Service Bulletin

0199-17-11048/0 EN
This Circular supersedes:

Date: 13.11.2013 DEUTZ AG

Author: Rudolf Fischer, VE-FI Ottostraße 1
51149 Köln

Phone: +49 (0) 221 822-3008 www.deutz.com

Fax: +49 (0) 221 822-15 3008

2.9 / 3.6
● D 2.9 L4 / TD 2.9 L4 / TCD 2.9 L4 / TD 3.6 L4 / TCD 3.6 L4
● Assemblies:
17

High-pressure pump

Removal and installation

The high safety and quality level of our engines is constantly ensured by technical improve-
ments and further developments. There may therefore be some deviations between the
documentation and the present state of technical knowledge.

The following change(s) has/have necessitated this Service Bulletin:

● Introduction of updated job card(s)

See appendix/appendices

– Introduction
Mounting compound
for

Item Name
1 Round sealing ring
2 Spacer

Note:
The part numbers indicated in this document are not subject to updating.
Binding for the identification of spare parts is exclusively the spare parts documentation.
It is absolutely prohibited to multiply, publish or hand over this document - also excerpts of it.

M0169-17-0011 / M0183-17-0009

OBJ_DOKU-38850-001.fm 1/3 © 2013

 Service Bulletin
0199-17-11048/0

A1 High-pressure pump

– Modified tightening specification

for
Hexagonal nut(s)

The following tightening specifications must now be observed:

Hexagonal nut(s)
Torque
Item Formerly: Now:
1 21 Nm 20 Nm

A2 Hexagonal nut(s)

OBJ_DOKU-38850-001.fm 2/3 © 2013

 Service Bulletin
0199-17-11048/0 EN

All figures and graphics are only examples.

The work is described in the following job cards enclosed in the appendix:
The already updated job cards can be retrieved via SERPIC for the exact corresponding
engine series number.

If you have questions on this topic, please contact the staff member(s) below.
Email: service-kompaktmotoren.de@deutz.com

For the America region:

Email: service@deutzusa.com

For the Asia region:

Email: dapservice@deutz.com

This document has been created digitally and is valid without a signature.

Enclosure(s):

Job card(s)

W 17-01-04

Engine type
Language: D / TD / TCD 2.9 L4 TD / TCD 3.6 L4

– German OBJ_DOKU-35867-001.fm OBJ_DOKU-35930-001.fm

 – English OBJ_DOKU-36285-001.fm OBJ_DOKU-36281-001.fm

– Spanish OBJ_DOKU-36461-001.fm OBJ_DOKU-36457-001.fm

– French OBJ_DOKU-36640-001.fm OBJ_DOKU-36636-001.fm

– Italian OBJ_DOKU-36816-001.fm OBJ_DOKU-36812-001.fm

OBJ_DOKU-38850-001.fm 3/3 © 2013

 High-pressure pump
W 17-01-04
OBJ_DOKU-36285-001.fm

Removing and installing the high-pressure pump

Standard tools: – Safety information / User
– Separating tool information
Special tools:
– Special wrench 02992112 Danger!
– Disassembly tool 02992127 Do not carry out work on the fuel system
– Plugs/caps 01899144 when the engine is running.
The fuel system is under high pressure -
– Mounting compound 01008420
Danger of death.
The fuel pressure can continuously remain
up to several 100 bar even after stopping
the engine.
Here the fuel pressure is only reduced if
the fuel system is opened and the fuel can 6
escape outside.

Attention!
Ensure utmost cleanliness for all work.
Remove any paint residue and dirt par-
ticles before disassembly.
Clean the area around the components
concerned carefully. Blow wet parts dry
with compressed air.
Observe the safety regulations and natio-
nal specifications for handling fuels.
Close all connections immediately after
opening with new, clean plugs/caps.
Do not remove plugs/caps until immedia-
tely before assembling.
Collect leaking operating substances in
suitable vessels and dispose of according
to regulations.

Removing the high-pressure pump

1 High-pressure pump
2 Toothed wheel
3 Washer
4 Hexagonal nut
5 Spacer
6 O-ring
7 Hexagonal nut
8 O-ring
291 Mounting compound

© 52987-0

© 05/2013
1/8
 High-pressure pump
W 17-01-04
OBJ_DOKU-36285-001.fm

● Unlock cable plug and remove.

● Remove high-pressure line.

● Remove fuel pipes.
 Module 21
● Remove cap (1).
 Module 09
● Install turning gear / locking device.
 Modules 44, 49

6
© 52463-0

● Turn crankshaft in engine direction of rotation until

markings are in line.
(1) Marking gear case
(2) Marking high-pressure pump gear wheel

Attention!
Do not turn the crankshaft any more!

© 52464-0

● Unscrew nuts (1).

