You are on page 1of 344

Workshop Manual

Competence level 3

TD/TCD 2012 2V
Mechanical Injection

t
no
is
rm
fo
d.

ic
te

t. n
ec

en t r o
ot

m ec
pr

ee e l
ht

gr o r
ig

0312 3822 en
ra d
yr

io t e
op

pr r i n
sc

ur r p
ti

t o he
en

ou e i t
m
cu

ith i n
do

w n
ed t i o
is
Th

w u
lo i b
al t r
i s
D

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.

Regarding copyright questions and licensing agreements
please contact : VS-DL, Mr. Lippke
Phone.: + 49 (0) 221 822-2599
E-Mail: lippke.d@deutz.com
DEUTZ AG
Informations Systeme Vertrieb u. Service
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

Printed in Germany
All rights reserved
1st Edition © 02/2011
The engine company. Order No. 0312 3822 en

TD 2012 2V
TCD 2012 2V Table of contents

1 Foreword

2 General

3 User notes
3.1 General
3.2 Specifications
3.3 Operating manual and workshop manual
3.4 Job cards
3.5 Explanation of symbols

5 Job card overview
5.1 Sorted alphabetically
5.2 Sorted numerically
5.3 Job card references

6 Job cards

7 Commercial tools

8 Special tools

© 11/2006 1/2 13962-001

TD 2012 2V
Table of contents TCD 2012 2V

© 11/2006 2/2 13962-001

DEUTZ engines Foreword

1

1 Foreword

© 05/2005 1/4 13963-001

Foreword DEUTZ engines

1

© 05/2005 2/4 13963-001

The manufacturer will not a wide range of applications. z The engines made by DEUTZ are developed for sidered improper use. retain the for the intended purpose. repaired by persons who are familiar with this z We have done our best to highlight the differenc- and are aware of the risks involved. and repair and that they have understood the contents. main- z Make sure that this documentation is available to tenance and repair instructions relevant to your everyone involved in the operation. ments are met. Unauthorised mod- z This engine is built exclusively for purpose ac. elastic re- taining rings etc. z Maximum economy. A wide range of var- be liable for damages resulting from this. described in this documentation are installed in The engine may only be used. You will avoid accidents. Failure to observe equipment manufacturer (use for the intended this will void the warranty! purpose). es so that you can easily find the operating. z Engine parts such as springs. Only parts released by 1 manufacturer's warranty and possess a fully the manufacturer for the respective purpose may functional and ready to operate engine. z The pertinent rules for the prevention of acci- dents and other generally recognised health and We are at your service for any questions you may safety regulations must be observed. z Repair of the engine must correspond to its use mentation. z The engine is equipped according to the installa- servance of the operating. be used for conversion work. z Prerequisite for proper maintenance and repair is the availability of all the necessary equipment.e. tion case. maintenance and re. The iants ensures that the respective special require- user bears the sole risk. Your DEUTZ AG © 05/2005 3/4 13963-001 . maintenance engine. pose an increased risk of injury when handled incorrectly. maintained and your engine necessarily. clamps. ifications to the engine exclude manufacturer lia- cording to the scope of delivery . Any use above and beyond this is con. i. z Use for the intended purpose also includes ob. DEUTZ engines Foreword z Read and observe the information in this docu. conventional and special tools and their perfect condition. have in this matter.defined by the bility for resulting damages. z 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. not all the parts and components pair instructions specified by the manufacturer. reliability and long life is only guaranteed when using DEUTZ original parts.

Foreword DEUTZ engines 1 © 05/2005 4/4 13963-001 .

DEUTZ engines General 2 2 General © 11/2005 1/4 13964-001 .

General DEUTZ engines 2 © 11/2005 2/4 13964-001 .

The profound expertise gained through this. Maintenance and care are the only way the engine can satisfy the demands you make on it. It goes without saying that the high environmental protection requirements are also met. © 11/2005 3/4 13964-001 . Compli- ance with the prescribed maintenance times and the careful execution of maintenance and care work are therefore essential. high reliability 2 and low fuel consumption. must be particular- ly heeded. Please consult one of our service representatives responsible for operating faults and spare parts questions. attests to the fact that our engines possess all the qualities of long life. Difficult operating conditions. DEUTZ engines General DEUTZ engines are the product of years of re- search and development. in combination with high de- mands on quality. Our trained specialist personnel ensures fast and professional repairs using original DEUTZ spare parts in the event of damage. deviating from normal operation. Original spare parts from DEUTZ AG are always manufactured according to the state of the art.

General DEUTZ engines 2 © 11/2005 4/4 13964-001 .

DEUTZ engines User notes 3 3 User notes © 12/2005 1/8 13965-001 .

User notes DEUTZ engines 3 © 12/2005 2/8 13965-001 .

gine is running. Unauthorised persons are prohibited access to the machine room. Make sure no-one is standing in the danger area. © 12/2005 3/8 13965-001 . and are identified tion devices which are removed during maintenance in the job description. These are available from tions and parts due to further developments. illustra- cidents must be observed. tain the engine.2. – Do not work on the fuel system when the en- nical documentation on the execution of mainte. – Only store inflammable materials in the ma- chine room if they are essential for operation of the system. Reference is made in the workshop manual job cards to the regulations in chapter 3. DEUTZ engines User notes 3. Safety and protec- ing on the work being carried out. operating 3 manual and in the workshop manual must be carried mode and the operating and auxiliary materials be- out on schedule and completely. – After all work on the fuel system. The legally prescribed rules for the prevention of ac- There may be deviations in the descriptions.1 General 3. of the operation manual. These must – Wear close-fitting clothing and ear protectors be read before working on the engine and must be in the machine room when the engine is in op- strictly followed. it must be bleeded . z for the engine room: – Ensure adequate ventilation (do not cover air shafts). Check the filling and readiness for opera- tion regularly. The maintenance intervals and the work to be per. – Cleaning. The fuel system is under high nance work.2 Specifications The documentation of the workshop manual has 3. The maintenance ing used.2 Fuel system“. pressure . – Injection lines and high pressure pipes must not be deformed.2. maintenance and repair work may only be performed with the engine at a stand- still and secured against starting. Among other things it generally applies that: Caution! z for the personnel: The rules for the prevention of accidents and the safety regulations must be observed during mainte. professional associations or from dealers. – Only briefed personnel may operate or main- nance work. eration. chapter "6.danger of death. maintenance and repairs on the engine: – Wait 30 seconds after switching off the engine before working on the fuel sytem. These The maintenance work described in the operation are dependent on the application site. – Only start the engine when all the protective devices have been fitted.1 Accident prevention and safety regu- been created based on the engine available at the lations time of going to press. – Go to the workshop immediately in case of leaks in the fuel system. work must be replaced again afterwards. z for operation. – Smoking and naked flames are prohibited in the machine room. – Only deploy trained personnel to do repairs formed are specified in the maintenance schedule and maintenance work. The job cards contain tech. personnel must have the necessary technical Special protection measures are specified depend- knowledge to perform the work.see the operation manual. – Provide first aid kit and suitable fire extinguish- ers.

the workshop personnel fective hydraulic components on the Common should avoid the immediate danger zone or Rail System it is recommended to partition off a wear suitable protective clothing (such as pro. gines. from assembly work) with an industrial vacuum z Clean the whole engine and engine room with the cleaner or other suction device. Only suction may system closed before starting work on the fuel be used in assembly work on the open fuel sys- system. z Air currents which kick up dust. first cover up the control z Do not use used cleaning fluid or test fluid for unit. © 12/2005 4/8 13965-001 . tem. This must tective glasses) when performing tests on the be separate from other areas in which general running engine and during the first trial run. Notes and measures to be observed before z Only lint-free cleaning cloths may be used for starting work on the fuel system work on the fuel system. Clean the workshop floor regu- – Also carefully check all high pressure compo- larly. z Only work in clean overalls. ventilation systems and heating – Do not work near to sparks and flames. attention must be paid to cleanliness when working Notes and measures to be observed during work on the fuel system due to the high precision technol. running engine. z The fuel system must be closed. User notes DEUTZ engines – Damaged injection lines and high-pressure z Remove loose parts (for example paint chips pipes must be renewed. on the fuel system or with the fuel system open. fore work. Only use tools without damage to the DEUTZ engines consists of high-precision compo. z Regular cleaning of the workshop area is manda- tory. the cable plugs. – Always stay out of range of a fuel jet. dirt could be loosened (for example the bottom 3. Make a visual z Remove loose parts (for example paint chips inspection for leaks / damage to the fuel system. mon Rail System z Working materials and tools must be cleaned be- The DEUTZ Common Rail system used in the fore work. fans should be minimised.2 Cleanliness instructions and meas. Wear suitable protective clothing (for example protective glasses). plated. Only use tools without damage to the z Blowing (dry) with compressed air is only permis. Only suction may must never be connected when the engine is be used in assembly work on the open fuel sys- running. as it could cause severe injury. the open fuel system. such as those Leaks are a potential source of danger for caused by brake repairs or the starting of en- workshop personnel. Also. tem. No brake or performance test benches may nents visually before performing tests on the be kept or operated in the same room. vehicle repairs such as brake repairs are carried out. nections and the generator. part of the tipped driver cab) must be covered ures for handling the DEUTZ Com. Great plated. – Do not place hands near to a leak in the high z Only work on the fuel system in a clean environ- 3 pressure fuel system.2. cleaning. z Electrical plug connections must be plugged z Work on removed components may only be per- when spraying. z When using a steam jet. all other electrical plug con. from assembly work) with an industrial vacuum – Injection lines and high pressure fuel lines cleaner or other suction device. ogy. z The engine must be dry when you start working z Working materials and tools must be cleaned be- on the fuel system. should be avoided. ment (no dust. separate workshop area in the factory. the steam jet z Compressed air must not be used for cleaning on may not be pointed directly at them. – Never disconnect an injector when the engine z Areas of the engine room from which particles of is running. – Even if no leaks are discernible on the high z For work such as removal and installation on de- pressure fuel system. z No general machine tools may be operated in this room. chrome plating or tools which are not chrome- sible with the fuel system closed. Draughts. Avoid draughts (dust). no grinding or welding). formed at a suitably equipped workbench. – Smoking is strictly prohibited when working on the fuel system. with fresh clean film. chrome plating or tools which are not chrome- nents which are exposed to extreme stress.

seal- able bags or . z The workshop floor is sealed or tiled. lint-free cloths. z Store stoppers/caps free from dust and dirt in the original packaging and dispose of after using once. general machine tools.2. 3 must be closed immediately with suitable stop. transported and disposed of according to regula- z Removed parts may only be rubbed down with tions. parts / operating materials. Notes and measures for the vehicle workshop area z For work such as removal and installation on de- fective hydraulic components on the Common Rail System it is recommended to partition off a separate workshop area in the factory. The re- materials which can leave behind particles or fi. wood.in the packaging of the new parts. serve on his own responsibility. and directives which the system operator must ob- diately before installing. z No welding gear. z Only remove new parts from the original packag- ing just before installation.3 Disposal regulations The work described in the operation manual and workshop manual necessitates renewal of parts and © 12/2005 5/8 13965-001 . grinders. z Working materials and tools must be cleaned be- fore work. z Regular cleaning of the workshop area is manda- tory. clean. z Clean the removal and installation tools regularly and keep them in a closed tool cabinet. z Removed components must be kept in new. DEUTZ engines User notes z When removing and installing components. This must be separate from other areas in which general vehicle repairs such as brake repairs are carried out. 3. Draughts. newed parts / operating materials must be stored. The owner himself is responsible for this. bres (cardboard. Only use tools without damage to the chrome plating or tools which are not chrome- plated.if available . erned by regional. Notes and measures for workbench and tools in the vehicle hall z A special workbench must be set up for work on removed components. No dirt particles may be Disposal includes recycling and the scrapping of rubbed into the components. z Always use the original packaging of the new part to send back the removed components. national and international laws z The stoppers/caps may only be removed imme. cloths) may be used. z Remove loose parts (for example paint chips from assembly work) with an industrial vacuum cleaner or other suction device. no operating materials among other things. Details of disposal and their monitoring are gov- pers/caps. ventilation systems and heating fans should be minimised. brakes or performance test benches may be operated in this room. although recycling has z Openings on the components and on the engine priority.

.. Electrical system z W 02-04-01: Component grouping z W 02-04-01: Consecutive number © 12/2005 6/8 13965-001 .. Workshop manual 10. General / interdisciplinary activities pecially for the safety regulations.. Faults. 3. causes and remedies below: 8. Drive system fied technicians are required. The individual parts of this pattern are explained 7.... Engine description cial conditions to perform these work procedures. – 01 . Fuel system – 08 . The workshop must satisfy spe- 2... The "I" job card additionally documents the appro- It contains the following chapters: priate work procedures for repairing the engine and/ 1. The necessary tools and special tools are also specified in the "W" job The operation manual contains a general descrip- 3 tion and instructions for all other maintenance work.. Cylinder head nents for which more effort and appropriately quali. The workshop manual describes repairs to the engine and compo.. 4.3 Operation manual and workshop 3. the into "W" and "I" job cards... General or its components.. User notes DEUTZ engines 3. Maintenance The job card numbers follow the pattern W 02-04- 6... Speed governing – 06 . engine and/or its components... Lube oil system – 09 . Engine conservation z W 02-04-01: Documentation type 9. Other components – 13 ..Service – I .4 Job cards manual The job cards are divided in the workshop manual To structure the information to suit the user... Monitoring system – 12 . Care and maintenance work 01.. Compressed air system – 11 ... for example.... Contents. – 02 .. Cooling system – 10 .. – 03 .. Technical data – W. This applies es- – 00 .. Engine control system – 05 ... service documentation is divided into operation The "W" job card documents standard repairs on the manual and workshop manual.4. card. Exhaust system / Charging – 07 . Repair instructions The workshop manual assumes knowledge of the z W 02-04-01: Maintenance group contents of the operation manual..1 Numbering of job cards 5. Crankcase – 04 . Operating media 3.. Operation Special tools and machine tools must be available..

Caution! 3 5 16 Danger to the component/engine.Conventional tools © 12/2005 7/8 13965-001 . No potential danger for man 13 or machine. 15.4. Title of job card Test and setting data The necessary values are specified here.Date of issue of job card Tightening specification The necessary values are specified here. DEUTZ internal creation number For example: ID no. Engine type (e. a cross re- 13. oils.Note If several values are necessary.Page number 11. A01 001 = cylinder head screws 16. P01 61 = valve clearance. environmental 8 protection etc. Reference to other job cards If several values are necessary. DEUTZ engines User notes 3.Work sequence cations table. Tool Conventional and special tools required for 12 the work.Special tools. Graphic or photo lues table. work process. 15 6 7 Must be observed! 14 Note General notes on assembly. 5. sealants) 11 10 9 References to important documents or job cards for the 1. 9.5 Explanation of symbols Danger! 1 2 3 of death or to health.g. 8 Auxiliary materials Working materials required in addition to the tools for performing the work (e. 12.2 Structure of a job card 3. DEUTZ AG. auxiliary materials For example: ID no. Chapter ference is given to the Test and Setting Va- 8. Must be observed! For example: The incorrect use or conver- sion of the turbocharger can lead to serious Triebwerk W 02-04-01 4 injury. greases. Maintenance group to a document or a job card within the work 4. Non- 6 compliance can lead to destruction of the component/engine. TCD 2013 4V) Reference 3. 6. Job card number or topic process.Danger / Important ference is given to the Tightening Specifi- 14.g. publisher of service documentation For example: Job card W 04-05-05 2. inlet 10. a cross re- 7. adhesives.

User notes DEUTZ engines 3 © 12/2005 8/8 13965-001 .

1 Sorted alphabetically © 11/2005 1/20 OBJ_DOKU-13967-001.fm . TD 2012 2V Job card overview TCD 2012 2V Sorted alphabetically 5 5 Job card overview 5.

fm . Job card overview TD 2012 2V Sorted alphabetically TCD 2012 2V 5 © 11/2005 2/20 OBJ_DOKU-13967-001.

assembling and checking the rocker W 01-02-06 Cylinder head arm and rocker arm bracket Dismantling and assembling the air bearing W 09-13-01 Cooling system Installing and removing turning gear W 04-06-03 Engine control Mounting engine on assembly block and demoun- W 00-05-01 General ting Removing and and installing the fuel filter console W 07-10-08 Fuel system Removing and installing coolant pump W 09-07-08 Cooling system Removing and installing temperature transmitter W 09-12-01 Cooling system Removing and installing the air bearing W 09-13-04 Cooling system Removing and installing the camshaft W 04-05-05 Engine control Removing and installing the charge air line W 06-07-03 Exhaust system / Charging Removing and installing the connection housing W 03-09-04 Crankcase Removing and installing the crankcase bleeding W 03-01-11 Crankcase Removing and installing the crankshaft W 02-04-01 Drive system © 11/2005 3/20 OBJ_DOKU-13967-001. TD 2012 2V Job card overview TCD 2012 2V Sorted alphabetically Activity Job card Maintenance group Checking axial backlash of crankshaft (crankshaft W 02-01-04 Drive system removed) Checking fuel injectors W 07-07-05 Fuel system Checking piston overhang W 01-04-09 Cylinder head Checking the camshaft W 04-05-06 Engine control Checking the compression pressure W 00-02-06 General Checking the con rod W 02-03-01 Drive system 5 Checking the crankshaft W 02-01-07 Drive system Checking the cylinders W 03-03-01 Crankcase Checking the piston W 02-09-07 Drive system Checking the piston rings and piston ring grooves W 02-10-03 Drive system Checking the thermostat (in the removed state) W 09-08-01 Cooling system Checking the valve guide W 01-06-03 Cylinder head Checking the valve lag W 01-07-08 Cylinder head Checking the valves W 01-05-04 Cylinder head Determining the installation dimension of the injec- W 07-06-04 Fuel system tion pump (engine with injection adjuster) Determining the installation dimension of the injec- W 07-06-04 Fuel system tion pump (engine with injection adjuster) Determining the thickness of the shim (engine with W 07-06-03 Fuel system injection adjuster) Determining the thickness of the shim (engine wit- W 07-06-03 Fuel system hout injection adjuster) Disassembling.fm .

checking the mass com- W 02-08-01 Drive system pensation shafts Removing and installing.fm . testing camshaft bearing W 03-11-01 Crankcase Renewing the crankshaft sealing ring (flywheel side) W 02-02-02 Drive system Renewing the crankshaft sealing ring (opposite side W 02-02-04 Drive system to flywheel) © 11/2005 4/20 OBJ_DOKU-13967-001. checking and setting the W 05-04-14 Speed governing control linkage Removing and installing. Job card overview TD 2012 2V Sorted alphabetically TCD 2012 2V Activity Job card Maintenance group Removing and installing the cylinder head W 01-04-04 Cylinder head Removing and installing the engine shutdown W 11-00-03 Monitoring system Removing and installing the exhaust line W 06-01-05 Exhaust system / Charging Removing and installing the flywheel W 12-06-01 Other components Removing and installing the front cover (opposite W 03-08-01 Crankcase side to flywheel) Removing and installing the fuel injector pump W 07-04-01 Fuel system 5 Removing and installing the fuel injectors W 07-07-01 Fuel system Removing and installing the fuel supply pump W 07-11-01 Fuel system Removing and installing the gearcase cover W 04-04-09 Engine control Removing and installing the generator (V-belt drive) W 13-02-03 Electrical system Removing and installing the heating flange W 06-02-08 Exhaust system / Charging Removing and installing the lubricating oil pan W 08-04-07 Lube oil system (die-cast lubricating oil pan) Removing and installing the lubricating oil pan W 08-04-07 Lube oil system (metal lubricating oil pan) Removing and installing the oil cooler W 08-08-02 Lube oil system Removing and installing the oil cooler housing W 08-08-03 Lube oil system Removing and installing the oil pressure switch W 08-11-08 Lube oil system Removing and installing the oil suction pipe W 08-04-06 Lube oil system Removing and installing the piston and con rod W 02-09-03 Drive system Removing and installing the piston cooling nozzles W 02-15-01 Drive system Removing and installing the rocker arm and rocker W 01-02-02 Cylinder head arm bracket Removing and installing the speed governor W 05-05-01 Speed governing Removing and installing the starter W 13-03-02 Electrical system Removing and installing the thermostat W 09-08-02 Cooling system Removing and installing the turbocharger W 06-06-04 Exhaust system / Charging Removing and installing the valves W 01-05-01 Cylinder head Removing and installing the V-belt pulley W 12-01-04 Other components Removing and installing.

fm . TD 2012 2V Job card overview TCD 2012 2V Sorted alphabetically Activity Job card Maintenance group Renewing toothed starter flywheel ring W 12-06-03 Other components Setting valve clearance W 01-01-01 Cylinder head 5 © 11/2005 5/20 OBJ_DOKU-13967-001.

Job card overview TD 2012 2V Sorted alphabetically TCD 2012 2V 5 © 11/2005 6/20 OBJ_DOKU-13967-001.fm .

fm . TD 2012 2V Job card overview TCD 2012 2V Sorted numerically 5 5.2 Sorted numerically © 11/2005 7/20 OBJ_DOKU-13967-001.

fm . Job card overview TD 2012 2V Sorted numerically TCD 2012 2V 5 © 11/2005 8/20 OBJ_DOKU-13967-001.

testing camshaft bearing Crankcase W 04-04-09 Removing and installing the gearcase cover Engine control W 04-05-05 Removing and installing the camshaft Engine control W 04-05-06 Checking the camshaft Engine control W 04-06-03 Installing and removing turning gear Engine control © 11/2005 9/20 OBJ_DOKU-13967-001. assembling and checking the rocker W 01-02-06 Cylinder head arm and rocker arm bracket 5 W 01-04-04 Removing and installing the cylinder head Cylinder head W 01-04-09 Checking piston overhang Cylinder head W 01-05-01 Removing and installing the valves Cylinder head W 01-05-04 Checking the valves Cylinder head W 01-06-03 Checking the valve guide Cylinder head W 01-07-08 Checking the valve lag Cylinder head Checking axial backlash of crankshaft (crankshaft W 02-01-04 Drive system removed) W 02-01-07 Checking the crankshaft Drive system W 02-02-02 Renewing the crankshaft sealing ring (flywheel side) Drive system Renewing the crankshaft sealing ring (opposite side W 02-02-04 Drive system to flywheel) W 02-03-01 Checking the con rod Drive system W 02-04-01 Removing and installing the crankshaft Drive system Removing and installing.fm . TD 2012 2V Job card overview TCD 2012 2V Sorted numerically Job card Activity Maintenance group W 00-02-06 Checking the compression pressure General Mounting engine on assembly block and demoun- W 00-05-01 General ting W 01-01-01 Setting valve clearance Cylinder head Removing and installing the rocker arm and rocker W 01-02-02 Cylinder head arm bracket Disassembling. checking the mass com- W 02-08-01 Drive system pensation shafts W 02-09-03 Removing and installing the piston and con rod Drive system W 02-09-07 Checking the piston Drive system W 02-10-03 Checking the piston rings and piston ring grooves Drive system W 02-15-01 Removing and installing the piston cooling nozzles Drive system W 03-01-11 Removing and installing the crankcase bleeding Crankcase W 03-03-01 Checking the cylinders Crankcase Removing and installing the front cover (opposite W 03-08-01 Crankcase side to flywheel) W 03-09-04 Removing and installing the connection housing Crankcase W 03-11-01 Removing and installing.

checking and setting the W 05-04-14 Speed governing control linkage W 05-05-01 Removing and installing the speed governor Speed governing W 06-01-05 Removing and installing the exhaust line Exhaust system / Charging W 06-02-08 Removing and installing the heating flange Exhaust system / Charging W 06-06-04 Removing and installing the turbocharger Exhaust system / Charging W 06-07-03 Removing and installing the charge air line Exhaust system / Charging 5 W 07-04-01 Removing and installing the fuel injector pump Fuel system Determining the thickness of the shim (engine wit- W 07-06-03 Fuel system hout injection adjuster) Determining the thickness of the shim (engine with W 07-06-03 Fuel system injection adjuster) Determining the installation dimension of the injec- W 07-06-04 Fuel system tion pump (engine with injection adjuster) Determining the installation dimension of the injec- W 07-06-04 Fuel system tion pump (engine with injection adjuster) W 07-07-01 Removing and installing the fuel injectors Fuel system W 07-07-05 Checking fuel injectors Fuel system W 07-10-08 Removing and and installing the fuel filter console Fuel system W 07-11-01 Removing and installing the fuel supply pump Fuel system W 08-04-06 Removing and installing the oil suction pipe Lube oil system Removing and installing the lubricating oil pan W 08-04-07 Lube oil system (die-cast lubricating oil pan) Removing and installing the lubricating oil pan W 08-04-07 Lube oil system (metal lubricating oil pan) W 08-08-02 Removing and installing the oil cooler Lube oil system W 08-08-03 Removing and installing the oil cooler housing Lube oil system W 08-11-08 Removing and installing the oil pressure switch Lube oil system W 09-07-08 Removing and installing coolant pump Cooling system W 09-08-01 Checking the thermostat (in the removed state) Cooling system W 09-08-02 Removing and installing the thermostat Cooling system W 09-12-01 Removing and installing temperature transmitter Cooling system W 09-13-01 Dismantling and assembling the air bearing Cooling system W 09-13-04 Removing and installing the air bearing Cooling system W 11-00-03 Removing and installing the engine shutdown Monitoring system W 12-01-04 Removing and installing the V-belt pulley Other components W 12-06-01 Removing and installing the flywheel Other components W 12-06-03 Renewing toothed starter flywheel ring Other components © 11/2005 10/20 OBJ_DOKU-13967-001.fm . Job card overview TD 2012 2V Sorted numerically TCD 2012 2V Job card Activity Maintenance group Removing and installing.

fm . TD 2012 2V Job card overview TCD 2012 2V Sorted numerically Job card Activity Maintenance group W 13-02-03 Removing and installing the generator (V-belt drive) Electrical system W 13-03-02 Removing and installing the starter Electrical system 5 © 11/2005 11/20 OBJ_DOKU-13967-001.

fm . Job card overview TD 2012 2V Sorted numerically TCD 2012 2V 5 © 11/2005 12/20 OBJ_DOKU-13967-001.

