Deutz D 2008-2009

Workshop Manual D 2008/2009

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Note for printers Color: white Paper: Ikonofix 250 g/m2

Workshop Manual D 2008/2009

Workshop Manual

D 2008/2009

0312 3422 en

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

DEUTZ AG Service Information Systems Ottostraße 1 51149 Köln Deutschland Tel.: +49 (0) 221-822-0 Fax: +49 (0) 221-822-5850 Web: http://www.deutz.com http://www.deutz.com

The engine company.

Printed in Germany All rights reserved 1st Edition, 02/2006 Order No. 0312 3422 en

D 2008/2009 1

Foreword

2

General

3

User notes 3.1 3.2 3.2.1 3.2.1 3.2 3.2.2 3.3 3.3 3.4 3.5

4

Testing and setting data Tightening specifications

Job card overview 5.1

© 01/2006

General Specifications Safety Safety regula regulatio tions ns and and rule rules s for the prev prevent ention ion of accid accident ents s Disp Dispos osa al reg regul ula atio tions Oper Operat atin ing g manua anuall and works orksh hop manu manual al Job cards Explanation of of sy symbols

Technical data 4.1 4.2

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Table of contents

Sorted numerically

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Job cards

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Commercial tools

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Special tools

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Table of contents

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Foreword

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Foreword

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DEUTZ engines

Foreword 

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Read and observe the information in this documentation. You will avoid accidents, retain the manufacturer's warranty and possess a fully functional and ready to operate engine.

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This engine is built exclusively for purpose according to the scope of delivery - defined by the equipment manufacturer (use for the intended purpose). Any use above and beyond t his is considered improper use. The manufacturer will not be liable for damages resulting from this. The user bears the sole risk.

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Use for the intended purpose also includes observance of the operating, maintenance and repair instructions specified by the manufacturer. The engine may only be used, maintained and repaired by persons who are familiar with this and are aware of the risks involved.

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Make sure that this documentation is available to everyone involved in the operation, maintenance and repair and that they have understood the contents.

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Failure to observe this documentation may lead to malfunctions and engine damage as well as in jury to persons for which the manufacturer will not accept any liability.

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Prerequisite for proper maintenance and repair is the availability of all the necessary equipment, conventional and special tools and their perfect condition.

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Engine parts such as springs, clamps, elastic retaining rings etc. pose an increased risk of injury when handled incorrectly.

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The pertinent rules for the prevention of accidents and other generally recognised health and safety regulations must be observed.

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Repair of the engine must correspond to its use for the intended purpose. Only parts released by the manufacturer for the respective purpose may be used for conversion work. Unauthorised modifications to the engine exclude manufacturer liability for resulting damages. Failure to observe this will void the warranty!

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The engines made by DEUTZ are developed for a wide range of applications. A wide range of variants ensures that the respective special requirements are met.

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The engine is equipped according to the installation case, i.e. not all the parts and components described in this documentation are installed in your engine necessarily.

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We have done our best to highlight the differences so that you can easily find the operating, maintenance and repair instructions relevant to your engine.

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

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

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General

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General

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

2

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

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User notes 3.1 General

3.2 3.2 Spec Specif ific icat atio ions ns

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

3.2.1 Accident Accident preventio prevention n and and safety safety regulations

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

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

Caution! The rules for the prevention of accidents and the safety regulations must be observed during maintenance work.

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for the personnel: – Only briefed personnel may operate or maintain the engine. Unauthorised persons are prohibited access to the machine room.

Reference is made in the workshop manual job cards to the regulations in chapter 3.2. These must be read before working on the engine and must be strictly followed.

– Wear close-fitting clothing and ear protectors in the machine room when the engine is in operation. – Only deploy trained personnel to do repairs and maintenance work.

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

– Do not work on the fuel system when the engine is running. The fuel system is unde r high pressure - danger of death. – Go to the workshop immediately in case of leaks in the fuel system. 

for the engine room: – Ensure adequate ventilation (do not cover air shafts). – Provide first aid kit and suitable fire extinguishers. Check the filling and readiness for operation regularly. – Only store inflammable materials in the machine room if they are essential for operation of the system. – Smoking and naked flames are prohibited in the machine room.

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for operation, maintenance and repairs on the engine: – After all work on the fuel system, it must be bleeded - see the operation manual, chapter "6.2 Fuel system“. – Only start the engine when all the protective devices have been fitted. Make sure no-one is standing in the danger area. – Cleaning, maintenance and repair work may only be performed with the engine at a standstill and secured against starting. – Injection lines and high pressure pipes must not be deformed. – Damaged injection lines and high-pressure pipes must be renewed.

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User notes

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

3.3 Operat Operation ion manual manual and worksh workshop op manual

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

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

– Also carefully check all high pressure components visually before performing tests on the running engine. Wear suitable protective clothing (for example protective glasses). Leaks are a potential source of danger for workshop personnel.

The operation manual contains a general description and instructions for all other maintenance work. It contains the following chapters: 1. Conten Contents, ts, Genera Generall 2. Engine Engine desc descrip riptio tion n

– Even if no leaks are discernible on the high pressure fuel system, the workshop personnel should avoid the immediate danger zone or wear suitable protective clothing (such as protective glasses) when performing tests on the running engine and during the first trial run.

3. Opera Operati tion on

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

8. Engine Engine conse conserva rvation tion

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

10.Service

4. Operati Operating ng media media 5. Main Mainte tena nanc nce e 6. Care Care and mainten maintenance ance work work 7. Faults, Faults, causes causes and remedi remedies es 9. Techni Technical cal data data The workshop manual assumes knowledge of the contents of the operation manual. This applies especially for the safety regulations. The workshop manual describes repairs to the engine and components for which more effort and appropriately qualified technicians are required.

– Do not work near to sparks and flames.

3.2.2 3.2.2 Dispos Disposal al regula regulatio tions ns The work described in the operation manual and workshop manual necessitates renewal of parts and operating materials among other things. The renewed parts / operating materials must be stored, transported and disposed of according to regulations. The owner himself is responsible for this. Disposal includes recycling and the scrapping of parts / operating materials, although recycling has priority. Details of disposal and their monitoring are governed by regional, national and international laws and directives which the system operator must observe on his own responsibility.

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User notes 3.4 Job cards

3.4.2 3.4.2 Struct Structure ure of a job job card card

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

1

2

3

Triebwerk

5 16 6 15 6

7

14

3.4.1 3.4.1 Number Numbering ing of job cards cards

8

The job card numbers follow the pattern W 02-0401. 01. The individual parts of this pattern are explaine d below: 

4

W 02-04-01

W 02-04-01: Documentation type

13

12

8

– WWorkshop manual – I ...... Repair instructions 

W 02-04-01: 02-04-01: Maintenance group – 00 ... General / interdisciplinary activities 11

– 01 ... Cylinder head – 02 ... Drive system

10

– 03 ... Crankcase

1. DEUT DEUTZ Z AG, AG, publisher of service documentation

– 04 ... Engine control system

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

– 05 ... Speed governing

3. Mainte Maintenan nance ce group group

– 06 ... Exhaust system / Charging

4. Job card card numb number er or topic topic

– 07 ... Fuel system

5. Title Title of of job job card card

– 08 ... Lube oil system

6. Reference Reference to to other other job cards

– 09 ... Cooling system

7. Chap Chapte ter r

– 10 ... Compressed air system

8. Graphi Graphic c or or photo photo

– 11 ... Monitoring system

9. DEUTZ DEUTZ internal internal creatio creation n number number

– 12 ... Other components

10.Page number

– 13 ... Electrical system

11.Date of issue of job card

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W 02-04 02-04-01: -01: Component grouping

12.Note

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W 02-04-01 02-04-01:: Consecutive number

13.Danger / Important

9

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

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User notes 3.5 3.5 Expl Explan anat atio ion n of sym symbo bols ls Danger! of death or to health. Must be observed! For example: The incorrect use or conversion of the turbocharger can lead to serious injury. Caution! Danger to the component/engine. Noncompliance can lead to destruction of the component/engine. Must be observed! Note General notes on assembly, environmental protection etc. No potential danger for man or machine. Tool Conventional and special tools required for the work. Auxiliary materials Working materials required in addition to the tools for performing the work (e.g. greases, oils, adhesives, sealants) References to important documents or job cards for the work process. For example: Job card W 04-05-05 Reference to a document or a job card within the work process. Test and setting data The necessary values are specified here. If several values are necessary, a cross reference is given to the Test and Setting Values table. For example: ID no. P01 61 = valve clearance, inlet Tightening specification specification The necessary values are specified here. If several values are necessary, a cross reference is given to the Tightening Specifications table. For example: ID no. A01 001 = cylinder head screws

