

2

© 41274-0

© 01/2008

8/12

16374-001

D 2009 TD 2009

Fuel system W 07-04-01

Attention!

Install fuel pipes tension free! z Screw on union nuts (1). z Tighten lock nuts (1).

9 Nm

1

1

6 © 41273-0

Attention!

Install injection pipes without tension! z Mount high pressure pipes.

Note assignment and installation position of the injection lines.

2

z Screw on union nuts. z Mount pipe clamp (2). z Tighten screws (1).

1

1

© 41272-0

z Tighten union nuts (1) with special wrench.

28 Nm

1

1

1 1 © 41271-0

© 01/2008

9/12

16374-001

Fuel system W 07-04-01

D 2009 TD 2009

z Tighten screws (1).

9 Nm Ensure that the installation location is free from faults.

1

1

6 © 41272-1

© 01/2008

10/12

16374-001

D 2009 TD 2009

Fuel system W 07-04-01

Technical Data Tightening specifications ID no.

Name Injection pump gear wheel on injecA04 004 tion pump Injection pump gear wheel on injecA04 004 tion pump A04 022 Cap on gearcase cover A07 003 A07 006 A07 012 A07 013 A07 015

© 01/2008

Injection line on fuel injector/injection pump Injection lines, fastening, pipe clip Injection pump on crankcase Blocking screw on injection pump Fuel line on injection pump

Screw type

M8x70-8.8 M8x20-8.8

Notes / Remark

Value

Stage 1:

10 Nm

Stage 2:

81 Nm

Torx screw

27 Nm

M12x1.5

28 Nm

M6x10-8.8 M8x30-10.9

9 Nm 27 Nm 10 Nm 9 Nm

1/2’’

11/12

6

16374-001

Fuel system W 07-04-01

D 2009 TD 2009

6

© 01/2008

12/12

16374-001

D 2009 TD 2009

Fuel system W 07-04-14

Setting the injection pump Commercial available tools: –

– Service Bulletin 0168-17-9476

Attention!

The service for the injection pumps made

by DELPHI may only be performed by partners authorised by DEUTZ AG and/or DELPHI partners.

6

© 01/2008

1/2

16375-001

Fuel system W 07-04-14

D 2009 TD 2009

6

© 01/2008

2/2

16375-001

Fuel system W 07-07-01

D 2009 Removing and installing the fuel injectors Danger!

Commercial available tools: – Assembly pliers. . . . . . . . . . . . . . . . 8024

Wait 30 seconds after switching off the engine before working on the fuel system.

Special tools: – Puller. . . . . . . . . . . . . . . . . . . . . . 110090 – Special pliers. . . . . . . . . . . . . . . . 110120 – Special wrench . . . . . . . . . . . . . . 110520 – Extraction tool . . . . . . . . . . . . . . . 120680 – Slide hammer . . . . . . . . . . . . . . . 150800 – Plugs/caps . . . . . . . . . . . . . . . . . 170160

Attention!

Ensure utmost cleanliness when working on the fuel system.

Carefully clean the area around the affected parts. 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 fluids in suitable vessels and dispose of according to regulations.

– Fitting compound DEUTZ AP1908

The following work procedure describes the removal and installation of a fuel injector.

Proceed the same to remove another fuel injector.

Removing the fuel injectors 1

z Unscrew lock nuts (1) with special wrench.

1

1

1

1

© 41404-0

© 01/2008

1/8

16376-001

6

Fuel system W 07-07-01

D 2009

z Unscrew screw (1). z Remove pipe clamp (2). z Remove all injection pipes. z Visually inspect the components.

1

2

6 © 41405-0

z Pull leak fuel lines (1) off the fuel injectors with special pliers.

1

1

© 41406-0

z Unscrew fuel injector (1).

Attention!

1

Do not damage the sealing surfaces. z Remove sealing ring (2).

2

© 41407-0

© 01/2008

2/8

16376-001

Fuel system W 07-07-01

D 2009 Attention!

Do not damage the nozzle tip of the injector valve when removing the sealing ring (1). z Grip a tight sealing ring (1) with the assembly pliers (2) and pull off, turning slightly. z Visually inspect sealing surface. z Visually inspect the components.

1

2

6 © 41408-0

Removing a tightly fixed sealing ring from the cylinder head z Insert extraction device (1).

The holders (arrow) must sit in the bore of the sealing ring.

1

© 41409-0

z Turn in the spindle (1) until the sealing ring is fixed to the extraction device.

Hold extraction device against the flats.

1

© 41410-0

© 01/2008

3/8

16376-001

Fuel system W 07-07-01

D 2009

z Mount adapter (1) and slide hammer (2) on extraction device. z Remove tight sealing ring.

2

1

6 © 41411-0

Installing the fuel injector z Mount new sealing ring (1) on fuel injector.

1

© 41412-0

z Screw on fuel injector (1). z Tighten fuel injector.

1

68 Nm

© 41407-1

© 01/2008

4/8

16376-001

Fuel system W 07-07-01

D 2009 z Plug leak fuel lines (1) to the fuel injectors.

1

1

6 © 41406-0

z Mount high pressure pipes. z Screw on union nuts.

Attention!

Install injection pipes without tension! z Mount pipe clamp (2).

1

2

z Fasten screw (1).

© 41405-0

z Tighten union nuts (1) with special wrench.

28 Nm

1

1

1

1

1

© 41404-0

© 01/2008

5/8

16376-001

Fuel system W 07-07-01

D 2009

z Tighten screw (1).