3 Job card references © 11/2005 13/20 OBJ_DOKU-13967-001.fm . TD 2012 2V Job card overview TCD 2012 2V Job card references 5 5.

Job card overview TD 2012 2V Job card references TCD 2012 2V 5 © 11/2005 14/20 OBJ_DOKU-13967-001.fm .

TD 2012 2V Job card overview TCD 2012 2V Job card references 00 General Job card Activity and additional job cards necessary for its execution Checking the compression pressure W 00-02-06 W 01-01-01 W 07-07-01 Mounting engine on assembly block and demounting W 00-05-01 01 Cylinder head 5 Job card Activity and additional job cards necessary for its execution Setting valve clearance W 01-01-01 W 01-04-04 W 04-06-03 Removing and installing the rocker arm and rocker arm bracket W 01-02-02 W 01-01-01 W 01-04-04 Disassembling.fm . assembling and checking the rocker arm and rocker arm bracket W 01-02-06 W 01-02-02 Removing and installing the cylinder head W 01-04-04 W 01-01-01 W 01-02-02 W 01-04-09 W 06-01-05 W 06-07-03 W 07-07-01 W 09-13-04 Checking piston overhang W 01-04-09 W 01-04-04 W 04-06-03 Removing and installing the valves W 01-05-01 W 01-04-04 Checking the valves W 01-05-04 W 01-05-01 Checking the valve guide W 01-06-03 W 01-05-01 Checking the valve lag W 01-07-08 W 01-04-04 02 Drive system Job card Activity and additional job cards necessary for its execution Checking the axial clearance of the crankshaft W 02-01-04 W 02-04-01 W 03-08-01 W 04-04-09 Checking the crankshaft W 02-01-07 W 02-04-01 © 11/2005 15/20 OBJ_DOKU-13967-001.

testing camshaft bearing W 03-11-01 W 02-04-01 W 04-05-05 © 11/2005 16/20 OBJ_DOKU-13967-001.fm . Job card overview TD 2012 2V Job card references TCD 2012 2V 02 Drive system (continued) Job card Activity and additional job cards necessary for its execution Renewing the crankshaft sealing ring (flywheel side) W 02-02-02 W 12-06-01 Renewing the crankshaft sealing ring (opposite side to flywheel) W 02-02-04 W 12-01-04 Checking the con rod W 02-03-01 W 02-09-03 5 - Removing and installing the crankshaft W 02-04-01 W 02-01-07 W 02-09-03 W 03-08-01 W 04-04-09 Removing and installing. checking the mass compensation shafts W 02-08-01 W 04-04-09 Removing and installing the piston and con rod W 02-09-03 W 01-04-04 W 02-10-03 W 08-04-06 Checking the piston W 02-09-07 W 02-09-03 Checking the piston rings and piston ring grooves W 02-10-03 W 02-09-03 Removing and installing the piston cooling nozzles W 02-15-01 W 02-04-01 03 Crankcase Job card Activity and additional job cards necessary for its execution Removing and installing the crankcase bleeding W 03-01-11 Checking the cylinders W 03-03-01 W 02-09-03 Removing and installing the front cover (opposite side to flywheel) W 03-08-01 W 02-02-04 W 08-04-06 W 12-01-04 Removing and installing the connection housing W 03-09-04 Removing and installing.

fm . checking and setting the control linkage W 05-04-14 W 04-04-09 W 05-05-01 W 07-04-01 Removing and installing the speed governor W 05-05-01 06 Exhaust system / Charging Job card Activity and additional job cards necessary for its execution Removing and installing the exhaust line W 06-01-05 W 06-06-04 Removing and installing the heating flange W 06-02-08 Removing and installing the turbocharger W 06-06-04 Removing and installing the charge air line W 06-07-03 W 01-04-04 07 Fuel system Job card Activity and additional job cards necessary for its execution Removing and installing the fuel injector pump W 07-04-01 W 01-04-04 W 07-06-03 W 07-06-03 W 07-06-04 W 07-06-04 Determining the thickness of the shim (engine without injection adjuster) W 07-06-03 W 07-04-01 © 11/2005 17/20 OBJ_DOKU-13967-001. TD 2012 2V Job card overview TCD 2012 2V Job card references 04 Engine control Job card Activity and additional job cards necessary for its execution Removing and installing the gearcase cover W 04-04-09 W 02-02-02 W 03-09-04 W 05-05-01 W 08-04-07 W 12-06-01 W 13-03-02 Removing and installing the camshaft W 04-05-05 W 01-02-02 W 02-04-01 W 07-04-01 W 07-07-01 Checking the camshaft 5 W 04-05-06 W 04-05-05 Installing and removing turning gear W 04-06-03 05 Speed governing Job card Activity and additional job cards necessary for its execution Removing and installing.

fm . Job card overview TD 2012 2V Job card references TCD 2012 2V 07 Fuel system (continued) Job card Activity and additional job cards necessary for its execution Determining the thickness of the shim (engine with injection adjuster) W 07-06-03 W 07-04-01 Determining the installation dimension of the injection pump (engine with injection adjuster) W 07-06-04 W 07-04-01 Determining the installation dimension of the injection pump (engine with injection adjuster) W 07-06-04 W 07-04-01 5 Removing and installing fuel injectors W 07-07-01 W 01-04-04 W 07-07-05 Checking the fuel injector W 07-07-05 W 07-07-01 Removing and and installing the fuel filter console W 07-10-08 User notes Removing and installing the fuel supply pump (V-belt drive) W 07-11-01 User notes W 13-02-03 08 Lube oil system Job card Activity and additional job cards necessary for its execution Removing and installing the oil suction pipe W 08-04-06 W 08-04-07 Removing and installing the lubricating oil pan (die-cast lubricating oil pan) W 08-04-07 Removing and installing the lubricating oil pan (metal sheet lubricating oil pan) W 08-04-07 Removing and installing the oil cooler W 08-08-02 W 08-08-03 Removing and installing the oil cooler housing W 08-08-03 User notes Removing and installing the oil pressure switch W 08-11-08 User notes 09 Cooling system Job card Activity and additional job cards necessary for its execution Removing and installing the coolant pump (V-belt drive) W 09-07-08 W 07-11-01 W 09-13-04 © 11/2005 18/20 OBJ_DOKU-13967-001.

TD 2012 2V Job card overview TCD 2012 2V Job card references 09 Cooling system (continued) Job card Activity and additional job cards necessary for its execution Checking the thermostat (in the removed state) W 09-08-01 W 09-08-02 Removing and installing the thermostat W 09-08-02 Removing and installing the temperature transmitter W 09-12-01 Dismantling and assembling the air bearing 5 W 09-13-01 W 09-13-04 Removing and installing the air bearing W 09-13-04 11 Monitoring system Job card Activity and additional job cards necessary for its execution Removing and installing the engine shutdown W 11-00-03 12 Other components Job card Activity and additional job cards necessary for its execution Removing and installing the V-belt pulley W 12-01-04 W 04-06-03 W 13-02-03 Removing and installing flywheel W 12-06-01 Renewing toothed starter flywheel ring W 12-06-03 W 12-06-01 13 Electrical system Job card Activity and additional job cards necessary for its execution Removing and installing the generator W 13-02-03 Removing and installing the starter W 13-03-02 © 11/2005 19/20 OBJ_DOKU-13967-001.fm .

Job card overview TD 2012 2V Job card references TCD 2012 2V 5 © 11/2005 20/20 13967-001 .

DEUTZ engines Job cards 6 Job cards 6 © 11/2005 1/2 13968-001 .

Job cards DEUTZ engines 6 © 11/2005 2/2 13968-001 .

. 8005 – Torx tool set . . . . z Tighten screw (2).  W 01-01-01 z Removing fuel injectors. . . . . . . . z Insert connector (2). . . . . . . . 100190 6 Checking the compression pressure z Set valve clearance. .  16 Nm 2 1 © 46378-0 © 04/2007 1/4 13969-001 . . . . . . . 1 © 46377-1 z Mount clamping shoe (1). . 8189 Special tools: – Connector . . . . . . . . .  W 07-07-01 2 z Mount sealing ring (1). . . . . . . . . . . . . . . . . . . . . . TD 2012 2V General TCD 2012 2V W 00-02-06 Checking the compression pressure Commercial available tools: – W 01-01-01 – Compression pressure – W 07-07-01 tester. . .

engine installation site. If more than 15% deviation has been 1 determined. rement of all cylinders of an engine to each other. General TD 2012 2V W 00-02-06 TCD 2012 2V z Connect adapter (1) to connector.38 bar © 46308-0 The measured compression pressure depends on the starting speed during the measuring process and the altitude of the No. the cause should be determi. Therefore. limit Kompression in bar Compression value in bar values cannot be determined exactly. z Turn over engine with starter. The Pression en bar compression pressure measurement is Dat. _________ 10 15 20 25 30 35 40 only recommended as a reference measu- Zyl. 2 ned by disassembling the cylinder unit con. 3 cerned. 4 5 6 7 8 DBGM Made in Germany MOTOMETER © 33771-5 © 04/2007 2/4 13969-001 . 1 6 © 46379-0 z Connect compression pressure tester to connector.  30 .

z Install fuel injectors. z Remove clamping shoe (2). z Remove connector.  W 07-07-01 1 2 © 46378-1 © 04/2007 3/4 13969-001 . z Remove sealing ring. 1 6 © 46308-1 z Unscrew screw (1). TD 2012 2V General TCD 2012 2V W 00-02-06 z Remove the compression pressure tester and adapter (1).

General TD 2012 2V W 00-02-06 TCD 2012 2V 6 © 04/2007 4/4 13969-001 .

. . . . . TD 2012 2V General TCD 2012 2V W 00-05-01 Mounting engine on assembly block and demounting Commercial available tools: Different customer scopes are not taken – Lifting gear into account in the repair sequence shown – Suspension ropes here. accessories which deviate from the Special tools: standard equipment are not shown. . . .  70 Nm z Tighten screws (3) and lock nuts. . 6066 – Clamping bracket . z Insert engine in engine block. . . . . 6068 6 Mounting engine on assembly block z Hang the engine director onto the transport lashes (arrows) with support chain. . . . . . . . . . . . . . © 46446-0 z Mount clamping holder 6066/158-1 (1) on holder. . .6066/158 – Engine lifting device . . adap- ter plates . . . . . . . 3  90 Nm 1 3 2 © 46448-0 © 04/2007 1/4 13970-001 . . . . – Assembly block incl. . Remove all mounting feet. . . z Tighten screws (2) and lock nuts. – 4-cylinder  410 kg z Hang engine on workshop crane.

z Tighten screws (2). z Tighten screw (2).  70 Nm 2 z Tighten screws (3) and lock nuts.  70 Nm z Tighten screws (3) and lock nuts. General TD 2012 2V W 00-05-01 TCD 2012 2V z Mount clamping bracket 6066/158-2 (1) on holder.  90 Nm 3 1 3 © 46447-0 z Mount clamping holder 6066/158-4 (1) on crankcase.  70 Nm z Tighten screws (3) and lock nuts.  90 Nm 2 3 1 3 © 46450-0 © 04/2007 2/4 13970-001 . 1 2  90 Nm 3 3 6 © 46449-0 z Mount clamping bracket 6066/158-3 (1) on crank- case. z Tighten screws (2) and lock nuts.

1 1 6 © 46459-0 Demounting engine from assembly block z Hang the engine director onto the transport lashes (arrows) with support chain. z Unscrew screws (2). TD 2012 2V General TCD 2012 2V W 00-05-01 z Align engine on engine block. z Tighten all screws (1). z Remove clamping holder (1). – 4-cylinder  410 kg z Hang engine on workshop crane. 2 3 1 3 © 46450-0 © 04/2007 3/4 13970-001 . z Unhook the engine from the workshop crane. z Remove screws(3) and lock nuts. © 46446-0 z Loosen lock nuts.

1 3 © 46447-0 © 04/2007 4/4 13970-001 . z Remove clamping bracket (1). z Remove screws(3) and lock nuts. z Remove clamping holder (1). 3 z Unhook the engine from the workshop crane. General TD 2012 2V W 00-05-01 TCD 2012 2V z Loosen lock nuts. 2 Mount all mounting feet. z Remove screws(3) and lock nuts. z Remove clamping holder (1). 1 3 3 3 6 © 46449-1 z Loosen lock nuts. 3 1 3 3 © 46448-1 z Loosen lock nuts. z Remove screws(3) and lock nuts. z Set down engine. z Unscrew screw (2).

. . 8193 Special tools: – Turn-over gear . . . . . . . . 8196 – Screwdriver insert for slot. 8191 minutes before setting the valve clearance. . . 100320 6 Setting engine to valve overlap z Attach turning gear. . . .  W 01-04-04 z Turn crankshaft using the turning gear until the valve overlap of cylinder 1 is reached. . . . . . . . . . . . . . . . . . .  W 04-06-03 z Remove the cylinder head hood. . . . . © 46461-0 Arrangement of the inlet and exhaust val- ves. . . . . . . . . . IN = inlet valve EX = exhaust valve EX IN © 46381-0 © 04/2007 1/4 13971-001 . . . . . . Let the engine cool down for at least 30 ted screws. . . . . . . TD 2012 2V Cylinder head TCD 2012 2V W 01-01-01 Setting valve clearance Commercial available tools: – W 01-04-04 – Rotation angle disc . . . . . . . . . 8190 – W 04-06-03 – Open wrench size 13 . . . . . . – Screwdriver insert for Engine oil temperature < 80 °C hexagon socket head screws (5 mm) .

Do not rotate adjusting screw. Attention! Pay attention to versions of the adjusting screws (slotted. z Set the rotation angle disc in the direction of the ar- row to „0“. z Press in the adjusting screw (2) to the stop. Cylinder head TD 2012 2V W 01-01-01 TCD 2012 2V  4-cylinder Ignition sequence: 1-3-4-2 Valves Cylinders overlap 1 3 4 2 set to 4 2 1 3 Valve overlap means: The inlet valve starts opening. hexagonal 1 socket).exhaust valve closes. z Fix magnet of rotation angle disc on cylinder head. 6 © 46380-0 Setting the inlet valve clearance z Loosen lock nut (1). © 46382-0 z Set the rotation angle disc with a screwdriver insert at the adjusting screw. 2 The rocker arm must touch the thrust was- her of the spring cap (arrow). © 46462-0 © 04/2007 2/4 13971-001 . hexagonal.

TD 2012 2V Cylinder head TCD 2012 2V W 01-01-01 z Turn the adjusting screw in the direction of the arrow. z Press in the adjusting screw (2) to the stop. The rocker arm must touch the thrust was- her of the spring cap (arrow). 1 © 46464-0 Setting the exhaust valve clearance z Loosen lock nut (1).  20 Nm z Remove rotation angle disc. 2 1 © 46387-0 © 04/2007 3/4 13971-001 . – Inlet  75° 6 © 46463-0 z Hold adjusting screw. z Tighten lock nut (1) with open wrench.

 W 01-04-04 z Remove turning gear. – Outlet  120 ° © 46466-0 z Hold adjusting screw.  W 04-06-03 1 © 46467-0 © 04/2007 4/4 13971-001 . z Tighten lock nut (1) with open wrench. 6 © 46465-0 z Turn the adjusting screw in the direction of the arrow. z Mount cylinder head cover.  20 Nm z Remove rotation angle disc. Cylinder head TD 2012 2V W 01-01-01 TCD 2012 2V z Set the rotation angle disc on the adjusting screw with a screwdriver insert for slotted screws. z Fix magnet of rotation angle disc on cylinder head. z Set the rotation angle disc in the direction of the ar- row to „0“. Do not rotate adjusting screw.

Lay out components in the order in which they should be installed. . . . TD 2012 2V Cylinder head TCD 2012 2V W 01-02-02 Removing and installing the rocker arm and rocker arm bracket Commercial available tools: – W 01-01-01 – Pin wrench insert Torx E14 . . . . z Unscrew screw (2). . . 8190 6 Removing the rocker arm and rocker arm bracket z Remove the cylinder head hood.  W 01-04-04 2 z Unscrew the cylinder head screw (1) with the socket wrench insert. . . z Remove rocker arm bracket. . . Lay out components in the order in which they should be installed. . . . 1 © 46452-0 © 04/2007 1/4 13972-001 . 1 © 46451-2 z Remove push rods (1). . 8113 – W 01-04-04 – Rotation angle disc . . .

Note the assignment of the stop rods. Cylinder head TD 2012 2V W 01-02-02 TCD 2012 2V z Visually inspect the components. The ball heads (2) must be seated in the ladles of the stop rods . 1 © 46452-0 z Mount rocker arm bracket (1). The stop rod must be seated with the ball head in the ladle of the tappet. 1 2 © 46454-0 © 04/2007 2/4 13972-001 . 6 © 46453-0 Installing the rocker arm and rocker arm bracket z Insert stop rods (1).

– Pre-clamping value:  30 Nm Attention! Make sure that the stop rods are not under stress due to valve overlap when fastening the screw. z Turn in cylinder head screw (1). 3 times with written proof. © 46456-0 z Align rocker arm bracket symmetrically with the valve axles. © 46457-0 © 04/2007 3/4 13972-001 . otherwise renew every time they are loosened. 1 6 © 46455-0 Attention! Cylinder head screws can be used max. 1 z Lightly oil cylinder head screw (1). Do not tighten the screw. TD 2012 2V Cylinder head TCD 2012 2V W 01-02-02 z Fasten screw (1). z Tighten cylinder head screw with the socket wrench insert.

– Post-clamping value:  + 80 Nm + 90° z Set valve clearance.  21 Nm 1 6 © 46451-1 z Tighten cylinder head screw with the socket wrench insert.  W 01-01-01 © 46457-0 © 04/2007 4/4 13972-001 . Cylinder head TD 2012 2V W 01-02-02 TCD 2012 2V z Tighten screw (1).

. TD 2012 2V Cylinder head TCD 2012 2V W 01-02-06 Disassembling. . . . . . 100400 6 Disassembling the rocker arm bracket z Remove rocker arm and rocker arm bracket. . . . . . . © 46389-0 z Remove rocker arm. Lay out components in the order in which they should be installed. .  W 01-02-02 z Remove locking ring with locking ring pliers. . © 46390-0 © 04/2007 1/4 13973-001 . . . . assembling and checking the rocker arm and rocker arm bracket Commercial available tools: – W 01-02-02 – Internal measuring device – Micrometer gauge – Locking ring pliers Special tools: – Dial gauge.

02 −0 mm – Inlet +0.033  21. Attention! Pay attention to versions of the adjusting screws (slotted.033  21. Cylinder head TD 2012 2V W 01-02-06 TCD 2012 2V Checking the rocker arm z Measure rocker arm bore. Lay out components in the order in which they should be installed. z Check oil channels (arrows) for free passage.02 −0 mm When the wear limit is reached the rocker arm must be renewed. hexagonal socket). © 46392-0 © 04/2007 2/4 13973-001 . hexagonal. 6 © 39032-1 z Loosen lock nut (1). 2 1 © 46393-0 z Check components for visible signs of wear. – Outlet +0. z Unscrew adjusting screw (2).

z Loosen lock nuts (2). 3 © 46471-0 © 04/2007 3/4 13973-001 . © 46469-0 Assembling the rocker arm bracket z Lightly oil the rocker arm pin. 2 z Push rocker arm (1) onto rocker arm pin.052 mm When the wear limit is reached the rocker arm bracket must be replaced. 2 1 6 © 46468-0 Checking the rocker arm pin z Measure the diameter of journals with the microme- ter gauge. z Push rocker arm (2) onto rocker arm pin. Mount the rocker arm (2) on the inlet side. TD 2012 2V Cylinder head TCD 2012 2V W 01-02-06 z Screw in setting screw (1). +0  21 − 0. The rocker arm's sliding surface (3) must 1 face the threaded bore (arrow). Mount the rocker arm (1) on the outlet side.

z Install rocker arm and rocker arm bracket.  W 01-02-02 1 6 © 46453-1 © 04/2007 4/4 13973-001 . Cylinder head TD 2012 2V W 01-02-06 TCD 2012 2V z Insert new locking rings (1).

z Remove cylinder head cowling (2). 2 1 © 46471-1 z Cut through the gasket at the gates (1). . © 46587-0 © 04/2007 1/8 13974-001 . z Remove gasket. TD 2012 2V Cylinder head TCD 2012 2V W 01-04-04 Removing and installing cylinder head Commercial available tools: – W 01-01-01 – Pin wrench insert Torx E14 . . . . . . z Visually inspect the components. 8113 – W 01-02-02 – W 01-04-09 – W 06-01-05 – W 06-07-03 – W 07-07-01 – W 09-13-04 6 Removing cylinder head z Unscrew all screws (1).

 W 06-01-05 6 © 46590-0 z Removing fuel injectors. z Clean sealing surfaces.  W 09-13-04 z Remove the exhaust pipe. z Remove cylinder head. 1 © 46331-0 z Unscrew all screws (1) with the socket wrench insert.  W 06-07-03 2 z Unscrew screws (1).  W 01-02-02 z Remove the charge air pipe. z Remove holder (2).  W 07-07-01 z Remove rocker arm brackets. 1 © 46334-0 © 04/2007 2/8 13974-001 . 1 z Remove gasket. Cylinder head TD 2012 2V W 01-04-04 TCD 2012 2V z Remove the fan mounting.

7 mm cor- responds to cylinder head gasket with 3 holes (arrow).55 mm 1 0.66 .0. TD 2012 2V Cylinder head TCD 2012 2V W 01-04-04 Installing the cylinder head Measure the piston overhang on all pistons. © 44154-0 Make sure the clamping bushings (1) are in place. z Check piston overhang.33 . Select cylinder head gasket according to the largest piston projection measured.56 .76 mm 3 Example: Piston projection = 0. 1 © 46335-0 © 04/2007 3/8 13974-001 .65 mm 2 0.0.0.  W 01-04-09 6 © 42565-0 z Select cylinder head gasket according to the largest piston projection measured.  Piston projection Hole 0.

The sealing surfaces for the cylinder head gasket must be clean and free of oil. Label OBEN / TOP facing the cylinder head. © 46591-0 z Insert stop rods (1). 6 © 46336-0 z Fit cylinder head. Note the assignment of the stop rods. Cylinder head TD 2012 2V W 01-04-04 TCD 2012 2V z Fit a new cylinder head gasket. The stop rod must be seated with the ball head in the ladle of the tappet. 1 © 46452-0 © 04/2007 4/8 13974-001 .