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D 2008/2009

2 5 7 0 P

g e n c i n n a e t p i o s f d o e t r k o a r t t t s s l t t e a b a t t s s V o o e m r m h r t e e f h t h o t t t s n n n t o a l a n i l s o e n m o o o n e e C C o T t s p y m s g 1 3 o c 1 n 1 1 r 1 i l e 2 o 9 9 h o 0 0 t 1 C P P O P

t l e b V e h t f o n o i s n e T 1 2 2 1 P 8/14

5987-001

Technical data Tightening specifications

D 2008/2009

4

4.2 4.2

© 02/2006

Tigh Tighte teni ning ng spec specif ific icat atio ions ns

9/14

5987-001


D 2008/2009

4

© 02/2006

10/14

5987-001


D 2008/2009 - e m u a l l a c v t g s n o i P p

m N 7 2

m N ° ° 5 0 0 3 6 6

- e u l m a a l v c - g e n r i P p

m N 1 4

m N 5 3

m N 7 2

m N 7 2

m N 1 4

m N 5 1

m N 1 4

m N 1 2

m N 5 3

m N 7 2

m N 2 3

m N 9 3

m N 1 8

s e i r e S

/ 8 0 0 2 D 9 T 0 / 0 D 2

/ 8 0 0 2 D 9 T 0 / 0 D 2

/ 8 0 0 2 D 9 T 0 / 0 D 2

/ 8 0 0 2 D 9 T 0 / 0 D 2

/ 8 0 0 2 D 9 T 0 / 0 D 2

/ 8 0 0 2 D 9 T 0 / 0 D 2

/ 8 0 0 2 D 9 T 0 / 0 D 2

/ 8 0 0 2 D 9 T 0 / 0 D 2

/ 8 0 0 2 D 9 T 0 / 0 D 2

/ 8 0 0 2 D 9 T 0 / 0 D 2

/ 8 0 0 2 D 9 T 0 / 0 D 2

/ 8 0 0 2 D 9 T 0 / 0 D 2

/ 8 0 0 2 D 9 T 0 / 0 D 2

w e r c s g n i k c o L

t e k c o s n o g a x e H

5 . 1 x 0 1 M

5 2 . 1 x 8 M

0 . 1 x 8 M

5 2 . 1 x 8 M

5 2 . 1 x 8 M

5 . 1 x 4 1 M

5 . 1 x 4 1 M

e s a c k n a r c n o r e v o c e s a c r a e G

e s a c k n a r c n o n a p l i o g n i t a c i r b u L

n a p l i o g n i t a c i r b u l n o g u l p n i a r D

e s a c k n a r c o t g n i s u o h n o i t c e n n o C

0 2 0 3 0 A

0 3 0 3 0 A

1 3 0 3 0 A

0 8 0 3 0 A

s k r a m e R / s e t o N e p y t

s w e r c s w e n e s U 5 7 . 1 x 2 1 M

5 2 . 1 x 8 M

5 2 . 1 x 8 M

e m a N

e s a c k n a r c n o g n i t n u o m e n i g n E

e s a c k n a r c n o d a e h r e d n i l y C

d a e h r e d n i l y c n o t e k c a r b m r a r e k c o R

d a e h r e d n i l y c n o r e v o c d a e h r e d n i l y C

. o n D I

3 0 0 0 0 A

1 0 0 1 0 A

2 0 0 1 0 A

4 0 0 1 0 A

w e r c S

© 02/2006

5 . 1 x 0 1 M

5 2 . 1 x 8 M

5 2 . 1 x 8 M

d a e h r e d n i l y c n o g o l g n i t f i L

e s a c k n a r c n o g n i s u o h g n i r a e b n i a M

e s a c k n a r c n o g n i s u o h g n i r a e b n i a M

) y l b m e s s a ( g n i s u o h g n i r a e b n i a M

d o r g n i t c e n n o c n o p a c g n i r a e b d n e g i B

2 9 0 1 0 A

0 1 0 2 0 A

2 1 0 2 0 A

3 1 0 2 0 A

0 2 0 2 0 A

11/14

4

5987-001

Technical data Tightening specifications - e m u a l l a c v t g s n o i P p

4

D 2008/2009

m N 1 8


m N 1 8

m N 0 1

m N 1 2

m N 1 8

m N 7 2

m N 7 2

m N 7 2

m N 8 2

m N 9

m N 0 1

m N 5 1

m N 7 2

m N 1 2

m N 1 2

s e i r e S

/ 8 0 0 2 D 9 T 0 / 0 D 2

/ 8 0 0 2 D 9 T 0 / 0 D 2

/ 8 0 0 2 D 9 T 0 / 0 D 2

/ 8 0 0 2 D 9 T 0 / 0 D 2

/ 8 0 0 2 D 9 T 0 / 0 D 2

/ 8 0 0 2 D 9 T 0 / 0 D 2

/ 8 0 0 2 D 9 T 0 / 0 D 2

/ 8 0 0 2 D 9 T 0 / 0 D 2

/ 8 0 0 2 D 9 T 0 / 0 D 2

/ 8 0 0 2 D 9 T 0 / 0 D 2

/ 8 0 0 2 D 9 T 0 / 0 D 2

/ 8 0 0 2 D 9 T 0 / 0 D 2

/ 8 0 0 2 D 9 T 0 / 0 D 2

/ 8 0 0 2 D 9 T 0 / 0 D 2

5 7 . 1 x 2 1 M

5 2 . 1 x 8 M

5 2 . 1 x 8 M

5 . 1 x 2 1 M

0 . 1 x 6 M

5 2 . 1 x 8 M

5 2 . 1 x 8 M

5 . 1 x 0 1 M

d a e h r e d n i l y c n o d l o f i n a m e k a t n I

d a e h r e d n i l y c n o r o t c e j n i l e u f e o h s g n i p m a l C

s e p i p e r u s s e r p h g i h r o f s t u n n o i n U

s e p i p e r u s s e r p h g i h r o f p m a l c e p i P

p m u p r o t c e j n i l e u f n o w e r c s g n i k c o l B

p m u p y l p p u s l e u f n o e n i l e l u F

e s a c k n a r c n o p m u p y l p p u s l e u F

e s a c k n a r c n o p m u p r o t c e j n i l e u F

e l o s n o c r e t l i f l e u f n o s e n i l l e u F

0 3 0 6 0 A

1 0 0 7 0 A

3 0 0 7 0 A

6 0 0 7 0 A

3 1 0 7 0 A

9 1 0 7 0 A

4 2 0 7 0 A

1 3 0 7 0 A

4 8 0 7 0 A


w e r c s x r o T 5 7 . 1 x 2 1 M

5 . 1 x 4 1 M

e m a N

t f a h s m a c n o r a e g d e h t o o t t f a h s m a C

p m u p r o t c e j n i l e u f n o r a e g d e h t o o t r o t c e j n i l e u F

e s a c k n a r c n o t f a h s m a c r e h s a w t s u r h T

e s a c k n a r c n o r a e g r e l d I

d a e h r e d n i l y c n o d l o f i n a m t s u a h x E

. o n D I

1 0 0 4 0 A

4 0 0 4 0 A

5 0 0 4 0 A

1 1 0 4 0 A

1 0 0 6 0 A

w e r c S

© 02/2006

5 2 . 1 x 8 M

12/14

5987-001


D 2008/2009 - e m u a l l a c v t g s n o i P p

m N 9


m N 1 4

m N 1 4

s e i r e S

/ 8 0 0 2 D 9 T 0 / 0 D 2

/ 8 0 0 2 D 9 T 0 / 0 D 2


w e r c S

m N 4

m N 1 4

m N 7 2

m N 7 2

m N 7 2

m N 6 9

m N 0 0 3

m N 9

m N 1 4

m N 2 2

m N 1 2

m N 1 2

/ 8 0 0 2 D 9 T 0 / 0 D 2

/ 8 0 0 2 D 9 T 0 / 0 D 2

/ 8 0 0 2 D 9 T 0 / 0 D 2

/ 8 0 0 2 D 9 T 0 / 0 D 2

/ 8 0 0 2 D 9 T 0 / 0 D 2

/ 8 0 0 2 D 9 T 0 / 0 D 2

/ 8 0 0 2 D 9 T 0 / 0 D 2

/ 8 0 0 2 D 9 T 0 / 0 D 2

/ 8 0 0 2 D 9 T 0 / 0 D 2

/ 8 0 0 2 D 9 T 0 / 0 D 2

/ 8 0 0 2 D 9 T 0 / 0 D 2

/ 8 0 0 2 D 9 T 0 / 0 D 2

0 . 1 x 6 M

5 . 1 x 0 1 M

" 8 / 3

5 2 . 1 x 8 M

5 2 . 1 x 8 M

5 . 1 x 2 1 M

5 . 1 x 0 2 M

0 . 1 x 6 M

5 . 1 x 0 1 M

5 2 . 1 x 8 M

5 2 . 1 x 8 M

p m u p t n a l o o c n o r e l l e p m i n a f d n a y e l l u p t l e b V

g n i s u o h n o i t c e n n o c n o r e t r a t S

r e v o c e s a c r a e g n o r o t a r e n e G

5 2 . 1 x 8 M k a r b d n a r e v o c e s a c r a e g n t o e k ) r c o t a r r b a n e n o e r g o ( t t a e r e k c n a e r t e G B k