9 Nm Ensure that the installation location is free from faults.

1

6 Š 41405-1

Š 01/2008

6/8

16376-001

Fuel system W 07-07-01

D 2009 Technical Data Tightening specifications ID no.

Name A07 001 Fuel injector on cylinder head Injection line on fuel injector/injection A07 003 pump A07 006 Injection lines, fastening, pipe clip

Screw type M22

Notes / Remark

Value 68 Nm

M12x1.5

28 Nm

M6x10-8.8

9 Nm

6

© 01/2008

7/8

16376-001

Fuel system W 07-07-01

D 2009

6

© 01/2008

8/8

16376-001

Fuel system W 07-07-01

TD 2009 Removing and installing the fuel injectors Danger!

Commercial available tools: – Assembly pliers. . . . . . . . . . . . . . . . 8024

Wait 30 seconds after switching off the engine before working on the fuel system.

Special tools: – Puller. . . . . . . . . . . . . . . . . . . . . . 110090 – Special pliers. . . . . . . . . . . . . . . . 110120 – Special wrench . . . . . . . . . . . . . . 110520 – Disassembly tool. . . . . . . . . . . . . 110901 – Extraction tool . . . . . . . . . . . . . . . 120690 – Slide hammer . . . . . . . . . . . . . . . 150800 – Plugs/caps . . . . . . . . . . . . . . . . . 170160

Attention!

Ensure utmost cleanliness when working on the fuel system.

Carefully clean the area around the affected parts. 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 fluids in suitable vessels and dispose of according to regulations.

– Fitting compound DEUTZ AP1908

The following work procedure describes the removal and installation of a fuel injector.

Proceed the same to remove another fuel injector.

Removing the fuel injectors z Unscrew lock nuts (1) with special wrench.

1

1

1 1 © 41271-0

© 01/2008

1/8

16377-001

6

Fuel system W 07-07-01

TD 2009

z Unscrew screws (1). z Remove pipe clamp (2). z Remove all injection pipes. z Visually inspect the components.

2

1

1

6 © 41272-0

z Pull leak fuel lines off the fuel injectors with special pliers.

© 41285-0

z Unscrew screw (1).

1

z Remove clamping shoe (2).

2

z Pull out fuel injector (3).

Attention!

Do not damage the sealing surfaces.

Up to two sealing rings per fuel injector may be installed depending on the version.

3

4

z Remove sealing ring (4). z Visually inspect sealing surface. z Visually inspect the components.

© 41097-0

© 01/2008

2/8

16377-001

Fuel system W 07-07-01

TD 2009 Removing stuck fuel injectors z Assembly sliding hammer (1) and puller (2). z Tighten lock nut (3).

1

2

3

6 © 41360-0

z Mount sliding hammer on fuel injector. z Screw on lock nut (1). z Pull out stuck fuel injector.

1

© 41286-0

Attention!

Do not damage the nozzle tip of the injector valve when removing the sealing ring (1). z Grip a tight sealing ring (1) with the assembly pliers (2) and pull off, turning slightly.

1 2

© 46846-0

© 01/2008

3/8

16377-001

Fuel system W 07-07-01

TD 2009

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

1

6 © 00000-0

Removing a tightly fixed sealing ring from the cylinder head z Insert extraction device (1).

The holders (arrow) must sit in the bore of the sealing ring.

1

© 41354-0

z Turn in the spindle (1) until the sealing ring is fixed to the extraction device.

Hold extraction device against the flats.

1

© 41366-0

© 01/2008

4/8

16377-001

Fuel system W 07-07-01

TD 2009 z Mount adapter (1) and slide hammer (2) on extraction device. z Remove tight sealing ring.

2

1

6 © 41367-0

Installing the fuel injector z Mount new O-ring (1). z Coat the O-ring with fitting compound.

1

© 41368-0

z Mount new sealing ring (1) on fuel injector.

Attention!

Up to two sealing rings per fuel injector may be installed depending on the version.

See spare parts documentation.

1

© 41098-1

© 01/2008

5/8

16377-001

Fuel system W 07-07-01

TD 2009

z Insert fuel injector (3).

The leak fuel connection faces the exhaust pipe.

2

z Mount clamping shoe (2).

1

3

Note installation position of the clamping shoe. z Tighten screw (1).

35 Nm

6 © 41097-1

z Plug hose pipes (1) to the fuel injectors.

1

1

© 41289-0

z Mount high pressure pipes. z Screw on union nuts.

Attention!

Install injection pipes without tension!

2

z Mount pipe clamp (2). z Tighten screws (1).

1

1

© 41272-0

© 01/2008

6/8

16377-001

Fuel system W 07-07-01

TD 2009 z Tighten union nuts (1) with special wrench.

28 Nm

1

1

1 1

6 © 41271-0

z Tighten screws (1).

9 Nm Ensure that the installation location is free from faults.

1

1

© 41272-1

© 01/2008

7/8

16377-001

Fuel system W 07-07-01

TD 2009

Technical Data Tightening specifications ID no.

Name A07 001 Fuel injector on cylinder head Injection line on fuel injector/injection A07 003 pump A07 006 Injection lines, fastening, pipe clip

Screw type M8x35-10.9

Notes / Remark Torx screw

Value 35 Nm

M12x1.5

28 Nm

M6x10-8.8

9 Nm

6

© 01/2008

8/8

16377-001

D 2009 TD 2009

Fuel system W 07-10-08

Removing and installing the fuel filter console Commercial available tools

– User notes – Operation manual

Special tools: – Special wrench . . . . . . . . . . . . . . 170050 – Plugs/caps . . . . . . . . . . . . . . . . . 170160

Danger!

