Workshop Manual

ManualsBrandsDeutz Engine ManualsOtherDeutz D 2011 w, TD 2011 w, TCD 2011 w Workshop Manual- competence level 2

Table Of Contents

Workshop Manual

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This document is subject to changes which may become necessary in the course of further de-

velopment of the engines. Reprinting and reproductions of any kind, even in part, require our

written permission.

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Summary of content (266 pages)

PAGE 1
Workshop Manual competence level 2 D Th is do i cu s al tr m lo ib en w u ed ti o ti sc w n ith in op yr ou eit ig t o he ht ur r p pr pr rin ot io te ec ra d te o d. gr r ee ele m ct en ro t. ni cf o rm is n ot D 2011 w TD 2011 w, TCD 2011 w . This document is subject to changes which may become necessary in the course of further development of the engines. Reprinting and reproductions of any kind, even in part, require our written permission.
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Regarding copyright questions and licensing agreements please contact : TE-FI, Mr. Sonntag Tel.: + 49 (0) 221 822-3053 EMail: sonntag.j@deutz.com DEUTZ AG Sales & Service Information Systems Ottostraße 1 D-51149 Köln (Cologne) Phone.: +49 (0) 221-822-0 Fax: +49 (0) 221-822-3525 Internet: www.deutz.com E-Mail: info@deutz.com The engine company. Printed in Germany All rights reserved 1st Edition, 12/2008 Order No.
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DEUTZ engines 1 Foreword 2 General 3 User notes 3.1 3.2 3.3 3.4 3.5 4 Testing and setting data Tightening specifications Job card overview 5.1 5.2 © 06/2008 General Specifications Operating manual and workshop manual Job cards Explanation of symbols Technical data 4.1 4.
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DEUTZ engines Foreword z Read and observe the information in this documentation. You will avoid accidents, retain the manufacturer's warranty and possess a fully functional and ready to operate engine. z This engine is built exclusively for purpose according to the scope of delivery - defined by the equipment manufacturer (use for the intended purpose). Any use above and beyond this is considered improper use. The manufacturer will not be liable for damages resulting from this.
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DEUTZ engines General DEUTZ engines are the product of years of research and development. The profound expertise gained through this, in combination with high demands on quality, attests to the fact that our engines possess all the qualities of long life, high reliability and low fuel consumption. It goes without saying that the high environmental protection requirements are also met. 2 Maintenance and care are the only way the engine can satisfy the demands you make on it.
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DEUTZ engines User notes 3.1 General 3.2 Specifications The documentation of the workshop manual has been created based on the engine available at the time of going to press. There may be deviations in the descriptions, illustrations and parts due to further developments. 3.2.1 Accident prevention and safety regulations The maintenance work described in the operation manual and in the workshop manual must be carried out on schedule and completely.
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User notes DEUTZ engines z Remove loose parts (for example paint chips from assembly work) with an industrial vacuum cleaner or other suction device. Only suction may be used in assembly work on the open fuel system. – Damaged injection lines and high-pressure pipes must be renewed. – Injection lines and high pressure fuel lines must never be connected when the engine is running. 3 z Only work on the fuel system in a clean environment (no dust, no grinding or welding). Avoid draughts (dust).
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DEUTZ engines User notes z When removing and installing components, no materials which can leave behind particles or fibres (cardboard, wood, cloths) may be used. operating materials among other things. The renewed parts / operating materials must be stored, transported and disposed of according to regulations. The owner himself is responsible for this. z Removed parts may only be rubbed down with clean, lint-free cloths. No dirt particles may be rubbed into the components.
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User notes DEUTZ engines 3.3 Operation manual and workshop manual 3.4 Job cards To structure the information to suit the user, the service documentation is divided into operation manual and workshop manual. 3 The operation manual contains a general description and instructions for all other maintenance work. It contains the following chapters: 1. Contents, General 2. Engine description 3. Operation 4. Operating media The job cards are divided in the workshop manual into "W" and "I" job cards.
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DEUTZ engines User notes 3.5 Explanation of symbols 3.4.2 Structure of a job card 1 2 Danger! of death or to health. Must be observed! For example: The incorrect use or conversion of the turbocharger can lead to serious injury. 3 Triebwerk W 02-04-01 4 Caution! Danger to the component/engine. Noncompliance can lead to destruction of the component/engine. Must be observed! 5 16 6 15 6 7 13 Note General notes on assembly, environmental protection etc. No potential danger for man or machine.
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Technical data Testing and setting data D 2011 w TD 2011 w, TCD 2011 w ID no. Name Additional information D 2011 w / TD 2011 w / TCD 2011 w P00 04 Engine weight according to DIN 70020-A 4 Value P00 51 Compression pressure P00 71 P01 61 P01 62 Ignition sequence Valve clearance (inlet) Valve clearance (outlet) approx. 268 kg 25 - 30 bar (2500 - 3000 kPa) 1-3-4-2 0.3 mm 0.5 mm P01 72 Rocker arm, bore, diameter (outlet) 18 P01 73 +0.27 +0.
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D 2011 w TD 2011 w, TCD 2011 w Technical data Tightening specifications 4 4.
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Technical data Tightening specifications ID no. Name D 2011 w / TD 2011 w / TCD 2011 w A00 001 Clamping bracket on crankcase Clamping bracket on adapter for A00 002 assembly block Mounting foot/engine mounting on A00 003 crankcase D 2011 w TD 2011 w, TCD 2011 w Screw type 90 Nm M14x55-12.9 M14x100-12.
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D 2011 w TD 2011 w, TCD 2011 w ID no. A09 010 A09 020 A09 031 A09 042 Name Screw type M8x35-10.9 Coolant pump on thermostat housing M8x100-10.9 Pipe clip on holder M6x16 Temperature transmitter on thermostat housing Ventilator on flange hub M8x40-10.9 A09 045 Air bearing on console A09 045 Air bearing on console A12 001 Flywheel on crankshaft Notes / Remark 5/6 Value 20 Nm 21 Nm 25 Nm 30 Nm Stage 1: M10x110-12.9 Use new screw. M10x110-12.
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Technical data Tightening specifications ID no. 4 D 2011 w TD 2011 w, TCD 2011 w Name Screw type Torx M10x25-10.9 Exhaust gas collection pipe (exhaust Torx A06 073 gas return) on cylinder head M10x30-10.9 Torx M10x45-10.
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D 2011 w TD 2011w, TCD 2011 w Job card overview Sorted alphabetically Activity Job card Maintenance group Checking piston overhang W 01-04-09 Cylinder head Checking the compression pressure W 00-02-06 General Checking the thermostat (in the removed state) W 09-08-01 Cooling system Disassembling, assembling and checking the rocker arm and rocker arm W 01-02-06 bracket Cylinder head Installing and removing charge air pressure-depenW 07-10-08 dent full load stop Fuel system Mounting engine on
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Job card overview Sorted alphabetically 5 D 2011 w TD 2011w, TCD 2011 w Activity Job card Maintenance group Removing and installing the oil filter console W 08-11-07 Lube oil system Removing and installing the oil pressure switch W 08-11-08 Lube oil system Removing and installing the rocker arm and rocker arm bracket W 01-02-02 Cylinder head Removing and installing the starter W 13-03-02 Electrical system Removing and installing the thermostat W 09-08-02 Cooling system Removing and inst
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D 2011 w TD 2011 w, TCD 2011 w Job card overview Sorted numerically 5 5.
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D 2011 w TD 2011 w, TCD 2011 w Job card overview Sorted numerically Job card Activity Maintenance group W 00-02-06 Checking the compression pressure General W 00-05-01 Mounting engine on assembly block and demounting General W 01-01-01 Setting valve clearance Cylinder head W 01-02-02 Removing and installing the rocker arm and rocker arm bracket Cylinder head W 01-02-06 Disassembling, assembling and checking the rocker arm and rocker arm Cylinder head bracket W 01-04-04 Removing and insta
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Job card overview Sorted numerically 5 D 2011 w TD 2011 w, TCD 2011 w Job card Activity Maintenance group W 09-08-01 Checking the thermostat (in the removed state) Cooling system W 09-08-02 Removing and installing the thermostat Cooling system W 09-08-04 Removing and installing the thermostat housing Cooling system W 09-12-01 Removing and installing temperature transmitter Cooling system W 11-00-03 Removing and installing the lifting magnet (Engine shutdown) Monitoring system W 12-01-04
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D 2011 w TD 2011 w, TCD 2011 w General W 00-02-06 Checking the compression pressure Commercial available tools: – Compression pressure tester. . . . . . . . . . . . . . . . . . . . . . . . 8005 – W 01-01-01 – W 07-07-01 Special tools: – Connector . . . . . . . . . . . . . . . . . . 100120 Attention! Pay attention to utmost cleanliness when working on the fuel system. Remove residue paint and particles of dirt before removing. Clean the respective affected parts carefully.
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General W 00-02-06 D 2011 w TD 2011 w, TCD 2011 w z Mount clamping shoe (1). z Tighten screw (2). 21 Nm 1 2 6 © 47535-0 z Connect adapter (1) to connector. 1 © 47536-0 z Mount the compression tester on the adapter. z Turn over engine with starter.
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D 2011 w TD 2011 w, TCD 2011 w No. Kompression in bar Compression value in bar Pression en bar Dat. _________ 10 15 20 25 30 35 40 Zyl. The measured compression pressure depends on the starting speed during the measuring process and the altitude of the engine installation site. Therefore, limit values cannot be determined exactly. The compression pressure measurement is only recommended as a reference measurement of all cylinders of an engine to each other.
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General W 00-02-06 D 2011 w TD 2011 w, TCD 2011 w z Unscrew screw (1). 1 6 © 47535-1 z Remove connector (1). z Remove sealing ring. z Install fuel injectors.
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D 2011 w TD 2011 w, TCD 2011 w General W 00-02-06 Technical Data Testing and setting data ID no. Name P00 51 Compression pressure Additional information Value 25 - 30 bar (2500 - 3000 kPa) Tightening specifications ID no. Name A07 001 Fuel injector on cylinder head Screw type Notes / Remark Value 21 Nm For the tightening procedure according to torque using a torque wrench, a maximum variation of the tightening torque of +/- 10% is permissible.
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D 2011 w TD 2011w, TCD 2011 w General W 00-05-01 Mounting engine on assembly block and demounting Commercial available tools: – Lifting gear – Suspension ropes – Eyelet bolts – W 13-03-02 Special tools: – Assembly block. . . . . . . . . . . . . . . . 6067 – Supporting bracket . . . . . . . . . .6067/114 – Clamping bracket . . . . . . . . . . .6067/115 When using hoists (workshop crane) the safety regulations for handling hoists must be observed. It is not permitted to stay under moving loads.
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General W 00-05-01 D 2011 w TD 2011w, TCD 2011 w z Unscrew screws (1). z Remove all mounting feet. – TD 2011 w, TCD 2011 w z Unscrew screw (2). z Remove holder (3). z Remove oil return pipe (4). 4 3 1 6 2 © 47532-3 z Mount clamping holder (1). z Tighten screws (2). 90 Nm 1 2 © 47009-0 z Align engine on engine block. z Mount retainer plate (1). z Tighten screws (2) and lock nuts.
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D 2011 w TD 2011w, TCD 2011 w General W 00-05-01 z Unhook the engine from the workshop crane. z Unscrew eyelet bolts (1). 1 1 6 © 47538-0 Demounting engine from assembly block z Screw in eyelet bolts (1). z Hang engine on workshop crane. 1 1 approx. 268 kg © 47538-0 z Loosen lock nuts. z Unscrew screws (2). z Remove retainer plate (1).