6 4 0 2 1 A

1 0 0 3 1 A

2 1 0 3 1 A

3 1 0 3 1 A

w e r c s w o l l o H 5 . 1 x 0 1 M

" 4 / 3

e m a N

e s a c k n a r c n o e l o s n o c r e t l i f l e u F

e s a c k n a r c n o e l o s n o c r e t l i f l i O

e s a c k n a r c n o p m u p l i o g n i t a c i r b u L

. o n D I

7 8 0 7 0 A

3 0 0 8 0 A

0 1 0 8 0 A

© 02/2006

e s a c k n a r c n o r e d l o h e p i p n o i t c u s l i O

e s a c k n a r c n o e v l a v g n i t a l u g e r e r u s s e r p l i O

6 1 0 8 0 A

8 9 0 8 0 A

d a e h r e d n i l y c n o e l z z o n t e l t u O

r e v o c e s a c r a e g n o p m u p t n a l o o C

e s a c k n a r c n o l e e h w y l F

e s a c k n a r c n o y e l l u p t l e b V

5 0 0 9 0 A

0 1 0 9 0 A

1 0 0 2 1 A

1 3 0 2 1 A

13/14

8 1 0 3 1 A 5987-001

4


D 2008/2009

- e m u a l l a c v t g s n o i P p

4


m N 5 1

m N 5 . 2

m N 9

s e i r e S

/ 8 0 0 2 D 9 T 0 / 0 D 2

/ 8 0 0 2 D 9 T 0 / 0 D 2

/ 8 0 0 2 D 9 T 0 / 0 D 2

w e r c S

0 . 1 x 0 1 M

7 . 0 x 4 M

e m a N

d a e h r e d n i l y c n o g u l p g n i t a e H

g u l p g n i t a e h n o l i a r g n i t c e n n o C

r e t r a t s n o ) 0 3 . l c ( e l b a C

. o n D I

2 3 0 3 1 A

3 3 0 3 1 A

1 7 0 3 1 A


© 02/2006

14/14

5987-001

D 2008/2009

Job card overview

5

© 02/2006

5

Job card overview

5.1

Sorted numerically

1/4

5988-001

Job card overview Sorted numerically

D 2008/2009

5

© 02/2006

2/4

5988-001

Job card overview Sorted numerically

D 2008/2009

Job card

Activity

Maintenance group

W 01-02-02

Removing and installing the rocker arm

Cylinder head

W 01-04-04

Removing and installing the cylinder head

Cylinder head

W 01-04-09

Measuring the piston projection

Cylinder head

W 01-05-01

Removing and installing the valves

Cylinder head

W 02-01-04

Checking the axial clearance of the crankshaft

Drive system

W 02.0 02.02. 2.02 02

Rene Renewi wing ng the the cra crank nksh shaf aftt sea seali ling ng ring ring (fly (flywh whee eell sid side) e) Driv Drive e syst system em

W 02-02-04

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

W 02-04-01

Removing and installing the crankshaft

Drive system

W 02 02-09-03

Removing an and in installing th the pi piston an and co con ro rod

Drive sy system

W 02-09-07

Checking the piston

Drive system

W 03-09-04

Remo emoving and installing the the conne nnection housing

Crank ankcase

W 04-04-09

Removing and installing the gearcase cover

Crankcase

W 04-05-05

Removing and installing the camshaft

Engine control

W 06-01-05

Removing and inst nstalling the exhaust ust manifold

Exhaust system / Charging

W 06 06-07-03

Removi oving an and in instal talling th the ai air in intake ma manifold

Exhaust sy system / Ch Charging

W 07-04-01

Removing and installing the fuel injector pump

Fuel system

W 07-07-01

Removing and installing the fuel injectors

Fuel system

W 0707-10 10-0 -08 8

Rem Removin oving g and and and and ins insta tall llin ing g the the fuel fuel filt filter er cons consol ole e

Fuel Fuel sys system tem

W 07-11-01

Removing and installing th the fu fuel supply pump

Fuel system

W 08 08-04-05 -05

Removing an and ins insttalling the lu lubricating oi oil pu pump

Lube oi oil sy system

W 08-04-06

Removing and in installing th the oil suction pi pipe

Lube oil system

W 08 08-04-07

Removing an and in installing th the lu lubricating oi oil pan

Lube oi oil sy system

W 08-11-10

Removing and installing the oil pressure regulating Lube oil system valve

W 09-07-08

Removing and installing the coolant pump

Cooling system

W 09-0 09-088-01 01

Chec Checki king ng the the cool coolan antt ther thermo most stat at when when unin uninst stal alle led d

Cool Coolin ing g syst system em

W 09-08-02 -02

Removing and installing the coolant thermostat

Cooling system

W 12-0 12-022-02 02

Rem Removin oving g and and inst instal allling ing the the V-be V-belt lt,, V-be V-belt lt pull pulley ey

Othe Otherr com compone ponent nts s

W 12-06-01

Removing and installing the flywheel

Other components

W 13-02-03

Removing and installing the generator

Electrical system

W 13-03-02

Removing and installing the starter

Electrical system

W 13-06-01

Removing and installing the heating plugs

Electrical system

© 02/2006

3/4

5

5988-001

D 2008/2009

Job card overview

5

© 02/2006

4/4

5988-001

DEUTZ engines

6

© 11/2005

Job cards

Job cards

6

1/2

5989-001

DEUTZ engines

Job cards

6

© 11/2005

2/2

5989-001

Cylinder head W 01-02-02

D 2008/2009 Removing and installing the rocker arm Commercial available tools

6

Removing the rocker arm 

Loosen hose clip (1).



Unscrew Unscrew screws (2).



Remove Remove cylinder cylinder head cover (3).



Remove Remove gasket (4).









© 41001-1



Unscrew Unscrew screw (1).



Remove Remove rocker arm bearing bearing (2).



Remove Remove rocker rocker arm (3).

1

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

2

Visually inspect the components.

3

© 41183-0

02/2006

1/2

5991-001


D 2008/2009

Installing the rocker arm 

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



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

1

Align rocker arm centred to the valve spring! 

2

3

Fasten Fasten screw screw (1).

6 © 41002-1



Press down down rocker arm (1) and pushrod. pushrod.



Tighten Tighten screw (2).

 27 Nm Oil rocker arm lightly! 



© 41004-1



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



Mount new gasket gasket (4).



Mount cylinder cylinder head head cover (3).



Fit on the venting venting hose hose (1).



Tighten Tighten screws screws (2).

2

3

 27 Nm

1

4

Tightening sequence: From the centre outwards. 

Tighten Tighten hose hose clip (1).

© 41001-2

02/2006

2/2

5991-001


D 2008/2009 Removing and installing cylinder head Commercial available tools

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

6

Removing the cylinder head 

1. Valve Valve



2. Rocker Rocker arm



3. Cylinder Cylinder head bolts 4. Pushrods Pushrods 5. Thermostat Thermostat housing 6. Fuel injector injector 7. Coolant Coolant duct



 



© 41014-0



Remove rocker arm.

 W 01-02-02 

Remove exhaust manifold.

 W 06-01-05 

Remove intake manifold.

 W 06-07-03

© 41006-1

© 02/2006

1/6

5992-001

Cylinder head W 01-04-04 

D 2008/2009

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



Visually inspect the components. 

6 © 41007-1

Representation: 3-cylinder engine Loosen the screws in the specified order. 

Remove screws. 















© 41178-0

Representation: 4-cylinder engine Loosen the screws in the specified order. 

Remove screws. 



















© 41177-0

© 02/2006

2/6

5992-001


D 2008/2009 

Lift the cylinder head carefully from the crankcase.



Remove gasket.



Clean sealing surfaces. Do not place cylinder head on sealing surface.

6 © 41009-1

Installing the cylinder head 



Measure piston projection.

 W 01-04-09 Note installation position of the hydro tappets. Make sure the clamping clamping bushings bushings (1) are in place. 

© 41010-0



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.

© 41011-1

© 02/2006

3/6

5992-001


D 2008/2009

Fit cylinder head. Pay attention to clamping bushings (1).







6 © 41012-1

Representation: 3-cylinder engine

Attention! Use new screws. 

Oil the cylinder head screws slightly.



Tighten the screws according to the tightening sequence.

















– Step 1:

 35 Nm – Step 2:

 60° – Step 3: © 41178-0

 60° Representation: 4-cylinder engine

Attention! Use new screws. 

Oil the cylinder head screws slightly.
























– Step 1:

 35 Nm – Step 2:

 60° – Step 3: © 41177-0

 60°

© 02/2006

4/6

5992-001


D 2008/2009 

Lightly oil pushrods.



Insert pushrods pushrods in hydro-tappets hydro-tappets (1). Note installation position!



6 © 41013-1



Mount intake manifold.

 W 06-07-03 

Install exhaust manifold.

 W 06-01-05 

Install rocker arm.