1 2 6 © 46454-0 z Fasten screw (1). The ball heads (2) must be seated in the ladles of the stop rods . Do not tighten the screw. © 46456-0 © 04/2007 5/8 13974-001 . TD 2012 2V Cylinder head TCD 2012 2V W 01-04-04 z Mount rocker arm bracket (1). 1 z Lightly oil cylinder head screw (1). otherwise renew every time they are loosened. z Turn in cylinder head screw (1). 1 © 46455-0 Attention! Cylinder head screws can be used max. 3 times with written proof.

 21 Nm 1 © 46451-1 z Tighten all cylinder head screws according to the tightening sequence. Cylinder head TD 2012 2V W 01-04-04 TCD 2012 2V z Align rocker arm bracket symmetrically with the valve axles. z Tighten cylinder head screw with the socket wrench insert. – Post-clamping value:  30 Nm + 80 Nm + 90° Use socket wrench insert.  30 Nm Attention! Make sure that the stop rods are not under stress due to valve overlap when fastening the screw. 6 © 46457-0 z Tighten screw (1). 14 6 4 12 18 10 2 8 16 17 9 1 7 15 13 5 3 11 © 45131-0 © 04/2007 6/8 13974-001 .

Remove burr from cut surfaces. z Tighten screws (1). z Install the charge air pipe. z Cut through the new gasket at the gates (1).  W 09-13-04 © 46590-0 Installing cylinder head cover. © 46587-0 © 04/2007 7/8 13974-001 . TD 2012 2V Cylinder head TCD 2012 2V W 01-04-04 z Mount holder (2).  W 01-02-02 z Set valve clearance.  W 06-07-03 z Install rocker arm brackets. 2  W 01-01-01 z Install fuel injectors.  W 06-01-05 z Install fan mounting. 1  W 07-07-01 6 © 46331-0 z Install the exhaust pipe. Attention! Do not bend or deform metal beading gas- ket.

z Mount new gasket. Cylinder head TD 2012 2V W 01-04-04 TCD 2012 2V z Clean sealing surfaces. z Mount cylinder head cover. Ensure that the installation location is free from faults. © 46473-2 © 04/2007 8/8 13974-001 .  11 Nm 1 6 © 46474-2 Pay attention to perfect installation position (arrow). z Tighten all screws (1) alternately.

. . . . . . 100400 – Measuring device . . . TD 2012 2V Cylinder head TCD 2012 2V W 01-04-09 Checking piston overhang Commercial available tools – W 01-04-04 – W 04-06-03 Special tools: – Turn-over gear . . . . .  W 04-06-03 z Remove cylinder head. . . . . . . . . © 46333-0 © 04/2007 1/4 13976-001 . . . 100750 6 Checking piston overhang z Attach turning gear. 100330 – Dial gauge. . . . . . . . . .  W 01-04-04 © 46474-0 z Turn the crankshaft until the respective piston is just in front of the top dead centre (arrow). . . . . . . . . . .

Cylinder head TD 2012 2V W 01-04-09 TCD 2012 2V z Insert dial gauge into measuring beam. Schematic representation 1 2 © 34151-2 © 04/2007 2/4 13976-001 . z Place shims (1) and measuring beam (2) on the seal- ing surface of the crankcase. z Apply stylus of the dial gauge to the crankcase seal- ing surface with pre-tension (arrow). © 43614-1 z Measure at the points (1) and (2) on the piston. 2 1 1 6 © 30240-4 z Move the measuring beam. z Adjust dial gauge to "0".

56 .0.7 mm cor- responds to cylinder head gasket with 3 holes (arrow). 6 © 43514-1 z Select cylinder head gasket according to the largest piston projection measured.  W 04-06-03 © 46474-0 © 04/2007 3/4 13976-001 .33 . z Apply stylus to the specified measuring points under pre-tension.0.0. Note greatest measured value.55 mm 1 0.76 mm 3 Example: Piston projection = 0. TD 2012 2V Cylinder head TCD 2012 2V W 01-04-09 z Move the measuring beam.66 .65 mm 2 0.  Piston projection Hole 0.  W 01-04-04 z Remove turning gear. z Continue turning the crankshaft evenly until the re- versal point of the pointer on the dial gauge is reached. © 44154-0 z Install cylinder head. The stylus may not be positioned on the labelling of the piston.

Cylinder head TD 2012 2V W 01-04-09 TCD 2012 2V 6 © 04/2007 4/4 13976-001 .

. . . 2 © 42583-0 z Remove snap ring (1). . . 8024 – Assembly lever . . . . . . . . . . TD 2012 2V Cylinder head TCD 2012 2V W 01-05-01 Removing and installing the valves Commercial available tools: – W 01-04-04 – Slide gauge – Assembly pliers. . . . . . . . . . . . Danger! Risk of injury! Snap ring springs off. . . .  W 01-04-04 1 z Mount support bracket (1) on base plate (2). . . . . . . . . . . . . . 121410 – Assembly sleeves . . . 9017 Special tools: – Support bracket . . . . . . . . . . . . . . . . 121420 6 Removing the valves z Remove cylinder head. . . . 1 © 42584-0 © 04/2007 1/6 13977-001 . . . 120910 – Assembly tool . . . . . . . . . . . . . . . z Mount cylinder head on support bracket. . . . . . . 120900 – Base plate. .

© 42587-0 © 04/2007 2/6 13977-001 . 2 © 42586-0 z Remove valve shaft seal with assembly pliers. Cylinder head TD 2012 2V W 01-05-01 TCD 2012 2V z Remove thrust washer (1). z Remove both tapper collets (2). z Remove assembly lever. valve springs and valves. 1 z Remove valve spring plates. 1 6 © 42585-0 z Install assembly lever (1). z Press down valve spring with assembly lever.

z Push assembly sleeve (1) over the valve V-grooves. z Measure valve spring length with slide gauge. z Insert and hold valve. the valve spring must be renewed. © 35856-2 z Oil the valve stem lightly. check and visually inspect for damage. 1 2 © 42589-0 © 04/2007 3/6 13977-001 . 6 © 42588-0 z Install valves. TD 2012 2V Cylinder head TCD 2012 2V W 01-05-01 z Clean cylinder head.  59 mm When the wear limit is reached.

Cylinder head TD 2012 2V
W 01-05-01 TCD 2012 2V

z Push new valve shaft seal (1) over the assembly
sleeve.
z Remove assembly sleeve.

1

6
© 42590-1

z Press in valve shaft seal to stop with assembly
tool (1).

1

© 42591-0

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

2

1

© 42592-0

© 04/2007 4/6 13977-001

TD 2012 2V Cylinder head
TCD 2012 2V W 01-05-01

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

1
6
© 42593-0

z Remove assembly lever.
z Insert thrust washer (1).

1

© 42585-0

z Insert spring ring (1).
Pay attention to the correct fit of the spring
ring in the groove.

1

© 42594-0

© 04/2007 5/6 13977-001

Cylinder head TD 2012 2V
W 01-05-01 TCD 2012 2V

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

6 2
© 42583-0

© 04/2007 6/6 13977-001

TD 2012 2V Cylinder head
TCD 2012 2V W 01-05-04

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

6

Checking valve stem diameter
z Remove valves.
 W 01-05-01
z Measure valve stem diameter with micrometer
gauge.
– Inlet valve
+0
 7,98 −0,015 mm
– Exhaust valve
+0
 7,96 −0,015 mm

© 42182-1

Checking valve edge thickness
z Measure valve edge thickness with slide gauge.
– Inlet valve
 2,3 mm
– Exhaust valve
 1,61 mm

© 42183-1

© 04/2007 1/2 13978-001

Cylinder head TD 2012 2V
W 01-05-04 TCD 2012 2V

Checking valve head diameter
z Measure valve head diameter with slide gauge.
– Inlet valve
+0,1
 41,7 −0,1 mm
– Exhaust valve
+0,1
 35,9 −0,1 mm
z Install valves.
 W 01-05-01

6
© 42184-1

© 04/2007 2/2 13978-001

TD 2012 2V Cylinder head
TCD 2012 2V W 01-06-03

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

6

Checking the valve guide
z Remove valves.
 W 01-05-01
z Visually inspect valve guide for wear.
z Mount magnetic measuring stand.
z Insert dial gauge.
z Insert new valve.
z Place stylus on the valve stem under pre-
tension (arrow).
z Adjust dial gauge to "0".

© 42595-0

Measure valve stem clearance
z Move valve back and forth in direction of arrow.
– Inlet valve
+0
 0,028 - 0,068 − 0,015 mm
– Exhaust valve
+0
 0,048 - 0,088 − 0,015 mm
The whole rocker path must be taken into
consideration.

© 42597-0

© 04/2007 1/2 13979-001

 W 01-05-01 6 © 42596-0 © 04/2007 2/2 13979-001 . z Remove dial gauge. z Install valves. Cylinder head TD 2012 2V W 01-06-03 TCD 2012 2V z Remove magnetic measuring stand.

. . . . . 2 © 44178-0 z Screw cylinder head onto support bracket (1) and base plate (2). . . 120910 seat insert and/or valve must be renewed. . . . . . . TD 2012 2V Cylinder head TCD 2012 2V W 01-07-08 Checking the valve lag Commercial available tools: – W 01-04-04 – Depth-measuring appliance Special tools: Attention! – Support bracket . . . . 120900 When the wear limit is reached. . . . the valve – Base plate. . . 6 Checking the valve lag z Remove cylinder head. . . . 1 2 © 46588-0 ©04/2007 1/2 13981-001 . . 1  W 01-04-04 z Mount support bracket (1) on base plate (2). . . . .

z Remove support bracket from base plate (2).  W 01-04-04 1 2 © 46588-0 ©04/2007 2/2 13981-001 .1 mm – Exhaust valve +0.1 mm 6 © 42598-0 z Remove cylinder head from support bracket (1).9 −0.9 −0.15  0. z Install cylinder head. – Inlet valve +0. Cylinder head TD 2012 2V W 01-07-08 TCD 2012 2V z Measure the valve lag from the centre of the valve head to the cylinder head sealing surface.15  0.

. . 8035 Special tools: – Dial gauge. z Adjust dial gauge to "0". 100400 6 z Remove front cover. . .0. . . © 44180-0 © 04/2007 1/6 13983-001 .  W 03-08-01 z Remove the gear case cover. .3 mm In case of deviating axial clearance.1 . . z Apply stylus to the crankshaft end with pre-tension. . .  0. . . . . . . . z Press crankshaft in direction of arrow. the permissible axial clearance should be set by changing the thrust ring halves. z Insert dial gauge. . . . .  W 04-04-09 z Mount magnetic measuring stand. . . © 44179-0 z Press crankshaft in direction of arrow. . . z Read off measured value. . . TD 2012 2V Drive system TCD 2012 2V W 02-01-04 Checking the axial clearance of the crankshaft Commercial available tools: – W 02-04-01 8190 – Magnetic measuring stand – W 03-08-01 – Micrometer gauge – W 04-04-09 – Internal measuring device – Socket wrench insert .

Drive system TD 2012 2V W 02-01-04 TCD 2012 2V z Unscrew screws (1). © 43504-0 © 04/2007 2/6 13983-001 .05  2. z Remove lower bearing shell.20 −0 mm z Select thrust ring halves according to measured val- ue. Overmeasure +0. Use socket wrench insert. 1 z Remove bearing cap (2). © 44182-0 z Measure the strength of thrust ring halves.05  2. – Standard +0. z Remove both thrust ring halves (arrows).00 −0 mm – 1. 2 1 6 © 44181-0 z Remove both thrust ring halves (arrows).

z Measure width with micrometer gauge. dimension (a). z Push the internal measuring device between the test surfaces of the micrometer gauge and set to "0". z Note measured value. dimension (b). TD 2012 2V Drive system TCD 2012 2V W 02-01-04 z Remove crankshaft.  W 02-04-01 z Set micrometer gauge to 32 mm. © 42606-0 z Place thrust ring halves on bearing caps (arrows). 6 © 35825-2 z Measure locating bearing width z Note measured value. © 35827-2 © 04/2007 3/6 13983-001 .

8 mm (b) = 32.  0. 1 © 44183-0 z Install upper thrust ring halves according to meas- ured axial clearance.1 .7 mm Dimension (a) . 1 © 44184-0 © 04/2007 4/6 13983-001 .  W 02-04-01 6 © 00000-0 Make sure the clamping bushings (1) are in place. Oil grooves (1) of the thrust ring halves face the web face (2) of the crankshaft (arrows) 2 Insert thrust ring halves between crank- case and crankshaft web (arrows).0.1 mm z Install crankshaft.3 mm Calculation example Desired: Axial backlash Given: - Measured: (a) = 32.Dimension (b) Result: = 0. Drive system TD 2012 2V W 02-01-04 TCD 2012 2V z Determine axial backlash.

1 © 44186-1 © 04/2007 5/6 13983-001 . Otherwise renew every time they are loo- sened. 1 © 44185-0 z Tighten screws (1) with the socket wrench insert. The gate (arrow) on the bearing cap faces the manifold side. TD 2012 2V Drive system TCD 2012 2V W 02-01-04 z Fix both thrust ring halves with a little grease to the bearing cap. 1 6 © 42663-0 z Insert bearing cap (1). Bearing cap with identification “2“. Use lower thrust ring halves with guide lug (arrow).  50 Nm + 90° + 90° Attention! Screws can be reused a maximum 3 times with written documentation. Install thrust ring halves according to mea- sured axial clearance. 2 The oil grooves (1) face the crankshaft web face.

1 . Drive system TD 2012 2V W 02-01-04 TCD 2012 2V z Check axial backlash of crankshaft.  W 04-04-09 6 © 44187-0 © 04/2007 6/6 13983-001 .  W 03-08-01 z Remove the gear case cover.  0. z Install front cover.3 mm z Remove magnetic measuring stand. z Remove dial gauge.0.

. . . . . . © 42602-0 z Put hardness tester on journal. . . . TD 2012 2V Drive system TCD 2012 2V W 02-01-07 Checking the crankshaft Commercial available tools: – W 02-04-01 – Magnetic measuring stand – Micrometer gauge – Internal measuring device – Prisms – Hardness tester Special tools: – Dial gauge.  W 02-04-01 z Place crankshaft on prism. 100400 6 Checking the bearing pin hardness z Remove crankshaft. . . . . . . . © 30560-1 © 04/2007 1/4 13984-001 . .

at least +6  55 HRc The measured value is to be converted according to the table of the measuring device. Drive system TD 2012 2V W 02-01-07 TCD 2012 2V z Raise stylus (1) and press release (2). – Nominal value. © 36424-2 © 04/2007 2/4 13984-001 . Stylus (1) falls down. © 43515-0 Diagram for measuring the journals at the points 1 and 2 in the levels a and b. briefly strikes the sur- face and jumps up to the measured value. 1 2 6 © 43499-0 z Read off displayed value (arrow) from hardness test- er.

z Apply stylus to the main bearing pin with pre-tension (arrow) and adjust dial gauge to "0".1 mm z Remove magnetic measuring stand. – Standard +0  84 − 0.02 mm – Undermeasure stage  0. z Turn crankshaft evenly and check rotation. z Insert dial gauge.25 mm See schematic diagram for measuring points. +0  62.25 mm See schematic diagram for measuring points. 6 © 42603-0 Checking the diameter of the lifting jour- nals z Measure lifting journal with micrometer gauge. TD 2012 2V Drive system TCD 2012 2V W 02-01-07 Checking the diameter of the main bearing pins z Measure main bearing pin with micrometer gauge.994 −0. z Remove dial gauge.  0.02 mm – Undermeasure stage  0. © 42605-0 © 04/2007 3/4 13984-001 . © 42604-0 Checking the rotation z Mount magnetic measuring stand.

Undermeasure stage  0.  W 02-04-01 © 42607-0 © 04/2007 4/4 13984-001 . 1 z Visually inspect gear wheel (2). z Push the internal measuring device between the test surfaces of the micrometer gauge and set to "0".2 −0 mm – 1.4 mm © 42606-0 Visual inspection z Check the running surfaces (1) of the crankshaft sealing rings visually. +0. 6 © 35825-2 z Measure bearing width with internal measuring de- vice between thelay-on surfaces of the thrust rings.04  32. Drive system TD 2012 2V W 02-01-07 TCD 2012 2V Measuring the fit bearing width z Set micrometer gauge to 32 mm. 1 2 z Install crankshaft.

TD 2012 2V Drive system TCD 2012 2V W 02-02-02 Renewing the crankshaft sealing ring (flywheel side) Commercial available tools: – W 12-06-01 – Pricker. . . Attention! Do not damage the gearcase cover and crankshaft. . . . . . 8198 – Assembly lever . . . . . . . . . . . . . . . . . . . 1 © 46561-0 © 04/2007 1/4 13985-001 . . . . . . . . . . . . . . . . . . . 142830 – Self-tapping screw – Washer 6 Removing the crankshaft sealing ring z Remove flywheel. . . . . . . 9017 Special tools: – Assembly tool .  W 12-06-01 z Make a hole of approximately 3 mm in the crankshaft sealing ring with a pricker. . © 46472-0 z Screw in a self-tapping screw (1) with washer. .

The bores in the guide sleeve must match the threaded holes in the crankshaft flange. 1 2 © 46563-0 z Oil the sealing lip of the crankshaft sealing ring light- ly. z Visually inspect the crankshaft sealing ring running surface. 6 © 46562-0 Installing the crankshaft sealing ring z Mount guide sleeve (1). The sealing lip faces the crankcase. Drive system TD 2012 2V W 02-02-02 TCD 2012 2V z Pull out the crankshaft sealing ring with assembly le- ver. z Place the crankshaft sealing ring carefully on the pe- ripheral surface. z Tighten screws (2). © 46564-0 © 04/2007 2/4 13985-001 .

1st repair .installation stage = 0 discs.first assembly = 2 discs . 1 2 © 46567-0 © 04/2007 3/4 13985-001 . TD 2012 2V Drive system TCD 2012 2V W 02-02-02 z Mount shims (1). z Screw on nut (2). 1 © 46566-0 z Plug in the bearing (1). 1 6 © 46565-0 z Mount assembly sleeve (1). If there is a run-in groove on the crankshaft flange it is possible to mount the crankshaft sealing ring in three installation depths: .2nd repair . z Press on the crankshaft sealing ring to the stop.installation stage = 1 disc .

1  W 12-06-01 6 © 44197-0 © 04/2007 4/4 13985-001 . The crankshaft sealing ring is now at the pre-selected installation depth. z Install flywheel. Drive system TD 2012 2V W 02-02-02 TCD 2012 2V z Tighten nut to the stop of the assembly sleeve (1). z Remove assembly tool.

. © 43643-0 z Screw in a self-tapping screw (1) with washer. . . . . . . . . . . . 1 © 44872-0 © 04/2007 1/6 13986-001 . . . . . . . . . . . . . . . . . . 9017 Special tools: – Assembly tool .  W 12-01-04 z Make a hole of approximately 3 mm in the crankshaft sealing ring with a pricker. . . . . TD 2012 2V Drive system TCD 2012 2V W 02-02-04 Renewing the crankshaft sealing ring (opposite side to flywheel) Commercial available tools: – W 12-01-04 – Pricker. . . . . . . Attention! Do not damage the front cover or cranks- haft. . . . 142670 – Self-tapping screw – Washer 6 Removing the crankshaft sealing ring z Remove V-belt pulley. . . . . . . . . 8198 – Assembly lever . .

1 © 44875-0 z Mount guide sleeve (1). Make sure the clamping bushing (2) is in line with the bore (3). 1 2 3 © 42623-0 © 04/2007 2/6 13986-001 . 6 © 44873-0 Installing the crankshaft sealing ring z Remove clamping bushing (1). Drive system TD 2012 2V W 02-02-04 TCD 2012 2V z Pull out the crankshaft sealing ring with assembly le- ver. z Visually inspect the crankshaft sealing ring running surface.

z Pay attention to installation depth of crankshaft seal- ing ring and select shim accordingly. – First assembly = 2 shims – 1. TD 2012 2V Drive system TCD 2012 2V W 02-02-04 z Tighten screws (1). 1 6 © 44877-0 z Oil the sealing lip of the crankshaft sealing ring light- ly. © 44878-0 z Mount shims (1). z Place the crankshaft sealing ring carefully on the pe- ripheral surface. Repair installation depth = 1 shim – Maximum installation depth = without washers 1 © 44879-0 © 04/2007 3/6 13986-001 . The sealing lip faces the crankcase.

© 44882-1 © 04/2007 4/6 13986-001 . 2 1 © 44881-0 z Tighten nut to the stop of the assembly sleeve (1). z Press on the crankshaft sealing ring to the stop. 1 6 © 44880-0 z Plug in the bearing (1). 1 z Remove assembly tool. Drive system TD 2012 2V W 02-02-04 TCD 2012 2V z Mount assembly sleeve (1). z Turn on nut (2). The crankshaft sealing ring is now at the pre-selected installation depth.

z Install V-belt pulley. TD 2012 2V Drive system TCD 2012 2V W 02-02-04 z Knock in the clamping sleeve (1) to the stop.  W 12-01-04 1 6 © 42622-0 © 04/2007 5/6 13986-001 .

Drive system TD 2012 2V W 02-02-04 TCD 2012 2V 6 © 04/2007 6/6 13986-001 .

. . . . – Set micrometer gauge to 38 mm. . – Mount dial gauge with approx. . .  W 02-09-03 z Remove piston from con rod. TD 2012 2V Drive system TCD 2012 2V W 02-03-01 Checking the con rod Commercial available tools: – W 02-09-03 – Micrometer gauge – Internal measuring device – Rotation angle disc . . . . . . 8190 – Con rod test device Special tools: – Dial gauge. . . . . 100400 6 z Remove piston and connecting rod. . . 1 mm pre-tension in the internal measuring device. . . . . © 40592-1 Checking small end bush z Prepare internal measuring device: – Mount probe bolt for the appropriate measuring range in the internal measuring device. © 34768-2 © 04/2007 1/10 13987-001 . . . . . . . . – 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".

The dimension A is required to determine the piston bolt clearance. Drive system TD 2012 2V W 02-03-01 TCD 2012 2V Diagram for measuring the small end bush at the points "a" and "b" in the levels "1" and "2". The dimension B is required to determine the piston bolt clearance. dimension (A).010 mm Measuring points see diagram. 6 © 37239-1 z Insert internal measuring device. z Balance the internal measuring device at the given measuring points and read off the measured value at the reversal point of the pointer. +0  38 −0.006 mm z Note the measured value.025 +0. dimension B. z Note the measured value.  38. © 34770-2 Checking diameter of the piston bolt z Measure piston pin with micrometer gauge. © 35908-2 © 04/2007 2/10 13987-001 .

© 44212-0 z Tighten screws alternately with rotation angle disc and socket wrench insert.000 mm Result: = 0.025 mm 6 Checking the con rod bearing bore z Mount big end bearing cap.38.000 mm Dimension (a) .025 . The identification numbers (1) on the con 26519 rod and the big end bearing cap must be identical and opposite to each other when assembled.041 mm Calculation example Desired: Piston pin clearance Given: - Measured: Internal diameter small end bush (a) (a) = 38. Attention! 26519 Note the assignment of the big end bearing 1 cap.  0.025 mm Diameter piston pin (b) (b) = 38. TD 2012 2V Drive system TCD 2012 2V W 02-03-01 Determining piston pin clearance The piston pin clearance is given by the difference between the internal diameter of the small end bush (a) and the piston pin diameter (b).  30 Nm + 60° + 30° © 44213-0 © 04/2007 3/10 13987-001 .0.Dimension (b) 38.025 mm .

1 mm pre-tension in the internal measuring device. 6 © 36094-1 Diagram for measuring the con rod bearing bore at the points "a" and "b" in the levels "1" and "2". z Balance the internal measuring device at the given measuring points and read off the measured value at the reversal point of the pointer. – Set micrometer gauge to 66 mm. Drive system TD 2012 2V W 02-03-01 TCD 2012 2V z Prepare internal measuring device: – Mount probe bolt for the appropriate measuring range in the internal measuring device. additional measurements must be made with new bearing shells. – Mount dial gauge with approx. © 37239-1 z Insert internal measuring device.019 mm If the measured values deviate slightly.  66.6 +0. © 44214-0 © 04/2007 4/10 13987-001 . – 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".