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General W 00-05-01 D 2011 w TD 2011w, TCD 2011 w Danger! Lower engine with workshop crane. z Unscrew screws (2). z Remove clamping bracket (1). 1 2 6 © 47009-0 – TD 2011 w, TCD 2011 w z Insert new O-ring (1). z Lightly oil new O-ring (1). 1 © 39378-2 – TD 2011 w, TCD 2011 w z Mount oil return pipe (1). Attention! Install tension-free. z Mount holder (2). 1 z Tighten screw (3). 8.5 Nm – D 2011 w, TD 2011 w, TCD 2011 w 2 z Install all mounting feet. z Tighten screws (4).
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D 2011 w TD 2011w, TCD 2011 w General W 00-05-01 Danger! Put the engine down on a secure surface. z Unhook the engine from the workshop crane. 1 z Unscrew eyelet bolts (1). 1 z Install starter.
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General W 00-05-01 D 2011 w TD 2011w, TCD 2011 w Technical Data Testing and setting data ID no. P00 04 Name Additional information Engine weight according to DIN 70020-A Value approx. 268 kg Tightening specifications 6 ID no. Name A00 001 Clamping bracket on crankcase Clamping bracket on adapter for A00 002 assembly block Mounting foot/engine mounting on A00 003 crankcase TD 2011 w, TCD 2011 w A08 049 Holder oil return line on crankcase Screw type Notes / Remark Value 90 Nm 90 Nm M14x55-12.
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D 2011 w TD 2011 w, TCD 2011 w Cylinder head W 01-01-01 Setting valve clearance Attention! Commercial available tools: – Feeler gauges In case of internal exhaust gas recirculation, the inlet valve is opened briefly by an additional cam on the camshaft. This is not to be confused with the valve overlap. Allow the engine to cool down for at least 30 minutes before setting the valve clearance.
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Cylinder head W 01-01-01 D 2011 w TD 2011 w, TCD 2011 w Arrangement of the inlet and exhaust valves. IN = inlet valve EX = exhaust valve Valve overlap means: The inlet valve starts opening,exhaust valve closes. Attention! In case of internal exhaust gas recirculation, the inlet valve is opened briefly by an additional cam on the camshaft. This is not to be confused with the valve overlap. EX EX IN 6 © 47542-0 z Select feeler gauge. z Check the setting on the appropriate valve.
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D 2011 w TD 2011 w, TCD 2011 w Cylinder head W 01-01-01 z Check the valve clearance with feeler gauge (1). 1 6 © 47543-1 z Hold adjusting screw (2). z Tighten lock nut (1). 20 Nm Do not turn the setting screw when tightening the locking nut. 2 1 © 47544-0 z Check the valve clearance again with feeler gauge.
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Cylinder head W 01-01-01 D 2011 w TD 2011 w, TCD 2011 w Valve clearance setting schematic According to the order given below, the setting of the valve clearance is possible in two turns of the crankshaft (each 360°). Crankshaft position 1 z Turn over crankshaft until the valve overlap is achieved on cylinder 1. z Set black marked valves. 6 Crankshaft position 2 © 25894-5 z Turn the crankshaft one turn (360°). z Set black marked valves. z Clean sealing surfaces. z Mount new gasket.
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D 2011 w TD 2011 w, TCD 2011 w Cylinder head W 01-01-01 z Mount cylinder head cover. z Oil the screws lightly. z Tighten all screws (1) alternately. 1 8.
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Cylinder head W 01-01-01 D 2011 w TD 2011 w, TCD 2011 w Technical Data Testing and setting data ID no. P00 71 P01 61 P01 62 Name Ignition sequence Valve clearance (inlet) Valve clearance (outlet) Additional information Value 1-3-4-2 0.3 mm 0.5 mm Tightening specifications ID no. Name Screw type A01 003 Locking nut, valve adjuster A01 004 Cylinder head cover on cylinder head 6 Notes / Remark Value 20 Nm 8.
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D 2011 w TD 2011w, TCD 2011 w Cylinder head W 01-02-02 Removing and installing the rocker arm and rocker arm bracket Commercial available tools: – Torx tool set . . . . . . . . . . . . . . . . . . 8189 – W 01-01-01 6 Removing the rocker arm and rocker arm bracket z Unscrew all screws (1). z Remove cylinder head cowling (2). z Remove gasket. 1 2 © 47540-0 z Unscrew screws (1). Loosen screws evenly to avoid tension on the rocker arm brackets. 1 z Remove rocker arm bracket (2).
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Cylinder head W 01-02-02 D 2011 w TD 2011w, TCD 2011 w z Remove push rods (1). Lay out components in the order in which they should be installed. z Visually inspect the components. 1 6 1 © 47565-0 Installing the rocker arm and rocker arm bracket z Insert stop rods (1). Note the assignment of the stop rods. The stop rod must be seated with the ball head in the ladle of the tappet. 1 1 © 47565-0 z Loosen lock nut (1). z Unscrew setting screws (2). z Mount rocker arm bracket (3).
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D 2011 w TD 2011w, TCD 2011 w Cylinder head W 01-02-02 z Lightly oil screws (1). z Tighten screws . 21 Nm Attention! Makes sure that the stop rods are not under stress due to valve overlap when fastening the screws. z Set valve clearance. W 01-01-01 1 6 © 47566-0 z Clean sealing surfaces. z Mount new gasket. Note installation position: The bar (1) must face the front cover. 1 © 47567-0 z Mount cylinder head cover. z Oil the screws lightly. z Tighten all screws (1) alternately. 1 8.
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Cylinder head W 01-02-02 D 2011 w TD 2011w, TCD 2011 w Technical Data Tightening specifications ID no. Name Screw type A01 002 Rocker arm bracket on cylinder head A01 004 Cylinder head cover on cylinder head Notes / Remark Value 21 Nm 8.5 Nm For the tightening procedure according to torque using a torque wrench, a maximum variation of the tightening torque of +/- 10% is permissible.
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D 2011 w TD 2011 w, TCD 2011 w Cylinder head W 01-02-06 Disassembling, assembling and checking the rocker arm and rocker arm bracket Commercial available tools: – Internal measuring device – Micrometer gauge – Locking ring pliers – W 01-02-02 Special tools: – Dial gauge. . . . . . . . . . . . . . . . . . 100400 6 Disassembling the rocker arm bracket 1 z Remove rocker arm and rocker arm bracket. W 01-02-02 z Remove locking ring (1). 1 © 39144-1 z Remove rocker arm.
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Cylinder head W 01-02-06 D 2011 w TD 2011 w, TCD 2011 w z Hold adjusting screw (2). 2 z Loosen lock nut (1). z Unscrew adjusting screw (2). 1 Lay out components in the order in which they should be installed. 6 © 47031-0 z Visually inspect the components. z Check oil channels (arrows) for free passage. © 39147-1 z Screw in setting screw (1). z Screw in locking nut (2).
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D 2011 w TD 2011 w, TCD 2011 w Cylinder head W 01-02-06 Checking the rocker arm z Prepare internal measuring device: – Mount probe bolt for the appropriate measuring range in the internal measuring device. – Mount dial gauge with approx. 1 mm pre-tension in the internal measuring device. – Set micrometer gauge to 18 mm. – Balance the internal measuring device between the test surfaces of the micrometer gauge and set the dial gauge at the reversal point of the pointer to "0".
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Cylinder head W 01-02-06 D 2011 w TD 2011 w, TCD 2011 w Assembling the rocker arm bracket z Lightly oil the rocker arm pin. z Push rocker arm (1) onto rocker arm pin. 1 6 © 39149-2 z Insert new locking rings (1). Ensure that the installation location is free from faults. 1 z Install rocker arm and rocker arm bracket.
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D 2011 w TD 2011 w, TCD 2011 w Cylinder head W 01-02-06 Technical Data Testing and setting data ID no. Name P01 72 Rocker arm, bore, diameter (outlet) P01 73 P01 74 Additional information Value 18 +0.27 +0.27 mm Rocker arm, bore, diameter (inlet) 18 Rocker arm pin, diameter +0.01 17,97 −0.
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D 2011 w TD 2011 w, TCD 2011 w Cylinder head W 01-04-04 Removing and installing cylinder head Commercial available tools: – Socket wrench insert Torx E18 . . . . . . . . . . . . . . . . . . . . . . . . . 8116 – Dog wrench. . . . . . . . . . . . . . . . . . . 8018 – Rotation angle disc . . . . . . . . . . . . . 8190 Special tools: – Plugs/caps . . . . . . . . . . . . . . . . . 170160 – W 01-02-02 – W 01-04-09 – W 06-02-03 . . . . . . . . . . . . TD 2011 w, TCD 2011 w – W 06-07-03 . . . . . . . . . . . .
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Cylinder head W 01-04-04 D 2011 w TD 2011 w, TCD 2011 w z Unscrew lock nuts (1) with dog wrench. z Remove thermostat housing. W 09-08-04 – D 2011 w z Remove the air intake pipe. 1 W 06-07-03 – TD 2011 w, TCD 2011 w z Remove the charge air pipe. W 06-02-03 1 z Remove exhaust gas collection pipe. W 06-09-08 6 © 47550-0 z Remove rocker arm and rocker arm bracket. W 01-02-02 z Remove push rods (1). Lay out components in the order in which they should be installed. Note order of cylinders.
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D 2011 w TD 2011 w, TCD 2011 w Cylinder head W 01-04-04 Installing the cylinder head Measure the piston overhang on all pistons. Select cylinder head gasket according to the largest piston projection measured. z Check piston overhang. W 01-04-09 6 © 47552-0 z Select cylinder head gasket according to the largest piston projection measured. – 1 recess 0.325 - 0.604 mm – 2 recesses 0.605 - 0.704 mm – 3 recesses 0.705 - 0.804 mm Example:Piston overhang = 0.
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Cylinder head W 01-04-04 D 2011 w TD 2011 w, TCD 2011 w z Clean sealing surfaces. The sealing surfaces for the cylinder head gasket must be clean and free of oil. 1 1 Make sure the clamping bushings (1) are in place. 6 © 47549-0 z Fit a new cylinder head gasket. Label OBEN / TOP facing the cylinder head. 1 © 47549-1 z Fit cylinder head. z Oil the cylinder head screws slightly. Attention! 1 Screws can be reused a maximum 3 times with written documentation. z Fasten all screws (1).
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D 2011 w TD 2011 w, TCD 2011 w Cylinder head W 01-04-04 z Tighten cylinder head screws with socket wrench insert according to the tightening sequence. – Stage 1: 30 Nm – Stage 2: 80 Nm 8 6 4 5 9 10 3 1 2 7 – Stage 3: 160 Nm – Stage 4: 90° 6 © 39154-2 z Insert stop rods (1). z Install rocker arm and rocker arm bracket. W 01-02-02 – D 2011 w z Install the air intake pipe. W 06-07-03 – TD 2011 w, TCD 2011 w z Install the charge air pipe.
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Cylinder head W 01-04-04 D 2011 w TD 2011 w, TCD 2011 w z Position clamping claws (1). Attention! 2 Install tension-free. z Tighten screws (2).
