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Deutz Engine TCD 2015 Workshop Manual - Job Card Overview

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100% found this document useful (5 votes)

7K views638 pages

Deutz Engine TCD 2015 Workshop Manual - Job Card Overview

Uploaded by

LUKAS

We take content rights seriously. If you suspect this is your content, claim it here.

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Download as PDF, TXT or read online on Scribd

You are on page 1/ 638

TCD 2015 Job card overview

5
5 Job card overview
5.1 Sorted alphabetically

© 06/2006 1/22 8146-001

Job card overview
Sorted alphabetically TCD 2015

© 06/2006 2/22 8146-001

TCD 2015 Job card overview

Activity Job card Maintenance group

Checking and setting fuel injectors W 07-07-05 Fuel system
Checking and setting plunger lift of injection pumps W 07-06-04 Fuel system
Checking axial backlash of crankshaft (crankshaft
W 02-01-04 Drive system
installed)
Checking axial backlash of crankshaft (crankshaft
W 02-01-04 Drive system
removed)
Checking piston overhang W 01-04-09 Cylinder head
Checking the camshaft W 04-05-06 Engine control 5
Checking the compression pressure W 00-02-06 General
Checking the con rod W 02-03-01 Drive system
Checking the crankshaft W 02-01-07 Drive system
Checking the overhang of the cylinder liner W 03-03-08 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 valve guide W 01-06-03 Cylinder head
Checking the valve lag W 01-07-08 Cylinder head
Checking the valves W 01-05-04 Cylinder head
Checking thermostat (removed state) W 09-08-01 Cooling system
Disassembling, assembling and checking the rocker
W 01-02-06 Cylinder head
arm and rocker arm bracket
Dismantling and assembling fuel injector W 07-07-02 Fuel system
Dismantling and assembling genset support W 03-08-03 Crankcase
Grinding the cylinder head sealing surface I 01-04-08 Cylinder head
Installing and removing turning gear W 04-06-03 Engine control
Mounting engine on assembly block and demoun-
W 00-05-01 General
ting
Removing and installing charge air pipe (A-bank) W 06-07-03 Exhaust system / Charging
Removing and installing charge air pipe (B-bank) W 06-07-03 Exhaust system / Charging
Removing and installing connecting pipe W 06-02-05 Exhaust system / Charging
Removing and installing connecting pipe
W 06-02-05 Exhaust system / Charging
(Railway)
Removing and installing coolant pump W 09-07-08 Cooling system
Removing and installing crankcase breather (oil se-
W 03-01-11 Crankcase
parator)
Removing and installing exhaust line (A-bank) W 06-01-05 Exhaust system / Charging
Removing and installing exhaust line (B-bank) W 06-01-05 Exhaust system / Charging
Removing and installing exhaust manifold W 06-01-07 Exhaust system / Charging

© 06/2006 3/22 8146-001

Job card overview TCD 2015

Activity Job card Maintenance group

Removing and installing exhaust manifold (A-bank)
W 06-01-07 Exhaust system / Charging
(Railway)
Removing and installing exhaust manifold (B-bank)
W 06-01-07 Exhaust system / Charging
(Railway)
Removing and installing exhaust pipe (A-bank) W 06-01-06 Exhaust system / Charging
Removing and installing exhaust pipe (B-bank) W 06-01-06 Exhaust system / Charging
Removing and installing flame glow plug W 07-01-02 Fuel system
Removing and installing flame glow plug (Railway) W 07-01-02 Fuel system
5
Removing and installing flywheel W 12-06-01 Other components
Removing and installing fuel pipes W 07-10-06 Fuel system
Removing and installing fuel pipes (flame glow
W 07-01-04 Fuel system
plugs)
Removing and installing fuel pipes (flame glow
W 07-01-04 Fuel system
plugs) (Railway)
Removing and installing fuel pipes
W 07-10-06 Fuel system
(Railway)
Removing and installing fuel pressure holding valve W 07-13-01 Fuel system
Removing and installing fuel pressure holding valve
W 07-13-01 Fuel system
(Railway)
Removing and installing fuel shut-off valve (flame
W 07-01-03 Fuel system
glow plugs)
Removing and installing fuel shut-off valve (flame
W 07-01-03 Fuel system
glow plugs) (Railway)
Removing and installing gear case cover
W 04-04-09 Engine control
(Railway)
Removing and installing genset support W 03-08-01 Crankcase
Removing and installing hydraulic pump drive W 12-08-04 Other components
Removing and installing injection pump camshaft W 04-05-07 Engine control
Removing and installing injection pumps (cylinder
W 07-04-01 Fuel system
A1)
Removing and installing injection pumps (cylinder
W 07-04-01 Fuel system
A2-B3)
Removing and installing lubricating oil pan
W 08-04-07 Lube oil system
(Railway)
Removing and installing oil pressure pick-up W 08-11-09 Lube oil system
Removing and installing oil suction pipe
W 08-04-06 Lube oil system
(Railway)
Removing and installing pressure sensor/tempera-
W 13-08-01 Electrical system
ture sensor (charge air)
Removing and installing pressurestat W 08-11-10 Lube oil system
Removing and installing rear cover W 03-09-01 Crankcase

© 06/2006 4/22 8146-001

TCD 2015 Job card overview

Activity Job card Maintenance group

Removing and installing small end bush I 02-03-03 Drive system
Removing and installing tappets, checking tappet
W 04-02-02 Engine control
bores
Removing and installing temperature transmitter W 07-09-01 Fuel system
Removing and installing temperature transmitter W 09-12-01 Cooling system
Removing and installing the cable harness W 13-01-02 Electrical system
Removing and installing the camshaft W 04-05-05 Engine control
Removing and installing the charge air line W 06-02-03 Exhaust system / Charging 5
Removing and installing the connection housing W 03-09-04 Crankcase
Removing and installing the crankshaft W 02-04-01 Drive system
Removing and installing the cylinder head W 01-04-04 Cylinder head
Removing and installing the cylinder liner W 03-03-02 Crankcase
Removing and installing the fuel injectors W 07-07-01 Fuel system
Removing and installing the fuel supply pump W 07-11-01 Fuel system
Removing and installing the gearcase cover W 04-04-09 Engine control
Removing and installing the generator (V-belt drive) W 13-02-03 Electrical system
Removing and installing the impulse transmitter
W 05-07-03 Speed governing
(camshaft)
Removing and installing the impulse transmitter
W 05-07-01 Speed governing
(crankshaft)
Removing and installing the lubricating oil pan W 08-04-07 Lube oil system
Removing and installing the oil cooler W 08-08-02 Lube oil system
Removing and installing the oil suction pipe W 08-04-06 Lube oil system
Removing and installing the piston and con rod W 02-09-03 Drive system
Removing and installing the piston cooling nozzle W 02-15-01 Drive system
Removing and installing the rocker arm and rocker
W 01-02-02 Cylinder head
arm bracket
Removing and installing the starter W 13-03-02 Electrical system
Removing and installing the valves W 01-05-01 Cylinder head
Removing and installing thermostat W 09-08-02 Cooling system
Removing and installing thermostat housing W 09-08-04 Cooling system
Removing and installing torsional vibration damper W 12-01-04 Other components
Removing and installing turbocharger W 06-06-04 Exhaust system / Charging
Removing and installing turbocharger (A-bank)
W 06-06-04 Exhaust system / Charging
(Railway)
Removing and installing turbocharger (B-bank)
W 06-06-04 Exhaust system / Charging
(Railway)
Removing and installing, testing camshaft bearing W 03-11-01 Crankcase

© 06/2006 5/22 8146-001

Job card overview TCD 2015

Activity Job card Maintenance group

Renewing injection pipes (A-bank) W 07-03-01 Fuel system
Renewing injection pipes (B-bank) W 07-03-01 Fuel system
Renewing the crankshaft sealing ring (flywheel side) W 02-02-02 Drive system
Renewing the crankshaft sealing ring (opposite side
W 02-02-04 Drive system
to flywheel)
Renewing toothed starter flywheel ring W 12-06-03 Other components
Renewing valve guide (oversize, pressed version) I 01-06-04 Cylinder head
5 Repairing the collar rest of the cylinder liner I 03-10-05 Drive system
Replacing valve seat insert (oversize) I 01-07-09 Cylinder head
Setting valve clearance W 01-01-01 Cylinder head
Testing the cylinder liner W 03-03-01 Crankcase

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Job card overview
TCD 2015 Sorted numerically

5
5.2 Sorted numerically

© 06/2006 7/22 8146-001

Job card overview
Sorted numerically TCD 2015

© 06/2006 8/22 8146-001

TCD 2015 Job card overview

Job card Activity Maintenance group

I 01-04-08 Grinding the cylinder head sealing surface Cylinder head
I 01-06-04 Renewing valve guide (oversize, pressed version) Cylinder head
I 01-07-09 Replacing valve seat insert (oversize) Cylinder head
I 02-03-03 Removing and installing small end bush Drive system
I 03-10-05 Repairing the collar rest of the cylinder liner Drive system
W 00-02-06 Checking the compression pressure General

W 00-05-01
Mounting engine on assembly block and demoun-
General 5
ting
W 01-01-01 Setting valve clearance Cylinder head
Removing and installing the rocker arm and rocker
W 01-02-02 Cylinder head
arm bracket
Disassembling, assembling and checking the rocker
W 01-02-06 Cylinder head
arm and rocker arm bracket
W 01-04-04 Removing and installing the cylinder head Cylinder head
W 01-04-09 Checking piston overhang Cylinder head
W 01-05-01 Removing and installing the valves Cylinder head
W 01-05-04 Checking the valves Cylinder head
W 01-06-03 Checking the valve guide Cylinder head
W 01-07-08 Checking the valve lag Cylinder head
Checking axial backlash of crankshaft (crankshaft
W 02-01-04 Drive system
removed)
Checking axial backlash of crankshaft (crankshaft
W 02-01-04 Drive system
installed)
W 02-01-07 Checking the crankshaft Drive system
W 02-02-02 Renewing the crankshaft sealing ring (flywheel side) Drive system
Renewing the crankshaft sealing ring (opposite side
W 02-02-04 Drive system
to flywheel)
W 02-03-01 Checking the con rod Drive system
W 02-04-01 Removing and installing the crankshaft Drive system
W 02-09-03 Removing and installing the piston and con rod Drive system
W 02-09-07 Checking the piston Drive system
W 02-10-03 Checking the piston rings and piston ring grooves Drive system
W 02-15-01 Removing and installing the piston cooling nozzle Drive system
Removing and installing crankcase breather (oil se-
W 03-01-11 Crankcase
parator)
W 03-03-01 Testing the cylinder liner Crankcase
W 03-03-02 Removing and installing the cylinder liner Crankcase
W 03-03-08 Checking the overhang of the cylinder liner Crankcase

© 06/2006 9/22 8146-001

Job card overview TCD 2015

Job card Activity Maintenance group

W 03-08-01 Removing and installing genset support Crankcase
W 03-08-03 Dismantling and assembling genset support Crankcase
W 03-09-01 Removing and installing rear cover Crankcase
W 03-09-04 Removing and installing the connection housing Crankcase
W 03-11-01 Removing and installing, testing camshaft bearing Crankcase
Removing and installing tappets, checking tappet
W 04-02-02 Engine control
bores
5 W 04-04-09 Removing and installing the gearcase cover Engine control
Removing and installing gear case cover
W 04-04-09 Engine control
(Railway)
W 04-05-05 Removing and installing the camshaft Engine control
W 04-05-06 Checking the camshaft Engine control
W 04-05-07 Removing and installing injection pump camshaft Engine control
W 04-06-03 Installing and removing turning gear Engine control
Removing and installing the impulse transmitter
W 05-07-01 Speed governing
(crankshaft)
Removing and installing the impulse transmitter
W 05-07-03 Speed governing
(camshaft)
W 06-01-05 Removing and installing exhaust line (A-bank) Exhaust system / Charging
W 06-01-05 Removing and installing exhaust line (B-bank) Exhaust system / Charging
W 06-01-06 Removing and installing exhaust pipe (A-bank) Exhaust system / Charging
W 06-01-06 Removing and installing exhaust pipe (B-bank) Exhaust system / Charging
W 06-01-07 Removing and installing exhaust manifold Exhaust system / Charging
Removing and installing exhaust manifold (A-bank)
W 06-01-07 Exhaust system / Charging
(Railway)
Removing and installing exhaust manifold (B-bank)
W 06-01-07 Exhaust system / Charging
(Railway)
W 06-02-03 Removing and installing the charge air line Exhaust system / Charging
W 06-02-05 Removing and installing connecting pipe Exhaust system / Charging
Removing and installing connecting pipe
W 06-02-05 Exhaust system / Charging
(Railway)
W 06-06-04 Removing and installing turbocharger Exhaust system / Charging
Removing and installing turbocharger (A-bank)
W 06-06-04 Exhaust system / Charging
(Railway)
Removing and installing turbocharger (B-bank)
W 06-06-04 Exhaust system / Charging
(Railway)
W 06-07-03 Removing and installing charge air pipe (A-bank) Exhaust system / Charging
W 06-07-03 Removing and installing charge air pipe (B-bank) Exhaust system / Charging
W 07-01-02 Removing and installing flame glow plug Fuel system

© 06/2006 10/22 8146-001

TCD 2015 Job card overview

Job card Activity Maintenance group

W 07-01-02 Removing and installing flame glow plug (Railway) Fuel system
Removing and installing fuel shut-off valve (flame
W 07-01-03 Fuel system
glow plugs)
Removing and installing fuel shut-off valve (flame
W 07-01-03 Fuel system
glow plugs) (Railway)
Removing and installing fuel pipes (flame glow
W 07-01-04 Fuel system
plugs)
Removing and installing fuel pipes (flame glow
W 07-01-04 Fuel system
plugs) (Railway) 5
W 07-03-01 Renewing injection pipes (A-bank) Fuel system
W 07-03-01 Renewing injection pipes (B-bank) Fuel system
Removing and installing injection pumps (cylinder
W 07-04-01 Fuel system
A1)
Removing and installing injection pumps (cylinder
W 07-04-01 Fuel system
A2-B3)
W 07-06-04 Checking and setting plunger lift of injection pumps Fuel system
W 07-07-01 Removing and installing the fuel injectors Fuel system
W 07-07-02 Dismantling and assembling fuel injector Fuel system
W 07-07-05 Checking and setting fuel injectors Fuel system
W 07-09-01 Removing and installing temperature transmitter Fuel system
W 07-10-06 Removing and installing fuel pipes Fuel system
Removing and installing fuel pipes
W 07-10-06 Fuel system
(Railway)
W 07-11-01 Removing and installing the fuel supply pump Fuel system
W 07-13-01 Removing and installing fuel pressure holding valve Fuel system
Removing and installing fuel pressure holding valve
W 07-13-01 Fuel system
(Railway)
W 08-04-06 Removing and installing the oil suction pipe Lube oil system
Removing and installing oil suction pipe
W 08-04-06 Lube oil system
(Railway)
W 08-04-07 Removing and installing the lubricating oil pan Lube oil system
Removing and installing lubricating oil pan
W 08-04-07 Lube oil system
(Railway)
W 08-08-02 Removing and installing the oil cooler Lube oil system
W 08-11-09 Removing and installing oil pressure pick-up Lube oil system
W 08-11-10 Removing and installing pressurestat Lube oil system
W 09-07-08 Removing and installing coolant pump Cooling system
W 09-08-01 Checking thermostat (removed state) Cooling system
W 09-08-02 Removing and installing thermostat Cooling system

© 06/2006 11/22 8146-001

Job card overview TCD 2015

Job card Activity Maintenance group

W 09-08-04 Removing and installing thermostat housing Cooling system
W 09-12-01 Removing and installing temperature transmitter Cooling system
W 12-01-04 Removing and installing torsional vibration damper Other components
W 12-06-01 Removing and installing flywheel Other components
W 12-06-03 Renewing toothed starter flywheel ring Other components
W 12-08-04 Removing and installing hydraulic pump drive Other components
W 13-01-02 Removing and installing the cable harness Electrical system
5 W 13-02-03 Removing and installing the generator (V-belt drive) Electrical system
W 13-03-02 Removing and installing the starter Electrical system
Removing and installing pressure sensor/tempera-
W 13-08-01 Electrical system
ture sensor (charge air)

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Job card overview
TCD 2015 Job card references

5
5.3 Job card references

© 06/2006 13/22 8146-001

Job card overview
Job card references TCD 2015

© 06/2006 14/22 8146-001

TCD 2015 Job card overview

00 General
Job card Activity and additional job cards necessary for its execution
Checking the compression pressure
W 00-02-06
W 01-01-01 W 07-07-01
Mounting engine on assembly block and demounting
W 00-05-01
W 13-02-03

01 Cylinder head 5
Job card Activity and additional job cards necessary for its execution
Setting valve clearance
W 01-01-01
W 04-06-03
Removing and installing the rocker arm and rocker arm bracket
W 01-02-02 W 07-03-01 W 07-03-01
W 01-01-01 W 04-06-03
(A-bank) (B-bank)
Disassembling, assembling and checking the rocker arm and rocker arm bracket
W 01-02-06
W 01-02-02
Removing and installing the cylinder head
W 06-01-05 W 06-01-05 W 06-07-03
W 01-02-02 W 01-04-09
W 01-04-04 (A-bank) (B-bank) (A-bank)
W 06-07-03
W 07-07-01
(B-bank)
Grinding the cylinder head sealing surface
I 01-04-08
W 01-05-01
Checking piston overhang
W 01-04-09
W 01-04-04 W 04-06-03
Removing and installing the valves
W 01-05-01
W 01-04-04
Checking the valves
W 01-05-04
W 01-05-01
Checking the valve guide
W 01-06-03
W 01-05-01
Renewing valve guide (oversize, pressed version)
I 01-06-04
W 01-05-01 W 01-06-03
Checking the valve lag
W 01-07-08
W 01-04-04
Replacing valve seat insert (oversize)
I 01-07-09
W 01-05-01 W 01-07-08

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Job card overview TCD 2015

02 Drive system
Job card Activity and additional job cards necessary for its execution
Checking axial backlash of crankshaft (crankshaft removed)
W 02-01-04
W 02-04-01
Checking axial backlash of crankshaft (crankshaft installed)
W 02-01-04
W 03-08-01 W 03-09-01
Checking the crankshaft
W 02-01-07
5 W 02-04-01
Renewing the crankshaft sealing ring (flywheel side)
W 02-02-02
W 12-06-01
Renewing the crankshaft sealing ring (opposite side to flywheel)
W 02-02-04

Checking the con rod

W 02-03-01
W 02-09-03
Removing and installing small end bush
I 02-03-03

Removing and installing the crankshaft

W 02-04-01
W 02-01-04 W 02-01-07 W 03-08-01 W 03-09-01 W 07-07-01
Removing and installing the piston and con rod
W 02-09-03 W 08-04-06
W 01-04-04 W 02-10-03 W 08-04-06
(Railway)
Checking the piston
W 02-09-07
W 02-09-03
Checking the piston rings and piston ring grooves
W 02-10-03
W 02-09-03
Removing and installing the piston cooling nozzle
W 02-15-01
W 02-09-03

03 Crankcase
Job card Activity and additional job cards necessary for its execution
Removing and installing crankcase breather (oil separator)
W 03-01-11

Testing the cylinder liner

W 03-03-01
W 03-03-02
Removing and installing the cylinder liner
W 03-03-02
W 02-09-03 W 03-03-01 W 03-03-08

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TCD 2015 Job card overview

03 Crankcase (continuation)
Job card Activity and additional job cards necessary for its execution
Checking the overhang of the cylinder liner
W 03-03-08
W 01-04-04
Removing and installing genset support
W 06-07-03 W 06-07-03
W 03-08-01 W 02-02-04 W 08-04-06 W 09-07-08
(A-bank) (B-bank)
W 09-08-04

W 03-08-03
Dismantling and assembling genset support 5
W 03-08-01
Removing and installing rear cover
W 03-09-01
W 02-02-02 W 03-09-04 W 08-04-07
Removing and installing the connection housing
W 03-09-04
W 05-07-01 W 06-01-07 W 12-06-01 W 13-03-02
Repairing the collar rest of the cylinder liner
I 03-10-05
W 03-03-02
Removing and installing, testing camshaft bearing
W 03-11-01
W 04-05-05

04 Engine control
Job card Activity and additional job cards necessary for its execution
Removing and installing tappets, checking tappet bores
W 04-02-02
W 04-05-05
Removing and installing the gearcase cover
W 04-04-09
W 06-06-04
Removing and installing gear case cover
(Railway)
W 04-04-09
W 07-13-01
(Railway)
Removing and installing the camshaft
W 01-02-02 W 02-04-01 W 04-05-06 W 05-07-03 W 06-06-04
W 04-05-05
W 07-04-01 W 07-04-01
W 07-06-04
(cylinder A1) (cylinder A2-B3)
Checking the camshaft
W 04-05-06
W 04-05-05
Removing and installing injection pump camshaft
W 01-02-02 W 02-02-02 W 03-08-01 W 03-09-04 W 04-06-03
W 04-05-07
W 07-04-01 W 07-04-01
W 05-07-03 W 06-06-04 W 07-06-04
(cylinder A1) (cylinder A2-B3)

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Job card overview TCD 2015

04 Engine control (continuation)

Job card Activity and additional job cards necessary for its execution
Installing and removing turning gear
W 04-06-03

05 Speed governing
Job card Activity and additional job cards necessary for its execution
Removing and installing the impulse transmitter (crankshaft)
5 W 05-07-01
W 04-06-03
Removing and installing the impulse transmitter (camshaft)
W 05-07-03
W 04-06-03 W 06-06-04

06 Exhaust system / Charging

Job card Activity and additional job cards necessary for its execution
Removing and installing exhaust line (A-bank)
W 06-01-05 W 06-01-06
(A-bank)
Removing and installing exhaust line (B-bank)
W 06-01-05 W 06-01-06
(B-bank)
Removing and installing exhaust pipe (A-bank)
W 06-01-06

Removing and installing exhaust pipe (B-bank)

W 06-01-06

Removing and installing exhaust manifold

W 06-01-07 W 06-01-06 W 06-01-06
W 06-06-04
(A-bank) (B-bank)
Removing and installing exhaust manifold (A-bank)
(Railway)
W 06-01-07
W 06-06-04
(A-bank)
Removing and installing exhaust manifold (B-bank)
(Railway)
W 06-01-07
W 06-06-04
(B-bank)
Removing and installing the charge air line
W 06-02-03

Removing and installing connecting pipe

W 06-02-05
W 07-01-04

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TCD 2015 Job card overview

06 Exhaust system / Charging (continuation)

Job card Activity and additional job cards necessary for its execution
Removing and installing connecting pipe
(Railway)
W 06-02-05
W 07-01-04
(Railway)
Removing and installing the turbocharger
W 06-06-04
W 06-02-03
Removing and installing turbocharger (A-bank)
W 06-06-04 (Railway) 5

Removing and installing turbocharger (B-bank)

W 06-06-04 (Railway)

Removing and installing charge air pipe (A-bank)

W 06-07-03 W 07-03-01
W 03-01-11 W 06-02-05
(A-bank)
Removing and installing charge air pipe (B-bank)
W 06-07-03
(B-bank) W 07-03-01
W 06-02-05
(B-bank)

07 Fuel system
Job card Activity and additional job cards necessary for its execution
Removing and installing flame glow plug
W 07-01-02
W 07-01-04
Removing and installing flame glow plug (Railway)
W 07-01-02 W 07-01-04
(Railway)
Removing and installing fuel shut-off valve (flame glow plugs)
W 07-01-03

Removing and installing fuel shut-off valve (flame glow plugs) (Railway)
W 07-01-03

Removing and installing fuel pipes (flame glow plugs)

W 07-01-04
W 06-02-03
Removing and installing fuel pipes (flame glow plugs) (Railway)
W 07-01-04

Renewing injection pipes (A-bank)

W 07-03-01

© 06/2006 19/22 8146-001

Job card overview TCD 2015

07 Fuel system (continuation)

Job card Activity and additional job cards necessary for its execution
Renewing injection pipes (B-bank)
W 07-03-01
W 06-02-03
Removing and installing injection pumps (cylinder A1)
W 07-04-01 W 06-07-03 W 07-10-06
W 04-06-03 W 07-10-06
(A-bank) (Railway)
Removing and installing injection pumps (cylinder A2-B3)

5 W 03-01-11 W 04-06-03
W 07-03-01 W 07-03-01
W 07-10-06
W 07-04-01 (A-bank) (B-bank)
W 07-10-06
(Railway)
Checking and setting plunger lift of injection pumps
W 06-06-04 W 06-06-04
W 07-04-01
W 04-06-03 W 06-06-04 (A-bank) (B-bank)
W 07-06-04 (cylinder A1)
(Railway) (Railway)
W 07-04-01
(cylinder A2-B3)
Removing and installing the fuel injectors
W 07-07-01 W 07-03-01 W 07-03-01
W 07-07-05
(A-bank) (B-bank)
Dismantling and assembling fuel injector
W 07-07-02
W 07-07-01 W 07-07-05
Checking and setting fuel injectors
W 07-07-05
W 07-07-01 W 07-07-02
Removing and installing temperature transmitter
W 07-09-01 W 06-07-03
(B-bank)
Removing and installing fuel pipes
W 07-10-06 W 06-07-03 W 06-07-03
(A-bank) (B-bank)
Removing and installing fuel pipes
W 07-10-06 (Railway)

Removing and installing the fuel supply pump

W 07-11-01

Removing and installing fuel pressure holding valve

W 07-13-01 W 06-07-03
(A-bank)

© 06/2006 20/22 8146-001

TCD 2015 Job card overview

07 Fuel system (continuation)

Job card Activity and additional job cards necessary for its execution
Removing and installing fuel pressure holding valve
W 07-13-01 (Railway)

08 Lube oil system

Job card Activity and additional job cards necessary for its execution
Removing and installing the oil suction pipe 5
W 08-04-06
W 08-04-07
Removing and installing oil suction pipe
(Railway)
W 08-04-06
W 08-04-07
(Railway)
Removing and installing the lubricating oil pan
W 08-04-07
W 13-03-02
Removing and installing lubricating oil pan
W 08-04-07 (Railway)

Removing and installing the oil cooler

W 08-08-02 W 06-07-03
W 09-08-04
(A-bank)
Removing and installing oil pressure pick-up
W 08-11-09

Removing and installing pressurestat

W 08-11-10 W 06-07-03
W 03-01-11
(B-bank)

09 Cooling system
Job card Activity and additional job cards necessary for its execution
Removing and installing coolant pump
W 09-07-08

Checking thermostat (removed state)

W 09-08-01
W 09-08-02
Removing and installing thermostat
W 09-08-02
W 09-08-01 W 09-08-04
Removing and installing thermostat housing
W 09-08-04
W 07-01-04

© 06/2006 21/22 8146-001

Job card overview TCD 2015

09 Cooling system (continuation)

Job card Activity and additional job cards necessary for its execution
Removing and installing temperature transmitter
W 09-12-01

12 Other components
Job card Activity and additional job cards necessary for its execution
Removing and installing torsional vibration damper
5 W 12-01-04

Removing and installing flywheel

W 12-06-01

Renewing toothed starter flywheel ring

W 12-06-03
W 12-06-01
Removing and installing hydraulic pump drive
W 12-08-04 W 06-01-06
(A-bank)

13 Electrical system
Job card Activity and additional job cards necessary for its execution
Removing and installing the cable harness
W 13-01-02
W 06-02-03
Removing and installing the generator (V-belt drive)
W 13-02-03

Removing and installing the starter

W 13-03-02

Removing and installing pressure sensor/temperature sensor (charge air)

W 13-08-01

© 06/2006 22/22 8146-001

DEUTZ engines Job cards

6 Job cards
6

© 11/2005 1/2 8147-001

Job cards DEUTZ engines

© 11/2005 2/2 8147-001

General
TCD 2015 W 00-02-06

Checking the compression pressure

Commercial available tools: – W 01-01-01
– Compression pressure – W 07-07-01
tester. . . . . . . . . . . . . . . . . . . . . . . . 8005
Special tools:
– Connector . . . . . . . . . . . . . . . . . . 100130
– Grooved nut wrench . . . . . . . . . . 110130

Checking the compression pressure

z Check and set valve clearance.
W 01-01-01
z Removing fuel injectors.
W 07-07-01 2
z Mount sealing ring (1).
Use sealing ring (1) for fuel injector.

z Insert connector (2). 1

z Tighten union screw with grooved nut wrench.

A07 001

© 06/2006 1/4 8148-001

General
W 00-02-06 TCD 2015

z Connect adapter (1) to connector.

6
© 40641-0

z Mount the compression tester on the adapter.

z Turn over engine with starter.
P00 51

The measured compression pressure

depends on the starting speed during the
measuring process and the altitude of the No.
engine installation site. Therefore, limit Kompression in bar
Compression value in bar
values cannot be determined exactly. The Pression en bar
compression pressure measurement is Dat. _________
10 15 20 25 30 35 40
only recommended as a reference measu-
Zyl.

rement of all cylinders of an engine to each

other. If more than 15% deviation has been 1
determined, the cause should be determi- 2
ned by disassembling the cylinder unit con- 3
cerned. 4
5
6
7
8
DBGM Made in Germany
MOTOMETER
© 33771-5

© 06/2006 2/4 8148-001

General
TCD 2015 W 00-02-06

z Remove the compression pressure tester.

z Remove adapter (1).
1

6
© 40641-0

z Unscrew union screw with grooved nut wrench.

z Remove connector (2).

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

© 06/2006 3/4 8148-001

General
W 00-02-06 TCD 2015

© 06/2006 4/4 8148-001

General
TCD 2015 W 00-05-01

Mounting engine on assembly block and demounting

Commercial available tools: – W 13-02-03
– Lifting gear
– Suspension ropes
Special tools: Different customer scopes are not taken
– Assembly block incl. adap- into account in the repair sequence shown
ter plates . . . . . . . . . . . . . . . . . . . . . 6066 here, accessories which deviate from the
– Clamping bracket . . . . . . . . . . .6066/151 standard equipment are not shown.

Mounting engine on assembly block

z Remove generator.
W 13-02-03
z Unscrew screws (1). 1
z Remove heat shield (2). 2

z Screw in eyelet bolts (1).

z Hang engine on workshop crane.

1 1

© 06/2006 1/6 8149-001

General
W 00-05-01 TCD 2015

z Unscrew all screws (1).

z Remove all mounting feet (2).

6
© 40652-0

z Mount all clamping brackets (1).

z Tighten screws (2).
A00 001

2 2

1 1

2 2

z Unscrew screws (1).

z Remove all mounting feet (2).

1
1

© 06/2006 2/6 8149-001

General
TCD 2015 W 00-05-01

z Insert engine in engine block.

z Mount clamping bracket on the adapter plates.
z Align all clamping brackets (1) on the adapter
plates (2) of the assembly block.
z Tighten screws .
A00 002 1

2
6
© 40649-0

z Align engine on engine block.

z Unhook the engine from the workshop crane.

Demounting engine from assembly block

z Hang engine on workshop crane.
z Remove screws.
z Remove all clamping brackets (1) from the adapter
plates (2).
z Lift engine off the assembly block. 1

© 06/2006 3/6 8149-001

General
W 00-05-01 TCD 2015

z Mount all mounting feet (1).

z Tighten screws (2). 1
A00 003

2 2

6
© 40991-0

z Unscrew screws (2).

z Remove all clamping brackets (1).

2 2

1 1

2 2

z Mount all mounting feet (2).

z Tighten all screws (1).
A00 003 1

© 06/2006 4/6 8149-001

General
TCD 2015 W 00-05-01

z Set down engine.

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

6
© 40645-0

z Mount heat shield (2).

z Tighten screws (1).
A13 006
z Install generator. 1
W 13-02-03 2

© 06/2006 5/6 8149-001

General
W 00-05-01 TCD 2015

© 06/2006 6/6 8149-001

Cylinder head
TCD 2015 W 01-01-01

Setting valve clearance

Commercial available tools: – W 04-06-03
– Rotation angle disc . . . . . . . . . . . . . 8190
– Screwdriver insert for slot-
ted screws. . . . . . . . . . . . . . . . . . . . 8191 Allow the engine to cool down for at least
– Open wrench size 13 . . . . . . . . . . . 8196 30 minutes before setting the valve clea-
rance. Engine oil temperature < 80 °C
– Locking agent
DEUTZ DW 59 The following work process describes set-
ting of the valve clearance on an exhaust
valve. The setting procedure for an inlet
valve is analogous under consideration of
the specified rotation angle size.

z Unscrew screws (1).

z Remove cylinder head cover (2).
z Remove gasket.
z Attach turning gear.
W 04-06-03
2

1 1

Setting engine to valve overlap

z Turn crankshaft using the turning gear until the valve
overlap of cylinder A1 is reached.
T01 63

© 06/2006 1/4 8150-001

Cylinder head
W 01-01-01 TCD 2015

Valve overlap means:

The inlet valve starts opening,exhaust
valve closes.

6
© 40629-0

Arrangement of the inlet and exhaust val-

ves.
IN = inlet valve
EX = exhaust valve

IN IN

EX EX

Setting valve clearance

z Loosen lock nut (1).
z Press in the adjusting screw (2) to the stop.

© 06/2006 2/4 8150-001

Cylinder head
TCD 2015 W 01-01-01

z Set the rotation angle disc with a screwdriver insert

at the adjusting screw.
z Fix magnet of rotation angle disc on cylinder head.
z Set rotation angle disc to "0".
Do not rotate adjusting screw.

P01 61
P01 62

6
© 40632_1

z Turn the adjusting screw in the direction of the arrow.

P01 62

z Tighten lock nut (1) with open wrench.

A01 003
Do not rotate adjusting screw.

z Remove rotation angle disc.

Set all other valves according to the valve
setting schematic T01 63.

© 06/2006 3/4 8150-001

Cylinder head
W 01-01-01 TCD 2015

z Clean sealing surfaces.

z Mount new gasket (1).
Note installation position. 1
Position gasket over the profile washer (2).

6
© 40802-0

z Mount cylinder head cover.

Profile washer (1) may not be trapped
underneath the sealing surface (2) of the 2
cylinder head cover. 1

z Lightly oil screws (1).

z Tighten screws (1).
A01 005
z Remove turning gear.
W 04-06-03

1 1

© 06/2006 4/4 8150-001

Cylinder head
TCD 2015 W 01-02-02

Removing and installing the rocker arm and rocker arm bracket
Commercial available tools: – W 01-01-01
– Feeler gauges – W 04-06-03
– W 07-03-01 . . . . . . . . . . . . (A-bank)
– Locking agent – W 07-03-01 . . . . . . . . . . . . (B-bank)
DEUTZ DW 59

Removing the rocker arm and rocker arm

bracket
z Removing high pressure pipes (A-bank). 1 1
W 07-03-01
z Removing high pressure pipes (B-bank). 2

W 07-03-01
z Unscrew screws (1).
z Remove cylinder head cowling (2).
z Remove gasket.

1
© 42215-1

z Unscrew screws (arrows).

Loosen screws evenly to avoid tension on
the rocker arm brackets. 1

z Remove rocker arms (1), (2) and rocker arm

brackets (3) together.
3
Lay out components in the order in which
they should be installed. 3 2

© 06/2006 1/6 8151-001

Cylinder head
W 01-02-02 TCD 2015

z Remove push rods (1).

Lay out components in the order in which
they should be installed. 1

6
© 42219-1

z Visually inspect the components.

Installing the rocker arm and rocker arm

bracket
1
z Insert stop rods (1).
Note assignment!

© 06/2006 2/6 8151-001

Cylinder head
TCD 2015 W 01-02-02

The pushrod must be seated with the ball

head in the ladle of the tappet.

z Attach turning gear.

W 04-06-03

6
© 40490-0

z Turn crankshaft until reaching the base circle posi-

tion of inlet and exhaust cams of the respective cylin-
der.
z Mount rocker arm bracket.
Attention! 2
The longer side (1) must point upwards.

The ball heads (2) must be seated in the

ladles of the pushrods . 1

z Align rocker arm to the pushrods/valves.

z Tighten screws (1) alternately.

1 1

© 06/2006 3/6 8151-001

Cylinder head
W 01-02-02 TCD 2015

Checking axial backlash of the rocker arm

z Measure the axial backlash between the rocker arm
bracket (1) and rocker arm (2) with a feeler gauge.
P01 75 1
The rocker arm (2) is on the opposite side
on the rocker arm bracket (3).
The setting is made by moving the rocker 3
arm brackets.

6
© 42221-1

z Tighten screws (1) alternately.