Wait 30 seconds after switching off the engine before working on the fuel system.

Attention!

Ensure utmost cleanliness when working on the fuel system.

Carefully clean the area around the affected parts. 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 fluids in suitable vessels and dispose of according to regulations.

Removing the fuel filter console z Loosen water drainage screw (1).

Collect draining water and dispose of properly. z Unscrew fuel filter (2) with special wrench.

Collect draining fuel and dispose of according to regulations.

2

1 © 41346-0

© 01/2008

1/4

16378-001

6

Fuel system W 07-10-08

D 2009 TD 2009

z Unscrew hollow screw (1). z Remove sealing rings. z Unscrew fuel pipes (2).

1

z Pull off fuel return line.

Collect draining fuel and dispose of according to regulations.

2 2

6 © 41361-0

z Unscrew screws (1). z Remove fuel filter console (2). z Visually inspect the components.

1

2 © 41347-0

Installing the fuel filter console z Install the fuel filter console (2). z Tighten screws (1).

1

41 Nm z Clean sealing surfaces.

2 © 41347-0

© 01/2008

2/4

16378-001

D 2009 TD 2009

Fuel system W 07-10-08

z Mount fuel pipes. z Tighten hollow screw (1) with new sealing rings.

21 Nm

1

z Tighten union nuts (2).

9 Nm z Mount fuel return line.

Check fuel lines and renew if necessary.

2

Note assignment and installation position of the fuel lines.

2

6 © 41361-0

z Lightly oil gasket on new fuel filter. z Screw on fuel filter by hand.

The seal must fit evenly.

z Tighten the fuel filter by another half turn (tightening torque see fuel filter print).

© 41346-1

© 01/2008

3/4

16378-001

Fuel system W 07-10-08

D 2009 TD 2009

Technical Data Tightening specifications ID no.

Name Fuel lines on fuel supply pump and A07 019 fuel filter console A07 084 Fuel line to fuel filter console A07 087 Fuel filter console to crankcase

Screw type

Notes / Remark

Value

1/2’’

9 Nm

M10x1.5 Hollow screw M10x25-10.9

21 Nm 41 Nm

6

© 01/2008

4/4

16378-001

D 2009 TD 2009

Fuel system W 07-11-01

Removing and installing the fuel supply pump Commercial available tools

– User notes – Operation manual

Special tools: – Disassembly tool. . . . . . . . . . . . . 110901 – Plugs/caps . . . . . . . . . . . . . . . . . 170160

Danger!

Wait 30 seconds after switching off the engine before working on the fuel system.

Attention!

Ensure utmost cleanliness when working on the fuel system.

Carefully clean the area around the affected parts. 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 fluids in suitable vessels and dispose of according to regulations.

Removing the fuel supply pump Danger!

Wait 30 seconds after switching off the engine before working on the fuel system. z Unscrew union nuts (1).

1

Collect draining fuel and dispose of according to regulations. z Remove fuel pipe.

1

© 41342-0

© 01/2008

1/4

16379-001

6

Fuel system W 07-11-01

D 2009 TD 2009

z Unscrew all screws (1). z Remove fuel supply pump (2). z Remove adapter (3). z Remove pump tappet.

2 1

1

3

6 © 41343-0

z Visually inspect the components.

© 41344-0

Installing the fuel supply pump z Clean sealing surfaces. z Insert new sealing ring (1).

1

© 41344-1

© 01/2008

2/4

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D 2009 TD 2009

Fuel system W 07-11-01

z Insert new sealing ring (1).

1

6 © 41345-0

z Turn crankshaft. z Install pump tappet.

The pump plunger must touch the base circle of the camshaft.

2

z Mount adapter (3).

Note installation position.

1

1

z Mount fuel supply pump (2). z Tighten all screws (1).

27 Nm 3

© 41343-0

z Mount fuel pipe. z Tighten lock nuts (1).

9 Nm Bleed the fuel system via the manual fuel pump on the fuel pre-filter according to the operation manual.

1

1

© 41342-0

© 01/2008

3/4

16379-001

Fuel system W 07-11-01

D 2009 TD 2009

Technical Data Tightening specifications ID no.

Name Fuel lines on fuel supply pump and A07 019 fuel filter console A07 024 Fuel supply pump on crankcase

Screw type

Notes / Remark

Value

1/2’’

9 Nm

M8x55-10.9

27 Nm

6

© 01/2008

4/4

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D 2009 TD 2009

Lube oil system W 08-04-05

Removing and installing the lubricating oil pump Commercial available tools

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

6

Removing the lubricating oil pump z Remove the gear case cover.

W 04-04-09 z Remove intermediate gear wheel.

W 02-04-01 z Remove oil suction pipe W 08-04-06

© 41106-2

z Unscrew screws (1). z Remove lubricating oil pump (2). z Visually inspect the components.

1 2 © 41107-0

© 01/2008

1/4

16380-001

Lube oil system W 08-04-05

D 2009 TD 2009

Installing the lubricating oil pump z Insert lubricating oil pump (2).

Note installation position.

z Tighten screws (1).

4 Nm + 9 Nm

1 2

6

© 41107-0

z Install oil suction pipe.

W 08-04-06 z Install intermediate gear wheel.

W 02-04-01 z Install the gear case cover.