© 52465-1

© 05/2013
2/8
 High-pressure pump
W 17-01-04
OBJ_DOKU-36285-001.fm

Attention!
Do not twist the high-pressure pump.
Do not twist the spacer.
Do not damage the components.
● Pull out high-pressure pump (1) slightly.
● Loosen spacer (2) carefully.
● Push spacer (2) up to the high-pressure pump (1).
The spacer must rest on the high-pressure
pump.

6
© 52791-0

● Pull high-pressure pump (1) via pin bolts and tilt

slightly.
● Turn high-pressure pump sideways and pull it up to
remove it.
Attention!
Do not turn the crankshaft any more!

© 52792-0

Attention!
Do not damage the high-pressure pump
gear wheel.

Use a suitable tool.

● Hold high-pressure pump gear wheel (1).

● Unscrew nut (2).
● Remove washer (3).
● Pull off high-pressure pump gear wheel (1) with sep-
arating tool.
● Remove spacer (4).
● Visually inspect the components.

© 52466-0

© 05/2013
3/8
 High-pressure pump
W 17-01-04
OBJ_DOKU-36285-001.fm

● Remove the O-rings (1) with the disassembly tool.

● Visually inspect the components.

6
© 51435-0

Installing the high-pressure pump

● Clean sealing surfaces.
● Mount new O-rings (1).
● Push on spacer (2).
Attention!
Ensure that the installation location is free
from faults.
Recess (3) is on the fuel supply side.

© 51436-0

Attention!
Ensure that the installation location is free
from faults.
Do not damage the high-pressure pump
gear wheel.
The clamping pin (1) must engage in the
groove (2).
● Mount high-pressure pump gear wheel (3).
● Fit washer (4).
● Turn in nut (5).
Use a suitable tool.

● Hold high-pressure pump gear wheel (3).

● Tighten nut (5).
© 52467-0
 80 Nm

© 05/2013
4/8
 High-pressure pump
W 17-01-04
OBJ_DOKU-36285-001.fm

● Coat the O-ring (1) with fitting compound.

● Coat bordering surfaces of the spacer (2) with
mounting compound.

6
© 53500-0

Attention!
Observe direction of rotation of the high-
pressure pump drive!
View Direction of rotation
On high-pressure pump drive left (anti-clockwise)

Attention!
Dry running is not permissible.
Sufficient fuel pressure must be available
at the high-pressure pump.
Fuel pressure at the supply: at least 4.3 bar

© 52468-1

Attention!
Observe position of the drive shaft and
high-pressure pump.

(1) Marking high-pressure pump gear wheel

– Dimension X
90°

© 53501-0

© 05/2013
5/8
 High-pressure pump
W 17-01-04
OBJ_DOKU-36285-001.fm

● Insert high-pressure pump (1) sideways from above.

Attention!
Do not twist the high-pressure pump.

6
© 52792-0

Markings must be in alignment.

(1) Marking gear case

(2) Marking high-pressure pump gear wheel

© 52464-0

Attention!
Do not twist the high-pressure pump.

● Screw on nuts (1).

● Tighten nuts (1).
 20 Nm

© 52465-1

© 05/2013
6/8
 High-pressure pump
W 17-01-04
OBJ_DOKU-36285-001.fm

● Install the sealing cover (1).

 Module 09
● Install fuel pipes.
● Fit new high-pressure line.
 Module 21
● Plug in and lock cable plug.
● Remove turning gear / locking device.
 Modules 44, 49

6
© 52463-0

© 05/2013
7/8
 High-pressure pump
W 17-01-04
OBJ_DOKU-36285-001.fm

Technical Data
Tightening specifications
ID no. Name Screw type Notes / Remark Value
High-pressure pump gear wheel and Hold high-pressure pump
A17 004 80 Nm
high-pressure pump drive shaft gear wheel.
A17 031 High-pressure pump on crankcase 20 Nm

For the tightening procedure according to torque using a torque wrench, a maximum variation of the
tightening torque of +/- 10% is permissible.

© 05/2013
8/8
 High-pressure pump
W 17-01-04
OBJ_DOKU-36281-001.fm

Removing and installing the high-pressure pump

Standard tools: – Safety information / User
– Separating tool information
Special tools:
– Special wrench 02992112 Danger!
– Disassembly tool 02992127 Do not carry out work on the fuel system
– Plugs/caps 01899144 when the engine is running.
The fuel system is under high pressure -
– Mirror
Danger of death.
– Marker pen, waterproof,
permanent The fuel pressure can continuously remain
– Mounting compound 01008420 up to several 100 bar even after stopping
the engine.
Here the fuel pressure is only reduced if
the fuel system is opened and the fuel can 6
escape outside.

Attention!
Ensure utmost cleanliness for all work.
Remove any paint residue and dirt par-
ticles before disassembly.
Clean the area around the components
concerned carefully. Blow wet parts dry
with compressed air.
Observe the safety regulations and natio-
nal specifications for handling fuels.
Close all connections immediately after
opening with new, clean plugs/caps.
Do not remove plugs/caps until immedia-
tely before assembling.
Collect leaking operating substances in
suitable vessels and dispose of according
to regulations.