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D 2011 w TD 2011 w, TCD 2011 w Cylinder head W 01-04-04 Technical Data Testing and setting data ID no. Name P02 75 Piston overhang P02 76 Piston overhang P02 77 Piston overhang Additional information Identification, cylinder head gasket = 1 recess Identification, cylinder head gasket = 2 recesses Identification, cylinder head gasket = 3 recesses Value 0.325 - 0.604 mm 0.605 - 0.704 mm 0.705 - 0.
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D 2011 w TD 2011 w, TCD 2011 w Cylinder head W 01-04-09 Checking piston overhang Commercial available tools 8190 – W 01-04-04 Special tools: – Dial gauge. . . . . . . . . . . . . . . . . . 100400 – Digital dial gauge . . . . . . . . . . . . 100410 – Measuring device . . . . . . . . . . . . 100750 – Holder . . . . . . . . . . . . . . . . . . . . . 150180 6 Checking piston overhang z Remove cylinder head.
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Cylinder head W 01-04-09 D 2011 w TD 2011 w, TCD 2011 w – Recess cylinder head z Insert dial gauge 100410 in measuring beam. z Place holders (1) on the sealing surface of the crankcase. z Place measuring beam (2) on the holders. z Apply stylus of the dial gauge to the crankcase sealing surface with pre-tension (arrow). z Adjust dial gauge to "0". 2 6 1 1 © 46933-0 z Measure at the points (1) and (2) on the piston. 1 Schematic representation 2 © 34151-2 z Move the measuring beam.
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D 2011 w TD 2011 w, TCD 2011 w Cylinder head W 01-04-09 – Recess cylinder head z Move the measuring beam. z Apply the stylus to the piston base (arrow) under pretension. z Continue turning the crankshaft evenly until the reversal point of the pointer on the dial gauge is reached. The stylus may not be positioned on the labelling of the piston. Note greatest measured value. 6 © 46934-0 z Select cylinder head gasket according to the largest piston projection measured. – 1 recess 0.325 - 0.
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Cylinder head W 01-04-09 D 2011 w TD 2011 w, TCD 2011 w – Recess cylinder head z Select cylinder head gasket according to the largest piston projection measured. – 1 recess 9.820 - 10.140 mm – 2 recesses 10.141 - 10.239 mm – 3 recesses 10.240 - 10.310 mm 6 Example:Piston overhang = 10.150 mm, corresponds to cylinder head gasket with 2 recesses (arrow). z Remove the measuring device and holders. © 47552-1 z Install cylinder head.
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D 2011 w TD 2011 w, TCD 2011 w Cylinder head W 01-04-09 Technical Data Testing and setting data ID no.
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D 2011 w TD 2011 w, TCD 2011 w Crankcase W 03-01-11 Removing and installing the crankcase bleeding Commercial available tools Special tools: – Disassembly tool. . . . . . . . . . . . . 110901 6 Removing the crankcase bleeding z Unscrew screw (1). z Remove crankcase bleeding (2). 1 2 © 47152-0 z Remove the O-ring (1) with the disassembly tool. z Visually inspect the components.
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Crankcase W 03-01-11 D 2011 w TD 2011 w, TCD 2011 w Install crankcase bleeding z Clean sealing surfaces. z Insert new O-ring (1). 1 6 © 47160-0 z Mount crankcase vent (2). Ensure that the installation location is free from faults. The crankcase bleeding must fit evenly. 1 z Tighten screw (1). 8.
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D 2011 w TD 2011 w, TCD 2011 w Crankcase W 03-01-11 Technical Data Tightening specifications ID no. Name Crankcase bleeding on front cover / A03 060 on cylinder head cover / on cylinder head Screw type Notes / Remark Value 8.5 Nm For the tightening procedure according to torque using a torque wrench, a maximum variation of the tightening torque of +/- 10% is permissible.
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D 2011 w TD 2011 w, TCD 2011 w Exhaust system/Charging W 06-01-05 Removing and installing the exhaust line Commercial available tools: – Torx tool set . . . . . . . . . . . . . . . . . . 8189 – W 06-06-04 6 Removing exhaust line – TD 2011 w, TCD 2011 w z Remove turbocharger. W 06-06-04 z Unscrew all screws (1). 1 z Remove exhaust line (2). 1 1 2 1 © 47523-1 z Remove gaskets (1).
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Exhaust system/Charging W 06-01-05 D 2011 w TD 2011 w, TCD 2011 w z Unscrew studs (1). z Visually inspect the components. 1 1 6 © 47524-0 Installing exhaust line 2 z Clean sealing surfaces. z Turn on new pin bolts (1). z Tighten pin bolts (1). 1 12 Nm 1 2 © 47524-1 z Clean sealing surfaces. z Mount exhaust line (1). z Mount new gaskets. Note installation position. 2 z Turn in new screws (2). 2 1 z Tighten new screws (2). 55 Nm – TD 2011 w, TCD 2011 w z Install the turbocharger.
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D 2011 w TD 2011 w, TCD 2011 w Exhaust system/Charging W 06-01-05 Technical Data Tightening specifications ID no. Name A06 001 Exhaust pipe at cylinder head A06 004 Pin bolts on exhaust pipe Screw type Torx screw, coated coated Notes / Remark Value Use new screws. 55 Nm Use new pin bolts 12 Nm For the tightening procedure according to torque using a torque wrench, a maximum variation of the tightening torque of +/- 10% is permissible.
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Exhaust system/Charging W 06-02-03 TD 2011 w, TCD 2011 w Removing and install the charge air line Commercial available tools: – Torx tool set . . . . . . . . . . . . . . . . . . 8189 – W 06-06-04 – W 06-01-05 6 Remove charge air line z Remove turbocharger. W 06-06-04 2 z Remove the exhaust pipe. 1 1 W 06-01-05 1 z Unscrew all screws (1). z Remove charge air pipe (2). z Remove seals. 1 1 © 47525-2 z Clean sealing surfaces.
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Exhaust system/Charging W 06-02-03 TD 2011 w, TCD 2011 w Install charge air line z Mount charge air line (1). z Mount new gaskets. z Tighten screws (2) alternately working from the centre to the outside. 21 Nm 1 2 2 2 z Install the exhaust pipe. W 06-01-05 z Install the turbocharger.
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TD 2011 w, TCD 2011 w Exhaust system/Charging W 06-02-03 Technical Data Tightening specifications ID no. Name A06 030 Charge air pipe on cylinder head Screw type Torx screw, coated Notes / Remark Value Use new screws. 21 Nm For the tightening procedure according to torque using a torque wrench, a maximum variation of the tightening torque of +/- 10% is permissible.
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Exhaust system/Charging W 06-06-04 TD 2011 w, TCD 2011 w Removing and installing the turbocharger Commercial available tools: – Clamping tongs. . . . . . . . . . . . . . . . 9088 – Spring band pliers . . . . . . . . . . . . . . 9090 Attention! – Lubricating oil – Fitting compound DEUTZ S1 Collect leaking operating substances in suitable vessels and dispose of according to regulations. Do not remove the stoppers/caps until immediately before assembly. 6 Removing turbocharger z Unscrew screw (1).
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Exhaust system/Charging W 06-06-04 TD 2011 w, TCD 2011 w z Loosen spring band clip (1) with spring band pliers. 2 z Remove reducer (2). 1 6 © 47554-0 z Unscrew hollow screw (1). z Remove lubricating oil pipe (2). z Remove sealing rings. z Press in stoppers. 1 2 © 47526-0 z Loosen spring band clip (1) with spring band pliers. z Pull off spring band clip (1) in the direction of the arrow.
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Exhaust system/Charging W 06-06-04 TD 2011 w, TCD 2011 w z Unscrew nuts (1). 1 1 6 © 47528-0 z Remove turbocharger in the direction of the arrow. z Remove gasket (1). 1 © 47555-0 z Remove the O-ring (1) with the disassembly tool. z Unscrew screw-in nipple (2). z Remove sealing ring (3).
PAGE 94
Exhaust system/Charging W 06-06-04 TD 2011 w, TCD 2011 w z Unscrew studs (1). z Check components for visible signs of wear. 1 1 6 © 47523-0 Installing the turbocharger z Mount sealing ring (1). z Tighten screw-in nipple (2). 40 Nm z Insert new O-ring (3). 2 1 3 © 47529-1 z Clean sealing surfaces. z Coat pin bolts with mounting compound. z Screw in studs (1). z Tighten all pin bolts (1).
PAGE 95
Exhaust system/Charging W 06-06-04 TD 2011 w, TCD 2011 w z Mount gasket (1). z Plug in the tubing connection (2). z Insert turbocharger in the direction of the arrow. 1 2 6 © 47555-1 z Mount turbocharger (1). z Turn on new nuts (2). z Tighten nuts (2). 2 21 Nm 2 1 © 47528-1 z Position the spring band clip (1) with the spring band pliers. z Pull out stoppers. z Fill in clean lubricating oil (arrow).
PAGE 96
Exhaust system/Charging W 06-06-04 TD 2011 w, TCD 2011 w z Mount lubrication oil line (1). z Mount sealing rings (2). z Screw on hollow screw (3). 3 2 1 6 © 47526-1 z Insert new O-ring (1). z Lightly oil new O-ring (1). 1 © 39378-2 z Mount oil return pipe (1). z Mount holder (2). z Tighten screw (3). 8.5 Nm 4 Attention! 1 Install tension-free. z Mount new sealing rings (4). 5 z Tighten hollow screw (5).
PAGE 97
Exhaust system/Charging W 06-06-04 TD 2011 w, TCD 2011 w Attention! Install tension-free. z Tighten hollow screw (1). 29 Nm 1 6 © 47526-2 z Mount the reducer (1). 1 Attention! Install tension-free. 2 z Position spring band clip (2) with spring band pliers. © 47554-1 z Position hose clip (1) with clamping tongs.
PAGE 98
Exhaust system/Charging W 06-06-04 TD 2011 w, TCD 2011 w Technical Data Tightening specifications ID no. Name Screw type Notes / Remark A06 004 Pin bolts on exhaust pipe coated Use new pin bolts A06 020 Turbocharger on exhaust pipe M8 Lubricating oil pipe on turbocharger / A08 042 Hollow screw Replace sealing rings crankcase Oil return line, hex spuds to turbochA08 044 M16x1.5 Use new sealing ring arger Torx, A08 049 Holder oil return line on crankcase M6x14-8.8 6 Value 12 Nm 21 Nm 29 Nm 40 Nm 8.
PAGE 99
Exhaust system/Charging W 06-07-03 D 2011 w Removing and installing the intake manifold Commercial available tools: – Torx tool set . . . . . . . . . . . . . . . . . . 8189 – W 06-01-05 6 Removing the intake manifold z Remove the exhaust pipe. 2 W 06-01-05 z Unscrew all screws (1). z Remove intake manifold (2). z Remove seals. 1 1 1 1 © 47645-0 z Clean sealing surfaces.
PAGE 100
Exhaust system/Charging W 06-07-03 D 2011 w Installing the intake manifold z Mount new gaskets. 1 z Mount intake manifold (1). z Tighten new screws (2) alternately working from the centre to the outside. 21 Nm z Install the exhaust pipe.
PAGE 101
Exhaust system/Charging W 06-07-03 D 2011 w Technical Data Tightening specifications ID no. Name Air suction intake pipe on cylinder A06 030 head Screw type Torx screw, coated Notes / Remark Value Use new screws. 21 Nm For the tightening procedure according to torque using a torque wrench, a maximum variation of the tightening torque of +/- 10% is permissible.