 W 01-02-02

© 41006-1

© 02/2006

5/6

5992-001


D 2008/2009

6

© 02/2006

6/6

5992-001


D 2008/2009 Measuring the piston projection Commercial available tools: – Micrometer gauge

– W 01-04-04

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

6



Remove cylinder head.

 W 01-04-04 

Clean sealing surfaces.

© 41155-0



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

© 41156-0

© 02/2006

1/4

5993-001


D 2008/2009



Insert dial gauge into measuring beam.



Place shims shims (1) and measuri measuring ng beam (2) on the the sealing surface of the crankcase.



Apply the stylus to the piston base (arrow) under pretension.





Continue turning the crankshaft evenly until the reversal point of the pointer on the dial gauge is reached. The piston is now at top dead centre (TDC). 

6 © 41149-0



Move the measuring beam.

Apply stylus of the dial gauge to the crankcase sealing surface with with pre-tension pre-tension (arrow). (arrow).



Adjust dial gauge to "0".



© 41157-0

Measuring points see diagram. Meas Measur uring ing poin points ts (1) (1) and and (2). (2).





© 41148-0

© 02/2006

2/4

5993-001


D 2008/2009 Align the measuring apparatus on the spacing washers in such a way that the stylus lies on the specified measuring points.



Measuring points see diagram. Do not position the stylus on the piston marking. 

Note the largest measured value.



Compare actual value with setpoint value.

 P02 75

6 © 41149-1

© 02/2006

3/4

5993-001


D 2008/2009

6

© 02/2006

4/4

5993-001


D 2008/2009 Removing and installing the valves Commercial available tools: – Assembly pliers. . . . . . . . . . . . . . . . 8024 – Assembly lever . . . . . . . . . . . . . . . . 9017

– W 01-04-04 – W 07-07-01 – W 13-06-01

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

6

Removing the valves 1. Exhaust Exhaust valve



2. Inlet valve 3. Valve spring spring 

4. Rocker Rocker arm 5. Pushrod Pushrod





 © 41018-1



Remove Remove cylinder cylinder head (1).

 W 01-04-04 





Remove Remove heating heating plugs plugs (2).

 W 13-06-01 



Remove Remove fuel injectors injectors (3).

 W 07-07-01

© 41019-0

© 02/2006

1/4

5996-001


D 2008/2009

Attach assembly lever with screw (1) to cylinder head.





Press down valve spring with assembly lever.



Remove Remove both tapper tapper collets (2).



Remove valve spring plates, valve springs and valves.



Remove assembly lever.





6

© 41020_2



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





© 41021-1



Clean cylinder head, check and visually inspect for damage.




© 41022-1

© 02/2006

2/4

5996-001


D 2008/2009 Installing the valves 

Oil the valve stem lightly.



Insert and hold valve.



Mount assembly sleeve.



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



6 © 41023-1



Mount assembly lever.



Insert valve spring.



Insert valve valve spring spring plate (2).



Press down the valve spring with the assembly lever and insert insert both tapper collets collets (1).  

© 41179_0



Remove assembly lever. Make sure the tapper collets fit correctly in the valve keyway. keyway.

© 41024-1

© 02/2006

3/4

5996-001


D 2008/2009

Install cylinder head (1)

 W 01-04-04 





Install fuel injectors (3)

 W 07-07-01 



Install heating plugs (2)

 W 13-06-01

6 © 41019-0

© 02/2006

4/4

5996-001

Drive system W 02-01-04

D 2008/2009 Checking the axial clearance of the crankshaft Commercial available tools: – Magnetic measuring stand – Micrometer gauge

8190

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

6

Checking the axial backlash 

Mount magnetic measuring stand.



Insert dial gauge.

Apply stylus to the crankshaft end with pre-tension.

 

Press crankshaft in direction of arrow.




© 41158-1



Push crankshaft in the direction of the arrow and read off the value on the meter.

 P02 34 

Compare actual value with setpoint value.



Remove magnetic measuring stand.



Remove dial gauge.

 © 41159-1

© 02/2006

1/2

5997-001


D 2008/2009

6

© 02/2006

2/2

5997-001


D 2008/2009 Renewing the crankshaft sealing ring (flywheel side) Commercial available tools: – Pricker. . . . . . . . . . . . . . . . . . . . . . . 8198 – Assembly lever . . . . . . . . . . . . . . . . 9017

– W 12-06-01

Special tools: – Assembly tool . . . . . . . . . . . . . . . 142780 – Self-tapping screw – Washer

6

Removing the crankshaft sealing ring 

Remove flywheel.

 W 12-06-01

© 41025-0



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

Attention! Do not damage the main bearing housing and crankshaft.

© 41026-0

© 02/2006

1/2

5999-001


D 2008/2009



Turn in a self-tapping screw with washer.



Pull out the crankshaft sealing ring with assembly lever.



Visually inspect all running surfaces.

6 © 41027-0

Installing the crankshaft sealing ring Use new crankshaft sealing ring. The sealing lip faces the crankcase. 

Oil the sealing lip of the crankshaft sealing ring lightly.



Place the crankshaft sealing ring on the assembly tool.



Mount the assembly tool on the crankcase pin.



Drive in crankshaft sealing ring to the stop with the assembly tool. 1 mm installati installation on depth between connecconnection housing and crankshaft sealing ring.

© 41028-1



Remove assembly tool.



Install flywheel.

 W 12-06-01

© 41025-0

© 02/2006

2/2

5999-001


D 2008/2009 Renewing the crankshaft sealing ring (opposite side to flywheel) Commercial available tools: – Pricker. . . . . . . . . . . . . . . . . . . . . . . 8198 – Assembly lever . . . . . . . . . . . . . . . . 9017

– W 12-02-02

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

6

Removing the crankshaft sealing ring 

Remove V-belt pulley.

 W 12-02-02 

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

Attention! Do not damage the gearcase cover and crankshaft.

© 41174-0



Turn in a self-tapping screw with washer.



Pull out the crankshaft sealing ring with assembly lever.



Visually inspect all running surfaces.

© 41173-0

© 02/2006

1/2

6000-001


D 2008/2009

Installing the crankshaft sealing ring Use new crankshaft sealing ring. The sealing lip faces the crankcase. 

Oil the sealing lip of the crankshaft sealing ring lightly.



Place the crankshaft sealing ring on the assembly tool.



Mount the assembly tool on the crankcase pin.



Drive in crankshaft sealing ring to the stop with the assembly tool. The installation depth is determined by the assembly tool.

6






Install V-belt pulley.

© 41055-0

 W 12-02-02

© 02/2006

2/2

6000-001


D 2008/2009 Removing and installing the crankshaft Commercial available tools: – Assembly lever – 3-arm puller

– W 02-01-04 – W 02.02.02 – W 02-09-03 – W 04-04-09 – W 08-11-10 08-11-10 – W08-04-06 – W 12-06-01

Special tools: – Dial gauge. . . . . . . . . . . . . . . . . . 100400 – Assembly tool . . . . . . . . . . . . . . . 143860 – Assembly tool . . . . . . . . . . . . . . . 143870 – Threaded rod . . . . . . . . . . . . . . . 143880

6

Removing crankshaft 1. Crankshaft Crankshaft 2. Connecting Connecting rod 

3. Piston Piston 4. Bearing Bearing housing



5. Main bearing bearing housing







© 41033-2



Remove gear case cover.

 W 04-04-09 

Remove flywheel.

 W 12-06-01 

Remove piston and connection rod.

 W 02-09-03

© 41029-2

© 02/2006

1/10

6001-001

Drive system W 02-04-01 




Pull out journal journal (2).



Remove Remove idler idler gear (3).

D 2008/2009







6 © 41030-0






Remove Remove camshaft camshaft toothed wheel (2).





© 41031-0



Pull off camshaft toothed wheel with 3-arm puller.

© 41032-0

© 02/2006

2/10

6001-001


D 2008/2009 




Lever out main main bearing housing housing (2) with a suitable tool in the recess clearances. Make sure that the thrust washer halves do not fall into the crankcase.






6

 © 41034-1






Remove Remove oil suction suction pipe pipe (2).



Unscrew Unscrew fixing fixing screws (3).



Remove Remove oil pressure regulating regulating valve (4).







 W 08-11-10



© 41059-0



Remove crankshaft.




© 41035-0

© 02/2006

3/10

6001-001


D 2008/2009

Removing the main bearing 

Insert thrust pad (1) in bearing bush.



Insert threaded threaded rod (2).



Insert counter counter support support (3).



Mount washers and screw on nuts. 1

3

6

2

© 41060-1



Turn the nut nut (1) clockwise. clockwise. The bearing bush is pressed onto the crankcase by the thrust pad.



Dismantle assembly tool.



Remove bearing bush.

1

© 41061-1



Clamp main bearing housing in the vice. Use cushioned jaws. 2



Insert thrust pad (1) in bearing bush.






Insert counter counter support support (3).



Mount washers and screw on nuts.