W 04-04-09

© 41106-2

© 01/2008

2/4

16380-001

D 2009 TD 2009

Lube oil system W 08-04-05

Technical Data Tightening specifications ID no.

Name A08 010 Lubricating oil pump on crankcase

Screw type M6x25-8.8

Notes / Remark

Value 4 Nm + 9 Nm

6

© 01/2008

3/4

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Lube oil system W 08-04-05

D 2009 TD 2009

6

© 01/2008

4/4

16380-001

D 2009 TD 2009

Lube oil system W 08-04-06

Removing and installing the oil suction pipe Commercial available tools

– W 08-04-07

6

Removing the oil suction pipe z Remove lubricating oil pan.

W 08-04-07

© 41108-0

z Unscrew screw (1). z Remove oil suction pipe (2). z Remove O-ring (3). z Visually inspect the components.

3 1 2 © 41109-0

© 01/2008

1/4

16381-001

Lube oil system W 08-04-06

D 2009 TD 2009

Installing the oil suction pipe z Insert new O-ring (3). z Lightly oil O-ring (3). z Mount oil suction pipe (2). z Tighten screw (1).

41 Nm

3 1

6

2 © 41109-0

z Install lubricating oil pan.

W 08-04-07

© 41108-0

© 01/2008

2/4

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D 2009 TD 2009

Lube oil system W 08-04-06

Technical Data Tightening specifications ID no.

Name Screw type A08 016 Oil suction pipe, holder on crankcase M10x80-8.8

Notes / Remark

Value 41 Nm

6

© 01/2008

3/4

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Lube oil system W 08-04-06

D 2009 TD 2009

6

© 01/2008

4/4

16381-001

D 2009 TD 2009

Lube oil system W 08-04-07

Removing and installing the lubricating oil pan Commercial available tools

– Operation manual

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

Observe the appropriate operating instructions for emptying and filling the engine.

6

Removing the lubricating oil pan z Unscrew locking screws (1).

Collect lubricating oil and dispose of according to regulations. z Insert new sealing ring. z Tighten locking screws (1).

39 Nm

1

1

© 41110-1

z Unscrew all screws (1). z Remove strips (2).

2

z Remove strips (3).

3

z Remove lubricating oil pan. z Remove gasket. z Visually inspect the components.

1

© 41111-1

© 01/2008

1/4

16382-001

Lube oil system W 08-04-07

D 2009 TD 2009

Installing the lubricating oil pan z Clean sealing surfaces. z Grease lubricating oil pan (arrows).

1

z Mount new gasket. z Mount lubricating oil pan.

Attention!

Do not move the gasket when mounting the lubricating oil pan.

Note installation position. z Mount strips (1). z Tighten screws (arrows). z Fasten all screws.

6 © 41112-1

z Tighten the screws according to the tightening sequence.

7

8

32 Nm

6

5

4

17

18

19

Representation: 4-cylinder engine 9

20

26

21

25

22

24

23

12

16

11

10

1

2

3

13

14

15

© 41259-0

z Fill in lubricating oil according to operating manual.

max. min.

© 41142-0

© 01/2008

2/4

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D 2009 TD 2009

Lube oil system W 08-04-07

Technical Data Tightening specifications ID no.

Name

Screw type

A03 030 Lubricating oil pan on crankcase

M8x20-8.8

A03 031 Locking screw on lubricating oil pan

M14x14

Notes / Remark Observe tightening sequence.

Use new Cu sealing ring.

Value 32 Nm 39 Nm

6

© 01/2008

3/4

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Lube oil system W 08-04-07

D 2009 TD 2009

6

© 01/2008

4/4

16382-001

D 2009 TD 2009

Lube oil system W 08-08-02

Removing and installing the lubricating oil cooler Commercial available tools

– Operation manual

Special tools: – Special wrench . . . . . . . . . . . . . . 170050

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 z Remove lubricating oil filter (1) with special wrench 170050. z Drain lubricating oil, collect and dispose of according to regulations. z Loosen hose clips (2).

2

1 © 41291-0

z Pull off hose pipe (1). z Pull off hose pipe (2). z Drain, collect and dispose of coolant according to regulations.

1

2

© 41290-0

© 01/2008

1/6

16383-001

Lube oil system W 08-08-02

D 2009 TD 2009

z Unscrew hollow screw (1). z Remove lubricating oil cooler (2). z Remove sealing ring.

1

2

6

© 41292-0

z Visually inspect the components.

© 41293-0

Removing the adapter z Unscrew hollow screw (2). z Remove adapter (1). z Remove sealing ring.

2 1 © 41295-0

© 01/2008

2/6

16383-001

D 2009 TD 2009

Lube oil system W 08-08-02

z Visually inspect the components.

6 © 41296-0

Installing the adapter z Clean sealing surfaces. z Insert new sealing ring (1).

1 © 41297-0

z Mount sealing ring (2). z Fit new sealing rings (1).

2

1

1

© 41298-0

© 01/2008

3/6

16383-001

Lube oil system W 08-08-02

D 2009 TD 2009

z Mount adapter (1). z Tighten hollow screw (2).

41 Nm

2 1

6

© 41295-0

Installing the lubricating oil cooler z Clean sealing surfaces. z Insert new sealing ring (1).

1 © 41294-0

z Mount lubricating oil cooler (2). z Tighten hollow screw (1).