PAGE 103
Exhaust system/Charging W 06-09-06 D 2011 w Removing and installing the exhaust gas return valve Commercial available tools: – Special bit, 70 mm long. . . . . . . . . . 9120 6 Removing the exhaust gas return valve z Unscrew screw (1) with special bit. z Remove safety cover (2). z Unlock cable plug (3) and remove. 1 2 3 © 46964-0 z Pull out pipe holder (1).
PAGE 104
Exhaust system/Charging W 06-09-06 D 2011 w z Unscrew hollow screws (1). z Remove pipe (2). 3 z Remove sealing rings (3). 1 3 2 1 6 © 46935-0 z Unscrew hollow screw (1). z Remove sealing rings (2). z Unscrew hollow screw (3). z Remove sealing rings (4). z Remove pipe (5). 2 1 5 3 4 © 46938-0 z Unscrew screws (1).
PAGE 105
Exhaust system/Charging W 06-09-06 D 2011 w z Remove gasket (1). 1 6 © 46940-0 z Unscrew screws (1). 1 z Remove the exhaust gas return valve. 1 © 46941-0 z Remove gasket (1).
PAGE 106
Exhaust system/Charging W 06-09-06 D 2011 w z Visually inspect the components. 6 © 46965-0 Installing the exhaust gas return valve z Clean sealing surfaces. z Mount gasket (1). z Mount exhaust gas return valve (2). 1 2 © 46943-0 z Tighten screws (1). 1 z Tighten screws (1).
PAGE 107
Exhaust system/Charging W 06-09-06 D 2011 w z Clean sealing surfaces. z Mount gasket (1). z Mount exhaust gas collection pipe (2). z Fasten screws (3). z Tighten screws (3). 1 20 Nm 3 3 2 6 © 46939-1 z Insert pipe (5). z Mount new sealing rings (4). z Screw on hollow screw (3). z Mount sealing rings (2). z Tighten hollow screw (1). 2 29 Nm 1 z Tighten hollow screw (3). 12 Nm 5 3 4 © 46938-0 z Insert pipe (1). z Mount sealing rings (2). 2 z Screw on hollow screw (3).
PAGE 108
Exhaust system/Charging W 06-09-06 D 2011 w z Press in pipe holder (1). 1 6 © 46937-0 z Plug in the cable plug (3). z Mount the safety cover (2). z Fasten screw (1). z Tighten screw (1) with special bit.
PAGE 109
Exhaust system/Charging W 06-09-06 D 2011 w Technical Data Tightening specifications ID no.
PAGE 111
Exhaust system/Charging W 06-09-07 D 2011 w Removing and installing the exhaust gas return pipe Commercial available tools: – Special bit, 70 mm long. . . . . . . . . . 9120 6 Removing the exhaust gas return pipe z Unscrew screw (1). z Remove safety cover (2). z Unlock cable plug (3) and remove. 1 2 3 © 46964-0 z Pull out pipe holder (1).
PAGE 112
Exhaust system/Charging W 06-09-07 D 2011 w z Unscrew hollow screws (1). z Remove pipe (2). 3 z Remove sealing rings (3). 1 3 2 1 6 © 46935-0 z Unscrew hollow screw (1). z Remove sealing rings (2). z Unscrew hollow screw (3). z Remove sealing rings (4). z Remove pipe (5). 2 1 5 3 4 © 46938-0 z Unscrew screws (1).
PAGE 113
Exhaust system/Charging W 06-09-07 D 2011 w z Remove gasket (1). 1 6 © 46940-0 z Unscrew screws (1). z Remove the exhaust return pipe. 1 1 1 1 © 46961-0 z Remove gasket (1).
PAGE 114
Exhaust system/Charging W 06-09-07 D 2011 w z Unscrew screws (3). z Remove exhaust gas return valve (2). z Remove gasket (1). 1 2 3 3 6 © 46960-0 z Visually inspect the components. © 46963-0 Installing the exhaust gas return pipe z Clean all sealing surfaces. z Mount gasket (1). 1 z Mount exhaust gas return valve (2). z Fasten screws (3). 2 z Tighten screws (3).
PAGE 115
Exhaust system/Charging W 06-09-07 D 2011 w z Clean all sealing surfaces. z Mount gasket (1). 1 6 © 46962-0 z Install the exhaust gas return pipe. z Tighten screws (1). z Tighten screws (1). 8.5 Nm 1 1 1 1 © 46961-0 z Clean sealing surfaces. z Mount gasket (1). z Mount exhaust gas collection pipe (2). z Fasten screws (3). z Tighten screws (3).
PAGE 116
Exhaust system/Charging W 06-09-07 D 2011 w z Insert pipe (5). z Mount new sealing rings (4). z Screw on hollow screw (3). z Mount sealing rings (2). z Tighten hollow screw (1). 2 29 Nm 1 z Tighten hollow screw (3). 12 Nm 5 3 4 6 © 46938-0 z Insert pipe (1). z Mount sealing rings (2). 2 z Screw on hollow screw (3). z Mount new sealing rings (4). 3 z Turn in hollow screw (5). z Tighten hollow screw (5). 29 Nm z Tighten hollow screw (3).
PAGE 117
Exhaust system/Charging W 06-09-07 D 2011 w z Plug in the cable plug (3). z Mount the safety cover (2). z Fasten screw (1). z Tighten screw (1).
PAGE 118
Exhaust system/Charging W 06-09-07 D 2011 w Technical Data Tightening specifications ID no.
PAGE 119
Exhaust system/Charging W 06-09-08 D 2011 w Removing and installing the exhaust gas collection pipe (Exhaust gas recirculation) Commercial available tools: – Cleaning brush . . . . . . . . . . . . . . . . 8167 – W 06-01-05 – W 06-09-07 6 Remove exhaust gas collection pipe z Remove the exhaust pipe. W 06-01-05 z Remove the exhaust return pipe. W 06-09-07 1 z Unscrew screws (1). © 46946-0 z Unscrew screws (1). Note different screw lengths. 2 3 z Remove throttle (2). z Remove gaskets (3).
PAGE 120
Exhaust system/Charging W 06-09-08 D 2011 w z Remove gaskets (1). 1 6 © 46948-0 z Clean exhaust channels (1) with cleaning brush (2). z Clean all sealing surfaces. 1 1 2 1 © 46949-0 Install exhaust gas collection pipe z Check that mounting lugs (1) are sufficiently pre-tensioned.
PAGE 121
Exhaust system/Charging W 06-09-08 D 2011 w z Mount gasket (1). Make sure that the installation site of the mounting lugs (2) is in perfect condition. 2 2 1 6 © 46951-0 z Mount new gaskets (3). z Mount new throttle (2). Note installation position. 2 The marking (arrow) on the throttle is dependent on the engine version. z Insert exhaust gas collection pipe. 3 1 z Turn in new screws (1). © 46952-1 z Turn in new screws (1). z Tighten new screws (1).
PAGE 122
Exhaust system/Charging W 06-09-08 D 2011 w z Tighten new screws (1). 55 Nm z Install the exhaust gas return pipe. W 06-09-07 z Install the exhaust pipe.
PAGE 123
Exhaust system/Charging W 06-09-08 D 2011 w Technical Data Tightening specifications ID no. Name A06 073 Exhaust gas collection pipe (exhaust gas return) on cylinder head Screw type Notes / Remark Torx M10x25-10.9 Torx Use new screws. M10x30-10.9 Torx M10x45-10.9 Value 55 Nm For the tightening procedure according to torque using a torque wrench, a maximum variation of the tightening torque of +/- 10% is permissible.
PAGE 125
D 2011 w TD 2011 w, TCD 2011 w Fuel system W 07-02-07 Removing and installing the lifting magnet (Start amount release) Commercial available tools: – Plier insert. . . . . . . . . . . . . . . . . . . . 8027 Collect leaking operating substances in suitable vessels and dispose of according to regulations. Special tools: – Disassembly tool. . . . . . . . . . . . . 110901 6 Remove lifting magnet z Pull out cable plug (1). 1 © 47128-0 z Unscrew lifting magnet (1) with plier insert.
PAGE 126
Fuel system W 07-02-07 D 2011 w TD 2011 w, TCD 2011 w z Remove the O-ring (1) with the disassembly tool. z Visually inspect the components. 1 6 © 47392-0 Install lifting magnet z Insert new O-ring (1). 1 © 47392-0 z Clean all sealing surfaces. z Insert lifting magnet (1).
PAGE 127
D 2011 w TD 2011 w, TCD 2011 w Fuel system W 07-02-07 z Tighten lifting magnet (1) with plier insert. 10 Nm 1 Note direction of terminal. 6 © 39664-1 z Plug in the cable plug (1).
PAGE 128
Fuel system W 07-02-07 D 2011 w TD 2011 w, TCD 2011 w Technical Data Tightening specifications ID no. Name Screw type Lifting magnet (start amount release) A05 065 on front cover Notes / Remark Value 10 Nm For the tightening procedure according to torque using a torque wrench, a maximum variation of the tightening torque of +/- 10% is permissible.
PAGE 129
D 2011 w TD 2011 w, TCD 2011 w Fuel system W 07-03-01 Renewing the injection lines Danger! Commercial available tools: – Dog wrench. . . . . . . . . . . . . . . . . . . 8018 Wait 30 seconds after switching off the engine before working on the fuel system. Special tools: – Plugs/caps . . . . . . . . . . . . . . . . . 170160 Attention! Pay attention to utmost cleanliness when working on the fuel system. Remove residue paint and particles of dirt before removing.
PAGE 130
Fuel system W 07-03-01 D 2011 w TD 2011 w, TCD 2011 w z Remove injection pipes (1). Lay out components in the order in which they should be installed. 1 Note assignment! 1 6 © 47652-0 z Mount the caps (1). 1 1 © 47654-0 z Visually inspect the components.
PAGE 131
D 2011 w TD 2011 w, TCD 2011 w Fuel system W 07-03-01 Installing injection pipes z Pull off the caps (1). z Mount new injection pipe. 1 6 1 © 47654-0 z Screw on union nuts (1). Attention! 1 Install injection line without tension. Note installation position. 1 1 1 © 00000-0 z Tighten union nuts (1) with claw spanner.
PAGE 132
Fuel system W 07-03-01 D 2011 w TD 2011 w, TCD 2011 w Technical Data Tightening specifications ID no. Name Screw type Injection line on fuel injector / injection A07 003 M12x1.5 pump Notes / Remark Value 25 Nm For the tightening procedure according to torque using a torque wrench, a maximum variation of the tightening torque of +/- 10% is permissible.
PAGE 133
D 2011 w TD 2011 w, TCD 2011 w Fuel system W 07-07-01 Removing and installing the fuel injectors Commercial available tools: – Assembly pliers. . . . . . . . . . . . . . . . 8024 – W 07-03-01 – W07-07-02 Special tools: – Puller. . . . . . . . . . . . . . . . . . . . . . 110090 – Slide hammer . . . . . . . . . . . . . . . 150800 – Plugs/caps . . . . . . . . . . . . . . . . . 170160 Danger! Wait 30 seconds after switching off the engine before working on the fuel system.
PAGE 134
Fuel system W 07-07-01 D 2011 w TD 2011 w, TCD 2011 w z Unscrew screw (1). z Remove clamping shoe (2). 1 2 6 © 47562-0 z Pull out fuel injector (1) and sealing ring (arrow). Lay out components in the order in which they should be installed. Note cylinder assignment. 1 © 47636-0 Removing stuck fuel injectors z Assembly sliding hammer (1) and puller (2). z Tighten lock nut (3).