Turn nut nut (4) clockwise clockwise..

1

3

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

4 © 41057-2

© 02/2006

4/10

6001-001


D 2008/2009 Installing the main bearing 

Oil bearing bush with engine oil.



Press in bearing bush with assembly tool 143870. Make sure the bearing bush is not twisted. The installation depth is determined by the assembly tool. Mark the position of the lubricating oil bore on the main bearing housing.

6 © 41058-1



Oil bearing bush with engine oil.



Mount bearing bush.



Mount guide plate (1).






Insert counter support.



Mount washers and screw on nuts.





Mark position of the lubricating oil bore. Position bearing bush.

© 41062-1



Turn the nut nut (1) clockwise. clockwise. The bearing bush is pressed into the crankcase by the thrust pad. The installation depth is determined by the assembly tool. Make sure the bearing bush is not twisted.

1

© 41063-1

© 02/2006

5/10

6001-001


Dismantle assembly tool.






Check that the lubricating oil bore is in line.

D 2008/2009

If the lubricating oil bore is not in line, the bearing bush must be removed and reinstalled. 

Check installation depth of the bearing bush with depth measuring appliance.

 ca. 3 mm

6 © 41064-1

Installing the crankshaft 

Lightly Lightly oil bearing bush (1) with engine engine oil.



Push crankshaft into crankcase.



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

Insert thrust thrust washers (4) at the rear with grease. Lubricating oil grooves face the crankshaft.  

© 41036-1



Push in the crankshaft in the direction of the arrow to the stop.



Tighten Tighten locating locating screws (1).



Install oil suction pipe.

 W 08-04-06



© 41037-1

© 02/2006

6/10

6001-001


D 2008/2009 

Install Install main bearing bearing housing (1).




– Step 1:

 15 Nm – Step 2:

 27 Nm 

Renewing the crankshaft sealing ring.

 W 02-02-02

2

6

1 © 41038-1



Check axial backlash of crankshaft.

 W 02-01-04 

Heat up crankshaft crankshaft toothed wheel to approx. 100 °C. 

Danger! Danger of burning! 

Mount crankshaft crankshaft toothed toothed wheel (1). Note installation position of Woodruff key (2) and groove groove..





Install oil pressure regulating valve.

 W 08-11-10

© 41039-0



Mount camshaft toothed wheel. Mount camshaft toothed wheel with the bore on the clampi clamping ng pin (1).








© 41065-1

© 02/2006

7/10

6001-001


D 2008/2009

The marks marks (1) of the crankshaft crankshaft toothed wheel and the camshaft toothed wheel must be in line! 


 81 Nm

 

6 © 41081-1



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

© 41066-0



Oil the journal lightly.



Insert the journal carefully into the needle bearing.



Tighten screw.

 81 Nm

© 41067-0

© 02/2006

8/10

6001-001


D 2008/2009 

Install piston and connection rods.

 W 02-09-03 

Mount gearcase cover.

 W 04-04-09 

Install flywheel.

 W 12-06-01

6 © 41029-2

© 02/2006

9/10

6001-001


D 2008/2009

6

© 02/2006

10/10

6001-001


D 2008/2009 Removing and installing the piston and con rod Commercial available tools

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

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

6

Removing the piston and con rod 

1. Piston rings 2. Piston Piston



3. Piston pin 4. Connection Connection rod



5. Big end bearing bearing cap



6. Coolant duct in the crankcase crankcase

 

© 41042-0



Remove cylinder head.

 W 01-04-04 

Remove lubricating oil pan.

 W 08-04-07 

Remove oil suction pipe.

 W 08-04-06 

Pull out oil dipstick.

© 41040-0

© 02/2006

1/6

6002-001


D 2008/2009

Removing the big end bearing cap 

Position lifting bearing journal in LDC position.






Remove Remove big end bearing bearing cap (2).



Remove Remove bearing bearing shell shell (3). Lay out components in the order in which they should be installed. Note order of cylinders. 





6 © 41041-0



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



Remove Remove con rod bearing bearing shells (1).




1

© 41043-1

Removing the piston 

Remove locking ring with locking ring pliers.



Press piston bolts out of piston and con rod.



Remove connection rod.




© 41044-1

© 02/2006

2/6

6002-001


D 2008/2009 

Remove piston rings with universal piston ring pliers.



Check piston.

 W 02-09-07

6 © 41045-0

Completing con rod and piston 

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



Insert con rod. The labelling on the piston base and the numbered label of the connection rod face the camshaft side.



Oil the piston bolt lightly.



Press the piston bolt through.



Insert new locking ring. Ensure that the installation location is free from faults. © 41047-1

Installing the piston and con rod 

Insert bearing shell in the con rod. Note the assignment of the bearing shells. The anti-rotatio anti-rotation n lock (1) must lock in groove groove (2).



Insert bearing shell in the respective big end bearing cap. 2

Note the assignment of the bearing shells. The anti-rotation lock must lock in groove.

? 1

© 41048-1

© 02/2006

3/6

6002-001


D 2008/2009

Install piston rings with universal piston ring pliers.

Arrange the piston ring joints with an offset of about 120° to each other. other.



Do not turn the piston rings any further.

 

6

 © 41046-0



Lightly oil cylinder running surface, piston, piston rings and lifting bearing journal lightly.



Clamp piston rings with piston ring compressor.



Set lifting journal at bottom dead centre (BDC).



Push piston and con rod completely into cylinder. The piston ring compressor must lie flat on the crankcase.



Press the con rod carefully against the lifting journal.



© 41049-0

Note installation position! The numbered label faces the camshaft side.

1

x x x x x x

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

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



UT

Tighten new screws.

 35 Nm © 41068-1

© 02/2006

4/6

6002-001


D 2008/2009 

Insert oil dipstick.



Install oil suction pipe.

 W 08-04-06 

Install lubricating oil pan.

 W 08-04-07 

Install cylinder head.

 W 01-04-04

6 © 41040-0

© 02/2006

5/6

6002-001


D 2008/2009

6

© 02/2006

6/6

6002-001


D 2008/2009 Checking the piston Commercial available tools: – Micrometer gauge – Internal measuring device

– W 02-09-03

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

When the piston wear limit is reached the piston must be replaced.

6

Checking the piston bolt bore 

Remove piston.

 W 02-09-03

© 41044-1



Prepare internal measuring device:

– Mount probe bolt for the appropriate measuring range in the internal measuring device. – Mount dial gauge with with approx. 1 mm pre-tension in the internal measuring device. – Set micrometer gauge to 28 mm. – Balance the internal measuring device between the test surfaces of the micrometer gauge and set the dial gauge at the reversal point of the pointer to "0".

© 34768-2

© 02/2006

1/4

6003-001


D 2008/2009

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

6 © 37239-1



Insert internal measuring device in the piston bolt bore.



Balance the internal measuring device at the given measuring points and read off the measured value at the reversal point of the pointer. See schematic diagram for measuring points.

 P02 78

© 43483-0

Checking the piston diameter Diagram for measuring the piston diameter at the measur measuring ing points points "1, 2 and 3", transtransverse to the piston bolt bore. 





© 41154-0

© 02/2006

2/4

6003-001


D 2008/2009 

Measure piston diameter with micrometer gauge. See schematic diagram for measuring points.

 P02 71 

Complete con rod and piston.

 W 02-09-03

6 © 43427-0

© 02/2006

3/4

6003-001


D 2008/2009

6

© 02/2006

4/4

6003-001

Crankcase W 03-09-04

D 2008/2009 Removing and installing the connection housing Commercial available tools

– W 13-03-02 – W 12-06-01

6

Removing the connection housing 

Remove Remove starter (1).

 W 13-03-02 

Remove Remove flywhee flywheell (2).

 W 12-06-01





© 41070-0



Remove screws.



Remove connection housing.



Visually inspect the component.

© 41071-0

© 02/2006

1/2

6006-001

Crankcase W 03-09-04

D 2008/2009

Installing the connection housing 

Mount connection housing.



Tighten screws.

 81 Nm

6 © 41072-0



Install Install flywheel flywheel (1).

 W 12-06-01 

Install Install starter (2).

 W 13-03-02





© 41073-0

© 02/2006

2/2

6006-001

Engine control W 04-04-09

D 2008/2009 Removing and installing the gearcase cover Commercial available tools Special tools: – Assembly tool . . . . . . . . . . . . . . . 142790

– W 12-02-02 – W 09-07-08 – W 13-02-03 – W 08-11-10 08-11-10 – W 08-10-07 Collect leaking operating substances in suitable vessels and dispose of according to regulations. The engine oil and coolant should be added according to the operating manual.

6

Removing the gearcase 


 W 12-02-02 

Remove fan impeller.



Remove generator.

 W 13-02-03 

Remove coolant pump.

 W 09-07-08 

Remove oil filter.

© 41051-1



Remove oil filter console.

© 41052-0

© 02/2006

1/4

6007-001

Engine control W 04-04-09 

Remove screws.



Remove gearcase cover.