A01 002
z Check and set valve clearance.
W 01-01-01
1
1

z Clean sealing surfaces.

z Mount new gasket. 1
z Mount cylinder head cover.
z Fasten screws. 2
2
Screw length:
M8 x 80 mm (1)
M8 x 70 mm (2)
M8 x 30 mm (3)

3
© 42216-1

© 06/2006 4/6 8151-001

Cylinder head
TCD 2015 W 01-02-02

z Tighten screws .
A01 004
z Installing high pressure pipes (A-bank)
W 07-03-01
z Installing high pressure pipes (B-bank)
W 07-03-01
z Remove turning gear.
W 04-06-03

6
© 42223-1

© 06/2006 5/6 8151-001

Cylinder head
W 01-02-02 TCD 2015

© 06/2006 6/6 8151-001

Cylinder head
TCD 2015 W 01-02-06

Disassembling, assembling and checking the rocker arm and rocker arm
bracket
Commercial available tools: – W 01-02-02
– Internal measuring device
– Micrometer gauge
Special tools:
– Dial gauge. . . . . . . . . . . . . . . . . . 100400
– Disassembly/assembly
tool . . . . . . . . . . . . . . . . . . . . . . . 170120

Disassembling the rocker arm bracket

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

Checking rocker arm (inlet valves)

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 to the reversal point of the pointer to
"0".

© 06/2006 1/6 8152-001

Cylinder head
W 01-02-06 TCD 2015

z Measure rocker arm bore.

P01 73
When the wear limit is reached the rocker
arm must be renewed.

6
© 34825-2

z Visually inspect the components.

z Check ball stud (1) and adjusting screws (2) for
1
wear.
The components must be renewed in case
of excessive wear.

z Check oil channel (3) for free passage.

3
2

Renewing ball stud

z Place disassembly/assembly tool (1) underneath.
z Press out ball stud.

© 06/2006 2/6 8152-001

Cylinder head
TCD 2015 W 01-02-06

z Mount new ball stud (1).

Notch (2) faces vertically to the rocker arm
shaft.

6
© 34828_3

z Place disassembly/assembly tool underneath.

z Press in ball stud (1).
z Check oil channel for free passage.

Checking rocker arm (exhaust valves)

z Measure rocker arm bore.
P01 72
When the wear limit is reached the rocker
arm must be renewed.

© 06/2006 3/6 8152-001

Cylinder head
W 01-02-06 TCD 2015

z Visually inspect the components.

z Check ball stud (1) and adjusting screws (2) for 1
wear.
The components must be renewed in case
of excessive wear.

2
6
© 36750-1

Renewing ball stud

z Place disassembly/assembly tool (1) underneath.
z Press out ball stud.

z Place disassembly/assembly tool (1) underneath.

z Press in new ball stud (2).

© 06/2006 4/6 8152-001

Cylinder head
TCD 2015 W 01-02-06

Checking rocker arm shaft

z Measure diameter with micrometer gauge.
P01 74
When the wear limit is reached the rocker
arm shaft must be renewed.

z Check oil channels for free passage.

6
© 34834-2

Assembling the rocker arm bracket

z Push rocker arm onto rocker arm shaft.
1
The oil bores (1) must face upwards and
the recess clearances (2) for the screws of
the rocker arm brackets to the adjusting
screws.

z Push rocker arm brackets onto rocker arm shaft.

Attention!
The longer side (1) must point upwards.
The clamping grooves (2) must face the
adjusting screws (3) .
1

2 3

© 06/2006 5/6 8152-001

Cylinder head
W 01-02-06 TCD 2015

z Insert all screws (1).

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

6
© 34837_3

© 06/2006 6/6 8152-001

Cylinder head
TCD 2015 I 01-04-08

Grinding the cylinder head sealing surface

Commercial available tools: – W 01-05-01
– Surface milling machine
– Roughness measuring unit
– Depth-measuring The relevant manufacturer’s specifications
appliance must be observed when working with the
surface milling machine.

Prepare cylinder head

z Remove valves.
W 01-05-01
z Deburr the upper face of the cylinder head.
The upper face of the cylinder head must
be burr-free and free of gasket remains to
guarantee correct clamping of the cylinder
head.

Grinding cylinder head surface

z Clamp cylinder head on surface milling machine.
z Align cylinder head.
z Align tool of the surface milling machine with the cyl-
inder head.

© 06/2006 1/4 8153-001

Cylinder head
I 01-04-08 TCD 2015

z Grind cylinder head sealing surface.

z Check the cylinder head sealing surface.
If the cylinder head sealing surface is not
level, recognisable from differences in
colour of the machined surface, the sur-
face must be reground.
The adjustment range of the tool is a
maximum 0.2 mm per grind.

6
© 39759-1

Checking the cylinder head sealing sur-

face
z Visually inspect the cylinder head sealing surface.
z Visually inspect the combustion chamber surface.
z Measure the roughness of the cylinder head sealing
surface with the roughness measuring instrument.
P01 93
If the measured value is out of tolerance,
the cylinder head sealing surface must be
remachined with different setting data for
the surface milling machine.

z Measure cylinder head height with depth measuring

appliance.
P01 08
P01 09
When the wear limit is reached, the cylin-
der head must be renewed.

© 06/2006 2/4 8153-001

Cylinder head
TCD 2015 I 01-04-08

z Remove cylinder head from the surface milling ma-

chine.

6
© 39758-1

z Attach the repair date and company logo to the cylin-

der head.
Attention!
Do not mark identification on a sealing sur-
face.

Mark the cylinder head after every repair.

z Install valves.
W 01-05-01

© 06/2006 3/4 8153-001

Cylinder head
I 01-04-08 TCD 2015

© 06/2006 4/4 8153-001

Cylinder head
TCD 2015 W 01-04-04

Removing and installing cylinder head

Commercial available tools: – W 01-02-02
– Socket wrench insert . . . . . . . . . . . 8016 – W 01-04-09
– Rotation angle disc . . . . . . . . . . . . . 8190 – W 06-01-05 . . . . . . . . . . . . (A-bank)
– W 06-01-05 . . . . . . . . . . . . (B-bank)
– W 06-07-03 . . . . . . . . . . . . (A-bank)
– W 06-07-03 . . . . . . . . . . . . (B-bank)
– W 07-07-01

Removing the cylinder head

z Remove charge air pipe (A-bank).
W 06-07-03
z Remove charge air pipe (B-bank).
W 06-07-03
z Remove exhaust line (A-bank)
W 06-01-05
z Remove exhaust pipe (B-bank)
W 06-01-05

z Remove rocker arm and rocker arm bracket.

W 01-02-02
z Removing fuel injectors.
W 07-07-01
Lay out components in the order in which
they should be installed.

© 06/2006 1/4 8154-001

Cylinder head
W 01-04-04 TCD 2015

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

z Remove cylinder head.
z Remove gasket.
z Visually inspect the components. 1

1
6
© 42235-1

Installing the cylinder head

z Check piston overhang.
W 01-04-09
Determine the cylinder head gasket sepa-
rately for every cylinder.

z Select new cylinder head gasket according to meas-

ured piston overhang.
P02 75
P02 76
P02 77
Example: Piston overhang = 0.05 mm, cor-
responds to cylinder head gasket with
1 hole (arrow).

© 06/2006 2/4 8154-001

Cylinder head
TCD 2015 W 01-04-04

z Clean sealing surfaces.

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
© 45812_1

z Fit cylinder head.

z Oil the cylinder head screws slightly.
Attention!
Screws can be reused a maximum 3 times
with written documentation.
z Fasten screws.

z Tighten screws alternately with rotation angle disc

and socket wrench insert.
A01 001

© 06/2006 3/4 8154-001

Cylinder head
W 01-04-04 TCD 2015

z Install rocker arm and rocker arm bracket.

W 01-02-02
z Install fuel injectors.
W 07-07-01
z Install charge air pipe (A-bank)
W 06-07-03
z Install charge air pipe (B-bank)
W 06-07-03
z Install exhaust pipe (A-bank)
W 06-01-05

6 z Install exhaust pipe (B-bank)

W 06-01-05
© 40583-0

© 06/2006 4/4 8154-001

Cylinder head
TCD 2015 W 01-04-09

Checking piston overhang

Commercial available tools: – W 01-04-04
8190

– Magnetic measuring stand – W 04-06-03

Special tools:
– Dial gauge. . . . . . . . . . . . . . . . . . 100400
– Measuring instrument with
measuring plate . . . . . . . . . . . . . 100850

Checking piston overhang

z Remove cylinder head.
W 01-04-04
z Insert screws and washers (1) diagonally opposed.
z Tighten screws until they touch the cylinder liner. 1
Washers:
Maximum thickness 4 mm
Screw length:
M16 x 90

z Attach turning gear.

W 04-06-03
z Turn the crankshaft until the respective piston is just
in front of the top dead centre (arrow).

© 06/2006 1/4 8155-001

Cylinder head
W 01-04-09 TCD 2015

z Make sure the clamping bushings (arrows) are in

place.

6
© 45766-0

z Place measuring instrument (1) on measuring

plate (2). 3
z Insert dial gauges (3) with pre-tension in the measur-
ing instrument.
z Turn the dial until the pointer points to "0".

z Place the measuring instrument over the clamping

bushings (arrows).
z Read off measured value of both dial gauges.
z 1st dial gauge:
– Note measured value, dimension (a).
z 2nd dial gauge:
– Note measured value, dimension (b).

© 06/2006 2/4 8155-001

Cylinder head
TCD 2015 W 01-04-09

z Form and note average value.

Calculation example
Desired: Dimension x (average value of both dial gauges)
Given: -
Measured: Dimension a (measured value 1st dial gauge)
Dimension b (measured value 2nd dial gauge)
Calculation: Dimension x = (dimension a + dimension b) : 2
(0.39 mm + 0.45 mm) : 2
Result: = 0.42 mm

P02 75
P02 76
P02 77
z Remove measuring instrument.
6
© 45767-2

z Unscrew screws (1).

z Remove turning gear.
W 04-06-03
z Install cylinder head.
W 01-04-04 1

© 06/2006 3/4 8155-001

Cylinder head
W 01-04-09 TCD 2015

© 06/2006 4/4 8155-001

Cylinder head
TCD 2015 W 01-05-01

Removing and installing the valves

Commercial available tools: – W 01-04-04
– Slide gauge
– Assembly pliers. . . . . . . . . . . . . . . . 8024
– Assembly lever . . . . . . . . . . . . . . . . 9017
Special tools:
– Support bracket . . . . . . . . . . . . . 120900
– Base plate. . . . . . . . . . . . . . . . . . 120910
– Assembly tool . . . . . . . . . . . . . . . 121410
– Assembly sleeves . . . . . . . . . . . . 121420

Removing the valves

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

z Install assembly lever (1).

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

© 06/2006 1/4 8156-001

Cylinder head
W 01-05-01 TCD 2015

z Disassemble valve stem gasket with assembly plier.

6
© 42336-1

z Clean cylinder head.

z Check cylinder head.
z Visually inspect the components.

Installing the valves

z Measure valve spring length with slide gauge.
P01 51
When the wear limit is reached, the valve
spring must be renewed.

© 06/2006 2/4 8156-001

Cylinder head
TCD 2015 W 01-05-01

z Oil the valve stem lightly.

z Insert and hold valve.
z Push assembly sleeve (2) over the valve V-
grooves (1).

6
© 42334-1

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

z Insert valve spring (1).

z Insert valve spring plate (2).
2

© 06/2006 3/4 8156-001

Cylinder head
W 01-05-01 TCD 2015

z Mount assembly lever.

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

6
© 42330-1

z Remove assembly lever.

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

© 06/2006 4/4 8156-001

Cylinder head
TCD 2015 W 01-05-04

Checking the valves

Commercial available tools: – W 01-05-01
– Micrometer gauge
– Slide gauge
Clean valves before testing.
When the wear limit is reached, the valve
must be renewed.

Checking valve stem diameter

z Remove valves.
W 01-05-01
z Measure valve stem diameter with micrometer
gauge.
P01 31
P01 32

Checking valve edge thickness

z Measure valve edge thickness with slide gauge.
P01 35
P01 36

© 06/2006 1/2 8157-001

Cylinder head
W 01-05-04 TCD 2015

Checking valve head diameter

z Measure valve head diameter with slide gauge.
P01 37
P01 38
z Install valves.
W 01-05-01

6
© 42184-1

© 06/2006 2/2 8157-001

Cylinder head
TCD 2015 W 01-06-03

Checking the valve guide

Commercial available tools: – W 01-05-01
– Magnetic measuring stand
Special tools:
– Dial gauge. . . . . . . . . . . . . . . . . . 100400 New valves are used for testing.
When the wear limit is reached, the valve
guide must be renewed.

Checking the valve guide

z Remove valves.
W 01-05-01
z Visually inspect valve guide for wear.

Measure valve stem clearance

z Mount magnetic measuring stand.
z Insert dial gauge.
z Insert new valve.
z Place stylus under pre-tension on the valve
head (arrow).
z Turn the dial until the pointer points to "0".

© 06/2006 1/2 8158-001

Cylinder head
W 01-06-03 TCD 2015

z Move valve back and forth in direction of arrow.

P01 33
P01 34
The valve stem ends must be flush with the
valve guide.
The whole tilt distance must be taken into
account.

6
© 40715-0

z Remove magnetic measuring stand.

z Remove dial gauge.
z Install valves.
W 01-05-01

© 06/2006 2/2 8158-001

Cylinder head
TCD 2015 I 01-06-04

Renewing the valve guide

(oversize, pressed version)
Commercial available tools: – W 01-05-01
– Reamers – W 01-06-03
– Plug gauges
– Cylinder head machining Danger!
tool
– Press Danger of injury, do not touch supercooled
– Press-out pin components or the liquid nitrogen!
– Press-in pin Wear protective gloves and glasses!
– Industrial vacuum cleaner
Attention!
– Nitrogen (liquid) The press-in process must be carried out
without interruption as a result of the tem-
perature difference between the cylinder 6
head and the valve seat insert.
The necessary work steps must be practi-
sed before pressing in.

The relevant manufacturer’s specifications

must be observed when working with the
cylinder head machining tool.

Checking the valve guide

z Check valve guides.
W 01-06-03
z Check valve guide with plug gauge (1).
P01 14 1

P01 15
The target area of the plug gauge must be
able to move upwards and downwards with
light suction.

© 06/2006 1/6 8159-001

Cylinder head
I 01-06-04 TCD 2015

Pressing out valve guide

z Press out valve guide with press-out pin (1).

6
© 39749-1

Check housing bore for valve guide

z Visually inspect housing bore (arrow).
If the housing bore is heavily scored, the
housing bore must be reamed to the next
oversize dimension.

z Check housing bore for valve guide with plug

gauge (1).
P01 05
P01 06
P01 07
1
The target area of the plug gauge must be
able to move upwards and downwards with
light suction.
The no-go limit of the gauge plug must not
fit into the housing bore. If the no-go limit
fits, it must be reamed to the next oversize.
When the wear limit of the 2nd oversize
stage is reached, the cylinder head must
be renewed.
© 39750-1

© 06/2006 2/6 8159-001

Cylinder head
TCD 2015 I 01-06-04

Prepare housing bore for the valve guide

(oversize)
z Clamp cylinder head on cylinder head machining
tool.
z Seal coolant channels.
z Align cylinder head.

6
© 39751-1

z Align bore unit and mandrin guide (1) with the hous-
ing bore.
The housing bores can have different dia-
meters, a suitable mandrin guide for align-
ment with the bore unit must therefore be
selected. The mandrin guide must move
easily in the housing bore without noticea-
ble resistance.
1

z Ream housing bore to oversize level.

P01 06
P01 07
Attention!
The reamer has a left twist and must
always be turned in or out in clockwise
direction. Never turn reamers anti-clock-
wise. The cuttings resulting from removing
the material can get stuck and damage the
cutting.
z Blow out housing bore with compressed air.

© 06/2006 3/6 8159-001

Cylinder head
I 01-06-04 TCD 2015

z Check housing bore for valve guide with plug

gauge (1).
Use corresponding plug gauge.
The target area of the plug gauge must be
able to move upwards and downwards with
light suction.
1

6
© 39750-1

The no-go limit of the gauge plug (1) must

not fit into the housing bore.
If the no-go limit fits, it must be reamed to
the next oversize.
When the wear limit of the 2nd oversize
stage is reached, the cylinder head must
be renewed. 1
P01 06
P01 07

z Unclamp cylinder head.

z Blast cylinder head clean with compressed air.

© 06/2006 4/6 8159-001

Cylinder head
TCD 2015 I 01-06-04

Press in valve guide

z Mount cylinder head.
z Select valve guide to fit housing bore.
P01 11
P01 12
P01 13

6
© 39754-1

z Supercool valve guide in liquid nitrogen.

Use a suitable container for the liquid nitro-
gen and a suitable tool for inserting and
removing the components.
At the beginning of the metal cooling, the
liquid nitrogen boils strongly, the bubbling
up process continues until the metal parts
have reached the temperature of the liquid
nitrogen (-196 °C).
The valve guide has the correct tempera-
ture if the bubbling up process of the nitro-
gen has finished.

z Push valve guide (1) onto press-in pin (2).

Note post-assembly position of the valve
guide.
The remote side (arrow) must face the
press-in pin.

© 06/2006 5/6 8159-001

Cylinder head
I 01-06-04 TCD 2015

z Press in valve guide until it touches the press-in pin.

z Remove the press-in pin.
z Remove the cylinder head.

6
© 39756-1

z Attach the repair date and company logo to the cylin-

der head.
Attention!
Do not mark identification on a sealing sur-
face.

Mark the cylinder head after every repair.

z Install valves.
W 01-05-01

© 06/2006 6/6 8159-001

Cylinder head
TCD 2015 W 01-07-08

Checking the valve lag

Commercial available tools: – W 01-04-04
– Depth-measuring
appliance
Special tools: Attention!
– Support bracket . . . . . . . . . . . . . 120900 When the wear limit is reached, the valve
– Base plate. . . . . . . . . . . . . . . . . . 120910 seat insert and/or valve must be renewed.

Checking the valve lag

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

z Mount depth measuring appliance on cylinder head

sealing surface.
z Measure valve stand back.
P01 45
P01 46

© 06/2006 1/2 8160-001

Cylinder head
W 01-07-08 TCD 2015

z Remove cylinder head from support bracket (1).

z Remove support bracket from base plate (2).
z Install cylinder head. 1
W 01-04-04

2
6
© 40650_1

© 06/2006 2/2 8160-001

Cylinder head
TCD 2015 I 01-07-09

Renewing valve seat insert

(oversize)
Commercial available tools: – W 01-05-01
– Tenon milling machine, – W 01-07-08
10 mm
– Internal measuring device Danger!
– Slide gauge
– Cylinder head machining Danger of injury, do not touch supercooled
tool components or the liquid nitrogen!
– Press Wear protective gloves and glasses!
– Industrial vacuum cleaner
– Press-in pin Attention!
– Upright drilling machine The press-in process must be carried out
without interruption as a result of the tem-
– Nitrogen (liquid) perature difference between the cylinder 6
head and the valve seat insert.
The necessary work steps must be practi-
sed before pressing in.

The relevant manufacturer’s specifications

must be observed when working with the
cylinder head machining tool.
The respective valve guide must be availa-
ble for replacing a valve seat insert.

z Check valve stand back.

W 01-07-08
z Remove valves.
W 01-05-01

© 06/2006 1/8 8161-001

Cylinder head
I 01-07-09 TCD 2015

Checking valve seat insert

z Check valve seat inserts (1).
Ensure that the installation location is free 1
from faults.

6
© 39739-1

Removing valve seat insert

z Clamp in cylinder head.
z Align valve seat insert with tenon milling machine.

z Mill valve seat insert on the sides (arrow) until it can

be removed without tension.
Attention!
Do not damage cylinder head.

© 06/2006 2/8 8161-001

Cylinder head
TCD 2015 I 01-07-09

z Fit protective underlay (arrow).

z Lever valve seat insert out.
Attention!
Do not damage cylinder head.

z Unclamp cylinder head.

6
© 39742-1

Checking housing bore for valve seat in-

sert
Diagram for measuring the housing bore at
the points "a" and "b", in the centre of 1
level "1".

z Measure housing bore with internal measuring de-

vice.
Measuring points see diagram.

z Read off measured value.

P01 01
P01 02
P01 03
P01 04
When the wear limit of the 2nd oversize
stage is reached, the cylinder head must
be renewed.

© 06/2006 3/8 8161-001

Cylinder head
I 01-07-09 TCD 2015

Alternatively, the diameter of the housing

bore can be determined with the aid of a
measuring guide ring (1).
The measuring guide ring can, for
example, be a valve seat insert turned to
half its size in height which is inserted in
the hole.

6
© 36641-1

Prepare housing bore for the valve seat

insert (oversize)
z Set cutting tool.
P01 03
P01 04

z Clamp cylinder head on cylinder head machining

tool.
z Seal coolant channels.
z Align cylinder head.

© 06/2006 4/8 8161-001

Cylinder head
TCD 2015 I 01-07-09

The valve guides can have different diame-

ters, a suitable mandrin guide for alignment
with the bore unit must therefore be selec-
ted. The mandrin guide must move easily
in the valve guide without noticeable resi- 1
stance.
z Align bore unit and mandrin guide (1) with the hous-
ing bore.

6
© 39746-1

z Bore housing bore to oversize level.

Attention!
The valve seat insert support (arrow) must
not be machined with the cutting tool.
z Remove chips thoroughly.

z Measure housing bore with internal measuring de-

vice.
P01 03
P01 04

© 06/2006 5/8 8161-001

Cylinder head
I 01-07-09 TCD 2015

Press in valve seat insert

z Mount cylinder head.
z Select valve seat insert to fit housing bore.
P01 21
P01 22
P01 23
P01 24

6
© 39748-1

z Supercool valve seat insert in liquid nitrogen.

Use a suitable container for the liquid nitro-
gen and a suitable tool for inserting and
removing the components.
At the beginning of the metal cooling, the
liquid nitrogen boils strongly, the bubbling
up process continues until the metal parts
have reached the temperature of the liquid
nitrogen (-196 °C).
The valve seat insert has the correct tem-
perature if the bubbling up process of the
nitrogen has finished.

z Push valve seat insert (1) onto press-in pin (2).

Note installation position.
The valve seat surface must point to the 2
press-in pin.

© 06/2006 6/8 8161-001

Cylinder head
TCD 2015 I 01-07-09

z Press the valve seat insert (1) with press-in pin (2)
into the housing bore (3) until it is in position (arrow).
z Remove the cylinder head.
z Machine valve seat insert. 2

6
© 36633-1

z Attach the repair date and company logo to the cylin-

der head.
Attention!
Do not mark identification on a sealing sur-
face.

Mark the cylinder head after every repair.

z Install valves.
W 01-05-01
z Check valve stand back.
W 01-07-08

© 06/2006 7/8 8161-001

Cylinder head
I 01-07-09 TCD 2015

© 06/2006 8/8 8161-001

Drive system
TCD 2015 W 02-01-04

Checking axial backlash of crankshaft

(crankshaft removed)
Commercial available tools: – W 02-04-01
8190

– Micrometer gauge
– Internal measuring device

Checking the axial backlash

z Remove crankshaft.
W 02-04-01

z Set micrometer gauge to 38 mm.

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

© 06/2006 1/2 8162-001

Drive system
W 02-01-04 TCD 2015

z Measure locating bearing width

z Note measured value, dimension (a).
P02 11
P02 12
P02 13

6
© 42324-1

z Place thrust ring halves on bearing caps (arrows).

z Measure width with micrometer gauge.
z Note measured value, dimension (b).
z Determine axial backlash.
Calculation example
Desired: Axial backlash
Given: -
Measured: (a) = 38.6 mm
(b) = 38.4 mm
Calculation: Axial backlash = dimension (a) - dimension (b)
38.6 mm - 38.4 mm
Result: = 0.2 mm

P02 34
With deviating axial backlash:
Set axial backlash by changing the thrust
ring halves. © 40600-0

z Install crankshaft.
W 02-04-01

© 06/2006 2/2 8162-001

Drive system
TCD 2015 W 02-01-04

Checking axial backlash of crankshaft

(crankshaft installed)
Commercial available tools: – W 03-08-01
8190

– Magnetic measuring stand – W 03-09-01

– Micrometer gauge
– Socket wrench insert, size
24, reinforced
– Socket wrench insert . . . . . . . . . . . 8035
– Rotation angle disc . . . . . . . . . . . . . 8190
Special tools:
– Dial gauge. . . . . . . . . . . . . . . . . . 100400

Checking the axial backlash

z Remove genset support.
W 03-08-01
z Remove rear cover.
W 03-09-01

z Mount magnetic measuring stand.

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

© 06/2006 1/6 8163-001

Drive system
W 02-01-04 TCD 2015

z Press crankshaft in direction of arrow.

z Read off measured value.
P02 34
With deviating axial backlash:
Note measured value, dimension (a).
Set axial backlash by changing the thrust
ring halves.

6
© 40588-0

Changing thrust ring halves

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

z Unscrew screws (1) with the socket wrench

insert size 24.
z Remove bearing cap (2). 1
z Remove lower bearing shell.
z Remove bottom thrust ring halves (arrows).

© 06/2006 2/6 8163-001

Drive system
TCD 2015 W 02-01-04

z Remove top thrust ring halves (arrows).

6
© 40595-0

z Measure thickness of the top and bottom thrust ring

halves.
z Note measured value, dimension (b).
z Determine thickness of the new thrust ring halves.
P02 35
P02 36
P02 37
Calculation example
Desired: Thickness of the new thrust ring halves
Given: (x) = thickness for standard, oversize
level 1 and 2
(y) = axial backlash (nominal)
(values from the technical data)
Measured: (a) = 0.4 mm axial backlash (actual)
(b) = 3.26 mm (thickness of the old thrust ring
halves) © 43504-0
Calculation: (x) - (b) = (c)
3.36 mm - 3.26 mm = 0.1 mm
Dimension (a) - Dimension (c)
Result: = 0.3 mm
Value must be within the given axial
backlash (y).
z Select new thrust ring halves according to calculated
value.

© 06/2006 3/6 8163-001

Drive system
W 02-01-04 TCD 2015

z Install upper thrust ring halves according to meas-

ured axial clearance.
Oil grooves (1) of the thrust ring halves
face the crankshaft web face (2). 2
Insert thrust ring halves between crank-
case and crankshaft web (arrow).

6
© 40596-0

z Fix thrust ring halves with a little grease to the bear-

ing cap.
z Install lower thrust ring halves according to meas-
ured axial backlash.
Use thrust ring halves with guide
lug (arrow).
The oil grooves (1) face the crankshaft web
face.
Bearing cap has identification “3“.

z Insert bearing cap (1).

The identification "3" on the bearing cap
must be legible from the flywheel side.

z Align bearing cap.

Press the crankshaft to the flywheel side
first and then in the opposite direction.

© 06/2006 4/6 8163-001

Drive system
TCD 2015 W 02-01-04

z Tighten screws (arrows).

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

6
© 40597-0

z Lightly oil screws (1).

z Tighten screws (1).
Attention!
Screws can be reused a maximum 3 times
with written documentation.
1

z Tighten screws (arrow) with the socket wrench

insert size 24 and rotation angle disc.
A02 010

© 06/2006 5/6 8163-001

Drive system
W 02-01-04 TCD 2015

z Tighten screws (arrow) with the socket wrench

insert 8035 and rotation angle disc.
A02 011

6
© 40492-0

z Check axial backlash of crankshaft.

P02 34

z Remove magnetic measuring stand.

z Remove dial gauge.
z Install genset support.
W 03-08-01
z Mount rear cover.
W 03-09-01

© 06/2006 6/6 8163-001

Drive system
TCD 2015 W 02-01-07

Checking the crankshaft

Commercial available tools: – W 02-04-01
– Magnetic measuring stand
– Micrometer gauge
– Internal measuring device
– Prisms
– Hardness tester
Special tools:
– Dial gauge. . . . . . . . . . . . . . . . . . 100400

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

z Pull off gear wheel (1).

z Remove friction disc.

© 06/2006 1/6 8164-001

Drive system
W 02-01-07 TCD 2015

z Visually inspect the components.

6
© 40586-0

z Position friction disc on parallel pin (2).

Use friction disc with locating hole.

1
z Mount gear wheel (1).

z Visually inspect peripheral surfaces (1).

z Visually inspect gear wheel (2).

1 1

© 06/2006 2/6 8164-001

Drive system
TCD 2015 W 02-01-07

z Put hardness tester on journal.

6
© 34754-2

z Raise stylus (1) and press release (2).

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

z Read off displayed value (arrow) from hardness test-

er.
P02 07
The measured value is to be converted
according to the table of the measuring
device.

© 06/2006 3/6 8164-001

Drive system
W 02-01-07 TCD 2015

Diagram for measuring the journals at the

points 1 and 2 in the levels a and b.

6
© 36424-2

Checking the diameter of the main bearing

pins
z Measure main bearing pin with micrometer gauge.
P02 03
P02 04
P02 06
Measuring points see diagram.

Checking the diameter of the lifting jour-

nals
z Measure lifting journal with micrometer gauge.
P02 22
P02 23
P02 25
Measuring points see diagram.

© 06/2006 4/6 8164-001

Drive system
TCD 2015 W 02-01-07

Checking the rotation

z Mount magnetic measuring stand.
z Insert dial gauge.
z Apply stylus to the main bearing pin with pre-tension
(arrow) and adjust dial gauge to "0".
z Turn crankshaft evenly and check rotation.
P02 26
z Remove magnetic measuring stand.
z Remove dial gauge.

6
© 42325-1

Measuring the fit bearing width

z Set micrometer gauge to 38 mm.
z Push the internal measuring device between the test
surfaces of the micrometer gauge and set to "0".

z Measure bearing width with internal measuring de-

vice between thelay-on surfaces of the thrust rings.
P02 11
P02 12
P02 13

© 06/2006 5/6 8164-001

Drive system
W 02-01-07 TCD 2015

z Install crankshaft.
W 02-04-01

6
© 40485-0

© 06/2006 6/6 8164-001

Drive system
TCD 2015 W 02-02-02

Renewing the crankshaft sealing ring

(flywheel side)
Commercial available tools: – W 12-06-01
– Depth-measuring
appliance
– Pricker. . . . . . . . . . . . . . . . . . . . . . . 8198
– Assembly lever . . . . . . . . . . . . . . . . 9017
Special tools:
– Assembly tool . . . . . . . . . . . . . . . 142650

– Self-tapping screw
– Washer

Removing the crankshaft sealing ring

z Remove flywheel.
W 12-06-01
z Loosen crankshaft sealing ring in its seat evenly with
a mandrel.
z Make a hole in the crankshaft sealing ring with a
pricker.
Attention!
Do not damage the rear cover and cranks-
haft!

z Turn in a self-tapping screw with washer.

© 06/2006 1/6 8165-001

Drive system
W 02-02-02 TCD 2015

z Pull out the crankshaft sealing ring with assembly le-

ver.

6
© 36764-1

z Visually inspect all running surfaces.

Install crankshaft sealing ring

z Select shim (1).
Use the shim with identification "Rep-
Stage". 1

© 06/2006 2/6 8165-001

Drive system
TCD 2015 W 02-02-02

z Mount shim (1).

Pay attention to alignment of the
clampingbushing (2) and locating hole (3).

6
© 36755-1

z Turn bolt (1) with thread (2) into crankshaft.

Use new crankshaft sealing ring.

z Oil the sealing lip of the crankshaft sealing ring light-

ly.
z Place the crankshaft sealing ring carefully on the pe-
ripheral surface.
The sealing lip faces the crankcase.

© 06/2006 3/6 8165-001

Drive system
W 02-02-02 TCD 2015

z Place assembly sleeve (1) on bolt (2).

z Press on assembly sleeve.
The assembly sleeve is evenly in contact
with the crankshaft sealing ring.
1

6 2
© 36759-1

z Push pressure cross-member (1) onto bolt (2).

z Mount washers.
z Screw on nuts.

z Tighten screw (1) until the assembly sleeve (2) is

touching.
z Remove assembly tool.
2

© 06/2006 4/6 8165-001

Drive system
TCD 2015 W 02-02-02

z Check installation depth (1) with depth measuring

appliance.
P03 25
z Install flywheel.
W 12-06-01

6
© 40960-0

© 06/2006 5/6 8165-001

Drive system
W 02-02-02 TCD 2015

© 06/2006 6/6 8165-001

Drive system
TCD 2015 W 02-02-04

Renewing the crankshaft sealing ring

(opposite side to flywheel)
Commercial available tools:
– Depth-measuring
appliance
– Pricker. . . . . . . . . . . . . . . . . . . . . . . 8198
– Assembly lever . . . . . . . . . . . . . . . . 9017
Special tools:
– Assembly tool . . . . . . . . . . . . . . . 142640

– Self-tapping screw
– Washer

Removing the crankshaft sealing ring

z Unscrew all screws (1).
z Remove flanged hub with torsional vibration damper
and V-belt pulley.
Block flywheel with suitable tool. 1

z Loosen crankshaft sealing ring in its seat evenly with

a mandrel.
z Make a hole in the crankshaft sealing ring with a
pricker.
Attention!
Do not damage the genset support and
crankshaft!

© 06/2006 1/6 8166-001

Drive system
W 02-02-04 TCD 2015

z Turn in a self-tapping screw with washer.

6
© 40661-0

z Pull out the crankshaft sealing ring with assembly le-

ver.

z Visually inspect all running surfaces.

© 06/2006 2/6 8166-001

Drive system
TCD 2015 W 02-02-04

Install crankshaft sealing ring

z Select shim (1).
Use the shim with identification "Rep-
Stage". 1

6
© 37153-2

z Mount shim (1).

z Turn bolt (1) with thread (2) into crankshaft.

© 06/2006 3/6 8166-001

Drive system
W 02-02-04 TCD 2015

Use new crankshaft sealing ring.

z Oil the sealing lip of the crankshaft sealing ring light-

ly.
z Place the crankshaft sealing ring carefully on the pe-
ripheral surface.
The sealing lip faces the crankcase.

6
© 35203-2

z Place assembly sleeve (1) on bolt (2).

z Press on assembly sleeve.
The assembly sleeve is evenly in contact
with the crankshaft sealing ring.

z Push pressure cross-member (1) onto bolt (2).

z Mount washers.
z Screw on nuts.

© 06/2006 4/6 8166-001

Drive system
TCD 2015 W 02-02-04

z Tighten screw (1) until the assembly sleeve (2) is

touching.
z Remove assembly tool. 2

1
6
© 35206-2

z Check installation depth (1) with depth measuring

appliance.
P03 26

z Remove flanged hub with torsional vibration damper

and V-belt pulley.
z Lightly oil screws (1).
Block flywheel with suitable tool.

1
z Tighten all screws (1) alternately.
A12 030

© 06/2006 5/6 8166-001

Drive system
W 02-02-04 TCD 2015

© 06/2006 6/6 8166-001

Drive system
TCD 2015 W 02-03-01

Checking the con rod

Commercial available tools: – W 02-09-03
– Micrometer gauge
– Internal measuring device
– Con rod test device
Special tools:
– Dial gauge. . . . . . . . . . . . . . . . . . 100400

z Remove piston and connecting rod.

W 02-09-03

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 52 mm.
– Balance the internal measuring device between
the test surfaces of the micrometer gauge and set
the meter at the reversal point of the pointer to "0".

© 06/2006 1/10 8167-001

Drive system
W 02-03-01 TCD 2015

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.
P02 43
Measuring points see diagram.

z Note measured value, dimension (a).

Checking piston pin

z Measure piston pin with micrometer gauge.
P02 61
z Note measured value, dimension (b).

© 06/2006 2/10 8167-001

Drive system
TCD 2015 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).
P02 45
P02 62
Calculation example
Desired: Piston pin clearance
Given: -
Measured: Internal diameter small end bush (a)
(a) = 52.040 mm
Diameter piston pin (b)
(b) = 52.000 mm
Calculation: Dimension (a) - Dimension (b) 6
52.040 mm - 52.000 mm
Result: = 0.040 mm

Checking the con rod bearing bore

z Mount big end bearing cap.
1
Attention!
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.

z Tighten screws .
A02 020

© 06/2006 3/10 8167-001

Drive system
W 02-03-01 TCD 2015

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 95 mm.
– Balance the internal measuring device between
the test surfaces of the micrometer gauge and set
the meter 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".

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.
P02 55
If the measured values deviate slightly,
additional measurements must be made
with new bearing shells.