41 Nm

1

2 © 41292-0

© 01/2008

4/6

16383-001

D 2009 TD 2009

Lube oil system W 08-08-02

z Mount the hose pipe (1). z Mount the hose pipe (2).

2

1

6 © 41290-0

z Position hose clips (1). z Fasten hose clips with hose clip pliers.

1

© 41291-1

z Lightly oil sealing ring on new oil filter cartridge. z Screw on lubricating oil filter (1) by hand.

Hand tighten

1 © 41291-2

© 01/2008

5/6

16383-001

Lube oil system W 08-08-02

D 2009 TD 2009

Technical Data Tightening specifications ID no.

Name Lubricating oil filter on lubricating oil A08 001 cooler A08 003 Adapter on gearcase cover A08 051 Lubricating oil cooler on adapter

Screw type M14x1.5 3/4“ M22x1.5

Notes / Remark Oil gasket lightly.

See operating manual

Value Hand tighten 41 Nm 41 Nm

6

Š 01/2008

6/6

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D 2009 TD 2009

Lube oil system W 08-11-08

Removing and installing the oil pressure switch Commercial available tools

– User notes

Special tools: – Long socket wrench insert . . . . . 110700 – Plugs/caps . . . . . . . . . . . . . . . . . 170160

Pay attention to utmost cleanliness when working on the lube oil system.

Carefully clean the area around the affected parts. Blow damp areas dry with compressed air.

Observe the safety regulations and national specifications for handling lube oils.

Close all connections immediately after opening with new, clean plugs/caps.

Do not remove plugs/caps until immediately before assembling.

Removing the oil pressure switch z Disconnect cable connections. z Unscrew oil pressure switch (1).

Collect lubricating oil and dispose of according to regulations.

1

© 41340-0

z Visually inspect the components.

© 41341-0

© 01/2008

1/4

16384-001

6

Lube oil system W 08-11-08

D 2009 TD 2009

Installing the oil pressure switch z Clean components.

6 © 41341-0

z Tighten the oil pressure switch (1) with the socket wrench insert.

– M10x1 20 Nm – M12x1.5 / M14x1.5 50 Nm z Connect cable.

Ensure that the connection is perfect.

z Fill in lubricating oil according to operating manual.

1

© 41340-0

© 01/2008

2/4

16384-001

D 2009 TD 2009

Lube oil system W 08-11-08

Technical Data Tightening specifications ID no.

Name A08 091 Oil pressure switch in crankcase A08 091 Oil pressure switch in crankcase

Screw type M10x1 M12x1 M14x1.5

Notes / Remark

Value 20 Nm 50 Nm

6

© 01/2008

3/4

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Lube oil system W 08-11-08

D 2009 TD 2009

6

© 01/2008

4/4

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D 2009 TD 2009

Lube oil system W 08-11-10

Removing and installing the oil pressure regulating valve Commercial available tools

– W 04-04-09

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

6

Removing the oil pressure regulating valve z Remove the gear case cover.

W 04-04-09

© 41115-0

z Unscrew oil pressure regulating valve. z Visually inspect the component.

© 41116-0

© 01/2008

1/4

16385-001

Lube oil system W 08-11-10

D 2009 TD 2009

Installing the oil pressure regulating valve z Insert oil pressure regulating valve. z Tighten oil pressure control valve.

21 Nm

6 © 41116-0

z Install the gear case cover.

W 04-04-09

© 41115-0

© 01/2008

2/4

16385-001

D 2009 TD 2009

Lube oil system W 08-11-10

Technical Data Tightening specifications ID no.

Name Oil pressure control valve on crankA08 098 case

Screw type 3/8“

Notes / Remark

Value 21 Nm

6

© 01/2008

3/4

16385-001

Lube oil system W 08-11-10

D 2009 TD 2009

6

© 01/2008

4/4

16385-001

D 2009 TD 2009

Cooling system W 09-07-08

Removing and installing the coolant pump Commercial available tools

– W 12-02-02 – W 13-02-03 – Operation manual 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 Drain, collect and dispose of coolant according to regulations. z Loosen screws (1).

1

1

© 41332-0

z Loosen screws (1). z Hold nut (2).

1

z Press generator in direction of arrow.

1

z Remove V-belt.

2 1 © 41323-0

© 01/2008

1/6

16386-001

Cooling system W 09-07-08

D 2009 TD 2009

z Unscrew screws (1). z Remove V-belt pulley (2).

1

1

6 © 41333-0

z Loosen hose clip (1). z Pull off hose pipe (2).

Collect and dispose of coolant according to regulations.

2

1

© 41334-0

z Unscrew all screws (2).

Collect and dispose of coolant according to regulations. z Remove coolant pump (1). z Remove gasket.

1 2

© 41335-0

© 01/2008

2/6

16386-001

D 2009 TD 2009

Cooling system W 09-07-08

z Visually inspect the components.

6 © 41336-0

Installing coolant pump z Clean sealing surfaces. z Mount gasket (1).

1

© 41337-0

z Mount coolant pump (1). z Fasten all screws (2).

Note different screw lengths.

1 2

© 41335-0

© 01/2008

3/6

16386-001

Cooling system W 09-07-08

D 2009 TD 2009

z Tighten the screws according to the tightening sequence.

2

27 Nm Tightening order: screw (1), then screw (2), then the other screws in any order.

1

6

© 41335-3

z Mount the hose pipe (2). z Position hose clip (1). z Fix the hose clip with the hose clip pliers.

2

1

© 41334-0

z Mount V-belt pulley (2). z Tighten screws (1). z Mount V-belt.