D 2008/2009

Attention! Do not damage the sealing surfaces. 




Visually Visually inspect sealing surfaces (arrows). (arrows).

6 © 41053-0

Installing the gearcase cover 

Knock out crankshaft crankshaft sealing sealing ring (1).

Attention! Do not damage sealing surface when knocking out. 

1


© 41054-1



Fix the new gasket to the crankcase with a little grease. Note installation position! Make sure the clamping clamping bushings bushings (1) are in place.





© 41056-0

© 02/2006

2/4

6007-001


D 2008/2009 


 

Ensure that the installation location is free from faults. 














 27 Nm

        

6 





 © 41069-1



Mount oil filter console.



Tighten screws.

 41 Nm

© 41052-0



Install oil filter.



Install coolant pump.

 W 09-07-08 

Install generator.

 W 13-02-03 

Install crankshaft sealing ring (flywheel side).

 W 02-02-04 

Install fan impeller.




 W 12-02-02

© 41051-1

© 02/2006

3/4

6007-001


D 2008/2009

6

© 02/2006

4/4

6007-001


D 2008/2009 Removing and installing the camshaft Commercial available tools Special tools: – Fixing pin . . . . . . . . . . . . . . . . . . 144180 – Dial gauge. . . . . . . . . . . . . . . . . . 100400

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

6

Removing the camshaft 

Remove Remove cylinder cylinder head (1).



 W 01-04-04 

Remove Remove gearcase gearcase cover (2).

 W 04-04-09 

Remove fuel supply pump (3).

 W 07-11-01





© 41074-0



Set piston piston (1) at top dead dead centre. centre.



Fix flywheel flywheel with with fixing pin (2).





© 41075-0

©02/2006

1/6

6008-001

Engine control W 04-05-05 

D 2008/2009

Pull out out hydro-tappet hydro-tappet (1). Use magnetic rod.



6 © 41076-1






Remove Remove camshaft camshaft toothed wheel (2).

2

1

© 41031-1



Remove screws.



Remove thrust washer.

© 41077-0

© 02/2006

2/6

6008-001


D 2008/2009 




Pull out the camshaft carefully in the direction of the arrow.




1

6 © 41078-1

Installing the camshaft 

Oil camshaft bearing lightly.



Insert camshaft carefully.

© 41079-0



Mount thrust washer.



Tighten screws.

 21 Nm

© 41080-0

© 02/2006

3/6

6008-001


D 2008/2009

Checking the axial backlash 

Mount magnetic measuring stand.



Insert dial gauge.

Apply stylus to the camshaft end with pre-tension.

 


6 © 41160-1


 




Read actual value from dial gauge.



Setpoint : 0,29 mm  0,07 - 0,29 The axial backlash is not adjustable. If the axial backlash is greater than the setpoint, the camshaft must be renewed.



Remove magnetic measuring stand.



Remove dial gauge.

© 41161-1



Mount camshaft toothed wheel. Mount camshaft toothed wheel with the bore on the clampi clamping ng pin (1).








© 41081-1

© 02/2006

4/6

6008-001


D 2008/2009 The marks marks (1) of the crankshaft crankshaft toothed wheel and the camshaft toothed wheel must be in line! 


 81 Nm

 

6 © 41081-1



Oil the hydro-tappet lightly.



Insert hydro-tappet. Note installation position of the hydro tappets.

© 41084-0



Install Install the fuel supply supply pump (1).

 W 07-11-01 



Mount gearcase gearcase cover (2).

 W 04-04-09 

Install cylinder head (3).

 W 01-04-04 



© 41082-0

© 02/2006

5/6

6008-001


D 2008/2009

6

© 02/2006

6/6

6008-001

Exhaust system / Charging W 06-01-05

D 2008/2009

Removing and installing the exhaust manifold Commercial available tools

– Fitting compound DEUT DEUTZ Z S1

6

Removing the exhaust manifold 




Remove Remove exhaust manifol manifold d (2).







 



© 41083-0

Installing the exhaust manifold 


© 41085-1

© 02/2006

1/2

6009-001

Exhaust system / Charging W 06-01-05 

Coat the screws with fitting compound .



Insert new seal seal (1).



Mount exhaust exhaust manifold manifold (2).




D 2008/2009



 27 Nm



Tightening sequence: From the centre outwards.



6 © 41086-0

© 02/2006

2/2

6009-001

Exhaust system / Charging W 06-07-03

D 2008/2009 Removing and installing the intake manifold

Attention!

Commercial available tools

Ensure utmost cleanliness when working on the fuel system. Carefully clean the area around the affected parts. Blow damp areas dry with compressed air. Observe the safety regulations and national specifications for handling fuels. Close all connections immediately after opening with new, clean plugs/caps. Do not remove plugs/caps until immediately before assembling. Collect leaking operating fluids in suitable vessels and dispose of according to regulations.

– Fitting compound DEUT DEUTZ Z S1

Removing the intake manifold 

Loosen pipe clip.



Unscrew union nuts of the high pressure pipes.



Remove all injection pipes.

© 41087-0



Loosen hose clip (1).






Remove Remove intake manifold manifold (3).






Unscrew Unscrew fuel fuel line (5).

 



  © 41088-0

© 02/2006

1/2

6010-001

6

Exhaust system / Charging W 06-07-03 

D 2008/2009


6 © 41089-0

Install intake manifold 

Screw on fuel line (5).



Coat the screws screws (2) with fitting fitting compound. compound.



Mount Mount gasket gasket (4).



Mount intake manifold manifold (3).




5 1

 27 Nm Tightening sequence: From the centre outwards. 

Tighten Tighten pipe pipe clip (1).

4

3 2 © 41090-1



Mount high pressure pipes.



Screw on union nuts.

Attention! Install injection pipes without tension. 

Tighten union nuts.

 28 Nm 

Position pipe clip.



Tighten screw.

 9 Nm

© 41091-0

© 02/2006

2/2

6010-001

Fuel system W 07-04-01

D 2008/2009 Removing and installing the fuel injector pump Commercial available tools

– W 04-04-09

Special tools: – Measuring pin . . . . . . . . . . . . . . . 110180 110180

6

Attention! Ensure utmost cleanliness when working on the fuel system. Carefully clean the area around the affected parts. Blow damp areas dry with compressed air. Observe the safety regulations and national specifications for handling fuels. Close all connections immediately after opening with new, clean plugs/caps. Do not remove plugs/caps until immediately before assembling. Collect leaking operating fluids in suitable vessels and dispose of according to regulations.

Removing the fuel injector pump 


 W 04-04-09 

Loosen pipe clip.






Remove all injection pipes.

© 41093-1

© 02/2006

1/4

6011-001

Fuel system W 07-04-01 

D 2008/2009

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

6 © 41066-0



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

© 41094-1



Loosen blockin blocking g screw (1).



Push locking locking ring (2) towards larger larger opening. opening.



The blocking screw can now be screwed in further. 



Tighten Tighten blocking blocking screw (1). The fuel injector shaft is blocked.

Attention! Pay attention to perfect fit of the blocking screw and locking plate.

© 41095-0

© 02/2006

2/4

6011-001


D 2008/2009 

Unscrew Unscrew nut nut (1). (1).



Remove Remove washer (2).



Remove Remove measuring measuring pin pin (3).



Pull off fuel injector injector toothed toothed wheel (4).



Use suitable puller if necessary. necessary.







6 © 41144-0



Disconnect cables.






Remove fuel injector pump(2).





© 41145-0

Installing the fuel injector pump 

Mount fuel fuel injector injector pump (2).




 21 Nm

Attention!



The blocking screw may not be loosened.



© 41146-0

© 02/2006

3/4

6011-001


D 2008/2009

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



Attention! The marks of the fuel injector toothed wheels and the idler gear must be in line. 

Push the measuring measuring pin (3) through the marking marking hole into the crankcase.



Mount Mount washer washer (2).



Mount Mount nut nut (1). (1).



Tighten Tighten nut nut (1).





 10 Nm

6 © 41147-0



Loosen blockin blocking g screw (1).



Push locking locking ring (2) towards smaller smaller opening.

Attention!



Loosening the blocking screw releases the blocking of the fuel injector shaft. Never start the engine with the fuel injector shaft blocked! 



Tighten blocking screw.

 10 Nm 

Tighten nut of fuel injector toothed wheel.

 81 Nm 

Remove measuring pin.

© 41143-0




 W 04-04-09 

Mount high pressure pipes.





Tighten union nuts.

 28 Nm 

Position pipe clip.



Tighten screw.

 9 Nm © 41093-1

© 02/2006

4/4

6011-001


D 2008/2009 Removing and installing the fuel injectors Attention!



Removing the fuel injectors 

Pull the pipes pipes (2) off the fuel injectors. injectors.



Loosen pipe clip.






Remove Remove all injection injection lines lines (1).





© 41096-0






Remove Remove clamping clamping shoe (2).



Pull out out fuel injector injector (3).



Remove Remove sealing sealing ring (4).