© 06/2006 4/10 8167-001

Drive system
TCD 2015 W 02-03-01

Checking internal diameter of the con rod

bearing shells
z Remove screws. 2
z Remove the con rod bearing cover.
z Insert bearing shell in the con rod.
Attention!
Note the assignment of the bearing shells.
Insert big end bearing shell with the black
anodised rear side (arrow) in the connec-
ting rod. 1
The anti-rotation lock (1) must lock in
groove (2).

6
© 36768-1

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).

z Mount big end bearing cap.

Attention!
Note the assignment of the big end bearing 1
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.

© 06/2006 5/10 8167-001

Drive system
W 02-03-01 TCD 2015

z Tighten screws .
A02 020

6
© 34778-2

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 91 mm.
– Balance the internal measuring device between
the test surfaces of the micrometer gauge and set
the meter at the reversal point of the pointer to "0".

Diagram for measuring the inside diameter

of the con rod bearing shells at the
points "a" and "b" in the levels "1" and "2".

© 06/2006 6/10 8167-001

Drive system
TCD 2015 W 02-03-01

z Insert internal measuring device.

z Balance the internal measuring device at the given
measuring points and read off the measured value at
the reversal point of the pointer.
z Note measured value, dimension (a).
P02 52
P02 54
If the values up to maximum 0.015 mm are
above the bearing tolerances, the connec-
ting rod can still be used.
When the limit value is reached, the con-
necting rod must be replaced.

6
© 34775-2

Checking the diameter of the lifting jour-

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

z Measure lifting journal with micrometer gauge.

P02 22
P02 23
P02 25
Measuring points see diagram.

z Note measured value, dimension (b).

© 06/2006 7/10 8167-001

Drive system
W 02-03-01 TCD 2015

Determine big end bearing clearance

The big end bearing clearance is given by
the difference between the internal diame-
ter of the big end bearing shell (a) and the
lifting journal diameter (b).
P02 56
P02 57
Calculation example
Desired: Big end bearing clearance
Given: -
Measured: Internal diameter big end bearing shell (a)
(a) =88.060 mm
Diameter lifting journal (b)
(b) = 88.000 mm
6 Calculation: Dimension (a) - Dimension (b)
88.060 mm - 88.000 mm
Result: = 0.60 mm

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

Checking the con rod

Attention!
Aligning the con rod is not permissible.

z Check that the con rod is parallel.

P02 41
Check con rod without bearing shells on
the con rod test device.
Permissible deviation (a) at a
distance of (x).

© 06/2006 8/10 8167-001

Drive system
TCD 2015 W 02-03-01

z Check the angle of the con rod.

P02 42
Permissible deviation from (A) to (B) at a
distance of (x).

6
© 35881-2

z Install piston and connecting rod.

W 02-09-03

© 06/2006 9/10 8167-001

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W 02-03-01 TCD 2015

© 06/2006 10/10 8167-001

Drive system
TCD 2015 I 02-03-03

Removing and installing small end bush

Commercial available tools: Danger!
– Press or threaded spindle Danger of injury, do not touch hot parts!
Special tools: Danger of injury, do not touch supercooled
– Base plate. . . . . . . . . . . . . . . . . . 131200 components or the liquid nitrogen!
– Assembly tool kit. . . . . . . . . . . . . 131210
Wear protective gloves and glasses!
– Nitrogen (liquid)
– Degreasing agent/cleaning
Attention!
The press-in process must be carried out
agent
without interruption as a result of the tem-
– Compressed air
perature difference between the small end
– Heating oven
bush and the connecting rod.
The necessary work steps must be practi-
sed before pressing in. 6
The pressing out of the small end bush is
shown with pneumatic press.
A threaded spilndle can also be used alter-
natively.

Removing the small end bush

Attention! 3
Never hammer out the small end bush!

z Insert big end bearing holder (3) in base plate (2). 1

z Insert removal gauge (1) in base plate.
Attention!
Do not confuse the removal gauge with the
installation gauge!

The groove (arrow) must face the big end

bearing holder.
Make sure the removal gauge is inserted
flush! 2

© 06/2006 1/6 8168-001

Drive system
I 02-03-03 TCD 2015

z Insert the bottom part of the assembly tool (3) into the
removal gauge from below. 1
z Place the connecting rod (1) on the base plate. 2
The flat side (arrow) of the connecting rod
must face down.

z Turn the bottom part (3) into the top part (2) of the as-
sembly tool.

6
© 40403-0

z Align the top part (1) of the assembly tool and remov-
al gauge (2).
The top part of the assembly tool and the
removal gauge are level with the angled
surfaces (arrows) of the big end bearing.

z Screw the top part (1) and bottom part (2) of the as-
sembly tool together.

© 06/2006 2/6 8168-001

Drive system
TCD 2015 I 02-03-03

z Align the pneumatic press horizontally on the base

plate.
The press-out die is in the centre above
the top of the assembly tool.

6
© 36284-2

z Press out the small end bush with slight pressure.

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

Installing small end bush

z Insert big end bearing holder (3) in base plate (2). 3
z Insert installation gauge (1) in base plate.
The groove (arrow) must face the big end
bearing holder.
1
Make sure the installation gauge is inser-
ted flush.

© 06/2006 3/6 8168-001

Drive system
I 02-03-03 TCD 2015

z Heat up the connecting rod (1).

P02 47
z Place the connecting rod on the base plate (2). 1
The flat side (arrow) of the connecting rod
must face down.

2
6
© 40406-0

z Cool down the small end bush (1) in liquid nitrogen.

P02 46

z Place supercooled small end bush (1) on installation

mandrel (3).
The index pin (2) is sitting correctly in the
groove (arrow) of the small end bush. 1

2
3

© 06/2006 4/6 8168-001

Drive system
TCD 2015 I 02-03-03

z Insert installation mandrel (1) with small end bush (2)

in con rod bore.
The small end bush must be insertable in
the connecting rod bore with little force.
Note installation position of the small end
1
bush.
z Pull out the installation mandrel.
The small end bush may not slip. 2

6
© 36290-3

z Check installation position.

Position of the bush joint (arrow) looking at
the flat side of the connecting rod shank.

Mechanical machining of the small end

bush is necessary after assembly work.

z Spindle the small end bush to dimension A.

Dimensions Maximum Minimum
dimension dimension
Bore of small
end bush 52.055 mm 52.040 mm
dimension A
Piston pin dia-
52.000 mm 51.992 mm
meter
Theoretical
0.063 mm 0.040 mm
clearance

© 06/2006 5/6 8168-001

Drive system
I 02-03-03 TCD 2015

© 06/2006 6/6 8168-001

Drive system
TCD 2015 W 02-04-01

Removing and installing the crankshaft

Commercial available tools: – W 02-01-04 . . . . . . . . . . . . (crankshaft
– Socket wrench insert, size removed)
24, reinforced – W 02-01-04 . . . . . . . . . . . . (crankshaft
– Socket wrench insert, size installed)
14, reinforced . . . . . . . . . . . . . . . . . 8015 – W 02-01-07
– Socket wrench insert, size – W 03-08-01
22, reinforced . . . . . . . . . . . . . . . . . 8035 – W 03-09-01
– Rotation angle disc . . . . . . . . . . . . . 8190 – W 07-07-01
Special tools:
– Turn-over gear . . . . . . . . . . . . . . 100350

Removing crankshaft
z Removing fuel injectors.
W 07-07-01
z Remove genset support.
W 03-08-01
z Remove rear cover.
W 03-09-01

z Fasten all screws (1).

© 06/2006 1/14 8169-001

Drive system
W 02-04-01 TCD 2015

z Mount turning gear (1).

6
© 40471-0

z Set the counterweights (1) of cylinders A1/B1 at bot-

tom dead centre.
1
T00 81
z Turn the crankshaft with the turning gear.
z Unscrew screws (2).
z Remove counterweights (1).
Lay out components in the order in which 2
2
they should be installed.

z Set the counterweights (1) of cylinders A3/B3 at bot-

tom dead centre.
z Unscrew screws (2).
z Remove counterweights (1).
Lay out components in the order in which
they should be installed. 2 2

© 06/2006 2/14 8169-001

Drive system
TCD 2015 W 02-04-01

z Place lifting journal of the respective cylinder at bot-

tom dead centre (BDC).
Attention!
Do not jam the con rods when turning the
crankshaft.

6
© 40496-0

z Unscrew screws (1) with the socket wrench

insert 8015.
z Remove all big end bearing caps (2).
z Remove bearing shell.
Lay out components in the order in which
they should be installed.
Note order of cylinders.
2 1

Attention!
Do not jam the con rods when turning the
crankshaft.
Do not damage the big end bearing shells.
z Turn the crankshaft with the turning gear evenly.
The marking on the crankshaft gear wheel
must be between the markings on the
camshaft gear wheel (1).

1
© 40482-0

© 06/2006 3/14 8169-001

Drive system
W 02-04-01 TCD 2015

z Unscrew all screws (1) with the socket wrench

insert 8035. 1
z Unscrew all screws (2) with the socket wrench
insert size 24.

6 1
© 40483-1

z Remove bearing cap (1).

z Remove bearing shell.
z Remove bottom thrust ring halves (arrows). 1
z Remove all main bearing covers (2).
z Remove the main bearing shells.
Lay out components in the order in which
they should be installed.

1 - 2724 A
2 - 2724 A
3 - 2724 A
4 - 2724 A

Note order of cylinders.

z Press the con rods carefully out of the lifting journal.

© 06/2006 4/14 8169-001

Drive system
TCD 2015 W 02-04-01

z Remove turn-over gear.

z Lift out the crankshaft.
z Place crankshaft on prism.

6
© 42145-1

z Remove top thrust ring halves (arrows).

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

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

© 06/2006 5/14 8169-001

Drive system
W 02-04-01 TCD 2015

Installing the crankshaft

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

6
© 37042-1

z Insert lower main bearing shells in the respective

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

z Insert bearing shell in the con rod.

Attention!
Note the assignment of the bearing shells.
Insert big end bearing shell with the black
1
anodised rear side in the connecting rod.
The anti-rotation lock (1) must lock in
groove (2).

© 06/2006 6/14 8169-001

Drive system
TCD 2015 W 02-04-01

z Insert big end bearing shells in the respective big end

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

6
© 36769-1

z Lightly oil bearing surfaces.

z Insert the crankshaft carefully in the crankcase.

Attention!
Do not jam the con rods when inserting the
crankshaft!
z Set the crankshaft in line with the camshaft (1) .
The marking on the crankshaft gear wheel
must be between the marking points on the
camshaft gear wheel.

© 06/2006 7/14 8169-001

Drive system
W 02-04-01 TCD 2015

z Fasten all screws (1).

z Mount the turning gear.

6
© 40470-0

z Install upper thrust ring halves according to meas-

ured axial clearance.
The oil grooves (1) face the crankshaft
web face (2).
Insert thrust ring halves between crank- 2
case and crankshaft web (arrows).

z Install lower thrust ring halves according to meas-

ured axial backlash.
z Fix thrust ring halves with a little grease to the bear-
ing cap.
Use thrust ring halves with guide
lug (arrow).
Oil grooves (1) face the crankshaft web
face.
Bearing cap has identification “3“.

© 06/2006 8/14 8169-001

Drive system
TCD 2015 W 02-04-01

z Insert bearing cap (1).

z Insert main bearing covers (2).
Note assignment and installation position: 1
Assignment of the main bearing covers:
With identification "1" = flywheel side.
With identification "4" = side opposite flyw-
heel side.

1 - 2724 A
2 - 2724 A
3 - 2724 A
4 - 2724 A
Identifications legible from the flywheel
side.

2 2 2

6
© 42146-2

z Fasten all screws (1).

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

1
© 42147-1

z Oil the screws lightly.

z Fasten all screws (1).
Attention!
Screws can be used a maximum 3 times
with written documentation.
z Move the crankshaft axially to and fro.
The bearing is aligned in position as a
result.
1

© 06/2006 9/14 8169-001

Drive system
W 02-04-01 TCD 2015

z Tighten all screws (arrow) with the socket wrench in-

sert size 24 and rotation angle disc.
A02 010
Attention!
Do not jam the main bearing cover.

6
© 40491-0

z Tighten all screws (arrow) with the socket wrench in-

sert 8035 and rotation angle disc.
A02 011

z Check installation position of the connecting rods.

The flattened side (arrow) faces the flyw-
heel on the A-bank and the genset support
on the B-bank.

© 06/2006 10/14 8169-001

Drive system
TCD 2015 W 02-04-01

z Pull con rods carefully on to the lifting journal.

6
© 42151-1

z Place lifting journal of the respective cylinder at bot-

tom dead centre (BDC).
Attention!
Do not jam the con rods when turning the
crankshaft.

z Mount big end bearing cap.

Attention!
Note assignment and installation position:
The identification numbers (1) on the con-
necting rod and the big end bearing cover
must be identical and opposite to each
other when assembled.

© 06/2006 11/14 8169-001

Drive system
W 02-04-01 TCD 2015

z Tighten new screws with the socket wrench insert

8015 and rotation angle disc.
A02 020

6
© 37056-1

z Place crankshaft web of the respective cylinder at

bottom dead centre (BDC).
z Pay attention to clamping bushing (1).

1 1

Attention!
Note assignment and installation position: 1 1 1
Assignment of the counterweights:
Counterweight with
identification "1" = flywheel side.
Flattened sides (1) face the main bearing
cover.
4

© 06/2006 12/14 8169-001

Drive system
TCD 2015 W 02-04-01

z Insert counterweights according to the identification.

1
6
© 42153-1

z Oil the screws lightly.

z Tighten screws .
A02 001

z Remove turning gear (1).

© 06/2006 13/14 8169-001

Drive system
W 02-04-01 TCD 2015

z Unscrew all screws (1).

6
© 40470-0

z Check axial backlash of crankshaft (crankshaft in-

stalled).
W 02-01-04

z Mount rear cover.

W 03-09-01
z Install genset support.
W 03-08-01
z Install fuel injectors.
W 07-07-01

© 06/2006 14/14 8169-001

Drive system
TCD 2015 W 02-09-03

Removing and installing the piston and con rod

Commercial available tools: – W 01-04-04
– Locking ring pliers – W 02-10-03
– Socket wrench insert . . . . . . . . . . . 8015 – W 08-04-06
– Rotation angle disc . . . . . . . . . . . . . 8190 – W 08-04-06 . . . . . . . . . . . . (Railway)
Special tools:
– Piston ring compressor . . . . . . . . 130650

Removing the piston and con rod

z Remove cylinder head.
W 01-04-04
z Insert screws and washers (1) diagonally opposed.
1
Washers:
Maximum thickness 4 mm
Screw length:
M16 x 90
z Tighten screws until they touch the cylinder liner.

z Remove oil suction pipe

W 08-04-06
z Remove oil suction pipe (Railway).
W 08-04-06

© 06/2006 1/8 8170-001

Drive system
W 02-09-03 TCD 2015

z Set piston at bottom dead centre (BDC).

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

6
© 42375-1

z Remove big end bearing cover with bearing shell.

Lay out components in the order in which
they should be installed.
Note order of cylinders.
T00 81
z Visually inspect the components.

z Set piston at top dead centre (TDC).

z Remove bearing shell.
z Press out the piston and connection rod.
Attention!
Do not jam the connecting rod in the cylin-
der liner when removing!

Lay out components in the order in which

they should be installed.
Note order of cylinders.

© 06/2006 2/8 8170-001

Drive system
TCD 2015 W 02-09-03

z Visually inspect the components.

6
© 40592-0

z Remove locking ring with locking ring pliers.

z Press out piston pin.
z Remove locking ring with locking ring pliers.
z Visually inspect the components.
Attention!
Make sure the surface of the piston is flaw-
less.

Installing the piston and con rod

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

© 06/2006 3/8 8170-001

Drive system
W 02-09-03 TCD 2015

z Insert con rod.

Attention!
The concave surface (arrow) of the con-
necting rod must face the recess (1) for the
piston cooling nozzle on the piston.

1
6
© 40967-0

z Oil the piston bolt lightly.

z Insert piston pin in piston.
z Insert new locking ring.
Ensure that the installation location is free
from faults.

Attention!
Note the assignment of the bearing shells.
Insert big end bearing shell with the black 2
anodised rear side (arrow) in the connec-
ting rod.
The anti-rotation lock (1) must lock in
groove (2).
z Insert bearing shell in the con rod.

© 06/2006 4/8 8170-001

Drive system
TCD 2015 W 02-09-03

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).

6
© 36769-1

z Arrange the piston ring joints with an offset of

about 120° to each other.
z Check piston rings and piston ring grooves.
W 02-10-03

z Lightly oil cylinder running surface, piston, piston

rings and lifting bearing journal lightly.
z Clamp piston rings with piston ring compressor (1).
Do not turn the piston rings any further.

© 06/2006 5/8 8170-001

Drive system
W 02-09-03 TCD 2015

z Set lifting journal at bottom dead centre (BDC).

z Push piston and con rod completely into cylinder lin-
er.
Note the cylinder assignment of the piston.
Note identification (1) of the installation
position on the piston base.
The arrow must point to the exhaust gas 1
side.
The piston ring compressor must lie flat on
the cylinder liner.

6
© 36772-1

z Check installation position of the connecting rods.

Attention!
The flattened side (1) must face the adja-
cent lifting crank web (2). 1 1

2
2

z Press the con rod carefully against the lifting journal.

Attention!
Do not jam the con rod with the crankshaft.
Do not damage the piston cooling nozzle.

© 06/2006 6/8 8170-001

Drive system
TCD 2015 W 02-09-03

z Mount big end bearing cap.

Attention!
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.

6
© 42382-1

z Tighten new screws with the socket wrench insert

and rotation angle disc.
A02 020

z Install oil suction pipe.

W 08-04-06
z Install oil suction pipe (Railway).
W 08-04-06

© 06/2006 7/8 8170-001

Drive system
W 02-09-03 TCD 2015

z Unscrew screws with washers (1).

z Install cylinder head.
W 01-04-04

6
© 40873-0

© 06/2006 8/8 8170-001

Drive system
TCD 2015 W 02-09-07

Checking the piston

Commercial available tools: – W 02-09-03
– Micrometer gauge
– Internal measuring device
Special tools: When the piston wear limit is reached, the
– Dial gauge. . . . . . . . . . . . . . . . . . 100400 piston must be renewed.

Checking the piston bolt bore

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

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 52 mm.
– Balance the internal measuring device between
the test surfaces of the micrometer gauge and set
the meter at the reversal point of the pointer to "0".

© 06/2006 1/4 8171-001

Drive system
W 02-09-07 TCD 2015

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.

z Balance the internal measuring device at the given
measuring points and read off the measured value at
the reversal point of the pointer.
P02 78
Measuring points see diagram.

Checking the piston diameter

Diagram for measuring the piston diameter
at the measuring points "1, 2 and 3", trans-
verse to the piston bolt bore.

© 06/2006 2/4 8171-001

Drive system
TCD 2015 W 02-09-07

z Measure diameter with micrometer gauge.

Measuring points see diagram.

P02 71
P02 72
P02 73

6
© 40969-0

z Install piston and connecting rod.

W 02-09-03

© 06/2006 3/4 8171-001

Drive system
W 02-09-07 TCD 2015

© 06/2006 4/4 8171-001

Drive system
TCD 2015 W 02-10-03

Checking the piston rings and piston ring grooves

Commercial available tools: – W 02-09-03
– Feeler gauges
Special tools:
– Universal piston ring pliers . . . . . 130300
– Trapezoidal groove wear
gauge . . . . . . . . . . . . . . . . . . . . . 130400

Checking the piston rings and piston ring

grooves
z Remove piston and connecting rod.
W 02-09-03
z Set universal piston ring pliers to the piston diameter.
P02 73
z Remove piston rings with universal piston ring pliers.

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

© 06/2006 1/4 8172-001

Drive system
W 02-10-03 TCD 2015

z Measure piston ring groove for first piston ring with

trapezoidal groove wear gauge.

6
© 33866-2

If there is a gap "S" between the trapezoi-

dal groove wear gauge and piston, the
piston can be used again. S

If the trapezoidal groove wear gauge is

touching the piston (arrow), the piston
must be changed.

© 06/2006 2/4 8172-001

Drive system
TCD 2015 W 02-10-03

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.

6
© 42321-1

z Measure the piston ring joint clearance with a feeler

gauge.
P02 84
P02 85
P02 86
When the wear limit is reached, the piston
ring must be renewed.

Installing piston rings

Order and position of the piston rings as 1
seen from the piston base:
- Double-sided keystone ring (1)
2
- Taper-faced ring (2)
- Bevelland-edge oil control ring with coiled
spring expander (3)
3
Identification “Top“ in (1) and (2) facing
combustion chamber

© 06/2006 3/4 8172-001

Drive system
W 02-10-03 TCD 2015

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
© 42318-1

Checking the piston ring axial clearance

Check with new piston rings.

z Check axial backlash with feeler gauge between pis-

ton ring and piston ring groove.
P02 88
P02 89
When the piston wear limit is reached, the
piston must be renewed.

z Install piston and connecting rod.

W 02-09-03

© 06/2006 4/4 8172-001

Drive system
TCD 2015 W 02-15-01

Removing and installing the piston cooling nozzle

Commercial available tools – W 02-09-03

Special tools:
– Tester . . . . . . . . . . . . . . . . . . . . . 102560
– Dipstick . . . . . . . . . . . . . . . . . . . . 102565

Removing the piston cooling nozzle

z Remove piston and connecting rod.
W 02-09-03
z Unscrew relief valve (1). 2
1
z Remove piston cooling nozzle (2).

Installing the piston cooling nozzle

z Mount piston cooling nozzle.
z Screw on the relief valve hand tight.
The flattened side (1) faces the cylinder
liner.
1

© 06/2006 1/4 8173-001

Drive system
W 02-15-01 TCD 2015

Check the jet position of the piston cooling

nozzle.
Attention!
Do not damage the cylinder liner when
1
inserting the tester.
z Insert tester in cylinder liner.
z Set tester with the bores (1) over the clamping
bushings (2).

6
© 40787-0

z Insert dipstick (1) in the bores (2) of the tester.

1
2

z Insert the tip of the dipstick (1) without using force

into the opening in the piston cooling nozzle (2).
The piston cooling nozzle must be turned.

Attention!
If it cannot be turned, the piston cooling 1
nozzle must be renewed!
The piston cooling nozzle may not be bent!
The piston cooling nozzle must be in line 2
with the dipstick!

© 06/2006 2/4 8173-001

Drive system
TCD 2015 W 02-15-01

z Tighten the relief valve.

A08 081
Attention!
Make sure the piston cooling nozzle is not
twisted!

6
© 42358-1

z Remove the dipstick.

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

© 06/2006 3/4 8173-001

Drive system
W 02-15-01 TCD 2015

© 06/2006 4/4 8173-001

Crankcase
TCD 2015 W 03-01-11

Removing and installing the crankcase breather

(oil separator)
Commercial available tools Collect leaking operating substances in
suitable vessels and dispose of according
to regulations.

Removing the crankcase bleeding

z Unscrew screw (1).

z Loosen hose clip (1).

z Loosen hose clip (2).
z Pull out pipe (3).
z Remove intake elbow (4).

4
2 3

© 06/2006 1/6 8174-001

Crankcase
W 03-01-11 TCD 2015

z Loosen hose clips (1).

6
© 40667-0

z Loosen pipe clamp (1).

z Pull out oil separator (1) together with pipe.

© 06/2006 2/6 8174-001

Crankcase
TCD 2015 W 03-01-11

z Pull off pipe (1).

6
© 45401-0

z Visually inspect the components.

Install crankcase bleeding

z Mount pipe (1).
1
z Fill oil syphon (2) with engine oil.

© 06/2006 3/6 8174-001

Crankcase
W 03-01-11 TCD 2015

z Insert oil separator (1) in flanged pipe (2).

Do not move the spring (arrow).
1

6 2

z Mount intake elbow (4).

Note installation position.

z Position hose clip (1).

z Tighten hose clip (1).
1
A06 021
z Mount pipe (3).
z Position hose clip (2).
z Tighten hose clip (2).
A03 064
4
2 3

z Position pipe clamp (1).

z Tighten pipe clip (1).
A03 060

© 06/2006 4/6 8174-001

Crankcase
TCD 2015 W 03-01-11

z Position hose clips (1).

z Tighten hose clips (1).
A03 064

6
© 40667-0

z Tighten screw (1).

A03 069

© 06/2006 5/6 8174-001

Crankcase
W 03-01-11 TCD 2015

© 06/2006 6/6 8174-001

Crankcase
TCD 2015 W 03-03-01

Testing the cylinder liner

Commercial available tools: – W 03-03-02
– Depth-measuring
appliance
– Micrometer gauge The following work sequence must be car-
– Internal measuring device ried out on every cylinder unit of a cylinder
Special tools: bank.
– Dial gauge. . . . . . . . . . . . . . . . . . 100400

Testing the cylinder liner

z Remove cylinder liner.
W 03-03-02
z Visually inspect the cylinder running surface.

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 42 mm.
– Balance the internal measuring device between
the test surfaces of the micrometer gauge and set
the meter at the reversal point of the pointer to "0".

© 06/2006 1/4 8175-001

Crankcase
W 03-03-01 TCD 2015

Diagram for measuring the cylinder run-

ning surface at the points "a" and "b" in the
levels "1 - 4".

4
6
© 37238-1

z Remove shim ring (1).

z Visually inspect collar rest (arrow).
1
z Visually inspect sealing surface.

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.
P03 31
Measuring points see diagram.
When the wear limit is reached, the cylin-
der liner must be renewed.

© 06/2006 2/4 8175-001

Crankcase
TCD 2015 W 03-03-01

z Measure collar height in area (X) with micrometer

gauge.
P03 36
Carry out the measurement at several pla- X
ces on the collar rest.

z Install cylinder liner.

W 03-03-02

6
© 42395-1

© 06/2006 3/4 8175-001

Crankcase
W 03-03-01 TCD 2015

© 06/2006 4/4 8175-001

Crankcase
TCD 2015 W 03-03-02

Removing and installing the cylinder liner

Commercial available tools: – W 02-09-03
– Depth-measuring – W 03-03-01
appliance – W 03-03-08
Special tools:
– Assembly device. . . . . . . . . . . . . 150120
– Extraction tool . . . . . . . . . . . . . . . 150130

– Fitting compound
DEUTZ AP1908

Removing the cylinder liner

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

z Mark installation position of the cylinder liner on the

crankcase.
z Mark cylinder liner with the cylinder designation.

© 06/2006 1/6 8176-001

Crankcase
W 03-03-02 TCD 2015

z Fold back plate and insert puller.

– Place the plate (1) with the lay-on surfaces against
the cylinder liner (2) and hold them together.
– Mount the counter holder (3) on the crankcase (4) .
Attention! 1
3
Do not damage the peripheral surfaces
and the sealing surfaces.
Do not damage the piston cooling nozzle.

The counterweights of the crankshaft face

the lubricating oil pan.
4
2

6
© 36782-1

z Pull the cylinder liner up and out.

Turn the nut in the direction of the arrow.

z Remove the disassembly device.

z Pull the cylinder liner up and out.

z Remove shim ring (1).

z Visually inspect collar rest (arrow).
1
z Visually inspect sealing surface.

© 06/2006 2/6 8176-001

Crankcase
TCD 2015 W 03-03-02

z Remove both O-rings (arrows).

z Test the cylinder liners.
W 03-03-01

6
© 42231-1

Install cylinder liner

z Insert new O-rings (arrows).
Pull the O-rings apart slightly to prevent
them falling out during assembly.

z Measure collar rest with depth measuring appliance.

P03 35
Carry out the measurement at several pla-
ces on the collar rest.

© 06/2006 3/6 8176-001

Crankcase
W 03-03-02 TCD 2015

z Insert shim ring (1).

A centring lug (2) points up. 1

6
© 39911-0

z Coat the cylinder liner in the "X" area with fitting com-
pound.
Make sure that the liner surface and the
crankcase are absolutely clean before
installing the cylinder liner.

z Insert the cylinder liner (1) in the crankcase.

© 06/2006 4/6 8176-001

Crankcase
TCD 2015 W 03-03-02

z Screw in retaining pins (1).

Screw retaining pins into a threaded bore
for screws of the cylinder head.

z Mount pressure plate (2) on cylinder liner.

Make sure the pressure plate is fit evenly. 2 1

6
© 42232-1

z Press in cylinder liner to stop.

z Remove the assembly device.

z Check the overhang of the cylinder liner.

W 03-03-08
z Install piston and connecting rod.
W 02-09-03

© 06/2006 5/6 8176-001

Crankcase
W 03-03-02 TCD 2015

© 06/2006 6/6 8176-001

Crankcase
TCD 2015 W 03-03-08

Checking the overhang of the cylinder liner

Commercial available tools: – W 01-04-04
– Magnetic measuring stand
Special tools:
– Dial gauge. . . . . . . . . . . . . . . . . . 100400

Checking the overhang of the cylinder lin-

er
z Remove cylinder head.
W 01-04-04
z Insert screws and washers (1) diagonally opposed. 1
z Tighten screws until they touch the cylinder liner.
Washers:
Maximum thickness 4 mm
Screw length:
M16 x 90

z Mount magnetic measuring stand.

z Insert dial gauge.
z Apply stylus of the dial gauge to the crankcase seal-
ing surface with pre-tension (arrow).
z Turn the dial until the pointer points to "0".

© 06/2006 1/2 8177-001

Crankcase
W 03-03-08 TCD 2015

z Loosen magnetic measuring stand.

z Turn the magnetic measuring stand carefully until the
stylus is touching the sealing surface of the cylinder
liner (arrow).
z Mount magnetic measuring stand.
z Read off measured value.
P03 39
Make measurements at at least 3 other
points on the cylinder liner.

6
© 45761-0

z Unscrew screws (1).

z Install cylinder head.
W 01-04-04

© 06/2006 2/2 8177-001

Crankcase
TCD 2015 W 03-08-01

Removing and installing genset support

Commercial available tools: – W 02-02-04
– Open wrench size SW 22 – W 06-07-03 . . . . . . . . . . . . (A-bank)
– W 06-07-03 . . . . . . . . . . . . (B-bank)
– Packing compound – W 08-04-06
DEUTZ DW 47 – W 09-07-08
– W 09-08-04

Collect leaking operating substances in

suitable vessels and dispose of according
to regulations.

Removing genset support

z Remove charge air pipe (A-bank).
W 06-07-03
z Remove charge air pipe (B-bank).
W 06-07-03
z Unscrew screws (1).
z Remove the holder (2). 2

z Unscrew screw (1).

z Remove the holder (2).
z Unscrew hollow screw (3).
z Remove sealing rings (4).
1

2 3

© 06/2006 1/14 8178-001

Crankcase
W 03-08-01 TCD 2015

z Unscrew nut (1).

z Remove the holder (2).

6
© 40521-0

z Unscrew hollow screw (1).

Hold overflow valve.

z Remove fuel pipe (3).

z Remove sealing rings (2).

1
3

z Remove thermostat housing.

W 09-08-04
z Remove coolant pump.
W 09-07-08
1
z Unscrew all screws (1).
z Remove flanged hub with torsional vibration damper
and V-belt pulley.
Block flywheel with suitable tool.

© 06/2006 2/14 8178-001

Crankcase
TCD 2015 W 03-08-01

z Remove cable tie (1).

6
© 40532-0

z Remove cable tie (1).

© 06/2006 3/14 8178-001

Crankcase
W 03-08-01 TCD 2015

z Remove oil suction pipe.

W 08-04-06

6
© 40535-0

z Unscrew lock nut (1).

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

z Unscrew screws (1).

z Unscrew screws (2).

2
1

© 06/2006 4/14 8178-001

Crankcase
TCD 2015 W 03-08-01

z Unscrew all screws (1).

z Remove holder.

6
© 40539-0

z Unscrew screws (1).

z Unscrew screws (2).

1
2

© 06/2006 5/14 8178-001

Crankcase
W 03-08-01 TCD 2015

z Unscrew screws (1).

z Remove genset support.
z Remove gasket.
1
Attention!
Do not damage the crankshaft journal
when removing the genset support.

The teeth of the oil pump gears and the

idler gear must grip the teeth of the cranks- 1
haft drive wheel.
Use suitable workshop crane.

6
© 40542-0

z Visually inspect the components.

z Knock out crankshaft sealing ring (1).

Attention!
Do not damage sealing surface when
knocking out.

© 06/2006 6/14 8178-001

Crankcase
TCD 2015 W 03-08-01

Installing genset support

z Clean sealing surfaces.
z Fix new O-rings (1) with a little grease.

1 1

6
© 40545-0

z Fix new gasket (1) to the crankcase with a little

grease.
The oil pan sealing surface on the crank-
case must face upwards. 1
Make sure the parallel pins (arrows) are in
place.

z Install genset support.

Use suitable workshop crane.
1

z Centre genset support above the parallel pins.

z Fix genset support with screws (1).
The teeth of the oil pump gears and the
idler gear must grip the teeth of the cranks-
haft drive wheel.
Screw length:
M10 x 150 mm

© 06/2006 7/14 8178-001

Crankcase
W 03-08-01 TCD 2015

z Tighten screws (1) alternately.

Screw length:
1
M10 x 150 mm

6
© 40548-0

z Tighten screws alternately.

Screw length:
M10 x 65 mm (1)
M10 x 100 mm (2)

1
2

z Tighten screws (1) alternately.

Screw length:
1
M10 x 110 mm

© 06/2006 8/14 8178-001

Crankcase
TCD 2015 W 03-08-01

z Mount holder.
z Fasten all screws (1).
TIghten screws only after mounting the
connecting pipe.

6
© 40539-0

z Tighten screws alternately.

Screw length:
M10 x 70 mm (1)
1
M10 x 110 mm (2)

2
1

z Tighten screws alternately.

A03 020

© 06/2006 9/14 8178-001

Crankcase
W 03-08-01 TCD 2015

z Cut off overhanging gasket (arrows) flush with the

sealing surface of the oil tray.

6
© 40549-0

z Mount new sealing rings.

z Mount the lubricating oil pipe.
z Screw on hollow screw (2).
z Screw on lock nut (1).
1

z Tighten hollow screw (2).

A08 013
z Tighten lock nut (1).
A08 014
1

© 06/2006 10/14 8178-001

Crankcase
TCD 2015 W 03-08-01

z Clean sealing surfaces.

z Install oil suction pipe.
W 08-04-06
Before mounting the lubricating oil pan, fill
in the joints crankcase/genset support
(arrows) with packing compound.

6
© 40550-0

z Fix the cable strand with cable tie (1) without tension.

© 06/2006 11/14 8178-001

Crankcase
W 03-08-01 TCD 2015

z Fix the cable strand with cable tie (1) without tension.
z Install crankshaft sealing ring (opposite side to fly-
wheel)
W 02-02-04

6
© 40532-0

z Mount the torsional vibration damper.

z Tighten all screws (1) alternately.
A12 030
Block flywheel with suitable tool.
1

z Install coolant pump.

W 09-07-08
z Install thermostat housing.
W 09-08-04

z Insert new sealing rings (3).

z Mount fuel pipe (2).
z Screw on hollow screw (1).

1
3

© 06/2006 12/14 8178-001

Crankcase
TCD 2015 W 03-08-01

z Oil the thread lightly.

z Mount holder (2).
z Screw on nut (1).

6
© 40521-0

z Mount new sealing rings (4).

z Screw on hollow screw (3).
z Mount holder (2).
z Oil thread and head contact surface lightly.
z Fasten screw (1). 1

2 3

z Tighten hollow screw (1).

Hold overflow valve.

A12 093
z Tighten nut (2).
1
A07 044

© 06/2006 13/14 8178-001

Crankcase
W 03-08-01 TCD 2015

z Tighten screw (1).

A07 044
z Tighten hollow screw (2).
A12 092
1

6
© 40555-0

z Mount holder (2).

z Tighten screws (1).
A07 044
z Install charge air pipe (A-bank)
W 06-07-03
z Install charge air pipe (B-bank)
W 06-07-03 2

© 06/2006 14/14 8178-001

Crankcase
TCD 2015 W 03-08-03

Dismantling and assembling genset support

Commercial available tools – W 03-08-01

Dismantling genset support

z Remove genset support.
W 03-08-01 1
z Unscrew screw (1).
z Remove thrust washer (2). 2
z Remove idler gear (3).

z Unscrew screws (1).

z Unscrew screws (2).
z Remove lubricating oil pump (3).
1

3 1

© 06/2006 1/10 8179-001

Crankcase
W 03-08-03 TCD 2015

z Pull out plug element (1).

6
© 40558-0

z Unscrew nut (1).

z Remove adapter (2).
z Remove O-rings.