1

1

© 41333-0

© 01/2008

4/6

16386-001

D 2009 TD 2009

Cooling system W 09-07-08

z Press generator in direction of arrow.

1

V-belt is clamped.

4

z Tighten screw (1).

21 Nm z Hold nut (2). z Tighten screw (3).

21 Nm z Tighten screw (4).

21 Nm

2

6

3 © 41323-1

z Tighten screws (1).

9 Nm z Check V-belt tension.

1

W 13-02-03 z Fill cooling system according to the operating manual.

1

© 41332-0

© 01/2008

5/6

16386-001

Cooling system W 09-07-08

D 2009 TD 2009

Technical Data Tightening specifications ID no.

A09 010 A12 046 A13 012 A13 015 A13 016

Name

Screw type M8x70-8.8 Coolant pump on gearcase cover M8x30-10.9 V-belt pulley on coolant pump M6x10-8.8 Generator on gearcase cover M8x120-8.8 Generator on clamping bracket M8x20-8.8 Clamping bracket on gearcase cover M8x16-8.8

Notes / Remark Observe tightening sequence.

Value 27 Nm 9 Nm 21 Nm 21 Nm 21 Nm

6

Š 01/2008

6/6

16386-001

D 2009 TD 2009

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

© 41120-0

z Measure beginning of stroke, dimension (a).

a

z Note measured value, dimension (a).

© 41121-0

© 01/2008

1/4

16387-001

Cooling system W 09-08-01

D 2009 TD 2009

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

6 © 41123-0

z Measure end of stroke, dimension (b).

b

z Note measured value, dimension (b).

© 41122-0

z Determine stroke.

b

Calculation example Desired: Stroke Given: Measured: Beginning of stroke, dimension (a) (a) = 31.2 mm End of stroke, dimension (b) (b) = 40.2 mm Calculation: Dimension (b) - dimension (a) 40.2 mm - 31.2 mm Result: = stroke = 9 mm

z Compare result with setpoint value.

– Nominal value stroke travel: at least 9 mm © 41122-0

© 01/2008

2/4

16387-001

D 2009 TD 2009

Cooling system W 09-08-01

z Install thermostat.

W 09-08-02

6 © 41120-0

© 01/2008

3/4

16387-001

Cooling system W 09-08-01

D 2009 TD 2009

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

Š 01/2008

4/4

16387-001

D 2009 TD 2009

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.

The appropriate documentation of the vehicle/equipment manufacturer should be observed for emptying and filling the cooling system.

6

Removing the thermostat z Unscrew screw (1). z Unscrew screws (2). z Remove gasket.

1

2

© 41267-0

z Unscrew screws (1). z Remove exhaust gas return pipe (2). z Remove gasket.

2 1

© 41268-0

© 01/2008

1/6

16388-001

Cooling system W 09-08-02

D 2009 TD 2009

z Loosen hose clip (2). z Pull off hose pipe (1).

1

2

6 © 41326-1

z Unscrew screw (1). z Remove outlet nozzle (2).

1

2

© 41327-0

z Remove sealing ring (1). z Remove thermostat (2). z Visually inspect the components. z Check thermostat.

W 09-08-01

2

1 © 41328-0

© 01/2008

2/6

16388-001

D 2009 TD 2009

Cooling system W 09-08-02

Installing the thermostat z Clean sealing surfaces. z Insert new sealing ring (1).

1

6 © 41329-0

z Insert thermostat (1).

1 © 41330-0

z Mount outlet nozzle (2).

Note installation position.

z Fasten screw (1).

1

2

© 41327-0

© 01/2008

3/6

16388-001

Cooling system W 09-08-02

D 2009 TD 2009

z Mount the hose pipe (1). z Position hose clip (2). z Tighten hose clip (2).

1

2

6 © 41326-1

z Mount new gasket. z Mount the exhaust gas return pipe (2). z Tighten screws (1).

2 1

© 41268-0

z Mount new gasket. z Tighten screws (2). z Fasten screw (1).

1

2

© 41267-0

© 01/2008

4/6

16388-001

D 2009 TD 2009

Cooling system W 09-08-02

z Tighten screws (1).

20 Nm

1

6 © 41268-1

z Tighten screws (2).

25 Nm z Tighten screw (1).

27 Nm 1

2

© 41267-0

z Tighten screw (1).

27 Nm

1

© 41331-0

© 01/2008

5/6

16388-001

Cooling system W 09-08-02

D 2009 TD 2009

Technical Data Tightening specifications ID no.

Name A06 059 Exhaust return pipe to cooler Exhaust retgurn pipe to exhaust A06 070 return valve A09 002 Outlet nozzles on cylinder head

Screw type M8x12-10.9

Notes / Remark

Value 25 Nm

M8x20-8.8

20 Nm

M8x30-10.9

27 Nm

6

Š 01/2008

6/6

16388-001

D 2009 TD 2009

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

Š 41338-0

z Visually inspect the component.

Š 41339-0

Š 01/2008

1/4

16389-001

Cooling system W 09-12-01

D 2009 TD 2009

Installing temperature transmitter z Clean components. z Insert gasket (1) with packing compound.

1

6 © 41339-1

z Tighten temperature transmitter (1).

4 Nm z Connect cable.

Ensure that the connection is perfect.

1

© 41338-0

© 01/2008

2/4

16389-001

D 2009 TD 2009

Cooling system W 09-12-01

Technical Data Tightening specifications ID no.