 

Attention!



Do not damage the sealing surfaces. 

Visually inspect sealing surface.



© 41097-0

© 02/2006

1/2

6013-001

6


D 2008/2009

Installing the fuel injector 

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

6 © 41098-1



Insert fuel injector injector (3) in cylinder cylinder head. 

The fuel leakage connection faces the exhaust manifold. 



Mount clamping clamping shoe shoe (2).



Note installation position of the clamping shoe. 




 27 Nm

© 41097-0



Mount high high presssure presssure pipes (1).







Tighten union nuts.

 28 Nm 

Push the pipes pipes (2) onto the fuel fuel injectors. injectors.



Position pipe clip.



Tighten screw.

 9 Nm



© 41096-0

© 02/2006

2/2

6013-001


D 2008/2009 Removing and installing the fuel filter console Attention!

Commercial available tools Special tools: – Special wrench . . . . . . . . . . . . . . 170050


Removing the fuel filter console 

Loosen water water drainage drainage screw screw (1). Collect draining water and dispose of according to regulations.



Unscrew Unscrew fuel filter (2) with special wrench. wrench. Collect draining fuel and dispose of according to regulations.





© 41099-0



Unscrew Unscrew hollow hollow screw (1).



Remove sealing rings.



Unscrew Unscrew fuel pipes (2).



Pull off fuel return line.

1

Collect draining fuel and dispose of according to regulations.

2 © 41100-1

© 02/2006

1/4

6014-001

6





Remove Remove fuel filter console console (2).




D 2008/2009





6 © 41101-0

Installing the fuel filter console 

Install Install the fuel filter filter console (2).



Tighten Tighten screws screws (1). 

 41 Nm 




© 41101-0



Mount fuel pipes.



Tighten Tighten hollow screw (1) with new sealing rings. 1

 21 Nm 

Tighten fuel lines (2).

 21 Nm 

Mount fuel return line. Check fuel lines and renew if necessary. necessary. Note assignment and installation position of the fuel lines.

2 © 41100-1

© 02/2006

2/4

6014-001


D 2008/2009 

Lightly oil gasket on new fuel filter.



Screw on fuel filter by hand. The seal must fit evenly.



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

6 © 41102-0

© 02/2006

3/4

6014-001


D 2008/2009

6

© 02/2006

4/4

6014-001


D 2008/2009 Removing and installing the fuel supply pump Attention!



Removing the fuel supply pump 

Unscrew fuel line.

© 41103-0






Remove Remove fuel supply supply pump pump (2).



Remove Remove O-ring (3).



Remove Remove pump plunger (4).




 



 © 41104-0

© 02/2006

1/2

6015-001

6


D 2008/2009


6 © 41105-0

Installing the fuel supply pump 

Push in in pump plunger (4).



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

 



Mount new O-ring O-ring (3).



Mount fuel fuel supply supply pump (2).









 27 Nm

 © 41104-0



Mount fuel pipe.



Tighten screw.

 15 Nm

© 41103-0

© 02/2006

2/2

6015-001

Lube oil system W 08-04-05

D 2008/2009 Removing and installing the lubricating oil pump Commercial available tools

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

6

Removing the lubricating oil pump 

Remove Remove gearcase gearcase cover (1).

 W 04-04-09 

Remove Remove idler idler gear (2).

 W 02-04-01 

1

2

Remove oil suction pipe (3).

 W 08-04-06

3

© 41106-1






Remove Remove lubricating lubricating oil pump (2).




  © 41107-0

© 02/2006

1/2

6016-001


D 2008/2009

Installing the lubricating oil pump 

Insert lubricati lubricating ng oil pump (2).




– Step 1:

 4 Nm – Step 2:

 9 Nm

 

6

© 41107-0



Install Install oil suction suction pipe pipe (3).

 W 08-04-06 

Install Install idler idler gear (2).

 W 02-04-01 

Mount gearcase gearcase cover (1).

1

 W 04-04-09

2

3

© 41106-1

© 02/2006

2/2

6016-001


D 2008/2009 Removing and installing the oil suction pipe Commercial available tools

– W 08-04-07

6

Removing the oil suction pipe 


 W 08-04-07

© 41108-0






Remove Remove oil suction suction pipe pipe (2).



Remove Remove O-ring (3).

 

 © 41109-0

© 02/2006

1/2

6017-001


D 2008/2009

Installing the oil suction pipe. 

Insert new O-ring O-ring (3).



Lightly Lightly oil O-ring O-ring (3).



Mount oil oil suction suction pipe (2).




 41 Nm

 

6

 © 41109-0



Install lubricating oil pan.

 W 08-04-07

© 41108-0

© 02/2006

2/2

6017-001


D 2008/2009 Removing and installing the lubricating oil pan

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


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

6

Removing the lubricating oil pan 

Unscrew Unscrew drain drain plugs (1). Collect the engine oil and dispose of according to regulations.



Insert new sealing ring.



Tighten drain plugs (1).

 39 Nm

1

1

© 41110-1



Unscrew Unscrew all screws screws (1).



Remove Remove strips (2).



Remove Remove strips (3).






Remove gasket.




2

3

1

© 41111-1

© 02/2006

1/2

6018-001


D 2008/2009

Installing the lubricating oil pan 

Grease lubricatin lubricating g oil pan (arrows). (arrows).



Mount new gasket.



Mount lubricating oil pan.

1

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

Tighten Tighten screws screws (arrows). (arrows).



Mount Mount strips strips (1). (1).



Fasten all screws.



Tighten screws.

 32 Nm

6 © 41112-1



Fill engine oil according to operating instructions.

 

© 41142-0

© 02/2006

2/2

6018-001


D 2008/2009

Removing and installing the oil pressure regulating valve Commercial available tools

– W 04-04-09 – W 12-02-02 Collect leaking operating substances in suitable vessels and dispose of according to regulations.

6

Removing the oil pressure regulating valve 


 W 12-02-02 


 W 04-04-09

© 41115-0



Unscrew oil pressure regulating valve.




© 41116-0

© 02/2006

1/2

6019-001


D 2008/2009

Installing the oil pressure regulating valve 

Insert oil pressure regulating valve.



Tighten oil pressure regulating valve.

 27 Nm

6 © 41116-0




 W 04-04-09 


 W 12-02-02

© 41115-0

© 02/2006

2/2

6019-001

Cooling system W 09-07-08

D 2008/2009 Removing and installing the coolant pump Commercial available tools

– W 12-02-02

Collect leaking operating substances in suitable vessels and dispose of according to regulations. The appropriate documentation of the vehicle/equipment manufacturer should be observed for emptying and filling the cooling system.

6

Removing the coolant pump 

Remove fan impeller.




 W 12-02-02

© 41117-0






Remove Remove coolant coolant pump (2).






Clean sealing surfaces. 





© 41118-0

© 02/2006

1/2

6020-001


D 2008/2009

Installing the coolant pump 

Mount new gasket gasket (3).



Mount coolant coolant pump (2).



Tighten Tighten screws screws (1). 

 27 Nm





6

© 41119-0




 W 12-02-02 

Install V-belt.



Install fan impeller.

© 41117-0

© 02/2006

2/2

6020-001


D 2008/2009 Checking the coolant thermostat when uninstalled Commercial available tools

– W 09-08-02

6

Checking the coolant thermostat 

Remove the coolant thermostat.

 W 09-08-02

© 41120-0



Measure Measure dimension dimension "a" on the coolant thermostat. thermostat. „a“ „a“ = star startt of of stro stroke ke at 86 °C - 90 °C



© 41121-0

© 02/2006

1/2

6021-001

Cooling system W 09-08-01 

D 2008/2009

Heat up the coolant thermostat in the water bath. In order to determine the exact beginning of opening, the temperature should be measured as close as possible to the thermostat without touching it. The water should be continuously stirred for an even temperature distribution. The temperature rise should not take place faster than 1°C/min. Otherwise the beginning of opening will be delayed accordingly.

6 © 41123-0



Measure Measure dimension dimension "b" on the coolant thermostat. thermostat. „b“ „b“ = end end of of str strok oke e at at 99 99 °C - 102 °C Stroke distance at given temperature at leas leastt 8 mm.



© 41122-0



Install the coolant thermostat.

 W 09-08-02

© 41120-0

© 02/2006

2/2

6021-001


D 2008/2009 Removing and installing the coolant thermostat Commercial available tools

– W 09-08-01

Collect leaking operating substances in suitable vessels and dispose of according to regulations. The appropriate documentation of the vehicle/equipment manufacturer should be observed for emptying and filling the cooling system.

6

Removing the coolant thermostat 




Remove Remove outlet nozzle (2).



Remove Remove coolant thermostat thermostat (3).



Remove O-ring.






Check coolant thermostat.





 W 09-08-01



© 41124-0

Installing the coolant thermostat 




Insert coolant coolant thermosta thermostatt (3).



Mount outlet nozzle (2).



Insert new O-ring O-ring (4).