2
© 45371_1

z Unscrew screws (1).

z Remove bearing housing (2).
The fuel supply pump, idler gear and fuel
pipes remain installed on the bearing hou- 1
sing.
z Remove O-ring. 2

© 06/2006 2/10 8179-001

Crankcase
TCD 2015 W 03-08-03

z Unscrew screws (1).

z Remove ground cable (2).
z Remove holder (3). 2

3 1
1

6
© 40560_1

z Unscrew all screws (1).

z Remove holder.

z Unscrew all screws (3).

z Unscrew screws (2).
z Remove holder (1).
z Remove oil cooler cover (4).
3 4 1

2
2

© 06/2006 3/10 8179-001

Crankcase
W 03-08-03 TCD 2015

z Unscrew screws (1).

z Remove oil cooler (2).
z Remove O-rings.

1
1

6
© 40563-0

Assembling genset support

z Clean sealing surfaces.
z Insert new O-rings (1).
z Insert new O-rings (2).

1 1

2 2

z Mount oil cooler (2).

z Tighten screws (1).
A08 051

1
1

© 06/2006 4/10 8179-001

Crankcase
TCD 2015 W 03-08-03

z Clean sealing surfaces.

z Mount new gasket.
z Mount oil cooler cover (4).
z Mount holder (1).
z Fasten all screws. 3 4 1
Screw length:
M8 x 35 mm (2)
M8 x 65 mm (3)

2
2

6
© 40562_1

z Mount holder (1).

z Fasten all screws (2).

z Align oil cooler cover.

The lay-on surfaces of the oil cooler cover
and the genset support must contact the
holders.
Do not move gasket. 1

z Tighten all screws (1) alternately.

A08 050

© 06/2006 5/10 8179-001

Crankcase
W 03-08-03 TCD 2015

z Unscrew all screws (1).

z Remove holder.
The screws for both holders are not tighte-
ned until after mounting the connecting
pipe. 1

6
© 40525-0

z Mount holder (3).

z Mount ground cable (2).
z Tighten screws (1). 2
A13 018

3 1
1

z Insert new O-ring.

z Insert bearing housing (2).
z Tighten screws (1).
A07 024 1

© 06/2006 6/10 8179-001

Crankcase
TCD 2015 W 03-08-03

z Position O-rings.
z Mount adapter (2).
z Tighten nut (1).
A08 002

2
6
© 45371_1

z Lightly oil O-ring.

z Mount new O-ring (1).

z Insert plug element (1).

© 06/2006 7/10 8179-001

Crankcase
W 03-08-03 TCD 2015

z Pay attention to clamping bushing (1).

6
© 40528-0

z Insert new O-ring.

z Mount lubricating oil pump (3).

z Oil the screws lightly.
z Fasten screws.
Screw length: 1
M10 x 75 mm (1)
M8 x 45 mm (2).

3 1

© 06/2006 8/10 8179-001

Crankcase
TCD 2015 W 03-08-03

z Tighten screws (1).

A08 010
z Tighten screws (2).
1
A08 011

6
© 40648-0

z Lightly oil journal (1).

z Lightly oil bearing bush (2).
3
z Mount idler gear (3).
The collar (arrow) of the idler gear faces
the genset support.

z Mount thrust washer (2).

z Fasten screw (1). 1
The bevelled side (arrow) of the thrust
washer must face upwards.

© 06/2006 9/10 8179-001

Crankcase
W 03-08-03 TCD 2015

z Tighten screw (1).

A04 011
z Install genset support. 1
W 03-08-01

6
© 40537-0

© 06/2006 10/10 8179-001

Crankcase
TCD 2015 W 03-09-01

Removing and installing rear cover

Commercial available tools – W 02-02-02
– W 03-09-04
– W 08-04-07
– Locking agent
DEUTZ DW 59

Removing rear cover

z Remove connection housing.
W 03-09-04
z Remove lubricating oil pan. 1

W 08-04-07
z Unscrew all screws (1).
z Remove rear cover 2.
2
z Remove gasket.

z Knock out crankshaft sealing ring (1).

Attention!
Do not damage the sealing surfaces.

© 06/2006 1/4 8180-001

Crankcase
W 03-09-01 TCD 2015

z Visually inspect the components.

6
© 40685-0

Installing rear cover

z Clean sealing surfaces.
z Make sure the clamping bushings (arrows) are in
place.
The slots in the clamping bushings must
face downwards.

z Insert new seal (1).

© 06/2006 2/4 8180-001

Crankcase
TCD 2015 W 03-09-01

z Mount rear cover.

Use new sealing rings.

z Fasten screws. 1
z Insert screws (1) with locking agent.
Screw length:
M8 x 30 mm (1),(3)
M8 x 45 mm (2)
3 3
z Tighten screws alternately.
A03 010
2

6
© 40688_1

The gasket (arrows) must be flush with the

sealing surface of the oil pan.

z Install lubricating oil pan.

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

© 06/2006 3/4 8180-001

Crankcase
W 03-09-01 TCD 2015

© 06/2006 4/4 8180-001

Crankcase
TCD 2015 W 03-09-04

Removing and installing the connection housing

Commercial available tools: – W 05-07-01
– Rotation angle disc . . . . . . . . . . . . . 8190 – W 06-01-07
– W 12-06-01
– Locking agent – W 13-03-02
DEUTZ DW 59

Removing the connection housing

z Install impulse transmitter (crankshaft).
W 05-07-01
z Remove starter.
W 13-03-02
z Remove exhaust manifold.
W 06-01-07
z Remove flywheel.
W 12-06-01

z Unscrew screws (arrows).

© 06/2006 1/6 8181-001

Crankcase
W 03-09-04 TCD 2015

z Unscrew screws (1).

z Unscrew screws (2).
z Remove flange housing (3).

6 3

z Unscrew screws (1).

z Unscrew screws (arrows).

z Unscrew all screws (1).

z Remove connection housing.

© 06/2006 2/6 8181-001

Crankcase
TCD 2015 W 03-09-04

z Visually inspect the components.

6
© 40899-0

Installing the connection housing

z Clean contact surfaces.
z Coat connection housing on lay-on surface (arrow)
with locking agent.

Make sure the parallel pins (arrows) are in

place.

© 06/2006 3/6 8181-001

Crankcase
W 03-09-04 TCD 2015

z Mount connection housing.

Centre above the parallel pins.

z Fasten screws.
1
Insert screws with locking agent.
Note different screw lengths.
M12 x 35 mm (1)
M12 x 90 mm (2). 2

z Tighten screws (1).

A03 081

6
© 40694-0

z Tighten screws (1) alternately.

A03 082

z Fasten screws.
Insert screws with locking agent.
Note different screw lengths.
M12 x 200 mm (1)
M12 x 175 mm (arrows).
1
z Tighten screws (1) alternately.
A03 088

© 06/2006 4/6 8181-001

Crankcase
TCD 2015 W 03-09-04

z Tighten screws (arrows).

A03 089

6
© 40697-0

z Mount new O-ring (1).

z Coat lay-on surface (arrow) with locking agent.

z Mount flange housing (3).

z Lightly oil screws (1).
z Tighten screws (1).
Screw length:
M10 x 110 mm
1
z Insert screws (2) with locking agent.
z Tighten screws (2).
Screw length:
M10 x 210 mm

z Tighten screws (1).

2
A12 058
3

© 06/2006 5/6 8181-001

Crankcase
W 03-09-04 TCD 2015

z Tighten screws (1).

A12 059

6
© 40698-0

z Tighten screws (arrows).

A03 080

z Install flywheel.
W 12-06-01
z Install starter.
W 13-03-02
z Install impulse transmitter (crankshaft).
W 05-07-01
z Install exhaust manifold.
W 06-01-07

© 06/2006 6/6 8181-001

Crankcase
TCD 2015 I 03-10-05

Repairing the collar rest of the cylinder liner

Commercial available tools – W 03-03-02

Special tools:
– Tool kit. . . . . . . . . . . . . . . . . . . . . 150030
In case of coolant leakage or damage to
– Repair kits the sealing assembly crankcase/cylinder
– Fitting compound liner/cylinder head, the collar rest of the
DEUTZ AP 1908 cylinder liner in the crankcase can be
– Cleaning agent (e.g. com- repaired.
merically available brake The following work sequence must be car-
cleaner) ried out on every cylinder unit of a cylinder
bank.

Grinding in collar rest surface

z Remove cylinder liner.
1
W 03-03-02
z Seal the insides of the crankcase with cover
plates (1).

z Clean collar rest (1).

z Clean inside of the crankcase.
Use cleaning agent.

1
© 39902-0

© 06/2006 1/8 8182-001

Crankcase
I 03-10-05 TCD 2015

Grinding for cleaning the collar rest

z Apply post-grinding paste (1) to the collar rest (2). 1 2
z Add a little clean water.

6
© 39908-0

z Mount the bracket and handles on the grinding/sur-

face plate.
Note the different processing sides of the A
grinding/surface plate:
A - grinding side
B - surface side
Grinding side “A“ faces down.
z Place grinding side “A“ on collar rest.

z Turn the grinding/surface plate (1) forwards and

backwards evenly (approx. 180°).
z Grind the collar rest lightly.
Note soft grinding noise.

z Clean the collar rest. 1

z Remove grind paste and grinding particles.
Use cleaning agent.

© 06/2006 2/8 8182-001

Crankcase
TCD 2015 I 03-10-05

Check
z Move the bracket on the griding/surface plate.
B
Spotting side “B“ facing downwards.

z Apply surface paste thinly to the surface side “B“.

Applying it too thickly makes it impossible
to detect recesses in the collar rest.

6
© 39916-0

z Place surface side “B“ on collar rest.

Note the different processing sides of the
grinding/surface plate:
A - grinding side
B - surface side
z Surface the collar rest.

The surfacing shows up recesses (1) in the

collar rest.

© 06/2006 3/8 8182-001

Crankcase
I 03-10-05 TCD 2015

Grinding
z Move the bracket on the griding/surface plate.
A
Grinding side “A“ faces down.

6
© 39904-0

z Apply pre-grinding paste (1) to the collar rest (2).

z Add a little clean water.
1

z Place grinding side “A“ on collar rest.

z Turn the grinding/surface plate (1) forwards and
backwards evenly (approx. 180°).
Lift the grinding/surface plate slightly
several times for the grinding paste to
spread evenly.
Note rough grinding noise. 1
z Remove grind paste and grinding particles.
z Clean the collar rest.
Use cleaning agent.

© 06/2006 4/8 8182-001

Crankcase
TCD 2015 I 03-10-05

Check
z Check the contact pattern.
An even contact pattern must exist.
Otherwise, repeat the grinding and sur-
face process.
z Clean the collar rest.

6
© 39912-0

Regrinding
z Move the bracket on the griding/surface plate.
A
Grinding side “A“ faces down.

z Apply post-grinding paste (1) to the collar rest (2).

z Add a little clean water.
1

© 06/2006 5/8 8182-001

Crankcase
I 03-10-05 TCD 2015

z Turn the grinding/surface plate (1) forwards and

backwards evenly (approx. 180°).
Lift the grinding/surface plate slightly
several times for the grinding paste to
spread evenly.
Note soft grinding noise.
z Clean the collar rest. 1
z Remove grind paste and grinding particles.
Repeat the surface process to check.

6
© 39906-0

z Clean inside of the crankcase.

z Remove cover plates (1).
z Check the inside of the crankcase for cleanliness. 1
The tool set must be cleaned and the grin-
ding/surface plate oiled slightly for corro-
sion protection.

Assembly
z Insert new O-rings (1).
z Coat the O-rings with fitting compound. 1

© 06/2006 6/8 8182-001

Crankcase
TCD 2015 I 03-10-05

z Insert shim ring (1).

A centring lug (2) points up. 1

6
© 39911-0

z Insert new cylinder liner (1).

W 03-03-02
1

© 06/2006 7/8 8182-001

Crankcase
I 03-10-05 TCD 2015

© 06/2006 8/8 8182-001

Crankcase
TCD 2015 W 03-11-01

Removing and installing, testing camshaft bearing

Commercial available tools: – W 04-05-05
– Micrometer gauge
– Internal measuring device
Special tools:
– Dial gauge. . . . . . . . . . . . . . . . . . 100400
– Assembly tool . . . . . . . . . . . . . . . 143830

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 70 mm.
– Balance the internal measuring device between
the test surfaces of the micrometer gauge and set
the meter at the reversal point of the pointer to "0".

© 06/2006 1/8 8183-001

Crankcase
W 03-11-01 TCD 2015

Diagram for measuring the camshaft bea-

ring 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.
P03 13
P03 14
Measuring points see diagram.
When the wear limit is reached, the cams-
haft bearing must be replaced.

Removing camshaft bearing

z Insert spindle (1) with puller bush (2) on the opposite
side to the flywheel.

© 06/2006 2/8 8183-001

Crankcase
TCD 2015 W 03-11-01

z Insert counter bearing (1) on the flywheel side.

1 6
© 34712-1

z Mount spacing sleeve (1).

z Mount ball bearing (2).
z Screw on nut.

z Pull out the camshaft bearings one after another.

Do not pull out the camshaft bearing (flyw-
heel side).

© 06/2006 3/8 8183-001

Crankcase
W 03-11-01 TCD 2015

z Insert spindle with puller bush on flywheel side.

z Mount counter bearing (1) on flywheel side.
z Mount spacing sleeve.
z Mount ball bearing.
z Screw on nut.
z Pull out flywheel side camshaft bearing. 1

6
© 34716-2

Installing camshaft bearing

Diagram for the installation depth of the
camshaft bearings.

Measuring the depth from the flywheel side

A 0 mm
0,2 D C B A
B 172,5 0,2 mm
0,2
C 337,5 0,2 mm
0,2
D 502,5 0,2 mm

z Mount the new camshaft bearing (flywheel side) so

that the recess (1) faces the flywheel.
The diagram shows the camshaft bearing
in the installed state.
The camshaft bearing (flywheel side) has
two lubricating oil bores.
Make sure the lubricating oil bores (2) in
the camshaft bearing and crankcase are in
line.

© 06/2006 4/8 8183-001

Crankcase
TCD 2015 W 03-11-01

z Insert spindle with counter bearing on the opposite

side to the flywheel.
z Insert puller bush in camshaft bearing and push onto
the spindle.

6
© 34718-2

z Mount spacing sleeve.

z Mount ball bearing.
z Screw on nut.
z Press in camshaft bearing (flywheel side).
Installation depth, see diagram.

z Check that the lubricating oil bores (1) are in line.

If the lubricating oil bore is not in line, the
camshaft bearing must be removed and re-
installed.

© 06/2006 5/8 8183-001

Crankcase
W 03-11-01 TCD 2015

z Mount the new middle camshaft bearings on the op-

posite side to the flywheel so that the recess (1) fac-
es the flywheel.
The diagram shows the camshaft bearing 1
in the installed state.
The middle camshaft bearings have three
lubricating oil bores.
Make sure the lubricating oil bores (2) in
the camshaft bearing and crankcase are in
line.

6
© 37180-1

z Mount the new camshaft bearing (opposite side to

flywheel) so that the recess (1) faces the flywheel.
The diagram shows the camshaft bearing
in the installed state. 2
The camshaft bearing (opposite side to fly-
wheel) has three lubricating oil bores.
Make sure the lubricating oil bores (2) in
the camshaft bearing and crankcase are in
line.

z Insert puller bush in camshaft bearing.

z Insert spindle with puller bush on flywheel side.

© 06/2006 6/8 8183-001

Crankcase
TCD 2015 W 03-11-01

z Mount counter bearing.

z Mount spacing sleeve.
z Mount ball bearing.
z Screw on nut.
z Insert the camshaft bearings one after another.
Attention!
Do not damage the camshaft bearings
when moving the assembly tool!

Installation depth, see diagram.

6
© 34714-2

z Check that the lubricating oil bores (1) are in line.

If the lubricating oil bore is not in line, the
camshaft bearing must be removed and re-
installed.
1
z Install the camshaft.
W 04-05-05

© 06/2006 7/8 8183-001

Crankcase
W 03-11-01 TCD 2015

© 06/2006 8/8 8183-001

Engine control
TCD 2015 W 04-02-02

Remove and installing tappets, checking tappet bores

Commercial available tools: – W 04-05-05
– Micrometer gauge
– Internal measuring device

Removing tappets.
z Remove camshaft.
W 04-05-05
z Remove tappets.
Lay out components in the order in which
they should be installed.
Note order of cylinders.

z Visually inspect the components.

© 06/2006 1/2 8184-001

Engine control
W 04-02-02 TCD 2015

Measuring tappet bores

z Set micrometer gauge to 25 mm.
z Push the internal measuring device between the test
surfaces of the micrometer gauge and set to "0".

6
© 35825-2

z Measure tappet bore with internal measuring device.

P03 23
P03 24

Installing tappets
z Oil all tappets lightly.
z Insert all tappets.
Note the assignment of the tappets.

z Install the camshaft.

W 04-05-05

© 06/2006 2/2 8184-001

Engine control
TCD 2015 W 04-04-09

Removing and installing the gearcase cover

Commercial available tools – W 06-06-04

– Packing compound Collect leaking operating substances in

DEUTZ DW 48 suitable vessels and dispose of according
to regulations.

Removing the gearcase

z Remove turbocharger.
W 06-06-04

z Loosen hose clip (1).

z Pull off pipe (2).

1
2

© 06/2006 1/6 8185-001

Engine control
W 04-04-09 TCD 2015

z Unscrew screws (1).

6
© 40702-0

z Unscrew screws (1).

z Remove spacing sleeves.
z Unscrew all screws (2).
z Remove heat shield (3). 1
2

z Unscrew screws (1).

z Remove the holder (2).

© 06/2006 2/6 8185-001

Engine control
TCD 2015 W 04-04-09

z Unscrew screw (1).

z Remove pipe clamp (2).

6
© 40705-0

z Unscrew all screws (1).

z Remove gear case cover (2).

z Visually inspect the components.

© 06/2006 3/6 8185-001

Engine control
W 04-04-09 TCD 2015

Installing the gearcase cover

Attention!
Do not damage the sealing surfaces.
1
2
z Clean sealing surfaces. 2
z Apply packing compound evenly to the sealing sur-
face.
z Mount gear case cover (1).
z Mount holder (2).
z Tighten all screws (3) alternately.
A04 020 3

6
© 40708-0

z Mount pipe clamp (2).

z Tighten screw (1).
A08 045

z Mount holder (2).

z Tighten screws (1).
A12 071

© 06/2006 4/6 8185-001

Engine control
TCD 2015 W 04-04-09

z Mount heat shield (3).

z Insert spacing sleeves with screws (1).
z Tighten screws (1).
z Fasten all screws (2). 1
2
z Tighten all screws.
A12 071
3

6
© 40703-0

z Tighten screws (1).

A13 094

z Push on pipe (2).

z Tighten hose clip (1).
A03 064

1
2

© 06/2006 5/6 8185-001

Engine control
W 04-04-09 TCD 2015

z Install the turbocharger.

W 06-06-04

6
© 40700-0

© 06/2006 6/6 8185-001

Engine control
TCD 2015 Railway W 04-04-09

Removing and installing the gearcase cover

Commercial available tools – W 07-13-01 . . . . . . . . . . . . (Railway)

Collect leaking operating substances in

suitable vessels and dispose of according
to regulations.

Removing the gearcase

z Unlock cable plug (1) and remove.
z Remove cable tie (2).
z Lay cable bare.

z Unscrew screws (1).

z Remove washers.
z Remove fuel pressure holding valve.
W 07-13-01 1

© 06/2006 1/6 8186-001

Engine control
W 04-04-09 TCD 2015 Railway

z Unscrew screw (1).

z Remove washer.
3
z Remove spacing sleeve (2).
z Loosen pipe clamp (3).

6
© 45775-0

z Unscrew screws (1).

z Remove washer.
z Remove the holder (2). 3
z Remove holder (3).

1
2

z Unscrew all screws (1).

z Remove gear case cover (2).
z Remove gasket.

© 06/2006 2/6 8186-001

Engine control
TCD 2015 Railway W 04-04-09

z Visually inspect the components.

6
© 40707-0

Installing the gearcase cover

z Clean sealing surfaces.
z Mount new gasket.
z Mount gear case cover (1).
z Tighten screws (2) alternately. 1
A04 020

z Mount holder (3).

z Mount holder (2).
z Mount washer. 3
z Tighten screws (1).
A12 071

1
2

© 06/2006 3/6 8186-001

Engine control
W 04-04-09 TCD 2015 Railway

z Position pipe clamp (3).

z Position spacing sleeve (2).
3
z Mount washer.
z Tighten screw (1).
A12 096

6
© 45775-0

z Position cable harness rail with cable harness.

z Position pipe clamp (1).
z Mount washers.
z Fasten screws. 3 1
Note different screw lengths:
M6 x 12 mm (1)
M6 x 16 mm (2)
z Tighten screws .
A13 094
2

z Install fuel pressure holding valve.

W 07-13-01

© 06/2006 4/6 8186-001

Engine control
TCD 2015 Railway W 04-04-09

z Plug in the cable plug (1).

Ensure that the cables are connected pro-
perly.

z Fix cable with cable tie (2).

6
© 42108-1

© 06/2006 5/6 8186-001

Engine control
W 04-04-09 TCD 2015 Railway

© 06/2006 6/6 8186-001

Engine control
TCD 2015 W 04-05-05

Removing and installing the camshaft

Commercial available tools: – W 01-02-02
– Lifting gear – W 02-04-01
– Depth-measuring – W 04-05-06
appliance – W 05-07-03
– Magnetic measuring stand – W 06-06-04
– Rotation angle disc . . . . . . . . . . . . . 8190 – W 07-04-01 . . . . . . . . . . . . (Cylinder A1)
Special tools: – W 07-04-01 . . . . . . . . . . . . (Cylinder
– Dial gauge. . . . . . . . . . . . . . . . . . 100400 A2-B3)
– Counter support . . . . . . . . . . . . . 144150 – W 07-06-04

– Packing compound
DEUTZ DW 48
– Locking agent
DEUTZ DW 72 6

Removing the camshaft

z Remove rocker arm brackets.
W 01-02-02
z Remove crankshaft.
W 02-04-01
z Remove impulse transmitter (camshaft).
W 05-07-03

z Remove injection pumps (cylinder A1).

W 07-04-01
z Remove injection pumps (cylinder A2-B3).
W 07-04-01
1
Do not remove injection pump housing.

2
z Unscrew hollow screw (1).
z Place fuel hose (2) to one side.
z Remove sealing rings.

© 06/2006 1/24 8187-001

Engine control
W 04-05-05 TCD 2015

z Unscrew screws (1).

z Place cable harness rail (2) with cable harness to
one side.

6
© 40410-0

z Unscrew all screws (3).

z Remove spacing sleeves. 1
z Unscrew all screws (2).
z Remove heat shield (1).

z Unscrew screws (1).

z Remove the holder (2).

© 06/2006 2/24 8187-001

Engine control
TCD 2015 W 04-05-05

z Unscrew screw (1).

z Remove pipe clamp (2).

6
© 40413-0

z Unscrew all screws (1).

z Remove gear case cover (2).

1 2

z Remove cable tie (1).

© 06/2006 3/24 8187-001

Engine control
W 04-05-05 TCD 2015

z Unscrew screws (1).

z Remove cover (2) .
z Remove cover (3).
3
2

6
© 40416-0

z Unscrew screws (1).

z Remove pad thrust bearing (2).
1

z Unscrew all screws (1).

z Remove gear wheel (2).
Attention!
2
Make sure no parts fall into the crankcase!

Concealed screws can be accessed by

turning the crankshaft with the turning gear.
Press back the injection pump camshaft
carefully as far as it goes.

© 06/2006 4/24 8187-001

Engine control
TCD 2015 W 04-05-05

z Unscrew screw (1).

6
© 40419-0

z Unscrew screw (1).

z Remove bolt (1).

z Remove idler gear (2).

© 06/2006 5/24 8187-001

Engine control
W 04-05-05 TCD 2015

z Unscrew screw (1).

6
© 40422-0

z Unscrew screw (1).

z Remove bolt (1).

z Remove idler gear (2).

© 06/2006 6/24 8187-001

Engine control
TCD 2015 W 04-05-05

z Unscrew all screws (1).

z Remove cover (2) .
z Remove gasket.

6
© 40425-0

z Insert counter support (1) in the toothing of the cam-

shaft gear wheel.

z Turn the camshaft gear wheel in the direction of

the A-bank.
z Block the camshaft gear wheel with the counter hold-
er on the crankcase (arrow).

© 06/2006 7/24 8187-001

Engine control
W 04-05-05 TCD 2015

z Loosen screw (1).

z Turn back the camshaft gear wheel.
z Remove counter holder (2).

1
6
© 40428-0

z Unscrew screw (1).

z Remove camshaft toothed wheel (2).
Press back the injection pump camshaft
carefully as far as it goes.

z Turn engine 180°.

z Press in all tappets.
z Hang engine on workshop crane.
z Unhook the engine from the assembly block on one
side.
z Pull out the camshaft (1) carefully to the flywheel
side.

© 06/2006 8/24 8187-001

Engine control
TCD 2015 W 04-05-05

z Check camshaft.
W 04-05-06

6
© 36812-1

Installing the camshaft

z Oil camshaft bearing lightly.
z Oil cam shaft pin lightly.
z Insert camshaft carefully.
The locating hole (1) of the camshaft faces
towards the lubricating oil pan.

z Measure the overhang of the parallel pin with the

depth measuring appliance.
P04 39
z Correct overhang.

© 06/2006 9/24 8187-001

Engine control
W 04-05-05 TCD 2015

z Insert camshaft gear wheel (2).

z Lightly oil screw (1).
z Fasten screw (1).
Make sure that the parallel pin on the
camshaft gear wheel and the locating hole
on the camshaft are in line. 2

6
© 40429-0

z Insert counter support (1) in the toothing of the cam-

shaft gear wheel.
z Turn the camshaft gear wheel in the direction of
the B-bank.
z Block the camshaft gear wheel with the counter hold-
er on the crankcase (arrow).
1

z Tighten screw (arrow).

A04 001
z Turn back the camshaft gear wheel.
z Remove counter holder.

© 06/2006 10/24 8187-001

Engine control
TCD 2015 W 04-05-05

Determining axial backlash of the cam-

shaft
z Push back the camshaft as far as it goes.
z Measure the camshaft stand back from the lay-on
surface on the camshaft gear wheel to the crankcase
with the depth measuring appliance (arrows).
z Note measured value, dimension (a).

6
© 40434-0

z Mount new gasket (1).

z Measure the flange height from the running surfaces
to the lay-on surface with the depth measuring appli-
ance (arrows).
z Note measured value, dimension (b).
z Determine axial backlash.
P04 35
Calculation example
Desired: Axial backlash
Given: -
Measured: (a) = 45.80 mm
(b) = 45.50 mm
Calculation: Axial backlash = dimension (a) - dimension (b)
45.80 mm - 45.50 mm
Result: = 0.30 mm
1
z Correct deviation with gaskets.
© 42273-2

P04 37

z Mount cover (2).

Insert screws with locking agent.

z Fit new sealing rings.

z Tighten all screws (1). 1
A04 002

© 06/2006 11/24 8187-001

Engine control
W 04-05-05 TCD 2015

z Mount new O-ring (1).

z Lightly oil O-ring.
z Check oil channel (arrow) for free passage.

6 1
© 40435-0

z Lightly oil bearing liner (1) with engine oil.

z Insert idler gear (2).
The collar (arrow) faces the bearing bush.

z Insert bolt (1).

© 06/2006 12/24 8187-001

Engine control
TCD 2015 W 04-05-05

z Lightly oil screw (1).

z Tighten screw (1).
A04 013
Screw length:
M12 x 80 mm

6
© 40423-0

z Lightly oil screw (1).

z Tighten screw (1).
A04 012

z Mount new O-ring (1).

z Lightly oil O-ring.
z Check oil channel (arrow) for free passage.

1
© 40435-0

© 06/2006 13/24 8187-001

Engine control
W 04-05-05 TCD 2015

z Lightly oil bearing liner (1) with engine oil.

z Insert idler gear (2).
The collar (arrow) faces the bearing bush.

1
6
© 40436-0

z Insert bolt (1).

z Lightly oil screw (1).

z Tighten screw (1).
A04 013
Screw length:
1
M12 x 100 mm

© 06/2006 14/24 8187-001

Engine control
TCD 2015 W 04-05-05

z Lightly oil screw (1).

z Tighten screw (1).
A04 012

6
© 40419-0

Checking the tooth edge clearance of the

idler gear (B-bank)
z Mount magnetic measuring stand.
z Insert dial gauge.
z Turn idler gear in direction of arrow until it stops.
z Apply stylus under pre-tension to a tooth flank.
z Adjust dial gauge to "0".

z Turn idler gear in direction of arrow until it stops.

z Read off measured value.
P04 44
Repeat the measuring process on several
tooth flanks.

z Remove magnetic measuring stand.

z Remove dial gauge.

© 06/2006 15/24 8187-001

Engine control
W 04-05-05 TCD 2015

Checking the tooth edge clearance of the

idler gear (A-bank)
z Mount magnetic measuring stand.
z Insert dial gauge.
z Turn idler gear in direction of arrow until it stops.
z Apply stylus under pre-tension to a tooth flank.
z Adjust dial gauge to "0".

6
© 40442-0

z Turn idler gear in direction of arrow until it stops.

z Read off measured value.
P04 44
Repeat the measuring process on several
tooth flanks.

z Remove magnetic measuring stand.

z Remove dial gauge.

z Position the injection pump camshaft.

The locating hole (arrow) faces upwards.

© 06/2006 16/24 8187-001

Engine control
TCD 2015 W 04-05-05

z Position camshaft gear wheel.

The marking (1) faces towards the cranks-
haft.

6
© 42289-1

Overview of the gear train and the mar-

kings of the control times: 1
Injection pump camshaft gear wheel (1)
Camshaft gear wheel (2) 2
Idler gear (3).
Crankshaft gear wheel (4)
Marking injection pump camshaft / idler
3
gear (5)
5
Marking camshaft / crankshaft (6)

4
6
© 40445-1

z Position injection pump camshaft gear wheel.

The marking (1) faces the camshaft gear
wheel.

© 06/2006 17/24 8187-001

Engine control
W 04-05-05 TCD 2015

z Insert the injection pump camshaft gear wheel in the

camshaft gear wheel.
The marking on the gear wheel must be
between the markings of the injection
pump camshaft gear wheel (1).

6 1

Attention!
Make sure no parts fall into the crankcase!

z Fasten all screws (1).

Concealed screws can be accessed by
turning the crankshaft with the turning gear.

Checking the tooth edge clearance of the

injection pump camshaft gear wheel
z Mount magnetic measuring stand.
z Insert dial gauge.
z Turn gear wheel in direction of arrow until it stops.
z Apply stylus under pre-tension to a tooth flank.
z Adjust dial gauge to "0".

© 06/2006 18/24 8187-001

Engine control
TCD 2015 W 04-05-05

z Turn gear wheel in direction of arrow until it stops.

z Read off measured value.
P07 20
Repeat the measuring process on several
tooth flanks.

z Remove magnetic measuring stand.

z Remove dial gauge.

6
© 40450-0

z Install crankshaft.
W 02-04-01
Do not install the turbocharger.

z Install rocker arm brackets.

W 01-02-02
z Check and set plunger lift of injection pumps.
W 07-06-04

z Tighten all screws (1).

A04 004
Concealed screws can be accessed by
turning the crankshaft with the turning gear.

© 06/2006 19/24 8187-001

Engine control
W 04-05-05 TCD 2015

z Mount pad thrust bearing (2).

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

6
© 40989-0

Checking and setting axial backlash of the

injection pump camshaft
z Insert feeler gauge blade between gear wheel of the
injection pump camshaft and the pad thrust
bearing (arrow). 1
z Press the pad thrust bearing onto the feeler gauge
blade.
z Fasten screw (1).
z Check axial backlash.
P04 43

z Insert feeler gauge blade between gear wheel of the

injection pump camshaft and the pad thrust
bearing (arrow).
z Press the pad thrust bearing onto the feeler gauge
blade.
z Fasten screw (1). 1
z Check axial backlash.
P04 43

© 06/2006 20/24 8187-001

Engine control
TCD 2015 W 04-05-05

z Tighten screws (1).

A04 015
z Check axial backlash again.
P04 43
Check axial backlash on both sides bet- 1
ween
pad thrust bearing and gear
wheel (arrows).

6
© 40514-0

z Clean sealing surfaces.

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

z Press in the cover (3) to the stop.

z Mount cover (2).
Insert screws with locking agent.

z Tighten screws (1). 3

2
A04 022

© 06/2006 21/24 8187-001

Engine control
W 04-05-05 TCD 2015

z Fix cable tie (1).

6
© 40459-0

z Clean sealing surfaces.

z Apply packing compound evenly to the sealing sur-
face of the gear case.
Use packing compound DEUTZ DW 48.

2
z Mount gear case cover (1). 2
z Mount holder (2).
1
z Tighten all screws (3) alternately.
A04 020

z Mount pipe clamp (2).

z Tighten screw (1).
A08 045

© 06/2006 22/24 8187-001

Engine control
TCD 2015 W 04-05-05

z Mount holder (2).

z Tighten screws (1).
A12 071

6
© 40455-0

z Mount heat shield (1).

z Insert screws (3) with spacing sleeves. 1
z Tighten screws (2).
z Tighten screws (2 and 3) alternately.
A12 071

z Tighten screws (1).

A13 094

© 06/2006 23/24 8187-001

Engine control
W 04-05-05 TCD 2015

z Mount new sealing rings.

z Position fuel hose (2).
z Tighten hollow screw (1).
A12 090
1

6
© 40458-0

z Install impulse transmitter (camshaft).

W 05-07-03
z Install injection pumps (cylinder A1).
W 07-04-01
z Install injection pumps (cylinder A2-B3).
W 07-04-01
z Install the turbocharger.
W 06-06-04

© 06/2006 24/24 8187-001

Engine control
TCD 2015 W 04-05-06

Checking the camshaft

Commercial available tools: – W 04-05-05
– Depth-measuring appli-
ance
– Micrometer gauge

Checking the camshaft

z Remove camshaft.
W 04-05-05
z Visually inspect cams and bearing pins for wear.
Repairing the camshaft is not permissible.
The camshaft must be renewed.

z Visually inspect the components.

Diagram for measuring the journals at the

points 1 and 2 in the levels a and b.

© 06/2006 1/4 8188-001

Engine control
W 04-05-06 TCD 2015

z Measure the diameter of journals with the microme-

ter gauge.
P04 31
Measuring points see diagram.
When the wear limit is reached, the cams-
haft must be renewed.

6
© 42128-1

Checking the camshaft gear wheel

z Unscrew all screws (1).
1

z Remove idler gear (1).

z Visually inspect the idler gear (1) for wear.
z Visually inspect the camshaft gear wheel (2) for 2
wear.
1

© 06/2006 2/4 8188-001

Engine control
TCD 2015 W 04-05-06

z Insert parallel pin (1).

6
© 40603-0

z Measure the overhang of the parallel pin with the

depth measuring appliance.
P04 39
z Correct overhang.

z Place camshaft gear wheel on idler gear.

Note installation position.
The marking (1) on the idler gear faces the 2
camshaft gear wheel.
The markings (1) and (2) must be opposite
in line.

© 06/2006 3/4 8188-001

Engine control
W 04-05-06 TCD 2015

z Lightly oil screws (1).

z Tighten screws (1) alternately.
A04 003 1
z Install the camshaft.
W 04-05-05

6
© 40601-0

© 06/2006 4/4 8188-001

Engine control
TCD 2015 W 04-05-07

Removing and installing injection pump camshaft

Commercial available tools: – W 01-02-02
– Depth-measuring – W 02-02-02
appliance – W 03-08-01
– Magnetic measuring stand – W 03-09-04
Special tools: – W 04-06-03
– Turn-over gear . . . . . . . . . . . . . . 100350 – W 05-07-03
– Dial gauge. . . . . . . . . . . . . . . . . . 100400 – W 06-06-04
– Counter support . . . . . . . . . . . . . 144150 – W 07-04-01 . . . . . . . . . . . . (Cylinder A1)
– W 07-04-01 . . . . . . . . . . . . (Cylinder
– Packing compound A2-B3)
DEUTZ DW 48 – W 07-06-04
– Locking agent
DEUTZ DW 72 Collect leaking operating substances in
suitable vessels and dispose of according 6
to regulations.