PAGE 135
D 2011 w TD 2011 w, TCD 2011 w Fuel system W 07-07-01 z Mount sliding hammer on fuel injector. z Screw on lock nut (1). z Pull out stuck fuel injector. 1 6 © 47564-0 z Grip a tight sealing ring (1) with the assembly pliers (2) and pull off, turning slightly. Attention! Do not damage the nozzle tip! 1 2 © 43303-0 z Visually inspect the components. z Check the fuel injector.
PAGE 136
Fuel system W 07-07-01 D 2011 w TD 2011 w, TCD 2011 w Installing the fuel injector z Mount new sealing ring (1) on fuel injector. 6 © 47351-0 z Insert fuel injector. z Mount clamping shoe. Note installation position of the clamping shoe. z Fasten screws. © 39488-1 z Tighten screw (1).
PAGE 137
D 2011 w TD 2011 w, TCD 2011 w Fuel system W 07-07-01 z Install injection lines.
PAGE 138
Fuel system W 07-07-01 D 2011 w TD 2011 w, TCD 2011 w Technical Data Tightening specifications ID no. Name A07 001 Fuel injector on cylinder head Screw type Notes / Remark Value 21 Nm For the tightening procedure according to torque using a torque wrench, a maximum variation of the tightening torque of +/- 10% is permissible.
PAGE 139
Fuel system W 07-08-01 TD 2011 w, TCD 2011 w Removing and installing the lifting magnet (charge air pressure-dependent full load stop) Commercial available tools: – Plier insert. . . . . . . . . . . . . . . . . . . . 8027 Special tools: – Disassembly tool. . . . . . . . . . . . . 110901 6 Remove lifting magnet z Pull out cable plug. z Unscrew lifting magnet (1) with plier insert. 1 © 47646-0 z Remove the O-ring with the disassembly tool. z Visually inspect the components.
PAGE 140
Fuel system W 07-08-01 TD 2011 w, TCD 2011 w Install lifting magnet z Mount new O-ring. z Insert lifting magnet (1). 1 6 © 47648-0 z Tighten lifting magnet (1) with plier insert.
PAGE 141
Fuel system W 07-08-01 TD 2011 w, TCD 2011 w Technical Data Tightening specifications ID no. Name A06 094 Lifting magnet on fuel filter console Screw type Notes / Remark Renew O-ring Value 10 Nm For the tightening procedure according to torque using a torque wrench, a maximum variation of the tightening torque of +/- 10% is permissible.
PAGE 143
Fuel system W 07-08-02 TD 2011 w, TCD 2011 w Installing and removing charge air pressure-dependent full load stop Commercial available tools: – Plier insert. . . . . . . . . . . . . . . . . . . . 8027 – W 07-10-08 Special tools: – Disassembly tool. . . . . . . . . . . . . 110901 6 Removing the charge air-pressure dependent full load stop z Remove fuel filter console. W 07-10-08 z Unscrew screws (1). 1 © 39385-2 z Remove cover (1). z Remove diaphragms (2). z Remove spring (3).
PAGE 144
Fuel system W 07-08-02 TD 2011 w, TCD 2011 w z Unscrew lifting magnet (1) with plier insert. 1 6 © 39387-1 z Remove the O-ring with the disassembly tool. z Visually inspect the components. © 47647-0 Installing the charge air-pressure dependent full load stop z Clean sealing surfaces. 1 z Mount new O-ring. z Tighten lifting magnet (1) with plier insert.
PAGE 145
Fuel system W 07-08-02 TD 2011 w, TCD 2011 w z Insert spring (1). z Insert diaphragm (2) and cap (3). Attention! Note installation position. 3 2 1 6 © 39389-1 z Tighten screws (1). 8 Nm z Install the fuel filter console.
PAGE 146
Fuel system W 07-08-02 TD 2011 w, TCD 2011 w Technical Data Tightening specifications ID no. Name Screw type A06 094 Lifting magnet on fuel filter console Cap on charge air-dependent full load A07 096 stop Notes / Remark Renew O-ring Value 10 Nm 8 Nm For the tightening procedure according to torque using a torque wrench, a maximum variation of the tightening torque of +/- 10% is permissible.
PAGE 147
D 2011 w TD 2011 w, TCD 2011 w Fuel system W 07-10-06 Removing and installing fuel pipes Commercial available tools: – Hose clip pliers . . . . . . . . . . . . . . . . 8011 – Torx tool set . . . . . . . . . . . . . . . . . . 8189 – Spring band pliers . . . . . . . . . . . . . . 9090 Danger! Special tools: – Plugs/caps . . . . . . . . . . . . . . . . . 170160 Attention! Wait 30 seconds after switching off the engine before working on the fuel system.
PAGE 148
Fuel system W 07-10-06 D 2011 w TD 2011 w, TCD 2011 w z Loosen spring band clips (1) with spring band pliers. 1 1 6 © 47572-0 z Pull off hose pieces (1) in the direction of the arrow. 1 © 47573-0 z Loosen hose clip (1). z Pull off fuel pipe (2). z Pull off protective hose (3). Collect draining fuel and dispose of according to regulations.
PAGE 149
D 2011 w TD 2011 w, TCD 2011 w Fuel system W 07-10-06 z Loosen hose clip (1). z Pull off fuel pipe (2). Collect draining fuel and dispose of according to regulations. 2 1 6 © 47614-0 z Unscrew hollow screws (1). z Remove fuel pipe (2). z Remove sealing rings. 1 1 2 © 47616-0 z Unscrew hollow screws (1). z Remove fuel return line (2). Remove fuel return line in the direction of the flywheel. 2 z Remove sealing rings.
PAGE 150
Fuel system W 07-10-06 D 2011 w TD 2011 w, TCD 2011 w z Visually inspect the components. 6 © 47618-0 Installing fuel pipes z Mount fuel return pipe (1). z Mount sealing rings (2). 1 z Tighten hollow screw (3). 29 Nm 2 2 3 3 2 3 © 47617-1 z Mount fuel pipe (1). z Mount sealing rings (2). z Tighten hollow screw (3).
PAGE 151
D 2011 w TD 2011 w, TCD 2011 w Fuel system W 07-10-06 z Mount fuel hose (2). Lay hose without contact. Ensure that the installation location is free from faults. z Mount new hose clip (1). z Fix the hose clip (1) with the hose clip pliers. Ensure that the installation location is free from faults. 2 1 6 © 47614-0 z Slip protective hose (3) over with mounting compound. Lay hose without contact. Ensure that the installation location is free from faults. z Mount fuel hose (2). z Mount new hose clip (1).
PAGE 152
Fuel system W 07-10-06 D 2011 w TD 2011 w, TCD 2011 w z Push on hose pieces (1) in the direction of the arrow. 1 6 © 47573-1 z Position spring band clips (1) with spring band pliers. 1 1 © 47572-0 z Position clamping claws (1). Attention! 2 Install tension-free. z Tighten screws (2).
PAGE 153
D 2011 w TD 2011 w, TCD 2011 w Fuel system W 07-10-06 Technical Data Tightening specifications ID no. A07 015 A07 061 A09 020 Name Fuel supply line to injection pump Fuel return line on injection pump Pipe clip on holder Screw type Notes / Remark Hollow screw Replace sealing rings Hollow screw Replace sealing rings M6x16 Value 29 Nm 29 Nm 21 Nm For the tightening procedure according to torque using a torque wrench, a maximum variation of the tightening torque of +/- 10% is permissible.
PAGE 155
Fuel system W 07-10-08 TD 2011 w, TCD 2011 w Removing and installing the fuel filter console Danger! Commercial available tools: – Hose clip pliers . . . . . . . . . . . . . . . . 8011 – Torx tool set . . . . . . . . . . . . . . . . . . 8189 Wait 30 seconds after switching off the engine before working on the fuel system. Special tools: – Disassembly tool. . . . . . . . . . . . . 110901 – Special wrench . . . . . . . . . . . . . . 170050 – Plugs/caps . . . . . . . . . . . . . . . . .
PAGE 156
Fuel system W 07-10-08 TD 2011 w, TCD 2011 w z Pull off hose pipe (1). 1 6 © 47593-0 z Unscrew screws (1). z Remove fuel filter console (2). 1 2 1 © 47594-0 z Remove the O-ring (1) with the disassembly tool.
PAGE 157
Fuel system W 07-10-08 TD 2011 w, TCD 2011 w z Visually inspect the components. 6 © 47596-0 Installing the fuel filter console z Clean sealing surfaces. © 47597-0 z Insert new sealing ring (1).
PAGE 158
Fuel system W 07-10-08 TD 2011 w, TCD 2011 w z Install the fuel filter console (2). z Tighten screws (1). 22 Nm 1 2 1 6 © 47594-0 z Mount the hose pipe (1). 1 © 47593-0 Note assignment! Lay hoses without contact. 1 z Install fuel hoses. z Mount new hose clips (1). z Fasten hose clips (1) with hose clip pliers. Ensure that the installation location is free from faults.
PAGE 159
Fuel system W 07-10-08 TD 2011 w, TCD 2011 w z Position protective hoses, dimension X.
PAGE 160
Fuel system W 07-10-08 TD 2011 w, TCD 2011 w Technical Data Tightening specifications ID no. Name Fuel filter console/full load stop to A07 087 crankcase Screw type Torx, M8x50-8.8 Notes / Remark Value 22 Nm For the tightening procedure according to torque using a torque wrench, a maximum variation of the tightening torque of +/- 10% is permissible.
PAGE 161
D 2011 w TD 2011 w, TCD 2011 w Fuel system W 07-11-01 Removing and installing the fuel supply pump Danger! Commercial available tools: – Hose clip pliers . . . . . . . . . . . . . . . . 8011 Wait 30 seconds after switching off the engine before working on the fuel system. Special tools: – Disassembly tool. . . . . . . . . . . . . 110901 – Plugs/caps . . . . . . . . . . . . . . . . . 170160 Attention! Pay attention to utmost cleanliness when working on the fuel system.
PAGE 162
Fuel system W 07-11-01 D 2011 w TD 2011 w, TCD 2011 w z Loosen hose clip (1). z Pull off fuel pipe (2). z Pull off protective hose (3). Collect draining fuel and dispose of according to regulations. 1 6 3 2 © 47610-0 z Unscrew screws (1). z Remove fuel supply pump (2). 1 2 1 © 47609-0 z Remove the O-ring (1) with the disassembly tool. z Visually inspect the components.
PAGE 163
D 2011 w TD 2011 w, TCD 2011 w Fuel system W 07-11-01 Installing the fuel supply pump z Turn the crankshaft until the eccentric of the camshafts is in the top dead centre (arrow). 6 © 47398-0 z Insert new O-ring (1). z Oil tappet (2) lightly with lubricating oil. 1 2 © 47176-0 z Clean all sealing surfaces. z Mount fuel supply pump. z Press fuel supply pump centrally on the crankcase. z Tighten screws (1).
PAGE 164
Fuel system W 07-11-01 D 2011 w TD 2011 w, TCD 2011 w z Slip protective hose (3) over with mounting compound. Lay hose without contact. z Mount fuel hose (2). z Mount new hose clip (1). 1 6 3 2 © 47610-0 z Position protective hose, dimension X. 20 mm X © 47610-1 z Fix the hose clip (1) with the hose clip pliers. Ensure that the installation location is free from faults.
PAGE 165
D 2011 w TD 2011 w, TCD 2011 w Fuel system W 07-11-01 z Insert oil dipstick (1).