The anti-rotation lock (1) must lock in groove (2). 2 1 © 44215-0 z Insert bearing shell in the respective big end bearing cap. z Remove the con rod bearing cover. TD 2012 2V Drive system TCD 2012 2V W 02-03-01 Checking internal diameter of the con rod bearing shells z Remove screws. Attention! Note the assignment of the bearing shells. Make sure the clamping bushings (1) are in place. The anti-rotation lock (1) must lock in 1 groove (2). 1 6 © 44440-0 z Insert bearing shell in the con rod. 2 © 44216-0 © 04/2007 5/10 13987-001 . Attention! Note the assignment of the bearing shells.

Drive system TD 2012 2V W 02-03-01 TCD 2012 2V z Mount big end bearing cap. 1 mm pre-tension in the internal measuring device. – 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".  30 Nm + 60° + 30° © 44218-0 z Prepare internal measuring device: – Mount probe bolt for the appropriate measuring range in the internal measuring device. – Mount dial gauge with approx. 2651 9 6 © 44217-0 z Tighten screws alternately with rotation angle disc and socket wrench insert. © 36094-1 © 04/2007 6/10 13987-001 . Attention! The identification numbers (1) on the con- 2651 necting rod and the big end bearing cover must be identical and opposite to each 1 9 other when assembled. – Set micrometer gauge to 63 mm.

When the wear limit is reached the con rod must be replaced.065 mm z Note measured value. See schematic diagram for measuring points. TD 2012 2V Drive system TCD 2012 2V W 02-03-01 Diagram for measuring the inside diameter of the con rod bearing shells at the points "a" and "b" in the levels "1" and "2". © 44219-0 Checking the diameter of the lifting jour- nals Diagram for measuring the journals at the points 1 and 2 in the levels a and b.  63. z Balance the internal measuring device at the given measuring points and read off the measured value at the reversal point of the pointer. © 36424-2 © 04/2007 7/10 13987-001 .63.026 . dimension (a). 6 © 37239-1 z Insert internal measuring device.

+0  62. z Note measured value.12 mm z Remove screws.032 .073 mm Calculation example Desired: Big end bearing clearance Given: - Measured: Internal diameter big end bearing shell (a) (a) = 63. 6 © 36424-2 Determine big end bearing clearance The big end bearing clearance is given by the difference between the internal diame- ter of the big end bearing shell (a) and the lifting journal diameter (b). © 44218-0 © 04/2007 8/10 13987-001 .026 mm Diameter lifting journal (b) (b) = 62.992 mm Dimension (a) .  0.Dimension (b) Result: = 0.994 −0.25 mm Measuring points see diagram.0.02 mm – Undermeasure stage  0. z Remove the con rod bearing cover.034 mm – Wear limit  0. dimension (b). Drive system TD 2012 2V W 02-03-01 TCD 2012 2V z Measure lifting journal with micrometer gauge.

z Check the angle of the con rod. z Permissible deviation from (C) to (D).  0.  0.  W 02-09-03 © 30580-1 © 04/2007 9/10 13987-001 . z Permissible deviation from (A) to (B). 6 © 30579-1 z Move test fork in direction of arrow. B z Move test fork in direction of arrow. TD 2012 2V Drive system TCD 2012 2V W 02-03-01 Checking the con rod z Mount connecting rod on test instrument without bearing shells.04 mm Distance between “C“ and “D“ = 100 mm C D z Assembly pistons and con rod.04 mm Distance between “A“ and “B“ = 100 mm. z Install piston and connecting rod. A Attention! Aligning the con rod is not permissible. z Check that the con rod is parallel.

Drive system TD 2012 2V W 02-03-01 TCD 2012 2V 6 © 04/2007 10/10 13987-001 .

. . .  W 03-08-01 z Remove the gear case cover. . . . . . . . . . . . z Remove all con rod bearing covers.  W 04-04-09 © 42647-2 z Screw in screws (1). . . 8035 – W 04-04-09 – Turn-over gear . z Remove con rod bearing shells. . . . . . 100330 6 Removing crankshaft z Remove front cover. . . TD 2012 2V Drive system TCD 2012 2V W 02-04-01 Removing and installing the crankshaft Commercial available tools – W 02-01-07 – W 02-09-03 Special tools: – W 03-08-01 – Socket wrench insert .  W 02-09-03 1 1 © 42648-1 © 04/2007 1/8 13989-001 .

1 1 © 42653-1 © 04/2007 2/8 13989-001 . The marking on the camshaft gear wheel is covered by the crankshaft flange when it is 1 in line. 2 © 42652-0 Removing the main bearing cover z Unscrew all screws (1) with the socket wrench insert. 1 3 6 © 42651-0 z Turn the crankshaft evenly until the marking (1) on the crankshaft flange is in line with your mark (2) on the camshaft gear wheel. Drive system TD 2012 2V W 02-04-01 TCD 2012 2V z Make a mark (1) on the camshaft gear wheel for as- sistance. Attention! Do not jam the con rods when turning the crankshaft. 2 Your mark must be on a line between the marking (2) and the middle (3) of the camshaft.

Lay out components in the order in which they should be installed. 1 Lay out components in the order in which they should be installed. 1 moved). z Remove all main bearing covers (2). Note order of cylinders. z Check axial backlash of crankshaft (crankshaft re. z Remove bearing shell. z Remove bearing shells.  W 02-01-07 © 44231-2 © 04/2007 3/8 13989-001 . TD 2012 2V Drive system TCD 2012 2V W 02-04-01 z Remove bearing cap (1). z Visually inspect the components. z Lift out the crankshaft. Note order of cylinders. © 42655-1 z Remove both thrust ring halves (arrows). 2 6 © 44228-1 z Press the con rods carefully out of the lifting journal. z Remove all main bearing shells (1). z Remove both thrust ring halves (arrows).

The anti-rotation lock (1) must lock in groove (2). Drive system TD 2012 2V W 02-04-01 TCD 2012 2V Installing the crankshaft z Insert upper main bearing shells. Note the assignment of the bearing shells. 1 2 © 44233-0 Make sure the clamping bushings (arrows) are in place. 1 2 6 © 42658-0 z Insert lower main bearing shells in the respective main bearing cover. © 44231-1 © 04/2007 4/8 13989-001 . The anti-rotation lock (1) must lock in groove (2). Note the assignment of the bearing shells.

The marking (1) on the crankshaft flange must be in line with your mark (2). TD 2012 2V Drive system TCD 2012 2V W 02-04-01 z Position camshaft. Make sure that the markings match up. Attention! Do not jam the con rods when inserting the crankshaft! z Set the crankshaft in line with the camshaft. The bore (1) must be facing the cylinder head. 1 6 © 42661-0 z Insert the crankshaft carefully in the crankcase. 1 2 © 42652-0 © 04/2007 5/8 13989-001 . z Lightly oil bearing surfaces. © 44238-2 z Check control times.

Use thrust ring halves with guide lug (arrow). Thrust ring halves. Bearing cap with identification “2“. Note assignment and installation position: 1 Insert main bearing cover with the number 1 on the flywheel side. bet- ween the crankshaft and the crankcase (arrows). Gate (arrow) on the bearing cover faces 7 6 5 4 3 2 1 the manifold side. Drive system TD 2012 2V W 02-04-01 TCD 2012 2V z Install upper thrust ring halves according to meas- ured axial clearance. 2 © 44240-1 © 04/2007 6/8 13989-001 . Oil grooves (1) of the thrust ring halves 2 face the web face (2) of the crankshaft (arrows) 1 6 © 42662-0 z Fix both thrust ring halves with a little grease to the bearing cap. z Insert main bearing cover (2) according to the num- bering. Oil grooves (1) face the crankshaft web face. without guide lugs. 2 1 © 42663-0 Mounting the main bearing cover z Insert bearing cap (1).

 W 02-09-03 6 © 44241-1 z Unscrew screws (1). TD 2012 2V Drive system TCD 2012 2V W 02-04-01 z Main bearing cover with socket wrench insert and ro- tary angle disc.  50 Nm + 90° + 90° Attention! Screws can be reused a maximum 3 times with written documentation. z Install the con rod bearing cover. 1 1 © 42648-1 z Install the gear case cover.  W 04-04-09 z Install front cover.  W 03-08-01 © 42647-2 © 04/2007 7/8 13989-001 . Otherwise renew every time they are loo- sened.

Drive system TD 2012 2V
W 02-04-01 TCD 2012 2V

6

© 04/2007 8/8 13989-001

TD 2012 2V Drive system
TCD 2012 2V W 02-08-01

Removing and installing, checking the mass compensation shafts
Commercial available tools: – W 04-04-09
– Micrometer gauge
– Torque wrench
Special tools:
– Centring bolts (2x) . . . . . . . . . . . 100810

– Chalk
– Locking agent
DEUTZ DW 72

6

Removing the mass compensation shafts
z Remove the gear case cover.
 W 04-04-09
z Set piston cylinder 1 at top dead centre.
The marking (1) on the crankshaft flange
must be in line with your mark (2).

2

1

© 36652-2

z Unscrew screw (1).
z Remove washer (2).
z Remove idler gear (3).
z Remove the bearing pin.

1

3
2

© 46605-0

© 04/2007 1/8 13990-001

Drive system TD 2012 2V
W 02-08-01 TCD 2012 2V

z Unscrew screw (1).
z Remove lubricating oil pipe (2).
z Remove idler gear (3).
z Remove the bearing pin.
1

2

3

6
© 46606-0

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

1
1

2
2

© 46607-0

z Pull out mass compensation shafts in direction of ar-
row.
Attention!
Do not damage the mass compensation
shafts.

© 36666-3

© 04/2007 2/8 13990-001

TD 2012 2V Drive system
TCD 2012 2V W 02-08-01

Checking the mass compensation shafts
z Check components for visible signs of wear.

6
© 36664-1

z Measure the diameter of journals with the microme-
ter gauge.
 54 − 0,02 mm

© 36665-1

Installing the mass compensation shafts
z Oil the journal lightly.
z Insert mass compensation shafts in direction of ar-
row.
The weight position (1) faces the lubrica-
ting oil pan.

1
© 36666-4

© 04/2007 3/8 13990-001

Drive system TD 2012 2V
W 02-08-01 TCD 2012 2V

z Unscrew locking screws (1).

1

1

6
© 36651-2

z Insert centring bolt (1).
z Fix mass compensation shafts with centring bolts (1).
Attention!
Do not turn the mass compensation shafts 1
any more!

1

© 36659-2

z Install shims (2).
z Tighten screws (1).
Do not tighten the screw.

1
1

2
2

© 46607-0

© 04/2007 4/8 13990-001

TD 2012 2V Drive system
TCD 2012 2V W 02-08-01

z Mount intermediate gear of the B-side.
Position the intermediate gear (1) centred
with the threaded bore (2).
2
If the tooth edges do not match, the
crankshaft can easily be turned.

Attention!
Do not turn the mass compensation shafts
any more!

1
6
© 36669-1

z Lightly oil journal (1).
z Insert bearing pin (1).
z Mount washer (2).
z Turn in screw (3).
Insert screw with safety agent
DEUTZ DW 72.
Do not tighten the screw. 1

3

2
© 36670-2

z Make help marks (1) and (2).
z Turn out centring bolts (A-side).
z Turn mass compensation shaft two teeth in direction
of the arrow.
1

2

© 36656-2

© 04/2007 5/8 13990-001

Position the intermediate gear (1) centred 1 with the threaded bore (2). z Insert bearing pin (1). Turn the mass compensation shaft in the direction of the arrow until the help marks are in line. 1 © 36667-2 z Insert new O-ring (1). Drive system TD 2012 2V W 02-08-01 TCD 2012 2V z Insert the intermediate wheel (1) into the toothing from above. 2 6 © 36657-2 z Lightly oil journal (1). 1 © 36668-2 © 04/2007 6/8 13990-001 .

z Tighten locking screws (1). 1 2 6 © 36658-2 z Unscrew all centring bolts (1). z Fasten screw (2).  9 Nm 1 1 © 36651-2 © 04/2007 7/8 13990-001 . Do not tighten the screw. 1 1 © 36659-2 z Mount new sealing rings. Insert screw with safety agent DEUTZ DW 72. TD 2012 2V Drive system TCD 2012 2V W 02-08-01 z Mount lubrication oil line (1).

Drive system TD 2012 2V W 02-08-01 TCD 2012 2V z Tighten screws (1).  W 04-04-09 1 1 2 6 © 36660-2 © 04/2007 8/8 13990-001 .  22 Nm z Install the gear case cover.  29 Nm z Tighten screws (2).

. . . z Remove big end bearing cap (2). 6 Removing the piston and con rod z Remove cylinder head. . . . . 130670 Collect leaking operating substances in suitable vessels and dispose of according to regulations. z Unscrew screws (1). .  W 01-04-04 z Remove oil suction pipe  W 08-04-06 z Pull out oil dipstick. Lubricating oil and coolant must be filled according to the instructions in the opera- ting manual. TD 2012 2V Drive system TCD 2012 2V W 02-09-03 Removing and installing the piston and con rod Commercial available tools: – W 01-04-04 – Rotation angle disc . . . z Remove bearing shell. © 46480-0 © 04/2007 1/8 13991-001 . . . Lay out components in the order in which they should be installed. . . . 2 1 Note order of cylinders. © 46477-0 Removing the big end bearing cap z Turn the crankshaft with the turning gear. . z Set lifting journal at bottom dead centre (BDC). 8190 – W 02-10-03 Special tools: – W 08-04-06 – Piston ring compressor . . . .

z Visually inspect the components. Lay out components in the order in which they should be installed. 1 © 44250-0 z Remove locking ring. Drive system TD 2012 2V W 02-09-03 TCD 2012 2V z Remove piston and connecting rod. Note order of cylinders. 6 © 46478-0 z Remove con rod bearing shells (1). z Press out piston pin. © 44251-0 © 04/2007 2/8 13991-001 . z Visually inspect the components.

Ensure that the installation location is free from faults. z Insert new locking ring. 6 © 44252-0 z Insert con rod. 1 © 44253-0 z Oil the piston bolt lightly. © 44254-0 © 04/2007 3/8 13991-001 . Ensure that the installation location is free from faults. 26519 The flywheel/crankshaft symbol (1) on the piston base must face to the right and the 2 identification number (2) on the con rod must face upwards. z Press the piston bolt through. TD 2012 2V Drive system TCD 2012 2V W 02-09-03 Completing con rod and piston z Insert new locking ring.

Attention! Note the assignment of the bearing shells. Drive system TD 2012 2V W 02-09-03 TCD 2012 2V Installing the piston and con rod Make sure the clamping bushings (1) are in place. The anti-rotation lock (1) must lock in 1 groove (2). The anti-rotation lock (1) must lock in groove (2). 2 © 44216-0 © 04/2007 4/8 13991-001 . 2 1 © 46295-0 z Insert bearing shell in the respective big end bearing cap. 1 6 1 © 46296-0 z Insert bearing shell in the con rod. Note the assignment of the bearing shells.

Note the cylinder assignment of the piston. piston. Note the label indicating the installation position on the piston base. The piston ring compressor must lie flat on the cylinder liner. 1 © 44255-0 z Set lifting journal at bottom dead centre (BDC).  W 02-10-03 6 © 42380-1 z Lightly oil cylinder running surface. piston rings and lifting bearing journal lightly. Do not turn the piston rings any further. 1 The symbol flywheel/crankshaft (1) must face the flywheel. z Clamp piston rings with piston ring compressor (1). z Push piston and con rod completely into cylinder lin- er. z Check piston rings and piston ring grooves. © 45004-1 © 04/2007 5/8 13991-001 . TD 2012 2V Drive system TCD 2012 2V W 02-09-03 z Arrange the piston ring joints with an offset of about 120° to each other.

6 © 46481-0 Installing the big end bearing cap z Mount big end bearing cap. Drive system TD 2012 2V W 02-09-03 TCD 2012 2V z Press the con rod carefully against the lifting journal.  30 Nm + 60° + 30° Attention! Renew screws every time they are loose- ned. Attention! Do not jam the con rod with the crankshaft. © 46482-0 z Tighten new screws with rotation angle disc. © 46483-0 © 04/2007 6/8 13991-001 .

 W 08-04-06 z Install cylinder head. TD 2012 2V Drive system TCD 2012 2V W 02-09-03 z Insert oil dipstick. z Install oil suction pipe.  W 01-04-04 6 © 46479-0 © 04/2007 7/8 13991-001 .

Drive system TD 2012 2V W 02-09-03 TCD 2012 2V 6 © 04/2007 8/8 13991-001 .

. – Set micrometer gauge to 38 mm. .  W 02-09-03 © 44262-0 z Prepare internal measuring device: – Mount probe bolt for the appropriate measuring range in the internal measuring device. 6 Checking the piston bolt bore z Remove piston from con rod. . – 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". 100400 piston must be renewed. . . . . TD 2012 2V Drive system TCD 2012 2V W 02-09-07 Checking the piston Commercial available tools: – W 02-09-03 – Micrometer gauge – Internal measuring device Special tools: When the piston wear limit is reached. . – Mount dial gauge with approx. 1 mm pre-tension in the internal measuring device. . © 34768-2 © 04/2007 1/4 13992-001 . . . . . . . . . the – Dial gauge.

trans- verse to the piston bolt bore. + 0. 6 © 37239-1 z Insert internal measuring device in the piston bolt bore.004 mm See schematic diagram for measuring points. © 43483-0 Checking the piston diameter Diagram for measuring the piston diameter at the measuring points "1.009  38 + 0. Drive system TD 2012 2V W 02-09-07 TCD 2012 2V Diagram for measuring the piston bolt bore at the points "a" and "b" in the levels "1" and "2". z Balance the internal measuring device at the given measuring points and read off the measured value at the reversal point of the pointer. 2 and 3". 3 2 1 © 37244-1 © 04/2007 2/4 13992-001 .

007 mm +0.770 −0.007 mm 101.009 mm 101.012 +0. TD 2012 2V Drive system TCD 2012 2V W 02-09-07 z Measure piston diameter with micrometer gauge.088 − 0.009 mm +0.009 +0.012 mm 100.009 16 mm 100.5 mm 100.007 50 mm 100. z Assemble con rod and piston.820 −0.007 + 0.320 −0.588 −0.012 78.  Diameter Measuring Standard Overmeasure height +0.  W 02-09-03 6 © 43427-0 © 04/2007 3/4 13992-001 .012 mm See schematic diagram for measuring points.270 −0.

Drive system TD 2012 2V W 02-09-07 TCD 2012 2V 6 © 04/2007 4/4 13992-001 .

 W 02-09-03 z Set universal piston ring pliers to the piston diameter. . . . . . .  101 mm z Remove piston rings with universal piston ring pliers. z Visually inspect piston. . © 44263-1 z Clean piston. . 130300 – Trapezoidal groove wear gauge . . . . . . . TD 2012 2V Drive system TCD 2012 2V W 02-10-03 Checking the piston rings and piston ring grooves Commercial available tools: – W 02-09-03 – Feeler gauges Special tools: – Universal piston ring pliers . . . z Visually inspect piston ring grooves. . . . . . . © 44264-1 © 04/2007 1/4 13993-001 . . . 130440 6 Checking the piston rings and piston ring grooves z Remove piston from con rod.

6 © 33866-3 If there is a gap "S" between the trapezoi- dal groove wear gauge and piston. Drive system TD 2012 2V W 02-10-03 TCD 2012 2V z Measure piston ring groove for first piston ring with trapezoidal groove wear gauge. S © 33867-3 If the trapezoidal groove wear gauge is touching the piston (arrow). © 33868-3 © 04/2007 2/4 13993-001 . the piston must be changed. the piston can be used again.

55 mm When the wear limit is reached. the piston ring must be renewed. piston ring = bevelland-edge oil control ring  0.0. .5 .0 mm – 3. piston ring = taper-faced ring  1.Double-sided keystone ring (1) 1 .Taper-faced ring (2) .Bevelland-edge oil control ring with coiled 2 spring expander (3) “Top“ label faces the combustion chamber.35 mm – 2.20 . Order and position of the piston rings as seen from the piston base.0. z Align the piston ring in the cylinder by pushing the piston. piston ring = double keystone ring  0.2. 3 © 44267-0 © 04/2007 3/4 13993-001 . © 45012-1 z Install piston rings. TD 2012 2V Drive system TCD 2012 2V W 02-10-03 Checking the piston ring joint clearance z Insert the piston ring (1) in the cylinder. 1 6 © 45011-1 z Measure the piston ring joint clearance with a feeler gauge. – 1.3 .

Drive system TD 2012 2V W 02-10-03 TCD 2012 2V z Install piston rings with universal piston ring pliers. 6 © 44268-0 Checking the piston ring axial clearance Check with new piston rings.0. piston ring  0. © 44269-0 z Assemble con rod and piston. z Check axial backlash with feeler gauge between pis- ton ring and piston ring groove.06 .04 mm When the piston wear limit is reached. the piston must be renewed. piston ring  0. – 2.02 .  W 02-09-03 © 44270-0 © 04/2007 4/4 13993-001 .08 mm – 3.0. Set spring joint of the bevelland-edge oil control ring 180° to the ring joint.

1 © 44272-0 © 04/2007 1/2 13994-001 . 1 © 44271-0 z Pull out piston cooling nozzle (1) with pliers. TD 2012 2V Drive system TCD 2012 2V W 02-15-01 Removing and installing the piston cooling nozzles Commercial available tools – W 02-04-01 6 Removing the piston cooling nozzles z Remove crankshaft.  W 02-04-01 z Screw self-tapping screw (1) carefully into the piston cooling nozzle.

z Install crankshaft. z Knock in new piston cooling nozzle (1) with pin to the stop. Drive system TD 2012 2V W 02-15-01 TCD 2012 2V Installing the piston cooling nozzles z Clean the bores for the piston cooling nozzles in the crankcase.  W 02-04-01 1 6 © 44273-0 © 04/2007 2/2 13994-001 .

. z Pull off hose pipe (1). 3 z Unscrew screws (2). . 1 © 46475-0 © 04/2007 1/2 13995-001 . . TD 2012 2V Crankcase TCD 2012 2V W 03-01-11 Removing and installing the crankcase bleeding Commercial available tools: – Spring band pliers . . z Insert new seal (1). . . z Clean sealing surfaces. . . 1 © 46473-3 z Visually inspect the component. . . . . 2 z Remove crankcase bleeding (3). . 9090 6 Removing the crankcase bleeding z Loosen the spring band clip with spring band pliers and pull down.

z Position spring band clip with spring band pliers. Pay attention to perfect installation position (arrow). 1 2 © 46473-4 © 04/2007 2/2 13995-001 .  21 Nm z Position hose pipe (2). Crankcase TD 2012 2V W 03-01-11 TCD 2012 2V z Mount crankcase bleeding (1). 1 6 © 46476-0 z Tighten screws (1).

– Dial gauge. . .  W 02-09-03 z Check cylinder for visible signs of wear. 1 mm pre-tension in the internal measuring device. . . . . – 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". © 46474-0 z Prepare internal measuring device: – Mount probe bolt for the appropriate measuring range in the internal measuring device. . 100400 6 Checking the cylinders z Remove piston and connecting rod. . – Mount dial gauge with approx. – Set micrometer gauge to 101 mm. . © 36094-1 © 04/2007 1/2 13996-001 . . . . TD 2012 2V Crankcase TCD 2012 2V W 03-03-01 Checking the cylinder Commercial available tools: – W 02-09-03 – Micrometer gauge – Internal measuring device – Depth-measuring The crankshaft bearing covers must be appliance mounted properly for measuring the cylin- Special tools: ders. . . . . .

 W 02-09-03 © 46470-0 © 04/2007 2/2 13996-001 . Crankcase TD 2012 2V W 03-03-01 TCD 2012 2V Diagram for measuring the cylinder run- ning surface at the points "a" and "b" in the levels "1" .02  101 −0 mm See schematic diagram for measuring points. z Compare actual value with setpoint value. +0."3". a b 1 a b 2 a b 3 6 © 39100-1 z Insert internal measuring device in cylinder. z Balance the internal measuring device at the given measuring points and read off the measured value at the reversal point of the pointer. z Install piston and connecting rod.