Removing injection pump camshaft

z Remove impulse transmitter (camshaft).
W 05-07-03
z Remove injection pumps (cylinder A1).
W 07-04-01
z Remove injection pumps (cylinder A2-B3).
W 07-04-01
z Remove genset support.
W 03-08-01
z Remove turbocharger.
W 06-06-04

z Unscrew hollow screw (1).

z Place fuel hose (2) to one side.
z Remove sealing rings.

© 06/2006 1/32 8189-001

Engine control
W 04-05-07 TCD 2015

z Unscrew screws (1).

6
© 40453-0

z Unscrew all screws (3).

z Remove spacing sleeves. 1
z Unscrew all screws (2).
z Remove heat shield (1).

z Unscrew screws (1).

z Remove the holder (2).

© 06/2006 2/32 8189-001

Engine control
TCD 2015 W 04-05-07

z Unscrew screw (1).

z Remove pipe clamp (2).

6
© 40456-0

z Unscrew all screws (1).

z Remove gear case cover (2).
1

z Remove cable tie (1).

© 06/2006 3/32 8189-001

Engine control
W 04-05-07 TCD 2015

z Unscrew screws (1).

z Remove cover (2) .
z Remove cover (3).

3
2

1
6
© 40460-0

z Unscrew screws (1).

z Remove pad thrust bearing (2).
z Attach turning gear. 1

W 04-06-03

z Loosen all screws (1).

Concealed screws can be accessed by
turning the crankshaft with the turning gear.

© 06/2006 4/32 8189-001

Engine control
TCD 2015 W 04-05-07

z Turn over crankshaft until the valve overlap is

achieved on cylinder no. B2.
T01 63
Valve overlap means:
The inlet valve starts opening,exhaust
valve closes.

6
© 40465-0

The locking pin of the turning gear must

snap into the tooth notch (1) of the starter
ring gear.
The second tooth notch (2) must face the
B-bank.

1
2

Attention!
Make sure no parts fall into the crankcase!

z Unscrew screws (1).

z Pull locking pin.
Concealed screws can be accessed by
turning the crankshaft with the turning gear.

1 1

© 06/2006 5/32 8189-001

Engine control
W 04-05-07 TCD 2015

z Turn over crankshaft until the valve overlap is

achieved on cylinder no. B2.
z Unscrew screws (1).
z Remove gear wheel (2).
Attention! 2
Make sure no parts fall into the crankcase!

Press back the injection pump camshaft

carefully as far as it goes.

z Remove turning gear. 1

W 04-06-03

6
© 40467-0

z Remove rocker arm brackets.

W 01-02-02
z Remove connection housing.
W 03-09-04
z Remove crankcase sealing ring (flywheel side) 1

W 02-02-02
z Unscrew screw (1).

z Unscrew screw (1).

© 06/2006 6/32 8189-001

Engine control
TCD 2015 W 04-05-07

z Remove bolt (1).

z Remove idler gear (2).

1
6
© 40421-0

z Unscrew screw (1).

© 06/2006 7/32 8189-001

Engine control
W 04-05-07 TCD 2015

z Remove bolt (1).

z Remove idler gear (2).

6
© 40424-0

z Unscrew all screws (1).

z Remove cover (2) .
z Remove gasket.

z Insert counter support (1) in the toothing of the cam-

shaft gear wheel.

© 06/2006 8/32 8189-001

Engine control
TCD 2015 W 04-05-07

z Fasten all screws (1).

6
© 40470-0

z Mount turning gear (1).

z Turn the camshaft gear wheel in the direction of

the A-bank.
z Block the camshaft gear wheel with the counter hold-
er on the crankcase (arrow).

© 06/2006 9/32 8189-001

Engine control
W 04-05-07 TCD 2015

z Loosen screw (1).

6
© 40473-0

z Turn the crankshaft with the turning gear evenly.

The marking on the crankshaft gear wheel
must be between the markings on the
camshaft gear wheel (1).
1
z Remove counter holder.

z Unscrew screw (1).

z Remove camshaft gear wheel (2)
Push back the camshaft carefully as far as
it goes.
2

© 06/2006 10/32 8189-001

Engine control
TCD 2015 W 04-05-07

z Tighten screws (1).

z Pull out the injection pump camshaft carefully.
Attention!
Do not damage the camshaft and camshaft
bearing!
1

6
© 40475-0

z Visually inspect the components.

Installing injection pump camshaft

z Unscrew screw (1).

© 06/2006 11/32 8189-001

Engine control
W 04-05-07 TCD 2015

z Fasten screw (1).

z Pull out cover (2).

6
© 40994-0

z Oil camshaft bearing lightly.

z Oil cam shaft pin lightly.
z Insert the injection pump camshaft carefully.

Attention!
Do not damage the camshaft and camshaft
bearing!
z Move the injection pump camshaft over the opposite
side to the flywheel.
Use a suitable tool.

© 06/2006 12/32 8189-001

Engine control
TCD 2015 W 04-05-07

z Unscrew screws (1).

6
© 40475-0

z Mount new O-ring (1).

z Lightly oil O-ring.

z Mount cover (2).

z Unscrew screw (1).

© 06/2006 13/32 8189-001

Engine control
W 04-05-07 TCD 2015

z Lightly oil screw (1).

z Tighten screw (1).
A04 005

6
© 40993-0

Installing camshaft gear wheel

Overview of the gear train and the mar- 1
kings of the control times:
Injection pump camshaft gear wheel (1) 2
Camshaft gear wheel (2)
Idler gear (3).
Crankshaft gear wheel (4) 3
Marking injection pump camshaft / idler 5
gear (5)
Marking camshaft / crankshaft (6)

4
6
© 40445-1

z Measure the overhang of the parallel pin with the

depth measuring appliance.
P04 39
z Correct overhang.

© 06/2006 14/32 8189-001

Engine control
TCD 2015 W 04-05-07

z Insert camshaft gear wheel.

The marking on the crankshaft gear wheel
must be between the markings on the
camshaft gear wheel (1).
1
Make sure that the parallel pin on the
camshaft gear wheel and the locating hole
on the camshaft are in line.

6
© 40474-0

z Lightly oil screw (1).

z Fasten screw (1).

z Insert counter support (1) in the toothing of the cam-

shaft gear wheel.
z Turn the crankshaft evenly with the turning gear until
the counter holder blocks on the B-bank of the
crankcase (arrow).

© 06/2006 15/32 8189-001

Engine control
W 04-05-07 TCD 2015

z Tighten screw (1).

A04 001

6
© 40473-0

z Turn the crankshaft with the turning gear evenly.

The marking on the crankshaft gear wheel
must be between the markings on the
camshaft gear wheel (1).
1
z Remove counter holder.

Determining axial backlash of the cam-

© 06/2006 16/32 8189-001

Engine control
TCD 2015 W 04-05-07

z Mount new gasket (1).

P04 37

z Mount cover (2).

Insert screws with locking agent.

z Fit new sealing rings.

1
z Tighten all screws (1).
A04 002

z Mount new O-ring (1).

z Lightly oil O-ring.
z Check oil channel (arrow) for free passage.

1
© 40435-0

© 06/2006 17/32 8189-001

Engine control
W 04-05-07 TCD 2015

z Lightly oil bearing liner (1) with engine oil.

z Insert idler gear (2).
The collar (arrow) faces the bearing bush.

1
6
© 40438-0

z Insert bolt (1).

z Lightly oil screw (1).

z Tighten screw (1).
A04 013
Screw length:
M12 x 80 mm

© 06/2006 18/32 8189-001

Engine control
TCD 2015 W 04-05-07

z Lightly oil screw (1).

z Tighten screw (1).
A04 012

6
© 40422-0

z Mount new O-ring (1).

z Lightly oil O-ring.
z Check oil channel (arrow) for free passage.

1
© 40435-0

z Lightly oil bearing liner (1) with engine oil.

z Insert idler gear (2).
The collar (arrow) faces the bearing bush.

© 06/2006 19/32 8189-001

Engine control
W 04-05-07 TCD 2015

z Insert bolt (1).

1
6
© 40439-0

z Lightly oil screw (1).

z Tighten screw (1).
A04 013
Screw length:
1
M12 x 100 mm

z Lightly oil screw (1).

z Tighten screw (1).
A04 012

© 06/2006 20/32 8189-001

Engine control
TCD 2015 W 04-05-07

Checking the tooth edge clearance of the

6
© 40440-0

z Turn idler gear in direction of arrow until it stops.

z Read off measured value.
P04 44
Repeat the measuring process on several
tooth flanks.

z Remove magnetic measuring stand.

z Remove dial gauge.

Checking the tooth edge clearance of the

© 06/2006 21/32 8189-001

Engine control
W 04-05-07 TCD 2015

z Turn idler gear in direction of arrow until it stops.

z Read off measured value.
P04 44
Repeat the measuring process on several
tooth flanks.

z Remove magnetic measuring stand.

z Remove dial gauge.

6
© 40443-0

z Position the injection pump camshaft.

The locating hole (arrow) faces upwards.

z Turn the crankshaft with the turning gear evenly.

The marking on the crankshaft gear wheel
must be between the markings on the
camshaft gear wheel (1).
1

© 06/2006 22/32 8189-001

Engine control
TCD 2015 W 04-05-07

z Remove turning gear (1).

6
© 40471-0

z Unscrew all screws (1).

z Position injection pump camshaft gear wheel.

The marking (1) faces the camshaft gear
wheel.

© 06/2006 23/32 8189-001

Engine control
W 04-05-07 TCD 2015

z Insert the injection pump camshaft gear wheel in the

camshaft gear wheel.
The marking on the gear wheel must be
between the markings of the injection
pump camshaft gear wheel (1).

6 1

z Tighten screws (1).

Attention!
Make sure no parts fall into the crankcase!

Checking the tooth edge clearance of the

© 06/2006 24/32 8189-001

Engine control
TCD 2015 W 04-05-07

z Turn gear wheel in direction of arrow until it stops.

z Read off measured value.
P07 20
Repeat the measuring process on several
tooth flanks.

z Remove magnetic measuring stand.

z Remove dial gauge.

6
© 40450-0

z Install crankshaft sealing ring (flywheel side)

W 02-02-02
z Install connection housing.
W 03-09-04
Do not install the turbocharger.

z Attach turning gear.

W 04-06-03

Attention!
Make sure no parts fall into the crankcase!

z Fasten all screws (1).

Concealed screws can be accessed by
turning the crankshaft with the turning gear.

© 06/2006 25/32 8189-001

Engine control
W 04-05-07 TCD 2015

z Install genset support.

W 03-08-01
z Install rocker arm brackets.
W 01-02-02
z Check and set plunger lift of injection pumps.
W 07-06-04

6
© 40503-0

z Tighten all screws (1).

A04 004
Concealed screws can be accessed by
turning the crankshaft with the turning gear.

z Mount pad thrust bearing (2).

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

© 06/2006 26/32 8189-001

Engine control
TCD 2015 W 04-05-07

Checking and setting axial backlash of the

6
© 40512-0

z Insert feeler gauge blade between gear wheel of the

injection pump camshaft and the pad thrust
bearing (arrow).
z Press the pad thrust bearing onto the feeler gauge
blade.
z Fasten screw (1). 1
z Check axial backlash.
P04 43

z Tighten screws (1).

A04 015
z Check axial backlash again.
P04 43
Check axial backlash on both sides bet- 1
ween
pad thrust bearing and gear
wheel (arrows).

© 06/2006 27/32 8189-001

Engine control
W 04-05-07 TCD 2015

z Clean sealing surfaces.

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

6
© 40515-0

z Press in the cover (3) to the stop.

z Mount cover (2).
Insert screws with locking agent.

z Tighten screws (1). 3

2
A04 022

z Fix cable tie (1).

© 06/2006 28/32 8189-001

Engine control
TCD 2015 W 04-05-07

z Clean sealing surfaces.

z Apply packing compound evenly to the sealing sur-
face of the gear case.
Use packing compound DEUTZ DW 48.

2
z Mount gear case cover (1). 2
z Mount holder (2).
1
z Tighten all screws (3) alternately.
A04 020

6
© 40516-0

z Mount pipe clamp (2).

z Tighten screw (1).
A08 045

z Mount holder (2).

z Tighten screws (1).
A12 071

© 06/2006 29/32 8189-001

Engine control
W 04-05-07 TCD 2015

z Mount heat shield (1).

z Insert screws (3) with spacing sleeves. 1
z Tighten screws (2).
z Tighten screws (2 and 3) alternately.
A12 071

2
6
© 40517-0

z Tighten screws (1).

A13 094

z Mount new sealing rings.

z Position fuel hose (2).
z Tighten hollow screw (1).
A12 090
1

© 06/2006 30/32 8189-001

Engine control
TCD 2015 W 04-05-07

z Install injection pumps (cylinder A1).

W 07-04-01
z Install injection pumps (cylinder A2-B3).
W 07-04-01
z Install impulse transmitter (camshaft).
W 05-07-03
z Install the turbocharger.
W 06-06-04
z Remove turning gear.
W 04-06-03

6
© 40518-0

© 06/2006 31/32 8189-001

Engine control
W 04-05-07 TCD 2015

© 06/2006 32/32 8189-001

Engine control
TCD 2015 W 04-06-03

Installing and removing turning gear

Commercial available tools The turning gear 100350 can be used at
the front end of the crankshaft depending
Special tools: on the installation relations.
– Turn-over gear . . . . . . . . . . . . . . 100300

– Locking agent
DEUTZ DW 59

Attaching turning gear

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

2
1

z Insert turn-over gear (1).

z Insert centering pin (2) in threaded bore (3).

1 2

© 06/2006 1/2 8190-001

Engine control
W 04-06-03 TCD 2015

z Tighten screw (1).

A03 085
Gear wheel of the turning gear grips the
starter gear ring.

6
© 40463-0

Removing turning gear

z Unscrew screw (1).
z Remove turn-over gear.

z Clean sealing surfaces.

z Mount new gasket.
z Mount cover (2).
z Insert screws (1) with locking agent.
z Tighten screws (1).
A03 085
2
1

© 06/2006 2/2 8190-001

Speed control
TCD 2015 W 05-07-01

Removing and installing the impulse transmitter

(crankshaft)
Commercial available tools – W 04-06-03

Special tools:
– Dial gauge. . . . . . . . . . . . . . . . . . 100400
Read out error memory of the motor con-
– Dial gauge adapter . . . . . . . . . . . 101830
trol timer with SERDIA.
– Turn-over gear . . . . . . . . . . . . . . 100300

– Fitting compound
DEUTZ AP1908

Removing the impulse transmitter

z Attach turning gear.
W 04-06-03
z Unlock cable plug (1) and disconnect.
1
z Remove cable tie (2).

z Remove cable tie (1).

© 06/2006 1/6 8191-001

Speed control
W 05-07-01 TCD 2015

z Unscrew screw (1).

z Remove impulse transmitter (2).
z Remove seals.

6
© 40711-0

z Visually inspect the components.

z Clean components.
z Clean sealing surfaces.

Installing the impulse transmitter

z Turn the crankshaft with the turning gear evenly.
Through the installation opening of the
impulse transmitter, no bore (arrow) may
be visible on the flywheel.

© 06/2006 2/6 8191-001

Speed control
TCD 2015 W 05-07-01

z Insert dial gauge in adapter (1).

6
© 45897-0

z Insert adapter with dial gauge under pre-tension in

the base plate (1).
z Fix dial gauge in adapter.
z Turn the dial until the pointer points to "0".

z Insert and press in adapter with dial gauge into the

connection housing until it stops.
The stylus of the dial gauge must touch the
level flywheel surface.

z Note measured value.

z Make 120° orientation marks on the vibration damp-
er.
Attention!
Remove adapter and dial gauge before
turning the crankshaft.
z Turn the crankshaft to the next 120° mark in direction
of rotation.
z Note measured value.
z Select lowest measured value of 3 measurements,
dimension (a). © 45899-0

© 06/2006 3/6 8191-001

Speed control
W 05-07-01 TCD 2015

z Measure distance, dimension (b).

0,1
24 0,2 mm
z Note measured value.
z Calculate difference between dimension (a) and
dimension (b), dimension (y).
Calculation example
Desired: Dimension (y)
Given: Dial gauge adapter dimension = 24.00 mm
Measured: Dimension (a) = dial gauge adapter dimension + b
lowest measured value
Dimension (a) = 24.00 mm + 0.49 mm
Dimension (a) = 24.49 mm
Dimension (b) = 24.00 mm
Calculation: Dimension (y) = dimension (a) - dimension (b)

6
Dimension (y) = 24.49 mm - 24.00 mm
Result: Dimension (y) = 0.49 mm
© 45878-1

z Determine tightness of the impulse transmitter under

compliance with the permissible distance c
dimension (c).
Calculation example 1
Desired: Compliance with the permissible distance, di-
mension (c)
Gasket
Given: MInimum distance dimension (c1) = 1.00 mm
Dimension (y)
Thickness of gasket = 0.30 mm
Thickness of gasket = 0.50 mm
Measured: -
Calculation: Dimension (c) = minimum
distance dimension (c1) -
dimension (y) + thickness of the gasket
Dimension (c) = 1.00 mm - 0.49 mm + 0.50 mm 2
Dimension (c) = 1.01 mm
Result: Dimension (c) corresponds to the permissible di-
stance, therefore a gasket with a thickness of © 45904-0
0.50 mm must be used.

z Permissible distance (c) between flywheel (1) and

impulse transmitter (2).
P05 91

© 06/2006 4/6 8191-001

Speed control
TCD 2015 W 05-07-01

z Select new gaskets.

Gaskets are available in thicknesses of 0.3
mm and 0.5 mm.
The correct distance (c) is reached by pla-
cing the appropriate number of gaskets
underneath.
z Remove dial gauge.

6
© 45882-0

z Mount new gasket(s) according to the determined

distance.
z Press in impulse transmitter (2).
Attention!
Do not damage the component.

z Tighten screw (1).

A05 011 1

z Fix cable tie (1).

© 06/2006 5/6 8191-001

Speed control
W 05-07-01 TCD 2015

z Plug cable plugs (1) together.

Ensure that the cables are connected pro-
perly.

z Fix cable tie (2).

z Remove turning gear. 1

W 04-06-03
Delete error entry in the error memory of
the motor control timer with SERDIA.

6
© 40710-0

© 06/2006 6/6 8191-001

Speed control
TCD 2015 W 05-07-03

Removing and installing the impulse transmitter

(camshaft)
Commercial available tools – W 04-06-03
– W 06-06-04
Special tools:
– Dial gauge adapter . . . . . . . . . . . 101830
Read out error memory of the motor con-
– Turn-over gear . . . . . . . . . . . . . . 100300
trol timer with SERDIA.
– Fitting compound
DEUTZ AP 1908
– Locking agent
DEUTZ DW 72

Removing the impulse transmitter

z Attach turning gear.
W 04-06-03
z Remove turbocharger.
W 06-06-04

z Unlock cable plug (1) and disconnect.

© 06/2006 1/8 8192-001

Speed control
W 05-07-03 TCD 2015

z Remove cable tie (1).

6
© 40718-0

z Unscrew screws (1).

z Remove cover (2) .

z Unscrew screw (1).

z Remove impulse transmitter (2).
z Remove seals.
1

© 06/2006 2/8 8192-001

Speed control
TCD 2015 W 05-07-03

z Remove protective foil.

z Unlock cable plug (1) and disconnect.
z Visually inspect the components.
z Clean components. 1

6
© 00000-0

Installing the impulse transmitter

z Turn the crankshaft with the turning gear evenly.
The pin (arrow) must be in the centre of the
installation opening.

z Insert dial gauge in adapter (1).

© 06/2006 3/8 8192-001

Speed control
W 05-07-03 TCD 2015

z Insert adapter with dial gauge under pre-tension in

the base plate (1).
z Fix dial gauge in adapter.
z Turn the dial until the pointer points to "0".

6
© 45898-0

z Insert and press in adapter with dial gauge into the

connection housing until it stops.
The stylus of the dial gauge must touch the
pin of the camshaft gear.

z Note measured value.

z Measure distance, dimension (b).

0,1
24 0,2 mm
z Note measured value.
z Calculate difference between dimension (a) and
dimension (b), dimension (y).
Calculation example
Desired: Dimension (y)
Given: Dial gauge adapter dimension = 24.00 mm
Measured: Dimension (a) = dial gauge adapter dimension + b
lowest measured value
Dimension (a) = 24.00 mm + 0.76 mm
Dimension (a) = 24.76 mm
Dimension (b) = 23.90 mm
Calculation: Dimension (y) = dimension (a) - dimension (b)
Dimension (y) = 24.76 mm - 23.90 mm
Result: Dimension (y) = 0.86 mm
© 45878-1

© 06/2006 4/8 8192-001

Speed control
TCD 2015 W 05-07-03

z Determine tightness of the impulse transmitter under

compliance with the permissible distance c
dimension (c).
Calculation example 1
Desired: Compliance with the permissible distance, di-
mension (c)
Gasket
Given: Minimum distance dimension (c1) = 0.30 mm
Dimension (y)
Thickness of gasket = 0.30 mm
Thickness of gasket = 0.50 mm
Measured: -
Calculation: Dimension (c) = minimum
distance dimension (c1) -
dimension (y) + thickness of the gasket
Dimension (c) = 0.30 mm - 2
0.86 mm + (2x0.50 mm)
Dimension (c) = 0.44 mm
6
Result: Dimension (c) corresponds to the permissible di- © 45903-0
stance, therefore two gaskets with a thickness of
0.50 mm must be used.
z Permissible distance (c) between camshaft gear
wheel (1) and impulse transmitter (2).
P05 92

z Select new gaskets.

Gaskets are available in thicknesses of 0.3
mm and 0.5 mm.
The correct distance (c) is reached by pla-
cing the appropriate number of gaskets
underneath.

© 06/2006 5/8 8192-001

Speed control
W 05-07-03 TCD 2015

z Remove dial gauge.

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

6
© 45878-2

z Plug cable plugs (1) together.

Ensure that the cables are connected pro-
perly.
1
z Wrap the cable plug in protective foil.

z Clean sealing surfaces.

z Mount new gasket(s) according to the determined
distance.
z Press in impulse transmitter (2).
1
Attention!
Do not damage the component!

z Tighten screw (1). 2

A05 012

© 06/2006 6/8 8192-001

Speed control
TCD 2015 W 05-07-03

z Mount cover (2).

z Insert screws (1) with locking agent.
z Tighten screws .
A04 022

6
© 40719-0

z Fix cable tie (1).

z Plug cable plugs (1) together.

Ensure that the cables are connected pro-
perly.

© 06/2006 7/8 8192-001

Speed control
W 05-07-03 TCD 2015

z Install the turbocharger.

W 06-06-04
Delete error entry in the error memory of
the motor control timer with SERDIA.

6
© 40716-0

© 06/2006 8/8 8192-001

Exhaust system/Charging
TCD 2015 W 06-01-05

Removing and installing exhaust line

(A-bank)
Commercial available tools – W 06-01-06 . . . . . . . . . . . . (A-bank)

– Fitting compound
DEUTZ S1

Removing exhaust line

z Remove exhaust pipe (A-bank).
W 06-01-06

z Loosen screws (1).

© 06/2006 1/4 8193-001

Exhaust system/Charging
W 06-01-05 TCD 2015

z Unscrew screws (1).

z Remove exhaust line (2).

6 2

z Unscrew screws (1).

z Remove seals.

z Visually inspect the components.

© 06/2006 2/4 8193-001

Exhaust system/Charging
TCD 2015 W 06-01-05

Installing exhaust line

z Clean sealing surfaces.
z Mount new gaskets.
Note installation position.
The strap (arrow) must face the cylinder
head cover.
z Coat the screws with fitting compound .
z Tighten screws (1).

6
© 45374-0

z Mount exhaust line (2).

z Coat the screws with fitting compound .
z Tighten screws (1).

z Tighten all the screws (1) alternately from the centre

outwards.
A06 001

© 06/2006 3/4 8193-001

Exhaust system/Charging
W 06-01-05 TCD 2015

z Install exhaust pipe (A-bank).

W 06-01-06

6
© 40722-0

© 06/2006 4/4 8193-001

Exhaust system/Charging
TCD 2015 W 06-01-05

Removing and installing exhaust line

(B-bank)
Commercial available tools – W 06-01-06 . . . . . . . . . . . . (B-bank)

– Fitting compound
DEUTZ S1

Removing exhaust line

z Remove exhaust pipe (B-bank).
W 06-01-06
1
z Loosen screws (1).

z Unscrew screws (1).

z Remove exhaust line (2).

© 06/2006 1/4 8194-001

Exhaust system/Charging
W 06-01-05 TCD 2015

z Unscrew screws (1).

z Remove seals.

1
6
© 40730-0

z Visually inspect the components.

Installing exhaust line

z Clean sealing surfaces.
z Mount new gaskets.
Note installation position.
The strap (arrow) must face the cylinder
head cover.
z Coat the screws with fitting compound .
z Tighten screws (1).

© 06/2006 2/4 8194-001

Exhaust system/Charging
TCD 2015 W 06-01-05

z Mount exhaust line (2).

z Coat the screws with fitting compound .
z Tighten screws (1).

6
© 45809-0

z Tighten all the screws (1) alternately from the centre

outwards.
A06 001
z Install exhaust pipe (B-bank). 1
W 06-01-06

© 06/2006 3/4 8194-001

Exhaust system/Charging
W 06-01-05 TCD 2015

© 06/2006 4/4 8194-001

Exhaust system/Charging
TCD 2015 W 06-01-06

Removing and installing exhaust pipe

(A-bank)
Commercial available tools

– Fitting compound
DEUTZ S1

Removing exhaust pipe

z Unscrew nuts (arrows). 1
z Remove screws.
z Unscrew screws (1).
z Remove sealing rings.
z Remove exhaust pipe (2). 2

Install exhaust pipe.

2
z Position exhaust pipe (1).
Note installation position.

1
z Insert sealing ring.
Note installation position.
The cone (arrow) faces the exhaust pipe.

z Mount flange (2) on exhaust manifold.

z Coat the screws with fitting compound .
z Fasten screws (3).

3
© 36795-1

© 06/2006 1/2 8195-001

Exhaust system/Charging
W 06-01-06 TCD 2015

z Insert sealing ring.

Note installation position. 1
The cone (arrow) faces the exhaust pipe.

z Mount flange (1) on exhaust line.

z Coat the screws with fitting compound .
z Tighten screws (2).
z Screw on nuts (3).

3
2

6
© 36796-1

z Tighten screws (1) alternately.

A06 002
Ensure uniform distance (arrow) of flange
connection.

z Tighten nuts (1) alternately.

A06 003
Ensure uniform distance (arrow) of flange
connection.

© 06/2006 2/2 8195-001

Exhaust system/Charging
TCD 2015 W 06-01-06

Removing and installing exhaust pipe

(B-bank)
Commercial available tools

– Fitting compound
DEUTZ S1

Removing exhaust pipe

z Unscrew nuts (arrows).
1
z Remove screws.
z Unscrew screws (1).
z Remove sealing rings.
z Remove exhaust pipe (2).

Install exhaust pipe.

z Position exhaust pipe (1).
Note installation position.
1

z Insert sealing ring. 2

Note installation position.
The cone (arrow) faces the exhaust pipe.

z Mount flange (2) on exhaust manifold.

z Coat the screws with fitting compound .
z Fasten screws (3).

3
© 36799-1

© 06/2006 1/2 8196-001

Exhaust system/Charging
W 06-01-06 TCD 2015

z Insert sealing ring.

Note installation position. 1
The cone (arrow) faces the exhaust pipe.

z Mount flange (1) on exhaust line.

z Coat the screws with fitting compound .
z Tighten screws (2).
z Screw on nuts (3).

6 2 3
© 36800-1

z Tighten nuts (1) alternately.

A06 002
Ensure uniform distance (arrow) of flange
connection.

z Tighten nuts (1) alternately.

A06 003
Ensure uniform distance (arrow) of flange
connection.

© 06/2006 2/2 8196-001

Exhaust system/Charging
TCD 2015 W 06-01-07

Removing and installing exhaust manifold

Commercial available tools – W 06-01-06 . . . . . . . . . . . . (A-bank)
– W 06-01-06 . . . . . . . . . . . . (B-bank)
– W 06-06-04

Removing exhaust manifold

z Remove turbocharger.
W 06-06-04
z Remove exhaust pipe (A-bank).
W 06-01-06
z Remove exhaust pipe (B-bank).
W 06-01-06

z Unscrew all screws (1).

z Remove exhaust manifold (2).
z Visually inspect the components.
1

© 06/2006 1/2 8197-001

Exhaust system/Charging
W 06-01-07 TCD 2015

Installing exhaust manifold

z Mount exhaust manifold (2).
z Tighten all screws (1).
1
A06 010

6
© 40732-0

z Install exhaust pipe (A-bank).

W 06-01-06
z Install exhaust pipe (B-bank).
W 06-01-06
z Install the turbocharger.
W 06-06-04

© 06/2006 2/2 8197-001

Exhaust system/Charging
TCD 2015 Railway W 06-01-07

Removing and installing exhaust manifold

(A-bank)
Commercial available tools – W 06-06-04 . . . . . . . . . . . . (A-bank)

– Fitting compound
DEUTZ S1

Removing exhaust manifold

z Remove turbocharger (A-bank).
W 06-06-04
z Unscrew nuts (1).
z Remove screws.
z Remove the holder (2).

2
© 42079-1

z Unscrew nuts (1).

z Remove washers.
z Remove screws.
z Remove exhaust manifold (2).
z Visually inspect the components.

© 06/2006 1/2 8198-001

Exhaust system/Charging
W 06-01-07 TCD 2015 Railway

Installing exhaust manifold

z Clean sealing surfaces.
z Mount exhaust manifold (2).
z Coat the screws with fitting compound .
z Insert screws.
z Mount washers.
1
z Tighten nuts (1).
A06 010

6
© 42081-2

z Mount holder (2).

z Insert screws.
z Tighten nuts (1).
A06 034
z Install turbocharger (A-bank).
W 06-06-04

2
© 42079-1

© 06/2006 2/2 8198-001

Exhaust system/Charging
TCD 2015 Railway W 06-01-07

Removing and installing exhaust manifold

(B-bank)
Commercial available tools – W 06-06-04 . . . . . . . . . . . . (B-bank)

– Fitting compound
DEUTZ S1

Removing exhaust manifold

z Remove turbocharger (B-bank).
W 06-06-04

z Unscrew nuts (1).

z Remove washers.
z Remove screws.
z Remove exhaust manifold (2).
z Visually inspect the components. 2

© 06/2006 1/2 8199-001

Exhaust system/Charging
W 06-01-07 TCD 2015 Railway

Installing exhaust manifold

z Clean sealing surfaces.
z Mount exhaust manifold (2).
z Coat the screws with fitting compound .
2
z Insert screws.
z Tighten nuts (1).
A06 010

6 1

z Install turbocharger (B-bank).

W 06-06-04

© 06/2006 2/2 8199-001

Exhaust system/Charging
TCD 2015 W 06-02-03

Remove and install the charge air line

Commercial available tools

– Fitting compound
DEUTZ AP1908

Remove charge air line

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

z Pull out plug element (1).

© 06/2006 1/4 8200-001

Exhaust system/Charging
W 06-02-03 TCD 2015

z Unscrew nuts (1).

z Remove washers.
z Remove charge air manifold (2).
z Remove gasket. 1
z Visually inspect the components.

6
© 45403-0

Install charge air line

z Mount new gasket.
z Mount charge air manifold (2).
1
z Mount washers and screw on nuts.
z Tighten nuts (1).
A06 046

z Mount new O-rings (1).

z Coat the O-rings with fitting compound.

© 06/2006 2/4 8200-001

Exhaust system/Charging
TCD 2015 W 06-02-03

z Insert plug element (1).

6
© 40768-1

z Clean sealing surfaces.

z Mount charge air line.
z Tighten screws .
A06 030
Screw length:
1
M10 x 65 mm (1)
M10 x 85 mm (2) 2

© 06/2006 3/4 8200-001

Exhaust system/Charging
W 06-02-03 TCD 2015

© 06/2006 4/4 8200-001

Exhaust system/Charging
TCD 2015 W 06-02-05

Removing and installing connecting pipe

Commercial available tools – W 07-01-04

Removing connecting pipe

z Remove fuel pipes (flame glow plugs).
W 07-01-04

z Unlock cable plug (1) and remove.

© 06/2006 1/10 8201-001

Exhaust system/Charging
W 06-02-05 TCD 2015

z Unscrew nut (1).

Mark assignment of cables/connections
before removing.

z Remove cables (2) from both flame glow plugs. 1

6
© 40739-0

z Unscrew nuts (1).

z Remove the holder (2).
z Remove screws. 1

z Unscrew screws (1).

z Place cable harness to one side.

© 06/2006 2/10 8201-001

Exhaust system/Charging
TCD 2015 W 06-02-05

z Unscrew screws (1).

1
1

6
© 40742-0

z Unscrew nuts (1).

z Remove the holder (2).

z Unscrew nuts (1).

z Remove the holder (2).

© 06/2006 3/10 8201-001

Exhaust system/Charging
W 06-02-05 TCD 2015

z Unscrew nuts (1).

z Remove the holder (2).

6
© 40745-0

z Unscrew nuts (1).

z Remove connecting pipe (1).

z Remove seals.

© 06/2006 4/10 8201-001

Exhaust system/Charging
TCD 2015 W 06-02-05

z Visually inspect the components.

6
© 40748-0

Installing connecting pipe

z Clean sealing surfaces.
z Mount new gaskets.
z Mount connecting pipe (1).
1

z Screw on nuts (1).

© 06/2006 5/10 8201-001

Exhaust system/Charging
W 06-02-05 TCD 2015

z Mount holder (2).

z Screw on nuts (1).

6
© 40745-0

z Mount holder (2).

z Screw on nuts (1).

z Mount holder (2).

z Screw on nuts (1).

© 06/2006 6/10 8201-001

Exhaust system/Charging
TCD 2015 W 06-02-05

z Tighten screws (1).

A06 056

1
1

6
© 40742-0

z Tighten nuts (arrows).

A06 033

z Lay cable.
z Tighten screws .
A13 090
Screw length: 2
M8 x 20 mm (1)
M8 x 16 mm (2)
1

© 06/2006 7/10 8201-001

Exhaust system/Charging
W 06-02-05 TCD 2015

z Unscrew screws (1).

z Remove end plate.
z Remove gasket.
1

6
© 40751-0

z Mount new gasket.

z Mount end plate.
z Insert screws.
1
Screw length:
M10 x 45 mm (1)
M10 x 55 mm (2)

z Mount holder (1).

z Tighten nuts (arrows).
A06 034

1
© 40950-0

© 06/2006 8/10 8201-001

Exhaust system/Charging
TCD 2015 W 06-02-05

z Plug cables (2) to both flame glow plugs.

Attention!
Note assignment and polarity of the electri-
cal connections!

Connect cables according to marks made 1

before removing.

z Mount washer.
z Tighten nut (1).
2
A13 035

6
© 40739-0

z Plug in the cable plug (1).

z Install fuel pipes (flame glow plugs).

W 07-01-04

© 06/2006 9/10 8201-001

Exhaust system/Charging
W 06-02-05 TCD 2015

© 06/2006 10/10 8201-001

Exhaust system/Charging
TCD 2015 Railway W 06-02-05

Removing and installing connecting pipe

Commercial available tools – W 07-01-04 . . . . . . . . . . . . (Railway)

Ensure that the cables are connected pro-

perly.

Removing connecting pipe

z Unlock cable plug (1) and remove.

z Unscrew screw (1).

z Remove spring washer.
z Remove ground cable.
Mark assignment of cables/connections
before removing.

© 06/2006 1/10 8202-001

Exhaust system/Charging
W 06-02-05 TCD 2015 Railway

z Remove fuel pipes (flame glow plugs), (Railway).

W 07-01-04

6
© 42025-2

z Unscrew nuts (1).

z Remove washers.

1
1

z Remove cables (1).

Mark assignment of cables/connections
before removing.

© 06/2006 2/10 8202-001

Exhaust system/Charging
TCD 2015 Railway W 06-02-05

z Unscrew screw (1).

z Place fuel shut-off valve (2) to one side.

6
© 42186-1

z Unscrew screw (1).

z Place cable harness to one side.

z Unscrew screws (1).

z Loosen the holder (2).
1 2

© 06/2006 3/10 8202-001

Exhaust system/Charging
W 06-02-05 TCD 2015 Railway

z Unscrew screws (1).

6
© 42501-1

z Unscrew nuts (1).

z Remove washers.
z Remove holder.
z Place cables to one side.