Name Temperature transmitter on cylinder A09 031 head

Screw type

Notes / Remark Insert gasket with packing compound.

Value 4 Nm

6

Š 01/2008

3/4

16389-001

Cooling system W 09-12-01

D 2009 TD 2009

6

© 01/2008

4/4

16389-001

D 2009 TD 2009

Other components W 12-02-02

Removing and installing the V-belt pulley Commercial available tools: – V-belt tension measuring device . . . . . . . . . . . . . . . . . . . . . . . 8115

– W 12-02-02

Special tools: – Blocking tool . . . . . . . . . . . . . . . . 144210

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, V-belt pulley 1

z Loosen screws (1). z Hold nut (2).

1

z Press generator in direction of arrow. z Remove V-belt.

2 1 © 41323-0

z Insert blocking tool (1). z Tighten screw (2).

2 1

© 41352-0

© 01/2008

1/4

16390-001

Other components W 12-02-02

D 2009 TD 2009

z Unscrew screw (1). z Remove V-belt pulley (2). z Visually inspect the components.

2

1

6 © 41325-0

Installing the V-belt, V-belt pulley z Mount V-belt pulley (2). z Tighten screw (1).

300 Nm

2

1

© 41325-0

z Unscrew screw (2). z Remove blocking tool (1). z Mount V-belt. z Check V-belt tension.

W 12-02-02

2 1

© 41352-0

© 01/2008

2/4

16390-001

D 2009 TD 2009

Other components W 12-02-02

Technical Data Tightening specifications ID no.

Name A12 031 V-belt pulley on crankshaft

Screw type Notes / Remark M20x55-10.9

Value 300 Nm

6

Š 01/2008

3/4

16390-001

Other components W 12-02-02

D 2009 TD 2009

6

Š 01/2008

4/4

16390-001

D 2009 TD 2009

Other components W 12-06-01

Removing and installing the flywheel Commercial available tools Special tools: – Blocking tool . . . . . . . . . . . . . . . . 144210

6

Removing the flywheel z Insert blocking tool (1). z Tighten screw (2).

2 1

© 41352-0

z Unscrew all screws (1).

1

© 41362-0

© 01/2008

1/4

16391-001

Other components W 12-06-01

D 2009 TD 2009

z Unscrew screw (2). z Remove blocking tool (1). z Remove flywheel. z Visually inspect the components.

2 1

6 © 41352-0

Installing the flywheel z Mount flywheel. z Turn in new screws (1).

1

© 41362-0

z Insert blocking tool (1). z Tighten screw (2).

2 1

© 41352-0

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See graphic for tightening sequence.

3

1 6

z Tighten all screws.

96 Nm

6

5 2 4 © 41181-1

z Unscrew screw (2). z Remove blocking tool (1).

2 1

© 41352-0

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Technical Data Tightening specifications ID no.

Name A12 001 Flywheel on crankshaft

Screw type Notes / Remark M12x50-10.9 Use new screws.

Value 96 Nm

6

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Removing and installing the generator (V-belt drive) Commercial available tools: – V-belt tension measuring device . . . . . . . . . . . . . . . . . . . . . . . 8115

– Operation manual

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 generator z Disconnect the battery. z Remove cable from generator.

© 41135-1

z Loosen screws (1). z Hold nut (2).

1

z Press generator in direction of arrow.

1

z Remove V-belt.

2 1 © 41323-0

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z Unscrew screws (1). z Hold nut (2). z Remove generator.

1

2

6

1 © 41535-0

z Visually inspect the components.

© 41324-0

Installing the generator z Mount generator. z Tighten screws (1).

1

z Hold nut (2). z Mount V-belt.

2 1 © 41535-0

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z Press generator in direction of arrow.

1

V-belt is clamped.

4

z Tighten screw (1).

21 Nm z Hold nut (2). z Tighten screw (3).

21 Nm z Tighten screw (4).

21 Nm

2

6

3 © 41323-1

z Remove cable from generator. z Connect the battery.

© 41135-1

Check V-belt tension with V-belt tension measuring device z Lower indicator arm (1) into V-belt tension measuring device. z Mount V-belt tension measuring device on V-belt.

1

© 41129-0

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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.

– First assembly: 450 N – Check after running for 15 minutes under load: +20

300 −20 N Note different units on the scale.

6

z If the nominal value is not reached, the tensioning process must be repeated.

1 © 41130-0

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Technical Data Testing and setting data ID no.

P12 11

Name V-belt tension

P12 21

V-belt tension

Additional information First assembly Check after 15 minutes running under load.

Value 450 N 300 +20 −20 N

Tightening specifications ID no.

A13 012 A13 015 A13 016

Name Generator on gearcase cover Generator on clamping bracket Clamping bracket on gearcase cover

Screw type M8x120-8.8 M8x20-8.8 M8x16-8.8

Notes / Remark

Value 21 Nm 21 Nm 21 Nm

6

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Removing and installing the starter Commercial available tools

6

Removing the starter z Disconnect the battery's negative terminal. z Disconnect cables. z Unscrew screws (1). z Remove starter.

1

z Visually inspect the component.

© 41138-1

Installing the starter z Insert starter. z Tighten screws (1).

41 Nm z Connect cables.

9 Nm

1

Note the assignment of the terminal designations. z Connect the battery's negative terminal.

© 41139-2

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Technical Data Tightening specifications ID no.