Removing the high-pressure pump

1 High-pressure pump
2 Spacer
3 Hexagonal nut
4 Washer
5 O-ring
6 Hexagonal nut
7 O-ring
293 Mounting compound

© 51433-1

© 05/2013
1/8
 High-pressure pump
W 17-01-04
OBJ_DOKU-36281-001.fm

● Unlock cable plug and remove.

● Remove high-pressure line.

● Remove fuel pipes.
 Module 21
● Unscrew locking screw (1).
● Remove sealing ring.
 Module 09
● Install turning gear / locking device.
 Modules 44, 49

6
© 50702-0

● Turn crankshaft in engine direction of rotation until

marking is visible.
(1) Marking high-pressure pump gear wheel

© 50703-0

● Apply help marking (1).

High-pressure pump gear wheel and inter-
mediate gear

Attention!
Do not turn the crankshaft any more!

© 50704-0

© 05/2013
2/8
 High-pressure pump
W 17-01-04
OBJ_DOKU-36281-001.fm

● Unscrew nuts (1).

Attention!
Do not twist the high-pressure pump.
Do not twist the spacer.
Do not damage the components.
● Remove high-pressure pump (2).
Attention!
Do not turn the crankshaft any more!

6
© 50705-0

Attention!
Do not damage the high-pressure pump
gear wheel.

Use a suitable tool.

● Hold high-pressure pump gear wheel (1).

● Unscrew nut (2).
● Remove washer (3).
● Pull off high-pressure pump gear wheel (1) with sep-
arating tool.
● Remove spacer (4).
● Visually inspect the components.

© 51434-0

● Remove the O-rings (1) with the disassembly tool.

Attention!
All the help markings must be transferred
when renewing/changing a part.
Do not turn the crankshaft any more!

© 51435-0

© 05/2013
3/8
 High-pressure pump
W 17-01-04
OBJ_DOKU-36281-001.fm

Installing the high-pressure pump

● Clean sealing surfaces.
● Mount new O-rings (1).
● Push on spacer (2).
Attention!
Ensure that the installation location is free
from faults.
Recess (3) is on the fuel supply side.

6
© 51436-0

● Mount high-pressure pump gear wheel (1).

Attention!
Pay attention to installation position.

(2) Surrounding groove

(3) Marking

© 51437-0

Attention!
Ensure that the installation location is free
from faults.
Do not damage the high-pressure pump
gear wheel.
The clamping pin (1) must engage in the
groove (2).
● Fit washer (3).
● Screw on nut (4).
Use a suitable tool.

● Hold high-pressure pump gear wheel (5).

● Tighten nuts (4).
 80 Nm
© 51438-0

© 05/2013
4/8
 High-pressure pump
W 17-01-04
OBJ_DOKU-36281-001.fm

● Coat the O-ring (1) with fitting compound.

● Coat bordering surfaces of the spacer (2) with
mounting compound.

6
© 53500-0

Attention!
Observe direction of rotation of the high-
pressure pump drive!
Observe position of the drive shaft and
high-pressure pump.
(1) Marking high-pressure pump gear wheel

View Direction of rotation

On high-pressure pump drive right (clockwise)

Attention!
Dry running is not permissible.
Sufficient fuel pressure must be available
at the high-pressure pump.
Fuel pressure at the supply: at least 4.3 bar

© 51439-0

● Install high-pressure pump.

Markings must be visible.
Help marking must match.
(1) Marking high-pressure pump gear wheel
Help marking high-pressure pump gear wheel
(2)
and intermediate gear

© 50713-0

© 05/2013
5/8
 High-pressure pump
W 17-01-04
OBJ_DOKU-36281-001.fm

Attention!
Do not twist the high-pressure pump.

● Screw on nuts (1).

● Tighten nuts (1).
 20 Nm
● Install locking screw.
 Module 09
● Install fuel pipes.
● Fit new high-pressure line.
 Module 21
● Plug in and lock cable plug.
6 ● Remove turning gear / locking device.
 Modules 44, 49 © 50714-0

© 05/2013
6/8
 High-pressure pump
W 17-01-04
OBJ_DOKU-36281-001.fm

Technical Data
Tightening specifications
ID no. Name Screw type Notes / Remark Value
High-pressure pump gear wheel and Hold high-pressure pump
A17 004 80 Nm
high-pressure pump drive shaft gear wheel.
A17 031 High-pressure pump on crankcase 20 Nm

For the tightening procedure according to torque using a torque wrench, a maximum variation of the
tightening torque of +/- 10% is permissible.

© 05/2013
7/8
 High-pressure pump
W 17-01-04
OBJ_DOKU-36281-001.fm

© 05/2013
8/8