1
1

z Unscrew all nuts (1).

z Remove connecting pipe (2).
z Remove gasket.
z Visually inspect the components.
1
1

© 06/2006 4/10 8202-001

Exhaust system/Charging
TCD 2015 Railway W 06-02-05

Installing connecting pipe

z Clean sealing surfaces.
z Mount new gaskets.
z Mount connecting pipe (1).

6
© 42421-1

z Mount washers.
z Mount holder (1).
z Screw on nuts.

1
1

z Screw on all nuts (1).

1
1

© 06/2006 5/10 8202-001

Exhaust system/Charging
W 06-02-05 TCD 2015 Railway

z Tighten screws (1).

A06 056

6
© 42501-1

z Tighten all nuts (1).

A06 033

1
1

z Position holder (2).

z Tighten screws (1).
1 2
A13 090

© 06/2006 6/10 8202-001

Exhaust system/Charging
TCD 2015 Railway W 06-02-05

Attention!
Lay the cables free from chafing and ten-
sion.
z Tighten screw (1).
A13 090

6
© 42418-1

z Mount fuel shut-off valve (2).

z Position pipe clamp.
z Fasten screw (1).

z Position fuel shut-off valve.

P07 91
Note installation dimensions (X).

© 06/2006 7/10 8202-001

Exhaust system/Charging
W 06-02-05 TCD 2015 Railway

Attention!
Note assignment and polarity of the electri-
cal connections!
z Connect plus cable (R3.1) to flame glow plug (1).
z Connect plus cable (R3.2) to flame glow plug (2).
z Mount washers. 1
z Screw on nuts.

6
© 45928-0

z Tighten nuts (1).

A13 035
z Install fuel pipes (flame glow plugs), (Railway).
W 07-01-04

1
1

z Connect ground cable.

z Mount spring washer.
z Tighten screw (1).
A07 058

© 06/2006 8/10 8202-001

Exhaust system/Charging
TCD 2015 Railway W 06-02-05

z Tighten screw (1).

A13 090

1
6
© 42423-1

z Plug in the cable plug (1).

Ensure that the cables are connected pro-
perly.

© 06/2006 9/10 8202-001

Exhaust system/Charging
W 06-02-05 TCD 2015 Railway

© 06/2006 10/10 8202-001

Exhaust system/Charging
TCD 2015 W 06-06-04

Removing and installing the turbocharger

Commercial available tools – W 06-02-03

Special tools:
– Special wrench . . . . . . . . . . . . . . 170100
Collect leaking operating substances in
– Fitting compound suitable vessels and dispose of according
DEUTZ S1 to regulations.

Removing turbocharger
z Remove the charge air pipe.
W 06-02-03

z Unscrew lock nuts (1) with special wrench.

z Remove screw-in nipple.
z Remove sealing rings.
1

© 06/2006 1/8 8203-001

Exhaust system/Charging
W 06-06-04 TCD 2015

z Unscrew screw (1).

z Remove holder (2).
z Remove lubricating oil pipe (3).

6
© 40755-0

z Unscrew screw (1).

z Loosen hose clips (2).

z Pull off pipe.

z Remove intake elbow (1).

© 06/2006 2/8 8203-001

Exhaust system/Charging
TCD 2015 W 06-06-04

z Unscrew screw (1).

6
© 40758-0

z Pull out oil return pipe (1).

z Unscrew all screws (1).

z Remove turbocharger (2).

© 06/2006 3/8 8203-001

Exhaust system/Charging
W 06-06-04 TCD 2015

z Unscrew screws (1).

z Remove oil return pipe (2).
z Remove gasket. 1

6
© 40761-0

z Visually inspect the components.

Installing the turbocharger

z Mount new gaskets.
z Mount oil return pipe (2). 1
z Tighten screws (1).
A08 044

© 06/2006 4/8 8203-001

Exhaust system/Charging
TCD 2015 W 06-06-04

z Clean sealing surfaces.

z Mount turbocharger (2).
z Coat the screws with fitting compound .
z Tighten all screws (1).
A06 020 2

6
© 40760-0

z Mount oil return pipe (1).

z Tighten screw (1).

A08 044

© 06/2006 5/8 8203-001

Exhaust system/Charging
W 06-06-04 TCD 2015

z Mount intake elbow (1).

Note installation position.

1
z Insert pipe.

6
© 40757-0

z Position hose clips.

z Tighten hose clip (2).
A03 064
z Tighten hose clip (3).
1
A06 021
3
z Tighten screw (1).
A03 069

z Mount lubricating oil pipe (3).

z Position holder (2).
z Tighten screw (1).
A08 079 1

© 06/2006 6/8 8203-001

Exhaust system/Charging
TCD 2015 W 06-06-04

z Mount new sealing rings.

z Tighten screw-in nipple.
z Tighten both lock nuts (1) with a special wrench.
A08 040

6
© 40763-0

z Install the charge air pipe.

W 06-02-03

© 06/2006 7/8 8203-001

Exhaust system/Charging
W 06-06-04 TCD 2015

© 06/2006 8/8 8203-001

Exhaust system/Charging
TCD 2015 Railway W 06-06-04

Removing and installing turbocharger

(A-bank)
Commercial available tools Collect leaking operating substances in
suitable vessels and dispose of according
to regulations.
– Fitting compound
DEUTZ S1

Removing turbocharger
z Unscrew screw (1).
z Loosen pipe clip (2).

2 1

z Unscrew union nuts (1).

z Remove lubricating oil pipe (2).

© 06/2006 1/6 8204-001

Exhaust system/Charging
W 06-06-04 TCD 2015 Railway

z Unscrew screws (1).

z Remove oil return pipe (2).
z Remove gasket.
1

6
© 42050-1

z Loosen hose clip (1).

z Loosen hose clip (2).

2
© 42051-2

z Pull off tubing connection (1).

z Pull off bleeding hose (2).
z Remove breather pipe (3). 2

© 06/2006 2/6 8204-001

Exhaust system/Charging
TCD 2015 Railway W 06-06-04

z Unscrew nuts (arrows).

z Remove turbocharger (1).

6
© 42053-1

z Unscrew screw-in nipple (1).

z Remove sealing ring.
z Visually inspect the components.
1

Installing the turbocharger

z Mount new sealing ring.
z Tighten screw-in nipple (1).
1
A12 098

© 06/2006 3/6 8204-001

Exhaust system/Charging
W 06-06-04 TCD 2015 Railway

z Clean sealing surfaces.

z Mount turbocharger (1).
z Tighten nuts (arrows).
A06 020

6
© 42053-1

z Mount breather pipe (3).

z Plug in breather pipe (2).
z Plug in the tubing connection (1). 2

z Position hose clip (1).

z Tighten hose clip (1).
A03 070
z Position hose clip (2). 1
z Tighten hose clip (2).
A06 024

2
© 42051-2

© 06/2006 4/6 8204-001

Exhaust system/Charging
TCD 2015 Railway W 06-06-04

z Mount new gasket.

z Mount oil return pipe (2).
z Tighten screws (1).
1
A08 044

6
© 42050-1

z Mount lubricating oil pipe (2).

z Screw on union nuts (1).
A12 082

z Position pipe clamp (2).

z Tighten screw (1).
A08 045

2 1

© 06/2006 5/6 8204-001

Exhaust system/Charging
W 06-06-04 TCD 2015 Railway

© 06/2006 6/6 8204-001

Exhaust system/Charging
TCD 2015 Railway W 06-06-04

Removing and installing turbocharger

(B-bank)
Commercial available tools Collect leaking operating substances in
suitable vessels and dispose of according
to regulations.
– Fitting compound
DEUTZ S1

Removing turbocharger
z Unscrew union nuts (1).
z Remove lubricating oil pipe (2).
1

z Unscrew screws (1).

z Remove oil return pipe (2).
1
z Remove gasket.

© 06/2006 1/6 8205-001

Exhaust system/Charging
W 06-06-04 TCD 2015 Railway

z Loosen hose clip (1).

z Loosen hose clip (2).
1

6
© 42059-2

z Pull off tubing connection (1).

z Pull off bleeding hose (2).
z Remove breather pipe (3).
2

1
© 42058-2

z Unscrew nuts (arrows).

z Remove turbocharger (1).

© 06/2006 2/6 8205-001

Exhaust system/Charging
TCD 2015 Railway W 06-06-04

z Unscrew screw-in nipple (1).

z Remove sealing ring.
z Visually inspect the components.
1

6
© 42054-1

Installing the turbocharger

z Mount new sealing ring.
z Tighten screw-in nipple (1).
1
A12 098

z Clean sealing surfaces.

z Mount turbocharger (1).
z Tighten nuts (arrows).
A06 020
1

© 06/2006 3/6 8205-001

Exhaust system/Charging
W 06-06-04 TCD 2015 Railway

z Mount breather pipe (3).

z Plug in breather pipe (2).
z Plug in the tubing connection (1).
2

6
1
© 42058-2

z Position hose clip (1).

z Tighten hose clip (1).
A03 070 1

z Position hose clip (2).

z Tighten hose clip (2).
A06 024

z Mount new gasket.

z Mount oil return pipe (2).
1
z Tighten screws (1).
A08 044

© 06/2006 4/6 8205-001

Exhaust system/Charging
TCD 2015 Railway W 06-06-04

z Mount lubricating oil pipe (2).

z Screw on union nuts (1).
A12 082
1

1 6
© 42056-1

© 06/2006 5/6 8205-001

Exhaust system/Charging
W 06-06-04 TCD 2015 Railway

© 06/2006 6/6 8205-001

Exhaust system/Charging
TCD 2015 W 06-07-03

Removing and installing charge air pipe

(A-bank)
Commercial available tools – W 03-01-11
– W 06-02-05
Special tools: – W 07-03-01 . . . . . . . . . . . . (A-bank)
– Special wrench . . . . . . . . . . . . . . 110510

Removing charge air pipe

z Remove connecting pipe.
W 06-02-05
z Removing high pressure pipes (A-bank).
W 07-03-01

z Removing the crankcase breather.

W 03-01-11
z Unscrew screw (1).

© 06/2006 1/6 8206-001

Exhaust system/Charging
W 06-07-03 TCD 2015

z Unscrew screws (1).

z Place fuel hose (2) to one side.

1 2

6
© 40554-0

z Unscrew all screws (1).

z Remove the holder (2).

2 1

z Unscrew screws (1) with special wrench.

z Unscrew screws (2).
3
z Remove charge air pipe (3).
z Remove seals.

1 2

© 06/2006 2/6 8206-001

Exhaust system/Charging
TCD 2015 W 06-07-03

z Visually inspect the components.

6
© 40568-0

Installing charge air pipe

z Clean sealing surfaces.
z Mount new gaskets.
Note installation position.

z Turn in all screws (1) a few turns. 1

Screw length:
M8 x 65 mm

z Insert charge air pipe.

z Fasten all screws (1).
Screw length:
M8 x 100 mm
1

© 06/2006 3/6 8206-001

Exhaust system/Charging
W 06-07-03 TCD 2015

z Mount spacing sleeve (arrow).

z Mount holder.
z Fasten screw (1).
Screw length:
M8 x 120 mm

6
© 40576-0

z Tighten screw (1).

A12 071

z Tighten screws (1) alternately with special wrench.

A06 030

1 1

© 06/2006 4/6 8206-001

Exhaust system/Charging
TCD 2015 W 06-07-03

z Position fuel hose (2).

z Tighten screws (1).
A12 095
z Install crankcase breather.
W 03-01-11
1 2

6
© 40554-0

z Installing high pressure pipes (A-bank)

W 07-03-01
z Install connecting pipe.
W 06-02-05

© 06/2006 5/6 8206-001

Exhaust system/Charging
W 06-07-03 TCD 2015

© 06/2006 6/6 8206-001

Exhaust system/Charging
TCD 2015 W 06-07-03

Removing and installing charge air pipe

(B-bank)
Commercial available tools – W 06-02-05
– W 07-03-01 . . . . . . . . . . . . (B-bank)
Special tools:
– Special wrench . . . . . . . . . . . . . . 110510

Removing charge air pipe

z Remove connecting pipe.
W 06-02-05
z Removing high pressure pipes (B-bank).
W 07-03-01

z Unscrew all screws (1).

© 06/2006 1/4 8207-001

Exhaust system/Charging
W 06-07-03 TCD 2015

z Unscrew screws (1) with special wrench.

z Unscrew screws (2).
z Remove charge air pipe (3). 3
z Remove seals.

6
© 40570-0

z Visually inspect the components.

Installing charge air pipe

z Clean sealing surfaces.
z Mount new gaskets.
Note installation position.

1
z Turn in all screws (1) a few turns.
Screw length:
M8 x 65 mm

© 06/2006 2/4 8207-001

Exhaust system/Charging
TCD 2015 W 06-07-03

z Insert charge air pipe.

z Fasten all screws (1).
Screw length:
M8 x 100 mm

6
© 40569-0

z Tighten screws (1) alternately with special wrench.

A06 030

1
1

z Installing high pressure pipes (A-bank)

W 07-03-01
z Install connecting pipe.
W 06-02-05

© 06/2006 3/4 8207-001

Exhaust system/Charging
W 06-07-03 TCD 2015

© 06/2006 4/4 8207-001

Fuel system
TCD 2015 W 07-01-02

Removing and installing flame glow plug

Commercial available tools – W 07-01-04

Special tools:
– Plugs/caps . . . . . . . . . . . . . . . . . 170160
Attention!
Pay attention to utmost cleanliness when
working on the fuel system.
Remove residue paint and particles of dirt
before removing.
Clean the respective affected parts care-
fully. Blow damp areas dry with compres-
sed air.
Observe the safety regulations and natio-
nal specifications for handling fuels.
Close all connections immediately after
6
opening with new, clean plugs/caps.
Do not remove plugs/caps until immedia-
tely before assembling.
Collect leaking operating substances in
suitable vessels and dispose of according
to regulations.

Removing flame glow plug

z Remove fuel pipes (flame glow plugs).
W 07-01-04
1
z Unscrew nut (1).
z Remove cables (2).
Mark assignment of cables/connections
before removing. 2

© 06/2006 1/4 8208-001

Fuel system
W 07-01-02 TCD 2015

z Loosen lock nut (1).

z Unscrew flame glow plug (2).
z Remove gasket.

2 1

6
© 40771-0

z Visually inspect the components.

Installing flame glow plug

z Mount new gasket.
z Screw in flame glow plug.
P13 66
Note screw-in height dimension (X).

© 06/2006 2/4 8208-001

Fuel system
TCD 2015 W 07-01-02

z Install fuel pipes (flame glow plugs).

W 07-01-04

6
© 40773-0

z Tighten lock nut (1).

A07 059

z Plug in cable lug (2).

Attention! 1
Note assignment and polarity of the electri-
cal connections!

Connect cables according to marks made 2

before removing.

z Mount washer.
z Tighten nut (1).
A13 035

© 06/2006 3/4 8208-001

Fuel system
W 07-01-02 TCD 2015

© 06/2006 4/4 8208-001

Fuel system
TCD 2015 Railway W 07-01-02

Removing and installing flame glow plug

Commercial available tools – W 07-01-04 . . . . . . . . . . . . (Railway)

Removing flame glow plug

z Unscrew screw (1).
z Remove spring washer.
z Remove ground cable.
Mark assignment of cables/connections
before removing.

© 06/2006 1/6 8209-001

Fuel system
W 07-01-02 TCD 2015 Railway

z Remove fuel pipes (flame glow plugs), (Railway).

W 07-01-04

6
© 42025-2

z Unscrew nuts (1).

z Remove washers.

1
1

z Remove cables (1).

Mark assignment of cables/connections
before removing.

© 06/2006 2/6 8209-001

Fuel system
TCD 2015 Railway W 07-01-02

z Loosen lock nut (2).

z Unscrew flame glow plug (1).
z Remove insulating washer (3).

2
3

6
© 42187-1

z Unscrew adapter (1).

z Remove sealing ring.

z Unscrew lock nut.

z Visually inspect the components.

© 06/2006 3/6 8209-001

Fuel system
W 07-01-02 TCD 2015 Railway

Installing flame glow plug

z Mount new gasket.
z Tighten adapter (1).
A07 057

6
© 42188-1

z Screw on lock nut.

z Mount insulating washer (1).

z Screw in flame glow plug (2).

© 06/2006 4/6 8209-001

Fuel system
TCD 2015 Railway W 07-01-02

z Position flame glow plug.

P13 66
Note screw-in height dimension (X).
Screw-in nipple (1) faces crankshaft at a
right angle (90°).
1

6
© 45911-0

z Tighten lock nut (1).

A07 059

Attention!
Note assignment and polarity of the electri-
cal connections!
z Connect plus cable (R3.1) to flame glow plug (1).
z Connect plus cable (R3.2) to flame glow plug (2).
1

© 06/2006 5/6 8209-001

Fuel system
W 07-01-02 TCD 2015 Railway

z Mount washers.
z Screw on nuts.
z Tighten nuts (1).
A13 035
z Install fuel pipes (flame glow plugs), (Railway).
1
W 07-01-04
1

6
© 42185-2

z Connect ground cable.

z Mount spring washer.
z Tighten screw (1).
A07 058

© 06/2006 6/6 8209-001

Fuel system
TCD 2015 W 07-01-03

Removing and installing fuel shut-off valve

(flame glow plugs)
Commercial available tools Attention!
Pay attention to utmost cleanliness when
Special tools:
working on the fuel system.
– Plugs/caps . . . . . . . . . . . . . . . . . 170160
Remove residue paint and particles of dirt
before removing.
Clean the respective affected parts care-
fully. Blow damp areas dry with compres-
sed air.
Observe the safety regulations and natio-
nal specifications for handling fuels.
Close all connections immediately after
opening with new, clean plugs/caps. 6
Do not remove plugs/caps until immedia-
tely before assembling.
Collect leaking operating substances in
suitable vessels and dispose of according
to regulations.

Removing fuel shut-off valve

z Unlock cable plug (1) and remove.

© 06/2006 1/6 8210-001

Fuel system
W 07-01-03 TCD 2015

z Hold screw-in nipple.

z Unscrew lock nut (1).
z Hold screw-in nipple.
z Unscrew lock nut (2).
z Remove fuel pipe (3). 1

3
6
© 40776-0

z Unscrew screw (1).

z Remove spacing sleeve.
z Remove fuel shut-off valve (2).
z Remove pipe clamp. 1

z Unscrew screw-in nipple (1).

z Visually inspect the components. 1

© 06/2006 2/6 8210-001

Fuel system
TCD 2015 W 07-01-03

Installing fuel shut-off valve

z Tighten screw-in nipple (1). 1

A07 068

6
© 40779-0

z Position pipe clamp.

z Screw on lock nut (1).
1

z Screw on lock nut (1).

© 06/2006 3/6 8210-001

Fuel system
W 07-01-03 TCD 2015

z Position spacing sleeve.

z Fasten screw (1).

6
© 40782-0

z Position fuel shut-off valve.

P07 91
Note installation dimensions (X). X

z Tighten screw (1).

A07 093

© 06/2006 4/6 8210-001

Fuel system
TCD 2015 W 07-01-03

z Position fuel pipe.

P07 92
Note installation angle, dimension (X).

6
© 45407-0

Attention!
Install fuel pipes tension free!

z Hold screw-in nipple.

z Tighten lock nuts (1).
1
A07 018

z Plug in the cable plug (1).

© 06/2006 5/6 8210-001

Fuel system
W 07-01-03 TCD 2015

© 06/2006 6/6 8210-001

Fuel system
TCD 2015 Railway W 07-01-03

Removing and installing fuel shut-off valve

Removing fuel shut-off valve

z Unlock cable plug (1) and remove.

© 06/2006 1/6 8211-001

Fuel system
W 07-01-03 TCD 2015 Railway

z Unscrew hollow screw (1).

z Remove sealing rings.
Collect draining fuel and dispose of accor-
ding to regulations.

z Seal hose pipe (2).

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

6
© 42021-1

z Hold screw-in nipple.

z Unscrew lock nut (1).

z Unscrew screw (1).

z Remove fuel shut-off valve (2).
z Remove pipe clamp.

1
2

© 06/2006 2/6 8211-001

Fuel system
TCD 2015 Railway W 07-01-03

z Unscrew screw-in nipple (1).

z Visually inspect the components.

6
© 45913-0

Installing fuel shut-off valve

z Tighten screw-in nipple (1).
A07 068
z Mount pipe clamp (2).

1 2

z Screw on lock nut (1).

1
© 42024-1

© 06/2006 3/6 8211-001

Fuel system
W 07-01-03 TCD 2015 Railway

z Position pipe clamp.

z Fasten screw (1).

6
© 42023-2

z Position fuel shut-off valve.

P07 91
Note installation dimensions (X).

z Tighten screw (1).

A07 093

© 06/2006 4/6 8211-001

Fuel system
TCD 2015 Railway W 07-01-03

z Hold screw-in nipple.

z Tighten lock nuts (1).
A07 018
Attention!
Install fuel pipes tension free!

1
6
© 42022-1

z Position hose pipe (2).

Attention!
Lay the hose pipe free from chafing and
tension.
z Mount new sealing rings.
z Tighten hollow screw (1).
A12 090 1

z Plug in the cable plug (1).

Ensure that the cables are connected pro-
perly.

© 06/2006 5/6 8211-001

Fuel system
W 07-01-03 TCD 2015 Railway

© 06/2006 6/6 8211-001

Fuel system
TCD 2015 W 07-01-04

Removing and installing fuel pipes

(flame glow plugs)
Commercial available tools – W 06-02-03

Special tools:
– Plugs/caps . . . . . . . . . . . . . . . . . 170160
Danger!
Wait 30 seconds after switching off the
engine before working on the fuel system.

Attention!
Pay attention to utmost cleanliness when
working on the fuel system.
Remove residue paint and particles of dirt
before removing. 6
Clean the respective affected parts care-
fully. Blow damp areas dry with compres-
sed air.
Observe the safety regulations and natio-
nal specifications for handling fuels.
Close all connections immediately after
opening with new, clean plugs/caps.
Do not remove plugs/caps until immedia-
tely before assembling.
Collect leaking operating substances in
suitable vessels and dispose of according
to regulations.

Removing fuel pipes

z Remove the charge air pipe.
W 06-02-03
z Unscrew screw (1). 1
z Loosen pipe clip (2).

© 06/2006 1/4 8212-001

Fuel system
W 07-01-04 TCD 2015

z Unscrew union nuts (1).

1
1

6
© 45378-0

z Remove fuel pipes (1).

z Visually inspect the components.

© 06/2006 2/4 8212-001

Fuel system
TCD 2015 W 07-01-04

Installing fuel pipes

z Mount fuel pipes (1).

6
© 45376-0

z Screw on union nuts (1).

1
1

z Position pipe clamp (2).

z Fasten screw (1).

© 06/2006 3/4 8212-001

Fuel system
W 07-01-04 TCD 2015

z Tighten lock nuts (1).

A12 080
Attention!
Install fuel pipe tension free.
1

6
© 40952-0

z Tighten lock nuts (1).

A12 080
Attention!
Install fuel pipe tension free.

z Tighten screw (1).

A07 044
z Install the charge air pipe.
W 06-02-03
1

© 06/2006 4/4 8212-001

Fuel system
TCD 2015 Railway W 07-01-04

Removing and installing fuel pipes

(flame glow plugs)
Commercial available tools Danger!
Special tools: Wait 30 seconds after switching off the
– Plugs/caps . . . . . . . . . . . . . . . . . 170160 engine before working on the fuel system.

Attention!
Pay attention to utmost cleanliness when
working on the fuel system.
Remove residue paint and particles of dirt
before removing.
Clean the respective affected parts care-
fully. Blow damp areas dry with compres-
sed air. 6
Observe the safety regulations and natio-
nal specifications for handling fuels.
Close all connections immediately after
opening with new, clean plugs/caps.
Do not remove plugs/caps until immedia-
tely before assembling.
Collect leaking operating substances in
suitable vessels and dispose of according
to regulations.

Removing fuel pipes

z Remove cable tie (1).
z Unscrew screw (2).
z Loosen pipe clip.

© 06/2006 1/4 8213-001

Fuel system
W 07-01-04 TCD 2015 Railway

z Unscrew union nuts (1).

z Remove fuel pipe (2).

1
1

6
© 42026-1

z Unscrew union nuts (1).

z Remove fuel pipe (2).

1 2

z Hold screw-in nipple.

z Unscrew lock nut (1).
z Remove distributor (2).
2
z Visually inspect the components.

© 06/2006 2/4 8213-001

Fuel system
TCD 2015 Railway W 07-01-04

Installing fuel pipes

z Mount distributor (2).
Note installation position. 2

z Screw on lock nut (1).

6
© 42029-1

z Mount fuel pipe (2).

z Screw on union nuts (1).

1 2

z Mount fuel pipe (2).

z Screw on union nuts (1).

1
1

© 06/2006 3/4 8213-001

Fuel system
W 07-01-04 TCD 2015 Railway

Attention!
Install fuel pipe tension free.

z Tighten lock nuts (1).

A12 080 1

6
© 42027-1

Attention!
Install fuel pipe tension free.

z Tighten lock nuts (1).

1
A12 080
z Hold screw-in nipple.
z Tighten lock nut (2).
A07 018
2

z Position pipe clip.

z Tighten screw (2).
A07 044
z Lay cable harness and fix with cable tie (1).

© 06/2006 4/4 8213-001

Fuel system
TCD 2015 W 07-03-01

Renewing injection pipes

(A-bank)
Commercial available tools: Danger!
– Dog wrench. . . . . . . . . . . . . . . . . . . 8018 Wait 30 seconds after switching off the
Special tools: engine before working on the fuel system.
– Plugs/caps . . . . . . . . . . . . . . . . . 170160
Attention!
Pay attention to utmost cleanliness when
working on the fuel system.
Remove residue paint and particles of dirt
before removing.
Clean the respective affected parts care-
fully. Blow damp areas dry with compres-
sed air. 6
Observe the safety regulations and natio-
nal specifications for handling fuels.
Close all connections immediately after
opening with new, clean plugs/caps.
Do not remove plugs/caps until immedia-
tely before assembling.
Collect leaking operating substances in
suitable vessels and dispose of according
to regulations.
Injection pipes may not be bent.

Removing injection pipes

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

1 1

© 06/2006 1/6 8214-001

Fuel system
W 07-03-01 TCD 2015

z Unscrew screw (1).

z Remove pipe clamp (2).

6
© 40792-0

z Unscrew lock nuts (1) with dog wrench.

z Remove injection line.
Lay out components in the order in which
they should be installed.
Note cylinder assignment.
1

z Visually inspect the components.

z Renew damaged profile washers.

© 06/2006 2/6 8214-001

Fuel system
TCD 2015 W 07-03-01

Installing injection pipes

z Mount new injection pipe.
z Screw on union nuts (1).
Attention!
Install injection pipes without tension! 1

Note assignment and installation position

of the injection lines.

6
© 40793-0

z Oil the injection pipe in the area of the profile

washer (1).
z Position profile washer (1).
The profile washer must be at the upper
web (arrow) of the cylinder head cowling.
1

z Tighten lock nuts (1) with dog wrench.

A07 003

© 06/2006 3/6 8214-001

Fuel system
W 07-03-01 TCD 2015

z Tighten lock nuts (1) with dog wrench.

A07 003

6
© 40801-0

z Position pipe clamp (2).

z Tighten screw (1).
A07 006

z Clean sealing surfaces.

z Mount new gasket (1).
Note installation position. 1
Position gasket over the profile washer (2).

© 06/2006 4/6 8214-001

Fuel system
TCD 2015 W 07-03-01

z Mount cylinder head cover.

Profile washer (1) may not be trapped
underneath the sealing surface (2) of the 2
cylinder head cover. 1

6
© 40803-0

z Lightly oil screws (1).

z Tighten screws (1).
A01 005

1 1

© 06/2006 5/6 8214-001

Fuel system
W 07-03-01 TCD 2015

© 06/2006 6/6 8214-001

Fuel system
TCD 2015 W 07-03-01

Renewing injection pipes

(B-bank)
Commercial available tools: – W 06-02-03
– Dog wrench. . . . . . . . . . . . . . . . . . . 8018
Special tools:
– Plugs/caps . . . . . . . . . . . . . . . . . 170160 Danger!
Wait 30 seconds after switching off the
engine before working on the fuel system.

Removing injection pipes

z Remove the charge air pipe.
W 06-02-03
z Unscrew screws (1).
z Remove cylinder head cover (2).
2
z Remove gasket.

1
1

© 06/2006 1/6 8215-001

Fuel system
W 07-03-01 TCD 2015

z Unscrew screw (1).

z Remove pipe clamp (2).

6
© 40794-0

z Unscrew lock nuts (1) with dog wrench.

z Remove injection line.
Lay out components in the order in which
they should be installed.
Note cylinder assignment. 1

z Visually inspect the components.

z Renew damaged profile washers.

© 06/2006 2/6 8215-001

Fuel system
TCD 2015 W 07-03-01

Installing injection pipes

z Mount new injection pipe.
z Screw on union nuts (1).
Attention! 1
Install injection pipes without tension!

Note assignment and installation position

of the injection lines.

6
© 40795-0

z Oil the injection pipe in the area of the profile

washer (1).
z Position profile washer (1).
The profile washer must be at the upper
web (arrow) of the cylinder head cowling.
1

z Tighten lock nuts (1) with dog wrench.

A07 003

© 06/2006 3/6 8215-001

Fuel system
W 07-03-01 TCD 2015

z Tighten lock nuts (1) with dog wrench.

A07 003

6
© 40798-0

z Position pipe clamp (2).

z Tighten screw (1).
A07 006
1

z Clean sealing surfaces.

z Mount new gasket (1).
Note installation position.
Position gasket over the profile washer (2). 1

© 06/2006 4/6 8215-001

Fuel system
TCD 2015 W 07-03-01

z Mount cylinder head cover.

Profile washer (1) may not be trapped
underneath the sealing surface (2) of the
cylinder head cover.
1
2

6
© 40636-0

z Lightly oil screws (1).

z Tighten screws (1).
A01 005
z Install the charge air pipe.
W 06-02-03

1
1

© 06/2006 5/6 8215-001

Fuel system
W 07-03-01 TCD 2015

© 06/2006 6/6 8215-001

Fuel system
TCD 2015 W 07-04-01

Removing and installating injection pumps.

(Cylinder A1)
Commercial available tools: – W 04-06-03
– Open wrench size SW 22 – W 06-07-03 . . . . . . . . . . . . (A-bank)
Special tools: – W 07-10-06
– Plugs/caps . . . . . . . . . . . . . . . . . 170160 – W 07-10-06 . . . . . . . . . . . . (Railway)

– Locking agent Attention!

DEUTZ DW 59 Pay attention to utmost cleanliness when
working on the fuel system.
Remove residue paint and particles of dirt
before removing.
Clean the respective affected parts care-
fully. Blow damp areas dry with compres-
sed air.
6
Observe the safety regulations and natio-
nal specifications for handling fuels.
Close all connections immediately after
opening with new, clean plugs/caps.
Do not remove plugs/caps until immedia-
tely before assembling.
Collect leaking operating substances in
suitable vessels and dispose of according
to regulations.

Read out error memory of the motor con-

trol timer with SERDIA.

Removing the fuel injector pump

z Remove charge air pipe (A-bank).
W 06-07-03

© 06/2006 1/10 8216-001

Fuel system
W 07-04-01 TCD 2015

z Unscrew screws (1).

z Remove the holder (2).

1
6
© 40808-0

z Unscrew screw (1).

z Remove the holder (2).
z Unscrew hollow screw (3).
z Remove sealing rings.
1
2 3

z Unscrew nut (1).

z Remove the holder (2).

© 06/2006 2/10 8216-001

Fuel system
TCD 2015 W 07-04-01

z Unscrew hollow screw (1).

Hold overflow valve.

z Remove fuel pipe (2).

z Remove sealing rings.

6
© 40522-0

z Loosen screws (1).

z Pull off cables (2).

z Unscrew screws (1).

Loosen screws evenly to avoid jamming
the injection pump.

z Remove fuel injector pump(2).

Lay out components in the order in which 1
they should be installed.

© 06/2006 3/10 8216-001

Fuel system
W 07-04-01 TCD 2015

z Pull out roller tappet (1).

Attention!
Do not damage the roller tappet!
1
Lay out components in the order in which
they should be installed.

6
© 40810-0

z Visually inspect the components.

Removing injection pump housing

z Remove fuel pipes.
W 07-10-06
z Remove fuel pipes (Railway).
W 07-10-06
2
z Unscrew screws (1).
z Remove injection pump housing (2).
Lay out components in the order in which 1
they should be installed.
Note cylinder assignment.

© 06/2006 4/10 8216-001

Fuel system
TCD 2015 W 07-04-01

z Visually inspect the components.

6
© 40812-0

Installing injection pump housing

z Clean contact surfaces.
z Mount new O-ring (1).

z Oil the shank of the injection pump housing lightly.

z Press the injection pump housing into the stop in the
crankcase.
Note cylinder assignment.
The pilot pin (1) must lock in
groove (arrow).

1
© 40813-0

© 06/2006 5/10 8216-001

Fuel system
W 07-04-01 TCD 2015

z Lightly oil screws (1).

z Tighten screws (1).
A07 009

6
© 45388-0

z Install fuel pipes.

W 07-10-06
z Install fuel pipes (Railway).
W 07-10-06
Do not install fuel pipe (1). 1
Do not install charge air pipe (A-bank).

Installing the fuel injector pump

Note the assignment of the injection pump/
roller tappet when replacing the injection
pump and/or roller tappet.

© 06/2006 6/10 8216-001

Fuel system
TCD 2015 W 07-04-01

z Attach turning gear.

W 04-06-03
z Turn the injection pump camshaft with the turning
gear until the cam for the injection pump is on the
cam base circle (arrow).

6
© 42163-1

z Oil the roller tappet lightly.

z Insert roller tappet.
The pilot pin (1) must lock in
groove (arrow).

z Mount new O-rings (1).

z Oil O-rings lightly.

© 06/2006 7/10 8216-001

Fuel system
W 07-04-01 TCD 2015

z Insert injection pump (1).

The cable connections (3) of the injection
pumps must face the genset support.
1
z Lightly oil screws (2).
z Tighten screws (2). 2
3

6
© 40954-0

z Tighten screws (1) alternately.

A07 012
Attention!
Do not turn the camshaft until all the injec-
tion pumps are installed. Danger of brea-
king the tappet!
1

z Plug in cables (2).

T13 054
Note assignment!

z Tighten screws (1).

A13 054
1

© 06/2006 8/10 8216-001

Fuel system
TCD 2015 W 07-04-01

z Mount new sealing rings.

z Mount fuel pipe (2).
z Screw on hollow screw (1).

6
© 40522-0

z Oil the thread lightly.

z Mount holder (2).
z Screw on nut (1).

z Mount new sealing rings.

z Screw on hollow screw (3).
z Mount holder (2).
z Oil thread and head contact surface lightly.
z Fasten screw (1). 1
2 3

© 06/2006 9/10 8216-001

Fuel system
W 07-04-01 TCD 2015

z Tighten hollow screw (1).

Hold overflow valve.

A12 093
z Tighten nut (2).
1
A07 044

6
© 40565-0

z Tighten screw (1).

A07 044
z Tighten hollow screw (2).
A12 092
1

z Mount holder (2).

z Tighten screws (1).
A07 044
z Install charge air pipe (A-bank)
W 06-07-03
z Remove turning gear.
W 04-06-03
Delete error entry in the error memory of 2
the motor control timer with SERDIA.

Fuel system
TCD 2015 W 07-04-01

Removing and installing injection pumps

(Cylinder A2-B3)
Commercial available tools – W 03-01-11
– W 04-06-03
Special tools: – W 07-03-01 . . . . . . . . . . . . (A-bank)
– Plugs/caps . . . . . . . . . . . . . . . . . 170160 – W 07-03-01 . . . . . . . . . . . . (B-bank)
– W 07-10-06
– Locking agent
– W 07-10-06 . . . . . . . . . . . . (Railway)
DEUTZ DW 59
Attention!
Pay attention to utmost cleanliness when
working on the fuel system.
Remove residue paint and particles of dirt
before removing.
Clean the respective affected parts care-
6
fully. Blow damp areas dry with compres-
sed air.
Observe the safety regulations and natio-
nal specifications for handling fuels.
Close all connections immediately after
opening with new, clean plugs/caps.
Do not remove plugs/caps until immedia-
tely before assembling.
Collect leaking operating substances in
suitable vessels and dispose of according
to regulations.

Read out error memory of the motor con-

trol timer with SERDIA.