 W 12-01-04 z Remove oil suction pipe  W 08-04-06 © 46397-0 z Turn the engine on the assembly block. 1 © 44542-1 © 04/2007 1/6 13997-001 . z Unscrew all screws (1). TD 2012 2V Crankcase TCD 2012 2V W 03-08-01 Removing and installing the front cover (opposite side to flywheel) Commercial available tools – W 02-02-04 – W 08-04-06 – W 12-01-04 6 Remove the front cover z Removing torsional vibration damper. z Remove front cover. z Remove gasket.

Attention! Do not damage sealing surface when knocking out. z Mount new gasket. Crankcase TD 2012 2V W 03-08-01 TCD 2012 2V z Visually inspect the components. 1 © 42997-0 Make sure the clamping bushings (1) are in place. 6 © 42996-0 Install front cover z Knock out crankshaft sealing ring (1). 1 © 44545-1 © 04/2007 2/6 13997-001 .

z Align front cover flush with the oil tray sealing sur- face. The inner rotor and crankshaft only match up in one position. © 44551-1 © 04/2007 3/6 13997-001 . 6 © 44547-1 z Mount front cover. Do not tighten screws. © 44548-1 z Cut off overhanging gasket (arrows) flush with the sealing surface of the oil tray. The countersinks on the crankshaft and the guides on the inner rotor must match (arrows). z Fasten screws. TD 2012 2V Crankcase TCD 2012 2V W 03-08-01 z Position the inner rotor on the crankshaft.

Crankcase TD 2012 2V W 03-08-01 TCD 2012 2V z Tighten the screws according to the tightening se- quence.  W 08-04-06 © 44548-1 © 04/2007 4/6 13997-001 . – Pre-clamping value:  3 Nm – Post-clamping value:  21 Nm 6 © 36521-1 z Fill lubricating oil into the oil pump housing. © 45369-0 z Install oil suction pipe.

TD 2012 2V Crankcase TCD 2012 2V W 03-08-01 z Turn the engine on the assembly block.  W 12-01-04 © 46397-0 © 04/2007 5/6 13997-001 . z Install crankshaft sealing ring (opposite side to fly- wheel)  W 02-02-04 6 © 43492-2 z Install torsional vibration damper.

Crankcase TD 2012 2V W 03-08-01 TCD 2012 2V 6 © 04/2007 6/6 13997-001 .

1 z Visually inspect the components. . Use socket wrench insert. . . . . . . . 1 2 1 1 © 42698-1 z Unscrew screws (1). . z Remove connection housing. . . 8114 6 Removing the connection housing z Unscrew screws (1). 1 1 1 1 1 © 42699-1 © 04/2007 1/4 13998-001 . . . 8113 – Socket wrench insert . TD 2012 2V Crankcase TCD 2012 2V W 03-09-04 Removing and installing the connection housing Commercial available tools: – Socket wrench insert . . . z Remove the cover (2). . . . . .

z Centre connection housing over the clamping bush- ings. 1 6 © 44083-1 z Mount connection housing. z Fasten screws. (3) (4) and (5) alternately. M12 = (1) 2 M16 = (2) 1 1 2 2 © 42703-1 z Tighten the screws according to the tightening se- quence.  99 Nm 3 5 z Tighten screws (2). (3). 4 2 Use socket wrench insert. 2 Note different screw lengths. 6 z Pre-tighten screws (2). Crankcase TD 2012 2V W 03-09-04 TCD 2012 2V Installing the connection housing 1 z Clean contact surfaces. – Pre-clamping value:  99 Nm z Tighten screws (1) and (6). Make sure the clamping bushings (1) are in place. (4) and (5) alternately. – Post-clamping value:  243 Nm © 44085-0 © 04/2007 2/4 13998-001 . See graphic for tightening sequence. 1 z Fasten screw (1) hand tight.

1  9 Nm The hollow gorge (1) faces the lube oil tray. TD 2012 2V Crankcase TCD 2012 2V W 03-09-04 z Press on cover plate to the stop. 2 2 2 6 © 42704-1 © 04/2007 3/4 13998-001 . z Tighten screws (2).

Crankcase TD 2012 2V W 03-09-04 TCD 2012 2V 6 © 04/2007 4/4 13998-001 .

. . . . 143840 6 Testing camshaft bearing z Remove crankshaft. . . . . . . .  W 04-05-05 © 42710-1 z Prepare internal measuring device: – Mount probe bolt for the appropriate measuring range in the internal measuring device. testing camshaft bearing Commercial available tools: – W 02-04-01 – Micrometer gauge – W 04-05-05 – Internal measuring device Special tools: – Dial gauge. . . . . . . . 1 mm pre-tension in the internal measuring device. . . . . . . . © 34768-2 © 04/2007 1/6 13999-001 . TD 2012 2V Crankcase TCD 2012 2V W 03-11-01 Removing and installing.  W 02-04-01 z Remove camshaft. 100400 – Assembly tool . . – Set micrometer gauge to 70 mm. . – Mount dial gauge with approx. . . . – Balance the internal measuring device between the test surfaces of the micrometer gauge and set the meter at the reversal point of the pointer to "0". .

z Insert guide piece (2).080 mm Measuring points see diagram. z Balance the internal measuring device at the given measuring points and read off the measured value at the reversal point of the pointer. the cams- haft bearing must be replaced.054  63 mm – Wear limit  63. 6 © 37239-1 z Insert internal measuring device. Crankcase TD 2012 2V W 03-11-01 TCD 2012 2V Diagram for measuring the camshaft bea- ring at the points "a and b" in the levels "1 and 2". + 0. z Insert counter support (3). When the wear limit is reached. © 46337-0 Removing camshaft bearing z Insert spindle (1). 3 2 1 © 45259-0 © 04/2007 2/6 13999-001 .

z Remove bearing bush. 2 1 © 46338-0 Installing camshaft bearing Mark position of the lubricating oil bore. z Screw on nut (2). 1 2 6 © 45266-1 z Hold spindle (1). z Tighten nut (2). Tighten the nut further until the bearing liner falls out. z Remove assembly tool. TD 2012 2V Crankcase TCD 2012 2V W 03-11-01 z Insert pressure piece (1). © 45268-0 © 04/2007 3/6 13999-001 .

2 1 z Insert pressure piece (3). z Position new bearing liner on the pressure piece. 1 1 6 © 45269-0 z Insert spindle (1). The bearing bush is pressed into the crankcase by the thrust pad. © 46338-1 © 04/2007 4/6 13999-001 . Attention! Make sure that the lubricating oil bores are 3 in line. © 45267-1 z Press in the bearing liner flush with the assembly de- vice. z Insert counter bearing (2). Crankcase TD 2012 2V W 03-11-01 TCD 2012 2V z Check that the lubricating oil bores (1) are in line.

the camshaft bearing must be removed and re- installed. 1 6 © 45502-1 z Install the camshaft.  W 02-04-01 © 42710-1 © 04/2007 5/6 13999-001 .  W 04-05-05 z Install crankshaft. TD 2012 2V Crankcase TCD 2012 2V W 03-11-01 z Check that the lubricating oil bores (1) are in line. If the lubricating oil bore is not in line.

Crankcase TD 2012 2V W 03-11-01 TCD 2012 2V 6 © 04/2007 6/6 13999-001 .

 W 05-05-01 © 46488-1 z Remove lubricating oil pan.  W 03-09-04 z Remove flywheel. 2 1 © 46419-2 © 04/2007 1/6 14000-001 . 1 z Unscrew screws (1).  W 08-04-07 z Turn the engine on the assembly block.  W 12-06-01 z Remove speed governor. z Remove cover (2).  W 13-03-02 z Remove connection housing. TD 2012 2V Engine control TCD 2012 2V W 04-04-09 Removing and installing the gearcase cover Commercial available tools – W 02-02-02 – W 03-09-04 – W 05-05-01 – Packing compound – W 08-04-07 DEUTZ DW 67 – W 12-06-01 – W 13-03-02 6 Removing the gearcase z Remove starter.

z Remove gearcase cover. Engine control TD 2012 2V W 04-04-09 TCD 2012 2V z Unscrew screws (1). © 42750-0 © 04/2007 2/6 14000-001 . Attention! Do not damage sealing surface when 1 knocking out. 1 1 1 6 © 46596-0 z Unscrew screws (1). 1 1 1 © 46599-0 z Knock out crankshaft sealing ring (1).

1. Use packing compound DEUTZ DW 67. z Apply packing compound (arrow). TD 2012 2V Engine control TCD 2012 2V W 04-04-09 Installing the gearcase cover z Clean sealing surfaces. Do not tighten screws. 1 1 © 46598-0 z Fasten screws. 1 2 2 © 46596-1 © 04/2007 3/6 14000-001 . Screws M8 x 45 mm (1) Screws M8 x 35 mm (2) Do not tighten screws. Note different screw lengths.4 mm. Sealing bead thickness approx. Do not move the gearcase cover after 1 mounting. The sealing surfaces must be dry and free from grease and dirt. z Mount gearcase cover. z Tighten screws (1). Attention! The assembly must be completed within 1 hour at most. 6 © 42525-0 z Align gearcase cover.

1 © 46460-0 © 04/2007 4/6 14000-001 . The sealing surfaces must be dry and free from grease and dirt. 6 © 46597-0 z Tighten the screws according to the tightening se- quence. z Lightly oil O-ring. The oil tray sealing surface on the crank- case must face downwards. z Mount new O-ring (1). Engine control TD 2012 2V W 04-04-09 TCD 2012 2V z Press up gearcase cover and align flush with the oil tray sealing surface (arrows). 5 6 7  30 Nm 4 1 3 2 12 8 13 11 10 14 9 © 36520-3 z Clean sealing surfaces.

1  21 Nm z Install new crankshaft sealing ring (flywheel side). TD 2012 2V Engine control TCD 2012 2V W 04-04-09 z Press in cover (2) to the stop. z Tighten screws (1).  W 13-03-02 z Turn the engine on the assembly block. z Install lubricating oil pan.  W 08-04-07 © 42759-0 © 04/2007 5/6 14000-001 .  W 03-09-04 z Install flywheel.  W 12-06-01 z Install speed governor.  W 02-02-02 2 6 1 © 46419-2 z Install connection housing. Use screws M8 x 45 mm.  W 05-05-01 z Install starter.

Engine control TD 2012 2V
W 04-04-09 TCD 2012 2V

6

© 04/2007 6/6 14000-001

TD 2012 2V Engine control
TCD 2012 2V W 04-05-05

Removing and installing the camshaft
Commercial available tools: – W 01-02-02
– Lifting gear – W 02-04-01
– W 07-04-01
– W 07-07-01

6

Removing the camshaft
z Remove injection pumps.
 W 07-04-01
z Removing fuel injectors.
 W 07-07-01
z Remove rocker arm and rocker arm bracket.
 W 01-02-02
z Remove crankshaft.
 W 02-04-01

© 42705-0

z Screw in screws (1).
z Hang crankcase on suitable workshop crane.

1
1

© 42707-0

© 04/2007 1/4 14001-001

Engine control TD 2012 2V
W 04-05-05 TCD 2012 2V

z Remove clamping bracket (1) from the adapter
plates (2).

1
1

2
2
6
© 42708-0

z Push away the assembly block on the flywheel side.

© 42709-0

z Press in all tappets.
z Pull out the camshaft (1) carefully to the flywheel
side.

1

© 42710-0

© 04/2007 2/4 14001-001

TD 2012 2V Engine control
TCD 2012 2V W 04-05-05

z Remove all tappets (arrow).
Lay out components in the order in which
they should be installed.
Note order of cylinders.
z Visually inspect the components.

6
© 42711-0

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

© 42711-0

z Oil camshaft bearing lightly.
z Oil cam shaft pin lightly.
z Insert camshaft carefully.
The bore (1) must be facing the cylinder
head.

1

© 42712-0

© 04/2007 3/4 14001-001

Engine control TD 2012 2V
W 04-05-05 TCD 2012 2V

z Push on and align the flywheel side assembly block.
z Mount the clamping bracket (1) on the adapter
plate (2).
 90 Nm
1
1

2
2
6
© 42708-0

z Unhook the crankcase from the workshop crane.
z Unscrew screws (1).

1
1

© 42707-0

z Install crankshaft.
 W 02-04-01
z Install rocker arm and rocker arm bracket.
 W 01-02-02
z Install fuel injectors.
 W 07-07-01
z Install injection pumps.
 W 07-04-01

© 42705-0

© 04/2007 4/4 14001-001

TD 2012 2V Engine control
TCD 2012 2V W 04-05-06

Checking the camshaft
Commercial available tools: – W 04-05-05
– Micrometer gauge
– Prisms

6

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

© 42713-0

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

© 36424-2

© 04/2007 1/2 14002-001

Engine control TD 2012 2V W 04-05-06 TCD 2012 2V z Measure the bearing pin. When the limit value is reached the cams- haft must be replaced.05  63 − 0.  W 04-05-05 © 42713-0 © 04/2007 2/2 14002-001 . 6 © 42714-0 z Check camshaft gear wheel for visible signs of wear. z Install the camshaft.07 mm See schematic diagram for measuring points. − 0.

. 100320 6 Disassembly z Unscrew screws (1). . . . TD 2012 2V Engine control TCD 2012 2V W 04-06-03 Installing and removing turning gear Commercial available tools The turning gear 100330 may also be used depending on the installation ratio. . z Remove cover (2). . . 1 1 2 1 © 46419-0 Attaching turning gear z Insert turn-over gear (1). . . The toothed gear of the turn-over gear 2 must grip into the teeth of the camshaft wheel. . z Tighten screws (2). Special tools: – Turn-over gear . 1 2 © 46420-0 © 04/2007 1/2 14003-001 . . . .

 21 Nm 2 3 1 © 46419-1 © 04/2007 2/2 14003-001 . z Tighten screw (2). z Mount new O-ring (1). z Lightly oil O-ring.  30 Nm 1 z Tighten screws (1). z Remove turning gear (1). Engine control TD 2012 2V W 04-06-03 TCD 2012 2V Removing turning gear z Unscrew screws (2). 1 © 46460-0 z Press in the cover (3) to the stop. 2 1 6 2 © 46420-0 z Clean the sealing surface on cover and gearcase.

. 1 © 46355-0 z Pull out control linkage. .  W 05-05-01 z Remove the gear case cover. . .  W 04-04-09 z Remove injection pumps. . . . . . . . .  W 07-04-01 z Unscrew screw (1). . . 100800 6 Removing the control linkage z Remove speed governor. checking and setting the control linkage Commercial available tools: – W 04-04-09 – Slide gauge – W 05-05-01 Special tools: – W 07-04-01 – Setting device . © 46356-0 © 04/2007 1/6 14004-001 . TD 2012 2V Speed control TCD 2012 2V W 05-04-14 Removing and installing.

 10 Nm Attention! Self-locking screw! z Install the gear case cover.  W 04-04-09 1 © 46355-0 © 04/2007 2/6 14004-001 . © 46356-0 z Tighten new screw (1). z Measure width of the groove (1).03  5 −0.06 mm 1 1 1 6 © 46346-0 Installing the control linkage z Insert control linkage. Speed control TD 2012 2V W 05-04-14 TCD 2012 2V z Visually inspect control linkage. +0.

Start position! 6 © 46344-1 Measure control linkage travel (injection pumps removed) z Install setting device (1). 1 © 46340-1 z Bring control linkage into stop position. Stop position! No uneven resistance may occur. z Measure distance between control linkage and set- ting device. z Release control linkage. TD 2012 2V Speed control TCD 2012 2V W 05-04-14 z Press the control linkage slowly in the direction of the arrow. © 46341-0 © 04/2007 3/6 14004-001 . The control linkage must be pressed back into the initial position from any position by the spring force.

Speed control TD 2012 2V
W 05-04-14 TCD 2012 2V

z Release control linkage.
Start position!

z Measure distance between control linkage and set-
ting device.
– Difference between stop and start position gives
the control linkage travel.
Calculation example
Desired: Control linkage travel
Given: -
Measured: Stop position (a)
(a) = 30.7 mm
Start position (b)
(b) = 13.4 mm
6 Dimension (a) - Dimension (b)
Result: = 17.3 mm
© 46343-0
Nominal di- = 17.0 mm - 17.5 mm
mension

z Turn setting device.
z Turn in knurled screw (1) until reaching the stop po-
sition.
z Install injection pumps.
 W 07-04-01

1

© 46342-1

Measure control linkage travel (injection
pumps installed)
z Install setting device (1).

1

© 46357-0

© 04/2007 4/6 14004-001

TD 2012 2V Speed control
TCD 2012 2V W 05-04-14

z Bring control linkage into stop position.
z Measure distance between control linkage and set-
ting device.

6
© 46358-0

z Release control linkage.
Start position!

z Measure distance between control linkage and set-
ting device.
– Difference between stop and start position gives
the control linkage travel.
Calculation example
Desired: Control linkage travel
Given: -
Measured: Stop position (a)
(a) = 30.5 mm
Start position (b)
(b) = 13.4 mm
Dimension (a) - Dimension (b)
Result: = 17.1 mm
© 46359-0
Nominal di- = >16.8 mm
mension

z Check smooth action of the control linkage.
z Press the control linkage slowly in the direction of the
arrow.
No uneven resistance may occur.

z Release control linkage.
The control linkage must be pressed back
into the initial position from any position by
the spring force.
Start position!

© 46344-1

© 04/2007 5/6 14004-001

Speed control TD 2012 2V
W 05-04-14 TCD 2012 2V

Measure control linkage standback dimen-
sion for governor adaptation
z Measured standback dimension from gear case cov-
er to stop position.
Attention!
The determined dimension must be speci-
fied when changing or repairing the gover-
nor.
z Install speed governor.
 W 05-05-01

6
© 46345-0

© 04/2007 6/6 14004-001

TD 2012 2V Speed control
TCD 2012 2V W 05-05-01

Removing and installing the speed governor
Commercial available tools

– Packing compound
DEUTZ DW 73

6

Removing the speed governor.
z Disconnect cables.
z Unscrew hollow screw (1).
z Remove sealing rings.

1

© 46487-0

z Unscrew screws (1).
z Remove speed governor.

1

1

1
© 46488-0

© 04/2007 1/4 14005-001

Speed control TD 2012 2V
W 05-05-01 TCD 2012 2V

z Clean sealing surfaces.
z Visually inspect the component.

6
© 46489-0

Installing the speed governor
z Apply packing compound evenly to the sealing sur-
face of the gear case.
The sealing surfaces must be dry and free
from grease and dirt.

© 46348-1

z Install speed governor.
z Mount speed governor.
Turn the governor toothed wheel (1)
slightly if necessary to enable tracking.
1

© 46347-1

© 04/2007 2/4 14005-001

TD 2012 2V Speed control
TCD 2012 2V W 05-05-01

z Tighten the screws according to the tightening se-
quence.
 17 Nm
The existing control linkage standback 3 1
dimension must be set on the new gover-
nor when the governor is changed.

5 2 4 6
© 46349-0

z Tighten hollow screw (1).
 18 Nm
Use new sealing rings.

z Connect cable.
Ensure that the connection is perfect.

1

© 46487-0

© 04/2007 3/4 14005-001

Speed control TD 2012 2V W 05-05-01 TCD 2012 2V 6 © 04/2007 4/4 14005-001 .

TD 2012 2V Exhaust system/Charging TCD 2012 2V W 06-01-05 Removing and installing the exhaust line Commercial available tools – W 06-06-04 – Fitting compound DEUTZ S1 6 Removing exhaust line z Remove turbocharger. 1 1 2 © 46354-0 z Remove seals. z Remove studs. z Remove exhaust line (2). © 46484-0 © 04/2007 1/4 14006-001 . 1 1 z Remove spacing sleeves.  W 06-06-04 z Unscrew nuts (1).

z Mount spacer sleeves (1). z Mount new gaskets. 6 © 46485-0 Installing exhaust line z Clean sealing surfaces. z Coat new pin bolts with DEUTZ S1 mounting com- pound. 1 2 © 46486-0 © 04/2007 2/4 14006-001 . Exhaust system/Charging TD 2012 2V W 06-01-05 TCD 2012 2V z Visually inspect the component. z Mount new studs. © 46484-0 z Mount exhaust line (2).

 25 Nm Tightening sequence from inside to out- side. 2 2 2 2 6 © 46354-3 z Tighten all nuts (1). z Install the turbocharger. TD 2012 2V Exhaust system/Charging TCD 2012 2V W 06-01-05 z Turn on new nuts (2).  W 06-06-04 1 © 46354-2 © 04/2007 3/4 14006-001 . start with nut (1).

Exhaust system/Charging TD 2012 2V W 06-01-05 TCD 2012 2V 6 © 04/2007 4/4 14006-001 .

z Remove gasket (2). z Unscrew screws (1). 1 © 46360-0 z Remove hose nozzles (1). 1 3 2 © 44360-1 © 04/2007 1/2 14007-001 . 1 Attention! Hold on the hexagon of the plus pole screw. TD 2012 2V Exhaust system/Charging TCD 2012 2V W 06-02-08 Removing and install the heating flange Commercial available tools 6 Removing the heating flange z Disconnect cables. z Remove gasket (3). z Remove heating flange.

z Tighten screws alternately. © 46360-0 © 04/2007 2/2 14007-001 . z Mount hose nozzles (1). 1 3 2 © 44360-1 z Tighten screws (1). z Mount heating flange. z Mount gasket (2). 6 © 44831-0 Installing the heating flange z Mount gasket (3). Exhaust system/Charging TD 2012 2V W 06-02-08 TCD 2012 2V z Visually inspect the component. 1  3 Nm + 30° z Connect cable.  20 Nm Attention! Hold on the hexagon of the plus pole 1 screw.

. . z Remove sealing rings. 1 z Remove lubricating oil pipe (2). TD 2012 2V Exhaust system/Charging TCD 2012 2V W 06-06-04 Removing and installing the turbocharger Commercial available tools Collect leaking operating substances in suitable vessels and dispose of according Special tools: to regulations. . . . . 2 1 © 46500-0 © 04/2007 1/6 14008-001 . . . . 2 1 © 46499-0 z Unscrew hollow screws (1). . 110901 Emptying and filling the engine with opera- – Fitting compound ting media must be carried out according to DEUTZ S1 the operating manual and the appropriate documentation of the vehicle/equipment manufacturer. . . – Disassembly tool. z Unscrew screw (1). 6 Removing turbocharger z Hold nut (2).

1 6 © 46501-0 z Remove oil return pipe (1). z Remove holder. z Unscrew the pin bolts. z Remove gasket. z Visually inspect the components. 1 1 2 © 46503-0 © 04/2007 2/6 14008-001 . Exhaust system/Charging TD 2012 2V W 06-06-04 TCD 2012 2V z Unscrew screw (1). 1 © 46502-0 z Unscrew nuts (1). z Remove turbocharger (2).

z Insert new pin bolts with mounting compound. z Tighten nuts (1). TD 2012 2V Exhaust system/Charging TCD 2012 2V W 06-06-04 Installing the turbocharger z Clean sealing surfaces. z Lightly oil O-ring.  22 Nm 1 1 2 © 46503-0 © 04/2007 3/6 14008-001 . 1 © 46437-0 z Mount turbocharger (2). z Mount new studs. z Mount gasket (1). 1 6 © 46504-0 z Insert new O-ring (1).

1 sion-free. 2 sion-free.  34 Nm 3 6 © 46500-1 z Insert new O-ring (1). 2 © 46507-0 © 04/2007 4/6 14008-001 . Exhaust system/Charging TD 2012 2V W 06-06-04 TCD 2012 2V z Mount lubricating oil pipe (2). z Insert hollow screws (1) with new sealing rings ten.  18 Nm z Insert hollow screws (3) with new sealing rings ten. 1 © 46438-0 z Connect oil return pipe (2) in direction of arrow. z Lightly oil O-ring.