PAGE 166
Fuel system W 07-11-01 D 2011 w TD 2011 w, TCD 2011 w Technical Data Tightening specifications ID no. Name A07 024 Fuel supply pump on crankcase Screw type Notes / Remark Value 21 Nm For the tightening procedure according to torque using a torque wrench, a maximum variation of the tightening torque of +/- 10% is permissible.
PAGE 167
D 2011 w TD 2011 w, TCD 2011 w Lube oil system W 08-08-02 Removing and installing the lubricating oil cooler Commercial available tools – W 08-11-07 Collect leaking operating substances in suitable vessels and dispose of according to regulations. Emptying and filling the engine with operating media must be carried out according to the operating manual and the appropriate documentation of the vehicle/equipment manufacturer. 6 Removing the lubricating oil cooler 1 z Remove oil filter console.
PAGE 168
Lube oil system W 08-08-02 D 2011 w TD 2011 w, TCD 2011 w Installing the lubricating oil cooler z Visually inspect the components. 6 © 47519-0 z Clean sealing surfaces. z Insert new sealing ring (1). 1 © 47518-0 z Mount lubricating oil cooler (1). 2 Ensure that the installation location of the sealing ring is free from faults. 1 2 z Tighten screws (2). z Tighten screws (2). 13 Nm z Mount oil filter console.
PAGE 169
D 2011 w TD 2011 w, TCD 2011 w Lube oil system W 08-08-02 Technical Data Tightening specifications ID no. Name Screw type Lubricating oil cooler on oil filter conA08 051 M6x16-10.9 sole Notes / Remark Value 13 Nm For the tightening procedure according to torque using a torque wrench, a maximum variation of the tightening torque of +/- 10% is permissible.
PAGE 171
D 2011 w TD 2011 w, TCD 2011 w Lube oil system W 08-11-07 Removing and installing the oil filter console Commercial available tools: – Torx tool set . . . . . . . . . . . . . . . . . . 8189 – Operation manual – W 08-08-02 Special tools: – Disassembly tool. . . . . . . . . . . . . 110901 – Special wrench . . . . . . . . . . . . . . 170050 Collect leaking operating substances in suitable vessels and dispose of according to regulations.
PAGE 172
Lube oil system W 08-11-07 D 2011 w TD 2011 w, TCD 2011 w z Unscrew hollow screw (1). z Remove sealing rings (2). 1 2 6 © 47514-0 z Unscrew lubricating oil filter (1) with special wrench. Collect draining lubricating oil and dispose of properly. 1 © 47515-0 z Unscrew screws (1). z Unscrew screw (2). z Remove oil filter console (3).
PAGE 173
D 2011 w TD 2011 w, TCD 2011 w Lube oil system W 08-11-07 z Remove gasket (1). z Clean sealing surfaces. 1 6 © 47520-0 Installing oil filter console z Visually inspect the components. © 47521-0 z Fix new gasket (1) to the crankcase with a little grease.
PAGE 174
Lube oil system W 08-11-07 D 2011 w TD 2011 w, TCD 2011 w z Mount oil filter console (1). Do not move gasket. 3 z Tighten screws (2). z Turn in screw (3). z Tighten screws (2). 21 Nm 2 2 z Tighten screw (3). 21 Nm 1 6 © 47516-1 z Clean sealing surfaces. z Lightly oil sealing ring on new lubricating oil filter. z Tighten the lubricating oil filter (1) according to the operating instructions. Operation manual 1 © 47515-0 z Insert control line (1). z Mount sealing rings (2).
PAGE 175
D 2011 w TD 2011 w, TCD 2011 w Lube oil system W 08-11-07 z Push on hose pieces (1) in the direction of the arrow. 1 6 © 47573-1 z Position the spring band clip (1) with the spring band pliers.
PAGE 176
Lube oil system W 08-11-07 D 2011 w TD 2011 w, TCD 2011 w Technical Data Tightening specifications ID no. Name Screw type Notes / Remark Torx M8x50-8.8 A08 003 Oil filter console on crankcase Torx M8x90-8.8 Control line to oil filter console / crank- Hollow screw A08 048 case M10x1 Value 21 Nm 18 Nm For the tightening procedure according to torque using a torque wrench, a maximum variation of the tightening torque of +/- 10% is permissible.
PAGE 177
D 2011 w TD 2011 w, TCD 2011 w Lube oil system W 08-11-08 Removing and installing the oil pressure switch Collect leaking operating substances in suitable vessels and dispose of according to regulations. Commercial available tools 6 Removing the oil pressure switch z Pull out cable plug (1). 1 © 47344-0 z Unscrew oil pressure switch (1).
PAGE 178
Lube oil system W 08-11-08 D 2011 w TD 2011 w, TCD 2011 w z Visually inspect the components. 6 © 47433-0 Installing the oil pressure switch z Screw on oil pressure switch (1). 1 © 47434-0 z Tighten oil pressure switch (1).
PAGE 179
D 2011 w TD 2011 w, TCD 2011 w Lube oil system W 08-11-08 z Plug in the cable plug (1). Ensure that the connection is perfect.
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Lube oil system W 08-11-08 D 2011 w TD 2011 w, TCD 2011 w Technical Data Tightening specifications ID no. Name A08 091 Oil pressure switch on crankcase Screw type M10x1 Notes / Remark Value 13 Nm For the tightening procedure according to torque using a torque wrench, a maximum variation of the tightening torque of +/- 10% is permissible.
PAGE 181
D 2011 w TD 2011 w, TCD 2011 w Lube oil system W 08-11-12 Removing and installing the thermostat (Lubricating oil cooler) Commercial available tools: – Slide gauge – Torx tool set . . . . . . . . . . . . . . . . . . 8189 Collect leaking operating substances in suitable vessels and dispose of according to regulations. Special tools: – Disassembly tool. . . . . . . . . . . . .
PAGE 182
Lube oil system W 08-11-12 D 2011 w TD 2011 w, TCD 2011 w z Remove the O-ring (1) with the disassembly tool. 1 6 © 47439-0 z Visually inspect the components. © 47568-0 Installing the thermostat z Measure length of the compressor spring with calliper gauge. 45.7 mm When the wear limit is reached, the compressor spring must be renewed.
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D 2011 w TD 2011 w, TCD 2011 w Lube oil system W 08-11-12 z Clean sealing surfaces. z Oil the thermostat lightly. z Insert compression spring. z Insert thermostat (1). Note installation position. 1 6 © 47575-0 z Lightly oil new O-ring (1). z Insert new O-ring (1). 1 © 47439-0 z Tighten screw plug (1).
PAGE 184
Lube oil system W 08-11-12 D 2011 w TD 2011 w, TCD 2011 w Technical Data Testing and setting data ID no. P08 74 Name Thermostat, compression spring, length Additional information Value 45.7 mm Tightening specifications ID no. Name Thermostat on crankcase, locking A08 072 screw, Screw type Notes / Remark Value 90 Nm For the tightening procedure according to torque using a torque wrench, a maximum variation of the tightening torque of +/- 10% is permissible.
PAGE 185
D 2011 w TD 2011 w, TCD 2011 w Lube oil system W 08-16-01 Removing and installing the control line Commercial available tools – W 07-10-08 – W 08-11-07 Collect leaking operating substances in suitable vessels and dispose of according to regulations. Emptying and filling the engine with operating media must be carried out according to the operating manual and the appropriate documentation of the vehicle/equipment manufacturer. 6 Removing control line z Unscrew hollow screw (1).
PAGE 186
Lube oil system W 08-16-01 D 2011 w TD 2011 w, TCD 2011 w z Visually inspect sealing surfaces (arrows). 6 © 47651-0 z Visually inspect the components. © 47649-0 Installing control line z Insert control line (1). 1 z Mount sealing rings (2). z Screw in all hollow screws. 2 z Tighten hollow screws (3). 2 18 Nm 2 Attention! Install tension-free.
PAGE 187
D 2011 w TD 2011 w, TCD 2011 w Lube oil system W 08-16-01 z Install the fuel filter console. W 07-10-08 z Mount oil filter console. W 08-11-07 z Insert control line (1). 1 z Mount sealing rings (2). z Tighten hollow screw (3).
PAGE 188
Lube oil system W 08-16-01 D 2011 w TD 2011 w, TCD 2011 w Technical Data Tightening specifications ID no. Name Screw type Notes / Remark Control line to oil filter console / crank- Hollow screw A08 048 case M10x1 Value 18 Nm For the tightening procedure according to torque using a torque wrench, a maximum variation of the tightening torque of +/- 10% is permissible.
PAGE 189
D 2011 w TD 2011 w, TCD 2011 w Cooling system W 09-07-08 Removing and installing the coolant pump Commercial available tools 8190 – Operation manual – W 13-02-03 Special tools: – Disassembly tool. . . . . . . . . . . . . 110901 Collect leaking operating substances in suitable vessels and dispose of according to regulations. The appropriate documentation of the vehicle/equipment manufacturer should be observed for emptying and filling the cooling system. 6 Removing coolant pump z Remove V-belt.
PAGE 190
Cooling system W 09-07-08 D 2011 w TD 2011 w, TCD 2011 w z Clean sealing surfaces. 6 © 47511-0 Installing coolant pump z Clean sealing surfaces. z Insert new O-ring (1). 1 © 47512-0 z Mount coolant pump (1). Pay attention to different screw lengths. Screws M8 x 35 mm (2) 1 Screw M8 x 100 mm (3) z Tighten screws (2). 2 2 20 Nm z Tighten screw (3).
PAGE 191
D 2011 w TD 2011 w, TCD 2011 w Cooling system W 09-07-08 z Install V-belt. W 13-02-03 z Fill cooling system according to the operating manual.
PAGE 192
Cooling system W 09-07-08 D 2011 w TD 2011 w, TCD 2011 w Technical Data Tightening specifications ID no. Name Screw type Notes / Remark M8x35-10.9 A09 010 Coolant pump on thermostat housing M8x100-10.9 Value 20 Nm For the tightening procedure according to torque using a torque wrench, a maximum variation of the tightening torque of +/- 10% is permissible.
PAGE 193
D 2011 w TD 2011 w, TCD 2011 w Cooling system W 09-08-01 Checking the thermostat (in the removed state) Commercial available tools: – Thermometer – W 09-08-02 Danger! Risk of injury! Hot water and hot thermostat. 6 Checking thermostat z Remove thermostat. W 09-08-02 z Measure beginning of stroke, dimension (a). z Note measured value, dimension (a). © 34679-3 z Heat up the thermostat in the water bath.
PAGE 194
Cooling system W 09-08-01 D 2011 w TD 2011 w, TCD 2011 w z Measure end of stroke, dimension (b). z Note measured value, dimension (b). 6 © 34679-2 z Determine stroke. Calculation example Desired: Stroke Given: Measured: Beginning of stroke, dimension (a) End of stroke, dimension (b) Calculation: Dimension (b) - dimension (a) Result: = stroke z Compare result with setpoint value. – Nominal value stroke travel: at least 9 mm z Install thermostat.
PAGE 195
D 2011 w TD 2011 w, TCD 2011 w Cooling system W 09-08-01 Technical Data Testing and setting data ID no.
PAGE 197
D 2011 w TD 2011 w, TCD 2011 w Cooling system W 09-08-02 Removing and installing the thermostat Commercial available tools – W 09-08-01 Collect leaking operating substances in suitable vessels and dispose of according to regulations. Emptying and filling the engine with operating media must be carried out according to the operating manual and the appropriate documentation of the vehicle/equipment manufacturer. 6 Removing the thermostat z Unscrew screws (1). z Remove outlet nozzle (2).