Removing injection pumps

z Removing the crankcase breather.
W 03-01-11
z Removing high pressure pipes (A-bank).
W 07-03-01
1 2
z Removing high pressure pipes (B-bank).
W 07-03-01
z Unscrew screws (1).
z Place fuel hose (2) to one side.

Fuel system
W 07-04-01 TCD 2015

z Loosen screws (1).

z Pull off cables (2).

6
© 45384-0

z Unscrew screws (1).

Loosen screws evenly to avoid jamming
the injection pump.

z Remove fuel injector pump(2).

Lay out components in the order in which
they should be installed. 1
Note cylinder assignment.

z Pull out roller tappet (1).

Attention!
Do not damage the roller tappet!
1
Lay out components in the order in which
they should be installed.
Note cylinder assignment.

Fuel system
TCD 2015 W 07-04-01

z Visually inspect the components.

6
© 40807-0

Removing injection pump housing

z Remove fuel pipes.
W 07-10-06
z Remove fuel pipes (Railway).
W 07-10-06
2
z Unscrew screws (1).
z Remove injection pump housing (2).
Lay out components in the order in which
they should be installed.
Note cylinder assignment.
1

z Visually inspect the components.

Fuel system
W 07-04-01 TCD 2015

Installing injection pump housing

z Clean contact surfaces.
z Mount new O-ring (1).

6
© 42159-2

The injection pump housings differ.

Mount the injection pump housing with the
bevel (arrow) on the B-bank.

z Oil the shank of the injection pump housing lightly.

z Press the injection pump housing into the stop in the
crankcase.
Note cylinder assignment.
The pilot pin (1) must lock in
groove (arrow).

1
© 45389-0

Fuel system
TCD 2015 W 07-04-01

z Lightly oil screws (1).

z Tighten screws (1).
A07 009
z Install fuel pipes.
W 07-10-06
z Remove fuel pipes (Railway).
W 07-10-06

6
© 40814-0

Installing injection pumps

Note the assignment of the injection pump/
roller tappet when replacing the injection
pump and/or roller tappet.

z Attach turning gear.

W 04-06-03
z Turn the injection pump camshaft with the turning
gear until the cam for the injection pump is on the
cam base circle (arrow).

Fuel system
W 07-04-01 TCD 2015

z Oil the roller tappet lightly.

z Insert roller tappet.
The pilot pin (1) must lock in
groove (arrow).

6
© 42164-1

z Mount new O-rings (1).

z Oil O-rings lightly.

z Insert injection pump (1).

Note assignment!
A-bank:
The cable connections (3) of the injection
pumps must face the genset support.
B-bank:
2
The cable connections (3) of the injection 3
pumps must face the flywheel.
z Lightly oil screws (2).
z Tighten screws (2).

Fuel system
TCD 2015 W 07-04-01

z Tighten screws (1) alternately.

A07 012
Attention!
Do not turn the camshaft until all the injec-
tion pumps are installed. Danger of brea-
king the tappet!
1

6
© 45383-0

z Plug in cables (2).

T13 054
Note assignment!

z Tighten screws (1).

A13 054
1

z Position fuel hose (2).

z Tighten screws (1).
A12 095

1 2

Fuel system
W 07-04-01 TCD 2015

z Installing high pressure pipes (A-bank)

W 07-03-01
z Installing high pressure pipes (B-bank)
W 07-03-01
z Install crankcase breather.
W 03-01-11
z Remove turning gear.
W 04-06-03
Delete error entry in the error memory of
the motor control timer with SERDIA.

6
© 40956-0

Fuel system
TCD 2015 W 07-06-04

Checking and setting plunger lift of injection pumps

Commercial available tools: – W 04-06-03
– Feeler gauges – W 06-06-04
Special tools: – W 06-06-04 . . . . . . . . . . . . (A-bank,
– Dial gauge. . . . . . . . . . . . . . . . . . 100410 Railway)
– Dial gauge holder – W 06-06-04 . . . . . . . . . . . . (B-bank,
with stylus extension. . . . . . . . . . 103240 Railway)
– Measuring pin . . . . . . . . . . . . . . . 110180 – W 07-04-01 . . . . . . . . . . . . (Cylinder A1)
– Plugs/caps . . . . . . . . . . . . . . . . . 170160 – W 07-04-01 . . . . . . . . . . . . (Cylinder
A2-B3)
– Packing compound
DEUTZ DW 48 Attention!
– Locking agent Pay attention to utmost cleanliness when
DEUTZ DW 72 working on the fuel system.
Remove residue paint and particles of dirt 6
before removing.
Clean the respective affected parts care-
fully. Blow damp areas dry with compres-
sed air.
Observe the safety regulations and natio-
nal specifications for handling fuels.
Close all connections immediately after
opening with new, clean plugs/caps.
Do not remove plugs/caps until immedia-
tely before assembling.
Collect leaking operating substances in
suitable vessels and dispose of according
to regulations.

Read out error memory of the motor con-

trol timer with SERDIA.

Checking plunger lift of injection pumps

z Remove injection pumps (cylinder A1).
W 07-04-01
z Remove injection pumps (cylinder A2-B3).
W 07-04-01
Do not remove injection pump housing.

z Attach turning gear.

W 04-06-03

Fuel system
W 07-06-04 TCD 2015

z Turn over crankshaft until the valve overlap is

achieved on cylinder no. B2.
T01 63
Valve overlap means:
Inlet valves begin to open and exhaust val-
ves close.
Observe valve clearance setting diagram.

6
© 40465-0

In case of valve overlap of cylinder no. B2:

The locking pin of the turning gear must
snap into the tooth notch (1) of the starter
ring gear.
The second tooth notch (2) must face the
B-bank.

1
2

z Pull locking pin (1).

z Turn crankshaft in the opposite direction to the en-
gine rotation (arrow) a ¼ turn with the turning gear.
1

Fuel system
TCD 2015 W 07-06-04

z Unscrew hollow screw (1).

z Place fuel hose (2) to one side.
z Remove sealing rings.

6
© 40458-0

The injection pump cams for cylinder

no. A1 must be on the base circle (arrow).

z Oil the roller tappet lightly.

z Insert roller tappet.
Note the assignment of the roller tappet.
The pilot pin (1) must lock in
groove (arrow).
1

Fuel system
W 07-06-04 TCD 2015

z Mount dial gauge holder (1).

z Tighten screws (2).
A07 012

6
© 40499-0

z Insert dial gauge holder (1) with stylus extension.

z Mount stylus with 6 mm pre-tension on the roller tap-
pet.
z Turn the crankshaft alternately in and against engine
direction.
1
z Check installation position of the dial gauge.
Dial gauge must run on the base circle of
the injection camshaft.
The display of the dial gauge may not
move.
z Adjust dial gauge to "0".

z Set crankshaft with turning gear in engine direction of

rotation (arrow) to ignition TDC, cylinder no. A1.
The locking pin of the turning gear must
snap into the starter gear ring.

Fuel system
TCD 2015 W 07-06-04

z Read and note the measured value.

P07 19

6
© 40503-0

Setting plunger lift of injection pumps

All injection pumps must be removed.
1
z Remove turbocharger.
W 06-06-04
z Remove turbocharger (A-bank, Railway).
W 06-06-04
z Remove turbocharger (B-bank, Railway).
W 06-06-04
z Unscrew screws (1).

z Unscrew all screws (3).

z Remove spacing sleeves. 1
z Unscrew all screws (2).
z Remove heat shield (1).

Fuel system
W 07-06-04 TCD 2015

z Unscrew screws (1).

z Remove the holder (2).

6
© 40506-0

z Unscrew screw (1).

z Remove pipe clamp (2).

z Unscrew all screws (1).

z Remove gear case cover (2).

1 2

Fuel system
TCD 2015 W 07-06-04

z Remove cable tie (1).

6
© 40459-0

z Unscrew screws (1).

z Remove cover (2) .
z Remove cover (3).

3
2

z Unscrew screws (1).

z Remove pad thrust bearing (2).

Fuel system
W 07-06-04 TCD 2015

z Loosen all screws (1).

6
© 40464-0

z Pull locking pin (1).

z Turn crankshaft in the opposite direction to the en-
gine rotation (arrow) a ¼ turn with the turning gear.
Dial gauge must read "0" again. 1

z Set crankshaft with turning gear in engine direction of

rotation (arrow) to ignition TDC, cylinder no. A1.
The locking pin of the turning gear must
snap into the starter gear ring.

Fuel system
TCD 2015 W 07-06-04

z Turn the injection pump camshaft with the screws in

engine direction of rotation (arrow) until the pre-
scribed plunger lift is reached.
P07 19

6
© 40509-0

z Pre-tighten screws (1).

A04 004
When pre-tightening the screws, press the
gear wheel lightly in the opposite direction
to engine rotation (arrow) against the tooth
flanks.
z Check the setting of the plunger lift again.

z Remove dial gauge.

z Remove dial gauge holder.

Fuel system
W 07-06-04 TCD 2015

z Tighten all screws (1).

A04 004
z Pull locking pin.
Concealed screws can be accessed by
turning the crankshaft with the turning gear.

6
© 40464-0

z Mount pad thrust bearing (2).

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

Checking and setting axial backlash of the

Fuel system
TCD 2015 W 07-06-04

z Insert feeler gauge blade between gear wheel of the

injection pump camshaft and the pad thrust
bearing (arrow).
z Press the pad thrust bearing onto the feeler gauge
blade.
z Fasten screw (1). 1
z Check axial backlash.
P04 43

6
© 40513-0

z Tighten screws (1).

A04 015
z Check axial backlash again.
P04 43
Check axial backlash on both sides bet- 1
ween
pad thrust bearing and gear
wheel (arrows).

z Clean sealing surfaces.

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

Fuel system
W 07-06-04 TCD 2015

z Press in the cover (3) to the stop.

z Mount cover (2).
Insert screws with safety agent
DEUTZ DW 72.

z Tighten screws (1). 3

2
A04 022

1
6
© 40460-0

z Fix cables with cable ties (1).

z Clean sealing surfaces.

z Apply packing compound evenly to the sealing sur-
face of the gear case.
z Mount gear case cover (1).
z Mount holder (2).
z Tighten all screws (3) alternately. 2
2
A04 020
1

Fuel system
TCD 2015 W 07-06-04

z Mount pipe clamp (2).

z Tighten screw (1).
A08 045

6
© 40456-0

z Mount holder (2).

z Tighten screws (1).
A12 071

z Mount heat shield (1).

z Insert screws (3) with spacing sleeves. 1
z Tighten screws (2).
z Tighten screws (2 and 3) alternately.
A12 071

Fuel system
W 07-06-04 TCD 2015

z Tighten screws (1).

A13 094
z Install the turbocharger.
W 06-06-04 1

z Install turbocharger (A-bank, Railway).

W 06-06-04
z Install turbocharger (B-bank, Railway).
W 06-06-04

6
© 40453-0

z Mount new sealing rings.

z Position fuel hose (2).
z Tighten hollow screw (1).
A12 090
1

z Install injection pumps (cylinder A1).

W 07-04-01
z Install injection pumps (cylinder A2-B3).
W 07-04-01
z Remove turning gear.
W 04-06-03
Delete error entry in the error memory of
the motor control timer with SERDIA.

Fuel system
TCD 2015 W 07-07-01

Removing and installing the fuel injectors

Commercial available tools: – W 07-03-01 . . . . . . . . . . . . (A-bank)
– Assembly pliers. . . . . . . . . . . . . . . . 8024 – W 07-03-01 . . . . . . . . . . . . (B-bank)
Special tools: – W 07-07-05
– Puller. . . . . . . . . . . . . . . . . . . . . . 110030
– Grooved nut wrench . . . . . . . . . . 110130 Danger!
– Disassembly tool. . . . . . . . . . . . . 110901 Wait 30 seconds after switching off the
– Extraction tool . . . . . . . . . . . . . . . 120660 engine before working on the fuel system.
– Slide hammer . . . . . . . . . . . . . . . 150800
– Plugs/caps . . . . . . . . . . . . . . . . . 170160 Attention!
Pay attention to utmost cleanliness when
– Fitting compound working on the fuel system.
DEUTZ S1 Remove residue paint and particles of dirt
before removing.
Clean the respective affected parts care- 6
fully. Blow damp areas dry with compres-
sed air.
Observe the safety regulations and natio-
nal specifications for handling fuels.
Close all connections immediately after
opening with new, clean plugs/caps.
Do not remove plugs/caps until immedia-
tely before assembling.
Collect leaking operating substances in
suitable vessels and dispose of according
to regulations.

Removing fuel injector

z Removing high pressure pipes (A-bank).
W 07-03-01
z Removing high pressure pipes (B-bank).
W 07-03-01

Fuel system
W 07-07-01 TCD 2015

z Unscrew union screw with grooved nut wrench.

6
© 40643-0

z Pull out fuel injector (1) and sealing ring (arrow).

Removing stuck fuel injectors

z Assembly sliding hammer (1) and puller (2).
z Tighten lock nut (3).

Fuel system
TCD 2015 W 07-07-01

z Mount sliding hammer on fuel injector.

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

6
© 40816-0

z Grip a tight sealing ring (1) with the assembly

pliers (2) and pull off, turning slightly.
Attention!
Do not damage the nozzle tip!

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.

Fuel system
W 07-07-01 TCD 2015

z Turn in the spindle.

The sealing ring must be fixed on the pul-
ler.
Hold puller on hexagon.
1
z Mount adapter (1) and slide hammer (2) on extrac-
tion device.
z Remove tight sealing ring.

6
© 45420-0

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

z Visually inspect the components.

z Check the fuel injector.
W 07-07-05

Fuel system
TCD 2015 W 07-07-01

Installing the fuel injector

z Insert new O-ring (arrow).
z Coat the thread (1) with fitting compound.

6
© 40818-0

z Coat the nozzle holder shaft in the (X) area with fit-
ting compound.
z Coat the lay-on surface of the sealing ring (arrow)
with fitting compound.
z Mount new sealing ring (1) on fuel injector. X
1

z Push the union screw (1) in the direction of the arrow.

Attention!
Do not damage the O-ring!

Fuel system
W 07-07-01 TCD 2015

z Insert fuel injector.

z Tighten union screw with grooved nut wrench.
A07 001

6
© 40643-0

z Installing high pressure pipes (A-bank)

W 07-03-01
z Installing high pressure pipes (B-bank)
W 07-03-01

Fuel system
TCD 2015 W 07-07-02

Dismantling and assembling fuel injector

Commercial available tools: – W 07-07-01
– Socket wrench insert . . . . . . . . . . . 8017 – W 07-07-05
Special tools:
– Holder . . . . . . . . . . . . . . . . . . . . . 110110

Dismantling fuel injector

z Removing fuel injectors.
W 07-07-01
z Check and set fuel injectors.
W 07-07-05
z Insert fuel injector in holder.
z Unscrew nozzle cap nut with socket wrench insert.

z Dismantle fuel injector.

Lay out components in the order in which
they should be installed.
6
z Visually inspect the components.
5
– Shim (1) 4
3
– Compression spring (2) 2
– Thrust bolt (3) 1
– Intermediate piece (4)
– Injection nozzle (5)
– Nozzle cap nut (6)
z Clean the parts in clean diesel fuel.
z Blow components dry with air.

Fuel system
W 07-07-02 TCD 2015

Assembling fuel injector

z Check injection nozzle.
Attention!
Do not touch the nozzle needle with your
1
fingers!
Nozzle needle (1) and nozzle body (2) are
folded together and may not be switched or 2
changed individually!

6
© 33904-2

The nozzle needle (1) must slide slowly

and without jolting into its seat by the force
of its own weight with the nozzle body (2)
held vertically.
In case of abrupt sliding of the nozzle 1
needle, clean the injection nozzle again in
the diesel bath, renew if necessary.
Also clean the new injection nozzle in the 2
clean diesel bath.

z Visually inspect the seat surfaces of the intermediate

piece for wear.
Make sure the centering pins (arrows) are
in place.

Fuel system
TCD 2015 W 07-07-02

z Select shim for setting the opening pressure.

The opening pressure depends on the
thickness of the shim.
A thicker shim gives a higher opening pres-
sure.
z Insert shim.

6
© 36274-2

z Insert compression spring.

z Insert thrust bolt.

Fuel system
W 07-07-02 TCD 2015

z Insert intermediate piece with the centering pins in

the bores of the nozzle holder.
The countersink must face the thrust bolt.

6
© 33909-2

z Mount the injection nozzle with the centre bores on

the centering pins of the intermediate piece.
The nozzle needle may not fall out of the
nozzle body.

z Screw on the nozzle cap nut.

Fuel system
TCD 2015 W 07-07-02

z Tighten nozzle cap nut.

A07 002
z Remove fuel injector from holder.
z Check and set fuel injectors.
W 07-07-05
z Install fuel injectors.
W 07-07-01

6
© 33912-2

Fuel system
W 07-07-02 TCD 2015

Fuel system
TCD 2015 W 07-07-05

Checking and setting fuel injectors

Commercial available tools: – W 07-07-01
– Socket wrench insert . . . . . . . . . . . 8017 – W 07-07-02
– Nozzle tester. . . . . . . . . . . . . . . . . . 8008
Special tools: Danger!
– Holder . . . . . . . . . . . . . . . . . . . . . 110110 Danger of injury when handling the nozzle
tester.
The fuel penetrates deep into the flesh
through the nozzle jet!
Caution, blood poisoning!

After about three or four actuations of the

hand lever, the spring space above the
nozzle needle in the injection valve fills up 6
with diesel fuel/test oil. Then it is no longer
possible to actuate the hand lever.
The nozzle cap nut must be loosened care-
fully before every test procedure to release
pressure from the spring space.
Only use pure test oil according to ISO
4113 or clean diesel fuel to test the fuel
injectors.

z Removing fuel injectors.

W 07-07-01

Fuel system
W 07-07-05 TCD 2015

Connecting the fuel injector to the nozzle

tester
z Insert fuel injector in holder.
z Loosen nozzle cap nut approx. 180° with socket
wrench insert (release pressure) and re-tighten.
A07 002

6
© 36271-2

z Connect the fuel injector to the nozzle tester

Checking opening pressure

z Press down the lever of the nozzle tester slowly with
the pressure gauge connected.
z Read off measured value.
The pressure at which the pointer stands
still or suddenly drops is the opening pres-
sure.
Repeat test 3 times.

Fuel system
TCD 2015 W 07-07-05

z Compare measured values.

P07 52
The measured values of three tests must
match the test value.

z In case of deviations from the test value, the fuel in-

jector must be dismantled or exchanged.
W 07-07-02

6
© 36293-2

Checking tightness
z Blow the injection nozzle and nozzle holder dry with
air.
z Press the hand lever of the tester down slowly until
about 20 bar below the previously read opening
pressure are reached.

Injection nozzle is tight if it does not drip

within 10 seconds.

Fuel system
W 07-07-05 TCD 2015

z If the injection nozzle drips, the fuel injector must be

dismantled or exchanged.
W 07-07-02
Attention!
Repairs are not permitted!

6
© 36295-2

Checking the easy action of the nozzle

needle
z Switch off the tester’s pressure gauge.
z Carry out chatter and jet test of the nozzle needle.
The easy action of the nozzle needle in the
nozzle body is checked by the acoustic
chatter test.
Increasing wear in the needle seat of the
fuel injectors changes the chatter behavior
of the injecton nozzle.
A used fuel injector must buzz audibly and
atomize the fuel finely when the lever is
actuated quickly.

z If the injection nozzle does not buzz audibly, it must

be dismantled and cleaned.
W 07-07-02
The injection nozzle must be changed if it
does not buzz after cleaning.
The jet profile may deviate considerably
from that of a new fuel injector.

Fuel system
TCD 2015 W 07-07-05

Removing the fuel injector from the nozzle

tester
z Loosen nozzle cap nut approx. 180° with socket
wrench insert (release pressure) and re-tighten.
A07 002
Attention!
The pressure in the spring space must be
reduced before installing the fuel injectors.
z Install fuel injectors.
W 07-07-01

6
© 36271-2

Fuel system
W 07-07-05 TCD 2015

Fuel system
TCD 2015 W 07-09-01

Removing and installing temperature transmitter

Commercial available tools – W 06-07-03 . . . . . . . . . . . . (B-bank)

Attention!
Pay attention to utmost cleanliness when
working on the fuel system.
Remove residue paint and particles of dirt
before removing.
Clean the respective affected parts care-
fully. Blow damp areas dry with compres-
sed air.
Observe the safety regulations and natio-
nal specifications for handling fuels.
Close all connections immediately after
6
opening with new, clean plugs/caps.
Do not remove plugs/caps until immedia-
tely before assembling.
Collect leaking operating substances in
suitable vessels and dispose of according
to regulations.

Read out error memory of the motor con-

trol timer with SERDIA.

Removing temperaure transmitter

z Remove charge air pipe (B-bank).
W 06-07-03

Fuel system
W 07-09-01 TCD 2015

z Unlock cable plug (1) and remove.

6
© 40823-0

z Unscrew temperature transmitter (1).

z Visually inspect the components.

Fuel system
TCD 2015 W 07-09-01

Installing temperature transmitter

z Tighten temperature transmitter (1).
A07 023

6
© 40824-0

z Plug in the cable plug (1).

z Install charge air pipe (B-bank)

W 06-07-03
Delete error entry in the error memory of
the motor control timer with SERDIA.

Fuel system
W 07-09-01 TCD 2015

Fuel system
TCD 2015 W 07-10-06

Removing and installing fuel pipes

Commercial available tools: – W 06-07-03 . . . . . . . . . . . . (A-bank)
– Open wrench size SW 22 – W 06-07-03 . . . . . . . . . . . . (B-bank)
Special tools:
– Plugs/caps . . . . . . . . . . . . . . . . . 170160 Attention!
Pay attention to utmost cleanliness when
working on the fuel system.
Remove residue paint and particles of dirt
before removing.
Clean the respective affected parts care-
fully. Blow damp areas dry with compres-
sed air.
Observe the safety regulations and natio-
nal specifications for handling fuels.
Close all connections immediately after
6
opening with new, clean plugs/caps.
Do not remove plugs/caps until immedia-
tely before assembling.
Collect leaking operating substances in
suitable vessels and dispose of according
to regulations.

Ensure that the cables are connected pro-

perly.

Removing fuel pipes

z Remove charge air pipe (A-bank).
W 06-07-03
z Remove charge air pipe (B-bank).
W 06-07-03

Fuel system
W 07-10-06 TCD 2015

z Loosen screws (1).

z Pull the cables (2) off all injection pumps.
Mark assignment of cables/connections
before removing.

6
© 45384-0

z Remove cable tie (1).

z Unlock cable plug (2) and disconnect.

z Unlock cable plug (1) and remove.

Fuel system
TCD 2015 W 07-10-06

z Unlock cable plug (1) and remove.

6
© 40610-0

z Unscrew screws (1).

1 1

z Unscrew nuts (1).

z Unscrew the nuts (2).
z Remove washers.
z Remove cables.
Mark assignment of cables/connections 2
before removing. 1

z Place cable harness rail with cable harness to one

side.

Fuel system
W 07-10-06 TCD 2015

z Unscrew screws (1).

z Remove the holder (2).

6
© 40613-0

z Unscrew screw (1).

z Remove the holder (2).
z Unscrew hollow screw (3).
z Remove sealing rings. 1

2 3

z Unscrew nut (1).

z Remove the holder (2).

Fuel system
TCD 2015 W 07-10-06

z Unscrew hollow screw (1).

Hold overflow valve.

z Remove fuel pipe (2).

z Remove sealing rings.
1

6
© 40615-0

z Unscrew hollow screw (1).

z Remove sealing rings.
z Place fuel hose (2) to one side.

z Unscrew nuts (1).

z Remove the holder (2).

Fuel system
W 07-10-06 TCD 2015

z Unscrew lock nut (1).

z Remove fuel pipe (2).

6
© 40618-0

z Unscrew all screws (1).

z Remove fuel pipes (2).
z Remove seals.

z Visually inspect the components.

Fuel system
TCD 2015 W 07-10-06

Installing fuel pipes

z Mount new gaskets (1).

6
© 40621-0

Note assignment!
The lug (1) must lock in groove (2).

2 1

z Mount fuel pipes (2).

z Tighten all screws (1).
A07 015
Do not move the gaskets when mounting
the fuel pipes. 1

Fuel system
W 07-10-06 TCD 2015

z Mount fuel pipe (2).

z Screw on lock nut (1).

6
© 40618-0

z Oil the thread lightly.

z Mount holder (2).
z Tighten nuts (1).
A07 044
1

z Tighten lock nut (1).

A07 066

Fuel system
TCD 2015 W 07-10-06

z Mount new sealing rings.

z Position fuel hose (2).
z Tighten hollow screw (1).
A12 090
1

6
© 40616-0

z Mount new sealing rings.

z Mount fuel pipe (2).
z Screw on hollow screw (1).

z Oil the thread lightly.

z Mount holder (2).
z Screw on nut (1).

Fuel system
W 07-10-06 TCD 2015

z Mount new sealing rings.

z Screw on hollow screw (3).
z Mount holder (2).
z Oil thread and head contact surface lightly. 1
z Fasten screw (1).
2 3

6
© 40623-0

z Tighten hollow screw (1).

Hold overflow valve.

A12 093
z Tighten nut (2). 1
A07 044
2

z Tighten screw (1).

A07 044
z Tighten hollow screw (2).
1
A12 092
2

Fuel system
TCD 2015 W 07-10-06

z Mount holder (2).

z Tighten screws (1).
A07 044

6
© 40613-0

z Position cable harness rail with cable harness.

z Plug cables.
Attention!
Note assignment and polarity of the electri-
cal connections!
2
Connect cables according to marks made 1
before removing.

z Mount washers.
z Tighten nuts (1).
A13 037
z Tighten nuts (2).
A13 038

z Tighten screws (1).

A13 094

1 1

Fuel system
W 07-10-06 TCD 2015

z Plug in the cable plug (1).

6
© 40610-0

z Plug in the cable plug (1).

z Plug together the cable plugs (2).

z Fix cable tie (1).

Fuel system
TCD 2015 W 07-10-06

Clamp all injection pumps.

z Plug in cables (2).

T13 054
z Tighten screws (1).
A13 054
1

6
© 45384-0

z Install charge air pipe (A-bank)

W 06-07-03
z Install charge air pipe (B-bank)
W 06-07-03

Fuel system
W 07-10-06 TCD 2015

Fuel system
TCD 2015 Railway W 07-10-06

Removing and installing fuel pipes

Commercial available tools Attention!
Pay attention to utmost cleanliness when
Special tools:
working on the fuel system.
– Plugs/caps . . . . . . . . . . . . . . . . . 170160
Remove residue paint and particles of dirt
before removing.
Clean the respective affected parts care-
fully. Blow damp areas dry with compres-
sed air.
Observe the safety regulations and natio-
nal specifications for handling fuels.
Close all connections immediately after
opening with new, clean plugs/caps.
Do not remove plugs/caps until immedia-
tely before assembling. 6
Collect leaking operating substances in
suitable vessels and dispose of according
to regulations.

Ensure that the cables are connected pro-

perly.

Removing fuel pipes

z Loosen screws (1).
Mark assignment of cables/connections
before removing.

z Remove cables.

Fuel system
W 07-10-06 TCD 2015 Railway

z Unlock cable plug (1) and remove.

z Remove cable tie (2).

6
© 42108-1

z Unlock cable plug (1) and remove.

z Unlock cable plug (2) and remove.

z Unscrew screws (arrows).

z Place cable harness rail with cable harness to one
side.

Fuel system
TCD 2015 Railway W 07-10-06

z Unscrew hollow screw (1).

z Remove sealing rings.
z Place hose pipe (2) to one side.
1

6
© 42112-1

z Unscrew all screws (1).

z Remove fuel pipes (2).
z Remove seals.

z Visually inspect the components.

Fuel system
W 07-10-06 TCD 2015 Railway

Installing fuel pipes

z Mount new gaskets (1).

1 1

6
© 42114-2

Note assignment!
The lug (1) must lock in groove (2).

2 1

z Mount fuel pipes (2).

z Tighten all screws (1).
A07 015
Do not move the gaskets when mounting
the fuel pipes.
2

Fuel system
TCD 2015 Railway W 07-10-06

z Mount hose line (2).

z Mount new sealing rings.
z Screw on hollow screw (1).
1

6
© 42112-1

z Position cable harness rail with cable harness.

z Position pipe clamp (arrow).
z Fasten screws.
Note different screw lengths:
M6 x 12 mm (1)
M6 x 16 mm (2) 1
z Tighten screws .
1
A13 094

z Position hose line (1).

Observe installation angle dimension X = 1
10°.

z Tighten hollow screw (2).

A12 090

1
2

Fuel system
W 07-10-06 TCD 2015 Railway

z Plug in the cable plug (1).

z Plug in the cable plug (2).

1
6
© 45854-0

z Plug cable plugs (1) together.

z Fix cable with cable tie (2).

Clamp all injection pumps.

z Plug in cables (1).

T13 054
Attention!
Note assignment and polarity of the electri-
cal connections! 1
Connect cables according to marks made
before removing.

z Tighten screws .
A13 054

Fuel system
TCD 2015 W 07-11-01

Removing and installing the fuel supply pump

Commercial available tools: Attention!
– Magnetic measuring stand Pay attention to utmost cleanliness when
Special tools: working on the fuel system.
– Plugs/caps . . . . . . . . . . . . . . . . . 170160 Remove residue paint and particles of dirt
before removing.
Clean the respective affected parts care-
fully. Blow damp areas dry with compres-
sed air.
Observe the safety regulations and natio-
nal specifications for handling fuels.
Close all connections immediately after
opening with new, clean plugs/caps.
Do not remove plugs/caps until immedia-
tely before assembling. 6
Collect leaking operating substances in
suitable vessels and dispose of according
to regulations.

Removing the fuel supply pump

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

2
1

Fuel system
W 07-11-01 TCD 2015

z Unscrew hollow screws (1).

z Remove fuel pipes (2).
z Remove sealing rings.

6
© 40828-0

z Unscrew hollow screw (1).

z Unscrew lock nut (2).
z Remove lubricating oil pipe.
z Remove sealing rings. 1

z Unscrew screws (1).

z Remove fuel supply pump (2).

Fuel system
TCD 2015 W 07-11-01

z Visually inspect the components.

6
© 40961-0

Installing the fuel supply pump

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

z Install fuel pump.

z Insert the driver (1) in the groove (2).

Fuel system
W 07-11-01 TCD 2015

z Tighten screws (1).

A07 024

6
© 40832-0

z Mount new sealing rings.

z Mount the lubricating oil pipe.
z Screw on hollow screw (1).
z Tighten lock nut (2). 1

A08 014
z Tighten hollow screw (1).
A08 013
2

z Mount new sealing rings.

z Mount fuel pipes (2).
z Tighten hollow screws (1).
A07 034

Fuel system
TCD 2015 W 07-11-01

z Mount holder (2).

z Tighten screws (1).
A07 044

2
1

6
© 40827-0

Fuel system
W 07-11-01 TCD 2015

Fuel system
TCD 2015 W 07-13-01

Removing and installing fuel pressure holding valve

Commercial available tools: – W 06-07-03 . . . . . . . . . . . . (A-bank)
– Open wrench size SW 22
Special tools:
– Plugs/caps . . . . . . . . . . . . . . . . . 170160 Attention!
Pay attention to utmost cleanliness when
working on the fuel system.
Remove residue paint and particles of dirt
before removing.
Clean the respective affected parts care-
fully. Blow damp areas dry with compres-
sed air.
Observe the safety regulations and natio-
nal specifications for handling fuels.
Close all connections immediately after
6
opening with new, clean plugs/caps.
Do not remove plugs/caps until immedia-
tely before assembling.
Collect leaking operating substances in
suitable vessels and dispose of according
to regulations.

Removing fuel pressure holding valve

z Remove charge air pipe (A-bank).
W 06-07-03
z Unscrew screws (1).
z Remove the holder (2).

Fuel system
W 07-13-01 TCD 2015

z Unscrew screw (1).

z Remove the holder (2).
z Unscrew hollow screw (3).
z Remove sealing rings.
1
2 3

6
© 40520-0

z Unscrew nut (1).

z Remove the holder (2).

z Unscrew hollow screw (1).

Hold overflow valve.

z Remove fuel pipe (2).

z Remove sealing rings.

Fuel system
TCD 2015 W 07-13-01

z Unscrew hollow screw (1).

z Remove sealing rings.
z Place hose pipe (2) to one side.
1

6
© 40948-0

z Hold the connector.

z Unscrew overflow valve (3).
z Remove sealing ring.
z Unscrew lock nut (1).
z Remove connector (2). 1

z Visually inspect the components.

Fuel system
W 07-13-01 TCD 2015

Installing fuel pressure holding valve

z Mount new sealing ring.
z Screw on overflow valve (1).
1

6
© 40947-0

z Insert connector (2).

Note installation position.
Connection of the hose line faces the heat
shield.
z Hold the connector. 1
z Tighten union nuts (1) with open wrench.
A07 066

z Hold the connector.

z Tighten overflow valve (1) with open wrench.
A07 067

Fuel system
TCD 2015 W 07-13-01

z Position hose line (1).

z Mount sealing rings (3).
z Tighten hollow screw (2).
A12 090
2
Attention!
Lay the hose pipe free from chafing and 1
tension.
3

6
© 40948-1

z Mount new sealing rings.

z Mount fuel pipe (2).
z Screw on hollow screw (1).

z Oil the thread lightly.

z Mount holder (2).
z Screw on nut (1).

Fuel system
W 07-13-01 TCD 2015

z Mount new sealing rings.

z Screw on hollow screw (3).
z Mount holder (2).
z Oil thread and head contact surface lightly.
z Fasten screw (1). 1
2 3

6
© 40520-0

z Tighten hollow screw (1).

Hold overflow valve.

A12 093
z Tighten nut (2).
1
A07 044

z Tighten screw (1).

A07 044
z Tighten hollow screw (2).
A12 092
1

Fuel system
TCD 2015 W 07-13-01

z Mount holder (2).

z Tighten screws (1).
A07 044
z Install charge air pipe (A-bank)
W 06-07-03

6
© 40519-0

Fuel system
W 07-13-01 TCD 2015

Fuel system
TCD 2015 Railway W 07-13-01

Removing and installing fuel pressure holding valve

Commercial available tools: Attention!
– Open wrench size SW 22 Pay attention to utmost cleanliness when
Special tools: working on the fuel system.
– Plugs/caps . . . . . . . . . . . . . . . . . 170160 Remove residue paint and particles of dirt
before removing.
Clean the respective affected parts care-
fully. Blow damp areas dry with compres-
sed air.
Observe the safety regulations and natio-
nal specifications for handling fuels.
Close all connections immediately after
opening with new, clean plugs/caps.
Do not remove plugs/caps until immedia-
tely before assembling. 6
Collect leaking operating substances in
suitable vessels and dispose of according
to regulations.

Removing fuel pressure holding valve

z Hold overflow valve (1).
z Unscrew screw-in nipple (2).
z Remove sealing ring.

2
1

Fuel system
W 07-13-01 TCD 2015 Railway

z Hold connector (1).

z Unscrew overflow valve (2).
z Remove sealing ring.

1
6
© 45915-1

z Unscrew screw (1).

z Remove washer.
z Loosen pipe clip. 1

z Unscrew hollow screw (1).

z Remove sealing rings.
z Place hose pipe (2) to one side.
z Unscrew union nut (3).
2
z Remove connector.

3 1

Fuel system
TCD 2015 Railway W 07-13-01

z Visually inspect the components.

6
© 45769-0

Installing fuel pressure holding valve

z Mount new sealing ring.
z Screw on overflow valve (1).
1

z Mount new sealing ring.

z Screw on screw-in nipple (1).

Fuel system
W 07-13-01 TCD 2015 Railway

z Mount hose line (1).

z Mount new sealing rings.
z Screw on hollow screw (2).

6
© 45918-0

z Insert connector.
z Screw on lock nut (1).

z Position connector (1).

Arrange hexagon area (1) horizontally.
The connection (2) faces approx. 45° to
the left.

Fuel system
TCD 2015 Railway W 07-13-01

z Hold connector (1).

z Tighten union nuts (2) with open wrench.
A07 066

6
© 45921-1

z Hold connector (1).

z Tighten overflow valve (2) with open wrench.
A07 067

z Hold overflow valve (1).

z Tighten screw-in nipple (2).
A07 069

2
1

Fuel system
W 07-13-01 TCD 2015 Railway

z Position pipe clamp (1).

z Mount washer.
z Tighten screw (2).
A13 094 2

6
© 45924-0

z Position hose line (1).