TD 2012 2V Exhaust system/Charging TCD 2012 2V W 06-06-04 z Push oil return line (1) into crankcase (arrow). z Tighten screw (1). z Mount holder. z Tighten screw (2).  13 Nm 2 1 © 46499-0 © 04/2007 5/6 14008-001 .  21 Nm 1 2 6 © 46501-1 z Hold nut (2).

Exhaust system/Charging TD 2012 2V W 06-06-04 TCD 2012 2V 6 © 04/2007 6/6 14008-001 .

TD 2012 2V Exhaust system/Charging TCD 2012 2V W 06-07-03 Removing and install the charge air line Commercial available tools – W 01-04-04 – Locking agent DEUTZ DW 72 6 Remove charge air line z Unscrew hollow screws (1). 1 © 46490-0 z Disconnect cables. z Unscrew screws (1). z Remove plug piece. 1 1 z Remove gasket. z Remove sealing rings. z Remove charge air manifold (2). 2 1 © 46491-0 © 04/2007 1/4 14009-001 .

z Mount new gaskets (1). 2 z Remove charge air pipe (2). © 46493-0 z Mount charge air line. © 46494-0 © 04/2007 2/4 14009-001 .  W 01-04-04 z Unscrew all screws (1). Ensure that the installation location is free 1 from faults. z Visually inspect the component. Exhaust system/Charging TD 2012 2V W 06-07-03 TCD 2012 2V z Remove the cylinder head hood. 1 6 © 46492-0 Install charge air line z Clean sealing surfaces. z Remove seals.

1 © 46433-0 © 04/2007 3/4 14009-001 . z Tighten screws . z Mount new gasket (1). Do not move gaskets.  W 01-04-04 z Clean sealing surfaces. 1 © 46496-0 z Fit new sealing rings (1). 6 © 46495-0 z Mount cylinder head cover. TD 2012 2V Exhaust system/Charging TCD 2012 2V W 06-07-03 z Fasten screws.  11 Nm Tightening sequence: From the centre out- wards.

1 © 46491-1 z Tighten hollow screw (1). Exhaust system/Charging TD 2012 2V W 06-07-03 TCD 2012 2V z Coat plug piece (1) with mounting compound. 1 6 © 46498-0 z Mount charge air manifold. z Insert plug element (1). z Insert screws (2) with locking agent.  18 Nm Use new sealing rings.  30 Nm z Connect cable. 3 Note different screw lengths: M8 x 30 mm (1) M8 x 95 mm (2) 2 M8 x 80 mm (3) z Tighten screws . z Insert screws (1) with locking agent. 1 © 46490-0 © 04/2007 4/4 14009-001 . z Fasten screws.

. . . . . . . . . . . . 100320 – W 07-06-04 . . (engine wit- – Pressing device . . Remove residue paint and particles of dirt before removing. . . . . . . © 04/2007 1/14 14010-001 . . . . . . Blow damp areas dry with compres- sed air. . . . . . . . . . . . . . . 100830 hout injection – Special pliers. The EP-code must be changed on the company plate. . . . (engine with – Special wrench . . . . Close all connections immediately after opening with new. . . . . 170160 6 Attention! – Fitting compound Pay attention to utmost cleanliness when DEUTZ AP1908 working on the fuel system. . . . . . . . . . . . 110030 – W 07-06-04 . . . . . . . Observe the safety regulations and natio- nal specifications for handling fuels. . . . . . . . . (engine with – Rotation angle disc . . . . . . . . . . . . . . . . Clean the respective affected parts care- fully. . . – W 07-06-03 . . . . . . . camshaft or roller tappet. . TD 2012 2V Fuel system TCD 2012 2V W 07-04-01 Removing and installing the fuel injector pump Commercial available tools: – W 01-04-04 – Socket wrench insert. . . . When changing the fuel injector pump the thickness of the shim must be redetermi- ned. . . . . . . . . . . . 103220 adjuster) – Puller. . . . . . . clean plugs/caps. Do not remove plugs/caps until immedia- tely before assembling. Collect leaking operating substances in suitable vessels and dispose of according to regulations. . . . . . 12-edge hout injection – Multi-toothed socket adjuster) wrench insert . the corrected fuel injector pump installation dimension "EK " and the corresponding EP code must be determi- ned and changed on the company plate. . . (engine wit- 10 mm. When changing the crankcase. . . . . . . . . 150800 ster) – Plugs/caps . . . . . . . . . . 110500 injection adju- – Slide hammer . . . . . . . 8190 injection adju- Special tools: ster) – Turn-over gear . . . 8117 – W 07-06-03 . . . . . . . . . . . . . . . . . . . . . . . . . . .

Fuel system TD 2012 2V W 07-04-01 TCD 2012 2V Removing the fuel injector pump z Pull out the cable plug from the engine shutdown.  W 01-04-04 1 6 © 46474-3 z Unscrew screws (1). 1 © 46371-0 z Pull out engine shutdown (1). z Remove cylinder head cover (1). 1 © 46364-0 © 04/2007 2/14 14010-001 .

TD 2012 2V Fuel system TCD 2012 2V W 07-04-01 z Insert pressing device (1). (control linkage stop position) 1 © 46373-0 © 04/2007 3/14 14010-001 . 1 6 © 46365-0 z Tighten screws (1). Turn knurled screw to stop. 1 © 46372-0 z Turn knurled screw (1).

The toothed gear of the turn-over gear must grip into the teeth of the camshaft 2 wheel. z Tighten screws (2). © 35356-1 © 04/2007 4/14 14010-001 . 1 2 © 00000-0 z Turn crankshaft in engine direction of rotation until the cam for actuating the fuel injector pump of the corresponding cylinder is on the base circle. Example: Inlet valve cylinder 1 is open. Fuel system TD 2012 2V W 07-04-01 TCD 2012 2V z Unscrew screws (1). 1 1 2 6 1 © 46419-0 z Insert turn-over gear (1). z Remove cover (2).

© 46426-0 © 04/2007 5/14 14010-001 . TD 2012 2V Fuel system TCD 2012 2V W 07-04-01 z Remove injection line with special wrench. 6 © 46424-1 z Unscrew screws (1). 1 © 46425-0 z Remove flange.

1 © 46427-0 z Pull out fuel injector pump. 1 2 3 6 © 40958-0 z Apply slide hammer to fuel injector pump. z Screw on lock nut (1). Fuel system TD 2012 2V W 07-04-01 TCD 2012 2V If fuel injector pump is stuck tight: z Assembly sliding hammer (1) and puller (2). z Pull out stuck fuel injector pump. z Visually inspect the component. © 46418-0 © 04/2007 6/14 14010-001 . z Tighten lock nut (3).

z Visually inspect the components. camshaft © 46421-1 or roller tappet. z Determining the thickness of the shim (engine without injection adjuster)  W 07-06-03 z Determining the thickness of the shim (engine with injection adjuster) 1  W 07-06-03 z Insert roller tappet (1) with special pliers. 1 6 © 46421-1 Installing the fuel injector pump When changing the fuel injector pump the thickness of the shim must be redetermi- ned. When changing the crankcase. z Determining the installation dimension of the fuel in- jector pump (engine without injection adjuster)  W 07-06-04 z Determining the installation dimension of the fuel in- jector pump (engine with injection adjuster)  W 07-06-04 © 04/2007 7/14 14010-001 . TD 2012 2V Fuel system TCD 2012 2V W 07-04-01 z Pull out roller tappet (1) with special pliers. z Remove shim. the corrected fuel injector pump installation dimension "EK " and the corresponding EP code must be determi- ned and changed on the company plate. The EP-code must be changed on the company plate.

z Insert the fuel injector pump control lever (1) in the control linkage. © 46369-0 z Coat the locating hole in the crankcase and the O- rings of the fuel injector pump with mounting com- pound. z Install the fuel injector. 1 © 46418-1 © 04/2007 8/14 14010-001 . Fuel system TD 2012 2V W 07-04-01 TCD 2012 2V z Insert new O-rings (1). z Set the roller tappet of the respective cylinder on the base circle. 1 6 © 39865-1 z Turn the fuel injector pump control lever to approx. centre position.

z Tighten screws evenly with the socket wrench insert. Chamfer must face the fuel injector pump body. 1 1 © 46366-0 © 04/2007 9/14 14010-001 . 1 2 © 46430-0 z Turn screws (1) 190° in direction of arrow. z Lightly oil screws (1). 6 © 46426-0 Start respectively with screw (2). z Lightly oil screws (2).  5 Nm + 80° Attention! The flange must contact evenly. TD 2012 2V Fuel system TCD 2012 2V W 07-04-01 z Mount flange.

2 1 © 46372-1 © 04/2007 10/14 14010-001 . z Remove pressing device (2). 6 © 46429-0 Start respectively with screw (2). z Tighten screws (1) and (2).  25 Nm 1 2 © 46430-0 z Unscrew screws (1). Fuel system TD 2012 2V W 07-04-01 TCD 2012 2V z Turn injection pump carefully with multi-toothed socket wrench insert in direction of arrow to the tan- gible stop.  5 Nm + 150° z Tighten new injection lines with special wrench.

2 1 2 6 © 00000-0 z Clean the sealing surface on cover and gearcase. z Lightly oil O-ring. z Tighten screw (2). 1 © 46460-0 z Press in the cover (3) to the stop.  30 Nm 1 z Tighten screws (1).  21 Nm 2 3 1 © 46419-1 © 04/2007 11/14 14010-001 . TD 2012 2V Fuel system TCD 2012 2V W 07-04-01 z Unscrew screws (2). z Remove turning gear (1). z Mount new O-ring (1).

 21 Nm 1 © 46371-0 © 04/2007 12/14 14010-001 . z Actuate the shutdown lever between start and stop position. 6 1 © 46417-0 z Press the control linkage into the stop position with the shutdown lever and hold. z Insert engine shutdown (1). Fuel system TD 2012 2V W 07-04-01 TCD 2012 2V Attention! Check control linkage for smooth action. z Mount new O-ring (1). 1 © 46364-0 z Tighten screws (1). z Lightly oil O-ring.

TD 2012 2V Fuel system TCD 2012 2V W 07-04-01 z Mount cylinder head cover (1). 1 6 © 46474-3 © 04/2007 13/14 14010-001 .  W 01-04-04 z Plug cable plug to engine shutdown.

Fuel system TD 2012 2V W 07-04-01 TCD 2012 2V 6 © 04/2007 14/14 14010-001 .

Example: EK = 120. Example: EP-code 295 for cylinder 1 (1) z Read and note the corrected fuel injector pump dimension EK based on the EP-code.  W 07-04-01 © 46418-0 z Read EP-code according to the cylinder concerned from the company plate. Lubricating oil temperature < 40 °C All contact and measuring surfaces must be absolutely clean to rule out measuring errors! 6 The following procedure describes the work for one fuel injector pump example. The work procedure is the same for any other fuel injector pump.see Technical Data 1 © 46416-0 © 04/2007 1/2 14011-001 .875 mm  Table 3 . TD 2012 2V Fuel system TCD 2012 2V W 07-06-03 Determining the thickness of the shim (Engine without injection adjuster) Commercial available tools: – W 07-04-01 – Torque wrench Let the engine cool down for at least one hour. z Remove fuel injector.

 W 07-04-01 © 46418-0 © 04/2007 2/2 14011-001 . 117. z Read and note basic dimension L0 of the injection pump. e.955 mm Select SS according to table 2 SS = 3. e. Fuel system TD 2012 2V W 07-06-03 TCD 2012 2V z Read code number of the (new) fuel injector pump for fuel injector pump length dimension A. g. Example: Dimension A = 42 z Note dimension A for the calculation of the theoretical shim thickness TS.(117. 120.see Technical Data Calculation example Desired: Theoretical shim thickness TS 6 Shim thickness SS Given: Code for fuel injector pump length A © 30095-3 Basic dimension of the fuel injector pump L0 from table 1 e.(L0 + A/100) TS = 120. Example: 117.875 mm . z Install the fuel injector.875 mm Calculation: TS = EK .2. 295 Corrected fuel injector pump installation dimension EK from table 3 according to the EP- code.5 mm EP-code (company plate) .5 mm  Table 1 .g.117.875 mm .see Technical Data z Calculate the thickness of the shim.0 mm z Place determined shim on roller tappet. 3 .92 mm Result: TS= 2.g.  Tables 1.5 mm + 42/100 mm) TS = 120.

TD 2012 2V Fuel system TCD 2012 2V W 07-06-03 Determining the thickness of the shim (Engine with injection adjuster) Commercial available tools – W 07-04-01 Let the engine cool down for at least one hour.65 mm  Table 3.  W 07-04-01 © 46418-0 z Read EP-code according to the cylinder concerned from the company plate. Example: EK = 117. The work procedure is the same for any other fuel injector pump.see Technical Data 1 © 46416-0 © 04/2007 1/2 14012-001 .1 . Example: EP-code 670 for cylinder 1 (1) z Read and note the corrected fuel injector pump dimension EK based on the EP-code. z Remove fuel injector. Lubricating oil temperature < 40 °C All contact and measuring surfaces must be absolutely clean to rule out measuring errors! 6 The following procedure describes the work for one fuel injector pump example.

g.65 mm .see Technical Data 23 z Calculate the thickness of the shim.27 mm Select SS according to table 2.g.38 mm Result: TS= 6.111.1 according to the EP-code.65 mm .15 mm  Table 1. Example: Dimension A = 23 z Note dimension A for the calculation of the theoretical shim thickness TS. 3.15 mm EP-code (company plate) .65 mm Calculation: TS = EK .g. 117.  W 07-04-01 © 46418-0 © 04/2007 2/2 14012-001 .1 .1. z Install the fuel injector.(111.1 e. e.  Tables 1. z Read and note basic dimension L0 of the injection pump.1.(L0 + A/100) TS = 117. Example: 111.15 mm + 23/100 mm) TS = 117.25 mm z Place determined shim on roller tappet.see Technical Data Calculation example Desired: Theoretical shim thickness TS 6 Shim thickness SS Given: Code for fuel injector pump length A © 39865-0 Basic dimension of the fuel injector pump L0 from table 1.1 .1 SS = 6. 111. 670 Corrected fuel injector pump installation dimension EK from table 3. Fuel system TD 2012 2V W 07-06-03 TCD 2012 2V z Read code number of the (new) fuel injector pump for fuel injector pump length dimension A. 2. e.

z Clean surface of the roller tappet. z Remove fuel injector. . 100410 Let the engine cool down for at least one – Measuring device . . . . . . . . z Place spacer disc (5 mm) on the roller tappet. 103210 hour. . . . . TD 2012 2V Fuel system TCD 2012 2V W 07-06-04 Determining the installation dimension of the injector pump (Engine without injection adjuster) Commercial available tools – W 07-04-01 Special tools: – Digital dial gauge . .  W 07-04-01 © 46418-0 Lubricating oil residue on the surface of the roller tappet can falsify the measuring result. z Insert roller tappet in the fuel injector pump shaft with special pliers. . . . The work procedure is the same for any other fuel injector pump. . . © 46421-0 © 04/2007 1/6 14013-001 . Lubricating oil temperature < 40 °C All contact and measuring surfaces must be absolutely clean to rule out measuring errors! 6 The following procedure describes the work for one fuel injector pump example. . . . .

z Tighten knurled screw of the dial gauge holder. short (2) on dial gauge holder (1). 6 © 35356-1 z Mount measuring foot. © 39859-0 © 04/2007 2/6 14013-001 . 1 2 © 39858-0 z Insert dial gauge in dial gauge holder. Fuel system TD 2012 2V W 07-06-04 TCD 2012 2V z Turn crankshaft with turning gear in engine direction of rotation until the cam for actuating the fuel injector pump for cylinder 1 is on the base circle. Inlet valve cylinder 1 is open.

TD 2012 2V Fuel system TCD 2012 2V W 07-06-04 z Insert spacer in the setting master with special pliers. Note unit of dimension.25 mm © 39861-0 z Clean contact and measuring surfaces on the crank- case. z Set dial gauge to "0" with pre-tension. Depth dimension of the setting master cor- responds to: Le = 122. z Align the dial gauge holder. z Insert the dial gauge holder carefully in the fuel injec- tor pump shaft. z Screw in screws (1) with spacer sleeves (2).  15 Nm 1 1 2 2 © 46422-0 © 04/2007 3/6 14013-001 . 6 © 39860-0 z Insert dial gauge holder in the setting master. z Tighten screws (1).

713 mm z Note corrected fuel injector pump installation dimen- sion ’’EK’’.0 mm Result: L = 125.20 mm Calculation: L = Le . © 39870-0 z Read code number of the fuel injector pump for fuel injector pump length dimension A. z Note dimension A for the calculation of the theoretical shim thickness TS.X + d "L" L = 122.Vh nominal value EK = 125. 6 © 46423-2 z Remove dial gauge holder.337 mm Result: EK = 119. Given: Dimension L Commencement of delivery (company plate) Camshaft type W (company plate) Pre-stroke Vh nominal value from table 1 Calculation: EK = L . z Calculate corrected fuel injector pump installation di- mension ’’EK’’. Fuel system TD 2012 2V W 07-06-04 TCD 2012 2V The dial gauge now shows a value in the plus or minus range.2.20 mm + 5.25 mm Thickness of the shim (d) = 5 mm Measured: Display dial gauge X = + 2. – Example: Dimension A = 42 © 30095-3 © 04/2007 4/6 14013-001 .05 mm .25 mm . z Calculate dimension "L".05 mm z Note dimension "L".see Technical Data Calculation example Desired: Corrected fuel injector pump installation dimen- sion ’’EK’’.  Table 1 . Calculation example Desired: Dimension L Given: Depth setting master Le = 122.5.

the newly determined cor- rected fuel injector pump installation dimension "EK " and the corresponding EP code must be determined and changed on the company plate.(117.713 mm . z Install the fuel injector.g.793 mm Select SS according to table 2 SS = 1. see above calculation) Code for fuel injector pump length A Basic dimension of the fuel injector pump L0 from table 1 e.see Technical Data Calculation example Desired: EP-code © 46418-0 Calculation example (continued) Given: Corrected fuel injector pump installation dimen- sion EK (redetermined. camshaft or roller tappet.  Tables 1. 117.(L0 + A/100) TS = 119.2.5 mm Calculation: TS = EK . When changing the crankcase.713 mm .  W 07-04-01 Repeat the measuring process for every fuel injector pump. TD 2012 2V Fuel system TCD 2012 2V W 07-06-04 z Calculate the thickness of the shim. see above calculation) EK = 119.92 mm Result: TS= 1.8 mm 6 z Place determined shim on roller tappet.  Table 3 .725 mm Calculation: Select EP-code according to table 3 Result: EP-code = 249 © 04/2007 5/6 14013-001 . z Determine EP-code.see Technical Data Calculation example Desired: Theoretical shim thickness TS Shim thickness SS Given: Corrected fuel injector pump installation dimen- sion EK (redetermined.117. 3 .5 mm + 42/100 mm) TS = 119.713 mm EK symmetrically rounded = 119.

Fuel system TD 2012 2V W 07-06-04 TCD 2012 2V 6 © 04/2007 6/6 14013-001 .

. 100410 hour. . .  W 07-04-01 © 46418-0 Lubricating oil residue on the surface of the injection adjuster can falsify the measuring result. TD 2012 2V Fuel system TCD 2012 2V W 07-06-04 Determining the installation dimension of the injection pump (Engine with injection adjuster) Commercial available tools: – W 07-04-01 – Torque wrench Special tools: – Turn-over gear . . z Remove fuel injector. . . . . The work procedure is the same for any other fuel injector pump. . . z Clean surface of the injection adjuster. . . . . 100320 Let the engine cool down for at least one – Digital dial gauge . . z Insert roller tappet in the fuel injector pump shaft with special pliers. . . Lubricating oil temperature < 40 °C – Measuring device . . . . . . . . . . . . . 103210 All contact and measuring surfaces must be absolutely clean to rule out measuring errors! 6 The following procedure describes the work for one fuel injector pump example. . . . . . © 46421-0 © 04/2007 1/6 14014-001 . .

Fuel system TD 2012 2V W 07-06-04 TCD 2012 2V z Turn crankshaft with turning gear in engine direction of rotation until the cam for actuating the fuel injector pump for cylinder 1 is on the base circle. © 39859-0 © 04/2007 2/6 14014-001 . 6 © 35356-1 z Mount measuring foot. z Tighten knurled screw of the dial gauge holder. Inlet valve cylinder 1 is open. short (2) on dial gauge holder (1). 1 2 © 39858-0 z Insert dial gauge in dial gauge holder.

Note unit of dimension.25 mm © 39861-0 z Clean contact and measuring surfaces on the crank- case. z Tighten screws (1). z Screw in screws (1) with spacer sleeves (2). z Align the dial gauge holder. Depth dimension of the setting master cor- responds to: Le = 122. 6 © 39860-0 z Insert dial gauge holder in the setting master. z Set dial gauge to "0" with pre-tension.  15 Nm 1 1 2 2 © 46422-0 © 04/2007 3/6 14014-001 . z Insert the dial gauge holder carefully in the fuel injec- tor pump shaft. TD 2012 2V Fuel system TCD 2012 2V W 07-06-04 z Insert spacer in the setting master with special pliers.

z Note dimension A for the calculation of the theoretical shim thickness TS.5.Vh nominal value EK = 122. z Calculate dimension "L".45 mm Calculation: L = (Le + 1 mm) .25 mm .(+ 0. Given: Dimension L Commencement of delivery (company plate) Camshaft type W Pre-stroke Vh nominal value from table 1.25 mm Working piston travel = + 1 mm Measured: Display dial gauge X = + 0.80 mm .0.463 mm z Note corrected fuel injector pump installation dimen- sion ’’EK’’.1 .  Table 1.X L = (122. © 39870-0 z Read code number of the fuel injector pump for fuel injector pump length dimension A. – Example: Dimension A = 23 23 © 39865-0 © 04/2007 4/6 14014-001 .45 mm Result: L = 122. Add 1 mm working piston travel of the injection adjuster (see calculation example). Calculation example Desired: Dimension L Given: Depth setting master Le = 122.see Technical Data Calculation example Desired: Corrected fuel injector pump installation dimen- sion ’’EK’’.45 mm) L = 123. © 39866-0 z Remove dial gauge holder.25 mm + 1 mm) .337 mm Result: EK = 117. Fuel system TD 2012 2V W 07-06-04 TCD 2012 2V The dial gauge now shows a value in the plus or minus range. z Calculate corrected fuel injector pump installation di- mension ’’EK’’.80 mm 6 z Note dimension "L".1 Calculation: EK = L .

111.  W 07-04-01 Repeat the measuring process for every fuel injector pump.463 mm .38 mm Result: TS= 6.g.111.1.(111.1 .1.1 .463 mm EK symmetrically rounded = 117. TD 2012 2V Fuel system TCD 2012 2V W 07-06-04 z Calculate the thickness of the shim. 2. see above calculation) EK = 117.475 mm Calculation: Select EP-code according to table 3. see above calculation) Code for fuel injector pump length A Basic dimension of the fuel injector pump L0 from table 1.see Technical Data Calculation example Desired: Theoretical shim thickness TS Shim thickness SS Given: Corrected fuel injector pump installation dimen- sion EK (redetermined.  Table 3. 3.see Technical Data Calculation example Desired: EP-code © 46418-0 Calculation example (continued) Given: Corrected fuel injector pump installation dimen- sion EK (redetermined. When changing the crankcase.1 mm 6 z Place determined shim on roller tappet.463 mm .1 Result: EP-code = 663 © 04/2007 5/6 14014-001 . the newly determined cor- rected fuel injector pump installation dimension "EK " and the corresponding EP code must be determined and changed on the company plate. z Install the fuel injector.(L0 + A/100) TS = 117.1 e. z Determine EP-code.1 SS = 6.15 mm + 23/100 mm) TS = 117. camshaft or roller tappet.083 mm Select SS according to table 2.15 mm Calculation: TS = EK .  Tables 1.

Fuel system TD 2012 2V W 07-06-04 TCD 2012 2V 6 © 04/2007 6/6 14014-001 .