PAGE 198
Cooling system W 09-08-02 D 2011 w TD 2011 w, TCD 2011 w z Check thermostat. W 09-08-01 z Visually inspect the components. 6 © 46984-0 Installing the thermostat z Clean sealing surfaces. z Insert thermostat (1). 1 © 46983-0 z Clean sealing surfaces. z Insert new O-ring (1).
PAGE 199
D 2011 w TD 2011 w, TCD 2011 w Cooling system W 09-08-02 z Mount outlet nozzle (2). z Tighten screws (1).
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Cooling system W 09-08-02 D 2011 w TD 2011 w, TCD 2011 w Technical Data Tightening specifications ID no. Name Screw type A09 002 Outlet nozzles on thermostat housing M8x30-10.9 Notes / Remark Value 22 Nm For the tightening procedure according to torque using a torque wrench, a maximum variation of the tightening torque of +/- 10% is permissible.
PAGE 201
D 2011 w TD 2011 w, TCD 2011 w Cooling system W 09-08-04 Removing and installing the thermostat housing Commercial available tools: – Spring band pliers . . . . . . . . . . . . . . 9090 8190 – Operation manual – W 12-02-01 Special tools: – Disassembly tool. . . . . . . . . . . . . 110901 Collect leaking operating substances in suitable vessels and dispose of according to regulations.
PAGE 202
Cooling system W 09-08-04 D 2011 w TD 2011 w, TCD 2011 w z Unscrew screw (1). z Unscrew screws (2). z Remove the thermostat housing (3). 3 2 2 1 6 2 © 46990-0 z Pull out plug element (1). z Pull out plug element (2). 1 2 © 46991-0 z Remove the O-ring (1) with the disassembly tool.
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D 2011 w TD 2011 w, TCD 2011 w Cooling system W 09-08-04 Installing thermostat housing z Clean all sealing surfaces. z Visually inspect the components. 6 © 46993-0 z Insert new O-ring (1). 1 © 46992-0 z Insert plug element (1). z Insert plug element (2).
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Cooling system W 09-08-04 D 2011 w TD 2011 w, TCD 2011 w z Mount thermostat housing (1). Ensure that the installation location is free from faults. z Tighten screws (2). 1 34 Nm z Turn in screw (3). 2 2 3 6 2 © 46990-1 z Coat hose pieces with mounting compound. z Push on hose pieces (1) in the direction of the arrow. 1 © 47522-1 z Position the spring band clip (1) with the spring band pliers. z Install V-belt. 1 z Check V-belt tension.
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D 2011 w TD 2011 w, TCD 2011 w Cooling system W 09-08-04 Technical Data Tightening specifications ID no. Name A09 001 Thermostat housing to crankcase Screw type Notes / Remark M8x100-10.9 Value 34 Nm For the tightening procedure according to torque using a torque wrench, a maximum variation of the tightening torque of +/- 10% is permissible.
PAGE 207
D 2011 w TD 2011 w, TCD 2011 w Cooling system W 09-12-01 Removing and installing temperature transmitter Collect leaking operating substances in suitable vessels and dispose of according to regulations. Commercial available tools Emptying and filling the engine with operating media must be carried out according to the operating manual and the appropriate documentation of the vehicle/equipment manufacturer. 6 Removing temperaure transmitter z Disconnect cable connections.
PAGE 208
Cooling system W 09-12-01 D 2011 w TD 2011 w, TCD 2011 w Installing temperature transmitter z Tighten temperature transmitter (1). 25 Nm Make sure the sealing ring is in place. z Connect cable. Ensure that the connection is perfect.
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D 2011 w TD 2011 w, TCD 2011 w Cooling system W 09-12-01 Technical Data Tightening specifications ID no. Name Temperature transmitter on thermoA09 031 stat housing Screw type Notes / Remark Value 25 Nm For the tightening procedure according to torque using a torque wrench, a maximum variation of the tightening torque of +/- 10% is permissible.
PAGE 211
D 2011 w TD 2011 w, TCD 2011 w Monitoring system W 11-00-03 Removing and installing the lifting magnet (Engine shutdown) Commercial available tools – W 12-02-01 Special tools: – Disassembly tool. . . . . . . . . . . . . 110901 6 Remove lifting magnet 3 – Version with V-belt tensioning pulley z Remove V-belt. W 12-02-01 1 z Loosen screws (1). z Swing V-belt tensioning pulley (2) in the direction of the arrow. z Remove V-belt (3). 4 2 © 46986-0 z Unscrew screw (1). z Unscrew screw (2).
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Monitoring system W 11-00-03 D 2011 w TD 2011 w, TCD 2011 w z Remove cable tie (1). z Unscrew screws (2). 2 z Remove lifting magnet (3). 1 3 2 6 © 47606-0 z Remove the O-ring (1) with the disassembly tool. z Visually inspect the components. 1 © 47355-0 Install lifting magnet z Insert new O-ring (1).
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D 2011 w TD 2011 w, TCD 2011 w Monitoring system W 11-00-03 z Insert lifting magnet (1). z Tighten screws (2). 2 8.5 Nm z Fasten cable plug with cable tie (3). 3 1 2 6 © 47606-1 z Mount V-belt tensioning pulley (1). z Fasten screw (2). z Turn in screw (3). z Mount and tighten V-belt.
PAGE 214
Monitoring system W 11-00-03 D 2011 w TD 2011 w, TCD 2011 w Technical Data Tightening specifications ID no. Name Lifting magnet (engine shutdown) on A05 041 front cover Screw type Notes / Remark Value 8.5 Nm For the tightening procedure according to torque using a torque wrench, a maximum variation of the tightening torque of +/- 10% is permissible.
PAGE 215
D 2011 w TD 2011 w, TCD 2011 w Other components W 12-01-04 Removing and installing the V-belt pulley Commercial available tools – W 12-02-01 6 Removing the V-belt pulley z Remove V-belt. W 12-02-01 z Unscrew screws (1). z Remove fan (2). 1 1 2 © 47574-0 z Unscrew screws (1). z Remove flange hub (2).
PAGE 216
Other components W 12-01-04 D 2011 w TD 2011 w, TCD 2011 w z Remove V-belt pulley (1). 1 6 © 47014-0 z Remove centrifugal disc (1). Note installation position. 1 z Visually inspect the components. © 47015-0 Installing the V-belt pulley z Mount centrifugal disc (1). Note installation position.
PAGE 217
D 2011 w TD 2011 w, TCD 2011 w Other components W 12-01-04 z Mount V-belt pulley (1). 1 6 © 47014-0 z Mount flange hub (2). z Tighten screws (1). 43 Nm 1 2 1 © 47013-0 Attention! Note installation position: "Engine side" label faces engine! z Mount fan (2). z Tighten screws (1). 30 Nm 1 z Install V-belt.
PAGE 218
Other components W 12-01-04 D 2011 w TD 2011 w, TCD 2011 w Technical Data Tightening specifications ID no. Name A09 042 Ventilator on flange hub V belt pulley/flange hub on output A12 031 flange Screw type M8x40-10.9 M10x30-8.8 Notes / Remark Value 30 Nm 43 Nm For the tightening procedure according to torque using a torque wrench, a maximum variation of the tightening torque of +/- 10% is permissible.
PAGE 219
D 2011 w TD 2011 w, TCD 2011 w Other components W 12-02-01 Renew V-belts, check V-belt tension Attention! Commercial available tools: – V-belt tension measuring device . . . . . . . . . . . . . . . . . . . . . . . 8115 – Rotation angle disc . . . . . . . . . . . . . 8190 Only test / tighten / renew V-belts when the engine is not running. The V-belt tension of new V-belts must be checked after they have been running for 15 minutes.
PAGE 220
Other components W 12-02-01 D 2011 w TD 2011 w, TCD 2011 w z Loosen screws (1). z Loosen screw (2). 3 1 z Swing generator (3) in the direction of the arrow. 2 6 © 46987-0 z Unscrew screw (1). z Remove air bearing (2). 2 z Remove V-belt pulley (3). z Remove V-belt (4). 1 4 3 © 46988-0 Installing the V-belt. z Mount V-belt (1). 3 Note V-belt length. z Mount V-belt pulley (2). 4 z Insert air bearing (3). z Turn in screw (4).
PAGE 221
D 2011 w TD 2011 w, TCD 2011 w Other components W 12-02-01 z Swing generator (1) in the direction of the arrow. 1 z Tighten screws (2). 2 z Fasten screws (3). 6 3 © 46987-1 z Tighten new screw (1). – Stage 1: 30 Nm z Tighten screw (1) with socket wrench insert and rotation angle disc. 1 – Stage 2: 120° © 46988-2 Check V-belt tension with V-belt tension measuring device z Lower indicator arm (1) into V-belt tension measuring device.
PAGE 222
Other components W 12-02-01 D 2011 w TD 2011 w, TCD 2011 w z Mount V-belt tension measuring device on V-belt. The V-belt must be between the guides (arrow). 6 © 46997-1 z Press the V-belt measuring device against the V-belt with the button (1) until you hear it click. z Read measured value at the intersection (arrow) of the indicator arm and scale. +50 450 −50 N Note different units on the scale. 1 z If the nominal value is not reached, the tensioning process must be repeated.
PAGE 223
D 2011 w TD 2011 w, TCD 2011 w Other components W 12-02-01 – Version with V-belt tensioning pulley 1 z Mount V-belt (1). z Swing V-belt tensioning pulley (2) in the direction of the arrow. 3 z Fasten screws (3). 6 2 © 46986-1 z Press clamping strap (1) in direction of arrow with a suitable tool. 1 © 46996-0 z Mount V-belt tension measuring device on V-belt. The V-belt must be between the guides (arrow).
PAGE 224
Other components W 12-02-01 D 2011 w TD 2011 w, TCD 2011 w z Press the V-belt measuring device against the V-belt with the button (1) until you hear it click. z Read measured value at the intersection (arrow) of the indicator arm and scale. +50 450 −50 N 1 Note different units on the scale. z If the nominal value is not reached, the tensioning process must be repeated. 6 © 46998-0 z Tighten screws (1).
PAGE 225
D 2011 w TD 2011 w, TCD 2011 w Other components W 12-02-01 Technical Data Testing and setting data ID no. Name Additional information P12 11 V-belt tension, individual V-belts AVX 10 First assembly P12 21 V-belt tension, individual V-belts AVX 10 Check after 15 minutes running under load Value +50 450 −50 N +20 300 −20 N Tightening specifications ID no.
PAGE 227
D 2011 w TD 2011 w, TCD 2011 w Other components W 12-06-01 Removing and installing the flywheel Commercial available tools: – Self-made mandrin guide – Rotation angle disc . . . . . . . . . . . . . 8190 6 Removing the flywheel z Block flywheel with suitable tool. z Unscrew all screws (1). z Screw two long screws into the threaded bores. To improve the removal and installation of the flywheel. 1 z Remove flywheel. © 47216-0 z Visually inspect the components.
PAGE 228
Other components W 12-06-01 D 2011 w TD 2011 w, TCD 2011 w Installing the flywheel z Screw two long screws into the threaded bores. To improve the removal and installation of the flywheel. 1 z Insert self-made mandrin guide (1). For example a pin bolt. z Mount flywheel. The bores in the flywheel must match the threaded bores in the crankshaft flange. 6 © 47460-0 z Turn in new screws (1). Attention! Renew screws every time they are loosened. z Remove self-made mandrin guide.