Observe installation angle dimension X =
10°.

Attention!
Lay the hose pipe free from chafing and 1
tension.
z Tighten hollow screw (2). X
A12 090

1
2

Lube oil system
TCD 2015 W 08-04-06

Removing and installing the oil suction pipe

Commercial available tools – W 08-04-07

Collect leaking operating substances in

suitable vessels and dispose of according
to regulations.

Removing the oil suction pipe

z Remove lubricating oil pan.
W 08-04-07
z Unscrew screws (1).
1
z Remove oil suction pipe (2).
z Remove gasket.

z Unscrew screws (1).

z Remove the holder (2).
z Visually inspect the components.

2
© 40834-0

Lube oil system
W 08-04-06 TCD 2015

Installing the oil suction pipe

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

6 2
© 40834-0

z Clean sealing surfaces.

z Mount new gasket.
z Mount oil suction pipe (2).
Attention!
Ensure that the installation location is free 1
from faults.
Install tension-free.
z Tighten screws (1).
1

z Tighten screws (1).

A08 016

Lube oil system
TCD 2015 W 08-04-06

z Tighten screws (1).

A08 015
z Tighten screws (2).
A08 016
z Install lubricating oil pan. 1
W 08-04-07

6
© 40962-0

Lube oil system
W 08-04-06 TCD 2015

Lube oil system
TCD 2015 Railway W 08-04-06

Removing and installing the oil suction pipe

Commercial available tools – W 08-04-07 . . . . . . . . . . . . (Railway)

Collect leaking operating substances in

suitable vessels and dispose of according
to regulations.

Removing the oil suction pipe

z Remove lubricating oil pan (Railway).
W 08-04-07
z Unscrew screws (1). 2
z Remove oil suction pipe (2).
z Remove gasket.

z Unscrew screws (1).

z Remove the holder (2).
z Visually inspect the components.

Lube oil system
W 08-04-06 TCD 2015 Railway

Installing the oil suction pipe

z Mount holder (1).
z Tighten screws (2).
A08 016

6
© 42171-1

z Clean sealing surfaces.

z Mount new gasket.
z Mount oil suction pipe.
z Fasten screws.
Ensure that the installation location is free
from faults.
Note different screw lengths:
M8 x 25 mm (1)
M8 x 20 mm (2)
1 2

z Tighten screws (1).

A08 015
z Tighten screws (2).
A08 016
Attention!
Install tension-free!

z Install lubricating oil pan (Railway).

W 08-04-07 1 2

Lube oil system
TCD 2015 W 08-04-07

Removing and installing the lubricating oil pan

Commercial available tools – W 13-03-02

– Packing compound Collect leaking operating substances in

DEUTZ DW 47 suitable vessels and dispose of according
– Engine oil to regulations.
The appropriate operating manual should
be observed for emptying and filling the
engine.

Removing the lubricating oil pan

z Remove starter.
W 13-03-02
z Unscrew locking screw (1).
z Drain, collect and dispose of engine oil according to
regulations.

z Oil the screw plug lightly.

z Mount new sealing ring.
z Tighten screw plug (1).
A03 031

Lube oil system
W 08-04-07 TCD 2015

z Pull out oil dipstick (1).

z Turn engine 180°.

6
© 40837-0

z Unscrew screws (1).

z Unscrew all screws (1).

z Remove cables (2).
The holders (3) remain on the cables.

Lube oil system
TCD 2015 W 08-04-07

z Remove lubricating oil pan.

z Remove gasket (1).

1
6
© 40840-0

z Unscrew lock nut (1).

z Remove guide tube (2).
z Remove screw-in nipple.
z Visually inspect the components.

Installing the lubricating oil pan

z Tighten screw-in nipple (1).
A08 038 1
z Mount guide tube.
z Tighten union nut.
A08 035

Lube oil system
W 08-04-07 TCD 2015

z Clean sealing surfaces.

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

z Apply packing compound to the joints (arrows).

6
© 40843-0

z Select new gasket.

z Mount gasket (1).

Strap (arrow) faces generator.
“TOP“ label faces crankcase.

Lube oil system
TCD 2015 W 08-04-07

z Mount lubricating oil pan.

z Align lubricating oil pan to crankcase.
Ensure that the installation location of the
gasket is free from faults.

6
© 40846-0

z Mount holder (3).

z Position cable (2).
z Tighten screws (1) alternately.

z Tighten all screws.

A03 030
See graphic for tightening sequence. 24 20 16 12 8 4 1 5 9 13 17 21

28 25

30 29

27 26

23 19 15 11 7 3 2 6 10 14 18 22

Lube oil system
W 08-04-07 TCD 2015

z Tighten screws (1).

A03 080

6
© 40838-0

z Turn engine 180°.

z Insert oil dipstick (1).

z Fill engine oil according to operating instructions.

z Install starter.
W 13-03-02

Lube oil system
TCD 2015 Railway W 08-04-07

Removing and installing the lubricating oil pan

Commercial available tools Collect leaking operating substances in
suitable vessels and dispose of according
to regulations.
– Packing compound The appropriate operating manual should
DEUTZ DW 47 be observed for emptying and filling the
– Fitting compound engine.
DEUTZ AP1908
– Engine oil

Removing the lubricating oil pan

z Unscrew locking screw (1).
z Drain, collect and dispose of engine oil according to
regulations.

z Oil the screw plug lightly.

z Mount new sealing ring.
z Tighten screw plug (1).
A03 031
z Turn engine 180°.

Lube oil system
W 08-04-07 TCD 2015 Railway

z Unscrew all screws (1).

z Remove washers.
z Remove all half-flanges (2).
z Remove both flanged sockets (3).
1

6
© 45867-0

z Unscrew screws (1).

z Remove connecting flange (2).

2
1

z Unscrew screws (1).

z Remove the holder (2).

Lube oil system
TCD 2015 Railway W 08-04-07

z Unscrew all screws (1).

z Remove cables (2).
The holders (3) remain on the cables.
2 1

z Loosen lubricating oil pan.

6
© 45861-0

z Pull lubricating oil pan in direction of arrow.

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

z Pull out plug elements (1).

Lube oil system
W 08-04-07 TCD 2015 Railway

z Insert new O-rings (arrows).

z Coat the O-rings with fitting compound.

6
© 45863-0

z Insert plug elements (1).

Mount lube oil tray with gasket.

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

z Apply packing compound to the joints (arrows).

Lube oil system
TCD 2015 Railway W 08-04-07

z Mount new gasket (1).

The bright side of the gasket faces the
crankcase.
In case of metal bead seals, the beading
faces the crankcase. 1

6
© 45864-0

Mount lube oil tray with packing com-

pound.
z Apply packing compound evenly to the sealing sur-
face and in the beading of the lube oil tray.
Apply the packing compound in an even
bead (thickness approx. 3.5 mm).
The position of the packing compound is
only partly illlustrated.

z Mount lubricating oil pan.

z Push on lubricating oil pan in direction of arrow.
Attention!
Do not move or damage O-rings.

Lube oil system
W 08-04-07 TCD 2015 Railway

z Align lubricating oil pan to crankcase.

Attention!
Do not move gasket/packing compound.
Do not move the gasket when mounting
the lubricating oil pan.

6
© 45865-0

z Mount holder (arrows).

z Position cable.
z Tighten screws alternately.

z Tighten all screws.

A03 030
See graphic for tightening sequence. 24 20 16 12 8 4 1 5 9 13 17 21

28 25

30 29

27 26

23 19 15 11 7 3 2 6 10 14 18 22

Lube oil system
TCD 2015 Railway W 08-04-07

z Insert new O-rings (arrows).

z Coat the O-rings with fitting compound.

6
© 37110-1

z Mount connecting flange (2).

Attention!
The labels “IN“ and “EX“ on the connecting EX IN
flange and the lubricating oil pan must
match.
z Tighten screws (1).
A03 035 1

z Insert new O-rings (arrows).

z Coat the O-rings with fitting compound.

Lube oil system
W 08-04-07 TCD 2015 Railway

z Mount half-flange (1).

z Mount washers.
z Tighten screws (2).
z Insert flanged socket (3).
3

6 2

z Mount half-flange (1).

z Mount washers.
z Tighten screws (2).
2

z Mount half-flange (1).

z Mount washers.
z Tighten screws (2).
3
z Insert flanged socket (2).
z Align both flanged sockets centrally. 2
z Tighten all screws.
A03 034

Lube oil system
TCD 2015 Railway W 08-04-07

z Mount holder (2).

z Tighten screws (1).
A13 098
1
z Turn engine 180°.
z Fill engine oil according to operating instructions.
2

1 6
© 42442-1

Lube oil system
W 08-04-07 TCD 2015 Railway

Lube oil system
TCD 2015 W 08-08-02

Removing and installing the oil cooler

Commercial available tools – W 06-07-03 . . . . . . . . . . . . (A-bank)
– W 09-08-04

Collect leaking operating substances in

suitable vessels and dispose of according
to regulations.

Removing the oil cooler

z Remove charge air pipe (A-bank).
W 06-07-03
z Remove thermostat housing.
W 09-08-04

z Unscrew screws (1).

z Remove the holder (2).

Lube oil system
W 08-08-02 TCD 2015

z Unscrew screw (1).

z Remove the holder (2).

1
2

6
© 40850-0

z Unscrew nut (1).

z Remove the holder (2).

z Unscrew hollow screw (1).

Hold overflow valve.

z Remove fuel pipe (2).

z Remove sealing rings.
1

Lube oil system
TCD 2015 W 08-08-02

z Unscrew screws (1).

1
1

6
© 40853-0

z Unscrew all screws (1).

z Remove oil cooler cover (2).
z Remove gasket.

z Unscrew screws (1).

z Remove oil cooler (2).
z Remove O-rings.

1 1

Lube oil system
W 08-08-02 TCD 2015

z Visually inspect the components.

6
© 40856-0

Installing the oil cooler

z Clean sealing surfaces.
z Insert new O-rings (1).
z Insert new O-rings (2). 1 1

2 2

z Mount oil cooler (2).

z Align oil cooler.
z Tighten screws (1).
A08 051

1 1

Lube oil system
TCD 2015 W 08-08-02

z Clean sealing surfaces.

z Mount new gasket.
z Mount oil cooler cover.
z Mount holder (1).
z Tighten screws (2). 1
Screw length:
M8 x 35 mm

z Fasten all screws (3).

Screw length: 2 2
M8 x 65 mm

3 6
© 40858-0

z Align oil cooler cover (2).

The lay-on surfaces of the oil cooler cover
and the genset support must contact the
holders.
Do not move gasket.
1
z Tighten all screws (1) alternately.
A08 050

z Tighten screws (1).

A06 058

1
1

Lube oil system
W 08-08-02 TCD 2015

z Mount new sealing rings.

z Mount fuel pipe (2).
z Screw on hollow screw (1).

6
© 40852-0

z Oil the thread lightly.

z Mount holder (2).
z Screw on nut (1).

z Mount holder (2).

z Oil thread and head contact surface lightly.
z Fasten screw (1).

1
2

Lube oil system
TCD 2015 W 08-08-02

z Mount holder (2).

z Tighten screws (1).
A07 044

6
© 40519-0

z Tighten hollow screw (1).

A12 093
Hold overflow valve.

1
z Tighten nut (2).
3
A07 044 2
z Tighten screw (3).
A07 044

z Install thermostat housing.

W 09-08-04
z Install charge air pipe (A-bank)
W 06-07-03

Lube oil system
W 08-08-02 TCD 2015

Lube oil system
TCD 2015 W 08-11-09

Removing and installing oil pressure pick-up

Commercial available tools Read out error memory of the motor con-
trol timer with SERDIA.
Special tools:
Collect leaking operating substances in
– Socket wrench insert . . . . . . . . . 110700
suitable vessels and dispose of according
to regulations.

Removing oil pressure pick-up

z Pull out cable plug (1).

z Unscrew oil pressure pick-up (1) with the socket

wrench insert.

Lube oil system
W 08-11-09 TCD 2015

z Visually inspect the components.

6
© 40862-0

Installing oil pressure pick-up

z Mount new gasket.
z Insert oil pressure pick-up (1). 1
z Tighten oil pressure pick-up with socket wrench in-
sert.
A08 091

z Plug in the cable plug (1).

Delete error entry in the error memory of
the motor control timer with SERDIA.
1

Lube oil system
TCD 2015 W 08-11-10

Removing and installing pressurestat

Commercial available tools: – W 03-01-11
– Depth-measuring – W 06-07-03 . . . . . . . . . . . . (B-bank)
appliance
Collect leaking operating substances in
suitable vessels and dispose of according
to regulations.

Removing pressurestat
z Removing the crankcase breather.
W 03-01-11
z Remove charge air pipe (B-bank).
W 06-07-03

z Remove cable tie (1).

z Unlock cable plug (2) and remove.

Lube oil system
W 08-11-10 TCD 2015

z Unlock cable plug (1) and remove.

6
© 40609-0

z Unlock cable plug (1) and remove.

z Unscrew screws (1).

z Remove the holder (2).

Lube oil system
TCD 2015 W 08-11-10

z Unscrew nuts (1).

z Remove the holder (2).

6
© 40972-0

z Unscrew lock nut (1).

z Remove fuel pipe (2).

z Unscrew locking screw (1).

z Remove sealing ring.

Lube oil system
W 08-11-10 TCD 2015

z Unscrew valve housing (1).

z Remove sealing ring.
Do not move the adjusting bolt (2).
1

6
© 40866-0

If the same oil pressure is to be set again,

the overhang of the adjusting bolt must be
measured before removing.
z Measure overhang (X) from adjusting bolt (1) to
crankcase with the depth measuring appliance.
z Note measured value.

1
X

z Unscrew adjusting bolt (1).

z Remove compression spring.
z Remove valve plunger.
1

Lube oil system
TCD 2015 W 08-11-10

z Visually inspect the components.

– Adjusting bolt (1).
– Compression spring (2)
– Valve plunger (3)
1 2 3

6
© 42460-1

Installing pressurestat
Overhang dimension (X) for basic setting
of adjusting bolt.
If the same oil pressure is to be set again,
the overhang dimension (X) noted before
removal must be reset.
P08 63

z Insert valve plunger.

z Insert compression spring.
z Screw in adjusting bolt (1).
P08 63 1
Note overhang dimension of the adjusting
bolt.

Lube oil system
W 08-11-10 TCD 2015

z Mount new sealing ring.

z Oil the thread valve housing lightly.
z Tighten valve housing (1).
A03 051
Do not move the adjusting bolt (2).

6
© 40869-0

z Mount new sealing ring.

z Tighten screw plug (1).
A08 071

z Mount fuel pipe (2).

z Screw on lock nut (1).

Lube oil system
TCD 2015 W 08-11-10

z Oil the thread lightly.

z Mount holder (2).
z Tighten nuts (1).
A07 044
1

6
© 40972-0

z Tighten lock nut (1).

A07 066

z Mount holder (2).

z Tighten screws (1).
A07 044

Lube oil system
W 08-11-10 TCD 2015

z Plug in the cable plug (1).

6
© 40864-0

z Plug in the cable plug (1).

z Plug in the cable plug (2).

z Fix cable tie (1).

Lube oil system
TCD 2015 W 08-11-10

z Install charge air pipe (B-bank)

W 06-07-03
z Install crankcase breather.
W 03-01-11

6
© 40848-0

Lube oil system
W 08-11-10 TCD 2015

Cooling system
TCD 2015 W 09-07-08

Removing and installing the coolant pump

Commercial available tools Collect leaking operating substances in
suitable vessels and dispose of according
Special tools: to regulations.
– Disassembly tool. . . . . . . . . . . . . 110901

– Fitting compound
DEUTZ AP1908

Removing coolant pump

z Unscrew screws (1).
z Removing screw-in nipple (2).
z Remove gasket.

z Visually inspect the components.

Cooling system
W 09-07-08 TCD 2015

z Unscrew all screws (1).

6
© 40871-0

z Tighten screws (1).

Use three studs M8 to push the coolant
pump off the genset support. 1 1

z Press off the coolant pump.

z Remove gasket.

z Remove screws.
z Remove the O-ring (1) with the disassembly tool.
z Remove the O-ring (2) with the disassembly tool.

Cooling system
TCD 2015 W 09-07-08

z Visually inspect the components.

6
© 40874-0

Installing coolant pump

z Insert new O-rings.
O-rings:
75 x 3 mm (1)
80 x 3 mm (2)
z Coat the O-rings with fitting compound. 1

z Clean sealing surfaces.

Check drainage holes (arrows) for free
passage.

Cooling system
W 09-07-08 TCD 2015

z Screw in studs (1).

To fix the gasket and the coolant pump.
1 1

z Mount new gasket.

6
© 40877-0

z Insert coolant pump.

The gear wheel (1) must engage the toot-
hing of the idler gear (2).

Attention!
Do not damage the gasket.
Do not move gasket.

1
2

z Lightly oil screws (1).

z Fasten all screws (1).
z Unscrew studs (2). 1
2 2

Cooling system
TCD 2015 W 09-07-08

z Lightly oil screws (1).

z Tighten screws (1).
z Tighten screws (1) alternately.
A09 010 1 1

6
© 40879-0

z Clean sealing surfaces.

z Mount new gasket.
z Mount inlet adapter (2).
z Lightly oil screws (1).
z Tighten screws (1).
A09 011 2

Cooling system
W 09-07-08 TCD 2015

Cooling system
TCD 2015 W 09-08-01

Checking the thermostat when uninstalled

Commercial available tools: – W 09-08-02
– Thermometer

Danger!
Risk of injury!
Hot water and hot thermostat.

Checking thermostat
z Remove thermostats.
W 09-08-02
z Measure beginning of stroke, dimension (a).
z Note measured value, dimension (a).

z Heat up the thermostat in the water bath.

z Determine beginning of opening.
In order to determine the exact beginning
of opening, the temperature should be
measured as close as possible to the ther-
mostat.
Do not touch 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 begin-
ning of opening will be delayed accordin-
gly.
P09 11
P09 12
© 34680-2

Cooling system
W 09-08-01 TCD 2015

z Measure end of stroke, dimension (b).

z Note measured value, dimension (b).

6
© 34679-2

z Determine stroke.
Calculation example
Desired: Stroke
Given: -
Measured: Beginning of stroke, dimension (a)
End of stroke, dimension (b)
Dimension (b) - dimension (a)
Result: = stroke
z Compare result with setpoint value.
P09 13
z Install thermostats.
W 09-08-02

Cooling system
TCD 2015 W 09-08-02

Removing and installing thermostats

Commercial available tools – W 09-08-01
– W 09-08-04

– Fitting compound Collect leaking operating substances in

DEUTZ AP1908 suitable vessels and dispose of according
to regulations.

Removing thermostats
z Remove thermostat housing.
W 09-08-04 2

z Unscrew all screws (1).

z Remove outlet nozzle (2). 1

z Remove thermostats (1).

Cooling system
W 09-08-02 TCD 2015

z Visually inspect the components.

z Check thermostats.
W 09-08-01

6
© 40882-0

Installing thermostats
z Select thermostats.
1
z Coat the sealing rings with fitting compound.
z Fit new sealing rings (1).
Note different opening
temperatures (arrows) of the thermostats.

P09 11
P09 12

Note installation position.

The markings (3) face upwards.
Note thermostat assignment.
z Insert thermostat (1). 3
1 2
P09 12
z Insert thermostat (2).
P09 11

Cooling system
TCD 2015 W 09-08-02

z Mount outlet nozzle (2).

z Tighten all screws (1).
A09 002 2
z Install thermostat housing.
W 09-08-04 1

6
© 40880_1

Cooling system
W 09-08-02 TCD 2015

Cooling system
TCD 2015 W 09-08-04

Removing and installing the thermostat housing

Commercial available tools – W 07-01-04

Collect leaking operating substances in

suitable vessels and dispose of according
to regulations.

Removing thermostat housing

z Remove fuel pipes (flame glow plugs).
W 07-01-04

z Unscrew screws (1).

Cooling system
W 09-08-04 TCD 2015

z Unscrew screws (1).

z Place holder (2) to one side.

6
© 40887-0

z Unscrew screw (1).

z Remove spacing sleeve.
z Place pipe to one side.

z Unscrew hollow screw (1).

z Remove sealing rings.

Cooling system
TCD 2015 W 09-08-04

z Unscrew screw (2).

z Remove holder (1).
2
z Unlock cable plug (3) and remove.

6
© 40890-0

z Unscrew screws (arrows).

z Remove the thermostat housing (1).

z Unlock cable plug (2) and remove.
z Remove gasket. 1

Cooling system
W 09-08-04 TCD 2015

z Visually inspect the components.

6
© 40893-0

Installing thermostat housing

z Clean sealing surfaces.
1
z Mount new gasket.
z Mount thermostat housing (1).
Do not move gasket.

z Plug in the cable plug (2). 2

z Fasten screws.
Note different screw lengths.
M8 x 90 mm (1)
M8 x 65 mm (2)

2 1 2

Cooling system
TCD 2015 W 09-08-04

z Mount holder (1).

z Fasten screw (2).
2
Screw length:
M8 x 140 mm.
TIghten screw only after mounting the fuel
pipes (flame glow plugs). 1

z Plug in the cable plug (3).

6
© 40890-0

z Tighten screws (1).

A09 001
z Tighten screws (2).
A09 001

2 1 2

z Mount new sealing rings.

z Tighten hollow screw (1).
A12 092

Cooling system
W 09-08-04 TCD 2015

z Mount fuel pipe.

z Position spacing sleeve.
z Fasten screw (1).

6
© 40888-0

z Position fuel shut-off valve.

P07 91
Note installation dimensions (X). X

z Tighten screw (1).

A07 093

Cooling system
TCD 2015 W 09-08-04

z Mount holder (2).

z Tighten screws (1).
A09 001
Screw length:
M8 x 150 mm

6
© 40887-0

z Tighten screws (1).

A13 094

z Install fuel pipes (flame glow plugs).

W 07-01-04

Cooling system
W 09-08-04 TCD 2015

Cooling system
TCD 2015 W 09-12-01

Removing and installing temperature transmitter

Commercial available tools Read out error memory of the motor con-
trol timer with SERDIA.
Collect leaking operating substances in
suitable vessels and dispose of according
to regulations.

Removing temperaure transmitter

z Unlock cable plug (1) and remove.

z Unscrew temperature transmitter (1).

Cooling system
W 09-12-01 TCD 2015

z Visually inspect the components.

6
© 44084-0

Installing temperature transmitter

z Tighten temperature transmitter (1).
A09 031

z Plug in the cable plug (1).

Delete error entry in the error memory of
the motor control timer with SERDIA.

Other components
TCD 2015 W 12-01-04

Removing and installing torsional vibration damper

Commercial available tools

Removing the torsional vibration damper

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

z Pull off torsional vibration damper (1).

Danger!
1
Risk of injury!

Other components
W 12-01-04 TCD 2015

z Visually inspect the components.

6
© 40898-0

Installing the torsional vibration damper

z Mount torsional vibration damper (1).
1

z Mount V-belt pulley (2).

z Lightly oil screws (1).
z Tighten all screws (1) alternately.
A12 031
1

Other components
TCD 2015 W 12-06-01

Removing and installing flywheel

Commercial available tools: Attention!
– Socket wrench insert . . . . . . . . . . . 8016 Do not turn the crankshaft without screws/
– Rotation angle disc . . . . . . . . . . . . . 8190 mandrin guide.
Special tools: The crankshaft gear wheel is positioned by
– Self-made mandrin guide screws/mandrin guide.
The position of the crankshaft gear wheel
will change without fixing.

Removing flywheel
z Unscrew all screws (1).
Block flywheel with suitable tool.

1
z Remove thrust washer (2).
2

z Insert self-made mandrin guide.

z Remove flywheel.
z Remove friction disc.
Attention!
Do not turn the crankshaft without screws/
mandrin guide.
The crankshaft gear wheel is positioned by
screws/mandrin guide.
The position of the crankshaft gear wheel
will change without fixing.

Other components
W 12-06-01 TCD 2015

z Visually inspect the components.

6
© 40903-0

Install flywheel
z Position friction disc.
Make sure the clamping bushing (1) is in
place.

z Mount flywheel.
Make sure the clamping bushing and loca-
1
ting hole are in line.

z Insert thrust washer (2).

z Lightly oil screws (1).
z Fasten all screws (1).
z Remove self-made mandrin guide.
Attention! 1
Renew screws every time they are loo-
sened. 2
z Tighten all screws (1) with the socket wrench insert.
A12 001
Block flywheel with suitable tool.

Other components
TCD 2015 W 12-06-03

Renewing toothed starter ring on the flywheel

Commercial available tools – W 12-06-01

Danger!
Danger of injury, do not touch hot parts!

Removing toothed starter ring

z Remove flywheel.
W 12-06-01
z Check marking.
The marking (arrow) is on the flywheel and
exactly in the middle of the tooth notch of
the toothed starter ring.

z Remove toothed starter ring with suitable tool.

Other components
W 12-06-03 TCD 2015

z Visually inspect joint (arrow) and contact surface.

z Clean flywheel.
The joint and contact surface must be free
from grease and dirt.

6
© 34765-2

Install toothed starter ring

z Check marking of new toothed starter ring.
The marking (arrow) is on the flywheel and
exactly in the middle of the tooth notch of
the toothed starter ring.

z Heat up toothed starter ring to 220 °C.

z Place toothed starter ring on flywheel.
The markings on the flywheel and toothed
starter ring must match.
The toothed starter ring must lie evenly on
the joint of the flywheel.

Other components
TCD 2015 W 12-06-03

z Install flywheel.
W 12-06-01

6
© 40907-0

Other components
W 12-06-03 TCD 2015

Other components
TCD 2015 W 12-08-04

Removing and installing hydraulic pump drive

Commercial available tools – W 06-01-06 . . . . . . . . . . . . (A-bank)

Special tools:
– Disassembly tool. . . . . . . . . . . . . 110901
Collect leaking operating substances in
– Fitting compound suitable vessels and dispose of according
DEUTZ AP1908 to regulations.
– Locking agent
DEUTZ DW 59

Removing hydraulic pump drive

z Remove exhaust pipe (A-bank).
W 06-01-06 1

z Unscrew screw (1).

z Unscrew lock nuts (2).
z Remove lubricating oil pipe (3). 3 2

z Unscrew screws (1).

z Remove flange housing (2).

1
2

Other components
W 12-08-04 TCD 2015

z Unscrew screws (1).

z Remove hydraulic pump drive (2).

6
© 40910-0

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

z Visually inspect the components.

Installing hydraulic pump drive

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

Other components
TCD 2015 W 12-08-04

z Insert hydraulic pump drive.

The gear wheel (1) must engage the toot-
hing of the idler gear (2).
2

6
© 40913-0

z Lightly oil screws (1).

z Tighten screws (1).
A12 057
1

z Mount new O-ring (1).

z Coat lay-on surface (arrow) with locking agent.

Other components
W 12-08-04 TCD 2015

z Mount flange housing (1).

z Lightly oil screws (2).
z Tighten screws (2).
Screw length:
M10 x 110 mm 2 1

z Insert screws (3) with locking agent.

z Fasten screws (3).
Screw length:
M10 x 210 mm

6
© 40915-0

z Tighten screws (1).

A12 058
z Tighten screws (2).
A12 059
1

z Mount lubricating oil pipe (3).

z Fasten screw (1).
z Tighten lock nut (2). 1
A12 082
z Tighten screw (1).
A08 045 3 2
z Install exhaust pipe (A-bank).
W 06-01-06

Electrical system
TCD 2015 W 13-01-02

Removing and installing the cable harness

Commercial available tools – W 06-02-03

Attention!
Note assignment and polarity of the electri-
cal connections!

Removing the cable harness

z Remove the charge air pipe.
W 06-02-03

z Disconnect the battery's negative terminal.

z Disconnect cables.

Electrical system
W 13-01-02 TCD 2015

z Remove cable tie (1).

6
© 40534-0

z Remove cable tie (1).

z Unlock cable plug (1) and remove.

Electrical system
TCD 2015 W 13-01-02

z Unscrew nut (1).

z Remove washer.
z Remove cables (2).
Mark assignment of cables/connections
before removing.
1

6
© 40920-0

z Unlock cable plug (1) and remove.

z Remove cable tie (1).

Electrical system
W 13-01-02 TCD 2015

z Loosen screws (1).

z Pull cables off all injection pumps.
Mark assignment of cables/connections
before removing.

6
© 40923-0

z Remove cable tie (1).

z Unlock cable plug (2) and disconnect.

z Unlock cable plug (1) and remove.

Electrical system
TCD 2015 W 13-01-02

z Unlock cable plug (1) and remove.

6
© 40926-0

z Remove cable tie (1).

1 1 1

z Unscrew nuts (1).

z Unscrew the nuts (2).
z Remove washers. 1
z Remove cables.
Mark assignment of cables/connections
before removing.

Electrical system
W 13-01-02 TCD 2015

z Unscrew screws (1).

6
© 40929-0

Mark assignment of cables/connections

before removing.
1
z Unscrew nut (1).
2
z Remove washer.
z Remove cables (2).

z Remove cable tie (1).

Electrical system
TCD 2015 W 13-01-02

z Unscrew lock nut (1).

6
© 40933-0

z Unscrew lock nut (1).

z Unscrew screw (1).

z Remove fuel pipe.

Electrical system
W 13-01-02 TCD 2015

z Pull out cable plug (1).

6
© 40936-0

z Remove cable tie (1).

z Unlock cable plug (2) and disconnect.

z Remove cable tie (1).

Electrical system
TCD 2015 W 13-01-02

z Unlock cable plug (1) and remove.

6
© 40937-0

z Unscrew screws (1).

z Unscrew screw (1).

Electrical system
W 13-01-02 TCD 2015

z Unlock central plug (1) (arrow) and pull off from hold-
er.

6
© 40940-0

z Visually inspect the components.

Installing the cable harness

z Position the cable harness on the engine according-
ly.
z Lay the cable plugs to the individual components.

Electrical system
TCD 2015 W 13-01-02

z Push the central plug onto the holder until it snaps in.
z Tighten screw (1).
A12 095

6
© 40939-0

z Tighten screws .
A13 090
Screw length:
M8 x 20 mm (1) 2
M8 x 16 mm (2)

z Plug in the cable plug (1).

Electrical system
W 13-01-02 TCD 2015

z Lay cable harness and fix with cable ties (1).

6
© 40532-0

z Plug together the cable plugs (2).

z Lay cable harness and fix with cable ties (1).

z Plug in the cable plug (1).

Electrical system
TCD 2015 W 13-01-02

z Mount fuel pipe.

z Position pipe clip.
z Fasten screw (1).

6
© 40935-0

z Tighten lock nut (1).

A12 080
Attention!
Install fuel pipe tension free. 1

z Tighten lock nut (1).

A12 080

Electrical system
W 13-01-02 TCD 2015

z Tighten screw (1).

A07 044

6
© 40935-0

z Lay cable harness and fix with cable tie (1).

z Plug in cables (2).

Attention! 1
Note assignment and polarity of the electri-
cal connections! 2
Connect cables according to marks made
before removing.

z Mount washer.
z Tighten nut (1).
A13 035

Electrical system
TCD 2015 W 13-01-02

z Tighten screws (1).

A13 094

6
© 40929-0

z Plug cables.
Attention!
Note assignment and polarity of the electri- 1
cal connections!

Connect cables according to marks made

before removing.

z Mount washers.
z Tighten nuts (1).
A13 037
2
z Tighten nuts (2).
A13 038

z Lay cable harness and fix with cable ties (1).

1 1 1

Electrical system
W 13-01-02 TCD 2015

z Plug in the cable plug (1).

6
© 40926-0

z Plug in the cable plug (1).

z Plug together the cable plugs (2).

z Lay cable harness and fix with cable tie (1).

Electrical system
TCD 2015 W 13-01-02

z Plug cables to all injection pumps.

T13 054
Attention!
Note assignment and polarity of the electri-
cal connections!

Connect cables according to marks made

before removing.
1
z Tighten screws (1).
A13 054

6
© 40923-0

z Lay cable harness and fix with cable tie (1).

z Plug in the cable plug (1).

Electrical system
W 13-01-02 TCD 2015

z Plug in cables (2).

Attention!
Note assignment and polarity of the electri-
cal connections!

Connect cables according to marks made

1
before removing.

z Mount washer.
z Tighten nut (1).
2
A13 035

6
© 40920-0

z Plug in the cable plug (1).

z Lay cable harness and fix with cable ties (1).

Electrical system
TCD 2015 W 13-01-02

z Lay cable harness and fix with cable ties (1).

6
© 40534-0

z Connect cables.
z Connect the battery's negative terminal.

z Install the charge air pipe.

W 06-02-03

Electrical system
W 13-01-02 TCD 2015

Electrical system
TCD 2015 W 13-02-03

Removing and installing the generator

(V-belt drive)
Commercial available tools: Attention!
– V-belt tension measuring Only test / tighten / renew V-belts when the
device . . . . . . . . . . . . . . . . . . . . . . . 8115 engine is not running.

The V-belt tension of new V-belts must be

checked after they have been running for
15 minutes.

Removing the generator

z Disconnect the battery's negative terminal.
z Remove cable from generator.
Note assignment! 1
- (1) = terminal W
- (2) = terminal D+
- (3) = terminal B+

3
© 45411-0

z Loosen screws (1).

Electrical system
W 13-02-03 TCD 2015

z Loosen nut (1).

6
© 40976-0

z Loosen screw (1).

z Press generator in direction of arrow.

z Remove V-belt (1).

Electrical system
TCD 2015 W 13-02-03

z Unscrew screws (1).

Hold nuts.

z Remove generator (2).

2 6
© 40979-0

z Visually inspect the components.

Installing the generator

z Mount generator.
z Insert screws.
Note different screw lengths: 1
M10 x 100 mm (1)
M10 x 120 mm (2)
z Fasten screws.
Hold nuts.

Electrical system
W 13-02-03 TCD 2015

z Tighten screws (1).

A13 015
Hold nuts.

6
© 45396-0

z Mount V-belt (1).

z Tighten V-belt (1) by turning the clamping screw (2).

A13 017
z Fasten screws (3). 3

2 1

Electrical system
TCD 2015 W 13-02-03

Check V-belt tension with V-belt tension

measuring device
z Lower indicator arm (1) into V-belt tension measuring
device.
1

6
© 39582_2

z Mount V-belt tension measuring device on V-belt.

The V-belt must be between the
guides (arrow).

z Press the V-belt measuring device against the V-belt

with the button (1) until you hear it click.

Electrical system
W 13-02-03 TCD 2015

z Read measured value at the intersection (arrow) of

the indicator arm and scale.
P12 11
P12 21
Note different units on the scale.

z If the nominal value is not reached, the tensioning

process must be repeated.

6
© 45413-0

z Tighten screws (1).

A13 012

z Tighten nut (1).

A13 017

Electrical system
TCD 2015 W 13-02-03

z Remove cable from generator.

Note assignment!
- (1) = terminal W
- (2) = terminal D+
1
- (3) = terminal B+
z Connect the battery's negative terminal.

3 6
© 45411-0

Electrical system
W 13-02-03 TCD 2015

Electrical system
TCD 2015 W 13-03-02

Removing and installing the starter

Commercial available tools

– Fitting compound
DEUTZ AP1908

Removing the starter

z Disconnect the battery's negative terminal.
z Disconnect cables.

z Unscrew nuts (1).

z Remove starter.

Electrical system
W 13-03-02 TCD 2015

z Visually inspect the components.

6
© 40945-0

Installing the starter

z Insert new O-ring (arrow).
z Coat the O-ring with fitting compound.

z Insert starter.
z Tighten nuts (1).
A13 001

Electrical system
TCD 2015 W 13-03-02

z Connect cables.
z Connect the battery's negative terminal.

6
© 40917-0

Electrical system
W 13-03-02 TCD 2015

Electrical system
TCD 2015 W 13-08-01

Removing and installing the pressure/temperature sensor

(charge air)
Commercial available tools Read out error memory of the motor con-
trol timer with SERDIA.

– Fitting compound
DEUTZ AP1908

Remove pressure/temperature sensor

z Unlock cable plug (1) and remove. 1

z Unscrew screw (1).

z Remove pressure/temperature sensor
z Visually inspect the components.

Electrical system
W 13-08-01 TCD 2015

Installing the pressure/temperature sensor

z Mount new O-ring (1).
z Lightly coat O-ring with fitting compound.

6
© 42002-2

z Insert pressure/temperature sensor.

z Tighten screw (1).
A13 046

z Plug in the cable plug (1).

Delete error entry in the error memory of 1
the motor control timer with SERDIA.

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