. . Observe the safety regulations and natio- 6 nal specifications for handling fuels. . . . . . . . . . . . . . . Carefully clean the area around the affec- ted parts. 110030 – Extraction tool . . . clean plugs/caps. . . . . Collect leaking operating fluids in suitable vessels and dispose of according to regu- lations. . 1 © 46569-0 © 04/2007 1/4 14015-001 . . . . . . 120660 Danger! – Special wrench . . Proceed the same to remove another fuel injector. . .  W 01-04-04 z Unscrew union nut (1) with special wrench. . – Fitting compound Attention! DEUTZ AP1908 Ensure utmost cleanliness when working on the fuel system. . . . Do not remove plugs/caps until immedia- tely before assembling. . . TD 2012 2V Fuel system TCD 2012 2V W 07-07-01 Removing and installing the fuel injectors Commercial available tools – W 01-04-04 – W 07-07-05 Special tools: – Puller. . . . The following work procedure describes the removal and installation of a fuel injec- tor. . 110500 Wait 30 seconds after switching off the – Slide hammer . 150800 engine before working on the fuel system. . . . . . . Close all connections immediately after opening with new. . . . . . Blow damp areas dry with com- pressed air. . . . . . Removing fuel injector z Remove the cylinder head hood. . . . . .

3 1 2 © 46571-0 Removing stuck fuel injectors z Assembly sliding hammer (1) and puller (2). z Remove clamping shoe (2). z Remove sealing rubber from injection line. z Tighten lock nut (3). 1 2 3 © 46571-0 © 04/2007 2/4 14015-001 . z Remove injection line. Fuel system TD 2012 2V W 07-07-01 TCD 2012 2V z Unscrew union nut (1) with special wrench. z Pull out fuel injector (3). 1 6 © 46570-0 z Unscrew screw (1).

1 2 © 46435-0 © 04/2007 3/4 14015-001 . 6 © 46568-0 z Visually inspect the components. z Check the fuel injector. 1 z Pull out stuck fuel injector. z Pull out stuck sealing ring on cylinder head with ex- traction tool. z Screw on lock nut (1). z Mount sealing ring (2).  W 07-07-05 © 45414-0 Installing the fuel injector z Mount new O-ring (1). TD 2012 2V Fuel system TCD 2012 2V W 07-07-01 z Mount sliding hammer on fuel injector.

z Mount cylinder head cover. 2  25 Nm z Mount the sealing rubber (3). The countersink (1) on the fuel injector must face away from the clamping shoe.  16 Nm 3 1 2 © 46571-0 z Install new high pressure pipe (1). z Tighten screw (1). Fuel system TD 2012 2V W 07-07-01 TCD 2012 2V Attention! Note installation position. z Tighten union nuts (2) with special wrench. 1  W 01-04-04 3 2 © 46431-0 © 04/2007 4/4 14015-001 . z Mount clamping shoe (2). 1 6 © 46436-0 z Insert fuel injector (3).

. . . . . . . . . . . . . . . . . . . . . TD 2012 2V Fuel system TCD 2012 2V W 07-07-05 Checking fuel injectors Commercial available tools: – W 07-07-01 – Socket wrench insert size 15 . . . . . . the spring space above the nozzle needle in the injection valve fills up 6 with diesel fuel/test oil. 8012 – Nozzle tester. . The fuel penetrates deep into the flesh through the nozzle jet! Caution. . . . . . . . Then it is no longer possible to actuate the hand lever. Only use pure test oil according to ISO 4113 or clean diesel fuel to test the fuel injectors. . . . . . . . . . . . blood poisoning! After about three or four actuations of the hand lever. . . . . . The nozzle cap nut must be loosened care- fully before every test procedure to release pressure from the spring space. . . . z Removing fuel injectors. 8008 Danger! Special tools: Danger of injury when handling the nozzle – Holder . . . 110110 tester.  W 07-07-01 © 45414-0 © 04/2007 1/6 14016-001 . . . . . . . .

Repeat test 3 times. z Loosen nozzle cap nut approx.  35 Nm 6 © 36271-2 z Connect the fuel injector to the nozzle tester © 35889-2 Checking opening pressure z Press down the lever of the nozzle tester slowly with the pressure gauge connected. © 36293-2 © 04/2007 2/6 14016-001 . The pressure at which the pointer stands still or suddenly drops is the opening pres- sure. z Read off measured value. Fuel system TD 2012 2V W 07-07-05 TCD 2012 2V Connecting the fuel injector to the nozzle tester z Insert fuel injector in holder. 180° with socket wrench insert (release pressure) and re-tighten.

TD 2012 2V Fuel system TCD 2012 2V W 07-07-05 z Compare measured values. z Press the hand lever of the tester down slowly until about 20 bar below the previously read opening pressure are reached. the fuel in- jector must be renewed. z In case of deviations from the test value. 6 © 36293-2 Checking tightness z Blow the injection nozzle and nozzle holder dry with air. © 36293-2 Injection nozzle is tight if it does not drip within 10 seconds.  220 bar The measured values of three tests must match the test value. © 36294-2 © 04/2007 3/6 14016-001 .

The jet profile may deviate considerably from that of a new fuel injector. z Carry out chatter and jet test of the nozzle needle. Attention! Repairs are not permitted! 6 © 36295-2 Checking the easy action of the nozzle needle z Switch off the tester’s pressure gauge. The easy action of the nozzle needle in the nozzle body is checked by the acoustic chatter test. Increasing wear in the needle seat of the fuel injectors changes the chatter behavior of the injecton nozzle. the fuel injector must be renewed. A used fuel injector must buzz audibly and atomize the fuel finely when the lever is actuated quickly. © 36296-2 © 04/2007 4/6 14016-001 . Fuel system TD 2012 2V W 07-07-05 TCD 2012 2V z If the injection nozzle drips. the fuel injector must be renewed. © 36296-2 z If the injection nozzle does not buzz audibly.

z Install fuel injectors. TD 2012 2V Fuel system TCD 2012 2V W 07-07-05 Removing the fuel injector from the nozzle tester z Loosen nozzle cap nut approx. 180° with socket wrench insert (release pressure) and re-tighten.  35 Nm Attention! The pressure in the spring space must be reduced before installing the fuel injectors.  W 07-07-01 6 © 36271-2 © 04/2007 5/6 14016-001 .

Fuel system TD 2012 2V W 07-07-05 TCD 2012 2V 6 © 04/2007 6/6 14016-001 .

1 ding to regulations. . Blow damp areas dry with com- pressed air. Collect leaking operating fluids in suitable vessels and dispose of according to regu- lations. . . . . . © 46583-0 © 04/2007 1/4 14017-001 . . z Remove sealing rings. 170050 – Plugs/caps . Observe the safety regulations and natio- 6 nal specifications for handling fuels. . . . . . Close all connections immediately after opening with new. . TD 2012 2V Fuel system TCD 2012 2V W 07-10-08 Removing and installing the fuel filter console Commercial available tools – User notes – Operation manual Special tools: – Special wrench . . Attention! Ensure utmost cleanliness when working on the fuel system. 170160 Danger! Wait 30 seconds after switching off the engine before working on the fuel system. . . Do not remove plugs/caps until immedia- tely before assembling. . . . . clean plugs/caps. . . Removing the fuel filter console z Unscrew hollow screws (1). . . . . Collect draining fuel and dispose of accor. . . Carefully clean the area around the affec- ted parts. .

z Mount nut (1). 1 2 z Fasten screw (2). © 46586-0 © 04/2007 2/4 14017-001 . © 46585-0 Installing the fuel filter console z Mount the fuel filter console. Fuel system TD 2012 2V W 07-10-08 TCD 2012 2V z Unscrew screws (1). 1 2 6 © 46584-0 z Visually inspect the component. z Remove fuel filter console (2).

1 z Tighten screws . © 46583-1 © 04/2007 3/4 14017-001 . Bleed the fuel system via the manual fuel pump on the fuel pre-filter according to the operation manual.  30 Nm 2 6 © 46523-1 z Tighten hollow screw (1) with new sealing rings. 2  39 Nm 1 Attention! Lay the hose pipe free from chafing and tension. z Fasten screw (2). TD 2012 2V Fuel system TCD 2012 2V W 07-10-08 z Mount nut (1).  39 Nm z Tighten hollow screw (2) with new sealing rings.

Fuel system TD 2012 2V W 07-10-08 TCD 2012 2V 6 © 04/2007 4/4 14017-001 .

. . Do not remove plugs/caps until immediately before assembling. Only test / tighten / renew V-belts with the engine at a standstill. Collect escaping fuel in suita- ble vessels and dispose of according to regulations. . . . Blow damp areas dry with compressed air. . © 46572-0 © 04/2007 1/4 14018-001 . . TD 2012 2V Fuel system TCD 2012 2V W 07-11-01 Removing and installing the fuel supply pump Commercial available tools – W 13-02-03 – User notes Special tools: – Operation manual – Plugs/caps . . . . Clean the affected parts carefully. . Observe the safety regulations and specific national 6 rules for handling fuels. 1 Collect draining fuel and dispose of accor- ding to regulations. z Unscrew hollow screw (1). Seal all connec- tions immediately with new and clean plugs/caps after opening. . 170160 Danger! Wait 30 seconds after switching off the engine before working on the fuel system. Attention! Pay attention to utmost cleanliness when working on the fuel system. . . Removing the fuel supply pump Danger! Wait 30 seconds after switching off the engine before working on the fuel system. . .

z Press clamping strap (1) in direction of arrow with a suitable tool. 1 z Visually inspect the components. z Remove fuel supply pump. 1 © 46375-1 © 04/2007 2/4 14018-001 . 1 1 © 46574-0 z Mount V-belt. z Remove V-belt. 1 6 © 46573-0 Installing the fuel supply pump z Mount fuel supply pump. z Tighten screws (1). Fuel system TD 2012 2V W 07-11-01 TCD 2012 2V z Unscrew screws (1).

Bleed the fuel system via the manual fuel pump on the fuel pre-filter according to the 1 operation manual. TD 2012 2V Fuel system TCD 2012 2V W 07-11-01 z Pre-tighten screws (1). © 46572-0 © 04/2007 3/4 14018-001 .  39 Nm (M12x1. z Check V-belt tension.  W 13-02-03 1 1 6 © 46375-0 z Tighten hollow screw (1).5) Use new sealing rings.

Fuel system TD 2012 2V W 07-11-01 TCD 2012 2V 6 © 04/2007 4/4 14018-001 .

M8 x 25 mm (1) M8 x 16 mm (2) 1 2 © 42767-1 © 04/2007 1/2 14019-001 . 1 z Fasten screws. Note different screw lengths.  W 08-04-07 z Unscrew screws (1). Note installation position. TD 2012 2V Lube oil system TCD 2012 2V W 08-04-06 Removing and installing the oil suction pipe Commercial available tools – W 08-04-07 6 Removing the oil suction pipe z Remove lubricating oil pan. 2 z Remove gasket. 1 1 © 42766-1 Installing the oil suction pipe z Clean sealing surfaces. z Mount oil suction pipe. z Mount new gasket. z Visually inspect the components. 1 z Remove oil suction pipe (2).

 21 Nm z Install lubricating oil pan. Lube oil system TD 2012 2V W 08-04-06 TCD 2012 2V z Tighten screws (1).  W 08-04-07 1 1 1 6 © 42768-1 © 04/2007 2/2 14019-001 .

z Remove gasket. z Remove washer. TD 2012 2V Lube oil system TCD 2012 2V W 08-04-07 Removing and installing the lubricating oil pan (die-cast lubricating oil pan) Commercial available tools Collect leaking operating substances in suitable vessels and dispose of according to regulations. z Remove filler neck (2). collect and dispose of according to regulations. – Packing compound Emptying and filling the engine with opera- DEUTZ DW 74 ting media must be carried out according to the operating manual and the appropriate documentation of the vehicle/equipment manufacturer. z Remove sealing ring. 6 Removing the lubricating oil pan z Unscrew locking screw (1). 2 1 1 © 46592-0 © 04/2007 1/4 14020-001 . z Drain lubricating oil. 1 © 46593-0 z Unscrew screws (1).

Apply the packing compound in an even bead (thickness approx. Lube oil system TD 2012 2V W 08-04-07 TCD 2012 2V z Unscrew all screws (1).5 mm). z Apply packing compound evenly to the sealing sur- face. z Remove lubricating oil pan. 1 6 © 46594-3 z Visually inspect the components. © 43451-0 © 04/2007 2/4 14020-001 . © 44948-0 Installing the lubricating oil pan z Clean sealing surfaces. 3. The position of the packing compound is only partly illlustrated. The sealing surfaces must be dry and free from grease and dirt.

Do not move the packing compound when 1 mounting the lube oil tray. © 44951-0 © 04/2007 3/4 14020-001 . Screw length: 1 M8 x 35 mm © 46594-3 z Align lubricating oil pan to crankcase. TD 2012 2V Lube oil system TCD 2012 2V W 08-04-07 z Mount lubricating oil pan. Screw length: 2 M8 x 130 mm (1) M8 x 110 mm (2) 2 1 6 © 46594-2 z Fasten all screws (1). z Fasten screws.

20 18 12 22 8 See graphic for tightening sequence. z Fasten screws (3).5) z Fill in lubricating oil according to operating manual.  55 Nm (M18 x 1. z Mount new gasket. Lube oil system TD 2012 2V W 08-04-07 TCD 2012 2V z Tighten the screws according to the tightening se- quence.  30 Nm 2 3 © 46592-1 z Insert new sealing ring. z Mount disc. z Tighten screw plug (1). z Fasten screw (2). 21 4 1 19 5  30 Nm 9 13 11 7 15 3 17 2 14 16 6 6 10 © 45133-0 z Clean sealing surfaces. z Tighten screws (3). 1 © 46593-0 © 04/2007 4/4 14020-001 . z Mount filler neck (1). 1  30 Nm z Tighten screw (2).

– Separating tool . . . Special tools: Seal all openings. . . 1 © 45971-0 © 04/2007 1/6 14021-001 . z Remove sealing ring. 151500 Collect leaking operating substances in – Packing compound suitable vessels and dispose of according DEUTZ DW 74 to regulations. . . z Drain lubricating oil. . . . 6 Removing the lubricating oil pan z Unscrew locking screw (1). 1 © 44480-0 z Unscrew all screws (1). TD 2012 2V Lube oil system TCD 2012 2V W 08-04-07 Removing and installing the lubricating oil pan (metal sheet lubricating oil pan) Commercial available tools: Attention! – Wire brush Make sure that no gasket residue falls into – 4 pin bolts M8x70 the crankcase. Emptying and filling the engine with opera- ting media must be carried out according to the operating manual and the appropriate documentation of the vehicle/equipment manufacturer. collect and dispose of according to regulations. . . . .

Lube oil system TD 2012 2V W 08-04-07 TCD 2012 2V z Drive in separating tool (1) to the stop (2). 1 © 45970-0 z Lever out lubricating oil pan. Attention! The tool can only be driven in in the area of the crankcase. © 45968-0 © 04/2007 2/6 14021-001 . 2 Do not damage the sealing surfaces. Separation in the area of aluminium parts is not allowed. 2 Do not damage the sealing surfaces. Separation in the area of aluminium parts is not allowed. Attention! The tool can only be driven in in the area of the crankcase. 1 6 © 45969-0 z Drive in second separating tool (1) to the stop (2). z Remove lubricating oil pan.

© 45967-1 © 04/2007 3/6 14021-001 . 6 © 43450-1 Installing the lubricating oil pan z Scrape off sealing compound with separating tool. z Clean the sealing surface on the crankcase with a wire brush. The sealing surfaces must be dry and free from grease and dirt. TD 2012 2V Lube oil system TCD 2012 2V W 08-04-07 z Visually inspect the component. © 45973-0 Attention! Wear protective glasses.

screw four pin bolts (1) diagonally opposed into the crankcase. 3. Lube oil system TD 2012 2V W 08-04-07 TCD 2012 2V Attention! Wear protective glasses. The sealing surfaces must be dry and free from grease and dirt. © 45678-0 © 04/2007 4/6 14021-001 . z Align the lubricating oil pan in the appropriate instal. 1 lation position with the pin bolts. 6 © 45972-0 z Apply packing compound evenly to the sealing sur- face and in the beading of the lube oil tray. Attention! Do not move the lubricating oil pan any more. z Clean the sealing surface on the lubricating oil pan with a wire brush. Observe the drying time for the packing compound. Apply the packing compound in an even bead (thickness approx. © 43451-0 z To align the lubricating oil pan. The position of the packing compound is only partly illlustrated.5 mm). z Unscrew the pin bolts. z Mount lubricating oil pan.

Note different screw lengths. TD 2012 2V Lube oil system TCD 2012 2V W 08-04-07 z Fasten all screws (1). 1 6 © 45971-0 z Tighten the screws according to the tightening se- quence.  30 Nm 24 20 16 12 8 4 1 5 9 13 17 21 25 29 Representation: Tightening sequence 6- cylinder 28 32 31 34 27 33 23 19 15 11 7 3 2 6 10 14 18 22 26 30 © 43414-0 Representation: Tightening sequence 4- cylinder 20 16 12 8 4 1 5 9 13 17 24 21 26 25 23 22 19 15 11 7 3 2 6 10 14 18 © 43413-0 © 04/2007 5/6 14021-001 .

5) z Fill in lubricating oil according to operating manual. 1 6 © 44480-0 © 04/2007 6/6 14021-001 .  55 Nm (M18x1. Lube oil system TD 2012 2V W 08-04-07 TCD 2012 2V z Insert new sealing ring. z Tighten screw plug (1).

6 Removing the oil cooler z Remove oil cooler housing.  W 08-08-03 © 46509-0 z Remove locking plate (1). TD 2012 2V Lube oil system TCD 2012 2V W 08-08-02 Removing and installing the oil cooler Commercial available tools – W 08-08-03 – Fitting compound Collect leaking operating substances in DEUTZ AP1908 suitable vessels and dispose of according to regulations. Emptying and filling the engine with opera- ting media must be carried out according to the operating manual and the appropriate documentation of the vehicle/equipment manufacturer. 1 © 46510-0 © 04/2007 1/4 14022-001 .

z Remove sealing rings. z Coat the sealing rings with fitting compound. z Insert new sealing rings (1). Lube oil system TD 2012 2V W 08-08-02 TCD 2012 2V z Unscrew screws (1). 1 1 6 © 46511-0 z Remove oil cooler (2). z Visually inspect the components. 2 © 46512-0 Installing the oil cooler z Clean sealing surfaces. 1 1 © 46513-0 © 04/2007 2/4 14022-001 .

TD 2012 2V Lube oil system TCD 2012 2V W 08-08-02 z Align oil cooler. Use new sealing rings. z Tighten screws (1). z Insert screws.  22 Nm 1 1 © 46511-0 z Insert locking plate (1). 6 © 46514-0 z Tighten screws (1) alternately.  W 08-08-03 1 © 46510-0 © 04/2007 3/4 14022-001 . z Install oil cooler housing.

Lube oil system TD 2012 2V W 08-08-02 TCD 2012 2V 6 © 04/2007 4/4 14022-001 .

. . . 170160 Collect leaking operating substances in suitable vessels and dispose of according – Fitting compound to regulations. DEUTZ AP1908 Emptying and filling the engine with opera- ting media must be carried out according to the operating manual and the appropriate documentation of the vehicle/equipment manufacturer. z Drain. . . 6 Removing the oil cooler housing z Disconnect cables. . . . . . . . . . collect and dispose of coolant according to regulations. . . . . . . . . 1 © 46515-0 © 04/2007 1/6 14023-001 . TD 2012 2V Lube oil system TCD 2012 2V W 08-08-03 Removing and installing the oil cooler housing Commercial available tools: – Operation manual – Hose clip pliers . . 8011 – User notes Special tools: – Plugs/caps . . . . . . © 46509-0 z Unscrew locking screw (1). . . .

1 2 © 46518-0 © 04/2007 2/6 14023-001 . 1 © 46517-0 z Unscrew screws (1). collect and dispose of according to regu- lations. Lube oil system TD 2012 2V W 08-08-03 TCD 2012 2V z Loosen hose clips (1). z Drain fuel. z Remove hose pipe (2). 1 2 1 6 © 46543-0 z Unscrew hollow screw (1). z Remove fuel filter console (2). z Remove sealing rings.

TD 2012 2V Lube oil system TCD 2012 2V W 08-08-03 z Unscrew screws (1). z Remove oil cooler housing (2). © 46534-0 Installing the oil cooler housing z Clean sealing surfaces. 1 2 1 6 © 46519-0 z Visually inspect the component. © 46521-0 © 04/2007 3/6 14023-001 . 1 1 z Remove gasket. z Mount new gasket.

3 2 Pay attention to different screw lengths. 2 1 © 46522-0 z Mount nut (1).  30 Nm 2 © 46523-0 © 04/2007 4/6 14023-001 . z Fasten screw (2).  30 Nm 1 3 1 2 6 © 46519-1 z Mount the fuel filter console. 1 z Tighten screws . Lube oil system TD 2012 2V W 08-08-03 TCD 2012 2V z Mount oil cooler housing. z Mount nut (1). z Fasten screws. z Fasten screw (2). 1 M8 x 55 mm (1) M8 x 90 mm (2) M8 x 110 mm (3) z Tighten screws alternately.

z Mount the hose pipe (1). 1 © 46549-0 © 04/2007 5/6 14023-001 . z Fasten hose clips with hose clip pliers. 1 © 46548-0 z Position hose clips. z Fasten hose clips with hose clip pliers.  39 Nm Attention! Lay the hose pipe free from chafing and tension. z Mount the hose pipe (1). 1 6 © 46517-0 z Position hose clips. TD 2012 2V Lube oil system TCD 2012 2V W 08-08-03 z Tighten hollow screw (1) with new sealing rings.

Bleed the fuel system via the manual fuel pump on the fuel pre-filter according to the operation manual. Ensure that the connection is perfect. 1 6 © 46550-0 © 04/2007 6/6 14023-001 . z Connect cables. z Tighten screw plug (1). Lube oil system TD 2012 2V W 08-08-03 TCD 2012 2V z Mount new sealing ring.

1 © 42865-1 z Unscrew oil pressure switch (1). Close all connections immediately after opening with new. Removing the oil pressure switch z Unlock cable plug (1) and remove. Carefully clean the area around the affec- ted parts. . . . . Collect lubricating oil and dispose of accor- ding to regulations. . 170160 working on the lube oil system. Blow damp areas dry with com- pressed air. . 110700 Pay attention to utmost cleanliness when – Plugs/caps . . . . clean plugs/caps. 1 © 42866-0 © 04/2007 1/2 14024-001 . Observe the safety regulations and natio- nal specifications for handling lube oils. . . TD 2012 2V Lube oil system TCD 2012 2V W 08-11-08 Removing and installing the oil pressure switch Commercial available tools: – User notes – Special tools: – Long socket wrench insert . . Do not remove plugs/caps until immedia. 6 tely before assembling. . . z Visually inspect the components. . . . . . .

 40 Nm 1 6 © 42866-0 z Plug in the cable plug (1). Lube oil system TD 2012 2V W 08-11-08 TCD 2012 2V Installing the oil pressure switch z Tighten oil pressure switch (1) with new sealing ring. Ensure that the connection is perfect. 1 © 42865-1 © 04/2007 2/2 14024-001 .

TD 2012 2V Cooling system TCD 2012 2V W 09-07-08 Removing and installing the coolant pump Commercial available tools – W 07-11-01 – W 09-13-04 Collect leaking operating substances in suitable vessels and dispose of according to regulations. 1 © 46575-0 z Visually inspect the components. © 46576-0 © 04/2007 1/4 14025-001 . 1 1  W 09-13-04 z Remove fuel supply pump. 1 Collect and dispose of coolant according to regulations. 6 Removing coolant pump z Remove the fan mounting.  W 07-11-01 z Unscrew screws (1). Emptying and filling the engine with opera- ting media must be carried out according to the operating manual and the appropriate documentation of the vehicle/equipment manufacturer.

z Clean sealing surfaces. 1 © 46578-0 © 04/2007 2/4 14025-001 . then the other screws in any order. 6 © 46577-0 z Mount new gasket. Cooling system TD 2012 2V W 09-07-08 TCD 2012 2V Installing coolant pump The sealing surfaces must be dry and free from grease and dirt. z Mount coolant pump (1). then screw (2). Attention! Use new coated screws. 1 z Fasten screws. © 46575-1 z Tighten the screws according to the tightening se- quence.  30 Nm 2 Tightening order: screw (1).