Name A13 001 Starter on connection housing A13 071 Cable (terminal 30) to starter

Screw type M10x45-8.8 M8

Notes / Remark

Value 41 Nm 9 Nm

6

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Removing and installing the glow plugs Commercial available tools

6

Removing the glow plugs z Disconnect the battery. z Unscrew nuts (1). z Remove connecting rail (2).

1

1

2

© 41319-0

z Unscrew charge air pressure switch (1).

1

© 41320-0

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z Unscrew glow plugs (1).

1

1

6 © 41321-0

z Visually inspect the components.

© 41322-0

Installing the glow plugs z Tighten glow plugs (1).

15 Nm 1

1

© 41321-0

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z Tighten charge air pressure switch (1).

20 Nm

1

6 © 41320-0

z Mount the connecting rail (2). z Tighten nuts (1).

2.5 Nm z Connect the battery.

1

1

2

© 41319-0

© 01/2008

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Technical Data Tightening specifications ID no.

Name A13 032 Glow plug on cylinder head A13 033 Connecting rail to glow plug Charge air pressure switch in charge A13 046 air line

Screw type M10 M4 M10

Notes / Remark Locking nut

Value 15 Nm 2.5 Nm 20 Nm

6

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7

Standard tools

Standard tools 7

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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: info@wilbaer.de 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 8011 Hose clip pliers Loosen and fasten hose clips e. g. fuel return pipe

© 39426-1

8024 Assembly pliers Removing valve shaft seals

© 37509-2

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Standard tools 8115 V-belt tension measuring device 150 to 600 N Check V-belt tension

© 35416-3

7 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

8190 Rotation angle disc with solenoid

© 42528-1

© 01/2008

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Standard tools

8198 Pricker Removing rotary shaft lip seal

© 43206-1

7 8200 Counter support Removing the camshaft bearing

© 41162-1

9017 Assembly lever e. g. removing and installing valves

© 37511-2

© 01/2008

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Standard tools 9123 Special bit 25 mm long for safety screw on injection pump toothed gear cap

Š 39435-1

7

Š 01/2008

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8

Special tools

Special tools

8

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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: info@wilbaer.de Web: http://www.deutz-tools.com

8

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Special tools

100170 Connector (in conjunction with compression pressure tester 8005) (in conjunction with clamping claw 100210)

© 39400-1

100210 Clamping claw (in conjunction with adapter 100170)

8

© 41363-0

100220 Connector (in conjunction with compression pressure tester 8005)

© 40400-0

© 01/2008

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Special tools 100400 Dial gauge with fixing wheel Measuring range 0 - 10 mm / 0.01 mm

© 35424-1

8

100750 Measuring device Measuring bar with two shims (in conjunction with 100400 and 100410) Checking valve lag dimension Checking piston projection

© 39402-2

103220 Special pliers for removing the roller tappet

© 43175-0

© 01/2008

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Special tools

110090 Puller (in connection with sliding hammer 150800) Removing fuel injector

© 35433-2

110120 Special pliers Disassembly/assembly for leak fuel pipes

8

© 41369-0

110180 Measuring pin Positioning the fuel injector pump toothed wheel

© 41171-0

© 01/2008

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Special tools 110520 Special wrench Wrench size 16 mm, Removing and installing injection pipes

© 35436-0

8

110540 Extraction tool Pull off injection pump toothed gear

© 41190-0

110700 Socket wrench insert long version

© 43198-2

© 01/2008

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Special tools

110901 Disassembly tool Removing and installing the O-rings

© 45950-1

120690 Puller (in connection with sliding hammer 150800) Removing fuel injector

8

© 45111-0

120900 Support bracket pivoting Clamping cylinder head

© 35438-3

© 01/2008

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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

121420 Assembly sleeves Set of assembly sleeves for valve shaft seal

© 43210-0

121430 Assembly tool Mounting valve shaft seal

© 37614-2

© 01/2008

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Special tools

130300 Universal piston ring pliers Removing and installing the piston rings

© 43021-0

130510 Piston ring compressor Piston diameter 90 mm

8

© 39408-1

142780 Assembly tool Installing crankshaft sealing ring (flywheel side)

© 41168-0

© 01/2008

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Special tools 142790 Assembly tool Installing crankshaft sealing ring (opposite side to flywheel)

© 41169-0

8

143500 Internal extractor Removing the camshaft bearing (in conjunction with holder 8200)

© 41169-0

143860 Disassembly/assembly tool.

Removing and installing main bearing Crankcase

© 41164-1

© 01/2008

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Special tools

143870 Disassembly/assembly tool.

Removing and installing main bearing Main bearing housing

© 41165-1

143890 Assembly tool Installing the camshaft bearing

8

© 41166-2

144180 Fixing pin Fixing the flywheel

© 41163-0

© 01/2008

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Special tools 144190 Counter support Hold crankshaft on the V-belt pulley.

© 41370-0

8

144200 Blocking tool Blocking gear drive

© 41188-0

144240 Blocking tool Blocking flywheel

© 41371-0

© 01/2008

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Special tools

150800 Slide hammer Removing fuel injector

© 35449-2

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

© 01/2008

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Special tools 6067 Assembly block Engine clamping, one-sided

© 35451-2

8

6067 200 Clamping bracket consisting of: 1 clamping holder 6067 201 left, 1 clamping holder 6067 202 right (in conjunction with assembly block 6067) Engine clamping, one-sided

© 41187-0

6068 Engine lifting device Load (2000 kg), 3-point suspension, spindle clamp, cross member, chains and hooks

© 43184-0

© 01/2008

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