PAGE 229
D 2011 w TD 2011 w, TCD 2011 w Other components W 12-06-01 Technical Data Tightening specifications ID no. Name Screw type A12 001 Flywheel on crankshaft A12 001 Flywheel on crankshaft A12 001 Flywheel on crankshaft Notes / Remark Stage 1: Use new screws Stage 2: Stage 3: Value 30 Nm 60° 30° For the tightening procedure according to torque using a torque wrench, a maximum variation of the tightening torque of +/- 10% is permissible.
PAGE 231
D 2011 w TD 2011 w, TCD 2011 w Other components W 12-08-02 Removing and installing the hydraulic pump Commercial available tools – Graphite grease G 500 6 Removing the hydraulic pump z Remove the hydraulic pipes. z Press in stoppers. z Unscrew screws (1). z Remove hydraulic pump (2). 1 z Remove coupling sleeve. 2 © 39090-2 z Pull off the collars (1). z Clean coupling sleeve (2). z Check components for visible signs of wear.
PAGE 232
Other components W 12-08-02 D 2011 w TD 2011 w, TCD 2011 w Installing hydraulic pump z Pull collar (1) onto coupling sleeve (3). 3 z Align cutting on the toothing of the coupling sleeve. z Pull collar (2) onto coupling sleeve (3). z Align cutting on the toothing of the coupling sleeve. z Grease inner toothing of the coupling sleeve. 2 1 6 © 39092-2 z Grease gear shaft (1). z Push on coupling sleeve (2). Note installation position. 2 Toothing of the coupling sleeve must engage with the gear shaft.
PAGE 233
D 2011 w TD 2011 w, TCD 2011 w Other components W 12-08-02 z Insert hydraulic pump (1) and coupling sleeve. Toothing of the coupling sleeve must engage with the gear shaft. z Tighten screws (2). 57 Nm 2 z Pull out stoppers. z Insert hydraulic pipes.
PAGE 234
Other components W 12-08-02 D 2011 w TD 2011 w, TCD 2011 w Technical Data Tightening specifications ID no. Name Hydraulic pump on hydraulic pump A12 051 console Screw type Notes / Remark Value 57 Nm For the tightening procedure according to torque using a torque wrench, a maximum variation of the tightening torque of +/- 10% is permissible.
PAGE 235
D 2011 w TD 2011 w, TCD 2011 w Electrical system W 13-02-03 Removing and installing the generator Commercial available tools – W 12-02-01 6 Removing the generator z Disconnect the battery's negative terminal. z Remove cable from generator. 1 Note assignment! - (1) = terminal W - (2) = terminal D+ - (3) = terminal B+ z Remove V-belt. W 12-02-01 2 3 © 47600-0 z Loosen screw (1). z Unscrew nut (2). z Hold screw (3). 2 z Remove protective plate (4). 1 z Remove protective plate (5).
PAGE 236
Electrical system W 13-02-03 D 2011 w TD 2011 w, TCD 2011 w z Unscrew screw (1). z Remove generator. 1 6 © 47602-0 Installing the generator z Mount generator. z Fasten screw (1). 1 © 47602-0 z Mount generator. z Insert screw (1). z Mount protective plate (2). 4 z Mount protective plate (3). z Screw on nut (4).
PAGE 237
D 2011 w TD 2011 w, TCD 2011 w Electrical system W 13-02-03 z Remove cable from generator. Note assignment! - (1) = terminal W 1 - (2) = terminal D+ - (3) = terminal B+ – (Position 2) 3.5 Nm – (Position 3) 6.5 Nm 2 z Install V-belt. W 12-02-01 z Connect the battery's negative terminal.
PAGE 238
Electrical system W 13-02-03 D 2011 w TD 2011 w, TCD 2011 w Technical Data Tightening specifications ID no. Name Charging current cable to generator A13 081 B+ A13 082 Cable G1.D+ to generator Screw type Notes / Remark Value 6.5 Nm M5 3.5 Nm For the tightening procedure according to torque using a torque wrench, a maximum variation of the tightening torque of +/- 10% is permissible.
PAGE 239
D 2011 w TD 2011 w, TCD 2011 w Electrical system W 13-03-02 Removing and installing the starter Commercial available tools 6 Removing the starter – TD 2011 w, TCD 2011 w 1 z Disconnect the battery's negative terminal. z Disconnect cables. z Unscrew screws (1). z Remove shielding plate (2). 2 © 47578-0 z Unscrew screws (1). z Remove starter.
PAGE 240
Electrical system W 13-03-02 D 2011 w TD 2011 w, TCD 2011 w z Visually inspect the components. 6 © 47476-0 Installing the starter z Insert starter. z Tighten screws (1). 43.5 Nm 1 1 © 47579-0 z Mount shielding plate (1). z Tighten screws (2). 2 Make sure that the installation site of the rubber pad (3) is in perfect condition. z Tighten screws (2). 8.5 Nm z Connect cables. – see Technical Circular 0199-44-1163 z Connect the battery's negative terminal.
PAGE 241
D 2011 w TD 2011 w, TCD 2011 w Electrical system W 13-03-02 Technical Data Tightening specifications ID no. Name A13 001 Starter on crankcase A13 009 Shield on crankcase Screw type M6x14-8.8 Notes / Remark Value 43.5 Nm 8.5 Nm For the tightening procedure according to torque using a torque wrench, a maximum variation of the tightening torque of +/- 10% is permissible.
PAGE 243
D 2011 w TD 2011 w, TCD 2011 w Electrical system W 13-06-01 Removing and installing the heating plugs Commercial available tools Special tools: – Assembly tool . . . . . . . . . . . . . . . 120440 6 Removing the glow plugs z Disconnect the battery. z Disconnect cables from heating plugs. z Unscrew heating plugs (1) with assembly tool. 1 © 46969-0 z Visually inspect the component.
PAGE 244
Electrical system W 13-06-01 D 2011 w TD 2011 w, TCD 2011 w Installing the glow plugs z Screw in heating plug (1). z Tighten heating plug (1) with assembly tool. 21 Nm z Connect cables to heating plugs. z Connect the battery.
PAGE 245
D 2011 w TD 2011 w, TCD 2011 w Electrical system W 13-06-01 Technical Data Tightening specifications ID no. Name A13 032 Heating plug on cylinder head Screw type Notes / Remark Value 21 Nm For the tightening procedure according to torque using a torque wrench, a maximum variation of the tightening torque of +/- 10% is permissible.
PAGE 247
D 2011 w TD 2011 w, TCD 2011 w Electrical system W 13-06-02 Removing and installing the glow plug Commercial available tools 6 Removing the glow plug z Disconnect cable connections. z Unscrew glow plug (1). z Remove sealing ring. 1 © 47477-0 z Visually inspect the components.
PAGE 248
Electrical system W 13-06-02 D 2011 w TD 2011 w, TCD 2011 w Installing the glow plug z Insert new sealing ring. z Insert glow plug (1). 1 6 © 47479-0 z Tighten glow plug (1). 60 Nm z Connect cable.
PAGE 249
D 2011 w TD 2011 w, TCD 2011 w Electrical system W 13-06-02 Technical Data Tightening specifications ID no. Name Glow plug in charge air line / intake A13 031 pipe A13 034 Cable connection to glow plug Screw type Notes / Remark Value 60 Nm 4 Nm For the tightening procedure according to torque using a torque wrench, a maximum variation of the tightening torque of +/- 10% is permissible.
PAGE 252
D 2011 w TD 2011 w, TCD 2011 w Standard tools Orders The tools can be ordered directly, stating the order number, from: WILBAER Wilhelm Bäcker GmbH & Co.KG Postfach 14 05 80 42826 Remscheid Germany Tel.: +49 (0) 2191 9339-0 Fax: +49 (0) 2191 9339-200 E-mail: info@wilbaer.de Web: http://www.deutz-tools.
PAGE 253
D 2011 w TD 2011 w, TCD 2011 w Standard tools 8005 Compression pressure tester for diesel engines 10 - 40 bar Checking compression pressure © 35410-3 7 8011 Hose clip pliers Loosen and fasten hose clips e. g.
PAGE 254
D 2011 w TD 2011 w, TCD 2011 w Standard tools 8024 Assembly pliers Removing valve shaft seals © 37509-2 7 8027 Plier insert Removing and installing the lifting magnet © 39531-1 8115 V-belt tension measuring device 150 to 600 N Check V-belt tension © 35416-3 © 12/2008 4/8 19492-001
PAGE 255
D 2011 w TD 2011 w, TCD 2011 w Standard tools 8116 Socket wrench insert Torx - E18 © 35415-1 7 8167 Cleaning brush Cleaning exhaust channels © 46283-0 8189 Torx tool set Contents of case: - Double-ended ring spanner E6/E8 - Double-ended ring spanner E10/E12 Socket wrench insert E8 and E10 (1/4 inch) - Socket wrench insert E10 and E12 (3/8 inch) - Socket wrench insert E18 (1/2 inch) © 39432-1 © 12/2008 5/8 19492-001
PAGE 256
D 2011 w TD 2011 w, TCD 2011 w Standard tools 8190 Rotation angle disc with magnet (e. g.
PAGE 260
D 2011 w TD 2011 w, TCD 2011 w Special tools Orders The tools can be ordered directly, stating the order number, from: WILBAER Wilhelm Bäcker GmbH & Co.KG Postfach 14 05 80 42826 Remscheid Germany Tel.: +49 (0) 2191 9339-0 Fax: +49 (0) 2191 9339-200 E-mail: info@wilbaer.de Web: http://www.deutz-tools.
PAGE 261
D 2011 w TD 2011 w, TCD 2011 w Special tools 100120 Connector (in conjunction with compression pressure tester 8005) © 39400-1 100400 Dial gauge with fixing wheel Measuring range 0 - 10 mm / 0.01 mm 8 © 35424-1 100410 Digital gauge Measuring range 0 - 30 mm / 0.
PAGE 262
D 2011 w TD 2011 w, TCD 2011 w Special tools 100750 Measuring device Measuring bar with two shims (in conjunction with 100400 and 100410) Checking valve lag dimension Checking piston projection © 39402-2 8 110090 Puller (in connection with sliding hammer 150800) Removing fuel injector © 35433-2 110901 Disassembly tool (part of assembly case 110900) Removing and installing the O-rings © 45950-1 © 12/2008 4/8 19496-001
PAGE 263
D 2011 w TD 2011 w, TCD 2011 w Special tools 120440 Assembly tool Removing and installing the glow plugs © 40333-1 150180 Holder (in conjunction with measuring device 100750) Measure piston overhand on recess cylinder head 8 © 43181-0 150800 Slide hammer Removing fuel injector © 35449-2 © 12/2008 5/8 19496-001
PAGE 264
D 2011 w TD 2011 w, TCD 2011 w Special tools 170050 Special wrench Unscrewing the filter cartridges © 37629-2 8 170160 Stoppers/caps 1 set of differently-sized stoppers and caps Sealing openings on the fuel system © 43663-0 6067 Assembly block Engine clamping, one-sided © 39424-1 © 12/2008 6/8 19496-001
PAGE 265
D 2011 w TD 2011 w, TCD 2011 w Special tools 6067/114 Supporting bracket (in conjunction with assembly block 6067) Engine clamping, one-sided © 39369-1 6067/115 Clamping bracket (in conjunction with assembly block 6067) Engine clamping, one-sided 8 © 39425-1 © 12/2008 7/8 19496-001