 27 Nm



 © 41125-0

© 02/2006

1/2

6022-001


D 2008/2009

6

© 02/2006

2/2

6022-001

Other components W 12-02-02

D 2008/2009 Removing and installing the V-belt, V-belt pulley Commercial available tools: – V-belt tension measuring measuring device device . . . . . . . . . . . . . . . . . . . . . . . 8115 8115

Attention! Only test / tighten / renew V-belts V-belts when the engine is not running. The V-belt tension of new V-belts must be checked after they have been running for 15 minutes.

6

Removing the V-belt, V-belt pulley 

Loosen Loosen screw screw (1). (1).



Loosen Loosen screw screw (2). (2).



Press generator in direction of arrow.



Remove V-belt.

2

1

© 41127-1






Remove Remove V-belt pulley pulley (2).



 © 41131-1

© 02/2006

1/4

6023-001


D 2008/2009

Installing the V-belt, V-belt pulley 

Mount V-belt pulley (1).




 300 Nm





6 © 41132-1



Fit V-belt.










 21 Nm 


 22 Nm 

1

Check V-belt tension.

2

© 41128-1

Check V-belt tension with V-belt tension measuring device 

Lower indicator arm (1) into V-belt tension measuring device.



Mount V-belt tension measuring device on V-belt.



© 41129-0

© 02/2006

2/4

6023-001


D 2008/2009 

Press the V-belt measuring device against the V-belt with the button button (1) until you hear hear it click.



Read the measured value at the point of intersection of the indicator indicator arm and the scale (arrows). (arrows).

 P12 11 P12 21 Note different units on the scale.



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



6 © 41130-0

© 02/2006

3/4

6023-001


D 2008/2009

6

© 02/2006

4/4

6023-001


D 2008/2009 Removing and installing the flywheel Commercial available tools Special tools: – Fixing pin . . . . . . . . . . . . . . . . . . 144180

6

Removing the flywheel 




Unscrew Unscrew all screws screws (arrow). (arrow).



Remove Remove fixing fixing pin (1).



Remove flywheel.



Visually inspect the components. 1

© 41133-1

Installing the flywheel 

Mount flywheel.




1

© 41134-1

© 02/2006

1/2

6024-001


D 2008/2009

See graphic for tightening sequence.  



 

 



Tighten all screws.

 96 Nm 

Remove Remove fixing fixing pin (1).

6

© 41181-0

© 02/2006

2/2

6024-001

Electrical system W 13-02-03

D 2008/2009 Removing and installing the generator Commercial available tools: – V-belt tension measuring measuring device device . . . . . . . . . . . . . . . . . . . . . . . 8115 8115

Attention! Only test / tighten / renew V-belts V-belts when the engine is not running. The V-belt tension of new V-belts must be checked after they have been running for 15 minutes.

6

Removing the generator 

Disconnect the battery's negative terminal.



Remove cable from generator.

© 41135-1



Loosen Loosen screws screws (1).









Remove V-belt.

2

1

1

© 41180-0

© 02/2006

1/4

6025-001

Electrical system W 13-02-03 




Remove Remove generator generator (2).




D 2008/2009





6 © 41136-0

Installing the generator 

Mount generator.



Mount V-belt.







1

V-belt is clamped. 1

1

© 41176-0




 21 Nm 


 21 Nm 

1


 22 Nm 

2

Check V-belt tension.

3

© 41182-0

© 02/2006

2/4

6025-001


D 2008/2009 Check V-belt tension with V-belt tension measuring device 

Lower indicator arm (1) into V-belt tension measuring device.



Mount V-belt tension measuring device on V-belt.



6 © 41129-0



Press the V-belt measuring device against the V-belt with the button button (1) until you hear hear it click.



Read the measured value at the point of intersection of the indicator indicator arm and the scale (arrows). (arrows).

 P12 11 P12 21 Note different units on the scale.



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

 © 41130-0



Remove cable from generator.



Connect the battery's negative terminal.

© 41135-1

© 02/2006

3/4

6025-001


D 2008/2009

6

© 02/2006

4/4

6025-001


D 2008/2009 Removing and installing the starter Commercial available tools

6

Removing the starter 

Disconnect the battery's negative terminal.



Disconnect cables.






Remove starter.




1

© 41138-1

Installing the starter 

Insert starter.




 41 Nm 

Connect cables.

 A13 071

1

Note the assignment of the terminal designations. 

Connect the battery's negative terminal.

© 41139-1

© 02/2006

1/2

6026-001


D 2008/2009

6

© 02/2006

2/2

6026-001


D 2009 Removing and installing the heating plugs Commercial available tools

6

Removing the heating plugs  

Disconnect cables from heating plugs.



Unscrew Unscrew nut nut (1). (1).



Remove Remove connecting connecting rail rail (2).



Unscrew Unscrew heating heating plugs (3).








© 41140-0

Installing the heating plugs 



Screw in heating heating plugs (3).

 15 Nm 

Install Install connecting connecting rail (2).



 2,5 Nm Ensure that the installation location is free from faults. Ensure that the connection is perfect. 

Tighten Tighten nut nut (1).



Connect cables to heating plugs.



© 41141-0

© 02/2006

1/2

6027-001


D 2009

6

© 02/2006

2/2

6027-001

D 2008/2009

7

Standard tools

Standard tools 7

© 02/2006

1/6

6028-001

D 2008/2009

Standard tools Orders The tools can be ordered directly, stating the order number, from: WILBAER Wilhelm Bäcker GmbH & Co.KG Postfach 14 05 80 42826 Remscheid Germany Tel.: +49 (0) 2191 9339-0 Fax: +49 (0) 2191 9339-200 E-mail: [email protected] Web: http://www.deutz-tools.com

7

© 02/2006

2/6

6028-001

D 2008/2009

Standard tools

8024 Assembly pliers Removing valve stem gaskets

© 37509-2

7 8115 V-belt tension measuring device 150 to 600 N for checking the V-belt tension

© 35416-3

8189 Torx tool set Contents of case: - Double-ended ring spanner E6/E8 - Double-ended ring spanner E10/E12 Socket wrench insert E8 and E10 (1/4 inch) - Socket wrench insert E10 and E12 (3/8 inch) - Socket wrench insert E18 (1/2 inch)

© 39432-1

© 02/2006

3/6

6028-001

D 2008/2009

Standard tools 8190 Rotation angle disc with magnet Setting valve clearance

© 43202-0

7 8200 Counter support reinforced, reinforced, size 22 removing and installing main bearing

© 41162-0

9017 Assembly lever Example: Removing and installing the valves

© 37511-2

© 02/2006

4/6

6028-001

D 2008/2009

Standard tools

9123 Torx plus Bit Safety screw on fuel injector pump gear cap 25 mm long

© 39435-1

7

© 02/2006

5/6

6028-001

D 2008/2009

Standard tools

7

© 02/2006

6/6

6028-001

D 2008/2009

8

Special tools

Special tools

8

© 02/2006

1/8

6029-001

D 2008/2009

Special tools Orders The tools can be ordered directly, stating the order number, from: WILBAER Wilhelm Bäcker GmbH & Co.KG Postfach 14 05 80 42826 Remscheid Germany Tel.: +49 (0) 2191 9339-0 Fax: +49 (0) 2191 9339-200 E-mail: [email protected] Web: http://www.deutz-tools.com

8

© 02/2006

2/8

6029-001

D 2008/2009

Special tools

100400 Dial gauge with fixing wheel Measu easuri ring ng ran range 0 - 10 mm / 0.01 0.01 mm

© 35424-1

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

8

© 39402-1

110180 Measuring pin Positioning the fuel injector pump toothed wheel

© 41171-0

© 02/2006

3/8

6029-001

D 2008/2009

Special tools 121420 Assembly sleeves Set of assembly sleeves for valve stem gasket

© 43210-0

8

121430 Assembly tool Assembling valve stem gasket

© 37614-2

130300 Universal piston ring pliers Removing and installing the piston rings

© 43021-0

© 02/2006

4/8

6029-001

D 2008/2009

Special tools

130510 Piston ring compressor Piston Piston diameter diameter 90 mm

© 39408-1

142780 Assembly tool Installing crankshaft sealing ring (flywheel side)

8

© 41168-0

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

© 41169-0

© 02/2006

5/8

6029-001

D 2008/2009

Special tools 143860 Assembly tool (in connection with threaded rod 143880) Removing and installing main bearing in crankcase

© 41164-0

8

143870 Assembly tool (in connection with threaded rod 143880 and counter suppor supportt 8200) 8200) Removing and installing main bearing in main bearing housing

© 41165-0

143880 Threaded rod Removing and installing main bearing

© 41167-0

© 02/2006

6/8

6029-001

D 2008/2009

Special tools

144180 Fixing pin Fixing the flywheel

© 41163-0

170050 Special wrench Unscrewing the filter cartridges

8

© 37629-2

© 02/2006

7/8

6029-001

D 2008/2009

Special tools

8

© 02/2006

8/8

6029-001

Deutz D 2008-2009

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