 W 09-13-04 6 © 46580-0 © 04/2007 3/4 14025-001 . TD 2012 2V Cooling system TCD 2012 2V W 09-07-08 z Install fuel pump.  W 07-11-01 z Install fan mounting.

Cooling system TD 2012 2V W 09-07-08 TCD 2012 2V 6 © 04/2007 4/4 14025-001 .

 W 09-08-02 z Measure beginning of stroke. 6 Checking thermostat z Remove thermostat. z Note measured value. © 34679-3 z Heat up the thermostat in the water bath. the temperature should be measured as close as possible to the ther- mostat. dimension (a). In order to determine the exact beginning of opening. dimension (a). Otherwise the begin- ning of opening will be delayed accordin- gly.  83 °C © 34680-2 © 04/2007 1/2 14026-001 . TD 2012 2V Cooling system TCD 2012 2V W 09-08-01 Checking the thermostat (in the removed state) Commercial available tools: – W 09-08-02 – Thermometer Danger! Risk of injury! Hot water and hot thermostat. The temperature rise should not take place faster than 1°C/min. The water should be continuously stirred for an even temperature distribution. z Determine beginning of opening.

Cooling system TD 2012 2V W 09-08-01 TCD 2012 2V z Measure end of stroke.dimension (a) Result: = stroke z Compare result with setpoint value. z Note measured value. dimension (b).  W 09-08-02 © 34679-1 © 04/2007 2/2 14026-001 . Calculation example Desired: Stroke Given: - Measured: Beginning of stroke. dimension (b). – Nominal value stroke travel:  at least 8 mm z Install thermostat. dimension (a) End of stroke. 6 © 34679-2 z Determine stroke. dimension (b) Dimension (b) .

– Fitting compound Emptying and filling the engine with opera- DEUTZ AP1908 ting media must be carried out according to the operating manual and the appropriate documentation of the vehicle/equipment manufacturer. z Visually inspect the components. 6 Removing the thermostat z Unscrew screws (1). TD 2012 2V Cooling system TCD 2012 2V W 09-08-02 Removing and installing the thermostat Commercial available tools Collect leaking operating substances in suitable vessels and dispose of according to regulations. 1 2 1 © 46294-0 z Remove coolant thermostat (1). 1 © 46524-0 © 04/2007 1/2 14027-001 . z Remove outlet nozzle (2).

6 © 44439-0 z Insert coolant thermostat. © 46524-1 z Mount outlet nozzle (2). z Coat the sealing ring with fitting compound. z Tighten screws (1).  30 Nm 1 2 1 © 46294-0 © 04/2007 2/2 14027-001 . 1 z Insert new sealing ring (1). Cooling system TD 2012 2V W 09-08-02 TCD 2012 2V Installing the thermostat z Clean sealing surfaces.

TD 2012 2V Cooling system TCD 2012 2V W 09-12-01 Removing and installing temperature transmitter Commercial available tools Collect leaking operating substances in suitable vessels and dispose of according to regulations. Emptying and filling the engine with opera- ting media must be carried out according to the operating manual and the appropriate documentation of the vehicle/equipment manufacturer. 1 © 46374-0 © 04/2007 1/2 14028-001 . 1 © 46353-1 z Unscrew temperature transmitter (1). 6 Removing temperaure transmitter z Unlock cable plug (1) and remove.

1 © 46353-1 © 04/2007 2/2 14028-001 . Ensure that the connection is perfect.  24 Nm Make sure the sealing ring is in place. 6 © 44084-0 Installing temperature transmitter z Tighten temperature transmitter (1). Cooling system TD 2012 2V W 09-12-01 TCD 2012 2V z Visually inspect the component. 1 © 46374-0 z Plug in the cable plug (1).

. . . . . . TD 2012 2V Cooling system TCD 2012 2V W 09-13-01 Dismantling and assembling the air bearing Commercial available tools: – W 09-13-04 – 2-arm puller – Internal extractor – Extension for extraction tool – Locking ring pliers – Press – Screw . . z Hold nut (2). 2 © 46525-0 z Turn in screw (1) a few turns. . 1  W 09-13-04 z Unscrew screw (1). . . M10 x 40 mm – Washer 6 Dismantling the air bearing z Remove the fan mounting. . 1 © 46526-0 © 04/2007 1/8 14029-001 . . . . .

z Splay the internal extractor to the stop. © 46529-0 © 04/2007 2/8 14029-001 . 6 © 46527-0 z Insert internal extractor (1). Cooling system TD 2012 2V W 09-13-01 TCD 2012 2V Attention! Do not damage the component. z Pull off V-belt pulley with 2-arm puller. 1 © 46528-0 z Mount counter holder.

TD 2012 2V Cooling system TCD 2012 2V W 09-13-01 z Pull out ball bearing and hollow shaft. 6 © 46530-0 z Remove locking ring (2). Screw length: M10 x 40 mm (1) 1 2 © 46532-0 © 04/2007 3/8 14029-001 . 2 © 46531-0 z Insert screw (1) and washer (2).

Cooling system TD 2012 2V W 09-13-01 TCD 2012 2V z Turn extension (1) onto screw (2). 1 2 6 © 46547-0 z Mount counter holder. z Pull out ball bearing and nut. © 46533-0 z Press out nut. © 46535-0 © 04/2007 4/8 14029-001 .

© 46537-0 z Press in nut. 6 © 46536-0 Assembling the fan drive z Press in hollow shaft. © 46538-0 © 04/2007 5/8 14029-001 . z Visually inspect the components. TD 2012 2V Cooling system TCD 2012 2V W 09-13-01 z Press out the hollow shaft.

© 46540-0 z Insert locking ring (2). Attention! Ensure that the installation location is free from faults. z Mount ball bearing. Cooling system TD 2012 2V W 09-13-01 TCD 2012 2V Nut (1) faces downwards. 2 © 46531-0 © 04/2007 6/8 14029-001 . 1 6 © 46539-0 z Press out ball bearing over the outer ring.

– Stage 1: 1  3 Nm – Stage 2:  124 Nm z Install fan drive. 6 © 46542-0 z Mount V-belt pulley (1). z Fasten screw (2).  W 09-13-04 2 © 46525-0 © 04/2007 7/8 14029-001 . z Tighten screw (1). 2 1 © 46526-1 z Hold nut (2). TD 2012 2V Cooling system TCD 2012 2V W 09-13-01 z Press out ball bearing over the outer ring.

Cooling system TD 2012 2V W 09-13-01 TCD 2012 2V 6 © 04/2007 8/8 14029-001 .

z Pull out plug element (2). 2 © 46552-1 © 04/2007 1/4 14030-001 . 6 Removing the fan mounting z Unscrew screws (1). TD 2012 2V Cooling system TCD 2012 2V W 09-13-04 Removing and installing the air bearing Commercial available tools Emptying and filling the engine with opera- ting media must be carried out according to the operating manual and the appropriate – Fitting compound documentation of the vehicle/equipment DEUTZ AP1908 manufacturer. z Remove the fan mounting. 1 1 1 © 46551-0 z Remove gasket (1). 1 z Visually inspect the components.

z Coat the sealing rings with fitting compound. 1 6 © 46553-0 z Fit new sealing rings (1). Cooling system TD 2012 2V W 09-13-04 TCD 2012 2V Installing the fan mounting z Insert new sealing ring (1). 1 © 46554-1 z Insert plug element (1). z Coat the sealing ring with fitting compound. 1 © 46555-0 © 04/2007 2/4 14030-001 .

TD 2012 2V Cooling system TCD 2012 2V W 09-13-04 z Mount air bearing. z Tighten screws (1). 1 Note different screw lengths. Attention! Ensure that the installation location is free from faults. 1  60 Nm 6 © 46551-0 © 04/2007 3/4 14030-001 . 1 z Tighten screws (1).

Cooling system TD 2012 2V W 09-13-04 TCD 2012 2V 6 © 04/2007 4/4 14030-001 .

TD 2012 2V Monitoring system TCD 2012 2V W 11-00-03 Removing and installing the engine shutdown Commercial available tools 6 Removing the engine shutdown z Pull out the cable plug from the engine shutdown. z Unscrew screws (1). z Visually inspect the components. 1 © 46432-0 z Pull out engine shutdown (1). 1 © 46434-0 © 04/2007 1/2 14031-001 .

1 © 46434-0 z Tighten screws (1). z Lightly oil O-ring.  21 Nm z Plug cable plug to engine shutdown. z Actuate the shutdown lever between start and stop position. Monitoring system TD 2012 2V W 11-00-03 TCD 2012 2V Installing the engine shutdown Attention! Check control linkage for smooth action. 6 1 © 46417-0 z Press the control linkage into the stop position with the shutdown lever and hold. z Insert engine shutdown (1). z Mount new O-ring (1). 1 © 46432-0 © 04/2007 2/2 14031-001 .

z Unscrew screws (1) with the socket wrench insert. . 8114 6 Removing the V-belt pulley z Loosen screws (1). 1 1 © 46375-0 z Attach turning gear. . . . . 8190 – Socket wrench insert Torx E20 . . . . . . . . . . . . . . . . z Remove V-belt pulley. . . .  W 04-06-03 z Block flywheel with turning gear. . 1 1 © 46600-0 © 04/2007 1/4 14032-001 . . z Remove V-belt. . . . . . . TD 2012 2V Other components TCD 2012 2V W 12-01-04 Removing and installing the V-belt pulley Commercial available tools: – W 04-06-03 – Torque wrench – W 13-02-03 – Rotation angle disc . . . . . .

1 2 © 46603-0 © 04/2007 2/4 14032-001 . The bore (1) must match the bore (2). Other components TD 2012 2V W 12-01-04 TCD 2012 2V z Visually inspect the component. 6 © 46601-0 Installing the V-belt pulley Make sure the clamping bushing (1) is in place. 1 © 46602-0 z Mount V-belt pulley.

Screws: M16 x 1.  40 Nm + 60° + 60° z Remove turning gear.  W 04-06-03 z Install V-belt. TD 2012 2V Other components TCD 2012 2V W 12-01-04 Attention! Renew screws every time they are loo- sened.5 z Tighten new screws with the socket wrench insert and rotation angle disc.  W 13-02-03 6 © 46604-0 © 04/2007 3/4 14032-001 .

Other components TD 2012 2V W 12-01-04 TCD 2012 2V 6 © 04/2007 4/4 14032-001 .

. . 8190 – Self-made mandrin guide 6 Removing the flywheel z Remove stopper (1). . . z Unscrew screws (1). . . z Visually inspect the components. z Remove flywheel. 1 1 1 © 31115-2 z Block flywheel with suitable tool. 1 © 42825-1 © 04/2007 1/2 14033-001 . . . . TD 2012 2V Other components TCD 2012 2V W 12-06-01 Removing and installing the flywheel Commercial available tools: – Rotation angle disc . . . .

z Tighten screws alternately. © 31115-1 © 04/2007 2/2 14033-001 . 6 © 34224-2 Attention! Renew screws every time they are loo- sened. – M10 x 30:  30 Nm + 60° + 30° – M10 x 35 . Other components TD 2012 2V W 12-06-01 TCD 2012 2V Installing the flywheel z Insert self-made guide pin (arrow).M10 x 85:  30 Nm + 60° + 60° © 42826-0 z Drive plugs into the threaded bores (arrows) to the stop. The bores in the flywheel must match the threaded bores in the crankshaft flange.

© 45699-0 © 04/2007 1/2 14034-001 . © 45698-0 z Remove toothed starter ring with suitable tool. do not touch hot parts! 6 Removing toothed starter ring z Remove flywheel. TD 2012 2V Other components TCD 2012 2V W 12-06-03 Renewing toothed starter ring on the flywheel Commercial available tools – W 12-06-01 8190 Danger! Danger of injury. Block flywheel with suitable tool.  W 12-06-01 z Drill toothed wheel.

Other components TD 2012 2V W 12-06-03 TCD 2012 2V z Clean flywheel. © 45701-0 z Install flywheel. z Place toothed starter ring on flywheel. 6 © 45700-0 Install toothed starter ring z Heat up toothed starter ring to 220 °C. z Visually inspect flywheel. The toothed starter ring must lie evenly on the joint of the flywheel.  W 12-06-01 © 45702-0 © 04/2007 2/2 14034-001 .

The V-belt tension of new V-belts must be checked after they have been running for 15 minutes. . . 1 1 © 46375-0 © 04/2007 1/4 14035-001 . . . 8115 engine is not running. . . . . 6 Removing the generator z Disconnect the battery's negative terminal. . .(2) = terminal D+ 2 . . . 1 Note assignment! . . . . . .(1) = terminal W . . TD 2012 2V Electrical system TCD 2012 2V W 13-02-03 Removing and installing the generator (V-belt drive) Commercial available tools: Attention! – V-belt tension measuring Only test / tighten / renew V-belts when the device . . z Remove cable from generator. . . .(3) = terminal B+ 3 © 46557-0 z Loosen screws (1).

z Tighten screws (2). z Press clamping strap (1) in direction of arrow with a suitable tool.9  30 Nm 4 © 46558-1 Installing the V-belt. 1 z Visually inspect the components. – M8-10.9 1 2 3  30 Nm z Tighten screw (1). 3 z Remove generator (2). z Mount V-belt. – M8-10. 1 © 46375-1 © 04/2007 2/4 14035-001 . – M8-10. z Loosen screw (1). 2 z Unscrew screws (3). 3 6 © 46558-0 Installing the generator z Mount generator (3). Electrical system TD 2012 2V W 13-02-03 TCD 2012 2V z Remove V-belt.9  30 Nm z Tighten screw (4).

© 46559-0 © 04/2007 3/4 14035-001 . 1 © 44591-0 z Mount V-belt tension measuring device on V-belt. TD 2012 2V Electrical system TCD 2012 2V W 13-02-03 z Pre-tighten screws (1). The V-belt must be between the guides (arrow). 1 1 6 © 46375-0 Check V-belt tension with V-belt tension measuring device z Lower indicator arm (1) into V-belt tension measuring device.

(3) = terminal B+ z Connect the battery's negative terminal.(2) = terminal D+ 1 . z Read measured value at the intersection (arrow) of the indicator arm and scale. the tensioning process must be repeated.9  30 Nm 1 1 © 46375-0 z Remove cable from generator. – First assembly:  650 Nm – Check after running for 15 minutes under load: 1  400 Nm Note different units on the scale. z If the nominal value is not reached.(1) = terminal W . Note assignment! . 6 © 46560-0 z Tighten screws (1). – M8-10. 2 3 © 46557-0 © 04/2007 4/4 14035-001 . Electrical system TD 2012 2V W 13-02-03 TCD 2012 2V z Press the V-belt measuring device against the V-belt with the button (1) until you hear it click.

1 z Connect the battery's negative terminal. z Unscrew screws (1). 1 z Disconnect cables. TD 2012 2V Electrical system TCD 2012 2V W 13-03-02 Removing and installing the starter Commercial available tools 6 Removing the starter z Disconnect the battery's negative terminal. 1 © 46556-0 Installing the starter z Insert starter. z Visually inspect the components. – M10x38-10.9  60 Nm – Nut M8  40 Nm – Pin bolt  10 Nm z Connect cables. © 46556-0 © 04/2007 1/2 14036-001 . z Remove starter. 1 z Tighten screws (1).

Electrical system TD 2012 2V W 13-03-02 TCD 2012 2V 6 © 04/2007 2/2 14036-001 .

fm . TD 2012 2V TCD 2012 2V Standard tools 7 Standard tools 7 © 04/2007 1/10 OBJ_DOKU-14037-001.

7 © 04/2007 2/10 OBJ_DOKU-14037-001.fm . TD 2012 2V Standard tools TCD 2012 2V Orders Conventional tools / special tools: These must be ordered like normal DEUTZ spare parts with specification of the order number.

TD 2012 2V TCD 2012 2V Standard tools 8002 Pressure pump Checking cooling system for leak-tightness © 35409-2 7 8005 Compression pressure tester for diesel engines 10 .fm .40 bar Checking compression pressure © 35410-3 8008 Nozzle tester with spray mist collecting vessel Check injection nozzles © 35411-2 © 04/2007 3/10 OBJ_DOKU-14037-001.

fuel return pipe © 39426-1 7 8012 Socket wrench insert Wrench size 15. g.fm . TD 2012 2V Standard tools TCD 2012 2V 8011 Hose clip pliers Loosen and fasten hose clips e. long © 35412-3 8024 Assembly pliers Removing valve shaft seals © 37509-2 © 04/2007 4/10 OBJ_DOKU-14037-001.

E 14 © 43022-0 8114 Socket wrench insert Torx .E 20 © 35415-1 © 04/2007 5/10 OBJ_DOKU-14037-001. size 22 removing and installing main bearing © 37504-2 7 8113 Socket wrench insert Torx . TD 2012 2V TCD 2012 2V Standard tools 8035 Socket wrench insert reinforced.fm .

Socket wrench insert E18 (1/2 inch) © 39432-1 © 04/2007 6/10 OBJ_DOKU-14037-001.fm .Socket wrench insert E10 and E12 (3/8 inch) .Double-ended ring spanner E6/E8 .Double-ended ring spanner E10/E12 Socket wrench insert E8 and E10 (1/4 inch) . TD 2012 2V Standard tools TCD 2012 2V 8115 V-belt tension measuring device 150 to 600 N Check V-belt tension © 35416-3 7 8117 Multi-toothed socket wrench insert For turning the fuel injector pump © 46422-0 8189 Torx tool set Contents of case: .

fm . TD 2012 2V TCD 2012 2V Standard tools 8190 Rotation angle disc with magnet Setting valve clearance © 42528-1 7 8191 Screwdriver insert for slotted screw Valve clearance setting © 43060-0 8192 Bowl wrench Fuel pre-filter (type: Racor) © 43193-1 © 04/2007 7/10 OBJ_DOKU-14037-001.

fm . 3/8 inch. TD 2012 2V Standard tools TCD 2012 2V 8193 Screwdriver insert with pressed in hexagonal pin (5 mm). © 43019-0 © 04/2007 8/10 OBJ_DOKU-14037-001. for torque wrench Tighten lock nut of the valve clearance setting screw. long version (in conjunction with rotation angle disc 8190) © 43183-0 7 8194 Screwdriver insert with pressed in hexagon pin (4 mm). 1/2 inch. long version (in connection with rotation angle disc 8190 and reduc- er 1/2 to 3/8 inch) © 43183-0 8196 Open end wrench adapter Size 13.

removing and installing valves © 37511-2 © 04/2007 9/10 OBJ_DOKU-14037-001. TD 2012 2V TCD 2012 2V Standard tools 8198 Pricker Removing rotary shaft lip seal © 43206-0 7 8199 Crowfoot wrench Size 15 3/4 inch (in connection with rotation angle disc 8190) © 44309-0 9017 Assembly lever e.fm . g.

TD 2012 2V Standard tools TCD 2012 2V 9090 Spring band pliers 320 mm Tighten spring clamp © 35420-3 7 © 04/2007 10/10 OBJ_DOKU-14037-001.fm .

TD 2012 2V TCD 2012 2V Special tools 8 Special tools 8 © 04/2007 1/14 OBJ_DOKU-14038-001.fm .

8 © 04/2007 2/14 OBJ_DOKU-14038-001. TD 2012 2V Special tools TCD 2012 2V Orders Conventional tools / special tools: These must be ordered like normal DEUTZ spare parts with specification of the order number.fm .

fm . TD 2012 2V TCD 2012 2V Special tools 100190 Connector (in conjunction with compression pressure tester 8005) © 42524-0 100320 Turning gear 8 flywheel side © 35422-1 100330 Turning gear V-belt pulley Turning crankshaft on torsional vibration damper © 48242-0 © 04/2007 3/14 OBJ_DOKU-14038-001.

01 mm © 43205-0 100750 Measuring device Measuring bar with two shims (in conjunction with 100400 and 100410) Checking valve lag dimension Checking piston projection © 39402-2 © 04/2007 4/14 OBJ_DOKU-14038-001.01 mm © 35424-1 100410 8 Digital gauge Measuring range 0 .30 mm / 0.10 mm / 0. TD 2012 2V Special tools TCD 2012 2V 100400 Dial gauge with fixing wheel Measuring range 0 .fm .

fm . TD 2012 2V TCD 2012 2V Special tools 100800 Setting device For measuring the control linkage travel and blocking the control linkage © 46441-0 100810 Centring bolts 8 for mass compensation shafts © 46439-0 100830 Pressing device For control linkage © 46443-0 © 04/2007 5/14 OBJ_DOKU-14038-001.

TD 2012 2V Special tools TCD 2012 2V 103210 Measuring device For base circle measurement (in engines with injection adjuster) © 46444-0 103220 8 Special pliers (part of measuring device 103210) for removing the roller tappet © 43175-0 110030 Puller (in connection with sliding hammer 150800) Removing fuel injector © 35433-2 © 04/2007 6/14 OBJ_DOKU-14038-001.fm .

TD 2012 2V TCD 2012 2V Special tools 110110 Holder Wrench size 11. clamp the injection valve in the vice © 35434-2 110500 Special wrench 8 Wrench size 17 Removing and installing high-pressure lines © 35436-1 110700 Socket wrench insert long Installing and removing pressure sensors (rail pressure. oil pressure. fuel pressure) © 43198-2 © 04/2007 7/14 OBJ_DOKU-14038-001.fm .

fm . TD 2012 2V Special tools TCD 2012 2V 110901 Disassembly tool (part of assembly case 110900) Removing and installing the O-rings © 45950-1 120440 8 Assembly tool Removing and installing the glow plugs © 40333-1 120660 Puller (in connection with sliding hammer 150800) Removing fuel injector © 45111-0 © 04/2007 8/14 OBJ_DOKU-14038-001.

TD 2012 2V TCD 2012 2V Special tools 120900 Support bracket pivoting Clamping cylinder head © 35438-3 120910 Base plate 8 (in conjunction with support bracket 120900 if support bracket is not screwed tightly) © 35439-3 121410 Assembly tool Mounting valve shaft seal © 37614-2 © 04/2007 9/14 OBJ_DOKU-14038-001.fm .

fm . TD 2012 2V Special tools TCD 2012 2V 121420 Assembly sleeves Set of assembly sleeves for valve shaft seal © 43210-0 130300 8 Universal piston ring pliers Removing and installing the piston rings © 43021-0 130440 Trapezoidal groove wear gauge Piston diameter 101 mmChecking piston ring groove © 36461-2 © 04/2007 10/14 OBJ_DOKU-14038-001.

TD 2012 2V TCD 2012 2V Special tools 130670 Piston ring compressor Piston diameter 101 mm Installing piston © 39408-1 142670 Assembly tool 8 Installing crankshaft sealing ring (opposite side to flywheel) © 35445-1 142830 Assembly tool Installing crankshaft sealing ring (flywheel side) © 35446-1 © 04/2007 11/14 OBJ_DOKU-14038-001.fm .

TD 2012 2V Special tools TCD 2012 2V 143840 Assembly tool Removing and installing camshaft bearing © 46440-0 144800 8 Counter support for torsional vibration dampers © 35453-1 150800 Slide hammer Removing fuel injector © 35449-2 © 04/2007 12/14 OBJ_DOKU-14038-001.fm .

fm . TD 2012 2V TCD 2012 2V Special tools 151500 Separating tool Removing metal sheet lubricating oil pan from crank- case © 45974-0 170050 Special wrench 8 Unscrewing the filter cartridges © 37629-2 170160 Stoppers/caps 1 set of differently-sized stoppers and caps Sealing openings on the fuel system © 43663-0 © 04/2007 13/14 OBJ_DOKU-14038-001.

cross member. chains and hooks © 43184-0 © 04/2007 14/14 OBJ_DOKU-14038-001. double-sided © 35452-1 6068 Engine lifting device Load (2000 kg). 3-point suspension.fm . spindle clamp. 1 holder 6066/158-2 rear left. TD 2012 2V Special tools TCD 2012 2V 6066 Assembly block Engine clamping. 1 holder 6066/158-4 front left (in connection with assembly block 6066) Clamping of the engine. 1 holder 6066/158-3 front right. double-sided © 35451-2 6066/158 8 Clamping bracket consisting of: 1 holder 6066/158-1 rear right.